TRACTION UNIT MODEL: 30782 10001 & UP FORM NO. 3311-762 OPERATOR’'S MANUAL \ [ TOR | LARGES LORELEI RT3 The GROUNDS MASTER 72 conforms to the American National Standards Institute’s safety standards for riding mowers; thus, Toto proudly displays the ANSI safety seal. To assure maximum safety, optimum performance, and to gain knowledge of the machine, it is essential that you or any other operator of the machine read and understand the contents of this manual before the engine is started.
FOREWORD The GROUNDS MASTER 72 was developed to satisfy the demand for a maneuverable, intermediate size, turf maintenance rotary mower. The machine has advanced concepts in engineering, and design; and if maintained properly, it will give excellent service, Since the GROUNDS MASTER 72 is a high-quality product, Toto is concerned about the future use of the machine and safety of the user. Therefore, read this manual to familiarize yourself with proper set-up, operation and maintenance instructions.
TABLE OF CONTENTS SAFETY INSTRUCTIONS .o . SAFETY AND INSTRUCTION DECALS SPECIFICATIONS LOOSE PARTS . SET-UP INSTRUCTIONS BEFORE OPERATING Check Crankcase Oil . Fill Fuel Tank with Diesel Fuel Check Cooling System Check Hydraulic System Oil CONTROLS . OPERATING INSTRUCTIONS Starting/Stopping Engine Priming Fuel System Checking Interlock Switches Pushing or Towing Traction Unit Operating Characteristics . . .
A SAFETY INSTRUCTIONS The GROUNDS MASTER 72 was tested and certified by TOR for compliance with the B71.1b— 1977 specifications of the American National Standards Institute. However, improper use or maintenance of the machine can result in injury. To reduce the potential for injury, comply with the following safety instructions. BEFORE OPERATING 1. Read and understand the contents of this manual before starting and operating the machine. Become familiar with all controls and know how to stop quickly.
A SAFETY INSTRUCTIONS 15. Never raise the cutting unit or other attached implement while the blades or other parts are rotating. 16. 1f cutting blades or other implement components strike a solid object or the machine vibrates abnormally, disengage PTQ, move throttle to SLOW, set parking brake and shut engine off. Remove key from switch to prevent possibility of accidental starting. Check cutting unit or other implement and traction unit for damage and defective parts.
SAFETY AND INSTRUCTION DECALS r“fi* ON POWER OFF ) & A Caution 1. KEEP ALL SHIELDS IN PLACE. 2. BEFORE LEAVING OPERATORS POSITION. A. MOVE TRANSMISSION TO NEUTRAL B. BEY PARKING BRAKE. C. DISENGAGE POWER TAKE OFF D. SHUT OFF ENGINE. £ REMOVE ignition KEY 3. WAIT FOR ALL MOVEMENT TO STOP BEFORE SERVICING MACHINE 4. STOP ENGINE BEFORE ACING FUEL OR LIFTING HOOD, 5. KEEP PEOPLE AND PETS A SAFE DISTANCE AWAY FROM MACHINE NEAR PTO LEVER {Part No. 27-7280} USE DIESEL FUEL ONLY ALONGSIDE FUEL CAP CAUTION .
SPECIFICATIONS Engine: The 4-cycle, 3 cylinder, overhead valve Mitsubishi diesel engine, Model K3D, is water cooled and delivers 21 HP (15.7 kw) @ 3000 rpm. Cylinder bore is 2.7/8 in. (73 mm), stroke is in. {78 mm) and displacement is 58.7 cu. in. {879 cc}. Compression ratio is 23:1, Crankcase oil capacity w/filter is 3.7 qt. (3.5 L). Filter is full flow, replaceable, screw-on type. Mechanical centrifugal type governor limits maximum no-load engine speed to 3200 £ 50 rpm. Die speed is 1500 + 50 rpm.
SPECIFICATIONS Dimensions and Weights {approx}: Traction Unit Length: 112in. (2.8 m) wit Width: {2.17 m} Cutting Unit Height: 50 in. {1.27 m) Curb Weight: 1650 Ib (748 Kg} Optional Equipment: Leaf Mulches Kit, Model No. 30732 {For Model 30721 C.U) Standard Seat Kit, Model No. 30785 Deluxe Seat Kit, Model No. 30786 Cutting Unit, Model No. 30721 (L.H. Side Discharge} Cutting Unit, Model No, 30710 {Rear Discharge) Tire Chains, Part No. 11-0390 V-Plow — 48 in. {1.219 m} for snow removal Moet No.
SET-UP INSTRUCTIONS INSTALL STEERING GEAR ASSEMBLY Tools Required: Pliers, 3/8 and Socket 1. Pivot steering post upward until holes in steering tower line up with holes in side of steering gear, Retain steering gear to steering tower with two cap screws {3/8 and {dishwashers {3/8 med}, but do not tighten the cap screws {Fig. 1). Figure 1 1. Caps craws & dishwashers 2. Install cotter pin (3/32 x 1/2in. 2.
SET-UP INSTRUCTIONS Figure 4 1. Cutout 2. Jam nut 3. Steering wield cap REMOVE BATTERY FROM CHASSIS 1. Release the two latches holding instrument cover in place, Carefully remove instrument cover 1o expose the battery, 2. Remove two wing nuts and the hold down strap that secure battery and seat switch in place (Fig. 5). Lift battery out of Chassis, Keep wing aunts and hold down strap in a safe place for later use, Fiats 7. Wing mats 2. Hold down strap 3. Positive terminal 4.
SET-UP INSTRUCTIONS 6. Mount seat and seat support to unit with pivot shaft and roll pin {Fig. 8). Algae 1. Pivot shaft 2. Ell pin 6. Install seat support rod bracket with jam nut {Fig. 8}, 10 seat support 7. Hold seat up with seat support rod. Seat Kit, Model No, 30786, Deluxe Seat: 1. Remove seat and hardware from carton, 2. Mount seat support bracket to frame {Fig. 6}. Note: When mounting bracket, slide left cap screw in bracket before lowering into mounting position. 3.
SET-UP INSTRUCTIONS Figure 12 1. Set suppose rod 2. Lynch pi 2. Slowly push machine off pallet. 3. Close by-pass valve by rotating it clockwise until it is securely seated. Do not exceed 5 to 8 ft-b {7 to 11 N'm}. Do not start engine when naive is open. CONNECT BATTERY CABLES Tools Required Open End Wrench 1. Install battery and secure with hold down strap and wing nuts {Fig. 5). Remove tape over ends of each cable. 2. Slide the red, positive battery cable (Fig.
SET-UP INSTRUCTIONS Figure 14 Jam nut 2x 4in (81 x 102 mmj block Sett hand push arm . Naif joint mount . 2-3/8 in. (60 mmi GiA N 6. Remove spring pin from cylinder pin and slide cylinder pin out of cylinder. 7. Raise front of lift arm until hole in movable end of cylinder lines up with holes in lift arm brackets. Hold parts together with cylinder pin, spring pin and cotter pin. Cotter pin must be to the outside {page 52, Fig 78). 8.
BEFORE OPERATING 4. The engine uses any high-quality detergent oil having the American Petroleum Institute — AP “service classification” SE, CC Note: CD classification is an acceptable substitute. Oil viscosity recommendations are: SAE 10W-30, Figure 16 £ O Fife hot IMPORTANT: Check level of oil after every 5 hours of operation or daily. Change oil after every 50 hours of operation and change the oil filter after the first 50 hours and every 100 hours thereafter.
BEFORE OPERATING A DANGER Because diesel fuel is flammable, caution must be used when storing or handling it. Do not fill fuel tank while engine is running, hot or when machine is in an enclosed area. Vapors may build up and be ignited by a spark or flame source many feet away, DO NOT SMOKE while filling the fuel tank to prevent the possibility of an explosion. Always fill fuel tank outside and wipe up any spilled diesel fuel before starting engine.
CONTROLS Traction Pedal (Fig. 19} — Traction pedal has two functions; one is to make the machine move forward, the other is 1o make it move backward. Using the heel and toe of the right foot, depress top of pedal to move forward and bottom of pedal to move backward. Ground speed is proportionate to how far pedal is depressed. For maximum ground speed with no load, traction pedal must be fully depressed while throttle is in FAST position. Maximum speed forward is approximately 9.
CONTROLS Figure 21 PTO fever 8. Temp gauge snd reset Hair metro 7. Glow plug switch and indicator Fief gauge 8. Key switch Oil pressure Indicator 9. Throttle contra Am mater 10. Battery cover SA N Hour Meter (Fig. 21} — The hour meter registers accumulated hours of engine operation. Use the hour meter to determine intervals for service maintenance and lubrication, Fuel Gauge {Fig. 21) — Indicates quantity of fuel remaining in fuel tank. Oil Pressure Warning Light (Fig.
CONTROLS A 40 amp circuit breaker is also incorporated to protect the entire wiring circuit. A reset button is located on the lower side of the panel, which can be reached after removal of the battery cover {Fig. 21, 23}, The bitten should be depressed if a total loss of all electrical functions should occur. However, the electrical system should first be checked to ascertain the reason for the malfunction; refer to Electrical Troubleshooting, pages 24-29. iy 72 1.
OPERATING INSTRUCTIONS STARTING/STOPPING ENGINE IMPORTANT: The fuel system must be primed if any of the following situations have occurred: A. Initial start up of a new machine, B. Engine has ceased running due to lack of fuel, C. Maintenance has been performed upon fuel system components; ie., filter replaced, separator serviced, etc. Refer to Priming Fuel system, page 19. 1. Ensure parking brake is set, PTO lever is in OFF position {Fig. 21} and lift lever is in TRANSPORT or FLOAT position {Fig. 20).
OPERATING INSTRUCTIONS 8. Turn key in ignition switch to the RUN position. Electric fuel pump will begin operation, thereby forcing air out around air bleed screw. Leave key in RUN position until solid stream of fuel flows out around screw. Tighten screw and turn key to OFF. NOTE: After engine Has operated for a few minutes, stop engine, recheck fuel filter and breed off any trapped air, Note: Normally, engine should start after above priming procedures are followed.
OPERATING INSTRUCTIONS 4. Move PTQ lever to OFF position. Raise off the seat and depress traction pedal slowly while engine is running. The engine should stop. f engine stops, the neutral switch is operating correctly, [f engine does not stop, there is a defect in the electrical system; refer to Electrical Troubleshooting, pages 24-29. 5. If all the switches operated correctly, the machine can be operated.
LUBRICATION MAINTENANCE GREASING BEARINGS, BUSHINGS, GEAR BOX AND BRAKE CABLES Tools Required: Clean Rag, and Grease Gun w/No. 2 General Purpose Lithium Grease The traction unit must be lubricated regularity, If machine is operated under normal conditions, lubricate all bearings and bushings after every 50 hours of operation. 1. The traction unit bearings and bushing that must be lubricated are: PTO shaft and yokes (Fig. 30); tight arm pivot (Fig. 31); right and left push arm ball joints {Fig.
LUBRICATION MAINTENANCE REPLACING/PACKING REAR WHEEL BEARINGS Pack the rear wheel bearings with Molybdenum general purpose lithium grease, after every 500 hours of operation or once a year. If operating conditions are extremely dusty or dirty, it may be necessary to pack the bearings more often. 1. Jack up rear of machine until tire is off shop floor. Support machine with jack stand to prevent it from falling. 2. Remove dust cap from rear wheel.
ELECTRICAL MAINTENANCE TROUBLESHOOTING PROBLEM: STARTER SOLENOID CLICKS, BUT STARTER WILL NOT CRANK. (IF SOLENOID CLICKS INTERLOCK SYSTEM IS NOT AT FAULT) Sold ot Swoon TR welfare Temperature e [r84 AMMETER CIRCUIT INVOLVED WITH CRANKING ENGINE PROBLEM: NOTHING HAPPENS WHEN START ATTEMPT IS MADE. REFER TO CIRCUIT DIAGRAM ABOVE.
REPLACING SEAT SWITCH 1. Raise seat and hold it up with seat support rod. 2. Remove instrument cover, disconnect negative battery cable from battery and separate wire harness connectors {Fig. 41). Remove cap screw and lockout {Fig. 41) and lift switch up to disengage locating pin on bottom of switch from hole in mounting bracket. Figure 41 . Connectors Cops craw and knockout . Switch . Mounting bracket Aot 3. To install new switch, set it on mounting bracket {Fig.
AIR CLEANER MAINTENANCE GENERAL MAINTENANCE PRACTICES Inspect air cleaner and hose periodically to maintain maximum engine protection and to ensure maximum service life, 1. Assure hose between air cleaner and carburetor is clamped securely in place. Replace the hose if it is cracked or punctured. 2. Check air cleaner body for dents and other damage which could possibly cause an air leak. Replace a damaged air cleaner body. 3. Insure dust cap is sealing around bottom of air cleaner body. 4.
AIR CLEANER MAINTENANCE A. Prepare a solution of filter cleaner and water and soak filter element about 15 minutes, Refer to directions on filter cleaner carton for complete information. B. After soaking filter for 15 minutes, rinse it with clear water. Maximum water pressure must not exceed 40 psi {276 kPa} to prevent damage to the filter element. €. Dry filter element using warm, flowing air {160°F {71°C} max}. or allow element to air-dry.
ENGINE MAINTENANCE 4. Remove oil drain plug and allow oil to flow into drain pan. Remove and replace oil filter {Fig. 46}, refer to parts catalog for part number. Figure 46 1. Dipstick 2 Dipstick tube 2 Neap oil Tevet between notches 4. Engine o4 filter 5. After oil is drained, reinstall drain plug and wipe up any oil that spilled. 6. Fill crankcase with oil; refer to Check Crankcase Qil, page 13. SERVICING FUEL SYSTEM Note: Refer to Fill Fuel Tank With Diesel Fuel, page 14, for proper fuel recommendations.
ENGINE MAINTENANCE 4. Install new element to base, carefully inserting inside toward outside of element. Hold air nozzle roll pin into single centered outlet passage. at least one inch {25 mm) from filer and move up and down while rotating filter. Do not exceed 100 5. Engage lower element tab to slot in base. Press psi {688 kPa) 1o avoid filter damage, zz Nate Replace the filter if there is any visible dirt clamp is securely in place. innocence i 6.
ENGINE MAINTENANCE 3. Reverse procedures to install new assembly. Ensure line clamps are tight to prevent air from entering system. 4. Prime the fuel system; refer to Priming Fuel System, page 19. BLEEDING AIR FROM INJECTORS Note: This procedure should be used only if fuel system has been purged of air through normal priming procedures and engine still will not start; refer to Priming Fuel System, page 19, 1. Loosen the pipe connection to the No. 1 nozzle and holder assembly, 2.
ENGINE MAINTENANCE 4. Insert pry bar between alternator and engine and pry out on alternator {Fig. 53). 5. Hold alternator in position after proper belt tension setting is achieved and tighten alternator and brace bolts to secure adjustment. Note: Metric wrenches will be required. Cooling Fan Belt 1. Unlatch and open hood. 2. Remove cap screws (5) securing fan belt guard and remove guard {Fig. 54). Figure 54 1. Fan belt guard 3. Belt should deflect midway between the pulleys with § Ibf (22 N} {Fig.
ENGINE MAINTENANCE ASAMA, A CAUTION Be careful while working around muffler as it may be hot and could cause injury. 3. Start engine, plug the normal muffler exit with block of wood or metal plate so exhaust flow will be forced out the clean-out port (Fig. 56). Continue to block exit until carbon deposits cease coming out port. A CAUTION Do not stand in line with the clean cut port, 4. Stop engine, replace pipe plug and lower and latch hood. TRACTION DRIVE MAINTENANCE ADJUSTING TRACTION CONTROL ROD 1.
TRACTION DRIVE MAINTENANCE 4. Start engine and allow it to idle for & minutes to heat oil in transmission to operating temperature. 5. Release parking brake; then check left front wheel that is off shop floor. Wheel must not be rotating. If wheel is rotating, proceed to step 6 for an adjustment. If wheel is not rotating, proceed to step 8. Verify the adjustment with throttle in SLOW and FAST position. 6. Because the wheel is rotating, the pump plate must be adjusted.
TRACTION DRIVE MAINTENANCE 3. If drive coupling assembly must be disassembled, separate rubber couplings from power shaft by removing four nuts, flat washers and cap screws {Fig. 69}. INSTALLING DRIVE COUPLING 1. Assemble rubber couplings and power shaft with cap screws. Flat washers and nut (Fig. 59}. 2. Position drive coupling assembly between engine and transmission hub, and align the holes.
PTO DRIVE MAINTENANCE CORRECTING PTO DRIVE BELT SLIPPAGE If belt begins to slip because it has stretched or because of worn linkage. 1. Unlatch and remove instrument cover, 2. Move PTO control lever to ON position. 3. Measure length of PTO spring between flat washers (Fig. 63}, There should be a spring length of in. {81 mm}. Figure 63 1. in. (81 mom) 2. PTO actuating arm 3 Lock not 4. To adjust, hold head of adjusting screw with wrench {under PTQ actuating arm) and turn lockout {Fig. 63). 5.
PTO DRIVE MAINTENANCE pin, and slide spacer, brake and spring off the pins {Fig. 64}, 4. To install new brake, slide spring onto Sarge mounting pin. Then slide brake onto mounting pin and small locating pin. 5. Move PTO lever to OFF and position the brake in grooves of pulley. Slide spacer onto mounting pin and secure all parts in place with knockout. Tighten lockout until spacer contacts brake. ALIGNING PTO PULLEY AND ENGINE PULLEY 1.
STEERING MAINTENANCE ADJUSTING STEERING GEAR Adjustment of steering wheel backlash or “play” is recommended after the first 50 hours of initial operation and every 250 hours thereafter, 1. Place machine on level surface, lower implement and set parking brake, 2. Raise rear wheels slightly off floor and place blocks under frame so machine is securely supported. Be sure blocks allow wheels to turn freely, 3.
STEERING MAINTENANCE Note: Since right side of cutting unit is used for trimming, always assure a full right turn can be made. 5. Tighten jam nuts on rear steering rod. 6. Adjust toe-in of the rear wheels; refer to Adjusting Rear Wheel Toe-In, page 41, ADJUSTING REAR WHEEL BEARINGS 1. Jack up rear of machine until wheel is off shop floor. Use jack stands or block the machine to prevent it from falling accidentally. 2. Remove dust cap from end of wheel spindle.
BRAKE MAINTENANCE 5. Remove wheel nuts and slide wheel and tire 7. Loosen star nut about 12 to 15 notches or assembly off studs. Rotate brake drum until until brake drum rotates freely. adjusting slot is at bottom and centered over star nut that adjusts brake shoes {Fig, 72). 8. Install wheal and tire assembly on studs with five wheel nuts, Tighten nuts to 45-55 ft-In {816. Using a brake adjusting tool or screwdriver, 75 N-m}. rotate star-nut {Fig. 73} down until brake drum (Fig.
HYDRAULIC SYSTEM MAINTENANCE FORWARD TRACTION OPERATION The hydro static transmission consists of a charge pump, variable displacement pump and a fixed displacement motor. The schematic {Fig. 74) shows flow of the hydraulic oil during forward operation.
HYDRAULIC SYSTEM MAINTENANCE LIFTING OPERATION When sift lever is actuated to raise the cutting unit, the charge pump supplies oil to the lift valve, Oil goes in one side of the lift valve, to the lift cylinder, out the lift cylinder, back to the sift valve, to the oil cooler and to the pump housing (Fig.
HYDRAULIC SYSTEM MAINTENANCE TROUBLESHOOTING SYSTEM JERKY WHEN STARTING INSPECT FRICTION WHEEL {INSPECT INSPECT INSPECT CONTRACTION [ TRACTION CONTROL [ gu] Acceleration | g CHARGE CHECK PEDAL LINKAGE VALVES VALVES ! T WORN DEFECTIVE DEFECTIVE f + + ROTATE Mo REPAIR REPAIR REPAIR REPLACE REPLACE REPLACE REPLACE SYSTEM OPERATES IN ONLY ONE DIRECTION INSPECT INSPECT INSPECT mftfl&" ] ACCELERATION | ] CHARGE LINKAGE VALVES CHEEK VALVES DEFECTIVE DEFECTIVE REPAIR REPAIR REPAIR OR OR OR REPLACE REPLACE REPLACE
HYDRAULIC SYSTEM MAINTENANCE ADJUSTING LIFT LEVER LATCH A lift lever latch that is positioned incorrectly can cause the lift lever to hold the spool in an actuated position when the implement is in the FLOAT position. This will cause oil in the hydraulic system to overheat, When lift lever latch is adjusted correctly, the lift lever should just clear the rounded part of the latch as lever is moved into FLOAT position. 1. Unscrew ball from lift lever. 2.
HYDRAULIC SYSTEM MAINTENANCE 4. Start engine, raise implement and hold [ift arm up with overhead hoist to prevent implement from moving down. Shut engine off. 5. Disconnect cylinder hose from 90° fitting on lift valve (Fig. 79). Keep end of hose higher than cylinder to prevent oil from draining out the hose. Plug end of the hose. Figure 19 L. Cylinder hose 2. Lift valve 6. Release overhead hoist and watch the lift arm and implement.
HYDRAULIC SYSTEM MAINTENANCE 2. Lubricate gasket on oil filter with SAE 10W-40 SC or SE oil. Then fill the filter with the same oil. 3. Install filter by hand until gasket contacts mourning head; then an additional 1/2 turn. 4. Start engine and check for hydraulic oil leaks. Allow engine to run for about 2 minutes so any air in the system is purged — removed. 5. Shut engine off and check level of transmission oil; refer to Check Hydraulic System Qil, page 15.
SERVICE INTERVAL CHART Date Hour Meter Reading Service Interval * Daily 100 | 150 | 200 | 300 Check Interlock System Daily Check Engine Oil Level Daily Check Transmission Oil Level Daily Check Radiator and Coolant {more often when conditions are dirty) Daily Water Separator {Visual) Daily Replace Hydraulic Oil Filter {Initial) 10 Tighten Front Wheel Nuts {Initial) 2&10 Change Engine Oil Filter (initial} 50 Change Engine Gil {more often when conditions are dirty} 50 Check Steering Gear {Initial check only} 5
The Torn Promise A ONE YEAR LIMITED WARRANTY ON COMMERCIAL PRODUCTS OTHER THAN WALK ROTARY MOWERS, TRIMMERS AND BLOWERS. The Tore Company promises to repair your TOR Product if defective in materials or workmanship. The following time periods from the date of purchase apply: Commercial Products . Nevi-Duty Walk Rotary Mowers Trimmers and Blowers .