Reelmaster® 7000-D 4-Wheel Drive Traction Unit

1. Remove the reel motors from the shipping brackets.

2. Remove and discard the shipping brackets.

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

   

   Figure 4

   1. Counterweight

Figure 5

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 6).

   

   Figure 6

   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 7).

   

   Figure 7

   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 8).

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

   

   Figure 8

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

   

   Figure 9

   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 10).

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

   

   Figure 10

   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 11

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 11).

   

   Figure 12

   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 13).

   

   Figure 13

   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 14).

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

   

   Figure 14

   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 15

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 16).

   

   Figure 16

   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 17).

   

   Figure 17

   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 18).

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

   

   Figure 18

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

   

   Figure 19

   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 20).

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

   

   Figure 20

   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 21).

Figure 21

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

Increase the pivot angle of the rear cutting units by removing the 2 spacers, 2 hex-socket screws, and 2 flange locknuts (Figure 22 and Figure 23) from the carrier frames of cutting units 2 and 3.

Figure 22

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

Figure 23

1. Hex-socket screw
2. Spacer
3. Carrier frame
4. Flange locknut

1. Ensure that the countersunk thrust washer is inserted over the carrier-frame shaft (Figure 24).

   

   Figure 24

   1. Thrust washer (countersunk)
   2. Carrier-frame shaft

2. Coat the carrier-frame shaft with clean grease (Figure 25).

   

   Figure 25

   1. Carrier-frame shaft

3. Repeat steps 1 and 2 for the other cutting units.

1. Slide a cutting unit under the lift arm (Figure 26).

   

   Figure 26

   1. Lynch pin
   2. Pivot yoke
   3. Carrier-frame shaft

2. Insert the shaft of the carrier frame into the pivot yoke of the lift arm.

3. Secure the carrier-frame shaft to the pivot yoke with the lynch pin.

4. Repeat steps 1 and 3 at the other front cutting-unit positions.

1. Slide a cutting unit under the lift arm (Figure 27).

   

   Figure 27

   1. Lift-arm pivot shaft
   2. Thrust washer (countersunk)
   3. Carrier-frame shaft
   4. Lynch pin

2. Insert the lift-arm shaft into the lift arm and secure it with the lynch pin.

3. Repeat step 2 for the other rear cutting unit.

1. Remove the lynch pin and washer securing the lift-arm pivot shaft to the lift arm and slide the lift-arm pivot shaft out of the lift arm (Figure 28).

   

   Figure 28

   1. Lift arm (rear cutting unit)
   2. Lift-arm pivot shaft
   3. Thrust washer
   4. Lynch pin

2. Insert the lift-arm yoke onto the carrier frame shaft (Figure 29).

   

   Figure 29

   1. Lift-arm pivot shaft
   2. Thrust washer (countersunk)
   3. Carrier-frame shaft
   4. Lynch pin

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

   

   Figure 30

   1. Lift arm (rear cutting unit)
   2. Lift-arm pivot shaft
   3. Thrust washer
   4. Lynch pin

4. Insert the lift-arm shaft into the lift arm and secure it with the lynch pin.

5. Repeat steps 1 through 4 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).

Enter the following cutting-unit information into the InfoCenter:

• Blade count; refer to Setting the Blade Count.

• Mow speed; refer to Setting the Mow Speed.

• Height of cut; refer to Setting the Height of Cut (HOC).

Note: You need the PIN code to change the blade count, mow speed, and height of cut values in the InfoCenter.

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.

Use the fuel gauge (Figure 44) at the top of the tank to determine the fuel level.

Figure 44

1. Fuel gauge

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

• The engine has shut off because the machine ran out of fuel.

• Maintenance was performed on the fuel system components.

1. Sit in the operator’s seat, engage the parking brake, and ensure that your foot is off the traction pedal.

2. Move the engine-throttle control to the SLOW position.

3. Turn the key to the RUN position.

   Note: The glow-plug indicator displays in the InfoCenter.

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

   Important: Do not run the starter motor more than 15 seconds at a time, or premature starter failure may result. If the engine fails to start after 15 seconds, turn the key to the OFF position, check the controls and procedures, wait 15 additional seconds, and repeat the starting procedure.When the temperature is less than -7°C (20°F), the starter motor can be run for 30 seconds on then 60 seconds off for 2 attempts.

5. When the engine starts, release the key.

6. Adjust the engine speed.

1. Park the machine on a level surface.

2. Press the PTO switch to the DISENGAGE position.

3. Move the engine-throttle control to the SLOW position.

4. Engage the parking brake.

5. Lower the cutting units.

   Important: Lowering the cutting units relieves the hydraulic load from the system, prevents wear on system parts, and prevents accidental lowering of the cutting units.

6. Rotate the key to OFF and remove the key.

7. Wait for all moving parts to stop.

Lock the cutting-unit pivots to prevent the cutting units from rotating downhill when cutting across the face of a hill.

1. Secure the carrier frame of the cutting unit to the pivot yoke with the snapper pin as shown in Figure 45.

   

   Figure 45

   1. Pivot yoke
   2. Snapper pin
   3. Carrier frame (cutting unit)

2. Repeat step 1 at the other cutting units.

1. Drive the machine to the job site and align the machine outside the cutting area for the first cutting pass.

2. Ensure that the PTO switch is set to the DISENGAGE position (Figure 46).

   

   Figure 46

   1. Engine-throttle control
   2. PTO switch
   3. Mow/raise control lever

3. Use your foot to move the lever for the mow-speed limiter forward, to the MOW position (Figure 47).

   

   Figure 47

   1. Mow-speed limiter

4. Move the engine-throttle control to the FAST position.

5. Press the PTO switch to the ENGAGE position.

6. Begin driving the machine into the cutting area, and move the lower mow/raise control lever forward.

   Note: The cutting units start running as they lower. The front cutting units are timed to lower before the rear cutting units

7. When you complete the mowing pass, move the lever for the mow-speed limiter backward to lift the cutting units.

8. Perform a tear-shaped turn to quickly line up for your next pass.

1. Press the PTO switch to the DISENGAGE position (Figure 48).

   

   Figure 48

   1. PTO switch
   2. Mow/raise control lever

2. Move the lower mow/raise control lever rearward to raise the cutting units (transport position).

3. Move the lever for the mow-speed limiter rearward to the TRANSPORT position (Figure 49).

   

   Figure 49

   1. Mow-speed limiter

4. Press the traction pedal to drive the machine.

   Important: Be careful when driving between objects so that you do not accidentally damage the machine or cutting units. Use extra care when operating the machine on slopes. Drive slowly and avoid sharp turns on slopes to prevent a rollover.

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).

Note: To remove all counterbalance force, position the long leg of the torsion spring below the capscrew, washer, spacer, and locknut.

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

2. Insert a tube or similar object over the long leg of the spring, and lift the spring leg to relieve pressure on the spacer (Figure 51).

   Note: Have another person help by lifting and lowering the spring leg.

   

   Figure 51

   1. Lift arm (rear—cutting unit #2 or #3)
   2. Torsion spring
   3. Locknut
   4. Lift-arm plate
   5. Spacer
   6. Washer
   7. Capscrew

3. While holding the spring, remove the bolt, washer, and locknut from the lift plate (Figure 51).

4. Align the spring leg above the desired hole location.

5. Install the capscrew, washer, spacer, and locknut at the hole location.

6. Slowly lower the spring leg onto the spacer.

7. Repeat the steps through 5 at the rear cutting unit-lift arm.

The lift-arm switch (Figure 40) is located behind the right, front lift arm (cutting unit #5).

Figure 52

1. Lift-arm switch
2. Switch bracket (slotted)
3. Flange-head screw

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. Loosen the 2 flange-head screws that secure the switch bracket to the carrier frame for the front cutting unit-lift arms.

3. Move the switch bracket as follows:

   • To increase the cutting unit-turnaround height, move the bracket up.

   • To decrease the cutting unit-turnaround height, move the bracket down.

4. Tighten the 2 flange-head screws.

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

• Replace worn or damaged parts for safety.

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

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

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

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

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

2. Remove the lynch pins that secure the roll-bar pins at each side of the roll bar (Figure 53).

   

   Figure 53

   1. Lynch pin
   2. Upper holes (pivot brackets)
   3. Roll-bar pin
   4. Roll-bar and lynch pins (lower holes—pivot brackets)

3. Support the weight of the upper roll-bar tube while removing roll-bar pins from the pivot brackets.

4. Carefully lower the upper roll-bar tube until it rests on the stops.

5. Insert the roll-bar pins into the lower holes in the pivot brackets, and secure the roll-bar pins to the brackets with the lynch pins.

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

2. Remove the lynch pins that secure the roll-bar pins at each side of the roll bar (Figure 54).

   

   Figure 54

   1. Roll-bar pin
   2. Lynch pin
   3. Upper holes (pivot brackets)

3. Removing roll-bar pins from the pivot brackets.

4. Carefully lift the upper roll-bar tube until the holes in the pivot bracket align with the holes in the lower roll-bar tube.

5. Insert the roll-bar pins into the holes in the pivot bracket and lower roll-bar tube.

6. Secure the roll-bar pins to the brackets and lower roll-bar tubes with the lynch pins.

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

• Tie the machine down securely.

The tie-down points are in the following locations:

• On each side of the frame under the front steps

• The rear bumper

Figure 55

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

In an emergency, you can move the machine by opening tow bypass valve of the traction hydraulic pump, installing a hydraulic hose to bypass the check valve, and then pushing or towing the machine.

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

1. Park the machine on a level surface, 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.

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

   

   Figure 59

   1. Hood latch (2)

2. Use the handle at the back of the hood to 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. Release the rubber latch from the battery-compartment cover (Figure 59).

   

   Figure 61

   1. Battery-compartment cover
   2. Latch (rubber)

2. Rotate the cover up.

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 seat support (Figure 63).

   

   Figure 63

   1. Slot (seat support)
   2. Prop rod

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

   

   Figure 64

   1. Slot (seat support)
   2. Prop rod

2. Carefully lower the seat until it latches securely.

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

Use the following as machine-lift points:

• Front of the machine—at the frame of the machine, forward of the wheel-drive motors (Figure 65).

  Important: Do not support the machine at the wheel-drive motors. Keep the lifting equipment clear of hydraulic tubing and hoses.

  

  Figure 65

• Rear of the machine—at the center of the axle (Figure 66)

  Note: Locate the jackstands of the specified capacity at both sides of the gear case and under the axle.

  Important: Do not support the machine at the tie rod.

  

  Figure 66

Grease Specification: No. 2 lithium grease

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

2. The grease fitting locations and quantities are as follows:

   • Brake shaft pivot bearings (5), refer to Figure 67

     

     Figure 67

   • Rear axle-pivot bushing and steering cylinder, refer to Figure 68

     

     Figure 68

   • Steering cylinder ball joints (2), refer to Figure 69

     

     Figure 69

     1. Top fitting on king pin

   • Tie rod ball joints (2), refer to Figure 69

   • King pin bushings (2), refer to Figure 69.

     Note: The top fitting on the king pin should only be lubricated annually (2 pumps).

   • Lift arm bushings (1 per cutting unit), refer to Figure 70

     

     Figure 70

   • Lift cylinder bushings (2 per cutting unit), refer to Figure 70

   • Lift arm pivot bushings (1 per cutting unit), refer to Figure 71

   • Cutting unit carrier frame (2 per cutting unit), refer to Figure 71

   • Cutting unit lift arm pivot (1 per cutting unit), refer to Figure 71

     

     Figure 71

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 72).

   Note: If a red band displays in the service indicator, change the air filter; refer to Removing the Filter.

   

   Figure 72

   1. Service indicator

4. Squeeze the dust-ejector valve (Figure 73).

   

   Figure 73

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

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

API service category: CH-4 or higher.

Use the following engine oil viscosity grade:

• Preferred oil: SAE 15W-40: above -18°C (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.

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

Note: The best time to check the engine oil is when the engine is cool before it has been started for the day. If the engine has already been run, wait 10 minutes before checking the oil level.

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 right side of the engine, remove the dipstick from the dipstick tube (Figure 78) and wipe the dipstick with a clean rag.

   

   Figure 78

   1. Dipstick tube
   2. Dipstick
   3. Full oil-level mark
   4. Add oil-level mark

4. Fully insert the dipstick down into the dipstick tube, then pull the dipstick out and check the oil level.

   Note: If the oil level is between the Full and Add oil-level marks, you do not need to add oil; skip to step 7.

5. If the oil level is low, at the right side of the engine—remove the oil-fill cap (Figure 79) and gradually add small amounts of oil, checking the level frequently, until the level reaches the Full mark on the dipstick.

   Important: Keep the engine-oil level between the upper and lower limits on the dipstick. Overfilling or underfilling the engine oil may cause severe engine damage.

   

   Figure 79

   1. Oil filler port
   2. Oil-fill cap

6. Install the oil-fill cap and dipstick.

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

Approximately 9.5 L (10 US qt) with the filter.

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 82).

   

   Figure 82

   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.

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 83).

   

   Figure 83

   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 84).

   

   Figure 84

   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 85).

   

   Figure 85

   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 85).

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 battery-compartment cover; refer to Accessing the Battery Compartment.

3. Disconnect the negative battery cable (Figure 86).

   

   Figure 86

   1. Positive battery cable
   2. Negative battery cable

4. Slide the rubber boot 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 87).

   

   Figure 87

   1. Positive battery cable
   2. Negative battery cable

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. Close and latch the battery-compartment cover.

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 battery-compartment cover; refer to Accessing the Battery Compartment.

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. Wash 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 battery-compartment cover.

The fuse block is in the battery compartment.

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

2. Open the battery-compartment cover; refer to Accessing the Battery Compartment.

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

   

   Figure 88

   1. Fuse block
   2. Maxi fuse socket

4. Close and latch the battery-compartment cover.

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 115 to 136 N∙m (85 to 100 ft-lb).

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

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

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

2. Chock the rear wheels and raise the front of machine; refer to Specifications and Locating the Jacking Points.

3. Support the front frame of the machine with jack stands.

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

   

   Figure 89

   1. Front drive wheels

5. Repeat step 4 for the other drive wheel.

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

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

1. Park the machine on level surface, position the wheel so that the fill plug is at the 12 o'clock position, the check plug is at 3 o'clock position, and the drain plug is at the 6 o'clock position (Figure 90).

   

   Figure 90

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

2. Remove the check plug at the 3 o’clock position (Figure 90).

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

   

   Figure 91

   1. Check-plug hole
   2. Check plug

3. If the oil level is low, remove the fill plug at the 12 o’clock position and add oil until it begins to flow out of the hole at the 3 o’clock position.

4. Check the O-ring for the plug(s) for wear or damage.

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

5. Install the plug(s).

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

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

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

Axle Oil Specification: SAE 85W-140 gear oil

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

2. Remove a check plug from 1 end of the axle housing (Figure 96).

   

   Figure 96

   1. Check plug (axle housing)
   2. Fill plug (axle housing)

3. Check the gear oil level in the axle through the check-plug hole.

   Note: The gear-oil level is correct if the oil level is at the bottom of the check-plug hole.

4. If the gear-oil level low, remove the fill plug and add the specified gear oil to raise the oil level to the bottom of the check-plug hole.

5. Install the check plug.

6. If removed, install the fill plug.

Rear Axle Oil Capacity: 2.4 L (80 fl oz)

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

2. Clean the area around the 3 drain plugs (Figure 97)—1 at each bevel-gear case (outboard of the axle housings) and 1 in the center-gear case.

   

   Figure 97

   1. Drain plug (axle case—outboard)
   2. Axle housing
   3. Drain plug (center gear case)

3. Remove each drain plug (Figure 97) and allow the oil to drain into a drain pan.

4. Remove the 2 axle housing check plugs and the fill plug to ease in draining of the oil (Figure 98).

   

   Figure 98

   1. Check plug (axle housing)
   2. Fill plug (axle housing)

5. Install the 3 drain plugs and the check plug at the axle housing with the breather fitting.

6. At the fill plug axle port, fill the axle with approximately 2.37 L (80 fl oz) of 85W-140 gear oil or until the oil level is at the bottom of the hole.

7. Install the check plug and the fill plug.

Reduction-Gear Case Oil Specification: SAE 85W-140 gear oil

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

2. Remove the check/fill plug from the left side of the reduction-gear case (Figure 99).

   

   Figure 99

   1. Check/fill plug
   2. O-ring
   3. Reduction-gear case

3. Check the O-ring for the plug is not worn or damaged.

4. Check the gear-case oil level.

   Note: The gear-oil level is correct if the oil level is at the bottom of the check/fill-plug hole.

5. If the gear-oil level is low, add enough of the specified case oil to bring the level up to the bottom of the check/fill-plug hole.

6. Install the check/fill plug.

The machine must not move forward or backward when you release the traction pedal. If the machine moves, adjust the traction drive for neutral.

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

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

3. Jack up the left side of the machine until the left front tire is off the shop floor. Support the machine with jack stands to prevent it from falling accidentally; refer to Specifications and Locating the Jacking Points.

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

5. Adjust the jam nuts on the rod end to move the traction rod forward to eliminate forward creep or rearward to eliminate rearward creep (Figure 104 and Figure 105).

   

   Figure 104

   

   Figure 105

   1. Jam nuts
   2. Traction hub pivot
   3. Traction rod
   4. Rod end

6. When the wheel stops rotating, tighten the jam nuts to secure the adjustment.

7. Shut off the engine and remove the key.

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

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

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

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

   Note: The front measurement must be 3 mm (1/8 inch) less than the rear measurement (Figure 106).

   

   Figure 106

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

1. At the rear axle, remove the cotter pin and the slotted nut from either tie-rod end (Figure 107).

   

   Figure 107

   1. Slotted nut
   2. Cotter pin
   3. Axle case-steering arm
   4. Tie-rod end
   5. Clamp
   6. Nut and bolt

2. Separate the tie-rod end from the axle case-steering arm.

3. Loosen the clamps at both ends of the tie rods (Figure 107).

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

5. Tighten the clamp at the detached end of the tie rod.

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

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

8. Assemble the tie-rod end to the axle case-steering arm with the slotted nut.

9. Measure the toe-in; refer to Checking the Rear-Wheel Alignment.

10. If needed, remove the slotted nut and repeat steps 2 through 9.

11. When the difference between the front and rear measurements are 3 mm (1/8 inch) less, tighten the slotted nut and install a new cotter pin.

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 Checking the Coolant Level.

2. Open the hood, and wait for the engine to cool; refer to Opening the Hood.

3. Carefully remove the radiator cap (Figure 108).

   

   Figure 108

   1. Cap (expansion tank)
   2. Radiator cap
   3. Neck
   4. Full mark

4. Check the coolant level in the radiator.

   Note: The coolant level is correct if it is to the top of the filler neck of the radiator (Figure 108).

5. Check the coolant level in the expansion tank.

   Note: The coolant level is correct if it is to the FULL mark of the expansion tank.

6. If the coolant is low, add the specified coolant to the radiator, expansion tank, or both; refer to Coolant Specification.

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

8. 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 rear screen (Figure 109).

   

   Figure 109

   1. Latch keeper
   2. Rear screen latch

3. Clean both sides of the screen.

4. Lift the screen off the hinge pins, and remove the screen from the machine.

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

6. Clean both sides of the oil cooler/radiator area (Figure 110) thoroughly with compressed air. Start from the front and blow the debris out toward the back. Then clean from the back side and blow toward the front. Repeat the procedure several times until all chaff and debris is removed.

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

   

   Figure 110

   1. Oil cooler/radiator

7. Close and latch the hood, Closing the Hood.

8. Assemble the screen onto the hinge pins (Figure 111).

   

   Figure 111

   1. Latch keeper
   2. Rear screen latch

9. 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 for maintenance; refer to Preparing for Maintenance.

2. Disengage the pedal-locking latch between the brake pedals (Figure 112) so that both pedals work independently of each other.

   

   Figure 112

   1. Brake pedals locked
   2. Brake pedals unlocked

3. Loosen the front jam nut on the threaded end of the brake cable (Figure 113).

   

   Figure 113

   1. Left brake cable
   2. Right brake cable
   3. Jam nuts
   4. Front of the machine

4. To reduce free travel of the brake pedals, tighten the rear jam nut to move the cable rearward until the brake pedals have 0 to 13 mm (0 to 1/2 inch) of free travel.

   Note: Ensure that there is no brake-cable tension when the pedal is released.

5. Tighten the front jam nut after the brakes are adjusted correctly.

6. If needed, repeat steps 3 through 5 at the other brake cable.

Check the condition and tension of the belts (Figure 114) 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 114).

   

   Figure 114

   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.

Check the hydraulic lines and hoses for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration, and chemical deterioration. Make all necessary repairs before operating.

The reservoir is filled at the factory with high-quality hydraulic fluid. Check the level of the hydraulic fluid before you first start the engine and daily thereafter; 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 gallons) pails or 208 L (55 US gallons) from your authorized Toro distributor.

The reservoir is filled at the factory with high-quality hydraulic fluid.

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

2. Clean the area around the filler neck and cap of the hydraulic tank (Figure 115).

   

   Figure 115

   1. Hydraulic-tank cap
   2. Dipstick
   3. Full mark
   4. Add mark

3. Remove the hydraulic-tank cap from the tank.

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

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

   The correct hydraulic-fluid level is between the Full mark and the Add mark on the dipstick.

6. If the level is low, add the specified hydraulic fluid to raise the fluid level to the Full mark.

7. Install the dipstick and hydraulic-tank cap to the tank.

Use the following Toro hydraulic filters:

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

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

Wash the machine as needed using water alone or with a mild detergent. You may use a rag when washing the machine.

Important: Do not use brackish or reclaimed water to clean the machine.

Important: Do not use power-washing equipment to wash the machine. Power-washing equipment may damage the electrical system, loosen important decals, or wash away necessary grease at friction points. Avoid excessive use of water near the control panel, engine, and battery.

Important: Do not wash the machine with the engine running. Washing the machine with the engine running may result in internal engine damage.