Reelmaster® 7000-D 4-Wheel Drive Traction Unit

Pull out on the lever to slide the seat fore or aft (Figure 30).

Rotate the knob to adjust the seat armrest angle (Figure 30).

Move the lever to adjust the seat back angle (Figure 30).

The weight gauge indicates when the seat is adjusted to the weight of the operator (Figure 30). Height adjustment is made by positioning the suspension within the range of the green region.

Figure 30

1. Weight gauge
2. Weight adjusting lever
3. Fore and aft adjusting lever
4. Seat back adjusting lever
5. Armrest adjusting knob

Adjust the seat to your weight (Figure 30). Pull up on the lever to increase the air pressure and push down to decrease the air pressure. The proper adjustment is attained when the weight gauge is in the green region.

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

Important: Bleed the fuel system if any of the following situations have occurred:

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

• Maintenance has been performed upon the fuel system components.

1. Remove your foot from the traction pedal and ensure that the pedal is in the NEUTRAL position.

   Note: Ensure that the parking brake is engaged.

2. Move the engine-speed switch to the LOW IDLE position.

3. Turn the key to the RUN position.

   Note: The glow indicator will light.

4. When the glow indicator dims, turn the key to the START position.

5. Release the key immediately when the engine starts and allow it to return to the RUN position.

6. Adjust the engine speed.

   Important: Do not run the starter motor more than 15 seconds at a time or premature starter failure may result. If the engine fails to start after 15 seconds, turn the key to the OFF position, recheck the controls and procedures, wait 15 additional seconds, and repeat the starting procedure.

   When the temperature is less than -7°C (20°F), the starter motor can be run for 30 seconds on then 60 seconds off for 2 attempts.

   Caution

   Contact with moving parts could result in injury.

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

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

Note: Lower the cutting units to the ground whenever you park the machine. This relieves the hydraulic load from the system, prevents wear on system parts, and also prevents accidental lowering of the cutting units.

1. Return the engine speed to low idle.

2. Move the PTO switch to the OFF position.

3. Engage the parking brake.

4. Rotate the key to OFF.

5. Remove the key from the switch to prevent accidental starting.

The engine speed switch has 2 modes to change the engine speed. Momentarily tapping the switch increases or decreases the engine speed in 100-rpm increments. Holding the switch down moves the engine speed directly to high or low idle, depending on which side of the switch you press.

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 35 Check EngineSPN 3719, FMI 16	The computer de-rates the engine power to 85%.	Perform a parked regeneration as soon as possible; refer to Parked or Recovery Regeneration.
Level 2: Engine Warning	Figure 36 Check EngineSPN 3719, FMI 0	The computer de-rates the engine power to 50%.	Perform a recovery regeneration as soon as possible; refer to Parked or Recovery Regeneration.

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 37 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 38 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 39 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 40).

   

   Figure 40

2. Press the right button to select the DPF Regeneration entry (Figure 40).

Time Since Last Regeneration

Access the DPF Regeneration menu, press the center button to scroll down to the LAST REGEN field (Figure 41).

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

Figure 41

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 42).

Figure 42

• Use the DPF operation table to understand the current state of DPF operation (Figure 43).

  

  Figure 43

  .

  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 44); refer to the soot-load table.

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

  

  Figure 44

  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 45

• The high exhaust-temperature icon displays in the InfoCenter (Figure 45).

• 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 46) every 15 minutes while the engine requests a reset regeneration.

Figure 46

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 47).

   

   Figure 47

2. Press the right button to change the inhibit regeneration setting from On to Off (Figure 47) or from Off to On (Figure 48).

   

   Figure 48

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 49). Press button 3 to set inhibit regeneration setting to OFF and continue with the reset regeneration.

Figure 49

Note: If the engine exhaust temperature is too low, the InfoCenter displays ADVISORY #186 (Figure 50) to inform you to set the engine to full throttle (high idle).

Figure 50

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 rough conditions or in areas of thatch buildup.

You can adjust each counterbalance spring to 1 of 4 settings. Each increment increases or decreases the 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 counterbalance (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 to relieve the spring tension during the adjustment (Figure 71).

   Caution

   The springs are under tension and could cause personal injury.

   Use caution when adjusting the springs.

3. While relieving the spring tension, remove the bolt and locknut securing the spring actuator to the bracket (Figure 71).

   

   Figure 71

   1. Spring
   2. Spring actuator

4. Move the spring actuator to the desired hole location and secure it with the locknut.

5. Repeat the procedure on the remaining 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 behind the front right lift arm (Figure 72).

   

   Figure 72

   1. Switch

3. Loosen the switch mounting screws (Figure 72) and move the switch up to increase the lift-arm turnaround height or move the switch down to decrease the lift-arm turnaround height.

4. Tighten the mounting screws.

You can fold the roll bar down to allow access into areas of restricted height.

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. Support the weight of the upper frame of the roll bar while removing the snap pins and clevis pins from the pivot brackets (Figure 73).

   

   Figure 73

   1. Upper frame
   2. Clevis pins
   3. Snap pins
   4. Lower holes

3. Carefully lower the frame downward until it rests on the stops.

4. Insert the clevis pins in the lower holes and secure them with the snap pins to support the upper frame in its lowered position.

5. To raise the frame, follow these instructions in reverse order.

• Keep all nuts, bolts, and screws correctly torqued ensure that the equipment is in safe working condition.

• Replace worn or damaged parts for safety.

• Ensure that the seat belt and mountings are in safe working order.

• Wear the seat belt when the roll bar is raised and no seat belt when the roll bar is lowered.

Important: The roll bar is an integral safety device. Keep the roll bar in the raised position when operating the mower. Lower the roll bar temporarily only when absolutely necessary.

The machine has interlock switches in the electrical system. These switches are designed to shut off the engine when you rise from the seat while pressing the traction pedal. However, you may rise from the seat while the engine is running and the traction pedal is in neutral. Although the engine continues to run if you disengage the PTO switch and release the traction pedal, shut off the engine before rising from the seat.

To check the operation of the interlock switches, do the following steps:

1. Drive the machine slowly to a large, relatively open area.

2. Lower the cutting units, shut off the engine, and engage the parking brake.

3. Sit on the seat and press the traction pedal.

4. Try to start the engine.

   Note: The engine should not crank. If the engine cranks, there is a malfunction in the interlock system; correct it before operating the machine.

5. Sit on the seat and start the engine.

6. Rise from the seat and move the PTO switch to the On position.

   Note: The PTO should not engage. If the PTO engages, there is a malfunction in the interlock system; correct it before operating the machine.

7. Sit on the seat, engage the parking brake, and start the engine.

8. Move the traction pedal out of the NEUTRAL position.

   Note: The engine should shut off. If the engine does not shut off, there is a malfunction in the interlock system; correct it before operating the machine.

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

• Tie the machine down securely.

The tie-down points are in the following locations:

• On each side of the frame under the front steps

• The rear bumper

Figure 74

1. Front tie-down points
2. Rear tie-down point

Note: Support the machine with jack stands whenever you work under the machine.

The jacking points are in the following locations:

• On the front of the machine on the frame on the inside of each drive tire

• On the rear of the machine at the center of the axle

In an emergency, you can move the machine by actuating the bypass valve in the variable displacement hydraulic pump and installing a hydraulic hose to bypass the check valve, 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) or for more than 0.4 km (1/4 mile), because internal transmission damage may occur. The bypass valve must be open whenever you push or tow the machine. Additionally, you need to install a hydraulic hose to bypass the check valve whenever you push or tow the machine in reverse.

If you need to push or tow your machine, you will likely need to move it both forward and in reverse. To ensure that the drive system does not become damaged from pushing or towing, it is best to prepare the machine for both forward and reverse pushing or towing.

1. Release the hood latches (Figure 78) and pivot open the hood.

   

   Figure 78

   1. Hood latch (2)

2. Remove the cotter pins securing the rear hood brackets to the frame pins and lift off the hood.

The machine has grease fittings that must be lubricated regularly with No. 2 lithium grease. If you operate the machine under normal conditions, lubricate all bearings and bushings after every 50 hours of operation or immediately after every washing.

The grease fitting locations and quantities are as follows:

• Brake shaft pivot bearings (5) (Figure 79)

  

  Figure 79

• Rear axle pivot bushings (2) (Figure 80)

  

  Figure 80

• Steering cylinder ball joints (2) (Figure 81)

  

  Figure 81

  1. Top fitting on king pin

• Tie rod ball joints (2) (Figure 81)

• King pin bushings (2) (Figure 81). The top fitting on the king pin should only be lubricated annually (2 pumps).

• Lift arm bushings (1 per cutting unit) (Figure 82)

  

  Figure 82

• Lift cylinder bushings (2 per cutting unit) (Figure 82)

• Lift arm pivot bushings (1 per cutting unit) (Figure 83)

• Cutting unit carrier frame (2 per cutting unit) (Figure 83)

• Cutting unit lift arm pivot (1 per cutting unit) (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 (Figure 84) requires it. Changing the air filter before it is necessary only increases the chance of dirt entering the engine when the filter is removed.

Figure 84

1. Service indicator

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

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. Pull the latch outward and rotate the air-cleaner cover counterclockwise (Figure 85).

   

   Figure 85

   1. Service indicator
   2. Latch
   3. Cover

3. Remove the cover from the air-cleaner body.

4. 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.

5. Remove and replace the primary filter (Figure 86).

   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 86

   1. Primary filter

   Important: Never attempt to clean the safety filter (Figure 87). Replace the safety filter with a new one after every 3 primary filter services.

   

   Figure 87

   1. Safety filter

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

7. Remove the rubber outlet valve from the cover, clean the cavity, and install the outlet valve.

8. Install the cover, orienting the rubber outlet valve in a downward position—between approximately 5 o’clock to 7 o’clock when viewed from the end.

9. Reset the indicator (Figure 84) if it shows red.

If engine faults , , or display in the InfoCenter(Figure 91), clean the soot filter using the steps that follow:

Figure 91

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.

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 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.

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

Inspect the fuel lines 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.

   

   Figure 92

   1. 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 mounting surface, then rotate it an additional 1/2 turn.

8. Tighten the drain plug on the bottom of the filter canister.

The engine fuel filter should be replaced after every 400 hours of operation.

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 fuel-filter head (Figure 93).

   

   Figure 93

   1. Fuel-filter head
   2. Fuel filter

3. Remove the filter and clean the filter-head mounting surface (Figure 93).

4. Lubricate the filter gasket with clean lubricating engine oil. Refer to the engine owner’s manual, included with the machine, for additional information.

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

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

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

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

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. Unlatch and raise the operator's console panel (Figure 94).

   

   Figure 94

   1. Operator's console panel
   2. Latch

   Danger

   Battery electrolyte contains sulfuric acid, which is fatal if consumed and causes severe burns.

   • Do not drink electrolyte and avoid contact with skin, eyes, or clothing. Wear safety glasses to shield your eyes and rubber gloves to protect your hands.

   • Fill the battery where clean water is always available for flushing the skin.

3. Connect a 3 to 4 A battery charger to the battery posts.

4. Charge the battery at a rate of 3 to 4 A for 4 to 8 hours.

5. When the battery is charged, disconnect the charger from the electrical outlet and battery posts.

6. Install the positive cable (red) to the positive (+) terminal and the negative cable (black) to the negative (-) terminal of the battery (Figure 95).

   

   Figure 95

   1. Positive battery cable
   2. Negative battery cable

7. Secure the cables to the posts with cap screws and nuts.

   Make sure that the positive (+) terminal is all of the way onto the post and the cable is positioned snug to the battery. The cable must not contact the battery cover.

8. Slide the rubber boot over the positive terminal to prevent a possible short from occurring.

9. Coat both battery connections with Grafo 112X (skin-over) grease, Toro Part No. 505-47, petroleum jelly, or light grease to prevent corrosion.

10. Slide the rubber boot over the positive terminal.

11. Close the console panel and secure the latch.

Important: Before welding on the machine, disconnect the negative cable from the battery to prevent damage to the electrical system.

Note: Check the battery condition weekly or after every 50 hours of operation. Keep the terminals and the entire battery case clean because a dirty battery will discharge slowly.

Clean the battery as follows:

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. Remove the battery from the machine.

3. Wash the entire case with a solution of baking soda and water.

4. Rinse the case with clean water.

5. Coat the battery posts and cable connectors with Grafo 112X (skin-over) grease (Toro Part No. 505-47) or petroleum jelly to prevent corrosion.

The fuses are located under the operator’s control panel.

Figure 96

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

Unhook the latch and raise the operator's console panel (Figure 97) to expose the fuses (Figure 98).

Figure 97

1. Operator's console panel
2. Latch

Figure 98

1. Fuses

The tires are overinflated for shipping. Therefore, release some of the air to reduce the pressure. The correct air pressure in the tires is 83 to 103 kPa (12 to 15 psi). Check the tire pressure daily.

Important: Maintain the recommended pressure in all tires to ensure a good quality of cut and proper machine performance. Do not underinflate the tires.

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

Note: The front wheel nuts are 1/2–20 UNF. The rear wheel nuts are M12 x 1.6-6H (metric).

There should be no end-play in the planetary drives/drive wheels (i.e., the wheels should not move when you pull or push them in a direction parallel to the axle).

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

2. Chock the rear wheels and raise the front of machine, supporting the front axle/frame on jack stands.

   Danger

   A machine on a jack may be unstable and slip off the jack, injuring anyone beneath it.

   • Do not start the engine while the machine is on a jack.

   • Always remove the key from the switch before getting off the machine.

   • Block the tires when you are raising the machine with a jack.

   • Support the machine with jack stands.

3. Grasp 1 of the front drive wheels and push/pull it toward and away from the machine, noting any movement.

   

   Figure 99

   1. Front drive wheels

4. Repeat step 3 for the other drive wheel.

5. If either wheel moves, contact your authorized Toro distributor to have the planetary drive rebuilt.

Lubricant Specification: high quality SAE 85W-140 gear lubricant

1. Park the machine on level surface, position the wheel so that the fill plug is at the 12 o'clock position, the check plug is at 3 o'clock position, and the drain plug is at the 6 o'clock position (Figure 100).

   

   Figure 100

   1. Fill plug (12 o’clock position)
   2. Check plug (3 o’clock position)
   3. Drain plug (6 o’clock position)

2. Remove the check plug at the 3 o’clock position (Figure 100).

   The oil level should be at the bottom of the check-plug hole.

   

   Figure 101

   1. Check-plug hole
   2. Check plug

3. If the oil level is low, remove the fill 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. Check the O-ring for the plug(s) for wear or damage.

   Note: Replace the O-ring(s) as needed.

5. Install the plug(s).

6. Repeat steps 1 through 5 on the planetary gear assembly at the other side of the machine.

Lubricant specification: high quality SAE 85W-140 gear lubricant

Planetary and brake housing lubrication capacity: 0.65 L (22 fl oz)

The rear axle is shipped from the factory filled with SAE 85W-140 gear lubricant. The capacity is 2.4 L (80 fl oz).

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. Remove a check plug from 1 end of the axle (Figure 106) and make sure that the oil is up to the bottom of the hole. If the level is low, remove the fill plug (Figure 106) and add enough oil to bring the level up to the bottom of the check-plug holes.

   

   Figure 106

   1. Check plug
   2. Fill plug

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 3 drain plugs, 1 on each end and 1 in the center (Figure 107).

   

   Figure 107

   1. Drain plugs

3. Remove the 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 2.37 L (80 fl oz) of 85W-140 gear lube or until the oil is up to the bottom of the hole.

7. Install the check plug.

The gear box is filled with SAE 85W-140 gear lubricant. The capacity is 0.5 L (16 fl oz).

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. Remove the check/fill plug from the left side of the gear box (Figure 108) and make sure that lubricant is up to the bottom of the hole. If the level is low, add enough lubricant to bring the level up to the bottom of the hole.

   

   Figure 108

   1. Gear box
   2. Check/fill plug

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

1. Park the machine on a level surface, shut off the engine, position the speed control into the low range, and lower the cutting units.

2. Press only the right brake pedal and engage the parking brake.

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

4. Start the engine and allow it run at low idle.

5. 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 109).

   

   Figure 109

   1. Pump-rod jam nuts
   2. Pump control tube

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

7. Shut off the engine and release the right brake.

8. Remove the jack stands and lower the machine to the shop floor.

9. Test drive the machine to ensure that it does not creep.

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. Measure the center-to-center distance (at axle height) at the front and rear of the steering tires.

   Note: The front measurement must be 3 mm (1/8 inch) less than the rear measurement (Figure 110).

   

   Figure 110

   1. Front of the traction unit
   2. 3 mm (1/8 inch) less than the rear of the tire
   3. Center-to-center distance

3. To adjust the toe-in, remove the cotter pin and the nut from either tie-rod ball joint (Figure 111).

   

   Figure 111

   1. Tie-rod clamp
   2. Tie-rod ball joint

4. Remove the tie-rod ball joint from the axle case support.

5. Loosen the clamps at both ends of the tie rods (Figure 111).

6. Rotate the detached ball joint inward or outward 1 complete revolution.

7. Tighten the clamp at the loose end of the tie rod.

8. Rotate the entire tie-rod assembly the same direction (inward or outward) 1 complete revolution.

9. Tighten the clamp at the connected end of the tie rod.

10. Install the ball joint in the axle case support and tighten the nut finger tight.

11. Measure the toe-in.

12. Repeat the procedure if necessary.

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

Check the level of the coolant at the beginning of each day. The capacity of the system is 12.3 L (13 US qt).

1. Carefully remove the radiator cap.

   Caution

   If the engine has been running, the pressurized, hot coolant can escape and cause burns.

   • Do not open the radiator cap when the engine is running.

   • Use a rag when opening the radiator cap, and open the cap slowly to allow steam to escape.

   

   Figure 112

   1. Expansion tank

2. Check the coolant level in the radiator.

   Note: The radiator should be filled to the top of the filler neck and the expansion tank filled to the Full mark (Figure 112).

3. If the coolant is low, add a 50/50 mixture of water and ethylene glycol antifreeze.

   Note: Do not use water only or alcohol/methanol-based coolants.

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

Remove debris from the engine area, oil cooler, and radiator daily. Clean them more frequently in dirty conditions.

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. Unlatch and swing open the rear screen (Figure 113).

   

   Figure 113

   1. Rear screen latch

3. Clean the screen thoroughly of all debris.

   Note: To remove the screen, lift off the hinge pins.

4. Clean both sides of the oil cooler/radiator area (Figure 114) thoroughly with compressed air. Start from the front and blow the debris out toward the back. Then clean from the back side and blow toward the front. Repeat the procedure several times until all chaff and debris is removed.

   

   Figure 114

   1. Oil cooler/radiator

   Important: Cleaning the oil cooler/radiator with water will promote premature corrosion damage to components and compact debris.

5. Close the rear screen and secure it with the latch.

Adjust the service brakes when there is more than 13 mm (1/2 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. Park the machine on a level surface, lower the cutting units, engage the parking brake, shut off the engine, and remove the key.

2. Disengage the locking latch from the brake pedals so that both pedals work independently of each other.

3. To reduce free travel of the brake pedals, tighten the brakes as follows:

   1. Loosen the front nut on the threaded end of the brake cable (Figure 115).

      

      Figure 115

      1. Brake cable

   2. Tighten the rear nut to move the cable backward until the brake pedals have 0 to 13 mm (0 to 1/2 inch) of free travel.

      Note: Make sure that there is no brake tension when the pedal is released.

   3. Tighten the front nuts after the brakes are adjusted correctly.

Check the condition and tension of the belts (Figure 116) after every 100 operating hours.

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. Proper tension will allow 10 mm (3/8 inch) deflection when a force of 45 N (10 lb) is applied on the belt midway between the pulleys.

3. If the deflection is not 10 mm (3/8 inch), loosen the alternator mounting bolts (Figure 116).

   

   Figure 116

   1. Alternator
   2. Mounting bolt

4. Increase or decrease the tension of the alternator belt and tighten the bolts.

5. 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.

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.

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 filler neck and cap of the hydraulic tank (Figure 117).

   

   Figure 117

   1. Hydraulic-tank cap

3. Remove the cap from the filler neck.

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

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

   The fluid level should be between the 2 marks on the dipstick.

6. If the level is low, add the appropriate fluid to raise the level to the upper mark.

7. 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 Level of 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.

28.4 L (7.5 US gallons); refer to Hydraulic Fluid Specifications

If the fluid becomes contaminated, contact your local authorized Toro distributor, because the system must be flushed. 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. Disconnect the case return line from the bottom of the reservoir and let the hydraulic fluid flow into a large drain pan.

4. Connect the line 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.

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

8. Check for leaks and shut off the engine.

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

   Note: Do not overfill the hydraulic system.

Use Toro replacement filters Part No. 94-2621 for the rear (cutting unit) of the machine and Part No. 75-1310 for the front (charge) of the machine.

Important: Using another type of filter 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.

3. Place a drain pan under the filter and remove the filter (Figure 118 and Figure 119).

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

   

   Figure 118

   1. Hydraulic filter
   

   Figure 119

   1. Hydraulic filter

5. Ensure that the filter mounting area is clean.

6. Screw the filter on until the gasket contacts the mounting plate; then tighten the filter an additional 1/2 turn.

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

8. Shut off the engine and check for leaks.

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 PTO switch to the OFF position.

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

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

4. Select either front, rear, or both backlap levers to determine which units to backlap (Figure 120).

5. 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 idle engine speed.

   Danger

   Contact with the cutting units could cause personal injury.

   Be certain that you are clear of the cutting units before proceeding.

6. With the mow-speed limiter in the MOW position, move the PTO switch to the ON position.

7. Press the lift switch to start the backlapping operation on the designated reels.

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

   Note: Do not use a short-handled brush.

   

   Figure 120

   1. Front-backlap lever
   2. Rear-backlap lever

9. If the reels stall or become erratic while backlapping, increase the throttle speed until the reel stabilizes.

10. To make an adjustment to the cutting units while backlapping, turn the reels off by pressing the rear of the lift switch; move the PTO switch to the OFF position and shut off the engine. After completing any adjustments, repeat steps 5 through 9.

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

12. When finished, return the backlap levers to the MOW position, lower the hood, and wash all lapping compound off the cutting units. Adjust the cutting unit reel-to-bedknife as needed. Move the cutting unit reel-speed controls to the desired mowing position.

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

    Note: Additional instructions and procedures on backlapping are available in the Toro Sharpening Reel and Rotary Mowers Manual, Form No. 80-300SL.

    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.