Toro 4520 Manuals

Manuals and User Guides for Toro 4520. We have 6 Toro 4520 manuals available for free PDF download: Service Manual, Operator's Manual

Toro 4520 Service Manual (332 pages)

Brand: Toro | Category: Lawn Mower | Size: 33 MB

This Page Is Intentionally Blank.

3
- Service Manual
  1
- Table of Contents
  3
Chapter 1 Safety

7
- General Safety Instructions 1
  7
- General Safety Instructions
  8
  - Before Operating
    8
    
    While Operating
    9
    
    Maintenance and Service
    10
- Jacking Instructions
  11
- Safety and Instruction Decals
  12
- Chapter 2 -- Product Records and Maintenance
  13
- Maintenance
  13
- Product Records
  13
- Equivalents and Conversions
  14
- Torque Specifications
  15
Chapter 3 Gasoline Engine

19
- General Information 3
  19
- Specifications
  20
- General Information
  21
  - Operator's Manual
    21
- Fuel Evaporative Control System
  22
- Adjustments
  25
  - Choke Cable Adjustment
    25
    
    Throttle Cable Adjustment
    25
- Service and Repairs
  26
  - Fuel Evaporative Control System (Serial Number below 312000000)
    26
    
    Fuel Evaporative Control System (Serial Number above 312000000)
    28
    
    Fuel Tank
    30
    
    Engine
    32
    
    Engine Removal
    32
    
    Engine Installation
    34
Chapter 4 Diesel Engine

35
- Adjustments
  35
- General Information
  35
- Kubota Workshop Manual, Diesel Engine
  35
- Service and Repairs
  35
- Specifications
  35
- Chapter 5 -- Hydraulic System
  36
- Specifications
  36
- General Information
  37
  - Operator's Manual
    37
  - Adjust Throttle Control
    39
  - Adjustments 4
    39
  - Air Cleaner Assembly
    40
  - Service and Repairs 4
    40
  - Exhaust System
    42
  - Fuel Tank
    44
  - Radiator
    46
  - Engine
    48
    
    Engine Removal
    48
    
    Engine Installation
    50
  - Engine Bell Housing
    52
Chapter 5 Hydraulic System

53
- Specifications 5
  53
- Specifications
  55
- General Information
  56
  - Operator's Manuals
    56
  - Check Hydraulic Fluid Level
    56
  - Pushing Traction Unit
    56
  - Relieving Hydraulic System Pressure
    57
  - Traction Circuit Component Failure
    57
  - Hydraulic Hoses
    58
  - Hydraulic Hose and Tube Installation
    59
- Hydraulic Schematic
  62
- Hydraulic Flow Diagrams
  64
  - Traction Circuit
    65
    
    Lower Cutting Units
    67
    
    Raise Cutting Units
    69
    
    Mow and Backlap
    71
    
    Right and Left Turn
    73
- Special Tools
  74
  - Hydraulic Test Fitting Kit
    76
  - Measuring Container
    77
- Troubleshooting
  78
  - General Hydraulic System Problems
    78
    
    Testing 5
    79
    
    Traction Circuit Problems
    79
    
    Mow Circuit Problems
    80
    
    Lift/Lower Circuit Problems
    81
    
    Adjustments 5
    82
    
    Steering Circuit Problems
    82
  - Testing
    84
    
    Charge Relief Valve Pressure Test
    86
    
    Wheel Motor Efficiency Test
    90
    
    Steering/Lift Relief Valve Pressure Test
    92
    
    Service and Repairs 5
    93
    
    Lower Cutting Units Relief Valve (RV)
    94
    
    Pressure Test
    95
    
    Steering/Lift Circuit Gear Pump Flow Test
    96
    
    Power Steering Valve Test
    98
    
    Mow Circuit Gear Pump Flow Test
    100
    
    Mow Circuit Relief Pressure Test
    102
    
    Reel Motor Case Drain Flow Test
    104
  - Adjustments
    106
    
    Adjust Manifold Relief Valves
    106
    
    Adjust Traction Control Assembly
    107
  - Service and Repairs
    108
  - General Precautions for Removing and Installing Hydraulic System Components
    108
  - General Information 6
    108
  - Flush Hydraulic System
    109
  - Filtering Closed--Loop Traction Circuit
    110
  - Special Tools 6
    110
  - Hydraulic System Start--Up
    111
  - Gear Pump
    112
  - Gear Pump Service
    114
  - Piston (Traction) Pump
    118
  - Piston (Traction) Pump Service
    122
  - Piston Pump Crush Ring Replacement
    124
  - Front Wheel Motors
    126
  - Rear Wheel Motor (Optional 3WD)
    128
  - Wheel Motor Service
    130
  - Cutting Reel Motors
    132
  - Cutting Reel Motor Service
    134
  - Mow Control Manifold
    138
  - Mow Control Manifold Service
    140
  - Control Manifold Cartridge Valve Service
    143
  - Lift Cylinders
    144
  - Lift Cylinder Service
    146
  - Lift Control Manifold
    148
  - Lift Control Manifold Service
    150
  - Power Steering Valve
    152
  - Power Steering Valve Service
    154
  - Steering Cylinder
    156
  - Steering Cylinder Service
    158
Chapter 6 Electrical System

171
- Electrical System Quick Checks 6
  171
- General Information
  173
- System Operation
  173
  - Operator's Manual
    173
    
    CAN--Bus Communications
    173
    
    Electrical Drawings
    173
    
    Toro Electronic Controller (TEC)
    173
  - Turf Guardian
    174
- Special Tools
  176
- Troubleshooting
  178
  - Diagnostic Light
    178
    
    Diagnostic Display
    182
    
    Adjustments 6
    187
    
    Starting Problems
    187
    
    General Run & Transport Problems
    189
    
    Cutting Unit Operating Problems
    190
    
    TEC Logic Chart (Greensmaster 3300)
    191
    
    TEC Logic Chart (Greensmaster 3400)
    192
- Electrical System Quick Checks
  193
  - Battery Test (Open Circuit)
    193
    
    Charging System Test
    193
    
    Glow Plug System
    193
- Adjustments
  194
  - Parking Brake Switch
    194
    
    Neutral and Mow Switches
    195
- Component Testing
  196
  - Ignition Switch (Serial Number below 312000000)
    196
    
    Ignition Switch (Serial Number above 312000000)
    197
    
    Service and Repairs 6
    197
    
    Engine Oil Pressure Indicator Light (Greensmaster 3300)
    198
    
    Indicator Lights (Greensmaster 3400)
    199
    
    Hour Meter
    200
  - Fusible Links
    204
  - Seat Switch
    205
  - Neutral and Mow Switches
    206
  - Parking Brake Switch
    207
- Chapter 7 - - Chassis
  208
- Joystick Raise and Lower Switches
  208
- Backlap Switch
  209
- Hydraulic Solenoid Valve Coils
  210
- Main Power, Charge Circuit (Greensmaster 3300), Glow (Greensmaster 3400) and Fan (Greensmaster 3400) Relays
  212
- Kill (Greensmaster 3300) and Start (Greensmaster 3400) Relays
  213
- Toro Electronic Controller (TEC)
  214
- CAN--Bus Termination Resistors
  215
- Turf Guardian TM Leak Detector Oil Level Sensor (if Equipped)
  216
- Turf Guardian TM Leak Detector Alarm (if Equipped)
  217
- Starter Solenoid (Greensmaster 3300)
  218
- Fuel Pump (Greensmaster 3400)
  219
- Specifications 7
  219
- Fuel Solenoid (Greensmaster 3400)
  220
- Temperature Sender (Greensmaster 3400)
  221
- Diode Assembly (Greensmaster 3400)
  222
- Service and Repairs
  224
- Verify Interlock System Operation
  224
- Battery Care
  225
- Battery Storage
  225
- Battery Service
  226
Chapter 7 Chassis

231
- General Information 7
  231
- Specifications
  232
- General Information
  233
  - Operator's Manuals
    233
- Special Tools
  234
- Adjustments
  235
  - Parking Brake Adjustment
    235
- Service and Repairs
  236
  - Wheels
    236
    
    Brake Service
    238
    
    Brake Cables
    240
    
    Rear Wheel Spindle Assembly
    242
    
    Rear Steering Fork
    244
    
    Control Console
    246
    
    Tank Mount Plate Assembly
    248
    
    Cutting Unit Suspension Crossarm Assembly
    250
    
    Cutting Unit Suspension Assembly
    252
    
    Cutting Unit Suspension Service
    254
    
    Chassis
    256
    
    Frame Assembly
    256
Chapter 8 Dpa Cutting Units

257
- Specifications 8
  257
- Specifications
  258
- General Information
  259
  - Cutting Unit Operator's Manual
    259
    
    Supporting Cutting Unit When Servicing
    259
- Special Tools
  260
- Factors that Can Affect Cutting Performance
  262
- Set up and Adjustments
  266
  - Characteristics
    266
    
    Leveling Rear Roller
    267
- Service and Repairs
  268
  - Backlapping
    268
    
    Bedbar Assembly
    270
    
    Bedbar Adjuster Service
    272
    
    Bedknife Replacement and Grinding
    274
    
    Reel Assembly Removal and Installation
    276
    
    Reel Assembly Installation
    277
    
    Reel Assembly Removal
    277
    
    Reel Assembly Service
    280
    
    Preparing Reel for Grinding
    282
    
    Reel Motor Adapter
    283
    
    Front Roller
    284
    
    Rear Roller
    285
    
    Roller Service
    286
Chapter 9 Groomer

291
- Specifications
  292
- General Information
  293
- Troubleshooting
  294
  - Factors Affecting Grooming
    294
  - Grooming Reel Mechanical Problems
    295
- Adjustments
  296
  - Height/Depth of Groomer Adjustment
    296
- Service and Repairs
  297
  - Groomer Belt Replacement
    297
  - Groomer Cover
    298
  - Grooming Reel
    300
  - Grooming Reel
    304
  - Grooming Reel Service
    307
  - Grooming Reel Bearing Replacement
    308
  - Idler Assembly
    310
  - Drive)
    312
  - Idler Assembly
    312
  - Lift Arm Assembly
    314
  - Groomer Brush
    316

Toro 4520 Operator's Manual (56 pages)

Traction Unit

Brand: Toro | Category: Lawn Mower | Size: 6 MB

Table of Contents
3
Safety
4
- General Safety
  4
- Safety and Instructional Decals
  4
Setup
9
- Installing the Roll Bar
  10
- Installing the Seat
  10
- Installing the Service and Clip Decals
  10
- Installing the Steering Wheel
  11
- Activating and Charging the Battery
  12
- Installing the Oil Cooler
  13
- Installing the Grass-Basket Hooks
  14
- Installing the Cutting Units
  14
- Adding Rear Weight
  14
- Installing the CE Guard Kit
  15
- Installing the CE Decals
  15
- Reducing the Tire Pressure
  16
- Burnishing the Brakes
  16
Product Overview
16
- Controls
  16
- Specifications
  20
- Attachments/Accessories
  20
- Before Operation
  21
  - Before Operation Safety
    21
  - Fuel Specification
    21
  - Filling the Fuel Tank
    22
  - Performing Daily Maintenance
    22
- During Operation
  22
- After Operation
  27
  - After Operation Safety
    27
  - Inspecting and Cleaning after Mowing
    28
  - Hauling the Machine
    28
  - Towing the Machine
    29
Maintenance
30
- Maintenance Safety
  30
- Recommended Maintenance Schedule(S)
  31
  - Daily Maintenance Checklist
    32
- Engine Maintenance
  33
  - Engine Safety
    33
  - Servicing the Air Cleaner
    33
  - Servicing the Engine Oil
    33
- Fuel System Maintenance
  35
- Electrical System Maintenance
  37
- Electrical System Safety
  37
- Servicing the Battery
  37
- Locating the Fuses
  37
Drive System Maintenance
38
Cooling System Maintenance
40
Brake Maintenance
41
- Burnishing the Brakes
  41
- Adjusting the Brakes
  41
Belt Maintenance
41
- Adjusting the Alternator Belt
  41
Hydraulic System Maintenance
42
Cutting Unit Maintenance
44
- Blade Safety
  44
- Installing and Removing the Cutting Units
  44
- Checking the Reel-To-Bedknife Contact
  47
- Backlapping the Reels
  47
- Setting the Reel Speed
  48
- Reel Speed Table
  49
Diagnostics System
49
- Diagnosing the Service Indicator Light
  49
Storage
50
- Storage Safety
  50
- Preparing the Machine for Storage
  50

Toro 4520 Operator's Manual (52 pages)

Traction Unit

Brand: Toro | Category: Lawn Mower | Size: 3 MB

Introduction
2
Table of Contents
3
Safety
4
- Safe Operating Practices
  4
- Maintenance and Storage
  5
- Toro Mower Safety
  6
- Sound Power Level
  7
- Sound Pressure Level
  7
- Vibration Level
  7
- Safety and Instructional Decals
  8
Setup
13
- Installing the Roll Bar
  14
- Installing the Seat
  14
- Installing the Steering Wheel
  14
- Activating and Charging the Battery
  15
- Optional Oil Cooler
  16
- Installing the Grass Basket Hooks
  16
- Installing the Cutting Units
  17
- Adding Rear Weight
  18
- Installing EU Decals
  19
Product Overview
19
- Controls
  19
  - Throttle Control
    20
  - Ignition Switch
    20
  - Engine Oil Pressure Light
    21
  - Hour Meter
    21
- Specifications
  23
- Attachments/Accessories
  23
Operation
23
- Think Safety First
  23
- Checking the Engine Oil
  23
- Filling the Fuel Tank
  24
- Checking the Cooling System
  26
- Checking the Hydraulic Fluid Level
  26
- Draining Water from the Fuel Filter
  27
- Checking the Tire Pressure
  28
- Checking the Torque of the Wheel Nuts
  28
- Checking the Reel-To-Bedknife Contact
  28
- Break-In Period
  28
- Starting and Stopping the Machine
  28
- Checking the Safety Interlock System
  29
- Installing and Removing the Cutting Units
  30
- Setting the Reel Speed
  32
- Preparing the Machine for Mowing
  32
- Training Period
  32
- Before Mowing
  32
- Mowing Procedures
  33
- Transport Operation
  34
- Inspection and Cleanup after Mowing
  34
- Towing the Machine
  34
Maintenance
35
- Recommended Maintenance Schedule(S)
  35
  - Daily Maintenance Checklist
    36
- Engine Maintenance
  37
  - Servicing the Air Cleaner
    37
  - Changing the Engine Oil and Filter
    37
- Fuel System Maintenance
  38
  - Fuel Filter/Water Separator
    38
  - Fuel Lines and Connections
    39
- Electrical System Maintenance
  39
  - Servicing the Battery
    39
  - Storing the Battery
    40
  - Fuses
    40
- Drive System Maintenance
  41
- Cooling System Maintenance
  42
  - Cleaning the Radiator Screen
    42
- Brake Maintenance
  43
  - Adjusting the Brakes
    43
- Belt Maintenance
  43
  - Adjusting the Alternator Belt
    43
- Hydraulic System Maintenance
  44
  - Changing the Hydraulic Oil and Filter
    44
  - Checking the Hydraulic Lines and Hoses
    44
- Cutting Unit Maintenance
  45
  - Backlapping the Reels
    45
- Diagnostics System
  46
  - Diagnosing the Service Indicator Light
    46
Storage
47
Schematics
48
The Toro Total Coverage Guarantee
52

Toro 4520 Operator's Manual (48 pages)

traction unit

Brand: Toro | Category: Lawn Mower | Size: 3 MB

Introduction
2
Table of Contents
3
Safety
4
Setup
12
- Installing the Roll Bar
  13
- Installing the Seat
  13
- Installing the Steering Wheel
  13
- Activating and Charging the Battery
  14
- Installing the Oil Cooler (Optional)
  15
- Installing the Grass Basket Hooks
  15
- Installing the Cutting Units
  16
- Adding Rear Weight
  18
- Installing EU Decals
  18
Product Overview
18
- Controls
  18
  - Throttle Control
    19
  - Ignition Switch
    19
  - Engine Oil Pressure Light
    20
  - Hour Meter
    20
  - Fuel Shutoff Valve
    21
- Specifications
  22
- Attachments/Accessories
  22
Operation
22
- Think Safety First
  22
- Checking the Engine Oil
  22
- Filling the Fuel Tank
  23
- Using Biodiesel Fuel
  24
- Checking the Cooling System
  25
- Checking the Hydraulic Fluid Level
  25
- Draining Water from the Fuel Filter
  27
- Checking the Tire Pressure
  27
- Checking the Torque of the Wheel Nuts
  27
- Checking the Reel-To-Bedknife Contact
  27
- Break-In Period
  28
- Starting and Stopping the Machine
  28
- Checking the Safety Interlock System
  28
- Installing and Removing the Cutting Units
  29
- Setting the Reel Speed
  31
- Mowing with the Machine
  32
- Transporting the Machine
  33
- Cleaning and Inspecting the Machine
  33
- Towing the Machine
  33
Maintenance
34
Drive System Maintenance
40
Cooling System Maintenance
41
- Cleaning the Radiator Screen
  41
Brake Maintenance
42
- Adjusting the Brakes
  42
Belt Maintenance
42
- Adjusting the Alternator Belt
  42
Hydraulic System Maintenance
43
- Changing the Hydraulic Oil and Filter
  43
- Checking the Hydraulic Lines and Hoses
  43
Cutting Unit Maintenance
44
- Backlapping the Reels
  44
Diagnostics System
45
- Diagnosing the Service Indicator Light
  45
Storage
45
The Toro Total Coverage Guarantee
48

Toro 4520 Operator's Manual (48 pages)

traction unit

Brand: Toro | Category: Lawn Mower | Size: 3 MB

Table of Contents
3
Safety
4
Setup
11
- Installing the Roll Bar
  12
- Installing the Seat
  12
- Installing the Steering Wheel
  12
- Activating and Charging the Battery
  13
- Installing the Oil Cooler (Optional)
  14
- Installing the Grass-Basket Hooks
  14
- Installing the Cutting Units
  15
- Adding Rear Weight
  15
- Installing EU Decals
  15
- Reducing the Tire Pressure
  15
- Burnishing the Brakes
  15
Product Overview
16
- Controls
  16
  - Hour Meter
    17
  - Ignition Switch
    17
- Specifications
  19
- Attachments/Accessories
  19
Operation
20
- Think Safety First
  20
- Checking the Engine Oil
  20
- Filling the Fuel Tank
  21
- Using Biodiesel Fuel
  22
- Checking the Cooling System
  23
- Checking the Hydraulic-Fluid Level
  23
- Draining Water from the Fuel Filter
  24
- Checking the Reel-To-Bedknife Contact
  25
- Checking the Tire Pressure
  25
- Checking the Torque of the Wheel Nuts
  25
- Breaking in the Machine
  25
- Starting and Stopping the Engine
  25
- Checking the Safety Interlock System
  26
- Installing and Removing the Cutting Units
  26
- Setting the Reel Speed
  29
- Mowing
  29
- Inspecting and Cleaning after Mowing
  30
- Driving the Machine Without Mowing
  30
- Transporting the Machine
  30
- Towing the Machine
  31
Maintenance
33
- Recommended Maintenance Schedule(S)
  33
  - Daily Maintenance Checklist
    34
- Engine Maintenance
  35
  - Servicing the Air Cleaner
    35
  - Changing the Engine Oil and Filter
    35
- Fuel System Maintenance
  36
  - Replacing the Fuel Filter/Water Separator
    36
  - Inspecting the Fuel Lines and Connections
    37
- Electrical System Maintenance
  37
  - Servicing the Battery
    37
- Storing the Battery
  38
- Locating the Fuses
  38
- Jump-Starting the Machine
  39
Drive System Maintenance
39
Cooling System Maintenance
41
- Cleaning the Radiator Screen
  41
Brake Maintenance
42
- Adjusting the Brakes
  42
Belt Maintenance
42
- Adjusting the Alternator Belt
  42
Hydraulic System Maintenance
43
- Changing the Hydraulic Fluid and Filter
  43
- Checking the Hydraulic Lines and Hoses
  43
Cutting Unit Maintenance
44
- Backlapping the Reels
  44
Diagnostics System
45
- Diagnosing the Service Indicator Light
  45
Storage
45

Toro 4520 Operator's Manual (48 pages)

Traction Unit

Brand: Toro | Category: Lawn Mower | Size: 1 MB

Table of Contents
3
Safety
4
- General Safety
  4
- Safety and Instructional Decals
  4
Setup
9
- Installing the Roll Bar
  10
- Installing the Seat
  10
- Installing the Steering Wheel
  10
- Activating and Charging the Battery
  11
- Installing the Oil Cooler (Optional)
  12
- Installing the Grass-Basket Hooks
  13
- Installing the Cutting Units
  13
- Adding Rear Weight
  13
- Installing EU Decals
  13
- Installing the CE Guard Kit
  14
- Reducing the Tire Pressure
  14
- Burnishing the Brakes
  14
Product Overview
14
- Controls
  14
- Specifications
  18
- Attachments/Accessories
  18
Operation
18
- Before Operation Safety
  18
- Filling the Fuel Tank
  19
- Performing Daily Maintenance
  20
- During Operation Safety
  20
- Breaking in the Machine
  21
- Starting and Shutting off the Engine
  21
- Checking the Safety-Interlock System
  22
- Driving the Machine Without Mowing
  22
- Mowing
  23
- After Operation Safety
  24
- Inspecting and Cleaning after Mowing
  24
- Hauling the Machine
  24
- Towing the Machine
  25
Maintenance
26
- Recommended Maintenance Schedule(S)
  26
  - Daily Maintenance Checklist
    27
- Pre-Maintenance Procedures
  28
  - Pre-Maintenance Safety
    28
- Engine Maintenance
  28
  - Engine Safety
    28
  - Servicing the Air Cleaner
    28
  - Servicing the Engine Oil
    29
- Fuel System Maintenance
  31
- Electrical System Maintenance
  32
  - Electrical System Safety
    32
  - Servicing the Battery
    32
  - Locating the Fuses
    33
- Drive System Maintenance
  33
  - Checking the Tire Pressure
    33
- Checking the Torque of the Wheel Nuts
  33
- Adjusting the Transmission for Neutral
  33
- Adjusting the Transport Speed
  34
- Adjusting the Mowing Speed
  35
Cooling System Maintenance
35
Brake Maintenance
36
- Adjusting the Brakes
  36
Belt Maintenance
37
- Adjusting the Alternator Belt
  37
Hydraulic System Maintenance
37
Cutting Unit Maintenance
40
Diagnostics System
44
- Diagnosing the Service Indicator Light
  44
Storage
45

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Toro 4520 Service Manual (332 pages)

Table of Contents

This Page Is Intentionally Blank.

Chapter 1 Safety

Chapter 3 Gasoline Engine

Chapter 4 Diesel Engine

Chapter 5 Hydraulic System

Chapter 6 Electrical System

Chapter 7 Chassis

Chapter 8 Dpa Cutting Units

Chapter 9 Groomer

Toro 4520 Operator's Manual (56 pages)

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Toro 4520 Operator's Manual (52 pages)

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Toro 4520 Operator's Manual (48 pages)

Table of Contents

Toro 4520 Operator's Manual (48 pages)

Table of Contents

Toro 4520 Operator's Manual (48 pages)

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