Form No. 3407-540 Rev C MB TX 2500 Tracked Mud Buggy Model No. 68138—Serial No. 400000000 and Up Model No. 68138G—Serial No. 400000000 and Up Register at www.Toro.com.
accessory information, help finding a dealer, or to register your product. WARNING CALIFORNIA Proposition 65 Warning This product contains a chemical or chemicals known to the State of California to cause cancer, birth defects, or reproductive harm. The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
Contents Safety ....................................................................... 4 Safe Operating Practices.................................... 4 Safety and Instructional Decals .......................... 7 Product Overview ................................................... 10 Controls ........................................................... 10 Specifications .................................................. 10 Operation .................................................................
Safety – Never fuel or drain the machine indoors. – Never store the machine or fuel container inside where there is an open flame, such as near a water heater or furnace. Improper use or maintenance of the machine can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety-alert symbol , which means Caution, Warning, or Danger—personal safety instruction.
• Do not touch parts which may be hot from • • • • • 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 machine and any hazard. operation. Allow them to cool before attempting to maintain, adjust, or service. Check for overhead clearances (i.e., branches, doorways, electrical wires) before driving under any objects and do not contact them.
Maintenance and Storage – Keep container nozzle in contact with the tank during filling. • Let the engine cool before storing and do not store • Battery acid is poisonous and can cause burns. the machine near an open flame. Avoid contact with skin, eyes, and clothing. Protect your face, eyes, and clothing when working with a battery. • Engage the parking brake, shut off the engine, and wait for all movement to stop before adjusting, cleaning, or repairing the machine. • Battery gases can explode.
Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or missing. decal115-4212 115-4212 1. Hydraulic-fluid level 3. Warning—do not touch the hot surface. 2. Read the Operator's Manual. decal132-8961 132-8961 1. Battery charging condition 4. Hopper is lowering. 2. Hour meter 5. Hopper is down. 3. Hopper is raising. 6. Hopper is lowering automatically.
decal137-0575 137-0575 1. Read the Operator’s Manual. 2. Transmission fluid 3.
decal137-3715 137-3715 1. Parking-brake release 7. Explosion hazard—shut off the engine 13. Lower hopper before adding fuel; no fire, open flames, or smoking when adding fuel. 2. Parking brake 8. Machine tipping hazard—do not drive 14. Move the handles in to operate. forward with the hopper raised; do not drive down slopes with the hopper raised; do not drive across slopes with the hopper raised; drive slowly with the hopper down. 3. Warning—read the Operator’s Manual; hearing protection must be worn.
Parking Brake Lever Product Overview To engage the parking brake, pull back the lever. (Figure 4). To disengage the parking brake, push the lever forward. Hour Meter The hour meter records the number of hours the engine has operated. It operates when the engine is running. Use these times for scheduling regular maintenance (). Choke Control g038268 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 3 1. Hopper 4.
Operation • Do not use gasoline containing methanol. • Do not store fuel either in the fuel tank or fuel containers over the winter unless you use a fuel stabilizer. Note: Determine the left and right sides of the machine from the normal operating position. • Do not add oil to gasoline. 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.
Using Stabilizer/Conditioner DANGER In certain conditions during fueling, static electricity can be released causing a spark, which can ignite the fuel vapors. A fire or explosion from fuel can burn you and others and can damage property. Use a fuel stabilizer/conditioner in the machine to provide the following benefits: • Keeps fuel fresh during storage of 90 days or less. For longer storage, drain the fuel tank.
Performing Daily Maintenance Operating the Throttle The throttle control moves between FAST and SLOW positions (Figure 8). Before starting the engine each day, perform the following procedures: Always use the FAST position when moving the machine. • Check the engine-oil level—refer to Checking the Engine-Oil Level (page 20).
Operating the Choke Starting the Engine Use the choke to start a cold engine. 1. Pull up the choke knob to engage the choke before using the key switch (Figure 9). 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. Note: Ensure that you fully engage the choke.
Shutting Off the Engine 1. Move the throttle between the FAST and SLOW positions. 2. Engage the parking brake. 3. Turn the key switch to the OFF position and remove the key. 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. 4.
Transporting the Machine Lifting the Machine Use a heavy-duty trailer or truck with full-width ramps to transport the machine. Ensure that the 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.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 10 hours • Check and adjust the track tension (every 10 hours until 50 hours). Before each use or daily • • • • • • • • Check the engine-oil level. Clean the blower housing (more often under extremely dusty, dirty conditions). Check the condition of the track. Check the parking brake operation.
Pre-Maintenance Procedures Releasing the Cushion for Rear Access You can release the cushion for rear access to the machine for maintenance or adjustment. 1. Lower the platform. 2. Loosen the twist knobs on each side of the machine (Figure 16). g185887 Figure 17 1. Cylinder lock 4. g032556 2. Cushion 3. Remove the cushion and lower it to the platform. 4. Perform any maintenance or adjustment on the machine. 5. Raise the cushion, and slide it onto the pins on both sides of the machine. 6.
Lubrication Engine Maintenance Greasing the Machine Servicing the Air Cleaner Service Interval: Every 50 hours Service Interval: Every 25 hours—Service or replace the air-cleaner foam element (more often under extremely dusty, dirty conditions). When operating the machine under normal conditions, lubricate all grease fittings for the bearings and bushings with No. 2 lithium grease. Lubricate the bearings and bushings immediately after every washing, regardless of the interval listed.
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 Full mark or below the low mark. Otherwise, you may damage the engine. g028106 Figure 20 1. Air-cleaner cover 3. Paper element 1.
Changing the Engine Oil and Filter Service Interval: Every 100 hours Oil Type:: Detergent oil (API service SJ or higher) Engine Oil Capacity: 1.9 L (2.0 US quarts) g185888 Viscosity: Refer to the table below. g031623 Figure 23 g017552 Figure 22 5. 6. Note: Dispose of the used oil at a recycling center. 1. Park the machine on a level surface, move the motion-control levers to the NEUTRAL-LOCK position, engage the parking brake, raise the hopper, and install the cylinder lock. 2.
7. Removing the Spark Plug Slowly pour approximately 80% of the specified oil into the filler tube (Figure 25). 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. Before removing the spark plug(s), clean the area around the base of the plug to keep dirt and debris out of the engine. 4. Remove the spark plug (Figure 26).
Installing the Spark Plug Fuel System Maintenance Replacing the Fuel Filter Service Interval: Every 100 hours/Yearly (whichever comes first) (more often under dusty, dirty conditions). 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. Replace the fuel filter as shown in Figure 29.
Draining the Fuel Tank Removing the Fuel Tank You can drain the fuel tank by removing it and pouring the fuel out of the fill neck; refer to Removing the Fuel Tank (page 24). You can also drain the fuel tank by using a siphon in the following procedure. 1. Lower the platform. 2. Release the cushion; refer to Releasing the Cushion for Rear Access (page 18). 3. Remove the cross bracket (Figure 31). DANGER In certain conditions, fuel is extremely flammable and highly explosive.
Electrical System Maintenance WARNING Incorrect battery-cable routing could damage the machine and cables, causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. Servicing the Battery • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. Service Interval: Every 50 hours WARNING • Always connect the positive (red) battery cable before connecting the negative (black) cable.
Charging the Battery Servicing the Fuses The electrical system is protected by fuses and requires no maintenance. If a fuse blows, check the component or circuit for a malfunction or short. WARNING Charging the battery produces gasses that can explode. Never smoke near the battery and keep sparks and flames away from battery. Important: Always keep the battery fully charged (1.265 specific gravity) to prevent battery damage when the temperature is below 0°C (32°F). 1.
Adjusting the Track Tension Drive System Maintenance If you place the tab of the tensioning tool along the rear edge of the tension nut, the other end of the tensioning tool should align with the edge of the tension arm as shown in Figure 36. If the distance is not correct, adjust the track tension using the following procedure: Servicing the Tracks Service Interval: Before each use or daily—Check the condition of the track.
4. 5. 6. 7. Clean the drive sprocket, the front wheel, and the road wheels. The road wheels should spin freely when clean. Remove the bolt (1/4 x 1-5/8 inch), spacer, and nut (Figure 36). 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 36.
3. Release the cushion and remove the fuel tank; refer to Removing the Fuel Tank (page 24). 4. Raise the rear of the machine and support the machine on jack stands. 5. Remove the skid plate (Figure 36). g189571 Figure 41 1. Engine pulley 3. Transmission pulley (2) 2. Idler pulley 4. Belt g203662 Figure 39 1. Rear bolt (2) 9. 3. Side bolt (4) 2. Skid plate 6. Remove the extension spring (Figure 38). 7. Remove the 2 bolts and 2 nuts and loosen the 2 set screws on the coupler.
Controls System Maintenance Adjusting the Motion-Control Levers If the motion-control levers do not align horizontally, 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 42). 3. Check if the right motion-control lever aligns horizontally with the left motion-control lever (Figure 42). g189389 Figure 43 1.
4. Release the parking brake. 5. Move the motion-control levers forward. Hydraulic System Maintenance Note: The machine should move forward. WARNING Note: If the machine does not move forward, refer to Adjusting the Parking Brake (page 31). 6. Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Fluid injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury; otherwise gangrene may result.
4. Remove the 6 bolts (2 rear, 4 side) from the skid plate and remove the skid plate (Figure 47). g203616 Figure 45 1. Expansion-tank cap 3. Fluid at fill line g203662 Figure 47 2. Sight window 1. Rear bolt (2) 5. 3. Side bolt (4) 2. Skid plate If the oil level is low, remove the cap lock and cap from the top of the expansion tank (Figure 46), and add enough of the specified hydraulic fluid to raise it to the proper level. 5.
Bleeding the Hydraulic Drive System Bleed the traction hydraulic system whenever you perform maintenance on the hydrostatic transmission or add hydraulic fluid to the expansion tank. g203517 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.
Servicing the Hydraulic Lift System Checking the Hydraulic-Fluid Level for the Lift System g185888 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 to spot leaks.
Changing the Hydraulic Fluid for the Lift System Replacing the Hydraulic Filter for the Lift System Service Interval: Every 300 hours Service Interval: Every 300 hours 1. Important: Do not substitute an automotive oil Park the machine on a level surface, move the motion-control levers to the NEUTRAL-LOCK position, engage the parking brake, raise the hopper, and install the cylinder lock. 2. Shut off the machine and remove the key. Allow the machine to cool completely. 3.
5. Shut off the engine and check for leaks. 6. Check the fluid level in the reservoir tank, refer to (page ). Cleaning Removing Debris from the Machine Note: Do not overfill the reservoir tank. 7. Remove the cylinder lock and lower the hopper. Service Interval: Before each use or daily Checking the Hydraulic Lines Every 100 hours Service Interval: Every 40 hours—Check the hydraulic lines for leaks, loose fittings, kinked lines, loose mounting supports, wear, and deterioration.
Storage 1. Shut off the engine and engage the parking brake. 2. Remove dirt and grime from the external parts of the entire machine, especially the engine. Clean dirt and chaff from the outside of the engine cylinder head fins and blower housing. 3. Service the air cleaner; refer to Servicing the Air Cleaner (page 19). 4. Grease the machine; refer to Greasing the Machine (page 19). 5. Change the engine crankcase oil; refer to Changing the Engine Oil and Filter (page 21). 6.
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Concrete, Masonry, and Compaction Equipment The Toro Warranty A limited warranty (see warranty periods below) Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Concrete, Masonry, and Compaction Equipment Products listed below to be free from defects in materials or workmanship. a dealer or by you, is at your expense.
