Toro 68138 Operator'S Manual Download

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Form No. 3421-177 Rev C

MB TX 2500 Tracked Mud Buggy

Model No. 68138—Serial No. 402100000 and Up

Model No. 68138G—Serial No. 402100000 and Up

Model No. 68138HD—Serial No. 400000000 and Up

Original

Instructions

(EN)

*3421-177* C

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Summary of Contents for 68138

Page 1: ...68138 Serial No 402100000 and Up Model No 68138G Serial No 402100000 and Up Model No 68138HD Serial No 400000000 and Up Original Instructions EN 3421 177 C www discount equipment com G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 2: ...ne needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulotte Barreto Power Blanket Nifty Lift Atlas Copco Chicago Pneumatic Allmand Miller Curber Skyjack Lull Skytrak Tsurumi Husquvarna Target Stow Wacker Sakai Mi T M Sullair Basic Dynapac MBW Weber Bartell Bennar Newman Haulotte Ditch Runner Menegotti M...

Page 3: ...to the State of California to cause cancer birth defects or other reproductive harm Introduction This machine is intended to be used by professional hired operators in commercial applications This machine is a stable reliable and productive machine for carrying and moving materials for any job site It is primarily designed to move concrete mortar gravel dirt or debris around job sites Read this in...

Page 4: ...ecommended Maintenance Schedule s 17 Pre Maintenance Procedures 18 Releasing the Cushion for Rear Access 18 Using the Cylinder Lock 18 Lubrication 19 Greasing the Machine 19 Engine Maintenance 19 Servicing the Air Cleaner 19 Checking the Engine Oil Level 20 Changing the Engine Oil and Filter 21 Servicing the Spark Plugs 22 Cleaning the Blower Housing 23 Fuel System Maintenance 24 Replacing the Fue...

Page 5: ...ace Do not store the machine or fuel container where there is an open flame spark or pilot light such as on a water heater or other appliance If you spill fuel do not attempt to start the engine avoid creating any source of ignition until the fuel vapors have dissipated Check that the operator s presence controls safety switches and shields are attached and functioning properly Do not operate the ...

Page 6: ... end so when traveling up or down slopes with a full hopper walk behind the machine with the full hopper uphill Identify hazards at the base of the slope Do not operate the machine near drop offs ditches embankments water or other hazards The machine could suddenly roll over if a wheel or track goes over the edge or the edge collapses Keep a safe distance twice the width of the machine between the...

Page 7: ...om the battery Keep your body and hands away from pinhole leaks or nozzles that eject high pressure hydraulic fluid Use cardboard or paper to find hydraulic leaks never use your hands Hydraulic fluid escaping under pressure can penetrate skin and cause injury requiring surgery within a few hours by a qualified surgeon otherwise gangrene may result Safety and Instructional Decals Safety decals and ...

Page 8: ... automatically decal132 9051 132 9051 1 Tie down point decal132 9052 132 9052 1 Main 15 A 3 Logic 7 5 A 2 Auxiliary 15 A decal137 0575 137 0575 1 Read the Operator s Manual 3 Cold fill line 2 Transmission fluid decal137 8899 137 8899 1 Read the Operator s Manual 7 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 9: ...ring protection must be worn 9 Warning keep bystanders a safe distance away from the machine watch behind you when moving in reverse 15 Right traction controls 4 Warning all operators should be trained before operating the machine 10 Warning engage the parking brake shut off the engine and remove the key before leaving the operator s position 16 Engine speed control 5 Warning keep away from moving...

Page 10: ...e has operated It operates when the engine is running Use these times for scheduling regular maintenance Figure 4 Choke Control Use the choke to start a cold engine Pull the choke knob up to engage it Push the choke knob down to disengage it Figure 4 Key Switch Use the key switch to start the engine Figure 4 The switch has 3 positions OFF RUN and START Throttle Lever The throttle lever is variable...

Page 11: ... right sides of the machine from the normal operating position Important Before operating check the fuel and oil level and remove debris from the machine Also ensure that the area is clear of people and debris Adding Fuel For best results use only clean fresh less than 30 days old unleaded gasoline with an octane rating of 87 or higher R M 2 rating method ETHANOL Gasoline with up to 10 ethanol gas...

Page 12: ...gnite the fuel vapors A fire or explosion from fuel can burn you and others and can damage property Always place fuel containers on the ground away from your vehicle before filling Do not fill fuel containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge When practical remove fuel...

Page 13: ...he Engine Oil Level page 20 Check the hydraulic fluid level for the drive system refer to Checking the Hydraulic Fluid Level for the Drive System page 32 Check the hydraulic fluid level for the lift system refer to Checking the Hydraulic Fluid Level for the Lift System page 34 Operating the Parking Brake Always engage the parking brake when you stop the machine or leave it unattended Before each u...

Page 14: ...ition Starting the Engine 1 Engage the parking brake 2 Engage the choke Note A warm or hot engine may not require choking You may need to repeat the starting cycle when you start the engine for the first time after you have filled a completely empty fuel system with fuel 3 Move the throttle between the FAST and SLOW positions 4 Turn the key switch to the START position 5 When the engine starts dis...

Page 15: ...opper 2 Lower the hopper Removing Debris from the Machine 1 Park the machine on a level surface move the motion control levers to the NEUTRAL LOCK position engage the parking brake and lower the hopper 2 Shut off the engine and remove the key Allow the engine to cool 3 Clean the inside of the hopper using a hose Important Do not use a hammer to remove material from the inside of the hopper this ma...

Page 16: ... trailer or truck has all the necessary brakes lighting and marking as required by law Please carefully read all the safety instructions Knowing this information could help you your family pets or bystanders avoid injury Refer to your local ordinances for trailer and tie down requirements Important Do not operate or drive the machine on roadways 1 Lower the hopper 2 If using a trailer connect it t...

Page 17: ...d to locate the 2 lift loops and attach a chain or straps at each of the loops as shown in Figure 14 Note Take up the slack in the chain or straps to properly balance the unit g194436 Figure 14 1 Lift points under hopper 2 Rear tie down loops 16 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 18: ...machine grease immediately after every washing Check the battery Check and adjust the track tension Every 100 hours Replace the air cleaner paper element more often under extremely dusty dirty conditions Change the engine oil and the engine oil filter Check the spark plug Remove the cooling shrouds and clean the cooling areas more often under extremely dusty dirty conditions Replace the fuel filte...

Page 19: ...rking brake and fully raise the hopper 2 Remove the 2 cotterless pins securing the cylinder lock to the machine 3 Slide the cylinder lock over the lift cylinder rod and secure with the cotterless pins Figure 16 g185887 Figure 16 1 Cylinder lock 2 Lift cylinder rod 4 Slowly lower the hopper until the cylinder lock contacts the cylinder body and rod end Removing and Storing the Cylinder Lock Importa...

Page 20: ...ten under extremely dusty dirty conditions Every 100 hours Replace the air cleaner paper element more often under extremely dusty dirty conditions Note Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure Note Service the air cleaner more often under extremely dusty dirty conditions Removing the Elements 1 R...

Page 21: ...all the foam element onto the paper element 2 Install the elements onto the air cleaner base Figure 19 3 Install the cover and secure it with the latches Figure 18 Checking the Engine Oil Level Service Interval Before each use or daily Important Remember to add 80 of the oil and then gradually fill it to the Full mark on the dipstick Important Do not run the engine with the oil level above the Ful...

Page 22: ...e motion control levers to the NEUTRAL LOCK position engage the parking brake raise the hopper and install the cylinder lock 2 Shut off the engine and remove the key 3 Perform the following steps to change the engine oil A Remove the drain plug and allow all of the existing oil to drain out of the engine Figure 22 g185888 g031623 Figure 22 B Install the drain plug Figure 22 Torque the plug to 13 6...

Page 23: ...ing the Spark Plugs Service Interval Every 100 hours Check the spark plug Every 300 hours Replace the spark plug The spark plugs are RFI compliant Equivalent alternate brand plugs can also be used Type Champion XC12YC Air Gap 0 76 mm 0 03 inch 22 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 24: ...he insulator usually means the air cleaner is dirty Set the gap to 0 76 mm 0 03 inch g027479 Figure 26 Installing the Spark Plug g028109 Figure 27 Important Ensure that the spark plug is tightened to the correct torque specification A loose spark plug may cause the cylinder head to overheat while an overtightened spark plug may cause damage to the threads in the cylinder head Cleaning the Blower H...

Page 25: ...ely flammable and highly explosive A fire or explosion from fuel can burn you and others and can damage property Drain fuel from the fuel tank when the engine is cold Do this outdoors in an open area Wipe up any fuel that spills Never smoke when draining fuel and stay away from an open flame or where a spark may ignite the fuel fumes 1 Park the machine on a level surface move the motion control le...

Page 26: ...omponents causing sparks Sparks can cause the battery gasses to explode resulting in personal injury When removing or installing the battery do not allow the battery terminals to touch any metal parts of the machine Do not allow metal tools to short between the battery terminals and metal parts of the machine WARNING Incorrect battery cable routing could damage the machine and cables causing spark...

Page 27: ...e 25 2 Perform the following steps to check the electrolyte level A Ensure that the cell covers are free from dirt and debris Important Dirt and debris that enters the battery cells causes damage to the battery B Remove the covers from the top of the cells C Ensure that the electrolyte solution covers the lead plates Use distilled water to top off the solution level if needed 3 Ensure that the fil...

Page 28: ...urface move the motion control levers to the NEUTRAL LOCK position engage the parking brake and lower the hopper 2 Shut off the engine and remove the key Allow the engine to cool 3 Lift support the side of the machine to be worked on so that the track is 3 to 4 inches 7 6 to 10 cm off the ground 4 Using a water hose or pressure washer remove dirt from each track system Important Ensure that you us...

Page 29: ...cks are off the ground 5 Clean the drive sprocket the front wheel and the road wheels The road wheels should spin freely when clean 6 Remove the bolt 1 4 x 1 5 8 inch spacer and nut Figure 35 7 Turn the tensioning bolt to adjust the distance between the tension nut and the end tangent of the tension tube until the distance is correct as shown in Figure 35 8 Align the closest notch in the tensionin...

Page 30: ...the fuel tank refer to Releasing the Cushion for Rear Access page 18 4 Inspect the belt Figure 37 Replace the belt if it is worn refer to Replacing the Drive Belt page 29 Note The signs of a worn belt include squealing while the belt is rotating frayed edges burn marks and cracks on the belt g189546 Figure 37 1 Extension spring 2 Belt Replacing the Drive Belt Service Interval Every 300 hours 1 Par...

Page 31: ...lly adjust the right side motion control lever 1 Park the machine on a level surface lower the hopper engage the parking brake shut off the engine and remove the key 2 Push the motion control levers down out of the NEUTRAL LOCK position Figure 41 3 Check if the right motion control lever aligns horizontally with the left motion control lever Figure 41 g009436 Figure 41 1 Left motion control lever ...

Page 32: ...ing Brake Service Interval Before each use or daily 1 Park the machine on a level surface lower the hopper and engage the parking brake 2 Start the engine and move the throttle lever to the FAST position 3 Move the motion control levers forward Note The machine should not move forward Note If the machine moves forward refer to Adjusting the Parking Brake page 31 4 Release the parking brake 5 Move ...

Page 33: ...l Before each use or daily 1 Park the machine on a level surface move the motion control levers to the NEUTRAL LOCK position engage the parking brake and lower the hopper 2 Shut off the engine and remove the key Allow the engine to cool 3 Open the cowl 4 Use the sight window to check the fluid level in the expansion tank Figure 44 Note The fluid level should be at the fill line on the decal g20361...

Page 34: ...n plugs 10 Loosen the vent plug in each transmission until loose Figure 48 Note This allows air to escape the hydraulic system as you add hydraulic fluid g203517 Figure 48 1 Vent plug 11 Slowly add approximately 6 2 L 208 fl oz fluid to the expansion tank until it starts to come out of the vent plugs Important Use the fluid specified in Servicing the Hydraulic Drive System page 32 or equivalent Ot...

Page 35: ...hecking the Hydraulic Fluid Level for the Lift System Service Interval Before each use or daily Reservoir tank capacity 1 4 L 1 5 US quarts Hydraulic fluid type Toro Premium All Season Hydraulic Fluid or Mobil 424 Hydraulic Fluid Important Always use the correct hydraulic fluid Unspecified fluids will damage the hydraulic system Note Many hydraulic fluids are almost colorless making it difficult t...

Page 36: ... pressurize the reservoir to 34 kPa 5 psi Loosen the cap slowly to avoid injury whenever adding oil or working on the hydraulic system Use a wrench on the hex directly under the cap 4 Place a large drain pan under the fittings at the bottom of the reservoir tank 5 Disconnect a hose fitting and allow the fluid to drain into the pan 6 When finished install and tighten the fitting Note Dispose of the...

Page 37: ... refer to Checking the Hydraulic Fluid Level for the Lift System page 34 Note Do not overfill the reservoir tank 7 Remove the cylinder lock and lower the hopper Checking the Hydraulic Lines Service Interval Every 40 hours Check the hydraulic lines for leaks loose fittings kinked lines loose mounting supports wear and deterioration Make necessary repairs before operating WARNING Hydraulic fluid esc...

Page 38: ...per using a hose 4 Clean any debris from under the hopper 5 Wipe away debris from the air cleaner 6 Clean any debris buildup on the engine and in the transmission with a brush or blower Important It is preferable to blow dirt out rather than washing it out If you use water keep it away from electrical parts and hydraulic valves Do not use a high pressure washer High pressure washing can damage the...

Page 39: ...the engine F Start and run the engine until it does not start again G Dispose of fuel properly Recycle as per local codes Important Do not store fuel containing stabilizer conditioner longer than the duration recommended by the fuel stabilizer manufacturer 7 Remove the spark plugs and check the condition of them refer to Checking the Spark Plug page 23 8 Prepare the engine as follows A With the sp...

Page 40: ...ools and hospitals and on a wide variety of products Additionally some online and mail order retailers provide Prop 65 warnings on their websites or in catalogs How do the California warnings compare to federal limits Prop 65 standards are often more stringent than federal and international standards There are various substances that require a Prop 65 warning at levels that are far lower than fede...

Page 41: ...ne needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulotte Barreto Power Blanket Nifty Lift Atlas Copco Chicago Pneumatic Allmand Miller Curber Skyjack Lull Skytrak Tsurumi Husquvarna Target Stow Wacker Sakai Mi T M Sullair Basic Dynapac MBW Weber Bartell Bennar Newman Haulotte Ditch Runner Menegotti M...

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Toro 68138, Operator'S Manual

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