Groundsmaster® 4010 Rotary Mower

• Read the Operator's Manual and other training material carefully. Be familiar with the controls, safety signs, and the proper use of the equipment.

• Never allow children or people unfamiliar with these instructions to use the mower. Local regulations may restrict the age of the operator.

• Never mow while people, especially children, or pets are nearby.

• Keep in mind that the operator or user is responsible for accidents or hazards occurring to himself or herself, other people, or property.

• Do not carry passengers.

• All drivers and mechanics should seek and obtain professional and practical instruction. The owner is responsible for training the users. Such instruction should emphasize:

  • the need for care and concentration when working with ride-on machines;

  • control of a ride-on machine sliding on a slope will not be regained by the application of the brake. The main reasons for loss of control are:

    • insufficient wheel grip;

    • being driven too fast;

    • inadequate braking;

    • the type of machine is unsuitable for its task;

    • lack of awareness of the effect of ground conditions, especially slopes;

    • incorrect hitching and load distribution.

• While mowing, always wear substantial, slip-resistant footwear, long trousers, hard hat, safety glasses, and hearing protection. Long hair, loose clothing or jewelry may get tangled in moving parts. Do not operate the equipment when barefoot or wearing open sandals.

• Thoroughly inspect the area where the equipment is to be used and remove all objects which may be thrown by the machine.

• Warning–fuel is highly flammable. Take the following precautions:

  • Store fuel in containers specifically designed for this purpose.

  • Refuel outdoors only and do not smoke while refuelling.

  • Add fuel before starting the engine. Never remove the cap of the fuel tank or add fuel while the engine is running or when the engine is hot.

  • If fuel is spilled, do not attempt to start the engine but move the machine away from the area of spillage and avoid creating any source of ignition until fuel vapors have dissipated.

  • Replace all fuel tank and container caps securely.

• Replace faulty silencers/mufflers.

• Before using, always visually inspect to see that the blades, blade bolts, and cutting assembly are not worn or damaged. Replace worn or damaged blades and bolts in sets to preserve balance.

• On multi-bladed machines, take care as rotating one blade can cause other blades to rotate.

• Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by the manufacturer.

• Check that operators presence controls, safety switches, and shields are attached and functioning properly. Do not operate unless they are functioning properly.

• Do not operate the engine in a confined space where dangerous carbon monoxide and other exhaust gasses can collect.

• Mow only in daylight or in good artificial light.

• Before attempting to start the engine, disengage all blade attachment clutches and engage the parking brake. Only start the engine from the operator's position. Always use the seat belt and ROPS together.

• Remember there is no such thing as a safe slope. Travel on grass slopes requires particular care. To guard against overturning:

  • Do not stop or start suddenly when going up or downhill.

  • The machine speed should be kept low on slopes and during tight turns.

  • Stay alert for humps and hollows and other hidden hazards.

  • Never mow across the face of the slope, unless the machine is designed for that purpose.

• Stay alert for holes in the terrain and other hidden hazards.

• Use care when using heavy equipment.

  • Do not turn sharply. Use care when reversing.

  • Use counterweight(s) or wheel weights when suggested in the Operator's Manual.

• Watch out for traffic when crossing or near roadways.

• Stop the blades from rotating before crossing surfaces other than grass.

• When using any attachments, never direct discharge of material toward bystanders nor allow anyone near the machine while in operation.

• Never operate the machine with damaged guards, shields, or without safety protective devices in place. Be sure all interlocks are attached, adjusted properly, and functioning properly.

• Before leaving the operators position:

  • Stop on level ground.

  • Disengage the power take-off.

  • Set the parking brake.

  • Stop the engine and remove the key.

• Disengage drive to attachments, stop the engine, and remove the ignition key:

  • before clearing blockages;

  • before checking, cleaning, or working on the machine;

  • 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.-lbs.);

  • if the machine starts to vibrate abnormally (check immediately).

• Disengage drive to attachments when transporting or not in use.

• Stop the engine and disengage drive to attachment:

  • before refuelling;

  • before making height adjustment.

• Reduce the throttle to low idle before stopping engine.

• Keep hands and feet away from the cutting units.

• Look behind before backing up to be sure of a clear path.

• Slow down and use caution when making turns and crossing roads and sidewalks.

• Do not operate the mower under the influence of alcohol or drugs.

• Lightning can cause severe injury or death. If lightning is seen or thunder is heard in the area, do not operate the machine; seek shelter.

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

• The operator shall turn on flashing warning lights, if provided, whenever traveling on a public road, except where such use is prohibited by law.

• Keep all nuts, bolts, and screws tight to be sure the equipment is in safe working condition.

• Never store the equipment with fuel in the tank inside a building where fumes may reach an open flame or spark.

• Allow the engine to cool before storing in any enclosure and do not store near flame.

• To reduce the fire hazard, keep the engine, silencer/muffler, battery compartment, cutting units, drives, and fuel storage area free of grass, leaves, or excessive grease. Clean up oil or fuel spillage.

• Replace worn or damaged parts for safety.

• If the fuel tank has to be drained, do this outdoors.

• On multi-bladed machines, take care as rotating one blade can cause other blades to rotate.

• When machine is to be parked, stored, or left unattended, lower the cutting units unless a positive mechanical lock is provided.

• Disengage drives, lower the cutting units, move traction pedal to Neutral, set parking brake, stop engine and remove key . Wait for all movement to stop before adjusting, cleaning or repairing.

• Park machine on level ground. Never allow untrained personnel to service machine.

• Use jack stands to support components when required.

• Carefully release pressure from components with stored energy.

• Disconnect battery before making any repairs. Disconnect the negative terminal first and the positive last. Reconnect positive first and negative last.

• Use care when checking blades. Wrap the blades or wear gloves, and use caution when servicing them. Only replace blades. Never straighten or weld them.

• Keep hands and feet away from moving parts. If possible, do not make adjustments with the engine running.

• Charge batteries in an open well ventilated area, away from spark and flames. Unplug charger before connecting or disconnecting from battery. Wear protective clothing and use insulated tools.

• Make sure all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition before applying pressure to the system.

• Keep your body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not your hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. If fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result.

Pull out on the lever to slide the seat fore or aft (Figure 6).

Rotate the knob to adjust the seat arm rest angle (Figure 6).

Move the lever to adjust the seat back angle (Figure 6).

Indicates when the seat is adjusted to the weight of the operator (Figure 6). Height adjustment is made by positioning the suspension within the range of the green region.

Figure 6

1. Weight gauge
2. Weight adjusting lever
3. Fore and Aft adjusting lever
4. Seat back adjusting lever
5. Arm rest adjusting knob (not shown-located under arm rest)

Adjust for operator weight (Figure 6). Pull up on the lever to increase the air pressure and push down to decrease the air pressure. The proper adjustment is attained when the weight gauge is in the green region.

Sets the cab to either recirculate the air in the cabin or to draw air into the cabin from outside (Figure 7).

• 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 7).

Rotate the temperature control knob to regulate the air temperature in the cab (Figure 7).

Use this switch to turn the wind shield wipers on or off (Figure 7).

Use this 15 amp, 12 V DC power outlet to power compatible devices (Figure 7).

Use this switch to turn the head lights and tail light on or off (Figure 7).

Use this switch to turn the flashers (hazard lights) on or off (Figure 7).

Use this switch to turn the air conditioning on or off (Figure 7).

Lift up on latches to open the wind shield (Figure 8). Press in on latch to lock wind shield in open position. Pull out and down on latch to close and secure wind shield.

Figure 8

1. Wind shield latch

Lift up on latches to open the rear window. Press in on latch to lock window in open position. Pull out and down on latch to close and secure window (Figure 8).

Important: The rear window must be closed before opening the hood or damage may occur.

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

Check level of coolant at the beginning of each day. Capacity of system is 8.52 L (9 qts) for the Groundsmaster 4000 and 20 L (14.5 qts) for the Groundsmaster 4010.

1. Carefully remove the radiator cap and expansion tank cap (Figure 12).

   Caution

   If the engine has been running, the pressurized, hot coolant can escape and cause burns.

   • Do not open the radiator cap when the engine is running.

   • Use a rag when opening the radiator cap, and open the cap slowly to allow steam to escape.

2. Check the coolant level in the radiator. The radiator should be filled to the top of the filler neck and the expansion tank filled to the Full mark.

   

   Figure 12

   1. Expansion tank

3. If the coolant is low, add a 50/50 mixture of water and ethylene glycol anti-freeze. Do not use water only or alcohol/methanol base coolants.

4. Install the radiator cap and expansion tank cap.

1. Park the machine on a level surface.

2. Using a clean rag, clean area around fuel tank cap.

3. Remove cap from the fuel tank (Figure 13).

   

   Figure 13

   1. Fuel tank cap

4. Fill the tank until the level is to the bottom of the filler neck with diesel fuel.

5. Install fuel tank cap tightly after filling tank.

   Note: If possible, fill the fuel tank after each use. This will minimize possible buildup of condensation inside the fuel tank.

The machines reservoir is filled at the factory with approximately 29 L (7.75 U.S. gallons) of high quality hydraulic fluid. Check the level of the hydraulic fluid before the engine is first started and daily thereafter. The recommended replacement fluid is:

Toro Premium All Season Hydraulic Fluid (Available in 18.9 L (5 gallon) pails or 208 L (55 gallon) drums. See parts catalog or Toro distributor for part numbers.)

Alternate fluids: If the Toro fluid is not available, other fluids may be used provided they meet all the following material properties and industry specifications. We do not recommend the use of synthetic fluid. Consult with your lubricant distributor to identify a satisfactory product.

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

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

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

1. Position the machine on a level surface, lower the cutting units, stop the engine, and remove the key.

2. Unlatch the seat, raise it, and engage the prop rod.

3. Clean the area around the filler neck and cap of the hydraulic tank (Figure 14). Remove the cap from the filler neck.

   

   Figure 14

   1. Hydraulic tank 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 between the 2 marks on the dipstick.

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

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

Check the oil level after every 400 hours of operation or if external leakage is noted. Use high quality SAE 85W-140 gear lube as a replacement.

1. With machine on level surface, position the wheel so one check plug (Figure 15) is at the 12 o'clock position and the other is at 3 o'clock position.

   

   Figure 15

   1. Check/drain plug (2)

2. Remove the plug at the 3 o’clock position (Figure 15). Oil level should be at the bottom of the check plug hole.

3. If the oil level is low, remove the plug at the 12 o’clock position and add oil until it begins to flow out of the hole at the 3 o’clock position.

4. Install both plugs.

The rear axle is filled with SAE 85W-140 gear lube. Check the oil level before the engine is first started and every 400 hours thereafter. The capacity is 2.4 liters (80 oz). Visually inspect for leaks daily.

1. Position the machine on a level surface.

2. Remove a check plug from one end of the axle (Figure 16) and make sure that the lubricant is up to the bottom of the hole. If the level is low, remove the fill plug (Figure 16) and add enough lubricant to bring the level up to the bottom of the check plug holes.

   

   Figure 16

   1. Check plug
   2. Fill plug

The gear box is filled with SAE 85W-140 gear lube. Check the oil level before the engine is first started and every 400 hours thereafter. The capacity is 0.5 liter (16 oz). Visually inspect for leaks daily.

1. Position the machine on a level surface.

2. Remove the check/fill plug from the left side of the gear box (Figure 17) and make sure that lubricant is up to the bottom of the hole. If the level is low, add enough lubricant to bring the level up to the bottom of the hole.

   

   Figure 17

   1. Gear box
   2. Check/fill plug

The tires are over-inflated for shipping. Therefore, release some of the air to reduce the pressure. The correct air pressure in the front and rear tires is 172-207 kPa (25-30 psi ).

Important: Maintain even pressure in all tires to ensure a good quality-of-cut and proper machine performance. Also, the Automatic Traction Assist will not work properly with improper tire pressure. Do not under-inflate. Replace worn or damaged tires with genuine Toro tires that are correctly sized for this machine.

Front Cutting Unit

The height-of-cut is adjustable from 25 to 127 mm (1 to 5 inches) in 13 mm (1/2 inch) increments. To adjust the height-of-cut on the front cutting unit, position the castor wheel axles in the upper or lower holes of the castor forks, add or remove an equal number of spacers from the castor forks, and secure the rear chain to the desired hole.

1. Start the engine and raise the cutting units so that the height-of-cut can be changed. Stop the engine and remove the key after the cutting unit is raised.

2. Position the castor wheel axles in the same holes in all castor forks. Refer to the following chart to determine the correct holes for the setting.

   

   Figure 18

   1. Tensioning cap
   2. Spacers
   3. Shims
   4. Top axle mounting hole
   5. Castor wheel

   Note: When operating in 64 mm (2-1/2 inch) height of cut or higher, the axle bolt must be installed in the lower castor fork hole to prevent grass buildup between the wheel and the fork. When operating in height of cuts lower than 64 mm (2-1/2 inches) and grass buildup is detected, reverse the machines direction to pull any clippings away from the wheel/fork area.

3. Remove the tensioning cap from the spindle shaft (Figure 18) and slide the spindle out of the castor arm. Put the 2 shims (3 mm [1/8 inch]) onto the spindle shaft as they were originally installed. These shims are required to achieve a level across the entire width of the cutting units. Slide the appropriate number of 13 mm (1/2 inch) spacers (refer to the chart below) onto the spindle shaft to get the desired height-of-cut; then slide the washer onto the shaft.

   Refer to the following chart to determine the combinations of spacers for the setting:

   

   Figure 19

4. Push the castor spindle through the front castor arm. Install the shims (as they were originally installed) and the remaining spacers onto the spindle shaft. Install the tensioning cap to secure the assembly.

5. Remove the hairpin cotter and clevis pin securing the height-of-cut chains to the rear of the cutting unit (Figure 20).

   

   Figure 20

   1. Height-of-cut chain
   2. Clevis pin and hair pin cotter

6. Mount the height-of-cut chains to the desired height-of-cut hole (Figure 21) with the clevis pin and hairpin cotter.

   

   Figure 21

   Note: When using 25 mm (1 inch), 38 mm (1-1/2 inch), or occasionally 51 mm (2 inch) height-of-cut, move the skids and gage wheels to the highest position.

Side Cutting Units

To adjust the height-of-cut on the side cutting units, add or remove an equal number of spacers from the castor forks, position the castor wheel axles in the high or low height-of-cut holes in the castor forks, and secure the pivot arms to the selected height-of-cut bracket holes.

1. Position the castor wheel axles in the same holes in all of the castor forks (Figure 22 and Figure 24). Refer to the following chart to determine the correct hole for the setting.

2. Remove the tensioning cap from the spindle shaft (Figure 22) and slide the spindle out of castor arm. Put the two shims (3 mm [1/8 inch]) onto spindle shaft as they were originally installed. These shims are required to achieve a level across the entire width of the cutting units. Slide the appropriate number of 13 mm (1/2 inch) spacers onto the spindle shaft to get the desired height-of-cut; then slide the washer onto the shaft.

   

   Figure 22

   1. Tensioning cap
   2. Spacers
   3. Shims
   4. To axle mounting hole
   5. Castor wheel

   Refer to the following chart to determine the combinations of spacers for the setting.

   

   Figure 23

3. Push the castor spindle through the castor arm. Install the shims (as originally installed) and the remaining spacers onto the spindle shaft. Install the tensioning cap to secure the assembly.

4. Remove the hairpin cotter and clevis pins from the castor pivot arms (Figure 24).

5. Rotate tension rod to raise or lower pivot arm until holes are aligned with selected height-of-cut bracket holes in the cutting unit frame (Figure 24 and Figure 25).

6. Insert the clevis pins and install the hairpin cotters.

7. Rotate tension rod counterclockwise (finger tight) to put tension on adjustment.

   

   Figure 24

   1. Castor pivot arm
   2. Axle mounting holes
   3. Clevis pin and hair pin cotter
   4. Tension rod
   

   Figure 25

8. Remove the hairpin cotters and clevis pins securing the damper links to the cutting unit brackets (Figure 26). Align the damper link holes with the selected height-of-cut bracket holes in the cutting unit frame (Figure 27), insert the clevis pins, and install the hairpin cotters.

   Important: The damper link length should never be adjusted. The length between the hole centers should be 13.7 cm (5-3/8 inches).

   

   Figure 26

   1. Damper link
   

   Figure 27

The skids should be mounted in the lower position when operating at heights of cut greater than 64 mm (2-1/2 inches) and in the higher position when operating at heights of cut lower than 64 mm (2-1/2 inches).

Note: When the skids become worn, you can switch the skid to the opposite sides of the mower, flipping them over. This will allow you to use the skids longer before replacing them.

1. Loosen the screw at the front of each skid (Figure 28).

   

   Figure 28

2. Remove the flange-head bolts and nuts from each skid (Figure 28).

3. Move each skid to the desired position and secure them with the flange-head bolts and nuts.

   Note: Only use the top or center sets of holes to adjust the skids. The bottom holes are used when switching sides at which time they become the top holes on the other side of the mower.

4. Torque the screw at the front of each skid to 9 to 11 N⋅m (80 to 100 in-lbs).

The cutting unit rollers should be mounted in the lower position when operating in height of cuts greater than 64 mm (2-1/2 inches) and in the higher position when operating in height of cuts lower than 64 mm (2-1/2 inches).

1. Remove the bolt and nut securing the gage wheel to the cutting unit brackets (Figure 29).

   

   Figure 29

   1. Gage wheel

2. Align the roller and spacer with the top holes in the brackets and secure them with the bolt and nut.

Due to differences in grass conditions and the counterbalance setting of the traction unit, it is advised that a sample area of grass be cut and the appearance checked before formal cutting is started.

1. Set all cutting units to the desired height of cut; refer to Adjusting the Height-of-Cut.

2. Check and adjust front and rear tractor tire pressure to 172 to 207 kPa (25 to 30 psi).

3. Check and adjust all castor tire pressures to 345 kPa (50 psi).

4. Check charge and counterbalance pressures with engine at high idle using test ports defined in Hydraulic Systems Test Ports. Adjust counterbalance to 2241 kPa (325 psi).

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

6. Cut grass in a test area to determine if all cutting units are cutting at the same height.

7. If cutting unit adjustments are still needed, find a flat surface using a 2 m (6 foot) or longer straight edge.

8. To ease measuring blade plane, raise the height of cut to 7.6 to 10.1 cm (3 to 4 inches); refer to Adjusting the Height-of-Cut.

9. Lower cutting units onto the flat surface. Remove the covers from the top of the cutting units.

10. Loosen the flange nut, securing the idler pulley, to release the belt tension on each cutting unit.

Front Cutting Unit Setup

Rotate blade on each spindle until the ends face forward and backward. Measure from the floor to the front tip of the cutting edge. Adjust 3 mm (1/8 inch) shims on front castor fork(s) to match height of cut to decal (Figure 30); refer to Adjusting the Cutting Unit Pitch.

Figure 30

1. Tensioning cap
2. Spacers
3. Shims
4. Top axle mounting hole
5. Castor wheel

Side Cutting Unit Setup

Rotate blade of each spindle until the ends face forward and backward. Measure from the floor to the front tip of the cutting edge. Adjust 3 mm (1/8 inch) shims on front castor arm(s) to match height of cut to decal (Figure 31). For the outside blade spindle only, refer to Adjusting the Cutting Unit Pitch.

Figure 31

1. Front castor arm
2. Shims
3. Front castor fork

Matching Height-of-Cut Between Cutting Units

1. Position blade side to side on outside spindle of both side cutting units. Measure from the floor to the tip of the cutting edge on both units and compare. These numbers should be within 3 mm (1/8 inch) of each other. Make no adjustment at this time.

2. Position blade side to side on inside spindle of side cutting unit and corresponding outside spindle of front cutting unit. Measure from the floor to the tip of the cutting edge on inside edge of side cutting unit to corresponding outside edge of front cutting unit and compare. The side cutting unit measurement should be within 3 mm (1/8 inch) of the front cutting unit.

   Note: All three cutting units castor wheels should remain on the ground with counterbalance applied.

   Note: If adjustments need to be made to match the cut between the front and side cutting units, make the adjustments to the side cutting units only.

3. If the inside edge of the side cutting unit is too high relative to the outside edge of the front cutting unit, remove one 3 mm (1/8 inch) shim from the bottom of the front inside castor arm on the side cutting unit (Figure 31). Recheck measurement between outside edges of both side cutting units and inside edge of side cutting unit to outside edge of front cutting unit.

4. If inside edge is still too high, remove an additional 3 mm (1/8 inch) shim from bottom of front inside castor arm of the side cutting unit and one 3 mm (1/8 inch) shim from the front outside castor arm of the side cutting unit.

5. If the inside edge of the side cutting unit is too low relative to the outside edge of the front cutting unit, add one 3 mm (1/8 inch) shim to the bottom of the front inside castor arm on the side cutting unit. Check measurement between outside edges of both side cutting units and inside edge of side cutting unit to outside edge of front cutting unit.

6. If inside edge is still too low, add an additional 3 mm (1/8 inch) shim to the bottom of front inside castor arm of the side cutting unit and add one 3 mm (1/8 inch) shim to the front outside castor arm of the side cutting unit.

7. Once cutting height matches at the edges of front and side cutting units, verify that side cutting unit pitch is still 8 to 11 mm (5/16 to 7/16 inch). Adjust as necessary.

While sitting in the seat, adjust the rear view mirror (Figure 32) to attain the best view out the rear window. Pull the lever rearward to tilt the mirror to reduce the brightness and glare of light.

While sitting in the seat, have a helper adjust the side view mirrors (Figure 32) to attain the best view around the side of the machine.

Figure 32

1. Side view mirrors
2. Rear view mirror
3. Lever

• 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	Fault Code	Engine Power Rating	Recommended Action
Level 1: Engine Warning	Figure 33 Check EngineSPN 3719, FMI 16	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 34 Check EngineSPN 3719, FMI 0	The computer de-rates the engine power to 50%	Perform a recovery regeneration as soon as possible; refer to Recovery Regeneration.

• 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 Advisory and Engine Warning Messages—Ash Accumulation

Indication Level	Advisory or Fault Code	Engine Speed Reduction	Engine Power Rating	Recommended Action
Level 1: System Advisory	Figure 35 Advisory #179	None	100%	Notify your service department that advisory #179 displays in the InfoCenter.
Level 2: Engine Warning	Figure 36 Check EngineSPN 3720, FMI 16	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 37 Check EngineSPN 3720, FMI 0	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 38 Check EngineSPN 3251, FMI 0	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

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	When the assist/reset-regeneration icon is displayed in the InfoCenter, an assist regeneration is in progress.
		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	When the assist/reset-regeneration icon is displayed in the InfoCenter, a regeneration is in progress.
	Also occurs every 100 hours to reset baseline sensor readings
		During reset regeneration, the computer controls the intake throttle and fuel injectors to increase the exhaust temperature during regeneration.
		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.
		Contact your Authorized Toro Distributor to have a service technician perform the recovery regeneration.
		• A recovery regeneration requires up to 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.

• Passive regeneration occurs as part of normal engine operation.

• While operating the machine, run the engine at full-engine speed when possible to promote DPF regeneration.

Figure 39

Assist/reset-regeneration icon

• The assist/reset-regeneration icon displays in the InfoCenter (Figure 39).

• The computer takes control of the intake throttle to increase the temperature of the engine exhaust.

• While operating the machine, run the engine at full engine speed when possible to promote DPF regeneration.

• The icon displays in the InfoCenter while the assist regeneration is processing.

• Whenever possible, do not shut off the engine or reduce engine speed while the assist regeneration is processing.

  Important: Allow the machine to complete the assist regeneration process before shutting off the engine.

  Note: The assist regeneration is finished processing when the icon disappears from the InfoCenter.

Figure 40

Assist/reset-regeneration icon

• The assist/reset-regeneration icon displays in the InfoCenter (Figure 40).

• The computer takes control of the intake throttle and changes the fuel injection operation to increase the temperature of the engine exhaust.

  Important: The assist/reset-regeneration icon indicates that the exhaust temperature discharged from of your machine may be hotter than during regular operation.

• While operating the machine, run the engine at full engine speed when possible to promote DPF regeneration.

• The icon displays in the InfoCenter while the reset regeneration is processing.

• Whenever possible, do not shut off the engine or reduce engine speed while the reset regeneration is processing.

  Important: Allow the machine to complete the reset regeneration process before shutting off the engine.

  Note: The reset regeneration is finished processing when the icon disappears from the InfoCenter.

Figure 41

Parked-regeneration request icon

• The parked-regeneration requested icon displays in the InfoCenter (Figure 41).

• If a parked regeneration is needed, the InfoCenter displays engine warning SPN 3719, FMI 16 (Figure 42) and the engine computer derates engine power to 85%.

  

  Figure 42

  Important: If you do not complete a parked regeneration within 2 hours, the engine computer derates engine power to 50%.

• A parked regeneration requires 30 to 60 minutes to complete.

• If you are authorized by your company, you need the PIN code to perform the parked-regeneration process.

• If you ignore the request for a parked regeneration (displayed in the InfoCenter) and continue to operate the machine, a critical amount of soot builds up in the DPF.

• If a recovery regeneration is needed, the InfoCenter displays engine warning SPN 3719, FMI 16 (Figure 54) and the engine computer derates engine power to 85%.

  

  Figure 54

  Important: If you do not complete a recovery regeneration within 15 minutes, the engine computer derates engine power to 50%.

• Perform a recovery-regeneration whenever there is a loss of engine power and a parked regeneration cannot effectively clean the DPF of soot.

• A recovery regeneration requires up to 4 hours to complete.

• You need a distributor technician to perform the recovery regeneration process; contact your Authorized Toro Distributor.

Mow either in the late morning to avoid the dew, which causes grass clumping, or in late afternoon to avoid the damage that can be caused by direct sunlight on the sensitive, freshly mowed grass.

Remove approximately 25 mm (1 inch) or no more than 1/3 of the grass blade when cutting. In exceptionally lush and dense grass, you may have to raise the height-of-cut to the next setting.

Under most normal conditions you will need to mow approximately every 4-5 days. But remember, grass grows at different rates at different times. This means that in order to maintain the same height-of-cut, which is a good practice, you will need to cut more frequently in early spring; as the grass growth rate slows in mid summer, cut only every 8-10 days. If you are unable to mow for an extended period due to weather conditions or other reasons, mow first with the height-of-cut at a high level; then mow again 2-3 days later with a lower height setting.

Use the transport latches when transporting over long distances, rough terrain, or when trailering.

To ensure optimum performance, clean the underside of the mower housing after each use. If residue is allowed to build up in the mower housing, cutting performance will decrease.

A blade pitch of 8 to 11 mm (5/16 to 7/16 inch) is recommended. A pitch larger than 8 to 11 mm (5/16 to 7/16 inch) will result in less power required, larger clippings, and a poorer quality of cut. A pitch less than 8 to 11 mm (5/16 to 7/16 inch) will result in more power required, smaller clippings and a better quality of cut.

• To limit solar heating, park the machine in a shaded area or leave the doors open in direct sun.

• Check to make sure the air conditioning condenser fins are clean.

• Operate the air conditioner blower at the mid speed setting.

• Verify continuous seal between the roof and the headliner. Correct as required.

• Measure the air temperature at the front center vent in the headliner (Typically stabilize at less than or equal to 50 degrees F.)

• Refer to the Service Manual for additional information

The machine has grease fittings that must be lubricated regularly with No. 2 general-purpose lithium-base grease. If the machine is operated under normal conditions, lubricate all bearings and bushings after every 50 hours of operation or immediately after every washing.

The grease fitting locations and quantities are:

Traction Unit

Maintenance Service Interval	Maintenance Procedure
Every 50 hours	Lubricate all grease fittings.

• Brake pedal pivot shaft bearings (2) (Figure 58)

• Front and rear axle pivot bushings (2) (Figure 59)

• Steering cylinder ball joints (2) (Figure 60)

• Tie rod ball joints (2) (Figure 60)

• King pin bushings (2) (Figure 60).The top fitting on the king pin should only be lubricated annually (2 pumps).

Figure 58

Figure 59

Figure 60

Front Cutting Unit

• Castor fork shaft bushings (2) (Figure 61)

• Spindle shaft bearings (3) (located under the pulley) (Figure 62)

• Idler arm pivot bushings (2) (Figure 62)

Figure 61

Figure 62

Front Lift Assemblies

• Lift arm cylinder bushings (2 each) (Figure 63)

• Lift arm ball joints (2) (Figure 64)

Figure 63

Figure 64

Side Cutting Units

• Castor fork shaft bushing (1) (Figure 65)

• Spindle shaft bearings (2 each) (located under the pulley)

• Idler arm pivot bushings (1) (located on the idler arm)

Figure 65

Side Lift Assemblies

• Main lift arm bushings (6) (Figure 66 and Figure 67)

• Bell crank pivot bushings (2) (Figure 68)

• Rear arm bushings (4) (Figure 68)

• Lift cylinder bushings (4) (Figure 69)

Figure 66

Figure 67

Figure 68

Figure 69

• Check the air cleaner body for damage which could cause an air leak. Replace if damaged. Check the whole intake system for leaks, damage or loose hose clamps.

• Service the air cleaner filter only when the service indicator requires it or every 400 hours (more frequently in extremely dusty or dirty conditions). Changing the air filter before it is necessary only increases the chance of dirt entering the engine when the filter is removed.

• Be sure the cover is seated correctly and seals with the air cleaner body.

• If advisory message displays in the InfoCenter, the DPF is nearing the recommended point for servicing the diesel-oxidation catalyst and the soot filter.

  

  Figure 76

• If engine faults , , or in the InfoCenter (Figure 77) display in the InfoCenter, clean the soot filter using the steps that follow:

  

  Figure 77

  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.

Drain water or other contaminants from water separator (Figure 78) daily. Replace filter canister after every 400 hours of operation.

1. Place a clean container under the fuel filter.

2. Loosen the drain plug on the bottom of the filter canister and open the vent on the top of the canister mount.

   

   Figure 78

   1. Water separator filter canister

3. Clean the area where the filter canister mounts.

4. Remove the filter canister and clean the mounting surface.

5. Lubricate the gasket on the filter canister with clean oil.

6. Install the filter canister by hand until the gasket contacts mounting surface, then rotate it an additional 1/2 turn.

7. Tighten the drain plug on the bottom of the filter canister and close the vent on the top of the canister mount.

The engine fuel filter should be replaced after every 400 hours of operation.

1. Clean the area around the fuel filter head (Figure 79).

   

   Figure 79

   1. Fuel Filter head
   2. Fuel Filter

2. Remove the filter and clean the filter head mounting surface (Figure 79).

3. Lubricate the filter gasket with clean lubricating engine oil. Refer to the engine operator'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. Start the engine and check for fuel leaks around the filter head.

Battery type is group 24.

Important: Before welding on the machine, disconnect the negative cable from the battery to prevent damage to the electrical system.

Note: Check the battery condition weekly or after every 50 hours of operation. Keep the terminals and the entire battery case clean because a dirty battery will discharge 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.

1. Open the battery cover (Figure 80). on the side of the shroud.

   Note: Press down on the flat surface above the battery cover to ease cover removal (Figure 80).

   

   Figure 80

   1. Battery cover
   2. Press down here
   

   Figure 81

   1. Battery

   Warning

   Charging the battery produces gasses that can explode.

   Never smoke near the battery and keep sparks and flames away from battery.

2. Remove the rubber boot from the positive terminal and inspect the battery.

   Warning

   Battery terminals or metal tools could short against metal components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury.

   • When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine.

   • Do not allow metal tools to short between the battery terminals and metal parts of the machine.

   Warning

   Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury.

   • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable.

   • Always connect the positive (red) battery cable before connecting the negative (black) cable.

3. Coat both battery connections with Grafo 112X (skin-over) grease, Toro Part No. 505-47, petroleum jelly, or light grease to prevent corrosion. Slide the rubber boot over the positive terminal.

4. Close the battery cover.

The traction unit fuses (Figure 82 thru Figure 84) are located under the power center cover.

Remove the 2 Allen head screws securing the power center cover to the frame and remove the cover (Figure 82).

Figure 82

1. Power center cover
2. Allen head screws (2)

Figure 83

1. Fuses

Figure 84

The cab fuses (Figure 85 and Figure 86) are located in the fuse box in the cab headliner (Cab model only).

Figure 85

1. Cab fuse box
2. Fuses

Figure 86

The traction pedal operating angle can be adjusted for operator comfort.

1. Loosen the 2 nuts and bolts securing the left side of the traction pedal to the bracket (Figure 87).

   

   Figure 87

   1. Traction pedal
   2. Mounting nuts and bolts (2)

2. Pivot the pedal to the desired operating angle and tighten the nuts (Figure 87)˙.

Change the oil initially after first 200 hours of operation. Thereafter change the oil every 800 hours, or yearly, whichever occurs first. Use a high quality SAE 85W-140 gear lube.

1. With the machine on a level surface, position a wheel so that one of the check plugs is at the lowest (6 o'clock) position (Figure 88).

   

   Figure 88

   1. Check/drain plug

2. Place a drain pan under the planetary hub, remove plug and allow oil to drain.

3. Place a drain pan under the brake housing, remove the drain plug and allow the oil to drain (Figure 89).

   

   Figure 89

   1. Drain plug
   2. Brake housing

4. When all of the oil has drained from both locations, re-install the plug in the brake housing.

5. Rotate the wheel until the open plug hole in the planetary is at the twelve o'clock position.

6. Through the open hole, slowly fill the planetary with 0.65 L (22 oz) of high quality SAE 85W-140 wt gear lube.

   Important: If the planetary fills before the 0.65 L (22 oz) of oil is added, wait one hour or install the plug and move the machine approximately ten feet to distribute the oil through the brake system. Then, remove the plug and add the remaining oil.

7. Install the plug.

8. Repeat the procedure on the opposite planetary/brake assembly.

Change the oil initially after the first 200 hours of operation and every 800 hours of operation thereafter.

1. Position the machine on a level surface.

2. Clean the area around the 3 drain plugs; 1 on each end and 1 in the center (Figure 90).

3. Remove the check plugs to ease in draining of the oil.

4. Remove the drain plugs and allow the oil to drain into the pans.

   

   Figure 90

   1. Drain plug location

5. Clean the area around the drain plug on the bottom of the gear box (Figure 91).

6. Remove the drain plug from the gear box and allow the oil to drain into a pan. Remove the fill plug to ease in draining of the oil.

   

   Figure 91

   1. Drain plug

7. Add enough oil to bring the level up to the bottom of the check plug holes; refer to Changing the Rear Axle Lubricant, and Checking the Rear Axle Gear Box Lubricant.

8. Install the plugs.

After every 800 operating hours or annually, check the rear wheel toe-in.

1. Measure the center-to-center distance (at axle height) at the front and rear of the steering tires. The front measurement must be 6 mm (1/4 inch) less than the rear measurement.

2. To adjust, loosen the clamps at both ends of the tie rods.

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

4. Tighten the tie rod clamps when the adjustment is correct.

Remove debris from the oil radiator/oil cooler daily. Clean them more frequently in dirty conditions.

This machine is equipped with a hydraulically driven fan drive system that automatically (or manually) reverses to reduce radiator/oil cooler and screen debris build-up. While this feature can help reduce the time required to clean radiator/oil cooler, it does not eliminate the need for routine cleaning. Periodic cleaning and inspection of the radiator/oil cooler is still required.

1. Turn the engine off and raise the hood. Clean the engine area thoroughly of all debris.

2. Clean both sides of the radiator/oil cooler area (Figure 92) thoroughly with compressed air. Start from the fan side and blow the debris out towards the back. Then clean from the back side and blow towards the front. Repeat procedure several times until all chaff and debris is removed.

   Important: Cleaning the radiator/oil cooler with water can promote premature corrosion and damage to components.

   

   Figure 92

   1. Radiator/oil cooler

3. Close the hood.

Adjust the service brakes when there is more than 25 mm (1 inch) of “free travel” of the brake pedal, or when the brakes do not work effectively. Free travel is the distance the brake pedal moves before braking resistance is felt.

1. Disengage the locking latch from the brake pedals so that both pedals work independently of each other.

2. To reduce free travel of the brake pedals, tighten the brakes:

   1. Loosen the 2 mounting screws and remove the brake adjustment cover (Figure 93).

      

      Figure 93

      1. Mounting screws
      2. Brake adjustment cover

   2. Loosen the front nut on the threaded end of the brake cable (Figure 94).

      

      Figure 94

      1. Brake cable adjusting nuts

   3. Tighten the rear nut to move the cable backward until the brake pedals have 13 to 25 mm (1/2 to 1 inch) of free travel.

   4. Tighten the front nuts after the brakes are adjusted correctly.

   5. Reinstall the brake adjustment cover.

Check the condition and tension of the belt (Figure 95) after every 100 operating hours.

1. Proper tension will allow 10 mm (3/8 inch) deflection when a force of 44 N (10 lb) is applied on the belt midway between the pulleys.

2. If the deflection is not 10 mm (3/8 inch), loosen the alternator mounting bolts (Figure 95). Increase or decrease the alternator belt tension and tighten the bolts. Check the deflection of the belt again to ensure that the tension is correct.

   

   Figure 95

   1. Alternator
   2. Mounting bolt
   3. Compressor
   4. Idler pulley

Cab model only

Check the condition and tension of the belt (Figure 95) after every 100 operating hours.

1. Proper tension will allow 10 mm (3/8 inch) deflection when a force of 44 N (10 lb) is applied on the belt midway between the pulleys.

2. If the deflection is not 10 mm (3/8 inch), loosen the idler pulley mounting bolt (Figure 95). Increase or decrease the compressor belt tension and tighten the bolt. Check the deflection of the belt again to ensure that the tension is correct.

Check the condition and tension of the cutting unit drive belts initially after 10 hours of operation and every 50 operating hours thereafter.

When properly tensioned, the inside measurement of the extension spring (hook to hook) should be approximately 8.9 cm ± .63 cm (3.50 ±.25 inch). Once the correct spring tension is attained, adjust the stop bolt (carriage bolt) until there is approximately .32 cm ± .152/.000 cm (.125 +.060/-.000 inch) clearance between the head of the bolt and the idler arm (Figure 96).

Note: Make sure the belt is positioned on the spring side of the belt guide (Figure 96).

Figure 96

1. Belt
2. Eye bolt
3. Extension spring
4. Belt guide
5. Flange nut
6. Stop bolt

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 belt is rotating, blades slipping when cutting grass, frayed edges, burn marks and cracks. Replace the belt if any of these conditions are evident.

1. Lower the cutting unit to the shop floor. Remove the belt covers from the top of the cutting unit and set the covers aside.

2. Loosen the eye bolt allowing the removal of the extension spring (Figure 96).

3. Loosen the flange nut securing the stop bolt to the mounting tab. Back off the nut enough to allow the idler arm to pass by the stop bolt (Figure 96). Move the idler pulley away from the belt to release belt tension.

   Note: If the stop bolt is ever removed from the mounting tab, make sure it is reinstalled in the hole that aligns the stop bolt head with the idler arm.

4. Remove the bolts securing the hydraulic motor to the cutting unit (Figure 97). Lift the motor off of the cutting unit and lay it on top of the cutting unit.

   

   Figure 97

   1. Hydraulic motor
   2. Mounting bolts

5. Remove the old belt from around the spindle pulleys and idler pulley.

6. Route the new belt around the spindle pulleys and idler pulley assembly.

7. Position the hydraulic motor on the cutting unit after routing the belt around the pulleys. Mount the motor to the cutting unit with the bolts previously removed.

   Note: Make sure the belt is positioned on the spring side of the belt guide (Figure 96).

8. Reconnect the extension spring (Figure 96) to the eye bolt and tension the belt as follows:

   • When properly tensioned, the inside measurement of the extension spring (hook to hook) should be approximately 8.9 cm ± .63 cm (3.50 ±.25 inch).

   • Once the correct spring tension is attained, adjust the stop bolt (carriage bolt) until there is approximately .32 cm ± .152/.000 cm (.125 +.060/-.000 inch) clearance between the head of the bolt and the idler arm.

Change the hydraulic fluid after every 800 operating hours, in normal conditions. If the fluid becomes contaminated, contact your local Toro distributor because the system must be flushed. Contaminated fluid looks milky or black when compared to clean oil.

1. Turn the engine off and raise the hood.

2. Remove the drain plug on the bottom front of the reservoir and let the hydraulic fluid flow into large drain pan. Install an tighten the plug when the hydraulic fluid stops draining.

3. Fill the reservoir (Figure 98) with hydraulic fluid; refer to Checking the Hydraulic Fluid.

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

   

   Figure 98

   1. Hydraulic reservoir

4. Install the reservoir cap. Start the engine and use all of the hydraulic controls to distribute hydraulic fluid throughout the system. Also check for leaks; then stop the engine.

5. Check the fluid level and add enough to raise level the level to the Full mark on the dipstick. Do not overfill.

Change the 2 hydraulic filters after every 800 operating hours, in normal conditions.

Use Toro replacement filters (Part No. 94-2621 for the left side of the machine and 75-1310 for the right side of the machine).

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

1. Position the machine on a level surface, lower the cutting units, stop the engine, engage the parking brakes, and remove the ignition key.

2. Clean the area around the filter mounting areas. Place a drain pan under the filter and remove the filter (Figure 99).

   

   Figure 99

   1. Hydraulic filter

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 an additional 1/2 turn.

5. Repeat the procedure on other filter (Figure 100).

   

   Figure 100

   1. Hydraulic filter

6. Once the reservoir is filled, start the engine and let it run at low idle for approximately two minutes. Activate steering and raise/lower cutting units several times to purge air from the system. Stop the engine and check for leaks.

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 counterbalance test port (Figure 101) is used to test the pressure in the counterbalance circuit. Recommended counterbalance pressure is 2241 kPa (325 psi). To adjust the counterbalance pressure, loosen the locknut, rotate the adjusting screw (Figure 101) clockwise to increase the pressure or counterclockwise to decrease the pressure and tighten the locknut. The engine must be running, the deck lowered and in float to check pressure.

Note: The castor wheels of all three cutting units should remain on the ground when adjusting the counterbalance and with counterbalance applied.

Figure 101

1. Counterbalance adjusting screw
2. Counterbalance test port

Note: Although not needed for normal maintenance procedures, the front cutting unit can be pivoted (tilted) to an upright position. Should you desire to tilt the cutting unit, proceed as follows:

1. Raise the front cutting unit slightly off of the floor, set the parking brake, and stop the engine. Remove the ignition key.

2. Remove the hairpin cotter and clevis pin securing the deck transport latch to the latch plate. Pivot latch toward rear of deck.

3. Remove the hairpin cotter and clevis pin securing the height-of-cut chains to the rear of the cutting unit.

4. Start the engine, slowly raise the front cutting unit, and stop the engine. Remove the ignition key.

5. Grasp the front of the cutting unit and lift it to an upright position.

6. Hold the cutting unit upright, fit the cable end over the pin on the cutting unit lift arm and secure it with the hairpin cotter (Figure 102).

   

   Figure 102

   1. Cable
   2. Pin

1. With the help of another person, hold the cutting unit upright, remove the hairpin cotter securing the cable end, and remove the cable from the pin.

2. Pivot (tilt) the cutting unit downward.

3. Store the cable under the operator's platform.

4. Sit on the seat, start the engine, and lower the cutting unit until it is slightly off of the floor.

5. Secure the height-of-cut chains to the rear of the cutting unit.

6. Pivot transport latch upward into position and secure with clevis pin and cotter pin.

The castor arms have bushings pressed into the top and bottom of the tube and after many hours of operation, the bushings will wear. To check the bushings, move the castor fork back and forth and from side to side. If the castor spindle is loose inside the bushings, the bushings are worn and must be replaced.

1. Raise the cutting unit so that the wheels are off of the floor. Block the cutting unit so that it cannot accidentally fall.

2. Remove the tensioning cap, spacer(s), and thrust washer from the top of the castor spindle.

3. Pull the castor spindle out of the mounting tube. Allow the thrust washer and spacer(s) to remain on the bottom of the spindle.

4. Insert a pin punch into the top or bottom of the mounting tube and drive the bushing out of the tube (Figure 105). Also drive the other bushing out of the tube. Clean the inside of the tubes to remove dirt.

   

   Figure 105

   1. Castor arm tube
   2. Bushings

5. Apply grease to the inside and outside of the new bushings. Using a hammer and flat plate, drive the bushings into the mounting tube.

6. Inspect the castor spindle for wear and replace it if it is damaged.

7. Push the castor spindle through the bushings and mounting tube. Slide the thrust washer and spacer(s) onto the spindle. Install the tensioning cap on the castor spindle to retain all parts in place.

1. Remove the locknut from the bolt holding the castor wheel assembly between the castor fork (Figure 106) or the castor pivot arm (Figure 107). Grasp the castor wheel and slide the bolt out of the fork or pivot arm.

   

   Figure 106

   1. Castor bolt
   2. Castor fork
   3. Bearing
   4. Bearing spacer
   

   Figure 107

   1. Castor wheel
   2. Castor pivot arm
   3. Bearing
   4. Bearing spacer

2. Remove the bearing from the wheel hub and allow the bearing spacer to fall out (Figure 106 and Figure 107). Remove the bearing from the opposite side of the wheel hub.

3. Check the bearings, spacer, and inside of the wheel hub for wear. Replace any damaged parts.

4. To assemble the castor wheel, push the bearing into the wheel hub. When installing the bearings, press on the outer race of the bearing.

5. Slide the bearing spacer into the wheel hub. Push the other bearing into the open end of the wheel hub to captivate the bearing spacer inside the wheel hub.

6. Install the castor wheel assembly between the castor 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. Position the machine on a level surface. Raise the cutting unit, engage the parking brake, put the traction pedal in neutral, put the PTO lever in the Off position, stop the engine, and remove the ignition key. Block the cutting unit to prevent it from accidentally falling.

2. Rotate the blade until the ends face forward and backward (Figure 108). Measure from the inside of the cutting unit to the cutting edge at the front of the blade. Remember this dimension.

   

   Figure 108

3. Rotate the opposite end of the blade forward. Measure between the cutting unit and cutting edge of the blade at the same position as in step 2. The difference between the dimensions obtained in steps 2 and 3 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 the Cutter Blade(s).

The blade must be replaced if a solid object is hit, the blade is out of balance, or if the blade 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 cutting unit to the highest position, engage the parking brake, stop the engine, and remove the ignition key. Block the cutting unit to prevent it from accidentally falling.

2. Grasp the end of the blade using a rag or thickly padded glove. Remove the blade bolt, anti-scalp cup, and blade from the spindle shaft (Figure 109).

3. Install the blade, anti-scalp cup, and blade bolt. Tighten the blade bolt to 115 to 149 N-m (85 to 110 ft-lb).

   Important: The curved part of the blade must be pointing toward the inside of the cutting unit to ensure proper cutting.

   Note: After striking a foreign object, torque all the spindle pulley nuts to 115 to 149 N-m (85 to 110 ft-lb).

   

   Figure 109

   1. Blade bolt
   2. Anti-scalp cup

Two areas must be considered when checking and servicing the cutter blade-the sail and the cutting edge. Both cutting edges and the sail, which is the turned up portion opposite 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 will gradually wear down during operation, and this condition is normal. As the sail wears down, the quality-of-cut will degrade somewhat, although the cutting edges are sharp. The cutting edge of the blade must be sharp so that the grass is cut rather than 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 cutting unit, engage the parking brake, put the traction pedal in neutral, put the PTO lever in the Off position, stop the engine, and remove the ignition key.

2. Examine the cutting ends of the blade carefully, especially where the flat and curved parts of the blade meet (Figure 110). 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 wear is noticed (Figure 110), replace the blade.

   

   Figure 110

   1. Cutting Edge
   2. Curved Area
   3. Wear/slot forming
   4. Crack

3. Examine the cutting edges of all of the blades. Sharpen the cutting edges if they are dull or nicked. Sharpen only the top of the cutting edge and maintain the original cutting angle to make sure of sharpness (Figure 111). The blade will remain balanced if the same amount of metal is removed from both cutting edges.

   Danger

   If the blade is allowed to wear, a slot will form between the sail and flat part of the blade. Eventually a piece of the blade may break off and be thrown from under the housing, possibly resulting in serious injury to you or bystanders.

   • Inspect the blade periodically for wear or damage.

   • Never try to straighten a blade that is bent or weld a broken or cracked blade.

   • Replace a worn or damaged blade.

   

   Figure 111

   1. Sharpen at original angle

   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 the Cutter Blade(s).

If there is mismatch between the blades, on a single cutting unit, the grass will appear streaked when it is cut. This problem can be corrected by making sure that the blades are straight and all of the blades are cutting on the same plane.

1. Using a 1 meter (3 foot) carpenters 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 cutting unit onto the flat surface. Remove the covers from the top of the cutting unit.

4. Loosen the flange nut securing the idler pulley to release the belt tension.

5. Rotate the blades until the ends face forward and backward. Measure from the floor to the front tip of the cutting edge. Remember this dimension. Then rotate the same blade so that the opposite end is forward, and measure again. 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. Make sure to measure all of the blades.

6. Compare the measurements of the outer blades with the center blade. The center blade must not be more than 10 mm (3/8 inch) lower than the outer blades. If the center blade is more than 10 mm (3/8 inch) lower than the outer blades, proceed to step 7 and add shims between the spindle housing and the bottom of the cutting unit.

7. Remove the bolts, flat washers, lock washers, and nuts from the outer spindle in the area where the shims must be added. To raise or lower the blade, add a shim, Part No. 3256-24, between the spindle housing and the bottom of the cutting unit. Continue to check the alignment of the blades and add shims until the tips of the blades are within the required dimension.

   Important: Do not use more than 3 shims at any 1 hole location. Use decreasing numbers of shims in adjacent holes if more than 1 shim is added to any 1 hole location.

8. Adjust the idler pulley and install the belt covers.

1. Remove the screws and grates from over both the in-cab and rear cab air filters (Figure 112).

   

   Figure 112

   1. Filter
   2. Grate
   3. Screw
   

   Figure 113

   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 it.

3. Install the filters and grate, securing them with the thumb screws.

1. Stop the engine and remove the key.

2. Remove the 6 nuts and washers from the bottom of the rear of the cab (Figure 114).

   

   Figure 114

   1. Washer
   2. Nut

3. Remove the cabin roof of the cab by removing the 22 bolts that secure the roof (Figure 115).

   

   Figure 115

   1. Cabin roof
   2. Air filters
   3. Air conditioning coils

4. Remove the air filters (Figure 115).

5. Remove and clean the air conditioning coils (Figure 115).

6. Replace the air conditioning coils, air filters and cabin roof.

Important: Use care around cab seals and lights (Figure 116). 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 pressure washer directly on cab seals and lights or under rear overhang.

Figure 116

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