Groundsmaster® 3500-D and 3505-D 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.

• If the operator or mechanic can not read the language of this manual, it is the owner’s responsibility to explain this material to them.

• Never allow children or people unfamiliar with these instructions to use or service 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 other people or their 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 following:

  • 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 as follows:

    • Insufficient wheel grip

    • Being driven too fast

    • Inadequate braking

    • The type of machine is unsuitable for the task

    • Lack of awareness of the effect of ground conditions, especially slopes

    • Incorrect hitching and load distribution

• While mowing, always wear substantial 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.

• 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 operator’s presence controls, safety switches and shields are attached and functioning properly. Do not operate unless they are functioning properly.

• To avoid personal injury or property damage, use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive.

• Extinguish all cigarettes, cigars, pipes, and other sources of ignition.

• Use only an approved fuel container.

• Never remove fuel cap or add fuel with the engine running.

• Allow engine to cool before refueling.

• Never refuel the machine indoors.

• Never store the machine or fuel container where there is an open flame, spark, or pilot light such as on a water heater or on other appliances.

• Never fill containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always place containers on the ground away from your vehicle before filling.

• Remove equipment from the truck or trailer and refuel it on the ground. If this is not possible, then refuel such equipment with a portable container, rather than from a fuel dispenser nozzle.

• Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Do not use a nozzle lock open device.

• If fuel is spilled on clothing, change clothing immediately.

• Never overfill fuel tank. Replace fuel cap and tighten securely.

• Do not operate the engine in a confined space where dangerous carbon monoxide fumes can collect.

• Mow only in daylight or in good artificial light.

• Before attempting to start the engine, disengage all blade attachment clutches, shift into neutral, and engage the parking brake. Only start the engine from the operator’s position. Never remove the ROPS and always wear the seat belts during operation.

• Do not put hands or feet near or under rotating parts. Keep clear of the discharge opening at all times.

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

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

  • Keep machine speeds 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 mower is designed for this purpose.

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

• 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.

• Do not change the engine governor settings or overspeed the engine. Operating the engine at excessive speed may increase the hazard of personal injury.

• Do the following before leaving the operator’s position:

  • Stop on level ground.

  • Disengage the power take-off and lower the attachments.

  • Change into neutral and set the parking brake.

  • Stop the engine and remove the key.

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

  • Before making height adjustments, unless the adjustment can be made from the operator’s position.

  • Before clearing blockages

  • Before checking, cleaning, or working on the mower

  • After striking a foreign object or if an abnormal vibration occurs (check immediately). Inspect the mower 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).

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

• Stop the engine and disengage the drive to attachments before the following:

  • Refueling

  • Making height adjustment, unless the adjustment can be made from the operator's position

• Reduce the throttle setting before stopping the engine and, if the engine is provided with a fuel shut-off valve, turn the fuel off at the conclusion of mowing.

• Never raise the cutting unit with the blades running.

• Keep hands and feet away from the cutting units.

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

• 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.

• To reduce the fire hazard, keep the engine, silencer/muffler, battery compartment fuel storage area, cutting units and drives 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, set parking brake, stop engine and remove key. Wait for all movement to stop before adjusting, cleaning or repairing.

• Shut off fuel while storing or transporting. Do not store fuel near flames.

• Park the 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 the 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.

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

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

• Tie the machine down securely using straps, chains, cable, or ropes. Both front and rear straps should be directed down and outward from the machine

Be sure to establish your own special procedures and work rules for unusual operating conditions (e.g., slopes too steep for operation). Survey the complete mowing site to determine which hills can be safely operated on. When performing this site survey, always use common sense and take into consideration the turf condition and the rollover risk. To determine which hills or slopes may be safely operated on, use the inclinometer provided with each machine. To perform a site survey, follow the procedure outlined in the Operation section of the this manual. The maximum side hill angle is detailed on the slope decal affixed near the angle indicator.

The operator must be skilled and trained in how to drive on hillsides. Failure to use caution on slopes or hills may cause the vehicle to tip or roll, possibly resulting in personal injury or death.

• Know how to stop the machine and engine quickly.

• Do not operate the machine while wearing tennis shoes or sneakers.

• Wearing safety shoes and long pants is advisable and required by some local ordinances and insurance regulations.

• Keep hands, feet, and clothing away from moving parts and the mower discharge area.

• Fill the fuel tank until level is 12 mm (1/2 inch) below the bottom of the filler neck. Do not overfill.

• Check the safety interlock switches daily for proper operation. If a switch should fail, replace the switch before operating the machine.

• When starting the engine, engage the parking brake, put the traction pedal in neutral, and disengage the blade drive. After the engine starts, release the parking brake and keep your foot off of the traction pedal. The machine must not move. If movement is evident, refer to the Maintenance section of this manual to adjust the traction drive.

• Use extreme caution when operating close to sand traps, ditches, creeks, steep hillsides, or other hazards.

• Reduce speed when making sharp turns.

• Do not turn on hills.

• Do not operate on a side hill that is too steep. A rollover may occur before losing traction.

• On models 30839, 30843 and 30807, the slope angle at which the machines will tip is dependent on many factors. Among these are mowing conditions such as wet or undulating terrain, speed (especially in turns), position of the cutting units (with the Sidewinder), tire pressure, and operator experience. At side hill angles of 20 degrees or less, the risk of a rollover is low. As the slope angle increases to a recommended maximum limit of 25 degrees, the risk of a rollover increases to a moderate level. Do not exceed a 25 degree side hill slope angle because the risk of a rollover and serious injury or death is very high.

• On model 30849, the slope angle at which the machine will tip is dependent on many factors. Among these are mowing conditions such as wet or undulating terrain, speed (especially in turns), position of the cutting units (with the Sidewinder), tire pressure, and operator experience. At side hill angles of 15 degrees or less, the risk of a rollover is low. As the slope angle increases to a recommended maximum limit of 20 degrees, the risk of a rollover increases to a moderate level. Do not exceed a 20 degree side hill slope angle because the risk of a rollover and serious injury or death is very high.

• For steering control, lower the cutting units when going down slopes.

• Avoid sudden stops and starts.

• Use the reverse pedal for braking.

• Watch for traffic when near or crossing roads. Always yield the right-of-way.

• Raise the cutting units when driving from one work area to another.

• Do not touch the engine, muffler, exhaust pipe, or hydraulic tank while the engine is running or soon after it has stopped because these areas could be hot enough to cause burns.

• This machine is not designed or equipped for on-road use and is a slow-moving vehicle. If you must cross or travel on a public road, you should be aware of and comply with local regulations, such as required lights, slow moving vehicle signs, and reflectors.

• Before servicing or making adjustments, stop the engine and remove the ignition key.

• Ensure that the entire machine is properly maintained and in good operating condition. Frequently check all nuts, bolts, screws, and hydraulic fittings.

• 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.

• Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved by stopping the engine and lowering the cutting units to the ground.

• If the engine must be running to perform a maintenance adjustment, keep hands, feet, clothing, and any parts of the body away from the cutting units, attachments, and any moving parts. Keep everyone away.

• Do not overspeed the engine by changing governor settings. To ensure safety and accuracy, have an Authorized Toro Distributor check the maximum engine speed with a tachometer.

• The engine must be shut off before checking the oil or adding oil to the crankcase.

• If major repairs are ever needed or if assistance is desired, contact an Authorized Toro Distributor.

• To ensure optimum performance and continued safety certification of the machine, use only genuine Toro replacement parts and accessories. Replacement parts and accessories made by other manufacturers could be dangerous, and such use could void the product warranty.

The front and rear cutting decks require different mounting positions. The front cutting deck has two mounting positions depending on what height-of-cut and degree of deck rotation you desire.

1. For heights of cut in the 2 to 7.6 cm (3/4 to 3 inch) range, mount the front carrier frames in the lower front mounting holes (Figure 16).

   Note: This permits more up travel of the cutting decks relative to tractor when approaching quick uphill changes in terrain. It does however limit the clearance of the chamber to the carrier when cresting sharp knolls.

   

   Figure 16

   1. Front deck mounting hole (upper)
   2. Front deck mounting hole (lower)
   3. Rear deck mounting hole

2. For heights of cut in the 6.3 to 10 cm (2-1/2 to 4 inch) range, mount the front carrier frames in the upper front mounting holes (Figure 16).

   Note: This increases the chamber to carrier clearance due to the higher position of the cutting chamber, but will cause the cutting deck to reach their maximum up travel sooner.

The front and rear cutting decks require different mounting positions. The rear cutting deck has one mounting position for proper alignment with the sidewinder under frame.

For all heights of cut, mount the rear cutting deck in the rear mounting holes (Figure 16).

1. Be sure that the parking brake is set and the cutting unit drive switch is in the Disengage position.

2. Remove your foot from the traction pedal and make sure that the pedal is in the neutral position.

3. Move the throttle lever to the 1/2 throttle position.

4. Insert the key into the switch and rotate it to the On/Preheat position until the glow plug indicator light goes out (approximately 7 seconds); then rotate the key to the Start position to engage the starter motor. Release the key when the engine starts. The key will move automatically to the On/Run position.

   Important: To prevent overheating of the starter motor, do not engage the starter longer than 15 seconds. After 10 seconds of continuous cranking, wait 60 seconds before engaging the starter motor again.

5. When the engine is started for the first time or after an overhaul of the engine, operate the machine in forward and reverse for one to two minutes. Also operate the lift lever and cutting unit drive switch to be sure of proper operation of all parts.

   Turn the steering wheel to the left and right to check steering response; then shut the engine off and check for oil leaks, loose parts, and any other noticeable malfunctions.

   Caution

   Stop the engine and wait for all moving parts to stop before checking for oil leaks, loose parts, and other malfunctions.

Move the throttle control to the Idle position, move the cutting unit drive switch to Disengage, and rotate the starter key to Off. Remove the key from the switch to prevent accidental starting.

This blade was designed to provide excellent lift and dispersion in almost any condition. If more or less lift and discharge velocity is required, consider a different blade.

Attributes: Excellent lift and dispersion in most conditions.

The blade generally performs best in lower heights of cut - 1.9 to 6.4 cm (3/4 to 2–1/2 inch).

Attributes:

• Discharge remains more even at lower heights of cut.

• Discharge has less tendency to throw left and thus a cleaner look around bunkers and fairways.

• Lower power requirement at lower heights and dense turf.

The blade generally performs better in the higher heights of cut - 7 to 10 cm (2 to 4 inch).

Attributes:

• More lift and higher discharge velocity.

• Sparse or limp turf is picked up significantly at higher heights of cut.

• Wet or sticky clippings are discharged more efficiently reducing congestion in the deck.

• Requires more horsepower to run.

• Tends to discharge further left and can tend to windrow at lower heights of cut.

This blade was designed to provide excellent leaf mulching.

Attributes: Excellent leaf mulching

• Practice operating the machine and become thoroughly familiar with it.

• Start the engine and run it at half idle until it warms up. Push the throttle lever all the way forward, lift the cutting units, disengage the parking brake, press the forward traction pedal, and carefully drive to an open area.

• Practice moving forward and reverse, and starting and stopping the machine. To stop, take your foot off of the traction pedal and let it return to neutral or press down on the reverse pedal to stop. Going down a hill, you may need to use the reverse pedal to stop.

• When driving on slopes, drive slowly to maintain steering control and avoid turns to prevent rollovers. In side hill situations you should shift the sidewinder cutting units to the uphill side to give you more stability. Conversely, shifting the cutting units to the down hill side will give you less stability. This should always be done before going on a side hill.

• When possible, mow up and down hills rather than across them. Have the cutting units lowered when going down a hill to maintain steering control. Do not attempt to turn on a hill.

• Practice driving around obstacles with the cutting units up and down. Be careful when driving between narrow objects so you do not damage the machine or cutting units.

• On the Sidewinder unit, get a feel for the reach of the cutting units so you do not hang them up or damage them in any way.

• Do not shift the units from side to side, unless the cutting units are down and the machine is moving, or the cutting units are up in the transport position. Shifting the cutting units when they are down and the machine is not moving may cause turf damage.

• Always drive slowly in rough areas.

• If a person appears in or near the operating area, stop the machine, and do not start it again until the area is cleared. The machine is designed for one person. Never let anyone else ride on the machine with you. This is extremely dangerous and could result in serious injury.

• Accidents can happen to anyone. The most common causes are excessive speed, sudden turns, terrain (not knowing which slopes and hills can be mowed safely), not stopping the engine before leaving the operator’s seat, and drugs which impair your alertness. Cold capsules or prescription drugs may cause drowsiness, as can alcohol and other drugs. Stay alert and stay safe. Failure to do so could result in serious injury.

• The Sidewinder offers up to a maximum of 33 cm (13 inches) of overhang, allowing you to trim closer to the edge of sand traps and other obstacles, while at the same time keeping the tractor tires as far away from the edge of traps or water hazards as possible.

• If an obstacle is in the way, shift the cutting units to easily mow around it.

• When transporting the machine from one work area to another, raise the cutting units to the fully up position, move the mow/transport slide to the left to transport, and place the throttle in the Fast position.

Change mowing patterns often to minimize aftercut appearance issues induced by repetitive operation in only one direction.

The counterbalance system maintains hydraulic back pressure on the deck lift cylinders. This counterbalance pressure transfers cutting deck weight to the mower's drive wheels to improve traction. The counterbalance pressure has been factory set to an optimal balance of aftercut appearance and traction capability in most turf conditions. Decreasing the counterbalance setting can produce a more stable cutting deck, but can decrease the traction capability. Increasing the counterbalance setting can increase the traction capability, but may result in aftercut appearance issues. Reference the service manual for your traction unit for instructions to adjust counterbalance pressure.

Reference Aftercut Appearance Troubleshooting Guide available at www.Toro.com

• Practice operating the machine and become thoroughly familiar with it.

• Start the engine and run it at half idle until it warms up. Push the throttle lever all the way forward, lift the cutting units, disengage the parking brake, press the forward traction pedal, and carefully drive to an open area.

• Practice moving forward and reverse, and starting and stopping the machine. To stop, take your foot off of the traction pedal and let it return to neutral or press down on the reverse pedal to stop. Going down a hill, you may need to use the reverse pedal to stop.

• When driving on slopes, drive slowly to maintain steering control and avoid turns to prevent rollovers.

• When possible, mow up and down hills rather than across them. Have the cutting units lowered when going down a hill to maintain steering control. Do not attempt to turn on a hill.

• Practice driving around obstacles with the cutting units up and down. Be careful when driving between narrow objects so you do not damage the machine or cutting units.

• On the Sidewinder unit, get a feel for the reach of the cutting units so you do not hang them up or damage them in any way.

• Do not shift the units from side to side, unless the cutting units are down and the machine is moving, or the cutting units are up in the transport position. Shifting the cutting units when they are down and the machine is not moving may cause turf damage.

• Always drive slowly in rough areas.

• If a person appears in or near the operating area, stop the machine, and do not start it again until the area is cleared. The machine is designed for one person. Never let anyone else ride on the machine with you. This is extremely dangerous and could result in serious injury.

• Accidents can happen to anyone. The most common causes are excessive speed, sudden turns, terrain (not knowing which slopes and hills can be mowed safely), not stopping the engine before leaving the operator’s seat, and drugs which impair your alertness. Cold capsules or prescription drugs may cause drowsiness, as can alcohol and other drugs. Stay alert and stay safe. Failure to do so could result in serious injury.

• The Sidewinder offers up to a maximum of 33 cm (13 inches) of overhang, allowing you to trim closer to the edge of sand traps and other obstacles, while at the same time keeping the tractor tires as far away from the edge of traps or water hazards as possible.

• If an obstacle is in the way, shift the cutting units to easily mow around it.

• When transporting the machine from one work area to another, raise the cutting units to the fully up position, move the mow/transport slide to the left to transport, and place the throttle in the Fast position.

• To begin cutting, engage the cutting units, then approach the mowing area slowly. Once the front cutting units are over the mowing area, lower the cutting units.

• To achieve the professional straight-line cut and striping that is desirable for some applications, find a tree or other object in the distance and drive straight toward it.

• As soon as the front cutting units reach the edge of the mowing area, lift the cutting units and perform a tear drop shaped turn to quickly line you up for your next pass.

• To mow around bunkers, ponds, or other contours easily, use the Sidewinder and move the control lever left or right, depending on your mowing application. The cutting units can also be shifted to vary tire tracking.

• The cutting units tend to throw grass to the left side of the machine. If trimming around bunkers, it is best to mow in a clockwise direction to prevent throwing clippings into the bunker.

• The cutting units can be equipped with bolt-in mulching baffles. The mulching baffles perform well when turf is maintained on a regular schedule to avoid removing more than 25 mm (1 inch) of growth per cutting. When too much growth is cut with the mulching baffles installed, after-cut appearance may deteriorate and the observed power to cut the turf increases. The mulching baffles also perform well for shredding leaves in the fall of the year.

Mow 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 one inch or no more than 1/3 of the grass blade when cutting. In exceptionally lush and dense grass you may have to raise your height–of–cut setting another notch.

A sharp blade cuts cleanly and without tearing or shredding the grass blades like a dull blade. Tearing and shredding causes the grass to turn brown at the edges which impairs growth and increases susceptibility to diseases. Make sure blade is in good condition and a full sail is present.

Make sure cutting chambers are in good condition. Straighten any bends in chamber components to assure correct blade tip/chamber clearance.

At the completion of mowing operation, thoroughly wash the machine with a garden hose without a nozzle so that excessive water pressure will not cause contamination and damage to the seals and bearings. Make sure that the radiator and oil cooler are kept free of dirt or grass clippings. After cleaning, it is recommended that the machine be inspected for possible hydraulic fluid leaks, damage or wear to the hydraulic and mechanical components, and the cutting unit blades checked for sharpness.

Important: After washing the machine, move the Sidewinder mechanism from left to right several times to remove water between the bearing blocks and cross tube.

The hood may be easily removed to ease maintenance procedures in the engine area of the machine.

1. Unlatch and raise the hood.

2. Remove the hairpin cotter securing the hood pivot to the mounting brackets (Figure 35).

   

   Figure 35

   1. Hairpin cotter

3. Slide the hood to the right side, lift the other side, and pull it out of the brackets.

Note: Reverse the procedure to install the hood.

When servicing the cutting decks, use the service latch to prevent injury.

1. Center the cutting deck sidewinder with the traction unit.

2. Raise the cutting decks to the transport position.

3. Set the parking brake and turn off the machine.

4. Release the latch rod (Figure 36) from front carrier frame retainer.

   

   Figure 36

   1. Service latch hook

5. Lift the outside of the front cutting decks and place the latch over the frame pin mounted on the front of the operator's platform (Figure 36).

6. Sit on the operator seat and start the traction unit.

7. Lower the cutting decks to the mow position.

8. Turn off the machine and remove the key.

9. Reverse this procedure to unlatch the cutting decks.

The machine has grease fittings that must be lubricated regularly with No. 2 General-purpose, lithium base grease. Bearings and bushings must be lubricated daily when operating conditions are extremely dusty and dirty. Dusty and dirty operating conditions could cause dirt to get into the bearings and bushings, resulting in accelerated wear. Lubricate grease fittings immediately after every washing, regardless of interval specified.

The grease fitting locations and quantities are:

• Rear cutting unit pivot (Figure 37)

  

  Figure 37

• Front cutting unit pivot (Figure 38)

  

  Figure 38

• SideWinder cylinder ends (2) (Figure 39)

  

  Figure 39

• Steering pivot (Figure 40)

  

  Figure 40

• Rear lift arm pivot and lift cylinder (2) (Figure 41)

  

  Figure 41

• Left front lift arm pivot and lift cylinder (2) (Figure 42)

  

  Figure 42

• Right front lift arm pivot and lift cylinder (2) (Figure 43)

  

  Figure 43

• Neutral adjust mechanism (Figure 44)

  

  Figure 44

• Mow/transport slide (Figure 45)

  

  Figure 45

• Belt tension pivot (Figure 46)

  

  Figure 46

• Steering cylinder (Figure 47).

  

  Figure 47

  Note: If desired, an additional grease fitting may be installed in the other end of the steering cylinder. Remove the tire, install the fitting, grease the fitting, remove the fitting, and install the plug (Figure 48).

  

  Figure 48

• Cutting unit spindle shaft bearings (2 per cutting unit) (Figure 49)

  Note: Either fitting can be used, which ever is more accessible. Pump grease into the fitting until a small amount appears at bottom of the spindle housing (under the deck).

  

  Figure 49

• Rear roller bearings (2 per cutting unit) (Figure 50)

  

  Figure 50

  Note: Make sure the grease groove in each roller mount aligns with the grease hole in each end of the roller shaft. To help align the groove and hole, there is also an alignment mark on one end of the roller shaft.

  Important: Do not lubricate the Sidewinder cross tube. The bearing blocks are self-lubricated.

• 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 at the recommended service interval or earlier if engine performance suffers due to extremely dusty, dirty conditions. Changing the air filter before it is necessary only increases the chance of dirt entering the engine when the filter is removed.

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

1. Release the latches securing the air cleaner cover to the air cleaner body (Figure 51).

   

   Figure 51

   1. Air cleaner cover
   2. Air cleaner latch

2. Remove the cover from the air cleaner body.

3. Before removing the filter, use low pressure air (40 psi, clean and dry) to help remove large accumulations of debris packed between outside of primary filter and the canister. Avoid using high pressure air which could force dirt through the filter into the intake tract. This cleaning process prevents debris from migrating into the intake when the primary filter is removed.

4. Remove and replace the primary filter (Figure 52).

   Cleaning of the used element is not recommended due to the possibility of damage to the filter media.

   

   Figure 52

   1. Primary filter

5. Inspect the new filter for shipping damage, checking the sealing end of the filter and the body. Do not use a damaged element.

6. Insert the new filter by applying pressure to the outer rim of the element to seat it in the canister. Do not apply pressure to the flexible center of the filter.

7. Clean the dirt ejection port located in the removable cover. Remove the rubber outlet valve from the cover, clean the cavity and replace the outlet valve.

8. Install the cover orienting the rubber outlet valve in a downward position—between approximately 5:00 to 7:00 when viewed from the end.

9. Secure the cover latches.

1. Remove either drain plug (Figure 53) and let oil flow into a drain pan. When the oil stops flowing, install the drain plug.

   

   Figure 53

   1. Engine oil drain plug

2. Remove the oil filter (Figure 54). Apply a light coat of clean oil to the new filter seal before screwing it on. Do not overtighten.

   

   Figure 54

   1. Engine oil filter

3. Add oil to the crankcase; refer to Checking the Engine Oil Level.

Drain and clean the tank if the fuel system becomes contaminated or if the machine will be stored for an extended period of time. Use clean fuel to flush out the tank.

Inspect the fuel lines and connections for deterioration, damage, or loose connections.

1. Place a clean container under the fuel filter.

2. Loosen the drain valve on the bottom of the filter canister (Figure 55).

   

   Figure 55

   1. Water separator/filter canister
   2. Vent plug
   3. Drain valve

3. Tighten the valve after draining.

1. Clean the area where the filter canister mounts (Figure 55).

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

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

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

Note: This procedure should be used only if the fuel system has been purged of air through normal priming procedures and the engine will not start; refer to Bleeding the Fuel System.

1. Loosen the pipe connection to the No. 1 nozzle and holder assembly.

   

   Figure 56

   1. Fuel injectors

2. Move the throttle to the Fast position.

3. Turn the key in the key switch to the Start position and watch the fuel flow around the connector. Turn the key to the Off position when solid flow is observed.

4. Tighten the pipe connector securely.

5. Repeat the procedure on the remaining nozzles.

The battery electrolyte level must be properly maintained and the top of the battery kept clean. lf the machine is stored in a location where temperatures are extremely high, the battery will run down more rapidly than if the machine is stored in a location where temperatures are cool.

Maintain the cell level with distilled or demineralized water. Do not fill the cells above the bottom of the split ring inside each cell. Install the filler caps with the vents pointing to the rear (toward the fuel tank).

Keep the top of the battery clean by washing it periodically with a brush dipped in ammonia or bicarbonate of soda solution. Flush the top surface with water after cleaning. Do not remove the filler caps while cleaning.

The battery cables must be tight on the terminals to provide good electrical contact.

If corrosion occurs at the terminals, disconnect the cables, negative (–) cable first, and scrape the clamps and terminals separately. Reconnect the cables, positive (+) cable first, and coat the terminals with petroleum jelly.

The fuses in machines electrical system are located under console cover.

If the machine moves when the traction pedal is in the NEUTRAL position, adjust the traction cam.

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

2. Chock or block the front and rear wheels on one side.

3. Raise the opposite front and rear wheel off the floor and place support blocks under the frame.

   Warning

   If the machine is not supported adequately, it may accidentally fall, injuring anyone under the machine.

   A front wheel and a rear wheel must be raised off the ground; otherwise, the machine will move during adjustment.

4. Loosen the locknut on the traction adjustment cam (Figure 57).

   

   Figure 57

   1. Traction adjustment cam
   2. Locknut

   Warning

   The engine must be running so that you can make a final adjustment of the traction adjustment cam. Contact with hot or moving parts can result in personal injury.

   Keep your hands, feet, face, and other body parts away from the muffler, other hot parts of the engine, and rotating parts.

5. Start the engine and rotate the cam hex in both directions to determine the mid position of the neutral span.

6. Tighten the locknut securing the adjustment.

7. Shut off the engine.

8. Remove the support blocks and lower the machine to the shop floor. Test drive the machine to ensure that it does not move when the traction pedal is in neutral.

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

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

2. Remove the access panel (Figure 58).

   

   Figure 58

   1. Access panel
   2. Oil cooler
   3. Radiator

3. Unlatch the oil cooler and pivot it rearward (Figure 59). Clean both sides of the oil cooler and radiator area thoroughly with water or compressed air. Pivot the oil cooler back into position.

   

   Figure 59

4. Install the access panel and close the hood.

1. Loosen the set screw securing the knob to the parking brake lever (Figure 60).

   

   Figure 60

   1. Parking brake lever
   2. Knob
   3. Set screw

2. Rotate the knob until a force of 41–68 N-m (30–40 lb) is required to actuate the lever.

3. Tighten the set screw after the adjustment has been attained.

1. Position the throttle lever rearward so it stops against the control panel slot.

2. Loosen the throttle cable connector on the injection pump lever arm (Figure 63).

   

   Figure 63

   1. Injection pump lever arm

3. Hold the injection pump lever arm against the low idle stop and tighten the cable connector.

4. Loosen the screws securing the throttle control to the control panel.

5. Push the throttle control lever all of the way forward.

6. Slide the stop plate until it contacts the throttle lever and tighten the screws securing the throttle control to the control panel.

7. If the throttle does not stay in position during operation, torque the locknut, used to set the friction device on the throttle lever, to 5–6 N-m (40–55 inch-lb). The maximum force required to operate the throttle lever should be 27 N-m (20 lb).

Use a genuine Toro replacement filter, Part No. 86-3010.

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 brake, and remove the key from the ignition switch.

2. Pinch off the hose to the filter mounting plate.

3. Clean around the filter mounting area. Place a drain pan under the filter (Figure 64) and remove the filter.

   

   Figure 64

   1. Hydraulic filter

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

5. Ensure that the filter mounting area is clean. Screw the filter on until the gasket contacts the mounting plate; then tighten the filter 1/2 turn.

6. Release the hose to the filter mounting plate.

7. Start the engine and let it run for about two minutes to purge air from the system. Stop the engine and check for leaks.

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. Disconnect the hydraulic line (Figure 65) or remove the hydraulic filter (Figure 64) and let the hydraulic fluid flow into a drain pan. Install the hydraulic line when hydraulic fluid stops draining.

   

   Figure 65

   1. Hydraulic line

3. Fill the reservoir (Figure 66) with approximately 13.2 liters (3.5 U.S. gallons) of hydraulic fluid; refer to Checking the Hydraulic System.

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

   

   Figure 66

   1. Hydraulic fill cap

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

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

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

1. Position the machine on a level surface, lower the cutting decks to the floor, shut the engine off, and engage the parking brake.

2. Disconnect and remove the hydraulic motor from the deck (Figure 67). Cover the top of the spindle to prevent contamination.

   

   Figure 67

   1. Motor mounting screws

3. Remove the lynch pin or retaining nut securing the deck carrier frame to the lift arm pivot pin (Figure 68).

   

   Figure 68

   1. Lynch pin
   2. Lift arm pivot pin

4. Roll the cutting deck away from the traction unit.

1. Position machine on a level surface and shut engine off.

2. Move cutting deck into position in front of traction unit.

3. Slide deck carrier frame onto lift arm pivot pin. Secure with lynch pin or retaining nut (Figure 68).

4. Install the hydraulic motor to the deck (Figure 67). Make sure that the O-ring is in position and not damaged.

5. Grease the spindle.

The rotary deck comes from the factory preset at 5 cm (2.00 inch) height-of-cut and blade rake of 7.9 mm ( 0.310 inch). The left-hand and right-hand heights are also preset to within ± 0.7 mm (0.030 inch) of the other.

The cutting deck is designed to withstand blade impacts without deformation of the chamber. If a solid object is struck, inspect the blade for damage and the blade plane for accuracy.

Inspect the front roller for wear, excess wobble, or binding. Service or replace the roller or components if any of these conditions exist.