Operator’s Manual Part No. 111-1037 Rev A Reelmaster 4240-D Code: 652D-Serial No.
ATTENTION THIS SYMBOL MEANS BE ALERT! YOUR SAFETY IS INVOLVED READ THIS MANUAL BEFORE USING THE REELMASTER® 4240-D. IT IS ESSENTIAL THAT OPERATORS STUDY IT FOR THEIR OWN SAFETY. ALL OPERATORS SHOULD SEEK AND OBTAIN PROFESSIONAL AND PRACTICAL INSTRUCTIONS ON THE SAFE USE OF THE MOWER. THESE SERVICES ARE AVAILABLE THROUGH TORO APPROVED COMMERCIAL DEALERS.
1.4 CONTENTS 1.4 CONTENTS Page No. SAFETY PRECAUTIONS. Training. Preparation. Operation. Handling and storage of fluids. Maintenance and storage. Decals. EC CONFORMITY INFORMATION. Noise levels / Vibration Levels. EC Declaration of Conformity. INTRODUCTION. SPECIFICATIONS. Engine. Transmission system. Cutterhead drive system. Cutterhead lift system and steering. Hydraulic system. Vehicle specifications. Operator controls. Instrumentation. Weight and dimensions.
CONTENTS 1.5 1.5 Continued. Page No. Fuel level gauge. Hourmeter. Transmission neutral indicator light. Cutterhead drive switch indicator light. Parking brake indicator light. Hydraulic return filter indicator light. Hydraulic transmission filter indicator light. Transmission system ‘Work’ mode indicator light. Cutterhead position control. Dual lift configuration control. Cutterhead drive engagement. Weight transfer/traction assistance. Starting the engine. Stopping the engine. General operating hints.
SAFETY PRECAUTIONS 1.6 1.6 READ THIS MANUAL BEFORE USING THE REELMASTER® 4240-D, IT IS ESSENTIAL THAT OPERATORS STUDY IT FOR THEIR OWN SAFETY. THE FOLLOWING PRECAUTIONS MUST BE TAKEN TO HELP PREVENT ACCIDENTS. A CAREFUL OPERATOR WHO USES COMMON SENSE IS THE SAFEST OPERATOR. TRAINING Read the instructions carefully. Be familiar with the controls and the proper use of the equipment. Learn how to stop the mower quickly in an emergency.
1.7 PREPARATION SAFETY PRECAUTIONS 1.7 Continued. Ensure that the cutterheads are fully raised with the latches and safety locks engaged in position before transporting the mower. Replace faulty silencers. Check the condition of the tyres and ensure that they are inflated to the correct pressures, refer SPECIFICATIONS. This is particularly important if the machine is to be taken on the public highway. Check that the mower is in good working order, paying particular attention to the brakes and steering.
SAFETY PRECAUTIONS 1.8 OPERATION 1.8 Continued. Do not use on a slope of more than 16 degrees. Care should be taken when using the mower on any slope where ground conditions are such that there may be a risk of the mower rolling over. The requirements of SI 1998 No. 2306 “Provision and Use of Work Equipment Regulations” should be considered. Stability angles given are maximum figures for a machine equipped with a R.O.P.S and are for guidance only.
1.9 OPERATION SAFETY PRECAUTIONS 1.9 Continued. Watch out for traffic when crossing or near roadways. Use extreme caution when reversing. Disengage the cutterhead drive system before crossing surfaces other than grass. When using the machine, never direct the discharge of material towards bystanders or allow anyone near the machine while in operation. Never operate the mower with damaged guards, shields or without safety protective devices in place and in good working order.
1.10 SAFETY PRECAUTIONS 1.10 HANDLING AND STORAGE OF FLUIDS Hydraulic Oil - Avoid contact with eyes and prolonged contact with skin. - Protective goggles should be worn when pouring. - Use of gloves or barrier cream is recommended. - Wash hands thoroughly after contact. - Store under cover, away from heat and sources of ignition. Diesel Oil - Avoid skin and eye contact. - Wear impervious gloves when regular contact is likely and goggles when there is risk of splashing.
1.11 SAFETY PRECAUTIONS 1.11 MAINTENANCE AND STORAGE Take care when rotating a cutting cylinder as this can cause other cylinders to rotate. When the machine is to be parked, stored or left unattended, lift the cutterheads to the transport position and engage the safety locks or lower the cutterheads to the ground. Keep all nuts, bolts, and screws tight to be sure the equipment is in safe working condition. Allow the engine to cool before storing in any enclosure.
1.12 SAFETY PRECAUTIONS 1.12 DECALS b a P I II III P j Decal - Inclines Part No: 111-0936 (A) e d O 994912 (REV. 1) Decal - Control Panel Part No: 994912 (1) Location: Control Panel.
SAFETY PRECAUTIONS 1.13 DECALS 1.13 Continued. Decal - Jacking / Support Point Part No: 70-13-072 Location: Front Axle - 2 Points Rear Towing Eye Jacking and support point Decal - Engine Fan / Radiator Part No: 70-13-073 Location: Engine Fan Cowl a) Danger of severing fingers b) Caution c) Warning - Hot surfaces Decal - Tyre Pressure Part No.
SAFETY PRECAUTIONS 1.14 DECALS 1.14 Continued. Decal - Serial Number Location: Rear Bulkhead RM4240-D REELMASTER RPM:2800 kW:35.3 kg:1750 Code Serial No: 652D 270000001 105dB Decal - Prevent Platform Damage Part No. 924828 Location : Platform, Seatwell PREVENT PLATFORM DAMAGE ! ENGAGE PARKING BRAKE AND DROP CUTTERHEADS BEFORE RAISING/LOWERING PLATFORM. POUR EVITER DES DOMMAGES, METTRE LE FREIN DE PARKING ET POSER LES TETES DE COUPES AVANT DE BOUGER LA PLATE-FORME. ..
1.15 EC CONFORMITY INFORMATION 1.15 NOISE LEVELS Operators Daily Personal Noise Exposure: The Toro Company has no control over site conditions, duration of use, state of maintenance or adjustment of the mower.
1.16 EC CONFORMITY INFORMATION 1.16 EC DECLARATION OF CONFORMITY EC DECLARATION OF CONFORMITY Manufactured for The Toro Company By: HAYTER LIMITED, Spellbrook, Bishop’s Stortford, Herts. CM23 4BU.
INTRODUCTION 1.17 1.17 INTRODUCTION The Toro Reelmaster® 4240-D is a diesel engine powered self propelled machine with hydraulic systems for ground drive, cutterhead drive, cutterhead lift and steering. The machine operates in four wheel drive at all times, however, the transmission system can be operated in both ‘work’ and ‘transport’ modes. These modes can be selected by the operator.
1.18 SPECIFICATIONS 1.18 SPECIFICATIONS ALL FIGURES ARE NOMINALLY QUOTED AT THE RATED ENGINE SPEED OF 2800 RPM UNLESS OTHERWISE STATED. ENGINE Type: Kubota V2203 Diesel. 4 Cylinders in line. Power Rating: 35.3 kw (47.3hp) @ 2800 RPM. DIN 70020. Capacity: 2197 cc (134 cu in). Air Cleaner: Clean air drawn through screened air intake in-front of radiator via a cyclonic air cleaner with built in pre-cleaner. Cooling System: Water-Cooled. Battery: 12V. 480 Amps S.A.E. Alternator: 40 Amps.
1.19 SPECIFICATIONS 1.19 TRANSMISSION SYSTEM Drive Type: Hydraulic. Pump: Variable displacement hydraulic piston pump with integral charge pump servo assisted. Wheel Motors: Front Axle - ‘Twin Lock’ Radial piston, fixed displacement, with integral disc brake (pressure released). Rear Axle - Radial piston, fixed displacement. Differential Lock: Electro - hydraulic control valve with pedal control (only available in ‘Work’ mode). Drive: Four wheel drive in ‘Work’ and ‘Transport’ modes.
1.20 SPECIFICATIONS 1.20 CUTTERHEAD LIFT SYSTEM AND STEERING Drive Type: Hydraulic. Pump: Hydraulic gear pump with integral relief valve. Delivery Rate: 11 Litres per minute (2.9 UK gallons per minute). Steering: Power beyond hydrostatic steering valve with priority flow to steering and auxiliary flow to cutterhead lift system. Manual emergency steering. Cutterhead Lift Control: Mechanical-hydraulic. Wing Units: Mechanical spring power assistance to lower. Relief Valve: 105 bar (1522 psi).
SPECIFICATIONS 1.21 1.21 VEHICLE SPECIFICATIONS Travel Speed: Tyres 0-25 km/h (0-15 mph) forward. 0-11 km/h (0-7 mph) reverse. Tyre Type Recommended Tyre Pressures Road Conditions Turf Conditions Max Pressure Front axle 26 x 12 - 12 4 ply Trelleborg turf pattern. 0.7 bar (10 psi ) 1.4 bar (20 psi) 1.7 bar (25 psi) Rear axle 20x10.0-8 4 ply Dico turf pattern. 0.7 bar (10 psi). 1.4 bar (20 psi) 1.7 bar (25 psi) Wheel Nut Torque Setting: Front axle Rear axle 200Nm (148 Ibf.
1.22 SPECIFICATIONS 1.22 OPERATOR CONTROLS Steering: Automotive padded steering wheel with adjustable steering column. Cylinder Drive: Electrical switch (forward - off - reverse). Engine Speed: Hand operated lever. Parking Brake: Hand operated lever. Forward and Reverse: Separate foot operated pedals. Ignition: Key start, shut - off and engine preheat. Differential Lock: Foot pedal. ‘Work’ or ‘Transport’ modes: Electrical Switch. Cutterhead Position: Hand operated lever.
SPECIFICATIONS 1.23 1.23 WEIGHT AND DIMENSIONS Wheel Base: 1610 mm (63.4") . Working Width: 3640 mm (143.3"). Cutting Width: 3460 mm (136.2"). Transport Width: 1850 mm (72.8") at 13mm (0.5") height of cut. Overall Length: 2930 mm (115.4"). Overall Height: 1750 mm (68.9") with R.O.P.S folded. 2404 mm (94.6") with R.O.P.S in its vertical operating position. Approx. Working Weight: Including 2 post R.O.P.S, 8 inch 6 blade cutterheads and full tank of fuel.
1.24 SPECIFICATIONS 1.24 CUTTERHEADS MK3 200mm Cutterhead MK3 254mm Cutterhead Cutting Width: 762 mm (30"). 762 mm (30"). Cylinder Diameter: 200 mm (8"). 254 mm (8"). Cylinder Speed: 1050 rpm approx. 1050 rpm approx. Height of Cut: 12mm(.5") - 80mm(3"). 12mm(.5") - 80mm(3"). Number of Blades: 4, 6, 8, 10 4, 6 Smooth Rear Roller: Standard. Standard. Smooth Front Roller: Optional. - Grooved Front Roller: Optional. - Configuration: Fixed / Floating. Fixed.
1.25 OPERATING THE MOWER 1.25 SAFETY NOTICE WARNING: PREVENT ACCIDENTS - Before operating the mower it is essential that; - The operator reads and understands this manual. - The operator platform latching mechanism is fully engaged and in good working order, refer Operator Platform Latching Mechanism. - The daily maintenance checks have been properly carried out and the mower is in good working order. - The operator should wear safety clothing and eye protection.
1.26 OPERATING THE MOWER 1.26 IDENTIFICATION OF CONTROLS 1. Parking brake lever. 2. Lighting switch (supplied with lighting kit). 3. Warning beacon switch (supplied with beacon kit). 4. Hazard warning switch (supplied with lighting kit). 5. Cutterhead position controls. 6. Throttle control lever. 7. Ignition key. 8. Cutterhead drive switch. 9. Dip beam / main beam light switch (supplied with lighting kit). 10. Direction indicator switch (supplied with lighting kit). 11. Horn button. 12.
1.27 OPERATING THE MOWER 1.27 BRAKING SYSTEM Parking Brake Engaged Parking Brake : Move the parking brake lever to its rear position to engage the parking brake. Do not operate the mower with the parking brake engaged. P WARNING : PREVENT ACCIDENTS - The parking brake operates on the front wheels only. Do not park the mower on a slope. Service brakes : Service braking is achieved by the hydraulic transmission system.
1.28 OPERATING THE MOWER 1.28 WORK/TRANSPORT MODES WARNING : PREVENT ACCIDENTS - Ensure that the mode elected is appropriate to the mode of operation of the machine. Select ‘Work’ mode when operating the mower in conditions of poor traction when maximum tractive performance is required. Selecting ‘Work’ mode will enable the use of the differential lock. Select ‘Transport’ mode when operating the mower in conditions of good traction.
1.29 OPERATING THE MOWER 1.29 DIFFERENTIAL LOCK WARNING : PREVENT ACCIDENTS - Do not engage the differential lock at high speed. The turning circle will increase with the differential lock engaged. The differential lock is effective only when ‘Work’ mode is selected. The differential lock operates in both ‘forwards’ and ‘reverse’ and can be engaged whilst the mower is travelling slowly. Engage the differential lock to prevent excessive wheel spin when the drive wheels lose traction.
OPERATING THE MOWER 1.30 1.30 FORWARD TRAVEL SPEED BACKSTOP LEVER The backstop lever can be used to limit the movement of the forward pedal for accurate forward travel speed, and the clip rate required. Operate the lever in a forward direction to increase the travel speed setting and in a rearward direction to decrease. Note: This is not a cruise control device. Releasing the forward travel pedal will allow it to return to neutral.
1.31 OPERATING THE MOWER 1.31 ADJUSTABLE STEERING COLUMN WARNING: PREVENT ACCIDENTS - Before operating the mower, ensure that the steering column adjuster mechanism is in good working order and that the steering wheel is locked securely in position. WARNING: PREVENT ACCIDENTS - Adjustment of the steering wheel and steering column should only be carried out when the mower is at a standstill with the parking brake engaged.
1.32 OPERATING THE MOWER 1.32 FOLDING THE ROPS The R.O.P.S frame may be folded down to allow access into areas of restricted height. WARNING: PREVENT ACCIDENTS - While the R.O.P.S frame is folded down it does not provide any protection in the event of a roll-over and should not be considered as a Roll Over Protective Structure. 1). Lower all cutterheads, apply the parking brake and switch of the engine. 2).
OPERATING THE MOWER 1.33 1.33 fig.
1.34 OPERATING THE MOWER 1.34 OPERATOR SEAT WARNING: PREVENT ACCIDENTS - Before operating the mower ensure that the operator seat mechanisms are in good working order and that the seat is locked securely in position. WARNING: PREVENT ACCIDENTS - Adjustment of the seat mechanisms should only be carried out when the mower is at a standstill with the parking brake engaged. Fore/Aft Adjustment: Move lever ‘B’ upwards to adjust the Fore/Aft position of the seat.
1.35 OPERATING THE MOWER 1.35 WARNING SYSTEMS Engine coolant overheating warning : The engine coolant warning light illuminates and the horn is actuated. Hydraulic oil overheating warning : The hydraulic oil warning light illuminates and the horn is actuated when the hydraulic oil in the reservoir exceeds 95˚C (203oF) approx. Low battery charge warning : The battery charge warning light illuminates. Low engine oil pressure warning light : The engine oil pressure warning light illuminates.
1.36 OPERATING THE MOWER 1.36 IGNITION KEY O 0 = Engine off. I II I = Engine run / Auxiliary on. II = Engine pre-heat. III = Engine start. III WARNING : PREVENT ACCIDENTS - Always remove the ignition key when the mower is not in use. IMPORTANT : PREVENT DAMAGE - Always fit the protective cap when the ignition key is removed to prevent ingress of dirt and moisture from damaging the mechanism. ENGINE PRE-HEAT INDICATOR LIGHT Turn the ignition key to position II.
1.37 OPERATING THE MOWER 1.37 TRANSMISSION NEUTRAL INDICATOR LIGHT Illuminates when the travel control pedal is in the neutral position and the ignition key is turned to position ‘I’. Note: The parking brake must be engaged for the transmission neutral indicator light to illuminate. N WS041 CUTTERHEAD DRIVE SWITCH INDICATOR LIGHT Illuminates when the cutterhead drive switch is in the ‘off’ position and the ignition key is turned to position ‘I’.
1.38 OPERATING THE MOWER 1.38 CUTTERHEAD POSITION CONTROL 4A953B03A 1 The cutterheads may be raised or lowered using the bank of 3 lift control levers. 2 3 To lower the cutterheads, operate the lift control levers in a downward direction until locked in position 1. If the cutterhead drive switch is in the ‘ON’ position, the cylinder drive will engage when the cutterheads are approximately 300mm(11.8") above ground level.
1.39 OPERATING THE MOWER 1.39 CUTTERHEAD DRIVE ENGAGEMENT The cutterhead drive can be engaged only when the operator is seated correctly, refer - OPERATOR PRESENCE CONTROLS. Briefly operate the lift control levers to raise the cutterheads, thereby removing the cutterhead suspension deadweights and wing units stored energy reaction from the transport latch mechanisms. 1 2 3 Release the cutterhead latches.
OPERATING THE MOWER 1.40 1.40 WEIGHT TRANSFER / TRACTION ASSISTANCE A variable hydraulic weight transfer system is provided for improving tyre grip with the grass surface ‘Traction Assistance’. Hydraulic pressure in the cutterhead lift system provides a lifting force which reduces cutterhead weight on the ground and transfers the weight as a downward force onto the mower’s tyres. This action is known as ‘Weight Transfer’.
OPERATING THE MOWER 1.41 STARTING THE ENGINE 1.41 Continued. O I II Starting a cold engine: Set the throttle control lever to approximately 70% full throttle. III Turn the ignition key to the ‘ignition on’ position "I" and check that the engine oil pressure and battery charge warning lights illuminate. Turn the ignition key to the ‘preheat’ position "II" and hold until the engine pre-heat indicator light goes out. Turn the ignition key to the ‘start’ position "III" and hold to crank the engine.
1.42 OPERATING THE MOWER 1.42 GENERAL OPERATING HINTS 1. The rotational speed of the cutting cylinders should always be kept as high as possible in order to maintain the highest quality of cut. This in turn requires that the engine speed be kept as high as possible. 2. The quality of cut will deteriorate if the forward speed is excessive. Always balance the quality of cut with the workrate required and set the forward speed accordingly. 3. Never let the engine labour.
1.43 OPERATING THE MOWER 1.43 UNBLOCKING CUTTING CYLINDERS WARNING: PREVENT ACCIDENTS - Before attempting to clear any blockage from the cutting cylinders on this machines ensure all of the following: - Stop the machine on level ground. - Apply the parking brake and disengage all drives. - Lower the cutting units to the ground or securely lock in the designated transport positions. - Stop the engine and remove the ignition key to isolate all power sources and check that they are stopped.
1.44 OPERATING THE MOWER 1.44 CUTTERHEAD GENERAL INFORMATION The mower is designed to be used with MK3 200mm(8") fixed or floating cutterheads or MK3 254mm(10") fixed cutterheads. It is essential that the relationship between the bottom blades and the cutting cylinders are kept in good adjustment and that cutting edges are kept sharp to ensure good cutting performance, minimum power consumption and prolonged life for the cutting edges, refer - MAINTENANCE - Cutterheads.
1.45 OPERATING THE MOWER 1.45 MK3 200mm(8") FIXED CUTTERHEAD B Height of cut adjustment: The height of cut is gauged by the position of the rear roller. Turn the adjusting nut assembly ‘B’ both ends clockwise to decrease height of cut ‘E’ or anti-clockwise to increase height of cut ‘E’. E 1D876P08B IMPORTANT: PREVENT DAMAGE - Do not attempt to unlock the nut assemblies, ‘B’.
1.46 OPERATING THE MOWER 1.46 MK3 200mm(8") FLOATING CUTTERHEAD A Pivot knuckle fixing: Secure the bolt in the rear “floating” slot position ‘A’ as shown. 1D876P07A B Height of cut adjustment: The height of cut is gauged by the position of the front and rear rollers. To alter the rear roller position, turn the adjusting nut assembly ‘B’ both ends clockwise to decrease height of cut ‘E’ or anti-clockwise to increase height of cut ‘E’.
1.47 MAINTENANCE 1.47 MAINTENANCE WARNING : PREVENT ACCIDENTS - When carrying out maintenance procedures it is essential that: - The engine is switched off and the ignition key removed. - The parking brake is applied. - There is no pressure in the hydraulic system. - The cutterheads are fully down on the ground. - The safety precautions in this manual have been read and understood. WARNING : PREVENT ACCIDENTS - Stored energy devices and systems are used on the Reelmaster® 4240-D.
MAINTENANCE 1.48 MAINTENANCE 1.48 Continued. WARNING : PREVENT ACCIDENTS - Use hazardous substances carefully. The following fluids are identified as being hazardous; Substances Assessed risk Diesel oil Lubricating oil Hydraulic oil Grease Anti - freeze Battery acid Low Low Low Low Medium High When using any of the above fluids it is recommended that eye protection and gloves are worn and that care is taken to prevent spillage. Avoid contact with skin; wash off spillage with soap and water.
MAINTENANCE 1.49 1.49 ENGINE ENGINE Refer to the Engine Operator's Manual for maintenance information. RUNNING IN PERIOD Check wheel nut torque settings: During first 50 hours of use and in addition to routine checks. Refer DAILY AND BEFORE USE. Check wheel nut torques twice a day. Front axle wheel nut torque setting - 200 Nm (148 Ibf.ft). Rear axle wheel nut torque setting - 54 Nm (40 Ibf.ft).
MAINTENANCE 1.50 RUNNING IN PERIOD - AT FIRST 50 HOURS 1.50 Continued. Change the hydraulic oil return filter: Unscrew and remove the return filter canister and discard. Refit a new filter canister (part no. 924692). Left Hand Side of Machine 2 1 1P953C16A 1. Hydraulic oil return filter. 2. Engine fuel filter.
1.51 MAINTENANCE 1.51 DAILY AND BEFORE USE Check engine oil level: If the oil level is below the upper mark on the dipstick, top up with the correct grade of engine oil to the required level, refer - ENGINE MANUAL. Check engine radiator coolant level: WARNING: PREVENT ACCIDENTS - Avoid scalding. DO NOT remove the radiator filler cap unless the engine is cool. Turn the filler cap slowly to release system pressure before removing the filler cap completely. ONLY REMOVE RADIATORCAPWHEN ENGINEIS COOL.
1.52 DAILY AND BEFORE USE MAINTENANCE 1.52 Continued. 2 Clean the radiator screen: Clean the radiator screen. Check the oil cooler and engine radiator grille for debris and clean as necessary, using a brush or airline. If water is used, these areas should be allowed to dry out completely before use. 1 3 IMPORTANT: PREVENT DAMAGE - NEVER operate the mower with a damaged radiator screen or engine damage could result from overheating. Clean the radiator screen more regularly in dry conditions. 1.
1.53 DAILY AND BEFORE USE MAINTENANCE 1.53 Continued. Check hydraulic hose-lines: Inspect hydraulic hose-lines for signs of wear or damage. WARNING: PREVENT ACCIDENTS - ALWAYS replace worn or damaged hydraulic hose-lines immediately. DO NOT operate the mower with defective hydraulic hose-lines. Inspect the mower for signs of oil leakage. Tighten fittings or replace seals as required. Check fasteners: Check that all nuts, bolts and pins are secured correctly in place and in good condition.
1.54 DAILY AND BEFORE USE MAINTENANCE 1.54 Continued. Check operator presence controls: WARNING : PREVENT ACCIDENTS - Keep bystanders away when checking operator presence control interlock switches. DO NOT use the mower unless the operator presence controls work correctly as described below. If difficulties arise, consult your "Toro dealer”. Operator presence seat switch: Sit on the operator seat and start the engine.
1.55 MAINTENANCE 1.55 EVERY 50 HOURS Perform routine checks : Refer - DAILY BEFORE USE. Check cutterhead roller bearing adjustment: IMPORTANT : PREVENT DAMAGE - It is essential that the cutterhead roller bearings are kept in good adjustment in order to ensure maximum working life. If end float is allowed to become excessive, premature bearing failure will result. Grip the roller and move from side to side and up and down.
MAINTENANCE 1.56 EVERY 50 HOURS 1.56 Continued. Grease pivot points : Clean and grease all grease points with a good quality compound of the grade specified, refer SPECIFICATIONS. Replace any grease nipples which are damaged. Grease all cutterhead grease points and ensure that sufficient grease is injected such that clean grease is seen to escape from the roller end caps. This provides visible evidence that the roller seals have been purged of grass debris etc. and will ensure maximum working life.
1.57 MAINTENANCE 1.57 EVERY 250 HOURS Perform routine checks : Refer - DAILY BEFORE USE. - EVERY 50 HOURS. Check battery condition : WARNING : PREVENT ACCIDENTS - Explosive gases are produced by the battery. Work in a well ventilated area, away from all sources of ignition. Battery fluids are corrosive. Take care to avoid contact with the skin or eyes. In the event of a spillage, drench the affected area with water. If the eyes are affected, seek medical attention.
MAINTENANCE 1.58 1.58 EVERY 500 HOURS Perform routine checks : refer - DAILY BEFORE USE. - EVERY 50 HOURS. - EVERY 250 HOURS. Thoroughly clean the machine: IMPORTANT: PREVENT DAMAGE - Keep water away from electrical components. Use a dry cloth or brush to clean such areas. Service the hydraulic system : This procedure is best carried out when the hydraulic oil is warm (not hot). Lower the cutterheads to the ground and drain the hydraulic system by removing the hydraulic tank drain plug.
MAINTENANCE 1.59 EVERY 500 HOURS 1.59 Continued. Renew the engine air cleaner filter: Check the condition of the air cleaner hoses. Replace any hose which is damaged and tighten the connections, refer ENGINE MANUAL. ENGINE Renew the engine fuel filter element: Refer - ENGINE MANUAL. ENGINE Check electrical system: Inspect all electrical connections and cables and replace any which are damaged or corroded. Spray a good quality water inhibitor on to exposed connections to prevent moisture ingress.
MAINTENANCE 1.60 EVERY 500 HOURS 1.60 Continued. Check the engine overheat warning system: Turn the ignition key to the ‘ignition on’ position 'I'. Disconnect the red/grey wire terminal from the engine temperature switch and touch the metal terminal of this wire onto a suitable earth point, ensuring that the metal surfaces make good contact. The horn will sound and the engine coolant temperature warning light will illuminate to confirm correct operation.
1.61 MAINTENANCE 1.61 CUTTERHEAD CYLINDER TO BOTTOM BLADE ADJUSTMENT IMPORTANT : PREVENT DAMAGE - It is essential that the relationship between the bottom blades and the cutting cylinders is kept in good adjustment in order to ensure good cutting performance, minimum power consumption and prolonged life for the cutting edges. Carry out the following procedure before commencing work and re-check the settings every few hours.
MAINTENANCE 1.62 1.62 CUTTERHEAD BACKLAPPING This process is recommended for restoring the sharp cutting edges to cylinders and bottom blades which are essential for good quality grass cutting. This process can only deal with a small amount of metal removal to restore the cutting edges. If the blade edges are seriously worn or damaged it will be necessary to remove the component parts and have them reground. The backlapping process: 1.
1.63 MAINTENANCE 1.63 CUTTERHEAD GRINDING It will be necessary to carry out a grinding operation to correct cylinder spiral edges or bottom blade edges which have become excessively rounded or distorted. Bottom blades which are nearing the end of their wear life should be replaced. The new blades should be ground on their holders prior to fitting, refer - CUTTERHEAD BOTTOM BLADE REPLACEMENT.
1.64 MAINTENANCE 1.64 RAISING THE MOWER OFF THE GROUND WARNING: PREVENT ACCIDENTS - Before raising the mower ensure that: - The lifting device to be used is in good condition and capable of supporting the weight of the mower securely. Minimum lift capacity 2000 Kg (2 tons). - The mower is on level ground. - The parking brake is applied. - The engine is switched off and the ignition key removed. - The ground under the lifting device is level and firm.
MAINTENANCE 1.65 1.65 TOWING THE MOWER Towing procedure : Connect a rigid tow bar between the towing eye on the mower and a suitable towing vehicle. Ensure that the towing vehicle specification is suited to braking the combined vehicle weight to rest whilst effecting complete control at all times. Ensure that the towing vehicle’s parking brake is applied. Chock the mower front wheels to prevent the mower rolling away.
1.66 TOWING THE MOWER MAINTENANCE 1.66 Continued. De-commission the hydraulic service braking system as follows:- Bypass Valve Open the transmission bypass valve situated as shown on top of the transmission pump. The valve is fully open at 3 anti-clockwise revolutions. Do not open the valve past 3 revolutions. The steering must be operated manually when the mower is being towed. The steering will feel heavy as there is no hydraulic assistance when the engine is switched off.
1.67 GRASS CUTTING FAULTS 1.67 GRASS CUTTING FAULTS FAULT POSSIBLE CAUSE REMEDY Areas of uncut grass at point of overlap between cutting cylinders. Turning too tightly. Reduce turning radius. Mower sliding sideways when travelling across face of a slope. Mow up/down slope. One end of cutterhead out of ground contact caused by: Ridge lines in the cut across the direction of travel over full width. - Poorly routed hoses or wrongly positioned hydraulic adaptors.
1.68 GRASS CUTTING FAULTS GRASS CUTTING FAULTS 1.68 Continued. FAULT POSSIBLE CAUSE REMEDY Some uncut or poorly cut strands of grass.. Cutting cylinder is partially out of contact with the bottom blade. Readjust cutting cylinder to bottom blade. Cutting cylinder is in heavy contact with the bottom blade. Readjust cutting cylinder to the bottom blade. Height of cut is too high. Lower height of cut setting. Cutting edges of cutting cylinders/bottom blades are rounded.
1.69 GRASS CUTTING FAULTS GRASS CUTTING FAULTS 1.69 Continued. FAULT POSSIBLE CAUSE REMEDY Excessive bottom blade wear.. Bottom blade in heavy ground contact. Raise height of cut. Cutting edges of the cutting cylinder/bottom blade are rounded. Backlap or regrind to restore cutting edges. Cylinder is in heavy contact with the bottom blade. Readjust the cutting cylinder to the bottom blade. Damaged cutting cylinder or bottom blade. Regrind or replace as necessary.
1.70 TROUBLE SHOOTING 1.70 TROUBLE SHOOTING When using the following chart it may be found that overhaul of major components or hydraulic pressure adjustments are necessary. In this case it is recommended that your dealer make these repairs as he is properly equipped to do this work. WARNING: PREVENT ACCIDENTS - ALWAYS Apply the parking brake, switch off the engine and remove the ignition key before attempting to work on the mower.
TROUBLE SHOOTING 1.71 TROUBLE SHOOTING 1.71 Continued. PROBLEM POSSIBLE CAUSE REMEDY Differential lock non operational. Defective switch. Check switch and replace if necessary. Defective solenoid valve. Service or replace solenoid valve. Defective wiring. Check wiring/connections as necessary. Blocked radiator screen. Clean screen. Blocked oil cooler fins. Clean fins. Blocked engine radiator matrix. Clean matrix. Low relief valve setting. Have relief valve cleaned and pressure checked.
1.72 TROUBLE SHOOTING TROUBLE SHOOTING 1.72 Continued. PROBLEM POSSIBLE CAUSE REMEDY Lack of transmission drive. Parking brake engaged. Release parking brake. Low oil level. Fill reservoir to correct level. Incorrect oil used. Drain reservoir and refill with correct oil. Defective travel pedal linkage. Check linkage and replace defective parts. Defective transmission pump. Have the transmission pump overhauled by your Toro dealer. Transmission relief valve open.
1.73 TROUBLE SHOOTING TROUBLE SHOOTING 1.73 Continued. PROBLEM POSSIBLE CAUSE REMEDY Excessive noise in hydraulic system. Faulty pump. Identify noisy pump and service or replace. Faulty motor. Identify noisy motor and service or replace. Air leaking into system. Tighten or replace hydraulic fittings particularly in suction lines. Suction strainer blocked or damaged. Clean and replace suction strainer or renew as necessary. Excessive oil viscosity due to cold conditions.
1.74 TROUBLE SHOOTING TROUBLE SHOOTING 1.74 Continued. PROBLEM POSSIBLE CAUSE REMEDY After initial satisfactory operation machine loses power. Worn pump or motor. Replace as necessary. Low hydraulic oil level. Fill hydraulic oil tank to correct level. Incorrect oil viscosity. Renew oil in hydraulic tank with hydraulic oil of correct viscosity grade, refer - SPECIFICATIONS. Oil filter element blocked. Change filter element. Faulty pressure relief valve.
1.75 TROUBLE SHOOTING TROUBLE SHOOTING 1.75 Continued. PROBLEM POSSIBLE CAUSE REMEDY One cylinder rotates slowly. Cutting cylinder bearing seized. Replace as necessary. Incorrect rotation motor fitted. Check motor and replace if necessary. Diverter valve only partly open. Free off and lubricate or replace diverter valve as necessary. Motor integral check valve jammed open. Have check valve cleaned and checked. Cutting cylinder tight on the bottom blade. Readjust setting. Motor worn.
1.76 TROUBLE SHOOTING TROUBLE SHOOTING 1.76 Continued. PROBLEM POSSIBLE CAUSE REMEDY Cutterheads fail to start up when lowered into work. Faulty seat sensor switch. Check mechanical and electrical operation of switch. Low oil level. Fill hydraulic oil reservoir to correct level. Diverter valve jammed. Free off and lubricate or replace the diverter valve as necessary. Sheared drive shaft. Check motor and cylinder drive shafts and replace if necessary.
35 34 30 B P/R G/P B B U/R U/R N W N/W W/R W/R 2 W/B P/R 1 P/Y 31 36 N/R G/U L/Y 30 29 W/B W/G 5 3 B B B G/N 37 6 N N/W 4 L/Y L L G/P G/P L B 57 58 L N/Y W/N L/Y W/B B 15 L/Y O 14 B/P 13 11 7 W/U B/P W/U N/B 9 W/Y W/P 12 10 O B 59 U/R 49a 56 49 N N R/S Y/B P/R Y/B P P/R U/R N/R P/B O P/R 21 U/B B U/B B 38 42 W/P 32 B W/U Y/B P/R B R U/G B 39 R N U/G B Y/B 19 18 N 17 16 41 W/R 22 30 17 58 15 W
1.78 ITEM NO. ELECTRICAL CIRCUIT DIAGRAM DESCRIPTION PART NO. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Switch - Parking Brake Interlock. Glow Plug Timer. Light - Parking Brake. Light - Glow Plugs. Light - Neutral. Light - Cutterhead Drive Off. Light - Return Filter. Light - Pressure Filter. Light - Battery Warning. Light - Engine Oil Pressure. Light - Engine Coolant Temperature. Light - Hydraulic Oil Temperature. Diodes - Overheat - Audible Warning.
35 34 30 B P/R G/P B B U/R U/R N W N/W W/R W/R 2 W/B P/R 1 P/Y 31 36 N/R G/U L/Y 30 29 W/B W/G 5 3 B B B G/N 37 6 N N/W 4 L/Y L L G/P G/P L B 57 58 L N/Y W/N L/Y W/B B 15 L/Y O 14 B/P 13 11 7 W/U B/P W/U N/B 9 W/Y W/P 12 10 O B 59 U/R 49a 56 49 N N R/S 31 P/R P/R 53 P P/R 8 Y/B P/R Y/B P P/R U/R N/R P/B O P/R 21 U/B B U/B B 8 7 6 5 4 3 2 42 W/P 32 B W/U Y/B P/R B R U/G B 39 R N U/G B Y/B 19 18
1.80 ITEM NO. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. ELECTRICAL CIRCUIT DIAGRAM DESCRIPTION PART NO. Alternator/Regulator. Engine Temperature Sender (supplied with temp kit). Glow Plugs. Switch - Engine Overheat. Solenoid - Fuel Engine. Hourmeter. Switch - Return filter. Solenoids - Work/Transport Mode.
1.81 TRANSMISSION / BRAKE - HYDRAULIC CIRCUIT 4P953C03 1.
1.82 ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 TRANSMISSION / BRAKE - HYDRAULIC CIRCUIT DESCRIPTION PART NO.
19 18 17 6 8 10 20 15 14 16 9 54 54 7 5 47 TPC D1 D2 D3 11 12 13 HL LB LBX 46 25 21 4 22 PX 45 26 2 23 1 34 31 28 P T B A 3 24 PX 44 35 33 32 30 29 27 53 50 52 51 DC RB MB 49 2P953C01A 48 T FB HL B2 D1 B1 37 22 42 39 PX P T B A 23 36 21 43 41 40 38 1.83 HYDRAULIC CIRCUIT DIAGRAM 1.
1.84 ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 HYDRAULIC CIRCUIT DIAGRAM DESCRIPTION 1.84 PART NO. Gear pump - Centre Cutterhead Drive. 74-06-154 Gear pump - Wing Cutterhead Drive. 74-06-154 Gear pump - Steering and Cutterhead Lift 74-06-154 Relief Valve - Steering 110 bar Steering Unit 910649W Check Valve - Steering Shock Bypass R.H. Check Valve - Steering Shock Bypass L.H.
WARRANTY 1.85 1.85 The Toro Commercial Parts Warranty A Ninety - Day Limited Warranty Conditions and Products Covered The Toro Company (Toro) and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial Product (“Part”) to be free from defects in materials or workmanship for ninety (90) days. Where a warrantable condition exists, we will repair the Part at no cost to you.
1.86 WARRANTY 1.86 The Toro General Commercial Products Warranty A Two-Year Limited Warranty Conditions and Products Covered The Toro Company (Toro) and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial Product (“Product”) to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first.
1.87 NOTES 1.
1.88 CUSTOMER INFORMATION 1.88 MACHINE DETAILS Model: Machine Serial No.: Engine Serial No.: Cutterhead Serial No.s: Transmission Pump Serial No.: Transmission Valve Block Front Serial No.: Cutter Control Valve (Front & Centre) Serial No.: Cutter Control Valve (Wing) Serial No.
