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

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Page 1

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)

Page 2

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.

Contactusatwww.Toro.com.

PrintedintheUSA.

AllRightsReserved

Page 3

Contents

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

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

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

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

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

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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.

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•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

Page 6

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

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

UncertaintyValue(K)=0.5m/s

Measuredvaluesweredeterminedaccordingtothe proceduresoutlinedinEN836.

Page 7

SafetyandInstructionalDecals

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.

Page 8

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.

115-2048

Page 9

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.

Page 10

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.

Page 11

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.

Page 12

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

Page 13

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.

Page 14

Setup

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescription

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

–

4 2 1 1 1 1 1

Checkuidlevels.

Installcuttingunits.

Makecuttingunitadjustmentsifneeded.

Addrearballast(ifrequired).

InstalltheCEdecals.

Readthemanualsandviewthetraining materialbeforeoperatingthemachine.

CheckingFluidLevels

NoPartsRequired

Procedure

Beforestartingtheengineforthersttime,checkthe followinguidlevels:

•Engineoil

RefertoCheckingtheEngineOil.

•Enginecoolant

RefertoCheckingtheCoolingSystem.

•Hydraulicoil

RefertoCheckingtheHydraulicOil.

•Rearaxlelubricant

RefertoCheckingtheRearAxleLubricant.

Page 15

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).

4.Lynchpin

5.Steeringlockingpin

Page 16

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:

Page 17

InstallingCuttingUnits Models03863and03864

Partsneededforthisprocedure:

5/7Liftchain

5/7Chainbracket

U-bolt

5/7

5/7Screw

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

Page 18

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).

Page 19

G003321

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.

Page 20

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).

Page 21

MakingAlternateCuttingUnit Adjustments

NoPartsRequired

Procedure

Thefactorysetsthetractorappropriatelyformost fairwaymowingapplications.Severaladjustmentsfor ne-tuningthemachineforparticularapplicationsare includedintheCuttingUnitMaintenancesectionas follows:

•Adjustingthecuttingunitloweringrate

Adjuststhespeedatwhichthecuttingunitslower.

•Adjustingtheliftedheightoftheouterfrontcutting units

Adjuststheturnaroundheightoftheouterfront cuttingunitstoprovidegreaterclearanceon contouredfairways.

•Adjustingthetravelofthefrontthreecuttingunits

InstallingCEDecals

Partsneededforthisprocedure:

CEdecals

CEcerticate

Procedure

IfyouwillbeusingthemachineinaCEcountry,install thesuppliedCEdecalsoverthecorrespondingANSI decalsontheproduct.StoretheCEcerticatesinasafe location.

ReadingtheManualsand StoringAdditionalParts

Adjuststhedownwardtravelofthefrontthree cuttingunitstoallowforhighlycontouredfairways.

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

separately)

Partsneededforthisprocedure:

Operator'sManual

EngineOperator'sManual

PartsCatalog

OperatorTrainingMaterial

DiagnosticACEdisplayoverlay

1Ignitionkeysonring

1Hoodlockkey

Screw

2Wingnut

Procedure

1.Readthemanuals.

2.ViewtheOperatorTrainingMaterial.

3.ThediagnosticACEdisplayoverlayisfordiagnosing machinemalfunctions.Storeitinasafelocation.

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

Page 22

ProductOverview

g019447

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.

Page 23

G019448

Figure22

G019449

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.

Page 24

G019525

1.Hourmeter

G019451

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)

Page 25

G019452

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 .

Page 26

Operation

g019453

G019454

G019455

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

Page 27

atthebeginningofeachdaybeforestartingtheengine.

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

Page 28

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).

Page 29

G019457

Note:Manyhydraulicuidsarealmostcolorless,

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.

Page 30

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).

2.Ventplug

Page 31

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(

Figure38).

Page 32

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

Page 33

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

Page 34

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

Page 35

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.

Page 36

ServiceIntervalChart

g023347

Figure40

Page 37

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.

Fortheweekof: MaintenanceCheckItem

Mon.Tues.Wed.Thurs.Fri.

Sat.Sun.

1.Checktheglowplugandinjectornozzlesifhardstarting,excesssmoke,orroughrunningisnoted.

2.Checkwiththeenginerunningandoilatoperatingtemperature.

3.Immediatelyaftereverywashing,regardlessoftheintervallisted

Page 38

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

Page 39

•Rearliftcylinderpivot(2)(Figure45).

g019489

G019490

G019494

g019492

G019493

•Rearliftarmpivots(2)(Figure48).

Figure45

•Liftarmpivot(3)(Figure46).

Figure46

•Rearaxlepivot(Figure47).

Figure48

•Brakepedalshaft(1)(Figure49).

Figure49

Figure47

Page 40

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.

Page 41

ServicingtheEngineOiland

g019470

g019471

g019472

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.

Page 42

FuelSystem

G019473

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.

Page 43

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

Page 44

ofbakingsodaandwater.Rinsewithclearwater.Coat

G019475

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

Page 45

Figure62

Switch

ToroPartNo.75-1010ToroPartNo.70-1480

HoneywellPartNo.1TL1-2HellaPartNo.8741 1B

Relay

Page 46

DriveSystem

g019500

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.

Page 47

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).

Page 48

RearWheelToe-In

G019499

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.

Page 49

CoolingSystem

g019478

g019479

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.

Page 50

BrakeMaintenance

G019480

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

Page 51

HydraulicSystem

G019521

g019482

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.

Page 52

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).

Page 53

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

Page 54

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

Page 55

Figure82

g019483

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.

Page 56

AdjustingtheTravelofthe

g019484

FrontThreeCuttingUnits

Additionaldownwardtravelofthefrontthreecutting unitsmaybedesirableinhighlycontouredlocations.If anyofthefrontthreecuttingunitsliftofftheground whencrestingahill,thefrontcarrierframemaybe loweredbyremovingmountingboltsandrepositioning frameinthebottomsetofholesinthemainframe

Figure85).Contactyourdistributorforassistance.

(

Note:Movingthecarrierframedownwilldecreasethe amountofclearancebetweenthecuttingunitsandthe groundinturnaroundandtransportpositionsandmay requireadjustingtheliftchainlengthonthecuttingunit.

1.Carrierframemountingbolts

Figure85

Page 57

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.

Page 58

Schematics

ElectricalSchematic,Allmodels(Rev .A)

Page 59

ElectricalSchematic,Model03808and03813only(Rev.A)

Page 60

HydraulicSchematic,Model03806(Rev .-)

Page 61

HydraulicSchematic,Model03807and03812(Rev .-)

Page 62

HydraulicSchematic,Model03808and03813(Rev.A)

Page 63

Notes:

Page 64

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:commercial.warranty@toro.com

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