Form No. 3363-235 Rev B Reelmaster® 2000 Traction Unit Model No. 03431—Serial No. 310000001 and Up To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com.
injury or death if you do not follow the recommended precautions. 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. Figure 1 1. Safety alert symbol This manual uses 2 other words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention.
Contents Premaintenance Procedures.................................... 37 Removing the Hood ........................................... 38 Lubrication............................................................. 38 Greasing the Bearings and Bushings.................... 38 Engine Maintenance............................................... 40 Servicing the Air Cleaner .................................... 40 Changing the Engine Oil and Filter ..................... 40 Fuel System Maintenance ...................
Safety ◊ Lack of awareness of the effect of ground conditions, especially slopes ◊ 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, ISO standard 5395:1990, and ANSI B71.4-2004 specifications in effect at time of production, when equipped with rear weight. Refer to the section in this manual on Installing Rear Weight.
• • • • • • • • • – 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. – 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.
• Use jack stands to support components when required. • Carefully release pressure from components with stored energy. • Disconnect battery 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.
• To ensure safety and accuracy, have an Authorized Toro Distributor check the maximum engine speed with a tachometer. Maximum governed engine speed should be 3200 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 was determined according to the procedures outlined in EN 836.
98-4387 106-8120 1. Warning—wear hearing protection. 1. Thrown object hazard—keep bystanders a safe distance from the machine. 2. Cutting hazard of hand and foot—stay away from moving parts. Battery Symbols Some or all of these symbols are on your battery 106-5976 1. Engine coolant under pressure 2. Explosion hazard—read the Operator’s Manual. 3. Warning—do not touch the hot surface. 4. Warning—read the Operator’s Manual. 1. Explosion hazard 2. No fire, open flame, or smoking. 3.
104-3991 9
4-3994 (Affix over decal part no. 104–3991 for CE) 1. Read the Operator’s Manual. 2. Warning—read the Operator’s Manual, do not use starting fluid. 3. Raise and lower the reels. 4. Lower the reels. 5. Neutral 9. Push off 6. Raise the reels. 10. Engine—stop 7. Power take-off (PTO) 8. Pull on 11. Engine—run 12. Engine—start 104-4096 10 13. Fast 14.
5–3037 11
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 10 11 Use Qty. Wheel assembly Lug nut 1 4 Install the rear wheel. Rear carrier frame 1 Adjust the rear carrier frame height.
Description Use Qty. Operator’s Manual Engine Operator’s Manual 1 1 Read before operating the machine. Operator training material 1 View before operating the machine. Parts Catalog 1 View and order parts. Certificate of compliance 1 CE certification Note: Determine the left and right sides of the machine from the normal operating position.
• If the distance is correct, remove the carrier frame and proceed with the setup instructions. • 1 If the distance is not 1/4 inch (6 mm), adjust the lift cylinder as follows: 2 A. Remove the clevis pin securing the rod end of the lift cylinder to the lift arm (Figure 3). B. Loosen the hex nut securing the clevis to the cylinder rod. C. Rotate the clevis end in or out until you attain 1/4 inch (6 mm) clearance. Check the adjustment and repeat steps 2 through 3 as required. 3 1. Carrier frame 2.
8. Secure the other end of the lift chain to the hole in the lift arm mounting tab with clevis pins and cotter pins. Use the appropriate hole in the lift arm as designated in Figure 7. 1 1 2 2 G009853 Figure 5 G009855 Figure 7 2. Pivot rod 1. Lift arm 1. 27 inch cutting unit (inner hole) 2. Secure the pivot rod to the lift arm with a bolt (5/16 x 7/8 inch) and lock washer. 3. Loosen the top bolt securing the left counterbalance arm to the frame (Figure 6). 9.
3 2 2 3 1 1 G009856 Figure 8 1. Spider coupling 2. Reel motor 3. O-ring G009857 Figure 9 1. Thrust washer 3. Insert the O-ring (supplied with the cutting unit) on the flange of the drive motor (Figure 8). 2. Carrier frame 4. Mount the motor and the spider coupling to the drive end of the cutting unit and secure them with 2 bolts provided with the cutting unit (Figure 8). 2. Slide the cutting unit carrier frame onto the pivot rod and secure it with a flat washer and flange-head bolt (Figure 9).
Note: Selecting the #4 hole position (increasing the spring tension) will reduce the weight on the inboard end of the cutting unit, increase the weight on the outboard end of the cutting unit, and increase traction. Selecting the #2 hole position has the opposite affect.
Installing the Counterbalance Springs on 32 Inch Cutting Units 1. Mount a spring anchor to the rear inboard side of each front cutting unit lift tab with 2 bolts (1/4 x 3/4 inch) and locknuts, as shown in Figure 14. 2 Figure 12 1. Counterbalance arm 2. Top bolt 3. Bottom bolt 1 4. Spring shackle 5. Clevis pin and cotter pin G009862 Figure 14 1. Cutting unit lift tab 2. Spring anchor 2.
B. Move the shackle up or down on the counterbalance arm until it is aligned with the desired hole on the arm. Install the clevis pin and cotter pin. 8 Adding Rear Ballast Figure 15 1. Counterbalance arm 2. Top bolt 3. Bottom bolt 4. Spring shackle 5. Clevis pin and cotter pin 6. Chain, clevis, and clevis pin Parts needed for this procedure: Varies Rear weight kit(s) Procedure This unit complies with ANSl B71.4–2004 Standards and all applicable European requirements when equipped with rear ballast.
solution is slush free to -12°F (-24°C) and will freeze solid at -52°F (-46°C). The 5 lb. (2.3 kg) per gallon (liter) solution is slush free to -50° F (-45°C) and will freeze solid at -62°F (-52°C). Charging the battery produces gasses that can explode. Never smoke near the battery and keep sparks and flames away from battery. 9 3. When the battery is charged, disconnect the charger from the electrical outlet and battery posts. Activating and Charging the Battery 4. Remove the filler caps.
Product Overview 10 Controls Installing CE Compliant Decals Traction and Stopping Pedal Parts needed for this procedure: 1 Decal 104–3994 1 Decal 106–8119 The traction pedal (Figure 17) has three functions: to make the machine move forward, to move it backward, and to stop the machine. Using the heel and toe of the right foot, press the top of the pedal to move forward and the bottom of the pedal to move backward or to assist in stopping when moving forward (Figure 18).
Cutting Unit Lift Lever Lock (Figure 17) is set at the factory to provide 3 MPH maximum speed in reverse. The cutting unit lift lever lock (Figure 19) locks cutting units in the raised position for transporting. Starter Switch Cutting Unit Drive Switch The starter switch (Figure 19), used to start, stop, and preheat the engine, has three positions: Off, On, and Start. Rotate the key clockwise to the On position and hold it until the glow plug light goes out.
Glow Plug Indicator The indicator light (Figure 20) will glow when glow plugs are operating. Reel Engage Indicator The reel engage indicator light (Figure 20) will glow when reels are lowered to cutting position. Parking Brake Whenever the engine is shut off, engage the parking brake to prevent accidental movement of the machine. To engage the parking brake, pull back on the lever. Reel Speed Control Figure 22 1.
Operation Note: Determine the left and right sides of the machine from the normal operating position. If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Figure 23 Lower the cutting units to the ground, set the parking brake, and remove the key from the ignition switch before servicing or making adjustments to the machine. 1. Dipstick 3. Remove the dipstick and check the oil level on the dipstick.
Fuel is harmful or fatal if swallowed. Long-term exposure to vapors can cause serious injury and illness. • Avoid prolonged breathing of vapors. • Keep face away from nozzle and fuel tank or conditioner opening. • Keep fuel away from eyes and skin. Biodiesel Ready This machine can also use a biodiesel blended fuel of up to B20 (20% biodiesel, 80% petrodiesel). The petrodiesel portion should be low or ultra low sulfur. Observe the following precautions: Figure 25 1.
Note: If possible, fill the fuel tank after each use. This will minimize possible buildup of condensation inside the fuel tank. 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. 1. Park the machine on a level surface. • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any fuel that spills. 3. Remove the cap from the fuel tank (Figure 26). 2.
3. If the coolant level is low, replenish the system. Do not overfill. 4. Install the radiator and expansion tank caps. If the engine has been running, the pressurized, hot coolant can escape and cause burns. Checking the Hydraulic Fluid • Do not open the radiator cap when the engine is running. Service Interval: Before each use or daily • Use a rag when opening the radiator cap, and open the cap slowly to allow steam to escape. The hydraulic reservoir is filled at the factory with approximately 3.
Note: The tires are over-inflated for shipping. Therefore, release some of the air to reduce the pressure before using the machine for the first time. by mineral-based hydraulic fluids will change the biodegradability and toxicity of this oil. When changing from standard fluid to the biodegradable type, be certain to follow the approved flushing procedure. Contact your local Toro Distributor for details. Checking the Reel to Bedknife Contact 1.
Note: Normally, the engine should start after the above bleeding procedures are followed. However, if the engine does not start, air may be trapped between injection pump and injectors; refer to Bleeding Air from the Injectors. 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.
Towing the Traction Unit Checking the Operation of the Interlock Switches In case of an emergency, the machine can be towed for a short distance. However, we do not recommend this as a standard procedure. Service Interval: Before each use or daily Important: Do not tow the machine faster than 2 to 3 MPH because the drive system may become damaged. If the machine must be moved a considerable distance, transport it on a truck or trailer. 1.
units. Adjust the speed selector to maintain constant ground speed and quality of cut. However, when on hilly terrain, do not use the speed selector. 1 Follow the operating guidelines presented in this manual and know how to operate the machine safely on all types of terrain. 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.
and use extreme caution before turning to reduce the risk of tipping or losing control. Watch carefully for and avoid holes in the terrain, sudden drop-offs, and other hidden hazards. To prevent costly damage and down time, familiarize yourself with the width of the machine. Do not attempt to pass between immovable objects placed close together. Variable Reel Speed Selection Chart—8 Blade Reel Height of Cut (inches) 3WD Speeds 3–5 MPH 2WD Speeds 6–7 MPH 2-1/2 (2.50) 3* 3 2-3/8 (2.
LED inspection and conventional device and wire harness integrity testing. Measure disconnected component impedance, impedance through wire harness (disconnect at SCM), or by temporarily ”test energizing” the specific component. The SCM does not connect to an external computer or hand held device, can not be re–programmed, and does not record intermittent fault troubleshooting data. The decal on the SCM only includes symbols. Three LED output symbols are shown in the output box. All other LED’s are inputs.
Function Start Run (off unit) Run (on unit) Mow Backlap Hi-Temp Power On – – – – – – Inputs In Neutral Start On Brake Off PTO On – – O O – + O O O O O O O – – O O O O – – In Seat Hi Temp Backlap Start – O O O O O – O O O O – + O – – O Note: - Indicates a circuit closed to ground. - LED ON O Indicates a circuit open to ground or de-energized - LED OFF + Indicates an energized circuit (clutch coil, solenoid, or start input) LED ON.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval After the first hour Maintenance Procedure • Torque the wheel lug nuts to 45 to 65 ft-lb (61 to 88 N-m). After the first 5 hours • Change the hydraulic oil filter. After the first 8 hours • Check the condition and tension of the alternator belt. • Check the condition and tension of the hydraulic pump belt.
Daily Maintenance Checklist Duplicate this page for routine use. Maintenance Check Item For the week of: Mon. Tues. Wed. Thurs. Fri. Sat. Check the safety interlock operation. Check the brake operation. Check the engine oil level. Check the cooling system fluid level. Drain the water/fuel separator. Check the air filter, dust cup, and burp valve. Check the oil cooler, radiator and screen for debris. Check for unusual engine noises.1 Check for unusual operating noises.
Service Interval Chart Figure 35 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.
Lubrication Removing the Hood Remove the hood to ease maintenance procedures in the engine area of the machine, as follows: Greasing the Bearings and Bushings 1. Unlatch and raise the hood. 2. Remove the cotter pin securing the hood pivot to the mounting brackets (Figure 36). Service Interval: Every 50 hours (Grease immediately after every washing regardless of the interval listed.) Lubricate all grease fittings for the bearings and bushings with No. 2 General Purpose Lithium Base Grease.
• Lift arms (3) (Figure 39) • Traction pedal pivot (Figure 42) Figure 42 Figure 39 • Neutral centering (Figure 43) • Rear lift cylinder pivot (Figure 40) Figure 43 Figure 40 • Pivot rods (3) (Figure 41) Figure 41 39
Engine Maintenance Cleaning of the used element is not recommended due to the possibility of damage to the filter media. 5. Inspect the new filter for shipping damage, checking the sealing end of the filter and the body. Do not use a damaged element. Servicing the Air Cleaner Service Interval: Every 200 hours (Service it more frequently in extremely dirty or dusty conditions.) 6. Insert the new filter by applying pressure to the outer rim of the element to seat it in the canister.
Fuel System Maintenance 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. • Use a funnel and fill the fuel tank outdoors, in an open area, when the engine is off and is cold. Wipe up any fuel that spills. Figure 46 1. Oil filter • Do not fill the fuel tank completely full. Add fuel to the fuel tank until the level is 1/4 to 1/2 inch (6 to 13 mm) below the bottom of the filler neck.
2 1 3 G009880 Figure 47 1. Fuel filter/water separator canister 2. Vent plug 3. Drain valve Figure 48 1. Fuel injectors 3. Close and tighten the drain valve. 2. Slowly move the throttle to the full Fast position. Replacing the Fuel Filter Canister 3. Turn the key in the key switch to the Start position and watch the fuel flow around the connector. When you observe a solid flow of fuel, turn the key to the Off position. Service Interval: Every 400 hours 4. Tighten the pipe connector securely. 1.
Electrical System Maintenance high, the battery will run down more rapidly than if the machine is stored in a location where temperatures are cool. Important: Before welding on the machine, disconnect both cables from the battery, both wire harness plugs from the electronic control module, and the terminal connector from the alternator to prevent damage to the electrical system. Check the electrolyte level every 25 operating hours or, if machine is in storage, every 30 days.
Drive System Maintenance Adjusting the Traction Drive for Neutral If the machine moves when the traction pedal is in the neutral position, the traction cam must be adjusted. 1. Park the machine on a level surface and turn the engine off. 2. Raise one front wheel off of the floor and place support blocks under the frame. Figure 49 1. Fuse block If the machine is not supported adequately, it may accidentally fall, injuring anyone under the machine. 3.
7. Remove the support blocks and lower the machine to the shop floor. Test drive the machine to make sure it does not move when the traction pedal is in neutral. Cooling System Maintenance 8. After adjusting the pump plate, check the neutral switch operation and adjust, if necessary. Removing Debris from the Cooling System Adjusting the Neutral Switch Service Interval: Before each use or daily—Remove debris from the screen, oil coolers, and radiator.
Brake Maintenance Adjusting the Parking Brake 1. Remove both front wheels. 2. Make sure that the brake is in the Off position. 3. Loosen the jam nut on the clevis (Figure 55). Figure 54 1. Radiator 2. Oil cooler 3. Thoroughly clean the oil cooler (Figure 54) and remove any other debris that may have collected around the components. 4. Install the screen. Figure 55 1. Upper brake lever 2. Clevis 4. Remove the cotter pin securing the top of the clevis to the upper brake lever. 5.
Belt Maintenance Tighten the nut on the adjustment rod (Figure 57) until the desired belt tension is attained. Make sure the belts are properly tensioned to ensure proper operation of the machine and prevent unnecessary wear. On new belts, check the tension after 8 hours operation. Note: Tighten the belt to eliminate slippage (squealing under load) but do not overtighten.
Controls System Maintenance 1 Adjusting the Traction Pedal If the traction pedal contacts the footrest when it is pushed fully forward or maximum forward traction speed is unattainable, adjust the traction pedal linkage. 3 2 G009903 Figure 59 1. To expose the traction rod, remove the right panel. 1. Damper 2. Damper pivot 2. Loosen the jam nuts on each end of the traction rod barrel (Figure 58). 3. Damper bracket 3. Press the traction pedal fully forward. 4.
Hydraulic System Maintenance Changing the Hydraulic Fluid Service Interval: After the first 5 hours—Change the hydraulic oil filter. Every 200 hours—Change the hydraulic oil filter. Every 400 hours/Yearly (whichever comes first)—Change the hydraulic fluid. Use a genuine Toro oil filter for replacement. Refer to Checking the Hydraulic Fluid Level for replacement hydraulic fluid specifications. Figure 61 1. Hydraulic oil filter 1.
Hydraulic System Test Ports Cutting Unit System Maintenance The test ports are used to test pressure in the hydraulic circuits. Contact your local Toro distributor for assistance. Backlapping the Cutting Units • Use Test Port #1 (Figure 62) to measure forward traction pressure. While backlapping, the reels may stall and then restart. Placing your hands or feet in the reel area while backlapping will result in injury or death. • Never place hands or feet in the reel area while the engine is running.
Storage 4. Make the initial reel to bedknife adjustments appropriate for backlapping on all cutting units. Start the engine and set the engine to low idle speed. Preparing the Traction Unit 5. Engage the reels by pulling out the knob on the instrument panel. 1. Thoroughly clean the traction unit, cutting units, and engine. 2. Check the tire pressure. Inflate all traction unit tires to 16 to 20 psi (110 to 138 kPa). 3. Check all fasteners for looseness and tighten them as necessary. 4.
3. Refill the oil pan with designated quantity of motor oil. 4. Start the engine and run it at idle speed for approximately two minutes. 5. Stop the engine. 6. Thoroughly drain all fuel from the fuel tank, lines, and the fuel filter/water separator assembly. 7. Flush the fuel tank with fresh, clean diesel fuel. 8. Secure all fuel system fittings. 9. Thoroughly clean and service the air cleaner assembly. 10. Seal the air cleaner inlet and the exhaust outlet with weatherproof tape. 11.
Schematics G009907 Electrical Schematic (Rev.
G009977 Hydraulic Schematic (Rev.
G009978 Hydraulic Schematic, with 3-Wheel Drive Kit Installed (Rev.
Toro General Commercial Products 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).
