1. Manuals
  2. Brands
  3. Toro Manuals
  4. Lawn Mower
  5. 3806
  6. Operator's manual

Toro 03806 Operator's Manual

Traction unit
Hide thumbs Also See for 03806:
Table of Contents

Advertisement

Quick Links

See also: Operator's Manual
Form No. 3354-511 Rev B
Reelmaster® 6500-D and
6700-D Traction Unit
Model No. 03806—Serial No. 260000001 and Up
Model No. 03807—Serial No. 260000001 and Up
Model No. 03808—Serial No. 260000001 and Up
Register your product at www.Toro.com
Original Instructions (EN)

Advertisement

Table of Contents
loading

Related Manuals for Toro 03806

Summary of Contents for Toro 03806

  • Page 1 Form No. 3354-511 Rev B Reelmaster® 6500-D and 6700-D Traction Unit Model No. 03806—Serial No. 260000001 and Up Model No. 03807—Serial No. 260000001 and Up Model No. 03808—Serial No. 260000001 and Up Register your product at www.Toro.com Original Instructions (EN)

  • Page 2: Table Of Contents

    Vibration Level........6 or additional information, contact an Authorized Safety and Instructional Decals .... 7 Service Dealer or Toro Customer Service and have Setup ..............13 the model and serial numbers of your product 1 Checking Fluid Levels ..... 13 ready.
  • Page 3 Starting and Stopping ......25 Brake Maintenance ........45 Bleeding the Fuel System ....25 Adjusting the Service Brakes ....45 Pushing or Towing the Belt Maintenance........45 Machine ......26 Checking the Alternator Belt....45 Checking the Interlock Hydraulic System Maintenance ....45 Switches ......

  • Page 4: Safety

    Safety • Wear appropriate clothing including hard hat, safety glasses and ear protection. Long hair, loose clothing or jewelry may get tangled in This machine meets or exceeds CEN standard moving parts. EN 836:1997, ISO standard 5395:1990, and • Inspect the area where the equipment is to be ANSI B71.4-1999 specifications in effect at the time of production when, ballast is added;...

  • Page 5: Toro Mower Safety

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

  • Page 6: Sound Pressure Level

    A damaged reel or • If major repairs are ever needed or if assistance bedknife must be repaired or replaced before is desired, contact an Authorized Toro operation is continued. Distributor. • Traverse slopes carefully. Do not start or stop •...

  • 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. 93-6680 104-5229 1. Read the Operator’s 3. Fuse for headlights Manual.
  • Page 8 93-6696 1. Stored energy hazard—read the Operator’s Manual. 93-6687 1. Do not step here. 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 9 108-6708 105-0123 Model 03807 1. Throttle—slow 7. Reels disabled—lift and lower 2. Throttle—fast 8. Headlights (optional) 3. Reels raised and off 9. Headlights—On 4. Reels lowered and on when enabled—forward and backlap 10. Headlights—Off 5. Reels—enabled 11. Read the Operators Manual. 6.
  • Page 10 104-9296 Models 03806 and 03807 1. Throttle—slow 4. Reels lowered and on when 7. Reels disabled—lift and lower10. Headlights—Off enabled—forward and backlap 2. Throttle—fast 5. Reels enabled 8. Headlights (optional) 11. Read the Operator’s Manual for further instructions. 3. Reels raised and off 6.
  • Page 11 104-9295 Replaces 104–9294 for CE 1. Read the Operator’s Manual. 3. Warning—Read the 5. Warning—keep bystanders 7. Warning—use a rollover Operator’s Manual. a safe distance from the protection system and wear machine. the seat belt. 2. Do not tow the machine. 4.
  • Page 12 106-6754 1. Warning—do not touch the hot surface. 2. Cutting/dismemberment hazard, fan and entanglement hazard, belt—stay away from moving parts. 67-7960 105-9268 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: Setup

    Setup Loose Parts Use the chart below to verify that all parts have been shipped. Step Description Qty. – No parts required Check uid levels. Large O-ring 14/10 Counter weight Install the cutting units. Steering locking pin Make cutting unit adjustments if –...
  • Page 14 Step 3. Lubricate and install a large O-ring into bearing housing groove on each end of cutting unit (Figure 4 & Figure 7). Installing the Cutting Units Parts needed for this step: 14/10 Large O-ring Counter weight Steering locking pin Procedure Figure 4 1.

  • Page 15: Making Alternate Cutting Unit Adjustments

    7. Insert the horizontal shaft of the pivot knuckle into the mounting tube of the carrier frame (Figure 5). 8. Secure pivot knuckle to carrier frame with a thrust washer, flat washer and a flange head capscrew (Figure 5). 9. Insert a thrust washer onto vertical shaft of pivot knuckle (Figure 5).

  • Page 16: Adding Rear Ballast

    • Adjusting the lifted height of the outer front Step cutting units Adjusts the turnaround height of the outer front cutting units to provide greater clearance on contoured fairways. Installing CE Decals • Adjusting the travel of the front three cutting units Parts needed for this step: Adjusts the downward travel of the front three...

  • Page 17: Product Overview

    Product Overview Figure 8 3. Cutting unit 1. Steering wheel 5. Manual tube 7. Roll over protection system (ROPS) 2. Brake pedals 4. Traction pedal 6. Hood Controls Traction Pedal The traction pedal (Figure 9) controls forward and reverse operation. Depress top of pedal to move forward and bottom to move backward.

  • Page 18: Brake Pedals

    Speedometer The speedometer (Figure 9) indicates ground speed at which machine is traveling. Brake Pedals Two brake pedals (Figure 9) operate individual wheel brakes for turning assistance, parking, and to aid in obtaining better sidehill traction. Locking pin connects the pedals for parking brake operation and transport.

  • Page 19: Throttle Control

    Reels can be raised but not lowered when in mid position. Figure 11 Hour Meter Models 03806 and 03807 The hour meter (Figure 12) shows total hours that 1. Lower mow/raise control 6. Glow plug indicator light machine has been operated.
  • Page 20 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. Figure 12 1. Hour meter Backlap Knobs Figure 14 1. Seat adjusting lever 2.
  • Page 21 Contact • Fuses are blown. your Authorized Service Dealer or Distributor or • No battery power. go to www.Toro.com for a list of all approved attachments and accessories. Check electrical connections, input fuses and diagnostic light bulb to determine malfunction.

  • Page 22: Specifications

    • 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. 1. Park machine on a level surface. Release hood latch and open hood (Figure 16).

  • Page 23: Filling The Fuel Tank

    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. 1.

  • Page 24: Checking The Hydraulic Fluid

    Note: This is vegetable-oil based biodegradable 2. Fill tank to about one inch below top tank, not oil tested and approved by Toro for this model. filler neck with No. 2 diesel fuel. Then install This fluid is not as resistant to high temperatures cap.

  • Page 25: Checking The Tire Pressure

    Note: We recommend that anytime the 4. If level is low, add appropriate fluid to raise level to full mark. machine is parked (short or long term) the cutting units should be lowered to the ground. 5. Install dipstick and cap onto filler neck. This relieves pressure from the lift circuit and eliminates the risk of the cutting units Checking the Tire Pressure...

  • Page 26: Pushing Or Towing The Machine

    Pushing or Towing the Machine In an emergency, the machine can be moved by actuating the bypass valve in the variable displacement hydraulic pump and pushing or towing the machine. Important: Do not push or tow the machine faster than 2-3 mph (3-4.8 km/h) because internal transmission damage may occur.

  • Page 27: Checking The Interlock

    Checking the Interlock sure correct overlay decal is positioned on Switches Diagnostic ACE display. If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. • Do not tamper with the interlock switches. • Check the operation of the interlock switches daily and replace any damaged switches before operating the machine.

  • Page 28: Fault Memory And Retrieval

    ECU problem. If this occurs, contact your Toro Distributor for assistance. 5. The “outputs displayed” LED, on lower right column of Diagnostic ACE, should Fault Memory and Retrieval be illuminated.

  • Page 29: Hydraulic Solenoid Valve

    Important: The display will show Solenoid Function eight (8) individual records with the fault MSV2 Rear reel circuit displayed on the 8th record. Each record Lift front wing cutting units will be displayed for 10 seconds. Be sure Lift front center cutting to have the Diagnostic Tool display on unit Outputs to see fault.
  • Page 30 Important: Before mowing grass, practice Transport operating the machine in turns. Turf damage Move the Enable/Disable switch to Joy Stick in turns may occur especially under soft or Disable (mid position), lock brake pedals together wet grass conditions if the turn is completed and raise the cutting units to the transport at a high speed or at a small turning radius.

  • Page 31: 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 rst 1–4 hours of After the rst 8 operating operation and then after 10 hours of operation).

  • Page 32: Service Interval Chart

    Important: Refer to your engine Operator’s Manual for additional maintenance procedures. If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition and disconnect the wire from the spark plug before you do any maintenance.

  • Page 33: Daily Maintenance Checklist

    Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Maintenance Check Item Mon. Tues. Wed. Thurs. Sat. Sun. Fri. Check safety interlock operation. Check brake operation. Check engine oil and fuel level. Check cooling system uid level. Drain the water/fuel separator.
  • Page 34 Figure 31 Figure 29 • Rear axle tie rod (2) (Figure 30) • Steering cylinder ball joints (2) (Figure 30) • King pin bushings (2) (Figure 30). The top fitting on the king pin should only be lubricated annually (2 pumps). Figure 32 •...

  • Page 35: Engine Maintenance

    Figure 34 Figure 37 • Rear axle pivot (Figure 35) Engine Maintenance Servicing the Air Cleaner Check the air cleaner body for damage which could cause an air leak. Replace if damaged. Check the whole intake system for leaks, damage or loose hose clamps.
  • Page 36 Figure 39 Figure 40 1. Air cleaner latch 2. Air cleaner cover 1. Air cleaner primary lter 2. Remove the cover from the air cleaner body. Important: Never attempt to clean the Before removing the filter, use low pressure safety filter (Figure 41). Replace the safety air (40 psi, clean and dry) to help remove filter with a new one after every three large accumulations of debris packed between...

  • Page 37: Servicing The Engine Oil And Filter

    Servicing the Engine Oil and Filter Change oil and filter initially after the first 50 hours of operation, thereafter change oil and filter every 150 hours. 1. Remove drain plug (Figure 42) and let oil flow into drain pan. When oil stops, install drain plug.

  • Page 38: Fuel Lines And Connections

    Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage. • Use a funnel and fill the fuel tank outdoors, in an open area, when the engine is off and is cold.

  • Page 39: Bleeding Air From Injectors

    Note: Do not use water to clean engine, as damage may occur. Electrical System Maintenance Battery Care Warning Figure 47 1. Fuel pre-lter CALIFORNIA Proposition 65 Warning Note: Bleeding fuel system is required after Battery posts, terminals, and related accessories contain lead and lead replacing the fuel filter/water separator filter compounds, chemicals known to the State of or the fuel filter.

  • Page 40: Fuses

    Rinse with clear water. Coat the battery posts and cable connectors with Grafo 112X (skin-over) grease (Toro Part No. 505-47) or petroleum jelly to prevent corrosion. Figure 50 Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns.

  • Page 41: Drive System Maintenance

    6. Install a 10 amp. fuse to fuse block at location shown on fuse block decal. Do not exceed fuse rating. Figure 51 Switch Relay Toro Part No. 75-1010 Toro Part No. 70-1480 Honeywell Part No. 1TL1-2 Hella Part No. 87411 B Drive System Maintenance...

  • Page 42: Changing The Planetary Gear Drive Oil

    Figure 53 Figure 55 1. Brake housing 2. Check plug location 1. Drain plug location 2. Check plug location 3. Add gear oil to the hole in the planetary, if 4. When all of the oil has drained, install the necessary, to bring the oil up to the proper bottom plug in the brake housing.

  • Page 43: Changing The Rear Axle

    Rear Wheel Toe-In After every 800 operating hours or annually, check the rear wheel toe-in. 1. Measure the center-to-center distance (at axle height) at the front and rear of the steering tires. The front measurement must be 1/8 in. (3 mm) less than the rear measurement. 2.

  • Page 44: Cooling System Maintenance

    only the right brake pedal and engage the parking brake. 2. Jack up left side of machine until front tire is off the shop floor. Support machine with jack stands to prevent it from falling accidentally. Note: On 4 wheel drive models, left rear tire must also be off the shop floor.

  • Page 45: Brake Maintenance

    Change hydraulic fluid after every 800 operating hours, in normal conditions. If fluid becomes Belt Maintenance contaminated, contact your local Toro distributor because the system must be flushed. Contaminated Checking the Alternator fluid looks milky or black when compared to clean oil.

  • Page 46: Replacing The Hydraulic Filter

    GREEN zone. When the indicator is in the RED zone, the filter element should be changed. Use the Toro replacement filter (Part No. 94-2621). Important: Use of any other filter may void the warranty on some components.

  • Page 47: Hydraulic System Test Ports

    Hydraulic System Test Ports rear cutting units. The test ports are used to test pressure in the hydraulic circuits. Contact your local Toro distributor for assistance. 1. Test Port A (Figure 66 and Figure 67) is used to assist in trouble shooting the hydraulic circuit for the lift cylinders.

  • Page 48: Cutting Unit Maintenance

    6. Test Port F is used to measure traction reverse 1. Position the machine on a level surface, lower pressure (Figure 69). the cutting units, stop the engine, engage the parking brake, and move the Enable/Disable 7. Test Port G is used to measure steering circuit switch to disable position.

  • Page 49: Adjust Turf Compensation

    Move Lower Mow/Lift control forward to start backlapping operation on designated reels. 8. Apply lapping compound with a long handle brush (Toro Part No. 29-9100). Never use a short handled brush (Figure 71). Figure 71 1. Long handled brush 9.

  • Page 50: Adjusting The Cutting Unit

    Note: As compressed spring length (A) decreases, weight transfer from front roller to Figure 75 rear roller increases and carrier frame/cutting Models 03806 and 03807 unit rotation angle (B) decreases. 1. Adjustment valves Note: As gap (C) between spring bracket and washer increases, cutting unit ground 2.

  • Page 51: Cutting Units (Enable Position)

    as required. Tighten set screw securing may be increased to provide additional ground adjustment. clearance on contoured fairways. Note: The RM CONFIG time delay should not Rear Cutting Unit be changed from the original setting of 0 when 5. Locate valve in front of rear axle for rear using this method to adjust turn around height.
  • Page 52 Note: Moving the carrier frame down will decrease the amount of clearance between the cutting units and the ground in turnaround and transport positions and may require adjusting the lift chain length on the cutting unit. Figure 78 1. Carrier frame mounting bolts...

  • Page 53: Storage

    B. Clean the battery, terminals, and posts with a wire brush and baking soda solution. 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 54: Schematics

    Schematics Electrical Schematic (Rev. -)
  • Page 55 Hydraulic Schematic, Model 03806 (Rev. -)
  • Page 56 Hydraulic Schematic, Model 03807 (Rev. -)
  • Page 57 Hydraulic Schematic, Model 03808 (Rev. -)
  • Page 60 (Dealer) to obtain guarantee policies for your country, province, or state. If for any reason you are dissatised with your Distributor’s service or have difculty obtaining guarantee information, contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty Company.

This manual is also suitable for:

03807Reelmaster 6500-dReelmaster 6700-d03808

Table of Contents