Toro 03540 Reelmaster 5200-D, 03543 Reelmaster 5400-D Operator's Manual

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Form No. 3355-138 Rev B

Reelmaster® 5200-D/5400-D Two-Wheel and Four-Wheel Drive Traction Units

Model No. 03540 —Serial No. 260000201 and Up Model No. 03543 —Serial No. 260000201 and Up Model No. 03544 —Serial No. 260000201 and Up

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Warning

CALIFORNIA

Pr oposition 65 W ar ning

Diesel engine exhaust and some of its constituents ar e kno wn to the State of Calif or nia to cause cancer , bir th defects, and other r epr oducti v e har m.

Important: T his engine is not equipped with a spar k ar r ester muf ﬂer . It is a violation of Calif or nia Public R esource Code Section 4442 to use or operate the engine on an y f or est-co v er ed, br ush-co v er ed, or g rass-co v er ed land. Other states or federal ar eas may ha v e similar la ws.

Introduction

R ead this infor mation carefully to lear n ho w to operate and maintain y our product properly and to a v oid injur y and product damag e . Y ou are responsible for operating the product properly and safely .

Y ou ma y contact T oro directly at www .T oro .com for product and accessor y infor mation, help ﬁnding a dealer , or to register y our product.

W henev er y ou need ser vice , g en uine T oro par ts , or additional infor mation, contact an A uthorized Ser vice Dealer or T oro Customer Ser vice and ha v e the model and serial n umbers of y our product ready . T he model and serial n umbers are on a plate mounted on the left side of the foot rest. W rite the n umbers in the space pro vided.

Model No.

Serial No.

T his man ual identiﬁes potential hazards and has safety messag es identiﬁed b y the safety aler t symbol ( Figure 1 ), whic h signals a hazard that ma y cause serious injur y or death if y ou do not follo w the recommended precautions .

Figure 1

1. Safety alert symbol

T his man ual uses 2 other w ords to highlight infor mation. Impor tant calls attention to special mec hanical infor mation and Note emphasizes g eneral infor mation w or th y of special attention.

Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safe Operating Practices . . . . . . . . . . . . . . . . . . . . . . 4

T oro Riding Mo w er Safety . . . . . . . . . . . . . . . . . . . 6

Sound Pressure Lev el . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Sound P o w er Lev el . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Vibration Lev el . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Safety and Instr uctional Decals . . . . . . . . . . . . 8

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1 Connecting the Batter y . . . . . . . . . . . . . . . . . . . . 13

2 Mounting the Hood Latc h (CE

Units Only) . . . . . . . . . . . . . . . . . . . . . . . 14

3 R e placing the P anel F asteners

(CE Units Only) . . . . . . . . . . . . . . . . 15

4 Adjusting the Tire Pressure . . . . . . . . . . . . . . 16

5 Installing the Cutting Units . . . . . . . . . . . . . . 16

6 Adjusting the T urf Compensation

Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

7 Adjusting the Lifted Height

of the Outer F ront

Cutting Units (Enable

P osition) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

8 Installing R ear W eights . . . . . . . . . . . . . . . . . . . . 20

9 Installing CE Decals . . . . . . . . . . . . . . . . . . . . . . . . 21

10 R eading the Man ual and Viewing

the Safety Video . . . . . . . . . . . . . . . . . 21

Product Ov er view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Speciﬁcations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Chec king the Engine Oil Lev el . . . . . . . . . . . 26

Chec king the Cooling System . . . . . . . . . . . . . 27

Filling the Fuel T ank . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Chec king the T ransmission

Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Chec king the Hy draulic Fluid

Lev el . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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Chec king the R ear Axle

Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Chec king the R eel to Bedknife

Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Chec k the T or que of the W heel

Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . 30

Star ting and Stopping the

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Setting the R eel Speed . . . . . . . . . . . . . . . . . . . . . . . . 31

Adjusting the Lift Ar m Do wn

Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

T o wing the T raction Unit . . . . . . . . . . . . . . . . . . . 33

Understanding the Diagnostic

Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Diagnostic Ace Displa y . . . . . . . . . . . . . . . . . . . . . . 34

Chec king the Interloc k

Switc hes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Hy draulic V alv e Solenoid

Functions . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Operating Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

R ecommended Maintenance

Sc hedule(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Daily Maintenance Chec klist . . . . . . . . . . . . . . 41

Ser vice Inter v al Char t . . . . . . . . . . . . . . . . . . . . . . . . 42

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Greasing the Bearings and

Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Ser vicing the Air Cleaner . . . . . . . . . . . . . . . . . . . 44

Ser vicing the Engine Oil and

Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Adjusting the T hrottle . . . . . . . . . . . . . . . . . . . . . . . 45

Fuel System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Draining the Fuel T ank . . . . . . . . . . . . . . . . . . . . . . 46

Chec king the Fuel Lines and

Connections . . . . . . . . . . . . . . . . . . . . . . 46

Draining the Fuel Filter/W ater

Se perator . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

R e placing the Fuel Filter

Canister . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

R e placing the Fuel Preﬁlter . . . . . . . . . . . . . . . . 47

Bleeding Air from the Fuel

Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Electrical System Maintenance . . . . . . . . . . . . . . . . . . . 47

Ser vicing the Batter y . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Optional Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Dri v e System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 49

Adjusting the T raction Dri v e for

Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Chec king and Adjusting the

T raction Linkag e . . . . . . . . . . . . . . . 49

Changing the T ransmission

Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

R e placing the T ransmission Oil

Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Changing the R ear Axle

Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Adjusting the R ear W heel

T oe-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Cooling System Maintenance . . . . . . . . . . . . . . . . . . . . . 52

R emo ving Debris from the Cooling

System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Brak e Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Adjusting the Ser vice Brak es . . . . . . . . . . . . . . 52

Belt Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

T ensioning the Alter nator Belt . . . . . . . . . . . 53

T ensioning the Cooling F an

Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Hy draulic System Maintenance . . . . . . . . . . . . . . . . . . 54

Changing the Hy draulic Fluid . . . . . . . . . . . . . 54

R e placing the Hy draulic Filter . . . . . . . . . . . . 54

Chec king the Hy draulic Lines and

Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Hy draulic System T est P or ts . . . . . . . . . . . . . . . 55

Cutting Unit System Maintenance . . . . . . . . . . . . . . 56

Adjusting the Cutting Unit Lift

Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Bac klapping the Cutting Units . . . . . . . . . . . . 57

Storag e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Pre paring the T raction Unit . . . . . . . . . . . . . . . . 59

Pre paring the Engine . . . . . . . . . . . . . . . . . . . . . . . . . 59

Sc hematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

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Safety

T his machine meets or ex ceeds CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-1999 speciﬁcations in ef fect at time of pr oduction, when ballast is installed according to the char t on pa ge 19.

Impr oper use or maintenance by the operator or o wner can r esult in injur y . T o r educe the potential f or injur y , compl y with these safety instr uctions and al w ays pay attention to the safety aler t symbol, which means Caution, W ar ning , or Danger—per sonal safety instr uction. F ailur e to compl y with the instr uction may r esult in per sonal injur y or death.

Safe Operating Practices

T he follo wing instr uctions are from the CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-1999.

Training

• R ead the operator’ s man ual and other training material carefully . Be familiar with the controls , safety signs , and the proper use of the equipment.

• Nev er allo w c hildren or people unfamiliar with these instr uctions to use or ser vice the mo w er . Local regulations ma y restrict the ag e of the operator .

• Nev er mo w while people , especially c hildren, or pets are nearb y .

• K ee p in mind that the operator or user is responsible for accidents or hazards occur ring to other people or their proper ty .

• Do not car r y passeng ers .

• All dri v ers and mec hanics should seek and

obtain professional and practical instr uction. T he o wner is responsible for training the users . Suc h instr uction should emphasize:

– the need for care and concentration when

w orking with ride-on mac hines;

– control of a ride-on mac hine sliding on a

slope will not be reg ained b y the application of the brak e . T he main reasons for loss of control are:

◊ insufﬁcient wheel g rip;

◊ being dri v en too fast;

◊ inadequate braking;

◊ the type of mac hine is unsuitable for its

task;

◊ lac k of a w areness of the effect of

g round conditions , especially slopes;

◊ incor rect hitc hing and load distribution.

• T he o wner/user can prev ent and is responsible for accidents or injuries occur ring to himself or herself , other people , or proper ty .

Preparation

• W hile mo wing, alw a ys w ear substantial footw ear , long trousers , hard hat, safety glasses , and ear protection. Long hair , loose clothing, or jew elr y ma y g et tangled in mo ving par ts . Do not operate the equipment when barefoot or w earing open sandals .

• T horoughly inspect the area where the equipment is to be used and remo v e all objects whic h ma y be thro wn b y the mac hine .

• W ar ning —Fuel is highly ﬂammable . T ak e the follo wing precautions:

– Store fuel in containers speciﬁcally designed

for this pur pose .

– R efuel outdoors only and do not smok e

while refuelling .

– Add fuel before star ting the engine . Nev er

remo v e the cap of the fuel tank or add fuel while the engine is r unning or when the engine is hot.

– If fuel is spilled, do not attempt to star t the

engine but mo v e the mac hine a w a y from the area of spillag e and a v oid creating any source of ignition until fuel v apors ha v e dissipated.

– R e place all fuel tanks and container caps

securely .

• R e place faulty silencers/m ufﬂers .

• Ev aluate the ter rain to deter mine what

accessories and attac hments are needed to properly and safely perfor m the job . Only use accessories and attac hments appro v ed b y the man ufacturer .

• Chec k that operator’ s presence controls , safety switc hes and shields are attac hed and

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functioning properly . Do not operate unless they are functioning properly .

Operation

• Do not operate the engine in a conﬁned space where dang erous carbon mono xide fumes can collect.

• Mo w only in da ylight or in g ood ar tiﬁcial light.

• Before attempting to star t the engine ,

diseng ag e all blade attac hment clutc hes , shift into neutral, and eng ag e the parking brak e .

• R emember there is no suc h thing as a safe slope . T ra v el on g rass slopes requires par ticular care . T o guard ag ainst o v er tur ning:

– do not stop or star t suddenly when g oing

up or do wnhill;

– eng ag e clutc h slo wly , alw a ys k ee p mac hine

in g ear , especially when tra v elling do wnhill;

– mac hine speeds should be k e pt lo w on

slopes and during tight tur ns;

– sta y aler t for humps and hollo ws and other

hidden hazards;

– nev er mo w across the face of the slope ,

unless the mo w er is designed for this pur pose .

• Sta y aler t for holes in the ter rain and other hidden hazards .

• Use care when pulling loads or using hea vy equipment.

– Use only appro v ed dra wbar hitc h points .

– Limit loads to those y ou can safely control.

– Do not tur n shar ply . Use care when

rev ersing .

– Use counterw eight(s) or wheel w eights

when sug g ested in the operator’ s man ual.

• W atc h out for trafﬁc when crossing or near roadw a ys .

• Stop the blades rotating before crossing surfaces other than g rass .

• W hen using any attac hments , nev er direct disc harg e of material to w ard b ystanders nor allo w any one near the mac hine while in operation.

• Nev er operate the mac hine with damag ed guards , shields , or without safety protecti v e devices in place . Be sure all interloc ks are

attac hed, adjusted properly , and functioning properly .

• Do not c hang e the engine g o v er nor settings or o v er -speed the engine . Operating the engine at ex cessi v e speed ma y increase the hazard of personal injur y .

• Before lea ving the operator’ s position:

– stop on lev el g round; – diseng ag e the po w er tak e-off and lo w er the

attac hments;

– c hang e into neutral and set the parking

brak e;

– stop the engine and remo v e the k ey .

• Diseng ag e dri v e to attac hments when transpor ting or not in use .

• Stop the engine and diseng ag e dri v e to attac hment:

– before refuelling; – before remo ving the g rass catc her/catc hers; – before making height adjustment unless

adjustment can be made from the operator’ s

position. – before clearing bloc kag es; – before c hec king, cleaning or w orking on

the mo w er; – after striking a foreign object or if an

abnor mal vibration occurs . Inspect the

mo w er for damag e and mak e re pairs before

restar ting and operating the equipment.

• R educe the throttle setting during engine r un-out and, if the engine is pro vided with a shut-off v alv e , tur n the fuel off at the conclusion of mo wing .

• K ee p hands and feet a w a y from the cutting units .

• Look behind and do wn before bac king up to be sure of a clear path.

• Slo w do wn and use caution when making tur ns and crossing roads and sidew alks . Stop cylinders/reels if not mo wing .

• Do not operate the mo w er under the inﬂuence of alcohol or dr ugs .

• Use care when loading or unloading the mac hine into a trailer or tr uc k.

• Use care when approac hing blind cor ners , shr ubs , trees , or other objects that ma y obscure vision.

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Maintenance and Storage

• K ee p all n uts , bolts and screws tight to be sure the equipment is in safe w orking condition.

• Nev er store the equipment with fuel in the tank inside a building where fumes ma y reac h an open ﬂame or spark.

• Allo w the engine to cool before storing in any enclosure .

• K ee p hands and feet a w a y from mo ving par ts . If possible , do not mak e adjustments with the engine r unning .

• Charg e batteries in an open w ell v entilated area, a w a y from spark and ﬂames . Unplug c harg er before connecting or disconnecting from batter y . W ear protecti v e clothing and use insulated tools .

• T o reduce the ﬁre hazard, k ee p the engine , silencer/m ufﬂer , batter y compar tment and fuel storag e area free of g rass , lea v es , or ex cessi v e g rease .

• Chec k the g rass catc her frequently for w ear or deterioration.

• K ee p all par ts in g ood w orking condition and all hardw are and h y draulic ﬁttings tightened. R e place all w or n or damag ed par ts and decals .

• If the fuel tank has to be drained, do this outdoors .

• Be careful during adjustment of the mac hine to prev ent entrapment of the ﬁng ers betw een mo ving blades and ﬁx ed par ts of the mac hine .

• On m ulti-cylinder/m ulti-reel mac hines , tak e care as rotating one cylinder/reel can cause other cylinders/reels to rotate .

• Diseng ag e dri v es , lo w er the cutting units , set parking brak e , stop engine and remo v e k ey and disconnect spark plug wire . W ait for all mo v ement to stop before adjusting, cleaning or re pairing .

• Clean g rass and debris from cutting units , dri v es , silencers/m ufﬂers , and engine to help prev ent ﬁres . Clean up oil or fuel spillag e .

• Use jac k stands to suppor t components when required.

• Carefully release pressure from components with stored energ y .

• Disconnect batter y and remo v e spark plug wire before making any re pairs . Disconnect the neg ati v e ter minal ﬁrst and the positi v e last. R econnect positi v e ﬁrst and neg ati v e last.

• Use care when c hec king the cylinders/reels . W ear glo v es and use caution when ser vicing them.

Toro Riding Mower Safety

T he follo wing list contains safety infor mation speciﬁc to T oro products or other safety infor mation that y ou m ust kno w that is not included in the CEN , ISO , or ANSI standard.

T his product is capable of amputating hands and feet and thro wing objects . Alw a ys follo w all safety instr uctions to a v oid serious injur y or death.

Use of this product for pur poses other than its intended use could pro v e dang erous to user and b ystanders .

Engine exhaust contains carbon mono xide, which is an odor less, deadl y poison that can kill y ou.

Do not r un engine indoor s or in an enclosed ar ea.

• Kno w ho w to stop the engine quic kly .

• Do not operate the mac hine while w earing

tennis shoes or sneak ers .

• W earing safety shoes and long pants is advisable and required b y some local ordinances and insurance regulations .

• Handle fuel carefully . Wipe up any spills .

• Chec k the safety interloc k switc hes daily

for proper operation. If a switc h should fail, re place the switc h before operating the mac hine . After ev er y tw o years , re place all four interloc k switc hes in the safety system, whether they are w orking properly or not.

• Before star ting the engine , sit on the seat.

• Using the mac hine demands attention. T o

prev ent loss of control:

Page 7

– Do not dri v e close to sand traps , ditc hes ,

creeks , or other hazards .

– R educe speed when making shar p tur ns .

A v oid sudden stops and star ts .

– W hen near or crossing roads , alw a ys yield

the right-of-w a y .

– Apply the ser vice brak es when g oing

do wnhill to k ee p forw ard speed slo w and to maintain control of the mac hine .

• T he g rass bask ets m ust be in place during operation of the cylinders/reels or thatc hers for maxim um safety . Shut the engine off before emptying the bask ets .

• Raise the cutting units when dri ving from one w ork area to another .

• Do not touc h the engine , silencer/m ufﬂer , or exhaust pipe while the engine is r unning or soon after it has stopped because these areas could be hot enough to cause bur ns .

system m ust be reliev ed b y stopping the engine and lo w ering the cutting units and attac hments to the g round.

• Chec k all fuel lines for tightness and w ear on a regular basis . Tighten or re pair them as needed.

• If the engine m ust be r unning to perfor m a maintenance adjustment, k ee p hands , feet, clothing, and any par ts of the body a w a y from the cutting units , attac hments , and any mo ving par ts , especially the screen at the side of the engine . K ee p ev er y one a w a y .

• T o ensure safety and accuracy , ha v e an A uthorized T oro Distributor c hec k the maxim um engine speed with a tac hometer . Maxim um g o v er ned engine speed should be 2900 RPM.

• If major re pairs are ev er needed or if assistance is desired, contact an A uthorized T oro Distributor .

• Sta y clear of the rotating screen at the side of the engine to prev ent direct contact with y our body or clothing .

• If the engine stalls or loses headw a y and cannot mak e it to the top of a slope , do not tur n the mac hine around. Alw a ys bac k slo wly , straight do wn the slope .

• W hen a person or pet appears unexpectedly in or near the mo wing area, stop mo wing . Careless operation, combined with ter rain angles , ricoc hets , or improperly positioned guards can lead to thro wn object injuries . Do not resume mo wing until the area is cleared.

Maintenance and Storage

• Mak e sure all h y draulic line connectors are tight and all h y draulic hoses and lines are in g ood condition before applying pressure to the system.

• K ee p y our body and hands a w a y from pin hole leaks or nozzles that eject h y draulic ﬂuid under high pressure . Use paper or cardboard, not y our hands , to searc h for leaks . Hy draulic ﬂuid escaping under pressure can ha v e sufﬁcient force to penetrate the skin and cause serious injur y . Seek immediate medical attention if ﬂuid is injected into skin.

• Use only T oro-appro v ed attac hments and re placement par ts . T he w ar ranty ma y be v oided if used with unappro v ed attac hments .

Sound Pressure Level

T his unit has an equi v alent contin uous A-w eighted sound pressure at the operator ear of: 88 dB(A), based on measurements of identical mac hines per EN 11094 and EN 836.

Sound Power Level

T his unit has a guaranteed sound po w er lev el of: 105 dB A/1 pW , based on measurements of identical mac hines per EN 11094.

Vibration Level

T his unit does not ex ceed a vibration lev el of 2.5

m/s

at the hands based on measurements of

identical mac hines per EN 1033.

T his unit does not ex ceed a vibration lev el of 0.5

m/s

at the posterior based on measurements of

identical mac hines per EN 1032.

• Before disconnecting or perfor ming any w ork on the h y draulic system, all pressure in the

Page 8

Safety and Instructional Decals

Safety decals and instr uctions are easily visible to the operator and are located near any area of potential dang er . R e place any decal that is damag ed or lost.

1. Read the Operator’s Manual.

93-6693

1. Crushing hazard of hand—wait for moving parts to stop.

104-2052

110-9721

Page 9

1. Throttle—slow 4. Reels lowered and on when enabled—forward and backlap

2. Throttle—fast 5. Reels enabled

3. Reels raised and off 6. Reels disabled—lift only 9. Headlights—On

104-9298

1. Read the Operator’s Manual .

104-9296

7. Reels disabled—lift and lower 10. Headlights—Off

8. Headlights (optional) 11. Read the Operator’s Manual for further instructions.

1. Read the Operator’s

2. Headlights

94-6767

3. Engine—start

Manual.

Page 10

93-6697

1. Read the Operator’s Manual .

2. Add SAE 80w-90 (API GL-5) oil every 50 hours.

98-9335

1. Cutting/dismemberment hazard, fan—stay away from moving parts.

93-6696

1. Stored energy hazard—read the Operator’s Manual .

98-9342

1. Reel—height of cut 4. Machine speed

2. Reel—mow and backlap 5. Rear reels circuit controls

3. Read the Operator’s

Manual.

6. Front reels circuit controls

106-9224

1. Warning—read the Operator’s Manual.

2. Cutting hazard of hand and foot—stop the reels before touching.

93-6699

1. Machine speed 3. Continuous variable setting

2. Slow

4. Fast

93-6691

1. Read the Operator’s Manual.

Page 11

93-6692

1. Read the Operator’s Manual —do not prime or use starting uid.

93-6686

1. Hydraulic oil

2. Read the Operator’s Manual.

93-1263

1. Read the Operator’s Manual.

2. To engage the parking brake, connect the brake pedals with the locking pin, push down on both pedals, and pull the brake latch out.

3. To release the parking brake, press both pedals until the parking brake latch retracts.

4. Danger—reels enabled.

1. Wheel torque specications

2. Read the Operator’s Manual .

106-9206

93-6689

1. Warning—do not carry passengers.

93-6680

Battery Symbols

Some or all of these symbols are on your battery

1. Explosion hazard 6. Keep bystanders a safe

2. No re, open ame, or smoking.

3. Caustic liquid/chemical burn hazard

4. Wear eye protection

5. Read the Operator’s

Manual.

distance from the battery.

7. Wear eye protection; explosive gases can cause blindness and other injuries

8. Battery acid can cause blindness or severe burns.

9. Flush eyes immediately with water and get medical help fast.

10. Contains lead; do not discard.

1. Read the Operator’s

Manual.

2. Engine—stop 5. Engine—start

3. On

105-7506

4. Engine—preheat

Page 12

1. Read the Operator’s Manual .

2. Do not tow the machine. 4. Cutting hazard of hand

3. Warning—Read the Operator’s Manual .

or foot—stay away from moving parts.

104-9294

5. Warning—keep bystanders a safe distance from the machine.

6. Warning—lock the parking brake, stop the engine, and remove the ignition key before leaving the machine.

7. Warning—use a rollover protection system and wear the seat belt.

8. Tipping hazard—lower the cutting unit when driving down slopes.

1. Read the Operator’s Manual .

2. Do not tow the machine. 4. Cutting hazard of hand

3. Warning—Read the Operator’s Manual .

or foot—stay away from moving parts.

104-9295

(Cover 104–9296 for CE)

5. Warning—keep bystanders

6. Warning—lock the parking

a safe distance from the machine.

brake, stop the engine, and remove the ignition key before leaving the machine.

7. Warning—use a rollover protection system and wear the seat belt.

8. Tipping hazard—lower the cutting unit when driving down slopes and do not drive across or down slopes greater than 15 degrees.

Page 13

Setup

Loose Parts

Use the chart below to verify that all parts have been shipped.

Step

3 4

5 6

No parts required

Locking hood switch Lock washer Nut 1 Key 2 Hood latch bracket Bolt (1/4 x 3/4 inch) Flat washer (1/4 inch) Locknut (1/4 inch) Flange-head bolt (5/16 x 5/8 inch) Flange-head bolt (5/16 x 3/4 inch)

No parts required

Cutting unit (sold separately)

No parts required

Description

Qty.

–

1 1

1 2 2 2 1 1

–

Connect the Battery

Mount the hood latch.

Replace the panel fasteners (CE only).

Adjust the tire pressure.

Install the cutting units

Adjust the turf compensation spring.

Adjust the lifted height of the outer front cutting units (enable position).

Use

Rear weights (size varies with

8 9

conguration). CE decal

Blank service decal Operator’s Manual Engine Operator’s Manual Parts Catalog CE certicate Safety Video Diagnostic ACE display overlay

Note: Deter mine the left and right sides of the mac hine from the nor mal operating position.

Varies

1 1 1 1 1 2 1 1

Install rear weights.

Install the CE Decals

Read the Operator’s Manual and watch the video before operating the machine.

Page 14

Step

Connecting the Battery

No Parts Required

Charging the batter y pr oduces gasses that can explode.

Nev er smok e near the batter y and k eep spar ks and ﬂames a w ay fr om the batter y .

Procedure

Warning

CALIFORNIA

Pr oposition 65 W ar ning

Batter y posts, ter minals, and r elated accessories contain lead and lead compounds, chemicals kno wn to the State of Calif or nia to cause cancer and r epr oducti v e har m. W ash hands after handling .

Connecting ca bles to the wr ong post could r esult in per sonal injur y and/or dama ge to the electrical system.

1. Open hood.

2. Ensure that the batter y is securely fastened in place and c hec k the batter y c harg e with a h y drometer . If the batter y needs c harging, ensure that the positi v e (+) cable is disconnected from the batter y before connecting the c harg er ( Figure 2 ).

Batter y ter minals or metal tools could shor t a gainst metal tractor components, causing spar ks. Spar ks can cause the batter y gasses to explode, r esulting in per sonal injur y .

• W hen r emo ving or installing the batter y , do not allo w the batter y ter minals to touch an y metal par ts of the tractor .

• Do not allo w metal tools to shor t betw een the batter y ter minals and metal par ts of the tractor .

3. Slide the red, positi v e batter y cable onto the positi v e batter y post and tighten the n ut securely .

Incor r ect batter y ca ble r outing could dama ge the tractor and ca bles, causing spar ks. Spar ks can cause the batter y gasses to explode, r esulting in per sonal injur y .

• Al w ays disconnect the negati v e (black) batter y ca ble bef or e disconnecting the positi v e (r ed) ca ble.

Figure 2

1. Positive battery cable 2. Negative battery cable

• Al w ays connect the positi v e (r ed) batter y ca ble bef or e connecting the negati v e (black) ca ble.

4. Slide the blac k, neg ati v e batter y cable onto the neg ati v e batter y post and tighten the n ut securely .

5. Coat both batter y connections with Grafo 112X (skin o v er) g rease (T oro P ar t No . 505-47), petroleum jelly , or light g rease to prev ent cor rosion and slide the r ubber boot o v er the positi v e ter minal.

6. Close the hood.

Page 15

Step

Mounting the Hood Latch (CE Units Only)

Parts needed for this step:

Locking hood switch

Lock washer 1 Nut 2 Key 1

Hood latch bracket 2

Bolt (1/4 x 3/4 inch) 2

Flat washer (1/4 inch) 2

Locknut (1/4 inch)

Procedure

1. R emo v e the plug from the hole in the left front cor ner of the hood ( Figure 3 ).

Figure 4

1. Locking switch 2. Latch bracket

4. Loosely mount the latc h brac k et to the radiator suppor t with 2 bolts (1/4 x 3/4 inc h), ﬂat w ashers , and loc kn uts ( Figure 4 ).

5. Adjust the latc h brac k et, until it is aligned with the switc h latc h, then tighten the bolts .

Figure 3

1. Hood plug

2. Open the hood.

3. Mount the loc king switc h to the hood with a loc k w asher and n ut. P osition the switc h with the latc h to w ard the front of the mac hine ( Figure 4 ).

6. R otate the latc h to the loc k ed and unloc k ed positions with the k ey . R emo v e the k ey and store it in a memorable place .

7. Close the hood.

Step

Replacing the Panel Fasteners (CE Units Only)

Parts needed for this step:

Flange-head bolt (5/16 x 5/8 inch)

Flange-head bolt (5/16 x 3/4 inch)

Procedure

1. R emo v e the fasteners securing the left front cor ner of the ﬂoor panel and the left end of the access panel to the frame ( Figure 5 ).

Page 16

Figure 5

1. Floor panel 2. Access panel

2. R e place the ﬂoor panel fastener with a ﬂang e-head bolt (5/16 x 5/8 inc h) supplied in loose par ts ( Figure 5 ).

Step

Installing the Cutting Units

Parts needed for this step:

Cutting unit (sold separately)

Procedure

1. R emo v e the cutting units from the car tons . Assemble and adjust the as described in the cutting unit Operator’ s Manual .

2. If y ou will be using bask ets on the cutting units , use the c har t belo w ( Figure 6 ) to deter mine the locations at whic h y ou need to mount bask et guides to the cutting unit car rier frames . If y ou will not be using bask ets , proceed to ste p 4 .

3. R e place the access panel fastener with a ﬂang e-head bolt (5/16 x 3/4 inc h) supplied in loose par ts ( Figure 5 ).

Step

Adjusting the Tire Pressure

No Parts Required

Procedure

T he tires are o v er -inﬂated for shipping . T herefore , release some of the air to reduce the pressure . Cor rect air pressure in the front and rear tires is 10 to 15 psi (69 to 103 kP a).

Important: Maintain ev en pr essur e in all tir es to ensur e unif or m contact with the turf.

Figure 6

3. Mount a bask et guide ( Figure 7 ) to the appropriate side of eac h cutting unit car rier frame ( Figure 8 ) with a bolt (5/16 x 1-3/4 inc hes), ﬂat w asher , and loc k w asher or fasteners previously remo v ed, as sho wn in Figure 7 .

Page 17

Figure 7

1. Carrier frame 2. Basket guide

4. Install a roll pin ( Figure 8 ) into the hole in the appropriate side of eac h cutting unit car rier frame ( Figure 6 ).

Figure 8

1. Carrier frame 3. Basket bracket

2. Roll pin 4. Basket collar

Figure 9

1. Cutting unit mounting shaft

2. Carrier frame pivot tube 5. Lock washer

3. Thrust washer 6. Bolt

4. Flat washer

6. Secure the shaft in the pi v ot tube with a thr ust w asher , ﬂat w asher , loc k w asher , and bolt ( Figure 9 ).

7. Assemble the mounting n uts for the reel dri v e motor to eac h cutting unit ( Figure 10 ). Lea v e appro ximately 1/2 inc h (1.25 cm) of threads exposed on eac h mounting stud.

5. Align the mounting shaft of the cutting unit with the pi v ot tube on the car rier frame . Inser t the shaft into the tube ( Figure 9 ).

Figure 10

1. Reel drive motor

2. Mounting nuts

8. Coat the spline shaft of the motor with clean g rease and install the motor b y rotating it cloc kwise so that the motor ﬂang es clear the studs . R otate the motor countercloc kwise until the ﬂang es encircle the studs and tighten the

Page 18

mounting n uts . Ensure that the w ashers are ag ainst the n uts .

9. Detac h the loc k-up c hain from the lift ar m and secure it to the cross tube on eac h rear cutting unit with a bolt, ﬂat w asher , and loc kn ut ( Figure 11 ).

Figure 11

1. Lock-up chain

Important: Mak e sur e that all h y draulic hoses ar e r outed a w ay fr om cutting unit so that when the cutting unit pi v ots ex cessi v e r ub bing does not occur .

10. Chec k the adjustment of the loc k-up rollers ( Figure 12 ). W hen properly adjusted, they will contact the loc k-up lev ers on rear lift ar ms and suppor t the cutting units when fully raised.

the bask et brac k et and pressing the opposite mounting pin into the pi v oting brac k et.

Step

Adjusting the Turf Compensation Spring

No Parts Required

Procedure Important: T his adjustment is needed f or

Cutting Unit Models 03527 and 03528 onl y . T he turf compensation spring ( Figur e 13 ),

connecting car rier frame to cutting unit, contr ols the amount of f or e-aft r otation a v aila ble.

T he turf compensation spring also transfers w eight from the front to the rear roller . (T his helps to reduce a w a v e patter n in the turf , also kno wn as bobbing .)

Figure 12

1. Lock-up rollers 2. Lock-up levers

11. Mount a bask et to eac h cutting unit car rier frame b y inser ting the bask et mounting pin into

Figure 13

Important: Mak e spring adjustments with

the cutting unit mounted to the traction unit and lo w er ed to the shop ﬂoor .

1. Tighten the loc kn ut on the rear of the spring rod until the g ap (C) betw een the rear of the

Page 19

spring brac k et and front of the w asher is 1.25 inc hes (3.2 cm) ( Figure 13 ).

2. Tighten the hex n uts on the front end of the spring rod until the compressed length (A) of spring is 6.25 inc hes (32.8 cm) ( Figure 13 ).

As the compressed spring length (A) decr eases , w eight transfer from the front roller to the rear roller incr eases and the car rier frame/cutting unit rotation angle (B) decr eases .

As the g ap (C) betw een the spring brac k et and w asher incr eases , the car rier frame/cutting unit rotation angle (B) incr eases .

Step

Adjusting the Lifted Height of the Outer Front Cutting Units (Enable Position)

No Parts Required

Procedure

T he tur naround height of the front outer cutting units (#4 & #5) ma y be increased to pro vide additional g round clearance on contoured fairw a ys .

Note: T he RM CONFIG time dela y should not be c hang ed from the original setting of 0 when using this method to adjust tur n around height.

Figure 14

1. Lift arm switch 3. Lift arm ag

2. Carriage bolt nut

3. Mo v e the lift switc h brac k et inw ard in the slot until the desired position is attained.

4. Set the distance betw een the lift ar m switc h and the ﬂag on the lift ar m to appro ximately

0.062 inc hes (1.6 mm).

5. Tighten the car riag e bolt n ut.

T o increase the tur n around height of the front cutting units proceed as follo ws:

1. P osition the mac hine on a lev el surface , lo w er the cutting units , and stop the mac hine .

2. Loosen the car riag e bolt n ut securing the lift ar m switc h brac k et to the No . 4 lift ar m (left front) ( Figure 14 ).

Page 20

Step

Installing Rear Weights

Parts needed for this step:

Varies

Rear weights (size varies with conguration).

Procedure

T he R eelmaster 5200-D & 5400-D T raction Units comply with CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-1999 Standards when equipped with rear w eights and 90 lb of calcium c hloride ballast is added to rear wheels . Use the c har t belo w to deter mine the combinations of w eights required for y our conﬁguration. Order par ts from y our local A uthorized T oro Distributor .

Traction Unit

Conguration

2wd Traction Unit

with ROPS w/o

baskets

2wd Traction Unit

with ROPS with

baskets

2wd Traction Unit

w/o ROPS w/o

baskets

2wd Traction Unit

w/o ROPS with

baskets

4wd Traction Unit

with ROPS w/o

baskets

4wd Traction Unit

with ROPS with

baskets

Rear Weight

Required

291 lb (132 kg)

358 lb (162 kg)

157 lb (71 kg)

224 lb (102 kg)

157 lb (71 kg)

249 lb (113)

75-6690 and 98-9780

Weight Part

Number

75-6690

Weight

Description

Rear Weight Kit

Rear Weight Kit and

Rear Weight Kit—25 lb

Qty

2 and 1

Important: If a punctur e occur s in a tir e with calcium chloride, r emo v e the machine fr om the turf ar ea as quickl y as possible. T o pr ev ent possible dama ge to the turf, immediatel y soak the af fected ar ea with w ater .

Page 21

Step

Installing CE Decals

Parts needed for this step:

CE decal

Blank service decal

Procedure

1. Place the CE decal onto the traction unit near the model and serial n umber plate .

2. Place the blank ser vice decal near the English ser vice decal and write the ser vice infor mation into the blank for m in the appropriate languag e using a per manent mark er .

Step

Reading the Manual and Viewing the Safety Video

Parts needed for this step:

Operator’s Manual

Engine Operator’s Manual

Parts Catalog

CE certicate

Safety Video

Diagnostic ACE display overlay

Procedure

• R ead the Operator’ s Manual .

• View the safety video .

• Store all documentation in a safe place for

future use .

• Fill out the registration card.

• Use the diagnostic A CE displa y o v erla y when

troubleshooting problems with the mac hine (store it in the ser vice shop until needed).

Page 22

Product Overview

1. Operator’s seat

2. Rollover protection system (ROPS), along with the seat belt

3. Front cutting units

Figure 15

4. Rear cutting units

5. Air cleaner

6. Engine hood

Figure 16

1. Seat adjusting lever 2. Seat adjusting knob

Traction Pedal

T he traction pedal ( Figure 17 ) controls forw ard and rev erse operation. Press the top of the pedal to mo v e forw ard and the bottom to mo v e rearw ard. Ground speed de pends on ho w far y ou press the pedal. F or no load, maxim um g round speed, fully press the pedal while the throttle is in the F ast position.

Controls

Seat Controls

T he seat adjusting lev er ( Figure 16 ) allo ws y ou to adjust the seat 4 inc hes fore and aft. T he seat adjusting knob ( Figure 16 ) adjusts the seat for the operator’ s w eight. T o adjust the seat fore and aft, pull the lev er on the left side of the seat assembly outw ard. After mo ving the seat to the desired location, release the lev er to loc k the seat into position. T o adjust for the operator’ s w eight, tur n the spring tension knob cloc kwise to increase tension or countercloc kwise to decrease tension.

T o stop , reduce foot pressure on the traction pedal and allo w it to retur n to the center position.

Figure 17

1. Traction pedal

Traction Speed Limiter

Preset this lev er ( Figure 18 ) to limit the amount the traction pedal can be pressed in the forw ard direction to maintain a constant mo wing speed.

Page 23

Figure 18

1. Traction speed limiter 5. Parking brake latch

2. Reel control light 6. Locking pin

3. Speedometer 7. Key switch

4. Brake pedals

Reel Control Light

T his light ( Figure 18 ) illuminates when the glo w plugs are preheating, or blinks when there is a control system problem or when the g round speed during mo wing approac hes the maxim um preset mo wing speed.

Speedometer

T he speedometer ( Figure 18 ) indicates the g round speed at whic h mac hine is tra v eling .

Engine Coolant Temperature Warning Light

T his light ( Figure 19 ) illuminates and the engine shuts do wn when the engine coolant reac hes a dang erously high temperature .

Figure 19

1. Lower mow/raise control lever

2. Fuel gauge 7. Charge indicator

3. Engine coolant temperature gauge

4. Engine oil pressure warning light

5. Engine coolant temperature warning light

6. Glow plug indicator light

8. Throttle control

9. Enable/disable switch

Brake Pedals

T w o foot pedals ( Figure 18 ) operate indi vidual wheel brak es for tur ning assistance , parking, and to aid in obtaining better side-hill traction. A loc king pin connects the pedals for parking brak e operation and transpor t.

Parking Brake Latch

A knob on the left side of console ( Figure 18 ) actuates the parking brak e loc k. T o eng ag e the parking brak e , connect the pedals with the loc king pin, push do wn on both pedals , and pull the parking brak e latc h out. T o release parking brak e , press both pedals until the parking brak e latc h retracts .

Key Switch

T he k ey switc h ( Figure 18 ) has three positions: Off , On/Preheat, and Star t.

Throttle Control

Mo v e the throttle control ( Figure 19 ) forw ard to increase the engine speed and rearw ard to decrease speed.

Fuel Gauge

T he fuel g aug e ( Figure 19 ) sho ws the amount of fuel in the tank.

Lower Mow/Raise Control Lever

T his lev er ( Figure 19 ) raises and lo w ers the cutting units and also star ts and stops the reels .

Glow Plug Indicator Light

T his light ( Figure 19 ) blinks when the glo w plugs are preheating .

Page 24

Engine Oil Pressure Warning Light

T his light ( Figure 19 ) indicates dang erously lo w engine oil pressure .

Charge Indicator

T he c harg e indicator ( Figure 19 ) illuminates when the system c harging circuit malfunctions .

Enable/Disable Switch

Use the enable/disable switc h ( Figure 19 ) in conjunction with the lo w er mo w/raise control lev er to operate the reels . T he reels can be raised but not lo w ered when in the mid position.

Backlap Switch

Use the bac klap switc h ( Figure 20 ) in conjunction with the lo w er mo w/raise control lev er for bac klapping the reels .

Figure 20

1. Backlap switch

Figure 21

1. Reel speed controls

Hour Meter

T he hour meter ( Figure 22 ) sho ws the total hours that the mac hine has been operated.

Reel Speed Controls

T he reel speed controls ( Figure 21 ) control the speed of front and rear cutting units . T he ﬁrst position is for bac klapping . T he remaining positions are for mo wing operations .

Figure 22

1. Hour meter

Page 25

Specications

Note: Speciﬁcations and design are subject to c hang e without notice .

Width of Cut Transport Width Width, to the Outside of the Front Tires Width, to the Outside of the Rear Tires Length, without Grass Baskets Length, with Grass Baskets Height, without ROPS Installed Height, with ROPS Installed Height of Cut, 5 Blade Cutting Units Height of Cut, 8 Blade Cutting Units Weight, Models 03540 and 03543, with 8 Blade Cutting Units, Baskets,

and Full Fluid Levels Weight, Model 03544, with 8 Blade Cutting Units, Baskets, and Full Fluid

Levels

1/2 to 3/4 inches (13 to 19 mm)

1/4 to 5/8 inches (6 to 16 mm)

95 inches (241.3 cm)

87 inches (221 cm) 87 inches (221 cm)

52-1/2 inches (133 cm)

103-1/2 inches (263 cm)

116 inches (294.6 cm)

56-1/2 inches (143.5 cm)

85 inches (216 cm)

2320 lb (1053 kg)

2675 lb (1214 kg)

Attachments/Accessories

A selection of T oro appro v ed attac hments and accessories are a v ailable for use with the mac hine to enhance and expand its capabilities . Contact y our A uthorized Ser vice Dealer or Distributor or g o to www .T oro .com for a list of all appro v ed attac hments and accessories .

Page 26

Operation

Note: Deter mine the left and right sides of the

mac hine from the nor mal operating position.

If y ou lea v e the k ey in the ignition s witch, someone could accidentl y star t the engine and seriousl y injur e y ou or other bystander s.

R emo v e the k ey fr om the ignition s witch and lo w er the cutting units to the g r ound bef or e ser vicing or making adjustments to the machine.

Checking the Engine Oil Level

T he engine is shipped with oil in the crankcase; ho w ev er , the oil lev el m ust be c hec k ed before and after the engine is ﬁrst star ted.

Figure 23

Reelmaster 5200

1. Dipstick 2. Oil ll cap

Crankcase capacity is appro ximately 4 qt (2.8 l) with the ﬁlter .

Use high-quality engine oil that meets the follo wing speciﬁcations:

• API Classiﬁcation Lev el R equired: CH-4, CI-4 or higher

• Prefer red oil: SAE 15W -40 (abo v e 0_F)

• Alter nate oil: SAE 10W -30 or 5W -30 (all

temperatures)

T oro Premium Engine oil is a v ailable from y our distributor in either 15W -40 or 10W -30 viscosity . See the par ts catalog for par t n umbers .

1. P ark the mac hine on a lev el surface , stop the engine , and remo v e the k ey from the ignition switc h.

2. Open the hood.

3. R emo v e the dipstic k, wipe it clean, and install it (R eelmaster 5200— Figure 23 , R eelmaster 5400— Figure 24 ).

Figure 24

Reelmaster 5400

1. Dipstick 2. Oil ll cap

4. R emo v e dipstic k and c hec k oil lev el on dipstic k.

T he oil lev el should be up to the Full mark .

5. If the oil lev el is belo w the Full mark, remo v e the ﬁll cap and add oil until lev el reac hes the Full mark on dipstic k.

Do not o v erﬁll.

Page 27

Important: Be sur e to k eep the engine oil lev el betw een the upper and lo w er limits on the oil gauge. Engine f ailur e may occur as a r esult of o v er ﬁlling or under ﬁlling the engine oil.

6. Install the oil ﬁll cap and close the hood.

Checking the Cooling System

Clean debris off of the screen, oil cooler , and front of the radiator daily and more often if conditions are extremely dusty and dir ty . R efer to section on R emo ving Debris from the Cooling System in Cooling System Maintenance , pag e 52 .

T he cooling system is ﬁlled with a 50/50 solution of w ater and per manent eth ylene glycol antifreeze . Chec k the lev el of coolant in the expansion tank at the beginning of eac h da y before star ting the engine . T he capacity of the cooling system is 9.6 quar ts (9 l).

Figure 25

1. Expansion tank

2. If the coolant lev el is lo w , remo v e the expansion tank cap and re plenish the system.

Do not o v erﬁll.

3. Install the expansion tank cap .

If the engine has been r unning , the pr essuriz ed, hot coolant can escape and cause bur ns.

• Do not open the radiator cap when the engine is r unning .

• Use a ra g when opening the radiator cap , and open the cap slo wl y to allo w steam to escape.

1. Chec k the lev el of coolant in the expansion tank ( Figure 25 ).

T he coolant lev el should be betw een the marks on the side of the tank.

Filling the Fuel Tank

1. R emo v e the fuel tank cap ( Figure 26 ).

Figure 26

1. Fuel tank cap

2. Fill the tank to about one inc h belo w the top tank, not the ﬁller nec k, with No . 2 diesel fuel.

Page 28

Under cer tain conditions, diesel fuel and fuel v apor s ar e highl y ﬂamma ble and explosi v e. A ﬁr e or explosion fr om fuel can bur n y ou and other s and can cause pr oper ty dama ge.

• Use a funnel and ﬁll the fuel tank outdoor s, in an open ar ea, when the engine is of f and is cold. W ipe up an y fuel that spills.

• Do not ﬁll the fuel tank completel y full. Add fuel to the fuel tank until the lev el is 1/4 to 1/2 inch (6 to 13 mm) belo w the bottom of the ﬁller neck. T his empty space in the tank allo ws the fuel to expand.

• Nev er smok e when handling fuel, and stay a w ay fr om an open ﬂame or wher e fuel fumes may be ignited by a spar k.

• Stor e fuel in a clean, safety-appr o v ed container and k eep the cap in place.

3. Install the fuel tank cap .

Figure 27

1. Transmission dipstick cap

4. Screw the dipstic k cap into the ﬁller nec k.

5. R emo v e the dipstic k and c hec k lev el of the ﬂuid.

6. If the lev el is not within 1/2 inc h (1.25 cm) from the g roo v e in the dipstic k, add enough ﬂuid to raise the lev el to the g roo v e .

Important: Do not o v erﬁll by mor e than 1/4 inch (6 mm) a bo v e the g r oo v e.

7. Screw the dipstic k cap ﬁng er -tight onto the ﬁller nec k. It is not necessar y to tighten the cap with a wrenc h.

Checking the Transmission Fluid

T he front axle housing acts as the reser v oir for the transmission ﬂuid. T he transmission and axle housing are shipped from the factor y with appro ximately 5 quar ts (4.7 l) of Mobil 424 h y draulic ﬂuid. Ho w ev er , c hec k the lev el of transmission ﬂuid before star ting the engine for the ﬁrst time and daily thereafter .

1. P osition the mac hine on a lev el surface , lo w er the cutting units , and stop the engine .

2. R emo v e the ﬂoor panel.

3. Unscrew the dipstic k cap from the transmission ﬁller nec k ( Figure 27 ) and wipe it with a clean rag .

Checking the Hydraulic Fluid Level

T he mac hine’ s reser v oir is ﬁlled at the factor y with appro ximately 7.5 U .S . g allons (13.2 l) of high quality h y draulic ﬂuid. Check the lev el of

the h y draulic ﬂuid bef or e the engine is ﬁr st star ted and dail y ther eafter . T he recommended

re placement ﬂuid is as follo ws:

Toro Premium Transmission/Hydraulic Tractor Fluid (Available in 5 gallon pails or 55

gallon drums. See parts catalog or Toro distributor for part numbers.)

Alter nate ﬂuids: If the T oro ﬂuid is not a v ailable , other petroleum-based Uni v ersal T ractor Hy draulic Fluids (UTHF) ma y be used, pro vided its speciﬁcations fall within the listed rang e for all the follo wing material proper ties and it meets industr y standards . W e do not recommend the use of synthetic ﬂuid. Consult with y our lubricant distributor to identify a satisfactor y product

Page 29

Note: T oro will not assume responsibility for damag e caused b y improper substitutions , so use only products from re putable man ufacturers who will stand behind their recommendation.

High Viscosity Index/Low Pour Point Anti-wear Hydraulic Fluid, ISO VG 46

Material Properties:

Viscosity, ASTM D445

Viscosity Index ASTM D2270 Pour Point, ASTM D97

Industry Specications:

API GL-4, AGCO Poweruid 821 XL, Ford New Holland FNHA-2-C-201.00, Kubota UDT, John Deere J20C, Vickers 35VQ25 and Volvo WB-101/BM

cSt @ 40°C 55 to 62 cSt @ 100°C 9.1 to 9.8 140 to 152

-35°F to -46°F

Note: Many h y draulic ﬂuids are almost colorless , making it difﬁcult to spot leaks . A red dye additi v e for the h y draulic system oil is a v ailable in 2/3 oz. (20 ml) bottles . One bottle is sufﬁcient for 4-6 g al (15-22 1) of h y draulic oil. Order par t no . 44-2500 from y our authorized T oro distributor .

1. P osition the mac hine on a lev el surface , lo w er the cutting units , and stop the engine .

Checking the Rear Axle Lubricant

Note: T his procedure is for Model 03544 only .

T he rear axle of Model 03544 has three se parate reser v oirs whic h use SAE 80W -90 w eight g ear lube . Although the axle is shipped with lubricant from the factor y , c hec k the lev el before operating the mac hine .

1. P osition the mac hine on a lev el surface .

2. R emo v e the 3 c hec k plugs from axle ( Figure 29 and Figure 30 ) and mak e sure lubricant is up to bottom of eac h hole .

2. Clean the area around the ﬁller nec k and cap of the h y draulic tank ( Figure 28 ).

Figure 28

1. Hydraulic tank cap

3. R emo v e the cap from the ﬁller nec k.

4. R emo v e the dipstic k from the ﬁller nec k and wipe it with a clean rag .

5. Inser t the dipstic k into the ﬁller nec k; then remo v e it and c hec k the ﬂuid lev el.

Figure 29

1. Check plug 2. Fill plug

Figure 30

1. Left check plug (rear of the axle)

T he ﬂuid lev el should be within 1/4 inc h (6 mm) of the mark on the dipstic k.

6. If the lev el is lo w , add the appropriate ﬂuid to raise the lev el to the full mark.

7. Install the dipstic k and cap onto the ﬁller nec k.

3. If the lev el is lo w , remo v e the center ﬁll plug and add enough lubricant to bring the lev el up to the bottom of the center c hec k plug hole .

Page 30

4. R emo v e eac h end c hec k plug and add enough lubricant to bring the lev el up to the bottom of eac h c hec k plug hole .

5. Install all plugs .

Checking the Reel to Bedknife Contact

Eac h da y before operating, c hec k reel to bedknife contact, reg ardless if the quality of cut had previously been acce ptable . T here m ust be light contact across the full length of the reel and the bedknife (refer to Adjusting the R eel to Bedknife in the cutting unit Operator’ s Manual ).

Check the Torque of the Wheel Nuts

T or que the wheel n uts to 75 to 80 ft-lb (102 to 108 N ⋅ m) after 1-4 hour s of operation and ag ain after 10 hour s of operation. T or que ev er y 250 hour s thereafter .

Under cer tain conditions, diesel fuel and fuel v apor s ar e highl y ﬂamma ble and explosi v e. A ﬁr e or explosion fr om fuel can bur n y ou and other s and can cause pr oper ty dama ge.

• Use a funnel and ﬁll the fuel tank outdoor s, in an open ar ea, when the engine is of f and is cold. W ipe up an y fuel that spills.

• Do not ﬁll the fuel tank completel y full. Add fuel to the fuel tank until the lev el is 1/4 to 1/2 in. (6 to 13 mm) belo w the bottom of the ﬁller neck. T his empty space in the tank allo ws the fuel to expand.

• Nev er smok e when handling fuel, and stay a w ay fr om an open ﬂame or wher e fuel fumes may be ignited by a spar k.

• Stor e fuel in a clean, safety-appr o v ed container and k eep the cap in place.

F ailur e to maintain pr oper torque of the wheel n uts could r esult in per sonal injur y .

Bleeding the Fuel System

Y ou m ust bleed the fuel system before star ting the engine if any of the follo wing situations ha v e occur red:

• Initial star t up of a new mac hine .

• Engine has ceased r unning due to lac k of fuel.

• Maintenance has been perfor med upon

fuel system components; i.e ., ﬁlter re placed, se parator ser viced, etc .

1. P ark the mac hine on a lev el surface and ensure that the fuel tank is at least half full.

2. Open the hood.

3. Open the air bleed screw on the fuel injection pump ( Figure 31 ) with a 12 mm wrenc h.

1. Fuel injection pump bleed screw

Figure 31

Page 31

4. T ur n the k ey in the ignition switc h to the On position. T he electric fuel pump will begin operation, thereb y forcing air out around the air bleed screw . Lea v e the k ey in the On position until a solid stream of fuel ﬂo ws out around the screw .

5. Tighten the screw and tur n the k ey to the Off position.

Note: Nor mally , the engine should star t after the abo v e bleeding procedures are follo w ed. Ho w ev er , if engine does not star t, air ma y be trapped betw een injection pump and injectors; refer to Bleeding Air from the Injectors in Fuel System Maintenance , pag e 46 .

Starting and Stopping the Engine

Important: Y ou must bleed the fuel system

bef or e star ting the engine if y ou ar e star ting the engine f or the ﬁr st time, the engine has stopped due to lack of fuel, or y ou ha v e perf or med maintenance on the fuel system; r efer to Bleeding the Fuel System.

Starting the Engine

1. Sit on the seat, k ee p y our foot off of the traction pedal so that it is in Neutral, eng ag e the parking brak e , set the throttle to the F ast position, and ensure that the Enable/Disable switc h is in the Disable position.

Stopping the Engine

1. Mo v e all controls to Neutral, set the parking brak e , and mo v e the throttle to the idle position.

2. T ur n the k ey to the Off position and remo v e it from the switc h.

Important: Allo w the engine to idle f or 5 min utes bef or e shutting it of f after a full load operation. F ailur e to do so may lead to turbo-charger tr ouble.

Setting the Reel Speed

T o ac hiev e a consistent, high quality-of-cut and a unifor m after cut appearance , it is impor tant that y ou set the reel speed controls (located under the seat) cor rectly . Adjust the reel speed controls as follo ws:

1. Select the height-of-cut at whic h the cutting units are set.

2. Choose the desired g round speed best suited for conditions .

3. Using the appropriate g raph on decal 98-9342 ( Figure 32 ) for 5 blade or 8 blade cutting units , deter mine the proper reel speed setting .

2. T ur n the ignition switc h to the On/Preheat position.

An automatic timer will control the glo w plug preheat for 6 seconds .

3. After preheating the glo w plugs , tur n k ey to the Star t position.

Crank the engine for no long er than 15 seconds . R elease the k ey when the engine star ts . If additional preheating is required, tur n k ey to the Off position and then to the On/Preheat position. R e peat this process as required.

4. R un the engine at idle speed or par tial throttle until it w ar ms up .

Note: Mo v e the throttle to the F ast position when restar ting a w ar m engine .

Page 32

Figure 32

Decal 98-9342

1. Reel—height of cut 4. Machine speed

2. Reel—mow and backlap 5. Rear reels circuit controls

3. Read the Operator’s

Manual.

6. Front reels circuit controls

4. T o set the reel speed, rotate knobs ( Figure 33 ) until the indicator ar ro ws are in line with the n umber designating the desired setting .

Figure 33

1. Reel speed control knobs

Note: T he reel speed can be increased or decreased to compensate for turf conditions .

Adjusting the Lift Arm Down Pressure

Y ou can adjust the do wn pressure spring on eac h cutting unit lift ar m to compensate for different turf conditions . Increased do wn pressure will help k ee p the cutting units on the g round when mo wing at higher speeds and helps maintain a unifor m height-of-cut in rough conditions or in areas of thatc h build up .

Y ou can adjust eac h do wn pressure spring to one of four settings . Eac h increment increases or decreases do wn pressure on the cutting unit b y 8 lb (3.6 kg).

1. P osition the mac hine on a lev el surface , lo w er the cutting units , stop the engine , eng ag e the parking brak es , and remo v e the k ey from ignition switc h.

2. R emo v e the ﬂoor plate in front of the seat and open the hood to g ain access to all 5 springs .

T he springs ar e under tension.

Use caution when adjusting them.

3. Place an open end wrenc h on the hex shaft of the spring brac k et ( Figure 34 ).

Page 33

Figure 34

1. Spring bracket hex shaft 2. Retaining bracket

4. R emo v e the bolt and loc kn ut securing retaining brac k et ( Figure 34 ), while rotating the hex shaft to reliev e spring tension.

5. Mo v e the spring brac k et to the desired location and install the bolt and loc kn ut, while rotating the hex shaft to reliev e spring tension.

Towing the Traction Unit

If it becomes necessar y to to w the mac hine , to w it forw ard only , for a shor t distance and at a speed no g reater than 3 mph (4.8 kph).

Figure 35

1. Drive shaft

3. R emo v e the dri v e shaft.

Important: If y ou do not r emo v e the dri v e shaft bef or e to wing , the transmission input shaft will not be a ble to r otate, thus not allo wing the transmission to maintain its inter nal lubrication. Sev er e dama ge to the h y dr ostatic transmission may occur .

4. Attac h a suitable c hain, strap , or cable to the center of the front frame member ( Figure 36 ).

Important: If these to wing limits ar e ex ceeded, sev er e dama ge to the h y dr ostatic transmission may occur .

T o to w a disabled mac hine:

1. Loosen and remo v e the bolts securing the dri v e shaft to the engine dri v e coupler .

2. Loosen the bolts clamping the dri v e shaft to the transmission ( Figure 35 ).

Figure 36

1. Center of front frame member

Note: Loc k both brak e pedals tog ether before to wing .

5. Attac h the other end of the to wing device to a v ehicle that is capable of to wing the mac hine safely and at speeds belo w 3 mph (4.8 kph).

Important: An operator must be on the machine to steer it and k eep the traction pedal full y depr essed in the f orw ard position while to wing .

6. W hen to wing is completed, install the dri v e-shaft as sho wn in Figure 35 . T he splines

Page 34

are designed to allo w assembly only when the tw o halv es of the shaft are properly oriented.

• Loop-bac k is not connected.

• T he light is bur ned out.

Understanding the Diagnostic Light

T he mac hine is equipped with a diagnostic light whic h indicates if the electronic controller is functioning cor rectly . T he g reen diagnostic light is located under the control panel, next to the fuse bloc k ( Figure 37 ). W hen the electronic controller is functioning cor rectly and the k ey switc h is mo v ed to the On position, the controller diagnostic light will be illuminated. T he light will blink if the controller detects a malfunction in the electrical system. T he light will stop blinking and automatically reset when the k ey switc h is tur ned to the Off position.

• Fuses are blo wn.

• It is not functioning cor rectly .

Chec k the electrical connections , input fuses , and diagnostic light bulb to deter mine the malfunction. Ensure that the loop-bac k connector is secured to the wire har ness connector .

Diagnostic Ace Display

T he mac hine is equipped with an electronic controller whic h controls most mac hine functions . T he controller deter mines what function is required for v arious input switc hes (i.e . seat switc h, k ey switc h, etc .) and tur ns on the outputs to actuate solenoids or rela ys for the requested mac hine function.

F or the electronic controller to control the mac hine as desired, eac h of the input switc hes , output solenoids , and rela ys m ust be connected and functioning properly .

Figure 37

1. Diagnostic light

W hen the controller diagnostic light blinks , one of the follo wing problems has been detected b y the controller :

• One of the outputs has been shor ted.

• One of the outputs is open circuited.

Using the diagnostic displa y , deter mine whic h output is malfunctioning; refer to Chec king the Interloc k Switc hes .

Use the Diagnostic A CE displa y to help v erify and cor rect electrical functions of the mac hine .

Checking the Interlock Switches

T he pur pose of the interloc k switc hes are to prev ent the engine from cranking or star ting unless the traction pedal is in the Neutral position, the Enable/Disable switc h is in the Disable position, and the Lo w er Mo w/Raise control is in the Neutral position. In addition, the engine should stop when the traction pedal is pressed with operator off of the seat.

If the diagnostic light is not illuminated when the k ey switc h is in the On position, this indicates that the electronic controller is not operating . P ossible causes are as follo ws:

Page 35

If safety inter lock s witches ar e disconnected or dama ged the machine could operate unexpectedl y causing per sonal injur y .

• Do not tamper with the inter lock s witches.

• Check the operation of the inter lock s witches dail y and r eplace an y dama ged s witches bef or e operating the machine.

• R eplace s witches ev er y tw o y ear s r egardless of whether they ar e operating pr oper l y or not.

Verifying the Interlock Switch Function

1. P ark the mac hine on a lev el surface , lo w er the cutting units , stop the engine , and eng ag e the parking brak e .

2. Open control panel co v er .

Figure 39

1. Diagnostic ACE

6. T ur n the k ey switc h to the On position, but do not star t the mac hine .

3. Locate the wire har ness and connectors near the controller ( Figure 38 ).

Figure 38

1. Wire harness and connectors

4. Carefully unplug loop bac k connector from har ness connector .

5. Connect the Diagnostic A CE displa y connector to the har ness connector ( Figure 39 ).

Note: Mak e sure cor rect o v erla y decal is positioned on Diagnostic A CE displa y .

Note: T he red text on the o v erla y decal refers to input switc hes and the g reen text refers to outputs .

7. T he “inputs displa yed” LED , on the lo w er right column of the Diagnostic A CE, should be illuminated. If the “outputs displa yed” LED is illuminated, press the tog gle button, on Diagnostic A CE, to c hang e LED to “inputs displa yed”.

T he Diagnostic A CE will illuminate the LED associated with eac h of the inputs when that input switc h is closed.

8. Indi vidually , c hang e eac h of the switc hes from open to closed (i.e ., sit on seat, eng ag e traction pedal, etc .), and note that the appropriate LED on Diagnostic A CE will blink on and off when cor responding switc h is closed. R e peat this for all switc hes that y ou can c hang e b y hand.

9. If a switc h is closed and the appropriate LED does not tur n on, c hec k all wiring and connections to the switc h and/or c hec k the switc hes with an ohm meter . R e place any defecti v e switc hes and re pair any defecti v e wiring .

Page 36

Note: T he Diagnostic A CE also has the ability to detect whic h output solenoids or rela ys are tur ned on. T his is a quic k w a y to deter mine if a mac hine malfunction is electrical or h y draulic .

Verifying Output Function

1. P ark the mac hine on a lev el surface , lo w er the cutting units , stop the engine , and eng ag e the parking brak e .

2. Open control panel co v er .

3. Locate wire har ness and connectors near controller .

4. Carefully unplug loopbac k connector from har ness connector .

5. Connect the Diagnostic A CE connector to the har ness connector .

Note: Mak e sure cor rect o v erla y decal is positioned on Diagnostic A CE.

6. T ur n the k ey switc h to the ON position, but do not star t mac hine .

Note: T he red text on the o v erla y decal refers to input switc hes and the g reen text refers to outputs .

7. T he “outputs displa yed” LED , on lo w er right column of Diagnostic A CE, should be illuminated. If the “inputs displa yed” LED is illuminated, press the tog gle button, on the Diagnostic A CE, to c hang e the LED to “outputs displa yed”.

Note: It ma y be necessar y to tog gle betw een “inputs displa yed” and “outputs displa yed” sev eral times to do the follo wing ste p . T o tog gle bac k and for th, press the tog gle button once . T his ma y be done as often as required. Do not hold the button.

Note: If any output LED is blinking, this indicates an electrical problem with that OUTPUT . R e pair or re place defecti v e electrical par ts immediately . T o reset a blinking LED , tur n the k ey switc h the Off position, then bac k to the On position.

If no output LEDs are blinking, but the cor rect output LEDs do not illuminate , v erify that the required input switc hes are in the necessar y positions to allo w that function to occur . V erify cor rect switc h function.

If the output LEDs are on as speciﬁed, but the mac hine does not function properly , this indicates a non-electrical problem. R e pair as necessar y .

Note: Due to electrical system constraints , the output LEDs for “ST AR T”, “PREHEA T”, and “ETR/AL T” ma y not blink ev en though an electrical problem ma y exist for those functions . If the mac hine problem appears to be with one of these functions , be cer tain to c hec k the electrical circuit with a v olt/ohm meter to v erify that no electrical problem exists to these functions .

If eac h output switc h is in the cor rect position and functioning cor rectly , but the output LEDs are not cor rectly illuminated, this indicates an ECU problem. If this occurs , contact y our T oro Distributor for assistance .

Important: T he Dia gnostic ACE display must not be left connected to the machine. It is not designed to withstand the en vir onment of the machine’ s ev er y day use. W hen done using the Dia gnostic ACE, disconnect it fr om the machine and connect loop-back connector to har ness connector . T he machine will not operate without loopback connector installed on the har ness. Stor e the Dia gnostic ACE in dr y , secur e location in the shop , not on the machine.

8. Sit on the seat and attempt to operate the desired function of the mac hine . (If y ou need help v erifying the cor rect input settings for eac h function, refer to Figure 40 ). T he appropriate output LEDs should illuminate to indicate that the ECU is tur ning on that function. (R efer to the logic c har t ( Figure 40 ) to be cer tain of the speciﬁed output LEDs .

Page 37

Diagnostic ACE Logic Grid

Figure 40

Page 38

Hydraulic Valve Solenoid Functions

Use the list belo w to identify and describe the different functions of the solenoids in the h y draulic manifold. Eac h solenoid m ust be energized to allo w function to occur .

Solenoid Function

S1 S2 S3 S4 S5 S6 S7

S8, S9

Front reel circuit Rear reel circuit Lift/lower front wing cutting units Lift/lower center cutting unit Lift/lower rear cutting unit Lower any cutting units Lift any cutting units Backlap any cutting units

Operating Tips

Familiarization

Before mo wing g rass , practice operating the mac hine in an open area. Star t and stop the engine . Operate in forw ard and rev erse . Lo w er and raise the cutting units and eng ag e and diseng ag e the reels . W hen y ou feel familiar with the mac hine , practice operating up and do wn slopes at different speeds .

before contin uing operation. Serious damag e could occur if y ou operate the mac hine with a malfunction.

Mowing

Star t the engine and mo v e the throttle to the F ast position. Mo v e the Enable/Disable switc h to the Enable position and use the Lo w er Mo w/Raise lev er to control the cutting units (the front cutting units are timed to lo w er before the rear cutting units). T o mo v e forw ard and cut g rass , press the traction pedal forw ard.

Note: Allo w the engine to idle for 5 min utes before shutting it off after a full load operation. F ailure to do so ma y lead to turbo-c harg er trouble .

Transport

Mo v e the Enable/Disable switc h to the Disable position and raise the cutting units to the transpor t position. Be careful when dri ving betw een objects so y ou do not accidentally damag e the mac hine or cutting units . Use extra care when operating the mac hine on slopes . Dri v e slo wly and a v oid shar p tur ns on slopes to prev ent roll o v ers . Lo w er the cutting units when g oing do wnhill for steering control.

T he brak es can be used to assist in tur ning the mac hine . Ho w ev er , use them carefully , especially on soft or w et g rass conditions because the turf ma y be tor n accidentally . Y ou ma y also use indi vidual tur ning brak es to help maintain traction. F or example , in some slope conditions , the uphill wheel slips and loses traction. If this situation occurs , press the uphill tur n pedal g radually and inter mittently until the uphill wheel stops slipping, thus , increasing traction on the do wnhill wheel.

W hen operating the machine, al w ays use the seat belt and R OPS to gether .

Warning System

If a w ar ning light comes on during operation, stop the mac hine immediately and cor rect the problem

Page 39

Maintenance

Note: Deter mine the left and right sides of the mac hine from the nor mal operating position.

Recommended Maintenance Schedule(s)

Maintenance Service

Interval

After the rst operating

hour

After the rst 8 operating

hours

After the rst 10

operating hours

After the rst 50

operating hours

After the rst 200

operating hours

Before each use or daily

Maintenance Procedure

•

Torque the wheel lug nuts to 75 to 80 ft-lb (102 to 108 N ⋅ m).

• Check the condition and tension of the alternator belt.

• Check the condition and tension of the cooling fan belt.

•

Torque the wheel lug nuts to 75 to 80 ft-lb (102 to 108 N ⋅ m).

• Change the engine oil and lter.

• Check the engine RPM (idle and full throttle).

• Replace the transmission oil lter.

• Check the engine oil level.

• Check the cooling system.

• Check the transmission uid.

• Check the hydraulic uid level.

• Check the rear axle lubricant (Model 03544 only).

• Check the reel to bedknife contact.

• Check the operation of the interlock switches.

• Inspect the air cleaner for damage and check the service indicator. If it is red, service the air cleaner.

• Check and clean out the air lter precleaner bowl (more often in dusty and dirty conditions).

• Drain water and other contaminants from the fuel lter/water separator.

• Remove debris from the screen, oil coolers, and radiator (more frequently in dirty operating conditions).

• Check the hydraulic lines and hoses for leaks, kinked lines, loose mounting supports, wear, loose ttings, weather deterioration, and chemical deterioration.

Every 50 hours

Every 100 hours

Every 150 hours

Every 200 hours

Every 250 hours

• Grease the bearings and bushings.

• Check the condition of and clean the battery.

• Check the battery cable connections.

• Inspect the cooling system hoses.

• Check the condition and tension of the alternator belt.

• Check the condition and tension of the cooling fan belt.

• Change the engine oil and lter.

• Lubricate the front axle bearings.

• Drain moisture from the fuel and hydraulic uid tanks.

• Check the reel bearing preload.

•

Torque the wheel lug nuts to 75 to 80 ft-lb (102 to 108 N ⋅ m).

Page 40

Maintenance Service

Interval

Every 400 hours

Every 800 hours

Every 2 years

Maintenance Procedure

• Check the fuel lines and connections for deterioration, damage, or loose connections.

• Replace the fuel lter canister.

• Replace the fuel prelter.

• Check the traction linkage movement.

• Check the engine RPM (idle and full throttle).

• Change the transmission uid.

• Replace the transmission lter.

• Change the rear axle lubricant (Model 03544 only)

• Check the rear wheel toe-in.

• Change the hydraulic uid.

• Change the hydraulic lter (sooner if the service interval indicator on the lter head is in the Red zone).

• Pack the rear wheel bearings (2-wheel drive only)

• Adjust the engine valves (refer to the engine Operator’s Manual)

• Drain and clean the fuel tank.

• Flush and replace the cooling system uid.

• Drain and ush the hydraulic tank.

• Replace all moving hoses.

• Replace the safety interlock switches

Important: R efer to y our Engine Operator’ s Man ual f or additional maintenance pr ocedur es.

Page 41

Daily Maintenance Checklist

Duplicate this page for routine use.

Maintenance Check Item

For the week of:

Mon. Tues.

Check the safety interlock operation. Check the brake operation. Check the engine oil and fuel level. Drain the water/fuel separator. Check the air lter restriction indicator. Check the radiator and screen for debris. Check unusual engine noises.

Check unusual operating noises. Check the transmission oil level. Check the hydraulic system oil level. Check the hydraulic lter indicator.

Check hydraulic hoses for damage. Check for uid leaks. Check the tire pressure. Check the instrument operation. Check the reel-to-bedknife adjustment. Check the height-of-cut adjustment. Check the shear pins on the cutting units. Lubricate all grease ttings.

Touch-up damaged paint.

1 . C h e c k t h e g l o w p l u g a n d i n j e c t o r n o z z l e s i f h a r d s t a r t i n g , e x c e s s s m o k e , o r r o u g h r u n n i n g i s n o t e d . 2 . C h e c k w i t h t h e e n g i n e r u n n i n g a n d t h e o i l a t o p e r a t i n g t e m p e r a t u r e . 3 . I m m e d i a t e l y a f t e r e v e r y w a s h i n g , r e g a r d l e s s o f t h e i n t e r v a l l i s t e d .

Wed. Thurs.

Fri.

Sat. Sun.

Notation for Areas of Concern

Inspection performed by:

Item Date

1 2 3 4 5 6 7 8

Information

Page 42

Service Interval Chart

1. Read the Operator’s Manual.

Figure 41

If y ou lea v e the k ey in the ignition s witch, someone could accidentl y star t the engine and seriousl y injur e y ou or other bystander s.

R emo v e the k ey fr om the ignition bef or e y ou do an y maintenance.

Lubrication

Greasing the Bearings and Bushings

If y ou operate the mac hine under nor mal conditions , lubricate all g rease ﬁttings for the bearings and bushings after ev er y 50 hour s of operation with No . 2 General Pur pose Lithium Base Grease . Lubricate bearings and bushings immediatel y after ev er y w ashing, reg ardless of the inter v al listed.

T he g rease ﬁtting locations and quantities are as follo ws:

• 3 ﬁttings on the engine dri v e shaft ( Figure 42 )

• 2 ﬁttings on eac h cutting unit car rier frame and

pi v ot (10 total) ( Figure 43 )

Figure 42

Page 43

Figure 43

• 5 ﬁttings on the lift ar m pi v ots ( Figure 44 )

• 1 ﬁtting on the dri v e shaft clutc h ( Figure 44 )

Figure 45

• 1 ﬁtting on the traction control linkag e at the transmission ( Figure 46 )

• 1 ﬁtting on the dri v e shaft suppor t bearing ( Figure 46 )

• 3 ﬁttings on the rear axle dri v e shaft ( Figure 46 )

Figure 46

Figure 44

• 2 ﬁttings on the rear axle tie rod ( Figure 45 )

• 2 ﬁttings on the steering cylinder ball joints

( Figure 45 )

• 2 ﬁttings on the axle steering pi v ots ( Figure 45 )

• 2 ﬁttings on the rear axle pi v ot ( Figure 45 )

• 1 ﬁtting on the brak e pedal ( Figure 47 )

Figure 47

• 5 ﬁttings on the lift cylinders ( Figure 48 )

Page 44

Figure 48

• 1 ﬁtting on the fan shaft ( Figure 49 ).

1. R emo v e the thumb screw and se parate the co v er from the precleaner bo wl ( Figure 50 ).

Figure 50

1. Air cleaner indicator

2. Precleaner bowl

3. Dust cap

2. Empty the precleaner bo wl and wipe it clean.

3. Assemble and install the precleaner bo wl, co v er , and thumb screw .

Figure 49

Engine Maintenance

Servicing the Air Cleaner

General Air Cleaner Maintenance

• Chec k the air cleaner body for damag e whic h could cause an air leak. R e place it if it is damag ed. Chec k the whole intak e system for leaks , damag e , or loose hose clamps .

• Ser vice the air cleaner ﬁlter only when the ser vice indicator requires it (tur ns red). Changing the air ﬁlter before it is necessar y only increases the c hance of dir t entering the engine when the ﬁlter is remo v ed.

• Be sure the co v er is seated cor rectly and seals with the air cleaner body .

Servicing the Air Cleaner Precleaner Bowl

Nor mally , inspect the precleaner bo wl daily . W hen conditions are extremely dusty and dir ty , inspect it more frequently . Do not let dust or debris build up abo v e the lev el mark ed on the precleaner bo wl.

Note: W hen operating the mac hine in extremely dusty conditions , an optional extension tube (T oro P ar t No . 43-3810), whic h raises precleaner bo wl abo v e the hood, thus , lengthening the time betw een precleaner bo wl ser vicing, is a v ailable from y our local authorized T oro Distributor .

Servicing the Air Cleaner

Only ser vice the air cleaner when the ser vice indicator on the air cleaner housing tur ns red ( Figure 50 ).

1. R elease the latc hes and remo v e the co v er from the air cleaner body ( Figure 50 ).

2. Before remo ving the ﬁlter , use lo w pressure air (40 psi, clean and dr y) to help remo v e larg e accum ulations of debris pac k ed betw een the outside of the primar y ﬁlter and the canister .

Important: A v oid using high pr essur e air which could f orce dir t thr ough the ﬁlter into the intak e tract. T his cleaning pr ocess pr ev ents de bris fr om mig rating into the intak e when the primar y ﬁlter is r emo v ed.

3. R emo v e and re place the primar y ﬁlter ( Figure 51 ).

Cleaning of the used element is not recommended due to the possibility of damag e to the ﬁlter media.

Page 45

1. R emo v e the drain plug ( Figure 52 ) and let the oil ﬂo w into a drain pan.

Figure 52

1. Engine oil drain plug

Figure 51

1. Filter element

4. Inspect the new ﬁlter for shipping damag e , c hec king the sealing end of the ﬁlter and the body .

Important: Do not use a dama ged element.

5. Inser t the new ﬁlter b y applying pressure to the outer rim of the element to seat it in the canister .

Important: Do not appl y pr essur e to the ﬂexible center of the ﬁlter .

6. Clean the dir t ejection por t located in the remo v able co v er . R emo v e the r ubber outlet v alv e from the co v er , clean the ca vity , and re place the outlet v alv e .

7. Install the co v er orienting the r ubber outlet v alv e in a do wnw ard position—betw een appro ximately 5:00 to 7:00 when view ed from the end.

2. W hen the oil stops , install the drain plug .

3. R emo v e the oil ﬁlter ( Figure 53 ).

Figure 53

1. Engine oil lter

4. Apply a light coat of clean oil to the new ﬁlter seal.

5. Install the re placement oil ﬁlter to the ﬁlter adapter . T ur n the oil ﬁlter cloc kwise until the r ubber g ask et contacts the ﬁlter adapter , then tighten the ﬁlter an additional 1/2 tur n.

8. Secure the co v er latc hes .

9. R eset the indicator ( Figure 50 ) if it is sho wing red.

Servicing the Engine Oil and Filter

Chang e the engine oil and ﬁlter initially after the ﬁrst 50 hours of operation and ev er y 150 hours thereafter .

Important: Do not o v er -tighten the ﬁlter .

6. Add oil to the crankcase; refer to Chec king the Engine Oil in Operation , pag e 26 .

Adjusting the Throttle

1. P osition the throttle lev er forw ard so that it stops ag ainst the seat base slot.

2. Loosen the throttle cable connector on the lev er ar m at the injection pump .

Page 46

3. Hold the injection pump lev er ar m ( Figure 54 ) ag ainst the high idle stop and tighten the cable connector .

Note: W hen tightened, the cable connector m ust be free to swi v el.

Figure 54

1. Injection pump lever arm

Draining the Fuel Tank

Drain and clean the fuel tank ev er y 2 years . Also , drain and clean the tank if the fuel system becomes contaminated or if the mac hine is to be stored for an extended period. Use clean fuel to ﬂush out the tank.

Checking the Fuel Lines and Connections

Chec k the fuel lines and connections ev er y 400 hours or yearly , whic hev er comes ﬁrst. Inspect them for deterioration, damag e , or loose connections .

Draining the Fuel Filter/Water Seperator

4. T or que the loc kn ut used to set the friction device on the throttle lev er to 40-55 in-lb (4.5 to 6 N ⋅ m). T he maxim um force required to operate the throttle lev er should be 20 lb (9 kg).

Fuel System Maintenance

Under cer tain conditions, diesel fuel and fuel v apor s ar e highl y ﬂamma ble and explosi v e. A ﬁr e or explosion fr om fuel can bur n y ou and other s and can cause pr oper ty dama ge.

• Use a funnel and ﬁll the fuel tank outdoor s, in an open ar ea, when the engine is of f and is cold. W ipe up an y fuel that spills.

• Nev er smok e when handling fuel, and stay a w ay fr om an open ﬂame or wher e fuel fumes may be ignited by a spar k.

• Stor e fuel in a clean, safety-appr o v ed container and k eep the cap in place.

Drain w ater or other contaminants from the fuel ﬁlter/w ater se parator ( Figure 55 ) daily .

Figure 55

1. Fuel lter canister/water separator

1. Locate the fuel ﬁlter , under the h y draulic tank, and place a clean container under it.

2. Loosen the drain plug on the bottom of the ﬁlter canister and allo w it to drain.

3. W hen ﬁnished, tighten the drain plug .

2. Drain plug

Page 47

Replacing the Fuel Filter

Bleeding Air from the Fuel

Canister

R e place the ﬁlter canister after ev er y 400 hours of operation.

1. Clean the area where the ﬁlter canister mounts ( Figure 55 ).

2. R emo v e the ﬁlter canister and clean the mounting surface ( Figure 55 ).

3. Lubricate the g ask et on the new ﬁlter canister with clean oil.

4. Install the ﬁlter canister b y hand until the g ask et contacts the mounting surface , then rotate it an additional 1/2 tur n ( Figure 55 ).

Replacing the Fuel Prelter

R e place the fuel preﬁlter after ev er y 400 operating hours or yearly , whic hev er occurs ﬁrst.

1. R emo v e the screw securing the preﬁlter to the frame rail.

2. Clamp both fuel lines that connect to the fuel preﬁlter so that the fuel cannot drain when y ou remo v e the lines .

Injectors

Note: T his procedure should be used only if the

fuel system has been purg ed of air through nor mal priming procedures and the engine will not star t; refer to Bleeding the Fuel System in Operation , pag e 26 .

1. Loosen the pipe connection to the No . 1 nozzle and holder assembly ( Figure 57 ).

3. Loosen the hose clamps at both ends of the preﬁlter and pull the fuel lines off of it ( Figure 56 ).

Figure 56

1. Fuel prelter 2. Hose clamps

4. Slide the hose clamps onto ends of the fuel lines .

5. Push the fuel lines onto the new preﬁlter and secure them with the hose clamps ( Figure 56 ).

Important: Ensur e that the ar r o w on the side of the pr eﬁlter points to w ard the injection pump .

Figure 57

1. Fuel injector nozzle and holder assemblies

2. Mo v e the throttle to the F ast position.

3. T ur n the k ey in the k ey switc h to the Star t position and w atc h the fuel ﬂo w around the connector . W hen y ou obser v e a solid ﬂo w of fuel, tur n the k ey to the Off position.

4. Tighten the pipe connector securely .

5. R e peat ste ps 1 through 4 on the remaining nozzles .

Electrical System Maintenance

Important: Bef or e w elding on the machine, disconnect both ca bles fr om the batter y , both wir e har ness plugs fr om the electr onic contr ol unit, and the ter minal connector fr om the alter nator to pr ev ent dama ge to the electrical system.

Page 48

Servicing the Battery

Warning

CALIFORNIA

Pr oposition 65 W ar ning

Batter y electr ol yte contains sulfuric acid which is a deadl y poison and causes sev er e bur ns.

• Do not drink electr ol yte and a v oid contact with skin, ey es, or clothing . W ear safety g lasses to shield y our ey es and r ub ber g lo v es to pr otect y our hands.

Figure 58

1. Fuses

• Fill the batter y wher e clean w ater is al w ays a v aila ble f or ﬂushing the skin.

Charging the batter y pr oduces gasses that can explode.

Nev er smok e near the batter y and k eep spar ks and ﬂames a w ay fr om it.

Chec k the batter y condition w eekly or after ev er y 50 hours of operation. K ee p the ter minals and the entire batter y case clean because a dir ty batter y will disc harg e slo wly . T o clean the batter y , w ash the entire case with a solution of baking soda and w ater . Rinse it with clear w ater . Coat the batter y posts and cable connectors with Grafo 112X (skin-o v er) g rease (T oro P ar t No . 505-47) or petroleum jelly to prev ent cor rosion.

Fuses

Figure 59

1. Read the Operator’s

Manual.

2. Headlights

3. Engine—start

Optional Lighting

Important: If y ou add optional lighting

to the machine, use the f ollo wing schematic and par t n umber s to pr ev ent dama ge to the electrical system.

T here are 4 fuses in the electrical system. T hey are located belo w the control panel ( Figure 58 and Figure 59 ).

Page 49

1. Traction adjustment cam

Figure 61

Figure 60

Note: Mak e sure a g ood g round is ac hiev ed to

prev ent damag e to mac hine .

Drive System Maintenance

Adjusting the Traction Drive for Neutral

T he mac hine m ust not cree p when traction pedal is released. If it does cree p , an adjustment adjust it as follo ws:

1. P ark the mac hine on a lev el surface , stop the engine , and lo w er the cutting units to the ﬂoor . Press only the right brak e pedal and eng ag e the parking brak e .

2. J ac k up the left side of the mac hine until the front tire is off the shop ﬂoor . Suppor t the mac hine with jac k stands to prev ent it from falling accidentally .

Note: On 4-wheel dri v e models , the left, rear tire m ust also be off the shop ﬂoor or the 4-wheel dri v e , dri v e-shaft m ust be remo v ed.

T he engine must be r unning so the ﬁnal adjustment of the traction adjustment cam can be perf or med. T his could cause per sonal injur y .

K eep hands, feet, f ace, and other body par ts a w ay fr om the muf ﬂer , other hot par ts of the engine, and an y r otating par ts.

4. Star t the engine and rotate the cam hex in either direction until the wheel ceases rotation.

5. Tighten the loc kn ut to secure the adjustment.

6. Stop the engine and release the right brak e . R emo v e the jac k stands and lo w er the mac hine to the shop ﬂoor .

7. T est dri v e the mac hine to mak e sure it does not cree p .

Checking and Adjusting the Traction Linkage

Due to nor mal w ear in the control linkag e and h y drostatic transmission, an increased amount of force ma y be required to retur n the transmission to neutral. P eriodically c hec k the mac hine .

1. P ark the mac hine on a lev el surface , lo w er the cutting units to the ﬂoor , and stop the engine .

3. Under the right side of the mac hine , loosen the loc kn ut on the traction adjustment cam ( Figure 61 ).

2. Connect the brak e pedals tog ether with the loc king pin, push both pedals do wn, and pull the parking brak e latc h out.

Page 50

3. Loosen the inner loc kn ut securing the eye bolt to the spring anc hor plate ( Figure 62 ).

Figure 62

1. Spring anchor plate 4. Outer locknut

2. Eye bolt 5. Shorten distance to decrease time required to stop machine.

3. Inner locknut

4. R otate the outer loc kn ut cloc kwise until the distance betw een the inside of the eye bolt loop and the inside of the spring anc hor plate is shor tened 1/8 inc h, as sho wn in Figure 62 . Tighten the inner loc kn ut.

5. Operate the mac hine and c hec k the stopping distance . R e peat procedure if required.

Note: Shor tening the distance betw een the inside of eye bolt loop and inside of the spring anc hor plate increases the pedal force on the traction pedal. T herefore , do not o v er adjust.

Changing the Transmission

Figure 63

1. Transmission suction line 2. Transmission oil lter

3. R emo v e the line from the transmission allo wing the ﬂuid to drain into the drain pan.

4. Install the suction line to the transmission.

5. Fill the transmission with oil; refer to Chec king the T ransmission Fluid in Operation , pag e 26 .

6. Before star ting the engine , after c hanging the transmission ﬂuid, disconnect the r un (ETR) solenoid on the engine , and crank the engine for 15 seconds . T his allo ws the c harg e pump to ﬁll the transmission with ﬂuid before y ou star t the engine .

Replacing the Transmission Oil Filter

R e place the transmission ﬁlter initially after the ﬁrst 200 operating hours and ev er y 800 operating hours or ann ually , whic hev er occurs ﬁrst, thereafter .

Fluid

Chang e the transmission ﬂuid after ev er y 800 hours of operation or ann ually , whic hev er occurs ﬁrst, in nor mal conditions .

1. P osition the mac hine on a lev el surface , lo w er the cutting units , stop the engine , eng ag e the parking brak es , and remo v e the k ey from the ignition switc h.

2. Clean the area around the suction line on the bottom of the transmission ( Figure 63 ) and place a drain pan under the line .

Only the T oro re placement ﬁlter (P ar t No . 110-4146) can be used in the h y draulic system.

Important: Use of an y other ﬁlter may v oid the w ar ranty on some components.

1. P osition the mac hine on a lev el surface , lo w er the cutting units , stop the engine , eng ag e the parking brak es , and remo v e the k ey from the ignition switc h.

2. Clean the area around the ﬁlter mounting area ( Figure 63 ) and place drain pan under ﬁlter .

3. R emo v e the ﬁlter .

4. Lubricate the g ask et on the new ﬁlter with h y draulic oil.

Page 51

5. Ensure that the ﬁlter mounting area is clean.

6. Install the ﬁlter b y hand until the g ask et contacts the mounting surface , then rotate it an additional 1/2 tur n.

7. Star t the engine and let it r un for about tw o min utes to purg e air from the system.

8. Stop the engine and c hec k for leaks .

9. Chec k the transmission ﬂuid lev el and re plenish it if necessar y .

Changing the Rear Axle Lubricant

Note: T his procedure is for model 03544 only .

Chang e the oil in the rear axle after ev er y 800 operating hours .

1. P osition the mac hine on a lev el surface .

2. Clean the area around the drain plugs ( Figure 64 ).

of the steering tires . If the toe-in is not within speciﬁcations , adjust it as described belo w for y our model.

Chec k the rear wheel toe-in after ev er y 800 operating hours or ann ually .

Models 03540 and 03543

1. R otate the steering wheel so that the rear wheels are straight ahead.

2. Loosen the jam n uts on both tie rods ( Figure 65 ).

Figure 64

1. Drain plugs

3. R emo v e the plugs , allo wing the oil to drain into drain pans .

4. After the oil is drained, apply thread loc king compound to the drain plug threads and install them in the axle .

5. Fill the axle with lubricant; refer to Chec king the R ear Axle Lubricant in Operation , pag e 26 .

Adjusting the Rear Wheel Toe-in

Figure 65

1. Tie rods

3. Adjust both tie rods equally until the center -to-center distance at the front of the rear wheels is 0 to 1/8 inc h (0 to 3 mm) less than at the rear of the wheels .

4. W hen toe-in is cor rect, tighten the jam n uts ag ainst the tie rods .

Model 03544

1. R otate the steering wheel so that the rear wheels are straight ahead.

2. R emo v e the cotter pin and slotted hex n ut from either tie rod ball joint. Use a ball joint fork and remo v e the tie rod ball joint from the axle case suppor t.

3. Loosen the clamps on both ends of the tie rod ( Figure 66 ).

T he rear wheels should ha v e 0 to 1/8 inc h (0 to 3 mm) toe-in when they are pointed straight ahead. T o c hec k the toe-in, measure the center -to-center distance , at axle height, in the front and rear

Page 52

Figure 66

1. Tie rod

4. R otate the detac hed ball joint inw ard or outw ard 1 complete rev olution. Tighten the clamp at the loose end of the tie rod.

5. R otate the entire tie rod assembly the same direction (inw ard or outw ard) 1 complete rev olution. Tighten the clamp at the connected end of the tie rod.

6. Install the ball joint in the axle case suppor t and tighten the slotted hex n ut ﬁng er tight.

7. Measure the distance at the front and rear of the rear wheels at axle height. T he distance at the front of the rear wheels should be 0 to 1/8 inc h (0 to 3 mm) less than the distance measured at the rear of the wheels .

Figure 67

1. Screen

4. Clean the screen thoroughly with compressed air .

5. Slightly raise the oil coolers and pi v ot themforw ard ( Figure 67 ).

6. T horoughly clean both sides of the oil coolers and the radiator area with compressed air .

7. Pi v ot the oil coolers bac k into position.

8. Install the screen and close the hood.

Brake Maintenance

8. R e peat ste ps 3 through 7 if necessar y .

9. Tighten the ball joint hex n ut and install a new cotter pin.

Cooling System Maintenance

Removing Debris from the Cooling System

R emo v e debris from the screen, oil coolers , and radiator daily (clean more frequently in dir ty conditions).

1. T ur n the engine off and raise the hood.

2. T horoughly clean all debris out of the engine area.

3. Loosen the clamps and pull up on the screen to slide it out of the mounting trac ks ( Figure 67 ).

Adjusting the Service Brakes

Adjust the ser vice brak es when there is more than 1 inc h of free tra v el of the brak e pedal, or when the brak es do not w ork effecti v ely . F ree tra v el is the distance the brak e pedal mo v es before y ou feel braking resistance .

1. Diseng ag e the loc king pin from brak e pedals so that both pedals w ork inde pendently of eac h other .

2. T o reduce free tra v el of the brak e pedals , tighten the brak es b y loosening the front n ut on the threaded end of the brak e cable ( Figure 68 ).

Page 53

Figure 68

1. Brake cables

3. Tighten the rear n ut to mo v e the cable bac kw ard until brak e pedals ha v e 1/2 to 1 inc h (1.25 to 2.5 cm) of free tra v el.

4. Tighten the front n uts .

Figure 69

1. Alternator belt

3. Loosen the bolt securing the brace to the engine ( Figure 69 ) and the bolt securing the alter nator to the brace .

2. Brace

Belt Maintenance

Chec k the condition and tension of all belts after the ﬁrst da y of operation and ev er y 100 operating hours thereafter .

Tensioning the Alternator Belt

1. Open the hood.

2. Chec k the tension of the alter nator belt b y de pressing it ( Figure 69 ) midw a y betw een the alter nator and the crankshaft pulleys with 22 lb (10 kg) of force .

T he belt should deﬂect 7/16 inc h (11 mm). If the deﬂection is incor rect, proceed to ste p 3 . If cor rect, contin ue operation.

4. Inser t a pr y bar betw een the alter nator and the engine and pr y out on the alter nator .

5. W hen y ou ac hiev e the proper tension, tighten the alter nator and brace bolts to secure the adjustment.

Tensioning the Cooling Fan Belt

1. Loosen the loc kn ut on the belt tensioner lev er ( Figure 70 ).

Page 54

Figure 71

1. Hydraulic uid reservoir

R emo v e the drain plug from the bottom of the h y draulic ﬂuid reser v oir ( Figure 71 ) and let the h y draulic ﬂuid ﬂo w into the drain pan.

Figure 70

1. Cooling fan belt 2. Tensioner lever

2. Apply 5 to 10 lb (2.25 to 4.5 kg) of force at end of lev er to set the proper tension on the fan belt.

3. Tighten the loc kn ut to secure the adjustment.

Hydraulic System Maintenance

Changing the Hydraulic Fluid

Chang e h y draulic ﬂuid after ev er y 800 operating hours , in nor mal conditions . If ﬂuid becomes contaminated, contact y our local T oro distributor because the system m ust be ﬂushed. Contaminated ﬂuid looks milk y or blac k when compared to clean oil.

1. Stop the engine and raise the hood.

2. Place a larg e drain pan under the drain plug under the h y draulic ﬂuid reser v oir ( Figure 71 ).

3. Install and tighten the plug when h y draulic ﬂuid stops draining .

4. Fill the reser v oir with appro ximately 8.5 U .S . g allons (32 l) of h y draulic ﬂuid; refer to Chec king the Hy draulic Fluid in Operation , pag e 26 .

Important: Use onl y h y draulic ﬂuids speciﬁed. Other ﬂuids could cause system dama ge.

5. Install the reser v oir cap .

6. Star t the engine and use all of the h y draulic controls to distribute h y draulic ﬂuid throughout the system. Also c hec k for leaks .

7. Stop the engine .

8. Chec k the lev el of the h y draulic ﬂuid and add enough to raise lev el to the Full mark on the dipstic k.

Important: Do not o v er -ﬁll.

Replacing the Hydraulic Filter

T he h y draulic system ﬁlter head is equipped with a ser vice inter v al indicator . With the engine r unning, view the indicator , it should be in the Green zone . W hen the indicator is in the R ed zone , the c hang e the h y draulic ﬁlter .

Use the T oro re placement ﬁlter (P ar t No . 75-1310).

Important: Use of an y other ﬁlter may v oid the w ar ranty on some components.

Page 55

1. P osition the mac hine on a lev el surface , lo w er the cutting units , stop the engine , eng ag e the parking brak es , and remo v e the k ey from the ignition switc h.

Hy draulic ﬂuid escaping under pr essur e can penetrate skin and cause injur y .

2. Clean the area around the ﬁlter mounting area ( Figure 72 ) and place drain pan under ﬁlter .

Figure 72

1. Hydraulic lter

3. R emo v e the ﬁlter .

• Mak e sur e all h y draulic ﬂuid hoses and lines ar e in good condition and all h y draulic connections and ﬁttings ar e tight bef or e appl ying pr essur e to the h y draulic system.

• K eep y our body and hands a w ay fr om pin hole leaks or nozzles that eject high pr essur e h y draulic ﬂuid.

• Use cardboard or paper to ﬁnd h y draulic leaks.

• Safel y r eliev e all pr essur e in the h y draulic system bef or e perf or ming an y w or k on the h y draulic system.

• Get immediate medical help if ﬂuid is injected into skin.

Hydraulic System Test Ports

Use the h y draulic system test por ts to test the pressure in the h y draulic circuits . Contact y our local T oro distributor for assistance .

4. Lubricate the g ask et on the new ﬁlter with h y draulic oil.

5. Ensure that the ﬁlter mounting area is clean.

6. Install the ﬁlter b y hand until the g ask et contacts the mounting surface , then rotate it an additional 1/2 tur n.

7. Star t the engine and let it r un for about tw o min utes to purg e air from the system.

8. Stop the engine and c hec k for leaks .

Checking the Hydraulic Lines and Hoses

Daily , c hec k h y draulic lines and hoses for leaks , kink ed lines , loose mounting suppor ts , w ear , loose ﬁttings , w eather deterioration, and c hemical deterioration. Mak e all necessar y re pairs before operating .

Use T est P or t #1 ( Figure 73 ) to assist in troubleshooting the h y draulic circuit for the front cutting units and lift cylinders .

Use T est P or t #2 ( Figure 73 ) to assist in troubleshooting the h y draulic circuit for the rear cutting units .

Use T est P or t #3 (not sho wn—located on the rear of the h y drostatic transmission) used to measure the c harg e pressure of the transmission.

Page 56

Figure 73

1. Test port #1

2. Test port #2

Cutting Unit System Maintenance

Adjusting the Cutting Unit Lift Rate

T he cutting unit lift circuit is equipped with 3 adjustable v alv es used to ensure that the cutting units do not raise too quic kly and bang ag ainst the lift stops . Adjust the cutting unit lift rate as follo ws:

Adjusting the Center Cutting Unit

1. Locate the v alv e behind the access panel abo v e the operator’ s platfor m ( Figure 74 ).

Figure 74

1. Center cutting unit adjustment valve

2. Loosen the setscrew on the v alv e and rotate the v alv e appro ximately 1/2 tur n cloc kwise .

3. V erify the lift rate adjustment b y raising and lo w ering the cutting unit sev eral times . Adjust as required.

4. After attaining the desired lift rate , tighten the setscrew to loc k the adjustment.

Adjusting the Outside Front Cutting Units

1. Locate the v alv e on the ﬂo w di vider (under the foot rest) ( Figure 75 ).

Figure 75

1. Outside front cutting units adjustment valve

Page 57

2. Loosen the setscrew on the v alv e and rotate the v alv e appro ximately 1/2 tur n cloc kwise .

3. V erify the lift rate adjustment b y raising and lo w ering the cutting unit sev eral times . Adjust as required.

4. After attaining the desired lift rate , tighten the setscrew to loc k the adjustment.

Adjusting the Rear Cutting Units

Note: W hen bac klapping, the front units all

operate tog ether , and the rear units operate tog ether .

1. P osition the mac hine on a lev el surface , lo w er the cutting units , stop the engine , eng ag e the parking brak e , and mo v e the Enable/Disable switc h to disable position.

2. Unloc k and raise the seat to expose the controls .

1. Raise the hood and locate the v alv e on left, rear side of the mac hine ( Figure 76 ).

Figure 76

1. Rear cutting units adjustment valve

2. Loosen the setscrew on the v alv e and rotate the v alv e appro ximately 1/2 tur n cloc kwise .

3. V erify the lift rate adjustment b y raising and lo w ering the cutting unit sev eral times . Adjust as required.

4. After attaining the desired lift rate , tighten the setscrew to loc k the adjustment.

3. Mak e initial reel to bedknife adjustments appropriate for bac klapping on all cutting units whic h are to be bac klapped; refer to the cutting unit Operator’ s Manual .

4. Star t the engine and r un at idle speed.

Changing the engine speed while backlapping may cause the r eels to stall.

• Nev er change the engine speed while backlapping .

• Onl y backlap at idle engine speed.

5. Set both reel speed controls to position 11.

6. Select either front or rear on the bac klap switc h to deter mine whic h units to bac klap .

T o a v oid per sonal injur y , be cer tain that y ou ar e clear of the cutting units bef or e pr oceeding .

7. Mo v e the Enable/Disable switc h to the Enable position. Mo v e the Lo w er Mo w/Lift control forw ard to star t the bac klapping operation on the designated reels .

Backlapping the Cutting Units

Contact with the r eels or other mo ving par ts can r esult in per sonal injur y .

• K eep ﬁnger s, hands, and clothing a w ay fr om the r eels or other mo ving par ts.

• Nev er attempt to tur n the r eels by hand or f oot while the engine is r unning .

8. F or the cutting units being bac klapped, mo v e the reel speed control to position 1.

9. Apply lapping compound with the long handle br ush supplied with mac hine . Nev er use a shor t handled br ush.

10. If the reels stall or become er ratic while bac klapping, select a higher speed setting until the speed stabilizes , then retur n the reel speed to setting 1 or to y our desired speed.

11. T o mak e an adjustment to the cutting units while bac klapping, tur n the reels off b y mo ving the Lo w er Mo w/Raise lev er rearw ard; the

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Enable/Disable switc h to the Disable position, and stop the engine . After completing adjustments , re peat ste ps 5 through 10 .

12. R e peat the procedure for all cutting units y ou w ant to bac klap .

13. W hen ﬁnished, retur n the bac klap switc h to the Off position, lo w er the seat, tighten both loc king bolts securely , and w ash all lapping compound off of the cutting units . Adjust cutting unit reel to bedknife as needed.

Important: If the backlap s witch is not r etur ned to the Of f position after backlapping , the cutting units will not raise or function pr oper l y .

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Storage

10. Seal the air cleaner inlet and the exhaust outlet with w eather proof tape .

Preparing the Traction Unit

1. T horoughly clean the traction unit, cutting units , and engine .

2. Chec k the tire pressure . Inﬂate all traction unit tires to 15 to 20 psi (103 to 138 kP a).

3. Chec k all fasteners for looseness and tighten them as necessar y .

4. Grease all g rease ﬁttings and pi v ot points . Wipe up any ex cess lubricant.

5. Lightly sand and use touc h-up paint on painted areas that are scratc hed, c hipped, or r usted. R e pair any dents in the metal body .

6. Ser vice the batter y and cables as follo ws:

A. R emo v e the batter y ter minals from the

batter y posts .

B . Clean the batter y , ter minals , and posts with

a wire br ush and baking soda solution.

C . Coat the cable ter minals and batter y posts

with Grafo 112X skin-o v er g rease (T oro P ar t No . 505-47) or petroleum jelly to prev ent cor rosion.

11. Chec k the antifreeze protection and add as needed for expected minim um temperature in y our area.

D . Slo wly rec harg e the batter y ev er y 60 da ys

for 24 hours to prev ent lead sulfation of the batter y .

Preparing the Engine

1. Drain the engine oil from the oil pan and re place the drain plug .

2. R emo v e and discard the oil ﬁlter . Install a new oil ﬁlter .

3. R eﬁll the oil pan with 4 quar ts of motor oil.

4. Star t the engine and r un it at idle speed for appro ximately tw o min utes .

5. Stop the engine .

6. T horoughly drain all fuel from the fuel tank, lines , and the fuel ﬁlter/w ater se parator assembly .

7. Flush the fuel tank with fresh, clean diesel fuel.

8. Secure all fuel system ﬁttings .

9. T horoughly clean and ser vice the air cleaner assembly .

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Schematics

Hydraulic Schematic (Rev. -)

Page 61

Electrical Schematic (Rev. -)

Page 62

Page 63

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The Toro General Commercial Products Warranty

A Two-Year Limited Warranty

Conditions and Products Covered

The Toro® Company and its afliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial Product (“Product") to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs rst. Where a warrantable condition exists, we will repair the Product at no cost to you including diagnosis, labor, parts, and transportation. This warranty begins on the date the Product is delivered to the original retail purchaser.

P r o d u c t e q u i p p e d w i t h h o u r m e t e r

Instructions for Obtaining Warranty Service

You are responsible for notifying the Commercial Products Distributor or Authorized Commercial Products Dealer from whom you purchased the Product as soon as you believe a warrantable condition exists.

If you need help locating a Commercial Products Distributor or Authorized Dealer, or if you have questions regarding your warranty rights or responsibilities, you may contact us at:

Toro Commercial Products Service Department

Toro Warranty Company

8111 Lyndale Avenue South

Bloomington, MN 55420-1196

952-888-8801 or 800-982-2740

E-mail: commercial.service@Toro.com

Owner Responsibilities

As the Product owner, you are responsible for required maintenance and adjustments stated in your Operator’s Manual . Failure to perform required maintenance and adjustments can be grounds for disallowing a warranty claim.

Items and Conditions Not Covered

Not all product failures or malfunctions that occur during the warranty period are defects in materials or workmanship. This express warranty does not cover the following:

• Product failures which result from the use of non-Toro

replacement parts, or from installation and use of add-on, modied, or unapproved accessories

• Product failures which result from failure to perform required

maintenance and/or adjustments

• Product failures which result from operating the Product in

an abusive, negligent or reckless manner

• Parts subject to consumption through use unless found to be

defective. Examples of parts which are consumed, or used

up, during normal Product operation include, but are not limited to, blades, reels, bedknives, tines, spark plugs, castor wheels, tires, lters, belts, and certain sprayer components such as diaphragms, nozzles, and check valves, etc.

• Failures caused by outside inuence. Items considered to be

outside inuence include, but are not limited to, weather, storage practices, contamination, use of unapproved coolants, lubricants, additives, or chemicals, etc.

• Normal “wear and tear" items. Normal “wear and tear"

includes, but is not limited to, damage to seats due to wear or abrasion, worn painted surfaces, scratched decals or windows, etc.

Parts

Parts scheduled for replacement as required maintenance are warranted for the period of time up to the scheduled replacement time for that part.

Parts replaced under this warranty become the property of Toro. Toro will make the nal decision whether to repair any existing part or assembly or replace it. Toro may use factory remanufactured parts rather than new parts for some warranty repairs.

General Conditions

Repair by an Authorized Toro Distributor or Dealer is your sole remedy under this warranty.

Neither The Toro® Company nor Toro Warranty Company is liable for indirect, incidental or consequential damages in connection with the use of the Toro Products covered by this warranty, including any cost or expense of providing substitute equipment or service during reasonable periods of malfunction or non-use pending completion of repairs under this warranty. Except for the Emissions warranty referenced below, if applicable, there is no other express warranty. All implied warranties of merchantability and tness for use are limited to the duration of this express warranty.

Some states do not allow exclusions of incidental or consequential damages, or limitations on how long an implied warranty lasts, so the above exclusions and limitations may not apply to you.

This warranty gives you specic legal rights, and you may also have other rights which vary from state to state.

Note regarding engine warranty: The Emissions Control System on your Product may be covered by a separate warranty meeting requirements established by the U.S. Environmental Protection Agency (EPA) and/or the California Air Resources Board (CARB). The hour limitations set forth above do not apply to the Emissions Control System Warranty. Refer to the Engine Emission Control Warranty Statement printed in your operator’s manual or contained in the engine manufacturer’s documentation for details.

Countries Other than the United States or Canada

Customers who have purchased Toro products exported from the United States or Canada should contact their Toro Distributor (Dealer) to obtain guarantee policies for your country, province, or state. If for any reason you are dissatised with your Distributor’s service or have difculty obtaining guarantee information, contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty Company.

374-0031 Rev C