Manuals+

Toro Reelmaster 3100-D Operator's Manual

Form No.: 3322-575 Rev A

Model Numbers: 03200 - 90001 & UP, 03201 - 90151 & UP, 03220, 03221

Brand: Toro

Product Type: Commercial Mower

The Toro logo is displayed prominently.

Safety Alert Symbol: A triangular symbol indicates CAUTION, WARNING, or DANGER. It signifies a personal safety instruction. Failure to comply may result in personal injury.

Introduction

This operator's manual provides instructions on safety, operation, and maintenance for the Toro Reelmaster 3100-D. It emphasizes safety, mechanical, and general product information. DANGER, WARNING, and CAUTION messages identify safety concerns. The triangular safety alert symbol highlights important safety messages. "IMPORTANT" denotes special mechanical information, and "NOTE" highlights general product information requiring special attention.

Identification and Ordering

Model and Serial Number

The model and serial number for the traction unit are located on a plate on the left front frame member. The model and serial number for the cutting unit are on a plate on the top front of the center cutting unit. These numbers should be used in all correspondence and when ordering parts.

To order replacement parts from an authorized TORO Distributor, provide the following:

  1. Model and serial numbers of the machine.
  2. Part number, description, and quantity of parts desired.

NOTE: Do not order by reference number if a parts catalog is being used; use the part number.

Table of Contents

Safety, Specifications, Before Operating, Controls, Operating Instructions, Maintenance (including Maintenance Schedule, Aircleaner Maintenance, Engine Maintenance, Hydraulic Maintenance, Brake Maintenance, Electrical Maintenance, Backlapping, Preparation for Seasonal Storage), Identification and Ordering, The Toro Promise.

Safety Instructions

Supervisors' Responsibilities

  1. Ensure operators are thoroughly trained and familiar with the manual and machine labels.
  2. Establish special procedures for unusual operating conditions (e.g., steep slopes). Survey mowing sites for rollover risk, considering turf condition. Use the provided inclinometer to determine safe mowing slopes. A 1.5-meter board can be used to measure slope angles. THE MAXIMUM SIDE HILL ANGLE SHOULD NOT BE GREATER THAN 25 DEGREES.

Before Operating

  1. Operate only after reading and understanding this manual. Replacement manuals are available from Toro Distributors.
  2. Only trained operators skilled in slope operation should use the machine. Never allow untrained individuals or children to operate it.
  3. Become familiar with controls and know how to stop the machine and engine quickly.
  4. Do not carry passengers. Keep children and pets away from the operating area.
  5. Keep all shields, safety devices, and decals in place. Repair or replace damaged, malfunctioning, or illegible items before operating.
  6. Always wear substantial shoes. Avoid sandals, tennis shoes, or sneakers. Do not wear loose-fitting clothing that could get caught in moving parts.
  7. Wearing safety glasses, safety shoes, long pants, and a helmet is advisable and may be required.
  8. Ensure the work area is clear of objects that could be thrown by the reels.
  9. Fill the fuel tank with diesel fuel before starting. Handle fuel carefully as it is highly flammable. Use approved containers. Do not remove the fuel cap when the engine is hot or running. Do not smoke while handling fuel. Fill the tank outdoors, not overfilling (leave ~2.5 cm space).

While Operating

  1. Do not run the engine in confined areas without adequate ventilation; exhaust fumes are hazardous.
  2. Sit on the seat when starting and operating.
  3. Check interlock switches daily for proper operation. Do not bypass the system. Replace switches every two years. Shut off the engine before getting off the seat.
  4. Operators must be skilled and trained in hillside operation. Failure to use caution can lead to tipping or rolling, resulting in serious injury or death. Always wear a seat belt.
  5. The triplex mower has a unique drive system for superior traction on hills. If operated on too steep a side hill, rollover may occur before traction is lost.
  6. The tipping angle depends on factors like turf conditions, speed, cutting unit position, tire pressure, and operator experience. At 20 degrees or less, rollover risk is low. At 25 degrees, risk is moderate. DO NOT EXCEED A 25-DEGREE SIDE HILL ANGLE DUE TO HIGH RISK OF ROLLOVER AND SERIOUS INJURY OR DEATH. Be alert for terrain hazards. Use extreme caution near sand traps, ditches, creeks, and steep hillsides. Reduce speed on sharp turns. Do not turn on hills. Avoid sudden stops/starts. Use the reverse pedal for braking. Lower cutting units when going down slopes for steering control.
  7. When starting the engine: Engage the parking brake. Ensure the traction pedal is in neutral and the reel drive is disengaged. After starting, release the parking brake and ensure the machine does not move. If it moves, the neutral linkage needs adjustment.
  8. Before backing up, look to the rear. Watch for traffic when near or crossing roads. Yield the right of way.
  9. Keep hands, feet, and clothing away from moving parts and the reel discharge area. Ensure grass baskets are in place.
  10. Noise levels may exceed 85 dB(A). Ear protectors are recommended for prolonged exposure.
  11. Raise cutting units when moving between work areas.
  12. Do not touch the engine, muffler, exhaust pipe, or hydraulic tank while hot, as they can cause burns.
  13. If a cutting unit strikes an object or vibrates abnormally, stop immediately, turn off the engine, wait for motion to stop, and inspect for damage. Repair or replace damaged reels or bedknives before continuing.
  14. Before getting off the seat: Move traction pedal to neutral, set parking brake, disengage cutting units (wait for reels to stop), stop the engine, and remove the key.
  15. When leaving the machine unattended, ensure reels are stopped, the key is removed, and the parking brake is set.

Maintenance Safety

  1. Before servicing or making adjustments, stop the engine and remove the key.
  2. Check interlock switches daily. Do not defeat the system.
  3. Frequently check and tighten all nuts, bolts, screws, and hydraulic fittings.
  4. Ensure hydraulic line connectors are tight and hoses/lines are in good condition before applying pressure.
  5. Keep body and hands away from pinhole leaks or high-pressure fluid nozzles. Use cardboard/paper to find leaks. Escaping fluid can penetrate skin and cause serious damage. Injected fluid requires immediate surgical removal to prevent gangrene.
  6. Before working on the hydraulic system, relieve all pressure by stopping the engine and lowering cutting units.
  7. For major repairs or assistance, contact an Authorized Toro Distributor.
  8. Keep the engine area free of grease, grass, leaves, and dirt to reduce fire hazard.
  9. If the engine must run for adjustments, keep hands, feet, clothing, and body parts away from cutting units and moving parts. Keep everyone away.
  10. Do not overspeed the engine by changing governor settings. Have an Authorized Toro Distributor check maximum engine speed.
  11. Shut off the engine before checking or adding oil.

Use genuine TORO replacement parts and accessories for optimum performance and safety. Non-Toro parts could be dangerous and void the warranty.

Symbol Glossary

This section defines various symbols used in the manual.

Additional symbols include:

Specifications

Before Operating

⚠️ CAUTION: Before servicing or making adjustments, stop the engine and remove the key from the switch.

Check Crankcase Oil (Fig. 1-2)

The engine is shipped with oil; check level before and after first start. Crankcase capacity is 2.8 L with filter.

  1. Position machine on a level surface.
  2. Remove, wipe, and reinsert dipstick. Check oil level. Add oil to reach the FULL mark if low.
  3. If oil level is low, remove oil fill cap and gradually add small quantities of oil, checking level frequently until it reaches the FULL mark.
  4. The engine uses high-quality 10W30 detergent oil (API classification CD, CE, CF CF-4, or CG-4).
  5. Install oil fill cap and close hood.

IMPORTANT: Check oil level every 5 operating hours or daily. Change oil every 50 hours.

Fill the Fuel Tank (Fig. 3)

The engine uses No. 2 diesel fuel. Fuel tank capacity is approx. 28.4 L.

  1. Clean the area around the fuel tank cap.
  2. Remove the fuel tank cap.
  3. Fill the tank to the bottom of the filler neck. DO NOT OVERFILL. Reinstall cap.
  4. Wipe up any spilled fuel to prevent fire hazard.

⛔ DANGER: Diesel fuel is flammable. Use caution when storing or handling. Do not smoke while filling. Do not fill while the engine is running, hot, or in an enclosed area. Always fill outdoors and wipe spills before starting. Store fuel in a clean, safety-approved container with cap in place. Use diesel fuel only.

Check the Cooling System (Fig. 4 & 5)

Clean debris from radiator and oil cooler daily, or hourly in dusty conditions. Cooling system capacity is 5.7 L.

⚠️ CAUTION: Pressurized hot coolant can escape when the radiator cap is removed. Only open when the engine is cold.

  1. The cooling system uses a 50/50 water and ethylene glycol anti-freeze solution. Check coolant level daily before starting.
  2. Check coolant level in the expansion tank. With a cold engine, level should be midway between the marks.
  3. If coolant is low, remove expansion tank cap and replenish. DO NOT OVERFILL.
  4. Install expansion tank cap.

Check the Hydraulic System Fluid (Fig. 6)

The hydraulic system uses anti-wear hydraulic fluid. Reservoir capacity is 13.2 L (DTE 15M from factory). Check fluid level before first start and daily thereafter.

IMPORTANT: Use only specified hydraulic fluids. Other fluids can cause system damage.

Note: Red dye additive available (Part No. 44-2500). One bottle for 15-19 L.

  1. Position machine on a level surface, lower cutting units, and stop the engine.
  2. Clean around the hydraulic tank filler neck and cap. Remove the cap.

Figure 6 shows the Hydraulic Tank Cap.

  1. Remove dipstick, wipe clean, reinsert, and check fluid level. Level should be within 6 mm of the mark.
  2. If low, add appropriate fluid to the full mark.
  3. Install dipstick and cap.

Check Wheel Nut Torque

Torque wheel nuts to 61–88 Nm after 1–4 hours of operation, again after 10 hours, and every 200 hours thereafter. Failure to maintain proper torque can result in wheel failure or loss, causing personal injury.

WARNING: Torque wheel nuts to 61–88 Nm 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 a wheel and may result in personal injury.

Check Tire Pressure

Tires are overinflated for shipping. Release air to correct pressure. Correct pressure is 97–124 kPa.

IMPORTANT: Maintain recommended tire pressure for quality of cut and machine performance. DO NOT UNDER INFLATE.

Check the Reel-to-Bedknife Contact

Each day before operating, check reel-to-bedknife contact. There must be light contact across the full length of the reel and bedknife (refer to Adjusting The Reel-to-Bedknife Contact in the cutting unit operator's manual).

Controls

Traction Pedals (Fig. 7): Depress forward pedal for forward movement. Depress reverse pedal for backward movement or to help stop. Allow pedal to return to neutral to stop.

Mow/Transport Slide (Fig. 7): Move slide left to transport, right to mow. Cutting units operate only in mow position. Mow speed is factory set at 6 mph but can be adjusted via speed stop screw (Fig. 8).

Figure 7 shows Traction Pedals, Mow/Transport Slide, Tilt Steering Lever, and Indicator Slot. Figure 8 shows the Speed Stop Screw.

Tilt Steering Lever (Fig. 7): Pull lever back to tilt steering wheel, then push lever forward to tighten.

Starter Switch (Fig. 9): Positions: OFF, ON/PREHEAT, START. Turn key to ON/PREHEAT until glow plug light goes out (~7 sec), then turn to START. Release key when engine starts. Key returns to ON/RUN. Turn to OFF to stop engine. Remove key to prevent accidental starting.

Throttle (Fig. 9): Move forward to increase engine speed, rearward to decrease.

Cutting Unit Shift Lever (Fig. 9): Move forward to lower cutting units. Units won't drop unless engine is running and won't operate when raised. Pull rearward to RAISE. Model 03201: Move left/right to shift units in same direction (only when raised or machine is moving). Lever does not need to be held forward to lower units.

Indicator Slot (Fig. 9): Shows when cutting units are in the center position.

Cutting Unit Drive Switch (Fig. 9): Two positions: ENGAGE and DISENGAGE. Rocker switch operates a solenoid valve.

Figure 9 shows the control panel layout with numbered controls: 1. Throttle, 2. Hour meter, 3. Temperature light, 4. Oil pressure light, 5. Glow plug indicator light, 6. Alternator light, 7. Cutting unit drive switch, 8. Cutting unit shift lever, 9. Ignition switch, 10. Parking brake, 11. Lift lever lock.

Hour Meter (Fig. 9): Indicates total operating hours when key switch is ON.

Engine Coolant Temperature Warning Light (Fig. 9): Glows if coolant temp is high. Engine will stop if traction unit is not stopped and temp rises.

Oil Pressure Warning Light (Fig. 9): Glows if oil pressure drops below a safe level.

Alternator Light (Fig. 9): Should be off when engine is running. If on, check charging system.

Glow Plug Indicator (Fig. 9): Glows when glow plugs are operating.

Parking Brake (Fig. 9): Engage when engine is off to prevent movement. Pull up on lever. Engine stops if traction pedal is depressed with parking brake engaged.

Lift Lever Lock (Fig. 9): Move lever rearward to prevent cutting units from dropping.

Reel Speed Control (Fig. 10): Located under console cover. Turn knob to set clip rate (reel speed) for height of cut and mower speed. Refer to Selecting Clip Rate section.

Backlap Control (Fig. 10): Located under console cover. Turn clockwise for backlapping, counterclockwise for mowing. Do not change knob position when reels are turning.

Figure 10 shows: 1. Reel speed control, 2. Backlap control.

Fuel Gauge (Fig. 11): Shows fuel level in the tank.

Seat Adjustments (Fig. 11):

Figure 11 shows: 1. Fore and aft lever, 2. Fuel gauge.

Operating Instructions

Starting/Stopping the Engine

IMPORTANT: The fuel system may need bleeding if: A. Initial start of a new engine. B. Engine ran out of fuel. C. Maintenance performed on fuel system components (e.g., filter replaced).

Refer to Bleeding The Fuel System.

  1. Ensure parking brake is set and reel drive switch is DISENGAGE.
  2. Remove foot from traction pedal and ensure it is in neutral.
  3. Move throttle lever to half-throttle.
  4. Insert key, turn to ON/PREHEAT until glow plug indicator light goes out (~7 sec), then turn to START. Release key when engine starts. Key moves to ON/RUN.

IMPORTANT: To prevent starter motor overheating, do not engage starter longer than 15 seconds. After 10 seconds of cranking, wait 60 seconds before cranking again.

  1. When starting for the first time or after overhaul, operate machine forward/reverse for 1-2 minutes. Operate lift lever and reel drive switch to ensure proper operation.
  2. Turn steering wheel to check response. Shut off engine and check for leaks, loose parts, or malfunctions.

⚠️ CAUTION: Shut engine off and wait for all moving parts to stop before checking for oil leaks, loose parts, and other malfunctions.

  1. To stop engine: Move throttle to IDLE, move reel drive switch to DISENGAGE, turn starter key to OFF. Remove key.

Bleeding The Fuel System (Fig. 12)

  1. Park on a level surface. Ensure fuel tank is at least half full.
  2. Unlatch and raise hood.

⛔ DANGER: Diesel fuel is flammable. Use caution when storing or handling. Do not smoke while filling. Do not fill while engine is running, hot, or in an enclosed area. Always fill outdoors and wipe spills before starting. Store fuel in a clean, safety-approved container with cap in place. Use diesel fuel only.

  1. Open air bleed screw on fuel injection pump (Fig. 16).
  2. Turn key to ON. Electric fuel pump operates, forcing air out around bleed screw. Leave key ON until solid stream of fuel flows out. Tighten screw, turn key OFF.

Figure 12 shows the fuel injection pump bleed screw.

Note: Engine should start after bleeding. If not, air may be trapped; refer to Bleeding Air From The Injectors.

Check Operation of the Interlock Switches

⚠️ CAUTION: Do not disconnect safety switches. Check operation daily. Replace faulty switches. Replace all switches every two years.

  1. Ensure bystanders are away from operation area. Keep hands and feet away from cutting units.
  2. With operator on seat, engine must not start with reel switch engaged or traction pedal engaged. Correct if not operating properly.
  3. With operator on seat, traction pedal neutral, parking brake off, reel switch OFF, engine should start. Rise from seat and slowly depress traction pedal; engine should stop in 1-3 seconds. Correct if this does not happen.
  4. With operator on seat, engine running, reel transport slide in mow, reel switch ON, lower cutting units. Reels should engage. Pull back lift lever; reels should stop when fully raised. Correct if this does not happen.

Note: Interlock switch on parking brake stops engine if traction pedal is depressed with parking brake engaged.

Towing The Traction Unit (Fig. 13)

Towing is for emergency use only; Toro does not recommend it as standard procedure.

IMPORTANT: Do not tow faster than 2-3 mph to avoid drive system damage. For longer distances, transport on a truck or trailer.

  1. Locate by-pass valve on pump and turn 90°.
  2. Before starting engine, close by-pass valve by rotating 90°. Do not start engine with valve open.

Figure 13 shows the by-pass valve.

Operating Characteristics

⛔ DANGER: The mower's unique traction system allows forward movement on side hills even if the uphill wheel lifts off the ground. This can cause serious injury or death from rollover.

The slope angle for tipping depends on mowing conditions (wet/undulating turf, speed, cutting unit position, tire pressure, operator experience). At 20 degrees or less, rollover risk is low. At 25 degrees, risk is moderate. DO NOT EXCEED A 25-DEGREE SIDE HILL SLOPE ANGLE DUE TO THE VERY HIGH RISK OF ROLLOVER AND SERIOUS INJURY OR DEATH.

Perform a site survey to determine safe operating slopes, considering turf condition and rollover risk. Use the inclinometer. A 1.5-meter board can average slope but not account for dips/holes. THE MAXIMUM SIDE HILL ANGLE SHOULD NOT BE GREATER THAN 25 DEGREES.

Practice operating the Reelmaster to become familiar with it.

Start engine at half idle until warm. Push throttle forward, lift cutting units, disengage parking brake, press forward traction pedal, and drive to an open area.

Practice forward and reverse movement, starting and stopping. To stop, release traction pedal to neutral or press reverse pedal. Going downhill may require reverse pedal for stopping.

When driving on slopes, drive slowly for steering control and to prevent rollovers. On side hills, shift sidewinder cutting units uphill for stability. Shifting downhill reduces stability.

Mow up and down hills rather than across them when possible. Lower cutting units when going downhill for steering control. Do not turn on hills.

Practice driving around obstacles with reels up and down. Be careful between narrow objects to avoid damaging the machine or cutting units.

Understand the reach of Sidewinder cutting units to avoid snagging or damage.

Do not shift units side-to-side unless units are down and machine is moving, or units are up in transport position. Shifting units when down and not moving may cause turf damage.

The Reelmaster is a precision machine; drive slowly in rough areas.

If a person enters the operating area, stop the machine and do not restart until the area is clear. The Reelmaster is a one-person machine; never let anyone else ride. This is dangerous and could cause serious injury.

Accidents can happen. Common causes include excessive speed, sudden turns, terrain (knowing safe slopes), not stopping the engine before leaving the seat, and using impairing drugs. Stay alert and safe.

The Sidewinder offers up to 58 cm of overhang, allowing closer trimming to obstacles while keeping tires further from hazards.

If an obstacle is present, shift cutting units to mow around it.

⚠️ CAUTION: This product may exceed noise levels of 85 dB(A). Ear protectors are recommended for prolonged exposure to reduce potential hearing damage.

When transporting, raise cutting units fully, move Mow/Transport slide left, and set throttle to FAST. Units will not operate in transport.

Mowing Techniques

To begin cutting, engage reels, then approach mowing area. Once front reels are over the area, lower cutting units.

For straight-line cuts and striping, find a distant object and drive straight toward it.

As front reels reach the edge of the mowing area, lift cutting units and perform a tear drop turn for the next pass.

Mowing around contours (bunkers, ponds) is easy with the Reelmaster 3100-D with Sidewinder. Use the Sidewinder application by moving the control lever left or right. Cutting units can also be shifted to vary tire tracking.

Reelmaster 3100-D cutting units can throw clippings front or rear. Front throw is for smaller grass amounts for a better appearance; close the rear shield for front throw.

⚠️ CAUTION: Shut engine off and wait for all moving parts to stop before opening or closing cutting unit shields.

When cutting large amounts of grass, position shields just below horizontal. Do not open shields too far, as clippings can build up on the frame, radiator screen, and engine area.

Cutting units have balance weights for an even cut. Weights can be added or removed if mismatch occurs.

After Mowing

Thoroughly wash the machine with a garden hose (no nozzle) to avoid damaging seals and bearings. Ensure radiator and oil cooler are free of dirt/grass. After cleaning, inspect for hydraulic fluid leaks, component damage, or wear. Check cutting units for sharpness and reel-to-bedknife adjustment.

IMPORTANT: After washing, move the Sidewinder mechanism (model 03201 only) from left to right several times to remove water from bearing blocks and cross tube.

Selecting Clip Rate (Reel Speed)

To achieve a consistent, high-quality cut and uniform appearance, match reel speed to height of cut.

IMPORTANT: If reel speed is too slow, clip marks may be visible. If too fast, the cut may appear fuzzy.

Adjust clip rate (reel speed) as follows:

  1. Verify height-of-cut setting on cutting units. Using the chart, find the height-of-cut listing nearest the actual setting and look across to find the corresponding number. Note: Higher number means higher speed.

Figure 14 shows the Reel speed control.

8 BLADE REEL REEL SPEED SELECTION CHART

Height of Cut Reel Speed Setting
2-1/4 2.25 3*
2-1/8 2.13 3*
2 2.00 3*
1-7/8 1.88 3*
1-3/4 1.75 3*
1-5/8 1.63 3*
1-1/2 1.50 3
1-3/8 1.38 3
1-1/4 1.25 4
1-1/8 1.13 4
1 1.00 5
7/8 0.88 5
3/4 0.75 7
5/8 0.63 11*
1/2 0.50 11*
3/8 0.38 11*

* This height of cut and/or mowing speed not recommended for 8-blade reels.

Note: Positions 9 to 11 give the same reel speed.

1 5 BLADE REEL REEL SPEED SELECTION CHART

Height of Cut Reel Speed Setting
2-1/2 2.50 3
2-3/8 2.38 3
2-1/4 2.25 3
2-1/8 2.13 3
2 2.00 3
1-7/8 1.88 4
1-3/4 1.75 4
1-5/8 1.63 5
1-1/2 1.50 5
1-3/8 1.38 5
1-1/4 1.25 6
1-1/8 1.13 8
1 1.00 11
7/8 0.88 11*
3/4 0.75 11*
5/8 0.63 11*
1/2 0.50 11*
3/8 0.38 11*

* This height of cut and/or mowing speed not recommended for 5 blade reels.

2. Turn the reel speed control knob to the number setting determined in step 1.

3. Operate the machine for several days, then examine the cut for satisfaction. The reel speed knob may be set one position higher or lower to account for grass condition, length removed, and personal preference.

Maintenance

Maintenance Schedule

This section outlines maintenance procedures and intervals.

Maintenance Procedure Every 50 hours Every 100 hours Every 200 hours Every 400 hours Every 800 hours
Inspect the air filter, Dust Cup and Burp Valve ✔
Lubricate all grease fittings ✔
Change the engine oil ✔
Check battery fluid level ✔
Check battery cable connections ✔
+Check alternator fan belt tension ✔
+Change the engine oil and filter
Inspect the Traction Belt
Replace the air filter
+Replace the hydraulic filter
+Torque the wheel lug nuts
Replace the hydraulic fluid
Replace the fuel/water separator filter
Replace the fuel pre-filter
Inspect traction cable movement
Inspect the spider coupling for wear
‡Check engine RPM (idle and full throttle)
Adjust valves
+Initial break in at 8 hours
‡Initial break in at 50 hours
Replace moving hoses
Replace safety switches
Fuel tank--drain and flush
Hydraulic tank--drain and flush
Cooling system--drain and flush

Recommendations: Items are recommended every 2000 hours or 2 years, whichever occurs first.

Daily Maintenance Checklist

Lubrication

Greasing Bearings and Bushings (Fig. 15-26)

The traction unit has grease fittings requiring No. 2 General Purpose Lithium Base Grease. Lubricate bearings and bushings after every 50 hours of operation under normal conditions. Lubricate daily in extremely dusty/dirty conditions. Lubricate immediately after every washing, regardless of interval.

Bearings and bushings to lubricate include: Rear cutting unit pivot (Fig. 15), Front cutting unit pivot (Fig. 16), Sidewinder cylinder ends (2) (Model 03201 only) (Fig. 17), Steering pivot (Fig. 18), Rear lift arm pivot and lift cylinder (2) (Fig. 19), Left front lift arm pivot and lift cylinder (2) (Fig. 20), Right front lift arm pivot and lift cylinder (2) (Fig. 21), Neutral adjust mechanism (Fig. 22), Mow/Transport slide (Fig. 23), Belt tension pivot (Fig. 24), Steering cylinder (Fig. 25).

Figures 15-26 illustrate locations of grease fittings.

Note: An additional grease fitting may be installed in the steering cylinder end; tire must be removed, fitting installed, greased, removed, and plug installed (Fig. 26).

IMPORTANT: Do not lubricate Sidewinder (model 03201) cross tube; bearing blocks are self-lubricated.

Servicing the Air Cleaner (Fig. 28 & 29)

⚠️ CAUTION: Before servicing, stop engine and remove key.

Hood Removal (Fig. 27)

  1. Unlatch and raise hood.
  2. Remove cotter pin securing hood pivot.
  3. Slide hood right, lift other side, and pull out of brackets.
  4. Reverse procedure to reinstall.

Figure 27 shows cotter pin removal.

General Air Cleaner Maintenance

  1. Check air cleaner body for damage causing air leaks. Replace damaged body.
  2. Service air cleaner filter every 200 hours (more often in dusty conditions).
  3. Ensure cover seals around the air cleaner body.

Figure 28 shows air cleaner components: 1. Air cleaner dust cup, 2. Air cleaner latches. Figure 29 shows the filter element.

Servicing Steps:

  1. Release latches securing air cleaner cover. Separate cover and body. Clean inside of cover.
  2. Gently slide filter out to reduce dust dislodged. Avoid knocking filter against body.
  3. Inspect filter; discard if damaged. Do not wash.

Washing Method:

  1. Soak filter element in a solution of filter cleaner and water for ~15 minutes (refer to cleaner carton).
  2. After soaking, rinse with clear water (max 276 kPa). Rinse from clean to dirty side.
  3. Dry filter element with warm, flowing air (max 71°C) or air dry. Do not use a light bulb.

Compressed Air Method:

  1. Blow compressed air from inside to outside of dry filter element (max 689 kPa).
  2. Keep air hose nozzle at least 5 cm from filter, move nozzle up/down while rotating element. Inspect for holes/tears.
  1. Inspect new filter for shipping damage. Check sealing end. Do not install damaged filter.
  2. Insert new filter into air cleaner body, ensuring proper seal by applying pressure to outer rim. Do not press flexible center.
  3. Reinstall cover and secure latches, ensuring TOP side is up.

Engine Oil and Filter (Fig. 30 & 31)

Change oil and filter initially after first 50 hours. Thereafter, change oil every 50 hours and filter every 100 hours.

  1. Remove drain plug, let oil drain into pan. Install plug when oil stops flowing.
  2. Remove oil filter. Apply light coat of clean oil to new filter seal before screwing on. DO NOT OVER TIGHTEN.
  3. Add oil to crankcase (refer to Check The Engine Oil).

Figure 30 shows the Engine Oil Drain Plug. Figure 31 shows the Engine Oil Filter.

Fuel System

Fuel Tank

Drain and clean fuel tank every 2 years, or if contaminated, or for extended storage. Use clean fuel to flush.

Fuel Lines and Connections

Check lines and connections every 400 hours or yearly. Inspect for deterioration, damage, or loose connections.

Water Separator (Fig. 32)

Drain water or contaminants daily.

  1. Place clean container under fuel filter.
  2. Loosen drain plug on bottom of filter canister. Tighten after draining.

Figure 32 shows the Water Separator and Drain Plug.

Replace filter canister every 400 hours.

  1. Clean area where canister mounts.
  2. Remove canister and clean mounting surface.
  3. Lubricate gasket with clean oil.

Install canister by hand until gasket contacts surface, then turn an additional 1/2 turn.

Replacing the Fuel Pre Filter (Fig. 33)

Replace fuel pre filter (inside frame rail below water separator) every 400 operating hours or yearly.

  1. Remove screw securing filter to frame rail.
  2. Clamp fuel lines to prevent fuel drainage when lines are removed.
  3. Loosen hose clamps at both ends of filter and pull lines off.

Figure 33 shows the Fuel Pre Filter and Hose Clamps.

  1. Slide hose clamps onto fuel line ends. Push lines onto filter and secure. Arrow on filter points toward injection pump.

⛔ DANGER: Diesel fuel is flammable. Use caution when storing or handling. Do not smoke while filling. Do not fill while engine is running, hot, or in an enclosed area. Always fill outdoors and wipe spills before starting. Store fuel in a clean, safety-approved container with cap in place. Use diesel fuel only.

Bleeding Air From Injectors (Fig. 34)

Note: Use this procedure only if fuel system purged via normal priming and engine won't start. Refer to Bleeding The Fuel System.

  1. Loosen pipe connection to No. 1 nozzle and holder assembly.

Figure 34 shows Fuel Injectors (3).

  1. Move throttle to FAST position.
  2. Turn key to START, watch fuel flow around connector. Turn key to OFF when solid flow is observed.
  3. Tighten pipe connector securely.
  4. Repeat steps for remaining nozzles.

Engine Cooling System (Fig. 35 & 36)

  1. Removing Debris: Remove debris from oil cooler and radiator daily; more frequently in dirty conditions.
  2. Turn engine off and raise hood. Clean engine area.
  3. Remove access panel.

Figure 35 shows: 1. Access panel, 2. Oil cooler, 3. Radiator. Figure 36 shows the engine area.

  1. Unlatch oil cooler, pivot rearward. Clean cooler and radiator area with water or compressed air. Pivot cooler back.
  2. Install access panel and close hood.

Servicing the Engine Belts

Check condition and tension of all belts after the first day of operation and every 100 hours thereafter.

Alternator/Fan Belt (Fig. 37)

  1. Open hood.
  2. Check tension by depressing belt midway between pulleys with 30 Nm force. Belt should deflect 11 mm. If incorrect, proceed to step 3.
  3. Loosen bolt securing brace to engine and bolt securing alternator to brace.
  4. Insert pry bar between alternator and engine, pry outward on alternator.
  5. When correct tension is achieved, tighten alternator and brace bolts.

Figure 37 shows the Alternator/Fan Belt.

Hydrostat Drive Belt Replacement (Fig. 38)

  1. Insert nut driver or tubing onto belt-tensioning spring end.

WARNING: Use caution when releasing spring tension; it is under heavy load.

  1. Push down and forward on spring end to unhook from bracket and release tension.
  2. Replace belt.
  3. Reverse procedure to tension spring.

Figure 38 shows: 1. Hydrostat Drive Belt, 2. Spring end.

Adjusting the Throttle (Fig. 39)

  1. Position throttle lever rearward to stop against control panel slot.
  2. Loosen throttle cable connector on lever arm at injection pump.

Figure 39 shows the Injection Pump Lever Arm.

  1. Hold injection pump lever arm against low-idle stop and tighten cable connector.
  2. Loosen screws securing throttle control to control panel.
  3. Push throttle control lever all the way forward.
  4. Slide stop plate until it contacts throttle lever and tighten screws securing throttle control.
  5. If throttle does not stay in position, torque lock nut for friction device. Max force to operate lever should be 27 Nm.

⚠️ CAUTION: Before servicing, stop engine and remove key.

Changing Hydraulic Fluid (Fig. 40-42)

Change hydraulic fluid every 400 operating hours in normal conditions. If fluid is contaminated, contact Toro distributor for flushing. Contaminated fluid appears milky or black.

  1. Turn engine off and raise hood.
  2. Disconnect hydraulic line or remove filter; let fluid drain into pan. Reinstall line after draining stops.

Figure 40 shows a Hydraulic line. Figure 41 shows a Hydraulic Filter. Figure 42 shows the Hydraulic Reservoir.

IMPORTANT: Use only specified hydraulic fluids. Other fluids could cause system damage.

  1. Install reservoir cap. Start engine and use all hydraulic controls to distribute fluid. Check for leaks. Stop engine.
  2. Check fluid level and add enough to reach FULL mark on dipstick. DO NOT OVER FILL.

Replacing Hydraulic Filter (Fig. 43)

Change hydraulic filter initially after first 10 hours, then every 200 hours or yearly. Use genuine Toro filter. Change hydraulic oil every 400 hours or yearly.

Use Toro replacement filter (Part No. 54-0110).

IMPORTANT: Use of any other filter may void warranty on some components.

  1. Position machine on level surface, lower cutting units, stop engine, engage parking brake, remove key.
  2. Pinch off hose to filter mounting plate.
  3. Clean area around filter mounting area. Place drain pan under filter and remove filter.

Figure 43 shows Test Port #1.

  1. Lubricate new filter gasket and fill filter with hydraulic fluid.
  2. Ensure filter mounting area is clean. Screw filter on until gasket contacts plate, then tighten 1/2 turn.
  3. Start engine and run for ~2 minutes to purge air. Stop engine and check for leaks.

Checking Hydraulic Lines and Hoses

Daily, check lines and hoses for leaks, kinks, loose supports, wear, loose fittings, weather/chemical deterioration. Make repairs before operating.

WARNING: Keep body and hands away from pinhole leaks or high-pressure fluid nozzles. Use cardboard/paper to find leaks. Escaping fluid can penetrate skin and cause injury. Injected fluid requires immediate surgical removal to prevent gangrene.

Hydraulic System Test Ports (Fig. 43)

Test port used to test pressure in hydraulic circuit. Contact local Toro distributor for assistance.

  1. Test Port #1 is used for troubleshooting forward traction hydraulic circuit.

Adjusting the Traction Drive for Neutral (Fig. 44)

If machine "creeps" when traction pedal is neutral, adjust traction cam.

  1. Park on level surface, turn engine off.
  2. Raise one front wheel and one rear wheel off floor; place support blocks under frame.

WARNING: One front and one rear wheel must be raised. Machine will move during adjustment. Ensure machine is supported to prevent accidental fall.

  1. Loosen locknut on traction adjustment cam.

Figure 44 shows: 1. Traction adjustment cam, 2. Locknut.

WARNING: Engine must be running for final adjustment. Keep hands, feet, face away from muffler, hot parts, and rotating parts.

  1. Start engine and turn cam hex in both directions to find mid-position of neutral span.
  2. Tighten locknut.
  3. Stop engine.
  4. Remove support blocks and lower machine. Test drive to ensure no creep.

Brake Maintenance

Adjusting the Parking Brake (Fig. 45)

Check adjustment every 200 hours.

  1. Loosen set screw securing knob to parking brake lever.
  2. Turn knob until 41–54 Nm force is required to actuate lever.
  3. Tighten set screw after adjustment.

Figure 45 shows: 1. Parking brake lever, 2. Knob, 3. Setscrew.

Battery Care

  1. Maintain proper battery electrolyte level and keep top clean. High temperatures can cause battery to run down faster.
  2. Check electrolyte level every 25 operating hours or every 30 days if in storage.
  3. Maintain cell level with distilled or demineralized water. Do not fill above bottom of split ring inside cells. Point vents to rear (toward fuel tank).

⚠️ CAUTION: Wear safety goggles and rubber gloves when working with electrolyte. Charge battery in a well-ventilated area. Gases produced are explosive; keep flames and sparks away. Nausea may result from inhaling gases. Unplug charger before connecting/disconnecting leads.

  1. Keep battery top clean by washing periodically with a brush dipped in ammonia or bicarbonate of soda solution. Flush with water. Do not remove fill caps while cleaning.
  2. Battery cables must be tight for good electrical contact.

WARNING: Connecting cables to the wrong post can cause personal injury and/or electrical system damage.

  1. If corrosion occurs at terminals, disconnect cables (negative first), scrape clamps and terminals separately. Reconnect cables (positive first) and coat terminals with petroleum jelly.
  2. Always disconnect battery ground cable (-) first to prevent wiring damage from shorts.

Battery Storage

If storing machine >30 days, remove battery, charge fully, and store on shelf. Leave cables disconnected. Store battery in a cool atmosphere to prevent charge deterioration. Ensure battery is fully charged to prevent freezing. Specific gravity of a fully charged battery is 1.265–1.299.

Fuses

Fuses are located under the console cover.

Backlapping

⛔ DANGER: TO AVOID PERSONAL INJURY OR DEATH: Never place hands or feet in reel area while engine is running.

  1. Position machine on clean, level surface, lower cutting units, stop engine, engage parking brake, remove key.
  2. Remove console cover to expose controls.
  3. Turn backlap knob to backlap position. Turn reel speed knob to position 1.

Note: Seat switch is bypassed when backlap knob is in backlap position. Operator does not need to be seated, but parking brake must be engaged or engine won't run.

⚠️ CAUTION: Do not turn backlap knob from mow to backlap while engine is running, as damage to reels may occur.

Figure 46 shows: 1. Backlap knob, 2. Reel speed knob.

  1. Make initial reel-to-bedknife adjustments for backlapping on all cutting units. Start engine and set to low idle speed.
  2. Engage reels by engaging PTO switch.
  3. Apply lapping compound with a long-handled brush.

⚠️ CAUTION: Be careful when lapping reel; contact with reel or moving parts can cause personal injury.

  1. To adjust cutting units while backlapping, disengage reels and turn engine OFF. After adjustments, repeat steps 4–6.
  2. When backlap operation is complete, stop engine, turn backlap knob to MOW, set reel speed controls to desired mowing setting, and wash off all lapping compound.

NOTE: Additional backlapping instructions are in TORO Sharpening Reel & Rotary Mowers Manual Form No. 80-300SL.

NOTE: For a better cutting edge, run a file across the front face of the bedknife after lapping to remove burrs.

Preparation for Seasonal Storage

Traction Unit

  1. Thoroughly clean traction unit, cutting units, and engine.
  2. Check tire pressure. Inflate all tires to 97–124 kPa.
  3. Check all fasteners for looseness; tighten as necessary.
  4. Grease or oil all grease fittings and pivot points. Wipe up excess lubricant.
  5. Cover entire length of Sidewinder (Model 03201) cross tube with light oil to prevent rust. Wipe off oil after storage.
  6. Lightly sand and use touch-up paint on painted areas that are scratched, chipped, or rusted. Repair dents.
  7. Service battery and cables:
  1. Remove battery terminals from posts.
  2. Clean battery, terminals, and posts with wire brush and baking soda solution.
  3. Coat cable terminals and battery posts with Grafo 112X grease (Toro Part No. 505-47) or petroleum jelly to prevent corrosion.
  4. Slowly recharge battery every 60 days for 24 hours to prevent lead sulfation.

Engine

  1. Drain engine oil from oil pan and replace drain plug.
  2. Remove and discard oil filter. Install new oil filter.
  3. Refill oil pan with approx. 3.8 L of SAE 10W-30 motor oil.
  4. Start engine and run at idle for ~2 minutes.
  5. Stop engine.
  6. Thoroughly drain all fuel from tank, lines, fuel filter, and water separator assembly.
  7. Flush fuel tank with fresh, clean diesel fuel.
  8. Secure all fuel system fittings.
  9. Thoroughly clean and service air cleaner assembly.
  10. Seal air cleaner inlet and exhaust outlet with weatherproof tape.
  11. Check anti-freeze protection and add as needed for expected minimum temperature.

Identification and Ordering

Model and Serial Number

The mower has two identification numbers: model and serial. They are stamped on a plate riveted to the frame. Supply these numbers in correspondence for correct information and parts.

Note: Do not order by reference number if using a parts catalog; use the part number.

To order replacement parts from an Authorized TORO Service Dealer, supply:

  1. Model and serial numbers of the mower.
  2. Part number, description, and quantity of part(s) desired.

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