Reelmaster® 5010-H Traction Unit

1. Unlatch the seat base, tilt the seat and base open, and support it with the prop rods (Figure 4).

   

   Figure 4

   1. Latch (seat base)
   2. Prop rods

2. Unplugging the 48 VDC system battery-disconnect jumper (Figure 5).

   

   Figure 5

   1. 48 V system connector
   2. Battery-disconnect jumper

3. At each cutting unit lift arm, remove the snapper pin that secures the cap to the pivot yoke, and remove the cap (Figure 6).

   

   Figure 6

   1. Snapper 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 7) is installed at the proper end of the cutting unit as described in the cutting unit Operator's Manual.

   

   Figure 7

   1. Counterweight

4. Coat the carrier-frame shaft with clean grease (Figure 8).

   

   Figure 8

   1. Carrier-frame shaft

5. Repeat steps 1 through 4 for the other cutting units.

Figure 9

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 10).

   

   Figure 10

   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 11).

   

   Figure 11

   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 12).

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

   

   Figure 12

   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 13) with the flange locknut (3/8 inch).

   

   Figure 13

   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 14).

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

   

   Figure 14

   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).

8. Repeat steps 1 through 7 for the other cutting unit.

1. Slide a cutting unit under the lift arm (Figure 15).

   

   Figure 15

   1. Cap
   2. Snapper pin
   3. Pivot yoke
   4. Carrier frame shaft

2. Assemble the pivot yoke onto the carrier frame shaft.

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

4. Secure the cap and the carrier-frame shaft to the pivot 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 pivot yoke (Figure 16) to lock the cutting unit. Use the slot for a steering cutting unit.

   

   Figure 16

   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 17).

   

   Figure 17

   1. Cap
   2. Snapper pin
   3. Pivot yoke
   4. Carrier frame shaft

2. Assemble the pivot yoke onto the carrier frame shaft.

3. Assemble the cap to the pivot yoke and align the holes in the carrier frame shaft, pivot yoke, 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 pivot yoke (Figure 17) to lock the cutting unit. Use the slot for a steering cutting unit.

   

   Figure 18

   1. Snapper-pin positions
   2. Hole (pivot yoke)
   3. Slot (pivot yoke)

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

1. Remove the lynch pin and washer securing the to the pivot yoke to the lift arm, and slide the shaft out of the lift arm (Figure 19).

   

   Figure 19

   1. Lynch pin
   2. Pivot yoke
   3. Lift arm (rear cutting unit)
   4. Washer

2. Assemble the pivot yoke onto the carrier frame shaft (Figure 20).

   

   Figure 20

   1. Cap
   2. Snapper pin
   3. Pivot yoke
   4. Carrier frame shaft

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

4. Secure the pivot yoke 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 pivot yoke (Figure 21) to lock the cutting unit. Use the slot for a steering cutting unit.

   

   Figure 21

   1. Snapper-pin positions
   2. Hole (pivot yoke)
   3. Slot (pivot yoke)

5. Slide a cutting unit under the lift arm (Figure 22).

   

   Figure 22

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

6. Insert the pivot yoke 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 23).

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

Figure 23

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

1. Apply a coat of clean grease to the splines of the reel-motor shaft.

2. Apply a coat of oil the reel motor O-ring and install it onto the motor flange.

3. Align the motor to the cutting unit so that the motor flanges clear the bolts clockwise (Figure 24).

   Important: Make sure that the reel-motor cable is not twisted, kinked, or at risk of being pinched.

   

   Figure 24

   1. Reel-drive motor
   2. Mounting bolt (2)

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

5. Torque the mounting bolts to 19 to 25 N∙m (14 to 18 ft-lb).

6. Repeat steps 1 through 5 at the other cutting units.

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 37).

   

   Figure 37

   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 38).

   

   Figure 38

   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 39).

   

   Figure 39

   1. CE warning decal
   2. Warning decal 133-293

2. Remove the backing from the CE warning decal.

3. Apply the CE warning decal over decal 133-293.

Pull the seat-position lever (Figure 45) to move the seat forward and rearward. Release the lever to lock the seat position.

Rotate the weight-adjusting knob until your weight is displayed in the window of the weight gauge.

Rotate the height-adjusting knob to change the height of the 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.

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, shut off the engine, and remove the key.

2. Using a clean rag, clean the area around the 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 to the bottom of the filler neck with diesel fuel.

5. Install fuel-tank cap tightly after filling 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 Performing Daily Maintenance.

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 6.4 km/h (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 .

Important: You must bleed the fuel system before starting the engine if you are starting the engine for the first time, the engine has shut off 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 engine-speed switch 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 turbo-charged engine.

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

The turf-compensation spring (Figure 50) 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 50).

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

   

   Figure 50

   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 50.

   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.

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 51).

   

   Figure 51

   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 23).

   

   Figure 52

3. Loosen the jam nut that secures lift-arm switch to the switch plate (Figure 53).

   

   Figure 53

   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.

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 continues to show the calculated reel speed based on blade count, mow speed, and HOC, but the new value is also displayed.

   Note: The reel speed may need to be increased or decreased to compensate for varying turf conditions.

Figure 54

5 inch (127 mm) Reel Speed Chart

Figure 55

7 inch (178 mm) Reel Speed Chart

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 InfoCenter, above the display screen (Figure 56). 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 56

1. Diagnostic light

Figure 57

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

• Front—the hole in the jack brackets of the front-axle tube (Figure 57).

• Rear—the frame hoops at each side of the machine.

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

• Tie the machine down securely.

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

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

1. Engage the parking brake, shut off the engine, and remove the key.

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

3. At the variable-displacement pump, rotate the bypass-valve bolt 1-1/2 turns to open and allow oil to bypass internally (Figure 58).

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

   

   Figure 58

   1. Bypass-valve bolt

4. Close and latch the hood.

5. Push or tow the machine.

6. Before starting the engine, close the bypass valve. 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.

2. Engage the parking brake.

3. Press the enable/disable switch to the DISENGAGE position.

4. Move the lower mow/raise control to the MOW position.

5. Shut off the engine, and remove the key.

6. Wait for all parts to stop moving.

7. Allow the engine to cool.

1. Release the 2 hood latches (Figure 59).

   

   Figure 59

   1. Hood latch (2)

2. Rotate open the hood.

1. Carefully rotate the hood closed (Figure 60).

   

   Figure 60

   1. Hood latch (2)

2. Secure the hood with the 2 hood latches.

1. Remove the ball pin from the screen latch (Figure 61).

   

   Figure 61

   1. Ball pin
   2. Screen latch

2. Unlatch and open the screen.

1. Close and latch the screen (Figure 62).

   

   Figure 62

   1. Ball pin
   2. Screen latch

2. Insert the ball pin through the screen latch.

1. Move the seat latch outward (Figure 63).

   

   Figure 63

   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 64).

   

   Figure 64

   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 65).

   

   Figure 65

   1. Prop rod
   2. Rod-guide plate

2. Carefully lower the seat until it latches securely.

1. Remove the 4 flange-head capscrews and 4 flange locknuts that secure the upper and lower generator cooling-air shrouds (Figure 66).

   

   Figure 66

   1. Flange-head capscrew
   2. Upper generator cooling-air shroud
   3. Flange locknut
   4. Lower generator cooling-air shroud

2. Separate the shrouds.

3. Lift the upper shroud to access the grease fittings of the driveshaft.

1. Align the grooves in the top and bottom generator cooling-air shrouds with the driveshaft-brush seal and the flange of the generator cover (Figure 67).

   

   Figure 67

   1. Upper generator cooling-air shroud
   2. Driveshaft-brush seal
   3. Flange (generator cover)
   4. Lower generator cooling-air shroud

2. Align the holes in the generator cooling-air shrouds with the compression-limiting pins.

3. Secure the halves of the generator cooling-air shrouds and compression-limiting pins with the 4 flange-head capscrews and 4 flange locknuts (Figure 68).

   

   Figure 68

   1. Flange-head capscrew
   2. Upper generator cooling-air shroud
   3. Flange locknut
   4. Lower generator cooling-air shroud

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

Use the following as machine-lift points:

Figure 69

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 69).

• Rear—the rear-axle tube.

Grease Specification: No. 2 lithium grease

1. Prepare the machine for maintenance; refer to Preparing for Maintenance. Open the hood; refer to Opening the Hood

2. Separate the generator cooling-air shrouds; refer to Separating the Generator Cooling-Air Shrouds.

3. Lubricate all grease fittings for the bearings and bushings with the specified grease. The grease fitting locations and quantities are as follows:

   • Pump driveshaft U-joint (3) (Figure 70)

     Note: Access the pump driveshaft from the bottom of the machine.

     

     Figure 70

   • Cutting-unit lift-arm cylinders (2 each) (Figure 71)

     

     Figure 71

   • Lift-arm pivots (1 each) (Figure 71)

   • Cutting-unit carrier-frame and pivot (2 each) (Figure 72)

     

     Figure 72

   • Lift-arm-pivot shaft (1 each) (Figure 73)

     

     Figure 73

   • Rear axle tie rod (2) (Figure 74)

     

     Figure 74

   • Axle-steering pivot (1) (Figure 75)

     

     Figure 75

   • Steering-cylinder ball joints (2) (Figure 76)

     

     Figure 76

   • Brake pedal (1) (Figure 77)

     

     Figure 77

4. Assemble the generator cooling-air shrouds; refer to Assembling the Generator Cooling-Air Shrouds.

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

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. Check the service indicator at the end of the air filter housing (Figure 78).

   

   Figure 78

   1. Service indicator

4. If a red band displays in the service indicator, change the air filter; refer to Servicing the Air Cleaner.

5. Squeeze the dust-ejector valve (Figure 79).

   

   Figure 79

6. Close and latch the hood; refer to Closing 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 filter only when the service indicator requires it. Changing the air filter before it is necessary only increases the chance of dirt entering the engine when you remove the filter.

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

Figure 80

1. If a red band displays in the service indicator, press the reset button at the end of the indicator (Figure 81).

   

   Figure 81

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

Use high-quality, low-ash engine oil that meets or exceeds API service category CH-4 or higher.

Use the following engine oil viscosity grade:

• Preferred oil: SAE 15W-40 (above 0°F)

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

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

Important: Check the engine oil daily. If the engine-oil level is above the Full mark on the dipstick, the engine oil may be diluted with fuel;If the engine oil level is above the Full mark, change the engine oil.

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 with oil.

Important: Keep the engine oil level between the upper and lower limits on the oil gauge; the engine may fail if you run it with too much or too little oil.

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 the engine oil (Figure 82).

   

   Figure 82

   Important: Be sure to keep the level of the engine oil between the upper and lower limits on the oil gauge. Engine failure may occur because of over filling or under filling the engine oil.

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

Approximately 3.3 L (3.5 US qt) with the filter.

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

2. Drain the oil and change the filter.

   

   Figure 83

   Important: Do not overtighten the filter.

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

4. Add oil to the crankcase; refer to Oil Specification, Crankcase Oil Capacity, and Checking the Level of the Engine Oil.

5. 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; Opening the Hood.

3. Align a drain pan under the drain valve of the fuel-water separator (Figure 84).

   

   Figure 84

   1. Drain valve (fuel-water separator)

4. Open the valve and drain the water and contaminants from the separator.

5. Close the valve of the fuel-water separator.

6. Start the engine and check for leaks.

   Note: Repair all leaks.

7. Shut off the engine and remove the key.

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

1. Fully drain the fuel-water separator; refer to Draining Water from the Fuel-Water Separator.

2. Clean the filter head and filter canister (Figure 85).

   

   Figure 85

   1. Filter head
   2. Filter canister

3. Remove the filter canister, and clean the mounting surface of the filter head.

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

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

6. Tighten the drain valve at the bottom of the filter canister.

7. Start the engine and check for leaks.

   Note: Repair all leaks.

8. Shut off the engine and remove the key.

9. Close and latch the hood; Closing 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 86).

   

   Figure 86

   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.

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

Fuel-tank capacity: 53 L (14 US gallons)

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

2. Align a drain pan under the fuel tank-drain valve (Figure 87).

   

   Figure 87

   1. Drain valve (fuel tank)

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

4. Use clean fuel to flush out the tank.

5. Close the drain valve.

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 97).

   

   Figure 97

   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 98).

   

   Figure 98

   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 12 V 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 12 V 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 12 V 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 Servicing the 12 V 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 99).

   

   Figure 99

   1. Control-arm cover
   2. Latch

3. Replace the open fuse (Figure 100) with the same fuse type and amperage rating.

   

   Figure 100

   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 open the hood; refer to Opening the Hood.

3. At the front, left side of the engine, remove the cover for the 48 V fuse-block.

   

   Figure 101

   1. Cover
   2. Maxi fuse
   3. 48 V fuse block

4. Replace the open fuse with a fuse of the same type and amperage rating.

   Note: Refer to the decal on the cover.

   

   Figure 102

5. Assemble the cover to the 48 V fuse-block.

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

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

2. Unlatch and open the hood; refer to Opening the Hood.

3. At the front, left side of the engine, Remove the cap from the in-line fuse holder labeled .

   

   Figure 103

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

4. Replace the open fuse with a fuse of the same type and amperage rating.

5. Assemble the cap to the in-line fuse holder.

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

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

2. Unlatch and open the hood; refer to Opening the Hood.

3. At the rear, right side of the engine, remove the cover of the in-line fuse holder labeled .

   

   Figure 104

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

4. Replace the open fuse with a fuse of the same type and amperage rating.

5. Assemble the cap to the in-line fuse holder.

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

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 105).

   

   Figure 105

   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 Specifications and Jacking Point Locations.

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 106).

   

   Figure 106

   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 107).

   

   Figure 107

   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 108).

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

   

   Figure 108

   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.

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 expansion tank (Figure 109).

   Note: The coolant level is correct if it is between the add and full marks on the side of the tank.

   

   Figure 109

   1. Expansion tank cap
   2. Full mark
   3. Add mark

4. If the coolant level is low, remove the expansion-tank cap and add the specified coolant until the level it is at the full mark.

   Note: Do not overfill the expansion tank with coolant.

5. Install the expansion-tank 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 110).

   

   Figure 110

   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 111).

   

   Figure 111

   1. Oil cooler
   2. Oil-cooler latches

8. Thoroughly clean both sides of the oil cooler and the radiator (Figure 112) with compressed air.

   

   Figure 112

   1. Radiator

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

10. Close and latch the screen.

Adjust the service brakes when there is more than 13 mm (1/2 inch) of free travel of the brake pedal, or if the brakes slip. Free travel is the distance the brake pedal moves before you feel braking-pedal resistance.

1. Prepare the machine, refer to Preparing for Maintenance.

2. Release the parking brake.

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

4. Lightly press the brake pedal; and measure the distance the pedal moves without resistance (Figure 113).

   Note: Adjust the brakes if there is more than 2.5 cm (1 inch) of free travel (Figure 113) of the brake pedal, or if more parking-brake force is required.

   

   Figure 113

   1. Free travel

5. To reduce brake pedal-free travel, loosen the front jam nuts on the threaded end of each brake cable (Figure 114).

   

   Figure 114

   1. Front jam nut (brake cable)
   2. Rear jam nut

6. Tighten the rear nuts to move the cable backward, until brake pedal has 6 to 13 mm (1/4 to 1/2 inch) of free travel (Figure 113), before the parking brake engages the wheels.

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

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

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

1. Prepare the machine, refer to Preparing for Maintenance.

2. Loosen the 2 screws securing the parking-brake pawl to the frame (Figure 115).

   

   Figure 115

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

3. Press the parking-brake pedal forward until the brake detent completely engages on the brake pawl (Figure 115).

4. Tighten the 2 screws locking the adjustment.

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

6. Check the adjustment and adjust it as required.

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

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

3. Check the tension of the alternator belt by pressing it (Figure 116) midway between the alternator and the crankshaft pulleys with 10 kg (22 lb) of force.

   Note: The belt should deflect 11 mm (7/16 inch). If the deflection is incorrect, proceed to step 4. If belt tension is correct, skip to step 7.

   

   Figure 116

   1. Brace
   2. Alternator belt
   3. Pivot bolt

4. Loosen the bolt securing the alternator to the brace, and the alternator pivot bolt. (Figure 116)

5. Insert a pry bar between the alternator and the engine and move the alternator outward.

6. When the belt is tensioned as described in step 3, tighten the bolts securing the alternator to the brace, and the alternator pivot bolt.

7. 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. Toro Premium Synthetic Biodegradable Hydraulic Fluid is available from your authorized Toro distributor in 19 L (5 US gallons) pails or 208 L (55 US gallons) drums.

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 117).

   

   Figure 117

   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.

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

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

3. At the left side of the machine, align a drain pan under the charge filter (Figure 118).

   

   Figure 118

   1. Filter head
   2. Charge filter

4. Remove the filter.

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

6. Apply a thin coat of the specified hydraulic fluid to the gasket of the new charge filter.

7. 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.

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

1. Start the engine and run it for 2 minutes to purge air from the hydraulic system.

2. Shut off the engine, remove the key, and check for leaks at the return and charge filters.

   Note: Repair all hydraulic leaks.

41.6 L (11 US gallons); refer to Hydraulic Fluid Specification

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 90° fitting (Figure 119) of the hydraulic tank; refer to Hydraulic Fluid Capacity.

   

   Figure 119

   1. 90° fitting (hydraulic tank)
   2. Tube (cooler return)

3. Disconnect the cooler-return tube from the 90° fitting, and allow the tank to drain.

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

5. Fill the tank with the specified hydraulic fluid; refer to Hydraulic Fluid Specification 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

Each day before operating, check the reel-to-bedknife contact, regardless if 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.

Note: When backlapping, the front units all operate together, and the rear units operate together.

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.