Toro 03806, 03808, 03813, reelmaster 6500-D, 03807 Operator's Manual

FormNo.3375-301RevC

Reelmaster

®

6500-Dand6700-D

TractionUnit

ModelNo.03806—SerialNo.313000001andUp

ModelNo.03807—SerialNo.313000001andUp

ModelNo.03808—SerialNo.313000001andUp

ModelNo.03812—SerialNo.313000001andUp

ModelNo.03813—SerialNo.313000001andUp

ToregisteryourproductordownloadanOperator'sManualorPartsCatalogatnocharge,gotowww.T oro.com.OriginalInstructions(EN)

ThisproductcomplieswithallrelevantEuropean
directives,fordetailspleaseseetheseparateproduct
specicDeclarationofConformity(DOC)sheet.

WARNING

CALIFORNIA

Proposition65Warning

Dieselengineexhaustandsomeofits
constituentsareknowntotheStateof

Californiatocausecancer,birthdefects,

andotherreproductiveharm.

Figure1

Important:Thisengineisnotequippedwitha

sparkarrestermufer.ItisaviolationofCalifornia
PublicResourceCodeSection4442touseoroperate
theengineonanyforest-covered,brush-covered,or
grass-coveredland.Otherstatesorfederalareas
mayhavesimilarlaws.

Introduction

Thismachineisaride-on,reel-bladelawnmower
intendedtobeusedbyprofessional,hiredoperatorsin
commercialapplications.Itisprimarilydesignedfor
cuttinggrassonwell-maintainedlawnsinparks,golf
courses,sportselds,andoncommercialgrounds.Itis
notdesignedforcuttingbrush,mowinggrassandother
growthalongsidehighways,orforagriculturaluses.

Readthisinformationcarefullytolearnhowtooperate
andmaintainyourproductproperlyandtoavoidinjury
andproductdamage.Youareresponsibleforoperating
theproductproperlyandsafely.

YoumaycontactTorodirectlyatwww .Toro.comfor
productandaccessoryinformation,helpndingadealer,
ortoregisteryourproduct.

1.Locationofthemodelandserialnumbers

ModelNo.

SerialNo.

Thismanualidentiespotentialhazardsandhassafety
messagesidentiedbythesafetyalertsymbol(Figure2),
whichsignalsahazardthatmaycauseseriousinjury
ordeathifyoudonotfollowtherecommended
precautions.

Figure2

1.Safetyalertsymbol.

Thismanualusestwootherwordstohighlight
information.Importantcallsattentiontospecial
mechanicalinformationandNoteemphasizesgeneral
informationworthyofspecialattention.

Wheneveryouneedservice,genuineToroparts,
oradditionalinformation,contactanAuthorized
ServiceDealerorToroCustomerServiceandhave
themodelandserialnumbersofyourproductready.
Figure1identiesthelocationofthemodelandserial
numbersontheproduct.Writethenumbersinthe
spaceprovided.

©2013—TheT oro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Contactusatwww.Toro.com.

2

PrintedintheUSA.

AllRightsReserved

Contents

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

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

SafeOperatingPractices.......................................4

ToroMowerSafety...............................................5

SoundPowerLevel...............................................6

SoundPowerLevel...............................................6

SoundPressureLevel...........................................6

VibrationLevel....................................................6

SafetyandInstructionalDecals.............................7

Setup.........................................................................14

1CheckingFluidLevels......................................14

2InstallingCuttingUnitsModels03860,03861

and03862.......................................................14

3InstallingCuttingUnitsModels03863and

03864.............................................................16

4MakingAlternateCuttingUnit

Adjustments...................................................21

5AddingRearBallast..........................................21

6InstallingCEDecals........................................21

7ReadingtheManualsandStoringAdditional

Parts...............................................................21

ProductOverview......................................................22

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

Specications.....................................................25

Attachments/Accessories...................................25

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

CheckingtheEngineOil.....................................26

CheckingtheCoolingSystem..............................26

FillingtheFuelTank...........................................27

CheckingtheHydraulicFluid..............................29

CheckingtheTirePressure.................................30

CheckingtheReeltoBedknifeContact................30

StartingandStopping.........................................30

BleedingtheFuelSystem....................................30

PushingorTowingtheMachine..........................31

CheckingtheInterlockSwitches.........................31

FaultMemoryandRetrieval................................33

HydraulicSolenoidValveFunctions....................33

OperatingTips...................................................34

Maintenance...............................................................35

RecommendedMaintenanceSchedule(s)................35

ServiceIntervalChart.........................................36

DailyMaintenanceChecklist...............................37

Lubrication.............................................................38

GreasingtheBearingsandBushings....................38

EngineMaintenance...............................................40

ServicingtheAirCleaner....................................40

ServicingtheEngineOilandFilter......................41

AdjustingThrottle..............................................41

FuelSystemMaintenance.......................................42

FuelTank...........................................................42

FuelLinesandConnections................................42

FuelFilter/WaterSeparator................................42

BleedingAirFromInjectors...............................43

ElectricalSystemMaintenance................................43

BatteryCare.......................................................43

Fuses..................................................................44

OptionalLighting...............................................44

DriveSystemMaintenance.....................................46

CheckingtheTorqueoftheWheelNutsor

Bolts..............................................................46

CheckingthePlanetaryGearDrive

Oil..................................................................46

ChangingthePlanetaryGearDrive

Oil..................................................................46

CheckingtheRearAxleLubricant.......................47

ChangingtheRearAxleLubricant.......................47

RearWheelT oe-In.............................................48

AdjustingtheTractionDriveforNeutral.............48

CoolingSystemMaintenance..................................49

RemovingDebris...............................................49

MaintainingtheCoolingSystem..........................49

BrakeMaintenance.................................................50

AdjustingtheServiceBrakes...............................50

BeltMaintenance....................................................50

CheckingtheAlternatorBelt...............................50

HydraulicSystemMaintenance...............................51

ChangingtheHydraulicFluid.............................51

ReplacingtheHydraulicFilter.............................51

CheckingtheHydraulicLinesandHoses.............51

HydraulicSystemTestPorts...............................52

CuttingUnitMaintenance.......................................53

CuttingUnitKickstandModels03863and

03864.............................................................53

Backlapping........................................................53

AdjustingtheCuttingUnitLoweringRate

......................................................................54

LiftedHeightofOuterFrontCuttingUnits

(EnablePosition)............................................55

AdjustingtheTraveloftheFrontThree

CuttingUnits..................................................56

Storage.......................................................................57

TractionUnit......................................................57

Engine...............................................................57

Schematics.................................................................58

3

Safety

ThismachinemeetsorexceedsCENstandard
EN836:1997,ISOstandard5395:1990,andANSI
B71.4-2004specicationsineffectatthetimeof
productionwhenballastisadded;refertoAdding
RearBallastinSetUpsection.

Note:Theadditionofattachmentsmadeby
othermanufacturersthatdonotmeetAmerican
NationalStandardsInstitutecerticationwillcause
noncomplianceofthismachine.

•Inspecttheareawheretheequipmentistobeused
andremoveallobjectssuchasrocks,toysandwire
whichcanbethrownbythemachine.

•Useextracarewhenhandlingdieselfuel.Itis
ammableandvaporsareexplosive.

Useonlyanapprovedcontainer.

•Neverremovegascaporaddfuelwithengine
running.Allowenginetocoolbeforerefueling.Do
notsmoke.

•Neverrefuelordrainthemachineindoors.

Improperuseormaintenancebytheoperatororowner
canresultininjury.Toreducethepotentialforinjury,
complywiththesesafetyinstructionsandalwayspay
attentiontothesafetyalert
CAUTION,WARNING,orDANGER-“personalsafety
instruction.”Failuretocomplywiththeinstructionmay
resultinpersonalinjuryordeath.

symbol,whichmeans

SafeOperatingPractices

ThefollowinginstructionsarefromtheCENstandard
EN836:1997,ISOstandard5395:1990,andANSI
B71.4-2004.

Training

•ReadtheOperator'sManualandothertraining
material.Iftheoperator(s)ormechanic(s)cannot
readEnglishitistheowner'sresponsibilitytoexplain
thismaterialtothem.

•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.The
ownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperateor
servicetheequipment.Localregulationsmayrestrict
theageoftheoperator.

•Theowner/usercanpreventandisresponsiblefor
accidentsorinjuriesoccurringtohimselforherself,
otherpeopleorproperty.

•Checkthatoperator'spresencecontrols,safety
switchesandshieldsareattachedandfunctioning
properly.Donotoperateunlesstheyarefunctioning
properly.

Operation

•Neverrunanengineinanenclosedarea.

•Onlyoperateingoodlight,keepingawayfromholes
andhiddenhazards.

•Besurealldrivesareinneutralandparkingbrakeis
engagedbeforestartingengine.Onlystartengine
fromtheoperator'sposition.Alwaysuseseatbelts
whenROPSisprovided.

•Slowdownanduseextracareonhillsides.Besure
totravelintherecommendeddirectiononhillsides.
Turfconditionscanaffectthemachine'sstability.
Usecautionwhileoperatingneardrop-offs.

•Slowdownandusecautionwhenmakingturnsand
whenchangingdirectionsonslopes.

•Neveroperatewithguardsnotsecurelyinplace.Be
sureallinterlocksareattached,adjustedproperly,
andfunctioningproperty.

•Donotchangetheenginegovernorsettingor
overspeedtheengine.

•Stoponlevelground,raisethecuttingunits,
disengagedrives,engageparkingbrake(ifprovided),
shutoffenginebeforeleavingtheoperator'sposition
foranyreasonincludingemptyingthegrassbaskets.

Preparation

•Evaluatetheterraintodeterminewhataccessories
andattachmentsareneededtoproperlyand
safelyperformthejob.Onlyuseaccessoriesand
attachmentsapprovedbythemanufacturer.

•Wearappropriateclothingincludinghardhat,safety
glassesandearprotection.Longhair,looseclothing
orjewelrymaygettangledinmovingparts.

•Stopequipmentandinspectthemachineafter
strikingobjectsorifanabnormalvibrationoccurs.
Makenecessaryrepairsbeforeresumingoperations.

•Keephandsandfeetawayfromthecuttingunits.

•Lookbehindanddownbeforebackinguptobesure
ofaclearpath.

•Nevercarrypassengersandkeeppetsandbystanders
away.

4

•Slowdownandusecautionwhenmakingturns
andcrossingroadsandsidewalks.Stopreelsifnot
mowing.

•Donotoperatethemowerundertheinuenceof
alcoholordrugs.

•Lightningcancausesevereinjuryordeath.If
lightningisseenorthunderisheardinthearea,do
notoperatethemachine;seekshelter.

•Usecarewhenloadingorunloadingthemachine
intoatrailerortruck.

ToroMowerSafety

Thefollowinglistcontainssafetyinformationspecicto
Toroproductsorothersafetyinformationthatyoumust
knowthatisnotincludedintheANSIstandards.

Thisproductiscapableofamputatinghandsand
feetandthrowingobjects.Alwaysfollowallsafety
instructionstoavoidseriousinjuryordeath.

Useofthisproductforpurposesotherthanitsintended
usecouldprovedangeroustouserandbystanders.

•Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscurevision.

MaintenanceandStorage

•Disengagedrives,raisethecuttingunits,setparking
brake,stopengineandremovekey.Waitforall
movementtostopbeforeadjusting,cleaningor
repairing.

•Cleangrassanddebrisfromcuttingunits,drives,
mufers,andenginetohelppreventres.Cleanup
oilorfuelspillage.

•Letenginecoolbeforestoringanddonotstorenear
ame.

•Shutofffuelwhilestoringortransporting.Donot
storefuelnearamesordrainindoors.

•Parkmachineonlevelground.Neverallowuntrained
personneltoservicemachine.

•Usejackstandstosupportcomponentswhen
required.

•Carefullyreleasepressurefromcomponentswith
storedenergy.

•Disconnectbatterybeforemakinganyrepairs.
Disconnectthenegativeterminalrstandthe
positivelast.Reconnectpositiverstandnegative
last.

•Usecarewhencheckingthereels.W earglovesand
usecautionwhenservicingthem.

•Keephandsandfeetawayfrommovingparts.If
possible,donotmakeadjustmentswiththeengine
running.

•Chargebatteriesinanopenwellventilatedarea,
awayfromsparkandames.Unplugchargerbefore
connectingordisconnectingfrombattery.W ear
protectiveclothinganduseinsulatedtools.

•Keepallpartsingoodworkingconditionandall
hardwareandhydraulicttingstightened.Replaceall
wornordamageddecals.

Operation

•Sitontheseatwhenstartingandoperatingthe
machine.

•Alwayswearsubstantialshoes.Donotoperatethe
machinewhilewearingsandals,tennisshoes,or
sneakers.

•Wearingsafetyshoesandlongpantsisadvisableand
requiredbysomelocalordinancesandinsurance
regulations.

•Handlefuelcarefully.Wipeupanyspills.

•Checkthesafetyinterlockswitchesdailyforproper
operation.Ifaswitchshouldfail,replacetheswitch
beforeoperatingthemachine.

•Usingthemachinedemandsattention.Toprevent
lossofcontrol:

–Donotdriveclosetosandtraps,ditches,creeks,

orotherhazards.

–Reducespeedwhenmakingsharpturns.Avoid

suddenstopsandstarts.

–Whennearorcrossingroads,alwaysyieldthe

right-of-way.

–Applytheservicebrakeswhengoingdownhillto

keepforwardspeedslowandtomaintaincontrol
ofthemachine.

•Donottouchtheengine,mufer,orexhaustpipe
whiletheengineisrunningorsoonafterithas
stoppedbecausetheseareascouldbehotenough
tocauseburns.

•Ifacuttingunitstrikesasolidobjectorvibrates
abnormally,stopimmediately ,turntheengineoff,
waitforallmotiontostop,andinspectthemachine
fordamage.Adamagedreelorbedknifemustbe
repairedorreplacedbeforeoperationiscontinued.

•Traverseslopescarefully.Donotstartorstop
suddenlywhentravelinguphillordownhill.

•Theoperatormustbeskilledandtrainedinhowto
driveonhillsides.Failuretousecautiononslopesor
hillsmaycauselossofcontrolandcausethevehicle
totiporroll,possiblyresultinginpersonalinjury

5

ordeath.AlwaysusetheseatbeltandRollOver
ProtectionSystem(ROPS)together.

•Iftheenginestallsorlosesheadwayandcannotmake
ittothetopofaslope,donotturnthemachine
around.Alwaysbackslowly,straightdowntheslope.

SoundPowerLevel

Reelmaster6500

Thisunithasaguaranteedsoundpowerlevelof101
dBA,whichincludesanUncertaintyValue(K)of1dBA.

•Whenapersonorpetappearsunexpectedlyin
ornearthemowingarea,stopmowing.Careless
operation,combinedwithterrainangles,ricochets,
orimproperlypositionedguardscanleadtothrown
objectinjuries.Donotresumemowinguntilthe
areaiscleared.

•Donotparkonslopesunlessthewheelsarechocked
orblocked.

MaintenanceandStorage

•Makesureallhydrauliclineconnectorsaretightand
allhydraulichosesandlinesareingoodcondition
beforeapplyingpressuretothesystem.

•Keepyourbodyandhandsawayfrompinhole
leaksornozzlesthatejecthydraulicuidunderhigh
pressure.Usepaperorcardboard,notyourhands,
tosearchforleaks.Hydraulicuidescapingunder
pressurecanhavesufcientforcetopenetratethe
skinandcauseseriousinjury.

•Beforedisconnectingorperforminganyworkon
thehydraulicsystem,allpressureinthesystemmust
berelievedbystoppingtheengineandloweringthe
cuttingunitsandattachmentstotheground.

•Iftheenginemustberunningtoperforma
maintenanceadjustment,keephands,feet,clothing,
andanypartsofthebodyawayfromthecutting
units,attachmentsandanymovingparts.Keep
everyoneaway.

•Theenginemustbeshutoffbeforecheckingtheoil
oraddingoiltothecrankcase.

•Ifmajorrepairsareeverneededorifassistanceis
desired,contactanAuthorizedToroDistributor.

Soundpowerlevelwasdeterminedaccordingtothe
proceduresoutlinedinEN11094.

SoundPowerLevel

Reelmaster6700

Thisunithasaguaranteedsoundpowerlevelof103
dBA,whichincludesanUncertaintyValue(K)of1dBA.

Soundpowerlevelwasdeterminedaccordingtothe
proceduresoutlinedinEN11094.

SoundPressureLevel

Thisunithasasoundpressurelevelattheoperator’ s
earof90dBA,whichincludesanUncertaintyValue(K)
of1dBA.

Soundpressurelevelwasdeterminedaccordingtothe
proceduresoutlinedinEN836.

VibrationLevel

Hand-Arm

Measuredvibrationlevelforrighthand=0.69m/s

Measuredvibrationlevelforlefthand=1.04m/s

UncertaintyValue(K)=0.5m/s

Measuredvaluesweredeterminedaccordingtothe
proceduresoutlinedinEN836.

WholeBody

Measuredvibrationlevel=0.55m/s

2

2

2

2

•Tomakesureofoptimumperformanceand
continuedsafetycerticationofthemachine,use
onlygenuineTororeplacementpartsandaccessories.
Replacementpartsandaccessoriesmadebyother
manufacturerscouldbedangerous,andsuchuse
couldvoidtheproductwarranty.

UncertaintyValue(K)=0.5m/s

Measuredvaluesweredeterminedaccordingtothe
proceduresoutlinedinEN836.

6

2

SafetyandInstructionalDecals

2

1

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof
potentialdanger.Replaceanydecalthatisdamagedorlost.

105-7506

1.ReadtheOperator's

Manual.

2.Engine—stop5.Engine—start

3.On

4.Engine—preheat

93-6693

1.Crushinghazardofhand—waitformovingpartstostop.

114–9600

93-6699

1.Machinespeed

2.Slow

3.Continuousvariable
setting

4.Fast

93-9425

1.ReadtheOperator'sManual.

2.Hydraulichosesareunderpressure—stayawayfrom
movingparts.

1.Hydraulicoil

2.ReadtheOperator'sManual.

93-6696

1.Storedenergyhazard—readtheOperator'sManual.

93-6686

93-6687

1.Donotstephere.

7

93–6689

93-1263

1.Danger—donotsitontheplasticshroud.

93–6681

1.Cutting/dismembermenthazard—stayawayfrommoving
parts.

115-2047

1.Warning—donottouchthehotsurface.

93-1263

1.ReadtheOperator'sManual.

2.Toengagetheparkingbrake,connectthebrakepedals
withthelockingpin,pushdownonbothpedals,andpullthe
brakelatchout.

3.Toreleasetheparkingbrake,pressbothpedalsuntilthe
parkingbrakelatchretracts.

4.Danger—reelsenabled.

104-9298

1.ReadtheOperator'sManual.

1.ReadtheOperator'sManual.

115-2048

8

105-0123

Model03808and03813

1.Throttle—slow

2.Throttle—fast8.Headlights(optional)

3.Reelsraisedandoff9.Headlights—On

4.Reelsloweredandonwhenenabled—forwardandbacklap10.Headlights—Off

5.Reels—enabled

6.Reelsdisabled—liftonly

7.Reelsdisabled—liftandlower

11.ReadtheOperatorsManual.

104-9296

Models03806,03807and03812

1.Throttle—slow4.Reelsloweredandonwhen

2.Throttle—fast

3.Reelsraisedandoff6.Reelsdisabled—liftonly9.Headlights—On

enabled—forwardand
backlap

5.Reelsenabled

7.Reelsdisabled—liftand
lower

8.Headlights(optional)11.ReadtheOperator's

10.Headlights—Off

Manualforfurther
instructions.

9

117–2718

106-6755

1.Enginecoolantunder
pressure.

2.Explosionhazard—read
theOperator'sManual.

3.Warning—donottouchthe
hotsurface.

4.Warning—readthe

Operator'sManual.

115-2045

1.Warning—readtheOperator'sManual.

2.Cuttinghazardofhandorfoot—stayawayfrommovingparts;keepallguardsinplace.

3.Warning—donotoperatethismachineunlessyouaretrained.

4.Tippinghazard—lowerthecuttingunitwhendrivingdownslopes;slowmachinebeforeturning,donotturnathighspeeds.

5.Warning—weartheseatbeltwhenseatedintheoperator'sposition.

6.Warning—readtheOperator'sManual;donottowthemachine.

7.Thrownobjecthazard—keepbystandersasafedistancefromthemachine.

8.Warning—locktheparkingbrake,stoptheengineandremovetheignitionkeybeforeleavingthemachine.

10

115-2046

(Afxoverpartno.115–2045forCE*)

*ThissafetydecalincludesaslopewarningrequiredonthemachineforcompliancetotheEuropeanLawnMowerSafetyStandardEN836:1997.Theconservativemaximum

slopeanglesindicatedforoperationofthismachineareprescribedbyandrequiredbythisstandard.

1.Warning—readtheOperator'sManual.

2.Cuttinghazardofhandorfoot—stayawayfrommovingparts;keepallguardsinplace.

3.Warning—donotoperatethismachineunlessyouaretrained.

4.Tippinghazard—lowerthecuttingunitwhendrivingdownslopes;donotmowonslopesgreaterthan15degrees.

5.Warning—weartheseatbeltwhenseatedintheoperator'sposition.

6.Warning—readtheOperator'sManual;donottowthemachine.

7.Thrownobjecthazard—keepbystandersasafedistancefromthemachine.

8.Warning—locktheparkingbrake,stoptheengineandremovetheignitionkeybeforeleavingthemachine.

11

115-2049

Models03806,03807and03812

93-6668

1.ReadtheOperator'sManualforinformationonchargingthe
battery;containslead;donotdiscard.

1.Reel—heightofcut

2.Reel—mowandbacklap5.Rearreelscircuitcontrols

3.ReadtheOperator's

Manual.

4.Machinespeed

6.Frontreelscircuitcontrols

106-6754

1.Warning—donottouchthehotsurface.

2.Cutting/dismembermenthazard,fanandentanglement
hazard,belt—stayawayfrommovingparts.

115-8000

Model03808and03813

1.Reel—heightofcut

2.Reel—mowandbacklap5.Rearreelscircuitcontrols

3.ReadtheOperator's

Manual.

4.Machinespeed

6.Frontreelscircuitcontrols

12

BatterySymbols

Someorallofthesesymbolsareonyourbattery

1.Explosionhazard

2.Nore,opename,or
smoking.

3.Causticliquid/chemical
burnhazard

4.Weareyeprotection9.Flusheyesimmediately

5.ReadtheOperator's

Manual.

6.Keepbystandersasafe

7.Weareyeprotection;

8.Batteryacidcancause

10.Containslead;donot

distancefromthebattery .

explosivegasescan
causeblindnessandother
injuries

blindnessorsevereburns.

withwaterandgetmedical
helpfast.

discard.

13

Setup

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescription

1

2

3

4

5

6

7

Nopartsrequired

LargeO-ring14/10
Counterweight7/5
Steeringlockingpin7/5
Liftchain5/7
Chainbracket5/7
U-bolt
Nut
Screw5/7
Washer
Nut
LargeO-ring5/7

Nopartsrequired

Calciumchloride(obtainseparately)
Rearweightkit,partnumber104–1478

(obtainseparately)
CEdecals
CEcerticate
Operator'sManual
EngineOperator'sManual
PartsCatalog
OperatorTrainingMaterial
DiagnosticACEdisplayoverlay
Ignitionkeysonring1
Hoodlockkey1
Screw
Wingnut2

10/14

100lb

Qty.

5/7

5/7
5/7

Use

–

–

1

4
2
1
1
1
1
1

2

Checkuidlevels.

Installcuttingunits.

Installcuttingunits.

Makecuttingunitadjustmentsifneeded.

Addrearballast(ifrequired).

InstalltheCEdecals.

Readthemanualsandviewthetraining
materialbeforeoperatingthemachine.

1

CheckingFluidLevels

NoPartsRequired

Procedure

Beforestartingtheengineforthersttime,checkthe
followinguidlevels:

•Engineoil

RefertoCheckingtheEngineOil.

•Enginecoolant

RefertoCheckingtheCoolingSystem.

•Hydraulicoil

RefertoCheckingtheHydraulicOil.

•Rearaxlelubricant

RefertoCheckingtheRearAxleLubricant.

14

2

InstallingCuttingUnits
Models03860,03861and
03862

Partsneededforthisprocedure:

14/10LargeO-ring

7/5Counterweight

7/5Steeringlockingpin

MounttheCuttingUnits

Cuttingunitmodels03860,03861,and03862canbe
installedatanyofthemountinglocationsonthetraction
unit.Figure3showstheorientationofthehydraulic
drivemotorforeachofthelocations.Foranyofthe
locationsrequiringthemotortobemountedontheright
endofthecuttingunit,installacounterweightonthe
leftendofthecuttingunit.Forthelocationsrequiring
themotortobemountedontheleftend,installa
counterweightontherightendofthecuttingunit.

Note:Counterweightmountingcapscrewsareshipped
installedontherightbearinghousingofthecutting
units.Thecapscrewsonleftbearinghousingaretobe
usedforsecuringthehydraulicmotor.

Figure4

1.Bearinghousing

2.Largeo-ring

Note:Beforeinstallingcuttingunitmotorsor
counterweights,lubricateinternalsplinesofcutting
unitreelshaftswithgrease.

4.Installacounterweightontoappropriateendofeach
cuttingunitwithcapscrewsprovided(

5.Thoroughlygreasethecuttingunitreelbearingsprior
toinstallationonthetractionunit.Greaseshould
beevidentattheinboardreelseals;refertoCutting
UnitOperator'sManualforgreasingprocedure.

6.Insertathrustwasherontohorizontalshaftofpivot
knuckleasshownin(

3.Counterweight

Figure4).

Figure5).

Figure3

1.Removecuttingunitsfromcartons.Assembleand
adjustperCuttingUnitOperator'sManual.

2.Removeprotectiveplugsfromeachendofcutting
unit.

3.LubricateandinstallalargeO-ringintobearing
housinggrooveoneachendofcuttingunit

Figure4&Figure7).

(

Figure5

1.Carrierframe

2.Pivotknuckle

3.Liftarmsteeringplate

7.Insertthehorizontalshaftofthepivotknuckleinto
themountingtubeofthecarrierframe(Figure5).

8.Securepivotknuckletocarrierframewithathrust
washer,atwasherandaangeheadcapscrew
(Figure5).

9.Insertathrustwasherontoverticalshaftofpivot
knuckle(Figure5).

15

4.Lynchpin

5.Steeringlockingpin

10.Ifremoved,inserttheverticalshaftofthepivot
knuckleintoliftarmpivothub(Figure5).Guide
thepivotknuckleinplacebetweenthetworubber
centeringbumpersintheundersideoftheliftarm
steeringplate.

11.Insertthelynchpinintothecrossholeonthepivot
knuckleshaft(

Figure5).

12.Removenutsecuringturfcompensationspring
mountingbrackettocuttingunitstabilizerear
(Figure6).Inserttipperchainontocapscrewand
securewithnutremoved.

Figure6

1.Liftchain2.Cuttingunitstabilizerear

TheTurfCompensationSpring(Figure8),connecting
carrierframetocuttingunit,controlstheamountof
fore-aftrotationavailable,aswellastheamountof
groundclearanceintransportandturnaround.

TheTurfCompensationSpringalsotransfersweight
fromthefronttorearroller.Thishelpstoreduceawave
patternintheturf,alsoknownasbobbing.

Important:Makespringadjustmentswithcutting
unitmountedtotractionunitandloweredtoshop
oor.

1.Tightenlocknutonrearofspringroduntilthegap
(C)betweenrearofspringbracketandfrontof
washeris1in.(25mm)(

Figure8).

13.Mountthemotortothedriveendofthecuttingunit
andsecurewithtwocapscrewsprovided(

Figure7

1.Motor

2.O-ring

Figure7).

Note:Ifxedcuttingunitpositionisrequired,
insertsteeringlockingpinintopivotknuckle
mountinghole(Figure5).

14.Hookspringwirearoundbottomofsteeringlocking
pin(Figure5).

AdjustTurfCompensationSpring

Figure8

2.Tightenhexnutsonfrontendofspringroduntilthe
compressedlength(A)ofspringis8in.(203mm)

Figure8).

(

Note:Whencuttingroughorundulatingturf,
increasecompressedlength(A)ofspringto8-1/2in.
(216mm)andgap(C)betweenrearofspringbracket
andfrontofwasherto1-1/2in.(38mm)(

Figure8).

Note:Ascompressedspringlength(A)decreases,
weighttransferfromfrontrollertorearroller
increasesandcarrierframe/cuttingunitrotation
angle(B)decreases.

Note:Asgap(C)betweenspringbracketand
washerincreases,cuttingunitgroundclearance
decreasesandcarrierframe/cuttingunitrotation
angle(B)increases.

Tractorsaresetupatthefactoryappropriatelyformost
fairwaymowingapplications.Thefollowingadjustment
isforne-tuningthemachinetotheapplication:

16

3

InstallingCuttingUnits
Models03863and03864

Partsneededforthisprocedure:

5/7Liftchain

5/7Chainbracket

U-bolt

5/7

5/7Screw

5/7

5/7

5/7LargeO-ring

Nut

Washer

Nut

10/14

MounttheLiftBracketsandChains

knuckle(Figure10).Rotatethebrackets45degrees
totheoutboardsideofthemachine.

Figure10

MountachainbrackettoeachliftarmwithaU-boltand
2nuts.Positionthebracketsasfollows:

1.Onliftarms#1,#4and#5,positionthechain
bracketsandU-bolts15inchesbehindthecenter
lineofthepivotknuckle(
and#5thebracketsshouldberotatedtotheright
10degreesfromvertical(Figure9).Onliftarm#4
thebracketshouldberotatedtotheleft10degrees
fromvertical(Figure9).

Figure9).Onliftarms#1

3.Onliftarms#6and#7,positionthebracketsand
U-bolts14.5inchesbehindthecenterlineofthe
pivotknuckle(
degreestotheoutboardsideofthemachine.

4.TightenalltheU-boltnutsto38–48ft-lbs.

Figure11).Rotatethebrackets10

Figure11

Figure9

2.Onliftarms#2and#3,positionthebracketsand
U-bolts15inchesbehindthecenterlineofthepivot

5.Mountaliftchaintoeachchainbracketwithascrew ,
washerandnut,positioningasshowninFigure12

17

Figure12

1.Liftchain2.Chainbracket

AdjusttheRearShield

Undermostconditions,bestdispersionisattained
whentherearshieldisclosed(frontdischarge).When
conditionsareheavyorwet,rearshieldmaybeopened.

MounttheCounterWeights

Allcuttingunitsareshippedwiththecounterweight
mountedtotheleftendofthecuttingunit.Usethe
followingdiagramtodeterminethepositionofthe
counterweightsandreelmotors.

Figure14

1.Onthe#2,#4and#6cuttingunits,removethe2
capscrewssecuringthecounterweighttotheleft
endofthecuttingunit.Removethecounterweight

Figure15).

(

Toopentherearshield(

Figure13),loosenthecapscrew
securingtheshieldtotheleftsideplate,rotatetheshield
totheopenpositionandtightenthecapscrew .

Figure13

1.Rearshield

2.Capscrew

Figure15

1.Counterweight

2.Onrightendofcuttingunit,removetheplasticplug
fromthebearinghousing(Figure16).

3.Removethe2capscrewsfromtherightsideplate
(Figure16).

18

G003321

1

2

Figure16

thepivotknuckleinplacebetweenthetworubber
centeringbumpersintheundersideoftheliftarm
steeringplate.

6.Insertthelynchpinintothecrossholeonthepivot
knuckleshaft(Figure17).

7.Securetheliftarmchaintothecuttingunitchain
bracket(

Figure18)withthesnapperpinasfollows:

A.Oncuttingunits#1,4,5,6and7,onlyuse6of

thechainlinks.

B.Oncuttingunits#2and3,useall7ofthechain

links.

1.Plasticplug

2.Capscrew(2)

4.Installthecounterweighttotherightendofthe
cuttingunitwiththe2screwspreviouslyremoved.

5.Looselyinstallthe2reelmotormountingcapscrews
totheleftsideplateofthecuttingunit(Figure16).

MounttheCuttingUnits

1.Insertathrustwasherontohorizontalshaftofpivot
knuckleasshowninFigure17.

Figure17

Figure18

1.Liftchain2.Snapperpin

8.Coatthesplineofthereelmotorwithcleangrease.

9.OilthereelmotorO-ringandinstallitontothe
motorange.

10.Installthemotorbyrotatingitclockwisesothat
themotorangesclearthecapscrews(

Figure19).
Rotatethemotorcounterclockwiseuntiltheanges
encirclethecapscrewsthentightenthecapscrews

1.Carrierframe

2.Pivotknuckle

3.Liftarmsteeringplate

4.Lynchpin

5.Steeringlockingpin

2.Insertthehorizontalshaftofthepivotknuckleinto
themountingtubeofthecarrierframe(Figure17).

3.Securepivotknuckletocarrierframewithathrust
washer,atwasherandaangeheadcapscrew
(Figure17).

4.Insertathrustwasherontoverticalshaftofpivot
knuckle(

Figure17).

5.Ifremoved,inserttheverticalshaftofthepivot
knuckleintoliftarmpivothub(

Figure17).Guide

Important:Makesurethereelmotorhoses
arenottwisted,kinkedorintheriskofbeing
pinched.

19

Figure20

Figure19

1.Reeldrivemotor

2.Capscrew

Note:Ifxedcuttingunitpositionisrequired,
insertsteeringlockingpinintopivotknuckle
mountinghole(

Figure17).

11.Hookspringwirearoundbottomofsteeringlocking
pin(Figure17).

AdjusttheTurfCompensationSpring

Tractorsaresetupatthefactoryappropriatelyformost
fairwaymowingapplications.

Thefollowingadjustmentsareavailableforne-tuning
ofthemachinetotheapplication:

TheTurfCompensationSpring(Figure20)transfers
weightfromthefronttorearroller.Thishelpstoreduce
awavepatternintheturf,alsoknownasbobbing.

Important:Makespringadjustmentswithcutting
unitmountedtotractionunitandloweredtoshop
oor.

2.Tightenhexnutsonfrontendofspringroduntil
thecompressedlength(A)ofspringis6.25in.(159
mm)(Figure20).

Note:Whenoperatingonroughterrain,decrease
thespringlengthby1/2inch.Groundfollowingwill
beslightlydecreased.

Note:Ascompressedspringlength(A)decreases,
weighttransferfromfrontrollertorearroller
increasesandcarrierframe/cuttingunitrotation
angle(B)decreases.

Note:Asgap(C)betweenspringbracketand
washerincreases,cuttingunitgroundclearance
decreasesandcarrierframe/cuttingunitrotation
angle(B)increases.

Note:Whencuttingundulatingturf,increasethe
compressedspringlength(A)andthegapwidth(C)
1/2inch(

Figure20).

1.Tightenlocknutonrearofspringroduntilthegap
(C)betweenrearofspringbracketandfrontof
washeris2in.(51mm)(

Figure20).

20

4

6

MakingAlternateCuttingUnit
Adjustments

NoPartsRequired

Procedure

Thefactorysetsthetractorappropriatelyformost
fairwaymowingapplications.Severaladjustmentsfor
ne-tuningthemachineforparticularapplicationsare
includedintheCuttingUnitMaintenancesectionas
follows:

•Adjustingthecuttingunitloweringrate

Adjuststhespeedatwhichthecuttingunitslower.

•Adjustingtheliftedheightoftheouterfrontcutting
units

Adjuststheturnaroundheightoftheouterfront
cuttingunitstoprovidegreaterclearanceon
contouredfairways.

•Adjustingthetravelofthefrontthreecuttingunits

InstallingCEDecals

Partsneededforthisprocedure:

4

CEdecals

2

CEcerticate

Procedure

IfyouwillbeusingthemachineinaCEcountry,install
thesuppliedCEdecalsoverthecorrespondingANSI
decalsontheproduct.StoretheCEcerticatesinasafe
location.

7

ReadingtheManualsand
StoringAdditionalParts

Adjuststhedownwardtravelofthefrontthree
cuttingunitstoallowforhighlycontouredfairways.

5

AddingRearBallast

Partsneededforthisprocedure:

100lb

Procedure

TocomplywithCENstandardEN836:1997,ISO
standard5395:1990,andtheANSIB71.4-2004
Standard,add100lb(45kg)ofcalciumchloride
ballasttotherearwheelsandinstalltherearweightkit
(PartNumber104-1478).

Calciumchloride(obtainseparately)

Rearweightkit,partnumber104–1478(obtain

1

separately)

Partsneededforthisprocedure:

1

Operator'sManual

1

EngineOperator'sManual

1

PartsCatalog

1

OperatorTrainingMaterial

1

DiagnosticACEdisplayoverlay

1Ignitionkeysonring

1Hoodlockkey

2

Screw

2Wingnut

Procedure

1.Readthemanuals.

2.ViewtheOperatorTrainingMaterial.

3.ThediagnosticACEdisplayoverlayisfordiagnosing
machinemalfunctions.Storeitinasafelocation.

Important:Ifapunctureoccursinatirewith
calciumchloride,removeunitfromturfareaas
quicklyaspossible.Topreventpossibledamageto
turf,immediatelysoakaffectedareawithwater.

21

ProductOverview

g019447

1

2

3

4

5

6

7

8

9

Controls

TractionPedal

Thetractionpedal(Figure21)controlsforwardand
reverseoperation.Depresstopofpedaltomoveforward
andbottomtomovebackward.Groundspeeddepends
onhowfarpedalisdepressed.Fornoload,maximum
groundspeed,fullydepresspedalwhilethrottleisin
FAST.

Tostop,reducefootpressureontractionpedaland
allowittoreturntocenterposition.

•Themachineisbeingoperatedfasterthanthe
maximumspeedvalueinitiallyprogrammedintothe
ECU.

•Anelectricalmalfunctionhasbeendetected(open
orshortedoutput.

•Ahydraulicleakhasbeendetected(Onlyif
Turfdefenderleakdetectorisinstalledonmachine)

•Acommunicationserrorhasbeendetected(Onlyif
Turfdefenderleakdetectorisinstalledonmachine)

KeySwitch

Thekeyswitch(Figure21)hasthreepositions:OFF ,
ON/PreheatandSTART.

Speedometer

Thespeedometer(Figure21)indicatesgroundspeedat
whichmachineistraveling.

BrakePedals

Twobrakepedals(Figure21)operateindividualwheel
brakesforturningassistance,parking,andtoaidin
obtainingbettersidehilltraction.Lockingpinconnects
thepedalsforparkingbrakeoperationandtransport.

Figure21

1.Tractionpedal6.Parkingbrakelatch

2.Forwardspeedlimiter7.Lockingpin

3.Reddiagnosticlight8.Reversespeedlimiter

4.Speedometer

5.Brakepedals

9.Keyswitch

ForwardSpeedLimiter

Presettheforwardspeedlimiter(Figure21)tolimit
theamountthetractionpedalcanbedepressedinthe
forwarddirectiontomaintainaconstantmowingspeed.

RedDiagnosticLight

Thereddiagnosticlight(Figure21),locatedonsteering
tower,isusedtoconveyseveraldifferentmessages.
Whilestartingthemachine,thelightwillilluminatewhen
theglowplugsareon.

Ifthelightblinksduringoperation,itmayindicateany
ofthefollowing:

ParkingBrakeLatch

Aknobontheleftsideofconsoleactuatesparkingbrake
lock(Figure21).Toengageparkingbrake,connect
pedalswithlockingpin,pushdownonbothpedalsand
pullparkingbrakelatchout.Toreleaseparkingbrake,
depressbothpedalsuntilparkingbrakelatchretracts.

ReverseSpeedLimiter

Adjustthescrew(Figure21)tolimittheamountthe
tractionpedalcanbedepressedintherearwarddirection
tolimitspeed.

LowerMow/RaiseControlLever
(Joystick)

Thelever(Figure22andFigure23)raisesandlowersthe
cuttingunitsandalsostartsandstopsthereels.

FuelGauge

Thefuelgauge(Figure22andFigure23)indicateslevel
offuelintank.

EngineOilPressureWarningLight

Thislight(Figure22andFigure23)indicatesdangerously
lowengineoilpressure.

22

G019448

1

2

3

4

5

6

7

8

9

10

11

Figure22

G019449

1

2

3

4

5

6

7

8

9

Model03808and03813

1.Throttlecontrol

2.Lowermow/raisecontrol
lever

3.Fuelgauge

4.Chargeindicator10.Enable/disableswitch

5.Engineoilpressure
warninglight

6.Enginecoolant
temperaturewarning
light

7.Glowplugindicatorlight

8.Enginecoolant
temperaturegauge

9.Enable/disableswitch(#7)
rightrear

(Master)

11.Enable/disableswitch(#6)
leftrear

ThrottleControl

Movethecontrol(Figure22andFigure23)forwardto
increaseenginespeed,rearwardtodecreasespeed.

EngineCoolantTemperatureWarning
Light

Thelight(Figure22andFigure23)illuminatesand
theengineshutsdownwhenthecoolantreachesa
dangerouslyhightemperature.

GlowPlugIndicatorLight

Figure23

Models03806,03807and03812

1.Throttlecontrol6.Enginecoolant

2.Lowermow/raisecontrol
lever

3.Fuelgauge8.Enginecoolant

4.Chargeindicator9.Enable/disableswitch

5.Engineoilpressure
warninglight

temperaturewarning
light

7.Glowplugindicatorlight

temperaturegauge

(Master)

Enable/DisableSwitches

Theenable/disableswitches(Figure22andFigure23)
areusedinconjunctionwiththelowermow/raise
controllever(Joystick)tooperatereels.Reelscanbe
raisedbutnotloweredwheninmidposition.

HourMeter

Thehourmeter(Figure24)showstotalhoursthat
machinehasbeenoperated.

Whentheindicatorlight(Figure22andFigure23)islit,
indicatesglowplugsareon.

ChargeIndicator

Thechargeindicator(Figure22andFigure23)
illuminateswhensystemchargingcircuitmalfunctions.

23

G019525

1

1.Hourmeter

G019451

1

2

adjustsseatforoperatorsweight.Toadjustseatfore
andaft,pullleveronleftsideofseatassemblyoutward.
Aftermovingseattodesiredlocation,releaseleverto
lockseatintoposition.Toadjustforoperatorsweight,
turnspringtensionknob;clockwisetoincreasetension,
counterclockwisetodecreasespringtension.

Figure24

BacklapKnobs

Thebacklapknobs(Figure25)areusedin
conjunctionwithlowermow/raisecontrollever
forbacklappingoperation.RefertoBacklappingin
CuttingUnitMaintenance(page53).

Figure25

Figure26

1.Seatadjustingknob2.Seatadjustinglever

GreenDiagnosticLight

Themachineisequippedwithadiagnosticlightwhich
indicatesiftheelectroniccontrollerisfunctioning
correctly.Thegreendiagnosticlight(Figure27)is
locatedunderthecontrolpanel,nexttothefuseblock.
Whentheelectroniccontrollerisfunctioningcorrectly
andthekeyswitchismovedtotheONposition,the
controllerdiagnosticlightwillbeilluminated.Thelight
willblinkifthecontrollerdetectsamalfunctionin
theelectricalsystem.Thelightwillstopblinkingand
automaticallyresetwhenthekeyswitchisturnedtothe
OFFposition.

1.Backlapknobs2.Reelcontrolknobs

ReelSpeedControls

ControlsRPMoffrontandrearcuttingunits(Figure25).
#1positionisforbacklapping.Remainingsettingsare
formowingoperations.Seedecalunderseatforproper
settings.

Seat

Theseatadjustinglever(Figure26)allows4inchfore
andaftadjustment.Theseatadjustingknob(Figure26)

24

G019452

1

TheDiagnosticACEdisplayisatooltohelptheuser
verifycorrectelectricalfunctionsofthemachine.

Specications

Note:Specicationsanddesignaresubjecttochange

withoutnotice.

Figure27

1.Greendiagnosticlight

Whenthecontrollerdiagnosticlightblinks,oneofthe
followingproblemshasbeendetectedbythecontroller:

•Oneoftheoutputshasbeenshorted.

•Oneoftheoutputsisopencircuited.

Usingthediagnosticdisplay,determinewhichoutput
ismalfunctioning,refertoCheckingInterlock
Switches.

Ifthediagnosticlightisnotilluminatedwhenthe
keyswitchisintheOnposition,thisindicatesthat
theelectroniccontrollerisnotoperating.Possible
causesare:

•Loopbackisnotconnected.

•Thelightisburnedout.

Width-of-cut,model03806,
03807and03812

Width-of-cut,model03808and
03813

Overallwidth,Transport89inches(226cm)

Overallwidth,Operational110inches(279cm)

Overalllength120inches(305cm)

HeightWithROPSinstalled84inches(213cm)

Weight*,model038063200lb(1451kg)

Weight*,model03807and
03812

Weight*,model03808and
03813

*With5bladecuttingunitsandfulluidlevels.

96inches(244cm)

133inches(338cm)

3300lb(1496kg)

3950lb(1792kg)

Attachments/Accessories

AselectionofToroapprovedattachmentsand
accessoriesisavailableforusewiththemachineto
enhanceandexpanditscapabilities.Contactyour
AuthorizedServiceDealerorDistributororgoto
www.Toro.comforalistofallapprovedattachments
andaccessories.

•Fusesareblown.

•Nobatterypower.

Checkelectricalconnections,inputfusesand
diagnosticlightbulbtodeterminemalfunction.
Makesureloopbackconnectorissecuredtowire
harnessconnector.

DiagnosticACEDisplay(Optional)

Themachineisequippedwithanelectroniccontroller
whichcontrolsmostmachinefunctions.Thecontroller
determineswhatfunctionisrequiredforvariousinput
switches(i.e.seatswitch,keyswitch,etc.)andturns
ontheoutputstoactuatesolenoidsorrelaysforthe
requestedmachinefunction.

Fortheelectroniccontrollertocontrolthemachineas
desired,eachoftheinputswitches,outputsolenoidsand
relaysmustbeconnectedandfunctioningproperly .

25

Operation

g019453

1

G019454

1

G019455

1

Note:Determinetheleftandrightsidesofthe
machinefromthenormaloperatingposition.

CheckingtheEngineOil

ServiceInterval:Beforeeachuseordaily

Theengineisshippedwithoilinthecrankcase;
however,theoillevelmustbecheckedbeforeandafter
theengineisrststarted.

Crankcasecapacityisapproximately7.5qt.(7l)with
thelter.

Usehigh-qualityengineoilthatmeetsthefollowing
specications:

Figure29

1.Dipstick

•APIClassicationLevelRequired:CH-4,CI-4or
higher.

•Preferredoil:SAE15W -40(above0°F)

•Alternateoil:SAE10W -30or5W-30(all
temperatures)

Note:ToroPremiumEngineoilisavailablefromyour
distributorineither15W-40or10W-30viscosity.See
thepartscatalogforpartnumbers.

Note:Thebesttimetochecktheengineoiliswhen
theengineiscoolbeforeithasbeenstartedforthe
day.Ifithasalreadybeenrun,allowtheoiltodrain
backdowntothesumpforatleast10minutesbefore
checking.Iftheoillevelisatorbelowthe“add”mark
onthedipstick,addoiltobringtheoilleveltothe“full”
mark.DONOTOVERFILL.Iftheoillevelisbetween
the“full”and“add”marks,nooiladditionisrequired.

1.Parkmachineonalevelsurface.Releasehoodlatch
andopenhood(

Figure28).

3.Ifoillevelislow,removellercap(Figure30)and
addoiluntillevelreachesFULLmarkondipstick.
Donotoverll.

Figure30

1.Fillercap

4.Installllercap.

5.Closehoodandsecurelatch.

Figure28

1.Hoodlatch

2.Removedipstick(Figure29),wipecleanandreinstall
dipstick.Pullitoutagainandcheckoillevelon
dipstick:OillevelshouldbeuptoFULLmarkon
dipstick.

CheckingtheCoolingSystem

ServiceInterval:Beforeeachuseordaily

Cleandebrisoffscreen,oilcoolerandfrontof
radiatordaily,moreoftenifconditionsareextremely
dustyanddirty;refertoRemovingDebrisin
CoolingSystemMaintenance(page49).

Thecoolingsystemislledwitha50/50solution
ofwaterandpermanentethyleneglycolantifreeze.
Checklevelofcoolantinradiatorandexpansiontank

26

atthebeginningofeachdaybeforestartingtheengine.

1

G019456

Capacityofcoolingsystemis10quarts(9.4l).

CAUTION

Iftheenginehasbeenrunning,pressurizedhot
coolantcanescapeandcauseburnsiftheradiator
capisremoved.

Allowtheenginetocoolatleast15minutesoruntil
theradiatorcapiscoolenoughtotouchwithout
burninghands.

1.Carefullyremoveradiatorcapandexpansiontank
cap(Figure31).

2.Checklevelofcoolantinradiatorandinexpansion

Figure31).

tank(

Radiatorshouldbelledtothetopofthellerneck
andtheexpansiontanklledtotheFullmark.

Figure32

1.Ventplug

4.Installradiatorcapandexpansiontankcap.

5.Closehoodandsecurelatch.

FillingtheFuelTank

Figure31

1.Expansiontank

3.FillexpansiontanktotheFullmarkandradiator
tothetopofthellerneck.Donotoverllthe

expansiontank.

Note:Ifairistrappedissystem,removeventplug

Figure32),fromtopofradiatorsidetank,toallow

(
trappedairtoescape.Reinstallventplugusing
Teonthreadsealant.

DANGER

Undercertainconditions,dieselfuelandfuel
vaporsarehighlyammableandexplosive.Are
orexplosionfromfuelcanburnyouandothersand
cancausepropertydamage.

•Useafunnelandllthefueltankoutdoors,in
anopenarea,whentheengineisoffandiscold.
Wipeupanyfuelthatspills.

•Donotllthefueltankcompletelyfull.Add
fueltothefueltankuntilthelevelis1in.(25
mm)belowthebottomofthellerneck.This
emptyspaceinthetankallowsthefuelto
expand.

•Neversmokewhenhandlingfuel,andstay
awayfromanopenameorwherefuelfumes
maybeignitedbyaspark.

•Storefuelinaclean,safety-approvedcontainer
andkeepthecapinplace.

Useonlyclean,freshdieselfuelorbiodieselfuelswith
low(<500ppm)orultralow(<15ppm)sulfurcontent.
Theminimumcetaneratingshouldbe40.Purchase
fuelinquantitiesthatcanbeusedwithin180daysto
ensurefuelfreshness.

Fueltankcapacity:15USgallons(57l)

Usesummergradedieselfuel(No.2-D)attemperatures
above20°F(-7°C)andwintergrade(No.1-Dor
No.1-D/2-Dblend)belowthattemperature.Useof
wintergradefuelatlowertemperaturesprovideslower

27

ashpointandcoldowcharacteristicswhichwillease
startingandreducefuellterplugging.

Useofsummergradefuelabove20°F(-7°C)will
contributetowardlongerfuelpumplifeandincreased
powercomparedtowintergradefuel.

Important:Donotusekeroseneorgasoline
insteadofdieselfuel.Failuretoobservethis
cautionwilldamagetheengine.

DANGER

Incertainconditions,fuelisextremelyammable
andhighlyexplosive.Areorexplosionfromfuel
canburnyouandothersandcandamageproperty.

•Fillthefueltankoutdoors,inanopenarea,
whentheengineiscold.Wipeupanyfuelthat
spills.

•Neverllthefueltankinsideanenclosedtrailer.

WARNING

Fuelisharmfulorfatalifswallowed.Long-term
exposuretovaporscancauseseriousinjuryand
illness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgastankor
conditioneropening .

•Keepfuelawayfromeyesandskin.

BiodieselReady

Thismachinecanalsouseabiodieselblendedfuel
ofuptoB20(20%biodiesel,80%petrodiesel).The
petrodieselportionshouldbeloworultralowsulfur.
Observethefollowingprecautions:

•Thebiodieselportionofthefuelmustmeet
specicationASTMD6751orEN14214.

•TheblendedfuelcompositionshouldmeetASTM
D975orEN590.

•Paintedsurfacesmaybedamagedbybiodiesel
blends.

•UseB5(biodieselcontentof5%)orlesserblends
incoldweather.

•Monitorseals,hoses,gasketsincontactwithfuelas
theymaybedegradedovertime.

•Fuellterpluggingmaybeexpectedforatimeafter
convertingtobiodieselblendsd.

•Contactyourdistributorifyouwishformore
informationonbiodiesel.

•Neversmokewhenhandlingfuel,andstay
awayfromanopenameorwherefuelfumes
maybeignitedbyaspark.

•Storefuelinanapprovedcontainerandkeepit
outofthereachofchildren.Neverbuymore
thana30-daysupplyoffuel.

•Donotoperatewithoutentireexhaustsystem
inplaceandinproperworkingcondition.

DANGER

Incertainconditionsduringfueling,static
electricitycanbereleasedcausingasparkwhich
canignitethefuelvapors.Areorexplosionfrom
fuelcanburnyouandothersandcandamage
property.

•Alwaysplacefuelcontainersontheground
awayfromyourvehiclebeforelling.

•Donotllfuelcontainersinsideavehicleoron
atruckortrailerbedbecauseinteriorcarpets
orplastictruckbedlinersmayinsulatethe
containerandslowthelossofanystaticcharge.

•Whenpractical,removeequipmentfromthe
truckortrailerandrefueltheequipmentwith
itswheelsontheground.

•Ifthisisnotpossible,thenrefuelsuch
equipmentonatruckortrailerfromaportable
container,ratherthanfromafueldispenser
nozzle.

•Ifafueldispensernozzlemustbeused,keep
thenozzleincontactwiththerimofthefuel
tankorcontaineropeningatalltimesuntil
fuelingiscomplete.

1.Parkthemachineonalevelsurface.

2.Usingacleanrag,cleanareaaroundfueltankcap.

3.Removecapfromthefueltank(Figure33).

28

1

G019457

Note:Manyhydraulicuidsarealmostcolorless,

1

G019458

makingitdifculttospotleaks.Areddyeadditivefor
thehydraulicsystemoilisavailablein2/3oz.(20ml)
bottles.Onebottleissufcientfor4-6gal(15-221)
ofhydraulicoil.Orderpartno.44-2500fromyour
authorizedTorodistributor.

BiodegradableHydraulicFluid-Mobil224H

ToroBiodegradableHydraulicFluid(Availablein5gallon

pailsor55gallondrums.SeepartscatalogorT orodistributor
forpartnumbers.)

Alternateuid:MobilEAL224H

Figure33

1.Fueltankcap

4.Fillthetankuntilthelevelistothebottomofthe
llerneckwithdieselfuel.

5.Installfueltankcaptightlyafterllingtank.

Note:Ifpossible,llthefueltankaftereachuse.
Thiswillminimizepossiblebuildupofcondensation
insidethefueltank.

CheckingtheHydraulicFluid

ServiceInterval:Beforeeachuseordaily

Themachinesreservoirislledatthefactorywith
approximately8.5U.S.gallons(32l)ofhighquality
hydraulicuid.Checkthelevelofthehydraulicuid
beforetheengineisrststartedanddailythereafter.
Therecommendedreplacementuidisasfollows:

ToroPremiumAllSeasonHydraulicFluid(Availablein5
gallonpailsor55gallondrums.SeepartscatalogorT oro
distributorforpartnumbers.)

Note:Thisisvegetable-oilbasedbiodegradableoil
testedandapprovedbyToroforthismodel.Thisuid
isnotasresistanttohightemperaturesasstandard
uid,soinstallanoilcoolerifrequiredbytheoperator
manualandfollowrecommendeduidchangeintervals
withthisuid.Contaminationbymineral-based
hydraulicuidswillchangethebiodegradabilityand
toxicityofthisoil.Whenchangingfromstandarduid
tothebiodegradabletype,becertaintofollowthe
approvedushingprocedure.ContactyourlocalT oro
Distributorfordetails.

1.Positionmachineonalevelsurface,lowerthe
cuttingunitsandstoptheengine.

2.Cleanareaaroundllerneckandcapofhydraulic

Figure34).Removecapfromllerneck.

tank(

Alternateuids:IftheTorouidisnotavailable,other
uidsmaybeusedprovidedtheymeetallthefollowing
materialpropertiesandindustryspecications.Wedo
notrecommendtheuseofsyntheticuid.Consult
withyourlubricantdistributortoidentifyasatisfactory
productNote:Torowillnotassumeresponsibilityfor
damagecausedbyimpropersubstitutions,souseonly
productsfromreputablemanufacturerswhowillstand
behindtheirrecommendation.

HighViscosityIndex/LowPourPointAnti-wearHydraulic
Fluid,ISOVG46

MaterialProperties:

Viscosity,ASTMD445cSt@40°C44to48

ViscosityIndexASTM
D2270
PourPoint,ASTMD97-34°Fto-49°F

IndustrySpecications:

VickersI-286-S(QualityLevel),VickersM-2950-S
(QualityLevel),DenisonHF-0

cSt@100°C7.9to8.5
140to160

Figure34

1.Hydraulictankcap

3.Removedipstickfromllerneckandwipeitwith
acleanrag.Insertdipstickintollerneck;then
removeitandchecklevelofuid.Fluidlevelshould
bewithin1/4inchofmarkondipstick.

4.Iflevelislow ,addappropriateuidtoraiselevel
tofullmark.

5.Installdipstickandcapontollerneck.

29

CheckingtheTirePressure

BleedingtheFuelSystem

ServiceInterval:Beforeeachuseordaily

Thetiresareover-inatedforshipping.Therefore,
releasesomeoftheairtoreducethepressure.Correct
airpressureinthefrontandreartiresis15-20psi.

Important:Maintainevenpressureinalltiresto
ensureagoodquality-of-cutandpropermachine
performance.Donotunderinate.

CheckingtheReeltoBedknife
Contact

ServiceInterval:Beforeeachuseordaily

Eachdaybeforeoperating,checkreeltobedknife
contact,regardlessifqualityofcuthadpreviouslybeen
acceptable.Theremustbelightcontactacrossthefull
lengthofthereelandbedknife(refertoAdjustingReel
toBedknifeinCuttingUnitOperator'sManual).

StartingandStopping

1.Sitontheseat,keepfootofftractionpedal.
Ensureparkingbrakeisengaged,tractionpedal
isinNeutral,throttleisinSlowpositionandthe
Enable/DisableswitchisintheDisableposition.

2.TurnignitionswitchtoOn/Preheatposition.
Anautomatictimerwillcontrolpreheatfor
approximately6seconds.Afterpreheat,turnkey
toStartposition.Cranktheenginefornolonger
than15seconds.Releasekeywhenenginestarts.
Ifadditionalpreheatisrequired,turnkeytoOff
positionthentoOn/Preheatposition.Repeat
processasrequired.

1.Parkthemachineonalevelsurface.Makesurefuel
tankisatleasthalffull.

2.Unlatchandraisehood.

DANGER

Undercertainconditions,dieselfuelandfuel
vaporsarehighlyammableandexplosive.A
reorexplosionfromfuelcanburnyouand
othersandcancausepropertydamage.

•Useafunnelandllthefueltankoutdoors,
inanopenarea,whentheengineisoffand
iscold.Wipeupanyfuelthatspills.

•Donotllthefueltankcompletelyfull.Add
fueltothefueltankuntilthelevelis1in.
(25mm)belowthebottomofthellerneck.
Thisemptyspaceinthetankallowsthefuel
toexpand.

•Neversmokewhenhandlingfuel,andstay
awayfromanopenameorwherefuel
fumesmaybeignitedbyaspark.

•Storefuelinaclean,safety-approved
containerandkeepthecapinplace.

3.Openventplugonthefuellter/waterseparator
(Figure35).

3.Runengineatidlespeedorpartialthrottleuntil
enginewarmsup.

4.Tostop,moveallcontrolstoNeutralandsetparking
brake.Returnthrottletotheidleposition,turnkey
toOFFandremoveitfromswitch.

Important:Allowenginetoidlefor5minutes
beforeshuttingitoffafterafullloadoperation.
Failuretodosomayleadtoturbo-charger
trouble.

Note:Werecommendthatanytimethemachineis
parked(shortorlongterm)thecuttingunitsshould
beloweredtotheground.Thisrelievespressure
fromtheliftcircuitandeliminatestheriskofthe
cuttingunitsaccidentallyloweringtotheground.

Figure35

1.Fuellter/waterseparator

4.TurnkeyinignitionswitchtotheOnposition.
Electricfuelpumpwillbeginoperation,thereby
forcingairoutaroundventplug.LeavekeyinOn
positionuntilasolidstreamoffuelowsoutaround
plug.TightenplugandturnkeytoOFF .

5.Opentheairbleedscrewonthefuelinjectionpump
(Figure36).

30

2.Ventplug

g019459

Figure36

Figure37

1.Bypassvalve

1.Fuelinjectionpumpbleedscrew

6.TurnkeyinignitionswitchtotheOnposition.
Electricfuelpumpwillbeginoperation,thereby
forcingairoutaroundairbleedscrew .Leavekeyin
Onpositionuntilasolidstreamoffuelowsout
aroundscrew .TightenscrewandturnkeytoOff.

Note:Normally,engineshouldstartafterabove
bleedingproceduresarefollowed.However,if
enginedoesnotstart,airmaybetrappedbetween
injectionpumpandinjectors;refertoBleedingAir
FromInjectorsintheMaintenanceSection.

PushingorTowingthe
Machine

Inanemergency,themachinecanbemovedby
actuatingthebypassvalveinthevariabledisplacement
hydraulicpumpandpushingortowingthemachine.

Important:Donotpushortowthemachine
fasterthan2-3mph(3-4.8km/h)becauseinternal
transmissiondamagemayoccur.Thebypassvalve
mustbeopenwheneverthemachineispushedor
towed.

1.Thebypassvalveislocatedontopofvariable
displacementpump(
90°,ineitherdirection,toopenandallowoilto
bypassinternally.Becauseuidisbypassed,the
machinecanbemovedslowlywithoutdamaging
thetransmission.

Figure37).Rotatethevalve

2.Closethebypassvalvebeforestartingtheengine.
However,donotexceed5-8ft.-lb.(7-11N·m)
torquetoclosethevalve.

Important:Runningtheenginewiththe
bypassvalveopenwillcausethetransmission
tooverheat.

CheckingtheInterlock
Switches

CAUTION

Ifsafetyinterlockswitchesaredisconnectedor
damagedthemachinecouldoperateunexpectedly
causingpersonalinjury.

•Donottamperwiththeinterlockswitches.

•Checktheoperationoftheinterlockswitches
dailyandreplaceanydamagedswitchesbefore
operatingthemachine.

Thepurposeoftheinterlockswitchesaretoprevent
theenginefromcrankingorstartingunlessthetraction
pedalisinNeutral,theEnable/Disableswitchisin
DisableandtheLowerMow/Raisecontrolisinthe
neutralposition.Inaddition,theenginewillstopwhen
thetractionpedalisdepressedwitheithertheoperator
offtheseatortheparkingbrakeengaged.

Toverifyinterlockswitchfunction:

ServiceInterval:Beforeeachuseordaily

1.Parkmachineonalevelsurface,lowerthecutting
units,stoptheengineandengagetheparkingbrake.

2.Opencontrolpanelcover.Locatewireharnessand
loopbackconnector.Carefullyunplugloopback
connectorfromharnessconnector(

31

Figure38).

correspondingswitchisclosed.Repeatoneach
switchthatispossibletobechangedbyhand.

7.IfswitchisclosedandappropriateLEDdoesnot
turnon,checkallwiringandconnectionstoswitch
and/orcheckswitcheswithanohmmeter.Replace
anydamagedswitchesandrepairanydamaged
wiring.

Figure38

1.Loop-backconnector

3.ConnecttheDiagnosticACEdisplayconnector
totheharnessconnector(

Figure39).Makesure
correctoverlaydecalispositionedonDiagnostic
ACEdisplay.

Figure39

1.DiagnosticACE

4.TurnthekeyswitchtotheOnposition,butdonot
startmachine.

Note:Theredtextontheoverlaydecalrefersto
inputswitchesandthegreentextreferstooutputs.

5.The“inputsdisplayed”LED,onlowerrightcolumn
oftheDiagnosticACE,shouldbeilluminated.If
“outputsdisplayed”LEDisilluminated,pressand
releasethetogglebutton,onDiagnosticACE,to
changeLEDto“inputsdisplayed”.Donothold
buttondown.

6.TheDiagnosticACEwillilluminatetheLED
associatedwitheachoftheinputswhenthatinput
switchisclosed.

Individually,changeeachoftheswitchesfrom
opentoclosed(i.e.,sitonseat,engagetraction
pedal,etc.),andnotethattheappropriateLED
onDiagnosticACEwillblinkonandoffwhen

TheDiagnosticACEalsohastheabilitytodetect
whichoutputsolenoidsorrelaysareturnedon.This
isaquickwaytodetermineifamachinemalfunction
iselectricalorhydraulic.

Toverifyoutputfunction:

1.Parkmachineonalevelsurface,lowerthecutting
units,stoptheengineandengagetheparkingbrake.

2.Opencontrolpanelcover.Locatewireharness
andconnectorsnearcontroller.Carefullyunplug
loopbackconnectorfromharnessconnector.

3.ConnecttheDiagnosticACEconnectortothe
harnessconnector.Makesurecorrectoverlaydecal
ispositionedonDiagnosticACE.

4.TurnthekeyswitchtotheOnposition,butdonot
startmachine.

Note:Theredtextontheoverlaydecalrefersto
inputswitchesandthegreentextreferstooutputs.

5.The“outputsdisplayed”LED ,onlowerright
columnofDiagnosticACE,shouldbeilluminated.
If“inputsdisplayed”;LEDisilluminated,pressthe
togglebutton,onDiagnosticACE,tochangeLED
to“outputsdisplayed.”

Note:Itmaybenecessarytotogglebetween
“inputsdisplayed”and“outputsdisplayed”several
timestodothefollowingstep.Totogglebackand
forth,presstogglebuttononce.Thismaybedone
asoftenasrequired.Donotholdthebutton.

6.Sitontheseatandattempttooperatethedesired
functionofthemachine.Theappropriateoutput
LED'sshouldilluminatetoindicatethattheECU
isturningonthatfunction.(RefertoHydraulic
SolenoidValveFunctionstobecertainofthe
speciedoutputLEDs.)

Note:IfanyoutputLEDisblinking,this
indicatesanelectricalproblemwiththatOUTPUT.
Repair/replacedefectiveelectricalpartsimmediately .
ToresetablinkingLED,turnthekeyswitch“Off”,
thenback“On”andclearthecontrollersfault
memory(RefertoClearingtheFaultMemoryin
FaultMemoryandRetrieval).

IfnooutputLEDsareblinking,butthecorrect
outputLED'sdonotilluminate,verifythatthe

32

requiredinputswitchesareinthenecessary
positionstoallowthatfunctiontooccur.Verify
correctswitchfunction.

IftheoutputLEDsareonasspecied,butthe
machinedoesnotfunctionproperly,thisindicatesa
non-electricalproblem.Repairasnecessary.

TooldisplayonOutputstoseefault.The
Problemcircuitwillbeashing.Recordswill
repeatuntilkeyisturnedoff.Unitwillnotstart
inthismode.

ClearingtheFaultMemory(DiagnosticT ool
notrequired)

Note:Duetoelectricalsystemconstraints,
theoutputLED'sfor“Start”,“Preheat”and
“ETR/ALT”maynotblinkeventhoughan
electricalproblemmayexistforthosefunctions.If
themachineproblemappearstobewithoneof
thesefunctions,becertaintochecktheelectrical
circuitwithavolt/ohmmetertoverifythatno
electricalproblemexiststothesefunctions.

Ifeachinputswitchisinthecorrectposition
andfunctioningcorrectly,buttheoutputLEDs
arenotcorrectlyilluminated,thisindicatesan
ECUproblem.Ifthisoccurs,contactyourT oro
Distributorforassistance.

FaultMemoryandRetrieval

IftheControllersensesafaultononeoftheoutput
solenoids,itwillashthemachinesdiagnosticLamp

(ReelDiagnosticLamponconsoleorGreenDiagnostic
Lampunderconsole)andstorethefaultintothe
Controllers(ECU)memory.Thefaultcanthenbe
retrievedandviewedwiththeDiagnosticACEhand
heldtooloralaptop/PCatanytime.TheController
willstoreone(1)faultatatimeandwillnotstore
anotherdifferentfaultuntiltherstfaultiscleared.

7.RotateignitionkeytoOffposition.

8.TurnBacklapSwitchtotheFrontorRearBacklap
position.

9.TurntheReelControlSwitchtoEnableposition.

10.MovetheJoysticktotheRaisepositionandhold.

11.TurntheignitionkeytoOn,andcontinuetohold
theJoystickintheRaisepositionuntiltheReel
ControlLampstartstoash(approx.2seconds).

12.ReleasetheJoystickandturntheKeyOff.Memory
isnowcleared.

13.TurntheBacklapSwitchtoOffandEnableSwitch
toDisableposition.

Important:TheDiagnosticACEdisplaymust
notbeleftconnectedtothemachine.Itis
notdesignedtowithstandtheenvironment
ofthemachine'severydayuse.Whendone
usingDiagnosticACE,disconnectitfromthe
machineandreconnectloopbackconnectorto
harnessconnector.Machinewillnotoperate
withoutloopbackconnectorinstalledon
harness.StoreDiagnosticACEindry,secure
locationinshop,notonmachine.

RetrievingFaultInformation

RetrievingStoredFaults(Donotsitinseat)

1.RotateignitionkeytoOffposition.

2.ConnecttheHandheldDiagnosticTooltothe
desiredControllerLoopbackConnector(usethe
properoverlay).

3.MovetheJoysticktotheRaisepositionandhold.

4.RotateignitionkeytoOnposition,andcontinueto
holdtheJoystickinRaisepositionuntilthetopleft
DiagnosticToollightcomeson(approx.2seconds).

5.ReleasetheJoysticktothecenterposition.

6.HandheldToolwillnowplaybackthefaultretained
intheControllermemory.

Important:Thedisplaywillshoweight(8)
individualrecordswiththefaultdisplayedon
the8threcord.Eachrecordwillbedisplayed
for10seconds.BesuretohavetheDiagnostic

HydraulicSolenoidValve
Functions

Usethelistbelowtoidentifyanddescribethedifferent
functionsofthesolenoidsinthehydraulicmanifold.
Eachsolenoidmustbeenergizedtoallowfunctionto
occur.

Solenoid

MSV1

MSV2

SV4Liftfrontwingcuttingunits

SV3Liftfrontcentercuttingunit

SV5Liftrearcuttingunits

SV1Pressurizeraise/lower

SV2Direction:ON=Raise,

SV6Leftrearwingcuttingunit

Function

Frontreelcircuit

Rearreelcircuit

hydrauliccircuit

OFF=Lower

33

Solenoid

SV7

SV8

Function

Rightrearwingcuttingunit

LoadHolding

On.Themachineshouldnotbestarteduntilthe
glowplugcycleiscomplete.

Mowing

OperatingTips

Familiarization

Beforemowinggrass,practiceoperatingmachinein
anopenarea.Startandstoptheengine.Operatein
forwardandreverse.Lowerandraisecuttingunitsand
engageanddisengagereels.Whenyoufeelfamiliarwith
themachine,practiceoperatingupanddownslopes
atdifferentspeeds.

Thebrakescanbeusedtoassistinturningthemachine.
However,usethemcarefully,especiallyonsoftor
wetgrassconditionsbecausetheturfmaybetorn
accidentally.Individualturningbrakesmayalsobeused
tohelpmaintaintraction.Forexample,insomeslope
conditions,theuphillwheelslipsandlosestraction.If
thissituationoccurs,depressuphillturnpedalgradually
andintermittentlyuntiltheuphillwheelstopsslipping,
thus,increasingtractiononthedownhillwheel.

Important:Beforemowinggrass,practice
operatingthemachineinturns.Turfdamagein
turnsmayoccurespeciallyundersoftorwetgrass
conditionsiftheturniscompletedatahighspeed
oratasmallturningradius.Maintainaspeed
below3mphduringaturnandaturningradius
greaterthan8feettominimizeturfdamagefrom
tiresorcuttingunits.Mountingthecuttingunits
withthesteeringpininthefrontmountingholewill
allowthecuttingunittosteeritselfasthetraction
unitturnsprovidingoptimummaneuverabilityand
cuttingperformanceinturns.Duringcross-cutting
offairways,ateardropshapeturnisrecommended
toincreasecuttingproductivityandminimizeturf
damage.

StartengineandmovethrottletoFASTso
engineisrunningatmaximumspeed.Movethe
Enable/DisableswitchtoENABLEandusethe
LOWERMOW/RAISElevertocontrolthecutting
units(frontcuttingunitsaretimedtolowerbefore
therearcuttingunits).Tomoveforwardandcut
grass,presstractionpedalforward.Maintainaspeed
whichdoesnotresultintheReelControlLightbeing
illuminated.Graduallyincreaseordecreasetraction
speedtoensureproperclipismaintained.

Transport

MovetheEnable/DisableswitchtoJoyStickDisable
(midposition),lockbrakepedalstogetherandraisethe
cuttingunitstothetransportposition.Becarefulwhen
drivingbetweenobjectssoyoudonotaccidentally
damagethemachineorcuttingunits.Useextracare
whenoperatingmachineonslopes.Driveslowlyand
avoidsharpturnsonslopestopreventrollovers.The
cuttingunitsshouldbeloweredwhengoingdownhill
forsteeringcontrol.

DANGER

Whenoperatingthemachine,alwaysusetheseat
beltandROPStogether.Donotuseaseatbelt
withoutaROPS.

WarningSystem

Ifawarninglightcomesonduringoperation,stopthe
machineimmediatelyandcorrecttheproblembefore
continuingoperation.Seriousdamagecouldoccurif
themachineisoperatedwithamalfunction.

Important:TheRedDiagnosticLight,onthe
steeringtower,indicateswhentheglowplugsare

34

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst8hours

Aftertherst50hours

Aftertherst200hours

Beforeeachuseordaily

Every50hours

Every100hours

MaintenanceProcedure

•Checkthetorqueofthewheelnutsorbolts(aftertherst1–4hoursofoperation
andthenafter10hoursofoperation).

•Changetheengineoilandoillter.

•Changetheplanetarygeardriveoil.

•Changetherearaxlelubricant.

•Checktheengineoillevel.

•Checkandcleanthecoolingsystem.

•Checkthehydraulicuidlevel.

•Checkthetirepressure.

•Checkthereeltobedknifecontact.

•Checktheinterlockswitches.

•Drainthefuellter/waterseparator.

•Removedebrisfromtherearscreen,oilcooler,andradiator(morefrequentlyin
dirtyconditions).

•Inspectthehydrauliclinesandhosesforleaks,kinkedlines,loosemounting
supports,wear,loosettings,weatherdeterioration,andchemicaldeterioration.

•Greasethebearingsandbushings.

•Checktheconditionofthebattery.

•Inspectandtightenthecoolingsystemhosesandconnections.

•Checktheconditionandtensionofthealternatorbelt.

Every150hours

Every200hours

Every400hours

Every800hours

Every2years

Important:Refertoyourengine

•Changetheengineoilandoillter.

•Checkthetorqueofthewheelnutsorbolts.

•Servicetheaircleaner.(Servicetheaircleanerearlieriftheaircleanerindicator
showsred.Serviceitmorefrequentlyinextremelydirtyordustyconditions.)

•Checkthefuellinesandconnections.

•Replacethefuelltercanister.

•Checktheplanetarygeardriveoil(Also,checkifexternalleakageisobserved)

•Checktherearaxlelubricantlevel.

•Changetheplanetarygeardriveoil.(Oryearly,whichevercomesrst)

•Changetherearaxlelubricant.

•Checktherearwheeltoe-in.

•Changethehydraulicuid.

•Drainandcleanthefueltank.

•Drainandushthecoolingsystem.

•Replaceallmovinghoses.

•Drain/ushthehydraulictank.

Operator's Man ual

foradditionalmaintenanceprocedures.

CAUTION

Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineandseriouslyinjure
youorotherbystanders.

Removethekeyfromtheignitionanddisconnectthewirefromthesparkplugbeforeyoudoany
maintenance.Setthewireasidesothatitdoesnotaccidentallycontactthesparkplug.

35

ServiceIntervalChart

g023347

Figure40

36

DailyMaintenanceChecklist

Duplicatethispageforroutineuse.

Checksafetyinterlockoperation.

Checkbrakeoperation.

Checkengineoilandfuellevel.

Checkcoolingsystemuidlevel.

Drainthewater/fuelseparator.

Checktheairlterrestrictionindicator.

Checktheradiatorandscreenfordebris.

Checkunusualenginenoises.

Checkunusualoperatingnoises.

Checkthetransmissionoillevel.

Checkthehydraulicsystemoillevel.

Checkthehydrauliclterindicator.

Checkthehydraulichosesfordamage.

Checkforuidleaks.

Checkthetirepressure.

Checkinstrumentoperation.

Checkthereel-to-bedknifeadjustment.

Checktheheight-of-cutadjustment.

Lubricateallgreasettings.

Touchupdamagedpaint.

1

2

3

Fortheweekof: MaintenanceCheckItem

Mon.Tues.Wed.Thurs.Fri.

Sat.Sun.

1.Checktheglowplugandinjectornozzlesifhardstarting,excesssmoke,orroughrunningisnoted.

2.Checkwiththeenginerunningandoilatoperatingtemperature.

3.Immediatelyaftereverywashing,regardlessoftheintervallisted

37

Lubrication

g019485

g019486

g019487

g019495

GreasingtheBearingsand
Bushings

ServiceInterval:Every50hours

Themachinehasgreasettingsthatmustbelubricated
regularlywithNo.2GeneralPurposeLithiumBase
Grease.Ifmachineisoperatedundernormalconditions,
lubricateallbearingsandbushingsafterevery50hours
ofoperationorimmediatelyaftereverywashing.

Thegreasettinglocationsandquantitiesare:

•Cuttingunitcarrierframeandpivot(2ea.)
Figure41).

(

Figure42

1.Topttingonkingpin

Figure41

•Rearaxletierod(2)(Figure42).

•Steeringcylinderballjoints(2)(Figure42).

•Kingpinbushings(2)(

Figure42).Thetoptting

onthekingpinshouldonlybelubricated
annually(2pumps).

•Frontliftcylinders(3)(Figure43andFigure44).

Figure43

Figure44

38

•Rearliftcylinderpivot(2)(Figure45).

g019489

G019490

G019494

g019492

G019493

•Rearliftarmpivots(2)(Figure48).

Figure45

•Liftarmpivot(3)(Figure46).

Figure46

•Rearaxlepivot(Figure47).

Figure48

•Brakepedalshaft(1)(Figure49).

Figure49

Figure47

39

EngineMaintenance

Thiscleaningprocesspreventsdebrisfrommigrating
intotheintakewhentheprimarylterisremoved.

ServicingtheAirCleaner

ServiceInterval:Every400hours

Checktheaircleanerbodyfordamagewhichcould
causeanairleak.Replaceifdamaged.Checkthewhole
intakesystemforleaks,damageorloosehoseclamps.

Servicetheaircleanerlteronlywhentheservice
indicator(
beforeitisnecessaryonlyincreasesthechanceofdirt
enteringtheenginewhenthelterisremoved.

Figure50)requiresit.Changingtheairlter

Figure50

3.Removeandreplacetheprimarylter(

Figure52).

Cleaningoftheusedelementisnotrecommended
duetothepossibilityofdamagetotheltermedia.
Inspectthenewlterforshippingdamage,checking
thesealingendofthelterandthebody.Donot
useadamagedelement.Insertthenewlterby
applyingpressuretotheouterrimoftheelementto
seatitinthecanister.Donotapplypressuretothe

exiblecenterofthelter.

Figure52

1.Aircleanerprimarylter

1.Aircleanerindicator

Important:Besurethecoverisseatedcorrectly
andsealswiththeaircleanerbody.

1.Pullthelatchoutwardandrotatetheaircleaner
covercounterclockwise(Figure51).

Figure51

1.Aircleanerlatch2.Aircleanercover

2.Removethecoverfromtheaircleanerbody .Before
removingthelter,uselowpressureair(40psi,
cleananddry)tohelpremovelargeaccumulations
ofdebrispackedbetweenoutsideofprimarylter
andthecanister.Avoidusinghighpressureair

whichcouldforcedirtthroughthelterintothe
intaketract.

Important:Neverattempttocleanthesafety
lter(Figure53).Replacethesafetylterwitha
newoneaftereverythreeprimarylterservices.

Figure53

1.Aircleanersafetylter

4.Cleanthedirtejectionportlocatedintheremovable
cover.Removetherubberoutletvalvefromthe
cover,cleanthecavityandreplacetheoutletvalve.

5.Installthecoverorientingtherubberoutletvalvein
adownwardposition—betweenapproximately5:00
to7:00whenviewedfromtheend.

6.Resettheindicator(Figure50)ifitshowsred.

40

ServicingtheEngineOiland

g019470

1

g019471

1

g019472

1

2

AdjustingThrottle

Filter

ServiceInterval:Aftertherst50hours

Every150hours

Changeoilandlterinitiallyaftertherst50hoursof
operation,thereafterchangeoilandlterevery150
hours.

1.Removedrainplug(
drainpan.Whenoilstops,installdrainplug.

1.Drainplugs

Figure54)andletoilowinto

Figure54

1.Positionthrottleleverforwardsoitstopsagainst
seatbaseslot.

2.Loosenthethrottlecableconnectorontheleverarm
attheinjectionpump(

1.Injectionpumpleverarm

Figure56).

Figure56

2.Connector

3.Holdtheinjectionpumpleverarmagainstthehigh
idlestopandtightenthecableconnector.

Note:Whentightened,thecableconnectormustbe
freetoswivel.

2.Removeoillter(Figure55).Applyalightcoatof
cleanoiltothenewltersealbeforescrewingiton.
Donotover-tighten.

Figure55

1.Oillter

3.Addoiltothecrankcase.Capacityis7.5qt.(7L)
withlter.

4.Torquethelocknut,usedtosetthefrictiondeviceon
thethrottlelever,to40-55in-lb.Themaximumforce
requiredtooperatethethrottlelevershouldbe20lb.

41

FuelSystem

G019473

1

FuelLinesandConnections

Maintenance

FuelTank

ServiceInterval:Every2years

Drainandcleanfueltankevery2years.Also,drainand
cleantankiffuelsystembecomescontaminatedorif
machineistobestoredforanextendedperiod.Use
cleanfueltoushoutthetank.

Figure57

ServiceInterval:Every400hours

Checklinesandconnectionsevery400hoursoryearly,
whichevercomesrst.Inspectfordeterioration,
damage,orlooseconnections.

FuelFilter/WaterSeparator

ServiceInterval:Beforeeachuseordaily

Every400hours

Drainwaterorothercontaminantsfromfuellter/water
separator(Figure58)daily .

1.Locatefuellter,underhood,andplaceaclean
containerunderit.

2.Loosendrainplugonbottomofltercanister.
Tightenplugafterdraining.

1.Fueltankdrain

DANGER

Undercertainconditions,dieselfuelandfuel
vaporsarehighlyammableandexplosive.Are
orexplosionfromfuelcanburnyouandothersand
cancausepropertydamage.

•Useafunnelandllthefueltankoutdoors,in
anopenarea,whentheengineisoffandiscold.
Wipeupanyfuelthatspills.

•Donotllthefueltankcompletelyfull.Addfuel
tothefueltankuntilthelevelis1/4to1/2in.(6
to13mm)belowthebottomofthellerneck.
Thisemptyspaceinthetankallowsthefuelto
expand.

•Neversmokewhenhandlingfuel,andstayaway
fromanopenameorwherefuelfumesmaybe
ignitedbyaspark.

•Storefuelinaclean,safety-approvedcontainer
andkeepthecapinplace.

Figure58

1.Waterseparatorltercanister

Replaceltercanisterafterevery400hoursof
operation.

3.Cleanareawhereltercanistermounts.

4.Removeltercanisterandcleanmountingsurface.

5.Lubricategasketonltercanisterwithcleanoil.

6.Installltercanisterbyhanduntilgasketcontacts
mountingsurface,thenrotateanadditional1/2turn.

7.Tightenthedrainplugonthebottomofthelter
canister.

42

BleedingAirFromInjectors

ElectricalSystem

Note:Thisprocedureshouldbeusedonlyiffuel
systemhasbeenpurgedofairthroughnormalpriming
proceduresandenginewillnotstart;refertoBleeding
theFuelSysteminOperationSection.

1.LoosenthepipeconnectiontotheNo.1nozzleand
holderassembly .

Figure59

1.Fuelinjectors(4)

2.MovethrottletoFastposition.

3.TurnkeyinkeyswitchtoRunpositionandwatch
fuelowaroundconnector.TurnkeytoOffposition
whensolidowisobserved.

4.Tightenpipeconnectorsecurely .

5.Repeatsteps1through4onremainingnozzles.

Note:Fanshroudmaybeeasilyunboltedfrom
machinetosimplifycleaning.

6.Installrearscreenandsecurelatches.

Note:Donotusewatertocleanengine,asdamage
mayoccur.

Maintenance

BatteryCare

ServiceInterval:Every50hours

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandleadcompounds,

chemicalsknowntotheStateofCalifornia

tocausecancerandreproductiveharm.

Washhandsafterhandling.

Important:Beforeweldingonamachine,
disconnectbothcablesfromthebattery,disconnect
bothwireharnessplugsfromtheelectroniccontrol
unitandtheterminalconnectorfromthealternator
topreventdamagetotheelectricalsystem.

WARNING

Batteryterminalsormetaltoolscouldshortagainst
metaltractorcomponentscausingsparks.Sparks
cancausethebatterygassestoexplode,resulting
inpersonalinjury.

•Whenremovingorinstallingthebattery,donot
allowthebatteryterminalstotouchanymetal
partsofthemachine.

•Donotallowmetaltoolstoshortbetween
thebatteryterminalsandmetalpartsofthe
machine.

WARNING

Incorrectbatterycableroutingcoulddamagethe
tractorandcablescausingsparks.Sparkscancause
thebatterygassestoexplode,resultinginpersonal
injury.

•Alwaysdisconnectthenegative(black)battery
cablebeforedisconnectingthepositive(red)
cable.

•Alwaysconnectthepositive(red)batterycable
beforeconnectingthenegative(black)cable.

Note:Checkbatteryconditionweeklyorafterevery50
hoursofoperation.Keepterminalsandentirebattery
casecleanbecauseadirtybatterywilldischargeslowly.
Tocleanthebattery,washtheentirecasewithsolution

43

ofbakingsodaandwater.Rinsewithclearwater.Coat

G019475

1

thebatterypostsandcableconnectorswithGrafo112X
(skin-over)grease(ToroPartNo.505-47)orpetroleum
jellytopreventcorrosion.

DANGER

Batteryelectrolytecontainssulfuricacidwhichisa
deadlypoisonandcausessevereburns.

•Donotdrinkelectrolyteandavoidcontactwith
skin,eyesorclothing.Wearsafetyglassesto
shieldyoureyesandrubberglovestoprotect
yourhands.

•Fillthebatterywherecleanwaterisalways
availableforushingtheskin.

Fuses

OptionalLighting

Important:Ifoptionallightingisbeaddedto

thetractionunit,usetheinstructions,schematic
(Figure62),andpartnumberslistedbelowto
preventdamagetothetractionunitselectrical
system.

InstallationInstructions

1.Installarelayintotheopenconnectorunderconsole.

2.Installlightswitch.

Note:Punchoutincontrolpanelprovidedfor
switchinstallation.

3.Crimparingorforkterminalontoeachofthe
orangewires(J24&J25)underconsole.Secure
themtolightswitchterminals#2.

Thereare7fusesinthemachineselectricalsystem.
Theyarelocatedbelowtheoperatorscontrolpanel
(Figure60andFigure61).

Figure60

1.Fuses

4.Splicepower(+)wiresfromlightstoredwireatJ23.

5.Securegroundwiresfromlightstotheengineblock
ground.

6.Installa10amp.fusetofuseblockatlocationshown
onfuseblockdecal.Donotexceedfuserating.

Figure61

44

Figure62

Switch

ToroPartNo.75-1010ToroPartNo.70-1480

HoneywellPartNo.1TL1-2HellaPartNo.8741 1B

Relay

45

DriveSystem

g019500

1

g019501

Maintenance

ChangingthePlanetaryGear
DriveOil

ServiceInterval:Aftertherst200hours

CheckingtheTorqueofthe
WheelNutsorBolts

ServiceInterval:Aftertherst8hours

Every200hours

WARNING

Failuretomaintainpropertorqueofthewheelnuts
couldresultinpersonalinjury.

Torquethefrontwheelnutsandrearwheelboltsto
85-100ft.-lb.after

after 10 hour s of operation.

thereafter.

1-4 hour s of operation and a gain

Torqueevery200hours

CheckingthePlanetaryGear
DriveOil

ServiceInterval:Every400hours(Also,checkif

externalleakageisobserved)

Checktheoillevelevery400hoursofoperation.
UsehighqualitySAE85W-140wt.gearlubeasa
replacement.

1.Withmachineonlevelsurface,positionthewheel
soonecheckplug(Figure63)isatthe12o'clock
positionandtheotherisat3o'clockposition.

Every800hours(Oryearly,whichever
comesrst)

Changetheoilinitiallyafter200hoursoperation.
Thereafter,changetheoilevery800hours.Usehigh
qualitySAE85W -140wt.gearlubeasreplacement.

1.Withmachineonlevelsurface,positionawheel
sooneofthecheck/drainplugsisatthelowest(6
o’clock)position(

1.Check/drainplug

2.Placeadrainpanundertheplanetaryhub,remove
plugandallowoiltodrain.

3.Placeadrainpanunderthebrakehousing,remove
thedrainplugandallowtheoiltodrain(

Figure64).

Figure64

Figure65).

Figure63

1.Checkplug(2)

2.Removetheplugatthe3o’clockposition(Figure63).
Oillevelshouldbeatthebottomofthecheckplug
hole.

3.Iftheoillevelislow ,removetheplugatthe12
o’clockpositionandaddoiluntilitbeginstoow
outoftheholeatthe3o’clockposition.

4.Re-installbothplugs.

5.Repeatsteps1through4ontheoppositeplanetary
gearassembly.

Figure65

1.Brakehousingdrainplug

4.Whenalloftheoilhasdrainedfrombothlocations,
re-installthepluginthebrakehousing.

5.Rotatethewheeluntiltheopenplugholeinthe
planetaryisatthetwelveo'clockposition.

6.Throughtheopenhole,slowlylltheplanetarywith
22ounces.(0.6liter)ofhighqualitySAE85W -140
wt.gearlube.

46

Important:Iftheplanetaryllsbeforethe
22ounces(0.6liter)ofoilisadded,waitone
hourorinstalltheplugandmovethemachine
approximatelytenfeettodistributetheoil
throughthebrakesystem.Then,removethe
plugandaddtheremainingoil.

7.Re-installtheplug.

8.Repeattheprocedureontheopposite
planetary/brakeassembly .

CheckingtheRearAxle
Lubricant

ServiceInterval:Every400hours

TherearaxleisshippedfromthefactorylledwithSAE
85W-140wt.gearlube.Checklevelbeforeengineisrst
startedandevery400hoursthereafter.Capacityis80oz.
Visuallyinspectforleaksdaily.

1.Positionthemachineonalevelsurface.

2.Removeacheckplug(
axleandmakesurelubricantisuptobottomofhole.
Iflevelislow ,removethellplug(Figure66)and
addenoughlubricanttobringtheleveluptothe
bottomofthecheckplugholes.

Figure66)fromoneendof

Figure67

1.Drainpluglocation

3.Removethe(3)oillevelcheckplugsandmainaxle
ventcaptoeaseindrainingoftheoil.

4.Removethedrainplugsandallowtheoiltodrain
intothepans.

5.Installtheplugs.

6.Removeacheckplugandllaxlewithapproximately
80oz.of85W-140gearlubeoruntillubricantisup
tobottomofhole.

7.Installcheckplug.

Figure66

1.Checkplug

2.Fillplug

ChangingtheRearAxle
Lubricant

ServiceInterval:Aftertherst200hours

Every800hours

Changetheoilinitiallyaftertherst200hoursof
operationandevery800hoursofoperationthereafter.

1.Positionthemachineonalevelsurface.

2.Cleantheareaaroundthe3drainplugs,1oneach
endand1inthecenter(Figure67).

47

RearWheelToe-In

G019499

1

2

2

1

ServiceInterval:Every800hours

Afterevery800operatinghoursorannually,checkthe
rearwheeltoe-in.

1.Measurethecenter-to-centerdistance(ataxleheight)
atthefrontandrearofthesteeringtires.Thefront
measurementmustbe1/8in.(3mm)lessthanthe
rearmeasurement.

2.Toadjust,removethecotterpinandnutfromeither
tierodballjoint.Removetierodballjointfromaxle
casesupport(Figure68).

3.Loosentheclampsatbothendsofthetierods
(Figure68).

Note:On4wheeldrivemodels,leftreartiremust
alsobeofftheshopoor.

3.Startengineandallowrunatlowidle.

4.Adjustjamnutsonpumprodendtomovepump
controltubeforwardtoeliminateforwardcreepor
rearwardtoeliminaterearwardcreep(Figure69).

Figure69

Figure68

1.Tierodclamp2.Tierodballjoint

4.Rotatethedetachedballjointinwardoroutward
one(1)completerevolution.Tightenclampatloose
endoftierod.

5.Rotatetheentiretierodassemblythesamedirection
(inwardoroutward)one(1)completerevolution.
Tightenclampatconnectedendoftierod.

6.Installtheballjointintheaxlecasesupportand
tightenthenutngertight.Measuretoe-in.

7.Repeatprocedureifnecessary.

8.Tightenthenutandinstallanewcotterpinwhen
theadjustmentiscorrect.

AdjustingtheTractionDrive
forNeutral

Themachinemustnotcreepwhentractionpedalis
released.Ifitdoescreep,anadjustmentisrequired.

1.Pumprod2.Pumpcontroltube

5.Afterwheelrotationceases,tightenjamnutsto
secureadjustment.

6.Stoptheengineandreleasetherightbrake.Remove
jackstandsandlowerthemachinetotheshopoor.
Testdrivethemachinetomakesureitdoesnotcreep.

1.Parkmachineonalevelsurface,shutengineoffand
lowercuttingunitstotheoor.Depressonlythe
rightbrakepedalandengagetheparkingbrake.

2.Jackupleftsideofmachineuntilfronttireisoffthe
shopoor.Supportmachinewithjackstandsto
preventitfromfallingaccidentally.

48

CoolingSystem

g019478

g019479

1

2

Maintenance

RemovingDebris

ServiceInterval:Beforeeachuseordaily

Removedebrisfromrearscreen,oilcoolerandradiator
daily,cleanmorefrequentlyindirtyconditions.

Important:Neverspraywaterontoahotengineas
damagetoenginemayoccur.

1.Turnengineoff,releasehoodlatchandraisehood.
Cleanengineareathoroughlyofalldebris.Close
hood.

2.Unlatchandremoverearscreen(
screenthoroughly .

Figure70).Clean

Figure71

1.Oilcooler

2.Radiator

MaintainingtheCooling
System

ServiceInterval:Every100hours

Every2years

Capacityofthesystemis10qts.(9.4l).Alwaysprotect
coolingsystemwitha50/50solutionofwaterand
permanentethyleneglycolanti-freeze.Donotusewater
onlyinthecoolingsystem.

1.Afterevery100operatinghours,inspectandtighten
hoseconnections.Replaceanydeterioratedhoses.

2.Afterevery2years,drainandushthecooling
system.Addanti-freeze;refertoCheckingthe
CoolingSystemintheOperationSection.

Figure70

1.Rearscreen

3.Unscrewknobsandpivotoilcoolerrearward
(Figure71).Cleanbothsidesofoilcoolerand
radiatorareathoroughlywithcompressedair.Do
notusewater.Openhoodandblowdebrisout
towardbackofmachine.Pivotoilcoolerbackinto
positionandtightenknobs.

49

BrakeMaintenance

1

G019480

1

2

G019481

BeltMaintenance

AdjustingtheServiceBrakes

Adjusttheservicebrakeswhenthereismorethan1inch
offreetravelofthebrakepedal,orwhenthebrakesdo
notworkeffectively .Freetravelisthedistancethebrake
pedalmovesbeforebrakingresistanceisfelt.

1.Disengagelockingpinfrombrakepedalssoboth
pedalsworkindependentlyofeachother.

2.Toreducefreetravelofbrakepedals,tightenthe
brakesbylooseningthefrontnutonthethreaded
endofthebrakecable(
nuttomovecablebackwarduntilbrakepedalshave
1/2to1inchoffreetravel.Tightenfrontnutsafter
brakesareadjustedcorrectly.

Figure72).Thentightenrear

CheckingtheAlternatorBelt

ServiceInterval:Every100hours

Checkconditionandtensionofalternatorbeltafter
every100hoursofoperation(Figure73).Replacebelt
asrequired.Checkthetensionasfollows:

1.Openhood.

2.Checktensionbydepressingbeltmidwaybetween
alternatorandcrankshaftpulleyswith22lb.offorce.
Beltshoulddeect7/16in.Ifdeectionisincorrect,
proceedtostep

3.Ifcorrect,continueoperation.

1.Brakecables

Figure72

1.Alternatorbelt2.Brace

3.Loosenboltsecuringbracetoengineandbolt
securingalternatortobrace.

4.Insertprybarbetweenalternatorandengineandpry
outonalternator.

5.Whenpropertensionisachieved,tightenalternator
andbraceboltstosecureadjustment.

6.Tightenlocknuttosecureadjustment.

Figure73

50

HydraulicSystem

1

G019521

g019482

1

2

ReplacingtheHydraulicFilter

Maintenance

ChangingtheHydraulicFluid

ServiceInterval:Every800hours

Changehydraulicuidafterevery800operatinghours,
innormalconditions.Ifuidbecomescontaminated,
contactyourlocalTorodistributorbecausethesystem
mustbeushed.Contaminateduidlooksmilkyor
blackwhencomparedtocleanoil.

1.Turnengineoffandraisehood.

2.Removedrainplugfrombottomofreservoir
Figure74)andlethydraulicuidowintodrain

(
pan.Installandtightenplugwhenhydraulicuid
stopsdraining.

Thehydraulicsystemlterheadisequippedwitha
serviceintervalindicator.Withtheenginerunning,view
theindicator,itshouldbeintheGREENzone.When
theindicatorisintheREDzone,thelterelement
shouldbechanged.

UsetheT ororeplacementlter(PartNo.94-2621).

Important:Useofanyotherltermayvoidthe
warrantyonsomecomponents.

1.Positionmachineonalevelsurface,lowerthecutting
units,stoptheengine,engagetheparkingbrakesand
removekeyfromignitionswitch.

2.Cleanareaaroundltermountingarea.Placedrain
panunderlterandremovelter(

Figure75).

Figure74

1.Hydraulicreservoir

3.Fillreservoirwithapproximately8.5gallonsof
hydraulicuid;refertoCheckingtheHydraulicFluid.

Important:Useonlyhydraulicuidsspecied.
Otheruidscouldcausesystemdamage.

4.Installreservoircap.Startengineanduseallhydraulic
controlstodistributehydraulicuidthroughoutthe
system.Alsocheckforleaks.Thenstoptheengine.

5.Checklevelofuidandaddenoughtoraiselevelto
Fullmarkondipstick.Donotoverll.

Figure75

1.Hydrauliclter2.Serviceintervalindicator

3.Lubricatenewltergasketandllthelterwith
hydraulicuid.

4.Ensurethattheltermountingareaisclean.Screw
lteronuntilgasketcontactsmountingplate.Then
tightenlter1/2turn.

5.Startengineandletrunforabouttwominutesto
purgeairfromthesystem.Stoptheengineand
checkforleaks.

CheckingtheHydraulicLines
andHoses

ServiceInterval:Beforeeachuseordaily

Inspecthydrauliclinesandhosesdailyforleaks,kinked
lines,loosemountingsupports,wear,loosettings,
weatherdeteriorationandchemicaldeterioration.Make
allnecessaryrepairsbeforeoperating.

51

WARNING

Hydraulicuidescapingunderpressurecan
penetrateskinandcauseinjury.

•Makesureallhydraulicuidhosesandlinesare
ingoodconditionandallhydraulicconnections
andttingsaretightbeforeapplyingpressureto
thehydraulicsystem.

•Keepyourbodyandhandsawayfrompin
holeleaksornozzlesthatejecthighpressure
hydraulicuid.

•Usecardboardorpapertondhydraulicleaks.

•Safelyrelieveallpressureinthehydraulicsystem
beforeperforminganyworkonthehydraulic
system.

•Getimmediatemedicalhelpifuidisinjected
intoskin.

HydraulicSystemTestPorts

Thetestportsareusedtotestpressureinthehydraulic
circuits.ContactyourlocalTorodistributorfor
assistance.

1.TestPortA(Figure76andFigure77)isusedto
assistintroubleshootingthehydrauliccircuitfor
theliftcylinders.

Figure77

Models03806,03807and03812

1.TestportA(Liftcylinders)

2.TestPortB(Figure78)isusedtoassistintrouble
shootingthehydrauliccircuitforthefrontcutting
units.

3.TestPortC(

Figure78)isusedtoassistintrouble
shootingthehydrauliccircuitfortherearcutting
units.

1.TestportA(Liftcylinders)

Figure76

Model03808and03813

Figure78

1.TestportB(Frontcutting
units)

2.TestportC(Rearcutting
units)

4.TestPortDislocatedonthebottomofthe
hydrostatictransmission(Figure79)andisusedto
measurethechargepressureofthetransmission.

5.TestPortEisusedtomeasuretractionforward
pressure(Figure79).

52

6.TestPortFisusedtomeasuretractionreverse
pressure(Figure79).

CuttingUnitMaintenance

7.TestPortGisusedtomeasuresteeringcircuit
pressure(

1.TestportD(Charge
pressure)

2.TestportE(Traction
forwardpressure)

Figure79).

Figure79

3.TestportF(Traction
reversepressure)

4.TestportG(Steering
circuitpressure)

CuttingUnitKickstand
Models03863and03864

Wheneverthecuttingunithastobetippedtoexposethe
bedknife/reel,propuptherearofthecuttingunitwith
thekickstand(suppliedwiththetractionunit)tomake
surethenutsonthebackendofthebedbaradjusting
screwsarenotrestingontheworksurface(

Figure80).

Figure80

1.Cuttingunitkickstand

Backlapping

DANGER

Thereelsmaystallwhilebacklappingandcould
restartsuddenly.Contactwiththereelsduring
backlappingwillcausepersonalinjury.

•Neverplacehandsorfeetinthereelareawhile
theengineisrunning.

•Neverattempttoturnthereelsbyhandorfoot
ortouchthereelswhilebacklapping.

•Neverchangeenginespeedwhilebacklapping.
Onlybacklapatidlespeed.

•Stoptheengineandmovethedesiredreelspeed
selectorknob(s)onepositioncloserto“13.”

Note:Whenbacklapping,thefrontunitsalloperate
together,andtherearunitsoperatetogether.

1.Positionthemachineonalevelsurface,lowerthe
cuttingunits,stoptheengine,engagetheparking

53

brake,andmovetheEnable/Disableswitchto
disableposition.

2.Unlockandraisetheseattoexposecontrols.

3.Locatethereelspeedselectorknobsandbacklap
knobs(Figure81).Rotatethedesiredbacklap
knob(s)tothebacklappositionandthedesiredreel
speedselectorknob(s)toposition1.

Figure81

9.Ifreelsstallorbecomeerraticwhilebacklapping,
stopbacklappingbymovingtheLowerMow/Lift
controlleverrearward.Oncethereelshavestopped,
movethedesiredreelspeedselectorknob(s)one
positioncloserto13.Resumebacklappingby
movingtheLowerMow/Liftcontrolleverforward.

10.Tomakeanadjustmenttothecuttingunits
whilebacklapping,turnreelsOffbymoving
theLowerMow/Raiseleverrearward;movethe
Enable/DisableswitchtoDisableandturnthe
engineOff.Afteradjustmentshavebeencompleted,
repeatsteps

5through9.

11.Whenthecuttingunitisadequatelysharpened,a
burrwillformonthefrontedgeoftheknife.Using
ale,carefullyremovetheburrwithoutdullingthe
cuttingedge.

12.Repeatprocedureforallcuttingunitstobe
backlapped.

Whenbacklapoperationhasbeencompleted,return
thebacklapknobstotheforwardowposition,
lowerseatandwashalllappingcompoundoffcutting
units.Adjustcuttingunitreeltobedknifeasneeded.

1.Backlapknobs2.Reelspeedselectorknobs

Note:Backlappingspeedmaybeincreasedby
movingthereelspeedselectorknobtoward13.
Eachpositionwillincreasespeedapproximately100
rpm.Afterchangingselector,wait30secondsfor
thesystemtostabilizeatthenewspeed.

4.Makeinitialreeltobedknifeadjustmentsappropriate
forbacklappingonallcuttingunitswhicharetobe
backlapped.

5.Startengineandrunatidlespeed.

CAUTION

Contactwiththereelsorothermovingpartscan
resultinpersonalinjury.

•Keepnger,hands,andclothingawayfrom
thereelsandothermovingparts.

•Neveruseashorthandlesbrushtoapply
lappingcompound.

6.Selecteitherfront,rear,orbothbacklapknobsto
determinewhichreelswillbebacklapped.

7.MoveEnable/DisableswitchtoEnableposition.
MoveLowerMow/Liftcontrolforwardtostart
backlappingoperationondesignatedreels.

8.Applylappingcompoundwithalonghandlebrush
(ToroPartNo.29-9100).Neveruseashorthandled
brush.

Note:Ifthebacklapknobsarenotreturnedtothe
forwardowpositionafterbacklapping,thecutting
unitswillnotraiseorfunctionproperly.

AdjustingtheCuttingUnit
LoweringRate

Tractorsaresetupatthefactoryappropriatelyformost
fairwaymowingapplications.

Thefollowingadjustmentsareavailableforne-tuning
ofthemachinetotheapplication:

Thecuttingunitliftcircuitsareequippedwithadjustable
valvestoensurethecuttingunitsloweratthedesired
rate.Adjustasfollows:

Runtractionunituntiloperatingtemperatureisreached.

1.Locatethevalves,ontheliftmanifold,for
adjustingthedesiredcuttingunit(s)(Seechartand
Figure82andFigure83).

Valve

FC1#1(FrontCenter)

FC4#4(FrontWings)

FC5#2(Rear)

FC6#6(RearLeft)

FC7#7(RearRight)

CuttingUnitAffected

54

Figure82

g019483

1

2

3

Model03808and03813

1.Adjustmentvalvefor#1(FrontCenter)cuttingunit

2.Adjustmentvalvefor#4(FrontWings)cuttingunits

3.Adjustmentvalvesfor#2(Rear)cuttingunits

LiftedHeightofOuterFront
CuttingUnits(EnablePosition)

Theturnaroundheightofthefrontoutercuttingunits
(#4)andrear(#6)cuttingunitsmaybe
increasedtoprovideadditionalgroundclearanceon
contouredfairways.

Note:TheRMCONFIGtimedelayshouldnotbe
changedfromtheoriginalsettingof0whenusingthis
methodtoadjustturnaroundheight.

Toincrease/adjusttheturnaroundheightofthecutting
unitsproceedasfollows:

•Positionmachineonalevelsurface,lowerthecutting
unitsandstoptheengine.

•Loosenthecarriageboltnutsecuringtheliftarm
switchbrackettothe#4,6or7liftarms(

Figure84).

Figure83

Models03806,03807and03812

1.Adjustmentvalvefor#1(FrontCenter)cuttingunit

2.Adjustmentvalvefor#4(FrontWings)cuttingunits

3.Adjustmentvalvesfor#2(Rear)cuttingunits

4.Adjustmentvalvefor#6(RearLeft)cuttingunit

5.Adjustmentvalvefor#7(RearRight)cuttingunit

2.Loosenthelockingnutsonthevalves.

3.UsingaAllenHeadwrench,rotatetheappropriate
valveclockwisetoslowdowndroprateofcutting
units.

4.Verifytheliftrateadjustmentbyraisingandlowering
cuttingunitsseveraltimes.Readjustasrequired.

5.Tightenthelockingnuttosecuretheadjustment.

Figure84

#4shown

1.Liftarmswitch3.Liftarmag

2.Carriageboltnut

•Movetheliftswitchbracketupintheslottothe
desiredposition.

•Setthedistancebetweentheliftarmswitchandthe
agontheliftarmtoapproximately.062inches.

•Tightencarriageboltnut.

55

AdjustingtheTravelofthe

g019484

1

FrontThreeCuttingUnits

Additionaldownwardtravelofthefrontthreecutting
unitsmaybedesirableinhighlycontouredlocations.If
anyofthefrontthreecuttingunitsliftofftheground
whencrestingahill,thefrontcarrierframemaybe
loweredbyremovingmountingboltsandrepositioning
frameinthebottomsetofholesinthemainframe

Figure85).Contactyourdistributorforassistance.

(

Note:Movingthecarrierframedownwilldecreasethe
amountofclearancebetweenthecuttingunitsandthe
groundinturnaroundandtransportpositionsandmay
requireadjustingtheliftchainlengthonthecuttingunit.

1.Carrierframemountingbolts

Figure85

56

Storage

TractionUnit

1.Thoroughlycleanthetractionunit,cuttingunitsand
theengine.

2.Checkthetirepressure.Inatealltiresto15-20psi.

3.Checkallfastenersforlooseness;tightenas
necessary.

4.Greaseoroilallgreasettingsandpivotpoints.
Wipeupanyexcesslubricant.

5.Lightlysandandusetouch-uppaintonpaintedareas
thatarescratched,chipped,orrusted.Repairany
dentsinthemetalbody .

6.Servicethebatteryandcablesasfollows:

A.Removethebatteryterminalsfromthebattery

posts.

B.Cleanthebattery,terminals,andpostswithawire

brushandbakingsodasolution.

C.Coatthecableterminalsandbatterypostswith

Grafo112Xskin-overgrease(ToroPartNo.
505-47)orpetroleumjellytopreventcorrosion.

Engine

1.Draintheengineoilfromtheoilpanandreplace
thedrainplug.

2.Removeanddiscardtheoillter.Installanewoil
lter.

3.Relloilpanwith7.5qts.(7l)ofSAE15W -40CD ,
CE,CF,CF-4,orCG-4motoroil.

4.Starttheengineandrunatidlespeedfor
approximatelytwominutes.

5.Stoptheengine.

6.Flushthefueltankwithfresh,cleandieselfuel.

7.Secureallfuelsystemttings.

8.Thoroughlycleanandservicetheaircleaner
assembly.

9.Sealtheaircleanerinletandtheexhaustoutletwith
weatherprooftape.

10.Checkantifreezeprotectionandadda50/50
solutionofwaterandantifreezeasneededfor
expectedminimumtemperatureinyourarea.

D.Slowlyrechargethebatteryevery60daysfor24

hourstopreventleadsulfationofthebattery.

WARNING

Chargingthebatteryproducesgassesthat
canexplode.

Neversmokenearthebatteryandkeep
sparksandamesawayfrombattery.

57

Schematics

ElectricalSchematic,Allmodels(Rev .A)

58

ElectricalSchematic,Model03808and03813only(Rev.A)

59

HydraulicSchematic,Model03806(Rev .-)

60

HydraulicSchematic,Model03807and03812(Rev .-)

61

HydraulicSchematic,Model03808and03813(Rev.A)

62

Notes:

63

TheToroT otalCoverageGuarantee

ALimitedWarranty

ConditionsandProductsCovered

TheT oroCompanyanditsafliate,T oroWarrantyCompany ,pursuant
toanagreementbetweenthem,jointlywarrantyourT oroCommercial
product(“Product”)tobefreefromdefectsinmaterialsorworkmanship
fortwoyearsor1500operationalhours*,whicheveroccursrst.This
warrantyisapplicabletoallproductswiththeexceptionofAerators
(refertoseparatewarrantystatementsfortheseproducts).Wherea
warrantableconditionexists,wewillrepairtheProductatnocosttoyou
includingdiagnostics,labor,parts,andtransportation.Thiswarranty
beginsonthedatetheProductisdeliveredtotheoriginalretailpurchaser.
*Productequippedwithanhourmeter.

InstructionsforObtainingWarrantyService

YouareresponsiblefornotifyingtheCommercialProductsDistributoror
AuthorizedCommercialProductsDealerfromwhomyoupurchasedthe
Productassoonasyoubelieveawarrantableconditionexists.Ifyouneed
helplocatingaCommercialProductsDistributororAuthorizedDealer,or
ifyouhavequestionsregardingyourwarrantyrightsorresponsibilities,
youmaycontactusat:

ToroCommercialProductsServiceDepartment
ToroWarrantyCompany

811 1LyndaleAvenueSouth
Bloomington,MN55420-1196

952–888–8801or800–952–2740
E-mail:[e-mail]

OwnerResponsibilities

AstheProductowner,youareresponsibleforrequiredmaintenance
andadjustmentsstatedinyourOperator'sManual.Failuretoperform
requiredmaintenanceandadjustmentscanbegroundsfordisallowinga
warrantyclaim.

ItemsandConditionsNotCovered

Notallproductfailuresormalfunctionsthatoccurduringthewarranty
periodaredefectsinmaterialsorworkmanship.Thiswarrantydoesnot
coverthefollowing:

•Productfailureswhichresultfromtheuseofnon-T ororeplacement

parts,orfrominstallationanduseofadd-on,ormodiednon-T oro
brandedaccessoriesandproducts.Aseparatewarrantymaybe
providedbythemanufactureroftheseitems.

•Productfailureswhichresultfromfailuretoperformrecommended

maintenanceand/oradjustments.Failuretoproperlymaintainyour
ToroproductpertheRecommendedMaintenancelistedinthe
Operator’sManualcanresultinclaimsforwarrantybeingdenied.

•ProductfailureswhichresultfromoperatingtheProductinan

abusive,negligent,orrecklessmanner.

•Partssubjecttoconsumptionthroughuseunlessfoundtobe

defective.Examplesofpartswhichareconsumed,orusedup,
duringnormalProductoperationinclude,butarenotlimitedto,brake
padsandlinings,clutchlinings,blades,reels,rollersandbearings
(sealedorgreasable),bedknives,sparkplugs,castorwheelsand
bearings,tires,lters,belts,andcertainsprayercomponentssuchas
diaphragms,nozzles,andcheckvalves,etc.

•Failurescausedbyoutsideinuence.Conditionsconsideredtobe

outsideinuenceinclude,butarenotlimitedto,weather,storage
practices,contamination,useofunapprovedfuels,coolants,
lubricants,additives,fertilizers,water,orchemicals,etc.

•Failureorperformanceissuesduetotheuseoffuels(e.g.gasoline,

diesel,orbiodiesel)thatdonotconformtotheirrespectiveindustry
standards.

•Normalnoise,vibration,wearandtear,anddeterioration.

•Normal“wearandtear”includes,butisnotlimitedto,damageto

seatsduetowearorabrasion,wornpaintedsurfaces,scratched
decalsorwindows,etc.

Parts

Partsscheduledforreplacementasrequiredmaintenancearewarranted
fortheperiodoftimeuptothescheduledreplacementtimeforthatpart.
Partsreplacedunderthiswarrantyarecoveredforthedurationofthe
originalproductwarrantyandbecomethepropertyofT oro.T orowill
makethenaldecisionwhethertorepairanyexistingpartorassemblyor
replaceit.T oromayuseremanufacturedpartsforwarrantyrepairs.

DeepCycleandLithium-IonBatteryWarranty:

DeepcycleandLithium-Ionbatterieshaveaspeciedtotalnumberof
kilowatt-hourstheycandeliverduringtheirlifetime.Operating,recharging,
andmaintenancetechniquescanextendorreducetotalbatterylife.Asthe
batteriesinthisproductareconsumed,theamountofusefulworkbetween
chargingintervalswillslowlydecreaseuntilthebatteryiscompletelyworn
out.Replacementofwornoutbatteries,duetonormalconsumption,
istheresponsibilityoftheproductowner .Batteryreplacementmaybe
requiredduringthenormalproductwarrantyperiodatowner’sexpense.
Note:(Lithium-Ionbatteryonly):ALithium-Ionbatteryhasapartonly
proratedwarrantybeginningyear3throughyear5basedonthetime
inserviceandkilowatthoursused.RefertotheOperator'sManualfor
additionalinformation.

MaintenanceisatOwner’sExpense

Enginetune-up,lubrication,cleaningandpolishing,replacementoflters,
coolant,andcompletingrecommendedmaintenancearesomeofthe
normalservicesToroproductsrequirethatareattheowner’sexpense.

GeneralConditions

RepairbyanAuthorizedT oroDistributororDealerisyoursoleremedy
underthiswarranty.

NeitherTheToroCompanynorToroWarrantyCompanyisliablefor
indirect,incidentalorconsequentialdamagesinconnectionwiththe
useoftheT oroProductscoveredbythiswarranty,includingany
costorexpenseofprovidingsubstituteequipmentorserviceduring
reasonableperiodsofmalfunctionornon-usependingcompletion
ofrepairsunderthiswarranty.ExceptfortheEmissionswarranty
referencedbelow,ifapplicable,thereisnootherexpresswarranty .
Allimpliedwarrantiesofmerchantabilityandtnessforuseare
limitedtothedurationofthisexpresswarranty .

Somestatesdonotallowexclusionsofincidentalorconsequential
damages,orlimitationsonhowlonganimpliedwarrantylasts,sothe
aboveexclusionsandlimitationsmaynotapplytoyou.Thiswarranty
givesyouspeciclegalrights,andyoumayalsohaveotherrightswhich
varyfromstatetostate.

Noteregardingenginewarranty:

TheEmissionsControlSystemonyourProductmaybecoveredby
aseparatewarrantymeetingrequirementsestablishedbytheU.S.
EnvironmentalProtectionAgency(EP A)and/ortheCaliforniaAir
ResourcesBoard(CARB).Thehourlimitationssetforthabovedonot
applytotheEmissionsControlSystemWarranty .RefertotheEngine
EmissionControlWarrantyStatementsuppliedwithyourproductor
containedintheenginemanufacturer’sdocumentationfordetails

CountriesOtherthantheUnitedStatesorCanada

CustomerswhohavepurchasedT oroproductsexportedfromtheUnitedStatesorCanadashouldcontacttheirToroDistributor(Dealer)toobtain
guaranteepoliciesforyourcountry ,province,orstate.IfforanyreasonyouaredissatisedwithyourDistributor'sserviceorhavedifcultyobtaining
guaranteeinformation,contacttheT oroimporter.

374-0253RevB