Toro 04356, Greensmaster 3100 Operator's Manual
Form No. 3327-360
Greensmaster 3100 Two-Wheel Drive
Greensmaster Traction Unit
Model No. 04356—Serial No. 210000001 and Up
Operator ’s Manual
Domestic English (EN)
Warning
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
Important The engine in this product is not equipped
with a spark arrester muffler. It is a violation of California
Public Resource Code Section 4442 to use or operate this
engine on any forest-covered, brush-covered, or
grass-covered land as defined in CPRC 4126. Other states
or federal areas may have similar laws.
This spark ignition system complies with Canadian
ICES-002.
Ce système d’allumage par étincelle de véhicule est
conforme à la norme NMB-002 du Canada.
Contents
Page
Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Operating Practices 3. . . . . . . . . . . . . . . . . . . .
Toro Mower Safety 4. . . . . . . . . . . . . . . . . . . . . . . .
Sound Pressure 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sound Power 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vibration 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 6. . . . . . . . . . . . . . . . .
Specifications 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 9. . . . . . . . . . . . . . . . . . . . . .
Accessories 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Activating and Charging the Battery 10. . . . . . . . . . .
Mounting the Seat 11. . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Battery 11. . . . . . . . . . . . . . . . . . . . . . .
Installing the Steering Wheel 12. . . . . . . . . . . . . . . . .
Installing the Cutting Units 12. . . . . . . . . . . . . . . . . .
Rear Ballast 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before Operating 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Engine Oil 14. . . . . . . . . . . . . . . . . . . .
Filling the Gas Tank 15. . . . . . . . . . . . . . . . . . . . . . . .
Servicing the Hydraulic System 15. . . . . . . . . . . . . . .
Tire Pressure 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Torque of the Wheel Nuts 17. . . . . . . .
Operation 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Think Safety First 17. . . . . . . . . . . . . . . . . . . . . . . . . .
Controls 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Break-in Period 20. . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting the Engine 20. . . . . . . . . . . . . . . . . . . . . . . . .
Page
Checking the Interlock System 21. . . . . . . . . . . . . . .
Checking the Leak Detector (Fig. 22–25) 22. . . . . . .
Preparing the Machine for Mowing 23. . . . . . . . . . . .
Training Period 23. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before Mowing 23. . . . . . . . . . . . . . . . . . . . . . . . . . .
Mowing Procedures 23. . . . . . . . . . . . . . . . . . . . . . . .
Leak Detector Operation 24. . . . . . . . . . . . . . . . . . . .
Transport Operation 24. . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Cleanup After Mowing 25. . . . . . . . .
Maintenance 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule 25. . . . . . . . .
Daily Maintenance Checklist 26. . . . . . . . . . . . . . . . .
Lubrication 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the Engine Oil and Filter 29. . . . . . . . . . . .
Servicing the Air Cleaner 29. . . . . . . . . . . . . . . . . . . .
Adjusting the Throttle Control 30. . . . . . . . . . . . . . . .
Adjusting the Choke Control 30. . . . . . . . . . . . . . . . .
Adjusting the Carburetor and Speed Control 30. . . . .
Replacing the Spark Plugs 31. . . . . . . . . . . . . . . . . . .
Replacing the Fuel Filter 31. . . . . . . . . . . . . . . . . . . .
Changing the Hydraulic Oil and Filter 32. . . . . . . . . .
Checking the Hydraulic Lines and Hoses 32. . . . . . .
Adjusting the Brakes 32. . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Rear Camshaft 33. . . . . . . . . . . . . . . . .
Adjusting the Lift and Mow Pedal Height 34. . . . . . .
Leveling the Lift and Mow Pedals 34. . . . . . . . . . . . .
Adjusting the Traction Pedal 35. . . . . . . . . . . . . . . . .
Adjusting Cutting Unit Lift and Drop 35. . . . . . . . . .
Adjusting the Lift Cylinders 35. . . . . . . . . . . . . . . . .
Replacing the Seat Switch 36. . . . . . . . . . . . . . . . . . .
Replacing the Traction Switch 36. . . . . . . . . . . . . . . .
Replacing the Mow/Lift Switch 36. . . . . . . . . . . . . . .
Adjusting the Traction Return Linkage 37. . . . . . . . .
Battery Care 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Schematic 39. . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Schematic 40. . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Toro General Commercial Products Warranty 48. . .
Introduction
Read this manual carefully to learn how to operate and
maintain your product properly. The information in this
manual can help you and others avoid injury and product
damage. Although Toro designs and produces safe
products, you are responsible for operating the product
properly and safely.
2002 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
All Rights Reserved
2
Printed in the USA
Whenever you need service, genuine Toro parts, or
additional information, contact an Authorized Toro
Distributor or Toro Customer Service and have the model
and serial numbers of your product ready. Figure 1
illustrates the location of the model and serial numbers on
the product.
1
Safety
This machine meets or exceeds the B71.4 1999
specifications of the American National Standards
Institute, in effect at time of production, when 40 lb. of
ballast is added to the rear wheel.
Note: The addition of attachments made by other
manufacturers that do not meet American National
Standards Institute certification will cause noncompliance
of this machine.
Improper use or maintenance by the operator or owner
can result in injury. To reduce the potential for injury,
comply with these safety instructions and always pay
attention to the safety alert
CAUTION, WARNING, or DANGER—“personal
safety instruction.” Failure to comply with the
instruction may result in personal injury or death.
Safe Operating Practices
symbol, which means
Figure 1
1. Location of the model and serial numbers
Write the product model and serial numbers in the space
below:
Model No:
Serial No.
This manual identifies potential hazards and has special
safety messages that help you and others avoid personal
injury and even death. Danger, Warning, and Caution are
signal words used to identify the level of hazard. However,
regardless of the hazard, be extremely careful.
Danger signals an extreme hazard that will cause serious
injury or death if you do not follow the recommended
precautions.
Warning signals a hazard that may cause serious injury or
death if you do not follow the recommended precautions.
Caution signals a hazard that may cause minor or moderate
injury if you do not follow the recommended precautions.
This manual uses two other words to highlight information.
Important calls attention to special mechanical
information and Note: emphasizes general information
worthy of special attention.
The following instructions are from ANSI standard
B71.4—1999.
Training
• Read the Operator’s Manual and other training material.
If the operator(s) or mechanic(s) can not read English it
is the owner’s responsibility to explain this material to
them.
• Become familiar with the safe operation of the
equipment, operator controls, and safety signs.
• All operators and mechanics should be trained. The
owner is responsible for training the users.
• Never let children or untrained people operate or
service the equipment. Local regulations may restrict
the age of the operator.
• The owner/user can prevent and is responsible for
accidents or injuries occurring to himself or herself,
other people or property.
Preparation
• Evaluate the terrain to determine what accessories and
attachments are needed to properly and safely perform
the job. Only use accessories and attachments approved
by the manufacturer.
• Wear appropriate clothing including hard hat, safety
glasses and ear protection. Long hair, loose clothing or
jewelry may get tangled in moving parts.
• Inspect the area where the equipment is to be used and
remove all objects such as rocks, toys and wire which
can be thrown by the machine.
3
• Use extra care when handling gasoline and other fuels.
They are flammable and vapors are explosive.
– Use only an approved container.
– Never remove gas cap or add fuel with engine
running. Allow engine to cool before refueling. Do
not smoke.
– Never refuel or drain the machine indoors.
• Check that operator’s presence controls, safety switches
and shields are attached and functioning properly. Do
not operate unless they are functioning properly.
• Use care when approaching blind corners, shrubs, trees,
or other objects that may obscure vision.
Maintenance and Storage
• Disengage drives, raise the cutting units, set parking
brake, stop engine and remove key and disconnect spark
plug wire. Wait for all movement to stop before
adjusting, cleaning or repairing.
• Clean grass and debris from cutting units, drives,
mufflers, and engine to help prevent fires. Clean up oil
or fuel spillage.
Operation
• Never run an engine in an enclosed area.
• Only operate in good light, keeping away from holes
and hidden hazards.
• Be sure all drives are in neutral and parking brake is
engaged before starting engine. Only start engine from
the operator’s position. Use seat belts if provided.
• Slow down and use extra care on hillsides. Be sure to
travel in the recommended direction on hillsides. Turf
conditions can affect the machine’s stability. Use
caution while operating near drop-offs.
• Slow down and use caution when making turns and
when changing directions on slopes.
• Never operate with guards not securely in place. Be
sure all interlocks are attached, adjusted properly, and
functioning property.
• Do not change the engine governor setting or overspeed
the engine.
• Stop on level ground, raise the cutting units, disengage
drives, engage parking brake (if provided), shut off
engine before leaving the operator’s position for any
reason including emptying the grass baskets.
• Stop equipment and inspect the machine after striking
objects or if an abnormal vibration occurs. Make
necessary repairs before resuming operations.
• Let engine cool before storing and do not store near
flame.
• Shut off fuel while storing or transporting. Do not store
fuel near flames or drain indoors.
• Park machine on level ground. Never allow untrained
personnel to service machine.
• Use jack stands to support components when required.
• Carefully release pressure from components with stored
energy.
• Disconnect battery and remove spark plug wire before
making any repairs. Disconnect the negative terminal
first and the positive last. Reconnect positive first and
negative last.
• Use care when checking the reels. Wear gloves and use
caution when servicing them.
• Keep hands and feet away from moving parts. If
possible, do not make adjustments with the engine
running.
• Charge batteries in an open well ventilated area, away
from spark and flames. Unplug charger before
connecting or disconnecting from battery. Wear
protective clothing and use insulated tools.
• Keep all parts in good working condition and all
hardware and hydraulic fittings tightened. Replace all
worn or damaged decals.
• Keep hands and feet away from the cutting units.
• Look behind and down before backing up to be sure of
a clear path.
• Never carry passengers and keep pets and bystanders
away.
• Slow down and use caution when making turns and
crossing roads and sidewalks. Stop reels if not mowing.
• Do not operate the mower under the influence of
alcohol or drugs
• Use care when loading or unloading the machine into a
trailer or truck
Toro Mower Safety
The following list contains safety information specific to
Toro products or other safety information that you must
know that is not included in the ANSI standards.
This product is capable of amputating hands and feet and
throwing objects. Always follow all safety instructions to
avoid serious injury or death.
Use of this product for purposes other than its intended use
could prove dangerous to user and bystanders.
4
Operation
• Know how to stop the engine quickly.
• Always wear substantial shoes. Do not operate the
machine while wearing sandals, tennis shoes, or
sneakers.
• Wearing safety shoes and long pants is advisable and
required by some local ordinances and insurance
regulations.
• Handle gasoline carefully. Wipe up any spills.
• Check the safety interlock switches daily for proper
operation. If a switch should fail, replace the switch
before operating the machine. After every two years,
replace all four interlock switches in the safety system,
regardless if they are working properly or not.
• Before starting the engine, sit on the seat, depress the
lift pedal, and release it to ensure the cutting units are
disengaged. Verify that the traction system is in neutral
and the parking brake is set.
• Using the machine demands attention. To prevent loss
of control:
– Do not drive close to sand traps, ditches, creeks, or
other hazards.
– Reduce speed when making sharp turns. Avoid
sudden stops and starts.
– Watch out for traffic when near or crossing roads.
Always yield the right-of-way.
– Apply the service brakes when going downhill to
keep forward speed slow and to maintain control of
the machine.
• The grass baskets must be in place during operation of
the reels or thatchers for maximum safety. Shut the
engine off before emptying the baskets.
• Raise the cutting units when driving from one work
area to another.
• Do not touch the engine, muffler, or exhaust pipe while
the engine is running or soon after it has stopped
because these areas could be hot enough to cause burns.
• Stay clear of the rotating screen at the side of the engine
to prevent direct contact with your body or clothing.
• If a cutting unit strikes a solid object or vibrates
abnormally, stop immediately, turn the engine off, wait
for all motion to stop, and inspect the machine for
damage. A damaged reel or bedknife must be repaired
or replaced before operation is continued.
• Before getting off of the seat, move the shift selector to
N neutral, depress the lift pedal to raise the cutting
units, wait for the reels to stop spinning, and release lift
pedal. Set the parking brake. Stop the engine and
remove the key from the ignition switch.
• Traverse slopes carefully. Do not start or stop suddenly
when traveling uphill or downhill.
• The operator must be skilled and trained in how to drive
on hillsides. Failure to use caution on slopes or hills
may cause loss of control and cause the vehicle to tip or
roll, possibly resulting in personal injury or death.
• If the engine stalls or loses headway and cannot make it
to the top of a slope, do not turn the machine around.
Always back slowly, straight down the slope.
• When a person or pet appears unexpectedly in or near
the mowing area, stop mowing. Careless operation,
combined with terrain angles, ricochets, or improperly
positioned guards can lead to thrown object injuries. Do
not resume mowing until the area is cleared.
• Whenever the machine is left unattended, make sure the
cutting units are fully raised and the reels are not
spinning, the key is removed from the ignition switch,
and the parking brake is set.
Maintenance and Storage
• Make sure all hydraulic line connectors are tight and all
hydraulic hoses and lines are in good condition before
applying pressure to the system.
• Keep your body and hands away from pin hole leaks or
nozzles that eject hydraulic fluid under high pressure.
Use paper or cardboard, not your hands, to search for
leaks. Hydraulic fluid escaping under pressure can have
sufficient force to penetrate the skin and cause serious
injury.
• Before disconnecting or performing any work on the
hydraulic system, all pressure in the system must be
relieved by stopping the engine and lowering the cutting
units and attachments to the ground.
• Check all fuel lines for tightness and wear on a regular
basis. Tighten or repair them as needed.
• If the engine must be running to perform a maintenance
adjustment, keep hands, feet, clothing, and any parts of
the body away from the cutting units, attachments, and
any moving parts, especially the screen at the side of the
engine. Keep everyone away.
• Do not overspeed the engine by changing governor
settings. To ensure safety and accuracy, have an
Authorized Toro Distributor check the maximum engine
speed with a tachometer. Maximum governed engine
speed should be 2900 RPM.
• The engine must be shut off before checking the oil or
adding oil to the crankcase.
• If major repairs are ever needed or if assistance is
desired, contact an Authorized Toro Distributor.
5
• To make sure of optimum performance and continued
safety certification of the machine, use only genuine
Toro replacement parts and accessories. Replacement
parts and accessories made by other manufacturers
could be dangerous, and such use could void the
product warranty.
Sound Power
This unit has a guaranteed sound power level of 105 dBA,
based on measurements of identical machines per Directive
2000/14/EC.
Sound Pressure
This unit has a maximum sound pressure level at the
operator’s ear of 86 dBA, based on measurements of
identical machines per Directive 98/37/EC.
Safety and Instruction Decals
Safety decals and instructions are easily visible to the operator and are located near any area
of potential danger. Replace any decal that is damaged or lost.
93-8075
1. Press the lift pedal to
raise and stop the reels.
2. Press the mow pedal to
lower and start the reels.
Vibration
This unit does not exceed a hand/arm vibration level of
2
2.5 m/s
Directive 98/37/EC.
This unit does not exceed a whole body vibration level of
0.5 m/s2, based on measurements of identical machines per
Directive 98/37/EC.
, based on measurements of identical machines per
1. Lock and unlock the reels
1. Transmission
2. Forward motion
93-9898
93-8065
3. Neutral
4. Forward speeds
1. To lock the parking brake,
press the brake pedal and
the parking brake lock.
1. Read the
unlocking the steering arm.
Operator’s Manual
93-8062
2. To unlock the parking
brake, press the brake
pedal.
3. Parking brake lock
93-8068
for instructions on locking and
6
1. Failure/malfunction (Leak
detector alarm test)
2. Headlights
3. Off
4. Choke
5. On
6. Slow
93-8061 (Replace control panel)
7. Fast
8. Engine—stop
9. On
94-8036
10. Engine—start
11. Read the
12. Continuous variable setting
Operator’s Manual.
93-8067
1. Hydraulic oil 2. Read the
Manual.
62–5070
Operator’s
1. Warning—read the
instructions before
servicing or performing
maintenance.
1. Read the
7
93-8064 (for CE)
2. Cutting hazard of foot or
hand—stop the engine
and wait for moving parts
to stop.
93-6691
Operator’s Manual.
104-2053
93-8063 (for CE)
1. Warning—read the
2. Tipping hazard—do not use the machine on a slope greater
than 15 degrees.
3. Thrown object hazard—stay a safe distance from the machine.
4. Cutting hazard of hand or foot—stay away from moving parts.
5. Warning—lock the parking brake, stop the engine, and remove
the ignition key before leaving the machine.
Operator’s Manual.
93-7276
1. Explosion hazard—wear
eye protection.
2. Caustic liquid/chemical
burn hazard—to perform
first aid, flush with water.
3. Fire hazard—no fire, open
flames, or smoking.
4. Poison hazard—keep
children a safe distance
from the battery.
93-8069
1. Hot surface/burn hazard—stay a safe distance from the hot
surface.
1. Battery
2. Read the instructions
before servicing or
performing maintenance.
93-6668
3. Contains lead; do not
discard.
8
Specifications
Accessories
Note: Specifications and design subject to change without
notice.
General Specifications
Width of Cut 59 in. (149.9 cm)
Wheel Tread 49-1/2 in.
(125.7 cm)
Wheel Base 46-7/8 in.
(119.1 cm)
Overall Length 90 in. (228.6 cm)
Overall Width 69-3/4 in.
(117.2 cm)
Overall Height 48-1/2 in.
(123.2 cm)
Net Weight (wet) 1021 lb. (463 kg)
Weight with Reels 1261 lb. (572 kg)
1st Gear Speed 3.8 MPH approx.
(6.1 km/h)
2nd Gear Speed 8.1 MPH approx.
(13.0 km/h)
Reverse Speed 1.9 MPH approx.
(3.1 km/h)
Reel Speed 1975 RPM approx.
Clip Speed—11 Blade Cutting Unit 0.18 in. approx.
(4.6 mm)
Clip Speed—8 Blade Cutting Unit 0.25 in. approx.
(6.4 mm)
8 Blade, 4 Bolt Cutting Unit
(Heavy Duty)
8 Blade, 4 Bolt Cutting Unit Model No. 04408
11 Blade, 4 Bolt Cutting Unit Model No. 04406
8 Blade, SPA Cutting Unit Model No. 04468
11 Blade, SPA Cutting Unit Model No. 04450
8 Blade, 4 Bolt Cutting Unit Model No. 04470
11 Blade, 4 Bolt Cutting Unit Model No. 04471
8 Blade, SPA Cutting Unit Model No. 04472
11 Blade, SPA Cutting Unit Model No. 04473
Spiker Model No. 04494
Tri-Roller Model No. 04495
Groomer Kit (for use with cutting
unit models 04470, 04471, 04472,
and 04473)
Grooming Reel Kit (for use with
cutting unit models 04404, 04408,
04406, 04468, and 04450)
Thatching Reels Model No. 04493
Variable Traction Speed Kit Model No. 04422
Individual Reel Shut Off Kit Part No. 28-2150
Basket Reinforcement Kit Part No. 26-0900
Backlapping Kit Part No. 92-9656
Spark Arrester Part No. 83-2240
Three-Wheel Drive Kit Part No. 100-6441
Service Manual Part No. 92784SL
High Altitude Jet* Part No. 808413
* Order from your local Briggs & Stratton Dealer
Model No. 04404
Model No. 04456
Model No. 04455
Assembly
Note: Determine the left and right side of the machine from the normal operating position.
Description Qty. Use
Seat
Nut, 5/16
Seat cover
Steering wheel
Nut
Cap
Screw
Bolt, 1/4 x 5/8 in.
Nut, 1/4 in.
1
4
1
1
1
1
1
2
2
9
Mounting the seat slides and seat cover to the
seat base
Mounting the steering wheel
Securing the battery cables to the battery
Description UseQty.
Gauge bar
Screw, #10 x 5/8 in.
Jam nut, #10
Grass basket 3 Mounts to the pull frame
Ignition keys 2
Warning decal 1
Danger decal 3
Service decal 11
Operator’s Manual (traction unit)
Engine Operator’s Manual
Operator video 1 Watch before operating the machine.
Parts Catalog
Noise rating certificate
Pre-delivery sheet
Certificate of Compliance
1
1
1
2
1
1
1
1
1
Setting the height-of-cut
Affix over English warning decal (104-2053) for
CE.
Affix over English danger decal (62-5070) for
CE.
Affix appropriate language decal over English
service decal (94-8036) for CE.
Read before operating the machine.
Registration Card (traction unit)
Registration Card (cutting unit)
Note: Mounting fasteners for the Greensmaster 3100 cutting unit are included with the cutting units.
Note: Remove the shipping bracket and nut secured to rear wheel bolt.
Activating and Charging the
1
Fill out and return to Toro.
1
Danger
Battery
Battery electrolyte contains sulfuric acid which is a
Warning
Battery posts, terminals, and related accessories
contain lead and lead compounds, chemicals
known to the State of California to cause cancer
and reproductive harm. Wash hands after
handling.
Voltage: 12 v, 32 amp. hour
deadly poison and causes severe burns.
• Do not drink electrolyte and avoid contact with
skin, eyes or clothing. Wear safety glasses to
shield your eyes and rubber gloves to protect
your hands.
• Fill the battery where clean water is always
available for flushing the skin.
1. Remove the wing nuts, washers, and battery clamp and
lift out the battery.
2. Remove the filler caps from the battery and slowly fill
each cell until the electrolyte is up to the fill line.
3. Replace the filler caps and connect a battery charger to
the battery posts. Charge the battery at a rate of 3 to
4 amperes for 4 to 8 hours.
10
Warning
Charging the battery produces gasses that can
explode.
Never smoke near the battery and keep sparks and
flames away from battery.
4. When the battery is charged, disconnect the charger
from the electrical outlet and battery posts, and allow
the battery to sit for 5–10 minutes.
5. Remove the filler caps. Slowly add electrolyte to each
cell until the level is up to the fill line. Install the filler
caps.
Important Do not overfill the battery. Electrolyte will
overflow onto other parts of the machine and sever
corrosion and deterioration will result.
Mounting the Seat
Note: Mount the seat slides in the front set of mounting
holes to gain an additional 3 in. (7.6 cm) in the forward
adjustment, or in the rear mounting holes for an additional
3 in. (7.6 cm) in the rearward adjustment.
1. Support the seat base in the up position with the seat
support rod.
2. Remove the locknuts securing the seat slides to the
plywood shipping base. Discard the locknuts.
3. Secure the seat, seat panel, and seat slides to the seat
support with the locknuts (5/16 in.) (Fig. 2) supplied in
the loose parts. Mount the seat panel on the right side,
positioned as shown in Figure 2.
Installing the Battery
1. Mount the battery with the battery terminals toward the
front of the machine.
Warning
Battery terminals or metal tools could short
against metal tractor components causing sparks.
Sparks can cause the battery gasses to explode,
resulting in personal injury.
• When removing or installing the battery, do not
allow the battery terminals to touch any metal
parts of the tractor.
• Do not allow metal tools to short between the
battery terminals and metal parts of the tractor.
2. Connect the positive battery cable (red) from the starter
solenoid to the positive post (+) of the battery (Fig. 3).
Secure it with a wrench and coat the terminal with
petroleum jelly. Make sure the cable will clear the seat,
in the rear-most position, which could cause wear or
damage to the cable.
Warning
Incorrect battery cable routing could damage the
tractor and cables causing sparks. Sparks can
cause the battery gasses to explode, resulting in
personal injury.
• Always disconnect the negative (black) battery
cable before disconnecting the positive (red)
cable.
• Always connect the positive (red) battery cable
before connecting the negative (black) cable.
2
1
1. Seat support rod
2. Seat slide
Figure 2
3. Seat panel
2
3
Figure 3
1. Negative (–) 2. Positive (+)
11
1
3. Connect the two black ground cables (one connected to
the engine base, the other to the machine frame) to the
negative (–) post of the battery. Secure it with a wrench
and coat the terminal with petroleum jelly.
4. Install the battery clamp and washers and secure them
with the wing nuts.
2. Slide the cutting units under the pull frames and
position the hoop on the top of cutting units over the lift
arms (Fig. 5).
1
2
5. Place the terminal cover over
post.
the positive (+) battery
Installing the Steering Wheel
1. Slide the steering wheel onto the steering shaft and
secure it with the jam nut (Fig. 4). Torque it to 35 ft.-lb.
(47 N⋅m).
2
1
4
Figure 4
1. Steering wheel
2. Jam nut
3. Cap
4. Mounting screws
3
4
Figure 5
3
1. Hoop
2. Lift arm
3. Assemble the mount nuts for the reel drive motor to
each cutting unit. Leave approximately 1/2 in. (13 mm)
of threads exposed on each mount stud (Fig. 6).
3. Pull frame
4. Pull arm
2. Install the cap to the steering wheel with the screw
(Fig. 4).
Note: The steering wheel may be adjusted fore and aft for
operator comfort by loosening the three mounting screws,
pivoting the steering wheel to the desired operating
position, and tightening the screws (Fig. 4).
Installing the Cutting Units
For Cutting Unit Models 04404, 04406,
04408, 04450, and 04468
Note: When sharpening, setting the height-of-cut, or
performing other maintenance procedures on the cutting
units, store the cutting unit reel motors in the support tubes
on the front of the frame to prevent damage to the hoses.
1. Remove the cutting units from the cartons. Assemble
and adjust them per the cutting unit Operator’s Manual.
Use the gauge bar from the loose parts kit to adjust the
height of cut.
12
Figure 6
1. Motor mount nuts 2. Coat with grease
4. Remove the protective covers from the cutting units and
the reel drive motor shafts. Coat the spline shaft of the
motor with clean grease and install the motor by
rotating the motor clockwise so the motor flanges clear
the studs. Rotate the motor counterclockwise until the
flanges are encircling the studs and tighten the
mounting nuts (Fig. 6).
Note: Retain the protective covers for the cutting units.
Install them whenever the reel drive motors are
removed to protect the cutting unit bearings from
contamination.
5. Slide the sleeve back on the ball joint and rotate the pull
arm down so the socket fits over the ball stud. Release
the sleeve so it slides over the stud and locks the
assemblies together (Fig. 7).
12
For Cutting Unit Models 04470, 04471,
04472, and 04473
Note: When sharpening, setting the height-of-cut or
performing other maintenance procedures on the cutting
units, store the cutting unit reel motors in the support tubes
on the front of the frame to prevent damage to the hoses.
12
Figure 7
1. Slide back to mount 2. Ball stud
6. Mount the baskets on the pull frames, loosen the jam
nuts on the pull arms, and adjust the ball sockets until
there is 1/4 to 1/2 in. (6.4 to 12.7 mm) clearance
between the lip of the basket and the reel blades
(Fig. 8).
Note: This prevents the basket from tipping the cutting
unit forward, causing the hoop to come off of the lift
arm while in the mowing operation.
Note: Be sure the basket lips are equidistant from the
reel blades across each reel. If the basket is too close to
the reel, it is possible for the reel to contact the basket
when the cutting unit is raised off of the ground.
4
1. Remove the cutting units from the cartons. Assemble
and adjust them per the cutting unit Operator’s Manual.
Use the gauge bar from the loose parts kit to adjust the
height of cut.
2. Mount a washer and ball stud to each end of the front
roller on the cutting units (Fig. 9).
3
2
1
4
Figure 9
1. Pull frame
2. Lift roller
3. Lift arm
4. Pull arm
5. Ball stud
5
1 23
Figure 8
1. Jam nut
2. Pull arm
3. Ball joint—adjust for
clearance
4. 1/4–1/2 in. (6.4–12.7 mm)
clearance
7. Align the sockets in the ball joints so the open side of
the socket is centered towards the ball stud. Tighten the
jam nuts to secure the sockets in position (Fig. 8).
3. Slide the cutting unit under the pull frame while
hooking the lift roller onto the lift arm (Fig. 9).
4. Slide the sleeve back on the ball joint and rotate the pull
arm down so the socket fits over the ball stud. Release
the sleeve so it slides over the stud and locks the
assemblies together (Fig. 9).
5. Mount the baskets on the pull frames, loosen the jam
nuts on the pull arms, and adjust the ball sockets until
there is 1/4 to 1/2 in. (6.4 to 12.7 mm) clearance
between the lip of the basket and the reel blades or the
front shield.
Note: This prevents the basket from tipping the cutting
unit forward, causing the lift roller to come off of the
lift arm while in the mowing operation.
Be sure the basket lips are equidistant from the reel
blades all across each reel. If the basket is too close to
the reel, it is possible for the reel to contact the basket
when the cutting unit is raised off of the ground.
13
6. Align the sockets in the ball joints so the open side of
the socket is centered towards the ball stud. Tighten the
jam nuts to secure the sockets in position (Fig. 10).
3
1
Rear Ballast
This unit complies with the ANSI B71.4–1999 Standard
when 40 lb. of calcium chloride ballast is added to the rear
wheel.
Important If a puncture occurs in a tire with calcium
chloride, remove the unit from the turf area as quickly as
possible. To prevent possible damage to the turf,
immediately soak the affected area with water.
Before Operating
2
Figure 10
1. Ball joint
2. Pull arm
7. Assemble the mounting capscrews for the reel drive
motor to each cutting unit. Leave approximately 1/2 in.
(13 mm) of threads exposed on each mounting
capscrew (Fig. 11).
2
Figure 11
1. Capscrews 2. Drive motor
3. Jam nut
1
Note: Determine the left and right side of the machine from
the normal operating position.
Checking the Engine Oil
The engine is shipped with 1-3/4 quarts (1.65 liters)
(w/filter) of oil in the crankcase; however, the oil level
must be checked before and after the engine is first started.
The engine uses any high-quality detergent oil having the
American Petroleum Institute (API) service classification
of SG, SH, or SJ. The recommended viscosity (weight) is
SAE 30.
1. Position the machine on a level surface.
2. Unscrew the dipstick and wipe it with a clean rag.
Screw the dipstick into the tube and make sure it is
seated fully (Fig. 12). Unscrew the dipstick out of the
tube and check the oil level. If the oil level is low,
remove the filler cap from the valve cover and add
enough oil to raise the level to the Full mark on the
dipstick.
2
8. Remove the protective covers from the cutting units and
the reel drive motor shafts.
Note: Retain the protective covers for the cutting units.
Install them whenever the reel drive motors are removed to
protect the cutting unit bearings from contamination.
9. Using a hand pump grease gun, fill the cavity at the end
of the cutting unit with #2 general purpose grease.
10.Coat the spline shaft of the motor with clean grease and
install the motor by rotating the motor clockwise so that
the motor flanges clear the studs. Rotate the motor
counterclockwise until the flanges are encircling the
studs. Tighten the mounting capscrews (Fig. 11).
1
Figure 12
1. Dipstick 2. Filler cap
3. Pour oil into the opening in the valve cover until the oil
level is up to the Full mark on the dipstick. Add the oil
slowly and check the level often during this process. Do
not overfill.
14
Important Check the oil level every eight operating
hours or daily. Initially, change the oil after the first eight
hours or operation; thereafter, under normal conditions,
change the oil every 50 hours and the filter every 100
hours. However, change the oil more frequently when the
engine is operated in extremely dusty or dirty conditions.
4. Install the filler cap and dipstick firmly in place.
Filling the Gas Tank
Use unleaded regular gasoline suitable for automotive use
(85 pump octane minimum). Leaded regular gasoline may
be used if unleaded regular is not available.
Important Never use methanol, gasoline containing
methanol, or gasohol containing more than 10% ethanol
because the fuel system could be damaged. Do not mix oil
with gasoline.
Danger
1. Clean around the fuel tank cap and remove the cap
(Fig. 13). Add unleaded regular gasoline to the fuel tank
until the level is 1 in. (25 mm) below the bottom of the
filler neck. This space in the tank allows gasoline to
expand. Do not fill the fuel tank completely full.
Note: Fuel tank capacity is 7.5 gallons (28.4 liters)
1
m–5099
Figure 13
1. Fuel tank cap
In certain conditions, gasoline is extremely
flammable and highly explosive. A fire or
explosion from gasoline can burn you and others
and can damage property.
• Fill the fuel tank outdoors, in an open area,
when the engine is cold. Wipe up any gasoline
that spills.
• Do not fill the fuel tank completely full. Add
gasoline to the fuel tank until the level is 1 in.
(25 mm) below the bottom of the filler neck.
This empty space in the tank allows gasoline to
expand.
• Never smoke when handling gasoline, and stay
away from an open flame or where gasoline
fumes may be ignited by a spark.
• Store gasoline in an approved container and
keep it out of the reach of children. Never buy
more than a 30-day supply of gasoline.
• Always place gasoline containers on the ground
away from your vehicle before filling.
• Do not fill gasoline containers inside a vehicle or
on a truck or trailer bed because interior
carpets or plastic truck bed liners may insulate
the container and slow the loss of any static
charge.
• When practical, remove gas-powered equipment
from the truck or trailer and refuel the
equipment with its wheels on the ground.
• If this is not possible, then refuel such
equipment on a truck or trailer from a portable
container, rather than from a gasoline dispenser
nozzle.
• If a gasoline dispenser nozzle must be used, keep
the nozzle in contact with the rim of the fuel
tank or container opening at all times until
fueling is complete.
2. Install the fuel tank cap securely. Wipe up any gasoline
that may have spilled.
Servicing the Hydraulic System
The hydraulic system is designed to operate on anti-wear
hydraulic fluid. The hydraulic reservoir is filled at the
factory with approximately 8-1/2 gallons (32.2 liters) of
ISO VG 46/48 hydraulic fluid. The appropriate hydraulic
oils are listed below.
Important Use only the types of hydraulic fluids
specified. Other fluids could cause system damage.
Note: A red dye additive for the hydraulic system oil is
available in 2/3 oz. bottles. One bottle is sufficient for
4–6 gallons of hydraulic oil. Order Part No. 44-2500 from
your Authorized Toro Distributor. We do not recommend
the use of red dye additive for biodegradable fluid. Use
food coloring instead.
Group 1 Hydraulic Fluid (Moderate
climate—average duty)
Note: The fluids within this group are interchangeable.
ISO VG 46/68 multi-viscosity anti-wear hydraulic fluid
Mobil DTE 15M
Amoco Rykon Premium ISO 46
Castrol AWH 46
Chevron Rykon Premium Oil ISO 46
Conoco Hydroclear AW MV46
Exxon Univis N46
15
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