Toro 30410, Groundsmaster 4000-D, 30410TE Operator's Manual

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Page 1

FormNo.3358-715RevB

Groundsmaster

4000-DTraction

Unit

ModelNo.30410—SerialNo.2800000001andUp

ModelNo.30410TE—SerialNo.2800000001andUp

Registeratwww.T oro.com.OriginalInstructions(EN)

Page 2

Warning

CALIFORNIA

Proposition65Warning

Dieselengineexhaustandsomeofits constituentsareknowntotheStateof

Californiatocausecancer,birthdefects,

andotherreproductiveharm.

ThissparkignitionsystemcomplieswithCanadian ICES-002.

Important:Thisengineisnotequippedwitha sparkarrestermufer.ItisaviolationofCalifornia PublicResourceCodeSection4442touseoroperate theengineonanyforest-covered,brush-covered,or grass-coveredland.Otherstatesorfederalareas mayhavesimilarlaws.

Introduction

Readthisinformationcarefullytolearnhowtooperate andmaintainyourproductproperlyandtoavoidinjury andproductdamage.Youareresponsibleforoperating theproductproperlyandsafely.

Thismanualuses2otherwordstohighlightinformation. Importantcallsattentiontospecialmechanical informationandNoteemphasizesgeneralinformation worthyofspecialattention.

YoumaycontactTorodirectlyatwww .Toro.comfor productandaccessoryinformation,helpndinga dealer,ortoregisteryourproduct.

Wheneveryouneedservice,genuineToroparts,or additionalinformation,contactanAuthorizedService DealerorToroCustomerServiceandhavethemodel andserialnumbersofyourproductready.Writethe numbersinthespaceprovided.

ModelNo.

SerialNo.

Thismanualidentiespotentialhazardsandhas safetymessagesidentiedbythesafetyalertsymbol (Figure1),whichsignalsahazardthatmaycauseserious injuryordeathifyoudonotfollowtherecommended precautions.

1.Safetyalertsymbol

Figure1

Contactusatwww.Toro.com.

PrintedintheUSA.

AllRightsReserved

Page 3

Contents

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

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

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

ToroMowerSafety...............................................6

SoundPressureLevel...........................................7

SoundPowerLevel...............................................7

VibrationLevel.....................................................7

SafetyandInstructionalDecals.............................7

Setup..........................................................................13

1InstallingtheSeat,SeatBelt,andManual

Tube...............................................................14

2GreasingtheMachine......................................14

3ReplacingtheWarningDecal............................14

4ReadingtheManualsandViewingthe

DVD..............................................................14

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

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

Specications.....................................................17

Attachments/Accessories...................................17

Operation...................................................................17

BeforeOperating................................................17

StartingandStoppingtheEngine........................27

CheckingtheInterlockSwitches.........................28

PushingorTowingtheMachine..........................28

JackingPoints.....................................................29

TieDowns.........................................................29

OperatingCharacteristics...................................29

OperatingTips...................................................30

Maintenance...............................................................31

RecommendedMaintenanceSchedule(s)................31

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

ServiceIntervalChart.........................................32

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

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

EngineMaintenance...............................................36

AirCleanerMaintenance....................................36

ServicingtheEngineOilandFilter......................37

FuelSystemMaintenance.......................................37

ServicingtheFuelSystem...................................37

ServicingtheWaterSeparator.............................37

BleedingAirfromtheInjectors...........................38

ElectricalSystemMaintenance................................39

Activating,Charging,andConnectingthe

Battery...........................................................39

BatteryCare.......................................................40

Fuses..................................................................40

DriveSystemMaintenance.....................................41

ChangingthePlanetaryGearDrive

Oil..................................................................41

ChangingtheRearAxleLubricant.......................41

CheckingtheRearWheelToe-In.........................42

CoolingSystemMaintenance..................................43

ServicingtheEngineCoolingSystem..................43

BrakeMaintenance.................................................44

AdjustingtheServiceBrakes...............................44

BeltMaintenance....................................................44

ServicingtheAlternatorBelt...............................44

Re-tensioningtheBladeDriveBelts....................44

ReplacingtheBladeDriveBelt............................45

ControlsSystemMaintenance.................................46

AdjustingtheThrottle........................................46

AdjustingtheTractionPedalLinkage..................46

HydraulicSystemMaintenance...............................47

ChangingtheHydraulicFluid.............................47

ReplacingtheHydraulicFilters...........................47

CheckingtheHydraulicLinesandHoses.............47

HydraulicSystemTestPorts...............................48

AdjustingtheCuttingUnitFlowControl.............49

MowerMaintenance...............................................50

AdjustingtheTransportLatch............................50

Pivoting(Tilting)theFrontCuttingUnit

Upright..........................................................50

PivotingtheFrontCuttingUnitDown................51

AdjustingtheCuttingUnitPitch.........................51

ServicingtheCastorArmBushings.....................52

ServicingtheCastorWheelsandBearings............52

BladeMaintenance.................................................53

CheckingforaBentBlade...................................53

RemovingandInstallingtheCutter

Blade(s)..........................................................53

InspectingandSharpeningtheCutter

Blade(s)..........................................................54

CorrectingCuttingUnitMismatch......................55

SparkArrestorMaintenance...................................56

ServicingtheSparkArrestorMufer...................56

Storage.......................................................................56

PreparingforSeasonalStorage............................56

Schematics.................................................................57

Page 4

Safety

ThismachinemeetsorexceedsCENstandard EN836:1997,ISOstandard5395:1990,andANSI B71.4-2004specicationsineffectatthetimeof production.

Improperuseormaintenancebytheoperator orownercanresultininjury.Toreducethe potentialforinjury,complywiththesesafety instructionsandalwayspayattentiontothesafety alertsymbol,whichmeansCaution,Warning,or Danger—personalsafetyinstruction.Failureto complywiththeinstructionmayresultinpersonal injuryordeath.

SafeOperatingPractices

ThefollowinginstructionsarefromtheCENstandard EN836:1997,ISOstandard5395:1990,andANSI standardB71.4-2004.

Training

•ReadtheOperator’ sManualandothertrainingmaterial carefully.Befamiliarwiththecontrols,safetysigns, andtheproperuseoftheequipment.

•Neverallowchildrenorpeopleunfamiliarwiththese instructionstousethemower.Localregulationsmay restricttheageoftheoperator.

•Nevermowwhilepeople,especiallychildren,orpets arenearby .

•Keepinmindthattheoperatororuserisresponsible foraccidentsorhazardsoccurringtohimselfor herself,otherpeople,orproperty.

•Donotcarrypassengers.

•Alldriversandmechanicsshouldseekandobtain professionalandpracticalinstruction.Theowneris responsiblefortrainingtheusers.Suchinstruction shouldemphasize:

–theneedforcareandconcentrationwhen

workingwithride-onmachines;

–controlofaride-onmachineslidingonaslope

willnotberegainedbytheapplicationofthe brake.Themainreasonsforlossofcontrolare:

◊insufcientwheelgrip; ◊beingdriventoofast; ◊inadequatebraking; ◊thetypeofmachineisunsuitableforitstask; ◊lackofawarenessoftheeffectofground

conditions,especiallyslopes;

◊incorrecthitchingandloaddistribution.

Preparation

•Whilemowing,alwayswearsubstantialfootwear, longtrousers,hardhat,safetyglasses,andear protection.Longhair,looseclothingorjewelrymay gettangledinmovingparts.Donotoperatethe equipmentwhenbarefootorwearingopensandals.

•Thoroughlyinspecttheareawheretheequipment istobeusedandremoveallobjectswhichmaybe thrownbythemachine.

•Warning–fuelishighlyammable.Takethe followingprecautions:

–Storefuelincontainersspecicallydesignedfor

thispurpose.

–Refueloutdoorsonlyanddonotsmokewhile

refuelling.

–Addfuelbeforestartingtheengine.Never

removethecapofthefueltankoraddfuelwhile theengineisrunningorwhentheengineishot.

–Iffuelisspilled,donotattempttostartthe

enginebutmovethemachineawayfromthe areaofspillageandavoidcreatinganysourceof ignitionuntilfuelvaporshavedissipated.

–Replaceallfueltankandcontainercapssecurely.

•Replacefaultysilencers/mufers.

•Beforeusing,alwaysvisuallyinspecttoseethatthe blades,bladebolts,andcuttingassemblyarenot wornordamaged.Replacewornordamagedblades andboltsinsetstopreservebalance.

•Onmulti-bladedmachines,takecareasrotatingone bladecancauseotherbladestorotate.

•Evaluatetheterraintodeterminewhataccessories andattachmentsareneededtoproperlyand safelyperformthejob.Onlyuseaccessoriesand attachmentsapprovedbythemanufacturer.

•Checkthatoperatorspresencecontrols,safety switches,andshieldsareattachedandfunctioning properly.Donotoperateunlesstheyarefunctioning properly.

Operation

•Donotoperatetheengineinaconnedspacewhere dangerouscarbonmonoxidefumescancollect.

•Mowonlyindaylightoringoodarticiallight.

•Beforeattemptingtostarttheengine,disengageall bladeattachmentclutches,shiftintoneutral,and engagetheparkingbrake.Onlystarttheenginefrom theoperatorsposition.Useseatbelts,ifprovided.

•Rememberthereisnosuchthingasasafeslope. Travelongrassslopesrequiresparticularcare.To guardagainstoverturning:

Page 5

–Donotstoporstartsuddenlywhengoingupor

downhill.

•Disengagedrivetoattachmentswhentransporting ornotisuse.

–Themachinespeedshouldbekeptlowonslopes

andduringtightturns.

–Stayalertforhumpsandhollowsandother

hiddenhazards.

–Nevermowacrossthefaceoftheslope,unless

themachineisdesignedforthatpurpose.

•Stayalertforholesintheterrainandotherhidden hazards.

•Usecarewhenusingheavyequipment.

–Donotturnsharply.Usecarewhenreversing.

–Usecounterweight(s)orwheelweightswhen

suggestedintheOperator’ sManual.

•Watchoutfortrafcwhencrossingornearroadways.

•Stopthebladesfromrotatingbeforecrossing surfacesotherthangrass.

•Whenusinganyattachments,neverdirectdischarge ofmaterialtowardbystandersnorallowanyonenear themachinewhileinoperation.

•Neveroperatethemachinewithdamagedguards, shields,orwithoutsafetyprotectivedevicesinplace. Besureallinterlocksareattached,adjustedproperly, andfunctioningproperly .

•Stoptheengineanddisengagedrivetoattachment:

–beforerefuelling;

–beforemakingheightadjustmentunless

adjustmentcanbemadefromtheoperator’s position.

•Reducethethrottlesettingbeforestoppingengine and,iftheengineisprovidedwithafuelshut-off valve,turnthefueloffattheconclusionofmowing.

•Neverraisedeckwiththebladesrunning.

•Keephandsandfeetawayfromthecuttingunits.

•Lookbehindanddownbeforebackinguptobesure ofaclearpath.

•Slowdownandusecautionwhenmakingturnsand crossingroadsandsidewalks.

•Donotoperatethemowerundertheinuenceof alcoholordrugs.

•Usecarewhenloadingorunloadingthemachine intoatrailerortruck.

•Theoperatorshallturnonashingwarninglights, ifprovided,whenevertravelingonapublicroad, exceptwheresuchuseisprohibitedbylaw .

•Donotchangetheenginegovernorsettingsor overspeedtheengine.Operatingtheengineat excessivespeedmayincreasethehazardofpersonal injury.

•Beforeleavingtheoperatorsposition:

–Stoponlevelground.

–Disengagethepowertake-offandlowerthe

attachments.

–Changeintoneutralandsettheparkingbrake.

–Stoptheengineandremovethekey.

•Disengagedrivetoattachments,stoptheengine, anddisconnectthesparkplugwire(s)orremovethe ignitionkey:

–beforeclearingblockages;

–beforechecking,cleaning,orworkingonthe

machine;

–afterstrikingaforeignobject.Inspectthe

machinefordamageandmakerepairsbefore restartingandoperatingtheequipment.Torque allthespindlepulleynutsto130to150ft-lb(176 to203N⋅m);

–ifthemachinestartstovibrateabnormally(check

immediately).

MaintenanceandStorage

•Keepallnuts,bolts,andscrewstighttobesurethe equipmentisinsafeworkingcondition.

•Neverstoretheequipmentwithfuelinthetank insideabuildingwherefumesmayreachanopen ameorspark.

•Allowtheenginetocoolbeforestoringinany enclosureanddonotstorenearame.

•Toreducetherehazard,keeptheengine, silencer/mufer,batterycompartment,cuttingunits, drives,andfuelstorageareafreeofgrass,leaves,or excessivegrease.Cleanupoilorfuelspillage.

•Replacewornordamagedpartsforsafety.

•Ifthefueltankhastobedrained,dothisoutdoors.

•Onmulti-bladedmachines,takecareasrotatingone bladecancauseotherbladestorotate.

•Whenmachineistobeparked,stored,orleft unattended,lowerthecuttingunitsunlessapositive mechanicallockisprovided.

•Disengagedrives,lowerthecuttingunits,move tractionpedaltoNeutral,setparkingbrake,stop engineandremovekeyanddisconnectsparkplug

Page 6

wire.Waitforallmovementtostopbeforeadjusting, cleaningorrepairing.

•Shutofffuelwhilestoringortransporting.Donot storefuelnearames.

•Parkmachineonlevelground.Neverallowuntrained personneltoservicemachine.

•Usejackstandstosupportcomponentswhen required.

•Carefullyreleasepressurefromcomponentswith storedenergy.

•Disconnectbatteryorremovesparkplugwirebefore makinganyrepairs.Disconnectthenegativeterminal rstandthepositivelast.Reconnectpositiverst andnegativelast.

•Usecarewhencheckingblades.Wrapthebladesor weargloves,andusecautionwhenservicingthem. Onlyreplaceblades.Neverstraightenorweldthem.

•Keephandsandfeetawayfrommovingparts.If possible,donotmakeadjustmentswiththeengine running.

•Chargebatteriesinanopenwellventilatedarea, awayfromsparkandames.Unplugchargerbefore connectingordisconnectingfrombattery.W ear protectiveclothinganduseinsulatedtools.

ToroMowerSafety

Thefollowinglistcontainssafetyinformationspecic toToroproductsorothersafetyinformationthatyou mustknowthatisnotincludedintheCEN,ISO,or ANSIstandards.

Thisproductiscapableofamputatinghandsand feetandthrowingobjects.Alwaysfollowallsafety instructionstoavoidseriousinjuryordeath.

Useofthisproductforpurposesotherthanitsintended usecouldprovedangeroustouserandbystanders.

Engineexhaustcontainscarbonmonoxide, whichisanodorless,deadlypoisonthatcan killyou.

Donotrunengineindoorsorinanenclosed area.

attachedandtheseatislatchedtopreventtheseat frompivotingforward.

•Knowhowtostopthemachineandenginequickly .

•Donotoperatethemachinewhilewearingtennis shoesorsneakers.

•Wearingsafetyshoesandlongpantsisadvisableand requiredbysomelocalordinancesandinsurance regulations.

•Keephands,feet,andclothingawayfrommoving partsandthemowerdischargeareaandundersideof themowerwhiletheengineisrunning.

•Fillfueltankuntillevelis1inch(25mm)belowthe bottomofthellerneck.Donotoverll.

•Checkthesafetyinterlockswitchesdailyforproper operation.Ifaswitchshouldfail,replacetheswitch beforeoperatingthemachine.

•Checkcarefullyforoverheadclearances(i.e. branches,doorways,electricalwires)beforedriving underanyobjectsanddonotcontactthem.

•Donotmowinreverseunlessabsolutelynecessary.

•Reducespeedwhenmakingsharpturns.

•Avoidstartingorstoppingonaslope.Iftireslose traction,disengagethebladesandproceedslowly straightdowntheslope.Avoidraisingtheside cuttingunitsonaslope.

•Avoidturningonslopes.Ifyoumustturn,turn slowlyandgraduallydownhill,ifpossible.

•Whenoperatingthemachineonslopes,banks,or neardrop-offs,alwayshavetheROPSinstalled.

•WhenoperatingamachinewithaROPS,alwaysuse aseatbelt.

•Becertainthattheseatbeltcanbereleasedquicklyif themachineisdrivenorrollsintoapondorwater.

•Watchfortrafcwhennearorcrossingroads. Alwaysyieldtheright-of-way .

•Donotmowneardrop-offs,ditches,or embankments.Themachinecouldsuddenlyturn overifawheelgoesovertheedgeofaclifforditch, orifanedgecavesin.

•Donotmowonwetgrass.Reducedtractioncould causesliding.

•Useextracarewithotherattachments.Thesecan changethestabilityofthemachine.

•Turnoffthebladeswhennotmowing.

Operation

•BeforeoperatingamachinewithROPS(rollover protectionsystem),becertainthattheseatbeltsare

MaintenanceandStorage

•Donottouchequipmentorattachmentpartswhich maybehotfromoperation.Allowtocoolbefore attemptingtomaintain,adjust,orservice.

Page 7

•Neverstorethemachineorfuelcontainerinside wherethereisanopename,suchasnearawater heaterorfurnace.

•Keepnutsandboltstight,especiallytheblade attachmentbolts.Keepequipmentingood condition.

•Makesureallhydrauliclineconnectorsaretightand allhydraulichosesandlinesareingoodcondition beforeapplyingpressuretothesystem.

•Keepyourbodyandhandsawayfrompinhole leaksornozzlesthatejecthydraulicuidunderhigh pressure.Usepaperorcardboard,notyourhands, tosearchforleaks.Hydraulicuidescapingunder pressurecanhavesufcientforcetopenetratethe skinandcauseseriousinjury.Ifuidisinjectedinto theskinitmustbesurgicallyremovedwithinafew hoursbyadoctorfamiliarwiththisformofinjury organgrenemayresult.

•Iftheenginemustberunningtoperforma maintenanceadjustment,keephands,feet,clothing, andanypartsofthebodyawayfromthecutting units,attachments,andanymovingparts.Keep everyoneaway.

•Checkbrakeoperationfrequently.Adjustandservice asrequired.

•Batteryacidispoisonousandcancauseburns.Avoid contactwithskin,eyes,andclothing.Protectyour face,eyes,andclothingwhenworkingwithabattery.

•Batterygasescanexplode.Keepcigarettes,sparks, andamesawayfromthebattery.

•Theenginemustbeshutoffbeforecheckingtheoil oraddingoiltothecrankcase.

•Ifmajorrepairsareeverneededorifassistanceis desired,contactanAuthorizedToroDistributor.

onlygenuineTororeplacementpartsandaccessories. Replacementpartsandaccessoriesmadebyother manufacturerscouldbedangerous,andsuchuse couldvoidtheproductwarranty.

SoundPressureLevel

ThisunithasanequivalentcontinuousA-weighted soundpressurelevelattheoperatorearof89dBA, basedonmeasurementsofidenticalmachinesperISO 11201andEN836.

SoundPowerLevel

ThisunithasanequivalentcontinuousA-weighted soundpowerlevelattheoperatorearof105dBA/1pW , basedonmeasurementsofidenticalmachinesperEN

11094.

VibrationLevel

Hand-Arm

ThisunithasanequivalentcontinuousA-weighted hand/armvibrationlevelof2.5m/s measurementsofidenticalmachinesperEN1033and EN836.

WholeBody

ThisunithasanequivalentcontinuousA-weighted hand/armvibrationlevelof0.5m/s measurementsofidenticalmachinesperEN1032and EN836.

,basedon

•Tomakesureofoptimumperformanceand continuedsafetycerticationofthemachine,use

SafetyandInstructionalDecals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof potentialdanger.Replaceanydecalthatisdamagedorlost.

93-7272

1.Cutting/dismembermenthazard;fan—stayawayfrom movingparts.

Page 8

1.ReadtheOperator’sManual.

2.Donotusestartingaids.

93-7275

100-5693

1.Heightofcutadjustment

93-7818

1.Warning—readtheOperator’sManualforinstructionson torquingthebladebolt/nutto115to149N•m(85to1 10 ft-lb).

100-5623

1.Lowheightofcut adjustment

2.Highheightofcut adjustment

100-6578

1.Entanglementhazard,belt—donotoperatethemachine withtheshieldsorguardsremoved;alwayskeepthe shieldsandguardsinplace;stayawayfrommovingparts.

100-5622

1.Heightofcutadjustment

100-5624

1.Lowheightofcut adjustment

100-5623

2.Highheightofcut adjustment

Page 9

1.Heightofcutadjustment

104-2277

1.Heightofcutadjustment

100-5694

1.Lowheightofcut adjustment

104-3579

2.Highheightofcut adjustment

104-3578

1.Tolocktheparkingbrake, latchthepedalstogether, applythebrakepedals, andpullupontheknob.

2.Tounlocktheparking brake,steponthebrake pedals.

3.Parkingbrakelock indicator

104-3599

1.Donotstephere.

2.Tractionpedal

3.Traction—forward

4.Traction—reverse

5.Danger—shutoffPTOpriortoraisingthecuttingunits;do notoperatethecuttingunitswhentheyareintheraised position.

104-2277

4.ReadtheOperator’s

Manual.

5.Pressforoptional headlights.

6.Pressdownontheleverto tiltthesteeringwheel.

Page 10

104-8324

1.Raisecuttingunits2.Lowercuttingunits

104-8325

1.Lock/unlockthecuttingunitservicelock.

106–6752

(Afxoverpartno.112–9118forCE*)

*Thissafetydecalincludesaslopewarningrequiredonthemachine

forcompliancetotheEuropeanLawnMowerSafetyStandardEN836:1997.The

conservativemaximumslopeanglesindicatedforoperationofthismachineare

prescribedbyandrequiredbythisstandard.

1.Warning—readtheOperator’sManual.

2.Warning—locktheparkingbrake,stoptheengine,and removetheignitionkeybeforeleavingthemachine.

3.Warning—weartheseatbeltwhenseatedintheoperator’s position.

4.Cuttinghazardofhandorfoot—stayawayfrommoving parts.

5.Tippinghazard—lowerthecuttingunitwhendrivingdown slopes;donotdriveonslopesgreaterthan15degrees.

6.Thrownobjecthazard—keepbystandersasafedistance fromthemachine.

112-9118

1.Warning—readtheOperator’sManual.

2.Warning—locktheparkingbrake,stoptheengine,and removetheignitionkeybeforeleavingthemachine.

3.Warning—weartheseatbeltwhenseatedintheoperator’s position.

4.Cuttinghazardofhandorfoot—stayawayfrommoving parts.

5.Tippinghazard—lowerthecuttingunitwhendrivingdown slopes;slowmachinebeforeturning,donotturnathigh speeds

6.Thrownobjecthazard—keepbystandersasafedistance fromthemachine.

106-6753

1.Enginecoolantunderpressure

2.Explosionhazard—readtheOperator’sManual.

3.Warning—donottouchthehotsurface.

4.Warning—readtheOperator’sManual.

106-6754

1.Warning—donottouchthehotsurface.

2.Cutting/dismembermenthazard,fanandentanglement hazard,belt—stayawayfrommovingparts.

Page 11

106-6755

1.Enginecoolantunder pressure.

2.Explosionhazard—read theOperator’sManual.

3.Warning—donottouch thehotsurface.

4.Warning—readthe

Operator’sManual.

106-6764

1.Tostarttheengine,movethetractionpedaltoNeutral, pressthebrakepedal,movethethrottlelevertoFast,turn theignitionkeytoOn,andthenturntheignitionkeytoStart; readtheOperatorsManual.

2.Tostoptheengine,movethethrottlelevertoslow, disengagethePTO,settheparkingbrake,wait5minutes, turntheignitionkeytoStop,andremovethekey;readthe

OperatorsManual.

3.ReadtheOperatorsManual.

4.ToengagethePTO,pulluponthePTOswitchandmove itforward.

5.TodisengagethePTO,movethePTOswitchback.

6.Toswitchthetransmissiontohighspeed,raisethe attachmentliftandswitchthespeedcontroltoHigh.

BatterySymbols

Someorallofthesesymbolsareonyourbattery

1.Explosionhazard

2.Nore,opename,or smoking.

3.Causticliquid/chemical burnhazard

4.Weareyeprotection9.Flusheyesimmediately

5.ReadtheOperator’s

Manual.

6.Keepbystandersasafe

7.Weareyeprotection;

8.Batteryacidcancause

10.Containslead;donot

distancefromthebattery.

explosivegasescan causeblindnessandother injuries

blindnessorsevereburns.

withwaterandgetmedical helpfast.

discard.

110-3286

1.Poweroutlet

2.Seatswitch5.Startersolenoid

3.Ignitionswitch6.LightKit

4.PowerTakeOff(PTO)

Page 12

106-2046

1.PowerTake-off(PTO)

2.Engage7.Lock12.Pressthebutton

3.Disengage8.Flowdivider13.Keyswitch18.Enginecoolanttemperature

4.Transmission9.Unlock14.Engine—preheat

5.High

6.Low

10.Cruisecontrol(optional)

11.Silencerswitch16.Slow

17.Continuousvariablesetting

resetswitch

15.Fast

1.ReadtheOperator’sManual.

104-8336

Page 13

Setup

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescription

Seatkit(obtainseparately) Seatsuspensionkit(obtainseparately) Manualtube1

R-clamp2 Seatbelt Bolt2 Lockwasher2

Nopartsrequired

WarningDecal1

Operator’sManual EngineOperator’sManual PartsCatalog OperatorTrainingMaterials Pre-deliveryInspectionSheet CEcerticate

Note:Determinetheleftandrightsidesofthemachine fromthenormaloperatingposition.

Qty.

Use

1 1

Installtheseat,seatbelt,andmanual

–

1 1 1 1 1 1

tube.

Greasethemachine.

Usedonlyonmachinesrequiring EuropeanCEcompliance.

ReadthemanualsandwatchtheDVD beforeoperatingthemachine.Usethe remainingpartsfortheinstallationof attachments.

Page 14

InstallingtheSeat,SeatBelt,

GreasingtheBearingsandBushingsprocedureof Lubrication,page32.Failuretoproperlygreasethe machinewillresultinprematurefailureofcriticalparts.

andManualTube

Partsneededforthisprocedure:

Seatkit(obtainseparately)

Seatsuspensionkit(obtainseparately)

1Manualtube

2R-clamp

Seatbelt

2Bolt

2Lockwasher

Procedure

Themachineisshippedwithouttheseatassembly.A Seat,ModelNo.30622andSuspension,ModelNo. 30621orSeat,ModelNo.30396andSuspension,Model No.30398mustbepurchasedandinstalled.

1.Mountthemanualtubetotheseatsuspensionwith the2R-clampsincludedinlooseparts.

ReplacingtheWarningDecal

Partsneededforthisprocedure:

1WarningDecal

Procedure

OnmachinesusedoutsideoftheU .S.A.,replacethe warningdecal,partno.112–9118withthewarningdecal partno.106–6752.

ReadingtheManualsand ViewingtheDVD

2.Installtheseatbelttoeachsideoftheseatwitha boltandlockwasher,suppliedinlooseparts.Make suretheseatbeltretractorisattachedtotheleftside oftheseat.

Important:Makesurethattheseatswitchwire isconnectedtotheseatswitchconnectoronthe harness.

3.Slidetheseatcompletelyforwardandbackwardto ensureproperoperationandthatseatswitchwires andconnectorsarenotpinchedordonocontactany movingparts.

GreasingtheMachine

NoPartsRequired

Procedure

Partsneededforthisprocedure:

Operator’sManual

EngineOperator’sManual

PartsCatalog

OperatorTrainingMaterials

Pre-deliveryInspectionSheet

CEcerticate

Procedure

1.Readthemanuals.

2.ViewtheOperatorTrainingmaterials.

Beforethemachineisoperated,itmustbegreased toensureproperlubricatingcharacteristics;referto

Page 15

ProductOverview

load,maximumgroundspeed,fullypressthepedalwhile thethrottleisinFast.

Tostop,reduceyourfootpressureonthetractionpedal andallowittoreturntothecenterposition.

Important:Wheninthemowposition,thespeed limiterscrewmuststopthetractionpedalbeforethe pumpreachesfullstrokeordamagetothepump mayoccur.

BrakePedals

Twofootpedals(Figure2)operateindividualwheel brakesforturningassistance,parking,andtoaidin obtainingbettersidehilltraction.Alatchconnectsthe pedalsforparkingbrakeoperationandtransport.

PedalLockingLatch

Thepedallockinglatch(Figure2)connectsthepedals togethertoengagetheparkingbrake.

Figure2

1.Tractionpedal

2.Brakepedals7.Engineoilpressure

3.Pedallockinglatch8.Enginecoolant

4.Tiltsteeringlever

5.Parkingbrakelatch10.Temperaturegauge

6.Chargeindicator

warninglight

temperaturewarning light

9.Glowplugindicatorlight

Controls

Note:Determinetheleftandrightsidesofthemachine

fromthenormaloperatingposition.

Thismachineproducessoundlevelsinexcess of85dBAattheoperatorsearandcancause hearinglossthroughextendedperiodsof exposure.

Wearhearingprotectionwhenoperatingthis machine.

TiltSteeringLever

Pressthelever(Figure2)downtotiltthesteeringwheel tothedesiredposition.Thenreleasethelevertolock theadjustment.

ParkingBrakeLatch

Aknobontheleftsideoftheconsoleactuatesthe parkingbrakelock(Figure2).Toengagetheparking brake,connectthepedalswiththelockinglatch,push downonbothpedals,andpulltheparkingbrakelatch out.Toreleasetheparkingbrake,pressbothpedalsuntil theparkingbrakelatchretracts.

ChargeIndicator

Thechargeindicator(Figure2)illuminateswhenthe systemchargingcircuitmalfunctions.

EngineOilPressureWarningLight

Thelight(Figure2)illuminateswhentheengineoil pressureisdangerouslylow .

TractionPedal

Thetractionpedal(Figure2)controlsforwardand reverseoperation.Pressthetopofthepedaltomove forwardandthebottomtomovebackward.Ground speeddependsonhowfaryoupressthepedal.Forno

EngineCoolantTemperatureWarning Light

Thelight(Figure2)illuminatesandtheengineshuts downwhencoolantreachesanexcessivelyhigh temperature.

Page 16

GlowPlugIndicatorLight

PTOSwitch

Whenlit,theglowplugindicatorlight(Figure2) indicatesthattheglowplugsareon.

EngineTemperatureGauge

Thisgauge(Figure2)indicatestheenginecoolant temperature.

SpeedLimiter

Ifdesired,thescrewcanbeadjusted(Figure3)tolimit theamountthetractionpedalcanbedepressedinthe forwarddirectiontolimitthemowingspeed.

Important:Thetractionpedalmustcontactthe speedlimiterbeforereachingtheendofthepump stroketopreventpumpdamage.

ThePTOswitch(Figure4)hasthreepositions:On (engage),Neutral,andOff(disengage).Carefullylift andpushthePTOswitchforwardtotheOnposition tostarttheimplementorcuttingunitblades.Slowly pulltheswitchbackwardtotheOffpositiontostop implementoperation.

Hi-LoSpeedControl

Thecontrol(Figure4)allowsthespeedrangetoincrease fortransportofthemachine.

FlowDividerSwitch

Whenoperatinginmow(low)speed,pressandhold owdividerswitch(Figure4)toenhancetractiondrive performanceincompromisedoperatingconditions.

Figure3

1.Speedlimiter

LiftLevers

Thelevers(Figure4)raiseandlowerthecuttingunits.

CuttingUnitServiceLock

Thecuttingunitservicelock(Figure4)locksthefront cuttingunitliftleverwhenthecuttingunitisinthe raisedposition.

KeySwitch

Thekeyswitch(Figure4)hasthreepositions:Off, On/Preheat,andStart.

Figure4

1.Liftlever

2.Frontcuttingunitservice lock

3.Keyswitch10.Hourmeter

4.PTOswitch

5.Hi-lospeedcontrol12.Throttle

6.Flowdividerswitch13.Audiblealarm

7.Cruisecontrol(optional)

8.Alarmsilenceswitch

9.Temperatureresetswitch

11.Fuelgauge

14.Powerpoint

CruiseControl(Optional)

Thecruisecontrol(Figure4)setsthespeedofthe machine.

FuelGauge

Thefuelgauge(Figure4)indicatestheleveloffuelin thetank.

HourMeter

Thehourmeter(Figure4)showsthetotalhoursthatthe machinehasbeenoperated.

Page 17

TemperatureOverrideSwitch

ThrottleControl

Pressandholdtheresetswitch(Figure4)tostartthe engineafterhightemperatureshutdown.Useonlyfor

Movethecontrol(Figure4)forwardtoincreasethe enginespeedandrearwardtodecreasethespeed.

emergencyoperation.

AudibleAlarm

Thealarm(Figure4)isactivatedwhenthelowengine oilpressurelightilluminatesorthehighcoolant

PowerPoint

Thepowerpoint(Figure4)isusedtopoweroptional electricalaccessories.

temperaturelightilluminates.

AlarmSilenceSwitch

Thisswitch(Figure4)shutsofftheaudiblealarm.

Specications

Note:Specicationsanddesignaresubjecttochangewithoutnotice.

Widthofcut

overall

frontcuttingunit62inch(157cm)

sidecuttingunit

frontandonesidecuttingunit97inch(246cm)

Overallwidth

cuttingunitsdown

cuttingunitsup(transports)72inch(183cm)

Overalllength135inch(342cm)

Height

132inch(335cm)

42inch(107cm)

136inch(345cm)

55inch(140cm)

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

BeforeOperating

Ifyouleavethekeyintheignitionswitch, someonecouldaccidentlystarttheengineand seriouslyinjureyouorotherbystanders.

HeightwithROPS81inch(206cm)

Groundclearance6-1/2inch(17cm)

Wheeltread(tocenteroftire)

front45inch(1 14cm)

rear

Wheelbase

Weight(withcuttingunitsanduids)3860lb(1751kg)

47inch(119cm)

55-1/2in(141cm)

Attachments/Accessories

AselectionofToroapprovedattachmentsand accessoriesareavailableforusewiththemachineto enhanceandexpanditscapabilities.Contactyour AuthorizedServiceDealerorDistributororgoto www.Toro.comforalistofallapprovedattachments andaccessories.

Removethekeyfromtheignitionbeforeyoudo anymaintenance.

CheckingtheEngineOil

ServiceInterval:Beforeeachuseordaily

Theengineisshippedwithoilinthecrankcase; however,theoillevelmustbecheckedbeforeandafter theengineisrststarted.

Thecrankcasecapacityis8qt(7.6l)withthelter.

Usehigh-qualityengineoilthatmeetsthefollowing specications:

•APIClassicationLevelRequired:CH-4,CI-4or higher.

•Preferredoil:SAE15W -40(above0°F)

•Alternateoil:SAE10W-30or5W -30(all temperatures)

ToroPremiumEngineOilisavailablefromyour distributorineither15W-40or10W-30viscosity .See thepartscatalogforpartnumbers.

Page 18

1.Parkthemachineonalevelsurface.Unlockthe enginecoverlatches.

2.Opentheenginecover.

3.Removethedipstick,wipeitclean,installthe dipstickintothetube,andpullitoutagain.Theoil levelshouldbeuptotheFullmark(Figure5).

Figure5

1.Dipstick

4.IftheoilisbelowtheFullmark,removethellcap (Figure6)andaddoiluntilthelevelreachestheFull mark.Donotoverll.

Iftheenginehasbeenrunning,thepressurized, hotcoolantcanescapeandcauseburns.

•Donotopentheradiatorcapwhenthe engineisrunning.

•Usearagwhenopeningtheradiatorcap, andopenthecapslowlytoallowsteamto escape.

2.Checkthecoolantlevelintheradiator.Theradiator shouldbelledtothetopofthellerneckandthe expansiontanklledtotheFullmark.

Figure6

1.Oilllcap

5.Installtheoilllcapanddipstick.

6.Closetheenginecoverandsecureitwiththelatches.

CheckingtheCoolingSystem

ServiceInterval:Beforeeachuseordaily

Checklevelofcoolantatthebeginningofeachday. Capacityofsystemis2-3/4U.S.gallons(10.4l).

1.Carefullyremovetheradiatorcapandexpansion tankcap(Figure7).

Figure7

1.Expansiontank

3.Ifthecoolantislow ,adda50/50mixtureofwater andethyleneglycolanti-freeze.Donotusewater

onlyoralcohol/methanolbasecoolants.

4.Installtheradiatorcapandexpansiontankcap.

AddingFuel

Useonlyclean,freshdieselfuelorbiodieselfuelswith low(<500ppm)orultralow(<15ppm)sulfurcontent. Theminimumcetaneratingshouldbe40.Purchase fuelinquantitiesthatcanbeusedwithin180daysto ensurefuelfreshness.

Fueltankcapacity:19USgallons(72l)

Usesummergradedieselfuel(No.2-D)attemperatures above20°F(-7°C)andwintergrade(No.1-Dor No.1-D/2-Dblend)belowthattemperature.Useof wintergradefuelatlowertemperaturesprovideslower

Page 19

ashpointandcoldowcharacteristicswhichwillease startingandreducefuellterplugging.

Useofsummergradefuelabove20°F(-7°C)will contributetowardlongerfuelpumplifeandincreased powercomparedtowintergradefuel.

Important:Donotusekeroseneorgasoline insteadofdieselfuel.Failuretoobservethis cautionwilldamagetheengine.

Fuelisharmfulorfatalifswallowed.Long-term exposuretovaporscancauseseriousinjuryand illness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgastankor conditioneropening .

•Keepfuelawayfromeyesandskin.

BiodieselReady

Thismachinecanalsouseabiodieselblendedfuel ofuptoB20(20%biodiesel,80%petrodiesel).The petrodieselportionshouldbeloworultralowsulfur. Observethefollowingprecautions:

•Thebiodieselportionofthefuelmustmeet specicationASTMD6751orEN14214.

•TheblendedfuelcompositionshouldmeetASTM D975orEN590.

•Paintedsurfacesmaybedamagedbybiodiesel blends.

•UseB5(biodieselcontentof5%)orlesserblends incoldweather.

•Monitorseals,hoses,gasketsincontactwithfuelas theymaybedegradedovertime.

•Fuellterpluggingmaybeexpectedforatimeafter convertingtobiodieselblends.

•Contactyourdistributorifyouwishformore informationonbiodiesel.

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

•Fillthefueltankoutdoors,inanopenarea, whentheengineiscold.Wipeupanyfuel thatspills.

•Neverllthefueltankinsideanenclosed trailer.

•Neversmokewhenhandlingfuel,andstay awayfromanopenameorwherefuel fumesmaybeignitedbyaspark.

•Storefuelinanapprovedcontainerandkeep itoutofthereachofchildren.Neverbuy morethana30-daysupplyoffuel.

•Donotoperatewithoutentireexhaust systeminplaceandinproperworking condition.

Incertainconditionsduringfueling,static electricitycanbereleasedcausingaspark whichcanignitethefuelvapors.Areor explosionfromfuelcanburnyouandothers andcandamageproperty.

•Alwaysplacefuelcontainersontheground awayfromyourvehiclebeforelling.

•Donotllfuelcontainersinsideavehicle oronatruckortrailerbedbecauseinterior carpetsorplastictruckbedlinersmay insulatethecontainerandslowthelossof anystaticcharge.

•Whenpractical,removeequipmentfromthe truckortrailerandrefueltheequipment withitswheelsontheground.

•Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfroma portablecontainer,ratherthanfromafuel dispensernozzle.

•Ifafueldispensernozzlemustbeused,keep thenozzleincontactwiththerimofthefuel tankorcontaineropeningatalltimesuntil fuelingiscomplete.

1.Parkthemachineonalevelsurface.

Page 20

2.Usingacleanrag,cleanareaaroundfueltankcap.

3.Removecapfromthefueltank(Figure8).

HighViscosityIndex/LowPourPointAnti-wear

HydraulicFluid,ISOVG46(cont'd.)

Figure8

1.Fueltankcap

4.Fillthetankuntilthelevelistothebottomofthe llerneckwithdieselfuel.

5.Installfueltankcaptightlyafterllingtank.

Note:Ifpossible,llthefueltankaftereachuse. Thiswillminimizepossiblebuildupofcondensation insidethefueltank.

CheckingtheHydraulicFluid

ServiceInterval:Beforeeachuseordaily

Themachinesreservoirislledatthefactorywith approximately8U.S.gallons(30.2l)ofhighquality hydraulicuid.Checkthelevelofthehydraulic

uidbeforetheengineisrststartedanddaily thereafter.Therecommendedreplacementuidis:

ToroPremiumAllSeasonHydraulicFluid

(Availablein5gallonpailsor55gallondrums.Seeparts catalogorTorodistributorforpartnumbers.)

ViscosityIndexASTMD2270

PourPoint,ASTMD97-34°Fto-49°F

IndustrySpecications:VickersI-286-S(Quality

Level),VickersM-2950-S

(QualityLevel),Denison

140to160

HF-0

Note:Manyhydraulicuidsarealmostcolorless, makingitdifculttospotleaks.Areddyeadditivefor thehydraulicsystemoilisavailablein2/3oz(20ml) bottles.Onebottleissufcientfor4-6gallons(15-22

1)ofhydraulicoil.Orderpartno.44-2500fromyour authorizedTorodistributor.

BiodegradableHydraulicFluid-MobilEAL224H

ToroBiodegradableHydraulicFluid

Toro

(Availablein5gallonpailsor55gallondrums.Seeparts catalogorTorodistributorforpartnumbers.)

*Useonlywhentemperaturesareabove30°F .

Thisisvegetable-oilbasedbiodegradableoiltestedand approvedbyT oroforthismodel.Thisuidisnotas resistanttohightemperaturesasstandarduid,so followtherecommendeduidchangeintervalswith thisuid.Contaminationbymineral-basedhydraulic uidswillchangethebiodegradabilityandtoxicityof thisoil.Whenchangingfromstandarduidtothe biodegradabletype,becertaintofollowtheapproved ushingprocedure.ContactyourlocalToroDistributor fordetails.

1.Positionthemachineonalevelsurface,lowerthe cuttingunits,stoptheengine,andremovethekey.

Alternateuids:IftheTorouidisnotavailable,other uidsmaybeusedprovidedtheymeetallthefollowing materialpropertiesandindustryspecications.W edo notrecommendtheuseofsyntheticuid.Consult withyourlubricantdistributortoidentifyasatisfactory product.

Note:Torowillnotassumeresponsibilityfordamage causedbyimpropersubstitutions,souseonlyproducts fromreputablemanufacturerswhowillstandbehind theirrecommendation.

HighViscosityIndex/LowPourPointAnti-wear HydraulicFluid,ISOVG46

MaterialProperties:

St@40°C44to48 Viscosity,ASTMD445

St@100°C7.9to8.5

2.Unlatchtheseat,raiseit,andengagetheproprod.

3.Cleantheareaaroundthellerneckandcapofthe hydraulictank(Figure9).Removethecapfromthe llerneck.

Page 21

1.Hydraulictankcap

Figure9

4.Removethedipstickfromthellerneckandwipe itwithacleanrag.Insertthedipstickintotheller neck;thenremoveitandchecktheuidlevel.The uidlevelshouldbebetweenthetwomarksonthe dipstick.

5.Ifthelevelislow,addtheappropriateuidtoraise theleveltotheuppermark.

6.Installthedipstickandcapontothellerneck.

CheckingthePlanetaryGearDriveOil

ServiceInterval:Every400hours

Checktheoillevelafterevery400hoursofoperation orifexternalleakageisnoted.UsehighqualitySAE 85W-140gearlubeasareplacement.

Thecapacityofthesystemisapproximately16oz(0.5 l).

1.Withthemachineonalevelsurface,positionthe wheelsothatthecheck/drainplug(Figure10)isat eitherthe2or10o’clockposition.

Figure10

1.Check/drainplug

2.Removetheplugontheplanetary(Figure10) andchecktheplugonthebacksideofthebrake (Figure11).Oilshouldbeatthebottomofthe checkplugholeonthebacksideofthebrake.

Figure11

1.Brakehousing

2.Checkplug

3.Addgearoiltotheholeintheplanetary,ifnecessary, tobringtheoiluptotheproperlevel.Installthe plug.

4.Repeatsteps1-3ontheoppositegearassembly.

Page 22

CheckingtheRearAxleLubricant

ServiceInterval:Every400hours

Therearaxleisshippedfromthefactorylledwith SAE85W-140gearlube.Checktheoillevelbeforethe engineisrststartedandevery400hoursthereafter. Thecapacityis80oz(2.4l).Visuallyinspectforleaks daily.

1.Positionthemachineonalevelsurface.

2.Removeacheckplugfromoneendoftheaxle (Figure12)andmakesurethatthelubricantisupto thebottomofthehole.Ifthelevelislow,remove thellplug(Figure12)andaddenoughlubricantto bringtheleveluptothebottomofthecheckplug holes.

Figure13

1.Gearbox2.Check/llplug

CheckingtheTirePressure

ServiceInterval:Beforeeachuseordaily

Thetiresareover-inatedforshipping.Therefore, releasesomeoftheairtoreducethepressure.The correctairpressureinthefrontandreartiresis25-30 psi(172-207kPa).

Figure12

1.Checkplug

2.Fillplug

CheckingtheRearAxleGearBox Lubricant

ServiceInterval:Every400hours

Thegearboxisshippedfromthefactorylledwith SAE85W-140gearlube.Checktheoillevelbeforethe engineisrststartedandevery400hoursthereafter. Thecapacityis16oz(0.5l).Visuallyinspectforleaks daily.

1.Positionthemachineonalevelsurface.

2.Removethecheck/llplugfromtheleftsideofthe gearbox(Figure13)andmakesurethatlubricant isuptothebottomofthehole.Ifthelevelislow, addenoughlubricanttobringtheleveluptothe bottomofthehole.

Important:Maintainevenpressureinalltiresto ensureagoodquality-of-cutandpropermachine performance.

Do not under -inate.

CheckingtheTorqueoftheWheelNuts orBolts

ServiceInterval:Aftertherst10hours

Every200hours

Failuretomaintainpropertorqueofthewheel nutscouldresultinfailureorlossofwheeland mayresultinpersonalinjury.

Torquethefrontwheelnutsandrearboltsto85 to100ft-lb(115to136N⋅ ⋅⋅m)after1-4hoursof operationandagainafter10hoursofoperation. Torqueevery200hoursthereafter.

AdjustingtheHeight-of-Cut

FrontCuttingUnit

Theheight-of-cutisadjustablefrom1to5inches(25 to127mm)in1/2inch(13mm)increments.Toadjust theheight-of-cutonthefrontcuttingunit,positionthe castorwheelaxlesintheupperorlowerholesofthe

Page 23

castorforks,addorremoveanequalnumberofspacers fromthecastorforks,andsecuretherearchaintothe desiredhole.

1.Starttheengineandraisethecuttingunitssothat theheight-of-cutcanbechanged.Stoptheengine andremovethekeyafterthecuttingunitisraised.

2.Positionthecastorwheelaxlesinthesameholes inallcastorforks.Refertothefollowingchartto determinethecorrectholesforthesetting.

below)ontothespindleshafttogetthedesired height-of-cut;thenslidethewasherontotheshaft.

Refertothefollowingcharttodeterminethe combinationsofspacersforthesetting:

Figure15

4.Pushthecastorspindlethroughthefrontcastor arm.Installtheshims(astheywereoriginally installed)andtheremainingspacersontothe spindleshaft.Installthetensioningcaptosecure theassembly .

5.Removethehairpincotterandclevispinsecuring theheight-of-cutchainstotherearofthecutting unit(Figure16).

Figure14

1.Castorwheel4.Shims

2.Tensioningcap5.Axlemountingholes

3.Spacers

Note:Whenoperatingin2-1/2inch(64mm) heightofcutorhigher,theaxleboltmustbe installedinthelowercastorforkholetoprevent grassbuildupbetweenthewheelandthefork. Whenoperatinginheightofcutslowerthan2-1/2 inches(64mm)andgrassbuildupisdetected, reversethemachinesdirectiontopullanyclippings awayfromthewheel/forkarea.

3.Removethetensioningcapfromthespindleshaft (Figure14)andslidethespindleoutofthecastor arm.Putthe2shims(1/8inch[3mm])ontothe spindleshaftastheywereoriginallyinstalled.These shimsarerequiredtoachievealevelacrosstheentire widthofthecuttingunits.Slidetheappropriate numberof1/2inchspacers(refertothechart

Figure16

1.Height-of-cutchain

2.U-bolt

6.Mounttheheight-of-cutchainstothedesired height-of-cuthole(Figure17)withtheclevispin andhairpincotter.

Figure17

Page 24

Note:Whenusing1inch(25mm),1-1/2inch(38 mm),oroccasionally2inch(51mm)height-of-cut, movetheskidsandgagewheelstothehighestholes.

SideCuttingUnits

Toadjusttheheight-of-cutonthesidecuttingunits,add orremoveanequalnumberofspacersfromthecastor forks,positionthecastorwheelaxlesinthehighorlow height-of-cutholesinthecastorforks,andsecurethe pivotarmstotheselectedheight-of-cutbracketholes.

1.Positionthecastorwheelaxlesinthesameholes inallofthecastorforks(Figure18andFigure20). Refertothefollowingcharttodeterminethe correctholeforthesetting.

2.Removethetensioningcapfromthespindleshaft (Figure18)andslidethespindleoutofcastorarm. Putthetwoshims(1/8inch[3mm])ontospindle shaftastheywereoriginallyinstalled.Theseshims arerequiredtoachievealevelacrosstheentire widthofthecuttingunits.Slidetheappropriate numberof1/2inchspacersontothespindleshaft togetthedesiredheight-of-cut;thenslidethe washerontotheshaft.

Figure19

3.Pushthecastorspindlethroughthecastorarm. Installtheshims(asoriginallyinstalled)andthe remainingspacersontothespindleshaft.Installthe tensioningcaptosecuretheassembly .

4.Removethehairpincotterandclevispinsfromthe castorpivotarms(Figure20).

5.Rotatetensionrodtoraiseorlowerpivotarm untilholesarealignedwithselectedheight-of-cut bracketholesinthecuttingunitframe(Figure20 andFigure21).

6.Inserttheclevispinsandinstallthehairpincotters.

7.Rotatetensionrodcounterclockwise(ngertight) toputtensiononadjustment.

Figure20

1.Castorpivotarm3.Clevispinandhairpin

2.Axlemountingholes4.T ensionrod

cotter

Figure18

1.Castorwheel4.Shims

2.Tensioningcap5.Axlemountingholes

3.Spacers

Refertothefollowingcharttodeterminethe combinationsofspacersforthesetting.

Page 25

Figure21

Figure23

8.Removethehairpincottersandclevispinssecuring thedamperlinkstothecuttingunitbrackets (Figure22).Alignthedamperlinkholeswiththe selectedheight-of-cutbracketholesinthecutting unitframe(Figure23),inserttheclevispins,and installthehairpincotters.

Important:Thedamperlinklengthshould neverbeadjusted.Thelengthbetweenthehole centersshouldbe5-3/8inch(13.7cm).

AdjustingtheSkids

Theskidsshouldbemountedinthelowerposition whenoperatinginheightofcutsgreaterthan2-1/2 inches(64mm)andinthehigherpositionwhen operatinginheightofcutslowerthan2-1/2inches(64 mm).

Adjusttheskidsbyremovingtheangeboltandnuts, positioningthemasdesired,andinstallingthefasteners (Figure24).

Figure24

1.Skid

1.Damperlink

Figure22

AdjustingtheCuttingUnitRollers

Thecuttingunitrollersshouldbemountedinthelower positionwhenoperatinginheightofcutsgreaterthan 2-1/2inches(64mm)andinthehigherpositionwhen operatinginheightofcutslowerthan2-1/2inches(64 mm).

1.Removetheboltandnutsecuringthegagewheelto thecuttingunitbrackets(Figure25).

Page 26

Figure25

1.Gagewheel

2.Aligntherollerandspacerwiththetopholesinthe bracketsandsecurethemwiththeboltandnut.

CorrectingMismatchBetweenCutting Units

Duetodifferencesingrassconditionsandthe counterbalancesettingofthetractionunit,itisadvised thatgrassbecutandappearancecheckedbeforeformal cuttingisstarted.

FrontCuttingUnitSetup

Rotatebladeoneachspindleuntiltheendsfaceforward andbackward.Measurefromtheoortothefront tipofthecuttingedge.Adjust1/8inchshimson frontcastorfork(s)tomatchheightofcuttodecal (Figure26);refertoAdjustingtheCuttingUnitPitch procedureinMowerMaintenance,page50.

1.Setallcuttingunitstothedesiredheightofcut; refertoAdjustingtheHeightofCuttablein Specications,page17.

2.Checkandadjustfrontandreartractortirepressure to25-30psi(172-207kPa).

3.Checkandadjustallcastortirepressuresto50psi (345kPa).

4.Checkchargeandcounterbalancepressures withengineathighidleusingtestportsdened inHydraulicSystemsTestPorts.Adjust counterbalancesettingtobe220psi(1517kPa) higherthanchargepressurereading.

5.Checkforbentblades;refertoCheckingforaBent BladeprocedureinMowerMaintenance,page50.

6.Cutgrassinatestareatodetermineifallcutting unitsarecuttingatthesameheight.

7.Ifcuttingunitadjustmentsarestillneeded,ndaat surfaceusinga6foot(2m)orlongerstraightedge.

8.Toeasemeasuringbladeplane,raisetheheightof cuttothehighestposition;refertoAdjustingthe HeightofCut.

Figure26

1.Castorwheel4.Shims

2.Tensioningcap5.Axlemountingholes

3.Spacers

SideCuttingUnitSetup

Rotatebladeofeachspindleuntiltheendsfaceforward andbackward.Measurefromtheoortothefront tipofthecuttingedge.Adjust1/8inchshimson frontcastorarm(s)tomatchheightofcuttodecal (Figure27).Fortheoutsidebladespindleonly,referto AdjustingtheCuttingUnitPitchprocedureinMower Maintenance,page50.

9.Lowercuttingunitsontotheatsurface.Remove thecoversfromthetopofthecuttingunits.

10.Loosentheangenut,securingtheidlerpulley,to releasethebelttensiononeachcuttingunit.

Page 27

Figure27

1.Frontcastorarm

MatchingHeightOfCutBetweenCuttingUnits

1.Positionbladesidetosideonoutsidespindleof bothsidecuttingunits.Measurefromtheoor tothetipofthecuttingedgeonbothunitsand compare.Thesenumbersshouldbewithin1/8inch (3mm)ofeachother.Makenoadjustmentatthis time.

2.Positionbladesidetosideoninsidespindleofside cuttingunitandcorrespondingoutsidespindle offrontcuttingunit.Measurefromtheoorto thetipofthecuttingedgeoninsideedgeofside cuttingunittocorrespondingoutsideedgeoffront cuttingunitandcompare.Thesidecuttingunit measurementshouldbeapproximately3/8inch lessthanthefrontcuttingunitmeasurementtobe correct.Whenpropermachinecounterbalanceis appliedtothesidecuttingunitstheinsideedgewill liftupapproximately3/8inch(10mm).

Note:Allthreesidecuttingunitscastorwheels shouldremainonthegroundwithcounterbalance applied.

edgeofsidecuttingunittooutsideedgeoffront cuttingunit.

4.Ifinsideedgeisstilltoohigh,removeanadditional 1/8inchshimfrombottomoffrontinsidecastor armofthesidecuttingunitandone1/8inchshim fromthefrontoutsidecastorarmofthesidecutting unit.

5.Iftheinsideedgeofthesidecuttingunitistoolow relativetotheoutsideedgeofthefrontcuttingunit, addone1/8inchshimtothebottomofthefront insidecastorarmonthesidecuttingunit.Check measurementbetweenoutsideedgesofbothside cuttingunitsandinsideedgeofsidecuttingunitto outsideedgeoffrontcuttingunit.

6.Ifinsideedgeisstilltoolow ,addanadditional1/8 inchshimtothebottomoffrontinsidecastorarm ofthesidecuttingunitandaddone1/8inchshim tothefrontoutsidecastorarmofthesidecutting unit.

7.Oncecuttingheightmatchesattheedgesoffront andsidecuttingunits,verifythatsidecuttingunit pitchisstill1/4inch(6mm).Adjustasnecessary.

StartingandStoppingthe Engine

Important:Thefuelsystemwillautomatically

bleeditselfwhenanyofthefollowingsituations occur:

•Initialstartupofanewmachine.

•Theenginehasceasedrunningduetolackoffuel.

•Maintenancehasbeenperformeduponthefuel systemcomponents.

1.Ensurethattheparkingbrakeisset.Removeyour footfromthetractionpedalandensurethatitisin neutral.

2.Movethethrottlecontroltothemid-idleposition.

3.TurntheignitionkeytotheRunposition.Theglow indicatorwilllight.

Note:Ifadjustmentsneedtobemadetomatchthe cutbetweenthefrontandsidecuttingunits,make theadjustmentstothesidecuttingunitsonly.

3.Iftheinsideedgeofthesidecuttingunitistoo highrelativetotheoutsideedgeofthefrontcutting unit,removeone1/8inchshimfromthebottom ofthefrontinsidecastorarmonthesidecutting unit(Figure27).Recheckmeasurementbetween outsideedgesofbothsidecuttingunitsandinside

4.Whentheglowindicatordims,turntheignitionkey totheStartposition.Releasethekeyimmediately whentheenginestartsandallowittoreturntothe Runposition.Allowenginetowarmupatmid speed(withoutload),thenmovethethrottlecontrol tothedesiredposition.

Important:Donotrunthestartermotor morethan15secondsatatimeorpremature starterfailuremayresult.Iftheenginefailsto

Page 28

startafter15seconds,turnthekeytotheOff position,recheckthecontrolsandprocedures, wait15additionalseconds,andrepeatthe startingprocedure.

Whenthetemperatureislessthan20°F(-75C), preheatglowplugstwicepriortoinitialcranking attempt.Thestartermotorcanberunfor30 secondsonthen60secondsofffor2attempts.

5.Whentheengineisstartedforthersttime,orafter anoverhauloftheengine,transmission,oraxle, operatethemachineinforwardandreverse,off theground,foraminimumoftwominutes.Also operatetheliftleverandPTOlevertoensureproper operationofallparts.Turnthesteeringwheelto theleftandrighttochecksteeringresponse.Then shuttheengineoffandcheckforoilleaks,loose parts,andanyothernoticeabledifculties.

Shuttheengineoffandwaitforallmoving partstostopbeforecheckingforoilleaks,loose parts,andothermalfunctions.

6.Tostoptheengine,movethethrottlecontrol backwardtotheSlowposition,movethePTOlever totheOffposition,settheparkingbrake,androtate theignitionkeytoOff.Removethekeyfromthe switchtopreventaccidentalstarting.

oftheseatwhiletheengineisrunningandthetraction pedalisinneutral.Althoughtheenginewillcontinue torunifthePTOleverisdisengagedandthetraction pedalisreleased,itisstronglyrecommendedthatthe enginebestoppedbeforerisingfromtheseat.

Tochecktheoperationoftheinterlockswitches, performthefollowingprocedure:

1.Drivethemachineslowlytoalarge,relativelyopen area.Lowerthecuttingunit,stoptheengine,and applytheparkingbrake.

2.Sitontheseatanddepressthetractionpedal.Try tostarttheengine.Theengineshouldnotcrank. Iftheenginecranks,thereisamalfunctioninthe interlocksystemthatshouldbecorrectedbefore beginningoperation.

3.Sitontheseatandstarttheengine.Risefromthe seatandmovethePTOlevertoOn.ThePTO shouldnotengage.IfthePTOengages,thereisa malfunctionintheinterlocksystemthatshouldbe correctedbeforebeginningoperation.

4.Sitontheseat,engagetheparkingbrakeandstart theengine.Movethetractionpedaloutofthe neutralposition.Theengineshouldkill.Ifthe enginedoesnotkill,thereisamalfunctioninthe interlocksystemthatshouldbecorrectedbefore beginningoperation.

PushingorTowingthe

Important:Allowenginetoidlefor5minutes

beforeshuttingitoffafterafullloadoperation. Failuretodosomayleadtoturbo-chargertrouble.

CheckingtheInterlock Switches

Ifsafetyinterlockswitchesaredisconnected ordamagedthemachinecouldoperate unexpectedlycausingpersonalinjury.

•Donottamperwiththeinterlockswitches.

•Checktheoperationoftheinterlock switchesdailyandreplaceanydamaged switchesbeforeoperatingthemachine.

Themachinehasinterlockswitchesintheelectrical system.Theseswitchesaredesignedtostoptheengine whenoperatorgetsoffoftheseatwhenthetraction pedalisdepressed.However,theoperatormaygetoff

Machine

Inanemergency,themachinecanbemovedforwardby actuatingthebypassvalveinthevariabledisplacement hydraulicpumpandpushingortowingthemachine.

Donotpushortowthemachineformorethan1/4 mile(0.4km).

Important:Donotpushortowthemachine fasterthan2-3MPH(3-4.8km/h)becauseinternal transmissiondamagemayoccur.Thebypassvalve mustbeopenwheneverthemachineispushedor towed.

1.Raisetheseatandremovethebatterycover.The bypassvalveislocatedinfrontofthebattery (Figure28).

2.Rotatethevalve1/4turnineitherdirectiontoopen andallowoiltobypassinternally.Becauseuidis bypassed,themachinecanbeslowlymovedwithout damagingthetransmission.Notethepositionof thevalvewhenopeningorclosing.

3.Closethebypassvalvebeforestartingtheengine. However,donotexceed5to8ft-lb(7to11N⋅m) torquetoclosethevalve.

Page 29

1.Bypassvalveaccesshole

Figure28

JackingPoints

•Onthefrontofthemachineontheframeonthe insideofeachdrivetire

•Ontherearofthemachineatthecenteroftheaxle

TieDowns

•Oneachsideoftheframebythesidecuttingunit liftarms

•Frontcenteroftheoperator’splatform

•Therearbumper

Important:Ifthemachinemusttobe pushedortowedinreverse,thecheckvalve inthefour-wheeldrivemanifoldmustalsobe bypassed.Tobypassthecheckvalve,connect ahoseassembly(HosePartNo.95-8843, CouplerFittingNo.95-0985[Qty.2],and HydraulicFittingNo.340-77[Qty.2])tothe reversetractionpressuretestport(Figure29) andthereversefour-wheeldrivepressureport (Figure30).

Figure29

1.Reversetractionpressuretestport

OperatingCharacteristics

Practicedrivingthemachinebecauseithasahydrostatic transmissionanditscharacteristicsaredifferentthan manyturfmaintenancemachines.Somepointsto considerwhenoperatingthetractionunit,cutting unit,orotherimplementsarethetransmission,engine speed,loadonthecuttingbladesorotherimplement components,andtheimportanceofthebrakes.

Tomaintainenoughpowerforthetractionunitand implementwhileoperating,regulatethetractionpedal tokeeptheengineRPMhighandsomewhatconstant. Agoodruletofollowistodecreasethegroundspeed astheloadontheimplementincreases,andincreasethe groundspeedastheloaddecreases.

Therefore,allowthetractionpedaltomovebackward astheengineRPMdecreases,anddepressthepedal slowlyastheRPMincreases.Bycomparison,when drivingfromoneworkareatoanother,withnoload andcuttingunitraised,havethethrottleintheFast positionanddepressthetractionpedalslowlybutfully toattainmaximumgroundspeed.

Theowdividerenhancestractiondriveperformance incompromisedoperatingconditions.Theowdivider isforuseinlowspeedrangeonly.Whenapproaching anareaknowntocausewheelspin,depressandhold owdividerswitchuntilcompletelypastthearea.If atirespinswhileclimbingormaneuveringonslopes, depressswitchandslowlydriveoutofarea.Ifboth afrontandrearwheelspins,thesteeringbrakecan befeatheredtotransferthetorquefromthespinning wheelstooppositefrontwheel.

Figure30

1.Reversefour-wheeldrivepressuretestport

Anothercharacteristictoconsideristheoperation ofthepedalsthatareconnectedtothebrakes.The brakescanbeusedtoassistinturningthemachine. However,usethemcarefully,especiallyonsoftor wetgrassbecausetheturfmaybetornaccidentally.

Page 30

Anotherbenetofthebrakesistomaintaintraction. Forexample,insomeslopeconditions,theuphillwheel slipsandlosestraction.Ifthissituationoccurs,depress theuphillturnpedalgraduallyandintermittentlyuntil theuphillwheelstopsslipping,thus,increasingtraction onthedownhillwheel.

Useextracarewhenoperatingthemachineonslopes. Makesurethattheseatlatchisproperlysecuredandthe seatbeltisbuckled.Driveslowlyandavoidsharpturns onslopestopreventrollovers.Forsteeringcontrol,the cuttingunitmustbeloweredwhengoingdownhill.

Thisproductisdesignedtodriveobjectsinto thegroundwheretheyloseenergyquickly ingrassareas.However,carelessoperation, combinedwithterrainangle,ricochets,or improperlypositionedsafetyguardcanleadto thrownobjectinjuries.

•Whenapersonorpetappearssuddenlyinor nearthemowingarea,

•Donotresumemowinguntiltheareais cleared.

Beforestoppingtheengine,disengageallcontrolsand movethethrottletoSlow .MovingthethrottletoSlow reduceshighengineRPM,noise,andvibration.Turn thekeytoOfftostoptheengine.

stop mo wing

OperatingTips

MowWhenGrassisDry

Moweitherinthelatemorningtoavoidthedew,which causesgrassclumping,orinlateafternoontoavoidthe damagethatcanbecausedbydirectsunlightonthe sensitive,freshlymowedgrass.

SelecttheProperHeight-of-CutSetting toSuitConditions

Removeapproximately1inch(25mm)ornomorethan 1/3ofthegrassbladewhencutting.Inexceptionally lushanddensegrass,youmayhavetoraisethe height-of-cuttothenextsetting.

MowatProperIntervals

Undermostnormalconditionsyouwillneedtomow approximatelyevery4-5days.Butremember,grass growsatdifferentratesatdifferenttimes.Thismeans thatinordertomaintainthesameheight-of-cut,which isagoodpractice,youwillneedtocutmorefrequently inearlyspring;asthegrassgrowthrateslowsinmid summer,cutonlyevery8-10days.Ifyouareunableto mowforanextendedperiodduetoweatherconditions orotherreasons,mowrstwiththeheight-of-cutata highlevel;thenmowagain2-3dayslaterwithalower heightsetting.

Beforetransportingthemachine,raisethecuttingunits andsecurethetransportlatches(Figure31).

Figure31

1.Transportlatch(sidecuttingunits)

Transporting

Usethetransportlatcheswhentransportingoverlong distances,roughterrain,orwhentrailering.

AfterOperating

Toensureoptimumperformance,cleantheunderside ofthemowerhousingaftereachuse.Ifresidueis allowedtobuildupinthemowerhousing,cutting performancewilldecrease.

CuttingUnitPitch

Werecommendabladepitchof1/4inch(6mm).A pitchlargerthan1/4inch(6mm)willresultinless powerrequired,largerclippings,andapoorerquality ofcut.Apitchlessthan1/4inch(6mm)willresult inmorepowerrequired,smallerclippingsandabetter qualityofcut.

Page 31

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst10hours

Aftertherst50hours

Aftertherst200hours

Beforeeachuseordaily

Every50hours

Every100hours

Every150hours

MaintenanceProcedure

•T orquethewheellugnuts.

•Checkthefanandalternatorbelttension.

•Checkthebladedrivebelttension.

•Changetheengineoilandlter.

•ChecktheengineRPM(atidleandfullthrottle).

•Changethefrontplanetarygearoil.

•Changetherearaxleoil.

•Changethehydraulicoil.

•Changethehydraulicoillters.

•Checktheengineoillevel.

•Checkthecoolantlevel.

•Checkthehydraulicuidlevel.

•Checkthetirepressure.

•Lubricateallgreasettings.

•Inspecttheaircleaner.

•Checkthebatterylevelandcableconnections.

•Checkthebladedrivebelttension.

•Removealldebrisandchafffromtheradiatorandoilcooler.

•Inspectthecoolingsystemhoses.

•Checkthefanandalternatorbelttension.

•Changetheengineoilandlter.

Every200hours

Every400hours

Every800hours

Every2years

•T orquethewheellugnuts.

•Servicethesparkarrestor.

•Checktheplanetarygeardriveoil.

•Checktherearaxlelubricant.

•Checktherearaxlegearboxlubricant.

•Servicetheairlter(iftheindicatorshowsred).

•Inspectthefuellinesandconnections.

•Replacethefuelltercanister.

•ChecktheengineRPM(atidleandfullthrottle).

•Drainandcleanthefueltank.

•Changethefrontplanetarygearoil.

•Changetherearaxleoil.

•Checktherearwheeltoe-in.

•Inspectthebladedrivebelts.

•Changethehydraulicoil.

•Changethehydraulicoillters.

•Inspectthesidecuttingunitdamper.

•Inspectthecuttingunitcastorwheelassemblies.

•Checkandadjustthevalveclearance.

•Flushthecoolingsystemandreplaceuid.

•Replacemovinghoses.

Page 32

Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineandseriously injureyouorotherbystanders.

Removethekeyfromtheignitionbeforeyoudoanymaintenance.

Premaintenance Procedures

ServiceIntervalChart

Lubrication

GreasingtheBearingsand Bushings

Themachinehasgreasettingsthatmustbelubricated regularlywithNo.2GeneralPurposeLithiumBase Grease.Ifthemachineisoperatedundernormal conditions,lubricateallbearingsandbushingsafter every50hoursofoperationorimmediatelyafterevery washing.

Thegreasettinglocationsandquantitiesare:

TractionUnit

ServiceInterval:Every50hours

Figure32

•Brakeshaftpivotbearings(5)(Figure33)

•Tractionpedalpivotbushing(1)(Figure34)

•Frontandrearaxlepivotbushings(2)(Figure35)

•Steeringcylinderballjoints(2)(Figure36)

•Tierodballjoints(2)(Figure36)

•Kingpinbushings(2)(Figure36).

Thetopttingonthekingpinshould onlybelubricatedannually(2pumps).

Page 33

Figure33

Figure36

Figure34

Figure35

FrontCuttingUnit

•Castorforkshaftbushings(2)(Figure37)

•Spindleshaftbearings(3)(locatedunderthepulley) (Figure38)

•Idlerarmpivotbushings(2)(Figure38)

Figure37

Page 34

Figure38

FrontLiftAssemblies

•Liftarmbushings(2)(Figure39)

•Liftcylinderbushings(4)(Figure39)

•Liftarmballjoints(2)(Figure40)

Figure40

SideCuttingUnits

•Castorforkshaftbushing(1)(Figure41)

•Spindleshaftbearings(2each)(locatedunderthe pulley)

•Idlerarmpivotbushings(1)(locatedontheidler arm)

Figure39

Figure41

SideLiftAssemblies

•Mainliftarmbushings(6)(Figure42andFigure43),

Page 35

•Bellcrankpivotbushings(2)(Figure44)

•Reararmbushings(4)(Figure44)

•Liftcylinderbushings(4)(Figure45)

Figure44

Figure42

Figure43

Figure45

Page 36

EngineMaintenance

AirCleanerMaintenance

•Checktheaircleanerbodyfordamagewhichcould causeanairleak.Replaceifdamaged.Checkthe wholeintakesystemforleaks,damageorloosehose clamps.

•Servicetheaircleanerlteronlywhentheservice indicatorrequiresitorevery400hours(more frequentlyinextremelydustyordirtyconditions). Changingtheairlterbeforeitisnecessaryonly increasesthechanceofdirtenteringtheenginewhen thelterisremoved.

•Besurethecoverisseatedcorrectlyandsealswith theaircleanerbody.

3.Removetheprimarylter(Figure47).Cleaningof theusedelementisnotrecommendedduetothe possibilityofdamagetotheltermedia.Inspectthe newlterforshippingdamage,checkingthesealing endofthelterandthebody .Donotuseadamaged element.Donotremovethesafetylter(Figure48).

ServicingtheAirCleaner

ServiceInterval:Every50hours

Every400hours

1.Pullthelatchoutwardandrotatetheaircleaner covercounterclockwise(Figure46).

2.Removethecoverfromtheaircleanerbody.Before removingthelter,uselowpressureair(40psi, cleananddry)tohelpremovelargeaccumulations ofdebrispackedbetweenoutsideofprimarylter andthecanister.Avoidusinghighpressureairwhich couldforcedirtthroughthelterintotheintake tract.Thiscleaningprocesspreventsdebrisfrom migratingintotheintakewhentheprimarylteris removed.

Figure47

1.Aircleanerprimarylter

Figure48

1.Aircleanersafetylter

Important:Neverattempttocleanthesafety lter(Figure48).Replacethesafetylterwitha newoneaftereverythreeprimarylterservices.

Figure46

1.Aircleanerindicator3.Aircleanercover

2.Aircleanerlatch

4.Replacetheprimarylter(Figure47).

5.Insertthenewlterbyapplyingpressuretotheouter rimoftheelementtoseatitinthecanister.Donot applypressuretotheexiblecenterofthelter.

6.Cleanthedirtejectionportlocatedintheremovable cover.Removetherubberoutletvalvefromthe cover,cleanthecavityandreplacetheoutletvalve.

7.Installthecoverorientingtherubberoutletvalve (Figure46)inadownwardposition-between approximately5:00to7:00whenviewedfromthe end.Securethelatch.

Page 37

ServicingtheEngineOiland Filter

ServiceInterval:Aftertherst50hours

FuelSystem Maintenance

Every150hours

Changetheoilandlterinitiallyaftertherst50hours ofoperation;thereafterchangetheoilandlterevery 150hours.

1.Removeeitherdrainplug(Figure49)andlettheoil owintoadrainpan.Whentheoilstops,installthe drainplug.

Figure49

1.Engineoildrainplug

2.Removetheoillter(Figure50).Applyalightcoat ofcleanoiltothenewltersealbeforescrewingit on.Donotovertighten.

ServicingtheFuelSystem

Undercertainconditions,dieselfuelandfuel vaporsarehighlyammableandexplosive.A reorexplosionfromfuelcanburnyouand othersandcancausepropertydamage.

•Useafunnelandllthefueltankoutdoors, inanopenarea,whentheengineisoffand iscold.Wipeupanyfuelthatspills.

•Donotllthefueltankcompletelyfull.Add fueltothefueltankuntilthelevelis1/4to 1/2inch(6to13mm)belowthebottomof thellerneck.Thisemptyspaceinthetank allowsthefueltoexpand.

•Neversmokewhenhandlingfuel,andstay awayfromanopenameorwherefuel fumesmaybeignitedbyaspark.

•Storefuelinaclean,safety-approved containerandkeepthecapinplace.

Figure50

1.Engineoillter

3.Addoiltothecrankcase;refertoCheckingthe EngineOil.

FuelTank

ServiceInterval:Every800hours

Drainandcleanthefueltankevery800hours.Also, drainandcleanthetankiffuelsystembecomes contaminatedorifthemachinewillbestoredforan extendedperiodoftime.Usecleanfueltoushout thetank.

FuelLinesandConnections

ServiceInterval:Every400hours

Checkthefuellinesandconnectionsevery400hours oryearly,whichevercomesrst.Inspectthemfor deterioration,damage,orlooseconnections.

ServicingtheWaterSeparator

ServiceInterval:Every400hours

Drainwaterorothercontaminantsfromwaterseparator (Figure51)daily.Replaceltercanisterafterevery400 hoursofoperation.

1.Placeacleancontainerunderthefuellter.

Page 38

2.Loosenthedrainplugonthebottomofthelter canister.

Figure51

1.Waterseparatorltercanister

3.Cleantheareawheretheltercanistermounts.

4.Removetheltercanisterandcleanthemounting surface.

4.Tightenthepipeconnectorsecurely .

5.Repeattheprocedureontheremainingnozzles.

5.Lubricatethegasketontheltercanisterwithclean oil.

6.Installtheltercanisterbyhanduntilthegasket contactsmountingsurface,thenrotateitan additional1/2turn.

7.Tightenthedrainplugonthebottomofthelter canister.

BleedingAirfromtheInjectors

1.LoosenthepipeconnectiontotheNumber1 injectornozzleandholderassemblyattheinjection pump(Figure52).

Figure52

1.Number1injectornozzle

2.MovethethrottletotheFastposition.

3.TurnthekeyintheignitionswitchtotheStart positionandwatchthefuelowaroundthe connector.TurnthekeytotheOffpositionwhen solidowisobserved.

Page 39

ElectricalSystem Maintenance

Activating,Charging,and ConnectingtheBattery

ServiceInterval:Every50hours

Warning

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandleadcompounds,

chemicalsknowntotheStateofCalifornia

tocausecancerandreproductiveharm.

Washhandsafterhandling.

Note:Ifthebatteryisnotlledwithelectrolyteor activated,bulkelectrolytewith1.260specicgravity mustbepurchasedfromalocalbatterysupplyoutlet andaddedtothebattery.

Batteryelectrolytecontainssulfuricacidwhich isadeadlypoisonandcausessevereburns.

•Donotdrinkelectrolyteandavoidcontact withskin,eyesorclothing.Wearsafety glassestoshieldyoureyesandrubbergloves toprotectyourhands.

•Fillthebatterywherecleanwaterisalways availableforushingtheskin.

1.Raisetheseatandsecureitwiththeproprod.

2.Removethebatterycover(Figure53).

Figure53

1.Batterycover

3.Removethellercapsfromthebattery(Figure54) andslowlylleachcelluntilelectrolyteisjustabove theplates.

Figure54

1.Battery

4.Installthellercapsandconnecta3to4amp. batterychargertothebatteryposts.Chargethe batteryatarateof3to4amperesfor4to8hours.

Chargingthebatteryproducesgassesthatcan explode.

Neversmokenearthebatteryandkeepsparks andamesawayfrombattery.

5.Whenthebatteryischarged,disconnectthecharger fromtheelectricaloutletandbatteryposts.

6.Removethellercaps.Slowlyaddelectrolyteto eachcelluntilthelevelisuptothellring.Install thellercaps.

Important:Donotoverllthebattery. Electrolytewilloverowontootherpartsofthe machineandseverecorrosionanddeterioration willresult.

7.Installthepositivecable(red)tothepositive(+) terminalandthenegativecable(black)tothe

Page 40

negative(-)terminalofthebatteryandsecurethem withtheboltsandnuts.Makesurethatthepositive (+)terminalisallofthewayontothepostandthe cableispositionedsnugtothebattery.Thecable mustnotcontactthebatterycover.Slidetherubber bootoverthepositiveterminaltopreventapossible shortfromoccurring.

Batteryterminalsormetaltoolscouldshort againstmetalcomponentscausingsparks. Sparkscancausethebatterygassestoexplode, resultinginpersonalinjury.

•Whenremovingorinstallingthebattery,do notallowthebatteryterminalstotouchany metalpartsofthemachine.

•Donotallowmetaltoolstoshortbetween thebatteryterminalsandmetalpartsofthe machine.

asolutionofbakingsodaandwater.Rinsewithclear water.Coatthebatterypostsandcableconnectorswith Grafo112X(skin-over)grease(ToroPartNo.505-47) orpetroleumjellytopreventcorrosion.

Fuses

Thereare5fusesintheelectricalsystem.Theyare locatedbelowtheoperatorscontrolpanel(Figure55 andFigure56).

Incorrectbatterycableroutingcoulddamage themachineandcablescausingsparks.Sparks cancausethebatterygassestoexplode, resultinginpersonalinjury.

•Always

disconnect

thenegative(black) batterycablebeforedisconnectingthe positive(red)cable.

•Always

connect

thepositive(red)battery cablebeforeconnectingthenegative(black) cable.

8.CoatbothbatteryconnectionswithGrafo112X (skin-over)grease,T oroPartNo.505-47,petroleum jelly,orlightgreasetopreventcorrosion.Slidethe rubberbootoverthepositiveterminal.

9.Installthebatterycover.

BatteryCare

Batterytypeisgroup24.

Important:Beforeweldingonthemachine, disconnectthenegativecablefromthebatteryto preventdamagetotheelectricalsystem.

Figure55

1.Fuses

Figure56

1.Poweroutlet

2.Seatswitch5.Startersolenoid

3.Ignitionswitch6.Lightkit

4.PowerTakeOff(PTO)

Note:Checkthebatteryconditionweeklyorafterevery 50hoursofoperation.Keeptheterminalsandtheentire batterycasecleanbecauseadirtybatterywilldischarge slowly.Tocleanthebattery,washtheentirecasewith

Page 41

DriveSystem Maintenance

ChangingthePlanetaryGear DriveOil

ServiceInterval:Aftertherst200hours

Every800hours

Changetheoilinitiallyafterrst200hoursofoperation. Thereafterchangetheoilevery800hours,oryearly , whicheveroccursrst.UseahighqualitySAE85W-140 gearlube.

1.Withthemachineonalevelsurface,positionthe wheelsothatthecheck/drainplug(Figure57)isat thelowestposition.

tenortwoo’clockposition)untilthelevelisupto thebottomofthebrakehousingcheckhole.Install theplug.

8.Repeattheprocedureontheoppositegearassembly.

Figure58

1.Brakehousing

2.Drainplug

3.Checkplug

Figure57

1.Check/drainplug

2.Placeadrainpanunderthehub,removetheplug, andallowtheoiltodrain.

3.Whenalloftheoilhasdrained,positionthewheel sothattheplugholeisatthetenortwoo’clock position.

4.Placeadrainpanunderthebrakehousingonthe othersideofthewheel(Figure58).

5.Removetheplugfromthebottomofthehousing andallowtheoiltodrain.

ChangingtheRearAxle Lubricant

ServiceInterval:Aftertherst200hours

Every800hours

Changetheoilinitiallyaftertherst200hoursof operationandevery800hoursofoperationthereafter.

1.Positionthemachineonalevelsurface.

2.Cleantheareaaroundthe3drainplugs;1oneach endand1inthecenter(Figure59).

3.Removethecheckplugstoeaseindrainingoftheoil.

4.Removethedrainplugsandallowtheoiltodrain intothepans.

6.Whenalloftheoilhasdrained,installtheplugin thehousing.

7.Addapproximately16oz(0.5l)ofhighqualitySAE 85W-140gearlubetotheplanetaryllhole(atthe

Page 42

1.Drainpluglocation

Figure59

CheckingtheRearWheel Toe-In

ServiceInterval:Every800hours

Afterevery800operatinghoursorannually ,checkthe rearwheeltoe-in.

1.Measurethecenter-to-centerdistance(ataxleheight) atthefrontandrearofthesteeringtires.Thefront measurementmustbe1/4inch(6mm)lessthanthe rearmeasurement.

2.Toadjust,loosentheclampsatbothendsofthetie rods.

3.Rotatethetierodendtomovethefrontofthetire inwardoroutward.

5.Cleantheareaaroundthedrainplugonthebottom ofthegearbox(Figure60).

6.Removethedrainplugfromthegearboxandallow theoiltodrainintoapan.Removethellplugto easeindrainingoftheoil.

Figure60

1.Drainplug

4.Tightenthetierodclampswhentheadjustmentis correct.

7.Addenoughoiltobringtheleveluptothebottom ofthecheckplugholes;refertoCheckingtheRear AxleLubricant,andCheckingtheRearAxleGear BoxLubricant.

8.Installtheplugs.

Page 43

CoolingSystem Maintenance

ServicingtheEngineCooling System

ServiceInterval:Every100hours

Every2years

Removedebrisfromtheoilcoolerandradiator daily.Cleanthemmorefrequentlyindirtyconditions.

1.Turntheengineoffandraisethehood.Cleanthe engineareathoroughlyofalldebris.

2.Removetheknobs(Figure61)securingtheoilcooler totheframe.

Figure62

1.Oilcooler

4.Pivottheoilcoolerbackintoposition.Secureitto theframewiththeknobsandclosethehood.

2.Radiator

Figure61

1.Knobs

3.Pivottheoilcoolerrearward.Cleanbothsidesofthe oilcoolerandradiatorarea(Figure62)thoroughly withcompressedair.Startfromthefansideand blowthedebrisouttowardstheback.Thenclean fromthebacksideandblowtowardsthefront. Repeatprocedureseveraltimesuntilallchaffand debrisisremoved.

Important:Cleaningtheradiatororoilcooler withwatercanpromoteprematurecorrosion anddamagetocomponents.

Page 44

BrakeMaintenance

BeltMaintenance

AdjustingtheServiceBrakes

Adjusttheservicebrakeswhenthereismorethan1inch (25mm)of“freetravel”ofthebrakepedal,orwhenthe brakesdonotworkeffectively.Freetravelisthedistance thebrakepedalmovesbeforebrakingresistanceisfelt.

1.Disengagethelockinglatchfromthebrakepedalsso thatbothpedalsworkindependentlyofeachother.

2.Toreducefreetravelofthebrakepedals,tighten thebrakes:

A.Loosenthefrontnutonthethreadedendofthe

brakecable.

B.Tightentherearnuttomovethecablebackward

untilthebrakepedalshave1/2to1inch(13to 25mm)offreetravel.

C.Tightenthefrontnutsafterthebrakesare

adjustedcorrectly.

ServicingtheAlternatorBelt

ServiceInterval:Aftertherst10hours

Every100hours

Checktheconditionandtensionofthebelts(Figure63) afterevery100operatinghours.

1.Propertensionwillallow3/8inch(10mm) deectionwhenaforceof10lbisappliedonthe beltmidwaybetweenthepulleys.

2.Ifthedeectionisnot3/8inch(10mm),loosen thealternatormountingbolts(Figure63).Increase ordecreasethealternatorbelttensionandtighten thebolts.Checkthedeectionofthebeltagainto ensurethatthetensioniscorrect.

Figure63

1.Alternator2.Mountingbolt

Re-tensioningtheBladeDrive Belts

ServiceInterval:Aftertherst10hours

Every50hours

Checktheconditionandtensionofthecuttingunitdrive beltsinitiallyafter8hoursofoperationandevery50 operatinghoursthereafter.

Whenproperlytensioned,theextensionspring(hook tohook)measurementshouldbeapproximately3.50 ±.25inch(inside).Oncethecorrectspringtensionis attained,adjustthestopbolt(carriagebolt)untilthereis approximately.125+.060/-.000inchclearancebetween theheadoftheboltandtheidlerarm(Figure64).

Page 45

Note:Makesurethebeltispositionedonthespring sideofthebeltguide(Figure64).

Figure64

1.Belt4.Beltguide

2.Eyebolt5.Flangenut

3.Extensionspring

6.Stopbolt

ReplacingtheBladeDriveBelt

ServiceInterval:Every800hours

Thebladedrivebelt,tensionedbythespringloaded idlerpulley,isverydurable.However,aftermanyhours ofuse,thebeltwillshowsignsofwear.Signsofaworn beltare:squealingwhenbeltisrotating,bladesslipping whencuttinggrass,frayededges,burnmarksandcracks. Replacethebeltifanyoftheseconditionsareevident.

1.Lowerthecuttingunittotheshopoor.Remove thebeltcoversfromthetopofthecuttingunitand setthecoversaside.

2.Loosentheeyeboltallowingtheremovalofthe extensionspring(Figure64).

3.Loosentheangenutsecuringthestopbolttothe mountingtab.Backoffthenutenoughtoallowthe idlerarmtopassbythestopbolt(Figure64).Move theidlerpulleyawayfromthebelttoreleasebelt tension.

Figure65

1.Hydraulicmotor2.Mountingbolts

5.Removetheoldbeltfromaroundthespindlepulleys andidlerpulley.

6.Routethenewbeltaroundthespindlepulleysand idlerpulleyassembly .

7.Positionthehydraulicmotoronthecuttingunitafter routingthebeltaroundthepulleys.Mountthemotor tothecuttingunitwiththeboltspreviouslyremoved.

Note:Makesurethebeltispositionedonthespring sideofthebeltguide(Figure64).

8.Reconnecttheextensionspring(Figure64)tothe eyeboltandtensionthebeltasfollows:

•Whenproperlytensioned,theextension spring(hooktohook)measurementshouldbe approximately3.50±.25inch(inside).

•Oncethecorrectspringtensionisattained, adjustthestopbolt(carriagebolt)untilthereis approximately.125+.060/-.000inchclearance betweentheheadoftheboltandtheidlerarm.

Note:Ifthestopboltiseverremovedfromthe mountingtab,makesureitisreinstalledinthehole thatalignsthestopboltheadwiththeidlerarm.

4.Removetheboltssecuringthehydraulicmotorto thecuttingunit(Figure65).Liftthemotoroffofthe cuttingunitandlayitontopofthecuttingunit.

Page 46

ControlsSystem Maintenance

AdjustingtheThrottle

ServiceInterval:Aftertherst50hours

Every400hours

Adjustthethrottlecable(Figure66)sothatthegovernor leverontheenginecontactsthelowandhighspeedset boltsbeforethethrottlelevercontactstheslotinthe controlpanel.

Figure67

1.Tractionpedalstop

3.Loosenthejamnutsontherodendandadjustthe tractionrodlength(Figure68)sothatthepedal contactsthepedalstopwhenthepumpleverreaches fullstroke.Securethejamnuts.

2.Stand

Figure66

1.Throttlecable

AdjustingtheTractionPedal Linkage

Withthetractionpedalinthemowposition(lowspeed) itshouldreachfullstrokeatthesametimeitmakes contactwiththestop.Ifitdoesnot,performthe followingprocedure:

1.Parkthemachineonalevelsurface,stoptheengine, andlowerthecuttingunitstotheoor.Removethe ignitionkey .

2.Checkthetractionpedalstopadjustment.The distancefromthetopofthestandtothetopof thestopmustbe1-1/2inch(38mm)(Figure67). Loosenthenutsandadjust,asrequired.

Figure68

1.Rodend3.Neutralreturnspring assembly

2.Tractionrod4.Jamnut

4.Turnthekeyswitchtotherunpositionwithout startingtheengine.Loosenthejamnutandadjust theneutralreturnspringassemblyshaftlengthuntil theaudiblealarmbeginstosound.Securethejam nut.

5.Turnthekeyswitchoff.

Page 47

HydraulicSystem Maintenance

ReplacingtheHydraulicFilters

ServiceInterval:Aftertherst200hours

Every800hours

ChangingtheHydraulicFluid

ServiceInterval:Aftertherst200hours

Every800hours

Changethehydraulicuidafterevery800operating hours,innormalconditions.Iftheuidbecomes contaminated,contactyourlocalT orodistributor becausethesystemmustbeushed.Contaminateduid looksmilkyorblackwhencomparedtocleanoil.

1.Turntheengineoffandraisethehood.

2.Loosenthedrainvalveonthebottomofthe reservoirandletthehydraulicuidowintolarge drainpan.Closethevalvewhenthehydraulicuid stopsdraining.

3.Fillthereservoir(Figure68)withapproximately 8U .S.gallons(30l)ofhydraulicuid;referto CheckingtheHydraulicFluid.

Important:Useonlythehydraulicuids specied.Otheruidscouldcausesystem damage.

Changethe2hydraulicltersinitiallyaftertherst200 operatinghours.Thereafter,changetheltersafter every800operatinghours,innormalconditions.

UseTororeplacementlters(PartNo.94-2621forthe leftsideofthemachineand75-1310fortherightside ofthemachine).

Important:Useofanyotherltermayvoidthe warrantyonsomecomponents.

1.Positionthemachineonalevelsurface,lowerthe cuttingunits,stoptheengine,engagetheparking brakes,andremovetheignitionkey.

2.Cleantheareaaroundtheltermountingarea.Place adrainpanunderthelterandremovethelter (Figure70).

Figure69

1.Hydraulicreservoir

4.Installthereservoircap.Starttheengineanduseall ofthehydrauliccontrolstodistributehydraulicuid throughoutthesystem.Alsocheckforleaks;then stoptheengine.

5.Checktheuidlevelandaddenoughtoraiselevel theleveltotheFullmarkonthedipstick.Donot

overll.

Figure70

3.Lubricatethenewltergasketandllthelterwith hydraulicuid.

4.Ensurethattheltermountingareaisclean.Screw thelteronuntilthegasketcontactsthemounting plate;thentightenthelteranadditional1/2turn.

5.Oncethereservoirislled,starttheengineandlet itrunatlowidleforapproximatelytwominutes. Activatesteeringandraise/lowercuttingunits severaltimestopurgeairfromthesystem.Stopthe engineandcheckforleaks.

CheckingtheHydraulicLines andHoses

ServiceInterval:Every2years

Inspectthehydrauliclinesandhosesdailyfor leaks,kinkedlines,loosemountingsupports,wear, loosettings,weatherdeterioration,andchemical

Page 48

deterioration.Makeallnecessaryrepairsbefore operating.

Hydraulicuidescapingunderpressurecan penetrateskinandcauseinjury.

•Makesureallhydraulicuidhosesand linesareingoodconditionandallhydraulic connectionsandttingsaretightbefore applyingpressuretothehydraulicsystem.

•Keepyourbodyandhandsawayfrompin holeleaksornozzlesthatejecthighpressure hydraulicuid.

•Usecardboardorpapertondhydraulic leaks.

•Safelyrelieveallpressureinthehydraulic systembeforeperforminganyworkonthe hydraulicsystem.

•Seekimmediatemedicalattentionifuid isinjectedintoskin.

Figure72

1.TestportB

TestPortC(Figure73),locatedontheleftsideofthe machine,isusedtomeasuretheleftcuttingunitpressure.

HydraulicSystemTestPorts

Thetestportsareusedtotestthepressureinthe hydrauliccircuits.ContactyourlocalTorodistributor forassistanceorrefertotheGroundsmaster4000 servicemanual.

TestPortA(Figure71),locatedontheleftsideof themachine,isusedtomeasuretheforwardtraction pressure.

Figure71

1.TestportA

Figure73

1.TestportC

TestPortD(Figure74),locatedontherightsideof themachine,isusedtomeasuretherightcuttingunit pressure.

TestPortB(Figure72),locatedontherightsideof themachine,isusedtomeasurethereversetraction pressure.

Figure74

1.TestportD

TestPortE(Figure75),locatedundertheradiator,is usedtomeasurethefour-wheeldrivepressureinreverse.

Page 49

1.TestportE

Figure75

Figure77

1.TestportI2.TestportH

TestPortF(Figure76),locatedundertheseat,isused tomeasuretheliftcircuitpressure.

TestPortG(Figure76),locatedundertheseat,isused tomeasurethechargecircuitpressure.

Figure76

1.TestportF

2.TestportG

TestPortH(Figure77)isusedtomeasurethefront cuttingunitcircuitpressure.

TestPortJ(Figure77)isusedtomeasurethesteering circuitpressure.

Thecounterbalancetestport(Figure78)isused toadjustthepressureinthecounterbalancecircuit. Recommendedcounterbalancepressureis470psi(3241 kPa).T oadjustthecounterbalancepressure,rotatethe adjustingscrew(Figure78)clockwisetoincreasethe pressureorcounterclockwisetodecreasethepressure.

Figure78

1.Counterbalancetestport2.Counterbalanceadjusting screw

AdjustingtheCuttingUnit FlowControl

Theowcontrolvalve(Figure79)isusedtoadjustthe rateatwhichthefrontcuttingunitlowers.

Figure79

1.Flowcontrolvalve

Page 50

MowerMaintenance

Pivoting(Tilting)theFront CuttingUnitUpright

AdjustingtheTransportLatch

Ifthetransportlatch(Figure80)hastobeadjusted, adjustasfollows:

1.Raisethefrontcuttingunitfullyoffoftheoor,set theparkingbrake,andstoptheengine.Removethe ignitionkey .

2.Loosenangenutssecuringlatcharmpivotto tractionunitframe.

3.Movelatcharmpivotinoroutuntilrubbercushion ofadjustmentscrewiscenteredunderdecklatch. Tightenangenuts.

Note:Althoughnotneededfornormalmaintenance procedures,thefrontcuttingunitcanbepivoted(tilted) toanuprightposition(Figure82).Shouldyoudesireto tiltthecuttingunit,proceedasfollows:

Figure82

1.Raisethefrontcuttingunitslightlyoffoftheoor, settheparkingbrake,andstoptheengine.Remove theignitionkey .

Figure80

1.Latcharmpivot3.Decklatch

2.Adjustmentscrew

4.Clearancebetweenadjustmentscrewrubber (Figure81)cushionanddecklatchshouldbe.125 inch.Ifanadjustmentisrequired,loosennut onadjustmentscrew ,adjustscrewuntilrequired clearanceisattainedandtightennut.

Figure81

1.Adjustmentscrew2.Decklatch

2.Removethehairpincotterandclevispinsecuringthe decktransportlatchtothelatchplate(Figure83). Pivotlatchtowardrearofdeck.

Figure83

1.Transportlatch2.Latchplate

3.Removethehairpincotterandclevispinsecuringthe height-of-cutchainstotherearofthecuttingunit.

4.Starttheengine,slowlyraisethefrontcuttingunit, andstoptheengine.Removetheignitionkey.

5.Graspthefrontofthecuttingunitandliftittoan uprightposition.

6.Holdthecuttingunitupright,tthecableendover thepinonthecuttingunitliftarmandsecureitwith thehairpincotter(Figure84).

Page 51

Figure84

1.Cable

2.Pin

PivotingtheFrontCuttingUnit Down

1.Withthehelpofanotherperson,holdthecutting unitupright,removethehairpincottersecuringthe cableend,andremovethecablefromthepin.

4.Usingashortruler,measurefromtheoortothe fronttipoftheblade.Rotatethebladetiptotherear andmeasurefromtheoortothetipoftheblade.

5.Subtractthefrontdimensionfromtherear dimensiontocalculatethebladepitch.

AdjustingtheFrontCuttingUnit

1.Loosenthejamnutsonthetoporbottomofthe height-of-cutchainU-bolt(Figure85).

2.Adjusttheothersetofnutstoraiseorlowertherear ofthecuttingunitandattainthecorrectcuttingunit pitch.

3.Tightenthejamnuts.

2.Pivot(tilt)thecuttingunitdownward.

3.Storethecableundertheoperator’ splatform.

4.Sitontheseat,starttheengine,andlowerthecutting unituntilitisslightlyoffoftheoor.

5.Securetheheight-of-cutchainstotherearofthe cuttingunit.

6.Pivottransportlatchupwardintopositionandsecure withclevispinandcotterpin.

AdjustingtheCuttingUnit Pitch

MeasuringtheCuttingUnitPitch

Cuttingunitpitchisthedifferenceinheight-of-cutfrom thefrontofthebladeplanetothebackoftheblade plane.Tororecommendsabladepitchof1/4inch(6 mm).Thatisthebackofthebladeplaneis1/4inch(6 mm)higherthanthefront.

Figure85

1.Height-of-cutchain

2.U-bolt

AdjustingtheSideCuttingUnits

ServiceInterval:Every800hours

1.Removethetensioningcapfromthespindle shaftandslidethespindleoutofthecastorarm (Figure86).Repositiontheshims,asrequired,to raiseorlowerthecastorwheeluntilthecuttingunit hasthecorrectpitch.

2.Installthetensioningcap.

1.Positionthemachineonalevelsurfaceontheshop oor.

2.Setthecuttingunittothedesiredheight-of-cut.

3.Rotate1bladesothatitpointsstraightforward.

Page 52

Figure86

1.Castorwheel4.Shims

2.Tensioningcap5.Axlemountingholes

3.Spacers

Figure87

1.Castorarmtube

2.Bushings

5.Applygreasetotheinsideandoutsideofthenew bushings.Usingahammerandatplate,drivethe bushingsintothemountingtube.

6.Inspectthecastorspindleforwearandreplaceitif itisdamaged.

7.Pushthecastorspindlethroughthebushingsand mountingtube.Slidethethrustwasherandspacer(s) ontothespindle.Installthetensioningcaponthe castorspindletoretainallpartsinplace.

ServicingtheCastorWheels andBearings

ServiceInterval:Every800hours

ServicingtheCastorArm Bushings

Thecastorarmshavebushingspressedintothetopand bottomofthetubeandaftermanyhoursofoperation, thebushingswillwear.Tocheckthebushings,movethe castorforkbackandforthandfromsidetoside.Ifthe castorspindleislooseinsidethebushings,thebushings arewornandmustbereplaced.

1.Raisethecuttingunitsothatthewheelsareoffof theoor.Blockthecuttingunitsothatitcannot accidentallyfall.

2.Removethetensioningcap,spacer(s),andthrust washerfromthetopofthecastorspindle.

3.Pullthecastorspindleoutofthemountingtube. Allowthethrustwasherandspacer(s)toremainon thebottomofthespindle.

4.Insertapinpunchintothetoporbottomofthe mountingtubeanddrivethebushingoutofthetube (Figure87).Alsodrivetheotherbushingoutofthe tube.Cleantheinsideofthetubestoremovedirt.

1.Removethelocknutfromtheboltholdingthecastor wheelassemblybetweenthecastorfork(Figure88) orthecastorpivotarm(Figure89).Graspthecastor wheelandslidetheboltoutoftheforkorpivotarm.

Figure88

1.Castorwheel

2.Castorfork

3.Bearing

4.Bearingspacer

Page 53

Figure89

1.Castorwheel

2.Castorpivotarm

2.Removethebearingfromthewheelhuband allowthebearingspacertofallout(Figure88and Figure89).Removethebearingfromtheopposite sideofthewheelhub.

3.Checkthebearings,spacer,andinsideofthewheel hubforwear.Replaceanydamagedparts.

4.Toassemblethecastorwheel,pushthebearinginto thewheelhub.Wheninstallingthebearings,press ontheouterraceofthebearing.

5.Slidethebearingspacerintothewheelhub.Pushthe otherbearingintotheopenendofthewheelhubto captivatethebearingspacerinsidethewheelhub.

6.Installthecastorwheelassemblybetweenthecastor forkandsecureitinplacewiththeboltandlocknut.

3.Bearing

4.Bearingspacer

BladeMaintenance

CheckingforaBentBlade

Afterstrikingaforeignobject,inspectthemachinefor damageandmakerepairsbeforerestartingandoperating theequipment.Torqueallthespindlepulleynutsto130 to150ft-lb(176to203N⋅m).

1.Positionthemachineonalevelsurface.Raisethe cuttingunit,engagetheparkingbrake,putthe tractionpedalinneutral,putthePTOleverin theOffposition,stoptheengine,andremovethe ignitionkey .Blockthecuttingunittopreventitfrom accidentallyfalling.

2.Rotatethebladeuntiltheendsfaceforwardand backward(Figure90).Measurefromtheinsideof thecuttingunittothecuttingedgeatthefrontofthe blade.Rememberthisdimension.

Figure90

3.Rotatetheoppositeendofthebladeforward. Measurebetweenthecuttingunitandcuttingedge ofthebladeatthesamepositionasinstep2.The differencebetweenthedimensionsobtainedinsteps 2and3mustnotexceed1/8inch(3mm).Ifthe dimensionexceeds1/8inch(3mm),thebladeis bentandmustbereplaced;refertoRemovingand InstallingtheCutterBlade.

RemovingandInstallingthe CutterBlade(s)

Theblademustbereplacedifasolidobjectishit,the bladeisoutofbalance,orifthebladeisbent.Always usegenuineTororeplacementbladestobesureofsafety andoptimumperformance.Neverusereplacement bladesmadebyothermanufacturersbecausetheycould bedangerous.

1.Raisethecuttingunittothehighestposition,engage theparkingbrake,stoptheengine,andremovethe ignitionkey .Blockthecuttingunittopreventitfrom accidentallyfalling.

2.Grasptheendofthebladeusingaragorthickly paddedglove.Removethebladebolt,anti-scalpcup, andbladefromthespindleshaft(Figure91).

3.Installtheblade,anti-scalpcup,andbladebolt. Tightenthebladeboltto85to110ft-lb(115to149 N⋅m).

Page 54

Important:Thecurvedpartoftheblademust bepointingtowardtheinsideofthecuttingunit toensurepropercutting.

Note:Afterstrikingaforeignobject,torqueallthe spindlepulleynutsto130to150ft-lb(176to203 N⋅m).

Figure91

1.Bladebolt2.Anti-scalpcup

InspectingandSharpeningthe CutterBlade(s)

1.Positionthemachineonalevelsurface.Raisethe cuttingunit,engagetheparkingbrake,putthe tractionpedalinneutral,putthePTOleverin theOffposition,stoptheengine,andremovethe ignitionkey .

2.Examinethecuttingendsofthebladecarefully, especiallywheretheatandcurvedpartsofthe blademeet(Figure92).Sincesandandabrasive materialcanwearawaythemetalthatconnects theatandcurvedpartsoftheblade,checkthe bladebeforeusingthemower.Ifwearisnoticed (Figure92),replacetheblade.

Awornordamagedbladecanbreak,and apieceofthebladecouldbethrowninto theoperator’sorbystander’sarea,resulting inseriouspersonalinjuryordeath.Trying torepairadamagedblademayresultin discontinuedsafetycerticationoftheproduct.

•Inspectthebladeperiodicallyforwearor damage.

•Nevertrytostraightenabladethatisbent orweldabrokenorcrackedblade.

•Replaceawornordamagedblade.

Twoareasmustbeconsideredwhencheckingand servicingthecutterblade-thesailandthecuttingedge. Bothcuttingedgesandthesail,whichistheturned upportionoppositethecuttingedge,contributetoa goodquality-of-cut.Thesailisimportantbecauseit liftsthegrassupstraight,therebyproducinganeven cut.However,thesailwillgraduallyweardownduring operation,andthisconditionisnormal.Asthesail wearsdown,thequality-of-cutwilldegradesomewhat, althoughthecuttingedgesaresharp.Thecuttingedge oftheblademustbesharpsothatthegrassiscutrather thantorn.Adullcuttingedgeisevidentwhenthetips ofthegrassappearbrownandshredded.Sharpenthe cuttingedgestocorrectthiscondition.

Figure92

1.CuttingEdge3.Wear/slotForming

2.CurvedArea4.Crack

3.Examinethecuttingedgesofalloftheblades. Sharpenthecuttingedgesiftheyaredullornicked. Sharpenonlythetopofthecuttingedgeand maintaintheoriginalcuttingangletomakesure ofsharpness(Figure93).Thebladewillremain balancedifthesameamountofmetalisremoved frombothcuttingedges.

Page 55

Ifthebladeisallowedtowear,aslotwillform betweenthesailandatpartoftheblade (Figure92).Eventuallyapieceoftheblade maybreakoffandbethrownfromunderthe housing,possiblyresultinginseriousinjuryto youorbystanders.

•Inspectthebladeperiodicallyforwearor damage.

•Nevertrytostraightenabladethatisbent orweldabrokenorcrackedblade.

•Replaceawornordamagedblade.

forward,andmeasureagain.Thedifferencebetween thedimensionsmustnotexceed1/8inch(3mm). Ifthedimensionexceeds1/8inch(3mm),replace thebladebecauseitisbent.Makesuretomeasure alloftheblades.

6.Comparethemeasurementsoftheouterbladeswith thecenterblade.Thecenterblademustnotbemore than3/8inch(10mm)lowerthantheouterblades. Ifthecenterbladeismorethan3/8inch(10mm) lowerthantheouterblades,proceedtostep7and addshimsbetweenthespindlehousingandthe bottomofthecuttingunit.

7.Removethebolts,atwashers,lockwashers,and nutsfromtheouterspindleintheareawhere theshimsmustbeadded.Toraiseorlowerthe blade,addashim,PartNo.3256-24,betweenthe spindlehousingandthebottomofthecuttingunit. Continuetocheckthealignmentofthebladesand addshimsuntilthetipsofthebladesarewithinthe requireddimension.

Figure93

1.Sharpenatoriginalangle

Note:Removethebladesandsharpenthemona grinder.Aftersharpeningthecuttingedges,install thebladewiththeanti-scalpcupandbladebolt;refer toRemovingandInstallingtheCutterBlade(s).

CorrectingCuttingUnit Mismatch

Ifthereismismatchbetweentheblades,onasingle cuttingunit,thegrasswillappearstreakedwhenitiscut. Thisproblemcanbecorrectedbymakingsurethatthe bladesarestraightandallofthebladesarecuttingon thesameplane.

1.Usinga3foot(1meter)longcarpenterslevel,nd alevelsurfaceontheshopoor.

2.Raisetheheight-of-cuttothehighestposition;refer toAdjustingtheHeight-Of-Cut.

Important:Donotusemorethanthreeshimsat anyoneholelocation.Usedecreasingnumbers ofshimsinadjacentholesifmorethanoneshim isaddedtoanyoneholelocation.

8.Adjusttheidlerpulleyandinstallthebeltcovers.

3.Lowerthecuttingunitontotheatsurface.Remove thecoversfromthetopofthecuttingunit.

4.Loosentheangenutsecuringtheidlerpulleyto releasethebelttension.

5.Rotatethebladesuntiltheendsfaceforwardand backward.Measurefromtheoortothefronttipof thecuttingedge.Rememberthisdimension.Then rotatethesamebladesothattheoppositeendis

Page 56

SparkArrestor

Storage

Maintenance

ServicingtheSparkArrestor Mufer

ServiceInterval:Every200hours

Every200hoursoperation,clearthemuferofcarbon buildup.

1.Removethepipeplugfromtheclean-outportatthe lowersideofthemufer.

Themufermaybehotandcouldcauseinjury.

Becarefulwhileworkingaroundthemufer.

2.Starttheengine.Plugthenormalmuferexitwitha blockofwoodormetalplatesothattheexhaustow willbeforcedoutoftheclean-outport.Continueto blocktheexituntilcarbondepositsceasecoming outoftheport.

Donotstandinlinewiththeclean-outport.

Alwayswearsafetyglasses.

3.Stoptheengineandreplacethepipeplug.

PreparingforSeasonal Storage

TractionUnit

1.Thoroughlycleanthetractionunit,cuttingunits,and theengine.

2.Checkthetirepressure;refertoCheckingtheTire PressureprocedureinOperation,page17.

3.Checkallfastenersforlooseness;tightenas necessary.

4.Greaseoroilallgreasettingsandpivotpoints. Wipeupanyexcesslubricant.

5.Lightlysandandusetouch-uppaintonpaintedareas thatarescratched,chipped,orrusted.Repairany dentsinthemetalbody .

6.Servicethebatteryandcablesasfollows: A.Removethebatteryterminalsfromthebattery

posts.

B.Cleanthebattery,terminals,andpostswitha

wirebrushandbakingsodasolution.

C.Coatthecableterminalsandbatterypostswith

Grafo112Xskin-overgrease(ToroPartNo. 505-47)orpetroleumjellytopreventcorrosion.

D.Slowlyrechargethebatteryevery60daysfor24

hourstopreventleadsulfationofthebattery.

Engine

1.Draintheengineoilfromtheoilpanandinstallthe drainplug.

2.Removeanddiscardtheoillter.Installanewoil lter.

3.Relltheoilpanwith8qt(7.6l)ofSAE10W-30 CD,CE,CF,CF-4,orCG-4motoroil.

4.Starttheengineandrunitatidlespeedfor approximatelytwominutes.

5.Stoptheengine.

6.Flushthefueltankwithfresh,cleandieselfuel.

7.Secureallofthefuelsystemttings.

8.Thoroughlycleanandservicetheaircleaner assembly.

9.Sealtheaircleanerinletandtheexhaustoutletwith weatherprooftape.

10.Checktheantifreezeprotectionandadda50/50 solutionofwaterandethyleneglycolanti-freezeas neededfortheexpectedminimumtemperaturein yourarea.

Page 57

Schematics

ElectricalSchematic(Rev.A)

Page 58

HydraulicSchematic(Rev.F)

Page 59

Notes:

Page 60

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 agreement between them, jointly warrant your Toro Commercial Product (“Product”) to be free from defects in materials or workmanship for two 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, and certain sprayer components such as diaphragms, nozzles, and check valves, 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. Toro 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 the use of the Toro 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 Toro 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. C

Toro 30410, Groundsmaster 4000-D, 30410TE Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual