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Toro Reelmaster 5010-H Operator's Manual

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Operator's Manual
Reelmaster® 5010-H Traction Unit
Model—Serial Range
03950—400000000 and Up
*3464-478* A
3464-478A
Original Instructions (EN)

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Summary of Contents for Toro Reelmaster 5010-H

  • Page 1 Operator’s Manual Reelmaster® 5010-H Traction Unit Model—Serial Range 03950—400000000 and Up *3464-478* A 3464-478A Original Instructions (EN)

  • Page 2: Table Of Contents

    After Operation Safety........................2–4 Maintenance Safety ......................... 2–4 Engine Safety ..........................2–5 Electrical System Safety ......................2–5 © 2024—The Toro ® Company Contact us at www.Toro.com 8111 Lyndale Ave So Printed in the USA Bloomington, MN 55044 All rights reserved...

  • Page 3: Disclaimers And Regulatory Information

    Cooling System Safety........................ 2–5 Hydraulic System Safety......................2–5 Blade Safety ..........................2–6 Storage Safety ..........................2–6 Safety and Instructional Decals ....................2–7 Chapter 3: Setup........................... 3–1 1 Preparing the Machine......................... 3–1 2 Adjusting the Control-Arm Position................... 3–1 3 Installing the Cutting Units ......................3–2 Preparing the Machine ........................
  • Page 4 Overview of the Virtual Pedal Stop (VPS) Feature............. 5–17 Cruise Control ..........................5–18 Overview of the Acceleration Mode ..................5–20 Overview of the Warm-Up Mode..................... 5–20 Overview of Toro Smart Power™ ................... 5–20 Starting the Engine........................5–20 Shutting Off the Engine ......................5–22 Adjusting the Turf-Compensation Spring................5–22 Adjusting the Lift-Arm Counterbalance .................
  • Page 5 Inspecting the Seat Belt ......................6–43 Cleaning............................6–43 Washing the Machine ........................ 6–43 Chapter 7: Storage..........................7–1 Storing the Machine ......................... 7–1 Storing the Battery..........................7–1 The Toro Warranty California Proposition 65 Warning Information 3464-478 A Disclaimers and Regulatory Information:...

  • Page 6: Chapter 1: Introduction

    Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready. These numbers are located on the serial plate on your product .

  • Page 7: Manual Conventions

    Manual Conventions This manual identifies potential hazards and has safety messages identified by the safety- alert symbol, which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions. G405934 This manual uses 2 words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention.

  • Page 8: Chapter 2: Safety

    Chapter 2 Safety General Safety • This product is capable of amputating hands and feet and of throwing objects. • Read and understand the contents of this Operator’s Manual before starting the engine. • Use your full attention while operating the machine. Do not engage in any activity that causes distractions;...

  • Page 9: Fuel Safety

    • Before mowing, always inspect the machine to ensure that the cutting units are in good working condition. • Inspect the area where you will use the machine and remove all objects that the machine could throw. • This product generates an electromagnetic field. If you wear an implantable electronic medical device, consult your health care professional before using this product.

  • Page 10: Rollover Protection System (Rops) Safety

    • Operate the engine only in well-ventilated areas. Exhaust gasses contain carbon monoxide, which is lethal if inhaled. • Do not leave a running machine unattended. • Before you leave the operator’s position, do the following: – Park the machine on a level surface. –...

  • Page 11: After Operation Safety

    Slope Safety (continued) – Remove or mark obstructions such as ditches, holes, ruts, bumps, rocks, or other hidden hazards. Tall grass can hide obstructions. Uneven terrain could overturn the machine. – Be aware that operating the machine on wet grass, across slopes, or downhill may cause the machine to lose traction.

  • Page 12: Engine Safety

    • Keep all parts of the machine in good working condition and all hardware tightened. • Replace all worn or damaged decals. • To ensure safe, optimal performance of the machine, use only genuine Toro replacement parts. Replacement parts made by other manufacturers could be dangerous, and such use could void the product warranty.

  • Page 13: Blade Safety

    Hydraulic System Safety (continued) • Keep your body and hands away from pinhole leaks or nozzles that eject high-pressure hydraulic fluid. • Use cardboard or paper to find hydraulic leaks. • Safely relieve all pressure in the hydraulic system before performing any work on the hydraulic system.

  • Page 14: Safety And Instructional Decals

    Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or missing. Battery Symbols Some or all of these symbols are on your battery. s_batterysymbols2 Wear eye protection;...
  • Page 15 Decal Part: 106-6755 Engine coolant under pressure. Explosion hazard—read the Operator's Manual. Warning—do not touch the hot surface. Warning—read the Operator's Manual. s_decal106-6755 Decal Part: 110-9642 Stored energy hazard—read the Operator's Manual. Move the cotter pin to the hole closest to the rod bracket and then remove the lift arm and pivot yoke.
  • Page 16 Decal Part: 133-2930 s_decal133-2930 Warning—do not park on slopes; engage the Warning—do not operate this machine unless you parking brake, lower the cutting units, shut off the are trained. engine, and remove the ignition key before leaving Warning—wear hearing protection. the machine.
  • Page 17 Decal Part: 133-2931 CE Machines s_decal133-2931 Note: This machine complies with the industry standard stability test in the static lateral and longitudinal tests with the maximum recommended slope indicated on the decal. Review the instructions for operating the machine on slopes in the Operator's Manual as well as the conditions in which you would operate the machine to determine whether you can operate the machine in the conditions on that day and at that site.
  • Page 18 Decal Part: 136-2159 Move seat down Slide seat forward Rotate seat s_decal136-2159 Decal Part: 136-3702 Warning—Read the Operator’s Manual; wear a seatbelt; do not remove the roll bar. Warning—Do not modify the roll bar. s_decal136-3702 Safety: Safety and Instructional Decals Page 2–11 3464-478 A...
  • Page 19 Decal Part: 136-3731 s_decal136-3731 Caustic liquid/chemical burn hazard Read the Operator’s Manual. Explosion hazard Wear eye protection Contains lead; do not discard No fire, open flame, or smoking Keep bystanders away Decal Part: 136-3732 Acute toxicity Aspiration hazard Flammable gases Corrosive to metals/skin corrosion Environmental toxicity s_decal136-3732...
  • Page 20 Decal Part: 145-2498 TEC power relay Electrical power relay Read the Operator’s Manual for fuse information. Engine start relay TEC power controller Logic electrical power Key switch TEC power controller Air-ride seat Electrical power TEC power controller Headlights TEC power controller s_decal145-2498 USB power point Decal Part: 145-2549...
  • Page 21 Decal Part: 145-2572 s_decal145-2572 Engine coolant Read the Operator’s Manual for lubrication information. Engine oil level Check every 8 hours. Fuel Brake functions Read the Operator’s Manual. Hydraulic fluid Fuel/Water separator Tire pressure Fluids Engine air filter Capacity Engine oil Fluid interval (hours) Fan belt Filter interval (hours)

  • Page 22: Chapter 3: Setup

    Chapter 3 Setup Preparing the Machine 1. Park the machine on a level surface, lower the cutting units, and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop. 3. Check the tire air pressure before use. Note: The tires are overinflated for shipping.

  • Page 23: Installing The Cutting Units

    Installing the Cutting Units Parts Required Cutting units Preparing the Machine WARNING If you do not disconnect the power to the cutting units, someone could accidentally start the cutting unit, which could result in death or serious injury to hands and feet. Always separate the power-disconnect connectors before working on the cutting units.

  • Page 24: Preparing The Cutting Units

    Preparing the Machine (continued) IMPORTANT Retain the cap for later installation. G437958 Preparing the Cutting Units 1. Remove the cutting units from the cartons. Assemble and adjust them as described in the cutting unit Operator's Manual. 2. Install the counterweight to the appropriate end of the cutting unit as shown.

  • Page 25: Positioning The Turf-Compensation Spring

    Positioning the Turf-Compensation Spring Cutting Units 2 and 4 G402717 Cutting unit 3 Cutting unit 5 Weight Cutting unit 1 Reel motor Cutting unit 2 Cutting unit 4 1. If the hairpin is installed in the rear hole of the compensation-spring rod, remove the hairpin and insert it in the hole next to the bracket.

  • Page 26: Installing The Front Cutting Units To The Lift Arms

    Positioning the Turf-Compensation Spring (continued) 4. Assemble the bolt of the turf-compensation spring to the right tab of the carrier frame with the flange locknut (3/8 inch) G402721 5. Align the holes in the turf-compensator bracket with the holes in the cutting-unit frame. Note: The support loop of the hose guide aligns toward the center of the machine...

  • Page 27: Installing The Rear Cutting Units To The Lift Arms

    Installing the Rear Cutting Units to the Lift Arms Cutting Units adjusted for a 1.2 cm (3/4 inch) or Higher Height of Cut 1. Install the rear cutting units to the lift arms as shown. 2. Lock the cutting-unit pivot for cutting grass on a hill side.

  • Page 28: Locking The Cutting-Unit Pivot For Cutting Grass On A Hill Side

    Locking the Cutting-Unit Pivot for Cutting Grass on a Hill Side Lock the cutting-unit pivots with snapper pins prevent the cutting units from rotating downhill when cutting across the face of a hill. Note: Use the hole in the pivot yoke to lock the cutting unit.

  • Page 29: Mounting The Finishing Kits

    Installing the Reel Motors (continued) 4. Rotate the reel motor counterclockwise until the flanges encircle the bolts. 5. Torque the mounting bolts to 19 to 25 N∙m (14 to 18 ft-lb). 6. Repeat this procedure for the other cutting units. G402696 Mounting the Finishing Kits Parts Required...
  • Page 30 Note: When tightening the nuts, use a backup wrench to prevent the hose from twisting or kinking. 3. Insert the connector plate onto the bulkhead-mounting bolts with the connectors positioned as shown. 4. Secure the connector plate to one of the mounting bolts with the flange nut previously removed.
  • Page 31 Center front cutting unit (#1) (Underside of machine shown) Extra flange nut Connector plate Bulkhead bracket G402742 Right front cutting unit (#5) Extra flange nut Connector plate Bulkhead bracket G402743 3464-478A Page 3–10 Setup: Mounting the Finishing Kits...
  • Page 32 Right rear cutting unit (#3) Extra flange nut Connector plate Bulkhead bracket G402744 Setup: Mounting the Finishing Kits Page 3–11 3464-478 A...

  • Page 33: Using The Cutting-Unit Kickstand

    Using the Cutting-Unit Kickstand Parts Required Cutting-unit kickstand 1. When tipping a cutting unit to expose the bedknife/reel, prop up the rear of the cutting unit with the kickstand to ensure that the nuts on the back end of the bedbar adjusting screws are not resting on the work surface.

  • Page 34: Installing The 48 V Disconnect Jumper And Closing The Seat Base

    Installing the 48 V Disconnect Jumper and Closing the Seat Base 1. Apply dielectric grease to the contact surfaces of the battery disconnect jumper. 2. Plug the 48 V system connector into the battery-disconnect jumper G437957 3. Close and latch the seat base.

  • Page 35: Installing The Ce Hood Lock

    Installing the CE Hood Lock Parts Required Hood lock Seal Jam nut Washer 1. Raise the hood. 2. Remove the rubber grommet from the hole in the left side of the hood. G439569 3. Ensure that the seal is assembled to the hood lock 4.

  • Page 36: Installing The Ce Decals

    Installing the CE Decals CE Machines Parts Required Year of production decal CE decal Tilt danger decal Applying the CE Decal 1. Use rubbing alcohol and a clean rag to clean the area of the hood next to the hood lock and allow the hood to dry.

  • Page 37: Applying The Ce Warning Decal

    Applying the CE Warning Decal 1. Use rubbing alcohol and a clean rag to clean the surface of the existing decal and allow the decal to dry. 2. Remove the backing from the CE warning decal and apply the CE warning decal over the existing decal.

  • Page 38: Chapter 4: Product Overview

    Chapter 4 Product Overview Engine hood Operator's seat Control arm Steering wheel Seat-adjustment lever Front cutting units Rear cutting units G403839 Controls G461340 Headlight switch Key switch InfoCenter display Engine-speed switch Lower mow/raise control lever Tilt-steering pedal Cruise-control switch Parking-brake switch Traction pedal PTO switch Product Overview...

  • Page 39: Key Switch

    Key Switch On/preheat Start G453721 Lower Mow/Raise Control Lever Lower the cutting units—Engage the PTO first for cutting units to spin (Mow mode). Raise the cutting units—Disengage the PTO first for cutting units to stop spinning (Transport mode). Note: To partially raise the cutting units to the turnaround position, briefly pull the lever backward.

  • Page 40: Cruise-Control Switch

    Cruise-Control Switch Engage cruise control—briefly pivot the switch forward. Note: Use the display buttons to adjust the cruise control speed in 0.8 km/h (0.5 mph) increments. Turn on cruise control—pivot the switch to the middle position. Turn off cruise control—pivot the switch backward.

  • Page 41: Headlight Switch

    Headlight Switch G461393 InfoCenter Display The InfoCenter display shows information about your machine, such as the operating status, various diagnostics, and other information about the machine. The screens that display, depend on which buttons you select. The purpose of each button may change depending on what is required at the time.

  • Page 42: Tilt-Steering Pedal

    Tilt-Steering Pedal Press the tilt-steering pedal and raise or lower the steering tower to a comfortable operating position. G453181 Traction Pedal Move forward—press the top of the pedal. Note: To achieve maximum ground speed, set the maximum ground speed and press the pedal forward while in transport mode.

  • Page 43: Power Point

    Power Point The power point is a 12 V power supply for electronic devices. G453945 3464-478A Page 4–6 Product Overview: Controls...

  • Page 44: Seat Controls

    Seat Controls G446491 Height-adjustment knob Weight gauge Weight-adjustment knob Forward/backward lever Weight-Adjustment Knob Rotate the weight-adjustment knob until your weight is displayed in the window of the weight gauge. Decrease Increase G446496 Height-Adjustment Knob Raise Lower G446494 Product Overview: Controls Page 4–7 3464-478 A...
  • Page 45 Seat Controls (continued) Forward/Backward Lever Lock Unlock G446495 3464-478A Page 4–8 Product Overview: Controls...

  • Page 46: Cutting-Unit-Power Disconnect

    Cutting-Unit-Power Disconnect Before installing, removing, or working on the cutting units, disconnect the cutting units from the power supply by separating the cutting-unit-power-disconnect connector , located under the seat. Plug the connector back in before operating the machine. G454877 CAUTION If you do not disconnect the power to the cutting units, someone could accidentally start the cutting unit, causing serious injury to hands and feet.

  • Page 47: Attachments/Accessories

    *Weight includes fluids and 5-inch, 8-blade cutting units. Attachments/Accessories A selection of Toro approved attachments and accessories is available for use with the machine to enhance and expand its capabilities. Contact your Authorized Service Dealer or authorized Toro distributor or go to www.Toro.com...

  • Page 48: Chapter 5: Operation

    Chapter 5 Operation Before Operation Performing Daily Maintenance Before starting the machine each day, perform the Each Use/Daily procedures listed in the Maintenance Schedule. Fuel Fuel Specifications IMPORTANT Never use kerosene or gasoline instead of diesel fuel. Petroleum Diesel Type Use summer grade diesel fuel (No.
  • Page 49 Monitor seals, hoses, gaskets in contact with fuel as they may degrade over time. Fuel filter plugging may be expected for a time after converting to biodiesel blended. For more information on biodiesel, contact your authorized Toro distributor. Storage Acquire only enough clean, fresh diesel fuel or biodiesel fuel that you will consume within 180 days.

  • Page 50: Checking The Interlock Switches

    • Check the operation of the interlock switches daily and replace any damaged switches before operating the machine. IMPORTANT If your machine fails any of the interlock switch checks, contact your authorized Toro distributor. Preparing the Machine 1. Drive the machine slowly to an open area.
  • Page 51 Checking the Interlock Switches (continued) 4. Pull up the PTO switch to the E position. NGAGE 5. Lower the cutting units to engage the PTO. 6. Rise from the seat. Note: The PTO should not run when you are out of the operator’s seat. Checking the Parking Brake and Traction Pedal Run-Interlock 1.

  • Page 52: Overview Of The Infocenter Display

    Overview of the InfoCenter Display The InfoCenter display shows information about your machine such as the operating status, various diagnostics and other information about the machine. There are multiple screens on the display. You can switch between the screens, at any time, by pressing the back button and then using the up and down directional buttons.
  • Page 53 Overview of the InfoCenter Display (continued) Engine coolant Fault/warning temperature Traction or Traction Backlap Pedal Start the engine. The cutting units are up or raising. The PTO is engaged. The cutting units are down or lowering. The cruise control is Generator engaged.
  • Page 54 Description Faults The Faults menu contains a list of the recent machine faults. Refer to the Service Manual or contact your authorized Toro distributor for more information on the Faults menu and the information contained there. Service The Service menu contains information on the machine such as hours of use, counters, and other similar numbers.
  • Page 55 Overview of the InfoCenter Display (continued) Service (continued) Menu Item Description Traction Pump Calibrates the traction pump. Virtual Speed Sensor Calibrates the virtual speed sensor. Diagnostics Menu Item Description Traction Indicates the inputs and outputs for the traction pedal. Cutting Units Indicates the inputs and outputs for raising and lowering the cutting units.
  • Page 56 Overview of the InfoCenter Display (continued) Machine Settings Menu Item Description Front Backlap Controls the speed of the front reels in backlap mode. Rear Backlap Controls the speed of the rear reels in backlap mode. Mow Speed Controls the maximum speed while in mow (low range).
  • Page 57 Overview of the InfoCenter Display (continued) About (continued) Menu Item Description Generator S/W Revision Lists the software revision of the starter generator. Cutting Unit 1 S/W Revision Lists the software revisions of the eReel cutting units. Cutting Unit 2 S/W Revision Cutting Unit 3 S/W Revision Cutting Unit 4 S/W Revision Cutting Unit 5 S/W Revision...
  • Page 58 Note: The factory default PIN code for you machine is either 0000 or 1234. If you changed the PIN code and forgot the code, contact your authorized Toro distributor for assistance. 1. From the Main Menu, scroll down to Settings and press the select button.
  • Page 59 Overview of the InfoCenter Display (continued) 2. In Settings, scroll to Enter PIN and press the select button 3. To enter the PIN code, press the up/down navigation buttons until the correct first digit appears, then press the right navigation button to move on to the next digit.
  • Page 60 Overview of the InfoCenter Display (continued) 7. After you select Y , the interval screen clears and reverts back to the service hours selections. Setting the Blade Count 1. In Machine Settings, scroll down to Blade Count. 2. Press the right navigation button to change the blade count between 8 or 11 blade reels. Setting the Height of Cut (HOC) 1.

  • Page 61: Checking The Hydrostatic Braking Distance

    Overview of the InfoCenter Display (continued) 2. Use the left and right navigation buttons to increase and decrease the maximum mow speed in 0.8 km/h (0.5 mph) increments between 1.6 and 12.9 km/h (1.0 and 8.0 mph). Setting the Maximum Allowed Transport Speed The selected setting is displayed as an X on the traction-speed bar graph along with the cruise control and pedal stop settings.

  • Page 62: Overview Of Reverse Speeds

    Checking the Hydrostatic Braking Distance (continued) 5. Contact your Toro distributor if the stopping distance of the machine is not within 0.6 m (2 ft) of this distance. Overview of Reverse Speeds Transport Reverse Speed • If the maximum transport speed set by the supervisor is above 8.0 km/h (5.0 mph), the maximum reverse speed is 8.0 km/h (5.0 mph).

  • Page 63: During Operation

    Overview of the PowerMatch™ System (continued) Note: Toro recommends leaving Powershed O during most operating conditions. To turn off Powershed, scroll down to Powershed from Machine Settings and press the right navigation button to switch it O Overview of Powerboost Mode When the traction power demand continues to increase (e.g., driving on steeper hills) the...

  • Page 64: Overview Of The Traction Pedal

    Machine Operation (continued) 3. Practice moving forward and reverse, and starting and stopping the machine. To stop the machine, remove your foot from the traction pedal and let it return to N EUTRAL Note: When going downhill in the machine, you may need to engage the parking-brake switch or use the reverse pedal to stop.

  • Page 65: Cruise Control

    Overview of the Virtual Pedal Stop (VPS) Feature (continued) G462150s This speed is locked out under the protected PIN Indicates the maximum traction speed (pedal stop) menu. • This feature allows you to customize the speed settings for your comfort level, or to customize the speed settings to fit the application.
  • Page 66 Cruise Control (continued) • When in transport range, press the reverse traction pedal, engage the parking brake, or press the cruise control switch to the O position. • When in mow range, press the reverse traction pedal, engage the parking brake, disengage the PTO, or press the cruise control switch to the O position.

  • Page 67: Overview Of The Acceleration Mode

    Do not operate the machine until after the warm-up period. Overview of Toro Smart Power™ With Smart Power, the operator does not have to listen to the engine speed in heavy load conditions.
  • Page 68 Starting the Engine (continued) Note: Crank the engine for no longer than 15 seconds. Release the key when the engine starts. If additional preheating is required, turn the key to the O position and then to the O position. Repeat this process as required. REHEAT 4.

  • Page 69: Shutting Off The Engine

    Shutting Off the Engine 1. Move all controls to N , engage the parking brake, move the engine-speed switch EUTRAL to the L position and allow the engine to reach low idle speed. IMPORTANT Allow the engine to idle for 5 minutes before shutting it off after a full load operation. Failure to do so may damage engine components.

  • Page 70: Adjusting The Lift-Arm Counterbalance

    Adjusting the Lift-Arm Counterbalance Rear Cutting Units CAUTION The springs are under tension, and adjusting them could result in minor or moderate personal injury. Use caution when adjusting the springs. Adjust the amount of counterbalance force applied to the rear cutting-units to help compensate for different turf conditions, and to maintain a uniform height of cut in rough conditions or in areas of thatch buildup.

  • Page 71: Setting The Reel Speed

    Adjusting the Lift-Arm Turnaround Position (continued) 3. Loosen the jam nut that secures lift-arm switch to the switch plate 4. Adjust the lift-arm switch as follows: • To increase the lift-arm turnaround height, move the switch down. • To decrease the lift-arm turnaround height, move the switch up.
  • Page 72 Setting the Reel Speed (continued) Refer to Setting the Front and Rear Reel Speeds, page 5–13. To adjust the reel speed manually, complete the following: 1. Ensure that the Clip Control feature is O 2. In Machine Settings, enter the blade count, mow speed, and HOC to calculate the proper reel speed.

  • Page 73: Overview Of The Indicator Lights

    Setting the Reel Speed (continued) 7 inch (178 mm) Reel Speed Chart G439056 Overview of the Indicator Lights G461477 Indicator light • Flashing red—active fault • Solid red—active advisory • Solid blue—calibration/dialog messages • Solid green—normal operation Cutting Grass with the Machine 1.

  • Page 74: Operating Tips

    Cutting Grass with the Machine (continued) 4. Lower the cutting units completely with the lift/lower control lever. 5. Engage the PTO. Note: The cutting units will not start. Note: The engine speed automatically rises to high idle when you lower the cutting units and activate the PTO switch.
  • Page 75 Operating Tips (continued) Proper Mowing Techniques • To achieve the professional straight-line cut and striping that is desirable for some applications, find a tree or other object in the distance and drive straight toward it. • Maintain reel and bedknife sharpness. •...

  • Page 76: After Operation

    Operating Tips (continued) Maintaining the Machine after Mowing Complete the following steps after mowing: 1. Thoroughly wash the machine with a garden hose with no nozzle to avoid contamination and damage to the seals and bearings caused by excessive water pressure. 2.

  • Page 77: Hauling The Machine

    Tie-Down Point Locations (continued) G439096 Rear tie-down Hauling the Machine Follow the tips below when hauling the machine. • Use full-width ramps for loading the machine onto a trailer or truck. • Tie the machine down securely. Pushing or Towing the Machine In an emergency, you can move the machine forward by actuating the bypass valve in the variable-displacement hydraulic pump and pushing or towing the machine.
  • Page 78 Pushing or Towing the Machine (continued) G439099 3. Loosen the valves with 3 turns to allow the oil to bypass internally. Note: Because the fluid is bypassed, the machine can be moved slowly without damaging the transmission. 4. Locate the brake release manifold near the front right tire and behind the hydraulic tank. 5.
  • Page 79 Pushing or Towing the Machine (continued) IMPORTANT Do not pump the manifold after it does not pump easily. Damage could occur if the manifold is pumped too much. Note: Once the pressure is built up in the manifold, the brake will be released for approximately 60 minutes.

  • Page 80: Chapter 6: Maintenance

    Determine the left and right sides of the machine from the normal operating position. Note: Download a free copy of the electrical or hydraulic schematic by visiting www.Toro.com searching for your machine from the Manuals link on the home page. IMPORTANT Refer to your engine owner’s manual and cutting unit Operator's Manual for...
  • Page 81 Maintenance Qty Description Maintenance Procedure Part No. Service Interval Drain water or other contaminants from the fuel/water separator. Inspect the electrical cables. Check the tire air pressure. Check the coolant level. Remove any accumulated debris, including grass clippings, leaves, and any other foreign material from the machine (more frequently in dirty operating conditions).
  • Page 82 Maintenance Qty Description Maintenance Procedure Part No. Service Interval Service the air cleaner (more frequently in extremely dirty or dusty conditions). Service the air 108-3810 Air-cleaner filter cleaner earlier if the air-cleaner indicator shows red. Replace the fuel/water separator Fuel system water filter 110-9049 filter.

  • Page 83: Daily Maintenance Checklist

    Maintenance Qty Description Maintenance Procedure Part No. Service Interval an Authorized Service Dealer or Distributor or refer to the Service Manual). Replace the hydraulic hoses (take the machine to an Authorized Service Dealer or Distributor or refer to the Service Manual).

  • Page 84: Pre-Maintenance Procedures

    Maintenance Check Item For the week of: Mon. Tues. Wed. Thurs. Fri. Sat. Sun. Check the glow plug and injector nozzles if the engine starts hard, produces excess smoke, or runs rough. Immediately after every washing, regardless of the interval listed IMPORTANT Refer to your engine operator’s manual for additional maintenance procedures.

  • Page 85: Opening The Hood

    Opening the Hood Release the 2 hood latches and rotate open the hood. G437864 Closing the Hood Carefully rotate the hood closed and secure it with the 2 hood latches G424260 3464-478A Page 6–6 Maintenance: Pre-Maintenance Procedures...

  • Page 86: Opening The Screen

    Opening the Screen 1. Remove the ball pin from the screen latch 2. Unlatch and open the screen. G437850 Closing the Screen 1. Close and latch the screen. 2. Insert the ball pin through the screen latch G414734 Tilting the Seat 1.

  • Page 87: Lowering The Seat

    Lowering the Seat 1. Rotate the seat slightly, and lift the front prop rod out of the dent of the seat-support slot. 2. Carefully lower the seat until it latches securely. Separating the Generator Cooling-Air Shrouds 1. Remove the 4 bolts and 4 locknuts that secure the upper...

  • Page 88: Jacking Point Locations

    Assembling the Generator Cooling-Air Shrouds (continued) 2. Align the holes in the upper and lower generator cooling-air shrouds with the compression-limiting pins. 3. Secure the halves of the generator cooling-air shrouds and compression-limiting pins with the 4 bolts and 4 locknuts G414736 Jacking Point Locations Note:...

  • Page 89: Lubrication

    Jacking Point Locations (continued) G437877 Rear-axle tube Front of the machine Jack brackets (front-axle tube) Back of the machine Lubrication Greasing the Bearings and Bushings The machine has grease fittings that must be lubricated regularly. Dusty and dirty operating conditions could cause dirt to get into the bearings and bushings, resulting in accelerated wear.

  • Page 90: Grease Fitting Locations

    Greasing the Bearings and Bushings (continued) Grease Fitting Locations Grease Specification: No. 2 lithium grease Pump driveshaft U-joint (3) Note: Access the pump driveshaft from the bottom of the machine. G452383 G452384 Cutting-unit lift-arm cylinders (2 each) Lift-arm pivots (1 each) G452355 Cutting-unit carrier-frame and pivot (2 each) G452356...
  • Page 91 Greasing the Bearings and Bushings (continued) Lift-arm-pivot shaft (1 each) G452357 Rear axle tie rod (2) G452368 3464-478A Page 6–12 Maintenance: Lubrication...

  • Page 92: Engine Maintenance

    Greasing the Bearings and Bushings (continued) Axle-steering pivot (1) G452379 Steering-cylinder ball joints (2) G452380 Engine Maintenance Checking the Air Cleaner 1. Prepare the machine for maintenance. 2. Open the hood. 3. Check the service indicator at the end of the air filter housing.

  • Page 93: Resetting The Air Filter Service Indicator

    Checking the Air Cleaner (continued) 4. If a red band displays in the service indicator, change the air filter. 5. Squeeze the dust-ejector valve. 6. Close and latch the hood. G414762 Resetting the Air Filter Service Indicator 1. If a red band displays in the service indicator, press the reset button at the end of the indicator.

  • Page 94: Engine Oil Specifications

    Use the following engine oil viscosity grade: • Preferred oil: SAE 15W-40 [-17°C (above 0°F)] • Alternate oil: SAE 10W-30 or 5W-30 (all temperatures) Toro Premium Engine Oil is available from your authorized Toro distributor in either 15W-40 or 10W-30 viscosity grades. Crankcase Capacity Approximately 3.3 L (3.5 US qt) with the filter...
  • Page 95 Checking the Engine Oil Level (continued) IMPORTANT Check the engine oil daily. If the engine-oil level is above the Full mark on the dipstick, the engine oil may be diluted with fuel. If the engine oil level is above the Full mark, change the engine oil. If the oil level is at or below the Add mark on the dipstick, add oil to bring the oil level to the Full mark.

  • Page 96: Changing The Engine Oil And Filter

    Changing the Engine Oil and Filter 1. Prepare the machine for maintenance. 2. Drain the oil and change the filter. G437921 G437922 IMPORTANT Do not overtighten the filter. 3. Open the hood. 4. Add oil to the crankcase. Maintenance: Engine Maintenance Page 6–17 3464-478 A...

  • Page 97: Fuel System Maintenance

    Changing the Engine Oil and Filter (continued) 5. Close and latch the hood. Fuel System Maintenance This Operator’s Manual contains more detailed fuel and fuel system maintenance information than the engine Owner’s Manual, which is a general-purpose reference relating to fuel and fuel maintenance. Ensure that you understand that the fuel system maintenance, fuel storage, and fuel quality require your attention to avoid downtime and extensive engine repairs.

  • Page 98: Servicing The Fuel/Water Separator

    Servicing the Fuel/Water Separator Draining Water from the Fuel/Water Separator 1. Drain water from the fuel/water separator as shown. G452998 2. Prime the filter and the lines to the high pressure pump. Maintenance: Fuel System Maintenance Page 6–19 3464-478 A...

  • Page 99: Servicing The Fuel Filter

    Servicing the Fuel/Water Separator (continued) Replacing the Fuel/Water Separator Filter 1. Replace the filter as shown. G452996 2. Prime the filter and the lines to the high pressure pump. Servicing the Fuel Filter 1. Tilt the seat open. 2. Remove the floor plate by removing the 4 bolts securing it to the machine. 3.

  • Page 100: Draining The Fuel Tank

    Servicing the Fuel Filter (continued) 6. Install a new filter and connect the hoses. Note: Ensure that the filter is orientated as shown. 7. Slide the hose clamps back into place to secure the fuel hoses to the filter. 8. Prime the filter and the lines to the high pressure pump.

  • Page 101: Bleeding The Fuel System

    Bleeding the Fuel System 1. Prepare the machine for maintenance. 2. Ensure that the fuel tank is at least half full. 3. Open the hood. 4. Open the air-bleed screw on the fuel- injection pump. 5. Turn the ignition key to the O position.
  • Page 102 Cleaning the Fuel-Pickup Tube Screen (continued) 3. Remove the 2-socket connector of the fuel- sender harness from the 2-pin connector of the machine wire harness G415056 4. Move the clamps that secure the hoses to the fittings of the fuel sender inboard, and remove the hoses from the fittings.
  • Page 103 Cleaning the Fuel-Pickup Tube Screen (continued) Cleaning the Installing the Fuel-Pickup Tube 1. Clean the screen at the end of the fuel pick-up tube. G415060 2. Carefully assemble the fuel pick-up tube and float into the fuel tank. 3. Align the fittings for the pick-up tube and return tube inboard.

  • Page 104: Priming The Fuel System

    Cleaning the Fuel-Pickup Tube Screen (continued) 6. Plug the connector of the fuel-sender harness into the connector of the machine wire harness G415056 7. Install the fuel-sender cover to the fuel tank using the 5 screws G415055 Priming the Fuel System Prime the fuel system after the following scenarios: •...

  • Page 105: Electrical System Maintenance

    Priming the Fuel System (continued) B. Cycle the ignition key to the O position for 30 to 40 seconds. Note: This allows the ECU to power down. C. Cycle the key to the O position for 15 to 20 seconds. D.

  • Page 106: Connecting The Battery

    2. Install the negative battery cable (black) the negative (-) battery post. 3. Apply a coat of Grafo 112X (skin-over) grease, Toro Part No. 505-47 to the battery posts and battery-cable clamps. 4. Slide the rubber boot over the positive battery- cable clamp.

  • Page 107: Servicing The Battery

    Servicing the Battery Note: Keep the terminals and the entire battery case clean because a dirty battery will discharge slowly. 1. Prepare the machine for maintenance. 2. Open the screen. 3. Check the condition of the battery. Note: Replace a worn or damaged battery. 4.
  • Page 108 Replacing a 48 V Cutting Unit Fuse (continued) Cover Maxi fuse 48 V fuse block G416230 3. Locate the open fuse in the fuse block. 4. Replace the fuse with the same type and amperage fuse. Refer to the decal on the inside of the fuse-block cover for the amperages.

  • Page 109: Replacing The Reel Enable Fuse

    Replacing the Reel Enable Fuse 1. Prepare the machine for maintenance. 2. Unlatch and open the hood. 3. At the front, right side of the engine, remove the cap from the in-line fuse holder labeled “Enable Fuse 10 A 125 V” 4.

  • Page 110: Drive System Maintenance

    Drive System Maintenance Checking the Tire Pressure WARNING Low tire pressure decreases machine side hill stability. This could cause a rollover, which could result in death or serious injury. Do not under-inflate the tires. Note: Maintain the recommended pressure in all tires to ensure a good quality of cut and proper machine performance.

  • Page 111: Adjusting The Rear Wheel Toe-In

    Checking the Rear-Wheel Alignment (continued) G416236 Center-to-center distance Front of the traction unit 6 mm (1/4 inch) or less than the rear of the tire 4. If the measurement is greater than 6 mm (1/4 inch), adjust the rear wheel toe-in. Adjusting the Rear Wheel Toe-in 1.

  • Page 112: Cooling System Maintenance

    Cooling System Maintenance Coolant Specifications The coolant reservoir is filled at the factory with a 50/50 solution of water and ethylene glycol base extended-life coolant. IMPORTANT Use only commercially available coolants that meet the specifications listed in the Extended Life Coolant Standards Table. Do not use conventional (green) inorganic-acid technology (IAT) coolant in your machine.

  • Page 113: Checking The Coolant Level

    Coolant Specifications (continued) Cooling system capacity Approximately 6.6 L (7.0 US qt) Checking the Coolant Level CAUTION If the engine has been running, the pressurized, hot coolant can escape, which could result in minor or moderate injury. • Do not open the radiator cap when the engine is running. •...
  • Page 114 Cleaning the Engine Cooling System (continued) 3. Thoroughly clean all debris out of the engine area. 4. Close and latch the hood. 5. Release the rear screen latches and pivot the rear screen open. 6. Thoroughly clean the screen with compressed air.

  • Page 115: Belt Maintenance

    The reservoir is filled at the factory with high-quality hydraulic fluid. Check the level of the hydraulic fluid before you first start the engine and daily thereafter. Recommended hydraulic fluid: Toro PX Extended Life Hydraulic Fluid; available in 19 L (5 US gallon) pails or 208 L (55 US gallon) drums.

  • Page 116: Checking The Hydraulic-Fluid Level

    Toro Premium Synthetic Biodegradable Hydraulic Fluid is the only synthetic biodegradable fluid approved by Toro. This fluid is compatible with the elastomers used in Toro hydraulic systems and is suitable for a wide-range of temperature conditions. This fluid is compatible with conventional mineral oils, but for maximum biodegradability and performance, the hydraulic system should be thoroughly flushed of conventional fluid.

  • Page 117: Inspecting The Hydraulic Lines And Hoses

    Checking the Hydraulic-Fluid Level (continued) G417019 Add mark (dipstick) Full mark (dipstick) 5. If the level is low, add the appropriate amount of the specified fluid to raise the level to the full mark. 6. Install the dipstick onto the filler neck. Inspecting the Hydraulic Lines and Hoses Inspect the hydraulic lines and hoses for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration, and chemical deterioration.

  • Page 118: Checking For Leaks

    Repair all hydraulic leaks. Changing the Hydraulic Fluid If the fluid becomes contaminated, contact your Toro Distributor because the system must be flushed. Contaminated fluid looks milky or black when compared to clean fluid. 1. Prepare the machine for maintenance.

  • Page 119: Cutting Unit Maintenance

    Changing the Hydraulic Fluid (continued) G439327 90° fitting Manifold Loosen fitting here 3. Disconnect the 90° fitting from the manifold and allow the tank to drain. 4. When hydraulic fluid stops draining from the tank, connect the 90° fitting to the manifold. 5.

  • Page 120: Checking The Blade-Stop Time

    • Never attempt to turn the cutting units by hand or foot while the engine is running. Note: Additional instructions and procedures on backlapping are available in the Toro Reel Mower Basics (with sharpening guidelines), Form 09168SL. Preparing the Machine 1.
  • Page 121 Backlapping the Cutting Units (continued) 2. With the Mow/Transport lever in the M position, engage the PTO. Move the Lower Mow/Lift control forward to start the backlapping operation on the designated reels. 3. Apply lapping compound with a long-handled brush. DANGER Contacting the cutting units when they are moving will result in death or serious injury.

  • Page 122: Chassis Maintenance

    Backlapping the Cutting Units (continued) Note: Burrs or rough edges may result from lapping the cutting edge. For a better cutting edge, file across the cutting edge 90º to the front face of the bedknife to remove the burrs. 6. Adjust the cutting unit reel to bedknife as needed. 7.

  • Page 123: Chapter 7: Storage

    A. Remove the battery terminals from the battery posts. B. Clean the battery, terminals, and posts with a wire brush and baking-soda solution. C. Coat the cable terminals and battery posts with Grafo 112X skin-over grease (Toro Part No. 505-47) or petroleum jelly to prevent corrosion.
  • Page 124 the charge in the battery. To prevent the battery from freezing, ensure that it is fully charged. The specific gravity of a fully charged battery is 1.265 to 1.299. Storage: Storing the Battery Page 7–2 3464-478 A...

  • Page 125: The Toro Warranty

    Conditions and Products Covered Toro. Toro will make the final decision whether to repair any existing part or assembly or replace it. Toro may use remanufactured parts for warranty repairs.

  • Page 126: California Proposition 65 Warning Information

    Toro has chosen to provide consumers with as much information as possible so that they can make informed decisions about the products they buy and use. Toro provides warnings in certain cases based on its knowledge of the presence of one or more listed chemicals without evaluating the level of exposure, as not all the listed chemicals provide exposure limit requirements.
  • Page 127 Notes:...

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