Toro TM5490 Operator'S Manual Download Page 1

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Part No. 111-3933 Rev A

TM5490 and 7490
Trailed Gang Mower

Model No: 02700-Serial No. from 311000001

Model No: 02701-Serial No. from 311000001

Oper

tor

’s

Manual

Original Instructions (EN)
Date: 30.11.10

Summary of Contents for TM5490

Page 1: ...Part No 111 3933 Rev A TM5490 and 7490 Trailed Gang Mower Model No 02700 Serial No from 311000001 Model No 02701 Serial No from 311000001 Operator s Manual Original Instructions EN Date 30 11 10...

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Page 3: ...E USING THE TM5490 AND TM7490 MOWERS IT IS ESSENTIAL THAT OPERATORS STUDY IT FOR THEIR OWN SAFETY ALL OPERATORS SHOULD SEEK AND OBTAIN PROFESSIONALAND PRACTICAL INSTRUCTIONS ON THE SAFE USE OF THE MOW...

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Page 5: ...ar 1 21 Cutterheads 1 21 Weight and dimensions 1 22 TM5490 Delivery Check List 1 23 TM5490 General Assembly MK3 Cutterheads 1 24 ASSEMBLING THE MOWER TM5490 1 25 1 26 TM7490 Delivery Check List 1 27 T...

Page 6: ...f Season Winter Storage 1 67 Cutterhead Cylinder to Bottom Blade Adjustment 1 68 1 69 Cutterhead Back Lapping 1 70 1 71 Grinding 1 71 Bottom Blade Replacement 1 71 1 72 GRASS CUTTING FAULTS 1 73 1 74...

Page 7: ...e adequate care can affect stability leading to loss of control of the machine particularly when operating in transport mode Control of the trailed mower sliding on a slope will not be regained by app...

Page 8: ...the condition of the tyres and ensure that they are inflated to the correct pressures refer to SPECIFICATIONS This is particularly important if the machine is to be taken on the public highway Check t...

Page 9: ...carbon monoxide fumes can collect Mow only in daylight or in good artificial light Never start the tractor engine with the PTO engaged Stored energy devices are charged when the outer wing units are i...

Page 10: ...the mower rolling over The requirements of 89 355 EEC as amended by 95 63 EEC Provision and Use of Work Equipment Directive should be considered Stability angles given are maximum figures for a machi...

Page 11: ...t to be sure the equipment is in safe working condition Replace worn or damaged parts for safety Ensure that all safety decals are properly secured and in good condition Be careful during adjustment o...

Page 12: ...at the handbrake lever is firmly strapped to the towing device in the release position prior to replacing a brake cable and do not release until the replacement cable is correctly tensioned Failure to...

Page 13: ...understand the Operators Manual Decal Jacking Support Point Part No 70 13 072 0 Location Pump mounting plate bottom 1 Rear axle 2 A Jacking and Support Point Decal Tyre Pressure Part No 767810 0 Loca...

Page 14: ...erride lift control Decal Serial Number Location Front and side of bulkhead Decal Warning Cutterhead Latch TM7490 Part No 111 3908 A Location Outside of each wingarms A Locked position B Unlocked posi...

Page 15: ...ion Pump mounting plate front face A Caution B Do not operate PTO shaft without all guards in place C Lubricate PTO shaft every 8 hours D Rotational speed of PTO shaft Decal Drawbar Part No 66 13 015...

Page 16: ...ored Energy Device Part No 749804 0 Location Underside of each wing arm A Beware of stored energy device B Keep bystanders clear Decal Warning Towing Parking Part No 111 3910 A Location Pump cover A W...

Page 17: ...U ENGLAND Mower 02700 350 cm 1000 rpm TM7490 Mower 02701 478 cm 1000 rpm Trailed Gang Trailed Gang TM5490 Noise Levels The operator ear noise level for the Toro Trailed Gang Mowers is approximately 87...

Page 18: ...mance and reliability This manual contains advice on the TM5490 and TM7490 Trailed Gang Mowers which should be operated ser viced and repaired only by persons who are familiar with their particular ch...

Page 19: ...06 1300 2500 Particles ml 15 40 80 Particles ml 15 Maximum Oil Temperature 95 C 203 F Recommended Lubricants and Hydraulic Fluids Grease Points A good quality medium grease Cutterhead Grease Points A...

Page 20: ...ked lever control for reduced speed reverse rotation Cutterhead Lift System Drive Type Hydraulic Pump Hydraulic gear type Delivery Rate 15 litres per minute 3 3 UK gallons per minute Cutterhead Manual...

Page 21: ...maximum speed of these machines to 40 km hr 25 mph TM5490 TM7490 Cutterheads MK3 200 mm Cutterhead MK3 254 mm Cutterhead Cutting Width 762 mm 30 762 mm 30 Cylinder Diameter 200 mm 8 254 mm 10 Cylinder...

Page 22: ...7 Transport Height 1610 mm 63 4 Approx Working Weight 1385 kg 3053 lb Drawbar Weight Transport 50 kg 110 2 lb TM7490 Overall Working Width 4970 mm 195 7 Mowing Width 4780 mm 188 2 Transport Width 2370...

Page 23: ...2 18 BOLT CARR M10 25 HT 8 8 15 11 003 4 19 MK3 CUTTERHEAD ASSYS 02800 MK3 200MM 8 4 BLADE CUTTER UNIT 02801 MK3 200MM 8 6 BLADE CUTTER UNIT 02802 MK3 200MM 8 8 BLADE CUTTER UNIT 02803 MK3 200MM 8 10...

Page 24: ...ad Cutterheads 1 5 only Cutterhead 5 opposite hand Cutterhead 3 smaller image opposite Cutterheads 2 4 only Cutterheads 4 opposite hand Lighting board 2 1 3 5 4 FRONT 20 20 21 21 23 24 22 22 25 19 Sup...

Page 25: ...Unlock the cutterhead suspension arms by releasing the red transport latches to their released position and carefully lower the arms to the floor Refer to Commissioning the Mower and Attaching the Mo...

Page 26: ...handwheel assemblies Adjust the handwheel assemblies to provide the correct fastening centres and refit in the alternative positions Replace all fasteners and tighten securely 7 Secure the cutterheads...

Page 27: ...M 8 8 BLADE CUTTER UNIT 02803 MK3 200MM 8 10 BLADE CUTTER UNIT 02810 MK3 250MM 10 4 BLADE CUTTER UNIT 02811 MK3 250MM 10 6 BLADE CUTTER UNIT 02812 MK3 250MM 10 8 BLADE CUTTER UNIT 20 CAP NUT 10 11 100...

Page 28: ...6 6 11 18 17 32 33 Cutterhead Position Cutterhead Type 1 Left Hand with rear deflector and bump stop 2 Left Hand with bump stop and roller plate box 3 Left Hand with deflector 4 Left Hand 5 Right Hand...

Page 29: ...ition and carefully lower the arms to the floor Refer to Commissioning the Mower and Attaching the Mower to the Tractor 2 Unpack 7 Cutterheads item 19 3 Lay out the cutterheads around the mower in the...

Page 30: ...blies to provide the correct fastening centres and refit in the alternative positions Replace all fasteners and tighten securely 9 Secure the cutterheads to the mower in the correct positions using th...

Page 31: ...ll of grease via the grease nipples B This will require a significant quantity of a good quality medium grade grease 13 Assemble the lighting board brackets item 35 and 36 to the rear of the machine u...

Page 32: ...NO QTY ITEM NOTE 1 MOTOR 2 SCREW 3 SPRING WASHER 4 WASHER 5 PLUG PROTECTIVE COVER REMOVE AND DISCARD 6 COUNTER WEIGHT 7 CIRCLIP 8 CYLINDER ADJUSTMENT HAND WHEEL ASSEMBLY 9 O RING ASSEMBLING THE MOWER...

Page 33: ...in the fol lowing locations Cutterheads Rollers cylinder adjusters roller adjusters and bearing housings Cutterhead Suspension Assemblies Bushes Wheels Hubs Hydraulic Cylinders Pin bushes Power Take O...

Page 34: ...n the arms Then release the transport latches Engage P T O drive When starting the mower for the first time it is assumed that all cutterheads will be resting on the ground Ensure that the area sur ro...

Page 35: ...to rotate when they are 300 400 mm above ground Electrical controls only optional extra Reset the electrical control system It will be necessary to carry out this procedure when powering up the electr...

Page 36: ...the P T O drive stop the tractor engine apply the tractor parking brake and remove the ignition key before making any adjustments After making final adjustments operate each cir cuit in turn to elimi...

Page 37: ...ary reverse facility is provided in order to allow temporary blockages to be cleared from the cutterheads This facility should NOT be used to backlap the cylinders Commission the braking system Inspec...

Page 38: ...g Check the mower s braking performance If the braking effect at the L H and R H wheels is unequal adjust the wheel brake cables Repeat the braking test until satisfac tory performance is achieved Dri...

Page 39: ...tractor rear P T O is engaged The cutterheads may be raised or lowered via a remote control sited adjacent to the operator This procedure is best carried out after attaching the mower to the tractor...

Page 40: ...tor The tractor must be equipped with compat ible cigar lighter and lighting sockets The tractor should be equipped with turf pattern tyres to minimise damage to fine turf areas Consult your tractor o...

Page 41: ...of the tow hitch by fitting the drawbar in the appropriate mounting holes in the mower front plate 1 2 A 546 570 571 620 B 496 520 521 545 C 0 470 471 495 Assemble the drawbar to the mower in the requ...

Page 42: ...in the storage position when the P T O shaft is connected to the tractor Grease the P T O shaft Partially withdraw the telescoping P T O shaft to expose the grease nipple through the outer guard aper...

Page 43: ...her and mark off 40mm from the end of the guards as shown below Disassemble the shaft halves from tractor and mower Remove the plastic guard from each half using the following method Cut the inner and...

Page 44: ...king life If less than the minimum please contact Hayter Check the tractor three point linkage If the tractor is equipped with a three point linkage it is essential that the relationship with the mowe...

Page 45: ...n the P T O shaft rest Never rest the P T O shaft on the ground Disconnect the manual lever control Remove the control lever assembly from the tractor and attach it to the storage position on the mowe...

Page 46: ...d with their restraint chains The mower brake hose is securely connected to the tractor auxiliary brake connector The breakaway cable is properly connected between the mower brake system and the tract...

Page 47: ...the controls for the first time as air is purged from the hydraulic system Lower the cutterheads to the ground Operate the middle long control lever to raise the 5 central cutterheads No s 2 3 4 5 6...

Page 48: ...ad drive will engage approximately 300 400mm above the ground level when the override control switch is operated to lower the cutterheads For identification of controls please refer to page 1 13 Lift...

Page 49: ...operate the emergency stop button Operate the override control switch to the Neutral position and or disengage the tractor PTO drive In an emergency operate the emergency stop button Power indicator...

Page 50: ...e tractor PTO drive 5 Electrical lift control should now be restored Manual override control valve In the event of total electrical failure the cutterheads can be lifted into the transport position us...

Page 51: ...durability Ensure that the braking system is correctly maintained and in good working order refer to MAINTENANCE General operation Direct hydraulic braking via the tractor auxiliary braking system is...

Page 52: ...ir storage positions as shown 4 Re mount the tractor start the engine and set the engine speed to a fast idle Engage the rear P T O 5a Manual lever control Push the mower control levers forward into t...

Page 53: ...cutterheads are lowered using the individual control switches the cylinders will automatically start up when the cutterheads are within 300 400mm of the ground level 7 The mower is now ready for gras...

Page 54: ...some residual pressure in the hydraulic system which could cause injury through sudden move ment of the cylinder s when the blockage is released Wear protective gloves and use a suitable strong woode...

Page 55: ...r grass deflectors must always be correctly fitted The deflectors should be set as low as possible to deflect grass discharge to the ground WARNING PREVENT ACCIDENTS Always ensure that the grass defle...

Page 56: ...ng a height of cut gauge across the full width of each cutterhead for greater ac curacy as shown MK3 254 mm 10 Fixed Cutterhead Height of cut adjustment The height of cut is gauged by the position of...

Page 57: ...ive clearances between the cylinders and bottom blades will cause rapid wear to take place 5 Always disengage the tractor P T O when travelling across ungrassed areas Grass will lubricate the cutting...

Page 58: ...roadside kerbs ALWAYS travel at slow speed over obstacles to prevent damage to the tyres and wheels Ensure that tyres are inflated to the recommended pressures IMPORTANT PREVENT DAMAGE When the mower...

Page 59: ...afeguard the Toro warranty Always fit genuine Toro service parts as these are accu rately matched to the required duty Dirt and contamination are the enemies of any hydraulic system When carrying out...

Page 60: ...eyes wash with running water and seek medical attention if symptoms persist Avoid ingestion if swallowed seek medical at tention Keep clear of high pressure fluid escaping from pinholes cracked connec...

Page 61: ...Rotate the L H wheel in the direction of forward travel by hand and turn the brake shoe adjuster until the wheel cannot be rotated pre load the brakes Turn the brake ad juster back in increments of h...

Page 62: ...ected 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 and debris etc and will ensure maximum working li...

Page 63: ...Inspect the mower for signs of oil leakage and tighten fittings or replace seals as required WARNING PREVENT ACCIDENTS Always replace worn or damaged hydraulic hose lines immediately DO NOT operate th...

Page 64: ...o the shaft and gear box may result Check lighting equipment Inspect the electric cable assembly and lights for signs of damage and replace damaged components Ensure that the lights operate correctly...

Page 65: ...s necessary through the dipstick aperture Braking system Wipe away all corrosion and dirt deposits and oil all moving parts Every 250 Hours Perform routine checks Refer to DAILY BEFORE USE AND EVERY 5...

Page 66: ...he associated hydraulic hoses for leaks Always replace any leaking components Inspect the jockey wheel assembly Examine the wheel and tyre and ensure that they are in good condition Check that the jac...

Page 67: ...Refer to DAILY BE FORE USE EVERY 50 HOURS AND EVERY 500 HOURS Release the mower brakes Operate the mower handbrake downwards to its lowest position to release the mower brakes Adjust the cutting cylin...

Page 68: ...0 right angles to the bottom blade to obtain the correct cutting action WARNING PREVENT ACCIDENTS Ensure that people are clear of the cutting cylinders as rotation of one may cause others to rotate If...

Page 69: ...uation by increasing the contact pressure If the cutterheads are allowed to operate for more than a few hours without adjustment the running wear will eventually cause the cylinder to run out of conta...

Page 70: ...tting cylinders to run at a reduced speed in reverse on start up 3 Apply a medium grade detergent based carborundum paste to the cutting edges of the cylinder with a long handled brush 80 Grade Carbor...

Page 71: ...eplaced and these should be ground on their holders prior to fitting refer to BOTTOM BLADE REPLACEMENT When grinding operations are necessary it is es sential that both cylinders and bottom blades are...

Page 72: ...t the cut ting cylinder position to give adequate clearance for fitting the new bottom blade holder Refit the bottom blade holder assembly to the cutterhead us ing the original fixing bolts and tighte...

Page 73: ...crease tractor engine speed Height of cut too low Raise height of cut Ridge lines in the cut grass across the direction of travel over cutting width of one cylinder Cylinder is running slow Refer to T...

Page 74: ...linder bearings bearing housing pivots Replace worn parts Loose components in cutterhead Check and re tighten as necessary Scalping Undulations too severe for fixed cutterheads Use floating cutterhead...

Page 75: ...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...

Page 76: ...ect hose routing or incorrect orientation of hydraulic fittings Move cutterheads throughout extremes of movement and observe any tightness in the hoses Correctly route hoses and orientate fittings as...

Page 77: ...THE TRACTOR Damage due to contact with tractor drawbar pin Check and re adjust vertical alignment of mower towbar Excessive hand brake travel poor braking performance Worn brake shoes Adjust wheel br...

Page 78: ...5 Detail B Lift Control Block Detail A Electric Control Box 2 2D768T03 3 1 2F 2A 2E 2B 2D 2C 5 Detail A Detail B ITEM NO DESCRIPTION PART NO QTY ITEM NOTE ITEM No DESCRIPTION PART NO QTY ITEM NOTE 1 R...

Page 79: ...1 79 1 79 TM5490 HYDRAULIC CIRCUIT DIAGRAM 13 12 14 14 11 11 10 7 8 15 16 15 15 17 15 15 16 17 9 6 16...

Page 80: ...FT CYLINDER 63 06 001W 5 LIFT CYLINDER 74 06 012W 6 LIFT CONTROL VALVE 767603W 7 OVER RIDE CONTROL VALVE 767604W 8 CHECK VALVE 65 06 303 9 ROTARY VALVE 3 BANK 65 06 343W 10 RETURN FILTER 65 06 482 11...

Page 81: ...1 81 1 81 TM5490 ELECTRIC HYDRAULIC CIRCUIT DIAGRAM...

Page 82: ...TION STRAINER 8 HYDRAULIC CYLINDER NO 1 9 HYDRAULIC CYLINDER NO 2 10 HYDRAULIC CYLINDER NO 3 11 HYDRAULIC CYLINDER NO 4 12 HYDRAULIC CYLINDER NO 5 13 RETURN FILTER 14 HYDRAULIC CYLINDER ROTARY VALVE 1...

Page 83: ...Bar at 29 5 l min 115 Bar at 15 l min 250 Bar at 29 5 l min OVERRIDE VALVE MANUAL OPERATION TO BACKLAP LIFT VALVE BACKLAP VALVE ROTARY P P T T B A A1 1 8 9 10 11 12 13 13 14 15 16 16 16 17 18 18 18 1...

Page 84: ...R 74 06 012W 7 LIFT CYLINDER 66 06 001W 8 LIFT CONTROL VALVE 767603W 9 OVER RIDE CONTROL VALVE 767604W 10 CHECK VALVE 65 06 303 11 ROTARY VALVE 3 BANK 65 06 343W 12 RETURN FILTER 65 06 482 13 SUCTION...

Page 85: ...115 Bar at 15 l min 250 Bar at 29 5 l min MANUAL OPERATION TO BACKLAP BACKLAP VALVE ROTARY 33 30 15 16 17 1 7 3 5 4 2 6 18 19 20 21 22 23 24 25 26 27 28 29 7 6 1 14 5 36 35 31 32 34 2c 2d 2e 2f 2a 3...

Page 86: ...INDER NO 5 63 06 001W 1 12 HYDRAULIC CYLINDER NO 6 74 06 012W 1 13 HYDRAULIC CYLINDER NO 7 66 06 001W 1 14 HYDRAULIC CYLINDER ROTARY VALVE 15 ROTARY VALVE BLOCK 16 VALVE DIVERTER 17 HYDRAULIC MOTOR NO...

Page 87: ...1 87 1 87 TM5490 TM7490 ELECTRICAL CIRCUIT DIAGRAM...

Page 88: ...TE 1 SWITCH EMERGENCY STOP 111 1779 1 2 RELAY 111 0336 11 3 LED 111 1780 2 4 TOGGLE SWITCH 70 09 001 5 5 DIODE 111 0348 19 6 UMBILICAL CABLE INCLUDES ITEM 7 111 1790 1 7 PLUG AUTOMOTIVE 111 1636 1 8 R...

Page 89: ...not limited to weather storage practices contamination use of unapproved coolants lubricants additives fertilizers water or chemicals etc Normal noise vibration wear and tear and deterioration Normal...

Page 90: ...1 90 1 90 NOTES...

Page 91: ...1 91 1 91 NOTES...

Page 92: ...1 92 1 92 NOTES...

Page 93: ...1 93 1 93 CUSTOMER INFORMATION Machine Details Model Machine Serial No Cutterhead Serial No s...

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