Toro 02003, GROUNDS PRO 2000-D Operator's Manual

Page 1
FORM NO. 3322-204 Rev A
© The TORO Company 1999
To understand this product, and for safety and optimum performance, read this manual before starting operation. Pay special attention to SAFETY INSTRUCTIONS highlighted by this symbol.
MODEL 02003-90001 AND UP
GROUNDS PRO
OPERATOR’S
MANUAL
2000-D
Page 2
2
FOREWORD
This operator's manual has instructions on safety, proper set-up and operation, adjustments and maintenance. Therefore, anyone involved with the product, including the operator, should read and understand this manual. This manual emphasizes safety, mechanical and general product information. DANGER, WARNING and CAUTION identify safety messages. Whenever the triangular safety alert symbol appears, understand the safety message that follows. For complete safety instructions, read pages 3–5. IMPORTANT highlights special mechanical information and NOTE emphasizes general product information worthy of special attention.
Whenever you have questions or need service, contact your local authorized Toro Distributor. In addition to having a complete line of accessories and professional turf care service technicians, the distributor has a complete line of genuine TORO replacement parts to keep your machine operating properly. Keep your TORO all TORO. Buy genuine TORO parts and accessories.
SAFETY INSTRUCTIONS 3–5 SYMBOL GLOSSARY 6–8 SPECIFICATIONS 9–10 BEFORE OPERATING 11 CONTROLS 14 OPERATION 17 MAINTENANCE 22
TABLE OF CONTENTS
Page 3
Training
1. Read the instructions carefully. Be familiar with the
controls and the proper use of the equipment.
2. Never allow children or people unfamiliar with
these instructions to use the lawn mower. Local regulations may restrict the age of the operator.
3. Never mow while people, especially children, or
pets are nearby.
4. Keep in mind that the operator or user is
responsible for accidents or hazards occurring to other people or their property.
5. Do not carry passengers.
6. All drivers should seek and obtain professional and
practical instruction. Such instruction should emphasize:
the need for care and concentration when working with ride-on machines;
control of a ride-on machine sliding on a slope will not be regained by the application of the brake. The main reasons for loss of control are:
insufficient wheel grip; – being driven too fast; – inadequate braking; – the type of machine is unsuitable for its
task;
lack of awareness of the effects of ground
conditions, especially slopes;
##incorrect hitching and load distribution.
Preparation
1. While mowing, always wear substantial footwear
and long trousers. Do not operate the equipment when barefoot or wearing open sandals.
2. Thoroughly inspect the area where the equipment is
to be used and remove all objects which may be thrown by the machine.
3. WARNING—Petrol is highly flammable.
Store fuel in containers specifically designed for this purpose.
Refuel outdoors only and do not smoke while refueling.
Add fuel before starting the engine. Never remove the cap of the fuel tank or add petrol while the engine is running or when the engine is hot.
If petrol is spilled, do not attempt to start the engine but move the machine away from the are of spillage and avoid creating any source of ignition until petrol vapors have dissipated.
Replace all fuel tanks and container caps securely.
4. Replace faulty silencers.
Operation
1. Do not operate the engine in a confined space where
dangerous carbon monoxide fumes can collect.
2. Mow only in daylight or in good artificial light.
3. Before attempting to start the engine, disengage all
blade attachment clutches and shift into neutral.
4. Do not use on slopes of more than:
Never mow side hills over 5°
Never mow uphill over 10°
Never mow downhill over 15°
5. Remember there is no such thing as a “safe” slope.
Travel on grass slopes requires particular care. To guard against overturning:
do not stop or start suddenly when going up or downhill;
engage the clutch slowly, and always keep the machine in gear, especially when travailing downhill;
machine speeds should be kept low on slopes and during tight turns;
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Safety Instructions
Page 4
stay alert for bumps and hollows and other hidden hazards;
never mow across the face of the slope, unless the lawn mower is designed for this purpose.
6. Use care when pulling loads or using heavy
equipment.
Use only approved drawbar hitch points.
Limit loads to those you can safely control.
Do not turn sharply. Use care when reversing.
Use counterweight(s) or wheel weights when suggested in the instruction handbook.
7. Watch out for traffic when crossing or near
roadways.
8. Stop the blades rotating before crossing surfaces
other than grass.
9. When using any attachments, never direct discharge
of material toward bystanders nor allow anyone near the machine while in operation .
10. Never operate the lawn mower with defective
guards, shields or without safety protective devices in place.
11. Do not change the engine governor settings or
overspeed the engine. Operating the engine at excessive speeds may increase the hazard of personal injury.
12. Before leaving the operator’s position:
disengage the power take-off and lower the attachments;
change into neutral and set the parking brake;
stop the engine and remove the key.
13. Disengage the drive to attachments when
transporting or not in use.
14. Stop the engine and disengage the drive to the
attachment
before refueling;
before removing the grass catcher;
before making height adjustments unless the
adjustment can be made from the operator’s position.
before clearing blockages;
before checking, cleaning or working on the lawn mower;
after striking a foreign object. Inspect the lawn mower for damage and make repairs before restarting and operating the equipment.
15. Reduce the throttle setting during engine runout
and, if the engine is provided with a shutoff valve, turn the fuel off at the conclusion of mowing.
Maintenance and Storage
1. Keep all nuts, bolts and screws tight to be sure the
equipment is in safe working condition.
2. Never store the equipment with petrol in the tank
inside a building where fumes may reach an open flame or spark.
3. Allow the engine to cool before storing in any
enclosure.
4. To reduce the fire hazard, keep the engine, silencer,
battery compartment and petrol storage area free of grass, leaves, or excessive grease.
5. Check the grass catcher frequently for wear or
deterioration.
6. Replace worn or damaged parts for safety.
7. If the fuel tank has to be drained, this should be
done outdoors.
8. Be careful during adjustment of the machine to
prevent entrapment of the fingers between moving blades and fixed parts of the machine.
9. On multi-bladed machines, take care as rotating one
blade can cause other blades to rotate.
10. When the machine is to be parked, stored or left
unattended, lower the cutting means unless a positive mechanical lock is used.
Safety Instructions
4
Page 5
Sound & Vibration Levels
Sound Levels
This unit has a continuous A-weighted sound pressure level of 83 dB(A), based on measurements of identical machines per Directive 91/386/EEC and amendments.
Vibration Levels
This unit has a vibration level of 2.5 m/s2at the hands, based on measurements of identical machines per ISO 5349 procedures.
This unit does not exceed a vibration level of 0.5 m/s
2
at the posterior, based on measurements of identical machines per ISO 2631 procedures.
Safety Instructions
5
Page 6
6
Symbol Glossary
Caustic liquids, chemical burns to fingers or hand
Crushing of whole body, applied from above
Cutting or entanglement of foot, rotating auger
Poisonous fumes or toxic gases, asphyxiation
Crushing of torso, force applied from side
Severing of foot, rotating knives
Electrical shock, electrocution
Crushing of fingers or hand/, force applied from side
Severing of fingers or hand, impeller blade
High pressure fluid, injection into body
force applied from side
Wait until all machine components have completely stopped before touching them
High pressure spray, erosion of flesh
Crushing of whole body
Severing of fingers or hand, engine fan
High pressure spray, erosion of flesh
Crushing of head, torso and arms
Whole body entanglement, implement input drive line
Crushing of fingers
or hand,
force
applied from
above
Cutting of fingers or hand
Crushing of toes or foot, force applied from above
Cutting of footCrushing of leg,
Fingers or hand entangle­ment, chain drive
Hand & arm entanglement, belt drive
Explosion Fire or open
Shut off engine & remove key before performing mainten­ance or repair work
Thrown or fly­ing objects, whole body exposure
flame
Riding on this machine is allowed only on a passen­ger seat & only if the driver’s view is not hindered
Thrown or flying objects, face exposure
Secure lifting cylinder with locking device before getting in hazardous area
Consult technical manual for proper service procedures
Runover/back­over, (relevant machine to appear in dashed box)
Stay a safe distance from the machine
Fasten seat belts Safety alert
Machine tipping, riding mower
Stay clear of articulation area while engine is running
Machine rollover, ROPS (relevant machine to appear in dashed box)
Stored energy hazard, kickback or upward motion
Do not open or remove safety shields while engine is running
triangle
Do not step on loading platform if PTO is connected to tractor & engine is running
outline safety alert symbol
Hot surfaces, burns to fingers or hands
Do not step
Read operator’s manual
Page 7
Safety Instructions
7
Eye protection must be worn
Fire, open light & smoking prohibited
Level indicator
Head protection must be worn
Hydraulic system
Liquid level Filter Temperature Failure/
Hearing protection must be worn
Brake system
Caution, toxic risk
Oil Coolant (water) Intake air Exhaust gas Pressure
First aid
Malfunction
Flush with water Engine Transmission
Start switch/ mechanism
On/start Off/stop
Engage Disengage
Horn Battery charging
Machine travel direction, forward/rearward
Jack or support point
condition
Control lever operating direction, dual direction
Draining/ emptying
Attachment lower
Hourmeter/elapsed operating hours
Control lever operating direction, multiple direction
Engine lubricat­ing oil
Attachment raise
Fast Slow Continuous
Clockwise rotation
Engine lubricating oil pressure
Spacing distance Snow thrower,
Counter-clock­wise rotation
Engine lubricating oil level
collector auger
variable, linear
Grease lubrication point
Engine lubricating oil filter
Plus/increase/ positive polarity
Volume empty Volume full
Oil lubrication point
Engine lubricating oil temperature
Minus/decrease/ negative polarity
Lift point
Engine coolant
Page 8
Safety Instructions
8
Symbol Glossary, continued
Engine coolant pressure
Engine coolant f ilter
n/min
Engine failure/ malfunction
Transmission failure/malfunction
Engine rotational speed/frequency
Clutch Neutral High Low Forward Reverse Park
231
First gear Second gear
Engine lubricating oil pressure
Choke Primer (start aid) Electrical preheat
Engine intake/ combustion air
Engine intake/ combustion air pressure
(low t em perature start aid)
Engine intake/ air filter
Transmission oil Transmission oil
Engine start Engine stop
pressure
Transmission oil temperature
NHLFRP
Third gear (other #'s may be used until the maximum # of for­ward gears is reached.)
Hydraulic oil Hydraulic oil
Hydraulic oil pressure
Hydraulic oil level Hydraulic oil filter
temperature
Hydraulic oil failure/malfunction
Headlights Lock Unlock Differential lock 4-Wheel drive Power Take-Off Power Take-Off,
Reel cutting element, height adjustment
Parking brake Fuel Fuel level Fuel filter Fuel system
Traction Above working
temperature range
Drilling Manual metal arc
0430 weight Do not dispose
welding
in the garbage
failure/malfunction
Manual 0356 Water pump
CE logo
Diesel fuel Unleaded fuel
rotational speed
Reel cutting element
0626 Keep dry
Page 9
Engine: Briggs & Stratton Daihatsu, diesel, three-
cylinder, 4-cycle, overhead valve, water-cooled, 23 hp @ 3600 rpm, 850 cc displacement, governed speed of 3200 rpm. Mechanical fuel pump. 3.31 l oil capacity.
Cooling System: The cooling system is filled with a
50/50 solution of water and permanent ethylene glycol anti-freeze.
Fuel System: Fuel tank capacity 20 liters. Fuel filter
with water separator. Fuel shut-off valve.
Traction Drive: Eaton model 11 hydrostatic transmission
integrally coupled to a Peerless model 1310 axle. Travel speed range is 0–13.5Km/h (0–8.5 mph) forward and 4.8 Km/h reverse (0–3 mph).
Controls: Foot-operated traction pedal. hand-operated
throttle, ignition switch, PTO switch, lift lever, parking brake and seat adjustment.
Cutting Drive: Constant-tension belt drive system with
electric clutch utilizing a poly-V belt from the engine to the jackshaft and BX section V-belt drive from the jackshaft to each cutting unit.
Tires and Wheels: Two 23 x 8.5-12 front-drive turf tires
with 4-ply construction. Rear tires for the four-wheel configuration, 16 x 6.5-6 turf tires with 4-ply construction. Rear tire for the three-wheel configuration, 18 x 6.5-8 with 4-ply construction.
Electrical Features: 12-volt, 255 cold cranking amps at
180 C, 50-amp reserve capacity at 270 C. Battery, 16­amp alternator, seat, traction, PTO and parking brake interlock switches; electrical leads provided for optional light and hour meter installations.
Steering: Pinion and gear sector with solid control link
to the rear steer assembly, 2.5 turns lock to lock.
Brakes: Service braking accomplished through
hydrostatic transmission. Parking brake controls secondary shaft internal to the axle assembly and is actuated by a control lever.
Main Frame: All-steel welded construction utilizing
tubular and formed sheet metal sections
Seat: Standard cushion seat and optional deluxe
suspension seat with arm rest and weight adjustment. The seat is adjustable fore and aft. Arm rest kit also available.
Lift System: Category “0” A-Frame mounting system
connected to the tractor via parallel linkage. One double­acting 60 mm bore, 140-mm stroke hydraulic cylinder receiving oil from hydrostatic transmission charge pump via the control valve with float position. Maximum operating pressure is 6895 kPa. When the traction unit is equipped with cutting units, all three units are raised and lowered via the single control lever. The lift system works with the electric clutch to engage and disengage the cutting units.
Overall Dimensions and Weight:
Wheel Tread Width 105.3 cm Width across Front Tires 132 cm Wheel Base 138.5 cm Overall Length w/ Cutting Units Installed 229 cm Overall Height 119 cm Tractor Weight 50.4 kg Weight with 5-Blade Fixed Cutting Units 640 kg Weight with 8-Blade Floating Cutting Units 696 kg Overall Width w/Fixed-Head Units 195 cm Overall Width w/Floating Head Units 203 cm Transport Width w/Fixed Head Units 140 cm Transport Width w/Floating Head Units 200 cm
Optional Equipment:
Left. 5-Blade Fixed Cutting Unit (2 req.) Model No. 03434 Right. 5-Blade Fixed Cutting Unit Model No. 03436 Left 8-Blade Floating Cutting Unit (2 req.) Model No. 03437 Right 8-Blade Floating Cutting Unit Model No. 03439 Lift Arm Kit, Fixed Cutting Unit Model No. 02100 Lift Arm Kit, Floating Cuffing Unit Model No. 02101 Rear Axle, 4 Wheel Model No. 02201 Full Roller Kit* Model No. 03440 Sectional Roller Kit* Model No. 03445 Wiehle Roller Kit* Model No. 03450 Skid Kit* Model No. 03446 Anti-Scalp Roller Kit* Model No. 03447 Grass Basket Kit, Floating C.U. Model No. 02302 Grass Basket Kit, Fixed C.U. Model No. 02304
9
Specifications
Page 10
Remote Hydraulics Kit Model No. 02300 Power Take-off Kit, 1:1 Ratio Model No. 02301 Power Take-off Kit, 1.5:1 Ratio Model No. 02303 Standard Seat Kit Model No. 30769 Deluxe Suspension Seat Kit Model No. 02305 Arm Rest Kit for Model 30769 Model No. 30707 Debris Blower Model No. 02202 Large Pulley Kit Part No. 98-5413 Roller Scraper Kit* Part No. 60-9560 Comb Kit* Part No. 67-9400 Rear Weight Part No. 24-5790 Rear Weight (2) Part No. 24-5780 Gauge Bar Kit Part No. 13-8199 Backlap Kit Part No. 84-5510 Tire Chains Part No. 82531
*3 per kit
Specifications
10
Page 11
CHECK THE ENGINE OIL (Fig. 1)
The engine is shipped with 3.3 1 of oil. However, check the oil level before and after you first start the engine.
1. Position the machine on a level surface.
2. Unscrew the dipstick and wipe it with a clean cloth.
Screw the dipstick into the tube and make sure it is seated fully. Unscrew the dipstick and check the oil level. If it is low, remove the filler cap and add oil.
3. Use any high-quality detergent oil having the
American Petroleum Institute—API—”service classification” SE, SF or SG. Recommended viscosity (weight) is SAE 30. Refer to the Engine Operator’s Manual for additional information.
Figure 1
1. Dipstick
2. Filler cap
4. Pour the oil into opening in the valve cover until the
oil level is up to the ”FULL’” mark on the dipstick. Add the oil slowly and check the level often during this process. DO NOT OVERFILL.
IMPORTANT Check the oil level every 8 operating hours or daily. Initially, change the oil after the first 8 hours of operation; thereafter, under normal conditions, change the oil every 50 hours and filter every 100 hours. However, change it more often when operating the engine in extremely dusty or dirty conditions.
5. Install the filler cap and the dipstick.
CHECK THE COOLING SYSTEM (Fig. 2)
Clean debris from the hood screens, engine and radiator daily—more often if conditions are extremely dusty and dirty; refer to the section on the Engine Cooling System.
The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol anti-freeze.
Check level of coolant in expansion tank at beginning of each day before starting the engine.
1. Check the level of coolant in the expansion tank.
Coolant level should be between the marks on the side of the tank.
Figure 2
1. Expansion Tank
2. If coolant level is low, remove the expansion tank cap and replenish the system. DO NOT
OVERFILL.
3. Install the expansion tank cap.
FILL FUEL TANK (Fig. 3)
Fuel tank capacity is 20 liters.
1. Remove the fuel tank cap.
11
Before Operating
1
1
1
2
If the engine has been running, pressurized hot coolant can escape when the radiator cap is removed and cause burns.
CAUTION
Page 12
Before Operating
12
2. Fill the tank to about one inch below the top of the
tank, not the filler neck, with No. 2 diesel fuel. Then install the cap.
Figure 3
1. Fuel Tank Cap
DRAINING WATER FROM FUEL FILTER/WATER SEPARATOR (Fig. 4)
Any water accumulation should be drained from the fuel filter/water separator before each use.
1. Position machine on a level surface and stop the
engine.
2. Open the drain valve on the fuel filter/water
separator and drain any accumulated water.
Figure 4
1. Drain valve
NOTE: Because the accumulated water will be mixed with diesel fuel, drain the fuel filter into a suitable Container and dispose of properly.
CHECK THE HYDRAULIC SYSTEM FLUID
The hydraulic system is designed to operate on SAE 10W-30 engine oil or, as a substitute, SAE 10W-40 engine oil. The reservoir is filled at the factory with 4.7 l of 10W-30 engine oil. Check the oil level before first starting the engine and daily thereafter.
1. Position the machine on a level surface and stop the engine.
2. Remove the access panel to expose the hydraulic system dipstick filler cap.
Figure 5
1. Access panel
3. Remove the dipstick cap from the filler neck and wipe it with a clean cloth. Insert the dipstick cap
Because diesel fuel is flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill the fuel tank while the engine is running, hot, or when the machine is in an enclosed area. Always fill the fuel tank outside and wipe up any spilled diesel fuel before starting the engine. Store fuel in a clean, safety-approved container and keep the cap in place. Use diesel fuel for the engine only; not for any other purpose.
DANGER
1
1
1
Page 13
Before Operating
13
onto the filler neck; then remove it and check the oil level.
Figure 6
1. Dipstick filler cap
4. If the level is not within 3 cm from the FULL mark
on the dipstick, add SAE 10W-30 engine oil to raise the level to the FULL mark. Do not overfill.
5. Install the dipstick filler cap onto the filler neck.
6. Run the engine for one minute, recheck the oil level
and add more if needed.
CHECK TIRE PRESSURE
Correct air pressure in front and rear tires is 84–124 kPa.
LUBRICATE BEARINGS AND BUSHINGS
The traction unit and cutting unit’s grease fittings must be lubricated with No. 2 General Purpose Lithium Base Grease.
CHECK REEL-TO-BEDKNIFE CONTACT
Each day before operating, check reel-to-bedknife contact.. There must be light contact across the full length of the reel and bedknife. Refer to Adjusting the
Bedknife Parallel to the Reel.
Figure 7
1. Bedknife adjusting knob
1
Page 14
Traction Pedal (Fig. 8)—The traction pedal: 1) makes
the machine move forward, 2) moves it backward and 3) stops the machine. Using the heel and toe of your right foot, depress the top of the pedal to move forward and the bottom of the pedal to move backward or to assist in stopping when moving forward. Also, allow the pedal to move or move it to the neutral position to stop the machine. Do not rest the heel of your foot on reverse when going forward (Fig. 9).
Figure 8
1. Traction pedal
2. Parking brake
Figure 9
1. Forward
2. Reverse
Parking Brake (Fig. 8)—Whenever the engine is shut
off, the parking brake must be engaged to prevent accidental movement of the machine. To engage the parking brake, pull back on the lever. After releasing the parking brake, move the mower slightly in reverse to release the brakes before moving forward.
Throttle (Fig. 10)—The throttle is used to operate the
engine at various speeds. Moving the throttle upward
increases engine speed; downward decreases engine speed. The throttle also controls the speed of the reel blades and, with the traction pedal, controls the machine’s ground speed.
Hour Meter (Fig. 10)—Shows total hours that the
machine has been operated.
Lift Lever (Fig. 10)—The lift lever has four positions:
LOWER, RAISE, NEUTRAL and FLOAT. To lower the cutting units to the ground, move the lift lever forward. To raise the cutting units, pull the lift lever rearward to the RAISE position.
PTO Switch (Fig. 10)—The switch has two positions:
ENGAGE and DISENGAGE. Push the switch lever forward to engage the cutting units. Pull the switch level rearward to disengage the cutting units.
Figure 10
1. Throttle control
2. Choke control
3. PTO switch
4. Cutting unit lift lever
Ignition Switch (Fig. 11)—The ignition switch, used to start and stop the engine, has three positions: OFF, RUN (Glow Plug) and START. Turn the key clockwise— START position—to engage the starter motor. Release the key when the engine starts. The key will move automatically to the ON position. To shut the engine off, turn the key counterclockwise to the OFF position.
14
Controls
2
1
4
2
3
1
1
2
Page 15
Figure 11
1. Ignition switch
Charge Indicator Light (Fig. 12)—Illuminates when the charging system malfunctions.
Oil Pressure Light (Fig. 12)—When the oil light is ON, it indicates the engine oil pressure is low. After the engine starts, the light should go out. When the engine is running, the light comes ON if the oil pressure drops below a safe operating level. If the light comes on while the engine is running, stop the engine immediately and
correct the cause of low oil pressure.
Coolant Temperature Light (Fig. 12)—The coolant
temperature light shows when the engine cooling system is overheated.
Figure 12
1. Charge indicator light
2. Oil pressure light
3. Coolant temperature light
4. Glow plug indicator light
Glow Plug Indicator Light (Fig. 12)—The glow plug indicator light comes on when the ignition switch is in the RUN position but should be out when the engine is running.
Seat Adjustments
Fore and Aft Adjustment—Move the lever on the side
of the seat outward, slide the seat to the desired position and release the lever to lock the seat into position.
Deluxe Seat Adjustments (Fig. 13)
Fore and Aft Adjustment—Pull the handle on the left
side of the seat assembly outward. Release the handle to lock the seat position.
Operator Weight Adjustment—Turn the knob
clockwise to increase tension, counterclockwise to decrease tension.
Figure 13
1. Fore and aft lever
2. Weight adjustment lever
Cutting Unit Lock-up Lever (Fig. 14)—Locks the rear
cutting unit in the raised position.
Figure 14
1. Cutting unit lock-up lever
2. Seat adjusting screws
Fuel Valve (Fig. 15)—Close the fuel valve (located
under the fuel tank) when storing the machine.
Controls
15
1
1
2
1
2
3
4
Page 16
Figure 15
1. Fuel valve
Controls
16
1
Page 17
17
STARTING/STOPPING THE ENGINE
1. Be sure the parking brake is set and the PTO switch
is in the DISENGAGED position.
2. Remove your foot from the traction pedal and make
sure the pedal is in the neutral position.
3. Move the throttle lever to the SLOW position.
4. Turn the ignition key clockwise to the RUN
position. The glow plug indicator light will come on.
5. After the glow plug indicator light goes out, turn the
key to the START position. When the engine starts, release the key.
IMPORTANT. Use starting cycles of no more than 30 seconds per minute to avoid overheating the starter motor.
6. If the engine does not start immediately, move the
throttle control to FAST and turn the key to the START position.
NOTE: Additional starting cycles may be required when starting the engine for the first time after the fuel system has been completely without fuel.
7. Move the throttle to the SLOW position (if in
FAST) and let the engine warm up for a few minutes before applying load.
8. When engine is started for the first time, or after
overhauling the engine, operate the machine in forward and reverse for one to two minutes. Also operate the lift lever and PTO switch to be sure of proper operation of all parts.
Turn the steering wheel to the left and right to check steering response. Then shut the engine off and check for oil leaks, loose parts and any other noticeable malfunctions.
9. To stop the engine, move the throttle control downward to the SLOW position, move the PTO switch to OFF and turn the ignition key to OFF. Remove the key from the switch to prevent accidental starting.
10. Set the parking brake.
11. Close the fuel shut off valve before storing the
machine.
BLEEDING THE FUEL SYSTEM (Fig. 16)
1. Position the machine on a level surface. Make sure the fuel tank is at least half full.
2. Open the air bleed screw on the fuel injection pump.
3. Turn the ignition key to the ON position. The electric fuel pump will begin operation, thereby forcing air out around the bleed screw. Leave the key in the ON position until solid stream of fuel flows out around the screw. Tighten the screw and turn off the key.
Operation
Shut engine off and wait for all moving parts to stop before checking for oil leaks, loose parts and other malfunctions.
CAUTION
Because diesel fuel is flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill the fuel tank while the engine is running, hot, or when the machine is in an enclosed area. Always fill the fuel tank outside and wipe up any spilled diesel fuel before starting the engine. Store fuel in a clean, safety­approved container and keep the cap in place. Use diesel fuel for the engine only; not for any other purpose.
DANGER
Page 18
Figure 16
1. Fuel injection pump
2. Air bleed screw
OPERATING THE POWER TAKE OFF (PTO)
The power take off (PTO) switch engages and disengages power to the electric clutch.
Engaging the PTO
1. Release the parking brake.
2. Release pressure on the traction pedal to stop
movement.
3. To engage, lift the cover and move the PTO switch
forward to the “ON” position.
Disengaging the PTO
Closing the cover moves the PTO switch to the “OFF” (disengaged) position.
DRIVING FORWARD OR BACKWARD
Place the throttle control in the 3/4 position for best performance.
Forward
1. To go forward, place your foot on the traction pedal.
2. Release the parking brake.
3. Slowly press on the upper pad of the traction
control to move forward.
Backward
1. To go backward, place your foot on the traction
pedal.
2. Release the parking brake.
3. Slowly press on the lower pad of the traction pedal
to move rearward.
CHECK OPERATION OF INTERLOCK SWITCHES
1. With the operator off the seat, the traction pedal in
neutral and the PTO switch in the disengage position, the engine should start. If either the traction pedal is depressed or the PTO switch is engaged, the engine should stop. Correct the problem if the system is not operating properly.
2. With the operator in the seat, the parking brake
engaged and the engine running, depress the traction pedal either forward or reverse. The engine should stop. Correct the problem if the system is not operating properly.
3. With the operator in the seat, the parking brake
engaged and engine running, lower the cutting units to the ground. Engage the PTO switch, the electric clutch on the engine should engage. Raise the cutting units, the PTO switch should disengage. Correct the problem if the system is not operating properly.
IMPLEMENT LIFT LEVER
Operation
18
Do not disconnect the safety switches because they are for the operator’s protection. Check switch operation daily to be sure the system is operating correctly. If a switch is not operating correctly, replace it before operating the machine. Replace the switches every two years to be sure of maximum safety.
CAUTION
Page 19
Raising Attachments
Pull the implement lift lever rearward to raise an attachment to the desired height.
Lowering Attachments
Push the implement lift lever forward to lower the attachment.
NOTE: Hold the lift lever in the down position 1–2 seconds after the cutting unit touches the ground to retract the lift cylinder completely, allowing the cutting unit suspension to achieve proper position and to float with changes in ground contour. Return the lever to the neutral position to mow.
Refer to the attachment operator’s manual for proper lift system operation.
PUSHING OR TOWING THE MACHINE
In an emergency, the traction unit can be pushed or towed for a very short distance. TORO does not recommend this as standard procedure.
IMPORTANT: Do not push or tow the traction unit
faster than 3 to 5 kmh because the transmission may be damaged. If the traction unit must be moved a considerable distance, transport it on a truck or trailer.
1. To push or tow forward, the traction pedal must be
fully depressed forward.
2. To push or tow in reverse, the traction pedal must
be fully depressed in reverse.
TRAINING PERIOD
Before mowing with the Grounds Pro 2000-D, The TORO Company suggests you find a clear area and practice starting and stopping, raising and lowering the cutting units, turning, etc. This training period will be beneficial in gaining confidence in the performance of the Grounds Pro 2000-D.
BEFORE MOWING
Inspect the area for debris and clear the area. Determine the direction in which the area was last mowed. (Always mow in an alternate pattern from the previous mowing, so that the grass blades will be less apt to lay down and therefore be difficult to gather between the reel blades and bedknife.)
OPERATING CHARACTERISTICS
Practice operating the Grounds Pro 2000-D and become thoroughly familiar with it. Because of its hydrostatic transmission, its characteristics differ from many turf maintenance machines. Issues to consider when operating are the traction drive, engine speed and the load on the cutting units. Regulate the traction pedal to keep engine rpm high and somewhat constant while mowing to maintain adequate power for the traction and cutting units.
Follow operating guidelines presented in this manual and know how to operate the machine safely on all types of terrain. Use the slope gauge, page 34, to determine slope angles of questionable areas. Hills (or slopes) over 15 degrees should be traversed or mowed up and down, not side to side and hills over 20 degrees should generally be avoided unless special safeguards, skills and conditions exist.
Always plan well ahead to avoid the need for sudden stops, starts or turns. To stop, use the reverse pedal for braking. Before stopping the engine, disengage all controls, move the throttle to IDLE, and set the parking brake.
CAUTION: This product may exceed noise levels of 85
dB(A) at the operator position. Ear protectors are recommended for prolonged exposure to reduce the potential of permanent hearing damage.
TRANSPORT OPERATION
Be sure the lift arms are fully raised and the transport bracket is installed and secured with the retainer (Fig.
17). Also, lock the rear cutting unit in the raised position (Fig. 18).
Operation
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Page 20
While operating on slopes and uneven terrain, always reduce speed and use extreme caution before turning to reduce risk of tipping or losing control. Watch carefully and avoid holes in the terrain, sudden drop-offs and other hazards. To prevent costly damage and down time, familiarize yourself with the width of the Grounds Pro 2000-D. Do not attempt to pass between immovable objects placed close together.
Figure 17
1. Transport bracket
Figure 18
1. Rear cutting unit lock-up lover
INSPECTION AND CLEAN-UP AFTER MOWING
After mowing, thoroughly wash the machine with a garden hose—without a nozzle—so excessive water pressure will not cause contamination and damage seals and bearings.
Note: Do not spray water directly onto a hot engine or
hot bearings.
Make sure the cooling fins and the area around the engine air intake are kept free of dirt or grass clippings. After cleaning, inspect the machine for possible hydraulic fluid leaks, damage or wear to hydraulic and mechanical components. Check the cutting units for sharpness and correct reel-to-bedknife adjustment.
CUTTING UNIT CHARACTERISTICS
The single-knob bedknife adjustment system simplifies the procedure for delivering optimum mowing performance. The precise adjustment possible gives the control to provide a continual self-sharpening action— thus maintaining sharp cutting edges, good quality of cut, and greatly reduced need for routine backlapping.
Also, the rear roller positioning system permits optimum bedknife attitude and location for varying heights of cut and turf conditions.
DAILY CUTTING UNIT ADJUSTMENTS
Before each day’s mowing, or as needed, check each cutting unit to verify correct bedknife-to-reel contact. Do this even though quality of cut is acceptable.
1. Shut off the engine and lower the cutting units onto
a hard surface.
2. Slowly turn the reel in the reverse direction,
listening for reel-to-bedknife contact. If no contact is evident, turn the bedknife adjusting knob clockwise, one click at a time, until you feel or hear light contact.
3. If you feel excessive contact, turn the bedknife
adjusting knob counterclockwise, one click at a time, until no contact is evident. Then turn the knob one click at a time clockwise, until light contact is felt and heard.
IMPORTANT: Light contact is preferred at all
times, otherwise bedknife and reel edges will not self-sharpen. If excessive contact is maintained,
Operation
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Page 21
bedknife and reel wear will accelerate. Uneven wear can result, adversely affecting quality of cut.
Note: As the reel blades run against the bedknife, a
slight burr will appear on the front cutting edge surface over the full length of the bedknife. Occasionally running a file across the front edge to remove this burr will improve cutting.
After extended running, a ridge will eventually develop at both ends of the bedknife. These must be rounded off or filed flush with the cutting edge of bedknife to assure smooth operation.
Operation
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22
Maintenance
Maintenance Procedure Maintenance Interval & Service
Initial break in at 8 hours ‡Initial break in at 50 hours
De-carbon the combustion chamber Torque head bolts and adjust valves
Change hydraulic fluid ‡Check engine RPM (idle and full throttle) Change front axle oil Replace the fuel filter cartridge
Maintenance Schedule
Replace moving hoses Replace safety switches Fuel tank—drain and flush Hydraulic tank—drain and flush
Change the enging oil filterReplace the hydraulic filter
Adjust the clutch Change the hydraulic fluid filter
Service the air filter cartridge
Change engine oilTorque the wheel lug nuts
Check the fan belt
Change the engine oil and filterCheck the cutting unit’s belt tension
Check battery fluid/connections Lubricate grease fittings Service the air cleaner
Every
400
hours
Every
800
hours
Every
200
hours
Every
100
hours
Every
50
hours
Every
25
hours
Recommendations
Items are recommended every 1000 hours
or 2 years, whichever occurs first.
Daily Maintenance Checklist
Safety Interlock Operation Brake Operation Engine Oil & Fuel Level Cooling System Fluid Level‘ Air Cleaner Drain Water/Fuel Separator Clean Engine and Radiator Unusual Engine Noises Unusual Operating Noises
Hydraulic System Oil Level Hydraulic Hoses for Damage Fluid Leaks Tire Pressure Instrument Operations Reel-to-Bedknife Adjustment Height-of-Cut Adjustment Cutting Unit Belt Adjustment
Lubricate all grease fittings
1
Touch up damaged paint
1
= Immediately after every washing, regardless of the
interval listed
Page 23
LUBRICATION
GREASING BEARINGS AND BUSHINGS
The traction unit and cutting unit’s grease fittings must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. If the machine is operated under normal conditions, lubricate bearings and bushings after every 25 hours of operation. Bearings and bushings must be lubricated daily when operating conditions are extremely dusty and dirty. Dusty and dirty operating conditions could cause dirt to get into the bearings and bushings, resulting in accelerated wear. Lubricate grease fittings immediately after every washing, regardless of the interval listed.
The traction unit bearings and bushings, and the cutting unit lubrication points that must be lubricated are shown in the photos and illustrations.
Figure 19
Figure 20
Figure 21
Figure 22
Figure 23
Figure 24
23
Maintenance
Page 24
Figure 25
Figure 26
Figure 27
Figure 28
Figure 29
Figure 30
Figure 31
24
Maintenance
Page 25
25
Maintenance
CHANGING THE ENGINE OIL AND FILTER (Fig. 32–33)
Change the oil and filter initially after the first 8 hours of operation; thereafter change the oil every 100 hours and filter every 200 hours.
Note: Change the oil and filter every 25 hours when
operating under heavy load or high ambient temperatures.
1. Remove the drain plug and oil fill cap and let oil
flow into drain pan. When the oil stops, install the drain plug.
Figure 32
1. Drain plug
2. Remove the oil filter. Apply a light coat of clean oil
to the new filter gasket.
Figure 33
1. Oil filter
3. Screw the filter on by hand until the gasket contacts
the filter adapter, then tighten
1
2 to 3⁄4 turn further.
DO NOT OVER-TIGHTEN.
4. Add oil to the crankcase; refer to CHECK THE
ENGINE OIL.
5. Start the engine and check for leaks around the
filter.
6. Dispose of the oil properly.
SERVICING THE AIR CLEANER (Fig. 34)
Clean the air filter cartridge after every 25 operating hours. Service it more often (every few hours) if operating conditions are extremely dusty or sandy.
Replace the cartridge after every 100 operating hours, or yearly.
1. Unlock the clamps and remove the air cleaner
cover.
2. Remove the cartridge from the air cleaner body.
Before servicing or making adjustments to the machine, stop the engine and remove the key from the switch.
CAUTION
1
1
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26
Maintenance
Figure 34
1. Air cleaner cover
2. Air cleaner cartridge
3. Clean the cartridge by tapping gently on its end
with the handle of a screwdriver. Replace the cartridge if it is very dirty or damaged.
4. Install the cartridge in the body.
5. Install the cover and lock clamps.
FUEL SYSTEM
Fuel Tank
Drain and clean the fuel tank every 2 years. Also, drain and clean the tank if the fuel system becomes contaminated or if the machine is to be stored for an extended period. Use clean fuel to flush out the tank.
Fuel Lines and Connections
Check lines and connections every 400 hours or yearly, whichever comes first. Inspect for deterioration, damage, or loose connections.
Fuel Filter/Water Separator
Drain water or other contaminants from the fuel filter water separator (Fig. 35) daily.
1. Place a clean container under the fuel filter.
2. Loosen the drain plug on the bottom of the filter
canister. Tighten the plug after draining.
Figure 35
1. Fuel filter
Replace the filter canister after every 400 hours of operation.
1. Clean the area where the filter canister mounts.
2. Remove the filter canister and clean the mounting
surface.
3. Lubricate the gasket on the filter canister with clean
oil.
4. Install the filter canister by hand until the gasket
contacts the mounting surface, then turn it an additional 1/2 turn.
ADJUSTING THE THROTTLE CONTROL(Fig. 36)
Proper throttle operation depends proper adjustment. Before adjusting the carburetor, make sure the throttle control operates properly.
1. Move the remote throttle control lever to the SLOW
position.
2. Loosen the cable clamp screw securing the cable to
1
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27
Maintenance
the engine.
3. Move the cable until the speed control lever
contacts the idle speed screw.
Figure 36
1. Throttle cable
2. Cable clamp
3. Speed control lever
4. Idle speed screw
4. Tighten the cable clamp screw and check the engine
RPM setting.
ADJUSTING IDLE SPEED (Fig. 36)
1. Move the remote throttle control lever to the SLOW
position.
2. Loosen the lock nut on the idle speed screw.
3. Adjust the idle speed screw to obtain 1100 rpm.
4. Tighten the lock nut.
CHECKING THE PARKING BRAKE
1. Park the machine on a level surface, disengage the
PTO switch, set the parking brake and turn the ignition key to “OFF” to stop the engine. Remove the key.
2. The drive wheels must lock when the brake is
applied. Adjustment is required if the wheels turn and do not lock; refer to Adjusting the Brake.
3. Release the brake; wheels should turn freely.
4. If both conditions are met, no adjustment is
required.
IMPORTANT: With the parking brake released, the drive wheels must turn freely. If brake action and free wheel rotation cannot be achieved, contact your service dealer immediately.
ADJUSTING THE PARKING BRAKE (Fig. 37)
If drive wheels do not turn when the brake lever is in the OFF position, or the brake does not hold when the lever is in the ON position, an adjustment is required.
1. Move the brake lever to the ON position.
2. Measure the distance between the disc brake
actuating arm and the stop pin on the axle bracket assembly. Distance should be less than 6 mm.
3. If the distance is greater than 6 mm, tighten the
locknut to decrease distance.
4. With the brake lever OFF, check the clearance
between the brake pads and the disc with a feeler gauge. Correct clearance is approximately 2.5 mm (.010 in.).
5. The actuating arm should be no more than 10 mm
away from STOP with the brake lever in the OFF position.
Figure 37
1. Brake actuating arm
2. Stop pin
3. Locknut
4. Disc pad
5. Disc
Page 28
28
Maintenance
6. Check the brake operation again; refer to Checking
the Brake.
7. Check adjustment. Drive wheels should turn freely
when the brake lever is in the OFF position.
ADJUSTING TOE- IN & STEERING STOPS (Fig. 38)
(4-Wheel Axle Only)
1. Make sure both tie rods are adjusted to the same
length.
2. Measure toe-in distance (at axle height) at front and
rear of steering tires. Front measurement must be 2–4 mm less than the rear measurement.
3. Loosen the jam nuts and rotate the tie rod to adjust
the front of the tires in or out.
Figure 38
1. Tie rod
2. Steering stop
4. Loosen the jam nuts and adjust the left and right
steering stops to allow 6-mm clearance for steering arm in a full left and full right turn. Tighten jam nuts.
ADJUSTING THE TRANSMISSION FOR NEUTRAL (Fig. 39)
With the machine on a level surface and the parking brake disengaged, the machine must not creep when the traction pedal is released. If it does creep, an adjustment is required.
1. Park the machine on a level surface, lower the
cutting unit and shut off the engine. Disengage the PTO switch and engage the parking brake.
2. Jack up the front of the machine until the tires are
off the shop floor. Support the machine with jack stands to prevent it from falling accidentally.
3. Loosen the lock nut on the adjustment cam.
4. Start the engine and turn the adjusting cam in either
direction until the wheels stop rotating.
5. Stop the engine and tighten the lock nut to secure
adjustment.
6. Start the engine and check adjustment. Repeat
adjustment if necessary.
7. Stop the engine. Remove the jack stands and lower
the machine to the shop floor. Test drive the machine to be sure it does not creep.
Figure 39
1. Adjustment cam
2. Locknut
The engine must be running so final adjustment of the traction adjustment cam can be performed. To guard against possible personal injury, keep hands, feet, face and other parts of the body away from the muff muffler other hot parts of the engine, and other rotating parts.
WARNING
2
1
2
1
Page 29
29
Maintenance
ADJUSTING THE ELECTRIC CLUTCH (Fig. 40)
The clutch is adjusted to ensure proper engagement and braking action.
1. Disengage the PTO switch, set the parking brake,
and turn the ignition key to “OFF” to stop the engine. Remove the key.
2. Adjust the clutch by tightening or loosening the
lock nuts on the flange studs.
3. Check adjustment by inserting a feeler gauge
through the slots next to the studs.
4. The correct disengaged clearance between the
clutch plates is 0.23-0.30 mm. It will be necessary to check this clearance at each of the three slots to ensure the plates are parallel to each other.
Figure 40
1. Clutch
2. Locknut
3. Adjustment slot
CHANGING HYDRAULIC SYSTEM OIL (Fig. 41–42)
The hydraulic system oil must be changed after every 400 hours of operation or yearly, whichever comes first. The reservoir has a capacity of 4.7 l.
1. Park the machine on a level surface, lower the
cutting units, engage the parking brake, and shut off the engine.
2. Clean the area around the hydraulic oil filter and
remove the filter from the filter housing.
3. Disconnect the tube and hose assembly from the
reservoir and allow the oil to flow into a drain pan.
Figure 41
1. Hydraulic filter
Figure 42
1. Reservoir
2. Hose assembly
Note: To drain the oil remaining in the system, disconnect the spark plug wires and crank the engine for 15 seconds. This will pump the remaining oil out of the system. Do not crank the engine for more than 15 seconds.
4. Install the new hydraulic filter to the filter housing.
5. Install the tube assembly and hose assembly to the
reservoir.
6. Fill the reservoir to the proper level; refer to Check
Hydraulic System Fluid.
7. Place all controls in the neutral or disengaged
1
2
3
1
1
2
Page 30
30
position and start the engine. Run the engine at the lowest possible RPM to purge air from the system.
8. Run the engine until the lift cylinder extends and
retracts and forward and reverse wheel motion is achieved.
9. Stop the engine and check the oil level; add oil if
necessary.
10. Check all connections for leaks.
CHANGING THE HYDRAULIC OIL FILTER (Fig. 41)
The hydraulic oil filter must be serviced at regular intervals. The intervals are: initially, after the first 8 hours of operation, and thereafter every 200 hours of operation or yearly, whichever comes first. Use a genuine TORO oil filter for replacement.
1. Remove the hydraulic oil filter from the mounting
head.
2. Apply a film of oil on the gasket. Install the filter by
hand until the gasket contacts the mounting head; then tighten the filter an additional 3/4 turn.
3. Start the engine and check for oil leaks. Allow the
engine to run for about two minutes to purge air from the system. Then shut off the engine.
4. Check the level of oil; refer to Check the Hydraulic
System Fluid.
CHANGING FRONT AXLE OIL (Fig. 43)
After every 400 hours of operation, change the oil in the front axle.
1. Drive the machine for five minutes before changing
oil to warm the axle oil. Warm oil flows more freely and carries more contaminants than cold oil.
2. Clean the area around the drain plug and place a
drain pan below the drain plug on axle.
Figure 43
1. Drain plug
2. Fill plug
Remove the drain plug and allow the oil to flow into drain pan. After the oil is drained, reinstall drain plug.
Remove the fill plug and fill to plug level with ISO 150/220 (SAE EP-90) oil.
ADJUSTING THE CUTTING UNIT BELTS (Fig. 44)
Make sure cutting unit belts are properly tensioned to assure correct operation and prevent unnecessary wear. Check all belts often.
1. The cutting unit drive belts should have a maximum
deflection of 12 mm with a 3.7 kg load applied.
2. Loosen the jam nut on the front end of the belt
tension rod. Turn the rod to lengthen or shorten the rod to the desired length. Then tighten the jam nut.
Figure 44
1. Belt tension rod
Maintenance
1
2
1
Page 31
31
BATTERY CARE
1. Battery electrolyte level must be maintained and the
top of the battery kept clean. If the Grounds Pro 2000-D is stored in a location where temperatures are extremely high, the battery will run down more rapidly than if is stored in a cooler location.
2. Check the electrolyte level every 25 operating hours
or, if the machine is in storage, every 30 days.
3. Maintain cell level with distilled or demineralized
water. Do not fill cells above the bottom of the split ring inside each cell.
4. Keep the top of the battery clean by washing it
periodically with a brush dipped in ammonia or bicarbonate of soda solution. Flush the top surface with water after cleaning. Do not remove the fill
caps while cleaning.
5. Battery cables must be tight on terminals to provide
good electrical contact.
6. If corrosion occurs at terminals, disconnect the
cables—negative (–) cable first—and scrape the clamps and terminals separately. Reconnect the cables—positive (+) cable first—and coat the terminals with petroleum jelly.
WIRE HARNESS SERVICE
Prevent corrosion of wiring terminals by applying Grafo 11 2X (Skin-over) grease, Toro Part No. 505-47, to the inside of all harness connectors whenever the harness is replaced.
Whenever working with the electrical system, always disconnect the battery cables, negative (–) cable first to prevent possible wiring damage from electrical shorts.
Before welding on the machine, disconnect ground cable from the battery to prevent damage to the electrical system.
FUSES (Fig. 45)
There are two fuses (50 amp and 10 amp) in the machine’s electrical system. They are located under the hood against the back side of the seat panel.
Figure 45
1. Fuse block
BACKLAPPING THE CUTTING UNITS
The cutting units may be backlapped on the machine. Backlap Kit, Part no. 84-5510 is available from your Authorized TORO Distributor.
Backlap according to procedures in the Toro Sharpening Reel and Rotary Mowers Manual Form No. 80-300 PT.
Maintenance
Since the gasses from the battery and the gasoline fumes are explosive, keep open flames and electrical sparks away from the area; do not smoke.
CAUTION
Be careful when lapping the reel because contact with the reel or other moving parts can result in personal injury.
CAUTION
Under no circumstances use a short-handled paintbrush. APart #29-9100 handle assembly complete—or individual parts—are available from your local Authorized TORO Distributor.
DANGER
Page 32
IDENTIFICA TION AND ORDERING
MODEL AND SERIAL NUMBER
The mower has two identification numbers: a model number and a serial number. The two numbers are stamped into a plate that is riveted to the frame. In any correspondence concerning the mower, supply the model and serial numbers to assure that correct information and replacement parts are obtained.
Note: Do not order by reference number if a parts
catalog is being used; use the part number.
To order replacement parts from an Authorized TORO Service Dealer, supply the following information:
1. Model and serial numbers of the mower.
2. Part number, description and quantity of part(s)
desired.
32
Maintenance
Page 33
33
Fold along line
Align this edge with a vertical surface
(Tree, building, fence post, pole, etc.
Example:
Compare slope
with folded edge.
This is a 20° Slope
This is a 15° Slope
15° and 20° Slope Chart
Page 34
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