Form No. 3412-474 Rev A Reelmaster® 7000-D 4-Wheel Drive Traction Unit Model No. 03781—Serial No. 400000000 and Up Register at www.Toro.com.
This product complies with all relevant European directives. For details, please see the separate product specific Declaration of Conformity (DOC) sheet. WARNING CALIFORNIA Proposition 65 Warning This product contains a chemical or chemicals known to the State of California to cause cancer, birth defects, or reproductive harm. Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. g009699 Figure 1 1.
Contents Fuel System Maintenance ...........................................46 Draining the Fuel Tank ...........................................46 Checking the Fuel Lines and Connections ..................46 Servicing the Water Separator ..................................46 Cleaning the Fuel-Intake Screen ...............................46 Electrical System Maintenance ....................................47 Electrical System Safety...........................................
Safety • Keep clear of any discharge opening. Keep bystanders This machine has been designed to meet or exceed EN ISO 5395:2013 (when appropriate decals are applied), and ANSI B71.4-2012. • Keep children out of the operating area. Never allow and pets a safe distance away from the machine. children to operate the machine. • Stop the machine and shut off the engine before servicing, fueling, or unclogging the machine. General Safety Improperly using or maintaining this machine can result in injury.
decal93-6688 93-6688 decal117-4765 1. Warning—read the instructions before servicing or performing maintenance. 117-4765 1. Read the Operator's Manual. 2. Cutting hazard of hand or foot—stop the engine and wait for moving parts to stop. 2. Do not use starting aids. decal110-9642 decal117-4766 110-9642 117-4766 1. Stored energy hazard—read the Operator's Manual. 1. Cutting/dismemberment hazard; fan—stay away from moving parts. 2.
decal106-6754 106-6754 decal121-3887 1. Warning—do not touch the hot surface. 121–3887 2. Cutting/dismemberment hazard, fan and entanglement hazard, belt—stay away from moving parts. 1. Read the Operator’s Manual. decal121-3884 121–3884 1. Engine—stop 3. Engine—start 2. Engine—preheat decal125-4605 125–4605 decal112-5019 112-5019 1. Power seat, 10A 6. Power supplied, 10A 2. 7. Controller, 2A Work light, 10A 3. Engine, 10A 8. Power supplied, 7.5A 4. Cigarette lighter, 10A 9.
decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. decal120-1670 120-1670 1. Traction unit speed 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. 3.
decal120-1683 120-1683 1. Warning—read the Operator's Manual; do not operate the machine unless you have received training. 4. Warning—do not park the machine on slopes; engage the parking brake, lower the cutting units, shut off the engine, and remove the ignition key before leaving the machine. 2. Warning—read the Operator's Manual before towing the machine. 5. Thrown object hazard—keep bystanders a safe distance away from the machine. 3. Tipping hazard—slow machine before turning, do not turn at 6.
decal120-1686 120-1686 (Affix over Part No. 120-1683 for CE) * This safety decal includes a slope warning required on the machine for compliance to the European Lawn Mower Safety Standard EN ISO 5395:2013. The conservative maximum slope angles indicated for operation of this machine are prescribed by and required by this standard. 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.
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 Replace the decal for CE Compliance. Hood-lock bracket Rivet Screw (1/4 x 2 inch) Flat washer (1/4 inch) Locknut (1/4 inch) Front hose guide (right) Front hose guide (left) 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 unit, adjust the support rollers as follows: Warning decal Procedure Park the machine on a level surface, engage the parking brake, shut off the engine, and remove the key. On machines requiring CE Compliance, affix the CE warning decal (Part No.
1 2 G012629 g012629 Figure 6 2. Bolt and nut assembly 1. CE lock bracket g200373 Figure 4 5. Align the washers with the holes on the inside of the hood. 1. Hood latch 6. Rivet the brackets and the washers to the hood (Figure 6). 2. Remove the 2 rivets securing the hood-latch bracket to the hood (Figure 5). 2 7. Hook the latch onto the hood-latch bracket (Figure 7). 1 1 G012630 g012630 Figure 7 G012628 1. Hood latch g012628 Figure 5 1. Hood-latch bracket 3. 8.
9. Tighten the bolt securely but do not tighten the nut. 4 Installing the Cutting Units g003949 Figure 10 1. Turf compensation spring Parts needed for this procedure: 1 Front hose guide (right) 1 Front hose guide (left) 3. Spring tube 2. Rod bracket Procedure 1. Remove the reel motors from the shipping brackets. 2. Remove and discard the shipping brackets. B. Remove the flange nut securing the spring-tube bolt to the carrier-frame tab (Figure 10) C. Remove the assembly. D.
g031275 Figure 12 1. Cutting unit 1 5. Cutting unit 5 2. Cutting unit 2 6. Reel motor 3. Cutting unit 3 7. Weight 4. Cutting unit 4 g015160 Figure 13 1. Hose guide (left side shown) 3. Nuts 2. Rod bracket 1 1 g019602 g019602 Figure 14 1. Hose guides (each must lean toward the center cutting unit) Note: When installing or removing the cutting units, make sure that the hairpin cotter is installed in the spring-rod hole next to the rod bracket.
10. For the front cutting units, slide a cutting unit under the lift arm while inserting the shaft of the carrier frame up into the lift-arm pivot yoke (Figure 16). Make sure that the thrust washer is in position on the carrier frame shaft. 11. Secure the carrier-frame shaft to the lift-arm yoke with the klik pin (Figure 16). 12. To lock (fix) the steering on the cutting units, secure the pivot yoke to the carrier frame with the snapper pin (Figure 17). g033150 Figure 15 1. Hex-socket screw 2.
Note: 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 the weight from the front to the rear roller. This helps to reduce a wave pattern in the turf, also known as marcelling or bobbing. g003948 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 that the nuts on the back end of the bedbar adjusting screws are not resting on the work surface (Figure 22). g004144 Figure 23 1. Chain bracket 3. Cutting-unit kickstand 2.
8 Checking the Fluid Levels No Parts Required Procedure 1. Check the level of the rear axle lubricant before the engine is first started, refer to Checking the Oil Level of the Rear Axle (page 51). 2. Check the level of the hydraulic fluid before the engine is first started, refer to Checking the Level of the Hydraulic Fluid (page 29). g004552 Figure 24 3. Check the level of the engine oil before and after the engine is first started, refer to Checking the Level of the Engine Oil (page 26). 1.
Mow-Speed Limiter Product Overview 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 0.8 km/h (½ mile per hour). The more spacers that there are on the top of the bolt, the slower the machine goes. For transport, flip back the mow-speed limiter and the machine will have maximum transport speed.
Bag Holder blades. Push the button back to disengage the cutting-unit blades. Use the bag holder (Figure 29) for storage. g025902 Figure 27 1. Lower mow/raise control lever 2. Key switch 4. PTO switch 5. Engine-speed switch 3. InfoCenter 6. Headlight switch g033325 Figure 29 1. Bag holder Engine-Speed Switch The engine-speed switch (Figure 27) has 2 modes to change the engine speed. By momentarily tapping the switch, the engine speed can be increased or decreased in 100 rpm increments.
Using the InfoCenter LCD Display Adjusting the Seat The InfoCenter LCD display shows information about your machine such as the operating status, various diagnostics, and other information about the machine (Figure 32) There is a splash screen and main information screen of the InfoCenter. You can switch between the splash screen and main information screen at any time by pressing any of the InfoCenter buttons and then selecting the appropriate directional arrow. 1 TORO g033323 Figure 31 1.
InfoCenter Icon Description SERVICE DUE InfoCenter Icon Description (cont'd.
Using the Menus Engine Run To access the InfoCenter menu system, press the menu access button while at the main screen. This will bring you to the main menu. Refer to the following tables for a synopsis of the options available from the menus: Indicates the inputs, qualifiers, and outputs for starting the engine. Backlap Indicates the inputs, qualifiers, and outputs for operating the backlap function.
Machine Controller Revision Lists the software revision of the master controller. InfoCenter Revision Lists the software revision of the InfoCenter. CAN Bus Lists the machine communication bus status. Setting the Blade Count 1. In the Settings Menu, scroll down to Blade Count 2. Press the right button to change the Blade Count between 5, 8, or 11 blades. Setting the Mow Speed Protected Menus 1. In the Settings Menu, scroll down to Mow Speed.
Setting the Front and Rear Reel Speeds Specifications Although the front and rear reel speeds are calculated by inputting the number of blades, mow speed and HOC into the InfoCenter, you can manually change the setting to accommodate different mowing conditions. Note: Specifications and design are subject to change without notice. Traction Unit Specifications 1. Scroll down to the F Reel RPM, R Reel RPM, or both. 2. Press the right button to change the reel speed value.
Operation DANGER Operating on wet grass or steep slopes can cause sliding and loss of control. Note: Determine the left and right sides of the machine from the normal operating position. Before Operation Safety Wheels dropping over edges can cause rollovers, which may result in serious injury, death, or drowning. General Safety Read and follow the rollover protection instructions and warnings.
Note: Toro Premium Engine oil is available from your distributor in either 15W-40 or 10W-30 viscosity. See the parts catalog for part numbers. Note: The best time to check the engine oil is when the engine is cool before it has been started for the day. If it has already been run, allow the oil to drain back down to the sump for at least 10 minutes before checking. If the oil level is at or below the Add mark on the dipstick, add oil to bring the oil level to the Full mark. Do not overfill the engine.
Use summer-grade diesel fuel (No. 2-D) at temperatures above -7° C (20° F) and winter-grade (No. 1-D or No. 1-D/2-D blend) below that temperature. Use of winter-grade fuel at lower temperatures provides lower flash point and cold flow characteristics which will ease starting and reduce plugging of the fuel filter. CAUTION If the engine has been running, the pressurized, hot coolant can escape and cause burns. • Do not open the radiator cap when the engine is running.
DANGER 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. • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any fuel that spills. • Never fill the fuel tank inside an enclosed trailer. • Never smoke when handling fuel, and stay away from an open flame or where fuel fumes may be ignited by a spark. • Store fuel in an approved container and keep it out of the reach of children.
Viscosity, ASTM D445 Viscosity index, ASTM D2270 Pour point, ASTM D97 cSt @ 40°C (104°F) 44 to 48 cSt @ 100°C (212°F) 7.9 to 9.
During Operation Safety • Do not operate the machine when there is the risk of General Safety • • • The owner/operator can prevent and is responsible for • • • • • • • • • • • • • • • • • accidents that may cause personal injury or property damage. Wear appropriate clothing, including eye protection; slip-resistant, substantial foot protection; and hearing protection. Tie back long hair and do not wear jewelry. Do not operate the machine while ill, tired, or under the influence of alcohol or drugs.
• A rollover can occur before the tires lose traction. CAUTION • Avoid operating the machine on wet grass. Tires may Contact with moving parts could result in injury. lose traction; regardless if the brakes are available and functioning. Shut off the engine and wait for all moving parts to stop before checking for oil leaks, loose parts, and other malfunctions. • Avoid starting, stopping, or turning the machine on a slope. • Keep all movement on slopes slow and gradual.
height or move the switch down to decrease the lift-arm turnaround height. 4. Tighten the mounting screws. Folding the ROPS You can fold the ROPS frame down to allow access into areas of restricted height. WARNING The machine does not have a rollover protection system (ROPS) when the roll bar is folded down and should not be considered a ROPS. g015078 Figure 40 1. Spring Do not wear a seatbelt when the roll bar is lowered. 2. Spring actuator 1.
recommended that the engine be stopped before rising from the seat. WARNING The ROPS protection system may not be effective if the ROPS retaining bolt assemblies are loose, which may cause serious injury or even death in the event of a rollover. To check the operation of the interlock switches, perform the following procedure: 1. Drive the machine slowly to a large, relatively open area. 2. Lower the cutting units, shut off the engine, and engage the parking brake.
installing a hydraulic hose to bypass the check valve, and then pushing or towing the machine. 2. Connect a hydraulic hose between the diagnostic fitting installed in the rear traction manifold and the reverse traction pressure test port (Figure 44). Important: Do not push or tow the machine faster than 3 to 4.8 km/h (2 to 3 mph) or for more than 0.4 km (1/4 mile), because internal transmission damage may occur. The bypass valve must be open whenever you push or tow the machine.
Hauling the Machine 6. Install the diagnostic-fitting cap onto the fitting that you installed on the manifold. • Use full-width ramps for loading the machine onto a 7. Rotate the bypass valve 90° (1/4 turn) back before starting the engine. trailer or truck. • Tie the machine down securely. Note: Do not exceed 7 to 11 N∙m (5 to 8 ft-lb) torque to close the valve.
Important: Allow engine to idle for 5 minutes before shutting it off after a full load operation. This allows the turbocharger to cool down before shutting off the engine. Failure to do so may lead to turbocharger trouble. Before shutting off the engine, disengage all controls and move the throttle to SLOW . Moving the throttle to SLOW reduces high engine speed, noise, and vibration. Turn the key to OFF to shut off the engine.
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 200 hours Before each use or daily • Change the planetary gear drive oil. • Change the oil in the rear axle. • Change the hydraulic filters. • • • • • • • • Check the level of the engine oil. Check the cooling system.
Daily Maintenance Checklist Duplicate this page for routine use. Maintenance Check Item For the week of: Mon. Tues. Wed. Thurs. Fri. Check the safety interlock operation. Check the brake operation. Check the levels of the engine oil and fuel. Check the cooling-system fluid level. Drain the water/fuel separator. Check the air-filter service indicator. Check the radiator, oil cooler, and screen for debris. Check unusual engine noises.1 Check unusual operating noises.
Notation for Areas of Concern Inspection performed by: Item Date Information 1 2 3 4 5 6 7 8 Important: Refer to your engine operator's manual and cutting unit Operator's Manual for additional maintenance procedures. Note: To obtain an electrical schematic or a hydraulic schematic for your machine, visit www.Toro.com.
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. Pre-Maintenance Procedures Pre-Maintenance Safety • Before adjusting, cleaning, repairing, or leaving the machine, do the following: – Park the machine on a level surface. – Move the throttle switch to the low-idle position. – Disengage the cutting units. – Lower the cutting units.
Lubrication • Steering cylinder ball joints (2) (Figure 50) Greasing the Bearings and Bushings Service Interval: Every 50 hours The machine has grease fittings that must be lubricated regularly with No. 2 lithium grease. If the machine is operated under normal conditions, lubricate all bearings and bushings after every 50 hours of operation or immediately after every washing. The grease fitting locations and quantities are as follows: • Brake shaft pivot bearings (5) (Figure 48) g009706 Figure 50 1.
Engine Maintenance • Cutting unit carrier frame (2 per cutting unit) (Figure 52) • Cutting unit lift arm pivot (1 per cutting unit) (Figure 52) Engine Safety • Shut off the engine before checking the oil or adding oil to the crankcase. • Do not change the governor speed or overspeed the engine. Servicing the Air Cleaner Service Interval: Every 400 hours Check the air-cleaner body for damage which could cause an air leak. Replace it if it is damaged.
g011505 Figure 56 g011503 1. Safety filter Figure 54 1. Service indicator 2. Latch 3. Cover 6. Clean the dirt-ejection port located in the removable cover. 7. Remove the rubber outlet valve from the cover, clean the cavity, and install the outlet valve. 3. Remove the cover from the air-cleaner body. 4. Before removing the filter, use low-pressure air—275 kPa (40 psi), clean and dry—to help remove large accumulations of debris packed between outside of primary filter and the canister.
Adjusting the Throttle Adjust the throttle cable (Figure 59) 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. g008807 Figure 58 1. Oil filter g026803 5. Apply a light coat of clean oil to the new filter seal before installing it. g026803 Figure 59 Note: Do not overtighten the filter. 1. Throttle cable 6. Add oil to the crankcase; refer to Checking the Level of the Engine Oil (page 26).
Servicing the Water Separator Fuel System Maintenance Service Interval: Before each use or daily—Drain water or other contaminants from the 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. 1.
Electrical System Maintenance Electrical System Safety • Disconnect the battery before repairing the machine. Disconnect the negative terminal first and the positive last. Connect the positive terminal first and the negative last. • Charge the battery in an open, well-ventilated area, away from sparks and flames. Unplug the charger before connecting or disconnecting the battery. Wear protective clothing and use insulated tools.
WARNING Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. • Always connect the positive (red) battery cable before connecting the negative (black) cable. g016643 Figure 62 1. Positive battery cable Servicing the Battery 2.
g016642 decal125-4605 Figure 65 Figure 63 1. Fuses Park the machine on a level surface, lower the cutting units, engage the parking brake, shut off the engine, and remove the key. Unhook the latch and raise the operator's console panel (Figure 64) to expose the fuses (Figure 65). g200376 Figure 64 1. Operator's console panel 2.
Drive System Maintenance 3. Remove the plug at the 3 o’clock position (Figure 66). Note: The oil level should be at the bottom of the hole. 4. If the oil level is low, remove the plug at the 12 o’clock position and add oil until it begins to flow out of the hole at the 3 o’clock position. Checking the Torque of the Wheel Nuts 5. Install both plugs. Service Interval: After the first 8 hours 6. Repeat steps 2 through 5 on the opposite planetary gear assembly.
g009716 Figure 69 g019743 1. Check plug g019743 Figure 68 1. Brake housing 2. Drain plug 5. When all of the oil has drained from both locations, install the plug in the brake housing. 6. Rotate the wheel until the open plug hole in the planetary is at the 12 o'clock position. 7. Through the open hole, slowly fill the planetary with 0.65 L (22 fl oz) of high quality SAE 85W-140 wt. gear lube. Important: If the planetary fills before the 0.
Changing the Oil in the Rear Axle Service Interval: After the first 200 hours Every 800 hours 1. Park the machine on a level surface, lower the cutting units, engage the parking brake, shut off the engine, and remove the key. 2. Clean the area around the 3 drain plugs, 1 on each end and 1 in the center (Figure 70). g011488 Figure 71 1. Gear box 2. Check/fill plug Adjusting the Traction Drive for Neutral g009717 Figure 70 The machine must not creep when the traction pedal is released.
8. Remove the jack stands and lower the machine to the shop floor. 6. Rotate the detached ball joint inward or outward 1 complete revolution. 9. Test drive the machine to ensure that it does not creep. 7. Tighten the clamp at the loose end of the tie rod. 8. Rotate the entire tie-rod assembly the same direction (inward or outward) 1 complete revolution. Checking the Rear-Wheel Toe-In 9. Tighten the clamp at the connected end of the tie rod. 10.
Cooling System Maintenance Repeat the procedure several times until all chaff and debris is removed. Cooling System Safety • Swallowing engine coolant can cause poisoning; keep out of reach from children and pets. • Discharge of hot, pressurized coolant or touching a hot radiator and surrounding parts can cause severe burns. – Always allow the engine to cool at least 15 minutes before removing the radiator cap. – Use a rag when opening the radiator cap, and open the cap slowly to allow steam to escape.
Brake Maintenance Belt Maintenance Adjusting the Service Brakes Servicing the Alternator Belt Adjust the service brakes when there is more than 13 mm (1/2 inch) 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 Check the condition and tension of the belts (Figure 78) after every 100 operating hours. 1.
Replacing the Hydraulic Filters Hydraulic System Maintenance Service Interval: After the first 200 hours Every 800 hours Hydraulic System Safety Change the 2 hydraulic filters initially after the first 200 operating hours. Thereafter, change the filters after every 800 operating hours, in normal conditions. • Ensure that all hydraulic-fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system.
WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • Make sure that all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system. • 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.
Cutting Unit Maintenance 6. With the mow-speed limiter in the MOW position, move the PTO switch to the ON position. Cutting Unit Safety 7. Press the lift switch to start the backlapping operation on the designated reels. A worn or damaged cutting unit can break, and a piece of a reel or bedknife could be thrown at you or bystanders, resulting in serious personal injury or death. • Inspect the cutting units periodically for wear or damage. • Use care when checking the cutting units.
Storage Preparing the Traction Unit 1. Park the machine on a level surface, lower the cutting units, engage the parking brake, shut off the engine, and remove the key. 2. Thoroughly clean the traction unit, cutting units, and the engine. 3. Check the tire pressure; refer to Checking the Tire Pressure (page 30). 4. Check all fasteners for looseness; tighten them as necessary. 5. Grease or oil all grease fittings and pivot points. Wipe up any excess lubricant. 6.
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The Toro Warranty A Two-Year 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).
