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Toro Reelmaster 4240-D Operator'S Manual Download Page 45

MAINTENANCE

1.45

1.45

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. It is essential that this stored energy is safely dissipated before maintenance or other service or
operations are performed on these devices and systems on the machine.

Dissipate stored energy as described below:

Hydraulics:
Transmission System -

Ensure that the machine is on level ground, engage the parking brake and switch the

engine off. Depress the forward and reverse travel pedals alternatively several times.

Cutterhead Lift System -

Lower the cutterheads to the ground and switch the engine off. Raise and lower

the lift levers several times leaving them in the ‘down/float’ position.

Cutterhead Drive System  - 

Lower the cutterheads to the ground with the cutterhead drive switch in the ‘off’

position and switch the engine off.

Wing Cutterhead Springs - 

Lower the wing cutterheads to the ground.

Operator Platform Gas Spring - 

Raise the platform fully.

IMPORTANT: PREVENT DAMAGE:   Regular maintenance is essential for the continued safe oper-
ation of the machine. Correct servicing will prolong the working life of the machine and 
safeguard the "Toro Warranty". Always fit genuine service parts as these are 
accurately matched to the required duty.

Dirt and contamination are the enemies of any hydraulic system. When carrying out maintenance 
procedures on the hydraulic system always ensure that the work area and the components are 
thoroughly clean before, during and after refitting. Ensure that all open hydraulic lines and ports, etc. are
plugged during maintenance procedures.

The recommended service intervals are based on normal operating conditions. Severe or unusual 
conditions will necessitate shorter service intervals.

ALWAYS grease pivot points immediately after pressure washing or steam cleaning, refer - EVERY 50
HOURS, GREASE PIVOT POINTS.

WARNING: PREVENT ACCIDENTS - The engine, transmission oil and hydraulic systems will be hot
after machine use.  Allow the systems to cool before working on the machine, particularly before work-
ing on the engine or when changing oil or oil filters.

Summary of Contents for Reelmaster 4240-D

Page 1: ...Part No 111 0473 Rev B Reelmaster 4240 D Code 652D Serial No from 260000001 Operator s Manual Original Instructions EN ...

Page 2: ......

Page 3: ...UAL 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 ...

Page 4: ... Cutterheads OPERATING THE MOWER Safety notice Operator presence controls Identification of controls Braking system Throttle control Travel Work Transport modes Transport latches Differential lock Travel control pedals Forward travel speed backstop lever Operator platform latching mechanism Adjustable steering column Operator seat Warning systems Audible warning horn Ignition key Engine pre heat i...

Page 5: ...ing Cutterhead MAINTENANCE General safety and good practice Engine Running in period Running in period at first 50 hours Daily and before use Every 50 hours Every 250 hours Every 500 hours Cutterhead cylinder to bottom blade adjustment Cutterhead backlapping Cutterhead grinding Cutterhead bottom blade replacement Raising the mower off the ground Towing the mower GRASS CUTTING FAULTS TROUBLE SHOOTI...

Page 6: ... a slope will not be regained by application of the brake The main reasons for loss of control are Insufficient wheel grip Being driven too fast Inadequate braking The type of machine is unsuitable for the task Lack of awareness of the effect of ground conditions especially slopes Incorrect load distribution PREPARATION Check that the machine complies with all applicable regulations including thos...

Page 7: ... areas After refuelling and adding oil to the hydraulic oil tank ensure that the caps are replaced securely Check that all linkages connections and pivot nuts are secure and that wheel nuts are torqued correctly refer SPECIFICATIONS Before operating the machine ensure that there are no foreign objects or liquids on the platform or ped als ALWAYS KEEP THE OPERATOR PLATFORM CLEAR CLEAN OPERATION Do ...

Page 8: ...ular conditions such as wet grass or uneven ground may not permit safe operation on the slope limits stated Remember there is no such thing as a safe slope Travel on grass slopes requires particular care To guard against overturning or loss of traction when travelling or mowing on a slope Exercise extreme care when changing direction on a slope Do not stop or start suddenly Engage drive slowly Kee...

Page 9: ...securely lock the safety latches or alternatively lower cutterheads to the ground Change into neutral and set the parking brake Stop the engine and remove the ignition key Engage the parking brake disengage the drive to the cutterheads stop the engine and remove ignition key Before releasing blockages Before checking cleaning or working on the mower After striking a foreign object Inspect the mowe...

Page 10: ...hen there is risk of splashing Wash hands thoroughly after contact Store in a cool dry well ventilated place away from heat and sources of ignition in vessels specifi cally designed for storing fuel oils Lubricating Oil Avoid skin and eye contact Wear impervious gloves when regular contact is likely and goggles when there is risk of splashing Wash hands thoroughly after contact Store in a cool dry...

Page 11: ...eful during adjustment of the machine to prevent entrapment of the fingers between moving blades and fixed parts of the machine Never attempt to disconnect any part of the hydraulic system before de pressurisation This may be achieved by lowering all cutterheads to the ground stopping the engine and removing the ignition key Avoid skin or eye contact with hydraulic or diesel fluids Wear protective...

Page 12: ... Arms a Caution b Stop engine Remove ignition key before releasing or operating safety latches Decal Diesel Part No 70 13 078 Location Fuel Tank Diesel fuel only Decal Transmission Oil Part No 70 13 071 Location Oil Filler Bracket mounted behind Fuel Tank a Transmission oil b Read and understand the operators manual 0 19 19 924857 1 a b c d e f g h IMPORTANT WICHTIG BELANGRIJK BEFORE USE FILL MACH...

Page 13: ...Diff Lock Control Pedal Part No 953876 Location Centre Platform a Differential lock b Depress to engage diff lock c Release to dis engage diff lock d Reverse speed directional control e Forward speed directional control Decal Noise Part No 922854 Location Base of Seat on GRP HEIZKORPERDECKELENTFERNENERSTWENNDERMOTORKUHLIST ONLYREMOVERADIATORCAPWHENENGINEISCOOL VERWIJDERDERADIATORDOPPASNADATDEMOTOR...

Page 14: ...erial No 652D 260000001 RM4240 D REELMASTER kg 1750 RPM 2800 kW 35 3 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 VOORKOM BESCHADIGING ZET MACHINE OP HANDREM EN LAAT DE KOOIEN ZAKKEN VOORDAT HET BEDIENINGS PLATFORM NAAR VOREN GEKANTELD OF TERUG GEPLAATST WOR...

Page 15: ...o a daily per sonal noise exposure level in excess of 85 dB A LEP d Sound pressure level The maximum sound pressure level at the operator s position is 85 dB A measured in accordance with European Standard EN836 Sound power level The maximum sound power level is 105 dB A measured in accordance with EC Directive 2000 14 EC If hearing protection is required ear protectors with good attenuation in th...

Page 16: ...egulations transposed into national law Also Directive 2000 14 EC Noise emission in the environment by equipment for use outdoors and the regulations transposed into national law Procedure applied for the conformity assessment ANNEX VI procedure 1 Notified Body Sound Research Laboratories Ltd Holbrook House Little Waldingfield Sudbury Suffolk CO10 0TH ENGLAND Notified body identification No 1088 M...

Page 17: ...viced and repaired only by persons who are familiar with its particular characteristics and who are acquainted with the relevant safety pro cedures The safety precautions listed herein and all other generally recognised regulations on safety and all road traffic reg ulations must be observed at all times Any arbitrary modifications carried out to this machine may relieve The Toro Company of liabil...

Page 18: ...ting Idle Speed Fuel Type Fuel Tank Capacity IMPORTANT PREVENT DAMAGE for further information regarding the engine refer to ENGINE MANUAL Kubota V2203 Diesel 4 Cylinders in line 47 3hp 35 3 kw 2800 RPM DIN 70020 2197 cc Clean air drawn through screened air intake in front of radiator via a cyclonic air cleaner with built in pre cleaner Water Cooled 12V 480 Amps S A E 40 Amps 1 4 KW Electric Glow P...

Page 19: ...l disc brake pressure released Rear Axle Radial piston fixed displacement Electro hydraulic control valve with pedal control only avail able in Work mode Four wheel drive in Work and Transport modes Main service relief 350 bar 5075 psi differential Charge pressure relief 29 bar 421 psi differential Hydraulic Tandem hydraulic gear type 31 Litres per minute each circuit Hydraulic gear type reversibl...

Page 20: ... minute Power beyond hydrostatic steering valve with priority flow to steering and auxiliary flow to cutterhead lift system Manual emergency steering Mechanical hydraulic Mechanical spring power assistance to lower 105 bar 1522 psi Variable hydraulic applied weight transfer acting on all cutterheads Refer RECOMMENDED LUBRICANTS AND HYDRAULIC FLUIDS 77 Litres Forced air finned tube oil cooler 125 m...

Page 21: ...ith safety locks Backlapping facility Differential lock Engine coolant and hydraulic oil overheat audible warning horn Variable cutterhead weight transfer traction assistance Four wheel drive in Work and Transport modes Hydraulic oil filter blocked telltales on control panel Wing arm breakback Safety Features Neutral start interlock on transmission pump parking brake and cutterhead drive switch Op...

Page 22: ...harge Engine coolant temperature Hydraulic transmission oil temperature Digital hour meter Fuel level Hydraulic oil level sight glass Engine pre heat Hydraulic return filter blocked Hydraulic transmission filter blocked Cutterdeck drive switch off Parking brake engaged Transmission neutral Work mode active Steering Cylinder Drive Engine Speed Parking Brake Forward and Reverse Ignition Differential...

Page 23: ...raulic System Should you be in any doubt please contact your Toro dealer Using incorrect grades will cause premature wear of hydraulic components and invalidate warranty 1610 mm 3640 mm 3460 mm 1850 mm at 13mm height of cut 2930 mm 1570 mm 1800 kg less operator no options fitted The exact weight depends on the cutterhead configuration Ambient Temperature Range 0 30 C 32 86 F I S O viscosity grade ...

Page 24: ...ht of Cut Number of Blades Smooth Rear Roller Smooth Front Roller Grooved Front Roller Configuration MK3 200mm Cutterhead 762 mm 200 mm 1050 rpm approx 12 80 mm 4 6 8 10 Standard Optional Optional Fixed Floating MK3 254mm Cutterhead 762 mm 254 mm 1050 rpm approx 12 80 mm 4 6 Standard Fixed ...

Page 25: ... the operator must be seated before the parking brake is released for the engine to continue to run Note The engine will cut out if the operator leaves the seat WARNING PREVENT ACCIDENTS Do not operate the Reelmaster mower if the operator presence controls are defective in any way ALWAYS replace faulty parts and check that they function correctly before operating the mower SAFETY NOTICE WARNING PR...

Page 26: ...ing indicator 18 Glow plug indicator 19 Cutterhead drive off indicator 20 Parking brake indicator 21 Transmission neutral indicator 22 Weight transfer control 23 Work Transport mode switch 24 Centre cutterhead transport latch 25 LH front cutterhead transport latch 26 RH front cutterhead transport latch 27 Centre cutterhead transport latch 28 LH wing unit transport latch 29 RH wing unit transport l...

Page 27: ...king In the event of service brake failure switch off the ignition to bring the mower to a standstill WARNING PREVENT ACCIDENTS Take care when operating the brak ing system Remain seated and hold on to the steering wheel to prevent ejection from the mower caused by the front wheel brakes being applied suddenly when travelling THROTTLE CONTROL Operate the throttle control in a forward direction to ...

Page 28: ...ar Differential lock is not available for use when Transport mode is selected 1 Transport Mode 2 Work Mode OPERATING THE MOWER 1 28 1 28 1D924P07A TRANSPORT LATCHES WARNING PREVENT ACCIDENTS ALWAYS raise the cutterheads to the transport position and secure with the transport latches and safety locks when travelling between work areas Front and Wing cutterhead transport latches Centre cutterhead tr...

Page 29: ...ifferential lock pedal Disengaging differential lock Release the differential lock pedal TRAVEL CONTROL PEDALS WARNING PREVENT ACCIDENTS Ensure that the trans mission control cable is securely fastened to the travel control pedal mechanism Ensure that both the cable and pedals artic ulate freely through their full range of travel and that the mechanism freely returns to neutral when released WARNI...

Page 30: ... The gas spring will provide assistance Securing the platform Lower the platform carefully The gas spring will provide assistance Move the locking latch handle towards the front of the mower position A as the platform nears the fully lowered position This will ensure that the latch hooks clear the locking bar Fully lower the platform and move the locking handle towards the rear of the mower positi...

Page 31: ...olumn should only be carried out when the mower is at a standstill with the parking brake engaged Adjusting the angle of inclination of the steering wheel Move lever A downwards to adjust the angle of steering wheel Release the lever to lock the steering wheel in position Adjusting the length of the steering column Move the lever A upwards to adjust the length of the steering column Release the le...

Page 32: ...lease the lever to lock the seat in position Operator weight adjustment Rotate handle C clockwise as shown to increase suspension stiffness and counter clockwise to decrease Dial D indicates when the optimum suspension adjustment has been set according to operator weight kg Height adjustment Manually lift the seat for incremental height adjustment To lower lift the seat to beyond its highest setti...

Page 33: ...oil in the reser voir exceeds 95 C approx Low battery charge warning The battery charge warning light illuminates Low engine oil pressure warning light The engine oil pressure warning light illuminates AUDIBLE WARNING HORN Depress the horn button to provide an audible warning IMPORTANT PREVENT DAMAGE The horn is automatically actuated when an engine coolant or hydraulic oil overheat condition occu...

Page 34: ...m ENGINE PRE HEAT INDICATOR LIGHT Turn the ignition key to position II The engine pre heat indicator light will illuminate When the correct pre heat temperature is achieved the indicator light will switch off When this condition is achieved turn the ignition key to position III to start the engine IMPORTANT PREVENT DAMAGE Attempting to start a cold engine before the pre heat indicator light switch...

Page 35: ...to posi tion I HYDRAULIC RETURN FILTER INDICATOR LIGHT Illuminates when the return filter element is blocked Note The engine must be running for the hydraulic return filter indicator light to illuminate The indicator light may illuminate briefly when the hydraulic oil is cold HYDRAULIC TRANSMISSION FILTER INDICATOR LIGHT Illuminates when the transmission filter element is blocked Note The engine m...

Page 36: ...t 2 Neutral 3 Raise 4 LH Wing or LH Wing LH Front 5 Centre LH RH Front or Centre 6 RH Wing or RH Wing RH Front Depending on which lift configuration is selected Refer Dual Lift Configuration Control 4A953B03A 1 2 3 4 5 6 DUAL LIFT CONFIGURATION CONTROL The dual lift configuration control function enables the lift controls to be used in two ways as follows Five gang mode lift configuration 1 Contro...

Page 37: ...isms Release the cutterhead latches Operate the cutterhead position controls to the down float position and lower all cutterheads to the ground ready for mowing Forward rotation cutterhead drive engagement Operate the cutterhead drive switch to the Forward position Reverse rotation cutterhead drive engagement Operate the cutterhead drive switch to the Reverse position To disengage all cutterhead d...

Page 38: ...g the weight transfer hand wheel as follows Release the lock wheel underneath the hand wheel 1 2 turn anti clockwise and hold Rotate the hand wheel Anti clockwise to reduce weight transfer Clockwise to increase weight transfer Tighten the lock wheel STARTING THE ENGINE WARNING PREVENT ACCIDENTS Before starting the engine check that The area is clear of bystanders The cutterhead drive is disengaged...

Page 39: ...ng 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 As soon as the engine starts release the ignition key back to position I WARNING PREVENT DAMAGE When the engine is operating all warning lights should be off If a warning light illuminates stop...

Page 40: ...ive heat will build up if the cutting cylinders are run when not mowing and this will cause rapid wear to take place For this reason it is also wise to reduce cutting cylinder speed when mowing lightly grassed areas or when the grass is dry Cutting performance is best when cutting against the lie of the grass In order to take advantage of this fact the operator should attempt to alternate the dire...

Page 41: ... and is long enough to provide sufficient leverage to release the block age and any residual hydraulic system pressure by rotating or rocking the cylinder Make sure that the wood en instrument is properly supported in the cylinder and avoid the use of excessive force to prevent damage Only when the cylinder has a degree of free movement should the source of the blockage be removed Ensure that the ...

Page 42: ...requirements MK3 200mm Cutterhead illustrated Floating MK3 200mm Cutterheads When the mower is set up with floating cutterheads the height of cut is gauged by the front and rear rollers The cutterhead is allowed to pivot fore and aft as well as laterally This arrangement is recommended for high quality grass areas and performs well where grass is short and the ground undulations are severe Grass d...

Page 43: ...or rings C or by using a height of cut gauge across the full width of each cutterhead for greater accuracy as shown MK3 254mm FIXED CUTTERHEAD 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 IMPORTANT PREVENT DAMAGE Do not attempt t...

Page 44: ...E or anti clockwise to increase height of cut E IMPORTANT PREVENT DAMAGE Do not attempt to unlock the nut assemblies B To alter the front roller position loosen bolts F Release and turn adjusting nuts D both ends clockwise to increase the height of cut or anti clockwise to decrease the height of cut Ensure that all cutterheads are set at the same height of cut by referring to the indicator rings C...

Page 45: ...utterhead drive switch in the off position and switch the engine off Wing Cutterhead Springs Lower the wing cutterheads to the ground Operator Platform Gas Spring Raise the platform fully IMPORTANT PREVENT DAMAGE Regular maintenance is essential for the continued safe oper ation of the machine Correct servicing will prolong the working life of the machine and safeguard the Toro Warranty Always fit...

Page 46: ...ar of high pressure fluid escaping from pinholes cracked connections etc High pressure fluid can penetrate the skin Seek immediate medical advice if any fluid is injected into the skin Always use a piece of cardboard or paper when searching for leaks CAUTION PREVENT ENVIRONMENTAL DAMAGE Dispose of hazardous substances correctly When disposing of hazardous waste products take them to an authorised ...

Page 47: ...el nut torques twice a day Front axle wheel nut torque setting 200 Nm Rear axle wheel nut torque setting 54 Nm RUNNING IN PERIOD AT FIRST 50 HOURS Change the transmission oil filter Unscrew and remove the bottom of the transmission oil filter housing Withdraw the filter element and discard Refit a new filter element part no 924708 and replace the housing ENGINE 1P953C17 1 2 3 1 Transmission Oil Fi...

Page 48: ... 50 HOURS Change the hydraulic oil return filter Unscrew and remove the return filter canister and discard Refit a new filter canister part no 924692 1 2 1P953C16A 1 Hydraulic oil return filter 2 Engine fuel filter Continued Left Hand Side of Machine ...

Page 49: ...owly to release system pressure before removing the filler cap completely The coolant level should be 30 40mm below the top of the filler neck Top up with the correct coolant mixture refer ENGINE MANUAL IMPORTANT If you see RED in the Filter Blockage Indicator the air filter needs replacing Cleaning the air cleaner Remove the air filter and tap it repeatedly with the palm of the hand to remove dus...

Page 50: ...nditions Check fuel level Top up as necessary with diesel fuel Always top up before storing the mower over night to prevent water condensation from contaminating the fuel Check hydraulic oil level If the oil level is below the upper mark on the sight level gauge top up with the correct grade of hydraulic oil as necessary refer SPECIFICATIONS WARNING PREVENT DAMAGE If there is noticeable hydraulic ...

Page 51: ...ot pin both steering yokes and track rod ball joints refer EVERY 50 HOURS Grease pivot points Check cutterheads Examine the condition of the cutting cylinders and bottom blades Adjust as necessary refer MAINTENANCE CUTTERHEAD CYLINDER TO BOTTOM BLADE ADJUSTMENT Grease all cutterhead rollers with a good quality medium grade grease and ensure that sufficient grease is injected such that clean grease...

Page 52: ...ould illu minate Refer OPERATING THE MOWER Operate the switch to the forward position The indicator light should go out and the engine should not start when the ignition key is turned Repeat for the reverse position Parking brake interlock switch Stop the engine Engage the parking brake and turn the ignition key to position I The parking brake indicator light should illuminate Refer OPERATING THE ...

Page 53: ...er provided just sufficiently to remove any end float Note The roller should still rotate freely after adjustment Overtightening of nuts A could lead to premature bearing failure Check cutterhead rear roller scraper wire tension It is important that the scraper wires are correctly tensioned so as to ensure correct operation and maximum working life Carefully tighten the scraper wire retaining nuts...

Page 54: ...ints 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 ...

Page 55: ...MPORTANT PREVENT DAMAGE Check the condition of the battery cables Replace cables showing signs of wear or damage and tighten any loose connections as necessary Visually inspect transmission control cable and operating mechanism Check the condition and security of the cable and operating mechanism at the travel control pedals and trans mission pump ends Remove build up of dirt grit and other deposi...

Page 56: ...iner if there are any signs of damage Remove the oil filler cap strainer and clean before replacing Renew the strainer if there are any signs of damage Renew the return line oil filter element refer RUNNING IN PERIOD AT FIRST 50 HOURS Renew the transmission oil filter element refer RUNNING IN PERIOD AT FIRST 50 HOURS Replace the drain plug and refill the hydraulic tank with fresh clean hydraulic o...

Page 57: ...s to prevent moisture ingress Check rear wheel alignment To prevent excessive tyre wear and ensure safe machine operation the rear wheels must be correctly aligned to toe in by 3 8mm Set the rear wheels in the straight ahead position Measure and compare the distance between the front sidewalls and the rear sidewalls at the wheel centre height The distance between the front sidewalls must be set 3 ...

Page 58: ...system is faulty make repairs before operating the mower Check the hydraulic oil overheat warning system Turn the ignition key to the ignition on position I Disconnect the red blue wire terminal from the hydraulic tank temperature switch and touch the metal terminal of the wire onto a suitable earth point ensuring that the metal surfaces make good contact The horn will sound and the hydraulic oil ...

Page 59: ...as necessary Tighten nut A both ends If it is impossible to obtain a good clean paper cut across the entire length of the bottom blade it will be necessary to carry out the backlapping procedure to reprocess the cutting edges In severe cases it will be necessary to regrind the cutting cylinder and the bottom blade refer BACKLAPPING GRINDING Do not be tempted to over adjust causing heavy contact be...

Page 60: ...e cutterheads is clear of people and keep hands and feet clear of the cutting cylinders during the period when the mower engine is running Sit on the operator seat start the mower engine and set the engine speed at idle Operate the cutterhead drive switch to the reverse backlap position for a period of time and listen to the grinding action Operate the cutterhead drive switch to the off position a...

Page 61: ...der bottom blade grinding machine CUTTERHEAD BOTTOM BLADE REPLACEMENT Remove the bottom blade holder by removing the three fixing bolts at each end and withdraw from the cutterhead Remove the worn bottom blade and discard the countersunk screws and securing nuts Fit the new blade to the holder and loosely assemble with new countersunk screws and securing nuts Tighten the centre bolts to a torque o...

Page 62: ...n key removed The ground under the lifting device is level and firm The lifting device is secure against one of the mower lifting points If raising the front of the mower both of the rear wheels must be chocked securely to prevent the mower rolling away Note that the parking brake only operates on the front wheels WARNING PREVENT ACCIDENTS When the mower is raised off the ground NEVER crawl under ...

Page 63: ...on the front wheel motor disc brakes as follows i Identify the right hand front wheel motor disc brake assembly and remove the rubber plug item 2 Position a M12 x 40mm long setscrew item 5 with washer item 4 through the brake release bar item 3 and into the hole in the centre of the motor end plate Tighten the setscrew item 5 into the threaded hole in the brake piston until the brake is released i...

Page 64: ... to a torque of 48 52 Nm Re commission the front wheel motor disc brakes as follows i Identify the right hand front wheel motor disc brake assembly Rotate the setscrew item 5 anti clockwise and remove together with washer item 4 and brake release bar item 3 Reassemble the rubber plug item 2 into the motor end plate ii Identify the left hand front wheel motor disc brake assembly and repeat the prev...

Page 65: ...s seizing Grass build up under cutterhead GRASS CUTTING FAULTS Areas of uncut grass at point of overlap between cutting cylinders Ridge lines in the cut across the direction of travel over full width Ridge lines in the cut grass across the direction of travel over the cutting width of one cylinder Step in cut grass height at point of overlap between cutting cylinders Reduce turning radius Mow up d...

Page 66: ...E REMEDY Backlap or regrind to restore cutting edges Raise height of cut Readjust cutterhead to ensure bottom blade is parallel to ground Reduce forward speed Reduce weight transfer Replace worn parts Check and retighten as necessary Use floating cutterheads Raise height of cut Cutting cylinder is partially out of contact with the bottom blade Cutting cylinder is in heavy contact with the bottom b...

Page 67: ...utting edges of the cutting cylinder bottom blade are rounded Cylinder is in heavy contact with the bottom blade Damaged cutting cylinder or bottom blade Excessively abrasive ground conditions Raise height of cut Backlap or regrind to restore cutting edges Readjust the cutting cylinder to the bottom blade Regrind or replace as necessary Raise height of cut ...

Page 68: ...nterlock switch not energised Cutterhead drive interlock switch not energised Faulty electrical connection Terminal connection loose or corroded Loose or defective alternator belt Defective battery Electrical short circuit For all other engine problems refer ENGINE HANDBOOK REMEDY Remove foot from forward reverse travel pedal Check setting of transmission neutral interlock switch Operate parking b...

Page 69: ...ake discs PROBLEM Differential lock non operational Hydraulic oil sys tem overheating Incorrect brake operation REMEDY Check switch and replace if necessary Service or replace solenoid valve Check wiring connections as necessary Clean screen Clean fins Clean matrix Have relief valve cleaned and pressure checked Consult your Toro dealer Fill reservoir to correct level Disengage brakes Readjust sett...

Page 70: ... wiring Defective steering valve Defective hydraulic cylinder Damaged steering hose TROUBLE SHOOTING Continued REMEDY Release parking brake Fill reservoir to correct level Drain reservoir and refill with correct oil Check linkage and replace defective parts Have the transmission pump overhauled by your Toro dealer Close relief valve refer MAINTENANCE TOWING THE MOWER Replace drive coupling Replace...

Page 71: ...replace suction strainer or renew as necessary Allow system to warm up Have relief valve cleaned and pressure checked Consult your Toro dealer Fill hydraulic oil reservoir to correct level PROBLEM Excessive noise in hydraulic system POSSIBLE CAUSE Faulty pump Faulty motor Air leaking into system Suction strainer blocked or damaged Excessive oil viscosity due to cold conditions Low relief valve set...

Page 72: ... Problem Hydraulic Oil System Overheating Check and tighten fittings Replace hose if necessary Remove high spot with a stone and backlap to restore cutting edges Serious damage will necessitate regrinding Replace as necessary After initial satisfactory operation machine loses power Cylinder knocks while rotating PROBLEM POSSIBLE CAUSE REMEDY TROUBLE SHOOTING Continued High spot on cylinder or bott...

Page 73: ...BLEM REMEDY One cylinder rotates slowly Cutterhead fails to lift out of work Cutterheads do not follow ground contours Replace as necessary Check motor and replace if necessary Free off and lubricate or replace diverter valve as necessary Have check valve cleaned and checked Readjust setting Replace motor Replace seals Have relief valve cleaned and pressure checked Consult your Toro dealer Overhau...

Page 74: ... start up when lowered into work Cylinders rotate in wrong direction Check mechanical and electrical operation of switch Fill hydraulic oil reservoir to correct level Free off and lubricate or replace the diverter valve as necessary Check motor and cylinder drive shafts and replace if necessary Have relief valve cleaned and pressure checked Consult your Toro dealer Free off as necessary Readjust s...

Page 75: ...RS B BLACK N BROWN R RED O ORANGE Y YELLOW G GREEN U BLUE P PURPLE S SLATE W WHITE K PINK L LIGHT GREEN B R U G G B R U L L N B N W B N W N B N W W P B B P Y P R P R R P Y P B R S G N G 50a 33 40 B R W O B B R W 33 41 44 45 46 47 48 43 49 51 52 50 33 33 Braid B W R B R W G R G W B B G R B G W W Y P R U R B P N W W N R N W R N N Y G U N B N B 1 2 0 4 2 1 7 8 54 R W R R N N B 55 B B N 10 12 11 13 14...

Page 76: ...1 Fusebox 70 09 096 1 10A Cutter Drive Lift Configuration 70 09 026 2 10A Transmission Horn 70 09 026 3 3A Instruments 70 09 024 4 Blank Beacon 5 Blank Cab Wipers or Air Suspension Seat 6 Blank Lighting Kit 7 Blank Lighting Kit 8 30A Engine Start Fuel Solenoid 70 09 027 22 Switch Ignition 74 09 009 23 Switch Horn 924618 24 Relay Cutterhead Drive Warning Lamps 70 09 148 25 Relay Overheat Audible Wa...

Page 77: ...RS B BLACK N BROWN R RED O ORANGE Y YELLOW G GREEN U BLUE P PURPLE S SLATE W WHITE K PINK L LIGHT GREEN B R U G G B R U L L N B N W B N W N B N W W P B B P Y P R P R R P Y P B R S G N G 50a 33 40 B R W O B B R W 33 41 44 45 46 47 48 43 49 51 52 50 33 33 Braid B W R B R W G R G W B B G R B G W W Y P R U R B P N W W N R N W R N N Y G U N B N B 1 2 0 4 2 1 7 8 54 R W R R N N B 55 B B N 10 12 11 13 14...

Page 78: ... Engine Overheat 49 Solenoid Fuel SA 4259 12 50 Engine 950950 51 Hourmeter 910850 52 Switch Return filter 53 Solenoids Work Transport Mode 910627 54 Fuse Engine Glow plugs 60A 55 Fuse Main 60A 56 Diode Parking Brake 950868 57 Diode Seat Switch 950868 58 Relay Seat Switch 70 09 148 59 Delay Module Seat 924722 ITEM NO DESCRIPTION PART NO ...

Page 79: ...1 79 1 79 TRANSMISSION BRAKE HYDRAULIC CIRCUIT 4P953C03 ...

Page 80: ...9 Flow Divider Front Wheels 10 Valve Pilot Operated Diff Lock 11 Shuttle Valve Hot Oil Purge 953687 12 Relief Valve Hot Oil Purge 13 Relief Valve Serial Line 375 Bar 953710 14 Wheel Motor Rear 130cc Rev 953685 15 Pump Transmission 52cc Rev 953684 16 Relief Valve Charge Pump 29 Bar 17 Relief Valves Fwd Rev 350 Bar 18 Oil Cooler 950606 19 Filter Charge 10 Micron 950597 20 Filter Return 10 Micron 924...

Page 81: ... 54 17 14 15 18 19 13 12 11 20 5 6 7 8 10 47 HL 35 34 33 32 31 30 29 28 27 24 22 21 23 25 LB 26 LBX 46 PX 45 D3 D2 D1 TPC 9 P T B A 53 21 23 37 PX DC RB MB B1 HL T 49 48 FB B2 D1 T P A B 36 38 39 40 41 42 43 22 50 52 51 4 3 2 1 PX 44 2P953C01A ...

Page 82: ...ers Reverse 2 pl 70 06 246 Cutter Drive Control Manifold Front and Centre 910699 Restrictor Valve Variable Weight Transfer 910709 Relief Valve Cutterheads Front and Centre 250 bar 910708 Diverter Valve Centre Cutterhead 953601 Hydraulic Motor Centre Cutterhead 940602 Check Valve Orifice Motor Bypass Centre Cutterhead Diverter Valve L H Front Cutterhead 953601 Hydraulic Motor L H Front Cutterhead 9...

Page 83: ...ckless manner Parts subject to consumption through use unless found to be defective Examples of parts which are consumed or used up during normal Product operation include but are not limited to blades cylinders bedknives tines spark plugs castor wheels tires filters belts and certain sprayer components such as diaphragms nozzles and check valves etc Failures caused by outside influence Items cons...

Page 84: ...eckless manner Parts subject to consumption through use unless found to be defective Examples of parts which are consumed or used up during normal Product operation include but are not limited to blades reels bedknives tines spark plugs castor wheels tires filters belts and certain sprayer components such as diaphragms nozzles and check valves etc Failures caused by outside influence Items conside...

Page 85: ...1 85 1 85 NOTES ...

Page 86: ...N 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 ...

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