Toro 30301, 30301TC, 30302, 30302TC, GROUNDSMASTER 3000-D Operator's Manual

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Page 1

MODEL NO. 30301 - 220000001 & UP

MODEL NO. 30301TC - 220000001 & UP

MODEL NO. 30302 - 220000001 & UP

MODEL NO. 30302TC - 220000001 & UP

FORM NO. 3326-938

OPERATOR'S

MANUAL

GROUNDSMASTER® 3000-D

2 & 4 WHEEL DRIVE TRACTION UNITS

To understand this product, and for safety and optimum performance, read this manual before starting the engine. Pay special attention to SAFETY INSTRUCTIONS highlighted by this symbol.

It means CAUTION, WARNING or DANGER personal safety instruction. Failure to comply with the instruction may result in personal injury.

The GROUNDSMASTER 3000-D conforms to the B71.41999 specifications of the American National Standards Institute's safety standards for riding mowers: thus, TORO proudly displays the ANSI safety seal.

The TORO COMPANY - 2001

Page 2

FOREWORD

This operator's manual has instructions on safety, proper set-up and operation, adjustments and maintenance. Therefore, anyone involved with the product, including the operator, should read and understand this manual. Major sections are:

- Safety Instructions

- Specifications

- Set-up Instructions

- Before Operating

This manual emphasizes safety, mechanical and general product information. DANGER, WARNING and CAUTION identify safety messages. Whenever the triangular safety alert symbol appears, understand the safety message that follows. For complete safety instructions, read pages 4-6. IMPORTANT highlights special mechanical information and NOTE emphasizes general product information worthy of special attention.

Diesel engine exhaust and some of its constituents are known to the State of

California to cause cancer, birth defects,

or other reproductive harm.

- Know Your Controls

- Operating Instructions

- Maintenance

- Schematics

Whenever you have questions or need service, contact your local authorized Toro Distributor. In addition to having a complete line of accessories and professional turf care service technicians, the distributor has a complete line of genuine TORO replacement parts to keep your machine operating properly. Keep your TORO all TORO. Buy genuine TORO parts and accessories.

IDENTIFICATION AND ORDERING

MODEL AND SERIAL NUMBER

The model and serial number is on a plate that is mounted on the left side of operator platform behind footrest. Use model and serial number in all correspondence and when ordering parts.

To order replacement parts from an authorized TORO Distributor, supply the following information:

1. Model and serial numbers of the machine.

2. Part number, description and quantity of parts

desired.

Note: Do not order by reference number if a parts catalog is being used; use the part number.

Page 3

TABLE OF CONTENTS

IDENTIFICATION & ORDERING 2. . . . . . . . . . . . . .

Model And Serial Number 2. . . . . . . . . . . . . . . .

SAFETY INSTRUCTIONS 4. . . . . . . . . . . . . . . . . . . .

SAFETY INSTRUCTIONS & DECALS 7. . . . . . . . .

SPECIFICATIONS 9. . . . . . . . . . . . . . . . . . . . . . . . . .

LOOSE PARTS CHART 10. . . . . . . . . . . . . . . . . . . . .

SETUP INSTRUCTIONS 11. . . . . . . . . . . . . . . . . . .

Install Front and Rear Wheels 11. . . . . . . . . . . .

Install Steering Wheel 11. . . . . . . . . . . . . . . . . . .

Install Roll Bar 11. . . . . . . . . . . . . . . . . . . . . . . . . .

Grease Traction Unit 11. . . . . . . . . . . . . . . . . . . .

BEFORE OPERATING 12. . . . . . . . . . . . . . . . . . . . .

Check Engine Oil 12. . . . . . . . . . . . . . . . . . . . . . .

Check Cooling System 12. . . . . . . . . . . . . . . . . .

Fill Fuel Tank 12. . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Hydraulic Fluid 13. . . . . . . . . . . . . . . . . . .

Check Rear Axle Lubricant 13. . . . . . . . . . . . . . .

Check Tire Pressure 14. . . . . . . . . . . . . . . . . . . .

Check Torque Of Wheel Nuts 14. . . . . . . . . . . .

KNOW YOUR CONTROLS 15. . . . . . . . . . . . . . . . . .

OPERATING INSTRUCTIONS 16. . . . . . . . . . . . . . .

Starting And Stopping 16. . . . . . . . . . . . . . . . . . .

Priming Fuel System 16. . . . . . . . . . . . . . . . . . . .

Checking Interlock Switches 16. . . . . . . . . . . . .

Pushing or Towing Traction Unit 17. . . . . . . . . .

Operating Characteristics 17. . . . . . . . . . . . . . . .

LUBRICATION 19. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Greasing Bearings And Bushings 19. . . . . . . . .

DAILY MAINTENANCE CHECKLIST 20. . . . . . . . .

Page Page

MAINTENANCE SCHEDULE 21. . . . . . . . . . . . . . . .

AIR CLEANER MAINTENANCE 22. . . . . . . . . . . . .

General Air Cleaner Maintenance 22. . . . . . . . .

Servicing Air Cleaner 22. . . . . . . . . . . . . . . . . . . .

ENGINE MAINTENANCE 23. . . . . . . . . . . . . . . . . .

Engine Oil And Filter 23. . . . . . . . . . . . . . . . . . . .

Fuel System 23. . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Cooling System 24. . . . . . . . . . . . . . . . .

Engine Belts 24. . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Spark Arrester Muffler 25. . . . . . . . . . . .

HYDRAULIC MAINTENANCE 26. . . . . . . . . . . . . . .

Changing Hydraulic System Oil and Filter 26. .

Checking Hydraulic Lines And Hoses 27. . . . .

Hydraulic System Test Port 27. . . . . . . . . . . . . .

Adjusting Traction Drive Pedal Linkage 27. . . .

HYDRAULIC SCHEMATIC 28. . . . . . . . . . . . . . . . . .

BRAKE MAINTENANCE 29. . . . . . . . . . . . . . . . . . . .

Adjusting Service Brakes 29. . . . . . . . . . . . . . . .

AXLE MAINTENANCE 30. . . . . . . . . . . . . . . . . . . . . .

Changing Rear Axle Lubricant 30. . . . . . . . . . . .

Rear Wheel Toe-in 30. . . . . . . . . . . . . . . . . . . . .

ELECTRICAL MAINTENANCE 31. . . . . . . . . . . . . .

Battery Care 31. . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuses 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SCHEMATIC 32. . . . . . . . . . . . . . . . .

PREPARATION FOR SEASONAL STORAGE 33.

NOTES 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY Back Cover. . . . . . . . . . . . . . . . . . . . . . . . .

Page 4

SAFETY INSTRUCTIONS

This machine meets or exceeds the B71.4 1999 specifications of the American National Standards Institute, in effect at time of production, when 40 lbs. of ballast is added to the rear wheel.

Note: The addition of attachments made by other

manufacturers that do not meet American National Standards Institute certification will cause noncompliance of this machine.

Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means CAUTION, WARNING, or DANGER—“personal safety instruction.” Failure to comply with the instruction may result in personal injury or death.

Safe Operating Practices

The following instructions are from ANSI standard B71.4—1999.

Training

• Read the Operator ’s Manual and other training

material. If the operator(s) or mechanic(s) can not read English it is the owner’s responsibility to explain this material to them.

• Become familiar with the safe operation of the

equipment, operator controls, and safety signs.

• All operators and mechanics should be trained. The

owner is responsible for training the users.

• Never let children or untrained people operate or

service the equipment. Local regulations may restrict the age of the operator.

• The owner/user can prevent and is responsible for

accidents or injuries occurring to himself or herself, other people or property.

Preparation

• Evaluate the terrain to determine what accessories and

attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by the manufacturer.

• Wear appropriate clothing including hard hat, safety

glasses and ear protection. Long hair, loose clothing or jewelry may get tangled in moving parts.

• Inspect the area where the equipment is to be used and

remove all objects such as rocks, toys and wire which can be thrown by the machine.

• Use extra care when handling gasoline and other fuels.

They are flammable and vapors are explosive. – Use only an approved container. – Never remove gas cap or add fuel with engine

running. Allow engine to cool before refueling. Do not smoke.

– Never refuel or drain the machine indoors.

• Check that operator ’s presence controls, safety

switches and shields are attached and functioning properly. Do not operate unless they are functioning properly.

Operation

• Never run an engine in an enclosed area.

• Only operate in good light, keeping away from holes

and hidden hazards.

• Be sure all drives are in neutral and parking brake is

engaged before starting engine. Only start engine from the operator ’s position. Use seat belts if provided.

• Slow down and use extra care on hillsides. Be sure to

travel in the recommended direction on hillsides. Turf conditions can affect the machine’s stability. Use caution while operating near drop-offs.

• Slow down and use caution when making turns and

when changing directions on slopes.

• Never operate with guards not securely in place. Be

sure all interlocks are attached, adjusted properly, and functioning property.

• Do not change the engine governor setting or

overspeed the engine.

• Stop on level ground, raise the cutting unit, disengage

drives, engage parking brake (if provided), shut off engine before leaving the operator’s position for any reason.

• Stop equipment and inspect the machine after striking

objects or if an abnormal vibration occurs. Make necessary repairs before resuming operations.

• Keep hands and feet away from the cutting units.

• Look behind and down before backing up to be sure of

a clear path.

• Never carry passengers and keep pets and bystanders

away.

• Slow down and use caution when making turns and

crossing roads and sidewalks. Stop reels if not mowing.

• Do not operate the mower under the influence of

alcohol or drugs

Page 5

SAFETY INSTRUCTIONS

• Use care when loading or unloading the machine into a

trailer or truck

• Use care when approaching blind corners, shrubs,

trees, or other objects that may obscure vision.

Maintenance and Storage

• Disengage drives, raise the cutting units, set parking

brake, stop engine and remove key and disconnect spark plug wire. Wait for all movement to stop before adjusting, cleaning or repairing.

• Clean grass and debris from cutting units, drives,

mufflers, and engine to help prevent fires. Clean up oil or fuel spillage.

• Let engine cool before storing and do not store near

flame.

• Shut off fuel while storing or transporting. Do not store

fuel near flames or drain indoors.

• Park machine on level ground. Never allow untrained

personnel to service machine.

• Use jack stands to support components when required.

• Carefully release pressure from components with

stored energy.

• Disconnect battery before making any repairs.

Disconnect the negative terminal first and the positive last. Reconnect positive first and negative last.

• Use care when checking the blades. Wear gloves and

use caution when servicing them.

• Keep hands and feet away from moving parts. If

possible, do not make adjustments with the engine running.

• Charge batteries in an open well ventilated area, away

from spark and flames. Unplug charger before connecting or disconnecting from battery. Wear protective clothing and use insulated tools.

• Keep all parts in good working condition and all

hardware and hydraulic fittings tightened. Replace all worn or damaged decals.

Operation

• Know how to stop the engine quickly.

• Always wear substantial shoes. Do not operate the

machine while wearing sandals, tennis shoes, or sneakers.

• Wearing safety shoes and long pants is advisable and

required by some local ordinances and insurance regulations.

• Handle fuel carefully. Wipe up any spills.

• Check the safety interlock switches daily for proper

operation. If a switch should fail, replace the switch before operating the machine. After every two years, replace all three interlock switches in the safety system, regardless if they are working properly or not.

• Using the machine demands attention. To prevent loss

of control: – Do not drive close to sand traps, ditches, creeks, or

other hazards.

– Reduce speed when making sharp turns. Avoid

sudden stops and starts.

– Watch out for traffic when near or crossing roads.

Always yield the right-of-way.

– Apply the service brakes when going downhill to

keep forward speed slow and to maintain control of the machine.

• Raise the cutting unit when driving from one work

area to another.

• Do not touch the engine, muffler, or exhaust pipe

while the engine is running or soon after it has stopped because these areas could be hot enough to cause burns.

• If a cutting unit strikes a solid object or vibrates

abnormally, stop immediately, turn the engine off, wait for all motion to stop, and inspect the machine for damage. A damaged blade must be replaced before operation is continued.

Toro Mower Safety

The following list contains safety information specific to Toro products or other safety information that you must know that is not included in the ANSI standards.

This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death.

Use of this product for purposes other than its intended use could prove dangerous to user and bystanders.

• Traverse slopes carefully. Do not start or stop suddenly

when traveling uphill or downhill.

• The operator must be skilled and trained in how to

drive on hillsides. Failure to use caution on slopes or hills may cause loss of control and cause the vehicle to tip or roll, possibly resulting in personal injury or death.

• If the engine stalls or loses headway and cannot make

it to the top of a slope, do not turn the machine around. Always back slowly, straight down the slope.

Page 6

SAFETY INSTRUCTIONS

• When a person or pet appears unexpectedly in or near

the mowing area, stop mowing. Careless operation, combined with terrain angles, ricochets, or improperly positioned guards can lead to thrown object injuries. Do not resume mowing until the area is cleared.

• Whenever the machine is left unattended, make sure

the cutting unit is disengaged, the key is removed from the ignition switch, and the parking brake is set.

Maintenance and Storage

• Make sure all hydraulic line connectors are tight and

all hydraulic hoses and lines are in good condition before applying pressure to the system.

• Keep your body and hands away from pin hole leaks

or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not your hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury.

• Before disconnecting or performing any work on the

hydraulic system, all pressure in the system must be relieved by stopping the engine and lowering the cutting units and attachments to the ground.

• Check all fuel lines for tightness and wear on a regular

basis. Tighten or repair them as needed.

• Periodically inspect the roll bar and roll bar mounting.

Repair, as necessary. Do not weld, cut, drill, or modify roll bar in any manner.

• If the engine must be running to perform a

maintenance adjustment, keep hands, feet, clothing, and any parts of the body away from the cutting units, attachments, and any moving parts, especially the screen at the side of the engine. Keep everyone away.

• Do not overspeed the engine by changing governor

settings. To ensure safety and accuracy, have an Authorized Toro Distributor check the maximum engine speed with a tachometer.

• The engine must be shut off before checking the oil or

adding oil to the crankcase.

• If major repairs are ever needed or if assistance is

desired, contact an Authorized Toro Distributor.

• To make sure of optimum performance and continued

safety certification of the machine, use only genuine Toro replacement parts and accessories. Replacement parts and accessories made by other manufacturers could be dangerous, and such use could void the product warranty.

Page 7

SAFETY AND INSTRUCTION DECALS

The following safety and instruction decals are mounted on the traction unit. If any decal becomes damaged or illegible, install a new decal. Part numbers are listed below or in your parts catalog.

Part No. 67–1710

Part No. 93–5934

1. See Operator’s Manual

Part No. 93–5932

Part No. 93–5930

Part No. 93–5921–Model 30301

Part No. 93–5622–Model 30302

Part No. 77–3100

1. Keep hands away from fan blades

Part No. 93–7275

1. Read and understand Operator’s Manual

2. Do not prime engine or use starting fluid

Page 8

Part No. 92–5772

1. Press down on front of traction pedal to go forward; rear of pedal to go in reverse

Part No. 95–0814

1. To lock parking brake–Latch pedals together, apply brake pedals and pull up on knob

2. To unlock parking brake–step on brake pedals

3. Locks the parking brake

4. Optional light switch

5. Press down on lever to adjust steering wheel position

6. Read the operator’s manual

Part No. 93-8067

1. Read the operator’s manual for the correct hydraulic oil level.

1. Lower cutting unit

2. Raise cutting unit

3. PTO–On

4. PTO–Off

Part No. 93-5425

5. Engine–Stop

6. Engine–On

7. Engine–Off

8. Optional Cruise control–On

9. Optional Cruise control–Off

10. Hi–Lo speed–On

11. Hi–Lo speed–Off

12. Throttle–Slow

13. Throttle–Fast

14. Temperature reset button

Page 9

SPECIFICATIONS

Engine: Peugeot TUD5, 4 cylinder, 4 cycle, in-line,

over-head cam, liquid cooled diesel engine with centrifugal water pump. Available power, 36 hp at 2625 RPM. 1.5 liter displacement, governed to a maximum speed of 2780 RPM. Compression ratio 23.5:1. Glow plugs controlled by pre/post heat relay. Oil capacity

4.75 quart (4.5 liters) with oil filter. 12 volt type 4 starter motor with integral solenoid. 70 amp type 7 alternator with integral regulator.

Fuel Tank Capacity: 12 gallons diesel fuel

Radiator : Rear mount industrial radiator with tube and

fin construction: 4 rows, 5 fins per inch. Thermally stable water cooled hydrostatic system regulates operating temperature. Separate degassing bottle to remove air from cooling system fluid. System capacity approximately 11.5 quarts (10.9 liter).

Controls: Hand operated throttle, PTO switch, hydraulic lift/lower/counterbalance of implement, ground speed high/low range switch, ignition switch. Foot operated tilt steering locking lever, traction pedal, steering/parking brake pedals.

Gauges and Diagnostics: Gauge package includes fuel gauge, engine coolant temperature gauge, and hour meter. Indicator light for high engine coolant temperature, low engine oil pressure, alternator, low engine coolant level, water in fuel, glow plugs.

Electrical Features: 12 volt automotive type electrical system. 650 cold cranking amp battery performance at 00F. Dash mounted ignition switch. 70 amp alternator. PTO, seat and traction interlock switches.

Transaxle/PTO: Sauer-Sundstrand integrated hydrostatic transaxle (IHT-M15) incorporating the hydrostatic transmission, mechanical gearbox, differential, drive axle, power-take-off (PTO) system, implement hydraulic system pump and reservoir in a single component. Variable speed, axial piston, hydrostatic U-type transmission: gear type charge circuit hydraulics with filtration provides hydraulic flow for power steering and implement lift. Approximately 12 quart oil capacity. Single foot pedal control of forward/reverse ground speed. Two speed axle with "shift on the fly" speed range selection. 4wd is mechanically driven from front axle by a universal shaft. Double overrunning clutch provides 4wd function in forward and reverse preventing rear tire scuffing in turns. Both 2wd and 4wd have the same turning radius. Optional cruise control available.

Implement Lift: Twin hydraulic lift cylinders (2.5" bore x 3.5" stroke) provide lift, lower and counterbalance of implement via electrically actuated hydraulic control manifold.

Steering: Eaton Series 2 steering control unit with power beyond. Steering valve controls single steering cylinder. Steering system is single tie-rod type which provides identical steering performance on both two and four wheel drive versions. Tilt steering wheel with single lever control. 14" diameter steering wheel.

Ground Speed

Low speed - 0-8 mph, infinitely variable

High speed - 0-15 mph, infinitely variable

Clearance

Front ground clearance - 8.25 inches

Rear ground clearance - 2wd : 6.00 inches

4wd : 4.75 inches

Tires/Wheels/Pressures

Two front traction drive tires Models 30301 TC and 30302 TC - 25 x10.5-15 turf tread, 6 ply rating. Models 30301 and 30302 - 24 x13-12 turf tread, 4 ply rating.

Two rear steering tires Models 30301 TC and 30302 TC - 20 x 8-10, turf tread, 6 ply rating. Models 30301 and 30302 - 18 x 8.50-10, turf tread, 4 ply rating.

Tire pressure - 15 psi

Brakes: Individual mechanical caliper disc brakes provide both independent application for steering assist and combined application for parking brake function. Dynamic braking through the hydrostatic traction drive.

Seat: Deluxe high back seat. Optional seat suspension kit, Model 30395, or deluxe adjustable suspension kit, Model 30396.

Storage: Toolbox with cover located to the left of the seat base. Beverage holder integral to toolbox cover. Operator manual storage tube furnished for attachment to seat frame.

Weight: 2wd - 1930lbs (875kg)

4wd - 2030lbs (920kg)

Wheel Base: 55 inches

Tread Width: 53 inches

Specifications and design subject to change without notice.

Page 10

LOOSE PARTS CHART

Note: Use this chart as a checklist to assure all parts necessary for assembly have been received. Without these

parts, total setup cannot be completed. Some parts may have already been assembled at factory.

DESCRIPTION QTY. USE

Wheel nut 10 Mount Rear Wheels Wheel 2

Wheel nut 10 Mount Front Wheels Wheel 2

Steering Wheel 1 Foam Seal 1 Nut 1 Install Steering Wheel Washer 1 Cap 1

Seat Belt 1 Bolt 2 Install Seat Belts to Seat. (Model 30302 only) Lockwasher 2

Roll Bar (ROPS) 1 Bar Assembly 2 Bolt 8 Install Roll Bar. (Model 30302 only) Flat washer 8

Operator's Manual 2 Parts Catalog 1

Registration Card 1 Fill out and return to Toro

Hydraulic Oil Filter (94-3951) 1 Change after 200 hours

Page 11

SET-UP INSTRUCTIONS

INSTALL FRONT & REAR WHEELS

1. Mount wheels and torque mounting nuts to 7580

ft-lbs (102108 Nm).

INSTALLING STEERING WHEEL (Fig. 1)

1. Move rear wheels so they point straight ahead.

2. Slide steering wheel assembly onto steering shaft.

3. Loosely secure bar assembly to frame holder with

(4) bolts and flat washers (Fig. 2).

4. Tighten all fasteners to 100 ft-lb..

Figure 1

1. Steering Wheel

2. Flat Washer

3. Nut

4. Cap

3. Secure steering wheel to shaft with flat washer and

nut. Tighten nut it to 10-15 ft-lb.

4. Install cap on steering wheel.

INSTALL ROLL BAR (Fig. 2) Model 30302 only

1. Loosely mount a bar assembly to each end of roll

bar with (2) bolts and flatwashers.

2. Lower roll bar into frame holder, aligning mounting holes as shown in Fig. 2.

Figure 2

1. Roll Bar

2. Bar Assembly

3. Frame Holder

GREASE TRACTION UNIT

Before the machine is operated, it must be greased to assure proper operating characteristics; refer to Lubrication Maintenance. Failure to grease the machine will result in premature failure of critical parts.

Page 12

BEFORE OPERATING

CHECK COOLING SYSTEM (Fig. 5)

CAUTION

Before servicing or making adjustments to the machine, stop engine and remove key from the switch.

CHECK ENGINE OIL (Fig. 3 & 4)

Crankcase capacity is 4-3/4 qt. (4.5 l) with filter.

1. Park machine on a level surface. Rotate hood latch fully counterclockwise and open hood.

Capacity of system is 11.5 qts. (10.9 l).

Check cooling system if low water level light illuminates.

1. Park machine on a level surface. Release hood latch and open hood.

2. Remove degasser tank cap and check coolant level. Coolant level should be up to or above tabs In

degasser tank, when engine is cold.

CAUTION

If engine has been running, pressurized hot coolant can escape and cause burns if degasser cap is removed. Allow engine to cool at least 15 minutes or until the degasser cap is cool enough to touch without burning hand.

Figure 3

1. Hood Latch

2. Remove dipstick and wipe it with a clean rag. Insert

dipstick into tube and make sure it is fully seated. Remove dipstick and check level of oil. If level of oil is low, add enough oil to raise level to notch in dipstick. DO NOT OVERFILL.

Figure 4

1. Dipstick

2. Oil Fill Cap

3. If oil level is low, clean area around oil fill cap,

remove cap and add SAE 15W-40 CE oil until level reaches FULL mark on dipstick. DO NOT OVERFILL.

4. Install oil fill cap.

5. Close hood and secure latch. 12

Figure 5

1. Degasser Tank

3. If coolant is low, remove degasser tank cap and

add a 50/50 mixture of water and Peugeot recommended anti-freeze (Toro Part No. 93-7213).

DO NOT USE WATER ONLY OR ALCOHOL/METHANOL BASE COOLANTS.

4. Install degasser tank cap.

5. Close hood and secure latch.

FILL FUEL TANK (Fig. 6)

Capacity of fuel tank is 12 gal.

1. Remove fuel tank cap.

2. Fill tank to about one inch below top of tank, not

filler neck with No. 2 diesel fuel. Then install cap.

Page 13

BEFORE OPERATING

Figure 6

1. Fuel Tank Cap

DANGER

Because diesel fuel is flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot, or when machine is in an enclosed area. Always fill fuel tank outside and wipe up any spilled diesel fuel before starting the engine. Store fuel in a clean, safety-approved container and keep cap in place. Use diesel fuel for the engine only; not for any other purpose.

Universal Tractor Hydraulic Fluid

Mobil Mobil Fluid 424 Amoco 1000 Fluid Chevron Tractor Hydraulic Fluid Conoco Hydroclear Powertrain Exxon Univis N46 Pennzoil Hydra-Tranz Shell Donax TD Texaco TDH

IMPORTANT: Do Not Use Biodegradable Hydraulic Fluid.

Note: Many hydraulic fluids are almost colorless,

making it difficult to spot leaks. A red dye additive for the hydraulic system oil is available in 2/3 oz. (20 ml) bottles. One bottle is sufficient for 4-6 gal (15-22 1) of hydraulic oil. Order part no.44-2500 from your authorized Toro distributor.

1. Position machine on a level surface, raise the implement, and stop the engine.

2. Unscrew dipstick cap (Fig. 7) from the filler neck and wipe it with a clean rag. Screw dipstick cap finger tight onto filler neck. Unscrew the dipstick and check level of oil. If level is not up to FULL mark on dipstick (Fig. 7), add enough oil to raise level to mark. DO NOT OVERFILL.

3. Screw dipstick filler cap finger-tight onto filler neck.

4. Lower the implement.

CHECK HYDRAULIC FLUID (Fig. 7)

The The machines reservoir is filled at the factory with approximately 12 quarts of high quality tractor hydraulic fluid. Check level of hydraulic fluid before

engine is first started and daily thereafter.

Appropriate hydraulic oils are listed below.

The following list is not assumed to be all-inclusive. Hydraulic fluids produced by other manufacturers may be used if they can cross reference to find an equivalent to the products listed. Toro will not assume responsibility for damage caused by improper substitutions, so use only products from reputable manufacturers who will stand behind their recommendation.

Figure 7

1. Dipstick cap

CHECK REAR AXLE LUBRICANT (Fig. 8) (Model 30302 Only)

The rear axle reservoir uses Mobil 424 hydraulic fluid. Although the axle is shipped with lubricant from the factory, check the level before operating the machine.

1. Position the machine on a level surface.

2. Remove check plug from axle and make sure

lubricant is up to bottom of hole. If level is low, add enough lubricant to bring the level up to the bottom of the check hole (Fig. 8).

Page 14

BEFORE OPERATING

IMPORTANT: Maintain even pressure in all tires to

assure a good quality-of-cut and proper machine performance. DO NOT UNDER INFLATE.

CHECK TORQUE OF WHEEL NUTS

WARNING

Figure 8

1. Check Plug

2. Drain Plug

CHECK TIRE PRESSURE (Fig. 9)

The tires are over-inflated for shipping. Therefore, release some of the air to reduce the pressure. Correct air pressure in the front and rear tires is 15 psi.

Torque wheel nuts to 7580 ft-lb after 14 hours of operation and again after 10 hours of operation and every 200 hours thereafter. Failure to maintain proper torque could result in failure or loss of wheel and may result in personal injury.

Figure 9

1. Rear Tire

Page 15

KNOW YOUR CONTROLS

Traction Pedal (Fig. 10) - Controls forward and

reverse operation. Depress top of pedal to move forward and bottom to move backward. Ground speed depends on how far pedal is depressed. For no load, maximum ground speed, fully depress pedal while throttle is in FAST. To stop, reduce foot pressure on traction pedal and allow it to return to center position.

Figure 10

1. Traction Pedal

2. Brake Pedals

3. Parking Brake Latch

4. Tilt Steering Control

Brake Pedals (Fig. 10) - Two foot pedals operate

individual wheel brakes for turning assistance, parking and to aid in obtaining better sidehill traction. Locking strap connects the pedals for parking brake operation.

Parking Brake Latch (Fig. 10) - A knob on the left side of console actuates parking brake lock. To engage parking brake, connect pedals with locking strap, push down on both pedals and pull parking brake latch out. To release parking brake, depress both pedals until parking brake latch retracts.

Tilt Steering Control (Fig. 10) - Lever on rear of steering tower. Push lever downward to adjust steering wheel to desired fore or aft operating position and release lever to lock adjustment.

Charge Indicator (Fig. 11) - Illuminates when system charging circuit malfunctions.

Low Water Level Light (Fig. 11) - Indicates coolant water level is low.

Engine Coolant Temperature Warning Light (Fig. 11)

- The light illuminates and engine shuts down when coolant reaches a dangerously high temperature.

Engine Oil Pressure Warning Light (Fig. 11) Indicates dangerously low engine oil pressure.

Glow Plug Indicator Light (Fig. 11)- When lit, indicates glow plugs are on.

Water in Fuel Light (Fig. 11) - Indicates water in fuel system.

Temperature Gauge (Fig. 11)The temperature gauge registers the temperature of the coolant in the cooling system.

Temperature Reset Button (Fig. 11)  Press and hold reset button to start engine after high temperature shut down.

Hour Meter (Fig. 11) - Shows total hours that machine has been operated.

Fuel Gauge (Fig. 11) - Indicates level of fuel in tank.

Throttle Control (Fig. 11) - Move control forward to

increase engine speed, rearward to decrease speed.

Hi-Lo Speed Control (Fig. 11) - Allows speed range to increase for transport of machine.

Cruise Control (Optional) (Fig. 11) -Controls speed of machine.

Lift Lever (Fig. 11) - The lever raises and lowers the

cutting unit.

PTO Switch (Fig. 11) - The PTO switch has three positions: ON (engage), Neutral and OFF (disengage). Slowly lift and push PTO switch forward to ON position to start the implement or cutting unit blades. Slowly, pull switch backward to OFF position to stop implement operation. The only time PTO switch should be in the ON position is when implement or cutting unit is down in operating position.

Ignition Switch (Fig. 11) - Three positions: OFF, ON / Preheat and START.

Figure 11

1. Lift Lever

2. PTO Switch

3. Ignition Switch

4. Charge Indicator

5. Low Water Level Light

6. Engine Coolant Temperature Warning Light

7. Engine Oil Pressure Warning Light

8. Glow Plug Indicator Light

9. Water in Fuel Light

10. Temperature Gauge

11. Temperature Reset Button

12. Hour Meter

13. Fuel Gauge

14. Throttle Control

15. Hi-Lo Speed Control

16. Cruise Control (Optional)

Page 16

OPERATING INSTRUCTIONS

PRIMING FUEL SYSTEM (Fig. 12)

CAUTION

Before servicing or making adjustments to the machine, stop engine and remove key from the switch.

STARTING/STOPPING ENGINE

IMPORTANT: The fuel system must be bled if any of

the following situations have occurred:

A. Initial start up of a new machine.

B. Engine has ceased running due to lack of fuel.

C. Maintenance has been performed upon fuel system components.

D. Refer to Priming Fuel System.

1. Ensure parking brake is set. Remove foot from

traction pedal and insure it is in neutral.

2. Move throttle control to low idle position.

3. Turn ignition key to RUN position, glow indicator

will light.

IMPORTANT: The fuel system may need to be primed when a new engine is started for the first time, if it runs out of fuel or if maintenance is performed on the fuel system.

1. Unlatch and raise hood.

2. Insert a 3/16" hose over bleed screw and run other

end into a container to catch fuel.

3. Loosen fuel filter / water separator bleed screw (Fig. 12) a few turns. Pump priming plunger until a steady stream of fuel comes out of hole in bleed screw. When fuel stops foaming, tighten the bleed screw during the downstroke of the priming plunger. Wipe up any spilled fuel.

Note: Do not run starter motor more than 15 seconds at a time or premature starter failure may result. If engine fails to start after 15 seconds, turn key to OFF position, recheck controls and procedures, wait 15 additional seconds and repeat starter procedure.

4. When glow indicator dims, turn ignition key to

START position. Release key immediately when engine starts and allow it to return to RUN position. Move throttle control to desired position.

5. When engine is started for the first time, or after

overhaul of the engine, transmission or axle, operate the machine in forward and reverse for one or two minutes. Also operate the lift lever and PTO lever to assure proper operation of all parts. Turn steering wheel to the left and right to check steering response. Then shut engine off and check for oil leaks, loose parts, and any other noticeable difficulties.

CAUTION

Shut engine off and wait for all moving parts to stop before checking for oil leaks, loose parts, or other difficulties.

6. To stop engine, move throttle control backward to

SLOW position, move PTO lever to OFF position, and rotate ignition key to OFF. Remove key from switch to prevent accidental starting.

Figure 12

1. Primer Plunger 2. Bleed Screw

4. Pump priming plunger until resistance is felt. Try to

start engine. If engine does not start repeat step 3.

CHECKING INTERLOCK SWITCHES

The machine has interlock switches in the electrical system. These switches are designed to stop the engine when operator gets off the seat when traction pedal is depressed. However, operator may get off the seat while engine is running. Although engine will continue to run if PTO lever is disengaged and traction pedal is released, it is strongly recommended that the engine be stopped before dismounting from the seat.

CAUTION

Do not disconnect the interlock switches. Check operation of switches daily to assure in terlock system is operating correctly. If a switch is malfunctioning, replace it before op erating the machine. To ensure maximum safe ty, replace all switches after every two years or 1000 hours, whichever comes first.

Page 17

OPERATING INSTRUCTIONS

To check operation of interlock switches:

1. Drive the machine slowly to a large, relatively open area. Lower cutting unit, stop the engine and apply parking brake.

2. Sit on seat. Depress the traction pedal. Try to start the engine. The engine should not crank. If the engine cranks, there is a malfunction in the interlock system that should be corrected before beginning operation.

WARNING

Do not operate machine without implement unless the PTO driveshaft is also removed.

3. Sit on seat and start the engine. Raise off the seat

and move the PTO lever to ON. The PTO should not engage. If the PTO engages, there is a malfunction in the interlock system that should be corrected before beginning operation.

4. With the parking brake engaged, sit on seat and start the engine. Depress the traction pedal. The engine should kill when traction pedal is depressed. If the engine continues to run, there is a malfunction in the interlock system that should be corrected before beginning operation.

PUSHING OR TOWING TRACTION UNIT

(Fig. 13)

In an emergency, the traction unit can be pushed or towed. However, Toro does not recommend this as standard procedure.

IMPORTANT: Do no push or tow the traction unit faster than 10 mph. If traction unit must be moved a considerable distance, transport it on a truck or trailer.

1. Locate towing lever on right side of axle assembly.

2. Remove cotter pin and clevis pin securing lever to

plate on side of axle.

3. Pivot lever rearward until hole is aligned with rear hole in plate. Secure lever to rear hole with cotter pin and clevis pin previously removed.

4. After completion of towing operation, pivot lever back to original position and re-secure.

OPERATING CHARACTERISTICS

Practice driving the GROUNDSMASTER 3000D because it has a hydrostatic transmission and its characteristics are different than many turf maintenance machines. Some points to consider when operating the traction unit, cutting unit, or other implement are the transmission, engine speed, load on the cutting blades or other implement components, and the importance of the brakes.

To maintain enough power for the traction unit and implement while operating, regulate traction pedal to keep engine rpm high and somewhat constant. A good rule to follow is: decrease ground speed as the load on the implement increases, and increase ground speed as the load decreases.

Therefore, allow traction pedal to move backward as engine rpm decrease, and depress pedal slowly as rpm increase. By comparison, when driving from one work area to anotherwith no load and cutting unit raisedhave throttle in FAST position and depress traction pedal slowly but fully to attain maximum ground speed.

Another characteristic to consider is the operation of the pedals that are connected to the brakes. The brakes can be used to assist in turning the machine. However, use them carefully, especially on soft or wet grass because the turf may be torn accidentally. Another benefit of the brakes is to maintain traction. For example: in some slope conditions, the uphill wheel slips and loses traction. If this situation occurs, depress uphill turn pedal gradually and intermittently until the uphill wheel stops slipping, thus, increasing traction on the downhill wheel.

Figure 13

1. Towing Lever

Use extra care when operating machine on slopes. Make sure seat latch is properly secured. Drive slowly and avoid sharp turns on slopes to prevent roll overs. The cutting deck must be lowered when going downhill for steering control.

Page 18

OPERATING INSTRUCTIONS

WARNING

This product is designed to drive objects into the ground where they lose energy quickly in grassy areas. However, when a person or pet appears suddenly in or near mowing area, STOP MOWING. Careless operation, combined with terrain angle, ricochets, or improperly positioned safety guards can lead to thrown object inju ries. Do not resume mowing until area is cleared.

Before transporting machine, raise cutting deck and secure with transport latch.

Figure 14

1. Transport Latch

Before stopping the engine, disengage all controls and move throttle to SLOW. Moving throttle to SLOW reduces high engine rpm, noise, and vibration. Turn key to OFF to stop engine.

CAUTION: This product may exceed noise levels of 85 dB(A) at the operator position. Ear protectors are recommended, for prolonged exposure, to reduce the potential of permanent hearing damage.

Page 19

LUBRICATION

CAUTION

Before servicing or making adjustments to the machine, stop engine and remove key from the switch.

GREASING BEARINGS AND BUSHINGS

(Fig. 15-20)

The machine has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. If machine is operated under normal conditions, lubricate all bearings and bushings after every 50 hours of operation or immediately after every washing.

The grease fitting locations and quantities are:

2 Wheel Drive Models only-Steering cylinder ball joint, Rear axle tie rod (2), Rear axle pivot (1) Rear Spindle Shafts (2) (Fig. 15).

4 Wheel Drive Models only-Steering cylinder ball joints, Rear axle tie rod (2), Rear axle pivot (1), Double Cardan joints (2 ea. side) (Fig. 16) and Rear DrIve Shaft (3) (Fig.17)

All Models-Intermediate Drive Shaft (9) (Fig. 18); Pedal Pivots (5), Traction pedal (In square tube under floor plate) (1) (Fig. 19) and Lift arm pivot (2) (Fig. 20).

Figure 17

(4)

Figure 18

Figure 15

Figure 16

Figure 19

Figure 20

Page 20

DAILY MAINTENANCE CHECKLIST

Maintenance

Daily Maintenance: (duplicate this page for routine use) Check proper section of Operator's Manual for fluid specifications

Maintenance Check Item 

 Safety Interlock Operation  Brake Operation  Engine Oil & Fuel Level  Cooling System Fluid Level

Drain Water/Fuel Separator

 Radiator & Screen for Debris  Unusual Engine Noises  Unusual Operating Noises  Hydraulic System Oil Level  Hydraulic Hoses for Damage  Fluid Leaks  Tire Pressure  Instrument Operation

Lubricate All Grease Fittings Touch–up Damaged Paint

= Check glow plug and injector nozzles, if hard starting, excess smoke or rough running is noted.

= Immediately after every washing, regardless of the interval listed.

Daily Maintenance Check For Week Of _________________

MON TUES WED THURS FRI SAT SUN

Notation for areas of concern: Inspection performed by_____________________________

Item Date Information

Page 21

MAINTENANCE SCHEDULE

Minimum Recommended Maintenance Intervals

Maintenance Procedure

Lubricate All Grease Fittings

Inspect Air Filter

Check Battery Level/Cable Connections

 Change Engine Oil and Filter

Inspect Cooling System Hoses

 Check Fan and Alternator Belt Tension

 Torque Wheel Lug Nuts

Service Spark Arrester Muffler

Service Air Filter

Change Fuel Filter

Inspect Fuel Lines and Connections

 Check Engine RPM (idle and full throttle)

Check Rear Axle Oil Level (4wd)

 Change Hydraulic Oil  Change Hydraulic Oil Filter  Change Rear Axle Oil Level (4wd)

Every 50hrs

Maintenance Interval & Service

Every

800hrs

Every

100hrs

Every

200hrs

Every

400hrs

Inspect Engine Timing Belt (see note below)

Drain and Clean Fuel Tank

Pack 2WD Rear Axle Bearings

Check Rear Wheel Toe-In

 Initial break in at 10 hours  Initial break in at 50 hours  Initial break in at 200 hours

Replace Moving Hoses

Replace Safety Switches

Cooling System Flush/Replace Fluid

NOTE: Replace Timing Belt after every 2500 hours of operation or if worn, cracked, oil soaked or any time the Belt is removed or loosened.

Annual Recommendations:

Items listed are recommended every 1500

hours or 2 years, whichever occurs first.

Page 22

AIR CLEANER MAINTENANCE

CAUTION

Before servicing or making adjustments to the machine, stop engine and remove key from the switch.

GENERAL AIR CLEANER MAINTENANCE

1. Inspect air cleaner after every 50 hours of

operation. More frequent in dusty or dirty conditions.

2. Check air cleaner body for damage which could

possibly cause an air leak. Replace a damaged air cleaner body.

3. Service the air cleaner filter every 400 hours (more

frequently in extreme dusty or dirty conditions). Do not over service air filter.

4. Be sure cover is sealing around air cleaner body.

CAUTION

Never operate machine without complete air cleaner assembly in place and latched proper ly or a damaged air cleaner Debris entering en gine can cause engine failure.

SERVICING AIR CLEANER (Fig. 21 & 22)

1. Release latches securing air cleaner cover to air

cleaner body. Separate cover from body. Clean inside of air cleaner cover.

Figure 21

1. Air cleaner latches

2. Dust cup

2. Gently slide filter (Fig. 22) out of air cleaner body to

reduce the amount of dust dislodged. Avoid knocking filter against air cleaner body.

Figure 22

1. Air cleaner filter

3. Inspect filter and discard if damaged. Do not wash

or reuse a damaged filter.

Washing Method

A. Prepare a solution of filter cleaner and water and soak filter element about 15 minutes. Refer to directions on filter cleaner carton for complete information.

B. After soaking filter for 15 minutes, rinse it with clear water. Maximum water pressure must not exceed 40 psi to prevent damage to the filter element. Rinse filter from clean side to dirty to side.

C. Dry filter element using warm, flowing air (160F ) max), or allow element to air-dry. Do not use a light bulb to dry the filter element because damage could result.

Compressed Air Method

A. Blow compressed air from inside to the outside of dry filter element. Do not exceed 100 psi to prevent damage to the element.

B. Keep air hose nozzle at least 2" from filter and move nozzle up and down while rotating the filter element. Inspect for holes and tears by looking through the filter toward a bright light.

5. Inspect new filter for shipping damage. Check sealing end of filter. Do not install a damaged filter.

6. Insert new filter properly into air cleaner body. Make sure filter is sealed properly by applying pressure to outer rim of filter when installing. Do not press on flexible center of filter.

7. Reinstall cover and secure latches. Make sure cover is positioned with TOP side up.

Page 23

ENGINE MAINTENANCE

CAUTION

Before servicing or making adjustments to the machine, stop engine and remove key from the switch.

ENGINE OIL AND FILTER (Fig. 23-24)

Change oil and filter initially after the first 50 hours of operation, thereafter change oil and filter every 100 hours.

1. Remove drain plug (Fig. 23) and let oil flow into drain pan. When oil stops, install drain plug and new plug seal, Part No. 74-7850.

3. Add 15W-40 CE oil to crankcase. Capacity is 4.75 quarts with filter.

FUEL SYSTEM (Fig. 25)

Fuel Tank

Drain and clean fuel tank every 800 hours of operation or yearly, whichever comes first. Also, drain and clean tank if fuel system becomes contaminated or if machine is to be stored for an extended period. Use clean fuel to flush out the tank.

DANGER

Because diesel fuel is highly flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot, or when machine is in an enclosed area. Always fill fuel tank out side and wipe up any spilled diesel fuel before starting the engine. Store fuel in a clean, safety-approved container and keep cap in place. Use diesel fuel for the engine only; not for any other purpose.

Figure 23

1. Drain Plug

2. Remove oil filter (Fig. 24). Apply a light coat of clean

oil to the new filter seal before screwing it on. DO NOT OVER-TIGHTEN.

Fuel Lines and Connections

Check lines and connections every 400 hours or yearly, whichever comes first. Inspect for deterioration, damage, or loose connections.

Draining Fuel Filter / Water Separator

Drain water or other contaminants from fuel filter / water separator daily.

Figure 25

1. Fuel Filter

2. Drain Screw

3. Primer plunger

Figure 24

1. Oil Filter

1. Place a clean container under fuel filter.

2. Loosen drain screw on bottom of fuel filter and

press primer plunger until only fuel is evident draining into container.

3. Tighten drain screw. 23

Page 24

ENGINE MAINTENANCE

Changing Fuel Filter

Replace fuel filter if fuel flow becomes restricted, after every 400 hours of operation or annually, whichever comes first.

1. Loosen bolt and unscrew bottom filter cap from filter assembly. Remove cap, gaskets, oring and filter from assembly. Note position of gaskets and oring when disassembling from filter.

3. Install new filter, gaskets, oring with filter assembly cap.

4. Prime fuel system, refer to Priming Fuel System.

ENGINE COOLING SYSTEM (Fig. 26-27)

1. Removing Debris - Remove debris from rear

screen, oil cooler and radiator daily, clean more frequently in dirty conditions.

IMPORTANT: Never spray water onto a hot engine as damage to engine may occur.

A. Turn engine off and clean hood screen thoroughly.

D. Close hood and secure latch.

Note: Do not use water to clean engine or electrical components, as damage may occur.

2. Maintaining Cooling System - Capacity of the system is 11.5 quarts. Always protect cooling system with a 50/50 solution of water and Peugeot recommended anti-freeze (Part No. 93-7213). DO NOT USE WATER ONLY IN COOLING SYSTEM.

A. After every 100 operating hours, inspect and tighten hose connections. Replace any deteriorated hoses.

B. After every 2 years, drain and flush the cooling system. Add anti-freeze (refer to Check Cooling System).

ENGINE BELTS (Fig. 28)

Figure 26

1. Rear Screen

B. Release hood latch and raise hood. Clean engine area thoroughly of all debris.

C. Clean both sides of oil cooler and radiator area thoroughly with compressed air. Do not use water.

Check condition and tension of belts after every 100 hours of operation (Fig. 28). Replace belts as required.

Alternator Belt

1. Proper tension will allow 1/8 in. deflection on the

belt midway between the pulleys, when pressed firmly with thumb.

Figure 28

1. Fan Belt

2. If deflection exceeds 1/8 in., loosen alternator

Figure 27

1. Oil Cooler

2. Radiator

mounting bolts. Adjust belt tension and tighten mounting bolts. Check deflection of belt again to assure tension is correct.

2. Alternator belt

Page 25

Fan Belt

ENGINE MAINTENANCE

1. Proper tension will allow 3/8 in. deflection on the

belt midway between the pulleys, when pressed firmly with thumb.

2. If deflection exceeds 3/8 in., loosen pulley mounting bolt. Adjust belt tension and tighten mounting bolt. Check deflection of belt again to assure tension is correct.

SERVICING SPARK ARRESTOR MUFFLER

Every 200 hours operation, clear the muffler of carbon buildup.

1. Remove pipe plug from clean-out port at lower side of muffler.

CAUTION

Be careful while working around muffler as it may be hot and could cause injury.

2. Start engine. Plug the normal muffler exit with

block of wood or metal plate so exhaust flow will be forced out of the clean-out port. Continue to block exit until carbon deposits cease coming out port.

CAUTION

Do not stand in line with the clean-out port. Always wear safety glasses.

3. Stop engine and replace pipe plug.

Page 26

HYDRAULIC MAINTENANCE

CAUTION

Before servicing or making adjustments to the machine, stop engine and remove key from the switch.

CHANGING HYDRAULIC SYSTEM OIL & FILTER (Fig. 30 - 29)

The hydraulic system oil and filter must be changed initially at 200 hours and thereafter every 400 hours of operation or seasonally, whichever comes first. The hydraulic system is designed to operate on anti-wear hydraulic fluid. The machines reservoir is filled at the factory with approximately 12 quarts of high quality hydraulic fluid. Check level of hydraulic fluid before

engine is first started and daily thereafter.

Universal Tractor Hydraulic Fluid

Mobil Mobil Fluid 424 Amoco 1000 Fluid Chevron Tractor Hydraulic Fluid Conoco Hydroclear Powertrain Exxon Univis N46 Pennzoil Hydra-Tranz Shell Donax TD Texaco TDH

IMPORTANT: Do Not Use Biodegradable Hydraulic Fluid.

15. Start engine, park machine on a level surface,

lower implement to the shop floor, set the parking brake, and shut engine off.

16. Clean area around dipstick cap (Fig. 29) and remove cap from axle filler tube.

17. To ease access to axle housing drain plug (Fig. 30), implement may be removed from traction unit.

18. Remove drain plug from axle housing and allow oil to flow into drain pan.

Figure 30

1. Drain plug

19. Clean area around hydraulic oil filter and remove

filter (Fig. 31).

Figure 31

1. Hydraulic Filter

20. Lubricate new filter seal and install filter.

21. Install drain plug in axle housing (Fig. 30).

Figure 29

1. Dipstick cap

22. Through axle filler tube, fill axle to proper level with

Mobil 424 hydraulic fluid. Install dipstick cap.

23. Start and run the engine at idle speed for about two minutes, raise and lower implement and turn the steering wheel lock to lock to purge air trapped in the system. Shut the engine off.

24. Let machine set for two additional minutes, then remove dipstick and check oil level in axle. If level is low, add oil until level matches groove in dipstick. If level is too high, remove drain plug and drain oil until oil level matches Full mark on dipstick.

Page 27

HYDRAULIC MAINTENANCE

CHECKING HYDRAULIC LINES AND HOSES

Inspect hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration and chemical deterioration. Make all necessary repairs before operating.

WARNING

Keep body and hands away from pin hole leaks or nozzles that eject high pressure hy draulic fluid. Use cardboard or paper to find hydraulic leaks. Hydraulic fluid escaping un der pressure can penetrate skin and cause in jury. Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result.

HYDRAULIC SYSTEM TEST PORT (Fig. 32)

The test port is used to test pressure in the hydraulic circuits. Contact your local Toro distributor for assistance.

ADJUSTING TRACTION PEDAL LINKAGE

(Fig. 33 & 34)

Traction pedal to reach full stroke prior to contact with stop.

1. Park machine on a level surface, shut engine off

and lower cutting unit to the floor.

2. Check pedal stop adjustment. Distance from top of

stand to top of stop must be 1.25". Loosen jam nuts and adjust stop if required.

1.25"

Figure 33

1. Traction Pedal Stop

3. Loosen jam nuts securing traction rod to

transmission lever pivot capscrew.

1. Test Port #1 (Fig. 32) is used to adjust pressure in counterbalance circuit.

Figure 32

1. Test Port

Figure 34

1. Traction Rod

2. Capscrew

3. Lever

4. Adjust capscrew until traction pedal reaches full

forward stroke just before pedal contacts stop.

5. Tighten jam nuts to lock adjustment.

Page 28

15CC VARIABLE PUMP

IHT-M15 TRANSAXLE

CHARGE/ IMPLEMENT PUMP

INLET FILTER

CHARGE PRESSURE

PRIORITY VALVE

IMPLEMENT CIRCUIT PRESSURE RELIEF VALVE

"EASY-RIDE"

VALVES

25CC VARIABLE

MOTOR

LIFT/LOWER CONTROL

LIFT HOLD

LOWER/FLOAT

LIFT/ COUNTERBALANCE MANIFOLD

SOLENOIDS

ON OFF OFF

LIFT CYLINDERS

2.5" BORE

3.5" STROKE 1" ROD

OFF OFF ON

HYDRAULIC SCHEMATIC

CYL1 CYL2

T-2350-4

RESERVOIR

STEERING CONTROL UNIT

6.1 IN DISPLACEMENT

T1 T2

PBP

STEERING CYLINDER

1.625 BORE

7.00 STROKE .625 ROD

OUT

COOLER

OIL

ADJ ORIFICE STD .187

LC1 75-220 PSI

Page 29

BRAKE MAINTENANCE

ADJUSTING SERVICE BRAKES (Fig. 35)

If excessive pedal travel is required to engage brake or as brake pads wear, an adjustment to the brake linkage may be required.

1. Jack up front of machine and support with jack stands.

2. Remove left front tire.

3. With brake linkage bellcrank against frame stop,

loosen jam nut disconnect clevis from bellcrank and adjust linkage until there is a slight drag on rotor.

4. Back off clevis one full turn and reinstall to bellcrank.

5. Tighten jam nut.

6. Repeat procedure on opposite wheel.

Figure 35

1. Bellcrank

2. Frame stop

3. Linkage Clevis

Page 30

AXLE MAINTENANCE

CAUTION

Before servicing or making adjustments to the machine, stop engine and remove key from the switch.

CHANGING REAR AXLE LUBRICANT (Model 30302 only) (Fig. 36)

Initially, change oil in rear axle after 200 hours, thereafter change every 400 hours of operation.

REAR WHEEL TOE-IN (Fig. 37)

After every 800 operating hours or annually, check rear wheel toe-in.

1. Measure center-to-center distance (at axle height) at front and rear of steering tires. Front measurement must be 1/8 in. less than rear measurement.

2. To adjust toe-in:

1. Position machine on a level surface.

2. Clean area around drain plug on rear axle.

Figure 36

1. Check Plug

2. Drain Plug

3. Remove check plug to ease draining of oil.

4. Remove drain plug allowing oil to drain into pan.

5. Install drain plug.

6. Fill axle with approximately 16 oz. of Mobile 424 or

until lubricant is up to bottom of check hole.

7. Install check plug.

A. Remove cotter pins and nuts securing ball

joints to steering arms. Separate ball joint from arm.

B. Loosen clamps at both ends of tie rod.

C. Rotate ball joints to move front of tire inward or outward.

D. Tighten tie rod clamps when adjustment is correct.

Figure 37

1. Tie Rod

2. Tie Rod Clamps

Page 31

ELECTRICAL MAINTENANCE

BATTERY CARE

(Fig. 38)

Check battery condition weekly or after every 50 hours of operation. Keep terminals and entire battery case clean because a dirty battery will discharge slowly. To clean the battery, wash the entire case with solution of baking soda and water. Rinse with clear water. Coat the battery posts and cable connectors with Grafo 112X (skin-over) grease (Toro Part No. 50547) or petroleum jelly to prevent corrosion.

IMPORTANT: Before welding on the machine, disconnect both cables from the battery and the terminal connector from the alternator to prevent damage to the electrical system.

1. Remove strap, cover and foam block to access

battery.

CAUTION

Wear safety goggles and rubber gloves when working with electrolyte. Charge the battery in a well ventilated so gases produced while charging can dissipate. Since the gases are explosive, keep open flame and electrical spark away from the battery; do not smoke. Nausea may result if the gases are inhaled. Unplug charger from electrical outlet before connecting to, or disconnecting charger leads from battery posts.

Figure 38

1. Battery Cover

2. Strap

3. Foam block

4. Battery

5. Tray

FUSES (Fig. 39)

There are 5 fuses in the machines electrical system. Four fuses are located in compartment rear of control panel and one (80 amp) fuse is located by alternator.

Figure 39

1. Fuses

Page 32

T-2262-7

80A

RED

PRE/POST HEAT RELAY

RED

50A THERMALBREAKER

RED RED

RED

STARTER

BATTERY

PINK

LIGHT

WHITE

DIODE

ALTERNATOR

SENDER

BLUE

WHITE

TAN

LIGHT

GRN

GLOW

PLUGS

ORANGE

ORG

TEMP. RELAY

HIGH COOLANT

INJECTION ADVANCE

20A

NEUTRAL SWITCH

GRAY

10A

7.5A

BLUE

GREEN

IGNITION SWITCH

WHITE

START RELAY

TAN

12 VOLTS

RED

TAN

RED

NOTE: ALL GROUND WIRES ARE BLACK

FUEL STOP SOLENOID

WHI

HIGH TEMP SWITCH

LIGHT

GRAY

BRW

WHITE

PINK

BROWN

GRN

CAPACITOR

YEL

SEAT SWITCH

PINK

YEL

BLUE

DECK HOLD/LIFT SWITCH

HI TEMP OVERRIDE SWITCH

PINK

VIOLET

START

RUN

ORANGE

GRAY

WHITE

ORANGE

WHITE

HOURMETER

DECK FLOAT SWITCH

BLUE

BLU

TAN

BLUE

GRN

BLUE

DIODE

CAPACITOR

GRN

VIO.

OIL PRESSURE

H20 IN FUEL

WHITE

COOLANT LEVEL

SEAT

RELAY

BRW

RELAY

BLU

ORANGE

ORG

BLUE

TEMP GAUGE

FUEL GAUGE

FLOAT/HOLD SOLENOID

PINK

BRW

GRAY

DECK POSITION SWITCH

SV2

DIODE

IMPLEMENT FLOAT

RELAY

PINK

LIFT/XBAL SOLENOID

DIODE

OPTIONAL

PARKING BRAKE

BROWN

TRANSPORT

GRAY

SWITCH

HOLD

LOWER/FLOAT

SV1

CRUISE SWITCH

BRW

SERVICE BRAKE SWITCH

PTO SWITCH

LIFT

236

VIOLET

ORANGE

YELLOW

SV1 SV2

OFF

GREEN

TAN

WHI

CRUISE COIL

TAN

VIOLET

VIO.

BLU

PTO COIL

YEL

PINK

TRANSPORT COIL

RELAY

CRUISE

DIODE

LIGHT

RELAY

PTO

DIODE

RELAY

TRANSPORT

DIODE

LIGHT

ELECTRICAL SCHEMATIC

Page 33

PREPARATION FOR SEASONAL STORAGE

Traction Unit

1. Thoroughly clean the traction unit, cutting units

and the engine.

2. Check the tire pressure. Inflate all tires to 15-20 psi.

3. Check all fasteners for looseness; tighten as necessary.

4. Grease or oil all grease fittings and pivot points. Wipe up any excess lubricant.

5. Lightly sand and use touch-up paint on painted areas that are scratched, chipped, or rusted. Repair any dents in the metal body.

6. Service the battery and cables as follows:

a. Remove the battery cables from the battery posts.

b. Clean the battery, posts and cable connections with a wire brush and baking soda solution.

c. Coat the cable terminals and battery posts with Grafo 112X skin-over grease (Toro Part No. 50547) or petroleum jelly to prevent corrosion.

d. Slowly recharge the battery every 60 days for 24 hours to prevent lead sulfation of the battery.

Engine

1. Drain the engine oil from the oil pan and replace

the drain plug.

2. Remove and discard the oil filter. Install a new oil

filter.

3. Refill oil pan with 4.75 quarts of SAE15W40 CE

motor oil.

4. Start the engine and run at idle speed for

approximately two minutes.

5. Stop the engine.

6. Re-secure all fuel system fittings.

7. Thoroughly clean and service the air cleaner

assembly.

8. Seal the air cleaner inlet and the exhaust outlet with

weatherproof tape.

9. Check anti freeze protection and add a 50/50

solution of water and Peugeot recommended anti freeze, Part No. 93-7213, as needed for expected minimum temperature in your area.

Page 34

NOTES

Page 35

NOTES

Page 36

The Toro General Commercial Products Warranty

A Two-Year Limited Warranty

Conditions and Products Covered

The Toro Company and its affiliate, Toro Warranty Company, pursuant to an a g r eement between them, jointly warrant your 1996 or newer Toro Commercial Product (“Product”) purchased after January 1, 1997, to be free from defects in materials or workmanship for tw o years or 1500 operational hours*, whichever occurs first. Where a warrantable condition exists, we will repair the Product at no cost to you including diagnosis, labor, parts, and transportation. This warranty begins on the date the Product is delivered to the original retail purchaser.

* Product equipped with hour meter

Instructions for Obtaining Warranty Service

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

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

Toro Commercial Products Service Department Toro Warranty Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196 952-888-8801 or 800-982-2740 E-mail: commercial.service@toro.com

Owner Responsibilities

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

Items and Conditions Not Covered

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

• Product failures which result from the use of non-Toro replacement parts, or from installation and use of add-on, modified, or unapproved accessories

• Product failures which result from failure to perform required maintenance and/or adjustments

• Product failures which result from operating the Product in an abusive, negligent or reckless manner

• Parts subject to consumption through use unless found to be defective. Examples of parts which are consumed, or used up, during normal Product operation include, but are not limited to, blades, reels, bedknives, tines, spark plugs, castor wheels, tires, filters, belts, etc.

• Failures caused by outside influence. Items considered to be outside influence include, but are not limited to, weather, storage practices, contamination, use of unapproved coolants, lubricants, additives, or chemicals, etc.

• Normal “wear and tear” items. Normal “wear and tear” includes, but is not limited to, damage to seats due to wear or abrasion, worn painted surfaces, scratched decals or windows, etc.

Parts

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

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

General Conditions

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

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

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

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

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

Countries Other than the United States or Canada

Customers who have purchased Toro products exported from the United States or Canada should contact their T oro Distributor (Dealer) to obtain guarantee policies for your country, province, or state. If for any reason you are dissatisfied with your Distributor’s service or have difficulty obtaining guarantee information, contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty Company.

Part No. 374-0031 Rev. –