Toro 3206 User manual

FormNo.3361-268RevB
Reelmaster®3100-D
TractionUnit
ModelNo.03206—SerialNo.290000001andUp
ModelNo.03207—SerialNo.290000001andUp
ModelNo.03220
ModelNo.03221
ToregisteryourproductordownloadanOperator'sManualorPartsCatalogatnocharge,gotowww.Toro.com.OriginalInstructions(EN)

Introduction
Readthisinformationcarefullytolearnhowtooperate
andmaintainyourproductproperlyandtoavoidinjury
andproductdamage.Youareresponsibleforoperating
theproductproperlyandsafely.
YoumaycontactTorodirectlyatwww .Toro.comfor
productandaccessoryinformation,helpndinga
dealer,ortoregisteryourproduct.
Wheneveryouneedservice,genuineToroparts,or
additionalinformation,contactanAuthorizedService
DealerorToroCustomerServiceandhavethemodel
andserialnumbersofyourproductready.Figure1
identiesthelocationofthemodelandserialnumbers
ontheproduct.Writethenumbersinthespace
provided.
Figure1
1.Modelandserialnumberlocation
ModelNo.
SerialNo.
Thismanualidentiespotentialhazardsandhas
safetymessagesidentiedbythesafetyalertsymbol
(Figure2),whichsignalsahazardthatmaycauseserious
injuryordeathifyoudonotfollowtherecommended
precautions.
Figure2
1.Safetyalertsymbol
Thismanualuses2otherwordstohighlightinformation.
Importantcallsattentiontospecialmechanical
informationandNoteemphasizesgeneralinformation
worthyofspecialattention.
Warning
CALIFORNIA
Proposition65Warning
Dieselengineexhaustandsomeofits
constituentsareknowntotheStateof
Californiatocausecancer,birthdefects,
andotherreproductiveharm.
Important:Thisengineisnotequippedwitha
sparkarrestermufer.ItisaviolationofCalifornia
PublicResourceCodeSection4442touseoroperate
theengineonanyforest-covered,brush-covered,or
grass-coveredland.Otherstatesorfederalareas
mayhavesimilarlaws.
Contents
Introduction.................................................................2
Safety...........................................................................3
SafeOperatingPractices.......................................3
ToroMowerSafety...............................................5
SoundPowerLevel...............................................7
SoundPressureLevel...........................................7
VibrationLevel.....................................................7
SafetyandInstructionalDecals.............................8
Setup..........................................................................12
1InstallingtheWheels........................................13
2InstallingtheSteeringWheel............................13
3Activating,Charging,andConnectingthe
Battery...........................................................14
4CheckingtheAngleIndicator...........................15
5InstallingtheHoodLatch(CEOnly)................15
6InstallingtheExhaustGuard(CE
Only)..............................................................16
7InstallingtheRollBar.......................................16
8InstallingtheFrontLiftArms...........................17
9InstallingtheCarrierFramestotheCutting
Units..............................................................18
10MountingtheCuttingUnits............................19
11MountingtheCuttingUnitDrive
Motors...........................................................20
12AdjustingtheLiftArms.................................20
ProductOverview......................................................22
Controls.............................................................22
Specications.....................................................25
Attachments/Accessories...................................25
Operation...................................................................25
CheckingtheEngineOilLevel............................25
FillingtheFuelTank...........................................26
CheckingtheCoolingSystem..............................27
CheckingtheHydraulicSystem...........................28
©2009—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN554202
Contactusatwww.Toro.com.
PrintedintheUSA
AllRightsReserved

CheckingtheTirePressure.................................28
CheckingtheReel-to-BedknifeContact...............29
TorquingtheWheelNuts....................................29
StartingandStoppingtheEngine........................29
BleedingtheFuelSystem....................................29
CheckingtheInterlockSystem............................30
TowingtheTractionUnit....................................30
StandardControlModule(SCM)........................31
OperatingTips...................................................33
Maintenance...............................................................36
RecommendedMaintenanceSchedule(s)................36
DailyMaintenanceChecklist...............................37
ServiceIntervalChart.........................................38
PremaintenanceProcedures....................................38
RemovingtheHood...........................................38
Lubrication.............................................................39
GreasingtheBearingsAndBushings...................39
SealedBearings...................................................41
EngineMaintenance...............................................42
ServicingtheAirCleaner....................................42
ChangingtheEngineOilandFilter.....................42
FuelSystemMaintenance.......................................43
ServicingtheFuelTank......................................43
InspectingtheFuelLinesand
Connections...................................................43
DrainingtheWaterSeparator..............................43
ChangingtheFuelFilterCanister........................44
BleedingAirfromtheInjectors...........................44
ElectricalSystemMaintenance................................45
CaringfortheBattery.........................................45
StoringtheBattery..............................................46
Fuses..................................................................46
DriveSystemMaintenance.....................................46
AdjustingtheTractionDriveforNeutral.............46
CoolingSystemMaintenance..................................47
CleaningtheEngineCoolingSystem...................47
BrakeMaintenance.................................................48
AdjustingtheParkingBrake................................48
BeltMaintenance....................................................48
ServicingtheEngineBelts..................................48
ControlsSystemMaintenance.................................49
AdjustingtheThrottle........................................49
HydraulicSystemMaintenance...............................50
ChangingtheHydraulicFluid.............................50
ChangingtheHydraulicFilter.............................50
CheckingtheHydraulicLinesandHoses.............51
MiscellaneousMaintenance....................................51
BacklappingtheCuttingSystem..........................51
Storage.......................................................................52
PreparationforSeasonalStorage.........................52
Schematics.................................................................54
Safety
ThismachinemeetsorexceedsCENstandardEN
836:1997(whenappropriatedecalsapplied),and
ANSIB71.4-2004specicationsineffectatthetime
ofproductionwhenequippedwithrequiredweights
aslistedintheweightchart.
Improperuseormaintenancebytheoperator
orownercanresultininjury.Toreducethe
potentialforinjury,complywiththesesafety
instructionsandalwayspayattentiontothesafety
alertsymbol,whichmeansCaution,Warning,or
Danger—personalsafetyinstruction.Failureto
complywiththeinstructionmayresultinpersonal
injuryordeath.
SafeOperatingPractices
ThefollowinginstructionsarefromtheCENstandard
EN836:1997,ISOstandard5395:1990,andANSI
B71.4-2004.
Training
•ReadtheOperator’sManualandothertrainingmaterial
carefully.Befamiliarwiththecontrols,safetysigns,
andtheproperuseoftheequipment.
•Iftheoperatorormechaniccannotreadthelanguage
ofthismanual,itistheowner’sresponsibilityto
explainthismaterialtothem.
•Neverallowchildrenorpeopleunfamiliarwiththese
instructionstouseorservicethemower.Local
regulationsmayrestricttheageoftheoperator.
•Nevermowwhilepeople,especiallychildren,orpets
arenearby.
•Keepinmindthattheoperatororuserisresponsible
foraccidentsorhazardsoccurringtootherpeopleor
theirproperty.
•Donotcarrypassengers.
•Alldriversandmechanicsshouldseekandobtain
professionalandpracticalinstruction.Theowneris
responsiblefortrainingtheusers.Suchinstruction
shouldemphasizethefollowing:
–Theneedforcareandconcentrationwhen
workingwithride-onmachines
–Controlofaride-onmachineslidingonaslope
willnotberegainedbytheapplicationofthe
brake.Themainreasonsforlossofcontrolare
asfollows:
◊Insufcientwheelgrip
◊Beingdriventoofast
3

◊Inadequatebraking
◊Thetypeofmachineisunsuitableforthetask
◊Lackofawarenessoftheeffectofground
conditions,especiallyslopes
◊Incorrecthitchingandloaddistribution
Preparation
•Whilemowing,alwayswearsubstantialfootwear,
longtrousers,hardhat,safetyglasses,andhearing
protection.Longhair,looseclothing,orjewelrymay
gettangledinmovingparts.Donotoperatethe
equipmentwhenbarefootorwearingopensandals.
•Thoroughlyinspecttheareawheretheequipment
istobeusedandremoveallobjectswhichmaybe
thrownbythemachine.
•Warning—Fuelishighlyammable.Takethe
followingprecautions:
–Storefuelincontainersspecicallydesignedfor
thispurpose.
–Refueloutdoorsonlyanddonotsmokewhile
refueling.
–Addfuelbeforestartingtheengine.Never
removethecapofthefueltankoraddfuelwhile
theengineisrunningorwhentheengineishot.
–Iffuelisspilled,donotattempttostartthe
enginebutmovethemachineawayfromthe
areaofspillageandavoidcreatinganysourceof
ignitionuntilfuelvaporshavedissipated.
–Replaceallfueltankandcontainercapssecurely.
•Replacefaultysilencers/mufers.
•Evaluatetheterraintodeterminewhataccessories
andattachmentsareneededtoproperlyand
safelyperformthejob.Onlyuseaccessoriesand
attachmentsapprovedbythemanufacturer.
•Checkthatoperator’spresencecontrols,safety
switchesandshieldsareattachedandfunctioning
properly.Donotoperateunlesstheyarefunctioning
properly.
Operation
•Donotoperatetheengineinaconnedspacewhere
dangerouscarbonmonoxidefumescancollect.
•Mowonlyindaylightoringoodarticiallight.
•Beforeattemptingtostarttheengine,disengageall
bladeattachmentclutches,shiftintoneutral,and
engagetheparkingbrake.Onlystarttheenginefrom
theoperator’sposition.NeverremovetheROPS
andalwaysweartheseatbeltsduringoperation.
•Rememberthereisnosuchthingasasafeslope.
Travelongrassslopesrequiresparticularcare.Do
thefollowingtoguardagainstoverturning:
–Donotstoporstartsuddenlywhengoingupor
downhill.
–Keepmachinespeedslowonslopesandduring
tightturns.
–Stayalertforhumpsandhollowsandother
hiddenhazards.
–Nevermowacrossthefaceoftheslope,unless
themowerisdesignedforthispurpose.
•Stayalertforholesintheterrainandotherhidden
hazards.
•Watchoutfortrafcwhencrossingornearroadways.
•Stopthebladesfromrotatingbeforecrossing
surfacesotherthangrass.
•Whenusinganyattachments,neverdirectdischarge
ofmaterialtowardbystandersnorallowanyonenear
themachinewhileinoperation.
•Neveroperatethemachinewithdamagedguards,
shields,orwithoutsafetyprotectivedevicesinplace.
Besureallinterlocksareattached,adjustedproperly,
andfunctioningproperly.
•Donotchangetheenginegovernorsettingsor
overspeedtheengine.Operatingtheengineat
excessivespeedmayincreasethehazardofpersonal
injury.
•Dothefollowingbeforeleavingtheoperator’s
position:
–Stoponlevelground.
–Disengagethepowertake-offandlowerthe
attachments.
–Changeintoneutralandsettheparkingbrake.
–Stoptheengineandremovethekey.
•Disengagethedrivetoattachments,stopthe
engine,andremovetheignitionkeyinthefollowing
conditions:
–Beforerefueling
–Beforeremovingthegrasscatcher(s)
–Beforemakingheightadjustments,unlessthe
adjustmentcanbemadefromtheoperator’s
position.
–Beforeclearingblockages
–Beforechecking,cleaning,orworkingonthe
mower
–Afterstrikingaforeignobjectorifanabnormal
vibrationoccurs(checkimmediately).Inspect
themowerfordamageandmakerepairsbefore
restartingandoperatingtheequipment.
4

•Disengagethedrivetoattachmentswhen
transportingorwhenthemachineisnotinuse.
•Reducethethrottlesettingbeforestoppingthe
engineand,iftheengineisprovidedwithafuel
shut-offvalve,turnthefueloffattheconclusionof
mowing.
•Keephandsandfeetawayfromthecuttingunits.
•Lookbehindanddownbeforebackinguptobesure
ofaclearpath.
•Slowdownandusecautionwhenmakingturnsand
crossingroadsandsidewalks.Stopcylinders/reels
ifnotmowing.
•Donotoperatethemowerundertheinuenceof
alcoholordrugs.
•Usecarewhenloadingorunloadingthemachine
intoatrailerortruck.
•Theoperatorshallturnonashingwarninglights,
ifprovided,whenevertravelingonapublicroad,
exceptwheresuchuseisprohibitedbylaw .
•Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscurevision.
MaintenanceandStorage
•Keepallnuts,boltsandscrewstighttobesurethe
equipmentisinsafeworkingcondition.
•Neverstoretheequipmentwithfuelinthetank
insideabuildingwherefumesmayreachanopen
ameorspark.
•Allowtheenginetocoolbeforestoringinany
enclosure.
•Toreducetherehazard,keeptheengine,
silencer/mufer,batterycompartmentfuelstorage
area,cuttingunitsanddrivesfreeofgrass,leaves,or
excessivegrease.Cleanupoilorfuelspillage.
•Keepallpartsingoodworkingconditionandall
hardwareandhydraulicttingstightened.Replace
wornordamagedpartsanddecalsforsafety.
•Ifthefueltankhastobedrained,dothisoutdoors.
•Becarefulduringadjustmentofthemachineto
prevententrapmentofthengersbetweenmoving
bladesandxedpartsofthemachine.
•Onmulti-cylinder/multi-reelmachines,takecare
asrotatingonecylinder/reelcancauseother
cylinders/reelstorotate.
•Disengagedrives,lowerthecuttingunits,setparking
brake,stopengineandremovekey.Waitforall
movementtostopbeforeadjusting,cleaningor
repairing.
•Cleangrassanddebrisfromcuttingunits,drives,
silencers/mufers,andenginetohelppreventres.
Cleanupoilorfuelspillage.
•Shutofffuelwhilestoringortransporting.Donot
storefuelnearames.
•Parkthemachineonlevelground.
•Neverallowuntrainedpersonneltoservicethe
machine.
•Usejackstandstosupportcomponentswhen
required.
•Carefullyreleasepressurefromcomponentswith
storedenergy.
•Disconnectbatterybeforemakinganyrepairs.
Disconnectthenegativeterminalrstandthe
positivelast.Reconnectpositiverstandnegative
last.
•Usecarewhencheckingthecylinders/reels.Wear
glovesandusecautionwhenservicingthem.
•Keephandsandfeetawayfrommovingparts.If
possible,donotmakeadjustmentswiththeengine
running.
•Chargebatteriesinanopenwellventilatedarea,
awayfromsparkandames.Unplugchargerbefore
connectingordisconnectingfrombattery.Wear
protectiveclothinganduseinsulatedtools.
ToroMowerSafety
Thefollowinglistcontainssafetyinformationspecic
toToroproductsorothersafetyinformationthatyou
mustknowthatisnotincludedintheCEN,ISO,or
ANSIstandards.
Thisproductiscapableofamputatinghandsand
feetandthrowingobjects.Alwaysfollowallsafety
instructionstoavoidseriousinjuryordeath.
Useofthisproductforpurposesotherthanitsintended
usecouldprovedangeroustouserandbystanders.
Engineexhaustcontainscarbonmonoxide,
whichisanodorless,deadlypoisonthatcan
killyou.Donotrunengineindoorsorinan
enclosedarea.
Preparation
Besuretoestablishyourownspecialproceduresand
workrulesforunusualoperatingconditions(e.g.,
slopestoosteepforoperation).Surveythecomplete
5

mowingsitetodeterminewhichhillscanbesafely
operatedon.Whenperformingthissitesurvey,always
usecommonsenseandtakeintoconsiderationtheturf
conditionandtherolloverrisk.Todeterminewhichhills
orslopesmaybesafelyoperatedon,usetheinclinometer
providedwitheachmachine.Toperformasitesurvey,
followtheprocedureoutlinedintheOperationsection
ofthethismanual.Themaximumsidehillangleis
detailedontheslopedecalafxedneartheangle
indicator.
Training
Theoperatormustbeskilledandtrainedinhowtodrive
onhillsides.Failuretousecautiononslopesorhills
maycausethevehicletotiporroll,possiblyresulting
inpersonalinjuryordeath.
Operation
•Knowhowtostopthemachineandenginequickly.
•Donotoperatethemachinewhilewearingtennis
shoesorsneakers.
•Wearingsafetyshoesandlongpantsisadvisableand
requiredbysomelocalordinancesandinsurance
regulations.
•Keephands,feet,andclothingawayfrommoving
partsandthemowerdischargearea.
•Fillthefueltankuntillevelis1/2inch(12mm)
belowthebottomofthellerneck.Donotoverll.
•Checkthesafetyinterlockswitchesdailyforproper
operation.Ifaswitchshouldfail,replacetheswitch
beforeoperatingthemachine.
•Whenstartingtheengine,engagetheparkingbrake,
putthetractionpedalinneutral,anddisengage
thebladedrive.Aftertheenginestarts,releasethe
parkingbrakeandkeepyourfootoffofthetraction
pedal.Themachinemustnotmove.Ifmovement
isevident,refertotheMaintenancesectionofthis
manualtoadjustthetractiondrive.
•Useextremecautionwhenoperatingclosetosand
traps,ditches,creeks,steephillsides,orotherhazards.
•Reducespeedwhenmakingsharpturns.
•Donotturnonhills.
•Iftheenginestallsorlosesheadwayandcannotmake
ittothetopofaslope,donotturnthemachine
around.Alwaysbackslowly,straightdowntheslope.
•Donotoperateonasidehillthatistoosteep.A
rollovermayoccurbeforelosingtraction.
•Theslopeangleatwhichthemachinewilltipis
dependentonmanyfactors.Amongtheseare
mowingconditionssuchaswetorundulating
terrain,speed(especiallyinturns),positionofthe
cuttingunits(withtheSidewinder),tirepressure,
andoperatorexperience.Atsidehillanglesof15
degreesorless,theriskofarolloverislow .Asthe
slopeangleincreasestoarecommendedmaximum
limitof20degrees,theriskofarolloverincreasesto
amoderatelevel.Donotexceeda20degreeside
hillslopeanglebecausetheriskofarolloverand
seriousinjuryordeathisveryhigh.
•Forsteeringcontrol,lowerthecuttingunitswhen
goingdownslopes.
•Avoidsuddenstopsandstarts.
•Usethereversepedalforbraking.
•Watchfortrafcwhennearorcrossingroads.
Alwaysyieldtheright-of-way.
•Raisethecuttingunitswhendrivingfromonework
areatoanother.
•Donottouchtheengine,mufer,exhaustpipe,or
hydraulictankwhiletheengineisrunningorsoon
afterithasstoppedbecausetheseareascouldbehot
enoughtocauseburns.
•Thismachineisnotdesignedorequippedfor
on-roaduseandisaslow-movingvehicle.Ifyou
mustcrossortravelonapublicroad,youshould
beawareofandcomplywithlocalregulations,such
asrequiredlights,slowmovingvehiclesigns,and
reectors.
•Thegrassbasketsmustbeinplaceduringoperation
ofthecylinders/reelsorthatchersformaximum
safety.Shuttheengineoffbeforeemptyingthe
baskets.
•Whenapersonorpetappearsunexpectedlyinor
nearthemowingarea,stopmowing.Careless
operation,combinedwithterrainangles,ricochets,
orimproperlypositionedguardscanleadtothrown
objectinjuries.Donotresumemowinguntilthe
areaiscleared.
MaintenanceandStorage
•Beforeservicingormakingadjustments,stopthe
engineandremovetheignitionkey.
•Ensurethattheentiremachineisproperlymaintained
andingoodoperatingcondition.Frequentlycheck
allnuts,bolts,screws,andhydraulicttings.
•Makesureallhydrauliclineconnectorsaretightand
allhydraulichosesandlinesareingoodcondition
beforeapplyingpressuretothesystem.
•Keepyourbodyandhandsawayfrompinhole
leaksornozzlesthatejecthydraulicuidunderhigh
pressure.Usepaperorcardboard,notyourhands,
tosearchforleaks.Hydraulicuidescapingunder
6

pressurecanhavesufcientforcetopenetratethe
skinandcauseseriousinjury.Ifuidisinjectedinto
theskinitmustbesurgicallyremovedwithinafew
hoursbyadoctorfamiliarwiththisformofinjury
organgrenemayresult.
•Checkallfuellinesfortightnessandwearona
regularbasis.Tightenorrepairthemasneeded.
•Beforedisconnectingorperforminganyworkon
thehydraulicsystem,allpressureinthesystemmust
berelievedbystoppingtheengineandloweringthe
cuttingunitstotheground.
•Iftheenginemustberunningtoperforma
maintenanceadjustment,keephands,feet,clothing,
andanypartsofthebodyawayfromthecutting
units,attachments,andanymovingparts.Keep
everyoneaway.
•Donotoverspeedtheenginebychanginggovernor
settings.Toensuresafetyandaccuracy,havean
AuthorizedToroDistributorcheckthemaximum
enginespeedwithatachometer.
•Theenginemustbeshutoffbeforecheckingtheoil
oraddingoiltothecrankcase.
•Ifmajorrepairsareeverneededorifassistanceis
desired,contactanAuthorizedToroDistributor.
•Toensureoptimumperformanceandcontinued
safetycerticationofthemachine,useonly
genuineTororeplacementpartsandaccessories.
Replacementpartsandaccessoriesmadebyother
manufacturerscouldbedangerous,andsuchuse
couldvoidtheproductwarranty.
SoundPowerLevel
Thisunithasaguaranteedsoundpowerlevelof105
dBA,basedonmeasurementsofidenticalmachinesper
ISO11094.
SoundPressureLevel
ThisunithasanequivalentcontinuousA-weighted
soundpressurelevelattheoperatorearof83dBAbased
onmeasurementsofidenticalmachinesperEN836and
ISO11201.
VibrationLevel
Thisunitdoesnotexceedavibrationlevelof2.5m/s2at
thehandsbasedonmeasurementsofidenticalmachines
perEN836andEN1033.
Thisunitdoesnotexceedavibrationlevelof0.5m/s2
attheposteriorbasedonmeasurementsofidentical
machinesperEN836andEN1032.
7

SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof
potentialdanger.Replaceanydecalthatisdamagedorlost.
93-6681
1.Cutting/dismemberment—hazard,fan-stayawayfrom
movingparts.
93-7276
1.Explosionhazard—weareyeprotection.
2.Causticliquid/chemicalburnhazard—toperformrstaid,
ushwithwater.
3.Firehazard—nore,openames,orsmoking.
4.Poisonhazard—keepchildrenasafedistancefromthe
battery.
94-3353
Model03207only
1.Crushinghazardofhand—keepyourhandsasafedistance
away.
99-3444
99-3444
1.Reelspeed—fast2.Reelspeed—slow
99-3496
99-3558
CEonly
1.Warning—readtheOperator’sManual.
2.Tostarttheengine,sitontheseatandrotatetheignition
keytoOn/Preheatuntiltheglowplugindicatorlightgoes
out.Rotatethekeytostartanddisengagetheparking
brake.ReadtheOperator’sManualforfurtherinstructions.
3.Tostoptheengine,disengagethecuttingunits,rotatethe
ignitionkeytoOff,andremovethekey.Engagetheparking
brake.ReadtheOperator’sManualforfurtherinstructions.
100-4837
8

104-5181
CEonly
1.Warning—readtheOperator’sManual.
2.Tippinghazard—donotdriveonslopesgreaterthan15
degreesand,iftherollbarisinstalled,weartheseatbelt.
3.Thrownobjecthazard—keepbystandersasafedistance
fromthemachine.
4.Cuttinghazardofhandorfoot—stayawayfrommoving
parts.
5.Warning—locktheparkingbrake,stoptheengine,and
removetheignitionkeybeforeleavingthemachine.
104-5192
Model03207only
1.Engagethepowertakeoff
(PTO).
5.Raisethecuttingunits.9.Engine—run13.Slow
2.Disengagethepowertake
off(PTO).
6.Movethecuttingunitsto
theleft.
10.Engine—start
3.Lowerthecuttingunits.7.Moverearwardtolockthe
liftlever.
11.Fast
4.Movethecuttingunitsto
theright.
8.Engine—stop12.Continuousvariablesetting
9

104-5193
Model03206only
1.Engagethepowertakeoff
(PTO).
5.Raisethecuttingunits.9.Engine—run13.Slow
2.Disengagethepowertake
off(PTO).
6.Movethecuttingunitsto
theleft.
10.Engine—start
3.Lowerthecuttingunits.7.Moverearwardtolockthe
liftlever.
11.Fast
4.Movethecuttingunitsto
theright.
8.Engine—stop12.Continuousvariablesetting
106-6754
1.Warning—donottouchthehotsurface.
2.Cutting/dismembermenthazard,fanandentanglement
hazard,belt—stayawayfrommovingparts.
107-7801(CEonly)
Thissafetydecalincludesaslopewarningrequired
onthemachineforcompliancetotheEuropeanLawn
MowerSafetyStandardEN836:1997.Theconservative
maximumslopeanglesindicatedforoperationof
thismachineareprescribedbyandrequiredbythis
standard.
1.Tippinghazard—donotdriveonslopesgreaterthan15
degrees.
10

117-5104
BatterySymbols
Someorallofthesesymbolsareonyourbattery
1.Explosionhazard6.Keepbystandersasafe
distancefromthebattery.
2.Nore,opename,or
smoking.
7.Weareyeprotection;
explosivegasescan
causeblindnessandother
injuries
3.Causticliquid/chemical
burnhazard
8.Batteryacidcancause
blindnessorsevereburns.
4.Weareyeprotection9.Flusheyesimmediately
withwaterandgetmedical
helpfast.
5.ReadtheOperator’s
Manual.
10.Containslead;donot
discard.
11

Setup
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
Frontwheelassemblies2
1Rearwheelassembly1Installthewheels.
Steeringwheel1
Steeringwheelcap1
Largewasher1
Jamnut1
2
Screw1
Installthesteeringwheel.
4Inclinometer1Checktheangleindicator.
Hoodlockbracket1
Screw,1/4x1–1/2inches1
Flatwasher,1/4inch1
5Locknut,1/4inch1
InstalltheHoodLatch(CE).
Exhaustguard1
6Self-tappingscrew4InstalltheExhaustGuard(CE).
Rollbarassembly1
Flangeheadbolts4
Locknuts4
7Hoseclamp1
Installtherollbar.
Liftarms2
Pivotrod2
8Bolt(5/16x7/8inch)2
Installthefrontliftarms.(Partssupplied
intheLiftArmKit.)
9Nopartsrequired–Installthecarrierframestothecutting
units.
10Nopartsrequired–Mountthecuttingunits.
11Nopartsrequired–Mountthecuttingunitdrivemotors.
12Nopartsrequired–Adjusttheliftarms.
12

MediaandAdditionalParts
DescriptionQty.Use
Decal,CE6AfxtothemachineovercorrespondingEnglishdecals
forEuropeancompliance.
Ignitionkey2Starttheengine.
Operator’sManual1
EngineOperator’sManual1Readbeforeoperatingthemachine.
PartsCatalog1Usetolookupandorderparts.
Operatorvideo1Viewbeforeoperatingthemachine.
Pre-deliverychecklist1Checktoensurethatthemachinehasbeenproperlyset
up.
Certicateofcompliance1EnsureCEcompliance.
Note:Determinetheleftandrightsidesofthemachine
fromthenormaloperatingposition.
1
InstallingtheWheels
Partsneededforthisprocedure:
2Frontwheelassemblies
1Rearwheelassembly
Procedure
1.Mountawheelassemblyontoeachwheelhub(valve
stemoutward).
Important:Thereartirehasanarrowerrim
thanthefronttires.
2.Installlugnutsandtorqueto45to65ft-lb(61to
88N-m).
2
InstallingtheSteeringWheel
Partsneededforthisprocedure:
1Steeringwheel
1Steeringwheelcap
1Largewasher
1Jamnut
1Screw
Procedure
1.Slidethesteeringwheelontothesteeringshaft
(Figure3).
Figure3
1.Steeringwheel3.Jamnut
2.Washer4.Cap
2.Slidethewasherontothesteeringshaft(Figure3).
13

3.Securethesteeringwheeltotheshaftwithajam
nutandtightenitto20to26ft-lb(27to35N-m)
(Figure3).
4.Installthecaptothesteeringwheelandsecureit
withascrew(Figure3).
3
Activating,Charging,and
ConnectingtheBattery
NoPartsRequired
Procedure
Warning
CALIFORNIA
Proposition65Warning
Batteryposts,terminals,andrelated
accessoriescontainleadandleadcompounds,
chemicalsknowntotheStateofCalifornia
tocausecancerandreproductiveharm.
W ash hands after handling .
Note:Ifthebatteryisnotlledwithelectrolyteor
activated,bulkelectrolytewith1.260specicgravity
mustbepurchasedfromalocalbatterysupplyoutlet
andaddedtothebattery.
Batteryelectrolytecontainssulfuricacidwhich
isadeadlypoisonandcausessevereburns.
•Donotdrinkelectrolyteandavoidcontact
withskin,eyes,orclothing.Wearsafety
glassestoshieldyoureyesandrubbergloves
toprotectyourhands.
•Fillthebatterywherecleanwaterisalways
availableforushingtheskin.
1.Purchasebulkelectrolytewith1.260specicgravity
fromalocalbatterysupplyoutlet.
2.Openthehood.
3.Removethebatterycover(Figure4).
Figure4
1.Batterycover
4.Removethellercapsfromthebatteryandslowly
lleachcelluntilelectrolyteisjustabovetheplates.
5.Installthellercapsandconnecta3to4ampbattery
chargertothebatteryposts.Chargethebatteryata
rateof3to4ampsfor4to8hours.
Chargingthebatteryproducesgassesthatcan
explode.
•Keepsparksandamesawayfrombattery.
•Neversmokenearthebattery.
6.Whenthebatteryischarged,disconnectthecharger
fromtheelectricaloutletandbatteryposts.
7.Removethellercaps.Slowlyaddelectrolyteto
eachcelluntilthelevelisuptothellring.Install
thellercaps.
Important:Donotoverllthebattery.
Electrolytewilloverowontootherpartsofthe
machineandseverecorrosionanddeterioration
willresult.
8.Installthepositivecable(red)tothepositive(+)
terminalandthenegativecable(black)tothe
negative(–)terminalofthebatteryandsecurethem
withboltsandnuts(Figure5).Makesurethatthe
positive(+)terminalisallofthewayontothepost
andthecableispositionedsnugtothebattery.The
cablemustnotcontactthebatterycover.
14

Incorrectbatterycableroutingcoulddamage
thetractorandcablescausingsparks.Sparks
cancausethebatterygassestoexplode,
resultinginpersonalinjury.
•Alwaysdisconnectthenegative(black)
batterycablebeforedisconnectingthe
positive(red)cable.
•Alwaysconnectthepositive(red)battery
cablebeforeconnectingthenegative(black)
cable.
Figure5
1.Positive(+)batterycable2.Negative(–)batterycable
Important:Ifthebatteryiseverremoved,make
surethatthebatteryclampboltsareinstalled
withtheboltheadspositionedonthebottom
sideandthenutsonthetopside.Iftheclamp
boltsarereversed,theymayinterferewiththe
hydraulictubeswhenshiftingthecuttingunits.
9.CoatbothbatteryconnectionswithGrafo112X
(skinover)grease,ToroPartNo.505-47,petroleum
jelly,orlightgreasetopreventcorrosion.
10.Slidetherubberbootoverthepositiveterminalto
preventapossibleshortfromoccurring.
11.Installthebatterycover.
4
CheckingtheAngleIndicator
Partsneededforthisprocedure:
1Inclinometer
Procedure
Toreduceriskofinjuryordeathduetorollover,
donotoperatethemachineonsidehillssteeper
than25º.
1.Parkthemachineonaat,levelsurface.
2.Verifythatthemachineislevelbyplacingahand
heldinclinometer(suppliedwiththemachine)on
theframecrossrail,bythefueltank(Figure6).The
inclinometershouldreadzerodegreeswhenviewed
fromtheoperator’sposition.
Figure6
1.Angleindicator
3.Iftheinclinometerdoesnotreadzerodegrees,
movethemachinetoalocationwhereazerodegree
readingisobtained.Theangleindicator,mountedon
themachine,shouldnowreadzerodegreesaswell.
4.Iftheangleindicatordoesnotreadzerodegrees,
loosenthetwoscrewsandnutssecuringtheangle
indicatortothemountingbracket,adjustthe
indicatortoobtainazerodegreereading,andtighten
thebolts.
15

5
InstallingtheHoodLatch(CE
Only)
Partsneededforthisprocedure:
1Hoodlockbracket
1Screw,1/4x1–1/2inches
1Flatwasher,1/4inch
1Locknut,1/4inch
Procedure
1.Unhookthehoodlatchfromthehoodlatchbracket
(Figure7).
Figure7
1.Hoodlatch3.Hoodlockbracket
2.Hoodlatchbracket
2.Slidethehoodlockbracketontothelatch(Figure7).
3.Hookthelatchontothehoodlatchbracket
(Figure7).
4.Insertabolt(1/4x1-1/2inches)throughthehood
lockbracketandsecureitwithaatwasherand
locknut(Figure7).
6
InstallingtheExhaustGuard
(CEOnly)
Partsneededforthisprocedure:
1Exhaustguard
4Self-tappingscrew
Procedure
1.Positiontheexhaustguardaroundthemuferwhile
aligningthemountingholeswiththeholesinthe
frame(Figure8).
Figure8
1.Exhaustguard
2.Securetheexhaustguardtotheframewith4
self-tappingscrews(Figure8).
16

7
InstallingtheRollBar
Partsneededforthisprocedure:
1Rollbarassembly
4Flangeheadbolts
4Locknuts
1Hoseclamp
Procedure
Important:Neverweldormodifyarollover
protectionsystem(ROPS).Replaceadamaged
ROPS,donotrepairorrevise.Anyalterationofa
ROPSmustbeapprovedbythemanufacturer.
1.Lowertherollbarontothetractionunitmounting
brackets,aligningthemountingholes.Ensurethat
theventtubeontherollbarisontheleftsideof
themachine(Figure9).
Figure9
1.ROPS4.Fuellineventtubehose
2.Mountingbracket5.Hoseclamp
3.Venttube
2.Secureeachsideoftherollbartothemounting
bracketswith2angeheadboltsandlocknuts
(Figure9).Torquethefastenersto60ft-lb(81N-m).
3.Securethefuellineventhosetotheventtubeonthe
rollbarwiththehoseclamp.
Youmustconnectthefuellineventhosetothe
venttubepriortostartingtheengineorfuelwill
owfromthehose.
8
InstallingtheFrontLiftArms
Partsneededforthisprocedure:
2Liftarms
2Pivotrod
2Bolt(5/16x7/8inch)
Procedure
1.Removethe2boltsthatsecuretheliftarmpivot
shaftlinktotheliftarmpivotshafts,andremove
andretainthepivotshaftlinkandbolts(Figure10).
Figure10
1.Liftarm,pivotshaftlink2.Liftarmpivotshaft
2.Insertapivotrodintoeachliftarmandalignthe
mountingholes(Figure11).
Figure11
1.Liftarm2.Pivotrod
3.Securethepivotrodstotheliftarmswith2bolts
(5/16x7/8inch).
17

4.Inserttheliftarmsontotheliftarmpivotshafts
(Figure12),andsecureeachwithaliftarmpivot
shaftlinkandboltspreviouslyremoved.
Note:Torquetheboltsto70ft-lb(95N-m).
Figure12
1.Liftarm,right4.Mountingpin
2.Liftarm,left5.Liftcylinder
3.Retainingring6.Spacers(2)
5.Removetherearretainingringssecuringthe
mountingpinstoeachendoftheliftcylinder.
6.Securetherightendoftheliftcylindertotheright
liftarmwithapinand2spacers(Figure13).Secure
itwitharetainingring.
Figure13
1.Liftcylinder3.Clearancehere
2.Hoses
7.Securetheleftendoftheliftcylindertotheleftlift
armwithapin.Secureitwitharetainingring.
Note:Withtheliftarmsfullyraised,thehosesshould
beroutedasshowninFigure13andcleartheliftarmby
0.04to0.12inch(1to3mm).
9
InstallingtheCarrierFrames
totheCuttingUnits
NoPartsRequired
Procedure
1.Removethecuttingunitsfromthecartons.Adjust
themasdescribedintheCuttingUnitOperator’s
Manual.
2.Positionafrontcarrierframe(Figure14)ontoeach
frontcuttingunit.Alignthemountingholeswiththe
mountinglinksasshowninFigure16.
Figure14
1.Frontcarrierframe
3.Positiontherearcarrierframe(Figure15)ontothe
rearcuttingunit,andalignthemountingholeswith
themountinglinksasshowninFigure16.
18

Figure15
1.Rearcarrierframe
4.Secureeachmountinglinktothecarrierframewitha
bolt(3/8x2-1/4inch),2atwashers,andalocknut,
asshowninFigure16.Positionawasheroneach
sideofthelinkwhenmounting.Torquethefasteners
to31ft-lb(42N-m).
Figure16
1.Carrierframe
2.Mountinglink
3.Plug
10
MountingtheCuttingUnits
NoPartsRequired
Procedure
1.Slideathrustwasherontoeachfrontliftarmpivot
rod.
2.Slidethecuttingunitcarrierframeontothepivot
rodandsecureitwithalynchpin(Figure17).
Note:Onrearcuttingunit,positionthethrust
washerbetweentherearofthecarrierframeand
thelynchpin.
Figure17
1.Thrustwasher3.Lynchpin
2.Carrierframe
3.Greasealltheliftarmandcarrierframepivotpoints.
Important:Ensurethatthehosesarefreeof
twistsorsharpbendsandthattherearcutting
unithosesareroutedasshowin(Figure18).
Raisethecuttingunitsandshiftthemtotheleft
(model03206).Therearcuttingunithosesmust
notcontacttractioncablebracket.Reposition
thettingsand/orhoses,ifnecessary.
19

Figure18
4.Routeatipperchainupthroughtheslotontheend
ofeachcarrierframe.Securethetipperchaintothe
topofthecarrierframewithabolt,awasher,anda
locknut(Figure19).
Figure19
1.Tipperchain
11
MountingtheCuttingUnit
DriveMotors
NoPartsRequired
Procedure
1.Positionthecuttingunitsinfrontoftheliftarm
pivotrods.
2.Removetheweightsandgasket(Figure20)fromthe
insideendoftherighthandcuttingunit.
Figure20
1.Weights2.Gasket
3.Removetheplugfromthebearinghousingonthe
outsideendoftherighthandcuttingunitandinstall
theweightsandgasket.
4.Locatethespidercoupling(Figure21)shippedin
thebearinghousing.
Figure21
1.Spidercoupling3.O-ring
2.Reelmotor
5.Removetheshippingplugfromthebearinghousings
ontheremainingcuttingunits(Figure16).
6.InserttheO-ring(suppliedwiththecuttingunit)on
theangeofthedrivemotor.
7.Mountthemotorandthespidercouplingtothe
driveendofthecuttingunit,andsecureitwithtwo
capscrewsprovidedwithcuttingunit.
20