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Toro
Lawn Mower
03731
Toro 03731 Service Manual
468 pages
Manual
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Form
No.
15214SL
Rev
D
Reelmaster
®
7000
-D
(
Models
03780/A and 03781
)
Original Instructions (EN)
2
Table of Contents
This Page Is Intentionally Blank.
7
Table of Contents
7
Chapter 1 Safety
11
General Safety Instructions
12
Before Operating
12
While Operating
12
Maintenance and Service
13
Jacking Instructions
14
Safety and Instruction Decals
15
Chapter 2 Product Records and Maintenance
17
Maintenance
17
Product Records
17
Equivalents and Conversions
18
Torque Specifications
19
Fastener Identification
19
Using a Torque Wrench with an Offset Wrench
19
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)
20
Standard Torque for Dry, Zinc Plated and
21
Chapter 7 -- Axles, Planetaries and Brakes
22
Specifications
22
Other Torque Specifications
22
Conversion Factors
22
Chapter 3 Yanmar Diesel Engine
23
General Information
23
Manual
23
Service and Repairs
23
YANMAR TNV (Tier 4) SERIES TROUBLESHOOTING
23
Specifications
24
Chapter 8 -- Chassis
25
General Information
25
Operator's Manuals
25
Yanmar Service and Troubleshooting Manuals
25
Stopping the Engine
25
Engine Electronic Control Unit (ECU)
26
Yanmar Engine
27
Diesel Particulate Filter (DPF)
27
Service and Repairs
31
Air Cleaner System
31
Exhaust System
33
Fuel System
35
Check Fuel Lines and Connections
36
Drain and Clean Fuel Tank
36
Fuel Tank Installation
36
Fuel Tank Removal
36
Prime the Fuel System
36
Engine
41
Engine Removal
42
Engine Installation
43
Pump Adapter Plate
45
Chapter 4 Kubota Diesel Engine
47
Kubota Workshop Manual, Diesel Engine, 03--M--DI--E3B Series
47
Chapter 9 -- DPA Cutting Units
48
Specifications
48
General Information
49
Operator's Manual
49
Service and Repairs
50
Air Filter System
50
Exhaust System
52
Fuel System
54
Check Fuel Lines and Connections
55
Drain and Clean Fuel Tank
55
Fuel Tank Installation
55
Fuel Tank Removal
55
Prime Fuel System
56
Bleed Air from Injectors
57
Radiator/Hydraulic Oil Cooler
58
Engine
62
Engine Removal
63
Engine Installation
64
Pump Adapter Plate
68
Chapter 5 Hydraulic System
71
Specifications
72
General Information
73
Operator's Manual
73
Hydraulic Component Locations
73
Relieving Hydraulic System Pressure
74
Traction Circuit Component Failure
74
Towing Traction Unit
75
Hydraulic Hoses
76
Hydraulic Hose and Tube Installation
77
Hydraulic Fitting Installation
78
Hydraulic Schematic
81
Hydraulic Flow Diagrams
82
Traction Circuit: LOW Speed (Mow)
83
Traction Circuit: HIGH Speed (Transport)
85
Mow Circuit
87
Steering Circuit
89
Lower Cutting Units
91
Raise Cutting Units
93
Engine Cooling Fan Circuit
95
Special Tools
96
Troubleshooting
101
Testing
108
Traction Circuit Charge Pressure Test
110
Leakage Test
121
Pressure Test
125
Cutting Unit Circuit Pressure Test
128
Leakage Test
137
Steering/Lift Circuit Steering Relief Pressure Test
140
Steering Cylinder Test
142
Cooling Fan Circuit Pressure Test
146
Gear Pump Flow Test (Pump Sections P2 Thru P5)
152
Adjustments
156
Control Manifold Relief Valve Adjustment
156
Service and Repairs
157
General Precautions for Removing and Installing Hydraulic System Components
157
Check Hydraulic Lines and Hoses
158
Priming Hydraulic Pumps
158
Flush Hydraulic System
159
Filtering Closed- Loop Traction Circuit
160
Charge Hydraulic System
161
Gear Pump
162
Gear Pump Service
164
Piston (Traction) Pump
166
Piston (Traction) Pump Service
168
Rear Traction Manifold
170
Rear Traction Manifold Service
172
HI/LOW Range Manifold
174
Front Wheel Motors
176
Rear Axle Motor
178
Cutting Unit Motor
182
Cutting Unit Motor Service
184
Mow Control Manifold Service
190
Steering Control Valve
192
Steering Control Valve Service
194
Steering Cylinder
196
Steering Cylinder Service
198
Engine Cooling Fan Motor
200
Engine Cooling Fan Motor Service
204
Fan Control Manifold
206
Fan Control Manifold Service
208
Lift Manifold
210
Lift Manifold Service
212
Control Manifold Cartridge Valve Service
213
Lift Junction Manifold
214
Front Lift Cylinders
216
Rear Lift Cylinders
218
Lift Cylinder Service
220
Hydraulic Reservoir
222
Hydraulic Oil Cooler
224
Chapter 6 Electrical System
227
General Information
228
Operator's Manual
228
Engine Electrical Components
228
Can−Bus Communications
229
Engine Electronic Control Unit (ECU) (Yanmar Diesel Engines Only)
229
Electrical Drawings
231
Special Tools
232
Infocenter Display
234
Splash Screen
236
Main Information Screen
237
Main Menu Screen
238
Operator's Advisory Screen
238
Faults Screen
239
Service Screen
240
Diagnostics Screen
241
Settings Screen
243
About Screen
245
Troubleshooting
246
Operator Advisories
246
Using the Infocenter Display for Troubleshooting
248
Fault Codes
250
Starting Problems
252
General Run & Transport Problems
254
Cutting Unit Operating Problems
255
Cutting Unit Lift/Lower Problems
256
Electrical System Quick Checks
257
Battery Test (Open Circuit Test)
257
Charging System Test
257
Glow Plug System Test
257
Check Operation of Interlock Switches
258
Adjustments
259
HI/LOW (Transport/Mow) Switch
259
Cutting Unit Position Switch
260
Component Testing
261
Fusible Link Harness
261
Fuses
262
Toro Electronic Controller (TEC)
264
Ignition Switch
266
Reel Enable/Disable Switch
267
Engine Speed Switch
268
Lower/Raise Joystick Switches
269
Seat Switch
270
Traction Neutral Switch
271
Parking Brake Switch
272
HI/LOW (Transport/Mow) Switch
273
Cutting Unit Position Switch
274
Backlap Switches
275
Hydraulic Oil Temperature Sender
276
Engine Temperature Sender
277
Relays with Four (4) Terminals
278
Relays with Five (5) Terminals
280
Hydraulic Solenoid Valve Coils
282
Fuel Pump (Yanmar Diesel Engine Only)
283
Fuel Pump (Kubota Diesel Engine Only)
284
Fuel Stop Solenoid
285
Can−Bus Termination Resistor
286
Diode Assembly
287
Resister Assembly
287
Worklight Switch
288
Service and Repairs
289
Battery Storage
289
Battery Care
289
Battery Service
290
Battery Inspection and Maintenance
290
Battery Removal and Installation
290
Battery Specifications
290
Battery Testing
291
Battery Charging
292
Hydraulic Solenoid Valve Coils
293
Worklight Bulb Replacement
294
Chapter 7 Axles, Planetaries and Brakes
295
General Information
297
Operator's Manual
297
Adjustments
298
Planetary Drive End Play
298
Service and Repairs
300
Brake Assembly
300
Brake Inspection and Repair
304
Planetary Drive Assembly
306
OPH−2 Planetary Drive Service
308
Rear Axle Assembly
316
Rear Axle Service
320
Bevel Gear Case and Axle Case
322
Differential Shafts
326
Axle Shafts
327
Input Shaft/Pinion Gear
328
Differential Gear
330
Pinion Gear to Ring Gear Engagement
333
Chapter 8 Chassis
335
General Information
336
Operator's Manual
336
Cutting Unit Identification
336
Service and Repairs
338
Steering Column
338
Console Arm
340
Lift Arms for Front Cutting Units (#1, #4 and #5)
342
Lift Arms for Rear Cutting Units (#2 and #3)
344
Operator Seat
346
Operator Seat Service
348
Operator Seat Suspension
350
Hood
353
Chapter 9 Dpa Cutting Units
355
General Information
355
Service and Repairs
355
Chapter 4 -- Kubota Diesel Engine
356
Specifications
356
General Information
357
Cutting Unit Operator's Manual
357
Special Tools
358
Factors that Can Affect Cutting Performance
363
Adjustments
366
Characteristics
366
Reel Bearing Adjustment (Cutting Units with Painted Side Plates)
367
Leveling Rear Roller
368
Service and Repairs
370
Hydraulic Reel Motor
370
Backlapping
371
Bedbar Assembly
372
Bedknife Replacement and Grinding
374
Bedbar Adjuster Service
376
Reel Assembly
378
Reel Assembly Service (Cutting Units with Painted Side Plates)
382
Reel Assembly
384
Reel Assembly Service (Cutting Units with Aluminum Side Plates)
388
Preparing Reel for Grinding
390
Front Roller
392
Chapter 10 Belt Driven Groomer (Optional)
405
Grooming Performance
406
Troubleshooting
407
Groomer Reel Mechanical Problems
407
Adjustments
408
Groomer Height/Depth Adjustment
408
Service and Repairs
409
Groomer Drive Belt Replacement
409
Groomer Plate Assembly
410
Groomer Reel
414
Groomer Reel Service
416
Groomer Pivot Hub
418
Height Adjuster Assembly
420
Service and Repairs
424
Electrical Drawing Designations
442
Hydraulic Schematic
443
(Serial Numbers below 316000000)
444
Chapter 12
444
(Serial Numbers 316000001 to 403350000)
445
(Serial Numbers above 403350001)
446
(Serial Numbers 316000001 to 403350000)
448
(Serial Numbers above 403350001)
449
Cab
450
Seat and Console Wire Harness
463
(Serial Numbers below 403350000)
466
Other manuals for Toro 03731
Operator's Manual
144 pages
Installation Instructions
2 pages
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Toro 03731 Specifications
General
Starter Type
Recoil
Power Source
Gas
Cutting Width
22 inches
Oil Capacity
20 oz
Warranty
2-Year
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