Toro Reelmaster 3550 Traction Unit Riding Product Operator's Manual

Toro Reelmaster 3550 Traction Unit Riding Product Operator's Manual
Form No. 3432-531 Rev A
Reelmaster® 3555, 3575, and 3550
Traction Unit
Model No. 03820—Serial No. 403446001 and Up
Model No. 03821—Serial No. 403446001 and Up
Model No. 03910—Serial No. 403446001 and Up
Register at www.Toro.com.
Original Instructions (EN)
*3432-531* A
Visit www.Toro.com for more information, including
safety tips, training materials, accessory information,
help finding a dealer, or to register your product.
This product complies with all relevant European
directives. For details, please see the separate
product specific Declaration of Conformity (DOC)
sheet.
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. Figure 1
identifies the location of the model and serial numbers
on the product. Write the numbers in the space
provided.
It is a violation of California Public Resource Code
Section 4442 or 4443 to use or operate the engine on
any forest-covered, brush-covered, or grass-covered
land unless the engine is equipped with a spark
arrester, as defined in Section 4442, maintained in
effective working order or the engine is constructed,
equipped, and maintained for the prevention of fire.
Important: With your mobile device, you can
scan the QR code on the serial number decal (if
equipped) to access warranty, parts, and other
product information.
The enclosed engine owner's manual is supplied
for information regarding the US Environmental
Protection Agency (EPA) and the California Emission
Control Regulation of emission systems, maintenance,
and warranty. Replacements may be ordered through
the engine manufacturer.
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.
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.
Use of this product may cause exposure
to chemicals known to the State of
California to cause cancer, birth defects,
or other reproductive harm.
g240238
Figure 1
1. Model and serial number location
Model No.
Serial No.
This manual identifies potential hazards and has
safety messages identified by the safety-alert symbol
(Figure 2), which signals a hazard that may cause
serious injury or death if you do not follow the
recommended precautions.
Introduction
This machine is a ride-on, reel-blade lawn mower
intended to be used by professional, hired operators
in commercial applications. It is primarily designed
for cutting grass on well-maintained turf. Using this
product for purposes other than its intended use could
prove dangerous to you and bystanders.
Figure 2
Safety-alert symbol
Read this information carefully to learn how to operate
and maintain your product properly and to avoid
injury and product damage. You are responsible for
operating the product properly and safely.
This manual uses 2 words to highlight information.
Important calls attention to special mechanical
information and Note emphasizes general information
worthy of special attention.
© 2019—The Toro® Company
8111 Lyndale Avenue South
Bloomington, MN 55420
g000502
2
Contact us at www.Toro.com.
Printed in the USA
All Rights Reserved
Contents
Draining the Water Separator ........................... 44
Changing the Fuel Filter Canister...................... 44
Bleeding Air from the Injectors .......................... 44
Electrical System Maintenance ........................... 45
Electrical System Safety ................................... 45
Servicing the Battery......................................... 45
Checking the Fuses .......................................... 45
Drive System Maintenance .................................. 46
Checking the Tire Pressure............................... 46
Torquing the Wheel Nuts................................... 46
Adjusting the Traction Drive for Neutral ............. 46
Cooling System Maintenance .............................. 47
Cooling System Safety ..................................... 47
Checking the Cooling System ........................... 47
Cleaning the Engine Cooling System ................ 48
Brake Maintenance ............................................. 48
Adjusting the Parking Brake.............................. 48
Belt Maintenance ................................................ 49
Servicing the Engine Belts ................................ 49
Controls System Maintenance ............................. 50
Adjusting the Throttle........................................ 50
Hydraulic System Maintenance ........................... 50
Hydraulic System Safety................................... 50
Checking the Hydraulic Lines and
Hoses............................................................ 50
Checking the Hydraulic Fluid ............................ 50
Hydraulic Fluid Specifications........................... 51
Hydraulic Fluid Capacity ................................... 51
Changing the Hydraulic Fluid ............................ 52
Changing the Hydraulic Filter............................ 52
Cutting Unit System Maintenance ........................ 53
Blade Safety ..................................................... 53
Checking the Reel-to-Bedknife Contact ............ 53
Using the Optional Gauge Bar .......................... 54
Backlapping the Cutting Units ........................... 54
Cleaning .............................................................. 55
Washing the Machine ....................................... 55
Storage ................................................................... 56
Storage Safety.................................................. 56
Preparing the Traction Unit ............................... 56
Preparing the Engine ........................................ 56
Safety ....................................................................... 4
General Safety ................................................... 4
Engine-Emission Certification............................. 4
Safety and Instructional Decals .......................... 5
Setup ...................................................................... 13
1 Installing the Cutting Units.............................. 14
2 Adjusting the Turf Compensation
Spring ........................................................... 16
3 Installing the CE Decals ................................. 17
4 Installing the Hood Latch (CE Only)................ 17
5 Reducing the Tire Pressure............................ 18
6 Using the Cutting-Unit Kickstand.................... 18
Product Overview ................................................... 19
Controls ........................................................... 19
Specifications .................................................. 23
Attachments/Accessories ................................. 23
Before Operation ................................................. 24
Before Operation Safety ................................... 24
Performing Daily Maintenance.......................... 24
Filling the Fuel Tank .......................................... 24
Adjusting the Seat ............................................ 25
During Operation ................................................. 26
During Operation Safety ................................... 26
Starting the Engine ........................................... 27
Shutting Off the Engine..................................... 27
Setting the Reel Speed ..................................... 27
Adjusting the Lift-Arm Counterbalance ............. 29
Bleeding the Fuel System ................................. 29
Understanding the Diagnostic Light .................. 30
Understanding the Diagnostic ACE
Display .......................................................... 30
Checking the Interlock Switches ....................... 30
Operating Tips ................................................. 32
After Operation .................................................... 33
After Operation Safety ...................................... 33
Pushing or Towing the Machine ........................ 33
Hauling the Machine ......................................... 34
Identifying the Tie-Down Points ........................ 35
Maintenance ........................................................... 36
Maintenance Safety.......................................... 36
Recommended Maintenance Schedule(s) ........... 36
Daily Maintenance Checklist............................. 38
Pre-Maintenance Procedures .............................. 39
Removing the Hood .......................................... 39
Removing the Battery Cover ............................. 39
Lubrication .......................................................... 40
Greasing the Bearings and Bushings ................ 40
Engine Maintenance ........................................... 41
Engine Safety ................................................... 41
Checking the Engine-Oil Level.......................... 41
Servicing the Air Cleaner .................................. 42
Changing the Engine Oil and Filter.................... 43
Fuel System Maintenance ................................... 43
Servicing the Fuel Tank..................................... 43
Inspecting the Fuel Lines and
Connections.................................................. 43
3
Safety
This machine has been designed in accordance
with EN ISO 5395 (when you complete the setup
procedures) and ANSI B71.4-2017.
General Safety
This product is capable of amputating hands and feet
and of throwing objects.
• Read and understand the contents of this
Operator’s Manual before starting the engine.
• Use your full attention while operating the
machine. Do not engage in any activity that
causes distractions; otherwise, injury or property
damage may occur.
• Do not put your hands or feet near moving
components of the machine.
• Do not operate the machine without all guards
and other safety protective devices in place and
functioning properly on the machine.
• Keep bystanders and children out of the operating
area. Never allow children to operate the machine.
• Shut off the engine, remove the key, and wait
for all movement to stop before you leave the
operator’s position. Allow the machine to cool
before adjusting, servicing, cleaning, or storing it.
Improperly using or maintaining this machine can
result in injury. To reduce the potential for injury,
comply with these safety instructions and always
pay attention to the safety-alert symbol , which
means Caution, Warning, or Danger—personal safety
instruction. Failure to comply with these instructions
may result in personal injury or death.
Engine-Emission
Certification
The engine in this machine is EPA Tier 4 Final and EU
Stage V emissions compliant.
4
Safety and Instructional Decals
Safety decals and instructions are easily visible to the operator and are located near any area
of potential danger. Replace any decal that is damaged or missing.
decal133-8062
decal110-9642
133-8062
110-9642
1. Stored energy hazard—read the Operator's Manual.
2. Move the cotter pin to the hole closest to the rod bracket
and then remove the lift arm and pivot yoke.
decal93-7276
93-7276
1. Explosion hazard—wear eye protection.
2. Caustic liquid/chemical burn hazard—to perform first aid,
flush with water.
3. Fire hazard—no fire, open flames, or smoking.
4. Poison hazard—keep children away from the battery.
decal117-3270
117-3270
1. Warning—do not touch the hot surface.
99-3444
2. Cutting/dismemberment hazard, hand; entanglement
hazard, belt—stay away from moving parts, keep all guards
and shields in place.
decal99-3444
99-3444
1. Transport speed—fast
2. Mowing speed—slow
decal120-0627
120-0627
1. Cutting/dismemberment hazard, fan—stay away from
moving parts, keep all guards and shields in place.
decal106-6755
106-6755
1. Engine coolant under
pressure.
3. Warning—do not touch the
hot surface.
2. Explosion hazard—read
the Operator's Manual.
4. Warning—read the
Operator's Manual.
5
decal120-1683
120-1683
4. Warning—do not park the machine on slopes; engage the
parking brake, lower the cutting units, shut off the engine, and
remove the key before leaving the machine.
1. Warning—read the Operator's Manual; all operators should
be trained before operating the machine.
5. Thrown object hazard—keep bystanders away.
2. Warning—read the Operator's Manual before towing the
machine.
3. Tipping hazard—drive slowly when turning; do not turn sharply 6. Entanglement hazard, belt—stay away from moving parts;
while traveling fast; lower the cutting units when driving down
keep all guards and shields in place.
slopes; use a rollover protection system and wear the seatbelt.
6
decal120-2105
120-2105
1. Lower the cutting units.
5. Read the Operator’s Manual for
9. Engine—Start
information on starting the engine—sit
in the operator’s position, turn the key
to the engine preheat position, wait
until the engine preheat light turns off,
turn the key to the engine start position,
and disengage the parking brake.
2. Raise the cutting units.
10. Lights
6. Read the Operator’s Manual
for information on stopping the
engine—disengage the cutting units,
turn the key to the engine stop position,
remove the key from the ignition, and
engage the parking brake.
3. Pull up to engage the cutting units.
7. Engine—Shut off
11. Fast
4. Push down to disengage the cutting
units.
8. Engine—Preheat
12. Slow
decal121-7884
121–7884
1. 8 blade reel adjustment
3. Read the Operator’s Manual for information on adjusting the
reel.
2. 11 blade reel adjustment
7
decal133-4901
133-4901
1. 8-blade reel adjustment
3. Read the Operator’s Manual for information on adjusting the
reel.
2. 11-blade reel adjustment
8
Model 03910
decal121-7928
121-7928
Note: This machine complies with the industry standard stability test in the static lateral and longitudinal tests with the maximum
recommended slope indicated on the decal. Review the instructions for operating the machine on slopes in the Operator’s Manual as
well as the conditions in which you would operate the machine to determine whether you can operate the machine in the conditions
on that day and at that site. Changes in the terrain can result in a change in slope operation for the machine. If possible, keep the
cutting units lowered to the ground while operating the machine on slopes. Raising the cutting units while operating on slopes can
cause the machine to become unstable.
4. Warning—do not park the machine on slopes; engage the
parking brake, lower the cutting units, shut off the engine, and
remove the key before leaving the machine.
1. Warning—read the Operator's Manual; all operators should
be trained before operating the machine.
5. Thrown object hazard—keep bystanders away.
2. Warning—read the Operator's Manual before towing the
machine.
6. Entanglement hazard, belt—stay away from moving parts;
3. Tipping hazard—do not turn sharply while traveling fast; do
keep all guards and shields in place.
not drive up or down slopes greater than 22°; lower the cutting
units when driving down slopes; use a rollover protection
system and wear the seatbelt.
9
Models 03820 and 03821
Affix over Part No. 120-1683 for CE
decal138-1186
138-1186
Note: This machine complies with the industry standard stability test in the static lateral and longitudinal tests with the maximum
recommended slope indicated on the decal. Review the instructions for operating the machine on slopes in the Operator’s Manual as
well as the conditions in which you would operate the machine to determine whether you can operate the machine in the conditions
on that day and at that site. Changes in the terrain can result in a change in slope operation for the machine. If possible, keep the
cutting units lowered to the ground while operating the machine on slopes. Raising the cutting units while operating on slopes can
cause the machine to become unstable.
4. Warning—do not park the machine on slopes; engage the
parking brake, lower the cutting units, shut off the engine, and
remove the key before leaving the machine.
1. Warning—read the Operator's Manual; all operators should
be trained before operating the machine.
5. Thrown object hazard—keep bystanders away.
2. Warning—read the Operator's Manual before towing the
machine.
6. Entanglement hazard, belt—stay away from moving parts;
3. Tipping hazard—do not turn sharply while traveling fast; do
keep all guards and shields in place.
not drive up or down slopes greater than 16°; lower the cutting
units when driving down slopes; use a rollover protection
system and wear the seatbelt.
10
Model 03910
decal138-6980
138-6980
1. Read the Operator’s Manual.
Models 03820 and 03821
decal138-6981
138-6981
1. Read the Operator’s Manual.
11
decalbatterysymbols
Battery Symbols
Some or all of these symbols are on your battery.
1. Explosion hazard
6. Keep bystanders away
from the battery.
2. No fire, open flame, or
smoking
7. Wear eye protection;
explosive gases can
cause blindness and other
injuries.
3. Caustic liquid/chemical
burn hazard
4. Wear eye protection.
8. Battery acid can cause
blindness or severe burns.
9. Flush eyes immediately
with water and get medical
help fast.
5. Read the Operator's
Manual.
10. Contains lead; do not
discard
12
Setup
Loose Parts
Use the chart below to verify that all parts have been shipped.
Procedure
Description
1
2
3
4
5
6
Use
Qty.
Right hose guide
Left hose guide
1
1
Install the cutting units.
No parts required
–
Adjust the turf compensation spring.
Warning decal 121-7928 (machine
model 03910)
Warning decal 138-1186 (machine
models 03820 and 03821)
CE decal
Production year decal
Lock bracket
Rivet
Washer
Screw (1/4 x 2 inches)
Locknut (1/4 inch)
1
1
1
2
1
1
1
No parts required
–
Reduce the tire pressure.
Cutting-unit kickstand
1
Use the cutting-unit kickstand.
1
1
Install the CE decals, if required.
Install the hood latch (CE only).
Media and Additional Parts
Description
Use
Qty.
Keys
2
Start the engine.
Operator's Manual
Engine owner’s manual
1
1
Read the manuals before operating the machine.
Cutting performance paper
1
Use the paper for adjusting the cutting unit reel-to-bedknife
contact.
Shim
1
Use the shim for adjusting the cutting unit reel-to-bedknife
contact.
Note: Determine the left and right sides of the machine from the normal operating position.
13
compensation spring is mounted to the same
side of the cutting unit as the reel drive motor.
Position the turf compensation as follows:
1
A.
Installing the Cutting Units
Remove the 2 carriage bolts and nuts
securing the rod bracket to the cutting unit
tabs (Figure 4).
Parts needed for this procedure:
1
Right hose guide
1
Left hose guide
Procedure
1.
g003949
Park the machine on a level surface, engage the
parking brake, shut off the engine, and remove
the key from the ignition switch.
2.
Remove the reel motors from the shipping
brackets.
3.
Remove and discard the shipping brackets.
4.
Remove the cutting units from the cartons.
Assemble and adjust them as described in the
cutting unit Operator's Manual.
5.
Figure 4
1. Turf compensation spring
3. Spring tube
2. Rod bracket
B.
Remove the flange nut securing the spring
tube bolt to the carrier frame tab (Figure 4),
and remove the assembly.
C.
Mount the spring tube bolt to the opposite
tab on the carrier frame and secure it with
the flange nut.
Make sure that the counterweight (Figure 3) is
installed to the proper end of the cutting unit as
described in the cutting unit Operator's Manual.
Note: Position the bolt head to the outer
side of the tab as shown in Figure 4.
g003967
Figure 5
1. Opposite carrier frame tab
D.
2. Rod bracket
Mount the rod bracket to the cutting unit
tabs with the carriage bolts and nuts (Figure
5).
Note: When installing or removing the cutting
units, make sure that the hairpin cotter is
installed in the spring rod hole next to the rod
bracket. Otherwise, install the hairpin cotter in
the hole in the end of the rod.
g019938
7.
Figure 3
1. Counterweight
6.
All the cutting units are shipped with the turf
compensation spring mounted to the right
side of the cutting unit. Ensure that the turf
14
On cutting unit 4 (left front) and cutting unit 5
(right front), use the rod-bracket mounting nuts
to install the hose guides to the front of the
cutting-unit tabs. The hose guides should lean
toward the center cutting unit (Figure 6, Figure
7, Figure 8).
8.
Lower all the lift arms completely.
9.
Remove the snapper pin and the cap from the
lift-arm pivot yoke (Figure 9).
g031275
Figure 6
1. Cutting unit 1
5. Cutting unit 5
2. Cutting unit 2
6. Reel motor
3. Cutting unit 3
7. Weight
4. Cutting unit 4
g003975
Figure 9
1. Snapper pin
10.
2. Cap
For the front cutting units, slide a cutting unit
under the lift arm while inserting the carrier frame
shaft up into the lift-arm pivot yoke (Figure 10).
g015160
Figure 7
1. Hose guide (left side
shown)
3. Nuts
2. Rod bracket
g020321
Figure 10
1. Lift arm
3. Lift-arm pivot yoke
2. Carrier frame shaft
11.
g289454
Figure 8
Use the following procedure on the rear cutting
units when the height of cut is above 1.2 cm
(3/4 inch).
A.
1. Hose guides (each must lean toward the center cutting unit)
15
Remove the lynch pin and washer securing
the lift-arm pivot shaft to the lift arm and
slide the lift-arm pivot shaft out of the lift
arm (Figure 11).
Important: Make sure that the reel motor
hoses are not twisted, kinked, or at risk of
being pinched.
g003979
Figure 11
1. Lift-arm shaft lynch pin and washer
B.
Insert the lift-arm yoke onto the carrier
frame shaft (Figure 10).
C.
Insert the lift-arm shaft into the lift arm and
secure it with the washer and lynch pin
(Figure 11).
12.
Insert the cap over the carrier frame shaft and
lift-arm yoke.
13.
Secure the cap and the carrier frame shaft to the
lift-arm yoke with the snapper pin.
g020322
Figure 13
1. Reel-drive motor
Note: Use the slot if a steering cutting unit is
2
desired or use the hole if the cutting unit is to be
locked in position (Figure 9).
14.
2. Mounting nuts
Secure the lift-arm chain to the chain bracket
with the snapper pin (Figure 12).
Adjusting the Turf
Compensation Spring
Note: Use the number of chain links specified
in the cutting unit Operator's Manual.
No Parts Required
Procedure
The turf compensation spring (Figure 14) transfers
weight from the front to the rear roller. This helps
to reduce a wave pattern in the turf, also known as
marcelling or bobbing.
Important: Make spring adjustments with the
g003948
cutting unit mounted to the traction unit, pointing
straight ahead and lowered to the shop floor.
Figure 12
1. Lift-arm chain
3. Snapper pin
1.
2. Chain bracket
15.
Coat the spline shaft of the reel motor with clean
grease.
16.
Oil the reel-motor O-ring and install it onto the
motor flange.
17.
Install the motor by rotating it clockwise so that
the motor flanges clear the locknuts (Figure
13). Rotate the motor counterclockwise until the
flanges encircle the nuts, then tighten the nuts.
16
Make sure that the hairpin cotter is installed in
the rear hole in the spring rod (Figure 14).
4
Installing the Hood Latch
(CE Only)
Parts needed for this procedure:
1
Lock bracket
2
Rivet
1
Washer
1
Screw (1/4 x 2 inches)
1
Locknut (1/4 inch)
g020164
Figure 14
1. Turf compensation spring
3. Spring rod
2. Hairpin cotter
4. Hex nuts
2.
Procedure
Tighten the hex nuts on the front end of the
spring rod until the compressed length of the
spring (Figure 14) is 12.7 cm (5 inches) for
5-inch cutting units and 15.8 cm (6-1/4 inches)
for 7-inch cutting units.
1.
Unhook the hood latch from the hood-latch
bracket.
2.
Remove the 2 rivets securing the hood-latch
bracket to the hood (Figure 15) and remove the
hood-latch bracket from the hood.
Note: When operating on rough terrain,
decrease the spring length by 2.5 cm (1/2 inch).
Ground following will be slightly decreased.
3
Installing the CE Decals
Parts needed for this procedure:
1
Warning decal 121-7928 (machine model 03910)
1
Warning decal 138-1186 (machine models 03820 and
03821)
1
CE decal
1
Production year decal
g012628
Figure 15
1. Hood-latch bracket
3.
2. Rivets
While aligning the mounting holes, position the
CE lock bracket and the hood-latch bracket onto
the hood.
Note: The lock bracket must be against the
hood (Figure 16). Do not remove the bolt and
nut from the lock-bracket arm.
Procedure
On machines requiring CE compliance, apply the
production year decal (Part No. 133-5615) near the
serial plate, the CE decal (Part No. 93-7252) near
the hood lock, and the CE warning decal (Part No.
121-7928 for machine model 03910 and Part No.
138-1186 for machine models 03820 and 03821) over
the standard warning decal (Part No. 120-1683).
17
g012631
Figure 18
g012629
1. Bolt
2. Nut
Figure 16
1. CE lock bracket
3. Arm of hood-lock bracket
2. Bolt and nut
4.
Align the washers with the holes on the inside of
the hood.
5.
Rivet the brackets and the washers to the hood
(Figure 16).
6.
Hook the latch onto the hood-latch bracket
(Figure 17).
5
Reducing the Tire Pressure
No Parts Required
Procedure
The tires are overinflated at the factory for shipping
purposes. Reduce the pressure to the proper levels
before starting the machine; refer to Checking the Tire
Pressure (page 46).
6
g012630
Figure 17
1. Hood latch
7.
Using the Cutting-Unit
Kickstand
Screw the bolt into the other arm of the hood-lock
bracket to lock the latch in position (Figure 18).
Note: Tighten the bolt securely but do not
tighten the nut.
Parts needed for this procedure:
1
Cutting-unit kickstand
Procedure
Whenever you tip a cutting unit to expose the
bedknife/reel, prop up the rear of the cutting unit with
the kickstand to ensure that the nuts on the back end
of the bedbar adjusting screws are not resting on the
work surface (Figure 19).
18
Product Overview
g216864
Figure 21
g020158
Figure 19
1. Engine hood
5. Seat adjustment lever
2. Seat
6. Front cutting units
3. Control arm
7. Rear cutting units
4. Steering wheel
1. Cutting-unit kickstand
Secure the kickstand to the chain bracket with the
snapper pin (Figure 20).
Controls
g020079
Figure 22
1. Forward traction pedal
3. Mow/transport slide
2. Reverse traction pedal
4. Tilt-steering lever
g004144
Figure 20
1. Chain bracket
Traction Pedals
3. Cutting-unit kickstand
2. Snapper pin
Press the forward traction pedal (Figure 22) to move
forward. Press reverse traction pedal (Figure 22) 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.
19
Mow/Transport Slide
Using your heel, move the mow/transport slide (Figure
22) to the left to transport and to the right to mow. The
cutting units will only operate in the MOW position
and not lower in the TRANSPORT position.
Important: The mow speed is set at the factory to
9.7 km/h (6 mph). It can be increased or decreased
by adjusting the speed stop screw (Figure 23).
g019980
Figure 24
1. Parking brake
7. Oil-pressure light
2. Ignition switch
8. Temperature light
3. Enable/Disable switch
9. Light switch
g008888
Figure 23
1. Speed stop screw
4. Diagnostic light
10. Glow-plug indicator light
5. Lower mow/raise control
lever
6. Hour meter
11. Throttle
12. Alternator light
Tilt-Steering Lever
Pull the tilt-steering lever (Figure 22) back to tilt the
steering wheel to the desired position. Then push the
lever forward to secure the position.
Throttle
Move the throttle (Figure 24) forward to increase the
engine speed and rearward to decrease the engine
speed.
Ignition Switch
The ignition switch (Figure 24), used to start, shut
off, and preheat the engine, has 3 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 moves automatically to the ON/RUN position. To
shut off the engine, rotate the key to the OFF position.
Remove the key from the switch to prevent accidental
starting.
Enable/Disable Switch
Use the enable/disable switch (Figure 24) in
conjunction with the lower mow/raise control lever
to operate the cutting units. You cannot lower the
cutting units when the mow/transport lever is in
the TRANSPORT position.
Hour Meter
The hour meter (Figure 24) indicates the total hours
of machine operation. It starts to function whenever
the key switch is on.
Lower Mow/Raise Control Lever
This lever (Figure 24) raises and lowers the cutting
units and also starts and stops the reels when the
reels are enabled in the mow mode. You cannot
lower the cutting units when the mow/transport
lever is in the TRANSPORT position.
Note: When the cutting units are enabled, you do not
need to hold the lever in the forward position while the
cutting units are lowered or raised.
20
Diagnostic Light
Engine Coolant Temperature
Warning Light
The diagnostic light (Figure 24) will illuminate if the
system recognizes a system fault.
The temperature warning light (Figure 24) glows
if the engine coolant temperature is high. At this
temperature, the cutting units are disabled. If the
coolant temperature rises another 5.5° C (10° F), the
engine shuts off to prevent further damage.
Fuel Gauge
The fuel gauge (Figure 25) indicates the amount of
fuel in the tank.
Oil-Pressure Warning Light
The oil-pressure warning light (Figure 24) glows if the
engine oil pressure drops below a safe level.
Alternator Light
The alternator light (Figure 24) should be off when
the engine is running. If it is on, check the charging
system and repair it as necessary.
g019982
Figure 25
1. Fuel gauge
Glow-Plug Indicator
The glow-plug indicator light (Figure 24) glows when
the glow plugs are operating.
Power Point
The power point, located on the outside of the control
panel, is a 12 V power supply for electronic devices
(Figure 26).
Parking Brake
Whenever the engine is shut off, engage the parking
brake (Figure 24) to prevent accidental movement of
the machine. To engage the parking brake, pull up
on the lever. The engine stops when you press the
traction pedal with the parking brake engaged.
g019983
Figure 26
1. Power point
21
Reel Speed Control Knob
The reel speed control controls the speed of the
cutting units (Figure 27). The reel speed increases
as you turn the knob counterclockwise. Refer to the
reel speed chart decal (Figure 30), to determine the
proper reel speed.
g020248
Figure 27
1. Backlap lever
2. Reel speed control knob
Backlap Lever
Use the backlap lever in conjunction with the lower
mow/raise control lever for the reels (Figure 27).
22
Specifications
Note: Specifications and design are subject to
change without notice.
Dimensions
Reelmaster 3550
Reelmaster 3555
Reelmaster 3575
Width of Cut
208 cm (82 inches)
254 cm (100 inches)
254 cm (100 inches)
Overall Width
239 cm (94 inches)
284 cm (112 inches)
284 cm (112 inches)
Transport Width
231 cm (91 inches)
231 cm (91 inches)
231 cm (91 inches)
Overall Length
295 cm (110 inches)
267 cm (105 inches)
267 cm (105 inches)
188 cm (74 inches)
201 cm (79 inches)
206 cm (81 inches)
151 cm (59.5 inches)
152 cm (60 inches)
152 cm (60 inches)
Weight (configured)
900 kg (1985 lb)
1034 kg (2280 lb)
1157 kg (2550 lb)
Weight (no cutting units)
708 kg (1560 lb)
751 kg (1655 lb)
796 kg (1755 lb)
Height to top of ROPS
Wheel Base
Attachments/Accessories
A selection of Toro approved attachments and
accessories is available for use with the machine
to enhance and expand its capabilities. Contact
your Authorized Service Dealer or authorized Toro
distributor or go to www.Toro.com for a list of all
approved attachments and accessories.
To ensure optimum performance and continued safety
certification of the machine, use only genuine Toro
replacement parts and accessories. Replacement
parts and accessories made by other manufacturers
could be dangerous, and such use could void the
product warranty.
23
Performing Daily
Maintenance
Operation
Before Operation
Service Interval: Before each use or daily
Before Operation Safety
Before starting the machine each day, perform the
Each Use/Daily procedures listed in Maintenance
(page 36).
General Safety
Filling the Fuel Tank
• Never allow children or untrained people to
Use only clean, fresh diesel fuel or biodiesel fuels with
low (<500 ppm) or ultra-low (<15 ppm) sulfur content.
The minimum cetane rating should be 40. Purchase
fuel in quantities that can be used within 180 days
to ensure fuel freshness.
operate or service the machine. Local regulations
may restrict the age of the operator. The owner
is responsible for training all operators and
mechanics.
• Become familiar with the safe operation of the
The fuel tank capacity is approximately 42 L (11 US
gallons).
equipment, operator controls, and safety signs.
• Shut off the engine, remove the key, and wait
Use summer-grade diesel fuel (Number 2-D) at
temperatures above -7°C (20°F) and winter-grade
diesel fuel (Number 1-D or Number 1-D/2-D blend)
below -7°C (20°F). Using winter-grade fuel at lower
temperatures provides lower flash point and cold flow
characteristics which will ease starting and reduce
plugging of the fuel filter.
for all movement to stop before you leave the
operator’s position. Allow the machine to cool
before adjusting, servicing, cleaning, or storing it.
• Know how to stop the machine and shut off the
engine quickly.
• Do not operate the machine without all guards
and other safety protective devices in place and
functioning properly on the machine.
Using summer-grade fuel above -7°C (20°F) will
contribute toward longer fuel-pump life and increased
power compared to winter-grade fuel.
• Before mowing, always inspect the machine to
ensure that the cutting units are in good working
condition.
The machine is biodiesel ready.
This machine can also use a biodiesel blended fuel
of up to B20 (20% biodiesel, 80% petrodiesel). The
petrodiesel portion should be low or ultra-low sulfur.
Observe the following precautions:
• The biodiesel portion of the fuel must meet
specification ASTM D6751 or EN14214.
• The blended fuel composition should meet ASTM
D975 or EN590.
• Painted surfaces may be damaged by biodiesel
blends.
• Use B5 (biodiesel content of 5%) or lesser blends
in cold weather.
• Monitor seals, hoses, and gaskets in contact with
fuel as they may degrade over time.
• Expect plugging of the fuel filter for a time after
converting to biodiesel blends.
• Contact your authorized Toro distributor if you wish
for more information on biodiesel.
1. Park the machine on a level surface, lower the
cutting units, engage the parking brake, shut off
the engine, and remove the key from the ignition
switch.
2. Clean the area around the fuel-tank cap (Figure
28).
• Inspect the area where you will use the machine
and remove all objects that the machine could
throw.
Fuel Safety
• Use extreme care in handling fuel. It is flammable
and its vapors are explosive.
• Extinguish all cigarettes, cigars, pipes, and other
sources of ignition.
• Use only an approved fuel container.
• Do not remove the fuel cap or fill the fuel tank
while the engine is running or hot.
• Do not add or drain fuel in an enclosed space.
• Do not store the machine or fuel container where
there is an open flame, spark, or pilot light, such
as on a water heater or other appliance.
• If you spill fuel, do not attempt to start the engine;
avoid creating any source of ignition until the fuel
vapors have dissipated.
24
3.
4.
5.
6.
Raise the armrest and turn the knob, in either
direction, to provide the best comfort (Figure 29).
Remove the fuel-tank cap.
Fill the tank to the bottom of the filler neck. Do
not overfill the tank.
Install the cap.
To prevent a fire hazard, wipe up any fuel that
may have spilled.
g008884
Figure 28
1. Fuel-tank cap
Adjusting the Seat
Changing the Seat Position
The seat can move forward and backward. Position
the seat where you have the best control of the
machine and are most comfortable.
1. Move the lever sideways to unlock the seat
(Figure 29).
2. Slide the seat to the desired position and release
the lever to lock it in position.
g010515
Figure 29
Changing the Seat Suspension
You can adjust the seat to provide a smooth and
comfortable ride. Position the seat where you are
most comfortable.
To adjust it, turn the front knob in either direction to
provide the best comfort (Figure 29).
Changing the Back Position
You can adjust the back of the seat to provide a
comfortable ride. Position the back of the seat where
it is most comfortable.
To adjust it, turn the knob under the right armrest, in
either direction, to provide the best comfort (Figure
29).
Changing the Armrest Position
You can adjust the armrests to provide a comfortable
ride. Position the armrests where they are most
comfortable.
25
1. Backrest knob
3. Seat-suspension knob
2. Seat-position adjustment
lever
4. Armrest-adjusting knob
During Operation
•
During Operation Safety
Rollover Protection System
(ROPS) Safety
General Safety
• The owner/operator can prevent and is responsible
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
– Wait for all movement to stop.
Operate the machine only in good visibility and
appropriate weather conditions. Do not operate
the machine when there is the risk of lightning.
for accidents that may cause personal injury or
property damage.
Wear appropriate clothing, including eye
protection; long pants; substantial, slip-resistant
footwear; and hearing protection. Tie back long
hair and do not wear loose clothing or loose
jewelry.
Do not operate the machine while ill, tired, or
under the influence of alcohol or drugs.
Use your full attention while operating the
machine. Do not engage in any activity that
causes distractions; otherwise, injury or property
damage may occur.
Before you start the engine, ensure that all drives
are in neutral, the parking brake is engaged, and
you are in the operating position.
Do not carry passengers on the machine and keep
bystanders and children out of the operating area.
Operate the machine only in good visibility to avoid
holes or hidden hazards.
Avoid mowing on wet grass. Reduced traction
could cause the machine to slide.
Keep your 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 approaching blind corners, shrubs,
trees, or other objects that may obscure your
vision.
Stop the cutting units whenever you are not
mowing.
Slow down and use caution when making turns
and crossing roads and sidewalks with the
machine. Always yield the right-of-way.
Operate the engine only in well-ventilated areas.
Exhaust gases contain carbon monoxide, which
is lethal if inhaled.
Do not leave a running machine unattended.
Before you leave the operator’s position, do the
following:
– Park the machine on a level surface.
– Disengage the cutting unit(s) and lower the
attachments.
– Engage the parking brake.
– Shut off the engine and remove the key.
• Do not remove any of the ROPS components from
•
•
•
•
•
the machine.
Ensure that the seat belt is attached and that you
can release it quickly in an emergency.
Always wear your seat belt.
Check carefully for overhead obstructions and do
not contact them.
Keep the ROPS in safe operating condition by
thoroughly inspecting it periodically for damage
and keeping all the mounting fasteners tight.
Replace all damaged ROPS components. Do not
repair or alter them.
Slope Safety
• Slopes are a major factor related to loss of control
•
•
26
and rollover accidents, which can result in severe
injury or death. You are responsible for safe slope
operation. Operating the machine on any slope
requires extra caution.
Evaluate the site conditions to determine if the
slope is safe for machine operation, including
surveying the site. Always use common sense
and good judgment when performing this survey.
Review the slope instructions, listed below, for
operating the machine on slopes. Before you
operate the machine, review the site conditions to
determine whether you can operate the machine
in the conditions on that day and at that site.
Changes in the terrain can result in a change in
slope operation for the machine.
– Avoid starting, stopping, or turning the machine
on slopes. Avoid making sudden changes in
speed or direction. Make turns slowly and
gradually.
– Do not operate a machine under any conditions
where traction, steering, or stability is in
question.
– Remove or mark obstructions such as ditches,
holes, ruts, bumps, rocks, or other hidden
hazards. Tall grass can hide obstructions.
Uneven terrain could overturn the machine.
– Be aware that operating the machine on wet
grass, across slopes, or downhill may cause
the machine to lose traction.
– Use extreme caution when operating
the machine near drop-offs, ditches,
embankments, water hazards, or other
hazards. The machine could suddenly roll over
if a wheel goes over the edge or the edge
caves in. Establish a safety area between the
machine and any hazard.
CAUTION
Contact with moving parts could result
in injury.
Shut off the engine and wait for all
moving parts to stop before checking
for oil leaks, loose parts, and other
malfunctions.
– Identify hazards at the base of the slope.
If there are hazards, mow the slope with a
pedestrian-controlled machine.
– If possible, keep the cutting units lowered to
the ground while operating on slopes. Raising
the cutting units while operating on slopes can
cause the machine to become unstable.
Shutting Off the Engine
Starting the Engine
You may need to bleed the fuel system if any of the
following situations have occurred; refer to Bleeding
the Fuel System (page 29):
• Maintenance has been performed upon the fuel
system components; i.e. filter replaced, etc.
2.
Remove your foot from the traction pedal and
ensure 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.
Note: Release the key when the engine starts.
The key will move automatically to the ON/RUN
position.
Important: To prevent overheating of the
starter motor, do not engage the starter for
longer than 15 seconds. After 10 seconds of
continuous cranking, wait 60 seconds before
engaging the starter motor again.
5.
2.
Move the cutting unit drive switch to DISENGAGE.
3.
Rotate the key to OFF.
4.
Remove the key to prevent accidental starting.
To achieve a consistent, high quality of cut and a
uniform after-cut appearance, it is important that you
set the reel speed controls (located under the seat)
correctly. Adjust the reel speed controls as follows:
• The engine has ceased running due to lack of fuel.
Ensure that the parking brake is engaged and
the cutting unit drive switch is in the DISENGAGE
position.
Move the throttle control to the IDLE position.
Setting the Reel Speed
• Initial startup of a new engine
1.
1.
When the engine is started for the first time
or after an overhaul of the engine, operate
the machine in forward and reverse for 1 to 2
minutes. Also operate the lift lever and cutting
unit drive switch to ensure proper operation of
all parts.
Turn the steering wheel to the left and right
to check steering response; then shut off the
engine and check for oil leaks, loose parts, and
any other noticeable malfunctions.
27
1.
Select the height of cut at which the cutting units
are set.
2.
Choose the desired ground speed best suited
for conditions.
3.
Use the graph on the reel speed chart decals
(Figure 30 and Figure 31), to determine the
proper reel speed setting.
decal121-7884
Figure 30
Model 03820 and 03910
1. 8-blade reel adjustment
3. Read the Operator’s Manual for information on adjusting the
reel.
2. 11-blade reel adjustment
decal133-4901
Figure 31
Model 03821
1. 8-blade reel adjustment
3. Read the Operator’s Manual for information on adjusting the
reel.
2. 11-blade reel adjustment
4.
To set the reel speed, rotate the knob (Figure
32) until the indicator arrow is in line with the
number designating the desired setting.
28
g034346
Figure 33
1. Spring
3. Additional hole locations
2. Spring actuator
g020259
Figure 32
4.
Move the spring actuator to the desired hole
location and secure it with the bolt and the
locknut.
5.
Repeat the procedure on the remaining spring.
1. Reel speed control knob
Note: The reel speed can be increased or
decreased to compensate for turf conditions.
When using baskets, increase the reel speed to
improve collection performance.
Bleeding the Fuel System
Adjusting the Lift-Arm
Counterbalance
You can adjust the counterbalance on the lift arms of
the rear cutting units to compensate for different turf
conditions and to maintain a uniform height of cut in
rough conditions or in areas of thatch buildup.
1.
Park the machine on a level surface, lower the
cutting units, engage the parking brake, shut off
the engine, and remove the key.
2.
Ensure that the fuel tank is at least half full.
3.
Unlatch and raise the hood.
4.
Open the air-bleed screw on the fuel-injection
pump (Figure 34).
You can adjust each counterbalance spring to 1 of
4 settings. Each increment increases or decreases
counterbalance on the cutting unit by 2.3 kg (5 lb).
You can position the springs on the back side of the
first spring actuator to remove all counterbalance
(fourth position).
1. Park the machine on a level surface, lower the
cutting units, engage the parking brake, shut off
the engine, and remove the key from the ignition
switch.
2. Insert a tube or similar object onto the long
spring end to relieve the spring tension during
the adjustment (Figure 33).
g008891
Figure 34
1. Fuel-injection pump bleed screw
CAUTION
The springs are under tension and could
cause personal injury.
5.
Use caution when adjusting them.
3.
While relieving the spring tension, remove the
bolt and locknut securing the spring actuator to
the bracket (Figure 33).
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.
Note: Leave the key in the ON position until a
solid stream of fuel flows out around the screw.
29
6.
• Fuses are blown.
• It is not functioning correctly.
Tighten the screw and turn the ignition key to
OFF.
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 44).
Check the electrical connections, input fuses, and
diagnostic light bulb to determine the malfunction.
Ensure that the loop-back connector is secured to
the wire harness connector.
Understanding the
Diagnostic ACE Display
Understanding the
Diagnostic Light
The machine is equipped with an electronic controller
which controls most machine functions. The controller
determines what function is required for various input
switches (i.e., seat switch, key switch, etc.) and turns
on the outputs to actuate solenoids or relays for the
requested machine function.
The machine is equipped with a diagnostic light
that indicates if the electronic controller senses an
electronic malfunction. The diagnostic light is located
on the control panel (Figure 35). When the electronic
controller is functioning correctly and you move the
key switch to the ON position, the controller diagnostic
light turns on for 3 seconds and turn off to indicate
that the light is working properly. If the engine shuts
off, then the light turns on steady until the you change
key position. The light blinks if the controller detects a
malfunction in the electrical system. The light stops
blinking and automatically resets when you turn the
key switch to the OFF position once the fault has been
resolved.
For the electronic controller to control the machine as
desired, each of the input switches, output solenoids,
and relays must be connected and functioning
properly.
Use the Diagnostic ACE display to help verify and
correct electrical functions of the machine.
Checking the Interlock
Switches
Service Interval: Before each use or daily
The purpose of the interlock switches is to prevent the
engine from cranking or starting unless the traction
pedal is in the NEUTRAL position, the Enable/Disable
switch is in the DISABLE position, and the Lower
Mow/Raise control is in the NEUTRAL position. In
addition, the engine should shut off when you press
the traction pedal with no one in the seat or if the
parking brake is engaged.
g020251
Figure 35
1. Diagnostic light
CAUTION
When the controller diagnostic light blinks, 1 of
the following problems has been detected by the
controller:
• An output has been shorted.
• An output is open circuited.
If safety interlock switches are disconnected
or damaged, the machine could operate
unexpectedly, causing personal injury.
• Do not tamper with the interlock switches.
Using the diagnostic display, determine which output
is malfunctioning; refer to Checking the Interlock
Switches (page 30).
• Check the operation of the interlock
switches daily and replace any damaged
switches before operating the machine.
If the diagnostic light is not illuminated when the key
switch is in the ON position, this indicates that the
electronic controller is not operating. Possible causes
are as follows:
• The loop-back is not connected.
• The light is burned out.
Verifying the Interlock Switch
Function
1.
30
Park the machine on a level surface, lower the
cutting units, engage the parking brake, and
shut off the engine.
2.
Remove the cover from the control panel.
3.
Locate the wire harness and loop-back
connector (Figure 36).
Diagnostic ACE, to change LED to “inputs
displayed.”
The Diagnostic ACE illuminates the LED
associated with each of the inputs when that
input switch is closed.
8.
Individually, change each of the switches from
open to closed (i.e., sit on the seat, engage
the traction pedal, etc.), and note that the
appropriate LED on the Diagnostic ACE blinks
on and off when the corresponding switch is
closed. Repeat this for all switches that you can
change by hand.
9.
If a switch is closed and the appropriate
LED does not turn on, check all wiring and
connections to the switch and/or check the
switches with an ohm meter or multimeter.
Replace any malfunctioning switches and repair
any malfunctioning wiring.
g020260
Figure 36
Note: The Diagnostic ACE also has the ability
1. Loop-back connector
4.
Carefully unplug the loop-back connector from
the harness connector.
5.
Connect the Diagnostic ACE display connector
to the harness connector (Figure 37).
to detect which output solenoids or relays are
turned on. This is a quick way to determine if a
machine malfunction is electrical or hydraulic.
Verifying Output Function
Note: Ensure that the correct overlay decal is
1.
Park the machine on a level surface, lower the
cutting units, engage the parking brake, shut off
the engine, and remove the key.
2.
Remove the access panel from the side of the
control arm.
3.
Locate the wire harness and connectors near
the controller.
4.
Carefully unplug the loop-back connector from
the harness connector.
5.
Connect the Diagnostic ACE connector to the
harness connector.
positioned on the Diagnostic ACE display.
Note: Make sure that the correct overlay decal
is positioned on the Diagnostic ACE.
6.
g004140
Figure 37
Note: The red text on the overlay decal refers
to input switches and the green text refers to
outputs.
1. Diagnostic ACE
6.
Turn the key switch to the ON position, but do
not start the machine.
7.
Note: The red text on the overlay decal refers
to input switches and the green text refers to
outputs.
7.
Turn the key switch to the ON position, but do
not start the machine.
The “inputs displayed” LED, on the lower right
column of the Diagnostic ACE, should be
illuminated. If the “outputs displayed” LED
is illuminated, press the toggle button, on
The “outputs displayed” LED, on lower
right column of Diagnostic ACE, should be
illuminated. If the “inputs displayed” LED is
illuminated, press the toggle button, on the
Diagnostic ACE, to change the LED to “outputs
displayed”.
Note: It may be necessary to toggle between
“inputs displayed” and “outputs displayed”
several times to do the following step. To toggle
31
Operating Tips
back and forth, press the toggle button once.
This may be done as often as required. Do not
hold the button.
8.
Becoming Familiar with the
Machine
Sit on the seat and attempt to operate the
desired function of the machine. The appropriate
output LEDs should illuminate to indicate that
the ECM is turning on that function.
Before mowing grass, practice operating the machine
in an open area. Start and shut off the engine.
Operate in forward and reverse. Lower and raise
the cutting units and engage and disengage the
cutting units. When you feel familiar with the machine,
practice operating up and down slopes at different
speeds.
Note: If the correct output LEDs do not
illuminate, verify that the required input switches
are in the necessary positions to allow that
function to occur. Verify correct switch function.
If the output LEDs are on as specified, but
the machine does not function properly, this
indicates a non-electrical problem. Repair as
necessary.
Note: If each output switch is in the correct
Understanding the Warning
System
position and functioning correctly, but the output
LEDs are not correctly illuminated, this indicates
an ECM problem. If this occurs, contact your
authorized Toro distributor for assistance.
If a warning light comes on during operation, stop the
machine immediately and correct the problem before
continuing operation. Serious damage could occur if
you operate the machine with a malfunction.
Important: The Diagnostic ACE display
must not be left connected to the machine. It
is not designed to withstand the environment
of the everyday use of the machine. When
you are finished using the Diagnostic ACE,
disconnect it from the machine and connect
the loop-back connector to the harness
connector. The machine does not operate
without the loop-back connector installed on
the harness. Store the Diagnostic ACE in a
dry, secure location in the shop, not on the
machine.
Mowing Grass
Start the engine and move the throttle to the FAST
position. Move the Enable/Disable switch to the
ENABLE position and use the Lower Mow/Raise lever
to control the cutting units (the front cutting units
are timed to lower before the rear cutting units). To
move forward and cut grass, press the traction pedal
forward.
Driving the Machine in Transport
Mode
Move the Enable/Disable switch to the DISABLE
position and raise the cutting units to the transport
position. Move the Mow/Transport lever to the
TRANSPORT position. Be careful when driving between
objects so that you do not accidentally damage the
machine or the cutting units. Use extra care when
operating the machine on slopes. Drive slowly and
avoid sharp turns on slopes to prevent rollovers.
32
After Operation
The following Toro parts are needed to bypass the
check valve:
• Toro Part No. 59-7410, diagnostic fitting
After Operation Safety
• Toro Part No. 354-79, diagnostic-fitting cap
• Toro Part No. 95-8843, hydraulic hose
General Safety
• Toro Part No. 95-0985, coupler fitting (2)
• Shut off the engine, remove the key, and wait
• Toro Part No. 340-77, hydraulic fitting (2)
for all movement to stop before you leave the
operator’s position. Allow the machine to cool
before adjusting, servicing, cleaning, or storing it.
1.
• Clean grass and debris from the cutting units,
Install a diagnostic fitting in the unmarked port
located between ports M8 and P2 on the rear
traction manifold (Figure 38).
drives, mufflers, cooling screens, and engine
compartment to help prevent fires. Clean up oil or
fuel spills.
• Shut off the fuel while storing or hauling the
machine.
• Disengage the drive to the attachment whenever
you are hauling or not using the machine.
• Maintain and clean the seat belt(s) as necessary.
• Do not store the machine or fuel container where
there is an open flame, spark, or pilot light, such
as on a water heater or on other appliances.
Pushing or Towing the
Machine
g033131
Figure 38
In an emergency, you can move the machine
by actuating the bypass valve in the variable
displacement hydraulic pump and installing a
hydraulic hose to bypass the check valve, and then
pushing or towing the machine.
1. Rear traction manifold
(behind front left wheel)
2.
Important: Do not push or tow the machine faster
than 3 to 4.8 km/h (2 to 3 mph) or for more than
0.4 km (1/4 mile), because internal transmission
damage may occur. The bypass valve must be
open whenever you push or tow the machine.
Additionally, you need to install a hydraulic hose
to bypass the check valve whenever you push or
tow the machine in reverse.
2. Unmarked port
Connect a hydraulic hose between the
diagnostic fitting installed in the rear traction
manifold and the reverse traction pressure test
port (Figure 39).
Note: Use the hydraulic fittings and coupler
fittings as needed to install the hose.
If you need to push or tow your machine, you will
likely need to move it both forward and in reverse.
To ensure that the drive system does not become
damaged from pushing or towing, it is best to prepare
the machine for both forward and reverse pushing or
towing.
Preparing the Machine for Pushing
or Towing in Reverse
Important: If you need to push or tow the
machine in reverse, you must first bypass the
check valve in the 4-wheel-drive manifold.
33
Note: Do not exceed 7 to 11 N∙m (5 to 8 ft-lb)
torque to close the valve.
Pushing or Towing the Machine
Forward Only
If you need to push or tow the machine forward only,
you can just rotate the bypass valve.
Important: If you need to push or tow the
machine in reverse, refer to Preparing the Machine
for Pushing or Towing in Reverse (page 33).
1.
Open the hood and remove the center shroud.
2.
Rotate the bypass valve 90° (1/4 turn) in either
direction to open it and allow fluid to bypass
internally (Figure 40).
g033132
Figure 39
1. Reverse traction pressure
test port
3.
Note: Because the fluid bypasses the
2. Hydraulic fluid return filter
transmission, you can move the machine
forward slowly without damaging the
transmission.
Note the position of the valve when opening and
closing it.
Rotate the bypass valve 90° (1/4 turn) in either
direction to open it and allow fluid to bypass
internally (Figure 40).
3.
Note: Because the fluid bypasses the
transmission, you can move the machine slowly
without damaging the transmission.
Note the position of the valve when opening and
closing it.
Rotate the bypass valve 90° (1/4 turn) back
before starting the engine.
Note: Do not exceed 7 to 11 N∙m (5 to 8 ft-lb)
torque to close the valve.
Hauling the Machine
• Use full-width ramps for loading the machine onto
a trailer or truck.
• Tie the machine down securely.
g009703
Figure 40
1. Bypass valve
4.
When you are finished pushing or towing the
machine, remove the hydraulic hose that you
installed.
5.
Install the existing cap onto the reverse traction
pressure test port.
6.
Install the diagnostic-fitting cap onto the fitting
that you installed on the manifold.
7.
Rotate the bypass valve 90° (1/4 turn) back
before starting the engine.
34
Identifying the Tie-Down
Points
g198911
Figure 41
1. Tie-down loops
35
Maintenance
Note: Determine the left and right sides of the machine from the normal operating position.
Maintenance Safety
• Support the machine with jack stands whenever
you work under the machine.
• Before you leave the operator’s position, do the
• Carefully release pressure from components with
following:
stored energy.
– Park the machine on a level surface.
• Keep all parts of the machine in good working
– Disengage the cutting unit(s) and lower the
attachments.
condition and all hardware tightened.
• Replace all worn or damaged decals.
– Engage the parking brake.
• To ensure safe, optimal performance of the
– Shut off the engine and remove the key.
machine, use only genuine Toro replacement
parts. Replacement parts made by other
manufacturers could be dangerous, and such use
could void the product warranty.
– Wait for all movement to stop.
• Allow machine components to cool before
performing maintenance.
• If possible, do not perform maintenance while the
engine is running. Keep away from moving parts.
Recommended Maintenance Schedule(s)
Maintenance Service
Interval
Maintenance Procedure
After the first hour
• Torque the wheel nuts.
After the first 10 hours
• Torque the wheel nuts.
• Check the condition and tension of all belts.
After the first 50 hours
• Change the oil and oil filter.
Before each use or daily
• Inspect the seat belt(s) for wear, cuts, and other damage. Replace the seat belt(s) if
any component does not operate properly.
• Check the interlock system.
• Check the engine-oil level.
• Drain the water separator.
• Check the tire pressure.
• Check the engine-coolant level.
• Clean debris off of the radiator.
• Check the hydraulic lines and hoses.
• Check the level of the hydraulic fluid.
• Check the reel-to-bedknife contact.
Every 25 hours
• Check the electrolyte level (if machine is in storage, check every 30 days).
Every 50 hours
• Lubricate all bearings and bushings (daily when conditions are dusty and dirty).
Every 100 hours
• Check the condition and tension of all belts.
Every 150 hours
• Change the oil and oil filter.
Every 200 hours
• Service the air cleaner (more frequently in extremely dusty or dirty conditions).
• Torque the wheel nuts.
• Check the adjustment of the parking brake.
Every 400 hours
• Check the fuel lines and connections.
• Replace the fuel filter canister.
36
Maintenance Service
Interval
Every 800 hours
Maintenance Procedure
• If you are not using the recommended hydraulic fluid or have ever filled the reservoir
with an alternative fluid, change the hydraulic fluid.
• If you are not using the recommended hydraulic fluid or have ever filled the reservoir
with an alternative fluid, replace the hydraulic filter.
Every 1,000 hours
• If you are using the recommended hydraulic fluid, replace the hydraulic filter.
Every 2,000 hours
• If you are using the recommended hydraulic fluid, change the hydraulic fluid.
Every 2 years
• Drain and clean the fuel tank.
37
Daily Maintenance Checklist
Duplicate this page for routine use.
For the week of:
Mon.
Maintenance Check Item
Tues.
Wed.
Thurs.
Fri.
Sat.
Check the safety interlock
operation.
Check the brake operation.
Check the engine-oil level.
Check the cooling system
fluid level.
Drain the water/fuel
separator.
Check the air filter, dust cup,
and burp valve.
Check for unusual engine
noises.1
Check the radiator for debris.
Check for unusual operating
noises.
Check the hydraulic system
fluid level.
Check the hydraulic hoses
for damage.
Check for fluid leaks.
Check the fuel level.
Check the tire pressure.
Check the instrument
operation.
Check the height-of-cut
adjustment.
Lubricate all the grease
fittings.2
Touch-up any damaged
paint.
Wash the machine.
1Check
the glow plug and injector nozzles if starting is hard, there is excess smoke, or rough running is noted.
2Immediately
after every washing, regardless of the interval listed.
Notation for Areas of Concern
Inspection performed by:
Item
Date
Information
1
2
3
4
5
38
Sun.
6
7
8
Important: Refer to your engine owner’s manual and cutting unit Operator's Manual for additional
maintenance procedures.
Note: Download a free copy of the electrical or hydraulic schematic by visiting www.Toro.com and searching
for your machine from the Manuals link on the home page.
Pre-Maintenance
Procedures
Removing the Battery
Cover
Loosen the knobs and remove the battery cover
(Figure 43).
Removing the Hood
Note: Refer to Servicing the Battery (page 45) for
1.
Unlatch and raise the hood.
2.
Remove the hairpin cotter securing the hood
pivot to the mounting brackets (Figure 42).
more information.
g008908
Figure 42
1. Hairpin cotter
g034350
3.
Figure 43
Slide the hood to the right side, lift the other
side, and pull it out of the brackets.
1. Battery cover
Note: Reverse the procedure to install the hood.
39
Lubrication
Greasing the Bearings and
Bushings
Service Interval: Every 50 hours (daily when
conditions are dusty and dirty).
Park the machine on a level surface, lower the cutting
units, engage the parking brake, shut off the engine,
and remove the key from the ignition switch.
g034347
Figure 45
Lubricate the grease fittings regularly with No. 2
lithium grease. Lubricate the bearings and bushings
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 the grease
fittings immediately after every washing, regardless
of the interval specified.
• Rear lift-arm pivots and lift cylinders (3 each side);
refer to Figure 46.
The grease fitting locations and quantities are as
follows:
• Steering pivot (Figure 44)
g200803
Figure 46
• Cutting unit pivots (2 each); refer to Figure 47.
g008897
Figure 44
• Front lift-arm pivots and lift cylinders (3 each);
refer to Figure 45.
g020393
Figure 47
• Neutral adjust mechanism (Figure 48)
40
Engine Maintenance
Engine Safety
• Shut off the engine before checking the oil or
adding oil to the crankcase.
• Do not change the governor speed or overspeed
the engine.
g008901
Figure 48
Checking the Engine-Oil
Level
• Mow/transport slide (Figure 49)
Service Interval: Before each use or daily
The engine is shipped with oil in the crankcase;
however, the oil level must be checked before and
after the engine is first started.
Crankcase capacity is approximately 3.8 L (4 US qt)
with the filter.
Use high-quality engine oil that meets the following
specifications:
g008902
Figure 49
• API Classification Level Required: CH-4, CI-4 or
higher.
• Belt tension pivot (Figure 50)
• Preferred oil: SAE 15W-40 (above 0ºF (-17ºC))
• Alternate oil: SAE 10W-30 or 5W-30 (all
temperatures)
Note: Toro Premium Engine Oil is available from your
distributor in either 15W-40 or 10W-30 viscosity.
Note: The best time to check the engine oil is when
the engine is cool before it has been started for the
day. If it has already been run, allow the oil to drain
back down to the sump for at least 10 minutes before
checking. If the oil level is at or below the Add mark
on the dipstick, add oil to bring the oil level to the
Full mark. Do not overfill the engine. If the oil level
is between the Full and Add marks, no oil addition
is required.
g008903
Figure 50
41
1.
Park the machine on a level surface, lower the
cutting units, engage the parking brake, shut off
the engine, and remove the key.
2.
Remove the dipstick (Figure 51) and wipe it with
a clean rag.
1.
Park the machine on a level surface, lower the
cutting units, engage the parking brake, shut off
the engine, and remove the key.
2.
Release the latches securing the air-cleaner
cover to the air-cleaner body (Figure 53).
3.
Remove the cover from the air-cleaner body
(Figure 53).
4.
Before removing the filter, use low-pressure air
(276 kPa [40 psi], clean and dry) to help remove
large accumulations of debris packed between
outside of primary filter and the canister.
g008881
Figure 51
Note: Avoid using high-pressure air, which
could force dirt through the filter into the intake
tract. This cleaning process prevents debris
from migrating into the intake when you remove
the primary filter.
1. Dipstick
3.
Push the dipstick down into the dipstick tube and
make sure that it is seated fully. Pull the dipstick
out and check the oil level.
4.
If the oil level is low, remove the oil-fill cap
(Figure 52) and gradually add small quantities of
oil, checking the level frequently, until the level
reaches the Full mark on the dipstick.
5.
Remove and replace the filter (Figure 53).
Do not clean the used element because it could
damage the filter media.
g008882
Figure 52
1. Oil-fill cap
g002401
5.
Figure 53
Install the oil-fill cap and close the hood.
1. Air-cleaner cover
Servicing the Air Cleaner
6.
Service Interval: Every 200 hours (more frequently in
extremely dusty or dirty conditions).
• Check the air-cleaner body for damage which
2. Filter
Inspect the new filter for shipping damage,
checking the sealing end of the filter and the
body.
Important: Do not use a damaged element.
could cause an air leak. Replace it if it is damaged.
Check the whole intake system for leaks, damage,
or loose hose clamps.
7.
• Service the air cleaner at the recommended
Insert the new filter by applying pressure to the
outer rim of the element to seat it in the canister.
Important: Do not apply pressure to the
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 you remove the filter.
flexible center of the filter.
• Be sure that the cover is seated correctly and
seals with the air-cleaner body.
42
8.
Clean the dirt-ejection port located in the
removable cover.
9.
Remove the rubber outlet valve from the cover,
clean the cavity and replace the outlet valve.
10.
Install the cover orienting the rubber outlet valve
in a downward position—between approximately
5 o’clock to 7 o’clock when viewed from the end.
11.
Secure the cover latches.
Fuel System
Maintenance
Servicing the Fuel Tank
Changing the Engine Oil
and Filter
Service Interval: Every 2 years—Drain and clean the
fuel tank.
Service Interval: After the first 50 hours
Park the machine on a level surface, lower the cutting
units, engage the parking brake, shut off the engine,
and remove the key.
Every 150 hours
1.
Park the machine on a level surface, lower the
cutting units, engage the parking brake, shut off
the engine, and remove the key.
2.
Remove either drain plug (Figure 54) and let
the oil flow into a drain pan. When the oil stops
flowing, install the drain plug.
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.
Inspecting the Fuel Lines
and Connections
Service Interval: Every 400 hours/Yearly (whichever
comes first)
Park the machine on a level surface, lower the cutting
units, engage the parking brake, shut off the engine,
and remove the key from the ignition switch.
g020086
Figure 54
Inspect the fuel lines and connections for deterioration,
damage, or loose connections.
1. Engine-oil drain plugs
3.
Remove the oil filter (Figure 55).
g022147
Figure 55
1. Engine oil filter
4.
Apply a light coat of clean oil to the new filter
seal, and install the filter.
Important: Do not overtighten the filter.
5.
Add oil to the crankcase; refer to Checking the
Engine-Oil Level (page 41).
43
Draining the Water
Separator
Bleeding Air from the
Injectors
Service Interval: Before each use or daily
Note: Use this procedure only if the fuel system has
been purged of air through normal priming procedures
and the engine does not start; refer to Bleeding the
Fuel System (page 29).
1.
Park the machine on a level surface, lower the
cutting units, engage the parking brake, shut off
the engine, and remove the key from the ignition
switch.
2.
Place a clean container under the fuel filter.
3.
Loosen the drain valve on the bottom of the filter
canister (Figure 56).
1.
Park the machine on a level surface, lower the
cutting units, engage the parking brake, and
shut off the engine.
2.
Loosen the pipe connection to the No. 1 nozzle
and holder assembly.
g008913
Figure 57
g009880
1. Fuel injectors
Figure 56
1. Water separator/filter
canister
2. Vent plug
4.
3. Drain valve
3.
Move the throttle to the FAST position.
4.
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 there is a continuous flow.
5.
Tighten the pipe connector securely.
6.
Repeat the procedure on the remaining nozzles.
Tighten the valve after draining.
Changing the Fuel Filter
Canister
Service Interval: Every 400 hours
1.
Park the machine on a level surface, lower the
cutting units, engage the parking brake, shut off
the engine, and remove the key from the ignition
switch.
2.
Clean the area where the filter canister mounts
(Figure 56).
3.
Remove the filter canister and clean the
mounting surface.
4.
Lubricate the gasket on the filter canister with
clean oil.
5.
Install the filter canister by hand until the gasket
contacts the mounting surface; then rotate it an
additional 1/2 turn.
44
Electrical System
Maintenance
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.
Electrical System Safety
• Always disconnect the negative (black)
battery cable before disconnecting the
positive (red) cable.
• Disconnect the battery before repairing the
machine. Disconnect the negative terminal first
and the positive last. Connect the positive terminal
first and the negative last.
• Always connect the positive (red) battery
cable before connecting the negative
(black) cable.
• Charge the battery in an open, well-ventilated
area, away from sparks and flames. Unplug the
charger before connecting or disconnecting the
battery. Wear protective clothing and use insulated
tools.
Servicing the Battery
If corrosion occurs at the terminals, disconnect the
cables, negative (–) cable first, and scrape the clamps
and terminals separately. Connect the cables, positive
(+) cable first, and coat the terminals with petroleum
jelly.
Service Interval: Every 25 hours—Check the
electrolyte level (if machine is in
storage, check every 30 days).
Checking the Fuses
The fuses in the electrical system are located under
the control panel.
Park the machine on a level surface, lower the cutting
units, engage the parking brake, shut off the engine,
and remove the key from the ignition switch.
Maintain the battery electrolyte level and keep the top
of the battery clean. Store the machine where the
temperature is cooler rather than warmer to prevent
the battery from discharging more rapidly.
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).
DANGER
Battery electrolyte contains sulfuric acid
which is fatal if consumed and causes severe
burns.
• Do not drink electrolyte and avoid contact
with skin, eyes, or clothing. Wear eye
protection to shield your eyes and rubber
gloves to protect your hands.
• Fill the battery where clean water is always
available for flushing the skin.
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.
The battery cables must be tight on the terminals to
provide good electrical contact.
45
Drive System
Maintenance
WARNING
If the machine is not supported
adequately, it may accidentally fall,
injuring anyone under the machine.
Checking the Tire Pressure
A front wheel and a rear wheel must be
raised off the ground; otherwise, the
machine will move during adjustment.
Service Interval: Before each use or daily
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 83 kPa (12 psi).
3.
Loosen the locknut on the traction adjustment
cam (Figure 58).
Note: Maintain the recommended pressure in all tires
to ensure a good quality of cut and proper machine
performance.
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.
Torquing the Wheel Nuts
g008922
Figure 58
Service Interval: After the first hour
1. Traction adjustment cam
2. Locknut
After the first 10 hours
Every 200 hours
WARNING
Torque the wheel nuts to 103 to 127 N∙m (76 to 94
ft-lb).
The engine must be running so that
you can make a final adjustment of
the traction adjustment cam. Contact
with hot or moving parts can result in
personal injury.
WARNING
Failure to maintain proper torque of the wheel
nuts could result in personal injury.
Keep your hands, feet, face, and other
body parts away from the muffler, other
hot parts of the engine, and rotating
parts.
Maintain proper torque of the wheel nuts.
Adjusting the Traction
Drive for Neutral
If the machine moves when the traction pedal is in the
NEUTRAL position, adjust the traction cam.
1.
2.
Park the machine on a level surface, lower the
cutting units, engage the parking brake, shut off
the engine, and remove the key from the ignition
switch.
Raise a front wheel and a rear wheel off the floor
and place support blocks under the frame.
46
4.
Start the engine and rotate the cam hex in both
directions to determine the mid position of the
neutral span.
5.
Tighten the locknut securing the adjustment.
6.
Shut off the engine.
7.
Remove the support blocks and lower the
machine to the shop floor. Test drive the
machine to ensure that it does not move when
the traction pedal is in neutral.
Cooling System
Maintenance
CAUTION
If the engine has been running, the
pressurized, hot coolant can escape and
cause burns.
Cooling System Safety
• Do not open the radiator cap when the
engine is running.
• Swallowing engine coolant can cause poisoning;
keep out of reach from children and pets.
• Use a rag when opening the radiator cap,
and open the cap slowly to allow steam to
escape.
• Discharge of hot, pressurized coolant or touching
a hot radiator and surrounding parts can cause
severe burns.
– Always allow the engine to cool at least 15
minutes before removing the radiator cap.
– Use a rag when opening the radiator cap, and
open the cap slowly to allow steam to escape.
Checking the Cooling
System
Service Interval: Before each use or daily
Clean debris off the radiator daily (Figure 59). Clean
the radiator hourly if conditions are extremely dusty
and dirty; refer to Cleaning the Engine Cooling System
(page 48).
1.
Park the machine on a level surface, lower the
cutting units, engage the parking brake, shut off
the engine, and remove the key.
2.
Check the coolant level in the expansion tank
(Figure 60). With a cold engine, the coolant
level should be approximately midway between
the marks on the side of the tank.
3.
If the coolant level is low, remove the
expansion-tank cap and replenish the system.
Do not overfill the tank.
4.
Install the expansion-tank cap.
g008885
Figure 60
1. Expansion tank
g019984
Figure 59
1. Radiator
The cooling system is filled with a 50/50 solution
of water and permanent ethylene glycol antifreeze.
Check the coolant level at the beginning of each day
before starting the engine.
The capacity of the cooling system is approximately
5.7 L (6 US qt).
47
Brake Maintenance
Cleaning the Engine
Cooling System
Adjusting the Parking
Brake
Service Interval: Before each use or daily
Remove debris from the radiator daily. Clean it more
frequently in dirty conditions.
1.
Service Interval: Every 200 hours—Check the
adjustment of the parking brake.
Park the machine on a level surface, lower the
cutting units, engage the parking brake, shut off
the engine, and remove the key from the ignition
switch.
2.
Raise the hood.
3.
Clean the engine area thoroughly of all debris.
4.
Clean both sides of the radiator thoroughly with
compressed air (Figure 61).
1.
Park the machine on a level surface, lower the
cutting units, engage the parking brake, shut off
the engine, and remove the key from the ignition
switch.
2.
Loosen the setscrew securing the knob to the
parking-brake lever (Figure 62).
g008923
Figure 62
1. Parking-brake lever
3. Set screw
2. Knob
g019984
3.
Rotate the knob until a force of 133 to 178 N (30
to 40 lb) is required to actuate the lever.
4.
Tighten the setscrew after the adjustment has
been attained.
Figure 61
1. Radiator
5.
Close the hood.
48
Belt Maintenance
the engine, and remove the key from the ignition
switch.
2.
Servicing the Engine Belts
Service Interval: After the first 10 hours—Check the
condition and tension of all belts.
Insert a nut driver or small piece of tubing onto
the end of the belt tensioning spring.
WARNING
The spring is under a heavy load and
could cause personal injury
Every 100 hours—Check the condition and
tension of all belts.
Use caution when de-tensioning the
spring.
Tensioning the Alternator/Fan Belt
1.
Park the machine on a level surface, lower the
cutting units, engage the parking brake, shut off
the engine, and remove the key from the ignition
switch.
2.
Open the hood.
3.
Check the belt tension by pressing the belt
midway between the alternator and crankshaft
pulleys.
3.
Push down and forward on the spring end
(Figure 64) to unhook it from the bracket and
release tension on the spring.
Note: With 98 N (22 lb) of force, the belt should
deflect 11 mm (7/16 inch).
g008917
Figure 64
1. Hydrostat drive belt
g008916
Figure 63
1. Alternator/fan belt
4.
If the deflection is incorrect, complete the
following procedure to tension the belt:
A.
Loosen the bolt securing the brace to the
engine and the bolt securing the alternator
to the brace.
B.
Insert a pry bar between the alternator and
engine and pry the alternator outward.
C.
When the proper tension is achieved,
tighten the alternator and brace bolts to
secure the adjustment.
Replacing the Hydrostat Drive Belt
1.
Park the machine on a level surface, lower the
cutting units, engage the parking brake, shut off
49
2. Spring end
4.
Replace the belt.
5.
Reverse the procedure to tension the spring.
Controls System
Maintenance
Hydraulic System
Maintenance
Adjusting the Throttle
Hydraulic System Safety
1.
• Seek immediate medical attention if fluid is injected
Park the machine on a level surface, lower the
cutting units, engage the parking brake, shut off
the engine, and remove the key from the ignition
switch.
2.
Position the throttle lever rearward so that it
stops against the control panel slot.
3.
Loosen the throttle cable connector on the
injection pump lever arm (Figure 65).
into skin. Injected fluid must be surgically removed
within a few hours by a doctor.
• Ensure that all hydraulic-fluid hoses and lines are
in good condition and all hydraulic connections
and fittings are tight before applying pressure to
the hydraulic system.
• Keep your body and hands away from pinhole
leaks or nozzles that eject high-pressure hydraulic
fluid.
• Use cardboard or paper to find hydraulic leaks.
• Safely relieve all pressure in the hydraulic system
before performing any work on the hydraulic
system.
Checking the Hydraulic
Lines and Hoses
Service Interval: Before each use or daily
Check the 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.
g020336
Figure 65
1. Injection pump lever arm
4.
Hold the injection pump lever arm against the
low idle stop and tighten the cable connector.
5.
Loosen the screws securing the throttle control
to the control panel.
6.
Push the throttle control lever all of the way
forward.
7.
Slide the stop plate until it contacts the throttle
lever and tighten the screws securing the throttle
control to the control panel.
8.
If the throttle does not stay in position during
operation, torque the locknut, used to set the
friction device on the throttle lever, to 5 to 6 N∙m
(44 to 53 in-lb).
Checking the Hydraulic
Fluid
Service Interval: Before each use or daily—Check
the level of the hydraulic fluid.
The reservoir is filled at the factory with high-quality
hydraulic fluid. The best time to check the hydraulic
oil is when the fluid is cold. The machine should be in
its transport configuration.
Note: The maximum force required to operate
the throttle lever should be 89 N (20 lb).
50
1.
Park the machine on a level surface, lower the
cutting units, engage the parking brake, shut off
the engine, and remove the key.
2.
Clean the area around the filler neck and cap of
the hydraulic tank (Figure 66).
High Viscosity Index/Low Pour Point
Anti-wear Hydraulic Fluid, ISO VG 46
Material Properties:
Viscosity, ASTM D445
cSt @ 40°C (104°F)
44 to 48
140 or higher
Viscosity Index ASTM D2270
g008886
Pour Point, ASTM D97
-37°C to -45°C (-34°F
to -49°F)
Industry Specifications:
Eaton Vickers 694 (I-286-S,
M-2950-S/35VQ25 or
M-2952-S)
Figure 66
Note: Many hydraulic fluids are almost colorless,
making it difficult to spot leaks. A red dye additive for
the hydraulic fluid is available in 20 ml (0.67 fl oz)
bottles. A bottle is sufficient for 15 to 22 L (4 to 6 US
gallons) of hydraulic fluid. Order Part No. 44-2500
from your authorized Toro distributor.
1. Hydraulic-tank cap
3.
Remove the cap.
4.
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 6 mm (1/4
inch) of the mark on the dipstick.
5.
If the level is low, add the appropriate fluid to
raise the level to the full mark.
6.
Install the dipstick and cap onto the filler neck.
Important: Toro Premium Synthetic
Biodegradable Hydraulic Fluid is the only
synthetic biodegradable fluid approved by Toro.
This fluid is compatible with the elastomers used
in Toro hydraulic systems and is suitable for a
wide-range of temperature conditions. This fluid is
compatible with conventional mineral oils, but for
maximum biodegradability and performance, the
hydraulic system should be thoroughly flushed
of conventional fluid. The oil is available in 19 L
(5 US gallon) pails or 208 L (55 US gallon) drums
from your authorized Toro distributor.
Hydraulic Fluid
Specifications
The reservoir is filled at the factory with high-quality
hydraulic fluid. Check the level of the hydraulic fluid
before you first start the engine and daily thereafter;
refer to Checking the Hydraulic Fluid (page 50).
Hydraulic Fluid Capacity
22.7 L (6 US gallons); refer to Hydraulic Fluid
Specifications (page 51)
Recommended hydraulic fluid: Toro PX Extended
Life Hydraulic Fluid; available in 19 L (5 US gallon)
pails or 208 L (55 US gallon) drums.
Note: A machine using the recommended
replacement fluid requires less frequent fluid and filter
changes.
Alternative hydraulic fluids: If Toro PX Extended
Life Hydraulic Fluid is not available, you may use
another conventional, petroleum-based hydraulic fluid
having specifications that fall within the listed range
for all the following material properties and that it
meets industry standards. Do not use synthetic fluid.
Consult with your lubricant distributor to identify a
satisfactory product.
Note: Toro does not assume responsibility for
damage caused by improper substitutions, so use
products only from reputable manufacturers who will
stand behind their recommendation.
51
Changing the Hydraulic
Fluid
Important: Use only the hydraulic fluids
specified. Other fluids could cause system
damage.
Service Interval: Every 2,000 hours—If you
are using the recommended
hydraulic fluid, change the
hydraulic fluid.
Every 800 hours—If you are not using the
recommended hydraulic fluid or have ever
filled the reservoir with an alternative fluid,
change the hydraulic fluid.
WARNING
Hot hydraulic fluid can cause severe burns.
g008886
Allow the hydraulic fluid to cool before
performing any maintenance to the hydraulic
system.
Figure 68
1. Hydraulic fill cap
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.
2.
Park the machine on a level surface, lower the
cutting units, engage the parking brake, shut off
the engine, and remove the key from the ignition
switch.
5.
Install the reservoir cap. Start the engine and
use all of the hydraulic controls to distribute the
hydraulic fluid throughout the system.
6.
Check for leaks; then shut off the engine.
7.
Check the fluid level and add enough to raise
the level to Full mark on the dipstick.
Important: Do not overfill the reservoir.
Disconnect the large hydraulic hose (Figure 67)
from the reservoir and let the hydraulic fluid flow
into a drain pan.
Changing the Hydraulic
Filter
Service Interval: Every 1,000 hours—If you
are using the recommended
hydraulic fluid, replace the
hydraulic filter.
Every 800 hours—If you are not using the
recommended hydraulic fluid or have ever
filled the reservoir with an alternative fluid,
replace the hydraulic filter.
WARNING
Hot hydraulic fluid can cause severe burns.
Allow the hydraulic fluid to cool before
performing any maintenance to the hydraulic
system.
g020253
Figure 67
1. Hydraulic hose
3.
4.
Use a genuine Toro replacement filter, Part No.
86-3010.
Install the hydraulic hose when hydraulic fluid
stops draining.
Important: Use of any other filter may void the
warranty on some components.
Fill the reservoir (Figure 68) with approximately
22.7 L (6 US gallons) of hydraulic fluid; refer to
Hydraulic Fluid Specifications (page 51).
1.
52
Park the machine on a level surface, lower the
cutting units, engage the parking brake, shut off
Cutting Unit System
Maintenance
the engine, and remove the key from the ignition
switch.
2.
Clean around the filter mounting area. Place a
drain pan under the filter (Figure 69) and remove
the filter.
Blade Safety
A worn or damaged blade or bedknife can break, and
a piece could be thrown toward you or bystanders,
resulting in serious personal injury or death.
• Inspect the blades and bedknives periodically for
excessive wear or damage.
• Use care when checking the blades. Wear gloves
and use caution when servicing them. Only
replace or backlap the blades and bedknives;
never straighten or weld them.
• On machines with multiple cutting units, take care
when rotating a cutting unit; it can cause the reels
in the other cutting units to rotate.
Checking the
Reel-to-Bedknife Contact
g034351
Figure 69
1. Hydraulic filter
Service Interval: Before each use or daily
3.
Lubricate the new filter gasket and fill the filter
with hydraulic fluid.
4.
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.
5.
Start the engine and let it run for about 2 minutes
to purge air from the system. Shut off the engine
and check for leaks.
Each day before operating, check the reel-to-bedknife
contact, regardless of whether the quality of cut had
previously been acceptable. There must be light
contact across the full length of the reel and the
bedknife (refer to Adjusting the Reel to Bedknife in the
cutting unit Operator's Manual).
53
Using the Optional Gauge
Bar
4.
Start the engine and allow it to run at low idle
speed.
DANGER
Use the gauge bar (Figure 70) to adjust the cutting
unit. Refer to the cutting unit Operator's Manual for
the adjustment procedure.
Changing the engine speed while
backlapping may cause the cutting units
to stall.
• Never change the engine speed while
backlapping
• Backlap only at idle engine speed.
5.
Set the reel speed control to position 1 (Figure
71).
g004552
Figure 70
1. Gauge bar
4. Holes used for setting
groomer HOG
2. Height adjusting screw
5. Hole not used
3. Nut
Backlapping the Cutting
Units
g020248
Figure 71
1. Backlap lever
2. Reel speed control knob
WARNING
Contact with the cutting units or other moving
parts can result in personal injury.
• Keep your fingers, hands, and clothing
away from the cutting units and other
moving parts.
• Never attempt to turn the cutting units by
hand or foot while the engine is running.
6.
DANGER
Contacting the cutting units when they
are moving could cause personal injury.
To avoid personal injury, be certain that
you are clear of the cutting units before
proceeding.
Note: When backlapping, all the cutting units operate
together.
1.
Park the machine on a level surface, lower the
cutting units, engage the parking brake, shut off
the engine, and move the Enable/Disable switch
to the DISABLE position.
2.
Raise the floor panel to expose the controls.
3.
Make the initial reel-to-bedknife adjustments
appropriate for backlapping; refer to the cutting
unit Operator's Manual.
Move the backlap lever to the R (backlap)
position (Figure 71).
54
7.
With the Mow/Transport lever in the MOW
position, move the Enable/Disable switch to
the ENABLE position. Move the Lower Mow/Lift
control forward to start the backlapping operation
on the designated cutting units.
8.
Apply lapping compound with a long-handle
brush. Never use a short-handled brush.
9.
10.
Cleaning
If the cutting units stall or become erratic while
backlapping, select a higher reel speed setting
until the speed stabilizes, then return the reel
speed to setting 1 or to your desired speed.
Washing the Machine
To make an adjustment to the cutting units while
backlapping, turn the cutting units off by moving
the Lower Mow/Raise lever rearward; the
Enable/Disable switch to the DISABLE position,
and shut off the engine. After completing the
adjustments, repeat steps 5 through 9.
11.
Repeat the procedure for all the cutting units
that you want to backlap.
12.
When you are finished, return the backlap lever
to the MOW position, lower the floor panel, and
wash all lapping compound off of the cutting
units. Adjust the cutting unit reel-to-bedknife
contact as needed. Move the cutting unit reel
speed control to the desired mowing position.
Wash the machine as needed using water alone
or with a mild detergent. You may use a rag when
washing the machine.
Important: Do not use brackish or reclaimed
water to clean the machine.
Important: Do not use power-washing equipment
to wash the machine. Power-washing equipment
may damage the electrical system, loosen
important decals, or wash away necessary grease
at friction points. Avoid excessive use of water
near the control panel, engine, and battery.
Important: Do not wash the machine with the
engine running. Washing the machine with the
engine running may result in internal engine
damage.
Important: If the backlap switch is not
returned to the F (MOW) position after
backlapping, the cutting units will not raise
or function properly.
Note: For a better cutting edge, run a file across
the front face of the bedknife after lapping. This
removes any burrs or rough edges that may
have built up on the cutting edge.
55
Preparing the Engine
Storage
Storage Safety
• Shut off the engine, remove the key, and wait
for all movement to stop before you leave the
operator’s position. Allow the machine to cool
before adjusting, servicing, cleaning, or storing it.
1.
Drain the engine oil from the oil pan and install
the drain plug.
2.
Remove and discard the oil filter. Install a new
oil filter.
3.
Fill the engine with specified motor oil.
4.
Start the engine and run it at idle speed for
approximately 2 minutes.
5.
Shut off the engine and remove the key.
6.
Flush the fuel tank with fresh, clean fuel.
7.
Secure all of the fuel-system fittings.
8.
Thoroughly clean and service the air-cleaner
assembly.
9.
Seal the air-cleaner inlet and the exhaust outlet
with weatherproof tape.
10.
Check the antifreeze protection and add a
50/50 solution of water and ethylene glycol
antifreeze as needed for the expected minimum
temperature in your area.
• Do not store the machine or fuel container where
there is an open flame, spark, or pilot light, such
as on a water heater or other appliance.
Preparing the Traction Unit
1.
Park the machine on a level surface, lower the
cutting units, engage the parking brake, shut off
the engine, and remove the key.
2.
Thoroughly clean the traction unit, cutting units,
and the engine.
3.
Check the tire pressure; refer to Checking the
Tire Pressure (page 46).
4.
Check all fasteners for looseness; tighten them
as necessary.
5.
Grease or oil all grease fittings and pivot points.
Wipe up any excess lubricant.
6.
Lightly sand and use touch-up paint on painted
areas that are scratched, chipped, or rusted.
Repair any dents in the metal body.
7.
Service the battery and cables as follows; refer
to Electrical System Safety (page 45):
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 charge the battery every 60 days
for 24 hours to prevent lead sulfation of the
battery.
56
Notes:
EEA/UK Privacy Notice
Toro’s Use of Your Personal Information
The Toro Company (“Toro”) respects your privacy. When you purchase our products, we may collect certain personal information about you, either directly
from you or through your local Toro company or dealer. Toro uses this information to fulfil contractual obligations - such as to register your warranty,
process your warranty claim or to contact you in the event of a product recall - and for legitimate business purposes - such as to gauge customer
satisfaction, improve our products or provide you with product information which may be of interest. Toro may share your information with our subsidiaries,
affiliates, dealers or other business partners in connection these activities. We may also disclose personal information when required by law or in
connection with the sale, purchase or merger of a business. We will never sell your personal information to any other company for marketing purposes.
Retention of your Personal Information
Toro will keep your personal information as long as it is relevant for the above purposes and in accordance with legal requirements. For more information
about applicable retention periods please contact [email protected]
Toro’s Commitment to Security
Your personal information may be processed in the US or another country which may have less strict data protection laws than your country of residence.
Whenever we transfer your information outside of your country of residence, we will take legally required steps to ensure that appropriate safeguards are
in place to protect your information and to make sure it is treated securely.
Access and Correction
You may have the right to correct or review your personal data, or object to or restrict the processing of your data. To do so, please contact us by email
at [email protected] If you have concerns about the way in which Toro has handled your information, we encourage you to raise this directly with us.
Please note that European residents have the right to complain to your Data Protection Authority.
374-0282 Rev C
California Proposition 65 Warning Information
What is this warning?
You may see a product for sale that has a warning label like the following:
WARNING: Cancer and Reproductive Harm—www.p65Warnings.ca.gov.
What is Prop 65?
Prop 65 applies to any company operating in California, selling products in California, or manufacturing products that may be sold in or brought into
California. It mandates that the Governor of California maintain and publish a list of chemicals known to cause cancer, birth defects, and/or other
reproductive harm. The list, which is updated annually, includes hundreds of chemicals found in many everyday items. The purpose of Prop 65 is to
inform the public about exposure to these chemicals.
Prop 65 does not ban the sale of products containing these chemicals but instead requires warnings on any product, product packaging, or literature with
the product. Moreover, a Prop 65 warning does not mean that a product is in violation of any product safety standards or requirements. In fact, the
California government has clarified that a Prop 65 warning “is not the same as a regulatory decision that a product is ‘safe’ or ‘unsafe.’” Many of these
chemicals have been used in everyday products for years without documented harm. For more information, go to https://oag.ca.gov/prop65/faqs-view-all.
A Prop 65 warning means that a company has either (1) evaluated the exposure and has concluded that it exceeds the “no significant risk level”; or (2)
has chosen to provide a warning based on its understanding about the presence of a listed chemical without attempting to evaluate the exposure.
Does this law apply everywhere?
Prop 65 warnings are required under California law only. These warnings are seen throughout California in a wide range of settings, including but not
limited to restaurants, grocery stores, hotels, schools, and hospitals, and on a wide variety of products. Additionally, some online and mail order
retailers provide Prop 65 warnings on their websites or in catalogs.
How do the California warnings compare to federal limits?
Prop 65 standards are often more stringent than federal and international standards. There are various substances that require a Prop 65 warning
at levels that are far lower than federal action limits. For example, the Prop 65 standard for warnings for lead is 0.5 μg/day, which is well below
the federal and international standards.
Why don’t all similar products carry the warning?
•
•
Products sold in California require Prop 65 labelling while similar products sold elsewhere do not.
•
•
The enforcement of Prop 65 is inconsistent.
A company involved in a Prop 65 lawsuit reaching a settlement may be required to use Prop 65 warnings for its products, but other companies
making similar products may have no such requirement.
Companies may elect not to provide warnings because they conclude that they are not required to do so under Prop 65; a lack of warnings for a
product does not mean that the product is free of listed chemicals at similar levels.
Why does Toro include this warning?
Toro has chosen to provide consumers with as much information as possible so that they can make informed decisions about the products they buy and
use. Toro provides warnings in certain cases based on its knowledge of the presence of one or more listed chemicals without evaluating the level of
exposure, as not all the listed chemicals provide exposure limit requirements. While the exposure from Toro products may be negligible or well within the
“no significant risk” range, out of an abundance of caution, Toro has elected to provide the Prop 65 warnings. Moreover, if Toro does not provide these
warnings, it could be sued by the State of California or by private parties seeking to enforce Prop 65 and subject to substantial penalties.
Rev A
The Toro Warranty
Two-Year or 1,500 Hours Limited Warranty
Conditions and Products Covered
Parts
The Toro Company and its affiliate, Toro Warranty Company, pursuant
to an agreement between them, jointly warrant your Toro Commercial
product (“Product”) to be free from defects in materials or workmanship
for 2 years or 1,500 operational hours*, whichever occurs first. This
warranty is applicable to all products with the exception of Aerators
(refer to separate warranty statements for these products). Where a
warrantable condition exists, we will repair the Product at no cost to you
including diagnostics, labor, parts, and transportation. This warranty
begins on the date the Product is delivered to the original retail purchaser.
* Product equipped with an hour meter.
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 are covered for the duration of the
original product warranty and 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 remanufactured parts for warranty repairs.
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 800–952–2740
E-mail: [email protected]
Owner Responsibilities
As the product owner, you are responsible for required maintenance and
adjustments stated in your Operator's Manual. Repairs for product issues
caused by failure to perform required maintenance and adjustments are not
covered under this warranty.
Items and Conditions Not Covered
Not all product failures or malfunctions that occur during the warranty
period are defects in materials or workmanship. This 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, or modified non-Toro
branded accessories and products.
•
Product failures which result from failure to perform recommended
maintenance and/or adjustments.
•
Product failures which result from operating the Product in an abusive,
negligent, or reckless manner.
•
Parts consumed through use that are not defective. Examples of parts
which are consumed, or used up, during normal Product operation
include, but are not limited to, brake pads and linings, clutch linings,
blades, reels, rollers and bearings (sealed or greasable), bed knives,
spark plugs, castor wheels and bearings, tires, filters, belts, and certain
sprayer components such as diaphragms, nozzles, and check valves.
•
Failures caused by outside influence, including, but not limited to,
weather, storage practices, contamination, use of unapproved fuels,
coolants, lubricants, additives, fertilizers, water, or chemicals.
•
Failure or performance issues due to the use of fuels (e.g. gasoline,
diesel, or biodiesel) that do not conform to their respective industry
standards.
•
Normal noise, vibration, wear and tear, and deterioration. 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.
Deep Cycle and Lithium-Ion Battery Warranty
Deep cycle and Lithium-Ion batteries have a specified total number
of kilowatt-hours they can deliver during their lifetime. Operating,
recharging, and maintenance techniques can extend or reduce total
battery life. As the batteries in this product are consumed, the amount
of useful work between charging intervals will slowly decrease until the
battery is completely worn out. Replacement of worn out batteries,
due to normal consumption, is the responsibility of the product owner.
Note: (Lithium-Ion battery only): Pro-rated after 2 years. Refer to the
battery warranty for additional information.
Lifetime Crankshaft Warranty (ProStripe 02657 Model
Only)
The Prostripe which is fitted with a genuine Toro Friction Disc and
Crank-Safe Blade Brake Clutch (integrated Blade Brake Clutch (BBC) +
Friction Disc assembly) as original equipment and used by the original
purchaser in accordance with recommended operating and maintenance
procedures, are covered by a Lifetime Warranty against engine crankshaft
bending. Machines fitted with friction washers, Blade Brake Clutch (BBC)
units and other such devices are not covered by the Lifetime Crankshaft
Warranty.
Maintenance is at Owner’s Expense
Engine tune-up, lubrication, cleaning and polishing, replacement of filters,
coolant, and completing recommended maintenance are some of the
normal services Toro products require that are at the owner’s expense.
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 Emissions 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 supplied with your product or contained in the engine
manufacturer’s documentation.
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 your Authorized Toro Service Center.
374-0253 Rev F
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