Groundsmaster® 5900 Rotary Mower

Sets the cab to either recirculate the air in the cabin or to draw air into the cabin from outside (Figure 11).

• Set it to recirculate the air when using the air-conditioning.

• Set it to draw air in when using the heater or fan.

Rotate the fan control knob to regulate the speed of the fan (Figure 11).

Rotate the temperature control knob to regulate the air temperature in the cab (Figure 11).

Use this switch to turn the windshield wipers on or off (Figure 11).

Use this switch to turn the air conditioning on or off (Figure 11).

Lift up the latches to open the windshield (Figure 12). Press in the latch to lock the windshield in the open position. Pull out and down on the latch to close and secure the windshield.

Figure 12

1. Windshield latch

Lift up the latches to open the rear window. Press in on the latch to lock the window in OPEN position. Pull out and down on the latch to close and secure the window (Figure 12).

Important: Close the rear window before opening the hood or damage may occur to the hood or rear window.

Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking the Engine-Oil Level.

Before you start the engine and use the machine, check the cooling systems; refer to Checking the Engine-Cooling System and Cleaning the Cooling Systems.

Before you start the engine and use the machine, check the hydraulic system; refer to Checking the Hydraulic Fluid.

The correct air pressure in the front tires is 220 kPa (32 psi) and the rear tires is 207 kPa (30 psi) as shown in Figure 15.

Important: Maintain pressure in all tires to ensure a good quality of cut and proper machine performance. Do not underinflate the tires.Check the air pressure in all the tires before operating the machine.Traction performance, including tire-slip control, is dependent on the ratio of the tire size between the front and rear tires. Use only genuine Toro tires.

Figure 15

The correct air pressure in the caster wheel tires is 340 kPa (50 psi).

Important: Maintain pressure in all tires to ensure a good quality of cut and proper machine performance. Do not underinflate the tires.Check the air pressure in all the tires before operating the machine.

You can adjust the height of cut from 25 to 153 mm (1 to 6 inches) in 13 mm (1/2 inch) increments. To adjust the height of cut, position the caster-wheel axles in the upper or lower holes of the caster forks, add or remove an equal number of spacers from the caster forks, and adjust the rear chain (front deck only) to the desired holes.

Mount the roller in the lower position when operating at heights of cut greater than 51 mm (2 inches) and in a higher position when operating at heights of cut lower than 51 mm (2 inches).

Due to differences in grass conditions and the counterbalance setting of the traction unit, you should cut the grass and check the appearance before you begin mowing the entire area.

1. Set all mower decks to the desired height of cut; refer to Adjusting the Height of Cut.

2. Check and adjust the front and rear tire pressure.

   Note: The correct air pressure in the front tires is 220 kPa (32 psi) and the rear tires is 207 kPa (30 psi).

3. Check and adjust all caster tire pressures to 340 kPa (50 psi).

4. Check the lift and counterbalance pressures with the engine throttle at HIGH IDLE using the test ports; refer to Inspecting the Hydraulic System Test Ports.

5. Check for bent blades; refer to Checking for a Bent Blade.

6. Cut grass in a test area to determine if all mower decks are mowing at the same height.

7. If you need to adjust a mower deck, find a flat surface using a 2 m (6 ft) or longer straight edge to ensure that the surface is flat.

8. To ease measuring the blade plane, raise the height of cut to the highest position; refer to Adjusting the Height of Cut.

9. Lower the mower decks onto the flat surface and remove the covers from the tops of the mower decks.

1. Loosen the mounting nuts and position each headlight so that it points straight ahead.

   Note: Tighten the mounting nut just enough to hold the headlight in position.

2. Place a flat piece of sheet metal over the face of the headlight.

3. Mount a magnetic protractor onto the plate.

4. While holding the assembly in place, carefully tilt the headlight downward 3° then tighten the nut.

5. Repeat this procedure on the other headlight.

The machine safety-interlock system is designed to disable the traction drive when the operator leaves the seat with the traction pedal out of the NEUTRAL position. The deck drive also disengages under the same condition. However, you may get off the seat while the engine is running if the traction pedal is in the NEUTRAL position.

1. Drive the machine slowly to a large, open area.

2. Lower the mower deck(s), shut off the engine, and engage the parking brake.

The blades of the mower deck should come to a complete stop in approximately 5 seconds after you shut down the mower-deck-engagement switch.

Note: Ensure that the decks are lowered onto a clean section of turf or hard surface to avoid thrown dust and debris. To verify the stopping time, have someone stand back from the deck at least 6 m (20 ft) and watch the blades on 1 of the mower decks. Shut the mower decks down and record the time that it takes for the blades to come to a complete stop. If the time is greater than 7 seconds, adjust the braking valve; contact your Toro Distributor for assistance in making this adjustment.

1. Ensure that the parking brake is engaged.

2. Remove your foot from the traction pedal and ensure that it is in the NEUTRAL position.

3. Turn the ignition key to the RUN position.

4. When the glow indicator dims, turn the ignition key to the START position.

5. Release the key immediately when the engine starts and allow it to return to the RUN position.

6. Allow the engine to warm up at low speed (without load) for 3 to 5 minutes, then actuate the throttle switch to attain the desired engine speed.

   Important: The starter motor automatically disengages after 30 seconds to prevent premature starter motor failure. If the engine fails to start after 30 seconds, turn the key to the OFF position, check the controls and procedures again, wait 2 minutes, and repeat the starting procedure.

   Note: When the hydraulic-fluid temperature is below 4°C (40°F), the machine operates in a warm-up mode; limiting the engine speed to 1,650 rpm and preventing traction-drive operation in High range. When the fluid temperature reaches 4°C (40°F), the warm-up mode disables.

7. To shut off the engine, set the throttle switch to the LOW-IDLE position, move the PTO switch to the OFF position, engage the parking brake, and turn the ignition key to OFF.

8. Remove the key from the switch to prevent accidental starting.

Important: Allow the engine to idle for 5 minutes before shutting it off after a full-load operation. Failure to do so may lead to turbo-charger complications.

Note: Cutting grass at a rate that loads the engine promotes DPF regeneration.

1. Move the machine to the job site.

2. Whenever possible, set the engine-speed switch to high idle.

3. Engage the PTO switch.

4. Gradually move the traction pedal forward and slowly drive the machine over the mowing area.

5. Once the front of the cutting units are over the mowing area, lower the cutting units.

6. Cut grass so that the blades can cut and discharge clippings at a high rate while producing a good quality of cut.

   Note: If the cutting rate is too high, the quality of cut may deteriorate. Reduce the ground speed of the machine or reduce the width of cut to regain high idle engine speed.

7. When the cutting units are over the far edge of the mowing area, lift the cutting units.

8. Perform a tear-shaped turn to quickly line up for your next pass.

The diesel particulate filter (DPF) is part of the exhaust system. The diesel-oxidation catalyst of the DPF reduces harmful gasses and the soot filter removes soot from the engine exhaust.

The DPF regeneration process uses heat from the engine exhaust to incinerate the soot accumulated on the soot filter, converting the soot to ash, and clears the channels of the soot filter so that filtered engine exhaust flows out the DPF.

The engine computer monitors the accumulation of soot by measuring the back pressure in the DPF. If the back pressure is too high, soot is not incinerating in the soot filter through normal engine operation. To keep the DPF clear of soot, remember the following:

• Passive regeneration occurs continuously while the engine is running—run the engine at full engine speed when possible to promote DPF regeneration.

• If the back pressure is too high, the engine computer signals you through the InfoCenter when additional processes (assist and reset regeneration) are running.

Operate and maintain your machine with the function of the DPF in mind. Engine load at high idle engine speed generally produce adequate exhaust temperature for DPF regeneration.

Important: Minimize the amount of time that you idle the engine or operate the engine at low-engine speed to help reduce the accumulation of soot in the soot filter.

DPF Soot Accumulation

• Over time, the DPF accumulates soot in the soot filter. The computer for the engine monitors the soot level in the DPF.

• When enough soot accumulates, the computer informs you that it is time to regenerate the diesel particulate filter.

• DPF regeneration is a process that heats the DPF to convert the soot to ash.

• In addition to the warning messages, the computer reduces the power produced by the engine at different soot-accumulation levels.

Engine Warning Messages—Soot Accumulation

Indication Level	Regeneration Icon	Fault Code	Engine Power Rating	Recommended Action
Level 1: Engine Warning	Figure 30	Figure 31 Check Engine	The computer de-rates the engine power to 85%.	Perform a parked regeneration as soon as possible; refer to Parked Regeneration.
Level 2: Engine Warning	Figure 32	Figure 33 Check Engine	The computer de-rates the engine power to 50%.	Perform a recovery regeneration as soon as possible; refer to Recovery Regeneration.

DPF Ash Accumulation

• The lighter ash is discharged through the exhaust system; the heavier ash collects in the soot filter.

• Ash is a residue of the regeneration process. Over time, the diesel particulate filter accumulates ash that does not discharge with the engine exhaust.

• The computer for the engine calculates the amount of ash accumulated in the DPF.

• When enough ash accumulates, the engine computer sends information to the InfoCenter in the form of a system advisory or an engine fault to indicate the accumulation of ash in the DPF.

• The advisory and faults are indications that it is time to service the DPF.

• In addition to the warnings, the computer reduces the power produced by the engine at different ash-accumulation levels.

InfoCenter Active Fault Messages—Ash Accumulation

Indication Level	Active Fault	Engine Speed Reduction	Engine Power Rating	Recommended Action
Level 2: Engine Warning	Figure 34 Check EngineSPN 3720 Too High Severe	None	The computer de-rates the engine power to 85%	Service the DPF; refer to Servicing the Diesel-Oxidation Catalyst (DOC) and the Soot Filter.
Level 3: Engine Warning	Figure 35 Check EngineSPN 3720	None	The computer de-rates the engine power to 50%	Service the DPF; refer to Servicing the Diesel-Oxidation Catalyst (DOC) and the Soot Filter.
Level 4: Engine Warning	Figure 36 Check EngineSPN 3251 High	Engine speed at max torque + 200 rpm	The computer de-rates the engine power to 50%	Service the DPF; refer to Servicing the Diesel-Oxidation Catalyst (DOC) and the Soot Filter.

Regeneration Unavailable Messages

Unavailable Message Table

Message	Condition	Recommended Action
Figure 37	The engine is not running.	Start the engine.
Figure 38	The engine coolant temperature is cooler than 60°C (140°F).	Run the engine until the coolant temperature is hotter than 60°C (140°F).
Figure 39	The engine ran less than 50 hours since last regeneration.	Operate the machine until the parked regeneration icon displays in the InfoCenter.
	The exhaust temperature is less than 250°C (482°F)	Run the engine at full throttle or under high load before starting the parked regeneration.
	The engine ran less than 50 hours since last regeneration and the exhaust temperature is less than 250°C (482°F).	Operate the machine until the parked regeneration icon displays in the InfoCenter and run the engine at full throttle or under high load before starting the parked regeneration.
Figure 40	The engine speed is faster that slow idle.	Reduce the engine speed to slow idle.
Figure 41	The parking brake is not engaged.	Engage the parking brake.
Figure 42	The traction pedal is in the FORWARD or REVERSE position.	Move the traction pedal to the NEUTRAL position.
Figure 43	The engine computer has sent a diagnostic trouble code.	Troubleshoot the diagnostic fault code and/or repair the engine.
Figure 44	The soot filter needs service.	Refer to Servicing the Diesel-Oxidation Catalyst (DOC) and the Soot Filter.

Types of Diesel Particulate Filter Regeneration

Types of diesel particulate filter regeneration that are performed while the machine is operating:

Type of Regeneration	Conditions for DPF regeneration	DPF description of operation
Passive	Occurs during normal operation of the machine at high-engine speed or high-engine load	The InfoCenter does not display an icon indicating passive regeneration.
		During passive regeneration, the DPF processes high-heat exhaust gasses; oxidizing harmful emissions and burning soot to ash.
		Refer to Passive DPF Regeneration.
Assist	Occurs as a result of low-engine speed, low-engine load, or after the computer detects back pressure in the DPF	During assist regeneration, the computer controls the intake throttle to increase the exhaust temperature, enabling assist regeneration to occur.
		Refer to Assist DPF Regeneration.
Reset	Occurs after assist regeneration only if the computer detects that assist regeneration did not sufficiently reduce the soot level	During reset regeneration, the computer controls the intake throttle and fuel injectors to increase the exhaust temperature during regeneration.
	Also occurs every 100 hours to reset baseline sensor readings	Refer to Reset Regeneration.

Types of diesel particulate filter regeneration that require you to park the machine:

Type of Regeneration	Conditions for DPF regeneration	DPF description of operation
Parked	Soot buildup occurs as a result of prolonged operation at low-engine speed or low-engine load. May also occur as a result of using incorrect fuel or oil	When the parked-regeneration icon is displayed in the InfoCenter, a regeneration is requested.
	The computer detects back pressure due to soot buildup and requests a parked regeneration
		• Perform the parked regeneration as soon as possible to avoid needing a recovery regeneration.
		• A parked regeneration requires 30 to 60 minutes to complete.
		• You must have at least a 1/4 tank of fuel in the tank.
		• You must park the machine to perform a recovery regeneration.
		Refer to Parked Regeneration.
Recovery	Occurs as a result of ignoring parked regeneration requests and continuing operation, adding more soot when the DPF is already in need of a parked regeneration	When the recovery-regeneration icon is displayed in the InfoCenter, a recovery regeneration is requested.
		• A recovery regeneration requires approximately 4 hours to complete.
		• You must have at least a 1/2 tank of fuel in the machine.
		• You must park the machine to perform a recovery regeneration.
		Refer to Recovery Regeneration.

Practice driving the machine, as it has a hydrostatic transmission, and its characteristics may differ from other turf-maintenance machines.

With Toro Smart Power™, you do not have to listen to the engine speed in heavy load conditions. Smart Power prevents the engine from bogging down in heavy cutting conditions by automatically controlling the machine speed and optimizing cutting performance.

If Toro Smart Power™ is disabled, to maintain enough power for the traction unit and implement while operating, regulate the traction pedal to keep the engine speed (rpm) high and constant. Decrease the ground speed as the load on the implement increases, and increase the ground speed as the load decreases.

Allow the traction pedal to move backward as the engine speed (rpm) decreases, and press the pedal slowly as the engine speed increases. By comparison, when driving between work areas, with no load and the mower deck raised, set the throttle in the highest position and press the traction pedal slowly, but fully, to attain maximum ground speed.

Before stopping the engine, disengage all controls and decrease the engine speed to LOW IDLE (1,000 rpm). Turn the ignition key to the OFF position to shut off the engine.

Before transporting the machine, raise the mower decks and secure the transport latches on the wing mower deck (Figure 55).

Figure 55

1. Transport latch

This machine is designed with 2 voltage systems: 12 V and 24 V.

The 12 V system powers all functions of the machine, except for the engine-cooling fans and hydraulic-cooling fans. The 2 large 12 V batteries at the rear, right corner of the machine are connected in parallel to provide 12 V nominal. The 12 V engine alternator charges these batteries.

The 24 V system powers the engine-cooling fans and hydraulic-cooling fans. The 2 small 12 V batteries at the rear, left corner of the machine are connected in series to provide 24 V nominal. The 24 V alternator charges these batteries.

The battery-disconnect switch is located at the rear, right side of the machine. This switch can be used to disconnect power from the batteries during service or maintenance procedures.

The hydraulic-fan speed is controlled by hydraulic-fluid temperature. The radiator-fan speed is controlled by the engine-coolant temperature. A reverse cycle automatically initiates when either the engine coolant or hydraulic-fluid temperature reaches a certain point. This reversal blows debris off the screens, lowering the engine and hydraulic-fluid temperatures (Figure 56). Additionally, the radiator fans perform a reverse cycle every 21 minutes regardless of the coolant temperature.

Figure 56

Important: Do not push or tow the machine faster than 3 to 4.8 km/h (2 to 3 mph), because internal-transmission damage may occur.

1. Raise the hood and locate the bypass valves on the pump

   

   Figure 58

   1. Bypass valves (2)

2. Loosen both tow valves on the hydrostatic transmission.

3. Rotate each valve 3 turns counter-clockwise to open and allow oil to bypass internally.

4. Manually release the automatic parking brake using the bypass valve and plunger as shown in Figure 59.

   

   Figure 59

5. Close the bypass valves before starting the engine and torque to 70 N·m (52 ft-lb) to close the valve.

   Note: The manual parking-brake release automatically resets when the engine is started.

Front of the machine—under the front of the operator's platform (Figure 60)

Figure 60

1. Front tie downs

Rear of the machine—on the bumper (Figure 61)

Figure 61

1. Rear tie downs

• Use care when loading or unloading the machine into a trailer or a truck.

• Use full-width ramps for loading the machine into a trailer or a truck.

• Tie the machine down securely.

Open the hood to access the battery-disconnect switch.

Turn the battery-disconnect switch to the ON or OFF position to perform the following:

• To energize the machine electrically, rotate the battery-disconnect switch clockwise to the ON position (Figure 63).

• To de-energize the machine electrically, rotate the battery-disconnect switch counterclockwise to the OFF position (Figure 63).

  Important: Do not turn the battery-disconnect switch to the OFF position while the engine is running. Ensure that the machine is shut off before turning the battery-disconnect switch to the OFF position, as you may cause damage to the engine and/or machine.

  

  Figure 63

  1. Battery-disconnect switch (OFF position)
  2. Battery-disconnect switch (ON position)

Use the following as points to jack up the machine:

Front of the machine—on the frame, on the inside of each drive tire (Figure 64)

Figure 64

1. Front jacking point (2)

Rear of the machine—at the center of the axle (Figure 65)

Figure 65

1. Rear jacking point

The machine has grease fittings that you must lubricate regularly with No. 2 lithium grease. Also, lubricate the machine immediately after every washing.

Traction Unit

• 2 impact arms (Figure 69)

• 2 front deck-lift-cylinder pivots (Figure 69)

• 2 side deck-lift-cylinder pivots (Figure 69)

• 4 steering-cylinder-ball joints (Figure 70)

• 2 tie-rod-ball joints (Figure 70)

• 2 king-pin bushings (Figure 70)

• 1 rear axle-pivot bushing (Figure 71)

Figure 69

Figure 70

Figure 71

Front Mower Deck

• 2 caster-fork-shaft bushings (Figure 72)

• 5 spindle-shaft bearings (located on the spindle housing) as shown in Figure 72

• 3 idler-arm-pivot bushings (located on the idler-pivot shaft) as shown in Figure 72

• 4 winglet-deck bushings (located on the winglet-pivot pins) as shown in Figure 72

Figure 72

Wing Mower Decks (Each Wing)

• 4 caster-fork-shaft bushing (Figure 74)

• 3 spindle-shaft bearings (located on the spindle housing) as shown in Figure 74

• 2 idler-arm-pivot bushings (located on the idler-pivot shaft) as shown in Figure 74

Figure 74

Check the air-cleaner body for damage that could cause an air leak and replace it if it is damaged. Check the entire intake system for leaks, damage, or loose hose clamps. Also, inspect the rubber intake-hose connections at the air cleaner and turbocharger to ensure that the connections are complete.

Service the air-cleaner filter only when the “Check Air Filter” message is displayed on the InfoCenter (Figure 77). Changing the air filter before it is necessary only increases the chance of dirt entering the engine when you remove the filter.

Ensure that the cover is seated correctly and seals with the air-cleaner body.

Figure 77

Servicing the Air-Cleaner Cover

Maintenance Service Interval	Maintenance Procedure
Every 50 hours	Remove the air-cleaner cover and clean out the debris. Do not remove the filter.

Check the air-cleaner body for damage which could cause an air leak. Replace a damaged air cleaner body.

Clean the air-cleaner cover (Figure 78).

Figure 78

Refer to your engine operator’s manual for the adjustment procedure.

For information on cleaning the engine EGR cooler, refer to your engine operator’s manual.

For information on inspecting the engine crankcase-breather system, refer to your engine operator’s manual.

For information on checking and replacing fuel hoses and engine-coolant hoses, refer to your engine operator’s manual.

For information on lapping or adjusting the engine intake and exhaust valves, refer to your engine owner’s manual.

For information on inspecting and cleaning the engine-emission-control components, refer to your engine operator’s manual.

If engine faults , , or in the InfoCenter (Figure 85) display in the InfoCenter, clean the soot filter using the steps that follow:

Figure 85

Figure 86

Figure 87

1. Refer to the Engine section in the Service Manual for information on disassembling and assembling the diesel-oxidation catalyst and the soot filter of the DPF.

2. Refer to your Authorized Toro Distributor for diesel-oxidation catalyst and the soot filter replacement parts or service.

3. Contact your Authorized Toro Distributor to have them reset the engine ECU after you install a clean DPF.

1. Clean the area around the fuel-filter head (Figure 89).

   

   Figure 89

   1. Fuel-filter head
   2. Filter

2. Remove the filter and clean the filter-head-mounting surface (Figure 89).

3. Lubricate the filter gasket with clean, lubricating engine oil; refer to the engine owner's manual (included with the machine) for additional information.

4. Install the dry filter canister, by hand, until the gasket contacts the filter head, then rotate it an additional 1/2 turn.

5. Turn the ignition key to the RUN position so that the electric fuel pump can fill the fuel-filter canister.

6. Start the engine and check for fuel leaks around the filter head.

Important: If you are installing an auxiliary accessory to the machine, the only approved locations to source power are at the traction-unit fuse block (Figure 94) or the cab-fuse block (Figure 96). A maximum of 10 A is available from either location. Contact your local Toro distributor for assistance.

Note: Shut off the engine and remove the key before removing the fuses.

The traction-unit fuses (Figure 90) are located in the power-center console behind the seat (Figure 91).

Additional traction-unit fuses (Figure 92) are located on the rear, right side of the machine (Figure 93).

Figure 90

Figure 91

1. Power-center console
2. Knobs

Figure 92

Figure 93

1. Fuse block

Figure 94

1. Fuse block
2. Power leads

The cab fuses (Figure 95) are located in the fuse box on the cab headliner (Figure 96).

Figure 95

Figure 96

1. Cab fuse box
2. Fuses

Important: Before welding on the machine, disconnect the battery to prevent damage to the electrical system. Also, you must disconnect the engine controller, InfoCenter, and machine controllers before welding on the machine.

Note: Keep the terminals and the entire battery case clean, because a dirty battery discharges slowly. To clean the battery, wash the entire case with a solution of baking soda and water. Rinse with clear water. Coat the battery posts and cable connectors with Grafo 112X (skin-over) grease (Toro Part No. 505-47) or petroleum jelly to prevent corrosion.

Important: Keep the batteries fully charged. This is especially important to prevent battery damage when the temperature is below 32°F (0°C).

1. Perform the pre-maintenance procedure; refer to Pre-Maintenance Procedures.

2. Clean the exterior of the battery case and the battery posts.

   Note: Connect the leads of the battery charger to battery posts before connecting the charger to the electrical source.

3. Remove the covers from the jump posts (Figure 97).

   

   Figure 97

   1. Jump-post covers

4. Connect the positive lead of the battery charger to the positive jump post (Figure 98).

   

   Figure 98

   1. Positive (+) jump post
   2. Negative (-) jump post
   3. Negative (-) jumper-cable clamp
   4. Positive (+) jumper-cable clamp

5. Connect the negative lead of the battery charger to the negative jump post (Figure 98).

6. Connect the battery charger to the electrical source, and charge the battery according to the Battery-charging Table that follows.

   Important: Do not overcharge the battery.

   Battery-charger Table

   Charger setting	Charging time
   4 to 6 A	30 minutes
   25 to 30 A	10 to 15 minutes

7. When the batteries are fully charged, unplug the charger from the electrical source, then disconnect the charger leads from the jump posts (Figure 98).

Note: This procedure requires 2 people to perform. Ensure that the person making the connections wears the proper face protection, protective gloves, and clothing.

1. Park the machine on a level surface, engage the parking brake, lower the cutting deck, and shut off the engine.

2. Sit in the operator seat and have the other person make the connections.

   Note: Ensure that the jumper battery is a 12V battery.

   Important: If you are using another machine for power, ensure that the 2 machines are not touching each other.

3. Remove the covers from the jump posts (Figure 97).

4. Connect the positive (+) jumper cable to the positive jump post (Figure 99).

   

   Figure 99

   1. Positive (+) jump post
   2. Negative (-) jump post
   3. Negative (-) jumper-cable clamp
   4. Positive (+) jumper-cable clamp

5. Connect the negative (-) jumper cable to the negative jump post (Figure 99).

6. Start the engine.

   Important: If the engine starts and then stops, do not operate the starter motor until the starter motor stops turning. Do not operate the starter motor for more than 30 seconds at one time. Wait 30 seconds before operating the starter motor to cool the motor.

7. When the engine starts, have the other person disconnect the negative (-) jumper cable from the negative jump post and then disconnect the positive (+) jumper cable (Figure 99).

1. Open the hood and turn the battery-disconnect switch to the OFF position.

2. Remove the three 3 flange screws from each side of the rear bumper as shown in Figure 100.

3. Loosen the remaining flange screws securing the rear bumper to the frame and pivot the bumper downward.

   

   Figure 100

   1. Rear bumper
   2. Loosen this flange screw on both sides.
   3. Remove these 3 flange screws on both sides.

4. Loosen the knobs and remove both side shrouds (Figure 101).

   

   Figure 101

   1. Knobs
   2. Remove the side shrouds on both sides

5. Remove the 6 flange screws securing rear shroud to the frame and remove the rear shroud (Figure 102).

   

   Figure 102

   1. Rear shroud
   2. Flange screw

6. Remove the fasteners that secure the battery cover to the machine and remove the cover (Figure 103).

   Note: Make note of how and where the battery cables are installed.

7. Loosen and remove the battery cables from the batteries.

8. Remove the fasteners that secure the battery-hold downs.

9. Carefully remove the batteries from the machine (Figure 103).

   

   Figure 103

   1. Battery cover
   2. Battery-disconnect switch
   3. Batteries—12 V (for 12 VDC system)
   4. Batteries—12 V (for 24 VDC system)
   5. Positive (+) cable (for 12 VDC system)
   6. Cable assembly (for 24 VDC system)
   7. Cable - jumper (for 24 VDC system)
   8. Ground cable (-)
   9. Battery hold down
   10. Battery hold down

1. Secure the batteries with the hold downs (Figure 103).

2. Install the battery cables.

3. Position the battery cover in place and secure it with the removed fasteners.

4. Install the rear shroud (Figure 102).

5. Install the side shrouds (Figure 101).

6. Raise the rear bumper into position and install the flange screws. Tighten all the flange screws securing the rear bumper to the frame (Figure 100).

7. Turn the battery-disconnect switch to the ON position.

Contact your local Toro distributor or refer to the Toro Service Manual for assistance.

You can adjust the operating angle of the traction pedal for your comfort.

1. Loosen the 2 nuts and bolts securing the left side of the traction pedal to the bracket (Figure 104).

   

   Figure 104

   1. Traction pedal
   2. Mounting nuts and bolts

2. Pivot the pedal to the desired operating angle and tighten the nuts (Figure 104).

1. With the rear tires in a straight position, measure the outside distance (at axle height) at the front and rear of the rear tires (Figure 105).

   Note: The front measurement should be 0 to 3 mm (0 to 0.12 inch) greater than the rear measurement.

   

   Figure 105

   1. Outside distance
   2. Tie-rod clamps

2. To adjust the toe-in, loosen the clamps at both ends of the tie rods (Figure 105).

3. Rotate the tie-rod to move the front of the tire inward or outward.

4. Once you achieve the correct toe-in, tighten the tie-rod clamps.

The capacity of the system on a machine without a cab is 10.4 L (13.5 US qt) and with a cab is 17 L (18 US qt).

Recommended coolant: Ethelyne glycol anti-freeze and water (50/50 blend).

1. Carefully remove the radiator cap and expansion-tank cap (Figure 106).

   

   Figure 106

   1. Expansion-tank cap
   2. Radiator cap

2. Check the coolant level in the radiator (Figure 106).

   Note: When cool, the radiator should be filled to the top of the filler neck and the expansion tank filled to the Full mark.

3. If the coolant is low, add the recommended replacement coolant to the expansion tank to the Full mark.

   Note: Do not use water only or alcohol/methanol-based coolants.

4. Install the radiator cap and expansion-tank cap.

Perform the pre-maintenance procedure; refer to Pre-Maintenance Procedures.

Important: Do not use water to clean the radiator core or hydraulic-fluid-cooler core. Cleaning the radiator core or hydraulic-fluid-cooler core with water can promote premature corrosion and damage to components.

The capacity of the system on a machine without a cab is 10.4 L (13.5 US qt) and with a cab is 17 L (18 US qt).

1. Perform the pre-maintenance procedure; refer to Pre-Maintenance Procedures.

2. Remove the radiator cap.

3. With the radiator drain hose placed in a drain pan, open the drain valve on the radiator hose and drain the fluid into a drain pan (Figure 111).

   

   Figure 111

   1. Drain valve
   2. Radiator drain hose
   3. Radiator

4. Close the valve on the radiator drain hose (Figure 111).

5. Fill the radiator with coolant until the coolant level even with the lip of the filler port (Figure 112).

   

   Figure 112

   1. Radiator cap
   2. Expansion-tank cap

6. Install the radiator cap.

7. Remove the coolant hose from the engine-oil cooler (Figure 113).

   

   Figure 113

   1. Coolant hose

8. After draining the engine coolant, close the drain valve on the radiator drain hose and connect the coolant hose.

9. Remove the cap of the expansion tank and fill it to the Low mark with engine coolant. Install the cap.

10. Start and run the engine until it reaches operating temperature.

11. Check the engine-coolant level; refer to Checking the Engine-Cooling System.

12. Add coolant to the expansion tank to bring the coolant level to the Full mark.

13. Check all engine-coolant-hose connections for leaks.

Refer to the engine owner's manual (included with the machine) for the servicing procedure.

The AC compressor and 24 V alternator belt uses a spring-loaded tensioner that is pre-set at the factory. Refer to the Toro Service Manual for the servicing procedure.

The blade-drive belt, tensioned by the spring-loaded idler pulley, is very durable. However, after many hours of use, the belt will show signs of wear. Signs of a worn belt are squealing when the belt is rotating, blades slipping when cutting grass, frayed edges, burn marks, and cracks. Replace the belt if any of these signs occur.

The hydraulic-fluid reservoir is filled at the factory with approximately 62.7 L (16.6 US gallons) of high-quality hydraulic fluid. Check the level of the hydraulic fluid before you start the engine for the first time and daily thereafter.

Use Toro Premium All-Season Hydraulic Fluid (Available in 5-gallon pails or 55-gallon drums. See the Parts Catalog or Toro distributor for part numbers.)

If the Toro fluid is not available, you may use other fluids provided that they meet all the following material properties and industry specifications. Consult with your lubricant distributor to identify a satisfactory product.

Note: Toro does not assume responsibility for damage caused by improper substitutions, so use only products from reputable manufacturers who will stand behind their recommendation.

High-Viscosity Index/Low-Pour Point Anti-Wear Hydraulic Fluid, ISO VG 46

Important: The ISO VG 46 multigrade fluid offers optimal performance in a wide range of temperature conditions. For operation in consistently high ambient temperatures, 65°F (18°C) to 120°F (49°C), ISO VG 68 hydraulic fluid may offer improved performance.

Important: Many hydraulic fluids are almost colorless, making it difficult to spot leaks. A red dye additive for the hydraulic-system oil is available in 20ml (2/3 fl oz) bottles. 1 bottle is sufficient for 15 to 22 L (4 to 6 US gallons) of hydraulic oil. Order Toro Part No. 44-2500 from your authorized Toro distributor.

1. Perform the pre-maintenance procedure; refer to Pre-Maintenance Procedures.

2. On the right side of the machine, raise the access cover to expose the hydraulic-tank cap (Figure 120).

   

   Figure 120

   1. Hydraulic-tank cap

3. Clean the area around the filler neck and cap of the hydraulic tank (Figure 120).

4. Remove the cap from the filler neck.

5. Remove the dipstick from the filler neck and wipe it with a clean rag. Insert the dipstick into the filler neck, then remove it and check the fluid level (Figure 121).

   Note: The fluid level should be within the safe operating range on the dipstick.

   

   Figure 121

   1. Safe operating range

6. If the level is low, add the appropriate fluid to raise the level to the upper mark.

7. Install the dipstick and cap onto the filler neck.

8. Close the cover.

If the hydraulic fluid becomes contaminated, contact your local Toro distributor because the system must be flushed. Contaminated fluid looks milky or black when compared to clean fluid.

Use Toro replacement filters (Part No. 86-6110 for the left side of the machine and Part No. 75-1310 for the right side of the machine).

Important: Using any other filter may void the warranty on some components.

1. Park the machine on a level surface, engage the parking brake, lower the cutting deck, shut off the engine, and remove the key.

2. Place a large drain pan under the hydraulic-fluid tank.

3. Remove the hydraulic-tank cap and dipstick.

4. Remove the drain plug from the bottom of the tank and let the hydraulic fluid flow into the pan (Figure 122).

   

   Figure 122

   1. Hydraulic filters
   2. Drain plug

5. Install the drain plug when the hydraulic fluid stops draining.

6. Clean the area around the filter-mounting areas.

7. Place a drain pan under the filter and remove the filter (Figure 122).

8. Lubricate the new filter gasket and fill the filter with hydraulic fluid.

9. Ensure that each filter-mounting area is clean and screw the filter on until the gasket contacts the mounting plate; then tighten the filter an additional 1/2 turn.

10. Fill the reservoir with hydraulic fluid; refer to Checking the Hydraulic Fluid.

    Important: Use only the hydraulic fluids specified. Other fluids could cause system damage.

11. Install the reservoir dipstick and cap.

12. Start the engine and use all of the hydraulic controls to distribute hydraulic fluid throughout the system.

    Note: Also, check for leaks, then shut off the engine.

13. Check the fluid level and add enough to raise the level to the Full mark on the dipstick.

    Note: Do not overfill.

Inspect the hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration, and chemical deterioration. Make all necessary repairs before operating the machine.

The test ports are used to test the pressure in the hydraulic circuits. Contact your local Toro distributor or refer to the Toro Service Manual for assistance.

Note: Although not needed for normal maintenance procedures, you can pivot (tilt) the front mower deck upright.

1. Raise the front mower deck slightly off the floor.

2. Perform the pre-maintenance procedure; refer to Pre-Maintenance Procedures.

3. Remove the retainer clip and disconnect the damper assembly from the mower deck (Figure 123).

   

   Figure 123

   1. Damper assembly
   2. Retainer clip

4. Remove the hairpin cotter and clevis pin securing the height-of-cut chains to the rear of the mower deck (Figure 124).

   

   Figure 124

   1. Height-of-cut chain
   2. Clevis pin
   3. Hairpin cotter

5. Start the engine, slowly raise the front mower deck, shut off the engine, and remove the ignition key.

6. Wedge a block of wood between the rear of the deck and the machine (Figure 125).

   

   Figure 125

   1. Block of wood

1. With the help of another person holding the front of the mower deck, remove the block of wood.

2. Sit on the seat, start the engine, and lower the mower deck until it is slightly off the floor.

3. Secure the height-of-cut chains to the rear of the mower deck.

4. Connect the damper assembly and secure it with the retainer clip.

The caster arms have bushings pressed into the top and bottom of the tube, and after many hours of operation, the bushings wear. To check the bushings, move the caster fork back and forth and from side to side. If the caster spindle is loose inside the bushings, the bushings are worn; replace them.

Remove the tensioning cap and caster fork (Figure 128).

Note: Record the position of the washers and spacers before you remove them so that you do not need to adjust the deck pitch.

1. Remove the locknut from the bolt holding the caster-wheel assembly between the caster fork or the caster-pivot arm (Figure 129).

   

   Figure 129

   1. Caster wheel
   2. Caster fork
   3. Bearing
   4. Bearing spacer

2. Grasp the caster wheel and slide the bolt out of the fork or pivot arm (Figure 129).

3. Remove the bearing from the wheel hub and allow the bearing spacer to fall out (Figure 129).

4. Remove the bearing from the opposite side of the wheel hub (Figure 129).

5. Check the bearings, spacer, and inside of the wheel hub for wear.

   Note: Replace any damaged parts.

6. To assemble the caster wheel, push the bearing into the wheel hub.

   Note: When installing the bearings, press on the outer race of the bearing.

7. Slide the bearing spacer into the wheel hub and push the other bearing into the open end of the wheel hub to captivate the bearing spacer inside the wheel hub.

8. Install the caster-wheel assembly between the caster fork and secure it in place with the bolt and locknut.

After striking a foreign object, inspect the machine for damage and make repairs before restarting and operating the equipment. Torque all the spindle-pulley nuts to 176 to 203 N·m (130 to 150 ft-lb).

1. Raise the mower deck.

2. Perform the pre-maintenance procedure; refer to Pre-Maintenance Procedures.

3. Block the mower deck to prevent it from accidentally falling.

4. Rotate the blade until the ends face forward and backward, and measure from the inside of the mower deck to the cutting edge at the front of the blade (Figure 130).

   Note: Record this dimension.

   

   Figure 130

5. Rotate the opposite end of the blade forward and measure between the mower deck and cutting edge of the blade at the same position as in step 4.

   Note: The difference between the dimensions obtained in steps 4 and 5 must not exceed 3 mm (1/8 inch). If the dimension exceeds 3 mm (1/8 inch), the blade is bent and must be replaced; refer to Removing and Installing a Blade.

Replace the blade if it hits a solid object, if it is out of balance, or if it is bent. Always use genuine Toro replacement blades to be sure of safety and optimum performance. Never use replacement blades made by other manufacturers because they could be dangerous.

1. Raise the mower deck to the highest position.

2. Perform the pre-maintenance procedures; refer to Pre-Maintenance Procedures.

3. Block the mower deck to prevent it from accidentally falling.

4. Grasp the end of the blade using a rag or thickly padded glove and remove the blade bolt, anti-scalp cup, and blade from the spindle shaft (Figure 131).

   

   Figure 131

   1. Blade bolt
   2. Anti-scalp cup

5. Install the blade, anti-scalp cup, and blade bolt.

6. Torque the blade bolt to 115 to 149 N·m (85 to 110 ft-lb).

   Important: The curved part of the blade must point toward the inside of the mower deck to ensure proper mowing.

   Note: After striking a foreign object, torque all the spindle-pulley nuts to 176 to 203 N·m (130 to 150 ft-lb) and the blade bolts to 115 to 149 N·m (85 to 110 ft-lb).

You must consider 2 areas of the blade when checking and servicing it: the sail and the cutting edge. Both cutting edges and the sail, which is the turned-up portion opposite of the cutting edge, contribute to a good quality of cut. The sail is important because it lifts the grass up straight, thereby producing an even cut. However, the sail gradually wears down during operation, which is normal. As the sail wears down, the quality of cut degrades somewhat, although the cutting edges are sharp. The cutting edge of the blade must be sharp so that the grass is cut, not torn. A dull cutting edge is evident when the tips of the grass appear brown and shredded. Sharpen the cutting edges to correct this condition.

1. Position the machine on a level surface, raise the mower deck, engage the parking brake, put the traction pedal in NEUTRAL, ensure that the PTO switch is in the OFF position, shut off the engine, and remove the key.

2. Examine the cutting ends of the blade carefully (especially where the flat and curved parts of the blade meet) as shown in Figure 132.

   Note: Since sand and abrasive material can wear away the metal that connects the flat and curved parts of the blade, check the blade before using the mower. If you notice wear, replace the blade (Figure 132).

   

   Figure 132

   1. Cutting edge
   2. Curved area
   3. Wear/slot forming
   4. Crack

3. Examine the cutting edges of all of the blades.

4. Sharpen the cutting edges if they are dull or nicked (Figure 133).

   

   Figure 133

   1. Sharpen at the original angle.

   Note: Sharpen only the top of the cutting edge and maintain the original cutting angle to ensure the sharpness.

   Note: The blade will remain balanced if the same amount of metal is removed from both cutting edges.

Note: Remove the blades and sharpen them on a grinder. After sharpening the cutting edges, install the blade with the anti-scalp cup and blade bolt; refer to Removing and Installing a Blade.

When there is mismatch between the blades on a single mower deck, the grass appears streaked when it is cut. You can correct this problem by ensuring that the blades are straight.

1. Using a 1 m (3 ft) long carpenter’s level, find a level surface on the shop floor.

2. Raise the height-of-cut to the highest position; refer to Adjusting the Height of Cut.

3. Lower the mower deck onto a flat surface and remove the covers from the top of the mower deck.

4. Rotate the blades until the ends face forward and backward.

5. Measure from the floor to the front tip of the cutting edge (record this dimension).

6. Rotate the same blade, so that the opposite end is forward and measure it again.

   Note: The difference between the dimensions must not exceed 3 mm (1/8 inch). If the dimension exceeds 3 mm (1/8 inch), replace the blade, because it is bent. Measure all the blades.

7. Ensure that the deck is level from side to side and adjust as required.

8. Install the belt covers.

Important: Use care around the cab seals and lights (Figure 134). If you are using a pressure washer, keep the washer wand at least 0.6 m (2 ft) away from the machine. Do not use the pressure washer directly on the cab seals and lights or under the rear overhang.

Figure 134

1. Seal
2. Light
3. Keep wand 0.6 m (2 ft) away.
4. Do not pressure-wash under the rear overhang.

1. Remove the screws and grates from both the in-cab and rear cab air filters (Figure 135 and Figure 136).

   

   Figure 135

   In-Cab Air Filter

   1. Filter
   2. Grate
   3. Screw
   

   Figure 136

   Rear Cab Air Filter

   1. Filter
   2. Grate
   3. Screw

2. Clean the filters by blowing clean, oil-free, compressed air through them.

   Important: If either filter has a hole, tear, or other damage, replace the filter.

3. Install the filters and the grate with the thumbscrews.

The purpose of the cab pre-filter is to prevent large debris, such as grass and leaves from entering the cab filters.

1. Rotate the screen cover down.

2. Clean the filter with water.

   Note: Do not use a pressure washer.

   Important: If the filter has a hole, tear, or other damage, replace the filter.

3. Allow the pre-filter to dry before installing it into the machine.

4. Rotate the filter screen around the tabs until the latch locks into the latch-mount assembly (Figure 137).

   

   Figure 137

   1. Latch-mount assembly
   2. Latch
   3. Screen cover

1. Perform the pre-maintenance procedure; refer to Pre-Maintenance Procedures.

2. Disconnect the wire for each fan (Figure 138).

   

   Figure 138

   Right Fan Shown

   1. Fan
   2. Wire
   3. Knob

3. Remove the 2 knobs and remove the fan assembly.

4. Open the 4 latches on the air-conditioning assembly and remove the screen (Figure 139).

   

   Figure 139

   1. Air-conditioning-condenser coil
   2. Latch
   3. Air-conditioning screen

5. Remove the air filters (Figure 136).

6. Clean the air-conditioning assembly.

7. Install the air filters, screen, and fan assembly (Figure 136, Figure 138, and Figure 139).

8. Connect the wire for each fan (Figure 138).