Toro Outcross 9060 Service Manual
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Toro Outcross 9060 Service Manual

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© 2018—The Toro® Company
8111 Lyndale Avenue South
Bloomington, MN 55420
Outcross 9060
Models 07511AA/BA/CA/DA
Form No. 18234SL Rev B
Contact us at www.Toro.com.
Original Instructions (EN)
All Rights Reserved

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  • Page 1 Form No. 18234SL Rev B Outcross 9060 Models 07511AA/BA/CA/DA © 2018—The Toro® Company Original Instructions (EN) 8111 Lyndale Avenue South Contact us at www.Toro.com. Bloomington, MN 55420 All Rights Reserved...
  • Page 2 Revision History Revision Date Description Initial Release 10/2018 11/2018 Parker hydraulic valve service information Revision History Page 2 Outcross 9060 18234SL Rev B...
  • Page 3 Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail servicemanuals@toro.com...
  • Page 4 Reader Comments Page 4 Outcross 9060 18234SL Rev B...
  • Page 5 The purpose of this publication is to provide the service technician with information for troubleshooting, testing, and repairing the major systems and components of the Outcross 9060 traction unit (Model No. 07511AA, 07511BA, 07511CA, and 07511DA). Refer to the traction unit Operator’s Manual and accessory Installation Instructions for installation, operation, maintenance, and adjustment information.
  • Page 6 Operator’s Manual or accessory Installation Instructions. Note: Refer to the service decals on the machine and the machine Operator’s Manual and accessory Installation Instructions for commonly used fluid specifications and capacities. Preface Page 6 Outcross 9060 18234SL Rev B...

  • Page 7: Table Of Contents

    Appendix A ......................A–1 Electrical Drawing Designations..............A–2 Hydraulic Schematic ..................A–3 Electrical Schematic (part 1 of 3)..............A–4 Electrical Schematic (part 2 of 3)..............A–5 Electrical Schematic (part 3 of 3)..............A–6 Wire Harness Drawing – Frame ..............A–7 Outcross 9060 Page 7 Preface 18234SL Rev B...
  • Page 8 Danfoss Steering Unit Type OSPB, OSPC and OSPF Service Manual Gresen/Parker Hydraulics Model V10 Sectional Body Directional Control Valve Service Manual Carraro DriveTech Model 26.09M Axle Repair Manual Sanden SD Compressor Service Guide Preface Page 8 Outcross 9060 18234SL Rev B...
  • Page 9 Operating the Machine........................1–4 Maintenance and Service........................1–6 Jacking Instructions ..........................1–8 Raising the Front of the Machine......................1–8 Raising the Rear of the Machine ......................1–9 Safety and Instructional Decals ......................1–9 Outcross 9060 Page 1–1 Safety 18234SL Rev B...

  • Page 10: Safety Instructions

    Safety Instructions The Outcross 9060 machine is tested and certified by Toro for compliance with existing safety standards and specifications. Although hazard control and accident prevention are partially dependent upon the design and configuration of the machine, hazard control and accident prevention are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance and storage of the machine.

  • Page 11: Before Operating The Machine

    Installation Instructions for accessories that are installed on the machine. Additional copies of the traction unit Operator’s Manual and accessory Installation Instructions are available at www.toro.com. • View and understand the Operator and Safety Training Videos found at www.toro.com.

  • Page 12: Operating The Machine

    A damaged attachment must be repaired or replaced before operation is continued. 8. DON’T TAKE AN INJURY RISK! When a person or pet appears unexpectedly in or near the area while operating an attachment, STOP. Safety: Safety Instructions Page 1–4 Outcross 9060 18234SL Rev B...
  • Page 13 A. Keep bystanders away from the machine. B. Use the InchMode feature only on a level surface. C. While moving the machine, do not stand in front of or behind the machine. Outcross 9060 Page 1–5 Safety: Safety Instructions 18234SL Rev B...

  • Page 14: Maintenance And Service

    (-) cable to the frame when welding on the frame, or disconnect the ground (-) cable to the operator platform when welding on the operator platform. • If major repairs are necessary, contact your Authorized Toro Distributor. Safety: Safety Instructions Page 1–6 Outcross 9060...
  • Page 15 ISO standards for power, mass, vibration, and sound. To ensure the optimum performance and continued safety certification of the machine, use genuine Toro replacement parts and accessories. The replacement parts and accessories of other manufacturers can result in non-conformance with the safety standards and can void the warranty.

  • Page 16: Jacking Instructions

    2. Position the jack securely under the desired front jacking point. 3. After raising the front of the machine, use an appropriate jack stand under the vehicle frame to support the machine. Safety: Jacking Instructions Page 1–8 Outcross 9060 18234SL Rev B...

  • Page 17: Safety And Instructional Decals

    Safety and Instructional Decals Numerous safety and instruction decals are affixed to the traction unit and attachments of your Outcross 9060 machine. If any decal becomes illegible or damaged, install a new decal. Decal part numbers are listed in the Parts Catalog, traction unit Operator’s Manual, and accessory Installation Instructions.
  • Page 18 Safety: Safety and Instructional Decals Page 1–10 Outcross 9060 18234SL Rev B...

  • Page 19: Chapter 2: Specifications And Maintenance

    Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)..........2–9 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) ......... 2–10 Other Torque Specifications ......................2–11 Conversion Factors.......................... 2–11 Shop Supplies ............................ 2–12 Special Tools ............................2–14 Outcross 9060 Page 2–1 Specifications and Maintenance 18234SL Rev B...

  • Page 20: Specifications

    Specifications Overall Dimensions g231580 Figure 3 Outcross 9060 Specifications and Maintenance: Specifications Page 2–2 Outcross 9060 18234SL Rev B...

  • Page 21: Traction Unit

    Coolant capacity without Operator cab 7.6 L (8 US qt) with Operator cab 8.5 L (9 US qt) Alternator/Regulator 12 VDC, 55 A Engine weight (dry) 225 kg (496 lb) Outcross 9060 Page 2–3 Specifications and Maintenance: Specifications 18234SL Rev B...

  • Page 22: Hydraulic System

    Rear PTO gear box fluid capacity 1.4 L (1.5 US qt) Mobil 424® multipurpose tractor lubricant or equivalent Brake Assembly fluid capacity 160 ml (5.4 ounces) Mobil 424® multipurpose tractor lubricant Specifications and Maintenance: Specifications Page 2–4 Outcross 9060 18234SL Rev B...

  • Page 23: Chassis

    Item Description Bed capacity/volume Standard bed 453 kg (1,000 lb), 0.6 cubic meters (0.8 cubic yards) Cargo bed (optional) 2,041 kg (4,500 lb), 1 cubic meters (1.3 cubic yards) Outcross 9060 Page 2–5 Specifications and Maintenance: Specifications 18234SL Rev B...

  • Page 24: Torque Specifications

    Torque Specifications The recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual.

  • Page 25: Calculating The Torque Values When Using A Drive-Adapter Wrench

    If the listed torque recommendation for a fastener is 103 to 127 N∙m (76 to 94 ft-lb), the proper torque when using this torque wrench with a drive-adapter wrench would be 98 to 121 N∙m (72 to 89 ft-lb). Outcross 9060 Page 2–7 Specifications and Maintenance: Torque Specifications...

  • Page 26: Identifying The Fastener

    Toro recommends replacing fasteners with a locking feature once they have been removed because the effectiveness of the locking feature diminishes with each reuse. If it is necessary to reuse a fastener with a locking feature; apply a thread locking compound (Loctite for example) to the fastener during installation.

  • Page 27: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Inch Series)

    Note: The nominal torque values listed above for Grade 5 and 8 fasteners are based on 75% of the minimum proof load specified in SAE J429. The tolerance is approximately ± 10% of the nominal torque value. The thin height nuts include jam nuts. Outcross 9060 Page 2–9 Specifications and Maintenance: Torque Specifications...

  • Page 28: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Metric Fasteners)

    Note: The nominal torque values listed above are based on 75% of the minimum proof load specified in SAE J1199. The tolerance is approximately ± 10% of the nominal torque value. Specifications and Maintenance: Torque Specifications Page 2–10 Outcross 9060 18234SL Rev B...

  • Page 29: Other Torque Specifications

    Conversion Factors in-lb X 11.2985 = N∙cm N∙cm X 0.08851 = in-lb ft-lb X 1.3558 = N∙m N∙m X 0.7376 = ft-lb Outcross 9060 Page 2–11 Specifications and Maintenance: Torque Specifications 18234SL Rev B...

  • Page 30: Shop Supplies

    The sealant should remain semi-pliable to allow for component removal with standard tools. Some thread sealants may require the use of a cleaner or primer prior to use. Specifications and Maintenance: Shop Supplies Page 2–12 Outcross 9060 18234SL Rev B...
  • Page 31 Standard silicone sealants are designed to perform in temperatures from -51° F to 232° C (-60° F to 400° F), while high temperature variants can preform in temperatures up to 343° C (650° F) Outcross 9060 Page 2–13 Specifications and Maintenance: Shop Supplies...

  • Page 32: Special Tools

    Special Tools You can order these special tools from your Toro Distributor. Some tools may also be available from a local tool supplier. Hydraulic Pressure Testing Kit Toro Part No. TOR47009 Use this kit to take various pressure readings for diagnostic tests. Quick...
  • Page 33 20 to 150 LPM (4 to 40 GPM). Note: This tester does not include any hydraulic hoses or fittings; refer to Hydraulic Hose Kit Toro Part No. TOR6007 and Hydraulic Test Fitting Kit Tor Part No. TOR4079. Hydraulic O-Ring Kit Toro Part No.
  • Page 34 Hydraulic Test Fitting Kit Toro Part No. TOR4079 This kit includes a variety of O-ring face seal fittings to let you connect the test gauges into the system. FITTING TYPE SIZE PART NUMBER 4 ORFS (9/16–18) TOR4079–3 6 ORFS (11/16–16) TOR4079–12...
  • Page 35 Note: This kit does not include the hydraulic hoses; refer to Hydraulic Hose Kit (page 2–15). Note: The replacement filter element is Toro Part No. TOR6012. The filter element canister tightening torque is 34 N∙m (25 ft-lb). Remote Starter Switch After flushing the hydraulic system or replacing a hydraulic component (e.g.
  • Page 36 This excess current can damage the circuits that are not designed to carry it. Battery Terminal Protector Toro Part No. 107-0392 Use this aerosol spray on the battery terminals, ring terminals, and fork terminals to reduce corrosion problems. Apply the...
  • Page 37 3-Point Hitch Position Sensor Tool Toro Part No. 133–7818 Use to align 3-point hitch position sensor with the lift arm pivot shaft when installing the sensor. Thread sensor shaft into lift arm pivot shaft until it bottoms out. Turn sensor shaft out until it aligns with tool.
  • Page 38 Specifications and Maintenance: Special Tools Page 2–20 Outcross 9060 18234SL Rev B...

  • Page 39: Chapter 3: Troubleshooting

    3-Point Hitch System Problems ......................3–32 Attachment/Loader Problems ......................3–33 The information In this chapter is intended to help troubleshoot machine operation issues. Keep in mind there can be more than one cause for a machine malfunction. Outcross 9060 Page 3–1 Troubleshooting 18234SL Rev B...

  • Page 40: Gears - The Systematic Approach To Defining, Diagnosing And Solving Problems

    • Return the unit to service by repairing, rebuilding or replacing Solution Confirmation • Did the issue go away • Was the root cause of the issue correctly repaired • Are there any other new symptoms Troubleshooting: Attachment/Loader Problems Page 3–2 Outcross 9060 18234SL Rev B...

  • Page 41: Operator Advisories

    LIMITED DIFFERENTIAL To engage differential lock | Bring B2186 LOCK Traction Engaged machine to stop DENIED MODE B2484 CHANGE PTO Switch Engaged For Mode change | Disengage PTO DENIED Outcross 9060 Page 3–3 Troubleshooting: Attachment/Loader Problems 18234SL Rev B...
  • Page 42 For auxiliary hydraulics | Resolve B2523 HYDRAULICS Fault Active active fault DENIED AUXILIARY Neither In Seat Nor For auxiliary hydraulics | Must be B2525 HYDRAULICS Parking Brake Applied seated or set parking brake DENIED Troubleshooting: Attachment/Loader Problems Page 3–4 Outcross 9060 18234SL Rev B...
  • Page 43 Lower engine RPM DENIED Note: If “Unknown Cause” appears as an advisory description, a controller software issue may exist. If you are unable to clear this type of advisory, contact your Authorized Toro Distributor. Outcross 9060 Page 3–5 Troubleshooting: Attachment/Loader Problems...

  • Page 44: Machine And Engine Faults

    Machine and Engine Faults Machine faults are generated by the Toro Electronic Controller (TEC) to identify an electrical system malfunction (fault) that occurs during machine operation. Engine faults are generated by the by the Yanmar engine Electronic Control Unit (ECU) to identify an electrical system malfunction (fault) pertaining to the engine during operation.
  • Page 45 Test the engine start output circuit wiring between T1: TEC and Engine ECU Replace the T1: TEC (contact your Authorized Toro Distributor for assistance) P0616 Start Output – Overcurrent detected Check the engine start output circuit wiring Overcurrent on engine start output.
  • Page 46 Battery Test the engine start output circuit wiring battery between T1: TEC and Engine ECU Replace the T1: TEC (contact your Authorized Toro Distributor for assistance) P06E9 Starter Starter has been Starter output is Check key switch is not stuck in start...
  • Page 47 Test the traction coil wiring actual level of current to the traction coil. Test the traction coil and replace if necessary Replace T1: TEC (contact your Authorized Toro Distributor for assistance) P110D Traction Coil PWM convergence Traction is Use the InfoCenter to verify the traction coil...
  • Page 48 Test the traction coil and replace if necessary The second check is to verify that the PWM Replace T1: TEC (contact your Authorized duty cycle across the Toro Distributor for assistance) coil is not greater than the max allowed limit. P1124 Traction Overcurrent detected.
  • Page 49 Check the traction coil wiring and connector Test the traction coil wiring Test the traction coil and replace if necessary Replace T1: TEC (contact your Authorized Toro Distributor for assistance) P113C Traction Coil A current monitor Traction is Use the InfoCenter to verify the traction coil...
  • Page 50 Perform rear traction pump (P2) flow and pump (steering relief valve test and/or lift operation will also be affected). Confirm charge pressure at the test port provided and perform gear pump (P4) flow test. Troubleshooting: Attachment/Loader Problems Page 3–12 Outcross 9060 18234SL Rev B...
  • Page 51 Check alternator belt condition and adjust if necessary Check alternator wiring and connectors Test the alternator wiring Test the alternator; refer to the Yanmar TNV (Tier 4) Series Service Manual Outcross 9060 Page 3–13 Troubleshooting: Attachment/Loader Problems 18234SL Rev B...
  • Page 52 Test the engine run/fuel pump output circuit Battery wiring Test the electric fuel pump Replace the T1: TEC (contact your Authorized Toro Distributor for assistance) C1014 Engine Overcurrent detected in Check the engine run/fuel pump output Run/Fuel engine run/fuel pump...
  • Page 53 Indicates a short to Test the parking brake disengage output battery. circuit wiring Test the hydraulic solenoid valve SV2 coil Replace the T1: TEC (contact your Authorized Toro Distributor for assistance) C1024 Parking Brake Overcurrent detected Check the parking brake disengage output Disengage...
  • Page 54 Test the parking brake light output circuit to ground. wiring Test the parking brake light Replace the T2: TDM (contact your Authorized Toro Distributor for assistance) C10A5 Parking Brake Open circuit detected Check the parking brake indicator light Light Output -...
  • Page 55 Test the 3-point hitch lower output circuit to ground. wiring Test the hydraulic solenoid valve SP2 coil Replace the T1: TEC (contact your Authorized Toro Distributor for assistance) C1325 3-Point Hitch Open Circuit detected Check the 3-point hitch lower output circuit...
  • Page 56 Overcurrent Test the SCV relay Test all 4 of the hydraulic solenoid valve SCV coils Replace the T1: TEC (contact your Authorized Toro Distributor for assistance) C14A5 Optional Open Circuit detected Check the optional SCV output circuit wiring Solenoid on optional SCV output.
  • Page 57 Test the PTO output circuit wiring Test the hydraulic solenoid valve EH coil Replace the T1: TEC (contact your Authorized Toro Distributor for assistance) C14C5 PTO Output - Open Circuit detected Check the PTO output circuit wiring and all Open Circuit on PTO output.
  • Page 58 - Open Circuit on mode selector mode operation all circuit connectors and disable PTO Test the mode selector circuit wiring Test the mode selector if possible and replace if necessary Troubleshooting: Attachment/Loader Problems Page 3–20 Outcross 9060 18234SL Rev B...
  • Page 59 Power supply for Check power supply to T1: TEC outputs Output PWR 2 outputs 1-4 of T1: Test fuse F-A1 7.5A Failure TEC has failed. Test PWR 2 supply circuit wiring Outcross 9060 Page 3–21 Troubleshooting: Attachment/Loader Problems 18234SL Rev B...
  • Page 60 U1117 Source T1: TEC received a Machine is Update machine software (contact your Address message from another disabled Authorized Toro Distributor for assistance) Contention controller on the CAN Fault bus using the same source address U1308 Software T2: TDM software is...

  • Page 61: Using The Infocenter Display For Troubleshooting

    OFF, a problem with controller power (circuit wiring or fuse) may exist, or the controller software may require reloading or replacement. Contact your Authorized Toro Distributor for assistance. A faulty output component will not be identified by the Output screen. The Output screen reflects the actions of the controller, not the component(s) involved in the operation.
  • Page 62 Contact your Authorized Toro Distributor for assistance in reloading the machine software. Using the Outputs Screen Note: An inappropriate output reading may indicate an issue with the controller.
  • Page 63 ON and OFF. If the output reading is appropriate and the vehicle does not perform correctly, the parking brake switch light or its circuit wiring may be faulty and should be tested. Outcross 9060 Page 3–25 Troubleshooting: Attachment/Loader Problems 18234SL Rev B...

  • Page 64: General Hydraulic System Problems

    Repair or replace the drive axle motor. damaged. Note: If a traction circuit component has internal wear or damage, it is possible that the other traction components are also damaged. Troubleshooting: General Hydraulic System Problems Page 3–26 Outcross 9060 18234SL Rev B...

  • Page 65: Traction System Problems

    Clean or repair piston (traction) pump (traction) pump control assembly is passages. partially obstructed or damaged. The traction pump relief valves are Clean or repair the piston (traction) leaking or damaged. pump relief valves. Outcross 9060 Page 3–27 Troubleshooting: Traction System Problems 18234SL Rev B...
  • Page 66 Test the machine wire harness solenoid valve (SV2) circuit. Solenoid valve (SV2) in the main Clean the solenoid valve and replace manifold is leaking or faulty. the seals Replace solenoid valve if necessary. Troubleshooting: Traction System Problems Page 3–28 Outcross 9060 18234SL Rev B...
  • Page 67 Test the machine wire harness solenoid valve (SV3) circuit. Solenoid valve (SV3) in the main Clean the solenoid valve and replace manifold is leaking or faulty. the seals. Replace solenoid valve if necessary. Outcross 9060 Page 3–29 Troubleshooting: Traction System Problems 18234SL Rev B...

  • Page 68: Steering System Problems

    The suction filter or suction line is Secure, clean or replace the suction damaged, loose, or clogged. filter or suction line. Troubleshooting: Steering System Problems Page 3–30 Outcross 9060 18234SL Rev B...

  • Page 69: Pto System Problems

    (EH) circuit. Proportional solenoid valve (EH) in the Clean the solenoid valve and replace main manifold is stuck, leaking or faulty. the seals. Replace the solenoid valve if necessary. Outcross 9060 Page 3–31 Troubleshooting: PTO System Problems 18234SL Rev B...

  • Page 70: 3-Point Hitch System Problems

    The suction filter or suction line is Secure, clean or replace the suction damaged, loose, or clogged. filter or suction line. Troubleshooting: 3-Point Hitch System Problems Page 3–32 Outcross 9060 18234SL Rev B...

  • Page 71: Attachment/Loader Problems

    Gear Pump (P3) Flow Test in the Hydraulic System chapter of this manual. Loader cylinder operates in reverse. Hydraulic hoses to the steering Correct hydraulic hose connections. cylinders are connected incorrectly. Outcross 9060 Page 3–33 Troubleshooting: Attachment/Loader Problems 18234SL Rev B...
  • Page 72 The suction filter or suction line is Secure, clean or replace the suction damaged, loose, or clogged. filter or suction line. Troubleshooting: Attachment/Loader Problems Page 3–34 Outcross 9060 18234SL Rev B...
  • Page 73 Radiator ............................4–11 Fuel System ............................. 4–14 Engine.............................. 4–17 Flywheel Housing and Drive Coupler ....................4–23 Additional Reference Materials Yanmar TNV (Tier 4) Series Service Manual Yanmar TNV (Tier 4) Series Troubleshooting Manual Outcross 9060 Page 4–1 Engine 18234SL Rev B...

  • Page 74: General Information

    General Information This chapter provides information for repairing the various systems that support the Yanmar diesel engine used in the Outcross 9060. The general maintenance procedures are described in the Operator’s Manual and the Yanmar TNV Series Operation Manual supplied with the machine. Detailed information on engine...

  • Page 75: Chapter 4: Engine

    Yanmar SA-D connector Engine ECU The Yanmar engine that powers your Outcross 9060 machine uses an Electronic Control Unit (ECU) for engine management. The primary controller (T1: TEC), the status display controller (T2: TDM), the Yanmar Engine Control Unit (ECU),...

  • Page 76: Yanmar Engine

    Diesel particulate filter (DPF) Turbocharger The engine used on Outcross 9060 machine is a Yanmar TNV Series, turbocharged, diesel engine that complies with EPA Tier 4F emission regulations. The engine features include an electronic control unit (ECU) that controls a common rail fuel injection system, an exhaust gas recirculation (EGR) system, an electronic governor, a diesel exhaust particulate filter (DPF), and a turbocharger.

  • Page 77: Diesel Particulate Filter

    The length of time the engine will operate at a higher than normal exhaust temperature to burn out the soot is also related to the amount of particulate matter in the soot filter. Outcross 9060 Page 4–5 Engine: General Information...
  • Page 78 Do not shut off the engine or reduce the engine speed while the reset regeneration is processing. Engine: General Information Page 4–6 Outcross 9060 18234SL Rev B...
  • Page 79 When enough ash accumulates in the soot filter, the engine ECU will generate an engine fault to prompt servicing the DPF. In addition to an engine fault appearing on the T2: TDM display, the engine output power will be reduced. Outcross 9060 Page 4–7 Engine: General Information...

  • Page 80: Service And Repairs

    1. Remove the air cleaner components as necessary. 2. Examine the air cleaner assembly for wear or damage that could possibly cause air leaks. Engine: Service and Repairs Page 4–8 Outcross 9060 18234SL Rev B...
  • Page 81 Ensure that all the air cleaner components are in good condition and are properly secured during installation. 5. Assemble the air cleaner components as shown in Figure Outcross 9060 Page 4–9 Engine: Service and Repairs 18234SL Rev B...

  • Page 82: Exhaust System

    Flange nut (4 each) Muffler clamp (2 each) The engine that powers your Outcross 9060 machine is equipped with an exhaust system that includes a Diesel-Particulate Filter (DPF). The DPF includes a Diesel Oxidation Catalyst (DOC), a Soot Filter (SF), 2 temperature sensors, and a pressure differential sensor.

  • Page 83: Radiator

    Panel fastener (2 each) Bulb seal (2 each) Radiator The radiator on your Outcross 9060 is combined with the hydraulic fluid cooler. The procedure for removing and installing the radiator and hydraulic fluid cooler as an assembly is provided. Note: If desired, the radiator and hydraulic fluid cooler may be separated from each other in the machine and removed individually.
  • Page 84 3. Install the isolator mount, top bracket and top nut plate. 4. Install the fan shrouds. Center the fan shroud around the fan blades before tightening the shroud fasteners. Engine: Service and Repairs Page 4–12 Outcross 9060 18234SL Rev B...
  • Page 85 12. Continue to run the engine to obtain the operating temperature. Check the coolant and hydraulic fluid levels and adjust as necessary before returning the machine to service. 13. Install the front screen. Outcross 9060 Page 4–13 Engine: Service and Repairs 18234SL Rev B...

  • Page 86: Fuel System

    For testing procedures for the low pressure electric fuel pump and the electric fuel level sender; refer to Electrical Component Testing (page 6–14). Engine: Service and Repairs Page 4–14 Outcross 9060 18234SL Rev B...
  • Page 87 6. Support the fuel tank, then remove the 4 support bracket screws. Lower the fuel tank and bracket a few inches. 7. Disconnect the wire harness connection from the fuel sender. Outcross 9060 Page 4–15 Engine: Service and Repairs 18234SL Rev B...
  • Page 88 12. If the elbow fittings are removed from the fuel/water separator head, apply thread sealant to the fittings when installing. 13. To install the fuel tank, follow this procedure in reverse order. Engine: Service and Repairs Page 4–16 Outcross 9060 18234SL Rev B...

  • Page 89: Engine

    Removing and Installing the Hood (page 8–5). 5. Remove the air cleaner assembly; refer to Removing and Installing the Air Cleaner System (page 4–8). 6. Remove the left and right side shields. Outcross 9060 Page 4–17 Engine: Service and Repairs 18234SL Rev B...
  • Page 90 12. Remove the top nut plate and the fan shroud. Reinstall the top nut plate. 13. Remove the 4 flange nuts and carriage screws securing the radiator mount assembly to the frame and remove the radiator assembly from the machine. Engine: Service and Repairs Page 4–18 Outcross 9060 18234SL Rev B...
  • Page 91 21. Connect a suitable hoist or lift and load leveling bar to the front and rear lift tabs on engine. Do not allow the lift chains or straps to contact the DPF. Outcross 9060 Page 4–19 Engine: Service and Repairs...
  • Page 92 22. Remove lock nuts, snubbing washers and cap screws securing the engine mounts to the engine brackets. CAUTION Use 1 person to operate the lift or hoist while the other person guides the engine from the machine. Engine: Service and Repairs Page 4–20 Outcross 9060 18234SL Rev B...
  • Page 93 Do not allow the lift chains or straps to contact the DPF. CAUTION Use 1 person to operate the lift or hoist while the other person guides the engine into the machine. Outcross 9060 Page 4–21 Engine: Service and Repairs 18234SL Rev B...
  • Page 94 20. Start the engine and operate the hydraulic controls to properly fill the hydraulic system; refer to Charging the Hydraulic System (page 5–59). 21. Check and adjust the engine coolant level; refer to the traction unit Operator’s Manual. Engine: Service and Repairs Page 4–22 Outcross 9060 18234SL Rev B...

  • Page 95: Flywheel Housing And Drive Coupler

    23 to 28 N∙m (17 to 21 ft−lb). 4. Position flywheel housing to engine and secure with 8 flange head screws. Tighten screws in a crossing pattern from 36 to 57 N∙m (34 to 42 ft−lb). Outcross 9060 Page 4–23 Engine: Service and Repairs...
  • Page 96 Engine: Service and Repairs Page 4–24 Outcross 9060 18234SL Rev B...

  • Page 97: Chapter 5: Hydraulic System

    Tandem Piston (Traction) Pump (P1) and (P2) ................. 5–64 Tandem Piston (Traction) Pump (P1) and (P2) Service ..............5–68 Gear Pump (P3) and (P4) ........................ 5–70 Gear Pump (P3) and (P4) Service....................5–72 Axle Motors ............................5–76 Outcross 9060 Page 5–1 Hydraulic System 18234SL Rev B...
  • Page 98 Danfoss K and L Frame Variable Motors Service Manual Danfoss Steering Unit Type OSPB, OSPC and OSPF Service Manual Gresen/Parker Hydraulics Model V10 Sectional Body Directional Control Valve Service Manual Hydraulic System: Service and Repairs Page 5–2 Outcross 9060 18234SL Rev B...

  • Page 99: General Information

    FORWARD, REARWARD, fully LEFT, and fully RIGHT positions. 7. Turn the steering wheel in both the LEFT and the RIGHT directions. 8. Turn the key switch to the OFF position. Outcross 9060 Page 5–3 Hydraulic System: General Information...

  • Page 100: Towing The Traction Unit

    Do not start or run the engine when the valves are set to the bypass position. 1. Remove the access panel from the right side of the control console and retrieve the 6 mm hex wrench provided. Hydraulic System: General Information Page 5–4 Outcross 9060 18234SL Rev B...
  • Page 101 Repeat this step for each bypass valve assembly (4 total). 6. Push the manual valve down to engage the parking brake. 7. Secure the 6 mm hex wrench provided and install the access panel. Outcross 9060 Page 5–5 Hydraulic System: General Information...

  • Page 102: Traction Circuit (Closed-Loop) Component Failure

    Note: If traction circuit contamination exists, the traction pump and drive axle motor drains could allow contaminates to enter the hydraulic tank. The alternative to using the Toro high flow hydraulic filter kit after a traction circuit component failure would be to disassemble, drain and thoroughly clean all the components, the hydraulic tank, and the hydraulic tubes and hoses in the traction circuit.

  • Page 103: Hydraulic Hoses

    Note: If the hose has an elbow at one end, tighten the swivel nut on the elbow end before you tighten the nut on the straight end of the hose. For more hydraulic hose information, refer to the Toro Basics Series Training Book Hydraulic Hose Servicing (Part No. 94813SL).

  • Page 104: Installing Hydraulic Hoses And Tubes (O-Ring Face Seal)

    Calculating the Torque Values When Using a Drive-Adapter Wrench (page 2–7). g212098 Figure 20 Mark swivel nut and fitting Initial position Final position body Hydraulic System: General Information Page 5–8 Outcross 9060 18234SL Rev B...
  • Page 105 C. Use a wrench to tighten the nut to the correct Flats From Wrench Resistance (compare items 2 and 3 in Figure 20). Outcross 9060 Page 5–9 Hydraulic System: General Information 18234SL Rev B...

  • Page 106: Installing The Hydraulic Fittings (Sae Straight Thread O-Ring Fittings)

    Flats From Finger Tight (FFFT) Table (page 5–12). C. If the port material is aluminum, tighten the fitting to 60% of the listed value; refer to the Flats From Finger Tight (FFFT) Table (page 5–12). Hydraulic System: General Information Page 5–10 Outcross 9060 18234SL Rev B...
  • Page 107 Installing a fitting into an aluminum port requires reducing the installation torque. 7. Tighten the fitting lock nut (Step 4 in Figure 23): Outcross 9060 Page 5–11 Hydraulic System: General Information 18234SL Rev B...
  • Page 108 6 (3/8 inch) 1.50 ± 0.25 1.50 ± 0.25 8 (1/2 inch) 10 (5/8 inch) 1.50 ± 0.25 12 (3/4 inch) 1.50 ± 0.25 16 (1 inch) 1.50 ± 0.25 Hydraulic System: General Information Page 5–12 Outcross 9060 18234SL Rev B...

  • Page 109: Hydraulic Schematic

    Hydraulic Schematic The hydraulic schematic for the Outcross 9060 machine is located in Appendix A (page A–1). Outcross 9060 Page 5–13 Hydraulic System: Hydraulic Schematic 18234SL Rev B...

  • Page 110: Hydraulic Flow Diagrams

    Hydraulic Flow Diagrams Traction Circuit g235767 Traction Circuit Diagram (A – Forward) Hydraulic System: Hydraulic Flow Diagrams Page 5–14 Outcross 9060 18234SL Rev B...
  • Page 111 Solenoid CD-C1 (rear pump valve C1 – forward) The traction circuit of the Outcross 9060 machine consists of two closed-loop circuits, each with it’s own piston (traction) pump, axle motor, and control valves. The two traction pumps (P1) and (P2) are part of the tandem piston (traction) pump.
  • Page 112 (traction) pump to prevent contaminants from entering the closed-loop traction circuit. The charge filter is located on the right side of the machine behind the front axle. Traction Hydraulic System: Hydraulic Flow Diagrams Page 5–16 Outcross 9060 18234SL Rev B...
  • Page 113 TRACTION readings. Charge pressure can also be measured at the charge pressure test port located near the charge filter assembly. Measured pressure should be approximately 2,068 kPa (300 psi). Outcross 9060 Page 5–17 Hydraulic System: Hydraulic Flow Diagrams 18234SL Rev B...

  • Page 114: Steering Circuit

    Steering Circuit g235914 Steering Circuit Diagram (neutral position) Hydraulic System: Hydraulic Flow Diagrams Page 5–18 Outcross 9060 18234SL Rev B...
  • Page 115 Steering Circuit Diagram (turning to the right) Outcross 9060 Page 5–19 Hydraulic System: Hydraulic Flow Diagrams 18234SL Rev B...
  • Page 116 When a right turn is made with the engine running, the turning of the steering wheel positions the steering valve spool so that the load sense flow is blocked. Hydraulic System: Hydraulic Flow Diagrams Page 5–20 Outcross 9060 18234SL Rev B...
  • Page 117 Relief valve (RV1) controls the action of the steering priority valve (EC1) and allows the valve to divert only enough fluid flow to the steering circuit to maintain relief pressure. Outcross 9060 Page 5–21 Hydraulic System: Hydraulic Flow Diagrams...

  • Page 118: Hitch Cylinder Circuit

    Hitch Cylinder Circuit g236340 Hitch Cylinder Circuit Diagram (raising) Hydraulic System: Hydraulic Flow Diagrams Page 5–22 Outcross 9060 18234SL Rev B...
  • Page 119 Steering Circuit (page 5–18) for a full explanation of the steering priority valve (EC1) operation. Fluid flow continues through the flow regulator valve (EC2) where it dead heads at solenoid valve Outcross 9060 Page 5–23 Hydraulic System: Hydraulic Flow Diagrams 18234SL Rev B...
  • Page 120 Note: The minimum height the hitch arms can lower may be limited by the programmable attachment settings. Hydraulic System: Hydraulic Flow Diagrams Page 5–24 Outcross 9060 18234SL Rev B...

  • Page 121: Brake Circuit

    (SV2) de-energizes. The hydraulic pressure trapped in the circuit combined with the springs inside the brake assembly, shift manual valve (MP) and the allow the brake to engage. Outcross 9060 Page 5–25 Hydraulic System: Hydraulic Flow Diagrams...

  • Page 122: Differential Lock Circuit

    Differential Lock Circuit g237540 Differential Lock Circuit Diagram (engaged) Hydraulic System: Hydraulic Flow Diagrams Page 5–26 Outcross 9060 18234SL Rev B...
  • Page 123 NGAGE to the pistons of the differential lock assemblies. Each piston moves a fork and collar over a series of pins on the differential assembly to lock the axles together. Outcross 9060 Page 5–27 Hydraulic System: Hydraulic Flow Diagrams 18234SL Rev B...

  • Page 124: Pto Clutch Circuit

    PTO Clutch Circuit g237541 PTO Circuit Diagram (engaged) Hydraulic System: Hydraulic Flow Diagrams Page 5–28 Outcross 9060 18234SL Rev B...
  • Page 125 PTO clutch to engage the clutch. Note: Depending on the programmable attachment settings, raising and lowering the hitch may also disengage or engage the PTO. Outcross 9060 Page 5–29 Hydraulic System: Hydraulic Flow Diagrams...

  • Page 126: Attachment Circuit

    Attachment supply line flow is allowed to move in either direction with little to no pressure. The hydraulic load for the attachment circuit is limited to 20,684 kPa (3000 psi) by a relief valve in the auxiliary load valve. Hydraulic System: Hydraulic Flow Diagrams Page 5–30 Outcross 9060 18234SL Rev B...

  • Page 127: Front Loader Circuit

    Front Loader Circuit g262210 Front Loader Circuit Diagram (arms raising) Outcross 9060 Page 5–31 Hydraulic System: Hydraulic Flow Diagrams 18234SL Rev B...
  • Page 128 B. The hydraulic load for the optional loader circuit is limited to 20,684 kPa (3000 psi) by a relief valve in the auxiliary load valve. Hydraulic System: Hydraulic Flow Diagrams Page 5–32 Outcross 9060 18234SL Rev B...

  • Page 129: Selector Control Valve (Scv) Circuit (Optional)

    2. Refer to the selector control valve kit Installation Instructions for additional information. Outcross 9060 Page 5–33 Hydraulic System: Hydraulic Flow Diagrams 18234SL Rev B...

  • Page 130: Testing The Hydraulic System

    Hydraulic System: Testing the Hydraulic System Page 5–34 Outcross 9060 18234SL Rev B...
  • Page 131 10. After you connect the test equipment, check the hydraulic-fluid level in the hydraulic tank and ensure that the fluid level is correct. 11. Perform all the hydraulic tests with the hydraulic fluid at normal operating temperature. Outcross 9060 Page 5–35 Hydraulic System: Testing the Hydraulic System 18234SL Rev B...
  • Page 132 12. Record the results of all hydraulic tests performed. Hydraulic System: Testing the Hydraulic System Page 5–36 Outcross 9060 18234SL Rev B...

  • Page 133: Hydraulic Test Selection

    Traction Circuit Testing – Traction Pump (P1) and (P2) Flow and Relief Valve Tests The Outcross 9060 incorporates a tandem “dual” piston (traction) pump; one pump to drive the front axle and the other to drive the rear axle. Traction pump flow testing involves measuring the pump output flow in high range under load.

  • Page 134: Steering/Hitch Cylinder Circuit Testing - Steering Relief Valve (Rv1) Pressure Test

    2. Park the machine on a level surface, lower the attachments and stop the engine. Remove the key from the key switch. 3. Make sure the hydraulic tank is full. 4. Open the main instrument panel. Hydraulic System: Testing the Hydraulic System Page 5–38 Outcross 9060 18234SL Rev B...
  • Page 135 6. Thoroughly clean the main hydraulic manifold and plug at the G3 port. 7. Remove the plug from the G3 port of the main manifold and install a size 6 SAE-ORB (9/16–18) diagnostic connector and cap (Toro part nos. 59–7410 and 354–79).

  • Page 136: Steering/Hitch Cylinder Circuit Testing - Hitch Cylinder Test

    There are 2 cylinders involved with raising the hitch. The hitch is lowered by weight and is not “powered” downward. A procedure for checking the hitch cylinder condition (internal leakage) for this machine is being developed. Contact your local Toro Distributor for assistance Hydraulic System: Testing the Hydraulic System Page 5–40...

  • Page 137: Steering/Hitch Cylinder Circuit Testing - Hitch Cylinder Relief Valve (Rv2) Pressure Test

    2. Park the machine on a level surface, lower the attachments and stop the engine. Remove the key from the key switch. 3. Make sure the hydraulic tank is full. 4. Open the main instrument panel. Outcross 9060 Page 5–41 Hydraulic System: Testing the Hydraulic System 18234SL Rev B...
  • Page 138 6. Thoroughly clean the main hydraulic manifold and plug at the G3 port. 7. Remove the plug from the G3 port of the main manifold and install a size 6 SAE-ORB (9/16–18) diagnostic connector and cap (Toro part nos. 59–7410 and 354–79).

  • Page 139: Steering/Hitch Cylinder Circuit Testing - Gear Pump (P4) Flow Test

    Access to the gear pump (P4) outlet of this machine is difficult, and a procedure for checking the gear pump (P4) flow is being developed for this machine. Contact your local Toro Distributor for assistance Attachment/Loader Circuit Testing –...
  • Page 140 8. If circuit relief pressure reading is incorrect, clean, repair or replace the auxiliary load valve relief valve; refer to Auxiliary Load Valve Service (page 5–105). 9. After testing, remove the pressure gauge and install the supply line cap. Hydraulic System: Testing the Hydraulic System Page 5–44 Outcross 9060 18234SL Rev B...

  • Page 141: Attachment/Loader Circuit Testing - Gear Pump (P3) Flow Test

    Special Tools (page 2–14). 1. Park the machine on a level surface, lower the attachments and stop the engine. Remove the key from the key switch. Outcross 9060 Page 5–45 Hydraulic System: Testing the Hydraulic System 18234SL Rev B...
  • Page 142 8. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. Make sure the hydraulic reservoir is full. Hydraulic System: Testing the Hydraulic System Page 5–46 Outcross 9060 18234SL Rev B...
  • Page 143 14. After testing is complete, remove the hydraulic tester and any additional hoses or fittings installed for testing. Install the disconnected hydraulic hose; refer to Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) (page 5–8). Outcross 9060 Page 5–47 Hydraulic System: Testing the Hydraulic System 18234SL Rev B...

  • Page 144: Adjustments

    A 1/8 turn on the socket will make a measurable change in pressure 6. Install the cap on the valve 7. Recheck the relief valve pressure using the correct test procedure and readjust if needed. Hydraulic System: Adjustments Page 5–48 Outcross 9060 18234SL Rev B...

  • Page 145: Service And Repairs

    3. Remove all the caps or plugs from the hydraulic tubes, hydraulic fittings, and components before connecting them again. 4. Use proper tightening procedures when installing the hydraulic hoses and fittings; refer to Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) Outcross 9060 Page 5–49 Hydraulic System: Service and Repairs 18234SL Rev B...
  • Page 146 Charging the Hydraulic System (page 5–59). 8. Check for hydraulic-fluid leaks. Shut off the engine and repair leaks if necessary. Hydraulic System: Service and Repairs Page 5–50 Outcross 9060 18234SL Rev B...

  • Page 147: Checking The Hydraulic Lines And Hoses

    Check the hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration, and chemical deterioration. Repair the damaged hydraulic equipment before operating the machine. Outcross 9060 Page 5–51 Hydraulic System: Service and Repairs 18234SL Rev B...

  • Page 148: Flushing The Hydraulic System

    Tubes (O-Ring Face Seal) (page 5–8). IMPORTANT Using other hydraulic fluids could damage the hydraulic system. Use the hydraulic fluids that are specified in the traction unit Operator’s Manual. Hydraulic System: Service and Repairs Page 5–52 Outcross 9060 18234SL Rev B...
  • Page 149 Operator’s Manual. 9. Prime the hydraulic pumps; refer to Priming the Hydraulic Pumps (page 5–58). 10. Charge the hydraulic system; refer to Charging the Hydraulic System (page 5–59). Outcross 9060 Page 5–53 Hydraulic System: Service and Repairs 18234SL Rev B...

  • Page 150: Filtering The Closed-Loop Traction Circuit

    Filtering the Closed-Loop Traction Circuit The traction circuit of the Outcross 9060 machine consists of two closed-loop circuits, each with it’s own piston (traction) pump, drive axle motor, and control valves. The two traction pumps (P1) and (P2) are part of the tandem piston (traction) pump.
  • Page 151 A. If the front drive motor was serviced or replaced, disconnect the hydraulic hose at the M1 port (left) of the front drive motor. g262334 Figure 35 Rear Circuit Connection Rear drive motor M1 port Outcross 9060 Page 5–55 Hydraulic System: Service and Repairs 18234SL Rev B...
  • Page 152 6. Fill the hydraulic tank with the correct type and quantity of new hydraulic fluid; refer to the traction unit Operator’s Manual. 7. Start engine and run at low idle speed. Check for and correct any hydraulic leaks before proceeding. Hydraulic System: Service and Repairs Page 5–56 Outcross 9060 18234SL Rev B...
  • Page 153 13. Check the hydraulic fluid level in the tank and adjust as necessary; refer to the traction unit Operator’s Manual. 14. Operate the machine and check for leaks before returning the machine to service. Outcross 9060 Page 5–57 Hydraulic System: Service and Repairs 18234SL Rev B...

  • Page 154: Priming The Hydraulic Pumps

    Repeat the cranking procedure a second time. 6. Disconnect the remote starter switch leads from the machine. 7. Charge the hydraulic system; refer to Charging the Hydraulic System (page 5–59). Hydraulic System: Service and Repairs Page 5–58 Outcross 9060 18234SL Rev B...

  • Page 155: Charging The Hydraulic System

    B. Make sure one of the hydraulic fluid filters or the suction line is not loose C. Check for incorrect hose routing D. Ensure the suction line is not blocked Outcross 9060 Page 5–59 Hydraulic System: Service and Repairs 18234SL Rev B...
  • Page 156 Operator’s Manual. Note: If new fluid shows any signs of contamination, flush hydraulic system again until the fluid is clean; refer to Flushing the Hydraulic System (page 5–52). Hydraulic System: Service and Repairs Page 5–60 Outcross 9060 18234SL Rev B...

  • Page 157: Hydraulic Tank

    Hose clamp (2 each) Hydraulic hose (from main filter) Hose clamp Breather hose Hose clamp Straight barb fitting Adapter fitting Strainer assembly Cap screw (2 each) Breather Hose clamp Outcross 9060 Page 5–61 Hydraulic System: Service and Repairs 18234SL Rev B...
  • Page 158 Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) (page 5–8). 11. Fill the tank with new hydraulic fluid and check for leaks before returning the machine to service. Hydraulic System: Service and Repairs Page 5–62 Outcross 9060 18234SL Rev B...

  • Page 159: Hydraulic Fluid Cooler

    Panel fastener (2 each) Bulb seal (2 each) Radiator The hydraulic fluid cooler on your Outcross 9060 is combined with the radiator. The procedures for removing and installing the radiator and hydraulic fluid cooler as an assembly are provided; refer to Radiator (page 4–11).

  • Page 160: Tandem Piston (Traction) Pump (P1) And (P2)

    4. Remove the front loader control valve (if equipped); refer to Removing the Front Loader Control Valve (page 5–106). 5. Remove the main hydraulic manifold; Removing the Main Hydraulic Manifold (page 5–84). Hydraulic System: Service and Repairs Page 5–64 Outcross 9060 18234SL Rev B...
  • Page 161 Tandem piston (traction) pump Traction pressure sensor – front R-clamp Traction pressure sensor – rear Hanger plate 16. Remove the R-clamp (item 2 in Figure 30) from the hanger plate. Outcross 9060 Page 5–65 Hydraulic System: Service and Repairs 18234SL Rev B...
  • Page 162 11. Connect the wire harness at the 4 piston pump servo control solenoid coils. 12. Install the air flap (item 2 in Figure 29). 13. Install the manifold support assembly. Hydraulic System: Service and Repairs Page 5–66 Outcross 9060 18234SL Rev B...
  • Page 163 21. Charge the hydraulic system; refer to Charging the Hydraulic System (page 5–59). 22. Stop engine then check for and correct any hydraulic oil leaks. Check hydraulic fluid level and adjust if necessary. Outcross 9060 Page 5–67 Hydraulic System: Service and Repairs 18234SL Rev B...

  • Page 164: Tandem Piston (Traction) Pump (P1) And (P2) Service

    Tandem Piston (Traction) Pump (P1) and (P2) Service g242412 Figure 42 Hydraulic System: Service and Repairs Page 5–68 Outcross 9060 18234SL Rev B...
  • Page 165 For servo control solenoid coil service information, refer to Tandem Traction (Piston) Pump Control Solenoid Coils (page 6–75). Note: The forward and reverse solenoid valves and coils for both the front and rear pump are identical. Outcross 9060 Page 5–69 Hydraulic System: Service and Repairs 18234SL Rev B...

  • Page 166: Gear Pump (P3) And (P4)

    5. Mark the fitting orientation to allow for correct assembly then remove the fittings from the pump and discard the O-rings. 6. Remove the 2 cap screws and plain washers that secure the gear pump to the piston pump. Hydraulic System: Service and Repairs Page 5–70 Outcross 9060 18234SL Rev B...
  • Page 167 10. Charge the hydraulic system; refer to Charging the Hydraulic System (page 5–59). 11. Stop engine then check for and correct any hydraulic oil leaks. Check hydraulic fluid level and adjust if necessary. Outcross 9060 Page 5–71 Hydraulic System: Service and Repairs 18234SL Rev B...

  • Page 168: Gear Pump (P3) And (P4) Service

    IMPORTANT Keep pump bodies, gears, flanges and thrust plates for each pump section together; do not mix parts between pump sections. Hydraulic System: Service and Repairs Page 5–72 Outcross 9060 18234SL Rev B...
  • Page 169 Inspecting the Gear Pump If internal parts are found to be worn or damaged, gear pump replacement is necessary. 1. Remove any nicks and burrs from all parts with emery cloth. Outcross 9060 Page 5–73 Hydraulic System: Service and Repairs 18234SL Rev B...
  • Page 170 2. Install a new seal and retaining ring in the front cover; refer to Figure 3. Place the front flange, seal side down, on a flat surface. 4. Assemble the front gear pump section (P3) as follows: Hydraulic System: Service and Repairs Page 5–74 Outcross 9060 18234SL Rev B...
  • Page 171 12. Place a small amount of clean hydraulic oil in the pump inlet and rotate the drive shaft clockwise one revolution. If any binding is noted, disassemble the pump and check for assembly problems. Outcross 9060 Page 5–75 Hydraulic System: Service and Repairs...

  • Page 172: Axle Motors

    Note: The 2 cap screws that secure the rear axle motor to the motor mount also secure the hydraulic brake assembly. Hydraulic System: Service and Repairs Page 5–76 Outcross 9060 18234SL Rev B...
  • Page 173 B. Operate the machine slowly at first. C. Stop the engine then check for and correct any hydraulic leaks. D. Check the hydraulic fluid level and adjust if necessary. Outcross 9060 Page 5–77 Hydraulic System: Service and Repairs 18234SL Rev B...

  • Page 174: Axle Motor Service

    Plug and spring asm (2 each) Socket head screw (5 each) Output shaft Spool End cap Housing Relief valve poppet Dowel Bearing Spring Dowel pin Retaining ring Plug Hydraulic System: Service and Repairs Page 5–78 Outcross 9060 18234SL Rev B...

  • Page 175: Axle Differential Locks

    Axle Differential Locks The hydraulically actuated differential lock assemblies are incorporated into the axle assemblies; refer to the Carraro DriveTech Model 26.09M Axle Repair Manual for additional information. Outcross 9060 Page 5–79 Hydraulic System: Service and Repairs 18234SL Rev B...

  • Page 176: Hydraulic Brake Assembly

    5. Remove and inspect the rear drive coupler. 6. If fitting removal is necessary, mark the fitting orientation to allow for correct assembly then remove the fitting from the brake assembly and discard the O-rings. Hydraulic System: Service and Repairs Page 5–80 Outcross 9060 18234SL Rev B...
  • Page 177 7. Check the hydraulic brake oil level and adjust if necessary; refer to the traction unit Operator’s Manual. 8. Test the hydraulic brake operation before returning the machine to service. Outcross 9060 Page 5–81 Hydraulic System: Service and Repairs 18234SL Rev B...

  • Page 178: Hydraulic Brake Service

    2. Loosen the 4 hex head screws alternately and separate the power plate from the housing. 3. Remove the piston from the power plate with low pressure (103 kPa (15 psi)) compressed air through the hydraulic port. Hydraulic System: Service and Repairs Page 5–82 Outcross 9060 18234SL Rev B...
  • Page 179 4 hex head screws and tighten them sequentially one turn at a time until the power plate assembly in properly seated. Tighten the screws from 108 to 122 N∙m (80 to 90 ft-lb). Outcross 9060 Page 5–83 Hydraulic System: Service and Repairs...

  • Page 180: Main Hydraulic Manifold

    Removing the Main Hydraulic Manifold Read and adhere to the information provided in General Precautions for Removing and Installing the Hydraulic System Components (page 5–49) prior to removing hydraulic system components. Hydraulic System: Service and Repairs Page 5–84 Outcross 9060 18234SL Rev B...
  • Page 181 Tubes (O-Ring Face Seal) (page 5–8). 4. Connect the wire harness connectors to the cartridge valve solenoids. 5. Install the operator’s platform; refer to Installing the Operator’s Platform (page 8–13). Outcross 9060 Page 5–85 Hydraulic System: Service and Repairs 18234SL Rev B...

  • Page 182: Main Manifold Service

    Tighten the plugs to the torque value provided. Hydraulic System: Service and Repairs Page 5–86 Outcross 9060 18234SL Rev B...
  • Page 183 If the fitting or plug is removed, remove the orifice for cleaning and label its position for assembly purposes. Note: For cartridge valve service procedures, refer to Cartridge Valve Service (page 5–88). Outcross 9060 Page 5–87 Hydraulic System: Service and Repairs 18234SL Rev B...

  • Page 184: Cartridge Valve Service

    12 volt power source to the solenoid. While energized, flush out any contamination with a nonflammable aerosol brake cleaner. De-energize the solenoid. Repeat the flush Hydraulic System: Service and Repairs Page 5–88 Outcross 9060 18234SL Rev B...
  • Page 185 D. For solenoid valves, slide the solenoid coil onto the cartridge valve. Tighten the coil nut to the torque specification shown. If a problem still exists, remove the valve and clean it again or replace the valve. Outcross 9060 Page 5–89 Hydraulic System: Service and Repairs 18234SL Rev B...

  • Page 186: Steering Control Valve

    7. If fitting removal is necessary, mark the fitting orientation to allow for correct assembly then remove the fittings from the valve and discard the O-rings. Hydraulic System: Service and Repairs Page 5–90 Outcross 9060 18234SL Rev B...
  • Page 187 3. Connect the hydraulic hoses and lines to the steering control valve. 4. Install the dash cover and steering wheel; refer to Installing the Steering Wheel, Instrument Panels and Dash Cover (page 8–16). Outcross 9060 Page 5–91 Hydraulic System: Service and Repairs 18234SL Rev B...

  • Page 188: Steering Control Valve Service

    Spring (2 each) Ball Special screw Pin (2 each) Screw (6 each) The Outcross 9060 uses a Danfoss type OSPC steering control valve. For steering control valve repair procedures, refer to the Danfoss Steering Unit Type OSPB, OSPC and OSPF Service Manual.

  • Page 189: Steering Cylinders

    3. Remove the rear PTO gear box; refer to Removing the rear PTO Gear Box (page 7–21). 4. Raise the rear of the machine; refer to Jacking Instructions (page 1–8). Outcross 9060 Page 5–93 Hydraulic System: Service and Repairs 18234SL Rev B...
  • Page 190 8. Install the rear speed sensor and connect the wire harness to the sensor. 9. Install the bed; refer to Standard Bed (page 8–21). 10. Check the hydraulic fluid level and adjust if necessary before returning the machine to service. Hydraulic System: Service and Repairs Page 5–94 Outcross 9060 18234SL Rev B...

  • Page 191: Steering Cylinder Service

    When you clamp the steering cylinder in a vise, clamp against the mounting brackets only to prevent damage. Do not clamp the vise onto the barrel or rod. Outcross 9060 Page 5–95 Hydraulic System: Service and Repairs 18234SL Rev B...
  • Page 192 When you clamp the steering cylinder in a vise, clamp against the mounting brackets only to prevent damage. Do not clamp the vise onto the barrel or rod. Hydraulic System: Service and Repairs Page 5–96 Outcross 9060 18234SL Rev B...
  • Page 193 7. Secure the heads in the barrel with the external collars. Tighten the external collars with a strap, chain, or spanner wrench. 8. Install and tighten the set screws in the external collars. Outcross 9060 Page 5–97 Hydraulic System: Service and Repairs...

  • Page 194: 3-Point Hitch Cylinders

    6. Remove the lower pin securing the hitch cylinder to the frame and remove the cylinder from the machine. Hydraulic System: Service and Repairs Page 5–98 Outcross 9060 18234SL Rev B...
  • Page 195 7. Operate the 3-point hitch. Check for hydraulic leaks and correct if necessary. 8. Check the hydraulic fluid level and adjust if necessary before returning the machine to service. Outcross 9060 Page 5–99 Hydraulic System: Service and Repairs 18234SL Rev B...

  • Page 196: 3-Point Hitch Cylinder Service

    When you clamp the cylinder in a vise, clamp against the cylinder clevis only to prevent damage. Do not clamp the vise onto the barrel. 2. Mount the cylinder in a vise by clamping on the cylinder clevis. Hydraulic System: Service and Repairs Page 5–100 Outcross 9060 18234SL Rev B...
  • Page 197 2. Mount shaft securely in a vise and slide the external collar, head, and piston onto the shaft. 3. Install the locknut and tighten to 312 N∙m (230 ft-lb). 4. Slide cylinder barrel carefully over shaft assembly and install the external collar. Outcross 9060 Page 5–101 Hydraulic System: Service and Repairs 18234SL Rev B...

  • Page 198: Pto Clutch

    The hydraulically actuated PTO clutch assembly is incorporated into the front gear box assembly; refer to Front PTO Gear Box (page 7–14) PTO Clutch (page 7–19) for additional information. Hydraulic System: Service and Repairs Page 5–102 Outcross 9060 18234SL Rev B...

  • Page 199: Auxiliary Load Valve

    Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) (page 5–8). 4. Connect the frame wire harness to the hydraulic (AUX) switch. Outcross 9060 Page 5–103 Hydraulic System: Service and Repairs 18234SL Rev B...
  • Page 200 Attachment/Loader Circuit Testing – Relief Valve Pressure Test (page 5–43). 8. Check the hydraulic fluid level and adjust if necessary before returning the machine to service. Hydraulic System: Service and Repairs Page 5–104 Outcross 9060 18234SL Rev B...

  • Page 201: Auxiliary Load Valve Service

    V10 Sectional Body Directional Control Valve Service Manual. 1. Disassemble the auxiliary load valve as necessary. 2. Clean and inspect the section housings. 3. Install new seals where available. Outcross 9060 Page 5–105 Hydraulic System: Service and Repairs 18234SL Rev B...

  • Page 202: Front Loader Control Valve

    4. Remove the 4 cap screws securing the valve assembly to the machine and remove the valve assembly. 5. If hydraulic fittings will be removed, mark fitting orientation for proper assembly. Discard fitting O-rings. Hydraulic System: Service and Repairs Page 5–106 Outcross 9060 18234SL Rev B...
  • Page 203 5. Install the operator’s console; refer to Removing and Installing the Operator’s Console (page 8–17). 6. Check the hydraulic fluid level and adjust if necessary before returning the machine to service. Outcross 9060 Page 5–107 Hydraulic System: Service and Repairs 18234SL Rev B...

  • Page 204: Front Loader Control Valve Service

    V10 Sectional Body Directional Control Valve Service Manual. 1. Disassemble the auxiliary load valve as necessary. 2. Clean and inspect the section housings. 3. Install new seals where available. Hydraulic System: Service and Repairs Page 5–108 Outcross 9060 18234SL Rev B...

  • Page 205: Selector Control Valve Manifolds (Optional)

    6. If hydraulic fittings are to be removed from the manifold, mark the fitting orientation to allow for correct assembly. Remove the fittings from the manifold and discard the O−rings. Outcross 9060 Page 5–109 Hydraulic System: Service and Repairs 18234SL Rev B...
  • Page 206 Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) (page 5–8). 4. Connect the wire harness connectors to the cartridge valve solenoids. Hydraulic System: Service and Repairs Page 5–110 Outcross 9060 18234SL Rev B...

  • Page 207: Selector Control Valve Manifold (Optional) Service

    Tighten the plug to the torque value provided. Note: For cartridge valve service procedures, refer to Cartridge Valve Service (page 5–88). Outcross 9060 Page 5–111 Hydraulic System: Service and Repairs 18234SL Rev B...
  • Page 208 Hydraulic System: Service and Repairs Page 5–112 Outcross 9060 18234SL Rev B...

  • Page 209: Chapter 6: Electrical System

    Speed Sensors ..........................6–55 Traction Pressure Sensors....................... 6–57 Fuel Pump............................6–59 Fuel Level Sender ..........................6–61 Warning Buzzer..........................6–62 Relays with 4 Terminals ........................6–63 Relays with 5 Terminals ........................6–65 Outcross 9060 Page 6–1 Electrical System 18234SL Rev B...
  • Page 210 Tandem Traction (Piston) Pump Control Solenoid Coils ..............6–75 Service and Repairs ........................... 6–77 Caring for the Battery ........................6–77 Storing the Battery ........................... 6–79 Servicing the Battery ........................6–80 Electrical System: Service and Repairs Page 6–2 Outcross 9060 18234SL Rev B...

  • Page 211: General Information

    When servicing or troubleshooting the engine electrical components, use the correct engine service manual and troubleshooting manual. Yanmar engine service and troubleshooting manuals are available online, on the Toro Service Reference flash drive, and in print from your authorized Toro Distributor.

  • Page 212: Infocenter Display

    Controller Area Network (CAN) bus system. Note: The InfoCenter Display, TECs, TDM and the engine ECU used on the Outcross 9060 machine are matched for correct machine operation. If any of these components are replaced for any reason, system software needs to be reloaded (contact an Authorized Toro Distributor for assistance).
  • Page 213 InfoCenter Display (continued) g259842 Figure 67 InfoCenter Screens Outcross 9060 Page 6–5 Electrical System: General Information 18234SL Rev B...

  • Page 214: Primary Controller (T1: Tec)

    InchMode controller (T3: TEC) used on the Outcross 9060 machine communicate with each other on a Controller Area Network (CAN) bus system. Note: The InfoCenter Display, TECs, and the TDM used on the Outcross 9060 machine are matched for correct machine operation. If any of these components are replaced for any reason, system software needs to be reloaded (contact an Authorized Toro Distributor for assistance).

  • Page 215: Status Display Controller (T2: Tdm)

    Power for the TDM is available when the main power relay is energized (key switch is in the ON or START position). A 2 Amp fuse (F–A4) protects the TDM power circuit. Outcross 9060 Page 6–7 Electrical System: General Information...
  • Page 216 InchMode controller (T3: TEC) used on the Outcross 9060 machine communicate with each other on a Controller Area Network (CAN) bus system. Note: The InfoCenter Display, TECs, and the TDM used on the Outcross 9060 machine are matched for correct machine operation. If any of these components are replaced for any reason, system software needs to be reloaded (contact an Authorized Toro Distributor for assistance).

  • Page 217: Engine Electronic Control Unit (Ecu)

    Yanmar SA-D connector Engine ECU The Yanmar engine that powers your Outcross 9060 machine uses an Electronic Control Unit (ECU) for engine management. The engine ECU is located under the right side of the dash cover. All wire harness electrical connectors should be plugged into the ECU before the machine key switch is moved from the OFF position to either the ON or START position.

  • Page 218: Inchmode Controller (T3: Tec) (Optional)

    InchMode controller (T3: TEC) used on the Outcross 9060 machine communicate with each other on a Controller Area Network (CAN) bus system. Note: The InfoCenter Display, TECs, and the TDM used on the Outcross 9060 machine are matched for correct machine operation. If any of these components are replaced for any reason, system software needs to be reloaded (contact an Authorized Toro Distributor for assistance).

  • Page 219: Can−Bus Communications

    The primary controller (T1: TEC), the status display controller (T2: TDM), the Yanmar Engine Control Unit (ECU), the InfoCenter Display, and the optional InchMode controller (T3: TEC) used on the Outcross 9060 machine communicate with each other on a Controller Area Network (CAN) bus system.

  • Page 220: Electrical Drawings

    Electrical Drawings The electrical schematic and wire harness drawings for the Outcross 9060 machine are located in Appendix A (page A–1). Electrical System: Electrical Drawings Page 6–12 Outcross 9060 18234SL Rev B...

  • Page 221: Electrical System Quick Checks

    Replace any malfunctioning switches before operating the machine. Your Outcross 9060 is equipped with a primary (T1: TEC) and a (T2: TDM) which monitor interlock switch operation. If all of the interlock switches necessary to allow a specific machine operation are not in their desired position, the machine alarm will sound and an Operator’s Advisory may appear on the InfoCenter...

  • Page 222: Electrical Component Testing

    Fuse F−B2 (2 Amp) supplies unswitched power to the key switch and logic power to the T1: TEC • Fuse F−C2 (10 Amp) supplies unswitched power to expansion ports #1 and #2. Electrical System: Electrical Component Testing Page 6–14 Outcross 9060 18234SL Rev B...
  • Page 223 Fuse IF-2 (40 Amp) supplies power to the mixing box blower and the defroster blower. • Fuse IF-3 (20 Amp) supplies power to the windshield wipers. • Fuse IF-4 (25 Amp) supplies power to the condenser fans. Outcross 9060 Page 6–15 Electrical System: Electrical Component Testing 18234SL Rev B...
  • Page 224 1. Make sure that key switch is OFF and key is removed from switch. 2. Remove fuse from fuse block for testing. Fuse should have continuity across the terminals. Electrical System: Electrical Component Testing Page 6–16 Outcross 9060 18234SL Rev B...

  • Page 225: Fusible Link Harness

    To starter B+ terminal Fusible link for starter circuit The Outcross 9060 uses two (2) fusible links for circuit protection. These fusible links are located in a harness that connects the starter B+ terminal to the engine wire harness. If either of these links should fail, current to the protected circuits will be interrupted.

  • Page 226: Can Bus

    1. Make sure that key switch is OFF and key is removed from switch. 2. The Toro DIAG connector is part of the CAN bus and is located below the dash next to the main fuse block. Locate the Toro DIAG connector and remove the connector cover.

  • Page 227: Primary Controller (T1: Tec)

    Primary controller T1: TEC Platform harness connector Outcross 9060 machines use a primary controller (T1: TEC) to manage machine electrical functions. The T1: TEC is a 5004 series microcontroller that monitors the condition of various machine switches and sensors (inputs) and directs electrical power to control appropriate machine functions (outputs) based on the state of the inputs.
  • Page 228 The machine electrical schematic and wire harness drawings in Appendix A (page A–1) can be used to identify possible circuit problems between the controller and the input or output devices (e.g. switches and solenoid valve coils). Electrical System: Electrical Component Testing Page 6–20 Outcross 9060 18234SL Rev B...
  • Page 229 A controller may be damaged if an attempt is made to test it with an electrical test device (e.g. digital multimeter or test light). Note: The InfoCenter Display, TECs, and the TDM used on the Outcross 9060 machine are matched for correct machine operation. If any of these components are replaced for any reason, system software needs to be reloaded (contact an Authorized Toro Distributor for assistance).

  • Page 230: Status Display Controller (T2: Tdm)

    The primary controller (T1: TEC), the status display controller (T2: TDM), the Yanmar Engine Control Unit (ECU), the InfoCenter Display, and the optional InchMode controller (T3: TEC) used on the Outcross 9060 machine communicate with each other on a Controller Area Network (CAN) bus system.
  • Page 231 If connector pins are enlarged or damaged during testing, connector repair may be necessary for proper machine operation. g259386 Figure 82 Platform wire harness connector P15 Status display controller (T2: TDM) Outcross 9060 Page 6–23 Electrical System: Electrical Component Testing 18234SL Rev B...
  • Page 232 A controller may be damaged if an attempt is made to test it with an electrical test device (e.g. digital multimeter or test light). Note: The InfoCenter Display, TECs, and the TDM used on the Outcross 9060 machine are matched for correct machine operation. If any of these components are replaced for any reason, system software needs to be reloaded (contact an Authorized Toro Distributor for assistance).

  • Page 233: Inchmode Controller (T3: Tec) (Optional)

    The primary controller (T1: TEC), the status display controller (T2: TDM), the Yanmar Engine Control Unit (ECU), the InfoCenter Display, and the optional InchMode controller (T3: TEC) used on the Outcross 9060 machine communicate with each other on a Controller Area Network (CAN) bus system.
  • Page 234 A controller may be damaged if an attempt is made to test it with an electrical test device (e.g. digital multimeter or test light). Note: The InfoCenter Display, TECs, and the TDM used on the Outcross 9060 machine are matched for correct machine operation. If any of these components are replaced for any reason, system software needs to be reloaded (contact an Authorized Toro Distributor for assistance).

  • Page 235: Key Switch

    Appendix A (page A–1). 8. Install the switch, connect the wire harness and install the instrument panel after testing. 9. Connect the battery negative (-) cable at the battery. Outcross 9060 Page 6–27 Electrical System: Electrical Component Testing 18234SL Rev B...

  • Page 236: Mode Selector

    8. If the position sensor tests correctly and a circuit problem still exists, check the wire harnesses; refer to Appendix A (page A–1). 9. Install the mode selector and connect the wire harness after testing. Electrical System: Electrical Component Testing Page 6–28 Outcross 9060 18234SL Rev B...

  • Page 237: Parking Brake Switch

    Appendix A (page A–1). 9. Install the switch, connect the wire harness and install the instrument panel after testing. 10. Connect the battery negative (-) cable at the battery. Outcross 9060 Page 6–29 Electrical System: Electrical Component Testing 18234SL Rev B...

  • Page 238: Power Take Off (Pto) Enable Switch

    Appendix A (page A–1). 8. Install the switch, connect the wire harness and install the instrument panel after testing. 9. Connect the battery negative (-) cable at the battery. Electrical System: Electrical Component Testing Page 6–30 Outcross 9060 18234SL Rev B...

  • Page 239: Economy (Eco) Mode Switch

    Appendix A (page A–1). 9. Install the switch, connect the wire harness and install the instrument panel after testing. 10. Connect the battery negative (-) cable at the battery. Outcross 9060 Page 6–31 Electrical System: Electrical Component Testing 18234SL Rev B...

  • Page 240: Hydraulic Auxiliary (Aux) Switch

    5. When the joystick is any of the forward or rearward positions there should be no continuity (infinite ohms resistance) between the switch terminals. Electrical System: Electrical Component Testing Page 6–32 Outcross 9060 18234SL Rev B...
  • Page 241 7. If the switch tests correctly and a circuit problem still exists, check the wire harnesses; refer to Appendix A (page A–1). 8. Connect the wire harness and install the operator’s console after testing. Outcross 9060 Page 6–33 Electrical System: Electrical Component Testing 18234SL Rev B...

  • Page 242: Seat Switch

    7. If the switch tests correctly and a circuit problem still exists, check the wire harnesses; refer to Appendix A (page A–1). 8. Connect the wire harness after testing. Electrical System: Electrical Component Testing Page 6–34 Outcross 9060 18234SL Rev B...

  • Page 243: Paddle (3-Point Hitch) And Transmission Lever Switches

    There should be no continuity (infinite ohms resistance) across the switch terminals when the switch is released. Outcross 9060 Page 6–35 Electrical System: Electrical Component Testing 18234SL Rev B...
  • Page 244 6. After testing is complete, connect machine wire harness connector to the switch. 7. Install the dash cover; refer to Installing the Steering Wheel, Instrument Panels and Dash Cover (page 8–16). Electrical System: Electrical Component Testing Page 6–36 Outcross 9060 18234SL Rev B...

  • Page 245: Headlight/Worklight Switch

    Appendix A (page A–1). 8. Install the switch, connect the wire harness and install the instrument panel after testing. 9. Connect the battery negative (-) cable at the battery. Outcross 9060 Page 6–37 Electrical System: Electrical Component Testing 18234SL Rev B...

  • Page 246: Cruise Control Off/On/Set Switch

    Appendix A (page A–1). 8. Install the switch, connect the wire harness and install the instrument panel after testing. 9. Connect the battery negative (-) cable at the battery. Electrical System: Electrical Component Testing Page 6–38 Outcross 9060 18234SL Rev B...

  • Page 247: Cruise Control Speed Increase/Decrease Switch

    Appendix A (page A–1). 8. Install the switch, connect the wire harness and install the instrument panel after testing. 9. Connect the battery negative (-) cable at the battery. Outcross 9060 Page 6–39 Electrical System: Electrical Component Testing 18234SL Rev B...

  • Page 248: Air Conditioning On/Off Switch

    8. Install the switch, connect the wire harness, inspect and repair the roof seals as necessary, and install the roof after testing. 9. Connect the battery negative (-) cable at the battery. Electrical System: Electrical Component Testing Page 6–40 Outcross 9060 18234SL Rev B...

  • Page 249: Heater/Air Conditioning Blower Speed Switch

    8. Install the switch, connect the wire harness, inspect and repair the roof seals as necessary, and install the roof after testing. 9. Connect the battery negative (-) cable at the battery. Outcross 9060 Page 6–41 Electrical System: Electrical Component Testing...

  • Page 250: Inchmode Enable Switch (Optional)

    Appendix A (page A–1). 8. Install the switch, connect the wire harness and install the instrument panel after testing. 9. Connect the battery negative (-) cable at the battery. Electrical System: Electrical Component Testing Page 6–42 Outcross 9060 18234SL Rev B...

  • Page 251: Inchmode Raise/Lower And Forward/Reverse Switches (Optional)

    Appendix A (page A–1). 8. Install the switch, connect the wire harness and install the instrument panel after testing. 9. Connect the battery negative (-) cable at the battery. Outcross 9060 Page 6–43 Electrical System: Electrical Component Testing 18234SL Rev B...

  • Page 252: Loader Selector Control Valve (Scv) Switch (Optional)

    Appendix A (page A–1). 8. Connect the wire harness and install the switch and switch cap after testing. 9. Connect the battery negative (-) cable at the battery. Electrical System: Electrical Component Testing Page 6–44 Outcross 9060 18234SL Rev B...

  • Page 253: Traction Pedal Assembly

    6. Replace the traction pedal assembly if necessary. 7. If the traction pedal tests correctly and a circuit problem still exists, check the wire harnesses; refer to Appendix A (page A–1). Outcross 9060 Page 6–45 Electrical System: Electrical Component Testing 18234SL Rev B...
  • Page 254 Testing the Traction Pedal Assembly (continued) 8. Install the traction pedal assembly and connect the wire harness after testing. Electrical System: Electrical Component Testing Page 6–46 Outcross 9060 18234SL Rev B...

  • Page 255: Decelerator Pedal Position Sensor

    1. Park the machine on a level surface, lower any attachments and stop the engine. 2. Remove the decelerator pedal assembly. 3. Disconnect the machine wire harness connector from the decelerator pedal sensor, and remove the sensor from the machine Outcross 9060 Page 6–47 Electrical System: Electrical Component Testing 18234SL Rev B...
  • Page 256 Appendix A (page A–1). 7. Install the decelerator pedal sensor and connect the wire harness after testing. 8. Install the decelerator pedal assembly. Electrical System: Electrical Component Testing Page 6–48 Outcross 9060 18234SL Rev B...

  • Page 257: Decelerator Pedal Neutral Switch

    1. Park the machine on a level surface, lower any attachments and stop the engine. 2. Disconnect the wire harness connector from the switch. Outcross 9060 Page 6–49 Electrical System: Electrical Component Testing 18234SL Rev B...
  • Page 258 7. If the switch tests correctly and a circuit problem still exists, check the wire harnesses; refer to Appendix A (page A–1). 8. Connect the wire harness after testing. Electrical System: Electrical Component Testing Page 6–50 Outcross 9060 18234SL Rev B...

  • Page 259: 3-Point Hitch Position Sensor

    5. Using a multimeter (DC voltage setting) with the sensor rotated fully clockwise, approximately 4.5 VDC should be present at pin 3. 6. Replace the position sensor if necessary: Outcross 9060 Page 6–51 Electrical System: Electrical Component Testing 18234SL Rev B...
  • Page 260 Connect the wire harness after testing. 7. If the position sensor tests correctly and a circuit problem still exists, check the wire harnesses; refer to Appendix A (page A–1). Electrical System: Electrical Component Testing Page 6–52 Outcross 9060 18234SL Rev B...

  • Page 261: Hydraulic Fluid Temperature Sender

    3. Thoroughly clean the hydraulic tank around the temperature sender. Remove the sender from the tank and discard the O-ring. CAUTION Handle the hot oil with extreme care to prevent personal injury or fire. Outcross 9060 Page 6–53 Electrical System: Electrical Component Testing 18234SL Rev B...
  • Page 262 7. Use a new O-ring and install the sender in the hydraulic tank. Tighten the sender to 16 N∙m (12 ft-lb). 8. Connect the sender to the frame wire harness. 9. Fill hydraulic system to the proper level. Electrical System: Electrical Component Testing Page 6–54 Outcross 9060 18234SL Rev B...

  • Page 263: Speed Sensors

    4. Check the face of the sensor for damage. Replace the sensor if the face is chipped or scratched. 5. Test the machine wire harness to the speed sensor: Outcross 9060 Page 6–55 Electrical System: Electrical Component Testing 18234SL Rev B...
  • Page 264 This confirms the integrity of the circuit ground and signal wires. E. Turn the key switch to OFF. 6. If the wire harness tests correctly and a circuit problem still exists, replace the speed sensor. Electrical System: Electrical Component Testing Page 6–56 Outcross 9060 18234SL Rev B...

  • Page 265: Traction Pressure Sensors

    A. Set the key switch to the RUN position. B. Navigate to the InfoCenter Traction Inputs screen and scroll down to display the Front Traction and Rear Traction readings. Outcross 9060 Page 6–57 Electrical System: Electrical Component Testing 18234SL Rev B...
  • Page 266 5. Replace pressure sensor if necessary. Apply thread sealant to the sensor threads prior to installation and tighten to 20 N∙m (15 ft-lb). 6. Connect the frame wire harness to the pressure sensor after testing. Electrical System: Electrical Component Testing Page 6–58 Outcross 9060 18234SL Rev B...

  • Page 267: Fuel Pump

    3. Drain the fuel/water separator; refer to the traction unit Operator’s Manual. Verify filter element age and condition and replace if necessary. Outcross 9060 Page 6–59 Electrical System: Electrical Component Testing...
  • Page 268 350 ml (11.8 ounces) in 30 seconds. Replace the fuel pump if necessary. 6. Connect fuel hoses and secure with hose clamps. 7. Prime the fuel system; refer to Priming the Fuel System (page 4–15). Electrical System: Electrical Component Testing Page 6–60 Outcross 9060 18234SL Rev B...

  • Page 269: Fuel Level Sender

    8. If the sender tests correctly and a circuit problem still exists, check the wire harnesses; refer to Appendix A (page A–1). 9. Carefully install sender into fuel tank and install fuel tank assembly. Outcross 9060 Page 6–61 Electrical System: Electrical Component Testing 18234SL Rev B...

  • Page 270: Warning Buzzer

    3. Connect a 12 VDC power supply to the buzzer (+) terminal and a ground to the (-) terminal. The buzzer should sound. 4. Replace the buzzer if necessary. 5. Connect the platform wire harness to the buzzer and install the dash cover. Electrical System: Electrical Component Testing Page 6–62 Outcross 9060 18234SL Rev B...

  • Page 271: Relays With 4 Terminals

    Relays with 4 Terminals Outcross 9060 machines use a number of electrical relays that have four (4) terminals. A tag near the wire harness relay connector can be used to identify each relay. g256781 Figure 103 Main power relay Start Relay...
  • Page 272 8. If the relay tests correctly and a circuit problem still exists, check the wire harnesses; refer to Appendix A (page A–1). 9. Connect the wire harness, install any items removed to access the relay, and connect the battery ground cable. Electrical System: Electrical Component Testing Page 6–64 Outcross 9060 18234SL Rev B...

  • Page 273: Relays With 5 Terminals

    Relays with 5 Terminals Outcross 9060 machines use a number of electrical relays that have five (5) terminals. A tag near the wire harness relay connector can be used to identify each relay. g257158 Figure 105 EGR relay Brake light relay (optional) The Exhaust Gas Recirculation (EGR) relay is located under the main instrument panel.
  • Page 274 4 rear SCV hydraulic solenoid valves. The rear SCV relay is energized by the T1: TEC. g267770 Figure 107 Refrigerant receiver drier AC switch signal relay AC condenser fans relay AC clutch relay Electrical System: Electrical Component Testing Page 6–66 Outcross 9060 18234SL Rev B...
  • Page 275 71 to 88 ohms. 5. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12 VDC to terminal 85. The relay should Outcross 9060 Page 6–67 Electrical System: Electrical Component Testing 18234SL Rev B...
  • Page 276 8. If the relay tests correctly and a circuit problem still exists, check the wire harnesses; refer to Appendix A (page A–1). 9. Connect the wire harness, install any items removed to access the relay, and connect the battery ground cable. Electrical System: Electrical Component Testing Page 6–68 Outcross 9060 18234SL Rev B...

  • Page 277: Diode Assemblies

    TERMINAL B TERMINAL A Five (5) different diodes are used on the Outcross 9060 machines. The maximum current allowed through any of the diodes is 6 amps. The diodes can be identified by their black color and diode symbol on the end of the diode body.

  • Page 278: Resistor Assembly

    3. If the resistor tests correctly and a circuit problem still exists, check the wire harnesses; refer to Appendix A (page A–1). Electrical System: Electrical Component Testing Page 6–70 Outcross 9060 18234SL Rev B...

  • Page 279: Can-Bus Terminator Resistors

    C. If testing determines the external termination resistor is faulty, replace the resistor. D. After testing is complete, make sure the external termination resistor is fully installed into the connector and secured to the wire harness. Outcross 9060 Page 6–71 Electrical System: Electrical Component Testing 18234SL Rev B...
  • Page 280 2 and 3 of the Yanmar SA-D connector. E. If testing determines the integrated termination resistor is faulty, replace the engine ECU; contact an Authorized Toro Distributor for assistance. F. After testing is complete, install the SA-D connector cap, and make sure the external termination resistor is fully installed into the connector and secured to the wire harness.

  • Page 281: Hydraulic Solenoid Valve Coils

    Typically, a failed solenoid coil will either be shorted (very low or no resistance) or open (infinite resistance). 1. Locate the pump control solenoid coil to be tested and disconnect the wire harness connector from the coil. Outcross 9060 Page 6–73 Electrical System: Electrical Component Testing 18234SL Rev B...
  • Page 282 4. If the solenoid coil resistance is correct and a circuit problem still exists, check the wire harness; refer to Appendix A (page A–1). 5. After testing is completed, connect the wire harness connector to the solenoid coil. Electrical System: Electrical Component Testing Page 6–74 Outcross 9060 18234SL Rev B...

  • Page 283: Tandem Traction (Piston) Pump Control Solenoid Coils

    If the problem follows the exchanged coil, a problem with the coil is likely. If the problem remains unchanged, something other than the solenoid coil is at fault (e.g. traction pedal, circuit wiring, hydraulic problem). Outcross 9060 Page 6–75 Electrical System: Electrical Component Testing...
  • Page 284 4. If the solenoid coil resistance is correct and a circuit problem still exists, check the wire harness; refer to Appendix A (page A–1). 5. After testing is completed, connect the wire harness connector to the solenoid coil. Electrical System: Electrical Component Testing Page 6–76 Outcross 9060 18234SL Rev B...

  • Page 285: Service And Repairs

    Always disconnect the negative (-) cable first. Clean the cable clamps and terminals separately. Connect the battery cables. Always connect the positive (+) cable first. Apply a coating of Toro Part No. 107-0392 battery terminal protector or a light coat of petroleum jelly to the terminals to reduce corrosion after you make the connections.
  • Page 286 5. Check the battery-electrolyte level every 25 operating hours and every 30 days if machine is in storage. Note: Do not fill the cells above the fill line. 6. Maintain the cell level with the distilled or demineralized water. Electrical System: Service and Repairs Page 6–78 Outcross 9060 18234SL Rev B...

  • Page 287: Storing The Battery

    • with cables disconnected if stored on the machine • in a cool atmosphere to avoid quick deterioration of the battery charge • in an environment that will not be below freezing for an extended period Outcross 9060 Page 6–79 Electrical System: Service and Repairs...

  • Page 288: Servicing The Battery

    While working with the batteries, use extreme caution to avoid splashing or spilling of the electrolyte. Always wear the safety goggles and a face shield while working with batteries. Electrical System: Service and Repairs Page 6–80 Outcross 9060 18234SL Rev B...
  • Page 289 Make sure that the battery filler caps are secure and remove the battery from the battery compartment. Installing the Battery IMPORTANT To prevent possible electrical problems, install only a fully charged battery. Outcross 9060 Page 6–81 Electrical System: Service and Repairs 18234SL Rev B...
  • Page 290 6. Connect the negative (-) cable connector to the negative (-) battery terminal. 7. After you make the connections, apply battery terminal protector Toro Part No. 107-0392 or a light layer of petroleum jelly to the battery terminals and cable connectors to reduce corrosion.
  • Page 291 3. Do a high-discharge test with an adjustable load tester. This is a very reliable means of testing a battery as it simulates the battery cold-cranking capacity. A commercial battery load tester is required to do this test. Outcross 9060 Page 6–83 Electrical System: Service and Repairs...
  • Page 292 17.3 hrs @ 6 A 23 hrs @ 6 A above 250 6 hrs @ 10 A 12 hrs @ 10 A 18 hrs @ 10 A 24 hrs @ 10 A Electrical System: Service and Repairs Page 6–84 Outcross 9060 18234SL Rev B...
  • Page 293 Note: The battery is fully charged when the cells are gassing freely at a low charging rate and there is less than a 0.003 change in specific gravity for 3 consecutive readings. Outcross 9060 Page 6–85 Electrical System: Service and Repairs...
  • Page 294 Electrical System: Service and Repairs Page 6–86 Outcross 9060 18234SL Rev B...
  • Page 295 Front PTO Gear Box ........................7–14 PTO Clutch ............................7–19 Rear PTO Gear Box......................... 7–21 PTO Drive Shaft ..........................7–24 Additional Reference Materials Carraro DriveTech Model 26.09M Axle Repair Manual Outcross 9060 Page 7–1 Traction and PTO Drive 18234SL Rev B...

  • Page 296: General Information

    Refer to the traction unit Operator’s Manual and accessory Installation Instructions for additional information. Traction and PTO Drive: General Information Page 7–2 Outcross 9060 18234SL Rev B...

  • Page 297: Adjustments

    • Front Tie Rod Length = (10.22 ± 0.03 inch). • Rear Tie Rod Length = (10.45 ± 0.03 inch). 2. Tighten the jam nut. Adjusting Axle Stop Bolts g254450 Figure 118 Front axle Rear axle Outcross 9060 Page 7–3 Traction and PTO Drive: Adjustments 18234SL Rev B...
  • Page 298 Adjusting Axle Stop Bolts (continued) Adjust the axle stop bolts after the axle has been installed on the machine and the tie rods have been installed. Traction and PTO Drive: Adjustments Page 7–4 Outcross 9060 18234SL Rev B...

  • Page 299: Service And Repairs

    2. Use the flats on the steering cylinder rod nearest the tie rod being installed to hold the cylinder rod and install the inner tie rod. Outcross 9060 Page 7–5 Traction and PTO Drive: Service and Repairs...
  • Page 300 6. Grease the outer tie rod with Mobil high-temp XHP-222 grease or equivalent until the boot swells. Do not allow the grease to purge from boot. Traction and PTO Drive: Service and Repairs Page 7–6 Outcross 9060 18234SL Rev B...

  • Page 301: Front Axle

    Flange head screw (2 each) Flange head screw (4 each) Slotted nut Cover (2 each) Flat washer (4 each) Cotter pin Coupler assembly Tie rod assembly (2 each) Outcross 9060 Page 7–7 Traction and PTO Drive: Service and Repairs 18234SL Rev B...
  • Page 302 Operator’s Manual. 10. Grease the front axle with Mobil high-temp XHP-222 grease or equivalent; refer to the traction unit Operator’s Manual. Traction and PTO Drive: Service and Repairs Page 7–8 Outcross 9060 18234SL Rev B...
  • Page 303 Tighten the lug nuts in a crossing pattern from 380 to 434 N∙m (280 to 320 ft-lb). 12. Check and adjust front tire air pressure as necessary. Outcross 9060 Page 7–9 Traction and PTO Drive: Service and Repairs 18234SL Rev B...

  • Page 304: Rear Axle

    Flange nut (4 each) Removing the Rear Axle 1. Raise and support the rear of the machine; refer to Jacking Instructions (page 1–8). 2. Remove the rear wheels. Traction and PTO Drive: Service and Repairs Page 7–10 Outcross 9060 18234SL Rev B...
  • Page 305 Operator’s Manual. 11. Check the oil level in each wheel hub and the rear axle and adjust as necessary; refer to traction unit Operator’s Manual. Outcross 9060 Page 7–11 Traction and PTO Drive: Service and Repairs 18234SL Rev B...
  • Page 306 Tighten the lug nuts in a crossing pattern from 380 to 434 N∙m (280 to 320 ft-lb). 14. Check and adjust front tire air pressure as necessary. Traction and PTO Drive: Service and Repairs Page 7–12 Outcross 9060 18234SL Rev B...

  • Page 307: Front And Rear Axle Service

    Refer to the traction unit Operator’s Manual for axle fluid change procedures. Additional axle service information can be found in the Carraro Drivetech Repair Manual for Model 26.09M. Outcross 9060 Page 7–13 Traction and PTO Drive: Service and Repairs 18234SL Rev B...

  • Page 308: Front Pto Gear Box

    1. Remove the engine assembly; refer to Removing the Engine (page 4–17). 2. Remove the front PTO gearbox from the flywheel housing and retrieve the coupler and dowel pins. Traction and PTO Drive: Service and Repairs Page 7–14 Outcross 9060 18234SL Rev B...
  • Page 309 6. Install the plate and tighten the flange head screws from 24.5 to 32.5 N∙m (18 to 24 ft-lb). 7. Apply anti-seize lubricant to the splines of the output shaft and hub, then install the hub and retaining ring. Outcross 9060 Page 7–15 Traction and PTO Drive: Service and Repairs 18234SL Rev B...
  • Page 310 3. Retrieve the dowel pins from the cover or case, and retrieve the wave washers from the clutch shaft and the output shaft assemblies. 4. Remove the input shaft assembly from the gear box case. Traction and PTO Drive: Service and Repairs Page 7–16 Outcross 9060 18234SL Rev B...
  • Page 311 2. Fit the gear box to the housing and install the 7 flange head screws. Tighten screws in an alternating pattern from 46 to 57 N·m (34 to 42 ft-lb). Outcross 9060 Page 7–17 Traction and PTO Drive: Service and Repairs...
  • Page 312 Installing the Front PTO Gear Box (continued) 3. Apply a thin layer of anti-seize lubricant to the splines of the output shaft and the coupler, then install the coupler. Traction and PTO Drive: Service and Repairs Page 7–18 Outcross 9060 18234SL Rev B...

  • Page 313: Pto Clutch

    4. Use a press and spring compression tool part number 138–3968 to compress the clutch spring and remove the retaining ring, thrust washer and spring from the clutch shaft; refer to Spring Compression Tool (page 2–19). Outcross 9060 Page 7–19 Traction and PTO Drive: Service and Repairs 18234SL Rev B...
  • Page 314 13. Remove and discard the clutch shaft O-ring in the rear gear box housing. 14. Lubricate the new clutch shaft O-ring with petroleum grease and install onto the rear housing. Traction and PTO Drive: Service and Repairs Page 7–20 Outcross 9060 18234SL Rev B...

  • Page 315: Rear Pto Gear Box

    3. Support the rear PTO gear box from overhead. 4. Remove the 6 cap screws securing the rear of the gear box housing to the frame and lift the gearbox from the machine. Outcross 9060 Page 7–21 Traction and PTO Drive: Service and Repairs...
  • Page 316 1. Support the rear PTO gear box from overhead. 2. Lift the gearbox into the machine and install the 6 cap screws securing the rear of the gear box housing to the frame. Traction and PTO Drive: Service and Repairs Page 7–22 Outcross 9060 18234SL Rev B...
  • Page 317 4. Check and adjust the rear PTO gear box fluid level; refer to the traction unit Operator’s Manual. 5. Install the PTO drive shaft; refer to Installing the PTO Drive Shaft (page 7–26). Outcross 9060 Page 7–23 Traction and PTO Drive: Service and Repairs 18234SL Rev B...

  • Page 318: Pto Drive Shaft

    4. Remove the screws securing the flange yokes to the gear box hubs and remove the PTO shaft. 5. Slide the slip yoke off of the tube yoke. Traction and PTO Drive: Service and Repairs Page 7–24 Outcross 9060 18234SL Rev B...
  • Page 319 A. Apply a coating of grease to the bearing bores of the end yoke and the shaft yoke. Also, apply grease to the bearings and seal of the bearing Outcross 9060 Page 7–25 Traction and PTO Drive: Service and Repairs...
  • Page 320 4. Install the 2 shaft guards. 5. Grease the slip yoke grease fitting. 6. Install the PTO shaft cover. 7. Install the bed. Traction and PTO Drive: Service and Repairs Page 7–26 Outcross 9060 18234SL Rev B...
  • Page 321 Front Screen ............................8–3 Hood ..............................8–4 Operator Platform ..........................8–6 Steering Wheel, Instrument Panels and Dash Cover ............... 8–15 Operator’s Console .......................... 8–17 Seats..............................8–18 Standard Bed ........................... 8–21 Front Loader Attachment ......................... 8–22 Outcross 9060 Page 8–1 Chassis 18234SL Rev B...

  • Page 322: General Information

    Refer to the traction unit Operator’s Manual and accessory Installation Instructions for additional information. Chassis: General Information Page 8–2 Outcross 9060 18234SL Rev B...

  • Page 323: Service And Repairs

    5. Remove the bolt and nut from the screen hinge and remove the screen. 6. Inspect the screen for worn or damaged bumpers or seals and replace them as necessary. 7. To install the screen, follow this procedure in reverse order. Outcross 9060 Page 8–3 Chassis: Service and Repairs 18234SL Rev B...

  • Page 324: Hood

    Hood g249481 Figure 133 Lynch pin (2 each) lock nut Foam block (2 each) Hood skin Lock nut Hood frame Hood prop Washer Bulb seal Shoulder screw Shoulder screw Chassis: Service and Repairs Page 8–4 Outcross 9060 18234SL Rev B...
  • Page 325 5. Remove the lynch pins from the hood hinge and remove the hood. 6. Inspect the hood for worn or damaged seals (radiator area) and replace them as necessary. 7. To install the hood, follow this procedure in reverse order. Outcross 9060 Page 8–5 Chassis: Service and Repairs 18234SL Rev B...

  • Page 326: Operator Platform

    8–21), or the optional cargo bed Installation Instructions . 3. Remove the front cowl. 4. Disconnect the battery; refer to Removing the Battery (page 6–81). 5. Remove the front fenders. Chassis: Service and Repairs Page 8–6 Outcross 9060 18234SL Rev B...
  • Page 327 8. Disconnect the hoses at the hydraulic manifold ST and LS/OR1 ports. Cap the fittings and plug the hoses to prevent contamination from entering the hydraulic system. Outcross 9060 Page 8–7 Chassis: Service and Repairs 18234SL Rev B...
  • Page 328 2 connectors (under the right side of the dash cover). 11. Disconnect the 3–pin engine wire harness connector P63 from the main harness. 12. Disconnect the 7–pin engine wire harness connector P18 from the main harness. Chassis: Service and Repairs Page 8–8 Outcross 9060 18234SL Rev B...
  • Page 329 13. Remove the main instrument panel mounting screws and lift the panel to access the glow, start and EGR relays. Remove the cap screw securing the relay bracket to the frame and pass the assembly out of the operator platform. Outcross 9060 Page 8–9 Chassis: Service and Repairs...
  • Page 330 Hydraulic hose (front steering cylinder, left fitting) 14. Label and disconnect the 3 hoses at the rear bulkhead. Cap the fittings and plug the hoses to prevent contamination from entering the hydraulic system. Chassis: Service and Repairs Page 8–10 Outcross 9060 18234SL Rev B...
  • Page 331 Important: Do not allow refrigerant to discharge into the atmosphere. Before opening or disconnecting parts from the refrigerant circuit, empty the refrigerant into a specified recycling bottle, and dispose of it correctly. Outcross 9060 Page 8–11 Chassis: Service and Repairs 18234SL Rev B...
  • Page 332 20. Using the 4 lift points provided, raise the operator platform a few inches. Place blocks between the operator platform mounts and the chassis, then ensure all the required hoses and wire harnesses are disconnected and free to separate from the chassis. Chassis: Service and Repairs Page 8–12 Outcross 9060 18234SL Rev B...
  • Page 333 17. Connect the battery; refer to Installing the Battery (page 6–81). 18. Install the front cowl. 19. Install the bed; refer to Standard Bed (page 8–21), or the optional cargo bed Installation Instructions . Outcross 9060 Page 8–13 Chassis: Service and Repairs 18234SL Rev B...
  • Page 334 22. Operate the machine carefully at first to allow the hydraulic system to refill with fluid. Check for and correct any hydraulic leaks. Check and adjust the hydraulic fluid level as required; refer to the traction unit Operator’s Manual. Chassis: Service and Repairs Page 8–14 Outcross 9060 18234SL Rev B...

  • Page 335: Steering Wheel, Instrument Panels And Dash Cover

    Flange head screw (2 each) Button head screw (4 each) Instrument panel – console Steering column cover Flange nut (2 each) Button head screw (4 each) Steering wheel Instrument panel – steering Washer Outcross 9060 Page 8–15 Chassis: Service and Repairs 18234SL Rev B...
  • Page 336 35 N∙m (20 to 26 ft-lb). 8. Connect the battery; refer to Installing the Battery (page 6–81). 9. Verify instrument panel controls function before returning the machine to service. Chassis: Service and Repairs Page 8–16 Outcross 9060 18234SL Rev B...

  • Page 337: Operator's Console

    5. Remove the main instrument panel fasteners and move the panel to allow access to the 2 fasteners securing the dash cover to the console. 6. Remove the console. 7. To install the console, follow this procedure in reverse order. Outcross 9060 Page 8–17 Chassis: Service and Repairs 18234SL Rev B...

  • Page 338: Seats

    Lock nut (2 each) Cap screw (4 each) Apply medium strength thread locking compound and tighten the seat belt mounting screws from 68 to 81 N∙m (50 to 60 ft-lb). Chassis: Service and Repairs Page 8–18 Outcross 9060 18234SL Rev B...
  • Page 339 Mounting plate Lever Cable tie (3 each) Return spring Handle LH adjustment rail Torx screw (5 each) Bumper (2 each) RH adjustment rail Support bracket Washer Rail stop Cap screw Outcross 9060 Page 8–19 Chassis: Service and Repairs 18234SL Rev B...
  • Page 340 If the air spring assembly requires removal, the lower seat suspension must be removed from the seat platform. Chassis: Service and Repairs Page 8–20 Outcross 9060 18234SL Rev B...

  • Page 341: Standard Bed

    Flange head screw (4 each) CAUTION The standard bed weighs approximately 107 kg (235 lbs). Make sure the hoist, lift or stands used to remove the bed can properly support the weight. Outcross 9060 Page 8–21 Chassis: Service and Repairs 18234SL Rev B...

  • Page 342: Front Loader Attachment

    General Precautions for Removing and Installing the Hydraulic System Components (page 5–49) prior to removing hydraulic system components. CAUTION The front loader arm assembly weighs approximately 218 kg (480 lbs). Chassis: Service and Repairs Page 8–22 Outcross 9060 18234SL Rev B...
  • Page 343 Air Conditioning Compressor ......................9–9 Heating and Air Conditioning Components ..................9–11 Control Panel and Windshield Wiper Assembly ................9–12 Doors ............................... 9–15 Additional Reference Materials Sanden SD Compressor Service Guide Outcross 9060 Page 9–1 Operator Cab 18234SL Rev B...

  • Page 344: General Information

    For information regarding machine electrical cab components (switches and relays); refer to Chapter 6: Electrical System (page 6–1). The electrical schematic and wire harness drawings for the operator cab are included in Appendix A (page A–1). Operator Cab: General Information Page 9–2 Outcross 9060 18234SL Rev B...

  • Page 345: Air Conditioning System

    Make sure that exposed metal surfaces inside cab are insulated. • If the ambient temperatures exceeds 43C (110F) apply additional window tinting to lower the solar heat load to the cab. Outcross 9060 Page 9–3 Operator Cab: General Information 18234SL Rev B...

  • Page 346: Cab Heater System

    The fan motor is also used for the air conditioning system. • Operator controls to adjust the fan speed and to control the amount of coolant passing through the heater core (air temperature). Operator Cab: General Information Page 9–4 Outcross 9060 18234SL Rev B...

  • Page 347: Adjustments

    1. Loosen nut at bottom of tensioner plate and lift or gently pry compressor upward to decrease belt(s) deflection. 2. Tighten nut and recheck belt tension. Outcross 9060 Page 9–5 Operator Cab: Adjustments 18234SL Rev B...

  • Page 348: Adjusting The Doors

    3. Loosen the striker stud lock nut to move the striker stud and adjust the door fit. Disassemble the striker stud and rotate the adjuster to increase stud movement if necessary. Operator Cab: Adjustments Page 9–6 Outcross 9060 18234SL Rev B...

  • Page 349: Service And Repairs

    8. Always use a DOT approved tank for storing used and recycled refrigerants. Outcross 9060 Page 9–7 Operator Cab: Service and Repairs 18234SL Rev B...
  • Page 350 14. After installing air conditioning components, have a certified air conditioning service technician evacuate the air conditioning system completely, properly recharge the system with R134a refrigerant and then leak test the system. Operator Cab: Service and Repairs Page 9–8 Outcross 9060 18234SL Rev B...

  • Page 351: Air Conditioning Compressor

    Refrigerant hose (return) Pulley Carriage bolt (3 each) Cap screw (3 each) The air conditioning compressor used on the Outcross 9060 is a Sanden model SD7H15. For air conditioning compressor repair procedures; refer to the Sanden SD Compressor Service Guide.
  • Page 352 8. Have a certified air conditioning service technician evacuate the air conditioning system completely, properly recharge the system with R134a refrigerant and then leak test the system. air conditioning system capacity is 2.5 pounds of R134a refrigerant. Operator Cab: Service and Repairs Page 9–10 Outcross 9060 18234SL Rev B...

  • Page 353: Heating And Air Conditioning Components

    Heat valve Heater (engine coolant) hoses Remove the roof to access the heating and air conditioning components. Inspect and repair damaged roof seals as necessary before installing the roof. Outcross 9060 Page 9–11 Operator Cab: Service and Repairs 18234SL Rev B...

  • Page 354: Control Panel And Windshield Wiper Assembly

    4. Remove the 8 cap screw securing the control panel assembly to the left and right brackets, then lower the control panel enough to disconnect the Operator Cab: Service and Repairs Page 9–12 Outcross 9060 18234SL Rev B...
  • Page 355 (RH driver side wiper parallel to roof and LH passenger side wiper parallel to cab post). Install the flange nuts and tighten from 23 to 25 N∙m (17 to 18 ft-lb). 6. Connect the washer hoses at the bulkhead fittings. Outcross 9060 Page 9–13 Operator Cab: Service and Repairs 18234SL Rev B...
  • Page 356 Installing the Control Panel and Windshield Wiper Assembly (continued) 7. Test wiper and washer operation before returning the machine to service. Operator Cab: Service and Repairs Page 9–14 Outcross 9060 18234SL Rev B...

  • Page 357: Doors

    Door mount (LH shown) Washer (4 each) Shoulder bolt (2 each) Door spring (2 each) Striker stud (2 each) CAUTION Each door assembly weighs approximately 41 kg (90 lbs). Outcross 9060 Page 9–15 Operator Cab: Service and Repairs 18234SL Rev B...
  • Page 358 Install the gas spring (item 6) as shown, with the barrel end at the door and the rod end at the frame. Adjust the door fit against the frame as necessary; refer to Adjusting the Doors (page 9–6). Operator Cab: Service and Repairs Page 9–16 Outcross 9060 18234SL Rev B...

  • Page 359: Appendix A

    Wire Harness – Cab Work Light Kit (optional) ..................A–22 Wire Harness – Domestic Road Light Kit (optional)................A–23 Wire Harness – Turn Signal/Hazard Lights (optional)...............A–24 Wire Harness – International Road Light Kit (optional) ..............A–25 Outcross 9060 Page A–1 Foldout Drawings 18234SL Rev B...

  • Page 360: Electrical Drawing Designations

    Y or YE YELLOW Numerous harness wires used on the Toro machines include a line with an alternate color. These wires are identified with the wire color and line color with either a / or _ separating the color abbreviations listed above (e.g., R/BK is a red wire with a black line, OR_BK is an orange wire with a black line).

  • Page 361: Hydraulic Schematic

    Hydraulic Schematic g259663 Outcross 9060, Drawing 133-7829 Rev A, Sheet 1 of 1 18234SL Rev B Page A–3...

  • Page 362: Electrical Schematic (Part 1

    Electrical Schematic (part 1 of 3) g264053 Page A–4 18234SL Rev B Outcross 9060, Drawing 122-1360 Rev 1, Sheet 1 of 3...

  • Page 363: Electrical Schematic (Part 2

    Electrical Schematic (part 2 of 3) g264054 Outcross 9060, Drawing 122-1360 Rev 1, Sheet 2 of 3 18234SL Rev B Page A–5...

  • Page 364: Electrical Schematic (Part 3

    Electrical Schematic (part 3 of 3) g267771 Page A–6 18234SL Rev B Outcross 9060, Drawing 122-1063 Rev A, Sheet 3 of 3...

  • Page 365: Wire Harness Drawing - Frame

    Wire Harness Drawing – Frame g256296 Outcross 9060, Drawing 122-0923 Rev A, Sheet 1 of 1 18234SL Rev B Page A–7...

  • Page 366: Wire Harness Diagram - Frame

    Wire Harness Diagram – Frame g256295 Page A–8 18234SL Rev B Outcross 9060, Drawing 122-0923 Rev A, Sheet...

  • Page 367: Wire Harness Drawing - Platform

    Wire Harness Drawing – Platform g256443 Outcross 9060, Drawing 122-0922 Rev A, Sheet 18234SL Rev B Page A–9...

  • Page 368: Wire Harness Diagram - Platform

    Wire Harness Diagram – Platform g256441 Page A–10 18234SL Rev B Outcross 9060, Drawing 122-0922 Rev A, Sheet...

  • Page 369: Wire Harness Diagram - Platform (Continued

    Wire Harness Diagram – Platform (continued) g256442 Outcross 9060, Drawing 122-0922 Rev A, Sheet 18234SL Rev B Page A–11...

  • Page 370: Wire Harness Drawing - Engine

    Wire Harness Drawing – Engine g256294 Page A–12 18234SL Rev B Outcross 9060, Drawing 122-0921 Rev A, Sheet 1 of 1...

  • Page 371: Wire Harness Diagram - Engine

    Wire Harness Diagram – Engine g256293 Outcross 9060, Drawing 122-0921 Rev A, Sheet 1 of 1 18234SL Rev B Page A–13...

  • Page 372: Wire Harness - Headlights

    Wire Harness – Headlights g259593 Page A–14 18234SL Rev B Outcross 9060, Drawing 122-1045/122-1046 Rev A/A, Sheet 1 of 1...

  • Page 373: Wire Harness - Cab Rooftop

    Wire Harness – Cab Rooftop g256477 Outcross 9060, Drawing 122-1245 Rev B, Sheet 1 of 1 18234SL Rev B Page A–15...

  • Page 374: Wire Harness - Cab Control Panel

    Wire Harness – Cab Control Panel g256479 Page A–16 18234SL Rev B Outcross 9060, Drawing 122-1260 Rev A, Sheet 1 of 1...

  • Page 375: Wire Harness - Cab Heat/Air Conditioning

    Wire Harness – Cab Heat/Air Conditioning g256480 Outcross 9060, Drawing 122-1166 Rev A, Sheet 1 of 1 18234SL Rev B Page A–17...

  • Page 376: Wire Harness - Inchmode (Optional

    Wire Harness – InchMode (optional) g259592 Page A–18 18234SL Rev B Outcross 9060, Drawing 122-1385 Rev A, Sheet 1 of 1...

  • Page 377: Wire Harness - Loader Selector Control Valve (Scv) Switch (Optional)

    Wire Harness – Loader Selector Control Valve (SCV) Switch (optional) g260279 Outcross 9060, Drawing 122-1382 Rev A, Sheet 1 of 1 18234SL Rev B Page A–19...

  • Page 378: Wire Harness - Loader Selector Control Valve (Scv) Valve (Optional)

    Wire Harness – Loader Selector Control Valve (SCV) Valve (optional) g260280 Page A–20 18234SL Rev B Outcross 9060, Drawing 122-1383 Rev A, Sheet 1 of 1...

  • Page 379: Wire Harness - Rear Selector Control Valve (Scv) Kit (Optional

    Wire Harness – Rear Selector Control Valve (SCV) Kit (optional) g260281 Outcross 9060, Drawing 122-1384 Rev A, Sheet 1 of 1 18234SL Rev B Page A–21...

  • Page 380: Wire Harness - Cab Work Light Kit (Optional

    Wire Harness – Cab Work Light Kit (optional) g260313 Page A–22 18234SL Rev B Outcross 9060, Drawing 122-1248 Rev A, Sheet 1 of 1...

  • Page 381: Wire Harness - Domestic Road Light Kit (Optional

    Wire Harness – Domestic Road Light Kit (optional) g259650 Outcross 9060, Drawing 122-1387 Rev A, Sheet 1 of 1 18234SL Rev B Page A–23...

  • Page 382: Wire Harness - Turn Signal/Hazard Lights (Optional

    Wire Harness – Turn Signal/Hazard Lights (optional) g260339 Page A–24 18234SL Rev B Outcross 9060, Drawing 122-1249 Rev A, Sheet 1 of 1...

  • Page 383: Wire Harness - International Road Light Kit (Optional

    Wire Harness – International Road Light Kit (optional) g259651 Outcross 9060, Drawing 122-1386 Rev A, Sheet 1 of 1 18234SL Rev B Page A–25...

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