FORM NO. 3322-193 Rev A MODEL NO. 03422-90001 & UP MODEL NO. 03422TE-90001 & UP MODEL NO. 03427-90001 & UP MODEL NO. 03427TE-90001 & UP MODEL NO. 03471 MODEL NO. 03472 OPERATOR'S MANUAL REELMASTER 2300/2600-D TRACTION UNIT To assure maximum safety, optimum performance, and to gain knowledge of the product, it is essential that you or any other operator of the mower read and understand the contents of this manual before the engine is ever started.
FOREWORD The REELMASTER was developed to provide an efficient, reliable and time-saving method of mowing high quality turf. The latest concepts in engineering and design have been incorporated into this machine along with the highest quality parts and workmanship. Excellent service will be derived if proper operation and maintenance practices are followed. We know, since you have purchased the industry leader in mowing excellence, that future performance and dependability are of prime importance.
TABLE OF CONTENTS Page Page SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . 4-5 SAFETY INSTRUCTIONS & DECALS . . . . . . . . . . 6 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 LOOSE PARTS CHART . . . . . . . . . . . . . . . . . . . . . . . 8 SET UP INSTRUCTIONS . . . . . . . . . . . . . . . . . . 9-14 Install Rear Wheel . . . . . . . . . . . . . . . . . . . . . . . . 9 Installing Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY INSTRUCTIONS Improper use or maintenance by the operator or owner of the machine can result in injury. To reduce the potential for any injury, comply with the following safety instructions. WHILE OPERATING BEFORE OPERATING 12. Sit on the seat when starting and operating the machine. 1. Operate the machine only after reading and understanding the contents of this manual. A free replacement manual is available by sending complete model and serial number to: The Toro Company 8111 Lyndale Ave. S.
SAFETY INSTRUCTIONS 18. Do not touch engine, muffler, exhaust pipe or hydraulic tank while engine is running or soon after it has stopped because these areas could be hot enough to cause burns. 27. Before disconnecting or performing any work on the hydraulic system, all pressure in system must be relieved by stopping engine and lowering cutting units to the ground. 19. If a cutting unit strikes a solid object or vibrates abnormally, stop immediately.
SAFETY AND INSTRUCTION DECALS The following safety and instruction decals are affixed to the traction unit. If any decal becomes illegible or damaged, install a new decal. Part numbers are listed below and in your Parts Catalog. Order replacements from your Authorized Toro Distributor. ON HOOD HINGE (Part No. 94-5056) ON LEFT FENDER (Part No. 93-7267)) ON CARRIER FRAME (Part No. 94-3353) Warning! Pinch Point Between Carrier Frame and Cutting Unit ON INSTRUMENT PANEL (Part No.
SPECIFICATIONS Engine: Perkins, 4 cycle, 3 cylinder, liquid cooled, vertical OHV, diesel engine with centrifugal water pump. 18 hp (13.4 kW); governed to a maximum speed of 3200 rpm. 41.2 cu. in. (676 cc) displacement. Forced lubrication gear pump. Mechanical centrifugal governor. Mechanical fuel transfer pump. Fuel filter/water separator with replaceable filter element. 12 volt (0.7 kW) starter. Heavy duty remote mounted air cleaner Spin-on oil filter.
LOOSE PARTS CHART Note: Use this chart as a checklist to assure all parts necessary for assembly have been received. Without these parts, total set up cannot be completed. Some parts may have already been assembled at factory. Wheel Assy Flat washers Axle Locknut 1 2 1 1 Wheel Assy. Lug Nuts 1 4 Install rear wheel on model 03427 Flat Washer Capscrew Locknut 3 3 Mount carrier frames to cutting Units (supplied with Lift Arm kit) Lift Arms Pivot Rod Capscrews 5/16- 18 x 7/8"Lg.
SET UP INSTRUCTIONS INSTALL REAR WHEEL (Fig. 1 & 2) Model 03422- Two wheel drive 1. Mount wheel assembly to rear castor fork with (2) flat washers, axle and locknut. Washers to be positioned on outside of fork. Tighten nut to 45-65 ft-Ib. 1. Remove shipping ties securing lower seat slides to upper seat slides. Note orientation of lower slides for correct reinstallation. 2 3 1 2 Figure 1 1. Wheel assembly 2. Rear castor fork 3. Axle 1 Model 03427- Three wheel drive 1.
SET UP INSTRUCTIONS ADJUST REAR CARRIER FRAME HEIGHT (Fig. 4) 1. Slide rear carrier frame onto rear lift arm pivot rod. Do not install carrier frame to cutting unit at this time. 3. Secure each mounting link to carrier frame with a 3/8-16 x 2-1/4" lg capscrew, (2) flatwashers and a locknut, as shown in figure 5. Position a washer on each side of link when mounting. Torque to 31 ft-lb. 1 2. Raise lift arms and carrier frame fully. 3 2 1 3 2 3 Figure 5 1. Carrier frame 2. Mounting link 3.
SET UP INSTRUCTIONS 4. Mount the motor and the spider coupling to the drive end of the cutting unit and secure with two capscrews provided with cutting unit. 7 6 1 5. On center and left hand cutting units, remove bearing housing cover and install gasket (supplied with cutting units). 2 3 8 3 2 4 5 1 Figure 7 1. Counterbalance arm 2. Top capscrew 3. Bottom capscrew 4. Lift arm pivot pin 5. Tipper chain 6. Lift chain 7. Cylinder pin 8. Lift arm tab 6.
SET UP INSTRUCTIONS 1 1 3 2 Figure 12 1. Cutting unit lift tab Figure 11 1. Tipper chain (RM 2300) 2. Tipper chain (RM 2600) 3. Carrier frame 4. Grease all lift arm and carrier frame pivot points. INSTALL COUNTERBALANCE SPRINGS WARNING Use caution when tensioning springs as they are under heavy load. The counterbalance springs help balance the cutting units to allow equal amounts of weight (down pressure) to be distributed to each end of cutting unit.
SET UP INSTRUCTIONS Note: Selecting the #4 hole position (increasing spring tension) will reduce the weight on inboard end of cutting unit, increase the weight on outboard end of cutting unit and increase traction. Selecting the #2 hole position has opposite affect. 3. On rear cutting unit, hook spring into top hole on rear cutting unit lift tab.
SET UP INSTRUCTIONS Either Type 1 (77%) or Type 2 (94%) commercial calcium chloride flake may be used. Plain water freezes solid at 32 F (0 C). The 3-1/2 pound (1 .6 kg) calcium chloride to one gallon (3.8 L) of water solution is slush free to -12 F (-24 C), and will freeze solid at -52 F (-46 C). The 5 pound (2.3 kg) per gallon (liter) solution is slush free to -50 F (-45 C) and will freeze solid at -62 F (-52 C). 3 1 2 Figure 17 1. Rear counter balance spring 2. Vinyl cover 3. Spring shackle 9.
SET UP INSTRUCTIONS 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 bat tery posts. 6.
BEFORE OPERATING CAUTION Before servicing or making adjustments to the machine, stop engine and remove key from the switch. FILL FUEL TANK (Fig. 22) The engine runs on No. 2 diesel fuel. Fuel tank capacity is approximately 6.5 gallons. 1. Clean area around fuel tank cap. 1 CHECK CRANKCASE OIL (Fig. 20-21) The engine is shipped with oil in the crankcase; however, level of oil must be checked before and after the engine is first started. Crankcase capacity is approximately 3 qts. (2.8 l) with filter. 1.
BEFORE OPERATING Group 1 Hydraulic Fluid (Recommended for ambient temperatures consistently below 100° F.): ISO type 46/68 anti-wear hydraulic fluid 1 3 2 Figure 23 1. Radiator screen 2. Radiator 3. Oil cooler CAUTION If engine has been running, pressurized hot coolant can escape when radiator cap is removed and cause burns. Only open radiator cap when engine is cold. 1. Carefully remove cap from radiator.
BEFORE OPERATING 3. If fluid level is not at least at bottom of gauge when cold, remove cap from hydraulic fluid reservoir and slowly fill reservoir with Mobil 424 or equivalent hydraulic fluid until level in reaches bottom of sight gauge. DO NOT OVERFILL. 3. Inspect fuel filter and replace if dirty. Refer to Replacing Fuel Filter. DANGER Because diesel fuel is flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank.
CONTROLS Traction and Stopping Pedal (Fig. 27 & 28) Traction pedal has three functions: one, to make the machine move forward, two, to move it backward and three, to stop machine. Using the heel and toe of the right foot, depress top of pedal to move forward and bottom of pedal to move backward or to assist in stopping when moving forward. Also, allow pedal to move or move it to neutral position to stop machine. For operator comfort, do not rest heel of foot on reverse when operating forward. position.
CONTROLS Alternator Light (Fig. 29) The amp light should be off when engine is running. If it is on, the charging system should be checked and repaired as necessary. Glow Plug Indicator (Fig. 29) Indicator light will glow when glow plugs are operating. Cold Start Button (Fig. 29) When starting a cold engine, press cold start button to electrically de-clutch traction pump. When engine starts release button.
OPERATING INSTRUCTIONS STARTING/STOPPING ENGINE BLEEDING FUEL SYSTEM (Fig. 35-36) IMPORTANT: The fuel system may have to be bled if any of the following situations have occurred: 1. Park the machine on a level surface. Make sure fuel tank is at least half full. 2. Unlatch and raise hood. A. Initial start up of a new engine. DANGER B. Engine has ceased running due to lack of fuel. C. Maintenance has been performed upon fuel system components; i.e. filter replaced, etc. Refer to Bleeding Fuel System 1.
OPERATING INSTRUCTIONS extended, the light should go out and the reel motors stop turning. Correct problem if not operating properly. 1 5 4 5. With operator on seat, the engine must not start with either reel switch engaged or traction control engaged. Correct problem if not operating properly. TOWING TRACTION UNIT (Fig. 37) 3 In case of emergency, the Reelmaster can be towed for a short distance. However, Toro does not recommend this as a standard procedure.
OPERATING INSTRUCTIONS Follow operating guidelines presented in this manual and know how to operate the machine safely on all types of terrain. Use the slope gauge, page 39, to assist in determining slope angles of questionable areas. Hills (or slopes) over 15 degrees should be traversed or mowed up and down, not side to side and hills over 20 degrees should generally be avoided unless special safeguards, skills and conditions exist.
OPERATING INSTRUCTIONS BEFORE MOWING Inspect the area for debris and clear area if necessary. Determine the direction best to mow on the previous mowing direction. Always mow in an alternate pattern from the previous mowing, so that the grass blades will be less apt to lay down and therefore be difficult to gather between the reel blades and bedknife.
DAILY MAINTENANCE CHECKLIST Daily Maintenance: (duplicate this page for routine use) Check proper section of Operator's Manual for fluid specifications Daily Maintenance Check For Week Of _________________ Maintenance Check Item MON Safety Interlock Operation Brake Operation Engine Oil Level Cooling System Fluid Level TUES WED THURS FRI SAT SUN Drain Water/Fuel Separator Air Filter, Dust Cup & Burp Valve Radiator & Screen for Debris Unusual Engine Noises1 Unusual Op
MAINTENANCE SCHEDULE Minimum Recommended Maintenance Intervals Maintenance Procedure Inspect Air Filter, Dust Cup and Burp Valve Lube All Grease Fittings Change Engine Oil Check Engine Belt Tension Maintenance Interval & Service Every 50hrs Every 100hrs Every 200hrs Every 400hrs Change Engine Oil Filter Check Traction Belt Tension Service Air Filter Replace Fuel Filter/Water Separator Replace Hydraulic Filter Torque Wheel Lug Nuts Replace Hydraulic Fluid Check Battery Level/Connections Insp
SERVICE INTERVAL CHART LUBRICATION GREASING BEARINGS AND BUSHINGS Also, apply grease to slots in cylinder support (Fig. 46). (Fig. 39-46) The traction unit has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. If machine is operated under normal conditions, lubricate bearings and bushings after every 50 hours of operation. Bearings and bushings must be lubricated daily when operating conditions are extremely dusty and dirty.
LUBRICATION Figure 40 Figure 44 Figure 41 Figure 42 Figure 45 Figure 46 Figure 43 28
MAINTENANCE CAUTION 3 Before servicing or making adjustments to the machine, stop engine and remove key from the switch. 1 ÇÇÇ ÇÇÇ ÇÇÇ HOOD REMOVAL (Fig. 47) Hood may be easily removed to ease maintenance procedures in engine area of machine. 1. Unlatch and raise hood. 1 2. Remove cotter pin securing hood pivot to mounting brackets. Figure 48 1 1. Air cleaner latches 2. Dust cup 3. Filter 2. Gently slide filter out of air cleaner body to reduce the amount of dust dislodged.
MAINTENANCE CLEANING RADIATOR AND SCREEN (Fig. 49) CHANGING HYDRAULIC SYSTEM FLUID AND FILTER (Fig. 50-51) To prevent the system from overheating, radiator screen, radiator and oil cooler must be kept clean. Check the screen, radiator and oil cooler daily and, if necessary, clean any debris off these parts. Clean these components more frequently in dusty dirty conditions.
MAINTENANCE 6. Place all controls in neutral or disengaged position and start engine. Run engine at lowest possible RPM to purge the system of air. 7. Run engine until lift cylinders extend and retract and forward and reverse wheel motion is achieved. 8. Stop the engine and check the oil level in reservoir, add oil if necessary. 9. Check all connections for leaks. HYDRAULIC SYSTEM REPLACING FUEL FILTER (Fig. 54) Inspect fuel filter bowl, daily, for water or other contaminants.
MAINTENANCE ADJUSTING TRANSMISSION FOR NEUTRAL (Fig. 55) 4. After adjusting the pump plate, check neutral switch operation and if necessary, adjust as follows: If the machine creeps" when the traction control pedal is in the neutral position, the neutral return mechanism must be adjusted. 1. Block up under the frame so one of the front wheels is off the floor. Place selector control in two wheel drive position. 2.
MAINTENANCE ADJUST TRACTION PEDAL DAMPER (Fig. 58) 1 1. To expose traction pedal damper, remove right hand panel. 2. Loosen locknut securing damper pivot to damper bracket. 3. Depress traction pedal fully forward. Figure 57 1. Engine belt 2. Adjust belt to proper tension and tighten bolts. ADJUSTING TRACTION PEDAL (Fig. 58) If traction pedal contacts footrest when pushed fully forward or maximum forward traction speed is unattainable, an adjustment to the traction pedal linkage is required. 1.
MAINTENANCE BATTERY CARE BATTERY STORAGE 1. Battery electrolyte level must be properly maintained and the top of the battery kept clean. lf the machine is stored in a location where temperatures are extremely high, the battery will run down more rapidly than if the machine is stored in a location where temperatures are cool. If the machine will be stored more than 30 days, remove the battery and charge it fully. Either store it on the shelf on the machine.
BACKLAPPING DANGER TO AVOID PERSONAL INJURY OR DEATH: Never place hands or feet in reel area while engine is running. While backlapping, reels may stall and then restart. Do not attempt to restart reels by hand or foot. Do not adjust reels while engine is running. If reel stalls, stop engine before attempting to clear reel. 1. Position machine on a clean, level surface, lower the cutting units, stop the engine, engage parking brake and remove key from ignition switch. 2.
BROWN/WHITE ORANGE/WHITE ORANGE INDICATOR LIGHT CUTTING UNIT YELLOW GREEN CUTTING UNIT INTERLOCK SWITCH NORMALLY OPEN CLOSED WHEN CYLINDER IS RETRACTED BLACK CUTTING UNIT SOLENOID VALVE ORANGE/WHITE BLACK BLACK BLACK BLACK VOLTAGE REGULATOR/RECTIFIER BLUE GREEN BLACK ORANGE/WHITE ORANGE/WHITE BLACK BLACK AC AC ON OFF 85 86 TEMP SENDING UNIT TEMP GAUGE I G S + BLACK RED/BLACK RED/BLACK GREEN ORANGE ALTERNATOR WHITE/BLACK BLUE 30 87 ENGINE COOLANT BLACK HOUR METER PINK GR
LIFT CYL REAR INNER LIFT CYL FRONT B-UPPER REVERSE (FRONT LINE) OUTER A-LOWER WHEEL MOTOR LEFT 12 in3 [197cc] FORWARD (REAR LINE) 12 in3 [197cc] WHEEL MOTOR RIGHT T2 P1 CHARGE PUMP .42 IN3 [6.9CC] .49 in3 [8.0cc] REEL RELIEF 3000 psi R1 GEAR PUMP REEL ON-OFF VALVE S1 TOP FLOW CONTROL VALVE LC1 LOGIC VALVE FCI REEL SPEED CONTROLLER CHARGE RELIEF 100-150 psi TOW VALVE TRACTION PUMP 1.24 in3 [19.
LIFT CYL REAR INNER LIFT CYL FRONT B-UPPER REVERSE (FRONT LINE) OUTER A-LOWER 12 in3 [197cc] WHEEL MOTOR LEFT FORWARD (REAR LINE) 12 in3 [197cc] WHEEL MOTOR RIGHT T2 P1 CHARGE PUMP .42 IN3 [6.9CC] .49 in3 [8.
15 AND 20 SLOPE CHART Read all safety decals and safety instructions in this manual .
IDENTIFICATION AND ORDERING MODEL AND SERIAL NUMBER The mower has two identification numbers: a model number and a serial number. The two numbers are stamped into a plate that is riveted to the frame at rear of mower. In any correspondence concerning the mower, supply the model and serial numbers to assure that correct information and replacement parts are obtained. 40 Note: Do not order by reference number if a parts catalog is being used; use the part number.
I. CALIFORNIA EMISSION CONTROL SYSTEM WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Ishikawajima-Shibaura Machinery Co., Ltd. (ISM) are pleased to explain the emission control system warranty on your 1995 and later utility or lawn and garden equipment engine. In California, new utility and lawn and garden equipment engines must be designed, built and equipped to meet the State's stringent anti-smog standards.
2. WARRANTY PERIOD Any warranted part which is not scheduled for replacement as required maintenance in the written instructions of the Owner's Manual shall be warranted for the warranty period of two (2) years.
H.
The Toro Commercial Products Two Year Limited Warranty The Toro Company warrants your 1996 or newer Toro Commercial Product (Product") purchased after January 1, 1997, to be free from defects in materials or workmanship for the period of time listed below. Where a warrantable condition exists, Toro will repair the Product at no cost to you including diagnosis, labor, parts, and transportation. This warranty begins on the date the Product is delivered to the original retail purchaser.
