Toro 39519 Operator's Manual

Download

FormNo.3412-564RevB

30inStand-OnAerator

ModelNo.39519—SerialNo.400000000andUp

Registeratwww.T oro.com. OriginalInstructions(EN)

*3412-564*B

ThissparkignitionsystemcomplieswithCanadian ICES-002

Important:Thisengineisnotequippedwith

asparkarrestermufer.Itisaviolationof CaliforniaPublicResourceCodeSection4442to useoroperatetheengineonanyforest-covered, brush-covered,orgrass-coveredland.Other statesorfederalareasmayhavesimilarlaws.

TheenclosedEngineOwner'sManualis suppliedforinformationregardingtheUS EnvironmentalProtectionAgency(EPA)and theCaliforniaEmissionControlRegulationof emissionsystems,maintenance,andwarranty. Replacementsmaybeorderedthroughtheengine manufacturer.

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

Batteryposts,terminals,andrelated

accessoriescontainleadandlead

compounds,chemicalsknownto

theStateofCaliforniatocause

cancerandreproductiveharm.Wash

handsafterhandling.

Useofthisproductmaycauseexposure

tochemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

Visitwww.Toro.comforproductsafetyandoperation trainingmaterials,accessoryinformation,helpnding adealer,ortoregisteryourproduct.

Wheneveryouneedservice,genuineToroparts,or additionalinformation,contactanAuthorizedService DealerorToroCustomerServiceandhavethemodel andserialnumbersofyourproductready.Figure1 identiesthelocationofthemodelandserialnumbers ontheproduct.Writethenumbersinthespace provided.

g020219

Figure1

1.Locationofthemodelandserialnumbers

ModelNo.

SerialNo.

Thismanualidentiespotentialhazardsandhas safetymessagesidentiedbythesafety-alertsymbol (Figure2),whichsignalsahazardthatmaycause seriousinjuryordeathifyoudonotfollowthe recommendedprecautions.

Introduction

Thisaeratorisintendedtobeusedbytrained operatorsinresidentialandcommercialapplications. Itisprimarilydesignedforaeratingareasof well-maintainedlawnsonresidentialgrounds,parks, sportselds,andcommercialgrounds.Usingthis productforpurposesotherthanitsintendedusecould provedangeroustoyouandbystanders.

Readthisinformationcarefullytolearnhowtooperate andmaintainyourproductproperlyandtoavoid injuryandproductdamage.Youareresponsiblefor operatingtheproductproperlyandsafely .

Figure2

Safety-alertsymbol

Thismanualuses2wordstohighlightinformation. Importantcallsattentiontospecialmechanical informationandNoteemphasizesgeneralinformation worthyofspecialattention.

g000502

Contactusatwww.Toro.com.

PrintedintheUSA

AllRightsReserved

Contents

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

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

AeratorSafety....................................................6

SlopeIndicator...................................................7

SafetyandInstructionalDecals..........................8

Setup......................................................................12

1CheckingTirePressure..................................12

2ServicingtheBattery......................................12

3CheckingFluidLevels....................................13

4RemovingtheCylinderStop...........................14

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

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

Specications..................................................18

Operation................................................................18

CheckingtheEngine-OilLevel..........................18

AddingFuel......................................................19

LubricatingtheChains......................................20

CheckingtheSafety-InterlockSystem..............22

CheckingforLooseHardware...........................22

OperatingtheMachine.....................................22

TransportingtheMachine.................................25

LoadingtheMachine........................................26

Maintenance...........................................................27

RecommendedMaintenanceSchedule(s)...........27

Pre-MaintenanceProcedures..............................28

PreparingfortheMachinefor

Maintenance.................................................28

AccessingtheConsoleCompartment...............28

Lubrication..........................................................29

LubricatingtheGreaseFittings.........................29

LubricatingtheCasters.....................................30

EngineMaintenance...........................................32

ServicingtheAirCleaner..................................32

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

CheckingtheSparkPlugs.................................35

ServicingtheSparkPlug...................................35

CheckingtheSparkArrester(if

equipped)......................................................36

FuelSystemMaintenance...................................36

ServicingtheFuelFilter....................................36

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

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

ServicingtheFuses..........................................39

DriveSystemMaintenance..................................39

CheckingtheAirPressureintheTires...............39

CheckingtheWheelHubNuts..........................39

CheckingtheT orqueoftheWheelLug

Nuts..............................................................39

AdjustingtheCasterPivotBearings

Pre-Load.......................................................40

MaintainingtheChain.......................................40

CheckingtheTransmissionOutputShaftNut

Torque...........................................................41

BrakeMaintenance.............................................42

AdjustingtheParkingBrake..............................42

AdjustingtheBrakeSwitch...............................42

BeltMaintenance................................................43

CheckingtheConditionandTensionofthe

Belts..............................................................43

AdjustingtheAuxiliaryPumpDrive

Belt................................................................43

ReplacingtheTransmission-DriveBelt.............43

ControlsSystemMaintenance.............................44

AdjustingtheTraction-ControlLinkage.............44

HydraulicSystemMaintenance...........................45

MaintainingtheAuxiliaryHydraulic

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

MaintainingtheTransmission...........................47

TineMaintenance.................................................50

CheckingtheTines...........................................50

AdjustingtheTine-DriveChain.........................50

Cleaning..............................................................51

CleaningtheEngineandtheExhaust

SystemArea.................................................51

RemovingtheEngineShroudsandCleaning

theCoolingFins............................................51

CleaningtheDebrisfromtheMachine...............51

WasteDisposal.................................................51

Storage...................................................................52

Troubleshooting......................................................53

Schematics.............................................................55

Safety

Improperuseormaintenancecanresultininjury. Toreducethepotentialforinjury ,complywith thesesafetyinstructions,andpayattentiontothe safety-alertsymbol,whichmeansCaution,Warning, orDanger—personalsafetyinstruction.Failureto complywiththeinstructionsmayresultinpersonal injuryordeath.

WARNING

Removalormodicationoforiginal equipment,partsand/oraccessoriesmay alterthewarranty,controllability,andsafety ofthemachine.Unauthorizedmodications totheoriginalequipmentorfailuretouse originalToropartscouldleadtoserious injuryordeath.Unauthorizedchangestothe machine,engine,fuelorventingsystem,may violateapplicablesafetystandardssuchas: ANSI,OSHAandNFPAand/orgovernment regulationssuchasEPAandCARB.

Replaceallpartsincluding,butnotlimitedto, tires,belts,andfuelsystemcomponentswith originalT oroparts.

Important:Thismachinewasmanufactured

accordingtotheappropriateregulatorystandards ineffectatthetimeofmanufacture.Modifying thismachineinanywaymaycauseittobe outofcompliancewiththosestandardsand withtheinstructionsinthisOperator’sManual. Modicationstothismachineshouldonlybe madebyeitherthemanufactureroranAuthorized ToroDealer.

Thisproductiscapableofinjuringyourhandsand feet.Followallsafetyinstructionstoavoidserious injuryordeath.

Theowner/usercanpreventandisresponsiblefor accidentsorinjuriesoccurringtopeople,ordamage toproperty.

Anyuseofthismachineotherthanaeratingturfgrass couldprovedangeroustotheuserandbystanders.

Important:Theadditionofattachmentsmade

byothermanufacturersthatdonotmeetANSI certicationmaycausenoncomplianceofthis machine.

SafeOperatingPractices

ThefollowinginstructionsarefromANSIstandard B71.4-2012.

Training

•ReadtheOperator'sManualandothertraining

material.

Note:Iftheoperator(s)ormechanic(s)cannot

readthemanuallanguage,itistheowner's responsibilitytoexplainthismaterialtothem.

•Becomefamiliarwiththesafeoperationofthe

equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.

Theownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperateor

servicetheequipment.

Note:Localregulationsmayrestricttheageof

theoperator.

•Theowner/usercanpreventandisresponsible

foraccidentsorinjuriesoccurringtopeopleor damagetoproperty.

Preparation

•Evaluatetheterraintodeterminewhataccessories

andattachmentsareneededtoproperlyand safelyperformthejob.Onlyuseaccessoriesand attachmentsapprovedbythemanufacturer.

•Wearappropriateclothing;includingsafety

glasses,longpants,substantialslip-resistant footwear,gloves,andhearingprotection.

•Tiebacklonghair.Donotwearjewelry.

•Inspecttheareawheretheequipmentistobe

usedandensurethatallobjectsareremovedfrom theareabeforeuse.

•Checkthattheoperator'spresencecontrols,safety

switches,andshieldsareattachedandfunctioning properly.Donotoperatethemachineunlessthey arefunctioningproperly.

Operation

•Lightningcancausesevereinjuryordeath.If

lightningisseen,orthunderisheardinthearea, donotoperatethemachine;seekshelter.

•Donotrunanengineinanenclosedarea.

•Onlyoperateinwell-litareas,keepingawayfrom

holesandhiddenhazards.

•Ensurethatalldrivesareinneutralandthatthe

parkingbrakeisengagedbeforestartingengine. Onlystarttheenginefromtheoperator’sposition.

•Makesurethatyouhavegoodfootingwhileusing

thismachine,especiallywhenbackingup.

Note:Reducedfootingcouldcauseslipping.

•Slowdownanduseextracareonhillsides.Be

suretotravelsidetosideonhillsides.Turf conditionscanaffectthestabilityofthemachine. Usecautionwhileoperatingneardrop-offs.

•Slowdownandusecautionwhenmakingturns

andwhenchangingdirectionsonslopes.

•Donotoperatethemachinewithouttheshields

orotherguardssecurelyinplace.Besureall interlocksareattached,adjustedproperly,and functioningproperly.

•Donotchangetheenginegovernorsettingor

overspeedtheengine.

•Beforeleavingtheoperator’sposition:

–Stoponlevelground.

–Disengagetheparkingbrake(ifprovided).

–Shutofftheengine.

•Stoponlevelground,disengagedrives,engage

theparkingbrake(ifprovided),shutofftheengine beforeleavingtheoperator'spositionforany reason.

•Stopequipmentandinspectthetinesafterstriking

objectsorifanabnormalvibrationoccurs.Make thenecessaryrepairsbeforeresumingoperations.

•Keepyourhandsandfeetawayfromthetine

assembly.

•Lookbehindanddownbeforebackingupto

ensureaclearpath.

•Keeppetsandbystandersawayfromanoperating

machine.

•Slowdownandusecautionwhenmakingturns

andcrossingroadsandsidewalks.Fullyraisethe tinesifyouarenotaerating.

•Donotoperatethemachinewhileill,tired,or

undertheinuenceofalcoholordrugs.

•Usecarewhenapproachingblindcorners,shrubs,

trees,orotherobjectsthatmayobscurevision.

SafeHandlingofFuels

•Toavoidpersonalinjuryorpropertydamage,use

extremecareinhandlingfuel.Fuelisextremely ammableandthevaporsareexplosive.

•Useonlyanapprovedfuelcontainer.

•Donotremovethefuelcaporaddfuelwiththe

enginerunning.

•Allowtheenginetocoolbeforefueling.

•Neverrefuelordrainthemachineindoorsanddo

notsmokewhilerefuelingordraining.

•Donotstorethemachineorfuelcontainerwhere

thereisanopename,spark,orpilotlightsuchas onawaterheateroronotherappliances.

•Donotllcontainersinsideavehicle,onatruck,

oronatrailerbedwithaplasticliner.Alwaysplace containersonthegroundawayfromyourvehicle beforelling.

•Removeequipmentfromthetruckortrailerand

fuelitontheground.Ifthisisnotpossible, thenaddfuelwithsuchequipmentasaportable container,ratherthanfromafuel-dispensernozzle.

•Keepthenozzleincontactwiththerimofthefuel

tankorcontaineropeningatalltimesuntilfueling iscomplete.Donotuseanozzlelockopendevice.

•Iffuelisspilledonclothing,changeyourclothing

immediately.

•Donotoverllfueltank.Replacefuelcapand

tightensecurely.

MaintenanceandStorage

•Donotallowuntrainedpersonneltoservice

machine.

•Donottouchequipmentorattachmentpartswhich

maybehotfromoperation.Allowallofthepartsof themachinetocoolbeforeattemptingtomaintain, adjust,orservicethemachine.

•Keepyourhandsandfeetawayfrommoving

parts.Ifpossible,donotmakeadjustmentswith theenginerunning.

•Disengagethedrives,raisethetines,engagethe

parkingbrake,shutofftheengine,andremove thekeyordisconnectthespark-plugwire.Waitfor allmovementtostopbeforeadjusting,cleaning, orrepairing.

•Disconnectthebatteryorremovethespark-plug

wirebeforemakinganyrepairs.Disconnectthe negativeterminalrstandthepositiveterminal last.Reconnectthepositiverstandnegativelast.

•Usecarewhencheckingthetines.Wrapthetine(s)

orweargloves,andusecautionwhenservicing them.Onlyreplacetines;donotstraightenorweld them.

•Cleangrass,dirt,anddebrisfromthetines,drives,

mufers,andenginetohelppreventres.

•Cleanupoilorfuelspills.

•Parkthemachineonlevel,hardground.Never

allowuntrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhen

required.

•Carefullyreleasepressurefromcomponentswith

storedenergy.

•Lettheenginecoolbeforestoring.

•Keepallpartsingoodworkingconditionandall

hardwaretightened.Replaceallwornordamaged decals.

Hauling

•Usecarewhenloadingorunloadingthemachine

intoatraileroratruck.

•Donotaerateslopesgreaterthan15degrees.

•Avoidsuddenstartsandstopswhenaeratinguphill

becausethemachinemaytipbackward.

•Usefull-widthrampsforloadingmachineintoa

traileroratruck.

•Tiethemachinedownsecurelyusingstraps,

chains,cable,orropes.Bothfrontandrearstraps shouldbedirecteddownandoutwardfromthe machine.

AeratorSafety

Thefollowinglistcontainssafetyinformationspecic toToroproductsandothersafetyinformationyou mustknow.

GeneralOperation

•Checkcarefullyforoverheadclearances(i.e.

branches,doorways,electricalwires,etc.)before operatingunderanyobjects,anddonotcontact them.

•Usecautionwhenyouareridingontheplatform

anddrivingthemachineovercurbs,rocks,roots, orotherobstructions.

•Donotjerkthecontrols;useasteadymotion.

•Donotcarrypassengers.

•Donotcarryequipmentonthemachine.

SlopeOperation

Useextremecautionwhenaeratingand/orturning onslopesaslossoftractionand/ortip-overcould occur.Theoperatorisresponsibleforsafeoperation onslopes.

•UseFigure3tohelpyoudeterminetheappropriate

slopeangleofareatoaerate

Note:Themachineismorestablegoinguphill

withthetinesraised.

•Keepallmovementonslopesslowandgradual.

•Donotmakesuddenchangesinspeedor

direction.

•Reducethetine-downpressuretopreventthe

drivetiresfromraisingoffthegroundandto preventthefronttiresfromraisingofftheground whileaeratinguphill.

•Followthemanufacturer’srecommendationsfor

wheelweightsorcounterweightstoimprove stability.

•Useextracarewithattachments.

Note:Useofattachmentscanchangethestability

ofthemachine.

Service

•Toensureoptimumperformanceandcontinued

safetycerticationofthemachine,useonly genuineT ororeplacementpartsandaccessories. Replacementpartsandaccessoriesmadeby othermanufacturerscouldbedangerous,and suchusecouldvoidtheproductwarranty.

•Neverremoveortamperwithsafetydevices.

Checktheirproperoperationregularly.Neverdo anythingtointerferewiththeintendedfunctionofa safetydeviceortoreducetheprotectionprovided byasafetydevice.

•Checkbrakeoperationfrequently.Adjustand

serviceasrequired.

•Removeormarkobstaclessuchasrocks,tree

limbs,etc.fromtheaeratingarea.

•Watchforholes,rutsorbumps.

Note:T allgrasscanhideobstacles.

•Usecautionneardrop-offs,ditches,or

embankments.

Note:Themachinecouldsuddenlyturnoverifa

wheelgoesovertheedgeofaclifforditch,orif anedgecavesin.

•Beawarethatoperatingonwetgrass,across

steepslopesordownhillmaycausethemachine tolosetraction.Lossoftractiontothedrivewheels mayresultinslidingandalossofbrakingand steering.

SlopeIndicator

Figure3

Thispagemaybecopiedforpersonaluse.

1.Themaximumslopeyoucansafelyoperatethemachineonis15degrees.Usetheslopecharttodeterminethedegreeofslope ofhillsbeforeoperating.Donotoperatethismachineonaslopegreaterthan15degrees.Foldalongtheappropriateline tomatchtherecommendedslope.

2.Alignthisedgewithaverticalsurface,atree,building,fencepole,etc.

3.Exampleofhowtocompareslopewithfoldededge.

g011841

SafetyandInstructionalDecals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyarea ofpotentialdanger.Replaceanydecalthatisdamagedormissing.

93-6686

decal93-6686

1.Hydraulicuid2.ReadtheOperator's

115-2047

1.Warning—donottouchthehotsurface.

116-9391

Manual.

decal121-6150

121-6150

decal115-2047

1.Cuttinghazardofhandandfoot–stayawayfrommoving parts.

decal121-6161

121-6161

1.Entanglementhazard,belt—stayawayfrommovingparts; keepallguardsinplace.

decal116-9391

117-2718

120-9570

1.Warning—stayawayfrommovingparts,keepallguards andshieldsinplace.

decal121-6162

121-6162

decal117-2718

decal120-9570

1.Cutting/dismembermenthazardofhandorfoot—lower thetinestotheground;readtheOperator’sManualfor disassemblyprocedure.

121-6163

1.Presstolowerthetines.2.Releasetoraisethetines.

decal126-2054

126-2054

1.Wheellugnuttorque129N∙m(95ft-lb)(4x)

2.Wheelhubnuttorque319N∙m(235ft-lb)

3.ReadandunderstandtheOperator’sManualbefore performinganymaintenance;checkthetorqueevery100 hours.

decal121-6163

decal121-6164

121-6164

1.Fast6.Wheelsandtinesrotatewhenmoving backward

2.Slow7.Continuousvariablesetting

3.Neutral

4.Reverse

5.Wheelsandtinesrotatewhenmoving

8.Choke—on

9.Choke—off14.Warning—stayawayfrommoving

10.Warning—readtheOperator’sManual.15.Warning—shutofftheengine,engage

forward

11.Warning—keepbystandersaway .

12.Warning—donotoperatethemachine unlessyouaretrained.

13.Thrownobjecthazard—pickupdebris beforeoperatingthemachine.

parts;keepallguardsinplace.

theparkingbreak,andremovethekey beforeleavingthemachine.

126-4528

1.Rotatecounterclockwisetodecreasepressure5.Parkingbrake-release

2.Rotateclockwisetoincreasepressure6.Parkingbrake-engage

3.On-tinegroundengagementfootswitch7.Cutting/dismembermenthazardofhandorfoot,tines–stay awayfrommovingparts;keepallguardsinplace

4.Off-tinegroundengagementfootswitch

121-6166

decal126-4528

decal121-6166

1.Tippinghazard—donotturnsharplywhiletravellingfast;slow

downandturngradually.

2.Tippinghazard—donotoperatethemachineonslopes

greaterthan15degrees;donotoperatethemachinenear drop-offs.

3.Warning;tippinghazard—donotusesplitramps;usefull widthrampstoloadamachinefortransport;usealoading rampatamaximumof15degrees.

116–9392

1.Readtheinstructionsbeforeservicingorperformingmaintenance;readtheOperator’sManualforinformationonlubricating themachine.

decal116-9392

Setup

MediaandAdditionalParts

Description

Operator'sManual

Key2

CheckingTirePressure

NoPartsRequired

Procedure

1.Checkthetirepressureinthedrivetires.

Note:Properinationfordrivetiresis83to97

kPa(12to14psi).

2.Adjustthetirepressureifnecessary.

Qty.

Use

Readbeforeoperatingthemachine.

Startthemachine.

ServicingtheBattery

NoPartsRequired

Procedure

Note:Themachineisshippedwithalled,lead-acid

battery.

DANGER

Chargingorjumpstartingthebatterymay produceexplosivegases.Batterygasescan explodecausingseriousinjury.

•Keepsparks,ames,orcigarettesaway frombattery.

•Ventilatewhenchargingorusingbatteryin anenclosedspace.

•Makesurethattheventingpathofbattery isalwaysopenoncethebatteryislled withacid.

•Alwaysshieldeyesandfacefrombattery.

DANGER

Batteryelectrolytecontainssulfuricacid, whichispoisonousandcancausesevere burns.Swallowingelectrolytecanbefatalor ifittouchesskincancausesevereburns.

•Wearsafetyglassestoshieldyoureyes andrubberglovestoprotectyourskinand clothingwhenhandlingelectrolyte.

•Donotswallowelectrolyte.

•Intheeventofanaccident,ushwithwater andcalladoctorimmediately.

1.TurnthekeyintheignitionswitchtotheOFF positionandremovethekey.

2.Measurethevoltageofthebatterywitha voltmeter.

3.Usethetablebelowtolocatethechargestate orthebattery,andifneeded,thebattery-charger settingandchargingintervalrecommendedto chargethebatteryto12.6Vorgreater.

Important:Makesurethatthenegative

batterycableisdisconnectedandthe batterychargerusedforchargingthebattery hasanoutputof16Vand7Aorlessto avoiddamagingthebattery(seechartfor recommendedchargersettings).

BatteryChargeTable

Voltage Reading

12.6or

greater

12.4–12.6

12.2–12.4

12.0–12.2

11.7–12.0

11.7orless

Percent Charge

100%16volts/

75–100%16volts/

50–75%16volts/

25–50%14.4volts/

0–25%14.4volts/

0%14.4volts/

Maximum Charger Settings

7amps

4amps

2amps

Charging Interval

NoCharging Required

30Minutes

1Hour

2Hours

3Hours

6Hoursor More

Figure4

1.Screw

2.Washer5.Engine

3.Groundwire

4.Negativebatterycable

Note:Iftimedoesnotpermitchargingthe

batteryorifchargingequipmentisnotavailable, connectthenegativebatterycablesandrun thevehiclecontinuouslyfor20to30minutesto chargethebattery.

CheckingFluidLevels

g018126

CAUTION

IftheignitionisintheONpositionthere ispotentialforsparksandengagement ofcomponents.Sparkscouldcause anexplosionormovingpartscould accidentallyengagecausingpersonal injury.

BesureignitionswitchisintheOFF positionbeforechargingthebattery.

4.Ifthepositivecableisalsodisconnected, connectthepositive(red)cabletothepositive batteryterminalandslipterminalcoveroverthe positiveterminal.

5.Removethescrew,washer,andgroundcable fromtheengine.Connectthenegativebattery cableasshowninFigure4.

NoPartsRequired

Procedure

Checktheengine-oillevelbeforetheengineisrst started;refertoCheckingtheEngine-OilLevel(page

18).

Checkthetransmission-oillevelbeforetheengineis rststarted;refertoCheckingtheTransmission-Oil

Level(page47).

Checktheauxiliaryhydraulic-uidlevelbeforethe engineisrststarted;refertoCheckingtheAuxiliary

Hydraulic-FluidLevel(page45).

RemovingtheCylinder Stop

NoPartsRequired

Procedure

Note:Raisethetinesbeforeremovingthecylinder

stop.Runningtheenginechargesthehydraulic systemandraisesthetines.

1.Addasmallamountoffueltothefueltank;refer toAddingFuel(page19).

2.Openthefuel-shutoffvalvebyaligningthelever forthefuel-shutoffvalvewiththefuelline;refer toFuel-ShutoffValve(page17).

Figure5

1.Hairpin

2.Clevispin4.Cylinder

g020266

3.Cylinderstop

3.Movethemotion-controlleverstotheneutral positionandengagetheparkingbrake;referto

Traction-ControlLevers(page15).

4.PlacethethrottlemidwaybetweentheSLOWand FASTpositions;refertoThrottleLever(page16).

5.Pushforwardthechokelevertosetthechoketo theONposition;refertoChokeLever(page16).

6.TurnthekeyswitchtotheSTARTposition;refer toIgnitionSwitch(page16).

Note:Releasetheswitchassoonastheengine

starts.

Important:Donotcranktheengine

continuouslyformorethan10secondsat atime.Iftheenginedoesnotstart,allowa 60-secondcooldownperiodbetweenstarting attempts.Failuretofollowtheseguidelines canburnoutthestartermotor.

7.Graduallymovetheleverforthechokeleverto theOFFpositionastheenginewarmsup.

Note:Allowtheenginetorunanadditional30

seconds

11.Connectthespark-plugwires.

8.TurnthekeyswitchtotheOFFpositiontoshut offtheengine.

9.Removethekeyandpullthewiresoffthespark plugs.

Note:Pushthewiresasidesotheydonot

accidentallycontactthesparkplugs.

10.Removeandretainthehairpin,clevispin,and cylinderstopasshowninFigure5.

ProductOverview

g025895

Figure7

Figure6

1.Platform

2.Parking-brakeknob5.Fuelcap

3.Traction-controllevers

4.Enginecontrols

Controls

Traction-ControlLevers

Thetraction-controlleversarelocatedoneachsideof thetopconsole,andcontroltheforwardandreverse motionofthemachine.

Movetheleversforwardorbackwardtocontrolthe drivewheelonthesamesideforwardorreverse respectively.Thewheelspeedisproportionaltothe amounttheleverismoved.

1.Lefttraction-controllever

2.Righttraction-controllever

3.Frontreferencebar

4.Forward

g020220

5.Reverse

6.Frontofthemachine

7.Neutral

Tine-PressureControl

Thetine-pressurecontrolislocatedontheleftsideof thecontrolconsole(Figure8).

Usethetine-pressurecontroltoadjustthedownward pressureonthetinesandcoredepth.Rotatethe controlcounterclockwisetodecreasethepressure andthelengthoftheaerationplug;rotateclockwise toincreasepressureandincreasethelengthofthe aerationplug.

Important:Thetinesrotatewhenthe

traction-controlleversaremovedoutofthe Neutralposition.

Figure8

1.Tinedownpressuregauge

2.Tinedownpressure control

3.On/Off-tineground engagementfootswitch

4.Leftmotion-controllever

5.Frontreferencebar

6.Throttle12.Tinegroundengagement

7.Choke

8.Rightmotion-controllever

9.Hourmeter

10.Parkbrake

11.Ignitionswitch

ChokeLever

Thechokelever(Figure8)islocatedonthecontrol console(blacklever).

Thechokeleverisusedtoaidinstartingacold engine.TosetthechoketotheONposition,move thechokeleverforward.T oreducethechoke,move thechokeleverbackward.

Note:Pullthechokeleverbackintothedetenttoset

thechoketotheOFFposition.

Note:Donotrunawarmenginewiththechokein

theONposition.

Parking-BrakeHandle

Theparking-brakehandleislocatedonthecontrol console,totherightoftheignitionswitch(Figure8).

Note:Thebrakehandlesetsaparkingbrakeineach

g028268

footswitch

ofthetransmissions.

Tosetthebrake,pullthehandleoutandslideit backward.T orelease,pushthehandleforwardinto thedetent.

Whenparkingonasteepslope,thewheelsmustbe chockedorblockedinadditiontothebrakebeingset. Themachinemustbetieddownandbrakesetwhen transporting.

HourMeter

ThrottleLever

Thethrottlelever(Figure8)islocatedonthecontrol console(redlever).

Toincreaseenginespeed,movethethrottlelever forward.T odecreaseenginespeed,movethethrottle leverbackward.

Note:Movethethrottleleverforwardintothedetent

forfullthrottle.

Thehourmeterislocatedabovetheignitionswitch (Figure8).

Thehourmeterdisplaysthetotalnumberofhours thatyouhaverunthemachine.

IgnitionSwitch

Theignitionswitchislocatedontherightsideofthe controlconsole(Figure8).

Theswitchhas3positions:OFF,ON,andST ART (Figure9).

g008610

Figure9

1.Off3.Start

2.On

On/OffTineGroundEngagement FootSwitch

Locatedabovethetinedownpressurecontrolonthe controlconsole.

Toenablethetinesgroundengagement,pushdown onthetopoftheswitch.T odisablethetinesground engagement,pushdownontherearoftheswitch.

Tine-PressureGauge

Thetine-pressuregaugeislocatedinthemiddleof thecontrolconsole(Figure8).

Thetine-pressuregaugetoindicatesthedownward pressurethemachineexertsonthetineswhen aerating.

g025897

Figure10

1.Offposition2.Onposition

Tines-ElevationSwitch

Keepyouhandsandfeetawayfromthetines. Makesurethatthetinesareaisclearofany obstructionsbeforeloweringit.

Thetine-elevationswitchislocatedontheoperator platform(Figure8).

Tolowerthetinesintotheground,standonthe tine-elevationswitch.T oraisethetines,removeyour footfromtheswitch.

Fuel-ShutoffValve

Thefuel-shutoffvalveislocatedbehindtheengine andunderthefueltank(Figure10).

Usethefuel-shutoffvalvetoshutoffthefuelwhen themachinewillnotbeusedforafewdays,when transportingthemachinetoandfromthejobsite,or whenthemachineisparkedinsideabuilding.

Toopenforfuel-shutoffvalve,rotatethehandleofthe fuel-shutoffvalveuntilitisalignedwiththefuelline. Toclosethefuel-shutoffvalve,rotatethehandle90° tothefuelline.

DriveWheelReleaseValves

Thedrivewheelreleasevalvesarelocatedontheleft andrightsidesunderneaththefrontoftheunit.

Note:Duringnormaloperatingconditions,the

washerontheleverispositionedinsidetheslots.

Ifyouneedtopushthemachinebyhand,makesure thatthevalvesareinthe“released”position(Figure

11).

Figure11

1.Leverpositiontopushthe machine

2.Washeroutsideofslot

Toreleasethedrivewheels,movethelevertothe largeropeningoftheslot,pullitoutuntilthewasher isoutsidetheframe,thenmovetheleverbacktothe narrowportionoftheslot.Repeatthisoneachside ofthemachine.

3.Leverpositionfor operatingthemachine

4.Washerinsideslot

g031272

Disengagetheparkingbraketoallowyoutopushthe machinebyhand.

Operation

Important:Donottowthemachine.

Toresetthedrivesystembacktotheoperating position,movethelevertothelargeropeningofthe slot,pushinwarduntilthewasherisinsidetheframe, thenmovetheleverbacktothenarrowportionofthe slot.Repeatthisoneachsideofthemachine.

Specications

Height

Length

Width

AerationWidth

Coringrange5to13cm(2to5inches)

Weight

132cm(52inches)

162cm(64inches)

121cm(48inches)

76cm(30inches)

460kg(1,015lb)

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

CheckingtheEngine-Oil Level

ServiceInterval:Beforeeachuseordaily

OilType:Detergentoil(APIserviceSJorhigher)

Oilviscosity:Refertothetablebelow.

Figure12

Important:Donotoperatetheenginewiththeoil

levelbelowtheLow(orAdd)markonthedipstick, orovertheFullmark.

1.TurnthekeyintheignitionswitchtotheOFF position,removethekey,andwaitforallmoving partstostopbeforeleavingtheoperating position

2.Allowtheenginetocool.

3.Checktheengine-oillevelasshowninFigure

13.

g004216

AddingFuel

Fueltankcapacity:18.9L(5USGallons)

•Forbestresults,useonlyclean,fresh(lessthan

30daysold),unleadedgasolinewithanoctane ratingof87orhigher((R+M)/2ratingmethod).

g025899

•ETHANOL:Gasolinewithupto10%ethanol

(gasohol)or15%MTBE(methyltertiarybutyl ether)byvolumeisacceptable.Ethanoland MTBEarenotthesame.Gasolinewith15% ethanol(E15)byvolumeisnotapprovedforuse. Neverusegasolinethatcontainsmorethan10% ethanolbyvolume,suchasE15(contains15% ethanol),E20(contains20%ethanol),orE85 (containsupto85%ethanol).Usingunapproved gasolinemaycauseperformanceproblemsand/or enginedamagewhichmaynotbecoveredunder warranty.

•Donotusegasolinecontainingmethanol.

•Donotstorefueleitherinthefueltankorfuel

containersoverthewinterunlessafuelstabilizer isused.

Figure13

4.Iftheoillevelislow,wipeofftheareaaround theoilllcap,removecapandaddthespecied oiluntiltheoillevelisattheFullmarkonthe dipstick.

•Donotaddoiltogasoline

DANGER

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

•Fillthefueltankoutdoors,inanopenarea, andwhentheengineiscold.Wipeupany fuelthatspills.

•Donotllthefueltankcompletelyfull. Addfueltothefueltankuntilthelevelis6 to13mm(1/4to1/2inch)belowthebottom ofthellerneck.Thisemptyspaceinthe tankallowsthefueltoexpand.

•Neversmokewhenhandlingfuel,andstay

g025898

awayfromanopenameorwhereaspark mayignitethefuelfumes.

•Storefuelinanapprovedfuelcontainer andkeepitoutofthereachofchildren.

•Neverbuymorethana30-daysupplyof fuel.

Note:Donotoverlltheenginewithoil.

DANGER

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

Addthecorrectamountoffuelstabilizer/conditioner tothefuel.

Note:Afuelstabilizer/conditionerismost

effectivewhenmixedwithfreshfuel.T ominimize thechanceofvarnishdepositsinthefuelsystem, usefuelstabilizeratalltimes.

•Alwaysplacefuelcontainersontheground awayfromyourvehiclebeforelling.

•Donotllfuelcontainersinsideavehicle oronatruckortrailerbedbecauseinterior carpetsorplastictruckbedlinersmay insulatethecontainerandslowthelossof anystaticcharge.

•Whenpractical,removefuel-powered equipmentfromthetruckortrailerand refueltheequipmentwithitswheelsonthe ground.

•Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfroma portablecontainer,ratherthanfroma fuel-dispensernozzle.

•Ifafuel-dispensernozzlemustbeused, keepthenozzleincontactwiththerimof thefueltankorcontaineropeningatall timesuntilfuelingiscomplete.

WARNING

Fuelisharmfulorfatalifswallowed. Long-termexposuretovaporscancause seriousinjuryandillness.

FuelingtheMachine

1.Cleanaroundthefuel-tankcap.

2.Removethecapfromthetank.

3.Fillthefueltankwithunleadedfueltowithin6to 13mm(1/4to1/2inch)fromthetopofthetank.

Donotllintothellerneck.

Important:Donotllthetankmorethan

6mm(1/4inch)fromthetopofthetank becausethefuelmusthaveroomtoexpand.

4.Installthefuel-tankcapandwipeupanyspilled fuel.

LubricatingtheChains

CheckingtheConditionofthe Sprockets

ServiceInterval:Beforeeachuseordaily

1.TurnthekeyintheignitionswitchtotheOFF position,engagetheparkingbrake,waitforall movingpartstostop,andremovekey.

2.Inspectsprocketsforwearandreplaceas required(Figure14).

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandfueltank orconditionerbottleopening.

•Avoidcontactwithskin;washoffspillage withsoapandwater.

UsingStabilizer/Conditioner

Useafuelstabilizer/conditionerinthemachineto providethefollowingbenets:

•Keepsfuelfreshduringstorageof90daysorless.

Forlongerstorageitisrecommendedthatthefuel tankbedrained.

•Cleanstheenginewhileitruns

•Eliminatesgum-likevarnishbuildupinthefuel

system,whichcauseshardstarting

Important:Donotusefueladditives

containingmethanolorethanol.

1.TurnthekeyintheignitionswitchtotheOFF position,engagetheparkingbrake,waitforall movingpartstostop,andremovekey.

2.Raisethemachineandsupportitwithjack standswitha460kg(1,015lb)capacity.

CAUTION

Raisingthemachineforservice ormaintenancerelyingsolelyon mechanicalorhydraulicjackscouldbe dangerous.Themechanicalorhydraulic jacksmaynotbeenoughsupportormay malfunctionallowingthemachinetofall, whichcouldcauseinjury .

Donotrelysolelyonmechanical orhydraulicjacksforsupport.Use adequatejackstandsorequivalent support.

3.TurnthekeyintheignitionswitchtotheON position,andmovethrottlelevelaheadto1/2 throttleposition.

Figure14

1.Sprockets2.Chains

CheckingtheConditionofthe Chains

ServiceInterval:Beforeeachuseordaily

1.TurnthekeyintheignitionswitchtotheOFF position,engagetheparkingbrake,waitforall movingpartstostop,andremovekey.

2.Checkthechaintension(Figure14)atboth sidesofthemachine.

Note:Thechainsshouldmoveupanddown6

to12mm(1/4to1/2inch).

3.Ifchainspoporsnap;refertoAdjustingthe

JackshaftDriveChainTension(page40), AdjustingtheTensionontheDrive-WheelChain (page41),orAdjustingtheTine-DriveChain (page50).

g025984

WARNING

Enginemustberunninganddrivewheels mustbeturningsoadjustmentscanbe performed.Contactwithmovingpartsor hotsurfacesmaycausepersonalinjury.

Keepngers,hands,andclothingclear ofrotatingcomponentsandhotsurfaces.

4.Disengagetheparkingbrake.

5.Withtheenginerunning,slowlymovethe traction-controlleversforwardandlubricateall6 chains(Figure14).

6.Checktheconditionandtensionofthechains; refertoCheckingtheConditionoftheChains

(page21).

LubricatingtheChains

ServiceInterval:Beforeeachuseordaily

Important:Donotlubricatechainswith

penetratingoilorsolvents.Useoilorchain lubricant.

Checkingthe Safety-InterlockSystem

ServiceInterval:Beforeeachuseordaily

CAUTION

Ifsafetyinterlockswitchesaredisconnected ordamagedthemachinecouldoperate unexpectedlycausingpersonalinjury.

•Donottamperwiththeinterlockswitches.

•Checktheoperationoftheinterlock switchesdailyandreplaceanydamaged switchesbeforeoperatingthemachine.

UnderstandingtheSafety-InterlockSystem

Thesafetyinterlocksystemisdesignedtopreventthe enginefromstartingunlessthetraction-controllevers areintheneutralposition.

CheckingtheSafety-InterlockSystem

1.Disconnectthespark-plugwires;referto

RemovingtheSparkPlug(page35).

OperatingtheMachine

OpeningtheFuel-ShutoffValve

Rotatetheleverofthefuel-shutoffvalvetoalignthe leverwiththefuelline.

g025897

Figure15

1.Offposition2.Onposition

2.Whileonlevelground,blockthewheelsofthe machinetopreventunintendedmovement.

3.Disengagetheparkingbrake;referto

Parking-BrakeHandle(page16).

4.Withthetraction-controlleversintheneutral positionturnthekeytothestartposition—the startermustnotcrank;refertoTraction-Control

Levers(page15)andIgnitionSwitch(page16).

Note:Ifthemachinedoesnotpassthistest,donot

operate.ContactyourauthorizedT oroServiceDealer.

Important:Itisessentialthattheoperator

safetymechanismsbeconnectedandinproper operatingconditionpriortouseforaerating.

CheckingforLoose Hardware

ServiceInterval:Beforeeachuseordaily

1.TurnthekeyintheignitionswitchtotheOFF position,engagetheparkingbrake,waitforall movingpartstostop,andremovekey.

2.Visuallyinspectmachineforanyloosehardware oranyotherpossibleproblem.

Note:Tightenallloosehardwareorrepairthe

problembeforeoperatingthemachine.

StartingtheEngine

1.Movethetraction-controlleverstotheNEUTRAL positionandengagetheparkingbrake;refer toTraction-ControlLevers(page15)and

Parking-BrakeHandle(page16).

Note:Tostarttheengine,theparkingbrake

mustbeengaged.(Itisnotnecessaryforthe operatortobeontheplatform.)

2.Placethethrottlelevermidwaybetweenthe SLOWandFASTpositions;refertoThrottleLever

(page16).

3.Iftheengineiscold,pushthechokelever forwardtotheONposition;refertoChokeLever

(page16).

Note:Iftheengineiswarm,pullthechoke

levertotheOFFposition.

4.TurnthekeyintheignitionswitchtotheSTART position;refertoIgnitionSwitch(page16).

Note:Releasethekeyintheignitionswitchas

soonastheenginestarts.

3.Standontheswitchandmovethetraction-control leversforwardtoaerate(Figure16);referto

Traction-ControlLevers(page15).

4.Adjustthethrottlefortheworkingconditions; refertoThrottleLever(page16).

AdjustingtheTineDownPressure

Important:Keepthedrivetiresonthegroundat

alltimes.

Adjusttheplugdepthbyrotatingthetinepressure controlasfollows:

Note:Firsttimeuse:setthetinepressurecontrol

sothatthetine-pressuregauge(Figure17)indicates 24bar(350psi).

Important:Donotcranktheengine

continuouslyformorethantensecondsata time.Iftheenginedoesnotstart,allowa60 secondcool-downperiodbetweenstarting attempts.Failuretofollowtheseguidelines canburnoutthestartermotor

5.IfthechokeleverisintheONposition,gradually movethelevertowardtheOFFpositionasthe enginewarmsup.

LoweringtheTines

1.SetthrottlelevertotheMIDWAYposition;referto

ThrottleLever(page16).

2.Steponthetine-elevationswitchtolowerthe tines(Figure16).

Figure17

1.Tine-pressurecontrol3.Decreasepressure

2.Tine-pressuregauge

(shorterplug)

4.Increasepressure(longer plug)

•Rotatethetine-pressurecontrol

counterclockwise(Figure17)todecrease thedownwardpressureinordertoremovea shorterplug.

•Rotatethetine-pressurecontrolclockwise(Figure

17)toincreasedownwardpressureinorderto

removealongerplug.

Note:Idealplugdepthis7.6to10cm(3to4inches).

Rotatethetine-pressurecontroltoadapttothesoil conditions.

g025901

1.Tine-elevationswitch

Figure16

RaisingtheTines

Toraisethetines,removeyourfootfromthe tine-elevationswitch(Figure16).

g025900

Important:Thetinesrotatewhenthe

traction-controlleverismovedoutoftheNEUTRAL position.

StoppingtheEngine

1.Movethetraction-controlleverstotheNEUTRAL positionandbringthemachinetoafullstop; refertoTraction-ControlLevers(page15).

2.Liftyourfootoffofthetinegroundengagement footswitchcontroltoraisethetines;referto

RaisingtheTines(page23).

3.Placethethrottleinthemidwaybetweenthe SLOWandFASTpositions;refertoThrottleLever

(page16).

4.Allowtheenginetorunforaminimumof15 seconds,thenturnthekeyintheignitionswitch totheOFFpositiontoshutofftheengine;refer toIgnitionSwitch(page16).

5.Engagetheparkingbrake;refertoParking-Brake

Handle(page16).

6.Removethekeytopreventchildrenorother unauthorizedpersonsfromstartingtheengine.

7.Closethefuel-shutoffvalvewhenthemachine willnotbeinuseforafewdays,when transporting,orwhenthemachineisparked insideabuilding;refertoFuel-ShutoffValve

(page17).

Figure18

1.Lefttraction-controllever

2.Righttraction-controllever6.Neutral

3.Frontreferencebar

4.Frontofthemachine

5.Forward

7.Reverse

DrivingForward

1.Makesurethatthetraction-controlleversarein theNEUTRALposition.

2.Disengagetheparkingbrake.

3.T omoveforwardinastraightline,moveboth leversforwardwithequalpressure.

g020241

DrivingtheMachine

CAUTION

Machinecanspinveryrapidlybypositioning 1levertoomuchaheadoftheother.Operator maylosecontrolofthemachine,whichmay causedamagetothemachineorinjury .

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemaking sharpturns.

Important:Tobeginmovement(forwardor

backward),thebrakelevermustbedisengaged (pushedforward)beforethetraction-control leverscanbemoved.

g016672

Figure19

Toturnleftorright,pullthetraction-controllever backtowardneutralinthedesiredturndirection. Thetinescanbeinthedownpositionwhen makinggradualturns.

Tomakezeroturns,liftyourfootoffofthetine engagementfootswitchcontroltoraisethe tines.Theheadraisesin1second.

Important:Donotmakeazeroturnwhen

thetinesaredownasturftearingwillresult.

Themachinemovesfasterthefartheryoumove thetraction-controlleversfromtheneutral position.

4.T ostop,positionbothtraction-controlleversin theneutraloperateposition.

DrivinginReverse

1.Movethetraction-controlleverstothe NEUTRAL/OPERATEposition.

2.T omoverearwardinastraightline,slowlymove bothleversrearwardwithequalpressure.

CAUTION

Thismachinedoesnothaveproperturn signals,lights,reectivemarkings,ora slowmovingvehicleemblem.Drivingona streetorroadwaywithoutsuchequipment isdangerousandcanleadtoaccidents causingpersonalinjury.Drivingonastreetor roadwaywithoutsuchequipmentmayalsobe aviolationofStatelawsandtheoperatormay besubjecttotrafcticketsand/ornes.

Donotdriveamachineonapublicstreetor roadway.

Totransportthemachine:

1.Raisethetinesofthemachinebeforedriving ontothetrailerortruck.

2.Ifusingatrailer,connectittothetowingvehicle andconnectthesafetychains.

3.Ifapplicable,connectthetrailerbrakes.

4.Loadthemachineontothetrailerortruck.

Figure20

Toturnleftorright,releasepressureonthe traction-controllevertowardthedesiredturn direction.

Tomakezeroturns,liftyourfootoffofthe tine-elevationswitchtoraisethetines.Thehead raisesin1second.

Important:Donotmakeazeroturnwhen

thetinesareinthedownposition.

3.T ostop,positionbothtraction-controlleversin theNEUTRAL/OPERATEposition.

TransportingtheMachine

Machineweight:460kg(1,015lb)

Useaheavy-dutytrailerortrucktotransportthe machine.Ensurethatthetrailerortruckhasall thenecessarybrakes,lighting,andmarkingas requiredbylaw.Pleasecarefullyreadallthesafety instructions.

5.Shutofftheengine,removethekey,setthe

g016673

brake,andclosethefuelvalve.

6.Engagetheparkingbrakeandblockthetires.

7.Usethetie-downpointsonthemachineto securelybindthemachinetothetrailerortruck withstraps,chains,cable,orropes(Figure21).

Note:Refertoyourlocalordinancesforspecic

trailerandtie-downregulations.

g025949

Figure21

1.Tie-downpoints

LoadingtheMachine

Useextremecautionwhenloadingunitsontotrailers ortrucks.Use1full-widthrampthatiswideenoughto extendbeyondthereartiresisrecommendedinstead ofindividualrampsforeachsideofthemachine (Figure22).Theplatform,whendownandlockedinto position,mustextendbackbetweentherearwheels andservesasastopfortippingbackward.Havinga full-widthrampprovidesasurfacefortheplatformto contactifthemachinestartstotipbackward.Withthe platformup,afull-widthrampprovidesasurfaceto walkonbehindthemachine.

Therampshouldbelongenoughsothattheangles donotexceed15degrees(Figure22).Asteeper anglemaycausetinecomponentstogetcaught,as themachinemovesfromramptotrailerortruck.A steeperanglemayalsocausethemachinetotip backward.Ifloadingonornearaslope,positionthe trailerortrucksoitisonthedownsideoftheslope andtherampextendsuptheslope.Thisminimizes therampangle.Thetrailerortruckshouldbeaslevel aspossible.

Figure22

1.Trailer3.Notgreaterthan15

2.Full-widthramp

degrees

4.Full-widthramp(sideview)

g000951

WARNING

Loadingthemachineontoatrailerortruck increasesthepossibilityofbackwardtip-over, andcouldcauseseriousinjuryordeath.

•Useextremecautionwhenoperatinga machineonaramp.

•Useonlyasingle,full-widthramp;donot useindividualrampsforeachsideofthe machine.

•Ifindividualrampsmustbeused,use enoughrampstocreateanunbrokenramp surfacewiderthanthemachine.

•Donotexceeda15-degreeanglebetween rampandground,orbetweenaramp,a trailer,oratruck.

•Avoidsuddenaccelerationwhiledriving machineuparamptoavoidtipping backward.

•Avoidsuddendecelerationwhilebacking machinedownaramptoavoidtipping backward.

Theoperatorshoulddetermineifitisbesttohave theplatformupordownwhenloading,dependingon conditions.Ifitisnotpossibletouse1full-widthramp, useenoughindividualrampstosimulateafull-width, continuousramp.

Avoidsuddenaccelerationwhendrivinguparamp andsuddendecelerationwhenbackingdowna ramp.Bothmaneuverscancausethemachinetotip backward.

Maintenance

WARNING

Whileyouaremaintainingoradjustingthe machine,someonecouldstarttheengine. Accidentallystartingtheenginecould seriouslyinjureyouorotherbystanders.

Removethekeyfromtheignitionswitch, engageparkingbrake,andpullthewire(s) offthesparkplug(s)beforeyoudoany maintenance.Alsopushthewire(s)asideso itdoesnotaccidentallycontactthespark plug(s).

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst100hours

Beforeeachuseordaily

MaintenanceProcedure

•Changetheauxiliaryhydraulicreservoirlteranduid.

•Changethetransmissionlters.

•Fillthetransmissionwithoilwhenchangingthelter.

•Checktheengine-oillevel.

•Checktheconditionofthesprockets.

•Checktheconditionandtensionofthechains.

•Lubricatethechains.

•Checkthesafetyinterlocksystem.

•Checkforloosehardware.

•Checkthetines.

•Cleantheengineandtheexhaustsystemarea.

•Cleanthegrassanddebrisbuildupfromthemachine.

WARNING

Theenginecanbecomeveryhot.Touchinga hotenginecancausesevereburns.

Allowtheenginetocoolcompletelybefore serviceormakingrepairsaroundtheengine area.

Every25hours

Every50hours

Every80hours

Every100hours

Every160hours

Every200hours

•Greasethejackshaftbearings.

•Greasethewheelbearings.

•Greasethetineshaftbearings.

•Greasethetineassemblyidlers.

•Greasethecontrolpivots.

•Checksparkarrester(ifequipped).

•Checkthepressureinthetires.

•Checktheconditionandtensionofthebelts.

•Checktheauxiliaryhydraulic-uidlevel.

•Checkthehydraulictransmissionoil-level.

•Removetheengineshroudsandcleanthecoolingns.

•Check,cleanandgapthesparkplug.

•Checkthebattery.

•Checkthesparkplugs.

•Checkthepaperair-cleanerelement(moreoftenundersevereconditions).

•Changetheengine-oillter.

MaintenanceService

Every250hours

Every500hours

Interval

MaintenanceProcedure

•Replacetheprimaryaircleanerelement—checksecondaryaircleanerelement; replaceifdirty.(Mayneedmoreoftenundersevereconditions.SeetheEngine Owner’sManualforadditionalinformation.)

•Cleanthefoamair-cleanerelement(moreoftenundersevereconditions).

•Changetheauxiliaryhydraulicreservoirlteranduid.

•Changethetransmissionlters.

•Fillthetransmissionwithoilwhenchangingthelter.

•Replacethesecondaryaircleanerelement.(Mayneedmoreoftenundersevere conditions.SeetheEngineOwner’sManualforadditionalinformation.)

•Replacethepaperair-cleanerelement(moreoftenundersevereconditions).

Every800hours

Yearly

Yearlyorbeforestorage

•Replacethefuellter.

•Greasethefrontcasterpivots.

•Greasethebeltidlerpivot.

•Greasethecasterpivotsandhubs.

•Lubricatethecasterwheelhubs.

•Checkthetorqueofthewheelhubnuts.

•Checkthetorqueonthewheellugnuts.

•Checkthetorqueofthetransmissionoutputshaftnut.

•T ouchupchippedpaint

Pre-Maintenance Procedures

CAUTION

Raisingthemachineforserviceor maintenancerelyingsolelyonmechanical orhydraulicjackscouldbedangerous.The mechanicalorhydraulicjacksmaynotbe enoughsupportormaymalfunctionallowing themachinetofall,whichcouldcauseinjury.

AccessingtheConsole Compartment

RemovingtheConsolePad

1.Loosenthe4anged-headboltsthatsecurethe padtotheleftandrightconsolepanels(Figure

23).

Donotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

PreparingfortheMachine forMaintenance

Performthefollowingbeforeservicing,cleaning,or makinganyadjustmentstothemachine.

1.Movethemachinetoalevelsurface.

2.TurnthekeyintheignitionswitchtotheOFF position,engagetheparkingbrake,waitforall movingpartstostop.

3.Removethekeyfromthekeyswitch.

Figure23

1.Keyholeslot(console panel)

2.Fanged-headbolt

2.Liftuptheconsolepad(Figure23)approximately

13mm(1/2inch).

3.Pulltheconsolepadstraightbackandremove

thepadfromthemachine(Figure23).

g025880

3.Pad

InstallingtheConsolePad

1.Alignthe4anged-headboltsattheforward faceoftheconsolepadtothe4keyholeslotsin theframeoftheconsole(Figure23).

Lubrication

LubricatingtheGrease

2.Movethepadforwarduntilthepadisushto theconsoleframe(Figure23).

3.Movethepaddownuntiltheanged-headbolts areseatedinthekeyholeslots(Figure23).

4.T orquetheanged-headboltsto1978to2542 N-cm(175to225lb-in).

Fittings

Greasetype:NationalLubricatingGreaseInstitute

(NGLI)grade#2multi-purposegungrease.

Note:Refertothelubricationchartforservice

intervals.

LubricationChart

Fitting

Locations

1.FrontCaster Pivots

2.Jackshaft Bearings

3.Wheel Bearings

4.TineShaft Bearings

5.Tine AssemblyIdlers

6.Control Pivots

7.BeltIdler Pivot

8.FrontCaster Hubs

Initial

Pumps

1825hours

1225hours

1425hours

1225hours

1450hours

11Y early

Numberof

Places

Service Interval

2Yearly

Figure24

1.TurnthekeyintheignitionswitchtotheOFF position,engagetheparkingbrake,waitforall movingpartstostop,andremovethekey .

2.Wipecleanthegreasettingswitharag(Figure

24).

g020222

3.Connectagreaseguntothetting(Figure24).

RemovingtheCaster-WheelAssembly

4.Pumpgreaseintothettingsuntilgreasebegins tooozeoutofthebearings.

5.Wipeupanyexcessgrease.

LubricatingtheCasters

Greasetype:NationalLubricatingGreaseInstitute

(NGLI)grade#2multi-purposegungrease.

GreasingtheCasterPivots

ServiceInterval:Yearly

1.Removecapandhexplugfromthetopofthe casterpivot(Figure25).

1.TurnthekeyintheignitionswitchtotheOFF position,engagetheparkingbrake,waitforall movingpartstostop,andremovekey.

2.Liftthefrontofthemachineandsupportitwith jackstands.

3.Removethewheelnutandbolt,andremovethe caster-wheelassemblyfromthefork(Figure26).

g025953

Figure26

1.Wheelbolt3.Wheelnut

2.Caster-wheelassembly

Figure25

1.Hexplug

2.Greasetting4.Cap

2.Threadgreasettinginhole(Figure25).

3.Pumpgreaseintothettinguntilgreaseoozes outaroundtopbearing(Figure25).

4.Removegreasettingandinstalltheplugthat youremovedin1(Figure25).

5.Installthecapthatyouremovedinstep1(Figure

25).

3.Casterpivot

DisassemblingtheCaster-WheelHuband GreasingtheBearings

ServiceInterval:Yearly

Important:Usenewbearingsealswhen

lubricatingthecaster-wheelhubs.

Important:Topreventsealandbearingdamage,

checkthebearingadjustmentoften.Spinthe

g025955

castertire.Thetireshouldnotspinfreely(more than1or2revolutions)orhaveanysideplay.If thewheelspinsfreely,adjusttorqueonspacer nutuntilthereisaslightamountofdrag.Reapply thread-lockingadhesive.

Greasetype:NationalLubricatingGreaseInstitute

(NGLI)grade#2multi-purposegungrease.

1.Removethe2sealguardsfromthewheelhub (Figure27).

6.Repeatsteps1through5totheothercaster.

LubricatingtheCaster-Hubs Bearings

ServiceInterval:Yearly

Figure27

1.Axle(spacernutstill assembled)

2.Hub5.Bearingseal

3.Bearing

4.Spacernut

6.Sealguard

2.Remove1ofthespacernutsfromtheaxle

assemblyinthecasterwheel(Figure27).

Note:Notethatthread-lockingadhesivehas

beenappliedtolockthespacernutstotheaxle (Figure27).

3.Removetheaxle(withtheotherspacernutstill

assembledtoit)fromthecaster-wheelassembly (Figure27).

4.Pryoutbothofthebearingseals(Figure27).

Note:Discardtheoldseals.

5.Removebothofthebearingsandinspecteach

ofthemforwearordamage(Figure27).

Note:Replacethebearingifitiswornor

damaged.

6.Packthe2bearingswiththespeciedgrease.

AssemblingtheCaster-WheelHub

1.Install1bearingintothehubofthewheel(Figure

27).

2.Installthebearingsealintothehubatthe

bearing(Figure27).

3.Ifyouremoved(orbrokeloose)bothofthe

spacernutsfromtheaxleassembly,perform thefollowing:

A.Cleanthethreadsoftheaxleandspacer

nut.

B.Applythread-lockingadhesivetothe

threadsat1endoftheaxle.

C.Threadtheaxlenut,withthewrenchats

facingoutward,ontotheendoftheaxlethat ispreparedwiththread-lockingcompound (Figure27).

mm(1/8inch)fromtheoutersurfaceofthe spacernuttotheendoftheaxleinsidethe nut.

4.Inserttheassemblednutandaxleintothewheel atthesideofthewheelwiththenewsealand bearing(Figure27).

5.Withtheopenendofthewheelfacingup,llthe areainsidewheelcavity(aroundtheaxle)with thespeciedgrease.

g025954

6.Installtheotherbearingandnewsealintothe wheel(Figure27).

7.Applythread-lockingadhesivetothe2ndspacer nutandthreadontotheaxlewiththewrench atsfacingoutward.

8.T orquethespacernutto8to9N∙m(75to80 in-lb),loosen,thenre-torqueto2to3N∙m(20 to25in-lb).

Note:Makesureaxledoesnotextend

beyondeithernut.

9.Installthesealguardsoverthewheelhub (Figure27).

InstallingtheCaster-WheelAssembly

1.Aligntheholeintheaxleofthecaster-wheel assemblybetweentheholesintheforkofthe caster(Figure26).

2.Securethetotheforkwiththewheelnutand bolt(Figure26)thatyouremovedinstep3of

RemovingtheCaster-WheelAssembly(page

30).

3.T orquethewheelnutto91to113N∙m(67to 83ft-lb).

Note:Donotthreadspacernutallofthe

wayontotheaxle.Leaveapproximately3

EngineMaintenance

5.Carefullypullthefoamelementoffthepaper element(Figure28).

ServicingtheAirCleaner

ServiceInterval:Every250hours—Replacethe

primaryaircleanerelement— checksecondaryaircleaner element;replaceifdirty.(Mayneed moreoftenundersevereconditions. SeetheEngineOwner’sManualfor additionalinformation.)

Every500hours

Inspectthefoamandpaperelements,andreplace themiftheyaredamagedorexcessivelydirty .

Important:Donotapplyoiltothefoamorpaper

element.

RemovingtheFoamandPaper Elements

1.Shutofftheengine,engagetheparkingbrake, removethekey,andwaitforallmovingpartsto stopbeforeleavingtheoperatingposition.

2.Cleanaroundtheaircleanertopreventdirtfrom gettingintotheengineandcausingdamage (Figure28).

ServicingtheFoamAir-Cleaner Element

ServiceInterval:Every250hours(moreoftenunder

severeconditions).

1.Inspecttheelementfortears,anoilylm,or damaged(Figure28).

Important:Replacethefoamelementifit

iswornordamaged.

2.Washthefoamelementinliquidsoapand warmwater.Whentheelementisclean,rinse itthoroughly.

3.Drytheelementbysqueezingitinacleancloth.

ServicingthePaperAir-Cleaner Element

ServiceInterval:Every200hours—Checkthepaper

air-cleanerelement(moreoften undersevereconditions).

Every500hours—Replacethepaperair-cleaner element(moreoftenundersevereconditions).

Important:Donotwashthepaperair-cleaner

element.

1.Inspecttheelementfortears,anoilylm,or damagetotherubberseal(Figure28).

Figure28

1.Cover

2.Hoseclamp4.Foamelement

3.Rotatethecoverknobs1/4turncounterclockwise andremovetheair-cleanercover(Figure28).

4.Rotatethethumbscrewofthehoseclamp counterclockwiseuntilyoucanseparatethe air-cleanerassemblyfromtheinletduct(Figure

28).

3.Paperelement

Note:Replacethepaperelementifitis

damaged.

2.Cleanthepaperelementbygentlytappingitto removedustanddebris.

Note:Iftheelementisverydirty ,replacethe

air-cleanerelement.

Note:Donotusepressurizedairtocleanthe

paperelement.

InstallingtheFoamandPaper

g012352

Elements

Important:Topreventenginedamage,always

operatetheenginewiththecompletefoamand paperair-cleanerassemblyinstalled.

1.Carefullyslidethefoamelementontothepaper air-cleanerelement(Figure28).

2.Aligntheair-cleanerassemblyontotheinletduct andsecureitwiththehoseclamp(Figure28).

3.Aligntheair-cleanercoverontoenginecover andsecurethecoverbyrotatingthecoverknobs 1/4tunclockwise(Figure28).

ServicingtheEngineOil

OilType:Detergentoil(APIserviceSJorlater)

EngineOilCapacity:1.7L(1.8USqt)withthelter

removed;1.5L(1.6UDqt)withoutthelterremoved

Oilviscosity:Refertothetablebelow.

Figure29

g004216

ChangingtheEngineOil

Note:Disposeoftheusedoilatarecyclingcenter.

1.Parkthemachinesothatthedrainsideisslightly lowerthantheoppositesidetoassuretheoil drainscompletely.

2.Shutofftheengine,engagetheparkingbrake, removethekey,andwaitforallmovingpartsto stopbeforeleavingtheoperatingposition.

3.ChangetheengineoilasshowninFigure31.

Note:Torquedrainplugto27-33N∙m(20-24

ft-lb).

Figure30

g025979

Figure31

4.Slowlypourapproximately80%ofthespecied oilintothellertube,andslowlyaddthe additionaloiltobringittotheFullmark(Figure

32).

g025980

Figure32

5.Starttheengineanddrivetoaatarea.

6.Checktheengine-oillevel.

ChangingtheEngine-OilFilter

g025976

g026005

ServiceInterval:Every200hours

Note:Changetheengine-oilltermorefrequently

whenoperatingconditionsareextremelydustyor sandy.

1.Draintheoilfromtheengine;refertoChanging

theEngineOil(page33).

2.Placearagundertheoilltertosoakupany spilledoil.

Important:Spilledoilmaydrainunderthe

engineandontotheclutch.Oilspilledon theclutchmaydamagetheclutch,cause thebladestostopslowlywhentheclutchis intheOffposition,andcausetheclutchto slipwhentheclutchisswitchedtotheOn position.Wipeupanyspilledoil.

3.Changetheengine-oillter(Figure33).

g026006

Figure33

Note:Ensuretheoil-ltergaskettouchesthe

engine,andthenanextra3/4turniscompleted.

4.Fillthecrankcasewiththespeciedtypeofnew oil;refertoFigure29.

CheckingtheSparkPlugs

CheckingtheSparkPlug

ServiceInterval:Every160hours

Removesparkplugs,checkconditionandresetgaps, orreplacewithnewplugs.Seetheengineowner's manual.

ServicingtheSparkPlug

ServiceInterval:Every100hours

TypeforallEngines:NGKBPR4ESorequivalent

AirGap:0.75mm(0.03inch)

Makesurethattheairgapbetweenthecenterand sideelectrodesiscorrectbeforeinstallingthespark plug.

Useasparkplugwrenchforremovingandinstalling thesparkplug(s)andagappingtool/feelergaugeto checkandadjusttheairgap.Installanewspark plug(s)ifnecessary.

RemovingtheSparkPlug

Important:Donotcleanthesparkplug(s).

Alwaysreplacethesparkplug(s)whenithasa blackcoating,wornelectrodes,anoilylm,or cracks.

Ifyouseelightbrownorgrayontheinsulator,the engineisoperatingproperly.Ablackcoatingonthe insulatorusuallymeanstheaircleanerisdirty .

Setthegapto0.75mm(0.03inch).

g027479

Figure35

InstallingtheSparkPlug

1.Shutofftheengine,engagetheparkingbrake, removethekey,andwaitforallmovingpartsto stopbeforeleavingtheoperatingposition.

2.RemovethesparkplugasshowninFigure34.

Figure34

Tightenthesparkplug(s)to22N∙m(16ft-lb).

g025981

g027661

Figure36

g027478

Checkingthe

FuelSystem

SparkArrester

(ifequipped)

ServiceInterval:Every50hours

WARNING

Hotexhaustsystemcomponentsmayignite fuelvaporsevenaftertheengineisstopped. Hotparticlesexhaustedduringengine operationmayigniteammablematerials. Firemayresultinpersonalinjuryorproperty damage.

Donotrefuelorrunengineunlessspark arresterisinstalled.

1.Shutofftheengine,engagetheparkingbrake, removethekey,andwaitforallmovingpartsto stopbeforeleavingtheoperatingposition.

2.Allowthemufertocool.

3.Checkthesparkarresterforbreaksinthe spark-arresterscreenorwelds.

Maintenance

ServicingtheFuelFilter

ReplacingtheFuelFilter

ServiceInterval:Every800hours/Yearly(whichever

comesrst)

Note:Wipeupanyspilledfuel.

1.Shutofftheengine,engagetheparkingbrake, removethekey,andwaitforallmovingpartsto stopbeforeleavingtheoperatingposition.

2.Closethefuel-shutoffvalve;refertoFuel-Shutoff

Valve(page17).

3.Squeezetheendsofthehoseclampstogether andslidethemawayfromthelter(Figure37).

Note:Replacearresterifitiswornordamaged.

4.Ifyouseethatthescreenisplugged,perform thefollowing:

A.Removethesparkarrester.

B.Shakeloosetheparticlesfromofthe

arresterandcleanscreenwithawirebrush.

Note:Soakthearresterscreeninsolvent

ifnecessary.

C.Installsparkarresterontoexhaustoutlet.

g025982

Figure37

1.Hoseclamp3.Hose

2.Flowdirectionarrow(fuel lter)

4.Removethelterfromthefuelhoses(Figure

37).

Note:Donotinstalladirtylterifitisremoved

fromthefuelline.

5.Installanewlterwiththeow-directionarrow

alignedasillustratedinFigure37.

Note:Ensurethatthefuelhosesarefully

seatedontothehosettingsofthefuellter.

6.Alignthehoseclampsoverthehoseandthe

fuel-lterttings(Figure37).

7.Openthefuel-shutoffvalve;refertoOpeningthe

Fuel-ShutoffV alve(page22).

ElectricalSystem

8.Checkforfuelleaksandrepairifneeded.

9.Wipeupanyspilledfuel.

Maintenance

ServicingtheBattery

ServiceInterval:Every100hours

Alwayskeepthebatterycleanandfullycharged.Use apapertoweltocleanthebatterycase.Ifthebattery terminalsarecorroded,cleanthemwithasolutionof 4partswaterand1partbakingsoda.Applyalight coatingofgreasetothebatteryterminalstoprevent corrosion.

Voltage:12volts

DANGER

Donotdrinkelectrolyte,andavoidcontact withskin,eyesorclothing.Wearsafety glassestoshieldyoureyesandrubbergloves toprotectyourhands.

Batteryelectrolytecontainssulfuricacid whichisfatalifconsumedandcausessevere burns.

RemovingtheBattery

WARNING

Batteryterminalsormetaltoolscouldshort againstmetalmachinecomponentscausing sparks.Sparkscancausethebatterygasses toexplode,resultinginpersonalinjury.

•Whenremovingorinstallingthebattery, donotallowthebatteryterminalstotouch anymetalpartsofthemachine.

•Donotallowmetaltoolstoshortbetween thebatteryterminalsandmetalpartsofthe machine.

WARNING

Incorrectbattery-cableroutingcoulddamage themachineandcablescausingsparks. Sparkscancausethebatterygassesto explode,resultinginpersonalinjury.

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

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

1.Shutofftheengine,engagetheparkingbrake, removethekey,andwaitforallmovingpartsto stopbeforeleavingtheoperatingposition.

2.Removetheconsolepad;refertoRemovingthe

ConsolePad(page28).

4.Slidetheredterminalcoveroverthe positive-batteryterminal.

5.Installthenegativebatterycableandtheground wiretothenegative(-)batteryterminalwitha angedboltandangednut(Figure38).

3.Atthebattery,lifttheblackterminalcoveronthe negativecable(Figure38).

Figure38

1.Flangedbolt

2.Terminalcover

(black—negative-battery terminal)

3.Terminalcover

(red—positive-battery terminal)

4.Positive(+)battery

terminal

5.Negative(-)battery terminal

6.Flangednut

7.Batterytray

8.Batterystrap

4.Disconnectthenegativebatterycablefromthe negative(-)batteryterminal,andremovethe cablefromthebattery(Figure38).

5.Slidetheredterminalcoveroffthepositive batteryterminal(Figure38).

6.Slidetheblackterminalcoveroverthe negative-batteryterminal.

ChargingtheBattery

WARNING

Chargingthebatteryproducesgassesthat canexplode.

Neversmokenearthebatteryandkeepsparks andamesawayfrombattery .

Important:Alwayskeepthebatteryfullycharged

(1.265specicgravity)topreventbatterydamage whenthetemperatureisbelow32°F(0°C).

1.Removethebatteryfromthechassis;referto

RemovingtheBattery(page37).

g025881

2.Checktheelectrolytelevel.

3.Ensurethatthellercapsareinstalledonthe battery.

4.Chargethebatteryfor1hourat25to30amps or6hoursat4to6amps.

5.Whenthebatteryisfullycharged,unplugthe chargerfromtheelectricaloutlet,anddisconnect thechargerleadsfromthebatteryposts(Figure

39).

6.Installthebatteryontothemachineandconnect thebatterycables;refertoInstallingtheBattery

(page38).

Note:Donotrunthemachinewiththebattery

disconnected;electricaldamagemayoccur.

6.Disconnectthepositive(red)batterycable,and removethecablefromthebattery(Figure38).

7.Removethehookofthebatterystrapfromthe batterytray(Figure38),andremovethebattery.

InstallingtheBattery

1.Placethebatteryontothemachine(Figure38).

2.Securethebatterytothebatterytraywiththe batterystrap.

3.Installthepositive(red)batterycabletopositive (+)batteryterminalwithaangedboltand angednut(Figure38).

1.Positivebatterypost

2.Negativebatterypost

g000538

Figure39

3.Red(+)chargerlead

4.Black(-)chargerlead

ServicingtheFuses

DriveSystem

Theelectricalsystemisprotectedbyfuses,and requiresnomaintenance.Ifafuseblows,checkthe componentorcircuitforamalfunctionorshort.

1.Releasethecushionfromtherearofthe machine.

2.Removethenegative-batterycablefromthe batteryterminal;refertosteps4and5of

RemovingtheBattery(page37).

Note:Ensurethatthenegativebatterycable

doesnottouchthebatteryterminal.

3.Pullthefusefromthesocketofthefuseblock (Figure40).

Maintenance

CheckingtheAirPressure intheTires

ServiceInterval:Every50hours

Note:Thesemi-pneumaticcastertiresdonotneed

tobeinated.

1.Shutofftheengine,engagetheparkingbrake, removethekey,andwaitforallmovingpartsto stopbeforeleavingtheoperatingposition.

2.Checktirepressureindrivetires.

3.Inatedrivetiresto83-97kPa(12-14psi).

CheckingtheWheelHub Nuts

ServiceInterval:Yearly

Figure40

1.Fuseblock

4.Installafuseofthesametypeandamperesinto thesocketofthefuseblock(Figure40).

5.Installthenegative-batterycablefromthebattery terminal;refertosteps5and6ofInstallingthe

Battery(page38).

Torquethewheelhubnuts(Figure41)to285to350 N∙m(210to260ft-lb).

Note:Donotuseanti-seizecompoundonthewheel

hub.

g025983

g026029

Figure41

1.Lugnut2.Hubnut

CheckingtheTorqueofthe WheelLugNuts

ServiceInterval:Yearly

Torquethewheellugnuts(Figure41)to122to129 N∙m(90to95ft-lb).

AdjustingtheCasterPivot BearingsPre-Load

andtensionerplate,andthe2nutssecuringthe adjustmentboltatthetensionerplateasshown inFigure43.

Note:Ifyoudisassemblethecasterpivotbearings,

ensurethatthespring-discwashersareinstalledas showninFigure42.

1.Removedustcapfromcasterhub(Figure42).

Figure42

Note:Youmustloosenthenutsandboltsthat

securethetransmissionmountandtensioner plateatbothsidesofthemachine.

g026022

1.Dustcap

2.Locknut

3.Spring-discwashers

2.Tightenthelocknutclockwiseuntilspring-disc washersareat(Figure42).

3.Rotatethelocknutcounterclockwise1/4ofa turn(Figure42).

4.Installthedustcap(Figure42).

4.Spindle

5.Casterhub

MaintainingtheChain

AdjustingtheJackshaftDrive ChainTension

1.Shutofftheengine,engagetheparkingbrake, removethekey,andwaitforallmovingpartsto stopbeforeleavingtheoperatingposition.

2.Lifttherearofthemachineandsupportitusing jackstandsorequivalentsupport.

3.Checkthechainsonbothsidesofthemachine forpropertension.

Figure43

1.Hydromountingboltsand nuts

2.Nuts

3.Adjustmentbolt

5.Turntheadjustmentbolttomovetransmission

adjustmentplatesandtransmission.

6.Whenthechainscanmoveupanddown6to12

mm(1/4to1/2inch),tightenthenutsonboth sidesoftheadjustmentbolts.

7.Tightennutsandboltsthatsecurethehydro

mounting.

8.Adjusttraction-controllinkage,refertoAdjusting

theTraction-ControlLinkage(page44).

4.6-12mm(1/4-1/2inch)

5.Guardremovedforclarity

g020261

Note:Thechainsshouldmoveupanddown6

to12mm(1/4to1/2inch).

4.Ateachsideofthemachine,loosenthe3nuts andboltsthatsecurethetransmissionmount

AdjustingtheTensiononthe Drive-WheelChain

1.Shutofftheengine,engagetheparkingbrake, removethekey,andwaitforallmovingpartsto stopbeforeleavingtheoperatingposition.

2.Lifttherearofthemachineandsupportitusing jackstands.

3.Checkthetensionofthedrive-wheelchains (Figure44).

Note:Thechainsshouldmoveupanddown6

to12mm(1/4to1/2inch).

CheckingtheTransmission OutputShaftNutTorque

ServiceInterval:Yearly

Torquethenut(Figure45)onthetransmissionoutput taperedshaftto285-353N∙m(210-260ft-lb).

g025989

Figure45

1.Transmissionoutputshaftnut

Figure44

1.Locknut3.Drive-wheelchain

2.Idlersprocket

4.Loosenthelocknutandcarriageboltthatsecure theidlersprocket(Figure44).

5.Increaseordecreasechaintensionby performingthefollowing:

•Pushdownandforwardonthesprocket

toincreasethechaintensionasshownin

Figure44.

•Liftupandbackonthesprockettodecrease

thechaintension.

6.T orquethelocknutto91to113N∙m(67to83 ft-lb).

7.Checkthechaintensionandifnecessaryrepeat steps4through6untilyoucanmovethechain upanddown6to12mm(1/4to1/2inch).

g025990

BrakeMaintenance

AdjustingtheBrakeSwitch

1.Parkthemachineonalevelsurface.

AdjustingtheParking Brake

Iftheparkingbrakedoesnotholdsecurely,an adjustmentisrequired.

1.Parkthemachineonalevelsurface.

2.TurnthekeyintheignitionswitchtotheOFF positionandwaitforallmovingpartstostop.

3.Checktheairpressureinthedrivetires.

Note:Ifneeded,adjusttotherecommended

ination;refertoCheckingtheAirPressurein

theTires(page39).

4.Loosenthejamnutonthebrakecableunder theconsole(Figure46).

2.TurnthekeyintheignitionswitchtotheOFF positionandwaitforallmovingpartstostop.

3.Priortoadjustingthebrakeswitch,ensurethe parkingbrakeisproperlyadjusted;referto

AdjustingtheParkingBrake(page42).

4.Engagetheparkingbrake.

5.Checkthedistancebetweentheparking brake-switchbrackettothebrakearmofthe transmission(Figure47).

Note:Thedistanceshouldbe3.2mm(1/8

inch).

Figure46

1.7.9cm(3–1/8inch)

5.Engagetheparkingbrake(Figure46).

6.Adjustthejamnutpositionuntil7.9cm(3–1/8 inch)fromthebottomofthelinktothebottomof thespring(Figure46).

7.Securetheadjustmentofthecablebytightening thejamnuts(Figure46).

8.Checktheparkingbrake;ifnecessary,repeat steps4through7.

g025992

g025991

1.Brakearm(transmission)

2.Plunger(brakeswitch)5.Carriagebolt

3.Brake-switchbracket

6.Ifadjustmentisrequired,preformthefollowing:

A.Loosenthelocknutandcarriagebolt

securingtheparkingbrakeswitchbracket (Figure47).

B.Adjustthepositionofthebrake-switch

bracketuntilthegap(Figure47)between theswitchbracketandthebrakearmis3.2 mm(1/8inch)

C.Tightenthelocknutandcarriagebolt(Figure

47)securingthebrake-switchbracketto

1017to1243N-cm(90to110lb-in).

Figure47

4.Locknut

BeltMaintenance

CheckingtheCondition andTensionoftheBelts

ServiceInterval:Every50hours

1.Shutofftheengine,engagetheparkingbrake, removethekey,andwaitforallmovingpartsto stopbeforeleavingtheoperatingposition.

2.Raisethemachineandsupportitwithjack standswitha460kg(1,015lb)capacity.

3.Checktheauxiliarypump-drivebeltcondition andtension(Figure48).

Note:Thebeltshoulddeect1.3cm(1/2inch)

when1.4kg(3lb)offorceisappliedtothebelt midwaybetweentheauxiliarypumpandengine pulleys.Ifthebelttensionistoohighortoolow, refertoAdjustingtheAuxiliaryPumpDriveBelt

(page43).

4.Checkconditionofthetransmission-drivebelt (Figure48).

Note:Thetransmissionbelthasa

automatic-springtensioner.

Figure48

1.Transmission-drivebelt2.Auxiliarypump-drivebelt

g025997

Figure49

1.Auxiliarypump

2.Auxiliarypump-idlerpulley5.Auxiliarypump-drivebelt

3.Locknut(3/8inch)

3.Adjustthebelttensionasfollows:

4.Adjustmentslot(chassis)

•Movetheauxiliarypump-idlerpulley

rearwardandoutwardtotightenthebelt.

•Movetheauxiliarypump-idlerpulleyforward

andinwardtoloosenthebelt.

Note:Thebeltshoulddeect1.3cm(1/2inch)

when1.4kg(3lb)offorceisappliedtothebelt midwaybetweentheauxiliarypumpandengine pulleys.

4.Tightenthelocknutto37to45N∙m(27to33 ft-lb).

g025994

Replacingthe Transmission-DriveBelt

Note:Noadjustmentsarerequiredforbelttension.

AdjustingtheAuxiliary PumpDriveBelt

1.Shutofftheengine,engagetheparkingbrake, removethekey,andwaitforallmovingpartsto stopbeforeleavingtheoperatingposition.

2.Loosenthelocknut(3/8inch)thatsecuresthe auxiliarypump-idlerpulleytothechassisofthe machine.

1.Shutofftheengine,engagetheparkingbrake, removethekey,andwaitforallmovingpartsto stopbeforeleavingtheoperatingposition.

2.Insertabreakerbarintothesocketofthe belt-tensionbracketandmovethebracket outwardandforward(Figure50).

ControlsSystem Maintenance

Adjustingthe Traction-ControlLinkage

1.Parkthemachineonalevelsurface.

2.Shutofftheengine,engagetheparkingbrake, removethekey,andwaitforallmovingpartsto stopbeforeleavingtheoperatingposition.

3.Pushthecontrolleverallthewayforwardtothe frontreferencebar.

4.Ifthecontrollevercontactthereferencebar ordonotcontactthereferencebarperform thefollowing:

A.Releasethecontrolleverandallowitto

returntotheneutralposition.

B.Removethespring-clevispinfromthefork

ttingofthetraction-controllinkage(Figure

51).

Figure50

1.Transmissionpullys4.Enginepulley

2.Transmission5.Tensionerpulley

3.Socket(belt-tension bracket)

3.Slipthetransmission-drivebeltoftheengine,

tensioner,andtransmissionpulleys(Figure50).

4.Routethenewtransmission-drivebeltaround

theengine,tensioner,andtransmissionpulleys asshowninFigure50

5.Releasethebelt-tensionbracketandallowthe

springtotensionthebelt(Figure50).

Note:Makesurethatthebelt-tensionbracket

andpulleycanmovefreely.

g025999

g020223

Figure51

1.Spring-clevispin

2.Locknut

C.Adjusttheforkttingtosettheinitialgap

asfollows:

3.Turnbuckle

•Ifthecontrollevercontactsthe

referencebar,rotatetheforktting (Figure51)counterclockwise(asviewed fromthetopofthemachine).

•Ifthecontrolleverdoesnotcontacts

thereferencebar,rotatetheforktting (Figure51)counterclockwise.

D.Installthespringclevispin(Figure51)and

movethecontrolleverforward.

E.RepeatthisstepsAthroughDuntilthere

isagapapproximately1.6mm(1/16inch)

betweenthecontrolleverandthefront referencebar.

HydraulicSystem

F.Removethespring-clevispin,rotatethe

turnbuckleclockwise1-additionalturn,and insertthespring-clevispin(Figure51).

5.Repeatsteps4Athrough4Ffortheother

traction-controllinkage.

Maintenance

MaintainingtheAuxiliary HydraulicSystem

Hydraulicuidtype:AW-32hydrooil

CheckingtheAuxiliary Hydraulic-FluidLevel

ServiceInterval:Every50hours

1.Parkthemachineonalevelsurface.

2.Lowerthetinestotheground.

3.Shutofftheengine,engagetheparkingbrake, removethekey,andwaitforallmovingpartsto stopbeforeleavingtheoperatingposition.

4.Removetheconsolepad;refertoRemovingthe

ConsolePad(page28).

5.Cleanareaaroundhydraulicreservoircap (Figure52).

Figure52

1.Coldoillevel

6.Removethecapandcheckhydraulic-uidlevel inthereservoir(Figure52).

2.Hotoillevel

Note:Thehydraulic-uidlevelshouldcoverthe

wordColdthatisembossedintothebafeof thereservoir.

7.Ifnecessary,addthespeciedhydraulicuid tothereservoiruntiltheoilcoverstheColdoil levelonthebafe(Figure52).

Note:Thebafeionthereservoirislabeled

HotandCold.Y ouwillllthereservoirto

theappropriateleveldependinguponthe temperatureoftheoil.Theoillevelvarieswith

g025893

thetemperatureoftheoil.TheColdlevelshows theleveloftheoilwhenitisat24°C(75°F). TheHotlevelshowsthelevelofoilwhenitis at107°C(225°F).

Forexample:Iftheoilisatambient-air temperature(about24°C(75°F)),llonlytothe Coldlevel.Iftheoilisabout65°C(150°F),llto halfwaybetweentheHotandColdlevels.

8.Replacehydraulicreservoircapandtightenuntil snug(Figure52).

Note:Donotovertightenthereservoircap.

9.Installtheconsolepad;refertoRemovingthe

ConsolePad(page28).

ChangingtheAuxiliary Hydraulic-ReservoirOiland Filter

ServiceInterval:Aftertherst100hours

Every250hoursthereafter

1.Shutofftheengine,engagetheparkingbrake, removethekey,andwaitforallmovingpartsto stopbeforeleavingtheoperatingposition.

2.Carefullycleanareaaroundthefrontofthe auxiliarypump,thellcapforthereservoir,and thelter(Figure53).

Note:Itisimportantthatnodirtorcontamination

enterhydraulicsystem.

Figure54

1.Hydraulictting (auxiliary-hydraulicpump)

2.Inlethose

3.Draincontainer

4.Cleanaroundthettingforthehydraulicpump.

5.Rotatetheauxiliary-hydrauliclter

counterclockwiseandremoveitfromthe baseofthelteradapter(Figure55).

Note:theltertoremoveandallowoiltodrain.

g026010

Figure53

3.Atthefrontoftheauxiliary-hydraulicpump, removetheinlethosefromthehydraulictting inthepump,placetheendofthehoseinadrain container,andallowoiltodrain(Figure54).

g026007

Figure55

g026008

1.Auxiliary-hydrauliclter

2.Filteradapter

6.Applyathincoatofspeciedoilontothesealof thenewhydrauliclter.

7.Installthelterbyrotatingitclockwiseontothe lteradapteruntilthesealcontactsthelter adapter,thentightenthelteranadditional2/3 to3/4turn(Figure55).

8.Installtheinlethoseontothettinginthepump andtorquethehosettingto50N∙m(37ft-lb).

9.Addthespeciedoiluntilthelevelreachesthe Coldlllinelocatedonthereservoirtank;refer toCheckingtheAuxiliaryHydraulic-FluidLevel

(page45).

10.Startengineandraiseandlowerthetines.

11.Lowerthetinestothegroundandrellthe reservoirtotheColdllline.

Maintainingthe Transmission

Transmissionoiltype:T oro®HYPR-OIL™500

hydraulicoilorMobil®115W-50syntheticmotoroil.

Important:Usethespeciedoil.Otheruids

couldcausesystemdamage.

CheckingtheTransmission-Oil Level

ServiceInterval:Every50hours

1.Shutofftheengine,engagetheparkingbrake, removethekey,andwaitforallmovingpartsto stopbeforeleavingtheoperatingposition.

2.Allowthemachinetocooloff.

Note:Donotovertightentheexpansion-tank

cap.

3.Removethecapfromtheexpansiontankand checkthehydraulic-uidlevelinthetank(Figure

56).

Note:Thetransmission-oillevelshouldcover

theFullColdlinemoldedintothesideofthe tank.

Figure56

g025891

1.Cap3.FullColdline

2.Fillerneck(expansion

tank)

4.Ifnecessary,addthespeciedtransmissionoil untiltheoillevelisattheFullColdlineofthe expansiontank(Figure56).

5.Replaceexpansion-tankcapandtightenituntil snug.

ChangingtheTransmissionFilters

ServiceInterval:Aftertherst100hours

Every250hoursthereafter

Note:Donotchangethehydraulicsystemoil(except

forwhatcanbedrainedwhenchanginglter),unless theoilhasbeencontaminatedorbeenextremelyhot.

1.Shutofftheengine,engagetheparkingbrake, removethekey,andwaitforallmovingpartsto stopbeforeleavingtheoperatingposition.

2.Raisethemachineandsupportitwithjack standswitha460kg(1,015lb)capacity.

3.Removethe3washer-headbolts(1/4x3/4inch) thatsecurethelterguardtothetransmission, andremovetheguard(Figure57).

(Figure57),andtightentheboltsto1 117to1243 N-cm(90to110lb-in).

Figure57

1.Transmission

2.Filteradapter5.Filterguard

3.Transmissionlter

4.Washer-headbolts(1/4x 3/4inch)

4.Cleanthearoundthetransmissionlter(Figure

57).

5.Alignadrainpanunderthelter.

6.Rotatetheltercounterclockwiseandremove thelter(Figure57).

Note:Allowtheoiltocompletelydrainfromthe

lteradapterofthetransmission.

7.Applyathincoatofspeciedoilontothesealof thenewtransmissionlter.

8.Installthelterbyrotatingitclockwiseontothe lteradapteruntilthesealcontactsthebaseof theadapter,thentightenthelteranadditional 3/4to1turn(Figure57).

9.Installthelterguardwiththe3washer-head bolts(1/4x3/4inch)thatyouremovedinstep3

g026014

FillingtheTransmissionwithOil

ServiceInterval:Aftertherst100hours

Every250hoursthereafter

1.Raisetherearofmachineupandsupportwith jackstands(orequivalentsupport)justhigh enoughtoallowthedrivewheelstoturnfreely.

CAUTION

Donotrelysolelyonmechanical orhydraulicjacksforsupport.Use adequatejackstandsorequivalent support.

2.Alignadrainpanunderthesightplugsofthe transmissions(Figure58andFigure59).

Figure59

Lefttransmissionshown

1.Sightplug

2.Sight-plugport

3.Up

3.Attheinboardsideofthetransmission,near thetop,removethesightplugfrom1ofthe transmissions(Figure58andFigure59).

4.Addthespeciedoiltotheexpansiontank untiloilowsfromthesight-plugport;referto

CheckingtheTransmission-OilLevel(page47).

g026016

1.Sightplug

2.Sight-plugport

Figure58

Lefttransmissionshown

5.Installthesightplugandtorqueitto244N∙m (180in-lb).

6.Repeatsteps3through5fortheother transmission.

7.Addthespeciedoilintotheexpansiontankuntil theoillevelisattheFullColdlineofthetank.

8.Starttheengineandmovethethrottletothe1/2 enginespeedposition.

9.Disengagetheparkingbrake.

10.Slowlymovethetraction-controlleversinthe

g026015

forwardandreversedirections5to6times;refer toTraction-ControlLevers(page15).

Note:Cyclingthetraction-controlsforwardand

3.Up

reversepurgesairfromthetransmissions.

11.Stoppingtheengine.

12.Checktheoillevelintheexpansiontank, andaddthespeciedoilasrequired;referto

CheckingtheTransmission-OilLevel(page47).

13.Repeatsteps8through12untilalltheairis completelypurgedfromthetransmissions.

Note:Theairispurgedwhenthetransmissions

whenthetransmissionsoperateatnormalnoise levelsandsmoothlymoveforwardandreverse atnormalspeeds.

14.Lowerthemachineandremovethejackstands.

TineMaintenance

CheckingtheTines

ServiceInterval:Beforeeachuseordaily

1.Shutofftheengine,engagetheparkingbrake, removethekey,andwaitforallmovingpartsto stopbeforeleavingtheoperatingposition.

2.Raisethemachineandsupportitwithjack standswitha460kg(1,015lb)capacity.

7.Securethecoverpaneltothechassiswiththe 2boltsand2washers(Figure60)thatyou removedinstep3,andtorquetheboltsto37to 45N∙m(27to33lb-in)

AdjustingtheTine-Drive Chain

1.Shutofftheengine,engagetheparkingbrake, removethekey,andwaitforallmovingpartsto stopbeforeleavingtheoperatingposition.

CAUTION

Donotrelysolelyonmechanical orhydraulicjacksforsupport.Use adequatejackstandsorequivalent support.

3.Removethe2bolt(3/8x1inch)and2washers (3/8inch)thatsecuretherear-coverpaneltothe chassis,andremovethepanel(Figure60).

2.Removetherearcover;refertostep3of

CheckingtheTines(page50).

3.Checkthechainsonbothsidesofthemachine forpropertension.

Note:Thechainsshouldmoveupanddown6

to12mm(1/4to1/2inch).

4.Loosenthelocknutandcarriageboltthatsecure theidlersprocket(Figure61).

Figure61

1.Locknut

2.Idlersprocket

3.Carriagebolt

4.Slot(trailplate)

g026018

Figure60

1.Chassisholes3.Bolt(3/8x1inch)

2.Washer(3/8inch)

4.Removerocksandotherdebrisfromthetines.

5.Inspectthetinesforwearanddamage.

4.Rearpanel

Note:Replaceanytinesthatarewornor

damaged.

6.Aligntheholesintherear-coverpaneltothe holesinthechassis(Figure60).

5.Increaseordecreasechaintensionby performingthefollowing:

•Pushdownandforwardonthesprocket

toincreasethechaintensionasshownin

Figure61.

g026017

•Liftupandbackonthesprockettodecrease

thechaintension.

6.T orquethelocknutto91to113N∙m(67to83 ft-lb).

7.Checkthechaintensionandifnecessaryrepeat steps4through6untilyoucanmovethechain upanddown6to12mm(1/4to1/2inch).

8.Installtherearpanel;refertosteps6and7of

CheckingtheTines(page50).

Cleaning

CleaningtheDebrisfrom theMachine

CleaningtheEngineand theExhaustSystemArea

ServiceInterval:Beforeeachuseordaily(maybe

requiredmoreoftenindryordirty conditions.)

CAUTION

Excessivedebrisaroundenginecoolingair intakeandexhaustsystemareacancause engine,exhaustarea,andhydraulicsystemto overheatwhichcancreatearehazard.

Cleanalldebrisfromengineandexhaust systemarea.

1.Shutofftheengine,engagetheparkingbrake, removethekey,andwaitforallmovingpartsto stopbeforeleavingtheoperatingposition.

2.Cleanalldebrisfromscreenatthetopofthe engine,aroundengineshrouding,andexhaust systemarea.

ServiceInterval:Beforeeachuseordaily

1.Shutofftheengine,engagetheparkingbrake, removethekey,andwaitforallmovingpartsto stopbeforeleavingtheoperatingposition.

2.Cleanoffanyoil,debris,orgrassbuilduponthe machineandaeratordeck.

3.Cleanoffanydebrisorgrassunderthechain guards,aroundthefueltank,andaroundthe engineandexhaustarea.

WasteDisposal

DisposingoftheEngineOil

Engineoilandhydraulicuidarebothpollutantsto theenvironment.Disposeofusedoilatacertied recyclingcenteroraccordingtoyourstateandlocal regulations.

DisposingoftheBattery

3.Wipeupanyexcessivegreaseoroilaroundthe engineandexhaustsystemarea.

RemovingtheEngine ShroudsandCleaningthe CoolingFins

ServiceInterval:Every80hours

1.Shutofftheengine,engagetheparkingbrake, removethekey,andwaitforallmovingpartsto stopbeforeleavingtheoperatingposition.

2.Removecoolingshroudsfromengine.

3.Cleancoolingnsoftheengine.

Note:Alsocleandust,dirt,andoilfromexternal

surfacesofenginewhichcancauseimproper cooling.

4.Installthecoolingshroudsintotheengine.

Note:Operatingtheenginewithoutcooling

shroudscausesenginedamagedueto overheating.

DANGER

Batteryelectrolytecontainssulfuricacid, whichispoisonousandcancausesevere burns.Swallowingelectrolytecanbefatalor ifittouchesskincancausesevereburns.

•Wearsafetyglassestoshieldeyes,and rubberglovestoprotectskinandclothing whenhandlingelectrolyte.

•Donotswallowelectrolyte.

•Intheeventofanaccident,ushwithwater andcalladoctorimmediately.

Federallawstatesthatbatteriesshouldnotbeplaced inthegarbage.Managementanddisposalpractices forbatteriesmustfollowrelevantfederal,state,or locallaws.

Ifabatteryisbeingreplacedorifthemachine containingthebatteryisnolongeroperatingandis beingscrapped,removethebatteryandtakeittoa localcertiedrecyclingcenter.Ifnolocalrecycling isavailablereturnthebatterytoanycertiedbattery reseller.

Storage

1.Raisethetines,stopthemachine,shutoffthe engine,engagetheparkingbrake,andremove thekey.

2.Removedirtandgrimefromtheentiremachine.

Important:Youcanwashthemachinewith

milddetergentandwater.Donotpressure washthemachine.Avoidexcessiveuse ofwater,especiallyneartheengineand hydrostaticdrive.

3.Servicetheaircleaner;refertoServicingtheAir

Cleaner(page32).

4.Lubricatethemachine;refertoLubricatingthe

GreaseFittings(page29).

5.Changetheengineoil;refertoChangingthe

EngineOil(page33).

6.Checkandtightenallbolts,nuts,andscrews. Repairorreplaceanypartthatisdamaged.

7.Paintallscratchedorbaremetalsurfaces.Paint isavailablefromyourAuthorizedServiceDealer.

8.Storethemachineinaclean,drygarageor storagearea.

9.Coverthemachinetoprotectitandkeepitclean.

Troubleshooting

Problem

Thestarterdoesnotcrank.

Theenginedoesnotstart,startshard,or failstokeeprunning.

PossibleCauseCorrectiveAction

1.Theparkingbrakeisnotset.1.Engagetheparkingbrake.

2.Thebrakeswitchisnotadjusted properly.

3.Thebatterydoesnothaveafull charge.

4.Theelectricalconnectionsare corroded,looseorfaulty.

5.Afuseisblown.5.Replacetheblownfuse.

6.Arelayorswitchisfaulty.6.ContactanAuthorizedServiceDealer.

1.Thefueltankisempty.1.Fillthefueltank.

2.Thefuelshutoffvalveisclosed.2.Openthefuelshutoffvalve.

3.Thethrottleandchokearenotinthe correctposition.

4.Thereisdirtinthefuellter.4.Replacethefuellter.

5.Thereisdirt,water,orstalefuelisin thefuelsystem.

6.Theaircleanerisdirty.

7.Theelectricalconnectionsare corroded,looseorfaulty.

8.Arelayorswitchisfaulty.8.ContactanAuthorizedServiceDealer.

9.Thesparkplugisfaulty.

10.Thespark-plugwireisnotconnected.

2.Adjustthebrakeswitch.

3.Chargethebattery.

4.Checktheelectricalconnectionsfor goodcontact.Cleantheconnector terminalsthoroughlywithelectrical contactcleaner,applydielectric grease,andreconnect.

3.Besurethethrottlelevelismidway betweentheSlowandFastpositions, andthechokeisintheOnpositionfor acoldengineortheOffpositionfora warmengine.

5.ContactanAuthorizedServiceDealer.

6.Cleanorreplacetheaircleaner element.

7.Checktheelectricalconnections forgoodcontact.Cleanconnector terminalsthoroughlywithelectrical contactcleaner,applydielectric grease,andreconnect.

9.Clean,adjust,orreplacethespark plug.

10.Checkthespark-plugwireconnection.

Theenginelosespower.

Theengineoverheats.

Themachinepullsleftorright(withlevers fullyforward).

1.Theengineloadisexcessive.1.Reducethegroundspeedoraeration

2.Theaircleanerisdirty.

3.Theoillevelinthecrankcaseislow.3.Addoiltothecrankcase.

4.Thecoolingnsandairpassagesfor theengineareplugged.

5.Thereisdirtinthefuellter.5.Replacethefuellter.

6.Thereisdirt,water,orstalefuelisin thefuelsystem.

1.Theengineloadisexcessive.1.Reducethegroundspeedoraeration

2.Theoillevelinthecrankcaseislow.2.Addoiltothecrankcase.

3.Thecoolingnsandairpassagesfor theengineareplugged.

1.Thetirepressureindrivetiresisnot correct.

2.Thetrackingneedsadjustment.2.Adjustthetraction-controllinkage.

depth.

2.Cleanorreplacetheaircleaner element.

4.Removetheobstructionsfromthe coolingnsandairpassages.

6.ContactanAuthorizedServiceDealer.

depth.

3.Removetheobstructionsfromthe coolingnsandairpassages.

1.Adjustthetirepressureinthedrive tires.

Problem

PossibleCauseCorrectiveAction

Themachinedoesnotdrive.

Thereisabnormalvibration.

Thetinesdonotraise.

Thetinesdonotengagetheground.

1.Thetransmissionbeltworn,looseor broken.

2.Thetransmissionbeltisoffapulley.2.Changethebelt.

1.Atineisbent.1.Installanewtine.

2.Thetinemountingboltisloose.2.Tightenthetinemountingbolt.

3.Theenginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Thereisalooseenginepulleyoridler pulley.

5.Theenginepulleyisdamaged.

6.Abeltisdamaged.6.Installanewbelt.

7.Thechainsarenotproperlytensioned.

1.Thereisanauxiliarypumpbelt problem.

2.Thetinedownpressuresettingistoo low.

3.Thereisashortinthewiringharness.

4.Theauxiliaryreservoirislowonoil.4.Addoiltothereservoir.

1.Thetinedownpressuresettingistoo low.

2.Theharness/switchisdamaged.2.ContactanAuthorizedServiceDealer.

3.Theauxiliaryreservoirislowonoil.3.Addoiltothereservoir.

4.Thecylinderstopisinplace(model

39518).

1.Changethebelt.

4.Tightentheappropriatepulley.

5.ContactanAuthorizedServiceDealer.

7.Checkthejackshaftdrivechain tension,thedrivewheelchaintension, andthetinedrivechaintension.

1.T ensionorreplacethebelt.

2.Increasethedownpressure.

3.ContactanAuthorizedServiceDealer.

1.Increasethetinedownpressure.

4.Removethecylinderstop,clevispin, andhairpin.

Schematics

ElectricalDiagram(Rev .A)

g020224

ElectricalSchematic(Rev .A)

g020225

HydraulicDiagram(Rev .A)

g020226

CaliforniaProposition65WarningInformation

Whatisthiswarning?

Youmayseeaproductforsalethathasawarninglabellikethefollowing:

WARNING:CancerandReproductiveHarm—www.p65Warnings.ca.gov.

WhatisProp65?

Prop65appliestoanycompanyoperatinginCalifornia,sellingproductsinCalifornia,ormanufacturingproductsthatmaybesoldinorbroughtinto California.ItmandatesthattheGovernorofCaliforniamaintainandpublishalistofchemicalsknowntocausecancer,birthdefects,and/orother reproductiveharm.Thelist,whichisupdatedannually,includeshundredsofchemicalsfoundinmanyeverydayitems.ThepurposeofProp65isto informthepublicaboutexposuretothesechemicals.

Prop65doesnotbanthesaleofproductscontainingthesechemicalsbutinsteadrequireswarningsonanyproduct,productpackaging,orliteraturewith theproduct.Moreover,aProp65warningdoesnotmeanthataproductisinviolationofanyproductsafetystandardsorrequirements.Infact,the CaliforniagovernmenthasclariedthataProp65warning“isnotthesameasaregulatorydecisionthataproductis‘safe’or‘unsafe.’”Manyofthese chemicalshavebeenusedineverydayproductsforyearswithoutdocumentedharm.Formoreinformation,gotohttps://oag.ca.gov/prop65/faqs-view-all

AProp65warningmeansthatacompanyhaseither(1)evaluatedtheexposureandhasconcludedthatitexceedsthe“nosignicantrisklevel”;or(2) haschosentoprovideawarningbasedonitsunderstandingaboutthepresenceofalistedchemicalwithoutattemptingtoevaluatetheexposure.

Doesthislawapplyeverywhere?

Prop65warningsarerequiredunderCalifornialawonly.ThesewarningsareseenthroughoutCaliforniainawiderangeofsettings,includingbutnot limitedtorestaurants,grocerystores,hotels,schools,andhospitals,andonawidevarietyofproducts.Additionally ,someonlineandmailorder retailersprovideProp65warningsontheirwebsitesorincatalogs.

HowdotheCaliforniawarningscomparetofederallimits?

Prop65standardsareoftenmorestringentthanfederalandinternationalstandards.TherearevarioussubstancesthatrequireaProp65warning atlevelsthatarefarlowerthanfederalactionlimits.Forexample,theProp65standardforwarningsforleadis0.5μg/day,whichiswellbelow thefederalandinternationalstandards.

Whydon’tallsimilarproductscarrythewarning?

•ProductssoldinCaliforniarequireProp65labellingwhilesimilarproductssoldelsewheredonot.

•AcompanyinvolvedinaProp65lawsuitreachingasettlementmayberequiredtouseProp65warningsforitsproducts,butothercompanies

makingsimilarproductsmayhavenosuchrequirement.

•TheenforcementofProp65isinconsistent.

•CompaniesmayelectnottoprovidewarningsbecausetheyconcludethattheyarenotrequiredtodosounderProp65;alackofwarningsfora

productdoesnotmeanthattheproductisfreeoflistedchemicalsatsimilarlevels.

WhydoesToroincludethiswarning?

Torohaschosentoprovideconsumerswithasmuchinformationaspossiblesothattheycanmakeinformeddecisionsabouttheproductstheybuyand use.T oroprovideswarningsincertaincasesbasedonitsknowledgeofthepresenceofoneormorelistedchemicalswithoutevaluatingthelevelof exposure,asnotallthelistedchemicalsprovideexposurelimitrequirements.WhiletheexposurefromToroproductsmaybenegligibleorwellwithinthe “nosignicantrisk”range,outofanabundanceofcaution,T orohaselectedtoprovidetheProp65warnings.Moreover ,ifTorodoesnotprovidethese warnings,itcouldbesuedbytheStateofCaliforniaorbyprivatepartiesseekingtoenforceProp65andsubjecttosubstantialpenalties.

RevA

TheToroWarranty

Atwo-Y earLimitedWarranty

ConditionsandProductsCovered

TheToroCompanyanditsafliate,T oroWarrantyCompany,pursuant toanagreementbetweenthem,jointlywarrantyourT oroHydroject orProCoreAerator(“Product”)tobefreefromdefectsinmaterials orworkmanshipfortwoyearsor500operationalhours*,whichever occursrst.Thiswarrantyisapplicabletoallproducts(referto separatewarrantystatementsfortheseproducts).Whereawarrantable conditionexists,wewillrepairtheProductatnocosttoyouincluding diagnostics,labor,parts,andtransportation.Thiswarrantybegins onthedatetheProductisdeliveredtotheoriginalretailpurchaser. *Productequippedwithanhourmeter.

InstructionsforObtainingWarrantyService

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

CommercialProductsServiceDepartment ToroWarrantyCompany 811 1LyndaleAvenueSouth Bloomington,MN55420-1196 952–888–8801or800–952–2740 E-mail:commercial.warranty@toro.com

OwnerResponsibilities

AstheProductowner,youareresponsibleforrequiredmaintenanceand adjustmentsstatedinyourOperator’sManual.Failuretoperformrequired maintenanceandadjustmentscanbegroundsfordisallowingawarranty claim.

ItemsandConditionsNotCovered

Notallproductfailuresormalfunctionsthatoccurduringthewarranty periodaredefectsinmaterialsorworkmanship.Thiswarrantydoesnot coverthefollowing:

•Productfailureswhichresultfromtheuseofnon-Tororeplacement

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

•Productfailureswhichresultfromfailuretoperformrecommended

maintenanceand/oradjustments.Failuretoproperlymaintain yourToroproductpertherecommendedmaintenancelistedinthe Operator’sManualcanresultinclaimsforwarrantybeingdenied.

•ProductfailureswhichresultfromoperatingtheProductinanabusive,

negligentorrecklessmanner.

•Partssubjecttoconsumptionthroughuseunlessfoundtobedefective.

Examplesofpartswhichareconsumed,orusedup,duringnormal Productoperationinclude,butarenotlimitedto,brakespadsand linings,clutchlinings,blades,reels,bedknives,tines,sparkplugs, castorwheels,tires,lters,belts,andcertainsprayercomponents suchasdiaphragms,nozzles,andcheckvalves,etc.

•Failurescausedbyoutsideinuence.Itemsconsideredtobeoutside

inuenceinclude,butarenotlimitedto,weather,storagepractices, contamination,useofunapprovedcoolants,lubricants,additives, fertilizers,water,orchemicals,etc.

•Normalnoise,vibration,wearandtear,anddeterioration.

•Normal“wearandtear”includes,butisnotlimitedto,damagetoseats

duetowearorabrasion,wornpaintedsurfaces,scratcheddecalsor windows,etc.

Parts

Partsscheduledforreplacementasrequiredmaintenancearewarranted fortheperiodoftimeuptothescheduledreplacementtimeforthatpart. Partsreplacedunderthiswarrantyarecoveredforthedurationofthe originalproductwarrantyandbecomethepropertyofT oro.T orowillmake thenaldecisionwhethertorepairanyexistingpartorassemblyorreplace it.T oromayuseremanufacturedpartsforwarrantyrepairs.

MaintenanceisatOwner’sExpense

Enginetune-up,lubricationcleaningandpolishing,replacementofItems andConditionsNotCovered,lters,coolant,andcompletingrecommended maintenancearesomeofthenormalservicesT oroproductsrequirethat areattheowner’sexpense.

GeneralConditions

RepairbyanAuthorizedToroDistributororDealerisyoursoleremedy underthiswarranty.

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

Allimpliedwarrantiesofmerchantabilityandtnessforusearelimitedtothe durationofthisexpresswarranty .Somestatesdonotallowexclusionsof incidentalorconsequentialdamages,orlimitationsonhowlonganimplied warrantylasts,sotheaboveexclusionsandlimitationsmaynotapplytoyou.

Thiswarrantygivesyouspeciclegalrights,andyoumayalsohaveother rightswhichvaryfromstatetostate.

Noteregardingenginewarranty:

TheEmissionsControlSystemonyourProductmaybecoveredby aseparatewarrantymeetingrequirementsestablishedbytheU.S. EnvironmentalProtectionAgency(EP A)and/ortheCaliforniaAirResources Board(CARB).Thehourlimitationssetforthabovedonotapplytothe EmissionsControlSystemWarranty.RefertotheEngineEmissionControl WarrantyStatementprintedinyourOperator’sManualorcontainedinthe enginemanufacturer’sdocumentationfordetails

CountriesOtherthantheUnitedStatesorCanada

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

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Toro 39519 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual