Toro 3206 User manual

Operator’s Manual
English (EN, GB)
Form No. 3359–704 Rev A
Reelmaster)3100–D
Traction Unit
Model No. 03207—280000001 and Up
Model No. 03206—280000001 and Up
Model No. 03220
Model No. 03221

2
All Rights Reserved
Printed in the USA
W2008 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents
are known to the State of California to cause
cancer, birth defects, and other reproductive harm.
Warning
Important The engine in this product is not equipped
with a spark arrester muffler. It is a violation of California
Public Resource Code Section 4442 to use or operate this
engine on any forest-covered, brush-covered, or
grass-covered land as defined in CPRC 4126. Other states
or federal areas may have similar laws.
Contents
Page
Introduction 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Operating Practices 3. . . . . . . . . . . . . . . . . . . .
Toro Riding Mower Safety 5. . . . . . . . . . . . . . . . . .
Sound Pressure Level 6. . . . . . . . . . . . . . . . . . . . . .
Sound Power Level 6. . . . . . . . . . . . . . . . . . . . . . .
Vibration Level 6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 7. . . . . . . . . . . . . . . .
Specifications 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 11. . . . . . . . . . . . . . . . . . . . .
Setup 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts Chart 12. . . . . . . . . . . . . . . . . . . . . . . . .
Install Wheels 13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install Steering Wheel 13. . . . . . . . . . . . . . . . . . . . .
Activate, Charge and Connect Battery 13. . . . . . . .
Check Angle Indicator 14. . . . . . . . . . . . . . . . . . . . .
Install Hood Latch
(European Compliance) 14. . . . . . . . . . . . . . . . . . .
Install Exhaust Guard
(European Compliance) 15. . . . . . . . . . . . . . . . . . .
Install ROPS 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install Front Lift Arms 15. . . . . . . . . . . . . . . . . . . . .
Mount Carrier Frames To Cutting Units 16. . . . . . . .
Mount Cutting Units 17. . . . . . . . . . . . . . . . . . . . . . .
Mount Cutting Unit Drive Motors 18. . . . . . . . . . . .
Adjust Lift Arms 18. . . . . . . . . . . . . . . . . . . . . . . . .
Before Operating 20. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Crankcase Oil 20. . . . . . . . . . . . . . . . . . . . . .
Fill Fuel Tank 20. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Cooling System 21. . . . . . . . . . . . . . . . . . . . .
Checking the Hydraulic System 22. . . . . . . . . . . . . .
Check Tire Pressure 22. . . . . . . . . . . . . . . . . . . . . . .
Check Reel To Bedknife Contact 22. . . . . . . . . . . . .
Check Torque Of Wheel Nuts 23. . . . . . . . . . . . . . .
Controls 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting/Stopping Engine 26. . . . . . . . . . . . . . . . . . .
Bleeding Fuel System 26. . . . . . . . . . . . . . . . . . . . . .
Check Operation Of Interlock Switches 27. . . . . . . .
Towing Traction Unit 27. . . . . . . . . . . . . . . . . . . . . .
Operating Characteristics 27. . . . . . . . . . . . . . . . . . .
Mowing Techniques 28. . . . . . . . . . . . . . . . . . . . . . .
After Mowing 29. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting Clip Rate (Reel Speed) 29. . . . . . . . . . . . .
Standard Control Module (SCM) 30. . . . . . . . . . . . .
Lubrication 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule 35. . . . . . . . .
Daily Maintenance Checklist 36. . . . . . . . . . . . . . . .
Service Interval Chart 37. . . . . . . . . . . . . . . . . . . . . .
Hood Removal 37. . . . . . . . . . . . . . . . . . . . . . . . . . .
General Air Cleaner Maintenance 38. . . . . . . . . . . .
Servicing Air Cleaner 38. . . . . . . . . . . . . . . . . . . . . .
Engine Oil and Filter 38. . . . . . . . . . . . . . . . . . . . . .
Fuel System 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bleeding Air From Injectors 39. . . . . . . . . . . . . . . . .
Cleaning Engine Cooling System 40. . . . . . . . . . . . .
Servicing Engine Belts 40. . . . . . . . . . . . . . . . . . . . .
Adjusting Throttle 41. . . . . . . . . . . . . . . . . . . . . . . .
Changing Hydraulic Fluid 41. . . . . . . . . . . . . . . . . .
Replacing Hydraulic Filter 42. . . . . . . . . . . . . . . . . .
Checking Hydraulic Lines And Hoses 42. . . . . . . . .
Adjusting Traction Drive For Neutral 42. . . . . . . . .
Adjusting Parking Brake 43. . . . . . . . . . . . . . . . . . .
Battery Care 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Storage 44. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuses 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Backlapping 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Traction Unit 45. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Schematic 46. . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Schematic 47. . . . . . . . . . . . . . . . . . . . . .
The Toro General Commercial Products Warranty 48. .

3
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.
Whenever you need service, genuine Toro parts, or
additional information, contact an Authorized Service
Dealer or Toro Customer Service and have the model and
serial numbers of your product ready.The two numbers are
stamped into a plate that is riveted to the frame of mower.
Write the product model and serial numbers in the space
below:
Model No.
Serial No.
This manual identifies potential hazards and has special
safety messages that help you and others avoid personal
injury and even death. Danger, Warning, and Caution are
signal words used to identify the level of hazard. However,
regardless of the hazard, be extremely careful.
Danger signals an extreme hazard that will cause serious
injury or death if you do not follow the recommended
precautions.
Warning signals a hazard that may cause serious injury or
death if you do not follow the recommended precautions.
Caution signals a hazard that may cause minor or moderate
injury if you do not follow the recommended precautions.
This manual uses two other words to highlight information.
Important calls attention to special mechanical
information and Note: emphasizes general information
worthy of special attention.
Safety
This machine meets or exceeds CEN standard EN
836:1997, ISO standard 5395:1990, and ANSI
B71.4-2004 specifications in effect at the time of
production when rear tires are filled with calcium
chloride and two rear wheel weight kits (Part No.
11–0440) are installed.
Improper use or maintenance by the operator or owner
can result in injury. To reduce the potential for injury,
comply with these safety instructions and always pay
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.
Safe Operating Practices
The following instructions are from the CEN standard EN
836:1997, ISO standard 5395:1990, and ANSI B71.4-2004.
Training
•Read the operator’s manual and other training material
carefully. Be familiar with the controls, safety signs,
and the proper use of the equipment.
•Never allow children or people unfamiliar with these
instructions to use or service the mower. Local
regulations may restrict the age of the operator.
•Never mow while people, especially children, or pets
are nearby.
•Keep in mind that the operator or user is responsible for
accidents or hazards occurring to other people or their
property.
•Do not carry passengers.
•All drivers and mechanics should seek and obtain
professional and practical instruction. The owner is
responsible for training the users. Such instruction
should emphasize:
– the need for care and concentration when working
with ride-on machines;
– The main reasons for loss of control on a slope are:
•insufficient wheel grip;
•being driven too fast;
•inadequate braking;
•the type of machine is unsuitable for its task;
•lack of awareness of the effect of ground
conditions, especially slopes;
•incorrect hitching and load distribution.

4
•The owner/user can prevent and is responsible for
accidents or injuries occurring to himself or herself,
other people, or property.
Preparation
•While mowing, always wear substantial footwear, long
trousers, hard hat, safety glasses, and hearing
protection. Long hair, loose clothing, or jewelry may
get tangled in moving parts. Do not operate the
equipment when barefoot or wearing open sandals.
•Thoroughly inspect the area where the equipment is to
be used and remove all objects which may be thrown by
the machine.
•Warning—Fuel is highly flammable. Take the
following precautions:
– Store fuel in containers specifically designed for this
purpose.
– Refuel outdoors only and do not smoke while
refuelling.
– Add fuel before starting the engine. Never remove
the cap of the fuel tank or add fuel while the engine
is running or when the engine is hot.
– If fuel is spilled, do not attempt to start the engine
but move the machine away from the area of
spillage and avoid creating any source of ignition
until fuel vapors have dissipated.
– Replace all fuel tanks and container caps securely.
•Replace faulty silencers/mufflers.
•Evaluate the terrain to determine what accessories and
attachments are needed to properly and safely perform
the job. Only use accessories and attachments approved
by the manufacturer.
•Check that operator’s presence controls, safety switches
and shields are attached and functioning properly. Do
not operate unless they are functioning properly.
Operation
•Do not operate the engine in a confined space where
dangerous carbon monoxide fumes can collect.
•Mow only in daylight or in good artificial light.
•Before attempting to start the engine, disengage all
blade attachment clutches, shift into neutral, and engage
the parking brake.
•Do not use on slopes of more than 25°.
•Remember there is no such thing as a safe slope. Travel
on grass slopes requires particular care. To guard
against overturning:
– do not stop or start suddenly when going up or
downhill;
– machine speeds should be kept low on slopes and
during tight turns;
– stay alert for humps and hollows and other hidden
hazards;
– 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.
•Watch out for traffic when crossing or near roadways.
•Stop the blades rotating before crossing surfaces other
than grass.
•When using any attachments, never direct discharge of
material toward bystanders nor allow anyone near the
machine while in operation.
•Never operate the machine with damaged guards,
shields, or without safety protective devices in place. Be
sure all interlocks are attached, adjusted properly, and
functioning properly.
•Do not change the engine governor settings or
overspeed the engine. Operating the engine at excessive
speed may increase the hazard of personal injury.
•Before leaving the operator’s position:
– stop on level ground;
– disengage the power take-off and lower the
attachments;
– change into neutral and set the parking brake;
– stop the engine and remove the key.
•Disengage drive to attachments when transporting or
not in use.
•Stop the engine and disengage drive to attachment
– before refuelling;
– before removing the grass catcher/catchers;
– before making height adjustment unless adjustment
can be made from the operator’s position.
– before clearing blockages;
– before checking, cleaning or working on the mower;
– after striking a foreign object or if an abnormal
vibration occurs. Inspect the mower for damage and
make repairs before restarting and operating the
equipment.
•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.

5
•Keep hands and feet away from the cutting units.
•Look behind and down before backing up to be sure of
a clear path.
•Slow down and use caution when making turns and
crossing roads and sidewalks. Stop cylinders/reels if not
mowing.
•Do not operate the mower under the influence of
alcohol or drugs
•Use care when loading or unloading the machine into a
trailer or truck
•Use care when approaching blind corners, shrubs, trees,
or other objects that may obscure vision.
Maintenance and Storage
•Keep all nuts, bolts and screws tight to be sure the
equipment is in safe working condition.
•Never store the equipment with fuel in the tank inside a
building where fumes may reach an open flame or
spark.
•Allow the engine to cool before storing in any
enclosure.
•To reduce the fire hazard, keep the engine,
silencer/muffler, battery compartment and fuel storage
area free of grass, leaves, or excessive grease.
•Check the grass catcher frequently for wear or
deterioration.
•Keep all parts in good working condition and all
hardware and hydraulic fittings tightened. Replace all
worn or damaged parts and decals.
•If the fuel tank has to be drained, do this outdoors.
•Be careful during adjustment of the machine to prevent
entrapment of the fingers between moving blades and
fixed parts of the machine.
•On multi-cylinder/multi-reel machines, take care as
rotating one cylinder/reel can cause other
cylinders/reels to rotate.
•Disengage drives, lower the cutting units, set parking
brake, stop engine and remove key and disconnect spark
plug wire. Wait for all movement to stop before
adjusting, cleaning or repairing.
•Clean grass and debris from cutting units, drives,
silencers/mufflers, and engine to help prevent fires.
Clean up oil or fuel spillage.
•Use jack stands to support components when required.
•Carefully release pressure from components with stored
energy.
•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.
•Use care when checking the cylinders/reels. Wear
gloves and use caution when servicing them.
•Keep hands and feet away from moving parts. If
possible, do not make adjustments with the engine
running.
•Charge batteries in an open well ventilated area, away
from spark and flames. Unplug charger before
connecting or disconnecting from battery. Wear
protective clothing and use insulated tools.
Toro Riding Mower Safety
The following list contains safety information specific to
Toro products or other safety information that you must
know that is not included in the CEN, ISO, or ANSI
standard.
This product is capable of amputating hands and feet and
throwing objects. Always follow all safety instructions to
avoid serious injury or death.
Use of this product for purposes other than its intended use
could prove dangerous to user and bystanders.
Engine exhaust contains carbon monoxide, which
is an odorless, deadly poison that can kill you.
Do not run engine indoors or in an enclosed area.
Warning
•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.
•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.

6
•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.
•Know how to stop the engine quickly.
•Do not operate the machine while wearing tennis shoes
or sneakers.
•Wearing safety shoes and long pants is advisable and
required by some local ordinances and insurance
regulations.
•Handle fuel carefully. Wipe up any spills.
•Check the safety interlock switches daily for proper
operation. If a switch should fail, replace the switch
before operating the machine.
•Before starting the engine, sit on the seat.
•Using the machine demands attention. To prevent loss
of control:
– Do not drive close to sand traps, ditches, creeks, or
other hazards.
– Reduce speed when making sharp turns. Avoid
sudden stops and starts.
– This machine is not designed or equipped for
on–road use and is a “slow–moving vehicle.” If you
must cross or travel on a public road, you should be
aware of and comply with local regulations, such as
required lights, slow moving vehicle signs, and
reflectors.
– Apply the service brakes when going downhill to
keep forward speed slow and to maintain control of
the machine.
•The grass baskets must be in place during operation of
the cylinders/reels or thatchers for maximum safety.
Shut the engine off before emptying the baskets.
•Raise the cutting units when driving from one work
area to another.
•Do not touch the engine, silencer/muffler, or exhaust
pipe while the engine is running or soon after it has
stopped because these areas could be hot enough to
cause burns.
•If the engine stalls or loses headway and cannot make it
to the top of a slope, do not turn the machine around.
Always back slowly, straight down the slope.
•When a person or pet appears unexpectedly in or near
the mowing area, stop mowing. Careless operation,
combined with terrain angles, ricochets, or improperly
positioned guards can lead to thrown object injuries. Do
not resume mowing until the area is cleared.
Maintenance and Storage
•Make sure all hydraulic line connectors are tight and all
hydraulic hoses and lines are in good condition before
applying pressure to the system.
•Keep your body and hands away from pin hole leaks or
nozzles that eject hydraulic fluid under high pressure.
Use paper or cardboard, not your hands, to search for
leaks. Hydraulic fluid escaping under pressure can have
sufficient force to penetrate the skin and cause serious
injury. Seek immediate medical attention if fluid is
injected into skin.
•Before disconnecting or performing any work on the
hydraulic system, all pressure in the system must be
relieved by stopping the engine and lowering the cutting
units and attachments to the ground.
•Check all fuel lines for tightness and wear on a regular
basis. Tighten or repair them as needed.
•If the engine must be running to perform a maintenance
adjustment, keep hands, feet, clothing, and any parts of
the body away from the cutting units, attachments, and
any moving parts, especially the screen at the side of the
engine. Keep everyone away.
•To ensure safety and accuracy, have an Authorized Toro
Distributor check the maximum engine speed with a
tachometer. Maximum governed engine speed should be
2650 RPM.
•If major repairs are ever needed or if assistance is
desired, contact an Authorized Toro Distributor.
•Use only Toro-approved attachments and replacement
parts. The warranty may be voided if used with
unapproved attachments.
Sound Pressure Level
This unit has an equivalent continuous A–weighted sound
pressure level at the operator ear of 83 dBA, based on
measurements of identical machines per EN 836 and ISO
11201.
Sound Power Level
This unit has a guaranteed sound power level of:
105 dBA/1 pW, based on measurements of identical
machines per ISO 11094.
Vibration Level
This unit does not exceed a vibration level of 2.5 m/s@at
the hands based on measurements of identical machines per
ISO 5349 procedures EN 836 and ISO 1033.
This unit does not exceed a vibration level of .5 m/s@at the
posterior based on measurements of identical machines per
EN 836 and ISO 1032.

7
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.
104–5192 (Model 03207)
1. Engage the reels.
2. Disengage the reels.
3. Lower the reels.
4. Move the cutting units to the
right.
5. Raise the reels.
6. Move the cutting units to the
left.
7. Move rear ward to lock the
lift lever.
8. Engine—stop
9. Engine—run
10. Engine=start
11. Fast
12. Continuous variable setting
13. Slow

8
104-5193 (Model 03206)
1. Engage the reels.
2. Disengage the reels.
3. Lower the reels.
4. Raise the reels.
5. Move rear ward to lock the
lift lever.
6. Engine—stop
7. Engine—run
8. Engine=start
9. Fast
10. Continuous variable setting
11. Slow
99-3558 for CE
1. Warning—read the Operator’s Manual.
2. To start the engine, sit on the operator’s seat,, turn the key to
Run and wait for the engine preheat light to turn off, turn the
key to Start, and disengage the parking brake by moving the
lever down; read the Operators Manual.
3. To stop the engine, press the switch to disengage the reels,
turn the key to Stop and remove it, engage the parking brake
by pulling the lever up; read the Operators Manual.
94-3353 (Model 03206)
1. Crushing hazard of hand—keep your hands a safe distance
away.
93-6681
1. Cutting/dismemberment hazard, fan—stay away from moving
parts.

9
104-5199
99-3496

10
104-5181 for CE compliance
1. Warning—read the Operator’s Manual.
2. Tipping hazard—do not drive on slopes greater than 15
degrees and always wear the seat belt with ROPS.
3. Thrown object hazard—keep bystanders a safe distance from
the machine.
4. Cutting hazard of hand or foot—stay away from moving parts.
5. Warning—lock the parking brake, stop the engine, and remove
the ignition key before leaving the machine.
100-4837
107-7801 for CE compliance
*This safety decal includes aslope warning required on the
machine for compliance to the European Lawn Mower Safety
Standard EN836:1997. The conservative maximum slope
angles indicated for operation of this machine are prescribed
by and required by this standard.
1. Tipping hazard—do not drive on slopes greater than 15
degrees.
Battery Symbols
Some or all of these symbols are on your battery.
1. Explosion hazard
2. No fire, open flames, or
smoking.
3. Caustic liquid/chemical
burn hazard
4. Wear eye protection
5. Read the Operator’s
Manual.
6. Keep bystanders a safe
distance from the battery.
7. Wear eye protection;
explosive gases can
cause blindness and
other injuries
8. Battery acid can cause
blindness or severe
burns.
9. Flush eyes immediately
with water and get
medical help fast.
10. Contains lead; do not
discard.

11
Specifications
Note: Specifications and design subject to change without notice.
General 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 System 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. Shift lever only on Model 03206.
Gauges & Protective
Systems
Hour meter. 4 light warning cluster gauge: oil pressure, water temperature, amps,
glow plug and side hill angle indicator.
Cutting Unit Lift Hydraulic lift with automatic reel shut off.

12
Setup
Note: Determine the left and right sides of the machine from the normal operating position.
Loose Parts Chart
Note: Use this chart as a checklist to ensure all parts necessary for assembly have been shipped. If any of these parts are
missing, total setup cannot be completed.
Description Qty. Use
Wheel assembly 3Mount to wheel hubs
Steering wheel
Flat washer 21/32
Jam nut
Cover
Screw
1
1
1
1
1
Mount to steering shaft
Hood lock bracket
Screw 1/4–20 x 1–1/2” lg.
Flat washer 1/4
Lock nut 1/4–20
1
1
1
1
Mount to hood for European Compliance
Exhaust guard
Self tapping screw
1
4Mount to machine for European Compliance
Hose clamp 1Secure vent hose to vent tube of ROPS
Lift arms
Pivot rod
Capscrews 5/16–18 x 7/8” lg.
2
2
2
Install pivot rods to lift arms
(supplied with Lift Arm Kit)
Thrust washers
Lynch pin
2
2
Mount cutting units to lift arms
(supplied with Lift Arm Kit)
Key 2
Inclinometer 1 Use for site survey before operating machine
EEC Decal
EEC Certificate
4
2Affix to machine for European Compliance
Operator’s manual 2Read before operating the machine.
Engine operator’s manual 1Read before operating the machine.
Parts catalog 1
Operator training material 1View before operating the machine
Pre–delivery check list 1
Note: Specifications and design subject to change without notice.

13
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
1. Slide steering wheel onto steering shaft.
12
4
3
Figure 1
1. Steering wheel
2. Washer
3. Jam nut
4. Cap
2. Slide washer onto steering shaft.
3. Secure steering wheel to shaft with jam nut and tighten
it to 20–26 ft-lb.
4. Install cap to steering wheel with screw.
Activate, Charge and Connect
Battery
CALIFORNIA
Proposition 65 Warning
Battery posts, terminals, and related accessories
contain lead and lead compounds, chemicals
known to the State of California to cause cancer
and reproductive harm. Wash hands after
handling.
Warning
1. Open hood.
2. Remove battery cover.
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.
1
Figure 2
1. Battery cover
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 battery 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

14
must not contact battery cover. Slide the rubber boot
over the positive terminal to prevent possible short–out
from occurring.
•Connecting cables to the wrong post could
damage the electrical system and result in
personal injury.
Warning
21
Figure 3
1. Positive (+) battery cable 2. Negative (–) battery cable
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.
9. 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.
10. Install battery cover.
Check Angle Indicator
Danger
To reduce risk of injury or death due to rollover do
not operate on side hills steeper than 25 degrees.
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.
1
Figure 4
1. Angle indicator
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
(European Compliance)
1. Unhook hood latch from bracket.
2. Slide hood lock bracket onto latch.
1
2
3
Figure 5
1. Hood latch
2. Hood latch bracket
3. Hood lock bracket
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.

15
Install Exhaust Guard
(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.
1
Figure 6
1. Exhaust guard
Install ROPS
Important Never weld or modify ROPS. Replace a
damaged ROPS, do not repair or revise. Any alteration of
ROPS must be approved by manufacturer.
1. Lower ROPS frame onto traction unit mounting
brackets, aligning mounting holes. Vent tube, secured to
ROPS, must be positioned on left side of machine.
2. Secure each side of roll bar to mounting brackets with
(2) flange head capscrews and locknuts (Fig. 7). Torque
fasteners to 60 ft–lbs.
2
3
1
5
2
4
Figure 7
1. ROPS
2. Mounting bracket
3. Vent tube
4. Fuel line vent tube hose
5. Hose clamp
3. 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
Install Front Lift Arms
1. Remove (2) capscrews securing lift arm pivot shaft link
to lift arm pivot shafts. Remove and retain pivot shaft
link and capscrews (Fig. 8).
1
2
Figure 8
1. Lift arm pivot shaft link 2. Lift arm pivot shaft
2. Insert a pivot rod into each (R.H. & L.H.) lift arm and
align mounting holes (Fig. 9).
1
2
Figure 9
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.

16
5. Remove rear retaining rings securing mounting pins to
each end of lift cylinder.
1
2
3
5
4
4
6
Figure 10
1. Lift arm (R.H.)
2. Lift arm (L.H.)
3. Retaining ring
4. Mounting pin
5. Lift cylinder
6. Spacer (2)
6. Secure right end of lift cylinder to right lift arm with pin
and (2) spacers. Secure with retaining ring.
1
2
3
Figure 11
1. Lift cylinder
2. Hoses
3. Clearance here
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 14 and clear lift arm by .04–.12”.
Mount Carrier Frames To
Cutting Units
1. Remove cutting units from cartons. Adjust per Cutting
Unit Operator’s Manual.
2. Position a front carrier frame (Fig. 12) onto each front
cutting unit. Align mounting holes with mounting links
as shown in figure 14.
1
Figure 12
1. Front carrier frame
3. Position rear carrier frame (Fig. 13) onto rear cutting
unit, aligning mounting holes with mounting links as
shown in figure 14.
1
Figure 13
1. Rear carrier frame

17
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 14. Position a washer on
each side of link when mounting. Torque to 31 ft–lb.
1
2
3
FRONT
Figure 14
1. Carrier frame
2. Mounting link
3. Plug
Mount Cutting Units
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. 15).
Note: On rear cutting unit, thrust washer to be positioned
between rear of carrier frame and lynch pin.
1
3
2
Figure 15
1. Thrust washer
2. Carrier frame
3. Lynch pin
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. 16. Raise cutting units and shift them to
the left (Model 03206 only). Rear cutting unit hoses
must not contact traction cable bracket. Re–position
fittings and / or hoses, if required.
Figure 16
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. 17).
1
Figure 17
1. Tipper chain

18
Mount Cutting Unit Drive
Motors
1. Position cutting units in front of lift arm pivot rods.
2. Remove weights and gasket (Fig. 18) 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. 19) shipped in bearing housing.
1
2
Figure 18
1. Weights 2. Gasket
3. Remove shipping plug from bearing housings on
remaining cutting units (Fig. 14).
4. Insert O–ring (supplied with cutting unit) on flange of
drive motor.
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.
1
2
3
Figure 19
1. Spider coupling
2. Reel motor
3. O–ring
Adjust Lift Arms
1. Start engine, raise lift arms and check to make sure
clearance between each lift arm and floor plate bracket
is .18” – .32” (Fig. 20). If clearance is not in this range,
back off stop bolts (Fig. 22) and adjust cylinder to attain
clearance. To adjust cylinder, back off the jam nut on
the cylinder (Fig. 21), remove pin from rod end and
rotate clevis. Install pin and check clearance. Repeat
procedure if required. Tighten clevis jam nut.
1
2
3
Figure 20
1. Lift arm
2. Floor plate bracket
3. Clearance
1
2
Figure 21
1. Front cylinder 2. Jam nut

19
1
2
3
Figure 22
1. Stop bolt
2. Lift arm
3. Clearance
Note: If rear lift arm “clunks” during transport, clearance
can be reduced.
2. Check to make sure clearance between each lift arm and
stop bolt is .005” – .040” (Fig. 22). 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. 23). 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. 24).
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.
1
2
Figure 23
1. Wear bar 2. Bumper strap
12
Figure 24
1. Rear cylinder 2. Adjusting nut
Important Lack of clearance at front stops or rear
wear bar could damage lift arms.

20
Before Operating
Note: Determine the left and right sides of the machine
from the normal operating position.
Check Crankcase Oil
The engine is shipped with oil in the crankcase; however,
the oil level must be checked before and after the engine is
first started.
Crankcase capacity is approximately 4 qt. (2.8 l) with the
filter.
Use high-quality engine oil that meets the following
specifications:
API Classification Level Required: CH–4, CI–4 or
higher.
Preferred oil: SAE 15W–40 (above 0_F)
Alternate oil: SAE 10W–30 or 5W–30
(all temperatures)
Toro Premium Engine oil is available from your distributor
in either 15W–40 or 10W–30 viscosity. See the parts
catalog for part numbers.
1. Position machine on a level surface.
2. Remove dipstick (Fig. 25) 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.
1
Figure 25
1. Dipstick
3. If oil level is low, remove oil fill cap (Fig. 26) and
gradually add small quantities of oil, checking level
frequently, until level reaches FULL mark on dipstick.
4. Install oil fill cap and close hood.
Important Be sure to keep the engine oil level between
the upper and lower limits on the oil gauge. Engine failure
may occur as a result of over filling or under filling the
engine oil.
1
Figure 26
1. Oil fill cap
Fill Fuel Tank
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.
•Use a funnel and fill the fuel tank outdoors, in
an open area, when the engine is off and is cold.
Wipe up any fuel that spills.
•Do not fill the fuel tank completely full. Add fuel
to the fuel tank until the level is 1/4 to 1/2 in. (6
to 13 mm) below the bottom of the filler neck.
This empty space in the tank allows the fuel to
expand.
•Never smoke when handling fuel, and stay away
from an open flame or where fuel fumes may be
ignited by a spark.
•Store fuel in a clean, sealed, safety-approved
container.
Use only clean, fresh diesel fuel or biodiesel fuels with low
(<500 ppm) or ultra low (<15 ppm) sulfur content. The
minimum cetane rating should be 40. Purchase fuel in
quantities that can be used within 180 days to ensure fuel
freshness.
Fuel tank capacity: 7.5 U.S. gallons (28 l)
Use summer grade diesel fuel (No. 2–D) at temperatures
above 20 degrees F (–7 degrees C) and winter grade (No.
1–D or No. 1–D/2–D blend) below that temperature. Use of
winter grade fuel at lower temperatures provides lower
flash point and cold flow characteristics which will ease
starting and reduce fuel filter plugging.
Use of summer grade fuel above 20 degrees F (–7 degrees
C) will contribute toward longer fuel pump life and
increased power compared to winter grade fuel.