Operator’s Manual 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 Original Instructions (EN) Date: 30.11.
ATTENTION THIS SYMBOL MEANS BE ALERT! YOUR SAFETY IS INVOLVED READ THIS MANUAL BEFORE USING THE TM5490 AND TM7490 MOWERS. 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 OR TORO AUTHORISED COMMERCIAL DEALERS.
1.5 CONTENTS 1.5 CONTENTS Page No. SAFETY PRECAUTIONS Training Preparation Operation Slopes Handling and Storage of Fluids Maintenance and Storage Transport Speed Decals EC CONFORMITY INFORMATION Noise Levels EC Declaration of Conformity INTRODUCTION SPECIFICATIONS Hydraulic System Recommended Lubricants and Hydraulic Fluids P.T.O.
1.6 CONTENTS 1.6 CONTENTS Page No.
SAFETY PRECAUTIONS 1.7 1.7 READ THIS MANUAL BEFORE USING THE TRAILED GANG MOWER, IT IS ESSENTIAL THAT OPERATORS STUDY IT FOR THEIR OWN SAFETY. THE FOLLOWING PRECAUTIONS MUST BE TAKEN TO HELP PREVENT ACCIDENTS. A CAREFUL OPERATOR WHO USES COMMON SENSE IS THE SAFEST OPERATOR. Training Read the instructions carefully. Be familiar with the controls and the proper use of the equipment. Learn how to stop the mower quickly in an emergency.
1.8 SAFETY PRECAUTIONS 1.8 Preparation Check that the machine complies with all applicable regulations, including those in force when used on the public highway. Check that the lights are in full working order and function correctly from the tractor. While mowing, always wear substantial footwear and long trousers. Do not operate the equipment when barefoot or wearing open sandals. Eye protection should be worn.
1.9 SAFETY PRECAUTIONS 1.9 Preparation continued Check the mower hydraulic system, particularly the hydraulic hoses, fittings and hose supports. Worn, crushed or damaged hoses can burst, with risks to health and damage to the machine and surrounding turf 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 to SPECIFICATIONS.
1.10 SAFETY PRECAUTIONS 1.10 Operation continued Disengage the PTO drive, change into neutral, set the tractor parking brake, stop the engine and remove ignition key. Block the mower suddenly and operate the mower handbrake before performing any service or maintenance procedure: - Before releasing blockages. - Before checking, cleaning or working on the mower. - After striking a foreign object. Inspect the mower for damage and make repairs before restarting and operating the equipment.
1.11 SAFETY PRECAUTIONS 1.11 Handling and Storage of Fluids Hydraulic Oil - Avoid contact with eyes and prolonged contact with skin. - Protective goggles should be worn when pouring. - Use of gloves or barrier cream is recommended. - Wash hands thoroughly after contact. - Store under cover, away from heat and sources of ignition. Lubricating Oil - Avoid skin and eye contact. - Wear impervious gloves when regular contact is likely and goggles when there is risk of splashing.
1.12 SAFETY PRECAUTIONS 1.12 Maintenance and Storage continued When disconnecting the machine from the tractor, ensure that: - The PTO drive is disengaged, the tractor parking brake is applied, the engine is stopped and the ignition key is removed. - The mower handbrake is applied. - The jockey wheel jack is in a safe working condition and securely adjusted to support the front of the machine. - The PTO shaft is disconnected from the tractor and stored on the rest provided.
1.13 SAFETY PRECAUTIONS 1.13 Decals Decal - Danger Latch Part No: 70-13-077 (0) Location: Pivot arms - front face (centre arm - top face) A) Caution B) Stop tractor engine/remove ignition key before releasing or operating transport latches. A Decal - Hydraulic Oil Part No: 111-3901 (A) Location: Topside of tank - behind filler / breather. B A B A) Transmission Oil B) Read and understand the Operators Manual.
1.14 SAFETY PRECAUTIONS 1.14 Decals continued Decal - Electric Controls (Electric lift only) Part No: 111-1777 (A) A B C Location: Adjacent to control levers D F E Decal - Serial Number Location: Front and side of bulkhead SPELLBROOK, BISHOP'S STORTFORD, HERTS. CM23 4BU. ENGLAND. N N G H TM5490 5 GANG TRAILED MOWER kg:1110 RPM: Code Serial No: 02700 311000001 N I SPELLBROOK, BISHOP'S STORTFORD, HERTS. CM23 4BU. ENGLAND.
1.15 SAFETY PRECAUTIONS 1.
1.16 SAFETY PRECAUTIONS 1.
EC CONFORMITY INFORMATION 1.17 1.17 Noise Levels The operator ear noise level for the Toro Trailed Gang Mowers is approximately 87.5dB(A) Led. The operator ear noise level stated above refers only to the noise level generated by the mowing equipment. This measurement was taken outside the tractor cab at a point close to the rear screen and in line with the operator ear position. The tractor noise was eliminated from the measurement by use of an acoustic screen.
INTRODUCTION 1.18 1.18 Introduction This manual has been provided to ensure that safe operating practises and procedures are adhered to. The Toro TM5490 and TM7490 Trailed Gang Mowers are fully independent hydraulically powered machines suitable for tractors having a power range in excess of 33 kW (45 bhp). It is easily attached to the tractor ringhitch and powered from the rear 540rpm PTO.
SPECIFICATIONS 1.19 1.19 Specifications ALL FIGURES ARE NOMINALLY QUOTED AT THE RATED PTO SPEED OF 540 RPM UNLESS OTHERWISE STATED.
1.20 SPECIFICATIONS 1.20 Cutterhead Drive System Drive Type: Hydraulic Pump: Hydraulic gear type Delivery Rate: 29.5 Litres per minute (6.5 UK gallons per minute) Cutterhead Motors: Hydraulic gear type, reversible, pressure balanced with integral differential pressure sensing relief check valve. Direct drive Control: Tractor PTO drive.
SPECIFICATIONS 1.21 1.21 Running Gear Tyres: 245/70 ‘General’ Tyre Pressure: 2.
1.22 SPECIFICATIONS Weight and Dimensions TM5490 Overall Working Width: 3680 mm (144.9˝) Mowing Width: 3500 mm (137.8˝) Transport Width: 2120 mm (83.5˝) Overall Length: 3600 mm (141.7˝) 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 mm (93.3˝) Overall Length: 3600 mm (141.
1.23 TM5490 DELIVERY CHECK LIST ITEM NO. DESCRIPTION ITEM No. DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 1.23 PART NO. QTY ITEM NOTE PART NO. QTY ITEM NOTE DEFLECTOR-REAR 876040W BRACKET-DEFLECTOR, LH 876041 BRACKET-DEFLECTOR, RH 876042 BOLT-CARR [M10*55 GRADE 4.
TM5490 GENERAL ASSEMBLY MK3 CUTTERHEADS 1.24 Cutterhead Position 1 2 3 4 5 1.
1.25 ASSEMBLING THE MOWER - TM5490 Assembling the Mower WARNING - PREVENT ACCIDENTS: Take care to avoid the sharp edges of the cutting cylinder and bottom blade when lifting or working on the cutterhead. The cutterhead is heavy - It is recommended that suitable lifting equipment be used when removing the cutterhead from the carton and during installation. If lifting equipment is not available, the cutterhead should be lifted from each end as indicated, by two people.
1.26 ASSEMBLING THE MOWER - TM5490 Assembling the Mower continued 6. Modify the cylinder adjustment handwheel assemblies (Item 8) on cutterhead 3 to the angled back position. Remove the nuts, bolts and washers from alternative hole positions ‘A’. Remove the nuts, bolts and washers which attach the handwheel assemblies to cutterhead frame. Remove the ring bolt clamp nuts, washers and spring washers and remove the handwheel assemblies.
1.27 TM7490 DELIVERY CHECK LIST ITEM NO. DESCRIPTION ITEM No. DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 1.27 PART NO. QTY ITEM NOTE PART NO. QTY DEFLECTOR-REAR 876040W BRACKET-DEFLECTOR, LH 876041 BRACKET-DEFLECTOR, RH 876042 BOLT-CARR [M10*55 GRADE 4.
1 TM7490 GENERAL ASSEMBLY MK3 CUTTERHEADS 1.28 Cutterhead Position Cutterhead Type 1 Left Hand (with rear deflector and bump stop) 3 Left Hand (with deflector) 2 3 Left Hand (with bump stop and roller plate / box) 4 5 1 Left Hand 5 1.
1.29 ASSEMBLING THE MOWER - TM7490 Assembling the Mower WARNING - PREVENT ACCIDENTS : Take care to avoid the sharp edges of the cutting cylinder and bottom blade when lifting or working on the cutterhead. The cutterhead is heavy - It is recommended that suitable lifting equipment be used when removing the cutterhead from the carton and during installation. If lifting equipment is not available the cutterhead should be lifted from each end as indicated, by two people.
1.30 ASSEMBLING THE MOWER - TM7490 Assembling the Mower continued 7. Modify cutterheads 5, 6 and 7 from left hand to right hand configuration. Remove protective cover (Item 5) and discard. Remove circlip (Item 7). Remove counterweight (Item 6) together with ‘O’ ring (Item 9) and refit to the non-drive end. Tighten the socket head cap screws to a torque of 80 Nm. Refit the circlip to the drive end. Note: It is important that the circlip is fitted to the drive end. 8.
1.31 ASSEMBLING THE MOWER - TM7490 Assembling the Mower continued C) Align and mesh the motor shaft spline with the coupling on the cutting cylinder. Ensure that the motor is fully located into the bearing housing. If necessary, gently tap the motor into position with a SOFT mallet, until it butts up to the bearing housing. D) Secure the motor in position using the fasteners previously removed and torque to 80 Nm.
1.32 1.32 ASSEMBLING THE MOWER Assembling the Mower continued ITEM NO. DESCRIPTION ITEM No. DESCRIPTION 1. 2. 3. 4. 5. 6. 7. 8. 9. PART NO. QTY ITEM NOTE PART NO.
1.33 1.33 COMMISSIONING THE MOWER Commissioning the Mower (Mechanical Control) Check oil level: Remove the filler cap on top of the hydraulic tank. Fill the hydraulic tank with the correct grade of hydraulic oil before use, refer to SPECIFICATIONS - HYDRAULIC SYSTEM, to the upper black line on the oil level sight gauge. This may be found at the front of the tank under the pump cover. Replace the filler cap and wipe clean any spillage.
1.34 1.34 COMMISSIONING THE MOWER Commissioning the Mower continued Check that the backlap control valve is locked in the “Normal Operation” position: 1 3 2 Connect up the mower to a suitable tractor. IMPORTANT: PREVENT DAMAGE - Refer to ATTACHING THE MOWER TO THE TRACTOR and follow the instructions given, otherwise damage could result.
1.35 1.35 COMMISSIONING THE MOWER Commissioning the Mower continued After making final adjustments, operate each circuit in turn to eliminate any air from the hydraulic system and closely observe the movement of the hydraulic hoses. Ensure that the motor hoses move freely without impeding the movement of the cutterheads through the full range of travel. Observe the hoses at each cutterhead to ensure that their ability to follow ground contours is not impeded.
1.36 COMMISSIONING THE MOWER Commissioning the Mower continued Operate the Lift/Lower control switches in turn to lift the left hand wing cutterhead, the centre three cutterheads and the right hand wing cutterhead. Carry out this exercise with care and observe the movement of the cutterheads to ensure that they are not impeded by poor routing of the hydraulic hoses. WARNING: PREVENT ACCIDENTS - The centre cutterhead will stop rotating when the transport height is reached.
1.37 COMMISSIONING THE MOWER Commissioning the Mower continued Add hydraulic oil: With all cutterheads on the ground, disengage the P.T.O. and stop the tractor engine. Initial operation of the mower unit will drain oil from the hydraulic tank to fill hoses, hydraulic cylinders, etc. Top up the hydraulic tank with the correct grade of oil, to the upper black line in the sight glass, refer to SPECIFICATIONS HYDRAULIC SYSTEM.
1.38 COMMISSIONING THE MOWER Commissioning the Mower continued Lower the handbrake lever to its lowest position to release the brakes. Perform the following road tests: WARNING: PREVENT ACCIDENTS - ALWAYS perform road tests taking due consideration of other road users. Tests should be performed on a private road where possible. Drive the tractor/mower combination in a straight line at 20 m.p.h. (32 k.p.h.) and brake gradually and firmly without skidding. Check the mower’s braking performance.
1.39 PREPARING THE TRACTOR Preparing the Tractor Prepare the mower for transport: Start the tractor engine and engage the P.T.O. drive. Operate the override control lever to lift all cutterheads to the fully raised transport position. Stop the tractor engine, return to the mower and secure all cutterhead suspension arms and outer cutterheads in the transport position by locking the transport latch safety locks.
1.40 PREPARING THE TRACTOR Preparing the Tractor continued The mower electric remote control system incorporates a cigar lighter plug connector and the lighting system incorporates a conventional 7 pin plug connector. The tractor must be equipped with compatible cigar lighter and lighting sockets. The tractor should be equipped with turf pattern tyres to minimise damage to fine turf areas. Consult your tractor operators manual or tractor dealer for full details of recommended tyre equipment.
1.41 ATTACHING THE MOWER TO THE TRACTOR Attaching the Mower to the Tractor Prepare the tractor: Before attaching the mower to the tractor ensure that the tractor is properly prepared, refer to PREPARING THE TRACTOR. Assemble the mower tow-hitch to the tractor: Ensure that the tractor ring-hitch is in the normal towing position. The mower should be standing on level ground with the handbrake applied and supported at the front end by the jockey wheel.
1.42 ATTACHING THE MOWER TO THE TRACTOR Attaching the Mower to the Tractor continued WARNING - PREVENT ACCIDENTS: Do not use a damaged breakaway cable. Discard and replace before using the mower. Release the handbrake: Carefully operate the handbrake to its lowest position. Assemble the P.T.O. shaft: WARNING: PREVENT ACCIDENTS - Always examine the condition of the P.T.O. shaft and guards before use. Never use a damaged P.T.O. shaft assembly. IMPORTANT: PREVENT DAMAGE - When fitting the P.T.O.
1.43 ATTACHING THE MOWER TO THE TRACTOR Attaching the Mower to the Tractor continued Check and adjust the P.T.O. operating length: Check the minimum P.T.O. operating shaft length (maximum compressed condition). It is essential that the P.T.O. shaft is not fitted at this stage. Set the tractor/mower combination with the tractor straight ahead on a steep upward slope, with the mower on level ground as shown. Gently reverse the tractor a short distance to fully compress the tow hitch drawbar.
1.44 1.44 ATTACHING THE MOWER TO THE TRACTOR Attaching the Mower to the Tractor continued = Assemble the P.T.O. shaft to tractor / mower and check that shaft does not fully compress. Remove chocks from wheels. = Dia 25mm one wall only A Check the maximum P.T.O. operating shaft length (maximum extended condition): Remove the P.T.O. shaft and set the tractor/mower combination with tractor turning sharply on a steep downward slope and the mower on level ground. Set the tractor parking brake.
1.45 DISCONNECTING THE MOWER TO THE TRACTOR Disconnecting the Mower from the Tractor WARNING: PREVENT ACCIDENTS - Before attempting to disconnect the mower from the tractor always ensure that: - The tractor and the mower are on level ground. - The tractor parking brake is applied, the P.T.O. drive disengaged, the engine is stopped, the ignition key is removed and apply the mower handbrake. Engage the mower brakes: Carefully raise the handbrake lever to its highest position to engage the mower brakes.
1.46 OPERATING THE MOWER Disconnecting the Mower from the Tractor continued Move the tractor away from the mower: Check that there are no obstructions and that all connections to the mower have been disconnected before driving the tractor away from the mower. Safety WARNING: PREVENT ACCIDENTS - Before operating the mower it is essential that: - - The operator reads and understands this manual. The operator should wear safety clothing, with no loose items e.g. tie, belt, etc.
1.47 OPERATING THE MOWER Cutterhead Position Controls Check hydraulic system: Check and note any hydraulic leaks, keeping well clear of the rotating cutting cylinders. Disengage the P.T.O. and stop the tractor engine before attempting to tighten loose hydraulic unions. Operate the cutterhead lift/lower controls: Note that there is one short “Override” and three long “Independent” control levers. Operate all the control levers into the ‘Down/Cut’ position.
1.48 OPERATING THE MOWER 1.48 Cutterhead Position Controls (Electrical Control) The remote control cutterhead position controls include an override control switch and three individual lift/lower control switches. N Override control switch: Push the override control switch (A) away to lower cutterheads simultaneously and pull backwards to raise cutterheads simultaneously. Note: This function will only operate on cutterheads where the individual control switches are in the ‘Down/Cut’ position.
1.49 OPERATING THE MOWER 1.49 Cutterhead Drive Direction Control (Electrical Control) Note: The cutter head drive switch (E) will only operate when the override control switch (A) is in the down/cut position. E Forward rotation cutterhead drive engagement: Operate the cutterhead drive switch to the ‘Forward’ position. FORWARD Reverse rotation cutterhead drive engagement: Operate and hold the cutterhead drive switch to the ‘Reverse’ position.
1.50 OPERATING THE MOWER Cutterhead Drive Direction Control (Electrical Control) continued WARNING: PREVENT ACCIDENTS - For full safety isolation disengage the tractor PTO drive and lower the cutterheads to the ground. WARNING: PREVENT ACCIDENTS - For full safety isolation disengage the tractor PTO drive and lower the cutterheads to the ground. To restore the electrical lift control system after the emergency stop button has been operated: 1. Ensure the tractor PTO drive is disengaged. 2.
1.51 OPERATING THE MOWER 1.51 Cutterhead Drive Direction Control (Electrical Control) continued 8. Return the manual override control valve screw to its original position. On doing this the cutterhead arms will fully engage with the transport latches. A 9. Engage all transport latch safety locks as shown. 10. Latch outer cutterheads. Cutterhead Setup A - Manual override control valve All cutterheads should have been checked for cylinder to bottom blade adjustment and height of cut.
1.52 OPERATING THE MOWER 1.52 General 1. Mount the tractor, start the engine and set the engine speed at a fast idle. WARNING: PREVENT ACCIDENTS - Ensure that the immediate area is entirely clear of bystanders and obstructions which could interfere with the machine, before engaging the rear P.T.O. in the correct gear for 540 rpm. 2. Operate the mower override control switch to lift the dead weight of each cutterhead from its transport latch. WARNING: PREVENT ACCIDENTS - Disengage the tractor P.T.O.
1.53 OPERATING THE MOWER 1.53 General (Electric Lift Only) Override control: With the cutterheads on the ground set all the Lift/ Lower control switches to the ‘Down/Cut’ position and operate the override control switch to the ‘Neutral’ position. All cutting cylinders will stop immediately. Operate the override control switch to the ‘Raise’ position. All cutterheads will rise.
1.54 OPERATING THE MOWER Unblocking the Cutting Cylinders WARNING: PREVENT ACCIDENTS - Before attempting to clear any blockage from the cutting cylinders on this machines ensure, all of the following: - Stop the machine on level ground. - Apply the parking brake and disengage all drives. - Lower the cutting units to the ground or securely lock in the designated transport positions. - Stop the engine and remove the ignition key to isolate all power sources and check that they are stopped.
1.55 OPERATING THE MOWER 1.55 Cutterhead General Information The mower is designed to be used with MK3 200mm (8˝) fixed or floating cutterheads or MK3 254mm (10˝) fixed cutterheads. It is essential that the relationship between the bottom blades and the cutting cylinders are kept in good adjustment and that cutting edges are kept sharp to ensure good cutting performance, minimum power consumption and prolonged life for the cutting edges, refer to MAINTENANCE - CUTTERHEADS.
1.56 OPERATING THE MOWER 1.56 MK3 200 mm (8˝) Fixed Cutterhead Pivot knuckle fixing: Secure the bolt in the front “fixed” hole position ‘A’ as shown. A Height of cut adjustment: The height of cut is gauged by the position of the rear roller. B Turn the adjusting nut assembly ‘B’ both ends clockwise to decrease height of cut ‘E’ or anticlockwise to increase height of cut ‘E’. IMPORTANT: PREVENT DAMAGE - Do not attempt to unlock the nut assemblies, ‘B’.
1.57 OPERATING THE MOWER General Operating Hints 1. The rotational speed of the cutting cylinders should always be kept as high as possible in order to maintain the highest quality of cut. This in turn requires that the tractor engine speed be kept as high as possible without exceeding 540 rpm P.T.O. speed. 2. The quality of cut will deteriorate if the forward speed is excessive. Always balance the quality of cut with the work rate required and set the forward speed accordingly. 3.
1.58 OPERATING THE MOWER General Operating Hints continued WARNING: PREVENT ACCIDENTS - Take care when travelling over obstacles such as 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 is detached from the tractor always support the P.T.O. shaft on P.T.O. rest. Never allow the P.T.O. shaft to rest in contact with the ground. 1.
1.59 MAINTENANCE Maintenance WARNING: PREVENT ACCIDENTS - When carrying out maintenance procedures it is essential that: - The P.T.O drive is disengaged. The tractor is in neutral. The tractor parking brake is applied. The engine is switched off. The ignition key is removed. The mower handbrake is applied. The cutterheads are fully lowered to the ground. The hydraulic system pressure is fully released. The safety precautions listed in this manual have been read and understood.
MAINTENANCE 1.60 Maintenance continued WARNING: PREVENT ACCIDENTS - Use hazardous substances carefully. The following fluids are identified as being hazardous; Substances Diesel oil Lubricating oil Hydraulic oil Grease Assessed risk Low Low Low Low When using any of the above fluids it is recommended that eye protection and gloves are worn and that care is taken to prevent spillage. Avoid contact with skin; wash off spillage with soap and water.
1.61 MAINTENANCE 1.61 Running In Period During first 50 hours of use and in addition to routine checks, refer to DAILY BEFORE USE. Check wheel nut torque settings before use. Wheel nut torque setting - 224 Nm. At first 50 hours of use and in addition to routine checks, refer to DAILY BEFORE USE. Adjust the brake system. WARNING: PREVENT ACCIDENTS Ensure that the mower is securely coupled to the tractor, refer to ATTACHING THE MOWER TO THE TRACTOR.
MAINTENANCE 1.62 1.62 Running In Period continued Grease pivot points: Clean and grease all grease points with a good quality medium grade grease. 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 and debris etc. and will ensure maximum working life.
1.63 MAINTENANCE Daily And Before Use Check hydraulic oil level: Check the hydraulic oil level in the sight glass with all cutterheads lowered to the ground. The sight glass is located at the front of the hydraulic reservoir beneath the pump cover. If the level is below the top line, top up with the correct grade of hydraulic oil as necessary, refer to SPECIFICATIONS. IMPORTANT: PREVENT DAMAGE - If there is noticeable hydraulic oil loss, the leakage source must be found and sealed before using the mower.
1.64 MAINTENANCE Daily And Before Use continued Check towing eye: Inspect the towing eye for wear. Replace the towing eye when worn to ¾ of its original thickness. Lubricating the towing eye may extend the life of the eye. Lubricate the P.T.O shaft: Remove the P.T.O. shaft connection from tractor and withdraw the telescoping shaft to expose the grease nipple through the inner guard aperture. Apply a generous amount of grease of the correct grade, refer to SPECIFICATIONS. Reconnect to the tractor P.T.O.
1.65 MAINTENANCE 1.65 Every 50 Hours continued A Note: The roller should still rotate freely after adjustment. Overtightening of nuts ‘A’ could lead to premature bearing failure. Check wheel nut torque: Wheel nut torque setting - 224 Nm. Lubricate all grease points: Clean and grease all grease points, including hubs, tow hitch and pivot points with a good compound of the grade specified, refer to SPECIFICATIONS. Replace any grease nipples which are damaged.
1.66 MAINTENANCE 1.66 Every 250 Hours continued Inspect the brakes shoes for wear: Remove the wheel hubs and inspect the brake shoes. The shoes must be replaced if the lining thickness is less than 1.5mm. Use genuine Toro replacement parts. Do not reline brake shoes. Inspect the brake wedges: Check that the brake wedges operate the brake shoes correctly. Wedges which are worn excessively will not apply the brakes fully and must be replaced.
1.67 MAINTENANCE 1.67 Every 500 Hours Replace all brake cables. Service the pump gearbox: Drain the pump gearbox oil by removing the drain plug. Remove the dipstick. When the gearbox is fully drained, replace the drain plug. Refill the gearbox with new gear oil of the correct grade, refer to SPECIFICATIONS, to the upper mark on the dipstick. Replace the dipstick. Ensure that all plugs are tightened securely.
1.68 MAINTENANCE Cutterhead Cylinder to Bottom Blade Adjustment 0 90 IMPORTANT: PREVENT DAMAGE - It is essential that the relationship between the bottom blades and the cutting cylinders is kept in good adjustment in order to ensure good cutting performance, minimum power consumption and prolonged life for the cutting edges. Carry out the following procedure before commencing work and re-check the settings every few hours.
1.69 MAINTENANCE Cutterhead Cylinder to Bottom Blade Adjustment continued Do not be tempted to over adjust, thus causing heavy contact between the cylinder and bottom blade, as this will cause very rapid uneven wear to take place leading to tram lining and waviness of the cutting edges. The frictional losses will be high and a significant amount of power will be absorbed, thus reducing the power available for cutting.
MAINTENANCE 1.70 1.70 Cutterhead Back Lapping This process is recommended for restoring the sharp cutting edges to cylinders and bottom blades which are essential for good quality grass cutting. 1 This process can only deal with a small amount of metal removal to restore the cutting edges. If the blade edges are seriously worn or damaged it will be necessary to remove the component parts and have them reground. The back lapping process: 1. Lower the cutterheads to the ground.
1.71 MAINTENANCE Cutterhead Back Lapping continued 9. If further backlapping is necessary repeat steps 3 to 8. 10. Thoroughly remove and wash off all traces of the carborundum paste from the cylinders and bottom blades. 11. Move the control lever to the ‘Normal Operation’. As the backlap control lever is moved towards the ‘Normal Operation’ position the backlap control lock will be pushed outwards.
1.72 MAINTENANCE Cutterhead Bottom Blade Replacement continued The new bottom blade must be ground on its holder prior to refitting to the cutterhead. Adjust the cutting cylinder position to give adequate clearance for fitting the new bottom blade holder. Refit the bottom blade holder assembly to the cutterhead using the original fixing bolts and tighten to a torque of 35Nm (26 lbf.ft). Finally adjust the cylinder to the bottom blade, refer to CUTTERHEAD CYLINDER TO BOTTOM BLADE ADJUSTMENT. 1.
1.73 GRASS CUTTING FAULTS FAULT POSSIBLE CAUSE REMEDY Areas of uncut grass at point of overlap between cutting cylinders Turning too tightly Reduce turning radius Mower sliding sideways when travelling across face of slope Mow up/down slope 1.
1.74 GRASS CUTTING FAULTS 1.
TROUBLE SHOOTING 1.75 1.75 When using the following chart it may be found that overhaul of major components or hydraulic pressure adjustments are necessary. In this case it is recommended that your authorised dealer make these repairs as they are properly equipped to do this work. WARNING: PREVENT ACCIDENTS - ALWAYS Apply the parking brake, switch off the engine and remove the ignition key before attempting to work on the mower.
TROUBLE SHOOTING 1.76 1.76 FAULT POSSIBLE CAUSE REMEDY Cylinder ‘knocks’ while rotating High spot on cylinder or bottom blade due to contact with foreign object Remove high spot with a stone and back lap to restore cutting edges.
1.77 TROUBLE SHOOTING 1.77 FAULT POSSIBLE CAUSE REMEDY Heavy wear on P.T.O. shaft Lack of lubrication Re grease and repeat every 8 hours of work Insufficient overlap between shaft inner and outer sections Check and adjust the P.T.O.
CONNECTION DIAGRAM 1.78 ITEM NO. DESCRIPTION ITEM No. DESCRIPTION 1. 2. 3. 4. 5. 6. 1.78 PART NO. QTY ITEM NOTE PART NO.
TM5490 HYDRAULIC CIRCUIT DIAGRAM 1.79 17 15 15 17 15 15 15 13 16 16 14 12 14 16 9 11 11 10 8 7 6 1.
1.80 TM5490 HYDRAULIC CIRCUIT PARTS LIST ITEM NO. DESCRIPTION ITEM No. DESCRIPTION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. LIFT CYLINDER LIFT CYLINDER LIFT CYLINDER LIFT CYLINDER LIFT CYLINDER LIFT CONTROL VALVE OVER-RIDE CONTROL VALVE CHECK VALVE ROTARY VALVE 3 BANK RETURN FILTER SUCTION STRAINER TANDEM PUMP ASSEMBLY TANDEM PUMP ASSEMBLY 250 BAR RELIEF VALVE ASSEMBLY DIVERTER VALVE CUTTERHEAD MOTOR L.H. CUTTERHEAD MOTOR R.H 1.80 PART NO. QTY ITEM NOTE PART NO.
1.81 TM5490 ELECTRIC HYDRAULIC CIRCUIT DIAGRAM 1.
1.82 TM5490 ELECTRIC HYDRAULIC CIRCUIT PARTS LIST ITEM NO. DESCRIPTION ITEM No. DESCRIPTION 1. 2A. 2B. 2C. 2D. 2E. 2F. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. SOLENOID VALVE SOLENOID VALVE SOLENOID VALVE SOLENOID VALVE SOLENOID VALVE SOLENOID VALVE SOLENOID VALVE SOLENOID VALVE VALVE - MANUAL LIFT OVERRIDE SOLENOID VALVE CHECK VALVE SUCTION STRAINER HYDRAULIC CYLINDER NO. 1 HYDRAULIC CYLINDER NO. 2 HYDRAULIC CYLINDER NO.
17 17 17 19 18 18 6 2 4 16 PUMP ASSEMBLY 17 17 19 18 BACKLAP VALVE (ROTARY) 250 Bar at 29.5 l/min 15 5 3 250 Bar at 29.5 l/min 16 14 250 Bar at 29.5 l/min 16 17 19 18 7 1 115 Bar at 15 l/min PUMP ASSEMBLY 13 11 13 T LIFT VALVE MANUAL OPERATION TO BACKLAP 12 P T 10 B P A OVERRIDE VALVE A3 A2 A1 9 8 7 6 5 4 3 2 1 1.83 TM7490 HYDRAULIC CIRCUIT DIAGRAM 1.
1.84 TM7490 HYDRAULIC CIRCUIT PARTS LIST ITEM NO. DESCRIPTION ITEM No. DESCRIPTION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. LIFT CYLINDER LIFT CYLINDER LIFT CYLINDER LIFT CYLINDER LIFT CYLINDER LIFT CYLINDER LIFT CYLINDER LIFT CONTROL VALVE OVER-RIDE CONTROL VALVE CHECK VALVE ROTARY VALVE 3 BANK RETURN FILTER SUCTION STRAINER TANDEM PUMP ASSEMBLY TANDEM PUMP ASSEMBLY 250 BAR RELIEF VALVE ASSEMBLY DIVERTER VALVE CUTTERHEAD MOTOR L.H. CUTTERHEAD MOTOR R.H 1.84 PART NO.
33 20 18 16 15 6 2 4 21 19 17 24 22 BACKLAP VALVE (ROTARY) 250 Bar at 29.5 l/min 30 PUMP ASSEMBLY 5 3 25 23 250 Bar at 29.5 l/min 31 250 Bar at 29.5 l/min 32 28 26 7 1 29 27 115 Bar at 15 l/min PUMP ASSEMBLY 35 34 14 MANUAL OPERATION TO BACKLAP 36 5 6 1 7 8 P 2c 2b 2a 3 9 S1 10 S2 4 S3 2d 2e 2f 11 WT 12 T2 13 1.85 TM7490 ELECTRIC HYDRAULIC CIRCUIT DIAGRAM 1.
1.86 TM7490 ELECTRIC HYDRAULIC CIRCUIT PARTS LIST ITEM NO. DESCRIPTION ITEM No. DESCRIPTION 1.86 PART NO. QTY ITEM NOTE PART NO. QTY ITEM NOTE 1. 2A. 2B. 2C. 2D. 2E. 2F. 3. 4. 5. 6. 7. SOLENOID VALVE SOLENOID VALVE SOLENOID VALVE SOLENOID VALVE SOLENOID VALVE SOLENOID VALVE SOLENOID VALVE SOLENOID VALVE VALVE - MANUAL LIFT OVERRIDE SOLENOID VALVE CHECK VALVE HYDRAULIC CYLINDER NO. 1 66-06-001W 1 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33.
1.87 TM5490 & TM7490 ELECTRICAL CIRCUIT DIAGRAM 1.
1.88 TM5490 & TM7490 ELECTRICAL CIRCUIT DIAGRAM ITEM NO. DESCRIPTION ITEM No. DESCRIPTION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. SWITCH - EMERGENCY STOP RELAY LED TOGGLE SWITCH DIODE UMBILICAL CABLE (INCLUDES ITEM 7) PLUG AUTOMOTIVE RELAY HOUR METER SOLENOID 12V CCS5012D PROXIMITY SWITCH ASSEMBLY MAGNET 1.88 PART NO. QTY ITEM NOTE PART NO.
WARRANTY 1.89 1.89 The Toro Total Coverage Guarantee A Limited Warranty Conditions and Products Covered The Toro® Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial product (“Product”) to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first.
1.90 NOTES 1.
1.91 NOTES 1.
1.92 NOTES 1.
1.93 CUSTOMER INFORMATION 1.93 Machine Details Model: ......................................... Machine Serial No: ......................................... Cutterhead Serial No’s: ......................................... ......................................... ......................................... ......................................... ......................................... ................................
