Form No. 3376-315 Rev D Reelmaster® 7000-D 4-Wheel Drive Traction Unit Model No. 03708—Serial No. 313000001 and Up To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com.
You may contact Toro directly at www.Toro.com for product and accessory information, help finding a dealer, or to register your product. This product complies with all relevant European directives, for details please see the separate product specific Declaration of Conformity (DOC) sheet. Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready.
Contents Premaintenance Procedures.................................... 39 Removing the Hood ........................................... 39 Lubrication............................................................. 39 Greasing the Bearings and Bushings.................... 39 Engine Maintenance............................................... 41 Servicing the Air Cleaner .................................... 41 Servicing the Engine Oil and Filter...................... 42 Adjusting the Throttle ...................
Safety ◊ incorrect hitching and load distribution. • The owner/user can prevent and is responsible for accidents or injuries occurring to himself or herself, other people, or property. This machine meets or exceeds CEN standard EN 836:1997 (when appropriate decals applied), and ANSI B71.4-2004 specifications in effect at the time of production. Preparation • While mowing, always wear substantial footwear, long trousers, hard hat, safety glasses, and ear protection.
• • • • • • • • • • • – machine speeds should be kept low on slopes and during tight turns; – stay alert for humps and hollows and other hidden hazards; – Do not turn sharply. Use care when reversing. – Use counterweight(s) or wheel weights when suggested in the operator's manual. Stay alert for holes in the terrain and other hidden hazards. Watch out for traffic when crossing or near roadways. Stop the blades rotating before crossing surfaces other than grass.
positive last. Reconnect positive first and negative last. • Use care when checking the cylinders/reels. Wear gloves and use caution when servicing them. • Keep hands and feet away from moving parts. If possible, do not make adjustments with the engine running. • Charge batteries in an open well ventilated area, away from spark and flames. Unplug charger before connecting or disconnecting from battery. Wear protective clothing and use insulated tools.
and any parts of the body away from the cutting units, attachments, and any moving parts. • To ensure safety and accuracy, have an Authorized Toro Distributor check the maximum engine speed with a tachometer. • If major repairs are ever needed or if assistance is desired, contact an Authorized Toro Distributor. • Use only Toro-approved attachments and replacement parts. The warranty may be voided if used with unapproved attachments.
117-4765 1. Read the Operator's Manual. 2. Do not use starting aids. 117–2385 1. Read the Operators Manual. 2. Engine—start 3. Engine—preheat 4. Engine—stop 117-4766 1. Cutting/dismemberment hazard; fan—stay away from moving parts. 117–2718 117-2386 1. Raise deck 2. Blow off fan 3. Reverse 4. Automatic 106-6755 119-3905 1. Engine coolant under pressure. 3. Warning—do not touch the hot surface. 2. Explosion hazard—read the Operator's Manual. 4. Warning—read the Operator's Manual. 1.
3-6688 1. Warning—read the instructions before servicing or performing maintenance. 110-9642 2. Cutting hazard of hand or foot—stop the engine and wait for moving parts to stop. 1. Stored energy hazard—read the Operator's Manual. 2. Move the cotter pin to the hole closest to the rod bracket and then remove the lift arm and pivot yoke. 20A 10A 10A 10A 106-6754 10A 1. Warning—do not touch the hot surface. 2.
120-1686 Affix over part no. 120–1683 for CE* *This safety decal includes a slope warning required on the machine fro compliance to the European Lawn Mower Standard EN 836.1997. The conservative maximum slope angles indicated for operation of this machine are prescribed by and required by this standard. 1. Warning—read the Operator's Manual, do not operate this machine unless you are trained. 4.
Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. Keep bystanders a safe distance from the battery. 2. No fire, open flame, or smoking. 7. Wear eye protection; explosive gases can cause blindness and other injuries 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 5. Read the Operator's Manual. 120-1671 120-1670 1.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description 1 2 3 4 5 6 7 8 9 Use Qty. No parts required – Adjust the support rollers Warning decal 1 Used only on machines requiring CE Compliance. Hood lock bracket Rivet Screw, 1/4 x 2 inch Flat washer, 1/4 inch Locknut, 1/4 inch Front hose guide-R.H. Front hose guide-L.H. 1 2 1 2 1 1 1 No parts required – Adjust the turf compensation spring.
1 2 Adjusting the Support Rollers Replacing the Warning Decal for CE Compliance No Parts Required Parts needed for this procedure: Procedure 1 Depending on what width cutting units are to be installed on the traction, adjust the support rollers as follows: Warning decal Procedure • If using 27 inch cutting units, the rollers are to be installed in the upper mounting holes of support assembly channels (Figure 3). On machines requiring CE Compliance, affix the warning decal, part no.
1 2 G012629 Figure 6 2. Bolt and nut assembly 1. CE lock bracket 4. Align the washers with the holes on the inside of the hood. 5. Rivet the brackets and the washers to the hood (Figure 6). 6. Hook the latch onto the hood latch bracket (Figure 7). Figure 4 1. Hood latch 2. Remove the (2) rivets securing the hood latch bracket to the hood (Figure 5). Remove the hood latch bracket from the hood. 1 2 1 G012630 Figure 7 G012628 1. Hood latch Figure 5 1. Hood latch bracket 7.
4 Installing the Cutting Units Parts needed for this procedure: 1 1 Figure 10 1. Turf compensation spring Front hose guide-R.H. 3. Spring tube 2. Rod bracket Front hose guide-L.H. B. Remove the flange nut securing the spring tube bolt to the carrier frame tab (Figure 10) Remove the assembly. Procedure 1. Remove the reel motors from the shipping brackets. C. Mount the spring tube bolt to the opposite tab on the carrier frame and secure with the flange nut.
Figure 13 1. Hose guide (Left hand shown) 3. Nuts 2. Rod bracket 1 1 g019602 Figure 14 1. Hose guides (each must lean toward the center cutting unit) Note: When installing or removing the cutting units, make sure the hairpin cotter is installed in the spring rod hole next to the rod bracket. Otherwise, the hairpin cotter must be installed in the hole in the end of the rod. 6.
9. For the front cutting units, slide a cutting unit under the lift arm while inserting the carrier frame shaft up into the lift arm pivot yoke (Figure 16). Make sure the thrust washer is in position on the carrier frame shaft. 1 2 10. Secure the carrier frame shaft to the lift arm yoke with the Klik pin (Figure 16). 3 11. To lock (fix) the steering on the cutting units, secure the pivot yoke to the carrier frame with the snapper pin (Figure 17). G015978 4 Figure 15 1. Hex socket screw 2.
13. Secure the lift arm chain to the chain bracket with the snapper pin (Figure 19). Use the number of chain links described in the cutting unit Operator's Manual. 5 Adjusting the Turf Compensation Spring No Parts Required Procedure The turf compensation spring (Figure 21) transfers weight from the front to the rear roller. (This helps to reduce a wave pattern in the turf, also known as marcelling or bobbing.) Figure 19 1. Lift arm chain 3. Snapper pin 2.
6 Using the Cutting Unit Kickstand Parts needed for this procedure: 1 Cutting unit kickstand Procedure Whenever the cutting unit has to be tipped to expose the bedknife/reel, prop up the rear of the cutting unit with the kickstand to make sure the nuts on the back end of the bedbar adjusting screws are not resting on the work surface (Figure 22). Figure 23 1. Chain bracket 3. Cutting unit kickstand 2.
Product Overview 2. Check the hydraulic fluid level before the engine is first started, refer to Checking the Hydraulic Fluid Level in Operation. Controls 3. Check the engine oil level before and after the engine is first started, refer to Checking the Engine Oil Level in Operation. Brake Pedals Two foot pedals (Figure 25) operate individual wheel brakes for turning assistance and to aid in obtaining better side hill traction.
Charge Indicator toward you to the most comfortable position and then release the pedal. The charge indicator (Figure 27) illuminates when the system charging circuit malfunctions. Mow Speed Limiter Key Switch When the mow speed limiter (Figure 26) is flipped up it will control the mow speed and allow the cutting units to be engaged. Each spacer adjusts the mowing speed by ½ mile per hour. The more spacers you have, on the top of the bolt the slower you will go.
the machine, with the cutting units in the down position, press the lift switch down to allow the cutting units to float and mow. has two positions R (manual reverse) and Auto (normal). Refer to Engine Cooling Fan Operation in the Operation Section of manual. Throttle Control Bag Holder Move the control (Figure 27) forward to increase the engine speed and rearward to decrease the speed. Use the bag holder (Figure 28) for storage.
Weight gauge Indicates when the seat is adjusted to the weight of the operator (Figure 32). Height adjustment is made by positioning the suspension within the range of the green region. Figure 30 1. Reel speed controls Fuel Gauge Figure 32 The fuel gauge (Figure 31) indicates the level of fuel in the tank. 1. Weight gauge 4. Seat back adjusting lever 2. Weight adjusting lever 5. Arm rest adjusting knob 3. Fore and Aft adjusting lever Weight Adjusting Lever Adjust for operator weight (Figure 32).
Specifications Note: Specifications and design are subject to change without notice. Traction Unit Specifications Width of cut 121 inches (307 cm) Overall width, cutting units down 136 inches (345 cm) Overall width, cutting units up (transport) 94 inches (239 cm) Overall length 145.8 inches (370 cm) Height with ROPS 87 inches (220 cm) Track Width, front 90 inches (229 cm) Track Width, rear 55.
Operation 1. Park the machine on a level surface. 2. Unlock the hood latches and open the hood (Figure 33). Note: Determine the left and right sides of the machine from the normal operating position. CAUTION This machine produces sound levels in excess of 85 dBA at the operator's ear and can cause hearing loss through extended periods of exposure. Wear hearing protection when operating this machine.
Figure 35 1. Oil fill cap Note: When using different oil, drain all old oil from the crankcase before adding new oil. Figure 36 5. Install the oil fill cap and dipstick. 1. Expansion tank 6. Close the hood and secure it with the latches. 2. Check the coolant level in the radiator. The radiator should be filled to the top of the filler neck and the expansion tank filled to the FULL mark (Figure 36).
WARNING DANGER Fuel is harmful or fatal if swallowed. Long-term exposure to vapors can cause serious injury and illness. In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. • Avoid prolonged breathing of vapors. • Use a funnel and fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any fuel that spills. • Keep face away from nozzle and gas tank or conditioner opening.
140 to 160 Viscosity Index ASTM D2270 Pour Point, ASTM D97 -34°F to -49°F Industry Specifications: Vickers I-286-S (Quality Level), Vickers M-2950-S (Quality Level), Denison HF-0 DANGER In certain conditions during fueling, static electricity can be released causing a spark which can ignite the fuel vapors. A fire or explosion from fuel can burn you and others and can damage property. • Always place fuel containers on the ground away from your vehicle before filling.
3. Remove the dipstick from the filler neck and wipe it with a clean rag. Insert the dipstick into the filler neck; then remove it and check the fluid level. The fluid level should be between the two marks on the dipstick. 4. If the level is low, add the appropriate fluid to raise the level to the upper mark. 5. Install the dipstick and cap onto the filler neck. When the temperature is less than 20°F (-7°C), the starter motor can be run for 30 seconds on then 60 seconds off for 2 attempts.
pedal is released, it is strongly recommended that the engine be stopped before rising from the seat. neutral position. The engine should kill. If the engine does not kill, there is a malfunction in the interlock system that should be corrected before beginning operation. To check the operation of the interlock switches, perform the following procedure: 1. Drive the machine slowly to a large, relatively open area. Lower the cutting unit, stop the engine, and apply the parking brake.
Figure 41 1. Spring 2. Spring actuator 4. Move the spring actuator to the desired hole location and secure with locknut. 5. Repeat the procedure on the remaining spring. Figure 40 1. Reel speed control knob Adjusting the Lift Arm Turn Around Position Adjusting the Lift Arm Counterbalance 1. Position the machine on a level surface, lower the cutting units, stop the engine, engage the parking brakes, and remove the key from ignition switch. 2.
Jacking Points turn around height or move the switch down to decrease the lift arm turn around height. Tighten the mounting screws. • On the front of the machine on the frame on the inside of each drive tire • On the rear of the machine at the center of the axle Pushing or Towing the Machine Tie Downs In an emergency, the machine can be moved forward by actuating the bypass valve in the variable displacement hydraulic pump and pushing or towing the machine.
Verifying the Interlock Switch Function If the diagnostic light is not illuminated when the key switch is in the On position, this indicates that the electronic controller is not operating. Possible causes are as follows: 1. Park the machine on a level surface, lower the cutting units, stop the engine, and engage the parking brake. 2. Remove the access panel located beneath the front of the seat (Figure 45). 3. Locate the wire harness and connectors near the controller (Figure 45).
7. The “inputs displayed” LED, on the lower right column of the Diagnostic ACE, should be illuminated. If the “outputs displayed” LED is illuminated, press the toggle button, on Diagnostic ACE, to change LED to “inputs displayed”. forth, press the toggle button once. This may be done as often as required. Do not hold the button. 8. Sit on the seat and attempt to operate the desired function of the machine. The appropriate output LEDs should illuminate to indicate that the ECM is turning on that function.
Warning System brakes can be used to assist in turning the machine. However, use them carefully, especially on soft or wet grass because the turf may be torn accidentally. Another benefit of the brakes is to maintain traction. For example, in some slope conditions, the uphill wheel slips and loses traction. If this situation occurs, depress the uphill turn pedal gradually and intermittently until the uphill wheel stops slipping, thus, increasing traction on the downhill wheel.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 8 hours • Torque the wheel nuts. After the first 50 hours • Change the engine oil and filter. After the first 200 hours • Change the planetary gear drive oil. • Change the rear axle lubricant. • Change the hydraulic filters.
Daily Maintenance Checklist Duplicate this page for routine use. Maintenance Check Item For the week of: Mon. Tues. Wed. Thurs. Fri. Sat.
Service Interval Chart Figure 47 CAUTION If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition before you do any maintenance.
Premaintenance Procedures Lubrication Greasing the Bearings and Bushings Removing the Hood Service Interval: Every 50 hours 1. Release hood latches (Figure 48) and pivot open the hood. The machine has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. If the machine is operated under normal conditions, lubricate all bearings and bushings after every 50 hours of operation or immediately after every washing.
• Steering cylinder ball joints (2) (Figure 51) • Cutting unit carrier frame (2 per cutting unit) (Figure 53) • Cutting unit lift arm pivot (1 per cutting unit) (Figure 53) Figure 53 Figure 51 1. Top fitting on king pin • Tie rod ball joints (2) (Figure 51) • King pin bushings (2) (Figure 51). The top fitting on the king pin should only be lubricated annually (2 pumps).
Engine Maintenance which could force dirt through the filter into the intake tract. Servicing the Air Cleaner This cleaning process prevents debris from migrating into the intake when the primary filter is removed. Service Interval: Every 400 hours 3. Remove and replace the primary filter (Figure 56). Check the air cleaner body for damage which could cause an air leak. Replace if damaged. Check the whole intake system for leaks, damage or loose hose clamps.
Adjusting the Throttle Servicing the Engine Oil and Filter Adjust the throttle cable (Figure 60) so that the governor lever on the engine contacts the high speed set bolt at the same point that the throttle cable contacts the end of the slot in the control arm. Service Interval: After the first 50 hours Every 400 hours Change the oil and filter initially after the first 50 hours of operation; thereafter change the oil and filter every 400 hours. 1.
Servicing the Water Separator Fuel System Maintenance Service Interval: Before each use or daily—Drain water or other contaminants from fuel filter/water separator. DANGER Every 400 hours—Replace the fuel filter canister. Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage. Drain water or other contaminants from water separator daily.
Bleeding Air from the Injectors Electrical System Maintenance Note: This procedure should be used only if the fuel system has been purged of air through normal priming procedures and the engine will not start. Charging and Connecting the Battery 1. Loosen the pipe connection to the No. 1 injector nozzle and holder assembly at the injection pump (Figure 62).
2. Connect a 3 to 4 amp. battery charger to the battery posts. Charge the battery at a rate of 3 to 4 amperes for 4 to 8 hours. jelly, or light grease to prevent corrosion. Slide the rubber boot over the positive terminal. 6. Close the console panel and secure the latch. 3. When the battery is charged, disconnect the charger from the electrical outlet and battery posts. WARNING Battery terminals or metal tools could short against metal components causing sparks.
Fuses The fuses are located under the operators control panel. 20A 10A 10A 10A 10A 7.5A 7.5A 7.5A TEC-5002 2A 60A 120-1672 Figure 65 Figure 67 1. Fuses Unhook the latch and raise the operator's console panel (Figure 66) to expose the fuses (Figure 67). Figure 66 1. Operator's console panel 2.
Drive System Maintenance 4. Re-install both plugs. 5. Repeat steps 1 through 4 on the opposite gear assembly. Checking the Torque of the Wheel Nuts Changing the Planetary Gear Drive Oil Service Interval: After the first 8 hours Every 200 hours Service Interval: After the first 200 hours Every 800 hours (Or yearly, whichever comes first) WARNING Change the oil initially after first 200 hours of operation. Thereafter change the oil every 800 hours. Use a high quality SAE 85W-140 wt. gear lube. 1.
Changing the Rear Axle Lubricant 4. When all of the oil has drained from both locations, re-install the plug in the brake housing. 5. Rotate the wheel until the open plug hole in the planetary is at the twelve o'clock position. Service Interval: After the first 200 hours Every 800 hours 6. Through the open hole, slowly fill the planetary with 22 ounces. (0.6 liter) of high quality SAE 85W-140 wt. gear lube. 1. Position the machine on a level surface. 2.
Figure 73 1. Pump rod jam nuts Figure 75 2. Pump control tube 1. Tie rod clamp 2. Tie rod ball joint 5. After wheel rotation ceases, tighten jam nuts to secure adjustment. 3. Loosen the clamps at both ends of the tie rods (Figure 75). 6. Stop the engine and release the right brake. Remove jack stands and lower the machine to the shop floor. Test drive the machine to make sure it does not creep. 4. Rotate the detached ball joint inward or outward one (1) complete revolution.
Cooling System Maintenance Servicing the Engine Cooling System Service Interval: Before each use or daily Remove debris from the engine area, oil cooler and radiator daily. Clean them more frequently in dirty conditions. 1. Unlatch and swing open rear screen (Figure 76). Clean the screen thoroughly of all debris. Figure 77 Note: To remove the screen, lift off the hinge pins. 1. Oil cooler latches 3. Pivot the oil cooler rearward.
Brake Maintenance Belt Maintenance Adjusting the Service Brakes Servicing the Alternator Belt Adjust the service brakes when there is more than 1 in. (25 mm) of “free travel" of the brake pedal, or when the brakes do not work effectively. Free travel is the distance the brake pedal moves before braking resistance is felt. Service Interval: Every 100 hours 1. Disengage the locking latch from the brake pedals so that both pedals work independently of each other. 1. Proper tension will allow 3/8 in.
Hydraulic System Maintenance 3. Lubricate the new filter gasket and fill the filter with hydraulic fluid. Changing the Hydraulic Fluid Service Interval: Every 800 hours Change the hydraulic fluid after every 800 operating hours, in normal conditions. If the fluid becomes contaminated, contact your local Toro distributor because the system must be flushed. Contaminated fluid looks milky or black when compared to clean oil. 1. Turn the engine off and raise the hood. 2.
Checking the Hydraulic Lines and Hoses Cutting Unit Maintenance Backlapping the Cutting Units Service Interval: Before each use or daily Inspect the hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration, and chemical deterioration. Make all necessary repairs before operating. WARNING Contact with the reels or other moving parts can result in personal injury.
Cleaning Servicing the Spark Arrestor Muffler Service Interval: Every 200 hours Every 200 hours operation, clear the muffler of carbon buildup. 1. Remove the pipe plug from the clean-out port at the lower side of the muffler. CAUTION The muffler may be hot and could cause injury. Be careful while working around the muffler. Figure 83 1. Front backlap lever 2. Start the engine.
Storage Engine 1. Drain the engine oil from the oil pan and install the drain plug. 2. Remove and discard the oil filter. Install a new oil filter. 3. Refill the oil pan with 10 qt. (9.5 l) of SAE 15W-40 CH-4, CI-4, higher motor oil. 4. Start the engine and run it at idle speed for approximately two minutes. 5. Stop the engine. 6. Flush the fuel tank with fresh, clean diesel fuel. 7. Secure all of the fuel system fittings. 8. Thoroughly clean and service the air cleaner assembly. 9.
Schematics Hydraulic Schematic (Rev.
Electrical Schematic-Sheet 1 (Rev.
Electrical Schematic-Sheet 2 (Rev.
Notes: 59
The Toro Total Coverage Guarantee A Limited Warranty Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial product (“Product”) to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first. This warranty is applicable to all products with the exception of Aerators (refer to separate warranty statements for these products).
