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Toro 30839 Operator'S Manual Download Page 33

Maintenance

Note:

Determine the left and right sides of the

machine from the normal operating position.

Recommended Maintenance Schedule(s)

Maintenance Service

Interval

Maintenance Procedure

After the first hour

• Torque the wheel-lug nuts.

After the first 10 hours

• Torque the wheel-lug nuts.
• Check the condition and tension of all belts.
• Change the hydraulic filter.

After the first 50 hours

• Change the engine oil and engine-oil filter.

Before each use or daily

• Check the tire pressure.
• Check the safety-interlock system.
• Check the engine-oil level.
• Drain the water separator.
• Check the engine-coolant level.
• Clean debris off the radiator and oil cooler (clean them more frequently in dirty

conditions).

• Check the hydraulic-fluid level.
• Check the hydraulic lines and hoses.
• Check the blade stopping time.

Every 25 hours

• Check the electrolyte level. (If the machine is in storage, check it every 30 days.)

Every 50 hours

• Lubricate all of the bearings and bushings.
• Remove the air-cleaner cover and clean out the debris. Do not remove the filter.

Every 100 hours

• Check the condition and tension of all belts.

Every 150 hours

• Change the engine oil and engine-oil filter.

Every 200 hours

• Torque the wheel-lug nuts.
• Service the air-cleaner filter. (More frequently in extreme dusty or dirty conditions)
• Check the parking-brake adjustment.
• Change the hydraulic filter.

Every 400 hours

• Replace the fuel filter.
• Change the hydraulic fluid.

Every 500 hours

• Grease the bearings in the rear axle.

Every 1,000 hours

• Drain and clean the fuel tank.

Every 2 years

• Drain and clean the fuel tank.

CAUTION

If you leave the key in the ignition switch, someone could accidently start the engine and
seriously injure you or other bystanders.

Remove the key from the ignition before you do any maintenance.

33

 

Summary of Contents for 30839

Page 1: ...505 D Rotary Mower Model No 30807 Serial No 316000001 and Up Model No 30839 Serial No 316000001 and Up Model No 30843 Serial No 316000001 and Up Model No 30849 Serial No 316000001 and Up Register at www Toro com Original Instructions EN 3397 962 B ...

Page 2: ...essional hired operators in commercial applications It is primarily designed for cutting grass on well maintained lawns in parks golf courses sports fields and on commercial grounds It is not designed for cutting brush mowing grass and other growth alongside highways or for agricultural uses Read this information carefully to learn how to operate and maintain your product properly and to avoid inj...

Page 3: ... Maintenance Procedures 35 Pre Maintenance Safety 35 Preparing the Machine for Maintenance 36 Removing the Hood 36 Using the Cutting Deck Service Latch 36 Lubrication 37 Greasing the Bearings and Bushings 37 Engine Maintenance 39 Engine Safety 39 Servicing the Engine Oil 39 Servicing the Air Cleaner 41 Fuel System Maintenance 43 Draining the Fuel Tank 43 Servicing the Water Separator 43 Bleeding t...

Page 4: ...always pay attention to the safety alert symbol which means Caution Warning or Danger personal safety instruction Failure to comply with these instructions may result in personal injury or death You can find additional items of safety information in their respective sections throughout this manual Sound Power Level This unit has a guaranteed sound power level of 104 dBA which includes an Uncertain...

Page 5: ...ead the Operator s Manual for further instructions decal100 4837 100 4837 decal93 7276 93 7276 1 Explosion hazard wear eye protection 2 Caustic liquid chemical burn hazard to perform first aid flush with water 3 Fire hazard no fire open flames or smoking 4 Poison hazard keep children a safe distance from the battery decal93 7818 93 7818 1 Warning read the Operator s Manual for instructions on torq...

Page 6: ... cut decal106 6755 106 6755 1 Engine coolant under pressure 3 Warning do not touch the hot surface 2 Explosion hazard read the Operator s Manual 4 Warning read the Operator s Manual decal104 0484 104 0484 Models 30807 30839 and 30843 6 ...

Page 7: ... keep bystanders a safe distance from the machine 4 Cutting hazard of hand or foot stay away from moving parts 5 Warning lock the parking brake stop the engine and remove the ignition key before leaving the machine decal106 6754 106 6754 1 Warning do not touch the hot surface 2 Cutting dismemberment hazard fan and entanglement hazard belt stay away from moving parts 99 3444 decal99 3444 99 3444 1 ...

Page 8: ...al help fast 5 Read the Operator s Manual 10 Contains lead do not discard decal117 4764 117 4764 1 Thrown object hazard keep bystanders a safe distance from the machine 2 Cutting hazard of hand mower blade stay away from moving parts and keep all guards and shields in place 3 Cutting hazard of foot mower blade stay away from moving parts and keep all guards and shields in place decal106 9290 106 9...

Page 9: ...decal117 5103 117 5103 Models 30839 30843 and 30849 decal121 3532 121 3532 Model 30807 1 Read the Operator s Manual 4 Optional light 15A 2 SCM 2A 5 System gauges 10A 3 Main 15A 6 Engine start 10A 9 ...

Page 10: ... s position 2 Turn the ignition key to the engine run position 3 Wait for the engine preheat light to turn off 4 Turn the ignition key to the engine start position 5 Disengage the parking brake 5 Middle and right decks 12 For more information on stopping the engine read the Operator s Manual 1 Disengage the PTO 2 Turn the ignition key to the engine stop position 3 Remove the key from the ignition ...

Page 11: ...rn the ignition key to the engine run position 3 Wait for the engine preheat light to turn off 4 Turn the ignition key to the engine start position 5 Disengage the parking brake 4 Raise the deck 10 For more information on stopping the engine read the Operator s Manual 1 Disengage the PTO 2 Turn the ignition key to the engine stop position 3 Remove the key from the ignition 4 Engage the parking bra...

Page 12: ...pping screw 4 Install the exhaust guard CE only 6 No parts required Adjust the lift arms 7 No parts required Adjust the carrier frame 8 No parts required Adjust the height of cut 9 No parts required Adjust the roller scraper optional 10 No parts required Install the mulching baffle optional Media and Additional Parts Description Qty Use Ignition keys 2 Start the engine Operator s Manual 1 Engine O...

Page 13: ...iller caps from the battery and slowly fill each cell until the electrolyte is just above the plates 3 Install the filler caps and connect a 3 to 4 A battery charger to the battery posts Note Charge the battery at a rate of 3 to 4 A for 4 to 8 hours WARNING Charging the battery produces gasses that can explode Keep sparks and flames away from battery Never smoke near the battery 4 When the battery...

Page 14: ...7 petroleum jelly or light grease to prevent corrosion 10 Slide the rubber boot over the positive terminal to prevent a possible short from occurring 11 Install the battery cover 2 Checking the Angle Indicator Models 30807 30839 and 30843 Only Parts needed for this procedure 1 Inclinometer Procedure 1 Park the machine on a flat level surface 2 Verify that the machine is level by placing a handheld...

Page 15: ... the hood latch bracket 2 Remove the 2 rivets securing the hood latch bracket to the hood Figure 6 g031570 Figure 6 1 Rivets 2 Hood latch bracket 3 Remove the hood latch bracket from the hood 4 While aligning the mounting holes position the lock bracket and the hood latch bracket onto the hood Figure 7 Note The lock bracket must be against the hood Note Do not remove the bolt and nut from the lock...

Page 16: ... 9 1 Bolt 3 Arm of the hood lock bracket 2 Nut 5 Installing the Exhaust Guard CE Models Only Parts needed for this procedure 1 Exhaust guard 4 Self tapping screw Procedure 1 Position the exhaust guard around the muffler while aligning the mounting holes with the holes in the frame Figure 10 g008875 Figure 10 1 Exhaust guard 2 Secure the exhaust guard to the frame with 4 self tapping screws Figure ...

Page 17: ... D Install the pin and check the clearance Note Repeat the procedure if required E Tighten the clevis jam nut 2 Ensure that the clearance between each lift arm and stop bolt is 0 13 to 1 02 mm 0 005 to 0 040 inches as shown in Figure 12 Note If the clearance is not in this range adjust the stop bolts to attain the proper clearance 3 Start the engine raise the cutting units and ensure that the clea...

Page 18: ...phill terrain It does however limit the clearance of the chamber to the carrier when cresting sharp small hills g031576 Figure 16 1 Upper front deck mounting hole 3 Rear deck mounting hole 2 Lower front deck mounting hole 2 For heights of cut in the 6 3 to 10 cm 2 1 2 to 4 inches range mount the front carrier frames in the upper front mounting holes Figure 16 Note This increases the chamber to car...

Page 19: ...he designated height of cut hole and slot Figure 18 g026184 Figure 18 6 Position the tapped plate in line with the spacer 7 Install the bolt finger tight 8 Repeat steps 4 to 7 for each side adjustment 9 Tighten the 3 bolts to 41 N m 30 ft lb Note Tighten the front bolt first Note Adjustments of more than 3 8 cm 1 1 2 inches may require temporary assembly to an intermediate height to prevent bindin...

Page 20: ...Tilt steering lever 4 Forward traction pedal 2 Angle indicator 5 Mow transport slide 3 Reverse traction pedal 6 Indicator slot Traction Pedals Press the forward traction pedal to move forward Press reverse traction pedal to move backward or to assist in stopping when moving forward Figure 21 Note Allow the pedal to move or move it to the NEUTRAL position to stop the machine Mow Transport Slide Usi...

Page 21: ...e off rotate the key to the OFF position Note Remove the key from the switch to prevent accidental starting g031597 Figure 23 1 Parking brake 7 Glow plug indicator light 2 Cutting unit shift lever 8 Hour meter 3 Cutting unit drive switch 9 Throttle 4 Alternator light 10 Ignition switch 5 Oil pressure light 11 Lift lever lock 6 Temperature light Throttle Move the throttle forward to increase the en...

Page 22: ...t should be off when the engine is running Figure 23 Note If it is on the charging system should be checked and repaired as necessary Glow Plug Indicator Light The glow plug indicator light glows when the glow plugs are operating Figure 23 Parking Brake Whenever the engine is shut off engage the parking brake to prevent accidental movement of the machine To engage the parking brake pull up on the ...

Page 23: ...des of the machine from the normal operating position Before Operation Before Operation Safety General Safety Never allow children or untrained people to operate or service the machine Local regulations may restrict the age of the operator The owner is responsible for training all operators and mechanics Become familiar with the safe operation of the equipment operator controls and safety signs Kn...

Page 24: ... the fuel tank or container opening at all times until fueling is complete Do not use a nozzle lock open device If you spill fuel on your clothing change your clothing immediately Fill the fuel tank until the fuel level is 25 mm 1 inch below the bottom of the filler neck Do not overfill the fuel tank Replace the fuel tank cap and tighten it securely Selecting a Blade Using a Standard Combination S...

Page 25: ...rge velocity sparse or limp turf is picked up at a high height of cut wet or sticky clippings are discharged efficiently May improve dispersion and appearance in certain grass cutting applications good for leaf mulching Reduces roller buildup in certain applications Cons Does not lift the grass well in high height of cut applications wet or sticky grass has a tendency to build up in the chamber le...

Page 26: ...ur distributor for more information about biodiesel fuel 1 Clean the area around the fuel tank cap Figure 25 2 Remove the fuel tank cap 3 Fill the tank to the bottom of the filler neck Do not overfill Install the cap 4 To prevent a fire hazard wipe up any fuel that may have spilled g008884 Figure 25 1 Fuel tank cap Checking the Tire Pressure Service Interval Before each use or daily DANGER Low tir...

Page 27: ...e Keep all body parts including hands and feet away from all moving parts Do not operate the machine while ill tired or under the influence of alcohol or drugs Keep the direction of the mower discharge away from people and pets Do not mow in reverse unless it is absolutely necessary If you must mow in reverse look behind and down for small children before and while moving the machine in reverse St...

Page 28: ...lways keep all cutting units lowered Avoid turning the machine on slopes If you must turn turn slowly and gradually downhill if possible Use extra care while operating the machine with attachments they can affect the stability of the machine Starting and Stopping the Engine Starting the Engine 1 Ensure that the parking brake is set and the cutting unit drive switch is in the DISENGAGE position 2 R...

Page 29: ...he wire harness disconnect at SCM or by temporarily test energizing the specific component The SCM does not connect to an external computer or handheld device cannot be programmed again and does not record intermittent fault troubleshooting data The decal on the SCM includes only symbols The 3 LED output symbols are shown in the output box while all other LEDs are inputs as shown in Figure 27 g031...

Page 30: ... 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 When possible mow up and down hills rather than across them Have the cutting units lowered when going down a hill to mainta...

Page 31: ...fles are available for the cutting units The mulching baffles perform well when you maintain turf on a regular schedule to avoid removing more than 25 mm 1 inch of growth per cutting When you cut too much growth with the mulching baffles installed the after cut appearance may deteriorate and the observed power to cut the turf increases The mulching baffles also perform well for shredding leaves in...

Page 32: ...n other appliances Towing Safety Tow only with a machine that has a hitch designed for towing Do not attach towed equipment except at the hitch point Follow the manufacturer s recommendation for weight limits for towed equipment and towing on slopes On slopes the weight of the towed equipment may cause loss of traction and loss of control Never allow children or others in or on towed equipment Tra...

Page 33: ...stopping time Every 25 hours Check the electrolyte level If the machine is in storage check it every 30 days Every 50 hours Lubricate all of the bearings and bushings Remove the air cleaner cover and clean out the debris Do not remove the filter Every 100 hours Check the condition and tension of all belts Every 150 hours Change the engine oil and engine oil filter Every 200 hours Torque the wheel ...

Page 34: ...k for unusual operating noises Check the hydraulic system oil level Check the hydraulic hoses for damage Check for fluid leaks Check the fuel level Check the tire pressure Check the instrument operation Check the height of cut adjustment Lubricate all the grease fittings 2 Touch up any damaged paint 1Check the glow plug and injector nozzles if starting is hard there is excess smoke or rough runnin...

Page 35: ...r store the machine or leave it unattended lower the cutting units unless you use a positive mechanical lock If possible do not perform maintenance on the machine while the engine is running If you must run the engine to perform maintenance on the machine keep your hands feet other body parts and clothing away from all moving parts the mower discharge area and the underside of the mowers Do not to...

Page 36: ... to the right side lift the other side and pull it out of the brackets Note Reverse this procedure to install the hood Using the Cutting Deck Service Latch When servicing the cutting decks use the service latch to prevent injury 1 Center the cutting deck sidewinder with the traction unit 2 Raise the cutting decks to the transport position 3 Set the parking brake and turn off the machine 4 Release ...

Page 37: ...egularly with No 2 lithium grease Also lubricate the machine immediately after every washing The grease fitting locations and quantities are as follows Rear cutting unit pivot Figure 32 g008894 Figure 32 Front cutting unit pivot Figure 33 g008895 Figure 33 2 sidewinder cylinder ends Figure 34 g008896 Figure 34 Steering pivot Figure 35 g008897 Figure 35 2 rear lift arm pivots and lift cylinder Figu...

Page 38: ... Figure 39 g008901 Figure 39 Mow transport slide Figure 40 g008902 Figure 40 Belt tension pivot Figure 41 g008903 Figure 41 Steering cylinder Figure 42 g008904 Figure 42 Note If desired an additional grease fitting may be installed at the other end of the steering cylinder Remove the tire install the fitting grease the fitting remove the fitting and install the plug Figure 43 38 ...

Page 39: ...kcase however check the oil level before and after you start the engine for the first time The crankcase capacity is approximately 2 8 L 4 US qt with the filter Use high quality engine oil that meets the following specifications API Classification Level Required CH 4 CI 4 or higher Preferred oil SAE 15W 40 above 17º C 0º F Alternate oil SAE 10W 30 or 5W 30 all temperatures Note Toro Premium Engine...

Page 40: ...et it run 5 minutes to allow the oil to warm up 2 With the machine parked on a level surface stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 3 Change the engine oil as shown in Figure 47 g031623 Figure 47 4 Change the engine oil filter as shown in Figure 48 g027477 Figure 48 40 ...

Page 41: ...r cleaner and turbocharger to ensure that the connections are complete Ensure that the cover is seated correctly and seals with the air cleaner body Servicing the Air Cleaner Cover Service Interval Every 50 hours Remove the air cleaner cover and clean out the debris Do not remove the filter Check the air cleaner body for damage which could cause an air leak Replace a damaged air cleaner body Clean...

Page 42: ...ng end of the filter and the body Do not use a damaged element Important Do not attempt to clean the safety filter Replace the safety filter after every 3 primary filter services Figure 51 g032050 Figure 50 1 Rubber outlet valve 4 Air cleaner body 2 Air cleaner latch 5 Air cleaner restriction sending unit 3 Air cleaner primary filter 6 Rubber intake hose g008861 Figure 51 1 Safety filter 3 Replace...

Page 43: ...lter mounts Figure 52 2 Remove the filter and clean the mounting surface 3 Lubricate the gasket on the filter with clean oil 4 Install the filter by hand until the gasket contacts the mounting surface then rotate an additional 1 2 turn Bleeding the Fuel System 1 Perform the pre maintenance procedure refer to Preparing the Machine for Maintenance page 36 2 Ensure that the fuel tank is at least half...

Page 44: ...enance Electrical System Safety Disconnect the battery before repairing the machine Disconnect the negative terminal first and the positive last Connect the positive terminal first and the negative last Battery acid is poisonous and can cause burns Avoid contact with your skin eyes and clothing Protect your face eyes and clothing when working with a battery Battery gases can explode Keep cigarette...

Page 45: ...Sparks can cause the battery gases 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 If the terminals have corrosion disconnect the cables the negative cable first and scrape the clamps and terminals separately Connect the cab...

Page 46: ...sure that it does not move when the traction pedal is in neutral Cooling System Maintenance Cooling System Safety CAUTION Discharge of hot pressurized coolant or touching a hot radiator and surrounding parts can cause severe burns Do not remove the radiator cap when the engine is hot Always allow the engine to cool at least 15 minutes or until the radiator cap is cool enough to touch without burni...

Page 47: ...ly 5 7 L 6 US qt CAUTION If the engine has been running the pressurized hot coolant can escape and cause burns Do not open the radiator cap when the engine is running Use a rag when opening the radiator cap and open the cap slowly to allow steam to escape 1 Check the coolant level in the expansion tank Figure 57 Note With a cold engine the coolant level should be approximately midway between the m...

Page 48: ...5 Clean both sides of the oil cooler and radiator area thoroughly with water or compressed air 6 Pivot the oil cooler back into position 7 Install the access panel and close the hood Brake Maintenance Adjusting the Parking Brake Service Interval Every 200 hours Check the parking brake adjustment 1 Loosen the set screw securing the knob to the parking brake lever Figure 60 g031637 Figure 60 1 Knob ...

Page 49: ... engine and the bolt securing the alternator to the brace B Insert a pry bar between the alternator and engine and pry out at the alternator C When you obtain the proper tension tighten the alternator and brace bolts to secure the adjustment Replacing the Hydrostat Drive Belt 1 Insert a nut driver or small piece of tubing onto the end of the belt tensioning spring CAUTION The spring that tensions ...

Page 50: ...ght before applying pressure to the hydraulic system Keep your body and hands away from pinhole leaks or nozzles that eject high pressure hydraulic fluid Use cardboard or paper to find hydraulic leaks Safely relieve all pressure in the hydraulic system before performing any work on the hydraulic system Seek immediate medical attention if fluid is injected into skin Checking the Hydraulic System Se...

Page 51: ...ficult to spot leaks A red dye additive for the hydraulic system oil is available in 20 mL 2 3 oz bottles One bottle is sufficient for 15 to 22 L 4 to 6 US gallons of hydraulic oil Order Part No 44 2500 from your authorized Toro distributor Use the following procedure to check the hydraulic fluid 1 Perform the pre maintenance procedure refer to Preparing the Machine for Maintenance page 36 2 Clean...

Page 52: ...e Interval Every 400 hours If the fluid becomes contaminated contact your local Toro distributor to flush the system Contaminated fluid looks milky or black 1 Turn the engine off and raise the hood 2 Disconnect the hydraulic line or remove the hydraulic filter and let the hydraulic fluid flow into a drain pan Figure 65 and Figure 66 g031643 Figure 66 1 Hydraulic line 3 Install the hydraulic line w...

Page 53: ... could be thrown at you or bystanders resulting in serious personal injury or death Trying to repair a damaged blade may result in discontinued safety certification of the product Inspect the blade periodically for wear or damage Never try to straighten a blade that is bent or weld a broken or cracked blade Replace a worn or damaged blade Use care when checking the blades Wrap the blades or wear g...

Page 54: ...frame onto the lift arm pivot pin and secure it with the lynch pin or retaining nut Figure 69 4 Using the hydraulic motor mounting screws install the hydraulic motor to the deck Figure 68 Note Ensure that the O ring is properly positioned and not damaged 5 Grease the spindle Servicing the Blade Plane The rotary deck comes from the factory preset at 5 cm 2 inches height of cut and blade rake of 7 9...

Page 55: ...et front left or right from the deck frame Figure 71 g031647 Figure 71 1 Height of cut bracket 2 Shims 2 Adjust the 1 5 mm 0 06 inch shims and or 0 7 mm 0 03 inch shim between the deck frame and bracket to achieve the desired height of cut Figure 71 3 Install the height of cut bracket to the deck frame with the remaining shims assembled below the height of cut bracket Figure 71 4 Secure the socket...

Page 56: ...d curved parts of the blade check the blade before using the machine If you notice wear replace the blade refer to Removing the Blade page 55 g031648 Figure 73 1 Cutting edge 3 Damaged area wear slot or crack 2 Sail 4 Inspect the cutting edges of all the blades sharpen the cutting edges if they are dull or nicked sharpen only the top of the cutting edge and maintain the original cutting angle to e...

Page 57: ...g and drive the opposite bearing out by alternating taps to the opposite side of inner bearing race Note There should be a 1 5 mm 0 06 inch lip of inner race exposed 3 Push the second bearing out in the press 4 Inspect the roller housing bearings and bearing spacer for damage Figure 75 Note Replace damaged components and assemble the front roller Assembling the Front Roller 1 Pressing on the outer...

Page 58: ...ent the battery from freezing make sure it is fully charged The specific gravity of a fully charged battery is 1 265 to 1 299 D Clean the battery terminals and posts with a wire brush and baking soda solution E Coat the cable terminals and battery posts with Grafo 112X skin over grease Toro Part No 505 47 or petroleum jelly to prevent corrosion F Store the battery on the shelf or on the machine in...

Page 59: ...India 0091 44 2449 4387 Valtech Morocco 212 5 3766 3636 Jean Heybroek b v Netherlands 31 30 639 4611 Victus Emak Poland 48 61 823 8369 European Privacy Notice The Information Toro Collects Toro Warranty Company Toro respects your privacy In order to process your warranty claim and contact you in the event of a product recall we ask you to share certain personal information with us either directly ...

Page 60: ...not limited to damage to seats due to wear or abrasion worn painted surfaces scratched decals or windows etc Parts Parts scheduled for replacement as required maintenance are warranted for the period of time up to the scheduled replacement time for that part Parts replaced under this warranty are covered for the duration of the original product warranty and become the property of Toro Toro will ma...

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