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Main Manifold Service (continued)

IMPORTANT

A removable control orifice exists under the fitting in the LS/OR1
port, and under the plugs in the OR2 and OR3 ports of the main
hydraulic manifold. If the fitting or plug is removed, remove the
orifice for cleaning and label its position for assembly purposes.

Note:

For cartridge valve service procedures, refer to

Cartridge Valve Service

(page 5–88)

.

Outcross 9060

Page 5–87

Hydraulic System: Service and Repairs

18234SL Rev B

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Summary of Contents for 07511AA

Page 1: ...Form No 18234SL Rev B Outcross 9060 Models 07511AA BA CA DA 2018 The Toro Company 8111 Lyndale Avenue South Bloomington MN 55420 Original Instructions EN Contact us at www Toro com All Rights Reserved ...

Page 2: ...Revision History Revision Date Description A 10 2018 Initial Release B 11 2018 Parker hydraulic valve service information Revision History Page 2 Outcross 9060 18234SL Rev B ...

Page 3: ...ctively we encourage user feedback Please comment on the completeness accuracy organization usability and readability of this manual by an e mail to servicemanuals toro com or Mail to Technical Publication Manager Commercial The Toro Company 8111 Lyndale Avenue South Bloomington MN 55420 1196 Phone 1 952 887 8495 Outcross 9060 Page 3 Reader Comments 18234SL Rev B ...

Page 4: ...Reader Comments Page 4 Outcross 9060 18234SL Rev B ...

Page 5: ... change the product specifications or this publication without notice DANGER This safety symbol means danger When you see this symbol carefully read the instructions that follow Failure to obey the instructions could kill or cause serious permanent injury or disability WARNING This safety symbol means warning When you see this symbol carefully read the instructions that follow Failure to obey the ...

Page 6: ...n assembly torque requirement that is different than what is recommended in the Standard Torque Tables refer to Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series page 2 9 or Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners page 2 10 Fluid Specifications This icon is used to highlight fluid specifications and capacities that are less common and may not appe...

Page 7: ... 4 2 Service and Repairs 4 8 Chapter 5 Hydraulic System 5 1 General Information 5 3 Hydraulic Schematic 5 13 Hydraulic Flow Diagrams 5 14 Testing the Hydraulic System 5 34 Adjustments 5 48 Service and Repairs 5 49 Chapter 6 Electrical System 6 1 General Information 6 3 Electrical Drawings 6 12 Electrical System Quick Checks 6 13 Electrical Component Testing 6 14 Service and Repairs 6 77 Chapter 7 ...

Page 8: ...1 Wire Harness Cab Work Light Kit optional A 22 Wire Harness Domestic Road Light Kit optional A 23 Wire Harness Turn Signal Hazard Lights optional A 24 Wire Harness International Road Light Kit optional A 25 Additional Reference Materials Yanmar TNV Tier 4 Series Service Manual Yanmar TNV Tier 4 Series Troubleshooting Manual Danfoss H1 Closed Circuit Axial Piston Pumps Service Manual Danfoss H1 Cl...

Page 9: ...sibilities 1 2 Before Operating the Machine 1 3 Operating the Machine 1 4 Maintenance and Service 1 6 Jacking Instructions 1 8 Raising the Front of the Machine 1 8 Raising the Rear of the Machine 1 9 Safety and Instructional Decals 1 9 Outcross 9060 Page 1 1 Safety 18234SL Rev B ...

Page 10: ...ing safety instructions as well as information found in the traction unit Operator s Manual accessory Installation Instructions and the Operator and Safety Training Videos found on www toro com Supervisor s Responsibilities 1 Ensure that the machine operators are fully trained and familiar with the traction unit Operator s Manual all of the operating and safety decals on the machine and any operat...

Page 11: ...aring safety glasses safety shoes long pants and a helmet is advisable and required by some local safety and insurance regulations Make sure work area is clear of objects which might be picked up and thrown by the attachments Keep everyone especially children and pets away from the area of operation Ensure the safety interlocks are functioning properly Adjust or replace any malfunctioning switches...

Page 12: ...good artificial light B Watch for holes or other hidden hazards C Do not drive close to sand traps ditches creeks or other hazards D Traverse slopes carefully Do not start or stop suddenly when traveling uphill or downhill E Reduce speed when making sharp turns Avoid sudden stops and starts F Before backing up look to the rear to be sure no one is behind the machine G Watch out for traffic when ne...

Page 13: ...nd the pressure in the hydraulic lift circuit is released and accidentally lowering the attachment is avoided B Lower any attachments to the ground C Set the parking brake if the engine will be left running or stop the engine and remove the key from key switch 10 When using the optional InchMode feature A Keep bystanders away from the machine B Use the InchMode feature only on a level surface C Wh...

Page 14: ... system by parking the machine on a level surface lowering the cutting deck or implement completely and then shutting off the engine To reduce potential fire hazards keep the engine area free of excessive grease grass leaves and dirt Clean the protective screen on the machine frequently Check all fuel lines for tightness and wear on a regular basis Tighten or repair fuel lines as needed If you mus...

Page 15: ... to Machinery Directive 2006 42 EC Electromagnetic Compatibility EMC Directive 2014 30 EU and ISO standards for power mass vibration and sound To ensure the optimum performance and continued safety certification of the machine use genuine Toro replacement parts and accessories The replacement parts and accessories of other manufacturers can result in non conformance with the safety standards and c...

Page 16: ...id level surface such as a concrete floor Always block the wheels with chocks Use the correct blocks hoists and jacks to lift the machine Use the appropriate jack stands to support the raised machine Do Not use an attachment as a jacking point Raising the Front of the Machine g232342 Figure 1 1 Front jack point frame channel behind side plate 2 Front jack stand point frame channel behind side plat...

Page 17: ...nder the vehicle frame to support the machine Safety and Instructional Decals Numerous safety and instruction decals are affixed to the traction unit and attachments of your Outcross 9060 machine If any decal becomes illegible or damaged install a new decal Decal part numbers are listed in the Parts Catalog traction unit Operator s Manual and accessory Installation Instructions Order replacement d...

Page 18: ...Safety Safety and Instructional Decals Page 1 10 Outcross 9060 18234SL Rev B ...

Page 19: ...2 6 Calculating the Torque Values When Using a Drive Adapter Wrench 2 7 Identifying the Fastener 2 8 Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series 2 9 Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners 2 10 Other Torque Specifications 2 11 Conversion Factors 2 11 Shop Supplies 2 12 Special Tools 2 14 Outcross 9060 Page 2 1 Specifications and Maintenance ...

Page 20: ...Specifications Overall Dimensions g231580 Figure 3 Outcross 9060 Specifications and Maintenance Specifications Page 2 2 Outcross 9060 18234SL Rev B ...

Page 21: ...lywheel 2 Direction of rotation Counterclockwise viewed from the flywheel Fuel Diesel or Biodiesel fuel up to B20 with ultra low sulfur content Fuel tank capacity 53 4 L 14 1 US gallons Fuel pump Yanmar electric supply pump Fuel injection type Common rail system EPA Tier 4 certified Governor Electronic All Speed Low idle no load 1 200 100 rpm ECO mode no load 2 300 100 rpm High idle no load 3 000 ...

Page 22: ...si Steering RV1 20 684 kPa 3 000 psi Hitch lift RV2 20 684 kPa 3 000 psi Auxiliary load valve 20 684 kPa 3 000 psi Hydraulic filter Spin on cartridge type Hydraulic fluid Refer to the traction unit Operator s Manual Hydraulic tank capacity 48 L 12 75 gallons Traction and PTO Drive Item Description Tires Front Turf Tread 29 x 12 5 15 6 ply 151 to 165 kPa 22 to 24 psi Turf Tread 29 x 12 5 15 12 ply ...

Page 23: ... capacity volume Standard bed 453 kg 1 000 lb 0 6 cubic meters 0 8 cubic yards Cargo bed optional 2 041 kg 4 500 lb 1 cubic meters 1 3 cubic yards Outcross 9060 Page 2 5 Specifications and Maintenance Specifications 18234SL Rev B ...

Page 24: ...k nut hardness of the surface underneath the head of the fastener or similar condition which affects the installation As noted in the following tables the torque values should be reduced by 25 for lubricated fasteners or fasteners with a wet thread locking compound applied to achieve the similar stress as a dry fastener The torque values must be reduced when the fastener is threaded into the alumi...

Page 25: ...ng torque When using a torque wrench with a drive adapter wrench the calculated torque will be lower than the listed torque recommendation Example The measured effective length of the torque wrench distance from the center of the handle to the center of the square drive is 457 mm 18 inches The measured effective length of the torque wrench with the drive adapter wrench installed distance from the ...

Page 26: ...porated into the fastener and pre applied dry thread locking compound Keep in mind a fastener with a locking feature usually means there will be friction during initial installation and during removal Toro recommends replacing fasteners with a locking feature once they have been removed because the effectiveness of the locking feature diminishes with each reuse If it is necessary to reuse a fasten...

Page 27: ... 37 4 50 5 68 7 70 7 95 9 7 16 20 UNF 29 3 29 3 39 4 55 6 75 8 77 8 104 11 1 2 13 UNC 30 3 48 7 65 9 75 8 102 11 105 11 142 15 1 2 20 UNF 32 4 53 7 72 9 85 9 115 12 120 12 163 16 5 8 11 UNC 65 10 88 12 119 16 150 15 203 20 210 21 285 28 5 8 18 UNF 75 10 95 15 129 20 170 18 230 24 240 24 325 33 3 4 10 UNC 93 12 140 20 190 27 265 27 359 37 375 38 508 52 3 4 16 UNF 115 15 165 25 224 34 300 30 407 41 ...

Page 28: ...1 N m M20 X 2 5 325 33 ft lb 440 45 N m 450 46 ft lb 610 62 N m Note Reduce the torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as engine oil or a thread sealant such as Loctite Note The torque values must be reduced when installing the fasteners into threaded aluminum or brass The specified torque valu...

Page 29: ...0 ft lb 88 14 N m 1 2 20 UNF Grade 5 80 10 ft lb 108 14 N m M12 X 1 25 Class 8 8 80 10 ft lb 108 14 N m M12 X 1 5 Class 8 8 80 10 ft lb 108 14 N m For steel wheels and non lubricated fasteners Thread Cutting Screws Zinc Plated Steel Threads per Inch Thread Size Type A Type B Baseline Torque No 6 18 20 20 5 in lb No 8 15 18 30 5 in lb No 10 12 16 38 7 in lb No 12 11 14 85 15 in lb The hole size mat...

Page 30: ...ied after fastener installation Most thread locking compounds allow the fastener to be removed with standard tools once cured High strength thread locking compounds may require applying heat to the fastener and the surrounding area to allow fastener removal Note Some fasteners have a dry thread locking compound pre applied Patch Loc so no additional thread locking compound is necessary when instal...

Page 31: ... chemical residue and previously used gaskets or gasket compounds SILICONE SEALANT Designed for a broad variety of sealing and bonding requirements silicone sealants are usually room temperature vulcanizing RTV which form a flexible silicone rubber that bonds to a wide variety of smooth or porous materials when cured Standard silicone sealants are designed to perform in temperatures from 51 F to 2...

Page 32: ...nd components for flow and pressure capacities The tester flow measurement maximum is 57 LPM 15 GPM This tester includes the following Inlet Hose This hose connects the system circuit to the inlet side of the hydraulic tester Load Valve Turn the valve to restrict the flow to create a simulated working load in the circuit Pressure Gauge A glycerine filled pressure gauge 0 to 34 500 kPa 0 to 5 000 p...

Page 33: ... with a gauge rated at 20 to 150 LPM 4 to 40 GPM Note This tester does not include any hydraulic hoses or fittings refer to Hydraulic Hose Kit Toro Part No TOR6007 and Hydraulic Test Fitting Kit Tor Part No TOR4079 Hydraulic O Ring Kit Toro Part No 117 2727 This kit includes O rings in a variety of sizes for the face seal and port seal hydraulic connections To help prevent a hydraulic leak replace...

Page 34: ...9 17 6 ORFS 11 16 16 TOR4079 18 8 ORFS 13 16 16 TOR4079 19 CAP 2 each 10 ORFS 1 14 TOR4079 20 6 ORFS 11 16 16 to 8 SAE ORB 3 4 16 TOR4079 8 8 ORFS 13 16 16 to 8 SAE ORB 3 4 16 TOR4079 9 UNION 1 each 10 ORFS 1 14 to 8 SAE ORB 3 4 16 TOR4079 2 10 ORFS 1 14 to 8 SAE ORB 3 4 16 TOR4079 7 REDUCER 1 each 12 ORFS 1 3 16 12 to 8 SAE ORB 3 4 16 TOR4079 6 4 ORFS 9 16 18 TOR4079 10 6 ORFS 11 16 16 TOR4079 11...

Page 35: ...er to Hydraulic Hose Kit page 2 15 Note The replacement filter element is Toro Part No TOR6012 The filter element canister tightening torque is 34 N m 25 ft lb Remote Starter Switch After flushing the hydraulic system or replacing a hydraulic component e g gear pump piston pump drive motor it is necessary to prime the hydraulic pumps A remote starter switch can be used for this purpose A remote st...

Page 36: ...ems Apply the terminal protector to the connection after you secure the battery cable ring terminal or fork terminal Dielectric Gel Toro Part No 107 0342 Use the dielectric gel to prevent corrosion of unsealed connection terminals To ensure complete coating of the terminals liberally apply the gel to the component and wire harness connector plug the connector into the component unplug the connecto...

Page 37: ...ift arm pivot shaft until it bottoms out 2 Turn sensor shaft out until it aligns with tool 3 Lock sensor shaft in position with jam nut 1 Sensor tool 2 Sensor shaft 3 Jam nut Spring Compression Tool Toro Part No 138 3968 Use with a press to relieve PTO clutch piston spring load during PTO clutch service Outcross 9060 Page 2 19 Specifications and Maintenance Special Tools 18234SL Rev B ...

Page 38: ...Specifications and Maintenance Special Tools Page 2 20 Outcross 9060 18234SL Rev B ...

Page 39: ... 3 6 Using the InfoCenter Display for Troubleshooting 3 23 TRACTION example 3 23 General Hydraulic System Problems 3 26 Traction System Problems 3 27 Steering System Problems 3 30 PTO System Problems 3 31 3 Point Hitch System Problems 3 32 Attachment Loader Problems 3 33 The information In this chapter is intended to help troubleshoot machine operation issues Keep in mind there can be more than on...

Page 40: ...pothesis Narrow down the focus of the problem Assess Performance Ensure you have all the necessary tools for testing Test all potential causes of the failure Reevaluate and create a new hypothesis if necessary Repair Return the unit to service by repairing rebuilding or replacing Solution Confirmation Did the issue go away Was the root cause of the issue correctly repaired Are there any other new ...

Page 41: ...onds 30 second starter time out B2013 START DENIED Fault Active To start Resolve active faults B2016 START DENIED Auxiliary Hydraulic Switch Closed To start Disengage auxiliary hydraulics B2017 START DENIED Three Point Raise or Lower Switch Closed To start Disengage Three Point Raise Lower B2018 START DENIED Inch Mode Switches Closed To start Disengage Inch Mode Switch B2026 ENGINE ADVISORY Speed ...

Page 42: ...ED PTO Switch Closed For attachment change Disengage PTO B24CA ATTACHMENT CHANGE DENIED Auxiliary Hydraulic Switch Closed For attachment change Disengage auxiliary hydraulics B24DA ATTACHMENT ADVISORY Increase ground speed Attachment Increase Ground Speed B24EA ATTACHMENT MODE DENIED Controller Mismatch Attachment Mode Denied Attachment Mismatch between controllers B2503 PTO DENIED Fault Active To...

Page 43: ... STATUS Parked Regeneration Required Parked Regeneration Required See Service Menu B2805 REGEN STATUS Parked Regeneration Required No PTO Parked Regeneration Required PTO disabled B2806 REGEN STATUS Recovery Regeneration Required Recovery Regeneration Required See Service Menu B2807 REGEN STATUS Recovery Regeneration Required No PTO Recovery Regeneraton Required PTO disabled B280A REGEN STATUS Reg...

Page 44: ...eading a voltage outside the range it was designed to operate indicating an open circuit Traction is disabled until ignition key is cycled 1 Use the InfoCenter to verify sensor movement TRACTION INPUTS TR PEDAL SIGNAL 1 2 If no voltage reading is displayed A Check the traction pedal wiring and connector B Test the sensor wiring 3 Test the traction pedal assembly if possible and replace if necessar...

Page 45: ...on is disabled until ignition key is cycled 1 Make sure the decelerator pedal moves freely to its full rest up position 2 Use the InfoCenter to verify neutral switch operation TRACTION INPUTS BRAKE NEUTRAL ON 3 Use the InfoCenter to verify position sensor operation TRACTION INPUTS BRAKE PEDAL SIGNAL 4 If no voltage reading is displayed A Check the decelerator pedal position sensor wiring and conne...

Page 46: ...d replace if necessary P100C Engine Coolant Temperature Above Threshold PTO Disabled Engine coolant temperature has exceeded 105 C 221 F PTO is disabled 1 Allow engine to cool 2 Check fan condition and operation 3 Clear air flow passages 4 Check coolant level and condition adjust and replace as necessary 5 Check temperature sender wiring and connector 6 Test temperature sender and replace if neces...

Page 47: ...TION OUTPUTS FRONT FWD HYDRO 2 If no amperage reading is displayed A Check the traction coil wiring and connector B Test the traction coil wiring 3 Test the traction coil and replace if necessary 4 Replace T1 TEC contact your Authorized Toro Distributor for assistance P1114 Traction Coil front pump reverse valve C2 Overcurrent Overcurrent detected Indicates a short to ground 1 Use the InfoCenter t...

Page 48: ...C Traction Coil rear pump forward valve C1 Validation Failure Current Converge A current monitor which validates the intended traction coil current is indicating an unexpected variance between the desired level of current to the traction coil and the actual level of current to the traction coil Traction is disabled until ignition key is cycled 1 Use the InfoCenter to verify the traction coil opera...

Page 49: ...fy the traction coil operation TRACTION OUTPUTS REAR REV HYDRO 2 If no amperage reading is displayed A Check the traction coil wiring and connector B Test the traction coil wiring 3 Test the traction coil and replace if necessary 4 Replace T1 TEC contact your Authorized Toro Distributor for assistance P113D Traction Coil rear pump reverse valve C2 Validation Failure PWM Converge PWM convergence is...

Page 50: ...mperature Over Temp Hydraulic fluid temperature has exceeded 95 C 203 F Maximum traction speed is reduced 1 Make sure the auxiliary load valve joystick is not stuck in an enable position 2 Reduce traction speed 3 Allow hydraulic fluid to cool below 90 C 194 F P115C Rear Traction Hydraulic Circuit Charge Pressure Low Note If fault P114C is also present a charge circuit issue exists outside of the t...

Page 51: ...dal assembly if possible and replace if necessary P2132 Traction Pedal Analog Sensor APS2 Open Circuit Traction pedal analog sensor APS2 is reading a voltage outside the range it was designed to operate indicating an open circuit Traction is disabled until ignition key is cycled 1 Use the InfoCenter to verify sensor movement TRACTION INPUTS TR PEDAL SIGNAL 2 2 If no voltage reading is displayed A ...

Page 52: ... 3 Test the electric fuel pump 4 Replace the T1 TEC contact your Authorized Toro Distributor for assistance C1014 Engine Run Fuel Pump Output Overcurrent Overcurrent detected in engine run fuel pump output Indicates a short to ground 1 Check the engine run fuel pump output circuit wiring and all of the output circuit connectors 2 Test the engine run fuel pump output circuit wiring 3 Test the elect...

Page 53: ...ance C1093 Warning Buzzer Output Short to Battery Low current detected on warning buzzer output Indicates a short to battery 1 Check the warning buzzer output circuit wiring and all of the output circuit connectors 2 Test the warning buzzer output circuit wiring 3 Test the warning buzzer 4 Replace the T2 TDM contact your Authorized Toro Distributor for assistance C1094 Warning Buzzer Output Overcu...

Page 54: ...rer documentation supplier with brake controller 4 Replace the T1 TEC contact your Authorized Toro Distributor for assistance C10B4 Optional Brake Controller Output Overcurrent Overcurrent detected on optional brake controller output Indicates short to ground 1 Check the optional brake controller output circuit wiring and all of the output circuit connectors 2 Test the optional brake controller ou...

Page 55: ...ut Indicates a short to battery 1 Check the differential lock output circuit wiring and all of the output circuit connectors 2 Test the differential lock output circuit wiring 3 Test the hydraulic solenoid valve SV3 coil 4 Replace the T1 TEC contact your Authorized Toro Distributor for assistance C1454 Differential Lock Output Overcurrent Overcurrent detected on differential lock output Indicates ...

Page 56: ...s because of a short to battery short to ground or an open circuit Cycle the mode selector to LOW and back to HIGH key switch in RUN position to allow the software to determine the fault type C14B3 Range Hi Output Short to Battery Low current detected on range Hi output Indicates a short to battery 1 Check the range Hi output circuit wiring and all of the output circuit connectors 2 Test the range...

Page 57: ...ing and connector 2 Test the pressure sensor wiring 3 Test the pressure sensor if possible and replace if necessary C1524 Rear Hydraulic Pressure Sensor Short to Ground Rear hydraulic pressure sensor is shorted to ground out of range low PTO is disabled and machine enters limp mode after the machine comes to a stop 1 Check rear pressure sensor right side of traction pump wiring and connector 2 Tes...

Page 58: ...witch 3 Test the optional InchMode raise lower switch circuit wiring B1127 Optional InchMode Forward Reverse Switch Broken Both INCH MODE INPUTS INCH MODE FWD and INCH MODE INPUTS INCH MODE REV are active at the same time InchMode traction control is disabled 1 Check the optional InchMode forward reverse switch circuit wiring and all the circuit connectors 2 Test the optional InchMode forward reve...

Page 59: ...wer supply to T2 TDM A Test fuse F A4 2A B Test T2 TDM supply and ground circuit wiring 2 Test external CAN bus termination resistor 3 Test CAN bus resistance U012B CAN Bus Communication Fault Expansion Port example T3 InchMode option Optional InchMode feature shifts from an ACTIVE state to a PENDING state and InchMode control box switches are disabled 1 Check power supply to expansion port A Test...

Page 60: ...istance U1308 Software Version Incompatibility T2 TDM T2 TDM software is incompatible Machine is disabled Update machine software contact your Authorized Toro Distributor for assistance U1309 Software Version Incompatibility Expansion Port example T3 InchMode option Expansion Port example T3 InchMode option software is incompatible Machine is disabled Update machine software contact your Authorize...

Page 61: ...age does not change during component operation the component or its circuit wiring is faulty and should be tested refer to Electrical Component Testing page 6 14 and Appendix A page A 1 Note means no signal from the input is available and the input or its circuit wiring should be tested When the correct inputs are received by the controllers the outputs identified on the Output screen should show ...

Page 62: ...ne is running and the vehicle is in motion both FRONT and REAR TRACTION should display approximately the same pressure due to the traction pressure compensation feature If not one of the pressure sensors or its circuit wiring may be faulty and should be tested or the traction pressure compensation software may require reloading or replacement Contact your Authorized Toro Distributor for assistance...

Page 63: ...d be tested When the engine is running and the vehicle is stationary switching the parking brake switch ON and OFF toggles the PBRAKE DISENGAGE ON and OFF If the output reading is appropriate and the vehicle does not perform correctly the solenoid valve SV2 or its circuit wiring may be faulty and should be tested Switching the parking brake switch ON and OFF toggles the PBRAKE LIGHT ON and OFF If ...

Page 64: ...ction line The hydraulic fluid is contaminated or the fluid viscosity is too light Replace the hydraulic fluid Note Refer to the traction unit Operator s Manual for hydraulic fluid specifications The hydraulic fluid cooler is damaged or plugged Repair or replace the hydraulic fluid cooler The fluid cooler air flow is obstructed Verify cooling fan operation and remove debris from in and around the ...

Page 65: ...tionary Note If a traction circuit component has internal wear or damage it is possible that the other traction components are also damaged The traction pump is worn or damaged Verify traction pump operation refer to Traction Pump P1 and P2 Tests in the Hydraulic System chapter of this manual The traction response is sluggish The drive axle motor is worn or damaged Repair or replace the drive axle...

Page 66: ... traction pump relief valves are leaking or damaged Clean or repair the piston traction pump relief valves The traction pump is worn or damaged Verify traction pump operation refer to Traction Pump P1 and P2 Tests in the Hydraulic System chapter of this manual The drive axle motor is worn or damaged Repair or replace the drive axle motor No traction exists in either direction Note If a traction ci...

Page 67: ...ace the valve solenoid if necessary Test the machine wire harness solenoid valve SV3 circuit Solenoid valve SV3 in the main manifold is leaking or faulty Clean the solenoid valve and replace the seals The differential lock will not engage Replace solenoid valve if necessary Outcross 9060 Page 3 29 Troubleshooting Traction System Problems 18234SL Rev B ...

Page 68: ...place the seals Replace relief valve if necessary Steering priority valve EC1 in the main manifold is faulty Clean the relief valve and replace the seals Replace the priority valve if necessary Steering is sluggish operates poorly or is inoperative Steering control valve is worn or damaged Rebuild or replace the steering control valve Turning steering wheel turns wheels in the wrong direction Hydr...

Page 69: ...e solenoid if necessary Test the machine wire harness proportional solenoid valve EH circuit Proportional solenoid valve EH in the main manifold is stuck leaking or faulty Clean the solenoid valve and replace the seals The PTO shaft will not engage Replace the solenoid valve if necessary Outcross 9060 Page 3 31 Troubleshooting PTO System Problems 18234SL Rev B ...

Page 70: ...t in the Hydraulic System chapter of this manual Proportional solenoid valve SP1 SP2 or check valve CV2 in the main manifold is stuck leaking or faulty Clean the valve s and replace the seals Replace the valve s if necessary Hitch cylinders raise but will not stay up NOTE Hitch cylinders cannot provide an absolutely perfect seal The lift arms will eventually lower if left supporting an attachment ...

Page 71: ...ydraulic hoses to the steering cylinders are connected incorrectly Correct hydraulic hose connections A mechanical problem exists with the loader cylinder that affects operation example binding or worn pivots arms linkage or couplings Inspect loader components and repair or replace if necessary Relief valve in auxiliary load valve is stuck leaking or damaged Clean the relief valve and replace the ...

Page 72: ...ted as well Adjust the hydraulic fluid level Gear pumps P3 and P4 are noisy from cavitation steering traction charge lift circuit and attachment circuit performance is affected The suction filter or suction line is damaged loose or clogged Secure clean or replace the suction filter or suction line Troubleshooting Attachment Loader Problems Page 3 34 Outcross 9060 18234SL Rev B ...

Page 73: ...nic Control Unit ECU 4 3 Yanmar Engine 4 4 Diesel Particulate Filter 4 5 Service and Repairs 4 8 Air Cleaner System 4 8 Exhaust System 4 10 Radiator 4 11 Fuel System 4 14 Engine 4 17 Flywheel Housing and Drive Coupler 4 23 Additional Reference Materials Yanmar TNV Tier 4 Series Service Manual Yanmar TNV Tier 4 Series Troubleshooting Manual Outcross 9060 Page 4 1 Engine 18234SL Rev B ...

Page 74: ...traction unit Parts Catalog for this machine are available at www toro com Traction Unit Operator s Manual The traction unit Operator s Manual provides information regarding basic engine operation general engine maintenance and engine maintenance intervals for your machine Refer to the traction unit Operator s Manual for additional information Yanmar Service and Troubleshooting Manuals The engine ...

Page 75: ...U program If engine electrical components are replaced on the engine the Yanmar SmartAssist Direct tool SA D must be used to update the ECU program to ensure correct engine operation The Yanmar SA D connector is located near the engine ECU under the dash cover in the passenger foot well If the engine ECU identifies that an engine problem exists an engine fault will be displayed on the T2 TDM scree...

Page 76: ...rbocharger Glow plugs are used to assist starting the engine Numerous engine sensors are used to allow the ECU to monitor and control the engine operation for optimum engine performance During the operation of the engine if conditions warrant the ECU may generate an engine fault refer to Machine and Engine Faults page 3 6 Use the Yanmar TNV Tier 4 Series Troubleshooting Manual and the Yanmar Smart...

Page 77: ...chine Regeneration The engine ECU monitors the exhaust pressure before and after the soot filter in the DPF to determine if soot is accumulating If soot is accumulating during normal engine operation the pressure differential will increase The increase in pressure will signal the engine to begin a process called regeneration Regeneration increases the exhaust temperature and the length of time the...

Page 78: ...s because of prolonged operation at low engine speed low engine load or when the engine ECU detects the soot filter is becoming obstructed The engine ECU adjusts the exhaust intake throttle to raise the exhaust temperature The InfoCenter does not display an icon during assist regeneration Reset Occurs every 100 hours of engine operation Occurs after an assist regeneration if the engine ECU determi...

Page 79: ... requested Can only be initiated when prompted by the engine ECU The InfoCenter displays the stationary regeneration icon Manually initiate a recovery regeneration as soon as possible A recovery regeneration will take approximately 3 hours and should not be started with less than 1 2 tank of fuel The machine must remain stationary cannot be operated during the entire recovery regeneration process ...

Page 80: ... 6 Air cleaner inlet hose 12 Carriage screw 2 each Removing and Installing the Air Cleaner System Note Refer to the traction unit Operator s Manual for maintenance procedures and intervals of the air cleaner 1 Remove the air cleaner components as necessary 2 Examine the air cleaner assembly for wear or damage that could possibly cause air leaks Engine Service and Repairs Page 4 8 Outcross 9060 182...

Page 81: ...damage and replace the seals if necessary IMPORTANT Leaks in the air filter system will allow dirt to enter the engine and can cause serious engine damage Ensure that all the air cleaner components are in good condition and are properly secured during installation 5 Assemble the air cleaner components as shown in Figure 10 Outcross 9060 Page 4 9 Engine Service and Repairs 18234SL Rev B ...

Page 82: ...culate Filter page 4 5 Reconditioning the soot filter SF may be necessary over the life of the machine which will require exhaust system disassembly Soot filter reconditioning should be done by a company that has the necessary equipment Contact your Toro Distributor for information on reconditioning the soot filter The diesel oxidation catalyst DOC has a service life expectancy and requires replac...

Page 83: ... Radiator The radiator on your Outcross 9060 is combined with the hydraulic fluid cooler The procedure for removing and installing the radiator and hydraulic fluid cooler as an assembly is provided Note If desired the radiator and hydraulic fluid cooler may be separated from each other in the machine and removed individually Removing the Radiator and Hydraulic Fluid Cooler 1 Park the machine on a ...

Page 84: ...ulic fluid cooler and move the fuel cooler out of the way 7 Remove the top nut plate top bracket isolator mount and the fan shrouds 8 Carefully remove the radiator and hydraulic fluid cooler assembly from the machine 9 If necessary remove the hydraulic fittings from the hydraulic fluid cooler and discard the O rings 10 Cover or plug the openings in the hydraulic fluid cooler and radiator to preven...

Page 85: ...ervoir hose to the radiator and secure the hoses with the hose clamps 9 Fill the reservoir with coolant refer to the traction unit Operator s Manual 10 Add hydraulic fluid to the hydraulic reservoir as necessary refer to the traction unit Operator s Manual 11 Start the engine and check for coolant and hydraulic fluid leaks Repair any leaks as required 12 Continue to run the engine to obtain the op...

Page 86: ... 18 Fuel hose fuel cooler to tank 28 Fuel filter 9 Fuel hose separator head to fuel pump 19 Cap screw 3 each 10 Electric fuel pump 20 Clamp 3 each The fuel system includes a fuel tank with an electric fuel level sender on the right side of the machine a fuel water separator and a low pressure electric fuel pump located behind the fuel tank a fuel filter a mechanical high pressure fuel pump at the ...

Page 87: ...ngs as necessary Priming the Fuel System The fuel system needs to be primed before starting the engine for the first time after running out of fuel or after fuel system maintenance e g draining the fuel water separator replacing the fuel filter or disconnecting a fuel hose IMPORTANT Do not turn the key switch to the START position to prime the fuel system To prime the fuel system 1 Ensure that the...

Page 88: ... from the fuel tank 9 Cover or plug the fuel hoses or fitting openings to prevent contamination from entering the fuel system 10 Lower the tank and support bracket to the ground Separate the tank and bracket by removing the 3 clamps if necessary 11 If the fuel level sender is removed use a new gasket when installing the fuel sender 12 If the elbow fittings are removed from the fuel water separator...

Page 89: ...face lower any attachments shut off the engine and remove the key from the key switch 2 Disconnect the battery refer to Removing the Battery page 6 81 3 Remove the front screen refer to Removing and Installing the Front Screen page 8 3 4 Remove the hood refer to Removing and Installing the Hood page 8 5 5 Remove the air cleaner assembly refer to Removing and Installing the Air Cleaner System page ...

Page 90: ...in the coolant when the radiator or engine is hot WARNING Ethylene glycol antifreeze is poisonous Keep the coolant away from children and pets Keep the coolant in a labelled container Discard the coolant in accordance with local hazardous waste ordinances 8 Disconnect the reservoir hose at the radiator and remove the coolant reservoir assembly 9 Drain the coolant from the radiator 10 Disconnect th...

Page 91: ...rbox Plug the hydraulic lines and cap the fittings to prevent contamination from entering the hydraulic system 19 Disconnect the PTO drive shaft at the front hub and slide the drive shaft rearward 20 Disconnect the battery positive cable at starter solenoid and the engine ground cable near the left rear engine mount CAUTION Make sure that the hoist or lift and load leveling bar used to remove the ...

Page 92: ...ngine mount rear 2 each 4 Bracket front right 10 Bolt front 2 each 16 Flange nut 2 each 5 Lock washer 8 each 11 Flange head screw 17 Wire harness bracket 6 Cap screw 8 each 12 Wire harness bracket 18 Cap screw 22 Remove lock nuts snubbing washers and cap screws securing the engine mounts to the engine brackets CAUTION Use 1 person to operate the lift or hoist while the other person guides the engi...

Page 93: ...ine IMPORTANT Ensure that all parts are removed from the engine during maintenance or overhaul are correctly installed on the engine 1 If front engine mount brackets were removed from the engine tighten the bracket to engine fasteners from 46 to 57 N m 34 to 42 ft lb 2 Apply anti seize lubricant to the hydraulic pump drive coupler the gearbox output shaft and the pump input shaft Install the drive...

Page 94: ...cure the fuel hoses with hose clamps refer to Fuel System page 4 14 13 Install the air cleaner assembly refer to Removing and Installing the Air Cleaner System page 4 8 Note New radiator drain plugs are pre coated with thread sealant Clean the threads and apply thread sealant if installing a used drain plug 14 Ensure the radiator drain plug is installed and fill the radiator and reservoir with coo...

Page 95: ...onents as necessary 2 Position the drive coupler to the engine flywheel and align mounting holes Ensure that the coupler hub is away from the engine flywheel as shown 3 Use medium strength thread locking compound and secure the coupler to the engine flywheel with eight 8 cap screws and hardened washers Tighten cap screws in a crossing pattern from 23 to 28 N m 17 to 21 ft lb 4 Position flywheel ho...

Page 96: ...Engine Service and Repairs Page 4 24 Outcross 9060 18234SL Rev B ...

Page 97: ...nd Relief Valve Tests 5 37 Steering Hitch Cylinder Circuit Testing Steering Relief Valve RV1 Pressure Test 5 38 Steering Hitch Cylinder Circuit Testing Hitch Cylinder Test 5 40 Steering Hitch Cylinder Circuit Testing Hitch Cylinder Relief Valve RV2 Pressure Test 5 41 Steering Hitch Cylinder Circuit Testing Gear Pump P4 Flow Test 5 43 Attachment Loader Circuit Testing Relief Valve Pressure Test 5 4...

Page 98: ... Load Valve Service 5 105 Front Loader Control Valve 5 106 Front Loader Control Valve Service 5 108 Selector Control Valve Manifolds optional 5 109 Selector Control Valve Manifold optional Service 5 111 Additional Reference Materials Danfoss H1 Closed Circuit Axial Piston Pumps Service Manual Danfoss H1 Closed Circuit Axial Piston Pumps Repair Instructions Danfoss K and L Frame Variable Motors Ser...

Page 99: ...achine on an incline or slope the pressure in the traction circuit does not release 1 Move the machine to a level surface 2 Lower any attachments fully 3 Turn the key switch to the OFF position and allow the engine to stop 4 Make sure all electrically operated control valves are actuated by setting the key switch to the RUN position but Do Not start the engine 5 Slowly move the auxiliary load valv...

Page 100: ... and the hydraulic brake circuit must be manually pressurized to release the brake Move the machine at a speed below 3 2 kph 2 mph and for a very short distance If the machine needs to be moved more than a short distance the machine should be transported on a trailer IMPORTANT Do not start or run the engine when the valves are set to the bypass position 1 Remove the access panel from the right sid...

Page 101: ...tal 3 To release the brake lift and hold the manual valve while pumping the hand pump 4 Pump the hand pump until resistance is felt When enough pressure has been created the manual valve will remain in the raised position and the brake will be released 5 After towing and before starting the engine insert a 6 mm hex wrench through the valve plug and turn the plunger all the way out counterclockwise...

Page 102: ...ter Kit page 2 17 If a traction circuit failure is suspect the filter should be installed before connecting hydraulic test gauges to test traction circuit components or after replacing a failed traction circuit component The filter will ensure that contaminates are removed from the closed loop traction circuit and thus prevent additional component damage Refer to Filtering the Closed Loop Traction...

Page 103: ... refer to Relieving Pressure from the Hydraulic System page 5 3 Keep your body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Do not use your hands to search for leaks use a piece of paper or cardboard Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury If hydraulic fluid is injected into you...

Page 104: ...leeve fully touches the O ring in the fitting Figure 19 4 Use your hand to thread the swivel nut onto the fitting While you hold the hose tube in alignment with a wrench use a torque wrench to tighten the swivel nut to the recommended torque value within the specified range of torque values refer to the Hose Tube Installation Torque Table page 5 9 This procedure to tighten the swivel nut requires ...

Page 105: ...ch 1 2 to 3 4 8 1 2 inch 1 2 to 3 4 10 5 8 inch 1 2 to 3 4 12 3 4 inch 1 3 to 1 2 16 1 inch 1 3 to 1 2 5 If a torque wrench is not available or if space at the swivel nut prevents the use of a torque wrench use the alternative procedure Flats From Wrench Resistance FFWR given below A Use a wrench to tighten the swivel nut onto the fitting until you feel light resistance with the wrench approximate...

Page 106: ...ench and socket to tighten the fitting to the recommended torque value within the specified range of torque values refer to the Fitting Installation Torque Table page 5 12 Note It may be necessary to use a drive adapter wrench e g crowfoot wrench to install a hydraulic fitting refer to Calculating the Torque Values When Using a Drive Adapter Wrench page 2 7 5 If a torque wrench is not available or...

Page 107: ...t as far as possible Ensure that the back up washer is not loose and it is pushed up as far as possible Step 1 in Figure 23 5 Install the adjustable fitting into the port by hand until the washer contacts the face of the port Step 2 in Figure 23 6 If the adjustable fitting needs to align with another component rotate the fitting counterclockwise until it is aligned to the desired position Step 3 i...

Page 108: ...nger Tight FFFT Table page 5 12 Fitting Installation Torque Table Fitting Dash Size Fitting Port Side Thread Size inch threads per inch Installation Torque Into Steel Port Installation Torque Into Aluminum Port 4 7 16 20 21 to 25 N m 15 to 19 ft lb 13 to 15 N m 9 to 11 ft lb 5 1 2 20 25 to 29 N m 18 to 22 ft lb 15 to 20 N m 11 to 15 ft lb 6 9 16 18 47 to 56 N m 34 to 42 ft lb 28 to 35 N m 20 to 26...

Page 109: ...Hydraulic Schematic The hydraulic schematic for the Outcross 9060 machine is located in Appendix A page A 1 Outcross 9060 Page 5 13 Hydraulic System Hydraulic Schematic 18234SL Rev B ...

Page 110: ...Hydraulic Flow Diagrams Traction Circuit g235767 Traction Circuit Diagram AUTO HIGH Forward Hydraulic System Hydraulic Flow Diagrams Page 5 14 Outcross 9060 18234SL Rev B ...

Page 111: ...ed to the pump electro hydraulic servo piston assembly Pushing the traction pedal rotates a hall effect sensor that provides an input to the T1 TEC The T1 TEC sends a corresponding PWM Pulse Width Modulation output signal to the displacement control valve solenoids to move the pump swash plate accordingly and control the pump s output volume vehicle speed and traction control Traction circuit pres...

Page 112: ...s and drive axle motors use a small amount of hydraulic fluid for internal lubrication Fluid is designed to leak across the pump and motor parts and into the component case drain The tandem piston traction pump drains from its L3 port back to the hydraulic tank The drive motors drain from their L1 ports back to the hydraulic tank Each drive motor also includes a shuttle valve to increase the amoun...

Page 113: ... pump can be viewed while the vehicle is stationary using the InfoCenter SERVICE TRACTION TRACTION INPUTS FRONT TRACTION and REAR TRACTION readings Charge pressure can also be measured at the charge pressure test port located near the charge filter assembly Measured pressure should be approximately 2 068 kPa 300 psi Outcross 9060 Page 5 17 Hydraulic System Hydraulic Flow Diagrams 18234SL Rev B ...

Page 114: ...Steering Circuit g235914 Steering Circuit Diagram neutral position Hydraulic System Hydraulic Flow Diagrams Page 5 18 Outcross 9060 18234SL Rev B ...

Page 115: ...g235915 Steering Circuit Diagram turning to the right Outcross 9060 Page 5 19 Hydraulic System Hydraulic Flow Diagrams 18234SL Rev B ...

Page 116: ...ion at rest and the engine is running hydraulic fluid from gear pump P4 enters the main manifold port P flows through the steering priority valve EC1 and is routed to the steering valve where it dead heads at the control valve spool Fluid is also sent to both ends of the steering priority valve EC1 spool On one end of the spool fluid is directed to both the steering relief valve RV1 and also to or...

Page 117: ...ng valve returns to the neutral position when the steering wheel is released or turning is completed Steering Relief Operation When the steering cylinders reach the end of their stroke or if a wheel should encounter an obstruction e g a curb while steering the pressure in the steering circuit will rise When steering circuit pressure rises to approximately 20 684 kPa 3000 psi relief valve RV1 in th...

Page 118: ...Hitch Cylinder Circuit g236340 Hitch Cylinder Circuit Diagram raising Hydraulic System Hydraulic Flow Diagrams Page 5 22 Outcross 9060 18234SL Rev B ...

Page 119: ...nfigured to control the 3 point hitch automatically The gear pump section furthest from the piston pump gear pump section P4 supplies fluid to a variety of circuits including the hitch lift circuit Hydraulic fluid from gear pump P4 enters the main manifold port P and flows through the steering priority valve EC1 refer to Steering Circuit page 5 18 for a full explanation of the steering priority va...

Page 120: ...e RV2 opens to prevent circuit pressure from exceeding 20 684 kPa 3000 psi Note The maximum height the hitch arms can raise may be limited by the programmable attachment settings or by the bed active switch when an optional cargo box is installed Hold When the hitch paddle is released solenoid valve SP1 is de energized and the hydraulic fluid behind the cylinder piston is trapped to hold the cylin...

Page 121: ...draulic pressure available When the engine is running and the parking brake switch is set to ENGAGE position solenoid valve SV2 in the main manifold is de energized and hydraulic flow bypasses the brake circuit The brake remains engaged by the springs inside the brake assembly When the engine is running and the parking brake switch is set to the DISENGAGE position solenoid valve SV2 is energized a...

Page 122: ...Differential Lock Circuit g237540 Differential Lock Circuit Diagram engaged Hydraulic System Hydraulic Flow Diagrams Page 5 26 Outcross 9060 18234SL Rev B ...

Page 123: ...P1 Fluid is also sent to one end of the flow regulator valve EC2 spool As long as circuit flow is blocked at solenoid valve SP1 the flow regulator valve EC2 spool is shifted to direct flow to the traction charge 2 speed drive motor control brake release differential lock and PTO clutch circuits When the differential lock switch is set to the DISENGAGE position solenoid valve SV3 in the main manifo...

Page 124: ...PTO Clutch Circuit g237541 PTO Circuit Diagram engaged Hydraulic System Hydraulic Flow Diagrams Page 5 28 Outcross 9060 18234SL Rev B ...

Page 125: ...ked at solenoid valve SP1 the flow regulator valve EC2 spool is shifted to direct flow to the traction charge 2 speed drive motor control brake release differential lock and PTO clutch circuits When the PTO switch is set to the DISENGAGE position proportional solenoid valve EH in the main manifold is de energized and hydraulic flow bypasses the PTO clutch circuit Return springs on both sides of th...

Page 126: ...AL positions flow is directed to supply line A Return flow from supply line B is allowed to return to the hydraulic tank When the auxiliary load valve is in the NEUTRAL HOLD position flow bypasses the attachment supply lines A and B The flow either returns to the hydraulic tank or is made available to supply the hydraulic demands of the optional loader Return flow from both attachment supply lines...

Page 127: ...Front Loader Circuit g262210 Front Loader Circuit Diagram arms raising Outcross 9060 Page 5 31 Hydraulic System Hydraulic Flow Diagrams 18234SL Rev B ...

Page 128: ...he loader valve and is directed as follows based on the loader valve position When the loader control valve is in the NEUTRAL HOLD position flow bypasses the 2 loader lift supply lines and the 2 loader bucket supply lines In this position the hydraulic flow passes through the valve and returns to the hydraulic tank Return flow from the loader lift and bucket supply lines is blocked When the loader...

Page 129: ...SCV kit solenoid valves are de energized the right side set of hydraulic quick disconnect couplers standard are active and the No 1 Hydraulic Circuit icon appears on the InfoCenter display When the SCV kit solenoid valves are energized the left side set of hydraulic quick disconnect couplers supplied with kit are active and the No 2 Hydraulic Circuit icon appears on the InfoCenter display Loader f...

Page 130: ...o not use your hands to search for leaks use a piece of paper or cardboard Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury If hydraulic fluid is injected into your skin the fluid damage to your body must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result CAUTION Failing to us...

Page 131: ...erformance parameters aprox 3 per 100 engine rpm at full throttle IMPORTANT Hydraulic component output volume relates directly to engine RPM For every 100 engine rpm the following component output volumes will change by the volume listed Traction Pump 100 engine RPM 3 8 liters 1 gallon or 129 ounces of hydraulic fluid displaced per minute Gear Pump P3 100 engine RPM 1 7 liters 0 45 gallon or 57 ou...

Page 132: ...12 Record the results of all hydraulic tests performed Hydraulic System Testing the Hydraulic System Page 5 36 Outcross 9060 18234SL Rev B ...

Page 133: ...t reading to the charge pressure while the traction pump is under a moderate load swash plates open Charge pressure under no load at each traction piston pump can be viewed while the vehicle is stationary using the InfoCenter SERVICE TRACTION TRACTION INPUTS FRONT TRACTION and REAR TRACTION readings A procedure for checking the charge pressure while the traction pump is under load for this machine...

Page 134: ... hydraulic oil is at normal operating temperature by operating the machine for approximately ten 10 minutes 2 Park the machine on a level surface lower the attachments and stop the engine Remove the key from the key switch 3 Make sure the hydraulic tank is full 4 Open the main instrument panel Hydraulic System Testing the Hydraulic System Page 5 38 Outcross 9060 18234SL Rev B ...

Page 135: ...ached to test fitting in port G3 port of main manifold 9 Start engine and idle at low speed Check for hydraulic leakage at test connection and correct any issues before proceeding with test 10 Increase engine speed to 2300 RPM IMPORTANT Hold steering wheel at full lock only long enough to get a system pressure reading Holding the steering wheel against the stop for an extended period may damage st...

Page 136: ... Adjusting the Manifold Relief Valves page 5 48 D Clean repair or replace relief valve RV1 refer to Cartridge Valve Service page 5 88 14 When testing is complete disconnect pressure gauge from manifold and install the test fitting cap Steering Hitch Cylinder Circuit Testing Hitch Cylinder Test There are 2 cylinders involved with raising the hitch The hitch is lowered by weight and is not powered d...

Page 137: ...h cylinder lift stroke is limited electrically on machines with an optional cargo bed installed 1 Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten 10 minutes 2 Park the machine on a level surface lower the attachments and stop the engine Remove the key from the key switch 3 Make sure the hydraulic tank is full 4 Open the main instrument pane...

Page 138: ...o test fitting in port G3 port of main manifold 9 Start the engine and idle at low speed Check for hydraulic leakage at test connection and correct any issues before proceeding with test 10 Select AUTO LOW mode and increase engine speed to 2300 RPM IMPORTANT Hold paddle switch at full raise position only long enough to get a system pressure reading Holding the paddle switch at full raise position ...

Page 139: ...ump flow testing compares the gear pump flow under no load with the gear pump flow under load Previous gear pump flow tests involve installing a flow meter at or near the gear pump outlet Access to the gear pump P4 outlet of this machine is difficult and a procedure for checking the gear pump P4 flow is being developed for this machine Contact your local Toro Distributor for assistance Attachment ...

Page 140: ...speed to 2300 RPM 5 Shift the auxiliary load valve into the A position rearward 6 The pressure gauge reading should be 20 684 to 24 131 kPa 3000 to 3500 PSI 7 Release the joystick stop the engine and record the test results 8 If circuit relief pressure reading is incorrect clean repair or replace the auxiliary load valve relief valve refer to Auxiliary Load Valve Service page 5 105 9 After testing...

Page 141: ...e g attachment performance issues or the loader stalling when lifting heavy loads Continued operation with a worn inefficient gear pump can generate excessive heat and cause damage to seals and other components in the hydraulic system IMPORTANT To prevent hydraulic tester damage use a 57 LPM 15 GPM Hydraulic Tester pressure and flow and additional hoses and fittings for this test refer to Special ...

Page 142: ...w direction indicator on the tester is installed so the oil will flow from the disconnected hydraulic hose through the tester and into the auxiliary load valve P fitting 5 Install 15 GPM hydraulic tester flow and pressure in series with the disconnected hose and hydraulic fitting 6 Make sure the flow control valve on the tester is fully open 7 Start engine and increase engine speed to high idle sp...

Page 143: ... or damaged and should be service or replaced Note Gear pumps P3 and P4 must be serviced or replaced together 13 The hydraulic tester can be used to test the circuit relief pressure A Disconnect any attachment from the rear hydraulic supply lines B Make sure the flow control valve on the tester is fully open C Start engine and increase engine speed to 2300 RPM D Shift the auxiliary load valve into...

Page 144: ...hine on a level surface lower the attachments disengage the PTO and stop the engine Remove the key from the key switch 2 Locate the desired relief valve on the main manifold 3 Remove the cap on the relief valve with a hex key Allen wrench 4 To increase the pressure setting turn the adjustment socket on the valve in a clockwise direction A 1 8 turn on the socket will make a measurable change in pre...

Page 145: ...Relieving Pressure from the Hydraulic System page 5 3 5 The hydraulic fluid may be hot Be careful when you loosen and remove the hydraulic system components 6 Install clean caps or plugs on the hydraulic lines hydraulic fittings and components that are left open or exposed to prevent hydraulic system contamination Cap the opening as soon as the line or port is exposed After Repairing or Replacing ...

Page 146: ...ned from the pumps system drain flush or pump removal installation it is important to properly prime the hydraulic pumps refer to Priming the Hydraulic Pumps page 5 58 7 After you disconnect or replace any hydraulic component operate the machine functions slowly until the air is out of the system refer to Charging the Hydraulic System page 5 59 8 Check for hydraulic fluid leaks Shut off the engine...

Page 147: ...t high pressure hydraulic fluid Use a piece of cardboard or paper to find hydraulic leaks Release all pressure in the hydraulic system before performing any work on the system Seek immediate medical attention if hydraulic fluid is injected into your skin IMPORTANT Check the hydraulic lines and hoses daily for leaks kinked lines loose mounting supports wear loose fittings weather deterioration and ...

Page 148: ...c fluid to warm the fluid before draining IMPORTANT Follow all local codes and regulations when recycling or disposing the hydraulic fluid and filters 3 Drain the hydraulic tank into a suitable container refer to the traction unit Operator s Manual 4 Drain the hydraulic system hoses tubes lift cylinders and other components from low points in the system 5 Remove and replace the hydraulic fluid fil...

Page 149: ...ty of new hydraulic fluid refer to the traction unit Operator s Manual 9 Prime the hydraulic pumps refer to Priming the Hydraulic Pumps page 5 58 10 Charge the hydraulic system refer to Charging the Hydraulic System page 5 59 Outcross 9060 Page 5 53 Hydraulic System Service and Repairs 18234SL Rev B ...

Page 150: ...e motor is required to prevent debris from transmitting throughout the system If a filtering tool is not used to ensure system cleanliness repeat failures and subsequent damage to other hydraulic components in the system will occur To effectively remove contamination from the closed loop traction circuit use of a Toro bidirectional high flow hydraulic filter and hydraulic hose kit is recommended r...

Page 151: ...Front drive motor 2 M1 port A If the front drive motor was serviced or replaced disconnect the hydraulic hose at the M1 port left of the front drive motor g262334 Figure 35 Rear Circuit Connection 1 Rear drive motor 2 M1 port Outcross 9060 Page 5 55 Hydraulic System Service and Repairs 18234SL Rev B ...

Page 152: ...ront traction pump P1 failed disconnect the hydraulic hose at the B port middle right of the tandem piston traction pump E If the rear drive circuit is contaminated because rear traction pump P2 failed disconnect the hydraulic hose at the D port middle left of the tandem piston traction pump 5 Connect the temporary hydraulic filter in series between the disconnected fitting and hose Use a High Flo...

Page 153: ...hydraulic filter that is not bidirectional do not select reverse or operate the machine in the reverse direction If flow is reversed when using a filter that is not bidirectional debris from the filter will re enter the traction circuit 9 With a bidirectional hydraulic filter installed and the engine running at high idle speed alternately select forward and reverse direction Continue this process ...

Page 154: ... refer to the traction unit Operator s Manual g237772 Figure 37 1 Starter motor solenoid 2 START terminal Note A blue wire connects to the starter motor solenoid START terminal It is not necessary to remove this blue wire from the solenoid terminal for hydraulic pump priming 3 Access the terminals on the back of the starter motor 4 Connect remote starter switch electrical leads to the starter moto...

Page 155: ...ts 5 Prime the hydraulic pumps refer to Priming the Hydraulic Pumps page 5 58 WARNING Review and follow Jacking Instructions page 1 8 before jacking up the machine 6 Raise the wheels off the floor and support the machine with jack stands IMPORTANT Check hydraulic tank fluid level frequently while charging the system and add fluid as necessary 7 Start the engine and let it idle at low speed Note Th...

Page 156: ...nts or a front loader operate the attachment controls to fully cycle the attachment a few times 12 Operate the traction unit by gradually increasing its work load to full over a ten 10 minute period 13 Stop the machine check the hydraulic components for leaks and tighten any loose connections 14 Check the level and condition of the hydraulic fluid and adjust if necessary refer to the traction unit...

Page 157: ...amp 16 Cap screw 2 each 27 Elbow fitting 6 Hydraulic hose breather from rear PTO gear box 17 Plug 28 Elbow fitting 7 Straight barb fitting 18 Temperature sender 29 Hydraulic hose return from front PTO gear box 8 Hose clamp 2 each 19 Hydraulic hose from main filter 30 Hose clamp 9 Breather hose 20 Hose clamp 31 Straight barb fitting 10 Adapter fitting 21 Strainer assembly 32 Cap screw 2 each 11 Bre...

Page 158: ...lic system 6 Remove the 4 cap screws and flange nuts and remove the hydraulic tank from the machine 7 Remove the hydraulic fittings as necessary and discard O rings 8 To install the hydraulic tank follow this procedure in reverse order 9 Lubricate new O rings and place them onto the fittings If previously removed install the fittings into the tank ports using alignment marks made during removal re...

Page 159: ...e top 19 Hydraulic fluid cooler 6 Flange head screw 4 each 13 Fan shroud left 20 Pipe plug 7 Panel fastener 2 each 14 Bulb seal 2 each 21 Radiator The hydraulic fluid cooler on your Outcross 9060 is combined with the radiator The procedures for removing and installing the radiator and hydraulic fluid cooler as an assembly are provided refer to Radiator page 4 11 Note If desired the radiator and hy...

Page 160: ...draulic System Components page 5 49 prior to removing hydraulic system components 1 Remove the operator platform refer to Removing the Operator s Platform page 8 6 2 Drain the hydraulic tank into a suitable container refer to the traction unit Operator s Manual 3 Remove the auxiliary load valve refer to Removing the Auxiliary Load Valve page 5 103 4 Remove the front loader control valve if equippe...

Page 161: ...draulic hoses for proper reassembly 12 Mark the fitting orientation to allow for correct assembly then remove the fittings from the gear pump and discard the O rings 13 Remove the 2 cap screws and plain washers that secure the gear pump to the piston pump and slide the gear pump rearward and out of the machine 14 Plug the gear pump ports then locate and discard the O ring between the gear pump and...

Page 162: ...the front PTO gear box with 2 plain washers and cap screws Tighten the cap screws from 153 to 188 N m 113 to 139 ft lbs 5 Apply clean petroleum jelly or light grease to a new O ring item 7 in Figure 29 and position the O ring onto the gear pump flange 6 Apply anti seize lubricant to the splines of the gear pump shaft Align the gear pump shaft and slide the gear pump into the piston pump coupler 7 ...

Page 163: ...d Valve page 5 103 17 Install the operator platform refer to Installing the Operator s Platform page 8 13 18 Replace the hydraulic filters 19 Fill the hydraulic reservoir with new hydraulic oil 20 Prime the hydraulic pump refer to Priming the Hydraulic Pumps page 5 58 21 Charge the hydraulic system refer to Charging the Hydraulic System page 5 59 22 Stop engine then check for and correct any hydra...

Page 164: ...Tandem Piston Traction Pump P1 and P2 Service g242412 Figure 42 Hydraulic System Service and Repairs Page 5 68 Outcross 9060 18234SL Rev B ...

Page 165: ...h O ring 2 each 56 O ring 4 each 15 O ring 4 each 36 Screw 12 each 57 O ring 4 each 16 Piston ring 4 each 37 Roller bearing assembly 2 each 58 SCR valve plug 4 each 17 Plug with O ring 2 each 38 Retaining ring 59 Gasket 2 each 18 Plug with O ring 4 each 39 Lip seal 60 Valve plate CCW 19 O ring 4 each 40 O ring 61 Pin 2 each 20 Servo Cylinder 4 each 41 Shaft seal 62 Shaft rear 21 Locking plate 2 ea...

Page 166: ...lic tank into a suitable container refer to the traction unit Operator s Manual 3 To prevent contamination of the hydraulic system during pump removal thoroughly clean the exterior of the pump and fittings 4 Disconnect the suction hose from the bottom of the gear pump and the pressure hoses from the top of the gear pump Put plugs in open hydraulic hoses Label disconnected hydraulic hoses for prope...

Page 167: ... and lubricate new gear pump fitting O rings Install the fittings into pump ports using alignment marks made during removal and tighten the fittings refer to Installing the Hydraulic Fittings SAE Straight Thread O Ring Fittings page 5 10 5 Remove the plugs from the hydraulic hoses and install the hydraulic hoses to the gear pump refer to Installing Hydraulic Hoses and Tubes O Ring Face Seal page 5...

Page 168: ...nge 20 Cap screw 4 each 7 Pressure seal 4 each 14 Drive hub If items other than pump seals are worn or damaged the gear pump must be replaced as a complete assembly Individual gears housings and thrust plates are not available separately Disassemble inspect and assemble gear pump for cleaning inspection and seal replacement only IMPORTANT Keep pump bodies gears flanges and thrust plates for each p...

Page 169: ...ons 6 Support the pump assembly and gently tap the pump bodies with a soft face hammer to loosen the pump sections IMPORTANT Mark the relative positions of the gear teeth and the thrust plates so they can be reassembled in the same position Do not touch the gear surfaces as residue on hands may be corrosive to gear finish 7 Remove the thrust plates and the seals from each pump section Before remov...

Page 170: ...areas should not have excessive wear or scoring B The face of the thrust plates that are in contact with the gears should be free of wear roughness or scoring C The thickness of the thrust plates should be equal 5 Inspect the front flange and the rear cover for damage or wear Assembling the Gear Pump When assembling the pump check the marker line on each part to make sure the parts are properly al...

Page 171: ...al side up and the open side of the pressure seal pointing to the inlet side of the pump F Install the dowel pins in the body G Apply a light coating of petroleum jelly to the new body seals and body seal grooves in the body Install the new body seals into the body IMPORTANT Do not dislodge seals during installation H Align the marker lines and slide the body over the gear assembly 5 Install the d...

Page 172: ...ntact between the face of the speed sensor and the drive coupling during axle motor removal remove the speed sensor from the motor mount 2 To prevent contamination of the hydraulic system during motor removal thoroughly clean the exterior of the motor and fittings 3 Label and disconnect the hydraulic hoses from the axle motor To prevent contamination of hydraulic the system plug the disconnected h...

Page 173: ...the drive coupler splines and slide the drive coupler all the way onto the axle input shaft 3 If installing the rear axle motor A Apply anti seize lubricant to the splines of the hydraulic brake assembly B Align the hydraulic brake splines and slide the brake assembly shaft into the drive coupler C Install a new gasket between the hydraulic brake assembly and the rear axle motor 4 Apply anti seize...

Page 174: ...on 14 Cylinder block kit 24 Plug with O ring 2 each 5 O ring 15 Swashplate 25 Plug with O ring 6 O ring 16 Swashplate bearing asm 26 Plug and spring asm 2 each 7 Socket head screw 5 each 17 Output shaft 27 Spool 8 End cap 18 Housing 28 Relief valve poppet 9 Dowel 19 Bearing 29 Spring 10 Dowel pin 20 Retaining ring 30 Plug Hydraulic System Service and Repairs Page 5 78 Outcross 9060 18234SL Rev B ...

Page 175: ...efer to the Danfoss K and L Frame Variable Motors Service Manual for axle motor service information Axle Differential Locks The hydraulically actuated differential lock assemblies are incorporated into the axle assemblies refer to the Carraro DriveTech Model 26 09M Axle Repair Manual for additional information Outcross 9060 Page 5 79 Hydraulic System Service and Repairs 18234SL Rev B ...

Page 176: ... 2 To prevent contamination of the hydraulic system during brake removal thoroughly clean the exterior of the brake assembly and fittings 3 Disconnect the hydraulic hose from the brake assembly To prevent contamination of hydraulic the system plug the disconnected hose and cap the fitting 4 Separate the hydraulic brake assembly from the motor mount and remove the brake from the machine 5 Remove an...

Page 177: ...y onto the axle input shaft 3 Apply anti seize lubricant to the splines of the hydraulic brake assembly 4 Align the hydraulic brake splines and slide the brake assembly shaft into the drive coupler 5 Install a new gasket between the hydraulic brake assembly and the rear axle motor 6 Install the rear axle motor refer to Installing the Axle Motors page 5 77 7 Check the hydraulic brake oil level and ...

Page 178: ...ill drain plug 2 each 6 Shaft 14 Backup ring 22 Bleeder 7 Bearing 15 O ring 23 Gasket 2 each 8 Snap ring 16 O ring Disassembling the Hydraulic Brake 1 Remove one of the fill drain plugs and drain the oil from the brake housing 2 Loosen the 4 hex head screws alternately and separate the power plate from the housing 3 Remove the piston from the power plate with low pressure 103 kPa 15 psi compressed...

Page 179: ...scs CAUTION Piston installation depth is critical or the piston may cock resulting in lose of braking The surface of the piston at the base of the cutouts must be flush to 3 05 0 12 inch below the surface of the power plate 3 Lubricate the piston and power plate bore with clean hydraulic oil and use a press to fit the piston into the power plate Visually align the cutouts in the piston with the to...

Page 180: ...V1 is the location for the high low speed solenoid valve refer to the hydraulic schematic inAppendix A page A 1 to identify the function of the hydraulic lines and cartridge valves at each port Although not recommended for most situations relief valves RV1 and RV2 are adjustable refer to Adjusting the Manifold Relief Valves page 5 48 Removing the Main Hydraulic Manifold Read and adhere to the info...

Page 181: ...from the manifold and discard the O rings Installing the Main Hydraulic Manifold Note The main hydraulic manifold is aluminum 1 Lubricate new O rings and place them onto the fittings If previously removed install the fittings into the manifold ports using alignment marks made during removal refer to Installing the Hydraulic Fittings SAE Straight Thread O Ring Fittings page 5 10 2 Position the mani...

Page 182: ...re marked for easy identification of components and connections Example P is the pressure connection port from gear pump P4 and SV1 is the location for the high low speed solenoid valve refer to the hydraulic schematic in Appendix A page A 1 to identify the function of the hydraulic lines and cartridge valves at each port The main hydraulic manifold include several zero leak plugs These plugs have...

Page 183: ...ugs in the OR2 and OR3 ports of the main hydraulic manifold If the fitting or plug is removed remove the orifice for cleaning and label its position for assembly purposes Note For cartridge valve service procedures refer to Cartridge Valve Service page 5 88 Outcross 9060 Page 5 87 Hydraulic System Service and Repairs 18234SL Rev B ...

Page 184: ... the back up rings Remove and discard the seal kit from the cartridge valve 5 Visually inspect the manifold port and the cartridge valve A Check for damaged threads on the cartridge valve and in the manifold block B If valve sealing surfaces appear pitted or damaged the hydraulic system may be overheating or there may be water in the system C Contamination may cause valves to stick or hang up Cont...

Page 185: ...ending or distortion of the stem tube can cause binding and malfunction Make sure that deep well socket fully engages the valve base B Lubricate the threads on the cartridge valve with clean hydraulic fluid Thread the cartridge valve carefully into the correct manifold port The valve should thread in easily without binding C Tighten the cartridge valve using a deep well socket to the torque specif...

Page 186: ...nections before disconnecting the hydraulic lines to prevent system contamination 3 Disconnect the hydraulic hoses and tubes from the steering control valve Cap the fittings and plug the lines to prevent contamination from entering the system 4 Remove the four flange head screws securing the steering column and steering control valve to the plate 5 Remove the steering column and steering control v...

Page 187: ...ring column Install the alignment ring then hold the steering control valve and steering column to the plate and install the four flange head screws Tighten the screws from 46 to 57 N m 34 to 42 ft lb g242888 Figure 54 1 Pressure in port P 4 Right turn port R 2 Tank out port T 5 Load sensing port LS 3 Left turn port L 3 Connect the hydraulic hoses and lines to the steering control valve 4 Install ...

Page 188: ...wheel set 6 Check valve 15 LS check valve 24 End cover 7 Ball 3 each 16 Threaded bushing 25 Washer 7 each 8 Spring 2 each 17 Ball 26 Special screw 9 Pin 2 each 18 Screw 6 each The Outcross 9060 uses a Danfoss type OSPC steering control valve For steering control valve repair procedures refer to the Danfoss Steering Unit Type OSPB OSPC and OSPF Service Manual Hydraulic System Service and Repairs Pa...

Page 189: ...the information provided in General Precautions for Removing and Installing the Hydraulic System Components page 5 49 prior to removing hydraulic system components 1 Remove the bed refer to Standard Bed page 8 21 2 Disconnect the rear speed sensor from the frame wire harness and remove the rear speed sensor Cover the speed sensor face and plug or cover the sensor hole in the axle motor mount 3 Rem...

Page 190: ...l refer to Installing the Hydraulic Fittings SAE Straight Thread O Ring Fittings page 5 10 2 Install the steering cylinder to the machine and secure with 4 cap screws and flange nuts 3 Remove the caps and plugs from the fittings and hoses and connect the hydraulic lines to the cylinder refer to Installing Hydraulic Hoses and Tubes O Ring Face Seal page 5 8 4 Install the tie rods to the rear steeri...

Page 191: ...same Use the same service procedure for either cylinder The following service procedure assumes both tie rod assemblies have been previously removed from the cylinder assembly Disassembling the Steering Cylinder 1 Slowly pump the cylinder over a drain pan to remove any hydraulic fluid from the cylinder Plug both cylinder ports and clean the outer surface of the cylinder IMPORTANT When you clamp th...

Page 192: ...p scratches out of roundness and bending 3 Inspect the head rods and piston for excessive pitting scoring and wear 4 Check the re phasing valve in the piston that exists to allow synchronization of the front and rear steering cylinders The poppet valves should not be stuck in piston 5 Replace the cylinder if the internal components are worn or damaged Assembling the Steering Cylinder IMPORTANT Avo...

Page 193: ...hydraulic fluid and fit the piston and rod assembly into the cylinder barrel 6 Install the 2 spacers and the 2 head assemblies 7 Secure the heads in the barrel with the external collars Tighten the external collars with a strap chain or spanner wrench 8 Install and tighten the set screws in the external collars Outcross 9060 Page 5 97 Hydraulic System Service and Repairs 18234SL Rev B ...

Page 194: ...nents 1 Remove any attachments from the 3 point hitch 2 Remove the stabilizer assembly lift link assembly and standard arm assembly 3 Clean the fitting and hydraulic line connections before disconnecting the hydraulic lines to prevent system contamination 4 Remove the upper pin securing the hitch cylinder to the lift arm 5 Tilt the hitch cylinder rearward and disconnect the hydraulic hoses Cap the...

Page 195: ... the fittings and hoses and connect the hydraulic lines to the cylinder refer to Installing Hydraulic Hoses and Tubes O Ring Face Seal page 5 8 4 Install the upper pin securing the cylinder to the lift arm 5 Install the standard arm assembly lift link assembly and stabilizer assembly 6 Grease the lower cylinder pin fitting with Mobil high temp XHP 222 or equivalent 7 Operate the 3 point hitch Chec...

Page 196: ...tch Cylinder 1 Slowly pump the cylinder over a drain pan to remove any hydraulic fluid from the cylinder Plug both cylinder ports and clean the outer surface of the cylinder IMPORTANT When you clamp the cylinder in a vise clamp against the cylinder clevis only to prevent damage Do not clamp the vise onto the barrel 2 Mount the cylinder in a vise by clamping on the cylinder clevis Hydraulic System ...

Page 197: ...air 2 Inspect the internal surface of the barrel for deep scratches out of roundness and bending 3 Inspect the head shaft and piston for excessive pitting scoring and wear 4 Replace the cylinder if the internal components are worn or damaged Assembling the Hitch Cylinder IMPORTANT Avoid pinching cutting or otherwise damaging the O rings seals and the wear ring during assembly Lubricate the O rings...

Page 198: ...se by clamping on the cylinder clevis 6 Use a strap chain or spanner wrench to tighten the external collar Install and tighten the set screw PTO Clutch The hydraulically actuated PTO clutch assembly is incorporated into the front gear box assembly refer to Front PTO Gear Box page 7 14 and PTO Clutch page 7 19 for additional information Hydraulic System Service and Repairs Page 5 102 Outcross 9060 ...

Page 199: ...y Cap the fittings and plug the lines to prevent contamination from entering the system 5 Remove the 4 cap screws securing the valve assembly to the machine and remove the valve assembly 6 Remove and discard fitting O rings Installing the Auxiliary Load Valve 1 Lubricate new O rings and place them onto the fittings If previously removed install the fittings into the valve ports refer to Installing...

Page 200: ...alling the Operator s Console page 8 17 7 Test the attachment loader circuit relief valve pressure before returning the machine to service refer to Attachment Loader Circuit Testing Relief Valve Pressure Test page 5 43 8 Check the hydraulic fluid level and adjust if necessary before returning the machine to service Hydraulic System Service and Repairs Page 5 104 Outcross 9060 18234SL Rev B ...

Page 201: ...loat spool positioner Servicing the Auxiliary Load Valve For complete service information refer to the Gresen Parker Hydraulics Model V10 Sectional Body Directional Control Valve Service Manual 1 Disassemble the auxiliary load valve as necessary 2 Clean and inspect the section housings 3 Install new seals where available Outcross 9060 Page 5 105 Hydraulic System Service and Repairs 18234SL Rev B ...

Page 202: ... the Operator s Console page 8 17 2 Clean the fitting and hydraulic line connections before disconnecting the hydraulic lines to prevent system contamination 3 Disconnect the hydraulic lines at the valve assembly Cap the fittings and plug the lines to prevent contamination from entering the system 4 Remove the 4 cap screws securing the valve assembly to the machine and remove the valve assembly 5 ...

Page 203: ...s and plugs from the fittings and hydraulic lines and connect the hydraulic lines to the valve refer to Installing Hydraulic Hoses and Tubes O Ring Face Seal page 5 8 4 Operate the front loader control valve Check for hydraulic leaks and correct if necessary 5 Install the operator s console refer to Removing and Installing the Operator s Console page 8 17 6 Check the hydraulic fluid level and adju...

Page 204: ...ty plug seal kit 2 each 6 Spool seal 3 each Servicing the Loader Control Valve For complete service information refer to the Gresen Parker Hydraulics Model V10 Sectional Body Directional Control Valve Service Manual 1 Disassemble the auxiliary load valve as necessary 2 Clean and inspect the section housings 3 Install new seals where available Hydraulic System Service and Repairs Page 5 108 Outcros...

Page 205: ...to the information provided in General Precautions for Removing and Installing the Hydraulic System Components page 5 49 prior to removing hydraulic system components 1 The loader selector control valve manifolds are located on the right side loader arm The rear selector control valve manifolds are located on the right side frame rail behind the operator s platform Remove the bed to access the rea...

Page 206: ...hread O Ring Fittings page 5 10 2 Position the manifolds to the bracket and secure with 2 cap screws 3 Remove the caps and plugs from the fittings and hoses Properly connect the hydraulic lines to the manifold refer to Installing Hydraulic Hoses and Tubes O Ring Face Seal page 5 8 4 Connect the wire harness connectors to the cartridge valve solenoids Hydraulic System Service and Repairs Page 5 110...

Page 207: ... The selector control valve manifolds include a zero leak plug This plug has a tapered sealing surface on the plug head that is designed to resist vibration induced plug loosening The zero leak plug also has an O ring as a secondary seal If removing a zero leak plug is necessary lightly rap the plug head using a punch and hammer before using a hex wrench to remove the plug the impact will allow pl...

Page 208: ...Hydraulic System Service and Repairs Page 5 112 Outcross 9060 18234SL Rev B ...

Page 209: ...rking Brake Switch 6 29 Power Take Off PTO Enable Switch 6 30 Economy ECO Mode Switch 6 31 Hydraulic Auxiliary AUX Switch 6 32 Seat Switch 6 34 Paddle 3 Point Hitch and Transmission Lever Switches 6 35 Headlight Worklight Switch 6 37 Cruise Control Off On Set Switch 6 38 Cruise Control Speed Increase Decrease Switch 6 39 Air Conditioning On Off Switch 6 40 Heater Air Conditioning Blower Speed Swit...

Page 210: ...6 71 Hydraulic Solenoid Valve Coils 6 73 Tandem Traction Piston Pump Control Solenoid Coils 6 75 Service and Repairs 6 77 Caring for the Battery 6 77 Storing the Battery 6 79 Servicing the Battery 6 80 Electrical System Service and Repairs Page 6 2 Outcross 9060 18234SL Rev B ...

Page 211: ...on Instructions provide information regarding the operation general maintenance and maintenance intervals for the machine and its accessories Refer to the traction unit Operator s Manual and accessory Installation Instructions for additional information Yanmar Engine Electrical Components When servicing or troubleshooting the engine electrical components use the correct engine service manual and t...

Page 212: ... F B3 protects the InfoCenter power circuit The primary controller T1 TEC the status display controller T2 TDM the Yanmar Engine Control Unit ECU the InfoCenter Display and the optional InchMode controller T3 TEC used on the Outcross 9060 machine communicate with each other on a Controller Area Network CAN bus system Note The InfoCenter Display TECs TDM and the engine ECU used on the Outcross 9060...

Page 213: ...InfoCenter Display continued g259842 Figure 67 InfoCenter Screens Outcross 9060 Page 6 5 Electrical System General Information 18234SL Rev B ...

Page 214: ... attached to the machine under the main instrument panel Power for the T1 TEC logic and memory is available at all times unswitched The logic and memory circuit is protected by a 2 Amp fuse F B2 Power for the T1 TEC outputs is available when the main power relay is energized key switch is in the ON or START position A series of four 7 5 Amp fuses F A1 B1 C1 and D1 protect the T1 TEC output circuit...

Page 215: ...rical system voltage engine RPM 3 point hitch position and active faults A single button located near the T2 TDM is used to select the various display screens A red LED active fault indicator is also part of the T2 TDM The fault indicator flashes when one or more active machine or engine faults exist Power for the TDM is available when the main power relay is energized key switch is in the ON or S...

Page 216: ...The status of inputs to the controller can be monitored with the InfoCenter Display refer to Using the InfoCenter Display for Troubleshooting page 3 23 The primary controller T1 TEC the status display controller T2 TDM the Yanmar Engine Control Unit ECU the InfoCenter Display and the optional InchMode controller T3 TEC used on the Outcross 9060 machine communicate with each other on a Controller A...

Page 217: ...jectors EGR exhaust DPF are identified and matched in the engine ECU program If engine electrical components are replaced on the engine the Yanmar SmartAssist Direct tool SA D must be used to update the ECU program which will ensure correct engine operation The Yanmar SA D connector is located near the engine ECU just under the dash cover Contact your Toro distributor for assistance If the engine ...

Page 218: ...t base Power for the T3 TEC is available when the main power relay is energized key switch is in the ON or START position A 10 Amp fuse F C5 protects the T3 TEC power circuit The primary controller T1 TEC the status display controller T2 TDM the Yanmar Engine Control Unit ECU the InfoCenter Display and the optional InchMode controller T3 TEC used on the Outcross 9060 machine communicate with each ...

Page 219: ...needs four 4 wires to operate and communicate to the system CAN High CAN Low power and ground The key switch needs to be in the RUN or START position for the components on the network to be activated Two specially designed twisted wires form the CAN bus These wires provide the data pathways between the components on the network The engineering term for these cables are CAN High and CAN Low The CAN...

Page 220: ...rical Drawings The electrical schematic and wire harness drawings for the Outcross 9060 machine are located in Appendix A page A 1 Electrical System Electrical Drawings Page 6 12 Outcross 9060 18234SL Rev B ...

Page 221: ...mation Checking the Operation of the Interlock Switches CAUTION Do not disconnect safety switches They are for the operator s protection Check the operation of the interlock switches daily for proper operation Replace any malfunctioning switches before operating the machine Your Outcross 9060 is equipped with a primary T1 TEC and a T2 TDM which monitor interlock switch operation If all of the inte...

Page 222: ...lock located in the cab control panel above the passenger seat Machines with an optional Road Light kit include lighting circuits protected by fuses found in the kit wire harness under the roof Refer to the Electrical Schematic and Wire Harness Drawings Diagrams in Appendix A page A 1 for specific circuit information Fuse Identification Location and Function Main Fuse Block Fuse F A1 7 5 Amp suppl...

Page 223: ...can NA road light kit Fuse F C4 10 Amp supplies power to the horn Fuse F D4 10 Amp supplies power to the optional beacon Fuse F A5 10 Amp supplies power to the air ride seat compressor Fuse F B5 20 Amp supplies power to the optional trailer brake controller Fuse F C5 10 Amp supplies switched power to expansion ports 1 and 2 Fuse F D5 15 Amp supplies switched power to the rear attachment connector ...

Page 224: ...r 5 Amp fuses are integrated into the optional turn signal hazard wire harness Each fuse is in a separate covered fuse holder The harness is located under the roof Testing Fuses 1 Make sure that key switch is OFF and key is removed from switch 2 Remove fuse from fuse block for testing Fuse should have continuity across the terminals Electrical System Electrical Component Testing Page 6 16 Outcross...

Page 225: ... the Fusible Link Harness 1 Locate and unplug the fusible link harness connector from the engine wire harness 2 Use a multimeter to make sure that continuity exists between the fusible link terminals Note It is not recommended to replace individual fusible link conductors of the fusible link harness If any of the harness links are open failed replace the entire fusible link harness 3 If either fus...

Page 226: ...age 6 71 Testing the CAN bus g261747 Figure 78 1 Main fuse block 3 Connector cover 2 Toro DIAG connector 1 Make sure that key switch is OFF and key is removed from switch 2 The Toro DIAG connector is part of the CAN bus and is located below the dash next to the main fuse block Locate the Toro DIAG connector and remove the connector cover 3 Use a multimeter ohms setting to measure the resistance ac...

Page 227: ...electric fuel pump and the various hydraulic solenoid valves The status of inputs to the controller as well as outputs from the controllers can be monitored with the InfoCenter Display refer to Using the InfoCenter Display for Troubleshooting page 3 23 The T1 TEC is attached to the machine under the main instrument panel Power for the T1 TEC logic and memory is available at all times unswitched Th...

Page 228: ...DESCRIPTION OUT LS Cab Power Relay OUT 9 Front Traction Pump Forward Solenoid AB C1 OUT 1 Engine ECU START OUT 10 Front Traction Pump Reverse Solenoid AB C2 OUT 2 Engine ECU RUN OUT 11 Rear Traction Pump Forward Solenoid CD C1 OUT 3 Parking Brake Solenoid SV2 OUT 12 Rear Traction Pump Reverse Solenoid CD C2 OUT 4 High Range Traction Speed Solenoid SV1 OUT 13 PTO Enable Solenoid EH OUT 5 Differenti...

Page 229: ...pins are shown above If the wire harness connector is removed from the T1 TEC for any reason tighten the harness connector screw from 2 8 to 3 2 N m 25 to 28 in lb Because of the solid state circuitry built into the controller there is no method to test the controller directly A controller may be damaged if an attempt is made to test it with an electrical test device e g digital multimeter or test...

Page 230: ...power relay is energized key switch is in the ON or START position A 2 Amp fuse F A4 protects the TDM power circuit The T2 TDM is also a 2002 series microcontroller that monitors the condition of various machine switches and sensors inputs and communicates the status of these inputs to the T1 TEC via the CAN The status of inputs to the controller can be monitored with the InfoCenter Display refer ...

Page 231: ...DESCRIPTION OUT 1 Parking Brake Light OUT 2 Not Used OUT 3 Warning Buzzer The machine electrical schematic and wire harness drawings in Appendix A page A 1 can be used to identify possible circuit problems between the controller and the input or output devices IMPORTANT When testing for wire harness continuity at the connector for the controller take care to not damage the connector pins with mult...

Page 232: ...st the controller directly A controller may be damaged if an attempt is made to test it with an electrical test device e g digital multimeter or test light Note The InfoCenter Display TECs and the TDM used on the Outcross 9060 machine are matched for correct machine operation If any of these components are replaced for any reason system software needs to be reloaded contact an Authorized Toro Dist...

Page 233: ...hen the main power relay is energized key switch is in the ON or START position A 10 Amp fuse F C5 protects the T3 TEC power circuit The primary controller T1 TEC the status display controller T2 TDM the Yanmar Engine Control Unit ECU the InfoCenter Display and the optional InchMode controller T3 TEC used on the Outcross 9060 machine communicate with each other on a Controller Area Network CAN bus...

Page 234: ... wire harness connector P01 2 InchMode controller T3 TEC A 20 pin InchMode wire harness connector is attached to the controller The connection terminal function for the controller and the wire harness connector pins are shown above Because of the solid state circuitry built into the controller there is no method to test the controller directly A controller may be damaged if an attempt is made to t...

Page 235: ...ry 3 Remove the instrument panel from the console 4 Disconnect the wire harness connector from the switch and remove the switch from the instrument panel if necessary Note Key switch terminals 1 and 6 are connected internally Terminals 4 and 5 are also connected internally These terminals should have continuity regardless of the switch position 5 Use a multimeter ohms setting and the preceding tab...

Page 236: ...g can be tested as a T2 TDM input using the InfoCenter Display The current operating mode should be displayed on the main screen and the display should change with switch position changes If testing determines that a sensor and its circuit wiring are not functioning correctly proceed with the following test procedure 1 Park the machine on a level surface lower any attachments and stop the engine 2...

Page 237: ...g determines that the switch and circuit wiring are not functioning correctly proceed with the following test procedure 1 Park the machine on a level surface lower any attachments and stop the engine 2 Disconnect the battery negative cable at the battery 3 Remove the instrument panel from the dash 4 Disconnect the wire harness connector from the switch and remove the switch from the instrument pan...

Page 238: ...uit wiring are not functioning correctly proceed with the following test procedure 1 Park the machine on a level surface lower any attachments and stop the engine 2 Disconnect the battery negative cable at the battery 3 Remove the instrument panel from the console 4 Disconnect the wire harness connector from the switch and remove the switch from the instrument panel if necessary 5 Use a multimeter...

Page 239: ...e not functioning correctly proceed with the following test procedure 1 Park the machine on a level surface lower any attachments and stop the engine 2 Disconnect the battery negative cable at the battery 3 Remove the instrument panel from the dash 4 Disconnect the wire harness connector from the switch and remove the switch from the instrument panel if necessary 5 Use a multimeter ohms setting an...

Page 240: ...T1 TEC to control ground speed and engine speed Testing the Hydraulic AUX Switch The hydraulic AUX switch and its circuit wiring can be tested as a T1 TEC input using the InfoCenter Display refer to Using the InfoCenter Display for Troubleshooting page 3 23 If testing determines that the switch and circuit wiring are not functioning correctly proceed with the following test procedure 1 Remove the ...

Page 241: ... If the switch tests correctly and a circuit problem still exists check the wire harnesses refer to Appendix A page A 1 8 Connect the wire harness and install the operator s console after testing Outcross 9060 Page 6 33 Electrical System Electrical Component Testing 18234SL Rev B ...

Page 242: ...sting determines that the switches and circuit wiring are not functioning correctly proceed with the following test procedure 1 Park the machine on a level surface lower any attachments and stop the engine 2 Disconnect the wire harness connector from the switch 3 Check the continuity of the switch by connecting a multimeter ohms setting across the connector terminals 4 With no pressure on the seat...

Page 243: ...d and reverse The switches are normally open TEC inputs All 4 switches are identical Testing the Paddle and Transmission Lever Switches The paddle and transmission lever switches and their circuit wiring can be tested as a T1 TEC input using the InfoCenter Display refer to Using the InfoCenter Display for Troubleshooting page 3 23 If testing determines that any of the switches and their circuit wi...

Page 244: ... a circuit problem still exists check the wire harnesses refer to Appendix A page A 1 6 After testing is complete connect machine wire harness connector to the switch 7 Install the dash cover refer to Installing the Steering Wheel Instrument Panels and Dash Cover page 8 16 Electrical System Electrical Component Testing Page 6 36 Outcross 9060 18234SL Rev B ...

Page 245: ... the battery negative cable at the battery 3 Remove the instrument panel from the steering column cover 4 Disconnect the wire harness connector from the switch and remove the switch from the instrument panel if necessary 5 Use a multimeter ohms setting and the preceding table to determine whether continuity exists between the various terminals for each switch position 6 Replace the switch if neces...

Page 246: ...the FORWARD position the parking brake switch is engaged a speed sensor or hydraulic pressure sensor fault is active or when CAN communication between the T1 TEC and the T2 TDM is lost Testing the Cruise Control Off On Set Switch The cruise control off on set switch and its circuit wiring can be tested as a T2 TDM input using the InfoCenter Display refer to Using the InfoCenter Display for Trouble...

Page 247: ...e Switch The cruise control speed increase decrease switch and its circuit wiring can be tested as a T2 TDM input using the InfoCenter Display refer to Using the InfoCenter Display for Troubleshooting page 3 23 If testing determines that the switch and circuit wiring are not functioning correctly proceed with the following test procedure 1 Park the machine on a level surface lower any attachments ...

Page 248: ...nnect the battery negative cable at the battery 3 Remove the roof from the cab 4 Disconnect the wire harness connectors from the switch and remove the switch from the AC control panel if necessary 5 Use a multimeter ohms setting and the preceding table to determine whether continuity exists between the various terminals for each switch position 6 Replace the switch if necessary 7 If the switch tes...

Page 249: ... from the AC control panel if necessary 5 Use a multimeter ohms setting and the preceding table to determine whether continuity exists between the various terminals for each switch position 6 Replace the switch if necessary 7 If the switch tests correctly and a circuit problem still exists check the wire harnesses refer to Appendix A page A 1 8 Install the switch connect the wire harness inspect a...

Page 250: ...e tested as a T3 TEC input using the InfoCenter Display refer to Using the InfoCenter Display for Troubleshooting page 3 23 If testing determines that the switch and its circuit wiring are not functioning correctly proceed with the following test procedure 1 Park the machine on a level surface lower any attachments and stop the engine 2 Disconnect the battery negative cable at the battery 3 Remove...

Page 251: ...d their circuit wiring can be tested as a T3 TEC input using the InfoCenter Display refer to Using the InfoCenter Display for Troubleshooting page 3 23 If testing determines that a switch and its circuit wiring are not functioning correctly proceed with the following test procedure 1 Park the machine on a level surface lower any attachments and stop the engine 2 Disconnect the battery negative cab...

Page 252: ...er to Using the InfoCenter Display for Troubleshooting page 3 23 If testing determines that a switch and its circuit wiring are not functioning correctly proceed with the following test procedure 1 Park the machine on a level surface lower any attachments and stop the engine 2 Disconnect the battery negative cable at the battery 3 Remove the switch cap and switch from the joystick 4 Disconnect the...

Page 253: ...ay refer to Using the InfoCenter Display for Troubleshooting page 3 23 If testing determines that the assembly and its circuit wiring are not functioning correctly proceed with the following test procedure 1 Park the machine on a level surface lower any attachments and stop the engine 2 Disconnect the platform wire harness from the traction pedal Check the pedal and the harness connector for damag...

Page 254: ...ng the Traction Pedal Assembly continued 8 Install the traction pedal assembly and connect the wire harness after testing Electrical System Electrical Component Testing Page 6 46 Outcross 9060 18234SL Rev B ...

Page 255: ...hine is moving the machine will quickly come to a stop A decelerator pedal fault will disable traction control until the ignition key is cycled OFF and ON Testing the Decelerator Pedal Position Sensor The decelerator pedal sensor and its circuit wiring can be tested as a T1 TEC input using the InfoCenter Display refer to Using the InfoCenter Display for Troubleshooting page 3 23 If testing determi...

Page 256: ...oximately 5 000 ohms B Measure the resistance between the terminals A and C and then measure the resistance between the terminals A and B The total of the 2 measured resistances should be approximately 5 000 ohms C Rotate the decelerator pedal position sensor to other positions and repeat step B The total of the 2 measured resistances should always be approximately 5 000 ohms 5 Replace the deceler...

Page 257: ...al switch is monitored by the T1 TEC If a decelerator pedal fault occurs while the machine is moving the machine will quickly come to a stop A decelerator pedal fault will disable traction control until the ignition key is cycled OFF and ON Testing the Decelerator Pedal Neutral Switch The decelerator pedal neutral switch and its circuit wiring can be tested as a T1 TEC input using the InfoCenter D...

Page 258: ...sistance between the switch terminals 5 When the switch plunger is extended decelerator pedal depressed there should be no continuity infinite ohms resistance between the switch terminals 6 Replace the switch if necessary 7 If the switch tests correctly and a circuit problem still exists check the wire harnesses refer to Appendix A page A 1 8 Connect the wire harness after testing Electrical Syste...

Page 259: ...he 3 point position sensor and its circuit wiring can be tested as a T1 TEC input using the InfoCenter Display refer to Using the InfoCenter Display for Troubleshooting page 3 23 If testing determines that the sensor and its circuit wiring are not functioning correctly proceed with the following test procedure 1 Park the machine on a level surface and lower any attachments Use the status display a...

Page 260: ...ng and replace it if it is worn or damaged Install the V ring in the correct orientation refer to Figure 80 C Install the position sensor in the same position as recorded prior to switch removal Connect the wire harness after testing 7 If the position sensor tests correctly and a circuit problem still exists check the wire harnesses refer to Appendix A page A 1 Electrical System Electrical Compone...

Page 261: ...rmation for the TDM hydraulic temperature gauge Testing the Hydraulic Fluid Temperature Sender 1 Drain or pump approximately 30 liters 8 gallons of hydraulic tank fluid from the tank so the level is below the sender port 2 Locate hydraulic oil temperature sender and disconnect wire harness connector 3 Thoroughly clean the hydraulic tank around the temperature sender Remove the sender from the tank...

Page 262: ...you are testing 5 Check resistance of the sender with a multimeter ohms setting as the oil temperature increases A The meter should indicate from 11 6 to 13 5 kilohms at 20C 68F B The meter should indicate 2 3 to 2 5 kilohms at 60C 140F C The meter should indicate 605 to 669 ohms at 100C 212F 6 If the sender tests correctly and a circuit problem still exists check the wire harnesses refer to Appen...

Page 263: ...FF and ON Testing the Speed Sensors The speed sensors and their circuit wiring can be tested as a T1 TEC input using the InfoCenter Display refer to Using the InfoCenter Display for Troubleshooting page 3 23 If testing determines that a sensor and its circuit wiring are not functioning correctly proceed with the following test procedure Note Testing the speed sensor requires the use of specialized...

Page 264: ...e InfoCenter Traction Inputs screen and scroll down to display the Front Ground or Rear Ground readings D Connect a 12 VDC power supply across the signal pin C and ground pin B of the frame wire harness connector Rapidly open and close the test circuit repeatedly The InfoCenter speed reading should increase slightly This confirms the integrity of the circuit ground and signal wires E Turn the key ...

Page 265: ...o the rest position the machine will operate in limp home mode reduced ground speed and PTO disabled until the ignition key is cycled OFF and ON Testing the Pressure Sensors The pressure sensors and their circuit wiring can be tested as a T1 TEC input using the InfoCenter Display refer to Using the InfoCenter Display for Troubleshooting page 3 23 If testing determines that a sensor and its circuit...

Page 266: ...confirms the integrity of the circuit supply and signal wires E Turn the key switch to OFF 4 Test the pressure sensor A Remove the pressure sensor g259080 Figure 98 1 Pressure sensor 3 Multimeter probe 2 4 5 to 5 5 VDC power supply B Connect a 4 5 to 5 5 VDC power supply to the supply pin A and ground pin B of the sensor C Connect a multimeter set to DC voltage to the signal pin C and ground pin B...

Page 267: ...uring the amount of fuel an unrestricted pump can deliver over a set period of time 1 Park the machine on a level surface lower any attachments and set the key switch to OFF 2 Make sure fuel hoses are in good condition and free of obstructions Note Since the fuel water separator is upstream of the fuel pump the condition of the fuel water separator will influence fuel pump performance 3 Drain the ...

Page 268: ...T position 5 Place the disconnected hose end into a 0 95 liter 1 quart graduated cylinder and set the key switch to the ON RUN position for 30 seconds The pump should deliver approximately 350 ml 11 8 ounces in 30 seconds Replace the fuel pump if necessary 6 Connect fuel hoses and secure with hose clamps 7 Prime the fuel system refer to Priming the Fuel System page 4 15 Electrical System Electrica...

Page 269: ...4 Inspect sender gasket for damage and replace if necessary 5 Verify fuel sender float is able to move freely through its entire range of operation Note Before taking small resistance readings with a digital multimeter short meter test leads together The meter will display a small resistance value This internal resistance of the meter and test leads should be subtracted from the measured value of ...

Page 270: ... the Steering Wheel Instrument Panels and Dash Cover page 8 16 2 Disconnect the platform wire harness connector from the buzzer IMPORTANT Make sure to observe polarity on the alarm terminals when testing Damage to the alarm may result from an improper connection 3 Connect a 12 VDC power supply to the buzzer terminal and a ground to the terminal The buzzer should sound 4 Replace the buzzer if neces...

Page 271: ...r relay supplies power to the fuses and all of the circuits protected by the fuses in the cab fuse block refer to Fuse Identification Location and Function page 6 14 The cab power relay is energized when the key switch is in the START or RUN position The rear attachment power relay supplies power to rear attachments via the 7 pin rear attachment harness connector The rear attachment power relay is...

Page 272: ...r the tested component 4 Using a multimeter ohms setting measure coil resistance between terminals 85 and 86 Resistance should be between 70 and 100 ohms 5 Verify infinite resistance no continuity exists between terminals 30 and 87 6 Connect multimeter ohms setting leads to relay terminals 30 and 87 Ground terminal 86 and apply 12 VDC to terminal 85 The relay should make and break continuity betwe...

Page 273: ...ted under the main instrument panel The EGR relay is used to provide current to the engine EGR valve The EGR relay is energized by the Yanmar engine ECU The brake light relay for the optional International Road Light kit is located under the main instrument panel The brake light relay is used to provide power to the brake lights on international machines only The brake light relay is energized by ...

Page 274: ...ear SCV hydraulic manifolds The rear SCV relay is used to provide current to the 4 rear SCV hydraulic solenoid valves The rear SCV relay is energized by the T1 TEC g267770 Figure 107 1 Refrigerant receiver drier 3 AC switch signal relay 2 AC condenser fans relay 4 AC clutch relay Electrical System Electrical Component Testing Page 6 66 Outcross 9060 18234SL Rev B ...

Page 275: ...Center Display for Troubleshooting page 3 23 If testing determines that the relay and its circuit wiring are not functioning correctly proceed with the following test procedure 1 Make sure key switch is OFF Remove key from key switch 2 Disconnect the ground cable at the battery refer to Removing the Battery page 6 81 3 Access the relay to be tested and disconnect the wire harness connector from th...

Page 276: ...ould make and break continuity between terminals 30 and 87A as 12 VDC is applied and removed from terminal 85 7 Replace the relay as necessary 8 If the relay tests correctly and a circuit problem still exists check the wire harnesses refer to Appendix A page A 1 9 Connect the wire harness install any items removed to access the relay and connect the battery ground cable Electrical System Electrica...

Page 277: ...rent flow between the hazard switch and the turn signal switch of the optional International Road Light Kit right side lights The diode plugs into the international road light wire harness behind the main instrument panel A diode assembly D5 is used to control current flow between the hazard switch and the turn signal switch of the optional International Road Light Kit left side lights The diode p...

Page 278: ...y 1 Disconnect the resistor from the wire harness 2 Measure the resistance across the resistor terminals using a digital multimeter ohms setting The resistance across the terminals should be at or near the resistors rated resistance Replace the resistor if a reading other than the rated resistance is obtained 3 If the resistor tests correctly and a circuit problem still exists check the wire harne...

Page 279: ...Both terminator resistors are required for proper electrical system operation Testing the CAN bus Terminator Resistors g257672 Figure 110 1 CAN bus terminator resistor external 2 Keyway 1 One terminator resistor is external plugged into the platform wire harness 2 expansion port located near the rear attachment electrical connector below the right rear corner of the operator platform Locate the ex...

Page 280: ...e the resistance value for the integrated termination resistor There should be 120 ohms resistance between terminals 2 and 3 of the Yanmar SA D connector E If testing determines the integrated termination resistor is faulty replace the engine ECU contact an Authorized Toro Distributor for assistance F After testing is complete install the SA D connector cap and make sure the external termination r...

Page 281: ... be used to verify that output current from the appropriate controller is available for the solenoid coil but the display will not verify that the solenoid coil and circuit wiring is functioning correctly refer to Using the InfoCenter Display for Troubleshooting page 3 23 To assist in troubleshooting identical replaceable solenoid coils can be exchanged If the problem follows the coil the coil is ...

Page 282: ...pproximately 7 1 ohms when tested at 20 C 68 F These are replaceable coils B The coils of solenoid valves SV1 SV2 SV3 and EH on the main manifold are the same Resistance of these coils should be approximately 7 3 ohms when tested at 20 C 68 F These are not replaceable coils If one of these coils fail a resistance test replace the entire valve assembly refer to Cartridge Valve Service page 5 88 3 R...

Page 283: ...wer to the solenoid coils The coils are named for the pump they control AB front pump and CD rear pump and their control function C1 forward direction and C2 reverse direction Note A faulty solenoid coil or solenoid circuit wiring problem will not be identified by the Info Center Display The Info Center Display can be used to verify that output current from the appropriate controller is available ...

Page 284: ...the two 2 connector terminals on the solenoid coil Coil resistance should be 3 66 ohms when tested at 20 C 68 F g256511 Figure 114 1 Solenoid coil 3 Coil nut 2 O ring 2 each 3 Replace the coil as necessary A Use a 12 point 26 mm socket to remove the coil nut B Slide the coil and O rings from the valve stem Discard the O rings and clean all corrosion or dirt from the valve C Lubricate new O rings w...

Page 285: ...ls and entire battery case clean because a dirty battery will discharge slowly IMPORTANT Do not remove fill caps while cleaning A Clean battery by washing entire case with a solution of baking soda and water Rinse with clear water B Coat battery posts and cable connectors with Toro Part No 107 0392 battery terminal protector or petroleum jelly to prevent corrosion WARNING Connecting the cables to ...

Page 286: ... level every 25 operating hours and every 30 days if machine is in storage Note Do not fill the cells above the fill line 6 Maintain the cell level with the distilled or demineralized water Electrical System Service and Repairs Page 6 78 Outcross 9060 18234SL Rev B ...

Page 287: ...tery page 6 84 2 Store the battery on a shelf or on the machine with cables disconnected if stored on the machine in a cool atmosphere to avoid quick deterioration of the battery charge in an environment that will not be below freezing for an extended period Outcross 9060 Page 6 79 Electrical System Service and Repairs 18234SL Rev B ...

Page 288: ...s and caps Length 19 6 cm 10 9 inches Width 13 2 cm 6 6 inches Height 18 3 cm 8 0 inches The battery is the heart of the electrical system With the regular and correct service the battery life can be extended Additionally the battery and electrical component failure can be prevented CAUTION Battery electrolyte is corrosive and can burn skin and eyes and damage clothing While working with the batte...

Page 289: ... position 2 Remove the knobs washers and side cover from the left side of the machine 3 Disconnect the negative cable from the battery terminal then disconnect the positive cable from the battery terminal 4 Remove the two 2 wing nuts and the battery hold down rod 5 Make sure that the battery filler caps are secure and remove the battery from the battery compartment Installing the Battery IMPORTANT...

Page 290: ... Toro Part No 107 0392 or a light layer of petroleum jelly to the battery terminals and cable connectors to reduce corrosion 8 Make sure that rubber boot is properly placed over positive cable end and positive battery post 9 Install the side cover Inspecting Maintaining and Testing the Battery Temperature Correcting Specific Gravity Cell Temperature 100 F Cell Specific Gravity 1 245 38 C minus 27 ...

Page 291: ...s is clean before opening the caps A Use a hydrometer to measure the specific gravity of each cell Pull the electrolyte in and out of the hydrometer barrel before taking a reading to warm up the hydrometer At the same time take the temperature of the cell B Temperature correct each cell reading For each 6 C 10 F above 27 C 80 F add 0 004 to the specific gravity reading For each 6 C 10 F below 27 C...

Page 292: ...ons page 6 80 G Take a test voltage reading while still under load after 15 seconds then immediately remove the load H Use Minimum Voltage page 6 82 to determine the minimum voltage for the center cell electrolyte temperature reading I If the test voltage is below the minimum replace the battery If the test voltage is at or above the minimum return the battery to service Charging the Battery Batte...

Page 293: ...o dissipate the gases produced from the charging These gases are explosive keep open flame and electrical spark away from the battery Do not smoke Inhaling the battery gases can cause nausea Unplug the charger from the electrical outlet before connecting or disconnecting the charger leads from the battery terminals 3 Follow the battery charger manufacturer s instructions connect the charger cables...

Page 294: ...Electrical System Service and Repairs Page 6 86 Outcross 9060 18234SL Rev B ...

Page 295: ... the Tie Rod Length 7 3 Adjusting Axle Stop Bolts 7 3 Service and Repairs 7 5 Tie Rods 7 5 Front Axle 7 7 Rear Axle 7 10 Front and Rear Axle Service 7 13 Front PTO Gear Box 7 14 PTO Clutch 7 19 Rear PTO Gear Box 7 21 PTO Drive Shaft 7 24 Additional Reference Materials Carraro DriveTech Model 26 09M Axle Repair Manual Outcross 9060 Page 7 1 Traction and PTO Drive 18234SL Rev B ...

Page 296: ...Installation Instructions provide information regarding the operation general maintenance and maintenance intervals for the machine and its accessories Refer to the traction unit Operator s Manual and accessory Installation Instructions for additional information Traction and PTO Drive General Information Page 7 2 Outcross 9060 18234SL Rev B ...

Page 297: ...m nut and turn the inner tie rod shaft to adjust the tie rod length Front Tie Rod Length 10 22 0 03 inch Rear Tie Rod Length 10 45 0 03 inch 2 Tighten the jam nut Adjusting Axle Stop Bolts g254450 Figure 118 1 Front axle 2 Rear axle Outcross 9060 Page 7 3 Traction and PTO Drive Adjustments 18234SL Rev B ...

Page 298: ... Axle Stop Bolts continued Adjust the axle stop bolts after the axle has been installed on the machine and the tie rods have been installed Traction and PTO Drive Adjustments Page 7 4 Outcross 9060 18234SL Rev B ...

Page 299: ...tie rod being removed to hold the cylinder rod and remove the inner tie rod Installing the Tie Rods 1 Check and adjust the tie rod length if necessary refer to Adjusting the Tie Rod Length page 7 3 Note New inner tie rods have a thread locking compound pre applied on the steering cylinder end Clean the threads and apply a high strength thread locking compound if installing a used inner tie rod 2 U...

Page 300: ...axle stop bolts refer to Adjusting Axle Stop Bolts page 7 3 5 Continue to tighten the slotted nut to align if necessary and install a new cotter pin 6 Grease the outer tie rod with Mobil high temp XHP 222 grease or equivalent until the boot swells Do not allow the grease to purge from boot Traction and PTO Drive Service and Repairs Page 7 6 Outcross 9060 18234SL Rev B ...

Page 301: ...9 Spacer 4 each 4 Axle drive motor 12 Flange nut 2 each 20 Lug nut 12 each 5 Flange head screw 2 each 13 Retainer 2 each 21 Wheel assembly 2 each 6 Flange head screw 2 each 14 Flange head screw 4 each 22 Slotted nut 7 Cover 2 each 15 Flat washer 4 each 23 Cotter pin 8 Coupler assembly 16 Tie rod assembly 2 each Outcross 9060 Page 7 7 Traction and PTO Drive Service and Repairs 18234SL Rev B ...

Page 302: ... with 4 spacers plain washers and cap screws Tighten the screws from 359 to 386 N m 265 to 285 ft lb B Install the tie rod assemblies refer to Installing the Tie Rods page 7 5 2 If previously removed install the motor mount A Fit the motor mount to the axle with 4 cap screws Tighten the screws from 111 to 138 N m 82 to 102 ft lb B Install the covers 3 Raise and secure the axle to the machine with ...

Page 303: ...o the inner edge of the wheel and install the wheel Tighten the lug nuts in a crossing pattern from 380 to 434 N m 280 to 320 ft lb 12 Check and adjust front tire air pressure as necessary Outcross 9060 Page 7 9 Traction and PTO Drive Service and Repairs 18234SL Rev B ...

Page 304: ... 2 each 5 Cotter pin 2 each 13 Brake assembly 21 Lug nut 12 each 6 Slotted nut 2 each 14 Coupler assembly 22 Wheel assembly 2 each 7 Dowel pin 15 Cap screw 2 each 23 Steering cylinder 8 Rear speed sensor 16 Cap screw 2 each 24 Flange nut 4 each Removing the Rear Axle 1 Raise and support the rear of the machine refer to Jacking Instructions page 1 8 2 Remove the rear wheels Traction and PTO Drive S...

Page 305: ...m 111 to 138 N m 82 to 102 ft lb 3 Raise and secure the axle to the machine with 4 U bolts and flange nuts Ensure the axle is against the frame and each U bolt is flush against the bottom of the axle before tightening Tighten the U bolts as follows A Tighten each pair of U bolts in a crossing pattern to 81 N m 60 ft lb B Tighten each pair of U bolts in a crossing pattern to 169 N m 125 ft lb C Tig...

Page 306: ...tion unit Operator s Manual 13 Apply anti seize lubricant to the inner edge of the wheel and install the wheel Tighten the lug nuts in a crossing pattern from 380 to 434 N m 280 to 320 ft lb 14 Check and adjust front tire air pressure as necessary Traction and PTO Drive Service and Repairs Page 7 12 Outcross 9060 18234SL Rev B ...

Page 307: ...axle assembly Refer to the traction unit Operator s Manual for axle fluid change procedures Additional axle service information can be found in the Carraro Drivetech Repair Manual for Model 26 09M Outcross 9060 Page 7 13 Traction and PTO Drive Service and Repairs 18234SL Rev B ...

Page 308: ...Note The front PTO gear box output shaft seal can be replaced in the machine The PTO drive shaft must be disconnected but the gear box does not have to be removed Removing the Front PTO Gear Box 1 Remove the engine assembly refer to Removing the Engine page 4 17 2 Remove the front PTO gearbox from the flywheel housing and retrieve the coupler and dowel pins Traction and PTO Drive Service and Repai...

Page 309: ...and discard the shaft seal 4 Clean the gear box housing bore and cover the shaft splines with tape to protect the shaft seal during installation 5 Install the shaft seal and remove the tape from the shaft splines 6 Install the plate and tighten the flange head screws from 24 5 to 32 5 N m 18 to 24 ft lb 7 Apply anti seize lubricant to the splines of the output shaft and hub then install the hub an...

Page 310: ...ut shaft 9 Key 2 each 22 Plug 35 Gear 84T 10 Input shaft 23 Case 36 Wave washer 11 Bearing 24 Eyebolt 37 Cap screw 11 each 12 Wave washer 25 Coupler 38 13 Wave washer 26 Retaining ring 1 Remove the retaining ring and hub from the output shaft 2 Remove the socket head cap screws and use the tabs provided to pry the cover from the gear box 3 Retrieve the dowel pins from the cover or case and retriev...

Page 311: ...g surfaces with solvent and apply silicone sealant to only the mating surfaces 5 Place the wave washers over the clutch shaft and output shaft bearings 6 Fit the cover over the shaft bearings wave washers and dowel pins 7 Apply medium strength thread locking compound and install the socket head cap screws Tighten the cap screws in a crossing pattern from 31 to 36 N m 23 to 26 ft lb 8 Rotate the in...

Page 312: ...TO Gear Box continued 3 Apply a thin layer of anti seize lubricant to the splines of the output shaft and the coupler then install the coupler Traction and PTO Drive Service and Repairs Page 7 18 Outcross 9060 18234SL Rev B ...

Page 313: ...h refer to Removing the Front PTO Gear Box page 7 14 and Disassembling the Front PTO Gear Box page 7 16 PTO Clutch Service Note The disc packs are available in pre measured sets Do not mix old and new discs or replace discs individually 1 Pull and discard the bearing from the front of the clutch shaft 2 Remove the retaining ring thrust washers 77T gear and needle bearing from the clutch shaft 3 Re...

Page 314: ...rwise damage the surface of the clutch shaft when installing the retaining ring 9 Install the spring and thrust washer on the clutch shaft Compress the spring and install the retaining ring 10 Install the clutch disc pack in the basket and install the retaining ring 11 Coat the needle bearing with oil and install one of the thrust washers needle bearing 77T gear remaining thrust washer and the ret...

Page 315: ...ine The PTO drive shaft must be disconnected but the gear box does not have to be removed Removing the rear PTO Gear Box 1 Disconnect the breather hose from the top of the gear box 2 Remove the PTO drive shaft refer to Removing the PTO Drive Shaft page 7 24 3 Support the rear PTO gear box from overhead 4 Remove the 6 cap screws securing the rear of the gear box housing to the frame and lift the ge...

Page 316: ...shaft splines with tape to protect the shaft seal during installation 5 Install the shaft seal and remove the tape from the shaft splines 6 Install the retaining ring and the plate Tighten the flange head screws from 24 5 to 32 5 N m 18 to 24 ft lb 7 Apply a thin layer of anti seize lubricant to the splines of the input shaft and hub then install the hub and retaining ring Installing the Rear PTO ...

Page 317: ... top of the gear box 4 Check and adjust the rear PTO gear box fluid level refer to the traction unit Operator s Manual 5 Install the PTO drive shaft refer to Installing the PTO Drive Shaft page 7 26 Outcross 9060 Page 7 23 Traction and PTO Drive Service and Repairs 18234SL Rev B ...

Page 318: ... may be necessary to raise the operator platform to remove the PTO drive shaft If so block the operator platform to prevent it from lowering accidently 1 Remove the bed 2 Remove the PTO shaft cover 3 Remove the 2 shaft guards 4 Remove the screws securing the flange yokes to the gear box hubs and remove the PTO shaft 5 Slide the slip yoke off of the tube yoke Traction and PTO Drive Service and Repa...

Page 319: ...st one bearing and a large socket against the yoke on the opposite side B While supporting the large socket apply pressure on small socket to partially push the opposite bearing into the large socket C Remove the yoke from the press grasp the partially removed bearing and tap on the yoke to completely remove the bearing D Repeat the process for the remaining bearings 3 Thoroughly clean and inspect...

Page 320: ... Repeat procedure for the remaining bearings 5 Make sure that assembled joint moves without binding Slight binding can usually be eliminated by lightly rapping the yoke lugs with a soft faced hammer If binding continues disassemble the joint to identify the source of the binding Installing the PTO Drive Shaft 1 Apply a coating of grease to the slip yoke and tube yoke splines and fit the slip onto ...

Page 321: ...nd Accessory Installation Instructions 8 2 Service and Repairs 8 3 Front Screen 8 3 Hood 8 4 Operator Platform 8 6 Steering Wheel Instrument Panels and Dash Cover 8 15 Operator s Console 8 17 Seats 8 18 Standard Bed 8 21 Front Loader Attachment 8 22 Outcross 9060 Page 8 1 Chassis 18234SL Rev B ...

Page 322: ...cessory Installation Instructions provide information regarding the operation general maintenance and maintenance intervals for the machine and its accessories Refer to the traction unit Operator s Manual and accessory Installation Instructions for additional information Chassis General Information Page 8 2 Outcross 9060 18234SL Rev B ...

Page 323: ...ce lower any attachments shut off the engine and remove the key from the key switch 2 Release the hood latches and raise the hood 3 Release the front screen latch and tilt the screen forward 4 Remove the fasteners at either end of the screen tether 5 Remove the bolt and nut from the screen hinge and remove the screen 6 Inspect the screen for worn or damaged bumpers or seals and replace them as nec...

Page 324: ...33 1 Lynch pin 2 each 5 lock nut 9 Foam block 2 each 2 Hood skin 6 Lock nut 10 Hood frame 3 Hood prop 7 Washer 11 Bulb seal 4 Shoulder screw 8 Shoulder screw Chassis Service and Repairs Page 8 4 Outcross 9060 18234SL Rev B ...

Page 325: ... hood and remove the fasteners at either end of the hood prop CAUTION The hood assembly is bulky The hood assembly can safely be removed by two technicians one on each side of the machine 5 Remove the lynch pins from the hood hinge and remove the hood 6 Inspect the hood for worn or damaged seals radiator area and replace them as necessary 7 To install the hood follow this procedure in reverse orde...

Page 326: ...ange nut 4 each 9 Cap screw 4 each Removing the Operator s Platform 1 Remove the front loader if equipped 2 Remove the bed refer to Standard Bed page 8 21 or the optional cargo bed Installation Instructions 3 Remove the front cowl 4 Disconnect the battery refer to Removing the Battery page 6 81 5 Remove the front fenders Chassis Service and Repairs Page 8 6 Outcross 9060 18234SL Rev B ...

Page 327: ...y replaced during installation g255047 Figure 135 1 Access panel 4 Hydraulic manifold ST port 2 Battery negative cable 5 Hydraulic manifold LS OR1 port 3 Battery negative cable 6 Remove the access panel from the right side of the control console 7 Disconnect the battery positive and negative cables from the terminal bracket posts 8 Disconnect the hoses at the hydraulic manifold ST and LS OR1 ports...

Page 328: ...ne harness connector P18 9 Disconnect the engine wire harness from the engine ECU 10 Separate the operator platform wire harness from the frame wire harness at the 2 connectors under the right side of the dash cover 11 Disconnect the 3 pin engine wire harness connector P63 from the main harness 12 Disconnect the 7 pin engine wire harness connector P18 from the main harness Chassis Service and Repa...

Page 329: ...ly 13 Remove the main instrument panel mounting screws and lift the panel to access the glow start and EGR relays Remove the cap screw securing the relay bracket to the frame and pass the assembly out of the operator platform Outcross 9060 Page 8 9 Chassis Service and Repairs 18234SL Rev B ...

Page 330: ...itting 3 Hydraulic hose hydraulic tube 2 Hydraulic hose front steering cylinder left fitting 14 Label and disconnect the 3 hoses at the rear bulkhead Cap the fittings and plug the hoses to prevent contamination from entering the hydraulic system Chassis Service and Repairs Page 8 10 Outcross 9060 18234SL Rev B ...

Page 331: ...ont of the engine Cap the fittings and plug the hoses to prevent contamination from entering the engine or coolant lines IMPORTANT Important Do not allow refrigerant to discharge into the atmosphere Before opening or disconnecting parts from the refrigerant circuit empty the refrigerant into a specified recycling bottle and dispose of it correctly Outcross 9060 Page 8 11 Chassis Service and Repair...

Page 332: ...ob jam nut and rubber boot from the loader valve 19 Remove the 4 flange nuts snubbing washers and cap screws securing the operator platform to the frame CAUTION The standard operator platform assembly weighs approximately 748 kg 1 650 lb The operator platform and cab assembly weighs approximately 952 kg 2 100 lb Use an appropriate hoist to raise and lower the operator platform assembly 20 Using th...

Page 333: ...e used to secure these items to the machine Replace all cable ties and clamps that were removed from the machine during operator platform removal 5 Connect the refrigerant lines at the compressor if equipped 6 Connect the heater hoses at the engine if equipped 7 Connect the 3 hydraulic hoses to the bulkhead at the rear of the operator platform 8 Install the relay assembly and the main instrument p...

Page 334: ...d with air conditioning have a certified refrigeration technician fill recharge and test the air conditioning system 22 Operate the machine carefully at first to allow the hydraulic system to refill with fluid Check for and correct any hydraulic leaks Check and adjust the hydraulic fluid level as required refer to the traction unit Operator s Manual Chassis Service and Repairs Page 8 14 Outcross 9...

Page 335: ... 8 Button head screw 3 each 14 Steering wheel cover 3 Washer 2 each 9 Flange head screw 2 each 15 Button head screw 4 each 4 Steering column cover 10 Flange nut 2 each 16 Instrument panel console 5 Button head screw 4 each 11 Steering wheel 6 Instrument panel steering 12 Washer Outcross 9060 Page 8 15 Chassis Service and Repairs 18234SL Rev B ...

Page 336: ...r assembly purposes and disconnect the wire harness from the panel controls 7 Remove the steering column cover 8 Remove the console instrument panel fasteners and move the panel to allow access to the 2 dash cover to console fasteners 9 Remove the dash cover Installing the Steering Wheel Instrument Panels and Dash Cover 1 Install the dash cover 2 Install the 2 dash cover to console fasteners then ...

Page 337: ...he key switch 2 Disconnect the battery refer to Removing the Battery page 6 81 3 Remove the access panel from the left side of the console 4 Remove the console instrument panel Label all the wire harness connections for assembly purposes and disconnect the wire harness from the panel controls 5 Remove the main instrument panel fasteners and move the panel to allow access to the 2 fasteners securin...

Page 338: ... Flange head screw 4 each 4 Cap screw 4 each 10 Flange nut 4 each 5 Seat belt buckle 2 each 11 Spacer 2 each 6 Lock nut 2 each 12 Cap screw 4 each Apply medium strength thread locking compound and tighten the seat belt mounting screws from 68 to 81 N m 50 to 60 ft lb Chassis Service and Repairs Page 8 18 Outcross 9060 18234SL Rev B ...

Page 339: ... RH support cover 17 Magnet 29 Flat head screw 3 each 6 Bushing 2 each 18 Seat switch 30 Adaptor plate 7 Backrest 19 Rivet 4 each 31 Screw 8 Plug 2 each 20 Mounting plate 32 Lever 9 Cable tie 3 each 21 Return spring 33 Handle 10 LH adjustment rail 22 Torx screw 5 each 34 Nut 11 Bumper 2 each 23 RH adjustment rail 35 Support bracket 12 Washer 24 Rail stop 36 Cap screw Outcross 9060 Page 8 19 Chassi...

Page 340: ... assembly 14 Bellows 5 Tether 10 Handle 15 Lower suspension Remove the operator seat to gain access the seat suspension assembly Most of the operator seat suspension components can be serviced with the lower seat suspension mounted to the frame platform If the air spring assembly requires removal the lower seat suspension must be removed from the seat platform Chassis Service and Repairs Page 8 20...

Page 341: ...e nut 4 each 2 Flange head screw 4 each CAUTION The standard bed weighs approximately 107 kg 235 lbs Make sure the hoist lift or stands used to remove the bed can properly support the weight Outcross 9060 Page 8 21 Chassis Service and Repairs 18234SL Rev B ...

Page 342: ...assembly 4 Female coupler assembly Refer to General Precautions for Removing and Installing the Hydraulic System Components page 5 49 prior to removing hydraulic system components CAUTION The front loader arm assembly weighs approximately 218 kg 480 lbs Chassis Service and Repairs Page 8 22 Outcross 9060 18234SL Rev B ...

Page 343: ... 9 4 Adjustments 9 5 Adjusting the Compressor Belt Tension 9 5 Adjusting the Doors 9 6 Service and Repairs 9 7 General Precautions for Removing and Installing Air Conditioning System Components 9 7 Air Conditioning Compressor 9 9 Heating and Air Conditioning Components 9 11 Control Panel and Windshield Wiper Assembly 9 12 Doors 9 15 Additional Reference Materials Sanden SD Compressor Service Guide...

Page 344: ...ccessories Refer to the traction unit Operator s Manual and accessory Installation Instructions for additional information Electrical Components Schematics and Wire Harness Drawings For information regarding machine electrical cab components switches and relays refer to Chapter 6 Electrical System page 6 1 The electrical schematic and wire harness drawings for the operator cab are included in Appe...

Page 345: ...an motor is a component of the mixing box located in the cab headliner The fan motor is also used for the cab heating system Operator controls to turn the air conditioning on to adjust the fan speed and to control the cab air temperature Air Conditioning Performance There are a number of factors that can affect the performance of the machine air conditioning system To ensure the best system operat...

Page 346: ...ough the heater core A blower fan motor that provides air movement through the heater core and into the cab The fan motor is a component of the mixing box located in the cab headliner The fan motor is also used for the air conditioning system Operator controls to adjust the fan speed and to control the amount of coolant passing through the heater core air temperature Operator Cab General Informati...

Page 347: ...ension 19 mm 0 75 inch deflection when 6 8 kg 15 lb is applied half way between the engine and compressor pulleys 1 Loosen nut at bottom of tensioner plate and lift or gently pry compressor upward to decrease belt s deflection 2 Tighten nut and recheck belt tension Outcross 9060 Page 9 5 Operator Cab Adjustments 18234SL Rev B ...

Page 348: ... to ensure proper sealing at the 3 points indicated The distance between the sealing surface of the frame and the outer edge of the door trim when the door is fully latched should be from 19 to 25 mm 0 8 to 1 0 inch 3 Loosen the striker stud lock nut to move the striker stud and adjust the door fit Disassemble the striker stud and rotate the adjuster to increase stud movement if necessary Operator...

Page 349: ...r conditioning system components Thorough cleaning will prevent system contamination while performing service procedures 3 Before loosening or removing any air conditioning system hose or other component have a certified air conditioning service technician recover the system refrigerant and then evacuate the air conditioning system completely It is illegal to vent refrigerant to the atmosphere 4 P...

Page 350: ... caps are always placed on the pressure hose ports These caps prevent refrigerant leakage from the system 13 The drier receiver component is used to collect moisture that will reduce air conditioning performance If the air conditioning system is opened for component repair or replacement make sure that the drier receiver ports are plugged to prevent damage to the drier receiver If either the compr...

Page 351: ...ompressor 1 Disconnect the compressor electrical connector from machine wire harness WARNING The air conditioning system is under high pressure Do not loosen any system fitting or component until after the system has been completely discharged by a certified air conditioning service technician 2 Have refrigerant evacuated from air conditioning system by a certified air conditioning service technic...

Page 352: ...mize the gap between the compressor and the bracket before tightening fasteners 6 To install the compressor follow this procedure in reverse order 7 Adjust the compressor belt tension refer to Adjusting the Compressor Belt Tension page 9 5 8 Have a certified air conditioning service technician evacuate the air conditioning system completely properly recharge the system with R134a refrigerant and t...

Page 353: ...ter core 12 Condenser fans 3 Thermostat resistor 8 Pressure switch 13 Condenser 4 Blower 9 Drier receiver 5 Heat valve 10 Heater engine coolant hoses Remove the roof to access the heating and air conditioning components Inspect and repair damaged roof seals as necessary before installing the roof Outcross 9060 Page 9 11 Operator Cab Service and Repairs 18234SL Rev B ...

Page 354: ...Wiper Assembly Note If possible operate the windshield wipers to ensure the wiper motor shaft is in its home position prior to disassembly 1 Mark the wipers left and right Disconnect the washer supply hoses at the bulkhead fittings and remove windshield wipers 2 Remove the windshield wiper boots lock nuts cups and rubber washers from the roof panel 3 Remove the 4 cap screws securing the control pa...

Page 355: ...ement wiper motors are shipped with the shaft in the home position You may also energize and operate the wiper motor for at least one cycle to set the motor to its home position C Align the linkage drive arms as shown center arm cap screw head upward and fit the center arm over the wiper motor shaft Tighten the center arm cap screw from 11 to 12 N m 95 to 105 ft lb 3 Connect the control panel wire...

Page 356: ...ling the Control Panel and Windshield Wiper Assembly continued 7 Test wiper and washer operation before returning the machine to service Operator Cab Service and Repairs Page 9 14 Outcross 9060 18234SL Rev B ...

Page 357: ... 14 each 9 Retainer 8 each 15 Hex nut 2 each 4 Acorn nut 8 each 10 Flange head screw 8 each 16 Striker guard 2 each 5 Door mount LH shown 11 Washer 4 each 17 Shoulder bolt 2 each 6 Door spring 2 each 12 Striker stud 2 each CAUTION Each door assembly weighs approximately 41 kg 90 lbs Outcross 9060 Page 9 15 Operator Cab Service and Repairs 18234SL Rev B ...

Page 358: ...g item 6 as shown with the barrel end at the door and the rod end at the frame Adjust the door fit against the frame as necessary refer to Adjusting the Doors page 9 6 Operator Cab Service and Repairs Page 9 16 Outcross 9060 18234SL Rev B ...

Page 359: ...m Engine A 13 Wire Harness Headlights A 14 Wire Harness Cab Rooftop A 15 Wire Harness Cab Control Panel A 16 Wire Harness Cab Heat Air Conditioning A 17 Wire Harness InchMode optional A 18 Wire Harness Loader Selector Control Valve SCV Switch optional A 19 Wire Harness Loader Selector Control Valve SCV Valve optional A 20 Wire Harness Rear Selector Control Valve SCV Kit optional A 21 Wire Harness ...

Page 360: ...hines include a line with an alternate color These wires are identified with the wire color and line color with either a or _ separating the color abbreviations listed above e g R BK is a red wire with a black line OR_BK is an orange wire with a black line Wire Size The individual wires of the electrical harness diagrams in this chapter identify both the wire color and the wire size Examples 16 BK...

Page 361: ...Outcross 9060 Drawing 133 7829 Rev A Sheet 1 of 1 18234SL Rev B Page A 3 Hydraulic Schematic g259663 ...

Page 362: ...Page A 4 18234SL Rev B Outcross 9060 Drawing 122 1360 Rev 1 Sheet 1 of 3 Electrical Schematic part 1 of 3 g264053 ...

Page 363: ...Outcross 9060 Drawing 122 1360 Rev 1 Sheet 2 of 3 18234SL Rev B Page A 5 Electrical Schematic part 2 of 3 g264054 ...

Page 364: ...Page A 6 18234SL Rev B Outcross 9060 Drawing 122 1063 Rev A Sheet 3 of 3 Electrical Schematic part 3 of 3 g267771 ...

Page 365: ...Outcross 9060 Drawing 122 0923 Rev A Sheet 1 of 1 18234SL Rev B Page A 7 Wire Harness Drawing Frame g256296 ...

Page 366: ...Page A 8 18234SL Rev B Outcross 9060 Drawing 122 0923 Rev A Sheet Wire Harness Diagram Frame g256295 ...

Page 367: ...Outcross 9060 Drawing 122 0922 Rev A Sheet 18234SL Rev B Page A 9 Wire Harness Drawing Platform g256443 ...

Page 368: ...Page A 10 18234SL Rev B Outcross 9060 Drawing 122 0922 Rev A Sheet Wire Harness Diagram Platform g256441 ...

Page 369: ...Outcross 9060 Drawing 122 0922 Rev A Sheet 18234SL Rev B Page A 11 Wire Harness Diagram Platform continued g256442 ...

Page 370: ...Page A 12 18234SL Rev B Outcross 9060 Drawing 122 0921 Rev A Sheet 1 of 1 Wire Harness Drawing Engine g256294 ...

Page 371: ...Outcross 9060 Drawing 122 0921 Rev A Sheet 1 of 1 18234SL Rev B Page A 13 Wire Harness Diagram Engine g256293 ...

Page 372: ...Page A 14 18234SL Rev B Outcross 9060 Drawing 122 1045 122 1046 Rev A A Sheet 1 of 1 Wire Harness Headlights g259593 ...

Page 373: ...Outcross 9060 Drawing 122 1245 Rev B Sheet 1 of 1 18234SL Rev B Page A 15 Wire Harness Cab Rooftop g256477 ...

Page 374: ...Page A 16 18234SL Rev B Outcross 9060 Drawing 122 1260 Rev A Sheet 1 of 1 Wire Harness Cab Control Panel g256479 ...

Page 375: ...Outcross 9060 Drawing 122 1166 Rev A Sheet 1 of 1 18234SL Rev B Page A 17 Wire Harness Cab Heat Air Conditioning g256480 ...

Page 376: ...Page A 18 18234SL Rev B Outcross 9060 Drawing 122 1385 Rev A Sheet 1 of 1 Wire Harness InchMode optional g259592 ...

Page 377: ...Outcross 9060 Drawing 122 1382 Rev A Sheet 1 of 1 18234SL Rev B Page A 19 Wire Harness Loader Selector Control Valve SCV Switch optional g260279 ...

Page 378: ...Page A 20 18234SL Rev B Outcross 9060 Drawing 122 1383 Rev A Sheet 1 of 1 Wire Harness Loader Selector Control Valve SCV Valve optional g260280 ...

Page 379: ...Outcross 9060 Drawing 122 1384 Rev A Sheet 1 of 1 18234SL Rev B Page A 21 Wire Harness Rear Selector Control Valve SCV Kit optional g260281 ...

Page 380: ...Page A 22 18234SL Rev B Outcross 9060 Drawing 122 1248 Rev A Sheet 1 of 1 Wire Harness Cab Work Light Kit optional g260313 ...

Page 381: ...Outcross 9060 Drawing 122 1387 Rev A Sheet 1 of 1 18234SL Rev B Page A 23 Wire Harness Domestic Road Light Kit optional g259650 ...

Page 382: ...Page A 24 18234SL Rev B Outcross 9060 Drawing 122 1249 Rev A Sheet 1 of 1 Wire Harness Turn Signal Hazard Lights optional g260339 ...

Page 383: ...Outcross 9060 Drawing 122 1386 Rev A Sheet 1 of 1 18234SL Rev B Page A 25 Wire Harness International Road Light Kit optional g259651 ...

Page 384: ......

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