Reelmaster® 5610-D Traction Unit

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

Important: The fuel system automatically bleeds itself when any of the following situations occur:

• You are starting a new machine for the first time.

• The engine has ceased running due to lack of fuel.

• Maintenance has been performed upon the fuel system components.

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 MIDDLE position, and ensure that the Enable/Disable switch is in the DISABLE position.

2. Remove your foot from the traction pedal and make sure that the pedal is in the NEUTRAL position.

3. Turn the key to the RUN position.

4. 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.

1. Move all controls to NEUTRAL, engage the parking brake, move the engine-speed switch to the low idle position and allow the engine to reach low idle speed.

2. Turn the key to the OFF position and remove it from the switch.

Note: Cutting grass at a rate that loads the engine promotes DPF regeneration.

1. Move the machine to the job site and align the machine outside the cutting area for the first cutting pass.

2. Ensure that the PTO switch is set to the DISABLE position.

3. Move the lever for the mow-speed limiter forward.

4. Press the throttle-speed switch to set the engine speed to HIGH IDLE.

5. Use the joystick to lower the cutting units to the ground.

6. Press the PTO switch to prepare cutting units for operation.

7. Use the joystick to raise the cutting units off the ground.

8. Begin moving the machine toward the cutting area and lower the cutting units.

   Note: Cutting grass at a rate that loads the engine promotes DPF regeneration.

9. When you complete the mowing pass, use the joystick to lift the cutting units.

10. Perform a tear-shaped turn to quickly line up for your next pass.

The diesel particulate filter (DPF) is part of the exhaust system. The diesel-oxidation catalyst of the DPF reduces harmful gasses and the soot filter removes soot from the engine exhaust.

The DPF regeneration process uses heat from the engine exhaust to incinerate the soot accumulated on the soot filter, converting the soot to ash, and clears the channels of the soot filter so that filtered engine exhaust flows out the DPF.

The engine computer monitors the accumulation of soot by measuring the back pressure in the DPF. If the back pressure is too high, soot is not incinerating in the soot filter through normal engine operation. To keep the DPF clear of soot, remember the following:

• Passive regeneration occurs continuously while the engine is running—run the engine at full engine speed when possible to promote DPF regeneration.

• If the back pressure in the DPF is too high or a reset regeneration has not occurred for 100 hours, the engine computer signals you through the InfoCenter when reset regeneration is running.

• Allow the reset regeneration process to complete before shutting off the engine.

Operate and maintain your machine with the function of the DPF in mind. Engine load at high idle (full throttle) engine speed generally produces adequate exhaust temperature for DPF regeneration.

Important: Minimize the amount of time that you idle the engine or operate the engine at low-engine speed to help reduce the accumulation of soot in the soot filter.

DPF Soot Accumulation

• Over time, the diesel particulate filter accumulates soot in the soot filter. The computer for the engine monitors the soot level in the DPF.

• When enough soot accumulates, the computer informs you that it is time to regenerate the DPF.

• DPF regeneration is a process that heats the DPF to convert the soot to ash.

• In addition to the warning messages, the computer reduces the power produced by the engine at different soot-accumulation levels.

Engine Warning Messages—Soot Accumulation

Indication Level	Fault Code	Engine Power Rating	Recommended Action
Level 1: Engine Warning	Figure 31 Check EngineSPN 3719, FMI 16	The computer de-rates the engine power to 85%.	Perform a parked regeneration as soon as possible; refer to Servicing the Diesel-Oxidation Catalyst (DOC) and the Soot Filter.
Level 2: Engine Warning	Figure 32 Check EngineSPN 3719, FMI 0	The computer de-rates the engine power to 50%.	Perform a recovery regeneration as soon as possible; refer to Servicing the Diesel-Oxidation Catalyst (DOC) and the Soot Filter.

DPF Ash Accumulation

• The lighter ash is discharged through the exhaust system; the heavier ash collects in the soot filter.

• Ash is a residue of the regeneration process. Over time, the diesel particulate filter accumulates ash that does not discharge with the engine exhaust.

• The computer for the engine calculates the amount of ash accumulated in the DPF.

• When enough ash accumulates, the engine computer sends information to the InfoCenter in the form of an engine fault to indicate the accumulation of ash in the DPF.

• The fault messages indicate that it is time to service the DPF.

• In addition to the warnings, the computer reduces the power produced by the engine at different ash-accumulation levels.

InfoCenter Advisory and Engine Warning Messages—Ash Accumulation

Indication Level	Fault Code	Engine Speed Reduction	Engine Power Rating	Recommended Action
Level 1: Engine Warning	Figure 33 Check EngineSPN 3720, FMI 16	None	The computer de-rates the engine power to 85%.	Service the DPF; refer to Servicing the Diesel-Oxidation Catalyst (DOC) and the Soot Filter
Level 2: Engine Warning	Figure 34 Check EngineSPN 3720, FMI 16	None	The computer de-rates the engine power to 50%.	Service the DPF; refer to Servicing the Diesel-Oxidation Catalyst (DOC) and the Soot Filter
Level 3: Engine Warning	Figure 35 Check EngineSPN 3251, FMI 0	Engine speed at maximum torque + 200 rpm	The computer de-rates the engine power to 50%.	Service the DPF; refer to Servicing the Diesel-Oxidation Catalyst (DOC) and the Soot Filter

Types of Diesel Particulate Filter Regeneration

Types of diesel particulate filter regeneration that are performed while the machine is operating:

Type of Regeneration	Conditions that cause DPF regeneration	DPF description of operation
Passive	Occurs during normal operation of the machine at high-engine speed or high-engine load	• The InfoCenter does not display an icon indicating passive regeneration.
		• During passive regeneration, the DPF processes high-heat exhaust gasses, oxidizing harmful emissions, and burning soot to ash.
		Refer to Passive DPF Regeneration.
Assist	Occurs because of low-engine speed, low-engine load, or after the computer detects the DPF is becoming obstructed with soot	• The InfoCenter does not display an icon indicating assist regeneration.
		• During assist regeneration, the engine computer adjusts the engine settings to raise the exhaust temperature.
		Refer to Assist DPF Regeneration.
Reset	Occurs every 100 hours	• When the high exhaust-temperature icon is displayed in the InfoCenter, a regeneration is in progress.
	Also occurs after assist regeneration only if the computer detects that assist regeneration did not sufficiently reduce the soot level
		• During reset regeneration, the engine computer adjusts the engine settings to raise the exhaust temperature.
		Refer to Reset Regeneration.

Types of diesel particulate filter regeneration that require you to park the machine:

Type of Regeneration	Conditions that cause DPF regeneration	DPF description of operation
Parked	Occurs because the computer detects back pressure in the DPF due to soot buildup	• When the reset-standby/parked or recovery regeneration icon or ADVISORY #188 displays in the InfoCenter, a regeneration is requested.
	Also occurs because the operator initiates a parked regeneration
	May occur because you set the InfoCenter to inhibit reset regeneration and continued operating the machine, adding more soot when the DPF already needs a reset regeneration	• Perform the parked regeneration as soon as possible to avoid needing a recovery regeneration.
	May result from using the incorrect fuel or engine oil	• A parked regeneration requires 30 to 60 minutes to complete.
		• You must have at least a 1/4 tank of fuel in the tank.
		• You must park the machine to perform a parked regeneration.
		Refer to Parked or Recovery Regeneration.
Recovery	Occurs because the operator ignored requests for a parked regeneration and continued operating the machine, adding more soot to the DPF	• When the reset-standby/parked or recovery regeneration icon or ADVISORY #190 displays in the InfoCenter, a recovery regeneration is requested.
		• A recovery regeneration requires up to 3 hours to complete.
		• You must have at least a 1/2 tank of fuel in the machine.
		• You must park the machine to perform a recovery regeneration.
		Refer to Parked or Recovery Regeneration.

Accessing the DPF Regeneration Menus

Accessing the DPF Regeneration Menus

1. Access the Service menu, press the center button to scroll down to the DPF REGENERATION option (Figure 36).

   

   Figure 36

2. Press the right button to select the DPF Regeneration entry (Figure 36).

Time Since Last Regeneration

Access the DPF Regeneration menu, press the center button to scroll down to the LAST REGEN field (Figure 37).

Use the LAST REGEN field to determine how many hours you have run the engine since the last reset, parked, or recovery regeneration.

Figure 37

Technician Menu

Important: For operating convenience, you may decide to perform a parked regeneration before the soot load reaches 100%, provided the engine has run more than 50 hours since the last successful reset, parked, or recovery regeneration.

Use the technician menu to view the current state of engine regeneration control and view the reported soot level.

Access the DPF Regeneration menu, press the center button to scroll down to the TECHNICIAN option, and press the right button to select the Technician entry (Figure 38).

Figure 38

• Use the DPF operation table to understand the current state of DPF operation (Figure 39).

  

  Figure 39

  .

  DPF Operation Table

  State	Description
  Normal	The DPF is in normal-operating mode—passive regeneration.
  Assist Regen	The engine computer is performing an assist regeneration.
  Reset Stby	The engine computer is trying to run a reset regeneration, but 1 of the following conditions prevents regeneration:	The regen inhibit setting is set to ON.
  		The exhaust temperature is too low for regeneration.
  Reset Regen	The engine computer is running a reset regeneration.
  Parked Stby	The engine computer is requesting that you run a parked regeneration.
  Parked Regen	You initiated a parked regeneration request and the engine computer is processing the regeneration.
  Recov. Stby	The engine computer is requesting that you run a recovery regeneration.
  Recov. Regen	You initiated a recovery regeneration request and the engine computer is processing the regeneration.

• View the soot load which is measured as the percentage of soot in the DPF(Figure 40); refer to the soot-load table.

  Note: The soot load value varies as the machine is operated and DPF regeneration occurs.

  

  Figure 40

  Soot-Load Table

  Important Soot Load Values	Regeneration State
  0% to 5%	Minimum soot load range
  78%	The engine computer performs an assist regeneration.
  100%	The engine computer automatically requests a parked regeneration.
  122%	The engine computer automatically requests a recovery regeneration.

Reset Regeneration

Caution

The exhaust temperature is hot (approximately 600°C (1,112°F) during DPF regeneration. Hot exhaust gas can harm you or other people.

• Never operate the engine in an enclosed area.

• Make sure that there are no flammable materials around the exhaust system.

• Never touch a hot exhaust system component.

• Never stand near or around the exhaust pipe of the machine.

Figure 41

• The high exhaust-temperature icon displays in the InfoCenter (Figure 41).

• The engine computer adjusts engine settings to raise the exhaust temperature.

  Important: The high exhaust-temperature icon indicates that the exhaust temperature discharged from of your machine may be hotter than during regular operation.

• While operating the machine, run the engine at full engine speed and high load when possible to promote DPF regeneration.

• The icon displays in the InfoCenter while the reset regeneration is processing.

• Whenever possible, do not shut off the engine or reduce engine speed while the reset regeneration is processing.

  Important: Whenever possible, allow the machine to complete the reset regeneration process before shutting off the engine.

Periodic Reset Regeneration

If the engine has not completed a successful Reset, Parked, or Recovery regeneration in the previous 100 hours of engine operation, the engine computer will attempt to perform a reset regeneration.

Setting the Inhibit Regen

Reset Regeneration Only

Note: If you set the InfoCenter to inhibit regeneration, the InfoCenter displays ADVISORY #185 (Figure 42) every 15 minutes while the engine requests a reset regeneration.

Figure 42

A reset regeneration produces the elevated engine exhaust. If you are operating the machine around trees, brush, tall grass, or other temperature-sensitive plants or materials, you can use the Inhibit Regen setting to prevent the engine computer from performing a reset regeneration.

Important: When you shut off the engine and start it again, the inhibit regen setting defaults to OFF.

1. Access the DPF Regeneration menu, press the center button to scroll down to the INHIBIT REGEN option, and press the right button to select the Inhibit Regen entry (Figure 43).

   

   Figure 43

2. Press the right button to change the inhibit regeneration setting from On to Off (Figure 43) or from Off to On (Figure 44).

   

   Figure 44

Allowing a Reset Regeneration

The InfoCenter displays the high exhaust-temperature icon when the reset regeneration is in process.

Note: If INHIBIT REGEN is set to ON, the InfoCenter displays ADVISORY #185 (Figure 45). Press button 3 to set inhibit regeneration setting to OFF and continue with the reset regeneration.

Figure 45

Note: If the engine exhaust temperature is too low, the InfoCenter displays ADVISORY #186 (Figure 46) to inform you to set the engine to full throttle (high idle).

Figure 46

Note: When the reset regeneration completes, the high exhaust-temperature disappears from the InfoCenter screen.

You can adjust the counterbalance on the rear cutting-unit lift arms to compensate for different turf conditions and to maintain a uniform height of cut in the rough conditions or in areas of thatch buildup.

You can adjust each counterbalance spring to 1 of 4 settings. Each increment increases or decreases counterbalance on the cutting unit by 2.3 kg (5 lb). You can position the springs on the back side of the first spring actuator to remove all counter balance (fourth position).

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. Insert a tube or similar object onto the long spring end and pivot it around the spring actuator to the desired position (Figure 67).

   Caution

   The springs are under tension and could cause personal injury.

   Use caution when adjusting the springs.

   

   Figure 67

   1. Spring
   2. Spring actuator

3. Repeat the procedure on the other spring.

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. The lift-arm switch is located underneath the hydraulic tank behind the front, right lift arm (Figure 68).

3. Loosen the switch-mounting screws and move the switch down to increase the lift-arm turnaround height or move the switch up to decrease the lift-arm turnaround height (Figure 68).

   

   Figure 68

   1. Switch
   2. Lift-arm sensing device

4. Tighten the mounting screws.

To achieve a consistent, high quality of cut and a uniform after-cut appearance, it is important that you set the reel speed to the proper setting. Adjust the reel speed as follows:

1. In the InfoCenter, under the settings menu, enter the blade count, mow speed, and HOC to calculate the proper reel speed.

2. If further adjustments are required, in the settings menu, scroll down to the F Reel RPM, R Reel RPM, or both.

3. Press the right button to change the reel-speed value.

   Note: As you change the speed setting, the display continues to show the calculated reel speed based on blade count, mow speed and HOC, but the new value is also be displayed.

   Note: You may need to increase or decrease the reel speed to compensate for varying turf conditions.

Figure 69

5 inch (127 mm) Reel Speed Chart

Figure 70

7 inch (177.8 mm) Reel Speed Chart

The machine is equipped with a diagnostic light, which indicates if the machine detects a malfunction. The diagnostic light is located on the InfoCenter, above the display screen (Figure 71). When the machine is functioning properly and the key switch is moved to the ON/RUN position, the diagnostic light turns on briefly to indicate that the light is working properly. When a machine advisory message appears, the light illuminates when the message is present. When a fault message appears, the light blinks until the fault is resolved.

Figure 71

1. Diagnostic light

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 stop when you press the traction pedal while you are off the seat or if the parking brake is engaged.

• 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 72)

  

  Figure 72

  1. Front tie-down

• Rear—each side of the machine on the rear frame (Figure 73)

  

  Figure 73

  1. Rear tie-down

Note: Use jack stands to support the machine when required.

• Front—rectangular pad, under the axle tube, inside each front tire (Figure 74).

  

  Figure 74

  1. Front jacking point

• Rear—rectangular axle tube on the rear axle.

In an emergency, you can move the machine by actuating the bypass valve in the variable displacement hydraulic pump and 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. Rotate the bypass-valve bolt 1-1/2 turns to open and allow oil to bypass internally (Figure 75).

   Note: The bypass valve is located on the left side of the hydrostat. By bypassing the fluid, you can move the machine slowly without damaging the transmission.

   

   Figure 75

   1. Bypass-valve bolt

2. Close the bypass valve before starting the engine. However, do not exceed 7 to 11 N∙m (5 to 8 ft-lb) torque to close the valve.

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

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 the 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:

• Pump driveshaft (3) (Figure 76)

  

  Figure 76

• Cutting-unit lift-arm cylinders (2 each) (Figure 77)

  

  Figure 77

• Lift-arm pivots (1 each) (Figure 77)

• Cutting-unit carrier-frame and pivot (2 each) (Figure 78)

  

  Figure 78

• Lift-arm-pivot shaft (1 each) (Figure 79)

  

  Figure 79

• Rear axle tie rod (2) (Figure 80)

  

  Figure 80

• Axle-steering pivot (1) (Figure 81)

  

  Figure 81

• Steering-cylinder ball joints (2) (Figure 82)

  

  Figure 82

• Brake pedal (1) (Figure 83)

  

  Figure 83

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 requires it. Changing the air filter before it is necessary only increases the chance of dirt entering the engine when you remove the filter.

Important: Make sure that the cover is seated correctly and seals with the air-cleaner body.

Figure 84

If engine faults , , or display in the InfoCenter(Figure 87), clean the soot filter using the steps that follow:

Figure 87

1. Refer to the Engine section in the Service Manual for information on disassembling and assembling the diesel-oxidation catalyst and the soot filter of the DPF.

2. Refer to your authorized Toro distributor for diesel-oxidation catalyst and the soot filter replacement parts or service.

3. Contact your authorized Toro distributor to reset the engine ECU after you install a clean DPF.

1. Place a clean container under the fuel filter.

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

   

   Figure 88

   1. Water separator filter canister

3. Clean the area where the filter canister mounts.

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

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

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

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

1. Clean the area around the fuel-filter head (Figure 89).

   

   Figure 89

   1. Fuel-filter head
   2. Fuel filter

2. Remove the filter and clean the filter-head mounting surface (Figure 89).

3. Lubricate the filter gasket with clean lubricating engine oil. Refer to the engine operator's manual, included with the machine, for additional information.

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

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

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

The fuel pick-up tube, located inside the fuel tank, is equipped with a screen to help prevent debris from entering the fuel system. Remove the fuel pick-up tube and clean screen as required.

Keep the terminals and the entire battery case clean because a dirty battery discharges slowly. To clean the battery, wash the entire case with a solution of baking soda and water. Rinse it with clear water.

There are 8 fuses in the electrical system. The fuse block is located behind the control-arm-access panel (Figure 90).

Figure 90

1. Fuse block

Figure 91

Check the tire pressure. The correct air pressure in the front and rear tires is 83 to 103 kPa (12 to 15 psi).

Torque the wheel nuts to 94 to 122 N∙m (70 to 90 ft-lb).

The machine must not creep when you release the traction pedal. If it does creep, adjust it as follows:

1. Park the machine on a level surface, lower the cutting units to the ground, shut off the engine, and remove the key.

2. Jack up the front of the machine until the front tires are off the ground. Support the machine with jack stands to prevent it from falling accidentally.

   Note: On 4-wheel-drive models, the rear tires must also be off the ground.

3. On the right side of the hydrostat, loosen the locknut on the traction-adjustment cam (Figure 92).

   

   Figure 92

   1. Locknut
   2. Traction-adjustment cam

   Warning

   The engine must be running while you perform the final adjustment on the traction adjustment cam. This could cause personal injury.

   Keep your hands, feet, face, and other body parts away from the muffler, other hot parts of the engine, and any rotating parts.

4. Start the engine and rotate the cam hex in either direction until the wheels stop rotating.

5. Tighten the locknut to secure the adjustment.

6. Shut off the engine, remove the jack stands, and lower the machine to the ground.

7. Test drive the machine to make that sure that it does not creep.

1. Rotate the steering wheel to position the rear wheels straight ahead.

2. Loosen the jam nut on each end of the tie rod (Figure 93).

   Note: The end of the tie rod with the external groove is a left-hand thread.

   

   Figure 93

   1. Jam nut
   2. Tie rod
   3. Wrench slot

3. Using the wrench slot, rotate the tie rod.

4. Measure the distance at the front and rear of the rear wheels at axle height.

   Note: The distance at the front of the rear wheels should be less than 6 mm (1/4 inch) of the distance measured at the rear of the wheels.

5. Repeat this procedure as required.

Clean debris off the screen, oil cooler, and front of the radiator daily and more often if conditions are extremely dusty and dirty. Refer to Removing Debris from the Cooling System.

The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol antifreeze. Check the level of coolant in the expansion tank at the beginning of each day before starting the engine. The capacity of the cooling system is 6.6 L (7.0 US qt).

1. Check the level of coolant in the expansion tank (Figure 94).

   The coolant level should be between the marks on the side of the tank.

   

   Figure 94

   1. Expansion tank

2. If the coolant level is low, remove the expansion-tank cap and replenish the system. Do not overfill.

3. Install the expansion-tank cap.

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. Thoroughly clean all debris out of the engine area.

3. Unlatch the clamp and pivot open the rear screen (Figure 95).

   

   Figure 95

   1. Rear-screen latch
   2. Rear screen

4. Thoroughly clean both sides of the radiator/oil cooler with compressed air (Figure 96).

   

   Figure 96

   1. Radiator/oil cooler

5. Close the screen and secure the latch.

Adjust the brakes when there is more than 2.5 cm (1 inch) of free travel of the brake pedal, or when more holding force is required (Figure 97). Free travel is the distance that the brake pedal moves before you feel braking resistance.

Figure 97

1. Free travel

Note: Use the wheel-motor backlash to rock the drums back and forth to ensure that the drums are free prior to and after adjustment.

1. To reduce free travel of the brake pedals, tighten the brakes by loosening the front nut on the threaded end of the brake cable (Figure 98).

   

   Figure 98

   1. Brake cable
   2. Front nut

2. Tighten the rear nut to move the cable backward until brake pedals have 0.63 to 1.27 cm (1/4 to 1/2 inch) of free travel, before the wheel locks up (Figure 97).

3. Tighten the front nuts, ensuring that both cables actuate the brakes simultaneously.

   Note: Ensure that the cable conduit does not rotate while you are tightening the nuts.

If the parking brake fails to engage and latch, adjust the brake pawl.

1. Loosen the 2 screws securing the parking-brake pawl to the frame (Figure 99).

   

   Figure 99

   1. Brake cables
   2. Screw
   3. Parking-brake pawl
   4. Brake detent

2. Press the parking-brake pedal forward until the brake detent completely engages on the brake pawl (Figure 99).

3. Tighten the 2 screws to lock the adjustment.

4. Press the brake pedal to release the parking brake.

5. Check the adjustment and adjust as required.

Note: For proper belt tension, allow 10 mm (3/8 inch) deflection when a force of 44 N (10 lb) is applied on the belt midway between the pulleys.

1. If the deflection is not 10 mm (3/8 inch), loosen the alternator mounting bolts (Figure 100).

   

   Figure 100

   1. Mounting bolt
   2. Alternator

2. Increase or decrease the alternator-belt tension and tighten the bolts.

3. Check the deflection of the belt again to ensure that the tension is correct.

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.

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 101). Remove the cap from the filler neck.

   

   Figure 101

   1. Hydraulic-tank cap

3. Remove the dipstick from the filler neck and wipe it with a clean rag.

4. Insert the dipstick into the filler neck; then remove it and check the level of the fluid.

   Note: The fluid level should be within 6.3 mm (1/4 inch) of the mark on the dipstick.

   Important: Do not overfill the hydraulic tank.

5. If the level is low, add appropriate fluid to raise the level to the FULL mark.

6. 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.

30 L (8 US gallons); refer to Hydraulic Fluid Specifications

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

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. Raise the hood.

3. Place a large drain pan under the fitting secured to the bottom of the hydraulic-fluid reservoir (Figure 102).

   

   Figure 102

   1. Hose

4. Disconnect the hose from the bottom of the fitting and let the hydraulic fluid flow into the drain pan.

5. Install the hose when hydraulic fluid stops draining.

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

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

7. Install the reservoir cap.

8. Start the engine and use all of the hydraulic controls to distribute hydraulic fluid throughout the system.

9. Check for leaks.

10. Shut off the engine.

11. Check the level of the hydraulic fluid and add enough to raise the level to the FULL mark on the dipstick.

    Important: Do not overfill the reservoir.

The hydraulic system is equipped with a service-interval indicator (Figure 103). With the engine running at operating temperature, view the indicator, it should be in the green zone. When the indicator is in the red zone, change the hydraulic filters.

Figure 103

1. Hydraulic-filter-restriction indicator

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

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. Clean the area around the filter-mounting area and place a drain pan under the filter (Figure 104) and (Figure 105).

   

   Figure 104

   1. Hydraulic filter
   

   Figure 105

   1. Hydraulic filter

3. Remove the filter.

4. Lubricate the gasket on the new filter with hydraulic oil.

5. Ensure that the filter-mounting area is clean.

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

7. Repeat the procedure on the other filter.

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

9. Shut off the engine and check for leaks.

Use the hydraulic-system test ports to test the pressure in the hydraulic circuits. Contact your authorized Toro distributor for assistance.

Use the test ports on the front hydraulic tubes to assist in troubleshooting the traction circuit (Figure 106).

Figure 106

1. Traction-circuit test port

Use the test ports on the mow manifold block to assist in troubleshooting the mow circuit (Figure 107).

Figure 107

1. Mow-circuit test ports

Use the test port on the lift manifold block to assist in troubleshooting the lift circuit (Figure 108).

Figure 108

1. Lift-circuit test port

Each day before operating, check the reel-to-bedknife contact, regardless of whether the quality of cut had previously been acceptable. There must be light contact across the full length of the reel and the bedknife (refer to Adjusting the 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, engage the parking brake, shut off the engine, and move the Enable/Disable switch to the DISABLE position.

2. Unlock and raise the seat to expose the backlap levers (Figure 109).

3. Make initial reel-to-bedknife adjustments appropriate for backlapping on all cutting units that are to be backlapped; refer to the Operator's Manual for the cutting units.

4. Start the engine and run at low idle speed.

   Danger

   Changing the engine speed while backlapping may cause the reels to stall.

   • Never change the engine speed while backlapping.

   • Backlap only at low engine-idle speed.

5. Select either front, rear, or both backlap levers to determine which units to backlap (Figure 109).

   Danger

   To avoid personal injury, be certain that you are clear of the cutting units before proceeding.

6. With the Mow/Transport lever in the MOW position, 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.

7. Apply lapping compound with a long-handled brush.

   Important: Never use a short-handled brush.

8. If the reels stall or become erratic while backlapping, select a higher reel-speed setting until the speed stabilizes, then return the reel speed to your desired speed.

9. To adjust the cutting units while backlapping, turn the reels off by moving the Lower Mow/Raise lever rearward; the Enable/Disable switch to the DISABLE position, and shut off the engine.

   After completing adjustments, repeat steps 4 through 8.

   

   Figure 109

   1. Backlap levers

10. Repeat the procedure for all cutting units you want to backlap.

11. When finished, return the backlap levers to the MOW position, lower the seat, and wash all lapping compound off the cutting units.

    Note: Adjust the cutting-unit reel to bedknife as needed. Adjust the cutting-unit reel speed to the desired mowing setting.

    Important: If the backlap switch is not returned to the OFF position after backlapping, the cutting units do not raise or function properly.

    Note: For a better cutting edge, run a file across the front face of the bedknife after lapping. This removes any burrs or rough edges that may have built up on the cutting edge.

Wash the machine as needed using water alone or with a mild detergent. You may use a rag when washing the machine.

Important: Do not use brackish or reclaimed water to clean the machine.

Important: Do not use power-washing equipment to wash the machine. Power-washing equipment may damage the electrical system, loosen important decals, or wash away necessary grease at friction points. Avoid excessive use of water near the control panel, engine, and battery.

Important: Do not wash the machine with the engine running. Washing the machine with the engine running may result in internal engine damage.