Toro Outcross 9060 Service Repair Manual

Manuals: Service Repair Manual

Table of Content – Outcross 9060

Revision History
Reader Comments
Preface
Service Procedure Icons

Chapter 1 : Safety

Safety Instructions
Supervisor’s Responsibilities
Before Operating the Machine
Operating the Machine
Maintenance and Service
Jacking Instructions
Raising the Front of the Machine
Raising the Rear of the Machine
Safety and Instructional Decals

Chapter 2 : Specifications and Maintenance

Specifications
Overall Dimensions
Traction Unit
Engine
Hydraulic System
Traction and PTO Drive
Chassis
Torque Specifications
Calculating the Torque Values When Using a Drive-Adapter Wrench
Identifying the Fastener
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners)
Other Torque Specifications
Conversion Factors
Shop Supplies
Special Tools

Chapter 3 : Troubleshooting

GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems
Gather Information
Evaluate Potential Causes
Assess Performance
Repair
Solution Confirmation
Operator Advisories
Machine and Engine Faults
Using the InfoCenter display for Troubleshooting
TRACTION (example):
General Hydraulic System Problems
Traction System Problems
Steering System Problems
PTO System Problems
3-Point Hitch System Problems
Attachment, Loader Problems

Chapter 4 : Engine

General Information
Traction Unit Operator’s Manual
Yanmar Service and Troubleshooting Manuals
Shutting Off the Engine
Engine Electronic Control Unit (ECU)
Yanmar Engine
Diesel Particulate Filter
Service and Repairs
Air Cleaner System
Exhaust System
Radiator
Fuel System
Engine
Flywheel Housing and Drive Coupler

Chapter 5 : Hydraulic System

General Information
Traction Unit Operator’s Manual and Accessory Installation Instructions
Relieving Pressure from the Hydraulic System
Towing the Traction Unit
Traction Circuit (Closed-Loop) Component Failure
Hydraulic Hoses
Installing O-rings
Installing Hydraulic Hoses and Tubes (O-Ring Face Seal)
Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings)
Hydraulic Schematic
Hydraulic Flow Diagrams
Traction Circuit
Steering Circuit
Hitch Cylinder Circuit
Brake Circuit
Differential Lock Circuit
PTO Clutch Circuit
Attachment Circuit
Front Loader Circuit
Selector Control Valve (SCV) Circuit (optional)
Testing the Hydraulic System
Hydraulic Test Selection
Traction Circuit Testing
Steering, Hitch Cylinder Circuit Testing – Steering Relief Valve (RV1) Pressure Test
Steering, Hitch Cylinder Circuit Testing – Hitch Cylinder Relief Valve (RV2) Pressure Test
Steering, Hitch Cylinder Circuit Testing – Gear Pump (P4) Flow
Attachment, Loader Circuit Testing – Relief Valve Pressure Test
Attachment, Loader Circuit Testing – Gear Pump (P3) Flow Test
Service and Repairs
General Precautions for Removing and Installing the Hydraulic System Components
Checking the Hydraulic Lines and Hoses
Flushing the Hydraulic System
Filtering the Closed-Loop Traction Circuit
Priming the Hydraulic Pumps
Charging the Hydraulic System
Hydraulic Tank
Hydraulic Fluid Cooler
Tandem Piston (Traction) Pump (P1) and (P2)
Tandem Piston (Traction) Pump (P1) and (P2) Service
Gear Pump (P3) and (P4)
Gear Pump (P3) and (P4) Service
Axle Motors
Axle Motor Service
Axle Differential Locks
Hydraulic Brake Assembly
Hydraulic Brake Service
Main Hydraulic Manifold
Main Manifold Service
Cartridge Valve Service
Steering Control Valve
Steering Control Valve Service
Steering Cylinders
Steering Cylinder Service
3-Point Hitch Cylinders
3-Point Hitch Cylinder Service
PTO Clutch
Auxiliary Load Valve
Auxiliary Load Valve Service
Front Loader Control Valve
Front Loader Control Valve Service
Selector Control Valve Manifolds (optional)
Selector Control Valve Manifold (optional) Service

Chapter 6 : Electrical System

General Information
Traction Unit Operator’s Manual and Accessory Installation Instructions
Yanmar Engine Electrical Components
InfoCenter Display
Primary Controller (T1: TEC)
Status Display Controller (T2: TDM)
Engine Electronic Control Unit (ECU)
InchMode Controller (T3: TEC) (optional)
CAN bus Communications
Electrical Drawings
Electrical System Quick Checks
Testing the Charging System
Checking the Operation of the Interlock Switches
Electrical Component Testing
Fuses
Fusible Link Harness
CAN bus
Primary Controller (T1: TEC)
Status Display Controller (T2: TDM)
InchMode Controller (T3: TEC) (optional)
Key Switch
Mode Selector
Parking Brake Switch
Power Take Off (PTO) Enable Switch
Economy (ECO) Mode Switch
Hydraulic Auxiliary (AUX) Switch
Seat Switch
Paddle (3-Point Hitch) and Transmission Lever Switches
Headlight, Work Light Switch
Cruise Control Off, On, Set Switch
Cruise Control Speed Increase, Decrease Switch
Air Conditioning On, Off Switch
Heater, Air Conditioning Blower Speed Switch
InchMode Enable Switch (optional)
InchMode Raise, Lower and Forward, Reverse Switches (optional)
Loader Selector Control Valve (SCV) Switch (optional)
Traction Pedal Assembly
Decelerator Pedal Position Sensor
Decelerator Pedal Neutral Switch
3-Point Hitch Position Sensor
Hydraulic Fluid Temperature Sender
Speed Sensors
Traction Pressure Sensors
Fuel Pump
Fuel Level Sender
Warning Buzzer
Relays with 4 Terminals
Relays with 5 Terminals
Diode Assemblies
Resistor Assembly
CAN bus Terminator Resistors
Hydraulic Solenoid Valve Coils
Tandem Traction (Piston) Pump Control Solenoid Coils
Service and Repairs
Caring for the Battery
Storing the Battery
Servicing the Battery

Chapter 7 : Traction and PTO Drive

General Information
Traction Unit Operator’s Manual and Accessory Installation Instructions
Adjustments
Adjusting the Tie Rod Length
Adjusting Axle Stop Bolts
Service and Repairs
Tie Rods
Front Axle
Front Axle
Rear Axle
Rear Axle
Front and Rear Axle Service
Front PTO Gearbox
PTO Clutch Service
Rear PTO Gearbox
PTO Driveshaft

Chapter 8 : Chassis

General Information
Traction Unit Operator’s Manual and Accessory Installation Instructions
Service and Repairs
Front Screen
Hood
Operator Platform or Cab
Steering Wheel, Instrument Panels and Dash Cover
Operator’s Console
Seats
Standard Utility Box
Front Loader Attachment

Chapter 9 : Operator Cab

General Information
Traction Unit Operator’s Manual and Accessory Installation Instructions
Electrical Components, Schematics and Wire Harness Drawings
Air Conditioning System
Cab Heater System
Adjustments
Adjusting the Compressor Belt Tension
Adjusting the Doors
Service and Repairs
Heating and Air Conditioning Components
General Precautions for Removing and Installing Air Conditioning System Components
Air Conditioning Compressor
Control Panel and Windshield Wiper Assembly
Windshield
Doors
Appendix A: Foldout Drawings
Electrical Drawing Designations
Hydraulic Schematic
Hydraulic Schematic
Hydraulic Schematic
Electrical Schematic (part 1 of 3)
Electrical Schematic (part 2 of 3)
Electrical Schematic (part 3 of 3)
Wire Harness Drawing – Frame
Wire Harness Diagram – Frame
Wire Harness Drawing – Platform
Wire Harness Diagram – Platform
Wire Harness Diagram – Platform (continued)
Wire Harness Drawing – Engine
Wire Harness Diagram – Engine
Wire Harness – Headlights
Wire Harness – Cab Rooftop
Wire Harness – Cab Control Panel
Wire Harness – Cab Heat, Air Conditioning
Wire Harness – InchMode (optional)
Wire Harness – Loader Selector Control Valve (SCV) Switch (optional)
Wire Harness – Loader Selector Control Valve (SCV) Valve (optional)
Wire Harness – Rear Selector Control Valve (SCV) Kit (optional)
Wire Harness – Cab Work Light Kit (optional)
Wire Harness – Domestic Road Light Kit (optional)
Wire Harness – Turn Signal, Hazard Lights (optional)
Wire Harness – International Road Light Kit (optional)