Toro Dingo TX 525 User manual

TX525
Service Manual
Sitework Systems
Form No. 492-9195

This service manual was written expressly for Toro service technicians. The Toro company has made every effort to
make the information in this manual complete and correct.
Basic shop safety knowledge and mechanical/electrical skills are assumed. The Table of Contents lists the systems
and the related topics covered in this manual.
For service information on drive systems, please refer to the Hydro-Gear BDP-10A/16A/21L Pump service manual
(form no. 492-4789), Hydro-Gear P Series Pump service manual (form no. BLN 52503) and Parker-Ross TF wheel
motor service manual (form no. 492-4753). For information specic to the engines used on this unit, refer to the
appropriate engine manufacturer’s service and repair instructions.
Units covered on in this manual are: TX525 Wide and Narrow Track, model years 2007 - current
The manual may also be specied for use on later model products.
The hydraulic power system is precision machinery. Maintain strict cleanliness control during all stages of service
and repair. Cover or cap all hose ends and ttings whenever they are exposed. Even a small amount of dirt or other
contamination can severely damage the system.
We are hopeful that you will nd this manual a valuable addition to your service shop. If you have any questions or
comments regarding this manual, please contact us at the following address:
The Toro Company
LCB Technical Services
8111 Lyndale Avenue South
Bloomington, MN 55420
The Toro Company reserves the right to change product specications or this manual without notice.
ABOUT THIS MANUAL
Copyright© All Rights Reserved
©2010 The Toro Company

ii Rev. 000 TX525 Service Manual
8/01/10Revision 000 . . . . . . . . . . . . .
REVISIONS

iiiTX525 Service Manual Rev. 000
TABLE OF CONTENTS
SAFETY INFORMATION
General Information......................................................................................................................1-1
Think Safety First..........................................................................................................................1-1
SPECIFICATIONS
General Specications..................................................................................................................2-1
Dimensions...................................................................................................................................2-1
Periodic Maintenance Items .........................................................................................................2-2
Performance (Narrow Track) ........................................................................................................2-2
Performance (Wide Track)............................................................................................................2-2
Hydraulic System..........................................................................................................................2-3
Hydraulic System cont..................................................................................................................2-4
Electrical System..........................................................................................................................2-4
Track System................................................................................................................................2-4
Torque Specications ...................................................................................................................2-5
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)....................................2-6
Standard Torque for Dry, Zinc and Steel Fasteners (Metric Series) .............................................2-7
Other Torque Specications .........................................................................................................2-8
Equivalents and Conversions.......................................................................................................2-9
U.S. to Metric Conversions.........................................................................................................2-10
MAINTENANCE
Recommended Maintenance Schedule........................................................................................3-1
Greasing the Traction Unit............................................................................................................3-2
Maintaining the Road Wheels.......................................................................................................3-3
Hydraulic Reservoir Tank..............................................................................................................3-4
Location .................................................................................................................................3-4
Checking the Hydraulic Fluid .................................................................................................3-4
Replacing the Hydraulic Filter.......................................................................................................3-5
Changing the Hydraulic Fluid .......................................................................................................3-6
Checking the Hydraulic Lines.......................................................................................................3-7
Vents - Hydraulic Tank..................................................................................................................3-7
Engine Servicing...........................................................................................................................3-8
Servicing the Cooling System.......................................................................................................3-9
Cleaning Radiator ..................................................................................................................3-9
Engine Coolant ......................................................................................................................3-9
Changing Engine Coolant ....................................................................................................3-10
Changing Engine Coolant Assembly....................................................................................3-14
Fuel System................................................................................................................................3-18
Drain & Clean Fuel Tank ......................................................................................................3-18
Fuel Tank Removal ..............................................................................................................3-19
Fuel Tank Installation ...........................................................................................................3-21
Replacing the In-Line Fuel Filter (Serial numbers 280000500 & higher) .............................3-24
Air Filter ......................................................................................................................................3-24
Fuse Block..................................................................................................................................3-25
Hydrostatic Pump Belt................................................................................................................3-25
Alternator/Fan Belt......................................................................................................................3-26
Track Inspection .........................................................................................................................3-27
Battery Maintenance...................................................................................................................3-28
Testing ........................................................................................................................................3-29
Special Tools ..............................................................................................................................3-30

iv Rev. 000 TX525 Service Manual
TABLE OF CONTENTS
ENGINE
Radiator & Oil Cooler Replacement .............................................................................................4-1
Radiator & Oil Cooler Assembly Removal .............................................................................4-1
Oil Cooler Removal................................................................................................................4-6
Oil Cooler Installation.............................................................................................................4-7
Radiator Removal ................................................................................................................4-10
Radiator Installation .............................................................................................................4-12
Radiator & Oil Cooler Assembly Installation ........................................................................4-15
Mufer Assembly & Air Cleaner Assembly Removal ..................................................................4-21
Glow Plug, Fuel Injector Access ..........................................................................................4-21
Mufer Removal...................................................................................................................4-21
Air Cleaner Assembly Removal ...........................................................................................4-23
Air Cleaner Assembly & Mufer Assembly Installation.........................................................4-24
Air Cleaner Assembly Installation...............................................................................................4-24
Mufer Installation ......................................................................................................................4-25
Alternator Replacement..............................................................................................................4-27
Alternator Removal ..............................................................................................................4-27
Alternator Mounting Styles...................................................................................................4-28
Alternator Installation ...........................................................................................................4-32
Checking the Alternator Belt Tension ...................................................................................4-37
Cooling Fan Replacement..........................................................................................................4-37
Cooling Fan Removal ..........................................................................................................4-37
Cooling Fan Installation .......................................................................................................4-38
Flywheel Replacement ...............................................................................................................4-40
Flywheel Removal................................................................................................................4-40
Flywheel Installation.............................................................................................................4-44
Starter Replacement...................................................................................................................4-49
Starter Removal ...................................................................................................................4-49
Starter Installation ................................................................................................................4-52
Starter Solenoid Replacement....................................................................................................4-55
Starter Solenoid Removal ....................................................................................................4-55
Starter Solenoid Installation .................................................................................................4-59
Engine Removal .........................................................................................................................4-64
Engine Component Removal ...............................................................................................4-87
Engine Installation ......................................................................................................................4-96
Engine Component Installation ............................................................................................4-96
Engine Assembly Installation ............................................................................................. 4-110
Checking, Adding & Bleeding the Engine Coolant ...................................................................4-138
Throttle Cable Adjustment ........................................................................................................4-142
Throttle Cable Replacement.....................................................................................................4-144
Throttle Cable Removal .....................................................................................................4-144
Throttle Cable Installation ..................................................................................................4-147
Alternator Assembly Teardown .................................................................................................4-153
Alternator Testing......................................................................................................................4-159
Stator .................................................................................................................................4-159
Rotor ..................................................................................................................................4-160
Slip Ring.............................................................................................................................4-161
Brush Wear ........................................................................................................................4-161
Rectier..............................................................................................................................4-162
IC Regulator.......................................................................................................................4-162
Alternator Reassembly .............................................................................................................4-163
Starter Assembly Teardown......................................................................................................4-171
Starter Assembly Rebuild .........................................................................................................4-180

vTX525 Service Manual Rev. 000
TABLE OF CONTENTS
ENGINE cont.
Starter Assembly Testing ..........................................................................................................4-188
Brush Wear ........................................................................................................................4-188
Brush Holder ......................................................................................................................4-188
Armature Coil .....................................................................................................................4-189
Field Coil ............................................................................................................................4-189
ELECTRICAL
Electrical.......................................................................................................................................5-1
Heat Shield Removal .............................................................................................................5-1
Ignition Switch ..............................................................................................................................5-2
Purpose..................................................................................................................................5-2
Location .................................................................................................................................5-2
How It Works..........................................................................................................................5-2
Testing....................................................................................................................................5-3
Hour Meter....................................................................................................................................5-3
Purpose..................................................................................................................................5-3
Location .................................................................................................................................5-3
How It Works..........................................................................................................................5-4
Testing....................................................................................................................................5-4
Fuel Gauge...................................................................................................................................5-4
Purpose..................................................................................................................................5-4
Location .................................................................................................................................5-4
How It Works..........................................................................................................................5-4
Testing....................................................................................................................................5-4
Relay ............................................................................................................................................5-5
Purpose..................................................................................................................................5-5
Location .................................................................................................................................5-5
How It Works..........................................................................................................................5-5
Testing....................................................................................................................................5-6
Engine Oil Pressure and Battery Charge Indicator Light Cluster .................................................5-6
Purpose..................................................................................................................................5-6
Location .................................................................................................................................5-6
How It Works..........................................................................................................................5-7
Testing - Oil Pressure Light....................................................................................................5-7
Testing - Battery Charge Light ...............................................................................................5-7
Water Temperature and Glow Plug Indicator Light Cluster...........................................................5-7
Purpose..................................................................................................................................5-7
Location .................................................................................................................................5-7
How It Works..........................................................................................................................5-8
Testing - Water Temperature Light .........................................................................................5-8
Testing - Glow Plug Light .......................................................................................................5-8
Glow Plug Switch..........................................................................................................................5-8
Purpose..................................................................................................................................5-8
Location .................................................................................................................................5-8
How It Works..........................................................................................................................5-9
Testing....................................................................................................................................5-9
Water Temperature Sender ..........................................................................................................5-9
Purpose..................................................................................................................................5-9
Location .................................................................................................................................5-9
How It Works........................................................................................................................5-10
Testing..................................................................................................................................5-10

vi Rev. 000 TX525 Service Manual
TABLE OF CONTENTS
ELECTRICAL cont.
Oil Pressure Switch ....................................................................................................................5-10
Purpose................................................................................................................................5-10
Location ...............................................................................................................................5-10
How It Works........................................................................................................................5-10
Testing..................................................................................................................................5-10
Neutral Proximity (Magnetic) Switch........................................................................................... 5-11
Purpose................................................................................................................................ 5-11
Location ............................................................................................................................... 5-11
How It Works........................................................................................................................ 5-11
Testing..................................................................................................................................5-12
Fuel Sender................................................................................................................................5-12
Purpose................................................................................................................................5-12
Location ...............................................................................................................................5-12
How It Works........................................................................................................................5-12
Testing..................................................................................................................................5-13
Alarm, Low Engine Oil................................................................................................................5-13
Purpose................................................................................................................................5-13
Location ...............................................................................................................................5-13
How It Works........................................................................................................................5-13
Testing..................................................................................................................................5-13
Fuses..........................................................................................................................................5-14
Purpose................................................................................................................................5-14
Location ...............................................................................................................................5-14
How It Works........................................................................................................................5-14
Testing..................................................................................................................................5-14
Fusible Link ................................................................................................................................5-14
Purpose................................................................................................................................5-14
Location ...............................................................................................................................5-14
How It Works........................................................................................................................5-15
Testing..................................................................................................................................5-15
Glow Plug ...................................................................................................................................5-16
Purpose................................................................................................................................5-16
Location ...............................................................................................................................5-16
How It Works........................................................................................................................5-16
Testing..................................................................................................................................5-16
Battery ........................................................................................................................................5-17
Purpose................................................................................................................................5-17
Location ...............................................................................................................................5-17
How It Works........................................................................................................................5-17
Testing..................................................................................................................................5-17
Storage ................................................................................................................................5-18
Alternator....................................................................................................................................5-18
Purpose................................................................................................................................5-18
Location ...............................................................................................................................5-18
How It Works........................................................................................................................5-18
Testing..................................................................................................................................5-18
Starter.........................................................................................................................................5-19
Purpose................................................................................................................................5-19
Location ...............................................................................................................................5-19
How It Works........................................................................................................................5-19
Testing..................................................................................................................................5-19

viiTX525 Service Manual Rev. 000
TABLE OF CONTENTS
HYDRAULIC SYSTEM
2 Spool Loader Valve Replacement .............................................................................................6-1
2 Spool Loader Valve Removal..............................................................................................6-1
2 Spool Loader Valve Installation...........................................................................................6-5
Auxiliary Valve Replacement ........................................................................................................6-9
Auxiliary Valve Removal.........................................................................................................6-9
Auxiliary Valve Installation....................................................................................................6-14
Tandem Pump / Engine Coupling Assembly Replacement ........................................................6-19
Coupling Removal................................................................................................................6-19
Coupling Installation.............................................................................................................6-20
Hydraulic Oil Filter Head Replacement ......................................................................................6-22
Hydraulic Oil Filter Head Removal.......................................................................................6-22
Hydraulic Oil Filter Head Installation....................................................................................6-25
Hydraulic Tandem Pump Replacement ......................................................................................6-30
Hydraulic Tandem Pump Removal.......................................................................................6-30
Hydraulic Tandem Pump Installation....................................................................................6-37
Hydraulic Tandem Pump Rebuild ...............................................................................................6-42
6 gpm Pump Disassembly ...................................................................................................6-44
14 gpm Pump Disassembly .................................................................................................6-45
14 gpm Pump Assembly ......................................................................................................6-48
6 gpm Pump Assembly ........................................................................................................6-51
Hydraulic Tandem Pump Assembly......................................................................................6-54
Auxiliary Valve Rebuild ...............................................................................................................6-57
Auxiliary Valve......................................................................................................................6-57
Relief Assembly ...................................................................................................................6-64
Spool Assembly ...................................................................................................................6-64
Auxiliary Valve Assembly .....................................................................................................6-64
Loader Valve Rebuild .................................................................................................................6-72
Joystick Assembly Installation..............................................................................................6-74
Spool Removal.....................................................................................................................6-77
Spool Assembly ...................................................................................................................6-83
Main Relief Valve .................................................................................................................6-90
Work Port Relief...................................................................................................................6-92
Lift Cylinder Assembly Rebuild ...................................................................................................6-94
Lift Cylinder Disassembly.....................................................................................................6-96
Lift Cylinder Assembly........................................................................................................6-101
Tilt Cylinder Assembly Rebuild .................................................................................................6-103
Tilt Cylinder Disassembly...................................................................................................6-106
Tilt Cylinder Assembly........................................................................................................ 6-112
DRIVE SYSTEM
Lifting the Machine for Service .....................................................................................................7-1
Track Guide Alignment .................................................................................................................7-3
Belt Replacement .........................................................................................................................7-5
Belt Removal..........................................................................................................................7-5
Belt Installation.......................................................................................................................7-8
Idler Arm Replacement...............................................................................................................7-12
Idler Arm Removal ...............................................................................................................7-12
Idler Arm Assembly Installation ............................................................................................7-15
Right Hydrostatic Pump Replacement........................................................................................7-18
Right Hydrostatic Pump Removal ........................................................................................7-18
Right Hydrostatic Pump Installation .....................................................................................7-29

viii Rev. 000 TX525 Service Manual
TABLE OF CONTENTS
DRIVE SYSTEM cont.
Left Hydrostatic Pump Replacement..........................................................................................7-39
Left Hydrostatic Pump Removal ..........................................................................................7-39
Left Hydrostatic Pump Installation .......................................................................................7-48
Wheel Motor Replacement.........................................................................................................7-56
Wheel Motor Removal .........................................................................................................7-56
Wheel Motor Installation ......................................................................................................7-62
Track Replacement ....................................................................................................................7-68
Wide Track Removal............................................................................................................7-68
Wide Track Installation.........................................................................................................7-70
Narrow Track Removal ........................................................................................................7-72
Narrow Track Installation .....................................................................................................7-73
Track Guide Replacement..........................................................................................................7-75
Track Guide Removal ..........................................................................................................7-75
Track Guide Installation .......................................................................................................7-76
Road Wheel Replacement..........................................................................................................7-77
Road Wheel Removal ..........................................................................................................7-77
Road Wheel Rebuild ............................................................................................................7-79
Road Wheel Installation .......................................................................................................7-80
Tensioner Arm Replacement - Wide Track .................................................................................7-82
Tensioner Arm Removal - Wide Track..................................................................................7-82
Tensioner Arm Rebuild - Wide Track....................................................................................7-83
Tensioner Arm Installation - Wide Track...............................................................................7-87
Tensioner Arm Wheel Bearing Replacement - Wide Track.........................................................7-90
Tensioner Arm Wheel Bearing Removal - Wide Track .........................................................7-90
Tensioner Arm Wheel Bearing Installation - Wide Track ......................................................7-94
Tensioner Wheel Bearing Replacement - Narrow Track.............................................................7-97
Tensioner Wheel Bearing Removal - Narrow Track .............................................................7-97
Tensioner Wheel Bearing Installation - Narrow Track ..........................................................7-99
BRAKE ASSEMBLY
Parking Brake Assembly Replacement ........................................................................................8-1
Brake Assembly Removal 270000100 - 270000999..............................................................8-1
Brake Cable Replacement 270000100 - 270000999............................................................8-7
Brake Assembly Installation 270000100 - 270000999......................................................... 8-11
Brake Assembly Removal 280000100 & higher...................................................................8-18
Brake Cable Replacement 280000100 & higher..................................................................8-24
Brake Assembly Installation 280000100 & higher................................................................8-26
Brake Plate Replacement 280000100 & higher .........................................................................8-32
Brake Plate Removal ...........................................................................................................8-32
Brake Plate Installation ........................................................................................................8-36
Brake Handle Spring Bracket Assembly Replacement 280000100 & higher .............................8-40
Brake Handle Spring Bracket Assembly Removal ...............................................................8-40
Brake Handle Spring Bracket Assembly Installation ............................................................8-43
Brake Handle Replacement........................................................................................................8-48
Brake Handle Removal ........................................................................................................8-48
Brake Handle Installation .....................................................................................................8-51

ixTX525 Service Manual Rev. 000
TABLE OF CONTENTS
HYDRAULIC TESTING
TX525...........................................................................................................................................9-1
Introduction ............................................................................................................................9-1
Flow Testing ...........................................................................................................................9-1
Hydraulic Testing ..........................................................................................................................9-3
Hydrostatic Testing Procedures....................................................................................................9-3
Auxiliary Circuit Pressure Test ...............................................................................................9-4
Removal of Pressure Gauge..................................................................................................9-5
Auxiliary Circuit Flow Test ......................................................................................................9-7
Auxiliary Flow Testing.............................................................................................................9-7
Troubleshooting .....................................................................................................................9-7
Flow Meter Removal ..............................................................................................................9-7
Loader Circuit Flow Testing....................................................................................................9-8
Loader Circuit Pressure Test................................................................................................9-12
Traction Control Tracking Adjustment, Full Forward Position ..............................................9-17
Traction Control Neutral Adjustment ....................................................................................9-18
Purging Air Procedure..........................................................................................................9-19