Page 1
Groundsmaster 3500-D
Groundsmaster Traction Unit
Model No. 30821—Serial No. 250000001 and Up
Form No. 3352–379
Operator ’s Manual
English (EN, GB)
Page 2
Warning
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents
are known to the State of California to cause
cancer, birth defects, and other reproductive harm.
Contents
Introduction 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Operating Practices 3. . . . . . . . . . . . . . . . . . . .
Toro Mower Safety 5. . . . . . . . . . . . . . . . . . . . . . . .
Sound Power Level 6. . . . . . . . . . . . . . . . . . . . . . .
Sound Pressure Level 7. . . . . . . . . . . . . . . . . . . . . .
Vibration Level 7. . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 7. . . . . . . . . . . . . . . .
Specifications 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 11. . . . . . . . . . . . . . . . . . . . .
Optional Equipment 11. . . . . . . . . . . . . . . . . . . . . . .
Setup 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Activating, Charging, and Connecting the Battery 13
Installing the Seat 14. . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Angle Indicator 15. . . . . . . . . . . . . . . .
Installing the Hood Latch (CE) 15. . . . . . . . . . . . . .
Installing the Exhaust Guard (CE) 15. . . . . . . . . . . .
Adjusting the Lift Arms 16. . . . . . . . . . . . . . . . . . . .
Rear Ballast 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before Operating 17. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Crankcase Oil 17. . . . . . . . . . . . . . . . .
Filling the Fuel Tank 17. . . . . . . . . . . . . . . . . . . . . .
Checking the Cooling System 18. . . . . . . . . . . . . . .
Checking the Hydraulic System 19. . . . . . . . . . . . . .
Checking the Tire Pressure 19. . . . . . . . . . . . . . . . . .
Checking the Torque of the Wheel Nuts 20. . . . . . .
Page
Page
Operation 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting and Stopping the Engine 23. . . . . . . . . . . . .
Bleeding the Fuel System 23. . . . . . . . . . . . . . . . . . .
Checking the Interlock System 24. . . . . . . . . . . . . . .
Towing the Traction Unit 24. . . . . . . . . . . . . . . . . . .
Standard Control Module (SCM) 25. . . . . . . . . . . . .
Operating Characteristics 27. . . . . . . . . . . . . . . . . . .
Maintenance 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule 30. . . . . . . . .
Daily Maintenance Checklist 31. . . . . . . . . . . . . . . .
Greasing the Bearings and Bushings 32. . . . . . . . . .
Service Interval Chart 35. . . . . . . . . . . . . . . . . . . . . .
Removing the Hood 36. . . . . . . . . . . . . . . . . . . . . . .
General Air Cleaner Maintenance 36. . . . . . . . . . . .
Servicing the Air Cleaner 36. . . . . . . . . . . . . . . . . . .
Servicing the Engine Oil and Filter 37. . . . . . . . . . .
Servicing the Fuel System 37. . . . . . . . . . . . . . . . . .
Bleeding Air from the Injectors 38. . . . . . . . . . . . . .
Cleaning the Engine Cooling System 38. . . . . . . . . .
Servicing the Engine Belts 39. . . . . . . . . . . . . . . . . .
Adjusting the Throttle 40. . . . . . . . . . . . . . . . . . . . .
Changing the Hydraulic Fluid 40. . . . . . . . . . . . . . .
Replacing the Hydraulic Filter 41. . . . . . . . . . . . . . .
Checking the Hydraulic Lines and Hoses 41. . . . . . .
Adjusting the Traction Drive for Neutral 41. . . . . . .
Adjusting the Parking Brake 42. . . . . . . . . . . . . . . .
Caring for the Battery 42. . . . . . . . . . . . . . . . . . . . . .
Storing the Battery 43. . . . . . . . . . . . . . . . . . . . . . . .
Fuses 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Schematic 44. . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Schematic 45. . . . . . . . . . . . . . . . . . . . . .
Preparation for Seasonal Storage 46. . . . . . . . . . . . .
The Toro General Commercial Products Warranty 48. .
2004 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
All Rights Reserved
Printed in the USA
2
Page 3
Introduction
Read this manual carefully to learn how to operate and
maintain your product properly. The information in this
manual can help you and others avoid injury and product
damage. Although Toro designs and produces safe
products, you are responsible for operating the product
properly and safely.
Whenever you need service, genuine Toro parts, or
additional information, contact an Authorized Service
Dealer or Toro Customer Service and have the model and
serial numbers of your product ready. The two numbers are
stamped into a plate located on the frame of the mower.
Write the product model and serial numbers in the space
below:
Safe Operating Practices
The following instructions are from the CEN standard EN
836:1997, ISO standard 5395:1990, and ANSI standard
B71.4-1999.
Training
• Read the Operator’s Manual and other training material
carefully. Be familiar with the controls, safety signs,
and the proper use of the equipment.
• Never allow children or people unfamiliar with these
instructions to use the mower. Local regulations may
restrict the age of the operator.
• Never mow while people, especially children, or pets
are nearby.
Model No.
Serial No.
This manual identifies potential hazards and has special
safety messages that help you and others avoid personal
injury and even death. Danger, Warning, and Caution are
signal words used to identify the level of hazard. However,
regardless of the hazard, be extremely careful.
Danger signals an extreme hazard that will cause serious
injury or death if you do not follow the recommended
precautions.
Warning signals a hazard that may cause serious injury or
death if you do not follow the recommended precautions.
Caution signals a hazard that may cause minor or moderate
injury if you do not follow the recommended precautions.
This manual uses two other words to highlight information.
Important calls attention to special mechanical
information and Note: emphasizes general information
worthy of special attention.
• Keep in mind that the operator or user is responsible for
accidents or hazards occurring to himself or herself,
other people, or property.
• Do not carry passengers.
• All drivers and mechanics should seek and obtain
professional and practical instruction. The owner is
responsible for training the users. Such instruction
should emphasize:
– the need for care and concentration when working
with ride-on machines;
– control of a ride-on machine sliding on a slope will
not be regained by the application of the brake. The
main reasons for loss of control are:
• insufficient wheel grip;
• being drive too fast;
• inadequate braking;
• the type of machine is unsuitable for its task;
• lack of awareness of the effect of ground
conditions, especially slopes;
• incorrect hitching and load distribution.
Safety
This machine meets or exceeds CEN standard EN
836:1997, ISO standard 5395:1990, and ANSI
B71.4-1999 specifications in effect at the time of
production.
Improper use or maintenance by the operator or owner
can result in injury. To reduce the potential for injury,
comply with these safety instructions and always pay
attention to the safety alert symbol, which means
CAUTION, WARNING, or DANGER—“personal
safety instruction.” Failure to comply with the
instruction may result in personal injury or death.
Preparation
• While mowing, always wear substantial footwear, long
trousers, hard hat, safety glasses, and ear protection.
Long hair, loose clothing or jewelry may get tangled in
moving parts. Do not operate the equipment when
barefoot or wearing open sandals.
• Thoroughly inspect the area where the equipment is to
be used and remove all objects which may be thrown by
the machine.
3
Page 4
• Warning—fuel is highly flammable. Take the
following precautions:
– Never mow across the face of the slope, unless the
machine is designed for that purpose.
– Store fuel in containers specifically designed for this
purpose.
– Refuel outdoors only and do not smoke while
refuelling.
– Add fuel before starting the engine. Never remove
the cap of the fuel tank or add fuel while the engine
is running or when the engine is hot.
– If fuel is spilled, do not attempt to start the engine
but move the machine away from the area of
spillage and avoid creating any source of ignition
until fuel vapors have dissipated.
– Replace all fuel tank and container caps securely.
• Replace faulty silencers/mufflers.
• Before using, always visually inspect to see that the
blades, blade bolts, and cutting assembly are not worn
or damaged. Replace worn or damaged blades and bolts
in sets to preserve balance.
• On multi-bladed machines, take care as rotating one
blade can cause other blades to rotate.
• Evaluate the terrain to determine what accessories and
attachments are needed to properly and safely perform
the job. Only use accessories and attachments approved
by the manufacturer.
• Check that operator’s presence controls, safety
switches, and shields are attached and functioning
properly. Do not operate unless they are functioning
properly.
• Stay alert for holes in the terrain and other hidden
hazards.
• Watch out for traffic when crossing or near roadways.
• Stop the blades rotating before crossing surfaces other
than grass.
• When using any attachments, never direct discharge of
material toward bystanders nor allow anyone near the
machine while in operation.
• Never operate the machine with damaged guards,
shields, or without safety protective devices in place. Be
sure all interlocks are attached, adjusted properly, and
functioning properly.
• Do not change the engine governor settings or
overspeed the engine. Operating the engine at excessive
speed may increase the hazard of personal injury.
• Before leaving the operator’s position:
– Stop on level ground.
– Disengage the power take-off and lower the
attachments.
– Change into neutral and set the parking brake.
– Stop the engine and remove the key.
• Disengage drive to attachments, stop the engine, and
disconnect the spark plug wire(s) or remove the ignition
key:
– before clearing blockages;
Operation
• Do not operate the engine in a confined space where
dangerous carbon monoxide fumes can collect.
• Mow only in daylight or in good artificial light.
• Before attempting to start the engine, disengage all
blade attachment clutches, shift into neutral, and engage
the parking brake. Only start the engine from the
operator’s position. Use seat belts, if provided.
• Remember there is no such thing as a safe slope. Travel
on grass slopes requires particular care. To guard
against overturning:
– Do not stop or start suddenly when going up or
downhill.
– Engage the clutch slowly, always keep the machine
in gear, especially when travelling downhill.
– The machine speed should be kept low on slopes
and during tight turns.
– Stay alert for humps and hollows and other hidden
hazards.
– before checking, cleaning, or working on the
machine;
– after striking a foreign object. Inspect the machine
for damage and make repairs before restarting and
operating the equipment;
– if the machine starts to vibrate abnormally (check
immediately).
• Disengage drive to attachments when transporting or
not is use.
• Stop the engine and disengage drive to attachment:
– before refueling;
– before making height adjustment unless adjustment
can be made from the operator’s position.
• Reduce the throttle setting during engine shut down
and, if the engine is provided with a fuel shut-off valve,
turn the valve off at the conclusion of mowing.
• Never raise deck with the blades running.
• Keep hands and feet away from the cutting units.
4
Page 5
• Look behind and down before backing up to be sure of
a clear path.
• Slow down and use caution when making turns and
crossing roads and sidewalks.
• Do not operate the mower under the influence of
alcohol or drugs.
• Use care when loading or unloading the machine into a
trailer or truck.
• The operator shall turn on flashing warning lights, if
provided, whenever traveling on a public road, except
where such use is prohibited by law.
• Use care when checking blades. Wrap the blades or
wear gloves, and use caution when servicing them.
Only replace blades. Never straighten or weld them.
• Keep hands and feet away from moving parts. If
possible, do not make adjustments with the engine
running.
• Charge batteries in an open well ventilated area, away
from spark and flames. Unplug charger before
connecting or disconnecting from battery. Wear
protective clothing and use insulated tools.
Toro Mower Safety
Maintenance and Storage
• Keep all nuts, bolts, and screws tight to be sure the
equipment is in safe working condition.
• Never store the equipment with fuel in the tank inside a
building where fumes may reach an open flame or
spark.
• Allow the engine to cool before storing in any enclosure
and do not store near flame.
• To reduce the fire hazard, keep the engine,
silencer/muffler, battery compartment, cutting units,
drives, and fuel storage area free of grass, leaves, or
excessive grease. Clean up oil or fuel spillage.
• Replace worn or damaged parts for safety.
• If the fuel tank has to be drained, do this outdoors.
• On multi-bladed machines, take care as rotating one
blade can cause other blades to rotate.
• When machine is to be parked, stored, or left
unattended, lower the cutting units unless a positive
mechanical lock is provided.
• Disengage drives, lower the cutting units, move traction
pedal to Neutral, set parking brake, stop engine and
remove key. Wait for all movement to stop before
adjusting, cleaning or repairing.
• Shut off fuel while storing or transporting. Do not store
fuel near flames.
• Park machine on level ground. Never allow untrained
personnel to service machine.
The following list contains safety information specific to
Toro products or other safety information that you must
know that is not included in the CEN, ISO, or ANSI
standards.
This product is capable of amputating hands and feet and
throwing objects. Always follow all safety instructions to
avoid serious injury or death.
Use of this product for purposes other than its intended use
could prove dangerous to user and bystanders.
Warning
Engine exhaust contains carbon monoxide, which
is an odorless, deadly poison that can kill you.
Do not run engine indoors or in an enclosed area.
Preparation
• Be sure to establish your own special procedures and
work rules for unusual operating conditions (E.G.
slopes too steep for operation). Survey the complete
mowing site to determine which hills can be safely
operated on. When performing this site survey, always
use common sense and take into consideration the turf
condition and the rollover risk. To determine which hills
or slopes may be safely operated on, use the
inclinometer provided with each machine. To perform a
site survey, follow the procedure outlined in the
Operation section of the this manual. The maximum
side hill angle should not be greater than 25 degrees.
• Use jack stands to support components when required.
• Carefully release pressure from components with stored
energy.
• Disconnect battery or remove spark plug wire before
making any repairs. Disconnect the negative terminal
first and the positive last. Reconnect positive first and
negative last.
Training
• The operator must be skilled and trained in how to drive
on hillsides. Failure to use caution on slopes or hills
may cause the vehicle to tip or roll, possibly resulting in
personal injury or death.
5
Page 6
Operation
• Know how to stop the machine and engine quickly.
• Do not operate the machine while wearing tennis shoes
or sneakers.
• Wearing safety shoes and long pants is advisable and
required by some local ordinances and insurance
regulations.
• Keep hands, feet, and clothing away from moving parts
and the mower discharge area.
• Fill fuel tank until level is 1 in. (25 mm) below the
bottom of the filler neck. Do not overfill.
• Check the safety interlock switches daily for proper
operation. If a switch should fail, replace the switch
before operating the machine. After every two years,
replace all interlock switches in the safety system,
regardless if they are working properly or not.
• When starting the engine, engage the parking brake, put
the traction pedal in neutral, and disengage the blade
drive. After the engine starts, release the parking brake
and keep your foot off of the traction pedal. The
machine must not move. If movement is evident, refer
to the Maintenance section of this manual to adjust the
traction drive.
• Use extreme caution when operating close to sand traps,
ditches, creeks, steep hillsides, or other hazards.
• Reduce speed when making sharp turns.
• Do not turn on hills.
• Do not operate on a side hill that is too steep. A rollover
may occur before losing traction.
• The slope angle at which the machine will tip is
dependent on many factors. Among these are mowing
conditions such as wet or undulating turn, speed
(especially in turns), position of the cutting units (with
the Sidewinder), tire pressure, and operator experience.
At side hill angles of 20 degrees or less, the risk of a
rollover is low. As the slope angle increases to a
recommended maximum limit of 25 degrees, the risk of
a rollover increases to a moderate level. Do not exceed
a 25 degree side hill slope angle because the risk of a
rollover and serious injury or death is very high. The
machine is equipped with an angle indicator mounted
on the steering tube. This indicates the side hill angle
the machine is on and identifies the recommended
maximum limit of 25 degrees.
• For steering control, the cutting units must be lowered
when going down slopes.
• Raise the cutting units when driving from one work
area to another.
• Do not touch the engine, muffler, exhaust pipe, or
hydraulic tank while the engine is running or soon after
it has stopped because these areas could be hot enough
to cause burns.
Maintenance and Storage
• Before servicing or making adjustments, stop the engine
and remove the ignition key.
• Ensure that the entire machine is properly maintained
and in good operating condition. Frequently check all
nuts, bolts, screws, and hydraulic fittings.
• Make sure all hydraulic line connectors are tight and all
hydraulic hoses and lines are in good condition before
applying pressure to the system.
• Keep your body and hands away from pin hole leaks or
nozzles that eject hydraulic fluid under high pressure.
Use paper or cardboard, not your hands, to search for
leaks. Hydraulic fluid escaping under pressure can have
sufficient force to penetrate the skin and cause serious
injury. If fluid is injected into the skin it must be
surgically removed within a few hours by a doctor
familiar with this form of injury or gangrene may result.
• Before disconnecting or performing any work on the
hydraulic system, all pressure in the system must be
relieved by stopping the engine and lowering the cutting
units to the ground.
• If the engine must be running to perform a maintenance
adjustment, keep hands, feet, clothing, and any parts of
the body away from the cutting units, attachments, and
any moving parts. Keep everyone away.
• Do not overspeed the engine by changing governor
settings. To ensure safety and accuracy, have an
Authorized Toro Distributor check the maximum engine
speed with a tachometer.
• The engine must be shut off before checking the oil or
adding oil to the crankcase.
• If major repairs are ever needed or if assistance is
desired, contact an Authorized Toro Distributor.
• To make sure of optimum performance and continued
safety certification of the machine, use only genuine
Toro replacement parts and accessories. Replacement
parts and accessories made by other manufacturers
could be dangerous, and such use could void the
product warranty.
• Avoid sudden stops and starts.
• Use the reverse pedal for braking.
• Watch for traffic when near or crossing roads. Always
yield the right-of-way.
Sound Power Level
This unit has a guaranteed sound power level of 105 dBA,
based on measurements of identical machines per Directive
2000/14/EC and amendments.
6
Page 7
Sound Pressure Level
Vibration Level
This unit has an equivalent continuous A-weighted sound
pressure level at the operator ear of 89 dBA based on
measurements of identical machines per Directive
98/37/EC and amendments
Safety and Instruction Decals
Safety decals and instructions are easily visible to the operator and are located near any area
of potential danger. Replace any decal that is damaged or lost.
94-3353
1. Crushing hazard of fingers and hands—keep hands away.
This unit does not exceed a vibration level of 2.5 m/s2 at
the hands based on measurements of identical machines per
ISO 5349 procedures.
This unit does not exceed a vibration level of 0.5 m/s2 at
the posterior based on measurements of identical machines
per ISO 2631 procedures.
100-4837
99-3558 (for CE)
1. Warning—read the operator’s manual.
2. To start the engine, sit on the seat and rotate the ignition key to
On/Preheat until the glow plug indicator light goes out. Rotate
the key to start and disengage the parking brake. Read the
operator’s manual for further instructions.
3. To stop the engine, disengage the cutting units, rotate the
ignition key to Off, and remove the key. Engage the parking
brake. Read the operator’s manual for further instructions.
93-7276
1. Explosion hazard—wear
eye protection.
2. Caustic liquid
hazard—flush with water
and get medical help fast.
3. Fire hazard—fire, open
light, and smoking
prohibited.
4. Toxic hazard—keep
children away from the
battery.
93-7818
1. Warning—read the operator’s manual for blade torque
instructions.
7
Page 8
107-7801 (for CE)
1. Tipping hazard—do not drive on slopes greater than 15
degrees.
104-0484
43-8480
93-6681
1. Cutting/dismemberment hazard—stay away from moving parts.
99-3444
1. Reel speed—fast 2. Reel speed—slow
1. Height of cut
104-1086
8
Page 9
104-5181 (for CE)
1. Warning—read the
2. Tipping hazard—do not drive on slopes greater than 15
degrees and, if the roll bar is installed, wear the seat belt.
3. Thrown object hazard—keep bystanders a safe distance from
the machine.
4. Cutting hazard of hand or foot—stay away from moving parts.
5. Warning—lock the parking brake, stop the engine, and remove
the ignition key before leaving the machine.
Operator’s Manual.
Battery Symbols
Some or all of these symbols are on your battery.
1. Explosion hazard
2. No fire, open flames, or
smoking.
3. Caustic liquid/chemical
burn hazard
4. Wear eye protection
5. Read the
Manual.
6. Keep bystanders a safe
distance from the battery.
Operator’s
7. Wear eye protection;
explosive gases can
cause blindness and
other injuries
8. Battery acid can cause
blindness or severe
burns.
9. Flush eyes immediately
with water and get
medical help fast.
10. Contains lead; do not
discard.
106-6753 (for CE)
1. Thrown object
hazard—keep bystanders
a safe distance from the
machine.
2. Cutting/dismemberment
hazard of hand or foot,
mower blade—stay away
from moving parts.
106-6754
1. Warning—do not touch the hot surface.
2. Cutting/dismemberment hazard, fan and entanglement hazard,
belt—stay away from moving parts
9
Page 10
1. Engage the power take off
(PTO).
2. Disengage the power take
off (PTO).
104–5191
3. Lower the cutting units.
4. Move the cutting units to the
right.
5. Raise the cutting units.
6. Move the cutting units to the
left.
7. Move rear ward to lock the
lift lever.
8. Engine—stop
9. Engine—run
10. Engine=start
11. Fast
12. Continuous variable setting
13. Slow
107-7800
10
Page 11
Specifications
General Specifications
Kubota three-cylinder, 4-cycle liquid-cooled diesel engine. 32 hp @ 2800 RPM,
Engine
governed to 3050 RPM. 68.5 cu. in. (1124 cc) displacement. Heavy-duty, 2-stage,
remote mounted air cleaner. High water temperature shutdown switch.
Cooling system
Electrical
Fuel capacity 11 gallons
Traction drive
Hydraulic oil capacity/filter Remote mounted, 3.5 gallon oil reservoir. 10 micron remote mounted spin on filter.
Ground speed
Tires/wheels
Frame
Steering Power steering
Brakes
Radiator capacity is approximately 6 qt. of 50/50 mixture of ethylene glycol
anti-freeze. Remote mounted 1 qt. expansion tank.
12 volt Group 55, 585 cold cranking amps at 0°F (–18°C), 95 minute reserve
capacity at 80°F (27°C). 40 amp alternator with regulator/rectifier . Seat switch,
PTO, parking brake and traction interlock switches.
High torque hydraulic wheel motors, 3-wheel drive, oil cooler and shuttle valve
provide positive closed-loop cooling.
Infinitely variable speed selection in forward and reverse
Mowing speed: 0–6 MPH (adjustable)
Transport speed: 0–9 MPH
Reverse speed: 0–3.5 MPH
Front tires are 20 x 12-10 and rear tires are 20 x 10-10 tubeless, 4-ply rating with
demountable rims. Recommended tire pressure: 14–18 psi front and rear tires.
Tricycle vehicle with 3-wheel traction drive and rear wheel steering. Frame consists
of formed steel, welded steel, and steel tubing components.
Service braking accomplished through dynamic characteristics of Hydrostat.
Parking or emergency brake is actuated by over-center hand lever on the
operator’s right-hand side.
Foot operated forward and reverse traction pedals and mow/transport slide. Hand
Controls
Gauges and protective
systems
Seat Optional standard or deluxe seats
Cutting unit lift Hydraulic lift with automatic shut off
Note: Specifications and design subject to change without notice.
operated throttle, ignition switch, blade engagement switch, cutting unit lift, and shift
lever, parking brake, and seat adjustment.
Hour meter, 4 light warning cluster gauge: oil pressure, water temperature, amps,
glow plug, and side hill angle indicator.
Optional Equipment
Standard Seat Model No. 03224
11
Page 12
Setup
Note: Determine the left and right sides of the machine from the normal operating position.
Loose Parts
Note: Use this chart as a checklist to ensure that all parts necessary for assembly have been received. Without these parts,
total setup cannot be completed. Some parts may have already been assembled at the factory.
Description Qty. Use
Hood lock bracket
Screw, 1/4 x 1-1/2 in.
Flat washer, 1/4 in.
Locknut, 1/4 in.
Exhaust guard
Self-tapping screw
Inclinometer 1 For site survey before operating the machine
EEC Decal 6 Affix to machine for European compliance.
Key
EEC certificate
Parts Catalog
Operator’s Manual
Engine manual
Operator video 1 View before operating the machine.
Pre-delivery check list 1 Fill out before delivering to the customer.
1
1
1
1
1
4
2
1
1
2
1
Mount to the hood for European compliance.
Mount to machine for European compliance.
Read before operating the machine.
12
Page 13
Activating, Charging, and
Connecting the Battery
Warning
CALIFORNIA
Proposition 65 Warning
Battery posts, terminals, and related accessories
contain lead and lead compounds, chemicals
known to the State of California to cause cancer
and reproductive harm. Wash hands after
handling.
Note: If the battery is not filled with electrolyte or
activated, bulk electrolyte with 1.260 specific gravity must
be purchased from a local battery supply outlet and added
to the battery.
Danger
Battery electrolyte contains sulfuric acid which is a
deadly poison and causes severe burns.
• Do not drink electrolyte and avoid contact with
skin, eyes or clothing. Wear safety glasses to
shield your eyes and rubber gloves to protect
your hands.
• Fill the battery where clean water is always
available for flushing the skin.
1. Open the hood.
2. Remove the battery cover (Fig. 1).
Warning
Charging the battery produces gasses that can
explode.
Never smoke near the battery and keep sparks and
flames away from battery.
5. When the battery is charged, disconnect the charger
from the electrical outlet and battery posts.
6. Remove the filler caps. Slowly add electrolyte to each
cell until the level is up to the fill ring. Install the filler
caps.
Important Do not overfill the battery. Electrolyte will
overflow onto other parts of the machine and severe
corrosion and deterioration will result.
7. Install the positive cable (red) to the positive (+)
terminal and the negative cable (black) to the negative
(–) terminal of the battery and secure them with
capscrews and nuts (Fig. 2). Make sure that the positive
(+) terminal is all of the way onto the post and the cable
is positioned snug to the battery. The cable must not
contact the battery cover. Slide the rubber boot over the
positive terminal to prevent a possible short from
occurring.
Warning
Incorrect battery cable routing could damage the
tractor and cables causing sparks. Sparks can
cause the battery gasses to explode, resulting in
personal injury.
• Always disconnect the negative (black) battery
cable before disconnecting the positive (red)
cable.
• Always connect the positive (red) battery cable
before connecting the negative (black) cable.
1
Figure 1
1. Battery cover
3. Remove the filler caps from the battery and slowly fill
each cell until electrolyte is just above the plates.
4. Install the filler caps and connect a 3 to 4 amp. battery
charger to the battery posts. Charge the battery at a rate
of 3 to 4 amperes for 4 to 8 hours.
2
1. Positive (+) battery cable 2. Negative (–) battery cable
13
1
Figure 2
Page 14
Important If the battery is ever removed, make sure
that battery clamp bolts are reinstalled with the bolt heads
positioned on the bottom side and the nuts on the top side.
If the clamp bolts are reversed, they may interfere with the
hydraulic tubes when shifting the cutting units.
8. Coat both battery connections with Grafo 112X (skin
over) grease, Toro Part No. 505-47, petroleum jelly, or
light grease to prevent corrosion. Slide the rubber boot
over the positive terminal.
9. Install the battery cover.
1
2
3
Installing the Seat
The machine is shipped without the seat assembly. Deluxe
Seat Kit, Model No. 03225 or Standard Seat Kit, Model
No. 03224, must be installed as follows:
1. Remove the screws, washers, and spacers securing the
seat mounting straps to the traction unit frame (Fig. 3).
2
Figure 3
1. Seat mounting strap (2) 2. Spacer (2)
2. Secure the seat mounting straps to the seat adjusters
with 4 flange nuts (standard seat) or 4 bolts, flat
washers, and flange nuts (deluxe seat) (Fig. 4). The
mounting fasteners are supplied with the seat kits.
3. Attach the seat belt to the holes on each side of the seat
with 2 bolts and lockwashers (standard seat) or 2 bolts
and locknuts (deluxe seat) (Fig. 4). All mounting
fasteners are supplied with the seat kits.
1
Figure 4
1. Standard seat
2. Seat adjusters
3. Seat belt
6. On the deluxe seat only, route the unused seat switch
connector back under the seat strap and secure both
wires to the rear-most hole in the seat strap (Fig. 5) with
a cable tie (cable tie supplied with seat kit).
1
2
Figure 5
1. Seat switch wire 2. Cable tie
7. On the standard seat only, slide the seat all of the way
forward, pull the wire to the right so that the unused
connector is positioned as shown in Figure 6, and
secure the seat switch wire to the rear-most hole in the
seat strap with a cable tie (cable tie supplied with seat
kit).
4. Position the seat and seat straps on the frame aligning
mounting holes.
5. Route the seat switch wire under the right-hand seat
strap and connect it to the appropriate seat switch
connector on the wire harness.
1
Figure 6
1. Seat switch wire 2. Cable tie
14
2
Page 15
8. Mount the seat straps to the frame with the fasteners
and spacers removed in step 1.
9. Slide the seat completely forward and backward to
ensure proper operation and that the seat switch wires
and connectors are not pinched or do no contact any
moving parts.
4. Insert a bolt (1/4 x 1-1/2 in.) through the hood lock
bracket and secure it with a flat washer and locknut
(Fig. 8).
2
3
Checking the Angle Indicator
Danger
To reduce risk of injury or death due to rollover,
do not operate the machine on side hills steeper
than 25.
1. Park the machine on a flat, level surface.
2. Verify that the machine is level by placing a hand held
inclinometer (supplied with the machine) on the frame
cross rail, by the fuel tank (Fig. 7). The inclinometer
should read zero degrees when viewed from the
operator’s position.
1
Figure 8
1. Hood latch
2. Hood latch bracket
3. Hood lock bracket
Installing the Exhaust Guard
(CE)
1. Position the exhaust guard around the muffler while
aligning the mounting holes with the holes in the frame
(Fig. 9).
2. Secure the exhaust guard to the frame with 4
self-tapping screws (Fig. 9).
1
Figure 7
1. Angle indicator
3. If the inclinometer does not read zero degrees, move the
machine to a location where a zero degree reading is
obtained. The angle indicator, mounted on the machine,
should now read zero degrees as well.
4. If the angle indicator does not read zero degrees, loosen
the two screws and nuts securing the angle indicator to
the mounting bracket, adjust the indicator to obtain a
zero degree reading, and tighten the capscrews.
Installing the Hood Latch (CE)
1. Unhook the hood latch from the hood latch bracket
(Fig. 8).
2. Slide the hood lock bracket onto the latch (Fig. 8).
3. Hook the latch onto the hood latch bracket (Fig. 8).
1
Figure 9
1. Exhaust guard
15
Page 16
Adjusting the Lift Arms
1. Start the engine, raise the decks, and check to make sure
that the clearance between each lift arm and the floor
plate bracket is .18–.32 in. (5–8 mm) (Fig. 10). If the
clearance is not in this range, back off the stop bolts
(Fig. 11) and adjust the cylinder to attain clearance. To
adjust the cylinder, back off the jam nut on the cylinder
(Fig. 12), remove the pin from the rod end, and rotate
the clevis. Install the pin and check the clearance.
Repeat the procedure if required. Tighten the clevis jam
nut.
2
3
1
Figure 10
Decks removed for clarity
1. Lift arm
2. Floor plate bracket
3. Clearance
2
1
Figure 12
1. Front cylinder 2. Jam nut
3. Start the engine, raise the decks, and check to make sure
that the clearance between the wear strap on the top of
the rear cutting unit wear bar and the bumper strap is
0.02–0.10 in. (0.51–2.54 mm) (Fig. 13). If the clearance
is not in this range, adjust the rear cylinder to attain
clearance. To adjust the cylinder, lower the cutting units
and back off the jam nut on the cylinder (Fig. 14).
Grasp the cylinder rod close to the nut with a pliers and
rag and rotate the rod. Raise the cutting units and check
the clearance. Repeat the procedure if required. Tighten
the clevis jam nut.
Note: If the rear lift arm “clunks” during transport,
clearance can be reduced.
2. Check to make sure that the clearance between each lift
arm and stop bolt is 0.005–0.040 in. (0.13–1.02 mm)
(Fig. 11). If the clearance is not in this range, adjust the
stop bolts to attain clearance.
1
3
2
Figure 11
1. Stop bolt
2. Lift arm
3. Clearance
2
1
Figure 13
1. Wear bar 2. Bumper strap
2
1
Figure 14
1. Rear cylinder 2. Adjusting nut
Important Lack of clearance at the front stops or rear
wear bar could damage the lift arms.
16
Page 17
Rear Ballast
The Groundsmaster 3500 Traction unit with 27” Rotary
Cutting decks conforms to the B71.4-1999 standard when
50 lb. of calcium chloride ballast is added to the rear
wheels.
Important If a puncture occurs in a tire with calcium
chloride, remove the machine from the turf as quickly as
possible. To prevent possible damage to the turf,
immediately soak the affected area with water.
1
Figure 15
1. Dipstick
Before Operating
Caution
If you leave the key in the ignition switch, someone
could accidently start the engine and seriously
injure you or other bystanders.
Remove the key from the ignition before you do
any maintenance.
Checking the Crankcase Oil
The engine is shipped with oil in the crankcase; however,
the oil level must be checked before and after the engine is
first started.
Crankcase capacity is approximately 4 qt. (2.8 l) with the
filter.
Use high-quality engine oil that meets the following
specifications:
API Classification Level Required: CH–4, CI–4 or
higher.
3. If the oil level is low, remove the oil fill cap (Fig. 16)
and gradually add small quantities of oil, checking the
level frequently, until the level reaches the FULL mark
on the dipstick.
1
Figure 16
1. Oil fill cap
4. Install the oil fill cap and close the hood.
Important Check the oil level every 5 operating hours
or daily. Change the oil and filter initially after the first 50
hours of operation; thereafter change the oil and filter every
150 hours.
Preferred oil: SAE 15W–40 (above 0F)
Alternate oil: SAE 10W–30 or 5W–30
(all temperatures)
Toro Premium Engine oil is available from your distributor
in either 15W–40 or 10W–30 viscosity. See the parts
catalog for part numbers.
1. Position the machine on a level surface.
2. Remove the dipstick (Fig. 15) and wipe it with a clean
rag. Push the dipstick down into the dipstick tube and
make sure that it is seated fully. Pull the dipstick out
and check the oil level. If the oil level is low, add
enough oil to raise the level to the FULL mark on the
dipstick.
Filling the Fuel Tank
The engine runs on No. 2 diesel fuel.
Fuel tank capacity is approximately 11 gallons.
1. Clean the area around the fuel tank cap (Fig. 17).
17
Page 18
1
1. Fuel tank cap
2
3
Figure 17
1
2. Remove the fuel tank cap.
3. Fill the tank to the bottom of the filler neck. Do not
overfill. Install the cap.
4. To prevent a fire hazard, wipe up any fuel that may
have spilled.
Danger
Under certain conditions, diesel fuel and fuel
vapors are highly flammable and explosive. A fire
or explosion from fuel can burn you and others
and can cause property damage.
• Use a funnel and fill the fuel tank outdoors, in
an open area, when the engine is off and is cold.
Wipe up any fuel that spills.
• Do not fill the fuel tank completely full. Add fuel
to the fuel tank until the level is 1/4 to 1/2 in. (6
to 13 mm) below the bottom of the filler neck.
This empty space in the tank allows the fuel to
expand.
• Never smoke when handling fuel, and stay away
from an open flame or where fuel fumes may be
ignited by a spark.
• Store fuel in a clean, safety-approved container
and keep the cap in place.
Figure 18
1. Access panel
2. Radiator
The cooling system is filled with a 50/50 solution of water
and permanent ethylene glycol anti-freeze. Check the
coolant level at the beginning of each day before starting
the engine.
The capacity of the cooling system is approximately 6 U.S.
quarts (5.7 l).
3. Oil cooler
Caution
If the engine has been running, the pressurized,
hot coolant can escape and cause burns.
• Do not open the radiator cap when the engine is
running.
• Use a rag when opening the radiator cap, and
open the cap slowly to allow steam to escape.
1. Check the coolant level in the expansion tank (Fig. 19).
With a cold engine, the coolant level should be
approximately midway between the marks on the side
of the tank.
Checking the Cooling System
Clean debris off of the radiator and oil cooler daily
(Fig. 18). Clean the radiator hourly if conditions are
extremely dusty and dirty; refer to Cleaning the Engine
Cooling System, page 38.
2. If the coolant level is low, remove the expansion tank
cap and replenish the system. Do not overfill.
3. Install the expansion tank cap.
18
Page 19
1
1. Expansion tank
Figure 19
Biodegradable Hydraulic Fluid – Mobil 224H
Toro Biodegradable Hydraulic Fluid
(Available in 5 gallon pails or 55 gallon drums. See
parts catalog or Toro distributor for part numbers.)
Alternate fluid: Mobil EAL 224H
This is vegetable–oil based biodegradable oil tested and
approved by Toro for this model. This fluid is not as
resistant to to high temperatures as standard fluid, so install
an oil cooler if required by the operator manual and follow
recommended fluid change intervals with this fluid.
Contamination by mineral–based hydraulic fluids will
change the biodegradability and toxicity of this oil. When
changing from standard fluid to the biodegradable type, be
certain to follow the approved flushing procedure. Contact
your local Toro Distributor for details.
1. Position the machine on a level surface, lower the
cutting units, and stop the engine.
Checking the Hydraulic System
The machines reservoir is filled at the factory with
approximately 3.5 U.S. gallons (13.2 l) of high quality
hydraulic fluid. Check the level of the hydraulic fluid
before the engine is first started and daily thereafter.
The recommended replacement fluid is:
Toro Premium All Season Hydraulic Fluid
(Available in 5 gallon pails or 55 gallon drums. See
parts catalog or Toro distributor for part numbers.)
Alternate fluids: If the Toro fluid is not available, other
fluids may be used provided they meet all the following
material properties and industry specifications. We do not
recommend the use of synthetic fluid. Consult with your
lubricant distributor to identify a satisfactory product Note:
Toro will not assume responsibility for damage caused by
improper substitutions, so use only products from reputable
manufacturers who will stand behind their
recommendation.
High Viscosity Index/Low Pour Point Antiwear
Hydraulic Fluid, ISO VG 46
Material Properties:
Viscosity, ASTM D445 cSt @ 40C 44 to 48
cSt @ 100C 7.9 to 8.5
Viscosity Index ASTM D2270 140 to 160
2. Clean the area around the filler neck and cap of the
hydraulic tank (Fig. 20). Remove the cap.
1
Figure 20
1. Hydraulic tank cap
3. Remove the dipstick from the filler neck and wipe it
with a clean rag. Insert the dipstick into the filler neck;
then remove it and check the fluid level. The fluid level
should be within 1/4 inch (6 mm) of the mark on the
dipstick.
4. If the level is low, add the appropriate fluid to raise the
level to the full mark.
5. Install the dipstick and cap onto the filler neck.
Pour Point, ASTM D97 –34F to –49F
Industry Specifications:
Vickers I–286–S (Quality Level), Vickers M–2950–S
(Quality Level), Denison HF–0
Note: Many hydraulic fluids are almost colorless, making it
difficult to spot leaks. A red dye additive for the hydraulic
system oil is available in 2/3 oz. (20 ml) bottles. One bottle
is sufficient for 4–6 gal (15–22 1) of hydraulic oil. Order
part no.44–2500 from your authorized Toro distributor.
Checking the Tire Pressure
The tires are over-inflated for shipping. Therefore, release
some of the air to reduce the pressure. The correct air
pressure in the tires is 14–18 psi (97–124 kPa).
Important Maintain the recommended pressure in all
tires to ensure a good quality of cut and proper machine
performance.
19
Page 20
Danger
Low tire pressure decreases machine side hill
stability. This could cause a rollover, which may
result in personal injury or death.
Do not under-inflate the tires.
Checking the Torque of the
Wheel Nuts
Warning
Failure to maintain proper torque of the wheel
nuts could result in personal injury.
Torque the wheel nuts to 45–65 ft.-lb. (61–88 Nm)
after 1–4 hours of operation and again after 10
hours of operation. Torque every 200 hours
thereafter.
20
Page 21
Operation
Note: Determine the left and right sides of the machine
from the normal operating position.
Caution
This machine produces sound levels in excess of
85 dBA at the operators ear and can cause hearing
loss through extended periods of exposure.
Wear hearing protection when operating this
machine.
Controls
Traction Pedals
Depress the traction forward pedal (Fig. 21) to move
forward. Depress traction reverse pedal (Fig. 21) to move
backward or to assist in stopping when moving forward.
Also, allow the pedal to move or move it to the neutral
position to stop the machine.
Mow/Transport Slide
Using your heel, move the mow/transport slide (Fig. 21) to
the left to transport and to the right to mow. The cutting
units will only operate in the mow position.
Note: Mow speed is set at the factory to 6 MPH (9.7 km/h).
It can be increased or decreased by adjusting the speed stop
screw (Fig. 22).
4
6
5
3
2
1
1
Figure 22
1. Speed stop screw
Tilt Steering Lever
Pull the tilt steering lever (Fig. 21) back to tilt the steering
wheel to the desired position. Then push the lever forward
to tighten.
Indicator Slot
The slot in the operator platform (Fig. 21) indicates when
the cutting units are in the center position.
Angle Indicator
The angle indicator (Fig. 21) indicates the side hill angle of
the machine in degrees.
Ignition Switch
The ignition switch (Fig. 23), used to start, stop and preheat
the engine, has three positions: Off, On/Preheat, and Start.
Rotate the key to the On/Preheat position until the glow
plug indicator light goes out (approximately 7 seconds);
then rotate the key to the Start position to engage the starter
motor. Release the key when the engine starts. The key will
move automatically to the On/Run position. To shut the
engine off, rotate the key to the Off position. Remove the
key from the switch to prevent accidental starting.
1. Forward traction pedal
2. Reverse traction pedal
3. Mow/transport slide
Figure 21
4. Tilt steering lever
5. Indicator slot
6. Angle indicator
Throttle
Moving the throttle (Fig. 23) forward increases the engine
speed; rearward decreases the engine speed.
Cutting Unit Drive Switch
The cutting unit drive switch (Fig. 23) has two positions:
Engage and Disengage. The rocker switch operates a
solenoid valve on the valve bank to drive the cutting units.
21
Page 22
7
34
2
Danger
8
6
5
10
11
1. Throttle
2. Hour meter
3. Temperature light
4. Oil pressure light
5. Glow plug indicator light
6. Alternator light
9
Figure 23
7. Cutting unit drive switch
8. Cutting unit shift lever
9. Ignition switch
10. Parking brake
11. Lift lever lock
1
Hour Meter
The hour meter (Fig. 23) indicates the total hours of
machine operation. The hour meter starts to function
whenever the key switch is On.
Shifting the cutting units downhill decreases
machine stability. This could cause a rollover,
which may result in personal injury or death.
Shift the cutting units uphill while on a side hill.
Engine Coolant Temperature Warning
Light
The temperature warning light (Fig. 23) glows if the engine
coolant temperature is high. If the traction unit is not
stopped and the coolant temperature rises another 10°F, the
engine will kill.
Oil Pressure Warning Light
The oil pressure warning light (Fig. 23) glows if the engine
oil pressure drops below a safe level.
Alternator Light
The alternator light (Fig. 23) should be off when the engine
is running. If it is on, the charging system should be
checked and repaired as necessary.
Cutting Unit Shift Lever
To lower the cutting units to the ground, move the cutting
unit shift lever (Fig. 23) forward. The cutting units will not
drop unless the engine is running. To raise the cutting units,
pull the shift lever rearward to the Raise position.
Move the lever to the right or left to move the cutting units
in the same direction. This should only be done when the
cutting units are raised or if they are on the ground and the
machine is moving.
Note: The lever does not have to be held in the forward
position while the cutting units are lowered.
Glow Plug Indicator
The glow plug indicator light (Fig. 23) will glow when the
glow plugs are operating.
Parking Brake
Whenever the engine is shut off, the parking brake (Fig. 23)
must be engaged to prevent accidental movement of the
machine. To engage the parking brake, pull up on the lever.
The engine will stop if the traction pedal is depressed with
the parking brake engaged.
Lift Lever Lock
Move the lift lever lock (Fig. 23) rearward to prevent the
cutting units from dropping.
22
Page 23
Fuel Gauge
The fuel gauge (Fig. 24) registers the amount of fuel in the
tank.
Important To prevent overheating of the starter motor,
do not engage the starter longer than 15 seconds. After 10
seconds of continuous cranking, wait 60 seconds before
engaging the starter motor again.
Seat Adjustments
Fore and Aft Adjustment (Fig. 24)—Move the lever on the
side of the seat outward, slide the seat to the desired
position, and release the lever to lock the seat into position.
2
1
Figure 24
1. Fore and aft lever 2. Fuel gauge
5. When the engine is started for the first time, or after an
overhaul of the engine, operate the machine in forward
and reverse for one to two minutes. Also operate the lift
lever and deck drive switch to be sure of proper
operation of all parts.
Turn the steering wheel to the left and right to check
steering response; then shut the engine off and check for oil
leaks, loose parts, and any other noticeable malfunctions.
Caution
Shut the engine off and wait for all moving parts to
stop before checking for oil leaks, loose parts, and
other malfunctions.
6. To stop the engine, move the throttle control to the Idle
position, move the deck drive switch to Disengage, and
rotate the starter key to Off. Remove the key from the
switch to prevent accidental starting.
Bleeding the Fuel System
1. Park the machine on a level surface. Make sure that the
fuel tank is at least half full.
Starting and Stopping the
Engine
Important The fuel system may have to be bled if any
of the following situations have occurred:
• Initial start up of a new engine
• The engine has ceased running due to lack of fuel.
• Maintenance has been performed upon the fuel system
components; i.e. filter replaced, etc.
Refer to Bleeding the Fuel System, page 23.
1. Be sure that the parking brake is set and the deck drive
switch is in the Disengage position.
2. Remove your foot from the traction pedal and make
sure that the pedal is in the neutral position.
3. Move the throttle lever to the 1/2 throttle position.
4. Insert the key into the switch and rotate it to the
On/Preheat position until the glow plug indicator light
goes out (approximately 7 seconds); then rotate the key
to the Start position to engage the starter motor. Release
the key when the engine starts. The key will move
automatically to the On/Run position.
2. Unlatch and raise the hood.
Danger
Under certain conditions, diesel fuel and fuel
vapors are highly flammable and explosive. A fire
or explosion from fuel can burn you and others
and can cause property damage.
• Use a funnel and fill the fuel tank outdoors, in
an open area, when the engine is off and is cold.
Wipe up any fuel that spills.
• Do not fill the fuel tank completely full. Add fuel
to the fuel tank until the level is 1/4 to 1/2 in. (6
to 13 mm) below the bottom of the filler neck.
This empty space in the tank allows the fuel to
expand.
• Never smoke when handling fuel, and stay away
from an open flame or where fuel fumes may be
ignited by a spark.
• Store fuel in a clean, safety-approved container
and keep the cap in place.
3. Open the air bleed screw on the fuel injection pump
(Fig. 25).
23
Page 24
seat and slowly depress the traction pedal, the engine
should stop in one to three seconds. Correct problem if
it is not operating properly.
1
Figure 25
1. Fuel injection pump bleed screw
4. Turn the key in the ignition switch to the On position.
The electric fuel pump will begin operation, thereby
forcing air out around the air bleed screw. Leave the key
in the On position until a solid stream of fuel flows out
around the screw. Tighten the screw and turn the key to
Off.
Note: Normally the engine should start after the above
bleeding procedures are followed. However, if the engine
does not start, air may be trapped between the injection
pump and injectors; refer to Bleeding Air from the
Injectors, page 38.
Note: The machine is equipped with an interlock switch on
the parking brake. The engine will stop if the traction pedal
is depressed with the parking brake engaged.
Towing the Traction Unit
In case of an emergency, the machine can be towed for a
short distance; however, we do not recommend this as a
standard procedure.
Important Do not tow the machine faster than
2–3 MPH (3–4 km/h) because the drive system may
become damaged. If the machine must be moved a
considerable distance, transport it on a truck or trailer.
1. Locate the bypass valve on the pump (Fig. 26) and
rotate it 90°.
1
Checking the Interlock System
Caution
If safety interlock switches are disconnected or
damaged the machine could operate unexpectedly
causing personal injury.
• Do not tamper with the interlock switches.
• Check the operation of the interlock switches
daily and replace any damaged switches before
operating the machine.
• Replace switches every two years regardless of
whether they are operating properly or not.
1. Make sure that all bystanders are away from the area of
operation. Keep hands and feet away from the cutting
units.
2. While sitting on the seat, the engine must not start with
either the deck switch engaged or the traction pedal
engaged. Correct the problem if it is not operating
properly.
3. While sitting on the seat, put the traction pedal in
neutral, the parking brake off, and the deck switch in
the Off position. The engine should start. Rise from the
Figure 26
1. Bypass valve
2. Before starting the engine, close the bypass valve by
rotating it 90° (1/4 turn). Do not start the engine when
the valve is open.
24
Page 25
Standard Control Module
(SCM)
The Standard Control Module is a ”potted” electronic
device produced in a ”one size fits all” configuration. The
module uses solid state and mechanical components to
monitor and control standard electrical features required for
safe product operation.
The module monitors inputs including neutral, parking
brake, PTO, start, backlap, and high temperature. The
module energizes outputs including PTO, Starter, and ETR
(energize to run) solenoid.
The module is divided into inputs and outputs. Inputs and
outputs are identified by green LED indicators mounted on
the printed circuit board.
The start circuit input is energized by 12 VDC. All other
inputs are energized when the circuit is closed to ground.
Each input has a LED that is illuminated when the specific
circuit is energized. Use the input LED’s for switch and
input circuit troubleshooting.
Output circuits are energized by an appropriate set of input
conditions. The three outputs include PTO, ETR, and
START. Output LED’s monitor relay condition indicating
the presence of voltage at one of three specific output
terminals.
Output circuits do not determine output device integrity so
electrical troubleshooting includes output LED inspection
and conventional device and wire harness integrity testing.
Measure disconnected component impedance, impedance
through wire harness (disconnect at SCM), or by
temporarily ”test energizing” the specific component.
The SCM does not connect to an external computer or hand
held device, can not be re–programmed, and does not
record intermittent fault troubleshooting data.
The decal on the SCM only includes symbols. Three LED
output symbols are shown in the output box. All other
LED’s are inputs. The chart below identifies the symbols.
Backlap
Hi Temp
Inputs
Park Brake Off
Here are the logical troubleshooting steps for the SCM
device.
1. Determine the output fault you are trying to resolve
(PTO, START, or ETR).
2. Move key switch to ”ON” and ensure the red ”power”
LED is illuminated.
3. Move all input switches to ensure all LED’s change
state.
In Seat
PTO Switch
Neutral
PTO
Start
ETR
Start
Power
5. If specific output LED is illuminated without
appropriate output function, check output harness,
connections, and component. Repair as required.
6. If specific output LED is not illuminated, check both
fuses.
7. If specific output LED is not illuminated and inputs are
in appropriate condition, install new SCM and
determine if fault disappears.
Outputs
4. Position input devices at appropriate position to achieve
the appropriate output. Use the following logic chart to
determine the appropriate input condition.
25
Page 26
Each row (across) in the logic chart below identifies input and output requirements for each specific product function.
Product functions are listed in the left column. Symbols identify specific circuit condition including: energized to voltage,
closed to ground, and open to ground.
– Indicates a circuit closed to ground. – LED ON
O Indicates a circuit open to ground or de–energized – LED OFF
+ Indicates an energized circuit (clutch coil, solenoid, or start input) LED ON.
” ” A Blank indicates a circuit that is not involved with the logic.
To troubleshoot, turn on the key without starting the engine.
Identify the specific function that does not work and work
across the logic chart. Inspect the condition of each input
LED’s to ensure it matches the logic chart.
If the input LED’s are correct, check the output LED. If the
output LED is illuminated but the device is not energized,
measure available voltage at the output device, continuity
of the disconnected device, and potential voltage on the
ground circuit (floating ground). Repairs will vary
depending on your findings.
26
Page 27
Operating Characteristics
Danger
Practice moving forward and reverse, and starting and
stopping the machine. To stop, take your foot off of the
traction pedal and let it return to neutral or press down on
the reverse pedal to stop. Going down a hill, you may need
to use the reverse pedal to stop.
The mower has a unique traction system that will
allow the machine to move forward on side hills,
even if the uphill wheel should come off of the
ground. If this should happen, the operator or any
bystanders can be seriously injured or killed in a
rollover.
The slope angle at which the machine will tip is
dependent on many factors. Among these are:
mowing conditions such as wet of undulating turf,
speed (especially in turns), position of the cutting
units (with Sidewinder), tire pressure, and
operator experience.
At side hill angles of 20 degrees or less, the risk of a
rollover is low. As the slope angle increases to a
recommended maximum limit of 25 degrees, the
risk of a rollover increases to a moderate level. Do
not exceed a 25 degree side hill slope angle because
the risk of a rollover and serious injury or death is
very high.
To determine which hills or slopes may be safely
operated on, a site survey of the mowing area must
be done. When performing this site survey, always
use common sense and take into consideration the
turf condition and the rollover risk. To determine
which hills or slopes may be safely operated on, use
the inclinometer provided with each machine. To
perform a site survey, lay a 4 ft. 2x4 (1.25 meter
plank) on the slope surface and measure the angle
of the slope. The 2x4 will average the slope but will
not take into consideration dips or holes which can
cause a sudden change in side hill angle. The
maximum side hill angle should not be greater than
25 degrees.
Additionally, the machine is equipped with an
angle indicator mounted on the steering tube. This
indicates the side hill angle the machine is on and
identifies the recommended maximum limit of 25
degrees.
Always wear your seat belt.
Practice operating the machine and become thoroughly
familiar with it.
Start the engine and run it at half idle until it warms up.
Push the throttle lever all the way forward, lift the cutting
units, disengage the parking brake, press the forward
traction pedal, and carefully drive to an open area.
When driving on slopes, drive slowly to maintain steering
control and avoid turns to prevent rollovers. In side hill
situations you should shift the sidewinder cutting units
to the uphill side to give you more stability. Conversely,
shifting the cutting units to the down hill side will give
you less stability. This should always be done before
going on a side hill.
When possible, mow up and down hills rather than across
them. Have the cutting units lowered when going down a
hill to maintain steering control. Do not attempt to turn on a
hill.
Practice driving around obstacles with the decks up and
down. Be careful when driving between narrow objects so
you do not damage the machine or cutting units.
On the Sidewinder unit, get a feel for the reach of the
cutting units so you do not hang them up or damage them
in any way.
Do not shift the units from side to side, unless the cutting
units are down and the machine is moving, or the cutting
units are up in the transport position. Shifting the cutting
units when they are down and the machine is not moving
may cause turf damage.
Always drive slowly in rough areas.
If a person appears in or near the operating area, stop the
machine, and do not start it again until the area is cleared.
The machine is designed for one person. Never let anyone
else ride on the machine with you. This is extremely
dangerous and could result in serious injury.
Accidents can happen to anyone. The most common causes
are excessive speed, sudden turns, terrain (not knowing
which slopes and hills can be mowed safely), not stopping
the engine before leaving the operator’s seat, and drugs
which impair your alertness. Cold capsules or prescription
drugs may cause drowsiness, as can alcohol and other
drugs. Stay alert and stay safe. Failure to do so could result
in serious injury.
The Sidewinder offers up to a maximum of 13 inches
(33 cm) of overhang, allowing you to trim closer to the
edge of sand traps and other obstacles, while at the same
time keeping the tractor tires as far away from the edge of
traps or water hazards as possible.
If an obstacle is in the way, shift the cutting units to easily
mow around it.
When transporting the machine from one work area to
another, raise the cutting units to the fully up position,
move the mow/transport slide to the left to transport, and
place the throttle in the Fast position.
27
Page 28
Mowing Techniques
To begin cutting, engage the decks, then approach the
mowing area slowly. Once the front decks are over the
mowing area, lower the cutting units.
To achieve the professional straight-line cut and striping
that is desirable for some applications, find a tree or other
object in the distance and drive straight toward it.
As soon as the front decks reach the edge of the mowing
area, lift the cutting units and perform a tear drop shaped
turn to quickly line you up for your next pass.
• Requires more horsepower to run.
• Tends to discharge further left and can tend to
windrow at lower heights of cut.
Warning
Do not use the high lift blade with the mulching
baffle. The blade could break, resulting in personal
injury or death.
To mow around bunkers, ponds, or other contours easily,
use the Sidewinder and move the control lever left or right,
depending on your mowing application. The cutting units
can also be shifted to vary tire tracking.
The decks tend to throw grass to the left side of the
machine. If trimming around bunkers, it is best to mow in a
clockwise direction to prevent throwing clippings into the
bunker.
The cutting decks can be equipped with bolt-in mulching
baffles. The mulching baffles perform well when turf is
maintained on a regular schedule to avoid removing more
than 1 inch (25 mm) of growth per cutting. When too much
growth is cut with the mulching baffles installed, after-cut
appearance may deteriorate and the observed power to cut
the turf increases. The mulching baffles also perform well
for shredding leaves in the fall of the year.
Blade Selection
Standard Angled Sail
The blade generally performs best in lower heights of cut
(3/4 to 2–1/2 inch). The optional high lift parallel sail blade
performs better in the higher heights of cut (2 to 4 inch).
Attributes:
• Discharge remains more even at lower heights of
cut.
• Discharge has less tendency to throw left and thus a
cleaner look around bunkers and fairways.
• Lower power requirement at lower heights and
dense turf.
High Lift Parallel Sail
The blade generally performs better in the higher heights of
cut (2 to 4 inch).
Attributes:
• More lift and higher discharge velocity.
• Sparse or limp turf is picked up significantly at
higher heights of cut.
• Wet or sticky clippings are discharged more
efficiently reducing congestion in deck.
Mow When Grass is Dry
Mow either in the late morning to avoid the dew, which
causes grass clumping, or in late afternoon to avoid the
damage that can be caused by direct sunlight on the
sensitive, freshly mowed grass.
Select the Proper Height-of-Cut Setting to
Suit Conditions
Remove approximately one inch or no more than 1/3 of the
grass blade when cutting. In exceptionally lush and dense
grass you may have to raise your height–of–cut setting
another notch.
Always Start Mowing with Sharp Blades
A sharp blade cuts cleanly and without tearing or shredding
the grass blades like a dull blade. Tearing and shredding
causes the grass to turn brown at the edges which impairs
growth and increases susceptibility to diseases. Make sure
blade is in good condition and a full sail is present.
Check Condition of Deck
Make sure cutting chambers are in good condition.
Straighten any bends in chamber components to assure
correct blade tip/chamber clearance.
After Mowing
At the completion of mowing operation, thoroughly wash
the machine with a garden hose without a nozzle so that
excessive water pressure will not cause contamination and
damage to the seals and bearings. Make sure that the
radiator and oil cooler are kept free of dirt or grass
clippings. After cleaning, it is recommended that the
machine be inspected for possible hydraulic fluid leaks,
damage or wear to the hydraulic and mechanical
components, and the cutting unit blades checked for
sharpness.
Important After washing the machine, move the
Sidewinder mechanism from left to right several times to
remove water between the bearing blocks and cross tube.
28
Page 29
Grass Cutting: .75
o
is removed.
to 1.75 inch Height
of Cut
ion
Grass Cutting: 2.00
to 2.50 inch Height
Applicati
Pros
Cons
of Cut
Grass Cutting: 2.75
to 4.00 inch Height
of Cut
Leaf Mulching
Optional Equipment Configuration
Standard Angle Sail
Blade
Recommended in
most applications
Recommended for
thick or lush turf
May work well in
lush turf
Recommended for
use with the
mulching baffle
Even discharge at
lower height of cut
Cleaner look around
bunkers and fairways
Lower power
requirements
Does not lift the grass
well in high height of
cut applications
Wet or sticky grass
has a tendency to
build up in the chamber, leading to poor
quality of cut and
higher power requirement
High Lift Parallel
Sail Blade
DO NOT USE
WITH MULCHING
BAFFLE
May work well in
light or sparse turf
Recommended for
light or sparse turf
Recommended in
most applications
NOT ALLOWED
More lift and higher
discharge velocity
Sparse or limp turf is
picked up at high
height of cut
Wet or sticky
clippings are
discharged
efficiently
Requires more power
to run in some applications
Tends to windrow at
lower height of cut in
lush grass
DO NOT USE
WITH MULCHING
BAFFLE
Mulching Baffle Roller Scraper
Has been shown to
improve dispersion
and after cut perfor-
mance on northern
grasses that are cut at
least three times per
week and less than
1/3 of the grass blade
is removed.
DO NOT USE
WITH THE HIGH
LIFT PARALLEL
SAIL BLADE
Use with standard
angle sail blade only
May improve dispersion and appearance
in certain grass
cutting applications
Very good for leaf
mulching
Grass will build up in
the chamber if
attempting to remove
too much grass with
baffle in place
Can be used any time
that rollers build up
with grass or large
flat grass clumps of
grass are seen. The
scrapers may actually
increase clumping in
certain applications.
Reduces roller
buildup in certain
applications
29
Page 30
Maintenance
Note: Determine the left and right sides of the machine from the normal operating position.
Recommended Maintenance Schedule
Maintenance Service
Interval
After first 10 hours
After first 50 hours
Every 50 hours
Every 150 hours
Every 200 hours
Every 400 hours
Maintenance Procedure
• Check the fan and alternator belt tension.
• Replace the hydraulic filter.
• Torque the wheel lug nuts.
• Change the engine oil and filter.
• Check the engine RPM (at idle and full throttle).
• Inspect the air filter, dust cup, and burp valve.
• Lubricate all grease fittings.
• Check the battery cable connections.
• Check the fan and alternator belt tension.
• Check the battery fluid level.
• Change the engine oil and filter.
• Inspect the traction belt.
• Replace the air filter.
• Replace the hydraulic filter.
• Torque the wheel lug nuts.
• Replace the hydraulic fluid.
• Replace the fuel/water separator filter.
• Replace the fuel prefilter.
• Inspect the traction cable movement.
• Check the engine RPM (at idle and full throttle).
Every 800 hours or
annually, whichever
occurs first
Every 1000 hours or 2
years, whichever occurs
first
Important Refer to your engine operator’s manual and cutting unit operator’s manual for additional maintenance
procedures.
• Adjust the valves.
• Inspect, disassemble and install new seals in cutting unit roller assemblies.
• Replace all moving hoses.
• Replace the safety switches.
• Flush the cooling system and replace the fluid.
• Drain and flush the fuel tank.
• Drain and flush the hydraulic tank.
Caution
If you leave the key in the ignition switch, someone could accidently start the engine and
seriously injure you or other bystanders.
Remove the key from the ignition before you do any maintenance.
30
Page 31
Daily Maintenance Checklist
Duplicate this page for routine use.
For the week of:
Maintenance Check Item
Check the safety interlock operation.
Check brake operation.
Check the engine oil level.
Check the cooling system fluid level.
Drain the water/fuel separator.
Check the air filter, dust cup, and burp
valve.
Check the radiator and screen for
debris.
Check for unusual engine noises.
1
Check for unusual operating noises.
Check the hydraulic system oil level.
Check the hydraulic hoses for damage.
Check for fluid leaks.
Check the fuel level.
Check the tire pressure.
Check instrument operation.
Mon. Tues. Wed. Thurs. Fri. Sat. Sun.
Check the height-of-cut adjustment.
Lubricate all grease fittings.
2
Touch up damaged paint.
1
Check the glow plug and injector nozzles if starting is hard, there is excess smoke, or rough running is noted.
2
Immediately after every washing, regardless of the interval listed
Notation for Areas of Concern
Inspection performed by:
Item Date Information
1
2
3
4
5
6
7
8
9
10
31
Page 32
Greasing the Bearings and
Bushings
The traction unit has grease fittings that must be lubricated
regularly with No. 2 General Purpose Lithium Base Grease.
If the machine is operated under normal conditions,
lubricate the bearings and bushings after every 50 hours of
operation. The bearings and bushings must be lubricated
daily when operating conditions are extremely dusty and
dirty. Dusty and dirty operating conditions could cause dirt
to get into the bearings and bushings, resulting in
accelerated wear. Lubricate bearings and bushings
immediately after every washing, regardless of the interval
listed.
The grease fitting locations and quantities are:
• Rear cutting unit pivot (Fig. 27)
• Front cutting unit pivot (Fig. 28)
• SideWinder cylinder ends (2) (Fig. 29)
• Steering pivot (Fig. 30)
• Rear lift arm pivot and lift cylinder (2) (Fig. 31)
• Left front lift arm pivot and lift cylinder (2) (Fig. 32)
• Right front lift arm pivot and lift cylinder (2) (Fig. 33)
Figure 27
Figure 28
• Neutral adjust mechanism (Fig. 34)
• Mow/transport slide (Fig. 35)
• Belt tension pivot (Fig. 36)
• Steering cylinder (Fig. 37).
Note: If desired, an additional grease fitting may be
installed in the other end of the steering cylinder. Remove
the tire, install the fitting, grease the fitting, remove the
fitting, and install the plug (Fig. 38).
• Cutting unit spindle shaft bearings (1 per cutting unit)
(Fig. 39)
• Rear roller bearings (2 per cutting unit) (Fig. 40)
Note: The flush fittings on the rollers (Fig. 40) require a
grease gun nozzle adapter. Order Toro Part No. 107–1998
from your Authorized Toro Distributor.
Important Do not lubricate the Sidewinder cross tube.
The bearing blocks are self-lubricated.
(2)
Figure 29
32
Page 33
Figure 30
Figure 31
Figure 33
(2)
Figure 34
Figure 32
Figure 35
33
Page 34
Figure 36
Figure 37
Figure 39
Figure 40
Figure 38
See note
34
Page 35
Service Interval Chart
35
Page 36
Removing the Hood
The hood may be easily removed to ease maintenance
procedures in the engine area of the machine.
1. Unlatch and raise the hood.
2. Remove the cotter pin securing the hood pivot to the
mounting brackets (Fig. 41).
1
force dirt through the filter into the intake tract. This
cleaning process prevents debris from migrating into
the intake when the primary filter is removed.
2
1
Figure 42
1. Air cleaner cover 2. Air cleaner latch
Figure 41
1. Cotter pin
3. Slide the hood to the right side, lift the other side, and
pull it out of the brackets.
4. Reverse the procedure to install the hood.
General Air Cleaner
Maintenance
• Check the air cleaner body for damage which could
cause an air leak. Replace if damaged. Check the whole
intake system for leaks, damage or loose hose clamps.
• Service at the recommended service interval or earlier if
engine performance suffers due to extremely dusty,
dirty conditions. Changing the air filter before it is
necessary only increases the chance of dirt entering the
engine when the filter is removed.
• Be sure the cover is seated correctly and seals with the
air cleaner body.
3. Remove and replace the primary filter (Fig. 43).
Cleaning of the used element is not recommended due
to the possibility of damage to the filter media. Inspect
the new filter for shipping damage, checking the sealing
end of the filter and the body. Do not use a damaged
element. Insert the new filter by applying pressure to
the outer rim of the element to seat it in the canister. Do
not apply pressure to the flexible center of the filter.
4. Clean the dirt ejection port located in the removable
cover. Remove the rubber outlet valve from the cover,
clean the cavity and replace the outlet valve.
5. Install the cover orienting the rubber outlet valve in a
downward position – between approximately 5:00 to
7:00 when viewed from the end.
1
Servicing the Air Cleaner
Service the air cleaner filter every 200 hours (more
frequently in extreme dusty or dirty conditions).
1. Release the latches securing the air cleaner cover to the
air cleaner body (Fig. 42).
2. Remove the cover from the air cleaner body. Before
removing the filter, use low pressure air (40 psi, clean
and dry) to help remove large accumulations of debris
packed between outside of primary filter and the
canister. Avoid using high pressure air which could
Figure 43
1. Primary filter
6. Install the cover and secure the latches. Make sure that
the cover is positioned with the TOP side up.
36
Page 37
Servicing the Engine Oil and
Servicing the Fuel System
Filter
Change the oil and filter initially after the first 50 hours of
operation; thereafter change the oil and filter every 150
hours.
1. Remove either drain plug (Fig. 44) and let oil flow into
a drain pan. When the oil stops flowing, install the drain
plug.
1
Fuel Tank
Drain and clean the fuel tank every 2 years. Also, drain and
clean the tank if the fuel system becomes contaminated or
if the machine will be stored for an extended period of
time. Use clean fuel to flush out the tank.
Fuel Lines and Connections
Check the fuel lines and connections every 400 hours or
yearly, whichever comes first. Inspect them for
deterioration, damage, or loose connections.
Water Separator
Drain water or other contaminants from the water separator
(Fig. 46) daily.
1. Place a clean container under the fuel filter.
2. Loosen the drain plug on the bottom of the filter
canister (Fig. 46). Tighten the plug after draining.
Figure 44
1. Engine oil drain plug
2. Remove the oil filter (Fig. 45). Apply a light coat of
clean oil to the new filter seal before screwing it on. Do
not overtighten.
3. Add oil to the crankcase; refer to Checking the
Crankcase Oil, page 17.
1
Figure 45
1. Engine oil filter
1
2
Figure 46
1. Water separator 2. Drain plug
Replace the filter canister after every 400 hours of
operation.
1. Clean the area where the filter canister mounts.
2. Remove the filter canister and clean the mounting
surface.
3. Lubricate the gasket on the filter canister with clean oil.
4. Install the filter canister by hand until the gasket
contacts the mounting surface; then rotate an additional
1/2 turn.
37
Page 38
Replacing the Fuel Prefilter
Replace the fuel prefilter, located on the inside of the frame
rail below the water separator, after every 400 operating
hours or yearly, whichever occurs first.
1. Remove the screw securing the filter to the frame rail.
2. Clamp both fuel lines that connect to the fuel filter so
that fuel cannot drain when the lines are removed.
Danger
Under certain conditions, diesel fuel and fuel
vapors are highly flammable and explosive. A fire
or explosion from fuel can burn you and others
and can cause property damage.
• Use a funnel and fill the fuel tank outdoors, in
an open area, when the engine is off and is cold.
Wipe up any fuel that spills.
• Do not fill the fuel tank completely full. Add fuel
to the fuel tank until the level is 1/4 to 1/2 in. (6
to 13 mm) below the bottom of the filler neck.
This empty space in the tank allows the fuel to
expand.
• Never smoke when handling fuel, and stay away
from an open flame or where fuel fumes may be
ignited by a spark.
• Store fuel in a clean, safety-approved container
and keep the cap in place.
4. Remove the clamp from the fuel filter and slide it onto
the replacement filter. Push the fuel lines onto the
replacement fuel filter and secure them with the hose
clamps. Be sure that the arrow on the side of the filter
points toward the injection pump.
5. Secure the filter to the frame rail with the previously
removed screw.
Bleeding Air from the Injectors
Note: This procedure should be used only if the fuel system
has been purged of air through normal priming procedures
and the engine will not start; refer to Bleeding the Fuel
System, page 23.
1. Loosen the pipe connection to the No. 1 nozzle and
holder assembly.
1
3. Loosen the hose clamps at both ends of the filter
(Fig. 47) and pull the fuel lines off of the filter.
2
1
Figure 47
1. Fuel prefilter 2. Hose clamps
Figure 48
1. Fuel injectors
2. Move the throttle to the Fast position.
2
3. Turn the key in the key switch to the Start position and
watch the fuel flow around the connector. Turn the key
to the Off position when solid flow is observed.
4. Tighten the pipe connector securely.
5. Repeat the procedure on the remaining nozzles.
Cleaning the Engine Cooling
System
Remove debris from the oil cooler and radiator daily. Clean
them more frequently in dirty conditions.
38
Page 39
1. Turn the engine off and raise the hood. Clean the engine
area thoroughly of all debris.
2. Remove the access panel (Fig. 49).
3
2
1
Figure 49
1. Access panel
2. Oil cooler
3. Radiator
Alternator/Fan Belt
1. Open the hood.
2. Check the tension by depressing the belt midway
between the alternator and crankshaft pulleys with
22 lb. (30 N⋅m) of force. The belt should deflect
7/16 in. (11 mm). If the deflection is incorrect, proceed
to step 3. If it is correct, continue operation.
1
Figure 51
1. Alternator/fan belt
3. Unlatch the oil cooler and pivot it rearward (Fig. 50).
Clean both sides of the oil cooler and radiator area
thoroughly with water or compressed air. Pivot the oil
cooler back into position.
Figure 50
4. Install the access panel and close the hood.
Servicing the Engine Belts
3. Loosen the bolt securing the brace to the engine and the
bolt securing the alternator to the brace.
4. Insert a pry bar between the alternator and engine and
pry out on the alternator.
5. When the proper tension is achieved, tighten the
alternator and brace bolts to secure the adjustment.
Replacing the Hydrostat Drive Belt
1. Insert a nut driver or small piece of tubing onto the end
of the belt tensioning spring.
Warning
Use caution when de-tensioning the spring, as it is
under a heavy load.
2. Push down and forward on the spring end (Fig. 52) to
unhook it from the bracket and release tension on the
spring.
3. Replace the belt.
Check condition and tension of all belts after first day of
operation and every 100 operating hours thereafter.
4. Reverse the procedure to tension the spring.
39
Page 40
7. If the throttle does not stay in position during operation,
2
torque the locknut, used to set the friction device on the
throttle lever, to 40–55 in.-lb. (5–6 N⋅m). The maximum
force required to operate the throttle lever should be
20 lb. (27 N⋅m).
1
Figure 52
1. Hydrostat drive belt 2. Spring end
Adjusting the Throttle
1. Position the throttle lever rearward so it stops against
the control panel slot.
2. Loosen the throttle cable connector on the injection
pump lever arm (Fig. 53).
Changing the Hydraulic Fluid
Change the hydraulic fluid after every 400 operating hours,
in normal conditions. If the fluid becomes contaminated,
contact your local Toro distributor because the system must
be flushed. Contaminated fluid looks milky or black when
compared to clean oil.
1. Turn the engine off and raise the hood.
2. Disconnect the hydraulic line (Fig. 54) or remove the
hydraulic filter (Fig. 55) and let the hydraulic fluid flow
into a drain pan. Install the hydraulic line when
hydraulic fluid stops draining.
1
1
Figure 53
1. Injection pump lever arm
3. Hold the injection pump lever arm against the low idle
stop and tighten the cable connector.
4. Loosen the screws securing the throttle control to the
control panel.
5. Push the throttle control lever all of the way forward.
6. Slide the stop plate until it contacts the throttle lever
and tighten the screws securing the throttle control to
the control panel.
Figure 54
1. Hydraulic line
1
Figure 55
1. Hydraulic filter
3. Fill the reservoir (Fig. 56) with approximately 3.5 U.S.
gallons (13.2 l) of hydraulic fluid; refer to Checking the
Hydraulic System, page 19.
40
Page 41
Important Use only the hydraulic fluids specified.
Other fluids could cause system damage.
6. Start the engine and let it run for about two minutes to
purge air from the system. Stop the engine and check
for leaks.
1
Figure 56
1. Hydraulic reservoir
4. Install the reservoir cap. Start the engine and use all of
the hydraulic controls to distribute the hydraulic fluid
throughout the system. Also check for leaks; then stop
the engine.
5. Check the fluid level and add enough to raise the level
to FULL mark on the dipstick. Do not overfill.
Replacing the Hydraulic Filter
The hydraulic system filter must be changed initially, after
the first 10 hours of operation, and thereafter every 200
hours of operation or yearly, whichever comes first. Use a
genuine Toro oil filter for replacement. The hydraulic oil
must be changed every 400 hours of operation or yearly,
whichever comes first.
Use Toro replacement filter Part No. 86-3010.
Important Use of any other filter may void the
warranty on some components.
1. Position the machine on a level surface, lower the
cutting units, stop the engine, engage the parking brake,
and remove the key from the ignition switch.
2. Pinch off the hose to the filter mounting plate.
3. Clean around the filter mounting area. Place a drain pan
under the filter (Fig. 55) and remove the filter.
4. Lubricate the new filter gasket and fill the filter with
hydraulic fluid.
5. Ensure that the filter mounting area is clean. Screw the
filter on until the gasket contacts the mounting plate;
then tighten the filter 1/2 turn.
Checking the Hydraulic Lines
and Hoses
Daily, check hydraulic lines and hoses for leaks, kinked
lines, loose mounting supports, wear, loose fittings, weather
deterioration, and chemical deterioration. Make all
necessary repairs before operating.
Warning
Hydraulic fluid escaping under pressure can
penetrate skin and cause injury.
• Make sure all hydraulic fluid hoses and lines are
in good condition and all hydraulic connections
and fittings are tight before applying pressure to
the hydraulic system.
• Keep your body and hands away from pin hole
leaks or nozzles that eject high pressure
hydraulic fluid.
• Use cardboard or paper to find hydraulic leaks.
• Safely relieve all pressure in the hydraulic
system before performing any work on the
hydraulic system.
• Seek immediate medical attention if fluid is
injected into skin.
Adjusting the Traction Drive for
Neutral
If the machine moves when the traction pedal is in the
neutral position, the traction cam must be adjusted.
1. Park the machine on a level surface and turn the engine
off.
2. Raise one front wheel and one rear wheel off of the
floor and place support blocks under the frame.
Warning
If the machine is not supported adequately, it may
accidentally fall, injuring anyone under the
machine.
One front wheel and one rear wheel must be raised
off of the ground or the machine will move during
adjustment.
41
Page 42
3. Loosen the locknut on the traction adjustment cam
(Fig. 57).
3
1
2
1
2
Figure 57
1. Traction adjustment cam 2. Locknut
Warning
The engine must be running so a final adjustment
of the traction adjustment cam can be performed.
Contact with hot or moving parts can result in
personal injury.
Keep hands, feet, face, and other body parts away
from the muffler, other hot parts of the engine, and
other rotating parts.
4. Start the engine and rotate the cam hex in both
directions to determine the mid position of the neutral
span.
5. Tighten the locknut securing the adjustment.
6. Stop the engine.
7. Remove the support blocks and lower the machine to
the shop floor. Test drive the machine to make sure it
does not move when the traction pedal is in neutral.
Adjusting the Parking Brake
Check the adjustment of the parking brake every 200 hours.
Figure 58
1. Parking brake lever
2. Knob
3. Set screw
Caring for the Battery
The battery electrolyte level must be properly maintained
and the top of the battery kept clean. lf the machine is
stored in a location where temperatures are extremely high,
the battery will run down more rapidly than if the machine
is stored in a location where temperatures are cool.
Check the electrolyte level every 25 operating hours or, if
machine is in storage, every 30 days.
Maintain the cell level with distilled or demineralized
water. Do not fill the cells above the bottom of the split ring
inside each cell. Install the filler caps with the vents
pointing to the rear (toward the fuel tank).
Danger
Battery electrolyte contains sulfuric acid which is a
deadly poison and causes severe burns.
• Do not drink electrolyte and avoid contact with
skin, eyes or clothing. Wear safety glasses to
shield your eyes and rubber gloves to protect
your hands.
• Fill the battery where clean water is always
available for flushing the skin.
1. Loosen the set screw securing the knob to the parking
brake lever (Fig. 58).
2. Rotate the knob until a force of 30–40 lb. (41–68 N⋅m)
is required to actuate the lever.
3. Tighten the set screw after the adjustment has been
attained.
Keep the top of the battery clean by washing it periodically
with a brush dipped in ammonia or bicarbonate of soda
solution. Flush the top surface with water after cleaning.
Do not remove the filler caps while cleaning.
The battery cables must be tight on the terminals to provide
good electrical contact.
42
Page 43
Warning
Incorrect battery cable routing could damage the
tractor and cables causing sparks. Sparks can
cause the battery gasses to explode, resulting in
personal injury.
• Always disconnect the negative (black) battery
cable before disconnecting the positive (red)
cable.
• Always connect the positive (red) battery cable
before connecting the negative (black) cable.
Storing the Battery
If the machine will be stored more than 30 days, remove
the battery and charge it fully. Either store it on the shelf or
on the machine. Leave the cables disconnected if it is stored
on the machine. Store the battery in a cool atmosphere to
avoid quick deterioration of the charge in the battery. To
prevent the battery from freezing, make sure it is fully
charged. The specific gravity of a fully charged battery is
1.265–1.299.
Fuses
If corrosion occurs at the terminals, disconnect the cables,
negative (–) cable first, and scrape the clamps and terminals
separately. Reconnect the cables, positive (+) cable first,
and coat the terminals with petroleum jelly.
Always disconnect the battery cables, ground cable (–)
first, to prevent possible wiring damage from shorts
whenever working with the electrical system.
Warning
CALIFORNIA
Proposition 65 Warning
Battery posts, terminals, and related accessories
contain lead and lead compounds, chemicals
known to the State of California to cause cancer
and reproductive harm. Wash hands after
handling.
The fuses in machines electrical system are located under
console cover.
43
Page 44
Electrical Schematic
44
Page 45
Hydraulic Schematic
45
Page 46
Preparation for Seasonal
Storage
Traction Unit
1. Thoroughly clean the traction unit, cutting units, and
engine.
2. Check the tire pressure. Inflate all tires to 14–18 psi
(97–110 kPa).
3. Check all fasteners for looseness; tighten as necessary.
4. Grease or oil all grease fittings and pivot points. Wipe
up any excess lubricant.
5. Cover the entire length of the Sidewinder cross tube
with a light oil to prevent rust. After storage, wipe off
all of the oil.
6. Lightly sand and use touch-up paint on painted areas
that are scratched, chipped, or rusted. Repair any dents
in the metal body.
7. Service the battery and cables as follows:
A. Remove the battery terminals from the battery posts.
B. Clean the battery, terminals, and posts with a wire
brush and baking soda solution.
Engine
1. Drain the engine oil from the oil pan and replace the
drain plug.
2. Remove and discard the oil filter. Install a new oil filter.
3. Refill the oil pan with approximately 4 U.S. quarts
(3.8 l) of SAE15W-40 motor oil.
4. Start the engine and run it at idle speed for
approximately two minutes.
5. Stop the engine.
6. Thoroughly drain all fuel from the fuel tank, fuel lines,
fuel filter, and water separator assembly.
7. Flush the fuel tank with fresh, clean diesel fuel.
8. Secure all fuel system fittings.
9. Thoroughly clean and service the air cleaner assembly.
10.Seal the air cleaner inlet and the exhaust outlet with
weatherproof tape.
11. Check anti-freeze protection and add as needed for
expected minimum temperature in your area.
C. Coat the cable terminals and battery posts with
Grafo 112X skin-over grease (Toro Part No. 505-47)
or petroleum jelly to prevent corrosion.
D. Slowly recharge the battery every 60 days for 24
hours to prevent lead sulfation of the battery.
46
Page 47
47
Page 48
The Toro General Commercial Products Warranty
A Two-Year Limited Warranty
Conditions and Products Covered
The Toro Company and its affiliate, Toro Warranty Company,
pursuant to an a g r eement between them, jointly warrant your Toro
Commercial Product (“Product”) to be free from defects in
materials or workmanship for two years or 1500 operational
hours*, whichever occurs first. Where a warrantable condition
exists, we will repair the Product at no cost to you including
diagnosis, labor, parts, and transportation. This warranty begins
on the date the Product is delivered to the original retail purchaser.
* Product equipped with hour meter
Instructions for Obtaining Warranty Service
You are responsible for notifying the Commercial Products
Distributor or Authorized Commercial Products Dealer from whom
you purchased the Product as soon as you believe a warrantable
condition exists.
If you need help locating a Commercial Products Distributor or
Authorized Dealer, or if you have questions regarding your
warranty rights or responsibilities, you may contact us at:
Toro Commercial Products Service Department
Toro Warranty Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
952-888-8801 or 800-982-2740
E-mail: commercial.service@toro.com
Owner Responsibilities
As the Product owner, you are responsible for required maintenance and adjustments stated in your operator’s manual. Failure
to perform required maintenance and adjustments can be grounds
for disallowing a warranty claim.
Items and Conditions Not Covered
Not all product failures or malfunctions that occur during the
warranty period are defects in materials or workmanship. This
express warranty does not cover the following:
• Product failures which result from the use of non-Toro
replacement parts, or from installation and use of add-on,
modified, or unapproved accessories
• Product failures which result from failure to perform required
maintenance and/or adjustments
• Product failures which result from operating the Product in an
abusive, negligent or reckless manner
• Parts subject to consumption through use unless found to be
defective. Examples of parts which are consumed, or used up,
during normal Product operation include, but are not limited to,
blades, reels, bedknives, tines, spark plugs, castor wheels,
tires, filters, belts, and certain sprayer components such as
diaphragms, nozzles, and check valves, etc.
• Failures caused by outside influence. Items considered to be
outside influence include, but are not limited to, weather,
storage practices, contamination, use of unapproved coolants,
lubricants, additives, or chemicals, etc.
• Normal “wear and tear” items. Normal “wear and tear” includes,
but is not limited to, damage to seats due to wear or abrasion,
worn painted surfaces, scratched decals or windows, etc.
Parts
Parts scheduled for replacement as required maintenance are
warranted for the period of time up to the scheduled replacement
time for that part.
Parts replaced under this warranty become the property of Toro.
T oro will make the final decision whether to repair any existing part
or assembly or replace it. Toro may use factory remanufactured
parts rather than new parts for some warranty repairs.
General Conditions
Repair by an Authorized Toro Distributor or Dealer is your sole
remedy under this warranty.
Neither The Toro Company nor Toro Warranty Company is
liable for indirect, incidental or consequential damages in
connection with t h e use of the Toro Products covered by this
warranty, including any cost or expense of providing substitute equipment or service during reasonable periods of
malfunction or non-use pending completion of repairs under
this warranty. Except for the Emissions warranty referenced
below, if applicable, there is no other express warranty. All
implied warranties of merchantability and fitness for use are
limited to the duration of this express warranty.
Some states do not allow exclusions of incidental or consequential
damages, or limitations on how long an implied warranty lasts, so
the above exclusions and limitations may not apply to you.
This warranty gives you specific legal rights, and you may also
have other rights which vary from state to state.
Note regarding engine warranty: The Emissions Control System
on your Product may be covered by a separate warranty meeting
requirements established by the U.S. Environmental Protection
Agency (EPA) and/or the California Air Resources Board (CARB).
The hour limitations set forth above do not apply to the Emissions
Control System Warranty. Refer to the Engine Emission Control
Warranty Statement printed in your operator’s manual or contained in the engine manufacturer’s documentation for details.
Countries Other than the United States or Canada
Customers who have purchased Toro products exported from the United States or Canada should contact their Toro Distributor (Dealer)
to obtain guarantee policies for your country, province, or state. If for any reason you are dissatisfied with your Distributor’s service or
have difficulty obtaining guarantee information, contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty
Company.
Part No. 374-0031 Rev. C
Loading...