Toro 03807, Reelmaster 6500-D, Reelmaster 6700-D, 03808 Operator's Manual

Form No. 3354-511 Rev B

Reelmaster® 6500-D and 6700-D Traction Unit

Model No. 03806 —Serial No. 260000001 and Up Model No. 03807 —Serial No. 260000001 and Up Model No. 03808 —Serial No. 260000001 and Up

Warning

Model No.

CALIFORNIA

Pr oposition 65 W ar ning

Diesel engine exhaust and some of its constituents ar e kno wn to the State of Calif or nia to cause cancer , bir th defects, and other r epr oducti v e har m.

Important: T his engine is not equipped with a spar k ar r ester muf ﬂer . It is a violation of Calif or nia Public R esource Code Section 4442 to use or operate the engine on an y f or est-co v er ed, br ush-co v er ed, or g rass-co v er ed land. Other states or federal ar eas may ha v e similar la ws.

Introduction

R ead this infor mation carefully to lear n ho w to operate and maintain y our product properly and to a v oid injur y and product damag e . Y ou are responsible for operating the product properly and safely .

Y ou ma y contact T oro directly at www .T oro .com for product and accessor y infor mation, help ﬁnding a dealer , or to register y our product.

W henev er y ou need ser vice , g en uine T oro par ts , or additional infor mation, contact an A uthorized Ser vice Dealer or T oro Customer Ser vice and ha v e the model and serial n umbers of y our product ready . Figure 1 identiﬁes the location of the model and serial n umbers on the product. W rite the n umbers in the space pro vided.

Figure 1

1. Location of the model and serial numbers

Serial No.

T his man ual identiﬁes potential hazards and has safety messag es identiﬁed b y the safety aler t symbol ( Figure 2 ), whic h signals a hazard that ma y cause serious injur y or death if y ou do not follo w the recommended precautions .

Figure 2

1. Safety alert symbol.

T his man ual uses tw o other w ords to highlight infor mation. Impor tant calls attention to special mec hanical infor mation and Note emphasizes g eneral infor mation w or th y of special attention.

Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safe Operating Practices . . . . . . . . . . . . . . . . . . . . . . 4

T oro Mo w er Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Sound Pressure Lev el . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Vibration Lev el . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Safety and Instr uctional Decals . . . . . . . . . . . . 7

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1 Chec king Fluid Lev els . . . . . . . . . . . . . . . . . . . . . 13

2 Installing the Cutting Units . . . . . . . . . . . . . . 13

3 Making Alter nate Cutting Unit

Adjustments . . . . . . . . . . . . . . . . . . . . . . 15

4 Adding R ear Ballast . . . . . . . . . . . . . . . . . . . . . . . . . 16

5 Installing CE Decals . . . . . . . . . . . . . . . . . . . . . . . . 16

6 R eading the Man uals and Storing

Additional P ar ts . . . . . . . . . . . . . . . . . 16

Product Ov er view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Speciﬁcations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Chec king the Engine Oil . . . . . . . . . . . . . . . . . . . . 22

Chec king the Cooling System . . . . . . . . . . . . . 22

Filling the Fuel T ank . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Chec king the Hy draulic Fluid . . . . . . . . . . . . . 24

Chec king the Tire Pressure . . . . . . . . . . . . . . . . . 25

Chec king the R eel to Bedknife

Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Star ting and Stopping . . . . . . . . . . . . . . . . . . . . . . . . 25

Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . 25

Pushing or T o wing the

Mac hine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Chec king the Interloc k

Switc hes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

F ault Memor y and R etriev al . . . . . . . . . . . . . . . 28

Hy draulic Solenoid V alv e

Functions . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Operating Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

R ecommended Maintenance

Sc hedule(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Ser vice Inter v al Char t . . . . . . . . . . . . . . . . . . . . . . . . 32

Daily Maintenance Chec klist . . . . . . . . . . . . . . 33

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Greasing the Bearings and

Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Ser vicing the Air Cleaner . . . . . . . . . . . . . . . . . . . 35

Ser vicing the Engine Oil and

Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Adjusting T hrottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Fuel System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Fuel T ank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Fuel Lines and Connections . . . . . . . . . . . . . . . 38

Fuel Filter/W ater Se parator . . . . . . . . . . . . . . . 38

R e placing the Fuel Pre-Filter . . . . . . . . . . . . . . 38

Bleeding Air F rom Injectors . . . . . . . . . . . . . . . 39

Electrical System Maintenance . . . . . . . . . . . . . . . . . . . 39

Batter y Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Optional Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Dri v e System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 41

Chec king the T or que of the W heel

Nuts or Bolts . . . . . . . . . . . . . . . . . . . . . 41

Chec king the Planetar y Gear Dri v e

Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Changing the Planetar y Gear Dri v e

Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Chec king the R ear Axle

Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Changing the R ear Axle

Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . 43

R ear W heel T oe-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Adjusting the T raction Dri v e for

Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Cooling System Maintenance . . . . . . . . . . . . . . . . . . . . . 44

R emo ving Debris . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Maintaining the Cooling

System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Brak e Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Adjusting the Ser vice Brak es . . . . . . . . . . . . . . 45

Belt Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Chec king the Alter nator Belt . . . . . . . . . . . . . . 45

Hy draulic System Maintenance . . . . . . . . . . . . . . . . . . 45

Changing the Hy draulic Fluid . . . . . . . . . . . . . 45

R e placing the Hy draulic Filter . . . . . . . . . . . . 46

Chec king the Hy draulic Lines and

Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Hy draulic System T est P or ts . . . . . . . . . . . . . . . 47

Cutting Unit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Bac klapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Adjust T urf Compensation

Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Adjusting the Cutting Unit

Lo w ering Rate . . . . . . . . . . . . . . . . . . 50

Lifted Height of Outer F ront

Cutting Units (Enable

P osition) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Adjusting the T ra v el of the

F ront T hree Cutting

Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Storag e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

T raction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Sc hematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Safety

T his machine meets or ex ceeds CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-1999 speciﬁcations in ef fect at the time of pr oduction when, ballast is added; r efer to Adding R ear Ballast in Setup , pa ge 13 .

• W ear appropriate clothing including hard hat,

safety glasses and ear protection. Long hair , loose clothing or jew elr y ma y g et tangled in mo ving par ts .

• Inspect the area where the equipment is to be used and remo v e all objects suc h as roc ks , to ys and wire whic h can be thro wn b y the mac hine .

Note: T he addition of attac hments made b y other man ufacturers that do not meet American National Standards Institute cer tiﬁcation will cause noncompliance of this mac hine .

Improper use or maintenance b y the operator or o wner can result in injur y . T o reduce the potential for injur y , comply with these safety instr uctions and alw a ys pa y attention to the safety aler t symbol, whic h means CA UTION , W ARNING , or D ANGER-“personal safety instr uction. ” F ailure to comply with the instr uction ma y result in personal injur y or death.

Safe Operating Practices

T he follo wing instr uctions are from the CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-1999.

Training

• R ead the Operator’ s Man ual and other training material. If the operator(s) or mec hanic(s) can not read English it is the o wner’ s responsibility to explain this material to them.

• Become familiar with the safe operation of the equipment, operator controls , and safety signs .

• All operators and mec hanics should be trained. T he o wner is responsible for training the users .

• Nev er let c hildren or untrained people operate or ser vice the equipment. Local regulations ma y restrict the ag e of the operator .

• T he o wner/user can prev ent and is responsible for accidents or injuries occur ring to himself or herself , other people or proper ty .

Preparation

• Ev aluate the ter rain to deter mine what accessories and attac hments are needed to properly and safely perfor m the job . Only use accessories and attac hments appro v ed b y the man ufacturer .

• Use extra care when handling diesel fuel. It is ﬂammable and v apors are explosi v e .

Use only an appro v ed container .

• Nev er remo v e g as cap or add fuel with engine r unning . Allo w engine to cool before refueling . Do not smok e .

• Nev er refuel or drain the mac hine indoors .

• Chec k that operator’ s presence controls ,

safety switc hes and shields are attac hed and functioning properly . Do not operate unless they are functioning properly .

Operation

• Nev er r un an engine in an enclosed area.

• Only operate in g ood light, k ee ping a w a y from

holes and hidden hazards .

• Be sure all dri v es are in neutral and parking brak e is eng ag ed before star ting engine . Only star t engine from the operator’ s position. Use seat belts if pro vided.

• Slo w do wn and use extra care on hillsides . Be sure to tra v el in the recommended direction on hillsides . T urf conditions can affect the mac hine’ s stability . Use caution while operating near drop-offs .

• Slo w do wn and use caution when making tur ns and when c hanging directions on slopes .

• Nev er operate with guards not securely in place . Be sure all interloc ks are attac hed, adjusted properly , and functioning proper ty .

• Do not c hang e the engine g o v er nor setting or o v erspeed the engine .

• Stop on lev el g round, raise the cutting units , diseng ag e dri v es , eng ag e parking brak e (if pro vided), shut off engine before lea ving the operator’ s position for any reason including emptying the g rass bask ets .

• Stop equipment and inspect the mac hine after striking objects or if an abnor mal vibration

occurs . Mak e necessar y re pairs before resuming operations .

• K ee p hands and feet a w a y from the cutting units .

• Look behind and do wn before bac king up to be sure of a clear path.

• Nev er car r y passeng ers and k ee p pets and b ystanders a w a y .

• Charg e batteries in an open w ell v entilated area, a w a y from spark and ﬂames . Unplug c harg er before connecting or disconnecting from batter y . W ear protecti v e clothing and use insulated tools .

• K ee p all par ts in g ood w orking condition and all hardw are and h y draulic ﬁttings tightened. R e place all w or n or damag ed decals .

• Slo w do wn and use caution when making tur ns and crossing roads and sidew alks . Stop reels if not mo wing .

• Do not operate the mo w er under the inﬂuence of alcohol or dr ugs .

• Use care when loading or unloading the mac hine into a trailer or tr uc k.

• Use care when approac hing blind cor ners , shr ubs , trees , or other objects that ma y obscure vision.

Maintenance and Storage

• Diseng ag e dri v es , raise the cutting units , set parking brak e , stop engine and remo v e k ey . W ait for all mo v ement to stop before adjusting, cleaning or re pairing .

• Clean g rass and debris from cutting units , dri v es , m ufﬂers , and engine to help prev ent ﬁres . Clean up oil or fuel spillag e .

• Let engine cool before storing and do not store near ﬂame .

• Shut off fuel while storing or transpor ting . Do not store fuel near ﬂames or drain indoors .

• P ark mac hine on lev el g round. Nev er allo w untrained personnel to ser vice mac hine .

• Use jac k stands to suppor t components when required.

• Carefully release pressure from components with stored energ y .

• Disconnect batter y and remo v e spark plug wire before making any re pairs . Disconnect the neg ati v e ter minal ﬁrst and the positi v e last. R econnect positi v e ﬁrst and neg ati v e last.

• Use care when c hec king the reels . W ear glo v es and use caution when ser vicing them.

• K ee p hands and feet a w a y from mo ving par ts . If possible , do not mak e adjustments with the engine r unning .

Toro Mower Safety

T he follo wing list contains safety infor mation speciﬁc to T oro products or other safety infor mation that y ou m ust kno w that is not included in the ANSI standards .

T his product is capable of amputating hands and feet and thro wing objects . Alw a ys follo w all safety instr uctions to a v oid serious injur y or death.

Use of this product for pur poses other than its intended use could pro v e dang erous to user and b ystanders .

Operation

• Sit on the seat when star ting and operating the mac hine .

• Alw a ys w ear substantial shoes . Do not operate the mac hine while w earing sandals , tennis shoes , or sneak ers .

• W earing safety shoes and long pants is advisable and required b y some local ordinances and insurance regulations .

• Handle fuel carefully . Wipe up any spills .

• Chec k the safety interloc k switc hes daily

for proper operation. If a switc h should fail, re place the switc h before operating the mac hine . After ev er y tw o years , re place all three interloc k switc hes in the safety system, reg ardless if they are w orking properly or not.

• Using the mac hine demands attention. T o prev ent loss of control:

Do not dri v e close to sand traps , ditc hes , creeks , or other hazards .

• R educe speed when making shar p tur ns . A v oid sudden stops and star ts .

• Do not touc h the engine , m ufﬂer , or exhaust pipe while the engine is r unning or soon after

it has stopped because these areas could be hot enough to cause bur ns .

• If a cutting unit strik es a solid object or vibrates abnor mally , stop immediately , tur n the engine off , w ait for all motion to stop , and inspect the mac hine for damag e . A damag ed reel or bedknife m ust be re paired or re placed before operation is contin ued.

• T ra v erse slopes carefully . Do not star t or stop suddenly when tra v eling uphill or do wnhill.

• T he operator m ust be skilled and trained in ho w to dri v e on hillsides . F ailure to use caution on slopes or hills ma y cause loss of control and cause the v ehicle to tip or roll, possibly resulting in personal injur y or death. On 4 wheel dri v e models , alw a ys use the seat belt and R oll Ov er Protection System (R OPS) tog ether .

• If the engine stalls or loses headw a y and cannot mak e it to the top of a slope , do not tur n the mac hine around. Alw a ys bac k slo wly , straight do wn the slope .

• W hen a person or pet appears unexpectedly in or near the mo wing area, stop mo wing . Careless operation, combined with ter rain angles , ricoc hets , or improperly positioned guards can lead to thro wn object injuries . Do not resume mo wing until the area is cleared.

• Do not park on slopes unless the wheels are c hoc k ed or bloc k ed.

Maintenance and Storage

• Mak e sure all h y draulic line connectors are tight and all h y draulic hoses and lines are in g ood condition before applying pressure to the system.

clothing, and any par ts of the body a w a y from the cutting units , attac hments and any mo ving par ts . K ee p ev er y one a w a y .

• T he engine m ust be shut off before c hec king the oil or adding oil to the crankcase .

• If major re pairs are ev er needed or if assistance is desired, contact an A uthorized T oro Distributor .

• T o mak e sure of optim um perfor mance and contin ued safety cer tiﬁcation of the mac hine , use only g en uine T oro re placement par ts and accessories . R e placement par ts and accessories made b y other man ufacturers could be dang erous , and suc h use could v oid the product w ar ranty .

Sound Pressure Level

T his unit has an equi v alent contin uous A-w eighted sound pressure at the operator ear of: 86 dB(A), based on measurements of identical mac hines per Directi v e 98/37/EC and amendments .

Vibration Level

T his unit does not ex ceed a vibration lev el of

2.5 m/s² at the hands based on measurements of identical mac hines per ISO 5349 procedures .

T his unit does not ex ceed a vibration lev el of .5 m/s² at the posterior based on measurements of identical mac hines per ISO 2631 procedures .

• K ee p y our body and hands a w a y from pin hole leaks or nozzles that eject h y draulic ﬂuid under high pressure . Use paper or cardboard, not y our hands , to searc h for leaks . Hy draulic ﬂuid escaping under pressure can ha v e sufﬁcient force to penetrate the skin and cause serious injur y .

• Before disconnecting or perfor ming any w ork on the h y draulic system, all pressure in the system m ust be reliev ed b y stopping the engine and lo w ering the cutting units and attac hments to the g round.

• If the engine m ust be r unning to perfor m a maintenance adjustment, k ee p hands , feet,

Safety and Instructional

Decals

1. Read the Operator’s

2. Fuse for starter

Safety decals and instr uctions are easily visible to the operator and are located near any area of potential dang er . R e place any decal that is damag ed or lost.

93-6680

104-5229

3. Fuse for headlights

Manual.

(optional)

93-6686

1. Hydraulic oil

2. Read the Operator’s Manual.

105-7506

1. Read the Operator’s

Manual.

2. Engine—stop 5. Engine—start

3. On

4. Engine—preheat

93-6693

1. Crushing hazard of hand—wait for moving parts to stop.

93-6699

1. Machine speed 3. Continuous variable setting

2. Slow

4. Fast

93-9425

1. Read the Operator’s Manual.

2. Hydraulic hoses are under pressure—stay away from moving parts.

93-6696

1. Stored energy hazard—read the Operator’s Manual .

93-6687

1. Do not step here.

93-6689

1. Warning—do not carry passengers.

93-6681

1. Cutting/dismemberment—hazard, fan-stay away from moving parts..

93-1263

1. Read the Operator’s Manual.

2. To engage the parking brake, connect the brake pedals with the locking pin, push down on both pedals, and pull the brake latch out.

3. To release the parking brake, press both pedals until the parking brake latch retracts.

4. Danger—reels enabled.

93-1265

1. Hot surface/burn hazard—stay a safe distance from the hot surface.

104-9298

1. Read the Operator’s Manual .

108-6708

105-0123

Model 03807

1. Throttle—slow 7. Reels disabled—lift and lower

2. Throttle—fast

3. Reels raised and off 9. Headlights—On

4. Reels lowered and on when enabled—forward and backlap 10. Headlights—Off

5. Reels—enabled 11. Read the Operators Manual .

6. Reels disabled—lift only

8. Headlights (optional)

Models 03806 and 03807

1. Throttle—slow 4. Reels lowered and on when

enabled—forward and backlap

2. Throttle—fast 5. Reels enabled

3. Reels raised and off 6. Reels disabled—lift only 9. Headlights—On

104-9296

7. Reels disabled—lift and lower 10. Headlights—Off

8. Headlights (optional) 11. Read the Operator’s Manual for further instructions.

1. Read the Operator’s Manual .

2. Do not tow the machine. 4. Cutting hazard of hand

3. Warning—Read the Operator’s Manual .

or foot—stay away from moving parts.

104-9294

5. Warning—keep bystanders a safe distance from the machine.

6. Warning—lock the parking brake, stop the engine, and remove the ignition key before leaving the machine.

7. Warning—use a rollover protection system and wear the seat belt.

8. Tipping hazard—lower the cutting unit when driving down slopes.

1. Read the Operator’s Manual .

2. Do not tow the machine. 4. Cutting hazard of hand

3. Warning—Read the Operator’s Manual .

or foot—stay away from moving parts.

104-9295

Replaces 104–9294 for CE

5. Warning—keep bystanders a safe distance from the machine.

6. Warning—lock the parking brake, stop the engine, and remove the ignition key before leaving the machine.

7. Warning—use a rollover protection system and wear the seat belt.

8. Tipping hazard—lower the cutting unit when driving down slopes and do not drive across or down slopes greater than 15 degrees.

105-9268

1. Reel—height of cut 4. Machine speed

2. Reel—mow and backlap 5. Rear reels circuit controls

3. Read the Operator’s

Manual.

6. Front reels circuit controls

106-6754

1. Warning—do not touch the hot surface.

2. Cutting/dismemberment hazard, fan and entanglement hazard, belt—stay away from moving parts.

67-7960

Battery Symbols

Some or all of these symbols are on your battery

1. Explosion hazard 6. Keep bystanders a safe

2. No re, open ame, or smoking.

3. Caustic liquid/chemical burn hazard

4. Wear eye protection

5. Read the Operator’s

Manual.

distance from the battery.

7. Wear eye protection; explosive gases can cause blindness and other injuries

8. Battery acid can cause blindness or severe burns.

9. Flush eyes immediately with water and get medical help fast.

10. Contains lead; do not discard.

Setup

Loose Parts

Use the chart below to verify that all parts have been shipped.

Step

1 2 3

4 5

No parts required

Large O-ring Counter weight 7/5 Steering locking pin 7/5

No parts required

Calcium chloride (obtain separately)

Rear weight kit, part number 104–1478 (obtain separately)

CE decals CE certicate Operator’s Manual Engine Operator’s Manual Parts Catalog Diagnostic ACE display overlay Ignition keys on ring Hood lock key Gauge bar Screw 2 Wing nut

Description

Qty.

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14/10

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100lb

1 4

2 1 1 1 1 1 1 1

Check uid levels.

Install the cutting units.

Make cutting unit adjustments if needed.

Add rear ballast (if required).

Install the CE decals.

Read the manuals and watch the video before operating the machine.

Use

Step

Checking Fluid Levels

No Parts Required

Procedure

Before star ting the engine for the ﬁrst time , c hec k the follo wing ﬂuid lev els:

• Engine oil

R efer to Chec king the Engine Oil in Operation , pag e 22 .

• Engine coolant

R efer to Chec king the Cooling System Operation , pag e 22 .

• Hy draulic oil

R efer to Chec king the Hy draulic Oil in Operation , pag e 22 .

• R ear axle lubricant

R efer to Chec king the R ear Axle Lubricant in Dri v e System Maintenance , pag e 41 .

Step

Installing the Cutting Units

Parts needed for this step:

3. Lubricate and install a larg e O-ring into bearing housing g roo v e on eac h end of cutting unit ( Figure 4 & Figure 7 ).

14/10

Procedure

Cutting unit models 03860, 03861, and 03862 can be installed at any of the mounting locations on the traction unit. Figure 3 sho ws the orientation of the h y draulic dri v e motor for eac h of the locations . F or any of the locations requiring the motor to be mounted on the right end of the cutting unit, install a counter w eight on the left end of the cutting unit. F or the locations requiring the motor to be mounted on the left end, install a counter w eight on the right end of the cutting unit.

Note: Counterw eight mounting capscrews are shipped installed on the right bearing housing of the cutting units . T he capscrews on left bearing housing are to be used for securing the h y draulic motor .

Large O-ring 7/5 Counter weight 7/5 Steering locking pin

Figure 4

1. Bearing housing 3. Counterweight

2. Large o-ring

Note: Before installing cutting unit motors or counterw eights , lubricate inter nal splines of cutting unit reel shafts with g rease .

4. Install a counter w eight onto appropriate end of eac h cutting unit with capscrews pro vided ( Figure 4 ).

5. T horoughly g rease the cutting unit reel bearings prior to installation on the traction unit. Grease should be evident at the inboard reel seals; refer to Cutting Unit Operator’ s Manual for g reasing procedure .

6. Inser t a thr ust w asher onto horizontal shaft of pi v ot kn uc kle as sho wn in Figure 5 .

Figure 3

1. R emo v e cutting units from car tons . Assemble and adjust per Cutting Unit Operator’ s Manual .

2. R emo v e protecti v e plugs from eac h end of cutting unit.

Figure 5

1. Carrier frame 4. Lynch pin

2. Pivot knuckle 5. Steering locking pin

3. Lift arm steering plate

7. Inser t the horizontal shaft of the pi v ot kn uc kle into the mounting tube of the car rier frame ( Figure 5 ).

8. Secure pi v ot kn uc kle to car rier frame with a thr ust w asher , ﬂat w asher and a ﬂang e head capscrew ( Figure 5 ).

9. Inser t a thr ust w asher onto v er tical shaft of pi v ot kn uc kle ( Figure 5 ).

10. If remo v ed, inser t the v er tical shaft of the pi v ot kn uc kle into lift ar m pi v ot hub ( Figure 5 ). Guide the pi v ot kn uc kle in place betw een the tw o r ubber centering bumpers in the under side of the lift ar m steering plate .

11. Inser t the lync h pin into the cross hole on the pi v ot kn uc kle shaft ( Figure 5 ).

12. R emo v e n ut securing turf compensation spring mounting brac k et to cutting unit stabilizer ear ( Figure 6 ). Inser t tipper c hain onto capscrew and secure with n ut remo v ed.

Figure 7

1. Motor

Note: If ﬁx ed cutting unit position is required, inser t steering loc king pin into pi v ot kn uc kle mounting hole ( Figure 5 ).

14. Hook spring wire around bottom of steering loc king pin ( Figure 5 ).

2. O-ring

Figure 6

1. Lift chain 2. Cutting unit stabilizer ear

13. Mount the motor to the dri v e end of the cutting unit and secure with tw o capscrews pro vided ( Figure 7 ).

Step

Making Alternate Cutting Unit Adjustments

No Parts Required

Procedure

T he factor y sets the tractor appropriately for most fairw a y mo wing applications . Sev eral adjustments for ﬁne-tuning the mac hine for par ticular applications are included in Cutting Unit Maintenance , pag e 48 , as follo ws:

• Adjusting the turf compensation spring

Adjusts the amount of fore and aft rotation a v ailable , the amount of g round clearance in transpor t, and transfers the w eight from the front to rear roller , reducing bobbing (a w a v e patter n in the turf).

• Adjusting the cutting unit lo w ering rate

Adjusts the speed at whic h the cutting units lo w er .

• Adjusting the lifted height of the outer front cutting units

Adjusts the tur naround height of the outer front cutting units to pro vide g reater clearance on contoured fairw a ys .

Step

• Adjusting the tra v el of the front three cutting units

Adjusts the do wnw ard tra v el of the front three cutting units to allo w for highly contoured fairw a ys .

Step

Adding Rear Ballast

Parts needed for this step:

100lb

Procedure

T o comply with CEN standard EN 836:1997, ISO standard 5395:1990, and the ANSI B71.4-1999 Standard, add 100 lb (45 kg) of calcium c hloride ballast is to the rear wheels and install the rear w eight kit (P ar t Number 104-1478).

Important: If a punctur e occur s in a tir e with calcium chloride, r emo v e unit fr om turf ar ea as quickl y as possible. T o pr ev ent possible dama ge to turf, immediatel y soak af fected ar ea with w ater .

Calcium chloride (obtain separately) Rear weight kit, part number 104–1478 (obtain

separately)

Installing CE Decals

Parts needed for this step:

CE decals

CE certicate

Procedure

If y ou will be using the mac hine in a CE countr y , install the supplied CE decals o v er the cor responding ANSI decals on the product. Store the CE cer tiﬁcates in a safe location.

Step

Reading the Manuals and Storing Additional Parts

Parts needed for this step:

Operator’s Manual

Engine Operator’s Manual

Parts Catalog

Diagnostic ACE display overlay

Ignition keys on ring

Hood lock key

Gauge bar 2 Screw 2

Wing nut

Procedure

1. R ead the man uals .

2. View the Operator video .

3. T he diagnostic A CE displa y o v erla y is for diagnosing mac hine malfunctions . Store it in a safe location.

4. T he g aug e bar , screws , and wing n ut are for use in setting the cutting units (refer to the cutting unit Operator’ s Manual ). Store them in a safe location.

Product Overview

Figure 8

1. Steering wheel

2. Brake pedals 4. Traction pedal 6. Hood

3. Cutting unit

Controls

Traction Pedal

T he traction pedal ( Figure 9 ) controls forw ard and rev erse operation. De press top of pedal to mo v e forw ard and bottom to mo v e bac kw ard. Ground speed de pends on ho w far pedal is de pressed. F or no load, maxim um g round speed, fully de press pedal while throttle is in F AST .

T o stop , reduce foot pressure on traction pedal and allo w it to retur n to center position.

5. Manual tube 7. Roll over protection system (ROPS)

Speedometer

T he speedometer ( Figure 9 ) indicates g round speed at whic h mac hine is tra v eling .

Brake Pedals

T w o brak e pedals ( Figure 9 ) operate indi vidual wheel brak es for tur ning assistance , parking, and to aid in obtaining better sidehill traction. Loc king pin connects the pedals for parking brak e operation and transpor t.

Parking Brake Latch

Figure 9

1. Traction pedal 6. Parking brake latch

2. Forward speed limiter 7. Locking pin

3. Red diagnostic light 8. Reverse speed limiter

4. Speedometer 9. Key switch

5. Brake pedals

Forward Speed Limiter

Preset the forw ard speed limiter ( Figure 9 ) to limit the amount the traction pedal can be de pressed in the forw ard direction to maintain a constant mo wing speed.

Red Diagnostic Light

T he red diagnostic light ( Figure 9 ), located on steering to w er , is used to con v ey sev eral different messag es . W hile star ting the mac hine , the light will illuminate when the glo w plugs are on.

If the light blinks during operation, it ma y indicate any of the follo wing:

• T he mac hine is being operated faster than the maxim um speed v alue initially prog rammed into the ECU .

• An electrical malfunction has been detected (open or shor ted output.

• A h y draulic leak has been detected (Only if T urfdefender leak detector is installed on mac hine)

• A comm unications er ror has been detected (Only if T urfdefender leak detector is installed on mac hine)

A knob on the left side of console actuates parking brak e loc k ( Figure 9 ). T o eng ag e parking brak e , connect pedals with loc king pin, push do wn on both pedals and pull parking brak e latc h out. T o release parking brak e , de press both pedals until parking brak e latc h retracts .

Reverse Speed Limiter

Adjust the screw ( Figure 9 ) to limit the amount the traction pedal can be de pressed in the rearw ard direction to limit speed.

Lower Mow/Raise Control Lever (Joystick)

T he lev er ( Figure 10 and Figure 11 ) raises and lo w ers the cutting units and also star ts and stops the reels .

Key Switch

T he k ey switc h ( Figure 9 ) has three positions: OFF , ON/Preheat and ST AR T .

Figure 10

Engine Oil Pressure Warning Light

T his light ( Figure 10 and Figure 11 ) indicates dang erously lo w engine oil pressure .

Throttle Control

Mo v e the control ( Figure 10 and Figure 11 ) forw ard to increase engine speed, rearw ard to decrease speed.

Engine Coolant Temperature Warning Light

Model 03808

1. Lower mow/raise control lever

2. Fuel gauge 8. Throttle control

3. Engine coolant temperature gauge

4. Engine oil pressure warning light

5. Engine coolant temperature warning light

6. Glow plug indicator light

7. Charge indicator

9. Enable/disable switch

10. Enable/disable switch (#7)

11. Enable/disable switch (#6)

T he light ( Figure 10 and Figure 11 ) illuminates and the engine shuts do wn when the coolant reac hes a dang erously high temperature .

(Master)

right rear

left rear

Glow Plug Indicator Light

W hen the indicator light ( Figure 10 and Figure 11 ) is lit, indicates glo w plugs are on.

Charge Indicator

T he c harg e indicator ( Figure 10 and Figure 11 ) illuminates when system c harging circuit malfunctions .

Enable/Disable Switches

T he enable/disable switc hes ( Figure 10 and Figure 11 ) are used in conjunction with the lo w er mo w/raise control lev er (J o ystic k) to operate reels . R eels can be raised but not lo w ered when in mid position.

Figure 11

Models 03806 and 03807

1. Lower mow/raise control lever

2. Fuel gauge 7. Charge indicator

3. Engine coolant temperature gauge

4. Engine oil pressure warning light

5. Engine coolant temperature warning light

6. Glow plug indicator light

8. Throttle control

9. Enable/disable switch (Master)

Fuel Gauge

T he fuel g aug e ( Figure 10 and Figure 11 ) indicates lev el of fuel in tank.

Hour Meter

T he hour meter ( Figure 12 ) sho ws total hours that mac hine has been operated.

1. Hour meter

desired location, release lev er to loc k seat into position. T o adjust for operators w eight, tur n spring tension knob; cloc kwise to increase tension, countercloc kwise to decrease spring tension.

Figure 12

Backlap Knobs

T he bac klap knobs ( Figure 13 ) are used in conjunction with lo w er mo w/raise control lev er for bac klapping operation. R efer to Bac klapping in Cutting Unit Maintenance , pag e 48 .

Figure 13

1. Reel control knobs 2. Backlap knobs

Figure 14

1. Seat adjusting lever 2. Seat adjusting knob

Green Diagnostic Light

T he mac hine is equipped with a diagnostic light whic h indicates if the electronic controller is functioning cor rectly . T he g reen diagnostic light ( Figure 15 ) is located under the control panel, next to the fuse bloc k. W hen the electronic controller is functioning cor rectly and the k ey switc h is mo v ed to the ON position, the controller diagnostic light will be illuminated. T he light will blink if the controller detects a malfunction in the electrical system. T he light will stop blinking and automatically reset when the k ey switc h is tur ned to the OFF position.

Reel Speed Controls

Controls RPM of front and rear cutting units ( Figure 13 ). #1 position is for bac klapping . R emaining settings are for mo wing operations . See decal under seat for proper settings .

Seat

T he seat adjusting lev er ( Figure 14 ) allo ws 4 inc h fore and aft adjustment. T he seat adjusting knob ( Figure 14 ) adjusts seat for operators w eight. T o adjust seat fore and aft, pull lev er on left side of seat assembly outw ard. After mo ving seat to

Figure 15

1. Green diagnostic light

W hen the controller diagnostic light blinks , one of the follo wing problems has been detected b y the controller :

• One of the outputs has been shor ted.

• One of the outputs is open circuited.

Height With ROPS installed Weight*, model 03806

84 inches (213 cm)

3200 lb (1451 kg)

Using the diagnostic displa y , deter mine whic h output is malfunctioning, refer to Chec king Interloc k Switc hes in Operation , pag e 22 .

If the diagnostic light is not illuminated when the k ey switc h is in the On position, this indicates that the electronic controller is not operating . P ossible causes are:

• Loopbac k is not connected.

• T he light is bur ned out.

• Fuses are blo wn.

• No batter y po w er .

Chec k electrical connections , input fuses and diagnostic light bulb to deter mine malfunction. Mak e sure loopbac k connector is secured to wire har ness connector .

Diagnostic ACE Display (Optional)

T he mac hine is equipped with an electronic controller whic h controls most mac hine functions . T he controller deter mines what function is required for v arious input switc hes (i.e . seat switc h, k ey switc h, etc .) and tur ns on the outputs to actuate solenoids or rela ys for the requested mac hine function.

Weight*, model 03807

Weight*, model 03808

* W i t h 5 b l a d e c u t t i n g u n i t s a n d f u l l ﬂ u i d l e v e l s

3300 lb (1496 kg)

3950 lb (1792 kg)

Attachments/Accessories

A selection of T oro appro v ed attac hments and accessories are a v ailable for use with the mac hine to enhance and expand its capabilities . Contact y our A uthorized Ser vice Dealer or Distributor or g o to www .T oro .com for a list of all appro v ed attac hments and accessories .

F or the electronic controller to control the mac hine as desired, eac h of the input switc hes , output solenoids and rela ys m ust be connected and functioning properly .

T he Diagnostic A CE displa y is a tool to help the user v erify cor rect electrical functions of the mac hine .

Specications

Note: Speciﬁcations and design are subject to

c hang e without notice .

Width-of-cut, model 03806 and 03807

Width-of-cut, model 03808

Overall width, Transport Overall width, Operational Overall length

96 inches (244 cm)

133 inches (338 cm)

89 inches (226 cm) 110 inches (279 cm) 120 inches (305 cm)

Operation

Note: Deter mine the left and right sides of the

mac hine from the nor mal operating position.

Checking the Engine Oil

T he engine is shipped with oil in the crankcase; ho w ev er , the oil lev el m ust be c hec k ed before and after the engine is ﬁrst star ted.

Crankcase capacity is appro ximately 7.5 qt. (7 l) with the ﬁlter .

Use high-quality engine oil that meets the follo wing speciﬁcations:

Figure 17

1. Dipstick

• API Classiﬁcation Lev el R equired: CH-4, CI-4 or higher .

• Prefer red oil: SAE 15W -40 (abo v e 0°F)

• Alter nate oil: SAE 10W -30 or 5W -30 (all

temperatures)

Note: T oro Premium Engine oil is a v ailable from y our distributor in either 15W -40 or 10W -30 viscosity . See the par ts catalog for par t n umbers .

1. P ark mac hine on a lev el surface . R elease hood latc h and open hood ( Figure 16 ).

Figure 16

1. Hood latch

2. R emo v e dipstic k ( Figure 17 ), wipe clean and reinstall dipstic k. Pull it out ag ain and c hec k oil lev el on dipstic k: Oil lev el should be up to FULL mark on dipstic k.

3. If oil lev el is lo w , remo v e ﬁller cap ( Figure 18 ) and add oil until lev el reac hes FULL mark on dipstic k. Do not o v erﬁll.

Figure 18

1. Filler cap

4. Install ﬁller cap .

5. Close hood and secure latc h.

Checking the Cooling System

Clean debris off screen, oil cooler and front of radiator daily , more often if conditions are extremely dusty and dir ty; refer to R emo ving Debris in Cooling System Maintenance , pag e 44 .

T he cooling system is ﬁlled with a 50/50 solution of w ater and per manent eth ylene glycol antifreeze . Chec k lev el of coolant in radiator and expansion tank at the beginning of eac h da y before star ting the engine . Capacity of cooling system is 10 quar ts (9.4 l).

If the engine has been r unning , pr essuriz ed hot coolant can escape and cause bur ns if the radiator cap is r emo v ed.

Allo w the engine to cool at least 15 min utes or until the radiator cap is cool enough to touch without bur ning hands.

1. Carefully remo v e radiator cap and expansion tank cap ( Figure 19 ).

2. Chec k lev el of coolant in radiator and in expansion tank ( Figure 19 ).

Radiator should be ﬁlled to the top of the ﬁller nec k and the expansion tank ﬁlled to the Full mark.

Figure 20

1. Vent plug

4. Install radiator cap and expansion tank cap .

5. Close hood and secure latc h.

Filling the Fuel Tank

Figure 19

1. Expansion tank

3. Fill expansion tank to the Full mark and radiator to the top of the ﬁller nec k. Do not

o v erﬁll the expansion tank.

Note: If air is trapped is system, remo v e v ent plug ( Figure 20 ), from top of radiator side tank, to allo w trapped air to escape . R einstall v ent plug using T eﬂon thread sealant.

Under cer tain conditions, diesel fuel and fuel v apor s ar e highl y ﬂamma ble and explosi v e. A ﬁr e or explosion fr om fuel can bur n y ou and other s and can cause pr oper ty dama ge.

• Use a funnel and ﬁll the fuel tank outdoor s, in an open ar ea, when the engine is of f and is cold. W ipe up an y fuel that spills.

• Do not ﬁll the fuel tank completel y full. Add fuel to the fuel tank until the lev el is 1 in. (25 mm) belo w the bottom of the ﬁller neck. T his empty space in the tank allo ws the fuel to expand.

• Nev er smok e when handling fuel, and stay a w ay fr om an open ﬂame or wher e fuel fumes may be ignited by a spar k.

• Stor e fuel in a clean, safety-appr o v ed container and k eep the cap in place.

Capacity of fuel tank is 15 g al (57 l).

1. R emo v e fuel tank cap ( Figure 21 ).

Figure 21

1. Fuel tank cap

2. Fill tank to about one inc h belo w top tank, not ﬁller nec k with No . 2 diesel fuel. T hen install cap .

Checking the Hydraulic Fluid

T he mac hines reser v oir is ﬁlled at the factor y with appro ximately 8.5 U .S . g allons (32 l) of high quality h y draulic ﬂuid. Chec k the lev el of the h y draulic ﬂuid before the engine is ﬁrst star ted and daily thereafter . T he recommended re placement ﬂuid is as follo ws:

Note: Many h y draulic ﬂuids are almost colorless , making it difﬁcult to spot leaks . A red dye additi v e for the h y draulic system oil is a v ailable in 2/3 oz. (20 ml) bottles . One bottle is sufﬁcient for 4-6 g al (15-22 1) of h y draulic oil. Order par t no . 44-2500 from y our authorized T oro distributor .

Biodegradable Hydraulic Fluid - Mobil 224H

Toro Biodegradable Hydraulic Fluid (Available

in 5 gallon pails or 55 gallon drums. See parts catalog or Toro distributor for part numbers.)

Alternate uid: Mobil EAL 224H

Note: T his is v eg etable-oil based biodeg radable

oil tested and appro v ed b y T oro for this model. T his ﬂuid is not as resistant to high temperatures as standard ﬂuid, so install an oil cooler if required b y the operator man ual and follo w recommended ﬂuid c hang e inter v als with this ﬂuid. Contamination b y mineral-based h y draulic ﬂuids will c hang e the biodeg radability and to xicity of this oil. W hen c hanging from standard ﬂuid to the biodeg radable type , be cer tain to follo w the appro v ed ﬂushing procedure . Contact y our local T oro Distributor for details .

1. P osition mac hine on a lev el surface , lo w er the cutting units and stop the engine .

Toro Premium All Season Hydraulic Fluid

(Available in 5 gallon pails or 55 gallon drums. See parts catalog or Toro distributor for part numbers.)

Alter nate ﬂuids: If the T oro ﬂuid is not a v ailable , other ﬂuids ma y be used pro vided they meet all the follo wing material proper ties and industr y speciﬁcations . W e do not recommend the use of synthetic ﬂuid. Consult with y our lubricant distributor to identify a satisfactor y product Note: T oro will not assume responsibility for damag e caused b y improper substitutions , so use only products from re putable man ufacturers who will stand behind their recommendation.

High Viscosity Index/Low Pour Point Anti-wear Hydraulic Fluid, ISO VG 46

Material Properties:

Viscosity, ASTM D445

Viscosity Index ASTM D2270 Pour Point, ASTM D97

Industry Specications:

Vickers I-286-S (Quality Level), Vickers M-2950-S (Quality Level), Denison HF-0

cSt @ 40°C 44 to 48 cSt @ 100°C 7.9 to 8.5 140 to 160

-34°F to -49°F

2. Clean area around ﬁller nec k and cap of h y draulic tank ( Figure 22 ). R emo v e cap from ﬁller nec k.

Figure 22

1. Hydraulic tank cap

3. R emo v e dipstic k from ﬁller nec k and wipe it with a clean rag . Inser t dipstic k into ﬁller nec k; then remo v e it and c hec k lev el of ﬂuid. Fluid lev el should be within 1/4 inc h of mark on dipstic k.

4. If lev el is lo w , add appropriate ﬂuid to raise lev el to full mark.

5. Install dipstic k and cap onto ﬁller nec k.

Checking the Tire Pressure

T he tires are o v er -inﬂated for shipping . T herefore , release some of the air to reduce the pressure . Cor rect air pressure in the front and rear tires is 15-20 psi.

Important: Maintain ev en pr essur e in all tir es to ensur e a good quality-of-cut and pr oper machine perf or mance. Do not under inﬂate.

Checking the Reel to Bedknife Contact

Eac h da y before operating, c hec k reel to bedknife contact, reg ardless if quality of cut had previously been acce ptable . T here m ust be light contact across the full length of the reel and bedknife (refer to Adjusting R eel to Bedknife in Cutting Unit Operator’ s Manual ).

Starting and Stopping

1. Sit on the seat, k ee p foot off traction pedal. Ensure parking brak e is eng ag ed, traction pedal is in Neutral, throttle is in Slo w position and the Enable/Disable switc h is in the Disable position.

2. T ur n ignition switc h to On/Preheat position. An automatic timer will control preheat for appro ximately 6 seconds . After preheat, tur n k ey to Star t position. Crank the engine for no long er than 15 seconds . R elease k ey when engine star ts . If additional preheat is required, tur n k ey to Off position then to On/Preheat position. R e peat process as required.

3. R un engine at idle speed or par tial throttle until engine w ar ms up .

Note: W e recommend that anytime the mac hine is park ed (shor t or long ter m) the cutting units should be lo w ered to the g round. T his reliev es pressure from the lift circuit and eliminates the risk of the cutting units accidentally lo w ering to the g round.

Bleeding the Fuel System

1. P ark the mac hine on a lev el surface . Mak e sure fuel tank is at least half full.

2. Unlatc h and raise hood.

Under cer tain conditions, diesel fuel and fuel v apor s ar e highl y ﬂamma ble and explosi v e. A ﬁr e or explosion fr om fuel can bur n y ou and other s and can cause pr oper ty dama ge.

• Use a funnel and ﬁll the fuel tank outdoor s, in an open ar ea, when the engine is of f and is cold. W ipe up an y fuel that spills.

• Nev er smok e when handling fuel, and stay a w ay fr om an open ﬂame or wher e fuel fumes may be ignited by a spar k.

• Stor e fuel in a clean, safety-appr o v ed container and k eep the cap in place.

3. Open v ent plug on the fuel ﬁlter/w ater se parator ( Figure 23 ).

4. T o stop , mo v e all controls to Neutral and set parking brak e . R etur n throttle to the idle position, tur n k ey to OFF and remo v e it from switc h.

Important: Allo w engine to idle f or 5 min utes bef or e shutting it of f after a full load operation. F ailur e to do so may lead to turbo-charger tr ouble.

Figure 23

1. Fuel lter/water separator 2. Vent plug

4. T ur n k ey in ignition switc h to the On position. Electric fuel pump will begin operation, thereb y forcing air out around v ent plug . Lea v e k ey in On position until a solid stream of fuel ﬂo ws out around plug . Tighten plug and tur n k ey to OFF .

Pushing or Towing the Machine

In an emerg ency , the mac hine can be mo v ed b y actuating the b ypass v alv e in the v ariable displacement h y draulic pump and pushing or to wing the mac hine .

Important: Do not push or to w the machine f aster than 2-3 mph (3-4.8 km/h) because inter nal transmission dama ge may occur . T he bypass v alv e must be open whenev er the machine is pushed or to w ed.

1. T he b ypass v alv e is located on top of v ariable displacement pump ( Figure 25 ). R otate the v alv e 90°, in either direction, to open and allo w oil to b ypass inter nally . Because ﬂuid is b ypassed, the mac hine can be mo v ed slo wly without damaging the transmission.

5. Open the air bleed screw on the fuel injection pump ( Figure 24 ).

Figure 24

1. Fuel injection pump bleed screw

6. T ur n k ey in ignition switc h to the On position. Electric fuel pump will begin operation, thereb y forcing air out around air bleed screw . Lea v e k ey in On position until a solid stream of fuel ﬂo ws out around screw . Tighten screw and tur n k ey to Off .

Figure 25

1. Bypass valve

2. Close the b ypass v alv e before star ting the engine . Ho w ev er , do not ex ceed 5-8 ft.-lb . (7-11 N·m) tor que to close the v alv e .

Important: R unning the engine with the bypass v alv e open will cause the transmission to o v erheat.

Note: Nor mally , engine should star t after abo v e bleeding procedures are follo w ed. Ho w ev er , if engine does not star t, air ma y be trapped betw een injection pump and injectors; refer to Bleeding Air F rom Injectors in Fuel System Maintenance , pag e 37 .

Checking the Interlock Switches

If safety inter lock s witches ar e disconnected or dama ged the machine could operate unexpectedl y causing per sonal injur y .

• Do not tamper with the inter lock s witches.

• Check the operation of the inter lock s witches dail y and r eplace an y dama ged s witches bef or e operating the machine.

• R eplace s witches ev er y tw o y ear s r egardless of whether they ar e operating pr oper l y or not.

T he pur pose of the interloc k switc hes are to prev ent the engine from cranking or star ting unless the traction pedal is in Neutral, the Enable/Disable switc h is in Disable and the Lo w er Mo w/Raise control is in the neutral position. In addition, the engine will stop when the traction pedal is de pressed with either the operator off the seat or the parking brak e eng ag ed.

To verify interlock switch function:

1. P ark mac hine on a lev el surface , lo w er the cutting units , stop the engine and eng ag e the parking brak e .

2. Open control panel co v er . Locate wire har ness and loopbac k connector . Carefully unplug loopbac k connector from har ness connector ( Figure 26 ).

sure cor rect o v erla y decal is positioned on Diagnostic A CE displa y .

Figure 27

1. Diagnostic ACE

4. T ur n the k ey switc h to the On position, but do not star t mac hine .

Note: T he red text on the o v erla y decal refers to input switc hes and the g reen text refers to outputs .

5. T he “inputs displa yed” LED , on lo w er right column of the Diagnostic A CE, should be illuminated. If “outputs displa yed” LED is illuminated, press and release the tog gle button, on Diagnostic A CE, to c hang e LED to “inputs displa yed”. Do not hold button do wn.

6. T he Diagnostic A CE will illuminate the LED associated with eac h of the inputs when that input switc h is closed.

Indi vidually , c hang e eac h of the switc hes from open to closed (i.e ., sit on seat, eng ag e traction pedal, etc .), and note that the appropriate LED on Diagnostic A CE will blink on and off when cor responding switc h is closed. R e peat on eac h switc h that is possible to be c hang ed b y hand.

Figure 26

1. Loop-back connector

3. Connect the Diagnostic A CE displa y connector to the har ness connector ( Figure 27 ). Mak e

7. If switc h is closed and appropriate LED does not tur n on, c hec k all wiring and connections to switc h and/or c hec k switc hes with an ohm meter . R e place any damag ed switc hes and re pair any damag ed wiring .

T he Diagnostic A CE also has the ability to detect whic h output solenoids or rela ys are tur ned on. T his is a quic k w a y to deter mine if a mac hine malfunction is electrical or h y draulic .

To verify output function:

1. P ark mac hine on a lev el surface , lo w er the cutting units , stop the engine and eng ag e the parking brak e .

If the output LEDs are on as speciﬁed, but the mac hine does not function properly , this indicates a non-electrical problem. R e pair as necessar y .

2. Open control panel co v er . Locate wire har ness and connectors near controller . Carefully unplug loopbac k connector from har ness connector .

3. Connect the Diagnostic A CE connector to the har ness connector . Mak e sure cor rect o v erla y decal is positioned on Diagnostic A CE.

4. T ur n the k ey switc h to the On position, but do not star t mac hine .

Note: T he red text on the o v erla y decal refers to input switc hes and the g reen text refers to outputs .

5. T he “outputs displa yed” LED , on lo w er right column of Diagnostic A CE, should be illuminated. If “inputs displa yed”; LED is illuminated, press the tog gle button, on Diagnostic A CE, to c hang e LED to “outputs displa yed. ”

Note: It ma y be necessar y to tog gle betw een “inputs displa yed” and “outputs displa yed” sev eral times to do the follo wing ste p . T o tog gle bac k and for th, press tog gle button once . T his ma y be done as often as required. Do not hold the button.

6. Sit on the seat and attempt to operate the desired function of the mac hine . T he appropriate output LED’ s should illuminate to indicate that the ECU is tur ning on that function. (R efer to Hy draulic Solenoid V alv e Functions to be cer tain of the speciﬁed output LEDs .)

Note: If any output LED is blinking, this indicates an electrical problem with that OUTPUT . R e pair/re place defecti v e electrical par ts immediately . T o reset a blinking LED , tur n the k ey switc h “Off ”, then bac k “On” and clear the controllers fault memor y (R efer to Clearing the F ault Memor y in F ault Memor y and R etriev al).

If no output LEDs are blinking, but the cor rect output LED’ s do not illuminate , v erify that the required input switc hes are in the necessar y positions to allo w that function to occur . V erify cor rect switc h function.

Note: Due to electrical system constraints , the output LED’ s for “Star t”, “Preheat” and “ETR/AL T” ma y not blink ev en though an electrical problem ma y exist for those functions . If the mac hine problem appears to be with one of these functions , be cer tain to c hec k the electrical circuit with a v olt/ohm meter to v erify that no electrical problem exists to these functions .

If eac h input switc h is in the cor rect position and functioning cor rectly , but the output LEDs are not cor rectly illuminated, this indicates an ECU problem. If this occurs , contact y our T oro Distributor for assistance .

Fault Memory and Retrieval

If the Controller senses a f ault on one of the output solenoids , it will ﬂash the mac hines

diagnostic Lamp (R eel Diagnostic Lamp on console or Green Diagnostic Lamp under console) and store the fault into the Controllers (ECU) memor y . T he fault can then be retriev ed and view ed with the Diagnostic A CE hand held tool or a lap top/PC at anytime . T he Controller will store one (1) fault at a time and will not store another different fault until the ﬁrst fault is cleared.

Retrieving Fault Information

R etrieving Stor ed F aults (Do not sit in seat)

1. R otate ignition k ey to Off position.

2. Connect the Hand held Diagnostic T ool to the desired Controller Loopbac k Connector (use the proper o v erla y).

3. Mo v e the J o ystic k to the Raise position and hold.

4. R otate ignition k ey to On position, and contin ue to hold the J o ystic k in Raise position until the top left Diagnostic T ool light comes on (appro x. 2 seconds).

5. R elease the J o ystic k to the center position.

6. Hand held T ool will no w pla ybac k the fault retained in the Controller memor y .

Important: T he display will sho w eight (8) indi vidual r ecords with the f ault display ed on the 8th r ecord. Each r ecord will be display ed f or 10 seconds. Be sur e to ha v e the Dia gnostic T ool display on Outputs to see f ault. T he Pr oblem circuit will be ﬂashing . R ecords will r epeat until k ey is tur ned of f. Unit will not star t in this mode.

Clearing the F ault Memor y (Dia gnostic T ool not r equir ed)

7. R otate ignition k ey to Off position.

8. T ur n Bac klap Switc h to the F ront or R ear Bac klap position.

9. T ur n the R eel Control Switc h to Enable position.

10. Mo v e the J o ystic k to the Raise position and hold.

11. T ur n the ignition k ey to On, and contin ue to hold the J o ystic k in the Raise position until the R eel Control Lamp star ts to ﬂash (appro x. 2 seconds).

12. R elease the J o ystic k and tur n the K ey Off . Memor y is no w cleared.

13. T ur n the Bac klap Switc h to Off and Enable Switc h to Disable position.

Important: T he Dia gnostic ACE display must not be left connected to the machine. It is not designed to withstand the en vir onment of the machine’ s ev er y day use. W hen done using Dia gnostic ACE, disconnect it fr om the machine and r econnect loopback connector to har ness connector . Machine will not operate without loopback connector installed on har ness. Stor e Dia gnostic ACE in dr y , secur e location in shop , not on machine.

Solenoid Function

MSV2 SV4 SV3

SV5 SV1

SV2

SV 6 SV 7

SV8

Lift front wing cutting units

Lift front center cutting

Left rear wing cutting unit

Right rear wing cutting

Rear reel circuit

Lift rear cutting units

Pressurize raise/lower

hydraulic circuit

Direction: ON=Raise,

OFF= Lower

Load Holding

Operating Tips

Familiarization

Before mo wing g rass , practice operating mac hine in an open area. Star t and stop the engine . Operate in forw ard and rev erse . Lo w er and raise cutting units and eng ag e and diseng ag e reels . W hen y ou feel familiar with the mac hine , practice operating up and do wn slopes at different speeds .

T he brak es can be used to assist in tur ning the mac hine . Ho w ev er , use them carefully , especially on soft or w et g rass conditions because the turf ma y be tor n accidentally . Indi vidual tur ning brak es ma y also be used to help maintain traction. F or example , in some slope conditions , the uphill wheel slips and loses traction. If this situation occurs , de press uphill tur n pedal g radually and inter mittently until the uphill wheel stops slipping, thus , increasing traction on the do wnhill wheel.

unit

Hydraulic Solenoid Valve Functions

Use the list belo w to identify and describe the different functions of the solenoids in the h y draulic manifold. Eac h solenoid m ust be energized to allo w function to occur .

Solenoid Function

MSV1

Front reel circuit

Important: Bef or e mo wing g rass, practice operating the machine in tur ns. T urf dama ge in tur ns may occur especiall y under soft or w et g rass conditions if the tur n is completed at a high speed or at a small tur ning radius. Maintain a speed belo w 3 mph during a tur n and a tur ning radius g r eater than 8 feet to minimiz e turf dama ge fr om tir es or cutting units. Mounting the cutting units with the steering pin in the fr ont mounting hole will allo w the cutting unit to steer itself as the traction unit tur ns pr o viding optimum maneuv era bility and cutting perf or mance in tur ns. During cr oss-cutting of f airw ays, a tear dr op shape tur n is r ecommended to incr ease cutting pr oducti vity and minimiz e turf dama ge.

W hen operating the machine, al w ays use the seat belt and R OPS to gether . Do not use a seat belt without a R OPS .

Transport

Mo v e the Enable/Disable switc h to J o y Stic k Disable (mid position), loc k brak e pedals tog ether and raise the cutting units to the transpor t position. Be careful when dri ving betw een objects so y ou do not accidentally damag e the mac hine or cutting units . Use extra care when operating mac hine on slopes . Dri v e slo wly and a v oid shar p tur ns on slopes to prev ent roll o v ers . T he cutting units should be lo w ered when g oing do wnhill for steering control.

Warning System

If a w ar ning light comes on during operation, stop the mac hine immediately and cor rect the problem before contin uing operation. Serious damag e could occur if the mac hine is operated with a malfunction.

Important: T he R ed Dia gnostic Light , on the steering to w er , indicates when the g lo w plugs ar e On. T he machine should not be star ted until the g lo w plug cy cle is complete.

Mowing

Star t engine and mo v e throttle to F AST so engine is r unning at maxim um speed. Mo v e the Enable/Disable switc h to ENABLE and use the LO WER MO W/RAISE lev er to control the cutting units (front cutting units are timed to lo w er before the rear cutting units). T o mo v e forw ard and cut g rass , press traction pedal forw ard. Maintain a speed whic h does not result in the R eel Control Light being illuminated. Gradually increase or decrease traction speed to ensure proper clip is maintained.

Maintenance

Note: Deter mine the left and right sides of the mac hine from the nor mal operating position.

Recommended Maintenance Schedule(s)

Maintenance Service

Interval

After the rst 8 operating

hours

After the rst 50

operating hours

After the rst 200

operating hours

Before each use or daily

Every 50 hours

Maintenance Procedure

• Check the torque of the wheel nuts or bolts (after the rst 1–4 hours of operation and then after 10 hours of operation).

• Change the engine oil and oil lter.

• Change the planetary gear drive oil.

• Change the rear axle lubricant.

• Check the engine oil level.

• Check and clean the cooling system.

• Check the hydraulic uid level.

• Check the tire pressure.

• Check the reel to bedknife contact.

• Check the interlock switches.

• Drain the fuel lter/water separator.

• Remove debris from the rear screen, oil cooler, and radiator (more frequently in dirty conditions).

• Inspect the hydraulic lines and hoses for leaks, kinked lines, loose mounting supports, wear, loose ttings, weather deterioration, and chemical deterioration.

• Grease the bearings and bushings.

• Check the condition of the battery.

Every 100 hours

Every 150 hours

Every 200 hours

Every 400 hours

Every 800 hours

Every 2 years

• Inspect and tighten the cooling system hoses and connections.

• Check the condition and tension of the alternator belt.

• Change the engine oil and oil lter.

• Check the torque of the wheel nuts or bolts.

• 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 lter canister.

• Replace the fuel pre-lter.

• Check the rear axle lubricant level.

• Change the planetary gear drive oil.

• Change the rear axle lubricant.

• Check the rear wheel toe-in.

• Change the hydraulic uid.

Yearly

• Change the planetary gear drive oil.

• Drain and clean the fuel tank.

• Drain and ush the cooling system.

• Replace all moving hoses.

• Drain/ush the hydraulic tank.

Important: R efer to y our engine Operator’ s Man ual f or additional maintenance pr ocedur es.

If y ou lea v e the k ey in the ignition s witch, someone could accidentl y star t the engine and seriousl y injur e y ou or other bystander s.

R emo v e the k ey fr om the ignition and disconnect the wir e fr om the spar k plug bef or e y ou do an y maintenance. Set the wir e aside so that it does not accidentall y contact the spar k plug .

Service Interval Chart

Figure 28

Daily Maintenance Checklist

Duplicate this page for routine use.

Maintenance Check Item

Check safety interlock operation. Check brake operation. Check engine oil and fuel level. Check cooling system uid level. Drain the water/fuel separator. Check the air lter restriction indicator. Check the radiator and screen for debris. Check unusual engine noises. Check unusual operating noises. Check the transmission oil level. Check the hydraulic system oil level. Check the hydraulic lter indicator. Check the hydraulic hoses for damage. Check for uid leaks. Check the tire pressure. Check instrument operation. Check the reel-to-bedknife adjustment. Check the height-of-cut adjustment. Lubricate all grease ttings. Touch up damaged paint.

For the week of:

Mon. Tues.

Wed. Thurs.

Fri.

Sat. Sun.

1 . C h e c k t h e g l o w p l u g a n d i n j e c t o r n o z z l e s i f h a r d s t a r t i n g , e x c e s s s m o k e , o r r o u g h r u n n i n g i s n o t e d .

2 . C h e c k w i t h t h e e n g i n e r u n n i n g a n d o i l a t o p e r a t i n g t e m p e r a t u r e .

3 . I m m e d i a t e l y a f t e r e v e r y w a s h i n g , r e g a r d l e s s o f t h e i n t e r v a l l i s t e d .

Lubrication

Greasing the Bearings and Bushings

T he mac hine has g rease ﬁttings that m ust be lubricated regularly with No . 2 General Pur pose Lithium Base Grease . If mac hine is operated under nor mal conditions , lubricate all bearings and bushings after ev er y 50 hours of operation or immediately after ev er y w ashing .

T he g rease ﬁtting locations and quantities are:

• Cutting unit car rier frame and pi v ot (2 ea.) ( Figure 29 )

Figure 29

• R ear axle tie rod (2) ( Figure 30 )

• Steering cylinder ball joints (2) ( Figure 30 )

• King pin bushings (2) ( Figure 30 ). T he top ﬁtting on the king pin should onl y be lubricated ann uall y (2 pumps).

Figure 31

Figure 32

• R ear lift cylinder pi v ot (2) ( Figure 33 )

Figure 30

1. Top tting on king pin

• F ront lift cylinders (3) ( Figure 31 and Figure 32

Figure 33

• Lift ar m pi v ot (3) ( Figure 34 )

Figure 34

• R ear axle pi v ot ( Figure 35 )

Figure 35

• R ear lift ar m pi v ots (2) ( Figure 36 )

Figure 37

Engine Maintenance

Servicing the Air Cleaner

Chec k the air cleaner body for damag e whic h could cause an air leak. R e place if damag ed. Chec k the whole intak e system for leaks , damag e or loose hose clamps .

Ser vice the air cleaner ﬁlter only when the ser vice indicator ( Figure 38 ) requires it. Changing the air ﬁlter before it is necessar y only increases the c hance of dir t entering the engine when the ﬁlter is remo v ed.

Figure 36

• Brak e pedal shaft (1) ( Figure 37 )

Figure 38

1. Air cleaner indicator

Important: Be sur e the co v er is seated cor r ectl y and seals with the air cleaner body .

1. Pull the latc h outw ard and rotate the air cleaner co v er countercloc kwise ( Figure 39 ).

Figure 39

1. Air cleaner latch 2. Air cleaner cover

Figure 40

1. Air cleaner primary lter

2. R emo v e the co v er from the air cleaner body . Before remo ving the ﬁlter , use lo w pressure air (40 psi, clean and dr y) to help remo v e larg e accum ulations of debris pac k ed betw een outside of primar y ﬁlter and the canister .

A v oid using high pr essur e air which could f orce dir t thr ough the ﬁlter into the intak e tract.

T his cleaning process prev ents debris from mig rating into the intak e when the primar y ﬁlter is remo v ed.

3. R emo v e and re place the primar y ﬁlter ( Figure 40 ).

Cleaning of the used element is not recommended due to the possibility of damag e to the ﬁlter media. Inspect the new ﬁlter for shipping damag e , c hec king the sealing end of the ﬁlter and the body . Do not use a dama ged element. Inser t the new ﬁlter b y applying pressure to the outer rim of the element to seat it in the canister . Do not appl y

pr essur e to the ﬂexible center of the ﬁlter .

Important: Nev er attempt to clean the safety ﬁlter ( Figur e 41 ). R eplace the safety ﬁlter with a new one after ev er y thr ee primar y ﬁlter ser vices.

Figure 41

1. Air cleaner safety lter

4. Clean the dir t ejection por t located in the remo v able co v er . R emo v e the r ubber outlet v alv e from the co v er , clean the ca vity and re place the outlet v alv e .

5. Install the co v er orienting the r ubber outlet v alv e in a do wnw ard position—betw een appro ximately 5:00 to 7:00 when view ed from the end.

6. R eset the indicator ( Figure 38 ) if it sho ws red.

Servicing the Engine Oil and Filter

Chang e oil and ﬁlter initially after the ﬁrst 50 hours of operation, thereafter c hang e oil and ﬁlter ev er y 150 hours .

1. R emo v e drain plug ( Figure 42 ) and let oil ﬂo w into drain pan. W hen oil stops , install drain plug .

Figure 42

1. Drain plugs

Figure 44

1. Injection pump lever arm

3. Hold the injection pump lev er ar m ag ainst the high idle stop and tighten the cable connector .

Note: W hen tightened, the cable connector m ust be free to swi v el.

4. T or que the loc k n ut, used to set the friction device on the throttle lev er , to 40-55 in-lb . T he maxim um force required to operate the throttle lev er should be 20 lb .

2. Connector

2. R emo v e oil ﬁlter ( Figure 43 ). Apply a light coat of clean oil to the new ﬁlter seal before screwing it on. Do not o v er -tighten.

Figure 43

1. Oil lter

3. Add oil to the crankcase . Capacity is 7.5 qt. (7 L) with ﬁlter .

Adjusting Throttle

1. P osition throttle lev er forw ard so it stops ag ainst seat base slot.

Fuel System Maintenance

Fuel Tank

Drain and clean fuel tank ev er y 2 years . Also , drain and clean tank if fuel system becomes contaminated or if mac hine is to be stored for an extended period. Use clean fuel to ﬂush out the tank.

Figure 45

1. Fuel tank drain

2. Loosen the throttle cable connector on the lev er ar m at the injection pump ( Figure 44 ).

Under cer tain conditions, diesel fuel and fuel v apor s ar e highl y ﬂamma ble and explosi v e. A ﬁr e or explosion fr om fuel can bur n y ou and other s and can cause pr oper ty dama ge.

• Use a funnel and ﬁll the fuel tank outdoor s, in an open ar ea, when the engine is of f and is cold. W ipe up an y fuel that spills.

• Do not ﬁll the fuel tank completel y full. Add fuel to the fuel tank until the lev el is 1/4 to 1/2 in. (6 to 13 mm) belo w the bottom of the ﬁller neck. T his empty space in the tank allo ws the fuel to expand.

• Nev er smok e when handling fuel, and stay a w ay fr om an open ﬂame or wher e fuel fumes may be ignited by a spar k.

• Stor e fuel in a clean, safety-appr o v ed container and k eep the cap in place.

Figure 46

1. Fuel lter/water separator 2. Drain plug

R e place ﬁlter canister after ev er y 400 hours of operation.

3. Clean area where ﬁlter canister mounts .

4. R emo v e ﬁlter canister and clean mounting surface .

5. Lubricate g ask et on ﬁlter canister with clean oil.

Fuel Lines and Connections

Chec k lines and connections ev er y 400 hours or yearly , whic hev er comes ﬁrst. Inspect for deterioration, damag e , or loose connections .

Fuel Filter/Water Separator

Drain w ater or other contaminants from fuel ﬁlter/w ater se parator ( Figure 46 ) daily .

1. Locate fuel ﬁlter , under hood, and place a clean container under it.

2. Loosen drain plug on bottom of ﬁlter canister . Tighten plug after draining .

6. Install ﬁlter canister b y hand until g ask et contacts mounting surface , then rotate an additional 1/2 tur n.

Replacing the Fuel Pre-Filter

R e place the fuel pre-ﬁlter ( Figure 47 ), located betw een fuel the tank and fuel pump , after ev er y 400 operating hours or yearly , whic hev er occurs ﬁrst.

1. Clamp both fuel lines that connect to the fuel ﬁlter so that fuel cannot drain when the lines are remo v ed.

2. Loosen the hose clamps at both ends of the ﬁlter and pull the fuel lines off of the ﬁlter .

3. Slide the hose clamps onto the ends of the fuel lines . Push the fuel lines onto the fuel ﬁlter and secure them with the hose clamps . Be sure that the ar ro w on the side of the ﬁlter points to w ard the injection pump .

Note: Do not use w ater to clean engine , as damag e ma y occur .

Electrical System Maintenance

Battery Care

Figure 47

1. Fuel pre-lter

Note: Bleeding fuel system is required after re placing the fuel ﬁlter/w ater se parator ﬁlter or the fuel ﬁlter .

Bleeding Air From Injectors

Note: T his procedure should be used only if fuel

system has been purg ed of air through nor mal priming procedures and engine will not star t; refer to Bleeding the Fuel System in Operation , pag e 22 .

1. Loosen the pipe connection to the No . 1 nozzle and holder assembly .

Warning

CALIFORNIA

Pr oposition 65 W ar ning

Batter y posts, ter minals, and r elated accessories contain lead and lead compounds, chemicals kno wn to the State of Calif or nia to cause cancer and r epr oducti v e har m. W ash hands after handling .

Important: Bef or e w elding on a machine, disconnect both ca bles fr om the batter y , disconnect both wir e har ness plugs fr om the electr onic contr ol unit and the ter minal connector fr om the alter nator to pr ev ent dama ge to the electrical system.

Batter y ter minals or metal tools could shor t a gainst metal tractor components causing spar ks. Spar ks can cause the batter y gasses to explode, r esulting in per sonal injur y .

Figure 48

1. Fuel injectors (4)

2. Mo v e throttle to F ast position.

3. T ur n k ey in k ey switc h to R un position and w atc h fuel ﬂo w around connector . T ur n k ey to Off position when solid ﬂo w is obser v ed.

4. Tighten pipe connector securely .

5. R e peat ste ps 1 through 4 on remaining nozzles . Note: F an shroud ma y be easily unbolted

from mac hine to simplify cleaning .

6. Install rear screen and secure latc hes .

• W hen r emo ving or installing the batter y , do not allo w the batter y ter minals to touch an y metal par ts of the machine.

• Do not allo w metal tools to shor t betw een the batter y ter minals and metal par ts of the machine.

Incor r ect batter y ca ble r outing could dama ge the tractor and ca bles causing spar ks. Spar ks can cause the batter y gasses to explode, r esulting in per sonal injur y .

• Al w ays disconnect the negati v e (black) batter y ca ble bef or e disconnecting the positi v e (r ed) ca ble.

• Al w ays connect the positi v e (r ed) batter y ca ble bef or e connecting the negati v e (black) ca ble.

Note: Chec k batter y condition w eekly or after ev er y 50 hours of operation. K ee p ter minals and entire batter y case clean because a dir ty batter y will disc harg e slo wly . T o clean the batter y , w ash the entire case with solution of baking soda and w ater . Rinse with clear w ater . Coat the batter y posts and cable connectors with Grafo 112X (skin-o v er) g rease (T oro P ar t No . 505-47) or petroleum jelly to prev ent cor rosion.

Figure 49

1. Fuses

Batter y electr ol yte contains sulfuric acid which is a deadl y poison and causes sev er e bur ns.

• Do not drink electr ol yte and a v oid contact with skin, ey es or clothing . W ear safety g lasses to shield y our ey es and r ub ber g lo v es to pr otect y our hands.

• Fill the batter y wher e clean w ater is al w ays a v aila ble f or ﬂushing the skin.

Fuses

T here are 7 fuses in the mac hines electrical system. T hey are located belo w the operators control panel ( Figure 49 and Figure 50 ).

Figure 50

Optional Lighting

Important: If optional lighting is be added

to the traction unit, use the instr uctions, schematic ( Figur e 51 ), and par t n umber s listed belo w to pr ev ent dama ge to the traction units electrical system.

Installation Instructions

1. Install a rela y into the open connector under console .

2. Install light switc h. Note: Punc h out in control panel pro vided

for switc h installation.

3. Crimp a ring or fork ter minal onto eac h of the orang e wires (J 24 & J 25) under console . Secure them to light switc h ter minals #2 & #3.

4. Splice po w er (+) wires from lights to red wire at J 23.

5. Secure g round wires from lights to the engine bloc k g round.

6. Install a 10 amp . fuse to fuse bloc k at location sho wn on fuse bloc k decal. Do not ex ceed fuse rating .

Figure 51

Switch

Toro Part No. 75-1010 Toro Part No. 70-1480

Honeywell Part No. 1TL1-2 Hella Part No. 87411 B

Relay

Drive System Maintenance

Checking the Torque of the Wheel Nuts or Bolts

F ailur e to maintain pr oper torque of the wheel n uts could r esult in per sonal injur y .

T orque the fr ont wheel n uts and r ear wheel bolts to 85-100 ft.-lb . after 1-4 hour s of operation and a gain after 10 hour s of operation. T orque ev er y 200 hour s ther eafter .

Figure 52

1. Check/drain plug

2. R emo v e the plug on the planetar y ( Figure 52 ) and the c hec k plug on the bac k side of the brak e ( Figure 53 ).

Oil should be at the bottom of the c hec k plug hole on front and bac k side of the brak e .

Checking the Planetary Gear Drive Oil

1. With mac hine on lev el surface , position wheel so the c hec k/drain plug ( Figure 52 ) is at either 2 or 10 o’cloc k position.

Figure 53

1. Brake housing 2. Check plug location

Figure 55

1. Drain plug location 2. Check plug location

3. Add g ear oil to the hole in the planetar y , if necessar y , to bring the oil up to the proper lev el. Install the plug .

4. R e peat ste ps 1 through 3 on the opposite g ear assembly .

Changing the Planetary Gear Drive Oil

Chang e oil initially after 200 hours operation and ev er y 800 hours , or yearly . Use high quality SAE 85W -140 wt. g ear lube as re placement.

1. With mac hine on lev el surface , position wheel so the c hec k/drain plug is at lo w est position ( Figure 54 ).

4. W hen all of the oil has drained, install the bottom plug in the brak e housing .

5. P osition the wheel so that the plug hole is at the ten or tw o o’cloc k position on the planetar y .

6. Slo wly add appro ximately 16 oz. (0.5 l) of high quality SAE 85W -140 wt. g ear lube to the planetar y ﬁll hole (at the ten or tw o o’cloc k position) until the lev el is up to the bottom of the brak e housing c hec k hole . Install the plug .

7. R e peat the procedure on the opposite planetar y/brak e assembly .

Checking the Rear Axle Lubricant

T he rear axle is shipped from the factor y ﬁlled with SAE 85W -140 wt. g ear lube . Chec k lev el before engine is ﬁrst star ted and ev er y 400 hours thereafter . Capacity is 80 oz. Visually inspect for leaks daily .

Figure 54

1. Drain/check plug

2. Place drain pan under hub , remo v e plug and allo w oil to drain.

3. R emo v e both plugs from the bottom of the brak e housing and allo w the oil to drain ( Figure 55 ).

1. P osition the mac hine on a lev el surface .

2. R emo v e a c hec k plug ( Figure 56 ) from one end of axle and mak e sure lubricant is up to bottom of hole . If lev el is lo w , remo v e the ﬁll plug ( Figure 56 ) and add enough lubricant to bring the lev el up to the bottom of the c hec k plug holes .

Rear Wheel Toe-In

After ev er y 800 operating hours or ann ually , c hec k the rear wheel toe-in.

1. Measure the center -to-center distance (at axle height) at the front and rear of the steering tires . T he front measurement m ust be 1/8 in. (3 mm) less than the rear measurement.

Figure 56

1. Check plug 2. Fill plug

Changing the Rear Axle Lubricant

Chang e the oil initially after the ﬁrst 200 hours of operation and ev er y 800 hours of operation thereafter .

1. P osition the mac hine on a lev el surface .

2. Clean the area around the 3 drain plugs , 1 on eac h end and 1 in the center ( Figure 57 ).

2. T o adjust, remo v e the cotter pin and n ut from either tie rod ball joint. R emo v e tie rod ball joint from axle case suppor t ( Figure 58 ).

3. Loosen the clamps at both ends of the tie rods ( Figure 58 ).

Figure 58

1. Tie rod clamp 2. Tie rod ball joint

4. R otate the detac hed ball joint inw ard or outw ard one (1) complete rev olution. Tighten clamp at loose end of tie rod.

5. R otate the entire tie rod assembly the same direction (inw ard or outw ard) one (1) complete rev olution. Tighten clamp at connected end of tie rod.

Figure 57

1. Drain plug location

3. R emo v e the (3) oil lev el c hec k plugs and main axle v ent cap to ease in draining of the oil.

4. R emo v e the drain plugs and allo w the oil to drain into the pans .

5. Install the plugs .

6. R emo v e a c hec k plug and ﬁll axle with appro ximately 80 oz. of 85W -140 g ear lube or until lubricant is up to bottom of hole .

7. Install c hec k plug .

6. Install the ball joint in the axle case suppor t and tighten the n ut ﬁng er tight. Measure toe-in.

7. R e peat procedure if necessar y .

8. Tighten the n ut and install a new cotter pin when the adjustment is cor rect.

Adjusting the Traction Drive for Neutral

T he mac hine m ust not cree p when traction pedal is released. If it does cree p , an adjustment is required.

1. P ark mac hine on a lev el surface , shut engine off and lo w er cutting units to the ﬂoor . De press

only the right brak e pedal and eng ag e the parking brak e .

2. J ac k up left side of mac hine until front tire is off the shop ﬂoor . Suppor t mac hine with jac k stands to prev ent it from falling accidentally .

Note: On 4 wheel dri v e models , left rear tire m ust also be off the shop ﬂoor .

3. Star t engine and allo w r un at lo w idle .

4. Adjust jam n uts on pump rod end to mo v e pump control tube forw ard to eliminate forw ard cree p or rearw ard to eliminate rearw ard cree p ( Figure 59 ).

Figure 60

1. Rear screen

3. Unscrew knobs and pi v ot oil cooler rearw ard ( Figure 61 ). Clean both sides of oil cooler and radiator area thoroughly with compressed air . Do not use w ater . Open hood and blo w debris out to w ard bac k of mac hine . Pi v ot oil cooler bac k into position and tighten knobs .

Figure 59

1. Pump rod 2. Pump control tube

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

6. Stop the engine and release the right brak e . R emo v e jac k stands and lo w er the mac hine to the shop ﬂoor . T est dri v e the mac hine to mak e sure it does not cree p .

Cooling System Maintenance

Removing Debris

R emo v e debris from rear screen, oil cooler and radiator daily , clean more frequently in dir ty conditions .

Important: Nev er spray w ater onto a hot engine as dama ge to engine may occur .

1. T ur n engine off , release hood latc h and raise hood. Clean engine area thoroughly of all debris . Close hood.

2. Unlatc h and remo v e rear screen ( Figure 60 ). Clean screen thoroughly .

Figure 61

1. Oil cooler 2. Radiator

Maintaining the Cooling System

Capacity of the system is 10 qts . (9.4 l). Alw a ys protect cooling system with a 50/50 solution of w ater and per manent eth ylene glycol anti-freeze . Do not use w ater only in the cooling system.

1. After ev er y 100 operating hours , inspect and tighten hose connections . R e place any deteriorated hoses .

2. After ev er y 2 years , drain and ﬂush the cooling system. Add anti-freeze; refer to Chec king the Cooling System in Operation , pag e 22 .

Brake Maintenance

Adjusting the Service Brakes

Adjust the ser vice brak es when there is more than 1 inc h of free tra v el of the brak e pedal, or when the brak es do not w ork effecti v ely . F ree tra v el is the distance the brak e pedal mo v es before braking resistance is felt.

1. Diseng ag e loc king pin from brak e pedals so both pedals w ork inde pendently of eac h other .

2. T o reduce free tra v el of brak e pedals , tighten the brak es b y loosening the front n ut on the threaded end of the brak e cable ( Figure 62 ). T hen tighten rear n ut to mo v e cable bac kw ard until brak e pedals ha v e 1/2 to 1 inc h of free tra v el. Tighten front n uts after brak es are adjusted cor rectly .

Figure 62

1. Brake cables

Belt Maintenance

Checking the Alternator Belt

Chec k condition and tension of alter nator belt after ev er y 100 hours of operation ( Figure 63 ). R e place belt as required. Chec k the tension as follo ws:

1. Open hood.

Figure 63

1. Alternator belt

3. Loosen bolt securing brace to engine and bolt securing alter nator to brace .

4. Inser t pr y bar betw een alter nator and engine and pr y out on alter nator .

5. W hen proper tension is ac hiev ed, tighten alter nator and brace bolts to secure adjustment.

6. Tighten loc k n ut to secure adjustment.

2. Brace

Hydraulic System Maintenance

Changing the Hydraulic Fluid

Chang e h y draulic ﬂuid after ev er y 800 operating hours , in nor mal conditions . If ﬂuid becomes contaminated, contact y our local T oro distributor because the system m ust be ﬂushed. Contaminated ﬂuid looks milk y or blac k when compared to clean oil.

1. T ur n engine off and raise hood.

2. R emo v e drain plug from bottom of reser v oir ( Figure 64 ) and let h y draulic ﬂuid ﬂo w into drain pan. Install and tighten plug when h y draulic ﬂuid stops draining .

2. Chec k tension b y de pressing belt midw a y betw een alter nator and crankshaft pulleys with 22 lb . of force . Belt should deﬂect 7/16 in. If deﬂection is incor rect, proceed to ste p 3 . If cor rect, contin ue operation.

1. Hydraulic reservoir

Figure 64

Figure 65

1. Hydraulic lter 2. Service interval indicator

3. Fill reser v oir with appro ximately 8.5 g allons of h y draulic ﬂuid; refer to Chec king the Hy draulic Fluid in Operation , pag e 22 .

Important: Use onl y h y draulic ﬂuids speciﬁed. Other ﬂuids could cause system dama ge.

4. Install reser v oir cap . Star t engine and use all h y draulic controls to distribute h y draulic ﬂuid throughout the system. Also c hec k for leaks . T hen stop the engine .

5. Chec k lev el of ﬂuid and add enough to raise lev el to Full mark on dipstic k. Do not o v erﬁll.

Replacing the Hydraulic Filter

T he h y draulic system ﬁlter head is equipped with a ser vice inter v al indicator . With the engine r unning, view the indicator , it should be in the GREEN zone . W hen the indicator is in the RED zone , the ﬁlter element should be c hang ed.

3. Lubricate new ﬁlter g ask et and ﬁll the ﬁlter with h y draulic ﬂuid.

4. Ensure that the ﬁlter mounting area is clean. Screw ﬁlter on until g ask et contacts mounting plate . T hen tighten ﬁlter 1/2 tur n.

5. Star t engine and let r un for about tw o min utes to purg e air from the system. Stop the engine and c hec k for leaks .

Checking the Hydraulic Lines and Hoses

Inspect h y draulic lines and hoses daily for leaks , kink ed lines , loose mounting suppor ts , w ear , loose ﬁttings , w eather deterioration and c hemical deterioration. Mak e all necessar y re pairs before operating .

Use the T oro re placement ﬁlter (P ar t No . 94-2621).

Important: Use of an y other ﬁlter may v oid the w ar ranty on some components.

1. P osition mac hine on a lev el surface , lo w er the cutting units , stop the engine , eng ag e the parking brak es and remo v e k ey from ignition switc h.

2. Clean area around ﬁlter mounting area. Place drain pan under ﬁlter and remo v e ﬁlter ( Figure 65 ).

Hy draulic ﬂuid escaping under pr essur e can penetrate skin and cause injur y .

• Mak e sur e all h y draulic ﬂuid hoses and lines ar e in good condition and all h y draulic connections and ﬁttings ar e tight bef or e appl ying pr essur e to the h y draulic system.

• K eep y our body and hands a w ay fr om pin hole leaks or nozzles that eject high pr essur e h y draulic ﬂuid.

• Use cardboard or paper to ﬁnd h y draulic leaks.

• Safel y r eliev e all pr essur e in the h y draulic system bef or e perf or ming an y w or k on the h y draulic system.

• Get immediate medical help if ﬂuid is injected into skin.

Hydraulic System Test Ports

Figure 67

Models 03806 and 03807

1. Test port A (Lift cylinders)

2. T est P or t B ( Figure 68 ) is used to assist in trouble shooting the h y draulic circuit for the front cutting units .

3. T est P or t C ( Figure 68 ) is used to assist in trouble shooting the h y draulic circuit for the rear cutting units .

T he test por ts are used to test pressure in the h y draulic circuits . Contact y our local T oro distributor for assistance .

1. T est P or t A ( Figure 66 and Figure 67 ) is used to assist in trouble shooting the h y draulic circuit for the lift cylinders .

Figure 66

Model 03808

1. Test port A (Lift cylinders)

Figure 68

1. Test port B (Front cutting units)

2. Test port C (Rear cutting units)

4. T est P or t D is located on the bottom of the h y drostatic transmission ( Figure 69 ) and is used to measure the c harg e pressure of the transmission.

5. T est P or t E is used to measure traction forw ard pressure ( Figure 69 ).

6. T est P or t F is used to measure traction rev erse pressure ( Figure 69 ).

7. T est P or t G is used to measure steering circuit pressure ( Figure 69 ).

Figure 69

1. Test port D (Charge pressure)

2. Test port E (Traction forward pressure)

3. Test port F (Traction reverse pressure)

4. Test port G (Steering circuit pressure)

1. P osition the mac hine on a lev el surface , lo w er the cutting units , stop the engine , eng ag e the parking brak e , and mo v e the Enable/Disable switc h to disable position.

2. Unloc k and raise the seat to expose controls .

3. Locate the reel speed selector knobs and bac klap knobs ( Figure 70 ). R otate the desired bac klap knob(s) to the bac klap position and the desired reel speed selector knob(s) to position 1.

Cutting Unit Maintenance

Backlapping

T he r eels may stall while backlapping and could r estar t suddenl y . Contact with the r eels during backlapping will cause per sonal injur y .

• Nev er place hands or feet in the r eel ar ea while the engine is r unning .

• Nev er attempt to tur n the r eels by hand or f oot or touch the r eels while backlapping .

• Nev er change engine speed while backlapping . Onl y backlap at idle speed.

• Stop the engine and mo v e the desir ed r eel speed selector knob(s) one position closer to “13.”

Note: W hen bac klapping, the front units all operate tog ether , and the rear units operate tog ether .

Figure 70

1. Reel speed selector knobs 2. Backlap knobs

Note: Bac klapping speed ma y be increased b y mo ving the reel speed selector knob to w ard 13. Eac h position will increase speed appro ximately 100 r pm. After c hanging selector , w ait 30 seconds for the system to stabilize at the new speed.

4. Mak e initial reel to bedknife adjustments appropriate for bac klapping on all cutting units whic h are to be bac klapped.

5. Star t engine and r un at idle speed.

Contact with the r eels or other mo ving par ts can r esult in per sonal injur y .

• K eep ﬁnger , hands, and clothing a w ay fr om the r eels and other mo ving par ts.

• Nev er use a shor t handles br ush to appl y lapping compound.

6. Select either front, rear , or both bac klap knobs to deter mine whic h reels will be bac klapped.

7. Mo v e Enable/Disable switc h to Enable position. Mo v e Lo w er Mo w/Lift control forw ard to star t bac klapping operation on designated reels .

8. Apply lapping compound with a long handle br ush (T oro P ar t No . 29-9100). Nev er use a shor t handled br ush ( Figure 71 ).

Figure 71

1. Long handled brush

9. If reels stall or become er ratic while bac klapping, stop bac klapping b y mo ving the Lo w er Mo w/Lift control lev er rearw ard. Once the reels ha v e stopped, mo v e the desired reel speed selector knob(s) one position closer to

13. R esume bac klapping b y mo ving the Lo w er Mo w/Lift control lev er forw ard.

10. T o mak e an adjustment to the cutting units while bac klapping, tur n reels Off b y mo ving the Lo w er Mo w/Raise lev er rearw ard; mo v e the Enable/Disable switc h to Disable and tur n the engine Off . After adjustments ha v e been completed, re peat ste ps 5 through 9 .

11. W hen the cutting unit is adequately shar pened, a bur r will for m on the front edg e of the knife . Using a ﬁle , carefully remo v e the bur r without dulling the cutting edg e ( Figure 72 ).

Figure 72

12. R e peat procedure for all cutting units to be bac klapped.

W hen bac klap operation has been completed, retur n the bac klap knobs to the forw ard ﬂo w position, lo w er seat and w ash all lapping compound off cutting units . Adjust cutting unit reel to bedknife as needed.

Note: If the bac klap knobs are not retur ned to the forw ard ﬂo w position after bac klapping, the cutting units will not raise or function properly .

Adjust Turf Compensation Spring

T ractors are setup at the factor y appropriately for most fairw a y mo wing applications .

T he follo wing adjustments are a v ailable for ﬁne-tuning of the mac hine to the application:

T he T urf Compensation Spring ( Figure 73 ), connecting car rier frame to cutting unit, controls the amount of fore-aft rotation a v ailable , as w ell as the amount of g round clearance in transpor t and tur n around.

T he T urf Compensation Spring also transfers w eight from the front to rear roller . T his helps to reduce a w a v e patter n in the turf , also kno wn as bobbing .

Important: Mak e spring adjustments with cutting unit mounted to traction unit and lo w er ed to shop ﬂoor . R efer to Setup , pa ge 13 , f or mounting instr uctions.

Adjusting the Cutting Unit Lowering Rate

T he cutting unit lift circuits are equipped with adjustable v alv es to ensure the cutting units lo w er at the desired rate . Adjust as follo ws:

R un traction unit until operating temperature is reac hed.

1. Tighten loc k n ut on rear of spring rod until the g ap (C) betw een rear of spring brac k et and front of w asher is 1 in. (25 mm) ( Figure 73 ).

Figure 73

2. Tighten hex n uts on front end of spring rod until the compressed length (A) of spring is 8 in. (203 mm) ( Figure 73 ).

F ront Cutting Units

1. Locate v alv es under seat for adjusting front cutting units ( Figure 74 ).

Figure 74

Model 03808

1. Adjustment valve for front center cutting unit

2. Adjustment valve for front outside cutting units

3. Adjustment valves for wing cutting units

Note: W hen cutting rough or undulating turf , increase compressed length (A) of spring to 8-1/2 in. (216 mm) and g ap (C) betw een rear of spring brac k et and front of w asher to 1-1/2 in. (38 mm) ( Figure 73 ).

Note: As compressed spring length (A) decreases , w eight transfer from front roller to rear roller increases and car rier frame/cutting unit rotation angle (B) decreases .

Note: As g ap (C) betw een spring brac k et and w asher increases , cutting unit g round clearance decreases and car rier frame/cutting unit rotation angle (B) increases .

Figure 75

Models 03806 and 03807

1. Adjustment valves

2. Loosen set screws securing knob .

3. R otate appropriate v alv e cloc kwise to slo w do wn drop rate of cutting units .

4. V erify the lift rate adjustment b y raising and lo w ering cutting units sev eral times . R eadjust

as required. Tighten set screw securing adjustment.

ma y be increased to pro vide additional g round clearance on contoured fairw a ys .

R ear Cutting Unit

5. Locate v alv e in front of rear axle for rear cutting units ( Figure 76 ).

Figure 76

1. Adjustment valve for rear cutting unit

2. Locking pin

6. Loosen loc king ring securing knob ( Figure 76 ).

Note: T he RM CONFIG time dela y should not be c hang ed from the original setting of 0 when using this method to adjust tur n around height.

T o increase/adjust the tur n around height of the cutting units proceed as follo ws:

• P osition mac hine on a lev el surface , lo w er the cutting units and stop the engine .

• Loosen the car riag e bolt n ut securing the lift ar m switc h brac k et to the #4, 6 or 7 lift ar ms ( Figure 77 ). #4 sho wn in ﬁgure .

7. R otate v alv e cloc kwise to slo w do wn drop rate of rear cutting units .

8. V erify the lift rate adjustment b y raising and lo w ering cutting units sev eral times . R eadjust as required. Tighten loc king ring securing adjustment.

Wing Cutting Units

9. Locate v alv es under seat for adjusting wing cutting units ( Figure 74 ).

10. Loosen set screws securing knob .

11. R otate appropriate v alv e cloc kwise to slo w do wn drop rate of cutting units .

12. V erify the lift rate adjustment b y raising and lo w ering cutting units sev eral times . R eadjust as required. Tighten set screw securing adjustment.

Lifted Height of Outer Front Cutting Units (Enable Position)

T he tur naround height of the front outer cutting units (#4 & #5) and rear (#6 & #7) cutting units

Figure 77

1. Lift arm switch 3. Lift arm ag

2. Carriage bolt nut

• Mo v e the lift switc h brac k et up in the slot to the desired position.

• Set the distance betw een the lift ar m switc h and the ﬂag on the lift ar m to appro ximately .062 inc hes .

• Tighten car riag e bolt n ut.

Adjusting the Travel of the Front Three Cutting Units

Additional do wnw ard tra v el of the front three cutting units ma y be desirable in highly contoured locations . If any of the front three cutting units lift off the g round when cresting a hill, the front car rier frame ma y be lo w ered b y remo ving mounting bolts and re positioning frame in the bottom set of holes in the main frame ( Figure 78 ). Contact y our distributor for assistance .

Note: Mo ving the car rier frame do wn will decrease the amount of clearance betw een the cutting units and the g round in tur naround and transpor t positions and ma y require adjusting the lift c hain length on the cutting unit.

Figure 78

1. Carrier frame mounting bolts

Storage

Traction Unit

1. T horoughly clean the traction unit, cutting units and the engine .

2. Chec k the tire pressure . Inﬂate all tires to 15-20 psi.

3. Chec k all fasteners for looseness; tighten as necessar y .

4. Grease or oil all g rease ﬁttings and pi v ot points . Wipe up any ex cess lubricant.

5. Lightly sand and use touc h-up paint on painted areas that are scratc hed, c hipped, or r usted. R e pair any dents in the metal body .

6. Ser vice the batter y and cables as follo ws:

A. R emo v e the batter y ter minals from the

batter y posts .

B . Clean the batter y , ter minals , and posts with

a wire br ush and baking soda solution.

6. Flush the fuel tank with fresh, clean diesel fuel.

7. Secure all fuel system ﬁttings .

8. T horoughly clean and ser vice the air cleaner assembly .

9. Seal the air cleaner inlet and the exhaust outlet with w eather proof tape .

10. Chec k anti freeze protection and add a 50/50 solution of w ater and anti freeze as needed for expected minim um temperature in y our area.

C . Coat the cable ter minals and batter y posts

with Grafo 112X skin-o v er g rease (T oro P ar t No . 505-47) or petroleum jelly to prev ent cor rosion.

D . Slo wly rec harg e the batter y ev er y 60 da ys

for 24 hours to prev ent lead sulfation of the batter y .

Charging the batter y pr oduces gasses that can explode.

Nev er smok e near the batter y and k eep spar ks and ﬂames a w ay fr om batter y .

Engine

1. Drain the engine oil from the oil pan and re place the drain plug .

2. R emo v e and discard the oil ﬁlter . Install a new oil ﬁlter .

3. R eﬁll oil pan with 7.5 qts . (7 l) of SAE10W -30 CD , CE, CF , CF-4, or CG-4 motor oil.

4. Star t the engine and r un at idle speed for appro ximately tw o min utes .

5. Stop the engine .

Schematics

Electrical Schematic (Rev. -)

Hydraulic Schematic, Model 03806 (Rev. -)

Hydraulic Schematic, Model 03807 (Rev. -)

Hydraulic Schematic, Model 03808 (Rev. -)

The Toro General Commercial Products Warranty

A Two-Year Limited Warranty

Conditions and Products Covered

The Toro Company and its afliate, 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 rst. Where a warrantable condition exists, we will repair the Product at no cost to you including diagnosis, labor, parts, and transportation. This warranty begins on the date the Product is delivered to the original retail purchaser.

* P r o d u c t e q u i p p e d w i t h h o u r m e t e r

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 800-982-2740

E-mail: commercial.service@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 express 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, modied, or unapproved accessories

• Product failures which result from failure to perform required

maintenance and/or adjustments

• 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, blades, reels, bedknives, tines, spark plugs, castor wheels, tires, lters, belts, and certain sprayer components such as diaphragms, nozzles, and check valves, etc.

• Failures caused by outside inuence. Items considered to be

outside inuence include, but are not limited to, weather, storage practices, contamination, use of unapproved coolants, lubricants, additives, or chemicals, etc.

• Normal “wear and tear" items. 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 become the property of Toro. Toro will make the nal decision whether to repair any existing part or assembly or replace it. Toro may use factory remanufactured parts rather than new parts for some warranty repairs.

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 tness 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 specic 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 printed in your operator’s manual 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 dissatised with your Distributor’s service or have difculty obtaining guarantee information, contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty Company.

374-0031 Rev C

Toro 03807, Reelmaster 6500-D, Reelmaster 6700-D, 03808 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual