Reelmaster® 3555, 3575, and 3550 Traction Unit

1. Park the machine on a level surface, engage the parking brake, shut off the engine, and remove the key from the ignition switch.

2. Remove the reel motors from the shipping brackets.

3. Remove and discard the shipping brackets.

4. Remove the cutting units from the cartons. Assemble and adjust them as described in the cutting unit Operator's Manual.

5. Make sure that the counterweight (Figure 3) is installed to the proper end of the cutting unit as described in the cutting unit Operator's Manual.

   

   Figure 3

   1. Counterweight

All the cutting units are shipped with the turf compensation spring mounted at the right side of the cutting unit. Ensure that the turf compensation spring is mounted to the same side of the cutting unit as the reel drive motor.

Note: When installing or removing the cutting units, make sure that the hairpin cotter is installed in the spring rod hole next to the rod bracket. Otherwise, install the hairpin cotter in the hole in the end of the rod.

1. Remove the 2 carriage bolts and nuts securing the rod bracket to the cutting unit tabs (Figure 4).

   

   Figure 4

   1. Turf compensation spring
   2. Rod bracket
   3. Spring tube

2. Remove the flange nut securing the spring tube bolt to the carrier frame tab (Figure 4), and remove the assembly.

3. Mount the spring tube bolt to the opposite tab on the carrier frame and secure it with the flange nut.

   Note: Position the bolt head to the outer side of the tab as shown in Figure 4.

   

   Figure 5

   1. Opposite carrier frame tab
   2. Rod bracket

4. Mount the rod bracket to the cutting unit tabs with the carriage bolts and nuts (Figure 5).

Models 03820 and 03821

On cutting unit 4 (left front) and cutting unit 5 (right front), use the rod-bracket mounting nuts to install the hose guides to the front of the cutting-unit tabs. The hose guides should lean toward the center cutting unit (Figure 6, Figure 7, and Figure 8).

All Front Cutting Units, and Any Rear Cutting Units with a 1.2 cm (3/4 inch) or Lower Height of Cut

1. Lower all the lift arms completely.

2. Remove the snapper pin and the cap from the lift-arm pivot yoke (Figure 9).

   

   Figure 9

   1. Snapper pin
   2. Cap

3. For the front cutting units, slide a cutting unit under the lift arm while inserting the carrier frame shaft up into the lift-arm pivot yoke (Figure 10).

   

   Figure 10

   1. Lift arm
   2. Carrier frame shaft
   3. Lift-arm pivot yoke

Cutting Units adjusted for a 1.2 cm (3/4 inch) or Higher Height of Cut

1. Remove the lynch pin and washer securing the lift-arm pivot shaft to the lift arm and slide the lift-arm pivot shaft out of the lift arm (Figure 11).

   

   Figure 11

   1. Lift-arm shaft lynch pin and washer

2. Insert the lift-arm yoke onto the carrier frame shaft (Figure 10).

3. Insert the lift-arm shaft into the lift arm and secure it with the washer and lynch pin (Figure 11).

1. Insert the cap over the carrier frame shaft and lift-arm yoke.

2. Secure the cap and the carrier frame shaft to the lift-arm yoke with the snapper pin.

   Note: Use the slot if a steering cutting unit is desired or use the hole if the cutting unit is to be locked in position (Figure 9).

3. Secure the lift-arm chain to the chain bracket with the snapper pin (Figure 12).

   Note: Use the number of chain links specified in the cutting unit Operator's Manual.

   

   Figure 12

   1. Lift-arm chain
   2. Chain bracket
   3. Snapper pin

1. Coat the spline shaft of the reel motor with clean grease.

2. Lubricate the reel-motor O-ring with oil, and install it onto the motor flange.

3. Install the motor by rotating it clockwise so that the motor flanges clear the locknuts (Figure 13).

   Important: Ensure that the reel motor hoses are not twisted, kinked, or at risk of being pinched.

   

   Figure 13

   1. Reel-drive motor
   2. Mounting nuts

4. Rotate the motor counterclockwise until the flanges encircle the nuts.

5. Torque the nuts to 37 to 45 N∙m (27 to 33 ft-lb).

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

1. Start the engine, raise the cutting units, disengage the parking brake, and move the machine to an open flat area.

2. Engage the parking brake (Figure 28).

   

   Figure 28

3. Press the traction pedal to move the machine forward.

   Note: If the machine moves forward with the parking brake engaged, adjust parking brake; refer to Adjusting the Parking Brake.

   Note: Moving the machine forward with the parking brake engaged will cause the engine to shutoff.

4. If you adjusted the parking brake, repeat steps 2 and 3.

   Note: If the machine moves forward with the parking brake engaged: service the parking brakes, check left and right brake linkage for damage, and check the brake lever pivot for damage; refer to Servicing the Parking Brakes.

5. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operator’s seat.

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

The fuel tank capacity is approximately 42 L (11 US gallons).

Use summer-grade diesel fuel (Number 2-D) at temperatures above -7°C (20°F) and winter-grade diesel fuel (Number 1-D or Number 1-D/2-D blend) below -7°C (20°F). Using winter-grade fuel at lower temperatures provides lower flash point and cold flow characteristics which will ease starting and reduce plugging of the fuel filter.

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

The machine is biodiesel ready.

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

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

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

• Painted surfaces may be damaged by biodiesel blends.

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

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

• Expect plugging of the fuel filter for a time after converting to biodiesel blends.

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

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

2. Clean the area around the fuel-tank cap (Figure 29).

3. Remove the fuel-tank cap.

4. Fill the tank to the bottom of the filler neck. Do not overfill the tank.

5. Install the cap.

6. To prevent a fire hazard, wipe up any fuel that may have spilled.

   

   Figure 29

   1. Fuel-tank cap

You may need to bleed the fuel system if any of the following situations have occurred; refer to Bleeding the Fuel System:

• Initial startup of a new engine

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

• Maintenance has been performed upon the fuel system components; i.e. filter replaced, etc.

1. Ensure that the parking brake is engaged and the cutting unit drive switch is in the DISENGAGE position.

2. Remove your foot from the traction pedal and ensure 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 for 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 ensure proper operation of all parts.

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

   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.

1. Move the throttle control to the IDLE position.

2. Move the cutting unit drive switch to DISENGAGE.

3. Rotate the key to OFF.

4. Remove the key to prevent accidental starting.

To achieve a consistent, high quality of cut and a uniform after-cut appearance, it is important that you set the reel speed controls (located under the seat) correctly. Adjust the reel speed controls as follows:

1. Select the height of cut at which the cutting units are set.

2. Choose the desired ground speed best suited for conditions.

3. Use the graph on the reel speed chart decals (Figure 31 and Figure 32), to determine the proper reel speed setting.

   

   Figure 31

   Model 03820 and 03910

   1. 8-blade reel adjustment
   2. 11-blade reel adjustment
   3. Read the Operator’s Manual for information on adjusting the reel.
   

   Figure 32

   Model 03821

   1. 8-blade reel adjustment
   2. 11-blade reel adjustment
   3. Read the Operator’s Manual for information on adjusting the reel.

4. To set the reel speed, rotate the knob (Figure 33) until the indicator arrow is in line with the number designating the desired setting.

   

   Figure 33

   1. Reel speed control knob

   Note: The reel speed can be increased or decreased to compensate for turf conditions. When using baskets, increase the reel speed to improve collection performance.

You can adjust the counterbalance on the lift arms of the rear cutting units 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 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 from the ignition switch.

2. Insert a tube or similar object onto the long spring end to relieve the spring tension during the adjustment (Figure 34).

   Caution

   The springs are under tension and could cause personal injury.

   Use caution when adjusting them.

3. While relieving the spring tension, remove the bolt and locknut securing the spring actuator to the bracket (Figure 34).

   

   Figure 34

   1. Spring
   2. Spring actuator
   3. Additional hole locations

4. Move the spring actuator to the desired hole location and secure it with the bolt and 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. Ensure that the fuel tank is at least half full.

3. Unlatch and raise the hood.

4. Open the air-bleed screw on the fuel-injection pump (Figure 35).

   

   Figure 35

   1. Fuel-injection pump bleed screw

5. Turn the key in the ignition switch to the ON position. The electric fuel pump will begin operation, thereby forcing air out around the air-bleed screw.

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

6. Tighten the screw and turn the ignition key to OFF.

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

The machine is equipped with a diagnostic light that indicates if the electronic controller senses an electronic malfunction. The diagnostic light is located on the control panel (Figure 36). When the electronic controller is functioning correctly and you move the key switch to the ON position, the controller diagnostic light turns on for 3 seconds and turn off to indicate that the light is working properly. If the engine shuts off, then the light turns on steady until the you change key position. The light blinks if the controller detects a malfunction in the electrical system. The light stops blinking and automatically resets when you turn the key switch to the OFF position once the fault has been resolved.

When the controller diagnostic light blinks, 1 of the following problems has been detected by the controller:

• An output has been shorted.

• An output is open circuited.

Using the diagnostic display, determine which output is malfunctioning; refer to Checking the Interlock Switches.

If the diagnostic light is not illuminated when the key switch is in the ON position, this indicates that the electronic controller is not operating. Possible causes are as follows:

• The loop-back is not connected.

• The light is burned out.

• Fuses are blown.

• It is not functioning correctly.

  Check the electrical connections, input fuses, and diagnostic light bulb to determine the malfunction. Ensure that the loop-back connector is secured to the wire harness connector.

The machine is equipped with an electronic controller which controls most machine functions. The controller determines what function is required for various input switches (i.e., seat switch, key switch, etc.) and turns on the outputs to actuate solenoids or relays for the requested machine function.

For the electronic controller to control the machine as desired, each of the input switches, output solenoids, and relays must be connected and functioning properly.

Use the Diagnostic ACE display to help verify and correct electrical functions of the machine.

The purpose of the interlock switches is to prevent the engine from cranking or starting unless the traction pedal is in the NEUTRAL position, the Enable/Disable switch is in the DISABLE position, and the Lower Mow/Raise control is in the NEUTRAL position. In addition, the engine should shut off when you press the traction pedal with no one in the seat or if the parking brake is engaged.

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.

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

• Tie the machine down securely.

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 the Battery for more information.

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

Lubricate the grease fittings regularly with No. 2 lithium 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 as follows:

• 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 side); 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

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

Crankcase capacity is approximately 3.8 L (4 US qt) with the filter.

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

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

• Preferred oil: SAE 15W-40 (above 0ºF (-17ºC))

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

Note: Toro Premium Engine Oil is available from your distributor in either 15W-40 or 10W-30 viscosity.

Note: The best time to check the engine oil is when the engine is cool before it has been started for the day. If it has already been run, allow the oil to drain back down to the sump for at least 10 minutes before checking. If the oil level is at or below the Add mark on the dipstick, add oil to bring the oil level to the Full mark. Do not overfill the engine. If the oil level is between the Full and Add marks, no oil addition is required.

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

2. Remove the dipstick (Figure 52) and wipe it with a clean rag.

   

   Figure 52

   1. Dipstick

3. Push the dipstick down into the dipstick tube and make sure that it is seated fully. Pull the dipstick out and check the oil level.

4. If the oil level is low, remove the oil-fill cap (Figure 53) and gradually add small quantities of oil, checking the level frequently, until the level reaches the Full mark on the dipstick.

   

   Figure 53

   1. Oil-fill cap

5. Install the oil-fill cap and close the hood.

• 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 you remove the filter.

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

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

4. 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 you remove the primary filter.

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

   Do not clean the used element because it could damage the filter media.

   

   Figure 54

   1. Air-cleaner cover
   2. Filter

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

   Important: Do not use a damaged element.

7. 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.

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

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

10. 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.

11. Secure the cover latches.

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 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

3. Remove the oil filter (Figure 56).

   

   Figure 56

   1. Engine oil filter

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

   Important: Do not overtighten the filter.

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

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 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.

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

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

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

2. Place a clean container under the fuel filter.

3. 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

4. Tighten the valve after draining.

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

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

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

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

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

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

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

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

   

   Figure 58

   1. Fuel injectors

3. Move the throttle to the FAST position.

4. 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 there is a continuous flow.

5. Tighten the pipe connector securely.

6. Repeat the procedure on the remaining nozzles.

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

Maintain the battery electrolyte level and keep the top of the battery clean. Store the machine where the temperature is cooler rather than warmer to prevent the battery from discharging more rapidly.

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

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

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

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

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

The tires are over-inflated for shipping. Therefore, release some of the air to reduce the pressure. The correct air pressure in the tires is 83 kPa (12 psi).

Note: Maintain the recommended pressure in all tires to ensure a good quality of cut and proper machine performance.

Torque the wheel nuts to 103 to 127 N∙m (76 to 94 ft-lb).

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, lower the cutting units, engage the parking brake, shut off the engine, and remove the key from the ignition switch.

2. Raise a front wheel and a rear wheel off 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.

   A front wheel and a rear wheel must be raised off the ground; otherwise, 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 that you can make a final adjustment of the traction adjustment cam. Contact with hot or moving parts can result in personal injury.

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

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

Clean debris off the radiator daily (Figure 60). Clean the radiator hourly if conditions are extremely dusty and dirty; refer to Cleaning the Engine Cooling System.

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

The capacity of the cooling system is approximately 5.7 L (6 US qt).

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. Check the coolant level in the expansion tank (Figure 61). With a cold engine, the coolant level should be approximately midway between the marks on the side of the tank.

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

4. Install the expansion-tank cap.

   

   Figure 61

   1. Expansion tank

Remove debris from the radiator daily. Clean it 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 from the ignition switch.

2. Raise the hood.

3. Clean the engine area thoroughly of all debris.

4. Clean both sides of the radiator thoroughly with compressed air (Figure 62).

   

   Figure 62

   1. Radiator

5. Close the hood.

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

2. Loosen the setscrew securing the knob to the parking-brake lever (Figure 63).

   

   Figure 63

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

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

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

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

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

3. Loosen the throttle cable connector on the injection pump lever arm (Figure 79).

   

   Figure 79

   1. Injection pump lever arm

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

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

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

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

8. 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 in-lb).

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

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. The best time to check the hydraulic oil is when the fluid is cold. The machine should be in its transport configuration.

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 80).

   

   Figure 80

   1. Hydraulic-tank cap

3. Remove the cap.

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

5. If the level is low, add the 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

Material Properties:
	Viscosity, ASTM D445	cSt @ 40°C (104°F) 44 to 48
	Viscosity Index ASTM D2270	140 or higher
	Pour Point, ASTM D97	-37°C to -45°C (-34°F to -49°F)
	Industry Specifications:	Eaton Vickers 694 (I-286-S, M-2950-S/35VQ25 or M-2952-S)

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 gallon) pails or 208 L (55 US gallon) drums from your authorized Toro distributor.

22.7 L (6 US gallons); refer to Hydraulic Fluid Specifications

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

2. Disconnect the large hydraulic hose (Figure 81) from the reservoir and let the hydraulic fluid flow into a drain pan.

   

   Figure 81

   1. Hydraulic hose

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

4. Fill the reservoir (Figure 82) with approximately 22.7 L (6 US gallons) of hydraulic fluid; refer to Hydraulic Fluid Specifications.

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

   

   Figure 82

   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 shut off 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.

Use a genuine Toro replacement filter, Part No. 86-3010.

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

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

2. Clean around the filter mounting area. Place a drain pan under the filter (Figure 83) and remove the filter.

   

   Figure 83

   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. Shut off the engine and check for leaks.

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).

Use the gauge bar (Figure 84) to adjust the cutting unit. Refer to the cutting unit Operator's Manual for the adjustment procedure.

Note: When backlapping, all the cutting 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. 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 cutting units to stall.

   • Never change the engine speed while backlapping

   • Backlap only at idle engine speed.

5. Set the reel speed control to position 1 (Figure 85).

   

   Figure 85

   1. Backlap lever
   2. Reel speed control knob

6. Move the backlap lever to the R (backlap) position (Figure 85).

   Danger

   Contacting the cutting units 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 cutting units.

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

9. If the cutting units 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 cutting units off by moving the Lower Mow/Raise lever rearward; the Enable/Disable switch to the DISABLE position, and shut off the engine. After completing the 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 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.