Form No. 3444-143 Rev A Groundsmaster® 4100 or 4110 Rotary Mower Model No. 30608—Serial No. 408000000 and Up Model No. 30644—Serial No. 408000000 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 Understanding Auto Idle ................................... 41 Using the Cruise Control................................... 41 Starting the Engine ........................................... 41 Shutting Off the Engine..................................... 41 Using the Engine-Speed Switch........................ 41 Adjusting the Mowing Speed ............................ 41 Adjusting the Transport Speed.......................... 42 Diesel Particulate Filter Regeneration...............
Safety Belt Maintenance ................................................ 78 Servicing the Alternator Belt ............................. 78 Servicing the Air Conditioner Compressor Belt................................................................ 78 Tensioning the Blade-Drive Belts ...................... 78 Replacing the Blade-Drive Belt ......................... 79 Hydraulic System Maintenance ........................... 80 Hydraulic System Safety...................................
decal93-7272 93-7272 decal100-6578 100-6578 1. Cutting/dismemberment hazard; fan—stay away from moving parts. 1. Entanglement hazard, belt—do not operate the machine with the shields or guards removed; always keep the shields and guards in place; stay away from moving parts. decal93-7818 93-7818 1. Warning—read the Operator's Manual for instructions on torquing the blade bolt/nut to 115 to 149 N∙m (85 to 110 ft-lb). decal104-3579 104-3579 1. Low height-of-cut adjustment 2.
decal106-6754 106-6754 1. Warning—do not touch the hot surface. 2. Cutting/dismemberment hazard, fan; entanglement hazard, belt—stay away from moving parts. decal106-6755 106-6755 decal114-0849 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. 114–0849 4. Forward direction 1. Warning—1) Disengage the PTO; 2) Raise the deck 2. Do not place your foot here. 3. Direction pedal 6 5.
decal120-6604 decal120-4159 120-6604 120-4159 1. Off 2. Lights 3. On 4. Light switch location 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. 8. High 9. Traction drive 10. Low 11. PTO 5. Fast 12. Lower left deck 6. Variable speed adjustment 13. Lower center deck 7. Slow 3.
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—remove the pin, raise the doors, and exit the cab. decal121-1592 127-3700 decal130-5355 130-5355 1. Raise the left deck. 4. Lock the engine speed. 2. Raise the center deck. 5. Unlock the engine speed. 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.
decal133-8062 133-8062 decal120-0250 120-0250 1. Slow-moving vehicle decal114-0846 114-0846 1. Read the Operator’s Manual for information on starting the engine—1) Set to neutral; 2) Engage the brake; 3) Set the engine speed to slow; 4) Turn the key to preheat; 5) Turn the key to start the engine. 2.
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. Tipping hazard—lower the cutting unit when driving down slopes; slow the machine before turning; do not turn at high speeds. 8.
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) 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.
decal144-4162 144-4162 1. Read the Operator’s Manual before performing maintenance. 15. Read the Operator’s Manual before performing maintenance 2. Check every 8 hours 16. Fluid(s) 3. Engine coolant level 17. Capacity 4. Tire pressure 18. Fluid interval (hours) 5. Engine air filter 19. Filter change Interval 6. Fuel/water separator 20. Engine Oil 7. Diesel only 21. Hydraulic fluid 8. Hydraulic fluid 22. Hydraulic breather 9. Grease points 23. Engine air filter 10. Brake functions 24.
decal144-4165 144-4165 15. Read the Operator’s 1. Read the Operator’s Manual before performing Manual before performing maintenance maintenance. 2. Check every 8 hours 16. Fluid(s) 3. Engine coolant level 17. Capacity 4. Tire pressure 18. Fluid interval (hours) 5. Engine air filter 19. Filter change Interval 6. Fuel/water separator 20. Engine Oil 7. Diesel only 21. Hydraulic fluid 8. Hydraulic fluid 22. Hydraulic breather 9. Grease points 23. Engine air filter 10. Brake functions 24.
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 65). 2. Check the hydraulic-fluid level; refer to Checking the Hydraulic Fluid (page 80). 3. Check the cooling system; refer to Checking the Cooling System (page 76). 4. Check the planetary-gear-drive oil; refer to Checking the Planetary-Gear-Drive Oil (page 72). 5. Check the rear-axle lubricant; refer to Checking the Rear-Axle Lubricant (page 73). 6.
Parking-Brake Latch Product Overview To engage the parking brake, connect the 2 pedals together with the locking latch located behind the pedal pads, and push down on the parking-brake latch while you are pushing on the brake pedals (Figure 4). To release the parking brake, press the brake pedals and the latch will disengage allowing the pedals to come to the disengaged position. Ensure the pedals have fully retracted after disengaging the parking brake.
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. g196911 Figure 9 1. Windshield latch Rear Window Latch Lift up the latches to open the rear window. Press in on the latch to lock the window in OPEN position.
Specifications g203228 Figure 10 21
Description Figure 10 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 65). Before Operation Checking the Cooling System General Safety • Never allow children or untrained people to Before you start the engine and use the machine, check the cooling system; refer to Checking the Cooling System (page 76).
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 14 Rear Wheels g001055 Figure 12 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 15). 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 23).
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 25 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 31). 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.
Selecting a Blade Atomic Blade Flat-Sail Blade Standard-Sail Blade Medium-Sail Blade Grass conditions Wet, sticky, and spring growth Light or sparse turf Normal cutting All conditions to heavy growth Leaf mulching Works well Do not use Works well Works well Pros Less lift, breaks up clumped clippings Does not create lots of air flow in dusty, sandy, and sparse grass Good performance overall More lift and less turbulence than standard blade, overall good Cons Less lift and less dispersion
InfoCenter Icon Description SERVICE DUE InfoCenter Icon Description (cont'd.
InfoCenter Icon Description (cont'd.) Main Menu Menu Item Description Faults The Faults menu contains a list of the recent machine faults. Refer to the Service Manual or your authorized Toro distributor for more information on the Faults menu and the information contained there. Service The Service menu contains information on the machine such as hours of use and other similar numbers. Diagnostics The Diagnostics menu displays the state of each machine switch, sensor and control output.
Accessing Protected Menus Settings Menu Item Description Units Controls the units used on the InfoCenter; the menu choices are English or Metric Language Controls the language used on the InfoCenter* LCD Backlight Controls the brightness of the LCD display LCD Contrast Controls the contrast of the LCD display Protected Menus Allows a person authorized by your company with the PIN code to access protected menus.
until the last digit is entered and press the right button once more. 4. 4. When finished with the Protected Menu, press the left button to exit to the Main Menu, then press the left button to exit to the Run Menu. Press the middle button to enter the PIN code (Figure 34D). Wait until the red indicator light of the InfoCenter illuminates.
During Operation • Before you leave the operator’s position, do the following: – Park the machine on a level surface. During Operation Safety – Disengage the power takeoff and lower the attachments. General Safety – Engage the parking brake. • The owner/operator can prevent and is responsible – Shut off the engine and remove the key. • • • • • • • • • • • • • • • • for accidents that may cause personal injury or property damage.
Understanding the Operating Characteristics of the Machine • Lower a folding roll bar temporarily only when • • necessary. Do not wear the seat belt when the roll bar is folded down. Be aware that there is no rollover protection when a folded roll bar is in the down position. Check the area that you will be mowing and never fold down a folding roll bar in areas where there are slopes, drop-offs, or water.
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. Increasing the counterbalance setting can increase the traction capability, but may result in a poor after-cut appearance. Refer to the machine Service Manual for your traction unit for instructions to adjust the counterbalance pressure.
immediately when the engine starts and allow it to return to the RUN position. temperature or coolant reaches a certain temperature, a reverse fan cycle is automatically initiated. This cycle blows debris off the rear screen and lowers the engine-coolant, fuel, and hydraulic-fluid temperatures. Important: Do not run the starter motor You can complete a manually-initiated reverse cycle by simultaneously pressing the right and left buttons on the InfoCenter.
Operator the back pressure is too high, soot is not incinerating in the soot filter through normal engine operation. To keep the DPF clear of soot, remember the following: This feature allows the operator to adjust the maximum mowing speed (low range), within the supervisors pre-adjusted settings.
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 51). 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 51).
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.
Assist DPF Regeneration • The icon displays in the InfoCenter while the reset regeneration is processing. • The engine computer adjusts engine settings to • Whenever possible, do not shut off the engine or raise the exhaust temperature. reduce engine speed while the reset regeneration is processing. • While operating the machine, run the engine at full engine speed and high load when possible to promote DPF regeneration.
g227304 g224394 Figure 47 2. Figure 49 Press the right button to change the inhibit regeneration setting from On to Off (Figure 47) or from Off to On (Figure 48). Note: If the InfoCenter displays ADVISORY #186 (Figure 50), set the engine to full throttle (high idle) to allow the reset regeneration to continue.
Parked or Recovery Regeneration regeneration required—power takeoff disabled ADVISORY #189 (Figure 54). • When the engine computer requests either a parked regeneration or a recovery regeneration, the regeneration request icon (Figure 51) displays in the InfoCenter. g224398 Figure 54 Important: Perform a parked regeneration to restore the PTO function; refer to Preparing to Perform a Parked or Recovery Regeneration (page 51) and Performing a Parked or Recovery Regeneration (page 51).
Preparing to Perform a Parked or Recovery Regeneration 1. Ensure that the machine has fuel in the tank for the type of regeneration you are performing: • Parked Regeneration: Ensure that you g224399 Figure 58 have 1/4 tank of fuel before performing the parked regeneration. • Recovery Regeneration: Ensure that you Important: Perform a recovery regeneration have 1/2 tank of fuel before performing the recovery regeneration.
3. At the DPF checklist screen, verify that the parking brake is engaged and that the engine speed is set to low idle (Figure 63). g224402 g224407 g224629 Figure 61 2. At the VERIFY FUEL LEVEL screen, verify that you have 1/4 tank of fuel if you are performing the parked regeneration or 1/2 tank of fuel if you are performing the recovery regeneration, and press the right button to continue (Figure 62). g227679 Figure 63 4.
5. The InfoCenter displays the INITIATING DPF REGEN message (Figure 65). Check Message and Corrective Action Table (cont'd.) g224411 Corrective Action: Troubleshoot the engine fault and retry DPF regeneration. g227681 Figure 65 6. The InfoCenter displays the time to complete message (Figure 66). Corrective Action: Start and run the engine. Corrective Action: Run the engine to warm the coolant temperature to 60°C (140°F). g224406 g224406 Corrective Action: Change the engine speed to low idle.
Note: While the DPF regeneration Canceling a Parked or Recovery Regeneration runs, the InfoCenter displays the high exhaust-temperature icon 9. Use the Parked Regen Cancel or Recovery Regen Cancel setting to cancel a running parked or recovery regeneration process. . 1. When the engine computer completes a parked or recovery regeneration, the InfoCenter displays ADVISORY #183 (Figure 68). Press the left button to exit to the home screen. Access the DPF Regeneration menu (Figure 70).
Operating Tips components to ensure correct blade tip/chamber clearance. Changing Mowing Patterns Maintaining the Machine after Mowing Change mowing patterns often to minimize a poor after-cut appearance from repeatedly mowing in the same direction. After mowing, thoroughly wash the machine with a garden hose with no nozzle to avoid contamination and damage to the seals and bearings caused by excessive water pressure. Ensure that the radiator and oil cooler are kept free of dirt or grass clippings.
After Operation General Safety • Shut off the engine, remove the key, 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. • Clean grass and debris from the cutting units, mufflers, and engine compartment to help prevent fires. Clean up oil or fuel spills. • If the cutting units are in the transport position, use the positive mechanical lock (if available) before you leave the machine unattended.
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 a trailer or a truck. • Tie the machine down securely.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Important: Refer to your engine owner’s manual Note: Download a free copy of the electrical or for additional maintenance procedures. hydraulic schematic by visiting www.Toro.com and searching for your machine from the Manuals link on the home page.
Maintenance Service Interval Maintenance Procedure Every 25 hours • Check the electrolyte level (or every 30 days if the machine is in storage). Every 50 hours • • • • 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.
Pre-Maintenance Procedures Opening the Hood 1. Close the rear window of the cab (Figure 74). g037226 g037228 Figure 74 2. Release the 2 latches at the forward lower corners of the hood (Figure 75). g037227 Figure 75 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 75). Removing the Hood 61 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 76 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 80 1. Latch g011499 Figure 79 g009441 Figure 81 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 81) Note: You may need to manually trip the latches to gain access to the grease fittings (Figure 80). Use a pry bar to close and open the latch.
g244640 Figure 83 Center-Deck-Lift Assemblies Wing-Deck-Lift Assemblies • 2 (each side) lift-arm-cylinder bushings (Figure 84) The 4 wing deck-lift cylinder (Figure 86) • 2 lift-arm ball joints (Figure 85) g020455 Figure 84 g011502 Figure 86 Wing Cutting Units • 1 caster-fork-shaft bushing (Figure 87) • 2 (each side) spindle-shaft bearings—located under the pulley g011551 • 1 idler-arm-pivot bushings—located on the idler Figure 85 arm 64
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 88. g031675 Figure 89 4. Add oil to the crankcase. 5. Set the service due timer in the InfoCenter; refer to Setting the Service Due Timer (page 37). g031256 Figure 88 Note: When using different oil, drain all old oil from the crankcase before adding new oil. Servicing the Air Cleaner Crankcase Oil Capacity Service Interval: Before each use or daily—Check the air-cleaner indicator Approximately 5.7 L (6 US qt) with the filter.
g009709 Figure 90 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 91). g031861 Figure 91 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 92). Replace the safety filter after every 3 primary filter services.
g009712 Figure 92 1. Air-cleaner safety filter 2. Reset the indicator (Figure 90) if it shows red. Servicing the Diesel-Oxidation Catalyst (DOC) and the Soot Filter Service Interval: Every 3,000 hours or clean the soot filter if engine faults SPN 3720 FMI 16 or SPN 3720 FMI 0 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 95 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 98, Figure 99, and Figure 100). Remove the 2 screws securing the power-center cover to the frame and remove the cover (Figure 98). g036370 Figure 97 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 103). g032673 Figure 101 1. Cab fuse box 2. Fuses g009745 Figure 103 decal132-3600 Figure 102 1. Traction pedal 2. 2. Mounting nuts and bolts Pivot the pedal to the desired operating angle and tighten the nuts (Figure 103)˙.
1. 3. With machine on level surface, position the wheel so 1 check plug is at the 12 o'clock position and the other is at 3 o'clock position (Figure 104). Place a drain pan under the brake housing, remove the drain plug, and allow the oil to drain (Figure 106). g019500 g020680 Figure 104 Figure 106 1. Check/drain plug (2) 2. 1. Drain plug Remove the plug at the 3 o’clock position (Figure 104). 4. When all of the oil has drained from both locations, install the plug in the brake housing.
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 109). 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. g011487 Figure 107 1. Check plug 2.
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 74), and Checking the Rear-Axle-Gearbox Lubricant (page 74). 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.
Coolant Specification DANGER The rotating fans and drive belts can cause personal injury. • Do not operate the machine without the guards in place. • Keep your fingers, hands, and clothing clear of the rotating fan and drive belt. • Shut off the engine and remove the key before performing maintenance. The coolant reservoir is filled at the factory with a 50/50 solution of water and ethylene glycol base extended-life coolant.
Brake Maintenance cleaning and inspection of the radiator/oil cooler is still required. 1. Shut off the engine, remove the key, and raise the hood. 2. Clean the engine area thoroughly of all debris. 3. Clean both sides of the radiator/oil cooler area thoroughly with compressed air (Figure 112). Adjusting the Service Brakes 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.
Belt Maintenance 2. Servicing the Alternator Belt Service Interval: After the first 10 hours If the deflection is not 10 mm (3/8 inch), loosen the idler pulley mounting bolt (Figure 114). 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.
Replacing the Blade-Drive Belt 9. • 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). 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. Signs of a worn belt include squealing when the belt is rotating, blades slipping when cutting grass, frayed edges, burn marks, and cracks.
Hydraulic System Maintenance High Viscosity Index/Low Pour Point Anti-wear Hydraulic Fluid, ISO VG 46 (cont'd.) Material Properties: Hydraulic System Safety Viscosity, ASTM D445 • Seek immediate medical attention if fluid is injected into skin. Injected fluid must be surgically removed within a few hours by a doctor.
2. 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 118) with hydraulic fluid; refer to Checking the Hydraulic Fluid (page 80). Important: Use only the hydraulic fluids specified. Other fluids damage the system. g020456 Figure 118 1. Hydraulic reservoir 5.
Checking the Hydraulic Lines and Hoses Important: Use of any other filter may void the warranty on some components. 1. 2. Position the machine on a level surface, lower the cutting units, engage the parking brakes, shut off the engine, and remove the key from the ignition. Service Interval: Every 2 years WARNING Replace the hydraulic filters (Figure 119). Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • Seek immediate medical help if fluid is injected into skin.
Adjusting the Counterbalance Pressure Cutting Unit Maintenance The counterbalance test port is used to test the pressure in the counterbalance circuit (Figure 120). The recommended counterbalance pressure is 2241 kPa (325 psi). To adjust the counterbalance pressure, loosen the locknut, rotate the adjusting screw (Figure 120) clockwise to increase the pressure or counterclockwise to decrease the pressure, and tighten the locknut.
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. g020969 Figure 122 1. U-bolt 5. Position the machine on a level surface on the shop floor. 2. Set the cutting unit to the desired height of cut. 3.
Adjusting the Wing Cutting Units 1. Remove the cap screws and nuts securing the caster arm to the caster fork (Figure 124). 2. Position the shims, as required, to raise or lower the caster wheel until the cutting unit has the correct pitch. 3. Install the cap screws and nuts. g004737 Figure 125 1. Caster-arm tube 2. Bushings 5. Drive the other bushing out of the tube. 6. Clean the inside of the tubes to remove dirt. Installing the Bushings g011561 1.
Servicing the Caster Wheels and Bearings 4. Check the bearings, spacer, and inside of the wheel hub for wear and replace any damaged parts. Service Interval: Every 800 hours 5. To assemble the caster wheel, push the bearing into the wheel hub. 1. Remove the locknut from the bolt holding the caster-wheel assembly between the caster fork (Figure 126) or the caster-pivot arm (Figure 127). Note: When installing the bearings, press on the outer face of the bearing. 6.
Blade Maintenance Removing and Installing the Cutting-Unit Blade(s) Blade Safety 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. • Inspect the blade periodically for wear or damage. • Use care when checking the blades. Wrap the blades or wear gloves, and use caution when servicing the blades. Only replace or sharpen the blades; never straighten or weld them. 1.
Inspecting and Sharpening the Cutting Unit Blade(s) Both cutting edges and the sail, which is the turned-up portion opposite of the cutting edge, contribute to a good quality of cut. Maintain sharp blades throughout the cutting season. Sharp blades create a clean cut without tearing or shredding the grass blades. Check the blades for any wear or damage. The sail lifts the grass up straight, thereby producing an even cut and gradually wears down during operation. 1.
Cab Maintenance 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 87). Cleaning the Cab Important: Use care around the cab seals and Correcting a Cutting Unit Mismatch lights (Figure 133). If you are using a pressure washer, keep the washer wand at least 0.6 m (2 ft) away from the machine.
Cleaning the Cab Pre-Filter The purpose of the cab pre-filter is to prevent large debris, such as grass and leaves, from entering the cab filters. 1. Rotate the screen cover down. 2. Clean the filter with water. Note: Do not use a pressure washer. Important: 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.
Storage Storage Safety • Shut off the engine, remove the key, 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. • Do not store the machine or fuel container where there is an open flame, spark, or pilot light, such as on a water heater or other appliance. Preparing the Machine for Storage Important: Do not use brackish or reclaimed g028380 Figure 137 1. Washer water to clean the machine. 2.
2. Remove and discard the oil filter. Install a new oil filter. 3. Refill the oil pan with designated quantity of motor oil. 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. Flush the fuel tank with fresh, clean diesel fuel. 8. Secure all fuel-system fittings. 9.
Notes:
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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 Parts Conditions and Products Covered The Toro Company warrants 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).
