Form No. 3444-519 Rev A Groundsmaster® 4000 or 4010 Rotary Mower Model No. 30609—Serial No. 408000000 and Up Model No. 30636—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 Operating the Machine ..................................... 40 Understanding Counterbalance........................ 40 Using the Brake Pedals .................................... 40 Understanding Toro Smart Power™ ................. 41 Performing a Fan-Reverse Operation ............... 41 Understanding Auto Idle ................................... 41 Using Cruise Control......................................... 41 Starting the Engine ...........................................
Safety Brake Maintenance ............................................. 75 Adjusting the Service Brakes ............................ 75 Belt Maintenance ................................................ 76 Servicing the Alternator Belt ............................. 76 Servicing the Compressor Belt.......................... 76 Tensioning the Blade-Drive Belts ...................... 76 Replacing the Blade-Drive Belt ......................... 76 Hydraulic System Maintenance ...........................
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. decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. 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.
decal100-5693 decal104-3579 100-5693 104-3579 1. Height-of-cut adjustment 1. Low height-of-cut adjustment 2. High height-of-cut adjustment decal106-6754 decal100-5694 106-6754 100-5694 1. Warning—do not touch the hot surface. 1. Height-of-cut adjustment 2. Cutting/dismemberment hazard, fan; entanglement hazard, belt—stay away from moving parts. decal100-6578 100-6578 1.
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. Read the Operator’s Manual for information on shutting off the engine—1) Set the engine speed to slow; 2) Disengage the deck; 3) Lock the parking brake; 4) Wait 5 minutes; 5) Turn the key to shut off the engine; 6) Remove the key from the switch. 3. Read the Operator’s Manual.
decal120-0250 120-0250 1. Slow-moving vehicle decal120-4159 120-4159 1. Off 8. High 2. Lights 9. Traction drive 3. On 4. Light switch location 10. Low 11. PTO decal120-8947 5. Fast 12. Lower left deck 6. Variable speed adjustment 13. Lower center deck 7. Slow 120-8947 1. Warning—read the Operator’s Manual. 14. Lower right deck 4. If the roll bar is raised, wear the seat belt. 2. There is no rollover 5. If the roll bar is lowered, protection when the roll do not wear the seat belt. bar is down.
decal121-3884 121–3884 1. Engine—stop decal120-6604 120-6604 3. Engine—start 2. Engine—preheat 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. 3. Cutting/dismemberment hazard of foot, mower blade—stay away from moving parts; keep all guards and shields in place. decal121-3887 121–3887 1. Read the Operator’s Manual. decal121-1599 121-1599 1.
decal130-0611 130-0611 1. Warning—remove the pin, raise the doors, and exit the cab. decal127-3700 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. decal130-5356 130-5356 1. Use the foot pedal to move forward or in reverse. decal130-0594 130-0594 1.
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 Model with Cab Only 1. Fan (off) 3. Cold air 5. External air 7. Air conditioner (off) 2. Fan (on full) 4. Hot air 6. Internal air 8.
decal144-4163 144-4163 12. Fan belt tension 1. Read the Operator’s Manual for the operator presence controls. 2. Check every 8 hours 13. Radiator screen 3. Engine coolant level 14. Read the Operator’s Manual before performing maintenance. 4. Tire pressure 15. Hydraulic breather 5. Engine oil level 16. Safety air filter 6. Grease points 17. Rear axle 7. Fuel/water separator 18. Planetary drive 8. Fuel 9. Hydraulic fluid 19. Fluids 20. Capacity 10. Brake functions 21.
decal132-3600 132-3600 Model with 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. Auxiliary power (15 A) decal144-4164 144-4164 1. Check every 8 hours 12. Fan belt tension 2. Engine coolant level 13. Radiator screen 3. Tire pressure 14. Hydraulic breather 4. Engine oil level 15. Safety filter 5. Grease points 16.
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.
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. Operator's Manual 1 Review before operating the machine. Engine owner’s manual 1 Use to reference engine information.
3 Checking the Fluid Levels No Parts Required Procedure g279510 1. Check the engine-oil level; refer to Checking the Engine-Oil Level (page 64). 2. Check the hydraulic-fluid level; refer to Checking the Hydraulic Fluid (page 78). 3. Check the cooling system; refer to Checking the Cooling System (page 74). 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.
Parking-Brake Latch Product Overview To engage the parking brake, connect the two 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.
Seat Adjustments control, put the traction pedal into the NEUTRAL position, and move the machine at a slow speed. Seat-Adjustment Lever Note: The cutting units do not operate and/or cannot 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). be lowered from the transport position when the switch is in the high range.
Cab Controls Windshield Latch Lift up the latches to open the windshield (Figure 9). Press in the latch to lock windshield to the OPEN position. Pull out and down on the latch to close and secure the windshield. g032672 Figure 8 1. Air-conditioning switch 4. Temperature control 2. Air-recirculation control 5. Windshield-wiper switch 3. Fan control 6. Blank switches for optional kits g196911 Figure 9 1. Windshield latch Rear Window Latch Lift up the latches to open the rear window.
Specifications Note: Specifications and design are subject to change without notice.
Description Figure 10 reference Dimension or Weight Height with cab G 237 cm (93-1/2 inches) Height with roll bar I 218 cm (86 inches) Overall length F 342 cm (135 inches) Length for storage or transport E 338 cm (133 inches) C 335 cm (132 inches) Width of cut overall front cutting unit 157 cm (62 inches) side cutting unit 107 cm (42 inches) front and one side cutting unit 246 cm (97 inches) Overall width cutting units down D 345 cm (136 inches) cutting units up (transport position
Filling the Fuel Tank properly. Do not operate the machine unless they are functioning properly. • Before mowing, always inspect the machine to Fuel Tank Capacity ensure that the blades, blade bolts, and cutting assemblies are in good working condition. Replace worn or damaged blades and bolts in sets to preserve balance. Fuel tank capacity: 79 L (21 US gallons) Fuel Specification • Inspect the area where you will use the machine and remove all objects that the machine could throw.
Adding Fuel 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. 2-D) at temperatures above -7°C (20°F) and winter-grade fuel (No. 1-D or No. 1-D/2-D blend) below that temperature.
Checking the Tire Pressure Service Interval: Before each use or daily DANGER Low tire pressure decreases machine side-hill stability. This could cause a rollover, which may result in personal injury or death. Do not underinflate the tires. g033358 Figure 13 Front Wheels The correct air pressure in the tires is 172 to 207 kPa (25 to 30 psi). Important: Maintain the recommended pressure in all tires to ensure a good quality of cut and proper machine performance. Do not under-inflate the tires.
Adjusting the Roll Bar Lowering the Roll Bar Important: Lower the roll bar only when necessary. WARNING Important: Ensure that the seat is secured with To avoid injury or death from rollover: keep the roll bar in the raised locked position and use the seat belt. the seat latch. Ensure that the seat is secured with the seat latch. WARNING There is no rollover protection when the roll bar is in the down position.
1. Park the machine on a level surface. 2. Start the engine and raise the cutting units to change height of cut. 3. Shut off the engine, engage the parking brake, and remove the key from the ignition after the cutting unit is raised. 4. Position the caster-wheel axles in the same holes in all caster forks. decal100-5622nc Figure 18 7. Push the caster spindle through the front caster arm and install the shims (as they were originally installed) and the remaining spacers onto the spindle shaft. 8.
Note: When using 25 mm (1 inch), 38 mm (1-1/2 inches), or 51 mm (2 inches) heights of cut, move the skids and gauge wheels to the highest position. Side Cutting Units To adjust the height of cut on the side cutting units, add or remove an equal number of spacers from the caster forks, position the caster-wheel axles in the high or low height-of-cut holes in the caster forks, and secure the pivot arms to the selected height-of-cut bracket holes. 1.
7. Insert the clevis pins and install the hairpin cotters. Adjusting the Skids 8. Rotate the tension rod counterclockwise (finger tight) to put tension on adjustment. 9. Remove the hairpin cotters and clevis pins securing the damper links to the mower-deck brackets (Figure 25). 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).
Adjusting the Cutting Unit Rollers Correcting a Mismatch Between the Cutting Units The cutting unit rollers should be mounted in the lower position when operating at height of cuts greater than 64 mm (2-1/2 inches), and in the higher position when operating in height of cuts lower than 64 mm (2-1/2 inches). 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. 1.
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 30). 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.
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. g008870 Figure 31 1. Side-view mirrors 2. Rearview mirror Activating the Quiet Mode 3.
Using the InfoCenter Control InfoCenter Icon Description SERVICE DUE The InfoCenter LCD display shows information about your machine, such as the operating status, various diagnostics and other information about the machine (Figure 32). There is a splash screen and main information screen of the InfoCenter. You can switch between the splash screen and main information screen at any time by pressing any of the InfoCenter buttons and then selecting the appropriate directional arrow.
InfoCenter Icon Description (cont'd.) InfoCenter Icon Description (cont'd.) Temperature (hot) Switch Traction or Traction Pedal Operator must release the switch Denied or not allowed Operator should change to the indicated state Engine Start Symbols are often combined to form sentences.
Main Menu Settings Menu Item Description 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.
Accessing Protected Menus until the last digit is entered and press the right button once more. 4. 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 34D). Wait until the red indicator light of the InfoCenter illuminates.
• Keep your hands and feet away from rotating 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. parts. Keep clear of the discharge opening. • Look behind and down before backing up to be sure of a clear path. Setting the Service Due Timer • Use care when approaching blind corners, shrubs, This resets the service due hours after a scheduled maintenance procedure is performed. 1.
• Avoid starting, stopping, or turning the machine on • To disconnect the seat belt, hold the belt, press • • • the buckle button to release the belt, and guide the belt into the auto-retract opening. Ensure that you can release the belt quickly in an emergency. Check carefully for overhead obstructions and do not contact them. Keep the ROPS in safe operating condition by thoroughly inspecting it periodically for damage and keeping all the mounting fasteners tight. Replace damaged ROPS components.
• Always drive slowly in rough areas. conditions, the uphill wheel slips and loses traction. If this situation occurs, press the uphill brake pedal gradually and intermittently until the uphill wheel stops slipping, This action increases the traction on the downhill wheel. • If an obstacle is in the way, lift the cutting units to mow around it.
Starting the Engine Understanding Toro Smart Power™ Important: Bleed the fuel system if any of the following have occurred: With Smart Power, the operator does not have to listen to the engine speed in heavy load conditions. Smart Power prevents the engine from bogging down in heavy cutting conditions by automatically controlling the machine speed and optimizing cutting performance. • The engine has shut off due to lack of fuel. • Maintenance has been performed upon the fuel system components. 1.
Using the Engine-Speed Switch Note: When switching between low and high ranges, the settings transfer based on the previous setting. The settings are reset when the machine is turned off. The engine-speed switch has 2 modes to change the engine speed. By momentarily tapping the switch, the engine speed increases or decreases in 100-rpm increments. By holding the switch down, the engine automatically moves to HIGH or LOW IDLE, depending on which part of the switch you pressed.
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. Note: Download a free copy of the electrical or hydraulic schematic by visiting www.Toro.com and searching for your machine from the Manuals link on the home page. Note: If you are performing maintenance on the machine and run the engine with an engine exhaust-extraction duct, set the inhibit regen setting to ON; refer to Setting the Inhibit Regen (page 48).
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 • Change the engine oil and filter. • Clean the cab air filters; replace them if they are torn or excessively dirty. • Clean the air-conditioning assembly (more frequently in extremely dusty or dirty conditions).
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.
Lubrication Pre-Maintenance Procedures Greasing the Bearings and Bushings Removing the Hood 1. Unlatch and raise the hood. 2. Remove the hairpin cotter securing the hood pivot to the mounting brackets (Figure 74). Service Interval: Every 50 hours—Lubricate all of the bearings and bushings. Every 500 hours/Yearly (whichever comes first) The machine has grease fittings that you must lubricate regularly with No. 2 lithium grease. Also, lubricate the machine immediately after every washing.
g017810 Figure 78 Front Lift Assemblies • 2 (each side) lift-arm-cylinder bushings (Figure 79) • 2 lift-arm-ball joints (Figure 80) g011499 Figure 76 Front Cutting Unit g020455 • 2 caster-fork-shaft bushings (Figure 77) Figure 79 • 3 spindle-shaft bearings—located under the pulley (Figure 78) • 2 idler-arm-pivot bushings (Figure 78) g011551 Figure 80 Side Cutting Unit • 1 caster-fork-shaft bushing (Figure 81) g011557 Figure 77 • 2 (each side) spindle-shaft bearings—located under the pulley •
g011554 Figure 84 g011557 Figure 81 Side Lift Assemblies • • • • 6 main lift-arm bushings (Figure 82 and Figure 83) 2 bell-crank-pivot bushings (Figure 84) 4 rear arm bushings (Figure 84) 4 lift-cylinder bushings (Figure 85) g011555 Figure 85 g011552 Figure 82 g011553 Figure 83 63
Engine Maintenance Important: Keep the engine-oil level between the Engine Safety Check the engine-oil level; refer to Figure 86. upper and lower limits on the dipstick; the engine may fail if you run it with too much or too little oil. • 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.
g031675 Figure 87 4. Add oil to the crankcase. Servicing the Air Cleaner Service Interval: Every 400 hours Check the air-cleaner body for damage which could cause an air leak. Replace it if it is damaged. Check the whole intake system for leaks, damage, or loose hose clamps. Service the air-cleaner filter only when the service indicator (Figure 88) requires it. Changing the air filter before it is necessary only increases the chance of dirt entering the engine when you remove the filter.
g009712 Figure 90 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 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.
Servicing the Fuel Filter Electrical System Maintenance Service Interval: Every 400 hours 1. Clean the area around the fuel-filter head (Figure 93). 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.
4. Slide the rubber boot over the positive terminal. 5. Close the battery cover. Locating the Fuses The traction-unit fuses are located under the power-center cover (Figure 96, Figure 97, and Figure 98). Remove the 2 screws securing the power-center cover to the frame and remove the cover (Figure 96). g020451 Figure 95 1. Battery 2. 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 You can adjust the operating angle of the traction pedal for your comfort. 1. g032673 Figure 99 1. Cab fuse box Loosen the 2 nuts and bolts securing the left side of the traction pedal to the bracket (Figure 101). 2. Fuses g009745 Figure 101 1. Traction pedal decal117-2787 2. Mounting nuts and bolts Figure 100 2. Pivot the pedal to the desired operating angle and tighten the nuts (Figure 101).
g019500 Figure 102 g020680 Figure 104 1. Check/drain plug (2) 1. Drain plug 2. Remove the plug at the 3 o’clock position (Figure 102). 4. When all of the oil has drained from both locations, install the plug in the brake housing. the check-plug hole. 5. If the oil level is low, remove the plug at the 12 o’clock position and add oil until it begins to flow out of the hole at the 3 o’clock position. Rotate the wheel until the open plug hole in the planetary is at the 12 o'clock position. 6.
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 107). 3. Remove the check plugs to make draining the oil easier. 4. Remove the drain plugs and allow the oil to drain into the pans. g011487 Figure 105 1. Check plug 2. Fill plug Checking the Rear-Axle-Gearbox Lubricant Service Interval: Every 400 hours g011509 Figure 107 The gearbox is filled with SAE 85W-140 gear lube. The capacity is 0.
Checking the Rear Wheel Toe-In Cooling System Maintenance Service Interval: Every 800 hours 1. Cooling System Safety Measure the center-to-center distance (at axle height) at the front and rear of the steering tires. • Swallowing engine coolant can cause poisoning; keep out of reach from children and pets. Note: The front measurement must be 6 mm (1/4 inch) less than the rear measurement. • Discharge of hot, pressurized coolant or touching 2.
• Preferred: When mixing coolant from a 4. concentrate, mix it with distilled water. Preferred option: If distilled water is not available, use a pre-mix coolant instead of a concentrate. Minimum requirement: If distilled water and pre-mix coolant are not available, mix concentrated coolant with clean drinkable water. • • Install the radiator cap and expansion-tank cap.
4. Brake Maintenance Close the hood. 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. Free travel is the distance the brake pedal moves before you feel braking resistance. 1. Release the locking latch from the brake pedals so that both pedals work independently of each other. 2. To reduce free travel of the brake pedals, tighten the brakes as follows: A.
Belt Maintenance Tensioning the Blade-Drive Belts Servicing the Alternator Belt Service Interval: After the first 10 hours Every 50 hours Service Interval: After the first 10 hours Every 100 hours 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 inches). Once the correct spring tension is attained, adjust the stop bolt (carriage bolt) until there is approximately 2 to 5 mm (0.065 to 0.
2. Loosen the eye bolt allowing the removal of the extension spring (Figure 113). 3. Loosen the flange nut securing the stop bolt to the mounting tab and move the idler pulley away from the belt to release the belt tension (Figure 113). Hydraulic System Maintenance Hydraulic System Safety Note: Loosen the nut enough to allow the idler • Seek immediate medical attention if fluid is injected arm to pass the stop bolt. into skin. Injected fluid must be surgically removed within a few hours by a doctor.
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 116) with hydraulic fluid; refer to Checking the Hydraulic Fluid (page 78). 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 118). The recommended counterbalance pressure is 2241 kPa (325 psi). To adjust the counterbalance pressure, loosen the locknut, rotate the adjusting screw (Figure 118) clockwise to increase the pressure or counterclockwise to decrease the pressure, and tighten the locknut.
Cutting Unit Maintenance Pivoting the Front Cutting Unit Down Pivoting (Tilting) the Front Cutting Unit to the Upright Position Note: Although not needed for normal maintenance procedures, you can pivot (tilt) the front cutting unit to an upright position. 1. 2. Raise the front cutting unit slightly off the floor, engage the parking brake, shut off the engine, and remove the key.
Servicing the Caster-Arm Bushings Removing the Bushings The caster arms have bushings pressed into the top and bottom of the tube and after many hours of operation, the bushings develop wear. To check the bushings, move the caster fork back and forth and from side to side. If the caster spindle is loose inside the bushings, replace the bushings. g011490 Figure 120 1. Height-of-cut chain 1. Raise the cutting unit so that the wheels are off the floor and block the cutting unit so it cannot fall. 2.
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 123) or the caster-pivot arm (Figure 124). Note: When installing the bearings, press on the outer race of the bearing. 6.
Blade Maintenance replacement blades to ensure safety and optimum performance. 1. Park the machine on a level surface, raise the cutting unit to the transport position, engage the parking brake, shut off the engine, and remove the key. Blade Safety • 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.
remains balanced if the same amount of metal is removed from both cutting edges. traction pedal in NEUTRAL, put the PTO lever in the OFF position, shut off the engine, and remove the key from the ignition. 2. Examine the cutting ends of the blade carefully, especially where the flat and curved parts of the blade meet (Figure 127). Note: Because sand and abrasive material can wear away the metal that connects the flat and curved parts of the blade, check the blade before using the mower.
8. Cab Maintenance Remove the bolts, flat washers, lock washers, and nuts from the outer spindle in the area where you must add the shims. Cleaning the Cab Note: To raise or lower the blade, add a shim (Part No. 3256-24) between the spindle housing and the bottom of the cutting unit. Continue to check the alignment of the blades and add shims until the tips of the blades are within the required dimension. Important: Use care around the cab seals and lights (Figure 129).
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. g032323 Figure 133 Right fan shown 1. Fan 2. Wire Preparing the Machine for Storage 3. Knob Important: Do not use brackish or reclaimed 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.
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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).
