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Toro Reelmaster 2000, Operator'S Manual

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Toro Reelmaster 2000 Operator'S Manual Download Page 36

Daily Maintenance Checklist

Duplicate this page for routine use.

For the week of:

Maintenance Check Item

Mon.

Tues.

Wed.

Thurs.

Fri.

Sat.

Sun.

Check the safety interlock operation.

Check the brake operation.

Check the engine oil level.

Check the cooling system fluid level.

Drain the water/fuel separator.

Check the air filter, dust cup, and burp valve.

Check the oil cooler, radiator and screen for debris.

Check for unusual engine noises.

1

Check for unusual operating noises.

Check the hydraulic system oil level.

Check the hydraulic hoses for damage.

Check for fluid leaks.

Check the fuel level.

Check the tire pressure.

Check instrument operation.

Check reel-to-bedknife adjustment.

Check height-of-cut adjustment.

Lubricate all grease fittings.

2

Touch up damaged paint.

1. Check the glow plug and injector nozzles if hard starting, excess smoke, or rough running is noted.

2. Immediately after every washing, regardless of the interval listed

Notation for Areas of Concern

Inspection performed by:

Item

Date

Information

1

2

3

4

5

6

7

8

Important:

Refer to your

Engine Operator’s Manual

for additional maintenance procedures.

36

Summary of Contents for Reelmaster 2000

Page 1: ... 235 Rev B Reelmaster 2000 Traction Unit Model No 03431 Serial No 310000001 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: ...oduct properly and to avoid injury and product damage You are responsible for operating the product properly and safely You may contact Toro directly at www Toro com for product and accessory information help finding a dealer or to register your product Whenever you need service genuine Toro parts or additional information contact an Authorized Service Dealer or Toro Customer Service and have the ...

Page 3: ...ing 32 Transport Operation 32 Inspection and Clean Up After Mowing 32 Standard Control Module SCM 32 Maintenance 35 Recommended Maintenance Schedule s 35 Daily Maintenance Checklist 36 Service Interval Chart 37 Premaintenance Procedures 37 Removing the Hood 38 Lubrication 38 Greasing the Bearings and Bushings 38 Engine Maintenance 40 Servicing the Air Cleaner 40 Changing the Engine Oil and Filter ...

Page 4: ...Lack of awareness of the effect of ground conditions especially slopes Incorrect hitching and load distribution The owner user can prevent and is responsible for accidents or injuries occurring to himself or herself other people or property Preparation While mowing always wear substantial footwear long trousers hard hat safety glasses and ear protection Long hair loose clothing or jewelry may get ...

Page 5: ...gine is provided with a fuel shut off valve turn the fuel off at the conclusion of mowing Keep hands and feet away from the cutting units Look behind and down before backing up to be sure of a clear path Slow down and use caution when making turns and crossing roads and sidewalks Stop cylinders reels if not mowing Do not operate the mower under the influence of alcohol or drugs Lightning can cause...

Page 6: ...ot drive close to sand traps ditches creeks or other hazards Reduce speed when making sharp turns Avoid sudden stops and starts When near or crossing roads always yield the right of way Apply the service brakes when going downhill to keep forward speed slow and to maintain control of the machine Raise the cutting units when driving from one work area to another Do not touch the engine silencer muf...

Page 7: ...ssure level was determined according to the procedures outlined in EN 836 Vibration Level Hand Arm Measured vibration level for right hand 1 54 m s2 Measured vibration level for left hand 1 04 m s2 Uncertainty Value K 0 5 m s2 Measured values were determined according to the procedures outlined in EN 836 Whole Body Measured vibration level 6 22 m s2 Uncertainty Value K 0 4 m s2 Measured values wer...

Page 8: ...anders a safe distance from the machine 4 Cutting hazard of hand and foot stay away from moving parts keep all guards and shields in place 5 Warning lock the parking brake stop the engine and remove the ignition key before leaving the machine 106 8120 1 Thrown object hazard keep bystanders a safe distance from the machine 2 Cutting hazard of hand and foot stay away from moving parts Battery Symbol...

Page 9: ...104 3991 9 ...

Page 10: ...rator s Manual 5 Neutral 9 Push off 13 Fast 2 Warning read the Operator s Manual do not use starting fluid 6 Raise the reels 10 Engine stop 14 Slow 3 Raise and lower the reels 7 Power take off PTO 11 Engine run 4 Lower the reels 8 Pull on 12 Engine start 104 4096 10 ...

Page 11: ...115 3037 11 ...

Page 12: ...rust washer 3 Flat washer 3 6 Flange head bolt 3 Mount the cutting units Spring 3 Vinyl sleeve 1 Spring shackle 3 Clevis pin 6 Cotter pin 6 Shackle 32 inch cutting unit only 2 Spring anchor 32 inch cutting unit only 2 Bolt 1 4 x 3 4 inch 32 inch cutting unit only 4 7 Locknut 32 inch cutting unit only 4 Install the counterbalance springs supplied in the lift arm kit 8 Rear weight kit s Varies Add r...

Page 13: ... nut 2 Rear wheel hub 2 Install the lug nuts Figure 2 and tighten them to 45 to 65 ft lb 3 to 5 N m 2 Adjusting the Rear Carrier Frame Height Parts needed for this procedure 1 Rear carrier frame Procedure 1 Slide the rear carrier frame onto the rear lift arm pivot rod Figure 3 Do not install the carrier frame to the cutting unit at this time G009851 1 3 3 2 4 Figure 3 1 Rear carrier frame 3 Up sto...

Page 14: ...e 6 Washer 3 Bolt 3 8 x 2 1 4 inches 3 Locknut 3 8 inch Procedure 1 Remove the cutting units from the cartons Adjust them per the Cutting Unit Operator s Manual 2 Position a carrier frame onto each cutting unit aligning the mounting holes with the mounting links Figure 4 G009852 1 3 2 Figure 4 1 Carrier frame 3 Bearing housing cover 2 Mounting link 3 Secure each mounting link to the carrier frame ...

Page 15: ...o that the counterbalance arm fits into the slot in the pin Do not secure the counterbalance arm at this time 7 Secure one end of the lift chain to the lift cylinder pin with a clevis pin and cotter pin 8 Secure the other end of the lift chain to the hole in the lift arm mounting tab with clevis pins and cotter pins Use the appropriate hole in the lift arm as designated in Figure 7 G009855 2 1 Fig...

Page 16: ...Procedure 1 Slide a thrust washer onto the lift arm pivot rod Figure 9 G009857 1 2 3 Figure 9 1 Thrust washer 3 Flat washer and flange head bolt 2 Carrier frame 2 Slide the cutting unit carrier frame onto the pivot rod and secure it with a flat washer and flange head bolt Figure 9 Note On the rear cutting unit position the thrust washer between the rear of the carrier frame and the flat washer 3 S...

Page 17: ...ng tension increases the weight on the inboard end of the cutting unit and reduces the weight on outboard end Installing the Counterbalance Springs on 27 Inch Cutting Units 1 Hook the spring into the third hole from the top on the inboard side of both front cutting unit lift tabs and on the rear cutting unit lift tab Figure 11 Note Selecting the 4 hole position increasing the spring tension will r...

Page 18: ...e 14 G009862 1 2 Figure 14 1 Cutting unit lift tab 2 Spring anchor 2 On the front cutting units hook the spring into the second hole from the bottom 3 position in the spring anchor Figure 14 Note Selecting the 4 hole position increasing the spring tension will reduce the weight on the inboard end of the cutting unit increase the weight on the outboard end of the cutting unit and increase traction ...

Page 19: ...procedure Varies Rear weight kit s Procedure This unit complies with ANSl B71 4 2004 Standards and all applicable European requirements when equipped with rear ballast Use the following chart to determine the weight or combinations of weights needed Cutting Unit Configuration Weight Kits Required Standard machine with 27 inch cutting units 1 83 9370 2 83 9390 Standard machine with 27 inch cutting ...

Page 20: ... the filler caps with the vents pointing to the rear toward the fuel tank and connect a 3 to 4 amp battery charger to the battery posts Charge the battery at a rate of 3 to 4 amperes for 4 to 8 hours Charging the battery produces gasses that can explode Never smoke near the battery and keep sparks and flames away from battery 3 When the battery is charged disconnect the charger from the electrical...

Page 21: ...e Then shut the engine off and check for oil leaks loose parts and any other noticeable malfunctions Shut the engine off and wait for all moving parts to stop before checking for oil leaks loose parts and other malfunctions Product Overview Controls Traction and Stopping Pedal The traction pedal Figure 17 has three functions to make the machine move forward to move it backward and to stop the mach...

Page 22: ...inder is completely retracted before releasing the lift lever The cutting units will not operate unless the cylinder is retracted To raise the cutting units pull the lift lever rearward to the Raise position Cutting Unit Lift Lever Lock The cutting unit lift lever lock Figure 19 locks cutting units in the raised position for transporting Cutting Unit Drive Switch The switch Figure 19 has two posit...

Page 23: ...e rotating Seat Adjustment Move the lever on the side of the seat outward slide the seat forward or rearward to the desired position and release the lever to lock the seat into position Fuel Shut Off Valve Close the fuel shut off valve under the fuel tank Figure 22 when storing the machine Figure 22 1 Fuel shut off under the fuel tank Specifications Note Specifications and design are subject to ch...

Page 24: ...o Premium Engine oil is available from your distributor in either 15W 40 or 10W 30 viscosity 1 Park the machine on a level surface stop the engine set the parking brake and remove the key from the ignition switch 2 Remove the dipstick wipe it clean and install it ensuring that it is fully seated Figure 23 Figure 23 1 Dipstick 3 Remove the dipstick and check the oil level on the dipstick The oil le...

Page 25: ...mp life and increased power compared to winter grade fuel Important Do not use kerosene or gasoline instead of diesel fuel Failure to observe this caution will damage the engine Fuel is harmful or fatal if swallowed Long term exposure to vapors can cause serious injury and illness Avoid prolonged breathing of vapors Keep face away from nozzle and fuel tank or conditioner opening Keep fuel away fro...

Page 26: ... the equipment with its wheels on the ground If this is not possible then refuel such equipment on a truck or trailer from a portable container rather than from a fuel dispenser nozzle If a fuel dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete Note If possible fill the fuel tank after each use This wi...

Page 27: ...eet all the following material properties and industry specifications Toro does not recommend the use of synthetic fluid Consult with your lubricant distributor to identify a satisfactory product Note Toro will not assume responsibility for damage caused by improper substitutions so use only products from reputable manufacturers who will stand behind their recommendation High Viscosity Index Low P...

Page 28: ...he Tire Pressure Service Interval Before each use or daily Check to ensure that the air pressure in the tires is 16 20 psi 110 138 kPa Important Maintain the recommended pressure in all tires to ensure a good quality of cut and proper machine performance Do not under inflate Note The tires are over inflated for shipping Therefore release some of the air to reduce the pressure before using the mach...

Page 29: ... bleeding procedures are followed However if the engine does not start air may be trapped between injection pump and injectors refer to Bleeding Air from the Injectors Starting and Stopping the Engine Important You must bleed the fuel system before starting the engine if you are starting the engine for the first time the engine has stopped due to lack of fuel or you have performed maintenance on t...

Page 30: ...e lift cylinder is fully retracted As the lift cylinder is extended the light should go out and the reel motors should stop turning Correct the problem if it is not operating properly 6 With the operator on the seat the engine must not start with either the reel switch engaged or the traction control engaged Correct the problem if it is not operating properly Towing the Traction Unit In case of an...

Page 31: ...s Using the column of the chart listing either 5 or 8 blade reels find the height of cut listing nearest the actual height of cut setting Look across the chart to find the number corresponding to that height of cut 2 Ensure that the backlap knob is set in the Forward F position Figure 33 3 Turn the reel speed control knob Figure 33 to the number setting determined in step 1 G010094 1 2 Figure 33 1...

Page 32: ...le objects placed close together Inspection and Clean Up After Mowing At the completion of the mowing operation thoroughly wash the machine with a garden hose without a nozzle so that excessive water pressure will not cause contamination and damage to the seals and bearings Make sure that the radiator screen radiator and oil cooler are kept free of dirt or grass clippings After cleaning it is reco...

Page 33: ...rmine the output fault you are trying to resolve PTO Start or ETR 2 Move ignition switch to the On position and ensure the red power LED is illuminated 3 Move all input switches to ensure all LED s change state 4 Position input devices at appropriate position to achieve the appropriate output Use the following logic chart to determine the appropriate input condition If specific output LED is illum...

Page 34: ...t LED ON A Blank indicates a circuit that is not involved with the logic To troubleshoot turn on the key without starting the engine Identify the specific function that does not work and work across the logic chart Inspect the condition of each input LED s to ensure it matches the logic chart If the input LED s are correct check the output LED If the output LED is illuminated but the device is not...

Page 35: ...reen oil coolers and radiator Clean more frequently in dirty operating conditions Every 25 hours Check the electrolyte level and clean the battery Check the battery cable connections Every 50 hours Grease the bearings and bushings Grease immediately after every washing regardless of the interval listed Check the condition and tension of the alternator belt Every 100 hours Check the condition and t...

Page 36: ...ting noises Check the hydraulic system oil level Check the hydraulic hoses for damage Check for fluid leaks Check the fuel level Check the tire pressure Check instrument operation Check reel to bedknife adjustment Check height of cut adjustment Lubricate all grease fittings 2 Touch up damaged paint 1 Check the glow plug and injector nozzles if hard starting excess smoke or rough running is noted 2...

Page 37: ...re 35 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 before you do any maintenance Premaintenance Procedures 37 ...

Page 38: ... the hood Lubrication Greasing the Bearings and Bushings Service Interval Every 50 hours Grease immediately after every washing regardless of the interval listed Lubricate all grease fittings for the bearings and bushings with No 2 General Purpose Lithium Base Grease Lubricate bearings and bushings immediately after every washing regardless of the interval listed The grease fitting locations and q...

Page 39: ... Lift arms 3 Figure 39 Figure 39 Rear lift cylinder pivot Figure 40 Figure 40 Pivot rods 3 Figure 41 Figure 41 Traction pedal pivot Figure 42 Figure 42 Neutral centering Figure 43 Figure 43 39 ...

Page 40: ...he intake tract This cleaning process prevents debris from migrating into the intake when the filter is removed 4 Remove and discard the filter Figure 44 Cleaning of the used element is not recommended due to the possibility of damage to the filter media 5 Inspect the new filter for shipping damage checking the sealing end of the filter and the body Do not use a damaged element 6 Insert the new fi...

Page 41: ...he engine is off and is cold Wipe up any fuel that spills Do not fill the fuel tank completely full Add fuel to the fuel tank until the level is 1 4 to 1 2 inch 6 to 13 mm below the bottom of the filler neck This empty space in the tank allows the fuel to expand Never smoke when handling fuel and stay away from an open flame or where fuel fumes may be ignited by a spark Store fuel in a clean safet...

Page 42: ...ing surface then rotate it an additional 1 2 turn Bleeding Air from the Fuel Injectors Note This procedure should be used only if the fuel system has been purged of air through normal priming procedures and the engine will not start refer to Bleeding the Fuel System 1 Loosen the pipe connection to one of the fuel injectors Figure 48 Figure 48 1 Fuel injectors 2 Slowly move the throttle to the full...

Page 43: ... battery kept clean If the machine is stored in a location where temperatures are extremely high the battery will run down more rapidly than if the machine is stored in a location where temperatures are cool Check the electrolyte level every 25 operating hours or if machine is in storage every 30 days Maintain the cell level with distilled or demineralized water Do not fill the cells above the bot...

Page 44: ... accidentally fall injuring anyone under the machine 3 Loosen the locknut on the traction adjustment cam Figure 51 Figure 51 1 Traction adjustment cam The engine must be running so a final adjustment of the traction adjustment cam can be performed Contact with hot or moving parts can result in personal injury Keep hands feet face and other body parts away from the muffler other hot parts of the en...

Page 45: ...l switch 3 Adjust the switch location until a circuit is made when in neutral and broken with 1 inch 2 5 cm travel of the traction pedal 4 Tighten the locknut Cooling System Maintenance Removing Debris from the Cooling System Service Interval Before each use or daily Remove debris from the screen oil coolers and radiator Clean more frequently in dirty operating conditions Every 1 000 hours Every 2...

Page 46: ...nut on the clevis Figure 55 Figure 55 1 Upper brake lever 2 Clevis 4 Remove the cotter pin securing the top of the clevis to the upper brake lever 5 Rotate the clevis one turn at a time to decrease the distance between the levers 6 Install the clevis to the upper brake lever and tighten the jam nut Repeat the procedure on the opposite side of the machine 7 After any brake adjustment operate the ve...

Page 47: ...cedure to tension the belt 1 Loosen alternator mounting bolts Figure 56 Figure 56 1 Alternator belt 2 Brace 2 Using a bar rotate alternator until proper belt tension is attained then tighten mounting bolts Tensioning the Hydraulic Pump Belt Service Interval After the first 8 hours Every 100 hours Tension a new hydraulic pump belt so that it deflects 0 12 inch 3 mm with a 15 to 17 lb 7 to 7 5 kg lo...

Page 48: ...vel under the pedal may be adjusted for slower travel Speeds in excess of 3 mph 5 km h are not recommended 6 Check the neutral switch adjustment Adjusting the Traction Pedal Damper 1 To expose the traction pedal damper remove the right hand panel 2 Loosen the locknut securing the damper pivot to the damper bracket Figure 59 G009903 1 3 2 Figure 59 1 Damper 3 Damper bracket 2 Damper pivot 3 Press t...

Page 49: ...m type filter wrench Dispose of the oil filter properly Figure 61 1 Hydraulic oil filter 4 Apply a film of oil on the filter gasket Install the filter by hand until the gasket contacts the mounting head then tighten the filter an additional 3 4 turn 5 Fill the reservoir to the proper level refer to Checking the Hydraulic System Fluid 6 Place all controls in neutral or in the disengaged position an...

Page 50: ... death Never place hands or feet in the reel area while the engine is running Do not attempt to restart the reels by hand or foot Do not adjust the reels while the engine is running If the reel stalls stop the engine before attempting to clear the reel 1 Position the machine on a clean level surface lower the cutting units stop the engine engage the parking brake and remove the key from the igniti...

Page 51: ... 1 Thoroughly clean the traction unit cutting units and engine 2 Check the tire pressure Inflate all traction unit tires to 16 to 20 psi 110 to 138 kPa 3 Check all fasteners for looseness and tighten them as necessary 4 Grease all grease fittings and pivot points Wipe up any excess lubricant 5 Lightly sand and use touch up paint on painted areas that are scratched chipped or rusted Repair any dent...

Page 52: ... the fuel tank lines and the fuel filter water separator assembly 7 Flush the fuel tank with fresh clean diesel fuel 8 Secure all fuel system fittings 9 Thoroughly clean and service the air cleaner assembly 10 Seal the air cleaner inlet and the exhaust outlet with weatherproof tape 11 Check the antifreeze protection and add as needed for expected minimum temperature in your area 52 ...

Page 53: ...Schematics G009907 Electrical Schematic Rev A 53 ...

Page 54: ...G009977 Hydraulic Schematic Rev A 54 ...

Page 55: ...G009978 Hydraulic Schematic with 3 Wheel Drive Kit Installed Rev A 55 ...

Page 56: ...and tear and deterioration Normal wear and tear includes but is not limited to damage to seats due to wear or abrasion worn painted surfaces scratched decals or windows etc Parts Parts scheduled for replacement as required maintenance are war ranted for the period of time up to the scheduled replacement time for that part Parts replaced under this warranty are covered for the duration of the origi...

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