Reelmaster® 3555, 3575, and 3550 Traction Units

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

2. Remove the reel motors from the shipping brackets.

3. Remove and discard the shipping brackets.

4. Remove the cutting units from the cartons. Assemble and adjust them as described in the cutting unit Operator's Manual.

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

   

   Figure 3

   1. Counterweight

All the cutting units are shipped with the turf compensation spring mounted at the right side of the cutting unit. Ensure that the turf compensation spring is mounted to the same side of the cutting unit as the reel drive motor.

Note: When installing or removing the cutting units, make sure that the hairpin cotter is installed in the spring rod hole next to the rod bracket. Otherwise, install the hairpin cotter in the hole in the end of the rod.

1. Remove the 2 carriage bolts and nuts securing the rod bracket to the cutting unit tabs (Figure 4).

   

   Figure 4

   1. Turf compensation spring
   2. Rod bracket
   3. Spring tube

2. Remove the flange nut securing the spring tube bolt to the carrier frame tab (Figure 4), and remove the assembly.

3. Mount the spring tube bolt to the opposite tab on the carrier frame and secure it with the flange nut.

   Note: Position the bolt head to the outer side of the tab as shown in Figure 4.

   

   Figure 5

   1. Opposite carrier frame tab
   2. Rod bracket

4. Mount the rod bracket to the cutting unit tabs with the carriage bolts and nuts (Figure 5).

Models 03820 and 03821

On cutting unit 4 (left front) and cutting unit 5 (right front), use the rod-bracket mounting nuts to install the hose guides to the front of the cutting-unit tabs. The hose guides should lean toward the center cutting unit (Figure 6, Figure 7, and Figure 8).

All Front Cutting Units, and Any Rear Cutting Units with a 1.2 cm (3/4 inch) or Lower Height of Cut

1. Lower all the lift arms completely.

2. Remove the snapper pin and the cap from the lift-arm pivot yoke (Figure 9).

   

   Figure 9

   1. Snapper pin
   2. Cap

3. For the front cutting units, slide a cutting unit under the lift arm while inserting the carrier frame shaft up into the lift-arm pivot yoke (Figure 10).

   

   Figure 10

   1. Lift arm
   2. Carrier frame shaft
   3. Lift-arm pivot yoke

Cutting Units adjusted for a 1.2 cm (3/4 inch) or Higher Height of Cut

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 11).

   

   Figure 11

   1. Lift-arm shaft lynch pin and washer

2. Insert the lift-arm yoke onto the carrier frame shaft (Figure 10).

3. Insert the lift-arm shaft into the lift arm and secure it with the washer and lynch pin (Figure 11).

1. Insert the cap over the carrier frame shaft and lift-arm yoke.

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

   Note: Use the slot if a steering cutting unit is desired or use the hole if the cutting unit is to be locked in position (Figure 9).

3. Secure the lift-arm chain to the chain bracket with the snapper pin (Figure 12).

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

   

   Figure 12

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

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

2. Lubricate the reel-motor O-ring with oil, and install it onto the motor flange.

3. Install the motor by rotating it clockwise so that the motor flanges clear the locknuts (Figure 13).

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

   

   Figure 13

   1. Reel-drive motor
   2. Mounting nuts

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

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

1. Wipe clean the left frame near the model/serial plate with alcohol, and allow the frame to dry (Figure 21).

   

   Figure 21

   1. Model/serial plate
   2. Year of production decal

2. Remove the backing and apply the Year of Production decal to the frame near the serial plate as shown in Figure 21.

3. Wipe clean the left frame near the hood lock with alcohol, and allow the frame to dry (Figure 22).

   

   Figure 22

   1. CE hood latch
   2. CE decal (Part No. 133-8095)

4. Remove the backing and apply the CE decal Part No. 133-8095 to the frame as shown in Figure 22.

Machine Model 03910

1. Wipe clean the standard warning decal with alcohol, and allow the frame to dry (Figure 23).

   

   Figure 23

   1. CE warning decal (Part No. 121-7928)
   2. Standard warning decal

2. Remove the backing and apply the CE warning decal (Part No. 121-7928) over the standard warning decal as shown in Figure 23.

Machine Models 03820 and 03821

1. Wipe clean the standard warning decal with alcohol, and allow the frame to dry (Figure 24).

   

   Figure 24

   1. CE warning decal (Part No. 138-1186)
   2. Standard warning decal

2. Remove the backing and apply the CE warning decal (Part No. 138-1186) over the standard warning decal as shown in Figure 24.

Use the reel speed knob of the mower manifold to adjust the clip rate (reel speed) of the cutting units (Figure 30).

• Turn the reel speed knob counterclockwise to increase the reel speed.

• Turn the knob clockwise to slow the reel speed.

Refer to Clip Rate (Reel Speed) and Setting the Reel Speed for information on how to adjust the reel speed control.

The backlap lever to control the direction the cutting units rotate when you are mowing or when you backlap the reels and bedknives (Figure 30).

• Rotate the backlap lever to the F position when mowing.

• Rotate the lever to the R position when backlapping the cutting units.

Important: Do not change the backlap lever position while the reels are rotating.

Use only clean, fresh diesel fuel with ultra low (<15 ppm) or low (<1000 ppm) sulfur content. Purchase fuel in quantities that can be used within 180 days to ensure fuel freshness.

Important: If you use high-sulfur diesel fuel (sulfur content 0.50 % (5000 ppm) to 1.0 % (10000 ppm), change the engine oil and oil filter every 75 hours.

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

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

Fuel tank capacity: approximately 28 L (7.5 US gallons).

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

2. Clean the area around the fuel-tank cap (Figure 31).

   

   Figure 31

   1. Fuel-tank cap

3. Remove the fuel-tank cap.

4. Fill the tank to the bottom of the filler neck.

   Note: Do not overfill the fuel tank.

5. Install the cap.

6. Wipe up any spilled fuel.

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.

1. Start the engine, raise the cutting units, disengage the parking brake, and move the machine to an open flat area.

2. Engage the parking brake (Figure 32).

   

   Figure 32

3. Press the traction pedal to move the machine forward.

   Note: If the machine moves forward with the parking brake engaged, adjust parking brake; refer to Adjusting the Parking Brake.

   Note: Moving the machine forward with the parking brake engaged will cause the engine to shut off.

4. If you adjusted the parking brake, repeat steps 2 and 3.

   Note: If the machine moves forward with the parking brake engaged: service the parking brakes, check left and right brake linkage for damage, and check the brake lever pivot for damage; refer to Servicing the Parking Brakes.

5. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operator’s seat.

You may need to bleed the fuel system if any of the following situations have occurred; refer to Bleeding the Fuel System:

• You are starting the engine for the first time.

• The engine shut off because you ran the fuel tank empty.

• Someone performed fuel system maintenance, such as replacing the fuel filter.

1. Engage the parking brake and the press cutting unit drive switch to the DISENGAGE position (Figure 34).

   

   Figure 34

   1. Cutting unit drive switch
   2. Lower mow/raise control
   3. Disengage
   4. Lower

2. Remove your foot from the traction pedal and ensure that the pedal is in the NEUTRAL position.

3. Move the throttle lever to the 1/2 throttle position.

4. Insert the key into the switch and rotate it to the ON/PREHEAT position. Wait until the glow-plug indicator light shuts off (approximately 7 seconds).

5. Rotate the key to the START position to energize the starter motor; release the key when the engine starts.

   Important: To prevent overheating of the starter motor, do not engage the starter for longer than 15 seconds. After 10 seconds of continuous cranking, wait 60 seconds before engaging the starter motor again.

6. When you start the engine for the first time or after an overhaul of the engine, operate the machine in forward and reverse for 1 to 2 minutes. Also operate the lift lever and cutting unit drive switch to ensure proper operation of all traction and cutting unit systems.

   Turn the steering wheel to the left and right to check steering response; then shut off the engine and check for oil leaks, loose parts, and any other noticeable malfunctions.

   Caution

   Contact with moving parts could result in injury.

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

1. Move the throttle control to the IDLE position.

2. Engage the parking brake.

3. Move the cutting unit drive switch to DISENGAGE (Figure 35).

   

   Figure 35

   1. Cutting unit drive switch
   2. Lower mow/raise control
   3. Disengage
   4. Lower

4. Move the mow/transport slide right, to the MOW position (Figure 39).

   

   Figure 36

   1. Mow/transport slid
   2. Mow

5. Use the lower mow/raise control lever to lower the cutting units (Figure 35).

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

To achieve a consistent, high quality of cut and a uniform after-cut appearance, it is important to match the reel speed to the height of cut.

Important: If the reel speed is too slow, you may notice visible clip marks. If the reel speed is too fast, the cut may have a fuzzy appearance.

To achieve a consistent, high quality of cut and a uniform after-cut appearance, you must set the reel speed controls (located under the seat) correctly.

1. Select the height of cut at which the cutting units are set.

2. Choose the desired ground speed best suited for conditions.

3. Use the graph on the reel speed chart decals (Figure 40 and Figure 41), to determine the proper reel speed setting.

   Note: Take note of the reel-speed number.

4. Open the platform cover (Figure 42).

   

   Figure 42

   1. Reel speed chart decal (platform cover)
   2. Mower manifold

5. Rotate the knob (Figure 43) of the mower manifold until the indicator arrow is in line with the reel-speed number that you determined in step 3.

   Note: You can increase or decrease the reel speed to compensate for turf conditions. When using baskets, increase the reel speed to improve collection performance.

   

   Figure 43

   1. Reel speed control knob

6. Close the platform cover.

For Models 03820 and 03821 Only

You can adjust the counterbalance on the lift arms of the rear cutting units to compensate for different turf conditions and to maintain a uniform height of cut in rough conditions or in areas of thatch buildup.

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

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

2. Insert a tube or similar object onto the long spring end to relieve the spring tension during the adjustment (Figure 44).

   Caution

   The springs are under tension and could cause personal injury.

   Use caution when adjusting the spring tension.

3. While relieving the spring tension, remove the bolt and locknut securing the spring actuator to the bracket (Figure 44).

   

   Figure 44

   1. Spring
   2. Spring actuator
   3. Additional hole locations

4. Move the spring actuator to the desired hole location and secure it with the bolt and the locknut.

5. Repeat the procedure on the remaining spring.

You can adjust the configuration of the springs on the lift arms of the rear cutting units to provide down pressure. This is to compensate for different turf conditions where more downward force is needed.

To change to the down pressure configuration, the catch plate must be removed in order to switch the two springs from one side and the short leg of spring must now ride up against the top lip of the catch assembly (Figure 45).

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

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

2. Insert a tube or similar object onto the long spring end to relieve the spring tension during the adjustment (Figure 45).

   Caution

   The springs are under tension and could cause personal injury.

   Use caution when adjusting the spring tension.

3. While relieving the spring tension, remove the bolt and locknut securing the spring actuator to the bracket (Figure 45)

4. Move the spring actuator to the desired hole location and secure it with the bolt and the locknut.

5. Repeat the procedure on the remaining spring.

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

3. Unlatch and raise the hood.

4. Open the air-bleed screw on the fuel-injection pump (Figure 46).

   

   Figure 46

   1. Fuel-injection pump bleed screw

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

   The electric fuel pump runs, forcing air out around the air-bleed screw.

   Note: Leave the key in the ON position until a solid stream of fuel flows out around the screw.

6. Tighten the screw and turn the ignition key to OFF.

Note: The engine should start after you follow the procedure above. However, if the engine does not start, air may be trapped between the injection pump and injectors; refer to Bleeding Air from the Injectors.

The machine is equipped with a diagnostic light that indicates if the electronic controller senses an electronic fault. The diagnostic light is located on the control panel (Figure 47). When the electronic controller is functioning correctly and you move the key switch to the ON position, the controller diagnostic light turns on for 3 seconds and turn off to indicate that the light is working properly.

If the engine shuts off, the diagnostic light illuminates steady until the you change key position. The light blinks if the controller detects a fault in the electrical system. After you repair the fault, the light resets when you turn the key switch to the OFF position.

In case of an emergency, you can tow the machine for a short distance; however, Toro does not recommend this as a standard procedure.

Important: Do not tow the machine faster than 3 to 4 km/h (2 to 3 mph) because it may damage the drive system. If you must move the machine a considerable distance, transport it on a truck or trailer.

1. Unlatch and open the hood.

2. Near the right hood latch, rotate the bypass-valve handle on the pump 90° (Figure 48).

   

   Figure 48

   1. Bypass valve

3. Close and latch the hood.

4. Connect the tow vehicle to the machine at the tie-down points; refer to Identifying the Tie-Down Points.

5. Sit in the operator’s seat, and if needed, use the parking brake to control your machine while being towed.

   Important: Do not start the engine while the bypass valve is open.

6. Before starting the engine, close the bypass valve by rotating it 90° (1/4 turn).

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

• Tie the machine down securely.

1. Park the machine on a level surface.

2. Engage the parking brake.

3. Press the cutting unit drive switch to the DISENGAGE position (Figure 50).

   

   Figure 50

   1. Cutting unit drive switch
   2. Lower mow/raise control
   3. Engage
   4. Disengage
   5. Lower
   6. Raise

4. Move the mow/transport slide right, to the MOW position.

   

   Figure 51

   1. Mow/transport slid
   2. Mow

5. Move the lower mow/raise control lever forward (Figure 50).

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

7. Wait for all parts to stop moving.

Remove the 2 knobs that secure the battery cover to the machine, and remove the cover (Figure 49).

1. Release the latches at the left side and right side of the hood (Figure 52).

   

   Figure 53

   1. Hood latch

2. Rotate the hood up and back (Figure 53).

   

   Figure 54

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

Use the following as machine-lift points:

• Front—the jack brackets of the front-axle tube (Figure 55).

• Rear—the rear-axle tube.

Grease Specification: No. 2 lithium grease

The machine has grease fittings that you must lubricate regularly. Dusty and dirty operating conditions could cause dirt to get into the bearings and bushings, resulting in accelerated wear. Lubricate the grease fittings immediately after every washing, regardless of the interval specified.

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

2. Grease fittings at the locations and for quantities are as follows:

   • Steering pivot (Figure 56)

     

     Figure 56

   • Front lift-arm pivots and lift cylinders (3 each); refer to Figure 57.

     

     Figure 57

   • Rear lift-arm pivots and lift cylinders (3 each side); refer to Figure 58.

     

     Figure 58

   • Cutting unit pivots (2 each); refer to Figure 59.

     

     Figure 59

   • Neutral adjust mechanism (Figure 60)

     

     Figure 60

   • Mow/transport slide (Figure 61)

     

     Figure 61

   • Belt tension pivot (Figure 62)

     

     Figure 62

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

Service Category

ACEA—E6

API—CH-4 or higher

JASO—DH-2

Preferred oil viscosity: SAE 15W-40 [-17ºC (above 0°F)]

Alternate oil viscosity: 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: Toro Premium Engine oil is available from a distributor in either 15W-40 or 10W-30 viscosity. See the parts catalog for part numbers.

Note: The best time to check the engine oil is when the engine is cool before it has been started for the day. If it has already been run, allow the oil to drain back down to the sump for at least 10 minutes before checking. If the oil level is at or below the Add mark on the dipstick, add oil to bring the oil level to the Full mark. Do not overfill. If the oil level is between the Full and Add marks, you do not need to add oil.

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

2. Unlatch and open the hood.

3. Remove the dipstick (Figure 63) and wipe it with a clean rag.

   

   Figure 63

   1. Dipstick

4. Push the dipstick down into the dipstick tube and ensure that it is seated fully, then pull the dipstick out and check the oil level.

5. If the oil level is low, remove the oil-fill cap (Figure 64) and gradually add small quantities 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 64

   1. Oil-fill cap

6. Install the oil-fill cap and dipstick.

7. Close and latch the hood.

Crankcase capacity: approximately 3.8 L (4.0 US qt) with the filter

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

2. Unlatch and open the hood, and wait for the engine to cool.

3. Remove either drain plug (Figure 65) and let the oil flow into a drain pan; when the oil stops flowing, install the drain plug.

   

   Figure 65

   1. Drain plugs

4. Remove the oil filter (Figure 66).

   

   Figure 66

   1. Oil filter

5. Apply a light coat of clean oil to the new filter seal and install the oil filter.

   Note: Do not overtighten the filter.

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

7. Close and latch the hood.

This Operator’s Manual contains more detailed fuel and fuel system maintenance information than the engine Owner’s Manual, which is a general-purpose reference relating to fuel and fuel maintenance.

Ensure that you understand that the fuel system maintenance, fuel storage, and fuel quality require your attention to avoid downtime and extensive engine repairs.

The fuel system has extremely tight tolerances due to the emissions and control requirements. Diesel fuel quality and cleanliness is more important for the longevity of today’s high-pressure common rail (HPCR) fuel-injection system used on diesel engines.

Important: Water or air in the fuel system will damage your engine! Do not assume that new fuel is clean. Ensure that your fuel is from a quality supplier, store your fuel correctly, and use your fuel supply within 180 days.

Important: If you do not follow the procedures for fuel filter replacement, fuel system maintenance, and fuel storage, the engine fuel system could fail prematurely. Perform all fuel system maintenance at the specified intervals or whenever the fuel is contaminated or its quality is poor.

Appropriate fuel storage is critical for your engine. Proper maintenance of fuel storage tanks is often overlooked and leads to the contamination of fuel delivered to the machine.

• Acquire only enough fuel that you will consume within 180 days. Do not use fuel that has been stored for more than 180 days. This helps eliminate water and other contaminates in the fuel.

• If you do not remove the water from the storage tank or machine fuel tank, it can lead to rust or contamination in the storage tank and fuel system components. Tank sludge developed by mold, bacteria, or fungus restricts flow and clogs the filter and fuel injectors.

• Inspect your fuel storage tank and machine fuel tank regularly to monitor the fuel quality in the tank.

• Ensure that your fuel comes from a quality supplier.

• If you find water or contaminants in your storage tank or machine fuel tank, work with your fuel provider to correct the problem and perform all fuel system maintenance.

• Do not store diesel fuel in tanks or canisters made with zinc-plated components.

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

Drain and clean the tank if the fuel system becomes contaminated or if the machine will 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. Unlatch and open the hood.

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

   Note: Repair or replace any damaged or worn the fuel lines or fittings.

4. Close and latch the hood.

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

2. Unlatch and open the hood, and wait for the engine to cool.

3. Place a clean container under the fuel filter.

4. Loosen the drain valve on the bottom of the filter canister (Figure 68).

   

   Figure 68

   1. Water separator/filter canister
   2. Vent plug
   3. Drain valve

5. Tighten the valve after draining.

6. Start the engine, check for leaks, and shut off the engine.

   Note: Repair all fuel leaks.

7. Close and latch the hood.

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

2. Unlatch and open the hood, and wait for the engine to cool.

3. Clean the area where the filter canister mounts (Figure 68).

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 the mounting surface; then rotate an additional 1/2 turn.

7. Start the engine, check for leaks, and shut off the engine.

   Note: Repair all fuel leaks.

8. Close and latch the hood.

Note: Use this procedure only if the fuel system has been purged of air through normal priming procedures and the engine does not start; refer to Bleeding the Fuel System.

1. When possible, preform each step in Preparing for Maintenance.

2. Unlatch and open the hood, and if the engine is hot wait for it to cool.

3. Loosen the tube nut for the fuel line to the No. 1 fuel-injector nozzle.

   

   Figure 69

   1. Fuel injectors

4. Move the throttle to the FAST position.

5. Turn the key in the key switch to the START position and watch the fuel flow around the connector. Turn the key to the OFF position when there is a continuous flow.

   Important: To prevent overheating of the starter motor, do not engage the starter for longer than 15 seconds. After 10 seconds of continuous cranking, wait 60 seconds before engaging the starter motor again.

6. Tighten the tube nut securely.

7. Clean any fuel from the engine.

8. Repeat steps 3 through 7 for the remaining fuel-injector nozzles.

9. Start the engine, check for leaks, and shut off the engine.

   Note: Repair all fuel leaks.

10. Close and latch the hood.

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

2. Remove the battery cover; refer to Removing the Battery Cover.

3. Remove the filler caps of the battery.

4. Maintain the battery electrolyte level in the battery cells with distilled or demineralized water.

   Note: Do not fill the cells above the bottom of the split ring inside each cell.

5. Install the filler caps with the vents pointing to the rear (toward the fuel tank).

6. Clean the top of the battery by washing it periodically with a brush dipped in ammonia or bicarbonate of soda solution. Flush the top surface with water after cleaning.

   Important: Do not remove the filler caps while cleaning.

7. Check the battery cable clamps and battery posts for corrosion. If corrosion occurs, perform the following:

   1. Disconnect the negative (–) battery cable.

   2. Disconnect the positive (+) battery cable.

   3. Clean the clamps and posts separately.

   4. Connect the positive (+) battery cable.

   5. Connect the negative (–) battery cable.

   6. Coat the clamps and terminals with battery terminal protector.

8. Check that the battery cable clamps are tight on the battery posts.

9. Install the battery cover.

Note: Store the machine where the temperature is cooler rather than warmer to prevent the battery from discharging more rapidly.

Note: Maintain the recommended pressure in all tires to ensure a good quality of cut and proper machine performance.

1. Measure the air pressure in each tire. The correct air pressure in the tires is 83 kPa (12 psi).

2. If needed, add air to of remove air from the tires until you measure 83 kPa (12 psi).

Torque the wheel nuts to 103 to 127 N∙m (76 to 94 ft-lb) in a crossing pattern.

Torque the axle hub nuts to 339 to 373 N∙m (250 to 275 ft-lb).

If the machine moves when the traction pedal is in the NEUTRAL position, adjust the traction cam.

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

2. Raise a front wheel and a rear wheel off the floor and place support blocks under the frame.

   Warning

   If the machine is not supported adequately, it may accidentally fall, injuring anyone under the machine.

   Raise a front wheel and the rear wheel off the ground; otherwise, the machine will move during adjustment.

3. Loosen the locknut on the traction adjustment cam (Figure 72).

   

   Figure 72

   1. Traction adjustment cam
   2. Locknut

   Warning

   The engine must be running so that you can make a final adjustment of the traction adjustment cam. Contact with hot or moving parts can result in personal injury.

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

4. Start the engine and rotate the cam hex in both directions to determine the mid position of the neutral span.

5. Tighten the locknut securing the adjustment.

6. Shut off the engine.

7. Remove the support blocks and lower the machine to the shop floor. Test drive the machine to ensure that it does not move when the traction pedal is in neutral.

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

Ethylene-Glycol Coolant Type	Corrosion Inhibitor Type
Extended-life antifreeze	Organic-acid technology (OAT)
Important: Do not rely on the color of the coolant to identify the difference between conventional (green) inorganic-acid technology (IAT) coolant and extended-life coolant.Coolant manufacturers may dye extended-life coolant in one of the following colors: red, pink, orange, yellow, blue, teal, violet, and green. Use coolant that meets the specifications in the Extended Life Coolant Standards Table.

Extended Life Coolant Standards

ATSM International	SAE International
D3306 and D4985	J1034, J814, and 1941

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.

Cooling system capacity: approximately 5.7 L (6 US qt)

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

2. Unlatch and open the hood.

3. Check the coolant level in the expansion tank (Figure 73).

   

   Figure 73

   1. Expansion tank

   Note: With a cold engine, the coolant level should be approximately midway between the marks on the side of the tank.

4. If the coolant level is low remove the expansion tank cap, add the specified coolant to the tank until the coolant level is midway between the marks on the side of the tank, and assemble the cap to the tank.

   Important: Do not overfill the expansion tank.

5. Close and latch the hood.

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

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

2. Raise the hood.

3. Clean the engine area thoroughly of all debris.

4. Remove the lower radiator shield (Figure 74).

   

   Figure 74

   1. Radiator
   2. Lower radiator shield

5. Clean both sides of the radiator area thoroughly with water or compressed air (Figure 74).

6. Install the lower radiator shield.

7. Close and latch the hood.

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

2. Loosen the setscrew securing the knob to the parking-brake lever (Figure 75).

   

   Figure 75

   1. Parking-brake lever
   2. Knob
   3. Set screw

3. Rotate the knob until a force of 133 to 178 N (30 to 40 lb) is required to actuate the lever.

4. Tighten the setscrew.

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

2. Loosen the jam nut for the speed stop screw.

3. Adjust the speed stop screw as follow:

   Note: The mow speed is set at the factory to 9.7 km/h (6 mph).

   • To decrease the mow speed, rotate the speed stop screw (Figure 91) clockwise.

   • To increase the mow speed, rotate the speed stop screw counterclockwise.

   

   Figure 91

   1. Speed stop screw

4. Hold the stop screw and tighten the jam nut.

5. Test drive the machine to confirm the maximum mow speed adjustment.

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

2. Unlatch and open the hood.

3. Position the throttle lever rearward so that it stops against the control panel slot.

4. Loosen the throttle cable connector on the injection pump lever arm (Figure 92).

   

   Figure 92

   1. Injection pump lever arm

5. Hold the injection pump lever arm against the low idle stop and tighten the cable connector.

6. Loosen the screws securing the throttle control to the control panel.

7. Push the throttle control lever all the way forward.

8. Slide the stop plate until it contacts the throttle lever and tighten the screws securing the throttle control to the control panel.

9. If the throttle does not stay in position during operation, torque the locknut, used to set the friction device on the throttle lever, to 5 to 6 N∙m (44 to 53 in-lb).

   Note: The maximum force required to operate the throttle lever should be 89 N (20 lb).

10. Close and latch 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.

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

Material Properties:
	Viscosity, ASTM D445	cSt @ 40°C (104°F) 44 to 48
	Viscosity Index ASTM D2270	140 or higher
	Pour Point, ASTM D97	-37°C to -45°C (-34°F to -49°F)
	Industry Specifications:	Eaton Vickers 694 (I-286-S, M-2950-S/35VQ25 or M-2952-S)

Note: Many hydraulic fluids are almost colorless, making it difficult to spot leaks. A red dye additive for the hydraulic fluid is available in 20 ml (0.67 fl oz) bottles. A bottle is sufficient for 15 to 22 L (4 to 6 US gallons) of hydraulic fluid. Order Part No. 44-2500 from your authorized Toro distributor.

Important: Toro Premium Synthetic Biodegradable Hydraulic Fluid is the only synthetic biodegradable fluid approved by Toro. This fluid is compatible with the elastomers used in Toro hydraulic systems and is suitable for a wide-range of temperature conditions. This fluid is compatible with conventional mineral oils, but for maximum biodegradability and performance, the hydraulic system should be thoroughly flushed of conventional fluid. The oil is available in 19 L (5 US gallon) pails or 208 L (55 US gallon) drums from your authorized Toro distributor.

The reservoir is filled at the factory with high-quality hydraulic fluid. The best time to check the hydraulic oil is when the fluid is cold. The machine should be in its transport configuration.

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

2. Clean the area around the filler neck and cap of the hydraulic-fluid tank (Figure 93) and remove the cap.

   

   Figure 93

   1. Cap
   2. Filler neck (hydraulic-fluid reservoir)
   3. Dipstick

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

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

   Note: The fluid level should be within 6 mm (1/4 inch) of the mark on the dipstick.

5. If the level is low, add the specified fluid to raise the level to the full mark; refer to Hydraulic Fluid Specifications.

   Important: Do not overfill the hydraulic reservoir.

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

22.7 L (6 US gallons); refer to Hydraulic Fluid Specifications

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

2. Disconnect the large hydraulic hose (Figure 94) from the reservoir, and let the hydraulic fluid flow into a drain pan.

   

   Figure 94

   1. Hydraulic hose

3. Install the hydraulic hose when hydraulic fluid stops draining.

4. Fill the reservoir (Figure 95) with approximately 22.7 L (6 US gallons) of hydraulic fluid; refer to Hydraulic Fluid Specifications.

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

   

   Figure 95

   1. Cap
   2. Filler neck (hydraulic-fluid reservoir)
   3. Dipstick

5. Install the dipstick and cap onto the filler neck.

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

7. Check for leaks; then shut off the engine.

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

   Important: Do not overfill the reservoir.

Use a genuine Toro replacement filter (Part No. 86-3010).

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

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

2. Clean around the filter mounting area. Place a drain pan under the filter (Figure 96) and remove the filter.

   

   Figure 96

   1. Hydraulic filter
   2. Filter head

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

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

5. Start the engine and let it run for about 2 minutes to purge air from the system. Shut off the engine and check for leaks.

Check the reel-to-bedknife contact even if the quality of cut had been acceptable previously. There must be light contact across the full length of the reel and bedknife; refer to Adjusting Reel to Bedknife in the cutting unit Operator’s Manual.

Use the gauge bar (Figure 97) to adjust the cutting unit. Refer to the cutting unit Operator's Manual for the adjustment procedure.

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.