Groundsmaster® 4100 or 4110 Rotary Mower

Move the seat-adjustment lever on the side of the seat outward, slide the seat to the desired position, and release the lever to lock the seat into position (Figure 7).

Figure 7

1. Seat-adjustment lever
2. Armrest-adjustment knob
3. Weight-adjustment lever
4. Weight gauge
5. Seat-back adjustment lever

Rotate the knob to adjust the armrest angle (Figure 7).

Move the lever to adjust the seat-back angle (Figure 7).

The weight gauge indicates when the seat is adjusted to the weight of the operator (Figure 7). Adjust the height by positioning the suspension within the range of the green region.

Use this lever to adjust to the proper weight of the operator (Figure 7). Pull up the lever to increase the air pressure and push down to decrease the air pressure. The proper adjustment is correct 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 8).

• 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 8).

Rotate the temperature-control knob to regulate the air temperature in the cab (Figure 8).

Use this switch to turn the wind shield wipers on or off (Figure 8).

Use this switch to turn the air conditioning on or off (Figure 8).

Use this 15 A, 12 V DC power outlet to power compatible devices (Figure 8).

Use this switch to turn the headlights and tail light on or off (Figure 8).

Use this switch to turn the flashers (hazard lights) on or off (Figure 8).

Lift up the latches to open the windshield (Figure 9). Press in the latch to lock the windshield to the OPEN position. Pull out and down on the latch to close and secure the windshield.

Figure 9

1. Windshield latch

Lift up the latches to open the rear window. Press in on the latch to lock the window in OPEN position. Pull out and down on the latch to close and secure the window (Figure 9).

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

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

Before you start the engine and use the machine, check the cooling system; refer to Checking the Cooling System.

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

Drain water or other contaminants from the water separator; refer to Servicing the Water Separator.

The correct air pressure in the tires is 172 to 207 kPa (25 to 30 psi).

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

Figure 12

Torque the wheel-lug nuts to 115 to 136 N∙m (85 to 100 ft-lb) in the order shown in Figure 13 and Figure 14.

Figure 13

Front Wheels

Figure 14

Rear Wheels

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

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

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

3. Mount a magnetic protractor onto the plate.

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

5. Repeat the procedure on the other headlight.

Mount the skids 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).

Figure 26

Mount the mower-deck rollers in the lower position when operating at a height-of-cut greater than 64 mm (2-1/2 inches) and in the higher position when operating at a height-of-cut lower than 64 mm (2-1/2 inches).

Figure 27

Important: On multi-bladed machines, take care as rotating 1 blade can cause other blades to rotate.

To ensure proper operation of the cutting unit, there must be a 10 to 16 mm (0.38 to 0.62 inch) clearance between the tips of the side and center mower-deck blades (Figure 28).

1. Raise the cutting unit so the blades are visible and block the center deck section so it cannot fall accidentally.

   Note: The wing decks must be horizontal to the center cutting unit.

2. Rotate a center and adjoining side blade so the blade tips are aligned. Measure the distance between the blade tips (Figure 28).

   Note: The distance should be approximately 10 to 16 mm (0.38 to 0.62 inch).

   

   Figure 28

   1. Clearance of 0.38 to 0.62 inches (10-16mm)

3. To adjust distance, locate adjuster bolt on rear pivot link of the cutting unit (Figure 29).

4. Loosen the jam nut on the adjuster bolt.

5. Loosen or tighten the adjuster bolts until you attain a 10 to 16 mm (0.38 to 0.62 inch) clearance, then tighten the jam nut.

6. Repeat the procedure on the opposite side of the cutting unit.

   

   Figure 29

   1. Adjuster bolt
   2. Jam nut

Due to differences in grass conditions and the counterbalance setting of the traction unit, a sample area of grass should 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 the air pressure in the front and rear tire of the machine to 172 to 207 kPa (25 to 30 psi).

3. Check and adjust the air pressure in all of the caster tires for the cutting unit to 345 kPa (50 psi).

4. Check the charge and counterbalance pressures with the engine at HIGH IDLE, using hydraulic-test ports.

   Note: Adjust the 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 mower-deck adjustments are still needed, find a flat surface using a 2 m (6 ft) or a longer straight edge.

8. To ease measuring the 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 the cutting units onto a flat surface and 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.

The machine has interlock switches in the electrical system. These switches disengage either the traction unit or the PTO whenever you leave the seat. If you disengage the PTO and engage the parking brake before you leave the seat, the engine continues to run.

1. Drive the machine slowly to a large, open area. Lower the cutting unit, shut off the engine, and apply the parking brake.

2. Sit on the seat and press the traction pedal. Try to start the engine. The engine should not start. If the engine starts, there is a malfunction in the interlock system that should be corrected before beginning operation.

3. Sit on the seat, start the engine, and engage the PTO. While sitting in the seat with the PTO engaged, rise from the seat. The PTO should disengage after a slight delay. If the PTO engages, there is a malfunction in the interlock system that should be corrected before beginning operation.

4. Sit on the seat, engage the parking brake and start the engine. Move the traction pedal out of the NEUTRAL position. The InfoCenter should display “traction not allowed” and the machine should not move. If the machine does move, there is a malfunction in the interlock system that should be corrected before beginning operation.

The InfoCenter LCD display shows information about your machine, such as the operating status, various diagnostics and other information about the machine (Figure 32). There is a splash screen and main information screen of the InfoCenter. You can switch between the splash screen and main information screen at any time by pressing any of the InfoCenter buttons and then selecting the appropriate directional arrow.

Figure 32

1. Indicator light
2. Right button
3. Middle button
4. Left button

• Left Button, Menu Access/Back Button—press this button to access the InfoCenter menus. You can use it to exit any menu that you are currently using.

• Middle Button—use this button to scroll down menus.

• Right Button—use this button to open a menu where a right arrow indicates additional content.

• Beeper—activated when lowering the decks or for advisories and faults.

Note: The purpose of each button may change depending on what is required at the time. Each button is labeled with an icon displaying its current function.

InfoCenter Icon Description

SERVICE DUE	Indicates when scheduled service should be performed
	Hours remaining until service
	Reset the service hours
	Engine rpm/status—indicates the engine rpm
	Hour meter
	Info icon
	Sets the maximum traction speed
	Fast
	Slow
	Fan Reversal—indicates when the fan is reversed
	Fuel level
	Stationary regeneration required
	Air intake heater is active
	Raise the left deck
	Raise the center deck
	Raise the right deck
	Operator must sit in seat
	Parking Brake Indicator—indicates when the parking brake is on
	Identifies the range as High
	Neutral
	Identifies the range as Low
	Coolant Temperature-indicates the engine coolant temperature in either °C or °F
	Temperature (hot)
	Traction or Traction Pedal
	Denied or not allowed
	Engine Start
	PTO—indicates that the PTO is on
	Stop or shutdown
	Engine
	Key switch
	Indicates when the cutting units are being lowered
	Indicates when the cutting units are being raised
	PIN passcode
	Hydraulic-fluid Temperature—indicates the hydraulic-fluid temperature
	CAN bus
	InfoCenter
	Bad or failed
	Center
	Right
	Left
	Bulb
	Output of TEC controller or control wire in harness
	High: over-allowed range
	Low: under-allowed range
/	Out of range
	Switch
	Operator must release the switch
	Operator should change to the indicated state
Symbols are often combined to form sentences. Some examples are shown below
	Operator should put the machine in neutral
	Engine start denied
	Engine shutdown
	Engine coolant is too hot
	Hydraulic fluid is too hot
	Sit down or engage the parking brake
	DPF ash accumulation notification. Refer to Servicing the Diesel Particulate Filter (DPF) in the maintenance section for details
	Reset-standby regeneration request
	Parked or recovery regeneration request
	A parked or recovery regeneration is processing.
	High exhaust temperature
	NOx control diagnosis malfunction; drive the machine back to the shop and contact your authorized Toro distributor (software version R and later).

To access the InfoCenter menu system, press the menu access button while at the main screen. This will bring you to the main menu. Refer to the following tables for a synopsis of the options available from the menus:

*Only "operator-faced" text is translated. Faults, Service, and Diagnostics screens are "service-faced." Titles will be in the selected language, but menu items are in English.

There are 4 operating configuration settings that are adjustable within the Settings Menu of the InfoCenter: auto idle time delay, maximum mowing ground speed, maximum transport ground speed, and Smart Power. These settings are in the Protected Menu.

Note: The factory default PIN code for you machine is either 0000 or 1234.If you changed the PIN code and forgot the code, contact your authorized Toro distributor for assistance.

1. From the MAIN MENU, use the center button to scroll down to the SETTINGS MENU and press the right button (Figure 33).

   

   Figure 33

2. In the SETTINGS MENU, use the center button to scroll down to the PROTECTED MENU and press the right button (Figure 34A).

   

   Figure 34

3. To enter the PIN code, press the center button until the correct first digit appears, then press the right button to move on to the next digit (Figure 34B and Figure 34C). Repeat this step until the last digit is entered and press the right button once more.

4. Press the middle button to enter the PIN code (Figure 34D).

   Wait until the red indicator light of the InfoCenter illuminates.

   Note: If the InfoCenter accepts the PIN code and the protected menu is unlocked, the word “PIN” displays in the upper right corner of the screen.

Note: Rotate the key switch to the OFF position and then to the ON position locks the protected menu.

You can view and change the settings in the Protected Menu. Once you access the Protected Menu, scroll down to Protect Settings option. Use the right button to change the setting. Setting the Protect Settings to OFF allows you to view and change the settings in the Protected Menu without entering the PIN code. Setting the Protect Settings to ON hides the protected options and requires you to enter the PIN code to change the setting in the Protected Menu. After you set the PIN code, rotate the key switch OFF and back to the ON position to enable and save this feature.

1. In the Settings Menu, scroll down to Auto Idle.

2. Press the right button to change the auto idle time between Off, 8S, 10S, 15S, 20S, and 30S.

1. In the Settings Menu, scroll down to Mow Speed and press the right button.

2. Use the right button to increase the max full mow speed (50%, 75%, or 100%).

3. Use the center button to decrease the max full mow speed (50%, 75%, or 100%).

4. Press the left button to exit.

1. In the Settings Menu, scroll down to Transport Speed and press the right button.

2. Use the right button to increase the max transport speed (50%, 75%, or 100%).

3. Use the center button to decrease the max transport speed (50%, 75%, or 100%).

4. Press the left button to exit.

When finished with the Protected Menu, press the left button to exit to the Main Menu, then press the left button to exit to the Run Menu.

This resets the service due hours after a scheduled maintenance procedure is performed.

1. In the SERVICE MENU, navigate to the HOURS MENU.

2. Scroll down to the service symbol .

   Note: If service is currently due, the first icon shows NOW.

3. Below the first icon is the service symbol and 250.

4. Highlight the service symbol and press the right button.

5. When the new screen appears, confirm RESET SERVICE HOURS—Are you sure?

6. Select YES (center button) or NO (left button).

7. After you select YES, a screen prompts the clearing and reverts back to the SERVICE HOURS selections.

Practice driving the machine, because it has a hydrostatic transmission and its characteristics may differ from other turf-maintenance machines. Some points to consider when operating the traction unit, cutting unit, or other implements are that the transmission, engine speed, and the load on the mower blades or other implements affect machine performance.

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

You can use the brakes to assist in turning the machine. However, use them carefully, especially on soft or wet grass, because the turf may be torn accidentally. Another benefit of the brakes is to maintain traction. For example, in some slope conditions, the uphill wheel slips and loses traction. If this situation occurs, press the uphill brake pedal gradually and intermittently until the uphill wheel stops slipping, This action increases the traction on the downhill wheel.

Traction Assist is automatic and requires no operator input. When a wheel starts to slip, flow is automatically split between the front and rear wheels to minimize wheel slip and loss of traction.

Before stopping the engine, disengage all controls and change the throttle to the SLOW position. Changing the throttle to the SLOW position reduces high-engine speed, noise, and vibration. Turn the key to the OFF position to shut off the engine. Remove the key if you are leaving the operator’s position.

Before transporting the machine, raise the cutting units and secure the transport latches (Figure 35).

Figure 35

1. Transport latch (side cutting units)

• Start the engine and run it at the HALF IDLE position until it warms up. Move the engine-speed switch to HIGH IDLE, 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 the machine, remove your foot from the traction pedal and let it return to NEUTRAL or press down on the reverse pedal.

  Note: When going downhill in the machine, you may need to use the reverse pedal to stop.

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

• Always drive slowly in rough areas.

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

• When transporting the machine from 1 work area to another, raise the cutting units to the fully upward position, shut off the PTO, press the mow/transport switch to the TRANSPORT position, and place the throttle in the FAST position.

The counterbalance system maintains hydraulic back pressure on the deck-lift cylinders. This pressure improves traction by transferring the mower-deck weight to the mower-drive wheels. The counterbalance pressure has been set at the factory to an optimal balance of after-cut appearance and traction capability in most turf conditions.

Decreasing the counterbalance setting can produce a more stable cutting unit, but can decrease the traction capability. Increasing the counterbalance setting can increase the traction capability, but may result in a poor after-cut appearance. Refer to the machine Service Manual for your traction unit for instructions to adjust the counterbalance pressure.

Important: In emergency braking situations, remove your foot from the traction pedal and then press the brake pedals.

In the low speed range only, you can use the brakes individually for turning or to improve traction. Perform the following when using the brakes individually:

• Disconnect the pedal-locking latch (Figure 4).

• For turning assist, press the corresponding brake pedal to the side you are turning. This allows a tighter turning radius.

  Note: Use the individual brakes carefully, especially on soft or wet grass, because the turf may be torn accidentally.

• For traction assist, apply light pressure to the brake pedal corresponding to the front tire that is slipping. For example, in some slope conditions, the uphill wheel slips and loses traction. If this situation occurs, press the uphill brake pedal gradually and intermittently until the uphill wheel stops slipping, This action increases the traction on the downhill wheel.

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

Note: By default, the Smart Power feature is ON.

The machine-fan speed is controlled by the hydraulic-fluid temperature and engine-coolant temperature. When the hydraulic fluid, fuel temperature or coolant reaches a certain temperature, a reverse fan cycle is automatically initiated. This cycle blows debris off the rear screen and lowers the engine-coolant, fuel, and hydraulic-fluid temperatures.

You can complete a manually-initiated reverse cycle by simultaneously pressing the right and left buttons on the InfoCenter. It is recommended that you manually reverse the fan before you leave the work area or enter the maintenance or storage area.

The machine is equipped with auto idle, which automatically idles the engine when all the following functions are not used for a pre-determined time as previously set in the InfoCenter.

• The traction pedal is returned to the NEUTRAL position.

• The PTO is disengaged.

• None of the lift switches are activated.

  When you initiate any of the above functions, the machine automatically returns to the previous throttle position.

The cruise-control switch locks in the pedal position to maintain the desired ground speed. Pressing the rear of the switch turns cruise control off, the middle position of the switch enables the cruise-control function, and the front of the switch sets the desired ground speed.

Note: Pressing the brake pedal or moving the traction pedal into the reverse position, for 1 second, shuts off the cruise control.

Important: The fuel system automatically bleeds itself when any of the following situations occur:

• Initial start up of a new machine.

• The engine has ceased running due to lack of fuel.

• Maintenance has been performed upon the fuel system components.

1. Remove your foot from the traction pedal and ensure that it is in neutral. Ensure that the parking brake is set.

2. Move the engine-speed switch to the LOW-IDLE position.

3. Turn the ignition key to the RUN position.

   Note: The glow-plug indicator illuminates.

4. When the glow indicator dims, turn the ignition key to the START position. Release the key immediately when the engine starts and allow it to return to the RUN position.

   Important: Do not run the starter motor more than 30 seconds at a time or premature starter failure may result. If the engine fails to start after 30 seconds, turn the key to the OFF position, check the controls and procedures, wait 30 additional seconds, and repeat the starting procedure.

5. Allow engine to warm up at mid speed (without load), then move the throttle control to the desired position.

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

Important: Allow the engine to idle for 5 minutes before shutting it off after a full-load operation. This allows the turbocharger to cool down before shutting off the engine. Failure to do so may lead to turbocharger trouble.

Note: Lower the cutting units to the ground whenever machine is parked. This relieves the hydraulic load from the system, prevents wear on system parts, and also prevents accidental lowering of the cutting units.

1. Move the throttle control backward to the SLOW position.

2. Move the PTO switch to the OFF position.

3. Engage the parking brake.

4. Rotate the ignition key to the OFF position.

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

The engine speed switch has 2 modes to change the engine speed. By momentarily tapping the switch, the engine speed can be increased or decreased in 100-rpm increments. By holding the switch down, the engine automatically moves to HIGH or LOW IDLE, depending on which side of the switch you press.

Supervisor (Protected Menu)

This feature allows the supervisor to set the maximum mowing speed in increments of 5% between 30 and 100%, at which the operator can mow (low range).

Operator

This feature allows the operator to adjust the maximum mowing speed (low range), within the supervisors pre-adjusted settings. When in the InfoCenter splash or main screen, press the middle button ( icon) to adjust the speed.

Note: When switching between low and high ranges, the settings will transfer based on the previous setting. The settings are reset when the machine is turned off.

Note: You can also use this feature with cruise control.

Supervisor (Protected Menu)

This feature allows the supervisor to set the maximum transport speed in increments of 5% between 30 and 100%, at which the operator can transport (high range).

Refer to Setting the Maximum Allowed Transport Speed for the procedure to set the transport speed.

Operator

This feature allows the operator to adjust the maximum transport speed (high range) within the supervisors pre-adjusted settings. When in the InfoCenter splash or main screen, press the middle button ( icon) to adjust the speed.

Note: When switching between low and high ranges, the settings transfer based on the previous setting. The settings are reset when the machine is turned off.

Note: You can also use this feature in conjunction with cruise control.

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

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

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

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

• If the back pressure in the DPF is too high or a reset regeneration has not occurred for 100 hours, the engine computer signals you through the InfoCenter when reset regeneration is running.

• Allow the reset regeneration process to complete before shutting off the engine.

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

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

DPF Soot Accumulation

• Over time, the diesel particulate filter 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 DPF.

• 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 36 Check EngineSPN 3719, FMI 16	The computer de-rates the engine power to 85%.	Perform a parked regeneration as soon as possible; refer to Performing a Parked or Recovery Regeneration.
Level 2: Engine Warning	Figure 37 Check EngineSPN 3719, FMI 0	The computer de-rates the engine power to 50%.	Perform a recovery regeneration as soon as possible; refer to Performing a Parked or Recovery Regeneration.

DPF Ash Accumulation

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

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

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

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

• The fault messages indicate 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	Fault Code	Engine Speed Reduction	Engine Power Rating	Recommended Action
Level 1: Engine Warning	Figure 38 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 2: Engine Warning	Figure 39 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

Types of Diesel Particulate Filter Regeneration

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

Type of Regeneration	Conditions that cause 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 because of low-engine speed, low-engine load, or after the computer detects the DPF is becoming obstructed with soot	• The InfoCenter does not display an icon indicating assist regeneration.
		• During assist regeneration, the engine computer adjusts the engine settings to raise the exhaust temperature.
		Refer to Assist DPF Regeneration.
Reset	Occurs every 100 hours	• When the high exhaust-temperature icon is displayed in the InfoCenter, a regeneration is in progress.
	Also occurs after assist regeneration only if the computer detects that assist regeneration did not sufficiently reduce the soot level
		• During reset regeneration, the engine computer adjusts the engine settings to raise the exhaust temperature.
		Refer to Reset Regeneration.

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

Type of Regeneration	Conditions that cause DPF regeneration	DPF description of operation
Parked	Occurs because the computer detects back pressure in the DPF due to soot buildup	• When the reset-standby/parked or recovery regeneration icon or ADVISORY #188 displays in the InfoCenter, a regeneration is requested.
	Also occurs because the operator initiates a parked regeneration
	May occur because you set the InfoCenter to inhibit reset regeneration and continued operating the machine, adding more soot when the DPF already needs a reset regeneration	• Perform the parked regeneration as soon as possible to avoid needing a recovery regeneration.
	May result from using the incorrect fuel or engine oil	• 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 parked regeneration.
		Refer to Performing a Parked or Recovery Regeneration.
Recovery	Occurs because the operator ignored requests for a parked regeneration and continued operating the machine, adding more soot to the DPF	• When the reset-standby/parked or recovery regeneration icon or ADVISORY #190 displays in the InfoCenter, a recovery regeneration is requested.
		• A recovery regeneration requires up to 3 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 Performing a Parked or Recovery Regeneration.

Accessing the DPF Regeneration Menus

Accessing the DPF Regeneration Menus

1. Access the Service menu, press the center button to scroll down to the DPF REGENERATION option (Figure 40).

   

   Figure 40

2. Press the right button to select the DPF Regeneration entry (Figure 40).

Time Since Last Regeneration

Access the DPF Regeneration menu, press the center button to scroll down to the LAST REGEN field (Figure 41).

Use the LAST REGEN field to determine how many hours you have run the engine since the last reset, parked, or recovery regeneration.

Figure 41

Technician Menu

Important: For operating convenience, you may decide to perform a parked regeneration before the soot load reaches 100%, provided the engine has run more than 50 hours since the last successful reset, parked, or recovery regeneration.

Use the technician menu to view the current state of engine regeneration control and view the reported soot level.

Access the DPF Regeneration menu, press the center button to scroll down to the TECHNICIAN option, and press the right button to select the Technician entry (Figure 42).

Figure 42

• Use the DPF operation table to understand the current state of DPF operation (Figure 43).

  

  Figure 43

  .

  DPF Operation Table

  State	Description
  Normal	The DPF is in normal-operating mode—passive regeneration.
  Assist Regen	The engine computer is performing an assist regeneration.
  Reset Stby	The engine computer is trying to run a reset regeneration, but 1 of the following conditions prevents regeneration:	The regen inhibit setting is set to ON.
  		The exhaust temperature is too low for regeneration.
  Reset Regen	The engine computer is running a reset regeneration.
  Parked Stby	The engine computer is requesting that you run a parked regeneration.
  Parked Regen	You initiated a parked regeneration request and the engine computer is processing the regeneration.
  Recov. Stby	The engine computer is requesting that you run a recovery regeneration.
  Recov. Regen	You initiated a recovery regeneration request and the engine computer is processing the regeneration.

• View the soot load which is measured as the percentage of soot in the DPF(Figure 44); refer to the soot-load table.

  Note: The soot load value varies as the machine is operated and DPF regeneration occurs.

  

  Figure 44

  Soot-Load Table

  Important Soot Load Values	Regeneration State
  0% to 5%	Minimum soot load range
  78%	The engine computer performs an assist regeneration.
  100%	The engine computer automatically requests a parked regeneration.
  122%	The engine computer automatically requests a recovery regeneration.

Reset Regeneration

Caution

The exhaust temperature is hot (approximately 600°C (1,112°F) during DPF regeneration. Hot exhaust gas can harm you or other people.

• Never operate the engine in an enclosed area.

• Make sure that there are no flammable materials around the exhaust system.

• Never touch a hot exhaust system component.

• Never stand near or around the exhaust pipe of the machine.

Figure 45

• The high exhaust-temperature icon displays in the InfoCenter (Figure 45).

• The engine computer adjusts engine settings to raise the exhaust temperature.

  Important: The high exhaust-temperature 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 and high load 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: Whenever possible, allow the machine to complete the reset regeneration process before shutting off the engine.

Periodic Reset Regeneration

If the engine has not completed a successful Reset, Parked, or Recovery regeneration in the previous 100 hours of engine operation, the engine computer will attempt to perform a reset regeneration.

Setting the Inhibit Regen

Reset Regeneration Only

Note: If you set the InfoCenter to inhibit regeneration, the InfoCenter displays ADVISORY #185 (Figure 46) every 15 minutes while the engine requests a reset regeneration.

Figure 46

A reset regeneration produces the elevated engine exhaust. If you are operating the machine around trees, brush, tall grass, or other temperature-sensitive plants or materials, you can use the Inhibit Regen setting to prevent the engine computer from performing a reset regeneration.

Important: When you shut off the engine and start it again, the inhibit regen setting defaults to OFF.

1. Access the DPF Regeneration menu, press the center button to scroll down to the INHIBIT REGEN option, and press the right button to select the Inhibit Regen entry (Figure 47).

   

   Figure 47

2. Press the right button to change the inhibit regeneration setting from On to Off (Figure 47) or from Off to On (Figure 48).

   

   Figure 48

Allowing a Reset Regeneration

The InfoCenter displays the high exhaust-temperature icon when the reset regeneration is in process.

Note: If INHIBIT REGEN is set to ON, the InfoCenter displays ADVISORY #185 (Figure 49). Press button 3 to set inhibit regeneration setting to OFF and continue with the reset regeneration.

Figure 49

Note: If the InfoCenter displays ADVISORY #186 (Figure 50), set the engine to full throttle (high idle) to allow the reset regeneration to continue.

Figure 50

Note: When the reset regeneration completes, the high exhaust-temperature disappears from the InfoCenter screen.

In an emergency, you can move the machine forward by actuating the bypass valve in the variable-displacement hydraulic pump and pushing or towing the machine.

Important: Do not push or tow the machine faster than 3 to 4.8 km/h (2 to 3 mph) If you push or tow at a faster speed, internal transmission damage may occur.The bypass valves must be open whenever you push or tow the machine.

1. Raise the seat and locate the bypass valves, which are located below the front of the fuel tank (Figure 72).

   

   Figure 72

   1. Bypass valve (2)

2. Rotate each valve 3 counter-clockwise turns to open and allow the fluid to bypass internally.

   Note: Do not open more than 3 turns. Because the fluid is bypassed, the machine can be slowly moved without damaging the transmission.

3. Push or tow the machine.

4. Finish pushing or towing the machine and close the bypass valves. Torque the valve to 70 N∙m (52 ft-lb).

   Important: Ensure that the bypass valve is closed before you start the engine. Running the engine with an open bypass valve causes the transmission to overheat.

Important: If you must push or tow the machine in reverse, bypass the check valve in the 4-wheel drive manifold.To bypass the check valve, connect a hose assembly to the reverse traction pressure test port (located on the hydrostat) and on the port located between ports M8 and P2 on the rear traction manifold (located behind the front tire). The hose assembly includes 1 hose (Part No. 95-8843), 2 coupler fittings (Part No. 95-0985), and 2 hydraulic fittings (Part No. 340-77).

There are jacking points located at the front and rear of the machine.

• On the frame at the inside of each front drive tire

• At the center of the rear axle

• Remove the key and shut off the fuel (if equipped) before storing or hauling the machine.

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

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

• Tie the machine down securely.

There are tie downs located at the front and rear sides of the machine (Figure 73).

Note: Use properly-rated DOT-approved straps in 4 corners to tie down the machine.

• 2 on the front of the operator's platform

• Rear bumper

Figure 73

1. Rear tie-down point
2. Front tie-down points

1. Close the rear window of the cab (Figure 74).

   

   Figure 74

2. Release the 2 latches at the forward lower corners of the hood (Figure 75).

   

   Figure 75

   1. Hood latch
   2. Handle
   3. Prop rod

3. Using the handles that are adjacent to the latches, lift up and back the hood until the 2 prop rods are seated in the 2 rod brackets (Figure 75).

1. Unlatch and raise the hood.

2. Remove the hairpin cotter securing the hood pivot to the mounting brackets (Figure 76).

   

   Figure 76

   1. Hairpin cotter

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

Note: Reverse this procedure to install the hood.

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

The grease-fitting locations and quantities are:

Traction Unit

• 2 brake pedal pivot-shaft bearings (Figure 77)

• 2 front and rear-axle-pivot bushings (Figure 78)

• 2 steering-cylinder-ball joints (Figure 79)

• 2 tie-rod-ball joints (Figure 79)

• 2 king-pin bushings (Figure 79).

  Note: Lubricate only the top fitting on the king pin annually (2 pumps).

Figure 77

Figure 78

Figure 79

Center Cutting Unit

Note: You may need to raise the cutting unit to expose the grease fittings for the latch pivot and the lower link.

• 2 latch pivots (Figure 81)

  Note: You may need to manually trip the latches to gain access to the grease fittings (Figure 80). Use a pry bar to close and open the latch.

• 2 caster-fork-shaft bushings (Figure 82)

• 3 spindle-shaft bearings—located under the pulley (Figure 83)

• 2 idler-arm-pivot bushings (Figure 83)

Figure 80

1. Latch

Figure 81

Figure 82

Figure 83

Center-Deck-Lift Assemblies

• 2 (each side) lift-arm-cylinder bushings (Figure 84)

• 2 lift-arm ball joints (Figure 85)

Figure 84

Figure 85

Wing-Deck-Lift Assemblies

The 4 wing deck-lift cylinder (Figure 86)

Figure 86

Wing Cutting Units

• 1 caster-fork-shaft bushing (Figure 87)

• 2 (each side) spindle-shaft bearings—located under the pulley

• 1 idler-arm-pivot bushings—located on the idler arm

Figure 87

Check the air-cleaner body for damage, which could cause an air leak. Replace it if it is 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 (Figure 90). Changing the air filter before it is necessary only increases the chance of dirt entering the engine when you remove the filter.

Figure 90

1. Air-cleaner indicator

Important: Be sure that the cover is seated correctly and seals with the air-cleaner body.

1. Replace the air cleaner (Figure 91).

   

   Figure 91

   Note: Do not clean the used element due to the possibility of damage to the filter media.

   Important: Never attempt to clean the safety filter (Figure 92). Replace the safety filter after every 3 primary filter services.

   

   Figure 92

   1. Air-cleaner safety filter

2. Reset the indicator (Figure 90) if it shows red.

If engine faults , , or in the InfoCenter (Figure 93) display in the InfoCenter, clean the soot filter using the steps that follow:

Figure 93

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.

Service the water separator as shown in Figure 94.

After replacing the water separator, turn the key to ON for 10 seconds, but do not start the engine. Turn the key off and repeat this 2 more times.

Figure 94

1. Clean the area around the fuel-filter head (Figure 95).

   

   Figure 95

   1. Fuel-filter head
   2. Fuel filter

2. Remove the filter and clean the filter head mounting surface (Figure 95).

3. Lubricate the filter gasket with clean lubricating engine oil; refer to the engine owner's manual 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. Prime the fuel system to purge any air; refer to Priming the Fuel System.

Prime the fuel system before starting the engine for the first time, after running out of fuel, or after fuel system maintenance (e.g., draining the filter/water separator, replacing a fuel hose).

To prime the fuel system, perform the following steps:

1. Ensure that fuel is in the fuel tank.

2. Perform the following steps to prime the filter and the lines to the high pressure pump to prevent wear or damage to the pump:

   1. Cycle the key to the ON position for 15 to 20 seconds.

   2. Cycle the key to the OFF position for 30 to 40 seconds.

      Note: This allows the ECU to power down.

   3. Cycle the key to the ON position for 15 to 20 seconds.

   4. Inspect for leaks around the filter and hoses.

Important: Do not use the engine starter motor to crank the engine to prime the fuel system.

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

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

1. Open the battery cover on the side of the shroud (Figure 96).

   Note: Press down on the flat surface above the battery cover to ease the removal of the cover (Figure 96).

   

   Figure 96

   

   Figure 97

   1. Battery cover
   2. 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.

4. Slide the rubber boot over the positive terminal.

5. Close the battery cover.

The traction-unit fuses are located under the power-center cover (Figure 98, Figure 99, and Figure 100).

Remove the 2 screws securing the power-center cover to the frame and remove the cover (Figure 98).

Figure 98

1. Power-center cover
2. Screws

Figure 99

1. Fuses

Figure 100

The cab fuses are located in the fuse box in the cab headliner (Figure 101 and Figure 102).

Note: Cab model only

Figure 101

1. Cab fuse box
2. Fuses

Figure 102

1. Loosen the 2 nuts and bolts securing the left side of the traction pedal to the bracket (Figure 103).

   

   Figure 103

   1. Traction pedal
   2. Mounting nuts and bolts

2. Pivot the pedal to the desired operating angle and tighten the nuts (Figure 103)˙.

Use high quality SAE 85W-140 gear lube as a replacement.

1. With machine on level surface, position the wheel so 1 check plug is at the 12 o'clock position and the other is at 3 o'clock position (Figure 104).

   

   Figure 104

   1. Check/drain plug (2)

2. Remove the plug at the 3 o’clock position (Figure 104).

   Note: The 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.

Use a high-quality, SAE 85W-140 gear lube.

1. With the machine on a level surface, position a wheel so a check plug is at the lowest (6 o'clock) position (Figure 105).

   

   Figure 105

   1. Check/drain plug

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

3. Place a drain pan under the brake housing, remove the drain plug, and allow the oil to drain (Figure 106).

   

   Figure 106

   1. Drain plug
   2. Brake housing

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

5. Rotate the wheel until the open plug hole in the planetary is at the 12 o'clock position.

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

   Important: If the planetary fills before the 0.65 L (22 fl oz) of oil is added, wait 1 hour or install the plug and move the machine approximately 3 m (10 ft) 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.

The rear axle is filled with SAE 85W-140 gear lube. Check the lubricant level before you first start the engine and as recommended. The capacity is 2.4 L (80 fl oz). Visually inspect for leaks daily.

1. Position the machine on a level surface.

2. Remove a check plug from the end of the axle and ensure that the lubricant is up to the bottom of the hole (Figure 107).

   Note: If the level is low, remove the fill plug and add enough lubricant to bring the level up to the bottom of the check-plug holes.

   

   Figure 107

   1. Check plug
   2. Fill plug

The gearbox is filled with SAE 85W-140 gear lube. The capacity is 0.5 L (16 fl 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 gearbox and ensure that lubricant is up to the bottom of the hole (Figure 108).

   Note: If the level is low, add enough lubricant to bring the level up to the bottom of the hole.

   

   Figure 108

   1. Gearbox
   2. Check/fill plug

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 109).

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

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

   

   Figure 109

   1. Drain-plug location

5. Clean the area around the drain plug at the bottom of the gearbox (Figure 110).

6. Remove the drain plug from the gearbox and allow the oil to drain into a pan.

   Note: Remove the fill plug to ease in the draining of the oil.

   

   Figure 110

   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-Gearbox Lubricant.

8. Install the plugs.

1. Measure the center-to-center distance (at axle height) at the front and rear of the steering tires.

   Note: 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.

1. Lower the wing cutting units to the ground.

2. Raise the front of the machine several inches off the ground and support it with jackstands.

3. Refer to Pivoting (Tilting) the Center Cutting Unit to the Upright Position.

4. Pivot the mower deck forward so you can remove the tire.

The coolant reservoir is filled at the factory with a 50/50 solution of water and ethylene glycol base extended-life coolant.

Important: Use only commercially available coolants that meet the specifications listed in the Extended Life Coolant Standards Table.Do not use conventional (green) inorganic-acid technology (IAT) coolant in your machine. Do not mix conventional coolant with extended-life coolant.

Coolant Type Table

Extended Life Coolant Standards

Important: Coolant concentration should be a 50/50 mixture of coolant to water.

• Preferred: When mixing coolant from a concentrate, mix it with distilled water.

• Preferred option: If distilled water is not available, use a pre-mix coolant instead of a concentrate.

• Minimum requirement: If distilled water and pre-mix coolant are not available, mix concentrated coolant with clean drinkable water.

Check the coolant level at the beginning of each day. The capacity of the system is 8.5 L (9 US qt).

1. Carefully remove the radiator cap and expansion-tank cap (Figure 111).

2. Check the coolant level in the radiator.

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

   

   Figure 111

   1. Expansion tank

3. If the coolant is low, add a 50/50 mixture of water and ethylene glycol anti-freeze.

   Important: Do not use water only or alcohol/methanol based coolants, as this may cause damage.

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

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 the radiator/oil cooler and screen debris buildup. 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. Shut off the engine, remove the key, and raise the hood.

2. Clean the engine area thoroughly of all debris.

3. Clean both sides of the radiator/oil cooler area thoroughly with compressed air (Figure 112).

   Note: Start from the fan side and blow the debris out toward the back. Then, clean from the back side and blow toward the front. Repeat this 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 112

   1. Radiator/oil cooler

4. 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 you feel braking resistance.

1. Release 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 as follows:

   1. Loosen the front nut on the threaded end of the brake cable (Figure 113).

      

      Figure 113

      1. Brake cable

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

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

Proper tension of the belt allows 10 mm (3/8 inch) of deflection when a force of 44 N∙m (10 ft-lb) is applied on the belt midway between the pulleys.

If the deflection is not 10 mm (3/8 inch), loosen the alternator-mounting bolts (Figure 114).

Note: 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 114

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

Cab model only

Check the condition and tension of the belt (Figure 114) after every 100 operating hours.

1. Proper tension allows 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 114). 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.

When properly tensioned, the inside measurement of the extension spring (hook to hook) should be approximately 8.3 to 9.5 cm (3-1/4 to 3-3/4 inches). Once the correct spring tension is attained, adjust the stop bolt (carriage bolt) until there is approximately 2 to 5 mm (0.065 to 0.185 inch) clearance between the head of the bolt and the idler arm (Figure 115).

Note: Ensure that the belt is positioned on the spring side of the belt guide (Figure 115).

Figure 115

1. Extension spring
2. Stop bolt
3. Flange nut
4. Belt guide
5. Measurement (hook to hook)—approximately 8.3 to 9.5 cm (3-1/4 to 3-3/4 inches)
6. Eye bolt
7. Belt

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 include squealing when the 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 mower deck to the shop floor, remove the belt covers from the top of the mower deck, and set the covers aside.

2. Loosen the eye bolt (Figure 115).

3. Loosen the flange nut securing the stop bolt to the mounting tab and move the idler pulley away from the belt (Figure 115).

   Note: Loosen the nut enough to allow the idler arm to pass the stop bolt.

   Note: If you must remove the stop bolt from the mounting tab, install it in the hole that aligns the stop-bolt head with the idler arm.

4. Remove the bolts securing the hydraulic motor to the mower deck (Figure 116).

   

   Figure 116

   1. Hydraulic motor
   2. Mounting bolts

5. Lift the motor off the mower deck and lay it on top of the mower deck.

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

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

8. Position the hydraulic motor on the mower deck after routing the belt around the pulleys. Mount the motor to the mower deck with the bolts previously removed.

   Note: Ensure that the belt is positioned on the spring side of the belt guide (Figure 115).

9. Connect the extension spring (Figure 115) 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 8.3 to 9.5 cm (3-1/4 to 3-3/4 inch).

   • When you attain the correct spring tension, adjust the stop bolt (carriage bolt) until there is approximately 2 to 5 mm (0.065 to 0.185 inches) clearance between the head of the bolt and the idler arm.

Note: Although not needed, you can pivot (tilt) the center cutting unit.

1. Raise the center cutting unit slightly off the floor, set the parking brake, and shut off the engine, and remove the key.

2. Remove the hairpin cotter securing the dampers to lift arms (Figure 121).

   

   Figure 121

   1. Damper
   2. Hairpin cotter

3. Pivot the damper toward the deck housing.

4. Remove the hairpin cotter and clevis pin securing the height-of-cut chains to the rear of the cutting unit (Figure 122).

   

   Figure 122

   1. U-bolt
   2. Height-of-cut chain

5. Start the engine and slowly raise the center cutting unit.

6. Slowly raise each side cutting until the center of gravity shifts and the deck starts to rotate into the upright position.

7. Shut off the engine and remove the ignition key.

1. Slowly lower the wing cutting units until the center of gravity shifts and the center cutting unit rotates downward.

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

3. Shut off the engine, wait for all parts to stop moving, and remove the key.

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

5. Pivot the dampers upward into position and secure with a clevis pin and cotter pin.

1. Remove the locknut from the bolt holding the caster-wheel assembly between the caster fork (Figure 126) or the caster-pivot arm (Figure 127).

   Note: Grasp the caster wheel and slide the bolt out of the fork or pivot arm.

   

   Figure 126

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

   Figure 127

   1. Caster wheel
   2. Caster-pivot arm
   3. Bearing
   4. Bearing spacer

2. Remove the bearing from the wheel hub and allow the bearing spacer to fall out (Figure 126 and Figure 127).

3. Remove the bearing from the opposite side of the wheel hub.

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

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

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

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

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

The hinge cover prevents debris from escaping at hinge points between cutting units. If the cover(s) become damaged or worn, replace them.

Figure 128

1. Hinge point

After striking a foreign object, inspect the machine for damage and make repairs before starting and operating the equipment. Torque all of 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, shut off the engine, and remove the ignition key.

   Note: Block the cutting unit to prevent it from accidentally falling.

2. Rotate the blade until the ends face forward and backward and measure from the inside of the cutting unit to the cutting edge at the front of the blade (Figure 129).

   Note: Remember this dimension.

   

   Figure 129

3. Rotate the opposite end of the blade forward and measure between the cutting unit and cutting edge of the blade at the same position as in step 2.

   Note: 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 Cutting-Unit Blade(s).

Replace the blade if it hits a solid object, is out of balance, or is bent. Always use genuine Toro replacement blades to ensure safety and optimum performance.

1. Park the machine on a level surface, raise the cutting unit to the transport position, engage the parking brake, shut off the engine, and remove the key.

   Note: Block or lock the cutting unit to prevent it from accidentally falling.

2. Grasp the end of the blade using a rag or thickly-padded glove.

3. Remove the blade bolt, anti-scalp cup, and blade from the spindle shaft (Figure 130).

   

   Figure 130

   1. Blade bolt
   2. Anti-scalp cup

4. Install the blade, anti-scalp cup, and blade bolt and 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 spindle-pulley nuts to 115 to 149 N∙m (85 to 110 ft-lb).

Both cutting edges and the sail, which is the turned-up portion opposite of the cutting edge, contribute to a good quality of cut.

Maintain sharp blades throughout the cutting season. Sharp blades create a clean cut without tearing or shredding the grass blades.

Check the blades for any wear or damage. The sail lifts the grass up straight, thereby producing an even cut and gradually wears down during operation.

1. Park 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, shut off the engine, and remove the key from the ignition.

2. Examine the cutting ends of the blade carefully, especially where the flat and curved parts of the blade meet (Figure 131).

   Note: Because sand and abrasive material can wear away the metal that connects the flat and curved parts of the blade, check the blade before using the mower. If you notice wear (Figure 131), replace the blade.

   

   Figure 131

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

3. Examine the cutting edges of all of the blades and sharpen the cutting edges if they are dull or nicked (Figure 132).

   Note: Sharpen only the top of the cutting edge and maintain the original cutting angle to ensure sharpness (Figure 132). The blade remains balanced if the same amount of metal is removed from both cutting edges.

   

   Figure 132

   1. Sharpen at the 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 Cutting-Unit Blade(s).

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

1. Park the machine on a level surface.

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 and remove the covers from the top of the cutting unit.

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

5. Rotate the blades until the ends face forward and rearward and measure from the floor to the front tip of the cutting edge. Remember this dimension.

6. 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, as it is bent. Measure all the blades.

7. Compare the measurements of the outer blades with the center blade.

   Note: 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 8 and add shims between the spindle housing and the bottom of the cutting unit.

8. Remove the bolts, flat washers, lock washers, and nuts from the outer spindle in the area where you must add the shims.

   Note: 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.

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

Important: Use care around the cab seals and lights (Figure 133). If you are using a pressure washer, keep the washer wand at least 0.6 m (2 ft) away from the machine. Do not use the pressure washer directly on the cab seals and lights or under the rear overhang.

Figure 133

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

1. Remove the screws and grates from both the in-cab and rear cab air filters (Figure 134 and Figure 135).

   

   Figure 134

   In-Cab Air Filter

   1. Filter
   2. Grate
   3. Screw
   

   Figure 135

   Rear Cab Air Filter

   1. Filter
   2. Grate
   3. Screw

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

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

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

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

1. Rotate the screen cover down.

2. Clean the filter with water.

   Note: Do not use a pressure washer.

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

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

4. Rotate the filter screen around the tabs until the latch locks into the latch-mount assembly (Figure 136).

   

   Figure 136

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

1. Shut off the engine and remove the key.

2. Remove the 6 nuts and washers from the bottom of the rear of the cab (Figure 137).

   

   Figure 137

   1. Washer
   2. Nut

3. Remove the cabin roof of the cab by removing the 22 bolts that secure the roof (Figure 138).

   

   Figure 138

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

4. Remove the air filters (Figure 138).

5. Remove and clean the air-conditioning coils (Figure 138).

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