Form No. 3440-765 Rev A Groundsmaster® 5900 or 5910 Rotary Mower Model No. 31698—Serial No. 407050000 and Up Model No. 31699—Serial No. 407050000 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 General Safety ................................................. 57 Understanding the Audible Alarm ..................... 57 Pushing or Towing the Machine ........................ 58 Identifying the Tie-Down Points ........................ 59 Hauling the Machine ......................................... 59 Maintenance ........................................................... 60 Maintenance Safety.......................................... 60 Recommended Maintenance Schedule(s) ...........
Safety Servicing the 24 V Alternator Belt and AC Compressor Belt ........................................... 84 Replacing the Blade-Drive Belts ....................... 84 Hydraulic System Maintenance ........................... 86 Hydraulic System Safety................................... 86 Hydraulic Fluid Specifications........................... 86 Hydraulic Fluid Capacity ................................... 86 Checking the Hydraulic Fluid ............................ 86 Changing the Hydraulic Fluid ...
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. decal93-6674 93-6674 decal106-6754 1. Crushing hazard, hand—read the instructions before servicing or performing maintenance. 106-6754 1. Warning—do not touch the hot surface. 2. Cutting/dismemberment hazard, fan; entanglement hazard, belt—stay away from moving parts. decal93-6686 93-6686 1. Hydraulic fluid 2.
decal115-8155 115-8155 1. Warning—read the Operator's Manual, do not prime or use starting fluid. 114-0922 decal114-0922 114-0922 1. Belt routing decal117-3276 117-3276 decal114-0974 114-0974 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. 1. Belt routing decal117-4766 117-4766 1. Cutting/dismemberment hazard, fan—stay away from moving parts; keep all guards and shields in place.
decal120-6604 120-6604 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. decal130-0594 130-0594 Model with Cab Only 1. Warning—read the Operator’s Manual; when sitting in the cab, always wear a seat belt; wear hearing protection.
decal131-6025 131-6025 1. Height of cut decal132-1313 132-1313 1. Attention—move the key to the engine stop position before servicing the battery; do not service the battery with the engine running. 4. Positive terminal 2. Battery—disconnect 5. Negative terminal 3. Battery—connect 6. Read the Operator’s Manual for more information on servicing the battery. decal131-6026 131-6026 1. Height of cut decal132-1316 132-1316 1. Entanglement hazard, belt—keep away from moving parts.
decal132-1406 132-1406 1. Releasing the parking brake when the engine is off—1) Open the tow valves on the traction pump (read the Operator's Manual); 2) Push down and hold the black knob to release the parking brake; 3) Work the hand pump up and down. You can release the black knob after 2 to 3 pumps. The parking brake releases after 25 to 30 pumps. decal133-0980 2. Engaging the parking brake—pull up the black knob; the manual valve resets when you start the engine. 133-0980 Model with Cab Only 1.
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. Wear eye protection. 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. decal136-1003 136-1003 1. Cruise control—on 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 Model with Cab Only 1. Fan—off 2. Fan—on full 5. External air 6. Internal air 3. Cold air 4. Hot air 12 7. Air conditioner—on 8.
decal131-2348 131-2348 1. Headlights—off 4. Parking brake—off 7. Engine—stop 2. Headlights—on 5. Pivot the attachment left. 8. Engine—run, electric preheat 3. Parking brake—on 6. Pivot the attachment right. 9. Engine—start decal131-6027 131-6027 1. Height-of-cut settings 3. Lower caster position—heights of cut 76 to 153 cm (3 to 6 inches) 2.
decal132-1321 132-1321 1. Read the Operator’s Manual. 4. To engage the PTO, pull up the knob. 2. To start the engine: 1) Put the traction pedal in neutral; 2) Engage the parking brake; 3) Turn the key to the run position; 4) Turn the key to the engine start position. 5. To disengage the PTO, push down the knob. 3. To shut off the engine: 1) Move the throttle switch to slow; 2) Disengage the PTO; 3) Engage the parking brake; 4) Wait 5 minutes; 5) Turn the ignition key to Stop; and 6) Remove the key. 6.
decal136-1004 136-1004 1. Turn signals 7. Cutting unit—off 2. Beacon 8. Lower the left cutting unit. 3. Work light 9. Lower the center cutting unit. 4. Engine speed 10. Lower the right cutting unit. 5. Transmission 6. Cutting unit—on 11. Horn decal139-0977 139-0977 1. Read the Operator’s Manual.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description Qty. Use 1 No parts required – Remove the wing-deck-shipping straps and braces. 2 Right deck cover Left deck cover V-belt 1 1 2 Lower the front-deck winglets. No parts required – Check the tire and caster wheel pressure. No parts required – Level the front, center cutting unit. No parts required – Level the winglet decks to the front, center deck.
2. Remove the straps and braces securing the wing decks for shipping. 4. Install the front and rear stop bolts through the upper-mounting holes and eccentrics (Figure 4). Note: Ensure that the stop bolt engages the tab on the hinge pin. 2 Lowering the Front-Deck Winglets Parts needed for this procedure: 1 Right deck cover 1 Left deck cover 2 V-belt Procedure 1. Remove the nuts securing the front and rear stop bolts to the right winglet-deck mounts (Figure 3). g008868 Figure 4 1. Winglet 4.
8. B. Using a ratchet wrench or a similar tool, move the idler pulley away from the pulleys (Figure 5). C. Route the belt around the winglet-spindle pulley and the upper-spindle pulley on the front deck. D. Release the idler pulley to put tension on the belt. tire size between the front and rear tires. Use only genuine Toro tires. 4 Leveling the Front, Center Cutting Unit Install the winglet-deck cover and secure it with the rubber latch (Figure 6).
6. Adjust the forward eccentric until it just makes contact with the inner slot surface of the winglet-pivot brackets. 7. Tighten the bolt and nut for this eccentric to 149 N·m (110 ft-lb). 8. Repeat the procedure on the opposite winglet. 6 Checking the Fluid Levels No Parts Required Procedure g008868 Figure 7 1. Winglet 4. Eccentric 2. Hinge pin 5. Upper hole 3. Stop bolt 3. 4.
8 Installing the Decal (CE Machines Only) Parts needed for this procedure: 1 Production-year decal Procedure On machines requiring CE compliance, install the production-year decal included in the loose parts and the CE Kit, sold separately (Figure 9). g282517 Figure 9 1.
Product Overview g031657 Figure 10 1. Wing cutting unit 5. Fuel tank 2. Control panel 6. Steering wheel 3. Roll bar 7. Front cutting unit 4. Hood 8.
Controls Turn-Signal Switch Note: Determine the left and right sides of the Press the left side of the turn-signal switch to activate the left-turn signal and the right side of the switch to activate the right-turn signal (Figure 11). machine from the normal operating position. Note: The center position is off. Key Switch The key switch has 3 positions: STOP, RUN/PREHEAT , and START (Figure 11). PTO Switch The PTO switch has 2 positions: OUT (start) and IN (stop).
Throttle Switch Seat-Back-Adjustment Lever The throttle switch has 2 positions: IDLE (Figure 11). LOW IDLE and HIGH Move the lever to adjust the seat-back angle (Figure 12). Press the switch forward for 2 or more seconds to set the throttle at HIGH IDLE; press the switch rearward for 2 or more seconds to set the throttle at LOW IDLE; or momentarily press the switch in either direction to increase or decrease the engine speed in 100-rpm increments.
Cab Controls position. Pull out and down on the latch to close and secure the windshield. For Machines with a Cab g196911 Figure 14 1. Windshield latch g032672 Figure 13 1. Air-conditioning switch 4. Temperature control 2. Air-recirculation control 5. Windshield-wiper switch 3. Fan control 6. Blank switches for optional kits 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 Note: Specifications and design are subject to change without notice. g200003 Figure 15 Description Figure 15 reference Dimension or Weight Height with cab C 240 cm (94.
Width of cut overall D 488 cm (192 inches) front cutting unit 234 cm (92 inches) side cutting unit 145 cm (57 inches) front and one side cutting unit 361 cm (142 inches) Overall width cutting units down E 506 cm (199 inches) cutting units up (transport position) B 251 cm (99 inches) H 194 cm (76-1/2 inches) front A 159 cm (62.5 inches) rear J 142 cm (56 inches) Wheel base Wheel tread (tire center to center) Ground clearance 25.
Operation • Do not store the machine or fuel container where Note: Determine the left and right sides of the machine from the normal operating position. • If you spill fuel, do not attempt to start the engine; there is an open flame, spark, or pilot light, such as on a water heater or other appliance. avoid creating any source of ignition until the fuel vapors have dissipated.
Petroleum Diesel Fuel Table Cetane rating: 45 or higher Diesel fuel specification Sulfur content: Ultra-low sulfur (<15 ppm) ASTM D975 No. 1-D S15 Location 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.
Adding Fuel Checking the Tire Pressure 1. Park the machine on a level surface (Figure 16). 2. Shut off the engine, remove the key, and engage the parking brake. 3. Clean around the fuel-tank cap and remove the cap. 4. Add fuel and install the fuel-tank cap. Wipe up any spilled fuel. Service Interval: Before each use or daily The correct air pressure in the front tires is 220 kPa (32 psi) and the rear tires is 207 kPa (30 psi) as shown in Figure 17.
caster-spindle shaft and slide the caster shaft out of the caster arm (Figure 19). WARNING Failure to maintain the proper torque of the wheel nuts could result in failure or loss of a wheel, and may result in personal injury. Torque the front and rear-wheel nuts to 135 to 150 N·m (100 to 110 ft-lb) according to the maintenance schedule. Adjusting the Height of Cut You can adjust the height of cut from 25 to 153 mm (1 to 6 inches) in 13 mm (1/2 inch) increments.
Adjusting the Wing Cutting Units 1. Start the engine and raise the cutting units so you can change the height of cut. 2. Shut off the engine and remove the key after you raise the cutting unit. 3. Position the caster-wheel axles in the same holes in all of the caster forks; refer to the chart to determine the correct holes for the height-of-cut setting (Figure 22).
Adjusting the Skids Adjusting the Inner Skids Mount the inner skids in the lower position when operating at heights of cut greater than 51 mm (2 inches) and in the higher position when operating at heights of cut lower than 51 mm (2 inches). Adjust the inner skids (Figure 24). Important: Torque the screw at the front of each inner skid to 9 to 11 N·m (80 to 100 in-lb). g031661 Figure 23 1. Tensioning cap 4. Top axle-mounting hole 2. Spacers (6) 5. Caster wheel 3. Shims (2 top and 2 bottom) 5. 5.
Adjusting the Cutting Unit Anti-Scalp Rollers Mount the roller in the lower position when operating at heights of cut greater than 51 mm (2 inches) and in a higher position when operating at heights of cut lower than 51 mm (2 inches). g202202 Adjusting the Roller 1. Remove the roller shaft, screw, and nut securing the roller to the deck bracket (Figure 26). g033107 Figure 26 1. Roller g031063 2. Figure 25 2.
Matching the Height of Cut Between Cutting Units Correcting a Mismatch Between the Cutting Units Due to differences in grass conditions and the counterbalance setting of the traction unit, you should cut the grass and check the appearance before you begin mowing the entire area. 1. Set all cutting units to the desired height of cut; refer to Adjusting the Height of Cut (page 30). 2. Check and adjust the front and rear tire pressure.
Note: Check the measurement between the 8. 9. outside edges of both wing cutting units and the inside edge of the wing cutting unit to the outside edge of the front cutting unit again. If the inside edge is still too low, add an additional shim to the bottom of front, inside caster arm of the wing cutting unit and 1 shim to the front, outside caster arm of the wing cutting unit.
4. While holding the assembly in place, carefully tilt the headlight downward 3° then tighten the nut. 5. Repeat this procedure on the other headlight. Checking the PTO Safety-Interlock Function Checking the Safety-Interlock Switches 1. Start the engine. 2. With the engine running, rise from the seat and engage the PTO. Note: The PTO should not engage. If it does engage, there is a malfunction in the interlock system that you should correct before resuming operation.
During Operation • Before you leave the operator’s position, do the During Operation Safety General Safety • The owner/operator can prevent and is responsible • • • • • • • • • • • • • • • • for accidents that may cause personal injury or property damage. Wear appropriate clothing, including eye protection; long pants; substantial, slip-resistant footwear; and hearing protection. Tie back long hair and do not wear loose clothing or loose jewelry.
Starting the Engine surveying the site. Always use common sense and good judgment when performing this survey. 1. 2. • Review the slope instructions listed below for operating the machine on slopes and to determine whether you can operate the machine in the conditions on that day and at that site. Changes in the terrain can result in a change in slope operation for the machine. 3. 4. • Avoid starting, stopping, or turning the machine on 5. slopes. Avoid making sudden changes in speed or direction.
2. machine into or out of a building), you will not be able raise all the cutting units at once. Instead, you can only raise 1 cutting unit at a time. Diesel Particulate Filter Regeneration Push the deck-lift switches rearward to raise the decks. The diesel particulate filter (DPF) is part of the exhaust system. The diesel-oxidation catalyst of the DPF reduces harmful gasses and the soot filter removes soot from the engine exhaust. Lowering the Decks 1.
DPF Soot Accumulation • Over time, the diesel particulate filter accumulates soot in the soot filter. The computer for the engine monitors the soot level in the DPF. • When enough soot accumulates, the computer informs you that it is time to regenerate the DPF. • DPF regeneration is a process that heats the DPF to convert the soot to ash. • In addition to the warning messages, the computer reduces the power produced by the engine at different soot-accumulation levels.
InfoCenter Advisory and Engine Warning Messages—Ash Accumulation Indication Level Fault Code Level 1: Engine Warning Engine Speed Reduction Engine Power Rating Recommended Action None The computer de-rates the engine power to 85%. Service the DPF; refer to Servicing the Diesel-Oxidation Catalyst (DOC) and the Soot Filter (page 71) None The computer de-rates the engine power to 50%.
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.
2. Press the button 4 to select the Technician entry (Figure 38) The state and soot load information displays. • Use the DPF operation table to understand the current state of DPF operation (Figure 39). g241812 Figure 37 4. Press button 4 to return to the DPF regeneration screen or press button 5 to exit the service menu and return to the home screen.
Reset Regeneration Note: The soot load value varies as the machine is operated and DPF regeneration occurs. CAUTION The exhaust temperature is hot (approximately 600°C (1,112°F) during DPF regeneration. Hot exhaust gas can harm you or other people. • Never operate the engine in an enclosed area. • Make sure that there are no flammable materials around the exhaust system. • Never touch a hot exhaust system component. • Never stand near or around the exhaust pipe of the machine.
Periodic Reset Regeneration If the engine has not completed a successful Reset, Parked, or Recovery regeneration in the previous 100 hours of engine operation, the engine computer will attempt to perform a reset regeneration. 2. Press the button 4 to select the Inhibit Regen entry (Figure 43). 3. Press the button 4 to change the inhibit regeneration setting from On to Off (Figure 44) or from Off to On.
g241833 Figure 46 g243501 Note: When the reset regeneration completes, the high exhaust-temperature InfoCenter screen. Figure 48 disappears from the • Parked regeneration required ADVISORY #1212 (Figure 49) Note: Advisory #1212 displays every 15 minutes. Parked or Recovery Regeneration • When the engine computer requests either a parked regeneration or a recovery regeneration, the regeneration request icon (Figure 47) displays in the InfoCenter.
Recovery Regeneration Messages When a recovery regeneration is requested by the engine computer, the following messages display in the InfoCenter: Recovery regeneration required—power takeoff disabled ADVISORY #1214 (Figure 51) g241848 g241999 Figure 51 Important: Perform a recovery regeneration to restore the PTO function; refer to Preparing to Perform a Parked or Recovery Regeneration (page 49) and Parked or Recovery Regeneration (page 47).
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 have 1/4 tank of fuel before performing the parked regeneration. • Recovery Regeneration: Ensure that you have 1/2 tank of fuel before performing the recovery regeneration. 2. Move the machine outside to an area away from combustible materials. 3. Park the machine on a level surface. 4.
g241892 g241894 g241893 g241895 Figure 55 4. Figure 56 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 button 4 to continue (Figure 56). 5. 50 At the DPF checklist screen, verify that the parking brake is engaged, that the engine speed is set to low idle, press the button 4 to continue (Figure 57).
g241898 g241900 g241899 g241901 Figure 57 6. Figure 58 At the INITIATE DPF REGEN screen, press the button 4 to continue (Figure 58). 7. The InfoCenter displays the INITIATING DPF REGEN message (Figure 59). Note: If needed, press button 4 to cancel the regeneration process.
g241912 g241914 g241913 g241915 Figure 59 8. Figure 60 The InfoCenter displays the time to complete message (Figure 60). 9. Note: If needed, press button 4 to cancel the regeneration process. The engine computer checks the engine state and fault information. The InfoCenter may display the following messages found in the table that follows: Check Message and Corrective Action Table Parked Regen Recovery Regen Check Message: Less that 50 hours since last regeneration—press any key.
10. Check Message and Corrective Action Table (cont'd.) The InfoCenter displays the home screen and the regeneration acknowledge icon (Figure 61) appears in the lower right corner of the screen as the regeneration processes. Check Message: Diagnostic trouble code active 1220—press any key. Corrective Action: Troubleshoot the engine fault and retry DPF regeneration. g241917 Figure 61 Parked Regen Recovery Regen Check Message: Start engine 1222—press any key.
2. Press the button 4 to cancel a Parked Regen or cancel a Recovery Regen (Figure 65). g242002 g241969 Figure 63 Canceling a Parked or Recovery Regeneration Use the Parked Regen Cancel or Recovery Regen Cancel setting to cancel a running parked or recovery regeneration process. 1. g242003 Figure 65 Access the DPF Regeneration menu, and press buttons 1 or 2 to scroll down to the PARKED REGEN option or the RECOVERY REGEN option (Figure 64).
Understanding the Operating Characteristics of the Machine Understanding the 12 V and 24 V Electrical Systems This machine is designed with 2 voltage systems: 12 V and 24 V. Practice driving the machine, as it has a hydrostatic transmission, and its characteristics may differ from other turf-maintenance machines. The 12 V system powers all functions of the machine, except for the engine-cooling fans and hydraulic-cooling fans.
Automatic-Reversing Fan Cycle • If an obstacle is in the way, lift the cutting units to mow around it. • When transporting the machine from 1 work area to another, shut off the PTO, raise the cutting units to the fully upward position, press the mow/transport switch to the TRANSPORT position, engage the transport latches, and place the throttle in the FAST position. The hydraulic-fan speed is controlled by hydraulic-fluid temperature.
After Operation appearance may deteriorate and the observed power to cut the turf increases. The mulching baffles also perform well for shredding leaves in the fall. General Safety • Shut off the engine, remove the key, and wait Selecting the Proper Height-of-Cut Setting for all movement to stop before you leave the operator’s position. Allow the machine to cool before adjusting, servicing, cleaning, or storing it. Remove approximately one-third of the grass blade when mowing.
Pushing or Towing the Machine Important: Do not push or tow the machine faster than 3 to 4.8 km/h (2 to 3 mph). If you push or tow at a faster speed, internal transmission damage may occur. The bypass valves must be open whenever you push or tow the machine. 1. Raise the hood and locate the bypass valves on the pump. g311881 Figure 70 g021158 Figure 69 1. Bypass valve (2) 2. Loosen both tow valves on the hydrostatic transmission. 3.
Identifying the Tie-Down Points Front of the machine—under the front of the operator's platform (Figure 72) g008997 Figure 72 1. Front tie downs Rear of the machine—on the bumper (Figure 73) g009005 Figure 73 1. Rear tie downs 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.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Important: Refer to your engine owner's manual for additional maintenance procedures. Important: 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 46).
Maintenance Service Interval Every 100 hours Every 250 hours Maintenance Procedure • Inspect the cooling-system hoses. • • • • • • Check the wheel-lug nuts. Check and clean the air-cleaner filter elements. Replace if damaged. Check the whole air-intake system for leaks, damage, or loose hose clamps. Check the 12 V alternator-belt tension. Clean the cab air filters; replace them if they are torn or excessively dirty.
Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Maintenance Check Item Monday Tuesday Wednesday Thursday Friday Saturday Sunday 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 hydraulic-oil-cooler screens for debris and blow out with compressed air.
Pre-Maintenance Procedures Raising the Machine Use the following as points to jack up the machine: Front of the machine—on the frame, on the inside of each drive tire (Figure 75) Using the Battery-Disconnect Switch Open the hood to access the battery-disconnect switch. Turn the battery-disconnect switch to the ON or OFF position to perform the following: • To energize the machine electrically, rotate the battery-disconnect switch clockwise to the ON position (Figure 74).
Removing and Installing the Inner-Wing-Deck Covers Removing the Inner-Wing-Deck Covers 1. Lower the wing deck onto a level surface. 2. Disengage the cover latch. 3. Remove the bolt securing the belt cover (if equipped). 4. Lift the rear and inside cover edges off the mounting posts (Figure 77). g013894 Figure 79 1. Slide the cover out between the lift arm and roller. Installing the Inner-Wing-Deck Covers 1. Lower the wing deck onto a level surface. 2.
Lubrication Traction Unit • 2 impact arms (Figure 80) • 2 front deck-lift-cylinder pivots (Figure 80) Greasing the Bearings and Bushings • 2 side deck-lift-cylinder pivots (Figure 80) • 4 steering-cylinder-ball joints (Figure 81) Service Interval: Every 50 hours—Lubricate all grease fittings. • 2 tie-rod-ball joints (Figure 81) • 2 king-pin bushings (Figure 81) The machine has grease fittings that you must lubricate regularly with No. 2 lithium grease.
Front Cutting Unit • 3 spindle-shaft bearings (located on the spindle • 2 caster-fork-shaft bushings (Figure 83) • 5 spindle-shaft bearings (located on the spindle • 2 idler-arm-pivot bushings (located on the housing) as shown in Figure 85 idler-pivot shaft) as shown in Figure 85 housing) as shown in Figure 83 • 3 idler-arm-pivot bushings (located on the idler-pivot shaft) as shown in Figure 83 • 4 winglet-deck bushings (located on the winglet-pivot pins) as shown in Figure 83 g009151 Figure 85 g03
Engine Maintenance Important: Do not directly contact the engine-control unit (ECU) or electrical connectors with water, as this may cause damage; refer to Figure 87 for the ECU and electrical connections location. g021157 Figure 88 Servicing the Air-Cleaner Cover g033303 Service Interval: Every 50 hours—Remove the air-cleaner cover and clean out the debris. Do not remove the filter. Figure 87 Located on the left side of the machine under the hood 1.
Servicing the Air-Cleaner Filter Elements Note: Do not clean the used element due to the possibility of damage to the filter media. Note: Replace the secondary filter every 3 primary filter services (Figure 92). Service Interval: Every 250 hours—Check and clean the air-cleaner filter elements. Replace if damaged. Every 250 hours—Check the whole air-intake system for leaks, damage, or loose hose clamps. Every 500 hours—Replace the air-cleaner filter elements.
the 5 o’clock and 7 o’clock position when viewed from the end. 10. Secure the cover latches. Servicing the Engine Oil Oil Specification Use high-quality, low-ash engine oil that meets or exceeds the following specifications: • API service category CJ-4 or higher • ACEA service category E6 • JASO service category DH-2 Important: Using engine oil other than API CJ-4 or higher, ACEA E6, or JASO DH-2 may cause the diesel particulate filter to plug or cause engine damage.
g031260 g031551 g031336 Figure 94 4. Change the engine-oil filter (Figure 95). Note: Ensure that the oil-filter gasket touches g031261 Figure 95 the engine, and then an extra 3/4 turn is completed.
Adjusting the Engine-Valve Clearance Inspecting and Cleaning Engine-Emission-Control Components and Turbocharger Service Interval: Every 1,000 hours Refer to your engine owner’s manual for the adjustment procedure. Service Interval: Every 3,000 hours Cleaning the Engine EGR Cooler For information on inspecting and cleaning the engine-emission-control components, refer to your engine operator’s manual.
Fuel System Maintenance Servicing the Fuel System Service Interval: Every 3,000 hours Draining the Fuel Tank g243500 Service Interval: Every 800 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.
Replacing the Fuel Filter Element Service Interval: Every 500 hours—Replace the fuel-filter element. 1. Clean the area around the fuel-filter head (Figure 99). g031733 Figure 98 1. Vent plug 3. Drain valve 2. Water separator/filter 3. Tighten the valve after draining. g031734 Figure 99 Replacing the Water-Separator Element 1. Fuel-filter head 2. Filter 1. Place a clean container under the water separator. 2. 2.
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.
g032673 g033314 Figure 106 Figure 103 1. Cab fuse box 1. Fuse block g033290 Figure 104 1. Fuse block 2. Power leads The cab fuses (Figure 105) are located in the fuse box on the cab headliner (Figure 106). g031740 Figure 105 75 2.
Charging the Batteries WARNING Charging the batteries produces gasses that can explode. Do not smoke near the battery, and keep sparks and flames away from the batteries. Note: This procedure is for charging the 12 V system. Important: Keep the batteries fully charged. This is especially important to prevent battery damage when the temperature is below 32°F (0°C). 1. 2. 3. Perform the pre-maintenance procedure; refer to Pre-Maintenance Procedures (page 63).
1. 2. Removing the Batteries Park the machine on a level surface, engage the parking brake, lower the cutting deck, and shut off the engine. Sit in the operator seat and have the other person make the connections. Note: Ensure that the jumper battery is a 12V battery. 1. Open the hood and turn the battery-disconnect switch to the OFF position. 2. Remove the three 3 flange screws from each side of the rear bumper as shown in Figure 110. 3.
g199826 Figure 112 1. Rear shroud 6. 2. Flange screw Remove the fasteners that secure the battery cover to the machine and remove the cover (Figure 113). Note: Make note of how and where the battery cables are installed. 7. Loosen and remove the battery cables from the batteries. 8. Remove the fasteners that secure the battery-hold downs. 9. Carefully remove the batteries from the machine (Figure 113). g199822 Figure 113 1. Battery cover 6. Cable assembly (for 24 VDC system) 2.
Installing the Batteries 1. Secure the batteries with the hold downs (Figure 113). 2. Install the battery cables. 3. Position the battery cover in place and secure it with the removed fasteners. 4. Install the rear shroud (Figure 112). 5. Install the side shrouds (Figure 111). 6. Raise the rear bumper into position and install the flange screws. Tighten all the flange screws securing the rear bumper to the frame (Figure 110). 7. Turn the battery-disconnect switch to the ON position.
Checking the Rear Wheel Toe-In Cooling System Maintenance Service Interval: Every 1,000 hours—Check the rear wheel toe-in. 1. Cooling System Safety With the rear tires in a straight position, measure the outside distance (at axle height) at the front and rear of the rear tires (Figure 115). • Swallowing engine coolant can cause poisoning; keep out of reach from children and pets.
Cleaning the Cooling Systems CAUTION If the engine has been running, the pressurized, hot coolant can escape and cause burns. Service Interval: Before each use or daily • Do not open the radiator cap when the engine is running. Perform the pre-maintenance procedure; refer to Maintenance Safety (page 60). • Use a rag when opening the radiator cap, and open the cap slowly to allow steam to escape. Important: Do not use water to clean the radiator core or hydraulic-fluid-cooler core.
g033289 Figure 120 1. Hydraulic-fluid cooler g033277 1. Prop rod 3. Prop rod 2. Hydraulic-cooling fans Figure 118 3. Radiator 2. Engine-cooling fans Changing the Engine-CoolingSystem Fluid Cleaning the Hydraulic-Fluid Cooler 1. Raise the hood to the fully-open position. 2. Pivot the hydraulic-cooling fans upward and lock the prop rod into the notch (Figure 119). Service Interval: Every 2,000 hours/Every 2 years (whichever comes first)—Flush the engine-cooling system and replace the fluid.
g034935 Figure 123 1. Coolant hose g031321 Figure 121 1. Drain valve 2. Radiator drain hose After draining the engine coolant, close the drain valve on the radiator drain hose and connect the coolant hose. 9. Remove the cap of the expansion tank and fill it to the Low mark with engine coolant. Install the cap. 3. Radiator 4. Close the valve on the radiator drain hose (Figure 121). 5. Fill the radiator with coolant until the coolant level even with the lip of the filler port (Figure 122).
Belt Maintenance Servicing the 12 V Alternator Belt Service Interval: After the first 50 hours Every 250 hours Refer to the engine owner's manual (included with the machine) for the servicing procedure. Servicing the 24 V Alternator Belt and AC Compressor Belt Service Interval: After the first 10 hours Every 1,000 hours g009014 The AC compressor and 24 V alternator belt uses a spring-loaded tensioner that is pre-set at the factory. Refer to the Toro Service Manual for the servicing procedure.
8. Route the new belt around the spindle pulleys and idler-pulley assembly (Figure 126). 114-0922 decal114-0922nc Figure 126 9. 10. Adjust the stop screw on the idler pulley and tighten the jam nuts. Install the belt covers. g009009 Figure 127 Replacing the Wing Cutting-Unit Belts 1. Idler pulleys Note: To remove the lower belt, you must remove 6. Remove the old belt from around the spindle pulleys and idler pulley. 7.
Hydraulic System Maintenance High Viscosity Index/Low Pour Point Anti-wear Hydraulic Fluid, ISO VG 46 (cont'd.) 140 or higher Hydraulic System Safety Viscosity Index ASTM D2270 • Seek immediate medical attention if fluid is injected Pour Point, ASTM D97 into skin. Injected fluid must be surgically removed within a few hours by a doctor.
1. 2. 3. 4. g031318 Figure 130 Every 800 hours—If you are not using the recommended hydraulic fluid or have ever filled the reservoir with an alternative fluid, change the hydraulic fluid. Park the machine on a level surface, engage the parking brake, lower the cutting deck, shut off the engine, and remove the key. Place a large drain pan under the hydraulic-fluid tank. Remove the hydraulic-tank cap and dipstick.
Checking the Hydraulic Lines and Hoses hydraulic fluid, replace the hydraulic filter (sooner if the service interval indicator is in the red zone). Every 800 hours—If you are not using the recommended hydraulic fluid or have ever filled the reservoir with an alternative fluid, replace the hydraulic filter (sooner if the service interval indicator is in the red zone). Service Interval: Every 2 years WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury.
Cutting Unit Maintenance 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. Raise the front cutting unit slightly off the floor, engage the parking brake, shut off the engine, and remove the key. 2. Perform the pre-maintenance procedure; refer to Pre-Maintenance Procedures (page 63). 3.
Pivoting (Tilting) the Front Cutting-Unit Down 1. With the help of another person holding the front of the cutting unit, remove the block of wood. 2. Sit on the seat, start the engine, and lower the cutting unit until it is slightly off the floor. 3. Secure the height-of-cut chains to the rear of the cutting unit. 4. Connect the damper assembly and secure it with the retainer clip. 3. Measure from the floor to the back tip of the winglet blade and record this dimension. 4.
Adjusting the Wing Cutting-Unit Pitch 1. Servicing the Caster Wheels and Bearings Remove the tensioning cap from the caster-spindle shaft and slide the spindle out of the caster arm (Figure 138). Service Interval: Every 500 hours—Inspect the cutting unit caster-wheel assemblies. 1. Remove the locknut from the bolt holding the caster-wheel assembly between the caster fork or the caster-pivot arm (Figure 139). g008866 Figure 138 1. Tensioning cap 4. Top axle-mounting hole 2. Spacers 5.
Blade Maintenance 1. Blade Safety 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. Note: Block the cutting unit to prevent it from accidentally falling. • 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. 2.
Inspecting and Sharpening a Blade Service Interval: After the first 10 hours Every 50 hours g000276 Before each use or daily Figure 143 Both cutting edges and the sail, which is the turned-up portion opposite of the cutting edge, contribute to a good quality of cut. The sail lifts the grass up straight, thereby producing an even cut. However, the sail gradually wears down during operation, degrading the quality of cut, although the cutting edges remain sharp.
Cab Maintenance Cleaning the Cab Important: Use care around the cab seals and lights (Figure 144). If you are using a pressure washer, keep the washer wand at least 0.6 m (2 ft) away from the machine. Do not use the pressure washer directly on the cab seals and lights or under the rear overhang. g028378 Figure 145 In-Cab Air Filter 1. Filter 2. Grate 3. Screw g034330 Figure 144 1. Seal 2. Light 3. Keep wand 0.6 m (2 ft) away. g028379 Figure 146 Rear Cab Air Filter 4.
Cleaning the Cab Pre-Filter The cab pre-filter prevents large debris, such as grass and leaves, from entering the cab filters. 1. Rotate the screen cover down. 2. Clean the filter with water. Important: Do not use a pressure washer. Note: If the filter has a hole, tear, or other damage, replace the filter. 3. Allow the pre-filter to dry before installing it into the machine. 4. Rotate the filter screen around the tabs until the latch locks into the latch-mount assembly (Figure 147).
Storage 2. Remove and discard the oil filter. Install a new oil filter. Storage Safety 3. Refill the oil pan with designated quantity of motor oil. • Shut off the engine, remove the key, and wait 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.
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 Conditions and Products Covered Parts The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial product (“Product”) to be free from defects in materials or workmanship for 2 years or 1,500 operational hours*, whichever occurs first. This warranty is applicable to all products with the exception of Aerators (refer to separate warranty statements for these products).
