Toro 30411 Groundsmaster 4100-D, Groundsmaster 4000-D, 30411 Operator's Manual

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Form No. 3354-137 Rev D

Groundsmaster® 4100-D Traction Unit

Model No. 30411 —Serial No. 2600000001 and Up

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Warning

CALIFORNIA

Pr oposition 65 W ar ning

Diesel engine exhaust and some of its constituents ar e kno wn to the State of Calif or nia to cause cancer , bir th defects, and other r epr oducti v e har m.

Introduction

R ead this infor mation carefully to lear n ho w to operate and maintain y our product properly and to a v oid injur y and product damag e . Y ou are responsible for operating the product properly and safely .

Y ou ma y contact T oro directly at www .T oro .com for product and accessor y infor mation, help ﬁnding a dealer , or to register y our product.

W henev er y ou need ser vice , g en uine T oro par ts , or additional infor mation, contact an A uthorized Ser vice Dealer or T oro Customer Ser vice and ha v e the model and serial n umbers of y our product ready . W rite the n umbers in the space pro vided.

Model No.

Serial No.

T his man ual identiﬁes potential hazards and has safety messag es identiﬁed b y the safety aler t symbol ( Figure 1 ), whic h signals a hazard that ma y cause serious injur y or death if y ou do not follo w the recommended precautions .

Figure 1

1. Safety alert symbol

T his man ual uses 2 other w ords to highlight infor mation. Impor tant calls attention to special mec hanical infor mation and Note emphasizes g eneral infor mation w or th y of special attention.

Contents

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

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

Safe Operating Practices . . . . . . . . . . . . . . . . . . . . . . 4

T oro Mo w er Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Sound Pressure Lev el . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Sound P o w er Lev el . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Vibration Lev el . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Safety and Instr uctional Decals . . . . . . . . . . . . 8

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1 Installing the Seat, Seat Belt, and

Man ual T ube . . . . . . . . . . . . . . . . . . . . . 14

2 Greasing the Mac hine . . . . . . . . . . . . . . . . . . . . . 14

3 R eading the Man uals and Viewing

the D VD . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Product Ov er view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Speciﬁcations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Star ting and Stopping the

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Chec king the Interloc k

Switc hes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Pushing or T o wing the

Mac hine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

J ac king P oints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Tie Do wns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Operating Characteristics . . . . . . . . . . . . . . . . . . . 30

Operating Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

R ecommended Maintenance

Sc hedule(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Premaintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . 34

Ser vice Inter v al Char t . . . . . . . . . . . . . . . . . . . . . . . . 34

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Greasing the Bearings and

Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Air Cleaner Maintenance . . . . . . . . . . . . . . . . . . . . 38

Ser vicing the Engine Oil and

Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Fuel System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Ser vicing the Fuel System . . . . . . . . . . . . . . . . . . 40

Bleeding Air from the

Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Electrical System Maintenance . . . . . . . . . . . . . . . . . . . 41

Acti v ating, Charging, and

Connecting the

Batter y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

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Batter y Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Dri v e System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 43

Changing the Planetar y Gear Dri v e

Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Changing the R ear Axle

Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Chec king the R ear W heel

T oe-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Cooling System Maintenance . . . . . . . . . . . . . . . . . . . . . 45

Ser vicing the Engine Cooling

System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Brak e Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Adjusting the Ser vice Brak es . . . . . . . . . . . . . . 45

Belt Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Ser vicing the Alter nator Belt . . . . . . . . . . . . . . 46

R e-tensioning the Blade Dri v e

Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

R e placing the Blade Dri v e Belt . . . . . . . . . . . 46

Controls System Maintenance . . . . . . . . . . . . . . . . . . . . 47

Adjusting the T hrottle . . . . . . . . . . . . . . . . . . . . . . . 47

Adjusting the T raction P edal

Linkag e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Hy draulic System Maintenance . . . . . . . . . . . . . . . . . . 48

Changing the Hy draulic Fluid . . . . . . . . . . . . . 48

R e placing the Hy draulic

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Chec king the Hy draulic Lines and

Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Hy draulic System T est P or ts . . . . . . . . . . . . . . . 49

Adjusting the Cutting Unit Flo w

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Mo w er Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Pi v oting (Tilting) the F ront Cutting

Unit Upright . . . . . . . . . . . . . . . . . . . . . . 51

Pi v oting the F ront Cutting Unit

Do wn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Adjusting the Cutting Unit

Pitc h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Ser vicing the Castor Ar m

Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Ser vicing the Castor W heels and

Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

R e placing the Cutting Unit Hing e

Co v ers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Tightening the Loc kn uts . . . . . . . . . . . . . . . . . . . . 54

Blade Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Chec king for a Bent Blade . . . . . . . . . . . . . . . . . . 55

R emo ving and Installing the Cutter

Blade(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Inspecting and Shar pening the

Cutter Blade(s) . . . . . . . . . . . . . . . . . . 56

Cor recting Cutting Unit

Mismatc h . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Spark Ar restor Maintenance . . . . . . . . . . . . . . . . . . . . . . 57

Ser vicing the Spark Ar restor

Mufﬂer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Storag e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Pre paring for Seasonal

Storag e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Sc hematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

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Safety

T his machine meets or ex ceeds CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-1999 speciﬁcations in ef fect at the time of pr oduction.

Impr oper use or maintenance by the operator or o wner can r esult in injur y . T o r educe the potential f or injur y , compl y with these safety instr uctions and al w ays pay attention to the safety aler t symbol, which means Caution, W ar ning , or Danger—per sonal safety instr uction. F ailur e to compl y with the instr uction may r esult in per sonal injur y or death.

Safe Operating Practices

T he follo wing instr uctions are from the CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI standard B71.4-1999.

Training

• R ead the Operator’ s Manual and other training material carefully . Be familiar with the controls , safety signs , and the proper use of the equipment.

• Nev er allo w c hildren or people unfamiliar with these instr uctions to use the mo w er . Local regulations ma y restrict the ag e of the operator .

• Nev er mo w while people , especially c hildren, or pets are nearb y .

• K ee p in mind that the operator or user is responsible for accidents or hazards occur ring to himself or herself , other people , or proper ty .

• Do not car r y passeng ers .

• All dri v ers and mec hanics should seek and

obtain professional and practical instr uction. T he o wner is responsible for training the users . Suc h instr uction should emphasize:

◊ inadequate braking;

◊ the type of mac hine is unsuitable for its

task;

◊ lac k of a w areness of the effect of

g round conditions , especially slopes;

◊ incor rect hitc hing and load distribution.

• T he o wner/user can prev ent and is responsible for accidents or injuries occur ring to himself or herself , other people , or proper ty .

Preparation

• W hile mo wing, alw a ys w ear substantial footw ear , long trousers , hard hat, safety glasses , and ear protection. Long hair , loose clothing or jew elr y ma y g et tangled in mo ving par ts . Do not operate the equipment when barefoot or w earing open sandals .

• T horoughly inspect the area where the equipment is to be used and remo v e all objects whic h ma y be thro wn b y the mac hine .

• W ar ning –fuel is highly ﬂammable . T ak e the follo wing precautions:

– Store fuel in containers speciﬁcally designed

for this pur pose .

– R efuel outdoors only and do not smok e

while refuelling .

– Add fuel before star ting the engine . Nev er

remo v e the cap of the fuel tank or add fuel while the engine is r unning or when the engine is hot.

– If fuel is spilled, do not attempt to star t the

engine but mo v e the mac hine a w a y from the area of spillag e and a v oid creating any source of ignition until fuel v apors ha v e dissipated.

– R e place all fuel tank and container caps

securely .

– the need for care and concentration when

w orking with ride-on mac hines;

– control of a ride-on mac hine sliding on a

slope will not be reg ained b y the application of the brak e . T he main reasons for loss of control are:

◊ insufﬁcient wheel g rip;

◊ being dri v en too fast;

• R e place faulty silencers/m ufﬂers .

• Before using, alw a ys visually inspect to see that

the blades , blade bolts , and cutting assembly are not w or n or damag ed. R e place w or n or damag ed blades and bolts in sets to preser v e balance .

• On m ulti-bladed mac hines , tak e care as rotating one blade can cause other blades to rotate .

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• Ev aluate the ter rain to deter mine what accessories and attac hments are needed to properly and safely perfor m the job . Only use accessories and attac hments appro v ed b y the man ufacturer .

• Nev er operate the mac hine with damag ed guards , shields , or without safety protecti v e devices in place . Be sure all interloc ks are attac hed, adjusted properly , and functioning properly .

• Chec k that operators presence controls , safety switc hes , and shields are attac hed and functioning properly . Do not operate unless they are functioning properly .

Operation

• Do not operate the engine in a conﬁned space where dang erous carbon mono xide fumes can collect.

• Mo w only in da ylight or in g ood ar tiﬁcial light.

• Before attempting to star t the engine ,

diseng ag e all blade attac hment clutc hes , shift into neutral, and eng ag e the parking brak e . Only star t the engine from the operators position. Use seat belts , if pro vided.

• Do not use this mac hine on slopes g reater than 13°.

• R emember there is no suc h thing as a safe slope . T ra v el on g rass slopes requires par ticular care . T o guard ag ainst o v er tur ning:

– Do not stop or star t suddenly when g oing

up or do wnhill.

– Eng ag e the clutc h slo wly , alw a ys k ee p the

mac hine in g ear , especially when tra v elling do wnhill.

– T he mac hine speed should be k e pt lo w on

slopes and during tight tur ns .

– Sta y aler t for humps and hollo ws and other

hidden hazards .

– Nev er mo w across the face of the slope ,

unless the mac hine is designed for that pur pose .

• Sta y aler t for holes in the ter rain and other hidden hazards .

• W atc h out for trafﬁc when crossing or near roadw a ys .

• Stop the blades from rotating before crossing surfaces other than g rass .

• W hen using any attac hments , nev er direct disc harg e of material to w ard b ystanders nor allo w any one near the mac hine while in operation.

• Do not c hang e the engine g o v er nor settings or o v erspeed the engine . Operating the engine at ex cessi v e speed ma y increase the hazard of personal injur y .

• Before lea ving the operators position:

– Stop on lev el g round.

– Diseng ag e the po w er tak e-off and lo w er

the attac hments .

– Chang e into neutral and set the parking

brak e .

– Stop the engine and remo v e the k ey .

• Diseng ag e dri v e to attac hments , stop the engine , and disconnect the spark plug wire(s) or remo v e the ignition k ey:

– before clearing bloc kag es;

– before c hec king, cleaning, or w orking on

the mac hine;

– after striking a foreign object. Inspect

the mac hine for damag e and mak e re pairs before restar ting and operating the equipment. T or que all the spindle pulley n uts to 130 to 150 ft-lb (176 to 203 N ⋅ m);

– if the mac hine star ts to vibrate abnor mally

(c hec k immediately).

• Diseng ag e dri v e to attac hments when transpor ting or not is use .

• Stop the engine and diseng ag e dri v e to attac hment:

– before refuelling;

– before making height adjustment unless

adjustment can be made from the operator’ s position.

• R educe the throttle setting before stopping engine and, if the engine is pro vided with a fuel shut-off v alv e , tur n the fuel off at the conclusion of mo wing .

• Nev er raise dec k with the blades r unning .

• K ee p hands and feet a w a y from the cutting

units .

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• Look behind and do wn before bac king up to be sure of a clear path.

• Slo w do wn and use caution when making tur ns and crossing roads and sidew alks .

• Do not operate the mo w er under the inﬂuence of alcohol or dr ugs .

• Use care when loading or unloading the mac hine into a trailer or tr uc k.

• Use care when approac hing blind cor ners , shr ubs , trees , or other objects that ma y obscure vision.

• T he operator shall tur n on ﬂashing w ar ning lights , if pro vided, whenev er tra v eling on a public road, ex ce pt where suc h use is prohibited b y la w .

Maintenance and Storage

• K ee p all n uts , bolts , and screws tight to be sure the equipment is in safe w orking condition.

• Nev er store the equipment with fuel in the tank inside a building where fumes ma y reac h an open ﬂame or spark.

• Allo w the engine to cool before storing in any enclosure and do not store near ﬂame .

• T o reduce the ﬁre hazard, k ee p the engine , silencer/m ufﬂer , batter y compar tment, cutting units , dri v es , and fuel storag e area free of g rass , lea v es , or ex cessi v e g rease . Clean up oil or fuel spillag e .

• R e place w or n or damag ed par ts for safety .

• If the fuel tank has to be drained, do this

outdoors .

• On m ulti-bladed mac hines , tak e care as rotating one blade can cause other blades to rotate .

• W hen mac hine is to be park ed, stored, or left unattended, lo w er the cutting units unless a positi v e mec hanical loc k is pro vided.

• Diseng ag e dri v es , lo w er the cutting units , mo v e traction pedal to Neutral, set parking brak e , stop engine and remo v e k ey and disconnect spark plug wire . W ait for all mo v ement to stop before adjusting, cleaning or re pairing .

• Shut off fuel while storing or transpor ting . Do not store fuel near ﬂames .

• P ark mac hine on lev el g round. Nev er allo w untrained personnel to ser vice mac hine .

• Use jac k stands to suppor t components when required.

• Carefully release pressure from components with stored energ y .

• Disconnect batter y or remo v e spark plug wire before making any re pairs . Disconnect the neg ati v e ter minal ﬁrst and the positi v e last. R econnect positi v e ﬁrst and neg ati v e last.

• Use care when c hec king blades . W rap the blades or w ear glo v es , and use caution when ser vicing them. Only re place blades . Nev er straighten or w eld them.

• K ee p hands and feet a w a y from mo ving par ts . If possible , do not mak e adjustments with the engine r unning .

• Charg e batteries in an open w ell v entilated area, a w a y from spark and ﬂames . Unplug c harg er before connecting or disconnecting from batter y . W ear protecti v e clothing and use insulated tools .

Toro Mower Safety

T he follo wing list contains safety infor mation speciﬁc to T oro products or other safety infor mation that y ou m ust kno w that is not included in the CEN , ISO , or ANSI standards .

T his product is capable of amputating hands and feet and thro wing objects . Alw a ys follo w all safety instr uctions to a v oid serious injur y or death.

Use of this product for pur poses other than its intended use could pro v e dang erous to user and b ystanders .

Engine exhaust contains carbon mono xide, which is an odor less, deadl y poison that can kill y ou.

Do not r un engine indoor s or in an enclosed ar ea.

Operation

• Before operating a mac hine with R OPS (roll o v er protection system), be cer tain that the seat belts are attac hed and the seat is latc hed to prev ent the seat from pi v oting forw ard.

• Kno w ho w to stop the mac hine and engine quic kly .

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• Do not operate the mac hine while w earing tennis shoes or sneak ers .

tur n o v er if a wheel g oes o v er the edg e of a cliff or ditc h, or if an edg e ca v es in.

• W earing safety shoes and long pants is advisable and required b y some local ordinances and insurance regulations .

• K ee p hands , feet, and clothing a w a y from mo ving par ts and the mo w er disc harg e area and underside of the mo w er while the engine is r unning .

• Fill fuel tank until lev el is 1 inc h (25 mm) belo w the bottom of the ﬁller nec k. Do not o v erﬁll.

• Chec k the safety interloc k switc hes daily for proper operation. If a switc h should fail, re place the switc h before operating the mac hine . After ev er y tw o years , re place all interloc k switc hes in the safety system,

r egardless if they are w orking properly or not.

• Chec k carefully for o v erhead clearances (i.e .

branc hes , doorw a ys , electrical wires) before dri ving under any objects and do not contact them.

• Do not mo w in rev erse unless absolutely necessar y .

• R educe speed when making shar p tur ns .

• If a stee p slope m ust be ascended, bac k up the

hill and dri v e forw ard do wn the hill, k ee ping the mac hine in g ear .

• If y ou cannot bac k up a slope or if y ou feel uneasy on it, do not mo w it.

• A v oid star ting or stopping on a slope . If tires lose traction, diseng ag e the blades and proceed slo wly straight do wn the slope . A v oid raising the side cutting units on a slope .

• A v oid tur ning on slopes . If y ou m ust tur n, tur n slo wly and g radually do wnhill, if possible .

• W hen operating the mac hine on slopes , banks , or near drop-offs , alw a ys ha v e the R OPS installed.

• W hen operating a mac hine with a R OPS , alw a ys use a seat belt.

• Be cer tain that the seat belt can be released quic kly if the mac hine is dri v en or rolls into a pond or w ater .

• W atc h for trafﬁc when near or crossing roads . Alw a ys yield the right-of-w a y .

• Do not mo w on w et g rass . R educed traction could cause sliding .

• Do not tr y to stabilize the mac hine b y putting y our foot on the g round.

• Use extra care with other attac hments . T hese can c hang e the stability of the mac hine .

• W hen a person or pet appears unexpectedly in or near the mo wing area, stop mo wing . Careless operation, combined with ter rain angles , ricoc hets , or improperly positioned guards can lead to thro wn object injuries . Do not resume mo wing until the area is cleared.

• T ur n off the blades when not mo wing .

Maintenance and Storage

• Do not touc h equipment or attac hment par ts whic h ma y be hot from operation. Allo w to cool before attempting to maintain, adjust, or ser vice .

• Nev er store the mac hine or fuel container inside where there is an open ﬂame , suc h as near a w ater heater or fur nace .

• K ee p n uts and bolts tight, especially the blade attac hment bolts . K ee p equipment in g ood condition.

• Mak e sure all h y draulic line connectors are tight and all h y draulic hoses and lines are in g ood condition before applying pressure to the system.

• K ee p y our body and hands a w a y from pin hole leaks or nozzles that eject h y draulic ﬂuid under high pressure . Use paper or cardboard, not y our hands , to searc h for leaks . Hy draulic ﬂuid escaping under pressure can ha v e sufﬁcient force to penetrate the skin and cause serious injur y . If ﬂuid is injected into the skin it m ust be surgically remo v ed within a few hours b y a doctor familiar with this for m of injur y or g ang rene ma y result.

• If the engine m ust be r unning to perfor m a maintenance adjustment, k ee p hands , feet, clothing, and any par ts of the body a w a y from the cutting units , attac hments , and any mo ving par ts . K ee p ev er y one a w a y .

• Do not mo w near drop-offs , ditc hes , or embankments . T he mac hine could suddenly

• Chec k brak e operation frequently . Adjust and ser vice as required.

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• Batter y acid is poisonous and can cause bur ns . A v oid contact with skin, eyes , and clothing . Protect y our face , eyes , and clothing when w orking with a batter y .

• Batter y g ases can explode . K ee p cig arettes , sparks , and ﬂames a w a y from the batter y .

• T he engine m ust be shut off before c hec king the oil or adding oil to the crankcase .

• If major re pairs are ev er needed or if assistance is desired, contact an A uthorized T oro Distributor .

based on measurements of identical mac hines per EN 11094 and EN 836.

Sound Power Level

T his unit has an equi v alent contin uous A-w eighted sound po w er lev el at the operator ear of 105 dB A/1 pW , based on measurements of identical mac hines per EN 11094.

Vibration Level

• T o mak e sure of optim um perfor mance and contin ued safety cer tiﬁcation of the mac hine , use only g en uine T oro re placement par ts and accessories . R e placement par ts and accessories made b y other man ufacturers could be dang erous , and suc h use could v oid the product w ar ranty .

Sound Pressure Level

T his unit has an equi v alent contin uous A-w eighted sound pressure lev el at the operator ear of 89 dB A,

Safety and Instructional Decals

Safety decals and instr uctions are easily visible to the operator and are located near any area of potential dang er . R e place any decal that is damag ed or lost.

Hand-Arm

T his unit has an equi v alent contin uous A-w eighted hand/ar m vibration lev el of 2.5 m/s

, based on

measurements of identical mac hines per EN 1033.

Whole Body

T his unit has an equi v alent contin uous A-w eighted hand/ar m vibration lev el of 0.5 m/s

, based on

measurements of identical mac hines per EN 1033.

93-7272

1. Cutting/dismemberment hazard; fan—stay away fro moving parts.

93-7275

1. Read the Operator’s Manual.

2. Do not use starting aids.

93-7818

1. Warning—read the Operator’s Manual for instructions on torquing the blade bolt/nut to 115 to 149 N•m (85 to 110 ft-lb).

Page 9

1. Low height of cut adjustment

100-5623

2. High height of cut adjustment

1. Height of cut adjustment

100-5622

100-5624

1. Height of cut adjustment

100-5693

1. Height of cut adjustment

100-6578

1. Entanglement hazard, belt—do not operate the machine with the shields or guards removed; always keep the shields and guards in place; stay away from moving parts.

1. Low height of cut adjustment

1. Height of cut adjustment

100-5623

2. High height of cut adjustment

100-5694

104-3578

1. Height of cut adjustment

Page 10

104-2277

1. To lock the parking brake, latch the pedals together, apply the brake pedals, and pull up on the knob.

2. To unlock the parking brake, step on the brake pedals.

3. Parking brake lock indicator 6. Press down on the lever to

4. Read the Operator’s

Manual.

5. Press for optional headlights.

tilt the steering wheel.

104-3579

1. Low height of cut adjustment

2. High height of cut adjustment

104-3599

1. Do not step here.

2. Traction pedal

3. Traction—forward

4. Traction—reverse

5. Danger—shut off PTO prior to raising the cutting units; do not operate the cutting units when they are in the raised position.

1. Raise cutting units 2. Lower cutting units

104-8324

Page 11

104-8325

1. Lock/unlock the cutting unit service lock.

106-4250

1. Height of cut

106-6752

1. Warning—read the Operator’s Manual.

2. Warning—lock the parking brake, stop the engine, and remove the ignition key before leaving the machine.

3. Warning—wear the seat belt when seated in the operator’s position.

4. Cutting hazard of hand or foot—stay away from moving parts.

5. Tipping hazard—lower the cutting unit when driving down slopes; do not drive on slopes greater than 15 degrees.

6. Thrown object hazard—keep bystanders a safe distance from the machine.

1. Height of cut

106-6753

106-4251

1. Engine coolant under pressure

2. Explosion hazard—read the Operator’s Manual .

3. Warning—do not touch the hot surface.

4. Warning—read the Operator’s Manual .

106-6754

1. Warning—do not touch the hot surface.

2. Cutting/dismemberment hazard, fan and entanglement hazard, belt—stay away from moving parts.

Page 12

106-6755

1. Engine coolant under pressure.

2. Explosion hazard—read the

Operator’s Manual.

3. Warning—do not touch the hot surface.

4. Warning—read the

Operator’s Manual.

106-6764

1. To start the engine, move the traction pedal to Neutral, press the brake pedal, move the throttle lever to Fast, turn the ignition key to On, and then turn the ignition key to Start; read the Operators Manual.

2. To stop the engine, move the throttle lever to slow, disengage the PTO, set the parking brake, wait 5 minutes, turn the ignition key to Stop, and remove the key; read the

Operators Manual.

3. Read the Operators Manual.

4. To engage the PTO, pull up on the PTO switch and move it forward.

5. To disengage the PTO, move the PTO switch back.

6. To switch the transmission to high speed, raise the attachment lift and switch the speed control to High.

Battery Symbols

Some or all of these symbols are on your battery

1. Explosion hazard 6. Keep bystanders a safe

2. No re, open ame, or smoking.

3. Caustic liquid/chemical burn hazard

4. Wear eye protection

5. Read the Operator’s

Manual.

distance from the battery.

7. Wear eye protection; explosive gases can cause blindness and other injuries

8. Battery acid can cause blindness or severe burns.

9. Flush eyes immediately with water and get medical help fast.

10. Contains lead; do not discard.

110-3286

1. Power outlet

2. Seat switch 5. Starter solenoid

3. Ignition switch 6. Light Kit

4. Power Take Off (PTO)

Page 13

1. Power Take-off (PTO)

2. Engage

3. Disengage

4. Transmission

5. High

106-2046

6. Low

7. Lock 12. Press the button 17. Continuous variable setting

8. Flow divider 13. Key switch 18. Engine coolant temperature

9. Unlock 14. Engine—preheat

10. Cruise control (optional)

11. Silencer switch 16. Slow

reset switch

15. Fast

1. Read the Operator’s Manual.

104-8336

Page 14

Setup

Loose Parts

Use the chart below to verify that all parts have been shipped.

Step

Seat kit (obtain separately) Seat suspension kit (obtain

separately) Manual tube

R-clamp Seat belt Bolt Lock washer

No parts required

Operator’s Manual Engine Operator’s Manual Parts Catalog Operator Training DVD Pre-delivery Inspection Sheet CE certicate

Description

Note: Deter mine the left and right sides of the

mac hine from the nor mal operating position.

Step

Qty.

1 1 1

2 1 2 2

–

1 1 1 1 1 1

Install the seat, seat belt, and manual tube.

Grease the machine.

Read the manuals and watch the DVD before operating the machine. Use the remaining parts for the installation of attachments.

Use

Kit, Model No . 30621, m ust be purc hased and installed.

1. Mount the man ual tube to the seat suspension with the 2 R-clamps included in loose par ts .

Installing the Seat, Seat Belt, and Manual Tube

Parts needed for this step:

Seat kit (obtain separately)

Seat suspension kit (obtain separately)

Manual tube

R-clamp

Seat belt

Bolt

Lock washer

Procedure

T he mac hine is shipped without the seat assembly . T he Delux e Seat, Model No . 30398, and Seat Suspension Kit, Model No . 30396 or the Premium Seat, Model No . 30622, and Premium Suspension

2. Install the seat belt to eac h side of the seat with a bolt and loc k w asher , supplied in loose par ts .

Important: Mak e sur e that the seat s witch wir e is connected to the seat s witch connector on the har ness.

3. Slide the seat completely forw ard and bac kw ard to ensure proper operation and that seat switc h wires and connectors are not pinc hed or do no contact any mo ving par ts .

Page 15

Step

Greasing the Machine

No Parts Required

Procedure

Before the mac hine is operated, it m ust be g reased to ensure proper lubricating c haracteristics; refer to Greasing the Bearings and Bushings procedure of Lubrication , pag e 34 . F ailure to properly g rease the mac hine will result in premature failure of critical par ts .

Step

Reading the Manuals and Viewing the DVD

Parts needed for this step:

Operator’s Manual

Engine Operator’s Manual

Parts Catalog

Operator Training DVD

Pre-delivery Inspection Sheet

CE certicate

Procedure

1. R ead the man uals .

2. View the Operator T raining D VD .

Page 16

Product Overview

press the pedal while the throttle is in F ast.

T o stop , reduce y our foot pressure on the traction pedal and allo w it to retur n to the center position.

Important: T he speed limiter scr ew must stop the traction pedal bef or e the pump r eaches full str ok e or dama ge to the pump may occur .

Brake Pedals

T w o foot pedals ( Figure 2 ) operate indi vidual wheel brak es for tur ning assistance , parking, and to aid in obtaining better side hill traction. A latc h connects the pedals for parking brak e operation and transpor t.

Pedal Locking Latch

T he pedal loc king latc h ( Figure 2 ) connects the pedals tog ether to eng ag e the parking brak e .

pedal. F or no load, maxim um g round speed, fully

Figure 2

1. Traction pedal 6. Charge indicator

2. Brake pedals 7. Engine oil pressure warning

3. Pedal locking latch 8. Engine coolant

4. Tilt steering lever 9. Glow plug indicator light

5. Parking brake latch

light

temperature warning light

10. Temperature gauge

Controls

Note: Deter mine the left and right sides of the

mac hine from the nor mal operating position.

T his machine pr oduces sound lev els in ex cess of 85 dB A at the operator s ear and can cause hearing loss thr ough extended periods of exposur e.

W ear hearing pr otection when operating this machine.

Tilt Steering Lever

Press the lev er ( Figure 2 ) do wn to tilt the steering wheel to the desired position. T hen release the lev er to loc k the adjustment.

Parking Brake Latch

A knob on the left side of the console actuates the parking brak e loc k ( Figure 2 ). T o eng ag e the parking brak e , connect the pedals with the loc king latc h, push do wn on both pedals , and pull the parking brak e latc h out. T o release the parking brak e , press both pedals until the parking brak e latc h retracts .

Charge Indicator

T he c harg e indicator ( Figure 2 ) illuminates when the system c harging circuit malfunctions .

Engine Oil Pressure Warning Light

T he light ( Figure 2 ) illuminates when the engine oil pressure is dang erously lo w .

Traction Pedal

T he traction pedal ( Figure 2 ) controls forw ard and rev erse operation. Press the top of the pedal to mo v e forw ard and the bottom to mo v e bac kw ard. Ground speed de pends on ho w far y ou press the

Engine Coolant Temperature Warning Light

T he light ( Figure 2 ) illuminates and the engine shuts do wn when coolant reac hes an ex cessi v ely high temperature .

Page 17

Glow Plug Indicator Light

Key Switch

W hen lit, the glo w plug indicator light ( Figure 2 ) indicates that the glo w plugs are on.

Engine Temperature Gauge

T his g aug e ( Figure 2 ) indicates the engine coolant temperature .

Speed Limiter

Adjust the screw ( Figure 3 ) to limit the amount the traction pedal can be de pressed in the forw ard direction to limit speed.

Important: T he traction pedal must contact the speed limiter bef or e r eaching the end of the pump str ok e to pr ev ent pump dama ge.

T he k ey switc h ( Figure 4 ) has three positions: Off , On/Preheat, and Star t.

PTO Switch

T he PTO switc h ( Figure 4 ) has three positions: On (eng ag e), Neutral, and Off (diseng ag e). Carefully lift and push the PTO switc h forw ard to the On position to star t the implement or cutting unit blades . Slo wly pull the switc h bac kw ard to the Off position to stop implement operation.

Important: T he center lift lev er must momentaril y be pushed to the lo w er position to ena ble PT O circuit actuation by PT O s witch.

Hi-Lo Speed Control

T he control ( Figure 4 ) allo ws the speed rang e to increase for transpor t of the mac hine .

Figure 3

1. Speed limiter

Lift Levers

T he lift lev ers ( Figure 4 ) raise and lo w er the cutting units .

Important: T he center lift lev er must momentaril y be pushed to the lo w er position to ena ble PT O circuit actuation by PT O s witch.

Cutting Unit Service Lock

T he cutting unit ser vice loc k ( Figure 4 ) loc ks the front cutting unit lift lev er when the cutting unit is in the raised position.

Figure 4

1. Lift lever 8. Temperature reset switch

2. Front cutting unit service lock

3. Key switch 10. Fuel gauge

4. PTO switch 11. Throttle

5. Hi-lo speed control 12. Audible alarm

6. Cruise control (optional)

7. Alarm silence switch

9. Hour meter

13. Power point

Cruise Control (Optional)

T he cr uise control ( Figure 4 ) sets the speed of the mac hine .

Fuel Gauge

T he fuel g aug e ( Figure 4 ) indicates the lev el of fuel in the tank.

Page 18

Hour Meter

Alarm Silence Switch

T he hour meter ( Figure 4 ) sho ws the total hours

T his switc h ( Figure 4 ) shuts off the audible alar m.

that the mac hine has been operated.

Throttle Control

Temperature Override Switch

Mo v e the control ( Figure 4 ) forw ard to increase the

Press and hold the reset switc h ( Figure 4 ) to star t

engine speed and rearw ard to decrease the speed.

the engine after high temperature shut do wn. Use only for emerg ency operation.

Audible Alarm

T he alar m ( Figure 4 ) is acti v ated when the lo w

Power Point

T he po w er point ( Figure 4 ) is used to po w er optional electrical accessories .

engine oil pressure light illuminates or the high coolant temperature light illuminates .

Specications

Note: Speciﬁcations and design are subject to c hang e without notice .

Width of cut

overall

front cutting unit side cutting unit front and one side cutting

unit

Overall width

cutting units down

cutting units up (transports) 71 inch (180 cm) Overall length Height

124 inch (315 cm)

54 inch (137 cm)

37 inch (94 cm)

89 inch (226 cm)

127 inch (322 cm)

144 inch (366 cm)

58 inch (147 cm)

g o to www .T oro .com for a list of all appro v ed attac hments and accessories .

Height with ROPS

Ground clearance

Wheel tread (to center of tire)

front

rear

Wheel base

Weight (with cutting units and uids)

81 inch (206 cm)

6 inch (15 cm)

45 inch (114 cm) 47 inch (119 cm)

55-1/2 in (141 cm)

3905 lb (1757 kg)

Attachments/Accessories

A selection of T oro appro v ed attac hments and accessories are a v ailable for use with the mac hine to enhance and expand its capabilities . Contact y our A uthorized Ser vice Dealer or Distributor or

Page 19

Operation

Note: Deter mine the left and right sides of the

mac hine from the nor mal operating position.

Before Operating

If y ou lea v e the k ey in the ignition s witch, someone could accidentl y star t the engine and seriousl y injur e y ou or other bystander s.

R emo v e the k ey fr om the ignition bef or e y ou do an y maintenance.

Checking the Engine Oil

T he engine is shipped with oil in the crankcase; ho w ev er , the oil lev el m ust be c hec k ed before and after the engine is ﬁrst star ted.

T he crankcase capacity is 8 qt (7.6 l) with the ﬁlter .

Figure 5

1. Dipstick

4. If the oil is belo w the Full mark, remo v e the ﬁll cap ( Figure 6 ) and add oil until the lev el reac hes the Full mark. Do not o v erﬁll.

Use high-quality engine oil that meets the follo wing speciﬁcations:

• API Classiﬁcation Lev el R equired: CH-4, CI-4 or higher .

• Prefer red oil: SAE 15W -40 (abo v e 0°F)

• Alter nate oil: SAE 10W -30 or 5W -30 (all

temperatures)

T oro Premium Engine Oil is a v ailable from y our distributor in either 15W -40 or 10W -30 viscosity . See the par ts catalog for par t n umbers .

1. P ark the mac hine on a lev el surface . Unloc k the engine co v er latc hes .

2. Open the engine co v er .

3. R emo v e the dipstic k, wipe it clean, install the dipstic k into the tube , and pull it out ag ain. T he oil lev el should be up to the FULL mark ( Figure 5 ).

Figure 6

1. Oil ll cap

Note: W hen using different oil, drain all old oil from the crankcase before adding new oil.

5. Install the oil ﬁll cap and dipstic k.

6. Close the engine co v er and secure it with the latc hes .

Checking the Cooling System

Chec k lev el of coolant at the beginning of eac h da y . Capacity of system is 2-3/4 g allons (10.4 l).

1. Carefully remo v e the radiator cap and expansion tank cap ( Figure 7 ).

Page 20

If the engine has been r unning , the pr essuriz ed, hot coolant can escape and cause bur ns.

• Do not open the radiator cap when the engine is r unning .

• Use a ra g when opening the radiator cap , and open the cap slo wl y to allo w steam to escape.

2. Chec k the coolant lev el in the radiator . T he radiator should be ﬁlled to the top of the ﬁller nec k and the expansion tank ﬁlled to the Full mark.

Figure 8

1. Fuel tank cap

Under cer tain conditions, diesel fuel and fuel v apor s ar e highl y ﬂamma ble and explosi v e. A ﬁr e or explosion fr om fuel can bur n y ou and other s and can cause pr oper ty dama ge.

• Use a funnel and ﬁll the fuel tank outdoor s, in an open ar ea, when the engine is of f and is cold. W ipe up an y fuel that spills.

Figure 7

1. Expansion tank

3. If the coolant is lo w , add a 50/50 mixture of w ater and eth ylene glycol anti-freeze . Do not

use w ater onl y or alcohol/methanol base coolants.

4. Install the radiator cap and expansion tank cap .

Filling the Fuel Tank

T he capacity of the fuel tank is 19 g allons (72 l).

1. R emo v e the fuel tank cap ( Figure 8 ).

2. Fill the tank to about 1 inc h (25 mm) belo w the top of the tank, not the ﬁller nec k, with No . 2 diesel fuel. T hen install the cap .

• Do not ﬁll the fuel tank completel y full. Add fuel to the fuel tank until the lev el is 1/4 to 1/2 inch (6 to 13 mm) belo w the bottom of the ﬁller neck. T his empty space in the tank allo ws the fuel to expand.

• Nev er smok e when handling fuel, and stay a w ay fr om an open ﬂame or wher e fuel fumes may be ignited by a spar k.

• Stor e fuel in a clean, safety-appr o v ed container and k eep the cap in place.

Checking the Hydraulic Fluid

T he mac hines reser v oir is ﬁlled at the factor y with appro ximately 8 U .S . g allons (30.2 l) of high quality h y draulic ﬂuid. Check the lev el of the h y draulic

ﬂuid bef or e the engine is ﬁr st star ted and dail y ther eafter . T he recommended re placement

ﬂuid is:

T or o Pr emium All Season Hy draulic F luid

(A v ailable in 5 g allon pails or 55 g allon dr ums . See par ts catalog or T oro distributor for par t n umbers .)

Page 21

Alter nate ﬂuids: If the T oro ﬂuid is not a v ailable , other ﬂuids ma y be used pro vided they meet all the follo wing material proper ties and industr y speciﬁcations . W e do not recommend the use of synthetic ﬂuid. Consult with y our lubricant distributor to identify a satisfactor y product.

Note: T oro will not assume responsibility for damag e caused b y improper substitutions , so use only products from re putable man ufacturers who will stand behind their recommendation.

3 High Viscosity Index/Low Pour Point Anti-wear Hydraulic Fluid, ISO VG 46

Material Properties:

Viscosity, ASTM D445

Viscosity Index ASTM D2270

St @ 40° C 44 to 48

St @ 100° C 7.9 to 8.5

140 to 160

type , be cer tain to follo w the appro v ed ﬂushing procedure . Contact y our local T oro Distributor for details .

1. P osition the mac hine on a lev el surface , lo w er the cutting units , stop the engine , and remo v e the k ey .

2. Unlatc h the seat, raise it, and eng ag e the prop rod.

3. Clean the area around the ﬁller nec k and cap of the h y draulic tank ( Figure 9 ). R emo v e the cap from the ﬁller nec k.

Pour Point, ASTM D97

Industry Specications: Vickers I-286-S

-34° F to -49° F

(Quality Level), Vickers

M-2950-S (Quality

Level), Denison HF-0

Note: Many h y draulic ﬂuids are almost colorless , making it difﬁcult to spot leaks . A red dye additi v e for the h y draulic system oil is a v ailable in 2/3 oz (20 ml) bottles . One bottle is sufﬁcient for 4-6 g allons (15-22 1) of h y draulic oil. Order par t no . 44-2500 from y our authorized T oro distributor .

Biodeg rada ble Hy draulic F luid - Mobil EAL 224H

T or o Biodeg rada ble Hy draulic F luid

(A v ailable in 5 g allon pails or 55 g allon dr ums . See par ts catalog or T oro distributor for par t n umbers .)

* Use only when temperatures are abo v e 30° F .

T his is v eg etable-oil based biodeg radable oil tested and appro v ed b y T oro for this model. T his ﬂuid is not as resistant to high temperatures as standard ﬂuid, so install an oil cooler if required b y the operator man ual and follo w recommended ﬂuid c hang e inter v als with this ﬂuid. Contamination b y mineral-based h y draulic ﬂuids will c hang e the biodeg radability and to xicity of this oil. W hen c hanging from standard ﬂuid to the biodeg radable

Figure 9

1. Hydraulic tank cap

4. R emo v e the dipstic k from the ﬁller nec k and wipe it with a clean rag . Inser t the dipstic k into the ﬁller nec k; then remo v e it and c hec k the ﬂuid lev el. T he ﬂuid lev el should be betw een the tw o marks on the dipstic k.

5. If the lev el is lo w , add the appropriate ﬂuid to raise the lev el to the upper mark.

6. Install the dipstic k and cap onto the ﬁller nec k.

Checking the Planetary Gear Drive Oil

Chec k the oil lev el after ev er y 400 hours of operation or if exter nal leakag e is noted. Use high quality SAE 85W -140 g ear lube as a re placement.

T he capacity of the system is appro ximately 16 oz (0.5 l).

1. With the mac hine on a lev el surface , position the wheel so that the c hec k/drain plug ( Figure 10 ) is at either the 2 or 10 o’cloc k position.

Page 22

Figure 10

1. Check/drain plug

2. R emo v e the plug on the planetar y ( Figure 10 ) and c hec k the plug on the bac k side of the brak e ( Figure 11 ). Oil should be at the bottom of the c hec k plug hole on the bac k side of the brak e .

before the engine is ﬁrst star ted and ev er y 400 hours thereafter . T he capacity is 80 oz (2.4 l). Visually inspect for leaks daily .

1. P osition the mac hine on a lev el surface .

2. R emo v e a c hec k plug from one end of the axle ( Figure 12 ) and mak e sure that the lubricant is up to the bottom of the hole . If the lev el is lo w , remo v e the ﬁll plug ( Figure 12 ) and add enough lubricant to bring the lev el up to the bottom of the c hec k plug holes .

Figure 12

1. Check plug 2. Fill plug

Figure 11

1. Brake housing 2. Check plug

3. Add g ear oil to the hole in the planetar y , if necessar y , to bring the oil up to the proper lev el. Install the plug .

4. R e peat ste ps 1 - 3 on the opposite g ear assembly .

Checking the Rear Axle Gear Box Lubricant

T he g ear bo x is shipped from the factor y ﬁlled with SAE 85W -140 g ear lube . Chec k the oil lev el before the engine is ﬁrst star ted and ev er y 400 hours thereafter . T he capacity is 16 oz (0.5 l). Visually inspect for leaks daily .

1. P osition the mac hine on a lev el surface .

2. R emo v e the c hec k/ﬁll plug from the left side of the g ear bo x ( Figure 13 ) and mak e sure that lubricant is up to the bottom of the hole . If the lev el is lo w , add enough lubricant to bring the lev el up to the bottom of the hole .

Checking the Rear Axle Lubricant

T he rear axle is shipped from the factor y ﬁlled with SAE 85W -140 g ear lube . Chec k the oil lev el

Page 23

Figure 13

1. Gear box 2. Check/ll plug

Checking the Tire Pressure

T he tires are o v er -inﬂated for shipping . T herefore , release some of the air to reduce the pressure . T he cor rect air pressure in the front and rear tires is 25-30 psi (172-207 kP a).

1. Star t the engine and raise the cutting units so that the height-of-cut can be c hang ed. Stop the engine and remo v e the k ey after the cutting unit is raised.

2. P osition the castor wheel axles in the same holes in all castor forks . R efer to the follo wing c har t to deter mine the cor rect holes for the setting .

Important: Maintain ev en pr essur e in all tir es to ensur e a good quality-of-cut and pr oper machine perf or mance. Do not under -inﬂate.

Checking the Torque of the Wheel Nuts or Bolts

F ailur e to maintain pr oper torque of the wheel n uts could r esult in f ailur e or loss of wheel and may r esult in per sonal injur y .

T orque the fr ont wheel n uts and r ear bolts to 85-100 ft-lb (115-136 N ⋅ m) after 1-4 hour s of operation and a gain after 10 hour s of operation. T orque ev er y 200 hour s ther eafter .

Adjusting the Height-of-Cut

Center Cutting Unit

T he height-of-cut is adjustable from 1 to 5 inc hes (25 to 127 mm) in 1/2 inc h (13 mm) increments . T o adjust the height-of-cut on the front cutting unit, position the castor wheel axles in the upper or lo w er holes of the castor forks , add or remo v e an equal n umber of spacers from the castor forks , and secure the rear c hain to the desired hole .

Figure 14

1. Castor wheel 4. Shims

2. Tensioning cap

3. Spacers

5. Axle mounting holes

Note: W hen operating in 2-1/2 inc h (64 mm) height of cut or higher , the axle bolt m ust be installed in the lo w er castor fork hole to prev ent g rass buildup betw een the wheel and the fork. W hen operating in height of cuts lo w er than 2-1/2 inc hes (64 mm) and g rass buildup is detected, rev erse the mac hines direction to pull any clippings a w a y from the wheel/fork area.

3. R emo v e the tensioning cap from the spindle shaft ( Figure 14 ) and slide the spindle out of the castor ar m. Put the 2 shims (1/8 inc h [3 mm]) onto the spindle shaft as they w ere originally installed. T hese shims are required to ac hiev e a lev el across the entire width of the cutting units . Slide the appropriate n umber of 1/2

Page 24

inc h spacers (refer to the c har t belo w) onto the spindle shaft to g et the desired height-of-cut; then slide the w asher onto the shaft.

R efer to the follo wing c har t to deter mine the combinations of spacers for the setting:

Figure 15

Figure 17

Note: W hen using 1 inc h (25 mm), 1-1/2

inc h (38 mm), or occasionally 2 inc h (51 mm) height-of-cut, mo v e the skids and g ag e wheels to the highest holes .

4. Push the castor spindle through the front castor ar m. Install the shims (as they w ere originally installed) and the remaining spacers onto the spindle shaft. Install the tensioning cap to secure the assembly .

5. R emo v e the hair pin cotter and clevis pin securing the height-of-cut c hains to the rear of the cutting unit ( Figure 16 ).

Figure 16

1. Height-of-cut chain 2. U-bolt

W ing Cutting Units

T o adjust the height-of-cut on the side cutting units , add or remo v e an equal n umber of spacers from the castor forks , position the castor wheel axles in the high or lo w height-of-cut holes in the castor forks , and secure the pi v ot ar ms to the selected height-of-cut brac k et holes .

1. P osition the castor wheel axles in the same holes in all of the castor forks ( Figure 18 and Figure 20 ). R efer to the follo wing c har t to deter mine the cor rect hole for the setting .

2. R emo v e the tensioning cap from the spindle shaft ( Figure 18 ) and slide the spindle out of castor ar m. Put the tw o shims (1/8 inc h [3 mm]) onto spindle shaft as they w ere originally installed. T hese shims are required to ac hiev e a lev el across the entire width of the cutting units . Slide the appropriate n umber of 1/2 inc h spacers onto the spindle shaft to g et the desired height-of-cut; then slide the w asher onto the shaft.

6. Mount the height-of-cut c hains to the desired height-of-cut hole ( Figure 17 ) with the clevis pin and hair pin cotter .

Page 25

Figure 18

1. Castor wheel 4. Shims

2. Tensioning cap

3. Spacers

5. Axle mounting holes

height-of-cut brac k et holes in the cutting unit frame ( Figure 20 and Figure 21 ).

6. Inser t the clevis pins and install the hair pin cotters .

7. R otate tension rod countercloc kwise (ﬁng er tight) to put tension on adjustment.

Figure 20

1. Castor pivot arm

2. Axle mounting holes 4. Tension rod

3. Clevis pin and hair pin cotter

R efer to the follo wing c har t to deter mine the combinations of spacers for the setting .

Figure 19

3. Push the castor spindle through the castor ar m. Install the shims (as originally installed) and the remaining spacers onto the spindle shaft. Install the tensioning cap to secure the assembly .

4. R emo v e the hair pin cotter and clevis pins from the castor pi v ot ar ms ( Figure 20 ).

Figure 21

Adjusting the Skids

T he skids should be mounted in the lo w er position when operating in height of cuts g reater than 2-1/2 inc hes (64 mm) and in the higher position when operating in height of cuts lo w er than 2-1/2 inc hes (64 mm).

Adjust the skids b y remo ving the ﬂang e bolt and n uts , positioning them as desired, and installing the fasteners ( Figure 22 ).

5. R otate tension rod to raise or lo w er pi v ot ar m until holes are aligned with selected

Page 26

Figure 22

1. Skid

Adjusting the Cutting Unit Rollers

2. R otate a center and adjoining wing blade so there blade tips are aligned. Measure distance betw een blade tips , distance should be appro ximately 0.38-0.62 inc h (10-16 mm) ( Figure 24 ).

Figure 24

T he cutting unit rollers should be mounted in the lo w er position when operating in height of cuts g reater than 2-1/2 inc hes (64 mm) and in the higher position when operating in height of cuts lo w er than 2-1/2 inc hes (64 mm).

1. R emo v e the bolt and n ut securing the g ag e wheel to the cutting unit brac k ets ( Figure 23 ).

Figure 23

1. Gage wheel

3. T o adjust distance , locate adjuster bolt on rear pi v ot link of cutting unit ( Figure 25 ). Loosen jam n ut on adjuster bolt. Loosen or tighten adjuster bolts until 0.38-0.62 inc h (10-16 mm) clearance is attained, then tighten jam n ut.

4. R e peat procedure on opposite side of cutting dec k.

Figure 25

1. Adjuster bolt

2. Jam nut

2. Align the roller and spacer with the top holes in the brac k ets and secure them with the bolt and n ut.

Adjusting the Blade

T o ensure proper operation of the cutting unit, there m ust be 0.38-0.62 inc h (10-16 mm) clearance betw een the tips of the wing and center cutting unit blades ( Figure 24 ).

1. Raise cutting unit so blades are visible and bloc k center dec k section so it cannot fall accidentally . Wing dec ks m ust be horizontal to center cutting unit.

Correcting Mismatch Between Cutting Units

Due to differences in g rass conditions and the counterbalance setting of the traction unit, it is advised that g rass be cut and appearance c hec k ed before for mal cutting is star ted.

1. Set all cutting units to the desired height of cut; refer to Adjusting the Height of Cut table in Speciﬁcations , pag e 18 .

2. Chec k and adjust front and rear tractor tire pressure to 25-30 psi (172-207 kP a).

Page 27

3. Chec k and adjust all castor tire pressures to 50 psi (345 kP a).

4. Chec k c harg e and counterbalance pressures with engine at high idle using test por ts deﬁned in Hy draulic Systems T est P or ts . Adjust counterbalance setting to be 230 psi (1585 kP a) higher than c harg e pressure reading .

5. Chec k for bent blades; refer to Chec king for a Bent Blade procedure in Mo w er Maintenance , pag e 51 .

6. Cut g rass in a test area to deter mine if all cutting units are cutting at the same height.

7. If cutting unit adjustments are still needed, ﬁnd a ﬂat surface using a 6 foot (2 m) or long er straight edg e .

8. T o ease measuring blade plane , raise the height of cut to the highest position; refer to Adjusting the Height of Cut.

9. Lo w er cutting units onto the ﬂat surface . R emo v e the co v ers from the top of the cutting units .

10. Loosen the ﬂang e n ut, securing the idler pulley , to release the belt tension on eac h cutting unit.

Figure 26

1. Castor wheel 4. Shims

2. Tensioning cap

3. Spacers

5. Axle mounting holes

Center Cutting Unit Setup

R otate blade on eac h spindle until the ends face forw ard and bac kw ard. Measure from the ﬂoor to the front tip of the cutting edg e . Adjust 1/8 inc h shims on front castor fork(s) to matc h height of cut to decal ( Figure 26 ); refer to Adjusting the Cutting Unit Pitc h procedure in Mo w er Maintenance , pag e 51 .

W ing Cutting Unit Setup

R otate blade of eac h spindle until the ends face forw ard and bac kw ard. Measure from the ﬂoor to the front tip of the cutting edg e . Adjust 1/8 inc h shims on front castor ar m(s) to matc h height of cut to decal ( Figure 27 ). F or the outside blade spindle only , refer to Adjusting the Cutting Unit Pitc h procedure in Mo w er Maintenance , pag e 51 .

Page 28

Figure 27

1. Front castor arm

Matching Height Of Cut Betw een Cutting Units

1. P osition blade side to side on outside spindle of both wing cutting units . Measure from the ﬂoor to the tip of the cutting edg e on both units and compare . T hese n umbers should be within 1/8 inc h (3 mm) of eac h other .

2. Add or remo v e 1/8 inc h shims as needed on wing castor wheels . R ec hec k measurement betw een outside edg es of both wing cutting units and adjust as necessar y .

Starting and Stopping the

2. Mo v e the throttle control to the mid-idle position.

3. T ur n the ignition k ey to the R un position. T he glo w indicator will light.

4. W hen the glo w indicator dims , tur n the ignition k ey to the Star t position. R elease the k ey immediately when the engine star ts and allo w it to retur n to the R un position. Allo w engine to w ar m up at mid speed (without load), then mo v e the throttle control to the desired position.

Important: Do not r un the star ter motor mor e than 15 seconds at a time or pr ematur e star ter f ailur e may r esult. If the engine f ails to star t after 15 seconds, tur n the k ey to the Of f position, r echeck the contr ols and pr ocedur es, w ait 15 additional seconds, and r epeat the star ting pr ocedur e.

W hen the temperature is less than 20°F (-75C), preheat glo w plugs twice prior to initial cranking attempt. T he star ter motor can be r un for 30 seconds on then 60 seconds off for 2 attempts .

5. W hen the engine is star ted for the ﬁrst time , or after an o v erhaul of the engine , transmission, or axle , operate the mac hine in forw ard and rev erse for one or tw o min utes . Also operate the lift lev er and PTO lev er to ensure proper operation of all par ts . T ur n the steering wheel to the left and right to c hec k steering response . T hen shut the engine off and c hec k for oil leaks , loose par ts , and any other noticeable difﬁculties .

Engine

Important: T he fuel system will

automaticall y bleed itself when an y of the f ollo wing situations occur :

• Initial star t up of a new mac hine .

• T he engine has ceased r unning due to lac k of

fuel.

• Maintenance has been perfor med upon the fuel system components .

R efer to the Bleeding Air from the Injectors procedure in Fuel System Maintenance , pag e 40 .

1. Ensure that the parking brak e is set. R emo v e y our foot from the traction pedal and ensure that it is in neutral.

Shut the engine of f and w ait f or all mo ving par ts to stop bef or e checking f or oil leaks, loose par ts, and other malfunctions.

6. T o stop the engine , mo v e the throttle control bac kw ard to the Slo w position, mo v e the PTO lev er to the Off position, set the parking brak e , and rotate the ignition k ey to Off . R emo v e the k ey from the switc h to prev ent accidental star ting .

Page 29

Important: Allo w engine to idle f or 5 min utes bef or e shutting it of f after a full load operation. F ailur e to do so may lead to turbo-charger tr ouble.

Checking the Interlock Switches

4. Sit on the seat, eng ag e the parking brak e and star t the engine . Mo v e the traction pedal out of the neutral position. T he engine should kill. If the engine does not kill, there is a malfunction in the interloc k system that should be cor rected before beginning operation.

5. Sit on the seat, star t the engine and set speed rang e to lo w . Mo v e PTO switc h forw ard to eng ag e cutting units .

If safety inter lock s witches ar e disconnected or dama ged the machine could operate unexpectedl y causing per sonal injur y .

• Do not tamper with the inter lock s witches.

• Check the operation of the inter lock s witches dail y and r eplace an y dama ged s witches bef or e operating the machine.

• R eplace s witches ev er y tw o y ear s or 1500 hour s, whichev er occur s ﬁr st, r egardless of whether they ar e operating pr oper l y or not.

T he mac hine has interloc k switc hes in the electrical system. T hese switc hes are designed to stop the engine when operator g ets off of the seat when the traction pedal is de pressed. Ho w ev er , the operator ma y g et off of the seat while the engine is r unning and the traction pedal is in neutral. Although the engine will contin ue to r un if the PTO lev er is diseng ag ed and the traction pedal is released, it is strongly recommended that the engine be stopped before rising from the seat.

T o c hec k the operation of the interloc k switc hes , perfor m the follo wing procedure:

1. Dri v e the mac hine slo wly to a larg e , relati v ely open area. Lo w er the cutting unit, stop the engine , and apply the parking brak e .

2. Sit on the seat and de press the traction pedal. T r y to star t the engine . T he engine should not crank. If the engine cranks , there is a malfunction in the interloc k system that should be cor rected before beginning operation.

3. Sit on the seat and star t the engine . Rise from the seat and mo v e the PTO lev er to On. T he PTO should not eng ag e . If the PTO eng ag es , there is a malfunction in the interloc k system that should be cor rected before beginning operation.

Important: T he center lift lev er must momentaril y be pushed to the lo w er position to ena ble PT O circuit actuation by PT O s witch.

• Raise either wing cutting unit to the transpor t

position. T he cutting unit should tur n off . If the cutting unit does not stop , there is a malfunction in the interloc k system that should be cor rected before resuming operation.

• If the cutting unit is lo w ered ag ain the motor should re-star t. If the cutting unit does not re-star t, there is a malfunction in the interloc k system that should be cor rected before resuming operation.

• Raise the center cutting unit to the transpor t position. All the cutting units should stop r unning and not re-eng ag e when lo w ered to the g round. If the cutting unit does not stop when it is raised or if it re-star ts when it is lo w ered, there is a malfunction in the interloc k system that should be cor rected before resuming operation.

• With the cutting units eng ag ed, switc h the speed rang e from lo w to high. T he cutting units should stop . If the cutting units do not stop , there is a malfunction in the interloc k system that should be cor rected before resuming operation.

• If the operator rises from the seat with the cutting units eng ag ed and/or the traction pedal out of neutral, the cutting units m ust stop in appro ximately one second and engine m ust shutdo wn in appro ximately tw o seconds . If the cutting units do not stop and the engine does not shutdo wn, there is a malfunction in the interloc k system that should be cor rected before resuming operation.

Page 30

Pushing or Towing the Machine

In an emerg ency , the mac hine can be mo v ed forw ard b y actuating the b ypass v alv e in the v ariable displacement h y draulic pump and pushing or to wing the mac hine . Do not push or to w the

machine f or mor e than 1/4 mile (0.4 km). Important: Do not push or to w the machine

f aster than 2-3 MPH (3-4.8 km/h) because inter nal transmission dama ge may occur . T he bypass v alv e must be open whenev er the machine is pushed or to w ed.

1. Raise the seat and remo v e the batter y co v er . T he b ypass v alv e is located in front of the batter y ( Figure 28 ).

2. R otate the v alv e 905 in either direction to open and allo w oil to b ypass inter nally . Because ﬂuid is b ypassed, the mac hine can be slo wly mo v ed without damaging the transmission.

Note: R esistance will be felt on the v alv e when it is mo v ed to the open position.

Figure 29

1. Reverse traction pressure test port

3. Close the b ypass v alv e before star ting the engine . Ho w ev er , do not ex ceed 5 to 8 ft-lb (7 to 11 N ⋅ m) tor que to close the v alv e .

Figure 28

1. Bypass valve access hole

Important: If the machine must to be pushed or to w ed in r ev er se, the check v alv e in the f our -wheel dri v e manif old must also be bypassed. T o bypass the check v alv e, connect a hose assembl y (Hose P ar t No. 95-8843, Coupler Fitting No. 95-0985 [Qty . 2], and Hy draulic Fitting No. 340-77 [Qty . 2]) to the r ev er se traction pr essur e test por t ( Figur e 29 ) and the r ev er se f our -wheel dri v e pr essur e por t ( Figur e 30 ).

Figure 30

1. Reverse four-wheel drive pressure test port

Jacking Points

• On the front of the mac hine on the frame on the inside of eac h dri v e tire

• On the rear of the mac hine at the center of the axle

Tie Downs

• On eac h side of the frame b y the side cutting unit lift ar ms

• F ront center of the operator’ s platfor m

• T he rear bumper

Operating Characteristics

Practice dri ving the mac hine because it has a h y drostatic transmission and its c haracteristics are different than many turf maintenance mac hines . Some points to consider when operating the traction unit, cutting unit, or other implements are

Page 31

the transmission, engine speed, load on the cutting blades or other implement components , and the impor tance of the brak es .

T o maintain enough po w er for the traction unit and implement while operating, regulate the traction pedal to k ee p the engine RPM high and somewhat constant. A g ood r ule to follo w is to decrease the g round speed as the load on the implement increases , and increase the g round speed as the load decreases .

T his pr oduct is designed to dri v e objects into the g r ound wher e they lose energ y quickl y in g rass ar eas. Ho w ev er , car eless operation, combined with ter rain ang le, ricochets, or impr oper l y positioned safety guard can lead to thr o wn object injuries.

• W hen a per son or pet appear s suddenl y in or near the mo wing ar ea, stop mo wing .

T herefore , allo w the traction pedal to mo v e bac kw ard as the engine RPM decreases , and de press the pedal slo wly as the RPM increases . By comparison, when dri ving from one w ork area to another , with no load and cutting unit raised, ha v e the throttle in the F ast position and de press the traction pedal slo wly but fully to attain maxim um g round speed.

T he ﬂo w di vider enhances traction dri v e perfor mance in compromised operating conditions . T he ﬂo w di vider is for use in lo w speed rang e only . W hen approac hing an area kno wn to cause wheel spin, de press and hold ﬂo w di vider switc h until completely past the area. If a tire spins while climbing or maneuv ering on slopes , de press switc h and slo wly dri v e out of area. If both a front and rear wheel spins , the steering brak e can be feathered to transfer the tor que from the spinning wheels to opposite front wheel.

Another c haracteristic to consider is the operation of the pedals that are connected to the brak es . T he brak es can be used to assist in tur ning the mac hine . Ho w ev er , use them carefully , especially on soft or w et g rass because the turf ma y be tor n accidentally . Another beneﬁt of the brak es is to maintain traction. F or example , in some slope conditions , the uphill wheel slips and loses traction. If this situation occurs , de press the uphill tur n pedal g radually and inter mittently until the uphill wheel stops slipping, thus , increasing traction on the do wnhill wheel.

• Do not r esume mo wing until the ar ea is clear ed.

Before stopping the engine , diseng ag e all controls and mo v e the throttle to Slo w . Mo ving the throttle to Slo w reduces high engine RPM, noise , and vibration. T ur n the k ey to Off to stop the engine .

Before transpor ting the mac hine , raise the cutting units and secure the transpor t latc hes ( Figure 31 ).

Figure 31

1. Transport latch (wing cutting units)

Operating Tips

Mow When Grass is Dry

Use extra care when operating the mac hine on slopes . Mak e sure that the seat latc h is properly secured and the seat belt is buc kled. Dri v e slo wly and a v oid shar p tur ns on slopes to prev ent roll o v ers . F or steering control, the cutting unit m ust be lo w ered when g oing do wnhill.

Mo w either in the late mor ning to a v oid the dew , whic h causes g rass clumping, or in late after noon to a v oid the damag e that can be caused b y direct sunlight on the sensiti v e , freshly mo w ed g rass .

Page 32

Select the Proper Height-of-Cut Setting to Suit Conditions

R emo v e appro ximately 1 inc h (25 mm) or no more than 1/3 of the g rass blade when cutting . In ex ce ptionally lush and dense g rass , y ou ma y ha v e to raise the height-of-cut to the next setting .

Mow at Proper Intervals

Under most nor mal conditions y ou will need to mo w appro ximately ev er y 4-5 da ys . But remember , g rass g ro ws at different rates at different times . T his means that in order to maintain the same height-of-cut, whic h is a g ood practice , y ou will need to cut more frequently in early spring; as the g rass g ro wth rate slo ws in mid summer , cut only ev er y 8-10 da ys . If y ou are unable to mo w for an extended period due to w eather conditions or other reasons , mo w ﬁrst with the height-of-cut at a high lev el; then mo w ag ain 2-3 da ys later with a lo w er height setting .

Always Mow with Sharp Blades

Figure 32

1. Deck lift cylinder 2. Foam deck pad

Cutting Unit Pitch

W e recommend a blade pitc h of 1/4 inc h (6 mm). A pitc h larg er than 1/4 inc h (6 mm) will result in less po w er required, larg er clippings , and a poorer quality of cut. A pitc h less than 1/4 inc h (6 mm) will result in more po w er required, smaller clippings and a better quality of cut.

A shar p blade cuts cleanly and without tearing or shredding the g rass blades lik e a dull blade . T earing and shredding causes the g rass to tur n bro wn at the edg es whic h impairs g ro wth and increases susce ptibility to diseases .

Transporting

Use the transpor t latc hes when transpor ting o v er long distances , rough ter rain, or when trailering .

After Operating

T o ensure optim um perfor mance , clean the underside of the mo w er housing after eac h use . If residue is allo w ed to build up in the mo w er housing, cutting perfor mance will decrease .

Also , remo v e any debris whic h ma y ha v e collected betw een the dec k lift cylinders and the foam dec k pads ( Figure 32 ).

Page 33

Maintenance

Note: Deter mine the left and right sides of the mac hine from the nor mal operating position.

Recommended Maintenance Schedule(s)

Maintenance Service

Interval

After the rst 10

operating hours

After the rst 50

operating hours

After the rst 200

operating hours

Before each use or daily

Every 50 hours

Every 100 hours

Maintenance Procedure

• Torque the wheel lug nuts.

• Check the fan and alternator belt tension.

• Check the blade drive belt tension.

• Change the engine oil and lter.

• Check the engine RPM (at idle and full throttle).

• Torque the locknuts on the pivots.

• Change the front planetary gear oil.

• Change the rear axle oil.

• Change the hydraulic oil.

• Change the hydraulic oil lters.

• Check the engine oil level.

• Check the coolant level.

• Check the hydraulic uid level.

• Check the tire pressure.

• Lubricate all grease ttings.

• Inspect the air cleaner.

• Check the battery level and cable connections.

• Check the blade drive belt tension.

• Clean the underside of the mower housing and under the belt covers.

• Inspect the cooling system hoses.

• Check the fan and alternator belt tension.

Every 150 hours

Every 200 hours

Every 400 hours

Every 800 hours

Every 2 years

• Change the engine oil and lter.

• Torque the wheel lug nuts.

• Service the spark arrestor.

• Check the planetary gear drive oil.

• Check the rear axle lubricant.

• Check the rear axle gear box lubricant.

• Service the air lter (if the indicator shows red).

• Inspect the fuel lines and connections.

• Change the fuel lters (fuel/water and prelter).

• Check the engine RPM (at idle and full throttle).

• Drain and clean the fuel tank.

• Change the front planetary gear oil.

• Change the rear axle oil.

• Check the rear wheel toe-in.

• Inspect the blade drive belts.

• Change the hydraulic oil.

• Change the hydraulic oil lters.

• Inspect the cutting unit castor wheel assemblies.

• Check and adjust the valve clearance.

• Replace the safety switches.

• Flush the cooling system and replace uid.

• Replace moving hoses.

Page 34

If y ou lea v e the k ey in the ignition s witch, someone could accidentl y star t the engine and seriousl y injur e y ou or other bystander s.

R emo v e the k ey fr om the ignition bef or e y ou do an y maintenance.

Premaintenance Procedures

Service Interval Chart

Lubrication

Greasing the Bearings and Bushings

T he mac hine has g rease ﬁttings that m ust be lubricated regularly with No . 2 General Pur pose Lithium Base Grease . If the mac hine is operated under nor mal conditions , lubricate all bearings and bushings after ev er y 50 hours of operation or immediately after ev er y w ashing .

Bearings rarely fail from defects in materials or w orkmanship . T he most common reason for failure is moisture and contamination w orking its w a y past the protecti v e seals . Bearings that

Figure 33

are g reased will rely upon regular maintenance to purg e har mful debris from the bearing area. Sealed bearings , suc h as the castor wheel bearings , rely on an initial ﬁll of special g rease and a robust integ ral seal to k ee p contaminants and moisture out of the rolling elements .

T he sealed bearings require no lubrication or shor t ter m maintenance . T his minimizes routine ser vice required and reduces the potential of turf damag e due to g rease contamination. T hese sealed bearing pac kag es will pro vide g ood perfor mance and life under nor mal use , but periodic inspections of bearing condition and seal integ rity should be conducted to a v oid do wntime . T hese bearings should be inspected seasonally and re placed

Page 35

if damag ed or w or n. Bearings should operate smoothly with no detrimental c haracteristics suc h as high heat, noise , looseness or indications of cor rosion (r ust).

Due to the operating conditions these bearing/seal pac kag es are subject to (i.e . sand, turf c hemicals , w ater , impacts , etc .) they are considered nor mal w ear items . Bearings that fail due to causes other than defects in materials or w orkmanship are typically not co v ered under w ar ranty .

Note: Bearing life can be neg ati v ely affected b y improper w ash do wn procedures . Do not w ash do wn the unit when it is still hot and a v oid directing high-pressure or high v olume spra y at the bearings .

T he g rease ﬁtting locations and quantities are:

Traction Unit

• Brak e shaft pi v ot bearings (5) ( Figure 34 )

Figure 35

• T raction pedal pi v ot bushing (1) ( Figure 35 )

• F ront and rear axle pi v ot bushings (2)

( Figure 36 )

• Steering cylinder ball joints (2) ( Figure 37 )

• Tie rod ball joints (2) ( Figure 37 )

• King pin bushings (2) ( Figure 37 ). T he top ﬁtting on the king pin should onl y be lubricated ann uall y (2 pumps).

Figure 36

Figure 34

Figure 37

Center Cutting Unit

• Upper link pi v ot (4) ( Figure 38 )

Page 36

• Lo w er link pi v ot (2) ( Figure 38 )

• Latc h pi v ot (2) ( Figure 38 )

Note: Dec k ma y ha v e to be raised to expose the g rease ﬁttings for the lo w er link pi v ot and the latc h pi v ot.

• Castor fork shaft bushings (2) ( Figure 39 )

• Spindle shaft bearings (3) ( Figure 40 )

• Idler ar m pi v ot bushings (2) ( Figure 40 )

Figure 39

Figure 38

Figure 40

Center Lift Assemblies

• Lift ar m bushings (2) ( Figure 41 )

• Lift cylinder bushings (4) ( Figure 41 )

• Lift ar m ball joints (2) ( Figure 42 )

Page 37

Figure 43

Wing Cutting Units

• Castor fork shaft bushing (1 eac h) ( Figure 44 )

Figure 41

Figure 42

Wing Lift Assemblies

Wing lift cylinder (4) ( Figure 43 )

• Spindle shaft bearings (4)

• Idler ar m pi v ot bushings (1) (located on the

idler ar m)

Figure 44

Page 38

Engine Maintenance

Air Cleaner Maintenance

• Chec k the air cleaner body for damag e whic h could cause an air leak. R e place if damag ed. Chec k the whole intak e system for leaks , damag e or loose hose clamps .

• Ser vice the air cleaner ﬁlter only when the ser vice indicator requires it or ev er y 400 hours (more frequently in extremely dusty or dir ty conditions). Changing the air ﬁlter before it is necessar y only increases the c hance of dir t entering the engine when the ﬁlter is remo v ed.

• Be sure the co v er is seated cor rectly and seals with the air cleaner body .

Servicing the Air Cleaner

Chec k the air cleaner body for damag e whic h could possibly cause an air leak. R e place a damag ed air cleaner body .

Ser vice the air cleaner ﬁlters when the air cleaner indicator ( Figure 45 ) sho ws red or ev er y 400 hours (more frequently in extremely dusty or dir ty conditions). Do not o v er -ser vice the air ﬁlter .

Be sure that the co v er is sealing around the air cleaner body .

Figure 45

1. Air cleaner indicator 3. Air cleaner cover

2. Air cleaner latch

2. Before remo ving the ﬁlter ( Figure 46 ), use lo w pressure air (40 psi, clean and dr y) to help remo v e larg e accum ulations of debris pac k ed betw een outside of primar y ﬁlter and the canister . A v oid using high pressure air whic h could force dir t through the ﬁlter into the intak e tract. T his cleaning process prev ents debris from mig rating into the intak e when the primar y ﬁlter is remo v ed.

1. Pull the latc h outw ard and rotate the air cleaner co v er countercloc kwise . R emo v e the co v er from the body ( Figure 45 ). Clean the inside of the air cleaner co v er .

Figure 46

1. Air cleaner primary lter

3. R emo v e and re place the primar y ﬁlter . Cleaning of the used element is not recommended due to the possibility of damag e to the ﬁlter media. Inspect the new ﬁlter for shipping damag e , c hec king the sealing end of the ﬁlter and the body . Do not use a damag ed element. Inser t

Page 39

the new ﬁlter b y applying pressure to the outer rim of the element to seat it in the canister . Do not apply pressure to the ﬂexible center of the ﬁlter .

Important: Nev er attempt to clean the safety ﬁlter ( Figur e 47 ). R eplace the safety ﬁlter with a new one after ev er y thr ee primar y ﬁlter ser vices.

Figure 48

1. Engine oil drain plug

2. R emo v e the oil ﬁlter ( Figure 49 ). Apply a light coat of clean oil to the new ﬁlter seal before screwing it on. Do not o v er tighten.

Figure 47

1. Air cleaner safety lter

4. Clean the dir t ejection por t located in the remo v able co v er . R emo v e the r ubber outlet v alv e from the co v er , clean the ca vity and re place the outlet v alv e .

5. Install the co v er orienting the r ubber outlet v alv e in a do wnw ard position - betw een appro ximately 5:00 to 7:00 when view ed from the end.

6. R eset the indicator ( Figure 45 ) if it sho ws red.

Servicing the Engine Oil and Filter

Chang e the oil and ﬁlter initially after the ﬁrst 50 hours of operation; thereafter c hang e the oil and ﬁlter ev er y 150 hours .

1. R emo v e either drain plug ( Figure 48 ) and let the oil ﬂo w into a drain pan. W hen the oil stops , install the drain plug .

Figure 49

1. Engine oil lter

3. Add oil to the crankcase; refer to Chec king the Engine Oil.

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Fuel System Maintenance

Servicing the Fuel System

Under cer tain conditions, diesel fuel and fuel v apor s ar e highl y ﬂamma ble and explosi v e. A ﬁr e or explosion fr om fuel can bur n y ou and other s and can cause pr oper ty dama ge.

• Use a funnel and ﬁll the fuel tank outdoor s, in an open ar ea, when the engine is of f and is cold. W ipe up an y fuel that spills.

• Nev er smok e when handling fuel, and stay a w ay fr om an open ﬂame or wher e fuel fumes may be ignited by a spar k.

• Stor e fuel in a clean, safety-appr o v ed container and k eep the cap in place.

Fuel Tank

Figure 50

1. Water Separator

R e place ﬁlter canister after ev er y 400 hours of operation.

A. Clean the area where the ﬁlter canister

mounts .

B . R emo v e the ﬁlter canister and clean the

mounting surface .

C . Lubricate the g ask et on the ﬁlter canister

with clean oil.

D . Install the ﬁlter canister b y hand until the

g ask et contacts the mounting surface; then rotate it an additional 1/2 tur n.

2. Drain plug

Drain and clean the fuel tank ev er y 800 hours . Also , drain and clean the tank if fuel system becomes contaminated or if the mac hine will be stored for an extended period of time . Use clean fuel to ﬂush out the tank.

Fuel Lines and Connections

Chec k the fuel lines and connections ev er y 400 hours or yearly , whic hev er comes ﬁrst. Inspect them for deterioration, damag e , or loose connections .

Water Separator

Drain w ater or other contaminants from the w ater se parator ( Figure 50 ) daily .

1. Place a clean container under the fuel ﬁlter .

2. Loosen the drain plug on the bottom of the ﬁlter canister ( Figure 50 ). Tighten the plug after draining .

Replacing the Fuel Pre-Filter

R e place the fuel pre-ﬁlter ( Figure 51 ), located betw een fuel the tank and fuel pump , after ev er y 400 operating hours or yearly , whic hev er occurs ﬁrst.

1. Clamp both fuel lines that connect to the fuel ﬁlter so that fuel cannot drain when the lines are remo v ed.

2. Loosen the hose clamps at both ends of the ﬁlter and pull the fuel lines off of the ﬁlter .

Page 41

Electrical System Maintenance

Activating, Charging, and Connecting the Battery

Warning

CALIFORNIA

Pr oposition 65 W ar ning

Figure 51

1. Fuel pre-lter

3. Slide the hose clamps onto the ends of the fuel lines . Push the fuel lines onto the fuel ﬁlter and secure them with the hose clamps . Be sure that the ar ro w on the side of the ﬁlter points to w ard the injection pump .

Bleeding Air from the Injectors

1. Loosen the pipe connection to the Number 1 injector nozzle and holder assembly at the injection pump ( Figure 52 ).

Batter y posts, ter minals, and r elated accessories contain lead and lead compounds, chemicals kno wn to the State of Calif or nia to cause cancer and r epr oducti v e har m. W ash hands after handling .

Note: If the batter y is not ﬁlled with electrolyte or acti v ated, bulk electrolyte with 1.260 speciﬁc g ra vity m ust be purc hased from a local batter y supply outlet and added to the batter y .

1. Raise the seat and secure it with the prop rod.

2. R emo v e the batter y co v er ( Figure 53 ).

Figure 52

1. Number 1 injector nozzle

2. Mo v e the throttle to the F ast position.

3. T ur n the k ey in the ignition switc h to the Star t position and w atc h the fuel ﬂo w around the connector . T ur n the k ey to the Off position when solid ﬂo w is obser v ed.

4. Tighten the pipe connector securely .

5. R e peat the procedure on the remaining nozzles .

Figure 53

1. Battery cover

3. R emo v e the ﬁller caps from the batter y ( Figure 54 ) and slo wly ﬁll eac h cell until electrolyte is just abo v e the plates .

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Batter y electr ol yte contains sulfuric acid which is a deadl y poison and causes sev er e bur ns.

• Do not drink electr ol yte and a v oid contact with skin, ey es or clothing . W ear safety g lasses to shield y our ey es and r ub ber g lo v es to pr otect y our hands.

• Fill the batter y wher e clean w ater is al w ays a v aila ble f or ﬂushing the skin.

Important: Do not o v erﬁll the batter y . Electr ol yte will o v erﬂo w onto other par ts of the machine and sev er e cor r osion and deterioration will r esult.

7. Install the positi v e cable (red) to the positi v e (+) ter minal and the neg ati v e cable (blac k) to the neg ati v e (-) ter minal of the batter y and secure them with the bolts and n uts . Mak e sure that the positi v e (+) ter minal is all of the w a y onto the post and the cable is positioned sn ug to the batter y . T he cable m ust not contact the batter y co v er . Slide the r ubber boot o v er the positi v e ter minal to prev ent a possible shor t from occur ring .

Batter y ter minals or metal tools could shor t a gainst metal components causing spar ks. Spar ks can cause the batter y gasses to explode, r esulting in per sonal injur y .

Figure 54

1. Battery

4. Install the ﬁller caps and connect a 3 to 4 amp . batter y c harg er to the batter y posts . Charg e the batter y at a rate of 3 to 4 amperes for 4 to 8 hours .

Charging the batter y pr oduces gasses that can explode.

Nev er smok e near the batter y and k eep spar ks and ﬂames a w ay fr om batter y .

5. W hen the batter y is c harg ed, disconnect the c harg er from the electrical outlet and batter y posts .

6. R emo v e the ﬁller caps . Slo wly add electrolyte to eac h cell until the lev el is up to the ﬁll ring . Install the ﬁller caps .

• W hen r emo ving or installing the batter y , do not allo w the batter y ter minals to touch an y metal par ts of the machine.

• Do not allo w metal tools to shor t betw een the batter y ter minals and metal par ts of the machine.

Incor r ect batter y ca ble r outing could dama ge the machine and ca bles causing spar ks. Spar ks can cause the batter y gasses to explode, r esulting in per sonal injur y .

• Al w ays disconnect the negati v e (black) batter y ca ble bef or e disconnecting the positi v e (r ed) ca ble.

• Al w ays connect the positi v e (r ed) batter y ca ble bef or e connecting the negati v e (black) ca ble.

8. Coat both batter y connections with Grafo 112X (skin-o v er) g rease , T oro P ar t No . 505-47, petroleum jelly , or light g rease to prev ent

Page 43

cor rosion. Slide the r ubber boot o v er the positi v e ter minal.

9. Install the batter y co v er .

Battery Care

Batter y type is g roup 24.

Important: Bef or e w elding on the machine, disconnect the ter minal connector fr om the alter nator to pr ev ent dama ge to the electrical system.

Note: Chec k the batter y condition w eekly or after ev er y 50 hours of operation. K ee p the ter minals and the entire batter y case clean because a dir ty batter y will disc harg e slo wly . T o clean the batter y , w ash the entire case with a solution of baking soda and w ater . Rinse with clear w ater . Coat the batter y posts and cable connectors with Grafo 112X (skin-o v er) g rease (T oro P ar t No . 505-47) or petroleum jelly to prev ent cor rosion.

Fuses

T here are 5 fuses in the electrical system. T hey are located belo w the operators control panel ( Figure 55 and Figure 56 ).

Figure 56

1. Power outlet

2. Seat switch 5. Starter solenoid

3. Ignition switch 6. Light kit

4. Power Take Off (PTO)

Drive System Maintenance

Changing the Planetary Gear Drive Oil

Chang e the oil initially after ﬁrst 200 hours of operation. T hereafter c hang e the oil ev er y 800 hours , or yearly , whic hev er occurs ﬁrst. Use a high quality SAE 85W -140 g ear lube .

1. With the mac hine on a lev el surface , position the wheel so that the c hec k/drain plug ( Figure 57 ) is at the lo w est position.

Figure 55

1. Fuses

1. Check/drain plug

Figure 57

2. Place a drain pan under the hub , remo v e the plug, and allo w the oil to drain.

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3. W hen all of the oil has drained, position the wheel so that the plug hole is at the ten or tw o o’cloc k position.

4. Place a drain pan under the brak e housing on the other side of the wheel ( Figure 58 ).

5. R emo v e the plug from the bottom of the housing and allo w the oil to drain.

6. W hen all of the oil has drained, install the plug in the housing .

7. R emo v e c hec k plug from brak e housing ( Figure 58 ).

8. Add high quality SAE 85W -140 wt g ear lube to the planetar y ﬁll hole (at the ten or tw o o’cloc k position) and to the c hec k hole in brak e housing until the lev el is up to the bottom of the planetar y and brak e housing c hec k holes . Capacity is appro ximately 16 oz. (0.5 l).

9. Install the plugs .

10. R e peat the procedure on the opposite g ear assembly .

3. R emo v e the c hec k plugs to ease in draining of the oil.

4. R emo v e the drain plugs and allo w the oil to drain into the pans .

Figure 59

1. Drain plug location

5. Clean the area around the drain plug on the bottom of the g ear bo x ( Figure 60 ).

Figure 58

1. Brake housing 3. Check plug

2. Drain plug

Changing the Rear Axle Lubricant

Chang e the oil initially after the ﬁrst 200 hours of operation and ev er y 800 hours of operation thereafter .

1. P osition the mac hine on a lev el surface .

2. Clean the area around the 3 drain plugs; 1 on eac h end and 1 in the center ( Figure 59 ).

6. R emo v e the drain plug from the g ear bo x and allo w the oil to drain into a pan. R emo v e the ﬁll plug to ease in draining of the oil.

Figure 60

1. Drain plug

7. Add enough oil to bring the lev el up to the bottom of the c hec k plug holes; refer to Chec king the R ear Axle Lubricant, and Chec king the R ear Axle Gear Bo x Lubricant.

8. Install the plugs .

Page 45

Checking the Rear Wheel Toe-In

After ev er y 800 operating hours or ann ually , c hec k the rear wheel toe-in.

1. Measure the center -to-center distance (at axle height) at the front and rear of the steering tires . T he front measurement m ust be 1/4 inc h (6 mm) less than the rear measurement.

2. T o adjust, loosen the clamps at both ends of the tie rods .

3. R otate the tie rod end to mo v e the front of the tire inw ard or outw ard.

4. Tighten the tie rod clamps when the adjustment is cor rect.

Cooling System

Important: Cleaning the radiator or oil cooler with w ater can pr omote pr ematur e cor r osion and dama ge to components.

Figure 62

1. Oil cooler 2. Radiator

Maintenance

Servicing the Engine Cooling System

R emo v e debris from the oil cooler and radiator daily . Clean them more frequently in dir ty conditions .

1. T ur n the engine off and raise the hood. Clean the engine area thoroughly of all debris .

2. R emo v e the knobs ( Figure 61 ) securing the oil cooler to the frame .

4. Pi v ot the oil cooler bac k into position. Secure it to the frame with the knobs and close the hood.

Brake Maintenance

Adjusting the Service Brakes

Adjust the ser vice brak es when there is more than 1 inc h (25 mm) of “free tra v el” of the brak e pedal, or when the brak es do not w ork effecti v ely . F ree tra v el is the distance the brak e pedal mo v es before braking resistance is felt.

1. Diseng ag e the loc king latc h from the brak e pedals so that both pedals w ork inde pendently of eac h other .

2. T o reduce free tra v el of the brak e pedals , tighten the brak es:

A. Loosen the front n ut on the threaded end

of the brak e cable .

Figure 61

1. Knobs

3. Pi v ot the oil cooler rearw ard. Clean both sides of the oil cooler and radiator area ( Figure 62 ) thoroughly with compressed air .

B . Tighten the rear n ut to mo v e the cable

bac kw ard until the brak e pedals ha v e 1/2 to 1 inc h (13 to 25 mm) of free tra v el.

C . Tighten the front n uts after the brak es are

adjusted cor rectly .

Page 46

Belt Maintenance

Servicing the Alternator Belt

Chec k the condition and tension of the belts ( Figure 63 ) after ev er y 100 operating hours .

1. Proper tension will allo w 3/8 inc h (10 mm) deﬂection when a force of 10 lb is applied on the belt midw a y betw een the pulleys .

2. If the deﬂection is not 3/8 inc h (10 mm), loosen the alter nator mounting bolts ( Figure 63 ). Increase or decrease the alter nator belt tension and tighten the bolts . Chec k the deﬂection of the belt ag ain to ensure that the tension is cor rect.

Note: Mak e sure the belt is positioned on the spring side of the belt guide ( Figure 64 ).

Figure 64

1. Belt 4. Belt guide

2. Eye bolt 5. Flange nut

3. Extension spring

6. Stop bolt

Replacing the Blade Drive

Figure 63

1. Alternator 2. Mounting bolt

Re-tensioning the Blade Drive Belts

Chec k the condition and tension of the cutting unit dri v e belts initially after 8 hours of operation and ev er y 50 operating hours thereafter .

W hen properly tensioned, the extension spring (hook to hook) measurement should be appro ximately 3.50 ±.25 inc h (inside). Once the cor rect spring tension is attained, adjust the stop bolt (car riag e bolt) until there is appro ximately .125 +.060/-.000 inc h clearance betw een the head of the bolt and the idler ar m ( Figure 64 ).

Belt

T he blade dri v e belt, tensioned b y the spring loaded idler pulley , is v er y durable . Ho w ev er , after many hours of use , the belt will sho w signs of w ear . Signs of a w or n belt are: squealing when belt is rotating, blades slipping when cutting g rass , fra yed edg es , bur n marks and crac ks . R e place the belt if any of these conditions are evident.

1. Lo w er the cutting unit to the shop ﬂoor . R emo v e the belt co v ers from the top of the cutting unit and set the co v ers aside .

2. Loosen the eye bolt allo wing the remo v al of the extension spring ( Figure 64 ).

3. Loosen the ﬂang e n ut securing the stop bolt to the mounting tab . Bac k off the n ut enough to allo w the idler ar m to pass b y the stop bolt ( Figure 64 ). Mo v e the idler pulley a w a y from the belt to release belt tension.

Note: If the stop bolt is ev er remo v ed from the mounting tab , mak e sure it is reinstalled in the hole that aligns the stop bolt head with the idler ar m.

4. R emo v e the bolts securing the h y draulic motor to the cutting unit ( Figure 65 ). Lift the motor off of the cutting unit and la y it on top of the cutting unit.

Page 47

Figure 65

1. Hydraulic motor 2. Mounting bolts

Figure 66

1. Throttle cable

Adjusting the Traction Pedal Linkage

5. R emo v e the old belt from around the spindle pulleys and idler pulley .

6. R oute the new belt around the spindle pulleys and idler pulley assembly .

7. P osition the h y draulic motor on the cutting unit after routing the belt around the pulleys . Mount the motor to the cutting unit with the bolts previously remo v ed.

Note: Mak e sure the belt is positioned on the spring side of the belt guide ( Figure 64 ).

8. R econnect the extension spring ( Figure 64 ) to the eye bolt and tension the belt as follo ws:

• W hen properly tensioned, the extension spring (hook to hook) measurement should be appro ximately 3.50 ±.25 inc h (inside).

• Once the cor rect spring tension is attained, adjust the stop bolt (car riag e bolt) until there is appro ximately .125 +.060/-.000 inc h clearance betw een the head of the bolt and the idler ar m.

T he traction pedal should reac h full strok e at the same time it mak es contact with the stop . If it does not, perfor m the follo wing procedure:

1. P ark the mac hine on a lev el surface , stop the engine , and lo w er the cutting units to the ﬂoor . R emo v e the ignition k ey .

2. Chec k the traction pedal stop adjustment. T he distance from the top of the stand to the top of the stop m ust be 1-1/2 inc h (38 mm) ( Figure 67 ). Loosen the n uts and adjust, as required.

Controls System Maintenance

Adjusting the Throttle

Adjust the throttle cable ( Figure 66 ) so that the g o v er nor lev er on the engine contacts the lo w and high speed set bolts before the throttle lev er contacts the slot in the control panel.

Figure 67

1. Traction pedal stop 2. Stand

3. Loosen the jam n uts on the rod end and adjust the traction rod length ( Figure 68 ) so that the pedal contacts the pedal stop when the pump lev er reac hes full strok e . Secure the jam n uts .

Page 48

Figure 68

1. Rod end 3. Neutral return spring

2. Traction rod

4. T ur n the k ey switc h to the r un position without star ting the engine . Loosen the jam n ut and adjust the neutral retur n spring assembly shaft length until the audible alar m begins to sound. Secure the jam n ut.

5. T ur n the k ey switc h off .

assembly

4. Jam nut

Figure 69

1. Hydraulic reservoir

4. Install the reser v oir cap . Star t the engine and use all of the h y draulic controls to distribute h y draulic ﬂuid throughout the system. Also c hec k for leaks; then stop the engine .

5. Chec k the ﬂuid lev el and add enough to raise lev el the lev el to the FULL mark on the dipstic k. Do not o v erﬁll.

Replacing the Hydraulic

Hydraulic System Maintenance

Changing the Hydraulic Fluid

Chang e the h y draulic ﬂuid after ev er y 800 operating hours , in nor mal conditions . If the ﬂuid becomes contaminated, contact y our local T oro distributor because the system m ust be ﬂushed. Contaminated ﬂuid looks milk y or blac k when compared to clean oil.

1. T ur n the engine off and raise the hood.

2. Loosen the drain v alv e on the bottom of the reser v oir and let the h y draulic ﬂuid ﬂo w into larg e drain pan. Close the v alv e when the h y draulic ﬂuid stops draining .

3. Fill the reser v oir ( Figure 68 ) with appro ximately 8 g allons (30 l) of h y draulic ﬂuid; refer to Chec king the Hy draulic Fluid.

Filters

Chang e the 2 h y draulic ﬁlters initially after the ﬁrst 200 operating hours . T hereafter , c hang e the ﬁlters after ev er y 800 operating hours , in nor mal conditions .

Use T oro re placement ﬁlters (P ar t No . 94-2621 for the left side of the mac hine and 75-1310 for the right side of the mac hine).

Important: Use of an y other ﬁlter may v oid the w ar ranty on some components.

1. P osition the mac hine on a lev el surface , lo w er the cutting units , stop the engine , eng ag e the parking brak es , and remo v e the ignition k ey .

2. Clean the area around the ﬁlter mounting area. Place a drain pan under the ﬁlter and remo v e the ﬁlter ( Figure 70 ).

Important: Use onl y the h y draulic ﬂuids speciﬁed. Other ﬂuids could cause system dama ge.

Page 49

Figure 70

3. Lubricate the new ﬁlter g ask et and ﬁll the ﬁlter with h y draulic ﬂuid.

4. Ensure that the ﬁlter mounting area is clean. Screw the ﬁlter on until the g ask et contacts the mounting plate; then tighten the ﬁlter an additional 1/2 tur n.

5. Star t the engine and let it r un for about tw o min utes to purg e air from the system. Stop the engine and c hec k for leaks .

Hy draulic ﬂuid escaping under pr essur e can penetrate skin and cause injur y .

• Mak e sur e all h y draulic ﬂuid hoses and lines ar e in good condition and all h y draulic connections and ﬁttings ar e tight bef or e appl ying pr essur e to the h y draulic system.

• K eep y our body and hands a w ay fr om pin hole leaks or nozzles that eject high pr essur e h y draulic ﬂuid.

• Use cardboard or paper to ﬁnd h y draulic leaks.

• Safel y r eliev e all pr essur e in the h y draulic system bef or e perf or ming an y w or k on the h y draulic system.

• Seek immediate medical attention if ﬂuid is injected into skin.

Hydraulic System Test Ports

Checking the Hydraulic Lines and Hoses

Inspect the h y draulic lines and hoses daily for leaks , kink ed lines , loose mounting suppor ts , w ear , loose ﬁttings , w eather deterioration, and c hemical deterioration. Mak e all necessar y re pairs before operating .

T he test por ts are used to test the pressure in the h y draulic circuits . Contact y our local T oro distributor for assistance .

T est P or t A ( Figure 71 ), located on the left side of the mac hine , is used to measure the forw ard traction pressure .

Figure 71

1. Test port A

T est P or t B ( Figure 72 ), located on the right side of the mac hine , is used to measure the rev erse traction pressure .

Page 50

1. Test port B

T est P or t E ( Figure 75 ), located under the radiator , is used to measure the four -wheel dri v e pressure in rev erse .

Figure 72

T est P or t C ( Figure 73 ), located on the left side of the mac hine , is used to measure the left cutting unit pressure .

Figure 73

1. Test port C

T est P or t D ( Figure 74 ), located on the right side of the mac hine , is used to measure the right cutting unit pressure .

Figure 75

1. Test port E

T est P or t F ( Figure 76 ), located under the seat, is used to measure the lift circuit pressure .

T est P or t G ( Figure 76 ), located under the seat, is used to measure the c harg e circuit pressure .

1. Test port D

Figure 74

Figure 76

1. Test port F

2. Test port G

T est P or t H ( Figure 77 ) is used to measure the front cutting unit circuit pressure .

T est P or t J ( Figure 77 ) is used to measure the steering circuit pressure .

Page 51

Figure 77

1. Test port I

2. Test port H

T he counterbalance test por t ( Figure 78 ) is used to adjust the pressure in the counterbalance circuit. R ecommended counterbalance pressure is 470 psi (3241 kP a). T o adjust the counterbalance pressure , rotate the adjusting screw ( Figure 78 ) cloc kwise to increase the pressure or countercloc kwise to decrease the pressure .

Figure 78

1. Counterbalance test port 2. Counterbalance adjusting screw

Figure 79

1. Flow control valve

Mower Maintenance

Pivoting (Tilting) the Front Cutting Unit Upright

Note: Although not needed for nor mal

maintenance procedures , the front cutting unit can be pi v oted (tilted) to an upright position. Should y ou desire to tilt the cutting unit, proceed as follo ws:

1. Raise the center and wing cutting units slightly off of the ﬂoor , set the parking brak e , and stop the engine . R emo v e the ignition k ey .

2. R emo v e the hair pin cotter securing dampers to lift ar ms ( Figure 80 ). Pi v ot damper to w ard dec k housing .

Adjusting the Cutting Unit Flow Control

T he ﬂo w control v alv e ( Figure 79 ) is used to adjust the rate at whic h the cutting unit lo w ers .

Figure 80

1. Damper

2. Hair pin cotter

3. R emo v e the hair pin cotter and clevis pin securing the height-of-cut c hains to the rear of the cutting unit ( Figure 81 ).

Page 52

3. R otate 1 blade so that it points straight forw ard.

4. Using a shor t r uler , measure from the ﬂoor to the front tip of the blade . R otate the blade tip to the rear and measure from the ﬂoor to the tip of the blade .

5. Subtract the front dimension from the rear dimension to calculate the blade pitc h.

Adjusting the Front Cutting Unit

Figure 81

1. Height-of-cut chain

4. Star t the engine and slo wly raise the center cutting unit.

5. Slo wly raise eac h wing cutting until the center of g ra vity shifts and the dec k star ts to rotate into the upright position. Stop the engine and remo v e the ignition k ey .

Pivoting the Front Cutting Unit Down

1. Slo wly lo w er wing cutting units until the center of g ra vity shifts and the center cutting unit rotates do wnw ard.

2. Sit on the seat, star t the engine , and lo w er the center cutting unit until it is slightly off of the ﬂoor .

3. Secure the height-of-cut c hains to the rear of the cutting unit.

4. Pi v ot dampers upw ard into position and secure with clevis pin and cotter pin.

1. Loosen the jam n uts on the top or bottom of the height-of-cut c hain U-bolt ( Figure 82 ).

2. Adjust the other set of n uts to raise or lo w er the rear of the cutting unit and attain the cor rect cutting unit pitc h.

3. Tighten the jam n uts .

Figure 82

1. Height-of-cut chain 2. U-bolt

Adjusting the Wing Cutting Units

1. R emo v e the cap screws and n uts securing the castor ar m to the castor fork ( Figure 83 ).

Adjusting the Cutting Unit Pitch

Measuring the Cutting Unit Pitch

Cutting unit pitc h is the difference in height-of-cut from the front of the blade plane to the bac k of the blade plane . T oro recommends a blade pitc h of 1/4 inc h (6 mm). T hat is the bac k of the blade plane is 1/4 inc h (6 mm) higher than the front.

1. P osition the mac hine on a lev el surface on the shop ﬂoor .

2. Set the cutting unit to the desired height-of-cut.

2. R e position the shims , as required, to raise or lo w er the castor wheel until the cutting unit has the cor rect pitc h.

3. Install the cap screws and n uts .

Page 53

Figure 84

1. Castor arm tube 2. Bushings

5. Apply g rease to the inside and outside of the new bushings . Using a hammer and ﬂat plate , dri v e the bushings into the mounting tube .

6. Inspect the castor spindle for w ear and re place it if it is damag ed.

Figure 83

1. Castor wheel 4. Shims

2. Tensioning cap

3. Spacers

5. Axle mounting holes

Servicing the Castor Arm Bushings

T he castor ar ms ha v e bushings pressed into the top and bottom of the tube and after many hours of operation, the bushings will w ear . T o c hec k the bushings , mo v e the castor fork bac k and for th and from side to side . If the castor spindle is loose inside the bushings , the bushings are w or n and m ust be re placed.

1. Raise the cutting unit so that the wheels are off of the ﬂoor . Bloc k the cutting unit so that it cannot accidentally fall.

2. R emo v e the tensioning cap , spacer(s), and thr ust w asher from the top of the castor spindle .

7. Push the castor spindle through the bushings and mounting tube . Slide the thr ust w asher and spacer(s) onto the spindle . Install the tensioning cap on the castor spindle to retain all par ts in place .

Servicing the Castor Wheels and Bearings

1. R emo v e the loc kn ut from the bolt holding the castor wheel assembly betw een the castor fork ( Figure 85 ) or the castor pi v ot ar m ( Figure 86 ). Grasp the castor wheel and slide the bolt out of the fork or pi v ot ar m.

3. Pull the castor spindle out of the mounting tube . Allo w the thr ust w asher and spacer(s) to remain on the bottom of the spindle .

4. Inser t a pin punc h into the top or bottom of the mounting tube and dri v e the bushing out of the tube ( Figure 84 ). Also dri v e the other bushing out of the tube . Clean the inside of the tubes to remo v e dir t.

Figure 85

1. Castor wheel

2. Castor fork

3. Bearing

4. Bearing spacer

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Figure 86

1. Castor wheel

2. Castor pivot arm 4. Bearing spacer

3. Bearing

2. R emo v e the bearing from the wheel hub and allo w the bearing spacer to fall out ( Figure 85 and Figure 86 ). R emo v e the bearing from the opposite side of the wheel hub .

3. Chec k the bearings , spacer , and inside of the wheel hub for w ear . R e place any damag ed par ts .

4. T o assemble the castor wheel, push the bearing into the wheel hub . W hen installing the bearings , press on the outer race of the bearing .

5. Slide the bearing spacer into the wheel hub . Push the other bearing into the open end of the wheel hub to capti v ate the bearing spacer inside the wheel hub .

6. Install the castor wheel assembly betw een the castor fork and secure it in place with the bolt and loc kn ut.

Figure 87

1. Hinge cover

Tightening the Locknuts

After the ﬁrst 50 hours , the loc k n uts on the lo w er pi v ot links ( Figure 88 ), the lift ar m pins ( Figure 89 ) and the wing dec k cylinder mounts ( Figure 90 ) m ust be tor qued to 160 to 180 ft-lb (216 to 244 N ⋅ m).

Replacing the Cutting Unit Hinge Covers

T he hing e co v er prev ents debris from escaping at hing e points betw een cutting units . If co v er(s) ev er become damag ed or w or m they m ust be re placed.

Figure 88

1. Lower pivot link nut (4)

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1. Lift arm pin nut (2)

Figure 89

Figure 91

3. R otate the opposite end of the blade forw ard. Measure betw een the cutting unit and cutting edg e of the blade at the same position as in ste p 2 . T he difference betw een the dimensions obtained in ste ps 2 and 3 m ust not ex ceed 1/8 inc h (3 mm). If the dimension ex ceeds 1/8 inc h (3 mm), the blade is bent and m ust be re placed; refer to R emo ving and Installing the Cutter Blade .

Removing and Installing the Cutter Blade(s)

T he blade m ust be re placed if a solid object is hit, the blade is out of balance , or if the blade is bent. Alw a ys use g en uine T oro re placement blades to be sure of safety and optim um perfor mance . Nev er use re placement blades made b y other man ufacturers because they could be dang erous .

Figure 90

1. Wing deck cylinder pin nut (2)

Blade Maintenance

Checking for a Bent Blade

1. P osition the mac hine on a lev el surface . Raise the cutting unit, eng ag e the parking brak e , put the traction pedal in neutral, put the PTO lev er in the Off position, stop the engine , and remo v e the ignition k ey . Bloc k the cutting unit to prev ent it from accidentally falling .

2. R otate the blade until the ends face forw ard and bac kw ard ( Figure 91 ). Measure from the inside of the cutting unit to the cutting edg e at the front of the blade . R emember this dimension.

1. Raise the cutting unit to the highest position, eng ag e the parking brak e , stop the engine , and remo v e the ignition k ey . Bloc k the cutting unit to prev ent it from accidentally falling .

2. Grasp the end of the blade using a rag or thic kly padded glo v e . R emo v e the blade bolt, anti-scalp cup , and blade from the spindle shaft ( Figure 92 ).

3. Install the blade , anti-scalp cup , and blade bolt. Tighten the blade bolt to 85 to 110 ft-lb (115 to 149 N ⋅ m).

Important: T he cur v ed par t of the blade must be pointing to w ard the inside of the cutting unit to ensur e pr oper cutting .

Note: After striking a foreign object, tor que all the spindle pulley n uts to 130 to 150 ft-lb (176 to 203 N ⋅ m).

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Figure 92

1. Blade bolt 2. Anti-scalp cup

Inspecting and Sharpening the Cutter Blade(s)

A w or n or dama ged blade can br eak, and a piece of the blade could be thr o wn into the operator’ s or bystander’ s ar ea, r esulting in serious per sonal injur y or death. T r ying to r epair a dama ged blade may r esult in discontin ued safety cer tiﬁcation of the pr oduct.

lev er in the Off position, stop the engine , and remo v e the ignition k ey .

2. Examine the cutting ends of the blade carefully , especially where the ﬂat and cur v ed par ts of the blade meet ( Figure 93 ). Since sand and abrasi v e material can w ear a w a y the metal that connects the ﬂat and cur v ed par ts of the blade , c hec k the blade before using the mo w er . If w ear is noticed ( Figure 93 ), re place the blade .

• Inspect the blade periodicall y f or w ear or dama ge.

• Nev er tr y to straighten a blade that is bent or w eld a br ok en or crack ed blade.

• R eplace a w or n or dama ged blade.

T w o areas m ust be considered when c hec king and ser vicing the cutter blade-the sail and the cutting edg e . Both cutting edg es and the sail, whic h is the tur ned up por tion opposite the cutting edg e , contribute to a g ood quality-of-cut. T he sail is impor tant because it lifts the g rass up straight, thereb y producing an ev en cut. Ho w ev er , the sail will g radually w ear do wn during operation, and this condition is nor mal. As the sail w ears do wn, the quality-of-cut will deg rade somewhat, although the cutting edg es are shar p . T he cutting edg e of the blade m ust be shar p so that the g rass is cut rather than tor n. A dull cutting edg e is evident when the tips of the g rass appear bro wn and shredded. Shar pen the cutting edg es to cor rect this condition.

1. P osition the mac hine on a lev el surface . Raise the cutting unit, eng ag e the parking brak e , put the traction pedal in neutral, put the PTO

Figure 93

1. Cutting Edge 3. Wear/slot Forming

2. Curved Area 4. Crack

3. Examine the cutting edg es of all of the blades . Shar pen the cutting edg es if they are dull or nic k ed. Shar pen only the top of the cutting edg e and maintain the original cutting angle to mak e sure of shar pness ( Figure 94 ). T he blade will remain balanced if the same amount of metal is remo v ed from both cutting edg es .

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If the blade is allo w ed to w ear , a slot will f or m betw een the sail and ﬂat par t of the blade ( Figur e 93 ). Ev entuall y a piece of the blade may br eak of f and be thr o wn fr om under the housing , possibl y r esulting in serious injur y to y ou or bystander s.

• Inspect the blade periodicall y f or w ear or dama ge.

• Nev er tr y to straighten a blade that is bent or w eld a br ok en or crack ed blade.

• R eplace a w or n or dama ged blade.

Figure 94

1. Sharpen at original angle

Note: R emo v e the blades and shar pen them on a g rinder . After shar pening the cutting edg es , install the blade with the anti-scalp cup and blade bolt; refer to R emo ving and Installing the Cutter Blade(s).

5. R otate the blades until the ends face forw ard and bac kw ard. Measure from the ﬂoor to the front tip of the cutting edg e . R emember this dimension. T hen rotate the same blade so that the opposite end is forw ard, and measure ag ain. T he difference betw een the dimensions m ust not ex ceed 1/8 inc h (3 mm). If the dimension ex ceeds 1/8 inc h (3 mm), re place the blade because it is bent. Mak e sure to measure all of the blades .

6. Compare the measurements of the outer blades with the center blade . T he center blade m ust not be more than 3/8 inc h (10 mm) lo w er than the outer blades . If the center blade is more than 3/8 inc h (10 mm) lo w er than the outer blades , proceed to ste p 7 and add shims betw een the spindle housing and the bottom of the cutting unit.

7. R emo v e the bolts , ﬂat w ashers , loc k w ashers , and n uts from the outer spindle in the area where the shims m ust be added. T o raise or lo w er the blade , add a shim, P ar t No . 3256-24, betw een the spindle housing and the bottom of the cutting unit. Contin ue to c hec k the alignment of the blades and add shims until the tips of the blades are within the required dimension.

Important: Do not use mor e than thr ee shims at an y one hole location. Use decr easing n umber s of shims in adjacent holes if mor e than one shim is added to an y one hole location.

Correcting Cutting Unit Mismatch

If there is mismatc h betw een the blades , on a single cutting unit, the g rass will appear streak ed when it is cut. T his problem can be cor rected b y making sure that the blades are straight and all of the blades are cutting on the same plane .

1. Using a 3 foot (1 meter) long car penters lev el, ﬁnd a lev el surface on the shop ﬂoor .

2. Raise the height-of-cut to the highest position; refer to Adjusting the Height-Of-Cut.

3. Lo w er the cutting unit onto the ﬂat surface . R emo v e the co v ers from the top of the cutting unit.

4. Loosen the ﬂang e n ut securing the idler pulley to release the belt tension.

8. Adjust the idler pulley and install the belt co v ers .

Spark Arrestor Maintenance

Servicing the Spark Arrestor Mufer

Ev er y 200 hours operation, clear the m ufﬂer of carbon buildup .

1. R emo v e the pipe plug from the clean-out por t at the lo w er side of the m ufﬂer .

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T he muf ﬂer may be hot and could cause injur y .

Be car eful while w or king ar ound the muf ﬂer .

2. Star t the engine . Plug the nor mal m ufﬂer exit with a bloc k of w ood or metal plate so that the exhaust ﬂo w will be forced out of the clean-out por t. Contin ue to bloc k the exit until carbon de posits cease coming out of the por t.

Do not stand in line with the clean-out por t.

Al w ays w ear safety g lasses.

3. Stop the engine and re place the pipe plug .

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Storage

9. Seal the air cleaner inlet and the exhaust outlet with w eather proof tape .

Preparing for Seasonal Storage

Traction Unit

1. T horoughly clean the traction unit, cutting units , and the engine .

2. Chec k the tire pressure; refer to Chec king the Tire Pressure procedure in Operation , pag e 19 .

3. Chec k all fasteners for looseness; tighten as necessar y .

4. Grease or oil all g rease ﬁttings and pi v ot points . Wipe up any ex cess lubricant.

5. Lightly sand and use touc h-up paint on painted areas that are scratc hed, c hipped, or r usted. R e pair any dents in the metal body .

6. Ser vice the batter y and cables as follo ws:

A. R emo v e the batter y ter minals from the

batter y posts .

B . Clean the batter y , ter minals , and posts with

a wire br ush and baking soda solution.

10. Chec k the anti freeze protection and add a 50/50 solution of w ater and eth ylene glycol anti-freeze as needed for the expected minim um temperature in y our area.

C . Coat the cable ter minals and batter y posts

with Grafo 112X skin-o v er g rease (T oro P ar t No . 505-47) or petroleum jelly to prev ent cor rosion.

D . Slo wly rec harg e the batter y ev er y 60 da ys

for 24 hours to prev ent lead sulfation of the batter y .

Engine

1. Drain the engine oil from the oil pan and install the drain plug .

2. R emo v e and discard the oil ﬁlter . Install a new oil ﬁlter .

3. R eﬁll the oil pan with 8 qt (7.6 l) of SAE 10W -30 CD , CE, CF , CF-4, or CG-4 motor oil.

4. Star t the engine and r un it at idle speed for appro ximately tw o min utes .

5. Stop the engine .

6. Flush the fuel tank with fresh, clean diesel fuel.

7. Secure all of the fuel system ﬁttings .

8. T horoughly clean and ser vice the air cleaner assembly .

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Schematics

Electrical Schematic (Rev. A)

Page 61

Hydraulic Schematic (Rev. A)

Page 62

Page 63

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The Toro General Commercial Products Warranty

A Two-Year Limited Warranty

Conditions and Products Covered

The Toro® Company and its afliate, 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 rst. 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.

P r o d u c t e q u i p p e d w i t h h o u r m e t e r

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, modied, 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, lters, belts, and certain sprayer components such as diaphragms, nozzles, and check valves, etc.

• Failures caused by outside inuence. Items considered to be

outside inuence 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 nal 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 tness 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 specic 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 dissatised with your Distributor’s service or have difculty obtaining guarantee information, contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty Company.

374-0031 Rev C