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Toro 03806 Operator's Manual

Traction unit
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Form No. 3375-301 Rev C
Reelmaster
®
6500-D and 6700-D
Traction Unit
Model No. 03806—Serial No. 313000001 and Up
Model No. 03807—Serial No. 313000001 and Up
Model No. 03808—Serial No. 313000001 and Up
Model No. 03812—Serial No. 313000001 and Up
Model No. 03813—Serial No. 313000001 and Up
To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com.
Original Instructions (EN)

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Summary of Contents for Toro 03806

  • Page 1 Model No. 03808—Serial No. 313000001 and Up Model No. 03812—Serial No. 313000001 and Up Model No. 03813—Serial No. 313000001 and Up To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com. Original Instructions (EN)

  • Page 2: Introduction

    Important calls attention to special mechanical information and Note emphasizes general You may contact Toro directly at www.Toro.com for information worthy of special attention. product and accessory information, help finding a dealer, or to register your product.

  • Page 3: Table Of Contents

    Electrical System Maintenance........ 43 Safety ................4 Battery Care ............43 Safe Operating Practices ........4 Fuses..............44 Toro Mower Safety ..........5 Optional Lighting..........44 Sound Power Level..........6 Drive System Maintenance ........46 Sound Power Level..........6 Checking the Torque of the Wheel Nuts or Sound Pressure Level ...........

  • Page 4: Safety

    Safety • Inspect the area where the equipment is to be used and remove all objects such as rocks, toys and wire which can be thrown by the machine. This machine meets or exceeds CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI •...

  • Page 5: Toro Mower Safety

    Stop reels if not The following list contains safety information specific to mowing. Toro products or other safety information that you must • Do not operate the mower under the influence of know that is not included in the ANSI standards.

  • Page 6: Sound Power Level

    Uncertainty Value (K) = 0.5 m/s continued safety certification of the machine, use Measured values were determined according to the only genuine Toro replacement parts and accessories. procedures outlined in EN 836. Replacement parts and accessories made by other manufacturers could be dangerous, and such use...

  • Page 7: Safety And Instructional Decals

    Safety and Instructional 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. 105-7506 93-6699 1. Read the Operator's 4. Engine—preheat 1. Machine speed 3.
  • Page 8 93–6689 1. Danger—do not sit on the plastic shroud. 93–6681 1. Cutting/dismemberment hazard—stay away from moving parts. 93-1263 93-1263 1. Read the Operator's Manual. 2. To engage the parking brake, connect the brake pedals with the locking pin, push down on both pedals, and pull the brake latch out.
  • Page 9 4. Reels lowered and on when enabled—forward and backlap 10. Headlights—Off 5. Reels—enabled 11. Read the Operators Manual. 6. Reels disabled—lift only 104-9296 Models 03806, 03807 and 03812 1. Throttle—slow 4. Reels lowered and on when 7. Reels disabled—lift and 10. Headlights—Off enabled—forward and...
  • Page 10 117–2718 106-6755 1. Engine coolant under 3. Warning—do not touch the pressure. hot surface. 2. Explosion hazard—read 4. Warning—read the the Operator's Manual. Operator's Manual. 115-2045 1. Warning—read the Operator's Manual. 2. Cutting hazard of hand or foot—stay away from moving parts; keep all guards in place. 3.
  • Page 11 115-2046 (Affix over part no. 115–2045 for CE*) * This safety decal includes a slope 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.
  • Page 12 93-6668 1. Read the Operator's Manual for information on charging the battery; contains lead; do not discard. 115-2049 Models 03806, 03807 and 03812 1. Reel—height of cut 4. Machine speed 2. Reel—mow and backlap 5. Rear reels circuit controls 3. Read the Operator's 6.
  • Page 13 Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. Keep bystanders a safe distance from the battery. 2. No fire, open flame, or 7. Wear eye protection; smoking. explosive gases can cause blindness and other injuries 3.

  • Page 14: Setup

    Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description Qty. – No parts required Check fluid levels. Large O-ring 14/10 Counter weight Install cutting units. Steering locking pin Lift chain Chain bracket U-bolt 10/14 Install cutting units.

  • Page 15: Installing Cutting Unitsmodels 03860, 03861 And 03862

    Installing Cutting Units Models 03860, 03861 and 03862 Parts needed for this procedure: Figure 4 14/10 Large O-ring 1. Bearing housing 3. Counterweight Counter weight 2. Large o-ring Steering locking pin Note: Before installing cutting unit motors or Mount the Cutting Units counterweights, lubricate internal splines of cutting unit reel shafts with grease.
  • Page 16 10. If removed, insert the vertical shaft of the pivot The Turf Compensation Spring (Figure 8), connecting knuckle into lift arm pivot hub (Figure 5). Guide carrier frame to cutting unit, controls the amount of the pivot knuckle in place between the two rubber fore-aft rotation available, as well as the amount of centering bumpers in the under side of the lift arm ground clearance in transport and turn around.

  • Page 17: Installing Cutting Unitsmodels 03863 And 03864

    knuckle (Figure 10). Rotate the brackets 45 degrees to the outboard side of the machine. Installing Cutting Units Models 03863 and 03864 Parts needed for this procedure: Lift chain Chain bracket U-bolt 10/14 Screw Washer Large O-ring Figure 10 Mount the Lift Brackets and Chains 3.
  • Page 18 Mount the Counter Weights All cutting units are shipped with the counter weight mounted to the left end of the cutting unit. Use the following diagram to determine the position of the counter weights and reel motors. Figure 12 1. Lift chain 2.
  • Page 19 the pivot knuckle in place between the two rubber centering bumpers in the under side of the lift arm steering plate. 6. Insert the lynch pin into the cross hole on the pivot knuckle shaft (Figure 17). 7. Secure the lift arm chain to the cutting unit chain bracket (Figure 18) with the snapper pin as follows: A.
  • Page 20 Figure 20 2. Tighten hex nuts on front end of spring rod until Figure 19 the compressed length (A) of spring is 6.25in. (159 1. Reel drive motor 2. Capscrew mm) (Figure 20). Note: When operating on rough terrain, decrease Note: If fixed cutting unit position is required, the spring length by 1/2 inch.

  • Page 21: Making Alternate Cutting Unit Adjustments

    Making Alternate Cutting Unit Installing CE Decals Adjustments Parts needed for this procedure: No Parts Required CE decals CE certificate Procedure The factory sets the tractor appropriately for most Procedure fairway mowing applications. Several adjustments for fine-tuning the machine for particular applications are If you will be using the machine in a CE country, install included in the Cutting Unit Maintenance section as the supplied CE decals over the corresponding ANSI...

  • Page 22: Product Overview

    Product Overview • The machine is being operated faster than the maximum speed value initially programmed into the ECU. Controls • An electrical malfunction has been detected (open or shorted output. Traction Pedal • A hydraulic leak has been detected (Only if Turfdefender leak detector is installed on machine) The traction pedal (Figure 21) controls forward and •...

  • Page 23: Throttle Control

    G019448 Figure 22 Model 03808 and 03813 G019449 Figure 23 1. Throttle control 7. Glow plug indicator light Models 03806, 03807 and 03812 2. Lower mow/raise control 8. Engine coolant lever temperature gauge 1. Throttle control 6. Engine coolant 3. Fuel gauge 9.
  • Page 24 adjusts seat for operators weight. To adjust seat fore and aft, pull lever on left side of seat assembly outward. After moving seat to desired location, release lever to lock seat into position. To adjust for operators weight, turn spring tension knob; clockwise to increase tension, counterclockwise to decrease spring tension.

  • Page 25: Specifications

    Contact your the electronic controller is not operating. Possible Authorized Service Dealer or Distributor or go to causes are: www.Toro.com for a list of all approved attachments • Loopback is not connected. and accessories. • The light is burned out.

  • Page 26: Operation

    • Preferred oil: SAE 15W-40 (above 0°F) • Alternate oil: SAE 10W-30 or 5W-30 (all temperatures) Note: Toro Premium Engine oil is available from your distributor in either 15W-40 or 10W-30 viscosity. See the parts catalog for part numbers. Note: The best time to check the engine oil is when the engine is cool before it has been started for the day.

  • Page 27: Filling The Fuel Tank

    at the beginning of each day before starting the engine. Capacity of cooling system is 10 quarts (9.4 l). CAUTION If the engine has been running, pressurized hot coolant can escape and cause burns if the radiator cap is removed. Allow the engine to cool at least 15 minutes or until the radiator cap is cool enough to touch without burning hands.
  • Page 28 flash point and cold flow characteristics which will ease DANGER starting and reduce fuel filter plugging. In certain conditions, fuel is extremely flammable Use of summer grade fuel above 20° F (-7° C) will and highly explosive. A fire or explosion from fuel contribute toward longer fuel pump life and increased can burn you and others and can damage property.

  • Page 29: Checking The Hydraulic Fluid

    Order part no. 44-2500 from your authorized Toro distributor. Biodegradable Hydraulic Fluid - Mobil 224H Toro Biodegradable Hydraulic Fluid (Available in 5 gallon pails or 55 gallon drums. See parts catalog or Toro distributor for part numbers.) Alternate fluid: Mobil EAL 224H G019457...

  • Page 30: Checking The Tire Pressure

    Checking the Tire Pressure Bleeding the Fuel System 1. Park the machine on a level surface. Make sure fuel Service Interval: Before each use or daily tank is at least half full. The tires are over-inflated for shipping. Therefore, 2. Unlatch and raise hood. release some of the air to reduce the pressure.

  • Page 31: Pushing Or Towing The Machine

    Figure 37 1. Bypass valve g019459 Figure 36 1. Fuel injection pump bleed screw 2. Close the bypass valve before starting the engine. However, do not exceed 5-8 ft.-lb. (7-11 N·m) torque to close the valve. 6. Turn key in ignition switch to the On position. Electric fuel pump will begin operation, thereby Important: Running the engine with the forcing air out around air bleed screw.
  • Page 32 corresponding switch is closed. Repeat on each switch that is possible to be changed by hand. 7. If switch is closed and appropriate LED does not turn on, check all wiring and connections to switch and/or check switches with an ohm meter. Replace any damaged switches and repair any damaged wiring.

  • Page 33: Fault Memory And Retrieval

    12. Release the Joystick and turn the Key Off. Memory are not correctly illuminated, this indicates an is now cleared. ECU problem. If this occurs, contact your Toro Distributor for assistance. 13. Turn the Backlap Switch to Off and Enable Switch to Disable position.

  • Page 34: Operating Tips

    On. The machine should not be started until the Solenoid Function glow plug cycle is complete. SV 7 Right rear wing cutting unit Load Holding Mowing Start engine and move throttle to FAST so Operating Tips engine is running at maximum speed. Move the Enable/Disable switch to ENABLE and use the Familiarization LOWER MOW/RAISE lever to control the cutting...

  • Page 35: Maintenance

    Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Maintenance Procedure Interval • Check the torque of the wheel nuts or bolts (after the first 1–4 hours of operation After the first 8 hours and then after 10 hours of operation).

  • Page 36: Service Interval Chart

    Service Interval Chart g023347 Figure 40...

  • Page 37: Daily Maintenance Checklist

    Daily Maintenance Checklist Duplicate this page for routine use. Maintenance Check Item For the week of: Mon. Tues. Wed. Thurs. Fri. Sat. Sun. Check safety interlock operation. Check brake operation. Check engine oil and fuel level. Check cooling system fluid level. Drain the water/fuel separator.

  • Page 38: Lubrication

    Lubrication Greasing the Bearings and Bushings Service Interval: Every 50 hours The machine has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. If machine is operated under normal conditions, lubricate all bearings and bushings after every 50 hours of operation or immediately after every washing.
  • Page 39 • Rear lift cylinder pivot (2) (Figure 45). • Rear lift arm pivots (2) (Figure 48). g019492 g019489 Figure 45 Figure 48 • Lift arm pivot (3) (Figure 46). • Brake pedal shaft (1) (Figure 49). G019490 Figure 46 G019493 Figure 49 •...

  • Page 40: Engine Maintenance

    Engine Maintenance This cleaning process prevents debris from migrating into the intake when the primary filter is removed. 3. Remove and replace the primary filter (Figure 52). Servicing the Air Cleaner Cleaning of the used element is not recommended Service Interval: Every 400 hours due to the possibility of damage to the filter media.

  • Page 41: Servicing The Engine Oil And Filter

    Servicing the Engine Oil and Adjusting Throttle Filter 1. Position throttle lever forward so it stops against seat base slot. Service Interval: After the first 50 hours 2. Loosen the throttle cable connector on the lever arm Every 150 hours at the injection pump (Figure 56).

  • Page 42: Fuel System Maintenance

    Fuel Lines and Connections Fuel System Maintenance Service Interval: Every 400 hours Check lines and connections every 400 hours or yearly, whichever comes first. Inspect for deterioration, Fuel Tank damage, or loose connections. Service Interval: Every 2 years Fuel Filter/Water Separator Drain and clean fuel tank every 2 years.

  • Page 43: Bleeding Air From Injectors

    Bleeding Air From Injectors Electrical System Maintenance Note: This procedure should be used only if fuel system has been purged of air through normal priming procedures and engine will not start; refer to Bleeding Battery Care the Fuel System in Operation Section. 1.

  • Page 44: Fuses

    Rinse with clear water. Coat the battery posts and cable connectors with Grafo 112X Important: If optional lighting is be added to (skin-over) grease (Toro Part No. 505-47) or petroleum the traction unit, use the instructions, schematic jelly to prevent corrosion.
  • Page 45 Figure 62 Switch Relay Toro Part No. 75-1010 Toro Part No. 70-1480 Honeywell Part No. 1TL1-2 Hella Part No. 87411 B...

  • Page 46: Drive System Maintenance

    Changing the Planetary Gear Drive System Drive Oil Maintenance Service Interval: After the first 200 hours Checking the Torque of the Every 800 hours (Or yearly, whichever comes first) Wheel Nuts or Bolts Change the oil initially after 200 hours operation. Service Interval: After the first 8 hours Thereafter, change the oil every 800 hours.

  • Page 47: Checking The Rear Axle Lubricant

    Important: If the planetary fills before the 22 ounces (0.6 liter) of oil is added, wait one hour or install the plug and move the machine approximately ten feet to distribute the oil through the brake system. Then, remove the plug and add the remaining oil.

  • Page 48: Rear Wheel Toe-In

    Rear Wheel Toe-In Note: On 4 wheel drive models, left rear tire must also be off the shop floor. Service Interval: Every 800 hours 3. Start engine and allow run at low idle. After every 800 operating hours or annually, check the 4.

  • Page 49: Cooling System Maintenance

    Cooling System Maintenance Removing Debris Service Interval: Before each use or daily Remove debris from rear screen, oil cooler and radiator daily, clean more frequently in dirty conditions. g019479 Important: Never spray water onto a hot engine as Figure 71 damage to engine may occur.

  • Page 50: Brake Maintenance

    Brake Maintenance Belt Maintenance Adjusting the Service Brakes Checking the Alternator Belt Adjust the service brakes when there is more than 1 inch Service Interval: Every 100 hours of free travel of the brake pedal, or when the brakes do Check condition and tension of alternator belt after not work effectively.

  • Page 51: Hydraulic System Maintenance

    RED zone, the filter element should be changed. Service Interval: Every 800 hours Use the Toro replacement filter (Part No. 94-2621). Change hydraulic fluid after every 800 operating hours, Important: Use of any other filter may void the in normal conditions.

  • Page 52: Hydraulic System Test Ports

    The test ports are used to test pressure in the hydraulic 3. Test Port C (Figure 78) is used to assist in trouble circuits. Contact your local Toro distributor for shooting the hydraulic circuit for the rear cutting assistance.

  • Page 53: Cutting Unit Maintenance

    Cutting Unit Maintenance 6. Test Port F is used to measure traction reverse pressure (Figure 79). 7. Test Port G is used to measure steering circuit Cutting Unit Kickstand pressure (Figure 79). Models 03863 and 03864 Whenever the cutting unit has to be tipped to expose the bedknife/reel, prop up the rear of the cutting unit with the kickstand (supplied with the traction unit) to make sure the nuts on the back end of the bedbar adjusting...

  • Page 54: Adjusting The Cutting Unit Lowering Rate

    Move Lower Mow/Lift control forward to start #2 & #3 (Rear) backlapping operation on designated reels. 8. Apply lapping compound with a long handle brush #6 (Rear Left) (Toro Part No. 29-9100). Never use a short handled #7 (Rear Right) brush.

  • Page 55: Lifted Height Of Outer Front Cutting Units (Enable Position)

    #4, 6 or 7 lift arms (Figure 84). 3. Adjustment valves for #2 & #3 (Rear) cutting units Figure 83 g019483 Models 03806, 03807 and 03812 Figure 84 #4 shown 1. Adjustment valve for #1 (Front Center) cutting unit 2.

  • Page 56: Adjusting The Travel Of The Front Three Cutting Units

    Adjusting the Travel of the Front Three Cutting Units Additional downward travel of the front three cutting units may be desirable in highly contoured locations. If any of the front three cutting units lift off the ground when cresting a hill, the front carrier frame may be lowered by removing mounting bolts and repositioning frame in the bottom set of holes in the main frame (Figure 85).

  • Page 57: Storage

    C. Coat the cable terminals and battery posts with Grafo 112X skin-over grease (Toro Part No. 505-47) or petroleum jelly to prevent corrosion. D. Slowly recharge the battery every 60 days for 24 hours to prevent lead sulfation of the battery.

  • Page 58: Schematics

    Schematics Electrical Schematic, All models (Rev. A)
  • Page 59 Electrical Schematic, Model 03808 and 03813 only (Rev. A)
  • Page 60 Hydraulic Schematic, Model 03806 (Rev. -)
  • Page 61 Hydraulic Schematic, Model 03807 and 03812 (Rev. -)
  • Page 62 Hydraulic Schematic, Model 03808 and 03813 (Rev. A)
  • Page 63 Notes:...

  • Page 64: The Toro Total Coverage Guarantee

    Countries Other than the United States or Canada Customers who have purchased Toro products exported from the United States or Canada should contact their Toro Distributor (Dealer) to obtain guarantee policies for your country, province, or state. If for any reason you are dissatisfied with your Distributor's service or have difficulty obtaining guarantee information, contact the Toro importer.

This manual is also suitable for:

0380803813Reelmaster 6500-d03807Reelmaster 6700-d03812

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