Form No. 3428-786 Rev A Groundsmaster® 4100 or 4110 Rotary Mower Model No. 30608—Serial No. 403450001 and Up Model No. 30644—Serial No. 403450001 and Up Register at www.Toro.com.
This product complies with all relevant European directives; for details please see the separate product specific Declaration of Conformity (DOC) sheet. Visit www.Toro.com for product safety and operation training materials, accessory information, help finding a dealer, or to register your product.
Contents Hauling the Machine ......................................... 54 Locating the Tie-Down Points ........................... 54 Maintenance ........................................................... 55 Maintenance Safety.......................................... 55 Recommended Maintenance Schedule(s) ........... 55 Daily Maintenance Checklist............................. 57 Pre-Maintenance Procedures .............................. 59 Opening the Hood ............................................
Safety Servicing the Caster Wheels and Bearings........................................................ 83 Replacing the Cutting Unit Hinge Covers .......................................................... 84 Blade Maintenance .............................................. 84 Blade Safety ..................................................... 84 Checking for a Bent Blade ................................ 84 Removing and Installing the Cutting-Unit Blade(s) ....................................................
Engine-Emission Certification The engine in this machine is EPA Tier 4 Final and EU Stage V emissions compliant. Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or missing. decal58-6520 58-6520 1. Grease decal100-5622 100-5622 1. Height-of-cut adjustment decal93-6674 93-6674 1. Crushing hazard, hand—read the instructions before servicing or performing maintenance.
decal106-6755 decal104-3579 106-6755 104-3579 1. Low height-of-cut adjustment 2. High height-of-cut adjustment 1. Engine coolant under pressure. 3. Warning—do not touch the hot surface. 2. Explosion hazard—read the Operator's Manual. 4. Warning—read the Operator's Manual. decal106-4250 106-4250 1. Height-of-cut decal106-4251 106-4251 decal114-0849 114–0849 1. Height-of-cut 4. Forward direction 1. Warning—1) Disengage the PTO; 2) Raise the deck 2. Do not place your foot here. 3.
decal120-6604 decal120-4159 120-6604 120–4159 1. Thrown object hazard—keep bystanders away from the machine. 2. Cutting/dismemberment hazard of hand, mower blade—stay away from moving parts, keep all guards and shields in place. 1. Off 3. Cutting/dismemberment hazard of foot, mower blade—stay away from moving parts, keep all guards and shields in place. 5. Fast 12. Left deck—lower 6. Variable speed adjustment 13. Center deck—lower 2. Lights 3. On 4. Light switch location 7. Slow 7 8. High 9.
decal121-3887 121–3887 1. Read the Operator’s Manual. decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. decal120-8947 1. Explosion hazard 6. Keep bystanders away from the battery. 2. No fire, open flame, or smoking 7. Wear eye protection; explosive gases can cause blindness and other injuries. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection. 8. Battery acid can cause blindness or severe burns. 9.
decal130-0611 130-0611 1. Warning—1) Remove the pin; 2) Raise the doors; 3) Exit the cab. decal121-1592 127-3700 decal130-5355 1. Raise the left deck. 4. Lock the engine speed. 2. Raise the center deck. 5. Unlock the engine speed. 130-5355 1. Close the rear window. 2. Raise the hood. 3. Raise the right deck. decal130-5357 130-5357 1. Push forward to move forward. 2. Push back to reverse. decal130-5733 130-5733 1.
decal136-4436 136-4436 1. Read the Operator’s Manual for information on fuses. 7. Infocenter—2 A 2. Engine preheat—60 A 8. Headlights—15 A 3. Power supply—7.5 A 9. Power seat—10 A 4. Turn signals—10 A 10. Lighter—10 A 5. Engine control unit—10 A 11. Horn—10 A 6. System power—10 A decal114-0846 114-0846 1.
decal121-8378 121-8378 1. Fan—off 3. Cold air 5. External air 7. Air conditioner—on (If equipped) 2. Fan—on full 4. Hot air 6. Internal air 8. Air conditioner—off (If equipped) decal133-5618 133-5618 decal132-3600 132-3600 Cab only 1. Read the Operator's Manual for more information on fuses. 2. Headlight (25 A) 5. Working light (20 A) 3. Condenser fan and A/C clutch (30 A) 7. Cab light (15 A) 4. Fan (25 A) 8. Windshield wipers (15 A) 6.
decal120-0250 120-0250 1. Slow-moving vehicle decal117-2754 117-2754 1. Warning—read the Operator's Manual. 2. Warning—do not operate this machine unless you are trained. 3. Warning—wear the seatbelt when seated in the operator's position. 4. Warning—wear hearing protection. 5. Thrown object hazard—keep bystanders away. 6. Cutting hazard of hand or foot—stay away from moving parts; keep all guards and shields in place. 7.
decal137-5495 137-5495 1. Read the Operator’s Manual. decal137-5498 137-5498 1. Read the Operator’s Manual.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description 1 2 3 4 Use Qty. No parts required – Grease the machine. No parts required – Check the tire pressure. No parts required – Check the fluid levels. Production-year decal 1 Install the decal (CE machines only). Media and Additional Parts Description Use Qty.
3 Checking the Fluid Levels No Parts Required Procedure g279510 1. Check the engine-oil level; refer to Checking the Engine-Oil Level (page 63). 2. Check the hydraulic-fluid level; refer to Hydraulic Fluid Capacity (page 78). 3. Check the cooling system; refer to Checking the Cooling System (page 73). 4. Check the planetary-gear-drive oil; refer to Checking the Planetary-Gear-Drive Oil (page 70). 5. Check the rear-axle lubricant; refer to Checking the Rear-Axle Lubricant (page 71). 6.
Product Overview To engage the parking brake, connect the pedals with the locking latch, push down on both pedals, and pull the parking-brake latch out. To release the parking brake, press both pedals until the parking-brake latch retracts. Controls Note: Determine the left and right sides of the machine from the normal operating position. Key Switch The key switch (Figure 5) has 3 positions: OFF, ON/PREHEAT , and START . g203048 g028453 Figure 4 1. Brake pedal 4. Parking brake 2.
PTO Switch The PTO switch has 2 positions: OUT (START ) and IN (STOP). Pull the PTO button out to engage the mower-deck blades. Push the button in to disengage the mower-deck blades (Figure 5). High-Low Speed-Control Switch The High-Low speed-control switch allows the speed range to increase for transport of the machine (Figure 5). g028454 Figure 6 Mower decks do not operate in high range.
Seat Controls Cab Controls Seat-Adjustment Lever Move the seat-adjustment lever on the side of the seat outward, slide the seat to the desired position, and release the lever to lock the seat into position (Figure 7). g028431 Figure 8 1. Air-recirculation control 2. Fan control 5. Power outlet 6. Lights switch 3. Temperature control 7. Flashers switch 4. Windshield-wiper switch 8.
Flashers Switch Use this switch to turn the flashers (hazard lights) on or off (Figure 8). Windshield Latch Lift up the latches to open the windshield (Figure 9). Press in the latch to lock the windshield to the OPEN position. Pull out and down on the latch to close and secure the windshield. g020650 Figure 10 1. Indicator light 3. Middle button 2. Right button 4. Left button • Left Button, Menu Access/Back Button—press this button to access the InfoCenter menus.
InfoCenter Icon Description SERVICE DUE InfoCenter Icon Description (cont'd.
Using the Menus InfoCenter Icon Description (cont'd.) To access the InfoCenter menu system, press the menu access button while at the main screen. This brings you to the main menu. Refer to the following tables for a synopsis of the options available from the menus: Operator should change to the indicated state DPF ash accumulation notification.
Diagnostics Settings Menu Item Description Menu Item Description Engine Run Refer to the Service Manual or your authorized Toro distributor for more information on the Engine Run menu and the information contained there.
4. Accessing Protected Menus Note: The factory default PIN code for you machine is either 0000 or 1234. If you changed the PIN code and forgot the code, contact your authorized Toro distributor for assistance. 1. Press the middle button to enter the PIN code (Figure 12D). Wait until the red indicator light of the InfoCenter illuminates. Note: If the InfoCenter accepts the PIN code and the protected menu is unlocked, the word “PIN” displays in the upper right corner of the screen.
Specifications g203228 Figure 13 24
Description Figure 13 reference Dimension or Weight Height with cab A 237 cm (93 inches) Height with roll bar raised I 217 cm (85 inches) Height with roll bar lowered K 173 cm (68 inches) Overall length H 186 cm(152 inches) Length for storage G 184 cm (151 inches) D 315 cm (124 inches) Width of cut overall front cutting unit 137 cm (54 inches) side cutting unit 94 cm (37 inches) front and one side cutting unit 226 cm (89 inches) Overall width cutting units down E 323 cm (127 inch
Checking the Engine-Oil Level Operation Note: Determine the left and right sides of the machine from the normal operating position. Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking the Engine-Oil Level (page 63). Before Operation Checking the Cooling System Before Operation Safety General Safety Before you start the engine and use the machine, check the cooling system; refer to Checking the Cooling System (page 26).
Adding Fuel Petroleum Diesel Cetane rating: 45 or higher Sulfur content: Ultra-low sulfur (<15 ppm) Fuel Table Diesel fuel specification Location ASTM D975 No. 1-D S15 USA No. 2-D S15 EN 590 European Union ISO 8217 DMX International JIS K2204 Grade No. 2 Japan KSM-2610 Korea • Use only clean, fresh diesel fuel or biodiesel fuels. • Purchase fuel in quantities that can be used within 180 days to ensure fuel freshness. Use summer-grade diesel fuel (No.
g033359 Figure 17 Rear Wheels g001055 Figure 15 Adjusting the Mirrors Checking the Torque of the Wheel Lug Nuts Cab Model Only Service Interval: After the first hour While sitting in the seat, adjust the rearview mirror to attain the best view out the rear window (Figure 18). Pull the lever rearward to tilt the mirror to reduce the brightness and glare of light.
Aiming the Headlights Lowering the Roll Bar Optional Accessory 1. Loosen the mounting nuts and position each headlight so that it points straight ahead. Note: Tighten the mounting nut just enough to hold the headlight in position. 2. Place a flat piece of sheet metal over the face of the headlight. 3. Mount a magnetic protractor onto the plate. 4. While holding the assembly in place, carefully tilt the headlight downward 3°, then tighten the nut. 5. Repeat the procedure on the other headlight.
Adjusting the Height of Cut Note: These shims require a level across the entire width of the cutting units. Slide the appropriate number of 13 mm (1/2 inch) spacers (refer to the chart below) onto the spindle shaft to attain the desired height of cut; then slide the washer onto the shaft. Center Cutting Unit The height of cut is adjustable from 25 to 127 mm (1 to 5 inches) in 13 mm (1/2 inch) increments.
Note: These shims are required to achieve a level across the entire width of the cutting units. Slide the appropriate number of 13 mm (1/2 inch) spacers (refer to the chart below) onto the spindle shaft to attain the desired height-of-cut, then slide the washer onto the shaft. Refer to the following chart to determine the combinations of spacers for the setting (Figure 26).
Adjusting the Skids Mount the skids in the lower position when operating at heights of cut greater than 64 mm (2-1/2 inches) and in the higher position when operating at heights of cut lower than 64 mm (2-1/2 inches). decal100-5623nc Figure 28 8. Insert the clevis pins and install the hairpin cotters. 9. Rotate the tension rod counterclockwise (finger tight) to put tension on adjustment.
Adjusting the Blade Correcting a Mismatch Between the Cutting Units Important: On multi-bladed machines, take care as rotating 1 blade can cause other blades to rotate. Due to differences in grass conditions and the counterbalance setting of the traction unit, a sample area of grass should be cut and the appearance checked before formal cutting is started. To ensure proper operation of the cutting unit, there must be a 10 to 16 mm (0.38 to 0.
Setting Up the Center Cutting Unit Setting Up the Side Cutting Units Note: It is best to use the Toro tool (Part No. 121-3874) to tighten the tensioning cap. 1. Rotate the blade of each spindle until the ends face forward and backward. 1. Rotate the blade on each spindle until the ends face forward and backward. 2. Measure from the floor to the front tip of the cutting edge. 2. Measure from the floor to the front tip of the cutting edge. 3. 3.
Checking the Safety-Interlock Switches make the adjustments to the side cutting units only. 3. If the inside edge of the side cutting unit is too high relative to the outside edge of the front cutting unit, remove a shim from the bottom of the front, inside caster arm on the side cutting unit (Figure 34). Service Interval: Before each use or daily The machine has interlock switches in the electrical system. These switches disengage either the traction unit or the PTO whenever you leave the seat.
During Operation • Never leave a running machine unattended. • Before you leave the operator’s position, do the During Operation Safety following: General Safety – Disengage the power takeoff and lower the attachments. – Park the machine on a level surface. • The owner/operator can prevent and is responsible • • • • • • • • • • • • • • • – Engage the parking brake. for accidents that may cause personal injury or property damage.
• Initial start up of a new machine. • A cab installed by Toro is a roll bar. • Always wear your seat belt. • The engine has ceased running due to lack of fuel. • Maintenance has been performed upon the fuel Slope Safety system components. • Slopes are a major factor related to loss of control • • • • • • • • • • and rollover accidents, which can result in severe injury or death. You are responsible for safe slope operation. Operating the machine on any slope requires extra caution.
Understanding Smart Power® Traction Diesel Particulate Filter Regeneration With the Smart Power® function, you do not have to listen to the engine speed in heavy conditions. This function prevents bogging down in heavy turf by automatically controlling the machine speed and optimizing cutting performance. You can set a comfortable maximum ground speed and mow without having to manually reduce the traction speed when you mow in heavy conditions.
Engine Warning Messages—Soot Accumulation Indication Level Level 1: Engine Warning Fault Code g213866 Engine Power Rating Recommended Action The computer de-rates the engine power to 85%. Perform a parked regeneration as soon as possible; refer to Performing a Parked or Recovery Regeneration (page 47). The computer de-rates the engine power to 50%. Perform a recovery regeneration as soon as possible; refer to Performing a Parked or Recovery Regeneration (page 47).
DPF Ash Accumulation • When enough ash accumulates, the engine • The lighter ash is discharged through the exhaust system; the heavier ash collects in the soot filter. • Ash is a residue of the regeneration process. Over • time, the diesel particulate filter accumulates ash that does not discharge with the engine exhaust. • • The computer for the engine calculates the amount of ash accumulated in the DPF.
Types of Diesel Particulate Filter Regeneration Types of diesel particulate filter regeneration that are performed while the machine is operating: Type of Regeneration Conditions that cause DPF regeneration DPF description of operation Passive Occurs during normal operation of the machine at high-engine speed or high-engine load • The InfoCenter does not display an icon indicating passive regeneration.
Types of diesel particulate filter regeneration that require you to park the machine: (cont'd.) Type of Regeneration Conditions that cause DPF regeneration DPF description of operation Recovery Occurs because the operator ignored requests for a parked regeneration and continued operating the machine, adding more soot to the DPF • When the reset-standby/parked or recovery regeneration icon or ADVISORY #190 displays in the InfoCenter, a recovery regeneration is requested.
press the right button to select the Technician entry (Figure 42). DPF Operation Table (cont'd.) State Description Reset Regen The engine computer is running a reset regeneration. Parked Stby The engine computer is requesting that you run a parked regeneration. Parked Regen You initiated a parked regeneration request and the engine computer is processing the regeneration. Recov. Stby The engine computer is requesting that you run a recovery regeneration. Recov.
Reset Regeneration Periodic Reset Regeneration If the engine has not completed a successful Reset, Parked, or Recovery regeneration in the previous 100 hours of engine operation, the engine computer will attempt to perform a reset regeneration. CAUTION The exhaust temperature is hot (approximately 600°C (1,112°F) during DPF regeneration. Hot exhaust gas can harm you or other people. • Never operate the engine in an enclosed area. • Make sure that there are no flammable materials around the exhaust system.
2. Parked or Recovery Regeneration Press the right button to change the inhibit regeneration setting from On to Off (Figure 47) or from Off to On (Figure 48). • When the engine computer requests either a parked regeneration or a recovery regeneration, the regeneration request icon (Figure 49) displays in the InfoCenter. g224691 Figure 48 Assist DPF Regeneration • The engine computer adjusts engine settings to raise the exhaust temperature.
Important: Perform a recovery regeneration regeneration required—power takeoff disabled ADVISORY #189 (Figure 52). to restore the PTO function; refer to Preparing to Perform a Parked or Recovery Regeneration (page 46) and Performing a Parked or Recovery Regeneration (page 47). Note: The Home screen displays the PTO disabled Icon; refer to Figure 53 in Parked Regeneration Messages (page 45).
2. Move the machine outside to an area away from combustible materials. 3. Park the machine on a level surface. 4. Ensure that the traction control or motion-control levers are in the NEUTRAL position. 5. If applicable, shut off the PTO, and lower the cutting units or accessories. 6. Engage the parking brake. 7. Set the throttle to the low IDLE position.
3. At the DPF checklist screen, verify that the parking brake is engaged and that the engine speed is set to low idle (Figure 60). 5. The InfoCenter displays the INITIATING DPF REGEN message (Figure 62). g224411 g227681 Figure 62 6. g224407 The InfoCenter displays the time to complete message (Figure 63). g224406 g227679 Figure 60 4. At the INITIATE DPF REGEN screen, press the right button to continue (Figure 61). g224406 Figure 63 7.
displays ADVISORY #183 (Figure 65). Press the left button to exit to the home screen. Check Message and Corrective Action Table (cont'd.) Corrective Action: Start and run the engine. Corrective Action: Run the engine to warm the coolant temperature to 60°C (140°F). g224392 Figure 65 Note: If the regeneration fails to complete, the InfoCenter displays Advisory #184 (Figure 65). Press the left button to exit to the home screen. Corrective Action: Change the engine speed to low idle.
Canceling a Parked or Recovery Regeneration the engine automatically moves to HIGH or LOW IDLE, depending on which side of the switch you press. Use the Parked Regen Cancel or Recovery Regen Cancel setting to cancel a running parked or recovery regeneration process. 1. Adjusting the Mowing Speed Access the DPF Regeneration menu (Figure 67).
Understanding the Operating Characteristics of the Machine Adjusting the Transport Speed Supervisor (Protected Menu) This feature allows the supervisor to set the maximum transport speed in increments of 5% between 30 and 100%, at which the operator can transport (high range). Practice driving the machine, because it has a hydrostatic transmission and its characteristics are different than many turf-maintenance machines.
Understanding Counterbalance The counterbalance system maintains hydraulic back pressure on the deck-lift cylinders. This pressure improves traction by transferring the mower-deck weight to the mower-drive wheels. The counterbalance pressure has been set at the factory to an optimal balance of after-cut appearance and traction capability in most turf conditions. Decreasing the counterbalance setting can produce a more stable cutting unit, but can decrease the traction capability.
susceptibility to diseases. Ensure that the blade is in good condition and that there is a full sail. After Operation Checking the Condition of the Cutting Unit General Safety • Shut off the engine, remove the key (if equipped), and wait for all movement to stop before you leave the operator’s position, Allow the machine to cool before adjusting, servicing, cleaning, or storing it. Ensure that the cutting chambers are in good condition.
There are jacking points located at the front and rear of the machine. • On the frame at the inside of each front drive tire • At the center of the rear axle Hauling the Machine • Remove the key and shut off the fuel (if equipped) before storing or hauling the machine. • Use care when loading or unloading the machine into a trailer or a truck. • Use full-width ramps for loading the machine into g221674 a trailer or a truck. Figure 70 • Tie the machine down securely. 1. Bypass valve (2) 2.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. • If the cutting units are in the transport position, use Important: Refer to your engine owner’s manual the positive mechanical lock (if equipped) before you leave the machine unattended. for additional maintenance procedures. Note: Download a free copy of the electrical or • If possible, do not perform maintenance while the hydraulic schematic by visiting www.Toro.
Maintenance Service Interval Maintenance Procedure Every 100 hours • Inspect the cooling-system hoses and clamps. • Check the alternator-belt tension. • Check the compressor belt tension. Every 200 hours • Torque the wheel lug nuts. Every 250 hours • Clean the cab air filters; replace them if they are torn or excessively dirty. • Clean the air-conditioning coil.
Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Maintenance Check Item Monday Tuesday Wednesday Thursday Friday Saturday Check the safety-interlock operation. Check the brake operation. Check the engine-oil level. Check the cooling-system-fluid level. Drain the water/fuel separator. Check the air filter, dust cup, and burp valve. Check for unusual engine noises.1 Check the radiator and screen for debris Check for unusual operating noises.
Notation for Areas of Concern Inspection performed by: Item Date 58 Information
Pre-Maintenance Procedures Opening the Hood 1. Close the rear window of the cab (Figure 72). g037226 g037228 Figure 72 2. Release the 2 latches at the forward lower corners of the hood (Figure 73). g037227 Figure 73 1. Hood latch 3. Prop rod 2. Handle 3. Using the handles that are adjacent to the latches, lift up and back the hood until the 2 prop rods are seated in the 2 rod brackets (Figure 73). Removing the Hood 59 1. Unlatch and raise the hood. 2.
Lubrication Greasing the Bearings and Bushings Service Interval: Every 50 hours The machine has grease fittings that you must lubricate regularly with No. 2 lithium grease. Also, lubricate the machine immediately after every washing. g031613 Figure 74 1. Hairpin cotter The grease-fitting locations and quantities are: 3. Traction Unit Slide the hood to the right side, lift the other side, and pull it out of the brackets. • • • • • Note: Reverse this procedure to install the hood.
g009440 Figure 78 1. Latch g011499 Figure 77 g009441 Figure 79 Center Cutting Unit Note: You may need to raise the cutting unit to expose the grease fittings for the latch pivot and the lower link. • 2 latch pivots (Figure 79) Note: You may need to manually trip the latches to gain access to the grease fittings (Figure 78). Use a pry bar to close and open the latch.
g244640 Figure 81 Center-Deck-Lift Assemblies Wing-Deck-Lift Assemblies • 2 (each side) lift-arm-cylinder bushings (Figure 82) The 4 wing deck-lift cylinder (Figure 84) • 2 lift-arm ball joints (Figure 83) g020455 Figure 82 g011502 Figure 84 Wing Cutting Units • 1 caster-fork-shaft bushing (Figure 85) • 2 (each side) spindle-shaft bearings—located under the pulley g011551 • 1 idler-arm-pivot bushings—located on the idler Figure 83 arm 62
Engine Maintenance Engine Safety • Shut off the engine and remove the key before • checking the oil or adding oil to the crankcase. Do not change the governor speed or overspeed the engine.
Check the engine-oil level; refer to Figure 86. g031675 Figure 87 4. Add oil to the crankcase. g031256 Figure 86 Servicing the Air Cleaner Note: When using different oil, drain all old oil from the crankcase before adding new oil. Service Interval: Before each use or daily—Check the air-cleaner indicator Every 50 hours—Inspect the air cleaner.
g009709 Figure 88 1. Air-cleaner indicator Important: Be sure that the cover is seated correctly and seals with the air-cleaner body. 1. Replace the air cleaner (Figure 89). g031861 Figure 89 Note: Do not clean the used element due to the possibility of damage to the filter media. Important: Never attempt to clean the safety filter (Figure 90). Replace the safety filter after every 3 primary filter services.
g214715 g213864 g009712 g213863 Figure 90 Figure 92 1. Air-cleaner safety filter 2. Reset the indicator (Figure 88) if it shows red. Servicing the Diesel-Oxidation Catalyst (DOC) and the Soot Filter Service Interval: Every 6,000 hours or clean the soot filter if engine faults SPN 3720 FMI 16, SPN 3720 FMI 0, or SPN 3720 FMI 16 display in the InfoCenter.
Fuel System Maintenance Servicing the Fuel System Draining the Fuel Tank Service Interval: Every 1,000 hours—Drain and clean the fuel tank. Before storage—Drain and clean the fuel tank. In addition to the listed service interval, drain and clean the tank if the fuel system becomes contaminated or if you are storing the machine for an extended period. Use clean fuel to flush out the tank.
Electrical System Maintenance Electrical System Safety • Disconnect the battery before repairing the machine. Disconnect the negative terminal first and the positive last. Connect the positive terminal first and the negative last. • Charge the battery in an open, well-ventilated area, away from sparks and flames. Unplug the charger before connecting or disconnecting the battery. Wear protective clothing and use insulated tools. g021291 Figure 94 1. Fuel-filter head 2. Fuel filter 2.
5. Close the battery cover. Locating the Fuses The traction-unit fuses are located under the power-center cover (Figure 97, Figure 98, and Figure 99). Remove the 2 screws securing the power-center cover to the frame and remove the cover (Figure 97). g036370 Figure 96 1. Battery cover 2. 2. Battery Remove the rubber boot from the positive terminal and inspect the battery. WARNING Battery terminals or metal tools could short against metal components causing sparks.
Drive System Maintenance Adjusting the Traction-Pedal Angle 1. Loosen the 2 nuts and bolts securing the left side of the traction pedal to the bracket (Figure 102). g032673 Figure 100 1. Cab fuse box 2. Fuses g009745 Figure 102 decal132-3600 Figure 101 1. Traction pedal 2. 2. Mounting nuts and bolts Pivot the pedal to the desired operating angle and tighten the nuts (Figure 102)˙.
2. 3. 4. Remove the plug at the 3 o’clock position (Figure 103). 4. When all of the oil has drained from both locations, install the plug in the brake housing. Note: The oil level should be at the bottom of 5. Rotate the wheel until the open plug hole in the planetary is at the 12 o'clock position. 6. Through the open hole, slowly fill the planetary with 0.65 L (22 fl oz) of high quality SAE 85W-140 gear lube. the check-plug hole.
Checking the Rear-Axle-Gearbox Lubricant Changing the Rear-Axle Lubricant Service Interval: After the first 200 hours Every 800 hours 1. Position the machine on a level surface. 2. Clean the area around the 3 drain plugs; 1 on each end and 1 in the center (Figure 108). 3. Remove the check plugs to ease in the draining of the oil. 4. Remove the drain plugs and allow the oil to drain into the pans. Service Interval: Every 400 hours The gearbox is filled with SAE 85W-140 gear lube. The capacity is 0.
7. Add enough oil to bring the level up to the bottom of the check plug holes; refer to Changing the Rear-Axle Lubricant (page 72), and Checking the Rear-Axle Lubricant (page 71). 8. Install the plugs. Cooling System Maintenance Cooling System Safety • Swallowing engine coolant can cause poisoning; Checking the Rear Wheel Toe-In keep out of reach from children and pets. • Discharge of hot, pressurized coolant or touching a hot radiator and surrounding parts can cause severe burns.
g020441 Figure 110 1. Expansion tank 3. If the coolant is low, add a 50/50 mixture of water and ethylene glycol anti-freeze. g020452 Important: Do not use water only or Figure 111 alcohol/methanol based coolants, as this may cause damage. 4. 1. Radiator/oil cooler Install the radiator cap and expansion-tank cap. 4. Servicing the Engine-Cooling System Service Interval: Every 100 hours Every 2 years Remove debris from the oil radiator/oil cooler daily. Clean them more frequently in dirty conditions.
Brake Maintenance Belt Maintenance Adjusting the Service Brakes Servicing the Alternator Belt Adjust the service brakes when there is more than 25 mm (1 inch) of free travel of the brake pedal, or when the brakes do not work effectively. Free travel is the distance the brake pedal moves before you feel braking resistance. Service Interval: After the first 10 hours 1. 2.
2. Replacing the Blade-Drive Belt If the deflection is not 10 mm (3/8 inch), loosen the idler pulley mounting bolt (Figure 113). Increase or decrease the compressor belt tension and tighten the bolt. Check the deflection of the belt again to ensure that the tension is correct. Service Interval: Every 800 hours The blade-drive belt, tensioned by the spring-loaded idler pulley, is very durable. However, after many hours of use, the belt will show signs of wear.
9. Hydraulic System Maintenance Connect the extension spring (Figure 114) to the eye bolt and tension the belt as follows: • When properly tensioned, the inside measurement of the extension spring (hook to hook) should be approximately 8.3 to 9.5 cm (3-1/4 to 3-3/4 inch). Hydraulic System Safety • When you attain the correct spring tension, • Seek immediate medical attention if fluid is injected adjust the stop bolt (carriage bolt) until there is approximately 2 to 5 mm (0.065 to 0.
High Viscosity Index/Low Pour Point Anti-wear Hydraulic Fluid, ISO VG 46 (cont'd.) Material Properties: Viscosity, ASTM D445 cSt @ 40°C (104°F) 44 to 48 140 or higher Viscosity Index ASTM D2270 Pour Point, ASTM D97 -37°C to -45°C (-34°F to -49°F) Industry Specifications: Eaton Vickers 694 (I-286-S, M-2950-S/35VQ25 or M-2952-S) Note: Many hydraulic fluids are almost colorless, making it difficult to spot leaks. A red dye additive for the hydraulic fluid is available in 20 ml (0.67 fl oz) bottles.
2. Important: Use of any other filter may void the Remove the drain plug from the bottom, front of the reservoir and let the hydraulic fluid flow into a large drain pan. 3. Install and tighten the plug when the hydraulic fluid stops draining. 4. Fill the reservoir (Figure 117) with hydraulic fluid; refer to Servicing the Hydraulic System (page 77). warranty on some components. 1.
Adjusting the Counterbalance Pressure WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury. The counterbalance test port is used to test the pressure in the counterbalance circuit (Figure 119). The recommended counterbalance pressure is 2241 kPa (325 psi). To adjust the counterbalance pressure, loosen the locknut, rotate the adjusting screw (Figure 119) clockwise to increase the pressure or counterclockwise to decrease the pressure, and tighten the locknut.
Cutting Unit Maintenance Pivoting (Tilting) the Center Cutting Unit to the Upright Position Note: Although not needed, you can pivot (tilt) the center cutting unit. 1. Raise the center cutting unit slightly off the floor, set the parking brake, and shut off the engine, and remove the key. 2. Remove the hairpin cotter securing the dampers to lift arms (Figure 120). g020969 Figure 121 1. U-bolt g011514 2. Hairpin cotter 3. Pivot the damper toward the deck housing. 4.
Adjusting the Wing Cutting Units Adjusting the Cutting-Unit Pitch Measuring the Cutting-Unit Pitch Mower-deck pitch is the difference in height-of-cut from the front of the blade plane to the back of the blade plane. Use a blade pitch of 8 to 11 mm (5/16 to 7/16 inch). That is the back of the blade plane is 8 to 11 mm (5/16 to 7/16 inch) higher than the front. 1. Position the machine on a level surface on the shop floor. 2. Set the cutting unit to the desired height of cut. 3.
Servicing the Caster Wheels and Bearings Service Interval: Every 800 hours 1. g004737 Figure 124 1. Caster-arm tube Note: Grasp the caster wheel and slide the bolt 2. Bushings 5. Drive the other bushing out of the tube. 6. Clean the inside of the tubes to remove dirt. Remove the locknut from the bolt holding the caster-wheel assembly between the caster fork (Figure 125) or the caster-pivot arm (Figure 126). out of the fork or pivot arm. Installing the Bushings 1.
4. Check the bearings, spacer, and inside of the wheel hub for wear and replace any damaged parts. Blade Maintenance 5. To assemble the caster wheel, push the bearing into the wheel hub. Blade Safety • Inspect the blade periodically for wear or damage. Note: When installing the bearings, press on the outer face of the bearing. 6. 7. • Use care when checking the blades. Wrap the blades or wear gloves, and use caution when servicing the blades.
Removing and Installing the Cutting-Unit Blade(s) Inspecting and Sharpening the Cutting Unit Blade(s) Replace the blade if it hits a solid object, is out of balance, or is bent. Always use genuine Toro replacement blades to ensure safety and optimum performance. Both cutting edges and the sail, which is the turned-up portion opposite of the cutting edge, contribute to a good quality of cut. 1. Maintain sharp blades throughout the cutting season.
Note: Remove the blades and sharpen them on a grinder. After sharpening the cutting edges, install the blade with the anti-scalp cup and blade bolt; refer to Removing and Installing the Cutting-Unit Blade(s) (page 85). Correcting a Cutting Unit Mismatch When there is mismatch between the blades on a single cutting unit, the grass appears streaked when it is cut. You can correct this problem by ensuring that the blades are straight. 1. Park the machine on a level surface. 2.
Cab Maintenance Cleaning the Cab Important: Use care around the cab seals and lights (Figure 132). If you are using a pressure washer, keep the washer wand at least 0.6 m (2 ft) away from the machine. Do not use the pressure washer directly on the cab seals and lights or under the rear overhang. g028378 Figure 133 In-Cab Air Filter 1. Filter 2. Grate 3. Screw g034330 Figure 132 1. Seal 2. Light 3. Keep wand 0.6 m (2 ft) away. g028379 Figure 134 Rear Cab Air Filter 4.
Cleaning the Cab Pre-Filter The cab pre-filter prevents large debris, such as grass and leaves, from entering the cab filters. 1. Rotate the screen cover down. 2. Clean the filter with water. Important: Do not use a pressure washer. Note: If the filter has a hole, tear, or other damage, replace the filter. 3. Allow the pre-filter to dry before installing it into the machine. 4. Rotate the filter screen around the tabs until the latch locks into the latch-mount assembly (Figure 135).
Storage 2. Remove and discard the oil filter. Install a new oil filter. Storage Safety 3. Refill the oil pan with designated quantity of motor oil. • Shut off the engine, remove the key (if equipped), 4. Turn the key in the switch to the ON position, start the engine, and run it at idle speed for approximately 2 minutes. 5. Turn the key in the switch to the OFF position. 6. Thoroughly drain all fuel from the fuel tank, lines, and the fuel filter/water separator assembly. 7.
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California Proposition 65 Warning Information What is this warning? You may see a product for sale that has a warning label like the following: WARNING: Cancer and Reproductive Harm—www.p65Warnings.ca.gov. What is Prop 65? Prop 65 applies to any company operating in California, selling products in California, or manufacturing products that may be sold in or brought into California.
The Toro Warranty Two-Year or 1,500 Hours Limited Warranty Conditions and Products Covered Parts The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial product (“Product”) to be free from defects in materials or workmanship for 2 years or 1,500 operational hours*, whichever occurs first. This warranty is applicable to all products with the exception of Aerators (refer to separate warranty statements for these products).
