Reelmaster® 6700-D 4-Wheel Drive Traction Unit

Remove the tipper assemblies (if so equipped) from the number 1, number 2, and number 3 lift arms to avoid interference with the carrier frames of the cutting units.

1. Remove the locknut and the washer securing the pivot rod to the number 2 lift arm (Figure 3). Remove the pivot rod and spring from the lift arm. Repeat the procedure on the number 1 and number 3 lift arms.

   

   Figure 3

   1. Pivot rod
   2. Tipper support bracket w/roller

   Note: The tipper bracket with the roller and the tipper support brackets are not required when operating the DPA cutting units (Figure 3).

2. Disconnect the lift chains from the cutting units, if attached.

Mount a chain bracket to each lift arm with a U-bolt and 2 nuts. Position the brackets as follows:

Note: Refer to Figure 4 to determine the lift arm number being described.

Figure 4

1. Cutting unit 1
2. Cutting unit 2
3. Cutting unit 3
4. Cutting unit 4
5. Cutting unit 5
6. Cutting unit 6
7. Cutting unit 7
8. Reel motor
9. Weight

1. On lift arm numbers 1, 4, and 5, position the chain brackets and U-bolts 38.1 cm (15 inches) behind the center line of the pivot knuckle (Figure 5).

2. On lift arm numbers 1 and 5 the brackets should be rotated to the right 10 degrees from vertical (Figure 5).

3. On lift arm number 4 the bracket should be rotated to the left 10 degrees from vertical (Figure 5).

   

   Figure 5

   1. Lift arm number 5 = 38.1 cm (15 inches)
   2. Lift arm number 4 = 10 degrees
   3. Lift arm numbers 1 and 5 = 10 degrees

4. On lift arm numbers 2 and 3, position the brackets and U-bolts 38.1 cm (15 inches) behind the center line of the pivot knuckle (Figure 6).

   Note: Rotate the brackets 45 degrees to the outboard side of the machine.

   

   Figure 6

   1. Lift arm number 2 = 38.1 cm (15 inches)
   2. Lift arm number 3 = 45 degrees

5. On lift arm number 6 and number 7, position the brackets and U-bolts 36.8 cm (14.5 inches) behind the center line of the pivot knuckle (Figure 7).

   Note: Rotate the brackets 10 degrees to the outboard side of the machine.

   

   Figure 7

   1. Lift arm number 6 = 36.8 cm (14.5 inches)
   2. Lift arm number 7 = 10 degrees

6. Tighten all the U-bolt nuts to 52 to 65 N∙m (38 to 48 ft-lb).

7. Mount a lift chain to each chain bracket with a screw, a washer, and a nut, positioning them as shown in Figure 8.

   

   Figure 8

   1. Lift chain
   2. Chain bracket

Whenever the cutting unit has to be tipped to expose the bedknife/reel, prop up the rear of the cutting unit with the kickstand to make sure that the nuts on the back end of the bedbar adjusting screws are not resting on the work surface (Figure 9).

Figure 9

1. Kickstand

Under most conditions, best dispersion is attained when the rear shield is closed (front discharge). When conditions are heavy or wet, the rear shield may be opened.

To open the rear shield (Figure 10), loosen the cap screw securing the shield to the left side plate, rotate the shield to the open position, and tighten the cap screw.

Figure 10

1. Rear shield
2. Cap screw

All cutting units are shipped with the counterweight mounted to the left end of the cutting unit. Use the following diagram to determine the position of the counterweights and reel motors.

Note: Some traction units have only 5 cutting units.

Figure 11

1. Cutting unit 1
2. Cutting unit 2
3. Cutting unit 3
4. Cutting unit 4
5. Cutting unit 5
6. Cutting unit 6
7. Cutting unit 7
8. Reel motor
9. Weight

1. On cutting unit numbers 2, 4, and 6, remove the 2 cap screws securing the counterweight to the left end of the cutting unit.

   Note: Remove the counterweight (Figure 12).

   

   Figure 12

   1. Counterweight

2. On the right end of the cutting unit, remove the plastic plug from the bearing housing (Figure 13).

3. Remove the 2 cap screws from the right side plate (Figure 13).

   

   Figure 13

   1. Plastic plug
   2. Cap screw (2)

4. Install the counterweight to the right end of the cutting unit with the 2 screws previously removed.

5. Loosely install the 2 reel motor mounting cap screws to the left side plate of the cutting unit (Figure 13).

Figure 14 shows the orientation of the hydraulic drive motor for each of the cutting unit locations. For any of the locations requiring the motor to be mounted on the right end of the cutting unit, install a counter weight on the left end of the cutting unit. For the locations requiring the motor to be mounted on the left end, install a counter weight on the right end of the cutting unit.

Note: The counterweight mounting cap screws are shipped installed on the right bearing housing of the cutting units. The cap screws on the left bearing housing are to be used for securing the hydraulic motor.

Figure 14

1. Cutting unit 1
2. Cutting unit 2
3. Cutting unit 3
4. Cutting unit 4
5. Cutting unit 5
6. Cutting unit 6
7. Cutting unit 7
8. Reel motor
9. Weight

1. Remove the cutting units from the cartons. Assemble and adjust them per the cutting unit Operator's Manual.

2. Remove the protective plugs from each end of the cutting unit.

3. Lubricate and install a large O-ring into bearing housing groove on each end of cutting unit (Figure 15 & Figure 18).

   

   Figure 15

   1. Bearing housing
   2. Large o-ring
   3. Counterweight

   Note: Before installing the cutting unit motors or counterweights, lubricate the internal splines of the cutting unit reel shafts with grease.

4. Install a counter weight onto the appropriate end of each cutting unit with the cap screws provided (Figure 15).

5. Thoroughly grease the cutting unit reel bearings prior to installation on the traction unit. Grease should be evident at the inboard reel seals; refer to the cutting unit Operator's Manual for greasing procedure.

6. Insert a thrust washer onto the horizontal shaft of the pivot knuckle as shown in (Figure 16).

   

   Figure 16

   1. Carrier frame
   2. Pivot knuckle
   3. Lift arm steering plate
   4. Lynch pin
   5. Steering locking pin

7. Insert the horizontal shaft of the pivot knuckle into the mounting tube of the carrier frame (Figure 16).

8. Secure the pivot knuckle to the carrier frame with a thrust washer, a flat washer, and a flange-head cap screw (Figure 16).

9. Insert a thrust washer onto vertical shaft of pivot knuckle (Figure 16).

10. If removed, insert the vertical shaft of the pivot knuckle into lift arm pivot hub (Figure 16). Guide the pivot knuckle in place between the two rubber centering bumpers in the under side of the lift arm steering plate.

11. Insert the lynch pin into the cross hole on the pivot knuckle shaft (Figure 16).

12. Remove nut securing turf compensation spring mounting bracket to cutting unit stabilizer ear (Figure 17). Install the tipper chain onto the cap screw and secure it with the nut that you previously removed.

    

    Figure 17

    1. Lift chain
    2. Cutting unit stabilizer ear

13. Mount the motor to the drive end of the cutting unit and secure it with 2 cap screws (Figure 18).

    

    Figure 18

    1. Motor
    2. O-ring

    Note: If fixed cutting unit position is required, insert the steering locking pin into the pivot knuckle mounting hole (Figure 16).

14. Hook the spring wire around the bottom of the steering locking pin (Figure 16).

The turf-compensation spring transfers the weight from the front to the rear roller. This helps to reduce a wave pattern in the turf, also known as marcelling or bobbing.

Important: Make spring adjustments with the cutting unit mounted to the traction unit, pointing straight ahead and lowered to the shop floor.

1. Make sure that the hairpin cotter is installed in the rear hole in the spring rod (Figure 19).

   

   Figure 19

   1. Turf-compensation spring
   2. Hairpin cotter
   3. Spring rod
   4. Hex nuts

2. Tighten the hex nuts on the front end of the spring rod until the compressed length of the spring is 15.9 cm (6.25 inches); refer to Figure 19.

   Note: When operating on rough terrain decrease the spring length by 12.7 mm (0.5 inch). Ground following will be slightly shorter.

   Note: You must reset the turf-compensation setting if the HOC setting or the aggressiveness-of-cut setting is changed.

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

Fuel tank capacity: 57 liters (15 US gallons)

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 180 days to ensure fuel freshness.

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. Use of winter grade fuel at lower temperatures provides lower flash point and cold flow characteristics which will ease starting and reduce fuel filter plugging.

Use of 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.

Biodiesel Ready

This machine can also use a biodiesel blended fuel of up to B20 (20% biodiesel, 80% petrodiesel). The petrodiesel portion should be low or ultra low sulfur. Observe the following precautions:

• The biodiesel portion of the fuel must meet specification ASTM D6751 or EN14214.

• The blended fuel composition should meet ASTM D975 or EN590.

• Painted surfaces may be damaged by biodiesel blends.

• Use B5 (biodiesel content of 5%) or lesser blends in cold weather.

• Monitor seals, hoses, gaskets in contact with fuel as they may be degraded over time.

• Fuel filter plugging may be expected for a time after converting to biodiesel blendsd.

• Contact your distributor if you wish for more information on biodiesel.

1. Park the machine on a level surface, lower the cutting units, shut off the engine, engage the parking brake, and remove the key.

2. Using a clean rag, clean area around the fuel-tank cap.

3. Remove the cap from the fuel tank (Figure 27).

   

   Figure 27

   1. Fuel-tank cap

4. Fill the tank with fuel until the level is to the bottom of the filler neck.

5. Install the fuel-tank cap tightly after filling the tank.

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

1. Sit on the seat, keep your foot off the traction pedal so that it is in NEUTRAL, engage the parking brake, set the engine-speed switch to the SLOW position, and ensure that the Enable/Disable switch is in the DISABLE position.

2. Turn the key to the ON/PREHEAT position. An automatic timer controls the preheat for approximately 6 seconds.

3. When the glow indicator dims, turn the key to the START position. Release the key immediately when the engine starts and allow it to return to the RUN position. Allow the engine to warm up (without load), then move the throttle control to the desired position.

   Crank the engine for no longer than 15 seconds. Release the key when the engine starts. If additional preheat is required, turn the key to the OFF position and then to the ON/PREHEAT position. Repeat the process as required.

Move the throttle control to the IDLE position, move the reel drive switch to DISENGAGE, and rotate the key to the OFF position.

Note: Remove the key to prevent accidental starting.

Important: Allow the engine to idle for 5 minutes before shutting it off after a full load operation. Failure to do so may lead to turbocharger trouble.

Note: Lower the cutting units to the ground. This relieves pressure from the lift circuit and eliminates the risk of the cutting units accidentally lowering to the ground.

1. Park the machine on a level surface, lower the cutting units, shut off the engine, engage the parking brake, and remove the key.

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

3. Unlatch and raise the hood.

4. Open the vent plug on the fuel filter/water separator (Figure 28).

   

   Figure 28

   1. Fuel filter/water separator
   2. Vent plug

5. Turn the key to the ON position. The electric fuel pump will begin operation, thereby forcing air out around the vent plug. Leave the key in the ON position until a solid stream of fuel flows out around the plug. Tighten the plug and turn the key to the OFF position.

6. Open the air bleed screw on the fuel injection pump (Figure 29).

   

   Figure 29

   1. Fuel injection pump bleed screw

7. Turn the key to the ON position. The electric fuel pump will begin operation, thereby forcing air out around air bleed screw. Leave the key in the ON position until a solid stream of fuel flows out around the screw. Tighten the screw and turn key to the OFF position.

   Note: Normally, the engine should start after you follow the above procedure. However, if the engine does not start, air may be trapped between the injection pump and the injectors; refer to Bleeding Air from the Injectors.

The purpose of the interlock switches is to prevent the engine from cranking or starting unless the traction pedal is in the NEUTRAL position, the Enable/Disable switch is in the DISABLE position, and the Lower Mow/Raise control is in the NEUTRAL position. In addition, the engine should shut off when you press the traction pedal while you are off the seat or if the parking brake is engaged.

If the Controller senses a fault on one of the output solenoids, it will flash the machines diagnostic Lamp (Reel Diagnostic Lamp on console or Green Diagnostic Lamp under console) and store the fault into the Controller’s (ECU) memory. The fault can then be retrieved and viewed with the Diagnostic ACE handheld tool or a laptop/PC at anytime. The Controller will store 1 fault at a time and will not store another different fault until the first fault is cleared.

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

• Tie the machine down securely.

• Front—the hole in the rectangular pad, under the axle tube, inside each front tire (Figure 32)

  

  Figure 32

  1. Front tie-down

• Rear—each side of the machine on the rear frame (Figure 33)

  

  Figure 33

  1. Rear tie-down

In an emergency, you can move the machine by actuating the bypass valve in the variable displacement hydraulic pump, and then pushing or towing the machine.

Important: Do not push or tow the machine faster than 3 to 4.8 km/h (2 to 3 mph) because internal transmission damage may occur. The bypass valve must be open whenever you push or tow the machine.

1. The bypass valve is located on top of variable displacement pump (Figure 34). Rotate the valve 90°, in either direction, to open and allow oil to bypass internally.

   Note: You can now move the machine slowly without damaging the transmission.

   

   Figure 34

   1. Bypass valve

2. Close the bypass valve before starting the engine.

   Important: Running the engine with the bypass valve open will cause the transmission to overheat.

   Note: Do not exceed 7 to 11 N∙m (5 to 8 ft-lb) torque to close the valve.

Use the list below to identify and describe the different functions of the solenoids in the hydraulic manifold. Each solenoid must be energized to allow function to occur.

Lubricate all grease fittings for the bearings and bushings with No. 2 lithium grease.

The grease fitting locations and quantities are as follows:

• Cutting unit carrier frame and pivot (2) (Figure 35)

  

  Figure 35

• Rear axle tie rod (2) (Figure 36)

• Steering cylinder ball joints (2) (Figure 36)

• King pin bushings (2) (Figure 36) — The top fitting on the king pin should only be lubricated annually (2 pumps).

  

  Figure 36

  1. Top fitting on king pin

• Front lift cylinders (3) (Figure 37 and Figure 38)

  

  Figure 37

  

  Figure 38

• Rear lift cylinder pivot (2) (Figure 39)

  

  Figure 39

• Lift arm pivot (3) (Figure 40)

  

  Figure 40

• Rear axle pivot (Figure 41)

  

  Figure 41

• Rear lift arm pivots (2) (Figure 42)

  

  Figure 42

• Brake pedal shaft (1) (Figure 43)

  

  Figure 43

Check the air-cleaner body for damage which could cause an air leak. Replace it if it is damaged. Check the whole intake system for leaks, damage, or loose hose clamps.

Service the air-cleaner filter only when the service indicator (Figure 44) requires it. Changing the air filter before it is necessary only increases the chance of dirt entering the engine when you remove the filter.

Figure 44

1. Service indicator

Important: Ensure that the cover is seated correctly and seals with the air cleaner body.

1. Pull the latch outward and rotate the air cleaner cover counterclockwise (Figure 45).

   

   Figure 45

   1. Service indicator
   2. Latch
   3. Cover

2. Remove the cover from the air cleaner body. Before removing the filter, use low pressure air (275 kPa [40 psi], clean and dry) to help remove large accumulations of debris packed between outside of primary filter and the canister. Avoid using high pressure air which could force dirt through the filter into the intake tract.

   This cleaning process prevents debris from migrating into the intake when the primary filter is removed.

3. Remove and replace the primary filter (Figure 46).

   Cleaning of the used element is not recommended due to the possibility of damage to the filter media. Inspect the new filter for shipping damage, checking the sealing end of the filter and the body. Do not use a damaged element. Insert the new filter by applying pressure to the outer rim of the element to seat it in the canister. Do not apply pressure to the flexible center of the filter.

   

   Figure 46

   1. Air cleaner primary filter

   Important: Never attempt to clean the safety filter (Figure 47). Replace the safety filter with a new one after every three primary filter services.

   

   Figure 47

   1. Air cleaner safety filter

4. Clean the dirt ejection port located in the removable cover. Remove the rubber outlet valve from the cover, clean the cavity and replace the outlet valve.

5. Install the cover orienting the rubber outlet valve in a downward position—between approximately 5:00 to 7:00 when viewed from the end.

6. Reset the indicator (Figure 44) if it shows red.

The engine is shipped with oil in the crankcase; however, check the oil level before and after the engine is first started.

Use high-quality engine oil that meets the following specifications:

• API Classification Level Required: CH-4, CI-4 or higher.

• Preferred oil: SAE 15W-40: above -18°C (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.

Note: The best time to check the engine oil is when the engine is cool before it has been started for the day. If it has already been run, 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 Add mark on the dipstick, add oil to bring the oil level to the Full mark. Do not overfill the engine. If the oil level is between the Full and Add marks, no oil addition is required.

1. Park the machine on a level surface, lower the cutting units, shut off the engine, engage the parking brake, and remove the key.

2. Release the hood latch and open the hood (Figure 48).

   

   Figure 48

   1. Hood latch

3. Remove the dipstick (Figure 49), wipe it clean, install the dipstick into the tube, and pull it out again.

   Check the oil level on the dipstick; the oil level should be up to the Full mark on the dipstick.

   

   Figure 49

   1. Dipstick

4. If the oil is below the safe range, remove the fill cap (Figure 50) and add oil until the level reaches the Full mark.

   Important: Do not overfill the engine.

   

   Figure 50

   1. Fill cap

5. Install the oil fill cap and dipstick.

6. Close the hood and secure it with the latches.

Capacity: 7.0 L (7.5 US qt) with filter

Change the oil and filter initially after the first 50 hours of operation, thereafter change oil and filter every 150 hours.

1. Remove the drain plug (Figure 51) and let oil flow into a drain pan. When the oil stops, install the drain plug.

   

   Figure 51

   1. Drain plugs

2. Remove the oil filter (Figure 52). Apply a light coat of clean oil to the new filter seal before screwing it on. Do not overtighten the filter.

   

   Figure 52

   1. Oil filter

3. Add oil to the crankcase.

1. Position the throttle lever forward so that it stops against the seat base slot.

2. Loosen the throttle cable connector on the lever arm at the injection pump (Figure 53).

   

   Figure 53

   1. Injection pump lever arm
   2. Connector

3. Hold the injection pump lever arm against the high idle stop and tighten the cable connector.

   Note: When tightened, the cable connector must be free to swivel.

4. Torque the locknut, used to set the friction device on the throttle lever, to 4 to 6 N∙m (40 to 55 in-lb). The maximum force required to operate the throttle lever should be 80 N (20 lb).

Park the machine on a level surface, lower the cutting units, engage the parking brake, shut off the engine, and remove the key.

Drain and clean the fuel tank every 2 years. Also, drain and clean the tank if the fuel system becomes contaminated or if the machine is to be stored for an extended period. Use clean fuel to flush out the tank.

Figure 54

1. Fuel tank drain

Check the fuel lines and connections for deterioration, damage, or loose connections.

1. Park the machine on a level surface, lower the cutting units, engage the parking brake, shut off the engine, and remove the key.

2. Place a clean container under the fuel filter.

3. Loosen the drain plug on the bottom of the filter canister and open the vent on the top of the canister mount.

   

   Figure 55

   1. Water separator filter canister

4. Clean the area where the filter canister mounts.

5. Remove the filter canister and clean the mounting surface.

6. Lubricate the gasket on the filter canister with clean oil.

7. Install the filter canister by hand until the gasket contacts the mounting surface, then rotate it an additional 1/2 turn.

8. Tighten the drain plug on the bottom of the filter canister and close the vent on the top of the canister mount.

Note: Perform this procedure only when the fuel system has been purged of air through normal priming procedures and the engine does not start; refer to Bleeding the Fuel System.

1. Loosen the pipe connection to the No. 1 nozzle and holder assembly.

   

   Figure 56

   1. Fuel injectors (4)

2. Move the throttle to the FAST position.

3. Turn the key to the RUN position and watch for fuel to flow around the connector. Turn the key to the OFF position when you see a steady flow of fuel.

4. Tighten the pipe connector securely.

5. Repeat steps 1 through 4 on the remaining nozzles.

   Note: You can remove the fan shroud from the machine to simplify cleaning.

6. Install the rear screen and secure the latches.

   Important: Do not use water to clean the engine, as damage may occur.

The battery electrolyte level must be properly maintained and the top of the battery kept clean. If the machine is stored in a location where temperatures are extremely high, the battery will run down more rapidly than if the machine is stored in a location where temperatures are cool.

Maintain the cell level with distilled or demineralized water. Do not fill the cells above the bottom of the split ring inside each cell. Install the filler caps with the vents pointing to the rear (toward the fuel tank).

Keep the top of the battery clean by washing it periodically with a brush dipped in ammonia or bicarbonate of soda solution. Flush the top surface with water after cleaning. Do not remove the filler caps while cleaning.

The battery cables must be tight on the terminals to provide good electrical contact.

If corrosion occurs at the terminals, disconnect the cables, negative (–) cable first, and scrape the clamps and terminals separately. Connect the cables, positive (+) cable first, and coat the terminals with petroleum jelly.

There are 7 fuses in the electrical system. They are located below the control panel (Figure 57 and Figure 58).

Figure 57

1. Fuses

Figure 58

The tires are over-inflated for shipping. Therefore, release some of the air to reduce the pressure. Correct air pressure in the front and rear tires is 103 to 138 kPa (15 to 20 psi).

Torque the wheel nuts and bolts to 115 to 135 N∙m (85 to 100 ft-lb).

Check the oil level every 400 hours of operation. Use high quality SAE 85W-140 gear oil as a replacement.

1. With the machine on a level surface, position the wheel so that 1 check plug (Figure 59) is at the 12 o'clock position and the other is at the 3 o'clock position.

   

   Figure 59

   1. Check plug (2)

2. Remove the plug at the 3 o’clock position (Figure 59). The oil level should be at the bottom of the check plug hole.

3. If the oil level is low, remove the plug at the 12 o’clock position and add oil until it begins to flow out of the hole at the 3 o’clock position.

4. Install both plugs.

5. Repeat steps 1 through 4 on the opposite planetary gear assembly.

Change the oil initially after 200 hours operation. Thereafter, change the oil every 800 hours. Use high quality SAE 85W-140 gear oil as replacement.

1. With the machine on level surface, position a wheel so that one of the check/drain plugs is at the lowest (6 o’clock) position (Figure 60).

   

   Figure 60

   1. Check/drain plug

2. Place a drain pan under the planetary hub, remove the plug, and allow the oil to drain.

3. Place a drain pan under the brake housing, remove the drain plug, and allow the oil to drain (Figure 61).

   

   Figure 61

   1. Brake housing drain plug

4. When all of the oil has drained from both locations, install the plug in the brake housing.

5. Rotate the wheel until the open plug hole in the planetary is at the 12 o'clock position.

6. Install the plug.

7. Repeat the procedure on the opposite planetary/brake assembly.

The rear axle is shipped from the factory filled with SAE 85W-140 gear oil. Check the level before first starting the engine and every 400 hours thereafter. Capacity is 2.3 L (80 fl oz). Visually inspect for leaks daily.

1. Park the machine on a level surface, lower the cutting units, shut off the engine, engage the parking brake, and remove the key.

2. Remove a check plug (Figure 62) from 1 end of axle and make sure lubricant is up to the bottom of the hole. If the level is low, remove the fill plug (Figure 62) and add enough oil to bring the level up to the bottom of the check plug holes.

   

   Figure 62

   1. Check plug
   2. Fill plug

Change the oil initially after the first 200 hours of operation and every 800 hours of operation thereafter.

1. Park the machine on a level surface, lower the cutting units, shut off the engine, engage the parking brake, and remove the key.

2. Clean the area around the 3 drain plugs: 1 on each end and 1 in the center (Figure 63).

   

   Figure 63

   1. Drain plug location

3. Remove the 3 oil level check plugs and the main axle vent cap to ease in draining of the oil.

4. Remove the drain plugs and allow the oil to drain into the pans.

5. Install the plugs.

6. Remove a check plug and fill the axle with approximately 2.3 L (80 fl oz) of 85W-140 gear oil or until oil is up to the bottom of the hole.

7. Install the check plug.

After every 800 operating hours or annually, check the rear wheel toe-in.

1. Measure the center-to-center distance (at axle height) at the front and rear of the steering tires. The front measurement must be 3 mm (1/8 inch) less than the rear measurement.

2. To adjust the distance, remove the cotter pin and nut from either tie rod ball joint. Remove the tie rod ball joint from the axle case support (Figure 64).

3. Loosen the clamps at both ends of the tie rods (Figure 64).

   

   Figure 64

   1. Tie rod clamp
   2. Tie rod ball joint

4. Rotate the detached ball joint inward or outward 1 complete revolution. Tighten the clamp at the loose end of the tie rod.

5. Rotate the entire tie rod assembly the same direction (inward or outward) 1 complete revolution. Tighten the clamp at the connected end of the tie rod.

6. Install the ball joint in the axle case support and tighten the nut finger tight. Measure the toe-in.

7. Repeat the procedure if necessary.

8. Tighten the nut and install a new cotter pin when the adjustment is correct.

The machine must not creep when you release the traction pedal. If it does creep, an adjustment is required.

1. Park the machine on a level surface, lower the cutting units, shut off the engine, press only the right brake pedal and engage the parking brake.

2. Jack up left side of machine until the front tire and the rear tire are off the shop floor. Support the machine with jack stands to prevent it from falling accidentally.

3. Start the engine and allow it to run at low idle.

4. Adjust the jam nuts on the pump rod end to move the pump control tube forward to eliminate forward creep or rearward to eliminate rearward creep (Figure 65).

   

   Figure 65

   1. Pump rod
   2. Pump control tube

5. After wheel rotation ceases, tighten the jam nuts to secure the adjustment.

6. Shut off the engine and release the right brake. Remove the jack stands and lower the machine to the shop floor. Test drive the machine to ensure that it does not creep.

Remove debris from the rear screen, oil cooler, and radiator daily (more frequently in dirty conditions).

Important: Never spray water onto a hot engine as damage to the engine may occur.

1. Park the machine on a level surface, lower the cutting units, shut off the engine, engage the parking brake, and remove the key.

2. Open the hood.

3. Clean the engine area thoroughly of all debris.

4. Close the hood.

5. Unlatch and remove the rear screen (Figure 66).

   

   Figure 66

   1. Rear screen

6. Clean the screen thoroughly.

7. Unscrew the knobs and pivot the oil cooler rearward (Figure 67).

   

   Figure 67

   1. Oil cooler
   2. Radiator

8. Clean both sides of the oil cooler and radiator area thoroughly with compressed air. Do not use water.

9. Open the hood and blow the debris out toward the back of the machine.

10. Pivot the oil cooler back into position and tighten the knobs.

The capacity of the cooling system is 9.4 L (10 US qt).

1. Clean the debris off the screen, the oil cooler, and the front of the radiator daily (more often if conditions are extremely dusty and dirty); refer to Removing Debris.

   The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol antifreeze. Check the level of the coolant in the radiator and the expansion tank at the beginning of each day before starting the engine.

   Carefully remove the radiator cap and the expansion tank cap (Figure 68).

2. Check the level of coolant in the radiator and in the expansion tank (Figure 68).

   The radiator should be filled to the top of the filler neck and the expansion tank filled to the Full mark.

   

   Figure 68

   1. Expansion tank

3. Fill the expansion tank to the Full mark and the radiator to the top of the filler neck. Do not overfill the expansion tank.

   Note: If air is trapped in the system, remove the vent plug (Figure 69) from the top of the radiator side tank to allow trapped air to escape. Install the vent plug using PTFE thread sealant.

   

   Figure 69

   1. Vent plug

4. Install the radiator cap and the expansion tank cap.

5. Close the hood and secure the latches.

Capacity: 9.4 L (10 US qt)

Protect the cooling system with a 50/50 solution of water and permanent ethylene glycol anti-freeze. Do not use only water in the cooling system.

• After every 100 operating hours, inspect and tighten the hose connections. Replace any deteriorated hoses.

• After every 2 years, drain and flush the cooling system. Add anti-freeze; refer to Checking the Cooling System.

Adjust the service brakes when there is more than 2.5 cm (1 inch) of free travel of the brake pedal, or when the brakes do not work effectively. Free travel is the distance the brake pedal moves before braking resistance is felt.

1. Disengage the locking pin from the brake pedals so that both pedals work independently of each other.

2. To reduce the amount of free travel of the brake pedals, tighten the brakes by loosening the front nut on the threaded end of the brake cable (Figure 70). Then tighten rear nut to move cable backward until brake pedals have 1.2 to 2.5 cm (1/2 to 1 inch) of free travel. Tighten the front nuts after the brakes are adjusted correctly.

   

   Figure 70

   1. Brake cables

Check condition and tension of alternator belt after every 100 hours of operation (Figure 71). Replace belt as required. Check the tension as follows:

1. Open the hood.

2. Check the tension by pressing the belt midway between the alternator and the crankshaft pulleys with 97 N (22 lb) of force. The belt should deflect 1.1 cm (7/16 inch). If the deflection is incorrect, proceed to step 3. If it is correct, continue operation.

   

   Figure 71

   1. Alternator belt
   2. Brace

3. Loosen the bolt securing the brace to the engine and the bolt securing the alternator to the brace.

4. Insert a pry bar between the alternator and the engine and pry out on the alternator.

5. When proper tension is achieved, tighten the alternator and brace bolts to secure the adjustment.

6. Tighten the locknut to secure the adjustment.

1. Park the machine on a level surface, lower the cutting units, shut off the engine, engage the parking brake, and remove the key.

2. Clean the area around the filler neck and cap of the hydraulic tank (Figure 72). Remove the cap from the filler neck.

   

   Figure 72

   1. Hydraulic tank cap

3. Remove the dipstick from the filler neck and wipe it with a clean rag. Insert the dipstick into the filler neck, then remove it and check the level of the fluid. The fluid level should be within 6 mm (1/4 inch) of the mark on the dipstick.

4. If the level is low, add the appropriate fluid to raise the level to the full mark.

5. Install the dipstick and cap onto the filler neck.

The reservoir is filled at the factory with high-quality hydraulic fluid. Check the level of the hydraulic fluid before you first start the engine and daily thereafter; refer to Checking the Hydraulic Fluid.

Recommended hydraulic fluid: Toro PX Extended Life Hydraulic Fluid; available in 19 L (5 US gallon) pails or 208 L (55 US gallon) drums.

Note: A machine using the recommended replacement fluid requires less frequent fluid and filter changes.

Alternative hydraulic fluids: If Toro PX Extended Life Hydraulic Fluid is not available, you may use another conventional, petroleum-based hydraulic fluid having specifications that fall within the listed range for all the following material properties and that it meets industry standards. Do not use 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.

High Viscosity Index/Low Pour Point Anti-wear Hydraulic Fluid, ISO VG 46

Note: Many hydraulic fluids are almost colorless, making it difficult to spot leaks. A red dye additive for the hydraulic fluid is available in 20 ml (0.67 fl 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.

Important: Toro Premium Synthetic Biodegradable Hydraulic Fluid is the only synthetic biodegradable fluid approved by Toro. This fluid is compatible with the elastomers used in Toro hydraulic systems and is suitable for a wide-range of temperature conditions. This fluid is compatible with conventional mineral oils, but for maximum biodegradability and performance, the hydraulic system should be thoroughly flushed of conventional fluid. The oil is available in 19 L (5 US gallons) pails or 208 L (55 US gallons) from your authorized Toro distributor.

32 L (8.5 US gallons); refer to Hydraulic Fluid Specifications

If the fluid becomes contaminated, contact a Toro distributor to flush the hydraulic system. Contaminated hydraulic fluid looks milky or black when compared to clean fluid.

1. Park the machine on a level surface, lower the cutting units, shut off the engine, engage the parking brake, and remove the key.

2. Open the hood.

3. Remove the drain plug from the bottom of the reservoir (Figure 73) and let the hydraulic fluid flow into a drain pan.

   

   Figure 73

   1. Hydraulic reservoir

4. Install and tighten the plug when the hydraulic fluid stops draining.

5. Fill the reservoir with hydraulic fluid; refer to Hydraulic Fluid Specifications and Hydraulic Fluid Capacity.

   Important: Use only the hydraulic fluids specified. Other fluids could cause system damage.

6. Install the reservoir cap. Start the engine and use all the hydraulic controls to distribute the hydraulic fluid throughout the system.

7. Check for leaks.

8. Shut off the engine.

9. Check the level of the fluid and add enough to raise the level to the full mark on the dipstick.

   Important: Do not overfill the reservoir.

The hydraulic system filter head is equipped with a service interval indicator. With the engine running, view the indicator—it should be in the green zone. When the indicator is in the red zone, change the filter element.

Use the Toro replacement filter (Part No. 94-2621).

Important: Use of any other filter may void the warranty on some components.

1. Park the machine on a level surface, lower the cutting units, shut off the engine, engage the parking brake, and remove the key.

2. Clean the area around the filter mounting area. Place a drain pan under the filter and remove the filter (Figure 74).

   

   Figure 74

   1. Hydraulic filter
   2. Service interval indicator

3. Lubricate the new filter gasket and fill the filter with hydraulic fluid.

4. Ensure that the filter mounting area is clean. Screw the filter on until the gasket contacts the mounting plate. Then, tighten the filter 1/2 turn.

5. Start the engine and let it run for about 2 minutes to purge air from the system.

6. Shut off the engine and remove the key, and check for leaks.

Check the hydraulic lines and hoses for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration, and chemical deterioration. Make all necessary repairs before operating.

The test ports are used to test pressure in the hydraulic circuits. Contact your authorized Toro distributor for assistance.

1. Test Port A (Figure 75) is used to assist in troubleshooting the hydraulic circuit for the lift cylinders.

   

   Figure 75

   1. Test port A (lift cylinders)

2. Test Port B (Figure 76) is used to assist in troubleshooting the hydraulic circuit for the front cutting units.

3. Test Port C (Figure 76) is used to assist in troubleshooting the hydraulic circuit for the rear cutting units.

   

   Figure 76

   1. Test port B (front cutting units)
   2. Test port C (rear cutting units)

4. Test Port D is located on the bottom of the hydrostatic transmission (Figure 77) and is used to measure the charge pressure of the transmission.

5. Test Port E is used to measure traction forward pressure (Figure 77).

6. Test Port F is used to measure traction reverse pressure (Figure 77).

7. Test Port G is used to measure steering circuit pressure (Figure 77).

   

   Figure 77

   1. Test port D (charge pressure)
   2. Test port E (traction forward pressure)
   3. Test port F (traction reverse pressure)
   4. Test port G (steering circuit pressure)

Check the reel-to-bedknife contact even if the quality of cut had been acceptable previously. There must be light contact across the full length of the reel and bedknife; refer to Adjusting Reel to Bedknife in the cutting unit operator’s manual.

Note: When backlapping, the front units all operate together, and the rear units operate together.

1. Park the machine on a level surface, lower the cutting units, shut off the engine, engage the parking brake, and move the Enable/Disable switch to disable position.

2. Unlock and raise the seat to expose the controls.

3. Locate the reel speed selector knobs and backlap knobs (Figure 78). Rotate the desired backlap knob(s) to the backlap position and the desired reel speed selector knob(s) to position 1.

   

   Figure 78

   1. Backlap knobs
   2. Reel speed selector knobs

   Note: Backlapping speed may be increased by moving the reel speed selector knob toward 13. Each position increases the speed approximately 100 rpm. After changing the selector, wait 30 seconds for the system to stabilize at the new speed.

4. Make initial reel to bedknife adjustments appropriate for backlapping on all cutting units which are to be backlapped.

5. Start the engine and run it at idle speed.

6. Select either front, rear, or both backlap knobs to determine which reels will be backlapped.

7. Move the Enable/Disable switch to the Enable position. Move the Lower Mow/Lift control forward to start the backlapping operation on the designated reels.

8. Apply lapping compound with a long-handled brush (Toro Part No. 29-9100). Never use a short-handled brush.

9. If the reels stall or become erratic while backlapping, stop backlapping by moving the Lower Mow/Lift control lever rearward. Once the reels have stopped, move the desired reel speed selector knob(s) one position closer to 13. Resume backlapping by moving the Lower Mow/Lift control lever forward.

10. To make an adjustment to the cutting units while backlapping, stop the cutting units by moving the Lower Mow/Raise lever rearward; move the Enable/Disable switch to Disable and shut off the engine. After adjustments have been completed, repeat steps 5 through 9.

11. When the cutting unit is adequately sharpened, a burr will form on the front edge of the knife. Using a file, carefully remove the burr without dulling the cutting edge.

12. Repeat the procedure for all cutting units to be backlapped.

    When you are finished with the backlap operation, return the backlap knobs to the forward flow position, lower the seat, and wash all lapping compound off the cutting units. Adjust the reel-to-bedknife contact as needed.

    Note: If you do not return the backlap knobs to the forward flow position after backlapping, the cutting units will not raise or function properly.

The machine is set up at the factory for most fairway mowing applications.

The following adjustments are available for fine-tuning of the machine to the application:

The cutting unit lift circuits are equipped with adjustable valves to ensure that the cutting units lower at the desired rate. Adjust them as follows:

1. Run the machine until it warms up to operating temperature.

2. Locate the valves, on the lift manifold, for adjusting the desired cutting unit(s); refer to the chart and Figure 79.

   Valve	Cutting Unit Affected
   FC1	#1 (front center)
   FC4	#4 and #5 (front wings)
   FC5	#2 and #3 (rear)
   FC6	#6 (rear left)
   FC7	#7 (rear right)

   

   Figure 79

   1. Adjustment valve for #1 (front center) cutting unit
   2. Adjustment valve for #4 and #5 (front wings) cutting units
   3. Adjustment valves for #2 and #3 (rear) cutting units
   4. Adjustment valve for #6 (rear left) cutting unit
   5. Adjustment valve for #7 (rear right) cutting unit

3. Loosen the locking nuts on the valves.

4. Using a hex key, rotate the appropriate valve clockwise to slow down the drop rate of the cutting units.

5. Verify the lift rate adjustment by raising and lowering cutting units several times. Adjust it as required.

6. Tighten the locking nut to secure the adjustment.

You can increase the turnaround height of the front outer cutting units (#4 and #5) and rear cutting units (#6 and #7) to provide additional ground clearance on contoured fairways.

Note: The RM CONFIG time delay should not be changed from the original setting of 0 when using this method to adjust the turnaround height.

To increase/adjust the turn around height of the cutting units proceed as follows:

1. Park the machine on a level surface, lower the cutting units, shut off the engine, engage the parking brake, and remove the key.

2. Loosen the carriage bolt nut securing the lift arm switch bracket to the #4, 6, or 7 lift arms (Figure 80).

   

   Figure 80

   #4 shown

   1. Lift arm switch
   2. Carriage bolt nut
   3. Lift arm flag

3. Move the lift switch bracket up in the slot to the desired position.

4. Set the distance between the lift arm switch and the flag on the lift arm to approximately 1.6 mm (0.062 inch).

5. Tighten carriage bolt nut.

Additional downward travel of the front 3 cutting units may be desirable in highly contoured locations. If any of the front 3 cutting units lift off the ground when cresting a hill, you can lower the front carrier frame by removing the mounting bolts and positioning frame in the bottom set of holes in the main frame (Figure 81). Contact your authorized Toro distributor for assistance.

Note: Moving the carrier frame down decreases the amount of clearance between the cutting units and the ground in turnaround and transport positions and may require adjusting the lift chain length on the cutting unit.

Figure 81

1. Carrier frame mounting bolts