Document
Form No. 3368-984 Rev D
Reelmaster® 7000-D 4-Wheel
Drive Traction Unit
Model No. 03708—Serial No. 311000001 and Up
To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com.
Original Instructions (EN)
You may contact Toro directly at www.Toro.com for
product and accessory information, help finding a dealer,
or to register your product.
This product complies with all relevant European
directives, for details please see the separate product
specific Declaration of Conformity (DOC) sheet.
Whenever you need service, genuine Toro parts,
or additional information, contact an Authorized
Service Dealer or Toro Customer Service and have
the model and serial numbers of your product ready.
Figure 1 identifies the location of the model and serial
numbers on the right front frame member of the
product. Write the numbers in the space provided.
WARNING
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth defects,
and other reproductive harm.
Because in some areas there are local, state, or federal
regulations requiring that a spark arrester be used on the
engine of this machine, a spark arrester is incorporated
with the muffler assembly.
Genuine Toro spark arresters are approved by the USDA
Forestry Service.
Important: This engine is equipped with a spark
arrester muffler. It is a violation of California Public
Resource Code Section 4442 to use or operate
the engine on any forest-covered, brush-covered,
or grass-covered land without a spark arrester
muffler maintained in working order, or the engine
constricted, equipped, and maintained for the
prevention of fire. Other states or federal areas may
have similar laws.
Figure 1
1. Model and serial number location
Model No.
The enclosed Engine Owner's Manual is supplied
for information regarding the US Environmental
Protection Agency (EPA) and the California
Emission Control Regulation of emission systems,
maintenance, and warranty. Replacements may be
ordered through the engine manufacturer.
Serial No.
This manual identifies potential hazards and has safety
messages identified by the safety alert symbol (Figure 2),
which signals a hazard that may cause serious injury
or death if you do not follow the recommended
precautions.
Introduction
This machine is a ride-on, reel-blade lawn mower
intended to be used by professional, hired operators in
commercial applications. It is primarily designed for
cutting grass on well-maintained lawns in golf courses,
parks, sports fields, and on commercial grounds. It is
not designed for cutting brush, mowing grass and other
growth alongside highways, or for agricultural uses.
Figure 2
1. Safety alert symbol.
This manual uses two other words to highlight
information. Important calls attention to special
mechanical information and Note emphasizes general
information worthy of special attention.
Read this information carefully to learn how to operate
and maintain your product properly and to avoid injury
and product damage. You are responsible for operating
the product properly and safely.
© 2012—The Toro® Company
8111 Lyndale Avenue South
Bloomington, MN 55420
2
Contact us at www.Toro.com.
Printed in the USA.
All Rights Reserved
Contents
Removing the Hood ........................................... 38
Lubrication............................................................. 38
Greasing the Bearings and Bushings.................... 38
Engine Maintenance............................................... 40
Servicing the Air Cleaner .................................... 40
Servicing the Engine Oil and Filter...................... 41
Adjusting the Throttle ........................................ 41
Fuel System Maintenance ....................................... 42
Fuel Tank ........................................................... 42
Fuel Lines and Connections................................ 42
Servicing the Water Separator ............................. 42
Fuel Pick up Tube Screen.................................... 42
Bleeding Air from the Injectors........................... 43
Electrical System Maintenance................................ 43
Charging and Connecting the Battery .................. 43
Battery Care ....................................................... 44
Fuses.................................................................. 45
Drive System Maintenance ..................................... 46
Checking the Torque of the Wheel
Nuts............................................................... 46
Checking the Planetary Gear Drive
Oil.................................................................. 46
Changing the Planetary Gear Drive
Oil.................................................................. 46
Checking the Rear Axle Lubricant ....................... 47
Changing the Rear Axle Lubricant....................... 47
Adjusting the Traction Drive for Neutral ............. 48
Checking the Rear Wheel Toe-In......................... 48
Cooling System Maintenance .................................. 49
Servicing the Engine Cooling System .................. 49
Brake Maintenance ................................................. 50
Adjusting the Service Brakes............................... 50
Belt Maintenance.................................................... 50
Servicing the Alternator Belt............................... 50
Hydraulic System Maintenance ............................... 51
Changing the Hydraulic Fluid ............................. 51
Replacing the Hydraulic Filters ........................... 51
Checking the Hydraulic Lines and Hoses ............. 52
Cutting Unit Maintenance....................................... 52
Backlapping the Cutting Units ............................ 52
Cleaning ................................................................. 53
Servicing the Spark Arrestor Muffler................... 53
Storage....................................................................... 54
Engine ............................................................... 54
Traction Unit...................................................... 54
Schematics ................................................................. 55
Introduction................................................................. 2
Safety ........................................................................... 4
Safe Operating Practices ....................................... 4
Toro Riding Mower Safety .................................... 6
Sound Power Level............................................... 7
Sound Pressure Level ........................................... 7
Vibration Level .................................................... 7
Safety and Instructional Decals ............................. 7
Setup ......................................................................... 12
1 Replacing the Warning Decal for CE
Compliance .................................................... 13
2 Installing the Hood Lock for CE
Compliance .................................................... 13
3 Installing the Cutting Units .............................. 14
4 Adjusting the Turf Compensation
Spring ............................................................ 17
5 Using the Cutting Unit Kickstand ..................... 17
6 Greasing the Machine ...................................... 18
7 Checking Fluid Levels ...................................... 18
8 Using the Gauge Bar ........................................ 19
Product Overview ...................................................... 19
Controls ............................................................. 19
Specifications ..................................................... 23
Traction Unit Specifications................................ 23
Attachments/Accessories................................... 23
Operation................................................................... 24
Checking the Engine Oil Level............................ 24
Checking the Cooling System.............................. 25
Filling the Fuel Tank........................................... 25
Checking the Hydraulic Fluid Level..................... 27
Checking the Tire Pressure ................................. 28
Starting and Stopping the Engine ........................ 28
Checking the Interlock Switches ......................... 28
Setting the Reel Speed......................................... 29
Adjusting the Lift Arm Counterbalance............... 30
Adjusting the Lift Arm Turn Around
Position.......................................................... 30
Pushing or Towing the Machine .......................... 31
Jacking Points..................................................... 31
Tie Downs ......................................................... 31
Understanding the Diagnostic Light.................... 31
Diagnostic Ace Display....................................... 32
Checking the Interlock Switches ......................... 32
Operating Characteristics ................................... 33
Engine Cooling Fan Operation ........................... 34
Operating Tips ................................................... 34
Maintenance............................................................... 35
Recommended Maintenance Schedule(s) ................ 35
Daily Maintenance Checklist............................... 36
Service Interval Chart......................................... 37
Premaintenance Procedures.................................... 38
3
Safety
◊ 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.
This machine meets or exceeds CEN standard EN
836:1997 (when appropriate decals applied), and ANSI
B71.4-2004 specifications in effect at the time of
production.
Preparation
• 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.
• Warning—Fuel is highly flammable. Take the
following precautions:
– Store fuel in containers specifically designed for
this purpose.
– Refuel outdoors only and do not smoke while
refuelling.
– Add fuel before starting the engine. Never
remove the cap of the fuel tank or add fuel while
the engine is running or when the engine is hot.
– If fuel is spilled, do not attempt to start the
engine but move the machine away from the
area of spillage and avoid creating any source of
ignition until fuel vapors have dissipated.
– Replace all fuel tanks and container caps securely.
• 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.
Improper use or maintenance by the operator or
owner can result in injury. To reduce the potential
for injury, comply with these safety instructions
and always pay attention to the safety alert symbol,
which means CAUTION, WARNING, or DANGER"personal safety instruction." Failure to comply with the
instruction may result in personal injury or death.
Safe Operating Practices
The following instructions are from the CEN standard
EN 836:1997, ISO standard 5395:1990, and ANSI
B71.4-2004.
Training
• 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:
Operation
– the need for care and concentration when
working with ride-on machines;
• 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;
– 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;
4
•
•
•
•
•
•
•
•
•
•
•
– 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.
Maintenance and Storage
• 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
5
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.
•
•
•
Toro Riding Mower Safety
•
The following list contains safety information specific
to Toro products or other safety information that you
must know that is not included in the CEN, ISO, or
ANSI standard.
– Apply the service brakes when going downhill to
keep forward speed slow and to maintain control
of the machine.
When operating a machine with ROPS (roll-over
protection system) never remove the ROPS and
always use the seat belt.
Raise the cutting units when driving from one work
area to another.
Do not touch the engine, silencer/muffler, or
exhaust pipe while the engine is running or soon
after it has stopped because these areas could be hot
enough to cause burns.
On any hill, there is the possibility of tipping or
rolling over, but the risk increases as the slope angle
increases. Steep hills should be avoided.
Cutting units must be lowered when going down
slopes to maintain steering control
• Engage traction drive slowly, always keep foot on
traction pedal, especially when traveling downhill.
This product is capable of amputating hands and
feet and throwing objects. Always follow all safety
instructions to avoid serious injury or death.
Use reverse on traction pedal for braking.
• If the machine stalls when climbing a slope, do
not turn the machine around. Always back slowly,
straight down the slope.
• When a person or pet appears unexpectedly in
or near the mowing area, stop mowing. Careless
operation, combined with terrain angles, ricochets,
or improperly positioned guards can lead to thrown
object injuries. Do not resume mowing until the
area is cleared.
Use of this product for purposes other than its intended
use could prove dangerous to user and bystanders.
WARNING
Engine exhaust contains carbon monoxide, which
is an odorless, deadly poison that can kill you.
Do not run engine indoors or in an enclosed area.
• Know how to stop the engine quickly.
• Do not operate the machine while wearing tennis
shoes or sneakers.
• Wearing safety shoes and long pants is advisable and
required by some local ordinances and insurance
regulations.
• Handle fuel carefully. Wipe up any spills.
• Check the safety interlock switches daily for proper
operation. If a switch should fail, replace the switch
before operating the machine.
• Before starting the engine, sit on the seat.
• Using the machine demands attention. To prevent
loss of control:
– Do not drive close to sand traps, ditches, creeks,
embankments, or other hazards.
– Reduce speed when making sharp turns. Avoid
sudden stops and starts.
– When near or crossing roads, always yield the
right-of-way.
Maintenance and Storage
• Make sure all hydraulic line connectors are tight and
all hydraulic hoses and lines are in good condition
before applying pressure to the system.
• Keep your body and hands away from pin hole
leaks or nozzles that eject hydraulic fluid under
high pressure. Use paper or cardboard, not your
hands, to search for leaks. Hydraulic fluid escaping
under pressure can have sufficient force to penetrate
the skin and cause serious injury. Seek immediate
medical attention if fluid is injected into skin.
• Before disconnecting or performing any work on
the hydraulic system, all pressure in the system must
be relieved by stopping the engine and lowering the
cutting units and attachments to the ground.
• Check all fuel lines for tightness and wear on a
regular basis. Tighten or repair them as needed.
• If the engine must be running to perform a
maintenance adjustment, keep hands, feet, clothing,
6
and any parts of the body away from the cutting
units, attachments, and any moving parts.
• To ensure safety and accuracy, have an Authorized
Toro Distributor check the maximum engine speed
with a tachometer.
• If major repairs are ever needed or if assistance is
desired, contact an Authorized Toro Distributor.
• Use only Toro-approved attachments and
replacement parts. The warranty may be voided if
used with unapproved attachments.
Sound pressure level was determined according to the
procedures outlined in EN 836.
Vibration Level
Hand-Arm
Measured vibration level for right hand =0.3 m/s2
Measured vibration level for left hand =0.3 m/s2
Uncertainty Value (K) = 0.16 m/s2
Sound Power Level
Measured values were determined according to the
procedures outlined in EN 836.
This unit has a guaranteed sound power level of 101
dBA, which includes an Uncertainty Value (K) of 1 dBA.
Whole Body
Sound power level was determined according to the
procedures outlined in ISO 11094.
Uncertainty Value (K) = 0.1 m/s2
Measured vibration level = 0.2 m/s2
Measured values were determined according to the
procedures outlined in EN 836.
Sound Pressure Level
This unit has a sound pressure level at the operator’s
ear of 83 dBA, which includes an Uncertainty Value (K)
of 1 dBA.
Safety and Instructional Decals
Safety decals and instructions are easily visible to the operator and are located near any area of
potential danger. Replace any decal that is damaged or lost.
117-4763
2. To disengage the parking
1. To engage the parking
brake, disengage the
brake, secure the brake
locking pin and release the
pedals with the locking pin,
pedals.
press the parking brake
pedals and engage the toe
pedal.
119-3884
7
1. Off
2. Headlights
4. Fast, throttle
5. Slow, throttle
3. On
6. Power Take-off (PTO)
117-4765
1. Read the Operator's Manual.
2. Do not use starting aids.
117–2385
1. Read the Operators
Manual.
2. Engine—start
3. Engine—preheat
4. Engine—stop
117-4766
1. Cutting/dismemberment hazard; fan—stay away from
moving parts.
117–2718
117-2386
1. Raise deck
2. Blow off fan
3. Reverse
4. Automatic
106-6755
119-3905
1. Engine coolant under
pressure.
3. Warning—do not touch the
hot surface.
2. Explosion hazard—read
the Operator's Manual.
4. Warning—read the
Operator's Manual.
1. Reel speed
98-4387
1. Warning—wear hearing protection.
8
93-6688
1. Warning—read the
instructions before
servicing or performing
maintenance.
110-9642
2. Cutting hazard of hand or
foot—stop the engine and
wait for moving parts to
stop.
1. Stored energy hazard—read the Operator's Manual.
2. Move the cotter pin to the hole closest to the rod bracket
and then remove the lift arm and pivot yoke.
20A
10A
10A
10A
10A
106-6754
1. Warning—do not touch the hot surface.
2. Cutting/dismemberment hazard, fan and entanglement
hazard, belt—stay away from moving parts.
TEC-5002
2A
7.5A
7.5A
7.5A
60A
120-1672
120-1672
1. Starter, 20A
5. Gauges, 10A
2. Work light, 10A
6. GM4500 controller, 2A
3. Seat, 10A
7. Power supplied, 7.5A
4. Power point, 10A
8. Engine preheat, 60A
120-1683
1. Warning—read the Operator's Manual, do not operate this
machine unless you are trained.
4. Warning—do not park the machine on slopes; engage the
parking brake, lower the cutting units, stop the engine and
remove the ignition key before leaving the machine.
2. Warning—read the Operator's Manual before towing the
machine.
3. Tipping hazard—slow machine before turning, do not turn at
high speeds; lower the cutting unit when driving down slopes;
use a roll over protection system and wear the seat belt
5. Thrown object hazard—keep bystanders a safe distance from
the machine.
6. Entanglement hazard, belt—stay away from moving parts,
keep all guards and shields in place.
9
120-1686
Affix over part no. 120–1683 for CE*
*This safety decal includes a slope warning required on the machine fro compliance to the European Lawn Mower Standard EN 836.1997. The conservative maximum slope
angles indicated for operation of this machine are prescribed by and required by this standard.
1. Warning—read the Operator's Manual, do not operate this
machine unless you are trained.
4. Warning—do not park the machine on slopes; engage the
parking brake, lower the cutting units, stop the engine and
remove the ignition key before leaving the machine.
2. Warning—read the Operator's Manual before towing the
machine.
3. Tipping hazard—do not turn at high speeds, do not up and
down slopes greater than 16 degrees, do not mow across
slopes greater than 22 degrees; lower the cutting unit when
driving down slopes; use a roll over protection system and
wear the seat belt
5. Thrown object hazard—keep bystanders a safe distance from
the machine.
6. Entanglement hazard, belt—stay away from moving parts,
keep all guards and shields in place.
120-1681
1. 5 Blade cutting unit
3. 11 Blade cutting unit
5. Read the Operator's Manual.
2. 8 Blade cutting unit
4. Mow and backlap
6. Machine speed
10
Battery Symbols
Some or all of these symbols are on your battery
1. Explosion hazard
6. Keep bystanders a safe
distance from the battery.
2. No fire, open flame, or
smoking.
7. Wear eye protection;
explosive gases can
cause blindness and other
injuries
3. Caustic liquid/chemical
burn hazard
4. Wear eye protection
8. Battery acid can cause
blindness or severe burns.
9. Flush eyes immediately
with water and get medical
help fast.
5. Read the Operator's
Manual.
120-1671
120-1670
1. Traction unit speed
3. Fast
2. Slow
11
10. Contains lead; do not
discard.
Setup
Loose Parts
Use the chart below to verify that all parts have been shipped.
Procedure
Description
1
2
3
4
5
6
7
8
Use
Qty.
Used only on machines requiring CE
Compliance.
Warning decal
1
Hood lock bracket
Rivet
Screw, 1/4 x 2 inch
Flat washer, 1/4 inch
Locknut, 1/4 inch
Front hose guide-R.H.
Front hose guide-L.H.
1
2
1
2
1
1
1
No parts required
–
Adjust the turf compensation spring.
Cutting unit kickstand
1
Install the Cutting Unit Kickstand.
No parts required
–
Grease the machine.
No parts required
–
Check the rear axle lubricant, hydraulic
fluid, and engine oil levels
Gauge bar
1
Use the gauge bar to adjust the cutting
unit.
Used only on machines requiring
European CE Compliance.
Install the cutting units
Media and Additional Parts
Description
Use
Qty.
Operator's Manual
1
Read before operating machine
Engine Operator's Manual
1
Read before operating engine
Parts Catalog
1
Use to reference part numbers
Operator Training Material
1
View before operating machine
Certificate of Compliance
1
Use for CE Compliance
Note: Determine the left and right sides of the machine from the normal operating position.
12
1
Replacing the Warning Decal
for CE Compliance
Parts needed for this procedure:
1
Warning decal
Procedure
On machines requiring CE Compliance, affix the
warning decal, part no. 120–1683 over the warning decal
part no. 120–1686.
Figure 3
1. Hood latch
2
2. Remove the (2) rivets securing the hood latch bracket
to the hood (Figure 4). Remove the hood latch
bracket from the hood.
1
2
Installing the Hood Lock for
CE Compliance
Parts needed for this procedure:
1
Hood lock bracket
2
Rivet
1
Screw, 1/4 x 2 inch
2
Flat washer, 1/4 inch
1
Locknut, 1/4 inch
G012628
Figure 4
Procedure
1. Hood latch bracket
1. Unhook the hood latch from the hood latch bracket
(Figure 3).
2. Rivets
3. While aligning the mounting holes, position the CE
lock bracket and the hood latch bracket onto the
hood. The lock bracket must be against the hood
(Figure 4). Do not remove bolt and nut assembly
from the lock bracket arm.
13
1
3
2
Installing the Cutting Units
Parts needed for this procedure:
G012629
Figure 5
Front hose guide-R.H.
1
Front hose guide-L.H.
Procedure
2. Bolt and nut assembly
1. CE lock bracket
1
1. Remove the reel motors from the shipping brackets.
2. Remove the shipping brackets and discard.
4. Align the washers with the holes on the inside of the
hood.
5. Rivet the brackets and the washers to the hood
(Figure 5).
6. Hook the latch onto the hood latch bracket
(Figure 6).
3. Remove the cutting units from the cartons. Assemble
and adjust as described in the cutting unit Operator's
Manual.
4. Make sure the counter weight (Figure 8) is installed
to the proper end of the cutting unit as described in
the cutting unit Operator's Manual.
1
G012630
Figure 6
1. Hood latch
7. Screw the bolt into the other arm of hood lock
bracket to lock the latch in position (Figure 7).
Tighten bolt securely but do not tighten nut.
3
Figure 8
1. Counter weight
5. All the cutting units are shipped with the turf
compensation spring mounted to the right side of the
cutting unit. The turf compensation spring must be
mounted to the same side of the cutting unit as the
reel drive motor. Reposition the turf compensation
as follows:
2
1
G012631
Figure 7
1. Bolt
2. Nut
A. Remove the 2 carriage bolts and nuts securing
the rod bracket to the cutting unit tabs (Figure 9).
3. Arm of hood lock bracket
14
Figure 9
1. Turf compensation spring
3. Spring tube
2. Rod bracket
B. Remove the flange nut securing the spring tube
bolt to the carrier frame tab (Figure 9) Remove
the assembly.
C. Mount the spring tube bolt to the opposite tab
on the carrier frame and secure with the flange
nut. The bolt head is to be positioned to the
outer side of the tab as shown in Figure 10.
Figure 12
1. Hose guide (Left hand
shown)
3. Nuts
2. Rod bracket
Note: When installing or removing the cutting
units, make sure the hairpin cotter is installed
in the spring rod hole next to the rod bracket.
Otherwise, the hairpin cotter must be installed in
the hole in the end of the rod.
Figure 10
1. Opposite carrier frame tab
2. Rod bracket
6. On 27 inch cutting units only, increase the steering
on the rear cutting units by removing the (2) pivot
spacers, hex socket screws and flange lock nuts
(Figure 13) from the rear (#2 and #3) cutting unit
carrier frames (Figure 11).
D. Mount the rod bracket to the cutting unit tabs
with the carriage bolts and nuts (Figure 10). Also,
on the #4 (left front) cutting unit, mount the left
hand hose guide to the front of the cutting unit
tabs when reinstalling the rod bracket (Figure 12).
Note: 32 inch cutting units are not equipped with
pivot spacers.
Figure 11
Note: On the #5 (right front) cutting unit, use
the rod bracket mounting nuts to install the right
hand hose guide to the front of the cutting unit
tabs.
15
9. 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 14). Make sure
the thrust washer is in position on the carrier frame
shaft.
1
2
10. Secure the carrier frame shaft to the lift arm yoke
with the Klik pin (Figure 14).
3
11. To lock (fix) the steering on the cutting units, secure
the pivot yoke to the carrier frame with the snapper
pin (Figure 15).
G015978
4
Figure 13
1. Hex socket screw
2. Pivot spacer
3. Carrier frame
4. Flange lock nut
7. Lower all the lift arms completely.
1
8. Coat the carrier frame shaft with clean grease
(Figure 14).
G015977
Figure 15
1. Snapper pin
Note: Fixed steering is recommended when
cutting side hills.
12. Use the following procedure on the rear cutting units
when the height of cut is above 3/4 inch.
2
1
A. 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 16).
3
5
Figure 16
4
1. Lift arm pivot shaft lynch pin and washer
G015976
B. Insert the lift arm yoke onto the carrier frame
shaft (Figure 14).
Figure 14
1. Lift arm pivot yoke
4. Carrier frame shaft
2. Lift arm
3. Klik pin
5. Thrust washer
C. Insert the lift arm shaft into the lift arm
and secure it with the washer and lynch pin
(Figure 16).
16
13. Secure the lift arm chain to the chain bracket with
the snapper pin (Figure 17). Use the number of chain
links described in the cutting unit Operator's Manual.
4
Adjusting the Turf
Compensation Spring
No Parts Required
Procedure
The turf compensation spring (Figure 19) transfers
weight from the front to the rear roller. (This helps
to reduce a wave pattern in the turf, also known as
marcelling or bobbing.)
Figure 17
1. Lift arm chain
3. Snapper pin
2. Chain bracket
Important: Make spring adjustments with the
cutting unit mounted to the traction unit, pointing
straight ahead and lowered to the shop floor.
14. Coat the spline shaft of the reel motor with clean
grease.
1. Make sure the hairpin cotter is installed in the rear
hole in the spring rod (Figure 19).
15. Oil the reel motor O-ring and install it onto the
motor flange.
Note: When servicing the cutting unit, move the
hairpin cotter to the spring rod hole next to the turf
compensation spring.
16. Install the motor by rotating it clockwise so that the
motor flanges clear the bolts (Figure 18). Rotate the
motor counterclockwise until the flanges encircle the
bolts then tighten the bolts.
Important: Make sure the reel motor hoses
are not twisted, kinked or in the risk of being
pinched.
Figure 19
1. Turf compensation spring
3. Spring rod
2. Hair pin cotter
4. Hex nuts
2. Tighten the hex nuts on the front end of the spring
rod until the compressed length of the spring is 6.25
inches (15.9 cm) (Figure 19).
Note: When operating on rough terrain decrease
the spring length by 1/2 inch. Ground following will
be slightly decreased.
Figure 18
1. Reel drive motor
2. Mounting bolts
Note: The turf compensation setting will need to
be reset if the HOC setting or the Aggressiveness
of Cut setting is changed.
17
5
Using the Cutting Unit
Kickstand
Parts needed for this procedure:
1
Cutting unit kickstand
Procedure
Whenever the cutting unit has to be tipped to expose
the bedknife/reel, prop up the rear of the cutting unit
with the kickstand to make sure the nuts on the back
end of the bedbar adjusting screws are not resting on the
work surface (Figure 20).
Figure 21
1. Chain bracket
3. Cutting unit kickstand
2. Snapper pin
6
Greasing the Machine
No Parts Required
Procedure
Before the machine is operated, it must be greased to
ensure proper lubrication. Refer to Lubrication section.
Failure to properly grease the machine will result in
premature failure of critical parts.
Figure 20
1. Cutting unit kickstand
7
Secure the kickstand to the chain bracket with the
snapper pin (Figure 21).
Checking Fluid Levels
No Parts Required
Procedure
1. Check the rear axle lubricant level before the engine
is first started, refer to Checking the Rear Axle
Lubricant in Drive System Maintenance.
18
Product Overview
2. Check the hydraulic fluid level before the engine is
first started, refer to Checking the Hydraulic Fluid
Level in Operation.
Controls
3. Check the engine oil level before and after the engine
is first started, refer to Checking the Engine Oil
Level in Operation.
Brake Pedals
Two foot pedals (Figure 23) operate individual wheel
brakes for turning assistance and to aid in obtaining
better side hill traction.
8
Pedal Locking Latch
Using the Gauge Bar
The pedal locking latch (Figure 23) connects the pedals
together to engage the parking brake.
Parts needed for this procedure:
1
Parking Brake Pedal
Gauge bar
To engage the parking brake, (Figure 23) connect the
pedals together with the pedal locking latch, push down
on the right brake pedal while engaging the toe pedal. To
release the parking brake, press one of the brake pedals
until the parking brake latch retracts.
Procedure
Use the gauge bar to adjust the cutting unit. Refer to
the Cutting Unit Operator's Manual for the adjustment
procedures (Figure 22).
Figure 23
1. Brake pedal
4. Traction pedal
2. Pedal locking latch
5. Tilt steering pedal
3. Parking brake pedal
Figure 22
1. Gauge bar
2. Height adjusting screw
Traction Pedal
4. Holes used for setting
Groomer HOG
5. Hole not used
The traction pedal (Figure 23) controls forward and
reverse operation. Depress the top of the pedal to move
forward and the bottom to move backward. Ground
speed depends on how far the pedal is depressed. For
no load, maximum ground speed, fully depress the pedal
while the throttle is in Fast.
3. Nut
To stop, reduce your foot pressure on the traction pedal
and allow it to return to the center position.
Tilt Steering Pedal
To tilt the steering wheel towards you, press the foot
pedal (Figure 23) down, and pull the steering tower
19
Charge Indicator
toward you to the most comfortable position and then
release the pedal.
The charge indicator (Figure 25) illuminates when the
system charging circuit malfunctions.
Mow Speed Limiter
Key Switch
When the mow speed limiter (Figure 24) is flipped up it
will control the mow speed and allow the cutting units
to be engaged. Each spacer adjusts the mowing speed
by ½ mile per hour. The more spacers you have, on the
top of the bolt the slower you will go. For transport, flip
back the mow speed limiter and you will have maximum
transport speed.
The key switch (Figure 25) has three positions: Off,
On/Preheat, and Start.
PTO Switch
The PTO switch (Figure 25) has two positions: Out
(start) and In (stop). Pull the PTO button out to engage
the cutting unit blades. Push in the button to disengage
the cutting unit blades.
Speed Limiter Screws
Adjust the screw(s) (Figure 24) to limit the amount the
traction pedal can be depressed in the forward or reverse
direction to limit speed.
Important: The speed limiter screw must stop the
traction pedal before the pump reaches full stroke
or damage to the pump may occur.
Figure 24
1. Reverse speed limiter
screw
2. Forward speed limiter
screw
3. Spacers
4. Mow speed limiter
Figure 25
Diagnostic Light
The diagnostic light (Figure 25) will illuminate should a
system fault be recognized.
Engine Coolant Temperature Gauge
During normal operating conditions the gauge
(Figure 25) should be in the green range. Check the
cooling system if the gauge goes to the yellow or red
range.
1. Diagnostic light
7. Lift switch
2. Engine coolant
temperature gauge
8. Throttle control
3. Engine oil pressure
warning light
9. Light switch
4. Charge indicator
10. Glow plug indicator light
5. Key switch
11. Engine coolant
temperature warning
light
6. PTO switch
Lift Switch
Engine Oil Pressure Warning Light
The lift switch (Figure 25) raises and lowers the cutting
units. Press the switch forward to lower the cutting units
and backward to raise the cutting units. When starting
The light (Figure 25) illuminates when the engine oil
pressure is dangerously low.
20
the machine, with the cutting units in the down position,
press the lift switch down to allow the cutting units to
float and mow.
has two positions R (manual reverse) and Auto (normal).
Refer to Engine Cooling Fan Operation in the Operation
Section of manual.
Throttle Control
Bag Holder
Move the control (Figure 25) forward to increase the
engine speed and rearward to decrease the speed.
Use the bag holder (Figure 26) for storage.
Light Switch
Hour Meter
Press the lower edge of the switch (Figure 25) to turn on
the lights. Press the upper edge of the switch to turn
off the lights.
The hour meter (Figure 26) shows the total hours that
the machine has been operated.
Backlap Levers
Glow Plug Indicator Light
Use the backlap levers for backlapping the reels
(Figure 27).
When lit, the glow plug indicator light (Figure 25)
indicates that the glow plugs are on.
Engine Coolant Temperature Warning
Light
The light (Figure 25) illuminates and the cutting units
shut down (PTO disengages). If the temperature
continues to rise the engine will shut down.
Power Point
The power point (Figure 26) is used to power optional
12 volt electrical accessories.
Figure 27
1. Front backlap lever
2. Rear backlap lever
Reel Speed Control
The reel speed control regulates the speed of the front
and rear cutting units (Figure 28). The reel speed
increases as the knob is turned clockwise.
Figure 26
1. Power point
3. Bag holder
2. Engine cooling fan switch
4. Hour meter
Engine Cooling Fan Switch
The machine is equipped with a hydraulically driven auto
reversing engine cooling fan. The fan switch (Figure 26)
21
Weight gauge
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 28
1. Reel speed controls
Fuel Gauge
Figure 30
The fuel gauge (Figure 29) indicates the level of fuel in
the tank.
1. Weight gauge
4. Seat back adjusting lever
2. Weight adjusting lever
5. Arm rest adjusting knob
3. Fore and Aft adjusting
lever
Weight Adjusting Lever
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.
Figure 29
1. Fuel gauge
Seat Adjustments
Fore and Aft Adjusting Lever
Pull out on the lever to slide the seat fore or aft
(Figure 30).
Seat Arm Rest Adjusting Knob
Rotate the knob to adjust the seat arm rest angle
(Figure 30).
Seat Back Adjusting Lever
Move the lever to adjust the seat back angle (Figure 30).
22
Specifications
Note: Specifications and design are subject to change
without notice.
Traction Unit Specifications
Width of cut
121 inches (307 cm)
Overall width, cutting units
down
136 inches (345 cm)
Overall width, cutting units up
(transport)
94 inches (239 cm)
Overall length
145.8 inches (370 cm)
Height with ROPS
87 inches (220 cm)
Track Width, front
90 inches (229 cm)
Track Width, rear
55.5 inches (141 cm)
Wheel base
67-1/2 inches (171 cm)
Net Weight (with no cutting
units and no fluids)
3470 lb (1574 kg)
Attachments/Accessories
A selection of Toro approved attachments and
accessories are available for use with the machine to
enhance and expand its capabilities. Contact your
Authorized Service Dealer or Distributor or go to
www.Toro.com for a list of all approved attachments
and accessories.
23
Operation
1. Park the machine on a level surface.
2. Unlock the hood latches and open the hood
(Figure 31).
Note: Determine the left and right sides of the
machine from the normal operating position.
CAUTION
This machine produces sound levels in excess of
85 dBA at the operator's ear and can cause hearing
loss through extended periods of exposure.
Wear hearing protection when operating this
machine.
CAUTION
If you leave the key in the ignition switch, someone
could accidently start the engine and seriously
injure you or other bystanders.
Remove the key from the ignition before you do
any maintenance.
Figure 31
1. Hood latch
Checking the Engine Oil Level
3. Remove the dipstick, wipe it clean, install the
dipstick into the tube, and pull it out again.
Service Interval: Before each use or daily
The oil level should be in the safe range (Figure 32).
The engine is shipped with oil in the crankcase;
however, the oil level must be checked before and after
the engine is first started.
The crankcase capacity is approximately 10 qt. (9.5 l)
with the filter.
Use high-quality engine oil that meets the following
specifications:
• API Classification Level Required: CH-4, CI-4 or
higher.
• Preferred oil: SAE 15W-40 (above 0°F)
• Alternate oil: SAE 10W-30 or 5W-30 (all
temperatures)
Figure 32
Note: Toro Premium Engine oil is available
from your distributor in either 15W-40 or 10W-30
viscosity. See the parts catalog for part numbers.
1. Dipstick
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,
no oil addition is required.
4. If the oil is below the safe range, remove the fill cap
(Figure 33) and add oil until the level reaches the
FULL mark. Do not overfill.
24
Figure 33
1. Oil fill cap
Note: When using different oil, drain all old oil
from the crankcase before adding new oil.
Figure 34
5. Install the oil fill cap and dipstick.
1. Expansion tank
6. Close the hood and secure it with the latches.
2. Check the coolant level in the radiator. The radiator
should be filled to the top of the filler neck and the
expansion tank filled to the FULL mark (Figure 34).
Checking the Cooling System
Service Interval: Before each use or daily
Check level of coolant at the beginning of each day.
Capacity of system is 13 qt. (12.3 l).
3. If the coolant is low, add a 50/50 mixture of water
and ethylene glycol anti freeze. Do not use water
only or alcohol/methanol base coolants.
1. Carefully remove the radiator cap.
4. Install the radiator cap and expansion tank cap.
Filling the Fuel Tank
CAUTION
If the engine has been running, the pressurized,
hot coolant can escape and cause burns.
Use only clean, fresh diesel fuel or biodiesel fuels with
low (<500 ppm) or ultra low (<15 ppm) sulfur content.
The minimum cetane rating should be 40. Purchase
fuel in quantities that can be used within 180 days to
ensure fuel freshness.
• Do not open the radiator cap when the
engine is running.
• Use a rag when opening the radiator cap,
and open the cap slowly to allow steam to
escape.
Fuel tank capacity: 22 gallons (83 l).
Use summer grade diesel fuel (No. 2-D) at temperatures
above 20° F (-7° C) and winter grade (No. 1-D or
No. 1-D/2-D blend) below that temperature. Use of
winter grade fuel at lower temperatures provides lower
flash point and cold flow characteristics which will ease
starting and reduce fuel filter plugging.
Use of summer grade fuel above 20° F (-7° C) will
contribute toward longer fuel pump life and increased
power compared to winter grade fuel.
Important: Do not use kerosene or gasoline
instead of diesel fuel. Failure to observe this
caution will damage the engine.
25
WARNING
DANGER
Fuel is harmful or fatal if swallowed. Long-term
exposure to vapors can cause serious injury and
illness.
In certain conditions, fuel is extremely flammable
and highly explosive. A fire or explosion from fuel
can burn you and others and can damage property.
• Avoid prolonged breathing of vapors.
• Use a funnel and fill the fuel tank outdoors, in
an open area, when the engine is cold. Wipe
up any fuel that spills.
• Keep face away from nozzle and gas tank or
conditioner opening.
• Never fill the fuel tank inside an enclosed trailer.
• Keep fuel away from eyes and skin.
• Do not fill the fuel tank completely full. Add
fuel to the fuel tank until the level is 1 in. (25
mm) below the top of the tank, not the filler
neck. This empty space in the tank allows the
fuel to expand.
Biodiesel Ready
This machine can also use a biodiesel blended fuel
of up to B20 (20% biodiesel, 80% petrodiesel). The
petrodiesel portion should be low or ultra low sulfur.
Observe the following precautions:
• Never smoke when handling fuel, and stay
away from an open flame or where fuel fumes
may be ignited by a spark.
• The biodiesel portion of the fuel must meet
specification ASTM D6751 or EN14214.
• The blended fuel composition should meet ASTM
D975 or EN590.
• Store fuel in an approved container and keep it
out of the reach of children. Never buy more
than a 180-day supply of fuel.
• Painted surfaces may be damaged by biodiesel
blends.
• Do not operate without entire exhaust system
in place and in proper working condition.
• Use B5 (biodiesel content of 5%) or lesser blends
in cold weather.
1. Remove the fuel tank cap (Figure 35).
• Monitor seals, hoses, gaskets in contact with fuel as
they may be degraded over time.
• Fuel filter plugging may be expected for a time after
converting to biodiesel blends.
• Contact your distributor if you wish for more
information on biodiesel.
Figure 35
1. Fuel tank cap
2. Fill the tank to about 1 inch (25 mm) below the top
of the tank, not the filler neck, with No. 2 diesel
fuel. Then install the cap.
Note: If possible, fill the fuel tank after each use.
This will minimize possible buildup of condensation
inside the fuel tank.
26
140 to 160
Viscosity Index ASTM
D2270
Pour Point, ASTM D97
-34°F to -49°F
Industry Specifications:
Vickers I-286-S (Quality Level), Vickers M-2950-S
(Quality Level), Denison HF-0
DANGER
In certain conditions during fueling, static
electricity can be released causing a spark which
can ignite the fuel vapors. A fire or explosion from
fuel can burn you and others and can damage
property.
• Always place fuel containers on the ground
away from your vehicle before filling.
• Do not fill fuel containers inside a vehicle or on
a truck or trailer bed because interior carpets
or plastic truck bed liners may insulate the
container and slow the loss of any static charge.
• When practical, remove equipment from the
truck or trailer and refuel the equipment with
its wheels on the ground.
• If this is not possible, then refuel such
equipment on a truck or trailer from a portable
container, rather than from a fuel dispenser
nozzle.
• If a fuel dispenser nozzle must be used, keep
the nozzle in contact with the rim of the fuel
tank or container opening at all times until
fueling is complete.
Premium Biodegradable Hydraulic Fluid-Mobil
EAL EnviroSyn 46H
Important: Mobil EAL EnviroSyn 46H 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 5 gallon
(19 l) containers or 55 gallon drums from your
Mobil Distributor.
Note: Many hydraulic fluids are almost colorless,
making it difficult to spot leaks. A red dye additive for
the hydraulic system oil is available in 2/3 oz. (20 ml)
bottles. One bottle is sufficient for 4-6 gal (15-22 1)
of hydraulic oil. Order part no. 44-2500 from your
authorized Toro distributor.
Checking the Hydraulic Fluid
Level
1. Position the machine on a level surface, lower the
cutting units, stop the engine, and remove the key.
2. Clean the area around the filler neck and cap of the
hydraulic tank (Figure 36). Remove the cap from
the filler neck.
Service Interval: Before each use or daily
The machines reservoir is filled at the factory with
approximately 7.5 U.S. gallons (13.2 l) of high quality
hydraulic fluid. Check the level of the hydraulic fluid
before the engine is first started and daily thereafter.
The recommended replacement fluid is as follows:
Toro Premium All Season Hydraulic Fluid
(Available in 5 gallon pails or 55 gallon drums. See parts
catalog or Toro distributor for part numbers.)
Alternate fluids: If the Toro fluid is not available, other
fluids may be used provided they meet all the following
material properties and industry specifications. We do
not recommend the use of synthetic fluid. Consult
with your lubricant distributor to identify a satisfactory
product Note: Toro will not assume responsibility for
damage caused by improper substitutions, so use only
products 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
Figure 36
1. Hydraulic tank cap
cSt @ 40°C 44 to 48
cSt @ 100°C 7.9 to 8.5
27
3. Remove the dipstick from the filler neck and wipe
it with a clean rag. Insert the dipstick into the filler
neck; then remove it and check the fluid level. The
fluid level should be between the two marks on the
dipstick.
4. If the level is low, add the appropriate fluid to raise
the level to the upper mark.
5. Install the dipstick and cap onto the filler neck.
When the temperature is less than 20°F (-7°C), 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.
Stopping the Engine
Checking the Tire Pressure
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.
Service Interval: Before each use or daily
The tires are over-inflated for shipping. Therefore,
release some of the air to reduce the pressure. The
correct air pressure in the tires is 12–15 psi (83-103
kPa). Check the tire pressure daily.
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.
Important: Maintain the recommended pressure
in all tires to ensure a good quality-of-cut
and proper machine performance. Do not
under-inflate.
1. Move the throttle control backward to the Slow
position.
Starting and Stopping the
Engine
2. Move the PTO switch to the Off position.
3. Set the parking brake.
4. Rotate the ignition key to Off.
Starting the Engine
5. Remove the key from the switch to prevent
accidental starting.
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 throttle control 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. Move the throttle control to the
desired position.
Checking the Interlock
Switches
Service Interval: Before each use or daily
CAUTION
If safety interlock switches are disconnected or
damaged the machine could operate unexpectedly
causing personal injury.
• Do not tamper with the interlock switches.
• Check the operation of the interlock switches
daily and replace any damaged switches before
operating the machine.
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.
The machine has interlock switches in the electrical
system. These switches are designed to stop the engine
when operator gets off of the seat when the traction
pedal is depressed. However, the operator may get off
of the seat while the engine is running and the traction
pedal is in neutral. Although the engine will continue
to run if the PTO switch is disengaged and the traction
28
pedal is released, it is strongly recommended that the
engine be stopped before rising from the seat.
neutral position. The engine should kill. If the
engine does not kill, there is a malfunction in the
interlock system that should be corrected before
beginning operation.
To check the operation of the interlock switches,
perform the following procedure:
1. Drive the machine slowly to a large, relatively open
area. Lower the cutting unit, stop the engine, and
apply the parking brake.
Setting the Reel Speed
To achieve a consistent, high quality-of-cut and a
uniform after cut appearance, it is important that you
set the reel speed controls (located under the seat)
correctly. Adjust the reel speed controls as follows:
2. Sit on the seat and depress the traction pedal. Try
to start the engine. The engine should not crank.
If the engine cranks, there is a malfunction in the
interlock system that should be corrected before
beginning operation.
1. Select the height-of-cut at which the cutting units
are set.
3. Sit on the seat and start the engine. Rise from the
seat and move the PTO switch to On. The PTO
should not engage. If the PTO engages, there is a
malfunction in the interlock system that should be
corrected before beginning operation.
2. Choose the desired ground speed best suited for
conditions.
3. Using the appropriate graph on the decal (Figure 37)
determine the proper reel speed setting.
4. Sit on the seat, engage the parking brake and start
the engine. Move the traction pedal out of the
Figure 37
1. 5 blade cutting unit
3. 11 blade cutting unit
5. Read the Operator's Manual.
2. 8 blade cutting unit
4. Mow and backlap
6. Machine speed
To set the reel speed, rotate knobs (Figure 38) until
the indicator arrows are in line with the number
designating the desired setting.
Note: The reel speed can be increased or decreased
to compensate for turf conditions.
29
Figure 39
1. Spring
2. Spring actuator
4. Move the spring actuator to the desired hole
location and secure with locknut.
5. Repeat the procedure on the remaining spring.
Figure 38
1. Reel speed control knob
Adjusting the Lift Arm Turn
Around Position
Adjusting the Lift Arm
Counterbalance
1. Position the machine on a level surface, lower the
cutting units, stop the engine, engage the parking
brakes, and remove the key from ignition switch.
2. The lift arm switch is located behind the front right
lift arm (Figure 40).
You can adjust the counterbalance on the rear
cutting unit lift arms to compensate for different turf
conditions and to maintain a uniform height-of-cut in
the rough conditions or in areas of thatch build up.
You can adjust each counterbalance spring to one of
four settings. Each increment increases or decreases
counterbalance on the cutting unit by 5 lb (2.3 kg). The
springs can be positioned on the back side of the spring
actuator to remove all counter balance (forth position).
1. Position the machine on a level surface, lower the
cutting units, stop the engine, engage the parking
brakes, and remove the key from ignition switch.
2. Insert a tube or similar object onto the long
spring end to relieve the spring tension during the
adjustment (Figure 39).
CAUTION
The springs are under tension.
Use caution when adjusting them.
Figure 40
3. While relieving the spring tension, remove the bolt
and locknut securing the spring actuator to the
bracket (Figure 39).
1. Switch
3. Loosen the switch mounting screws (Figure 40)
and move the switch up to increase the lift arm
30
Jacking Points
turn around height or move the switch down to
decrease the lift arm turn around height. Tighten
the mounting screws.
• On the front of the machine on the frame on the
inside of each drive tire
• On the rear of the machine at the center of the axle
Pushing or Towing the
Machine
Tie Downs
In an emergency, the machine can be moved forward by
actuating the bypass valve in the variable displacement
hydraulic pump and pushing or towing the machine.
Do not push or tow the machine for more than 1/4
mile (0.4 km).
• On each side of the frame under the front steps
• The rear bumper
Understanding the Diagnostic
Light
Important: Do not push or tow the machine
faster than 2-3 MPH (3-4.8 km/h) because internal
transmission damage may occur. The bypass valve
must be open whenever the machine is pushed or
towed.
The machine is equipped with a diagnostic light which
indicates if the electronic controller senses an electronic
malfunction. The diagnostic light is located on the
control arm (Figure 42). When the electronic controller
is functioning correctly and the key switch is moved to
the On position, the controller diagnostic light will turn
ON for 3 seconds and turn OFF to indicate the light
is working properly. If the machine kills the light will
turn on steady until the key position is changed. The
light will blink if the controller detects a malfunction in
the electrical system. The light will stop blinking and
automatically reset when the key switch is turned to the
Off position once the fault has been resolved.
Important: If the machine must to be pushed or
towed in reverse, the check valve in the four-wheel
drive manifold must also be bypassed. To bypass
the check valve, connect a hose assembly (Hose
Part No. 95-8843, Coupler Fitting No. 95-0985
[Qty. 2], and Hydraulic Fitting No. 340-77 [Qty. 2])
to the reverse traction pressure test port and the
reverse four-wheel drive pressure port.
1. Open hood and remove the center shroud
2. Rotate the bypass valve 90° (1/4 turn) in either
direction to open and allow oil to bypass internally
(Figure 41). Because fluid is bypassed, the machine
can be slowly moved without damaging the
transmission. Note the position of the valve when
opening or closing.
Figure 42
1. Diagnostic light
When the controller diagnostic light blinks, one of the
following problems has been detected by the controller:
• One of the outputs has been shorted.
• One of the outputs is open circuited.
Figure 41
1. Bypass valve
3. Rotate the bypass valve 90° (1/4 turn) back before
starting the engine. Do not exceed 5-8 ft.-lb.
(7-11 N·m) torque to close the valve.
Using the diagnostic display, determine which output
is malfunctioning; refer to Checking the Interlock
Switches.
31
Verifying the Interlock Switch Function
If the diagnostic light is not illuminated when the key
switch is in the On position, this indicates that the
electronic controller is not operating. Possible causes
are as follows:
1. Park the machine on a level surface, lower the
cutting units, stop the engine, and engage the
parking brake.
2. Remove the access panel located beneath the front
of the seat (Figure 43).
3. Locate the wire harness and connectors near the
controller (Figure 43).
• Loop-back is not connected.
• The light is burned out.
• Fuses are blown.
• It is not functioning correctly.
Check the electrical connections, input fuses, and
diagnostic light bulb to determine the malfunction.
Ensure that the loop-back connector is secured to the
wire harness connector.
Diagnostic Ace Display
The machine is equipped with an electronic controller
which controls most machine functions. The controller
determines what function is required for various input
switches (i.e. seat switch, key switch, etc.) and turns
on the outputs to actuate solenoids or relays for the
requested machine function.
Figure 43
1. Wire harness and connectors
For the electronic controller to control the machine as
desired, each of the input switches, output solenoids,
and relays must be connected and functioning properly.
4. Carefully unplug loop back connector from harness
connector.
5. Connect the Diagnostic ACE display connector to
the harness connector (Figure 44).
Use the Diagnostic ACE display to help verify and
correct electrical functions of the machine.
Note: Make sure correct overlay decal is positioned
on Diagnostic ACE display.
Checking the Interlock
Switches
The purpose of the interlock switches is to prevent the
engine from cranking or starting unless the traction
pedal is in the Neutral position, the PTO switch is in
the OFF position, and the lift switch is in the Neutral
position. In addition, the engine should stop when the
traction pedal is pressed with operator off of the seat or
if the parking brake is left engaged.
CAUTION
If safety interlock switches are disconnected or
damaged the machine could operate unexpectedly
causing personal injury.
Figure 44
1. Diagnostic ACE
• Do not tamper with the interlock switches.
• Check the operation of the interlock switches
daily and replace any damaged switches before
operating the machine.
6. Turn the key switch to the On position, but do not
start the machine.
Note: The red text on the overlay decal refers to
input switches and the green text refers to outputs.
32
7. The “inputs displayed” LED, on the lower
right column of the Diagnostic ACE, should be
illuminated. If the “outputs displayed” LED is
illuminated, press the toggle button, on Diagnostic
ACE, to change LED to “inputs displayed”.
forth, press the toggle button once. This may be
done as often as required. Do not hold the button.
8. Sit on the seat and attempt to operate the desired
function of the machine. The appropriate output
LEDs should illuminate to indicate that the ECM is
turning on that function.
The Diagnostic ACE will illuminate the LED
associated with each of the inputs when that input
switch is closed.
8. Individually, change each of the switches from
open to closed (i.e., sit on seat, engage traction
pedal, etc.), and note that the appropriate LED
on Diagnostic ACE will blink on and off when
corresponding switch is closed. Repeat this for all
switches that you can change by hand.
9. If a switch is closed and the appropriate LED does
not turn on, check all wiring and connections to
the switch and/or check the switches with an ohm
meter. Replace any defective switches and repair
any defective wiring.
Note: If the correct output LEDs do not illuminate,
verify that the required input switches are in the
necessary positions to allow that function to occur.
Verify correct switch function.
If the output LEDs are on as specified, but the
machine does not function properly, this indicates a
non-electrical problem. Repair as necessary.
Note: If each output switch is in the correct position
and functioning correctly, but the output LEDs are not
correctly illuminated, this indicates an ECM problem. If
this occurs, contact your Toro Distributor for assistance.
Important: The Diagnostic ACE display must
not be left connected to the machine. It is not
designed to withstand the environment of the
machine's every day use. When done using the
Diagnostic ACE, disconnect it from the machine
and connect loop-back connector to harness
connector. The machine will not operate without
loopback connector installed on the harness. Store
the Diagnostic ACE in dry, secure location in the
shop, not on the machine.
Note: The Diagnostic ACE also has the ability to
detect which output solenoids or relays are turned
on. This is a quick way to determine if a machine
malfunction is electrical or hydraulic.
Verifying Output Function
1. Park the machine on a level surface, lower the
cutting units, stop the engine, and engage the
parking brake.
2. Remove the access panel located beneath the front
of the seat.
3. Locate wire harness and connectors near controller.
4. Carefully unplug loopback connector from harness
connector.
5. Connect the Diagnostic ACE connector to the
harness connector.
Operating Characteristics
Practice driving the machine because it has a hydrostatic
transmission and its characteristics are different than
many turf maintenance machines. Some points to
consider when operating the traction unit and cutting
units are the transmission, engine speed, load on the
cutting blades and the importance of the brakes.
To maintain enough power for the traction unit while
operating, regulate the traction pedal to keep the engine
RPM high and somewhat constant. A good rule to
follow is to decrease the ground speed as the load on
the cutting units increases, and increase the ground
speed as the load decreases.
Note: Make sure correct overlay decal is positioned
on Diagnostic ACE.
6. Turn the key switch to the ON position, but do not
start machine.
Note: The red text on the overlay decal refers to
input switches and the green text refers to outputs.
7. The “outputs displayed” LED, on lower right
column of Diagnostic ACE, should be illuminated.
If the “inputs displayed” LED is illuminated, press
the toggle button, on the Diagnostic ACE, to
change the LED to “outputs displayed”.
Therefore, allow the traction pedal to move backward
as the engine RPM decreases, and depress the pedal
slowly as the RPM increases. By comparison, when
driving from one work area to another, with no load
and cutting unit raised, have the throttle in the Fast
position and depress the traction pedal slowly but fully
to attain maximum ground speed.
Note: It may be necessary to toggle between
“inputs displayed” and “outputs displayed” several
times to do the following step. To toggle back and
Another characteristic to consider is the operation
of the pedals that are connected to the brakes. The
33
Warning System
brakes can be used to assist in turning the machine.
However, use them carefully, especially on soft or
wet grass because the turf may be torn accidentally.
Another benefit of the brakes is to maintain traction.
For example, in some slope conditions, the uphill wheel
slips and loses traction. If this situation occurs, depress
the uphill turn pedal gradually and intermittently until
the uphill wheel stops slipping, thus, increasing traction
on the downhill wheel.
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.
Mowing
Start the engine and move the throttle 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.
Use extra care when operating the machine on slopes.
Make sure that the seat latch is properly secured and the
seat belt is buckled. Drive slowly and avoid sharp turns
on slopes to prevent roll overs. For steering control, the
cutting unit must be lowered when going downhill.
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.
Transport
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.
Before stopping the engine, disengage all controls and
move the throttle to Slow. Moving the throttle to Slow
reduces high engine RPM, noise, and vibration. Turn
the key to Off to stop the engine.
Engine Cooling Fan Operation
The engine cooling fan switch has two positions for
controlling the operation of the fan. The two positions
are R and Auto. The fan has the ability to reverse
to blow debris off of the rear screen. Under normal
operating conditions, the switch should be in the Auto
position. In Auto, the fan speed will be controlled
by the coolant or hydraulic oil temperature and will
automatically reverse to blow debris off of the rear
screen. A reverse cycle is automatically initiated when
either the coolant or hydraulic temperature reaches
a certain point. By pressing the fan switch forward
into the R position, the fan will complete a manually
initiated reverse cycle. It is recommended to reverse the
fan when the rear screen is clogged or prior to entering
the shop or the storage area.
Operating Tips
Familiarization
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.
34
Maintenance
Note: Determine the left and right sides of the machine from the normal operating position.
Recommended Maintenance Schedule(s)
Maintenance Service
Interval
Maintenance Procedure
After the first 8 hours
• Torque the wheel nuts.
After the first 50 hours
• Change the engine oil and filter.
After the first 200 hours
• Change the planetary gear drive oil.
• Change the rear axle lubricant.
• Change the hydraulic filters.
Before each use or daily
•
•
•
•
•
•
•
•
•
•
Check the engine oil level.
Check the cooling system.
Check the hydraulic fluid level.
Check the tire pressure.
Check the interlock switches.
Check the operation of the interlock switches.
Drain water or other contaminants from the water separator.
Drain water or other contaminants from fuel filter/water separator.
Remove debris from the engine area, oil cooler, and radiator.
Inspect the hydraulic lines and hoses for leaks, kinked lines, loose mounting
supports, wear, loose fittings, weather deterioration, and chemical deterioration.
Every 50 hours
• Grease the bearings and bushings.
• Check the battery condition.
Every 100 hours
• Check the condition and tension of the alternator belt.
Every 150 hours
• Change the engine oil and filter.
Every 200 hours
• Torque the wheel nuts.
• Clean the spark arrestor muffler.
Every 400 hours
• Service the air cleaner. (Service the air cleaner earlier if the air cleaner indicator
shows red. Service it more frequently in extremely dirty or dusty conditions.)
• Check the fuel lines and connections.
• Replace the fuel filter canister.
• Check the planetary gear drive oil level (sooner if external leakage is noticed).
• Check the rear axle lubricant level.
Every 800 hours
•
•
•
•
•
•
Drain and clean the fuel tank.
Change the planetary gear drive oil.
Change the rear axle lubricant.
Check the rear wheel toe-in.
Change the hydraulic fluid.
Change the hydraulic filters.
Before storage
•
•
•
•
•
Drain and clean the fuel tank.
Check the tire pressure.
Check all fasteners.
Grease or oil all grease fittings and pivot points.
Paint chipped surfaces.
Yearly
• Check the fuel lines and connections.
• Change the planetary gear drive oil.
Important: Refer to your engine Operator's Manual and cutting unit Operator's Manual for additional
maintenance procedures.
35
Daily Maintenance Checklist
Duplicate this page for routine use.
Maintenance
Check Item
For the week of:
Mon.
Tues.
Wed.
Thurs.
Fri.
Sat.
Check the
safety interlock
operation
Check the brake
operation
Check the engine
oil and fuel level
Check the cooling
system fluid level
Drain the
water/fuel
separator
Check the air
filter restriction
indicator
Check the
radiator, oil cooler,
and screen for
debris
Check unusual
engine noises 1
Check unusual
operating noises
Check the
hydraulic system
oil level
Check hydraulic
hoses for damage
Check for fluid
leaks
Check the tire
pressure
Check the
instrument
operation
Check the
reel-to-bedknife
adjustment
Check the
height-of-cut
adjustment
Lubricate all
grease fittings
2
Touch-up
damaged paint.
1. Check the glow plug and injector nozzles if hard starting, excess smoke, or rough running is noted.
2. Immediately after every washing, regardless of the interval listed.
36
Sun.
Service Interval Chart
Figure 45
CAUTION
If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure
you or other bystanders.
Remove the key from the ignition before you do any maintenance.
37
Premaintenance
Procedures
Lubrication
Greasing the Bearings and
Bushings
Removing the Hood
Service Interval: Every 50 hours
1. Release hood latches (Figure 46) and pivot open 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 47)
Figure 46
1. Hood latch (2)
Figure 47
2. Remove the cotter pins securing the rear hood
brackets to the frame pins and lift off the hood.
• Rear axle pivot bushings (2) (Figure 48)
Figure 48
38
• Steering cylinder ball joints (2) (Figure 49)
• Cutting unit carrier frame (2 per cutting unit)
(Figure 51)
• Cutting unit lift arm pivot (1 per cutting unit)
(Figure 51)
Figure 51
Figure 49
1. Top fitting on king pin
• Tie rod ball joints (2) (Figure 49)
• King pin bushings (2) (Figure 49). The top fitting
on the king pin should only be lubricated
annually (2 pumps).
• Lift arm bushings (1 per cutting unit) (Figure 50)
Figure 50
• Lift cylinder bushings (2 per cutting unit) (Figure 50)
• Lift arm pivot bushings (1 per cutting unit)
(Figure 51)
39
Engine Maintenance
which could force dirt through the filter into the
intake tract.
Servicing the Air Cleaner
This cleaning process prevents debris from migrating
into the intake when the primary filter is removed.
Service Interval: Every 400 hours
3. Remove and replace the primary filter (Figure 54).
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.
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.
Service the air cleaner filter only when the service
indicator (Figure 52) 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 52
Figure 54
1. Air cleaner indicator
1. Air cleaner primary filter
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 53).
Important: Never attempt to clean the safety
filter (Figure 55). Replace the safety filter with a
new one after every three primary filter services.
Figure 55
1. Air cleaner safety filter
Figure 53
1. Air cleaner indicator
2. Air cleaner latch
3. Air cleaner cover
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.
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
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 52) if it shows red.
40
Adjusting the Throttle
Servicing the Engine Oil and
Filter
Adjust the throttle cable (Figure 58) so that the governor
lever on the engine contacts the high speed set bolt at
the same point that the throttle cable contacts the end of
the slot in the control arm.
Service Interval: After the first 50 hours
Every 150 hours
Change the oil and filter initially after the first 50 hours
of operation; thereafter change the oil and filter every
150 hours.
1. Remove the rear drain plug (Figure 56) and let the
oil flow into a drain pan. When the oil stops, install
the drain plug.
Figure 58
1. Throttle cable
Figure 56
1. Engine oil drain plug
2. Remove the oil filter (Figure 57). Apply a light coat
of clean oil to the new filter seal before screwing it
on. Do not overtighten.
Figure 57
1. Engine oil filter
3. Add oil to the crankcase; refer to Checking the
Engine Oil in Operation.
41
Servicing the Water Separator
Fuel System
Maintenance
Service Interval: Before each use or daily—Drain
water or other contaminants from
fuel filter/water separator.
DANGER
Every 400 hours—Replace the fuel
filter canister.
Under certain conditions, diesel fuel and fuel
vapors are highly flammable and explosive. A fire
or explosion from fuel can burn you and others and
can cause property damage.
Drain water or other contaminants from water separator
daily. Replace filter canister after every 400 hours of
operation.
• Fill the fuel tank outdoors, in an open area,
when the engine is off and is cold. Wipe up any
fuel that spills.
1. Place a clean container under the fuel filter(Figure 59).
2. Loosen the drain plug on the bottom of the filter
canister.
• Do not fill the fuel tank completely full. Add fuel
to the fuel tank until the level is 1 in. (25 mm)
below the top of the tank, not the filler neck.
This empty space in the tank allows the fuel to
expand.
• Never smoke when handling fuel, and stay away
from an open flame or where fuel fumes may be
ignited by a spark.
• Store fuel in a clean, safety-approved container
and keep the cap in place.
Fuel Tank
Figure 59
Every 800 hours—Drain and clean
the fuel tank.
1. Water separator filter canister
Before storage—Drain and clean the
fuel tank.
3. Clean the area where the filter canister mounts.
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.
4. Remove the filter canister and clean the mounting
surface.
5. Lubricate the gasket on the filter canister with clean
oil.
Fuel Lines and Connections
6. Install the filter canister by hand until the gasket
contacts mounting surface, then rotate it an
additional 1/2 turn.
Service Interval: Every 400 hours—Check the fuel
lines and connections.
7. Tighten the drain plug on the bottom of the filter
canister.
Yearly—Check the fuel lines and
connections.
Fuel Pick up Tube Screen
Check the fuel lines and connections every 400 hours
or yearly, whichever comes first. Inspect them for
deterioration, damage, or loose connections.
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.
42
Bleeding Air from the Injectors
Electrical System
Maintenance
Note: This procedure should be used only if the fuel
system has been purged of air through normal priming
procedures and the engine will not start.
Charging and Connecting the
Battery
1. Loosen the pipe connection to the No. 1 injector
nozzle and holder assembly at the injection pump
(Figure 60).
WARNING
CALIFORNIA
Proposition 65 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.
1. Unlatch and raise the operator's console panel
(Figure 61).
Figure 60
1. No. 1 injector nozzle
2. Move the throttle to the Fast position.
3. Turn the key in the ignition switch to the Start
position and watch the fuel flow around the
connector. Turn the key to the Off position when
solid flow is observed.
4. Tighten the pipe connector securely.
5. Repeat the procedure on the remaining nozzles.
Figure 61
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.
43
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.
jelly, or light grease to prevent corrosion. Slide the
rubber boot over the positive terminal.
6. Close the console panel and secure the latch.
3. When the battery is charged, disconnect the charger
from the electrical outlet and battery posts.
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.
WARNING
Charging the battery produces gasses that can
explode.
• When removing or installing the battery, do
not allow the battery terminals to touch any
metal parts of the machine.
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 62). 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.
• 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.
Battery Care
Service Interval: Every 50 hours
Important: Before welding on the machine,
disconnect the negative cable from the battery to
prevent damage to the electrical system.
Figure 62
1. Positive battery cable
2. Negative battery cable
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.
WARNING
CALIFORNIA
Proposition 65 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
44
Fuses
The fuses are located under the operators control panel.
20A
10A
10A
10A
10A
7.5A
7.5A
7.5A
TEC-5002
2A
60A
120-1672
Figure 63
Figure 65
1. Fuses
Unhook the latch and raise the operator's console panel
(Figure 64) to expose the fuses (Figure 65).
Figure 64
1. Operator's console panel
2. Latch
45
Drive System
Maintenance
3. Add gear oil to the hole in the planetary, if necessary,
to bring the oil up to the proper level. Install the
plug.
4. Repeat steps 1–3 on the opposite gear assembly.
Checking the Torque of the
Wheel Nuts
Changing the Planetary Gear
Drive Oil
Service Interval: After the first 8 hours
Service Interval: After the first 200 hours
Every 200 hours
Every 800 hours
WARNING
Yearly
Failure to maintain proper torque of the wheel nuts
could result in failure or loss of wheel and may
result in personal injury.
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.
Torque the front and rear wheel nuts to 85-100 ft.-lb.
(115-136 N·m) after 1-4 hours of operation and again
after 8 hours of operation. Torque every 200 hours
thereafter.
1. With the machine on a level surface, position the
wheel so that the check/drain plug (Figure 67) is at
the 6 o'clock position.
Note: Front wheel nuts are 1/2-20 UNF. Rear wheel
nuts are M12 x 1.6-6H (Metric).
Checking the Planetary Gear
Drive Oil
Service Interval: Every 400 hours
Check the oil level after every 400 hours of operation
or if external leakage is noted. Use high quality SAE
85W-140 wt. gear lube as a replacement.
Figure 67
1. Check/drain plug (6 o'clock position)
The capacity of the system is approximately 16 oz. (0.5 l).
1. With the machine on a level surface, position the
wheel so that the check/drain plug (Figure 66) is at
either the 3 or 9 o'clock position.
2. Place a drain pan under the hub, remove the plug,
and allow the oil to drain.
3. Place another drain pan under the brake housing on
the other side of the wheel (Figure 68).
Figure 66
1. Check/drain plug (3 or 9 o'clock position)
2. Remove the plug on the planetary (Figure 66). Oil
should be at the bottom of the check plug hole on
the back side of the brake.
46
Figure 69
2. Fill plug
1. Check plug
Figure 68
1. Brake housing
3. Check plug
Changing the Rear Axle
Lubricant
2. Drain plug
4. Remove check/drain plugs from the brake housing
and allow the oil to drain.
Service Interval: After the first 200 hours
Every 800 hours
5. When all of the oil has drained, install the bottom
plug in the brake housing.
1. Position the machine on a level surface.
6. Position the wheel so that the plug hole is at the 3 or
9 o'clock position on the planetary.
2. Clean the area around the 3 drain plugs, 1 on each
end and 1 in the center (Figure 70).
7. Slowly add approximately 16 oz. (0.5 l) of high
quality SAE 85W-140 wt. gear lube to the planetary
fill hole (at the ten or two o'clock position) until the
level is up to the bottom of the brake housing check
hole. Install the plug.
8. Repeat the procedure on the opposite
planetary/brake assembly.
Checking the Rear Axle
Lubricant
Figure 70
1. Drain plug location
Service Interval: Every 400 hours
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. (2.4 l). Visually inspect for leaks daily.
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.
1. Position the machine on a level surface.
5. Install the plugs.
2. Remove a check plug from one end of the axle
(Figure 69) and make sure that the lubricant is up to
the bottom of the hole. If the level is low, remove
the fill plug (Figure 69) and add enough lubricant to
bring the level up to the bottom of the check plug
holes.
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.
47
Adjusting the Traction Drive
for Neutral
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.
Figure 72
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.
1. Front of traction unit
2. 1/8 inch less than rear of
tire
3. Center to center distance
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 71).
2. To adjust, remove the cotter pin and nut from either
tie rod ball joint (Figure 73). Remove tie rod ball
joint from axle case support.
Figure 71
1. Pump rod jam nuts
Figure 73
2. Pump control tube
1. Tie rod clamp
2. Tie rod ball joint
5. After wheel rotation ceases, tighten jam nuts to
secure adjustment.
3. Loosen the clamps at both ends of the tie rods
(Figure 73).
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.
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.
Checking the Rear Wheel
Toe-In
6. Install the ball joint in the axle case support and
tighten the nut finger tight. Measure toe-in.
Service Interval: Every 800 hours/Yearly (whichever
comes first)
7. Repeat procedure if necessary.
1. Measure the center-to-center distance (at axle height)
at the front and rear of the steering tires. The front
measurement must be 1/8 in. (3 mm) less than the
rear measurement (Figure 72).
8. Tighten the nut and install a new cotter pin when
the adjustment is correct.
48
Cooling System
Maintenance
Servicing the Engine Cooling
System
Service Interval: Before each use or daily
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 74).
Clean the screen thoroughly of all debris.
Figure 75
Note: To remove the screen, lift off the hinge pins.
1. Oil cooler latches
3. Pivot the oil cooler rearward. Clean both sides of the
oil cooler and radiator area (Figure 76) 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 74
1. Rear screen latch
2. Rotate the latches (Figure 75) securing the oil cooler
to the frame.
Figure 76
1. Oil cooler
2. Radiator
Important: Cleaning the radiator or oil cooler
with water will promote premature corrosion
damage to components and compact debris.
4. Pivot the oil cooler back into position. Secure it to
the frame with the latches, close the screen.
49
Brake Maintenance
Belt Maintenance
Adjusting the Service Brakes
Servicing the Alternator Belt
Adjust the service brakes when there is more than 1 in.
(25 mm) 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.
Service Interval: Every 100 hours
1. Disengage the locking latch from the brake pedals so
that both pedals work independently of each other.
1. Proper tension will allow 3/8 in. (10 mm) deflection
when a force of 10 lb. is applied on the belt midway
between the pulleys.
Check the condition and tension of the belts (Figure 78)
after every 100 operating hours.
2. To reduce free travel of the brake pedals, tighten
the brakes:
2. If the deflection is not 3/8 in. (10 mm), loosen
the alternator mounting bolts (Figure 78). 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.
A. Loosen the front nut on the threaded end of the
brake cable (Figure 77).
Figure 77
1. Brake cable
B. Tighten the rear nut to move the cable backward
until the brake pedals have 1/2 to 1 in. (13 to
25 mm) of free travel.
Figure 78
1. Alternator
C. Tighten the front nuts after the brakes are
adjusted correctly.
50
2. Mounting bolt
Hydraulic System
Maintenance
3. Lubricate the new filter gasket and fill the filter with
hydraulic fluid.
Changing the Hydraulic Fluid
Service Interval: Every 800 hours
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 7.5 gallons of
hydraulic fluid; refer to Checking the Hydraulic Fluid.
Figure 79
1. Hydraulic filter
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 level
the level to the FULL mark on the dipstick. Do not
overfill.
Replacing the Hydraulic Filters
Service Interval: After the first 200 hours
Every 800 hours
Change the 2 hydraulic filters initially after the first 200
operating hours. Thereafter, change the filters after
every 800 operating hours, in normal conditions.
Figure 80
1. Hydraulic filter
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.
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.
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 79 and Figure 80).
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.
51
Checking the Hydraulic Lines
and Hoses
Cutting Unit Maintenance
Backlapping the Cutting Units
Service Interval: Before each use or daily
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.
WARNING
Contact with the reels or other moving parts can
result in personal injury.
• Keep fingers, hands, and clothing away from the
reels or other moving parts.
WARNING
• Never attempt to turn the reels by hand or foot
while the engine is running.
Hydraulic fluid escaping under pressure can
penetrate skin and cause injury.
Note: When backlapping, the front units all operate
together, and the rear units operate together.
• Make sure all hydraulic fluid hoses and lines are
in good condition and all hydraulic connections
and fittings are tight before applying pressure to
the hydraulic system.
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.
• Keep your body and hands away from pin
hole leaks or nozzles that eject high pressure
hydraulic fluid.
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.
• Use cardboard or paper to find hydraulic leaks.
• Safely relieve all pressure in the hydraulic system
before performing any work on the hydraulic
system.
4. Select either front, rear or both backlap levers to
determine which units to backlap (Figure 81).
• Seek immediate medical attention if fluid is
injected into skin.
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.
52
Cleaning
Servicing the Spark Arrestor
Muffler
Service Interval: Every 200 hours
Every 200 hours operation, clear the muffler of carbon
buildup.
1. Remove the pipe plug from the clean-out port at the
lower side of the muffler.
CAUTION
The muffler may be hot and could cause injury.
Be careful while working around the muffler.
Figure 81
1. Front backlap lever
2. Start the engine. Plug the normal muffler exit with a
block of wood or metal plate so that the exhaust flow
will be forced out of the clean-out port. Continue to
block the exit until carbon deposits cease coming
out of the port.
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.
CAUTION
Do not stand in line with the clean-out port.
Always wear safety glasses.
10. Repeat the procedure for all cutting units you want
to backlap.
3. Stop the engine and replace the pipe plug.
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.
53
Storage
Engine
1. Drain the engine oil from the oil pan and install the
drain plug.
2. Remove and discard the oil filter. Install a new oil
filter.
3. Refill the oil pan with 10 qt. (9.5 l) of SAE 15W-40
CH-4, CI-4, higher motor oil.
4. Start the engine and run it at idle speed for
approximately two minutes.
5. Stop the engine.
6. Flush the fuel tank with fresh, clean diesel fuel.
7. Secure all of the fuel system fittings.
8. Thoroughly clean and service the air cleaner
assembly.
9. Seal the air cleaner inlet and the exhaust outlet with
weatherproof tape.
10. Check the anti freeze protection and add a 50/50
solution of water and ethylene glycol anti-freeze as
needed for the expected minimum temperature in
your area.
Traction Unit
1. Thoroughly clean the traction unit, cutting units, and
the engine.
2. Check the tire pressure; refer to Checking the Tire
Pressure.
3. Check all fasteners for looseness; tighten as
necessary.
4. Grease or oil all grease fittings and pivot points.
Wipe up any excess lubricant.
5. Lightly sand and use touch-up paint on painted areas
that are scratched, chipped, or rusted. Repair any
dents in the metal body.
6. Service the battery and cables as follows:
A. Remove the battery terminals from the battery
posts.
B. Clean the battery, terminals, and posts with a wire
brush and baking soda solution.
C. Coat the cable terminals and battery posts with
Grafo 112X skin-over grease (Toro Part No.
505-47) or petroleum jelly to prevent corrosion.
D. Slowly recharge the battery every 60 days for 24
hours to prevent lead sulfation of the battery.
54
Schematics
Hydraulic Schematic (Rev. A)
55
Electrical Schematic-Sheet 1 (Rev. C)
56
Electrical Schematic-Sheet 2 (Rev. C)
57
Notes:
58
Notes:
59
The Toro Total Coverage Guarantee
A Limited Warranty
Conditions and Products Covered
The Toro Company and its affiliate, Toro Warranty Company, pursuant
to an agreement between them, jointly warrant your Toro Commercial
product (“Product”) to be free from defects in materials or workmanship
for two years or 1500 operational hours*, whichever occurs first. This
warranty is applicable to all products with the exception of Aerators
(refer to separate warranty statements for these products). Where a
warrantable condition exists, we will repair the Product at no cost to you
including diagnostics, labor, parts, and transportation. This warranty
begins on the date the Product is delivered to the original retail purchaser.
* Product equipped with an hour meter.
Instructions for Obtaining Warranty Service
You are responsible for notifying the Commercial Products Distributor or
Authorized Commercial Products Dealer from whom you purchased the
Product as soon as you believe a warrantable condition exists. If you need
help locating a Commercial Products Distributor or Authorized Dealer, or
if you have questions regarding your warranty rights or responsibilities,
you may contact us at:
Toro Commercial Products Service Department
Toro Warranty Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
952–888–8801 or 800–952–2740
E-mail: commercial.warranty@toro.com
Owner Responsibilities
As the Product owner, you are responsible for required maintenance
and adjustments stated in your Operator's Manual. Failure to perform
required maintenance and adjustments can be grounds for disallowing a
warranty claim.
Items and Conditions Not Covered
Not all product failures or malfunctions that occur during the warranty
period are defects in materials or workmanship. This warranty does not
cover the following:
•
Product failures which result from the use of non-Toro replacement
parts, or from installation and use of add-on, or modified non-Toro
branded accessories and products. A separate warranty may be
provided by the manufacturer of these items.
•
Product failures which result from failure to perform recommended
maintenance and/or adjustments. Failure to properly maintain your
Toro product per the Recommended Maintenance listed in the
Operator’s Manual can result in claims for warranty being denied.
•
Product failures which result from operating the Product in an
abusive, negligent, or reckless manner.
•
Parts subject to consumption through use unless found to be
defective. Examples of parts which are consumed, or used up,
during normal Product operation include, but are not limited to, brake
pads and linings, clutch linings, blades, reels, rollers and bearings
(sealed or greasable), bed knives, spark plugs, castor wheels and
bearings, tires, filters, belts, and certain sprayer components such as
diaphragms, nozzles, and check valves, etc.
•
Failures caused by outside influence. Conditions considered to be
outside influence include, but are not limited to, weather, storage
practices, contamination, use of unapproved fuels, coolants,
lubricants, additives, fertilizers, water, or chemicals, etc.
•
Failure or performance issues due to the use of fuels (e.g. gasoline,
diesel, or biodiesel) that do not conform to their respective industry
standards.
•
•
Normal noise, vibration, wear and tear, and deterioration.
Normal “wear and tear” includes, but is not limited to, damage to
seats due to wear or abrasion, worn painted surfaces, scratched
decals or windows, etc.
Parts
Parts scheduled for replacement as required maintenance are warranted
for the period of time up to the scheduled replacement time for that part.
Parts replaced under this warranty are covered for the duration of the
original product warranty and become the property of Toro. Toro will
make the final decision whether to repair any existing part or assembly or
replace it. Toro may use remanufactured parts for warranty repairs.
Deep Cycle and Lithium-Ion Battery Warranty:
Deep cycle and Lithium-Ion batteries have a specified total number of
kilowatt-hours they can deliver during their lifetime. Operating, recharging,
and maintenance techniques can extend or reduce total battery life. As the
batteries in this product are consumed, the amount of useful work between
charging intervals will slowly decrease until the battery is completely worn
out. Replacement of worn out batteries, due to normal consumption,
is the responsibility of the product owner. Battery replacement may be
required during the normal product warranty period at owner’s expense.
Note: (Lithium-Ion battery only): A Lithium-Ion battery has a part only
prorated warranty beginning year 3 through year 5 based on the time
in service and kilowatt hours used. Refer to the Operator's Manual for
additional information.
Maintenance is at Owner’s Expense
Engine tune-up, lubrication, cleaning and polishing, replacement of filters,
coolant, and completing recommended maintenance are some of the
normal services Toro products require that are at the owner’s expense.
General Conditions
Repair by an Authorized Toro Distributor or Dealer is your sole remedy
under this warranty.
Neither The Toro Company nor Toro Warranty Company is liable for
indirect, incidental or consequential damages in connection with the
use of the Toro Products covered by this warranty, including any
cost or expense of providing substitute equipment or service during
reasonable periods of malfunction or non-use pending completion
of repairs under this warranty. Except for the Emissions warranty
referenced below, if applicable, there is no other express warranty.
All implied warranties of merchantability and fitness for use are
limited to the duration of this express warranty.
Some states do not allow exclusions of incidental or consequential
damages, or limitations on how long an implied warranty lasts, so the
above exclusions and limitations may not apply to you. This warranty
gives you specific legal rights, and you may also have other rights which
vary from state to state.
Note regarding engine warranty:
The Emissions Control System on your Product may be covered by
a separate warranty meeting requirements established by the U.S.
Environmental Protection Agency (EPA) and/or the California Air
Resources Board (CARB). The hour limitations set forth above do not
apply to the Emissions Control System Warranty. Refer to the Engine
Emission Control Warranty Statement supplied with your product or
contained in the engine manufacturer’s documentation for details
Countries Other than the United States or Canada
Customers who have purchased Toro products exported from the United States or Canada should contact their Toro Distributor (Dealer) to obtain
guarantee policies for your country, province, or state. If for any reason you are dissatisfied with your Distributor's service or have difficulty obtaining
guarantee information, contact the Toro importer.
374-0253 Rev B
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