Reelmaster® 7000-D 4-Wheel Drive Traction Unit

• Read the operator's manual and other training material carefully. Be familiar with the controls, safety signs, and the proper use of the equipment.

• Never allow children or people unfamiliar with these instructions to use or service the mower. Local regulations may restrict the age of the operator.

• Never mow while people, especially children, or pets are nearby.

• Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people or their property.

• Do not carry passengers.

• All drivers and mechanics should seek and obtain professional and practical instruction. The owner is responsible for training the users. Such instruction should emphasize:

  • the need for care and concentration when working with ride-on machines;

  • control of a ride-on machine sliding on a slope will not be regained by the application of the brake. The main reasons for loss of control are:

    • insufficient wheel grip;

    • being driven too fast;

    • inadequate braking;

    • the type of machine is unsuitable for its task;

    • lack of awareness of the effect of ground conditions, especially slopes;

    • incorrect hitching and load distribution.

• The owner/user can prevent and is responsible for accidents or injuries occurring to himself or herself, other people, or property.

• While mowing, always wear substantial footwear, long trousers, hard hat, safety glasses, and ear protection. Long hair, loose clothing, or jewelry may get tangled in moving parts. Do not operate the equipment when barefoot or wearing open sandals.

• Thoroughly inspect the area where the equipment is to be used and remove all objects which may be thrown by the machine.

• Replace faulty silencers/mufflers.

• Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by the manufacturer.

• Check that the operator's presence controls, safety switches and shields are attached and functioning properly. Do not operate unless they are functioning properly.

• To avoid personal injury or property damage, use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive.

• Extinguish all cigarettes, cigars, pipes, and other sources of ignition.

• Use only an approved fuel container.

• Never remove fuel cap or add fuel with the engine running.

• Allow engine to cool before refueling.

• Never refuel the machine indoors.

• Never store the machine or fuel container where there is an open flame, spark, or pilot light such as on a water heater or on other appliances.

• Never fill containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always place containers on the ground away from your vehicle before filling.

• Remove equipment from the truck or trailer and refuel it on the ground. If this is not possible, then refuel such equipment with a portable container, rather than from a fuel dispenser nozzle.

• Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Do not use a nozzle lock open device.

• If fuel is spilled on clothing, change clothing immediately.

• Never overfill fuel tank. Replace fuel cap and tighten securely.

• Do not operate the engine in a confined space where dangerous carbon monoxide fumes can collect.

• Mow only in daylight or in good artificial light.

• Before attempting to start the engine, disengage all blade attachment clutches, shift into neutral, and engage the parking brake.

• Remember there is no such thing as a safe slope. Travel on grass slopes requires particular care. To guard against overturning:

  • do not stop or start suddenly when going up or downhill;

  • machine speeds should be kept low on slopes and during tight turns;

  • stay alert for humps and hollows and other hidden hazards;

  • Do not turn sharply. Use care when reversing.

  • Use counterweight(s) or wheel weights when suggested in the operator's manual.

• Stay alert for holes in the terrain and other hidden hazards.

• Watch out for traffic when crossing or near roadways.

• Stop the blades rotating before crossing surfaces other than grass.

• When using any attachments, never direct discharge of material toward bystanders nor allow anyone near the machine while in operation.

• Never operate the machine with damaged guards, shields, or without safety protective devices in place. Be sure all interlocks are attached, adjusted properly, and functioning properly.

• Do not change the engine governor settings or over-speed the engine. Operating the engine at excessive speed may increase the hazard of personal injury.

• Before leaving the operator's position:

  • stop on level ground;

  • disengage the power take-off and lower the attachments;

  • change into neutral and set the parking brake;

  • stop the engine and remove the key.

• Disengage drive to attachments when transporting or not in use.

• Stop the engine and disengage drive to attachment:

  • before refuelling;

  • before making height adjustment unless adjustment can be made from the operator's position.

  • before clearing blockages;

  • before checking, cleaning or working on the mower;

  • after striking a foreign object or if an abnormal vibration occurs. Inspect the mower for damage and make repairs before restarting and operating the equipment.

• Reduce the throttle setting during engine run-out and, if the engine is provided with a shut-off valve, turn the fuel off at the conclusion of mowing.

• Keep hands and feet away from the cutting units.

• Look behind and down before backing up to be sure of a clear path.

• Slow down and use caution when making turns and crossing roads and sidewalks. Stop cylinders/reels if not mowing.

• Do not operate the mower under the influence of alcohol or drugs.

• Lightning can cause severe injury or death. If lightning is seen or thunder is heard in the area, do not operate the machine; seek shelter.

• Use care when loading or unloading the machine into a trailer or truck.

• Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision.

• Keep all nuts, bolts and screws tight to be sure the equipment is in safe working condition.

• Never store the equipment with fuel in the tank inside a building where fumes may reach an open flame or spark.

• Allow the engine to cool before storing in any enclosure.

• To reduce the fire hazard, keep the engine, silencer/muffler, battery compartment and fuel storage area free of grass, leaves, or excessive grease.

• Keep all parts in good working condition and all hardware and hydraulic fittings tightened. Replace all worn or damaged parts and decals.

• If the fuel tank has to be drained, do this outdoors.

• Be careful during adjustment of the machine to prevent entrapment of the fingers between moving blades and fixed parts of the machine.

• On multi-cylinder/multi-reel machines, take care as rotating one cylinder/reel can cause other cylinders/reels to rotate.

• Disengage drives, lower the cutting units, set parking brake, stop engine and remove key from ignition. Wait for all movement to stop before adjusting, cleaning or repairing.

• Clean grass and debris from cutting units, drives, silencers/mufflers, and engine to help prevent fires. Clean up oil or fuel spillage.

• Use jack stands to support components when required.

• Carefully release pressure from components with stored energy.

• Disconnect battery before making any repairs. Disconnect the negative terminal first and the positive last. Reconnect positive first and negative last.

• Use care when checking the cylinders/reels. Wear gloves and use caution when servicing them.

• Keep hands and feet away from moving parts. If possible, do not make adjustments with the engine running.

• Charge batteries in an open well ventilated area, away from spark and flames. Unplug charger before connecting or disconnecting from battery. Wear protective clothing and use insulated tools.

• Use care when loading or unloading the machine into a trailer or truck.

• Use full width ramps for loading machine into trailer or truck.

• Tie the machine down securely using straps, chains, cable, or ropes. Both front and rear straps should be directed down and outward from the machine

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

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

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

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

Figure 30

1. Weight gauge
2. Weight adjusting lever
3. Fore and Aft adjusting lever
4. Seat back adjusting lever
5. Arm rest adjusting knob

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

Important: Use only ultra-low sulphur diesel fuel. Fuel with higher rates of sulfur degrades the diesel oxidation catalyst (DOC), which causes operational problems and shortens the service life of engine components.Failure to observe the following cautions may damage the engine.

• Never use kerosene or gasoline instead of diesel fuel.

• Never mix kerosene or used engine oil with the diesel fuel.

• Never keep fuel in containers with zinc plating on the inside.

• Do not use fuel additives.

83 L (22 US gallons)

1. Position the machine on a level surface, lower the cutting units, stop 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 35).

   

   Figure 35

   1. Fuel-tank cap

4. Fill the tank until the level is to the bottom of the filler neck with fuel.

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

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

Important: The fuel system must be bled if any of the following situations have occurred:

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

• Maintenance has been performed upon the fuel system components.

1. Remove your foot from the traction pedal and ensure that it is in neutral. Ensure that the parking brake is set.

2. Move the engine speed switch to the low idle position.

3. Turn the ignition key to the Run position. The glow indicator will light.

4. When the glow indicator dims, turn the ignition key to the Start position. Release the key immediately when the engine starts and allow it to return to the Run position. Adjust the engine speed.

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

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

   Caution

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

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

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

1. Return the engine speed to low idle.

2. Move the PTO switch to the Off position.

3. Set the parking brake.

4. Rotate the ignition key to Off.

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

• Over time, the DPF accumulates soot in the soot filter. The computer for the engine monitors the soot level in the DPF.

• When enough soot accumulates, the computer informs you that it is time to regenerate the diesel particulate filter.

• DPF regeneration is a process that heats the DPF to convert the soot to ash.

• In addition to the warning messages, the computer reduces the power produced by the engine at different soot-accumulation levels.

Engine Warning Messages—Soot Accumulation

Indication Level	Fault Code	Engine Power Rating	Recommended Action
Level 1: Engine Warning	Figure 37 Check EngineSPN 3719, FMI 16	The computer de-rates the engine power to 85%	Perform a parked regeneration as soon as possible; refer to Parked Regeneration.
Level 2: Engine Warning	Figure 38 Check EngineSPN 3719, FMI 0	The computer de-rates the engine power to 50%	Perform a recovery regeneration as soon as possible; refer to Recovery Regeneration.

• The lighter ash is discharged through the exhaust system; the heavier ash collects in the soot filter.

• Ash is a residue of the regeneration process. Over time, the diesel particulate filter accumulates ash that does not discharge with the engine exhaust.

• The computer for the engine calculates the amount of ash accumulated in the DPF.

• When enough ash accumulates, the engine computer sends information to the InfoCenter in the form of a system advisory or an engine fault to indicate the accumulation of ash in the DPF.

• The advisory and faults are indications that it is time to service the DPF.

• In addition to the warnings, the computer reduces the power produced by the engine at different ash-accumulation levels.

InfoCenter Advisory and Engine Warning Messages—Ash Accumulation

Indication Level	Advisory or Fault Code	Engine Speed Reduction	Engine Power Rating	Recommended Action
Level 1: System Advisory	Figure 39 Advisory #179	None	100%	Notify your service department that advisory #179 displays in the InfoCenter.
Level 2: Engine Warning	Figure 40 Check EngineSPN 3720, FMI 16	None	The computer de-rates the engine power to 85%	Service the DPF; refer to Servicing the Diesel-Oxidation Catalyst (DOC) and the Soot Filter
Level 3: Engine Warning	Figure 41 Check EngineSPN 3720, FMI 0	None	The computer de-rates the engine power to 50%	Service the DPF; refer to Servicing the Diesel-Oxidation Catalyst (DOC) and the Soot Filter
Level 4: Engine Warning	Figure 42 Check EngineSPN 3251, FMI 0	Engine speed at max torque + 200 rpm	The computer de-rates the engine power to 50%	Service the DPF; refer to Servicing the Diesel-Oxidation Catalyst (DOC) and the Soot Filter

Types of diesel particulate filter regeneration that are performed while the machine is operating:

Type of Regeneration	Conditions for DPF regeneration	DPF description of operation
Passive	Occurs during normal operation of the machine at high-engine speed or high-engine load	The InfoCenter does not display an icon indicating passive regeneration.
		During passive regeneration, the DPF processes high-heat exhaust gasses; oxidizing harmful emissions and burning soot to ash.
		Refer to Passive DPF Regeneration.
Assist	Occurs as a result of low-engine speed, low-engine load, or after the computer detects back pressure in the DPF	When the assist/reset-regeneration icon is displayed in the InfoCenter, an assist regeneration is in progress.
		During assist regeneration, the computer controls the intake throttle to increase the exhaust temperature, enabling assist regeneration to occur.
		Refer to Assist DPF Regeneration.
Reset	Occurs after assist regeneration only if the computer detects that assist regeneration did not sufficiently reduce the soot level	When the assist/reset-regeneration icon is displayed in the InfoCenter, a regeneration is in progress.
	Also occurs every 100 hours to reset baseline sensor readings
		During reset regeneration, the computer controls the intake throttle and fuel injectors to increase the exhaust temperature during regeneration.
		Refer to Reset Regeneration.

Types of diesel particulate filter regeneration that require you to park the machine:

Type of Regeneration	Conditions for DPF regeneration	DPF description of operation
Parked	Soot buildup occurs as a result of prolonged operation at low-engine speed or low-engine load. May also occur as a result of using incorrect fuel or oil	When the parked-regeneration icon is displayed in the InfoCenter, a regeneration is requested.
	The computer detects back pressure due to soot buildup and requests a parked regeneration
		• Perform the parked regeneration as soon as possible to avoid needing a recovery regeneration.
		• A parked regeneration requires 30 to 60 minutes to complete.
		• You must have at least a 1/4 tank of fuel in the tank.
		• You must park the machine to perform a recovery regeneration.
		Refer to Parked Regeneration.
Recovery	Occurs as a result of ignoring parked regeneration requests and continuing operation, adding more soot when the DPF is already in need of a parked regeneration	When the recovery-regeneration icon is displayed in the InfoCenter, a recovery regeneration is requested.
		Contact your Authorized Toro Distributor to have a service technician perform the recovery regeneration.
		• A recovery regeneration requires up to 4 hours to complete.
		• You must have at least a 1/2 tank of fuel in the machine.
		• You must park the machine to perform a recovery regeneration.
		Refer to Recovery Regeneration.

• Passive regeneration occurs as part of normal engine operation.

• While operating the machine, run the engine at full-engine speed when possible to promote DPF regeneration.

Figure 43

Assist/reset-regeneration icon

• The assist/reset-regeneration icon displays in the InfoCenter (Figure 43).

• The computer takes control of the intake throttle to increase the temperature of the engine exhaust.

• While operating the machine, run the engine at full engine speed when possible to promote DPF regeneration.

• The icon displays in the InfoCenter while the assist regeneration is processing.

• Whenever possible, do not shut off the engine or reduce engine speed while the assist regeneration is processing.

  Important: Allow the machine to complete the assist regeneration process before shutting off the engine.

  Note: The assist regeneration is finished processing when the icon disappears from the InfoCenter.

Figure 44

Assist/reset-regeneration icon

• The assist/reset-regeneration icon displays in the InfoCenter (Figure 44).

• The computer takes control of the intake throttle and changes the fuel injection operation to increase the temperature of the engine exhaust.

  Important: The assist/reset-regeneration icon indicates that the exhaust temperature discharged from of your machine may be hotter than during regular operation.

• While operating the machine, run the engine at full engine speed when possible to promote DPF regeneration.

• The icon displays in the InfoCenter while the reset regeneration is processing.

• Whenever possible, do not shut off the engine or reduce engine speed while the reset regeneration is processing.

  Important: Allow the machine to complete the reset regeneration process before shutting off the engine.

  Note: The reset regeneration is finished processing when the icon disappears from the InfoCenter.

Figure 45

Parked-regeneration request icon

• The parked-regeneration requested icon displays in the InfoCenter (Figure 45).

• If a parked regeneration is needed, the InfoCenter displays engine warning SPN 3719, FMI 16 (Figure 46) and the engine computer derates engine power to 85%.

  

  Figure 46

  Important: If you do not complete a parked regeneration within 2 hours, the engine computer derates engine power to 50%.

• A parked regeneration requires 30 to 60 minutes to complete.

• If you are authorized by your company, you need the PIN code to perform the parked-regeneration process.

• If you ignore the request for a parked regeneration (displayed in the InfoCenter) and continue to operate the machine, a critical amount of soot builds up in the DPF.

• If a recovery regeneration is needed, the InfoCenter displays engine warning SPN 3719, FMI 16 (Figure 58) and the engine computer derates engine power to 85%.

  

  Figure 58

  Important: If you do not complete a recovery regeneration within 15 minutes, the engine computer derates engine power to 50%.

• Perform a recovery-regeneration whenever there is a loss of engine power and a parked regeneration cannot effectively clean the DPF of soot.

• A recovery regeneration requires up to 4 hours to complete.

• You need a distributor technician to perform the recovery regeneration process; contact your Authorized Toro Distributor.

Before mowing grass, practice operating the machine in an open area. Start and stop the engine. Operate in forward and reverse. Lower and raise the cutting units and engage and disengage the reels. When you feel familiar with the machine, practice operating up and down slopes at different speeds.

If a warning light comes on during operation, stop the machine immediately and correct the problem before continuing operation. Serious damage could occur if you operate the machine with a malfunction.

Start the engine and move the engine speed switch to the Fast position. Move the Mow Speed Limiter to the mow position. Move the PTO switch to the ON position and use the Lift Switch to control the cutting units (the front cutting units are timed to lower before the rear cutting units). To move forward and cut grass, press the traction pedal forward.

Move the PTO switch to the OFF position and raise the cutting units to the transport position. Move the Mow Speed Limiter to the transport position. Be careful when driving between objects so 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 roll overs. Lower the cutting units when going downhill for steering control.

1. Release hood latches (Figure 63) and pivot open the hood.

   

   Figure 63

   1. Hood latch (2)

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

The machine has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. If the machine is operated under normal conditions, lubricate all bearings and bushings after every 50 hours of operation or immediately after every washing.

The grease fitting locations and quantities are as follows:

• Brake shaft pivot bearings (5) (Figure 64)

  

  Figure 64

• Rear axle pivot bushings (2) (Figure 65)

  

  Figure 65

• Steering cylinder ball joints (2) (Figure 66)

  

  Figure 66

  1. Top fitting on king pin

• Tie rod ball joints (2) (Figure 66)

• King pin bushings (2) (Figure 66). The top fitting on the king pin should only be lubricated annually (2 pumps).

• Lift arm bushings (1 per cutting unit) (Figure 67)

  

  Figure 67

• Lift cylinder bushings (2 per cutting unit) (Figure 67)

• Lift arm pivot bushings (1 per cutting unit) (Figure 68)

• Cutting unit carrier frame (2 per cutting unit) (Figure 68)

• Cutting unit lift arm pivot (1 per cutting unit) (Figure 68)

  

  Figure 68

Check the air cleaner body for damage which could cause an air leak. Replace if damaged. Check the whole intake system for leaks, damage or loose hose clamps.

Service the air cleaner filter only when the service indicator (Figure 69) requires it. Changing the air filter before it is necessary only increases the chance of dirt entering the engine when the filter is removed.

Figure 69

1. Air cleaner indicator

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

1. Pull the latch outward and rotate the air cleaner cover counterclockwise (Figure 70).

   

   Figure 70

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

2. Remove the cover from the air cleaner body. Before removing the filter, use low pressure air (40 psi, clean and dry) to help remove large accumulations of debris packed between outside of primary filter and the canister. Avoid using high pressure air which could force dirt through the filter into the intake tract.

   This cleaning process prevents debris from migrating into the intake when the primary filter is removed.

3. Remove and replace the primary filter (Figure 71).

   Cleaning of the used element is not recommended due to the possibility of damage to the filter media. Inspect the new filter for shipping damage, checking the sealing end of the filter and the body. Do not use a damaged element. Insert the new filter by applying pressure to the outer rim of the element to seat it in the canister. Do not apply pressure to the flexible center of the filter.

   

   Figure 71

   1. Air cleaner primary filter

   Important: Never attempt to clean the safety filter (Figure 72). Replace the safety filter with a new one after every three primary filter services.

   

   Figure 72

   1. Air cleaner safety filter

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

5. Install the cover orienting the rubber outlet valve in a downward position—between approximately 5:00 to 7:00 when viewed from the end.

6. Reset the indicator (Figure 69) if it shows red.

• If advisory message displays in the InfoCenter, the DPF is nearing the recommended point for servicing the diesel-oxidation catalyst and the soot filter.

  

  Figure 76

• If engine faults , , or in the InfoCenter (Figure 77) display in the InfoCenter, clean the soot filter using the steps that follow:

  

  Figure 77

  1. Refer to the Engine section in the Service Manual for information on disassembling and assembling the diesel-oxidation catalyst and the soot filter of the DPF.

  2. Refer to your Authorized Toro Distributor for diesel-oxidation catalyst and the soot filter replacement parts or service.

  3. Contact your Authorized Toro Distributor to have them reset the engine ECU after you install a clean DPF.

Drain and clean the fuel tank every 800 hours. Also, drain and clean the tank if fuel system becomes contaminated or if the machine will be stored for an extended period of time. Use clean fuel to flush out the tank.

Check the fuel lines and connections every 400 hours or yearly, whichever comes first. Inspect them for deterioration, damage, or loose connections.

Drain water or other contaminants from water separator daily. Replace filter canister after every 400 hours of operation.

1. Place a clean container under the fuel filter(Figure 78).

2. Loosen the drain plug on the bottom of the filter canister.

   

   Figure 78

   1. Water separator filter canister

3. Clean the area where the filter canister mounts.

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

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

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

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

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

1. Clean the area around the fuel filter head (Figure 79).

   

   Figure 79

   1. Fuel Filter head
   2. Fuel Filter

2. Remove the filter and clean the filter head mounting surface (Figure 79).

3. Lubricate the filter gasket with clean lubricating engine oil. Refer to the Engine Operator's Manual, included with the machine, for additional information.

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

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

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

1. Unlatch and raise the operator's console panel (Figure 80).

   

   Figure 80

   1. Operator's console panel
   2. Latch

   Danger

   Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns.

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

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

2. Connect a 3 to 4 amp. battery charger to the battery posts. Charge the battery at a rate of 3 to 4 amperes for 4 to 8 hours.

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

   Warning

   Charging the battery produces gasses that can explode.

   Never smoke near the battery and keep sparks and flames away from battery.

4. Install the positive cable (red) to the positive (+) terminal and the negative cable (black) to the negative (-) terminal of the battery (Figure 81). Secure cables to posts with capscrews and nuts. Make sure that the positive (+) terminal is all of the way onto the post and the cable is positioned snug to the battery. The cable must not contact the battery cover. Slide the rubber boot over the positive terminal to prevent a possible short from occurring.

   

   Figure 81

   1. Positive battery cable
   2. Negative battery cable

   Warning

   Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

5. Coat both battery connections with Grafo 112X (skin-over) grease, Toro Part No. 505-47, petroleum jelly, or light grease to prevent corrosion. Slide the rubber boot over the positive terminal.

6. Close the console panel and secure the latch.

   Warning

   Battery terminals or metal tools could short against metal components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury.

   • When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine.

   • Do not allow metal tools to short between the battery terminals and metal parts of the machine.

   Warning

   Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury.

   • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable.

   • Always connect the positive (red) battery cable before connecting the negative (black) cable.

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

Note: Check the battery condition weekly or after every 50 hours of operation. Keep the terminals and the entire battery case clean because a dirty battery will discharge slowly. To clean the battery, remove it from the machine, wash the entire case with a solution of baking soda and water. Rinse with clear water. Coat the battery posts and cable connectors with Grafo 112X (skin-over) grease (Toro Part No. 505-47) or petroleum jelly to prevent corrosion.

The fuses are located under the operators control panel.

Figure 82

Unhook the latch and raise the operator's console panel (Figure 83) to expose the fuses (Figure 84).

Figure 83

1. Operator's console panel
2. Latch

Figure 84

1. Fuses

Note: Front wheel nuts are 1/2-20 UNF. Rear wheel nuts are M12 x 1.6-6H (Metric).

Check the oil level after every 400 hours of operation. Use high quality SAE 85W-140 wt. gear lube as a replacement.

1. With machine on level surface, position the wheel so one check plug (Figure 85) is at the 12 o'clock position and the other is at 3 o'clock position.

   

   Figure 85

   1. Check/drain plug (2)

2. Remove the plug at the 3 o’clock position (Figure 85). Oil level should be at the bottom of the check plug hole.

3. If the oil level is low, remove the 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. Re-install both plugs.

5. Repeat steps 1 through 4 on the opposite planetary gear assembly.

Change the oil initially after first 200 hours of operation. Thereafter, change the oil every 800 hours, or yearly, whichever occurs first. Use a high quality SAE 85W-140 wt. gear lube as replacement.

1. With the machine on a level surface, position a wheel so that one of the check plugs is at the lowest (6 o'clock) position (Figure 86).

   

   Figure 86

   1. Check/drain plug

2. Place a drain pan under the planetary hub, remove plug and allow oil to drain.

3. Place a drain pan under the brake housing, remove the drain plug and allow the oil to drain (Figure 87).

   

   Figure 87

   1. Brake housing
   2. Drain plug

4. When all of the oil has drained from both locations, re-install the plug in the brake housing.

5. Rotate the wheel until the open plug hole in the planetary is at the twelve o'clock position.

6. Through the open hole, slowly fill the planetary with 0.65 liter (22 ounces) of high quality SAE 85W-140 wt. gear lube.

   Important: If the planetary fills before the 0.65 liter (22 ounces) of oil is added, wait one hour or install the plug and move the machine approximately ten feet to distribute the oil through the brake system. Then, remove the plug and add the remaining oil.

7. Re-install the plug.

8. Repeat the procedure on the opposite planetary/brake assembly.

The rear axle is shipped from the factory filled with SAE 85W-140 wt. gear lube. Check the oil level before the engine is first started and every 400 hours thereafter. The capacity is 80 oz. (2.4l). Visually inspect for leaks daily.

1. Position the machine on a level surface.

2. Remove a check plug from one end of the axle (Figure 88) and make sure that the lubricant is up to the bottom of the hole. If the level is low, remove the fill plug (Figure 88) and add enough lubricant to bring the level up to the bottom of the check plug holes.

   

   Figure 88

   1. Check plug
   2. Fill plug

1. Position the machine on a level surface.

2. Clean the area around the 3 drain plugs, 1 on each end and 1 in the center (Figure 89).

   

   Figure 89

   1. Drain plug location

3. Remove the (3) oil level check plugs and main axle vent cap to ease in draining of the oil.

4. Remove the drain plugs and allow the oil to drain into the pans.

5. Install the plugs.

6. Remove a check plug and fill axle with approximately 80 oz. of 85W-140 gear lube or until lubricant is up to bottom of hole.

7. Install check plug.

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

1. Park machine on a level surface, shut engine off, position speed control into LOW range and lower cutting units to the floor. Depress only the right brake pedal and engage the parking brake.

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

3. Start engine and allow run at low idle.

4. Adjust jam nuts on pump rod end to move pump control tube forward to eliminate forward creep or rearward to eliminate rearward creep (Figure 90).

   

   Figure 90

   1. Pump rod jam nuts
   2. Pump control tube

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

6. Stop the engine and release the right brake. Remove jack stands and lower the machine to the shop floor. Test drive the machine to make sure it does not creep.

1. Measure the center-to-center distance (at axle height) at the front and rear of the steering tires. The front measurement must be 3 mm (1/8 inch) less than the rear measurement (Figure 91).

   

   Figure 91

   1. Front of traction unit
   2. 1/8 inch less than rear of tire
   3. Center to center distance

2. To adjust, remove the cotter pin and nut from either tie rod ball joint (Figure 92). Remove tie rod ball joint from axle case support.

   

   Figure 92

   1. Tie rod clamp
   2. Tie rod ball joint

3. Loosen the clamps at both ends of the tie rods (Figure 92).

4. Rotate the detached ball joint inward or outward one (1) complete revolution. Tighten clamp at loose end of tie rod.

5. Rotate the entire tie rod assembly the same direction (inward or outward) one (1) complete revolution. Tighten clamp at connected end of tie rod.

6. Install the ball joint in the axle case support and tighten the nut finger tight. Measure toe-in.

7. Repeat procedure if necessary.

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

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

1. Unlatch and swing open rear screen (Figure 93). Clean the screen thoroughly of all debris.

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

   

   Figure 93

   1. Rear screen latch

2. Clean both sides of the oil cooler/radiator area (Figure 94) thoroughly with compressed air. Start from the front and blow the debris out towards the back. Then clean from the back side and blow towards the front. Repeat procedure several times until all chaff and debris is removed.

   

   Figure 94

   1. Oil cooler/radiator

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

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

Adjust the service brakes when there is more than 13 mm (1/2 inch) of “free travel" of the brake pedal, or when the brakes do not work effectively. Free travel is the distance the brake pedal moves before braking resistance is felt.

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

2. To reduce free travel of the brake pedals, tighten the brakes:

   1. Loosen the front nut on the threaded end of the brake cable (Figure 95).

      

      Figure 95

      1. Brake cable

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

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

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

Check the condition and tension of the belts (Figure 96) after every 100 operating hours.

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

2. If the deflection is not 10 mm (3/8 inch), loosen the alternator mounting bolts (Figure 96). Increase or decrease the alternator belt tension and tighten the bolts. Check the deflection of the belt again to ensure that the tension is correct.

   

   Figure 96

   1. Alternator
   2. Mounting bolt

Change the hydraulic fluid after every 800 operating hours, in normal conditions. If the fluid becomes contaminated, contact your local Toro distributor because the system must be flushed. Contaminated fluid looks milky or black when compared to clean oil.

1. Turn the engine off and raise the hood.

2. Disconnect the case return line from the bottom of the reservoir and let the hydraulic fluid flow into a large drain pan. Connect the line when the hydraulic fluid stops draining.

3. Fill the reservoir with approximately 28.4liters (7.5 gallons) of hydraulic fluid; refer to Checking the Hydraulic Fluid.

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

4. Install the reservoir cap. Start the engine and use all of the hydraulic controls to distribute hydraulic fluid throughout the system. Also check for leaks; then stop the engine.

5. Check the fluid level and add enough to raise the level to the FULL mark on the dipstick. Do not overfill.

Change the 2 hydraulic filters initially after the first 200 operating hours. Thereafter, change the filters after every 800 operating hours, in normal conditions.

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

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

1. Position the machine on a level surface, lower the cutting units, stop the engine, engage the parking brakes, and remove the ignition key.

2. Clean the area around the filter mounting area. Place a drain pan under the filter and remove the filter (Figure 97 and Figure 98).

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

   

   Figure 97

   1. Hydraulic filter
   

   Figure 98

   1. Hydraulic filter

4. Ensure that the filter mounting area is clean. Screw the filter on until the gasket contacts the mounting plate; then tighten the filter an additional 1/2 turn.

5. Start the engine and let it run for about two minutes to purge air from the system. Stop the engine and check for leaks.

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

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

1. Position the machine on a level surface, lower the cutting units, stop the engine, engage the parking brake, and move the PTO switch to OFF position.

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

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

4. Select either front, rear or both backlap levers to determine which units to backlap (Figure 99).

5. Start the engine and run at low idle speed.

   Danger

   Changing the engine speed while backlapping may cause the reels to stall.

   • Never change the engine speed while backlapping.

   • Only backlap at low idle engine speed.

   Danger

   To avoid personal injury, be certain that you are clear of the cutting units before proceeding.

6. With the Mow Speed Limiter in the mow position, move the PTO switch to the ON position. Press the Lift Switch to start the backlapping operation on the designated reels.

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

   

   Figure 99

   1. Front backlap lever
   2. Rear backlap lever

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

9. To make an adjustment to the cutting units while backlapping, turn the reels off by pressing the rear of the lift switch; move the PTO switch to the OFF position, and stop the engine. After completing adjustments, repeat steps through 8.

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

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

    Important: If the backlap switch is not returned to the Off position after backlapping, the cutting units will not raise or function properly.

    Note: Additional instructions and procedures on backlapping are available in the TORO Sharpening Reel & Rotary Mowers Manual Form No. 80–300SL.

    Note: For a better cutting edge, run a file across the front face of the bedknife after lapping. This will remove any burrs or rough edges that may have built up on the cutting edge.