Reelmaster® 5610 Traction Unit

1. Remove the reel motors from the shipping brackets.

2. Remove and discard the shipping brackets.

3. At each cutting unit lift arm, remove the lynch pin that secures the cap to the lift arm pivot yoke, and remove the cap (Figure 4).

   

   Figure 4

   1. Lynch pin
   2. Cap

1. Remove the cutting units from the cartons.

2. Assemble and adjust as described in the cutting unit Operator's Manual.

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

   

   Figure 5

   1. Counterweight

Figure 6

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

1. If the hairpin is installed in the rear hole of the compensation-spring rod—remove the hairpin and insert it in the hole next to the bracket (Figure 7).

   

   Figure 7

   1. Hairpin

2. Remove the 2 flange locknuts (3/8 inch) and 2 carriage bolts (3/8 x 1-1/4 inches) that secure the turf-compensator bracket to the cutting-unit frame (Figure 8).

   

   Figure 8

   1. Carriage bolt (3/8 x 1-1/4 inches)
   2. Turf-compensator bracket
   3. Flange locknut (3/8 inch)

3. Remove the flange locknut (3/8 inch) that secures the capscrew of the turf compensation spring to the right tab of the carrier frame, and remove the compensation spring from the cutting unit (Figure 9).

   Note: Do not remove the flange serrated nut from the capscrew.

   

   Figure 9

   1. Capscrew
   2. Right tab (Carrier frame)
   3. Flange locknut (3/8 inch)

4. Assemble the capscrew of the turf compensation spring to the right tab of the carrier frame (Figure 10) with the flange locknut (3/8 inch).

   

   Figure 10

   1. Flange locknut (3/8 inch)
   2. Right tab (Carrier frame)
   3. Capscrew

5. Align the studs of the left hose guide with the holes in the cutting-unit frame and the turf-compensator bracket (Figure 11).

   Note: The support loop of the hose guide aligns toward the centerline of the machine.

   

   Figure 11

   1. Turf-compensator bracket
   2. Flange locknut (3/8 inch)
   3. Stud (hose guide)
   4. Inboard

6. Assemble the hose guide and turf-compensator bracket to the cutting-unit frame with the 2 flange locknuts (3/8 inch).

7. Torque the locknuts and bolts to 37 to 45 N∙m (27 to 33 ft-lb).

Figure 12

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

1. If the hairpin is installed in the rear hole of the compensation-spring rod—remove the hairpin and insert it in the hole next to the bracket (Figure 12).

   

   Figure 13

   1. Hairpin

2. Remove the 2 flange locknuts (3/8 inch) and 2 carriage bolts (3/8 x 1-1/4 inches) that secure the turf-compensator bracket to the cutting-unit frame (Figure 14).

   

   Figure 14

   1. Carriage bolt (3/8 x 1-1/4 inches)
   2. Turf-compensator bracket
   3. Flange locknut (3/8 inch)

3. Align the studs of the right hose guide with the holes in the cutting-unit frame and the turf-compensator bracket (Figure 15).

   Note: Ensure that the support loop of the hose guide aligns toward the centerline of the machine.

   

   Figure 15

   1. Stud (hose guide )
   2. Turf-compensator bracket
   3. Flange locknut (3/8 inch)
   4. Inboard

4. Assemble the hose guide and turf-compensator bracket to the cutting-unit frame with the 2 flange locknuts (3/8 inch).

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

Figure 16

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

1. If the hairpin is installed in the rear hole of the compensation-spring rod—remove the hairpin and insert it in the hole next to the bracket (Figure 17).

   

   Figure 17

   1. Hairpin

2. Remove the 2 flange locknuts (3/8 inch) and 2 carriage bolts (3/8 x 1-1/4 inches) that secure the turf-compensator bracket to the cutting-unit frame (Figure 18).

   

   Figure 18

   1. Carriage bolt (3/8 x 1-1/4 inches)
   2. Turf-compensator bracket
   3. Flange locknut (3/8 inch)

3. Remove the flange locknut (3/8 inch) that secures the capscrew of the turf compensation spring to the right tab of the carrier frame, and remove the compensation spring from the cutting unit (Figure 19).

   Note: Do not remove the flange serrated nut from the capscrew.

   

   Figure 19

   1. Capscrew
   2. Right tab (Carrier frame)
   3. Flange locknut (3/8 inch)

4. Assemble the capscrew of the turf compensation spring to the right tab of the carrier frame (Figure 20) with the flange locknut (3/8 inch).

   

   Figure 20

   1. Flange locknut (3/8 inch)
   2. Right tab (Carrier frame)
   3. Capscrew

5. Align the holes in the turf-compensator bracket with the holes in the cutting-unit frame (Figure 21).

   Note: The support loop of the hose guide aligns toward the centerline of the machine.

   

   Figure 21

   1. Turf-compensator bracket
   2. Carriage bolt (3/8 x 1-1/4 inches)
   3. Flange locknut (3/8 inch)
   4. Inboard

6. Assemble the turf-compensator bracket to the cutting-unit frame with the 2 carriage bolts (3/8 x 1-1/4 inches) and 2 flange locknuts (3/8 inch).

7. Torque the locknuts and bolts to 37 to 45 N∙m (27 to 33 ft-lb).

For each cutting unit, secure the kickstand to the chain bracket with the snapper pin (Figure 22).

Figure 22

1. Chain bracket
2. Snapper pin
3. Cutting-unit kickstand

1. Slide a cutting unit under the lift arm (Figure 23).

   

   Figure 23

   1. Cap
   2. Snapper pin
   3. Lift-arm yoke
   4. Carrier frame shaft

2. Assemble the lift-arm yoke onto the carrier frame shaft.

3. Assemble the cap to the pivot-arm shaft, and align the holes in the carrier frame shaft, pivot arm shaft, and cap.

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

   Locking the Cutting-Unit Pivot for Cutting Grass on a Hill Side—Lock the cutting-unit pivots to prevent the cutting units from rotating downhill when cutting across the face of a hill. Use the hole in the lift-arm pivot shaft (Figure 24) to lock the cutting unit. Use the slot for a steering cutting unit.

   

   Figure 24

   1. Snap-pin positions
   2. Hole (lift-arm pivot shaft)
   3. Slot (lift-arm pivot shaft)

1. Slide a cutting unit under the lift arm (Figure 25).

   

   Figure 25

   1. Cap
   2. Snapper pin
   3. Lift-arm yoke
   4. Carrier frame shaft

2. Assemble the lift-arm yoke onto the carrier frame shaft.

3. Assemble the cap to the pivot-arm shaft, and align the holes in the carrier frame shaft, pivot arm shaft, and cap.

4. Secure the pivot arm shaft and cap to the carrier frame shaft with the snapper pin.

   Locking the Cutting-Unit Pivot for Cutting Grass on a Hill Side—Lock the cutting-unit pivots to prevent the cutting units from rotating downhill when cutting across the face of a hill. Use the hole in the lift-arm pivot shaft (Figure 25) to lock the cutting unit. Use the slot for a steering cutting unit.

   

   Figure 26

   1. Snap-pin positions
   2. Hole (lift-arm pivot shaft)
   3. Slot (lift-arm pivot shaft)

5. Repeat steps 1 and 2 for the other rear cutting unit.

1. Remove the lynch pin and washer securing the to the lift-arm pivot shaft to the lift arm, and slide the pivot shaft out of the lift arm (Figure 27).

   

   Figure 27

   1. Lift-arm pivot shaft 4.
   2. Lift-arm pivot shaft
   3. Lift arm (rear cutting unit)
   4. Washer

2. Assemble the lift-arm yoke onto the carrier frame shaft (Figure 28).

   

   Figure 28

   1. Cap
   2. Snapper pin
   3. Lift-arm yoke
   4. Carrier frame shaft

3. Assemble the cap to the pivot-arm shaft, and align the holes in the carrier frame shaft, pivot arm shaft, and cap.

4. Secure the pivot arm shaft and cap to the carrier frame shaft with the snapper pin.

   Locking the Cutting-Unit Pivot for Cutting Grass on a Hill Side—Lock the cutting-unit pivots to prevent the cutting units from rotating downhill when cutting across the face of a hill. Use the hole in the lift-arm pivot shaft (Figure 29) to lock the cutting unit. Use the slot for a steering cutting unit.

   

   Figure 29

   1. Snap-pin positions
   2. Hole (lift-arm pivot shaft)
   3. Slot (lift-arm pivot shaft)

5. Slide a cutting unit under the lift arm (Figure 30).

   

   Figure 30

   1. Lynch pin
   2. Lift-arm shaft
   3. Lift arm
   4. Washer

6. Insert the lift-arm shaft into the lift arm, and secure shaft to the arm with the lynch pin and washer.

7. Repeat steps 1 through 6 for the other rear cutting unit.

Secure the lift-arm chain to the chain bracket with the snapper pin (Figure 31).

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

Figure 31

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

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

2. Oil the reel motor O-ring and install it onto the motor flange.

3. Install the motor by rotating it clockwise so that the motor flanges clear the bolts (Figure 32).

   

   Figure 32

   1. Reel-drive motor
   2. Mounting bolts

4. Rotate the motor counterclockwise until the flanges encircle the bolts, and then tighten the bolts.

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

5. Torque the mounting bolts to (27 to 33 ft-lb).

1. Use rubbing alcohol and a clean rag to clean the area of the hood next to the hood lock, and allow the hood to dry. (Figure 38).

   

   Figure 38

   1. CE decal
   2. Hood lock

2. Remove the backing from the CE decal.

3. Apply the decal to the hood.

1. Use rubbing alcohol and a clean rag to clean the floor bracket area next to the serial plate, and allow the bracket to dry (Figure 39).

   

   Figure 39

   1. Year of production decal
   2. Serial plate

2. Remove the backing from the year of production decal.

3. Apply the decal to the floor bracket.

1. Use rubbing alcohol and a clean rag to clean the surface of warning decal 133-2930, and allow the decal to dry (Figure 40).

   

   Figure 40

   1. CE warning decal
   2. Warning decal 133-2930

2. Remove the backing from the CE warning decal.

3. Apply the CE warning decal over decal 133-2930.

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

Use summer grade diesel fuel (No. 2-D) at temperatures above -7°C (20°F) and winter grade (No. 1-D or No. 1-D/2-D blend) below that temperature. Use of winter grade fuel at lower temperatures provides lower flash point and cold flow characteristics which eases starting and reduces fuel filter plugging.

Use of summer grade fuel above -7°C (20°F) contributes toward longer fuel pump life and increased power compared to winter grade fuel.

Important: Do not use kerosene or gasoline instead of diesel fuel. Failure to observe this caution damages the engine.

Biodiesel Ready

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

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

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

• Painted surfaces may be damaged by biodiesel blends.

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

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

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

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

53 L (14 US gallons)

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

3. Remove the cap from the fuel tank (Figure 49).

   

   Figure 49

   1. Fuel-tank cap

4. Fill the tank until the level is 6 to 13 mm (1/4 to 1/2 inch) below the bottom of the filler neck.

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

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

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

Important: If your machine fails any of the interlock switch checks, contact your authorized Toro distributor.

To ensure optimum performance of the parking-brake system, burnish (break in) the brakes before use. Set the forward traction speed to 4 mph to match the reverse traction speed. (All 8 spacers moved to the top of the mow-speed control.) With the engine at high idle, proceed forward with the mow-speed-control stop engaged and ride the brake for 15 seconds. Proceed backward at full reverse speed and ride the brake for 15 seconds. Repeat this 5 times, waiting 1 minute between each forward and reverse cycle to avoid overheating the brakes. An adjustment to the brakes may be required after break-in; refer to Adjusting the Parking Brakes.

Important: You must bleed the fuel system before starting the engine if you are starting the engine for the first time, the engine has stopped due to lack of fuel, or you have performed maintenance on the fuel system; refer to Bleeding the Fuel System.

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

2. Turn the key to the ON/PREHEAT position.

   An automatic timer controls the glow plug preheat for 6 seconds.

3. After preheating the glow plugs, turn the key to the START position.

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

4. Run the engine at low idle speed until it warms up.

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

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

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

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

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

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

3. Press the right button to change the reel speed value. As the speed setting is changed, the display will continue to show the calculated reel speed based on blade count, mow speed and HOC, but the new value will also be displayed.

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

You can adjust the amount of counterbalance force applied to the rear cutting-units to help compensate for different turf conditions, and to maintain a uniform height of cut in rough conditions or in areas of thatch buildup.

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

Note: To remove all counterbalance force, position the long leg of the torsion spring above the shouldered stud.

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

2. Insert the long end of the counterbalance spring into a tube or similar object, and pivot the spring around the shouldered stud to the desired position (Figure 50).

   

   Figure 50

   1. Spring
   2. Shouldered stud

3. Repeat steps 1 and 2 at the other counterbalance spring.

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

2. The lift-arm switch is located underneath the hydraulic tank and inboard of the cutting unit #5 lift arm (Figure 51).

   

   Figure 51

3. Loosen the jam nut that secures lift-arm switch to the switch plate (Figure 52).

   

   Figure 52

   1. Switch
   2. Lift-arm sensing device

4. Adjust the lift-arm switch as follows:

   • To increase the lift-arm turnaround height, move the switch down.

   • To decrease the lift-arm turnaround height, move the switch up.

5. Tighten the jam nut.

The turf-compensation spring (Figure 53) transfers the weight from the front roller to the rear roller. This helps to reduce a wave pattern in the turf, also known as marcelling or bobbing.

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

1. Make sure that the hairpin is installed in the rear hole in the spring rod (Figure 53).

   Note: When servicing the cutting unit, move the hairpin to the spring-rod hole next to the turf-compensation spring.

   

   Figure 53

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

2. Tighten the hex nuts on the front end of the spring rod until the compressed length of the spring is 15.9 cm (6.25 inches); refer to Figure 53.

   Note: When operating on rough terrain decrease the spring length by 13 mm (1/2 inch). Ground following will be slightly decreased.

   Note: The turf compensation setting will need to be reset if the HOC setting or the Aggressiveness of Cut setting is changed.

The machine is equipped with a diagnostic light which indicates if the electronic controller senses an electronic malfunction. The diagnostic light is located on the control arm (Figure 54). When the machine is functioning properly and the key switch is moved to the ON/RUN position, the diagnostic light turns on briefly to indicate the light is working properly. When a machine advisory message is displayed, the light illuminates when the message is present. When a fault message is displayed, the light blinks until the fault is resolved.

Figure 54

1. Diagnostic light

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

• Tie the machine down securely.

• Front—the hole in the rectangular pad, under the axle tube, inside each front tire (Figure 55)

  

  Figure 55

  1. Front tie-down

• Rear—each side of the machine on the rear frame (Figure 56)

  

  Figure 56

  1. Rear tie-down

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

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

1. The bypass valve is located on the left side of the hydrostat (Figure 57). Rotate the bolt 1-1/2 turns to open and allow fluid to bypass internally.

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

   

   Figure 57

   1. Bypass valve

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

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

1. Park the machine on a level surface, press the enable/disable switch to the DISENGAGE and position, lower the cutting units, and engage the parking brake.

2. Shut off the engine, remove the key, and wait for all moving parts to stop.

3. Wait for the engine to cool.

1. Release the 2 hood latches (Figure 58).

   

   Figure 58

   1. Hood latch (2)

2. Rotate open the hood.

1. Carefully rotate the hood closed (Figure 59).

   

   Figure 59

   1. Hood latch (2)

2. Secure the hood with the 2 hood latches.

1. Remove the ball pin from the screen latch (Figure 60).

   

   Figure 60

   1. Ball pin
   2. Screen latch

2. Unlatch and open the screen.

1. Close and latch the screen (Figure 61).

   

   Figure 61

   1. Ball pin
   2. Screen latch

2. Insert the ball pin through the screen latch.

1. Move the seat latch outward (Figure 62).

   

   Figure 62

   1. Seat latch

2. Carefully rotate the seat up.

3. Ensure that the forward prop rod seats in the slot detent of the rod-guide plate (Figure 63).

   

   Figure 63

   1. Prop rod
   2. Rod-guide plate

1. Rotate the seat slightly, and lift the prop rod out of the dent of the seat support slot (Figure 64).

   

   Figure 64

   1. Prop rod
   2. Rod-guide plate

2. Carefully lower the seat until it latches securely.

Note: Support the machine with jack stands whenever you work under the machine; refer to Jacking Point Locations.

Use the following as machine-lift points:

Figure 65

1. Front of the machine
2. Jack brackets (front-axle tube)
3. Rear-axle tube
4. Back of the machine

• Front—the jack brackets of the front-axle tube (Figure 65).

• Rear—the rear-axle tube.

Grease Specification: No. 2 lithium grease

1. Prepare the machine for maintenance; refer to Preparing for Maintenance.

2. Open the hood; refer to Opening the Hood.

3. The lubricate the machine at the fittings at the locations as follows:

   • Pump-driveshaft U-joint (3) (Figure 66)

     Note: The pump-driveshaft is located Under the hood.

     

     Figure 66

   • Cutting-unit lift-arm cylinders (2 each) (Figure 67)

     

     Figure 67

   • Lift-arm pivots (1 each) (Figure 67)

   • Cutting-unit carrier-frame and pivot (2 each) (Figure 68)

     

     Figure 68

   • Lift-arm pivot shaft (1 each) (Figure 69)

     

     Figure 69

   • Rear axle tie rod (2) (Figure 70)

     

     Figure 70

   • Axle-steering pivot (1) (Figure 71)

     

     Figure 71

   • Steering-cylinder ball joints (2) (Figure 72)

     

     Figure 72

   • Brake pedal (1) (Figure 73)

     

     Figure 73

4. Close and latch the hood; refer toClosing the Hood.

Check the air-cleaner body for damage that 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 74) requires it. Changing the air filter before it is necessary only increases the chance of dirt entering the engine when the filter is removed.

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

1. Release the latches securing the air-cleaner cover to the air-cleaner body (Figure 74).

   

   Figure 74

   1. Air-cleaner cover
   2. Air-cleaner-cover latch
   3. Air-cleaner service indicator

2. Remove the cover from the air cleaner body. Before removing the filter, use low pressure air (40 psi, clean and dry) to help remove large accumulations of debris packed between outside of the 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 filter is removed.

3. Remove and replace the filter (Figure 75).

   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 75

   1. Air-cleaner cover
   2. Air-cleaner filter
   3. Air-cleaner indicator

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

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

6. Secure the latches.

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

Crankcase capacity is approximately 5.2 L (5.5 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 0 degrees F)

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

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

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

2. Open the hood.

3. Remove the dipstick, wipe it clean, and install it (Figure 76).

   

   Figure 76

   1. Dipstick

4. Remove the dipstick and check the oil level on the dipstick.

   Note: The oil level should be up to the Full mark.

5. If the oil level is below the Full mark, remove the fill cap (Figure 77), and add oil until the level reaches the Full mark on dipstick.

   

   Figure 77

   1. Oil-fill cap

   Important: Do not overfill. Be sure to keep the engine-oil level between the upper and lower limits on the oil gauge. Engine failure may occur as a result of over filling or under filling the engine oil.

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

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

1. Remove the drain plug (Figure 78) and let the oil flow into a drain pan.

   

   Figure 78

   1. Oil drain plug

2. When the oil stops, install the drain plug.

3. Remove the oil filter (Figure 79).

   

   Figure 79

   1. Oil filter

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

5. Install the replacement oil filter to the filter adapter. Turn the oil filter clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 1/2 turn.

   Important: Do not over-tighten the filter.

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

1. Prepare the machine for maintenance; refer to Preparing for Maintenance.

2. Open the hood; refer to Opening the Hood.

3. Place a drain pan under the fuel-water separator filter (Figure 80).

   

   Figure 80

   1. Drain valve (fuel-water separator filter)

4. Loosen the drain valve at the bottom of the fuel-water separator filter, and allow the fuel and water to drain.

5. Close the drain valve at the bottom of the fuel-water separator filter.

6. Close and latch the hood; refer toClosing the Hood.

1. Prepare the machine for maintenance; refer to Preparing for Maintenance.

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

3. Open the hood; refer to Opening the Hood.

4. Open the air-bleed screw on the fuel-injection pump (Figure 81).

   

   Figure 81

   1. Fuel-injection pump bleed screw

5. Turn the key in the ignition switch to the ON position.

   The electric fuel pump runs, 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.

7. Close and latch the hood; refer to Closing the Hood.

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

1. Prepare the machine for maintenance; refer to Preparing for Maintenance.

2. Open the hood; refer to Opening the Hood.

3. Inspect the fuel lines for wear, deterioration, damage, or loose fittings.

   Note: Repair or replace any worn or damaged fuel lines; tighten any loose fittings.

4. Close and latch the hood; refer to Closing the Hood.

1. Drain the fuel-water separator; refer to steps 1 through 4 in Draining the Fuel-Water Separator.

2. Clean the fuel-water separator filter and filter head (Figure 82).

   

   Figure 82

   1. Filter head
   2. Fuel-water separator filter

3. Remove the separator filter from the filter head.

4. Clean the filter-mounting surface of the filter head.

5. Apply a coat of clean fuel to the gasket of the new separator filter.

6. Thread the separator filter into the filter head until the gasket contacts mounting surface, then rotate the filter an additional 1/2 turn.

7. Check that the drain valve at the bottom of the fuel-water separator filter is closed.

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

9. Shutoff the engine, remove the key, close and latch the hood; refer to Closing the Hood.

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.

1. Prepare the machine for maintenance; refer to Preparing for Maintenance.

2. Align a drain container under the drain valve at the bottom of the fuel tank (Figure 83).

   

   Figure 83

   1. Drain valve (bottom of the fuel tank)

3. Open the drain valve and allow the fuel to drain.

4. If needed, add clean fuel to the fuel tank to flush it out.

5. Close the drain valve.

   Note: When you add fuel to the tank, check the drain valve for leaks.

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. Prepare the machine for maintenance; refer to Preparing for Maintenance.

2. Tilt the seat; refer to Tilting the Seat.

3. Remove the clamp that secures the hose to the fuel pick-up tube (Figure 84).

   

   Figure 84

   1. Screen (fuel pick-up tube)
   2. Fuel tank
   3. Hose clamp
   4. Hose

4. Remove the fuel pick-up tube and rubber bushing from the tank.

5. Clean the screen at the end of the fuel pick-up tube (Figure 84).

6. Insert the fuel pick-up tube and rubber bushing into the tank until the bushing is seated into the tank.

7. Assemble the hose onto the fuel pick-up tube and secure it with the clamp.

8. Lower and latch the seat; refer to Lowering the Seat.

1. Prepare the machine for maintenance; refer to Preparing for Maintenance.

2. Open the screen; refer to Opening the Screen.

3. Press the sides of the battery cover, and remove the cover from the battery tray (Figure 85).

   

   Figure 85

   1. Tab (battery cover)
   2. Negative battery cable
   3. Insulator cover (positive battery cable)
   4. Slot (battery tray)

4. Disconnect the negative battery cable.

5. Slide the insulator cover off the positive battery-cable clamp, and disconnect the positive battery cable.

1. Install the positive battery cable (red) to the positive (+) battery post (Figure 86).

   

   Figure 86

   1. Tab (battery cover)
   2. Negative battery cable
   3. Insulator cover (positive battery cable)
   4. Slot (battery tray)

2. Install the negative battery cable (black) to the negative (-) battery post.

3. Apply a coat of Grafo 112X (skin-over) grease, Toro Part No. 505-47 to the battery posts and battery-cable clamps.

4. Slide the rubber boot over the positive battery-cable clamp.

5. Assemble the cover over the battery, inserting the tabs of the cover into the slots in the battery tray.

6. Close and latch the screen; refer to Closing the Screen.

1. Disconnect the battery; refer to Disconnecting the Battery.

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

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

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

5. Connect the battery; refer to Connecting the Battery.

Note: Keep the terminals and the entire battery case clean because a dirty battery will discharge slowly.

1. Prepare the machine for maintenance; refer to Preparing for Maintenance.

2. Open the screen; refer to Opening the Screen.

3. Check the condition of the battery.

   Note: Replace a worn or damaged battery.

4. Disconnect the battery cables, and remove the battery from the machine; refer to Disconnecting the Battery.

5. Clean the entire battery case with a solution of sodium bicarbonate (baking soda) and water.

6. Rinse the case with clean water.

7. Assemble the battery to the machine and connect the battery cables; refer to Connecting the Battery.

8. Close and latch the screen; refer to Closing the Screen.

The fuse block is in the control arm.

1. Prepare the machine for maintenance; refer to Preparing for Maintenance.

2. Open the 2 latches that secure control-arm cove to the control arm, and remove the cover (Figure 87).

   

   Figure 87

   1. Control-arm cover
   2. Latch

3. Replace the open fuse (Figure 88) with the same fuse type and amperage rating.

   

   Figure 88

   1. Fuse block
   2. Fuse decal (inside the control-arm cover)

4. Assemble the control-arm cover to the control arm, and secure the cover with the 2 latches.

1. Prepare the machine for maintenance; refer to Preparing for Maintenance.

2. Unlatch and tilt seat; refer to Tilting the Seat.

3. Remove the cap from the in-line fuse holder labeled (Figure 89).

   

   Figure 89

   1. Cap
   2. Fuse
   3. Fuse holder (labeled )

4. Remove the fuse from the fuse holder.

5. Insert a fuse of the same type and amperage.

6. Assemble the cap onto the in-line fuse holder.

7. Lower and latch the seat; refer to Lowering the Seat.

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

1. Prepare the machine for maintenance; refer to Preparing for Maintenance.

2. Measure the tire air pressure.

   Note: The correct air pressure in the tires is 83 to 103 kPa (12 to 15 psi).

3. If needed add air to or remove air from the tire.

4. Repeat steps 2 and 3 at the other tires.

1. Prepare the machine for maintenance; refer to Preparing for Maintenance.

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

Important: The machine must not move when the traction pedal is released (in the NEUTRAL position). If the machine moves, adjust traction pump as follows:

1. Prepare the machine for maintenance; refer to Preparing for Maintenance.

2. Jack up the front of the machine until the both front tires are off the ground, and support the machine with jack stands, refer to Jacking Point Locations and Specifications.

3. From the bottom of the machine and at the right side of the traction pump, loosen the locknut that secures the neutral return-adjustment screw (Figure 90).

   

   Figure 90

   1. Neutral return-adjustment screw
   2. Locknut
   3. Traction pump

   Warning

   The engine must be running so the final adjustment of the traction adjustment cam can be performed. This could cause personal injury.

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

4. Start the engine and release the parking brake.

5. Rotate the neutral return-adjustment screw in either direction until the wheels stop rotating.

6. Torque the locknut to 22 N∙m (16 ft-lb).

7. Shut off the engine and remove the key.

8. Remove the jack stands, and lower the machine to the ground.

9. Test drive the machine to ensure that it does not move when the traction pedal is in the NEUTRAL position.

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

2. Prepare the machine for maintenance; refer to Preparing for Maintenance.

3. At axle height, measure the center-to-center distance at the front and rear of the steering tires.

   Note: The rear wheel toe-in adjustment is correct if the difference between the front wheel measurement and the rear wheel measurement is 6 mm (1/4 inch) or less. (Figure 91).

   

   Figure 91

   1. Front of the traction unit
   2. 6 mm (1/4 inch) or less than the rear of the tire
   3. Center-to-center distance

4. If the measurement is greater than 6 mm (1/4 inch), adjust the rear wheel toe-in; refer to Adjusting the Rear Wheel Toe-in.

1. Loosen the jam nut on each end of the tie rod (Figure 92).

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

   

   Figure 92

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

2. Using the wrench flat to rotate the tie rod.

3. At axle height, measure the center-to-center distance at the front and rear of the steering tires.

   Note: The rear wheel toe-in adjustment is correct if the difference between the front wheel measurement and the rear wheel measurement is 6 mm (1/4 inch) or less.

4. Repeat steps 2 and 3 as required.

5. Tighten the jam nuts.

The coolant reservoir is filled at the factory with a 50/50 solution of water and ethylene glycol base extended-life coolant.

Important: Use only commercially available coolants that meet the specifications listed in the Extended Life Coolant Standards Table.Do not use conventional (green) inorganic-acid technology (IAT) coolant in your machine. Do not mix conventional coolant with extended-life coolant.

Coolant Type Table

Extended Life Coolant Standards

Important: Coolant concentration should be a 50/50 mixture of coolant to water.

• Preferred: When mixing coolant from a concentrate, mix it with distilled water.

• Preferred option: If distilled water is not available, use a pre-mix coolant instead of a concentrate.

• Minimum requirement: If distilled water and pre-mix coolant are not available, mix concentrated coolant with clean drinkable water.

Coolant Capacity: 9.5 L (10.0 US qt)

1. Prepare the machine for maintenance; refer to Preparing for Maintenance.

2. Open the hood; refer to Opening the Hood.

3. Check the level of coolant in the reservoir (Figure 93).

   Note: The coolant level is correct if it is cold mark on the side of the tank when the engine is cold, and the hot mark when the engine is hot.

   

   Figure 93

   1. Cap (coolant reservoir)
   2. Hot engine-coolant mark
   3. Cold engine-coolant mark

4. If the coolant level is low, remove the coolant-reservoir cap and add the specified coolant until the level it is at the cold mark (for a cold engine) or hot mark (for a hot engine).

   Note: Do not overfill the expansion tank with coolant.

5. Install the coolant-reservoir cap.

6. Close and latch the hood; refer to Closing the Hood.

1. Prepare the machine for maintenance; refer to Preparing for Maintenance.

2. Open the hood; refer to Opening the Hood.

3. Thoroughly clean all debris out of the engine area.

4. Close and latch the hood; refer to Closing the Hood.

5. Unlatch the rear screen and pivot it open (Figure 94).

   

   Figure 94

   1. Latch
   2. Rear screen

6. Thoroughly clean the screen with compressed air.

7. Rotate the 2 oil-cooler latches inward, and tilt oil cooler (Figure 95).

   

   Figure 95

   1. Oil cooler
   2. Oil-cooler latches

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

   

   Figure 96

   1. Radiator

9. Raise the oil cooler and secure it with the 2 latches.

10. Close and latch the screen.

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

Figure 97

1. Free travel

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

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

   

   Figure 98

   1. Brake cables
   2. Front nuts

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

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

   Note: Ensure that the cable conduit does not rotate during the tightening procedure.

If the parking brake fails to engage and latch, an adjustment to the brake pawl is required.

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

   

   Figure 99

   1. Brake cables
   2. Screws (2)
   3. Parking brake pawl
   4. Brake detent

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

3. Tighten the 2 screws locking the adjustment.

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

5. Check the adjustment and adjust as required.

Check the condition and tension of the belts (Figure 100) 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. Open the hood; refer to Opening the Hood.

3. Check the condition of the alternator belt.

   Note: Replace a worn or damaged belt.

4. Check the belt tension.

   Note: Belt tension is correct when the belt deflects 10 mm (3/8 inch) when a force of 45 N (10 lb) is applied on the belt midway between the pulleys.

5. If belt deflection is more than or less than 10 mm (3/8 inch), loosen the alternator mounting bolts (Figure 100).

   

   Figure 100

   1. Mounting bolt
   2. Alternator

6. Increase or decrease the alternator-belt tension, and tighten the mounting bolts.

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

8. Close and latch the hood; refer to Closing the Hood.

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 Level.

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

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. Prepare the machine for maintenance; refer to Preparing for Maintenance.

2. Clean the area around the filler neck and the cap of the hydraulic tank (Figure 101).

   

   Figure 101

   1. Full mark (dipstick)
   2. Add mark (dipstick)

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

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

   Note: The fluid level should be within operating range on the dipstick.

   Important: Do not overfill the tank.

5. If the level is low, add the appropriate amount of fluid to raise the level to the full mark.

6. Install the cap/dipstick onto the filler neck.

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.

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

Changing the Return Filter

The hydraulic system is equipped with a return filter-service indicator (Figure 102). You view the filter-service indicator through the hole in the floor plate. With the engine running at operating temperature, check the color of the indicator as follows:

• Green indicates normal hydraulic-fluid flow through the filter.

• Ref indicates a restricted filter. Change the return filter.

Figure 102

1. Hydraulic-filter-restriction indicator

1. Prepare the machine for maintenance; refer to Preparing for Maintenance.

2. At the front of the machine, align a drain pan under the return filter (Figure 103).

   

   Figure 103

   1. Return filter
   2. Filter head

3. Remove the filter.

4. Wipe clean the filter mounting area of the filter head.

5. Apply a thin coat of the specified hydraulic fluid to the gasket of the new return filter.

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

34 L (9 US gallons); refer to Hydraulic Fluid Specifications

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

1. Prepare the machine for maintenance; refer to Preparing for Maintenance.

2. Place a large drain pan under the straight fitting (Figure 105) of the hydraulic tank.

   

   Figure 105

   1. Straight fitting (hydraulic tank)
   2. Hose (case drain)
   3. Return filter

3. Disconnect the case-drain hose from the straight fitting, and allow the tank to drain.

4. When hydraulic fluid stops draining from the tank, install the drain hose.

5. Fill the tank with the specified 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 tank cap.

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

8. Check for hydraulic-fluid leaks; refer to Checking for Leaks.

9. Check the level; refer to Checking the Hydraulic-Fluid Level

Check the reel-to-bedknife contact, regardless of whether the quality of cut had previously been acceptable. There must be light contact across the full length of the reel and the bedknife (refer to Adjusting the Reel to Bedknife in the cutting unit Operator's Manual).

Note: Additional instructions and procedures on backlapping are available in the Toro Reel Mower Basics (with sharpening guidelines)​, Form 09168SL.

1. Inspect the seat belt for wear, cuts, and other damage. Replace the seat belt(s) if any component does not operate properly.

2. Clean the seat belt as necessary.

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. Doing so may result in internal engine damage.