Toro 29519 Operator's Manual

FormNo.3417-602RevA

30inStand-OnAerator

ModelNo.29519—SerialNo.400000000andUp

Registeratwww.T oro.com.
OriginalInstructions(EN)

*3417-602*A

WARNING

CALIFORNIA

Proposition65Warning

Thisproductcontainsachemical

orchemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orreproductiveharm.

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

g020219

Figure1

Important:Thisengineisnotequippedwith

asparkarrestermufer.Itisaviolationof
CaliforniaPublicResourceCodeSection4442to
useoroperatetheengineonanyforest-covered,
brush-covered,orgrass-coveredland.Other
statesorfederalareasmayhavesimilarlaws.

TheenclosedEngineOwner'sManualis
suppliedforinformationregardingtheUS
EnvironmentalProtectionAgency(EPA)and
theCaliforniaEmissionControlRegulationof
emissionsystems,maintenance,andwarranty.
Replacementsmaybeorderedthroughtheengine
manufacturer.

Introduction

Thisaeratorisintendedtobeusedbytrained
operatorsinresidentialandcommercialapplications.
Itisprimarilydesignedforaeratingareasof
well-maintainedlawnsonresidentialgrounds,parks,
sportselds,andoncommercialgrounds.

Readtheinformationinthemanualcarefullytolearn
howtooperateandmaintainyourproductproperly
andtoavoidinjuryandproductdamage.Youare
responsibleforoperatingtheproductproperlyand
safely.

1.Locationofthemodelandserialnumbers

ModelNo.

SerialNo.

Thismanualidentiespotentialhazardsandhas
safetymessagesidentiedbythesafety-alertsymbol
(Figure2),whichsignalsahazardthatmaycause
seriousinjuryordeathifyoudonotfollowthe
recommendedprecautions.

g000502

Figure2

1.Safety-alertsymbol

Thismanualuses2wordstohighlightinformation.
Importantcallsattentiontospecialmechanical
informationandNoteemphasizesgeneralinformation
worthyofspecialattention.

YoumaycontactTorodirectlyatwww.Toro.com
forproductsafetyandoperationtrainingmaterials,
accessoryinformation,helpndingadealer,orto
registeryourproduct.

Wheneveryouneedservice,genuineToroparts,or
additionalinformation,contactanAuthorizedService
DealerorToroCustomerServiceandhavethemodel
andserialnumbersofyourproductready.Figure

1illustratesthelocationofthemodelandserial

numbersontheproduct.Writethenumbersinthe
spaceprovided.

©2017—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Contactusatwww.Toro.com.

2

PrintedintheUSA

AllRightsReserved

Contents

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

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

AeratorSafety....................................................6

SlopeIndicator...................................................7

SafetyandInstructionalDecals..........................8

Setup......................................................................12

1CheckingTirePressure..................................12

2ServicingtheBattery......................................12

3ServicingtheEngineOil.................................13

4ServicingtheTransmissionFluid....................14

5ServicingtheAuxiliaryHydraulic

Fluid..............................................................14

ProductOverview...................................................15

Controls...........................................................15

Specications..................................................18

Operation................................................................18

CheckingtheEngine-OilLevel..........................18

AddingFuel......................................................19

LubricatingtheChains......................................21

CheckingtheSafety-InterlockSystem..............22

CheckingforLooseHardware...........................22

OperatingtheMachine.....................................22

TransportingtheMachine.................................25

Maintenance...........................................................27

RecommendedMaintenanceSchedule(s)...........27

Pre-MaintenanceProcedures..............................28

PreparingfortheMachinefor

Maintenance.................................................28

AccessingtheConsoleCompartment...............28

Lubrication..........................................................29

LubricatingtheGreaseFittings.........................29

LubricatingtheCasters.....................................30

EngineMaintenance...........................................32

ServicingtheAirCleaner..................................32

ServicingtheEngineOil....................................33

ServicingtheSparkPlug...................................35

CheckingtheSparkArrester.............................36

FuelSystemMaintenance...................................36

ServicingtheFuelFilter....................................36

ElectricalSystemMaintenance...........................37

ServicingtheBattery.........................................37

ServicingtheFuses..........................................39

DriveSystemMaintenance..................................40

CheckingtheAirPressureintheTires...............40

CheckingtheWheelHubNuts..........................40

CheckingtheT orqueoftheWheelLug

Nuts..............................................................40

AdjustingtheCasterPivotBearings

Pre-Load.......................................................40

MaintainingtheChain.......................................40

CheckingtheT orqueoftheTransmission

OutputShaftNut...........................................42

BrakeMaintenance.............................................42

AdjustingtheParkingBrake..............................42

AdjustingtheBrakeSwitch...............................43

BeltMaintenance................................................43

CheckingtheConditionandTensionofthe

Belts..............................................................43

AdjustingtheAuxiliaryPump-Drive

Belt................................................................43

ReplacingtheTransmission-DriveBelt.............44

ControlsSystemMaintenance.............................45

AdjustingtheTraction-ControlLinkage.............45

HydraulicSystemMaintenance...........................46

MaintainingtheAuxiliaryHydraulic

System..........................................................46

MaintainingtheTransmission...........................47

TineMaintenance.................................................50

CheckingtheTines...........................................50

AdjustingtheTineDriveChain..........................50

Cleaning..............................................................51

CleaningtheEngineandtheExhaust

SystemArea.................................................51

RemovingtheEngineShroudsandCleaning

theCoolingFins............................................51

CleaningtheDebrisfromtheMachine...............51

WasteDisposal.................................................51

Storage...................................................................52

Troubleshooting......................................................53

Schematics.............................................................55

3

Safety

Improperuseormaintenancebytheoperatoror
ownercanresultininjury.Toreducethepotential

forinjury,complywiththesesafetyinstructions,and
payattentiontothesafety-alertsymbol,whichmeans
Caution,Warning,orDanger—“personalsafety
instruction.”Failuretocomplywiththeinstructions

mayresultinpersonalinjuryordeath.

WARNING

Removingormodifyingoriginalequipment,
partsand/oraccessoriesmayalterthe
warranty,controllability ,andsafetyofthe
machine.Unauthorizedmodicationstothe
originalequipmentorfailuretouseoriginal
Toropartscouldleadtoseriousinjuryor
death.Unauthorizedchangestothemachine,
engine,fuelorventingsystem,mayviolate
applicablesafetyandgovernmentstandards.

Replaceallpartsincluding,butnotlimitedto,
tires,belts,andfuelsystemcomponentswith
originalT oroparts.

SafeOperatingPractices

ThefollowinginstructionsarefromANSIstandard
B71.4-2012.

Training

•ReadtheOperator'sManualandothertraining

material.

Note:Iftheoperator(s)ormechanic(s)cannot

readthemanuallanguage,itistheowner's
responsibilitytoexplainthismaterialtothem.

•Becomefamiliarwiththesafeoperationofthe

equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.

Theownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperateor

servicetheequipment.

Note:Localregulationsmayrestricttheageof

theoperator.

•Theowner/usercanpreventandisresponsible

foraccidentsorinjuriesoccurringtohimselfor
herself,otherpeople,ordamagetoproperty.

Important:Thismachinewasmanufactured

accordingtotheappropriateregulatorystandards
ineffectatthetimeofmanufacture.Modifying
thismachineinanywaymaycauseittobe
outofcompliancewiththosestandardsand
withtheinstructionsinthisOperator’sManual.
Modicationstothismachineshouldbemade
onlybyeitherthemanufactureroranAuthorized
ServiceDealer.

Thisproductiscapableofinjuringyourhandsand
feet.Followallsafetyinstructionstoavoidserious
injuryordeath.

Theowner/usercanpreventandisresponsiblefor
accidentsorinjuriesoccurringtopeople,ordamage
toproperty.

Anyuseofthismachineotherthanaeratingturfgrass
couldprovedangeroustotheuserandbystanders.

Important:Theadditionofattachmentsmade

byothermanufacturersthatdonotmeetANSI
certicationmaycausenoncomplianceofthis
machine.

Preparation

•Evaluatetheterraintodeterminewhataccessories

andattachmentsareneededtoproperlyand
safelyperformthejob.Useonlyaccessoriesand
attachmentsapprovedbythemanufacturer.

•Wearappropriateclothing;includingsafety

glasses,longpants,substantial,slip-resistant
footwear,gloves,andhearingprotection.Tieback
longhair.Donotwearjewelry.

•Inspecttheareawhereyouwillusetheequipment

andremoveallobjectsfromtheareabeforeusing
themachine.

•Useextracarewhenhandlingfuels.Theyare

ammableanditsvaporsareexplosive.

–Useonlyanapprovedcontainer.

–Donotremovethefuelcaporaddfuelwiththe

enginerunning.Allowtheenginetocoolbefore
refueling.Donotsmokenearthemachine
whentheengineisrunning.

–Donotrefuelordrainthemachineindoors.

•Checkthattheoperator'spresencecontrols,safety

switches,andshieldsareattachedandfunctioning
properly.Donotoperatethemachineunlessthey
arefunctioningproperly.

4

Operation

Safehandlingoffuels

•Lightningcancausesevereinjuryordeath.If

lightningisseenorthunderisheardinthearea,do
notoperatethemachine;seekshelter.

•Donotrunanengineinanenclosedarea.

•Operatethemachineonlyinwell-litareas,keeping

awayfromholesandhiddenhazards.

•Ensurethatalldrivesareinneutralandthatthe

parkingbrakeisengagedbeforestartingthe
engine.Starttheengineonlyfromtheoperator’s
position.

•Makesurethatyouhavegoodfootingwhileusing

thismachine,especiallywhenbackingup.

Note:Reducedfootingcouldcauseslipping.

•Slowdownanduseextracareonhillsides.Be

suretotravelsidetosideonhillsides.Turf
conditionscanaffectthestabilityofthemachine.
Usecautionwhileoperatingneardrop-offs.

•Slowdownandusecautionwhenmakingturns

andwhenchangingdirectionsonslopes.

•Donotoperatethemachinewithouttheshields

orotherguardssecurelyinplace.Besureall
interlocksareattached,adjustedproperly,and
functioningproperly.

•Donotchangetheenginegovernorsettingor

overspeedtheengine.

•Stoponlevelground,disengagedrives,engage

theparkingbrake(ifprovided),shutofftheengine
beforeleavingtheoperator'spositionforany
reason.

•Toavoidpersonalinjuryorpropertydamage,use

extremecareinhandlingfuel.Fuelisextremely
ammableandthevaporsareexplosive.

•Extinguishallcigarettes,cigars,pipes,andother

sourcesofignition.

•Useonlyanapprovedfuelcontainer.

•Donotremovethefuelcaporaddfuelwiththe

enginerunning.

•Allowtheenginetocoolbeforefueling.

•Donotfuelthemachineindoors.

•Donotstorethemachineorfuelcontainerwhere

thereisanopename,spark,orpilotlightsuchas
onawaterheateroronotherappliances.

•Donotllcontainersinsideavehicle,onatruck,

oronatrailerbedwithaplasticliner.Alwaysplace
containersonthegroundawayfromyourvehicle
beforelling.

•Removeequipmentfromthetruckortrailerand

fuelitontheground.Ifthisisnotpossible,
thenaddfuelwithsuchequipmentasaportable
containerratherthanfromafuel-dispensernozzle.

•Keepthenozzleincontactwiththerimofthefuel

tankorcontaineropeningatalltimesuntilfueling
iscomplete.Donotuseanozzlelock-opendevice.

•Iffuelisspilledonclothing,changeyourclothing

immediately.

•Donotoverllthefueltank.Replacethefuelcap

andtightenitsecurely.

•Stopequipmentandinspectthetinesafterstriking

objectsorifanabnormalvibrationoccurs.Make
thenecessaryrepairsbeforeresumingoperations.

•Keepyourhandsandfeetawayfromthetine

assembly.

•Lookbehindanddownbeforebackingupto

ensureaclearpath.

•Stopthemachineifanyoneentersthearea.Keep

petsandbystandersawayfromanoperating
machine.

•Slowdownandusecautionwhenmakingturns

andcrossingroadsandsidewalks.Fullyraisethe
tinesifyouarenotaerating.

•Donotoperatethemachinewhileill,tired,or

undertheinuenceofalcoholordrugs.

•Usecarewhenloadingorunloadingthemachine

intoorfromatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs,

trees,orotherobjectsthatmayobscurevision.

MaintenanceandStorage

•Donotallowuntrainedpersonneltoservicethe

machine.

•Donottouchequipmentorattachmentpartsthat

maybehotfromoperation.Allowallofthepartsof
themachinetocoolbeforeattemptingtomaintain,
adjust,orservicethemachine.

•Keepyourhandsandfeetawayfrommoving

parts.Ifpossible,donotmakeadjustmentswith
theenginerunning.

•Disengagethedrives,raisethetines,engagethe

parkingbrake,shutofftheengine,andremove
thekeyordisconnectthespark-plugwire.Waitfor
allmovementtostopbeforeadjusting,cleaning,
orrepairing.

•Disconnectthebatteryorremovethespark-plug

wirebeforemakinganyrepairs.Disconnectthe
negativeterminalrstandthepositiveterminal
last.Connectthepositiverstandnegativelast.

5

•Usecarewhencheckingthetines.Wrapthetine(s)

orweargloves,andusecautionwhenservicing
them.Onlyreplacetines;donotstraightenorweld
them.

•Cleangrass,dirt,anddebrisfromthetines,drives,

mufers,andenginetohelppreventres.

•Cleanupoilorfuelspills.

•Parkmachineonlevel,hardground.Neverallow

untrainedpersonneltoservicethemachine.

•Usejackstandstosupportcomponentswhen

required.

•Carefullyreleasepressurefromcomponentswith

storedenergy.

•Donotstorefuelnearamesordrainthefuel

indoors.

•Lettheenginecoolbeforestoringthemachine.

•Keepallpartsingoodworkingconditionandall

hardwaretightened.Replaceallwornordamaged
decals.

Hauling

•Usecarewhenloadingorunloadingthemachine

intoatraileroratruck.

•Useafull-widthrampforloadingthemachineinto

atraileroratruck.

•Tiethemachinedownsecurelyusingstraps,

chains,cable,orropes.Bothfrontandrearstraps
shouldbedirecteddownandoutwardfromthe
machine.

AeratorSafety

Thefollowinglistcontainssafetyinformationspecic
toToroproductsandothersafetyinformationyou
mustknow.

•UseFigure3tohelpyoudeterminetheappropriate

slopeangleofareatoaerate.

•Removeormarkobstaclessuchasrocks,tree

limbs,etc.fromtheaeratingarea.

•Watchforholes,ruts,orbumps.

Note:T allgrasscanhideobstacles.

•Usecautionneardrop-offs,ditches,or

embankments.

Note:Themachinecouldsuddenlyturnoverifa

wheelgoesovertheedgeofaclifforditch,orif
anedgecavesin.

•Beawarethatoperatingonwetgrass,across

steepslopesordownhillmaycausethemachine
tolosetraction.Lossoftractiontothedrivewheels
mayresultinslidingandalossofbrakingand
steering.

•Donotaerateslopesgreaterthan15degrees.

•Avoidsuddenstartsandstopswhenaeratinguphill

becausethemachinemaytipbackward.

Note:Themachineismorestablegoinguphill

withthetinesraised.

•Keepallmovementonslopesslowandgradual.

•Donotmakesuddenchangesinspeedor

direction.

•Reducethetine-downpressuretopreventthe

drivetiresfromraisingoffthegroundandto
preventthefronttiresfromraisingofftheground
whileaeratinguphill.

•Followthemanufacturer’srecommendations

forwheelweightsorcounterweightstoimprove
stability.

•Useextracarewithattachments.

GeneralOperation

•Checkcarefullyforoverheadclearances(i.e.,

branches,doorways,electricalwires,etc.)before
operatingunderanyobjects,anddonotcontact
them.

•Usecautionwhenyouareridingontheplatform

anddrivingthemachineovercurbs,rocks,roots,
orotherobstructions.

•Donotjerkthecontrols;useasteadymotion.

•Donotcarrypassengers.

•Donotcarryequipmentonthemachine.

SlopeOperation

Useextremecautionwhenaeratingand/orturningon
slopesaslossoftractionand/ortip-overcouldoccur.
Youareresponsibleforsafeoperationonslopes.

Note:Useofattachmentscanchangethestability

ofthemachine.

Service

•Toensureoptimumperformanceandcontinued

safetycerticationofthemachine,useonly
genuineT ororeplacementpartsandaccessories.
Replacementpartsandaccessoriesmadeby
othermanufacturerscouldbedangerous,and
suchusecouldvoidtheproductwarranty.

•Neverremoveortamperwithsafetydevices.

Checktheirproperoperationregularly.Neverdo
anythingtointerferewiththeintendedfunctionofa
safetydeviceortoreducetheprotectionprovided
byasafetydevice.

•Checkthebrakeoperationfrequently.Adjustand

servicethebrakesasrequired.

6

SlopeIndicator

Figure3

Thispagemaybecopiedforpersonaluse.

1.Themaximumslopeyoucansafelyoperatethemachineonis15degrees.Usetheslopecharttodeterminethedegreeofslope
ofhillsbeforeoperating.Donotoperatethismachineonaslopegreaterthan15degrees.Foldalongtheappropriateline
tomatchtherecommendedslope.

2.Alignthisedgewithaverticalsurface,atree,building,fencepole,etc.

3.Exampleofhowtocompareslopewithfoldededge

7

g011841

SafetyandInstructionalDecals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyarea
ofpotentialdanger.Replaceanydecalthatisdamagedormissing.

93-6686

decal93-6686

1.Hydraulicuid2.ReadtheOperator's

115-2047

1.Warning—donottouchthehotsurface.

116-9391

Manual.

decal121-6150

121-6150

decal115-2047

1.Cuttinghazardofhandandfoot—stayawayfrommoving
parts.

decal121-6161

121-6161

1.Entanglementhazard,belt—stayawayfrommovingparts;
keepallguardsinplace.

decal116-9391

117-2718

120-9570

1.Warning—stayawayfrommovingparts;keepallguards
andshieldsinplace.

decal121-6162

121-6162

decal117-2718

decal120-9570

1.Cutting/dismembermenthazardofhandorfoot—lowerthe
tinestotheground;readtheOperator’sManualforthe
disassemblyprocedure.

8

121-6163

1.Presstolowerthetines.2.Releasetoraisethetines.

decal126-2054

126-2054

1.Wheellugnuttorque129N∙m(95ft-lb)(4x)

2.Wheelhubnuttorque319N∙m(235ft-lb)

3.ReadandunderstandtheOperator’sManualbefore
performinganymaintenance;checkthetorqueevery100
hours.

decal121-6163

decal121-6164

121-6164

1.Fast6.Wheelsandtinesrotatewhenmoving
backward

2.Slow7.Continuous-variablesetting

3.Neutral

4.Reverse

5.Wheelsandtinesrotatewhenmoving

8.Choke—on

9.Choke—off14.Warning—keepawayfrommoving

10.Warning—readtheOperator’sManual.15.Warning—shutofftheengine,engage

forward

11.Warning—keepbystandersasafe
distanceawayfromthemachine.

12.Warning—donotoperatethemachine
unlessyouaretrained.

13.Thrownobjecthazard—pickupdebris
beforeoperatingthemachine.

parts;keepallguardsinplace.

theparkingbreak,andremovethekey
beforeleavingthemachine.

9

126-4528

1.Rotatecounterclockwisetodecreasepressure5.Parkingbrake—Disengaged

2.Rotateclockwisetoincreasepressure6.Parkingbrake—Engaged

3.Tineground-engagementfootswitch—On7.Cutting/dismembermenthazardofhandorfoot,tines—stay
awayfrommovingparts;keepallguardsinplace

4.Tineground-engagementfootswitch—Off

121-6166

decal126-4528

decal121-6166

1.Tippinghazard—donotturnsharplywhiletravellingfast;slow

downandturngradually.

2.Tippinghazard—donotoperatethemachineonslopes

greaterthan15degrees;donotoperatethemachinenear
drop-offs.

3.Warning;tippinghazard—donotusesplitramps;usea
full-widthramptoloadamachinefortransport;usealoading
rampatamaximumof15degrees.

10

decal116-9392

116-9392

1.ReadandunderstandtheOperator’sManualbeforeservicing

9.Checktheauxiliaryhydraulictankevery50hours.

thismachine.

2.Greasethefrontcasterpivots(2x)every100hours.10.Greasethewheelbearings(2x)every25hours.

3.Refertotheengineowner’smanualforservice.11.Greasethetineassemblyidlers(2x)every25hours.

4.Checktheauxiliarypump-drivebelttensionevery50hours.12.Greasethetineshaftbearings(4x)every25hours.

5.Greasethefrontcasterwheelbearings(2x)every100hours.13.Checkthetirepressure,13psi,(2x)every50hours.

6.Greasethecontrolpivots(4x)every50hours.14.Cleanandoilthechainsandcheckthechaintension(2x)
every8hours.

7.Greasethejackshaftbearings(8x)every25hours.15.Greasethebeltidlerpivotevery100hours.

8.Checkthehydraulic-uidlevel(2x)every50hours.

11

Setup

MediaandAdditionalParts

Description

Operator'sManual

Key2

1

CheckingTirePressure

NoPartsRequired

Procedure

1.Checkthetirepressureinthedrivetires.

Note:Properinationfordrivetiresis83to97

kPa(12to14psi).

2.Adjustthetirepressureifnecessary .

Qty.

Use

1

Readbeforeoperatingthemachine.

Startthemachine.

DANGER

Chargingorjump-startingthebatterymay
produceexplosivegases.Batterygasescan
explode,causingseriousinjury.

•Keepsparks,ames,orcigarettesaway
fromthebattery.

•Ventilatewhenchargingorusingthe
batteryinanenclosedspace.

•Makesurethattheventingpathofthe
batteryisalwaysopenoncethebatteryis
lledwithacid.

•Alwaysshieldyoureyesandfacefromthe
battery.

2

ServicingtheBattery

NoPartsRequired

Procedure

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandlead

compounds,chemicalsknownto

theStateofCaliforniatocause

cancerandreproductiveharm.Wash

handsafterhandling.

DANGER

Batteryelectrolytecontainssulfuricacid,
whichispoisonousandcancausesevere
burns.Swallowingelectrolytecanbefatalor
ifittouchesskincancausesevereburns.

•Wearsafetyglassestoshieldyoureyes
andrubberglovestoprotectyourskinand
clothingwhenhandlingelectrolyte.

•Donotswallowelectrolyte.

•Intheeventofanaccident,ushwithwater
andcalladoctorimmediately.

Note:Themachineisshippedwithalled,lead-acid

battery.

12

1.MovethekeyswitchtotheOFFpositionand
removethekey.

2.Measurethevoltageofthebatterywitha
voltmeter.

3.Usethetablebelowtolocatethechargestate
orthebattery,andifneeded,thebattery-charger
settingandchargingintervalrecommendedto
chargethebatteryto12.6Vorgreater;referto
thebatterychargetablebelow.

Important:Makesurethatthenegative

batterycableisdisconnectedandthe
batterychargerusedforchargingthebattery
hasanoutputof16Vand7Aorlessto
avoiddamagingthebattery(seechartfor
recommendedchargersettings).

BatteryChargeTable

Voltage
Reading

12.6or

greater

12.4to12.6

12.2to12.4

12.0to12.2

11.7to12.0

11.7orless

Percent
Charge

100%

75to100%

50to75%

25to50%

0to25%

0%

Maximum
Charger
Settings

16V/

7A

16V/

7A

16V/

7A

14.4V/

4A

14.4V/

4A

14.4V/

2A

Charging
Interval

Nocharging
required

30minutes

1hour

2hours

3hours

6hoursor
more

Figure4

1.Screw

2.Washer5.Engine

3.Groundwire

4.Negativebatterycable

Note:Iftimedoesnotpermitchargingthe

batteryorifchargingequipmentisnotavailable,
connectthenegativebatterycablesandrun
thevehiclecontinuouslyfor20to30minutesto
chargethebattery.

3

ServicingtheEngineOil

NoPartsRequired

g018126

CAUTION

IfthekeyswitchisintheONposition,
thereispotentialforsparksand
engagementofcomponents.Sparks
couldcauseanexplosionormoving
partscouldaccidentallyengage,causing
personalinjury .

EnsurethatthekeyswitchisintheOFF
positionbeforechargingthebattery.

4.Ifthepositivecableisalsodisconnected,
connectthepositive(red)cabletothepositive
batteryterminalandsliptheterminalcoverover
thepositiveterminal.

5.Removethescrew,washer,andgroundcable
fromtheengine.Connectthenegativebattery
cableasshowninFigure4.

Procedure

Theengineisshippedwithoil;checktheengine-oil
leveland,ifnecessary,addoiltotheappropriatelevel.
RefertoCheckingtheEngine-OilLevel(page18)for
instructionsandtheoilspecication.

13

4

5

ServicingtheTransmission Fluid

NoPartsRequired

Procedure

Transmissionuidtype:T oroHypr-oil500

Themachineisshippedwithhydraulicuidinthe
expansiontank.

1.Runthemachineforapproximately15minutes
topurgeanyextraairoutofthehydraulic
system.

2.Shutofftheengineandallowthemachineto
cool.

3.Checkthehydraulic-uidlevelintheexpansion
tank(Figure5).

Note:Thetransmission-uidlevelshouldcover

theFullColdlinemoldedintothesideofthe
tank.

ServicingtheAuxiliary HydraulicFluid

NoPartsRequired

Procedure

Hydraulicuidtype:AW-32hydraulicuid

Note:Themachineisshippedwithhydraulicuid

inthereservoir.

1.Runthemachineforapproximately15minutes
topurgeanyextraairoutofthehydraulic
system.

2.Completelyraiseandlowerthetines3timesto
purgetheair.

3.Shutofftheengineandallowthemachineto
cool.

4.Loosenthe4boltsinsidetheframesecuringthe
padtothemachine.

5.Liftthepadupandbacktoremoveit(Figure6).

Figure5

1.Cap3.FullColdline

2.Fillerneck(expansion
tank)

4.Ifnecessary,addthespeciedtransmissionuid

untiltheuidlevelisattheFullColdlineofthe
expansiontank(Figure5).

5.Installthecapontotheexpansiontankand

tightenthecapuntilitissnug.

Note:Donotovertightenexpansion-tank

cap.

g025891

g018375

Figure6

6.Removethecapandcheckthehydraulic-uid
levelinthereservoir(Figure7).

Note:Thehydraulic-uidlevelshouldcoverthe

wordColdthatisembossedintothebafeof
thereservoir.

14

Figure7

1.Colduidlevel2.Hotuidlevel

ProductOverview

g025893

7.Ifnecessary ,addthespeciedhydraulicuidto

thereservoiruntiltheuidcoverstheColduid
levelonthebafe(Figure7).

Note:ThebafeinthereservoirislabeledHot

andCold.Fillthereservoirtotheappropriate
leveldependinguponthetemperatureofthe
uid.Theuidlevelvarieswiththetemperature
oftheuid.TheColdlevelshowsthelevelof
theuidwhenitisat24°C(75°F).TheHot
levelshowsthelevelofuidwhenitisat107°C
(225°F).

Forexample:Iftheuidisatambient-air
temperature,about24°C(75°F),llonlytothe
Coldlevel.Iftheuidisabout65°C(150°F),ll
tohalfwaybetweentheHotandColdlevels.

8.Replacethehydraulicreservoircapandtighten
ituntilsnug(Figure7).

Note:Donotovertightenthereservoircap.

9.Installthepadthatyouremovedinsteps4and

5toptheframe,andtightenthe4boltsto1978

to2542N∙cm(175to225in-lb).

Figure8

1.Platform

2.Parking-brakeknob5.Fuelcap

3.Motion-controllevers

4.Enginecontrols

Controls

Motion-ControlLevers

Themotion-controlleversarelocatedoneachsideof
thetopconsoleandcontroltheforwardandreverse
motionofthemachine.

Movetheleversforwardorbackwardtocontrolthe
drivewheelonthesamesideforwardorreverse
respectively.Thewheelspeedisproportionaltothe
amountyoumovethelever.

Important:Thetinesrotatewhenthe

motion-controlleversaremovedoutofthe
NEUTRALposition.

g020220

15

Figure9

g025895

1.Leftmotion-controllever

2.Rightmotion-controllever

3.Frontreferencebar

4.Forward

5.Reverse

6.Frontofthemachine

7.Neutral

Tine-PressureControl

Thetine-pressurecontrolislocatedontheleftsideof
thecontrolconsole(Figure10).

Usethetine-pressurecontroltoadjustthedownward
pressureonthetinesandcoredepth.Rotatethe
controlcounterclockwisetodecreasethepressure
andthelengthoftheaerationplug;rotateclockwise
toincreasepressureandincreasethelengthofthe
aerationplug.

Figure10

1.Tinedownpressuregauge

2.Tinedownpressure
control

3.On/Off-Tine
ground-engagement
footswitch

4.Leftmotion-controllever

5.Frontreferencebar

6.Throttlelever12.Tineground-engagement

7.Chokelever

8.Rightmotion-controllever

9.Hourmeter

10.Parkingbrake

11.Keyswitch

footswitch

ThrottleLever

Thethrottlelever(Figure10)islocatedonthecontrol
console(redlever).

g028268

Usethethrottlelevertocontrolenginespeed.Move
thethrottleleverforwardtoincreaseenginespeed;
movingthethrottleleverrearwardtodecreasethe
enginespeed.

Note:Movethethrottleleverforwardintothedetent

forfullthrottle.

ChokeLever

Thechokelever(Figure10)islocatedonthecontrol
console(blacklever).

Usethechokeleverisusedtoaidinstartingacold
engine.Movethechokeleverforwardtosetthe
choketotheONposition;movethechokelevertothe
rearwardtoreducethechoke.

Note:Pullthechokeleverbackintothedetenttoset

thechoketotheOFFposition.

16

Note:Donotrunawarmenginewiththechokein

theONposition.

On/OffTineGround-Engagement
FootSwitch

Parking-BrakeHandle

Theparking-brakehandleislocatedonthecontrol
console,totherightofthekeyswitch(Figure10).

Note:Thebrakehandleengagesaparkingbrakein

eachofthetransmissions.

•T oengagetheparkingbrake,pullthehandleout

andslideitrearward.

•T oreleasetheparkingbrake,pushthehandle

forwardintothedetent.

Whenparkingonasteepslope,chockorblockthe
wheelsinadditiontoengagingtheparkingbrake.Tie
downthemachineandengagetheparkingbrake
whentransportingthemachine.

HourMeter

Thehourmeterislocatedabovethekeyswitch
(Figure10).

Thehourmeterdisplaysthetotalnumberofhours
thatyouhaverunthemachine.

Thetineground-engagementfootswitchislocated
abovethetinedownpressurecontrolonthecontrol
console.

Pushdownonthetopoftheswitchtoenablethetine
ground-engagementfootswitch.Pushdowntherear
oftheswitchtodisablethefootswitch.

Tine-PressureGauge

Thetine-pressuregaugeislocatedinthemiddleof
thecontrolconsole(Figure10).

Thetine-pressuregaugetoindicatesthedownward
pressurethemachineexertsonthetineswhen
aerating.

Tines-ElevationSwitch

Keepyourhandsandfeetawayfromthetines.
Makesurethatthetinesareaisclearofany
obstructionsbeforeloweringit.

Thetine-elevationswitchislocatedontheoperator
platform(Figure10).

KeySwitch

Thekeyswitchislocatedontherightsideofthe
controlconsole(Figure10).

Usethekeyswitchtostartandshutofftheengine.
Theswitchhas3positions:OFF,ON,andSTART
(Figure11).

Figure11

1.OFF3.START

2.ON

Tolowerthetinesintotheground,standonthe
tine-elevationswitch.T oraisethetines,removeyour
footfromtheswitch.

Fuel-ShutoffValve

Thefuel-shutoffvalveislocatedbehindtheengine
andunderthefueltank(Figure12).

Usethefuel-shutoffvalvetoshutoffthefuelwhen
themachinewillnotbeusedforafewdays,when
transportingthemachinetoandfromthejobsite,or
whenthemachineisparkedinsideabuilding.

•T oopenforfuel-shutoffvalve,rotatethehandle

ofthefuel-shutoffvalveuntilitisalignedwiththe
fuelline.

g008610

•T oclosethefuel-shutoffvalve,rotatethehandle

90°tothefuelline.

17

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

CheckingtheEngine-Oil Level

ServiceInterval:Beforeeachuseordaily

OilType:Detergentoil(APIserviceSJorhigher)

Figure12

1.OFFposition2.ONposition

Specications

Height

Length

Width

Aerationwidth

Coringrange5.1to12.7cm(2to5inches)

Weight

AselectionofToroapprovedattachmentsand
accessoriesisavailableforusewiththemachineto
enhanceandexpanditscapabilities.Contactyour
AuthorizedServiceDealerorDistributor.

Tobestprotectyourinvestmentandmaintainoptimal
performanceofyourToroequipment,countonT oro
genuineparts.Whenitcomestoreliability,T oro
deliversreplacementpartsdesignedtotheexact
engineeringspecicationofourequipment.Forpeace
ofmind,insistonTorogenuineparts.

132cm(52inches)

163cm(64inches)

121cm(48inches)

76cm(30inches)

460kg(1,015lb)

g025897

Oilviscosity:Refertothetablebelow.

g004216

Figure13

Important:Donotoperatetheenginewiththeoil

levelbelowtheLow(orAdd)markonthedipstick,
orovertheFullmark.

1.Shutofftheengine,engagetheparkingbrake,

removethekey,andwaitforallmovingpartsto
stopbeforeleavingtheoperatingposition.

2.Allowtheenginetocool.

3.Checktheengine-oillevelasshowninFigure

14.

18

AddingFuel

Fuel-tankcapacity:18.9L(5USGallons)

•Forbestresults,useonlyclean,fresh(lessthan

30daysold),unleadedgasolinewithanoctane
ratingof87orhigher((R+M)/2ratingmethod).

g025899

•ETHANOL:Gasolinewithupto10%ethanol

(gasohol)or15%MTBE(methyltertiarybutyl
ether)byvolumeisacceptable.Ethanoland
MTBEarenotthesame.Gasolinewith15%
ethanol(E15)byvolumeisnotapprovedforuse.
Neverusegasolinethatcontainsmorethan10%
ethanolbyvolume,suchasE15(contains15%
ethanol),E20(contains20%ethanol),orE85
(containsupto85%ethanol).Usingunapproved
gasolinemaycauseperformanceproblemsand/or
enginedamagewhichmaynotbecoveredunder
warranty.

•Donotusegasolinecontainingmethanol.

•Donotstorefueleitherinthefueltankorfuel

containersoverthewinterunlessyouuseafuel
stabilizer.

Figure14

4.Iftheoillevelislow,wipeofftheareaaround
theoilllcap,removecapandaddthespecied
oiluntiltheoillevelisattheFullmarkonthe
dipstick.

•Donotaddoiltogasoline.

DANGER

Incertainconditions,fuelisextremely
ammableandhighlyexplosive.Areor
explosionfromfuelcanburnyouandothers
andcandamageproperty.

•Fillthefueltankoutdoors,inanopenarea,
andwhentheengineiscold.Wipeupany
fuelthatspills.

•Donotllthefueltankcompletelyfull.
Addfueltothefueltankuntilthelevelis6
to13mm(1/4to1/2inch)belowthebottom
ofthellerneck.Thisemptyspaceinthe
tankallowsthefueltoexpand.

•Neversmokewhenhandlingfuel,andstay

g025898

awayfromanopenameorwhereaspark
mayignitethefuelfumes.

•Storefuelinanapprovedfuelcontainer
andkeepitoutofthereachofchildren.

•Neverbuymorethana30-daysupplyof
fuel.

Note:Donotoverlltheenginewithoil.

19

DANGER

Incertainconditionsduringfueling,static
electricitycanbereleased,causingaspark,
whichcanignitethefuelvapors.Areor
explosionfromfuelcanburnyouandothers
andcandamageproperty.

•Alwaysplacefuelcontainersontheground
awayfromyourvehiclebeforelling.

•Donotllfuelcontainersinsideavehicle
oronatruckortrailerbedbecauseinterior
carpetsorplastictruckbedlinersmay
insulatethecontainerandslowthelossof
anystaticcharge.

•Whenpractical,removefuel-powered
equipmentfromthetruckortrailerand
refueltheequipmentwithitswheelsonthe
ground.

UsingStabilizer/Conditioner

Useafuelstabilizer/conditionerinthemachineto
providethefollowingbenets:

•Keepfuelfreshduringstorageof90daysorless.

Forlongerstorage,drainthefueltank.

•Cleantheenginewhileitruns

•Eliminategum-likevarnishbuildupinthefuel

system,whichcauseshardstarting

Important:Donotusefueladditives

containingmethanolorethanol.

Addthecorrectamountoffuelstabilizer/conditioner
tothefuel.

Note:Afuelstabilizer/conditionerismost

effectivewhenmixedwithfreshfuel.T ominimize
thechanceofvarnishdepositsinthefuelsystem,
usefuelstabilizeratalltimes.

•Ifthisisnotpossible,thenrefuelsuch
equipmentonatruckortrailerfroma
portablecontainerratherthanfroma
fuel-dispensernozzle.

•Ifyoumustuseafuel-dispensernozzle,
keepthenozzleincontactwiththerimof
thefueltankorcontaineropeningatall
timesuntilfuelingiscomplete.

WARNING

Fuelisharmfulorfatalifswallowed.
Long-termexposuretovaporscancause
seriousinjuryandillness.

•Avoidprolongedbreathingofvapors.

•Keepyourfaceawayfromthenozzleand
fueltankorconditionerbottleopening.

•Avoidcontactwithskin;washoffspills
withsoapandwater.

FuelingtheMachine

1.Cleanaroundthefuel-tankcap.

2.Removethecapfromthetank.

3.Fillthefueltankwithfueltowithin6to13mm

(1/4to1/2inch)fromthetopofthetank.Donot

llintothellerneck.

Important:Donotllthetankmorethan

6mm(1/4inch)fromthetopofthetank
becausethefuelmusthaveroomtoexpand.

4.Installthefuel-tankcapandwipeupanyspilled
fuel.

20

LubricatingtheChains

CheckingtheConditionofthe
Sprockets

ServiceInterval:Beforeeachuseordaily

1.Shutofftheengine,engagetheparkingbrake,
waitforallmovingpartstostop,andremove
thekey.

2.Inspectsprocketsforwearandreplaceas
required(Figure15).

3.Ifthechainspoporsnap;refertoAdjusting

theJackshaftDrive-ChainT ension(page40),
AdjustingtheDriveWheelChainTension(page

41),orAdjustingtheTineDriveChain(page50).

LubricatingtheChains

ServiceInterval:Beforeeachuseordaily

Important:Donotlubricatechainswith

penetratingoilorsolvents.Useoilorchain
lubricant.

1.Shutofftheengine,engagetheparkingbrake,
waitforallmovingpartstostop,andremove
thekey.

2.Raisethemachineandsupportitwithjack
standswitha460kg(1,015lb)capacity.

CAUTION

Raisingthemachineforservice
ormaintenancerelyingsolelyon
mechanicalorhydraulicjackscouldbe
dangerous.Themechanicalorhydraulic
jacksmaynotbeenoughsupportormay
malfunctionallowingthemachinetofall,
whichcouldcauseinjury .

Figure15

1.Sprockets2.Chains

CheckingtheConditionofthe
Chains

ServiceInterval:Beforeeachuseordaily

1.Shutofftheengine,engagetheparkingbrake,
waitforallmovingpartstostop,andremove
thekey.

2.Checkthechaintension(Figure15)atboth
sidesofthemachine.

Note:Thechainsshouldmoveupanddown6

to12mm(1/4to1/2inch).

Donotrelysolelyonmechanical
orhydraulicjacksforsupport.Use
adequatejackstandsorequivalent
support.

3.Starttheengineandmovethethrottlelevel
aheadtothehalf-throttleposition.

WARNING

g025984

Enginemustberunninganddrivewheels
mustbeturningsoadjustmentscanbe
performed.Contactwithmovingpartsor
hotsurfacesmaycausepersonalinjury.

Keepyourngers,hands,andclothing
clearofrotatingcomponentsandhot
surfaces.

4.Disengagetheparkingbrake.

5.Withtheenginerunning,slowlymovethe
motion-controlleversforwardandlubricateall6
chains(Figure15).

6.Checktheconditionandtensionofthechains;
refertoCheckingtheConditionoftheChains

(page21).

21

Checkingthe
Safety-InterlockSystem

ServiceInterval:Beforeeachuseordaily

CAUTION

Ifthesafety-interlockswitchesare
disconnectedordamaged,themachinecould
operateunexpectedly,causingpersonal
injury.

•Donottamperwiththeinterlockswitches.

•Checktheoperationoftheinterlock
switchesdailyandreplaceanydamaged
switchesbeforeoperatingthemachine.

UnderstandingtheSafety-InterlockSystem

Thesafety-interlocksystemisdesignedtopreventthe
enginefromstartingunlessthemotion-controllevers
areintheneutralposition.

OperatingtheMachine

UsingtheFuel-ShutoffValve

Rotatetheleverofthefuel-shutoffvalvetoalignthe
leverwiththefuelline.

g025897

Figure16

CheckingtheSafety-InterlockSystem

1.Disconnectthespark-plugwires.

2.Whileonlevelground,blockthewheelsofthe
machinetopreventunintendedmovement.

3.Disengagetheparkingbrake.

4.Withthemotion-controlleversintheneutral
positionturnthekeytotheSTARTposition—the
startermustnotcrank.

Note:Ifthemachinedoesnotpassthistest,do

notoperatethemachine.ContactyourAuthorized
ServiceDealer.

Important:Itisessentialthattheoperator

safetymechanismsareconnectedandinproper
operatingconditionpriortouse.

CheckingforLoose Hardware

ServiceInterval:Beforeeachuseordaily

1.Shutofftheengine,engagetheparkingbrake,
removethekey,andwaitforallmovingparts
tostop.

2.Visuallyinspectmachineforanyloosehardware
oranyotherpossibleproblem.

Note:Tightenallloosehardwareorrepairthe

problembeforeoperatingthemachine.

1.OFFposition2.ONposition

StartingtheEngine

1.Movethemotion-controlleverstotheneutral
positionandengagetheparkingbrake;refer
toMotion-ControlLevers(page15)and

Parking-BrakeHandle(page17).

Note:Tostarttheengine,theparkingbrake

mustbeengaged.Itisnotnecessaryforthe
operatortobeontheplatform.

2.Placethethrottlelevermidwaybetweenthe
SLOWandFASTpositions;refertoThrottleLever

(page16).

3.Iftheengineiscold,pushthechokelever
forwardtotheONposition;refertoChokeLever

(page16).

Note:Iftheengineiswarm,pullthechokelever

totheOFFposition.

4.RotatethekeyswitchtotheSTARTposition;
refertoKeySwitch(page17).

Note:Releasetheswitchassoonastheengine

starts.

Important:Donotcranktheengine

continuouslyformorethan10secondsat
atime.Iftheenginedoesnotstart,allowa
60-secondcooldownperiodbetweenstarting
attempts.Failuretofollowtheseguidelines
canburnoutthestartermotor.

22

5.IfthechokeleverisintheONposition,gradually
movethelevertowardtheOFFpositionasthe
enginewarmsup.

LoweringtheTines

1.SetthethrottlelevermidwaybetweentheSLOW
andFASTpositions;refertoThrottleLever(page

16).

2.Steponthetine-elevationswitchtolowerthe
tines(Figure17).

g025901

Figure18

Figure17

1.Tine-elevationswitch

3.Standontheswitchandmovethemotion-control
leversforwardtoaerate(Figure17).

4.Adjustthethrottlefortheworkingconditions;
refertoThrottleLever(page16).

AdjustingtheTineDownPressure

Important:Keepthedrivetiresonthegroundat

alltimes.

1.Tine-pressurecontrol3.Decreasepressure

2.Tine-pressuregauge

(shorterplug)

4.Increasepressure(longer
plug)

•Rotatethetine-pressurecontrol

counterclockwise(Figure18)todecrease
thedownwardpressureinordertoremovea
shorterplug.

•Rotatethetine-pressurecontrolclockwise(Figure

g025900

18)toincreasedownwardpressureinorderto

removealongerplug.

Note:Idealplugdepthis7.6to10cm(3to4inches).

Rotatethetine-pressurecontroltoadapttothesoil
conditions.

RaisingtheTines

Toraisethetines,removeyourfootfromthe
tine-elevationswitch(Figure17).

Important:Thetinesrotatewhenthe

motion-controlleverismovedoutoftheneutral
position.

Adjusttheplugdepthbyrotatingthetine-pressure
controlasfollows:

Note:Firsttimeuse:setthetine-pressurecontrol

sothatthetine-pressuregauge(Figure18)indicates
24bar(350psi).

ShuttingOfftheEngine

1.Movethemotion-controlleverstotheneutral
positionandbringthemachinetoafullstop;
refertoMotion-ControlLevers(page15).

2.Liftyourfootoffthetineground-engagement
footswitchcontroltoraisethetines;referto

RaisingtheTines(page23).

3.Placethethrottleinthemidwaybetweenthe
SLOWandFASTpositions;refertoThrottleLever

(page16).

4.Allowtheenginetorunforaminimumof15
seconds,thenturnthekeyswitchtotheOFF
positiontoshutofftheengine;refertoKey

Switch(page17).

5.Engagetheparkingbrake;refertoParking-Brake

Handle(page17).

23

6.Removethekeytopreventchildrenorother
unauthorizedpersonsfromstartingtheengine.

7.Closethefuel-shutoffvalvewhenthemachine
willnotbeusedforafewdays,when
transporting,orwhenthemachineisparked
insideabuilding;refertoUsingtheFuel-Shutoff

Valve(page22).

DrivingtheMachine

CAUTION

Machinecanspinveryrapidlybypositioning
1levertoomuchaheadoftheother.Youmay
losecontrolofthemachine,whichmaycause
damagetothemachineorinjury.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemaking
sharpturns.

Important:T odrivethemachine(forwardor

backward),disengagethebrakeleverbeforeyou
canmovethemotion-controllevers.

Figure19

1.Leftmotion-controllever

2.Rightmotion-controllever6.Neutral

3.Frontreferencebar

4.Frontofthemachine

5.Forward

7.Reverse

g016672

Figure20

4.T oturnleftorright,pullthemotion-controllever
backtowardneutralinthedesiredturndirection.
Thetinescanbeinthedownpositionwhen
makinggradualturns.

5.T omakezero-turns,liftyourfootoffthetine
engagementfootswitchcontroltoraisethe
tines.Theheadraisesin1second.

Important:Donotmakeazero-turnwhen

thetinesaredown,otherwiseyoumaytear
theturf.

6.T ostopthemachine,movebothmotion-control
leverstotheneutralposition.

g020241

DrivinginReverse

1.Movethemotion-controlleverstotheneutral
position.

2.T omoverearwardinastraightline,slowlymove
bothleversrearwardwithequalpressure.

DrivingForward

1.Makesurethatthemotion-controlleversarein
theneutralposition.

2.Disengagetheparkingbrake.

3.T omoveforwardinastraightline,moveboth
leversforwardwithequalpressure.

Note:Themachinemovesfasterthefarther

themotion-controlleversaremovedfromthe
neutralposition.

g016673

Figure21

24

3.T oturnleftorright,releasepressureonthe
motion-controllevertowardthedesiredturn
direction.

LoadingtheMachineontoa
TransportVehicle

4.T omakezero-turns,liftyourfootoffthe
tine-elevationswitchtoraisethetines.Thehead
raisesin1second.

Important:Donotmakeazero-turnwhen

thetinesareinthedownposition.

5.T ostopthemachine,positionbothmotion-control
leversintheneutraloperateposition.

TransportingtheMachine

Machineweight:460kg(1,015lb)

CAUTION

Thismachinedoesnothaveproperturn
signals,lights,reectivemarkings,ora
slowmovingvehicleemblem.Drivingona
streetorroadwaywithoutsuchequipment
isdangerousandcanleadtoaccidents,
causingpersonalinjury.Drivingonastreetor
roadwaywithoutsuchequipmentmayalso
beaviolationofstatelaws,andyoumaybe
subjecttotrafcticketsand/ornes.

Donotdrivethemachineonapublicstreet
orroadway.

WARNING

Loadingthemachineontoatrailerortruck
increasesthepossibilityoftip-overandcould
causeseriousinjuryordeath.

•Useextremecautionwhenoperatinga
machineonaramp.

•Useonlyasingle,full-widthramp;donot
useindividualrampsforeachsideofthe
machine.

•Ifyoumustuseindividualramps,use
enoughrampstocreateanunbrokenramp
surfacewiderthanthemachine.

•Donotexceeda15-degreeanglebetween
rampandground,orbetweenaramp,a
trailer,oratruck.

•Avoidsuddenaccelerationwhiledriving
machineuparamptoavoidtipping
backward.

•Avoidsuddendecelerationwhilebacking
machinedownaramptoavoidtipping
backward.

Important:Donotattempttoturnthemachine

whileontheramp;youmaylosecontrolanddrive
offtheside.

•Useextremecautionwhenloadingunitsonto

trailersortrucks.

•Use1full-widthrampthatiswideenoughto

extendbeyondthereartiresinsteadofindividual
rampsforeachsideofthemachine(Figure22).
Theplatform,whendownandlockedintoposition,
mustextendbackbetweentherearwheelsand
servesasastopfortippingbackward.Havinga
full-widthrampprovidesasurfacefortheplatform
tocontactifthemachinestartstotipbackward.
Withtheplatformup,afull-widthrampprovidesa
surfacetowalkonbehindthemachine.

•Therampshouldbelongenoughsothatthe

anglesdonotexceed15degrees(Figure22).
Asteeperanglemaycausetinecomponentsto
getcaught,asthemachinemovesfromrampto
trailerortruck.Asteeperanglemayalsocause
themachinetotipbackward.Ifloadingonornear
aslope,positionthetrailerortrucksoitisonthe
downsideoftheslopeandtherampextendsup
theslope.Thisminimizestherampangle.The
trailerortruckshouldbeaslevelaspossible.

25

TransportingtheMachine

Useaheavy-dutytrailerortrucktotransportthe
machine.Ensurethatthetrailerortruckhasall
thenecessarybrakes,lighting,andmarkingas
requiredbylaw.Pleasecarefullyreadallthesafety
instructions.

1.Raisethetinesofthemachinebeforedriving
ontothetrailerortruck.

2.Ifusingatrailer,connectittothetowingvehicle
andconnectthesafetychains.

3.Ifapplicable,connectthetrailerbrakes.

4.Loadthemachineontothetrailerortruck.

5.Shutofftheengine,removethekey,engagethe
parkingbrake,andclosethefuelvalve.

Figure22

1.Trailer3.Notgreaterthan

2.Full-widthramp

15degrees

4.Full-widthramp(sideview)

•Y oushoulddetermineifitisbesttohavethe

platformupordownwhenloading,dependingon
conditions.Ifitisnotpossibletouse1full-width
ramp,useenoughindividualrampstosimulatea
full-width,continuousramp.

•Avoidsuddenaccelerationwhendrivinguparamp

andsuddendecelerationwhenbackingdowna
ramp.Bothmaneuverscancausethemachineto
tipbackward.

g000951

6.Engagetheparkingbrakeandblockthetires.

7.Usethetie-downpointsonthemachineto
securelybindthemachinetothetrailerortruck
withstraps,chains,cable,orropes(Figure23).

Note:Refertoyourlocalordinancesforspecic

trailerandtie-downregulations.

g025949

Figure23

1.Tie-downpoints

26

Maintenance

WARNING

Whileyouaremaintainingoradjustingthe
machine,someonecouldstarttheengine.
Accidentallystartingtheenginecould
seriouslyinjureyouorotherbystanders.

Removethekeyfromthekeyswitch,engage
parkingbrake,andpullthewire(s)offthe
sparkplug(s)beforeyoudoanymaintenance.
Alsopushthewire(s)asidesoitdoesnot
accidentallycontactthesparkplug(s).

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst100hours

Beforeeachuseordaily

MaintenanceProcedure

•Changetheauxiliaryhydraulicreservoirlteranduid.

•Changethetransmissionlters.

•Fillthetransmissionwithuidwhenchangingthelter.

•Checktheengine-oillevel.

•Checktheconditionofthesprockets.

•Checktheconditionandtensionofthechains.

•Lubricatethechains.

•Checkthesafety-interlocksystem.

•Checkforloosehardware.

•Checkthetines.

•Cleantheengineandtheexhaustsystemarea(moreoftenindryordirtyconditions).

•Cleanthegrassanddebrisbuildupfromthemachine.

WARNING

Theenginecanbecomeveryhot.Touchinga
hotenginecancausesevereburns.

Allowtheenginetocoolcompletelybefore
serviceormakingrepairsaroundtheengine
area.

Every25hours

Every50hours

Every80hours

Every100hours

Every200hours

•Greasethejackshaftbearings.

•Greasethewheelbearings.

•Greasethetineshaftbearings.

•Greasethetineassemblyidlers.

•Cleanthefoamair-cleanerelement(moreofteninextremelydustyorsandy
conditions).

•Greasethecontrolpivots.

•Checksparkarrester(ifequipped).

•Checkthepressureinthetires.

•Checktheconditionandtensionofthebelts.

•Checktheauxiliaryhydraulic-uidlevel.

•Checkthehydraulictransmissionuidlevel.

•Removetheengineshroudsandcleanthecoolingns.

•Checkthepaperair-cleanerelement(moreofteninextremelydustyorsandy
conditions).

•Check,cleanandgapthesparkplug.

•Checkthebattery.

•Replacethepaperair-cleanerelement(moreofteninextremelydustyorsandy
conditions).

•Changetheengine-oillter(moreofteninextremelydustyorsandyconditions).

27

MaintenanceService

Every250hours

Interval

MaintenanceProcedure

•Replacetheprimaryair-cleanerelement(moreofteninextremelydustyorsandy
conditions).

•Checkthesecondaryair-cleanerelement(moreofteninextremelydustyorsandy
conditions).

•Changetheauxiliaryhydraulicreservoirlteranduid.

•Changethetransmissionlters.

•Fillthetransmissionwithuidwhenchangingthelter.

Every500hours

Every800hours

Yearly

Yearlyorbeforestorage

•Replacethesecondaryair-cleanerelement(moreofteninextremelydustyorsandy
conditions).

•Replacethefuellter.

•Greasethefrontcasterpivots.

•Greasethebeltidlerpivot.

•Greasethecasterpivotsandhubs.

•Lubricatethecaster-wheelhubs.

•Lubricatethecaster-wheelhubs.

•Checkthetorqueofthewheelhubnuts.

•Checkthetorqueonthewheellugnuts.

•Checkthetorqueofthetransmissionoutputshaftnut.

•T ouchupareaswithchippedpaint.

Pre-Maintenance
Procedures

CAUTION

Raisingthemachineforserviceor
maintenancerelyingsolelyonmechanical
orhydraulicjackscouldbedangerous.The
mechanicalorhydraulicjacksmaynotbe
enoughsupportormaymalfunctionallowing
themachinetofall,whichcouldcauseinjury.

AccessingtheConsole Compartment

RemovingtheConsolePad

1.Loosenthe4anged-headboltsthatsecurethe
padtotheleftandrightconsolepanels(Figure

24).

Donotrelysolelyonmechanicalorhydraulic
jacksforsupport.Useadequatejackstands
orequivalentsupport.

PreparingfortheMachine forMaintenance

Performthefollowingbeforeservicing,cleaning,or
makinganyadjustmentstothemachine.

1.Parkthemachineonalevelsurface.

2.Shutofftheengine,engagetheparkingbrake,
waitforallmovingpartstostop.

3.Removethekeyfromthekeyswitch.

Figure24

1.Keyholeslot(console
panel)

2.Fanged-headbolt

2.Liftuptheconsolepad(Figure24)approximately

13mm(1/2inch).

3.Pulltheconsolepadstraightbackandremove

thepadfromthemachine(Figure24).

28

g025880

3.Pad

InstallingtheConsolePad

1.Alignthe4anged-headboltsattheforward
faceoftheconsolepadtothe4keyholeslotsin
theframeoftheconsole(Figure24).

Lubrication

LubricatingtheGrease

2.Movethepadforwarduntilthepadisushto
theconsoleframe(Figure24).

3.Movethepaddownuntiltheanged-headbolts
areseatedinthekeyholeslots(Figure24).

4.Tightentheanged-headboltsto1978to2542
N∙cm(175to225in-lb).

Fittings

Greasetype:NationalLubricatingGreaseInstitute

(NGLI)grade#2multi-purposegungrease.

Note:Refertothelubricationchartforservice

intervals.

LubricationChart

Fitting

Locations

1.FrontCaster
Pivots

2.Jackshaft
Bearings

3.Wheel
Bearings

4.TineShaft
Bearings

5.Tine
AssemblyIdlers

6.Control
Pivots

7.BeltIdler
Pivot

8.FrontCaster
Hubs

Initial

Pumps

*0

1825hours

1225hours

1425hours

1225hours

1450hours

11Y early

*0

Numberof

Places

Service
Interval

2Yearly

2Yearly

Figure25

1.Shutofftheengine,engagetheparkingbrake,
waitforallmovingpartstostop,andremove
thekey.

2.Wipecleanthegreasettingswitharag(Figure

25).

29

g020222

3.Connectagreaseguntothetting(Figure25).

4.Pumpgreaseintothettingsuntilgreasebegins
tooozeoutofthebearings.

5.Wipeupanyexcessgrease.

LubricatingtheCaster-Hubs
Bearings

ServiceInterval:Yearly

RemovingtheCaster-WheelAssembly

LubricatingtheCasters

Greasetype:NationalLubricatingGreaseInstitute

(NGLI)gradeNo.2multi-purposegungrease.

GreasingtheCasterPivots

ServiceInterval:Yearly

1.Removecapandhexplugfromthetopofthe
casterpivot(Figure26).

1.Shutofftheengine,engagetheparkingbrake,
waitforallmovingpartstostop,andremove
thekey.

2.Liftthefrontofthemachineandsupportitwith
jackstands.

3.Removethewheelnutandbolt,andremovethe
caster-wheelassemblyfromthefork(Figure27).

g025953

Figure27

1.Wheelbolt3.Wheelnut

2.Caster-wheelassembly

Figure26

1.Hexplug

2.Greasetting4.Cap

2.Threadgreasettinginhole(Figure26).

3.Pumpgreaseintothettinguntilgreaseoozes
outaroundtopbearing(Figure26).

4.Removegreasettingandinstalltheplugthat
youremovedin1(Figure26).

5.Installthecapthatyouremovedinstep1(Figure

26).

6.Repeatsteps1through5totheothercaster.

3.Casterpivot

DisassemblingtheCaster-WheelHuband
GreasingtheBearings

ServiceInterval:Yearly

g025955

Important:Usenewbearingsealswhen

lubricatingthecaster-wheelhubs.

Important:Topreventsealandbearingdamage,

checkthebearingadjustmentoften.Spinthe
castertire.Thetireshouldnotspinfreely(more
than1or2revolutions)orhaveanysideplay.If
thewheelspinsfreely,adjusttorqueonspacer
nutuntilthereisaslightamountofdrag.Apply
thread-lockingcompound.

Greasetype:NationalLubricatingGreaseInstitute

(NGLI)gradeNo.2multi-purposegungrease.

1.Removethe2sealguardsfromthewheelhub
(Figure28).

30

Figure28

1.Axle(spacernutstill
assembled)

2.Hub5.Bearingseal

3.Bearing

4.Spacernut

6.Sealguard

2.Remove1ofthespacernutsfromtheaxle

assemblyinthecasterwheel(Figure28).

Note:Notethatthread-lockingcompoundhas

beenappliedtolockthespacernutstotheaxle
(Figure28).

3.Removetheaxle(withtheotherspacernutstill

assembledtoit)fromthecaster-wheelassembly
(Figure28).

4.Pryoutbothbearingseals(Figure28).

Note:Discardtheoldseals.

5.Removebothbearingsandinspectthemfor

wearordamage(Figure28).

Note:Replacethebearingifitiswornor

damaged.

6.Packthe2bearingswiththespeciedgrease.

AssemblingtheCaster-WheelHub

1.Install1bearingintothehubofthewheel(Figure

28).

2.Installthebearingsealintothehubatthe

bearing(Figure28).

3.Ifyouremoved(orbrokeloose)bothofthe

spacernutsfromtheaxleassembly,perform
thefollowing:

A.Cleanthethreadsoftheaxleandspacer

nut.

B.Applyathread-lockingcompoundtothe

threadsat1endoftheaxle.

C.Threadtheaxlenut,withthewrenchats

facingoutward,ontotheendoftheaxlethat
ispreparedwiththread-lockingcompound
(Figure28).

mm(1/8inch)fromtheoutersurfaceofthe
spacernuttotheendoftheaxleinsidethe
nut.

4.Inserttheassemblednutandaxleintothewheel
atthesideofthewheelwiththenewsealand
bearing(Figure28).

5.Withtheopenendofthewheelfacingup,llthe
areainsidewheelcavity(aroundtheaxle)with
thespeciedgrease.

g025954

6.Installtheotherbearingandnewsealintothe
wheel(Figure28).

7.Applyathread-lockingcompoundtothesecond
spacernutandthreaditontotheaxlewiththe
wrenchatsfacingoutward.

8.T orquethespacernutto8to9N∙m(75to80
in-lb),loosen,thentorqueit2to3N∙m(20to
25in-lb).

Note:Makesureaxledoesnotextend

beyondeithernut.

9.Installthesealguardsoverthewheelhub
(Figure28).

InstallingtheCaster-WheelAssembly

1.Aligntheholeintheaxleofthecaster-wheel
assemblybetweentheholesintheforkofthe
caster(Figure27).

2.Securethewheelassemblytotheforkwiththe
wheelnutandbolt(Figure27)thatyouremoved
instep3ofRemovingtheCaster-Wheel

Assembly(page30).

3.T orquethewheelnutto91to1 13N∙m(67to
83ft-lb).

Note:Donotthreadspacernutallofthe

wayontotheaxle.Leaveapproximately3

31

EngineMaintenance

ServicingtheAirCleaner

ServiceInterval:Every250hours—Replacethe

primaryair-cleanerelement(more
ofteninextremelydustyorsandy
conditions).

Every250hours—Checkthesecondary
air-cleanerelement(moreofteninextremely
dustyorsandyconditions).

Every500hours—Replacethesecondary
air-cleanerelement(moreofteninextremely
dustyorsandyconditions).

Inspectthefoamandpaperelements,andreplace
themiftheyaredamagedorexcessivelydirty .

Important:Donotapplyoiltothefoamorpaper

element.

RemovingtheFoamandPaper

air-cleanerassemblyfromtheinletduct(Figure

29).

5.Carefullypullthefoamelementoffthepaper
element(Figure29).

ServicingtheFoamAir-Cleaner
Element

ServiceInterval:Every25hours(moreoften

inextremelydustyorsandy
conditions).

1.Inspecttheelementfortears,anoilylm,or
damaged(Figure29).

Important:Replacethefoamelementifit

iswornordamaged.

2.Washthefoamelementinliquidsoapand
warmwater.Whentheelementisclean,rinse
itthoroughly.

3.Drytheelementbysqueezingitinacleancloth.

Elements

1.Shutofftheengine,engagetheparkingbrake,
removethekey,andwaitforallmovingpartsto
stopbeforeleavingtheoperatingposition.

2.Cleanaroundtheaircleanertopreventdirtfrom
gettingintotheengineandcausingdamage
(Figure29).

ServicingthePaperAir-Cleaner
Element

ServiceInterval:Every100hours—Checkthe

paperair-cleanerelement(more
ofteninextremelydustyorsandy
conditions).

Every200hours—Replacethepaperair-cleaner
element(moreofteninextremelydustyor
sandyconditions).

Important:Donotwashthepaperair-cleaner

element.

1.Inspecttheelementfortears,anoilylm,or
damagetotherubberseal(Figure29).

Note:Replacethepaperelementifitis

damaged.

2.Cleanthepaperelementbygentlytappingitto
removedustanddebris.

Note:Iftheelementisverydirty ,replacethe

air-cleanerelement.

Figure29

1.Cover

2.Hoseclamp4.Foamelement

3.Rotatethecoverknobs1/4turncounterclockwise
andremovetheair-cleanercover(Figure29).

4.Rotatethethumbscrewofthehoseclamp
counterclockwiseuntilyoucanseparatethe

3.Paperelement

g012352

32

Note:Donotusepressurizedairtocleanthe

paperelement.

InstallingtheFoamandPaper
Elements

Important:Topreventenginedamage,always

operatetheenginewiththecompletefoamand
paperair-cleanerassemblyinstalled.

1.Carefullyslidethefoamelementontothepaper
air-cleanerelement(Figure29).

2.Aligntheair-cleanerassemblyontotheinletduct
andsecureitwiththehoseclamp(Figure29).

3.Aligntheair-cleanercoverontotheenginecover
andsecurethecoverbyrotatingthecoverknobs
1/4turnclockwise(Figure29).

ServicingtheEngineOil

OilType:Detergentoil(APIserviceSJorlater)

EngineOilCapacity:1.7L(1.8USqt)withthelter

removed;1.5L(1.6USqt)withoutthelterremoved

Oilviscosity:Refertothetablebelow.

g025980

Figure31

Figure30

ChangingtheEngineOil

Note:Disposeoftheusedoilatarecyclingcenter.

1.Parkthemachinesothatthedrainsideisslightly
lowerthantheoppositesidetoassuretheoil
drainscompletely.

2.Shutofftheengine,engagetheparkingbrake,
removethekey,andwaitforallmovingpartsto
stopbeforeleavingtheoperatingposition.

3.ChangetheengineoilasshowninFigure32.

Note:Torquedrainplugto27to33N∙m(20

to24ft-lb).

g004216

g025979

Figure32

4.Slowlypourapproximately80%ofthespecied
oilintothellertube,andslowlyaddthe
additionaloiltobringittotheFullmark(Figure

33).

33

Figure33

5.Starttheengineanddrivetoaatarea.

6.Checktheengine-oillevel.

ChangingtheEngine-OilFilter

g025976

g026005

ServiceInterval:Every200hours(moreoften

inextremelydustyorsandy
conditions).

1.Draintheoilfromtheengine;refertoChanging

theEngineOil(page33).

2.Placearagundertheoilltertosoakupany
spilledoil.

Important:Spilledoilmaydrainunderthe

engineandontotheclutch.Oilspilledon
theclutchmaydamagetheclutch,cause
thebladestostopslowlywhentheclutchis
intheOFFposition,andcausetheclutchto
slipwhentheclutchisswitchedtotheON
position.Wipeupanyspilledoil.

3.Changetheengine-oillter(Figure34).

g026006

Figure34

Note:Ensurethattheoil-ltergaskettouches

theengine,andthenturnthelteranextra3/4
turn.

4.Fillthecrankcasewiththespeciedtypeofnew
oil;refertoFigure30.

34

ServicingtheSparkPlug

CheckingtheSparkPlug

ServiceInterval:Every100hours

TypeforallEngines:NGKBPR4ESorequivalent

AirGap:0.75mm(0.03inch)

Makesurethattheairgapbetweenthecenterand
sideelectrodesiscorrectbeforeinstallingthespark
plug.

Useasparkplugwrenchforremovingandinstalling
thesparkplug(s)andagappingtool/feelergaugeto
checkandadjusttheairgap.Installanewspark
plug(s)ifnecessary.

RemovingtheSparkPlug

1.Shutofftheengine,engagetheparkingbrake,
removethekey,andwaitforallmovingpartsto
stopbeforeleavingtheoperatingposition.

2.RemovethesparkplugasshowninFigure35.

Important:Donotcleanthesparkplug(s).

Alwaysreplacethesparkplug(s)whenithasa
blackcoating,wornelectrodes,anoilylm,or
cracks.

Ifyouseelightbrownorgrayontheinsulator,the
engineisoperatingproperly.Ablackcoatingonthe
insulatorusuallymeansthesparkplugisdirty .

Setthegapto0.75mm(0.03inch).

g027479

Figure36

InstallingtheSparkPlug

Figure35

Tightenthesparkplug(s)to22N∙m(16ft-lb).

g025981

g027478

g027735

Figure37

35

CheckingtheSpark

FuelSystem

Arrester

MachineswithaSparkArrester
Only

ServiceInterval:Every50hours

WARNING

Hotexhaustsystemcomponentsmayignite
fuelvaporsevenaftertheengineisshut
off.Hotparticlesexhaustedduringengine
operationmayigniteammablematerials.
Firemayresultinpersonalinjuryorproperty
damage.

Donotrefuelorrunengineunlessspark
arresterisinstalled.

1.Shutofftheengine,engagetheparkingbrake,
removethekey,andwaitforallmovingpartsto
stopbeforeleavingtheoperatingposition.

2.Allowthemufertocool.

Maintenance

ServicingtheFuelFilter

ReplacingtheFuelFilter

ServiceInterval:Every800hours/Yearly(whichever

comesrst)

Note:Wipeupanyspilledfuel.

1.Shutofftheengine,engagetheparkingbrake,
removethekey,andwaitforallmovingpartsto
stopbeforeleavingtheoperatingposition.

2.Closethefuel-shutoffvalve;refertoUsingthe

Fuel-ShutoffValve(page22).

3.Squeezetheendsofthehoseclampstogether
andslidethemawayfromthelter(Figure38).

3.Checkthesparkarresterforbreaksinthe
screenorwelds.

Note:Replacethesparkarresterifitisworn

ordamaged.

4.Ifyouseethatthescreenisplugged,perform
thefollowing:

A.Removethesparkarrester.

B.Shakeloosetheparticlesfromthearrester

andcleanscreenwithawirebrush.

Note:Soakthearresterscreeninsolvent

ifnecessary.

C.Installsparkarresterontoexhaustoutlet.

g025982

Figure38

1.Hoseclamp3.Hose

2.Flowdirectionarrow(fuel
lter)

4.Removethelterfromthefuelhoses(Figure

38).

Note:Donotinstalladirtylterafteritis

removedfromthefuelline.

5.Installanewlterwiththeow-directionarrow

alignedasillustratedinFigure38.

Note:Ensurethatthefuelhosesarefully

seatedontothehosettingsofthefuellter.

6.Alignthehoseclampsoverthehoseandthe

fuel-lterttings(Figure38).

36

7.Openthefuel-shutoffvalve;refertoUsingthe

Fuel-ShutoffValve(page22).

ElectricalSystem

8.Checkforfuelleaksandrepairifneeded.

9.Wipeupanyspilledfuel.

Maintenance

ServicingtheBattery

ServiceInterval:Every100hours

Alwayskeepthebatterycleanandfullycharged.Use
apapertoweltocleanthebatterycase.Ifthebattery
terminalsarecorroded,cleanthemwithasolutionof
4partswaterand1partbakingsoda.Applyalight
coatingofgreasetothebatteryterminalstoprevent
corrosion.

Voltage:12V

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandlead

compounds,chemicalsknownto

theStateofCaliforniatocause

cancerandreproductiveharm.Wash

handsafterhandling.

DANGER

Batteryelectrolytecontainssulfuricacid,
whichisfatalifconsumedandcausessevere
burns.

Donotdrinkelectrolyte,andavoidcontact
withskin,eyes,andclothing.Wearsafety
glassestoshieldyoureyesandrubbergloves
toprotectyourhands.

37

RemovingtheBattery

WARNING

Batteryterminalsormetaltoolscouldshort
againstmetalmachinecomponents,causing
sparks.Sparkscancausethebatterygasses
toexplode,resultinginpersonalinjury.

•Whenremovingorinstallingthebattery,
donotallowthebatteryterminalstotouch
anymetalpartsofthemachine.

•Donotallowmetaltoolstoshortbetween
thebatteryterminalsandmetalpartsofthe
machine.

WARNING

Incorrectbattery-cableroutingcoulddamage
themachineandcables,causingsparks.
Sparkscancausethebatterygassesto
explode,resultinginpersonalinjury.

•Alwaysdisconnectthenegative(black)
batterycablebeforedisconnectingthe
positive(red)cable.

•Alwaysconnectthepositive(red)battery
cablebeforeconnectingthenegative
(black)cable.

1.Shutofftheengine,engagetheparkingbrake,
removethekey,andwaitforallmovingpartsto
stopbeforeleavingtheoperatingposition.

2.Removetheconsolepad;refertoRemovingthe

ConsolePad(page28).

3.Onthebattery,lifttheblackterminalcoverfrom
thenegativecable(Figure39).

Figure39

1.Flangedbolt

2.Terminalcover
(black—negativebattery
terminal)

3.Terminalcover
(red—positivebattery
terminal)

4.Positive(+)battery
terminal

4.Disconnectthenegativebatterycablefromthe

negative(-)batteryterminal,andremovethe
cablefromthebattery(Figure39).

5.Slidetheredterminalcoveroffthepositive

batteryterminal(Figure39).

6.Disconnectthepositive(red)batterycable,and

removethecablefromthebattery(Figure39).

7.Removethehookofthebatterystrapfromthe

batterytray(Figure39),andremovethebattery.

5.Negative(-)battery
terminal

6.Flangednut

7.Batterytray

8.Batterystrap

g025881

InstallingtheBattery

1.Placethebatteryontothemachine(Figure39).

2.Securethebatterytothebatterytraywiththe
batterystrap.

3.Installthepositive(red)batterycabletopositive
(+)batteryterminalwithaangedboltand
angednut(Figure39).

4.Slidetheredterminalcoveroverthe
positive-batteryterminal.

5.Installthenegativebatterycableandtheground
wiretothenegative(-)batteryterminalwitha
angedboltandangednut(Figure39).

6.Slidetheblackterminalcoveroverthe
negative-batteryterminal.

38

ChargingtheBattery

ServicingtheFuses

WARNING

Chargingthebatteryproducesgassesthat
canexplode.

Neversmokenearthebatteryandkeepsparks
andamesawayfromthebattery.

Important:Alwayskeepthebatteryfullycharged

(1.265specicgravity)topreventbatterydamage
whenthetemperatureisbelow0°C(32°F).

1.Removethebatteryfromthechassis;referto

RemovingtheBattery(page38).

2.Checktheelectrolytelevel.

3.Ensurethatthellercapsareinstalledonthe
battery.

4.Chargethebatteryfor1hourat25to30Aor6
hoursat4to6A.

5.Whenthebatteryisfullycharged,unplugthe
chargerfromtheelectricaloutlet,anddisconnect
thechargerleadsfromthebatteryposts(Figure

40).

Theelectricalsystemisprotectedbyfuses,and
requiresnomaintenance.Ifafuseblows,checkthe
componentorcircuitforamalfunctionorshort.

1.Releasethecushionfromtherearofthe
machine.

2.Removethenegative-batterycablefromthe
batteryterminal;refertosteps4and5of

RemovingtheBattery(page38).

Note:Ensurethatthenegativebatterycable

doesnottouchthebatteryterminal.

3.Pullthefusefromthesocketofthefuseblock
(Figure41).

6.Installthebatteryontothemachineandconnect
thebatterycables;refertoInstallingtheBattery

(page38).

Note:Donotrunthemachinewiththebattery

disconnected;electricaldamagemayoccur.

Figure40

1.Positivebatterypost

2.Negativebatterypost

3.Red(+)chargerlead

4.Black(-)chargerlead

g025983

Figure41

1.Fuseblock

4.Installafuseofthesametypeandamperesinto
thesocketofthefuseblock(Figure41).

5.Installthenegative-batterycablefromthebattery
terminal;refertosteps5and6ofInstallingthe

g000538

Battery(page38).

39

DriveSystem

AdjustingtheCasterPivot

Maintenance

CheckingtheAirPressure intheTires

ServiceInterval:Every50hours

Note:Thesemi-pneumaticcastertiresdonotneed

tobeinated.

1.Shutofftheengine,engagetheparkingbrake,
removethekey,andwaitforallmovingpartsto
stopbeforeleavingtheoperatingposition.

2.Checkthepressureofthedrivetires.

3.Inatethedrivetiresto83to97kPa(12to14
psi).

CheckingtheWheelHub Nuts

ServiceInterval:Yearly

Torquethewheelhubnuts(Figure42)to285to350
N∙m(210to260ft-lb).

Note:Donotuseanti-seizecompoundonthewheel

hub.

BearingsPre-Load

Note:Ifyoudisassemblethecasterpivotbearings,

ensurethatthespring-discwashersareinstalledas
showninFigure43.

1.Removedustcapfromcasterhub(Figure43).

Figure43

1.Dustcap

2.Locknut

3.Spring-discwashers

4.Spindle

5.Casterhub

g026022

Figure42

1.Lugnut2.Hubnut

CheckingtheTorqueofthe WheelLugNuts

ServiceInterval:Yearly

Torquethewheellugnuts(Figure42)to122to129
N∙m(90to95ft-lb).

2.Tightenthelocknutclockwiseuntilthe
spring-discwashersareat(Figure43).

3.Rotatethelocknutcounterclockwise1/4turn
(Figure43).

4.Installthedustcap(Figure43).

MaintainingtheChain

AdjustingtheJackshaft

g026029

Drive-ChainTension

1.Shutofftheengine,engagetheparkingbrake,
removethekey,andwaitforallmovingpartsto
stopbeforeleavingtheoperatingposition.

2.Lifttherearofthemachineandsupportitusing
jackstandsorequivalentsupport.

3.Checkthechainsonbothsidesofthemachine
forpropertension.

Note:Thechainsshouldmoveupanddown6

to12mm(1/4to1/2inch).

4.Ateachsideofthemachine,loosenthe3nuts
andboltsthatsecurethetransmissionmount
andtensionerplate,andthe2nutssecuringthe

40

adjustmentboltatthetensionerplateasshown
inFigure44.

Note:Youmustloosenthenutsandboltsthat

securethetransmissionmountandtensioner
plateatbothsidesofthemachine.

AdjustingtheDriveWheelChain
Tension

1.Shutofftheengine,engagetheparkingbrake,
removethekey,andwaitforallmovingpartsto
stopbeforeleavingtheoperatingposition.

2.Lifttherearofthemachineandsupportitusing
jackstands.

3.Checkthetensionofthedrive-wheelchains
(Figure45).

Note:Thechainsshouldmoveupanddown6

to12mm(1/4to1/2inch).

Figure44

1.Hydromountingboltsand
nuts

2.Nuts

3.Adjustmentbolt

4.6to12mm(1/4-1/2inch)

5.Guardremovedforclarity

5.Turntheadjustmentbolttomovetransmission

adjustmentplatesandtransmission.

6.Whenthechainscanmoveupanddown6to12

mm(1/4to1/2inch),tightenthenutsonboth
sidesoftheadjustmentbolts.

7.Tightennutsandboltsthatsecurethehydro

mounting.

8.Adjustthetraction-controllinkage,referto

AdjustingtheTraction-ControlLinkage(page

45).

g025990

Figure45

1.Locknut3.Drive-wheelchain

2.Idlersprocket

g020261

4.Loosenthelocknutandcarriageboltthatsecure
theidlersprocket(Figure45).

5.Increaseordecreasechaintensionby
performingthefollowing:

•Pushdownandforwardonthesprocket

toincreasethechaintensionasshownin

Figure45.

•Liftupandbackonthesprockettodecrease

thechaintension.

6.T orquethelocknutto91to113N∙m(67to83
ft-lb).

7.Checkthechaintensionandifnecessaryrepeat
steps4through6untilyoucanmovethechain
upanddown6to12mm(1/4to1/2inch).

41

CheckingtheTorqueofthe
TransmissionOutputShaft

BrakeMaintenance

Nut

ServiceInterval:Yearly

Torquethenut(Figure46)onthetransmissionoutput
taperedshaftto285to353N∙m(210to260ft-lb).

Figure46

1.Transmissionoutputshaftnut

AdjustingtheParking Brake

Iftheparkingbrakedoesnotholdsecurely,an
adjustmentisrequired.

1.Parkthemachineonalevelsurface.

2.Shutoffengineandwaitforallmovingpartsto
stop.

3.Checktheairpressureinthedrivetires.

Note:Ifneeded,adjusttotherecommended

ination;refertoCheckingtheAirPressurein

theTires(page40).

4.Loosenthejamnutonthebrakecableunder
theconsole(Figure47).

g025989

Figure47

1.7.9cm(3-1/8inch)

5.Engagetheparkingbrake(Figure47).

6.Adjustthejamnutpositionuntil7.9cm(3-1/8
inch)fromthebottomofthelinktothebottomof
thespring(Figure47).

7.Securetheadjustmentofthecablebytightening
thejamnuts(Figure47).

8.Checktheparkingbrake;ifnecessary,repeat
steps4through7.

42

g025991

AdjustingtheBrakeSwitch

1.Parkthemachineonalevelsurface.

BeltMaintenance

2.Shutofftheengineandwaitforallmovingparts
tostop.

3.Priortheadjustingthebrakeswitchensurethat
theparkingbrakeisproperlyadjusted;referto

AdjustingtheParkingBrake(page42).

4.Engagetheparkingbrake.

5.Checkthedistancebetweentheparking
brake-switchbrackettothebrakearmofthe
transmission(Figure48).

Note:Thedistanceshouldbe3.2mm(1/8

inch).

CheckingtheCondition andTensionoftheBelts

ServiceInterval:Every50hours

1.Shutofftheengine,engagetheparkingbrake,
removethekey,andwaitforallmovingpartsto
stopbeforeleavingtheoperatingposition.

2.Raisethemachineandsupportitwithjack
standswitha460kg(1,015lb)capacity.

3.Checktheauxiliarypump-drivebeltcondition
andtension(Figure49).

Note:Thebeltshoulddeect1.3cm(1/2inch)

when1.4kg(3lb)offorceisappliedtothebelt
midwaybetweentheauxiliarypumpandengine
pulleys.Ifthebelttensionistoohighortoolow,
refertoAdjustingtheAuxiliaryPump-DriveBelt

(page43).

4.Checkconditionofthetransmission-drivebelt
(Figure49).

Note:Thetransmissionbelthasa

automatic-springtensioner.

Figure48

1.Brakearm(transmission)

2.Plunger(brakeswitch)5.Carriagebolt

3.Brake-switchbracket

6.Ifadjustmentisrequired,preformthefollowing:

A.Loosenthelocknutandcarriagebolt

securingtheparkingbrakeswitchbracket
(Figure48).

B.Adjustthepositionofthebrake-switch

bracketuntilthegap(Figure48)between
theswitchbracketandthebrakearmis3.2
mm(1/8inch)

C.Tightenthelocknutandcarriagebolt(Figure

48)securingthebrake-switchbracketto

1017to1243N∙cm(90to110in-lb).

4.Locknut

g025992

g025994

Figure49

1.Transmission-drivebelt2.Auxiliarypump-drivebelt

AdjustingtheAuxiliary Pump-DriveBelt

1.Shutofftheengine,engagetheparkingbrake,
removethekey,andwaitforallmovingpartsto
stopbeforeleavingtheoperatingposition.

2.Loosenthelocknut(3/8inch)thatsecuresthe
auxiliarypump-idlerpulleytothechassisofthe
machine.

43

Figure50

g025997

1.Auxiliarypump

2.Auxiliarypump-idlerpulley5.Auxiliarypump-drivebelt

3.Locknut(3/8inch)

4.Adjustmentslot(chassis)

3.Adjustthebelttensionasfollows:

•Movetheauxiliarypump-idlerpulley

rearwardandoutwardtotightenthebelt.

•Movetheauxiliarypump-idlerpulleyforward

andinwardtoloosenthebelt.

Note:Thebeltshoulddeect1.3cm(1/2inch)

when1.4kg(3lb)offorceisappliedtothebelt
midwaybetweentheauxiliarypumpandengine
pulleys.

4.Tightenlocknutto37to45N∙m(27to33ft-lb).

Replacingthe Transmission-DriveBelt

Note:Noadjustmentsarerequiredforbelttension.

1.Shutofftheengine,engagetheparkingbrake,
removethekey,andwaitforallmovingpartsto
stopbeforeleavingtheoperatingposition.

2.Insertabreakerbarintothesocketofthe
belt-tensionbracketandmovethebracket
outwardandforward(Figure51).

g025999

Figure51

1.Transmissionpulley4.Enginepulley

2.Transmission5.T ensionerpulley

3.Socket(belt-tension
bracket)

3.Slipthetransmission-drivebeltoftheengine,

tensioner,andtransmissionpulleys(Figure51).

4.Routethenewtransmission-drivebeltaround

theengine,tensioner,andtransmissionpulleys
asshowninFigure51

5.Releasethebelt-tensionbracketandallowthe

springtotensionthebelt(Figure51).

Note:Makesurethatthebelt-tensionbracket

andpulleycanmovefreely.

44

ControlsSystem

betweenthecontrolleverandthefront
referencebar.

Maintenance

Adjustingthe Traction-ControlLinkage

1.Parkthemachineonalevelsurface.

2.Shutofftheengine,engagetheparkingbrake,
removethekey,andwaitforallmovingpartsto
stopbeforeleavingtheoperatingposition.

3.Pushthecontrolleverallthewayforwardtothe
frontreferencebar.

4.Ifthecontrollevercontactthereferencebar
ordonotcontactthereferencebarperform
thefollowing:

A.Releasethecontrolleverandallowitto

returntotheneutralposition.

B.Removethespring-clevispinfromthefork

ttingofthetraction-controllinkage(Figure

52).

F.Removethespring-clevispin,rotatethe

turnbuckleclockwise1additionalturn,and
insertthespring-clevispin(Figure52).

5.Repeatsteps4Athrough4Ffortheother
traction-controllinkage.

Figure52

1.Spring-clevispin

2.Locknut

C.Adjusttheforkttingtosettheinitialgap

asfollows:

3.Turnbuckle

•Ifthecontrollevercontactsthe

referencebar,rotatetheforktting
(Figure52)counterclockwise(asviewed
fromthetopofthemachine).

•Ifthecontrolleverdoesnotcontacts

thereferencebar,rotatetheforktting
(Figure52)counterclockwise.

D.Installthespringclevispin(Figure52)and

movethecontrolleverforward.

E.RepeatthisstepsAthroughDuntilthere

isagapapproximately1.6mm(1/16inch)

g020223

45

HydraulicSystem
Maintenance

MaintainingtheAuxiliary HydraulicSystem

Hydraulicuidtype:AW-32hydraulicuid

CheckingtheAuxiliary

leveldependinguponthetemperatureofthe
uid.Theuidlevelvarieswiththetemperature
oftheuid.TheColdlevelshowsthelevelof
theuidwhenitisat24°C(75°F).TheHot
levelshowsthelevelofuidwhenitisat107°C
(225°F).

Forexample:Iftheuidisatambient-air
temperature,about24°C(75°F),llonlytothe
Coldlevel.Iftheuidisabout65°C(150°F),ll
tohalfwaybetweentheHotandColdlevels.

8.Replacethehydraulicreservoircapandtighten
ituntilitissnug(Figure53).

Hydraulic-FluidLevel

ServiceInterval:Every50hours

1.Parkthemachineonalevelsurface.

2.Lowerthetinestotheground.

3.Shutofftheengine,engagetheparkingbrake,
removethekey,andwaitforallmovingpartsto
stopbeforeleavingtheoperatingposition.

4.Removetheconsolepad;refertoRemovingthe

ConsolePad(page28).

5.Cleantheareaaroundthehydraulicreservoir
cap(Figure53).

Note:Donotovertightenthereservoircap.

9.Installtheconsolepad;refertoRemovingthe

ConsolePad(page28).

ChangingtheAuxiliaryHydraulic
ReservoirFluidandFilter

ServiceInterval:Aftertherst100hours

Every250hoursthereafter

1.Shutofftheengine,engagetheparkingbrake,
removethekey,andwaitforallmovingpartsto
stopbeforeleavingtheoperatingposition.

2.Carefullycleanareaaroundthefrontofthe
auxiliarypump,llcapforthereservoir,andlter
(Figure54).

Important:Ensurethatnodirtor

contaminationentershydraulicsystem.

Figure53

1.Colduidlevel2.Hotuidlevel

6.Removethecapandcheckhydraulic-uidlevel
inthereservoir(Figure53).

Note:Thehydraulic-uidlevelshouldcoverthe

wordColdthatisembossedintothebafeof
thereservoir.

7.Ifnecessary,addthespeciedhydraulicuidto
thereservoiruntiltheuidcoverstheColduid
levelonthebafe(Figure53).

Note:ThebafeionthereservoirislabeledHot

andCold.Fillthereservoirtotheappropriate

g025893

g026008

Figure54

46

3.Atthefrontoftheauxiliaryhydraulicpump,
removetheinlethosefromthehydraulictting
inthepump,placetheendofthehoseinadrain
container,andallowtheuidtodrain(Figure55).

Figure55

9.Addthespecieduiduntilthelevelreachesthe
Coldlllinelocatedonthereservoirtank;refer
toCheckingtheAuxiliaryHydraulic-FluidLevel

(page46).

10.Starttheengineandraiseandlowerthetines.

11.Lowerthetinestothegroundandrellthe
reservoirtotheColdllline.

Maintainingthe Transmission

Transmissionuidtype:T oro®HYPR-OIL™500

hydraulicuidorMobil®115W-50syntheticmotoroil.

Important:Usethespecieduid.Otheruids

g026010

couldcausesystemdamage.

1.Hydraulictting(auxiliary
hydraulicpump)

2.Inlethose

3.Draincontainer

4.Cleanaroundthettingforthehydraulicpump.

5.Rotatetheauxiliaryhydrauliclter

counterclockwiseandremoveitfromthe
baseofthelteradapter(Figure56).Allowthe
uidtodrain.

CheckingtheTransmissionFluid
Level

ServiceInterval:Every50hours

1.Shutofftheengine,engagetheparkingbrake,
removethekey,andwaitforallmovingpartsto
stopbeforeleavingtheoperatingposition.

2.Allowthemachinetocool.

3.Removethecapfromtheexpansiontankand
checkthehydraulic-uidlevelinthetank(Figure

57).

Note:Thetransmissionuidlevelshouldcover

theFullColdlinemoldedintothesideofthe
tank.

Figure56

1.Auxiliaryhydrauliclter

2.Filteradapter

6.Applyathincoatofspecieduidontotheseal
ofthenewhydrauliclter.

7.Installthelterbyrotatingitclockwiseontothe
lteradapteruntilthesealcontactsthelter
adapter,thentightenthelteranadditional2/3
to3/4turn(Figure56).

8.Installtheinlethoseontothettinginthepump
andtorquethehosettingto50N∙m(37ft-lb).

g026007

g025891

Figure57

1.Cap3.FullColdline

2.Fillerneck(expansion
tank)

47

4.Ifnecessary,addthespeciedtransmissionuid
untiltheuidlevelisattheFullColdlineofthe
expansiontank(Figure57).

5.Replaceexpansion-tankcapandtightenituntil
snug.

Note:Donotovertightentheexpansion-tank

cap.

ChangingtheTransmissionFilters

ServiceInterval:Aftertherst100hours

Every250hoursthereafter

Note:Donotchangethehydraulicsystemuid

(exceptforwhatcanbedrainedwhenchanginglter),
unlesstheuidhasbeencontaminatedorbeen
extremelyhot.

1.Shutofftheengine,engagetheparkingbrake,
removethekey,andwaitforallmovingpartsto
stopbeforeleavingtheoperatingposition.

2.Raisethemachineandsupportitwithjack
standswitha460kg(1,015lb)capacity.

3.Removethe3washer-headbolts(1/4x3/4inch)
thatsecurethelterguardtothetransmission,
andremovetheguard(Figure58).

7.Applyathincoatofspecieduidontotheseal
ofthenewtransmissionlter.

8.Installthelterbyrotatingitclockwiseontothe
lteradapteruntilthesealcontactsthebaseof
theadapter,thentightenthelteranadditional
3/4to1turn(Figure58).

9.Installthelterguardwiththe3washer-head
bolts(1/4x3/4inch)thatyouremovedinstep3
(Figure58),andtightentheboltsto1 117to1243
N∙cm(90to110in-lb).

FillingtheTransmissionswith
Fluid

ServiceInterval:Aftertherst100hours

Every250hoursthereafter

1.Raisetherearofmachineupandsupportwith
jackstands(orequivalentsupport)justhigh
enoughtoallowthedrivewheelstoturnfreely.

CAUTION

Raisingthemachineforservice
ormaintenancerelyingsolelyon
mechanicalorhydraulicjackscouldbe
dangerous.Themechanicalorhydraulic
jacksmaynotbeenoughsupportormay
malfunctionallowingthemachinetofall,
whichcouldcauseinjury .

Figure58

1.Transmission

2.Filteradapter5.Filterguard

3.Transmissionlter

4.Cleanthearoundthetransmissionlter(Figure

58).

5.Alignadrainpanunderthelter.

6.Rotatetheltercounterclockwiseandremove
thelter(Figure58).

4.Washer-headbolts(1/4x
3/4inch)

Note:Allowtheuidtocompletelydrainfrom

thelteradapterofthetransmission.

Donotrelysolelyonmechanical
orhydraulicjacksforsupport.Use
adequatejackstandsorequivalent
support.

2.Alignadrainpanunderthesightplugsofthe
transmissions(Figure59andFigure60).

g026014

48

1.Sightplug

2.Sight-plugport

Figure59

Lefttransmissionshown

8.Starttheengineandmovethethrottlemidway
betweentheSLOWandFASTpositions

9.Disengagetheparkingbrake.

10.Slowlymovethemotion-controlleversinthe
forwardandreversedirections5to6times.

Note:Cyclingthetraction-controlsforwardand

reversepurgesairfromthetransmissions.

11.Shutofftheengineandremovethekey.

12.Checktheuidlevelintheexpansiontank,
andaddthespecieduidasrequired;referto

g026015

CheckingtheTransmissionFluidLevel(page

47).

13.Repeatsteps8through12untilalltheairis
completelypurgedfromthetransmissions.

3.Up

Note:Theairispurgedwhenthetransmissions

whenthetransmissionsoperateatnormalnoise
levelsandsmoothlymoveforwardandreverse
atnormalspeeds.

14.Lowerthemachineandremovethejackstands.

Figure60

Lefttransmissionshown

1.Sightplug

2.Sight-plugport

3.Up

3.Attheinboardsideofthetransmission,near
thetop,removethesightplugfrom1ofthe
transmissions(Figure59andFigure60).

4.Addthespecieduidtotheexpansiontank
untiluidowsfromthesight-plugport;referto

CheckingtheTransmissionFluidLevel(page

47).

5.Installthesightplugandtorqueitto244N∙m
(180in-lb).

6.Repeatsteps3through5fortheother
transmission.

7.Addthespecieduidintotheexpansiontank
untiltheuidlevelisattheFullColdlineofthe
tank.

g026016

49

TineMaintenance

CheckingtheTines

ServiceInterval:Beforeeachuseordaily

1.Shutofftheengine,engagetheparkingbrake,
removethekey,andwaitforallmovingpartsto
stopbeforeleavingtheoperatingposition.

2.Raisethemachineandsupportitwithjack
standswitha460kg(1,015lb)capacity.

7.Securethecoverpaneltothechassiswiththe
2boltsand2washers(Figure61)thatyou
removedinstep3,andtorquetheboltsto37to
45N∙m(27to33in-lb)

AdjustingtheTineDrive Chain

1.Shutofftheengine,engagetheparkingbrake,
removethekey,andwaitforallmovingpartsto
stopbeforeleavingtheoperatingposition.

CAUTION

Raisingthemachineforservice
ormaintenancerelyingsolelyon
mechanicalorhydraulicjackscouldbe
dangerous.Themechanicalorhydraulic
jacksmaynotbeenoughsupportormay
malfunctionallowingthemachinetofall,
whichcouldcauseinjury .

Donotrelysolelyonmechanical
orhydraulicjacksforsupport.Use
adequatejackstandsorequivalent
support.

3.Removethe2bolts(3/8x1inch)and2washers
(3/8inch)thatsecuretherear-coverpaneltothe
chassis,andremovethepanel(Figure61).

2.Removetherearcover;refertostep3of

CheckingtheTines(page50).

3.Checkthechainsonbothsidesofthemachine
forpropertension.

Note:Thechainsshouldmoveupanddown6

to12mm(1/4to1/2inch).

4.Loosenthelocknutandcarriageboltthatsecure
theidlersprocket(Figure62).

Figure62

1.Locknut

2.Idlersprocket

3.Carriagebolt

4.Slot(trailplate)

g026018

Figure61

1.Chassisholes3.Bolt(3/8x1inch)

2.Washer(3/8inch)

4.Removerocksandotherdebrisfromthetines.

5.Inspectthetinesforwearanddamage.

4.Rearpanel

Note:Replaceanytinesthatarewornor

damaged.

6.Aligntheholesintherear-coverpaneltothe
holesinthechassis(Figure61).

5.Increaseordecreasechaintensionby
performingthefollowing:

•Pushdownandforwardonthesprocket

toincreasethechaintensionasshownin

Figure62.

g026017

50

•Liftupandbackonthesprockettodecrease

thechaintension.

6.T orquethelocknutto91to113N∙m(67to83
ft-lb).

7.Checkthechaintensionandifnecessaryrepeat
steps4through6untilyoucanmovethechain
upanddown6to12mm(1/4to1/2inch).

8.Installtherearpanel;refertosteps6and7of

CheckingtheTines(page50).

Cleaning

CleaningtheDebrisfrom theMachine

CleaningtheEngineand theExhaustSystemArea

ServiceInterval:Beforeeachuseordaily(more

oftenindryordirtyconditions).

CAUTION

Excessivedebrisaroundenginecoolingair
intakeandexhaustsystemareacancause
engine,exhaustarea,andhydraulicsystemto
overheat,whichcancreatearehazard.

Cleanalldebrisfromengineandexhaust
systemarea.

1.Shutofftheengine,engagetheparkingbrake,
removethekey,andwaitforallmovingpartsto
stopbeforeleavingtheoperatingposition.

2.Cleanalldebrisfromscreenatthetopofthe
engine,aroundengineshrouding,andexhaust
systemarea.

3.Wipeupanyexcessivegreaseoroilaroundthe
engineandexhaustsystemarea.

ServiceInterval:Beforeeachuseordaily

1.Shutofftheengine,engagetheparkingbrake,
removethekey,andwaitforallmovingpartsto
stopbeforeleavingtheoperatingposition.

2.Cleanoffanyoil,debris,orgrassbuilduponthe
machineandaeratordeck.

3.Cleanoffanydebrisorgrassunderthechain
guards,aroundthefueltank,andaroundthe
engineandexhaustarea.

WasteDisposal

DisposingoftheEngineOil

Engineoilandhydraulicuidarebothpollutantsto
theenvironment.Disposeofusedoilatacertied
recyclingcenteroraccordingtoyourstateandlocal
regulations.

DisposingoftheBattery

DANGER

RemovingtheEngine ShroudsandCleaningthe CoolingFins

ServiceInterval:Every80hours

1.Shutofftheengine,engagetheparkingbrake,
removethekey,andwaitforallmovingpartsto
stopbeforeleavingtheoperatingposition.

2.Removecoolingshroudsfromengine.

3.Cleancoolingnsoftheengine.

Note:Alsocleandust,dirt,andoilfromexternal

surfacesofengine,whichcancauseimproper
cooling.

4.Installthecoolingshroudsintotheengine.

Note:Operatingtheenginewithoutcooling

shroudswillcauseenginedamagedueto
overheating.

Batteryelectrolytecontainssulfuricacid,
whichispoisonousandcancausesevere
burns.Swallowingelectrolytecanbefatalor
cancausesevereburnsifittouchesskin.

•Wearsafetyglassestoshieldeyes,and
rubberglovestoprotectskinandclothing
whenhandlingelectrolyte.

•Donotswallowelectrolyte.

•Intheeventofanaccident,ushwithwater
andcalladoctorimmediately.

Federallawstatesthatbatteriesshouldnotbeplaced
inthegarbage.Managementanddisposalpractices
forbatteriesmustfollowrelevantfederal,state,or
locallaws.

Ifabatteryisbeingreplacedorifthemachine
containingthebatteryisnolongeroperatingandis
beingscrapped,removethebatteryandtakeittoa
localcertiedrecyclingcenter.Ifnolocalrecycling
isavailablereturnthebatterytoanycertiedbattery
reseller.

51

Storage

1.Raisethetines,stopthemachine,shutoffthe
engine,engagetheparkingbrake,andremove
thekey.

2.Removedirtandgrimefromtheentiremachine.

Important:Youcanwashthemachine

withmilddetergentandwater.Donot
pressure-washthemachine.Avoid
excessiveuseofwater,especiallynearthe
engineandhydrostaticdrive.

3.Servicetheaircleaner;refertoServicingtheAir

Cleaner(page32).

4.Lubricatethemachine;refertoLubrication

(page29).

5.Changetheengineoil;refertoChangingthe

EngineOil(page33).

6.Checkandtightenallbolts,nuts,andscrews.
Repairorreplaceanypartthatisdamaged.

7.Paintallscratchedorbaremetalsurfaces.Paint
isavailablefromyourAuthorizedServiceDealer.

8.Storethemachineinaclean,drygarageor
storagearea.

9.Coverthemachinetoprotectitandkeepitclean.

52

Troubleshooting

Problem

Thestarterdoesnotcrank.

Theenginedoesnotstart,startshard,or
failstokeeprunning.

PossibleCauseCorrectiveAction

1.Theparkingbrakeisnotengaged.1.Engagetheparkingbrake.

2.Thebrakeswitchisnotadjusted
properly.

3.Thebatterydoesnothaveafull
charge.

4.Theelectricalconnectionsare
corroded,looseorfaulty.

5.Afuseisblown.5.Replacetheblownfuse.

6.Arelayorswitchisdefective.6.ContactanAuthorizedServiceDealer.

1.Thefueltankisempty.1.Fillthefueltank.

2.Thefuel-shutoffvalveisclosed.2.Openthefuel-shutoffvalve.

3.Thethrottleandchokearenotinthe
correctposition.

4.Thereisdirtinthefuellter.4.Replacethefuellter.

5.Thereisdirt,water,orstalefuelisin
thefuelsystem.

6.Theaircleanerisdirty.

7.Theelectricalconnectionsare
corroded,looseorfaulty.

8.Arelayorswitchisdefective.8.ContactanAuthorizedServiceDealer.

9.Thesparkplugisfaulty.

10.Thespark-plugwireisnotconnected.

2.Adjustthebrakeswitch.

3.Chargethebattery.

4.Checktheelectricalconnectionsfor
goodcontact.Cleantheconnector
terminalsthoroughlywithelectrical
contactcleaner,applydielectric
grease,andreconnect.

3.Besurethatthethrottlelevelismidway
betweentheSLOWandFASTpositions,
andthechokeisintheONpositionfor
acoldengineortheOFFpositionfora
warmengine.

5.ContactanAuthorizedServiceDealer.

6.Cleanorreplacetheair-cleaner
element.

7.Checktheelectricalconnections
forgoodcontact.Cleanconnector
terminalsthoroughlywithelectrical
contactcleaner,applydielectric
grease,andreconnect.

9.Clean,adjust,orreplacethespark
plug.

10.Checkthespark-plugwireconnection.

Theenginelosespower.

Theengineoverheats.

Themachinepullsleftorright(withlevers
fullyforward).

1.Theengineloadisexcessive.1.Reducethegroundspeedoraeration

2.Theaircleanerisdirty.

3.Theoillevelinthecrankcaseislow.3.Addoiltothecrankcase.

4.Thecoolingnsandairpassagesfor
theengineareplugged.

5.Thereisdirtinthefuellter.5.Replacethefuellter.

6.Thereisdirt,water,orstalefuelisin
thefuelsystem.

1.Theengineloadisexcessive.1.Reducethegroundspeedoraeration

2.Theoillevelinthecrankcaseislow.2.Addoiltothecrankcase.

3.Thecoolingnsandairpassagesfor
theengineareplugged.

1.Thetirepressureindrivetiresisnot
correct.

2.Thetrackingneedsadjustment.2.Adjustthetraction-controllinkage.

depth.

2.Cleanorreplacetheair-cleaner
element.

4.Removetheobstructionsfromthe
coolingnsandairpassages.

6.ContactanAuthorizedServiceDealer.

depth.

3.Removetheobstructionsfromthe
coolingnsandairpassages.

1.Adjustthetirepressureinthedrive
tires.

53

Problem

PossibleCauseCorrectiveAction

Themachinedoesnotdrive.

Thereisabnormalvibration.

Thetinesdonotraise.

1.Thetransmissionbeltworn,loose,or
broken.

2.Thetransmissionbeltisoffapulley.2.Changethebelt.

1.Atineisbent.1.Installanewtine.

2.Thetinemountingboltisloose.2.Tightenthetinemountingbolt.

3.Theenginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Thereisalooseenginepulleyoridler
pulley.

5.Theenginepulleyisdamaged.

6.Abeltisdamaged.6.Installanewbelt.

7.Thechainsarenotproperlytensioned.

1.Thereisanauxiliarypumpbelt
problem.

2.Thetinedownpressuresettingistoo
low.

3.Thereisashortinthewiringharness.

4.Theauxiliaryreservoirislowonuid.4.Adduidtothereservoir.

1.Changethebelt.

4.Tightentheappropriatepulley.

5.ContactanAuthorizedServiceDealer.

7.Checkthejackshaftdrive-chain
tension,thedrivewheelchaintension,
andthetinedrive-chaintension.

1.T ensionorreplacethebelt.

2.Increasethedownpressure.

3.ContactanAuthorizedServiceDealer.

54

Schematics

ElectricalDiagram(Rev .A)

55

g020224

ElectricalSchematic(Rev .A)

56

g020225

HydraulicDiagram(Rev .A)

57

g020226

Notes:

Notes:

Alimitedwarranty(seewarrantyperiodsbelow)

TheToroWarranty

SWS
TurfRenovation

ConditionsandProductsCovered

TheT oroCompanyanditsafliate,ToroWarrantyCompany ,pursuanttoan
agreementbetweenthem,jointlywarrantyourT oroProductslistedbelowto
befreefromdefectsinmaterialsorworkmanship.

Thiswarrantycoversthecostofpartsandlabor,butyoumustpay
transportationcosts.

Thefollowingtimeperiodsapplyfromthedateofpurchase:

ProductsWarrantyPeriod

TurfRenovation
Walk-BehindAerator1year

•Engine2years
Stand-OnAerator

•Battery90daysPartsandLabor

•Engine2years

Dethatcher1year

•Engine2years
TurfSeeder

•Engine2years

Stand-OnSpreaderSprayer

•Battery90daysPartsandLabor

•Engine2years

Walk-BehindRotaryBroom1year

•Engine2years

Whereawarrantableconditionexists,wewillrepairtheProductatnocost
toyouincludingdiagnosis,labor,andparts.

1year

1yearPartsOnly

1year

1year

1yearPartsOnly

InstructionsforObtainingWarrantyService

IfyouthinkthatyourT oroProductcontainsadefectinmaterialsor
workmanship,followthisprocedure

1.ContactanyAuthorizedServicingOutlettoarrangeserviceattheir
dealership.T olocateoneconvenienttoyou,accessourwebsiteat
www.T oro.com.Select“WheretoBuy”andselect“Contractor”under
producttype.Y oumayalsocallourtollfreenumberbelow .

2.Bringtheproductandyourproofofpurchase(salesreceipt)tothem.

3.IfforanyreasonyouaredissatisedwiththeServiceOutlet’sanalysis
orwiththeassistanceprovided,contactusat:

SWSCustomerCareDepartment
ToroWarrantyCompany
811 1LyndaleAvenueSouth
Bloomington,MN55420-1196
TollFree:888-384-9940

**

ToroAuthorizedRentalCustomerswhohavepurchasedproductsdirectlyfromT oroandhave

signedtheT oroRentalCustomerAgreementhavetheabilitytoperformtheirownwarrantywork.

PleasevisitT oro’sRentalPortalforelectronicwarrantyclamlingproceduresorcallthetollfree

numberabove.

**

:

OwnerResponsibilities

YoumustmaintainyourToroProductbyfollowingthemaintenance
proceduresdescribedintheOperator’sManual.Suchroutinemaintenance,
whetherperformedbyadealerorbyyou,isatyourexpense.Parts

scheduledforreplacementasrequiredmaintenance(“MaintenanceParts”),
arewarrantedfortheperiodoftimeuptothescheduledreplacementtime
forthatpart.Failuretoperformrequiredmaintenanceandadjustmentscan
begroundsfordisallowingawarrantyclaim.

ItemsandConditionsNotCovered

Notallproductfailuresormalfunctionsthatoccurduringthewarrantyperiod
aredefectsinmaterialsorworkmanship.Thisexpresswarrantydoesnot
coverthefollowing:

•Productfailureswhichresultfrominstallationanduseofadd-on,

modied,orunapprovedaccessories

•Failuretoperformrequiredmaintenanceand/oradjustments

•Repairsnecessaryduetofailuretofollowrecommendedfuel

procedure(consultOperator'sManualformoredetails)

–Removingcontaminantsfromthefuelsystemisnotcovered

–Useofoldfuel(morethanonemonthold)orfuelwhichcontains

morethan10%ethanolormorethat15%MTBE

–Failuretodrainthefuelsystempriortoanyperiodofnon-use

overonemonth

•Productfailureswhichresultfromoperatingtheproductinanabusive,

negligentorrecklessmanner

•Partssubjecttoconsumptionthroughuseunlessfoundtobedefective.

Examplesofpartswhichareconsumed,include,belts,cutters,blades,
teeth,sparkplugs,tires,lters,etc.

•Failurescausedbyoutsideinuenceinclude,weather,storage,

contamination,lubricants,additives,orchemicals,etc.

•Normal“wearandtear”itemsincudespaintedsurfacesandscratched

decals,etc.

•Anycomponentcoveredbyaseparatemanufacturer’swarranty

•Pickupanddeliverycharges

GeneralConditions

RepairbyanAuthorizedServicingOutletorSelf-ServiceasanAuthorized
RentalCustomerisyoursoleremedyunderthewarranty.

NeitherTheToroCompanynorToroWarrantyCompanyisliablefor
indirect,incidentalorconsequentialdamagesinconnectionwiththe
useoftheToroProductscoveredbythiswarranty,includingany
costorexpenseofprovidingsubstituteequipmentorserviceduring
reasonableperiodsofmalfunctionornon-usependingcompletionof
repairsunderthiswarranty .Allimpliedwarrantiesofmerchantability
andtnessforusearelimitedtothedurationofthisexpresswarranty.
Somestatesdonotallowexclusionsofincidentalorconsequential
damages,orlimitationsonhowlonganimpliedwarrantylasts,sothe
aboveexclusionsandlimitationsmaynotapplytoyou.

Thiswarrantygivesyouspeciclegalrights,andyoumayalsohaveother
rightswhichvaryfromstatetostate.

ExceptfortheenginewarrantycoverageandtheEmissionswarranty
referencedbelow,ifapplicable,thereisnootherexpresswarranty .The
EmissionsControlSystemonyourProductmaybecoveredbyaseparate
warrantymeetingrequirementsestablishedbytheU.S.Environmental
ProtectionAgency(EPA)ortheCaliforniaAirResourcesBoard(CARB).
RefertotheCaliforniaEmissionControlWarrantyStatementsuppliedwith
yourProductorcontainedintheenginemanufacturer’sdocumentationfor
details.

CountriesOtherthantheUnitedStatesorCanada

CustomerswhohavepurchasedT oroproductsoutsidetheUnitedStatesorCanadashouldcontacttheirT oroDistributor(Dealer)toobtainguarantee
policiesforyourcountry,province,orstate.IfforanyreasonyouaredissatisedwithyourDistributor'sserviceorhavedifcultyobtainingguarantee
information,contacttheT oroimporter.Ifallotherremediesfail,youmaycontactusatT oroWarrantyCompany.

AustralianConsumerLaw:AustraliancustomerswillnddetailsrelatingtotheAustralianConsumerLaweitherinsidetheboxoratyourlocalT oro
Dealer.

374-0289RevD