Toro 30381N, Groundsmaster 7210 Operator's Manual

FormNo.3383-169RevA

Groundsmaster

®

7210Traction

Unit

ModelNo.30381N—SerialNo.314000001andUp

Registeratwww.T oro.com.
OriginalInstructions(EN)

*3383-169*A

WARNING

CALIFORNIA

Proposition65Warning

Thisproductcontainsachemicalorchemicals

knowntotheStateofCaliforniatocausecancer,

birthdefects,orreproductiveharm.

Dieselengineexhaustandsomeofits
constituentsareknowntotheStateof

Californiatocausecancer,birthdefects,

andotherreproductiveharm.

Becauseinsomeareastherearelocal,state,orfederal
regulationsrequiringthatasparkarresterbeusedonthe
engineofthismachine,asparkarresterisavailableas
anoption.Ifyourequireasparkarrester,contactyour
AuthorizedToroServiceDealer.

yourproductready.

Figure1identiesthelocationofthe
modelandserialnumbersonthetractionunit.Themodel
andserialnumbersforthecabareprintedonaplatelocated
oninsidethecab,ontheframeabovethedoor.Writethe
numbersinthespaceprovided.

GenuineT orosparkarrestersareapprovedbytheUSDA
ForestryService.

Important:ItisaviolationofCaliforniaPublic
ResourceCodeSection4442touseoroperatetheengine
onanyforest-covered,brush-covered,orgrass-covered
landwithoutasparkarrestermufermaintainedin
workingorder,ortheengineconstricted,equipped,and
maintainedforthepreventionofre.Otherstatesor
federalareasmayhavesimilarlaws.

Introduction

Important:Usethismanualinconjunctionwiththe

PolarTrackitoranyotherattachmentsOperator's
Manualforadditionalinformationonthesafeoperation
andmaintenanceofyourmachineandit'sattachments.

Thistractionunitisusedinthesummerwitharotary-blade
lawnmowerattachmentandinthewinterwithasnowremoval
attachmentandisintendedtobeusedbyprofessional,hired
operatorsincommercialapplications.

Readthisinformationcarefullytolearnhowtooperateand
maintainyourproductproperlyandtoavoidinjuryand
productdamage.Youareresponsibleforoperatingthe
productproperlyandsafely.

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Thismanualidentiespotentialhazardsandhassafety
messagesidentiedbythesafetyalertsymbol(Figure2),
whichsignalsahazardthatmaycauseseriousinjuryordeath
ifyoudonotfollowtherecommendedprecautions.

Figure2

1.Safetyalertsymbol

Thismanualalsouses2wordstohighlightinformation.
Importantcallsattentiontospecialmechanicalinformation
andNoteemphasizesgeneralinformationworthyofspecial
attention.

YoumaycontactT orodirectlyatwww .Toro.comforproduct
andaccessoryinformation,helpndingadealer,ortoregister
yourproduct.

Wheneveryouneedservice,genuineT oroparts,oradditional
information,contactanAuthorizedServiceDealerorToro
CustomerServiceandhavethemodelandserialnumbersof

©2014—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Contactusatwww.Toro.com.

2

PrintedintheUSA.

AllRightsReserved

Contents

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

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

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

SafetyandInstructionalDecals.................................6

Setup............................................................................9

1CheckingFluidLevels...........................................10

2ActivatingandChargingtheBattery........................10

3InstallingtheMowerDeck/PolarTrac.....................11

ProductOverview.........................................................19

Controls...............................................................19

Operation....................................................................21

AddingFuel...........................................................21

CheckingtheEngineOilLevel.................................22

CheckingtheCoolingSystem...................................22

CheckingtheHydraulicSystem................................22

ThinkSafetyFirst...................................................22

OperatingtheParkingBrake....................................23

StartingtheEngine.................................................23

DrivingtheMachine...............................................24

StoppingtheMachine/Engine.................................24

TheSafetyInterlockSystem.....................................25

PositioningtheSeat................................................26

UnlatchingtheSeat.................................................27

MovingaNon-functioningMachine.........................27

LoadingMachines..................................................27

TransportingtheMachine........................................28

OperatingFrontAttachmentswiththePolarTrac

KitInstalled.......................................................28

Maintenance.................................................................30

RecommendedMaintenanceSchedule(s)......................30

DailyMaintenanceChecklist....................................31

PremaintenanceProcedures........................................32

Lubrication...............................................................32

GreasingtheBearingsandBushings..........................32

EngineMaintenance..................................................33

AirCleanerMaintenance........................................33

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

FuelSystemMaintenance...........................................35

ServicingtheWaterSeparator..................................35

CleaningtheFuelTank............................................35

FuelLinesandConnections.....................................35

BleedingtheFuelSystem.........................................35

BleedingAirFromtheInjectors................................36

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

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

StoringtheBattery..................................................37

CheckingtheFuses.................................................37

CoolingSystemMaintenance......................................38

CheckingtheCoolingSystem..................................38

CleaningtheRadiator..............................................38

BrakeMaintenance....................................................39

AdjustingtheParkingBrakeInterlockSwitch..............39

BeltMaintenance......................................................40

CheckingtheAlternatorBeltTension........................40

ControlsSystemMaintenance.....................................40

AdjustingtheControlLeverNeutralInterlock

Switch...............................................................40

AdjustingtheControlLeverNeutralReturn...............40

AdjustingtheTractionDriveforNeutral....................41

AdjustingtheMaximumGroundSpeed.....................42

AdjustingtheTracking............................................43

HydraulicSystemMaintenance....................................44

CheckingtheHydraulicFluidLevel...........................44

ChangingtheHydraulicOilAndFilter.......................44

Storage........................................................................45

Machine................................................................45

Engine..................................................................45

3

Safety

ThismachinemeetsorexceedsANSIB71.4-2004
specicationsineffectatthetimeofproduction.

Preparation

•Whileoperating,alwayswearsubstantialfootwearand

longtrousers.Donotoperatetheequipmentwhen
barefootorwearingopensandals.

Improperuseormaintenancebytheoperatororownercan
resultininjury.Toreducethepotentialforinjury,comply
withthesesafetyinstructionsandalwayspayattentiontothe
safetyalertsymbol,whichmeansCaution,Warning,or
Danger—personalsafetyinstruction.Failuretocomplywith
theinstructionmayresultinpersonalinjuryordeath.

SafeOperatingPractices

ThefollowinginstructionsareadaptedfromANSI
B71.4-2012.

Thisproductiscapableofamputatinghandsandfeetand
throwingobjects.Alwaysfollowallsafetyinstructionsto
avoidseriousinjuryordeath.

Important:Refertothe

Man ual

foradditionalcabsafetyinformation.

Training

•ReadtheOperator'sManualandothertrainingmaterial

carefully.Befamiliarwiththecontrols,safetysigns,and
theproperuseoftheequipment.

•Neverallowchildrenorpeopleunfamiliarwiththese

instructionstousethemachine.Localregulationscan
restricttheageoftheoperator.

•Neveroperatewhilepeople,especiallychildren,orpets

arenearby.

•Keepinmindthattheoperatororuserisresponsiblefor

accidentsorhazardsoccurringtootherpeopleortheir
property.

•Donotcarrypassengers.

•Alldriversshouldseekandobtainprofessionaland

practicalinstruction.Suchinstructionshouldemphasize:

–theneedforcareandconcentrationwhenworking

withride-onmachines;

–controlofaride-onmachineslidingonaslopewill

notberegainedbytheapplicationofthecontrol
levers.Themainreasonsforlossofcontrolare:

R OPS Hard Ca b Operator's

•Thoroughlyinspecttheareawheretheequipmentisto

beusedandremoveallobjectswhichmaybethrownby
themachine.

•Replacefaultysilencers/mufers.

•Beforeusing,alwaysvisuallyinspecttoseethatthe

attachmentsarenotwornordamaged.Replacewornor
damagedcomponents.

SafeHandlingofFuels

•Toavoidpersonalinjuryorpropertydamage,use

extremecareinhandlinggasoline.Gasolineisextremely
ammableandthevaporsareexplosive.

•Extinguishallcigarettes,cigars,pipes,andothersources

ofignition.

•Useonlyanapprovedfuelcontainer.

•Neverremovefuelcaporaddfuelwiththeengine

running.

•Allowenginetocoolbeforerefueling.

•Neverrefuelthemachineindoors.

•Neverstorethemachineorfuelcontainerwherethereis

anopename,spark,orpilotlightsuchasonawater
heateroronotherappliances.

•Neverllcontainersinsideavehicleoronatruckor

trailerbedwithaplasticliner.Alwaysplacecontainerson
thegroundawayfromyourvehiclebeforelling.

•Removeequipmentfromthetruckortrailerandrefuelit

ontheground.Ifthisisnotpossible,thenrefuelsuch
equipmentwithaportablecontainer,ratherthanfroma
fueldispensernozzle.

•Keepthenozzleincontactwiththerimofthefueltank

orcontaineropeningatalltimesuntilfuelingiscomplete.
Donotuseanozzlelockopendevice.

•Iffuelisspilledonclothing,changeclothingimmediately.

•Neveroverllfueltank.Replacefuelcapandtighten

securely.

◊insufcienttrackgrip,especiallyonwetgrass,ice

orsnow;

◊beingdriventoofast;

◊inadequatebraking;

◊thetypeofmachineisunsuitableforitstask;

◊lackofawarenessoftheeffectofground

conditions,especiallyslopes;

◊incorrecthitchingandloaddistribution.

Operation

•Bealert,slowdownandusecautionwhenmakingturns.

Lookbehindandtothesidebeforechangingdirections.

•Engineexhaustcontainscarbonmonoxide,whichisan

odorless,deadlypoisonthatcankillyou.Donotrun
engineindoorsorinanenclosedareawherefumescan
collect.

•Operateonlyindaylightoringoodarticiallight.

4

•Lightningcancausesevereinjuryordeath.Iflightning

isseenorthunderisheardinthearea,donotoperate
themachine;seekshelter.

•Beforeattemptingtostarttheengine,disengageall

attachmentclutchesandplacethecontrolleversinthe
neutral,lockedposition.

•Whenoperatingneardrop-offsorbodiesofwater,donot

useonslopesgreaterthan15degrees.

•Usecarewhenpullingloadsorusingheavyequipment.

–Useonlyapproveddrawbarhitchpoints.
–Limitloadstothoseyoucansafelycontrol.
–Donotturnsharply.Usecarewhenreversing.

•Watchoutfortrafcwhencrossingornearroadways.

•Whenusinganyattachments,neverdirectdischargeof

materialtowardbystandersnorallowanyonenearthe
machinewhileinoperation.Someattachments,suchasa
snowthrower,arecapableofamputatinghandsandfeet
andthrowingobjects

•Neveroperatethemachinewithdamagedguards,shields,

orwithoutsafetyprotectivedevicesinplace.

•Donotchangetheenginegovernorsettingsoroverspeed

theengine.Operatingtheengineatexcessivespeedmay
increasethehazardofpersonalinjury.

•Beforeleavingtheoperatorsposition:

–disengagethepowertakeoffandlowerthe

attachments;
–placeinneutralandsettheparkingbrake;
–stoptheengineandremovethekey.

•Ifanattachmentshouldstarttovibrateabnormally,stop

themachineandcheckimmediatelyforthecause.

•Disengagedrivetoattachments,stoptheengine,setthe

parkingbrakeandremovetheignitionkey:

–beforeclearingblockagesoruncloggingchute;
–beforechecking,cleaningorworkingonthe

attachment
–afterstrikingaforeignobject.Inspecttheattachment

fordamageandmakerepairsbeforerestartingand

operatingtheequipment;
–ifthemachinestartstovibrateabnormally(check

immediately).

•Disengagedrivetoattachmentswhentransporting,notin

useoranytimetheattachmentisintheraisedposition.

•Stoptheengineanddisengagedrivetoattachment:

–beforerefuelling;
–beforemakingheightadjustmentunlessadjustment

canbemadefromtheoperatorsposition.

•UseonlyToroapprovedattachments.

SlopeOperation

•Rememberthereisnosuchthingasasafeslope.Travel

onslopesrequiresparticularcare.Toguardagainst
overturning:

–donotstoporstartsuddenlywhenonaslope;

–useslowspeedsonslopesandduringtightturns;

–stayalertforhumpsandhollowsandotherhidden

hazards;

•Donotoperateneardrop-offs,ditches,steepbanksor

water.Tracksdroppingoveredgescancauserollovers,
whichmayresultinseriousinjury,deathordrowning.

•Donotoperateonslopeswhereslipperyconditions

couldreducetractionandcouldcauseslidingandloss
ofcontrol.

•Donotmakesuddenturnsorrapidspeedchanges.

•Reducespeedanduseextremecautiononslopes.

•Removeormarkobstaclessuchasrocks,treelimbs,etc.

fromtheoperatingarea.Tallgrasscanhideobstacles.

•Watchforditches,holes,rocks,dips,andrisesthatchange

theoperatingangle,asroughterraincouldoverturnthe
machine.

•Avoidsuddenstartswhenoperatinguphillbecausethe

machinemaytipbackwards.

•Donotoperateoniceincapableofsupportingtheweight

ofthismachine.

MaintenanceandStorage

•Keepallnuts,boltsandscrewstighttobesurethe

equipmentisinsafeworkingcondition.

•Neverstoretheequipmentwithfuelinthetankinsidea

buildingwherefumesmayreachanopenameorspark.

•Allowtheenginetocoolbeforestoringinanyenclosure.

•Toreducetherehazard,keeptheengine,

silencer/mufer,batterycompartmentandfuelstorage
areafreeofgrass,leaves,orexcessivegrease.

•Replacewornordamagedpartsforsafety.

•Ifthefueltankhastobedrained,dothisoutdoors.

•Whenmachineistobeparked,storedorleftunattended,

lowertheattachmentunlessapositivemechanicallock
isused.

•UseonlygenuineTororeplacementpartstoensurethat

originalstandardsaremaintained.

Hauling

•Usecarewhenloadingorunloadingthemachineintoa

trailerortruck.

•Usefullwidthrampsforloadingmachineintotraileror

truck.

•Tiethemachinedownsecurelyusingstraps,chains,cable,

orropes.Bothfrontandrearstrapsshouldbedirected
downandoutwardfromthemachine.

5

SafetyandInstructional
Decals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaofpotential
danger.Replaceanydecalthatisdamagedorlost.

110-9772

1.Warning—readtheOperator'sManualbeforeoperatingand
donotoperatethismachineunlessyouaretrained.

2.Crushing/dismembermenthazardofbystanders—donot
carrypassengers,keepbystandersasafedistancefromthe
machine.

3.Warning—donotusedrugsoralcohol.

4.Warning—wearhearingprotection.11.Disengage

5.Tipping,dropoffhazard—donotoperatenearwaterdrop-offs,
stayasafedistancefromdrop-offs,slowmachinebefore
turning,donotturnathighspeeds,wearaseatbeltwhen
aROPSisinplace,donotwearaseatbeltwhenROPSis
lowered.

6.Tostarttheengine:clearanydebrisfromtheattachment,
disengagethePTO,movethemotioncontrolleverstothe
neutralposition,engagetheparkingbrake,turntheignitionto
Runandwaitfortheglowpluglighttoturnoff,turntheignition
keytoStart.

7.ReadtheOperator'sManual.

8.Warning—engagetheparkingbrake,stoptheengineand
removetheignitionkeybeforeleavingthemachine.

9.Cuttinghazardofhandorfoot—removetheignitionkey
andreadtheinstructionsbeforeservicingorperforming
maintenance,keepawayfrommovingparts.

10.Thrownobjecthazard—keepbystandersasafedistancefrom
themachine;keepalldeectorsandshieldsinplace.

12.Engage

13.Parkingbrake

1.Forward

2.Fast4.Neutral6.Backward

3.Slow

110-9774

5.Reverse7.Towvalvelocation;torque
thetowvalvesto6.78±

1.13N⋅m(60±10in-lbs).

8.ReadtheOperator's
Manualformore
informationonthehydraulic
oil.

6

110-9796

1.ReadtheOperator'sManualforinformationonfuses.

110-8253

1.PTO–Off4.Continuousvariable
setting

2.PTO—On5.Slow

3.Fast

110-8254

1.Engine–Stop3.Engine—Start

2.Engine—Run

106-6755

1.Enginecoolantunder
pressure.

2.Explosionhazard—read
theOperator'sManual.

106-9206

1.Wheeltorquespecications

2.ReadtheOperator'sManual.

3.Warning—donottouchthe
hotsurface.

4.Warning—readthe

Operator'sManual.

7

106-9290

1.Inputs5.Inseat

2.Notactive

3.Hightemperatureshutdown

4.Hightemperaturewarning8.Neutral

6.PowerTake-off(PTO)10.PowerTakeOff(PTO)

7.ParkingbrakeOff11.Start

9.Outputs13.Start

12.EnergizetoRun(ETR)

110-9781

1.Warning—readtheOperator'sManual.

2.Poisonandcausticliquid/chemicalburnhazard—keepchildrenasafedistancefromthebattery.

3.Warning—donottouchthehotsurface.

4.Cutting/dismembermenthazard,fanandentanglementhazard,belt—stayawayfrommovingparts.

5.Hydraulicoilinsystemunderpressure,escapinghydraulicoilpenetratingskinhazard,brokenhydrauliclineshazard—wear
protectivehandprotectionwhenhandlinghydraulicsystemcomponents.

14.Power

8

Setup

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescription

1

2

3

Nopartsrequired

Nopartsrequired

MowerDeckorPolarTracKit(sold
separately)

MediaandAdditionalParts

Description

Operator'sManual

EngineOperator'sManual

PartsCatalog

OperatorTrainingMaterials

Enginewarranty1

Qty.

–

–

1

Qty.

1

1

1Usetolookupandorderparts.

1

Readbeforeoperatingthemachine.

Readbeforeoperatingthemachine.

Viewbeforeoperatingthemachine.

Saveforfutureuse.

Use

Checkthehydraulicuid,engineoil,
andcoolantlevels.

Activateandchargethebattery

Installthemowerdeck/PolarTrac.

Use

9

1

CheckingFluidLevels

NoPartsRequired

Procedure

1.Checkthehydraulicuidlevelbeforestartingthe
engine,refertoCheckingtheHydraulicFluidLevelin
HydraulicSystemMaintenance.

2.Checktheengineoillevelbeforeandafterstarting
theengine,refertoCheckingtheEngineOilLevelin
EngineMaintenance.

3.Checkthecoolingsystembeforestartingtheengine;
refertoCheckingtheCoolingSysteminCooling
SystemMaintenance.

2

3.Carefullylleachcellwithelectrolyteuntiltheplates
arecoveredwithabout1/4inch(6mm)ofuid(Figure

4).

Figure4

1.Electrolyte

4.Allowapproximately20to30minutesforthe
electrolytetosoakintotheplates.Rellasnecessaryto
bringtheelectrolytetowithinabout6mm(1/4inch)
ofthebottomofthellwell(Figure4).

ActivatingandChargingthe Battery

NoPartsRequired

Procedure

Useonlyelectrolyte(1.265SpecicGravity)tollbattery
initially.

1.Removethebatteryfromthemachine.

Important:Donotaddelectrolytewhilethe
batteryisinthemachine.Youcouldspillit,
causingcorrosion.

2.Cleanthetopofthebatteryandremovetheventcaps
(Figure3).

WARNING

Chargingthebatteryproducesgassesthatcan
explode.

Neversmokenearthebatteryandkeepsparks
andamesawayfrombattery.

5.Connecta3to4ampbatterychargertothebattery
posts.Chargethebatteryatarateof3to4amps
untilthespecicgravityis1.250orhigherandthe
temperatureisatleast16°C(60°F.)withallcells
gasingfreely.

6.Whenthebatteryischarged,disconnectthecharger
fromtheelectricaloutletandbatteryposts.

Note:Afterthebatteryhasbeenactivated,add
onlydistilledwatertoreplacenormalloss,although
maintenance-freebatteriesshouldnotrequirewater
undernormaloperatingconditions.

WARNING

CALIFORNIA

Proposition65Warning

1.Ventcaps

Figure3

Batteryposts,terminals,andrelated

accessoriescontainleadandleadcompounds,

chemicalsknowntotheStateofCalifornia

tocausecancerandreproductiveharm.

Washhandsafterhandling.

10

WARNING

Batteryterminalsormetaltoolscouldshort
againstmetaltractorcomponentscausing
sparks.Sparkscancausethebatterygassesto
explode,resultinginpersonalinjury.

•Whenremovingorinstallingthebattery,
donotallowthebatteryterminalstotouch
anymetalpartsofthetractor.

•Donotallowmetaltoolstoshortbetween
thebatteryterminalsandmetalpartsof
thetractor.

7.Installthebatteryintothemachineandsecureit.

Important:Thebatterymustnotbeabletomove
orwigglewhenpushed.

8.First,installthepositivecable(red)tothepositive(+)
terminalandthenthenegativecable(black)tothe
negative(-)terminalofthebattery.Slidetherubber
bootoverthepositiveterminaltopreventapossible
shortfromoccurring.

3

InstallingtheMower Deck/PolarTrac

Partsneededforthisprocedure:

1

MowerDeckorPolarTracKit(soldseparately)

InstallingaMowerDeckKit

1.Removethetractionunitfromtheshippingpallet.

2.Placeajackstandundereachwheelmotorandaoor
jackundertherearbumper(
aoverheadhoist.

Figure5),orsuspendfrom

WARNING

Incorrectbatterycableroutingcoulddamage
themachineandcablescausingsparks.
Sparkscancausethebatterygassesto
explode,resultinginpersonalinjury.

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

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

WARNING

Connectingcablestothewrongpostcould
damagetheelectricalsystemandresultin
personalinjury.

Note:Ensurethatthebatterycablesareroutedaway
fromanysharpedgesormovingparts.

Figure5

1.Rearbumper2.Floorjack

3.Installthesummerdrivetires(Figure6)

Figure6

1.Summerdrivetire

4.Rollthesummerdeckandframeintopositionand
installtheve3/4inchbolts,washersandnutsthat
connectthedeckframetotherearframe(Figure7).

11

Removetheliftcylinderpinstogainaccesstothebolts

7

G024845

1

4

5

3

2

6

ontherighthandside.Torquetheboltsto265foot
pounds.

Figure7

1.3mountingbolts(3/4inch),washersandnuts(Leftside)

5.Removethefastenerssecuringtheverticaltubesupport
assembliestotherearofthedeckframe(
totheconversionbrackets(

Figure9).Also,removethe

Figure8)or

conversionbracketsfromthedeckframe,ifapplicable.

Figure9

1.Deckframe5.Selftappingscrew

2.Flangenut6.Verticaltubesupport

3.Conversionbracket(left
sideshown

4.Screw

assembly

7.Selftappingscrew

6.Pivotopentheoorplate(Figure10).

Figure10

1.Floorplate

7.Slidethedriveshaftontothegearboxshaft(Figure11).
Installtherollpinandtorquetheboltsto20-25N-m
(175-225in-lb).

Figure8

1.Deckframe3.Clevispin&screwpin
retainer

2.Verticaltubesupport

12

Figure13

G004634

1

2

3

4

5

1.Deckliftcylinder3.Screw

2.Retainingring

4.Cylinderpin&screw

Figure11

1.Driveshaft

2.Gearbox

3.Bolt

4.Rollpin

8.Routeandconnectthehydraulicpressureandtank
hosestothevalve(Figure12).

Figure12

1.Controlvalve

2.Tankhose

3.Pressurehose

9.Installtherearofthedeckliftcylinderontothepivot
pinandsecurewiththeretainingring(Figure13).

10.Securethefrontoftheliftcylindertothemowerframe
withthecylinderpinandscrew(Figure13).

11.PositiontheROPSassemblyontotheROPSposts.
Installthebolt,nut,hairpincotterandpinsecuring
eachROPSassemblytotheROPSposts(Figure14).

Note:Ifinstallinganalliedsuppliersmowerdeck,
ROPSKit,partno.117–9179mustbeinstalled.

Figure14

1.ROPS4.Bolt&nut

2.Pin

3.Cotterpin

5.ROPSpost

12.Startthemachine,raiseandlowerthedeck.Checkfor
leaksandmakesurethehosesdonotrubagainstthe
frame.

InstallingthePolarTracKit

1.Removethetractionunitfromtheshippingpallet.

2.Placeajackstandundereachwheelmotorandaoor
jackundertherearbumper(Figure15)orsuspend
fromaoverheadhoist.

13

Figure15

1.Rearbumper2.Floorjack

1.Driveshaft

Figure17

2.Frametube

3.Removethetwoscrewssecuringthewinterframeoor
platecovertotheoorandremovetheplate(Figure

16).

Figure16

1.Floorplatecover2.Mountingscrews

4.Carefullyrollthewinterframeassemblyintoposition
whileroutingthedriveshaftthroughtheframetube
(Figure17).

Note:Iftherearofthecabisnothighenoughtoclear
thecontrolhandles,evenlytightenthejackingbolts
oneachsideofthecabjacktubetoraisetherearof
thecab(Figure18).

Figure18

1.Jackingbolts

5.Routethehosesasfollows:

•Routethetankhoseundertheliftcylinderand

betweenthecylindermountingbracketstothe
valve(Figure19).

•RoutethepressurehosealongsidethePTOshaft

tothevalve(

Note:Toemphasisthehoserouting,thehosesare
shownwithoutthehosecoversinstalled.

14

Figure19).

Figure19

1.Tankhose2.Pressurehose

6.Connectthedriveshafttothegearboxshaftinthe
winterframeandtorquethebolts(5/16inch)to20to
25N-m(175-225in-lb).Installtherollpin(Figure20).

Figure21

1.Couplerpin

8.Adjusttheoorjackorrockthecabwithyourhands
asrequiredtoinstallthebolts(3/4inch)oneachside
(Figure22).Torquetheboltsto359N-m(265ft-lb).

Figure22

1.3/4inchbolts2.Couplerpin

Figure20

1.Pressurehose

2.Tankhose5.Bolts

3.Hosecover6.Rollpin

4.Cabletie

7.Adjusttheoorjacktolineupthe1.00inchholesinthe
frameandinstallacouplerpinoneachside(

Figure21).

Note:Thereartireswillneedtoberemovedtotorque
therearbolts(3/4inch).Aftertorquingtheframe
bolts,installthereartiresandtorquelugnutsto88to
115N-m(65to85ft-lb).

9.Insertarubbermountontoeachcabmountattherear
mountinglocations(Figure23).

15

Figure25

Figure23

1.Cabmount

2.Rubbermount

10.Lowerthecabintopositionbyslowlyandevenly
looseningthejackingboltsoneachendofthejacking
tube(Figure24).

1.Rubbermount

2.2.2cm(0.875inch)

12.Tightentheboltsandnutssecuringtherearcabmounts
totheROPSposts(Figure26).Adjusttheoorjackif
theboltsarebindinganddifculttoremove.

Figure26

Figure24

1.Jackingbolts

2.Cabjacktube

11.Attherearmountingpoints,securethecabtothe
machinewithabolt(1/2x3inches),steelwasher(1/2
x2–1/2inches),rubberwasher(1/2x2–1/2inches)
andnut(1/2inch)(Figure25).Tightenallfourcab
mountboltsuntiltherubbermountsarecompressed
toathicknessof2.2cm(7/8inch).

1.Cabmount3.Bolts&nuts

2.ROPSpost4.ROPSpost

13.Loosenthejackingboltsandremovethecabjacktube
fromthecutoutsinthecaboor(Figure27).

16

Figure27

G009488

1

2

1.Jackingbolts

2.Cabjacktube

14.Connectthehydraulicpressurehosetothevalvehard
lineandthetankhosetothevalve(Figure28).Retain
thehoseplugsforthesummerchangeover.

Note:Makesurethehosesarenotekinkedorare
rubbingagainstanymovingparts.

Note:Adjusttheangleofthettingstoaccommodate
theroutingofthehoses.

Figure29

1.Washer&nutonthebogiepivotstud

18.Raisetheoorjackuntilthefronttiresareoffofthe
groundhighenoughtoinstallthetrackbeneaththem
andsupporttheframewithjackstands.

19.Removethefrontandcentertiresfromthewinter
assembly(Figure30).

Figure30

1.Fronttire

20.Carefullyliftthetracksovertherearwheelandfront
hubs.Thedirectionofthetrackrotationisprintedon

Figure28

1.Pressurehose2.Tankhose

15.Raisetherearofthemachineuntil2jackstandscanbe
positionedunderthereartubeataheightthatsupports
thereartires2.5to7.5cm(1to3inches)offofthe
ground.

16.Lowertheoorjacksotherearframerestsonthejack

thetrack.TheVdesignintherubbertrackmustpoint
forward.

CAUTION

Thetrackguideshavemanypinchpoints.
Carefullygrasptherubbertrackontheouter
edgesoutboardofthesteelguideswhen
movingthetrack.

stands.Positiontheoorjackunderthecenterofthe
frontliftarmpivottube.

17.Removetheatwasher(1/2inch)andnut(1/2inch)
installedonthestudonthebogiepivot(

Figure29).

21.Adjusttheoorjacktoasuitableheighttoinstallthe
fronttire.Withahelper,liftthefrontofthetrack
enoughtocarefullyinstallthefronttires(

Figure31).

17

Figure31

22.Adjusttheoorjacktoasuitableheighttoinstallthe
centertire.Liftthecenterofthetrackenoughtoinstall
thecentertire.T orquethelugnutsto88to115N-m
(65to85ft-lb).

Figure32

23.Lowertheoorjackuntilthefrontwheelssupportthe
frame.Installtheatwashers(1/2inch)andlocknuts
onthebogiepivotstud(Figure29)andtorqueto102
N-m(75ft-lb).

Figure33

1.Accesscovers

25.Installthewinterframeoorplatecovertotheoor
withthescrewspreviouslyremoved(Figure34).

Note:Youmayneedtomovetheoorjacktotherear
bumpertoraisetherearofthemachinehighenoughto
installtheatwasherandlocknut.

24.Installthesideaccesscoverswiththescrewspreviously
removed(Figure33).

Figure34

1.Floorplatecover2.Mountingscrews

26.Connectthecabpressureandreturnhosestothequick
couplersontherearframemount(

18

Figure35).

Figure35

ProductOverview

Controls

Becomefamiliarwithallthecontrolsbeforeyoustartthe
engineandoperatethemachine(Figure37).

1.Pressurehose2.Returnhose

27.Removethecapandplugthecabwireharness
connectorintotheharnessontherearframemount
(Figure36).

Figure36

1.Cabwireharness
connector

2.Harnessconnectoronthe
rearframemount

Figure37

TractorControlPanel

1.Ignitionswitch

2.Enginecoolant
temperaturewarning
light

3.Glowpluglight

4.Powertakeoff(PTO)
Switch

5.Oilpressurewarninglight

6.Chargeindicatorlight

7.Throttlelever

8.Hourmeter

MotionControlLevers

Themotioncontrolleverscontroltheforwardandrearward
motionsaswellastheturningofthemachine.

ParkingBrakeLever

Whenevertheengineisshutoff,engagetheparkingbraketo
preventaccidentalmovementofthemachine.Toengagethe
parkingbrake,pulltheparkingbrakeleverrearwardandup
(Figure38).T oreleasetheparkingbrake,pushtheparking
brakeleverforwardanddown.

28.Startthemachine.Runtheliftarmupanddownand
checkforhydraulicleaks.Checktheantifreezelevel
andreplenishasrequired.

19

1.Parkingbrakelever

continuetorun.Ifthemachineisnotstoppedandthe
coolanttemperaturerisesanother20°F ,theenginewillstop.

Important:Iftheattachmentshutsdownandthe
temperaturewarninglightison,pushPTOknobdown,
drivetoasafeatarea,movethethrottlelevertothe
Slowposition,movethemotioncontrolleversintothe
neutrallockedposition,andengagetheparkingbrake.
Allowtheenginetoidleforseveralminuteswhileitcools
toasafelevel.Stoptheengineandcheckthecooling
system;refertoCheckingtheCoolingSysteminCooling
SystemMaintenance.

Figure38

ChargeIndicator

Illuminateswhenthesystemchargingcircuitmalfunctions.

CAUTION

Donotparkthemachineonaslope.

IgnitionSwitch

Theignitionswitchhasthreepositions:Off,On/Preheat,
andStart.

ThrottleLever

Thethrottlelevercontrolsthespeedoftheengine.Moving
thethrottleleverforwardtowardtheFastpositionincreases
theenginespeed.MovingitrearwardtowardtheSlow
positiondecreasestheenginespeed.Thethrottle,in
conjunctionwithmotioncontrollevers,controlsground
speedofthemachine.Alwaysrunthemachinewiththe
throttleintheFastpositionwhenusingattachments.

PowerTakeOff(PTO)Switch

Thepowertakeoff(PTO)switchstartsandstopspowered
attachments.

HourMeter

OilPressureWarningLight

Theoilpressurewarninglightglowswhentheoilpressurein
theenginedropsbelowasafelevel.Iflowoilpressureever
occurs,stoptheengineanddeterminethecause.Repairthe
damagebeforestartingtheengineagain.

FuelGauge

Thefuelgauge(Figure39)indicatesthequantityoffuel
remaininginthefueltanks.

Thehourmeterrecordsthenumberofhourstheengine
hasoperated.ItoperateswhenthekeyswitchisintheRun
position.Usethesetimesforschedulingregularmaintenance.

GlowPlugLight(OrangeLight)

Theglowplugindicatorlightturnsonwhentheignition
switchisturnedtotheOnposition.Itremainslitfor6
seconds.Whenthelightturnsoff,theengineisreadytobe
started.

EngineCoolantTemperatureWarning
Light

Thislightglowsandthepoweredattachmentswillstopif
theenginecoolanttemperatureishigh.Buttheenginewill

Figure39

1.Fuelgauge

20

Operation

Note:Determinetheleftandrightsidesofthemachine

fromthenormaloperatingposition.

DANGER

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

AddingFuel

Theenginerunsonclean,freshdieselfuelwithaminimum
octaneratingof40.Purchasefuelinquantitiesthatcanbe
usedwithin30daystoensurefuelfreshness.

Combinedtankcapacity:43.5liters(11.5USgallons)

Usesummergradedieselfuel(No.2-D)attemperatures
above-7°C(20°F)andwintergradedieselfuel(No.1-Dor
No.1-D/2-Dblend)below-7°C(20°F).Useofwintergrade
dieselfuelatlowertemperaturesprovideslowerashpoint
andpourpointcharacteristics,thereforeeasingstartingand
lesseningchancesofchemicalseparationofthefueldueto
lowertemperatures(waxappearance,whichmaypluglters).

Useofsummergradedieselfuelabove-7°C(20°F)will
contributetowardlongerlifeofthepumpcomponents.

Important:Donotusekeroseneorgasolineinsteadof
dieselfuel.Failuretoobservethiscautionwilldamage
theengine.

WARNING

Fuelisharmfulorfatalifswallowed.Long-term
exposuretovaporscancauseseriousinjuryand
illness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgastankor
conditioneropening.

•Keepfuelawayfromeyesandskin.

BiodieselReady

Thismachinecanalsouseabiodieselblendedfuelofup
toB20(20%biodiesel,80%petrodiesel).Thepetrodiesel
portionshouldbeloworultralowsulfur.Observethe
followingprecautions:

•Thebiodieselportionofthefuelmustmeetspecication

ASTMD6751orEN14214.

•TheblendedfuelcompositionshouldmeetASTMD975

orEN590.

•Paintedsurfacesmaybedamagedbybiodieselblends.

•UseB5(biodieselcontentof5%)orlesserblendsincold

weather.

•Monitorseals,hoses,gasketsincontactwithfuelasthey

maybedegradedovertime.

•Fuellterpluggingmaybeexpectedforatimeafter

convertingtobiodieselblended.

•Contactyourdistributorifyouwishformoreinformation

onbiodiesel.

•Fillthefueltankoutdoors,inanopenarea,when
theengineiscold.Wipeupanyfuelthatspills.

•Neverllthefueltankinsideanenclosedtrailer.

•Neversmokewhenhandlingfuel,andstayaway
fromanopenameorwherefuelfumesmaybe
ignitedbyaspark.

•Storefuelinanapprovedcontainerandkeepit
outofthereachofchildren.Neverbuymore
thana30-daysupplyoffuel.

•Donotoperatewithoutentireexhaustsystemin
placeandinproperworkingcondition.

DANGER

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

•Alwaysplacefuelcontainersonthegroundaway
fromyourvehiclebeforelling.

•Donotllfuelcontainersinsideavehicleoron
atruckortrailerbedbecauseinteriorcarpets
orplastictruckbedlinersmayinsulatethe
containerandslowthelossofanystaticcharge.

•Whenpractical,removeequipmentfromthe
truckortrailerandrefueltheequipmentwithits
wheelsontheground.

•Ifthisisnotpossible,thenrefuelsuch
equipmentonatruckortrailerfromaportable
container,ratherthanfromafueldispenser
nozzle.

•Ifafueldispensernozzlemustbeused,keepthe
nozzleincontactwiththerimofthefueltank
orcontaineropeningatalltimesuntilfuelingis
complete.

FillingtheFuelTank

1.Parkthemachineonalevelsurface.

Important:Thefueltanksareconnected,butthe
fueldoesnottransferquicklyfromonetanktothe
other.Itisimportantwhenllingthatyoupark
onalevelsurface.Ifyouparkonahill,youmay
inadvertentlyoverllthetanks.

2.Shuttheengineoffandsettheparkingbrake.

21

3.Cleanaroundeachfueltankcapandremovethecap.

Important:Donotopenthefueltankswhen
parkedonahill.Thefuelcouldspillout.

4.Addfueltobothfueltanks,untilthelevelisevenwith
thebottomofthellerneck(Figure40).Donotover

llthefueltanks.

DANGER

Operatingonicyorsteepslopescancausesliding
andlossofcontrol.

Atrackdroppingoveranedgecancausearollover,
whichmayresultinseriousinjury,death,or
drowning.

Alwaysusetheseatbelt.

Readandfollowtherolloverprotectioninstructions
andwarnings.

Toavoidlossofcontrolandpossibilityofrollover:

•Donotoperateneardrop-offsornearwater.

Figure40

1.Bottomofthellerneck

5.Installthefueltankcapssecurely.Wipeupanyfuel
thatmayhavespilled.

Note:Ifpossible,llthefueltanksaftereachuse.This
willminimizepossiblebuildupofcondensationinsidethe
fueltank.

CheckingtheEngineOilLevel

Beforeyoustarttheengineandusethemachine,checktheoil
levelintheenginecrankcase;refertoCheckingOilLevelin
EngineMaintenance.

CheckingtheCoolingSystem

Beforeyoustarttheengineandusethemachine,checkthe
coolingsystem;refertoCheckingtheCoolingSystemin
CoolingSystemMaintenance.

•Reducespeedanduseextremecautionon
slopes.

•Avoidsuddenturnsorrapidspeedchanges.

Figure41

1.SafeZone3.Water/unsafeice

2.Usewalkbehind
equipmentneardrop-offs
andwater.

CheckingtheHydraulic System

Beforeyoustarttheengineandusethemachine,checkthe
hydraulicsystem;refertoCheckingtheHydraulicSystemin
HydraulicSystemMaintenance.

ThinkSafetyFirst

Pleasereadallsafetyinstructionsandsymbolsinthesafety
section.Knowingthisinformationcouldhelpyouor
bystandersavoidinjury.

CAUTION

Thismachineproducessoundlevelsinexcessof
85dBAattheoperatorsearandcancausehearing
lossthroughextendedperiodsofexposure.

Wearhearingprotectionwhenoperatingthis
machine.

Theuseofprotectiveequipmentforeyes,ears,feet,andhead
isrecommended.

22

OperatingtheParkingBrake

Alwayssettheparkingbrakewhenyoustopthemachineor
leaveitunattended.

SettingtheParkingBrake

1.Movethemotioncontrollevers(Figure46)outtothe
neutrallockedposition.

2.Pullupandbackontheparkingbrakelevertosetthe
parkingbrake(Figure42).Theparkingbrakelever
shouldstayrmlyintheengagedposition.

StartingtheEngine

1.Sitontheseatandfastentheseatbelt.

2.Ensurethatthemotioncontrolsareintheneutral
lockedposition.

3.Settheparkingbrake;refertoSettingtheParking
Brake.

4.MovethePTO(powertakeoff)switchtotheoff
position(

Figure44).

Figure44

Figure42

1.Parkingbrakelever

WARNING

Theparkingbrakemaynotholdthemachine
parkedonaslopeandcouldcausepersonal
injuryorpropertydamage.

Donotparkonslopesunlessthetracksare
chockedorblocked

ReleasingtheParkingBrake

Pushforwardanddownontheparkingbrakelevertorelease
theparkingbrake(Figure42).

1.Ignitionswitch

2.Throttlecontrol

5.MovethethrottlelevermidwaybetweentheFastand
Slowpositions(Figure44).

6.TurntheignitionkeyclockwisetotheRunposition
(Figure45).

Theglowpluglightwillturnonfor6seconds.

1.Ignitionswitch

2.Off4.Start

7.Aftertheglowplugindicatorlightgoesout,turnthe
keytotheStartposition.Whentheenginestarts
releasethekey.

3.Glowpluglight

4.Powertakeoffswitch
(PTO)

Figure45

3.Run/glowpug

1.Parkingbrakelever

Important:Usestartingcyclesofnomorethan
15secondsperminutetoavoidoverheatingthe
startermotor.

Figure43

Note:Additionalstartingcyclesmayberequired

whenstartingtheengineforthersttimeafterthefuel
systemhasbeencompletelydrained.

23

8.LeavethethrottlemidwaybetweentheSlowandFast
positionsuntiltheengineandhydraulicsystemwarm
up.

CAUTION

Shuttheengineoffandwaitforallmoving
partstostopbeforecheckingforoilleaks,
looseparts,orothermalfunctions.

DrivingtheMachine

Thethrottlecontrolregulatestheenginespeedasmeasured
inrpm(revolutionsperminute).Placethethrottlecontrolin
theFastpositionforbestperformance.Alwaysoperateinthe
Fastthrottlepositionwhenrunningpoweredattachments.

CAUTION

Themachinecanturnveryrapidly.Youmaylose
controlofitandcausepersonalinjuryordamage
tomachine.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemakingsharp
turns.

1.Releasetheparkingbrake.

Note:Theenginewillkillifthetractioncontrollevers
aremovedoutoftheNeutral-Lockedpositionwith
theparkingbrakeengaged.

2.Movetheleverstothecenter,un-lockedposition.

3.Drivethemachineasfollows:

•Togostraightforward,slowlypushthemotion

controlleversforward(

Figure46).

•Togostraightrearward,slowlypullthemotion

controlleversrearward(Figure46).

•Toturn,slowthemachinebypullingbackonboth

leversandthenpushforwardontheleveronthe
oppositesidefromwhichyouwanttoturn(Figure

46).

•Tostop,pullthemotioncontrolleverstothe

neutralposition.

Note:Thefartheryoumovethetractioncontrol
leversineitherdirection,thefasterthemachinewill
moveinthatdirection.

Figure46

1.Motioncontrol
lever-neutrallocked
position

2.Centerun-lockposition

3.Forward

4.Backward

StoppingtheMachine/Engine

1.Movethetractioncontrolleverstoneutralandtothe
lockedposition.

2.DisengagethePTO,settheparkingbrake,andmove
thethrottlelevertotheSlowposition.

3.Lettheengineidlefor60seconds.

4.TurntheignitionkeytotheOffposition(Figure45).
Waitforallmovingpartstostopbeforeleavingthe
operatingposition.

5.Removethekeybeforetransportingorstoringmachine.

Important:Makesuretoremovethekeyasthe
fuelpumporaccessoriesmayrunandcausethe
batterytolosecharge.

CAUTION

Childrenorbystandersmaybeinjuredifthey
moveorattempttooperatethemachinewhile
itisunattended.

Alwaysremovetheignitionkeyandsetthe
parkingbrakewhenleavingthemachine
unattended,evenifjustforafewminutes.

24

TheSafetyInterlockSystem

CAUTION

Ifthesafetyinterlockswitchesaredisconnectedor
damagedthemachinecouldoperateunexpectedly
causingpersonalinjury.

•Donottamperwiththeinterlockswitches.

•Checktheoperationoftheinterlockswitches
dailyandreplaceanydamagedswitchesbefore
operatingthemachine.

UnderstandingtheSafetyInterlock
System

Thesafetyinterlocksystemisdesignedtopreventtheengine
fromstartingunless:

•Youaresittingontheseatortheparkingbrakeisengaged.

•Thepowertakeoff(PTO)isdisengaged.

•Themotioncontrolleversareintheneutrallocked

position

Nowstarttheengine.Whiletheengineisrunning,
centereithermotioncontrol;theengineshouldstop
within2seconds.Repeatfortheothermotioncontrol.

5.Withoutanoperatorontheseat,disengagetheparking
brake,movethePTOswitchtooff,andmovethe
motioncontrolleverstotheneutrallockedposition.
Trystartingtheengine;theengineshouldnotcrank.

UsingtheSCMtoDiagnoseSystem
Problems

Themachineisequippedwithastandardcontrolmodule
(SCM)monitoringsystemthattracksthefunctionofvarious
keysystems.TheSCMislocatedundertherightcontrol
panel.Accessitthroughthesidepanelcover(Figure47).Tip
theseatupandopenthesidepanelcoverbyreleasingthe2
latchesandpullingoutonit.

•Theenginetemperatureisbelowthemaximumoperating

temperature.

Thesafetyinterlocksystemalsoisdesignedtostoptheengine
whenthetractioncontrolsaremovedfromtheneutrallocked
positionwiththeparkingbrakeengaged.Ifyourisefromthe
seatwhenthePTOisengagedthereisa1seconddelayand
thentheenginestops.

TestingtheSafetyInterlockSystem

ServiceInterval:Beforeeachuseordaily

Testthesafetyinterlocksystembeforeyouusethemachine
eachtime.Ifthesafetysystemdoesnotoperateasdescribed
below,haveanAuthorizedServiceDealerrepairthesafety
systemimmediately.

1.Sittingontheseat,engagetheparkingbrakeandmove
thePTOtoon.Trystartingtheengine;theengine
shouldnotcrank.

2.Sittingontheseat,engagetheparkingbrakeandmove
thePTOtooff.Moveeithermotioncontrollever(out
ofneutrallockedposition).Trystartingtheengine;the
engineshouldnotcrank.Repeatforothercontrollever.

Figure47

1.Sidepanelcover

OnthefaceoftheSCMare11LEDsthatilluminateto
indicatevarioussystemconditions.Sevenoftheselightscan
beusedbytheoperatorforsystemdiagnosis.RefertoFigure
48foradescriptionofwhateachlightmeans.Fordetails
onusingtherestoftheSCMfunctions,refertotheService
Manual,availablethroughyourAuthorizedToroDistributor.

2.Latches

3.Sittingontheseat,engagetheparkingbrake,movethe
PTOswitchtooffandmovethemotioncontrollevers
totheneutrallockedposition.Nowstarttheengine.
Whiletheengineisrunning,releasetheparkingbrake,
engagethePTOandriseslightlyfromtheseat;the
engineshouldstopwithin2seconds.

4.Withoutanoperatorontheseat,engagetheparking
brake,movethePTOswitchtooffandmovethe
motioncontrolleverstotheneutrallockedposition.

25

Figure48

G006855

1234

1.Hightemperatureshutdown—theenginetemperaturehas
exceededsafelevelsandtheenginehasbeenshutdown.
Checkthecoolingsystem.

2.Hightemperaturewarning—theenginetemperatureis
approachingunsafelevelsandthePTOhasbeenshut
down.Checkthecoolingsystem.

3.Operatorisintheseat

4.ThePTOisOn

5.Theparkingbrakeisnotengaged

6.ControlsareinNeutral

7.TheSCMisreceivingpowerandisoperational

PositioningtheSeat

Figure49

1.Backrestknob3.Lumbarsupport
adjustmentknob

2.Seatsuspensionknob4.Seatpositionadjustment
lever

2.Slidetheseattothedesiredpositionandreleaselever
tolockinposition.

3.Verifythattheseathaslockedintoplacebyattempting
tomoveitbackandforth.

ChangingtheSeatPosition

Theseatcanmoveforwardandbackward.Positiontheseat
whereyouhavethebestcontrolofthemachineandaremost
comfortable.

1.Toadjust,movetheleversidewaystounlocktheseat
(Figure49).

ChangingtheSeatSuspension

Theseatcanbeadjustedtoprovideasmoothandcomfortable
ride.Positiontheseatwhereyouaremostcomfortable.

Withoutsittingontheseat,turntheknobinfronteither
directiontoprovidethebestcomfort(Figure49).

Figure50

1.Seatsuspensionknob2.Operatorweightsetting

ChangingtheBackPosition

Thebackoftheseatcanbeadjustedtoprovideacomfortable
ride.Positionthebackoftheseatwhereitismost
comfortable.

Toadjustit,turntheknob,undertheright-sidearmrest,in
eitherdirectiontoprovidethebestcomfort(

26

Figure49).

ChangingtheLumbarSupport

1

G025178

Thebackoftheseatcanbeadjustedtoprovideacustomized
lumbarsupportforyourlowerback.

Toadjustit,turntheknobundertheleft-sidearmrest,in
eitherdirectiontoprovidethebestcomfort(Figure49).

UnlatchingtheSeat

Toaccessthehydraulicandothersystemsundertheseat,you
needtounlatchtheseatandswingitforward.

1.Usetheseatpositionadjustmentlevertoslidetheseat
allthewayforward.

2.Liftupontheseatlatchlevertounlatchandpivotthe
seatforward(

Figure51).

2.Lifttheseat.

3.Rotatebothby-passvalvescounterclockwise2turns
(

Figure52).

Thisallowshydraulicuidtoby-passthepump
enablingthetrackstoturn.

Important:Donotrotatetheby-passvalvesmore
than2.5turns.Thispreventsvalvesfromcoming
outofthebodyandcausinguidtorunout.

Figure51

1.Seatlatch

MovingaNon-functioning Machine

Ifthemachinebreaksdown,runsoutoffuel,etc.youmay
needtopullitwithawinchtoloaditontoatrailer.Todoso,
yourstneedtoopenthehydraulicby-passvalves.

Important:Nevertowthemachinebecausehydraulic
damagemayoccur.

Figure52

1.Rightby-passvalve

4.Disengagetheparkingbrakebeforemovingthe
machine.

2.Leftby-passvalve

ChangingtoMachineOperation

Rotateeachby-passvalveclockwiseandhandtightenthem
(torqueofapproximately8N-m(71in-lb))(Figure52).

Note:Donotovertightentheby-passvalves.

Themachinewillnotdriveunlessby-passvalvesareturnedin.

LoadingMachines

Useextremecautionwhenloadingunitsontrailersortrucks.
Onefullwidthrampthatiswideenoughtoextendbeyond
theendofthetracksisrecommendedinsteadofindividual
rampsforeachsideoftheunit(
sectionofthemachineframeextendsbackbetweentherear
wheelsandservesasastopfortippingbackward.Havinga
fullwidthrampprovidesasurfacefortheframemembersto
contactiftheunitstartstotipbackward.Ifitisnotpossible
touseonefullwidthramp,useenoughindividualrampsto
simulateafullwidthcontinuousramp.

Figure53).Thelowerrear

MovingtheMachine

1.Disengagethepowertakeoff(PTO)andturnthe
ignitionkeytooff.Movetheleverstotheneutral
lockedpositionandapplytheparkingbrake.Remove
thekey.

Therampshouldbelongenoughsothattheanglesdonot
exceed15degrees(
attachmentcomponentstogetcaughtastheunitmovesfrom
ramptotrailerortruck.Steeperanglesmayalsocausethe
unittotipbackward.Ifloadingonornearaslope,position
thetrailerortrucksoitisonthedownsideoftheslopeand

27

Figure53).Asteeperanglemaycause

therampextendsuptheslope.Thiswillminimizetheramp
angle.Thetrailerortruckshouldbeaslevelaspossible.

Important:Donotattempttoturntheunitwhileon
theramp;youmaylosecontrolanddriveofftheside,or
thetracksmaycomeoff.

Ensurethatthetrailerortruckhasallnecessarylightingand
markingasrequiredbylaw.Pleasecarefullyreadallthesafety
instructions.Knowingthisinformationcouldhelpyouor
bystandersavoidinjury.

Totransportthemachine:

Avoidsuddenaccelerationwhendrivinguparampand
suddendecelerationwhenbackingdownaramp.Both
maneuverscancausetheunittotipbackward.

WARNING

Loadingaunitontoatrailerortruckincreasesthe
possibilityofbackwardtip-overandcouldcause
seriousinjuryordeath.

•Useextremecautionwhenoperatingauniton
aramp.

•Useonlyasingle,fullwidthramp;Donotuse
individualrampsforeachsideoftheunit.

•Ifindividualrampsmustbeused,useenough
rampstocreateanunbrokenrampsurfacewider
thantheunit.

•Donotexceeda15degreeanglebetweenramp
andgroundorbetweenrampandtrailerortruck.

•Avoidsuddenaccelerationwhiledrivingunitup
aramptoavoidtippingbackward.

•Avoidsuddendecelerationwhilebackingunit
downaramptoavoidtippingbackward.

•Ensurethatyourvehicle,hitch,safetychains,andtrailer

areadequatefortheloadyouarepullingandthatthey
meetalllocaltrafcregulationsforyourarea.

•Lockthebrakeandblockthetracks/tires.

•Securelyfastenthemachinetothetrailerortruckwith

straps,chains,cable,orropesasrequiredbylocaltrafc
regulationsinyourarea(Figure54).

Figure53

1.Trailer3.Notgreaterthan
15degrees

2.Fullwidthramp4.Fullwidthramp—sideview

TransportingtheMachine

Useaheavy-dutytrailerortrucktotransportthemachine.
Alwaystransport(trailer)themachinefacingforward.

Figure54

1.Fronttie-downs

2.Reartie-down(leftside
shown)

OperatingFrontAttachments withthePolarTracKitInstalled

ChangingtheAttachmentOrientation

Usetheattachmentcontrolpedals(Figure55)tocontrolthe
physicalorientationoftheattachment.Usetheleftpedalto
raiseandlowertheattachment.Usetherightpedaltoswing
theattachmenttotherightorleft.

Note:Therightpedalisnotusedonallattachments.Also,
onsnowthrowers,onlythechuteswingsrightandleft.

28

Figure55

5.Iftheattachmentispoweredbyhydraulics,connect
thehydrauliccouplerontheattachmenttothoseon
thefrontliftarm.

Important:Ensurethatthecouplersareclean
beforeconnectingthemtopreventhydraulic
systemcontamination.

6.IftheattachmentispoweredbythePTO ,extendthe
attachmentPTOshaftandinsertitontothemachine
PTOshaft(Figure57).

1.Presstolowerthe
attachment/liftarm

2.Presstoswingthe
attachmenttotheleft

3.Presstoraisethe
attachment/liftarm

4.Presstoswingthe
attachmenttotheright

Important:Donotcontinuetoholdapedalafterthe
attachmenthasnishedmoving.Doingsowilldamage
thehydraulicsystem.

Connecting/Disconnectingan
Attachment

ReadtheOperator'sManualsuppliedwiththeattachment
beforeoperating.

1.Lowerthefrontliftarm.

2.Drivethemachineintopositionbehindtheattachment
adapter.

3.Raisethemachineadapterontheliftarmintothe
attachmentadapter.

4.Securetheadapterstogetherwiththeattachmentpin
andhairpincotterasshownin

Figure56.

Figure57

1.PTOshaft

Note:Toremoveanattachment,performtheabovesteps
inreverse.

EngagingthePowerTakeOff(PTO)

Thepowertakeoff(PTO)switchstartsandstopspowered
attachments.

1.Iftheengineiscold,allowtheenginetowarmup5to
10minutesbeforeengagingthePTO.

2.Whileseatedintheseat,releasethepressureonthe
tractioncontrolleversandplacetheminneutral.

1.Attachmentpin

Figure56

2.Cotterpin

3.PulluponthePTOswitchtoengageit(

Figure58

1.PTOswitch

DisengagingthePTO

Todisengage,pushthePTOswitchtotheoffposition.

29

Figure58).

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

Important:Engineoil,batteries,hydraulicoil,andenginecoolantarepollutantstotheenvironment.Disposeof

theseaccordingtoyourstateandlocalregulations.

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst10hours

Aftertherst50hours

Aftertherst200hours

Beforeeachuseordaily

Every50hours

Every150hours

Every200hours

Every400hours

MaintenanceProcedure

•Checkthealternatorbelttension.

•Torquethewheellugnuts.

•Changetheengineoilandlter.

•Changethehydraulicoilandlter.

•Testthesafetysystem.

•Checktheengineoillevel.

•Checktheenginecoolantlevel.

•Cleantheradiatorwithcompressedair(donotusewater)

•Checkthehydraulicuidlevel.

•Greasethebearingandbushinggreasettings.(Greasemorefrequentlywhen
operatingconditionsareextremelydustyorsandy.)

•Checkbatterycableconnections.

•Changetheengineoilandlter.

•Inspectcoolingsystemhosesandseals.Replacethemifcrackedortorn.

•Checkthealternatorbelttension.

•Torquethewheellugnuts.

•Servicetheaircleaner.

•Replacethefuelltercanister.

•Checkthefuellinesandconnections.

Every800hours

Every1,500hours

Every2years

Important:Refertoyour

•Changethehydraulicoilandlter.

•Inspectenginevalveclearance.RefertoyourEngineOperator'sManual.

•Replacemovinghoses

•Drainandcleanthefueltank.

•Flushandreplacecoolingsystemuid.

Engine Operator's Man ual

foradditionalmaintenanceprocedures.AdetailedService

ManualisalsoavailableforpurchasefromyourAuthorizedToroDistributor.

Note:LookingforanElectricalSchematicorHydraulicSchematicforyourmachine?Downloadafreecopyoftheschematicby
visitingwww .T oro.comandsearchingforyourmachinefromtheManualslinkonthehomepage.

30

DailyMaintenanceChecklist

Duplicatethispageforroutineuse.

Fortheweekof: MaintenanceCheckItem

Mon.Tues.Wed.Thurs.Fri.

CheckSafetyInterlock
Operation

CheckParkingBrake
Operation

CheckFuelLevel

CheckHydraulicOilLevel

CheckEngineOilLevel

CheckCoolingSystemFluid
Level

CheckDrainWater/Fuel
Separator

CheckAirFilterRestriction
Indicator

CheckRadiator&Screenfor
Debris

CheckUnusualEngine
Noises

CheckUnusualOperating
Noises

CheckHydraulicHosesfor
Damage

CheckFluidLeaks

CheckTirePressure

CheckInstrumentOperation

LubricateAllGreaseFittings

Touch-upDamagedPaint

1.Checkglowplugandinjectornozzles,ifhardstarting,excesssmokeorroughrunningisnoted.

3

1

2

Sat.Sun.

2.Immediatelyaftereverywashing,regardlessoftheintervallisted.

3.Ifindicatorshowsred

NotationforAreasofConcern

Inspectionperformedby:

ItemDate

Information

CAUTION

Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineandseriouslyinjure
youorotherbystanders.

Removethekeyfromtheignitionbeforeyoudoanymaintenance.

31

Premaintenance
Procedures

Important:Thefastenersonthecoversofthismachine
aredesignedtoremainonthecoverafterremoval.
Loosenallofthefastenersoneachcoverafewturnsso
thatthecoverisloosebutstillattached,thengoback
andloosenthemuntilthecovercomesfree.Thiswill
preventyoufromaccidentallystrippingtheboltsfree
oftheretainers.

Lubrication

GreasingtheBearingsand Bushings

ServiceInterval:Every50hours(Greasemorefrequently

whenoperatingconditionsareextremely
dustyorsandy.)

GreaseType:No.2GeneralPurposeLithiumBaseGrease.

Important:Lubricatethegreasettingsimmediately
aftereverywashing,regardlessofintervalspecied.
Bearinglifecanbenegativelyaffectedbyimproperwash
downprocedures.Donotwashdowntheunitwhenit
isstillhotandavoiddirectinghigh-pressureorhigh
volumesprayatthebearingsorseals.

1.Wipethegreasettingscleansoforeignmattercannot
beforcedintothebearingorbushing.

2.Pumpgreaseintothettings.

3.Wipeoffexcessgrease.

32

EngineMaintenance

G004501

123456

7

Important:Donotcleantheusedelementto
avoiddamagetotheltermedia.

AirCleanerMaintenance

•Checktheaircleanerbodyfordamagewhichcould

possiblycauseanairleak.Replaceadamagedaircleaner
body.Checkthewholecleanairintakesystemforleaks,
damage,orloosehoseclamps.

•Servicetheaircleanerlterwhentheaircleanerindicator

(Figure59)showsredorevery400hours(morefrequently
inextremelydustyordirtyconditions).Donotover
servicetheairlter.

5.Inspectthenewlterforshippingdamage,checking
thesealingendofthelterandthebody.

Important:Donotuseadamagedelement.

6.Ensurethatthefoamgasketisinplaceinthecover
andthatitisnottornordamaged(Figure59).Ifitis
damaged,replaceit.

7.Insertthenewlterbyapplyingpressuretotheouter
rimoftheelementtoseatitinthecanister.

Important:Donotapplypressuretotheexible
centerofthelter.

8.Cleanthedirtejectionportlocatedintheremovable
cover,asfollows:

A.Removetherubberoutletvalvefromthecover

Figure59).

(

B.Cleanthecavity.

C.Replacetheoutletvalve.

9.Installthecoverorientingtherubberoutletvalveina
downwardposition—betweenapproximately5:00to
7:00whenviewedfromtheend.

Figure59

1.Aircleanerlatch5.Aircleanerbody

2.Aircleanercover6.Aircleanerindicator

3.Gasket

4.Filter

•Besurethecoverisseatedcorrectlyandsealswiththe

aircleanerbody.

ServicingtheAirCleaner

ServiceInterval:Every400hours

1.Pullthelatchoutwardandrotatetheaircleanercover
counter-clockwise(Figure59).

2.Removethecoverfromtheaircleanerbody(Figure

59).

3.Beforeremovingthelter,uselowpressureair(40psi,
cleananddry)tohelpremovelargeaccumulationsof
debrispackedbetweenoutsideofprimarylterand
thecanister.

Thiscleaningprocesspreventsdebrisfrommigrating
intotheintakewhentheprimarylterisremoved.

Important:Avoidusinghighpressureairwhich
couldforcedirtthroughthelterintotheintake
tract.

4.Removeandreplacetheprimarylter(

7.Rubberoutletvalve

Figure59).

10.Resettheindicator(Figure59)ifshowingred.

ServicingtheEngineOil

CheckingtheEngineOilLevel

ServiceInterval:Beforeeachuseordaily

Theengineisshippedwithoilinthecrankcase;however,the
oillevelmustbecheckedbeforeandaftertheengineisrst
started.Checkoillevelbeforeeachday'soperationoreach
timemachineisused.

Thecrankcasecapacityisapproximately3.8liters(4quarts)
withthelter.Usehigh-qualityengineoilthatmeetsthe
followingspecications:

•APIClassicationLevelRequired:CH-4,CI-4orhigher.

•Preferredoil:SAE15W-40(above-17°C(0°F)

•Alternateoil:SAE10W-30or5W-30(alltemperatures)

Note:T oroPremiumEngineoilisavailablefromyour
distributorineither15W-40or10W-30viscosity.Seethe
partscatalogforpartnumbers.

1.Parkthemachineonalevelsurface,lowerthe
attachment,movethethrottlelevertotheSlow
position,stoptheengine,andremovethekeyfromthe
ignitionswitch.Openthehood.

2.Removethedipstick(
installthedipstick.Removethedipstickandcheckthe
oillevel.

Figure60),wipeitclean,and

33

TheoillevelshouldbeuptotheFullmarkonthe
dipstick.

Figure61

Figure60

1.Dipstick

2.Oilll

3.IftheoillevelisbelowtheFullmark,removethell
cap(Figure60)andaddoiluntilthelevelreachesthe
Fullmarkonthedipstick.

Important:Donotoverll.

Note:Useacleanfunneltopreventspills.

4.Installtheoilllcapandclosethehood.

ChangingtheEngineOilAndFilter

ServiceInterval:Aftertherst50hours

Every150hours

Changetheoilandlterinitiallyafterrst50hoursof
operationandthenevery150hoursofoperationthereafter.If
possible,runtheenginejustbeforechangingtheoilbecause
warmoilowsbetterandcarriesmorecontaminantsthan
coldoil.

1.Oillter

2.Drainplug

4.Cleantheareaaroundthedrainplug.

5.Removethedrainplugandallowtheoiltoowinto
drainpan.

6.Removeandreplacetheoillter(

Figure61).

7.Aftertheoilisdrained,installthedrainplugandwipe
upanyoilthatisspilled.

8.Fillthecrankcasewithoil;refertoCheckingtheEngine
OilLevel.

1.Positionthemachineonalevelsurface.

2.Openthehood.

3.Setadrainpanundertheoilpanandinlinewiththe
drainplug(

Figure61).

34

FuelSystem
Maintenance

Note:RefertoAddingFuelforproperfuel
recommendations.

DANGER

5.Lubricatethegasketontheltercanisterwithcleanoil.

6.Installtheltercanisterbyhanduntilthegasket
contactsmountingsurface,thenrotateitanadditional
1/2turn.

7.Tightenthedrainplugonthebottomofthelter
canister.

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

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

•Donotllthefueltankcompletelyfull.Addfuel
tothefueltankuntilthelevelistothebottom
ofthellerneck.

•Neversmokewhenhandlingfuel,andstayaway
fromanopenameorwherefuelfumesmaybe
ignitedbyaspark.

•Storefuelinaclean,safety-approvedcontainer
andkeepthecapinplace.

ServicingtheWaterSeparator

ServiceInterval:Every400hours

Drainwaterorothercontaminantsfromwaterseparator
(

Figure62)daily.Replaceltercanisterafterevery400hours

ofoperation.

CleaningtheFuelTank

ServiceInterval:Every2years

Note:Also,drainandcleanthetankifthefuelsystem
becomescontaminatedorifthemachineistobestoredfor
anextendedperiod.

Usecleandieselfueltoushoutthetank.

FuelLinesandConnections

ServiceInterval:Every400hours/Yearly(whichevercomes

rst)

Inspectthefuellinesfordeterioration,damage,chafng,or
looseconnections.

BleedingtheFuelSystem

1.Parkthemachineonalevelsurface.Ensurethatthe
fueltankisatleasthalffull.

2.Unlatchandraisethehood.

3.Placearagundertheairbleedscrewonthefuel
injectionpumpandopenit(

Figure63).

1.Placeacleancontainerunderthefuellter.

2.Loosenthedrainplugonthebottomofthelter
canister.

Figure62

1.Waterseparatorltercanister

3.Cleantheareawheretheltercanistermounts.

4.Removetheltercanisterandcleanthemounting
surface.

Figure63

1.Fuelinjectionpumpbleedscrew

4.TurnthekeyintheignitionswitchtotheRunposition.

Theelectricfuelpumpwillbeginoperation,thereby
forcingairoutaroundtheairbleedscrew .

35

CAUTION

CAUTION

Theenginemaystartduringthisprocedure.
Movingfansandbeltsinarunningenginecan
severelyinjureyouorbystanders.

Keephands,ngers,looseclothing/jewelry,
andhairawayfromtheenginefanandbelt
duringthisprocedure.

5.LeavethekeyintheOnpositionuntilasolidstream
offuelowsoutaroundthescrew .

6.TightenthescrewandturnkeytotheOffposition.

Note:Normally,theengineshouldstartafterabove
bleedingproceduresarefollowed.However,ifengine
doesnotstart,airmaybetrappedbetweeninjection
pumpandinjectors;refertoBleedingAirFromthe
Injectors.

BleedingAirFromtheInjectors

Note:Thisprocedureshouldbeusedonlyifthefuelsystem

hasbeenpurgedofairthroughnormalprimingprocedures
andenginewillnotstart;refertoBleedingtheFuelSystem.

Theenginemaystartduringthisprocedure.
Movingfansandbeltsinarunningenginecan
severelyinjureyouorbystanders.

Keephands,ngers,looseclothing/jewelry,
andhairawayfromtheenginefanandbelt
duringthisprocedure.

4.Tightenthepipeconnectorsecurelywhenitattainsa
solidow .

5.TurnthekeytotheOffposition.

6.Repeatthisprocedurefortheremainingnozzles.

1.Placearagunderthepipeconnectioncomingfrom
theinjectionpumptotheNo.1injectornozzleas
illustratedinFigure64.

Figure64

1.PipeconnectionfromtheinjectionpumptotheNo.1
injectornozzle

2.MovethethrottletotheFastposition.

3.TurntheignitionkeytheStartpositionandwatchthe
fuelowaroundtheconnector.

36

ElectricalSystem
Maintenance

Important:Wheneverworkingwiththeelectrical
system,alwaysdisconnectthebatterycables,negative
(-)cablerst,topreventpossiblewiringdamagefrom
short-outs.

ServicingtheBattery

ServiceInterval:Every50hours—Checkbatterycable

connections.

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandleadcompounds,

chemicalsknowntotheStateofCalifornia

tocausecancerandreproductiveharm.

Washhandsafterhandling.

WARNING

Incorrectbatterycableroutingcoulddamagethe
machineandcablescausingsparks.Sparkscan
causethebatterygassestoexplode,resultingin
personalinjury.

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

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

StoringtheBattery

Ifthemachinewillbestoredmorethan30days,removethe
batteryandchargeitfully.Eitherstoreitonashelforon
themachine.Leavethecablesdisconnectedifitisstoredon
themachine.Storethebatteryinacoolatmospheretoavoid
quickdeteriorationofthechargeinthebattery.T oprevent
thebatteryfromfreezing,makesureitisfullycharged.The
specicgravityofafullychargedbatteryis1.265-1.299.

CheckingtheFuses

Keepthetopofthebatteryclean.Ifyoustorethemachinein
alocationwheretemperaturesareextremelyhigh,thebattery
willrundownmorerapidlythanifthemachineisstoredin
alocationwheretemperaturesarecool.

Keepthetopofthebatterycleanbywashingitperiodically
withabrushdippedinammoniaorbicarbonateofsoda
solution.Flushthetopsurfacewithwateraftercleaningit.
Donotremovethellcapswhilecleaningthebattery.

Thebatterycablesmustbetightontheterminalstoprovide
goodelectricalcontact.

Ifcorrosionoccursattheterminals,disconnectthecables,
negative(-)cablerst,andscrapetheclampsandterminals
separately.Reconnectthecables,positive(+)cablerst,and
coattheterminalswithpetroleumjelly.

WARNING

Batteryterminalsormetaltoolscouldshortagainst
metalmachinecomponentscausingsparks.Sparks
cancausethebatterygassestoexplode,resulting
inpersonalinjury.

•Whenremovingorinstallingthebattery,donot
allowthebatteryterminalstotouchanymetal
partsofthemachine.

Themachinefusesarelocatedunderthecontrolpanel.
Accessthemthroughthesidepanelcover(Figure65).To
openthesidepanelcover,releasethe2latchesandpullout
onit.

Figure65

1.Sidepanelcover

2.Latches

•Donotallowmetaltoolstoshortbetween
thebatteryterminalsandmetalpartsofthe
machine.

37

CoolingSystem
Maintenance

DANGER

Dischargeofhotpressurizedcoolantortouching
hotradiatorandsurroundingpartscancausesevere
burns.

•Donotremovetheradiatorcapwhentheengine
ishot.Alwaysallowtheenginetocoolatleast
15minutesoruntiltheradiatorcapiscool
enoughtotouchwithoutburningyourhand
beforeremovingtheradiatorcap.

•Donottouchradiatorandsurroundingparts
thatarehot.

DANGER

Therotatingfananddrivebeltcancausepersonal
injury.

•Donotoperatethemachinewithoutthecovers
inplace.

•Keepngers,handsandclothingclearof
rotatingfananddrivebelt.

•Shutofftheengineandremovetheignitionkey
beforeperformingmaintenance.

1.Checkthelevelofthecoolantintheexpansiontank
(Figure66).Thecoolantlevelshouldbebetweenthe
marksonthesideofthetank.

Figure66

1.Expansiontank

2.Ifcoolantlevelislow ,removetheexpansiontankcap
andreplenishthesystem.Donotoverll.

CAUTION

Swallowingenginecoolantcancause
poisoning.

•Donotswallowenginecoolant.

•Keepoutofreachfromchildrenandpets.

CheckingtheCoolingSystem

ServiceInterval:Beforeeachuseordaily—Checktheengine

coolantlevel.

Thecoolingsystemislledwitha50/50solutionofwater
andpermanentethyleneglycolantifreeze.Checkthelevelof
thecoolantintheexpansiontankatthebeginningofeachday
beforestartingtheengine.Thecapacityofthecoolingsystem
is7.5liters(6quarts).

3.Installtheexpansiontankcap.

CleaningtheRadiator

ServiceInterval:Beforeeachuseordaily—Cleanthe

radiatorwithcompressedair(donotuse
water)

Topreventtheenginefromoverheating,theradiatormust
bekeptclean.Normally,checktheradiatordailyand,if
necessary,cleananydebrisofftheseparts.However,itwill
benecessarytocheckandcleantheradiatorfrequentlyin
extremelydustyanddirtyconditions.

Note:IfthePTOorengineshutsoffduetooverheating,
rstchecktheradiatorforexcessivebuildupofdebris,ice,
orsnow .

Cleantheradiatorasfollows:

1.Openthehood.

2.Workingfromthefansideoftheradiator,blowout
debriswithlowpressure(50psi)compressedair(do
notusewater).Repeatthestepfromthefrontofthe
radiatorandagainfromthefanside.

38

3.Aftertheradiatoristhoroughlycleaned,cleanout
debristhatmayhavecollectedinthechannelatthe
radiatorbase.

BrakeMaintenance

4.Closethehood.

AdjustingtheParkingBrake InterlockSwitch

1.Stopthemachine,movethecontrolleversfullyinto
theneutral-lockedposition,settheparkingbrake,and
removetheignitionkey.

2.Unlatchtheseatandpivotitforward.

Note:Ifadditionalaccessisrequiredundertheseat,
thesidepanelsmayberemoved.

3.Loosenthetwojamnutssecuringtheparkingbrake
interlockswitchtothemountingbracket.

Figure67

1.Brakeshaftsensor

2.Jamnuts

4.Movetheswitchupordownonthebracketuntilthe
distancebetweenthebrakeshaftsensorandtheswitch
surfaceis3.9mm(5/32inch)(Figure67).

Note:Makesurethebrakeshaftsensordoesnot
contacttheswitchplunger.

5.Securetheswitchjamnuts.

6.Testtheadjustmentasfollows:

A.Ensurethattheparkingbrakeisengagedandyou

arenotsittingontheseat,thenstarttheengine.

B.Movethecontrolleversoutoftheneutrallocked

position.

Theengineshouldstop.Ifnot,recheckthe
adjustmentyoumadetotheswitch.

7.Lowertheseat.

3.Parkingbrakeinterlock
switch

4.5/32inch(3.9mm)

39

BeltMaintenance

CheckingtheAlternatorBelt

ControlsSystem
Maintenance

Tension

ServiceInterval:Aftertherst10hours

Every200hours

1.Apply10lbofforcetothealternatorbelt,midway
betweenthepulleys.

2.Ifthedeectionisnot10mm(3/8inch),loosenthe
alternatormountingbolts(

Figure68).

AdjustingtheControlLever NeutralInterlockSwitch

1.Stopthemachine,movethecontrolleversfullyinto
theneutral-lockedposition,settheparkingbrake,and
removetheignitionkey.

2.Unlatchtheseatandpivotitforward.

Note:Ifadditionalaccessisrequiredundertheseat,
thesidepanelsmayberemoved.

3.Loosenthe2screwssecuringtheinterlockswitch
(Figure69).

Figure68

1.Mountingbolt2.Alternator

3.Increaseordecreasethealternatorbelttensionand
tightenthebolts.

4.Checkthedeectionofthebeltagaintoensurethat
thetensioniscorrect.

Figure69

1.Controllever3.Screws

2.Neutralinterlockswitch

4.Holdingthecontrolleveragainsttheframe,movethe
switchtowardtheleveruntilthedistancebetweenlever
andswitchbodyis0.015to0.045inch(0.4to1mm)
(Figure69).

5.Securetheswitch.

6.Repeatsteps3to5fortheotherlever.

7.Lowertheseat.

4.0.4to1mm(0.015to

0.045inch)

AdjustingtheControlLever NeutralReturn

Ifthemotioncontrolleversdonotalignwiththeneutralslots
whenreleasedfromthereversedriveposition,adjustmentis
required.Adjusteachlever,spring,androdseparately.

40

1.DisengagethePTO ,movethemotioncontrolleversto
theneutrallockedpositionandsettheparkingbrake.

2.MovethethrottlelevertotheSlowposition,stopthe
engine,removethekey,andwaitforallmovingpartsto
stopbeforeleavingtheoperatingposition.

3.Unlatchtheseatandpivotitforward.

Note:Ifadditionalaccessisrequiredundertheseat,
thesidepanelsmayberemoved.

4.Moveoneoftheleverstotheneutralpositionbutnot
locked(Figure71).

5.Pulltheleverbackuntiltheclevispin(onanarm
abovethepivotshaft)contactstheendoftheslot(just
beginningtoputpressureonthespring)(Figure70).

8.Applyingslightrearwardpressureonthemotion
controllever,turntheheadoftheadjustmentbolt
intheappropriatedirectionuntilthecontrolleveris
centeredintheneutrallockposition(Figure70).

Note:Keepingrearwardpressureontheleverwill
keepthepinattheendoftheslotandallowthe
adjustmentbolttomovethelevertotheappropriate
position.

9.Tightenthenutandjamnut(Figure70).

10.Repeatsteps4through9fortheothercontrollever.

11.Lowertheseat.

AdjustingtheTractionDrive forNeutral

Thisadjustmentmustbemadewithtracksturning.

DANGER

Mechanicalorhydraulicjacksmayfailtosupport
machineandcauseaseriousinjury.

Figure70

1.Clevispin

2.Slot

3.Jamnuts

6.Checkwherethecontrolleverisrelativetonotchin
console(Figure71).Itshouldbecenteredallowing
levertopivotoutwardtotheneutrallockposition.

4.Adjustmentbolt

5.Yoke

•Usejackstandswhensupportingmachine.

•Donotusehydraulicjacks.

WARNING

Theenginemustberunningtoperformthis
adjustment.Contactwithmovingpartsorhot
surfacesmaycausepersonalinjury.

Keephands,feet,face,clothing,andotherbody
partsawayfromrotatingparts,mufer,andother
hotsurfaces.

1.Raisetheframeontostablejackstandssothatthe
trackscanrotatefreely.

2.Unlatchtheseatandpivotitforward.

Note:Ifadditionalaccessisrequiredundertheseat,
thesidepanelsmayberemoved.

3.Disconnecttheelectricalconnectorfromtheseat
safetyswitch.Temporarilyinstallajumperwireacross
terminalsinthewiringharnessconnector.

Figure71

1.Neutralposition2.Neutrallockedposition

7.Ifadjustmentisneeded,loosenthenutandjamnut
againsttheyoke(Figure70).

4.Starttheengine,ensurethatthethrottleleverismidway
betweentheFastandSlowpositions,andreleasethe
parkingbrake

Note:Themotioncontrolleversmustbeinthe
neutrallockedpositionwhilemakinganyadjustments.

5.Adjustthepumprodlengthononesidebyrotating
thehexshaft,intheappropriatedirection,untilthe
correspondingwheelisstillorslightlycreepingin
reverse(Figure72).

41

6.Movethemotioncontrolleverforwardandreverse,
thenbacktoneutral.Thewheelmuststopturningor
slightlycreepinreverse.

13.Removethejackstands.

AdjustingtheMaximum GroundSpeed

Note:Ifyouwishtoreducethemaximummachinespeed,

setthespeedforbothcontrolleversasdirectedbelow ,then
backeachstopboltoutanequalamounttowardthecontrol
leveruntilyoureachthemaximumspeedyoudesire(youwill
likelyhavetotestyouradjustmentseveraltimes).Ensurethat
themachinedrivesstraightanddoesnotturnwhenboth
controlleversarepushedallthewayforward.Ifthemachine
turns,youdonothavethestopboltsevenlysetandwillneed
toadjustthemfurther.

1.DisengagethePTO ,movethemotioncontrolleversto
theneutrallockedpositionandsettheparkingbrake.

2.MovethethrottlelevertotheSlowposition,stopthe
engine,removethekey,andwaitforallmovingpartsto
stopbeforeleavingtheoperatingposition.

3.Unlatchtheseatandpivotitforward.

Note:Ifadditionalaccessisrequiredundertheseat,
thesidepanelsmayberemoved.

4.Loosenthejamnutonthestopboltforoneofthe
controllevers(Figure73).

Figure72

1.Rightpumprod5.JamNut

2.Leftpumprod6.Hexshaft

3.Balljoint7.Balljoint

4.Bolt

7.MovethethrottlelevertotheFastposition.Makesure
wheelremainsstoppedorslightlycreepsinreverse,
adjustifnecessary.

8.Repeatsteps5through7fortheotherside.

9.Tightenthejamnutsattheballjoints(Figure70).

10.MovethethrottlelevertotheSlowpositionandstop
theengine.

11.Removethejumperwirefromthewireharness
connectorandplugtheconnectorintotheseatswitch.

WARNING

Electricalsystemwillnotperformproper
safetyshutoffwithjumperwireinstalled.

•Removejumperwirefromwireharness
connectorandplugconnectorintoseat
switchwhenadjustmentiscompleted.

•Neveroperatethisunitwithjumper
installedandseatswitchbypassed.

12.Lowertheseat.

Figure73

1.Stopbolt

2.Controllever4.1.5mm(0.060inch)

5.Threadthestopboltallthewayin(awayfromthe
controllever).

6.Pushthecontrolleverallthewayforwarduntilitstops
andholditthere.

7.Threadthestopboltout(towardsthecontrollever)
untilthereisagapof1.5mm(0.060inch)betweenthe
headofthestopboltandthecontrollever.

8.Tightenthejamnuttosecurethestopboltinplace.

9.Repeatsteps4through8fortheothercontrollever.

3.Jamnut

42

10.Lowertheseat.

AdjustingtheTracking

1.DisengagethePTO ,movethemotioncontrolleversto
theneutrallockedpositionandsettheparkingbrake.

2.MovethethrottlelevertotheSlowposition,stopthe
engine,removethekey,andwaitforallmovingpartsto
stopbeforeleavingtheoperatingposition.

3.Loosentheboltssecuringthecontrollevers(Figure74)

Figure74

1.Controllever

2.Controlleverpost

3.Bolts

4.Havesomeonepushthecontrolleverposts(notthe
controllevers)allthewayforwardintothemaximum
speedpositionandholdthemthere.

5.Adjustthecontrolleverssothattheylineup(Figure75)
andtightenthebolts,securingtheleverstotheposts.

Figure75

43

HydraulicSystem
Maintenance

Thereservoirislledatthefactorywithapproximately

4.7liters(5quarts)ofhighqualitytractor
transmission/hydraulicuid.Therecommended
replacementuidisasfollows:

ToroPremiumTransmission/HydraulicTractorFluid

(Availablein5gallonpailsor55gallondrums.Seeparts
catalogorTorodistributorforpartnumbers.)

Alternateuids:IftheTorouidisnotavailable,Mobil®424
hydraulicuidmaybeused.

Note:Torowillnotassumeresponsibilityfordamagecaused
byimpropersubstitutions.

Note:Manyhydraulicuidsarealmostcolorless,makingit
difculttospotleaks.Areddyeadditiveforthehydraulic
systemoilisavailablein20ml(2/3ounce.)bottles.One
bottleissufcientfor15-221iters(4-6gallons)ofhydraulic
oil.Orderpartnumber44-2500fromyourauthorizedToro
distributor.

CheckingtheHydraulicFluid Level

ServiceInterval:Beforeeachuseordaily

1.Positionthemachineonalevelsurface.Placethe
controlsintheneutrallockedpositionandstartthe
engine.RunengineatlowestpossibleRPMtopurge
thesystemofair.DonotengagethePTO.Raise
thedecktoextendliftcylinders,stoptheengine,and
removethekey.

Figure76

1.Dipstick2.Fillcap

4.Removethedipstickandwipeitwithacleanrag
(Figure76).

5.Placethedipstickintothellerneck;thenremoveit
andchecklevelofuid(Figure76).

Iflevelisnotwithinnotchedareaofthedipstick,add
enoughhighqualityhydraulicuidtoraiselevelto
withinthenotchedarea.Donotoverll.

6.Replacethedipstickandthreadthellcapnger-tight
ontollerneck.

7.Checkallhosesandttingsforleaks.

2.Raisetheseattoaccessthehydraulicuidtank.

3.Removethehydraulicllcap(Figure76)fromller
neck.

ChangingtheHydraulicOil AndFilter

ServiceInterval:Aftertherst200hours

Every800hours

1.DisengagethePTO ,movethemotioncontrolleversto
theneutrallockedpositionandsettheparkingbrake.

2.MovethethrottlelevertotheSlowposition,stopthe
engine,removethekey,andwaitforallmovingpartsto
stopbeforeleavingtheoperatingposition.

3.Placealargepanunderthehydraulicreservoirand
transmissioncaseandremovetheplugs,drainingallof
thehydraulicuid(Figure77).

44

Figure77

1.Hydraulicreservoirdrain
plug

2.Filter

4.Cleantheareaaroundthehydraulicoillterand
removeit(Figure77).

5.Immediatelyinstallanewhydraulicoillter.

6.Installthehydraulicreservoirandtransmissioncase
drainplugs.

7.Fillthereservoirtotheproperlevel;refertoChecking
theHydraulicFluid.

8.Starttheengineandcheckforoilleaks.Allowthe
enginetorunforaboutveminutes,thenshutitoff.

9.Aftertwominutes,checkthelevelofthehydraulic
uid;refertoCheckingtheHydraulicFluid.

3.Transmissioncasedrain
plug

Storage

Machine

1.Thoroughlycleanthemachine,deckandtheengine,
payingspecialattentiontotheseareas:

•Radiatorandradiatorscreen

•Underneaththedeck

•Underthedeckbeltcovers

•Counterbalancesprings

•PTOshaftassembly

•Allgreasettingsandpivotpoints

•Removethecontrolpanelandcleanoutinsideof

thecontrolbox

•Beneaththeseatplateandtopofthetransmission

2.Checkandadjustthetirepressure;refertoChecking
TirePressure.

3.Checkallfastenersforloosenessandtightenthemas
necessary.

4.Greaseoroilallgreasettings,pivotpoints,and
transmissionby-passvalvepins.Wipeoffanyexcess
lubricant.

5.Lightlysandandusetouchuppaintonpaintedareas
thatarescratched,chippedorrusted.Repairanydents
inthemetalbody.

6.Servicethebatteryandcablesasfollows:

A.Removethebatteryterminalsfromthebattery

posts.

B.Cleanthebattery,terminals,andpostswithawire

brushandbakingsodasolution.

C.Coatthecableterminalsandbatterypostswith

Grafo112Xskin-overgrease(T oroPartNo.
505-47)orpetroleumjellytopreventcorrosion.

D.Slowlyrechargethebatteryfor24hoursevery60

daystopreventleadsulfationofthebattery.

Engine

1.Draintheengineoilfromtheoilpanandreplacethe
drainplug.

2.Removeanddiscardtheoillter.Installanewlter.

3.Relltheenginewith3.8liters(4quarts)of
recommendedmotoroil.RefertoChangingthe
EngineOil.

4.Starttheengineandrunitatidlespeedfortwominutes.

5.Drainthefuelfromthefueltank,fuellines,pump,
lter,andseparator.Flushthefueltankwithclean
dieselfuelandconnectallfuellines.

6.Thoroughlycleanandservicetheaircleanerassembly.

7.Sealtheaircleanerinletandtheexhaustoutletwith
weatherproofmaskingtape.

45

8.Checktheoilllercapandfueltankcaptoensurethey
aresecurelyinplace.

46

Notes:

47

TheToroTotalCoverageGuarantee

ALimitedWarranty

ConditionsandProductsCovered

TheToroCompanyanditsafliate,ToroWarrantyCompany ,pursuant
toanagreementbetweenthem,jointlywarrantyourToroCommercial
product(“Product”)tobefreefromdefectsinmaterialsorworkmanship
fortwoyearsor1500operationalhours*,whicheveroccursrst.This
warrantyisapplicabletoallproductswiththeexceptionofAerators
(refertoseparatewarrantystatementsfortheseproducts).Wherea
warrantableconditionexists,wewillrepairtheProductatnocosttoyou
includingdiagnostics,labor,parts,andtransportation.Thiswarranty
beginsonthedatetheProductisdeliveredtotheoriginalretailpurchaser .
*Productequippedwithanhourmeter.

InstructionsforObtainingWarrantyService

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

ToroCommercialProductsServiceDepartment
ToroWarrantyCompany

811 1LyndaleAvenueSouth
Bloomington,MN55420-1 196

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

OwnerResponsibilities

AstheProductowner,youareresponsibleforrequiredmaintenance
andadjustmentsstatedinyourOperator'sManual.Failuretoperform
requiredmaintenanceandadjustmentscanbegroundsfordisallowinga
warrantyclaim.

ItemsandConditionsNotCovered

Notallproductfailuresormalfunctionsthatoccurduringthewarranty
periodaredefectsinmaterialsorworkmanship.Thiswarrantydoesnot
coverthefollowing:

•Productfailureswhichresultfromtheuseofnon-Tororeplacement

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

•Productfailureswhichresultfromfailuretoperformrecommended

maintenanceand/oradjustments.Failuretoproperlymaintainyour
ToroproductpertheRecommendedMaintenancelistedinthe
Operator’sManualcanresultinclaimsforwarrantybeingdenied.

•ProductfailureswhichresultfromoperatingtheProductinan

abusive,negligent,orrecklessmanner.

•Partssubjecttoconsumptionthroughuseunlessfoundtobe

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

•Failurescausedbyoutsideinuence.Conditionsconsideredtobe

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

•Failureorperformanceissuesduetotheuseoffuels(e.g.gasoline,

diesel,orbiodiesel)thatdonotconformtotheirrespectiveindustry
standards.

•Normalnoise,vibration,wearandtear,anddeterioration.

•Normal“wearandtear”includes,butisnotlimitedto,damageto

seatsduetowearorabrasion,wornpaintedsurfaces,scratched
decalsorwindows,etc.

Parts

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

DeepCycleandLithium-IonBatteryWarranty:

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

MaintenanceisatOwner’sExpense

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

GeneralConditions

RepairbyanAuthorizedT oroDistributororDealerisyoursoleremedy
underthiswarranty.

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

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

Noteregardingenginewarranty:

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

CountriesOtherthantheUnitedStatesorCanada

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

374-0253RevB