Form No. 3353–117 Reelmaster) 2000-D Traction Unit Model No.
Warning Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting and Stopping the Engine . . . . . . . . . . . . . . Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . Checking the Operation of the Interlock Switches Towing the Traction Unit . . . . . . . . . . . . . . . . . . . . Operating Characteristics . . . . . . . . . . . . . . . . . . . . Selecting the Clip Rate (Reel Speed) . . .
Introduction 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. 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.
Preparation – stay alert for humps and hollows and other hidden hazards; • While mowing, always wear substantial footwear, long trousers, hard hat, safety glasses, and ear protection. Long hair, loose clothing, or jewelry may get tangled in moving parts. Do not operate the equipment when barefoot or wearing open sandals. – 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.
• Carefully release pressure from components with stored energy. • 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. • 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. • Keep hands and feet away from the cutting units.
• 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. – Do not drive close to sand traps, ditches, creeks, or other hazards. – Reduce speed when making sharp turns. Avoid sudden stops and starts. • If major repairs are ever needed or if assistance is desired, contact an Authorized Toro Distributor. – When near or crossing roads, always yield the right-of-way.
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. 93-7267 1. Lock parking brake 93-6696 2. Unlock parking brake 1. Warning—spring loaded mechanism. Read the operator’s manual. 67-5360 94-5056 1. Slow reel speed 2. Fast reel speed 3. Reel height 4. 5 Blade cutting unit 5. 8 Blade cutting unit 93-6668 1. The battery contains lead. Do not dispose of in the garbage.
93-7276 1. 2. 3. 4. 106-5976 Explosion hazard—wear eye protection. Caustic liquid hazard—flush skin with water. Fire hazard—sparks, flame, and smoking prohibited. Poison—keep children away from the battery. 1. Engine coolant under pressure 2. Explosion hazard—read the Operator’s Manual. 106-8109 8 3. Warning—do not touch the hot surface. 4. Warning—read the Operator’s Manual.
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. 4. 5. 6. Raise and lower the reels. Lower the reels. Neutral Raise the reels. 7. 8. 9. 10. 10 Power take-off (PTO) Pull on Push off Engine—stop 11. 12. 13. 14.
Specifications Note: Specifications and design subject to change without notice. General Specifications Configuration Engine Tricycle vehicle with 2-wheel traction drive and rear wheel steering. Briggs & Stratton–Daihatsu, 4-cycle, 3-cylinder, liquid cooled, vertical OHV, diesel engine with centrifugal water pump. 18.4 hp (13.7 kW); governed to a maximum speed of 3200 RPM. 51.9 cu. in. (850 cc) displacement. Forced lubrication gear pump. Mechanical centrifugal governor. Mechanical fuel transfer pump.
Measurements Wheel tread width Wheel base Width Optional Equipment 54-1/2 in. (138 cm) 55 in. (140 cm) 76-1/2 in. (194 cm) Transport width with 27″ cutting units 72 in. (183 cm) with 32″ cutting units 85 in. (216 cm) Length 96 in. (244 cm) Height w/o seat 44 in. (112 cm) Weight Traction Unit without cutting units 1066 lb. (484 kg) Model 03210—27″ 5 blade cutting unit 136 lb. (62 kg) Model 03211—27″ 8 blade cutting unit 143 lb. (65 kg) Model 03214—27″ 11 blade cutting unit 149 lb.
Setup Note: Determine the left and right sides of the machine from the normal operating position. Loose Parts Note: Use this chart as a checklist to ensure that all parts necessary for assembly have been received. Without these parts, total setup cannot be completed. Some parts may have already been assembled at the factory. Description Qty. Use Wheel assembly 1 Lug nut 4 Seat stop bracket 1 Capscrew 5/16 x 1 in.
Description Qty. Instrument panel decal 1 Parts catalog 1 Certificate of compliance 1 Operator video 1 Operator’s manual 2 Engine operator’s manual 1 Use Affix to instrument panel for European compliance. View before operating the machine. Read before operating the machine. Installing the Rear Wheel 1. Mount the wheel assembly onto the rear wheel hub (Fig. 1). 1 2 2 3 Figure 1 1. Wheel assembly 2. Rear wheel hub 3. Lug nut 3 1 2. Install the lug nuts (Fig.
7. Using capscrew and nut removed and a 5/16 x 1” capscrew and nut supplied in loose parts, secure the seat stop and water separator to under side of skirt with (2) capscrews and locknuts. Position stop as shown in figure 3. 3 1 3 2 1 4 Figure 4 1. Rear carrier frame 2. Pivot rod 2 4. If an adjustment to the lift cylinder is required, proceed as follows: Figure 3 1. Seat stop 3. Up stop 4. Lift cylinder A. Remove the clevis pin securing the rod end of the lift cylinder to the lift arm (Fig. 4). 2.
1 7 1 2 6 2 3 8 4 3 5 Figure 5 1. Carrier frame 2. Mounting link 3. Bearing housing cover Figure 7 1. 2. 3. 4. Installing the Front Lift Arms 1. Insert a pivot rod into the left lift arm and align the mounting holes (Fig. 6). 2. Secure the pivot rod to the lift arm with a capscrew (5/16 x 7/8 in.) and lock washer. Counterbalance arm Top capscrew Bottom capscrew Lift arm pivot pin 5. 6. 7. 8. Tipper chain Lift chain Cylinder pin Lift arm tab 4.
Mounting the Cutting Unit Drive Motors 2 1. Position the cutting units in front of the pivot rods. 2. Remove the bearing housing cover (Fig. 5) from the inside end of the right-hand cutting unit. Install the cover and gasket (supplied with the cutting unit) on the outside end. Locate the spider coupling (Fig. 9) shipped in the bearing housing. 3 3. Insert the O-ring (supplied with the cutting unit) on the flange of the drive motor (Fig. 9). 1 4.
Note: 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. Decreasing the spring tension has the opposite affect. The counterbalance springs help balance the cutting units to allow equal amounts of weight (down pressure) to be distributed to each end of the cutting unit. The springs also transfer weight from the cutting units to the traction unit therefore, increasing traction.
32” Cutting Units 4 1 1. Mount a spring anchor to the rear inboard side of each front cutting unit lift tab with 2 capscrews (1/4 x 3/4 in.) and locknuts, as shown in Figure 15. 2 2 5 3 1 Figure 16 1. 2. 3. 4. 5. Clevis pin and cotter pin 6. Chain, clevis, and clevis pin 6. On the rear counterbalance arms, install the vinyl cover over the spring before hooking the other end of the spring into the spring shackle in the second hole from the top (Fig. 17). Figure 15 1.
Adding Rear Ballast Activating and Charging the Battery This unit complies with ANSl B71.4–1999 Standard and all applicable European requirements when equipped with rear ballast. Use the following chart to determine the weight or combinations of weights needed.
Important Do not overfill the battery. Electrolyte will overflow onto other parts of the machine and severe corrosion and deterioration will result. 5. Install the positive cable (red) to the positive (+) terminal and the negative cable (black) to the negative (—) terminal of the battery (Fig. 18) and secure them with capscrews and nuts. Slide the rubber boot over the positive terminal to prevent a possible short from occurring.
Before Operating Caution 1 If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Before servicing or making adjustments to the machine, stop the engine and remove the key from the ignition switch. Checking the Crankcase Oil Figure 20 1. Filler cap The engine is shipped with oil in the crankcase; however, the oil level must be checked before and after the engine is first started.
Filling the Fuel Tank Checking the Cooling System The engine runs on No. 2 diesel fuel. The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol anti-freeze. Check the coolant level at the beginning of each day before starting the engine. The cooling system capacity is approximately 5-1/4 quarts. The fuel tank capacity is approximately 6.5 gallons. Danger 1. Clean debris off of the radiator screen (Fig. 23), radiator (Fig. 24) and oil cooler (Fig.
Checking the Hydraulic System Caution The machines reservoir is filled at the factory with approximately 3.3 gallons (12.5 l) of high quality hydraulic fluid. Check the level of the hydraulic fluid before the engine is first started and daily thereafter. The recommended replacement fluid is: 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.
Note: When changing from one type of hydraulic fluid to the other, be certain to remove all the old fluid from the system, because some brands of one type are not completely compatible with some brands of the other type of hydraulic fluid. Checking the Tire Pressure 1. Position the machine on a level surface. Important Maintain the recommended pressure in all tires to ensure a good quality-of-cut and proper machine performance. Do not under-inflate. The tires are over-inflated for shipping.
Operation The reverse pedal stop (under the pedal) (Fig. 28) is set at the factory to provide 3 MPH maximum speed in reverse. Note: Determine the left and right sides of the machine from the normal operating position. Starter Switch The starter switch (Fig. 30), used to start, stop, and preheat the engine, has three positions: OFF, ON, and START. Rotate the key clockwise to ON position and hold until glow plug light goes out. Then rotate the key clockwise (START position) to engage the starter motor.
Cutting Unit Drive Switch Reel Engage Indicator The switch (Fig. 30) has two positions: ENGAGE and DlSENGAGE. The push-pull switch operates a solenoid valve on the valve bank, to drive the cutting units. The reel engage indicator light (Fig. 31) will glow when reels are lowered to cutting position. Parking Brake Hour Meter Whenever the engine is shut off, the parking brake must be engaged to prevent accidental movement of the machine. To engage the parking brake, pull back on the lever.
Turn the steering wheel to the left and right to check the steering response. Then shut the engine off and check for oil leaks, loose parts, and any other noticeable malfunctions. Caution Shut the engine off and wait for all moving parts to stop before checking for oil leaks, loose parts, and other malfunctions. 1 6. To stop the engine, move the throttle control downward to the IDLE position, move the reel drive switch to DISENGAGE, and rotate the ignition key to OFF. Remove the key from the switch.
3. With the engine running, the operator off of the seat, and the backlap knob rotated clockwise, the engine should not stop when the reel switch is turned ON. Correct the problem if it is not operating properly. Danger 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. 4.
2. Before starting the engine, close the bypass valve by rotating it 90° (the bypass valve lever should be vertical when closed). Do not start the engine when the valve is open. Adjust the clip rate (reel speed) as follows: 1. Verify the height-of-cut setting on the cutting units. Using the column of the chart listing either 5 or 8 blade reels, find the height of cut listing nearest the actual height-of-cut setting. Look across the chart to find the number corresponding to that height of cut.
Variable Reel Speed Selection Chart—5 Blade Reel Height of Cut (in.) Variable Reel Speed Selection Chart—8 Blade Reel 3WD 2WD Speeds Speeds 3–5 MPH 6–7 MPH Height of Cut (in.) 3WD 2WD Speeds Speeds 3–5 MPH 6–7 MPH 2-1/2 (2.50) 3 5 2-1/2 (2.50) 3* 3 2-3/8 (2.38) 3 5 2-3/8 (2.38) 3* 3 2-1/4 (2.25) 4 5 2-1/4 (2.25) 3* 3 2-1/8 (2.13) 4 5 2-1/8 (2.13) 3* 3 2 (2.00) 4 6 2 (2.00) 3* 3 1-7/8 (1.88) 4 6 1-7/8 (1.88) 3 4 1-3/4 (1.75) 5 7 1-3/4 (1.75) 3 4 1-5/8 (1.
Training Period Inspection and Clean-Up After Mowing Before mowing with the machine, we suggest that you find a clear area and practice starting and stopping, raising and lowering cutting units, turning, etc. This training period will be beneficial to the operator in gaining confidence in the performance of the machine.
Standard Control Module (SCM) Output circuits are energized by an appropriate set of input conditions. The three outputs include PTO, ETR, and START. Output LED’s monitor relay condition indicating the presence of voltage at one of three specific output terminals. The Standard Control Module is a ”potted” electronic device produced in a ”one size fits all” configuration.
Each row (across) in the logic chart below identifies input and output requirements for each specific product function. Product functions are listed in the left column. Symbols identify specific circuit condition including: energized to voltage, closed to ground, and open to ground. – 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 Maintenance Service Interval Maintenance Procedure Check the engine belt tension. Change the engine oil filter. Check the traction belt tension. Replace the hydraulic filter. Torque the wheel lug nuts. After first 10 hours • • • • • After first 50 hours • Change the engine oil and filter. • Check the engine RPM (idle and full throttle).
Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Maintenance Check Item Mon. Tues. Wed. Thurs. 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. Check the hydraulic system oil level.
Service Interval Chart 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 and disconnect the wire from the spark plug before you do any maintenance. Set the wire aside so that it does not accidentally contact the spark plug.
Greasing the Bearings and Bushings The traction unit has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. If the machine is operated under normal conditions, lubricate bearings and bushings after every 50 hours of operation. Bearings and bushings must be lubricated daily when operating conditions are extremely dusty and dirty. Dusty and dirty operating conditions could cause dirt to get into the bearings and bushings, resulting in accelerated wear.
General Air Cleaner Maintenance • Check the air cleaner body for damage which could cause an air leak. Replace if damaged. Check the whole intake system for leaks, damage or loose hose clamps. • Service the air cleaner filter every 200 hours or earlier if engine performance suffers due to extremely dusty, dirty conditions. Changing the air filter before it is necessary only increases the chance of dirt entering the engine when the filter is removed.
1. Park the machine on a level surface, lower the cutting units, set the parking brake, and turn the engine off. new filter by applying pressure to the outer rim of the element to seat it in the canister. Do not apply pressure to the flexible center of the filter. 2. Remove drain plug and let oil flow into drain pan. When oil stops, install drain plug. 4. Clean the dirt ejection port located in the removable cover.
Hydraulic System Test Ports 1 The test ports are used to test pressure in the hydraulic circuits. Contact your local Toro distributor for assistance. Test Port #1 (Fig. 51) is used to forward traction pressure. Test Port #2 (Fig. 51) is used to measure reverse traction pressure. 2 Figure 49 1. Reservoir plug 1 2. Reservoir outlet 3. Clean the area around the hydraulic oil filter (Fig. 50). Remove the filter from the bottom of the filter housing and allow the oil to flow into a drain pan.
1. Clean area around filter canister mounting surface. 5. Repeat steps 1-4 on No. 2 and 3 nozzles. 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. 2 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. 1 Figure 53 1. Drain plug Warning 2.
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. 8. After adjusting the pump plate, check the neutral switch operation and adjust, if necessary. 1 Adjusting Neutral Switch Whenever the pump plate is adjusted, check the neutral switch (Fig. 56) operation and, if necessary, adjust it as follows: Figure 57 1. Adjustment rod 1. Park the machine on a level surface and turn the engine off. 2.
2. Loosen the jam nuts on each end of the traction rod barrel (Fig. 59). 4. Fully compress the damper and then release it, allowing it to extend 0.08 in. Tighten the locknut securing the adjustment. 3. Rotate the rod barrel until the required pedal clearance or traction speed is attained. 5. When the traction pedal is fully depressed in the rearward direction, the damper must contact the reverse stop before extending the damper. 4. Tighten the jam nuts securing the adjustment. 5.
Storing the Battery Check the electrolyte level every 25 operating hours or, if machine is in storage, every 30 days. If the machine will be stored more than 30 days, remove the battery and charge it fully. Either store it on the shelf or on the machine. Leave the cables disconnected if it is stored on the machine. Store the battery in a cool atmosphere to avoid quick deterioration of the charge in the battery. To prevent the battery from freezing, make sure it is fully charged.
Backlapping Caution Danger Contact with the reel or other moving parts can result in personal injury. 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. 7. To make an adjustment to the cutting units while backlapping, turn the reels OFF by pushing in on the knob on the instrument panel and turning the engine OFF. After adjustments have been completed, repeat steps 4–6.
Electrical Schematic 47
Hydraulic Schematic 48
The 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.
