ProLine H800 Rotary Mower

Before starting the machine each day, perform the Each Use/Daily procedures listed in .

Front and rear tires air pressure specification: 140 kPa (20 psi).

Caster tires air pressure specification: 150 kPa (21 psi).

Check the air pressure in the front and rear tires. Add or remove air as needed to set the air pressure in the tires to the tire air pressure specification.

Important: Maintain pressure in all tires to ensure a good quality of cut and proper machine performance.Check the air pressure in all the tires before operating the machine.

Figure 12

Use only clean, fresh diesel fuel or biodiesel fuels with low (<500 ppm) or ultra low (<15 ppm) sulfur content. The minimum cetane rating should be 40. Purchase fuel in quantities that can be used within 180days to ensure fuel freshness.

Fuel tank capacity: 41 L (10.8 US gallons)

Use summer-grade diesel fuel (No. 2-D) at temperatures above -7°C (20°F) and winter-grade (No. 1-D or No. 1-D/2-D blend) below that temperature. Using winter-grade fuel at lower temperatures provides lower flash point and cold flow characteristics which will ease starting and reduce fuel filter plugging.

Using summer-grade fuel above -7°C (20°F) will contribute toward longer fuel pump life and increased power compared to winter-grade fuel.

Important: Do not use kerosene or gasoline instead of diesel fuel. Failure to observe this caution will damage the engine.

Filling the Fuel Tank

Note: If possible, fill the fuel tank after each use; this minimizes possible buildup of condensation inside the fuel tank.

Figure 13

Close section

Adjust the tilt-steering column to your desired position as shown in Figure 16.

Figure 16

The seat moves forward and backward. Position the seat where you have the best control of the machine and are most comfortable.

To adjust, pull the lever upward and move the seat forward or rearward (Figure 17).

Figure 17

1. Pull the seat-suspension lever out (Figure 18).

2. While sitting in the seat, adjust the seat suspension as follows:

   • For firmer suspension, pull the seat-suspension lever up as many times as necessary.

   • For softer suspension, push the seat-suspension lever down as many times as necessary.

3. When the arrow is in the middle, push the lever back in.

Figure 18

Pull the lever (Figure 19) upward to tilt the back of the seat.

Figure 19

Rotate the seat lumbar support (Figure 20) counterclockwise to increase the lumbar support.

Rotate the seat lumbar support clockwise to decrease the lumbar support.

Figure 20

Lift the seat-tilt lever (Figure 21) upward and tilt the seat forward.

Figure 21

Important: You might need to bleed the fuel system in any of the following situations: initially starting up a new machine, the engine no longer running due to lack of fuel, or fuel system components replaced or serviced.

1. Raise the roll bar and lock it into place.

2. Sit on the seat and fasten the seat belt.

3. Ensure that the parking brake is set and the PTO switch is in the OFF position.

4. Remove your foot from traction pedal and ensure that it is in neutral.

5. Rotate the key switch to the ON/PREHEAT position.

   Note: An automatic timer then controls the preheat for a few seconds.

6. After preheating, rotate the key switch to the Start position, crank the engine for no longer than 15 seconds, and release the key when the engine starts.

   Note: If additional preheating is required, turn the key to the OFF position, then to the ON/PREHEAT position. Repeat this process as required.

7. Move the throttle to idle speed or partial throttle and run the engine until it warms up.

   Important: When you start the engine for the first time; or after you change the engine oil, hydraulic fluid, overhaul the engine, or replace traction components; operate the machine in forward and reverse for 1 to 2 minutes. Also, operate the lift lever and PTO lever to ensure that all parts are properly operating. Turn the power-steering wheel to the left and right to check the steering response. Then shut the engine off, check the fluid levels, and check for oil leaks, loose parts, and any other malfunctions.

   Caution

   To prevent personal injury, shut the engine off and wait for all moving parts to stop before checking for oil leaks, loose parts, or other malfunctions.

8. To shut off the engine, move the throttle control rearward to the SLOW position, move the PTO switch to the OFF position and rotate key switch to the OFF position. Remove key from the switch to prevent accidental starting.

1. Push the brake pedal down.

2. Push the parking-brake lock down and remove your foot from the brake pedal to engage the parking brake.

Push the brake pedal down to disengage the parking brake.

You can adjust the height of cut continually from 20 to 110 mm (3/4 to 4-1/4 inches) by using the height-of-cut switch.

Push the height-of-cut switch (Figure 8) forward to lower the height of cut. Push the height-of-cut switch rearward to increase the height of cut.

Read the height of cut on the height-of-cut gauge to ensure that you are cutting at the desired height.

Note: If you leave the operator’s seat while the PTO switch is in the ON position, the machine will automatically shut off the engine.

Perform the following to reset the PTO function:

1. Push in the PTO switch knob.

2. Rotate the key to the OFF position.

3. Rotate the key to the ON/PREHEAT position, then start the engine.

4. Pull out the PTO switch knob.

Mount the skids in the lower position when operating at heights of cut greater than 51 mm (2 inches) and in a higher position when operating at heights of cut lower than 51 mm (2 inches).

Adjust the skids as shown in Figure 26.

Figure 26

Mount the roller in the lower position when operating at heights of cut greater than 51 mm (2 inches) and in a higher position when operating at heights of cut lower than 51 mm (2 inches).

1. Park the machine on a level surface.

2. Disengage the PTO, lower the mower deck, and engage the parking brake.

3. Shut off the engine and remove the key.

4. Remove the roller shaft, bolt, and nut securing the roller to the deck bracket (Figure 27).

   

   Figure 27

   1. Nut
   2. Roller shaft
   3. Bolt
   4. Roller

5. Align the roller with the appropriate holes and install the shaft with the bolt and nut (Figure 28).

   

   Figure 28

   1. Nut
   2. Roller shaft
   3. Bolt
   4. Roller

Mount the rollers so that there is a 19 mm (3/4 inch) clearance from the ground.

1. Park the machine on a level surface.

2. Disengage the PTO, lower the mower deck, and engage the parking brake.

3. Shut off the engine and remove the key.

4. Remove the lock pin from the roller pin (Figure 29).

   

   Figure 29

   1. Roller pin
   2. Lock pin

5. Move the roller pin up or down to the desired position and secure it with the lock pin (Figure 29).

6. Repeat steps 4 and 5 on the other side and ensure that it matches the other setting.

If the hopper sensor activates and the PTO automatically disengages when the hopper is not full or if the chute clogs before the sensor activates, you need to adjust the sensor position.

Adjust the sensor as follows:

1. Open the hopper door.

2. Adjust the hopper sensor based on the following:

   • For normal grass and weather conditions, rotate the sensor to the mid-point position (Figure 30).

   • For wet, dense grass conditions, when picking up leaves, or if the hopper fills before the sensor activates, rotate the sensor downward (Figure 30).

   • For dry, sparse grass conditions, or if the mower deck disengages before the hopper fills, rotate the sensor upward (Figure 30).

   

   Figure 30

   1. Position the hopper sensor upward when grass is thin or conditions are dry.
   2. Position the hopper sensor in the middle when grass and weather conditions are normal.
   3. Position the hopper sensor downward when grass is thick, contains leaves, or conditions are wet.

1. Park the machine on a level surface.

2. Disengage the PTO, lower the mower deck, and engage the parking brake.

3. Raise the hopper and secure it; refer to Raising the Hopper and Securing the Hopper in the Raised Position.

4. Shut off the engine and remove the key.

5. Tilt the seat forward.

6. Unlatch the grass chute (Figure 31).

   

   Figure 31

   1. Handle
   2. Latch
   3. Chute

7. Using the handle on the chute, remove the chute and clear it and the mower deck opening (Figure 31).

8. Install the chute and secure it with the latches (Figure 31).

1. Park the machine on a level surface.

2. Engage the parking brake.

3. Ensure that the fuel tank is at least half full.

4. Unlatch the radiator; refer to Accessing the Engine from the Right side.

5. Place a drain pan under the air-bleed screw.

6. Open the air-bleed screw on the fuel-injection pump (Figure 32).

   

   Figure 32

   1. Air-bleed screw

7. Rotate the key switch to the ON position.

   The electric fuel pump begins forcing air out around the air-bleed screw.

8. Leave the key switch in the ON position until a solid stream of fuel flows out around the screw.

9. Tighten the screw and rotate key switch to the OFF position.

   Note: The engine should start after you perform this procedure. However, if the engine does not start, air may be trapped between the injection pump and the injectors. Contact your authorized Toro distributor.

10. Wipe clean any fuel that has accumulated around the injection pump.

• Practice driving before operating the machine, because it has a hydrostatic transmission and its characteristics are different than some turf-maintenance machines.

• To maintain enough power for the machine and deck while mowing, regulate the traction pedal to keep the engine speed (rpm) high and constant. Decrease the ground speed as the load on the cutting blades increases; increase the ground speed as the load on the blades decreases. This allows the engine, working with the transmission, to sense the proper ground speed while maintaining a high blade-tip speed necessary for good quality of cut. Therefore, allow the traction pedal to move upward as the engine speed decreases, and press pedal slowly as the speed increases. When driving from 1 work area to another (with no load and the deck raised), have throttle in the FAST position and press the traction pedal slowly but fully to attain the maximum ground speed.

• Before shutting off the engine, move all controls to the NEUTRAL position and move the throttle to the SLOW position. Rotate the key switch to the OFF position to shut off the engine.

• The engine does not run when the engine coolant is in over-temperature condition. Let the engine and cooling system cool, and check the cooling system; refer to Checking the Cooling System and Coolant Level.

In an emergency, the machine can be pushed or towed for a very short distance. However, Toro does not recommend this as standard procedure.

Important: Pushing or towing the machine faster than 3 to 5 km/h (2 to 3 mph) may damage the transmission. If you must move the machine a considerable distance, transport it on a truck or trailer. Whenever you push or tow the machine, the bypass valve must be open.

• Use care when loading or unloading the machine into a trailer or a truck.

• Use full-width ramps for loading the machine into a trailer or a truck.

• Tie the machine down securely using straps, chains, cable, or ropes. Both front and rear straps should be directed down and outward from the machine.

  Loop tie-downs around the corners of the carrier frame (Figure 34).

  

  Figure 34

  1. Front tie-down locations

  Insert a bolt or drawbar pin into the tie-down location (Figure 35).

  

  Figure 35

  1. Rear tie-down location

1. Rotate the radiator or fuel tank out; refer to Accessing the Engine from the Right side or Accessing the Engine from the Left Side.

2. Place a jack under the frame tube (Figure 36 and Figure 37), directly under the ROPS tube, or as close as possible.

   

   Figure 36

   1. Frame tube on the right side of the machine
   

   Figure 37

   1. Frame tube on the left side of the machine

Jack up the rear, left or rear, right side of the machine using the jacking points shown in Figure 38.

Figure 38

1. Rear jacking points

1. Park the machine on a level surface.

2. Raise the hopper to the fully raised position; refer to Raising the Hopper.

3. Secure the hopper by performing the following:

   1. Push the pin on magnetic safety lock inward (Figure 39).

   2. While still holding the pin in, lower magnetic safety lock onto the hydraulic cylinder (Figure 39).

   3. Repeat steps 1 and 2 on the other side.

   

   Figure 39

Grease specification: No. 2 lithium grease

Important: Dusty and dirty operating conditions could cause dirt to get into the bearings and bushings, resulting in accelerated wear.

Note: Lubricate the grease fittings immediately after every washing, regardless of interval specified.

1. Wipe grease fitting clean so foreign matter cannot be forced into the bearing or bushing.

2. Pump grease into the bearing or bushing.

3. Wipe off excess grease.

Figure 40

Grease specification: No. 2 lithium grease

Important: Dusty and dirty operating conditions could cause dirt to get into the bearings and bushings, resulting in accelerated wear.

Note: Lubricate the grease fittings immediately after every washing, regardless of interval specified.

Note: Bearing life can be negatively affected by improper wash-down procedures. Do not wash down the machine when it is still hot and avoid directing high-pressure or high-volume spray at the bearings.

1. Wipe grease fitting clean so foreign matter cannot be forced into the bearing or bushing.

2. Pump grease into the bearing or bushing.

3. Wipe off excess grease.

The bearing and bushing lubrication points are as follows:

• Hopper arms—upper (Figure 41)

  

  Figure 41

• Hopper arms—lower, front (Figure 42)

  

  Figure 42

  Left side shown; repeat on other side

• Hopper arms—lower, rear(Figure 43)

  

  Figure 43

• Hopper pivots (Figure 44)

  

  Figure 44

• Tie-rod ends and rear pivot (Figure 45)

  

  Figure 45

• Brake pivot bushings and drive shaft (Figure 46)

  

  Figure 46

Note: Replace the air cleaner more frequently (every few hours) if operating conditions are extremely dusty or sandy.

Cleaning the Air-Cleaner Cover

Check the air-cleaner body for damage which could cause an air leak. Replace a damaged air-cleaner body.

Clean the air-cleaner cover as shown in Figure 50.

Figure 50

Close section

The engine ships with oil in the crankcase.

Crankcase capacity: approximately 3.4L (3.6US qt) with the filter.

Engine oil specification:

• Engine oil-type—API Classification Level Required: CH-4, CI-4 or higher.

• Engine oil visacosity

  • Preferred oil: SAE 15W-40 (above 0°F)

  • Alternate oil: SAE 10W-30 or 5W-30 (all temperatures)

Note: Toro Premium Engine Oil is available from your distributor in either 15W-40 or 10W-30 viscosity. See the parts catalog for part numbers.

Checking the Engine-Oil Level

Note: The best time to check the engine oil is when the engine is cool before it has been started for the day. If you have already run the engine, allow the oil to drain back down to the sump for at least 10 minutes before checking. If the oil level is at or below the low mark on the dipstick, add oil to bring the oil level to the high mark. Do not overfill. If the oil level is between the high and low marks, you do not need to add oil.

Check the engine-oil level as shown in Figure 52.

Figure 52

Close section

1. Clean the area around the fuel-filter head (Figure 54).

   

   Figure 54

   1. Fuel-filter head
   2. Filter

2. Remove the filter and clean the filter-head-mounting surface (Figure 54).

3. Lubricate the filter gasket with clean, lubricating engine oil; refer to the engine owner's manual (included with the machine) for additional information.

4. Tighten the dry filter canister, by hand, until the gasket contacts the filter head, then rotate it an additional 1/2 turn.

5. Pump the lever on the left side of the fuel pump until you fill the fuel-filter bowl (Figure 55).

   

   Figure 55

   1. Lever
   2. Fuel pump

1. Clean the area around the fuel-filter head (Figure 56).

   

   Figure 56

   1. Fuel-filter head
   2. Filter

2. Turn the lever on the fuel-filter head counterclockwise to the OFF position (Figure 57).

   

   Figure 57

3. Remove the filter and clean the filter-head-mounting surface (Figure 56).

4. Lubricate the filter gasket with clean, lubricating engine oil; refer to the engine owner's manual (included with the machine) for additional information.

5. Install the dry filter canister, by hand, until the gasket contacts the filter head, then rotate it an additional 1/2 turn.

6. Turn the lever on the fuel-filter head clockwise to the ON position (Figure 57).

7. Start the engine and check for fuel leaks around the filter head.

Empty and clean tank if fuel system becomes contaminated or if you store the machine for an extended period of time. Use clean diesel fuel to flush out the tank.

Inspect the fuel lines for deterioration, damage, or loose connections.

1. Park the machine on a level surface.

2. Disengage the PTO, lower the mower deck, and engage the parking brake.

3. Shut off the engine and remove the key.

4. Remove the 3 socket-head screws from the left console (Figure 58).

5. Remove the throttle-lever knob (Figure 58).

6. Lift the left console up and set it aside (Figure 58).

Figure 58

1. Slotted hex screw
2. Throttle-lever knob
3. Left console

The electrical system is protected by fuses. It requires no maintenance, however, if a fuse blows check the component/circuit for a malfunction or short.

The fuse block and fuses are located to the left of the operator’s seat (Figure 62).

Figure 62

1. Fuse block

Use the following table when replacing a fuse:

Figure 63

1. Security fuse (3 A)
2. PTO fuse (15 A)
3. Electronic control unit and buzzer fuse (5 A)
4. Differential lock fuse (5 A)
5. Mower deck valve and operator’s seat fuse (15 A)
6. Alternator and dashboard fuse (5 A)
7. Work lights, brake lights, full-beam lights, and light control unit fuse (15 A)
8. Pull and hazard light switch, spark plugs, and key switch fuse (30 A)

Figure 64

1. Right steady light and plate light fuse (3 A)
2. Left steady light fuse (3 A)
3. Full-beam light fuse (15 A)
4. Headlight fuse (10 A)
5. Warning device fuse (10 A)
6. Indicator lights fuse (7.5 A)
7. Rotating beacon light fuse (5 A)
8. Hazard-light switch fuse (15 A)

There are also 2 fuses (40 A) that protect the main machine wire harness (Figure 65).

Figure 65

1. Fuses (40 A)

Prevent corrosion of wiring terminals by applying Grafo 112X (Skin-over) grease, Toro Part No. 505-47, to the inside of all harness connectors whenever you replace the harness.

Important: Whenever working with the electrical system, always disconnect the battery cables, negative (-) cable first, to prevent possible wiring damage from short-outs.

Wheel lug nut torque specification: 85 to 90 N∙m (62 to 66 ft-lb)

Torque the lug nuts at the front and rear wheels in a crossing pattern as shown in Figure 66 to the specified torque.

Figure 66

The rear-axle-steering stops help prevent over-travel of the steering cylinder in case of impact on the rear wheels. Adjust the stops so that there is 0.23 cm (0.090 inch) clearance between the bolt head and the knuckle on the axle when you turn the steering wheel completely to the left or to the right.

Thread the bolts in or out until you attain a clearance of 0.23 cm (0.090 inch); refer to Figure 68.

Figure 68

1. Steering stop (right side shown)

Cooling system capacity: 7.5 L (8 US qt)

Coolant-type specification:

1. Check the level of the coolant in the expansion tank (Figure 69).

   

   Figure 69

   1. Expansion tank
   2. Cold line—19 mm (3/4 inch) from the bottom
   3. Hot line—19 mm (3/4 inch) from the top

2. If the coolant is low, remove the expansion-tank cap and add the recommended replacement coolant as required.

   Do not use water only or alcohol-based coolants.Do not overfill.

3. Install the expansion-tank cap.

To prevent the engine from overheating, keep the radiator screen and radiator clean. Check the radiator screen and radiator for buildup of grass, dust, and debris, and if necessary, clean any debris off these parts; refer to Cleaning the Radiator Screen and Radiator.

Note: If the PTO shuts off due to high engine temperature, first check the radiator screen and radiator for an excessive buildup of debris. Clean the system before operating the machine. Do not shut off the engine immediately; allow the engine to cool by running it without a load.

Clean the radiator as follows:

1. Remove the radiator screen.

2. Working from the fan side of the radiator, blow with low pressure, 172 kPa (25 psi), compressed air (do not use water). Repeat this step from the front of the radiator and again from the fan side.

3. After the radiator is thoroughly cleaned, clean out any debris that may have collected in the channel at the radiator base.

4. Clean the radiator screen and install it onto the machine.

After adjusting the service brakes after the first 50 hours of operation, you should need to adjust the brakes again only after considerable use.

There should be approximately an 13 mm (1/2 inch) gap from the brake pedal to the front end of the slot when the brake pedal is pressed down fully.

1. Push the brake pedal down to check if there is a sufficient gap in the front end of the slot (Figure 70).

   

   Figure 70

   1. Brake pedal
   2. Gap

2. Release the brake pedal.

3. If an adjustment is necessary, loosen the front and rear jam nuts on each side of the brake cables (Figure 71).

   

   Figure 71

   1. Brake cable
   2. Jam nut

4. Push the brake pedal down and move the brake cables forward or rearward.

5. Tighten the jam nuts to lock the cable positions.

6. Repeat steps 3 through 5 until you set the brake pedal to the desired position.

Check alternator belt for wear or damage.

Note: Replace the alternator belt if you find it worn or damaged.

1. Park the machine on a level surface.

2. Disengage the PTO, lower the mower deck, and engage the parking brake.

3. Shut off the engine and remove the key.

4. Access the engine from the left side; refer to Accessing the Engine from the Left Side.

5. Loosen the alternator pivot bolt and lock bolt (Figure 72).

6. Tension the alternator belt until you achieve 10 mm (3/8 inch) belt deflection midway between the pulleys with a force of 4.5 kg (10 lb).

7. Tighten the alternator lock bolt (Figure 72).

8. Tighten the alternator pivot bolt (Figure 72).

Figure 72

1. Alternator lock bolt
2. Alternator
3. Alternator pivot bolt
4. Alternator belt

1. Park the machine on a level surface.

2. Disengage the PTO, lower the mower deck, and engage the parking brake.

3. Raise and secure the hopper; refer to Raising the Hopper and Securing the Hopper in the Raised Position.

4. Shut off the engine and remove the key.

5. Open the engine-access cover; refer to Accessing the Engine from the Engine-Access Cover.

6. Adjust the air gap so that a 0.4 mm (0.015 inch) feeler gauge slides in between the clutch lining and friction plate with light pressure (Figure 74).

   Note: You can decrease the gap by turning the adjusting nut clockwise (Figure 74). The maximum service gap is 0.7 mm (0.030 inch). Adjust all 3 air gaps.

   

   Figure 74

   1. Clutch
   2. 0.4 mm (0.015 inch) air gap (3)
   3. Adjusting nut (3)
   4. Electrical connector
   5. PTO belt

7. After all 3 gaps have been set, check all 3 again.

   Note: Adjusting 1 gap can alter the other gaps.

The machines reservoir is filled at the factory with high quality hydraulic fluid.

Hydraulic system capacity: 6.0 L (6.3 US qt)

Hydraulic fluid type specification:

Alternate fluids: If the Toro fluid is not available, you may use other petroleum-based Universal Tractor Hydraulic Fluids (UTHF) provided that the specifications fall within the listed range for all the following material properties and that it meets industry standards. We do not recommend the use of synthetic fluid. Consult with your lubricant distributor to identify a satisfactory product.

Note: Toro does not assume responsibility for damage caused by improper substitutions, so use products only from reputable manufacturers who will stand behind their recommendation.

Note: Many hydraulic fluids are almost colorless, making it difficult to spot leaks. A red dye additive for the hydraulic fluid is available in 20ml (2/3fl oz) bottles. A bottle is sufficient for 15 to 22 L (4 to 6 US gallons) of hydraulic fluid. Order Part No. 44-2500 from your authorized Toro distributor.

Prepare the mower deck for maintenance; refer to Rotating the Mower Deck into the Maintenance Position.

1. Inspect the cutting edges (Figure 81).

2. If the edges are not sharp or have nicks, remove and sharpen the blade; refer to Sharpening and Balancing the Blades.

3. Inspect the blades, especially in the sail area.

4. If you notice any cracks, wear, or a slot forming in this area, immediately install a new blade (Figure 81).

   

   Figure 81

   1. Cutting edge
   2. Sail area
   3. Wear/slot forming
   4. Crack