Operator’s Manual Part No. 111-0477 Rev A Groundsmaster 3240-D Code: 653D-Serial No.
ATTENTION THIS SYMBOL MEANS BE ALERT! YOUR SAFETY IS INVOLVED READ THIS MANUAL BEFORE USING THE GROUNDSMASTER 3240-D. IT IS ESSENTIAL THAT OPERATORS STUDY IT FOR THEIR OWN SAFETY. ALL OPERATORS SHOULD SEEK AND OBTAIN PROFESSIONAL AND PRACTICAL INSTRUCTIONS ON THE SAFE USE OF THE MOWER. THESE SERVICES ARE AVAILABLE THROUGH TORO APPROVED COMMERCIAL DEALERS.
1.4 CONTENTS 1.4 CONTENTS Page No. SAFETY PRECAUTIONS. Training. Preparation. Operation. Maintenance and storage. Decals. EC CONFORMITY INFORMATION. Noise levels. EC Declaration of Conformity. INTRODUCTION. SPECIFICATIONS. Engine. Transmission system. Cutterdeck drive system. Cutterdeck lift system and steering. Hydraulic system. Vehicle specifications. Operator controls. Instrumentation. Weight and dimensions. Recommended lubricants and hydraulic fluids. Cutterdecks. OPERATING THE MOWER.
CONTENTS 1.5 1.5 Continued. Page No. Fuel level gauge. Hourmeter. Transmission neutral indicator light. Cutterdeck drive switch indicator light. Parking brake indicator light. Hydraulic return filter indicator light. Hydraulic transmission filter indicator light. Transmission system ‘Work’ mode indicator light. Cutterdeck position control. Cutterdeck drive engagement. Starting the engine. Stopping the engine. General operating hints. Cutterdeck gerneral information. MAINTENANCE. Engine.
1.6 SAFETY PRECAUTIONS 1.6 READ THIS MANUAL BEFORE USING THE GROUNDSMASTER 3240-D, IT IS ESSENTIAL THAT OPERATORS STUDY IT FOR THEIR OWN SAFETY. THE FOLLOWING PRECAUTIONS MUST BE TAKEN TO HELP PREVENT ACCIDENTS. A CAREFUL OPERATOR WHO USES COMMON SENSE IS THE SAFEST OPERATOR. TRAINING Read the instructions carefully. Be familiar with the controls and the proper use of the equipment. Learn how to stop the mower quickly in an emergency.
1.7 PREPARATION SAFETY PRECAUTIONS Continued. Ensure that the cutterdecks are fully raised with the latches and safety locks engaged in position before transporting the mower. Replace faulty silencers. Check the condition of the tyres and ensure that they are inflated to the correct pressures, refer SPECIFICATIONS. This is particularly important if the machine is to be taken on the public highway. Check that the mower is in good working order, paying particular attention to the brakes and steering.
SAFETY PRECAUTIONS 1.8 OPERATION 1.8 Continued. Do not use on a slope of more than 15 degrees. Care should be taken when using the mower on any slope where ground conditions are such that there may be a risk of the mower rolling over. The requirements of SI 1998 No. 2306 “Provision and Use of Work Equipment Regulations” should be considered. R.O.P.S (Roll Over Protective Structures) are available, refer to INTRODUCTION - Optional Extras.
1.9 OPERATION SAFETY PRECAUTIONS Continued. Watch out for traffic when crossing or near roadways. Use extreme caution when reversing. Disengage the cutterdeck drive system before crossing surfaces other than grass. When using the machine, never direct the discharge of material towards bystanders or allow anyone near the machine while in operation. Never operate the mower with damaged guards, shields or without safety protective devices in place and in good working order.
1.10 SAFETY PRECAUTIONS 1.10 MAINTENANCE AND STORAGE Take care when rotating a cutterblade as this can cause other cutterblades to rotate. When the machine is to be parked, stored or left unattended, lift the cutterdecks to the transport position and engage the safety locks or lower the cutterdecks to the ground. Keep all nuts, bolts, and screws tight to be sure the equipment is in safe working condition. Allow the engine to cool before storing in any enclosure.
1.11 SAFETY PRECAUTIONS 1.11 DECALS b a e P O 994912 (REV. 1) Decal - Control Panel Part No: 994910 Location: Control Panel. a) Ignition Switch h) Horn b) Engine Speed - Slow i) Cutters - Lift c) Engine Speed - Fast j) Cutters - Hold d) Parking Brake - Engage k) Cutters - Drop/Float f e) Parking Brake - Disengage l) Hour Meter g f) Cutters - Off g) Cutters - On d c I III II P i h k j l b a c Decal - Inclines Part No: 994915 (0) 0 - 15¡ 15¡+ 994915 (0) Location: Centre Platform.
SAFETY PRECAUTIONS 1.12 DECALS 1.12 Continued. Decal - Jacking / Support Point Part No: 70-13-072 Location: Front Axle - 2 Points Rear Towing Eye Jacking and support point Decal - Engine Fan / Radiator Part No: 70-13-073 Location: Engine Fan Cowl a) Danger of severing fingers b) Caution c) Warning - Hot surfaces Decal - Tyre Pressure Part No.
SAFETY PRECAUTIONS 1.13 Continued. Decal - Serial Number Location: Rear Bulkhead 2005 DECALS 1.13 GM3240-D GROUNDSMASTER kg:1800 Code RPM:2650 kW:44 Serial No: 653D 260000001 105dB Decal - Prevent Platform Damage Part No. 924828 Location : Platform, Seatwell PREVENT PLATFORM DAMAGE ! ENGAGE PARKING BRAKE AND DROP CUTTERHEADS BEFORE RAISING/LOWERING PLATFORM. POUR EVITER DES DOMMAGES, METTRE LE FREIN DE PARKING ET POSER LES TETES DE COUPES AVANT DE BOUGER LA PLATE-FORME. ..
SAFETY PRECAUTIONS 1.14 DECALS Continued. Decal - Warning Hands, Feet Part No: 40-13-010 (1) Location: On Decks. A A B A = 994805 B = 994806 LH 994806 X2 Decal - Sprung Hazard GM3240-D Part No: 994913_2 Location: Side of Machine. Take Care When Latching and Unlatching the Cutterdecks. Decal - Crushing Hand GM3240-D Part No: 994913_3 Location: Side of Machine. Warning of Crushing Hazard When Wing Decks are Being Raised. Keep Hands Clear. 994913_1 Rev.0.
1.15 EC CONFORMITY INFORMATION 1.15 Operators Daily Personal Noise Exposure: The Toro Company has no control over site conditions, duration of use, state of maintenance or adjustment of the mower.
1.16 EC CONFORMITY INFORMATION EC DECLARATION OF CONFORMITY EC DECLARATION OF CONFORMITY Manufactured for The Toro Company By: HAYTER LIMITED, Spellbrook, Bishop’s Stortford, Herts. CM23 4BU.
INTRODUCTION 1.17 1.17 INTRODUCTION The Toro Groundmaster 3240-D is a diesel engine powered self-propelled machine with hydraulic systems for ground drive, cutterdeck drives and steering. The machine can be operated in either two wheel or four wheel drive and a differential lock function may be selected in four wheel drive. The Toro Groundmaster 3240-D is a precision built machine designed solely for cutting grass and similar low lying ground vegetation within the limitations stated in this manual.
1.18 SPECIFICATIONS 1.18 SPECIFICATIONS ALL FIGURES ARE NOMINALLY QUOTED AT THE RATED NO LOAD ENGINE SPEED OF 2800 RPM UNLESS OTHERWISE STATED. ENGINE Type: Kubota V2003M - T diesel. 4 Cylinders in-line. Power Rating: 59hp (44 kw) @ 2800 RPM. DIN 70020. Capacity: 1999 cc. Air Cleaner: Clean air drawn through screened air intake in rear of engine cover via a cyclonic air cleaner with built in pre-cleaner. Cooling System: Water-Cooled. Battery: 12V. 480 Amps S.A.E. Alternator: 40 Amps.
1.19 SPECIFICATIONS 1.19 TRANSMISSION SYSTEM Drive Type: Hydraulic. Pump: Variable displacement hydraulic piston pump with integral charge pump and servo control. Wheel Motors: Front Axle - Twin lock radial piston, fixed displacement, with integral disc brake (pressure released) Rear Axle - Radial piston, fixed displacement with pedal control (only available in work mode). Differential Lock: Electro - hydraulic control valve. Drive: Front wheel drive in ‘Work’ and ‘Transport’ modes.
1.20 SPECIFICATIONS 1.20 CUTTERDECK LIFT SYSTEM AND STEERING Drive Type: Hydraulic. Pump: Hydraulic gear pump with integral relief valve. Delivery Rate: 11 Litres per minute. Steering: Power beyond hydrostatic steering valve with priority flow to steering and auxiliary flow to cutterdeck lift system. Manual emergency steering. Cutterdeck Lift Control: Mechanical-hydraulic. Relief Valve Setting: 120 bar (1523 psi) on pump.
SPECIFICATIONS 1.21 1.21 VEHICLE SPECIFICATIONS Travel Speed: Tyres 0-25 km/h 0-11 km/h (0-15 mph) forward. (0-7 mph) reverse. Tyre Type Recommended Tyre Pressures Road Conditions Turf Conditions Max Pressure Front axle 26 x 12 - 12 4 ply Trelleborg turf pattern. 0.7 bar (10 psi ) 1.4 bar (20 psi) 1.7 bar (25 psi) Rear axle 20 x 10.0 - 8 4 ply Dico turf pattern. 0.7 bar (10 psi). 1.4 bar (20 psi) 1.
1.22 SPECIFICATIONS 1.22 OPERATOR CONTROLS Steering: Automotive padded steering wheel with adjustable steering column. Cutter Drive: Electrical switch (on - off). Engine Speed: Hand operated lever. Parking Brake: Hand operated lever. Forward and Reverse: Separate foot operated pedals. Ignition: Key start, shut - off and engine preheat. Differential Lock: Foot pedal. ‘Work’ or ‘Transport’ modes: Electrical Switch. Cutterdeck Position: Hand operated lever. Horn: Button switch.
1.23 SPECIFICATIONS 1.23 WEIGHT AND DIMENSIONS Wheel Base: 1610 mm. Working Width: 3610 mm - At 100mm height of cut. Cutting Width: 3500 mm - At 100mm height of cut. Transport Width: 1774 mm- At 50mm height of cut. Overall Length: 3470 mm. Transport Height: 1605 mm. Approx. Working Weight: 1800 kg less operator, no options fitted. RECOMMENDED LUBRICANTS AND HYDRAULIC FLUIDS Grease Points: A good quality medium grease. Engine: Refer - ENGINE OPERATORS MANUAL.
1.24 SPECIFICATIONS 1.24 CUTTERDECKS Centre Cutterdeck Left/Right Cutterdecks Cutterdeck Width: 1675 mm 1150 mm Cutting Width: 1600 mm. 1090 mm. Cutterblade Length: 558 mm. 558 mm. Cutterblade Speed: 2400 rpm approx. 2400 rpm approx. Cutterblade Overlap: 63 mm 40mm Height of Cut: 26 - 127 mm. 26 - 127 mm.
OPERATING THE MOWER 1.25 1.25 SAFETY NOTICE WARNING: PREVENT ACCIDENTS - Before operating the mower it is essential that; - The operator reads and understands this manual. - The operator platform latching mechanism is fully engaged and in good working order, refer - Operator Platform Latching Mechanism. - The daily maintenance checks have been properly carried out and the mower is in good working order. - The operator should wear safety clothing and eye protection.
1.26 OPERATING THE MOWER 1.26 IDENTIFICATION OF CONTROLS 1. Parking brake lever. 2. Lighting switch (supplied with lighting kit). 3. Warning beacon switch (supplied with beacon kit). 4. Hazard warning switch (supplied with lighting kit). 5. Cutterdeck position controls. 6. Throttle control lever. 7. Ignition key. 8. Cutterdeck drive switch. 9. Dip beam / main beam light switch (supplied with lighting kit). 10. Direction indicator switch (supplied with lighting kit). 11. Horn button. 12.
1.27 1.27 OPERATING THE MOWER BRAKING SYSTEM Parking Brake Engaged Parking Brake : Move the parking brake lever to its rear position to engage the parking brake. Do not operate the mower with the parking brake engaged. P WARNING : PREVENT ACCIDENTS - The parking brake operates on the front wheels only. Do not park the mower on a slope. Service brakes : Service braking is achieved by the hydraulic transmission system.
1.28 OPERATING THE MOWER 1.28 WORK/TRANSPORT MODES WARNING : PREVENT ACCIDENTS - Ensure that the mode selected is appropriate to the mode of operation of the machine. Select ‘Work’ mode when operating the mower in conditions of poor traction when maximum tractive performance is required. Selecting ‘Work’ mode will enable the use of the differential lock. Select ‘Transport’ mode when operating the mower in conditions of good traction.
1.29 1.29 OPERATING THE MOWER DIFFERENTIAL LOCK WARNING : PREVENT ACCIDENTS - Do not engage the differential lock at high speed. The turning circle will increase with the differential lock engaged. The differential lock is effective only when ‘Work’ mode is selected. The differential lock operates in both ‘forwards’ and ‘reverse’ and can be engaged whilst the turf mower is travelling slowly. Engage the differential lock to prevent excessive wheel spin when the drive wheels lose traction.
OPERATING THE MOWER 1.30 1.30 FORWARD TRAVEL SPEED BACKSTOP LEVER The backstop lever can be used to limit the movement of the forward pedal for accurate forward travel speed, and the clip rate required. Operate the lever in a forward direction to increase the travel speed setting and in a rearward direction to decrease. Note: This is not a cruise control device. Releasing the forward travel pedal will allow it to return to neutral.
1.31 1.31 OPERATING THE MOWER ADJUSTABLE STEERING COLUMN WARNING: PREVENT ACCIDENTS - Before operating the mower, ensure that the steering column adjuster mechanism is in good working order and that the steering wheel is locked securely in position. WARNING: PREVENT ACCIDENTS - Adjustment of the steering wheel and steering column should only be carried out when the mower is at a standstill with the parking brake engaged.
1.32 OPERATING THE MOWER 1.32 OPERATOR SEAT WARNING: PREVENT ACCIDENTS - Before operating the mower ensure that the operator seat mechanisms are in good working order and that the seat is locked securely in position. WARNING: PREVENT ACCIDENTS - Adjustment of the seat mechanisms should only be carried out when the mower is at a standstill with the parking brake engaged. Fore/Aft Adjustment: Move lever ‘B’ upwards to adjust the Fore/Aft position of the seat.
1.33 OPERATING THE MOWER WARNING SYSTEMS Engine coolant overheating warning : The engine coolant warning light illuminates and the horn is actuated. Hydraulic oil overheating warning : The hydraulic oil warning light illuminates and the horn is actuated when the hydraulic oil in the reservoir exceeds 95˚C approx. Low battery charge warning : The battery charge warning light illuminates. Low engine oil pressure warning light : The engine oil pressure warning light illuminates.
1.34 OPERATING THE MOWER 1.34 IGNITION KEY O 0 = Engine off. I II I = Engine run / Auxiliary on. II = Engine pre-heat. III = Engine start. III WARNING : PREVENT ACCIDENTS - Always remove the ignition key when the mower is not in use. IMPORTANT : PREVENT DAMAGE - Always fit the protective cap when the ignition key is removed to prevent ingress of dirt and moisture from damaging the mechanism. ENGINE PRE-HEAT INDICATOR LIGHT Turn the ignition key to position II.
1.35 1.35 OPERATING THE MOWER TRANSMISSION NEUTRAL INDICATOR LIGHT Illuminates when the travel control pedal is in the neutral position and the ignition key is turned to position ‘I’. Note: The parking brake must be engaged for the transmission neutral indicator light to illuminate. N WS041 CUTTERDECK DRIVE SWITCH INDICATOR LIGHT Illuminates when the cutterdeck drive switch is in the ‘off’ position and the ignition key is turned to position ‘I’.
1.36 OPERATING THE MOWER 1.36 CUTTERDECK POSITION CONTROL 4A953B03A 1 The cutterdecks may be raised or lowered using the bank of 3 lift control levers. 2 3 To lower the cutterdecks, operate the lift control levers in a downward direction until locked in position 1. If the cutterdeck drive switch is in the ‘ON’ position, the cutterblade will engage when the cutterdecks are approximately 300mm above ground level.
1.37 OPERATING THE MOWER 1.37 STARTING THE ENGINE WARNING: PREVENT ACCIDENTS - Before starting the engine check that ; - The area is clear of bystanders. - The cutterdeck drive is disengaged. - The parking brake is engaged. - The travel control pedal is in neutral. - You have read and understood the SAFETY PRECAUTIONS section in this manual. This machine is fitted with an Engine Start Lockout, refer - OPERATOR PRESENCE CONTROLS.
1.38 1.38 OPERATING THE MOWER STOPPING THE ENGINE O 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 trouble. I II III GENERAL OPERATING HINTS 1. The rotational speed of the cutterblades should always be kept as high as possible in order to maintain the highest quality of cut. This in turn requires that the engine speed be kept as high as possible. 2.
OPERATING THE MOWER 1.39 1.39 CUTTERDECK GENERAL INFORMATION HEIGHT OF CUT ADJUSTMENT - FRONT CUTTERDECK To adjust the height of cut on the front cutterdeck follow the procedure below. Ensure that the mower is stationary on a level surface with the parking brake engaged and the cutterdeck drive disengaged. WARNING: PREVENT ACCIDENTS – Never adjust the height of cut with the engine running. Read all of these instructions before commencing 1. Raise deck to transport position and engage transport latches.
OPERATING THE MOWER 1.40 CUTTERDECK GENERAL INFORMATION 1.40 Continued. HEIGHT OF CUT ADJUSTMENT - L.H/R.H CUTTERDECKS To adjust the height of cut on the LH and RH cutterdecks follow the procedure below. Ensure that the mower is stationary on a level surface with the parking brake engaged and the cutterdeck drive disengaged. WARNING: PREVENT ACCIDENTS – Never adjust the height of cut with the engine running. Read all of these instructions before commencing 1.
1.41 MAINTENANCE MAINTENANCE WARNING : PREVENT ACCIDENTS - When carrying out maintenance procedures it is essential that: - The engine is switched off and the ignition key removed. - The parking brake is applied. - There is no pressure in the hydraulic system. - The cutterdecks are fully down on the ground. - The safety precautions in this manual have been read and understood. IMPORTANT: PREVENT DAMAGE - Regular maintenance is essential for the continued safe operation of the machine.
MAINTENANCE 1.42 MAINTENANCE 1.42 Continued. WARNING : PREVENT ACCIDENTS - Use hazardous substances carefully. The following fluids are identified as being hazardous; Substances Assessed risk Diesel oil Lubricating oil Hydraulic oil Grease Anti - freeze Battery acid Low Low Low Low Medium High When using any of the above fluids it is recommended that eye protection and gloves are worn and that care is taken to prevent spillage. Avoid contact with skin; wash off spillage with soap and water.
1.43 1.43 MAINTENANCE ENGINE ENGINE Refer to the Engine Operator's Manual for maintenance information. RUNNING IN PERIOD Check wheel nut torque settings: During first 50 hours of use and in addition to routine checks. Refer DAILY AND BEFORE USE. Check wheel nut torques twice a day. Front axle wheel nut torque setting - 200 Nm. Rear axle wheel nut torque setting - 54 Nm.
MAINTENANCE 1.44 RUNNING IN PERIOD - AT FIRST 50 HOURS Change the hydraulic oil return filter: Unscrew and remove the return filter canister and discard. Refit a new filter canister (part no. 924692). Left Hand Side of Machine 2 1 1P953C16A 1. Hydraulic oil return filter. 2. Engine fuel filter. 1.44 Continued.
1.45 1.45 MAINTENANCE DAILY AND BEFORE USE Check engine oil level: If the oil level is below the upper mark on the dipstick, top up with the correct grade of engine oil to the required level, refer - ENGINE MANUAL. Check engine radiator coolant level: WARNING: PREVENT ACCIDENTS - Avoid scalding. DO NOT remove the radiator filler cap unless the engine is cool. Turn the filler cap slowly to release system pressure before removing the filler cap completely. ONLY REMOVE RADIATORCAPWHEN ENGINEIS COOL.
1.46 DAILY AND BEFORE USE MAINTENANCE 1.46 Continued. 2 Clean the radiator screen: Clean the radiator screen. Check the oil cooler and engine radiator grille for debris and clean as necessary, using a brush or airline. If water is used, these areas should be allowed to dry out completely before use. 1 32 IMPORTANT: PREVENT DAMAGE - NEVER operate the mower with a damaged radiator screen or engine damage could result from overheating. Clean the radiator screen more regularly in dry conditions.
MAINTENANCE 1.47 DAILY AND BEFORE USE 1.47 Continued. Check hydraulic hose-lines: Inspect hydraulic hose-lines for signs of wear or damage. WARNING: PREVENT ACCIDENTS - ALWAYS replace worn or damaged hydraulic hose-lines immediately. DO NOT operate the mower with defective hydraulic hose-lines. Inspect the mower for signs of oil leakage. Tighten fittings or replace seals as required. Check fasteners: Check that all nuts, bolts and pins are secured correctly in place and in good condition.
1.48 DAILY AND BEFORE USE MAINTENANCE 1.48 Continued. Transmission neutral interlock switch: Stop the engine and engage the parking brake. Ensure that the drive pedal is in the stop (neutral) position and turn the ignition key to position ‘I’. The transmission neutral indicator light should illuminate. Refer - OPERATING THE MOWER. Depress the drive pedal. The indicator light should go out and the engine should not start when the ignition key is turned.
MAINTENANCE 1.49 EVERY 50 HOURS Perform routine checks : Refer - DAILY BEFORE USE. Check wheel nut torque settings: Front axle wheel nut torque setting - 200Nm. Rear axle wheel nut torque setting - 54 Nm. Grease pivot points : Clean and grease all grease points with a good quality compound of the grade specified, refer - SPECIFICATIONS. Replace any grease nipples which are damaged. GREASE POINTS Daily 50 Hour (Weekly) 1.
1.50 MAINTENANCE 1.50 EVERY 250 HOURS Perform routine checks : Refer - DAILY BEFORE USE. - EVERY 50 HOURS. Check battery condition : WARNING : PREVENT ACCIDENTS - Explosive gases are produced by the battery. Work in a well ventilated area, away from all sources of ignition. Battery fluids are corrosive. Take care to avoid contact with the skin or eyes. In the event of a spillage, drench the affected area with water. If the eyes are affected, seek medical attention.
MAINTENANCE 1.51 1.51 EVERY 500 HOURS Perform routine checks : refer - DAILY BEFORE USE. - EVERY 50 HOURS. - EVERY 250 HOURS. Thoroughly clean the machine: IMPORTANT: PREVENT DAMAGE - Keep water away from electrical components. Use a dry cloth or brush to clean such areas. Service the hydraulic system : This procedure is best carried out when the hydraulic oil is warm (not hot). Lower the cutterdecks to the ground and drain the hydraulic system by removing the hydraulic tank drain plug.
1.52 1.52 MAINTENANCE EVERY 500 HOURS Continued. Renew the engine air cleaner filter: Check the condition of the air cleaner hoses. Replace any hose which is damaged and tighten the connections, refer ENGINE MANUAL. ENGINE Renew the engine fuel filter element: Refer - ENGINE MANUAL. ENGINE Check electrical system: Inspect all electrical connections and cables and replace any which are damaged or corroded. Spray a good quality water inhibitor on to exposed connections to prevent moisture ingress.
MAINTENANCE 1.53 EVERY 500 HOURS 1.53 Continued. Check the engine overheat warning system: Turn the ignition key to the ‘ignition on’ position 'I'. Disconnect the red/grey wire terminal from the engine temperature switch and touch the metal terminal of this wire onto a suitable earth point, ensuring that the metal surfaces make good contact. The horn will sound and the engine coolant temperature warning light will illuminate to confirm correct operation.
1.54 MAINTENANCE 1.54 CUTTERDECKS Check tyres: Examine all tyres and replace any that are damaged. Check safety devices: WARNING: PREVENT ACCIDENTS - Ensure that all safety guards, shields and protective devices are securely in place and in good working order. Check that cutterdeck drive cut outs operate correctly and that the cutterblades do not continue to operate when the cutterdecks are more than 300mm above ground level. Check fasteners: Check all nuts, bolts, pins and locking devices.
1.55 MAINTENANCE 1.55 CUTTERBLADES Cutterblade Removal WARNING: PREVENT ACCIDENTS - ALWAYS switch off the engine, apply the parking brake and remove the ignition key before working on the cutterblades. The cutterblades have sharp edges. Wear strong gloves to protect the hands when working on the cutterblades. DO NOT operate tools towards the cutting edges to avoid the risk of injury should the tool slip. Always use genuine replacement parts.
MAINTENANCE 1.56 1.56 CUTTERBLADES 1. 2. 3. 4. 5. 6. Bolt - Motor Bolt - Cutterblade Locating Ring Cutterblade Mounting Key - Motor Cutterblade - Lock Tab 5 4 3 6 2 1 2 4D994C01A Regularly check that the cutterblade securing bolts (items 1 and 2) are tightened to the specified torque and re-new cutterbar - lock tabs. Bolt (item 1) - Torque to 70-95Nm. Bolt (item 2) - Torque to 40-55Nm. CS026 Ensure that each cutterblade is balanced.
1.57 MAINTENANCE 1.57 RAISING THE MOWER OFF THE GROUND WARNING: PREVENT ACCIDENTS - Before raising the mower ensure that: - The lifting device to be used is in good condition and capable of supporting the weight of the mower securely. Minimum lift capacity 2500 Kg. - The mower is on level ground. - The parking brake is applied. - The engine is switched off and the ignition key removed. - The ground under the lifting device is level and firm.
1.58 1.58 MAINTENANCE TOWING THE MOWER Towing procedure : Connect a rigid tow bar between the towing eye on the mower and a suitable towing vehicle. Ensure that the towing vehicle specification is suited to braking the combined vehicle weight to rest whilst effecting complete control at all times. Ensure that the towing vehicle’s parking brake is applied. Chock the mower front wheels to prevent the mower rolling away.
1.59 TOWING THE MOWER 1.59 MAINTENANCE Continued. De-commission the hydraulic service braking system as follows:- Bypass Valve Open the transmission bypass valve situated as shown on top of the transmission pump. The valve is fully open at 3 anti-clockwise revolutions. Do not open the valve past 3 revolutions. The steering must be operated manually when the mower is being towed. The steering will feel heavy as there is no hydraulic assistance when the engine is switched off.
1.60 GRASS CUTTING FAULTS 1.60 GRASS CUTTING FAULTS FAULT POSSIBLE CAUSE REMEDY Areas of uncut grass at point of overlap between cutterdecks Turning too tightly. Increase turning radius. Mower sliding sideways when travelling across face of a slope. Mow up/down slope. One end of cutterdeck out of ground contact caused by: - Poorly routed hoses or wrongly positioned hydraulic adaptors. Reroute hoses/reposition hydraulic adaptors. Step in cut grass height at point of overlap between cutterdecks.
1.61 GRASS CUTTING FAULTS GRASS CUTTING FAULTS 1.61 Continued. FAULT POSSIBLE CAUSE REMEDY Scalping. Undulations too severe for height of cut setting. Raise rear of cutting deck / Raise height of cut.
1.62 TROUBLE SHOOTING 1.62 TROUBLE SHOOTING When using the following chart it may be found that overhaul of major components or hydraulic pressure adjustments are necessary. In this case it is recommended that your dealer make these repairs as he is properly equipped to do this work. WARNING: PREVENT ACCIDENTS - ALWAYS Apply the parking brake, switch off the engine and remove the ignition key before attempting to work on the mower.
TROUBLE SHOOTING 1.63 TROUBLE SHOOTING 1.63 Continued. PROBLEM POSSIBLE CAUSE REMEDY Differential lock non operational. Defective switch. Check switch and replace if necessary. Defective solenoid valve. Service or replace solenoid valve. Defective wiring. Check wiring/connections as necessary. Blocked radiator screen. Clean screen. Blocked oil cooler matrix. Clean oil cooler matrix. Blocked engine radiator matrix. Clean matrix. Low relief valve setting.
1.64 TROUBLE SHOOTING TROUBLE SHOOTING 1.64 Continued. PROBLEM POSSIBLE CAUSE REMEDY One cutterblade rotates slowly. Motor integral check valve jammed open. Have check valve cleaned and checked. Motor worn. Replace motor. Lift cylinder seal failure. Replace seals. Pressure relief valve jammed open or wrongly set. Have relief valve cleaned and pressure checked. Consult your Toro dealer. Defective control valve. Overhaul control valve. Mechanical blockage. Remove blockage.
1.65 TROUBLE SHOOTING TROUBLE SHOOTING 1.65 Continued. PROBLEM POSSIBLE CAUSE REMEDY Cutterdecks fail to start up when lowered into work. Faulty seat sensor switch. Check mechanical and electrical operation of switch. Low oil level. Fill hydraulic oil reservoir to correct level. Faulty shut off sensor switch. Check mechanical adjustment and electrical operation. Pressure relief valve jammed open or wrongly set. Have relief valve cleaned and pressure checked. Consult your Toro dealer.
1.66 TROUBLE SHOOTING 1.66 TROUBLE SHOOTING Continued. PROBLEM POSSIBLE CAUSE REMEDY Lack of transmission drive. Parking brake engaged. Release parking brake. Low oil level. Fill reservoir to correct level. Incorrect oil used. Drain reservoir and refill with correct oil. Defective travel pedal linkage. Check linkage and replace defective parts. Defective transmission pump. Have the transmission pump overhauled by your Toro dealer. Transmission relief valve open.
1.67 TROUBLE SHOOTING TROUBLE SHOOTING Continued. PROBLEM POSSIBLE CAUSE REMEDY Excessive noise in hydraulic system. Faulty pump. Identify noisy pump and service or replace. Faulty motor. Identify noisy motor and service or replace. Air leaking into system. Tighten or replace hydraulic fittings particularly in suction lines. Suction strainer blocked or damaged. Clean and replace suction strainer or renew as necessary. Excessive oil viscosity due to cold conditions. Allow system to warm up.
1.68 TROUBLE SHOOTING TROUBLE SHOOTING 1.68 Continued. PROBLEM POSSIBLE CAUSE REMEDY After initial satisfactory operation machine loses power. Worn pump or motor. Replace as necessary. Low hydraulic oil level. Fill hydraulic oil tank to correct level. Incorrect oil viscosity. Renew oil in hydraulic tank with hydraulic oil of correct viscosity grade, refer - SPECIFICATIONS. Oil filter element blocked. Change filter element. Faulty pressure relief valve.
35 34 B B P/Y 31 P/R G/P N W N/W W/R W/R 2 W/B P/R 1 36 W/B L/Y G/U W/G 5 3 B B B G/N 37 6 N N/W 4 L/Y L L G/P G/P L B 57 58 L N/Y W/N L/Y W/B B 15 L/Y O 14 B/P 13 11 7 W/U B/P W/U N/B 9 W/Y W/P 12 10 O B P/R 58 U/R 49 49a 56 Y/B N N R/S Y/B P P/R N/R P/B O P/R 21 38 42 W/P B N B Y/B P/R W/U U/R R R 17 16 18 N 22 39 W/R 56 41 30 17 15 W 19 W/R 58 B N/R 20 55 UG 54 UB UG 19 UY UY UB 50a U/G N
1.70 ITEM NO. ELECTRICAL CIRCUIT DIAGRAM DESCRIPTION PART NO. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Switch - Parking Brake Interlock. Glow Plug Timer. Light - Parking Brake. Light - Glow Plugs. Light - Neutral. Light - Cutterdeck Drive Off. Light - Return Filter. Light - Pressure Filter. Light - Battery Warning. Light - Engine Oil Pressure. Light - Engine Coolant Temperature. Light - Hydraulic Oil Temperature. Diodes - Overheat - Audible Warning.
35 34 B B P/Y 31 P/R G/P N W N/W W/R W/R 2 W/B P/R 1 36 W/B L/Y G/U W/G 5 3 B B B G/N 37 6 N N/W 4 L/Y L L G/P G/P L B 57 58 L N/Y W/N L/Y W/B B 15 L/Y O 14 B/P 13 11 7 W/U B/P W/U N/B 9 W/Y W/P 12 10 O B P/R 58 U/R 49 49a 56 Y/B N N R/S Y/B P P/R N/R P/B O P/R 21 38 42 W/P B N B Y/B P/R W/U U/R R R 17 16 18 N 22 39 W/R 56 41 30 17 15 W 19 W/R 58 B N/R 20 55 UG 54 UB UG 19 UY UY UB 50a U/G N
1.72 ITEM NO. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. ELECTRICAL CIRCUIT DIAGRAM DESCRIPTION PART NO. Alternator/Regulator. Engine Temperature Sender (supplied with temp kit). Glow Plugs. Switch - Engine Overheat. Solenoid - Engine Fuel Engine V2003 M-T. Hourmeter. Switch - Return filter. Solenois - Work/Transport Mode. Switch - L/H Deck Interlock. Switch - Centre Deck Interlock. Fuse - Main 60A ? 994800 910850 910627 - 1.
23 1.73 TRANSMISSION / BRAKE - HYDRAULIC CIRCUIT 1.
1.74 ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 TRANSMISSION / BRAKE - HYDRAULIC CIRCUIT 1.74 DESCRIPTION PART NO.
19 19 10 12 20 18 13 11 14 21 21 9 15 16 17 22 25 A3 B3 27 24 P3 A1 B1 26 30 P2 23 A2 31 B2 31 01 R 29 28 32 02 T3 TC T T2 32 7 7 7 7 8 8 6 8 8 6 6 R324T Hyd Circ Dia(1) 8 8 8 1.75 HYDRAULIC CIRCUIT DIAGRAM 1.
1.76 ITEM NO. HYDRAULIC CIRCUIT DIAGRAM DESCRIPTION PART NO.
WARRANTY 1.77 1.77 The Toro Commercial Parts Warranty A Ninety - Day Limited Warranty Conditions and Products Covered The Toro Company (Toro) and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial Product (“Part”) to be free from defects in materials or workmanship for ninety (90) days. Where a warrantable condition exists, we will repair the Part at no cost to you.
1.78 WARRANTY 1.78 The Toro General Commercial Products Warranty A Two-Year Limited Warranty Conditions and Products Covered The Toro Company (Toro) 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.
1.79 NOTES 1.
1.80 CUSTOMER INFORMATION MACHINE DETAILS Model: Machine Serial No.: Engine Serial No.: Cutterdeck Serial No.s: Transmission Pump Serial No.: Transmission Valve Block Front Serial No.: Cutter Control Valve (Front & Centre) Serial No.: Cutter Control Valve (Wing) Serial No.: 1.
