Toro Outcross 9060 User manual

FormNo.18234SLRevB

Outcross9060

Models07511AA/BA/CA/DA

8111LyndaleAvenueSouth

Bloomington,MN55420

OriginalInstructions(EN)

Contactusatwww.Toro.com.

AllRightsReserved

RevisionHistory

RevisionDateDescription

A10/2018InitialRelease

B11/2018Parkerhydraulicvalveserviceinformation

RevisionHistoryPage2Outcross9060

18234SLRevB

ReaderComments

TheToroCompanyTechnicalAssistanceCentermaintainsacontinuous

efforttoimprovethequalityandusefulnessofitspublications.Todothis

effectively,weencourageuserfeedback.Pleasecommentonthecompleteness,

accuracy,organization,usability,andreadabilityofthismanualbyane-mail

to[email protected]

orMailto:

TechnicalPublicationManager,Commercial

TheToroCompany

8111LyndaleAvenueSouth

Bloomington,MN55420-1196

Phone:+1952-887-8495

Outcross9060Page3ReaderComments

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ReaderCommentsPage4Outcross9060

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Preface

Thepurposeofthispublicationistoprovidetheservicetechnicianwith

informationfortroubleshooting,testing,andrepairingthemajorsystemsand

componentsoftheOutcross9060tractionunit(ModelNo.07511AA,07511BA,

07511CA,and07511DA).

RefertothetractionunitOperator’sManualandaccessoryInstallation

Instructionsforinstallation,operation,maintenance,andadjustmentinformation.

KeepacopyoftheOperator’sManuals,accessoryInstallationInstructionsand

PartsCatalogsforyourmachineanditsaccessorieswiththisServiceManualfor

reference.AdditionalcopiesoftheOperator’sManuals,InstallationInstructions,

PartsCatalogsandthisServiceManualareavailableatwww.toro.com.

TheToroCompanyreservestherighttochangetheproductspecicationsor

thispublicationwithoutnotice.

DANGER

Thissafetysymbolmeansdanger.Whenyouseethissymbol,

carefullyreadtheinstructionsthatfollow.Failuretoobeythe

instructionscouldkillorcauseseriouspermanentinjuryordisability.

WARNING

Thissafetysymbolmeanswarning.Whenyouseethissymbol,

carefullyreadtheinstructionsthatfollow.Failuretoobeythe

instructionscanresultinseriousinjury.

CAUTION

Thissafetysymbolmeanscaution.Whenyouseethissymbol,

carefullyreadtheinstructionsthatfollow.Failuretoobeythe

instructionscanresultinminortomoderateinjury.

IMPORTANT

TheImportantnoticewillgivetheimportantinstructionswhichyou

mustfollowtopreventdamagetothesystemsorcomponentson

themachine.

Note:ANotewillprovideadditionalinformationaboutthecorrectoperation,

maintenance,service,testing,orrepairofthemachine.

Outcross9060Page5Preface

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ServiceProcedureIcons

ThefollowingiconsappearthroughoutthisServiceManualtobringattentionto

specicimportantdetailsofaserviceprocedure.

CriticalProcess

Thisiconisusedtohighlight:

•installingsafetyequipment(shields,guards,seatbelts,brakesandR.O.P .S.

components)thatmayhavebeenremoved

•dimensionsorsettingsthatmustbemaintainedforpropermachineoperation

•aspecicfastenertighteningsequence

•componentorientationthatmaynotbeobvious

CriticalTorque

Thisiconisusedtohighlightanassemblytorquerequirementthatisdifferentthan

whatisrecommendedintheStandardT orqueT ables;refertoStandardTorque

forDry,ZincPlated,andSteelFasteners(InchSeries)(page2–9)orStandard

TorqueforDry,ZincPlated,andSteelFasteners(MetricFasteners)(page2–10).

FluidSpecications

Thisiconisusedtohighlightuidspecicationsandcapacitiesthatareless

common,andmaynotappearonthemachineservicedecalorinthemachine

Operator’sManualoraccessoryInstallationInstructions.

Note:RefertotheservicedecalsonthemachineandthemachineOperator’s

ManualandaccessoryInstallationInstructionsforcommonlyuseduid

specicationsandcapacities.

PrefacePage6Outcross9060

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TableofContents
Preface................................................................................................................5
Chapter1:Safety............................................................................................1–1
SafetyInstructions.......................................................................................1–2
JackingInstructions.....................................................................................1–8
SafetyandInstructionalDecals....................................................................1–9
Chapter2:SpecicationsandMaintenance....................................................2–1
Specications...............................................................................................2–2
TorqueSpecications...................................................................................2–6
ShopSupplies............................................................................................2–12
SpecialT ools..............................................................................................2–14
Chapter3:Troubleshooting.............................................................................3–1
GEARS–TheSystematicApproachtoDening,DiagnosingandSolving
Problems......................................................................................................3–2
OperatorAdvisories......................................................................................3–3
MachineandEngineFaults...........................................................................3–6
UsingtheInfoCenterDisplayforTroubleshooting.......................................3–23
GeneralHydraulicSystemProblems..........................................................3–26
TractionSystemProblems..........................................................................3–27
SteeringSystemProblems.........................................................................3–30
PTOSystemProblems................................................................................3–31
3-PointHitchSystemProblems...................................................................3–32
Attachment/LoaderProblems.....................................................................3–33
Chapter4:Engine...........................................................................................4–1
GeneralInformation.....................................................................................4–2
ServiceandRepairs.....................................................................................4–8
Chapter5:HydraulicSystem...........................................................................5–1
GeneralInformation.....................................................................................5–3
HydraulicSchematic...................................................................................5–13
HydraulicFlowDiagrams............................................................................5–14
TestingtheHydraulicSystem......................................................................5–34
Adjustments...............................................................................................5–48
ServiceandRepairs...................................................................................5–49
Chapter6:ElectricalSystem...........................................................................6–1
GeneralInformation.....................................................................................6–3
ElectricalDrawings.....................................................................................6–12
ElectricalSystemQuickChecks..................................................................6–13
ElectricalComponentT esting.....................................................................6–14
ServiceandRepairs...................................................................................6–77
Chapter7:TractionandPTODrive..................................................................7–1
GeneralInformation.....................................................................................7–2
Adjustments.................................................................................................7–3
ServiceandRepairs.....................................................................................7–5
Chapter8:Chassis..........................................................................................8–1
GeneralInformation.....................................................................................8–2
ServiceandRepairs.....................................................................................8–3
Chapter9:OperatorCab.................................................................................9–1
GeneralInformation.....................................................................................9–2
Adjustments.................................................................................................9–5
ServiceandRepairs.....................................................................................9–7
AppendixA......................................................................................................A–1
ElectricalDrawingDesignations....................................................................A–2
HydraulicSchematic.....................................................................................A–3
ElectricalSchematic(part1of3)...................................................................A–4
ElectricalSchematic(part2of3)...................................................................A–5
ElectricalSchematic(part3of3)...................................................................A–6
WireHarnessDrawing–Frame....................................................................A–7
Outcross9060Page7Preface
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WireHarnessDiagram–Frame....................................................................A–8

WireHarnessDrawing–Platform.................................................................A–9

WireHarnessDiagram–Platform...............................................................A–10

WireHarnessDiagram–Platform(continued)............................................A–11

WireHarnessDrawing–Engine.................................................................A–12

WireHarnessDiagram–Engine.................................................................A–13

WireHarness–Headlights.........................................................................A–14

WireHarness–CabRooftop......................................................................A–15

WireHarness–CabControlPanel..............................................................A–16

WireHarness–CabHeat/AirConditioning..................................................A–17

WireHarness–InchMode(optional)...........................................................A–18

WireHarness–LoaderSelectorControlValve(SCV)Switch

(optional).....................................................................................................A–19

WireHarness–LoaderSelectorControlValve(SCV)Valve

(optional).....................................................................................................A–20

WireHarness–RearSelectorControlValve(SCV)Kit(optional)................A–21

WireHarness–CabWorkLightKit(optional)..............................................A–22

WireHarness–DomesticRoadLightKit(optional).....................................A–23

WireHarness–TurnSignal/HazardLights(optional)..................................A–24

WireHarness–InternationalRoadLightKit(optional)................................A–25

AdditionalReferenceMaterials

YanmarTNV(Tier4)SeriesServiceManual

YanmarTNV(Tier4)SeriesTroubleshootingManual

DanfossH1ClosedCircuitAxialPistonPumpsServiceManual

DanfossH1ClosedCircuitAxialPistonPumpsRepairInstructions

DanfossKandLFrameVariableMotorsServiceManual

DanfossSteeringUnitTypeOSPB,OSPCandOSPFServiceManual

Gresen/ParkerHydraulicsModelV10SectionalBodyDirectionalControlValve

ServiceManual

CarraroDriveTechModel26.09MAxleRepairManual

SandenSDCompressorServiceGuide

PrefacePage8Outcross9060

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Chapter1

Safety

TableofContents

SafetyInstructions................................................................................................................................1–2

Supervisor’sResponsibilities.............................................................................................................1–2

BeforeOperatingtheMachine...........................................................................................................1–3

OperatingtheMachine.......................................................................................................................1–4

MaintenanceandService...................................................................................................................1–6

JackingInstructions..............................................................................................................................1–8

RaisingtheFrontoftheMachine........................................................................................................1–8

RaisingtheRearoftheMachine........................................................................................................1–9

SafetyandInstructionalDecals............................................................................................................1–9

Outcross9060Page1–1Safety

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SafetyInstructions

TheOutcross9060machineistestedandcertiedbyToroforcompliance

withexistingsafetystandardsandspecications.Althoughhazardcontroland

accidentpreventionarepartiallydependentuponthedesignandcongurationof

themachine,hazardcontrolandaccidentpreventionarealsodependentupon

theawareness,concernandpropertrainingofthepersonnelinvolvedinthe

operation,transport,maintenanceandstorageofthemachine.Improperuseor

maintenanceofthemachinecanresultininjuryordeath.Toreducethepotential

forinjuryordeath,complywiththefollowingsafetyinstructions.

WARNING

Toreducethepotentialofinjuryordeath,complywiththefollowing

safetyinstructionsaswellasinformationfoundinthetractionunit

Operator’sManual,accessoryInstallationInstructions,andthe

OperatorandSafetyTrainingVideosfoundonwww.toro.com.

Supervisor’sResponsibilities

1.Ensurethatthemachineoperatorsarefullytrainedandfamiliarwiththe

tractionunitOperator’sManual,alloftheoperatingandsafetydecalsonthe

machine,andanyoperationinformationfoundintheInstallationInstructions

foraccessoriesthatareinstalledonthemachine.

2.Establishyourownspecialproceduresandworkrulesforunusualoperating

conditions(e.g.,slopestoosteepformachineoperation).Surveythework

sitecompletelytodeterminehillsonwhichyoucanoperatesafely.When

performingthissitesurvey,alwaysunderstandandtakeintoconsideration

theturfconditionandrolloverrisk.

Safety:SafetyInstructionsPage1–2Outcross9060

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BeforeOperatingtheMachine

•ReviewandunderstandthecontentsofthetractionunitOperator’sManual,

alloftheoperatingandsafetydecalsonthemachine,andanyoperation

informationfoundintheInstallationInstructionsforaccessoriesthatare

installedonthemachine.AdditionalcopiesofthetractionunitOperator’s

ManualandaccessoryInstallationInstructionsareavailableatwww.toro.com.

•ViewandunderstandtheOperatorandSafetyTrainingVideosfoundat

www.toro.com.

•Neverallowchildrentooperatethemachine.Neverallowadultstooperate

themachinewithoutproperinstructions.

•Becomefamiliarwiththecontrolsandknowhowtostopthemachineand

enginequickly.

•Keepalltheshields,safetydevices,anddecalsinplace.Ifashield,safety

device,ordecalisillegibleordamaged,repairorreplaceitbeforeoperating

themachine.

•Alwayswearsubstantialshoes.Donotoperatemachinewhilewearing

sandals,tennisshoesorsneakers.Donotwearloosettingclothingwhich

couldgetcaughtinmovingpartsandcausepersonalinjury.

•Wearingsafetyglasses,safetyshoes,longpantsandahelmetisadvisable

andrequiredbysomelocalsafetyandinsuranceregulations.

•Makesureworkareaisclearofobjectswhichmightbepickedupandthrown

bytheattachments.

•Keepeveryone,especiallychildrenandpets,awayfromtheareaofoperation.

•Ensurethesafetyinterlocksarefunctioningproperly.Adjustorreplace

anymalfunctioningswitchesorinterlockmechanismsbeforeoperatingthe

machine.RefertoCheckingtheOperationoftheInterlockSwitches(page

6–13)foradditionalinformation.

•Dieselfuelishighlyammable;handleitcarefully.

–Storefuelincontainersspecicallydesignedforstoringfuel.

–Donotremovethefueltankcapofthemachinewhiletheengineishot

orrunning.

–Donotsmokewhilehandlingfuel.

–Fillthefueltankoutdoorsandonlytoalevelwithinaninchofthetopof

thetank,notthellerneck.Donotoverllthefueltank.

–Replacethefueltankandfuelcontainercapssecurelyafterrefuelling

themachine.

–Ifyouspillfuel,donotattempttostarttheenginebutmovethemachine

awayfromthespill.Avoidcreatinganysourceofignitionuntilfuelvapors

havedissipated.Wipeupanyspilledfuel.

Outcross9060Page1–3Safety:SafetyInstructions

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OperatingtheMachine

DANGER

Theexhaustfumesarehazardousandhavethepotentialofcausing

injuryordeath.

Donotruntheengineinaconnedareawithoutadequateventilation.

Note:OperatoradvisoriesareautomaticallydisplayedbytheInfoCenterwhen

amachinefunctionispreventedandadditionalactionisrequired.Typically,an

advisorycanbeeliminatedwithachangeinmachinecontrolsbytheoperator.

RefertoOperatorAdvisories(page3–3)foradditionalinformation.

1.Sitontheoperatorseatwhenstartingthemachine.

2.Tostarttheengine:

A.DisengagethePTO(switchindownposition)

B.MovethetransmissionshiftlevertotheNEUTRALposition.

C.Ensurethattheauxiliaryhydraulicleverisinthecenterposition.

D.SettheignitionkeytotheRUNposition.

E.Engagetheparkingbrake(switchilluminated).

F.Keepyourfootofftheacceleratorpedal.

G.TurntheignitionkeytotheSTARTpositionandholduntiltheenginestarts

(nolongerthan20seconds).

3.Usingthemachinedemandsoperatorattention.T opreventlossofmachine

control:

A.Operatemachineattachmentsonlyindaylightorwhenthereisgood

articiallight.

B.Watchforholesorotherhiddenhazards.

C.Donotdriveclosetosandtraps,ditches,creeksorotherhazards.

D.Traverseslopescarefully.Donotstartorstopsuddenlywhentraveling

uphillordownhill.

E.Reducespeedwhenmakingsharpturns.Avoidsuddenstopsandstarts.

F.Beforebackingup,looktothereartobesurenooneisbehindthe

machine.

G.Watchoutfortrafcwhennearorcrossingroads.Alwaysyieldthe

right-of-way.

H.Depressthedeceleratorpedalwhengoingdownhilltokeepforward

speedslowandtomaintaincontrolofthemachine.

4.Keephands,feetandclothingawayfrommovingpartsandthedischarge

areaofanattachment.

5.Raisetheattachmentswhendrivingfromoneworkareatoanother.

6.Donottouchtheengine,muferorexhaustpipewhiletheengineisrunning

orsoonafteritisstoppedbecausetheseareascouldbehotenoughto

causeburns.

7.Ifanattachmentstrikesasolidobjectorvibratesabnormally,stop

immediately,turntheengineoff,waitforallmotiontostopandinspectfor

damage.Adamagedattachmentmustberepairedorreplacedbefore

operationiscontinued.

8.DON’TTAKEANINJURYRISK!Whenapersonorpetappears

unexpectedlyinorneartheareawhileoperatinganattachment,STOP.

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OperatingtheMachine(continued)

Carelessoperation,combinedwithterrainangles,ricochetsorimproperly

positionedguardscanleadtothrownobjectinjuries.Donotresume

operationuntiltheareaiscleared.

9.Beforegettingofftheseat:

A.Makesureanyattachmentsaredisengaged.

IMPORTANT

Whenanattachmentisloweredtotheground,thepressurein

thehydraulicliftcircuitisreleasedandaccidentallyloweringthe

attachmentisavoided.

B.Loweranyattachmentstotheground.

C.Settheparkingbrakeiftheenginewillbeleftrunning,or,stoptheengine

andremovethekeyfromkeyswitch.

10.WhenusingtheoptionalInchModefeature:

A.Keepbystandersawayfromthemachine.

B.UsetheInchModefeatureonlyonalevelsurface.

C.Whilemovingthemachine,donotstandinfrontoforbehindthemachine.

Outcross9060Page1–5Safety:SafetyInstructions

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MaintenanceandService

Themaintenanceproceduresandrecommendedserviceintervalsforyour

machinearecoveredinthetractionunitOperator’sManualandaccessory

InstallationInstructions.Refertothispublicationwhenperformingregular

equipmentmaintenance.Severalmaintenanceprocedureshavebreak-in

intervalsidentiedinthetractionunitOperator’sManualandaccessory

InstallationInstructions.RefertotheEngineOperator’sManualforadditional

enginespecicmaintenanceprocedures.

•Beforeservicingormakinganyadjustmentstothemachine,lowerany

attachments,shutofftheengine,andremovethekeyfromthekeyswitch.

•Ensurethatthemachineisinsafeoperatingconditionbykeepingallthe

nuts,bolts,andscrewstight.

•Ensurethatallofthehydrauliclineconnectorsaretightandthatallthe

hydraulichosesandlinesareingoodconditionbeforeapplyingpressureto

thehydraulicsystem.

•Useeyeprotectionwhenworkingonthehydraulicsystemandits

components.

•Keepyourbodyandhandsawayfrompin-holeleaksinthehydrauliclines

thatejecthydraulicuidunderhighpressure.Usecardboardorpapertond

hydraulicleaks.Thehydraulicuidescapingunderpressurecanpenetrate

theskinandcauseinjury.Ifhydraulicuidisaccidentallyinjectedintothe

skin,youmusthaveitsurgicallyremovedwithinafewhoursbyadoctor

familiarwiththistypeofinjury.Otherwise,gangrenemayresult.

•Beforedisconnectingorperforminganyworkonthehydraulicsystem,

releaseallthepressureinthesystembyparkingthemachineonalevel

surface,loweringthecuttingdeck(orimplement)completely,andthen

shuttingofftheengine.

•Toreducepotentialrehazards,keeptheengineareafreeofexcessive

grease,grass,leaves,anddirt.Cleantheprotectivescreenonthemachine

frequently.

•Checkallfuellinesfortightnessandwearonaregularbasis.Tightenor

repairfuellinesasneeded.

•Ifyoumustruntheenginetoperformmaintenanceortomakeanadjustment,

keepyourhands,feet,clothing,andotherpartsofthebodyawayfromany

attachmentsandothermovingparts.Keepbystandersaway.

•Shutofftheenginebeforecheckingoraddingoiltotheenginecrankcase.

•Disconnectthebatterybeforeservicingthemachine.Disconnectthenegative

batterycableandthenthepositivecable.Ifbatteryvoltageisnecessaryfor

troubleshootingortestprocedures,temporarilyconnectthebattery.Connect

thepositivebatterycableandthenthenegativecable.

•Batteryacidispoisonousandcancauseburns.Avoidacidcontactwithskin,

eyes,andclothing.Protectyourface,eyes,andclothingwhenworkingwitha

battery.

•Batterygasescanexplode.Keepcigarettes,sparks,andamesawayfrom

thebattery.

•Ifitisnecessarytoliftthemachinetoperformaserviceprocedure;refer

toJackingInstructions(page1–8).

•Beforeperforminganyweldingonthemachine,turnthekeyswitchto

theOFFposition.T opreventdamagetothemachineelectricalsystem,

disconnecttheground(-)cabletotheframewhenweldingontheframe,or

disconnecttheground(-)cabletotheoperatorplatformwhenweldingon

theoperatorplatform.

•Ifmajorrepairsarenecessary,contactyourAuthorizedT oroDistributor.

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MaintenanceandService(continued)

•Ensuretodisposeofpotentiallyharmfulwaste(e.g.,fuel,oil,enginecoolant,

lters,battery)inanenvironmentallysafemanner.Followalllocalcodesand

regulationswhenrecyclingordisposingofwaste.

•Atthetimeofmanufacture,themachineconformedtoMachineryDirective

2006/42/EC,ElectromagneticCompatibility(EMC)Directive2014/30/EU,

andISOstandardsforpower,mass,vibration,andsound.T oensurethe

optimumperformanceandcontinuedsafetycerticationofthemachine,use

genuineT ororeplacementpartsandaccessories.Thereplacementpartsand

accessoriesofothermanufacturerscanresultinnon-conformancewiththe

safetystandardsandcanvoidthewarranty.

Outcross9060Page1–7Safety:SafetyInstructions

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JackingInstructions

CAUTION

Failingtoproperlysupportthemachinewithappropriatejackstands

cancausethemachinetomoveorfallandcanresultinpersonal

injury.

Approximateweights:

•Basemodel=2,340kg(5,160lbs)

•Cabmodel=2,640kg(5,820lbs)

Whenchangingtheattachments,tires,orperformingotherservice:

•Beforeyouliftthemachine,removealltheattachmentsthatmay

interferewiththesafeandcorrectliftofthemachine.Removethe

frontloaderattachmentandcounterweightifequipped.

•Parkthemachineonasolidlevelsurface,suchasaconcrete

oor.

•Alwaysblockthewheelswithchocks.

•Usethecorrectblocks,hoists,andjackstoliftthemachine.

•Usetheappropriatejackstandstosupporttheraisedmachine.

•DoNotuseanattachmentasajackingpoint.

RaisingtheFrontoftheMachine

g232342

Figure1

1.Frontjackpoint(framechannelbehind

sideplate)

2.Frontjackstandpoint(framechannel

behindsideplate)

1.Blockthe2rearwheelswithchockstopreventthemachinefrommoving.

2.Positionthejacksecurelyunderthedesiredfrontjackingpoint.

3.Afterraisingthefrontofthemachine,useanappropriatejackstandunder

thevehicleframetosupportthemachine.

Safety:JackingInstructionsPage1–8Outcross9060

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RaisingtheRearoftheMachine

g232344

Figure2

1.Rearjackpoint2.Rearjackstandpoint(framechannel)

1.Blockthe2frontwheelswithchockstopreventthemachinefrommoving.

2.Positionthejacksecurelyunderthedesiredrearjackingpoint.

3.Afterraisingtherearofthemachine,useanappropriatejackstandunderthe

vehicleframetosupportthemachine.

SafetyandInstructionalDecals

Numeroussafetyandinstructiondecalsareafxedtothetractionunitand

attachmentsofyourOutcross9060machine.Ifanydecalbecomesillegible

ordamaged,installanewdecal.DecalpartnumbersarelistedintheParts

Catalog,tractionunitOperator’sManual,andaccessoryInstallationInstructions.

OrderreplacementdecalsfromanAuthorizedToroDistributor.

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Safety:SafetyandInstructionalDecalsPage1–10Outcross9060

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Chapter2

SpecicationsandMaintenance

TableofContents

Specications.......................................................................................................................................2–2

OverallDimensions............................................................................................................................2–2

TractionUnit.......................................................................................................................................2–3

Engine................................................................................................................................................2–3

HydraulicSystem...............................................................................................................................2–4

TractionandPTODrive......................................................................................................................2–4

Chassis..............................................................................................................................................2–5

TorqueSpecications...........................................................................................................................2–6

CalculatingtheT orqueValuesWhenUsingaDrive-AdapterWrench.................................................2–7

IdentifyingtheFastener......................................................................................................................2–8

StandardT orqueforDry,ZincPlated,andSteelFasteners(InchSeries)............................................2–9

StandardT orqueforDry,ZincPlated,andSteelFasteners(MetricFasteners).................................2–10

OtherTorqueSpecications.............................................................................................................2–11

ConversionFactors..........................................................................................................................2–11

ShopSupplies....................................................................................................................................2–12

SpecialTools......................................................................................................................................2–14

Outcross9060Page2–1SpecicationsandMaintenance

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