Toro 652D, Reelmaster 4240-D Operator's Manual

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Page 1

Part No. 111-0473 Rev B

Reelmaster 4240-D

Code: 652D-Serial No. from 260000001

Operator’s Manual

Original Instructions (EN)

Page 2

Page 3

ATTENTION

THIS SYMBOL MEANS

BE ALERT!

YOUR SAFETY IS INVOLVED

READ THIS MANUAL BEFORE USING THE REELMASTER® 4240-D.

IT IS ESSENTIAL THAT OPERATORS STUDY IT FOR THEIR OWN SAFETY.

ALL OPERATORS SHOULD SEEK AND OBTAIN PROFESSIONAL AND

PRACTICAL INSTRUCTIONS ON THE SAFE USE OF THE MOWER. THESE

SERVICES ARE AVAILABLE THROUGH TORO APPROVED COMMERCIAL DEALERS.

Page 4

CONTENTS

1.4

CONTENTS

SAFETY PRECAUTIONS.

Training.

Preparation.

Operation.

Handling and storage of fluids.

Maintenance and storage.

Decals.

EC CONFORMITY INFORMATION.

Noise levels.

EC Declaration of Conformity.

INTRODUCTION.

SPECIFICATIONS.

Engine.

Transmission system.

Cutterhead drive system.

Cutterhead lift system and steering.

Hydraulic system.

Vehicle specifications.

Operator controls.

Instrumentation.

Weight and dimensions.

Recommended lubricants and hydraulic fluids.

Cutterheads.

OPERATING THE MOWER.

Safety notice.

Operator presence controls.

Identification of controls.

Braking system.

Throttle control.

Travel.

Work/Transport modes.

Transport latches.

Differential lock.

Travel control pedals.

Forward travel speed backstop lever.

Operator platform latching mechanism.

Adjustable steering column.

Operator seat.

Warning systems.

Audible warning horn.

Ignition key.

Engine pre-heat indicator light.

Page No.

1.6 - 1.14

1.6

1.6 - 1.7

1.7 - 1.9

1.10

1.11

1.12 - 1.14

1.15 - 1.16

1.15

1.16

1.17

1.18 - 1.24

1.18

1.19

1.20

1.21

1.22

1.23

1.24

1.25 - 1.44

1.25

1.26

1.27

1.28

1.29

1.30

1.31

1.32

1.33

1.34

Page 5

CONTENTS

1.5

CONTENTS Continued.

Fuel level gauge.

Hourmeter.

Transmission neutral indicator light.

Cutterhead drive switch indicator light.

Parking brake indicator light.

Hydraulic return filter indicator light.

Hydraulic transmission filter indicator light.

Transmission system ‘Work’ mode indicator light.

Cutterhead position control.

Dual lift configuration control.

Cutterhead drive engagement.

Weight transfer/traction assistance.

Starting the engine.

Stopping the engine.

General operating hints.

Unblocking cutting cylinders.

Cutterhead general information.

MK3 200mm Fixed Cutterhead.

MK3 254mm Fixed Cutterhead.

MK3 200mm Floating Cutterhead.

MAINTENANCE.

General safety and good practice.

Engine.

Running in period.

Running in period - at first 50 hours.

Daily and before use.

Every 50 hours.

Every 250 hours.

Every 500 hours.

Cutterhead cylinder to bottom blade adjustment.

Cutterhead backlapping.

Cutterhead grinding.

Cutterhead bottom blade replacement.

Raising the mower off the ground.

Towing the mower.

GRASS CUTTING FAULTS.

TROUBLE SHOOTING.

ELECTRICAL CIRCUIT DIAGRAM.

TRANSMISSION/BRAKE HYDRAULIC CIRCUIT.

HYDRAULIC CIRCUIT DIAGRAM.

WARRANTY.

NOTES.

CUSTOMER INFORMATION.

Page No.

1.34

1.35

1.36

1.37

1.38

1.38 - 1.39

1.39

1.40

1.41

1.42

1.43

1.44

1.45 - 1.64

1.45 - 1.46

1.47

1.47 - 1.48

1.49 - 1.52

1.53 - 1.54

1.55

1.56 - 1.58

1.59

1.60

1.61

1.62

1.63 - 1.64

1.65 - 1.67

1.68 - 1.74

1.75 - 1.78

1.79 - 1.80

1.81 - 1.82

1.83 - 1.84

1.85

1.86

Page 6

SAFETY PRECAUTIONS

1.6

TRAINING

Read the instructions carefully. Be familiar with the controls and the proper use of the equipment. Learn how to stop the mower quickly in an emergency.

Never allow children or people unfamiliar with these instructions to use the mower. Local regulations may restrict the age of the operator.

Never mow while people, especially children, or pets are nearby.

Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people or their property.

Do not carry passengers.

All drivers should seek and obtain professional and practical instruction. Such instruction should emphasise:

The need for care and concentration when working with this machine.

The need to slow down when making tight turning manoeuvres. Failure to take adequate care can affect stability leading to loss of control of the machine particularly when operating in transport mode.

Control of a ride-on-machine sliding on a slope will not be regained by application of the brake. The main reasons for loss of control are:

- Insufficient wheel grip.

- Being driven too fast.

- Inadequate braking.

- The type of machine is unsuitable for the task.

- Lack of awareness of the effect of ground conditions, especially slopes.

- Incorrect load distribution.

PREPARATION

Check that the machine complies with all applicable regulations, including those in force when used on the public highway.

While mowing, always wear substantial footwear and long trousers. Do not operate the equipment when barefoot or wearing open sandals. Eye protection should be worn.

Thoroughly inspect the area where the equipment is to be used and remove all objects which can be thrown by the machine.

Never operate the machine without first checking that the operator platform latching mechanism is fully engaged and in good working order, refer - ‘OPERATOR PLATFORM LATCHING MECHANISM’.

READ THIS MANUAL BEFORE USING THE REELMASTER® 4240-D, IT IS ESSENTIAL THAT OPERATORS STUDY IT FOR THEIR OWN SAFETY.

THE FOLLOWING PRECAUTIONS MUST BE TAKEN TO HELP PREVENT ACCIDENTS. A CAREFUL OPERATOR WHO USES COMMON SENSE IS THE SAFEST OPERATOR.

Page 7

1.7

SAFETY PRECAUTIONS

PREPARATION Continued.

Ensure that the cutterheads are fully raised with the latches and safety locks engaged in position before transporting the mower.

Replace faulty silencers.

Check the condition of the tyres and ensure that they are inflated to the correct pressures, refer - SPECIFICATIONS. This is particularly important if the machine is to be taken on the public highway.

Check that the mower is in good working order, paying particular attention to the brakes and steering. Also ensure that the forward/reverse speed control pedals move freely to neutral when released.

Before use, always visually inspect to see that the blades, blade bolts and cutting cylinders are not worn or damaged. Replace worn or damaged components.

Check the mower hydraulic system, particularly the hydraulic hoses, fittings and hose supports. Worn, crushed or damaged hoses can burst, with risks to health and damage to the machine and surrounding turf areas.

After refuelling and adding oil to the hydraulic oil tank ensure that the caps are replaced securely.

Check that all linkages, connections and pivot nuts are secure and that wheel nuts are torqued correctly, refer - SPECIFICATIONS.

Before operating the machine, ensure that there are no foreign objects or liquids on the platform or pedals - ALWAYS KEEP THE OPERATOR PLATFORM CLEAR/CLEAN.

OPERATION

Do not operate the engine in a confined space where dangerous carbon monoxide fumes can collect.

Mow only in daylight or in good artificial light.

Before attempting to start the engine, engage the parking brake, disengage the cutterhead drive system and ensure that the forward/reverse speed controls are in the neutral position.

Never operate the machine without first checking that the operator platform latching mechanism is fully engaged and in good working order, refer - OPERATOR PLATFORM LATCHING MECHANISM.

Stored energy devices are charged when the outer wing units are in the transport position. Always operate the relevant lift controls to provide hydraulic support for the wing units suspensions before attempting to release the transport latches.

Page 8

1.8

SAFETY PRECAUTIONS

OPERATION Continued.

Do not use on a slope of more than 19 degrees. Care should be taken when using the mower on any slope where ground conditions are such that there may be a risk of the mower rolling over. The requirements of SI 1998 No. 2306 “Provision and Use of Work Equipment Regulations” should be considered. R.O.P.S (Roll Over Protective Structures) are available, refer to INTRODUCTION - Optional Extras.

Stability angles given are maximum figures and are for guidance only. Particular conditions such as wet grass or uneven ground may not permit safe operation on the slope limits stated.

Remember there is no such thing as a "safe" slope. Travel on grass slopes requires particular care. To guard against overturning or loss of traction when travelling or mowing on a slope:

- Exercise extreme care when changing direction on a slope.

- Do not stop or start suddenly.

- Engage drive slowly.

- Keep machine speed low.

- Avoid tight turns.

- Stay alert for humps, hollows and other hidden hazards.

- Keep away from sharp inclines and steep drops.

- A thorough risk assessment should be carried out by a competent person before travelling or mowing on a slope.

Never park on a slope.

3DA176

19 Degree slope

Ground level

Page 9

SAFETY PRECAUTIONS

1.9

OPERATION Continued.

Watch out for traffic when crossing or near roadways.

Use extreme caution when reversing.

Disengage the cutterhead drive system before crossing surfaces other than grass.

When using the machine, never direct the discharge of material towards bystanders or allow anyone near the machine while in operation.

Never operate the mower with damaged guards, shields or without safety protective devices in place and in good working order.

Do not change the engine governor settings or overspeed the engine. Operating an engine at excessive speed may increase the risk of personal injury.

Before leaving the operator's position:

- Disengage the drive to the cutterheads.

- Lift cutterheads to the transport position and securely lock the safety latches or alternatively lower cutterheads to the ground.

- Change into neutral and set the parking brake.

- Stop the engine and remove the ignition key.

Engage the parking brake, disengage the drive to the cutterheads, stop the engine and remove ignition key :

- Before releasing blockages.

- Before checking, cleaning or working on the mower.

- After striking a foreign object. Inspect the mower for damage and make repairs before restarting and operating the equipment.

- If the machine starts to vibrate abnormally ( check immediately ).

- Before refuelling.

- Before making cutterhead adjustments.

Disengage the drive to the cutterheads when transporting or not in use.

Reduce the throttle setting during engine run - out.

Never work on the mower when the engine is running.

Always keep feet and hands well away from the cutting cylinders when making adjustments.

Never operate the mower without first checking that the operator platform is securely latched.

Page 10

SAFETY PRECAUTIONS

1.10

HANDLING AND STORAGE OF FLUIDS

Hydraulic Oil

- Avoid contact with eyes and prolonged contact with skin.

- Protective goggles should be worn when pouring.

- Use of gloves or barrier cream is recommended.

- Wash hands thoroughly after contact.

- Store under cover, away from heat and sources of ignition.

Diesel Oil

- Avoid skin and eye contact.

- Wear impervious gloves when regular contact is likely and goggles when there is risk of splashing.

- Wash hands thoroughly after contact.

- Store in a cool dry well ventilated place away from heat and sources of ignition, in vessels specifically designed for storing fuel oils.

Lubricating Oil

- Avoid skin and eye contact.

- Wear impervious gloves when regular contact is likely and goggles when there is risk of splashing.

- Wash hands thoroughly after contact.

- Store in a cool dry well ventilated place away from heat and sources of ignition.

Anti- Freeze

- Keep away from heat, sparks, and flames.

- Avoid skin and eye contact and breathing vapours.

- Store in a closed container in a cool dry well ventilated area.

Page 11

SAFETY PRECAUTIONS

1.11

MAINTENANCE AND STORAGE

Take care when rotating a cutting cylinder as this can cause other cylinders to rotate.

When the machine is to be parked, stored or left unattended, lift the cutterheads to the transport position and engage the safety locks or lower the cutterheads to the ground.

Keep all nuts, bolts, and screws tight to be sure the equipment is in safe working condition.

Allow the engine to cool before storing in any enclosure.

To reduce the risk of fire, keep the engine, silencer, fuel tank and battery compartment free of grass, leaves or excessive grease.

Frequently check fuel lines and fittings for cracks or leaks and replace if necessary.

Replace worn or damaged parts for safety.

Ensure that all safety decals are properly secured and in good condition.

If the fuel tank has to be drained, this should be done outdoors.

Be careful during adjustment of the machine to prevent entrapment of the fingers between moving blades and fixed parts of the machine.

Never attempt to disconnect any part of the hydraulic system before de-pressurisation. This may be achieved by lowering all cutterheads to the ground, stopping the engine and removing the ignition key.

Avoid skin or eye contact with hydraulic or diesel fluids. Wear protective clothing.

Leaking fluids under pressure can penetrate the skin or eyes, causing serious injury. Always use a piece of cardboard or paper when searching for leaks.

Health and Safety at Work Act:

In accordance with section 6 of the Health and Safety at Work Act 1974, the Reelmaster® 4240-D has been designed and constructed so that, in so far as is reasonably practical, it will not endanger the safety and health of those working with it. This is, however, subject to the machine being properly used and maintained according to the conditions stated in this manual and elsewhere, which have been found necessary as a result of the research and testing of The Toro Company.

Page 12

994912 (REV. 1)

III

SAFETY PRECAUTIONS

1.12

DECALS

Decal - Control Panel Part No: 994912

Location: Control Panel. a) Ignition Switch h) Cutters - Off b) Engine Speed - Slow i) Cutters - Forward c) Engine Speed - Fast j) Horn d) Parking Brake - Engage k) Cutters - Lift e) Parking Brake - Disengage l) Cutters - Hold f) Weight Transfer - Control m) Cutters - Drop/Float g) Cutters - Reverse n) Hour Meter

Decal - Inclines Part No: 924857 (1)

Location: Centre Platform. a) Warning - Travel slowly when turning and on slopes b) Warning - Maximum slope without ROPS c) Warning - Seat belt must be worn with a ROPS fitted. d) Caution e) Read operators manual f) Stop engine/Remove ignition key before servicing or

maintenance g) Beware of flying objects h) Keep bystanders clear

Decal - Danger Latch Part No: 70-13-077 Location: LH / RH / Centre Arms a) Caution b) Stop engine/Remove ignition key before releasing or

operating safety latches

Decal - Diesel Part No: 70-13-078 Location: Fuel Tank Diesel fuel only

Decal - Transmission Oil Part No: 70-13-071 Location: Oil Filler Bracket mounted behind Fuel Tank. a) Transmission oil b) Read and understand the operators manual.

IMPOR TANT / WICHTIG / BELANGRIJK

BEFORE USE : FILL MACHINE WITH RECOM- MENDED OIL TOCORRECTLEVEL. F AILURE TO DOSOWILL CAUSE SERIOUS DAMAGEANDIN- VALIDATE WARRANTY.

AVANT L'UTILISA TION : IL EST IMPERATIF DE REMPLIR LA TONDEUSE AVEC UNE HUILE SPECIFIEE AUNIVEAU EXACT POUR NE PAS L'ENDOMMAGER SERIEUSEMENT ET ANNULER LAGARANTIE.

VOR DEM GEBRAUCH: F ÜLLEN SIE DIE MASCHINE MIT EMPFOHLENEM ÖL NACH,BIS AUF DEN RICHTIGEN ST AND. DIE NICHTBEACHTUNG DIESER INSTRUKTIONEN KANN ZU ERNSTHAFTEN SCHADEN F ÜHREN UNDDABEI WIRD DIE GARANTIEUNGÜLTIG.

VOOR GEBRUIK: VUL MACHINE MET VORRGESCHREVEN OLIE TOT HET JUISTE NIVEAU. HET NIET VOLGEN VANDEZE INSTRUKTIE LEIDT TOT ERNSTIGE SCHADE EN VER VAL VANDE GARANTIE.

0 - 19°19°+

924857 (1)

Page 13

SAFETY PRECAUTIONS

1.13

DECALS Continued.

Decal - Jacking / Support Point

Part No: 70-13-072 Location: Front Axle - 2 Points

Rear Towing Eye

Jacking and support point

Decal - Engine Fan / Radiator

Part No: 70-13-073 Location: Engine Fan Cowl a) Danger of severing fingers b) Caution c) Warning - Hot surfaces

Decal - Tyre Pressure

Part No. 950832 Location: LH/RH Chassis - 4 Places a) Mowing b) Road travel

Decal - Diff Lock / Control Pedal

Part No: 953876 Location: Centre Platform a) Differential lock b) Depress to engage diff-lock c) Release to dis-engage diff-lock d) Reverse speed - directional control e) Forward speed - directional control

Decal - Noise

Part No. 922854 Location: Base of Seat on GRP

HEIZKORPERDECKELENTFERNEN ERST WENNDERMOTORKUHL IST.

ONLY REMOVE RADIATOR CAP WHEN ENGINE IS COOL.

VERWIJDERDE RADIATORDOPPASNADAT DE MOTORIS AFGEKOELD.

IL FAUTTOUJOURSATTENDRE LE REFROIDISSEMENTDU MOTEUR AVANTDE RETIRER LE BOUCHONDURADIATEUR.

70-13-073 REV (.0.)

953876 REV.(0)

{

0.7 BAR

950832 Rev.2

10 PSI

1.4 BAR 20 PSI

Page 14

SAFETY PRECAUTIONS

1.14

DECALS Continued.

Decal - Serial Number

Location: Rear Bulkhead

Decal - Prevent Platform Damage

Part No. 924828 Location : Platform, Seatwell

Decal - Warning Platform Latch

Part No. 924868 Location: Next to Platform Latch Warning - Prevent Accidents: Ensure platform is correctly seated and the latch is fully locked before operating the machine.

Decal - Maintenance RM4240-D

Part No. 953812 Location: Underside of Engine Cover next to Latch.

Decal - Warning Crush Hazard

Part No. 953829 Location: Platform LH/RH Sides a) Warning of Cutterheads being Lowered b) Do Not Stand in the Area Indicated

When the Cutterheads are being Lowered or Raised

Decal - Pedal Backstop

Part No. 953877 Location: Platform RH Side

RPM

:2800 kW:35.3

2005

- PARKBREMSE

ZET

924828 REV.0.

924868 REV .0

RM4240-D REELMASTER

kg:1750

Code Serial No:

652D

260000001

105

PREVENT PLATFORM DAMAGE !

ENGAGE PARKING BRAKE AND DROP CUTTERHEADS BEFORE RAISING/LOWERING PLATFORM.

POUR EVITER DES DOMMAGES

METTRE LE FREIN DE PARKING ET POSER LES TETES DE COUPES AVANT DE BOUGER LA PLATE-FORME.

SCHADEN VERMEIDEN

FESTSETZEN UND DIE SCHNEIDEINHEITEN HERUNTERLASSEN BEVOR DIE SITZPLATTFORM GEKIPPT WIRD.

VOORKOM BESCHADIGING!

MACHINE OP HANDREM EN LAAT DE KOOIEN ZAKKEN, VOORDAT HET BEDIENINGS PLATFORM NAAR VOREN GEKANTELD OF TERUG GEPLAATST WORDT.

DAILY MAINTENANCE DAILY MAINTENANCE

FUEL LEVEL

ENGINE OIL

FUEL

TYRES

FASTENERS

AIR CLEANER

DAILY 50 HOURS (WEEKLY)DAILY (IF FITTED)

50 HOURS MAINTENANCE

CLEAN AND INSPECT THE MACHINE.

WHEEL NUT TORQUE

FRONT: 200Nm REAR: 54Nm

GREASE POINTS

SEAT SWITCH

HOSE LINES HYDRAULIC OIL

RADIATOR/SCREENS COOLANT LEVELCUTTERHEADS

953829(Rev.1.)

30 - 40mm

953812(Rev 1)

Page 15

EC CONFORMITY INFORMATION

1.15

NOISE LEVELS

Operators Daily Personal Noise Exposure: The Toro Company has no

control over site conditions, duration of use, state of maintenance or

adjustment of the mower. All of these factors will affect the operator's daily

personal noise exposure level - L

EP,d

Under typical working conditions operators could be exposed to a daily per-

sonal noise exposure level in excess of 85 dB (A) L

EP,d

Sound pressure level:

The maximum sound pressure level at the operator's position is 85 dB (A)

measured in accordance with European Standard EN836.

Sound power level:

The maximum sound power level is 105 dB(A) measured in accordance with

EC Directive 2000/14/EC.

If hearing protection is required, ear protectors with good attenuation in the

63 - 8000 Hz frequency range should be used.

Employers of personnel using this machine are advised to read the 'Noise at

Work Regulations' as the operator's daily personal exposure level could be

above the 'First Action Level'.

Wear Hearing

Protection

RM4240-D REELMASTER

RPM

kg:1750

Code Serial No:

652D

:2800 kW:35.3

260000001

105

2005

Page 16

EC CONFORMITY INFORMATION

1.16

EC DECLARATION OF CONFORMITY

Manufact ured for The Toro Company By: HAYTE R LIMITED, Spellbrook, Bishop’s Stortford, Herts. CM23 4BU. ENGLAND

declare that th e lawnmower:

Model name: Type: Model No: Cutting width: Speed of rotation of the cutting device: Engine manufacturer: Speedofrotationofengine:

RM4240-D Ride-on Cylinder CODE 652D 3460mm

1050 rpm Kubota 2800 rpm

Complies with the provisions of D irective: 98/37/EC Essential Health & Safety Requirements Relating to the Design & Construction of Machinery and Safety Components, as amended and the regulation s transposed into national law.

Also Directive 89/336/EEC Electromagnetic Compatibility, as amended and the regulations transposed into national law.

Also Directi ve 2000/14/EC Noise emission in the environm ent by equipment for use outdoors and the regulations transposed into national law. Procedure applied for the conformity assessment: ANNEX VI, proc edure 1.

Notified Body: Sound Research Laboratories Ltd. Holbrook House, Little Waldingfield, Sudbury , Suffolk. CO10 0TH. ENGLAND Notified body identification No: 1088

Measured sound power level:

Guaranteed sound power level:

Complies with harmonized standards: EN 292, EN 836 and EN ISO 14982

Signed

S.A Maryniak (Technical Director)

104 dB(A)

105 dB(A)

Date: 23.12.05 Declaration done and technical do cumentation k ept at: HAYTER LIMITED Spellbrook, Bishop’s Stortford, Herts. CM23 4BU ENGLAND

VIBRATION INFORMATION

The vibration level at the oper ator contact positions, measured in accordance with European Standard EN 836

CODE652D Steering Wheel Does not exceed 2.5ms-2Seat Does not exceed 0.5ms

-2

Page 17

INTRODUCTION

The Toro Reelmaster® 4240-D is a diesel engine powered self propelled machine with hydraulic systems for ground drive, cutterhead drive, cutterhead lift and steering. The machine operates in four wheel drive at all times, however, the transmission system can be operated in both ‘work’ and ‘transport’ modes. These modes can be selected by the operator. In order to optimise machine performance and reduce transmission system wear it is advisable to operate the machine in the appropriate mode. ‘Work’ signifies cutting operations and ‘Transport’ signifies travelling between work sites. A differential lock function may be selected.

The Toro Reelmaster® 4240-D is a precision built machine designed solely for cutting grass and similar low lying ground vegetation within the limitations stated in this manual. Use in any other way is considered as contrary to the intended use. Compliance with and strict adherence to the conditions of operation, service and repair as specified in this Operators Manual also constitute essential elements of the intended use. The way in which this machine is operated and maintained will have a profound effect on its performance and reliability.

This manual contains advice on the Toro Reelmaster® 4240-D which should be operated, serviced and repaired only by persons who are familiar with its particular characteristics and who are acquainted with the relevant safety procedures.

The safety precautions listed herein and all other generally recognised regulations on safety and all road traffic regulations must be observed at all times.

Any arbitrary modifications carried out to this machine may relieve The Toro Company of liability for any resulting damage or injury.

In the pursuit of continuous product development The Toro Company reserves the right to alter specifications without notice.

Cutterhead Variants: The Toro Reelmaster® 4240-D can be fitted with a range of cutterhead configurations and optional extras:

Optional Extras:

Beacon Kit - Amber flashing warning light.

Lighting Kit - Complies with EC traffic regulations.

R.O.P.S ( Roll Over Protective Structure ) 2 post design.

Cab R.O.P.S. - Full weather protection and roll - over protection.

We recommend the fitting of a Hayter approved R.O.P.S only, to increase operator safety in the event of a machine rolling over.

Note: with a R.O.P.S. fitted stability angle is decreased to 14 degrees, due to the higher centre of gravity of the machine

Left and Right: Throughout this manual the terms 'Left' and 'Right' refer to the machine when looking in the

direction of forward travel.

Fixed Heads

Cutterhead

Number of bladesCylinder diameter

MK3 Cutterhead

200mm

4, 6, 8, 10.

✓

Floating Heads with smooth or grooved front rollers

254mm

4, 6

✓

INTRODUCTION

1.17

Page 18

SPECIFICATIONS

1.18

SPECIFICATIONS

ALL FIGURES ARE NOMINALLY QUOTED AT THE RATED ENGINE SPEED OF 2800 RPM UNLESS OTHERWISE STATED.

ENGINE

Type:

Power Rating:

Capacity:

Air Cleaner:

Cooling System:

Battery:

Alternator:

Starter:

Cold Starting:

Idle Speed:

Fuel Type:

Fuel Tank Capacity

IMPORTANT: PREVENT DAMAGE - for further information regarding the engine, refer to ENGINE MANUAL .

Kubota V2203 Diesel. 4 Cylinders in line.

47.3hp (35.3 kw) @ 2800 RPM. DIN 70020.

2197 cc.

Clean air drawn through screened air intake in-front of radiator via a cyclonic air cleaner with built in pre-cleaner.

Water-Cooled.

12V. 480 Amps S.A.E.

40 Amps.

1.4 KW Electric.

Glow Plug.

1250(+50) R.P.M.

Diesel.

70 Litres

Page 19

SPECIFICATIONS

1.19

TRANSMISSION SYSTEM

Drive Type:

Pump:

Wheel Motors:

Differential Lock:

Drive:

Relief Valve Setting:

CUTTERHEAD DRIVE SYSTEM

Drive Type:

Pump:

Delivery Rate:

Cutterhead Motors:

Control:

Relief Valve Settings:

Hydraulic.

Variable displacement hydraulic piston pump with integral charge pump servo assisted.

Front Axle - ‘Twin Lock’ Radial piston, fixed displacement, with integral disc brake (pressure released). Rear Axle - Radial piston, fixed displacement.

Electro - hydraulic control valve with pedal control (only available in ‘Work’ mode).

Four wheel drive in ‘Work’ and ‘Transport’ modes.

Main service relief 350 bar (5075 psi) differential. Charge pressure relief 29 bar (421 psi) differential.

Hydraulic.

Tandem hydraulic gear type.

31 Litres per minute. (each circuit)

Hydraulic gear type, reversible, pressure balanced with integral differential pressure sensing relief check valve. Direct drive.

Electro-hydraulic. Automatic diverter valve safety cut-off.

250 bar (3625 psi) differential.

Page 20

SPECIFICATIONS

1.20

CUTTERHEAD LIFT SYSTEM AND STEERING

Drive Type:

Pump:

Delivery Rate:

Steering:

Cutterhead Lift Control:

Wing Units:

Relief Valve:

Weight Transfer:

HYDRAULIC SYSTEM

Hydraulic Oil Type:

Capacity:

Cooling:

Suction Line Filtration:

Return line Filtration:

Transmission Filtration:

Cleanliness Level:

Maximum Oil Temperature:

Hydraulic.

Hydraulic gear pump with integral relief valve.

11 Litres per minute.

Power beyond hydrostatic steering valve with priority flow to steering and auxiliary flow to cutterhead lift system. Manual emergency steering.

Mechanical-hydraulic.

Mechanical spring power assistance to lower.

105 bar (1522 psi).

Variable hydraulic applied weight transfer acting on all cutterheads.

Refer - RECOMMENDED LUBRICANTS AND HYDRAULIC FLUIDS.

77 Litres.

Forced air finned tube oil cooler.

125 micron no bypass mesh filter.

10 micron with 2 bar (29 psi) bypass check valve.

10 micron no bypass pressure filter.

ISO Code 18/13 or better (ISO 4406) 1300 - 2500 Particles/ml<15μ 40 - 80 Particles/ml>15μ

95 C

Page 21

SPECIFICATIONS

1.21

Wheel Nut Torque Setting: Front axle 200Nm

Service Brakes: Closed loop hydrostatic service braking operating on front wheels only.

Parking Brake: Lever operated oil immersed disc brakes on front wheels only. Pressurised hydraulic oil

release with mechanical override for emergency towing purposes.

Ground Clearance: 180mm at 13mm cut height and with cutterheads raised.

Steering: Hydrostatic rear wheel steering, emergency manual steering.

Features: Tilting operator platform.

Lockable engine cover. Adjustable suspension seat with folding arms. Adjustable steering column. Cutterhead parking latches with safety locks. Backlapping facility. Differential lock. Engine coolant and hydraulic oil overheat audible warning (horn). Variable cutterhead weight transfer/traction assistance. Four wheel drive in ‘Work’ and ‘Transport’ modes. Hydraulic oil filter blocked telltales on control panel. Wing arm breakback.

Safety Features: Neutral start interlock on transmission pump, parking brake and

cutterhead drive switch. Operator presence control (seat switch).

VEHICLE SPECIFICATIONS

Travel Speed:

0-25 km/h (0-15 mph) forward. 0-11 km/h (0-7 mph) reverse.

Tyre s Tyre Ty p e

Front axle

Rear axle

0.7 bar

(10 psi )

0.7 bar

(10 psi).

1.4 bar (20 psi)

Recommended Tyre Pressures

Turf Conditions

Max Pressure

Road Conditions

26 x 12 - 12 4 ply Trelleborg turf pattern.

20x10.0-8 4 ply Dico turf pattern.

1.7 bar (25 psi)

Rear axle 54Nm

Page 22

SPECIFICATIONS

1.22

Automotive padded steering wheel with adjustable steering column.

Electrical switch (forward - off - reverse).

Hand operated lever.

Separate foot operated pedals.

Key start, shut - off and engine preheat.

Foot pedal.

Electrical Switch.

Hand operated lever.

Electrical Switch (Two Positions).

Button switch.

Hand wheel.

Engine oil pressure. Battery charge. Engine coolant temperature. Hydraulic transmission oil temperature.

Digital hour meter. Fuel level. Hydraulic oil level sight glass.

Engine pre-heat. Hydraulic return filter blocked. Hydraulic transmission filter blocked. Cutterdeck drive switch off. Parking brake engaged. Transmission neutral. ‘Work’ mode active.

Steering:

Cylinder Drive:

Engine Speed:

Parking Brake:

Forward and Reverse:

Ignition:

Differential Lock:

‘Work’ or ‘Transport’ modes:

Cutterhead Position:

Cutterhead Lift Configuration:

Horn:

Weight Transfer:

OPERATOR CONTROLS

INSTRUMENTATION

Warning Lights:

Gauges:

Indicator Lights:

Page 23

SPECIFICATIONS

1.23

Wheel Base:

Working Width:

Cutting Width:

Transport Width:

Overall Length:

Overall Height:

Approx. Working Weight:

WEIGHT AND DIMENSIONS

RECOMMENDED LUBRICANTS AND HYDRAULIC FLUIDS

Grease Points: A good quality medium grease.

Engine: Refer - ENGINE OPERATORS MANUAL.

Hydraulic System:

Should you be in any doubt please contact your Toro dealer. Using incorrect grades will cause

premature wear of hydraulic components and invalidate warranty.

1610 mm.

3640 mm.

3460 mm.

1850 mm at 13mm height of cut.

2930 mm.

1570 mm.

1800 kg less operator, no options fitted. (The exact weight depends on the cutterhead configuration).

Ambient Temperature Range

0 - 30 C (32 - 86 F)

I S O viscosity grade 46 hydraulic oil.

15 - 40 C (59 - 104 F)

I S O viscosity grade 68 hydraulic oil.

Page 24

SPECIFICATIONS

1.24

CUTTERHEADS

Cutting Width:

Cylinder Diameter:

Cylinder Speed:

Height of Cut:

Number of Blades:

Smooth Rear Roller:

Smooth Front Roller:

Grooved Front Roller:

Configuration:

MK3 200mm Cutterhead

762 mm.

200 mm.

1050 rpm approx.

12 - 80 mm.

4, 6, 8, 10

Standard.

Optional.

Fixed / Floating.

MK3 254mm Cutterhead

762 mm.

254 mm.

1050 rpm approx.

12 - 80 mm.

4, 6

Standard.

Fixed.

Page 25

OPERATING THE MOWER

1.25

OPERATOR PRESENCE CONTROLS

Cutting Cylinder Drive Lockout: Drive to the cutting cylinders is only possible when the operator is

seated. If the operator raises off the seat for a period of more than one second, a switch is activated and drive to the cutting cylinders is automatically disengaged. To re-engage drive to the cutting cylinders, the operator must return to the seat, then operate the cutterhead drive switch to the ‘OFF’ position before moving it back to the ‘ON’ position. If the operator rises off the seat for a brief moment during normal work, drive to the cutting cylinders is not affected.

The engine can only be started with the cutterhead drive switch in the ‘OFF’ position.

Engine Start Lockout: The engine can only be started when the forward/reverse travel pedal is released to the 'NEUTRAL' position, the cutterhead drive switch is in the ‘OFF’ position and the parking brake is engaged. When these circumstances are satisfied, switches are activated permitting the engine to be started.

Engine Run Interlock: Once the engine is started the operator must be seated before the parking brake is released for the engine to continue to run.

Note: The engine will cut out if the operator leaves the seat.

WARNING: PREVENT ACCIDENTS - Do not operate the Reelmaster® mower if the operator presence controls are defective in any way. ALWAYS replace faulty parts and check that they function correctly before operating the mower.

SAFETY NOTICE

WARNING: PREVENT ACCIDENTS - Before operating the mower it is essential that;

- The operator reads and understands this manual.

- The operator platform latching mechanism is fully engaged and in good working order, refer - ‘OPERATOR PLATFORM LATCHING MECHANISM’.

- The daily maintenance checks have been properly carried out and the turf mower is in good working order.

- The operator should wear safety clothing and eye protection. Failure to do so could result in risk to health and safety.

- The area where the equipment is to be used is inspected and all objects which may be thrown by the machine are removed.

Operate safely on slopes;

It is essential to follow safe working practices when working on slopes. In order to avoid potentially hazardous situations, it is essential that the operator understands and observes the relevant safety precautions listed in this manual, refer - ‘SAFETY PRECAUTIONS’.

Page 26

OPERATING THE MOWER

1.26

1. Parking brake lever.

2. Lighting switch (supplied with lighting kit).

3. Warning beacon switch (supplied with beacon kit).

4. Hazard warning switch (supplied with lighting kit).

5. Cutterhead position controls.

6. Throttle control lever.

7. Ignition key.

8. Cutterhead drive switch.

9. Dip beam / main beam light switch (supplied with lighting kit).

10. Direction indicator switch (supplied with lighting kit).

11. Horn button.

12. Transmission oil filter indicator.

13. Oil pressure indicator.

14. Transmission temperature indicator.

15. Return oil filter indicator.

16. Battery warning indicator.

17. Engine temperature warning indicator.

18. Glow plug indicator.

19. Cutterhead drive off indicator.

20. Parking brake indicator.

21. Transmission neutral indicator.

22. Weight transfer control.

23. ‘Work/Transport’ mode switch.

24. Centre cutterhead transport latch.

25. LH front cutterhead transport latch.

26. RH front cutterhead transport latch.

27. Centre cutterhead transport latch.

28. LH wing unit transport latch.

29. RH wing unit transport latch.

30. Differential lock pedal.

31.Dual lift configuration switch.

32. Wash / wipe switch (supplied with cab kit).

33. Forward travel pedal.

34. Reverse travel pedal

35. Forward travel speed backstop lever.

36. Forward travel speed backstop cam.

37. Hour Meter

4A953B01A

HOURS

QUARTZ

CURTIS

1 10

1D953S01A

IDENTIFICATION OF CONTROLS

Page 27

OPERATING THE MOWER

1.27

BRAKING SYSTEM

Parking Brake : Move the parking brake lever to its rear position to engage

the parking brake. Do not operate the mower with the parking brake engaged.

WARNING : PREVENT ACCIDENTS - The parking brake operates on the front wheels only. Do not park the mower on a slope.

Service brakes : Service braking is achieved by the hydraulic transmission system. When the forward

or reverse travel pedals are released or the engine speed reduced, service braking becomes effective and travel speed is automatically reduced. To increase the braking effect, push the transmission pedals into the neutral position.

WARNING : PREVENT ACCIDENTS - The service braking system will not hold the mower at a standstill. ALWAYS ensure the parking brake is engaged to park the mower at a standstill.

Emergency Braking : In the event of service brake failure, switch off the

ignition to bring the mower to a standstill.

WARNING: PREVENT ACCIDENTS - Take care when operating the braking system. Remain seated and hold on to the steering wheel to prevent ejection from the mower caused by the front wheel brakes being applied suddenly when travelling.

THROTTLE CONTROL

Operate the throttle control in a forward direction to increase engine speed.

Operate the throttle control in a rearward direction to reduce engine speed.

Note that the engine speed dictates the speed of the other functions, i.e. travel, cutting cylinder, position controls.

TRAVEL

Forward travel: Depress the forward travel pedal to increase forward travel

speed. Release the pedal to reduce speed.

Reverse travel: Depress the reverse travel pedal to increase reverse travel speed. Release the pedal to reduce speed.

Stop (Neutral): Release the forward and reverse travel pedals.

Parking Brake EngagedParking Brake Engaged

Parking Brake Engaged

Engine Speed Engine Speed Fast Slow

Page 28

WARNING : PREVENT ACCIDENTS - Ensure that the mode elected is appropriate to the mode of operation of the machine.

Select ‘Work’ mode when operating the mower in conditions of poor traction when maximum tractive performance is required. Selecting ‘Work’ mode will enable the use of the differential lock.

Select ‘Transport’ mode when operating the mower in conditions of good traction. For example when travelling on the public highway or mowing large, level, open areas. Selecting ‘Transport’ mode in these conditions will reduce transmission system wear and tear.

Differential lock is not available for use when ‘Transport’ mode is selected.

1. Transport Mode

2. Work Mode

OPERATING THE MOWER

1.28

TRANSPORT LATCHES

WARNING : PREVENT ACCIDENTS - ALWAYS raise the cutterheads to the transport position and secure with the transport latches and safety locks when travelling between work areas.

Front and Wing cutterhead transport latches:

Centre cutterhead transport latch:

WARNING : PREVENT ACCIDENTS - Stored energy devices are charged when the outer wing units are in the transport position. Always operate the relevant lift controls to provide hydraulic support for the cutterhead suspensions before attempting to release the transport latches.

1. Transport latch.

2. Safety lock.

WORK/TRANSPORT MODES

1D924P07A

Page 29

OPERATING THE MOWER

1.29

DIFFERENTIAL LOCK

WARNING : PREVENT ACCIDENTS - Do not engage the differential lock at high speed. The turning circle will increase with the differential lock engaged.

The differential lock is effective only when ‘Work’ mode is selected. The differential lock operates in both ‘forwards’ and ‘reverse’ and can be engaged whilst the mower is travelling slowly. Engage the differential lock to prevent excessive wheel spin when the drive wheels lose traction. Engine power demand increases when the differential lock is engaged. Prevent excessive power requirements by operating with differential lock at SLOW speed.

Engaging differential lock: Depress the differential lock pedal.

Disengaging differential lock: Release the differential lock pedal.

TRAVEL CONTROL PEDALS

WARNING: PREVENT ACCIDENTS - Ensure that the transmission control cable is securely fastened to the travel control pedal mechanism. Ensure that both the cable and pedals articulate freely through their full range of travel and that the mechanism freely returns to neutral when released.

WARNING: PREVENT ACCIDENTS - Ensure that the control cable is correctly routed underneath the operator platform such that it is clear of any obstructions and impediments to its operation.

This is of particular importance after the platform has been opened and subsequently closed following inspection maintenance operations.

Before operating the machine, ensure that there are no foreign objects or liquids on the platform or pedals - ALWAYS KEEP THE OPERATOR PLATFORM CLEAR/CLEAN.

Page 30

OPERATING THE MOWER

1.30

WARNING: PREVENT ACCIDENTS - Never operate the mower without first checking that the operator platform latching mechanism is fully engaged and in good working order. Check behind the seat and ensure that the top of the platform is flush with the top of the fuel tank. Also check beneath the tool tray and ensure that the release lever is padlocked in the correct position.

IMPORTANT: PREVENT DAMAGE - Engage the parking brake and lower the cutterheads to the ground. Remove ignition key and close ignition cover before raising or lowering the platform.

Releasing the platform: Release and remove the tool tray from the left hand side of the platform.

Release the padlock securing the locking latch handle with the key provided. Move the locking latch handle towards the front of the mower (position A) until the latch hooks clear the locking bar and raise the platform. The gas spring will provide assistance.

Securing the platform: Lower the platform carefully. The gas spring will provide assistance. Move the locking latch handle towards the front of the mower (position A) as the platform nears the fully lowered position. This will ensure that the latch hooks clear the locking bar. Fully lower the platform and move the locking handle towards the rear of the mower (position B) until the latch hooks fully engage the locking bar. Replace the padlock in order to secure the locking latch handle in place.

OPERATOR PLATFORM LATCHING MECHANISM

1. Tool tray

2. Locking latch handle

3. Padlock

A. Release B. Lock

3D924S004A

The backstop lever can be used to limit the movement of the forward pedal for accurate forward travel speed, and the clip rate required. Operate the lever in a forward direction to increase the travel speed setting and in a rearward direction to decrease. Note: This is not a cruise control device. Releasing the forward travel pedal will allow it to return to neutral.

1D953S07A

FORWARD TRAVEL SPEED BACKSTOP LEVER

924868 REV .0

3D924S002A

Page 31

OPERATING THE MOWER

1.31

WARNING: PREVENT ACCIDENTS - Before operating the mower, ensure that the steering column adjuster mechanism is in good working order and that the steering wheel is locked securely in position.

WARNING: PREVENT ACCIDENTS - Adjustment of the steering wheel and steering column should only be carried out when the mower is at a standstill with the parking brake engaged.

Adjusting the angle of inclination of the steering wheel: Move lever ‘A’

downwards to adjust the angle of steering wheel. Release the lever to lock the steering wheel in position.

Adjusting the length of the steering column: Move the lever ‘A’ upwards to adjust the length of the steering column. Release the lever to lock the steering column in position.

ADJUSTABLE STEERING COLUMN

1D950R58

1D950R59

Page 32

OPERATING THE MOWER

1.32

WARNING: PREVENT ACCIDENTS - Before operating the mower ensure that the operator seat mechanisms are in good working order and that the seat is locked securely in position.

WARNING: PREVENT ACCIDENTS - Adjustment of the seat mechanisms should only be carried out when the mower is at a standstill with the parking brake engaged.

Fore/Aft Adjustment: Move lever ‘B’ upwards to adjust the Fore/Aft posi-

tion of the seat. Release the lever to lock the seat in position.

Operator weight adjustment: Rotate handle ‘C’ clockwise as shown to increase suspension stiffness and counter-clockwise to decrease. Dial ‘D’ indicates when the optimum suspension adjustment has been set according to operator weight (kg).

Height adjustment: Manually lift the seat for incremental height adjustment. To lower lift the seat to beyond its highest setting, then allow it to drop to the lowest setting.

Backrest adjustment: Pull handle ‘E’ outwards to adjust the seat backrest angle. Release the handle to lock the seat backrest in position.

OPERATOR SEAT

1D924T3

CCW

1D924T5

1D924T4

1D924T6

Page 33

OPERATING THE MOWER

1.33

WARNING SYSTEMS

Engine coolant overheating warning : The engine coolant warning

light illuminates and the horn is actuated.

Hydraulic oil overheating warning : The hydraulic oil warning light illuminates and the horn is actuated when the hydraulic oil in the reservoir exceeds 95˚C approx.

Low battery charge warning : The battery charge warning light illuminates.

Low engine oil pressure warning light : The engine oil pressure warning

light illuminates.

AUDIBLE WARNING HORN

Depress the horn button to provide an audible warning.

IMPORTANT : PREVENT DAMAGE - The horn is automatically actuated when an engine coolant or hydraulic oil overheat condition occurs. STOP the engine immediately and effect remedial action before restarting.

Page 34

OPERATING THE MOWER

1.34

E = Empty. F = Full.

IGNITION KEY

= Engine off.

I = Engine run / Auxiliary on. II = Engine pre-heat.

III = Engine start.

WARNING : PREVENT ACCIDENTS - Always remove the ignition key when the mower is not in use.

IMPORTANT : PREVENT DAMAGE - Always fit the protective cap when the ignition key is removed to prevent ingress of dirt and moisture from damaging the mechanism.

ENGINE PRE-HEAT INDICATOR LIGHT

Turn the ignition key to position II. The engine pre-heat indicator light will illuminate. When the correct pre-heat temperature is achieved, the indicator light will switch off. When this condition is achieved, turn the

ignition key to position III to start the engine.

IMPORTANT: PREVENT DAMAGE - Attempting to start a cold

engine before the pre-heat indicator light switches off can cause

unnecessary wear to the battery.

FUEL LEVEL GAUGE

Displays fuel tank level.

HOURMETER

Displays engine running hours.

III

FUEL

WS044

WS023

3 4 5 5 9

Page 35

OPERATING THE MOWER

1.35

TRANSMISSION NEUTRAL INDICATOR LIGHT

Illuminates when the travel control pedal is in the neutral position and the ignition key is turned to position ‘I’.

Note: The parking brake must be engaged for the transmission neutral indicator light to illuminate.

CUTTERHEAD DRIVE SWITCH INDICATOR LIGHT

Illuminates when the cutterhead drive switch is in the ‘off’ position and the ignition key is turned to position ‘I’.

PARKING BRAKE INDICATOR LIGHT

Illuminates when the parking brake is engaged and the ignition key is turned to position ’I’.

HYDRAULIC RETURN FILTER INDICATOR LIGHT

Illuminates when the return filter element is blocked.

Note: The engine must be running for the hydraulic return filter indicator light to illuminate. The indicator light may illuminate briefly when the hydraulic oil

is cold.

HYDRAULIC TRANSMISSION FILTER INDICATOR LIGHT

Illuminates when the transmission filter element is blocked.

Note: The engine must be running for the hydraulic return filter indicator light to illuminate. The indicator light may illuminate briefly when the hydraulic oil

is cold.

Illuminates when the transmission system ‘work’ mode is selected and the ignition key turned to position ‘I’

TRANSMISSION SYSTEM ‘WORK’ MODE INDICATOR LIGHT

WS041

WS046

WS045

WS043

WS042

WS055

Page 36

OPERATING THE MOWER

1.36

CUTTERHEAD POSITION CONTROL

The cutterheads may be raised or lowered using the bank of 3 lift control levers.

To lower the cutterheads, operate the lift control levers in a downward direction until locked in position 1. If the cutterhead drive switch is in the ‘ON’ position, the cylinder drive will engage when the cutterheads are approximately 300mm above ground level.

IMPORTANT: PREVENT DAMAGE - The lift control levers must be locked in position 1 while mowing. NEVER mow with the lift control levers in position 2 (neutral).

To raise the cutterheads, operate the lift control levers in an upward direction and hold in position 3. If the cutterhead drive switch is in the ‘ON’ position, the cylinder drive will disengage when the cutterheads are approximately 300mm above ground level. Release the lift control levers when the cutterheads are at the required height. The control levers will automatically return to position 2 (neutral).

1. Down / float

2. Neutral

3. Raise

4. LH Wing or LH Wing+LH Front*

5. Centre+LH/RH Front or Centre*

6. RH Wing or RH Wing+RH Front*

*Depending on which lift configuration is selected. Refer-Dual Lift Configuration Control.

DUAL LIFT CONFIGURATION CONTROL

The dual lift configuration control function enables the lift controls to be used in two ways as follows:

Five gang mode, lift configuration (1):

Control switch in position 1 LH lift lever (3) controls LH wing cutterhead Centre lift lever (4) controls LH front + centre + RH front cutterheads RH lift lever (5) controls RH wing cutterhead

Three/five gang mode, lift configuration (2):

Control switch in position 2 LH lift lever (3) controls LH wing + LH front cutterheads Centre lift lever (4) controls centre cutterhead RH lift lever (5) controls RH wing + RH front cutterheads

With the LH and RH wing cutterheads locked in the fully raised transport position.

Control switch in position 2 LH lift lever (3) controls LH front cutterhead Centre lift lever (4) controls centre cutterhead RH lift lever (5) controls RH front cutterhead

1. 5 Gang Mode

2. 3/5 Gang Mode

3. LH Lift Lever

4. Centre Lift Lever

5. RH Lift Lever

4A953B03A

3D95301

4A953B03B

Page 37

OPERATING THE MOWER

1.37

CUTTERHEAD DRIVE ENGAGEMENT

The cutterhead drive can be engaged only when the operator is seated correctly, refer - OPERATOR PRESENCE CONTROLS.

Briefly operate the lift control levers to raise the cutterheads, thereby removing the cutterhead suspension deadweights and wing units stored energy reaction from the transport latch mechanisms.

Release the cutterhead latches. Operate the cutterhead position controls to the down / float position and lower all cutterheads to the ground ready for mowing.

Forward rotation cutterhead drive engagement : Operate the cutterhead drive switch to the 'Forward' position.

Reverse rotation cutterhead drive engagement : Operate the cutterhead drive switch to the 'Reverse' position.

To disengage all cutterhead drives : Operate the cutterhead drive switch to the 'Off' position.

WARNING : PREVENT ACCIDENTS - Refer OPERATOR PRESENCE CONTROLS for additional information.

1. Forward.

2. Off.

3. Reverse.

WS047

Page 38

OPERATING THE MOWER

1.38

WEIGHT TRANSFER / TRACTION ASSISTANCE

A variable hydraulic weight transfer system is provided for improving tyre grip with the grass surface -

‘Traction Assistance’.

Hydraulic pressure in the cutterhead lift system provides a lifting force which reduces cutterhead weight on the ground and transfers the weight as a downward force onto the mower’s tyres. This action is known as ‘Weight Transfer’.

To engage weight transfer: The amount of weight transfer can be varied to suit operating conditions by rotating the weight transfer hand wheel as follows;

Release the lock wheel underneath the hand wheel 1/2 turn anti-clockwise and hold.

Rotate the hand wheel: - Anti-clockwise to reduce weight transfer.

- Clockwise to increase weight transfer.

Tighten the lock wheel.

STARTING THE ENGINE

WARNING: PREVENT ACCIDENTS - Before starting the engine check that ;

- The area is clear of bystanders.

- The cutterhead drive is disengaged.

- The parking brake is engaged.

- The travel control pedal is in neutral.

- You have read and understood the SAFETY PRECAUTIONS section in this manual.

This machine is fitted with an Engine Start Lockout, refer - OPERATOR PRESENCE CONTROLS.

1. Weight transfer hand wheel

2. Lock Wheel

3. Control Panel

1 10

QUARTZ

HOURS

CURTIS

4A922A02A

Page 39

OPERATING THE MOWER

1.39

STOPPING THE ENGINE

To stop the engine: Turn the ignition key to position '0'.

WARNING: PREVENT ACCIDENTS - If the engine fails to stop when the ignition key is turned to 'O' operate the fuel control lever to the engine ‘stop’ position as shown. Keep hands clear of moving objects and hot engine parts whilst the engine is running.

STARTING THE ENGINE Continued.

Starting a cold engine: Set the throttle control lever to approximately 70% full

throttle.

Turn the ignition key to the ‘ignition on’ position "I" and check that the engine oil pressure and battery charge warning lights illuminate.

Turn the ignition key to the ‘preheat’ position "II" and hold until the engine pre-heat indicator light goes out.

Turn the ignition key to the ‘start’ position "III" and hold to crank the engine. As soon as the engine starts release the ignition key back to position 'I'.

WARNING: PREVENT DAMAGE - When the engine is operating all warning lights should be ‘off’. If a warning light illuminates, stop the engine immediately and have the fault rectified before restarting.

Starting a warm engine: Engine pre-heating is unnecessary when restarting an engine which has been

stopped for a few minutes. Follow the cold engine starting procedure without holding in ‘preheat’ position “II”.

1. Engine pre-heat indicator light

1. Engine stop position

2. Engine run position

3. Stop solenoid

III

1 2

PS008

Page 40

OPERATING THE MOWER

1.40

GENERAL OPERATING HINTS

The rotational speed of the cutting cylinders should always be kept as high as possible in order to maintain the highest quality of cut. This in turn requires that the engine speed be kept as high as possible.

The quality of cut will deteriorate if the forward speed is excessive. Always balance the quality of cut with the workrate required and set the forward speed accordingly.

Never let the engine labour. Reduce the forward speed or increase the height of cut. Check that the cutting cylinders are not in heavy contact with their bottom blades.

Regularly check the cutting cylinder to bottom blade adjustment every few hours even though cutting performance appears to be satisfactory. Heavy contact or excessive clearances between the cylinder and bottom blades will cause rapid wear to take place.

Always disengage the cutterhead drive when travelling across ungrassed areas. Grass will lubricate the cutting edges whilst mowing. Excessive heat will build up if the cutting cylinders are run when not mowing and this will cause rapid wear to take place. For this reason it is also wise to reduce cutting cylinder speed when mowing lightly grassed areas or when the grass is dry.

Cutting performance is best when cutting against the lie of the grass. In order to take advantage of this fact, the operator should attempt to alternate the direction of mowing between cuts.

Take care not to leave uncut strips of grass at the overlap points between adjacent cutterheads, by avoiding tight turns.

It is generally wise to remove rear roller scrapers where conditions allow, as optimum grass discharge is achieved without them. Scrapers should be refitted when conditions are such that mud and grass start to build up on the rollers. When refitting the scraper wires, care must be taken to ensure that they are correctly tensioned, refer - MAINTENANCE - EVERY 50 HOURS.

WARNING : PREVENT ACCIDENTS -Take care when travelling over obstacles such as roadside kerbs. ALWAYS travel at slow speed over obstacles to prevent damage to the machines tyres, wheels and steering system. Ensure that tyres are inflated to the recommended pressures.

Page 41

OPERATING THE MOWER

1.41

UNBLOCKING CUTTING CYLINDERS

WARNING: PREVENT ACCIDENTS - Before attempting to clear any blockage from the cutting cylinders on this machines ensure all of the following:

- Stop the machine on level ground.

- Apply the parking brake and disengage all drives.

- Lower the cutting units to the ground or securely lock in the designated transport positions.

- Stop the engine and remove the ignition key to isolate all power sources and check that they are stopped.

- Release all stored energy devices.

- Check that all moving parts are stationary.

NEVER ATTEMPT TO ROTATE THE CUTTING CYLINDERS BY HAND as there may be some

residual pressure in the hydraulic system which could cause injury through sudden movement of the cylinder(s) when the blockage is released.

Always wear protective gloves and use a suitable strong wooden instrument. Ensure that this will fit between the blades and through the cylinder and is long enough to provide sufficient leverage to release the blockage and any residual hydraulic system pressure by rotating or rocking the cylinder. Make sure that the wooden instrument is properly supported in the cylinder and avoid the use of excessive force to prevent damage.

Only when the cylinder has a degree of free movement should the source of the blockage be removed. Ensure that the wooden instrument is also removed before restarting the power source.

If the cylinder requires readjustment or repair, refer - MAINTENANCE - Cutterheads.

With all cutterheads set at the same HOC via the indicator rings, it may be noticeable that the centre unit produces a higher cut finish compared to the wing units. The centre unit is pulled and the wing units are pushed this presents marginally different cutting angles relative to the ground. The amount of HOC variation, which results from this will be influenced by the terrain but satisfactory results can usually be achieved by setting the centre cutterhead HOC indicator ring lower than the wing unit settings.

CENTRE CUTTERHEAD HEIGHT OF CUT CORRECTION ADJUSTMENT

Page 42

OPERATING THE MOWER

1.42

CUTTERHEAD GENERAL INFORMATION

The mower is designed to be used with MK3 200mm fixed or floating cutterheads or MK3 254mm fixed cutterheads.

It is essential that the relationship between the bottom blades and the cutting cylinders are kept in good adjustment and that cutting edges are kept sharp to ensure good cutting performance, minimum power consumption and prolonged life for the cutting edges, refer - MAINTENANCE - Cutterheads.

Fixed MK3 200mm/254mm Cutterheads: When the mower is set up with fixed cutterheads the height of cut is gauged by the rear roller and the cutterhead is allowed to pivot laterally to follow ground contours. This arrangement is normally recommended for general mowing requirements.

(MK3 200mm Cutterhead illustrated).

Floating MK3 200mm Cutterheads: When the mower is set up with floating cutterheads the height of cut is gauged by the front and rear rollers. The cutterhead is allowed to pivot fore and aft as well as laterally. This arrangement is recommended for high quality grass areas and performs well where grass is short and the ground undulations are severe.

Grass deflectors: The rear grass deflectors must always be correctly fitted. The deflectors should be set as low as possible to deflect grass discharge to the ground.

WARNING: PREVENT ACCIDENTS - Always ensure that the grass deflectors are angled below horizontal level, otherwise risks to health and safety may result.

Height of cut gauge: An optional height of cut gauge is

available to assist in achieving accurate cut height settings. It is suitable for both fixed and floating cutterheads.

Part No. 63-01-760

1D876P02A

1D876P03A

1D876P04B

Page 43

OPERATING THE MOWER

1.43

MK3 200mm FIXED CUTTERHEAD

Height of cut adjustment: The height of cut is gauged by the

position of the rear roller.

Turn the adjusting nut assembly ‘B’ both ends clockwise to decrease height of cut ‘E’ or anti-clockwise to increase height of cut ‘E’.

IMPORTANT: PREVENT DAMAGE - Do not attempt to unlock the nut assemblies, ‘B’.

Ensure that all cutterheads are set at the same height of cut by either referring to the indicator rings ‘C’ or by using a height of cut gauge across the full width of each cutterhead for greater accuracy as shown.

MK3 254mm FIXED CUTTERHEAD

Height of cut adjustment: The height of cut is gauged by the

position of the rear roller.

Turn the adjusting nut assembly ‘B’ both ends clockwise to decrease height of cut ‘E’ or anti-clockwise to increase height of cut ‘E’.

IMPORTANT: PREVENT DAMAGE - Do not attempt to unlock the nut assemblies ‘B’.

1D876P08B

1D876P09A

1D876P16A

1D876P09A

Page 44

OPERATING THE MOWER

1.44

MK3 200mm FLOATING CUTTERHEAD

Pivot knuckle fixing: Secure the bolt in the rear “floating” slot

position ‘A’ as shown.

Height of cut adjustment: The height of cut is gauged by the position of the front and rear rollers.

To alter the rear roller position, turn the adjusting nut assembly ‘B’ both ends clockwise to decrease height of cut ‘E’ or anti-clockwise to increase height of cut ‘E’.

IMPORTANT: PREVENT DAMAGE - Do not attempt to unlock the nut assemblies, ‘B’.

To alter the front roller position loosen bolts ‘F’. Release and turn adjusting nuts ‘D’ both ends clockwise to increase the height of cut or anti-clockwise to decrease the height of cut.

Ensure that all cutterheads are set at the same height of cut by referring to the indicator rings ‘C’ or use the height of cut gauge across the full width of each cutterhead as shown.

Tighten nuts ‘D’ and ‘F’ both ends.

1D876P07A

1D876P06B

1D876P10A

Page 45

MAINTENANCE

1.45

MAINTENANCE

WARNING : PREVENT ACCIDENTS - When carrying out maintenance procedures it is essential that:

- The engine is switched off and the ignition key removed.

- The parking brake is applied.

- There is no pressure in the hydraulic system.

- The cutterheads are fully down on the ground.

- The safety precautions in this manual have been read and understood.

WARNING : PREVENT ACCIDENTS - Stored energy devices and systems are used on the Reelmaster® 4240-D. It is essential that this stored energy is safely dissipated before maintenance or other service or operations are performed on these devices and systems on the machine.

Dissipate stored energy as described below:

Hydraulics: Transmission System - Ensure that the machine is on level ground, engage the parking brake and switch the

engine off. Depress the forward and reverse travel pedals alternatively several times.

Cutterhead Lift System - Lower the cutterheads to the ground and switch the engine off. Raise and lower the lift levers several times leaving them in the ‘down/float’ position.

Cutterhead Drive System - Lower the cutterheads to the ground with the cutterhead drive switch in the ‘off’ position and switch the engine off.

Wing Cutterhead Springs - Lower the wing cutterheads to the ground.

Operator Platform Gas Spring - Raise the platform fully.

IMPORTANT: PREVENT DAMAGE: Regular maintenance is essential for the continued safe operation of the machine. Correct servicing will prolong the working life of the machine and safeguard the "Toro Warranty". Always fit genuine service parts as these are accurately matched to the required duty.

Dirt and contamination are the enemies of any hydraulic system. When carrying out maintenance procedures on the hydraulic system always ensure that the work area and the components are thoroughly clean before, during and after refitting. Ensure that all open hydraulic lines and ports, etc. are plugged during maintenance procedures.

The recommended service intervals are based on normal operating conditions. Severe or unusual conditions will necessitate shorter service intervals.

ALWAYS grease pivot points immediately after pressure washing or steam cleaning, refer - EVERY 50 HOURS, GREASE PIVOT POINTS.

WARNING: PREVENT ACCIDENTS - The engine, transmission oil and hydraulic systems will be hot after machine use. Allow the systems to cool before working on the machine, particularly before working on the engine or when changing oil or oil filters.

Page 46

MAINTENANCE

1.46

WARNING : PREVENT ACCIDENTS - Use hazardous substances carefully. The following fluids are identified as being hazardous;

When using any of the above fluids it is recommended that eye protection and gloves are worn and that care is taken to prevent spillage.

Avoid contact with skin; wash off spillage with soap and water.

In the case of battery acid drench with water and seek medical attention. Remove any contaminated clothing and clean thoroughly before use.

Avoid contact with eyes; wash with running water and seek medical attention if symptoms persist. In the case of battery acid, seek medical attention immediately.

Avoid ingestion; if swallowed seek medical attention.

Keep clear of high pressure fluid escaping from pinholes, cracked connections etc. High pressure fluid can penetrate the skin. Seek immediate medical advice if any fluid is injected into the skin. Always use a piece of cardboard or paper when searching for leaks.

CAUTION: PREVENT ENVIRONMENTAL DAMAGE - Dispose of hazardous substances correctly.

When disposing of hazardous waste products, take them to an authorised disposal site. Waste products must not be allowed to contaminate surface water, drains or sewerage systems.

CAUTION: PREVENT ENVIRONMENTAL DAMAGE - Dispose of a used battery correctly. The battery has a separate collection mark. This means that the battery must not be disposed of with general waste. It must be taken to an authorised disposal site

Assessed risk

Low Low Low Low Medium High

Substances

Diesel oil Lubricating oil Hydraulic oil Grease Anti - freeze Battery acid

MAINTENANCE Continued.

Page 47

MAINTENANCE

1.47

ENGINE

Refer to the Engine Operator's Manual for maintenance information.

RUNNING IN PERIOD

Check wheel nut torque settings:

During first 50 hours of use and in addition to routine checks. Refer DAILY AND BEFORE USE. Check wheel nut torques twice a day.

Front axle wheel nut torque setting - 200 Nm.

Rear axle wheel nut torque setting - 54 Nm.

RUNNING IN PERIOD - AT FIRST 50 HOURS

Change the transmission oil filter: Unscrew and remove the bottom of the

transmission oil filter housing. Withdraw the filter element and discard. Refit a new filter element (part no. 924708) and replace the housing.

1. Transmission Oil Filter.

2. Centre Cutterhead.

3. Hydraulic Oil Tank.

ENGINE

1P953C17

Page 48

MAINTENANCE

1.48

RUNNING IN PERIOD - AT FIRST 50 HOURS

Change the hydraulic oil return filter: Unscrew and remove the

return filter canister and discard. Refit a new filter canister (part no.

924692).

1. Hydraulic oil return filter.

2. Engine fuel filter.

Continued.

Left Hand Side of Machine

1P953C16A

Page 49

MAINTENANCE

1.49

HEIZKORPERDECKELENTFERNEN ERSTWENN DERMOTORKUHLIST.

ONLYREMOVERADIATORCAPWHEN ENGINEIS COOL.

VERWIJDERDE RADIATORDOPPASNADATDEMOTORIS AFGEKOELD.

ILFAUTTOUJOURSATTENDRELE REFROIDISSEMENTDUMOTEUR AVANTDE RETIRER LEBOUCHONDU RADIATEUR.

70-13-073 REV (.0.)

1. Air filter

2. Dust bowl

3. Dust boot

DAILY AND BEFORE USE

Check engine oil level: If the oil level is below the upper mark on the

dipstick, top up with the correct grade of engine oil to the required level, refer - ENGINE MANUAL.

Check engine radiator coolant level:

WARNING: PREVENT ACCIDENTS - Avoid scalding. DO NOT remove the radiator filler cap unless the engine is cool. Turn the filler cap slowly to release system pressure before removing the filler cap completely.

The coolant level should be 30 - 40mm below the top of the filler neck. Top up with the correct coolant mixture, refer - ENGINE MANUAL.

IMPORTANT: If you see RED in the Filter Blockage Indicator the air filter needs replacing.

Cleaning the air cleaner: Remove the air filter and tap it repeatedly with the palm of the hand to remove dust particles. DO NOT damage the air filter by hitting it against a hard object. Inspect the air filter for signs of damage.

IMPORTANT: PREVENT DAMAGE - Always replace a damaged air filter or damage to the engine will result. NEVER run the engine without the air filter correctly fitted.

Clean the inside of the cleaner dust bowl with a dry cloth and check that the dust boot is unobstructed.

Replace the air filter and assemble the dust bowl, with the dust boot facing below horizontal level.

30 - 40mm

1P924C13A

1D950R13A

Page 50

MAINTENANCE

1.50

1. Radiator screen.

2. Oil cooler

3. Radiator

DAILY AND BEFORE USE Continued.

Clean the radiator screen: Clean the radiator screen. Check

the oil cooler and engine radiator grille for debris and clean as necessary, using a brush or airline. If water is used, these areas should be allowed to dry out completely before use.

IMPORTANT: PREVENT DAMAGE - NEVER operate the mower with a damaged radiator screen or engine damage could result from overheating. Clean the radiator screen more regularly in dry conditions.

Check fuel level: Top up as necessary with diesel fuel.

Always top up before storing the mower over-night to prevent water condensation from contaminating the fuel.

Check hydraulic oil level: If the oil level is below the upper mark on the sight level gauge, top up with the correct grade of hydraulic oil as necessary, refer- SPECIFICATIONS.

WARNING : PREVENT DAMAGE - If there is noticeable hydraulic oil loss, the leakage source must be rectified before using the mower. NEVER operate the mower when the hydraulic oil level is below the bottom mark on the sight level gauge. NEVER operate the mower with contaminated oil.

1D924P06B

1. Sight level gauge

2. Oil tank

3. Oil filler cap.

4. Fuel tank.

1P953C14A

Page 51

MAINTENANCE

1.51

DAILY AND BEFORE USE Continued.

Check hydraulic hose-lines: Inspect hydraulic hose-lines for signs of wear or damage.

WARNING: PREVENT ACCIDENTS - ALWAYS replace worn or damaged hydraulic hose-lines

immediately. DO NOT operate the mower with defective hydraulic hose-lines.

Inspect the mower for signs of oil leakage. Tighten fittings or replace seals as required.

Check fasteners: Check that all nuts, bolts and pins are secured correctly in place and in good condition.

Check safety devices:

WARNING - PREVENT ACCIDENTS : Ensure that all safety guards, shields and protective devices are securely in place and in good working order.

Check tyres: Examine the condition of the tyres and check that inflation pressures are correctly set, refer - SPECIFICATIONS.

WARNING - PREVENT ACCIDENTS : Ensure that damaged tyres are replaced. Ensure that tyre tread depths comply with road traffic regulations.

Grease all rear axle components including the centre axle beam pivot pin, both steering yokes and track rod ball joints, refer -EVERY 50 HOURS Grease pivot points.

Check cutterheads: Examine the condition of the cutting cylinders and bottom blades. Adjust as necessary, refer - MAINTENANCE - CUTTERHEAD CYLINDER TO BOTTOM BLADE ADJUSTMENT.

Grease all cutterhead rollers with a good quality medium grade grease and ensure that sufficient grease is injected such that clean grease is seen to escape from the roller end caps, refer - MAINTENANCE EVERY 50 HOURS.

If no grease can be seen escaping from a roller end cap. It can be assumed that the rear seal has failed, resulting in the roller shell being filled with grease.

Note: Care should be taken if an industrial power greaser is used as this may result in damage to the bearing sealing arrangement.

Check forward/reverse travel pedal action: With the engine switched ‘off’, operate the forward and

reverse travel pedals through the full range of articulation and ensure that the mechanism returns freely to the neutral position.

WARNING - PREVENT ACCIDENTS: Do not operate the machine if there are any signs of

‘Stickiness’ in the pedal mechanism which prevents a free return to the neutral condition.

Page 52

MAINTENANCE

1.52

Check operator presence controls:

WARNING : PREVENT ACCIDENTS - Keep bystanders away when checking operator presence control interlock switches. DO NOT use the mower unless the operator presence controls work correctly as described below. If difficulties arise, consult your "Toro dealer”.

Operator presence seat switch: Sit on the operator seat and start the engine. Lower the cutterheads

to the ground and engage the cutter drive in the forward direction. Rise from the operators seat and check that the cutting cylinders come to a stop after an initial 0.5 to 1 second delay. Repeat with the cutting cylinders running in reverse.

Cutter drive interlock switch: Stop the mower engine. Operate the cutter drive switch to the ‘off’ position and turn the ignition key to position ‘I’. The cutterhead drive switch indicator light should illuminate. Refer - OPERATING THE MOWER.

Operate the switch to the ‘forward’ position. The indicator light should go out and the engine should not start when the ignition key is turned. Repeat for the ‘reverse’ position.

Parking brake interlock switch: Stop the engine. Engage the parking brake and turn the ignition key to position ‘I’. The parking brake indicator light should illuminate. Refer - OPERATING THE MOWER. Disengage the parking brake. The indicator light should go out and the engine should not start when the ignition key is turned.

Transmission neutral interlock switch: Stop the mower engine and remove the foot from the forward/reverse travel pedals. Turn the ignition key to position 'I’ and the transmission neutral indicator light should illuminate. Application of light pedal pressure in a forward and reverse direction should cause the indicator light to go out. Take extreme care to ensure that the area around the mower is clear before checking that the engine will not start under this condition.

DAILY AND BEFORE USE Continued.

Page 53

MAINTENANCE

1.53

EVERY 50 HOURS

Perform routine checks : Refer - DAILY BEFORE USE.

Check cutterhead roller bearing adjustment:

IMPORTANT : PREVENT DAMAGE - It is essential that the cutterhead roller bearings are kept in good adjustment in order to ensure maximum working life. If end float is allowed to become excessive, premature bearing failure will result.

Grip the roller and move from side to side and up and down. If excessive movement is detected, proceed as follows:

Carefully tighten nuts ‘A’ at each end of the roller with the spanner provided, just sufficiently to remove any end float.

Note: The roller should still rotate freely after adjustment. Overtightening of nuts ‘A’ could lead to premature bearing failure.

Check cutterhead rear roller scraper wire tension:

It is important that the scraper wires are correctly tensioned so as to ensure correct operation and maximum working life. Carefully tighten the scraper wire retaining nuts ‘B’ so as to just remove any slack from the scraper wires and then tighten nuts ‘B’ a further four full turns to correctly tension the wires.

IMPORTANT: PREVENT DAMAGE - Do not over tighten the scraper wires.

Check wheel nut torque settings:

Front axle wheel nut torque setting - 200Nm.

Rear axle wheel nut torque setting - 54 Nm.

3D924S001A

Page 54

MAINTENANCE

1.54

EVERY 50 HOURS Continued.

Grease pivot points :

Clean and grease all grease points with a good quality compound of the grade specified, refer SPECIFICATIONS.

Replace any grease nipples which are damaged.

Grease all cutterhead grease points and ensure that sufficient grease is injected such that clean grease is seen to escape from the roller end caps. This provides visible evidence that the roller seals have been purged of grass debris etc. and will ensure maximum working life.

Grease daily

Medium grade grease

Grease every 50 hours (Weekly)

Medium grade grease

Medium grade grease (if fitted)

Page 55

MAINTENANCE

1.55

EVERY 250 HOURS

Perform routine checks : Refer - DAILY BEFORE USE.

- EVERY 50 HOURS.

Check battery condition :

WARNING : PREVENT ACCIDENTS - Explosive gases are produced by the battery. Work in a well ventilated area, away from all sources of ignition.

Battery fluids are corrosive. Take care to avoid contact with the skin or eyes. In the event of a spillage, drench the affected area with water. If the eyes are affected, seek medical attention. Remove any contaminated clothing and clean thoroughly before use.

When removing the battery, always disconnect the negative (-) cable first.

When replacing the battery, always connect the negative (-) cable last.

Remove the tool tray to gain access to the battery. Remove any corrosion from the battery terminals using a wire brush and apply petroleum jelly to the terminals to prevent further corrosion. Clean the battery compartment.

Under normal operating conditions the battery will not require any further attention. If the machine has been subject to continuous use under high ambient temperature conditions, the battery electrolyte may require topping up. Remove the cell covers and top up with distilled water to a height 15mm below the top of the battery. Replace the cell covers.

IMPORTANT : PREVENT DAMAGE - Check the condition of the battery cables. Replace cables showing signs of wear or damage and tighten any loose connections as necessary.

Visually inspect transmission control cable and operating mechanism:

Check the condition and security of the cable and operating mechanism at the travel control pedals and transmission pump ends.

- Remove build up of dirt, grit and other deposits.

- Ensure that the ball joints are securely anchored and check that mounting brackets and cable anchors are tight and free from cracks.

- Inspect end fittings for wear, corrosion, broken springs and replace if necessary.

- Ensure that the rubber seals are correctly located and in good condition.

- Ensure that the articulating sleeves supporting the inner cable are in good condition and firmly attached to the outer cable assembly at the crimped connections. If there are any signs of cracking or detachment fit new cable immediately.

- Check that sleeves, rods and inner cable are free from bends, kinks and other damage. If there are any signs of such failure, fit a new cable immediately.

- Check the condition of the neutralising device and replace if worn.

- With the engine switched ‘Off ’, operate the pedal controls through the entire range and ensure that the mechanism moves smoothly and freely to the neutral position without ‘Sticking’ or ‘Hanging up’.

1. Battery

2. Tool Tray

1D924P14A

Outer Cover Sleeve Rod EndRubber Seal Rubber Seal

Page 56

MAINTENANCE

1.56

Perform routine checks : refer

Thoroughly clean the machine:

IMPORTANT: PREVENT DAMAGE - Keep water away from electrical components. Use a dry cloth or brush to clean such areas.

Service the hydraulic system : This procedure is best carried out when the hydraulic oil is warm (not

hot). Lower the cutterheads to the ground and drain the hydraulic system by removing the hydraulic tank drain plug. Remove the oil tank filler flange to gain access to the suction strainer. Unscrew and remove the strainer and clean with paraffin or petrol before replacing. Renew the strainer if there are any signs of damage.

Remove the oil filler cap strainer and clean before replacing. Renew the strainer if there are any signs of damage.

Renew the return line oil filter element, refer - RUNNING IN PERIOD AT FIRST 50 HOURS.

Renew the transmission oil filter element, refer - RUNNING IN PERIOD AT FIRST 50 HOURS.

Replace the drain plug and refill the hydraulic tank with fresh clean hydraulic oil of the recommended grade, refer - SPECIFICATIONS.

Run the machine and operate all hydraulic systems until the hydraulic oil is warm. Recheck the oil level and top up as necessary to the upper mark on the sight level gauge.

EVERY 500 HOURS

- DAILY BEFORE USE.

- EVERY 50 HOURS.

- EVERY 250 HOURS.

1. Drain plug

2. Oil tank filler flange

3. Suction strainer

4. Filler strainer

1D924P05C

Page 57

MAINTENANCE

1.57

3D3122A

x + 3 - 8mm

1. Wheel centre height

2. Tyre

3. Direction of forward travel

4. Track-rod assembly

EVERY 500 HOURS

Renew the engine air cleaner filter: Check the condition of the air cleaner

hoses. Replace any hose which is damaged and tighten the connections, refer ENGINE MANUAL.

Renew the engine fuel filter element: Refer - ENGINE MANUAL.

Check electrical system: Inspect all electrical connections and cables and replace any which are damaged

or corroded. Spray a good quality water inhibitor on to exposed connections to prevent moisture ingress.

Check rear wheel alignment: To prevent excessive tyre wear and ensure safe machine operation, the rear wheels must be correctly aligned to ‘toe - in’ by 3 - 8mm.

Set the rear wheels in the straight ahead position. Measure and compare the distance between the front sidewalls and the rear sidewalls at the wheel centre height. The distance between the front sidewalls must be set 3 - 8mm less than the distance between the rear sidewalls.

To adjust the alignment of the rear wheels, first back off the left hand and right hand locknuts on the track rod assembly. (Left hand locknut is a left hand thread). Rotate the track rod to achieve the correct ‘toe - in’ as described above and tighten the locknuts securely.

Continued.

ENGINE

Page 58

EVERY 500 HOURS Continued.

Check the engine overheat warning system: Turn the ignition key to the ‘ignition on’ position 'I'.

Disconnect the red/grey wire terminal from the engine temperature switch and touch the metal terminal of this wire onto a suitable earth point, ensuring that the metal surfaces make good contact. The horn will sound and the engine coolant temperature warning light will illuminate to confirm correct operation. If the system is faulty, make repairs before operating the mower.

Check the hydraulic oil overheat warning system: Turn the ignition key to the ‘ignition on’ position 'I'. Disconnect the red/blue wire terminal from the hydraulic tank temperature switch and touch the metal terminal of the wire onto a suitable earth point, ensuring that the metal surfaces make good contact. The horn will sound and the hydraulic oil temperature warning light will illuminate to confirm correct operation. If the system is faulty, make repairs before operating the mower.

MAINTENANCE

1.58

1. Temperature switch

2. Hydraulic oil tank

1. Temperature switch.

1P953C15A

Page 59

MAINTENANCE

1.59

CUTTERHEAD CYLINDER TO BOTTOM BLADE ADJUSTMENT

IMPORTANT : PREVENT DAMAGE - It is essential that the relationship between the bottom blades and the cutting cylinders is kept in good adjustment in order to ensure good cutting performance, minimum power consumption and prolonged life for the cutting edges.

Carry out the following procedure before commencing work and re-check the settings every few hours.

Check that the cutting cylinder is correctly set to the bottom blade by holding a thin piece of paper between the cutting cylinder and the bottom blade as shown. Carefully rotate the cylinder as shown and check that the paper is cut cleanly at all points along the length of the blade. Hold the paper at 90 degrees (right angles) to the bottom blade to obtain the correct cutting action.

WARNING: PREVENT ACCIDENTS - Ensure that people are clear of the cutting cylinders as rotation of one may cause others to rotate.

If adjustment is necessary proceed as follows;

Release nut 'A' 1/4 turn both ends.

Turn handwheel 'B' each end alternately whilst rotating the cutting cylinder backwards until the bottom blade is in 'fleeting' contact with the cylinder along its entire length. Re-check the cutting action along the length of the bottom blade using a thin piece of paper making marginal adjustments as necessary.

Tighten nut 'A' both ends.

If it is impossible to obtain a good clean paper cut across the entire length of the bottom blade it will be necessary to carry out the backlapping procedure to reprocess the cutting edges. In severe cases it will be necessary to regrind the cutting cylinder and the bottom blade, refer - BACKLAPPING / GRINDING.

Do not be tempted to over-adjust causing heavy contact between the cylinder and bottom blade as this will cause very rapid uneven wear to take place, leading to tramlining and waviness of the cutting edges. The frictional losses will be high and a significant amount of power will be absorbed thus reducing the power available for cutting. The heating effect due to friction will cause excessive expansion to take place which will further aggravate the situation by increasing the contact pressure.

If the cutterheads are allowed to operate for more than a few hours without adjustment the running wear will eventually cause the cylinder to run out of contact with the bottom blade. At this stage very rapid rounding of the cutting edges will occur as grass and abrasive particles pass through the clearance between the blades.

Lack of attention to adjustment can therefore be foolhardy as maintenance costs will escalate. Quality of cut will also be seriously affected as will the health and growth of the grass.

An experienced operator will notice when a cutterhead starts to go out of adjustment, when the grass ceases to be cut cleanly and the cut ends become ragged.

Page 60

MAINTENANCE

1.60

CUTTERHEAD BACKLAPPING

This process is recommended for restoring the sharp cutting edges to cylinders and bottom blades which are essential for good quality grass cutting.

This process can only deal with a small amount of metal removal to restore the cutting edges. If the blade edges are seriously worn or damaged it will be necessary to remove the component parts and have them reground.

The backlapping process:

Check that the mower engine is switched off and the parking brake applied.

Adjust the cutting cylinders to the bottom blades to obtain ‘fleeting contact’.

Apply a medium grade detergent based carborundum paste to the cutting edges of the cylinders with a long handled brush.

Ensure that the area surrounding the cutterheads is clear of people and keep hands and feet clear of the cutting cylinders during the period when the mower engine is running.

Sit on the operator seat, start the mower engine and set the engine speed at idle.

Operate the cutterhead drive switch to the 'reverse/backlap' position for a period of time and listen to the grinding action .

Operate the cutterhead drive switch to the 'off' position and switch off the mower engine when the grinding action has stopped.

Thoroughly clean the blade edges and adjust the cutting cylinders to the bottom blades. Check that a thin piece of paper can be cut cleanly at all points along the cutting edges while rotating the cylinders by hand.

If further backlapping is necessary repeat steps 2 to 8.

Thoroughly remove and wash off all traces of the carborundum paste from the cylinders and bottom blades.

10.

80 Grade Carborundum paste

0,45 kg

11,25 kg

Part No:

63-07-088

63-07-086

Page 61

MAINTENANCE

1.61

CUTTERHEAD GRINDING

It will be necessary to carry out a grinding operation to correct cylinder spiral edges or bottom blade edges which have become excessively rounded or distorted. Bottom blades which are nearing the end of their wear life should be replaced. The new blades should be ground on their holders prior to fitting, refer - CUTTERHEAD BOTTOM BLADE REPLACEMENT. When grinding operations are necessary it is essential that both cylinders and bottom blades are ground at the same time. The only exception to this rule is when a new cylinder is fitted in which case it is only necessary to grind the bottom blade. All such grinding operations should be carried out by your dealer on a quality, well maintained cylinder/ bottom blade grinding machine.

CUTTERHEAD BOTTOM BLADE REPLACEMENT

Remove the bottom blade holder by removing the three fixing bolts at each end and withdraw from the cutterhead. Remove the worn bottom blade and discard the countersunk screws and securing nuts. Fit the new blade to the holder and loosely assemble with new countersunk screws and securing nuts. Tighten the centre bolts to a torque of 40 Nm. Continue by tightening the remaining bolts to the same torque by working from the centre out towards the blade ends.

The new bottom blade must be ground on its holder prior to refitting to the cutterhead. Adjust the cutting cylinder position to give adequate clearance for fitting the new bottom blade holder. Refit the bottom blade holder assembly to the cutterhead using the original fixing bolts and tighten to a torque of 35 Nm. Finally adjust the cylinder to the bottom blade, refer - CUTTERHEAD CYLINDER TO BOTTOM BLADE ADJUSTMENT.

Page 62

MAINTENANCE

1.62

RAISING THE MOWER OFF THE GROUND

WARNING: PREVENT ACCIDENTS - Before raising the mower ensure that:

The lifting device to be used is in good condition and capable of supporting the weight of the mower securely. Minimum lift capacity 2000 Kg.

The mower is on level ground.

The parking brake is applied.

The engine is switched off and the ignition key removed.

The ground under the lifting device is level and firm.

The lifting device is secure against one of the mower lifting points.

If raising the front of the mower, both of the rear wheels must be chocked securely to prevent the mower rolling away. Note that the parking brake only operates on the front wheels.

WARNING: PREVENT ACCIDENTS - When the mower is raised off the ground:

NEVER crawl under the mower.

NEVER start the engine.

1. Front left hand lifting point

2. Front right hand lifting point

3. Rear towing eye and lifting point

4. Front towing eye

Page 63

MAINTENANCE

1.63

TOWING THE MOWER

Towing procedure : Connect a rigid tow bar between the towing eye on the mower and a suitable

towing vehicle. Ensure that the towing vehicle specification is suited to braking the combined vehicle weight to rest whilst effecting complete control at all times. Ensure that the towing vehicle’s parking brake is applied. Chock the mower front wheels to prevent the mower rolling away.

De-commission the front wheel motor disc brakes as follows :-

i) Identify the right hand front wheel motor disc brake assembly and remove the rubber plug (item 2). Position a M12 x 40mm long setscrew (item 5) with washer (item 4) through the brake release bar (item

3) and into the hole in the centre of the motor end plate. Tighten the setscrew (item 5) into the threaded hole in the brake piston until the brake is released.

ii) Identify the left hand front wheel motor disc brake assembly and repeat the previous procedure.

1. Front wheel motor.

2. Rubber plug.

3. Brake release bar.

4. Washer - M12 - (09485).

5. Setscrew M12 x 40 - (ZDH1L040U).

1D950R02

1D950R01

Page 64

MAINTENANCE

1.64

De-commission the hydraulic service braking system as follows:-

Open the transmission bypass valve situated as shown on top of the transmission pump. The valve is fully open at 3 anti-clockwise revolutions. Do not open the valve past 3 revolutions. The steering must be operated manually when the mower is being towed. The steering will feel heavy as there is no hydraulic assistance when the engine is switched off. The mower is now in a freewheel condition and can be towed for a short distance at slow speed. Remove wheel chocks before towing.

After towing the mower: To return the mower to its normal working condition the following procedure must be adopted.

Chock the front wheels and re-commission the hydraulic service braking system as follows :-

i) Close the transmission bypass valve. Turn clockwise and tighten to a torque of 48- 52 Nm.

Re-commission the front wheel motor disc brakes as follows :-

i) Identify the right hand front wheel motor disc brake assembly. Rotate the setscrew (item 5) anti-clockwise and remove together with washer (item 4) and brake release bar (item 3). Reassemble the rubber plug (item 2) into the motor end plate.

ii) Identify the left hand front wheel motor disc brake assembly and repeat the previous procedure.

Store the brake release bars, washers and setscrews (items 3, 4 and

5) for future use.

Remove the wheel chocks.

Disconnect the tow bar.

The mower braking system will now operate in the normal way.

WARNING: PREVENT ACCIDENTS - Before using the mower, ensure that the braking system operates correctly. Carry out initial checks with the mower at slow speed. Do not operate the mower with a defective braking system. Do not operate the mower with the brakes de-commissioned.

TOWING THE MOWER Continued.

1. Front wheel motor.

2. Rubber plug.

3. Brake release bar.

4. Washer - M12 - (09485).

5. Setscrew M12 x 40 - (ZDH1L040U).

Bypass Valve

1D950R01

Page 65

GRASS CUTTING FAULTS

1.65

Turning too tightly.

Mower sliding sideways when travelling across face of a slope.

One end of cutterhead out of ground contact caused by:

- Poorly routed hoses or wrongly positioned hydraulic adaptors.

- Pivot pins seizing.

- Grass build up under cutterhead.

Forward speed too high.

Cylinder speed too slow.

Height of cut too low.

Cylinder is running slow.

Inconsistent height of cut setting on one cylinder.

Raise/Lower position control not in float position.

One end of cutterhead out of ground contact caused by:

- Poorly routed hoses or wrongly positioned hydraulic adaptors.

- Pivot pins seizing.

- Grass build up under cutterhead.

GRASS CUTTING FAULTS

Areas of uncut grass at point of overlap between cutting cylinders.

Ridge lines in the cut across the direction of travel over full width.

Ridge lines in the cut grass across the direction of travel over the cutting width of one cylinder.

Step in cut grass height at point of overlap between cutting cylinders.

Reduce turning radius.

Mow up/down slope.

Reroute hoses/reposition hydraulic adaptors.

Free off and grease pivot pins.

Remove grass.

Reduce forward speed.

Increase mower engine speed.

Raise height of cut.

Refer - TROUBLE SHOOTING for remedy.

Check and readjust height of cut setting.

Operate position control to float position.

Reroute hoses/reposition hydraulic adaptors.

Free off and grease pivot pins.

Remove grass.

FAULT POSSIBLE CAUSE REMEDY

Page 66

GRASS CUTTING FAULTS

1.66

GRASS CUTTING FAULTS Continued.

Scalping.

Lines of uncut or badly cut grass in direction of travel.

Tramlining of cutting edges due to heavy contact caused by poor cutting cylinder to bottom blade adjustment.

Bottom blade in ground contact.

Nose down attitude of bottom blade.

Cutterheads bouncing.

Worn cylinder bearings/bearing housing pivots.

Loose components in cutterhead.

Undulations too severe for height of cut setting.

Height of cut too low.

FAULT

POSSIBLE CAUSE

REMEDY

Backlap or regrind to restore cutting edges.

Raise height of cut.

Readjust cutterhead to ensure bottom blade is parallel to ground.

Reduce forward speed. Reduce weight transfer.

Replace worn parts.

Check and retighten as necessary.

Use floating cutterheads.

Raise height of cut.

Cutting cylinder is partially out of contact with the bottom blade.

Cutting cylinder is in heavy contact with the bottom blade.

Height of cut is too high.

Cutting edges of cutting cylinders/bottom blades are rounded.

Readjust cutting cylinder to bottom blade.

Readjust cutting cylinder to the bottom blade.

Lower height of cut setting.

Backlap or regrind to restore cutting edges.

Some uncut or poorly cut strands of grass..

Page 67

GRASS CUTTING FAULTS

1.67

FAULT

POSSIBLE CAUSE

REMEDY

GRASS CUTTING FAULTS Continued.

Excessive bottom blade wear..

Bottom blade in heavy ground contact.

Cutting edges of the cutting cylinder/bottom blade are rounded.

Cylinder is in heavy contact with the bottom blade.

Damaged cutting cylinder or bottom blade.

Excessively abrasive ground conditions.

Raise height of cut.

Backlap or regrind to restore cutting edges.

Readjust the cutting cylinder to the bottom blade.

Regrind or replace as necessary.

Raise height of cut.

Page 68

1.68

TROUBLE SHOOTING

When using the following chart it may be found that overhaul of major components or hydraulic pressure adjustments are necessary. In this case it is recommended that your dealer make these repairs as he is properly equipped to do this work.

WARNING: PREVENT ACCIDENTS - ALWAYS Apply the parking brake, switch off the engine and remove the ignition key before attempting to work on the mower.

PROBLEM

Engine will not start with ignition key.

Flat Battery.

POSSIBLE CAUSE

Transmission neutral interlock switch not energised.

Parking brake interlock switch not energised.

Cutterhead drive interlock switch not energised.

Faulty electrical connection.

Terminal connection loose or corroded.

Loose or defective alternator belt.

Defective battery.

Electrical short circuit.

For all other engine problems, refer - ENGINE HANDBOOK.

REMEDY

Remove foot from forward/reverse travel pedal.

Check setting of transmission neutral interlock switch.

Operate parking brake lever to the ‘ON’ position.

Check setting of parking brake interlock switch.

Move cutterhead drive switch to the ‘OFF’ position.

Check setting of cutterhead interlock switch.

Trace and correct fault.

Clean and tighten terminal connections. Recharge battery.

Re-tension or replace drive belt, refer

- ENGINE HANDBOOK.

Recharge battery. Replace battery.

Trace short circuit and make good.

Page 69

1.69

TROUBLE SHOOTING

POSSIBLE CAUSE

Defective switch.

Defective solenoid valve.

Defective wiring.

Blocked radiator screen.

Blocked oil cooler fins.

Blocked engine radiator matrix.

Low relief valve setting.

Low oil level.

Brakes engaged.

Cutting cylinders tight on bottom blades.

Defective fan or fan drive.

Faulty wheel motor brake assembly.

Worn brake discs.

PROBLEM

Differential lock non operational.

Hydraulic oil system overheating.

Incorrect brake operation.

REMEDY

Check switch and replace if necessary.

Service or replace solenoid valve.

Check wiring/connections as necessary.

Clean screen.

Clean fins.

Clean matrix.

Have relief valve cleaned and pressure checked. Consult your Toro dealer.

Fill reservoir to correct level.

Disengage brakes.

Readjust settings.

Check fan operation and service as required.

Consult your Toro dealer.

Replace brake discs. Consult your Toro dealer.

TROUBLE SHOOTING Continued.

Page 70

1.70

TROUBLE SHOOTING

PROBLEM

Lack of transmission drive.

Forward/backward transmission creep in neutral.

Work/transport modes non-operational

Lack of steering.

POSSIBLE CAUSE

Parking brake engaged.

Low oil level.

Incorrect oil used.

Defective travel pedal linkage.

Defective transmission pump.

Transmission relief valve open.

Broken drive coupling.

Transmission filter blocked.

Transmission neutral adjustment incorrectly set.

Defective control switch.

Defective solenoid valve.

Defective wiring.

Defective steering valve.

Defective hydraulic cylinder.

Damaged steering hose.

TROUBLE SHOOTING Continued.

REMEDY

Release parking brake.

Fill reservoir to correct level.

Drain reservoir and refill with correct oil.

Check linkage and replace defective parts.

Have the transmission pump overhauled by your Toro dealer.

Close relief valve, refer - MAINTENANCE TOWING THE MOWER.

Replace drive coupling.

Replace transmission filter.

Readjust transmission neutral setting.

Check switch and replace if necessary. Service or replace solenoid valve.

Check wiring connections and repair/replace as necessary.

Service or replace steering valve.

Service or replace hydraulic cylinder.

Replace defective hose.

Page 71

1.71

TROUBLE SHOOTING

TROUBLE SHOOTING Continued.

REMEDY

Identify noisy pump and service or replace.

Identify noisy motor and service or replace.

Tighten or replace hydraulic fittings particularly in suction lines.

Clean and replace suction strainer or renew as necessary.

Allow system to warm up.

Have relief valve cleaned and pressure checked. Consult your Toro dealer.

Fill hydraulic oil reservoir to correct level.

PROBLEM

Excessive noise in hydraulic system.

POSSIBLE CAUSE

Faulty pump.

Faulty motor.

Air leaking into system.

Suction strainer blocked or damaged.

Excessive oil viscosity due to cold conditions.

Low relief valve setting.

Low hydraulic oil level.

Page 72

1.72

TROUBLE SHOOTING

Replace as necessary.

Fill hydraulic oil tank to correct level.

Renew oil in hydraulic tank with hydraulic oil of correct viscosity grade, refer - SPECIFICATIONS.

Change filter element.

Have relief valve cleaned and pressure checked. Consult your Toro dealer.

Check cylinder to bottom blade adjustment. Reduce workrate i.e. increase height of cut or reduce forward speed.

Incorrect hydraulic oil grade, refer - Problem ‘Hydraulic Oil System Overheating’.

Check and tighten fittings. Replace hose if necessary.

Remove high spot with a stone and backlap to restore cutting edges. Serious damage will necessitate regrinding.

Replace as necessary.

After initial satisfactory operation machine loses power.

Cylinder "knocks" while rotating.

PROBLEM POSSIBLE CAUSE

REMEDY

TROUBLE SHOOTING Continued.

High spot on cylinder or bottom blade due to contact with foreign object.

Worn cylinder bearings.

Worn pump or motor.

Low hydraulic oil level.

Incorrect oil viscosity.

Oil filter element blocked.

Faulty pressure relief valve.

Overheating.

Leaks on suction hose.

Page 73

1.73

TROUBLE SHOOTING

POSSIBLE CAUSE

Cutting cylinder bearing seized.

Incorrect rotation motor fitted.

Diverter valve only partly open.

Motor integral check valve jammed open.

Cutting cylinder tight on the bottom blade.

Motor worn.

Lift cylinder seal failure.

Pressure relief valve jammed open or wrongly set.

Defective control valve.

Mechanical blockage.

Incorrect hose routing or incorrect orientation of hydraulic fittings.

Tightness in pivots.

Mower operated in ‘hold’ position.

Weight transfer set too high.

PROBLEM

REMEDY

One cylinder rotates slowly.

Cutterhead fails to lift out of work.

Cutterheads do not follow ground contours.

Replace as necessary.

Check motor and replace if necessary.

Free off and lubricate or replace diverter valve as necessary.

Have check valve cleaned and checked.

Readjust setting.

Replace motor.

Replace seals.

Have relief valve cleaned and pressure checked. Consult your Toro dealer.

Overhaul control valve.

Remove blockage.

Move cutterheads throughout extremes of movement and observe any tightness in the hoses. Correctly route hoses and orientate fittings as necessary.

Free off and grease as necessary.

Move position control lever to 'float' position.

Reduce weight transfer.

TROUBLE SHOOTING Continued.

Page 74

1.74

TROUBLE SHOOTING

Faulty seat sensor switch.

Low oil level.

Diverter valve jammed.

Sheared drive shaft.

Pressure relief valve jammed open or wrongly set.

Cutting cylinder jammed.

Cutting cylinder tight on bottom blade.

Cutterhead control valve in the ‘off’ position caused by:

- Defective control valve.

- Electrical fault.

Hoses wrongly connected.

Cutterhead drive switch wrongly connected.

Cutterheads fail to start up when lowered into work.

Cylinders rotate in wrong direction.

Check mechanical and electrical operation of switch.

Fill hydraulic oil reservoir to correct level.

Free off and lubricate or replace the diverter valve as necessary.

Check motor and cylinder drive shafts and replace if necessary.

Have relief valve cleaned and pressure checked. Consult your Toro dealer.

Free off as necessary.

Readjust setting.

Overhaul control valve.

Have electrical system checked.

Check hydraulic circuit and reconnect as necessary.

Check switch electrical connections.

PROBLEM

POSSIBLE CAUSE

REMEDY

TROUBLE SHOOTING Continued.

Page 75

1.75

ELECTRICAL CIRCUIT DIAGRAM

G/N

COLOURS

P/R

B - BLACK

N - BROWN

R - RED

P/R

O - ORANGE

Y - YELLOW

G - GREEN

P/B

P/Y

P/B

P/Y

U - BLUE

P - PURPLE

R/S

S - SLATE

W - WHITE

K - PINK

G/W

L - LIGHT GREEN

N/W

N/B

R/N

W/R

G/R

R/W

G/W

N/B

N/Y

G/U

W/R

44 45

W/N

N/W

R/W

U/R

R/W

G/R

3P953D01B

W/Y

P/R

B/P

U/G

U/B

U/G

U/B

P/R

W/P

W/Y

N/Y

W/N

N/W

W/R

W/B

P/R

W/R

U/GU/B

N/R

50a

U/R

R/S

P/R

B/P

N/B

W/U

B/P

G/N

W/G

W/B

N/W

P/R

P/B

L/Y

N/B

12345678

N/R

L/Y

N/R

U/R

W/R

W/U

W/P

Y/B

P/R

Y/B

U/R

G/P

G/U

30 30

L/Y

P/Y

G/P

N/W

Braid

Y/B

49a

W/B

L/Y

P/R

Page 76

1.76

ELECTRICAL CIRCUIT DIAGRAM

1. Switch - Parking Brake Interlock. 950865

2. Glow Plug Timer. 15694-65992

3. Light - Parking Brake. 924601/950858

4. Light - Glow Plugs. 924601/950857

5. Light - Neutral. 924601/950862

6. Light - Cutterhead Drive Off. 924601/950861

7. Light - Return Filter. 924601/950866

8. Light - Pressure Filter. 924601/950863

9. Light - Battery Warning. 924601/924605

10. Light - Engine Oil Pressure. 924601/924606

11. Light - Engine Coolant Temperature. 924601/924602

12. Light - Hydraulic Oil Temperature. 924601/924603

13. Diodes - Overheat - Audible Warning. 950868

14. Switch - Beacon (supplied with beacon kit). 924608

15. Switch - Work/Transport Mode. 924607

16. Solenoid - Centre Cutterhead Drive Reverse. 70-06-246

17. Solenoid - Centre Cutterhead Drive Forwards. 70-06-246

18. Solenoid - Wing Cutterhead Drive Reverse. 70-06-246

19. Solenoid - Wing Cutterhead Drive Forwards. 70-06-246

20. Switch - Cutterhead Drive. 924864

21. Fusebox. 70-09-096

1. 10A Cutter Drive & Lift Configuration 70-09-026

2. 10A Transmission & Horn 70-09-026

3. 3A Instruments 70-09-024

4. Blank (Beacon) -

5. Blank (Cab Wipers) or (Air Suspension Seat) -

6. Blank (Lighting Kit) -

7. Blank (Lighting Kit) -

8. 30A Engine Start (Fuel Solenoid) 70-09-027

22. Switch - Ignition. 74-09-009

23. Switch - Horn. 924618

24. Relay - Cutterhead Drive Warning Lamps. 70-09-148

25. Relay - Overheat Audible Warning. 70-09-148

26. Relay - Neutral Stark 995718

27. Relay - Glow Plugs. 92462 5

28. Timer - Operator Presence Interlock. 70-01-512

29. Switch - Cutterhead Lift Configuration. 924608

30. Solenoids - Lift Configuration. 63-06-082

31. Temperature Gauge (supplied with temp kit). -

32. Relay - Fuel Solenoid 16259-60250

33. Connectors for Lighting Kit. -

34. Horn. 70-09-108

35. Switch - Operator Seat. 111-0410

36. Solenoid - Differential Lock. 910627

37. Switch - Differential Lock. 994860

38. Switch - Pressure Filter. -

39. Switch - Hydraulic Oil Temperature. 940852

40. Connection for Beacon Kit. -

41. Switch - Neutral/Starter Interlock. 111-0143

42. Battery. 70-09-015

43. Switch - Engine Oil Pressure. -

44. Starter Motor. -

ITEM NO. DESCRIPTION PART NO.

Page 77

1.77

ELECTRICAL CIRCUIT DIAGRAM

G/N

COLOURS

B - BLACK

P/R

N - BROWN

R - RED

P/R

O - ORANGE

Y - YELLOW

G - GREEN

P/B

P/Y

P/B

P/Y

U - BLUE

P - PURPLE

R/S

S - SLATE

W - WHITE

K - PINK

G/W

L - LIGHT GREEN

N/W

N/B

R/N

W/R

G/R

R/W

G/W

N/B

R/W

U/R

N/Y

G/U

W/R

44 45

W/N

B/P

N/W

R/W

W/Y

G/R

P/R

3P953D01B

U/G

U/B

U/G

U/B

P/R

W/P

W/Y

N/Y

W/N

N/W

W/R

W/B

P/R

W/R

U/GU/B

N/B

G/N

W/G

N/R

50a

U/R

R/S

P/R

W/U

B/P

W/U

B/P

P/R

P/B

L/Y

N/B

12345678

N/R

L/Y

W/R

W/U

W/P

Y/B

P/R

Y/B

U/R

G/P

N/W

Braid

Y/B

49a

W/B

L/Y

W/B

G/U

N/R

N/W

U/R

30 30

L/Y

P/Y

G/P

P/R

Page 78

1.78

ELECTRICAL CIRCUIT DIAGRAM

45. Alternator/Regulator. -

46. Engine Temperature Sender (supplied with temp kit). -

47. Glow Plugs. -

48. Switch - Engine Overheat. -

49. Solenoid - Fuel (SA 4259-12)

50. Engine. 950950

51. Hourmeter. 910850

52. Switch - Return filter. -

53. Solenoids - Work/Transport Mode. 910627

54. Fuse - Engine Glow plugs 60A -

55. Fuse - Main 60A -

56. Diode - Parking Brake 950868

57. Diode - Seat Switch 950868

58. Relay - Seat Switch 70-09-148

59. Delay Module - Seat 924722

ITEM NO. DESCRIPTION PART NO.

Page 79

1.79

TRANSMISSION / BRAKE - HYDRAULIC CIRCUIT

4P953C03

Page 80

1.80

TRANSMISSION / BRAKE - HYDRAULIC CIRCUIT

ITEM NO. DESCRIPTION PART NO.

1 Motor - Front Wheel Twinlock - 332cc/Rev 953686 2 Motor - Front Wheel Twinlock - 332cc/Rev 953682 3 Manifold - Front Transmission 953683 4 Valve - Solenoid - Work/Transport 5 Valve - Pilot Operated - Diff Lock 6 Relief Valve - Serial Lines - 80 bar 7 Valve Solenoid - Diff Lock 8 Relief Valve - Front Motor - 375 Bar 9 Flow Divider - Front Wheels 10 Valve - Pilot Operated - Diff Lock 11 Shuttle Valve - Hot Oil Purge 953687 12 Relief Valve - Hot Oil Purge 13 Relief Valve - Serial Line - 375 Bar 953710 14 Wheel Motor - Rear - 130cc/Rev 953685 15 Pump - Transmission - 52cc/Rev 953684 16 Relief Valve - Charge Pump - 29 Bar 17 Relief Valves - Fwd/Rev - 350 Bar 18 Oil Cooler 950606 19 Filter - Charge - 10 Micron 950597 20 Filter - Return - 10 Micron 924865 21 Hydraulic Oil Tank 953802 22 Check Valve - Transmission Fwd/Rev 23 Suction Strainer - 125 Micron 950608 24 Valve - Brake 70-06-015W 25 Check Valve 26 Orifice - 1.5mm Dia. -

Page 81

1.81

HYDRAULIC CIRCUIT DIAGRAM

TPAB

DCRBMB

2P953C01A

PT B A

4321

LBX

D3D2D1TPC

Page 82

1.82

HYDRAULIC CIRCUIT DIAGRAM

ITEM NO. DESCRIPTION PART NO.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

Gear pump - Centre Cutterhead Drive. 74-06-154 Gear pump - Wing Cutterhead Drive. 74-06-154 Gear pump - Steering and Cutterhead Lift 74-06-154 Relief Valve - Steering 110 bar Steering Unit 910649W Check Valve - Steering Shock Bypass R.H. Check Valve - Steering Shock Bypass L.H. Relief Valve - Steering Shock L.H. Relief Valve - Steering Shock R.H. Steering Cylinder - Rear Axle 70-01-195W Spool Valve - Cutterhead Lift L.H. Spool Valve - Cutterhead Lift Centre Spool Valve - Cutterhead Lift R.H Solenoid Valve 131 or 212 R.H 953609 Solenoid Valve 131 or 212 L.H. 953609 Hydraulic Cylinder - RH Wing Cutterhead. 953603 Hydraulic Cylinder - RH Front Cutterhead. 910109W Hydraulic Cylinder - Centre Cutterhead. 910109W Hydraulic Cylinder - LH Front Cutterhead. 910109W Hydraulic Cylinder - LH Wing Cutterhead. 953603 Solenoid Valve Assembly - Cutterhead Drive (2- pl). 70-06-245 Solenoid Cutting Cylinders Forwards (2-pl). 70-06-246 Solenoid Cutting Cylinders Reverse (2-pl). 70-06-246 Cutter Drive Control Manifold Front and Centre. 910699 Restrictor Valve - Variable Weight Transfer. 910709 Relief Valve - Cutterheads Front and Centre - 250 bar 910708 Diverter Valve - Centre Cutterhead. 953601 Hydraulic Motor - Centre Cutterhead. 940602 Check Valve/Orifice - Motor Bypass Centre Cutterhead. Diverter Valve - L.H. Front Cutterhead. 953601 Hydraulic Motor - L.H. Front Cutterhead. 940602 Check Valve/Orifice - L.H. Front Cutterhead. Diverter Valve - R.H. Front Cutterhead. 953601 Hydraulic Motor - R.H. Front Cutterhead. 910696 Check Valve/Orifice - R.H. Front Cutterhead. Cutter Drive Control Block Wing Cutterhead. 953600 Relief Valve - Wing Cutterhead - 250 bar. 953610 Diverter Valve - R.H. Wing Cutterhead. 953601 Hydraulic Motor - R.H. Wing Cutterhead. 910696 Check Valve/Orifice - R.H. Wing Cutterhead. Diverter Valve - L.H. Wing Cutterhead. 953601 Hydraulic Motor - L.H. Wing Cutterhead. 940602 Check Valve/Orifice - L.H. Wing Cutterhead. Test Point - Cutterhead Drive - Wing. 910615 Test Point - Cutterhead Drive - Front & Centre. 910615 Test Point - Weight Transfer. 910615 Front Transmission Manifold. 950616 Return Bypass Manifold. 910616 Check Valve - Oil Cooler Bypass - 4 bar. 910641 Suction Strainer. 950608 Oil Cooler. 950606 Return Filter - Bypass Check Valve - 2 Bar. 924865 Oil Tank. 953802 Orifice - Wing Cutterhead Hydraulic Cylinder 1.4mm (2 pl).65-06-019

Page 83

1.83

WARRANTYWARRANTY

The Toro Commercial Parts Warranty A Ninety - Day Limited Warranty

Conditions and Products Covered The Toro Company (Toro) and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial Product (“Part”) to be free from defects in materials or workmanship for ninety (90) days. Where a warrantable condition exists, we will repair the Part at no cost to you. This warranty begins on the date the Part is purchased by the original retail purchaser.

Instructions for Obtaining Warranty Service

You are responsible for notifying the nearest Commercial Products Distributor or Authorized Commercial Products Dealer for replacement as soon as you believe a warrantable condition exists. You must provide the Commercial Products Distributor with a copy of the original Parts purchase invoice for warranty consideration. The Commercial products Distributor will provide a replacement part, repair, or reimbursement at invoice amount.

If you need help locating a Commercial Products Distributor or Authorized Dealer, or if you have questions regarding your warranty rights or responsibilities, you may contact us at:

Toro Commercial Products Service Department Spellbrook Bishops Stortford CM23 4BU England +44 (0)1279 603019 Email: uk.service@toro.com

Items and Conditions Not Covered

Not all product failure or malfunctions that occur during the warranty period are defects in materials or workmanship. This express warranty does not cover the following:

- Part failures which result from installation and use of add-on, modified, or unapproved accessories

- Part failures which result from failure to perform required maintenance and/or adjustments

- Part failures which result from use in an abusive, negligent or reckless manner

- Parts subject to consumption through use unless found to be defective. Examples of parts which are consumed, or used up, during normal Product operation include, but are not limited to, blades, cylinders, bedknives, tines, spark plugs, castor wheels, tires, filters, belts and certain sprayer components such as diaphragms, nozzles, and check valves, etc.

- Failures caused by outside influence. Items considered to be outside influence include, but are not limited to, weather, storage practices, contamination, use of unapproved coolants, lubricants, additives, or chemicals, etc.

- Normal "wear and tear” items. Normal “wear and tearʼ includes, but is not limited to, damage to seats due to wear or abrasion, worn painted surfaces, scratched decals or windows, etc.

General Conditions

Repair or, at our option, replacement by an authorized Toro Distributor or Dealer is your sole remedy under this warranty. Parts replaced under this warranty become the property of Toro. Toro will make the final decision whether to repair any existing part or assembly or replace it. Toro may use factory remanufactured parts rather than new parts for some warranty repairs. Neither the Toro Company nor the Toro warranty Company is liable for indirect, incidental or consequential damages in connection with the use of the Toro Products covered by this warranty, including any cost or expense of providing substitute equipment or service during reasonable periods of malfunction or non-use pending completion of repairs under this warranty. Except for the Emissions warranty referenced below if applicable, there is no other express warranty. All implied warranties of merchantability and fitness for use are limited to the duration of this express warranty.

This warranty gives you the specific legal rights, and you may also have other rights which vary from country to country.

Page 84

1.84

WARRANTY

The Toro General Commercial Products Warranty A Two-Year Limited Warranty

Conditions and Products Covered

The Toro Company (Toro) and its affiliate, Toro Warranty Company, pursuant to an agreement between them,

ointly warrant your Toro Commercial Product (“Product”) to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first. Where a warrantable condition exists, we will repair the Product at no cost to you including diagnosis, labor, parts and transportation. This warranty begins on the date the Product is delivered to the original retail purchaser.

* Product equipped with hour meter

Instructions for Obtaining Warranty Service

You are responsible for notifying the Commercial Products Distributor or Authorized Dealer from whom you purchased the Product as soon as you believe a warrantable condition exists.

If you need help locating a Distributor or Authorized Dealer, or If you have any questions regarding your warranty rights or responsibilities, you may contact us at: Toro Commercial Products Service Department Spellbrook Bishops Stortford CM23 4BU England +44 (0)1279 603019 Email: uk.service@toro.com

Owner Responsibilities

As the Product owner, you are responsible for required maintenance and adjustments stated in your Operatorʼs Manual. Failure to perform required maintenance and adjustments can be grounds for disallowing a warranty claim.

Items and Conditions Not Covered

Not all product failure or malfunctions that occur during the warranty period are defects in materials or workmanship. This express warranty does not cover the following:

- Product failures which result from the use of non-Toro replacement parts, or from installation and use of add-on, modified, or unapproved accessories

- Product failures which result from failure to perform required maintenance and/or adjustments

- Product failures which result from operating the Product in an abusive, negligent or reckless manner

- Parts subject to consumption through use unless found to be defective. Examples of parts which are consumed, or used up, during normal Product operation include, but are not limited to, blades, reels, bedknives, tines, spark plugs, castor wheels, tires, filters, belts and certain sprayer components such as diaphragms, nozzles, and check valves, etc.

- Normal "wear and tear” items. Normal “wear and tearʼ includes, but is not limited to, damage to seats due to wear or abrasion, worn painted surfaces, scratched decals or windows, etc.

Parts

Parts scheduled for replacement as required maintenance are warranted for the period of time up to the scheduled replacement time for that part.

Parts replaced under this warranty become the property of Toro. Toro will make the final decision whether to repair any existing part or assembly or replace it. Toro may use factory remanufactured parts rather than new parts for some warranty repairs.

General Conditions

Repair by an authorized Toro Commercial Product Distributor or Authorized Dealer is your sole remedy under this warranty.

Neither the Toro Company nor the Toro Warranty Company is liable for indirect, incidental or consequential damages in connection with the use of the Toro Products covered by this warranty, including any cost or expense of providing substitute equipment or service during reasonable periods of malfunction or non-use pending completion of repairs under this warranty. Except for the Emissions warranty referenced below if applicable, there is no other express warranty. All implied warranties of merchantability and fitness for use are limited to the duration of this express warranty.

This warranty gives you the specific legal rights, and you may also have other rights which vary from country to country.

Page 85

1.85

NOTES

Page 86

1.86

CUSTOMER INFORMATION

MACHINE DETAILS

Model:

Machine Serial No.:

Engine Serial No.:

Cutterhead Serial No.s:

Transmission Pump Serial No.:

Transmission Valve Block Front Serial No.:

Cutter Control Valve (Front & Centre) Serial No.:

Cutter Control Valve (Wing) Serial No.:

Page 87