Toro ProLine H800 Rotary Mower User manual

FormNo.19241SLRevA

ProLineH800

(Models31050and31050TE)

8111LyndaleAvenueSouth

Bloomington,MN55420

OriginalInstructions(EN)

Contactusatwww.Toro.com.

AllRightsReserved

RevisionHistory

RevisionDateDescription

A

06/2020

Initialissue.

RevisionHistoryPage2

ProLineH800

19241SLRevA

ReaderComments

TheToroCompanyT echnicalAssistanceCentermaintainsacontinuous

efforttoimprovethequalityandusefulnessofitspublications.Todothis

effectively,weencourageuserfeedback.Pleasecommentonthecompleteness,

accuracy,organization,usability,andreadabilityofthismanualbyane-mail

to[email protected].

orMailto:

TechnicalPublicationManager,Commercial

TheToroCompany

8111LyndaleAvenueSouth

Bloomington,MN55420-1196

Phone:+1952-887-8495

ProLineH800

Page3

ReaderComments

19241SLRevA

NOTES:

Page4

ProLineH800

19241SLRevA

Preface

Thepurposeofthispublicationistoprovidetheservicetechnicianwiththe

informationfortroubleshooting,testing,andrepairofthemajorsystemsand

componentsontheProLineH800.

RefertotheOperator’sManualsforoperating,maintenance,andadjustment

instructions.SpaceisprovidedinChapter2(page2–1)ofthisbooktoinsertthe

Operator’sManualsandPartsCatalogforyourmachine.Additionalcopiesofthe

Operator’sManualsandPartsCatalogsareavailableatwww.toro.com.

TheToroCompanyreservestherighttochangetheproductspecicationsor

thispublicationwithoutnotice.

DANGER

Thissafetysymbolmeansdanger.Whenyouseethissymbol,

carefullyreadtheinstructionsthatfollow.Failuretoobeythe

instructionscouldkillorcauseseriouspermanentinjuryordisability.

WARNING

Thissafetysymbolmeanswarning.Whenyouseethissymbol,

carefullyreadtheinstructionsthatfollow.Failuretoobeythe

instructionscanresultinseriousinjury.

CAUTION

Thissafetysymbolmeanscaution.Whenyouseethissymbol,

carefullyreadtheinstructionsthatfollow.Failuretoobeythe

instructionscanresultinminortomoderateinjury.

IMPORTANT

TheImportantnoticewillgivetheimportantinstructionswhichyou

mustfollowtopreventdamagetothesystemsorcomponentson

themachine.

Note:ANotewillgivethegeneralinformationaboutthecorrectoperation,

maintenance,service,testing,orrepairofthemachine.

ProLineH800

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Preface

19241SLRevA

ServiceProcedureIcons

ThefollowingiconsappearthroughoutthisServiceManualtobringattentionto

specicimportantdetailsofaserviceprocedure.

CriticalProcess

Thisiconisusedtohighlight:

•Installingsafetyequipment(shields,guards,seatbelts,brakesandR.O.P .S.

components)thatmayhavebeenremoved.

•Dimensionsorsettingsthatmustbemaintainedforpropermachineoperation.

•Aspecicfastenertighteningsequence.

•Componentorientationthatmaynotbeobvious.

CriticalTorque

Thisiconisusedtohighlightanassemblytorquerequirementthatisdifferent

thanwhatisrecommendedintheStandardTorqueT ables;refertoT orque

Specications(page2–7).

FluidSpecications

Thisiconisusedtohighlightuidspecicationsandcapacitiesthatareless

common,andmaynotappearonthemachineservicedecalorinthemachine

Operator’sManual.

Note:RefertotheservicedecalonthemachineandthemachineOperator’s

Manualforcommonlyuseduidspecicationsandcapacities.

Preface

Page6

ProLineH800

19241SLRevA

TableofContents
Preface................................................................................................................5
Chapter1:Safety............................................................................................1–1
SafetyInstructions.......................................................................................1–2
JackingInstructions.....................................................................................1–7
SafetyandInstructionalDecals....................................................................1–9
Chapter2:SpecicationsandMaintenance....................................................2–1
Specications...............................................................................................2–2
TorqueSpecications...................................................................................2–7
ShopSupplies............................................................................................2–13
SpecialT ools..............................................................................................2–15
Chapter3:Troubleshooting.............................................................................3–1
GEARS–TheSystematicApproachtoDening,DiagnosingandSolving
Problems......................................................................................................3–2
GeneralHydraulicSystemProblems............................................................3–3
SteeringCircuitProblems.............................................................................3–5
TheHeightOfCutCircuitProblems..............................................................3–6
TheCuttingDeckLiftCircuitProblems..........................................................3–7
TheHopperLiftCircuit..................................................................................3–8
TheHopperTiltCircuit..................................................................................3–9
Chapter4:Engine...........................................................................................4–1
GeneralInformation.....................................................................................4–2
ServiceandRepairs.....................................................................................4–3
Chapter5:HydraulicSystem...........................................................................5–1
GeneralInformation.....................................................................................5–3
HydraulicSchematic...................................................................................5–13
HydraulicFlowDiagrams............................................................................5–14
TestingtheHydraulicSystem......................................................................5–32
ServiceandRepairs...................................................................................5–63
Chapter6:ElectricalSystem...........................................................................6–1
GeneralInformation.....................................................................................6–2
ElectricalSystemQuickChecks....................................................................6–3
TestingtheElectricalComponents................................................................6–6
ServiceandRepairs...................................................................................6–44
Chapter7:Chassis..........................................................................................7–1
GeneralInformation.....................................................................................7–2
ServiceandRepairs.....................................................................................7–3
Chapter8:AxleandPTO.................................................................................8–1
GeneralInformation.....................................................................................8–2
ServiceandRepairs.....................................................................................8–3
Chapter9:HopperAssembly..........................................................................9–1
GeneralInformation.....................................................................................9–2
ServiceandRepairs.....................................................................................9–3
Chapter10:CuttingUnit................................................................................10–1
GeneralInformation...................................................................................10–2
ServiceandRepairs...................................................................................10–3
AppendixA......................................................................................................A–1
ElectricalDrawingDesignations....................................................................A–2
HydraulicSchematic.....................................................................................A–3
ElectricalSchematic-Main...........................................................................A–5
ElectricalSchematic-Lights.........................................................................A–6
WireHarnessDiagram-Main.......................................................................A–7
WireHarnessDiagram-Lights.....................................................................A–8
AdditionalReferenceMaterials
Yanmar3TNV76ServiceManual
ProLineH800
Page7
Preface
19241SLRevA

Yanmar3TNV80FServiceManual

DanfossDDC20AxialPistonPumpServiceManual

ParkerTorqmotorServiceProcedure(TF ,TG,TH,andTLSeries)

GrammerSeatsRepairManual

Preface

Page8

ProLineH800

19241SLRevA

Chapter1

Safety

TableofContents

SafetyInstructions................................................................................................................................1–2

Supervisor’sResponsibilities.............................................................................................................1–2

BeforeOperatingtheMachine...........................................................................................................1–3

WhileOperatingtheMachine.............................................................................................................1–4

MaintenanceandService...................................................................................................................1–5

JackingInstructions..............................................................................................................................1–7

RaisingtheFrontoftheMachine........................................................................................................1–7

RaisingtheRearoftheMachine........................................................................................................1–9

SafetyandInstructionalDecals............................................................................................................1–9

ProLineH800

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Safety

19241SLRevA

SafetyInstructions

TheProLineH800machinesaretestedandcertiedbyT oroforcompliance

withexistingsafetystandardsandspecications.Althoughhazardcontroland

accidentpreventionarepartiallydependentuponthedesignandcongurationof

themachine,hazardcontrolandaccidentpreventionarealsodependentupon

theawareness,concernandpropertrainingofthepersonnelinvolvedinthe

operation,transport,maintenanceandstorageofthemachine.Improperuseor

maintenanceofthemachinecanresultininjuryordeath.Toreducethepotential

forinjuryordeath,complywiththefollowingsafetyinstructions.

WARNING

Toreducethepotentialofinjuryordeath,complywiththefollowing

safetyinstructionsaswellasinformationfoundintheOperator’s

Manuals.

Supervisor’sResponsibilities

1.EnsurethattheoperatorsarefullytrainedandfamiliarwiththeOperator’s

Manual,alloftheoperatingandsafetydecalsonthemachineandany

operationinformationfoundintheInstallationInstructionsforaccessories

thatareinstalledonthemachine.

2.Establishyourownspecialproceduresandworkrulesforunusualoperating

conditions(e.g.,slopestoosteepformachineoperation).Surveythemowing

sitecompletelytodeterminehillsonwhichyoucanoperatesafely.When

performingthissitesurvey,alwaysunderstandandtakeintoconsideration

theturfconditionandrolloverrisk.

Safety:SafetyInstructions

Page1–2

ProLineH800

19241SLRevA

BeforeOperatingtheMachine

•ReviewandunderstandthecontentoftheOperator’sManualsbeforestarting

andoperatingthemachine.Becomefamiliarwiththecontrolsandknowhow

tostopthemachineandenginequickly.AdditionalcopiesoftheOperator’s

Manualsareavailableatwww.toro.com.

•Neverallowchildrentooperatethemachine.Neverallowadultstooperate

themachinewithoutproperinstructions.

•Becomefamiliarwiththecontrolsandknowhowtostopthemachineand

enginequickly.

•Keepalltheshields,safetydevices,anddecalsinplace.Ifashield,safety

device,ordecalisillegibleordamaged,repairorreplaceitbeforeoperating

themachine.

•Alwayswearsubstantialshoes.Donotoperatethemachinewhilewearing

sandals,tennisshoesorsneakers.Donotwearloosettingclothingwhich

couldgetcaughtinmovingpartsandcausepersonalinjury.

•Wearingsafetyglasses,safetyshoes,longpantsandahelmetisadvisable

andrequiredbysomelocalsafetyandinsuranceregulations.

•Makesureworkareaisclearofobjectswhichmightbepickedupandthrown

bytheattachments.

•Keepeveryone,especiallychildrenandpets,awayfromtheareaofoperation.

•Ensurethesafetyinterlocksarefunctioningproperly.Adjustorreplace

anymalfunctioningswitchesorinterlockmechanismsbeforeoperatingthe

machine.RefertoCheckingtheOperationoftheInterlockSwitches(page

6–5)foradditionalinformation.

•Dieselfuelishighlyammable;handleitcarefully.

–Storefuelincontainersspecicallydesignedforstoringfuel.

–Donotremovethefueltankcapofthemachinewhiletheengineishot

orrunning.

–Donotsmokewhilehandlingthefuel.

–Fillthefueltankoutdoorsandonlytoalevelwithinaninchofthetopof

thetank,notthellerneck.Donotoverllthefueltank.

–Afterrefuelingthemachine,installthefueltankandfuelcontainercaps.

–Ifyouspillfuel,donotattempttostarttheenginebutmovethemachine

awayfromthespill.Avoidcreatinganysourceofignitionuntilfuelvapors

havedissipated.Wipeupanyspilledfuel.

ProLineH800

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Safety:SafetyInstructions

19241SLRevA

WhileOperatingtheMachine

•Sitontheseatwhenstartingandoperatingthemachine.

•Anytimeyouparkthemachine(shortorlongterm),lowerthecuttingdeckto

theground.

IMPORTANT

Whenyoulowerthecuttingdecktotheground,thepressurefrom

thehydraulicliftcircuitreleasesandpreventsthecuttingdeck

fromaccidentallylowering.

•Ifyouparkthemachineonaslope,blockorchockthewheels.

•Keephands,feetandclothingawayfrommovingpartsandthedischarge

areaofanattachment.

•Donottouchtheengine,muferorexhaustpipewhiletheengineisrunning

orsoonafteritisstoppedbecausetheseareascouldbehotenoughto

causeburns.

Beforestartingthemachine

DANGER

Theexhaustfumesarehazardousandhavethepotentialofinjury

ordeath.

Donotruntheengineinaconnedareawithoutadequateventilation.

1.Settheparkingbrake.

2.EnsurethatthetractionpedalisintheNEUTRALpositionandthePTOswitch

isintheOFF(disengaged)position.

3.Afteryoustarttheengine,releasetheparkingbrakeandkeepfootoffthe

tractionpedal.Ensurethatthemachinedoesnotmove.

Note:Ifmachinemovementisevident,thetractionpedallinkageisadjusted

incorrectly;therefore,shutofftheengineandadjustthetractionpedallinkage

untilthemachinedoesnotmovewhenyoureleasethetractionpedal;referto

theOperator'sManual.

CAUTION

Runningtheenginecausestheengine,radiator,andexhaustsystem

tobecomehot.Touchingahotengine,radiator,orexhaustsystem

canburnyou.

Donottouchtheengine,radiator,orexhaustsystemwhilethe

engineisrunningorsoonafteryoustopit.

Beforestoppingthemachine

1.EnsurethatthetractionpedalisintheNEUTRALposition.

2.Loweranddisengagethecuttingdeckandwaitforallmovingpartstostop.

3.Settheparkingbrake.

4.Shutofftheengineandremovethekeyfromthekeyswitch.

Safety:SafetyInstructions

Page1–4

ProLineH800

19241SLRevA

MaintenanceandService

•Beforeservicingormakinganyadjustmentstothemachine,lowerthecutting

deck,settheparkingbrake,shutofftheengine,andremovethekeyfromthe

keyswitch.

•Ensurethatthemachineisinsafeoperatingconditionbykeepingallthe

nuts,bolts,andscrewstight.

•Donotstorethemachineorafuelcontainerinsidewherethereisanopen

ame,suchasnearawaterheaterorfurnace.

•Ensurethatallofthehydrauliclineconnectorsaretightandthatallthe

hydraulichosesandlinesareingoodconditionbeforeapplyingpressureto

thehydraulicsystem.

•Keepyourbodyandhandsawayfrompin-holeleaksinthehydrauliclines

thatejecthydraulicuidunderhighpressure.Usecardboardorpapertond

hydraulicleaks.Thehydraulicuidescapingunderpressurecanpenetrate

theskinandcauseinjury.Ifhydraulicuidisaccidentallyinjectedintothe

skin,youmusthaveitsurgicallyremovedwithinafewhoursbyadoctor

familiarwiththistypeofinjury.Otherwise,gangrenemayresult.

•Beforedisconnectingorperforminganyworkonthehydraulicsystem,

releaseallthepressureinthesystembyparkingthemachineonalevel

surface,loweringthecuttingdeckcompletely,shuttingofftheengine,and

thenusingallofthehydrauliccontrols(pressingthetractionpedal,turning

thesteeringwheel,andpressingtheliftswitchtobothraiseandlower).

•Usecarewhencheckingorservicingthecuttingdeck.Wearglovesand

usecautionwhenservicingthedeck.

•Toreducepotentialrehazards,keeptheengineareafreeofexcessive

grease,grass,leaves,anddirt.Cleantheprotectivescreenonthemachine

frequently.

•Ifyoumustruntheenginetoperformmaintenanceortomakeanadjustment,

keepyourhands,feet,clothing,andotherpartsofthebodyawayfromthe

cuttingdeckandothermovingparts.Keepbystandersaway.

•Donotoverspeedtheenginebychangingtheenginegovernorsetting.

Toensuresafetyandaccuracy,checkthemaximumenginespeedwith

aphototac.

•Shutofftheenginebeforecheckingoraddingoiltotheenginecrankcase.

•Disconnectthebatterybeforeservicingthemachine.Disconnectthebattery

negativecableandthenthepositivecable.Ifbatteryvoltageisnecessaryfor

troubleshootingortestprocedures,temporarilyconnectthebattery.Connect

thepositivebatterycableandthenthenegativecable.

•Batteryacidispoisonousandcancauseburns.Avoidacidcontactwithskin,

eyes,andclothing.Protectyourface,eyes,andclothingwhenworkingwitha

battery.

•Batterygasescanexplode.Keepcigarettes,sparks,andamesawayfrom

thebattery.

•Whenchangingtheattachments,tires,orperformingotherservice,use

correctblocks,hoists,andjackstoraiseandsupportthemachine.Ensure

thatthemachineisparkedonasolidlevelsurface,suchasaconcreteoor.

Beforeyouliftthemachine,removealltheattachmentsthatmayinterfere

withthesafeandcorrectliftofthemachine.Alwaysblockthewheelswith

chocks.Useappropriatejackstandstosupporttheraisedmachine.Failing

toproperlysupportthemachinewithappropriatejackstandscancausethe

machinetomoveorfallandcanresultinpersonalinjury;refertoJacking

Instructions(page1–7).

•Ifmajorrepairsarenecessary,contactyourAuthorizedT oroDistributor.

ProLineH800

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Safety:SafetyInstructions

19241SLRevA

MaintenanceandService(continued)

•Ifweldingonthemachineisnecessary,disconnectthebatterynegativecable

topreventelectricalsystemdamage.

•Ensuretodisposeofpotentiallyharmfulwaste(e.g.,fuel,oil,enginecoolant,

lters,battery)inanenvironmentallysafemanner.Followalllocalcodesand

regulationswhenrecyclingordisposingofwaste.

•Atthetimeofmanufacture,themachineconformedtothesafetystandards

forridingmowers.Toensuretheoptimumperformanceandcontinued

safetycerticationofthemachine,usegenuineT ororeplacementpartsand

accessories.Thereplacementpartsandaccessoriesofothermanufacturers

canresultinnon-conformancewiththesafetystandardsandcanvoidthe

warranty.

Safety:SafetyInstructions

Page1–6

ProLineH800

19241SLRevA

JackingInstructions

CAUTION

Failingtoproperlysupportthemachinewithappropriatejackstands

cancausethemachinetomoveorfallandcanresultinpersonal

injury.

Whenchangingtheattachments,tires,orperformingotherservices,

dothefollowingsteps:

•Usecorrectblocks,hoists,andjackstoraiseandsupportthe

machine.

•Parkthemachineonasolidlevelsurface,suchasaconcrete

oor.

•Beforeyouliftthemachine,removealltheattachmentsthatmay

interferewiththesafeandcorrectliftofthemachine.

•Alwaysblockthewheelswithchocks.

•Useappropriatejackstandstosupporttheraisedmachine.

•Donotusethecuttingdeckasajackingpoint.

RaisingtheFrontoftheMachine

1.Settheparkingbrakeandblockthe2rearwheelswithchockstoprevent

themachinefrommoving.

g215339

Figure1

1.Handle2.Latch

2.Accessrightsideoftheengineasfollows:

A.Pushthelatchontheradiatorinwardtowardtheradiator(Figure1).

B.Usingthehandleonthesideoftheradiator,rotatetheradiatortoaccess

rightsideoftheengine(Figure1).

ProLineH800

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Safety:JackingInstructions

19241SLRevA

RaisingtheFrontoftheMachine(continued)

g216339

Figure2

1.Bolt2.Fuel-tankbracket

3.Accessleftsideoftheengineasfollows:

A.Removetheboltfromtheleftsideofthefuel-tankbracket(Figure2).

B.Rotatethefueltanktoaccesstheleftsideoftheengine(Figure2).

g224454

Figure3

1.Frametubeontherightsideofthemachine

g224455

Figure4

1.Frametubeontheleftsideofthemachine

4.PositionthejacksecurelyundertheframetubedirectlyundertheROPStube

orascloseaspossible(Figure3andFigure4).

Safety:JackingInstructions

Page1–8

ProLineH800

19241SLRevA

RaisingtheRearoftheMachine

g224613

Figure5

1.Rearjackingpoints

1.Settheparkingbrakeandblockthe2frontwheelswithchockstoprevent

themachinefrommoving.

2.Positionthejacksecurelyundertheframe(Figure5).

SafetyandInstructionalDecals

Numeroussafetyandinstructiondecalsareafxedtothetractionunitand

cuttingdeckofyourProLineH800.Ifanydecalbecomesillegibleordamaged,

installanewdecal.DecalpartnumbersarelistedinyourPartsCatalog.Order

replacementdecalsfromAuthorizedT oroDistributor.

ProLineH800

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Safety:SafetyandInstructionalDecals

19241SLRevA

Safety:SafetyandInstructionalDecals

Page1–10

ProLineH800

19241SLRevA

Chapter2

SpecicationsandMaintenance

TableofContents

Specications.......................................................................................................................................2–2

OverallDimensions............................................................................................................................2–2

Engine-ProLineH800(forModel31050)..........................................................................................2–3

Engine-ProLineH800(forModel31050TE)......................................................................................2–4

HydraulicSystem...............................................................................................................................2–5

Chassis..............................................................................................................................................2–6

TorqueSpecications...........................................................................................................................2–7

IdentifyingtheFastener......................................................................................................................2–7

CalculatingtheT orqueValuesWhenUsingaDrive-AdapterWrench.................................................2–9

StandardTorqueforDry,ZincPlated,andSteelFasteners(Inch)....................................................2–10

StandardT orqueforDry,ZincPlated,andSteelFasteners(MetricFasteners).................................2–11

OtherTorqueSpecications.............................................................................................................2–12

ConversionFactors..........................................................................................................................2–12

ShopSupplies....................................................................................................................................2–13

SpecialTools......................................................................................................................................2–15

ProLineH800

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SpecicationsandMaintenance

19241SLRevA