Toro 03808 Manuals

Manuals and User Guides for Toro 03808. We have 4 Toro 03808 manuals available for free PDF download: Service Manual, Operator's Manual

Toro 03808 Service Manual (328 pages)

Brand: Toro | Category: Lawn Mower | Size: 32.63 MB

Table of Contents
9
Equivalents and Conversions
10
Torque Specifications
11
Fastener Identification
11
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)
12
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Series)
13
Introduction
16
Specifications
17
General Information
18
Stopping the Engine
18
Check Engine Oil
18
Fill Fuel Tank
19
Check Cooling System
20
Adjustments
21
Adjust Throttle Cable
21
Adjust Alternator Belt
22
Service and Repairs
23
Bleed Fuel System
23
Bleed Air from Fuel Injectors
24
Change Engine Oil and Filter
24
Clean Radiator and Oil Cooler
25
Fuel Filter/Water Separator
26
Draining
26
Filter Element Replacement
26
Replace Fuel Prefilter
27
Fuel System
28
Check Fuel Lines and Connections
29
Fuel Tank Removal
29
Drain and Clean Fuel Tank
29
Fuel Tank Installation
29
Air Filter
30
General Maintenance
30
Service Air Cleaner
30
Radiator
32
Removal
33
Installation
33
Specifications
40
Pushing or Towing Traction Unit
43
Check Hydraulic Fluid
43
Hydraulic Schematics
44
Hydraulic Flow Diagrams
56
Traction Circuit
57
Lower Cutting Units
59
Raise Cutting Units
61
Mow and Backlap
63
Right and Left Turns
65
Special Tools
66
Troubleshooting
68
Testing
78
Before Performing Hydraulic Tests
78
Test No. 1: Traction Circuit Charge Pressure
79
Test No. 2: Traction Circuit Pressure
80
Test No. 3: Cutting Unit Drive Circuit Pressure
81
Test No. 4: Gear Pump Section P3 Flow and Relief Valve Pressure
82
Test No. 5: Gear Pump Section P1 & P2 Flow
83
Test No. 6: Reel Drive Motor Cross-Over Relief Pressure
84
Test No. 7: Reel Drive Motor Efficiency
86
Adjustments
88
Adjust Manifold Relief Valve (R1 and R2)
88
Adjust Traction Drive for Neutral
89
Adjust Cutting Unit Drop Rates (Serial Numbers below 280000000)
90
Adjust Cutting Unit Drop Rates (Serial Numbers above 280000000)
90
Service and Repairs
91
General Precautions for Removing and Installing Hydraulic System Components
91
Check Hydraulic Lines and Hoses
92
Flush Hydraulic System
92
Charge Hydraulic System
93
Change Hydraulic Fluid
94
Replace Hydraulic Oil Filter
95
Piston Pump (Traction Pump)
96
Disassembly
97
Assembly
98
Servo Control
100
Neutral Lockout Switch Disassembly
100
Neutral Lockout Switch Assembly
101
Gear Pump
102
Disassembly
103
Assembly
104
Wheel Motor
106
4WD Rear Axle Motor
108
Reel Motor (Barnes)
110
Adjusting Valve (Cross-Over Relief Valve) Service
111
Disassembly
111
Assembly
112
Reel Motor (Bosch)
112
Hydraulic Control Manifolds
114
Lift Manifold Removal and Installation
115
Valves
121
Rotary Cartridge Valves
121
Mow/Backlap Spools
123
Lift Cylinders
124
Lift Cylinder Service
126
Steering Cylinder (2WD)
128
Steering Cylinder (4WD)
130
Power Steering
132
Steering Valve
133
Steering Valve Service
134
Solenoid Valve SV10 and SV11 Service (RM 6700-D Only)
137
Hydraulic Reservoir
138
Hydraulic Oil Cooler
140
Special Tools
142
Troubleshooting
144
Understanding the Controllers
144
Understanding the Diagnostic Lamps
145
Using the Acet Diagnostic Display
146
Turfdefendertleak Detector
148
Leak Detector Troubleshooting Guide
152
Starting Problems
153
General Run and Transport Problems
154
Cutting Unit Operation Problems
155
Electrical System Quick Checks
157
Battery Test (Open Circuit Test)
157
Charging System Test
157
Voltage Drop Testing
157
Glow Plug System Test
158
Starting System Test
158
Component Testing
159
Ignition Switch
159
Glow and Start Relays
160
Fuses
161
Hydraulic Valve Solenoids
162
High Temperature Warning and Shutdown Switch
163
Warning Light Cluster
164
Run (ETR) Solenoid (Solenoid with 3 Wire Connector)
165
Run (ETR) Solenoid (Solenoid with 2 Wire Connector)
166
Fuel Gauge Sender
167
Fuel Gauge
168
Temperature Sender
169
Temperature Gauge
170
Hourmeter
171
Electronic Controller(S)
171
Parking Brake Switch
171
Engine Low Oil Pressure Switch
172
Speedometer Sensor
172
Speedometer
173
Reel Enable/Disable Switches
173
Reel Backlap Switches
174
Traction Neutral Switch
174
Seat Sensor
175
Joystick Raise and Lower/Mow Switches
175
Cutting Unit down Sensors
176
Cutting Unit #6 and #7 Reel On/Off Solenoids
176
SERVICE and REPAIRS
177
Battery Storage
177
Battery Care
177
Battery Service
178
Speedometer Sensor Replacement
181
Installing Optional Lighting
182
Specifications
184
Maintenance
185
Changing Planetary Gear Drive Lubricant
185
Changing Rear Axle Lubricant
186
Adjustments
187
Service Brake Adjustment
187
Rear Wheel Toe-In Adjustment
188
Repairs
189
Planetary Wheel Drive Service
189
Brake Service
191
Rear Axle Service (2WD)
193
Rear Axle Service (4WD)
196
Bevel Gear Case and Axle Case
198
Differential Shafts
202
Axle Shafts
203
Input Shaft/Pinion Gear
204
Differential Gear
206
Pinion Gear to Ring Gear Engagement
209
Specifications
212
Special Tools
213
Troubleshooting
215
Set-Up and Adjustments
217
Bedknife to Reel Adjustment
218
Adjusting and Leveling Rollers
219
Leveling Front Roller
221
Final Height of Cut Adjustment
222
Front Grass Shield Adjustment
222
Rear Shield Adjustment
223
Lift Chain Adjustment
223
Daily Adjustments
224
Service and Repairs
224
Backlapping
224
Bedbar Removal and Installation
226
Bedknife Replacement and Regrinding
228
Preparing Reel for Regrinding
229
Reel and Reel Bearings
230
Bearing Adjustment
230
Roller and Frame Service
233
Roller Bearing and Seal Replacement
234
Cutting Unit Installation
235
Lubrication
237
Troubleshooting
240
Factors Affecting Grooming
240
Groomer Reel Mechanical Problems
241
Adjustments
242
Groomer Height/Depth Adjustment
242
Service and Repairs
243
Groomer Belt Replacement
243
Groomer Reel
244
Groomer Reel Service
246
Idler Assembly
247
Groomer Drive
248
Groomer Height of Cut Assembly
250
Specifications
254
General Information
255
Cutting Unit Operator's Manual
255
Special Tools
256
Factors that Can Affect Cutting Performance
260
Set up and Adjustments
263
Characteristics
263
Reel Bearing Adjustment
264
Leveling Rear Roller
265
Service and Repairs
267
Hydraulic Reel Motor
267
Backlapping
268
Bedbar Assembly
270
Bedbar Adjuster Service
272
Bedknife Replacement and Grinding
273
Reel Assembly Removal and Installation
274
Reel Assembly Removal
275
Reel Assembly Installation
275
Reel Assembly Service
278
Preparing Reel for Grinding
280
Front Roller
282
Rear Roller
283
Roller Service (Greasable Bearings with Retaining Ring)
284
Roller Service (Greasable Bearings with Bearing Nut)
286
Rear Roller Brush (Optional)
288
Grooming Performance
294
Troubleshooting
295
Groomer Reel Mechanical Problems
295
Groomer Height/Depth Adjustment
296
Service and Repairs
297
Groomer Drive Belt Replacement
297
Groomer Plate Assembly
298
Groomer Reel
302
Groomer Reel Service
304
Groomer Pivot Hub
306
Height Adjuster Assembly
308
Reelmaster 6500-D Model 03806 & 03807
311
Electrical Schematic
311
Reelmaster 6500-D Model 03806 & 03807
312
Electrical Schematic
312
Reelmaster 6700-D Model 03808
313
Electrical Schematic
313
Reelmaster 6700-D Model 03808
314
Electrical Schematic
314
Reelmaster 6500-D/6700-D Ignition Switch Circuit (20 Amp Fuse)
315
Reelmaster 6500-D/6700-D Controller #1 Power Circuit (10 Amp Fuses)
316
Reelmaster 6500-D/6700-D Controller #1 Logic Circuit (5 Amp Fuse)
317
Reelmaster 6700-D Controller #2 Power Circuit (15 Amp Fuse)
318
Reelmaster 6500-D/6700-D Accessory Power and Controller #2 Logic Circuit (7.5 Amp Fuse)
320
Reelmaster 6500-D/6700-D Starter, Glow Plugs, and Alternator Circuits (Fusible Links)
322
Reelmaster 6500-D/6700-D Optional Lighting Circuit (10 Amp Fuse)
323
Reelmaster 6500-D/6700-D Optional Turfdefender Leak Detector
324
Reelmaster 6500-D/6700-D Wire Harnesses
325
Reelmaster 6500-D/6700-D Electrical Connector Drawing
326
Reelmaster 6700-D Secondary (#2) Electronic Controller Harness and Electrical Connector Drawing
328

Toro 03808 Operator's Manual (60 pages)

Traction Unit

Brand: Toro | Category: Lawn Mower | Size: 17.94 MB

Table of Contents
2
Introduction
2
Safety
4
- Safe Operating Practices
  4
- Toro Mower Safety
  5
- Sound Pressure Level
  6
- Vibration Level
  6
- Safety and Instructional Decals
  7
- Setup
  13
- Checking Fluid Levels
  13
- Installing the Cutting Units
  13
- Making Alternate Cutting Unit Adjustments
  15
- Adding Rear Ballast
  16
- Installing CE Decals
  16
- Reading the Manuals and Storing
  16
- Additional Parts
  16
Product Overview
17
- Controls
  17
  - Brake Pedals
    18
  - Key Switch
    18
  - Throttle Control
    19
  - Hour Meter
    19
  - Fuel Gauge
    19
- Speciﬁcations
  22
Operation
22
- Checking the Engine Oil
  22
- Checking the Cooling System
  22
- Filling the Fuel Tank
  23
- Checking the Hydraulic Fluid
  24
- Checking the Tire Pressure
  25
- Checking the Reel to Bedknife
  25
- Contact
  25
- Starting and Stopping
  25
- Bleeding the Fuel System
  25
- Pushing or Towing the Machine
  26
- Checking the Interlock
  27
  - Switches
    27
- Fault Memory and Retrieval
  28
- Hydraulic Solenoid Valve
  29
  - Functions
    29
- Operating Tips
  29
- Maintenance
  31
Recommended Maintenance
31
- Schedule(S)
  31
- Service Interval Chart
  32
- Daily Maintenance Checklist
  33
Lubrication
33
- Greasing the Bearings and Bushings
  33
Engine Maintenance
35
Fuel System Maintenance
37
- Fuel Tank
  37
- Fuel Lines and Connections
  38
- Fuel Filter/Water Separator
  38
- Replacing the Fuel Pre-Filter
  38
- Bleeding Air from Injectors
  39
Electrical System Maintenance
39
- Battery Care
  39
- Fuses
  40
- Optional Lighting
  40
Drive System Maintenance
41
- Checking the Torque of the Wheel
  41
  - Nuts or Bolts
    41
- Checking the Planetary Gear Drive
  41
  - Oil
    41
- Changing the Planetary Gear Drive Oil
  42
- Checking the Rear Axle
  42
  - Lubricant
    42
- Changing the Rear Axle
  43
  - Lubricant
    43
- Rear Wheel Toe-In
  43
- Adjusting the Traction Drive for Neutral
  43
Cooling System Maintenance
44
- Removing Debris
  44
- Maintaining the Cooling
  44
- System
  44
- Brake Maintenance
  45
- Adjusting the Service Brakes
  45
- Belt Maintenance
  45
- Checking the Alternator Belt
  45
- Hydraulic System Maintenance
  45
  - Changing the Hydraulic Fluid
    45
  - Replacing the Hydraulic Filter
    46
  - Checking the Hydraulic Lines and Hoses
    46
  - Hydraulic System Test Ports
    47
  - Cutting Unit Maintenance
    48
  - Backlapping
    48
  - Adjust Turf Compensation
    49
  - Spring
    49
  - Adjusting the Cutting Unit
    50
  - Lowering Rate
    50
  - Cutting Units (Enable Position)
    51
  - Adjusting the Travel of the Front Three Cutting Units
    51
Storage
53
- Traction Unit
  53
- Engine
  53
Schematics
54

Toro 03808 Operator's Manual (64 pages)

traction unit

Brand: Toro | Category: Lawn Mower | Size: 6.01 MB

Introduction
2
Table of Contents
3
Safety
4
- Safe Operating Practices
  4
- Toro Mower Safety
  5
- Sound Power Level
  6
- Sound Pressure Level
  6
- Vibration Level
  6
- Safety and Instructional Decals
  7
Setup
14
Product Overview
22
- Controls
  22
  - Throttle Control
    23
  - Hour Meter
    23
- Specifications
  25
- Attachments/Accessories
  25
Operation
26
- Checking the Engine Oil
  26
- Checking the Cooling System
  26
- Filling the Fuel Tank
  27
- Checking the Hydraulic Fluid
  29
- Checking the Tire Pressure
  30
- Checking the Reel to Bedknife Contact
  30
- Starting and Stopping
  30
- Bleeding the Fuel System
  30
- Pushing or Towing the Machine
  31
- Checking the Interlock Switches
  31
- Fault Memory and Retrieval
  33
- Hydraulic Solenoid Valve Functions
  33
- Operating Tips
  34
Maintenance
35
- Recommended Maintenance Schedule(S)
  35
  - Service Interval Chart
    36
  - Daily Maintenance Checklist
    37
- Lubrication
  38
  - Greasing the Bearings and Bushings
    38
- Engine Maintenance
  40
- Fuel System Maintenance
  42
  - Fuel Tank
    42
  - Fuel Lines and Connections
    42
  - Fuel Filter/Water Separator
    42
  - Bleeding Air from Injectors
    43
- Electrical System Maintenance
  43
  - Battery Care
    43
  - Fuses
    44
  - Optional Lighting
    44
- Drive System Maintenance
  46
- Cooling System Maintenance
  49
  - Removing Debris
    49
  - Maintaining the Cooling System
    49
- Brake Maintenance
  50
  - Adjusting the Service Brakes
    50
- Belt Maintenance
  50
  - Checking the Alternator Belt
    50
- Hydraulic System Maintenance
  51
- Cutting Unit Maintenance
  53
Storage
57
- Traction Unit
  57
- Engine
  57
Schematics
58
The Toro Total Coverage Guarantee
64

Toro 03808 Operator's Manual (60 pages)

traction unit

Brand: Toro | Category: Lawn Mower | Size: 5.61 MB

Introduction
2
Table of Contents
3
Safety
4
Setup
12
Product Overview
20
- Controls
  20
  - Key Switch
    21
  - Brake Pedals
    21
  - Hour Meter
    22
  - Fuel Gauge
    22
  - Throttle Control
    22
- Specifications
  24
- Attachments/Accessories
  24
Operation
24
- Checking the Engine Oil
  24
- Checking the Cooling System
  25
- Filling the Fuel Tank
  26
- Checking the Hydraulic Fluid
  26
- Checking the Tire Pressure
  27
- Checking the Reel to Bedknife Contact
  27
- Starting and Stopping
  27
- Bleeding the Fuel System
  27
- Pushing or Towing the Machine
  28
- Checking the Interlock Switches
  29
- Fault Memory and Retrieval
  30
- Hydraulic Solenoid Valve Functions
  31
- Operating Tips
  31
Maintenance
33
- Recommended Maintenance Schedule(S)
  33
  - Service Interval Chart
    34
  - Daily Maintenance Checklist
    34
- Lubrication
  35
  - Greasing the Bearings and Bushings
    35
- Engine Maintenance
  37
- Fuel System Maintenance
  39
  - Fuel Tank
    39
  - Fuel Lines and Connections
    39
  - Fuel Filter/Water Separator
    39
  - Replacing the Fuel Pre-Filter
    39
  - Bleeding Air from Injectors
    40
- Electrical System Maintenance
  41
  - Battery Care
    41
  - Fuses
    41
  - Optional Lighting
    42
- Drive System Maintenance
  43
- Cooling System Maintenance
  46
  - Removing Debris
    46
  - Maintaining the Cooling System
    46
- Brake Maintenance
  47
  - Adjusting the Service Brakes
    47
- Belt Maintenance
  47
  - Checking the Alternator Belt
    47
- Hydraulic System Maintenance
  48
- Cutting Unit Maintenance
  50
Storage
55
- Traction Unit
  55
- Engine
  55
Schematics
56

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