Form No. 3420-880 Rev C Groundsmaster® 5900 or 5910 Rotary Mower Model No. 31698—Serial No. 401420001 and Up Model No. 31699—Serial No. 401420001 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. Dealer or Toro Customer Service and have the model and serial numbers of your product ready. Figure 1 identifies the location of the model and serial numbers on the product. Write the numbers in the space provided.
Contents Pushing or Towing the Machine ........................ 56 Identifying the Tie-Down Points ........................ 57 Hauling the Machine ......................................... 57 Maintenance ........................................................... 58 Maintenance Safety.......................................... 58 Recommended Maintenance Schedule(s) ........... 58 Daily Maintenance Checklist............................. 59 Pre-Maintenance Procedures ..............................
Safety Hydraulic System Maintenance ........................... 84 Hydraulic System Safety................................... 84 Checking the Hydraulic Fluid ............................ 84 Changing the Hydraulic Fluid and Filters ............................................................ 85 Checking the Hydraulic Lines and Hoses............................................................ 86 Inspecting the Hydraulic System Test Ports .............................................................
Engine-Emission Certification The engine in this machine is EPA Tier 4 Final and EU Stage 3b emissions compliant. Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or missing. 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.
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 decal117-4979 117-4979 1. Entanglement hazard, belt—stay away from moving parts; keep all guards and shields in place.
decal133-5618 133-5618 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 decal127-0392 127-0392 1. Warning—keep away from hot surfaces. 1.
decal125-9688 125-9688 Model with Cab Only 1. Windshield wipers—off 3. Windshield wipers—on 2. Windshield wipers 4. Spray windshield washer fluid decal133-0980 133-0980 Model with Cab Only 1. Head light—on 4. Overhead light—off 2. Head light—off 5. Wipers—off 3. Overhead light—on 6. Wiper fluid—on decal130-5986 130-5986 Model with Cab Only 1. On 2. Beacon 3. Off decal133-1027 133-1027 Model with Cab Only 1. Fan—maximum 8 2.
decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. Keep bystanders a safe distance 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. decal136-0006 136-0006 1.
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.
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.
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 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 seat belt when seated in the operator's position. 4. Warning—wear hearing protection. 5.
decal132-3600 132-3600 Model with Cab Only decal132-1315 132-1315 1. Read the Operator's Manual for more information on fuses. 2. 24V system 5. 24V alt/terminal diode 3. Cab 7. ECU power (25 A) 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) 6. 24V enable relay (5 A) 4.
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. Upper caster position—heights of cut 25 to 102 cm (1 to 4 inches) decal131-6025 131-6025 1. Height of cut decal132-1313 132-1313 decal131-6026 131-6026 1. Height of cut 14 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.
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. 2.
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 deck. No parts required – Level the winglet decks to the front, center deck. No parts required – Check the fluid levels.
g008868 Figure 4 g009013 Figure 3 1. Winglet 4. Eccentric 2. Hinge pin 5. Upper hole 3. Stop bolt 6. Deck mounts 1. Winglet 4. Eccentric 2. Hinge pin 5. Lower hole 3. Bolt 5. 2. Note: Do not tighten the nuts at this time. While supporting the right winglet, remove the front and rear stop bolts from the deck mounts (Figure 3). Note: Leave the eccentrics positioned between Lower the winglet to the operating position. 4.
8. 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. 4 Leveling the Front, Center Deck Install the winglet-deck cover and secure it with the rubber latch (Figure 6). Note: Ensure that you slide the cover under the 9. front, center deck-cover tabs before inserting it onto the mounting hooks and post. No Parts Required Repeat this procedure on the other winglet.
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.
Product Overview g031657 Figure 9 1. Wing mower deck 5. Fuel tank 2. Control panel 6. Steering wheel 3. Roll bar 4. Hood 7. Front mower deck 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 10). 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 10). PTO Switch The PTO switch has 2 positions: OUT (start) and IN (stop).
Throttle Switch The throttle switch has 2 positions: IDLE (Figure 10). Cab Controls LOW IDLE For Machines with a Cab and HIGH 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. Light Switch Press the light switch upward to turn the lights to the ON position (Figure 10).
position. Pull out and down on the latch to close and secure the windshield. g196911 Figure 12 1. Windshield latch Rear Window Latch Lift up the latches to open the rear window. Press in on the latch to lock the window in OPEN position. Pull out and down on the latch to close and secure the window (Figure 12). Important: Close the rear window before opening the hood or damage may occur to the hood or rear window.
Specifications Note: Specifications and design are subject to change without notice. g200003 Figure 13 Description Figure 13 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.
Checking the Engine-Oil Level Operation Note: Determine the left and right sides of the machine from the normal operating position. Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking the Engine-Oil Level (page 67).
Adding Fuel Fuel Table Diesel fuel specification Location ASTM D975 No. 1-D S15 1. Park the machine on a level surface (Figure 14). 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. 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.
Checking the Tire Pressure 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. 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 15. Torque the front and rear-wheel nuts to 135 to 150 N·m (100 to 110 ft-lb) according to the maintenance schedule.
g031661 Figure 17 1. Tensioning cap 4. Top axle-mounting hole 2. Spacers (6) 5. Caster wheel 3. Shims (2 top and 2 bottom) g008979 5. Figure 18 Slide the appropriate number of spacers onto the shaft to get the desired height of cut. 1. Height-of-cut chain Note: Refer to the chart to determine the combinations of spacers for the setting (Figure 16). 10.
Adjusting the Wing Mower Decks 1. Start the engine and raise the mower decks so you can change the height of cut. 2. Shut off the engine and remove the key after you raise the mower deck. 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 20).
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 22). g202202 Important: Torque the screw at the front of each inner skid to 9 to 11 N·m (80 to 100 in-lb).
Adjusting the Mower Deck Anti-Scalp Rollers Correcting a Mismatch Between the Mower Decks 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). 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.
Matching the Height of Cut Between Mower Decks 1. Position the blade side to side on the outside spindle of both wing mower decks. 2. Measure from the floor to the tip of the cutting edge on both units and compare the measurements. Note: These numbers should be within 3 mm (1/8 inch) of each other. Make no adjustment at this time. 3. 4. Position the blade side to side on the inside spindle of the wing mower deck and the corresponding outside spindle of the front mower deck.
Note: Check the measurement between the outside edges of both wing mower decks and the inside edge of the wing mower deck to the outside edge of the front mower deck again. 8. 9. If the inside edge is still too low, add an additional shim to the bottom of front, inside caster arm of the wing mower deck and 1 shim to the front, outside caster arm of the wing mower deck. 3. Mount a magnetic protractor onto the plate. 4.
Checking the PTO Safety-Interlock Function 1. Start the engine. 2. With the engine running, rise from the seat and engage the PTO. During Operation During Operation Safety General Safety Note: The PTO should not engage. If it does • The owner/operator can prevent and is responsible engage, there is a malfunction in the interlock system that you should correct before resuming operation. 3. Sit on the seat and disengage the PTO. 4. With the engine running, engage the PTO and rise from the seat.
– Disengage the power takeoff and lower the attachments. it 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. – Engage the parking brake. • Avoid starting, stopping, or turning the machine on – Shut off the engine and remove the key. slopes. Avoid making sudden changes in speed or direction. Make turns slowly and gradually. – Wait for all moving parts to stop.
Starting the Engine the engine at low idle or transporting the machine into or out of a building), you will not be able raise all the mower decks at once. Instead, you can only raise 1 mower deck at a time. 1. Ensure that the parking brake is engaged. 2. Remove your foot from the traction pedal and ensure that it is in the NEUTRAL position. 3. Turn the ignition key to the RUN position. 4. When the glow indicator dims, turn the ignition key to the START position. 5.
Diesel Particulate Filter Regeneration 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. 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. • When enough soot accumulates, the computer informs you that it is time to regenerate the DPF.
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 69) 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 36) The state and soot load information displays. • Use the DPF operation table to understand the current state of DPF operation (Figure 37). g241812 Figure 35 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 41). 3. Press the button 4 to change the inhibit regeneration setting from On to Off (Figure 42) or from Off to On.
g241833 Figure 44 g243501 Note: When the reset regeneration completes, the high exhaust-temperature InfoCenter screen. Figure 46 disappears from the • Parked regeneration required ADVISORY #1212 (Figure 47) 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 45) 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 49) g241848 g241999 Figure 49 Important: Perform a recovery regeneration to restore the PTO function; refer to Preparing to Perform a Parked or Recovery Regeneration (page 47) and Performing a 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 53 4. Figure 54 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 54). 5. 48 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 55).
g241898 g241900 g241899 g241901 Figure 55 6. Figure 56 At the INITIATE DPF REGEN screen, press the button 4 to continue (Figure 56). 7. The InfoCenter displays the INITIATING DPF REGEN message (Figure 57). Note: If needed, press button 4 to cancel the regeneration process.
g241912 g241914 g241913 g241915 Figure 57 8. Figure 58 The InfoCenter displays the time to complete message (Figure 58). 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 59) 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 59 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 63). g242002 g241969 Figure 61 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 63 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 62).
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 between narrow objects so that you do not damage the machine or mower decks. • Always drive slowly in rough areas. • If an obstacle is in the way, lift the mower decks The hydraulic-fan speed is controlled by hydraulic-fluid temperature. The radiator-fan speed is controlled by the engine-coolant temperature. A reverse cycle automatically initiates both fans when either the engine coolant or hydraulic-fluid temperature reaches a certain point.
After Operation to avoid removing more than 25 mm (1 inch) of growth per cutting. When you cut too much growth with the mulching baffles installed, the after-cut appearance may deteriorate and the observed power to cut the turf increases. The mulching baffles also perform well for shredding leaves in the fall. After Operation Safety • Clean grass and debris from the cutting units, mufflers, and engine compartment to help prevent fires. Clean up oil or fuel spills.
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. g021158 Figure 67 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 69) g008997 Figure 69 1. Front tie downs Rear of the machine—on the bumper (Figure 70) g009005 Figure 70 1. Rear tie downs Hauling the Machine • Remove the key and shut off the fuel (if equipped) before storing or transporting 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. Maintenance Safety – Allow machine components to cool before performing maintenance. • Before adjusting, cleaning, repairing, or leaving the machine, do the following: – Park the machine on a level surface. – Move the throttle switch to the low-idle position. – Disengage the cutting units. – Lower the cutting units.
Maintenance Service Interval Maintenance Procedure Every 500 hours • • • • Change the engine oil and engine-oil filter. Inspect the fuel lines and connections. Replace the fuel-filter element. Inspect the mower deck caster-wheel assemblies. Every 800 hours • Drain and clean the fuel tank. Every 1,000 hours • • • • • • • • Every 1,500 hours • Clean the engine EGR cooler. • Inspect the engine crankcase-breather system.
For the week of: Maintenance Check Item Monday Tuesday Wednesday Thursday Friday Saturday Sunday Check the hydraulic hoses for damage. Check for fluid leaks. Check the fuel level. Check the tire and caster pressure. Check the instrument operation. Check the height-of-cut adjustment. Lubricate all of the grease fittings.2 Touch up any damaged paint. 1Check the glow plug, injector nozzles and engine air filters if starting is hard, there is excess smoke, or rough running is noted.
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 72) 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 71).
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 74). g013894 Figure 76 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 77) • 2 front deck-lift-cylinder pivots (Figure 77) Greasing the Bearings and Bushings • 2 side deck-lift-cylinder pivots (Figure 77) • 4 steering-cylinder-ball joints (Figure 78) Service Interval: Every 50 hours—Lubricate all grease fittings. • 2 tie-rod-ball joints (Figure 78) • 2 king-pin bushings (Figure 78) The machine has grease fittings that you must lubricate regularly with No. 2 lithium grease.
Front Mower Deck • 3 spindle-shaft bearings (located on the spindle • 2 caster-fork-shaft bushings (Figure 80) • 5 spindle-shaft bearings (located on the spindle • 2 idler-arm-pivot bushings (located on the housing) as shown in Figure 82 idler-pivot shaft) as shown in Figure 82 housing) as shown in Figure 80 • 3 idler-arm-pivot bushings (located on the idler-pivot shaft) as shown in Figure 80 • 4 winglet-deck bushings (located on the winglet-pivot pins) as shown in Figure 80 g009151 Figure 82 g0332
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 84 for the ECU and electrical connections location. g021157 Figure 85 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 84 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 89). Service Interval: Every 400 hours—Check the air-cleaner body for damage which could cause an air leak. Replace if damaged. Every 400 hours—Check the whole air-intake system for leaks, damage, or loose hose clamps.
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 91 4. Change the engine-oil filter (Figure 92). Note: Ensure that the oil-filter gasket touches g031261 Figure 92 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 Draining the Fuel Tank Service Interval: Every 800 hours—Drain and clean the fuel tank. g243500 Drain and clean the tank also if the fuel system becomes contaminated or if you are storing the machine for an extended period of time. Use clean fuel to flush out the tank. Inspecting the Fuel Lines and Connections Service Interval: Every 500 hours—Inspect the fuel lines and connections.
3. Replacing the Fuel Filter Element Tighten the valve after draining. Replacing the Water-Separator Element 1. Place a clean container under the water separator. 2. Drain some fuel by loosening the vent plug and opening the drain valve (Figure 95). 3. Clean the area where the filter element mounts to the head. 4. Remove the filter element. 5. Apply a coating of clean fuel or engine oil to the new O-ring and element seal. 6.
Electrical System Maintenance Electrical System Safety WARNING CALIFORNIA Proposition 65 Warning Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. decal136-0006 • Disconnect the battery before repairing the Figure 97 machine. Disconnect the negative terminal first and the positive last. Connect the positive terminal first and the negative last.
g032673 g033314 Figure 103 Figure 100 1. Cab fuse box 1. Fuse block 2. Fuses Checking the Condition of the Batteries Service Interval: Every 50 hours—Check the condition of the batteries. Important: Before welding on the machine, disconnect the battery to prevent damage to the electrical system. Also, you must disconnect the engine controller, InfoCenter, and machine controllers before welding on the machine. g033290 Figure 101 1.
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 61).
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 107. 3.
g199826 Figure 109 1. Rear shroud 6. 2. Flange screw Remove the fasteners that secure the battery cover to the machine and remove the cover (Figure 110). 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 110). g199822 Figure 110 1. Battery cover 6. Cable assembly (for 24 VDC system) 2.
Installing the Batteries 1. Secure the batteries with the hold downs (Figure 110). 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 109). 5. Install the side shrouds (Figure 108). 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 107). 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 112). • 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 Pre-Maintenance Procedures (page 61). • 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 117 1. Hydraulic-fluid cooler g033277 1. Prop rod 3. Prop rod 2. Hydraulic-cooling fans Figure 115 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 116). Service Interval: Every 1,000 hours—Flush the engine-cooling system and replace the fluid.
g034935 Figure 120 1. Coolant hose g031321 Figure 118 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 118). 5. Fill the radiator with coolant until the coolant level even with the lip of the filler port (Figure 119).
Belt Maintenance Servicing the 12 V Alternator Belt Service Interval: After the first 10 hours Every 1,000 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 123). 114-0922 decal114-0922nc Figure 123 9. 10. Adjust the stop screw on the idler pulley and tighten the jam nuts. Install the belt covers. g009009 Figure 124 Replacing the Wing Mower-Deck 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 Material Properties: Viscosity, ASTM D445 St @ 40°C 42 to 50 Hydraulic System Safety St @ 100°C 7.6 to 8.5 • Seek immediate medical attention if fluid is injected into skin. Injected fluid must be surgically removed within a few hours by a doctor.
5. Remove the dipstick from the filler neck and wipe it with a clean rag. Insert the dipstick into the filler neck, then remove it and check the fluid level (Figure 128). Note: The fluid level should be within the safe operating range on the dipstick. g031319 Figure 129 1. Hydraulic filters g009240 5. Install the drain plug when the hydraulic fluid stops draining. 6. Clean the area around the filter-mounting areas. 7. Place a drain pan under the filter and remove the filter (Figure 129). 8.
Checking the Hydraulic Lines and Hoses Cutting Unit Maintenance Service Interval: Every 2 years—Replace moving hydraulic lines and hoses. Pivoting (Tilting) the Front Mower Deck Upright Inspect the hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration, and chemical deterioration. Make all necessary repairs before operating the machine.
4. Connect the damper assembly and secure it with the retainer clip. Adjusting the Mower-Deck Pitch Measuring the Mower-Deck Pitch The mower-deck pitch is the difference between the height of cut from the front tip of the blade to the back tip. Set a blade pitch of 6.3 to 9.7 mm (0.25 to 0.38 inch); i.e., the back tip of the blade should be 7.5 mm (0.3 inch) higher than the front tip. 1.
Adjusting the Wing Mower-Deck Pitch 1. Remove the tensioning cap from the caster-spindle shaft and slide the spindle out of the caster arm (Figure 135). g009012 g008866 Figure 134 1. Height-of-cut chain Figure 135 3. Nut (2) 2. U-bolt 1. Tensioning cap 4. Top axle-mounting hole 2. Spacers 5. Caster wheel 3. Shims 6. 7. Adjust the other set of nuts to raise or lower the rear of the mower deck and attain the correct mower-deck pitch based on the average pitch of each blade. 2.
Blade Maintenance Servicing the Caster Wheels and Bearings Blade Safety Service Interval: Every 500 hours—Inspect the mower deck caster-wheel assemblies. 1. A worn or damaged blade can break, and a piece of the blade could be thrown toward you or bystanders, resulting in serious personal injury or death. Remove the locknut from the bolt holding the caster-wheel assembly between the caster fork or the caster-pivot arm (Figure 136). • Inspect the blade periodically for wear or damage.
Removing and Installing a Blade Inspecting and Sharpening a Blade Replace the blade if it hits a solid object, if it is out of balance, or if it is bent. Always use genuine Toro replacement blades to be sure of safety and optimum performance. Never use replacement blades made by other manufacturers because they could be dangerous. Service Interval: After the first 10 hours 1. Raise the mower deck to the highest position. 2.
Cab Maintenance Cleaning the Cab For Machines with a Cab g000276 Important: Use care around the cab seals and Figure 140 lights (Figure 141). 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. 1. Sharpen at the original angle. Note: Sharpen only the top of the cutting edge and maintain the original cutting angle to ensure the sharpness.
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 144).
Storage Preparing the Machine for Storage Preparing the Traction Unit 1. g032323 Figure 145 Right fan shown 1. Fan 2. Wire 2. 3. Knob 3. 3. Remove the 2 knobs and remove the fan assembly. 4. Open the 4 latches on the air-conditioning assembly and remove the screen. 4. 5. 6. g032324 Figure 146 1. Air-conditioning coil 3. Air-conditioning screen 2. Latch 5. Remove the air filters (see Figure 143). 6. Clean the air-conditioning assembly. 7.
9. Seal the air-cleaner inlet and the exhaust outlet with weatherproof tape. 10. Check the anti-freeze protection and add a 50/50 solution of water and ethylene glycol anti-freeze as needed for the expected minimum temperature in your area.
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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 A Two-Year Limited Warranty Conditions and Products Covered 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 two years or 1500 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).
