Groundsmaster 3500-D
Form No. 3354–406 Rev C
Groundsmaster) 3500-D
Groundsmaster Traction Unit
Model No. 30839—Serial No. 260000001 and Up
Operator’s Manual
English (EN, GB)
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting and Stopping the Engine . . . . . . . . . . . . . .
Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . .
Checking the Interlock System . . . . . . . . . . . . . . .
Towing the Traction Unit . . . . . . . . . . . . . . . . . . . .
Standard Control Module (SCM) . . . . . . . . . . . . . .
Operating Characteristics . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule . . . . . . . . .
Daily Maintenance Checklist . . . . . . . . . . . . . . . . .
Greasing the Bearings and Bushings . . . . . . . . . . .
Service Interval Chart . . . . . . . . . . . . . . . . . . . . . .
Removing the Hood . . . . . . . . . . . . . . . . . . . . . . . .
General Air Cleaner Maintenance . . . . . . . . . . . . .
Servicing the Air Cleaner . . . . . . . . . . . . . . . . . . . .
Servicing the Engine Oil and Filter . . . . . . . . . . . .
Servicing the Fuel System . . . . . . . . . . . . . . . . . . .
Bleeding Air from the Injectors . . . . . . . . . . . . . . .
Cleaning the Engine Cooling System . . . . . . . . . .
Servicing the Engine Belts . . . . . . . . . . . . . . . . . . .
Adjusting the Throttle . . . . . . . . . . . . . . . . . . . . . .
Changing the Hydraulic Fluid . . . . . . . . . . . . . . . .
Replacing the Hydraulic Filter . . . . . . . . . . . . . . . .
Checking the Hydraulic Lines and Hoses . . . . . . .
Adjusting the Traction Drive for Neutral . . . . . . . .
Adjusting the Parking Brake . . . . . . . . . . . . . . . . .
Caring for the Battery . . . . . . . . . . . . . . . . . . . . . .
Storing the Battery . . . . . . . . . . . . . . . . . . . . . . . . .
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . .
Preparation for Seasonal Storage . . . . . . . . . . . . . .
The Toro General Commercial Products Warranty . . .
Warning
CALIFORNIA
Proposition 65 Warning
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
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Operating Practices . . . . . . . . . . . . . . . . . . . .
Toro Mower Safety . . . . . . . . . . . . . . . . . . . . . . . .
Sound Power Level . . . . . . . . . . . . . . . . . . . . . . . .
Sound Pressure Level . . . . . . . . . . . . . . . . . . . . . . .
Vibration Level . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications . . . . . . . . . . . . . . . . . . . . .
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . .
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Activating, Charging, and Connecting the Battery
Checking the Angle Indicator . . . . . . . . . . . . . . . .
Installing the Hood Latch (CE) . . . . . . . . . . . . . . .
Installing the Exhaust Guard (CE) . . . . . . . . . . . . .
Adjusting the Lift Arms . . . . . . . . . . . . . . . . . . . . .
Rear Ballast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Crankcase Oil . . . . . . . . . . . . . . . . . .
Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . .
Checking the Cooling System . . . . . . . . . . . . . . . .
Checking the Hydraulic System . . . . . . . . . . . . . . .
Checking the Tire Pressure . . . . . . . . . . . . . . . . . .
Checking the Torque of the Wheel Nuts . . . . . . . .
W 2005 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
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All Rights Reserved
2
Printed in the USA
Introduction
CAUTION, WARNING, or DANGER—“personal
safety instruction.” Failure to comply with the
instruction may result in personal injury or death.
Read this manual carefully to learn how to operate and
maintain your product properly. The information in this
manual can help you and others avoid injury and product
damage. Although Toro designs and produces safe
products, you are responsible for operating the product
properly and safely.
Safe Operating Practices
The following instructions are from the CEN standard EN
836:1997, ISO standard 5395:1990, and ANSI standard
B71.4-1999.
Whenever you need service, genuine Toro parts, or
additional information, contact an Authorized Service
Dealer or Toro Customer Service and have the model and
serial numbers of your product ready. The two numbers are
stamped into a plate located on the frame of the mower.
Training
• Read the Operator’s Manual and other training material
carefully. Be familiar with the controls, safety signs,
and the proper use of the equipment.
Write the product model and serial numbers in the space
below:
• Never allow children or people unfamiliar with these
instructions to use the mower. Local regulations may
restrict the age of the operator.
Model No.
• Never mow while people, especially children, or pets
are nearby.
Serial No.
• Keep in mind that the operator or user is responsible for
accidents or hazards occurring to himself or herself,
other people, or property.
This manual identifies potential hazards and has special
safety messages that help you and others avoid personal
injury and even death. Danger, Warning, and Caution are
signal words used to identify the level of hazard. However,
regardless of the hazard, be extremely careful.
• Do not carry passengers.
• All drivers and mechanics should seek and obtain
professional and practical instruction. The owner is
responsible for training the users. Such instruction
should emphasize:
Danger signals an extreme hazard that will cause serious
injury or death if you do not follow the recommended
precautions.
– the need for care and concentration when working
with ride-on machines;
Warning signals a hazard that may cause serious injury or
death if you do not follow the recommended precautions.
– control of a ride-on machine sliding on a slope will
not be regained by the application of the brake. The
main reasons for loss of control are:
Caution signals a hazard that may cause minor or moderate
injury if you do not follow the recommended precautions.
This manual uses two other words to highlight information.
Important calls attention to special mechanical
information and Note: emphasizes general information
worthy of special attention.
• insufficient wheel grip;
Safety
• the type of machine is unsuitable for its task;
• being drive too fast;
• inadequate braking;
• lack of awareness of the effect of ground
conditions, especially slopes;
This machine meets or exceeds CEN standard EN
836:1997, ISO standard 5395:1990, and ANSI
B71.4-1999 specifications in effect at the time of
production when 50 lb. of calcium chloride ballast is
added to the rear wheels.
• incorrect hitching and load distribution.
Preparation
• While mowing, always wear substantial footwear, long
trousers, hard hat, safety glasses, and ear protection.
Long hair, loose clothing or jewelry may get tangled in
moving parts. Do not operate the equipment when
barefoot or wearing open sandals.
Improper use or maintenance by the operator or owner
can result in injury. To reduce the potential for injury,
comply with these safety instructions and always pay
symbol, which means
attention to the safety alert
3
• Thoroughly inspect the area where the equipment is to
be used and remove all objects which may be thrown by
the machine.
– The machine speed should be kept low on slopes
and during tight turns.
– Stay alert for humps and hollows and other hidden
hazards.
• Warning—fuel is highly flammable. Take the
following precautions:
– Never mow across the face of the slope, unless the
machine is designed for that purpose.
– Store fuel in containers specifically designed for this
purpose.
• Stay alert for holes in the terrain and other hidden
hazards.
– Refuel outdoors only and do not smoke while
refuelling.
• Watch out for traffic when crossing or near roadways.
– Add fuel before starting the engine. Never remove
the cap of the fuel tank or add fuel while the engine
is running or when the engine is hot.
• Stop the blades rotating before crossing surfaces other
than grass.
• When using any attachments, never direct discharge of
material toward bystanders nor allow anyone near the
machine while in operation.
– If fuel is spilled, do not attempt to start the engine
but move the machine away from the area of
spillage and avoid creating any source of ignition
until fuel vapors have dissipated.
• Never operate the machine with damaged guards,
shields, or without safety protective devices in place. Be
sure all interlocks are attached, adjusted properly, and
functioning properly.
– Replace all fuel tank and container caps securely.
• Replace faulty silencers/mufflers.
• Before using, always visually inspect to see that the
blades, blade bolts, and cutting assembly are not worn
or damaged. Replace worn or damaged blades and bolts
in sets to preserve balance.
• Do not change the engine governor settings or
overspeed the engine. Operating the engine at excessive
speed may increase the hazard of personal injury.
• Before leaving the operator’s position:
• On multi-bladed machines, take care as rotating one
blade can cause other blades to rotate.
– Stop on level ground.
– Disengage the power take-off and lower the
attachments.
• Evaluate the terrain to determine what accessories and
attachments are needed to properly and safely perform
the job. Only use accessories and attachments approved
by the manufacturer.
– Change into neutral and set the parking brake.
– Stop the engine and remove the key.
• Check that operator’s presence controls, safety
switches, and shields are attached and functioning
properly. Do not operate unless they are functioning
properly.
• Disengage drive to attachments, stop the engine, and
disconnect the spark plug wire(s) or remove the ignition
key:
– before clearing blockages;
Operation
– before checking, cleaning, or working on the
machine;
• Do not operate the engine in a confined space where
dangerous carbon monoxide fumes can collect.
– after striking a foreign object. Inspect the machine
for damage and make repairs before restarting and
operating the equipment;
• Mow only in daylight or in good artificial light.
• Before attempting to start the engine, disengage all
blade attachment clutches, shift into neutral, and engage
the parking brake. Only start the engine from the
operator’s position. Use seat belts, if provided.
– if the machine starts to vibrate abnormally (check
immediately).
• Disengage drive to attachments when transporting or
not is use.
• Remember there is no such thing as a safe slope. Travel
on grass slopes requires particular care. To guard
against overturning:
• Stop the engine and disengage drive to attachment:
– before refueling;
– Do not stop or start suddenly when going up or
downhill.
– before making height adjustment unless adjustment
can be made from the operator’s position.
– Engage the clutch slowly, always keep the machine
in gear, especially when travelling downhill.
4
• Carefully release pressure from components with stored
energy.
• Reduce the throttle setting during engine shut down
and, if the engine is provided with a fuel shut-off valve,
turn the valve off at the conclusion of mowing.
• Disconnect battery or remove spark plug wire before
making any repairs. Disconnect the negative terminal
first and the positive last. Reconnect positive first and
negative last.
• Never raise deck with the blades running.
• Keep hands and feet away from the cutting units.
• Look behind and down before backing up to be sure of
a clear path.
• Use care when checking blades. Wrap the blades or
wear gloves, and use caution when servicing them.
Only replace blades. Never straighten or weld them.
• Slow down and use caution when making turns and
crossing roads and sidewalks.
• Keep hands and feet away from moving parts. If
possible, do not make adjustments with the engine
running.
• Do not operate the mower under the influence of
alcohol or drugs.
• Charge batteries in an open well ventilated area, away
from spark and flames. Unplug charger before
connecting or disconnecting from battery. Wear
protective clothing and use insulated tools.
• Use care when loading or unloading the machine into a
trailer or truck.
• The operator shall turn on flashing warning lights, if
provided, whenever traveling on a public road, except
where such use is prohibited by law.
Toro Mower Safety
Maintenance and Storage
• Keep all nuts, bolts, and screws tight to be sure the
equipment is in safe working condition.
The following list contains safety information specific to
Toro products or other safety information that you must
know that is not included in the CEN, ISO, or ANSI
standards.
• Never store the equipment with fuel in the tank inside a
building where fumes may reach an open flame or
spark.
This product is capable of amputating hands and feet and
throwing objects. Always follow all safety instructions to
avoid serious injury or death.
• Allow the engine to cool before storing in any enclosure
and do not store near flame.
Use of this product for purposes other than its intended use
could prove dangerous to user and bystanders.
• To reduce the fire hazard, keep the engine,
silencer/muffler, battery compartment, cutting units,
drives, and fuel storage area free of grass, leaves, or
excessive grease. Clean up oil or fuel spillage.
Warning
• Replace worn or damaged parts for safety.
Engine exhaust contains carbon monoxide, which
is an odorless, deadly poison that can kill you.
• If the fuel tank has to be drained, do this outdoors.
Do not run engine indoors or in an enclosed area.
• On multi-bladed machines, take care as rotating one
blade can cause other blades to rotate.
Preparation
• When machine is to be parked, stored, or left
unattended, lower the cutting units unless a positive
mechanical lock is provided.
• Be sure to establish your own special procedures and
work rules for unusual operating conditions (E.G.
slopes too steep for operation). Survey the complete
mowing site to determine which hills can be safely
operated on. When performing this site survey, always
use common sense and take into consideration the turf
condition and the rollover risk. To determine which hills
or slopes may be safely operated on, use the
inclinometer provided with each machine. To perform a
site survey, follow the procedure outlined in the
Operation section of the this manual. The maximum
side hill angle should not be greater than 25 degrees.
• Disengage drives, lower the cutting units, move traction
pedal to Neutral, set parking brake, stop engine and
remove key. Wait for all movement to stop before
adjusting, cleaning or repairing.
• Shut off fuel while storing or transporting. Do not store
fuel near flames.
• Park machine on level ground. Never allow untrained
personnel to service machine.
• Use jack stands to support components when required.
5
Training
• For steering control, the cutting units must be lowered
when going down slopes.
• The operator must be skilled and trained in how to drive
on hillsides. Failure to use caution on slopes or hills
may cause the vehicle to tip or roll, possibly resulting in
personal injury or death.
• Avoid sudden stops and starts.
• Use the reverse pedal for braking.
• Watch for traffic when near or crossing roads. Always
yield the right-of-way.
Operation
• Raise the cutting units when driving from one work
area to another.
• Know how to stop the machine and engine quickly.
• Do not operate the machine while wearing tennis shoes
or sneakers.
• Do not touch the engine, muffler, exhaust pipe, or
hydraulic tank while the engine is running or soon after
it has stopped because these areas could be hot enough
to cause burns.
• Wearing safety shoes and long pants is advisable and
required by some local ordinances and insurance
regulations.
Maintenance and Storage
• Keep hands, feet, and clothing away from moving parts
and the mower discharge area.
• Before servicing or making adjustments, stop the engine
and remove the ignition key.
• Fill fuel tank until level is 1 in. (25 mm) below the
bottom of the filler neck. Do not overfill.
• Ensure that the entire machine is properly maintained
and in good operating condition. Frequently check all
nuts, bolts, screws, and hydraulic fittings.
• Check the safety interlock switches daily for proper
operation. If a switch should fail, replace the switch
before operating the machine. After every two years,
replace all interlock switches in the safety system,
regardless if they are working properly or not.
• Make sure all hydraulic line connectors are tight and all
hydraulic hoses and lines are in good condition before
applying pressure to the system.
• When starting the engine, engage the parking brake, put
the traction pedal in neutral, and disengage the blade
drive. After the engine starts, release the parking brake
and keep your foot off of the traction pedal. The
machine must not move. If movement is evident, refer
to the Maintenance section of this manual to adjust the
traction drive.
• Keep your body and hands away from pin hole leaks or
nozzles that eject hydraulic fluid under high pressure.
Use paper or cardboard, not your hands, to search for
leaks. Hydraulic fluid escaping under pressure can have
sufficient force to penetrate the skin and cause serious
injury. If fluid is injected into the skin it must be
surgically removed within a few hours by a doctor
familiar with this form of injury or gangrene may result.
• Use extreme caution when operating close to sand traps,
ditches, creeks, steep hillsides, or other hazards.
• Before disconnecting or performing any work on the
hydraulic system, all pressure in the system must be
relieved by stopping the engine and lowering the cutting
units to the ground.
• Reduce speed when making sharp turns.
• Do not turn on hills.
• Do not operate on a side hill that is too steep. A rollover
may occur before losing traction.
• If the engine must be running to perform a maintenance
adjustment, keep hands, feet, clothing, and any parts of
the body away from the cutting units, attachments, and
any moving parts. Keep everyone away.
• The slope angle at which the machine will tip is
dependent on many factors. Among these are mowing
conditions such as wet or undulating turn, speed
(especially in turns), position of the cutting units (with
the Sidewinder), tire pressure, and operator experience.
At side hill angles of 20 degrees or less, the risk of a
rollover is low. As the slope angle increases to a
recommended maximum limit of 25 degrees, the risk of
a rollover increases to a moderate level. Do not exceed
a 25 degree side hill slope angle because the risk of a
rollover and serious injury or death is very high. The
machine is equipped with an angle indicator mounted
on the steering tube. This indicates the side hill angle
the machine is on and identifies the recommended
maximum limit of 25 degrees.
• Do not overspeed the engine by changing governor
settings. To ensure safety and accuracy, have an
Authorized Toro Distributor check the maximum engine
speed with a tachometer.
• The engine must be shut off before checking the oil or
adding oil to the crankcase.
• If major repairs are ever needed or if assistance is
desired, contact an Authorized Toro Distributor.
• To make sure of optimum performance and continued
safety certification of the machine, use only genuine
Toro replacement parts and accessories. Replacement
6
Vibration Level
parts and accessories made by other manufacturers
could be dangerous, and such use could void the
product warranty.
This unit does not exceed a vibration level of 2.5 m/s2 at
the hands based on measurements of identical machines per
ISO 5349 procedures.
Sound Power Level
This unit does not exceed a vibration level of 0.5 m/s2 at
the posterior based on measurements of identical machines
per ISO 2631 procedures.
This unit has a guaranteed sound power level of 105 dBA,
based on measurements of identical machines per Directive
2000/14/EC and amendments.
Sound Pressure Level
This unit has an equivalent continuous A-weighted sound
pressure level at the operator ear of 89 dBA based on
measurements of identical machines per Directive
98/37/EC and amendments
Safety and Instruction 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.
94-3353
1. Crushing hazard of fingers and hands—keep hands away.
100-4837
93-7276
1. Explosion hazard—wear
eye protection.
2. Caustic liquid
hazard—flush with water
and get medical help fast.
99-3558 (for CE)
1. Warning—read the operator’s manual.
2. To start the engine, sit on the seat and rotate the ignition key to
On/Preheat until the glow plug indicator light goes out. Rotate
the key to start and disengage the parking brake. Read the
operator’s manual for further instructions.
3. To stop the engine, disengage the cutting units, rotate the
ignition key to Off, and remove the key. Engage the parking
brake. Read the operator’s manual for further instructions.
7
3. Fire hazard—fire, open
light, and smoking
prohibited.
4. Toxic hazard—keep
children away from the
battery.
93-7818
1. Warning—read the operator’s manual for blade torque
instructions.
43-8480
107-7801 (for CE)
93-6681
1. Tipping hazard—do not drive on slopes greater than 15
degrees.
1. Cutting/dismemberment hazard—stay away from moving parts.
99-3444
1. Reel speed—fast
104-0484
104-1086
1. Height of cut
8
2. Reel speed—slow
106-6753 (for CE)
104-5181 (for CE)
1. Thrown object
hazard—keep bystanders
a safe distance from the
machine.
1. Warning—read the Operator’s Manual.
2. Tipping hazard—do not drive on slopes greater than 15
degrees and, if the roll bar is installed, wear the seat belt.
3. Thrown object hazard—keep bystanders a safe distance from
the machine.
4. Cutting hazard of hand or foot—stay away from moving parts.
5. Warning—lock the parking brake, stop the engine, and remove
the ignition key before leaving the machine.
2. Cutting/dismemberment
hazard of hand or foot,
mower blade—stay away
from moving parts.
106-6754
1. Warning—do not touch the hot surface.
2. Cutting/dismemberment hazard, fan and entanglement hazard,
belt—stay away from moving parts
Battery Symbols
Some or all of these symbols are on your battery.
1. Explosion hazard
2. No fire, open flames, or
smoking.
3. Caustic liquid/chemical
burn hazard
4. Wear eye protection
5. Read the Operator’s
Manual.
6. Keep bystanders a safe
distance from the battery.
7. Wear eye protection;
explosive gases can
cause blindness and
other injuries
8. Battery acid can cause
blindness or severe
burns.
9. Flush eyes immediately
with water and get
medical help fast.
10. Contains lead; do not
discard.
9
104–5191
1. Engage the power take off
(PTO).
2. Disengage the power take
off (PTO).
3. Lower the cutting units.
4. Move the cutting units to the
right.
5. Raise the cutting units.
6. Move the cutting units to the
left.
7. Move rear ward to lock the
lift lever.
8. Engine—stop
107-7800
10
9.
10.
11.
12.
13.
Engine—run
Engine=start
Fast
Continuous variable setting
Slow
Specifications
General Specifications
Engine
Cooling system
Electrical
Kubota three-cylinder, 4-cycle liquid-cooled diesel engine. 32 hp @ 2800 RPM,
governed to 3050 RPM. 68.5 cu. in. (1124 cc) displacement. Heavy-duty, 2-stage,
remote mounted air cleaner. High water temperature shutdown switch.
Radiator capacity is approximately 6 qt. of 50/50 mixture of ethylene glycol
anti-freeze. Remote mounted 1 qt. expansion tank.
12 volt Group 55, 585 cold cranking amps at 0°F (–18°C), 95 minute reserve
capacity at 80°F (27°C). 40 amp alternator with regulator/rectifier. Seat switch,
PTO, parking brake and traction interlock switches.
Fuel capacity
11 gallons
Traction drive
High torque hydraulic wheel motors, 3-wheel drive, oil cooler and shuttle valve
provide positive closed-loop cooling.
Hydraulic oil capacity/filter Remote mounted, 3.5 gallon oil reservoir. 10 micron remote mounted spin on filter.
Infinitely variable speed selection in forward and reverse
Ground speed
Mowing speed: 0–6 MPH (adjustable)
Transport speed: 0–9 MPH
Reverse speed: 0–3.5 MPH
Tires/wheels
Frame
Steering
Brakes
Controls
Gauges and protective
systems
Seat
Cutting unit lift
Front tires are 20 x 12-10 and rear tires are 20 x 10-10 tubeless, 4-ply rating with
demountable rims. Recommended tire pressure: 14–18 psi front and rear tires.
Tricycle vehicle with 3-wheel traction drive and rear wheel steering. Frame consists
of formed steel, welded steel, and steel tubing components.
Power steering
Service braking accomplished through dynamic characteristics of Hydrostat.
Parking or emergency brake is actuated by over-center hand lever on the
operator’s right-hand side.
Foot operated forward and reverse traction pedals and mow/transport slide. Hand
operated throttle, ignition switch, blade engagement switch, cutting unit lift, and shift
lever, parking brake, and seat adjustment.
Hour meter, 4 light warning cluster gauge: oil pressure, water temperature, amps,
glow plug, and side hill angle indicator.
Standard
Hydraulic lift
Note: Specifications and design subject to change without notice.
11
Setup
Note: Determine the left and right sides of the machine from the normal operating position.
Loose Parts
Note: Use this chart as a checklist to ensure that all parts necessary for assembly have been received. Without these parts,
total setup cannot be completed. Some parts may have already been assembled at the factory.
Description
Qty.
Use
Hood lock bracket
1
Screw, 1/4 x 1-1/2 in.
1
Flat washer, 1/4 in.
1
Locknut, 1/4 in.
1
Exhaust guard
1
Self-tapping screw
4
Inclinometer
1
For site survey before operating the machine
EEC Decal
6
Affix to machine for European compliance.
Key
2
EEC certificate
1
Parts Catalog
1
Operator’s Manual
2
Engine manual
1
Operator video
1
View before operating the machine.
Pre-delivery check list
1
Fill out before delivering to the customer.
12
Mount to the hood for European compliance.
Mount to machine for European compliance.
Read before operating the machine.
Activating, Charging, and
Connecting the Battery
Warning
Charging the battery produces gasses that can
explode.
Warning
Never smoke near the battery and keep sparks and
flames away from battery.
CALIFORNIA
Proposition 65 Warning
5. When the battery is charged, disconnect the charger
from the electrical outlet and battery posts.
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.
6. Remove the filler caps. Slowly add electrolyte to each
cell until the level is up to the fill ring. Install the filler
caps.
Important Do not overfill the battery. Electrolyte will
overflow onto other parts of the machine and severe
corrosion and deterioration will result.
Note: If the battery is not filled with electrolyte or
activated, bulk electrolyte with 1.260 specific gravity must
be purchased from a local battery supply outlet and added
to the battery.
7. Install the positive cable (red) to the positive (+)
terminal and the negative cable (black) to the negative
(–) terminal of the battery and secure them with
capscrews and nuts (Fig. 2). Make sure that the positive
(+) terminal is all of the way onto the post and the cable
is positioned snug to the battery. The cable must not
contact the battery cover. Slide the rubber boot over the
positive terminal to prevent a possible short from
occurring.
Danger
Battery electrolyte contains sulfuric acid which is a
deadly poison and causes severe burns.
• Do not drink electrolyte and avoid contact with
skin, eyes or clothing. Wear safety glasses to
shield your eyes and rubber gloves to protect
your hands.
• Fill the battery where clean water is always
available for flushing the skin.
Warning
Incorrect battery cable routing could damage the
tractor and cables causing sparks. Sparks can
cause the battery gasses to explode, resulting in
personal injury.
1. Open the hood.
2. Remove the battery cover (Fig. 1).
• Always disconnect the negative (black) battery
cable before disconnecting the positive (red)
cable.
• Always connect the positive (red) battery cable
before connecting the negative (black) cable.
1
Figure 1
1. Battery cover
2
3. Remove the filler caps from the battery and slowly fill
each cell until electrolyte is just above the plates.
1
Figure 2
4. Install the filler caps and connect a 3 to 4 amp. battery
charger to the battery posts. Charge the battery at a rate
of 3 to 4 amperes for 4 to 8 hours.
1. Positive (+) battery cable
13
2. Negative (–) battery cable
Installing the Hood Latch (CE)
Important If the battery is ever removed, make sure
that battery clamp bolts are reinstalled with the bolt heads
positioned on the bottom side and the nuts on the top side.
If the clamp bolts are reversed, they may interfere with the
hydraulic tubes when shifting the cutting units.
1. Unhook the hood latch from the hood latch bracket
(Fig. 4).
2. Slide the hood lock bracket onto the latch (Fig. 4).
8. Coat both battery connections with Grafo 112X (skin
over) grease, Toro Part No. 505-47, petroleum jelly, or
light grease to prevent corrosion. Slide the rubber boot
over the positive terminal.
3. Hook the latch onto the hood latch bracket (Fig. 4).
4. Insert a bolt (1/4 x 1-1/2 in.) through the hood lock
bracket and secure it with a flat washer and locknut
(Fig. 4).
9. Install the battery cover.
2
Checking the Angle Indicator
3
Danger
1
To reduce risk of injury or death due to rollover,
do not operate the machine on side hills steeper
than 255.
Figure 4
1. Park the machine on a flat, level surface.
1. Hood latch
2. Hood latch bracket
2. Verify that the machine is level by placing a hand held
inclinometer (supplied with the machine) on the frame
cross rail, by the fuel tank (Fig. 3). The inclinometer
should read zero degrees when viewed from the
operator’s position.
3. Hood lock bracket
Installing the Exhaust Guard
(CE)
1. Position the exhaust guard around the muffler while
aligning the mounting holes with the holes in the frame
(Fig. 5).
2. Secure the exhaust guard to the frame with 4
self-tapping screws (Fig. 5).
1
Figure 3
1. Angle indicator
3. If the inclinometer does not read zero degrees, move the
machine to a location where a zero degree reading is
obtained. The angle indicator, mounted on the machine,
should now read zero degrees as well.
4. If the angle indicator does not read zero degrees, loosen
the two screws and nuts securing the angle indicator to
the mounting bracket, adjust the indicator to obtain a
zero degree reading, and tighten the capscrews.
1
Figure 5
1. Exhaust guard
14
Adjusting the Lift Arms
1. Start the engine, raise the decks, and check to make sure
that the clearance between each lift arm and the floor
plate bracket is .18–.32 in. (5–8 mm) (Fig. 6). If the
clearance is not in this range, back off the stop bolts
(Fig. 7) and adjust the cylinder to attain clearance. To
adjust the cylinder, back off the jam nut on the cylinder
(Fig. 8), remove the pin from the rod end, and rotate the
clevis. Install the pin and check the clearance. Repeat
the procedure if required. Tighten the clevis jam nut.
2
Figure 8
2
1. Front cylinder
2. Jam nut
3. Start the engine, raise the decks, and check to make sure
that the clearance between the wear strap on the top of
the rear cutting unit wear bar and the bumper strap is
0.02–0.10 in. (0.51–2.54 mm) (Fig. 9). If the clearance
is not in this range, adjust the rear cylinder to attain
clearance. To adjust the cylinder, lower the cutting units
and back off the jam nut on the cylinder (Fig. 10).
Grasp the cylinder rod close to the nut with a pliers and
rag and rotate the rod. Raise the cutting units and check
the clearance. Repeat the procedure if required. Tighten
the clevis jam nut.
3
1
Figure 6
Decks removed for clarity
1. Lift arm
2. Floor plate bracket
1
Note: If the rear lift arm “clunks” during transport,
clearance can be reduced.
3. Clearance
2. Check to make sure that the clearance between each lift
arm and stop bolt is 0.005–0.040 in. (0.13–1.02 mm)
(Fig. 7). If the clearance is not in this range, adjust the
stop bolts to attain clearance.
2
1
Figure 9
1
1. Wear bar
3
2. Bumper strap
2
Figure 7
1. Stop bolt
2. Lift arm
3. Clearance
1
2
Figure 10
1. Rear cylinder
2. Adjusting nut
Important Lack of clearance at the front stops or rear
wear bar could damage the lift arms.
15
Rear Ballast
and check the oil level. If the oil level is low, add
enough oil to raise the level to the FULL mark on the
dipstick.
The Groundsmaster 3500 Traction unit with 27” Rotary
Cutting decks conforms to the B71.4-1999 standard when
50 lb. of calcium chloride ballast is added to the rear
wheels.
Important If a puncture occurs in a tire with calcium
chloride, remove the machine from the turf as quickly as
possible. To prevent possible damage to the turf,
immediately soak the affected area with water.
1
Before Operating
Figure 11
1. Dipstick
Caution
3. If the oil level is low, remove the oil fill cap (Fig. 12)
and gradually add small quantities of oil, checking the
level frequently, until the level reaches the FULL mark
on the dipstick.
If you leave the key in the ignition switch, someone
could accidently start the engine and seriously
injure you or other bystanders.
1
Remove the key from the ignition before you do
any maintenance.
Checking the Crankcase Oil
The engine is shipped with oil in the crankcase; however,
the oil level must be checked before and after the engine is
first started.
Figure 12
Crankcase capacity is approximately 4 qt. (2.8 l) with the
filter.
1. Oil fill cap
Use high-quality engine oil that meets the following
specifications:
4. Install the oil fill cap and close the hood.
API Classification Level Required: CH–4, CI–4 or
higher.
Important Check the oil level every 5 operating hours
or daily. Change the oil and filter initially after the first 50
hours of operation; thereafter change the oil and filter every
150 hours.
Preferred oil: SAE 15W–40 (above 0_F)
Alternate oil: SAE 10W–30 or 5W–30
(all temperatures)
Filling the Fuel Tank
Toro Premium Engine oil is available from your distributor
in either 15W–40 or 10W–30 viscosity. See the parts
catalog for part numbers.
The engine runs on No. 2 diesel fuel.
1. Position the machine on a level surface.
Fuel tank capacity is approximately 11 gallons.
2. Remove the dipstick (Fig. 11) and wipe it with a clean
rag. Push the dipstick down into the dipstick tube and
make sure that it is seated fully. Pull the dipstick out
1. Clean the area around the fuel tank cap (Fig. 13).
2. Remove the fuel tank cap.
3. Fill the tank to the bottom of the filler neck. Do not
overfill. Install the cap.
16
4. To prevent a fire hazard, wipe up any fuel that may
have spilled.
1
2
3
1
Figure 13
1. Fuel tank cap
Figure 14
1. Access panel
2. Radiator
Danger
3. Oil cooler
The cooling system is filled with a 50/50 solution of water
and permanent ethylene glycol anti-freeze. Check the
coolant level at the beginning of each day before starting
the engine.
Under certain conditions, diesel fuel and fuel
vapors are highly flammable and explosive. A fire
or explosion from fuel can burn you and others
and can cause property damage.
The capacity of the cooling system is approximately 6 U.S.
quarts (5.7 l).
• Use a funnel and fill the fuel tank outdoors, in
an open area, when the engine is off and is cold.
Wipe up any fuel that spills.
• Do not fill the fuel tank completely full. Add fuel
to the fuel tank until the level is 1/4 to 1/2 in. (6
to 13 mm) below the bottom of the filler neck.
This empty space in the tank allows the fuel to
expand.
• Never smoke when handling fuel, and stay away
from an open flame or where fuel fumes may be
ignited by a spark.
• Store fuel in a clean, safety-approved container
and keep the cap in place.
Caution
If the engine has been running, the pressurized,
hot coolant can escape and cause burns.
• Do not open the radiator cap when the engine is
running.
• Use a rag when opening the radiator cap, and
open the cap slowly to allow steam to escape.
1. Check the coolant level in the expansion tank (Fig. 15).
With a cold engine, the coolant level should be
approximately midway between the marks on the side
of the tank.
Checking the Cooling System
Clean debris off of the radiator and oil cooler daily
(Fig. 14). Clean the radiator hourly if conditions are
extremely dusty and dirty; refer to Cleaning the Engine
Cooling System, page 36.
2. If the coolant level is low, remove the expansion tank
cap and replenish the system. Do not overfill.
3. Install the expansion tank cap.
17
Biodegradable Hydraulic Fluid – Mobil 224H
1
Toro Biodegradable Hydraulic Fluid
(Available in 5 gallon pails or 55 gallon drums. See
parts catalog or Toro distributor for part numbers.)
Alternate fluid: Mobil EAL 224H
This is vegetable–oil based biodegradable oil tested and
approved by Toro for this model. This fluid is not as
resistant to to high temperatures as standard fluid, so install
an oil cooler if required by the operator manual and follow
recommended fluid change intervals with this fluid.
Contamination by mineral–based hydraulic fluids will
change the biodegradability and toxicity of this oil. When
changing from standard fluid to the biodegradable type, be
certain to follow the approved flushing procedure. Contact
your local Toro Distributor for details.
Figure 15
1. Expansion tank
1. Position the machine on a level surface, lower the
cutting units, and stop the engine.
Checking the Hydraulic System
2. Clean the area around the filler neck and cap of the
hydraulic tank (Fig. 16). Remove the cap.
The machines reservoir is filled at the factory with
approximately 3.5 U.S. gallons (13.2 l) of high quality
hydraulic fluid. Check the level of the hydraulic fluid
before the engine is first started and daily thereafter.
The recommended replacement fluid is:
1
Toro Premium All Season Hydraulic Fluid
(Available in 5 gallon pails or 55 gallon drums. See
parts catalog or Toro distributor for part numbers.)
Alternate fluids: If the Toro fluid is not available, other
fluids may be used provided they meet all the following
material properties and industry specifications. We do not
recommend the use of synthetic fluid. Consult with your
lubricant distributor to identify a satisfactory product Note:
Toro will not assume responsibility for damage caused by
improper substitutions, so use only products from reputable
manufacturers who will stand behind their
recommendation.
Figure 16
1. Hydraulic tank cap
High Viscosity Index/Low Pour Point Antiwear
Hydraulic Fluid, ISO VG 46
3. 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. The fluid level
should be within 1/4 inch (6 mm) of the mark on the
dipstick.
Material Properties:
Viscosity, ASTM D445
4. If the level is low, add the appropriate fluid to raise the
level to the full mark.
cSt @ 40_C 44 to 48
cSt @ 100_C 7.9 to 8.5
5. Install the dipstick and cap onto the filler neck.
Viscosity Index ASTM D2270 140 to 160
Pour Point, ASTM D97
Checking the Tire Pressure
–34_F to –49_F
Industry Specifications:
Vickers I–286–S (Quality Level), Vickers M–2950–S
(Quality Level), Denison HF–0
The tires are over-inflated for shipping. Therefore, release
some of the air to reduce the pressure. The correct air
pressure in the tires is 14–18 psi (97–124 kPa).
Note: Many hydraulic fluids are almost colorless, making it
difficult to spot leaks. A red dye additive for the hydraulic
system oil is available in 2/3 oz. (20 ml) bottles. One bottle
is sufficient for 4–6 gal (15–22 1) of hydraulic oil. Order
part no.44–2500 from your authorized Toro distributor.
Important Maintain the recommended pressure in all
tires to ensure a good quality of cut and proper machine
performance.
18
Danger
Low tire pressure decreases machine side hill
stability. This could cause a rollover, which may
result in personal injury or death.
Do not under-inflate the tires.
Checking the Torque of the
Wheel Nuts
Warning
Failure to maintain proper torque of the wheel
nuts could result in personal injury.
Torque the wheel nuts to 45–65 ft.-lb. (61–88 NVm)
after 1–4 hours of operation and again after 10
hours of operation. Torque every 200 hours
thereafter.
19
Operation
Note: Determine the left and right sides of the machine
from the normal operating position.
1
Caution
This machine produces sound levels in excess of
85 dBA at the operators ear and can cause hearing
loss through extended periods of exposure.
Wear hearing protection when operating this
machine.
Figure 18
1. Speed stop screw
Controls
Traction Pedals
Tilt Steering Lever
Depress the traction forward pedal (Fig. 17) to move
forward. Depress traction reverse pedal (Fig. 17) to move
backward or to assist in stopping when moving forward.
Also, allow the pedal to move or move it to the neutral
position to stop the machine.
Pull the tilt steering lever (Fig. 17) back to tilt the steering
wheel to the desired position. Then push the lever forward
to tighten.
Mow/Transport Slide
The slot in the operator platform (Fig. 17) indicates when
the cutting units are in the center position.
Indicator Slot
Using your heel, move the mow/transport slide (Fig. 17) to
the left to transport and to the right to mow. The cutting
units will only operate in the mow position.
Angle Indicator
The angle indicator (Fig. 17) indicates the side hill angle of
the machine in degrees.
Note: Mow speed is set at the factory to 6 MPH (9.7 km/h).
It can be increased or decreased by adjusting the speed stop
screw (Fig. 18).
Ignition Switch
4
6
5
3
The ignition switch (Fig. 19), used to start, stop and preheat
the engine, has three positions: Off, On/Preheat, and Start.
Rotate the key to the On/Preheat position until the glow
plug indicator light goes out (approximately 7 seconds);
then rotate the key to the Start position to engage the starter
motor. Release the key when the engine starts. The key will
move automatically to the On/Run position. To shut the
engine off, rotate the key to the Off position. Remove the
key from the switch to prevent accidental starting.
1
2
Throttle
Moving the throttle (Fig. 19) forward increases the engine
speed; rearward decreases the engine speed.
Figure 17
1. Forward traction pedal
2. Reverse traction pedal
3. Mow/transport slide
Cutting Unit Drive Switch
4. Tilt steering lever
5. Indicator slot
6. Angle indicator
The cutting unit drive switch (Fig. 19) has two positions:
Engage and Disengage. The rocker switch operates a
solenoid valve on the valve bank to drive the cutting units.
20
7
4
3
Danger
2
Shifting the cutting units downhill decreases
machine stability. This could cause a rollover,
which may result in personal injury or death.
8
6
5
Shift the cutting units uphill while on a side hill.
10
11
9
Engine Coolant Temperature Warning
Light
1
The temperature warning light (Fig. 19) glows if the engine
coolant temperature is high. If the traction unit is not
stopped and the coolant temperature rises another 10°F, the
engine will kill.
Figure 19
1.
2.
3.
4.
5.
6.
Throttle
Hour meter
Temperature light
Oil pressure light
Glow plug indicator light
Alternator light
7.
8.
9.
10.
11.
Cutting unit drive switch
Cutting unit shift lever
Ignition switch
Parking brake
Lift lever lock
Oil Pressure Warning Light
The oil pressure warning light (Fig. 19) glows if the engine
oil pressure drops below a safe level.
Hour Meter
Alternator Light
The hour meter (Fig. 19) indicates the total hours of
machine operation. The hour meter starts to function
whenever the key switch is On.
The alternator light (Fig. 19) should be off when the engine
is running. If it is on, the charging system should be
checked and repaired as necessary.
Cutting Unit Shift Lever
Glow Plug Indicator
To lower the cutting units to the ground, move the cutting
unit shift lever (Fig. 19) forward. The cutting units will not
drop unless the engine is running. To raise the cutting units,
pull the shift lever rearward to the Raise position.
The glow plug indicator light (Fig. 19) will glow when the
glow plugs are operating.
Parking Brake
Move the lever to the right or left to move the cutting units
in the same direction. This should only be done when the
cutting units are raised or if they are on the ground and the
machine is moving.
Whenever the engine is shut off, the parking brake (Fig. 19)
must be engaged to prevent accidental movement of the
machine. To engage the parking brake, pull up on the lever.
The engine will stop if the traction pedal is depressed with
the parking brake engaged.
Note: The lever does not have to be held in the forward
position while the cutting units are lowered.
Lift Lever Lock
Move the lift lever lock (Fig. 19) rearward to prevent the
cutting units from dropping.
21
Fuel Gauge
Important To prevent overheating of the starter motor,
do not engage the starter longer than 15 seconds. After 10
seconds of continuous cranking, wait 60 seconds before
engaging the starter motor again.
The fuel gauge (Fig. 20) registers the amount of fuel in the
tank.
5. When the engine is started for the first time, or after an
overhaul of the engine, operate the machine in forward
and reverse for one to two minutes. Also operate the lift
lever and deck drive switch to be sure of proper
operation of all parts.
Seat Adjustments
Fore and Aft Adjustment (Fig. 20)—Move the lever on the
side of the seat outward, slide the seat to the desired
position, and release the lever to lock the seat into position.
Turn the steering wheel to the left and right to check
steering response; then shut the engine off and check for oil
leaks, loose parts, and any other noticeable malfunctions.
Caution
Shut the engine off and wait for all moving parts to
stop before checking for oil leaks, loose parts, and
other malfunctions.
6. To stop the engine, move the throttle control to the Idle
position, move the deck drive switch to Disengage, and
rotate the starter key to Off. Remove the key from the
switch to prevent accidental starting.
2
1
Bleeding the Fuel System
Figure 20
1. Fore and aft lever
1. Park the machine on a level surface. Make sure that the
fuel tank is at least half full.
2. Fuel gauge
2. Unlatch and raise the hood.
Starting and Stopping the
Engine
Danger
Under certain conditions, diesel fuel and fuel
vapors are highly flammable and explosive. A fire
or explosion from fuel can burn you and others
and can cause property damage.
Important The fuel system may have to be bled if any
of the following situations have occurred:
• Initial start up of a new engine
• The engine has ceased running due to lack of fuel.
• Use a funnel and fill the fuel tank outdoors, in
an open area, when the engine is off and is cold.
Wipe up any fuel that spills.
• Do not fill the fuel tank completely full. Add fuel
to the fuel tank until the level is 1/4 to 1/2 in. (6
to 13 mm) below the bottom of the filler neck.
This empty space in the tank allows the fuel to
expand.
• Never smoke when handling fuel, and stay away
from an open flame or where fuel fumes may be
ignited by a spark.
• Store fuel in a clean, safety-approved container
and keep the cap in place.
• Maintenance has been performed upon the fuel system
components; i.e. filter replaced, etc.
Refer to Bleeding the Fuel System, page 22.
1. Be sure that the parking brake is set and the deck drive
switch is in the Disengage position.
2. Remove your foot from the traction pedal and make
sure that the pedal is in the neutral position.
3. Move the throttle lever to the 1/2 throttle position.
4. Insert the key into the switch and rotate it to the
On/Preheat position until the glow plug indicator light
goes out (approximately 7 seconds); then rotate the key
to the Start position to engage the starter motor. Release
the key when the engine starts. The key will move
automatically to the On/Run position.
3. Open the air bleed screw on the fuel injection pump
(Fig. 21).
22
seat and slowly depress the traction pedal, the engine
should stop in one to three seconds. Correct problem if
it is not operating properly.
1
Note: The machine is equipped with an interlock switch on
the parking brake. The engine will stop if the traction pedal
is depressed with the parking brake engaged.
Towing the Traction Unit
In case of an emergency, the machine can be towed for a
short distance; however, we do not recommend this as a
standard procedure.
Figure 21
Important Do not tow the machine faster than
2–3 MPH (3–4 km/h) because the drive system may
become damaged. If the machine must be moved a
considerable distance, transport it on a truck or trailer.
1. Fuel injection pump bleed screw
4. Turn the key in the ignition switch to the On position.
The electric fuel pump will begin operation, thereby
forcing air out around the air bleed screw. Leave the key
in the On position until a solid stream of fuel flows out
around the screw. Tighten the screw and turn the key to
Off.
1. Locate the bypass valve on the pump (Fig. 22) and
rotate it 90°.
Note: Normally the engine should start after the above
bleeding procedures are followed. However, if the engine
does not start, air may be trapped between the injection
pump and injectors; refer to Bleeding Air from the
Injectors, page 36.
1
Checking the Interlock System
Figure 22
1. Bypass valve
Caution
2. Before starting the engine, close the bypass valve by
rotating it 90° (1/4 turn). Do not start the engine when
the valve is open.
If safety interlock switches are disconnected or
damaged the machine could operate unexpectedly
causing personal injury.
• Do not tamper with the interlock switches.
• Check the operation of the interlock switches
daily and replace any damaged switches before
operating the machine.
• Replace switches every two years regardless of
whether they are operating properly or not.
1. Make sure that all bystanders are away from the area of
operation. Keep hands and feet away from the cutting
units.
2. While sitting on the seat, the engine must not start with
either the deck switch engaged or the traction pedal
engaged. Correct the problem if it is not operating
properly.
3. While sitting on the seat, put the traction pedal in
neutral, the parking brake off, and the deck switch in
the Off position. The engine should start. Rise from the
23
Standard Control Module
(SCM)
Output circuits are energized by an appropriate set of input
conditions. The three outputs include PTO, ETR, and
START. Output LED’s monitor relay condition indicating
the presence of voltage at one of three specific output
terminals.
The Standard Control Module is a ”potted” electronic
device produced in a ”one size fits all” configuration. The
module uses solid state and mechanical components to
monitor and control standard electrical features required for
safe product operation.
Output circuits do not determine output device integrity so
electrical troubleshooting includes output LED inspection
and conventional device and wire harness integrity testing.
Measure disconnected component impedance, impedance
through wire harness (disconnect at SCM), or by
temporarily ”test energizing” the specific component.
The module monitors inputs including neutral, parking
brake, PTO, start, backlap, and high temperature. The
module energizes outputs including PTO, Starter, and ETR
(energize to run) solenoid.
The SCM does not connect to an external computer or hand
held device, can not be re–programmed, and does not
record intermittent fault troubleshooting data.
The module is divided into inputs and outputs. Inputs and
outputs are identified by green LED indicators mounted on
the printed circuit board.
The decal on the SCM only includes symbols. Three LED
output symbols are shown in the output box. All other
LED’s are inputs. The chart below identifies the symbols.
The start circuit input is energized by 12 VDC. All other
inputs are energized when the circuit is closed to ground.
Each input has a LED that is illuminated when the specific
circuit is energized. Use the input LED’s for switch and
input circuit troubleshooting.
Inputs
Backlap
PTO
Hi Temp
Start
In Seat
ETR
PTO Switch
Start
Outputs
Park Brake Off
Power
Neutral
5. If specific output LED is illuminated without
appropriate output function, check output harness,
connections, and component. Repair as required.
Here are the logical troubleshooting steps for the SCM
device.
1. Determine the output fault you are trying to resolve
(PTO, START, or ETR).
6. If specific output LED is not illuminated, check both
fuses.
2. Move key switch to ”ON” and ensure the red ”power”
LED is illuminated.
7. If specific output LED is not illuminated and inputs are
in appropriate condition, install new SCM and
determine if fault disappears.
3. Move all input switches to ensure all LED’s change
state.
4. Position input devices at appropriate position to achieve
the appropriate output. Use the following logic chart to
determine the appropriate input condition.
24
Each row (across) in the logic chart below identifies input and output requirements for each specific product function.
Product functions are listed in the left column. Symbols identify specific circuit condition including: energized to voltage,
closed to ground, and open to ground.
– Indicates a circuit closed to ground. – LED ON
O Indicates a circuit open to ground or de–energized – LED OFF
+ Indicates an energized circuit (clutch coil, solenoid, or start input) LED ON.
” ” A Blank indicates a circuit that is not involved with the logic.
To troubleshoot, turn on the key without starting the engine.
Identify the specific function that does not work and work
across the logic chart. Inspect the condition of each input
LED’s to ensure it matches the logic chart.
If the input LED’s are correct, check the output LED. If the
output LED is illuminated but the device is not energized,
measure available voltage at the output device, continuity
of the disconnected device, and potential voltage on the
ground circuit (floating ground). Repairs will vary
depending on your findings.
25
Operating Characteristics
Practice moving forward and reverse, and starting and
stopping the machine. To stop, take your foot off of the
traction pedal and let it return to neutral or press down on
the reverse pedal to stop. Going down a hill, you may need
to use the reverse pedal to stop.
Danger
The mower has a unique traction system that will
allow the machine to move forward on side hills,
even if the uphill wheel should come off of the
ground. If this should happen, the operator or any
bystanders can be seriously injured or killed in a
rollover.
When driving on slopes, drive slowly to maintain steering
control and avoid turns to prevent rollovers. In side hill
situations you should shift the sidewinder cutting units
to the uphill side to give you more stability. Conversely,
shifting the cutting units to the down hill side will give
you less stability. This should always be done before
going on a side hill.
The slope angle at which the machine will tip is
dependent on many factors. Among these are:
mowing conditions such as wet of undulating turf,
speed (especially in turns), position of the cutting
units (with Sidewinder), tire pressure, and
operator experience.
When possible, mow up and down hills rather than across
them. Have the cutting units lowered when going down a
hill to maintain steering control. Do not attempt to turn on a
hill.
Practice driving around obstacles with the decks up and
down. Be careful when driving between narrow objects so
you do not damage the machine or cutting units.
At side hill angles of 20 degrees or less, the risk of a
rollover is low. As the slope angle increases to a
recommended maximum limit of 25 degrees, the
risk of a rollover increases to a moderate level. Do
not exceed a 25 degree side hill slope angle because
the risk of a rollover and serious injury or death is
very high.
On the Sidewinder unit, get a feel for the reach of the
cutting units so you do not hang them up or damage them
in any way.
Do not shift the units from side to side, unless the cutting
units are down and the machine is moving, or the cutting
units are up in the transport position. Shifting the cutting
units when they are down and the machine is not moving
may cause turf damage.
To determine which hills or slopes may be safely
operated on, a site survey of the mowing area must
be done. When performing this site survey, always
use common sense and take into consideration the
turf condition and the rollover risk. To determine
which hills or slopes may be safely operated on, use
the inclinometer provided with each machine. To
perform a site survey, lay a 4 ft. 2x4 (1.25 meter
plank) on the slope surface and measure the angle
of the slope. The 2x4 will average the slope but will
not take into consideration dips or holes which can
cause a sudden change in side hill angle. The
maximum side hill angle should not be greater than
25 degrees.
Always drive slowly in rough areas.
If a person appears in or near the operating area, stop the
machine, and do not start it again until the area is cleared.
The machine is designed for one person. Never let anyone
else ride on the machine with you. This is extremely
dangerous and could result in serious injury.
Accidents can happen to anyone. The most common causes
are excessive speed, sudden turns, terrain (not knowing
which slopes and hills can be mowed safely), not stopping
the engine before leaving the operator’s seat, and drugs
which impair your alertness. Cold capsules or prescription
drugs may cause drowsiness, as can alcohol and other
drugs. Stay alert and stay safe. Failure to do so could result
in serious injury.
Additionally, the machine is equipped with an
angle indicator mounted on the steering tube. This
indicates the side hill angle the machine is on and
identifies the recommended maximum limit of 25
degrees.
The Sidewinder offers up to a maximum of 13 inches
(33 cm) of overhang, allowing you to trim closer to the
edge of sand traps and other obstacles, while at the same
time keeping the tractor tires as far away from the edge of
traps or water hazards as possible.
Always wear your seat belt.
Practice operating the machine and become thoroughly
familiar with it.
If an obstacle is in the way, shift the cutting units to easily
mow around it.
Start the engine and run it at half idle until it warms up.
Push the throttle lever all the way forward, lift the cutting
units, disengage the parking brake, press the forward
traction pedal, and carefully drive to an open area.
When transporting the machine from one work area to
another, raise the cutting units to the fully up position,
move the mow/transport slide to the left to transport, and
place the throttle in the Fast position.
26
Mowing Techniques
After Mowing
To begin cutting, engage the decks, then approach the
mowing area slowly. Once the front decks are over the
mowing area, lower the cutting units.
At the completion of mowing operation, thoroughly wash
the machine with a garden hose without a nozzle so that
excessive water pressure will not cause contamination and
damage to the seals and bearings. Make sure that the
radiator and oil cooler are kept free of dirt or grass
clippings. After cleaning, it is recommended that the
machine be inspected for possible hydraulic fluid leaks,
damage or wear to the hydraulic and mechanical
components, and the cutting unit blades checked for
sharpness.
To achieve the professional straight-line cut and striping
that is desirable for some applications, find a tree or other
object in the distance and drive straight toward it.
As soon as the front decks reach the edge of the mowing
area, lift the cutting units and perform a tear drop shaped
turn to quickly line you up for your next pass.
Important After washing the machine, move the
Sidewinder mechanism from left to right several times to
remove water between the bearing blocks and cross tube.
To mow around bunkers, ponds, or other contours easily,
use the Sidewinder and move the control lever left or right,
depending on your mowing application. The cutting units
can also be shifted to vary tire tracking.
The decks tend to throw grass to the left side of the
machine. If trimming around bunkers, it is best to mow in a
clockwise direction to prevent throwing clippings into the
bunker.
The cutting decks can be equipped with bolt-in mulching
baffles. The mulching baffles perform well when turf is
maintained on a regular schedule to avoid removing more
than 1 inch (25 mm) of growth per cutting. When too much
growth is cut with the mulching baffles installed, 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 of the year.
Mow When Grass is Dry
Mow either in the late morning to avoid the dew, which
causes grass clumping, or in late afternoon to avoid the
damage that can be caused by direct sunlight on the
sensitive, freshly mowed grass.
Select the Proper Height-of-Cut Setting to
Suit Conditions
Remove approximately one inch or no more than 1/3 of the
grass blade when cutting. In exceptionally lush and dense
grass you may have to raise your height–of–cut setting
another notch.
Always Start Mowing with Sharp Blades
A sharp blade cuts cleanly and without tearing or shredding
the grass blades like a dull blade. Tearing and shredding
causes the grass to turn brown at the edges which impairs
growth and increases susceptibility to diseases. Make sure
blade is in good condition and a full sail is present.
Check Condition of Deck
Make sure cutting chambers are in good condition.
Straighten any bends in chamber components to assure
correct blade tip/chamber clearance.
27
Maintenance
Note: Determine the left and right sides of the machine from the normal operating position.
Recommended Maintenance Schedule
Maintenance Service
Interval
Maintenance Procedure
After first 10 hours
• Check the fan and alternator belt tension.
• Replace the hydraulic filter.
• Torque the wheel lug nuts.
After first 50 hours
• Change the engine oil and filter.
• Check the engine RPM (at idle and full throttle).
Inspect the air filter, dust cup, and burp valve.
Lubricate all grease fittings.
Check the battery cable connections.
Check the fan and alternator belt tension.
Check the battery fluid level.
Every 50 hours
•
•
•
•
•
Every 150 hours
• Change the engine oil and filter.
• Inspect the traction belt.
Every 200 hours
• Replace the air filter.
• Replace the hydraulic filter.
• Torque the wheel lug nuts.
Every 400 hours
•
•
•
•
•
Every 800 hours or
annually, whichever
occurs first
Every 1000 hours or 2
years, whichever occurs
first
Important
procedures.
Replace the hydraulic fluid.
Replace the fuel/water separator filter.
Replace the fuel prefilter.
Inspect the traction cable movement.
Check the engine RPM (at idle and full throttle).
• Adjust the valves.
• Inspect, disassemble and install new seals in cutting unit roller assemblies.
•
•
•
•
•
Replace all moving hoses.
Replace the safety switches.
Flush the cooling system and replace the fluid.
Drain and flush the fuel tank.
Drain and flush the hydraulic tank.
Refer to your engine operator’s manual and cutting unit operator’s manual for additional maintenance
Caution
If you leave the key in the ignition switch, someone could accidently start the engine and
seriously injure you or other bystanders.
Remove the key from the ignition before you do any maintenance.
28
Daily Maintenance Checklist
Duplicate this page for routine use.
For the week of:
Maintenance Check Item
Mon.
Tues.
Wed.
Thurs.
Check the safety interlock operation.
Check brake operation.
Check the engine oil level.
Check the cooling system fluid level.
Drain the water/fuel separator.
Check the air filter, dust cup, and burp
valve.
Check the radiator and screen for
debris.
Check for unusual engine noises.1
Check for unusual operating noises.
Check the hydraulic system oil level.
Check the hydraulic hoses for damage.
Check for fluid leaks.
Check the fuel level.
Check the tire pressure.
Check instrument operation.
Check the height-of-cut adjustment.
Lubricate all grease fittings.2
Touch up damaged paint.
1Check
the glow plug and injector nozzles if starting is hard, there is excess smoke, or rough running is noted.
after every washing, regardless of the interval listed
2Immediately
Notation for Areas of Concern
Inspection performed by:
Item
Date
Information
1
2
3
4
5
6
7
8
9
10
29
Fri.
Sat.
Sun.
Greasing the Bearings and
Bushings
The traction unit has grease fittings that must be lubricated
regularly with No. 2 General Purpose Lithium Base Grease.
If the machine is operated under normal conditions,
lubricate the bearings and bushings after every 50 hours of
operation. The bearings and bushings must be lubricated
daily when operating conditions are extremely dusty and
dirty. Dusty and dirty operating conditions could cause dirt
to get into the bearings and bushings, resulting in
accelerated wear. Lubricate bearings and bushings
immediately after every washing, regardless of the interval
listed.
Figure 23
The grease fitting locations and quantities are:
• Rear cutting unit pivot (Fig. 23)
• Front cutting unit pivot (Fig. 24)
• SideWinder cylinder ends (2) (Fig. 25)
• Steering pivot (Fig. 26)
• Rear lift arm pivot and lift cylinder (2) (Fig. 27)
• Left front lift arm pivot and lift cylinder (2) (Fig. 28)
Figure 24
• Right front lift arm pivot and lift cylinder (2) (Fig. 29)
• Neutral adjust mechanism (Fig. 30)
• Mow/transport slide (Fig. 31)
• Belt tension pivot (Fig. 32)
• Steering cylinder (Fig. 33).
Note: If desired, an additional grease fitting may be
installed in the other end of the steering cylinder. Remove
the tire, install the fitting, grease the fitting, remove the
fitting, and install the plug (Fig. 34).
(2)
• Cutting unit spindle shaft bearings (1 per cutting unit)
(Fig. 35)
• Rear roller bearings (2 per cutting unit) (Fig. 36)
Note: The flush fittings on the rollers (Fig. 36) require a
grease gun nozzle adapter. Order Toro Part No. 107–1998
from your Authorized Toro Distributor.
Important Do not lubricate the Sidewinder cross tube.
The bearing blocks are self-lubricated.
Figure 25
30
Figure 29
Figure 26
(2)
Figure 30
Figure 27
Figure 31
Figure 28
31
Figure 35
Figure 32
Figure 36
Figure 33
Figure 34
See note
32
Service Interval Chart
33
Removing the Hood
force dirt through the filter into the intake tract. This
cleaning process prevents debris from migrating into
the intake when the primary filter is removed.
The hood may be easily removed to ease maintenance
procedures in the engine area of the machine.
1. Unlatch and raise the hood.
2
2. Remove the cotter pin securing the hood pivot to the
mounting brackets (Fig. 37).
1
1
Figure 38
1. Air cleaner cover
Figure 37
2. Air cleaner latch
3. Remove and replace the primary filter (Fig. 39).
Cleaning of the used element is not recommended due
to the possibility of damage to the filter media. Inspect
the new filter for shipping damage, checking the sealing
end of the filter and the body. Do not use a damaged
element. Insert the new filter by applying pressure to
the outer rim of the element to seat it in the canister. Do
not apply pressure to the flexible center of the filter.
1. Cotter pin
3. Slide the hood to the right side, lift the other side, and
pull it out of the brackets.
4. Reverse the procedure to install the hood.
General Air Cleaner
Maintenance
4. Clean the dirt ejection port located in the removable
cover. Remove the rubber outlet valve from the cover,
clean the cavity and replace the outlet valve.
• Check the air cleaner body for damage which could
cause an air leak. Replace if damaged. Check the whole
intake system for leaks, damage or loose hose clamps.
5. Install the cover orienting the rubber outlet valve in a
downward position – between approximately 5:00 to
7:00 when viewed from the end.
• Service at the recommended service interval or earlier if
engine performance suffers due to extremely dusty,
dirty conditions. Changing the air filter before it is
necessary only increases the chance of dirt entering the
engine when the filter is removed.
1
• Be sure the cover is seated correctly and seals with the
air cleaner body.
Servicing the Air Cleaner
Service the air cleaner filter every 200 hours (more
frequently in extreme dusty or dirty conditions).
1. Release the latches securing the air cleaner cover to the
air cleaner body (Fig. 38).
Figure 39
2. Remove the cover from the air cleaner body. Before
removing the filter, use low pressure air (40 psi, clean
and dry) to help remove large accumulations of debris
packed between outside of primary filter and the
canister. Avoid using high pressure air which could
1. Primary filter
6. Install the cover and secure the latches. Make sure that
the cover is positioned with the TOP side up.
34
Servicing the Engine Oil and
Filter
Servicing the Fuel System
Change the oil and filter initially after the first 50 hours of
operation; thereafter change the oil and filter every 150
hours.
Drain and clean the fuel tank every 2 years. Also, drain and
clean the tank if the fuel system becomes contaminated or
if the machine will be stored for an extended period of
time. Use clean fuel to flush out the tank.
Fuel Tank
1. Remove either drain plug (Fig. 40) and let oil flow into
a drain pan. When the oil stops flowing, install the drain
plug.
Fuel Lines and Connections
Check the fuel lines and connections every 400 hours or
yearly, whichever comes first. Inspect them for
deterioration, damage, or loose connections.
Water Separator
Drain water or other contaminants from the water separator
(Fig. 42) daily.
1. Place a clean container under the fuel filter.
2. Loosen the drain plug on the bottom of the filter
canister (Fig. 42). Tighten the plug after draining.
1
Figure 40
1. Engine oil drain plug
1
2. Remove the oil filter (Fig. 41). Apply a light coat of
clean oil to the new filter seal before screwing it on. Do
not overtighten.
3. Add oil to the crankcase; refer to Checking the
Crankcase Oil, page 16.
2
Figure 42
1. Water separator
2. Drain plug
Replace the filter canister after every 400 hours of
operation.
1
1. Clean the area where the filter canister mounts.
2. Remove the filter canister and clean the mounting
surface.
3. Lubricate the gasket on the filter canister with clean oil.
Figure 41
4. Install the filter canister by hand until the gasket
contacts the mounting surface; then rotate an additional
1/2 turn.
1. Engine oil filter
35
Replacing the Fuel Prefilter
4. Remove the clamp from the fuel filter and slide it onto
the replacement filter. Push the fuel lines onto the
replacement fuel filter and secure them with the hose
clamps. Be sure that the arrow on the side of the filter
points toward the injection pump.
Replace the fuel prefilter, located on the inside of the frame
rail below the water separator, after every 400 operating
hours or yearly, whichever occurs first.
1. Remove the screw securing the filter to the frame rail.
5. Secure the filter to the frame rail with the previously
removed screw.
2. Clamp both fuel lines that connect to the fuel filter so
that fuel cannot drain when the lines are removed.
Bleeding Air from the Injectors
Danger
Note: This procedure should be used only if the fuel system
has been purged of air through normal priming procedures
and the engine will not start; refer to Bleeding the Fuel
System, page 22.
Under certain conditions, diesel fuel and fuel
vapors are highly flammable and explosive. A fire
or explosion from fuel can burn you and others
and can cause property damage.
1. Loosen the pipe connection to the No. 1 nozzle and
holder assembly.
• Use a funnel and fill the fuel tank outdoors, in
an open area, when the engine is off and is cold.
Wipe up any fuel that spills.
• Do not fill the fuel tank completely full. Add fuel
to the fuel tank until the level is 1/4 to 1/2 in. (6
to 13 mm) below the bottom of the filler neck.
This empty space in the tank allows the fuel to
expand.
• Never smoke when handling fuel, and stay away
from an open flame or where fuel fumes may be
ignited by a spark.
• Store fuel in a clean, safety-approved container
and keep the cap in place.
1
3. Loosen the hose clamps at both ends of the filter
(Fig. 43) and pull the fuel lines off of the filter.
Figure 44
1. Fuel injectors
2. Move the throttle to the Fast position.
3. Turn the key in the key switch to the Start position and
watch the fuel flow around the connector. Turn the key
to the Off position when solid flow is observed.
2
2
4. Tighten the pipe connector securely.
1
5. Repeat the procedure on the remaining nozzles.
Figure 43
1. Fuel prefilter
2. Hose clamps
Cleaning the Engine Cooling
System
Remove debris from the oil cooler and radiator daily. Clean
them more frequently in dirty conditions.
36
Alternator/Fan Belt
1. Turn the engine off and raise the hood. Clean the engine
area thoroughly of all debris.
1. Open the hood.
2. Remove the access panel (Fig. 45).
2. Check the tension by depressing the belt midway
between the alternator and crankshaft pulleys with
22 lb. (30 N⋅m) of force. The belt should deflect
7/16 in. (11 mm). If the deflection is incorrect, proceed
to step 3. If it is correct, continue operation.
3
2
1
1
Figure 45
1. Access panel
2. Oil cooler
3. Radiator
Figure 47
1. Alternator/fan belt
3. Unlatch the oil cooler and pivot it rearward (Fig. 46).
Clean both sides of the oil cooler and radiator area
thoroughly with water or compressed air. Pivot the oil
cooler back into position.
3. Loosen the bolt securing the brace to the engine and the
bolt securing the alternator to the brace.
4. Insert a pry bar between the alternator and engine and
pry out on the alternator.
5. When the proper tension is achieved, tighten the
alternator and brace bolts to secure the adjustment.
Replacing the Hydrostat Drive Belt
1. Insert a nut driver or small piece of tubing onto the end
of the belt tensioning spring.
Warning
Use caution when de-tensioning the spring, as it is
under a heavy load.
Figure 46
4. Install the access panel and close the hood.
2. Push down and forward on the spring end (Fig. 48) to
unhook it from the bracket and release tension on the
spring.
Servicing the Engine Belts
3. Replace the belt.
4. Reverse the procedure to tension the spring.
Check condition and tension of all belts after first day of
operation and every 100 operating hours thereafter.
37
7. If the throttle does not stay in position during operation,
torque the locknut, used to set the friction device on the
throttle lever, to 40–55 in.-lb. (5–6 N⋅m). The maximum
force required to operate the throttle lever should be
20 lb. (27 N⋅m).
2
Changing the Hydraulic Fluid
1
Change the hydraulic fluid after every 400 operating hours,
in normal conditions. If the fluid becomes contaminated,
contact your local Toro distributor because the system must
be flushed. Contaminated fluid looks milky or black when
compared to clean oil.
1. Turn the engine off and raise the hood.
Figure 48
1. Hydrostat drive belt
2. Disconnect the hydraulic line (Fig. 50) or remove the
hydraulic filter (Fig. 51) and let the hydraulic fluid flow
into a drain pan. Install the hydraulic line when
hydraulic fluid stops draining.
2. Spring end
Adjusting the Throttle
1. Position the throttle lever rearward so it stops against
the control panel slot.
2. Loosen the throttle cable connector on the injection
pump lever arm (Fig. 49).
1
Figure 50
1
1. Hydraulic line
Figure 49
1. Injection pump lever arm
3. Hold the injection pump lever arm against the low idle
stop and tighten the cable connector.
1
4. Loosen the screws securing the throttle control to the
control panel.
Figure 51
1. Hydraulic filter
5. Push the throttle control lever all of the way forward.
6. Slide the stop plate until it contacts the throttle lever
and tighten the screws securing the throttle control to
the control panel.
3. Fill the reservoir (Fig. 52) with approximately 3.5 U.S.
gallons (13.2 l) of hydraulic fluid; refer to Checking the
Hydraulic System, page 18.
38
6. Start the engine and let it run for about two minutes to
purge air from the system. Stop the engine and check
for leaks.
Important Use only the hydraulic fluids specified.
Other fluids could cause system damage.
Checking the Hydraulic Lines
and Hoses
1
Daily, check hydraulic lines and hoses for leaks, kinked
lines, loose mounting supports, wear, loose fittings, weather
deterioration, and chemical deterioration. Make all
necessary repairs before operating.
Warning
Figure 52
Hydraulic fluid escaping under pressure can
penetrate skin and cause injury.
1. Hydraulic reservoir
• Make sure 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 pin hole
leaks or nozzles that eject high pressure
hydraulic fluid.
• Use cardboard or paper to find hydraulic leaks.
• Safely relieve all pressure in the hydraulic
system before performing any work on the
hydraulic system.
• Seek immediate medical attention if fluid is
injected into skin.
4. Install the reservoir cap. Start the engine and use all of
the hydraulic controls to distribute the hydraulic fluid
throughout the system. Also check for leaks; then stop
the engine.
5. Check the fluid level and add enough to raise the level
to FULL mark on the dipstick. Do not overfill.
Replacing the Hydraulic Filter
The hydraulic system filter must be changed initially, after
the first 10 hours of operation, and thereafter every 200
hours of operation or yearly, whichever comes first. Use a
genuine Toro oil filter for replacement. The hydraulic oil
must be changed every 400 hours of operation or yearly,
whichever comes first.
Adjusting the Traction Drive for
Neutral
Use Toro replacement filter Part No. 86-3010.
If the machine moves when the traction pedal is in the
neutral position, the traction cam must be adjusted.
Important Use of any other filter may void the
warranty on some components.
1. Park the machine on a level surface and turn the engine
off.
1. Position the machine on a level surface, lower the
cutting units, stop the engine, engage the parking brake,
and remove the key from the ignition switch.
2. Raise one front wheel and one rear wheel off of the
floor and place support blocks under the frame.
2. Pinch off the hose to the filter mounting plate.
Warning
3. Clean around the filter mounting area. Place a drain pan
under the filter (Fig. 51) and remove the filter.
If the machine is not supported adequately, it may
accidentally fall, injuring anyone under the
machine.
4. Lubricate the new filter gasket and fill the filter with
hydraulic fluid.
5. Ensure that the filter mounting area is clean. Screw the
filter on until the gasket contacts the mounting plate;
then tighten the filter 1/2 turn.
One front wheel and one rear wheel must be raised
off of the ground or the machine will move during
adjustment.
39
3. Loosen the locknut on the traction adjustment cam
(Fig. 53).
3
1
2
1
Figure 54
2
1. Parking brake lever
2. Knob
Figure 53
1. Traction adjustment cam
3. Set screw
2. Locknut
Caring for the Battery
Warning
The battery electrolyte level must be properly maintained
and the top of the battery kept clean. lf the machine is
stored in a location where temperatures are extremely high,
the battery will run down more rapidly than if the machine
is stored in a location where temperatures are cool.
The engine must be running so a final adjustment
of the traction adjustment cam can be performed.
Contact with hot or moving parts can result in
personal injury.
Check the electrolyte level every 25 operating hours or, if
machine is in storage, every 30 days.
Keep hands, feet, face, and other body parts away
from the muffler, other hot parts of the engine, and
other rotating parts.
Maintain the cell level with distilled or demineralized
water. Do not fill the cells above the bottom of the split ring
inside each cell. Install the filler caps with the vents
pointing to the rear (toward the fuel tank).
4. Start the engine and rotate the cam hex in both
directions to determine the mid position of the neutral
span.
Danger
5. Tighten the locknut securing the adjustment.
Battery electrolyte contains sulfuric acid which is a
deadly poison and causes severe burns.
6. Stop the engine.
7. Remove the support blocks and lower the machine to
the shop floor. Test drive the machine to make sure it
does not move when the traction pedal is in neutral.
• Do not drink electrolyte and avoid contact with
skin, eyes or clothing. Wear safety glasses to
shield your eyes and rubber gloves to protect
your hands.
• Fill the battery where clean water is always
available for flushing the skin.
Adjusting the Parking Brake
Check the adjustment of the parking brake every 200 hours.
1. Loosen the set screw securing the knob to the parking
brake lever (Fig. 54).
Keep the top of the battery clean by washing it periodically
with a brush dipped in ammonia or bicarbonate of soda
solution. Flush the top surface with water after cleaning.
Do not remove the filler caps while cleaning.
2. Rotate the knob until a force of 30–40 lb. (41–68 N⋅m)
is required to actuate the lever.
The battery cables must be tight on the terminals to provide
good electrical contact.
3. Tighten the set screw after the adjustment has been
attained.
40
Storing the Battery
Warning
If the machine will be stored more than 30 days, remove
the battery and charge it fully. Either store it on the shelf or
on the machine. Leave the cables disconnected if it is stored
on the machine. Store the battery in a cool atmosphere to
avoid quick deterioration of the charge in the battery. To
prevent the battery from freezing, make sure it is fully
charged. The specific gravity of a fully charged battery is
1.265–1.299.
Incorrect battery cable routing could damage the
tractor and cables causing sparks. Sparks can
cause the battery gasses to explode, resulting in
personal injury.
• Always disconnect the negative (black) battery
cable before disconnecting the positive (red)
cable.
• Always connect the positive (red) battery cable
before connecting the negative (black) cable.
Fuses
The fuses in machines electrical system are located under
console cover.
If corrosion occurs at the terminals, disconnect the cables,
negative (–) cable first, and scrape the clamps and terminals
separately. Reconnect the cables, positive (+) cable first,
and coat the terminals with petroleum jelly.
Always disconnect the battery cables, ground cable (–)
first, to prevent possible wiring damage from shorts
whenever working with the electrical system.
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.
41
Electrical Schematic
42
Hydraulic Schematic
43
Preparation for Seasonal
Storage
Engine
1. Drain the engine oil from the oil pan and replace the
drain plug.
Traction Unit
2. Remove and discard the oil filter. Install a new oil filter.
1. Thoroughly clean the traction unit, cutting units, and
engine.
3. Refill the oil pan with approximately 4 U.S. quarts
(3.8 l) of SAE15W-40 motor oil.
2. Check the tire pressure. Inflate all tires to 14–18 psi
(97–110 kPa).
4. Start the engine and run it at idle speed for
approximately two minutes.
3. Check all fasteners for looseness; tighten as necessary.
5. Stop the engine.
4. Grease or oil all grease fittings and pivot points. Wipe
up any excess lubricant.
6. Thoroughly drain all fuel from the fuel tank, fuel lines,
fuel filter, and water separator assembly.
5. Cover the entire length of the Sidewinder cross tube
with a light oil to prevent rust. After storage, wipe off
all of the oil.
7. Flush the fuel tank with fresh, clean diesel fuel.
8. Secure all fuel system fittings.
6. Lightly sand and use touch-up paint on painted areas
that are scratched, chipped, or rusted. Repair any dents
in the metal body.
9. Thoroughly clean and service the air cleaner assembly.
10. Seal the air cleaner inlet and the exhaust outlet with
weatherproof tape.
7. Service the battery and cables as follows:
11. Check anti-freeze protection and add as needed for
expected minimum temperature in your area.
A. Remove the battery terminals from the battery posts.
B. Clean the battery, terminals, and posts with a wire
brush and baking soda solution.
C. Coat the cable terminals and battery posts with
Grafo 112X skin-over grease (Toro Part No. 505-47)
or petroleum jelly to prevent corrosion.
D. Slowly recharge the battery every 60 days for 24
hours to prevent lead sulfation of the battery.
44
45
46
47
The Toro General Commercial Products 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. Where a warrantable condition
exists, we will repair the Product at no cost to you including
diagnosis, labor, parts, and transportation. This warranty begins
on the date the Product is delivered to the original retail purchaser.
* Product equipped with hour meter
Instructions for Obtaining Warranty Service
You are responsible for notifying the Commercial Products
Distributor or Authorized Commercial Products Dealer from whom
you purchased the Product as soon as you believe a warrantable
condition exists.
If you need help locating a Commercial Products Distributor or
Authorized Dealer, or if you have questions regarding your
warranty rights or responsibilities, you may contact us at:
Toro Commercial Products Service Department
Toro Warranty Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
952-888-8801 or 800-982-2740
E-mail: commercial.service@toro.com
Owner Responsibilities
As the Product owner, you are responsible for required maintenance and adjustments stated in your operator’s manual. Failure
to perform required maintenance and adjustments can be grounds
for disallowing a warranty claim.
Items and Conditions Not Covered
Not all product failures or malfunctions that occur during the
warranty period are defects in materials or workmanship. This
express warranty does not cover the following:
• Product failures which result from the use of non-Toro
replacement parts, or from installation and use of add-on,
modified, or unapproved accessories
• Product failures which result from failure to perform required
maintenance and/or adjustments
• Product failures which result from operating the Product in an
abusive, negligent or reckless manner
• Parts subject to consumption through use unless found to be
defective. Examples of parts which are consumed, or used up,
during normal Product operation include, but are not limited to,
blades, reels, bedknives, tines, spark plugs, castor wheels,
tires, filters, belts, and certain sprayer components such as
diaphragms, nozzles, and check valves, etc.
•
•
Failures caused by outside influence. Items considered to be
outside influence include, but are not limited to, weather,
storage practices, contamination, use of unapproved coolants,
lubricants, additives, or chemicals, etc.
Normal “wear and tear” items. Normal “wear and tear” includes,
but is not limited to, damage to seats due to wear or abrasion,
worn painted surfaces, scratched decals or windows, etc.
Parts
Parts scheduled for replacement as required maintenance are
warranted for the period of time up to the scheduled replacement
time for that part.
Parts replaced under this warranty become the property of Toro.
Toro will make the final decision whether to repair any existing part
or assembly or replace it. Toro may use factory remanufactured
parts rather than new parts for some warranty repairs.
General Conditions
Repair by an Authorized Toro Distributor or Dealer is your sole
remedy under this warranty.
Neither The Toro Company nor Toro Warranty Company is
liable for indirect, incidental or consequential damages in
connection with the use of the Toro Products covered by this
warranty, including any cost or expense of providing substitute equipment or service during reasonable periods of
malfunction or non-use pending completion of repairs under
this warranty. Except for the Emissions warranty referenced
below, if applicable, there is no other express warranty. All
implied warranties of merchantability and fitness for use are
limited to the duration of this express warranty.
Some states do not allow exclusions of incidental or consequential
damages, or limitations on how long an implied warranty lasts, so
the above exclusions and limitations may not apply to you.
This warranty gives you specific legal rights, and you may also
have other rights which vary from state to state.
Note regarding engine warranty: The Emissions Control System
on your Product may be covered by a separate warranty meeting
requirements established by the U.S. Environmental Protection
Agency (EPA) and/or the California Air Resources Board (CARB).
The hour limitations set forth above do not apply to the Emissions
Control System Warranty. Refer to the Engine Emission Control
Warranty Statement printed in your operator’s manual or contained in the engine manufacturer’s documentation for details.
Countries Other than the United States or Canada
Customers who have purchased Toro products exported from the United States or Canada should contact their Toro Distributor (Dealer)
to obtain guarantee policies for your country, province, or state. If for any reason you are dissatisfied with your Distributor’s service or
have difficulty obtaining guarantee information, contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty
Company.
Part No. 374-0031 Rev. C
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