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 people or damage to property.

• While mowing, always wear appropriate clothing, including eye protection, substantial, slip-resistant footwear, long trousers, and ear protection.

• Tie back long hair. Do not wear jewelry.

• 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 fuel. Fuel 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 machine when ill, tired, or 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 fasteners tight to be sure that 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 risk of fire, keep the engine, silencer/muffler, battery compartment and fuel storage area free of grass, leaves, or excessive grease. Clean up oil or fuel spillage.

• 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.

• 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 36).

   

   Figure 36

   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: Bleed the fuel system 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 the pedal is in the neutral position.

   Note: 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.

   Note: The glow indicator will light.

4. When the glow indicator dims, turn the ignition key to the Start position.

5. Release the key immediately when the engine starts and allow it to return to the Run position.

6. 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

   Contact with moving parts could cause injury.

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

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

Note: Lower the cutting units to the ground whenever you park the machine. 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 38 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 39 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 40 Advisory #179	None	100%	Notify your service department that advisory #179 displays in the InfoCenter.
Level 2: Engine Warning	Figure 41 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 42 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 43 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 44

Assist/reset-regeneration icon

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

• 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 45

Assist/reset-regeneration icon

• The assist/reset-regeneration icon displays in the InfoCenter (Figure 45).

• 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 46

Parked-regeneration request icon

• The parked-regeneration requested icon displays in the InfoCenter (Figure 46).

• If a parked regeneration is needed, the InfoCenter displays engine warning SPN 3719, FMI 16 (Figure 47) and the engine computer derates engine power to 85%.

  

  Figure 47

  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 59) and the engine computer derates engine power to 85%.

  

  Figure 59

  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.

Important: If you need to push or tow the machine in reverse, you must first bypass the check valve in the 4-wheel-drive manifold.

The following Toro parts are needed to bypass the check valve:

• 59-7410, diagnostic fitting

• 354-79, diagnostic-fitting cap

• 95-8843, hydraulic hose

• 95-0985, coupler fitting (2)

• 340-77, hydraulic fitting (2)

1. Install a diagnostic fitting in the unmarked port located between ports M8 and P2 on the rear traction manifold (Figure 62).

   

   Figure 62

   1. Rear traction manifold (behind front left wheel)
   2. Unmarked port

2. Connect a hydraulic hose between the diagnostic fitting installed in the rear traction manifold and the reverse traction pressure test port (Figure 63).

   Note: Use the hydraulic fittings and coupler fittings as needed to install the hose.

   

   Figure 63

   1. Reverse traction pressure test port
   2. Hydraulic fluid return filter

3. Rotate the bypass valve 90° (1/4 turn) in either direction to open it and allow fluid to bypass internally (Figure 64).

   Note: Because the fluid bypasses the transmission, you can move the machine slowly without damaging the transmission.Note the position of the valve when opening and closing it.

   

   Figure 64

   1. Bypass valve

4. When you are finished pushing or towing the machine, remove the hydraulic hose that you installed.

5. Install the existing cap onto the reverse traction pressure test port.

6. Install the diagnostic-fitting cap onto the fitting that you installed on the manifold.

7. Rotate the bypass valve 90° (1/4 turn) back before starting the engine.

   Note: Do not exceed 7 to 11 N·m (5 to 8 ft-lb) torque to close the valve.

If you need to push or tow the machine forward only, you can just rotate the bypass valve.

Important: If you need to push or tow the machine in reverse, refer to Preparing the Machine for Pushing or Towing in Reverse.

1. Open the hood and remove the center shroud.

2. Rotate the bypass valve 90° (1/4 turn) in either direction to open it and allow fluid to bypass internally (Figure 64).

   Note: Because the fluid bypasses the transmission, you can move the machine forward slowly without damaging the transmission.Note the position of the valve when opening and closing it.

3. Rotate the bypass valve 90° (1/4 turn) back before starting the engine.

   Note: Do not exceed 7 to 11 N·m (5 to 8 ft-lb) torque to close the valve.

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 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 rollovers. Lower the cutting units when going downhill for steering control.

1. Release the hood latches (Figure 66) and pivot open the hood.

   

   Figure 66

   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 lithium 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 67)

  

  Figure 67

• Rear axle pivot bushings (2) (Figure 68)

  

  Figure 68

• Steering cylinder ball joints (2) (Figure 69)

  

  Figure 69

  1. Top fitting on king pin

• Tie rod ball joints (2) (Figure 69)

• King pin bushings (2) (Figure 69). The top fitting on the king pin should only be lubricated annually (2 pumps).

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

  

  Figure 70

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

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

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

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

  

  Figure 71

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 (Figure 72) 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 72

1. Service indicator

Important: Be sure that 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 73).

   

   Figure 73

   1. Service indicator
   2. Latch
   3. Cover

2. Remove the cover from the air-cleaner body.

3. Before removing the filter, use low-pressure air—275 kPa (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.

4. Remove and replace the primary filter (Figure 74).

   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 74

   1. Primary filter

   Important: Never attempt to clean the safety filter (Figure 75). Replace the safety filter with a new one after every 3 primary filter services.

   

   Figure 75

   1. Safety filter

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

6. Remove the rubber outlet valve from the cover, clean the cavity, and install the outlet valve.

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

8. Reset the indicator (Figure 72) 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 79

• If engine faults , , or in the InfoCenter (Figure 80) display in the InfoCenter, clean the soot filter using the steps that follow:

  

  Figure 80

  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 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.

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

1. Place a clean container under the fuel filter.

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

   

   Figure 81

   1. 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 82).

   

   Figure 82

   1. Fuel-filter head
   2. Fuel filter

2. Remove the filter and clean the filter-head mounting surface (Figure 82).

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-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. Unlatch and raise the operator's console panel (Figure 83).

   

   Figure 83

   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 A  battery charger to the battery posts.

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

4. 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.

5. Install the positive cable (red) to the positive (+) terminal and the negative cable (black) to the negative (-) terminal of the battery (Figure 84).

   

   Figure 84

   1. Positive battery cable
   2. Negative battery cable

6. Secure the cables to the 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.

7. Slide the rubber boot over the positive terminal to prevent a possible short from occurring.

   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.

8. Coat both battery connections with Grafo 112X (skin-over) grease, Toro Part No. 505-47, petroleum jelly, or light grease to prevent corrosion.

9. Slide the rubber boot over the positive terminal.

10. 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. .

Clean the battery as follows:

1. Remove the battery from the machine.

2. Wash the entire case with a solution of baking soda and water.

3. Rinse the case with clean water.

4. 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 operator’s control panel.

Figure 85

Unhook the latch and raise the operator's console panel (Figure 86) to expose the fuses (Figure 87).

Figure 86

1. Operator's console panel
2. Latch

Figure 87

1. Fuses

Note: The front wheel nuts are 1/2–20 UNF. The 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 gear lube as a replacement.

1. With the machine on a level surface, position the wheel so that 1 check plug (Figure 88) is at the 12 o'clock position and the other is at the 3 o'clock position.

   

   Figure 88

   1. Check/drain plug (2)

2. Remove the plug at the 3 o’clock position (Figure 88).

   Note: The oil level should be at the bottom of the 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. 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 gear lube as a replacement.

1. With the machine on a level surface, position a wheel so that 1 of the check plugs is at the lowest (6 o'clock) position (Figure 89).

   

   Figure 89

   1. Check/drain plug

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

3. Place a drain pan under the brake housing, remove the drain plug, and allow the oil to drain (Figure 90).

   

   Figure 90

   1. Brake housing
   2. Drain plug

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

5. Rotate the wheel until the open plug hole in the planetary is at the 12 o'clock position.

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

   Important: If the planetary fills before the 0.65 liters (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. 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 gear lube. Check the oil level before the engine is first started and every 400 hours thereafter. The capacity is 2.4 L (80 fl oz). Visually inspect for leaks daily.

1. Position the machine on a level surface.

2. Remove a check plug from 1 end of the axle (Figure 91) and make sure that the oil is up to the bottom of the hole. If the level is low, remove the fill plug (Figure 91) and add enough oil to bring the level up to the bottom of the check-plug holes.

   

   Figure 91

   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 92).

   

   Figure 92

   1. Drain plugs

3. Remove the oil-level-check plugs and the 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 the axle with approximately 2.37 L (80 fl oz) of 85W-140 gear lube or until the oil is up to the bottom of the hole.

7. Install the check plug.

The gear box is filled with SAE 85W-140 gear lube. Check the oil level before the engine is first started and every 400 hours thereafter. The capacity is 0.5 L (16 fl oz). Visually inspect for leaks daily.

1. Position the machine on a level surface.

2. Remove the check/fill plug from the left side of the gear box (Figure 93) and make sure that lubricant is up to the bottom of the hole. If the level is low, add enough lubricant to bring the level up to the bottom of the hole.

   

   Figure 93

   1. Gear box
   2. Check/fill plug

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

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

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.

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

5. Adjust the jam nuts on the pump rod end to move the pump control tube forward to eliminate forward creep or rearward to eliminate rearward creep (Figure 94).

   

   Figure 94

   1. Pump-rod jam nuts
   2. Pump control tube

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

7. Stop the engine and release the right brake.

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

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

1. 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 95).

   

   Figure 95

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

2. To adjust the toe-in, remove the cotter pin and the nut from either tie-rod ball joint (Figure 96).

   

   Figure 96

   1. Tie-rod clamp
   2. Tie-rod ball joint

3. Remove the tie-rod ball joint from the axle case support.

4. Loosen the clamps at both ends of the tie rods (Figure 96).

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

6. Tighten the clamp at the loose end of the tie rod.

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

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

9. Install the ball joint in the axle case support and tighten the nut finger tight.

10. Measure the toe-in.

11. Repeat the procedure if necessary.

12. 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 the rear screen (Figure 97).

   

   Figure 97

   1. Rear screen latch

2. Clean the screen thoroughly of all debris.

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

3. Clean both sides of the oil cooler/radiator area (Figure 98) 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.

   

   Figure 98

   1. Oil cooler/radiator

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

4. 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 as follows:

   1. Loosen the front nut on the threaded end of the brake cable (Figure 99).

      

      Figure 99

      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 that 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 100) after every 100 operating hours.

1. Proper tension will allow 10 mm (3/8 inch) deflection when a force of 45 N (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 100).

   

   Figure 100

   1. Alternator
   2. Mounting bolt

3. Increase or decrease the tension of the alternator belt and tighten the bolts.

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

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 fluid.

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.

3. Connect the line when the hydraulic fluid stops draining.

4. Fill the reservoir with approximately 28.4 L (7.5 US gallons) of hydraulic fluid; refer to Checking the Level of the Hydraulic Fluid.

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

5. Install the reservoir cap.

6. Start the engine and use all of the hydraulic controls to distribute hydraulic fluid throughout the system.

7. Check for leaks and stop the engine.

8. Check the fluid level and add enough to raise the level to the Full mark on the dipstick.

   Note: Do not overfill the hydraulic system.

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.

3. Place a drain pan under the filter and remove the filter (Figure 101 and Figure 102).

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

   

   Figure 101

   1. Hydraulic filter
   

   Figure 102

   1. Hydraulic filter

5. Ensure that the filter mounting area is clean.

6. Screw the filter on until the gasket contacts the mounting plate; then tighten the filter an additional 1/2 turn.

7. Start the engine and let it run for about 2 minutes to purge air from the system.

8. 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 the 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 103).

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

   Contact with the cutting units could cause 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.

7. Press the Lift Switch to start the backlapping operation on the designated reels.

8. Apply lapping compound with a long-handled brush.

   Note: Do not use a short-handled brush.

   

   Figure 103

   1. Front-backlap lever
   2. Rear-backlap lever

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

10. 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 any adjustments, repeat steps 5 through 9.

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

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

    Important: If you do not return the backlap switch 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 and 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.