Form No. 3403-582 Rev B Groundsmaster® 5900 and 5910 Rotary Mower Model No. 31698—Serial No. 316000001 and Up Model No. 31699—Serial No. 316000001 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. WARNING CALIFORNIA Proposition 65 Warning This product contains a chemical or chemicals known to the State of California to cause cancer, birth defects, or reproductive harm. Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
Contents Operating Tips ................................................. 57 After Operation .................................................... 58 After Operation Safety ...................................... 58 Pushing or Towing the Machine ........................ 58 Identifying the Tie-Down Points ........................ 59 Hauling the Machine ......................................... 59 Maintenance ........................................................... 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 Checking the Hydraulic Fluid ............................ 86 Changing the Hydraulic Fluid and Filters ............................................................ 87 Checking the Hydraulic Lines and Hoses..............
Vibration Level Sound power level was determined according to the procedures outlined in ISO 11094. Hand-Arm Sound Pressure Level Model 31698 Model 31698 Measured vibration level for right hand = 0.8 m/s2 This unit has a sound pressure level at the operator’s ear of 90 dBA, which includes an Uncertainty Value (K) of 1.0 dBA. Measured vibration level for left hand = 1.0 m/s2 Sound pressure level was determined according to the procedures outlined in EN ISO 5395:2013.
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 lost. decal117-4766 117-4766 1. Cutting/dismemberment hazard, fan—stay away from moving parts; keep all guards and shields in place. decal117-3276 117-3276 decal114-0849 1. Engine coolant under pressure 3. Warning—do not touch the hot surface. 2. Explosion hazard—read the Operator's Manual. 4.
decal93-6674 93-6674 1. Crushing hazard, hand—read the instructions before servicing or performing maintenance. decal93-6687 93-6687 1. Do not step here. 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. decal120-6604 120-6604 decal93-7818 93-7818 1. Thrown object hazard—keep bystanders away from the machine. 2.
114-0922 decal114-4883 decal114-0922 114-4883 114-0922 1. Belt routing 1. Belt routing decal117-2718 117-2718 decal114-0974 114-0974 1. Belt routing 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. Thrown object hazard—keep bystanders a safe distance from the machine. 6.
decal93-6686 93-6686 1. Hydraulic oil 2. Read the Operator's Manual. decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 6. Keep bystanders a safe distance 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.
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) Set 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) Set 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.
decal132-3600 132-3600 Model with Cab Only 1. Read the Operator's Manual for more information on fuses. 2. Headlight—25 A 3. Condenser fan and A/C clutch—30 A 4. Fan—25 A 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 5. Working light—20 A 6. Auxiliary power—15 A 7. Cab light—15 A 8. Windshield wipers—15 A 6. 24V enable relay—5 A 4. Platform decal121-8378 121-8378 Model with Cab Only 1.
decal132-1314 132-1314 1. Resistor (2k Ohm) 13. Working light—10 A 2. TEC power diode 14. Head light—15 A 3. RAD diode 15. Ignition—10 A 4. HOC diode 16. Cigarette lighter—10 A 5. RAD fan fault 6. Contactor latch (24 V) 17. Electric seat—10 A 18. PTO—10 A 7. HOC fan fault 8. Load shed enable 19. Horn—30 A 20. Hazard light—10 A 9. Master—7.5 A 21. Telematics power—2 A 10. Logic power/master—2 A 22. Infocenter—2 A 11. Slave—7.5 A 23. For more information on fuses, read the Operator’s Manual.
decal131-2347 131-2347 9. Pull up to turn on the cutting 13. Lower the right cutting unit. unit. 10. Push down to turn off the 14. Cruise control—set cutting unit. 1. Left-turn signal 5. Engine speed—fast 2. Right-turn signal 6. Engine speed—slow 3. Beacon 7. Transmission—high range 11. Lower the left cutting unit. 4. Work light 8. Transmission—low range 12. Lower the center cutting unit. decal131-2349 131-2349 1. Raise the left cutting unit. 4. Cruise control—off 2.
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 15 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 will release 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.
Note: Ensure that the stop bolt engages the tab 2 on the hinge pin. 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. Eccentric 2. Hinge pin 5. Lower hole 3. Bolt 5. Install the nuts securing the stop bolts. Note: Do not tighten the nuts at this time. 6.
B. Using a ratchet wrench or a similar tool, move the idler pulley away from the pulleys (Figure 5). tire size between the front and rear tires. Only use genuine Toro tires. C. Route the belt around the winglet-spindle pulley and the upper-spindle pulley on the front deck. 4 D. Release the idler pulley to put tension on the belt. Leveling the Front, Center Deck 8. 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 1. Check the engine-oil level before starting the engine; refer to Checking the Engine-Oil Level (page 71). 2.
Product Overview g031657 Figure 9 1. Wing mower deck 5. Fuel tank 2. Control panel 6. Steering wheel 3. Rollover-Protection System (ROPS) 7. Front mower deck 4. Hood 8.
Controls Key Switch Note: Determine the left and right sides of the The key switch has 3 positions: STOP, RUN/PREHEAT , and START (Figure 10). machine from the normal operating position. High-Low Range-Speed Switch Press the front of the switch to select HIGH-SPEED RANGE. Press the rear of the switch to select LOW-SPEED RANGE. The machine must be stationary or traveling at less than 1.0 km/h (0.6 mph) to shift between HIGH and LOW (Figure 10).
Cab Controls Throttle Switch The throttle switch has 2 positions: IDLE (Figure 10). LOW IDLE Model 31699 Only 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.
InfoCenter Control Pull out and down on latch to close and secure wind shield. Start-Up Screen When you start the machine, the start-up screen appears, displaying the corresponding icons that apply (i.e., the parking brake is applied, the PTO is in the ON position, cruise control is in the ON position). Note: The following figure is an example screen; this screen is meant to show all of the potential icons that could appear on the screen while operating.
2 1 G033146 g033146 Figure 16 1. Tachometer 1 2 3 5 6 4 7 8 9 10 • 12 V battery-voltage indicator—top, left screen G033145 g033145 Figure 15 1. Screen 1—top, left screen 6. Audible alarm 2. Button 1 3. Screen 2—top, right screen 4. Button 2 5. Button 3 7. Button 4 8. Fault screen 2. Fuel-level indicator • (Figure 17) 24 V battery-voltage indicator—top, left screen(Figure 17) 1 2 9. Button 5 10. Exit 27.0 (24) 13.
Note: In example Figure 18, the engine-coolant Press the arrow keys to navigate the fault screen. fans are running at 50% speed in the reverse direction. Press any key to reveal the information keys on the screen. This display indicates (Figure 14) fan speed and direction. The fan speed is controlled by the hydraulic-fluid temperature or the engine-coolant temperature, and automatically reverses as needed.
Battery Voltage Main Menu This display shows both the 12 V and 24 V battery voltage (Figure 17). Press and hold the fifth button (far right) on the InfoCenter to access the main menu. From the main menu screen, you can access the Service screen, Diagnostics screen, Settings screen, or the About screen (Figure 19). Service-Due Indicator This display indicates the time until the next regular service interval. Note: After you service the machine, reset the Service Screen indicator.
G033170 G033168 g033170 g033168 Figure 22 Figure 20 6. Enter the default PIN, 5900, into the Enter PIN screen by using buttons 1 to 4 to select the digits and press button 5 to complete the PIN (Figure 23). 4. Press button 2 until you reach PIN Settings on the Display screen and press button 4 to select PIN Settings (Figure 21). G033169 g033169 G033171 Figure 21 1 2 3 4 5 g033171 Figure 23 5. From the PIN Setting screen, press button 4 to select PIN Entry (Figure 22). 1. Digit 1 4.
Changing the InfoCenter PIN 1. From the start-up screen, press and hold button 5 until the Main Menu appears (Figure 19). 2. Press button 2 until you reach Settings on the Main Menu screen and press button 4 to select Settings (Figure 19). 3. From the Settings screen, press button 4 to select Display (Figure 20). 4. Press button 2 until you reach PIN Settings on the Display screen and press button 4 to select PIN Settings (Figure 21). 5.
Changing the InfoCenter Display Brightness/Contrast 1. From the start-up screen, press button 5 to access the brightness/contrast pop-up-menu bar (Figure 27). G033179 1 g033179 Figure 28 1. Cruise-control selection G033178 1 2 3 4 4. From the Cruise Control screen, press button 1 to decrease the cruise-control speed or button 2 to increase the cruise-control speed (Figure 29). 5 g033178 Figure 27 1. Decrease brightness 4. Increase contrast 2. Increase brightness 5. Exit 3.
InfoCenter Advisories Operator advisories automatically display on the InfoCenter screen when a machine function requires additional action. For example, if you attempt to start the engine while pressing the traction pedal, an advisory displays, indicating that the traction pedal must be in the NEUTRAL position. For each advisory that occurs, there is a condition (e.g.
PTO Denied 110 Hydraulic oil too cold To engage PTO, let hydraulic oil warm up Cruise Control Denied 202 Too slow to capture cruise control Increase ground speed Deck Lower Denied 302 Can’t lower in transport To lower deck, return traction pedal to NEUTRAL Deck Lower Denied 303 Out of seat To lower deck, operator must be seated Deck Lower Denied 304 Service required To lower deck, requires service Deck Not Floating (on engine start) 402 Advise operator to press down switches To float,
Engine Advisory 1210 Engine derate due to high temperature Let engine cool Engine Advisory 1211 Engine speed restricted: hydraulic oil too cold Hydraulic oil is less than 4°C (40°F), so derate the engine speed to 1,650 rpm Fuel Level 1302 Fuel level is low Add fuel TP Not Calibrated 1402 Traction pedal is out of calibration Calibrate the traction pedal Teach 1500 Entered teach mode Entered traction pedal teach—please wait Teach 1502 Traction pedal is out of NEUTRAL Return traction ped
Deck Raise Denied 1605 Service required Contract your Toro distributor Deck Raise Denied 1606 All deck not raising together Increase the engine speed to 2,000 rpm, and the decks will raise one at a time when all 3 switches are held down simultaneously Specifications Note: Specifications and design are subject to change without notice.
Fuel Safety Operation DANGER Note: Determine the left and right sides of the In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any fuel that spills. • Never fill the fuel tank inside an enclosed trailer. • Never smoke when handling fuel, and stay away from an open flame or where fuel fumes may be ignited by a spark.
Fuel Table overfill the fuel tank. Replace the fuel-tank cap and tighten it securely. Diesel fuel specification Location Checking the Engine-Oil Level ASTM D975 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 71). EN 590 European Union ISO 8217 DMX International JIS K2204 Grade No. 2 Japan Checking the Cooling Systems KSM-2610 Korea No. 1-D S15 USA No.
Adding Fuel Checking the Tire Pressure 1. Park the machine on a level surface (Figure 31). Service Interval: Before each use or daily 2. Shut off the engine and engage the parking brake. 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 32. 3. Clean around the fuel-tank cap and remove the cap. Important: Maintain pressure in all tires to ensure a good quality of cut and proper machine performance. Do not underinflate the tires.
Checking the Torque of the Wheel-Lug Nuts Service Interval: After the first 10 hours Every 250 hours WARNING g031660 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. Figure 33 1. Caster wheel height-of-cut mounting holes Torque the front and rear-wheel nuts to 135 to 150 N·m (100 to 110 ft-lb) after 10 hours of operation. Torque the nuts every 250 hours thereafter. 2. Caster fork height-of-cut spacers 4.
Adjusting the Wing Mower Decks 8. Install the tensioning cap and tighten it with the supplied caster-cap wrench to secure the assembly (Figure 34). 1. Start the engine and raise the mower decks so you can change the height of cut. 9. Remove the hairpin cotter and clevis pin securing the height-of-cut chains to the rear of the mower deck (Figure 35). 2. Shut off the engine and remove the key after you raise the mower deck. 3.
g031661 Figure 38 1. Tensioning cap 4. Top axle-mounting hole 2. Spacers (6) 5. Caster wheel 3. Shims (2 top and 2 bottom) 5. 5. Install 2 shims onto the shaft as originally installed and slide the appropriate number of spacers onto the shaft to get the desired height of cut. g032003 Figure 39 6. Push the caster shaft through the caster arm. 7. Install the shims (as originally installed) and the remaining spacers onto the shaft. 8.
Adjusting the Mower Deck Anti-Scalp Rollers Adjusting the Outer Skids Mount the outer 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). 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).
Matching the Height of Cut Between Mower Decks Checking a Mismatch Between Mower Decks 1. Position the blade side to side on the outside spindle of both wing mower decks. 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. 2. Measure from the floor to the tip of the cutting edge on both units and compare the measurements. 1.
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. 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. 9. Once the mowing height matches at the edges of the front and wing mower decks, verify that the mower deck unit pitch is still 7.6 mm (0.
Adjusting the Mirrors Checking the Safety-Interlock Switches Model 31699 Only CAUTION Rear-View Mirror If safety-interlock switches are disconnected or damaged, the machine could potentially operate unexpectedly, causing personal injury. While sitting in the seat, adjust the rear-view mirror to attain the best view out of the rear window. Pull the lever rearward to tilt the mirror to reduce the brightness and glare of light (Figure 45). • Do not tamper with or disable the safety systems.
Checking the PTO Safety-Interlock Function During Operation During Operation Safety 1. Start the engine. 2. With the engine running, rise from the seat and engage the PTO. General Safety Note: The PTO should not engage. If it does • The owner/user can prevent and is responsible for engage, there is a malfunction in the interlock system that you should correct before resuming operation. accidents that may cause injuries to himself/herself and others and for damage to property.
Slope Safety • Slow down and use caution when making turns and crossing roads and sidewalks with the machine. Always yield the right-of-way. • Slow down the machine and use extra care on hillsides. Travel in the recommended direction on hillsides. Turf conditions can affect the stability of the machine. • Turn on the flashing warning lights on the machine whenever you travel on a public road, except where such use is prohibited by law.
Cutting Grass with the Machine OFF position, set the parking brake, and turn the ignition key to OFF. 8. Remove the key from the switch to prevent accidental starting. Note: Cutting grass at a rate that loads the engine promotes DPF regeneration. Important: Allow the engine to idle for 5 minutes before shutting it off after a full-load operation. Failure to do so may lead to turbo-charger complications. 1. Move the machine to the job site. 2. Whenever possible, set the engine-speed switch to high idle.
Diesel Particulate Filter Regeneration speed to help reduce the accumulation of soot in the soot filter. CAUTION 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. The exhaust temperature is hot (approximately 600°C (1112°F) during DPF parked regeneration or recovery regeneration. Hot exhaust gas can harm you or other people.
DPF Ash Accumulation • When enough ash accumulates, the engine • The lighter ash is discharged through the exhaust system; the heavier ash collects in the soot filter. • Ash is a residue of the regeneration process. Over • time, the diesel particulate filter accumulates ash that does not discharge with the engine exhaust. • • The computer for the engine calculates the amount of ash accumulated in the DPF.
Regeneration Unavailable Messages Unavailable Message Table Message Condition Recommended Action The engine is not running. Start the engine. The engine coolant temperature is cooler than 60°C (140°F). Run the engine until the coolant temperature is hotter than 60°C (140°F). The engine ran less than 50 hours since last regeneration. Operate the machine until the parked regeneration icon displays in the InfoCenter.
Unavailable Message Table (cont'd.) Message Condition Recommended Action The parking brake is not engaged. Engage the parking brake. The traction pedal is in the FORWARD or REVERSE position. Move the traction pedal to the NEUTRAL position. The engine computer has sent a diagnostic trouble code. Troubleshoot the diagnostic fault code and/or repair the engine. The soot filter needs service. Refer to Servicing the Diesel-Oxidation Catalyst (DOC) and the Soot Filter (page 74).
Types of Diesel Particulate Filter Regeneration Types of diesel particulate filter regeneration that are performed while the machine is operating: Type of Regeneration Conditions for 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.
Passive DPF Regeneration operate the machine (Figure 63), a critical amount of soot may accumulate in the DPF. • Passive regeneration occurs as part of normal engine operation. • While operating the machine, run the engine at full-engine speed when possible to promote DPF regeneration. Assist DPF Regeneration • The computer takes control of the intake throttle to increase the temperature of the engine exhaust.
g214647 Figure 65 g214884 • If you are authorized by your company, you need Figure 66 the PIN code to perform the recovery-regeneration process. 2. On the SERVICE menu, press button 1 or button 2 to navigate to the REGENERATION option, and press button 4 to select the REGENERATION entry (Figure 67). Preparing to Perform a Parked or Recovery Regeneration 1.
Note: If you press button 5 while the regeneration is processing, you will exit the regeneration process. At the EXIT screen press button 5 to return to the SERVICE menu (Figure 70). g214486 Figure 68 g214485 4. The InfoCenter displays a series of screens (Figure 69) as the regeneration processes: Figure 70 5. When regeneration completes, the COMPLETE screen displays in the InfoCenter. Press button 5 to return to the SERVICE menu (Figure 71). g214483 Figure 71 g214903 Figure 69 1.
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.
Operating Tips • Ensure that the air-conditioning screen is clean. • Ensure that the air-conditioning-condenser fins are clean. Selecting the Proper Height-of-Cut Setting • Operate the air-conditioner blower at the mid-speed setting. Remove approximately 25 mm (1 inch) or no more than a third of the grass blade when mowing. In exceptionally lush and dense grass, you may need to raise the height-of-cut to the next setting (Figure 74).
Pushing or Towing the Machine After Operation After Operation Safety Important: Do not push or tow the machine faster than 3 to 4.8 km/h (2 to 3 mph), because internal-transmission damage may occur. General Safety 1. Raise the hood and locate the bypass valves on the pump • Clean grass and debris from the cutting units, drives, mufflers, and engine to help prevent fires. Clean up oil or fuel spills. • Shut off the fuel while storing or transporting the machine.
Identifying the Tie-Down Points Front of the machine—under the front of the operator's platform (Figure 77) g008997 Figure 77 1. Front tie downs Rear of the machine—on the bumper (Figure 78) g031557 Figure 76 g009005 Figure 78 5. Close the bypass valves before starting the engine and torque to 70 N·m (52 ft-lb) to close the valve. 1. Rear tie downs Note: The manual parking-brake release automatically resets when the engine is started.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Important: Refer to your engine operator's manual for additional maintenance procedures. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 10 hours • • • • After the first 50 hours • Change the engine oil and engine-oil filter. Before each use or daily Check the wheel-lug nuts. Check the 12 V alternator belt.
Maintenance Service Interval Maintenance Procedure Every 2,000 hours • Check and replace (if necessary) fuel hoses and engine-coolant hoses. • Lap or adjust the engine intake and exhaust valves (if necessary). Every 3,000 hours • Inspect and clean (if necessary) the engine-emission-control components and turbocharger. Every 6,000 hours • Disassemble, clean, and assemble the soot filter of the DPF.
For the week of: Maintenance Check Item Monday Tuesday Wednesday Thursday Friday Saturday Sunday 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. 2Immediately after every washing, regardless of the interval listed.
Notation for Areas of Concern Inspection performed by: Item Date Information Service-Interval Chart decal132-1407 Figure 79 63
Pre-Maintenance Procedures Using the Battery-Disconnect Switch Open the hood to access the battery-disconnect switch. Pre-Maintenance Safety Turn the battery-disconnect switch to the ON or OFF position to perform the following: • Keep all parts of the machine in good working condition and all hardware tightened, especially blade-attachment hardware. Replace all worn or damaged decals. • To energize the machine electrically, rotate the battery-disconnect switch clockwise to the ON position (Figure 80).
Raising the Machine Removing and Installing the Inner-Wing-Deck Covers 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 81) 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 83). g008996 Figure 81 1.
Lubrication Greasing the Bearings and Bushings Service Interval: Every 50 hours—Lubricate all grease fittings. The machine has grease fittings that you must lubricate regularly with No. 2 lithium grease. Also, lubricate the machine immediately after every washing. g013894 Figure 85 Traction Unit 1. Slide the cover out between the lift arm and roller.
g031674 Figure 86 Front Mower Deck • 2 caster-fork-shaft bushings (Figure 89) • 5 spindle-shaft bearings (located on the spindle housing) as shown in Figure 89 • 3 idler-arm-pivot bushings (located on the idler-pivot shaft) as shown in Figure 89 • 4 winglet-deck bushings (located on the winglet-pivot pins) as shown in Figure 89 g008855 Figure 87 g033268 Figure 89 g009249 Figure 88 67
Front Lift Assemblies Wing Lift Assemblies (Per Wing) • 2 lift-arm bushings (Figure 90) • 3 main lift-arm bushings (Figure 92) • 2 lift-arm-ball joints (Figure 90) • 1 lift-cylinder bushing (Figure 92) • 2 front deck lift-cylinder pivots (Figure 90) g009248 Figure 92 g009247 Figure 90 Wing Mower Decks (Each Wing) • 4 caster-fork-shaft bushing (Figure 91) • 3 spindle-shaft bearings (located on the spindle housing) as shown in Figure 91 • 2 idler-arm-pivot bushings (located on the idler-pivot shaft
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 93 for the ECU and electrical connections location. g021 157 g021157 Figure 94 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 93 Located on the left side of the machine under the hood 1.
Servicing the Air-Cleaner Filter elements Service Interval: Every 400 hours Every 400 hours The air-intake system on this machine is continuously monitored by an air-restriction sensor that will display an advisory when the air filter needs to be replaced. Do not replace the elements until this occurs. Important: Replace the secondary filter element only every 3 primary filter services. Do not remove the secondary element when cleaning or replacing the primary element.
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 g031550 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.
Crankcase Oil Capacity 10.4 L (11 US qt) with the filter Changing the Engine Oil and Engine-Oil Filter Service Interval: After the first 50 hours—Change the engine oil and engine-oil filter. Every 500 hours—Change the engine oil and engine-oil filter. g031551 Note: Change the engine oil and filter more frequently when the operating conditions are extremely dusty or sandy. 1. Start the engine and let it run 5 minutes to allow the oil to warm up. 2.
Adjusting the Engine-Valve Clearance 4. Change the engine-oil filter (Figure 101). Note: Ensure that the oil-filter gasket touches the engine, and then an extra 3/4 turn is completed. Service Interval: Every 1,000 hours Refer to your engine operator’s manual for the adjustment procedure. Cleaning the Engine EGR Cooler Service Interval: Every 1,500 hours For information on cleaning the engine EGR cooler, refer to your engine operator’s manual.
Inspecting and Cleaning Engine-Emission-Control Components and Turbocharger 2. Refer to your Authorized Toro Distributor for diesel-oxidation catalyst and the soot filter replacement parts or service. 3. Contact your Authorized Toro Distributor to have them reset the engine ECU after you install a clean DPF. Service Interval: Every 3,000 hours For information on inspecting and cleaning the engine-emission-control components, refer to your engine operator’s manual.
Fuel System Maintenance 3. Tighten the valve after draining. Replacing the Water-Separator Element Servicing the Fuel System 1. Place a clean container under the water separator. Draining the Fuel Tank 2. Drain some fuel by loosening the vent plug and opening the drain valve (Figure 105). Service Interval: Every 800 hours—Drain and clean the fuel tank. 3. Clean the area where the filter element mounts to the head.
Replacing the Fuel Filter Element Electrical System Maintenance Service Interval: Every 500 hours—Replace the fuel-filter element. Electrical System Safety 1. Clean the area around the fuel-filter head (Figure 106). • Disconnect the battery before repairing the machine. • Turn the battery-disconnect switch to the OFF position. • Battery acid is poisonous and can cause burns. Avoid contact with your skin, eyes, and clothing. Protect your face, eyes, and clothing when working with a battery.
g033314 Figure 110 1. Fuse block g031737 Figure 107 g033290 Figure 111 1. Fuse block 2. Power leads The cab fuses (Figure 112) are located in the fuse box on the cab headliner (Figure 113). g031738 Figure 108 1. Power-center console 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. Important: Keep the batteries fully charged. This is especially important to prevent battery damage when the temperature is below 32° F (0° C). g032673 Figure 113 1. Cab fuse box 1. Perform the pre-maintenance procedure; refer to Pre-Maintenance Safety (page 64). 2. Fuses 2.
1. Park the machine on a level surface, stop the engine, and remove the ignition key. 2. Sit in the operator seat and have the other person make the connections. Note: Ensure that the jumper battery is a 12-volt battery. Important: If you are using another machine for power, ensure that the 2 machines are not touching each other. 3. Remove the covers from the jump posts (Figure 114). 4. Connect the positive (+) jumper cable to the positive jump post (Figure 116). g033269 Figure 115 1.
Drive System Maintenance Calibrating the Traction Pedal Service Interval: Every 1,000 hours—Calibrate the traction pedal. Contact your local Toro distributor or refer to the Toro Service Manual for assistance. Adjusting the Traction-Pedal Angle g034932 Figure 118 1. Outside distance You can adjust the operating angle of the traction pedal for your comfort. 2. Tie-rod clamps 2. To adjust the toe-in, loosen the clamps at both ends of the tie rods (Figure 118). 1.
Cooling System Maintenance DANGER The rotating fans and drive belts can cause personal injury. • Do not operate the machine without the covers in place. • Keep fingers, hands, and clothing clear of the rotating fan and drive belt. • Shut off the engine, remove the ignition key, and turn the battery-disconnect switch to the OFF position before performing maintenance. Cooling System Safety CAUTION Discharge of hot, pressurized coolant or touching a hot radiator and surrounding parts can cause severe burns.
Cleaning the Cooling Systems Service Interval: Before each use or daily Perform the pre-maintenance procedure; refer to Pre-Maintenance Safety (page 64). Important: Do not use water to clean the radiator core or hydraulic-fluid-cooler core. Cleaning the radiator core or hydraulic-fluid-cooler core with water can promote premature corrosion and damage to components. Cleaning the Radiator g033277 Figure 121 1. Raise the hood to the fully-open position. 1. Prop rod 2.
g033289 Figure 123 1. Hydraulic-fluid cooler 3. Prop rod 2. Hydraulic-cooling fans g031321 Figure 124 1. Drain valve 2. Radiator-drain hose Changing the Engine-CoolingSystem Fluid 3. Radiator 4. Close the valve on the radiator-drain hose (Figure 124). 5. Fill the radiator with coolant until the coolant level even with the lip of the filler port (Figure 125). Service Interval: Every 1,000 hours—Flush the engine-cooling system and replace the fluid.
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. g034935 Figure 126 Servicing the 24 V Alternator Belt and AC Compressor Belt 1. Coolant hose 8. After draining the engine coolant, close the drain valve on the radiator-drain hose and connect the coolant hose. Service Interval: After the first 10 hours 9.
8. Route the new belt around the spindle pulleys and idler-pulley assembly (Figure 129). 114-0922 decal114-0922nc Figure 129 9. Adjust the stop screw on the idler pulley and tighten the jam nuts. 10. Install the belt covers. Replacing the Wing Mower-Deck Belts g009014 Figure 127 1. Idler-stop screw Note: To remove the lower belt, you must remove 3. 2.5 mm to 4 mm (0.10 to 0.16 inch) the upper belt first. 2. Idler pulley 1. Lower the mower deck to the floor. 2.
Hydraulic System Maintenance Hydraulic System Safety WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • Ensure that all hydraulic-fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system. • Keep your body and hands away from pinhole leaks or nozzles that eject high-pressure hydraulic fluid. g009009 Figure 130 1. Idler pulleys • Use cardboard or paper to find hydraulic leaks. 6.
High-Viscosity Index/Low-Pour Point Anti-Wear Hydraulic Fluid, ISO VG 46 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 134). Material Properties: Viscosity, ASTM D445 St @ 40°C 42 to 50 Note: The fluid level should be within the safe operating range on the dipstick. St @ 100°C 7.6 to 8.
Checking the Hydraulic Lines and Hoses Service Interval: Every 2 years—Replace moving hydraulic lines and hoses. 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. Inspecting the Hydraulic System Test Ports g031319 Figure 135 1. Hydraulic filters 2. Drain plug The test ports are used to test the pressure in the hydraulic circuits.
Mower Maintenance Pivoting (Tilting) the Front Mower Deck Upright Note: Although not needed for normal maintenance procedures, you can pivot (tilt) the front mower deck upright. 1. Raise the front mower deck slightly off the floor. 2. Perform the pre-maintenance procedure; refer to Pre-Maintenance Safety (page 64). 3. Remove the retainer clip and disconnect the damper assembly from the mower deck (Figure 136). g008979 Figure 137 1. Height-of-cut chain 3. Hairpin cotter 2. Clevis pin 5.
Pivoting (Tilting) the Front Mower Deck Down 3. Measure from the floor to the back tip of the winglet blade and record this dimension. 4. Subtract the front dimension from the rear dimension to calculate the pitch of each blade. 1. With the help of another person holding the front of the mower deck, remove the block of wood. 5. Loosen the jam nuts on the top or bottom of the height-of-cut chain U-bolt (Figure 140). 2.
Adjusting the Wing Mower-Deck Pitch Servicing the Caster Wheels and Bearings 1. Remove the tensioning cap from the caster-spindle shaft and slide the spindle out of the caster arm (Figure 141). Service Interval: Every 500 hours—Inspect the mower deck 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 142). g008866 Figure 141 1. Tensioning cap 4. Top axle-mounting hole 2. Spacers 5.
Blade Maintenance Note: The difference between the dimensions obtained in steps 4 and 5 must not exceed 3 mm (1/8 inch). If the dimension exceeds 3 mm (1/8 inch), the blade is bent and must be replaced; refer to Removing and Installing a Blade (page 92). Blade Safety DANGER A worn or damaged blade can break, and a piece of the blade could be thrown at you or bystanders, resulting in serious personal injury or death.
Inspecting and Sharpening a Blade Service Interval: After the first 10 hours Every 50 hours g000276 Before each use or daily Figure 146 You must consider 2 areas of the blade when checking and servicing it: the sail and the cutting edge. 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 is important because it lifts the grass up straight, thereby producing an even cut.
Cab Maintenance 1 2 Cleaning the Cab For Machines with a Cab Important: Use care around the cab seals and lights (Figure 147). 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. 2 3 g028378 g028378 3 Figure 148 In-Cab Air Filter 1. Filter 2. Grate 3. Screw 1 1 4 2 G034330 Figure 147 1. Seal 3. Keep wand 0.6 m (2 ft) away. 2. Light 4.
Cleaning the Storage Air-Conditioning-Condenser Preparing the Machine for Coil Storage Service Interval: Every 250 hours Clean it more frequently in extremely dusty or dirty conditions. Preparing the Traction Unit 1. Perform the pre-maintenance procedure; refer to Pre-Maintenance Safety (page 64). 1. Thoroughly clean the traction unit, mower decks, and the engine. 2. Disconnect the wire for each fan (Figure 150).
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.
Notes:
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International Distributor List Distributor: Agrolanc Kft Asian American Industrial (AAI) B-Ray Corporation Brisa Goods LLC Casco Sales Company Ceres S.A. CSSC Turf Equipment (pvt) Ltd. Cyril Johnston & Co. Cyril Johnston & Co. Fat Dragon Femco S.A. FIVEMANS New-Tech Co., Ltd ForGarder OU G.Y.K. Company Ltd. Geomechaniki of Athens Golf international Turizm Hako Ground and Garden Hako Ground and Garden Hayter Limited (U.K.) Hydroturf Int. Co Dubai Hydroturf Egypt LLC Irrimac Irrigation Products Int'l Pvt Ltd.
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).
