Index

TORO 007
OPERATION
AND
SAFETY
INSTRUCTIONS

ã SANDVIK TAMROCK CORP. 4/98

Index

007

TAMROCK Corp., Turku Plant

P.O.BOX 434
20101 TURKU, FINLAND
+358--(0)205 44 131
fax +358--(0)205 44 130
telex 62 305 TLOAD FI T007---D ---OPE---E---001
4.98

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TABLE OF CONTENTS

Page
Declaration of comformity . . . . . . . . . . . . . . . . . 4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Main dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 6
Technical specification . . . . . . . . . . . . . . . . . . . . 7
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Instrument panel . . . . . . . . . . . . . . . . . . . . . . . 12
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Bucket hydraulics . . . . . . . . . . . . . . . . . . . . . . . 21
Brake systems . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Daily maintenance . . . . . . . . . . . . . . . . . . . . . . 33

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DECLARATION OF CONFORMITY

Manufacturer: TAMROCK CORP., Turku Plant

P.O. Box 434
FIN--20101 TURKU, FINLAND

Herewith declares that

TORO 007 LHD--loader,

has been designed and manufactured according to good mechanical engineering.

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GENERAL

This instruction manual shall facilitate the task to

become familiar with TORO loader and its intended use.
You are about to operate TORO 007, a diesel powered
rubber tired, low profile underground mining loader.

TORO loader is intended to load, haul and dump rock

material exclusively. Any other use different from this is
not considered as intended. The intended use also
includes to follow the instruction manual and to observe
inspection and maintenance rules.
The manufacturer or supplier will not be liable for any
damage resulting from the product misuse.

Each operator should familiarize himself with his

machine before operating it. This manual contains the
information which acquaints him with the components,
instruments and controls.

This instruction manual must be read and used by

each person in charge to work with TORO 007,
operating it, transporting it, servicing or repairing it.

The front of the unit is the end which points in the

normal travelling direction. With this unit it is the bucket
end. Right and left sides of the unit are designed in
reference to the operators position, looking toward the
front of the unit.

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MAIN DIMENSIONS

6
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TECHNICAL SPECIFICATION
Main dimensions
Total length 9 680 mm
Maximum width (without bucket) 2 485 mm
Height with cabin or canopy 2 395 mm
Height without canopy 1 990 mm

Weights
Operating weight (with canopy) 26 200 kg
Loaded weight 36 200 kg
Shipping weight 26 000 kg
Axle weights
without load front axle 11 700 kg
rear axle 14 500 kg
with load front axle 27 050 kg
rear axle 9 150 kg

Capacities
Tramming capacity 10 000 kg
Breakout force, tilt 163 kN (16300 kp)
Breakout force, lift 184 kN (18400 kp)
Tipping load 23 400 kg
Bucket std. 4.6 m3

Bucket motion times

Raising time 7,5 sec.
Lowering time 4,0 sec.
Tipping time 2,2 sec.

Driving speed
1st gear 5,0 km/h
2nd gear 9,2 km/h
3rd gear 15,2 km/h
4th gear 26,5 km/h

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Engine
Diesel engine Detroit Diesel S--50 DDEC
Engine output 187 kW (250 hp)/2100 r/min
Number of cylinders in line 4
Displacement 8,5 dm3
Cooling system water
Electric system 24 V
Combustion principle 4--stroke/turbo, intercooler

Power train
Torque converter 15”
Transmission Clark MHR33425, power shift gear box with
modulation, 4 + 4 speeds
Axles, front and rear Clark 19D--series with Posi--Torque differentials,
front axle fixed, rear axle oscillating ? ? _
Tyres 18.00 x 25, L5S
-- air pressure front 5,5 bar (550 kPa)
rear 4,0 bar (400 kPa)

Steering
Hydraulic, servo controlled power steering, articulated frame with two double--acting
Ø 125 mm hydraulic cylinders, turning angle ? 42,5_. Turning radius: inner 3270 mm, outer
6515 mm.
Main components
Steering and servo hydraulic pump (piston pump) Rexroth
Steering control (proportional valves) Rexroth
Steering main valve Rexroth
Steering cylinders Tamrock
Max pressure setting for piston pump 250 bar (25,0 MPa)
Pressure setting for the steering hydraulic main relief valve 120 bar (12,0 MPa)
Pressure setting for the shock load valves (2) 150 bar (15,0 MPa)

Bucket hydraulics
Lifted by two Ø 160 mm cylinders. Breakout by one Ø 200 mm cylinder with Z--linkage. The
bucket hydraulics has two pumps. One is for the servo circuit and other delivers oil flow to the
bucket hydraulic main valve. The oil flow from steering hydraulic pump is directed to bucket
hydraulics when steering is not used.
Main components
Bucket hydraulic cylinders Tamrock
Bucket hydraulic pump (piston pump) Rexroth
Control valve (proportional valves) Rexroth
Main valve Rexroth
Pressure setting for the servo circuit 35 bar (3,5 MPa)
Piston pump max. pressure setting 250 bar (25,0 MPa)
Pressure setting for the bucket hydraulics 250 bar (25,0 MPa)
Pressure setting for the shock load valves 280 bar (28,0 MPa)
Capacity of the hydraulic oil tank appr. 300 l

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Brake system
Service brakes
Spring applied (Posi--Stop) multi--disc liquid cooled wheel brakes. Brakes are pressure released
and spring applied. There are independent circuits for front and rear axle brakes.
Parking brake / Emergency brake
Parking brake (emergency brake) uses the same brakes as the service brakes and is controlled
with the parking brake button in the instrument panel (or the emergency stop button, optional)
Pushing the parking brake button engages the brake and pulling the three position button to third
position releases the brake.
The parking brake engages automatically if the engine is not running, brake accumulator
pressure is low or if the electric current is cut off. After automatic function the parking brake is
released by pulling the emergency brake button fully up.
Main components
Pressure accumulators Bosch
Brake pedal valve MICO
Charging valve Parker

Operator’s cabin
Equivalent continuous A--weighted sound pressure level in the cabin is 82 dB (A).
(Measurement according to ISO 6394 at high idle (2100) rpm)
Vibration: weighted root mean square acceleration value to which
-- the arms are subjected does not exceed 2,5 m/s2 (evaluation according to ISO 5349)
-- the body is subjected is 0,8 m/s2 (evaluation according to ISO 2631--1)
(Measurements mode according to committee draft ISO/CD 13538.)
Components:
Seat KAB 525
Gear shift control electric, Tamrock
Steering control valve electric, Gessman
Bucket control lever electric, Gessman
Accelerator pedal electric, Williams
Brake pedal hydraulic, Rexroth
Optional equipment:
Air conditioning unit Tamrock
Fire extinguishing system ANSUL
The controls, switches, instruments and indicator lights are within easy reach and sight of the
operator.

Make sure that they are in operating condition at all times.

Do not delay reporting and servicing of a defective component. Observe the gauges often and
obey their signals.
Read the remote control system instuctions carefully before operating the machine with remote
control.
In the beginning of the working period check the remote control system functioning according to
remote control system instructions.

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CONTROLS

10
2

6 5
8 9
1
5

4
3 4 7
3
1. Steering lever & gear selector 5. Bucket control lever
2. Brake pressures/ 6. Instrument panel
Hydr. return filter back pressure/ 7. Seat
Brake flushing filter back press. 8. Fire suppression system button
3. Brake pedal 9. Gear display
4. Accelerator pedal 10. Emergency exit

Steering lever & gear selector (1) N + ---

The four forward and reverse gears (speeds) of the Power--Shift
transmission are selected with buttons on the steering lever.
Gear selection manual mode: R
When gear is in neutral forward gears are selected with button (F) and F
reverse gears with button (R). Higher gears forward are selected by
pushing the button (f) and lower gears by pushing button (r). When
reversing, higher gears are selected by button (R) and lower by button
(F). Button (N) is for neutral. The selected gear and direction is shown
with a display behind the bucket control lever.
Gear selection automatic mode:
Driving direction is selected with buttons (F) forward and (R) reverse,
when the gear is on neutral. Highest allowed gear is selected by pushing
buttons (+) and (--). When driving backwards, higher gears are selected
by button (r) and lower by button (f). Button (n) is neutral. The highest
allowed gear, selected gear and direction is shown in a display behind the
bucket control lever (+ is forward, - is backwards).
Steering lever controls proportional valves electrically. When moving
the lever pilot pressure flows to the corresponding main valve spool end
and moves the spool. The gate from steering pump to steering cylinders
opens, and the machine turns.
Note! The machine does not turn and the gear is put into neutral if the
cabin door is open (safety feature).

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Brake pedal (3)
The foot operated brake pedal actuates the brake valve. The two--section valve has two pressure
adjusting sections, one for each brake circuit. Pressing the brake pedal opens both valves evenly
causing the pressure in the brake circuits to rise in relation to the pedal operating force.
Note! Never drive with your foot on the brake pedal!

Accelerator (4)
The foot operated accelerator pedal is electric. Do not press the pedal when starting the engine.

Boom and bucket control (5)

The lever controls electrically the proportional valves, which direct the servo pressure to the
corresponding actuators in the bucket hydraulics main valve.
The lever movements:
Push: bucket dump
Pull: bucket roll back
Turn right: boom up
Turn left: boom down
The button on the top of the lever is for the boom
suspension system. Pushing the button activates the
suspension system and indicator light in the instrument
panel comes on. The suspension system is disconnected
by pushing the same button second time. See the instrument panel.

Fire suppression system button (8)*

In case of fire shut down the engine and activate the extinguisher system by pulling the safety
ring pin and pushing down the button (8) on the activator. Leave the machine and the fire area
immediately and stand by at a safe distance. Heat remaining of the fire can cause reignition after
the extinguisher system has discharged. Stand by (with hand portable fire extinguisher if
available) until the possibility of reignition is past.
After the fire is out the machine should not be started until it has been serviced and cleaned.
Immediately recharge the fire extinguishing system.

Gear display (9)*

Gear display shows selected gear/gear range and direction.
Emergency exit (10)
The rear window of the operator cabin can be used as emergency exit. Pull from the exit
sign/ring and move the sign round the window so that the rope comes out of the window seal.
Push the rear window out of place and go out through the hole.

*optional equipment

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INSTRUMENT PANEL
12 13 29 1 2 3 4 5 6 7 8

36 43
37 44
38 45
39 46
40 47

41 48
42 49

32 30 10
19 18 24 14 34 15 26 35 16 17 31 9

25
33
20 21 28

11
23 27
22 22

1. Engine oil pressure 19. Torque converter lock--up off*

2. Engine temperature 20. Front lights
3. Transmission oil pressure 21. Rear lights
4. Transmission oil temperature 22. Wipers
5. Voltmeter 23. Washers
6. Hydraulic oil temperature 24. Open door*
7. Fuel level* 25. Close door*
8. Hour meter 26. Disconnect door hydraulics*
9. Gear selector mode 27. Ignition switch
10. Gear Display Select button 28. Horn
11. Tachometer 29. Emergency stop button*
12. Stop Engine Light 30. DDR--connector
13. Check Engine Light 31. Parking brake button
14. Data Request & Stop Engine Override 32. Brake releasing pump switch
15. Remote Control switch 33. Gear display
16. Boom suspension switch* (behind bucket control lever)
17. Air conditioner* 34. Forward speed signal light
18. Torque converter lock--up on* 35. Reverse speed signal light
* Optional equipment

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WARNING-- & SIGNAL LIGHTS

36. Parking brake on 43. Water level*
37. Service brake on 44. Hydraulic oil level*
38. Low brake accumulator pressure 45. Emergency steering*
39. Low engine oil pressure* 46. Blinkers*
40. Autom. lubrication* 47. Fuse blown*
41. ACL--unit grease tank empty* 48. Boom suspension system on*
42. Fuel level* 49. Converter lock--up on*
* Optional equipment

INSTRUMENTS
Engine oil pressure (1)
Minimum oil pressure with a warmed up engine at slow idle should be 0,35 bar (35 kPa), when
at operating speed (1800 rpm) the oil pressure should be over 1,93 bar (193 kPa).

Engine temperature (2)

Normal engine operating temperature 75...99 _C. If the temperature exceeds 100 _C shut off
engine and trouble shoot for the cause after the engine has cooled.

Transmission oil pressure (3)

This gauge shows the transmission clutch pressure. It should be between 16,5 bar (1655 kPa)
and 21,4 bar (2137 kPa). If the pressure in any clutch is more than 0,4 bar (40 kPa) different
from the others the clutch should be inspected.

Transmission oil temperature (4)

The transmission oil temperature should be below 120 _C.

Hydraulic oil temperature gauge (6)

The hydraulic oil temperature should be below 100 _C.
Gear Selector Mode switch (9)
The gear selection system is electric and logic controlled.
When Gear Selector Mode switch (9) is in manual position, the gears are selected manually with
buttons (F & R) on the steering lever.
With the switch (9) in AUTO position, the gears change automatically. The operator selects the
highest gear and driving direction with buttons (F, R, +, - ) on the steering lever.
Progr

Gear Display Select button (10)

When Gear Selector Mode switch (9) is in auto or manual position, pushing the Display Select
button brings the machine speed to the display (4 km/h is shown 40). With the switch (9) in
programming position, pushing the Display Select button shows the engine rews. Gear Display
Select button is also used when programming or changing the parameters of the programme.

”Stop Engine” and ”Check Engine” lights (12 & 13)

When ignition key is turned to power on position the ”Stop engine” and ”Check engine” lights
come on. If all the systems are OK, both lights will go out in approx. five seconds. If the
warning lights stay on, or if they do not come on momentarily after starting the engine, consult
with a DDEC techician.

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When the ”Stop Engine” light comes on, the computer has detected a major malfunction in the
engine that requires immediate attention. The conditions that cause the ”Engine Stop” light to
come on are:
D low coolant level
D high coolant temperature
D high engine oil temperature
D low engine oil pressure
D low transmission oil pressure (optional)
After the ”Stop Engine” light comes on the engine rpm will be reduced to certain level for 30
seconds and after that the engine will stop automatically. If the machine is operating in a critical
situation, the operator may select to ”override” the automatic stop by pressing the ”Stop Engine
Override” button (14) (on the instrument panel). While the button is pressed the engine
revolutions will rise to normal and after the button is released the revolutions will be reduced
again and engine will stop after 30 seconds. The operator must press the override button just
prior to engine shutdown and continue to do so until the machine can be brought to a safe stop.
See the Detroit Diesel Engine Operators Guide

Data request & stop engine override button (14)

A data request can be made by pushing the button and holding it there. This will cause the
Check Engine light (13) to flash a code number. More information about the codes in the Detroit
Diesel Engine Operator’s Guide.
See ”Stop Engine” (12) and ”Check Engine” (13) lights.
Boom suspension switch (16)*
The boom suspension switch has three positions OFF--AUTO--MANUAL. In AUTO position the
suspension system can be connected/disconnected with a button (on the bucket control lever)
when driving with second or higher speed. When first speed is selected the suspension system
will be automatically disconnected.
The switch in MAN--position keeps the suspension connected constantly.
There is a signal light illuminating in the instrument panel when the suspension is on.

Air conditioner switch (17)*

Air conditioner switch has three positions OFF - LOW SPEED - HIGH SPEED.

Torque converter lock--up (18, 19, 44)

Torque converter lock--up can be connected with all forward and reverse speeds by pushing
button (18). Converter lock--up is disconnected by pushing button (19). Signal light (44) in the
instrument panel is on when lock--up is connected. Always when changing speeds (gears) the
lock--up is disconnected automatically and must be connected with button (18) if needed.
See driving instructions.
Hydraulic door buttons (24, 25, 26)*
Opening and closing the door can be eased hydraulically. Pushing button (24) opens the door,
pushing button (25) closes the door and pushing button (26) disconnects the door hydraulics.

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Ignition key (27)
Turn the ignition key in the ignition switch
D Position P. parking lights on
D Position 0. electric current off
D Position 1. electric power on.
D Position 2. (preheating, not in Detroit Diesel engines)
D Position 3. starting the engine
See starting instructions.

Emergency stop button (29)*

Pushing the emrgency stop button stops the engine and applies the wheel brakes as well as the
parking brake. Pulling the button up disengages the wheel brakes. Parking brake must be
disengaged with parking brake button (31).
The button remains down and it must be pulled up before the motors can be started again.
DDR connector (30)*
Connector for the Diagnostic Data Reader (optional).
Parking brake button (31)
Pushing the button (31) engages the parking brake. The parking brake engages automatically if
D engine oil pressure drops
D brake accumulator oil pressure drops
D electric current is cut off
The parking brake is released by pulling the three position parking brake button up to third
position (engine running and accumulator pressure over 120 bar).
Brake releasing pump switch (32)*
Turning the switch clockwise starts the electrically operated pump. The pump stops when the
accumulator pressure reaches certain limit. The brake releasing pump can be used for towing
purposes only and must be disengaged after towing. The releasing system does not work if
engine is running.

Speed selector display (33)

Display shows the selected speed (and range). The signal lights (34, 35) show the selected
direction. When pushing the Gear Display Select button (10) the display shows the driving speed
(10 x km/h).
Signal light for service brake (37)
Signal light for service brake is on when brake pedal is pressed or when emergency brake is on.
Low brake accumulator pressure (38)
The warning light is on when the accumulator pressure drops below 12,0 MPa (120 bar)
Automatic central lubrication indicator light (40)*
The indicator light goes on and off while the system is working.
Fuse blown (47)
Indicator light illuminates when a circuit breaker has opened. The circuit breakers are in the
instrument panel.
* optional equipment
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CIRCUIT BREAKERS
The circuit breakers are located inside the instrument panel.

F1 F2 F3 F4 F5 F6 F7 F20 F21 F24 F55 F58

F1 Front lights 16 A F7 Driving direction lights 10 A

F2 Rear lights 16 A F20 Wipers, Washers * 16 A
F3 Central lubrication, Brake lights 10 A F21 Air conditioning unit * 16 A
F4 Engine start, Horn 16 A F24 Remote control * 10 A
F5 Instrument panel, 10 A F55 Electric steering * 6A
F6 Gear selector 16 A F58 Fuel filter heater * 16 A
* Optional equipment

BRAKE PRESSURE GAUGES

1.0 1.5 1.0 1.5 100 100

50 50
2.0 2.0
0.5 0.5 150 150

2.5 2.5 160 160

bar bar bar bar

50 51 52 53

50. Hydraulic oil return filter back pressure 52. Front brake circuit accumulator pressure
51. Brake flushing return filter 53. Rear brake circuit accumulator pressure
Return oil filter back pressure (50)
Measure the filter back pressure with the boom up or the hydraulic oil tank open. If the back
pressure exceeds 1,4 bar the filter element must be changed.

Brake flushing oil filter back pressure (51)

Measure the filter back pressure with the boom up or the hydraulic oil tank open. If the back
pressure exceeds 0,4 bar the filter element must be changed.

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TRANSMISSION TORO 007 is equipped with a torque

converter and hydraulically controlled
power--shift transmission.
Detroit s50 engine Torque converter Power---shift
transmission

Drop box Rear axle Front axle

The engine--mounted transfer gearbox

(“up--box”) drives the converter and four
b a speed power--shift transmission assembly
through a driveshaft. The gear ratios are
selected with electric gear selector (control
lever in the cabin). Four gears can be used for
driving forwards and backwards. The power
is directed from the transmission through
c driveshafts into the front and rear axle
differentials. The axle differentials drive
planetary wheel hubs.
The torque converter consists of an engine
driven impeller (a), a turbine (b) and a
reaction member (c). When the engine is
running the impeller forces oil into the
converter chamber against the turbine blades.
From there the oil travels through the reaction
member then back to the impeller. This
circulation causes the turbine to turn.
The converter charging pump draws oil from
the transmission sump and directs it through
the pressure regulating valve and oil filter.
The pressure regulating valve maintains
pressure to the transmission control cover for
actuating the direction and speed clutches.
This requires a small portion of the total
volume of oil used in the system. The
remaining volume of oil is directed through
the torque converter circuit to the oil cooler
and returns to the transmission for positive
lubrication.
After entering the converter housing the oil is directed through the stator support to the converter
blade cavity and exits in the passage between the turbine shaft and converter support. The oil then

17
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flows out of the converter to the oil cooler. After leaving the cooler, the oil is directed to a fitting in
the transmission. The oil then gravity drains to the transmission sump
The torque converter will multiply engine torque to its designated maximum multiplication ratio
when the output shaft is at zero RPM. Therefore, as the output shaft is decreasing in speed the
torque multiplication is increasing.
The shift control valve assembly consists of a valve body with spool type solenoid cartridge valves
which is controlled electronically.
With the engine running and the gear in neutral, oil pressure from the regulating valve is blocked at
the control valve. Selection of forward or reverse will direct oil, under pressure to either the
forward or reverse directional clutch as desired. When either directional clutch is selected the
opposite clutch is relieved of pressure and vents back through the direction selectional spool. The
same procedure is used in the speed selector.
The direction or speed clutch assembly consists of a drum with internal splines and a bore to
receive a hydraulically actuated piston. A steel disc with external splines is inserted into the drum
and rests against the piston. Next, a friction disc with splines at the inner diameter is inserted. Discs
are alternated until the required total is achieved. A heavy back--up plate is then inserted and
secured with a snap ring. A hub with O.D. splines is inserted into the splines of disc with teeth on
the inner diameter. The disc and hub are free to increase in speed or rotate in the opposite direction
as long as no pressure is present in that specific clutch.
To engage the clutch, as previously stated, the control valve is placed in the desired position. This
allows oil under pressure to flow from the control valve, through a tube, to the chosen clutch shaft.
Oil pressure sealing rings located on the clutch shaft direct oil under pressure to pass thru a drilled
passageway in the clutch shaft to enter the piston cavity. Pressure of the oil forces the piston and
disc against heavy back--up plate. The disc, with teeth on the outer diameter, clamping against disc
with teeth on the inner diameter, enables the hub and clutch shaft to be locked together and allows
them to drive as a unit.

Modulation
The load on the drive train components can become very high if the directions are changed too
abruptly.
The powershift transmission has a built--in protection against this form of damage. The clutch
modulation (gradual engagement) is standard in TORO 007 with Clark MHR33425 - transmission.
This kind of arrangement is used in applications requiring many rapid reversals in the duty cycle.
The pistons that force the clutch plates together and the control valve are designed to apply lower
force when the plates first engage and gradually increase the force until full engagement is made.
This provides a cushioning effect which prevents ”shift shock” or sudden high torque surges to the
drive line. The entire modulator sequence of events occurs in less than two seconds.
Lube oil is constantly directed through the clutches to prevent heat from building up during
engagement as well as to lubricate the bearing and gears.

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STEERING
1

12
13
8

9
11
11
10
5 7
10
6 3

1. Hydraulic oil tank 8. Steering main valve

2. Steering cylinders 9. Steering proportional valves
3. Tilt cylinder (magnetic valves)
4. Lift cylinder 10. Oil cooler
5. Bucket proportional valves
11. Relief valve
(magnetic valves)
6. Bucket main valve 12. Hydraulic pump (bucket hydr.)
7. Signal block 13. Hydraulic pump (steering & servo)
The TORO 007 has center--articulated load sensing power steering with two steering cylinders. The
drop box mounted piston pump (13) (variable displacement pump) delivers oil to a hydraulically
controlled steering main valve (8).
The steering servo pressure is controlled with electric lever and proportional valves (9). Turning the
lever causes the corresponding proportional valve to open and let the servo pressure to enter the
main valve spool end. Servo pressure is regulated to 35 bar in the brake valve assy. If the cabin
door is open, the electric circuit from the steering lever is cut off and turning the machine is
impossible.
Steering lever in neutral position, the steering system oil flows to through the steering main valve
(8) to the bucket main valve (6).
Steering system pressure is regulated to 120 bar and valves for outer shock load open at 150 bar.

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EMERGENCY STEERING (OPTIONAL)

5
1

3
6

2 4

1. Steering main valve 4. Magnetic valve

2. Relief valve 5. Magnetic valve
3. Pressure switch 6. Pressure accumulator
Emergency steering system consists pressure accumulator (6), pressure relief valve (2), pressure
switch (3) and two magnetic valves (4 & 5). The accumulator pre--charging (gas) pressure is 60 bar.
The pressure switch (3) lights a warning light in the instrument panel if the system pressure drops
below 100 bar.
The accumulator is charged by pressing the boom or bucket against the stops. Charging time is
about 4 to 10 sec.
The accumulators must be charged in the beginning of the working period, or if the emergency
steering warning light is on. The emergency steering system will keep the charge untill the engine
is stopped, electric current is off or engine oil pressure is low and the emergency steering system
will be activated.
If electric current is cut off or if engine is stopped the magnetic valve (5) opens a line from the
accumulator to tank and will empty the system in about 4 minutes (safety feature).

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BUCKET HYDRAULICS
1

12
13
8

9
11
11
10
5 7
10
6 3

1. Hydraulic oil tank 8. Steering main valve

2. Steering cylinders 9. Steering proportional valves
3. Tilt cylinder (magnetic valves)
4. Lift cylinder 10. Oil cooler
5. Bucket proportional valves
11. Relief valve
(magnetic valves)
6. Bucket main valve 12. Hydraulic pump (bucket hydr.)
7. Signal block 13. Hydraulic pump (steering & servo)
TORO 007 has load sensing bucket hydraulic system. The converter mounted piston pump (12)
delivers oil to the bucket main valve (6). Excess flow from steering hydraulics (when steering is
not used) flows to bucket main valve (6) from the steering main valve (8).
When moving the electric bucket control lever (5), pilot pressure (35 bar) flows from proportional
valves (5) through signal block (7) to main valve (6) and moves the main valve spools. Pilot
pressure from the signal block is also directed to the pump (12) control valve which regulates the
pump displacement and pressure. The pump pressure is regulated to max. 250 bar. High pressure
oil flows through main valve (6) to lift (4) or tilt cylinders (3) and the bucket moves. The bucket
system main relief valve is set to 270 bar and valves for outer shock loads will open at 280 bar.

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Boom suspension system (optional equipment)
The boom suspension system consists of a pressure accumulator (20) and two magnetic
valves (21). The pressure accumulator pre--charging (gas) pressure is 60 bar. The suspension
system system is charged from the bucket hydraulics during loading or by moving the boom
(or bucket) against the stops.
After the bucket is loaded and lowered against the stops, the boom suspension system can be
activated by pushing the button on the bucket control lever. Pushing the button lights a indicator
light and activates two magnetic valves. The other magnetic valve lets the accumulator oil
pressure to enter the cylinder piston end and the other lets the oil on the other side (piston rod
side) to flow freely to tank.
The system must always be disconnected before dumping or loading by pushing the button on
the lever second time.

20 21

22
Index

007

BRAKE SYSTEM
The wheel brakes are spring applied (Posi--Stop), liquid cooled multi disc type. The brakes are
released with hydraulic pressure. Oil from variable displacement pump (steering system pump)
flows to brake valve (3), where the system pressure is regulated to a proper working range
(150...185 bar)

1 5 8
4
6 7

9 3

14

12 12

10

10
11 11
12 13

1. Steering main valve 8. Pressure switch (110 bar)

2. High pressure oil filter low pressure - engages brake
3. Brake valve 9. Piston pump
4. Magnetic valve
10. Hydraulic oil tank
5. Pressure switch (20 bar)
parking brake signal light 11. Wheel brake
6. Pressure switch (90 bar) 12. Pressure accumulator (brake system)
service brake light
13. Pressure accumulator (servo system)
7. Pressure switch (120 bar)
low accumulator pressure warning light 14. Brake pedal valve

23
Index

007
When pressing the brake pedal oil flows from the wheel brakes (11) through brake valve (3) and
brake pedal valve (14) to hydraulic tank (10) and the spring force engages the brake. The brake
force is in relation to the pedal operating force.
Parking brake button in the instrument panel controls the magnetic valves (4). Pushing the
button engages the parking brake (wheel brakes) and pulling the three position parking brake
button to third position and released (returns to centre position).
Emergency brake button in the instrument panel controls the magnetic valve (14). Pushing the
emergency brake button cuts off the electric current and engages the parking brake (wheel
brakes). Parking brake engages automatically if brake accumulator-- or engine oil pressure is too
low or if electric current is cut off. Brake is released by pulling the three position parking brake
button to third position and released to second position. To release the brake the the accumulator
pressure must be at least 120 bar and engine running.
A electric-- or handpump has been added to the system to make it possible to release the brake
for example when towing. (See towing)
2
1 5 8
4
6 7

9 3

14

12 12

10

10
11 11
12 13

Brake tests
Service brake test: Press brake pedal, connect first gear and accelerate the engine.
The brake should hold 1870 rpm
Parking/Emergency brake test: The parking /emergency brake uses the same spring operated
wheel brakes as the service brake. Check that the parking/emergency brake applies when
pushing the lever forward or when pushing the button in the instrument panel.

24
Index

007

OPERATION
General
This manual includes important references to the
safe, competent and economical operation of the
TORO. The due to these references helps to avoid
possible danger, to reduce repair costs and
breakdowns, and to increase reliability, lifetime
and productivity of the TORO.
This manual must permanently be available in the
cabin when operating with TORO.
This manual must be read and used by each
person in charge to work with the TORO.
Always obey national mandatory rules relating to
accident prevention and enviromental protection.
The generally recognized technical rules for safe
and professional operation must also be observed.
Complete the instruction manual by instructions
including obligatory reporting and control
referring to company rules.

Intended use
The TORO is designed and constructed according
to the state of art and the recognized safety rules.
Nevertheless, its unintended, negligent and
careless use may cause damage to health of the
user or third persons, or prejudice the machine
and other properties.
The TORO shall be used only
. for its intended use
. when it is in proper technical condition
. conscious of safety and possible dangers
. in strict notice and use of the instruction
manual
Functional disorders must be corrected
immediately!
TORO loader is intended to load, haul and dump
rock material exclusively. Any other use different
from this is not considered as intended.

25
Index

007
What You should do
D make sure that all gauges and warning lamps function properly
D keep all safety and danger signs on the machine in legible condition,
observe and follow them
D shift the transmission to neutral during idle periods
D park on level ground, if possible
D turn wheels into bank or rib, or block the wheels when parking on a downgrade
D idle engine for at least four minutes before shutdown
D remember that an engaged transmission will not stop the machine from rolling because it
is equipped with a torque converter ' use the parking brake
D shut off the engine before turning the master switch off

What You should NOT do

D don’t spin the tires while loading
D don’t lift the front tires off the ground while loading
D don’t allow the machine to roll backwards with the transmission in forward while
working on steep grades
D don’t leave the unit unattended unless parked safely and the brakes are set

Read all instructions carefully and follow them

Safety precautions
D never attempt to clean, oil or adjust the machine while it is in motion
D do not operate with passengers
D do not grab the steering lever or wheel when climbing into the cabin
D be seated when operating the machine
D allow no persons in the hinge area, make sure that nobody is endangered before starting
the machine
D become a qualified operator
D in case of malfunction, stop immediately and safeguard the machine, have the
malfunction immediately cleared
D before operating the machine with remote control check the remote control system
functioning according to remote control system instructions

26
Index

007
Pre--start check list
Before starting the engine, check the following
D fuel and coolant levels
D all oil levels
D water level (machines with water scrubber)
D all lubrication points
D make sure that the safety link is removed
D make a general visual inspection of the machine, check for oil leaks and loose hoses,
frayed wires or other apparent maintenance needs; if anything looks suspicious call a
service man

Starting procedure
1. Turn the main switch to the “ON” position, and open the fuel tank shut--off valve.
2. Open the water tank shut--off valve (if equipped with water scrubber)
3. Check that the parking brake is on and the cabin door closed.
4. Check that the emergency stop button (optional) in the instrument panel is not pushed in.
5. Turn the ignition key to power on position and check the indicator lights. DDEC signal
lights should go off after about 5 seconds.
6. Do not touch the accelerator pedal until the engine has started.
7. Turn the ignition key to the start position. Let the key return to the ”power on” position
when the engine fires. Do not run the starter more than 20 seconds at a time. If the
engine does not start wait one minute before trying again.
8. Check the gauges and the indicator lights.
-- The engine oil pressure must be at least 35 kPa (0,35 bar) when idling and at least
190 kPa (1,9 bar) at operating speed.
-- The transmission oil pressure (clutch pressure) should be between 16,5 - 21,4 bar
(1655 - 2137 kPa) (with parking brake set, engine at low idle, shift thru directional
and speed clutches).
9. Check the transmission oil level.
10. After the low accumulator pressure warning light has gone off the parking brake can be
released by pulling the emergency stop button fully up. Release the button to the centre
position.

Note! Abnormal conditions

Because the TORO 007 normally operates in mine conditions, its engine, transmission and
hydraulic systems are filled with oils suitable for these conditions. However, in cold conditions
they may thicken. This makes starting difficult and may damage the torque converter and
hydraulic pumps. For this reason, avoid any temporary parking in frosty weather. If the machine
will work in very cold or very hot conditions, see the Workshop manual for the correct oils and
the Detroit Diesel Instruction Manual for the proper fuel.

Important: Never attempt to start TORO by towing

27
Index

007
Setting the unit in motion
1. Let the engine run at 1000 - 1500 r/min until the low accumulator pressure warning light
goes off.
2. Let the engine return to idle.
3. Check that the brake accumulator pressure is between 150 and 185 bar.
4. Press the brake pedal and release the parking brake.
5. Select the desired direction and 1st. gear. N + ---
Note! No gear will be engaged until parking brake is
released and cabin door closed.
The four forward and reverse gears (speeds) of the R
Power--Shift transmission are selected with buttons on the F
steering lever.
Gear selection manual mode:
Forward gears are selected with button (F) and reverse
gears with button (R) when the gear is on neutral. Higher
gears forward are selected by pushing the button (F) and
lower gears by pushing button (R). When driving
backwards, higher gears are selected by button (R) and
lower by button (F). Button (n) is neutral. The selected
gear and direction is shown with a display behind the
bucket control lever.
Gear selection automatic mode:
Driving direction is selected with forward (F) and reverse
(R) buttons. The speed range (highest gear allowed) is
selected by pushing buttons (+) and (--). The highest
possible gear, selected gear and direction is shown in a
display behind the bucket control lever (+ is for forward, - is for reverse gears).
6. Release the service brakes and press the accelerator evenly so the machine begins to
move.
7. When changing gears, release the accelerator pedal and change gear at the same time.
Before moving from one drive direction to another, bring the machine to a complete
stop.
Smooth shifting and direction changes protect the transmission against unnecessary
stress.
8. Test that the brakes function properly.
9. If the machine is operated with remote control check the remote control system
functioning according to remote control system instructions before every shift.
10. Machines with converter lock--up (optional). There is a lock--up position by both
forwards and reverse gears. When pushing the converter lock--up on button the converter
pump wheel and turbine wheel are locked together creating a mechanical connection.
The converter lock turnes automaticly off when gear is shifted. The converter lock can
also be turned off by pressing the converter lock off button.
11. Learn to use the converter lock--up smoothly!
Machines with emergency steering (optional equipment)
If the emergency steering warning light is on, charge the emergency steering accumulator by
pressing the boom down against the stops or steering the machine to full turn against the stops
until the warning light goes off. After the system has been charged the machine can be used
normally as machines without emergency steering.

28
Index

007
Loading
The effort spent in levelling the machine’s small operating area can pay dividends by increasing
its productivity. When loading, work the area on as wide as possible. Work the outer side of the
muck pile first and then center.
If you follow correct loading procedures, you and the machine will be a more efficient team.
Do not start lifting full loads until the engine and the converter are warmed up (converter
+40_C).
Approach the muck pile with the lift arms down. Before penetrating the muck pile, put the
bucket lip plate against or very close to the ground.
Drive ahead in first gear. Straighten the machine before penetrating the muck pile. Once you
have penetrated the muck pile it may be necessary to increase the throttle to keep up an even
speed.
To avoid wheel spin, move the bucket slightly with the tilt and/or the lift cylinder. This causes
the front tires to flatten out thus increasing the tire contact surface area.
If forward and breakout movements are combined properly the bucket can be filled with one
pass and without wheel spin.
If the muck pile is rammed unnecessarily a converter stall on the output shaft may occur. This
happens when there is full engine power without any wheel motion.

Do not lower the bucket cutting edge too much for it may cause the front wheels to rise off the
ground. This leaves the rear wheels as your only source of drive.

Avoid lifting up the rear axle for it puts unnecessary stress on the front axle.

29
Index

007

When the bucket has sufficiently penetrated the muck pile, turn it to the hauling position by
opening the bucket tilt valve completely. Do this quickly so the back of the bucket fills
completely. Engage the reversing gear and lower the bucket arms against the arm stops.
Machines with boom suspension system:
The boom suspension system is charged during the loading. Activate the suspension system after
the bucket is filled and boom is lowered against the stops by pushing the button on the bucket
control lever. Remember allways to disconnect the suspension by pushing the button again (the
indicator light will go off) before loading or emptying the bucket.
Always use the proper gears for driving. Use the diagram below to give you an idea of what gear
to choose when driving at a given speed on a gradient.

When driving downhill, select such a gear that you

can control the machine without excessive use of
brakes. As a general rule of tumb, when driving
downhill, select the same gear that you would use
if driving uphill.

30
Index

007
Before dumping remember to disengage the boom suspension (optional equipment). When
dumping lift the bucket high enough and dump. Always keep the service brakes on and the
transmission in neutral when dumping.
Tip the empty bucket back, reverse the machine and lower the bucket arms back to the lowest
position.

Parking and stopping the engine

1. Never park/stop the machine where it may block traffic.
2. Try to park/stop the machine on level ground. If this is impossible turn the machine so
that the bucket is facing downhill and is against the wall. Refer to the drawing below.

3. Put the transmission into neutral and release the brakes. If the machine does not move
you are parked safely.
4. Lower the bucket and boom to the lowest position and turn the cutting edge against the
ground.
5. Apply the parking brakes so that the indicator light is on.
6. Run the engine at 800 - 1000 rpm with no load for at least 4 minutes. Let engine return
to idle and turn the ignition key to the 0--position to shut down the engine.
7. Turn the main switch off.
8. Close the fuel tank shut--off valve.
9. Close the water tank shut--off valve (if equipped with water scrubber).

Important:
D Never turn the main switch off while the engine is running.
D Never park the machine on a gradient resting on the brakes only.
The selected gear has no influence on braking capacity.
D Refill the tank at end of each day’s operation to prevent condensation from
contaminating the fuel. Always stop the engine before filling the tank!
D During long engine idling periods with the transmission and boom control lever in
neutral, the engine coolant temperature may fall below the normal operating range.
When prolonged idling is necessary, maintain at least 800 - 1000 rpm.

31
Index

007

TOWING
Never attempt to start the engine by towing. If the machine must be towed follow the directions
below:
1. Apply parking brake and block all four wheels.
2. Because towing can damage the transmission and the converter, the front and rear drive
shaft must be disconnected as shown in the picture below.

Disconnect here

3. Towing vehicle must be as heavy as TORO 007 or heavier and it must have ample power
and braking capacity to move, stop and hold both machines.
4. Connect up the two machines with stiff towbar (and a secondary safety chain or wire
rope) with a necessary warning signal.
5. Release the steering hydraulics by disconnecting the hoses to steering cylinders.
Releasing the steering may cause that the machine turns by itself (especially on
gradient level). Be sure that the releasing does not cause danger to other people or
equipment.
6. If the engine can’t be started and brake system pressure has dropped, the parking brake
can be released by turning the switch of parking brake releasing system (in the
instrument panel). Turning the switch causes the electrically driven pump to start. The
pump works until the brake accumulator pressure is 110 bar. Pull the parking brake
button to release the brake.
Do not release the brake before the machine is properly connected to the towing
machine and the towing machine has an operator in the operator’s compartment.
Releasing the parking brake may cause that the machine starts to move (especially
on gradient level). Be sure that the releasing does not cause danger to other people or
equipment.
7. Tow as slowly and carefully as possible.
8. Remember to turn the pump off after towing.
9. When mounting the drive shafts, note that the yokes on both ends should be aligned
Tightening torques (dry):
UNF 3/8 bolts 45 Nm

32
Index

007

DAILY MAINTENANCE
Any work at the machine must be performed by reliable and trained personnel only, for
operation, maintenance and repair.
Work at the electric appliances of the machine must be performed by an electrician only or under
supervision of an electrician according to electro--technical regulations.
Personnel with particular know--how and experience in hydraulics only shall perform work at
the hydraulic appliances.

Refrain from any working method that would endanger safety.

Take the measures that the machine is operated only in a safe and operative condition.
Observe “ON” and “OFF” procedures in accordance with instruction manual.
Make sure that the engine is safeguarded against unexpected starting.
Do not stay or work under lifted bucket if it is not safely supported.
Keep all handles and steps free from dirt.
Re--assemble immediately all safety appliances which had to be dismantled because of
maintenance job.
Wear personal ear protection prescribed.
When using oil, grease and other chemical materials, observe the
product---related safety references.

Maintenance every shift

D Check V--belts
D Check engine oil level
D Check coolant level
D Check air filter indicator and air filter assembly condition.
D Check intake and exhaust ducting and connections.
D Check all hoses, fuel lines and cables visually. Check major components for oil leaks
and mounting.
D Check transmission and hydraulic oil levels.
D Check tyres and wheel nuts.
D Check warning and signal lights, driving and working lights.
D Grease drive shaft at centre articulation.
D Check the greasing points
D Test brake function.
D Check the steering locking system. Sit in the cabin (engine running), open the door
and push the steering lever (steering should not work when the door is open).
D Check remote control system functioning according to remote control system
instructions.
D Fill fuel tank. Always shut down the engine before filling the tank!
D Fill water tank (machines with exhaust water scrubber)

33