Toro 03206, 03207, 03220, 03221, Reelmaster 3100–D Operator's Manual
Reelmaster) 3100–D
Traction Unit
Model No. 03207—280000001 and Up
Model No. 03206—280000001 and Up
Model No. 03220
Model No. 03221
Form No. 3359–704 Rev A
Operator’s Manual
English (EN, GB)
Warning
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents
are known to the State of California to cause
cancer, birth defects, and other reproductive harm.
Important The engine in this product is not equipped
with a spark arrester muffler. It is a violation of California
Public Resource Code Section 4442 to use or operate this
engine on any forest-covered, brush-covered, or
grass-covered land as defined in CPRC 4126. Other states
or federal areas may have similar laws.
Contents
Page
Introduction 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Operating Practices 3. . . . . . . . . . . . . . . . . . . .
Toro Riding Mower Safety 5. . . . . . . . . . . . . . . . . .
Sound Pressure Level 6. . . . . . . . . . . . . . . . . . . . . .
Sound Power Level 6. . . . . . . . . . . . . . . . . . . . . . .
Vibration Level 6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 7. . . . . . . . . . . . . . . .
Specifications 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 11. . . . . . . . . . . . . . . . . . . . .
Setup 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts Chart 12. . . . . . . . . . . . . . . . . . . . . . . . .
Install Wheels 13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install Steering Wheel 13. . . . . . . . . . . . . . . . . . . . .
Activate, Charge and Connect Battery 13. . . . . . . .
Check Angle Indicator 14. . . . . . . . . . . . . . . . . . . . .
Install Hood Latch
(European Compliance) 14. . . . . . . . . . . . . . . . . . .
Install Exhaust Guard
(European Compliance) 15. . . . . . . . . . . . . . . . . . .
Install ROPS 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install Front Lift Arms 15. . . . . . . . . . . . . . . . . . . . .
Mount Carrier Frames To Cutting Units 16. . . . . . . .
Mount Cutting Units 17. . . . . . . . . . . . . . . . . . . . . . .
Mount Cutting Unit Drive Motors 18. . . . . . . . . . . .
Adjust Lift Arms 18. . . . . . . . . . . . . . . . . . . . . . . . .
Before Operating 20. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Crankcase Oil 20. . . . . . . . . . . . . . . . . . . . . .
Fill Fuel Tank 20. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Cooling System 21. . . . . . . . . . . . . . . . . . . . .
Checking the Hydraulic System 22. . . . . . . . . . . . . .
Check Tire Pressure 22. . . . . . . . . . . . . . . . . . . . . . .
Check Reel To Bedknife Contact 22. . . . . . . . . . . . .
Check Torque Of Wheel Nuts 23. . . . . . . . . . . . . . .
Controls 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting/Stopping Engine 26. . . . . . . . . . . . . . . . . . .
Bleeding Fuel System 26. . . . . . . . . . . . . . . . . . . . . .
Check Operation Of Interlock Switches 27. . . . . . . .
Towing Traction Unit 27. . . . . . . . . . . . . . . . . . . . . .
Operating Characteristics 27. . . . . . . . . . . . . . . . . . .
Mowing Techniques 28. . . . . . . . . . . . . . . . . . . . . . .
After Mowing 29. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting Clip Rate (Reel Speed) 29. . . . . . . . . . . . .
Standard Control Module (SCM) 30. . . . . . . . . . . . .
Lubrication 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule 35. . . . . . . . .
Daily Maintenance Checklist 36. . . . . . . . . . . . . . . .
Service Interval Chart 37. . . . . . . . . . . . . . . . . . . . . .
Hood Removal 37. . . . . . . . . . . . . . . . . . . . . . . . . . .
General Air Cleaner Maintenance 38. . . . . . . . . . . .
Servicing Air Cleaner 38. . . . . . . . . . . . . . . . . . . . . .
Engine Oil and Filter 38. . . . . . . . . . . . . . . . . . . . . .
Fuel System 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bleeding Air From Injectors 39. . . . . . . . . . . . . . . . .
Cleaning Engine Cooling System 40. . . . . . . . . . . . .
Servicing Engine Belts 40. . . . . . . . . . . . . . . . . . . . .
Adjusting Throttle 41. . . . . . . . . . . . . . . . . . . . . . . .
Changing Hydraulic Fluid 41. . . . . . . . . . . . . . . . . .
Replacing Hydraulic Filter 42. . . . . . . . . . . . . . . . . .
Checking Hydraulic Lines And Hoses 42. . . . . . . . .
Adjusting Traction Drive For Neutral 42. . . . . . . . .
Adjusting Parking Brake 43. . . . . . . . . . . . . . . . . . .
Battery Care 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Storage 44. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuses 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Backlapping 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Traction Unit 45. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Schematic 46. . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Schematic 47. . . . . . . . . . . . . . . . . . . . . .
The Toro General Commercial Products Warranty 48. .
W 2008 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
All Rights Reserved
Printed in the USA
2
Introduction
Safety
Read this manual carefully to learn how to operate and
maintain your product properly. The information in this
manual can help you and others avoid injury and product
damage. Although Toro designs and produces safe
products, you are responsible for operating the product
properly and safely.
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.The two numbers are
stamped into a plate that is riveted to the frame of mower.
Write the product model and serial numbers in the space
below:
Model No.
Serial No.
This manual identifies potential hazards and has special
safety messages that help you and others avoid personal
injury and even death. Danger, Warning, and Caution are
signal words used to identify the level of hazard. However,
regardless of the hazard, be extremely careful.
Danger signals an extreme hazard that will cause serious
injury or death if you do not follow the recommended
precautions.
Warning signals a hazard that may cause serious injury or
death if you do not follow the recommended precautions.
Caution signals a hazard that may cause minor or moderate
injury if you do not follow the recommended precautions.
This manual uses two other words to highlight information.
Important calls attention to special mechanical
information and Note: emphasizes general information
worthy of special attention.
This machine meets or exceeds CEN standard EN
836:1997, ISO standard 5395:1990, and ANSI
B71.4-2004 specifications in effect at the time of
production when rear tires are filled with calcium
chloride and two rear wheel weight kits (Part No.
11–0440) are installed.
Improper use or maintenance by the operator or owner
can result in injury. To reduce the potential for injury,
comply with these safety instructions and always pay
attention to the safety alert symbol, which means
CAUTION, WARNING, or DANGER—“personal
safety instruction.” Failure to comply with the
instruction may result in personal injury or death.
Safe Operating Practices
The following instructions are from the CEN standard EN
836:1997, ISO standard 5395:1990, and ANSI B71.4-2004.
Training
• Read the operator’s manual and other training material
carefully. Be familiar with the controls, safety signs,
and the proper use of the equipment.
• Never allow children or people unfamiliar with these
instructions to use or service the mower. Local
regulations may restrict the age of the operator.
• Never mow while people, especially children, or pets
are nearby.
• Keep in mind that the operator or user is responsible for
accidents or hazards occurring to other people or their
property.
• Do not carry passengers.
• All drivers and mechanics should seek and obtain
professional and practical instruction. The owner is
responsible for training the users. Such instruction
should emphasize:
– the need for care and concentration when working
with ride-on machines;
– The main reasons for loss of control on a slope are:
• insufficient wheel grip;
• being driven too fast;
• inadequate braking;
• the type of machine is unsuitable for its task;
• lack of awareness of the effect of ground
conditions, especially slopes;
• incorrect hitching and load distribution.
3
• The owner/user can prevent and is responsible for
accidents or injuries occurring to himself or herself,
other people, or property.
Preparation
• While mowing, always wear substantial footwear, long
trousers, hard hat, safety glasses, and hearing
protection. Long hair, loose clothing, or jewelry may
get tangled in moving parts. Do not operate the
equipment when barefoot or wearing open sandals.
• Thoroughly inspect the area where the equipment is to
be used and remove all objects which may be thrown by
the machine.
• Warning—Fuel is highly flammable. Take the
following precautions:
– Store fuel in containers specifically designed for this
purpose.
– Refuel outdoors only and do not smoke while
refuelling.
– Add fuel before starting the engine. Never remove
the cap of the fuel tank or add fuel while the engine
is running or when the engine is hot.
– If fuel is spilled, do not attempt to start the engine
but move the machine away from the area of
spillage and avoid creating any source of ignition
until fuel vapors have dissipated.
– Replace all fuel tanks and container caps securely.
• Replace faulty silencers/mufflers.
• Evaluate the terrain to determine what accessories and
attachments are needed to properly and safely perform
the job. Only use accessories and attachments approved
by the manufacturer.
• Check that operator’s presence controls, safety switches
and shields are attached and functioning properly. Do
not operate unless they are functioning properly.
– do not stop or start suddenly when going up or
downhill;
– machine speeds should be kept low on slopes and
during tight turns;
– stay alert for humps and hollows and other hidden
hazards;
– never mow across the face of the slope, unless the
mower is designed for this purpose.
• Stay alert for holes in the terrain and other hidden
hazards.
• Watch out for traffic when crossing or near roadways.
• Stop the blades rotating before crossing surfaces other
than grass.
• When using any attachments, never direct discharge of
material toward bystanders nor allow anyone near the
machine while in operation.
• Never operate the machine with damaged guards,
shields, or without safety protective devices in place. Be
sure all interlocks are attached, adjusted properly, and
functioning properly.
• Do not change the engine governor settings or
overspeed the engine. Operating the engine at excessive
speed may increase the hazard of personal injury.
• Before leaving the operator’s position:
– stop on level ground;
– disengage the power take-off and lower the
attachments;
– change into neutral and set the parking brake;
– stop the engine and remove the key.
• Disengage drive to attachments when transporting or
not in use.
• Stop the engine and disengage drive to attachment
– before refuelling;
Operation
• Do not operate the engine in a confined space where
dangerous carbon monoxide fumes can collect.
• Mow only in daylight or in good artificial light.
• Before attempting to start the engine, disengage all
blade attachment clutches, shift into neutral, and engage
the parking brake.
• Do not use on slopes of more than 25°.
• Remember there is no such thing as a safe slope. Travel
on grass slopes requires particular care. To guard
against overturning:
– before removing the grass catcher/catchers;
– before making height adjustment unless adjustment
can be made from the operator’s position.
– before clearing blockages;
– before checking, cleaning or working on the mower;
– after striking a foreign object or if an abnormal
vibration occurs. Inspect the mower for damage and
make repairs before restarting and operating the
equipment.
• Reduce the throttle setting during engine run-out and, if
the engine is provided with a shut-off valve, turn the
fuel off at the conclusion of mowing.
4
• Keep hands and feet away from the cutting units.
• Look behind and down before backing up to be sure of
a clear path.
• Slow down and use caution when making turns and
crossing roads and sidewalks. Stop cylinders/reels if not
mowing.
• Do not operate the mower under the influence of
alcohol or drugs
• Use care when loading or unloading the machine into a
trailer or truck
• Use care when approaching blind corners, shrubs, trees,
or other objects that may obscure vision.
• Disconnect battery and remove spark plug wire before
making any repairs. Disconnect the negative terminal
first and the 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.
Maintenance and Storage
• Keep all nuts, bolts and screws tight to be sure the
equipment is in safe working condition.
• Never store the equipment with fuel in the tank inside a
building where fumes may reach an open flame or
spark.
• Allow the engine to cool before storing in any
enclosure.
• To reduce the fire hazard, keep the engine,
silencer/muffler, battery compartment and fuel storage
area free of grass, leaves, or excessive grease.
• Check the grass catcher frequently for wear or
deterioration.
• Keep all parts in good working condition and all
hardware and hydraulic fittings tightened. Replace all
worn or damaged parts and decals.
• If the fuel tank has to be drained, do this outdoors.
• Be careful during adjustment of the machine to prevent
entrapment of the fingers between moving blades and
fixed parts of the machine.
• On multi-cylinder/multi-reel machines, take care as
rotating one cylinder/reel can cause other
cylinders/reels to rotate.
• Disengage drives, lower the cutting units, set parking
brake, stop engine and remove key and disconnect spark
plug wire. Wait for all movement to stop before
adjusting, cleaning or repairing.
• Clean grass and debris from cutting units, drives,
silencers/mufflers, and engine to help prevent fires.
Clean up oil or fuel spillage.
• Use jack stands to support components when required.
• Carefully release pressure from components with stored
energy.
Toro Riding Mower Safety
The following list contains safety information specific to
Toro products or other safety information that you must
know that is not included in the CEN, ISO, or ANSI
standard.
This product is capable of amputating hands and feet and
throwing objects. Always follow all safety instructions to
avoid serious injury or death.
Use of this product for purposes other than its intended use
could prove dangerous to user and bystanders.
Warning
Engine exhaust contains carbon monoxide, which
is an odorless, deadly poison that can kill you.
Do not run engine indoors or in an enclosed area.
• Be sure to establish your own special procedures and
work rules for unusual operating conditions (e.g. slopes
to steep for machine operation. Survey complete
mowing site to determine which hills can be safely
operated on. When performing this site survey always
use common sense and take into consideration the turf
condition and the rollover risk. To determine which
hills or slopes may be safely operated on use the
inclinometer provided with each machine. To perform a
site survey, lay a 4’ two by four on the slope surface and
measure the angle of the slope. The 2 by 4 will average
the slope but will not take into consideration dips or
holes. THE MAXIMUM SIDE HILL ANGLE
SHOULD NOT BE GREATER THAN 25
DEGREES.
• The Reelmaster 3100 is equipped with an angle
indicator, mounted on the steering tube, which indicates
the side hill angle the machine is operating on and
identifies the recommended maximum limit of 25
degrees. Stay alert for holes in terrain and other hidden
hazards which can cause a sudden change in side hill
angle.
5
• Use extreme caution when operating close to sand traps,
ditches, creeks, steep hillsides or other hazards. Reduce
speed when making sharp turns. Do not turn on hills.
Avoid sudden stops and starts. Use reverse pedal for
braking. Cutting units must be lowered when going
down slopes for steering control.
• Know how to stop the engine quickly.
• Do not operate the machine while wearing tennis shoes
or sneakers.
• Wearing safety shoes and long pants is advisable and
required by some local ordinances and insurance
regulations.
• Handle fuel carefully. Wipe up any spills.
• Check the safety interlock switches daily for proper
operation. If a switch should fail, replace the switch
before operating the machine.
• Before starting the engine, sit on the seat.
• Using the machine demands attention. To prevent loss
of control:
– Do not drive close to sand traps, ditches, creeks, or
other hazards.
– Reduce speed when making sharp turns. Avoid
sudden stops and starts.
– This machine is not designed or equipped for
on–road use and is a “slow–moving vehicle.” If you
must cross or travel on a public road, you should be
aware of and comply with local regulations, such as
required lights, slow moving vehicle signs, and
reflectors.
– Apply the service brakes when going downhill to
keep forward speed slow and to maintain control of
the machine.
• The grass baskets must be in place during operation of
the cylinders/reels or thatchers for maximum safety.
Shut the engine off before emptying the baskets.
• Raise the cutting units when driving from one work
area to another.
Maintenance and Storage
• Make sure all hydraulic line connectors are tight and all
hydraulic hoses and lines are in good condition before
applying pressure to the system.
• Keep your body and hands away from pin hole leaks or
nozzles that eject hydraulic fluid under high pressure.
Use paper or cardboard, not your hands, to search for
leaks. Hydraulic fluid escaping under pressure can have
sufficient force to penetrate the skin and cause serious
injury. Seek immediate medical attention if fluid is
injected into skin.
• Before disconnecting or performing any work on the
hydraulic system, all pressure in the system must be
relieved by stopping the engine and lowering the cutting
units and attachments to the ground.
• Check all fuel lines for tightness and wear on a regular
basis. Tighten or repair them as needed.
• If the engine must be running to perform a maintenance
adjustment, keep hands, feet, clothing, and any parts of
the body away from the cutting units, attachments, and
any moving parts, especially the screen at the side of the
engine. Keep everyone away.
• To ensure safety and accuracy, have an Authorized Toro
Distributor check the maximum engine speed with a
tachometer. Maximum governed engine speed should be
2650 RPM.
• If major repairs are ever needed or if assistance is
desired, contact an Authorized Toro Distributor.
• Use only Toro-approved attachments and replacement
parts. The warranty may be voided if used with
unapproved attachments.
Sound Pressure Level
This unit has an equivalent continuous A–weighted sound
pressure level at the operator ear of 83 dBA, based on
measurements of identical machines per EN 836 and ISO
11201.
Sound Power Level
• Do not touch the engine, silencer/muffler, or exhaust
pipe while the engine is running or soon after it has
stopped because these areas could be hot enough to
cause burns.
• If the engine stalls or loses headway and cannot make it
to the top of a slope, do not turn the machine around.
Always back slowly, straight down the slope.
• When a person or pet appears unexpectedly in or near
the mowing area, stop mowing. Careless operation,
combined with terrain angles, ricochets, or improperly
positioned guards can lead to thrown object injuries. Do
not resume mowing until the area is cleared.
This unit has a guaranteed sound power level of:
105 dBA/1 pW, based on measurements of identical
machines per ISO 11094.
Vibration Level
This unit does not exceed a vibration level of 2.5 m/s@ at
the hands based on measurements of identical machines per
ISO 5349 procedures EN 836 and ISO 1033.
This unit does not exceed a vibration level of .5 m/s@ at the
posterior based on measurements of identical machines per
EN 836 and ISO 1032.
6
Safety and Instruction Decals
Safety decals and instructions are easily visible to the operator and are located near any area
of potential danger. Replace any decal that is damaged or lost.
1. Engage the reels.
2. Disengage the reels.
3. Lower the reels.
4. Move the cutting units to the
right.
104–5192 (Model 03207)
5. Raise the reels.
6. Move the cutting units to the
left.
7. Move rear ward to lock the
lift lever.
8. Engine—stop
9. Engine—run
10. Engine=start
11. Fast
12. Continuous variable setting
13. Slow
7
1. Engage the reels.
2. Disengage the reels.
3. Lower the reels.
104-5193 (Model 03206)
4. Raise the reels.
5. Move rear ward to lock the
lift lever.
6. Engine—stop
7. Engine—run
8. Engine=start
9. Fast
10. Continuous variable setting
11. Slow
94-3353 (Model 03206)
1. Crushing hazard of hand—keep your hands a safe distance
away.
99-3558 for CE
1. Warning—read the Operator’s Manual.
2. To start the engine, sit on the operator’s seat,, turn the key to
Run and wait for the engine preheat light to turn off, turn the
key to Start, and disengage the parking brake by moving the
lever down; read the Operators Manual.
3. To stop the engine, press the switch to disengage the reels,
turn the key to Stop and remove it, engage the parking brake
by pulling the lever up; read the Operators Manual.
93-6681
1. Cutting/dismemberment hazard, fan—stay away from moving
parts.
8
104-5199
99-3496
9
104-5181 for CE compliance
1. Warning—read the Operator’s Manual.
2. Tipping hazard—do not drive on slopes greater than 15
degrees and always wear the seat belt with ROPS.
3. Thrown object hazard—keep bystanders a safe distance from
the machine.
4. Cutting hazard of hand or foot—stay away from moving parts.
5. Warning—lock the parking brake, stop the engine, and remove
the ignition key before leaving the machine.
100-4837
107-7801 for CE compliance
* This safety decal includes a slope warning required on the
machine for compliance to the European Lawn Mower Safety
Standard EN836:1997. The conservative maximum slope
angles indicated for operation of this machine are prescribed
by and required by this standard.
1. Tipping hazard—do not drive on slopes greater than 15
degrees.
Battery Symbols
Some or all of these symbols are on your battery.
1. Explosion hazard
2. No fire, open flames, or
smoking.
3. Caustic liquid/chemical
burn hazard
4. Wear eye protection
5. Read the Operator’s
Manual.
6. Keep bystanders a safe
distance from the battery.
7. Wear eye protection;
explosive gases can
cause blindness and
other injuries
8. Battery acid can cause
blindness or severe
burns.
9. Flush eyes immediately
with water and get
medical help fast.
10. Contains lead; do not
discard.
10
Specifications
Note: Specifications and design subject to change without notice.
General Specifications
Kubota three cylinder, 4 cycle liquid cooled diesel engine. 21.5 hp @ 2500 rpm
Engine
Governed to 2650 rpm. 68.5 cu. in. (1124 cc) displacement. Heavy duty, 2-stage,
remote mounted air cleaner. High water temperature shutdown switch.
Cooling System
Electrical
Fuel Capacity 7.5 gallons.
Traction Drive
Hydraulic System Remote mounted, 3.5 gallon oil reservoir. 10 micron remote mounted spin on filter.
Ground Speed
Tires/Wheels
Frame
Steering Power steering.
Brakes
Radiator capacity is approximately 6 qts. of 50/50 mixture of ethylene glycol
anti–freeze. Remote mounted 1 qt. expansion tank.
12 volt Group 55, 450 cold cranking amps at 0_F (–18_C), 75 minute reserve
capacity at 80_F (27_C). 40 amp alternator with regulator/rectifier. Seat switch,
PTO, parking brake and traction interlock switches.
High torque hydraulic wheel motors. 3–wheel drive. Oil cooler and shuttle valve
provide positive closed–loop cooling.
Infinitely variable speed selection in forward and reverse
Mowing speed: 0–6 mph (adjustable)
Transport speed: 0–9 mph
Reverse speed: 0–3.5 mph
Front tires are 20 x 12–10 tubeless tires and rear tires are 20 x 10–10 tubeless. All
have 4–ply rating with demountable rims. Recommended tire pressure: 14–18 psi
front and rear tires.
Tricycle vehicle with 3–wheel traction drive and rear wheel steering. Frame consists
of formed steel, welded steel and steel tubing components.
Service braking accomplished through dynamic characteristics of Hydrostat.
Parking or emergency brake is actuated by ratchet hand lever on the operator’s
right hand side.
Foot operated forward and reverse traction pedals and Mow/Transport slide. Hand
Controls
Gauges & Protective
Systems
Cutting Unit Lift Hydraulic lift with automatic reel shut off.
operated throttle, ignition switch, reel engagement switch, reel unit lift and shift
lever, parking brake and seat adjustment. Shift lever only on Model 03206.
Hour meter. 4 light warning cluster gauge: oil pressure, water temperature, amps,
glow plug and side hill angle indicator.
11
Setup
Note: Determine the left and right sides of the machine from the normal operating position.
Loose Parts Chart
Note: Use this chart as a checklist to ensure all parts necessary for assembly have been shipped. If any of these parts are
missing, total setup cannot be completed.
Description Qty. Use
Wheel assembly 3 Mount to wheel hubs
Steering wheel
Flat washer 21/32
Jam nut
Cover
Screw
Hood lock bracket
Screw 1/4–20 x 1–1/2” lg.
Flat washer 1/4
Lock nut 1/4–20
Exhaust guard
Self tapping screw
Hose clamp 1 Secure vent hose to vent tube of ROPS
Lift arms
Pivot rod
Capscrews 5/16–18 x 7/8” lg.
Thrust washers
Lynch pin
Key 2
1
1
1
1
1
1
1
1
1
1
4
2
2
2
2
2
Mount to steering shaft
Mount to hood for European Compliance
Mount to machine for European Compliance
Install pivot rods to lift arms
(supplied with Lift Arm Kit)
Mount cutting units to lift arms
(supplied with Lift Arm Kit)
Inclinometer 1 Use for site survey before operating machine
EEC Decal
EEC Certificate
Operator’s manual 2 Read before operating the machine.
Engine operator’s manual 1 Read before operating the machine.
Parts catalog 1
Operator training material 1 View before operating the machine
Pre–delivery check list 1
Note: Specifications and design subject to change without notice.
4
Affix to machine for European Compliance
2
12
Install Wheels
1. Mount a wheel assembly onto each wheel hub (valve
stem outward).
Important Rear tire has a narrower rim than front tires.
2. Install lug nuts and torque to 45–65 ft–Ib.
Install Steering Wheel
1. Slide steering wheel onto steering shaft.
4
3
1
2
2. Remove battery cover.
3. If Battery is not filled with electrolyte or activated, bulk
electrolyte with 1.260 specific gravity must be
purchased from a local battery supply outlet and added
to battery.
4. Remove filler caps from battery and slowly fill each
cell until electrolyte is just above the plates.
1
Figure 2
1. Battery cover
5. Replace filler caps and 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.
Figure 1
1. Steering wheel
2. Washer
2. Slide washer onto steering shaft.
3. Secure steering wheel to shaft with jam nut and tighten
it to 20–26 ft-lb.
4. Install cap to steering wheel with screw.
3. Jam nut
4. Cap
Activate, Charge and Connect
Battery
Warning
CALIFORNIA
Proposition 65 Warning
Battery posts, terminals, and related accessories
contain lead and lead compounds, chemicals
known to the State of California to cause cancer
and reproductive harm. Wash hands after
handling.
Caution
Wear safety goggles and rubber gloves when
working with electrolyte. Charge the battery in a
well ventilated place so gasses produced while
charging can dissipate. Since the gases are
explosive, keep open flames and electrical spark
away from the battery; do not smoke. Nausea may
result if the gases are inhaled. Unplug charger
from electrical outlet before connecting to or
disconnecting charger leads from battery posts.
6. When battery is charged, disconnect charger from
electrical outlet and battery posts.
7. Remove filler caps. Slowly add electrolyte to each cell
until level is up to fill ring. Install filler caps.
Important Do not overfill battery. Electrolyte will
overflow onto other parts of the machine and severe
corrosion and deterioration will result.
8. Install the positive cable (red) to the positive (+)
terminal and the negative cable (black) to the negative
(—) terminal of the battery and secure with capscrews
and nuts. Make sure positive (+) terminal is all the way
onto post and cable is positioned snug to battery. Cable
1. Open hood.
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must not contact battery cover. Slide the rubber boot
over the positive terminal to prevent possible short–out
from occurring.
Warning
• Connecting cables to the wrong post could
damage the electrical system and result in
personal injury.
2
1. Positive (+) battery cable 2. Negative (–) battery cable
Important If battery is ever removed, make sure
battery clamp bolts are reinstalled with bolt heads
positioned on bottom side and nuts on top side. If clamp
bolts are reversed, they may interfere with hard lines when
shifting cutting units.
9. Coat both battery connections with Grafo 112X (skin
over) grease, Toro Part No. 505–47, petroleum jelly or
light grease to prevent corrosion and slide rubber boot
over positive terminal.
1
Figure 3
1
Figure 4
1. Angle indicator
3. If inclinometer does not read zero degrees, move the
machine to a location where a zero degree reading is
obtained. The angle indicator, mounted on machine,
should now read zero degrees as well.
4. If angle indicator does not read zero degrees, loosen the
two screws and nuts securing angle indicator to
mounting bracket, adjust indicator to obtain a zero
degree reading and tighten capscrews.
Install Hood Latch
(European Compliance)
1. Unhook hood latch from bracket.
2. Slide hood lock bracket onto latch.
2
3
1
10. Install battery cover.
Check Angle Indicator
Danger
To reduce risk of injury or death due to rollover do
not operate on side hills steeper than 25 degrees.
1. Park machine on a flat, level surface.
2. Verify that the machine is level by placing a hand held
inclinometer (supplied with machine) on the frame
cross rail, by the tool box. The inclinometer should read
zero degrees, when viewed from the operator’s position.
Figure 5
1. Hood latch
2. Hood latch bracket
3. Re–hook latch onto bracket.
4. Insert 1/4–20 x 1–1/2” lg. capscrew thru hood lock
bracket and secure with a capscrew, flat washer and
locknut.
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3. Hood lock bracket
Install Exhaust Guard
(European Compliance)
3. Secure fuel line vent hose to vent tube on ROPS with
hose clamp.
1. Position exhaust guard around muffler while aligning
mounting holes with holes in frame.
2. Secure exhaust guard to frame with (4) self tapping
screws.
1
Figure 6
1. Exhaust guard
Install ROPS
Important Never weld or modify ROPS. Replace a
damaged ROPS, do not repair or revise. Any alteration of
ROPS must be approved by manufacturer.
1. Lower ROPS frame onto traction unit mounting
brackets, aligning mounting holes. Vent tube, secured to
ROPS, must be positioned on left side of machine.
2. Secure each side of roll bar to mounting brackets with
(2) flange head capscrews and locknuts (Fig. 7). Torque
fasteners to 60 ft–lbs.
Caution
Fuel line vent hose must be connected to vent tube
prior to starting engine or fuel will flow from hose.
Install Front Lift Arms
1. Remove (2) capscrews securing lift arm pivot shaft link
to lift arm pivot shafts. Remove and retain pivot shaft
link and capscrews (Fig. 8).
2
1
Figure 8
1. Lift arm pivot shaft link 2. Lift arm pivot shaft
2. Insert a pivot rod into each (R.H. & L.H.) lift arm and
align mounting holes (Fig. 9).
1
2
1. ROPS
2. Mounting bracket
3. Vent tube
3
5
4
Figure 7
1
2
4. Fuel line vent tube hose
5. Hose clamp
2
Figure 9
1. Lift arm 2. Pivot rod
3. Secure pivot rods to lift arms with a 5/16 – 18 x 7/8” lg.
capscrew.
4. Insert R.H. & L.H. lift arms onto lift arm pivot shafts.
Secure with lift arm pivot shaft link and capscrews
previously removed. Torque capscrews to 70 ft–lbs.
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