Toro Reelmaster 3100-D Operator's Manual

Introduction

This operator's manual provides essential information on safety, operation, and maintenance for the Toro Reelmaster 3100-D. Read this manual thoroughly before operating the machine to ensure safety and optimal performance. Pay special attention to SAFETY INSTRUCTIONS highlighted by the triangular alert symbol (⚠️).

⚠️ CAUTION, WARNING, or DANGER symbols indicate personal safety instructions. Failure to comply may result in personal injury.

"IMPORTANT" highlights special mechanical information, and "NOTE" emphasizes general product information.

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. Use these numbers in all correspondence and when ordering parts.

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

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

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

Safety Instructions

To reduce the potential for injury, comply with the following safety instructions.

Supervisors' Responsibilities

1. Ensure operators are thoroughly trained and familiar with the manual and machine labels.
2. Establish special procedures and work rules for unusual operating conditions (e.g., steep slopes). Survey mowing sites to determine safe operating areas, considering turf condition and rollover risk. Use an inclinometer for site surveys. The maximum side hill angle should not exceed 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 components 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. Safety glasses, safety shoes, long pants, and a helmet are advisable and may be required by local authorities or insurance regulations.
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 the engine. Handle fuel carefully as it is highly flammable. Use an approved fuel container. Do not remove the fuel cap when the engine is hot or running. Do not smoke while handling diesel fuel. Fill the tank outdoors, not overfilling, and not over 2.5 cm from the top.

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 the machine.
3. Check interlock switches daily for proper operation. Do not bypass the interlock system. Replace all interlock switches every two years.
4. The operator must be skilled and trained for hillside operation. Failure to use caution on slopes can lead to tipping or rolling, resulting in injury or death. Always wear your seat belt.
5. This triplex mower has a unique drive system for superior traction on hills. If operated on a side hill that is too steep, rollover may occur before losing traction.
6. The slope angle for tipping 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 increases moderately. DO NOT EXCEED 25 DEGREES SIDE HILL ANGLE due to high risk of rollover and serious injury or death. Stay alert for hazards like holes, ditches, and creeks. Reduce speed on sharp turns. Do not turn on hills. 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. Adjust neutral control linkage if necessary.
8. Before backing up, look to the rear and ensure no one is behind the machine. Watch for traffic. Yield the right of way.
9. Keep hands, feet, and clothing away from moving parts and the reel discharge area. Grass baskets must be in place.
10. This product may exceed 85 dB(A) noise levels. Ear protectors are recommended.
11. Raise cutting units when driving between work areas.
12. Do not touch hot engine, muffler, exhaust pipe, or hydraulic tank areas while hot.
13. If a cutting unit strikes an object or vibrates abnormally, stop immediately, turn off the engine, and inspect for damage. Repair or replace damaged parts 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 engine, and remove key.
15. Whenever the machine is unattended, ensure reels are not spinning, key is removed, and parking brake is set.

Maintenance Safety

1. Before servicing or adjusting, 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 are in good condition before applying pressure.
5. Keep body and hands away from high-pressure hydraulic fluid leaks. Use paper/cardboard to find leaks. Injected fluid can cause serious damage.
6. Before working on the hydraulic system, relieve all pressure by stopping the engine and lowering cutting units.
7. Contact an Authorized Toro Distributor for major repairs or assistance.
8. Keep the engine area free of grease, grass, leaves, and dirt to reduce fire hazard.
9. Keep hands, feet, clothing, and body parts away from cutting units and moving parts if the engine must be running for adjustments.
10. Do not overspeed the engine. 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

The document includes a comprehensive symbol glossary. Key symbols and their meanings include:

• ⚠️: Safety alert symbol, indicating CAUTION, WARNING, or DANGER.
• ?: Fire or open flame hazard.
• ⚡: Electrical shock hazard.
• ⏹️: STOP symbol, indicating to wait until machine components have completely stopped.
• ⬆️: Lift point.
• ⬇️: Lowering point.
• ⚙️: Grease lubrication point.
• ?: Oil lubrication point.
• ?️: Engine oil.
• ⛽: Fuel.
• ?️: Temperature.
• ❗: Failure/Malfunction.
• ▶️: Start switch/mechanism.
• ❌: Off/stop.
• ✅: Engage.
• ?: Disengage.
• ?: Lift point.
• ?: Clockwise rotation.
• ?: Counter-clockwise rotation.
• ?: Tire pressure.
• ?️: Engine oil.
• ?️: Engine coolant.
• ?️: Hydraulic oil.
• ?️: Fuel level.
• ?️: Oil pressure.
• ?️: Water temperature.
• ?️: Glow plug.
• ?️: Alternator.
• ?️: Parking brake.
• ?️: Headlights.
• ?️: Lock.
• ?️: Unlock.
• ?️: Differential lock.
• ?️: 4-Wheel drive.
• ?️: Power Take-Off.
• ?️: Reel cutting element.
• ?️: Traction.
• ?️: Drilling temperature range.
• ?️: Manual metal arc welding.
• ?️: Water pump.
• ?️: Keep dry.
• ?️: Weight.
• ?️: Do not dispose in garbage.
• ?️: CE logo.

The glossary also details numerous hazard symbols related to crushing, cutting, entanglement, burns, explosions, and more, along with symbols for safety equipment and procedures.

Specifications

Before Operating

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

Check Crankcase Oil (Fig. 1-2)

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

1. Position machine on a level surface.
2. Remove, wipe clean, and reinsert dipstick fully. Check level. Add oil to FULL mark if low.
3. If low, remove oil fill cap and add oil gradually, checking level frequently.
4. Engine requires high-quality 10W30 detergent oil (API service 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.

Diagram Description (Fig. 1-2): Shows the engine oil dipstick (1) and oil fill cap (1).

Fill the Fuel Tank (Fig. 3)

Engine uses No. 2 diesel fuel. Tank capacity: approx. 28.4 L.

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

DANGER: Diesel fuel is flammable. Use caution. Do not smoke while filling. Do not fill when engine is running, hot, or in an enclosed area. Always fill outdoors. Store fuel in a clean, safety-approved container. Use diesel fuel only.

Diagram Description (Fig. 3): Shows the fuel tank cap (1).

Check the Cooling System (Fig. 4 & 5)

Clean radiator and oil cooler debris daily (hourly in dusty conditions). Cooling system capacity: 5.7 L. Uses 50/50 water and ethylene glycol anti-freeze.

1. Check coolant level at the start of each day.
2. Check coolant level in the expansion tank (midway between marks when cold).
3. If low, remove expansion tank cap, replenish, and reinstall cap. DO NOT OVERFILL.

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

Diagram Description (Fig. 4): Shows access panel (1), radiator (2), and oil cooler (3).

Diagram Description (Fig. 5): Shows the expansion tank (1).

Check the Hydraulic System Fluid (Fig. 6)

System uses anti-wear hydraulic fluid. Reservoir filled with 13.2 L of DTE 15M fluid at factory. Check level daily.

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

Note: Red dye additive available (Part No. 44-2500).

1. Position machine on a level surface, lower cutting units, and stop engine.
2. Clean area around hydraulic tank filler neck and cap. Remove cap.
3. Remove dipstick, wipe clean, reinsert fully, and check fluid level (should be within 6 mm of the mark).
4. If low, add fluid to the full mark.
5. Install dipstick and cap.

Diagram Description (Fig. 6): Shows the hydraulic tank cap (1).

Check Tire Pressure

Tires are overinflated for shipping. Reduce air pressure to 97–124 kPa. Maintain recommended pressure for proper cut quality and performance. DO NOT UNDER INFLATE.

Check the Reel-to-Bedknife Contact

Each day, check reel-to-bedknife contact across the full length for light contact (refer to Adjusting The Reel-to-Bedknife Contact in the cutting unit operator's manual).

Check Wheel Nut Torque

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

⚠️ WARNING: Improper torque can lead to wheel failure or loss and personal injury.

Controls

Traction Pedals (Fig. 7): Forward pedal to move forward; reverse pedal to move backward or help stop. Pedal returns to neutral to stop.

Mow/Transport Slide (Fig. 7): Left for transport, right for mowing. Cutting units only operate in mow position. Mow speed factory set at 6 mph, adjustable via speed stop screw (Fig. 8).

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

Starter Switch (Fig. 9): Three positions: OFF, ON/PREHEAT, START. Turn to ON/PREHEAT for glow plugs (approx. 7 sec), then to START. Release key when engine starts. Key returns to ON/RUN. Turn to OFF to shut down.

Throttle (Fig. 9): Forward increases engine speed; rearward decreases speed.

Cutting Unit Shift Lever (Fig. 9): Forward to lower cutting units. Units drop only when engine is running. Pull rearward to RAISE. Model 03201: Lever moves units left/right (only when raised or on ground and moving).

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

Cutting Unit Drive Switch (Fig. 9): ENGAGE/DISENGAGE rocker switch.

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

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

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): Pull up to engage. Prevents accidental movement. Engine stops if traction pedal is depressed with parking brake engaged.

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

Reel Speed Control (Fig. 10): Adjusts clip rate (reel speed) for desired cut height and mower speed.

Backlap Control (Fig. 10): Clockwise for backlapping, counterclockwise for mowing. Do not change when reels are turning.

Fuel Gauge (Fig. 11): Shows fuel level.

Seat Adjustments (Fig. 11): Fore/aft adjustment via lever. Deluxe seat has weight adjustment and backrest incline adjustment.

Diagram Description (Fig. 7): Control panel layout: 1. Forward traction pedal, 2. Reverse traction pedal, 3. Mow/Transport slide, 4. Tilt steering lever, 5. Indicator slot.

Diagram Description (Fig. 8): Speed stop screw (1).

Diagram Description (Fig. 9): Console layout: 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.

Diagram Description (Fig. 10): Controls: 1. Reel speed control, 2. Backlap control.

Diagram Description (Fig. 11): Seat adjustments: 1. Fore and aft lever, 2. Fuel gauge.

Operating Instructions

Starting/Stopping the Engine

IMPORTANT: The fuel system may need to be bled if:

• It's the initial start-up of a new engine.
• The engine has run out of fuel.
• Maintenance has been performed on fuel system components (e.g., filter replacement).

Refer to Bleeding The Fuel System.

1. Ensure parking brake is set and reel drive switch is in DISENGAGE.
2. Ensure traction pedal is in neutral.
3. Move throttle lever to half-throttle.
4. Turn key to ON/PREHEAT until glow plug light goes out (approx. 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 engaging again.

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

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

6. To stop engine: Move throttle to IDLE, move reel drive to DISENGAGE, turn 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. Do not smoke while filling. Do not fill when engine is running, hot, or in an enclosed area. Always fill outdoors. Store fuel in a clean, safety-approved container. Use diesel fuel only.

3. Open air bleed screw on the fuel injection pump (Fig. 12).
4. Turn key to ON. Electric fuel pump will operate, forcing air out. Leave key ON until a solid stream of fuel flows. Tighten screw and turn key to OFF.

Diagram Description (Fig. 12): Fuel injection pump bleed screw (1).

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

Check Operation of the Interlock Switches

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

1. Ensure bystanders are away from the area. Keep hands/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 in neutral, parking brake off, and reel switch OFF, engine should start. Rise from seat and depress traction pedal; engine should stop in 1-3 seconds. Correct if this does not happen.
4. With operator on seat, engine running, mow/transport slide in MOW, and 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: Machine has an interlock switch on the parking brake. Engine stops if traction pedal is depressed with parking brake engaged.

Towing the Traction Unit (Fig. 13)

Towing is for emergency short distances 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 it 90°.
2. Before starting engine, close by-pass valve by rotating it 90°. Do not start engine when valve is open.

Diagram Description (Fig. 13): By-pass valve (1).

Operating Characteristics

DANGER: The mower has a unique traction system for side hills. If the uphill wheel lifts off the ground, operator or bystanders can be seriously injured or killed in a rollover.

The slope angle for tipping depends on mowing conditions (wet turf, speed, cutting unit position, tire pressure, operator experience). At 20 degrees or less, rollover risk is low. At 25 degrees, risk increases moderately. DO NOT EXCEED A 25-DEGREE SIDE HILL SLOPE ANGLE due to high risk of rollover and serious injury or death. Perform site surveys considering turf condition and rollover risk. Use inclinometer. Maximum side hill angle should not exceed 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/reverse, starting/stopping. To stop, release traction pedal to neutral or press reverse pedal. Going downhill, reverse pedal may be needed to stop.

When driving on slopes, drive slowly for steering control and avoid turns to prevent rollovers. On side hills, shift sidewinder cutting units to the up-hill side for stability. Always do this before going on a side hill. Shifting to the down-hill side reduces stability.

When possible, mow up and down hills, not across. Lower cutting units when going downhill for steering control. Do not turn on hills.

Practice driving around obstacles with reels up/down. Be careful between narrow objects to avoid damage.

Understand the reach of cutting units on the Sidewinder unit to avoid damage.

Do not shift units side-to-side unless cutting units are down and machine is moving, or units are up in transport position. Shifting units when down while 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 with you; this is extremely dangerous.

Common accident causes: excessive speed, sudden turns, terrain, not stopping engine before leaving seat, and drugs impairing alertness. Stay alert and safe.

The Sidewinder offers up to 58 cm of overhang for trimming closer to edges.

If an obstacle is in the way, shift cutting units to mow around it.

CAUTION: This product may exceed noise levels of 85 dB(A). Ear protectors are recommended.

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

Mowing Techniques

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

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

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

Mowing around contours (bunkers, ponds) is easy with the Sidewinder. Move control lever left or right for application. Cutting units can be shifted to vary tire tracking.

Reelmaster 3100-D cutting units can throw clippings forward or rearward. Front throw is used for smaller amounts of grass for a better appearance. To throw clippings forward, close the rear shield.

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 to avoid clippings building 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

Wash machine with a garden hose (no nozzle) to avoid contamination and damage to seals/bearings. Ensure radiator and oil cooler are free of dirt/grass. Inspect for hydraulic fluid leaks, damage, or wear. Check cutting units for sharpness and reel-to-bedknife adjustment.

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

Selecting Clip Rate (Reel Speed)

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

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

Adjust clip rate (reel speed) as follows:

1. Verify height-of-cut setting. Use chart listing 5- or 8-blade reels, find nearest height-of-cut, and note corresponding number. Higher number = higher speed.

Diagram Description (Fig. 14): Reel speed control (1).

2. Turn reel speed control knob to the number determined in step 1.
3. Operate machine for several days, examine cut for satisfaction. Knob can be set one position higher or lower for grass condition, length removed, and personal preference.

8 BLADE REEL REEL SPEED SELECTION CHART

5 BLADE REEL REEL SPEED SELECTION CHART

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

Maintenance

Maintenance Schedule

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

Daily Maintenance Checklist

• Safety interlock operation ✅
• Brake operation ✅
• Engine oil & fuel level ✅
• Cooling system fluid level ✅
• Drain water/fuel separator ✅
• Air filter, dust cup and burp ✅
• Radiator & screen for debris ✅
• Unusual engine noises ✅
• Unusual operating noises ✅
• Hydraulic system oil level ✅
• Hydraulic hoses for damage ✅
• Fluid leaks ✅
• Fuel level ✅
• Tire pressure ✅
• Instrument operations ✅
• Reel-to-bedknife adjustment ✅
• Height-of-cut adjustment ✅
• Lubricate all grease fittings ✅
• Touch-up damaged paint ✅

Lubrication

Greasing Bearings and Bushings (Fig. 15-26)

Lubricate traction unit grease fittings regularly with No. 2 General Purpose Lithium Base Grease. Lubricate after every 50 hours of operation, or daily in extremely dusty/dirty conditions. Lubricate immediately after every washing.

Lubrication points include: Rear cutting unit pivot, Front cutting unit pivot, Sidewinder cylinder ends (Model 03201 only), Steering pivot, Rear lift arm pivot and lift cylinder, Left front lift arm pivot and lift cylinder, Right front lift arm pivot and lift cylinder, Neutral adjust mechanism, Mow/Transport slide, Belt tension pivot, Steering cylinder.

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

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

Diagram Description (Fig. 15): Rear cutting unit pivot.

Diagram Description (Fig. 16): Front cutting unit pivot.

Diagram Description (Fig. 17): Sidewinder cylinder ends (Model 03201 only).

Diagram Description (Fig. 18): Steering pivot.

Diagram Description (Fig. 19): Rear lift arm pivot and lift cylinder (2).

Diagram Description (Fig. 20): Left front lift arm pivot and lift cylinder (2).

Diagram Description (Fig. 21): Right front lift arm pivot and lift cylinder (2).

Diagram Description (Fig. 22): Neutral adjust mechanism.

Diagram Description (Fig. 23): Mow/Transport slide.

Diagram Description (Fig. 24): Belt tension pivot.

Diagram Description (Fig. 25): Steering cylinder.

Diagram Description (Fig. 26): Additional grease fitting installation.

Servicing the Air Cleaner (Fig. 28 & 29)

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

Hood Removal (Fig. 27)

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

Diagram Description (Fig. 27): Cotter pin (1).

General Air Cleaner Maintenance

1. Check air cleaner body for damage that could cause an air leak. Replace if damaged.
2. Service air cleaner filter every 200 hours (more frequently in dusty conditions).
3. Ensure cover seals around the air cleaner body.

Servicing the Air Cleaner Element

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

Diagram Description (Fig. 28): Air cleaner dust cup (1), air cleaner latches (2).

Diagram Description (Fig. 29): Filter element (1).

Washing Method

1. Prepare filter cleaner solution and water. Soak element for approx. 15 minutes (refer to cleaner carton).
2. After soaking, rinse with clear water. Max water pressure: 276 kPa. Rinse from clean to dirty side.
3. Dry 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 pressure: 689 kPa.
2. Keep air hose nozzle at least 5 cm from filter, move up/down while rotating. Inspect for holes/tears by looking through filter toward a bright light.

4. Inspect new filter for shipping damage. Check sealing end. Do not install damaged filter.
5. Insert new filter into air cleaner body. Ensure proper seal by applying pressure to outer rim. Do not press flexible center.
6. Reinstall cover and secure latches. Ensure TOP side is up.

Engine Oil and Filter (Fig. 30 & 31)

Change oil and filter initially after 50 hours; thereafter, change oil every 50 hours and filter every 100 hours.

1. Remove drain plug, let oil drain into pan. Reinstall plug when flow stops.
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).

Diagram Description (Fig. 30): Engine oil drain plug (1).

Diagram Description (Fig. 31): Engine oil filter (1).

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.

Diagram Description (Fig. 32): Water Separator (1), Drain Plug (2).

Replace filter canister every 400 hours.

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

Install canister by hand until gasket contacts mounting 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 both fuel lines to prevent fuel drain when lines are removed.
3. Loosen hose clamps at both ends of filter and pull fuel lines off.

Diagram Description (Fig. 33): Fuel Pre Filter (1), Hose Clamps (2).

4. Slide hose clamps onto fuel line ends. Push fuel lines onto fuel filter and secure. Ensure arrow on filter points toward injection pump.

DANGER: Diesel fuel is flammable. Use caution. Do not smoke while filling. Do not fill when engine is running, hot, or in an enclosed area. Always fill outdoors. Store fuel in a clean, safety-approved container. Use diesel fuel only.

Bleeding Air From Injectors (Fig. 34)

Note: Use this procedure only if fuel system was purged and engine will not start; refer to Bleeding The Fuel System.

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

Diagram Description (Fig. 34): Fuel Injectors (3).

2. Move throttle to FAST position.
3. Turn key to START. Watch fuel flow around connector. Turn key to OFF when solid flow is observed.
4. Tighten pipe connector securely.
5. 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. A. Turn engine off, raise hood. Clean engine area.
3. B. Remove access panel.
4. C. Unlatch oil cooler, pivot rearward. Clean both sides of oil cooler and radiator area with water or compressed air. Pivot oil cooler back.
5. D. Install access panel and close hood.

Diagram Description (Fig. 35): Access panel (1), Oil cooler (2), Radiator (3).

Diagram Description (Fig. 36): Engine cooling system components.

Servicing the Engine Belts

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

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.

Diagram Description (Fig. 37): Alternator/fan belt (1).

Hydrostat Drive Belt Replacement (Fig. 38)

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

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

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

Diagram Description (Fig. 38): Hydrostat Drive Belt (1), Spring end (2).

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.

Diagram Description (Fig. 39): Injection Pump Lever Arm (1).

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

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

Changing Hydraulic Fluid (Fig. 40–42)

Change hydraulic fluid after every 400 operating hours in normal conditions. If fluid is contaminated (milky or black), contact Toro distributor for flushing. System capacity: approx. 13.2 L.

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

Diagram Description (Fig. 40): Hydraulic line (1).

Diagram Description (Fig. 41): Hydraulic filter (1).

Diagram Description (Fig. 42): Hydraulic Reservoir (1).

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

4. Install reservoir cap. Start engine and use all hydraulic controls to distribute fluid. Check for leaks. Stop engine.
5. Check fluid level and add to FULL mark on dipstick. DO NOT OVERFILL.

Replacing Hydraulic Filter (Fig. 43)

Change filter initially after 10 hours, then every 200 hours or yearly. Use genuine Toro filter (Part No. 54-0110). Hydraulic oil must be changed every 400 hours or yearly.

IMPORTANT: Use of any other filter may void warranty.

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. Place drain pan under filter and remove filter.

Diagram Description (Fig. 43): Test Port (1).

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

Checking Hydraulic Lines and Hoses

Daily, check for leaks, kinks, loose supports, wear, loose fittings, deterioration. Make necessary repairs before operating.

⚠️ WARNING: Keep body and hands away from high-pressure hydraulic fluid leaks. Use cardboard/paper to find leaks. Injected fluid can penetrate skin and cause injury. Seek immediate medical attention if injected.

Hydraulic System Test Ports (Fig. 43)

Test port used to test hydraulic circuit pressure. Contact Toro distributor for assistance. Test Port #1 is for troubleshooting the forward traction hydraulic circuit.

Adjusting the Traction Drive for Neutral (Fig. 44)

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

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

⚠️ WARNING: Machine will move during adjustment if not properly supported. Ensure machine is securely supported to prevent accidental fall.

3. Loosen locknut on traction adjustment cam.

Diagram Description (Fig. 44): Traction adjustment cam (1), Locknut (2).

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

4. Start engine and turn cam hex in both directions to find neutral span mid-position.
5. Tighten locknut.
6. Stop engine.
7. Remove support blocks, 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.

Diagram Description (Fig. 45): Parking brake lever (1), Knob (2), Setscrew (3).

Battery Care

1. Maintain proper electrolyte level and keep battery top clean. Store in cool location.
2. Check electrolyte level every 25 operating hours or every 30 days in storage.
3. Maintain cell level with distilled/demineralized water. Do not fill above split ring. Ensure vents point rearward.

⚠️ CAUTION: Wear safety goggles/rubber gloves. Charge in well-ventilated area. Gases are explosive; keep flames/sparks away. Do not smoke. Unplug charger before connecting/disconnecting leads.

4. Keep battery top clean by washing periodically with ammonia/baking soda solution. Rinse with water. Do not remove fill caps while cleaning.
5. Battery cables must be tight for good electrical contact.

⚠️ WARNING: Connecting cables incorrectly can cause injury or system damage.

6. If corrosion occurs, disconnect cables (negative first), scrape clamps/terminals. Reconnect (positive first) and coat with petroleum jelly.
7. Always disconnect battery ground cable () first to prevent wiring damage from short outs.

Battery Storage

If storing for >30 days, remove battery, charge fully, and store on machine shelf (disconnect cables). Store in cool atmosphere to avoid charge deterioration. Ensure fully charged to prevent freezing. Specific gravity of fully charged battery: 1.265–1.299.

Fuses

Fuses are located under the console cover.

Backlapping

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

• Reels may stall and restart during backlapping.
• Do not attempt to restart reels by hand/foot.
• Do not adjust reels while engine is running.
• If reel stalls, stop engine before clearing.

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 in seat, but parking brake must be engaged or engine will not run.

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

Diagram Description (Fig. 46): Backlap knob (1), Reel speed knob (2).

4. Make initial reel-to-bedknife adjustments for backlapping. Start engine and set to low idle speed.
5. Engage reels using PTO switch.
6. Apply lapping compound with a long-handled brush.

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

7. To adjust cutting units while backlapping, disengage reels, turn engine OFF. Repeat steps 4–6 after adjustments.
8. When backlap is complete, stop engine, turn backlap knob to MOW, set reel speed controls to desired mowing setting, and wash off lapping compound.

NOTE: Additional instructions on Backlapping 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 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 scratched, chipped, or rusted painted areas. Repair dents.
7. Service battery and cables:
8. A. Remove battery terminals.
9. B. Clean battery, terminals, and posts with wire brush and baking soda solution.
10. C. Coat cable terminals and battery posts with Grafo 112X grease or petroleum jelly to prevent corrosion.
11. D. 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 approx. 2 minutes.
5. Stop engine.
6. Thoroughly drain all fuel from fuel 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 all 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.