FORM NO. 3325-594 Rev A MODEL NO. 03200-210000001 & UP MODEL NO. 03201-210000001 & UP MODEL NO. 03220 MODEL NO. 03221 OPERATOR'S MANUAL REELMASTER 3100-D Traction Unit To assure maximum safety, optimum performance, and to gain knowledge of the product, it is essential that you or any other operator of the mower read and understand the contents of this manual before the engine is ever started. Pay particular attention to the SAFETY INSTRUCTIONS highlighted by this symbol.
FOREWORD The REELMASTER 3100 was developed to provide an efficient, reliable and time-saving method of mowing high quality turf. The latest concepts in engineering and design have been incorporated into this machine along with the highest quality parts and workmanship. Excellent service will be derived if proper operation and maintenance practices are followed. We know, since you have purchased the industry leader in mowing excellence, that future performance and dependability are of prime importance.
TABLE OF CONTENTS Page Page SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . 4-5 SAFETY INSTRUCTIONS & DECALS . . . . . . . . . . 6 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 LOOSE PARTS CHART . . . . . . . . . . . . . . . . . . . . . . . 8 SET UP INSTRUCTIONS . . . . . . . . . . . . . . . . . . 9-15 Install Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install Steering Wheel . . . . . . . . . . . . . . . . . . . .
SAFETY INSTRUCTIONS The REELMASTER 3100-D was tested and certified by TORO for compliance with the B71.4 1999 specifications of the American National Standards Institute. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern, and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine.
SAFETY INSTRUCTIONS 20. The slope angle at which the machine will tip is dependent on many factors. Among these are mowing conditions such as wet or undulating turf, speed (especially in turns), position of the cutting units (with sidewinder), tire pressure and operator experience. At side hill slope angles of 20 degrees or less the risk of a rollover is low. As the slope angle increases to a Toro recommended maximum limit of 25 degrees the risk of a rollover increases to a moderate level.
SAFETY AND INSTRUCTION DECALS The following safety and instruction decals are affixed to the traction unit. If any decal becomes illegible or damaged, install a new decal. Part numbers are listed below and in your Parts Catalog. Order replacements from your Authorized Toro Distributor. ON CONSOLE PANEL (Part No. 99-3443, Model 03200) (Part No. 99-3493, Model 03201) (Add Part No. 99-3558 for CE) ON SCISSORS LINKAGE (Part No.
SPECIFICATIONS Engine: Kubota three cylinder, 4 cycle liquid cooled diesel engine. 21.5 hp @ 2500 rpm Governed to 2650 rpm. 68.5 cu. in. (1124 cc) displacement. Heavy duty, 2 stage, remote mounted air cleaner. High water temperature shutdown switch. Cooling System: Radiator capacity is approximately 6 qts. of 50/50 mixture of ethylene glycol anti-freeze. Remote mounted 1 qt. expansion tank. Electrical: 12 volt Group 55, 450 cold cranking amps at 0 F (-18 C), 75 minute reserve capacity at 80 F (27 C).
LOOSE PARTS CHART Note: Use this chart as a checklist to assure all parts necessary for assembly have been received. Without these parts, total set up cannot be completed. Some parts may have already been assembled at factory. PART DESCRIPTION QTY. USE Wheel Assembly 3 Steering Wheel Jam Nut Cover Screw 1 1 1 1 Hood Lock Bracket Screw - 1/4-20 x 1-1/2" lg.
SET-UP INSTRUCTIONS INSTALL WHEELS 1. Mount a wheel assembly onto each wheel hub (valve stem outward). IMPORTANT: Rear tire has a narrower rim than front tires. 4. Remove filler caps from battery and slowly fill each cell until electrolyte is just above the plates. 5. Replace filler caps 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. CAUTION 2. Install lug nuts and torque to 45-65 ft-Ib. INSTALL STEERING WHEEL (Fig. 1) 1.
SET-UP INSTRUCTIONS IMPORTANT: If battery is ever removed, make sure battery clamp bolts are reinstalled with bolt heads positioned on bottom side and nuts on top side. If clamp bolts are reversed, they may interfere with hard lines when shifting cutting units. 5. Coat both battery connections with Grafo 112X (skin over) grease, Toro Part No. 505-47, petroleum jelly or light grease to prevent corrosion and slide rubber boot over positive terminal. 6. Install battery cover. INSTALL SEAT (Fig.
SET-UP INSTRUCTIONS CHECK ANGLE INDICATOR (Fig. 8) 3. Re-hook latch onto bracket. 4. Insert 1/4-20 x 1-1/2" lg. capscrew thru hood lock bracket and secure with a capscrew, flat washer and locknut. DANGER To reduce risk of injury or death due to rollover do not operate on side hills steeper than 25 . INSTALL EXHAUST GUARD (Fig. 10) (European Compliance) 1. Position exhaust guard around muffler while aligning mounting holes with holes in frame. 1 2.
SET-UP INSTRUCTIONS 4. Secure each side of roll bar to mounting brackets with (2) flange head capscrews and locknuts (Fig. 11). Torque fasteners to 60 ft-lbs. 2. Insert a pivot rod into each (R.H. & L.H.) lift arm and align mounting holes (Fig. 13). 5. Secure fuel line vent hose to vent tube on ROPS with hose clamp. 1 CAUTION Fuel line vent hose must be connected to vent tube prior to starting engine or fuel will flow from hose. 2 Figure 13 1. Lift arm 2. Pivot rod 1 3 2 3.
SET-UP INSTRUCTIONS 3. Position rear carrier frame (Fig. 17) onto rear cutting unit, aligning mounting holes with mounting links as shown in figure 18. 2 3 1 Figure 15 1. Lift cylinder 2. Hoses 3. Clearance here 1 7. Secure left end of lift cylinder to left lift arm with pin. Secure with retaining ring. Note: With lift arms fully raised, hoses should be routed as shown in figure 15 and clear lift arm by .04-.12". MOUNT CARRIER FRAMES TO CUTTING UNITS (Fig. 16 - 18) Figure 17 1.
SET-UP INSTRUCTIONS 1 2 3 1 Figure 21 1. Tipper chain Figure 19 1. Thrust washer 2. Carrier frame 3. Lynch pin 3. Grease all lift arm and carrier frame pivot points. IMPORTANT: Make sure hoses are free of twists or sharp bends and rear cutting unit hoses are routed as shown in Fig. 20. Raise cutting units and shift them to the left (Model 03201 only). Rear cutting unit hoses must not contact traction cable bracket. Re-position fittings and / or hoses, if required. MOUNT CUTTING UNIT DRIVE MOTORS (Fig.
SET-UP INSTRUCTIONS ADJUST LIFT ARMS (Fig. 24 - 28) 1. Start engine, raise lift arms and check to make sure clearance between each lift arm and floor plate bracket is .18" - .32" (Fig. 24). If clearance is not in this range, back off stop bolts (Fig. 26) and adjust cylinder to attain clearance. To adjust cylinder, back off the jam nut on the cylinder (Fig. 25), remove pin from rod end and rotate clevis. Install pin and check clearance. Repeat procedure if required. Tighten clevis jam nut.
BEFORE OPERATING CAUTION Before servicing or making adjustments to the machine, stop engine and remove key from the switch. IMPORTANT: Check level of oil every 5 operating hours or daily. Change oil after every 50 hours of operation. FILL FUEL TANK (Fig. 31) The engine runs on No. 2 diesel fuel. Fuel tank capacity is approximately 7.5 gallons. CHECK CRANKCASE OIL (Fig.
BEFORE OPERATING CAUTION If engine has been running, pressurized hot coolant can escape when radiator cap is removed and cause burns. Only open radiator cap when engine is cold. IMPORTANT: Use only types of hydraulic fluids specified. Other fluids could cause system damage. Group 1 Hydraulic Fluid (Moderate climateaverage duty) Note: The fluids within this group are interchangeable.
BEFORE OPERATING IMPORTANT: Group 1 fluids are recommended for use at typical ambient temperatures of 32 F (0 C) to 105 F (41 C). The ISO Type 46/68 fluid has been found to offer optimal performance in a wide range of temperature conditions for the average user. The Universal Tractor Fluids offer similar performance for those who prefer them, with perhaps some slight loss of efficiency at high ambient temperatures compared to the Type 46/68 fluids. 1.
CONTROLS Traction Pedals (Fig. 35) Depress traction forward pedal to move forward. Depress traction reverse pedal to move backward or to assist in stopping when moving forward. Also, allow pedal to move or move it to neutral position to stop machine. Mow/Transport Slide (Fig. 35) - Using your heel, move slide to the left to transport and to the right to mow. The cutting units will only operate in the mow position. Note: Mow speed is set at the factory to 6 mph.
CONTROLS Engine Coolant Temperature Warning Light (Fig. 37) Light glows if engine coolant temperature is high. If traction unit is not stopped and coolant temperature rises another 10 F., the engine will kill. Oil Pressure Warning Light (Fig. 37) Light glows if engine oil pressure drops below a safe level. Alternator Light (Fig. 37) The amp light should be off when engine is running. If it is on, the charging system should be checked and repaired as necessary. Glow Plug Indicator (Fig.
OPERATING INSTRUCTIONS STARTING/STOPPING ENGINE IMPORTANT: The fuel system may have to be bled if any of the following situations have occurred: A. Initial start up of a new engine. B. Engine has ceased running due to lack of fuel. C. Maintenance has been performed upon fuel system components; i.e. filter replaced, etc. Refer to Bleeding Fuel System 1. Be sure parking brake is set and Reel Drive switch is in DISENGAGE position. 2. Remove foot from traction pedal and make sure pedal is in neutral position.
OPERATING INSTRUCTIONS CHECK OPERATION OF INTERLOCK SWITCHES CAUTION Do not disconnect the safety switches be cause they are for the operator's protection. Check operation of the switches daily to be sure the interlock system is operating cor rectly. If a switch is not operating properly, replace it before operating the machine. Re place the switches every two years to be sure of maximum safety. 1. Make sure all bystanders are away from the area of operation. Keep hands and feet away from cutting units.
OPERATING INSTRUCTIONS Practice going both forward and in reverse, starting and stopping the machine. To stop, take your foot off 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 up hill side to give you more stability.
OPERATING INSTRUCTIONS When cutting off larger amounts of grass, the shields shown be positioned to just below horizontal. Do not open the shields too far or excessive clippings can build up on the frame, rear radiator screen and engine area. The cutting units are also equipped with balance weights, on the non-motor end, to give an even cut. Weights can be added or removed if mismatch occurs on your turf. 2. Turn the reel speed control knob to the number setting determined in step 1. 3.
DAILY MAINTENANCE CHECKLIST Daily Maintenance: (duplicate this page for routine use) Check proper section of Operator's Manual for fluid specifications Daily Maintenance Check For Week Of _________________ Maintenance Check Item MON Safety Interlock Operation Brake Operation Engine Oil Level Cooling System Fluid Level TUES WED THURS FRI SAT SUN Drain Water/Fuel Separator Air Filter, Dust Cup & Burp Valve Radiator & Screen for Debris Unusual Engine Noises1 Unusual Op
MAINTENANCE SCHEDULE Minimum Recommended Maintenance Intervals Maintenance Procedure Inspect Air Filter, Dust Cup and Burp Valve Lubricate All Grease Fittings Change Engine Oil Check Battery Cable Connections Maintenance Interval & Service Every 50hrs Every 100hrs Every 200hrs Every 400hrs Every 800hrs Check Fan and Alternator Belt Tensions Check Battery Fluid Level Change Engine Oil and Filter Inspect Traction Belt Replace Air Filter Replace Hydraulic Filter Torque Wheel Lug Nuts Replace Hydr
LUBRICATION GREASING BEARINGS AND BUSHINGS (Fig. 44-55) The traction unit has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. If machine is operated under normal conditions, lubricate bearings and bushings after every 50 hours of operation. Bearings and bushings must be lubricated daily when operating conditions are extremely dusty and dirty.
LUBRICATION Figure 49 Figure 53 Figure 50 Figure 54 Figure 51 Figure 55 (See note) Figure 52 28
GENERAL MAINTENANCE CAUTION 1 Before servicing or making adjustments to the machine, stop engine and remove key from the switch. HOOD REMOVAL (Fig. 56) Hood may be easily removed to ease maintenance procedures in engine area of machine. 1. Unlatch and raise hood. 2. Remove cotter pin securing hood pivot to mounting brackets. Figure 56 1. Cotter pin 3. Slide hood to right side, lift other side and pull out of brackets. 4. Reverse procedure to reinstall hood.
AIR CLEANER MAINTENANCE GENERAL AIR CLEANER MAINTENANCE 1. Check air cleaner body for damage which could possibly cause an air leak. Replace a damaged air cleaner body. 2. Service the air cleaner filter every 200 hours (more frequently in extreme dusty or dirty conditions). Do not over service air filter. 3. Be sure cover is sealing around air cleaner body. SERVICING AIR CLEANER (Fig. 57 & 58) 1. Release latches securing air cleaner cover to air cleaner body. Separate cover from body.
ENGINE MAINTENANCE ENGINE OIL AND FILTER (Fig. 59 & 60) Water Separator (Fig. 61) Change oil and filter initially after the first 50 hours of operation, thereafter change oil every 50 hours and filter every 100 hours. Drain water or other contaminants from water separator (Fig. 61) daily. 1. Remove either drain plug and let oil flow into drain pan. When oil stops, install drain plug. 2. Loosen drain plug on bottom of filter canister. Tighten plug after draining. 1.
ENGINE MAINTENANCE 4.. Slide hose clamps onto ends of fuel lines. Push fuel lines onto fuel filter and secure them with hose clamps. Be sure arrow on side of filter points toward the injection pump. B. Remove access panel. DANGER Because diesel fuel is flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot, or when machine is in an enclosed area.
ENGINE MAINTENANCE ADJUSTING THROTTLE (Fig. 68) 1. Position throttle lever rearward so it stops against control panel slot. 2. Loosen the throttle cable connector on the lever arm at the injection pump. 1 Figure 66 1. Alternator/fan Belt Hydrostat Drive Belt Replacement (Fig. 67) 1. Insert a nut driver or small piece of tubing onto end of belt tensioning spring. 1 WARNING Use caution when de-tensioning spring as it is under heavy load. 2.
HYDRAULIC MAINTENANCE CAUTION 1 Before servicing or making adjustments to the machine, stop engine and remove key from the switch. CHANGING HYDRAULIC FLUID (Fig. 69 - 71) Change hydraulic fluid after every 400 operating hours, in normal conditions. If fluid becomes contaminated, contact your local TORO distributor because the system must be flushed. Contaminated fluid looks milky or black when compared to clean oil. 1. Turn engine off and raise hood. 2.
HYDRAULIC MAINTENANCE WARNING Keep body and hands away from pin hole leaks or nozzles that eject high pressure hy draulic fluid. Use cardboard or paper to find hydraulic leaks. Hydraulic fluid escaping un der pressure can penetrate skin and cause in jury. Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result. ADJUSTING TRACTION NEUTRAL (Fig. 72) DRIVE FOR 1 2 Figure 72 1.
BRAKE MAINTENANCE ADJUSTING PARKING BRAKE (Fig. 73) 3 Check adjustment every 200 hours. 1. Loosen set screw securing knob to parking brake lever. 2. Rotate knob until a force of 30-40 lbs. is required to actuate lever. 1 2 3. Tighten set screw after adjustment has been attained. Figure 73 1. Parking brake lever 2. Knob 3.
ELECTRICAL MAINTENANCE BATTERY CARE 1. Battery electrolyte level must be properly maintained and the top of the battery kept clean. lf 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. 2. Check the electrolyte level every 25 operating hours or, if machine is in storage, every 30 days. 3. Maintain cell level with distilled or demineralized water.
BACKLAPPING DANGER TO AVOID PERSONAL INJURY OR DEATH: Never place hands or feet in reel area while engine is running. While backlapping, reels may stall and then restart. Do not attempt to restart reels by hand or foot. Do not adjust reels while engine is running. If reel stalls, stop engine before attempting to clear reel. 1. Position machine on a clean, level surface, lower 2 1 Figure 74 1. Backlap knob 2. Reel speed knob 4.
PK W R R R OR OR 1 B+ G Start OR (PULL) (HOLD) BK W D2 I Y S Y A B X Y (+) BK PK BU F4 5 A IGNITION SW. OR F3 5 A BATTERY (–) STOP –––– NONE RUN –––– B+I+A; X+Y START ––– B+I+S 2 GY HR HOUR METER (–) ENGINE GROUND SP FUEL PUMP FRAME GROUND ENGINE FL ENGINE OIL PRESSURE BU NOT SUPPLIED OPTIONAL LIGHT F2 F1 15 A FL FL FL WARNING 105C OVER TEMP SHUTDOWN 110C OVER TEMP L R W PK GY OVER TEMP.
HYDRAULIC SCHEMATIC FORWARD LOWER PORT DUMP VALVE M4 M5 TRACTION WHEEL MOTORS 3000 psi 100–150 psi P3 M6 HYDROSTAT TOP PORT UPPER PORT INTERNAL CASE DRAIN OIL COOLER T2 G1 T1 D1 P1 FC1 REEL SPEED CONTROLLER ENGINE RPM OIL FILTER M1 P1 P2 MD1 BACKLAPPING VALVE S1 M2 REEL ON–OFF VALVE R1 ST LC2 REEL RELIEF 3000 psi LC1 LOGIC VALVE CHG GEAR PUMP STRAINER PLG LV 1000 psi G2 CF CR MANIFOLD BLOCK IN OUT AUX IN V1 OUT A B POWER STEERING VALVE L R C D STEERI
PREPARATION FOR SEASONAL STORAGE Traction Unit D. Slowly recharge the battery every 60 days for 24 hours to prevent lead sulfation of the battery. 1. Thoroughly clean the traction unit, cutting units and the engine. Engine 2. Check the tire pressure. Inflate all tires to 14-18 psi. 1. Drain the engine oil from the oil pan and replace the drain plug. 3. Check all fasteners for looseness; tighten as necessary. 2. Remove and discard the oil filter. Install a new oil filter. 4.
IDENTIFICATION AND ORDERING MODEL AND SERIAL NUMBER The mower has two identification numbers: a model number and a serial number. The two numbers are stamped into a plate that is riveted to the frame of mower. In any correspondence concerning the mower, supply the model and serial numbers to assure that correct information and replacement parts are obtained. 42 Note: Do not order by reference number if a parts catalog is being used; use the part number.
NOTES 43
The Toro General Commercial Products Warranty A Two-Year Limited Warranty Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your 1996 or newer Toro Commercial Product (“Product”) purchased after January 1, 1997, to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first.
