Reelmaster® 3550 Traction Unit

• Read the Operator’s Manual and other training material carefully. Be familiar with the controls, safety signs, and the proper use of the equipment.

• If the operator or mechanic can not read the language of this manual, it is the owner’s responsibility to explain this material to them.

• Never allow children or people unfamiliar with these instructions to use or service the mower. Local regulations may restrict the age of the operator.

• Never mow while people, especially children, or pets are nearby.

• Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people or their property.

• Do not carry passengers.

• All drivers and mechanics should seek and obtain professional and practical instruction. The owner is responsible for training the users. Such instruction should emphasize the following:

  • The need for care and concentration when working with ride-on machines

  • Control of a ride-on machine sliding on a slope will not be regained by the application of the brake. The main reasons for loss of control are as follows:

    • Insufficient wheel grip

    • Being driven too fast

    • Inadequate braking

    • The type of machine is unsuitable for the task

    • Lack of awareness of the effect of ground conditions, especially slopes

    • Incorrect hitching and load distribution

• While mowing, always wear substantial, slip-resistant footwear, long trousers, hard hat, safety glasses, and hearing protection. Long hair, loose clothing, or jewelry may get tangled in moving parts. Do not operate the equipment when barefoot or wearing open sandals.

• Thoroughly inspect the area where the equipment is to be used and remove all objects which may be thrown by the machine.

• Replace faulty silencers/mufflers.

• Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by the manufacturer.

• Check that operator’s presence controls, safety switches and shields are attached and functioning properly. Do not operate unless they are functioning properly.

• Do not operate the engine in a confined space where dangerous carbon monoxide and other exhaust gasses can collect.

• Mow only in daylight or in good artificial light.

• Before attempting to start the engine, disengage all blade attachment clutches, shift into neutral, and engage the parking brake. Only start the engine from the operator’s position. Never remove the ROPS and always wear the seat belts during operation.

• Do not put hands or feet near or under rotating parts. Keep clear of the discharge opening at all times.

• Remember there is no such thing as a safe slope. Travel on grass slopes requires particular care. Do the following to guard against overturning:

  • Do not stop or start suddenly when going up or downhill.

  • Keep machine speeds low on slopes and during tight turns.

  • Stay alert for humps and hollows and other hidden hazards.

  • Never mow across the face of the slope, unless the mower is designed for this purpose.

• Stay alert for holes in the terrain and other hidden hazards.

• Watch out for traffic when crossing or near roadways.

• Stop the blades from rotating before crossing surfaces other than grass.

• When using any attachments, never direct discharge of material toward bystanders nor allow anyone near the machine while in operation.

• Never operate the machine with damaged guards, shields, or without safety protective devices in place. Be sure all interlocks are attached, adjusted properly, and functioning properly.

• Do not change the engine governor settings or overspeed the engine. Operating the engine at excessive speed may increase the hazard of personal injury.

• Do the following before leaving the operator’s position:

  • Stop on level ground.

  • Disengage the power take-off and lower the attachments.

  • Change into neutral and set the parking brake.

  • Stop the engine and remove the key.

• Disengage the drive to attachments, stop the engine, and remove the ignition key in the following conditions:

  • Before making height adjustments, unless the adjustment can be made from the operator’s position.

  • Before clearing blockages

  • Before checking, cleaning, or working on the mower

  • After striking a foreign object or if an abnormal vibration occurs (check immediately). Inspect the cutting units for damage and make repairs before restarting and operating the equipment.

• Disengage the drive to attachments when transporting or when not machine is not in use.

• Stop the engine and disengage the drive to attachments before the following:

  • Refueling

  • Making height adjustment, unless the adjustment can be made from the operator's position

• Reduce the throttle setting before stopping the engine and, if the engine is provided with a fuel shut-off valve, turn the fuel off at the conclusion of mowing.

• Never raise the cutting units with the reels running.

• Keep hands and feet away from the cutting units.

• Look behind and down before backing up to be sure of a clear path.

• Slow down and use caution when making turns and crossing roads and sidewalks.

• Do not operate the mower under the influence of alcohol or drugs.

• Lightning can cause severe injury or death. If lightning is seen or thunder is heard in the area, do not operate the machine; seek shelter.

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

• The operator shall turn on flashing warning lights, if provided, whenever traveling on a public road, except where such use is prohibited by law.

• The ROPS is an integral and effective safety device. Keep a folding ROPS in the raised and locked position and use the seat belt when operating the machine.

• Lower a folding ROPS temporarily only when absolutely necessary. Do not wear the seat belt when folded down.

• Be aware there is no rollover protection when a folded ROPS is in the down position.

• Be certain that the seat belt can be released quickly in the event of an emergency.

• Check the area to be mowed and never fold down a folding ROPS in areas where there are slopes, drop offs or water.

• Check carefully for overhead clearances (i.e. branches, doorways, electrical wires) before driving under any objects and do not contact them.

• Keep the ROPS in safe operating condition by periodically thoroughly inspecting for damage and keeping all mounting fasteners tight.

• Replace a damaged ROPS. Do not repair or revise.

• Do not remove the ROPS.

• Any alterations to a ROPS must be approved by the manufacturer.

• To avoid personal injury or property damage, use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive.

• Extinguish all cigarettes, cigars, pipes, and other sources of ignition.

• Use only an approved fuel container.

• Never remove fuel cap or add fuel with the engine running.

• Allow engine to cool before refueling.

• Never refuel the machine indoors.

• Never store the machine or fuel container where there is an open flame, spark, or pilot light such as on a water heater or on other appliances.

• Never fill containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always place containers on the ground away from your vehicle before filling.

• Remove equipment from the truck or trailer and refuel it on the ground. If this is not possible, then refuel such equipment with a portable container, rather than from a fuel dispenser nozzle.

• Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete.

• Do not use a nozzle lock open device.

• If fuel is spilled on clothing, change clothing immediately.

• Never overfill fuel tank. Replace fuel cap and tighten securely.

• Keep all nuts, bolts and screws tight to be sure the equipment is in safe working condition.

• Never store the equipment, with fuel in the tank, inside a building where fumes may reach an open flame or spark.

• Allow the engine to cool before storing in any enclosure.

• To reduce the fire hazard, keep the engine, silencer/muffler, battery compartment fuel storage area, cutting units and drives free of grass, leaves, or excessive grease. Clean up oil or fuel spillage.

• Replace worn or damaged parts for safety.

• If the fuel tank has to be drained, do this outdoors.

• When machine is to be parked, stored, or left unattended, lower the cutting units unless a positive mechanical lock is provided.

• Disengage drives, lower the cutting units, set parking brake, stop engine and remove key. Wait for all movement to stop before adjusting, cleaning or repairing.

• Shut off fuel while storing or transporting. Do not store fuel near flames.

• Park the machine on level ground. Never allow untrained personnel to service machine.

• Use jack stands to support components when required.

• Carefully release pressure from components with stored energy.

• Disconnect battery before making any repairs. Disconnect the negative terminal first and the positive last. Reconnect positive first and negative last.

• Keep hands and feet away from moving parts. If possible, do not make adjustments with the engine running.

• Charge batteries in an open well ventilated area, away from spark and flames. Unplug charger before connecting or disconnecting from battery. Wear protective clothing and use insulated tools.

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

• Use full width ramps for loading machine into trailer or 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.

Be sure to establish your own special procedures and work rules for unusual operating conditions (e.g., slopes too steep for operation). Survey the complete mowing site to determine which hills can be safely operated on. When performing this site survey, always use common sense and take into consideration the turf condition and the rollover risk. To determine which hills or slopes may be safely operated on, use the slope chart provided in the manual. To perform a site survey, follow the procedure outlined in the Operation section of the this manual. The maximum side hill angle is detailed on the slope decal affixed on the machine.

The operator must be skilled and trained in how to drive on hillsides. Failure to use caution on slopes or hills may cause the vehicle to tip or roll, possibly resulting in personal injury or death.

• Know how to stop the machine and engine quickly.

• Do not operate the machine while wearing tennis shoes or sneakers.

• Wearing safety shoes and long pants is advisable and required by some local ordinances and insurance regulations.

• Keep hands, feet, and clothing away from moving parts and the mower discharge area.

• Fill the fuel tank until level is 1/2 inch (12 mm) below the bottom of the filler neck. Do not overfill.

• Check the safety interlock switches daily for proper operation. If a switch should fail, replace the switch before operating the machine.

• When starting the engine, engage the parking brake, put the traction pedal in neutral, and disengage the blade drive. After the engine starts, release the parking brake and keep your foot off of the traction pedal. The machine must not move. If movement is evident, refer to the Maintenance section of this manual to adjust the traction drive.

• Use extreme caution when operating close to sand traps, ditches, creeks, steep hillsides, or other hazards.

• Reduce speed when making sharp turns.

• Do not turn on hills.

• Do not operate on a side hill that is too steep. A rollover may occur before losing traction.

• The slope angle at which the machines will tip is dependent on many factors. Among these are mowing conditions such as wet or undulating terrain, speed (especially in turns), position of the cutting units (up or down), tire pressure, and operator experience. At side hill angles of 20 degrees or less, the risk of a rollover is low. As the slope angle increases to a recommended maximum limit of 25 degrees, the risk of a rollover increases to a moderate level. Do not exceed a 25 degree side hill slope angle because the risk of a rollover and serious injury or death is very high.

• For steering control, lower the cutting units when going down slopes.

• Avoid sudden stops and starts.

• Use the reverse pedal for braking.

• Watch for traffic when near or crossing roads. Always yield the right-of-way.

• Raise the cutting units when driving from one work area to another.

• Do not touch the engine, muffler, exhaust pipe, or hydraulic tank while the engine is running or soon after it has stopped because these areas could be hot enough to cause burns.

• This machine is not designed or equipped for on-road use and is a slow-moving vehicle. If you must cross or travel on a public road, you should be aware of and comply with local regulations, such as required lights, slow moving vehicle signs, and reflectors.

• Before servicing or making adjustments, stop the engine and remove the ignition key.

• Ensure that the entire machine is properly maintained and in good operating condition. Frequently check all nuts, bolts, screws, and hydraulic fittings.

• Make sure all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition before applying pressure to the system.

• Keep your body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not your hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. If fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result.

• Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved by stopping the engine and lowering the cutting units to the ground.

• If the engine must be running to perform a maintenance adjustment, keep hands, feet, clothing, and any parts of the body away from the cutting units, attachments, and any moving parts. Keep everyone away.

• Do not overspeed the engine by changing governor settings. To ensure safety and accuracy, have an Authorized Toro Distributor check the maximum engine speed with a tachometer.

• The engine must be shut off before checking the oil or adding oil to the crankcase.

• If major repairs are ever needed or if assistance is desired, contact an Authorized Toro Distributor.

• To ensure optimum performance and continued safety certification of the machine, use only genuine Toro replacement parts and accessories. Replacement parts and accessories made by other manufacturers could be dangerous, and such use could void the product warranty.

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

1. To adjust, move the lever sideways to unlock seat (Figure 31).

2. Slide the seat to the desired position and release lever to lock in position.

The seat can be adjusted to provide a smooth and comfortable ride. Position the seat where you are most comfortable.

To adjust it, turn the knob in front either direction to provide the best comfort (Figure 31).

The back of the seat can be adjusted to provide a comfortable ride. Position the back of the seat where it is most comfortable.

To adjust it, turn the knob, under the right-side armrest, in either direction to provide the best comfort (Figure 31).

You can adjust the armrests to provide a comfortable ride. Position the armrests where they are most comfortable.

Raise the armrest and turn the knob, in either direction, to provide the best comfort (Figure 31).

Figure 31

1. Back rest knob
2. Seat position adjustment lever
3. Seat suspension knob
4. Armrest adjusting knob

1. Be sure that the parking brake is set and the cutting unit drive switch is in the Disengage position.

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

3. Move the throttle lever to the 1/2 throttle position.

4. Insert the key into the switch and rotate it to the On/Preheat position until the glow-plug indicator light goes out (approximately 7 seconds); then rotate the key to the Start position to engage the starter motor.

   Note: Release the key when the engine starts. The key will move automatically to the On/Run position.

   Important: To prevent overheating of the starter motor, do not engage the starter longer than 15 seconds. After 10 seconds of continuous cranking, wait 60 seconds before engaging the starter motor again.

5. When the engine is started for the first time or after an overhaul of the engine, operate the machine in forward and reverse for 1 to 2 minutes. Also operate the lift lever and cutting unit drive switch to be sure of proper operation of all parts.

   Turn the steering wheel to the left and right to check steering response; then shut the engine off and check for oil leaks, loose parts, and any other noticeable malfunctions.

   Caution

   Stop the engine and wait for all moving parts to stop before checking for oil leaks, loose parts, and other malfunctions.

Move the throttle control to the Idle position, move the cutting unit drive switch to Disengage, and rotate the starter key to Off. Remove the key from the switch to prevent accidental starting.

1. Park the machine on a level surface, lower the cutting units, stop the engine, and engage the parking brake.

2. Remove the cover from the control panel.

3. Locate the wire harness and loop-back connector (Figure 37).

   

   Figure 37

   1. Loop-back connector

4. Carefully unplug the loop-back connector from the harness connector.

5. Connect the Diagnostic ACE display connector to the harness connector (Figure 38).

   Note: Make sure correct overlay decal is positioned on Diagnostic ACE display.

   

   Figure 38

   1. Diagnostic ACE

6. Turn the key switch to the On position, but do not start the machine.

   Note: The red text on the overlay decal refers to input switches and the green text refers to outputs.

7. The “inputs displayed” LED, on the lower right column of the Diagnostic ACE, should be illuminated. If the “outputs displayed” LED is illuminated, press the toggle button, on Diagnostic ACE, to change LED to “inputs displayed”.

   The Diagnostic ACE will illuminate the LED associated with each of the inputs when that input switch is closed.

8. Individually, change each of the switches from open to closed (i.e., sit on seat, engage traction pedal, etc.), and note that the appropriate LED on Diagnostic ACE will blink on and off when corresponding switch is closed. Repeat this for all switches that you can change by hand.

9. If a switch is closed and the appropriate LED does not turn on, check all wiring and connections to the switch and/or check the switches with an ohm meter. Replace any defective switches and repair any defective wiring.

   Note: The Diagnostic ACE also has the ability to detect which output solenoids or relays are turned on. This is a quick way to determine if a machine malfunction is electrical or hydraulic.

1. Park the machine on a level surface, lower the cutting units, stop the engine, and engage the parking brake.

2. Remove the access panel from the side of the control arm.

3. Locate the wire harness and connectors near the controller.

4. Carefully unplug the loop-back connector from the harness connector.

5. Connect the Diagnostic ACE connector to the harness connector.

   Note: Make sure that the correct overlay decal is positioned on the Diagnostic ACE.

6. Turn the key switch to the On position, but do not start the machine.

   Note: The red text on the overlay decal refers to input switches and the green text refers to outputs.

7. The “outputs displayed” LED, on lower right column of Diagnostic ACE, should be illuminated. If the “inputs displayed” LED is illuminated, press the toggle button, on the Diagnostic ACE, to change the LED to “outputs displayed”.

   Note: It may be necessary to toggle between “inputs displayed” and “outputs displayed” several times to do the following step. To toggle back and forth, press the toggle button once. This may be done as often as required. Do not hold the button.

8. Sit on the seat and attempt to operate the desired function of the machine. The appropriate output LEDs should illuminate to indicate that the ECM is turning on that function.

   Note: If the correct output LEDs do not illuminate, verify that the required input switches are in the necessary positions to allow that function to occur. Verify correct switch function. If the output LEDs are on as specified, but the machine does not function properly, this indicates a non-electrical problem. Repair as necessary.

   Note: If each output switch is in the correct position and functioning correctly, but the output LEDs are not correctly illuminated, this indicates an ECM problem. If this occurs, contact your Toro Distributor for assistance

   Important: The Diagnostic ACE display must not be left connected to the machine. It is not designed to withstand the environment of the everyday use of the machine. When you are finished using the Diagnostic ACE, disconnect it from the machine and connect the loop-back connector to the harness connector. The machine will not operate without the loopback connector installed on the harness. Store the Diagnostic ACE in a dry, secure location in the shop, not on the machine.

The hood may be easily removed to ease maintenance procedures in the engine area of the machine.

1. Unlatch and raise the hood.

2. Remove the hairpin cotter securing the hood pivot to the mounting brackets (Figure 43).

   

   Figure 43

   1. Hairpin cotter

3. Slide the hood to the right side, lift the other side, and pull it out of the brackets.

Note: Reverse the procedure to install the hood.

Loosen the knobs and remove the battery cover (Figure 44).

Note: Refer to Servicing for the Battery for more information.

Figure 44

1. Battery cover

The machine has grease fittings that must be lubricated regularly with #2 general-purpose lithium-based grease. Lubricate the bearings and bushings daily when operating conditions are extremely dusty and dirty. Dusty and dirty operating conditions could cause dirt to get into the bearings and bushings, resulting in accelerated wear. Lubricate the grease fittings immediately after every washing, regardless of the interval specified.

The grease fitting locations and quantities are:

• Steering pivot (Figure 45)

  

  Figure 45

• Front lift-arm pivots and lift cylinders (3 each); refer to Figure 46.

  

  Figure 46

• Rear lift-arm pivots and lift cylinders (3 each); refer to Figure 47.

  

  Figure 47

• Cutting unit pivots (2 each); refer to Figure 48.

  

  Figure 48

• Neutral adjust mechanism (Figure 49)

  

  Figure 49

• Mow/transport slide (Figure 50)

  

  Figure 50

• Belt tension pivot (Figure 51)

  

  Figure 51

• Steering cylinder (Figure 52)

  

  Figure 52

  Note: If desired, an additional grease fitting may be installed in the other end of the steering cylinder. Remove the tire, install the fitting, grease the fitting, remove the fitting, and install the plug (Figure 53).

  

  Figure 53

• 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 at the recommended service interval or earlier if engine performance suffers due to extremely dusty, dirty conditions. Changing the air filter before it is necessary only increases the chance of dirt entering the engine when the filter is removed.

• Be sure that the cover is seated correctly and seals with the air-cleaner body.

1. Release the latches securing the air-cleaner cover to the air-cleaner body (Figure 54).

2. Remove the cover from the air-cleaner body (Figure 54).

3. Before removing the filter, use low-pressure air (276 kPa [40 psi], clean and dry) to help remove large accumulations of debris packed between outside of primary filter and the canister.

   Note: 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.

4. Remove and replace the filter (Figure 54).

   Cleaning of the used element is not recommended due to the possibility of damage to the filter media.

   

   Figure 54

   1. Air-cleaner cover
   2. Filter

5. Inspect the new filter for shipping damage, checking the sealing end of the filter and the body.

   Important: Do not use a damaged element.

6. Insert the new filter by applying pressure to the outer rim of the element to seat it in the canister.

   Important: Do not apply pressure to the flexible center of the filter.

7. Clean the dirt-ejection port located in the removable cover.

8. Remove the rubber outlet valve from the cover, clean the cavity and replace the outlet valve.

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

10. Secure the cover latches.

1. Remove either drain plug (Figure 55) and let the oil flow into a drain pan. When the oil stops flowing, install the drain plug.

   

   Figure 55

   1. Engine-oil drain plugs

2. Remove the oil filter (Figure 56).

   

   Figure 56

   1. Engine oil filter

3. Apply a light coat of clean oil to the new filter seal, and install the filter.

   Important: Do not overtighten the filter.

4. Add oil to the crankcase; refer to Checking the Engine-Oil Level.

Drain and clean the tank if the fuel system becomes contaminated or if the machine will be stored for an extended period of time. Use clean fuel to flush out the tank.

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

1. Place a clean container under the fuel filter.

2. Loosen the drain valve on the bottom of the filter canister (Figure 57).

   

   Figure 57

   1. Water separator/filter canister
   2. Vent plug
   3. Drain valve

3. Tighten the valve after draining.

1. Clean the area where the filter canister mounts (Figure 57).

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

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

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

Note: This procedure should be used only if the fuel system has been purged of air through normal priming procedures and the engine will not start; refer to Bleeding the Fuel System.

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

   

   Figure 58

   1. Fuel injectors

2. Move the throttle to the Fast position.

3. Turn the key in the key switch to the Start position and watch the fuel flow around the connector. Turn the key to the Off position when solid flow is observed.

4. Tighten the pipe connector securely.

5. Repeat the procedure on the remaining nozzles.

The battery electrolyte level must be properly maintained and the top of the battery kept clean. lf 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. Reconnect the cables, positive (+) cable first, and coat the terminals with petroleum jelly.

The fuses in the electrical system are located under the control panel.

If the machine moves when the traction pedal is in the neutral position, adjust the traction cam.

1. Park the machine on a level surface and turn the engine off.

2. Raise one front wheel and rear wheel off of the floor and place support blocks under the frame.

   Warning

   If the machine is not supported adequately, it may accidentally fall, injuring anyone under the machine.

   One front wheel and rear wheel must be raised off of the ground or the machine will move during adjustment.

3. Loosen the locknut on the traction adjustment cam (Figure 59).

   

   Figure 59

   1. Traction adjustment cam
   2. Locknut

   Warning

   The engine must be running so a final adjustment of the traction adjustment cam can be performed. Contact with hot or moving parts can result in personal injury.

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

4. Start the engine and rotate the cam hex in both directions to determine the mid position of the neutral span.

5. Tighten the locknut securing the adjustment.

6. Stop the engine.

7. Remove the support blocks and lower the machine to the shop floor. Test drive the machine to make sure that it does not move when the traction pedal is in neutral.

Remove debris from the radiator/oil cooler daily. Clean them more frequently in dirty conditions.

1. Turn the engine off and raise the hood. Clean the engine area thoroughly of all debris.

2. Clean both sides of the radiator/oil cooler thoroughly with compressed air (Figure 60).

   

   Figure 60

   1. Radiator/oil cooler

3. Close the hood.

1. Loosen the setscrew securing the knob to the parking-brake lever (Figure 61).

   

   Figure 61

   1. Parking-brake lever
   2. Knob
   3. Set screw

2. Rotate the knob until a force of 133 to 178 N (30 to 40 lb) is required to actuate the lever.

3. Tighten the setscrew after the adjustment has been attained.

1. Position the throttle lever rearward so it stops against the control panel slot.

2. Loosen the throttle cable connector on the injection pump lever arm (Figure 77).

   

   Figure 77

   1. Injection pump lever arm

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

4. Loosen the screws securing the throttle control to the control panel.

5. Push the throttle control lever all of the way forward.

6. Slide the stop plate until it contacts the throttle lever and tighten the screws securing the throttle control to the control panel.

7. If the throttle does not stay in position during operation, torque the locknut, used to set the friction device on the throttle lever, to 5 to 6 N-m (44 to 53 inch-lb).

   Note: The maximum force required to operate the throttle lever should be 89 N (20 lb).

Use a genuine Toro replacement filter, Part 86-3010.

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

1. Position the machine on a level surface, lower the cutting units, stop the engine, engage the parking brake, and remove the key from the ignition switch.

2. Clean around the filter mounting area. Place a drain pan under the filter (Figure 78) and remove the filter.

   

   Figure 78

   1. Hydraulic filter

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. Stop the engine and check for leaks.

If the fluid becomes contaminated, contact your local Toro distributor because the system must be flushed. Contaminated fluid looks milky or black when compared to clean oil.

1. Position the machine on a level surface, lower the cutting units, stop the engine, engage the parking brake, and remove the key from the ignition switch.

2. Disconnect the large hydraulic hose (Figure 79) from the reservoir and let the hydraulic fluid flow into a drain pan.

   

   Figure 79

   1. Hydraulic hose

3. Install the hydraulic hose when hydraulic fluid stops draining.

4. Fill the reservoir (Figure 80) with approximately 13.2 liters (3.5 US gallons) of hydraulic fluid; refer to Checking the Hydraulic System.

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

   

   Figure 80

   1. Hydraulic fill cap

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

6. Check for leaks; then stop the engine.

7. Check the fluid level and add enough to raise the level to Full mark on the dipstick.

   Important: Do not overfill the reservoir.

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.

Use the gauge bar (Figure 81) to adjust the cutting unit. Refer to the Cutting Unit Operator's Manual for the adjustment procedures.

Figure 81

1. Gauge bar
2. Height adjusting screw
3. Nut
4. Holes used for setting Groomer HOG
5. Hole not used

• Keep fingers, hands, and clothing away from the reels or other moving parts.

• Never attempt to turn the reels by hand or foot while the engine is running.

Note: When backlapping, all the cutting units operate together.

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

2. Raise the floor panel to expose the controls.

3. Make the initial reel to bedknife adjustments appropriate for backlapping; refer to the cutting unit Operator's Manual

4. Start the engine and allow it to 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

   • Only backlap at idle engine speed.

5. Set the reel speed control to position 1 (Figure 82).

   

   Figure 82

   1. Backlap lever
   2. Reel speed control knob

6. Move the backlap lever to the R (backlap) position (Figure 82).

   Danger

   Contacting the reels when they are moving could cause personal injury.

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

7. 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.

8. Apply lapping compound with a long handle brush. Never use a short handled brush.

9. 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 setting 1 or to your desired speed.

10. To make an adjustment to 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 stop the engine. After completing adjustments, repeat steps 5 through 9.

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

12. When you are finished, return the backlap lever to the Mow position, lower the floor panel, and wash all lapping compound off of the cutting units. Adjust the cutting unit reel-to-bedknife contact as needed. Move the cutting unit reel speed control to the desired mowing position.

    Important: If the backlap switch is not returned to the F (Mow) position after backlapping, the cutting units will not raise or function properly.

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