Toro 30447N, 30449N, Groundsmaster 4100-D, Groundsmaster 4110-D, 30447 Operator's Manual

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Page 1
FormNo.3374-304RevA
Groundsmaster
®
4100-Dand
4110-DRotaryMower
ModelNo.30447N—SerialNo.313000001andUp
ModelNo.30449N—SerialNo.313000001andUp
Registeratwww.T oro.com. OriginalInstructions(EN)
Page 2
WARNING
CALIFORNIA
Proposition65Warning
Dieselengineexhaustandsomeofits constituentsareknowntotheStateof
Californiatocausecancer,birthdefects,
andotherreproductiveharm.
Becauseinsomeareastherearelocal,state,orfederal regulationsrequiringthatasparkarresterbeusedonthe engineofthismachine,asparkarresterisincorporatedwith themuferassembly.
GenuineTorosparkarrestersareapprovedbytheUSDA ForestryService.
Important:Thisengineisequippedwithaspark arrestermufer.ItisaviolationofCaliforniaPublic ResourceCodeSection4442touseoroperatetheengine onanyforest-covered,brush-covered,orgrass-covered landwithoutasparkarrestermufermaintainedin workingorder,ortheengineconstricted,equipped,and maintainedforthepreventionofre.Otherstatesor federalareasmayhavesimilarlaws.
Thismanualidentiespotentialhazardsandhassafety messagesidentiedbythesafetyalertsymbol(Figure1), whichsignalsahazardthatmaycauseseriousinjuryordeath ifyoudonotfollowtherecommendedprecautions.
Figure1
1.Safetyalertsymbol
Thismanualuses2otherwordstohighlightinformation. Importantcallsattentiontospecialmechanicalinformation andNoteemphasizesgeneralinformationworthyofspecial attention.
Introduction
Thismachineisaride-on,rotary-bladelawnmowerintended tobeusedbyprofessional,hiredoperatorsincommercial applications.Itisprimarilydesignedforcuttinggrass onwell-maintainedlawnsinparks,sportselds,andon commercialgrounds.Itisnotdesignedforcuttingbrush, mowinggrassandothergrowthalongsidehighways,orfor agriculturaluses.
Readthisinformationcarefullytolearnhowtooperateand maintainyourproductproperlyandtoavoidinjuryand productdamage.Youareresponsibleforoperatingthe productproperlyandsafely.
YoumaycontactTorodirectlyatwww .Toro.comforproduct andaccessoryinformation,helpndingadealer,ortoregister yourproduct.
Wheneveryouneedservice,genuineT oroparts,oradditional information,contactanAuthorizedServiceDealerorToro CustomerServiceandhavethemodelandserialnumbersof yourproductready.Writethenumbersinthespaceprovided.
ModelNo.
SerialNo.
©2012—TheT oro®Company 8111LyndaleAvenueSouth Bloomington,MN55420
Contactusatwww.Toro.com.
2
PrintedintheUSA.
AllRightsReserved
Page 3
Contents
Introduction..................................................................2
Safety...........................................................................4
SafeOperatingPractices...........................................4
ToroMowerSafety..................................................6
EngineEmissionCertication...................................7
SafetyandInstructionalDecals.................................7
Setup...........................................................................13
GreasingtheMachine.............................................13
ProductOverview.........................................................14
Controls...............................................................14
Specications........................................................17
Attachments/Accessories........................................17
Operation....................................................................18
BeforeOperating...................................................18
AdjustingtheMirrors..............................................26
AimingtheHeadlights............................................26
StartingandStoppingtheEngine..............................26
EngineCoolingFanOperation.................................27
CheckingtheInterlockSwitches...............................27
PushingorTowingtheMachine................................28
JackingPoints........................................................28
TieDowns............................................................28
OperatingCharacteristics........................................29
OperatingTips......................................................29
Maintenance.................................................................31
RecommendedMaintenanceSchedule(s)......................31
ServiceIntervalChart.............................................32
Lubrication...............................................................32
GreasingtheBearingsandBushings..........................32
EngineMaintenance..................................................36
AirCleanerMaintenance.........................................36
ServicingtheEngineOilandFilter............................37
FuelSystemMaintenance...........................................37
ServicingtheFuelSystem........................................37
BleedingAirfromtheInjectors................................38
ElectricalSystemMaintenance....................................38
BatteryCare...........................................................38
Fuses....................................................................39
DriveSystemMaintenance.........................................41
ChangingthePlanetaryGearDriveOil......................41
ChangingtheRearAxleLubricant.............................41
CheckingtheRearWheelToe-In..............................42
ChangingtheFrontTires.........................................42
CoolingSystemMaintenance......................................43
ServicingtheEngineCoolingSystem........................43
BrakeMaintenance....................................................44
AdjustingtheServiceBrakes....................................44
BeltMaintenance......................................................44
ServicingtheAlternatorBelt....................................44
Re-tensioningtheBladeDriveBelts..........................44
ReplacingtheBladeDriveBelt.................................45
ControlsSystemMaintenance.....................................46
AdjustingtheThrottleCable....................................46
AdjustingtheTractionPedalLinkage........................46
HydraulicSystemMaintenance....................................47
ChangingtheHydraulicFluid...................................47
ReplacingtheHydraulicFilters.................................47
CheckingtheHydraulicLinesandHoses....................48
AdjustingtheCounterbalancePressure......................48
MowerMaintenance...................................................49
Pivoting(Tilting)theFrontCuttingUnit
Upright.............................................................49
PivotingtheFrontCuttingUnitDown.......................49
AdjustingtheCuttingUnitPitch...............................49
ServicingtheCastorArmBushings...........................50
ServicingtheCastorWheelsandBearings..................50
ReplacingtheCuttingUnitHingeCovers...................51
BladeMaintenance.....................................................52
CheckingforaBentBlade........................................52
RemovingandInstallingtheCutterBlade(s)...............52
InspectingandSharpeningtheCutterBlade(s)............52
CorrectingCuttingUnitMismatch............................53
SparkArrestorMaintenance........................................54
ServicingtheSparkArrestorMufer.........................54
CabMaintenance.......................................................55
CleaningtheCabAirFilters.....................................55
Storage........................................................................56
PreparingforSeasonalStorage.................................56
Schematics...................................................................57
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Safety
ThismachinemeetsorexceedsISOstandard5395:1990 andANSIB71.4-2004specicationsineffectatthetime ofproduction.
Improperuseormaintenancebytheoperatoror ownercanresultininjury.Toreducethepotential forinjury,complywiththesesafetyinstructionsand alwayspayattentiontothesafetyalertsymbol,which meansCaution,Warning,orDanger—personalsafety instruction.Failuretocomplywiththeinstructionmay resultinpersonalinjuryordeath.

SafeOperatingPractices

ThefollowinginstructionsarefromtheISOstandard 5395:1990andANSIstandardB71.4-2004.
Training
ReadtheOperator'sManualandothertrainingmaterial
carefully.Befamiliarwiththecontrols,safetysigns,and theproperuseoftheequipment.
Neverallowchildrenorpeopleunfamiliarwiththese
instructionstousethemower.Localregulationsmay restricttheageoftheoperator.
Nevermowwhilepeople,especiallychildren,orpetsare
nearby.
Keepinmindthattheoperatororuserisresponsiblefor
accidentsorhazardsoccurringtohimselforherself,other people,orproperty.
Donotcarrypassengers.
Alldriversandmechanicsshouldseekandobtain
professionalandpracticalinstruction.Theowneris responsiblefortrainingtheusers.Suchinstructionshould emphasize:
theneedforcareandconcentrationwhenworking
withride-onmachines;
controlofaride-onmachineslidingonaslopewill
notberegainedbytheapplicationofthebrake.The mainreasonsforlossofcontrolare:
insufcientwheelgrip;
beingdriventoofast;
inadequatebraking;
thetypeofmachineisunsuitableforitstask;
lackofawarenessoftheeffectofground
conditions,especiallyslopes;
Preparation
Whilemowing,alwayswearsubstantialfootwear,long
trousers,hardhat,safetyglasses,andhearingprotection. Longhair,looseclothingorjewelrymaygettangled inmovingparts.Donotoperatetheequipmentwhen barefootorwearingopensandals.
Thoroughlyinspecttheareawheretheequipmentisto
beusedandremoveallobjectswhichmaybethrownby themachine.
Warningfuelishighlyammable.Takethefollowing
precautions:
Storefuelincontainersspecicallydesignedforthis
purpose.
Refueloutdoorsonlyanddonotsmokewhile
refuelling.
Addfuelbeforestartingtheengine.Neverremove
thecapofthefueltankoraddfuelwhiletheengineis runningorwhentheengineishot.
Iffuelisspilled,donotattempttostarttheengine
butmovethemachineawayfromtheareaofspillage andavoidcreatinganysourceofignitionuntilfuel vaporshavedissipated.
Replaceallfueltankandcontainercapssecurely .
Replacefaultysilencers/mufers.
Beforeusing,alwaysvisuallyinspecttoseethatthe
blades,bladebolts,andcuttingassemblyarenotworn ordamaged.Replacewornordamagedbladesandbolts insetstopreservebalance.
Onmulti-bladedmachines,takecareasrotatingoneblade
cancauseotherbladestorotate.
Evaluatetheterraintodeterminewhataccessoriesand
attachmentsareneededtoproperlyandsafelyperform thejob.Onlyuseaccessoriesandattachmentsapproved bythemanufacturer.
Checkthatoperatorspresencecontrols,safetyswitches,
andshieldsareattachedandfunctioningproperly .Donot operateunlesstheyarefunctioningproperly.
Operation
Donotoperatetheengineinaconnedspacewhere
dangerouscarbonmonoxidefumescancollect.
Mowonlyindaylightoringoodarticiallight.
Beforeattemptingtostarttheengine,disengageallblade
attachmentclutches,shiftintoneutral,andengagethe parkingbrake.Onlystarttheenginefromtheoperator's position.Useseatbelts.
incorrecthitchingandloaddistribution.
Theowner/usercanpreventandisresponsiblefor
accidentsorinjuriesoccurringtohimselforherself,other people,orproperty.
Donotusethismachineonslopesgreaterthan15°.
Rememberthereisnosuchthingasasafeslope.Travel
ongrassslopesrequiresparticularcare.Toguardagainst overturning:
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Donotstoporstartsuddenlywhengoingupor
downhill.
Engagetheclutchslowly,alwayskeepthemachinein
gear,especiallywhentravellingdownhill.
Themachinespeedshouldbekeptlowonslopesand
duringtightturns.
Stayalertforhumpsandhollowsandotherhidden
hazards.
Nevermowacrossthefaceoftheslope,unlessthe
machineisdesignedforthatpurpose.
Stayalertforholesintheterrainandotherhiddenhazards.
Watchoutfortrafcwhencrossingornearroadways.
Stopthebladesfromrotatingbeforecrossingsurfaces
otherthangrass.
Whenusinganyattachments,neverdirectdischargeof
materialtowardbystandersnorallowanyonenearthe machinewhileinoperation.
Neveroperatethemachinewithdamagedguards,shields,
orwithoutsafetyprotectivedevicesinplace.Besureall interlocksareattached,adjustedproperly,andfunctioning properly.
Donotchangetheenginegovernorsettingsoroverspeed
theengine.Operatingtheengineatexcessivespeedmay increasethehazardofpersonalinjury.
Beforeleavingtheoperatorsposition:
Stoponlevelground.
Disengagethepowertake-offandlowerthe
attachments.
Changeintoneutralandsettheparkingbrake.
Stoptheengineandremovethekey .
Disengagedrivetoattachments,stoptheengine,and
disconnectthesparkplugwire(s)orremovetheignition key:
beforeclearingblockages;
beforechecking,cleaning,orworkingonthemachine;
afterstrikingaforeignobject.Inspectthemachine
fordamageandmakerepairsbeforerestartingand operatingtheequipment.T orqueallthespindlepulley nutsto130to150ft-lb(176to203Nm);
ifthemachinestartstovibrateabnormally(check
immediately).
Disengagedrivetoattachmentswhentransportingornot
inuse.
Stoptheengineanddisengagedrivetoattachment:
beforerefuelling;
beforemakingheightadjustmentunlessadjustment
canbemadefromtheoperator'sposition.
Reducethethrottlesettingbeforestoppingengineand
closethefuelshut-offvalveattheconclusionofmowing.
Neverraisedeckwiththebladesrunning.
Keephandsandfeetawayfromthecuttingunits.
Lookbehindanddownbeforebackinguptobesureof
aclearpath.
Slowdownandusecautionwhenmakingturnsand
crossingroadsandsidewalks.
Slowdownandusecautionwhenmakingturnsand
crossingroadsandsidewalks.
Donotoperatethemowerundertheinuenceofalcohol
ordrugs.
Lightningcancausesevereinjuryordeath.Iflightning
isseenorthunderisheardinthearea,donotoperate themachine;seekshelter.
Usecarewhenloadingorunloadingthemachineintoa
trailerortruck.
Usecarewhenapproachingblindcorners,shrubs,trees,
orotherobjectsthatmayobscurevision.
Theoperatorshallturnonashingwarninglights,if
provided,whenevertravelingonapublicroad,except wheresuchuseisprohibitedbylaw .
MaintenanceandStorage
Keepallnuts,bolts,andscrewstighttobesurethe
equipmentisinsafeworkingcondition.
Neverstoretheequipmentwithfuelinthetankinsidea
buildingwherefumesmayreachanopenameorspark.
Allowtheenginetocoolbeforestoringinanyenclosure
anddonotstorenearame.
Toreducetherehazard,keeptheengine,
silencer/mufer,batterycompartment,cuttingunits, drives,andfuelstorageareafreeofgrass,leaves,or excessivegrease.Cleanupoilorfuelspillage.
Replacewornordamagedpartsforsafety .
Ifthefueltankhastobedrained,dothisoutdoors.
Onmulti-bladedmachines,takecareasrotatingoneblade
cancauseotherbladestorotate.
Whenmachineistobeparked,stored,orleftunattended,
lowerthecuttingunitsunlessapositivemechanicallock isprovided.
Disengagedrives,lowerthecuttingunits,movetraction
pedaltoNeutral,setparkingbrake,stopengineand removekey.Waitforallmovementtostopbefore adjusting,cleaningorrepairing.
Shutofffuelwhilestoringortransporting.Donotstore
fuelnearames.
Parkmachineonlevelground.Neverallowuntrained
personneltoservicemachine.
Usejackstandstosupportcomponentswhenrequired.
Carefullyreleasepressurefromcomponentswithstored
energy.
Disconnectbatterybeforemakinganyrepairs.Disconnect
thenegativeterminalrstandthepositivelast.Reconnect positiverstandnegativelast.
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Usecarewhencheckingblades.Wrapthebladesor
weargloves,andusecautionwhenservicingthem.Only replaceblades.Neverstraightenorweldthem.
Keephandsandfeetawayfrommovingparts.Ifpossible,
donotmakeadjustmentswiththeenginerunning.
Chargebatteriesinanopenwellventilatedarea,away
fromsparkandames.Unplugchargerbeforeconnecting ordisconnectingfrombattery.W earprotectiveclothing anduseinsulatedtools.
Makesureallhydrauliclineconnectorsaretightandall
hydraulichosesandlinesareingoodconditionbefore applyingpressuretothesystem.
Keepyourbodyandhandsawayfrompinholeleaksor
nozzlesthatejecthydraulicuidunderhighpressure. Usepaperorcardboard,notyourhands,tosearchfor leaks.Hydraulicuidescapingunderpressurecanhave sufcientforcetopenetratetheskinandcauseserious injury.Ifuidisinjectedintotheskinitmustbesurgically removedwithinafewhoursbyadoctorfamiliarwiththis formofinjuryorgangrenemayresult.

ToroMowerSafety

ThefollowinglistcontainssafetyinformationspecictoToro productsorothersafetyinformationthatyoumustknowthat isnotincludedintheISOorANSIstandards.
Thisproductiscapableofamputatinghandsandfeetand throwingobjects.Alwaysfollowallsafetyinstructionsto avoidseriousinjuryordeath.
Useofthisproductforpurposesotherthanitsintendeduse couldprovedangeroustouserandbystanders.
WARNING
Engineexhaustcontainscarbonmonoxide,which isanodorless,deadlypoisonthatcankillyou.
Donotrunengineindoorsorinanenclosedarea.
Operation
BeforeoperatingamachinewithROPS(rollover
protectionsystem),becertainthattheseatbeltsare attachedandtheseatislatchedtopreventtheseatfrom pivotingforward.
Knowhowtostopthemachineandenginequickly.
Donotoperatethemachinewhilewearingtennisshoes
orsneakers.
Wearingsafetyshoesandlongpantsisadvisableand
requiredbysomelocalordinancesandinsurance regulations.
Keephands,feet,andclothingawayfrommovingparts
andthemowerdischargeareaandundersideofthe mowerwhiletheengineisrunning.
Fillfueltankuntillevelis1inch(25mm)belowthe
bottomofthellerneck.Donotoverll.
Checkthesafetyinterlockswitchesdailyforproper
operation.Ifaswitchshouldfail,replacetheswitch beforeoperatingthemachine.
Checkcarefullyforoverheadclearances(i.e.branches,
doorways,electricalwires)beforedrivingunderany objectsanddonotcontactthem.
Donotmowinreverseunlessabsolutelynecessary.
Reducespeedwhenmakingsharpturns.
Ifasteepslopemustbeascended,driveforwardupthe
hillanddriverearwarddownthehill,keepingthetraction driveengaged.
Ifyoucannotbackupaslopeorifyoufeeluneasyonit,
donotmowit.
Avoidstartingorstoppingonaslope.Iftireslosetraction,
disengagethebladesandproceedslowlystraightdown theslope.Avoidraisingthesidecuttingunitsonaslope.
Avoidturningonslopes.Ifyoumustturn,turnslowly
andgraduallydownhill,ifpossible.
Becertainthattheseatbeltcanbereleasedquicklyifthe
machineisdrivenorrollsintoapondorwater.
Watchfortrafcwhennearorcrossingroads.Always
yieldtheright-of-way.
Thismachineisnotdesignedorequippedforon-road useandisa“slow-movingvehicle”.Ifyoumustcross ortravelonapublicroad,youshouldbeawareofand complywithlocalregulations,suchasrequiredlights, slowmovingvehiclesigns,andreectors.
Donotmowneardrop-offs,ditches,orembankments.
Themachinecouldsuddenlyturnoverifawheelgoes overtheedgeofaclifforditch,orifanedgecavesin.
Donotmowonwetgrass.Reducedtractioncouldcause
sliding.
Useextracarewithotherattachments.Thesecanchange
thestabilityofthemachine.
Whenapersonorpetappearsunexpectedlyinornear
themowingarea,stopmowing.Carelessoperation, combinedwithterrainangles,ricochets,orimproperly positionedguardscanleadtothrownobjectinjuries.Do notresumemowinguntiltheareaiscleared.
Turnoffthebladeswhennotmowing.
MaintenanceandStorage
Donottouchequipmentorattachmentpartswhichmay
behotfromoperation.Allowtocoolbeforeattempting tomaintain,adjust,orservice.
Neverstorethemachineorfuelcontainerinsidewhere
thereisanopename,suchasnearawaterheateror furnace.
Keepnutsandboltstight,especiallythebladeattachment
bolts.Keepequipmentingoodcondition.
Iftheenginemustberunningtoperformamaintenance
adjustment,keephands,feet,clothing,andanypartsof
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thebodyawayfromthecuttingunits,attachments,and anymovingparts.Keepeveryoneaway.
Checkbrakeoperationfrequently.Adjustandserviceas
required.
Batteryacidispoisonousandcancauseburns.Avoid
contactwithskin,eyes,andclothing.Protectyourface, eyes,andclothingwhenworkingwithabattery.
Batterygasescanexplode.Keepcigarettes,sparks,and
amesawayfromthebattery.
Theenginemustbeshutoffbeforecheckingtheoilor
addingoiltothecrankcase.
SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaofpotential danger.Replaceanydecalthatisdamagedorlost.
Ifmajorrepairsareeverneededorifassistanceisdesired,
contactanAuthorizedToroDistributor.
Tomakesureofoptimumperformanceandcontinued
safetycerticationofthemachine,useonlygenuineToro replacementpartsandaccessories.Replacementparts andaccessoriesmadebyothermanufacturerscouldbe dangerous,andsuchusecouldvoidtheproductwarranty.
EngineEmissionCertication
TheengineinthismachineisEP ATier4icompliant.
93-7818
1.Warning—readtheOperator'sManualforinstructionson torquingthebladebolt/nutto115-149N-m(85-110ft-lb).
100-5622
1.Heightofcutadjustment
117–2718
106-4250
1.Heightofcut
93-6674
1.Lowheightofcut adjustment
1.Crushinghazard,hand—readtheinstructionsbefore servicingorperformingmaintenance.
100-5623
2.Highheightofcut adjustment
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58-6520
1.Grease
117–2385
1.ReadtheOperators Manual.
2.Engine—start4.Engine—stop
3.Engine—preheat
117–2754
1.Warning—readtheOperator'sManual.
2.Warning—donotoperatethismachineunlessyouaretrained.
3.Warning—weartheseatbeltwhenseatedintheoperator'sposition.
4.Warning—wearhearingprotection.
5.Thrownobjecthazard—keepbystandersasafedistancefromthemachine.
6.Cuttinghazardofhandorfoot—stayawayfrommovingparts;keepallguardsinplace.
7.Tippinghazard—lowerthecuttingunitwhendrivingdownslopes;slowmachinebeforeturning,donotturnathighspeeds
8.Warning—locktheparkingbrake,stoptheengineandremovetheignitionkeybeforeleavingthemachine.
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117–2387
1.Raiseleftdeck4.Coolingfan
2.Raisecenterdeck5.Reverse
3.Raiserightdeck6.Automatic
117-5723
1.Off
2.Headlights8.Tractioncontrol
3.On
4.Fast10.Locked
5.Slow
6.PowerT ake-off(PTO)
7.High
9.Low
11.Flowdivider
12.Unlocked
106-4251
1.Heightofcut
119-0067
1.Tolocktheparkingbrake, latchthepedalstogether, applythebrakepedals, andpullupontheknob.
2.Tounlocktheparking brake,steponthebrake pedals.
3.Parkingbrakelock indicator
9
4.ReadtheOperator's
Manual.
5.Pressdownontheleverto tiltthesteeringwheel.
Page 10
104-3599
1.Donotstephere.
2.Tractionpedal
3.Traction—forward
4.Traction—reverse
5.Danger—shutoffPTOpriortoraisingthecuttingunits;do notoperatethecuttingunitswhentheyareintheraised position.
119-0075
1.ReadtheOperator's Manualforfuse
information.
2.Enginepreheat—60Afuse8.Instuments—10Afuse
3.Engine,start—20Afuse9.Controlmodule—2Afuse
4.Headlights—10Afuse10.Controlmodule—2Afuse
5.Turnsignal—10Afuse11.Powerpoint—7.5Afuse
6.Powerseat—10Afuse
7.Powerpoint—10Afuse
104-3579
1.Lowheightofcut adjustment
2.Highheightofcut adjustment
93-7272
1.Cutting/dismembermenthazard;fan—stayawayfromoving parts.
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117-5735
1.ReadtheOperatorsManual;tostarttheengine,movethetractionpedaltoNeutral,applythebrake,movethethrottleswitchto slow,turntheignitionkeytoPreheat.WhentheWaittoStartAdvisoryclearsontheInfoCenterthenturntheignitionkeytoStart.
2.ReadtheOperatorsManual;tostoptheengine,movethethrottlelevertoslow,disengagethePTO,settheparkingbrake,wait5 minutes,turntheignitionkeytoStop,andremovethekey;readtheOperatorsManual.
3.ReadtheOperatorsManual.
4.ToengagethePTO,pulluponthePTOswitch.
5.TodisengagethePTO,pushdownonthePTOswitch.
6.Toswitchthetransmissiontohighspeed,fullyraisetheattachmentsandswitchthespeedcontroltoHigh.
119–0124
(Model30447only)
1.Warning—whenthecabwindowsareopenwearhearing
BatterySymbols
Someorallofthesesymbolsareonyourbattery
protection.
2.Closetherearwindowbeforeattemptingtoopenthehood.
1.Explosionhazard
2.Nore,opename,or smoking.
3.Causticliquid/chemical burnhazard
4.Weareyeprotection9.Flusheyesimmediately
5.ReadtheOperator's
Manual.
6.Keepbystandersasafe
7.Weareyeprotection;
8.Batteryacidcancause
10.Containslead;donot
distancefromthebattery .
explosivegasescan causeblindnessandother injuries
blindnessorsevereburns.
withwaterandgetmedical helpfast.
discard.
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1.ReadtheOperator'sManual.
106-6754
1.Warning—donottouchthehotsurface.
2.Cutting/dismembermenthazard,fanandentanglement hazard,belt—stayawayfrommovingparts.
115-8455
120-6604
1.Enginecoolantunder pressure.
2.Explosionhazard—read theOperator'sManual.
106-6755
3.Warning—donottouchthe hotsurface.
4.Warning—readthe
Operator'sManual.
1.Thrownobjecthazard—keepbystandersawayfromthe machine.
2.Cutting/dismembermenthazardofhand,mower blade—stayawayfrommovingparts,keepallguardsand shieldsinplace.
3.Cutting/dismembermenthazardoffoot,mowerblade—stay awayfrommovingparts,keepallguardsandshieldsin place.
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Setup
MediaandAdditionalParts
Description
Operator'sManual
EngineOperator'sManual
PartsCatalog
OperatorTrainingMaterials
Pre-deliveryInspectionSheet
Note:Determinetheleftandrightsidesofthemachine fromthenormaloperatingposition.
Qty.
GreasingtheMachine
Beforethemachineisoperated,itmustbegreasedtoensure properlubricatingcharacteristics;refertoGreasingthe BearingsandBushingsprocedureinLubrication.Failureto properlygreasethemachinewillresultinprematurefailureof criticalparts.
Use
1
1
1
1
1
Reviewbeforeoperatingmachine
Usetoreferenceengineinformation
Usetoreferencepartnumbers
Reviewbeforeoperatingmachine
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ProductOverview
Controls
Note:Determinetheleftandrightsidesofthemachine
fromthenormaloperatingposition.
TiltSteeringLever
PresstheleverFigure2downtotiltthesteeringwheelto thedesiredposition.Thenreleasethelevertolockthe adjustment.
ParkingBrakeLatch
CAUTION
Thismachineproducessoundlevelsinexcessof85 dBAattheoperatorsearandcancausehearingloss throughextendedperiodsofexposure.
Wearhearingprotectionwhenoperatingthis machine.
TractionPedal
Tostop,reduceyourfootpressureonthetractionpedaland allowittoreturntothecenterposition(Figure2).
Aknobontheleftsideoftheconsoleactuatestheparking brakelock(Figure2).Toengagetheparkingbrake,connect thepedalswiththelockinglatch,pushdownonbothpedals, andpulltheparkingbrakelatchout.Toreleasetheparking brake,pressbothpedalsuntiltheparkingbrakelatchretracts.
FuelGauge
Thefuelgauge(Figure2)indicatestheleveloffuelinthetank.
HazardLightSwitch(GM4100only)
Pressthehazardlightswitch(Figure2)toactivatethehazard lights.
SpeedLimiter
Ifdesired,thescrewcanbeadjusted(Figure3)tolimitthe amountthetractionpedalcanbedepressedintheforward directiontolimitthemowingspeed.
Figure2
1.Brakepedals6.Fuelgauge
2.Pedallockinglatch
3.Spaceforoptional accessory
4.Spaceforoptional accessory
5.Parkingbrakelatch
7.Hazardlightswitch(GM 4100only)
8.Tiltsteeringlever
9.Tractionpedal
BrakePedals
TwofootpedalsFigure2operateindividualwheelbrakesfor turningassistance,parking,andtoaidinobtainingbetterside hilltraction.Alatchconnectsthepedalsforparkingbrake operationandtransport.
PedalLockingLatch
ThepedallockinglatchFigure2connectsthepedalstogether toengagetheparkingbrake.
Figure3
1.Speedlimiter
Important:Wheninthemowposition,thespeedlimiter screwmuststopthetractionpedalbeforethepump reachesfullstrokeordamagetothepumpmayoccur.
DiagnosticLight
Thediagnosticlight(Figure4)willilluminateshouldasystem faultberecognized.
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Figure4
FlowDividerSwitch(optional)
Whenoperatinginmow(low)speed,pressandhold owdividerswitch(Figure4)toenhancetractiondrive performanceincompromisedoperatingconditions.
Hi-LoSpeedControl
Theswitch(Figure4)allowsthespeedrangetoincreasefor transportofthemachine.Cuttingdeckswillnotoperate inhighrange.Also,thedeckscannotbeloweredfromthe transportpositionwhentheswitchisinthehighrange.If theswitchismovedfromLOtoHIwiththecuttingdecks downand/orPTOonand/orcruisecontrolengaged,the transmissionwillnotchangetoHI.Forthechangetobe accomplished,theswitchmustbemovedtoLOandallthe requirementssatised.
1.Cruisecontrol(optional)
2.Lightswitch9.Engineoilpressure
3.Hi-Lospeedcontrol
4.Throttlecontrol11.Keyswitch
5.Glowplugindicatorlight12.PTOswitch
6.Enginecoolant temperaturewarning light
7.Diagnosticlight
8.Enginecoolant temperaturegauge
warninglight
10.Chargeindicator
13.Flowdividerswitch (optional)
14.Liftswitches
EngineCoolantTemperatureGauge
Duringnormaloperatingconditionsthegauge(Figure4) shouldbeinthegreenrange.Checkthecoolingsystemifthe gaugegoestotheyelloworredrange.
EngineOilPressureWarningLight
Thelight(Figure4)illuminateswhentheengineoilpressure isdangerouslylow.
LiftSwitches
Theliftswitches(Figure4)raiseandlowerthecutting units.Presstheswitchesforwardtolowerthecuttingunits andbackwardtoraisethecuttingunits.Whenstartingthe machine,withthecuttingunitsinthedownposition,pressthe liftswitchdowntoallowthecuttingunitstooatandmow.
Note:ThedeckswillnotlowerwhileintheHIspeedrange andtheywillnotraiseorloweriftheoperatorisoutofthe seatwhentheengineisrunning.
ThrottleControl
Movethecontrol(Figure4)forwardtoincreasetheengine speedandrearwardtodecreasethespeed.
LightSwitch
Presstheloweredgeoftheswitch(Figure4)toturnonthe lights.Presstheupperedgeoftheswitchtoturnoffthelights.
GlowPlugIndicatorLight
ChargeIndicator
Thechargeindicator(Figure4)illuminateswhenthesystem chargingcircuitmalfunctions.
KeySwitch
Thekeyswitch(Figure4)hasthreepositions:Off, On/Preheat,andStart.
PTOSwitch
ThePTOswitch(Figure4)hastwopositions:Out(start) andIn(stop).PullthePTObuttonouttoengagethecutting unitblades.Pushinthebuttontodisengagethecuttingunit blades.
Whenlit,theglowplugindicatorlight(Figure4)indicates thattheglowplugsareon.
EngineCoolantTemperatureWarning Light
Thelight(Figure4)illuminatesandthecuttingunitsshut down(PTOdisengages)iftheenginereachesanunsafe operatingtemperature.Ifthetemperaturecontinuestorise theenginewillshutdown.
EngineCoolingFanSwitch
Themachineisequippedwithahydraulicallydrivenauto reversingenginecoolingfan.Thefanswitch(Figure5)has
15
Page 16
twopositionsR(manualreverse)andAuto(normal).Refer
G011547
1
2
3
toEngineCoolingFanOperationintheOperationSection ofmanual.
Figure5
1.Powerpoint3.Hourmeter
2.Enginecoolingfanswitch
FanControl
Rotatethefancontrolknobtoregulatethespeedofthefan (Figure6).
TemperatureControl
Rotatethetemperaturecontrolknobtoregulatetheair temperatureinthecab(Figure6).
HourMeter
Thehourmeter(Figure5)showsthetotalhoursthatthe machinehasbeenoperated.
PowerPoint
Thepowerpoint(Figure5)isusedtopoweroptional electricalaccessories.
AudibleAlarm
Towarnbystanders,analarmwillsoundifthecuttingdecks areloweredwiththeengineoff.Thealarmwillquitsounding oncethedecklowerswitchisreleased.Also,thealarmwill soundiftheenginecoolanttemperaturereachesaset-point thatcutsoutthePTOoperation.Thealarmwillcontinue tosounduntilthecoolanttemperaturedropsbelowthe set-pointorthePTOswitchisdisengaged.
CabControls
Model30447only
Figure6
1.Windshieldwiperswitch5.Hazardlightswitch
2.Airconditioningswitch6.Turnsignalswitch
3.Temperaturecontrol7.Domelightswitch
4.Fancontrol
HazardLightSwitch
Presstheswitchtoactivatethehazardlights(Figure6).
TurnSignalSwitch
Presstheswitchtoactivatetheturnsignals(Figure6).
DomeLightSwitch
Presstheswitchtoactivatethedomelight(Figure6).
WindShieldLatch
WindShieldWiperSwitch
Pressfrontofswitchtoactivatethewindshieldwipers (Figure6)andrearofswitchtoturnoffthewipers.
AirConditioningSwitch
Pressfrontofswitchtoactivatetheairconditioning(Figure6) andrearofswitchtoturnofftheairconditioning.
Liftuponlatchestoopenthewindshield(Figure7).Press inonlatchtolockwindshieldinopenposition.Pulloutand downonlatchtocloseandsecurewindshield.
16
Page 17
1.Windshieldlatch
Figure7
Specications
Note:Specicationsanddesignaresubjecttochange
withoutnotice.
Widthofcut
overall
frontcuttingunit54inch(137cm)
sidecuttingunit
frontandonesidecuttingunit89inch(226cm)
Overallwidth
cuttingunitsdown
cuttingunitsup(transports)71inch(180cm)
Overalllength144inch(366cm)
Height
124inch(315cm)
37inch(94cm)
127inch(322cm)
58inch(147cm)
HeightwithROPS Heightwithcab
Groundclearance6inch(15cm)
Wheeltread(tocenteroftire)
front45inch(1 14cm) rear
Wheelbase
Weight(withcuttingunits) (Weightwithcabwithcuttingunits)
81inch(206cm)
91inch(231cm)
47inch(1 19cm)
55-1/2inch(141cm)
4211lb(1910kg)
4715lb(2139kg)

Attachments/Accessories

AselectionofToroapprovedattachmentsandaccessoriesare availableforusewiththemachinetoenhanceandexpand itscapabilities.ContactyourAuthorizedServiceDealeror Distributororgotowww .Toro.comforalistofallapproved attachmentsandaccessories.
17
Page 18
Operation
Note:Determinetheleftandrightsidesofthemachine
fromthenormaloperatingposition.

BeforeOperating

CAUTION
Ifyouleavethekeyintheignitionswitch,someone couldaccidentlystarttheengineandseriously injureyouorotherbystanders.
Removethekeyfromtheignitionbeforeyoudoany maintenance.
CheckingtheEngineOil
ServiceInterval:Beforeeachuseordaily
Theengineisshippedwithoilinthecrankcase;however,the oillevelmustbecheckedbeforeandaftertheengineisrst started.
Thecrankcasecapacityis10qt(9.5l)withthelter.
Usehigh-qualityengineoilthatmeetsthefollowing specications:
APIClassicationLevelRequired:CH-4,CI-4orhigher.
Preferredoil:SAE15W-40(above0°F)
Alternateoil:SAE10W-30or5W-30(alltemperatures)
ToroPremiumEngineOilisavailablefromyourdistributor ineither15W -40or10W -30viscosity .Seethepartscatalog forpartnumbers.
Note:Thebesttimetochecktheengineoiliswhenthe engineiscoolbeforeithasbeenstartedfortheday.Ifithas alreadybeenrun,allowtheoiltodrainbackdowntothe sumpforatleast10minutesbeforechecking.Iftheoillevel isatorbelowthe“add”markonthedipstick,addoiltobring theoilleveltothe“full”mark.DONOTOVERFILL.If theoillevelisbetweenthe“full”and“add”marks,nooil additionisrequired.
1.Parkthemachineonalevelsurface.Unlocktheengine coverlatches.
2.Opentheenginecover.
3.Removethedipstick,wipeitclean,installthedipstick intothetube,andpullitoutagain.Theoillevelshould beuptotheFULLmark(
Figure8).
Figure8
1.Dipstick
4.IftheoilisbelowtheFullmark,removethellcap (Figure9)andaddoiluntilthelevelreachestheFull mark.Donotoverll.
Figure9
1.Oilllcap
Note:Whenusingdifferentoil,drainalloldoilfrom thecrankcasebeforeaddingnewoil.
5.Installtheoilllcapanddipstick.
6.Closetheenginecoverandsecureitwiththelatches.
CheckingtheCoolingSystem
ServiceInterval:Beforeeachuseordaily
Checklevelofcoolantatthebeginningofeachday .Capacity ofsystemis13qts.(12.3l).
1.Carefullyremovetheradiatorcapandexpansiontank cap(
Figure10).
18
Page 19
CAUTION
Iftheenginehasbeenrunning,the pressurized,hotcoolantcanescapeandcause burns.
Donotopentheradiatorcapwhenthe engineisrunning.
Usearagwhenopeningtheradiatorcap, andopenthecapslowlytoallowsteamto escape.
2.Checkthecoolantlevelintheradiator.Theradiator shouldbelledtothetopofthellerneckandthe expansiontanklledtotheFullmark.
Important:Donotusekeroseneorgasolineinsteadof dieselfuel.Failuretoobservethiscautionwilldamage theengine.
WARNING
Fuelisharmfulorfatalifswallowed.Long-term exposuretovaporscancauseseriousinjuryand illness.
Avoidprolongedbreathingofvapors.
Keepfaceawayfromnozzleandgastankor conditioneropening .
Keepfuelawayfromeyesandskin.
BiodieselReady
Thismachinecanalsouseabiodieselblendedfuelofup toB20(20%biodiesel,80%petrodiesel).Thepetrodiesel portionshouldbeloworultralowsulfur.Observethe followingprecautions:
Thebiodieselportionofthefuelmustmeetspecication
ASTMD6751orEN14214.
Figure10
1.Expansiontank
3.Ifthecoolantislow ,adda50/50mixtureofwaterand ethyleneglycolanti-freeze.Donotusewateronlyor
alcohol/methanolbasecoolants.
4.Installtheradiatorcapandexpansiontankcap.
AddingFuel
Useonlyclean,freshdieselfuelorbiodieselfuelswithlow (<500ppm)orultralow(<15ppm)sulfurcontent.The minimumcetaneratingshouldbe40.Purchasefuelin quantitiesthatcanbeusedwithin180daystoensurefuel freshness.
Fueltankcapacity:19USgallons(72l)
Usesummergradedieselfuel(No.2-D)attemperatures above20°F(-7°C)andwintergrade(No.1-DorNo. 1-D/2-Dblend)belowthattemperature.Useofwintergrade fuelatlowertemperaturesprovideslowerashpointand coldowcharacteristicswhichwilleasestartingandreduce fuellterplugging.
Useofsummergradefuelabove20°F(-7°C)willcontribute towardlongerfuelpumplifeandincreasedpowercompared towintergradefuel.
TheblendedfuelcompositionshouldmeetASTMD975
orEN590.
Paintedsurfacesmaybedamagedbybiodieselblends.
UseB5(biodieselcontentof5%)orlesserblendsincold
weather.
Monitorseals,hoses,gasketsincontactwithfuelasthey
maybedegradedovertime.
Fuellterpluggingmaybeexpectedforatimeafter
convertingtobiodieselblendsd.
Contactyourdistributorifyouwishformoreinformation
onbiodiesel.
DANGER
Incertainconditions,fuelisextremelyammable andhighlyexplosive.Areorexplosionfromfuel canburnyouandothersandcandamageproperty.
Fillthefueltankoutdoors,inanopenarea,when theengineiscold.Wipeupanyfuelthatspills.
Neverllthefueltankinsideanenclosedtrailer.
Neversmokewhenhandlingfuel,andstayaway fromanopenameorwherefuelfumesmaybe ignitedbyaspark.
Storefuelinanapprovedcontainerandkeepit outofthereachofchildren.Neverbuymore thana30-daysupplyoffuel.
Donotoperatewithoutentireexhaustsystemin placeandinproperworkingcondition.
19
Page 20
DANGER
Incertainconditionsduringfueling,static electricitycanbereleasedcausingasparkwhich canignitethefuelvapors.Areorexplosionfrom fuelcanburnyouandothersandcandamage property.
Alwaysplacefuelcontainersonthegroundaway fromyourvehiclebeforelling.
Donotllfuelcontainersinsideavehicleoron atruckortrailerbedbecauseinteriorcarpets orplastictruckbedlinersmayinsulatethe containerandslowthelossofanystaticcharge.
Whenpractical,removeequipmentfromthe truckortrailerandrefueltheequipmentwithits wheelsontheground.
Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfromaportable container,ratherthanfromafueldispenser nozzle.
Ifafueldispensernozzlemustbeused,keepthe nozzleincontactwiththerimofthefueltank orcontaineropeningatalltimesuntilfuelingis complete.
1.Parkthemachineonalevelsurface.
2.Usingacleanrag,cleanareaaroundfueltankcap.
3.Removecapfromthefueltank(Figure11).
CheckingtheHydraulicFluid
ServiceInterval:Beforeeachuseordaily
Themachinesreservoirislledatthefactorywith approximately8U.S.gallons(30.2l)ofhighqualityhydraulic uid.Checkthelevelofthehydraulicuidbefore theengineisrststartedanddailythereafter.The recommendedreplacementuidis:
ToroPremiumAllSeasonHydraulicFluid(Availablein 5gallonpailsor55gallondrums.SeepartscatalogorToro distributorforpartnumbers.)
Alternateuids:IftheTorouidisnotavailable,otheruids maybeusedprovidedtheymeetallthefollowingmaterial propertiesandindustryspecications.W edonotrecommend theuseofsyntheticuid.Consultwithyourlubricant distributortoidentifyasatisfactoryproduct.
Note:Torowillnotassumeresponsibilityfordamage causedbyimpropersubstitutions,souseonlyproducts fromreputablemanufacturerswhowillstandbehindtheir recommendation.
HighViscosityIndex/LowPourPointAnti-wear HydraulicFluid,ISOVG46
MaterialProperties:
St@40°C44to48 Viscosity,ASTMD445
St@100°C7.9to8.5
ViscosityIndexASTMD2270
PourPoint,ASTMD97-34°Fto-49°F
IndustrySpecications:VickersI-286-S(Quality
Level),VickersM-2950-S
(QualityLevel),Denison
140to160
HF-0
Figure11
1.Fueltankcap
4.Fillthetankuntilthelevelistothebottomoftheller neckwithdieselfuel.
5.Installfueltankcaptightlyafterllingtank.
Note:Ifpossible,llthefueltankaftereachuse.This willminimizepossiblebuildupofcondensationinside thefueltank.
Note:Manyhydraulicuidsarealmostcolorless,makingit difculttospotleaks.Areddyeadditiveforthehydraulic systemoilisavailablein2/3oz(20ml)bottles.Onebottle issufcientfor4-6gallons(15-221)ofhydraulicoil.Order partno.44-2500fromyourauthorizedTorodistributor.
1.Positionthemachineonalevelsurface,lowerthe cuttingunits,stoptheengine,andremovethekey.
2.Unlatchtheseat,raiseit,andengagetheproprod.
3.Cleantheareaaroundthellerneckandcapofthe hydraulictank( llerneck.
20
Figure12).Removethecapfromthe
Page 21
Figure12
1.Hydraulictankcap
4.Removethedipstickfromthellerneckandwipeit withacleanrag.Insertthedipstickintothellerneck; thenremoveitandchecktheuidlevel.Theuidlevel shouldbebetweenthetwomarksonthedipstick.
CheckingthePlanetaryGearDriveOil
ServiceInterval:Every400hours
Checktheoillevelafterevery400hoursofoperationorif externalleakageisnoted.UsehighqualitySAE85W -140gear lubeasareplacement.
Thecapacityofthesystemisapproximately16oz(0.5l).
1.Withthemachineonalevelsurface,positionthewheel sothatthecheck/drainplug(Figure13)isateitherthe 3or9o'clockposition.
Figure13
5.Ifthelevelislow ,addtheappropriateuidtoraisethe leveltotheuppermark.
6.Installthedipstickandcapontothellerneck.
1.Check/drainplug
2.Addgearoiltotheholeintheplanetary,ifnecessary, tobringtheoiluptotheproperlevel.Installtheplug.
3.Repeattheprocedureontheoppositegearassembly.
CheckingtheRearAxleLubricant
ServiceInterval:Every400hours
TherearaxleislledwithSAE85W-140gearlube.Checkthe oillevelbeforetheengineisrststartedandevery400hours thereafter.Thecapacityis80oz(2.4l).Visuallyinspectfor leaksdaily.
1.Positionthemachineonalevelsurface.
2.Removeacheckplugfromoneendoftheaxle
Figure14)andmakesurethatthelubricantisuptothe
( bottomofthehole.Ifthelevelislow ,removethell plug(Figure14)andaddenoughlubricanttobringthe leveluptothebottomofthecheckplugholes.
Figure14
1.Checkplug
21
2.Fillplug
Page 22
CheckingtheRearAxleGearBox Lubricant
ServiceInterval:Every400hours
ThegearboxislledwithSAE85W -140gearlube.Check theoillevelbeforetheengineisrststartedandevery400 hoursthereafter.Thecapacityis16oz(0.5l).Visuallyinspect forleaksdaily.
1.Positionthemachineonalevelsurface.
2.Removethecheck/llplugfromtheleftsideofthe gearbox(Figure15)andmakesurethatlubricantis uptothebottomofthehole.Ifthelevelislow,add enoughlubricanttobringtheleveluptothebottom ofthehole.
CheckingtheTirePressure
ServiceInterval:Beforeeachuseordaily
Thetiresareover-inatedforshipping.Therefore,release someoftheairtoreducethepressure.Thecorrectair pressureinthefrontandreartiresis25-30psi(172-207kPa).
Important:Maintainevenpressureinalltirestoensure agoodquality-of-cutandpropermachineperformance.
Do not under -inate.
CheckingtheTorqueoftheWheelNuts orBolts
ServiceInterval:Aftertherst10hours
Every200hours
WARNING
Failuretomaintainpropertorqueofthewheelnuts couldresultinfailureorlossofwheelandmay resultinpersonalinjury.
Torquethefrontwheelnutsandrearboltsto85-100 ft-lb(115-136N⋅ ⋅⋅m)after1-4hoursofoperationand againafter10hoursofoperation.T orqueevery200 hoursthereafter.
Figure15
1.Gearbox2.Check/llplug
AdjustingtheHeight-of-Cut
CenterCuttingUnit
Theheight-of-cutisadjustablefrom1to5inches(25to 127mm)in1/2inch(13mm)increments.Toadjustthe height-of-cutonthefrontcuttingunit,positionthecastor wheelaxlesintheupperorlowerholesofthecastorforks, addorremoveanequalnumberofspacersfromthecastor forks,andsecuretherearchaintothedesiredhole.
1.Starttheengineandraisethecuttingunitssothatthe height-of-cutcanbechanged.Stoptheengineand removethekeyafterthecuttingunitisraised.
2.Positionthecastorwheelaxlesinthesameholesinall castorforks.Refertothefollowingcharttodetermine thecorrectholesforthesetting.
22
Page 23
Figure16
5.Removethehairpincotterandclevispinsecuringthe height-of-cutchainstotherearofthecuttingunit (
Figure18).
1.Tensioningcap4.Topaxlemountinghole
2.Spacers5.Castorwheel
3.Shims
Note:Whenoperatingin2-1/2inch(64mm)height ofcutorhigher,theaxleboltmustbeinstalledinthe lowercastorforkholetopreventgrassbuildupbetween thewheelandthefork.Whenoperatinginheight ofcutslowerthan2-1/2inches(64mm)andgrass buildupisdetected,reversethemachinesdirectionto pullanyclippingsawayfromthewheel/forkarea.
3.Removethetensioningcapfromthespindleshaft (Figure16)andslidethespindleoutofthecastorarm. Putthe2shims(1/8inch[3mm])ontothespindle shaftastheywereoriginallyinstalled.Theseshimsare requiredtoachievealevelacrosstheentirewidthof thecuttingunits.Slidetheappropriatenumberof1/2 inchspacers(refertothechartbelow)ontothespindle shafttogetthedesiredheight-of-cut;thenslidethe washerontotheshaft.
Refertothefollowingcharttodeterminethe combinationsofspacersforthesetting:
Figure18
1.Height-of-cutchain2.Clevispin&hairpincotter
6.Mounttheheight-of-cutchainstothedesired height-of-cuthole(
Figure19)withtheclevispinand
hairpincotter.
Figure19
Note:Whenusing1inch(25mm),1-1/2inch(38
mm),oroccasionally2inch(51mm)height-of-cut, movetheskidsandgagewheelstothehighestposition.
Figure17
4.Pushthecastorspindlethroughthefrontcastorarm. Installtheshims(astheywereoriginallyinstalled)and theremainingspacersontothespindleshaft.Installthe tensioningcaptosecuretheassembly .
WingCuttingUnits
Toadjusttheheight-of-cutonthesidecuttingunits,add orremoveanequalnumberofspacersfromthecastor forks,positionthecastorwheelaxlesinthehighorlow height-of-cutholesinthecastorforks,andsecurethepivot armstotheselectedheight-of-cutbracketholes.
1.Positionthecastorwheelaxlesinthesameholesinall ofthecastorforks(Figure20andFigure22).Referto thefollowingcharttodeterminethecorrectholefor thesetting.
2.Removethetensioningcapfromthespindleshaft (
Figure20)andslidethespindleoutofcastorarm.Put thetwoshims(1/8inch[3mm])ontospindleshaftas theywereoriginallyinstalled.Theseshimsarerequired toachievealevelacrosstheentirewidthofthecutting units.Slidetheappropriatenumberof1/2inchspacers
23
Page 24
ontothespindleshafttogetthedesiredheight-of-cut; thenslidethewasherontotheshaft.
Figure22
Figure20
1.Tensioningcap4.Topaxlemountinghole
2.Spacers5.Castorwheel
3.Shims
Refertothefollowingcharttodeterminethe combinationsofspacersforthesetting.
Figure21
3.Pushthecastorspindlethroughthecastorarm.Install theshims(asoriginallyinstalled)andtheremaining spacersontothespindleshaft.Installthetensioning captosecuretheassembly .
4.Removethehairpincotterandclevispinsfromthe castorpivotarms(Figure22).
1.Castorpivotarm3.Clevispinandhairpin cotter
2.Axlemountingholes4.T ensionrod
Figure23
AdjustingtheSkids
Theskidsshouldbemountedinthelowerpositionwhen operatinginheightofcutsgreaterthan2-1/2inches(64mm) andinthehigherpositionwhenoperatinginheightofcuts lowerthan2-1/2inches(64mm).
Adjusttheskidsbyremovingtheangeboltandnuts, positioningthemasdesired,andinstallingthefasteners (Figure24).
5.Rotatetensionrodtoraiseorlowerpivotarm untilholesarealignedwithselectedheight-of-cut bracketholesinthecuttingunitframe(Figure22and Figure23).
6.Inserttheclevispinsandinstallthehairpincotters.
7.Rotatetensionrodcounterclockwise(ngertight)to puttensiononadjustment.
Figure24
1.Skid
24
Page 25
AdjustingtheCuttingUnitRollers
Thecuttingunitrollersshouldbemountedinthelower positionwhenoperatinginheightofcutsgreaterthan2-1/2 inches(64mm)andinthehigherpositionwhenoperatingin heightofcutslowerthan2-1/2inches(64mm).
1.Removetheboltandnutsecuringthegagewheelto thecuttingunitbrackets(Figure25).
Figure25
1.Gagewheel
2.Aligntherollerandspacerwiththetopholesinthe bracketsandsecurethemwiththeboltandnut.
Figure27
1.Adjusterbolt2.Jamnut
CorrectingMismatchBetweenCutting Units
Duetodifferencesingrassconditionsandthecounterbalance settingofthetractionunit,itisadvisedthatasampleareaof grassbecutandappearancecheckedbeforeformalcutting isstarted.
1.Setallcuttingunitstothedesiredheightofcut;referto AdjustingtheHeightofCut.
2.Checkandadjustfrontandreartractortirepressureto 25-30psi(172-207kPa).
AdjustingtheBlade
Toensureproperoperationofthecuttingunit,theremustbe
0.38-0.62inch(10-16mm)clearancebetweenthetipsofthe wingandcentercuttingunitblades(Figure26).
1.Raisecuttingunitsobladesarevisibleandblockcenter decksectionsoitcannotfallaccidentally.Wingdecks mustbehorizontaltocentercuttingunit.
2.Rotateacenterandadjoiningwingbladesothereblade tipsarealigned.Measuredistancebetweenbladetips, distanceshouldbeapproximately0.38-0.62inch(10-16 mm)(
Figure26).
Figure26
3.Toadjustdistance,locateadjusterboltonrearpivot linkofcuttingunit( adjusterbolt.Loosenortightenadjusterboltsuntil
0.38-0.62inch(10-16mm)clearanceisattained,then tightenjamnut.
4.Repeatprocedureonoppositesideofcuttingdeck.
Figure27).Loosenjamnuton
3.Checkandadjustallcastortirepressuresto50psi(345 kPa).
4.Checkchargeandcounterbalancepressureswith engineathighidleusingtestportsdenedinHydraulic SystemsTestPorts.Adjustcounterbalancesettingtobe 230psi(1585kPa)higherthanchargepressurereading.
5.Checkforbentblades;refertoCheckingforaBent Blade.
6.Cutgrassinatestareatodetermineifallcuttingunits arecuttingatthesameheight.
7.Ifcuttingunitadjustmentsarestillneeded,ndaat surfaceusinga6foot(2m)orlongerstraightedge.
8.Toeasemeasuringbladeplane,raisetheheightofcut tothehighestposition;refertoAdjustingtheHeight ofCut.
9.Lowercuttingunitsontotheatsurface.Removethe coversfromthetopofthecuttingunits.
10.Loosentheangenut,securingtheidlerpulley,to releasethebelttensiononeachcuttingunit.
CenterCuttingUnitSetup
Rotatebladeoneachspindleuntiltheendsfaceforwardand backward.Measurefromtheoortothefronttipofthe cuttingedge.Adjust1/8inchshimsonfrontcastorfork(s)to matchheightofcuttodecal(Figure28);refertoAdjusting theCuttingUnitPitch.
25
Page 26
Figure28
1.Tensioningcap4.Topaxlemountinghole
2.Spacers5.Castorwheel
3.Shims
WingCuttingUnitSetup
Rotatebladeofeachspindleuntiltheendsfaceforwardand backward.Measurefromtheoortothefronttipofthe cuttingedge.Adjust1/8inchshimsonfrontcastorarm(s) tomatchheightofcuttodecal( bladespindleonly,refertoAdjustingtheCuttingUnitPitch.
Figure29).Fortheoutside

AdjustingtheMirrors

Model30447only
RearViewMirror
Whilesittingintheseat,adjusttherearviewmirror (Figure30)toattainthebestviewouttherearwindow .Pull theleverrearwardtotiltthemirrortoreducethebrightness andglareoflight.
SideViewMirrors
Whilesittingintheseat,haveahelperadjustthesideview mirrors(Figure30)toattainthebestviewaroundthesideof themachine.
Figure30
1.Sideviewmirrors
2.Rearviewmirror
3.Lever
Figure29
1.Castorarm3.Castorfork
2.Shims
MatchingHeightOfCutBetweenCuttingUnits
1.Positionbladesidetosideonoutsidespindleofboth wingcuttingunits.Measurefromtheoortothetip ofthecuttingedgeonbothunitsandcompare.These numbersshouldbewithin1/8inch(3mm)ofeach other.
2.Addorremove1/8inchshimsasneededonwing castorwheels.Recheckmeasurementbetweenoutside edgesofbothwingcuttingunitsandadjustasnecessary.

AimingtheHeadlights

1.Loosenthemountingnutsandpositioneachheadlight sothatitpointsstraightahead.Tightenthemounting nutjustenoughtoholdtheheadlightinposition.
2.Placeaatpieceofsheetmetaloverthefaceofthe headlight.
3.Mountamagneticprotractorontotheplate.While holdingtheassemblyinplace,carefullytilttheheadlight downward3degrees,thentightenthenut.
4.Repeattheprocedureontheotherheadlight.

StartingandStoppingthe Engine

Important:Thefuelsystemwillautomaticallybleed
itselfwhenanyofthefollowingsituationsoccur:
Initialstartupofanewmachine.
Theenginehasceasedrunningduetolackoffuel.
Maintenancehasbeenperformeduponthefuelsystem
components.
RefertotheBleedingAirfromtheInjectors.
26
Page 27
1.Ensurethattheparkingbrakeisset.Removeyourfoot fromthetractionpedalandensurethatitisinneutral.
2.Movethethrottlecontroltothemid-idleposition.

CheckingtheInterlock Switches

3.TurntheignitionkeytotheRunposition.Theglow indicatorwilllight.
4.Whentheglowindicatordims,turntheignitionkey totheStartposition.Releasethekeyimmediately whentheenginestartsandallowittoreturntothe Runposition.Allowenginetowarmupatmidspeed (withoutload),thenmovethethrottlecontroltothe desiredposition.
Important:Donotrunthestartermotormore than15secondsatatimeorprematurestarter failuremayresult.Iftheenginefailstostartafter15 seconds,turnthekeytotheOffposition,recheck thecontrolsandprocedures,wait15additional seconds,andrepeatthestartingprocedure.
Whenthetemperatureislessthan20°F(-75C),preheat glowplugstwicepriortoinitialcrankingattempt.The startermotorcanberunfor30secondsonthen60 secondsofffor2attempts.
5.Tostoptheengine,movethethrottlecontrolbackward totheSlowposition,movethePTOlevertotheOff position,settheparkingbrake,androtatetheignition keytoOff.Removethekeyfromtheswitchtoprevent accidentalstarting.
Important:Allowenginetoidlefor5minutesbefore shuttingitoffafterafullloadoperation.Failuretodo somayleadtoturbo-chargertrouble.

EngineCoolingFanOperation

Theenginecoolingfanswitchhastwopositionsfor controllingtheoperationofthefan.ThetwopositionsareR andAuto.Thefanhastheabilitytoreversetoblowdebris offoftherearscreen.Undernormaloperatingconditions, theswitchwillbeintheAutoposition.InAuto,thefanspeed willbecontrolledbythecoolantorhydraulicoiltemperature andwillautomaticallyreversetoblowdebrisoffoftherear screen.Areversecycleisautomaticallyinitiatedwheneither thecoolantorhydraulictemperaturereachesacertainpoint. BypressingthefanswitchforwardintotheRposition,the fanwillcompleteamanuallyinitiatedreversecycle.Itis recommendedtoreversethefanwhentherearscreenis cloggedorpriortoenteringtheshoporthestoragearea.
CAUTION
Ifsafetyinterlockswitchesaredisconnectedor damagedthemachinecouldoperateunexpectedly causingpersonalinjury.
Donottamperwiththeinterlockswitches.
Checktheoperationoftheinterlockswitches dailyandreplaceanydamagedswitchesbefore operatingthemachine.
Themachinehasinterlockswitchesintheelectricalsystem. Theseswitchesaredesignedtostoptheenginewhenthe operatorgetsoffoftheseatwhenthetractionpedalis depressed.However,theoperatormaygetoffoftheseat whiletheengineisrunningandthetractionpedalisinneutral. AlthoughtheenginewillcontinuetorunifthePTOleveris disengagedandthetractionpedalisreleased,itisstrongly recommendedthattheenginebestoppedbeforerisingfrom theseat.
Tochecktheoperationoftheinterlockswitches,perform thefollowingprocedure:
1.Drivethemachineslowlytoalarge,relativelyopen area.Lowerthecuttingunit,stoptheengine,andapply theparkingbrake.
2.Sitontheseatanddepressthetractionpedal.Tryto starttheengine.Theengineshouldnotcrank.Ifthe enginecranks,thereisamalfunctionintheinterlock systemthatshouldbecorrectedbeforebeginning operation.
3.Sitontheseatandstarttheengine.Risefromtheseat andmovethePTOlevertoOn.ThePTOshouldnot engage.IfthePTOengages,thereisamalfunctionin theinterlocksystemthatshouldbecorrectedbefore beginningoperation.
4.Sitontheseat,engagetheparkingbrakeandstartthe engine.Movethetractionpedaloutoftheneutral position.Theengineshouldkill.Iftheenginedoesnot kill,thereisamalfunctionintheinterlocksystemthat shouldbecorrectedbeforebeginningoperation.
5.Sitontheseat,starttheengineandsetspeedrangeto low .MovePTOswitchforwardtoengagecuttingunits.
Important:Thecenterliftlevermustmomentarily bepushedtothelowerpositiontoenablePTO circuitactuationbyPTOswitch.
Raiseeitherwingcuttingunittothetransportposition.
Thecuttingunitshouldturnoff.Ifthecuttingunitdoes notstop,thereisamalfunctionintheinterlocksystem thatshouldbecorrectedbeforeresumingoperation.
Ifthewingcuttingunitisloweredagainthemotorshould
re-start.Ifthecuttingunitdoesnotre-start,thereis
27
Page 28
amalfunctionintheinterlocksystemthatshouldbe correctedbeforeresumingoperation.
Iftheoperatorrisesfromtheseatwiththecuttingunits
engagedand/orthetractionpedaloutofneutral,the cuttingunitsmuststopinapproximatelyonesecondand enginemustshutdowninapproximatelytwoseconds.If thecuttingunitsdonotstopandtheenginedoesnot shutdown,thereisamalfunctionintheinterlocksystem thatshouldbecorrectedbeforeresumingoperation.

PushingorTowingthe Machine

Inanemergency,themachinecanbemovedforwardby actuatingthebypassvalveinthevariabledisplacement hydraulicpumpandpushingortowingthemachine.Donot
pushortowthemachineformorethan1/4mile(0.4km).
Important:Donotpushortowthemachinefasterthan 2-3MPH(3-4.8km/h)becauseinternaltransmission damagemayoccur.Thebypassvalvemustbeopen wheneverthemachineispushedortowed.
1.Raisetheseatandremovethebatterycover.Thebypass valveislocatedinfrontofthebattery(Figure31).
2.Rotatethevalve90degrees(1/4turn)ineither directiontoopenandallowoiltobypassinternally. Becauseuidisbypassed,themachinecanbeslowly movedwithoutdamagingthetransmission.
PartNo.95-8843,CouplerFittingNo.95-0985 [Qty.2],andHydraulicFittingNo.340-77 [Qty.2])tothereversetractionpressuretest port(
Figure32)andthereversefour-wheeldrive
pressureport(Figure33).
Figure32
1.Reversetractionpressuretestport
Note:Resistancewillbefeltonthevalvewhenitis movedtotheopenposition.
3.Rotatethevalve90degrees(1/4turn)backtoclosethe bypassvalvebeforestartingtheengine.However,do notexceed5to8ft-lb(7to11Nm)torquetoclose thevalve.
Figure31
1.Bypassvalveaccesshole
Important:Ifthemachinemusttobepushedor towedinreverse,thecheckvalveinthefour-wheel drivemanifoldmustalsobebypassed.Tobypass thecheckvalve,connectahoseassembly(Hose
Figure33
1.Reversefour-wheeldrivepressuretestport

JackingPoints

Therearejackingpointslocatedatthefrontandrearofthe machine.
Ontheframeattheinsideofeachfrontdrivetire
Atthecenteroftherearaxle

TieDowns

Therearetiedownslocatedatthefront,rearandsidesof themachine.
Oneachsideoftheframebythesidecuttingunitliftarms
Frontcenteroftheoperator'splatform
Therearbumper
28
Page 29

OperatingCharacteristics

Practicedrivingthemachinebecauseithasahydrostatic transmissionanditscharacteristicsaredifferentthanmany turfmaintenancemachines.Somepointstoconsiderwhen operatingthetractionunit,cuttingunit,orotherimplements arethetransmission,enginespeed,loadonthecuttingblades orotherimplementcomponents,andtheimportanceofthe brakes.
Tomaintainenoughpowerforthetractionunitand implementwhileoperating,regulatethetractionpedalto keeptheenginespeedhighandsomewhatconstant.Agood ruletofollowistodecreasethegroundspeedastheload ontheimplementincreases,andincreasethegroundspeed astheloaddecreases.
Therefore,allowthetractionpedaltomovebackwardasthe enginespeeddecreases,anddepressthepedalslowlyasthe speedincreases.Bycomparison,whendrivingfromonework areatoanother,withnoloadandcuttingunitraised,havethe throttleintheFastpositionanddepressthetractionpedal slowlybutfullytoattainmaximumgroundspeed.
Thebrakescanbeusedtoassistinturningthemachine. However,usethemcarefully,especiallyonsoftorwetgrass becausetheturfmaybetornaccidentally.Anotherbenet ofthebrakesistomaintaintraction.Forexample,insome slopeconditions,theuphillwheelslipsandlosestraction.If thissituationoccurs,depresstheuphillturnpedalgradually andintermittentlyuntiltheuphillwheelstopsslipping,thus, increasingtractiononthedownhillwheel.
Useextracarewhenoperatingthemachineonslopes.Make surethattheseatlatchisproperlysecuredandtheseatbelt isbuckled.Driveslowlyandavoidsharpturnsonslopesto preventrollovers.Forsteeringcontrol,thecuttingunitmust beloweredwhengoingdownhill.
Figure34
1.Transportlatch(wingcuttingunits)
OperatingTips
MowWhenGrassisDry
Moweitherinthelatemorningtoavoidthedew ,whichcauses grassclumping,orinlateafternoontoavoidthedamage thatcanbecausedbydirectsunlightonthesensitive,freshly mowedgrass.
SelecttheProperHeight-of-CutSetting toSuitConditions
Removeapproximately1inch(25mm)ornomorethan1/3 ofthegrassbladewhencutting.Inexceptionallylushand densegrass,youmayhavetoraisetheheight-of-cuttothe nextsetting.
WARNING
Thiscuttingunitisdesignedtodriveobjectsinto thegroundwheretheyloseenergyquicklyingrass areas.However,carelessoperation,combinedwith terrainangle,ricochets,orimproperlypositioned safetyguardcanleadtothrownobjectinjuries.
Whenapersonorpetappearssuddenlyinor nearthemowingarea,
stop mo wing
Donotresumemowinguntiltheareaiscleared.
Beforestoppingtheengine,disengageallcontrolsandmove thethrottletoSlow.MovingthethrottletoSlowreduceshigh enginespeed,noise,andvibration.TurnthekeytoOffto stoptheengine.
Beforetransportingthemachine,raisethecuttingunitsand securethetransportlatches(Figure34).
.
MowatProperIntervals
Undermostnormalconditionsyouwillneedtomow approximatelyevery4-5days.Butremember,grassgrowsat differentratesatdifferenttimes.Thismeansthatinorderto maintainthesameheight-of-cut,whichisagoodpractice, youwillneedtocutmorefrequentlyinearlyspring;asthe grassgrowthrateslowsinmidsummer,cutonlyevery8-10 days.Ifyouareunabletomowforanextendedperioddue toweatherconditionsorotherreasons,mowrstwiththe height-of-cutatahighlevel;thenmowagain2-3dayslater withalowerheightsetting.
AlwaysMowwithSharpBlades
Asharpbladecutscleanlyandwithouttearingorshredding thegrassbladeslikeadullblade.Tearingandshredding causesthegrasstoturnbrownattheedgeswhichimpairs growthandincreasessusceptibilitytodiseases.
29
Page 30
Transporting
Usethetransportlatcheswhentransportingoverlong distances,roughterrain,orwhentrailering.
AfterOperating
Toensureoptimumperformance,cleantheundersideofthe mowerhousingaftereachuse.Ifresidueisallowedtobuild upinthemowerhousing,cuttingperformancewilldecrease.
Also,removeanydebriswhichmayhavecollectedbetween thedeckliftcylindersandthefoamdeckpads(Figure35).
Figure35
1.Deckliftcylinder
2.Foamdeckpad
CuttingUnitPitch
Abladepitchof1/4inch(6mm)isrecommended.Apitch largerthan1/4inch(6mm)willresultinlesspowerrequired, largerclippings,andapoorerqualityofcut.Apitchlessthan 1/4inch(6mm)willresultinmorepowerrequired,smaller clippingsandabetterqualityofcut.
MaximizingAirConditioner Performance
Tolimitsolarheating,parkthemachineinashadedarea
orleavethedoorsopenindirectsun.
Checktomakesuretheairconditioningcondenserns
areclean.
Operatetheairconditionerbloweratthemidspeed
setting.
Verifycontinuoussealbetweentheroofandtheheadliner.
Correctasrequired.
Measuretheairtemperatureatthefrontcenterventin
theheadliner(Typicallystabilizeatlessthanorequalto 50degreesF .)
RefertotheServiceManualforadditionalinformation.
30
Page 31
Maintenance
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
RecommendedMaintenanceSchedule(s)
MaintenanceService
Interval
Aftertherst10hours
Aftertherst50hours
Aftertherst200hours
Beforeeachuseordaily
Every50hours
Every100hours
MaintenanceProcedure
•Torquethewheellugnuts.
•Checkthefanbelttension.
•Checkthebladedrivebelttension.
•Changetheengineoilandlter.
•Checktheenginespeed(atidleandfullthrottle).
•Changethefrontplanetarygearoil.
•Changetherearaxleoil.
•Changethehydraulicoil.
•Changethehydraulicoillters.
•Checktheengineoillevel.
•Checkthecoolantlevel.
•Checkthehydraulicuidlevel.
•Checkthetirepressure.
•Checktheaircleanerindicator.
•Checktheinterlockswitchoperation
•Lubricateallgreasettings.
•Checkthebladedrivebelttension.
•Checkthebatterylevelandcableconnections.
•Cleantheundersideofthemowerhousingandunderthebeltcovers.
•Inspectthecoolingsystemhosesandclamps.
•Checkthefanbelttension.
Every150hours
Every200hours
Every250hours
Every400hours
Every800hours
Every2years
•Changetheengineoilandlter.
•Torquethewheellugnuts.
•Servicethesparkarrestormufer
•Cleanthecabairlters.(Replacethemiftheyaretornorexcessivelydirty.)
•Checktheplanetarygeardriveoil.
•Checktherearaxlelubricant.
•Checktherearaxlegearboxlubricant.
•Servicetheairlter(iftheindicatorshowsred).
•Inspectthefuellinesandconnections.
•Replacethefuelltercanister.
•Checktheenginespeed(atidleandfullthrottle).
•Drainandcleanthefueltank.
•Changethefrontplanetarygearoil.
•Changetherearaxleoil.
•Checktherearwheeltoe-in.
•Inspectthebladedrivebelts.
•Changethehydraulicoil.
•Changethehydraulicoillters.
•Inspectthecuttingunitcastorwheelassemblies.
•Checkandadjustthevalveclearance.
•Flushthecoolingsystemandreplaceuid.
•Replacemovinghoses.
31
Page 32
CAUTION
Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineandseriouslyinjure youorotherbystanders.
Removethekeyfromtheignitionbeforeyoudoanymaintenance.

ServiceIntervalChart

Lubrication

GreasingtheBearingsand Bushings

Themachinehasgreasettingsthatmustbelubricated regularlywithNo.2GeneralPurposeLithiumBaseGrease. Ifthemachineisoperatedundernormalconditions,lubricate allbearingsandbushingsafterevery50hoursofoperationor immediatelyaftereverywashing.
Bearingsrarelyfailfromdefectsinmaterialsorworkmanship. Themostcommonreasonforfailureismoistureand contaminationworkingitswaypasttheprotectiveseals. Bearingsthataregreasedwillrelyuponregularmaintenance topurgeharmfuldebrisfromthebearingarea.Sealed bearings,suchasthecastorwheelbearings,relyonan initialllofspecialgreaseandarobustintegralsealtokeep contaminantsandmoistureoutoftherollingelements.
Thesealedbearingsrequirenolubricationorshortterm maintenance.Thisminimizesroutineservicerequired andreducesthepotentialofturfdamageduetogrease contamination.Thesesealedbearingpackageswillprovide goodperformanceandlifeundernormaluse,butperiodic
Figure36
inspectionsofbearingconditionandsealintegrityshould beconductedtoavoiddowntime.Thesebearingsshould beinspectedseasonallyandreplacedifdamagedorworn. Bearingsshouldoperatesmoothlywithnodetrimental characteristicssuchashighheat,noise,loosenessor indicationsofcorrosion(rust).
Duetotheoperatingconditionsthesebearing/sealpackages aresubjectto(i.e.sand,turfchemicals,water,impacts,etc.) theyareconsiderednormalwearitems.Bearingsthatfaildue tocausesotherthandefectsinmaterialsorworkmanshipare typicallynotcoveredunderwarranty.
Note:Bearinglifecanbenegativelyaffectedbyimproper washdownprocedures.Donotwashdowntheunitwhenit isstillhotandavoiddirectinghigh-pressureorhighvolume sprayatthebearings.
Thegreasettinglocationsandquantitiesare:
TractionUnit
ServiceInterval:Every50hours
Brakeshaftpivotbearings(5)(Figure37)
Tractionpedalpivotbushing(1)(Figure38)
32
Page 33
Frontandrearaxlepivotbushings(2)(Figure39)
Steeringcylinderballjoints(2)(Figure40)
Tierodballjoints(2)(Figure40)
Kingpinbushings(2)(
Figure40).
Thetopttingonthekingpinshouldonlybe lubricatedannually(2pumps).
Figure37
Figure40
CenterCuttingUnit
Note:Deckmayhavetoberaisedtoexposethegrease
ttingsforthelatchpivotandthelowerlink.
Figure38
Figure39
Latchpivot(2)(Figure42)
Note:Thelatch(Figure41)mayneedtobemanually trippedtogainaccesstothegreasetting.Useaprybar tocloseandre-openthelatch
Figure41
1.Latch
33
Page 34
Figure42
Lowerlinkpivot(4)(Figure43)
Upperlinkpivot(4)(Figure43)
Castorforkshaftbushings(2)(Figure44)
Spindleshaftbearings(3)(Figure45)
Idlerarmpivotbushings(2)(Figure45)
Figure43
Figure44
Figure45
34
Page 35
CenterLiftAssemblies
WingLiftAssemblies
Liftarmbushings(2)(Figure46)
Liftcylinderbushings(4)(Figure46)
Liftarmballjoints(2)(Figure47)
Figure46
Wingliftcylinder(4)(Figure48)
Figure48
WingCuttingUnits
Castorforkshaftbushing(1each)(Figure49)
Spindleshaftbearings(4)
Idlerarmpivotbushings(1)(locatedontheidlerarm)
Figure47
Figure49
35
Page 36
EngineMaintenance

AirCleanerMaintenance

Checktheaircleanerbodyfordamagewhichcouldcause
anairleak.Replaceifdamaged.Checkthewholeintake systemforleaks,damageorloosehoseclamps.
Servicetheaircleanerlteronlywhentheservice
indicatorrequiresitorevery400hours(morefrequently inextremelydustyordirtyconditions).Changingtheair lterbeforeitisnecessaryonlyincreasesthechanceof dirtenteringtheenginewhenthelterisremoved.
Besurethecoverisseatedcorrectlyandsealswiththe
aircleanerbody.
debrisfrommigratingintotheintakewhentheprimary lterisremoved.
Figure51
1.Aircleanerprimarylter
ServicingtheAirCleaner
ServiceInterval:Beforeeachuseordaily
Every400hours
Checktheaircleanerbodyfordamagewhichcouldpossibly causeanairleak.Replaceadamagedaircleanerbody.
Servicetheaircleanerlterswhentheaircleanerindicator (Figure50)showsredorevery400hours(morefrequently inextremelydustyordirtyconditions).Donotover-service theairlter.
Besurethatthecoverissealingaroundtheaircleanerbody .
1.Pullthelatchoutwardandrotatetheaircleanercover counterclockwise.Removethecoverfromthebody (Figure50).Cleantheinsideoftheaircleanercover.
3.Removeandreplacetheprimarylter.Cleaningofthe usedelementisnotrecommendedduetothepossibility ofdamagetotheltermedia.Inspectthenewlterfor shippingdamage,checkingthesealingendofthelter andthebody .Donotuseadamagedelement.Insert thenewlterbyapplyingpressuretotheouterrimof theelementtoseatitinthecanister.Donotapply pressuretotheexiblecenterofthelter.
Important:Neverattempttocleanthesafetylter (Figure52).Replacethesafetylterwithanew oneaftereverythreeprimarylterservices.
Figure52
Figure50
1.Aircleanerindicator3.Aircleanercover
2.Aircleanerlatch
2.Beforeremovingthelter(Figure51),uselow pressureair(40psi,cleananddry)tohelpremove largeaccumulationsofdebrispackedbetweenoutside ofprimarylterandthecanister.Avoidusinghigh pressureairwhichcouldforcedirtthroughthelter intotheintakearea.Thiscleaningprocessprevents
1.Aircleanersafetylter
4.Cleanthedirtejectionportlocatedintheremovable cover.Removetherubberoutletvalvefromthecover, cleanthecavityandreplacetheoutletvalve.
5.Installthecoverorientingtherubberoutletvalveina downwardposition-betweenapproximately5:00to 7:00whenviewedfromtheend.
6.Resettheindicator(
36
Figure50)ifitshowsred.
Page 37

ServicingtheEngineOiland Filter

ServiceInterval:Aftertherst50hours
FuelSystem Maintenance
Every150hours
Changetheoilandlterinitiallyaftertherst50hoursof operation;thereafterchangetheoilandlterevery150hours.
1.Removeeitherdrainplug(Figure53)andlettheoil owintoadrainpan.Whentheoilstops,installthe drainplug.
Figure53
1.Engineoildrainplug
2.Removetheoillter(Figure54).Applyalightcoatof cleanoiltothenewltersealbeforescrewingiton.
Donotovertighten.

ServicingtheFuelSystem

DANGER
Undercertainconditions,dieselfuelandfuel vaporsarehighlyammableandexplosive.Are orexplosionfromfuelcanburnyouandothersand cancausepropertydamage.
Useafunnelandllthefueltankoutdoors,in anopenarea,whentheengineisoffandiscold. Wipeupanyfuelthatspills.
Donotllthefueltankcompletelyfull.Addfuel tothefueltankuntilthelevelis1inch(25mm) belowthebottomofthellerneck.Thisempty spaceinthetankallowsthefueltoexpand.
Neversmokewhenhandlingfuel,andstayaway fromanopenameorwherefuelfumesmaybe ignitedbyaspark.
Storefuelinaclean,safety-approvedcontainer andkeepthecapinplace.
Figure54
1.Engineoillter
3.Addoiltothecrankcase;refertoCheckingtheEngine Oil.
FuelTank
ServiceInterval:Every800hours
Drainandcleanthefueltankevery800hours.Also,drainand cleanthetankiffuelsystembecomescontaminatedorifthe machinewillbestoredforanextendedperiodoftime.Use cleanfueltoushoutthetank.
FuelLinesandConnections
ServiceInterval:Every400hours
Checkthefuellinesandconnectionsevery400hoursor yearly,whichevercomesrst.Inspectthemfordeterioration, damage,orlooseconnections.
ServicingtheWaterSeparator
ServiceInterval:Every400hours
Drainwaterorothercontaminantsfromwaterseparator (
Figure55)daily.Replaceltercanisterafterevery400hours
ofoperation.
1.Placeacleancontainerunderthefuellter.
2.Loosenthedrainplugonthebottomofthelter canister.
37
Page 38
Figure55
1.Waterseparatorltercanister
3.Cleantheareawheretheltercanistermounts.
4.Removetheltercanisterandcleanthemounting surface.
5.Lubricatethegasketontheltercanisterwithcleanoil.
ElectricalSystem Maintenance

BatteryCare

Batterytypeisgroup24.
Important:Beforeweldingonthemachine,disconnect thenegativecablefromthebatterytopreventdamageto theelectricalsystem.
Note:Checkthebatteryconditionweeklyorafterevery 50hoursofoperation.Keeptheterminalsandtheentire batterycasecleanbecauseadirtybatterywilldischargeslowly. Tocleanthebattery,washtheentirecasewithasolution ofbakingsodaandwater.Rinsewithclearwater.Coat thebatterypostsandcableconnectorswithGrafo112X (skin-over)grease(T oroPartNo.505-47)orpetroleumjelly topreventcorrosion.
6.Installtheltercanisterbyhanduntilthegasket contactsmountingsurface,thenrotateitanadditional 1/2turn.
7.Tightenthedrainplugonthebottomofthelter canister.

BleedingAirfromtheInjectors

1.LoosenthetubeconnectiontotheNumber1injector nozzleandholderassemblyattheinjectionpump (Figure56).
WARNING
CALIFORNIA
Proposition65Warning
Batteryposts,terminals,andrelated
accessoriescontainleadandleadcompounds,
chemicalsknowntotheStateofCalifornia
tocausecancerandreproductiveharm.
Washhandsafterhandling.
1.Raisetheseatandsecureitwiththeproprod.
2.Removethebatterycover(
Figure57).
Figure56
1.Number1injectornozzle
2.MovethethrottletotheFastposition.
3.TurnthekeyintheignitionswitchtotheStartposition andwatchthefuelowaroundtheconnector.Turn thekeytotheOffpositionwhensolidowisobserved.
4.Tightenthetubeconnectorsecurely .
5.Repeattheprocedureontheremainingnozzles.
Figure57
1.Batterycover
38
Page 39
Figure58
g011539
1
G011542
1
2
2
10
20
7.5
7.5
10
7.5
7.5
10
7.5
7.5
10
1.Battery
WARNING
Chargingthebatteryproducesgassesthatcan explode.
WARNING
Incorrectbatterycableroutingcoulddamage themachineandcablescausingsparks. Sparkscancausethebatterygassesto explode,resultinginpersonalinjury.
Always
disconnect
thenegative(black) batterycablebeforedisconnectingthe positive(red)cable.
Always
connect
thepositive(red)battery cablebeforeconnectingthenegative (black)cable.
4.CoatbothbatteryconnectionswithGrafo112X (skin-over)grease,ToroPartNo.505-47,petroleum jelly,orlightgreasetopreventcorrosion.Slidethe rubberbootoverthepositiveterminal.
5.Installthebatterycover.

Fuses

Theretractionunitfuses(Figure59thruFigure61)are locatedunderthehoodinthefusebox.
Neversmokenearthebatteryandkeepsparks andamesawayfrombattery.
3.Removetherubberbootfromthepositiveterminal andinspectthebattery.
WARNING
Batteryterminalsormetaltoolscouldshort againstmetalcomponentscausingsparks. Sparkscancausethebatterygassesto explode,resultinginpersonalinjury.
Whenremovingorinstallingthebattery, donotallowthebatteryterminalstotouch anymetalpartsofthemachine.
Donotallowmetaltoolstoshortbetween thebatteryterminalsandmetalpartsof themachine.
Figure59
1.Fusebox
1.Fuses
Figure60
39
Page 40
Figure61
Figure62
1.Fuses2.Fuseboxcover
1.ReadtheOperator's Manualforfuse information.
2.Enginepreheat—60Afuse8.Instuments—10Afuse
3.Engine,start—20Afuse9.Controlmodule—2Afuse
4.Headlights—10Afuse10.Controlmodule—2Afuse
5.Turnsignal—10Afuse11.Powerpoint—7.5Afuse
6.PowerSeat—10Afuse
7.Powerpoint—10Afuse
Note:Thecabfuses(Figure62)arelocatedinthefusebox inthecabheadliner(model30447only).
40
Page 41
DriveSystem Maintenance

ChangingthePlanetaryGear DriveOil

ServiceInterval:Aftertherst200hours
Every800hours
Changetheoilinitiallyafterrst200hoursofoperation. Thereafterchangetheoilevery800hours,oryearly,whichever occursrst.UseahighqualitySAE85W-140gearlube.
1.Jackupthefrontofthemachineandsupportwith jackstands.
2.Removethefrontwheels.
3.Rotatethewheelsothatthecheck/drainplug (Figure63)isatthelowestposition.
Figure64
1.Brakehousing
2.Drainplug
ChangingtheRearAxle
3.Checkplug
Figure63
1.Check/drainplug
4.Placeadrainpanunderthehub,removetheplug,and allowtheoiltodrain.
5.Whenalloftheoilhasdrained,positionthewheelso thattheplugholeisatthe3or9o'clockposition.
6.Placeadrainpanunderthebrakehousingontheother sideofthewheel(Figure64).
7.Removetheplugfromthebottomofthehousingand allowtheoiltodrain.
8.Whenalloftheoilhasdrained,installthepluginthe housing.
9.Addapproximately16oz(0.5l)ofhighqualitySAE 85W-140gearlubetotheplanetaryllhole(atthe3or 9o'clockposition)untilthelevelisuptothebottomof thebrakehousingcheckhole.Installtheplug.
10.Repeattheprocedureontheoppositegearassembly.
Lubricant
ServiceInterval:Aftertherst200hours
Every800hours
Changetheoilinitiallyaftertherst200hoursofoperation andevery800hoursofoperationthereafter.
1.Positionthemachineonalevelsurface.
2.Cleantheareaaroundthe3drainplugs;1oneachend and1inthecenter(Figure65).
3.Removethecheckplugstoeaseindrainingoftheoil.
4.Removethedrainplugsandallowtheoiltodraininto thepans.
Figure65
1.Drainpluglocation
5.Cleantheareaaroundthedrainplugonthebottomof thegearbox(Figure66).
41
Page 42
6.Removethedrainplugfromthegearboxandallowthe oiltodrainintoapan.Removethellplugtoease indrainingoftheoil.
Figure66

CheckingtheRearWheel Toe-In

ServiceInterval:Every800hours
Afterevery800operatinghoursorannually ,checktherear wheeltoe-in.
1.Measurethecenter-to-centerdistance(ataxleheight) atthefrontandrearofthesteeringtires.Thefront measurementmustbe1/4inch(6mm)lessthanthe rearmeasurement.
2.Toadjust,loosentheclampsatbothendsofthetie rods.
3.Rotatethetierodendtomovethefrontofthetire inwardoroutward.
4.Tightenthetierodclampswhentheadjustmentis correct.
1.Drainplug
7.Addenoughoiltobringtheleveluptothebottom ofthecheckplugholes;refertoCheckingtheRear AxleLubricant,andCheckingtheRearAxleGearBox Lubricant.
8.Installtheplugs.

ChangingtheFrontTires

1.Lowerthewingcuttingunitstotheground.
2.Raisethefrontofthemachineseveralinchesoffthe groundandsupportw/jackstands.
3.RefertoPivoting(Tilting)theFrontCuttingUnit UprightinMowerMaintenance.
4.PivotCuttingunitforwardtoallowremovalofthetire requiringservice.
42
Page 43
CoolingSystem Maintenance

ServicingtheEngineCooling System

Removedebrisfromtheoilcoolerandradiatordaily .Clean themmorefrequentlyindirtyconditions.
Thismachineisequippedwithahydraulicallydrivenfandrive systemthatautomatically(ormanually)reversestoreduce radiatorandscreendebrisbuild-up.Whilethisfeaturecan helpreducethetimerequiredtocleanradiatorsandcoolers, itdoesnoteliminatetheneedforroutinecleaning.Periodic cleaningandinspectionoftheradiatorisstillrequired.
1.Turntheengineoffandraisethehood.Cleanthe engineareathoroughlyofalldebris.
2.Removetheknobs(Figure67)securingtheoilcooler totheframe.
Figure68
1.Oilcooler
4.Pivottheoilcoolerbackintoposition.Secureittothe framewiththeknobsandclosethehood.
2.Radiator
Figure67
1.Knobs
3.Pivottheoilcoolerrearward.Cleanbothsidesofthe oilcoolerandradiatorarea(Figure68)thoroughlywith compressedair.Startfromthefrontandblowthe debrisouttowardstheback.Thencleanfromtheback sideandblowtowardsthefront.Repeatprocedure severaltimesuntilallchaffanddebrisisremoved
Important:Cleaningtheradiatororoilcooler withwatercanpromoteprematurecorrosionand damagetocomponents.
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Page 44
BrakeMaintenance
BeltMaintenance

AdjustingtheServiceBrakes

Adjusttheservicebrakeswhenthereismorethan1inch(25 mm)of“freetravel”ofthebrakepedal,orwhenthebrakes donotworkeffectively.Freetravelisthedistancethebrake pedalmovesbeforebrakingresistanceisfelt.
1.Disengagethelockinglatchfromthebrakepedalsso thatbothpedalsworkindependentlyofeachother.
2.Toreducefreetravelofthebrakepedals,tightenthe brakes:
A.Loosenthefrontnutonthethreadedendofthe
brakecable.
B.Tightentherearnuttomovethecablebackward
untilthebrakepedalshave1/2to1inch(13to 25mm)offreetravel.
C.Tightenthefrontnutsafterthebrakesareadjusted
correctly.

ServicingtheAlternatorBelt

ServiceInterval:Aftertherst10hours
Every100hours
Checktheconditionandtensionofthebelts(Figure69)after every100operatinghours.
1.Propertensionwillallow3/8inch(10mm)deection whenaforceof10lbisappliedonthebeltmidway betweenthepulleys.
2.Ifthedeectionisnot3/8inch(10mm),loosenthe alternatormountingbolts(Figure69).Increaseor decreasethealternatorbelttensionandtightenthe bolts.Checkthedeectionofthebeltagaintoensure thatthetensioniscorrect.
Figure69
1.Alternator2.Mountingbolt

Re-tensioningtheBladeDrive Belts

ServiceInterval:Aftertherst10hours
Every50hours
Checktheconditionandtensionofthecuttingunitdrivebelts initiallyafter8hoursofoperationandevery50operating hoursthereafter.
Whenproperlytensioned,theextensionspring(hookto hook)measurementshouldbeapproximately3.50±.25inch (inside).Oncethecorrectspringtensionisattained,adjust thestopbolt(carriagebolt)untilthereisapproximately.125 +.060/-.000inchclearancebetweentheheadoftheboltand theidlerarm(
Note:Makesurethebeltispositionedonthespringside ofthebeltguide(
Figure70).
Figure70).
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Page 45
Figure70
1.Belt4.Beltguide
2.Eyebolt5.Flangenut
3.Extensionspring
6.Stopbolt

ReplacingtheBladeDriveBelt

Figure71
1.Hydraulicmotor2.Mountingbolts
5.Removetheoldbeltfromaroundthespindlepulleys andidlerpulley.
6.Routethenewbeltaroundthespindlepulleysandidler pulleyassembly.
7.Positionthehydraulicmotoronthecuttingunitafter routingthebeltaroundthepulleys.Mountthemotor tothecuttingunitwiththeboltspreviouslyremoved.
ServiceInterval:Every800hours
Thebladedrivebelt,tensionedbythespringloadedidler pulley,isverydurable.However,aftermanyhoursofuse, thebeltwillshowsignsofwear.Signsofawornbeltare: squealingwhenbeltisrotating,bladesslippingwhencutting grass,frayededges,burnmarksandcracks.Replacethebeltif anyoftheseconditionsareevident.
1.Lowerthecuttingunittotheshopoor.Removethe beltcoversfromthetopofthecuttingunitandsetthe coversaside.
2.Loosentheeyeboltallowingtheremovalofthe extensionspring(Figure70).
3.Loosentheangenutsecuringthestopbolttothe mountingtab.Backoffthenutenoughtoallowthe idlerarmtopassbythestopbolt(Figure70).Movethe idlerpulleyawayfromthebelttoreleasebelttension.
Note:Ifthestopboltiseverremovedfromthe mountingtab,makesureitisreinstalledintheholethat alignsthestopboltheadwiththeidlerarm.
4.Removetheboltssecuringthehydraulicmotortothe cuttingunit(Figure71).Liftthemotoroffofthe cuttingunitandlayitontopofthecuttingunit.
Note:Makesurethebeltispositionedonthespring sideofthebeltguide(Figure70).
8.Reconnecttheextensionspring(Figure70)totheeye boltandtensionthebeltasfollows:
Whenproperlytensioned,theextension
spring(hooktohook)measurementshouldbe approximately3.50±.25inch(inside).
Oncethecorrectspringtensionisattained,
adjustthestopbolt(carriagebolt)untilthereis approximately.125+.060/-.000inchclearance betweentheheadoftheboltandtheidlerarm.
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ControlsSystem Maintenance

AdjustingtheThrottleCable

ServiceInterval:Aftertherst50hours
Every400hours
Adjustthethrottlecable(Figure72)sothatthegovernor leverontheenginecontactsthelowandhighspeedsetbolts beforethethrottlelevercontactstheslotinthecontrolpanel.
Figure72
Figure73
1.Tractionpedalstop2.Jamnuts
3.Releasethetractionpedalandadjustthestopanother halftofullturnsothatthepedalcontactsthestopjust beforefullstrokeisattained,then,tightenthejamnuts (Figure73).
1.Throttlecable

AdjustingtheTractionPedal Linkage

Withthetractionswitchinthemowposition(lowspeed),the tractionpedalshouldcontactthestopjustbeforethepumpis atfullstroketopreventanydamagetothepump.Ifitdoes not,performthefollowingprocedure:
1.Parkthemachineonalevelsurface,stoptheengine, andlowerthecuttingunitstotheoor.Removethe ignitionkey.
2.Depressthetractionpedaluntilitisatfullstroke (Figure73).Thejamnutsmayhavetobeloosenedand thestoploweredtoattainfullstroke.
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HydraulicSystem Maintenance

ReplacingtheHydraulicFilters

ServiceInterval:Aftertherst200hours
Every800hours

ChangingtheHydraulicFluid

ServiceInterval:Aftertherst200hours
Every800hours
Changethehydraulicuidafterevery800operatinghours, innormalconditions.Iftheuidbecomescontaminated, contactyourlocalTorodistributorbecausethesystemmust beushed.Contaminateduidlooksmilkyorblackwhen comparedtocleanoil.
1.Turntheengineoffandraisethehood.
2.Loosenthedrainvalveonthebottomofthereservoir andletthehydraulicuidowintolargedrainpan. Closethevalvewhenthehydraulicuidstopsdraining.
3.Fillthereservoir( gallons(30l)ofhydraulicuid;refertoCheckingthe HydraulicFluid.
Important:Useonlythehydraulicuids specied.Otheruidscouldcausesystem damage.
Figure74)withapproximately8
Changethe2hydraulicltersinitiallyaftertherst200 operatinghours.Thereafter,changetheltersafterevery800 operatinghours,innormalconditions.
UseTororeplacementlters(PartNo.94-2621fortheleft sideofthemachineand75-1310fortherightsideofthe machine).
Important:Useofanyotherltermayvoidthewarranty onsomecomponents.
1.Positionthemachineonalevelsurface,lowerthe cuttingunits,stoptheengine,engagetheparking brakes,andremovetheignitionkey .
2.Cleantheareaaroundtheltermountingarea.Place adrainpanunderthelterandremovethelter (Figure75).
Figure74
1.Hydraulicreservoir
4.Installthereservoircap.Starttheengineanduseall ofthehydrauliccontrolstodistributehydraulicuid throughoutthesystem.Alsocheckforleaks;thenstop theengine.
5.Checktheuidlevelandaddenoughtoraiselevel theleveltotheFULLmarkonthedipstick.Donot
overll.
Figure75
3.Lubricatethenewltergasketandllthelterwith hydraulicuid.
4.Ensurethattheltermountingareaisclean.Screwthe lteronuntilthegasketcontactsthemountingplate; thentightenthelteranadditional1/2turn.
5.Starttheengineandletitrunforabouttwominutesto purgeairfromthesystem.Stoptheengineandcheck forleaks.
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Page 48
CheckingtheHydraulicLines
g011538
1 2
andHoses
ServiceInterval:Every2years
Inspectthehydrauliclinesandhosesdailyforleaks,kinked lines,loosemountingsupports,wear,loosettings,weather deterioration,andchemicaldeterioration.Makeallnecessary repairsbeforeoperating.
WARNING
Hydraulicuidescapingunderpressurecan penetrateskinandcauseinjury.
Makesureallhydraulicuidhosesandlinesare ingoodconditionandallhydraulicconnections andttingsaretightbeforeapplyingpressureto thehydraulicsystem.
Keepyourbodyandhandsawayfrompin holeleaksornozzlesthatejecthighpressure hydraulicuid.
Usecardboardorpapertondhydraulicleaks.
Safelyrelieveallpressureinthehydraulicsystem beforeperforminganyworkonthehydraulic system.
Seekimmediatemedicalattentionifuidis injectedintoskin.

AdjustingtheCounterbalance Pressure

Thecounterbalancetestport(Figure76)isusedtotest thepressureinthecounterbalancecircuit.Recommended counterbalancepressureis470psi(3241kPa).Toadjust thecounterbalancepressure,loosenthelocknut,rotatethe adjustingscrew(Figure76)clockwisetoincreasethepressure orcounterclockwisetodecreasethepressureandtighten thelocknut.
Figure76
1.Counterbalancetestport2.Counterbalanceadjusting screw
Note:Allthreesidecuttingunitscastorwheelsshould remainonthegroundwithcounterbalanceapplied.
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Page 49

MowerMaintenance

Pivoting(Tilting)theFront CuttingUnitUpright

Note:Althoughnotneededfornormalmaintenance
procedures,thefrontcuttingunitcanbepivoted(tilted)toan uprightposition.Shouldyoudesiretotiltthecuttingunit, proceedasfollows:
1.Raisethecenterandwingcuttingunitsslightlyoffof theoor,settheparkingbrake,andstoptheengine. Removetheignitionkey.
2.Removethehairpincottersecuringdamperstolift arms(
Figure77).Pivotdampertowarddeckhousing.

PivotingtheFrontCuttingUnit Down

1.Slowlylowerwingcuttingunitsuntilthecenterof gravityshiftsandthecentercuttingunitrotates downward.
2.Sitontheseat,starttheengine,andlowerthecenter cuttingunituntilitisslightlyoffoftheoor.
3.Securetheheight-of-cutchainstotherearofthe cuttingunit.
4.Pivotdampersupwardintopositionandsecurewith clevispinandcotterpin.

AdjustingtheCuttingUnit Pitch

MeasuringtheCuttingUnitPitch
Cuttingunitpitchisthedifferenceinheight-of-cutfromthe frontofthebladeplanetothebackofthebladeplane.T oro recommendsabladepitchof1/4inch(6mm).Thatisthe backofthebladeplaneis1/4inch(6mm)higherthanthe front.
Figure77
1.Damper2.Hairpincotter
3.Removethehairpincotterandclevispinsecuringthe height-of-cutchainstotherearofthecuttingunit (Figure78).
Figure78
1.Positionthemachineonalevelsurfaceontheshop oor.
2.Setthecuttingunittothedesiredheight-of-cut.
3.Rotate1bladesothatitpointsstraightforward.
4.Usingashortruler,measurefromtheoortothefront tipoftheblade.Rotatethebladetiptotherearand measurefromtheoortothetipoftheblade.
5.Subtractthefrontdimensionfromthereardimension tocalculatethebladepitch.
AdjustingtheFrontCuttingUnit
1.Loosenthejamnutsonthetoporbottomofthe height-of-cutchainU-bolt(Figure79).
2.Adjusttheothersetofnutstoraiseorlowertherearof thecuttingunitandattainthecorrectcuttingunitpitch.
3.Tightenthejamnuts.
1.Height-of-cutchain
4.Starttheengineandslowlyraisethecentercuttingunit.
5.Slowlyraiseeachwingcuttinguntilthecenterofgravity shiftsandthedeckstartstorotateintotheupright position.Stoptheengineandremovetheignitionkey.
2.U-bolt
49
Page 50
Figure79
1.Height-of-cutchain
2.U-bolt
AdjustingtheWingCuttingUnits
1.Removethecapscrewsandnutssecuringthecastor armtothecastorfork(Figure80).
2.Repositiontheshims,asrequired,toraiseorlowerthe castorwheeluntilthecuttingunithasthecorrectpitch.

ServicingtheCastorArm Bushings

Thecastorarmshavebushingspressedintothetopand bottomofthetubeandaftermanyhoursofoperation,the bushingswillwear.Tocheckthebushings,movethecastor forkbackandforthandfromsidetoside.Ifthecastor spindleislooseinsidethebushings,thebushingsareworn andmustbereplaced.
1.Raisethecuttingunitsothatthewheelsareoffof theoor.Blockthecuttingunitsothatitcannot accidentallyfall.
2.Removethetensioningcap,spacer(s),andthrust washerfromthetopofthecastorspindle.
3.Pullthecastorspindleoutofthemountingtube. Allowthethrustwasherandspacer(s)toremainon thebottomofthespindle.
4.Insertapinpunchintothetoporbottomofthe mountingtubeanddrivethebushingoutofthetube
Figure81).Alsodrivetheotherbushingoutofthe
( tube.Cleantheinsideofthetubestoremovedirt.
3.Installthecapscrewsandnuts.
Figure80
1.Castorarm3.Castorfork
2.Shims
Figure81
1.Castorarmtube
5.Applygreasetotheinsideandoutsideofthenew bushings.Usingahammerandatplate,drivethe bushingsintothemountingtube.
6.Inspectthecastorspindleforwearandreplaceitifit isdamaged.
7.Pushthecastorspindlethroughthebushingsand mountingtube.Slidethethrustwasherandspacer(s) ontothespindle.Installthetensioningcaponthe castorspindletoretainallpartsinplace.
2.Bushings

ServicingtheCastorWheels andBearings

ServiceInterval:Every800hours
1.Removethelocknutfromtheboltholdingthecastor wheelassemblybetweenthecastorfork( orthecastorpivotarm(Figure83).Graspthecastor wheelandslidetheboltoutoftheforkorpivotarm.
50
Figure82)
Page 51
Figure82

ReplacingtheCuttingUnit HingeCovers

Thehingecoverpreventsdebrisfromescapingathingepoints betweencuttingunits.Ifcover(s)everbecomedamagedor wormtheymustbereplaced.
1.Castorwheel
2.Castorfork
1.Castorwheel
2.Castorpivotarm
3.Bearing
4.Bearingspacer
Figure83
3.Bearing
4.Bearingspacer
2.Removethebearingfromthewheelhubandallowthe bearingspacertofallout(Figure82andFigure83). Removethebearingfromtheoppositesideofthe wheelhub.
Figure84
1.Hingecover
3.Checkthebearings,spacer,andinsideofthewheelhub forwear.Replaceanydamagedparts.
4.Toassemblethecastorwheel,pushthebearingintothe wheelhub.Wheninstallingthebearings,pressonthe outerraceofthebearing.
5.Slidethebearingspacerintothewheelhub.Pushthe otherbearingintotheopenendofthewheelhubto captivatethebearingspacerinsidethewheelhub.
6.Installthecastorwheelassemblybetweenthecastor forkandsecureitinplacewiththeboltandlocknut.
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Page 52

BladeMaintenance

CheckingforaBentBlade

1.Positionthemachineonalevelsurface.Raisethe cuttingunit,engagetheparkingbrake,putthetraction pedalinneutral,putthePTOleverintheOffposition, stoptheengine,andremovetheignitionkey.Blockthe cuttingunittopreventitfromaccidentallyfalling.
2.Rotatethebladeuntiltheendsfaceforwardand backward(Figure85).Measurefromtheinsideofthe cuttingunittothecuttingedgeatthefrontoftheblade. Rememberthisdimension.
Figure86
1.Bladebolt2.Anti-scalpcup

InspectingandSharpeningthe CutterBlade(s)

Figure85
3.Rotatetheoppositeendofthebladeforward.Measure betweenthecuttingunitandcuttingedgeoftheblade atthesamepositionasinstep2.Thedifference betweenthedimensionsobtainedinsteps2and3 mustnotexceed1/8inch(3mm).Ifthedimension exceeds1/8inch(3mm),thebladeisbentandmustbe replaced;refertoRemovingandInstallingtheCutter Blade.

RemovingandInstallingthe CutterBlade(s)

Theblademustbereplacedifasolidobjectishit,theblade isoutofbalance,orifthebladeisbent.Alwaysusegenuine Tororeplacementbladestobesureofsafetyandoptimum performance.Neverusereplacementbladesmadebyother manufacturersbecausetheycouldbedangerous.
1.Raisethecuttingunittothehighestposition,engage theparkingbrake,stoptheengine,andremovethe ignitionkey.Blockthecuttingunittopreventitfrom accidentallyfalling.
2.Grasptheendofthebladeusingaragorthickly paddedglove.Removethebladebolt,anti-scalpcup, andbladefromthespindleshaft(Figure86).
3.Installtheblade,anti-scalpcup,andbladebolt.Tighten thebladeboltto85to110ft-lb(115to149Nm).
Important:Thecurvedpartoftheblademustbe pointingtowardtheinsideofthecuttingunitto ensurepropercutting.
Note:Afterstrikingaforeignobject,torqueallthe spindlepulleynutsto130to150ft-lb(176to203 Nm).
DANGER
Awornordamagedbladecanbreak,andapiece ofthebladecouldbethrownintotheoperator's orbystander'sarea,resultinginseriouspersonal injuryordeath.Tryingtorepairadamagedblade mayresultindiscontinuedsafetycerticationof theproduct.
Inspectthebladeperiodicallyforwearor damage.
Nevertrytostraightenabladethatisbentor weldabrokenorcrackedblade.
Replaceawornordamagedblade.
Twoareasmustbeconsideredwhencheckingandservicing thecutterblade-thesailandthecuttingedge.Bothcutting edgesandthesail,whichistheturnedupportionopposite thecuttingedge,contributetoagoodquality-of-cut.The sailisimportantbecauseitliftsthegrassupstraight,thereby producinganevencut.However,thesailwillgraduallywear downduringoperation,andthisconditionisnormal.Asthe sailwearsdown,thequality-of-cutwilldegradesomewhat, althoughthecuttingedgesaresharp.Thecuttingedgeof theblademustbesharpsothatthegrassiscutratherthan torn.Adullcuttingedgeisevidentwhenthetipsofthegrass appearbrownandshredded.Sharpenthecuttingedgesto correctthiscondition.
1.Positionthemachineonalevelsurface.Raisethe cuttingunit,engagetheparkingbrake,putthetraction pedalinneutral,putthePTOleverintheOffposition, stoptheengine,andremovetheignitionkey.
2.Examinethecuttingendsofthebladecarefully, especiallywheretheatandcurvedpartsoftheblade meet(
Figure87).Sincesandandabrasivematerialcan wearawaythemetalthatconnectstheatandcurved partsoftheblade,checkthebladebeforeusingthe mower.Ifwearisnoticed(
Figure87),replacetheblade.
52
Page 53
DANGER
Ifthebladeisallowedtowear,aslotwillform betweenthesailandatpartoftheblade
Figure87).Eventuallyapieceoftheblade
( maybreakoffandbethrownfromunderthe housing,possiblyresultinginseriousinjury toyouorbystanders.
Inspectthebladeperiodicallyforwearor damage.
Nevertrytostraightenabladethatisbent orweldabrokenorcrackedblade.
Replaceawornordamagedblade.
Figure88
1.Sharpenatoriginalangle
Figure87
1.CuttingEdge3.Wear/slotForming
2.CurvedArea4.Crack
3.Examinethecuttingedgesofalloftheblades.Sharpen thecuttingedgesiftheyaredullornicked.Sharpen onlythetopofthecuttingedgeandmaintainthe originalcuttingangletomakesureofsharpness (Figure88).Thebladewillremainbalancedifthesame amountofmetalisremovedfrombothcuttingedges.
Note:Removethebladesandsharpenthemona grinder.Aftersharpeningthecuttingedges,installthe bladewiththeanti-scalpcupandbladebolt;referto RemovingandInstallingtheCutterBlade(s).

CorrectingCuttingUnit Mismatch

Ifthereismismatchbetweentheblades,onasinglecutting unit,thegrasswillappearstreakedwhenitiscut.This problemcanbecorrectedbymakingsurethatthebladesare straightandallofthebladesarecuttingonthesameplane.
1.Usinga3foot(1meter)longcarpenterslevel,nda levelsurfaceontheshopoor.
2.Raisetheheight-of-cuttothehighestposition;referto AdjustingtheHeight-Of-Cut.
3.Lowerthecuttingunitontotheatsurface.Remove thecoversfromthetopofthecuttingunit.
4.Loosentheangenutsecuringtheidlerpulleyto releasethebelttension.
5.Rotatethebladesuntiltheendsfaceforwardand backward.Measurefromtheoortothefronttipof thecuttingedge.Rememberthisdimension.Then rotatethesamebladesothattheoppositeendis forward,andmeasureagain.Thedifferencebetween thedimensionsmustnotexceed1/8inch(3mm).If thedimensionexceeds1/8inch(3mm),replacethe bladebecauseitisbent.Makesuretomeasureallof theblades.
53
Page 54
6.Comparethemeasurementsoftheouterbladeswith thecenterblade.Thecenterblademustnotbemore than3/8inch(10mm)lowerthantheouterblades.If thecenterbladeismorethan3/8inch(10mm)lower thantheouterblades,proceedtostep7andaddshims betweenthespindlehousingandthebottomofthe cuttingunit.
7.Removethebolts,atwashers,lockwashers,andnuts fromtheouterspindleintheareawheretheshims mustbeadded.Toraiseorlowertheblade,addashim, PartNo.3256-24,betweenthespindlehousingand thebottomofthecuttingunit.Continuetocheckthe alignmentofthebladesandaddshimsuntilthetipsof thebladesarewithintherequireddimension.
Important:Donotusemorethanthreeshimsat anyoneholelocation.Usedecreasingnumbersof shimsinadjacentholesifmorethanoneshimis addedtoanyoneholelocation.
8.Adjusttheidlerpulleyandinstallthebeltcovers.

SparkArrestor Maintenance

ServicingtheSparkArrestor Mufer
ServiceInterval:Every200hours
Every200hoursoperation,clearthemuferofcarbon buildup.
1.Removethepipeplugfromtheclean-outportatthe lowersideofthemufer.
CAUTION
Themufermaybehotandcouldcause injury.
Becarefulwhileworkingaroundthemufer.
2.Starttheengine.Plugthenormalmuferexitwitha blockofwoodormetalplatesothattheexhaustow willbeforcedoutoftheclean-outport.Continueto blocktheexituntilcarbondepositsceasecomingout oftheport.
CAUTION
Donotstandinlinewiththeclean-outport.
Alwayswearsafetyglasses.
3.Stoptheengineandreplacethepipeplug.
54
Page 55

CabMaintenance

CleaningtheCabAirFilters

ServiceInterval:Every250hours(Replacethemiftheyare
tornorexcessivelydirty.)
1.Removethethumbscrewsandgratesfromoverboth thein-cabandrearcabairlters(Figure89).
Figure89
1.Thumbscrew
2.Grate
2.Cleantheltersbyblowingclean,oilfree,compressed airthroughthem.
Important:Ifeitherlterhasahole,tear,orother damage,replaceit.
3.Installtheltersandgrate,securingthemwiththe thumbscrews.
3.Airlter
55
Page 56
Storage

PreparingforSeasonal Storage

TractionUnit
1.Thoroughlycleanthetractionunit,cuttingunits,and theengine.
2.Checkthetirepressure;refertoCheckingtheTire Pressure.
3.Checkallfastenersforlooseness;tightenasnecessary.
4.Greaseoroilallgreasettingsandpivotpoints.Wipe upanyexcesslubricant.
5.Lightlysandandusetouch-uppaintonpaintedareas thatarescratched,chipped,orrusted.Repairanydents inthemetalbody.
6.Servicethebatteryandcablesasfollows:
A.Removethebatteryterminalsfromthebattery
posts.
B.Cleanthebattery,terminals,andpostswithawire
brushandbakingsodasolution.
C.Coatthecableterminalsandbatterypostswith
Grafo112Xskin-overgrease(ToroPartNo. 505-47)orpetroleumjellytopreventcorrosion.
D.Slowlyrechargethebatteryevery60daysfor24
hourstopreventleadsulfationofthebattery.
Engine
1.Draintheengineoilfromtheoilpanandinstallthe drainplug.
2.Removeanddiscardtheoillter.Installanewoillter.
3.Relltheoilpanwith10qts(9.5l)ofSAE15W-40 CH-4,CI-4,orhighermotoroil.
4.Starttheengineandrunitatidlespeedfor approximatelytwominutes.
5.Stoptheengine.
6.Flushthefueltankwithfresh,cleandieselfuel.
7.Secureallofthefuelsystemttings.
8.Thoroughlycleanandservicetheaircleanerassembly .
9.Sealtheaircleanerinletandtheexhaustoutletwith weatherprooftape.
10.Checktheantifreezeprotectionandadda50/50 solutionofwaterandethyleneglycolanti-freezeas neededfortheexpectedminimumtemperatureinyour area.
56
Page 57
Schematics
g014815
ElectricalSchematic(Rev.D)
57
Page 58
g017775
ElectricalSchematic(Rev.D)
58
Page 59
g017776
ElectricalSchematic(Rev.D)
59
Page 60
g017779
ElectricalSchematic,GM4000/4100(Rev.D)
60
Page 61
g017780
ElectricalSchematic,GM4010(Rev.D)
61
Page 62
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ElectricalSchematic,GM4110(Rev.D)
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TheToroTotalCoverageGuarantee
ALimitedWarranty
ConditionsandProductsCovered
TheToroCompanyanditsafliate,T oroWarrantyCompany ,pursuant toanagreementbetweenthem,jointlywarrantyourT oroCommercial product(“Product”)tobefreefromdefectsinmaterialsorworkmanship fortwoyearsor1500operationalhours*,whicheveroccursrst.This warrantyisapplicabletoallproductswiththeexceptionofAerators (refertoseparatewarrantystatementsfortheseproducts).Wherea warrantableconditionexists,wewillrepairtheProductatnocosttoyou includingdiagnostics,labor,parts,andtransportation.Thiswarranty beginsonthedatetheProductisdeliveredtotheoriginalretailpurchaser. *Productequippedwithanhourmeter.
InstructionsforObtainingWarrantyService
YouareresponsiblefornotifyingtheCommercialProductsDistributoror AuthorizedCommercialProductsDealerfromwhomyoupurchasedthe Productassoonasyoubelieveawarrantableconditionexists.Ifyouneed helplocatingaCommercialProductsDistributororAuthorizedDealer,or ifyouhavequestionsregardingyourwarrantyrightsorresponsibilities, youmaycontactusat:
ToroCommercialProductsServiceDepartment ToroWarrantyCompany
811 1LyndaleAvenueSouth Bloomington,MN55420-1196
952–888–8801or800–952–2740 E-mail:commercial.warranty@toro.com
OwnerResponsibilities
AstheProductowner ,youareresponsibleforrequiredmaintenance andadjustmentsstatedinyourOperator'sManual.Failuretoperform requiredmaintenanceandadjustmentscanbegroundsfordisallowinga warrantyclaim.
ItemsandConditionsNotCovered
Notallproductfailuresormalfunctionsthatoccurduringthewarranty periodaredefectsinmaterialsorworkmanship.Thiswarrantydoesnot coverthefollowing:
Productfailureswhichresultfromtheuseofnon-Tororeplacement
parts,orfrominstallationanduseofadd-on,ormodiednon-T oro brandedaccessoriesandproducts.Aseparatewarrantymaybe providedbythemanufactureroftheseitems.
Productfailureswhichresultfromfailuretoperformrecommended
maintenanceand/oradjustments.Failuretoproperlymaintainyour ToroproductpertheRecommendedMaintenancelistedinthe Operator’sManualcanresultinclaimsforwarrantybeingdenied.
ProductfailureswhichresultfromoperatingtheProductinan
abusive,negligent,orrecklessmanner .
Partssubjecttoconsumptionthroughuseunlessfoundtobe
defective.Examplesofpartswhichareconsumed,orusedup, duringnormalProductoperationinclude,butarenotlimitedto,brake padsandlinings,clutchlinings,blades,reels,rollersandbearings (sealedorgreasable),bedknives,sparkplugs,castorwheelsand bearings,tires,lters,belts,andcertainsprayercomponentssuchas diaphragms,nozzles,andcheckvalves,etc.
Failurescausedbyoutsideinuence.Conditionsconsideredtobe
outsideinuenceinclude,butarenotlimitedto,weather,storage practices,contamination,useofunapprovedfuels,coolants, lubricants,additives,fertilizers,water,orchemicals,etc.
Failureorperformanceissuesduetotheuseoffuels(e.g.gasoline,
diesel,orbiodiesel)thatdonotconformtotheirrespectiveindustry standards.
Normalnoise,vibration,wearandtear,anddeterioration.
Normal“wearandtear”includes,butisnotlimitedto,damageto
seatsduetowearorabrasion,wornpaintedsurfaces,scratched decalsorwindows,etc.
Parts
Partsscheduledforreplacementasrequiredmaintenancearewarranted fortheperiodoftimeuptothescheduledreplacementtimeforthatpart. Partsreplacedunderthiswarrantyarecoveredforthedurationofthe originalproductwarrantyandbecomethepropertyofT oro.T orowill makethenaldecisionwhethertorepairanyexistingpartorassemblyor replaceit.T oromayuseremanufacturedpartsforwarrantyrepairs.
DeepCycleandLithium-IonBatteryWarranty:
DeepcycleandLithium-Ionbatterieshaveaspeciedtotalnumberof kilowatt-hourstheycandeliverduringtheirlifetime.Operating,recharging, andmaintenancetechniquescanextendorreducetotalbatterylife.Asthe batteriesinthisproductareconsumed,theamountofusefulworkbetween chargingintervalswillslowlydecreaseuntilthebatteryiscompletelyworn out.Replacementofwornoutbatteries,duetonormalconsumption, istheresponsibilityoftheproductowner.Batteryreplacementmaybe requiredduringthenormalproductwarrantyperiodatowner’sexpense. Note:(Lithium-Ionbatteryonly):ALithium-Ionbatteryhasapartonly proratedwarrantybeginningyear3throughyear5basedonthetime inserviceandkilowatthoursused.RefertotheOperator'sManualfor additionalinformation.
MaintenanceisatOwner’sExpense
Enginetune-up,lubrication,cleaningandpolishing,replacementoflters, coolant,andcompletingrecommendedmaintenancearesomeofthe normalservicesT oroproductsrequirethatareattheowner’sexpense.
GeneralConditions
RepairbyanAuthorizedT oroDistributororDealerisyoursoleremedy underthiswarranty .
NeitherTheToroCompanynorToroWarrantyCompanyisliablefor indirect,incidentalorconsequentialdamagesinconnectionwiththe useoftheToroProductscoveredbythiswarranty ,includingany costorexpenseofprovidingsubstituteequipmentorserviceduring reasonableperiodsofmalfunctionornon-usependingcompletion ofrepairsunderthiswarranty.ExceptfortheEmissionswarranty referencedbelow,ifapplicable,thereisnootherexpresswarranty . Allimpliedwarrantiesofmerchantabilityandtnessforuseare limitedtothedurationofthisexpresswarranty .
Somestatesdonotallowexclusionsofincidentalorconsequential damages,orlimitationsonhowlonganimpliedwarrantylasts,sothe aboveexclusionsandlimitationsmaynotapplytoyou.Thiswarranty givesyouspeciclegalrights,andyoumayalsohaveotherrightswhich varyfromstatetostate.
Noteregardingenginewarranty:
TheEmissionsControlSystemonyourProductmaybecoveredby aseparatewarrantymeetingrequirementsestablishedbytheU.S. EnvironmentalProtectionAgency(EP A)and/ortheCaliforniaAir ResourcesBoard(CARB).Thehourlimitationssetforthabovedonot applytotheEmissionsControlSystemWarranty.RefertotheEngine EmissionControlWarrantyStatementsuppliedwithyourproductor containedintheenginemanufacturer’sdocumentationfordetails
CountriesOtherthantheUnitedStatesorCanada
CustomerswhohavepurchasedT oroproductsexportedfromtheUnitedStatesorCanadashouldcontacttheirT oroDistributor(Dealer)toobtain guaranteepoliciesforyourcountry ,province,orstate.IfforanyreasonyouaredissatisedwithyourDistributor'sserviceorhavedifcultyobtaining guaranteeinformation,contacttheT oroimporter.
374-0253RevB
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