Form No. 3363-312 Rev C Reelmaster® 3100-D Traction Unit Model No. 03170—Serial No. 310000001 and Up Model No. 03171—Serial No. 310000001 and Up Model No. 03172 Model No. 03173 To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com.
Model No. Introduction Serial No. This product complies with all relevant European directives, for details please see the separate product specific Declaration of Conformity (DOC) sheet. This manual identifies potential hazards and has safety messages identified by the safety alert symbol (Figure 2), which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions.
Contents Sealed Bearings................................................... 44 Engine Maintenance............................................... 45 Servicing the Air Cleaner .................................... 45 Changing the Engine Oil and Filter ..................... 45 Fuel System Maintenance ....................................... 46 Servicing the Fuel Tank ...................................... 46 Inspecting the Fuel Lines and Connections...................................................
Safety ◊ Inadequate braking ◊ The type of machine is unsuitable for the task This machine meets or exceeds CEN standard EN 836:1997 (when appropriate decals applied), and ANSI B71.4-2004 specifications in effect at the time of production when equipped with required weights as listed in the weight chart.
• • • • • • • • • the operator’s position. Never remove the ROPS and always wear the seat belts during operation. Remember there is no such thing as a safe slope. Travel on grass slopes requires particular care. Do the following to guard against overturning: – Do not stop or start suddenly when going up or downhill. – Keep machine speeds low on slopes and during tight turns. – Stay alert for humps and hollows and other hidden hazards.
Preparation • On multi-cylinder/multi-reel machines, take care as rotating one cylinder/reel can cause other cylinders/reels to rotate. • Disengage drives, lower the cutting units, set parking brake, stop engine and remove key. Wait for all movement to stop before adjusting, cleaning or repairing. • Clean grass and debris from cutting units, drives, silencers/mufflers, and engine to help prevent fires. Clean up oil or fuel spillage. • Shut off fuel while storing or transporting.
• Do not operate on a side hill that is too steep. A rollover may occur before losing traction. operation, combined with terrain angles, ricochets, or improperly positioned guards can lead to thrown object injuries. Do not resume mowing until the area is cleared. • Model 03171-The slope angle at which the machine will tip is dependent on many factors.
Sound Power Level Vibration Level This unit has a guaranteed sound power level of 96 dBA, which includes an Uncertainty Value (K) of 1 dBA. Hand-Arm Sound power level was determined according to the procedures outlined in ISO 11094. Measured vibration level for left hand = .52 m/s2 Sound Pressure Level Measured values were determined according to the procedures outlined in EN 836. This unit has a sound pressure level at the operator’s ear of 82 dBA, which includes an Uncertainty Value (K) of 1 dBA.
104-5181 CE only 1. Warning—read the Operator’s Manual. 99-3558 CE only 2. Tipping hazard—do not drive on slopes greater than 15 degrees and, if the roll bar is installed, wear the seat belt. 1. Warning—read the Operator’s Manual. 3. Thrown object hazard—keep bystanders a safe distance from the machine. 4. Cutting hazard of hand or foot—stay away from moving parts. 2. To start the engine, sit on the seat and rotate the ignition key to On/Preheat until the glow plug indicator light goes out.
4-5192 Model 03207 only 1. Engage the power take off (PTO). 5. Raise the cutting units. 2. Disengage the power take off (PTO). 6. Move the cutting units to the left. 3. Lower the cutting units. 7. Move rear ward to lock the 11. Fast lift lever. 8. Engine—stop 12. Continuous variable setting 4. Move the cutting units to the right. 9. Engine—run 10. Engine—start 10 13.
104-5193 Model 03206 only 1. Engage the power take off (PTO). 5. Raise the cutting units. 2. Disengage the power take off (PTO). 6. Move the cutting units to the left. 3. Lower the cutting units. 7. Move rear ward to lock the 11. Fast lift lever. 8. Engine—stop 12. Continuous variable setting 4. Move the cutting units to the right. 9. Engine—run 10. Engine—start 117-5104 11 13.
Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. Keep bystandersa safe distance from the battery. 2. No fire, open flame, or smoking. 7. Wear eye protection; explosive gases can cause blindness and other injuries 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 5. Read the Operator's Manual. 10. Contains lead; do not discard.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 3 4 5 6 7 8 9 10 11 12 Description Use Qty. Front wheel assemblies Rear wheel assembly Steering wheel Steering wheel cap Large washer Jam nut Screw 2 1 1 1 1 1 1 Electrolyte A/R Install the wheels. Install the steering wheel. Activate, charge, and connect the battery.
Media and Additional Parts Description Use Qty. Decal, CE 6 Affix to the machine over corresponding English decals for European compliance. Ignition key 2 Start the engine. Operator's Manual Engine Operator's Manual 1 1 Read before operating the machine. Parts Catalog 1 Use to look up and order parts. Operator Training Material 1 View before operating the machine. Pre-delivery check list 1 Check to ensure that the machine has been properly set up.
3. Secure the steering wheel to the shaft with a jam nut and tighten it to 20 to 26 ft-lb (27 to 35 N-m) (Figure 3). 4. Install the cap to the steering wheel and secure it with a screw (Figure 3). 3 Figure 4 Activating, Charging, and Connecting the Battery 1. Battery cover 4. Remove the filler caps from the battery and slowly fill each cell until electrolyte is just above the plates. Parts needed for this procedure: A/R 5.
WARNING 4 Incorrect battery cable routing could damage the tractor and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. Checking the Angle Indicator • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. Parts needed for this procedure: 1 • Always connect the positive (red) battery cable before connecting the negative (black) cable.
1 5 2 Installing the Hood Latch (CE Only) Parts needed for this procedure: 1 Lock bracket 2 Rivet 1 Washer 1 Screw, 1/4 x 2 inches 1 Locknut, 1/4 inch G012629 Figure 8 2. Bolt and nut assembly 1. CE lock bracket 4. Align the washers with the holes on the inside of the hood. 5. Rivet the brackets and the washers to the hood (Figure 8). 6. Hook the latch onto the hood latch bracket (Figure 9). Procedure 1. Unhook the hood latch from the hood latch bracket. 2.
6 7 Installing the Exhaust Guard (CE Only) Installing the Roll Bar Parts needed for this procedure: Parts needed for this procedure: 1 Roll bar assembly 1 Exhaust guard 4 Flange head bolts 4 Self-tapping screw 4 Locknuts 1 Hose clamp Procedure Procedure 1. Position the exhaust guard around the muffler while aligning the mounting holes with the holes in the frame (Figure 11). Important: Never weld or modify a rollover protection system (ROPS).
4. Insert the lift arms onto the lift arm pivot shafts (Figure 15), and secure each with a lift arm pivot shaft link and bolts previously removed. 8 Note: Torque the bolts to 70 ft-lb (95 N-m). Installing the Front Lift Arms Parts needed for this procedure: 2 Lift arms 2 Pivot rod 2 Bolt (5/16 x 7/8 inch) Procedure 1. Remove the 2 bolts that secure the lift arm pivot shaft link to the lift arm pivot shafts, and remove and retain the pivot shaft link and bolts (Figure 13). Figure 15 1.
4. Position the rear carrier frame (Figure 18) onto the rear cutting unit. Figure 16 1. Front carrier frame 3. Secure the mounting links to the front carrier frames as follows: • Secure the front mounting links to the middle carrier frame holes with a bolt (3/8 x 2-1/4 inch), 2 flat washers, and a locknut, as shown in Figure 17. Position a washer on each side of the link when mounting. Torque the fasteners to 31 ft-lb (42 N-m).
3. Grease all the lift arm and carrier frame pivot points. Important: Ensure that the hoses are free of twists or sharp bends and that the rear cutting unit hoses are routed as show in (Figure 21). Raise the cutting units and shift them to the left (Model 03170). The rear cutting unit hoses must not contact traction cable bracket. Reposition the fittings and/or hoses, if necessary. Figure 19 3. Rear mounting link 1. Rear carrier frame 2.
11 Mounting the Cutting Unit Drive Motors No Parts Required Procedure 1. Position the cutting units in front of the lift arm pivot rods. Figure 24 2. Remove the weight and O-ring (Figure 23) from the inside end of the right hand cutting unit. 2. Reel motor 1. O-ring 6. Mount the motor to the drive end of the cutting unit, and secure it with two capscrews provided with cutting unit (Figure 24). 12 Adjusting the Lift Arms No Parts Required Procedure 1.
Note: If the clearance is not in this range, adjust the cylinder as follows: bumper strap is 0.02 to 0.10 inches (0.51 to 2.54 mm) (Figure 28). A. Back off the stop bolts and adjust the cylinder to attain the clearance (Figure 26). Figure 28 1. Wear bar If the clearance is not in this range, adjust the rear cylinder as follows: Figure 26 1. Stop bolt 2. Bumper strap A. Lower the cutting units and back off the jam nut on the cylinder (Figure 29). 3. Clearance 2. Lift arm B.
Product Overview Tilt Steering Lever Controls Pull the tilt steering lever (Figure 30) back to adjust the steering wheel to the desired position, then push the lever forward to tighten. Indicator Slot The slot in the operator platform (Figure 30) indicates when the cutting units are in the center position. Angle Indicator The angle indicator (Figure 30) indicates the side hill angle of the machine in degrees. Ignition Switch Figure 30 1. Forward traction pedal 4. Tilt steering lever 2.
Cutting Unit Drive Switch Glow Plug Indicator The cutting unit drive switch (Figure 32) has two positions: Engage and Disengage. The rocker switch operates a solenoid valve on the valve bank to drive the cutting units. The glow plug indicator light (Figure 32) will glow when the glow plugs are operating. Hour Meter The hour meter (Figure 32) indicates the total hours of machine operation. The hour meter starts to function whenever the key switch is On.
Fuel Gauge enhance and expand its capabilities. Contact your Authorized Service Dealer or Distributor or go to www.Toro.com for a list of all approved attachments and accessories. The fuel gauge (Figure 34) registers the amount of fuel in the tank. Figure 34 1. Fore and aft lever 2. Fuel gauge Fore and Aft Seat Adjustments Move the lever (Figure 34) on the side of the seat outward, slide the seat to the desired position, and release the lever to lock the seat into position.
Operation 3. Push the dipstick down into the dipstick tube and ensure that it is seated fully, then pull the dipstick out and check the oil level. Note: Determine the left and right sides of the machine from the normal operating position. 4. If the oil level is low, remove the oil fill cap (Figure 36) and gradually add small quantities of oil, checking the level frequently, until the level reaches the Full mark on the dipstick.
The minimum cetane rating should be 40. Purchase fuel in quantities that can be used within 180 days to ensure fuel freshness. 3. Fill the tank to the bottom of the filler neck. Do not overfill. The fuel tank capacity is approximately 7.5 gallons (28 liters). 5. Wipe up any fuel that may have spilled. Use summer grade diesel fuel (No. 2-D) at temperatures above 20°F (-7°C) and winter grade (No. 1-D or No. 1-D/2-D blend) below that temperature.
Pour Point, ASTM D97 -34°F to -49°F Industry Specifications: Vickers I-286-S (Quality Level), Vickers M-2950-S (Quality Level), Denison HF-0 Note: Many hydraulic fluids are almost colorless, making it difficult to spot leaks. A red dye additive for the hydraulic system oil is available in 2/3 oz. (20 ml) bottles. One bottle is sufficient for 4-6 U.S. gallons (15-22 1) of hydraulic oil. Order part no. 44-2500 from an authorized Toro distributor.
4. If the level is low, add the appropriate fluid to raise the level to the full mark. 5. Install the dipstick and cap onto the filler neck. • The engine has ceased running due to lack of fuel. • Maintenance has been performed upon the fuel system components; e.g., filter replaced, etc. Checking the Tire Pressure Starting the Engine Service Interval: Before each use or daily 1. Ensure that the parking brake is set and the reel drive switch is in the Disengage position. 2.
Checking the Interlock System DANGER 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. Service Interval: Before each use or daily CAUTION If the safety interlock switches are disconnected or damaged, the machine could operate unexpectedly, causing personal injury. • Use a funnel and fill the fuel tank outdoors, in an open area, when the engine is off and is cold.
The decal on the SCM only includes symbols. Three LED output symbols are shown in the output box. All other LEDs are inputs. The chart below identifies the symbols. Figure 42 1. Bypass valve 2. Before starting the engine, close the bypass valve by rotating it 90° (1/4 turn). Do not start the engine while the valve is open. Figure 43 Here are the logical troubleshooting steps for the SCM device. Standard Control Module (SCM) 1. Determine the output fault you are trying to resolve (PTO, START, or ETR).
INPUTS Function Power ON In Neutral Start ON Brake ON OUTPUTS PTO ON In Seat Hi Temp Backlap Start ETR PTO Start — — + O O — O O + + O Run (Off Unit) — — O O O O O O O + O Run (On Unit) — O O — O — O O O + O Mow — O O — — — O O O + + Backlap — — O O — O O — O + + Hi Temp — O O O — O • (–) Indicates a circuit closed to ground — LED ON. • (O) Indicates a circuit open to ground or de-energized — LED OFF.
Operating Tips General Tips for Model 03171 • DANGER The mower has a unique traction system that will allow the machine to move forward on side hills, even if the uphill wheel should come off of the ground. If this should happen, the operator or any bystanders could be seriously injured or killed in a rollover. • The slope angle at which the machine will tip is dependent on many factors.
General Tips for Model 03170 far away from the edge of traps or water hazards as possible. DANGER • If an obstacle is in the way, shift the cutting units to easily mow around it. The mower has a unique traction system that will allow the machine to move forward on side hills, even if the uphill wheel should come off of the ground. If this should happen, the operator or any bystanders could be seriously injured or killed in a rollover.
• Practice moving forward and reverse, and starting and stopping the machine. To stop, take your foot off of the traction pedal and let it return to neutral or press down on the reverse pedal to stop. Going down a hill, you may need to use the reverse pedal to stop. • When driving on slopes, drive slowly to maintain steering control and avoid turns to prevent rollovers. In side hill situations you should shift the sidewinder cutting units to the uphill side to give you more stability.
After Mowing REEL SPEED SELECTION CHART Height-of-Cut (inches) After mowing, thoroughly wash the machine with a garden hose without a nozzle to prevent excessive water pressure from prevent contamination and damage to the seals and bearings. Ensure that the radiator and oil cooler are kept free of dirt or grass clippings. After cleaning, inspect the machine for possible hydraulic fluid leaks, damage, or wear to the hydraulic and mechanical components.
Figure 44 1. Reel speed control 2. Backlap control 3. Operate the machine for several days, then examine the cut to ensure the quality of cut. The reel speed knob may be set one position on either side of the position indicated on the chart to account for differences in grass condition, grass length removed, and personal preference.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first hour • Torque the wheel nuts. After the first 10 hours • Torque the wheel nuts. • Check the condition and tension of all belts. • Change the hydraulic filter. After the first 50 hours • Change the oil and oil filter. Before each use or daily • • • • • • • • • Check the engine oil level.
Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Maintenance Check Item Mon. Tues. Wed. Thurs. Fri. Sat. Check the safety interlock operation. Check the brake operation. Check the fuel level. 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 for unusual engine noises.2 Check the radiator and screen for debris Check for unusual operating noises.
Notation for Areas of Concern (cont'd.) Service Interval Chart Figure 45 Premaintenance Procedures Removing the Hood The hood may be easily removed to ease maintenance procedures in the engine area of the machine. 1. Unlatch and raise the hood. Figure 46 2. Remove the cotter pin that secures the hood pivot to the mounting brackets (Figure 46). 1. Cotter pin 3. Slide the hood to the right side, lift the other side, and pull it out of the brackets. Note: Reverse the procedure to install the hood.
Lubrication Greasing the Bearings And Bushings Service Interval: Every 50 hours (Lubricate all bearings and bushings daily when conditions are dusty and dirty.) Every 500 hours/Yearly (whichever comes first) The machine has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. Bearings and bushings must be lubricated daily when the operating conditions are extremely dusty and dirty.
Figure 54 • Mow/transport slide (Figure 55) Figure 51 • Left front lift arm pivot and lift cylinder (2) (Figure 52) Figure 55 • Belt tension pivot (Figure 56) Figure 52 • Right front lift arm pivot and lift cylinder (2) (Figure 53) Figure 56 • Steering cylinder (Figure 57).
Due to the operating conditions these bearing/seal packages are subject to (i.e., sand, turf chemicals, water, impacts, etc.) they are considered normal wear items. Bearings that fail due to causes other than defects in materials or workmanship are typically not covered under the warranty. Note: Bearing life can be negatively affected by improper wash-down procedures. Do not wash down the unit when it is still hot and avoid directing high-pressure or high volume spray at the bearings.
Engine Maintenance Servicing the Air Cleaner Service Interval: Every 200 hours (More frequently in extreme dusty or dirty conditions) • Check the air cleaner body for damage which could cause an air leak. Replace it if it is damaged. Check the whole intake system for leaks, damage, or loose hose clamps. • Service the air cleaner at the recommended service interval or earlier if engine performance suffers due to extremely dusty, dirty conditions.
Fuel System Maintenance DANGER Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive. A fire or an 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. Wipe up any fuel that spills. Figure 61 1. Engine oil drain plug • Do not fill the fuel tank completely full. Add fuel to the fuel tank until the level is 1 in.
2 1 Figure 64 3 G009880 1. Fuel injectors Figure 63 1. Water separator/filter canister 2. Vent plug 3. Drain valve 2. Move the throttle to the Fast position. 3. Turn the key in the key switch to the Start position and watch the fuel flow around the connector. Turn the key to the Off position when you see a solid flow. 3. Tighten the valve after draining. 4. Tighten the pipe connector securely. Changing the Fuel Filter Canister 5. Repeat this procedure on the remaining nozzles.
Electrical System Maintenance ring inside each cell. Install the filler caps with the vents pointing to the rear (toward the fuel tank). Keep the top of the battery clean by washing it periodically with a brush dipped in ammonia or bicarbonate of soda solution. Flush the top surface with water after cleaning. Do not remove the filler caps while cleaning. Caring for the Battery Service Interval: Every 25 hours—Check the electrolyte level. (If machine is in storage, check every 30 days.
Drive System Maintenance Cooling System Maintenance Adjusting the Traction Drive for Neutral Cleaning the Engine Cooling System If the machine moves when the traction pedal is in the neutral position, adjust the traction cam. Service Interval: Before each use or daily Remove debris from the oil cooler and radiator daily. Clean them more frequently in dirty conditions. 1. Park the machine on a level surface and turn the engine off. 1. Turn the engine off and raise the hood. 2.
Brake Maintenance 6. Pivot the oil cooler back into position. 7. Install the access panel and close the hood. Adjusting the Parking Brake Service Interval: Every 200 hours—Check the parking brake adjustment. 1. Loosen the set screw that secures the knob to the parking brake lever (Figure 68). Figure 68 1. Parking brake lever 3. Set screw 2. Knob 2. Rotate the knob until you produce a force of 30–40 lb (41–68 N-m) needed to actuate the lever. 3. Tighten the set screw after attaining the adjustment.
Belt Maintenance 2. Push down and forward on the spring end (Figure 70) to unhook it from the bracket and release tension on the spring. Servicing the Engine Belts Service Interval: After the first 10 hours—Check the condition and tension of all belts. Every 100 hours—Check the condition and tension of all belts. Tensioning the Alternator/Fan Belt 1. Open the hood. 2.
Controls System Maintenance Hydraulic System Maintenance Adjusting the Throttle Changing the Hydraulic Fluid 1. Position the throttle lever rearward so that it stops against the control panel slot. Service Interval: Every 400 hours If the fluid becomes contaminated, contact a Toro distributor to flush the hydraulic system. Contaminated hydraulic fluid looks milky or black when compared to clean fluid. 2. Loosen the throttle cable connector on the injection pump lever arm (Figure 71). 1.
Important: Use only the hydraulic fluids specified. Other fluids could damage the hydraulic system. 8. Start the engine and let it run for about two minutes to purge the air from the system. 9. Stop the engine and check for leaks. Figure 74 1. Hydraulic fill cap 5. Install the reservoir cap, start the engine, and use all of the hydraulic controls to distribute the hydraulic fluid throughout the system. 6. Check for leaks; then stop the engine. 7.
Miscellaneous Maintenance Checking the Hydraulic Lines and Hoses Service Interval: Before each use or daily Backlapping the Cutting System Check hydraulic lines and hoses for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration, and chemical deterioration. Make all necessary repairs before operating. DANGER Contacting the reels may cause personal injury or death. WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury.
Storage Note: The seat switch is bypassed when the backlap control is in the backlap position. The operator does not need to be in the seat, but the parking brake must be engaged or the engine will not run. Preparation for Seasonal Storage Important: Do not rotate the backlap control from the mow position to the backlap position while engine is running. Otherwise, you may damage the reels. Follow these procedures anytime you will be storing the machine for more than 30 days. Traction Unit 4.
5. Start the engine and run it at idle speed for approximately two minutes. 6. Stop the engine. 7. Thoroughly drain all the fuel from the fuel tank, fuel lines, fuel filter, and water separator assembly. 8. Flush the fuel tank with fresh, clean diesel fuel. 9. Secure all fuel system fittings. 10. Thoroughly clean and service the air cleaner assembly. 11. Seal the air cleaner inlet and the exhaust outlet with weatherproof tape. 12.
Schematics G008924 Electrical Schematic (Rev.
Hydraulic Schematic-Model 03170 (Rev.
G008925 Hydraulic Schematic-Model 03171 (Rev.
The Toro Total Coverage Guarantee A Limited Warranty Conditions and Products Covered The Toro® Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial product (“Product”) to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first. This warranty is applicable to all products with the exception of Aerators (refer to separate warranty statements for these products).
