Toro 4520 User manual

FormNo.3380-291RevA
Greensmaster®3400TriFlex™
TractionUnit
ModelNo.04520—SerialNo.314000001andUp
g014597
Registeratwww.Toro.com.
OriginalInstructions(EN)*3380-291*A

ThisproductcomplieswithallrelevantEuropeandirectives;
fordetails,pleaseseetheseparateproductspecicDeclaration
ofConformity(DOC)sheet.
WARNING
CALIFORNIA
Proposition65Warning
Thisproductcontainsachemicalorchemicals
knowntotheStateofCaliforniatocausecancer,
birthdefects,orreproductiveharm.
Dieselengineexhaustandsomeofits
constituentsareknowntotheStateof
Californiatocausecancer,birthdefects,
andotherreproductiveharm.
Important:Thisengineisnotequippedwithaspark
arrestermufer.ItisaviolationofCaliforniaPublic
ResourceCodeSection4442touseoroperatetheengine
onanyforest-covered,brush-covered,orgrass-covered
land.Otherstatesorfederalareasmayhavesimilarlaws.
Introduction
Thismachineisaride-on,reel-bladelawnmowerintended
tobeusedbyprofessional,hiredoperatorsincommercial
applications.Itisprimarilydesignedforcuttinggrasson
well-maintainedlawnsinparks,golfcourses,sportselds,
andoncommercialgrounds.Itisnotdesignedforcutting
brush,mowinggrassandothergrowthalongsidehighways,
orforagriculturaluses.
Readthisinformationcarefullytolearnhowtooperateand
maintainyourproductproperlyandtoavoidinjuryand
productdamage.Youareresponsibleforoperatingthe
productproperlyandsafely.
YoumaycontactTorodirectlyatwww.Toro.comforproduct
andaccessoryinformation,helpndingadealer,ortoregister
yourproduct.
Wheneveryouneedservice,genuineToroparts,oradditional
information,contactanAuthorizedServiceDealerorToro
CustomerServiceandhavethemodelandserialnumbersof
yourproductready.Figure1identiesthelocationofthe
modelandserialnumbersontheproduct.Writethenumbers
inthespaceprovided.
g014685
1
Figure1
1.Modelandserialnumberlocation
ModelNo.
SerialNo.
Thismanualidentiespotentialhazardsandhassafety
messagesidentiedbythesafetyalertsymbol(Figure2),
whichsignalsahazardthatmaycauseseriousinjuryordeath
ifyoudonotfollowtherecommendedprecautions.
Figure2
1.Safetyalertsymbol
Thismanualuses2wordstohighlightinformation.
Importantcallsattentiontospecialmechanicalinformation
andNoteemphasizesgeneralinformationworthyofspecial
attention.
©2014—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN554202
Contactusatwww.Toro.com.
PrintedintheUSA
AllRightsReserved

Contents
Introduction..................................................................2
Safety...........................................................................4
SafeOperatingPractices...........................................4
ToroMowerSafety..................................................6
SoundPowerLevel..................................................8
SoundPressureLevel...............................................8
Hand-ArmVibrationLevel......................................8
WholeBodyVibrationLevel....................................8
SafetyandInstructionalDecals.................................8
Setup...........................................................................12
1InstallingtheRollBar...........................................13
2InstallingtheSeat.................................................13
3InstallingtheSteeringWheel..................................13
4ActivatingandChargingtheBattery........................13
5InstallingtheOilCooler(optional).........................15
6InstallingtheGrassBasketHooks..........................15
7InstallingtheCuttingUnits...................................15
8AddingRearWeight.............................................18
9InstallingEUDecals.............................................18
ProductOverview.........................................................18
Controls...............................................................18
Specications........................................................22
Attachments/Accessories........................................22
Operation....................................................................22
ThinkSafetyFirst...................................................22
CheckingtheEngineOil..........................................22
FillingtheFuelTank...............................................23
UsingBiodieselFuel...............................................24
CheckingtheCoolingSystem...................................25
CheckingtheHydraulicFluidLevel...........................25
DrainingWaterfromtheFuelFilter...........................27
CheckingtheTirePressure......................................27
CheckingtheTorqueoftheWheelNuts.....................27
CheckingtheReel-to-BedknifeContact.....................27
Break-inPeriod......................................................28
StartingandStoppingtheMachine............................28
CheckingtheSafetyInterlockSystem........................28
InstallingandRemovingtheCuttingUnits.................29
SettingtheReelSpeed.............................................31
MowingwiththeMachine.......................................32
TransportingtheMachine........................................33
CleaningandInspectingtheMachine........................33
TowingtheMachine...............................................33
Maintenance.................................................................34
RecommendedMaintenanceSchedule(s)......................34
DailyMaintenanceChecklist....................................35
EngineMaintenance..................................................36
ServicingtheAirCleaner.........................................36
ChangingtheEngineOilandFilter...........................36
FuelSystemMaintenance...........................................37
ServicingtheFuelFilter/WaterSeparator...................37
InspectingtheFuelLinesandConnections.................38
ElectricalSystemMaintenance....................................38
ServicingtheBattery...............................................38
StoringtheBattery..................................................39
LocatingtheFuses..................................................39
DriveSystemMaintenance.........................................40
AdjustingtheTransmissionforNeutral.....................40
AdjustingtheTransportSpeed.................................40
AdjustingtheMowingSpeed....................................40
CoolingSystemMaintenance......................................41
CleaningtheRadiatorScreen....................................41
BrakeMaintenance....................................................42
AdjustingtheBrakes...............................................42
BeltMaintenance......................................................42
AdjustingtheAlternatorBelt...................................42
HydraulicSystemMaintenance....................................43
ChangingtheHydraulicOilandFilter........................43
CheckingtheHydraulicLinesandHoses....................43
CuttingUnitMaintenance...........................................44
BacklappingtheReels.............................................44
DiagnosticsSystem....................................................45
DiagnosingtheServiceIndicatorLight......................45
Storage........................................................................45
3

Safety
ThismachinemeetsorexceedsCENstandardEN
836:1997,ISOstandard5395:1990,andANSIB71.4-2004
specicationsineffectatthetimeofproductionwhen
16.8kg(37lb)ofweightisaddedtotherearwheel.
Improperuseormaintenancebytheoperatororowner
canresultininjury.Toreducethepotentialforinjury,
complywiththesesafetyinstructionsandalwayspay
attentiontothesafetyalertsymbol(Figure2),which
meansCaution,Warning,orDanger—personalsafety
instruction.Failuretocomplywiththeinstructionmay
resultinpersonalinjuryordeath.
SafeOperatingPractices
ThefollowinginstructionsareadaptedfromCENstandard
EN836:1997,ISOstandard5395:1990,andANSI
B71.4-2012.
Training
•ReadtheOperator’sManualandothertrainingmaterial
carefully.Befamiliarwiththecontrols,safetysigns,and
theproperuseoftheequipment.
•Iftheoperatorormechaniccannotreadthelanguage
ofthismanual,itistheowner’sresponsibilitytoexplain
thismaterialtothem.
•Neverallowchildrenorpeopleunfamiliarwiththese
instructionstouseorservicethemower.Local
regulationsmayrestricttheageoftheoperator.
•Nevermowwhilepeople,especiallychildren,orpetsare
nearby.
•Keepinmindthattheoperatororuserisresponsiblefor
accidentsorhazardsoccurringtootherpeopleortheir
property.
•Donotcarrypassengers.
•Alldriversandmechanicsshouldseekandobtain
professionalandpracticalinstruction.Theowneris
responsiblefortrainingtheusers.Suchinstructionshould
emphasize:
–theneedforcareandconcentrationwhenworking
withride-onmachines;
–controlofaride-onmachineslidingonaslopewill
notberegainedbytheapplicationofthebrake.The
mainreasonsforlossofcontrolare:
◊insufcientwheelgrip;
◊beingdriventoofast;
◊inadequatebraking;
◊thetypeofmachineisunsuitableforthetask;
◊lackofawarenessoftheeffectofground
conditions,especiallyslopes.
◊Theowner/usercanpreventandisresponsible
foraccidentsorinjuriesoccurringtohimselfor
herself,otherpeople,orproperty
Preparation
•Whilemowing,alwayswearsubstantialfootwear,long
trousers,hardhat,safetyglasses,andhearingprotection.
Longhair,looseclothing,orjewelrymaygettangled
inmovingparts.Donotoperatetheequipmentwhen
barefootorwearingopensandals.
•Thoroughlyinspecttheareawheretheequipmentisto
beusedandremoveallobjectswhichmaybethrownby
themachine.
•Replacefaultysilencers/mufers.
•Evaluatetheterraintodeterminewhataccessoriesand
attachmentsareneededtoproperlyandsafelyperform
thejob.Onlyuseaccessoriesandattachmentsapproved
bythemanufacturer.
•Checkthatoperator’spresencecontrols,safetyswitches
andshieldsareattachedandfunctioningproperly.Donot
operateunlesstheyarefunctioningproperly.
Operation
•Donotoperatetheengineinaconnedspacewhere
dangerouscarbonmonoxidefumescancollect.
•Mowonlyindaylightoringoodarticiallight.
•Beforeattemptingtostarttheengine,disengageallblade
attachmentclutches,shiftintoneutral,andengagethe
parkingbrake.
•Rememberthereisnosuchthingasasafeslope.Travel
ongrassslopesrequiresparticularcare.Toguardagainst
overturning:
–donotstoporstartsuddenlywhengoingupor
downhill;
–machinespeedsshouldbekeptlowonslopesand
duringtightturns;
–stayalertforhumpsandhollowsandotherhidden
hazards;
–nevermowacrossthefaceoftheslope,unlessthe
mowerisdesignedforthispurpose.
•Stayalertforholesintheterrainandotherhiddenhazards.
•Watchoutfortrafcwhencrossingornearroadways.
•Stopthebladesfromrotatingbeforecrossingsurfaces
otherthangrass.
•Whenusinganyattachments,neverdirectdischargeof
materialtowardbystandersnorallowanyonenearthe
machinewhileinoperation.
•Neveroperatethemachinewithdamagedguards,shields,
orwithoutsafetyprotectivedevicesinplace.Besureall
4

interlocksareattached,adjustedproperly,andfunctioning
properly.
•Donotchangetheenginegovernorsettingsoroverspeed
theengine.Operatingtheengineatexcessivespeedmay
increasethehazardofpersonalinjury.
•Beforeleavingtheoperator’sposition:
–stoponlevelground;
–disengagethepowertake-offandlowerthe
attachments;
–changeintoneutralandsettheparkingbrake;
–stoptheengineandremovethekey.
•Disengagedrivetoattachmentswhentransportingornot
inuse.
•Stoptheengineanddisengagedrivetoattachment:
–beforerefuelling;
–beforeremovingthegrasscatcher/catchers;
–beforemakingheightadjustmentunlessadjustment
canbemadefromtheoperator’sposition.
–beforeclearingblockages;
–beforechecking,cleaningorworkingonthemower;
–afterstrikingaforeignobjectorifanabnormal
vibrationoccurs.Inspectthemowerfordamage
andmakerepairsbeforerestartingandoperatingthe
equipment.
•Reducethethrottlesettingbeforestoppingtheengine
and,iftheengineisprovidedwithafuelshut-offvalve,
turnthefueloffattheconclusionofmowing.
•Keephandsandfeetawayfromthecuttingunits.
•Lookbehindanddownbeforebackinguptobesureof
aclearpath.
•Slowdownandusecautionwhenmakingturnsand
crossingroadsandsidewalks.Stopthereelswhennot
mowing.
•Donotoperatethemowerundertheinuenceofalcohol
ordrugs.
•Lightningcancausesevereinjuryordeath.Iflightning
isseenorthunderisheardinthearea,donotoperate
themachine;seekshelter.
•Usecarewhenloadingorunloadingthemachineintoa
trailerortruck.
•Usecarewhenapproachingblindcorners,shrubs,trees,
orotherobjectsthatmayobscurevision.
RolloverProtectionSystem(ROPS)-
UseandMaintenance
•TheROPSisanintegralandeffectivesafetydevice.Keep
afoldingROPSintheraisedandlockedpositionanduse
theseatbeltwhenoperatingthemachine.
•LowerafoldingROPStemporarilyonlywhenabsolutely
necessary.Donotweartheseatbeltwhenfoldeddown.
•Beawarethereisnorolloverprotectionwhenafolded
ROPSisinthedownposition.
•Becertainthattheseatbeltcanbereleasedquicklyin
theeventofanemergency.
•Checktheareatobemowedandneverfolddowna
foldingROPSinareaswherethereareslopes,dropoffs
orwater.
•Checkcarefullyforoverheadclearances(i.e.branches,
doorways,electricalwires)beforedrivingunderany
objectsanddonotcontactthem.
•KeeptheROPSinsafeoperatingconditionby
periodicallythoroughlyinspectingfordamageand
keepingallmountingfastenerstight.
•ReplaceadamagedROPS.Donotrepairorrevise.
•DonotremovetheROPS.
•AnyalterationstoaROPSmustbeapprovedbythe
manufacturer.
SafeHandlingofFuels
•Toavoidpersonalinjuryorpropertydamage,use
extremecareinhandlinggasoline.Gasolineisextremely
ammableandthevaporsareexplosive.
•Extinguishallcigarettes,cigars,pipes,andothersources
ofignition.
•Useonlyanapprovedfuelcontainer.
•Neverremovefuelcaporaddfuelwiththeengine
running.
•Allowenginetocoolbeforerefueling.
•Neverrefuelthemachineindoors.
•Neverstorethemachineorfuelcontainerwherethereis
anopename,spark,orpilotlightsuchasonawater
heateroronotherappliances.
•Neverllcontainersinsideavehicleoronatruckor
trailerbedwithaplasticliner.Alwaysplacecontainerson
thegroundawayfromyourvehiclebeforelling.
•Removeequipmentfromthetruckortrailerandrefuelit
ontheground.Ifthisisnotpossible,thenrefuelsuch
equipmentwithaportablecontainer,ratherthanfroma
fueldispensernozzle.
•Keepthenozzleincontactwiththerimofthefueltank
orcontaineropeningatalltimesuntilfuelingiscomplete.
•Donotuseanozzlelockopendevice.
•Iffuelisspilledonclothing,changeclothingimmediately.
•Neveroverllfueltank.Replacefuelcapandtighten
securely.
MaintenanceandStorage
•Keepallnuts,boltsandscrewstighttobesurethe
equipmentisinsafeworkingcondition.
•Neverstoretheequipmentwithfuelinthetankinsidea
buildingwherefumesmayreachanopenameorspark.
5

•Allowtheenginetocoolbeforestoringinanyenclosure.
•Toreducetheriskofrehazard,keeptheengine,
silencer/mufer,batterycompartment,andfuelstorage
areafreeofgrass,leaves,orexcessivegrease.
•Replacewornordamagedpartsforsafety.
•Checkthegrasscatcherfrequentlyforwearor
deterioration.
•Keepallpartsingoodworkingconditionandallhardware
andhydraulicttingstightened.Replaceallwornor
damagedpartsanddecals.
•Ifthefueltankhastobedrained,dothisoutdoors.
•Becarefulduringadjustmentofthemachinetoprevent
entrapmentofthengersbetweenmovingbladesand
xedpartsofthemachine.
•Onmulti-reelmachines,takecareasrotatingonereelcan
causeotherreelstorotate.
•Disengagedrives,lowerthecuttingunits,setparking
brake,stopengineandremovekey.Waitforallmovement
tostopbeforeadjusting,cleaningorrepairing.
•Cleangrassanddebrisfromcuttingunits,drives,mufers,
andenginetohelppreventres.Cleanupoilorfuel
spillage.
•Usejackstandstosupportcomponentswhenrequired.
•Carefullyreleasepressurefromcomponentswithstored
energy.
•Disconnectbatterybeforemakinganyrepairs.Disconnect
thenegativeterminalrstandthepositivelast.Reconnect
positiverstandnegativelast.
•Usecarewhencheckingthereels.Wrapthereelsorwear
gloves,andusecautionwhenservicingthem.
•Keephandsandfeetawayfrommovingparts.Ifpossible,
donotmakeadjustmentswiththeenginerunning.
•Chargebatteriesinanopenwellventilatedarea,away
fromsparkandames.Unplugchargerbeforeconnecting
ordisconnectingfrombattery.Wearprotectiveclothing
anduseinsulatedtools.
Hauling
•Usecarewhenloadingorunloadingthemachineintoa
trailerortruck.
•Usefullwidthrampsforloadingmachineintotraileror
truck.
•Tiethemachinedownsecurelyusingstraps,chains,cable,
orropes.Bothfrontandrearstrapsshouldbedirected
downandoutwardfromthemachine.
ToroMowerSafety
ThefollowinglistcontainssafetyinformationspecictoToro
productsorothersafetyinformationthatyoumustknowthat
isnotincludedintheANSIstandards.
Thisproductiscapableofamputatinghandsandfeetand
throwingobjects.Alwaysfollowallsafetyinstructionsto
avoidseriousinjuryordeath.
Useofthisproductforpurposesotherthanitsintendeduse
couldprovedangeroustouserandbystanders.
Operation
•Knowhowtostoptheenginequickly.
•Alwayswearsubstantialshoes.Donotoperatethe
machinewhilewearingsandals,tennisshoes,orsneakers.
Wearingsafetyshoesandlongpantsisadvisableand
requiredbysomelocalordinancesandinsurance
regulations.
•Theoperatormustbeskilledandtrainedinhowtodrive
onhillsides.Failuretousecautiononslopesorhillsmay
causelossofcontrolandcausethevehicletotiporroll,
possiblyresultinginpersonalinjuryordeath.
•Handlefuelcarefully.Wipeupanyspills.
•Checkthesafetyinterlockswitchesdailyforproper
operation.Ifaswitchshouldfail,replacetheswitch
beforeoperatingthemachine
•Beforeattemptingtostarttheengine,sitontheseat,pull
theliftleverbackandreleaseittoensurethecutting
unitsaredisengaged.Verifythatthetractionsystemisin
neutralandtheparkingbrakeisset.
•Usingthemachinedemandsattention.Topreventloss
ofcontrol:
–Donotdriveclosetosandtraps,ditches,creeks,or
otherhazards.
–Reducespeedwhenmakingsharpturns.Avoid
suddenstopsandstarts.
–Watchoutfortrafcwhennearorcrossingroads.
Alwaysyieldtheright-of-way.
–Applytheservicebrakeswhengoingdownhillto
keepforwardspeedslowandtomaintaincontrolof
themachine.
•Thegrassbasketsmustbeinplaceduringoperation
ofthereelsorthatchersformaximumsafety.Shutthe
engineoffbeforeemptyingthebaskets.
•Raisethecuttingunitswhendrivingfromoneworkarea
toanother.
•Donottouchtheengine,mufer,orexhaustpipewhile
theengineisrunningorsoonafterithasstoppedbecause
theseareascouldbehotenoughtocauseburns.
•Beforegettingoffoftheseat,movethefunctionalcontrol
levertoneutral(N),raisethecuttingunitsandwaitfor
thereelstostopspinning.Settheparkingbrake.Stopthe
engineandremovethekeyfromtheignitionswitch.
•Traverseslopescarefully.Donotstartorstopsuddenly
whentravelinguphillordownhill.
6

•Theoperatormustbeskilledandtrainedinhowtodrive
onhillsides.Failuretousecautiononslopesorhillsmay
causelossofcontrolandcausethemachinetotiporroll,
possiblyresultinginpersonalinjuryordeath.
•Iftheenginestallsorlosesheadwayandcannotmakeit
tothetopofaslope,donotturnthemachinearound.
Alwaysbackslowly,straightdowntheslope.
•Whenapersonorpetappearsunexpectedlyinornear
themowingarea,stopmowing.Carelessoperation,
combinedwithterrainangles,ricochets,orimproperly
positionedguardscanleadtothrownobjectinjuries.Do
notresumemowinguntiltheareaiscleared.
•AlwaysusetheseatbeltwiththeROPSwhenoperating
themachine.
•Beforegettingoffoftheseat,movethefunctionalcontrol
levertoneutral(N),raisethecuttingunitsandwaitfor
thereelstostopspinning.Settheparkingbrake.Stopthe
engineandremovethekeyfromtheignitionswitch.
•Wheneverthemachineisleftunattended,makesurethe
cuttingunitsarefullyraised,thereelsarenotspinning,
thekeyisremovedfromtheignitionswitch,andthe
parkingbrakeisset.
MaintenanceandStorage
•Makesureallhydrauliclineconnectorsaretightandall
hydraulichosesandlinesareingoodconditionbefore
applyingpressuretothesystem.
•Keepyourbodyandhandsawayfrompinholeleaksor
nozzlesthatejecthydraulicuidunderhighpressure.
Usepaperorcardboard,notyourhands,tosearchfor
leaks.Hydraulicuidescapingunderpressurecanhave
sufcientforcetopenetratetheskinandcauseserious
injury.
•Beforedisconnectingorperforminganyworkonthe
hydraulicsystem,allpressureinthesystemmustbe
relievedbystoppingtheengineandloweringthecutting
unitsandattachmentstotheground.
•Checkallfuellinesfortightnessandwearonaregular
basis.Tightenorrepairthemasneeded.
•Iftheenginemustberunningtoperformamaintenance
adjustment,keephands,feet,clothing,andanypartsof
thebodyawayfromthecuttingunits,attachments,and
anymovingparts,especiallythescreenatthesideofthe
engine.Keepeveryoneaway.
•Toensuresafetyandaccuracy,haveanAuthorizedToro
Distributorcheckthemaximumenginespeedwitha
tachometer.Maximumgovernedenginespeedshould
be2900rpm.
•Theenginemustbeshutoffbeforecheckingtheoilor
addingoiltothecrankcase.
•Ifmajorrepairsareeverneededorifassistanceisdesired,
contactanAuthorizedToroDistributor.
•Toensureoptimumperformanceandcontinuedsafety
certicationofthemachine,useonlygenuineToro
replacementpartsandaccessories.Replacementparts
andaccessoriesmadebyothermanufacturerscouldbe
dangerous,andsuchusecouldvoidtheproductwarranty.
7

SoundPowerLevel
Thisunithasaguaranteedsoundpowerlevelof98dBA,
whichincludesanUncertaintyValue(K)of1dBA.
Soundpowerlevelwasdeterminedaccordingtothe
proceduresoutlinedinISO11094.
SoundPressureLevel
Thisunithasasoundpressurelevelattheoperator’searof84
dBA,whichincludesanUncertaintyValue(K)of1dBA.
Soundpressurelevelwasdeterminedaccordingtothe
proceduresoutlinedinEN836.
Hand-ArmVibrationLevel
Measuredvibrationlevelforrighthand=0.22m/s2
Measuredvibrationlevelforlefthand=0.24m/s2
UncertaintyValue(K)=0.24m/s2
Measuredvaluesweredeterminedaccordingtotheprocedures
outlinedinEN836.
WholeBodyVibrationLevel
Measuredvibrationlevel=0.41m/s2
UncertaintyValue(K)=0.21m/s2
Measuredvaluesweredeterminedaccordingtotheprocedures
outlinedinEN836.
SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaofpotential
danger.Replaceanydecalthatisdamagedorlost.
119-9343
8

115-8156
1.Reelheight3.8Bladecuttingunit5.14Bladecuttingunit7.Fast
2.5Bladecuttingunit4.11Bladecuttingunit6.Reelspeed8.Slow
115-8155
1.Warning—readtheOperator'sManual,donotprimeoruse
startinguid.
115-8203
1.ReadtheOperator's
manualforfuse
information.
2.Radiatorfan—50Amp
117–2718
121–5169
1.Slow5.Reelposition
setting
9.Slow—usefor
mowing
2.Continuous
variablesetting
6.Lowerand
engagethe
reels
10.Fast—usefor
transport
3.Fast7.Reel—backlapping 11.Functional
controllever
4.Raisethereels8.Neutral—use
forbacklapping
9

121–5172
1.Off3.On
2.Headlights
121–5170
1.Hydraulicoillevel4.Engine—start
2.ReadtheOperator’s
Manualbeforeservicingor
performingmaintenance.
5.Enginepreheat/run
3.Choke(gasolinemodels
only)
6.Engine—stop
119-9346
1.Presspedaltounlock2.ReadtheOperator's
Manualformore
information.
BatterySymbols
Someorallofthesesymbolsareonyourbattery.
1.Explosionhazard6.Keepbystandersasafe
distancefromthebattery.
2.Nore,openames,or
smoking.
7.Weareyeprotection;
explosivegasescan
causeblindnessandother
injuries.
3.Causticliquid/chemical
burnhazard
8.Batteryacidcancause
blindnessorsevereburns.
4.Weareyeprotection.9.Flusheyesimmediately
withwaterandgetmedical
helpfast.
5.ReadtheOperator’s
Manual.
10.Containslead;donot
discard.
121–2641
1.Warning—readthe
Operator’sManual,do
notoperatethismachine
unlessyouaretrained.
4.Tippinghazard—slow
machinebeforeturning,
donotturnathighspeeds.
2.Thrownobject
hazard—keepbystanders
asafedistancefromthe
machine.
5.Warning—locktheparking
brake,stoptheengine
andremovetheignition
keybeforeleavingthe
machine.
3.Cutting/dismemberment
hazardofhandorfoot,
mowerblade—stayaway
frommovingparts;keep
allguardsandshieldsin
place.
10

121–2640
1.Warning—readthe
Operator’sManual,do
notoperatethismachine
unlessyouaretrained.
4.Tippinghazard—donot
driveacrossslopesgreater
than15degreesordown
slopesgreaterthan15
degrees.
2.Thrownobject
hazard—keepbystanders
asafedistancefromthe
machine
5.Warning—locktheparking
brake,stoptheengine
andremovetheignition
keybeforeleavingthe
machine.
3.Cutting/dismemberment
hazardofhandorfoot,
mowerblade—stayaway
frommovingparts;keep
allguardsandshieldsin
place.
11

Setup
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
Rollbar1
Bolt(1/2x3-3/4inches)4
1Flange-nut(1/2inch)4
Installtherollbar.
2Seatcompletionkit1Installtheseattothebase.
Steeringwheel1
Locknut(1-1/2inches)1
Washer1
3Steeringwheelcap1
Installthesteeringwheel.
4Nopartsrequired–Activateandchargethebattery.
5Nopartsrequired–Installtheoilcooler(optional).
Grassbaskethook6
6Flangebolts12Installthegrassbaskethooks.
Gaugebar1
Cuttingunit(model04613,04614,or
04615)3
7GrassBasket3
Installthecuttingunits.
8
Weightkit,121–6665(purchase
separately)Note:Thiskitisnotrequired
forunitswiththe3wheeldrivekit
installed.
1Addrearweight.
9Warningdecal117-95371InstallEUdecals,ifrequired.
MediaandAdditionalParts
DescriptionQty.Use
Operator'sManual(tractionunit)1
EngineOperator'sManual(engine)1Readbeforeoperatingthemachine.
PartsCatalog1Saveforfuturepartsordering.
OperatorTrainingMaterials1Viewbeforeoperatingthemachine.
Pre-deliveryInspectionSheet1
Noiseratingcerticate1
Certicateofcompliance1
Saveforfuturereference.
Ignitionkeys2Starttheengine.
12

1
InstallingtheRollBar
Partsneededforthisprocedure:
1Rollbar
4Bolt(1/2x3-3/4inches)
4Flange-nut(1/2inch)
Procedure
1.Removethetopcratesupportfromthecrate.
2.Removetherollbarfromthecrate.
3.Installtherollbarintothepocketsoneachsideof
themachine,using4bolts(1/2x3-3/4inches)and4
ange-nuts(1/2inch)(Figure3).
g014601
1
2
3
Figure3
1.Rollbar3.Flange-nut(1/2inch)
2.Bolt(1/2x3-3/4inches)
4.Torquethefastenersto136to149N-m(100to110
ft-lb).
2
InstallingtheSeat
Partsneededforthisprocedure:
1Seatcompletionkit
Procedure
Acquireyourdesiredseatkitfromyourdistributorandinstall
itasdirectedintheinstructionincludedwiththekit.
3
InstallingtheSteeringWheel
Partsneededforthisprocedure:
1Steeringwheel
1Locknut(1-1/2inches)
1Washer
1Steeringwheelcap
Procedure
1.Slidethesteeringwheelontothesteeringshaft(Figure
4).
Figure4
1.Steeringwheel3.Jamnut
2.Washer4.Cap
2.Slidethewasherontothesteeringshaft(Figure4).
3.Securethesteeringwheeltotheshaftwithajamnut
andtightenitto27to35N-m(20to26ft-lb)(Figure4).
4.Installthecaptothesteeringwheelandsecureitwitha
screw(Figure4).
13

4
ActivatingandChargingthe
Battery
NoPartsRequired
Procedure
Useonlyelectrolyte(1.265specicgravity)tollbattery
initially.
1.Removethefastenersandbatteryclampandliftout
thebattery.
Important:Donotaddelectrolytewhilethe
batteryisinthemachine.Youcouldspillit,
causingcorrosion.
2.Cleanthetopofthebatteryandremovetheventcaps
(Figure5).
Figure5
3.Carefullylleachcellwithelectrolyteuntiltheplates
arecoveredwithabout6mm(1/4inch)ofuid(Figure
6).
Figure6
1.Electrolyte
4.Allowapproximately20to30minutesforthe
electrolytetosoakintotheplates.Fillasnecessaryto
bringtheelectrolytetowithinabout6mm(1/4inch)
ofthebottomofthellwell(Figure6).
WARNING
Chargingthebatteryproducesgassesthatcan
explode.
Neversmokenearthebatteryandkeepsparks
andamesawayfrombattery.
5.Connecta2to4ampbatterychargertothebattery
posts.Chargethebatteryfor2hoursat4ampsorfor
4hoursat2ampsuntilthespecicgravityis1.250or
higherandthetemperatureisatleast16°C(60°F)
withallcellsgassingfreely.
6.Whenthebatteryischarged,disconnectthecharger
fromtheelectricaloutletandbatteryposts.
Note:Afterthebatteryhasbeenactivated,add
onlydistilledwatertoreplacenormalloss,although
maintenance-freebatteriesshouldnotrequirewater
undernormaloperatingconditions.
WARNING
CALIFORNIA
Proposition65Warning
Batteryposts,terminals,andrelated
accessoriescontainleadandleadcompounds,
chemicalsknowntotheStateofCalifornia
tocausecancerandreproductiveharm.
Washhandsafterhandling.
14

WARNING
Batteryterminalsormetaltoolscouldshort
againstmetaltractorcomponentscausing
sparks.Sparkscancausethebatterygassesto
explode,resultinginpersonalinjury.
•Whenremovingorinstallingthebattery,
donotallowthebatteryterminalstotouch
anymetalpartsofthetractor.
•Donotallowmetaltoolstoshortbetween
thebatteryterminalsandmetalpartsof
thetractor.
WARNING
Failuretocorrectlyactivatethebatterymay
resultinbatterygassingand/orpremature
batteryfailure.
7.Placethebatteryonthebatterytrayandsecureitwith
thebatteryclampandfasternersremovedpreviously.
8.Installthepositivecable(red)tothepositive(+)
terminalandthenthenegativecable(black)tothe
negative(–)terminalofthebatteryandsecurethem
withtheboltsandnuts(Figure7).Slidetherubber
bootoverthepositiveterminaltopreventapossible
shortfromoccurring.
WARNING
Incorrectbatterycableroutingcoulddamagethe
tractorandcablescausingsparks.Sparkscancause
thebatterygassestoexplode,resultinginpersonal
injury.
•Alwaysdisconnectthenegative(black)battery
cablebeforedisconnectingthepositive(red)
cable.
•Alwaysconnectthepositive(red)batterycable
beforeconnectingthenegative(black)cable.
Figure7
1.Negative(-)
2.Positive(+)
5
InstallingtheOilCooler
(optional)
NoPartsRequired
Procedure
Ifyouareoperatingthemachineinhotclimates,where
ambienttemperaturesareabove29°C(85°F),orusingitfor
heavy-dutyuse(mowingotherthangreens,suchasfairways
orverticutting),installaHydraulicOilCoolerKit,PartNo.
117-9314,tothemachine.
6
InstallingtheGrassBasket
Hooks
Partsneededforthisprocedure:
6Grassbaskethook
12Flangebolts
Procedure
Installthe6grassbaskethooksontotheendsofthe
suspensionarmbarsusing12angebolts(Figure8).
Figure8
1.Flangebolt3.Suspensionarmbar
2.Grassbaskethook
15

7
InstallingtheCuttingUnits
Partsneededforthisprocedure:
1Gaugebar
3Cuttingunit(model04613,04614,or04615)
3GrassBasket
Procedure
Note:Whensharpening,settingtheheight-of-cut,or
performingothermaintenanceproceduresonthecutting
units,storethecuttingunitreelmotorsinthestoragelocation
onthefrontofthesuspensionarmstopreventdamageto
them.
Important:Donotraisethesuspensiontothetransport
positionwhenthereelmotorsareintheholdersinthe
machineframe.Damagetothemotorsorhosescould
result.
Important:Wheneverthecuttingunithastobetipped
toexposebedknife/reel,propuprearofcuttingunitto
makesurenutsonbackendofbedbaradjustingscrews
arenotrestingonworksurface(Figure9).
g014596 1
2
2
Figure9
1.Prop(notprovided)2.Bedknifeadjustingscrew
nut(2)
Note:Allcuttingunitsareshippedwiththecounterweight
mountedtotherightendandthemotormountanddrive
couplermountedtotheleftendofthecuttingunit.
1.Applygreasetotheinsidediameterofthedrivecoupler.
2.Thecuttingunitisshippedwithoutafrontroller.
Obtainaroller(ModelNo.04625,04626or04627)
fromyourlocalToroDistributor.Installtheroller
usingtheloosepartssuppliedwiththecuttingunitand
installationinstructionsincludedwiththeroller.
3.Ifinstallingthecentercuttingunit,liftuponthefoot
restandswingitup,allowingaccesstothecenter
cuttingunitposition(Figure10).
CAUTION
Thefootrestcanpinchngersifitfallsinto
theclosedposition.
Keepyourngersclearoftheareawherethe
footrestseatswhileitisopen.
g014602
1
2
Figure10
1.Footrest—closed2.Footrest—open
4.Positionthecuttingunitunderthesuspensionarm.
5.Withthelatchesonthesuspension-armbarpointing
up(i.e.,open)(Figure11),pushthesuspensionarm
downsothatthebartsoverthebaracrossthetopof
thecuttingunit(Figure12).
g014609
1
2
3
Figure11
1.Latch—closedposition3.Latch—openposition
2.Suspension-armbar
16

g01461 1
1
2
Figure12
1.Suspension-armbar2.Cutting-unitbar
6.Closethelatchesdownandaroundthecutting-unitbar
andlocktheminplace(Figure11).
Note:A“click”canbeheardandfeltwhenthelatches
areproperlylockedinplace.
7.Coatthesplineshaftofthecuttingunitmotorwith
cleangrease(Figure13).
8.Insertthemotorintotheleftsideofthecuttingunit
(asviewedfromtheoperator'sposition)andpullthe
motorretainingbaronthecuttingunittowardthe
motoruntilyouhearanaudible“click”frombothsides
ofthemotor(Figure13).
g014690
1
23
4
Figure13
1.Reelmotor3.Cavity
2.Splineshaft4.Motorretainingbar
9.Mountagrassbasketontothebaskethooksonthe
suspensionarm.
10.Repeatthisprocedurefortheothercuttingunits.
17

8
AddingRearWeight
Partsneededforthisprocedure:
1
Weightkit,121–6665(purchaseseparately)Note:
Thiskitisnotrequiredforunitswiththe3wheeldrive
kitinstalled.
Procedure
ThisunitcomplieswiththeANSIB71.4-2004andEN836
Standardswhenequippedwithweightkit121–6665.
Note:Iftheunitisequippedwithathreewheeldrivekit
additionalweightisnotrequiredtomeetANSIB71.4-2004
andEN836standards.
9
InstallingEUDecals
Partsneededforthisprocedure:
1Warningdecal117-9537
Procedure
IfthismachinewillbeusedintheEU,afxthewarningdecal
117-9537overEnglishwarningdecal117-9536.
ProductOverview
g014674
1
2
3
45
67
8
Figure14
1.Engine5.Steeringwheel
2.Rollbar6.Tractionpedal
3.Controlpanel7.Footrest
4.Seat8.Reelswithgrassbaskets
Controls
TractionPedal
Thetractionpedal(Figure15)hasthreefunctions:tomake
themachinemoveforward,tomoveitbackward,andtostop
themachine.Pressthetopofthepedaltomoveforward
andthebottomofthepedaltomovebackwardortoassist
instoppingwhenmovingforward.Also,allowthepedal
tomovetotheneutralpositiontostopthemachine.For
operatorcomfort,donotresttheheelofyourfootonreverse
whenoperatingforward(Figure16).
18

g014603
1
2
3
Figure15
1.Tractionpedal—forward3.Steeringarmlockingpedal
2.Tactionpedal—reverse
Figure16
SteeringArmLockingPedal
Pressthepedal(Figure15)andraiseorlowerthesteering
armforoperatorcomfort,then,releasethepedaltolockthe
arminplace.
ThrottleControl
Thethrottlecontrol(Figure17)givestheoperatortheability
tocontrolthespeedoftheengine.Movingthethrottle
controltowardtheFastpositionincreasestheenginerpm;
movingthethrottlecontroltowardSlowwilldecreasethe
enginerpm.Groundspeedsareasfollows:
•3.2to8km/h(2to5mph)forwardmowingspeed
•16km/h(10mph)maximumtransportspeed
•4.0km/h(2.5mph)reversespeed
Note:Theenginecannotbestoppedbytheuseofthe
throttlecontrol.
g014599
1
23
4
56
78
9
Figure17
1.Throttlecontrol6.Batterywarninglight
2.Raise/LowerMowControl7.Serviceindicatorlight
3.Functionalcontrollever8.Glowplugindicatorlight
4.Ignitionswitch9.Watertemperaturelight
5.Engineoilpressurelight
Raise/LowerMowControl
Movingthecontrol(Figure17)forwardduringoperation
lowersthecuttingunitsandstartsthereels.Pullbackonthe
controltostopthereelsandraisethecuttingunits.During
operationthereelscanbestoppedbypullingbackonthe
controlmomentarilyandreleasingit.Startthereelsby
movingthecontrolforward.
FunctionalControlLever
Thefunctionalcontrollever(Figure17)providestwotraction
selectionsplusaNeutralposition.Itispermissibletoshift
frommowtotransportortransporttomow(nottoneutral)
whilethemachineisinmotion.Nodamagewillresult.
•RearPosition—neutralandbacklapping
•MiddlePosition—usedformowingoperation
•FrontPosition—usedfortransportoperation
IgnitionSwitch
Insertthekeyintotheswitch(Figure17)andturnitclockwise
asfaraspossibletotheStartpositiontostarttheengine.
Releasethekeyassoonastheenginestarts;thekeywillmove
totheOnposition.TurnthekeycounterclockwisetotheOff
positiontostoptheengine.
BatteryWarningLight
Thelight(Figure17)glowsifthebatterychargeislow.
19

EngineOilPressureLight
Thelight(Figure17)glowsiftheengineoilpressuredrops
belowasafelevel.
WaterTemperatureLight
Thelight(Figure17)glowsandtheengineautomaticallyshuts
downwhentheenginecoolanttemperaturegetstoohigh.If
theengineshutsdown,youcanstarttheengineanddrive
themachinefor10secondsbeforeitwillshutdownagain,
allowingyoutomovethemachinetoalocationwhereyou
canallowittocooldown.
ServiceIndicatorLight
Theserviceindicatorlight(Figure17)illuminateswhenthe
machinesensorsdetectanissuewithoneofthesystems
ofthemachine.Ifthislightilluminates,stopwhatyouare
doinganddrivetoasafelocationwhereyouoraservice
techniciancandiagnosetheproblem.Formoreinformation
ondiagnosingsystemissuesusingtheserviceindicatorlight,
refertoDiagnosingtheServiceIndicatorLight(page45).
GlowPlugIndicatorLight
Whentheglowplugindicatorlight(Figure17)islit,it
indicatestheglowplugsareon.
Note:Theglowplugindicatorlightmayilluminatefora
shorttimeaftertheenginehasstarted;thisisnormal.
HourMeter
Thehourmeter(Figure18)indicatesthetotalhoursthe
machinehasoperated.Itstartstofunctionwheneverthekey
switchisrotatedtoOn.
g014600
1
Figure18
1.Hourmeter
ParkingBrakeLever
Pulluponthebrakelever(Figure15)tosettheparking
brake.Disengageitbypushingitforwardanddown.Lock
theparkingbrakeanytimeyouleavethemachine.
g01461 0
Figure19
BacklapLever
Thebacklapleverislocatedundertheplasticcovertotheleft
oftheseat.Usethebacklaplever(Figure20)inconjunction
withtheraise/lowermowcontrolleverandthereelspeed
controlforbacklappingthereels.
g014620
1
2
Figure20
1.Backlaplever—mow
position
2.Backlaplever—backlap
position
ReelSpeedControl
Thereelspeedcontrolislocatedundertheplasticcoverto
theleftoftheseat.Usethereelspeedcontrol(Figure21)to
adjusttherpmofthereels.
20