Toro 3200 User manual

FORM NO. 3325-594 Rev A
The TORO COMPANY - 2000
OPERATOR'S
MANUAL
REELMASTER3100-D
Traction Unit
MODEL NO. 03200-210000001 & UP
MODEL NO. 03201-210000001 & UP
MODEL NO. 03220
MODEL NO. 03221
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. Pay particular attention
to the SAFETY INSTRUCTIONS highlighted by this
symbol.
The safety alert symbol means CAUTION,
WARNING or DANGER - personal safety
instruction. Failure to comply with the instruction
may result in personal injury.
The Reelmaster 3100-D conforms to the American
National Standards Institute's safety standards for
Riding Mowers; thus, Toro proudly displays the
ANSI safety seal .

2
FOREWORD
The REELMASTER 3100 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. TORO also is concerned about future use of the machine and of the safety to
the user. Therefore, this manual should be read by you and those involved with the REELMASTER to ensure that
safety, proper set-up, operation and maintenance procedures are followed at all times. The major sections of the
manual are:
1. Safety Instructions 4. Operating Instructions
2. Set-up Instructions 5. Maintenance
3. Before Operating Instructions
Safety, mechanical and some general information in this manual is emphasized. DANGER, WARNING and
CAUTION identify safety messages. Whenever the triangular safety alert symbol appears, it is followed by a safety
message that must be read and understood. For more complete details concerning safety, read the safety
instructions on pages 4 and 5. IMPORTANT identifies special mechanical information and NOTE identifies general
information worthy of special attention.
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth defects,
or other reproductive harm.
This spark ignition system complies with Canadian ICES002.
Ce système d'allumage par étincelle de véhicule est conforme à la norme NMB002 du Canada.
Whenever you have questions or need service, contact your local authorized Toro Distributor. In addition to having a
complete line of accessories and professional turf care service technicians, the distributor has a complete line of
genuine TORO replacement parts to keep your machine operating properly. Keep your TORO all TORO. Buy
genuine TORO parts and accessories.

3
TABLE OF CONTENTS
Page Page
SAFETY INSTRUCTIONS 4-5. . . . . . . . . . . . . . . . . . .
SAFETY INSTRUCTIONS & DECALS 6. . . . . . . . . .
SPECIFICATIONS 7. . . . . . . . . . . . . . . . . . . . . . . . . . .
LOOSE PARTS CHART 8. . . . . . . . . . . . . . . . . . . . . . .
SETUP INSTRUCTIONS 9-15. . . . . . . . . . . . . . . . . .
Install Wheels 9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install Steering Wheel 9. . . . . . . . . . . . . . . . . . . .
Activate, Charge and Connect Battery 9. . . . . . .
Install Seat 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Angle Indicator 11. . . . . . . . . . . . . . . . . . . . .
Install Hood Latch 11. . . . . . . . . . . . . . . . . . . . . . . .
Install Exhaust Guard 11. . . . . . . . . . . . . . . . . . . . .
Install ROPS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install Front Lift Arms 12. . . . . . . . . . . . . . . . . . . . . .
Mount Carrier Frames To Cutting Units 13. . . . . .
Mount Cutting Units 13. . . . . . . . . . . . . . . . . . . . .
Mount Cutting Unit Drive Motors 14. . . . . . . . . . . .
Adjust Lift Arms 15. . . . . . . . . . . . . . . . . . . . . . . . . .
BEFORE OPERATING 16-18. . . . . . . . . . . . . . . . . . .
Check Crankcase Oil 16. . . . . . . . . . . . . . . . . . . . . .
Fill Fuel Tank 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Cooling System 16. . . . . . . . . . . . . . . . . . . .
Check Hydraulic System Fluid 17. . . . . . . . . . . . . .
Check Tire Pressure 18. . . . . . . . . . . . . . . . . . . . . .
Check Reel To Bedknife Contact 18. . . . . . . . . . . .
Check Torque Of Wheel Nuts 18. . . . . . . . . . . . . .
CONTROLS 19-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATING INSTRUCTIONS 21-24. . . . . . . . . . . . .
Starting/Stopping Engine 21. . . . . . . . . . . . . . . . . .
Bleeding Fuel System 21. . . . . . . . . . . . . . . . . . . . .
Check Operation of Interlock Switches 22. . . . . .
Towing Traction Unit 22. . . . . . . . . . . . . . . . . . . . . .
Operating Characteristics 22. . . . . . . . . . . . . . . . . .
Mowing Techniques 23. . . . . . . . . . . . . . . . . . . . . . .
After Mowing 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting Clip Rate (Reel Speed) 24. . . . . . . . . . .
DAILY MAINTENANCE CHECKLIST 25. . . . . . . . . . .
MAINTENANCE SCHEDULE 26. . . . . . . . . . . . . . . . . .
LUBRICATION 27-28. . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL MAINTENANCE 29. . . . . . . . . . . . . . . . . . .
Hood Removal 29. . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CLEANER MAINTENANCE 30. . . . . . . . . . . . . . .
General Air Cleaner Maintenance 30. . . . . . . . . . .
Servicing Air Cleaner 30. . . . . . . . . . . . . . . . . . . . . .
ENGINE MAINTENANCE 31-33. . . . . . . . . . . . . . . . .
Engine Oil and Filter 31. . . . . . . . . . . . . . . . . . . . . .
Fuel System 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bleeding Air From Injectors 32. . . . . . . . . . . . . . . .
Engine Cooling System 32. . . . . . . . . . . . . . . . . . .
Servicing Engine Belts 32. . . . . . . . . . . . . . . . . . . .
Adjusting Throttle 33. . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC MAINTENANCE 34-35. . . . . . . . . . . . .
Changing Hydraulic Fluid 34. . . . . . . . . . . . . . . . . .
Replacing Hydraulic Filter 34. . . . . . . . . . . . . . . . . .
Checking Hydraulic Lines and Hoses 34. . . . . . .
Adjusting Traction Drive For Neutral 35. . . . . . . . .
BRAKE MAINTENANCE 36. . . . . . . . . . . . . . . . . . . . . .
Parking Brake Adjustment 36. . . . . . . . . . . . . . . . .
ELECTRICAL MAINTENANCE 37. . . . . . . . . . . . . . . .
Battery Care 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Storage 37. . . . . . . . . . . . . . . . . . . . . . . . . .
Fuses 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BACKLAPPING 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SCHEMATIC 39. . . . . . . . . . . . . . . . . . .
HYDRAULIC SCHEMATIC 40. . . . . . . . . . . . . . . . . . . .
PREPARATION FOR SEASONAL STORAGE 41. . .
IDENTIFICATION AND ORDERING 42. . . . . . . . . . . .
NOTES 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY Back Cover. . . . . . . . . . . . . . . . . . . . . . . . .

4
SAFETY INSTRUCTIONS
The REELMASTER 3100-D was tested and certified
by TORO for compliance with the B71.41999
specifications of the American National Standards
Institute. Although hazard control and accident
prevention partially are dependent upon the design
and configuration of the machine, these factors are
also dependent upon the awareness, concern, and
proper training of the personnel involved in the
operation, transport, maintenance, and storage of the
machine. 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.
SUPERVISOR'S RESPONSIBILITIES
1. Make sure operators are thoroughly trained and
familiar with the Operator's Manual and all the labels on
the machine.
2. 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.
BEFORE OPERATING
3. Operate the machine only after reading and
understanding the contents of this manual and viewing
the Operator's Training Video supplied with the
machine. A free replacement manual is available by
sending complete model and serial number to:
The Toro Company
8111 Lyndale Ave. S.
Bloomington, MN 55420-1196.
4. Only trained operators, skilled in slope operation
and who have read this manual and viewed the
Operator's Training Video should operate the machine.
Never allow children to operate the machine or adults
to operate it without proper instructions.
5. Become familiar with the controls and know how to
stop the machine and engine quickly.
6. Do not carry passengers on the machine. Keep
everyone, especially children and pets, away from the
areas of operation.
7. Keep all shields, safety devices and decals in
place. lf a shield, safety device or decal is damaged,
malfunctioning or illegible, repair or replace it before
operating the machine.
8. Always wear substantial shoes. Do not operate
machine while wearing sandals, tennis shoes or
sneakers. Do not wear loose fitting clothing because it
could get caught in moving parts and possibly cause
personal injury.
9. Wearing safety glasses, safety shoes, long pants
and a helmet is advisable and required by some local
ordinances and insurance regulations.
10. Make sure the work area is clear of objects which
might be picked up and thrown by the reels.
11. Fill fuel tank with diesel fuel before starting engine.
Avoid spilling any fuel. Since fuel is highly flammable,
handle it carefully.
A. Use an approved fuel container.
B. Do not remove cap from fuel tank when engine
is hot or running.
C. Do not smoke while handling diesel fuel.
D. Fill fuel tank outdoors and not over one inch
from the top of the tank, (bottom of the filler neck).
Do not overfill.
WHILE OPERATING
12. Always wear your seat belt.
13. Do not run the engine in a confined area without
adequate ventilation. Exhaust fumes are hazardous
and could be deadly.
14. Sit on the seat when starting and operating the
machine.
15. Check interlock switches daily for proper operation
(Refer To Checking Interlock Switches, Page 19). Do
not rely entirely on safety switches shut off engine
before getting off seat. If a switch fails, replace it before
operating the machine. The interlock system is for your
protection, so do not bypass it. Replace all interlock
switches every two years.
16. Operator must be skilled and trained in how to
drive on hillsides. Failure to use caution on slopes or
hills may cause vehicle to tip or roll, possibly resulting
in personal injury or death.
17. This triplex mower has a unique drive system for
superior traction on hills. The uphill wheel will not spin
out and limit traction like conventional triplexes. If
operated on a side hill that is too steep, rollover will
occur before losing traction.
18. Before backing up, look to the rear and assure no
one is behind the machine. Watch out for traffic when
near or crossing roads. Always yield the right of way.
19. Keep hands, feet and clothing away from moving
parts and the reel discharge area. Grass baskets, if so
equipped, must be in place during reel operation for
maximum safety.

5
SAFETY INSTRUCTIONS
20. The slope angle at which the machine will tip is
dependent on many factors. Among these are mowing
conditions such as wet or undulating turf, speed
(especially in turns), position of the cutting units (with
sidewinder), tire pressure and operator experience. At
side hill slope angles of 20 degrees or less the risk of a
rollover is low. As the slope angle increases to a Toro
recommended maximum limit of 25 degrees the risk of
a rollover increases to a moderate level. DO NOT
EXCEED A 25 DEGREE SIDE HILL ANGLE
BECAUSE THE RISK OF A ROLLOVER AND
SERIOUS INJURY OR DEATH IS VERY HIGH. 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.
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.
21. When starting the engine:
A. Engage parking brake.
B. Be sure traction pedal is in neutral and reel
drive is in disengage position.
C. After engine starts, release parking brake and
keep foot off traction pedal. Machine must not
move. If movement is evident, the neutral control
linkage is incorrectly adjusted: therefore, shut
engine off and adjust until machine does not move
when traction pedal is released. Refer to Adjusting
Transmission for Neutral.
22. This product may exceed noise levels of 85 dB(A)
at the operator position. Ear protectors are
recommended for prolonged exposure to reduce the
potential of permanent hearing damage.
23. Raise the cutting units when driving from one work
area to another.
24. 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.
25. If a cutting unit strikes a solid object or vibrates
abnormally, stop immediately. Turn engine off, wait for
all motion to stop and inspect for damage. A damaged
reel or bedknife must be repaired or replaced before
operation is continued.
26. Before getting off the seat:
A. Move traction pedal to neutral.
B. Set the parking brake.
C. Disengage the cutting units and wait for the
reels to stop spinning.
D. Stop the engine and remove key from the
ignition switch.
27. Whenever machine is left unattended, make sure
reels are not spinning, key is removed from ignition
switch and parking brake is set.
MAINTENANCE
28. Before servicing or making adjustments to the
machine, stop the engine and remove key from switch
to prevent accidental starting of the engine.
29. Check performance of all interlock switches daily.
Do not defeat interlock system. It is for your protection.
30. To ensure entire machine is in good operating
condition, frequently check and keep all nuts, bolts,
screws and hydraulic fittings tight.
31. Make sure all hydraulic line connectors are tight,
and all hydraulic hoses and lines are in good condition
before applying pressure to the system.
32. Keep body and hands away from pin hole leaks or
nozzles that eject hydraulic fluid under high pressure.
Use paper or cardboard, not hands, to search for
leaks. Hydraulic fluid escaping under pressure can
have sufficient force to penetrate skin and do serious
damage. lf fluid is injected into the skin it must be
surgically removed within a few hours by a doctor
familiar with this form of injury or gangrene may result.
33. 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.
34. If major repairs are ever needed or if assistance is
desired, contact an Authorized Toro Distributor.
35. To reduce potential fire hazard, keep the engine
area free of excessive grease, grass, leaves and
accumulation of dirt.
36. If the engine must be running to perform a
maintenance adjustment, keep hands, feet, clothing,
and any other parts of the body away from the cutting
units and any moving parts. Keep everyone away.
37. Do not overspeed the engine by changing
governor settings. To assure safety and accuracy, have
an Authorized Toro Distributor check maximum engine
speed with a tachometer.
38. Engine must be shut off before checking oil or
adding oil to the crankcase.
39. To insure optimum performance and safety, use
genuine TORO replacement parts and accessories.
Replacement parts and accessories made by other
manufacturers could be dangerous, and such use
could void the product warranty of The Toro Company.

6
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 CONSOLE PANEL
(Part No. 99-3443, Model 03200)
(Part No. 99-3493, Model 03201)
(Add Part No. 99-3558 for CE)
ON SCISSORS LINKAGE
(Part No. 94-3353)
Model 03201 only
ON TOOL BOX COVER
(Part No. 99-3496)
(Part No. 99-3560 for CE)
Warning! Pinch Point
ON INSIDE OF TOOL BOX COVER
(Part No. 99-3494)
ON FAN SHROUD
(Part No. 93-6681)
ON ANGLE INDICATOR
(Part No. 100-4837)
(Part No. 100-4933 for CE)

7
SPECIFICATIONS
Engine: Kubota three cylinder, 4 cycle liquid cooled
diesel engine. 21.5 hp @ 2500 rpm 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: Radiator capacity is approximately
6 qts. of 50/50 mixture of ethylene glycol anti-freeze.
Remote mounted 1 qt. expansion tank.
Electrical: 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.
Fuel Capacity: 7.5 gallons.
Traction Drive: High torque hydraulic wheel motors.
3-wheel drive. Oil cooler and shuttle valve provide
positive closed-loop cooling.
Hydraulic Oil Capacity/Filter: Remote mounted, 3.5
gallon oil reservoir. 10 micron remote mounted spin on
filter.
Ground Speed: 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
Tires/Wheels: 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.
Frame: Tricycle vehicle with 3-wheel traction drive
and rear wheel steering. Frame consists of formed
steel, welded steel and steel tubing components.
Steering: Power steering.
Brakes: 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.
Controls: Foot operated forward and reverse traction
pedals and Mow/Transport slide. Hand operated
throttle, ignition switch, reel engagement switch, reel
unit lift and shift lever, parking brake and seat
adjustment.
Note: Shift lever only on Model 03201.
Gauges and Protective Systems: Hour meter. 4 light
warning cluster gauge: oil pressure, water
temperature, amps, glow plug and side hill angle
indicator.
Seat: Optional standard or deluxe seats.
Cutting Unit Lift: Hydraulic lift with automatic reel shut
off.
Optional Equipment:
Standard Seat Model 03224
Deluxe Suspension Seat Model 03225

8
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.
PART DESCRIPTION QTY. USE
Wheel Assembly 3 Mount to wheel hubs
Steering Wheel 1
Jam Nut 1 Mount to steering shaft
Cover 1
Screw 1
Hood Lock Bracket 1
Screw - 1/4-20 x 1-1/2" lg. 1 Mount to hood for European Compliance
Flat Washer - 1/4" 1
Lock Nut - 1/4-20 1
Exhaust Guard 1 Mount to machine for European Compliance
Self Tapping Screw 4
ROPS 1
Flange Head Capscrew 4 Mount to frame
Flange Nut 4
Hose Clamp 1 Secure vent hose to vent tube of ROPS
Lift Arms 2
Pivot Rod 2 Install pivot rods to lift arms
Capscrews5/16- 18 x 7/8"Lg. 2 (supplied with Lift Arm kit)
Thrust Washers 2 Mount cutting units to lift arms
Lynch Pin 2 (supplied with Lift Arm kit)
Key 2
Inclinometer 1 Use for site survey before operating machine
EEC Decal 4 Affix to machine for European Compliance
EEC Certificate 2
Operators Manual 2 Read before operating machine
Parts Catalog 1
Operator Video 1 View before operating machine
Engine Manual 1
Pre-Delivery Check List 1 Fill out before delivery to customer
Registration Card 1 Fill out and send to the Toro Co
Specifications and design subject to change without notice.

9
SET-UP INSTRUCTIONS
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 (Fig. 1)
1. Slide steering wheel onto steering shaft.
1. Steering Wheel
2. Jam Nut
3. Cap
Figure 1
1
2
3
2. Secure steering wheel to shaft with jam nut and
tighten it to 35 ftlb.
3. Install cap to steering wheel with screw.
ACTIVATE, CHARGE AND CONNECT
BATTERY (Fig. 2 & 3)
1. Open hood.
2. Remove battery cover.
Figure 2
1. Battery cover
1
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.
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.
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.
CAUTION
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 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 result in personal injury and/or
damage to the electrical system.
Figure 3
1. Positive (+) battery cable
2. Negative () battery cable
21

10
SET-UP INSTRUCTIONS
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.
5. 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.
6. Install battery cover.
INSTALL SEAT (Fig. 4 - 7)
The Reelmaster 3100 is shipped without the seat
assembly. Deluxe Seat Kit, Model 03225 or Standard
Seat Kit, Model 03224, must be installed as follows:
1. Remove capscrews securing seat mounting
straps to traction unit frame (Fig. 4).
Figure 4
1. Seat mounting strap (2)
1
2. Secure seat mounting straps to seat adjusters with
(4) flange nuts (standard seat) or (4) capscrews, flat
washers and flange nuts (deluxe seat). Mounting
fasteners supplied with seat kit loose parts.
Figure 5
1. Standard seat 2. Seat adjusters 3. Seat belt
1
2
3
3. Install seat belt to holes on each side of seat with
(2) bolts and lockwashers (standard seat) or (2) bolts
and locknuts (deluxe seat). All mounting fasteners
supplied with seat kit loose parts.
4. Position seat and seat straps on frame aligning
mounting holes.
5. Route seat switch wire under right hand seat strap
and connect to appropriate seat switch connector on
harness.
6. On deluxe seat only, route unused seat switch
connector back under seat strap and secure both
wires to rear most hole in seat strap (Fig. 6) with a cable
tie (cable tie supplied with seat kit).
Figure 6
1. Seat switch wire
2. Cable tie
12
7. On standard seat only, slide seat all the way
forward, pull wire to the right so unused connector is
positioned as shown in figure 7 and secure seat switch
wire to rear most hole in seat strap with a cable tie
(cable tie supplied with seat kit).
Figure 7
1. Seat switch wire
2. Cable tie
12
8. Mount seat straps to frame with fasteners
previously removed.
9. Slide seat completely forward and backward to
ensure proper operation and that seat switch wires and
connectors are not pinched or do no contact any
moving parts.

11
SET-UP INSTRUCTIONS
CHECK ANGLE INDICATOR (Fig. 8)
DANGER
To reduce risk of injury or death due to rollover
do not operate on side hills steeper than 25.
Figure 8
1
1
1. Angle indicator
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.
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 (Fig. 9)
(European Compliance)
1. Unhook hood latch from bracket.
2. Slide hood lock bracket onto latch.
Figure 9
1. Hood latch
2. Hood latch bracket
3. Hood lock bracket
1
2
3
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.
INSTALL EXHAUST GUARD (Fig. 10)
(European Compliance)
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.
Figure 10
1. Exhaust guard
1
INSTALL ROPS (Fig. 11)
IMPORTANT: Never weld or modify ROPS. Replace a
damaged ROPS, do not repair or revise. Any alteration
of ROPS must be approved by manufacturer.
3. Lower ROPS frame onto traction unit mounting
brackets, aligning mounting holes. Vent tube, secured
to ROPS, must be positioned on left side of machine.

12
SET-UP INSTRUCTIONS
4. Secure each side of roll bar to mounting brackets
with (2) flange head capscrews and locknuts (Fig. 11).
Torque fasteners to 60 ft-lbs.
5. Secure fuel line vent hose to vent tube on ROPS
with hose clamp.
Fuel line vent hose must be connected to
vent tube prior to starting engine or fuel will
flow from hose.
CAUTION
Figure 11
1. ROPS
2. Mounting bracket
3. Vent tube
4. Fuel line vent tube hose
5. Hose clamp
2
3
1
5
2
4
INSTALL FRONT LIFT ARMS (Fig. 12 - 26)
1. Remove (2) capscrews securing lift arm pivot shaft
link to lift arm pivot shafts. Remove and retain pivot
shaft link and capscrews (Fig. 12).
Figure 12
1. Lift arm pivot shaft link
2. Lift arm pivot shaft
1
2
2. Insert a pivot rod into each (R.H. & L.H.) lift arm and
align mounting holes (Fig. 13).
Figure 13
1
2
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.
5. Remove rear retaining rings securing mounting
pins to each end of lift cylinder.
Figure 14
1. Lift arm (R.H.)
2. Lift arm (L.H.)
3. Retaining ring
1
2
3
5
4
4
4. Mounting pin
5. Lift cylinder
6. Spacer (2)
6
6. Secure right end of lift cylinder to right lift arm with
pin and (2) spacers. Secure with retaining ring.

13
SET-UP INSTRUCTIONS
Figure 15
1. Lift cylinder
2. Hoses
3. Clearance here
1
2
3
7. Secure left end of lift cylinder to left lift arm with pin.
Secure with retaining ring.
Note: With lift arms fully raised, hoses should be
routed as shown in figure 15 and clear lift arm by
.04-.12".
MOUNT CARRIER FRAMES TO CUTTING
UNITS (Fig. 16 - 18)
1. Remove cutting units from cartons. Adjust per
Cutting Unit Operator's Manual.
2. Position a front carrier frame (Fig. 16) onto each
front cutting unit. Align mounting holes with mounting
links as shown in figure 18.
Figure 16
1. Front carrier frame
1
3. Position rear carrier frame (Fig. 17) onto rear
cutting unit, aligning mounting holes with mounting
links as shown in figure 18.
Figure 17
1
1. Rear carrier frame
4. 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 18. Position a washer on
each side of link when mounting. Torque to 31 ft-lb.
Figure 18
1. Carrier frame
2. Mounting link
3. Plug
1
2
3
FRONT
MOUNT CUTTING UNITS (Fig. 19-21)
1. Slide a thrust washer onto each front lift arm pivot
rod.
2. Slide cutting unit carrier frame onto pivot rod and
secure with a lynch pin (Fig. 19).
Note: On rear cutting unit, thrust washer to be
positioned between rear of carrier frame and lynch pin.

14
SET-UP INSTRUCTIONS
Figure 19
1. Thrust washer
2. Carrier frame
3. Lynch pin
1
3
2
3. Grease all lift arm and carrier frame pivot points.
IMPORTANT: Make sure hoses are free of twists or
sharp bends and rear cutting unit hoses are routed
as shown in Fig. 20. Raise cutting units and shift
them to the left (Model 03201 only). Rear cutting
unit hoses must not contact traction cable bracket.
Re-position fittings and / or hoses, if required.
4. Route a tipper chain up thru slot in end of each
carrier frame. Secure tipper chain to top of carrier
frame with a capscrew, washer and locknut (Fig. 21).
Figure 20
Figure 21
1. Tipper chain
1
MOUNT CUTTING UNIT DRIVE MOTORS
(Fig. 22 & 23)
1. Position cutting units in front of lift arm pivot rods.
2. Remove weights and gasket (Fig. 22) from inside
end of right hand cutting unit. Remove plug from
bearing housing on outside end of right hand cutting
unit and install weights and gasket. Locate spider
coupling (Fig. 23) shipped in bearing housing.
Figure 22
1. Weights
2. Gasket
1
2
3. Remove shipping plug from bearing housings on
remaining cutting units (Fig. 18).
4. Insert O-ring (supplied with cutting unit) on flange
of drive motor.
Figure 23
1. Spider coupling 2. Reel motor 3. O-ring
1
2
3
5. Mount the motor and the spider coupling to the
drive end of the cutting unit and secure with two
capscrews provided with cutting unit.

15
SET-UP INSTRUCTIONS
ADJUST LIFT ARMS (Fig. 24 - 28)
1. Start engine, raise lift arms and check to make sure
clearance between each lift arm and floor plate bracket
is .18" - .32" (Fig. 24). If clearance is not in this range,
back off stop bolts (Fig. 26) and adjust cylinder to attain
clearance. To adjust cylinder, back off the jam nut on
the cylinder (Fig. 25), remove pin from rod end and
rotate clevis. Install pin and check clearance. Repeat
procedure if required. Tighten clevis jam nut.
Figure 24
1. Lift arm 2. Floor plate bracket 3. Clearance
1
2
3
2. Check to make sure clearance between each lift
arm and stop bolt is .005" - .040" (Fig. 26). If clearance
is not in this range, adjust stop bolts to attain
clearance.
3. Start engine, raise lift arms and check to make sure
clearance between wear strap on top of rear cutting
unit wear bar and bumper strap is .020" - .100"
(Fig. 27). If clearance is not in this range, adjust rear
cylinder to attain clearance. To adjust cylinder, lower
the cutting units and back off the jam nut on the
cylinder (Fig. 28). Grasp cylinder rod close to the nut
with a pliers and rag and rotate the rod. Raise the
cutting units and check clearance. Repeat procedure if
required. Tighten clevis jam nut.
Figure 25
1. Front cylinder
2. Jam nut
1
2
Figure 26
1. Stop bolt
2. Lift arm
3. Clearance
1
2
3
Note: If rear lift arm clunks" during transport,
clearance can be reduced.
Figure 27
1. Wear bar
2. Bumper strap
1
2
Figure 28
1. Rear cylinder
2. Adjusting nut
12
IMPORTANT: Lack of clearance at front stops or
rear wear bar could damage lift arms.

16
BEFORE OPERATING
CAUTION
Before servicing or making adjustments
to the machine, stop engine and remove
key from the switch.
CHECK CRANKCASE OIL (Fig. 29-30)
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 4 qts. (2.8 l) with
filter.
1. Position machine on a level surface.
2. Remove dipstick and wipe it with a clean rag. Push
dipstick down into dipstick tube and make sure it is
seated fully. Pull dipstick out and check level of oil. If oil
level is low, add enough oil to raise level to FULL mark
on dipstick.
Figure 29
1
1. Dipstick
Figure 30
1. Oil fill cap
1
3. If oil level is low, remove oil fill cap and gradually
add small quantities of oil, checking level frequently,
until level reaches FULL mark on dipstick.
4. The engine uses any high-quality 10W30
detergent oil having the American Petroleum Institute
- API - service classification" CD, CE, CF CF-4 or
CG-4.
5. Install oil fill cap and close hood.
IMPORTANT: Check level of oil every 5 operating
hours or daily. Change oil after every 50 hours of
operation.
FILL FUEL TANK (Fig. 31)
The engine runs on No. 2 diesel fuel.
Fuel tank capacity is approximately 7.5 gallons.
1. Clean area around fuel tank cap.
Figure 31
1. Fuel tank cap
1
2. Remove fuel tank cap.
Because diesel fuel is flammable, use
caution when storing or handling it. Do
not smoke while filling the fuel tank. Do
not fill fuel tank while engine is running,
hot, or when machine is in an enclosed
area. Always fill fuel tank outside and
wipe up any spilled diesel fuel before
starting the engine. Store fuel in a clean,
safety-approved container and keep cap
in place. Use diesel fuel for the engine
only; not for any other purpose.
DANGER
3. Fill tank to bottom of filler neck. DO NOT
OVERFILL. Then install cap.
4. Wipe up any fuel that may have spilled to prevent a
fire hazard.
CHECK COOLING SYSTEM (Fig. 32 & 33)
Clean debris off radiator and oil cooler daily (Fig. 32),
hourly if conditions are extremely dusty and dirty; refer
to Cleaning Radiator.
1. The cooling system is filled with a 50/50 solution of
water and permanent ethylene glycol anti-freeze.
Check level of coolant at beginning of each day before
starting the engine. Capacity of cooling system is
approximately 6 quarts.

17
BEFORE OPERATING
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.
Figure 32
1. Access panel
2. Radiator
3. Oil cooler
1
3
2
2. Check level of coolant in expansion tank. With a
cold engine, coolant level should be midway (approx)
between the marks on side of tank.
Figure 33
1. Expansion tank
1
3. If coolant level is low, remove expansion tank cap
and replenish the system. DO NOT OVERFILL.
4. Install expansion tank cap.
CHECK HYDRAULIC SYSTEM FLUID
(Fig. 34)
The hydraulic system driving the reels is designed to
operate on anti-wear hydraulic fluid. The machines
reservoir is filled at the factory with approximately 3.5
gallons of DTE 15M hydraulic fluid. Check level of
hydraulic fluid before engine is first started and
daily thereafter.
IMPORTANT: Use only types of hydraulic fluids
specified. Other fluids could cause system
damage.
Group 1 Hydraulic Fluid (Moderate climate-
average duty)
Note: The fluids within this group are interchangeable.
ISO VG 46/68 multiviscosity antiwear
hydraulic fluid
Mobil DTE 15M
Amoco Rykon Premium ISO 46
Castrol AWH 46
Conoco Hydroclear AW MV46
Gulf Harmony HVI 46 AW
Kendall Hyken Golden MV SAE 5W20
Pennzbell AWX MV46
Phillips Magnus A KV 5W20
Shell Tellus T 46
Sunoco Sun Hyd. Oil 2105
Texaco Rando HDZ 46
Universal Tractor Hydraulic Fluid
Mobil Mobilfluid 424
Amoco 1000 Fluid
Chevron Tractor Hydraulic Fluid
Conoco Hydroclear Powertran
Esso Hydraul
Gulf Universal Tractor Fluid
Kendall Hyken 052
Marathon Marafluid Super HT
Pennzoil Hydratrans
Phillips HG Fluid
Shell Donax TD
76 Lubricants Hydraulic/Tractor Fluid
Sunoco TH Fluid
Texaco TDH
Group 2 Hydraulic Fluid (Hot Climate- Heavy Duty)
Note: The fluids within this group are interchangeable.
ISO VG 68 antiwear hydraulic fluid
Mobil DTE 26
Amoco Rykon AW No. 68
Castrol AWS 68
Chevron Hydraulic Oil AW ISO 68
Conoco Hydroclear AW 68
Exxon Nuto H 68
Gulf Harmony 68AW
Kendall Four Seasons AW 68
Marathon ISO 68
Pennzbell AW Hydraulic Oil 68
Phillips Magnus A ISO 68
Shell Tellus 68
76 Lubricants AW 68
Sunoco SunVis 868
Texaco Rando HD 68

18
BEFORE OPERATING
IMPORTANT: Group 1 fluids are recommended for use
at typical ambient temperatures of 32F (0C) to 105F
(41C). The ISO Type 46/68 fluid has been found to
offer optimal performance in a wide range of
temperature conditions for the average user. The
Universal Tractor Fluids offer similar performance for
those who prefer them, with perhaps some slight loss
of efficiency at high ambient temperatures compared
to the Type 46/68 fluids.
Group 2 fluids are recommended for heavyduty use in
hot climates where ambient temperatures range from
about 70F (20C) to 120F (49C). Use at lower
ambient temperatures may result in hard starting,
increased engine laboring while cold, sluggish or
nonoperating spool valves while cold and high filter
backpressure due to the higher viscosity of these
fluids.
Note: When changing from one type of hydraulic fluid
to another, be certain to remove all the old fluid from the
system, as some fluids are incompatible with others.
Group 3 Hydraulic Fluid (Biodegradable)
ISO VG 32/46 antiwear hydraulic fluid
Mobil EAL 224H
Note: This biodegradable hydraulic fluid is not
compatible with the fluids in Group 1 and 2.
Note: When changing from standard fluid to the
biodegradable type, be certain to follow approved
flushing procedures as published by Mobil. Contact
your local Toro Distributor for details.
IMPORTANT: Use only types of hydraulic fluids
specified. Other fluids could cause system
damage.
Note: A red dye additive for the hydraulic system fluid
is available in 2/3 oz. bottles. One bottle is sufficient for
4-6 gal. of hydraulic fluid. Order Part No. 44-2500
from your Authorized Toro Distributor.
Figure 34
1. Hydraulic Tank Cap
1
1. Position machine on a level surface, lower the
cutting units and stop the engine.
2. Clean area around filler neck and cap of hydraulic
tank. Remove cap from filler neck.
3. Remove dipstick from filler neck and wipe it with a
clean rag. Insert dipstick into filler neck; then remove it
and check level of fluid. Fluid level should be within 1/4
inch of mark on dipstick.
4. If level is low, add appropriate fluid to raise level to
full mark.
5. Install dipstick and cap onto filler neck.
CHECK TIRE PRESSURE
The tires are over-inflated for shipping. Therefore,
release some of the air to reduce the pressure. Correct
air pressure in tires is 14 -18 psi.
IMPORTANT: Maintain recommended pressure in all
tires to assure a good quality-of-cut and proper
machine performance.
DANGER
Low tire pressure decreases the machine's
sidehill stability. Do not under inflate tires. This
could cause a rollover, which may result in per
sonal injury or death.
CHECK REEL TO BEDKNIFE CONTACT
Each day before operating, check reel to bedknife
contact, regardless if quality of cut had previously been
acceptable. There must be light contact across the full
length of the reel and bedknife (refer to Adjusting Reel
to Bedknife in Cutting Unit Operator's Manual).
CHECK TORQUE OF WHEEL NUTS
WARNING
Torque wheel nuts to 4565 ft-lb after 14
hours of operation and again after 10 hours of
operation and every 200 hours thereafter.
Failure to maintain proper torque could result
in failure or loss of wheel and may result in
personal injury.

19
CONTROLS
Traction Pedals (Fig. 35)  Depress traction forward
pedal to move forward. Depress traction reverse 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.
Mow/Transport Slide (Fig. 35) - Using your heel,
move slide to the left to transport and to the right to
mow. The cutting units will only operate in the mow
position.
Note: Mow speed is set at the factory to 6 mph. It can
be increased or decreased by adjusting the speed
stop screw (Fig. 36)
1. Forward traction pedal
2. Reverse traction pedal
3. Mow/Transport slide
4. Tilt steering lever
5. Indicator slot
6. Angle indicator
Figure 35
1
2
4
3
5
6
1. Speed Stop Screw
Figure 36
1
Tilt Steering Lever (Fig. 35) - Pull lever back to
loosen to tilt the steering wheel to desired position.
Then push lever forward to tighten.
Angle Indicator (Fig. 35) - Indicates sidehill angle of
the machine in degrees.
Starter Switch (Fig. 37)  The starter switch, used to
start, stop and preheat the engine, has three positions:
OFF, ON/PREHEAT and START. Rotate key to
ON/PREHEAT position until glow plug indicator light
goes out (approximately 7 seconds), then rotate key to
START position to engage starter motor. Release key
when engine starts. The key will move automatically to
the ON/RUN position. To shut engine off, rotate key to
OFF position. Remove key from switch to prevent
accidental starting.
Throttle (Fig. 37)  Moving throttle forward increases
engine speed, rearward decreases engine speed.
Cutting Unit Shift Lever (Fig. 37) - To lower cutting
units to the ground, move lift lever forward. Cutting
units will not drop unless engine is running and will not
operate in raised position. To raise cutting units, pull lift
lever rearward to the RAISE position.
Model 03201 only- Move lever to the right or left to
move cutting units in same direction. This should only
be done when cutting units are raised or if they're on
the ground and the machine is moving.
DANGER
The machine is most stable on a side hill when
the cutting units are shifted uphill. Shifting cut
ting units downhill decreases machine stabil
ity. This could cause a rollover, which may re
sult in personal injury or death.
Note: Lever does not have to be held in forward
position while cutting units are lowered.
Indicator Slot (Fig. 35) - The slot in the operator's
platform indicates when the cutting units are in the
center position.
Cutting Unit Drive Switch (Fig. 37)  The switch has
two positions: ENGAGE and DlSENGAGE. Rocker
switch operates a solenoid valve, on valve bank, to
drive cutting units.
Figure 37
1. Throttle
2. Hour meter
3. Temperature light
4. Oil pressure light
5. Glow plug indicator light
6. Alternator light
7
81
3
4
5
6
2
9
10
7. Cutting unit drive switch
8. Cutting unit shift lever
9. Ignition switch
10. Parking brake
11. Lift lever lock
11
Hour Meter (Fig. 37)  Indicates the total hours of
machine operation. The Hour Meter starts to function
whenever the key switch is ON.

20
CONTROLS
Engine Coolant Temperature Warning Light
(Fig. 37)  Light glows if engine coolant temperature
is high. If traction unit is not stopped and coolant
temperature rises another 10F., the engine will kill.
Oil Pressure Warning Light (Fig. 37)  Light glows if
engine oil pressure drops below a safe level.
Alternator Light (Fig. 37)  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. 37)  Indicator light will
glow when glow plugs are operating.
Parking Brake (Fig. 37)  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 up on lever. Engine will stop if
traction pedal is depressed with parking brake
engaged.
Lift Lever Lock (Fig. 37)  Move lever rearward to
prevent cutting units from dropping.
Reel Speed Control - (Fig. 38)  (Located under
console cover) - To obtain the desired clip rate (reel
speed), rotate reel speed control knob to appropriate
setting for height-of-cut setting and mower speed.
Refer to Selecting Clip Rate section of Manual.
Backlap Control - (Fig. 38)  (Located under
console cover) - Rotate knob clockwise for
backlapping and counterclockwise for mowing. Do
not change knob position when reels are rotating.
Figure 38
1. Reel speed control
2. Backlap control
21
Fuel Gauge (Fig. 39)  Registers amount of fuel in
tank.
Seat Adjustments (Fig. 39)
Fore and Aft Adjustment  Move lever on side of seat
outward, slide seat to desired position and release
lever to lock seat into position.
Deluxe Seat Adjustments
Weight Adjustment  Push lever up or down to adjust
to operator's weight. Lever up  light operator, lever in
middle position  medium weight operator or lever
down for heavy operator.
Inclining Backrest  Turn handle to adjust angle of
backrest.
Figure 39
1. Fore and aft lever
2. Fuel gauge
21