FORM NO. 3322-575 Rev A MODEL NO. 03200 - 90001 & UP MODEL NO. 03201 - 90151 & UP MODEL NO. 03220 MODEL NO. 03221 OPERATOR S MANUAL ® REELMASTER® 3100-D To understand this product, and for safety and optimum performance, read this manual before starting the engine. Pay special attention to SAFETY INSTRUCTIONS highlighted by this symbol. It means CAUTION, WARNING or DANGER— personal safety instruction. Failure to comply with the instruction may result in personal injury.
This operator's manual has instructions on safety, operation, and maintenance. This manual emphasizes safety, mechanical and general product information. DANGER, WARNING and CAUTION identify safety messages. Whenever the triangular safety alert symbol appears, understand the safety message that follows. “IMPORTANT” highlights special mechanical information and “NOTE” emphasizes general product information worthy of special attention.
Safety Instructions To reduce the potential for any injury, comply with the following safety instructions. before operating the machine. 8. Always wear substantial shoes. Do not operate the machine while wearing sandals, tennis shoes or sneakers. Do not wear loose fitting clothing because it could get caught in moving parts and possibly cause personal injury. 9. Wearing safety glasses, safety shoes, long pants and a helmet is advisable and required by some local authorities and insurance regulations.
Safety drive on hillsides. Failure to use caution on slopes or hills may cause vehicle to tip or roll, possibly resulting in personal injury or death. Always wear your seat belt. 16. This triplex mower has a unique drive system for superior traction on hills. The uphill wheel will not spin out and limit traction like conventional triplexes. If operated on a side hill that is too steep, rollover will occur before losing traction. 17.
Safety 28. Check performance of all interlock switches daily. Do not defeat the interlock system. It is for your protection. parts and accessories made by other manufacturers could be dangerous, and such use could void the product warranty of The Toro Company. 29. To ensure the entire machine is in good operating condition, frequently check and keep all nuts, bolts, screws and hydraulic fittings tight. 30.
Symbol Glossary Caustic liquids, Poisonous Electrical shock, chemical burns to fumes or toxic electrocution fingers or hand gases, asphyxiation Crushing of whole body, applied from above Explosion Shut off engine & remove key before performing maintenance or repair work 6 High pressure High pressure Crushing of Crushing of spray, erosion of spray, erosion of fingers or hand, toes or foot, force flesh flesh force applied from applied from above above Crushing of Crushing of fingers Crushing of leg, Cr
Eye protection must be worn Head protection Hearing Caution, toxic must be worn protection must risk be worn First aid Fire, open light & smoking prohibited Hydraulic system Brake system Coolant (water) Intake air Exhaust gas Pressure Level indicator Liquid level Filter Temperature Failure/ Malfunction On/start Off/stop Engage Disengage Attachment lower Attachment raise Spacing distance Snow thrower, collector auger Plus/increase/ Minus/decrease/ positive polarity negative polarity Hor
Engine coolant pressure Engine coolant f Engine ilter lubricating oil pressure Engine failure/ malfunction Engine rotational Choke speed/frequency Engine intake/ Engine intake/ combustion air combustion air pressure Engine intake/ air filter Engine start Engine stop n/min Primer (start aid) Electrical preheat Transmission oil Transmission oil Transmission oil (low temperature pressure temperature start aid) NH L F RP Transmission Clutch failure/malfunction Neutral High Low Forward Reverse Par
Specifications Engine: Kubota three-cylinder, 4-cycle. liquid-cooled diesel engine. 16kW 2500 rpm. Governed to 2650 rpm. 1124 cc displacement. Heavy-duty, 2-stage, remote mounted air cleaner. High water temperature shutdown switch. Cooling System: Radiator capacity is approximately 5.7 L of 50/50 mixture of ethylene glycol anti-freeze. Remote mounted 1 L expansion tank. Electrical: 12-volt Group 55, 450-cold cranking amps at –18°C, 75-minute reserve capacity at 27°C.
Before Operating CAUTION Before servicing or making adjustments to the machine, stop the engine and remove the key from the switch. 3. If the oil level is low, remove the oil fill cap and gradually add small quantities of oil, checking the level frequently, until the level reaches the FULL mark on the dipstick. 4. The engine uses any high-quality 10W30 detergent oil having the American Petroleum Institute— API—“service classification” CD, CE, CF CF-4 or CG-4. 5.
Before Operating DANGER 2. Because diesel fuel is flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill the fuel tank while the engine is running, hot, or when the machine is in an enclosed area. Always fill the fuel tank outside and wipe up any spilled diesel fuel before starting the engine. Store the fuel in a clean, safety-approved container and keep the cap in place. Use Diesel fuel for the engine only; not for any other purpose.
Before Operating CHECK WHEEL NUT TORQUE 1 Torque wheel nuts to 61–88 Nm after 1–4 hours of operation and again after 10 hours of operation and every 200 hours thereafter. Failure to maintain proper torque could result in failure or loss of a wheel and may result in personal injury. WARNING Figure 6 1. Hydraulic Tank Cap 3. Remove the dipstick from the filler neck and wipe it with a clean cloth. Insert the dipstick into the filler neck; then remove it and check the level of fluid.
Controls Traction Pedals (Fig. 7)—Depress the traction-forward pedal to move forward. Depress the traction-reverse pedal to move backward or to help stop the machine when moving forward. Also, allow the pedal to move to the neutral position to stop the machine. Mow/Transport Slide (Fig. 7)—Using your heel, move the slide to the left to transport the machine 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 4 7 3 6 8 5 10 2 1 9 11 Figure 9 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Throttle Hour meter Temperature light Oil pressure light Glow plug indicator light Alternator light Cutting unit drive switch Cutting unit shift lover Ignition switch Parking brake Lift lever lock Hour Meter (Fig. 9)—Indicates the total hours of machine operation. The hour meter functions whenever the key switch is ON. Engine Coolant Temperature Warning Light (Fig.
Controls 2 1 Figure 11 1. Fore and aft lever 2.
Operating Instructions STARTING/STOPPING THE ENGINE CAUTION Shut the engine off and wait for all moving parts to stop before checking for oil leaks, loose parts and other malfunctions. 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. 6. The engine has run out of fuel. C. Maintenance has been performed on fuel system components; i.e., filter replaced, etc. Refer to Bleeding The Fuel System 1. 2.
Operating Instructions 4. 1 With the operator on the seat, the engine running, the reel transport slide in mow and the reel switch in the ON position, lower the cutting units. The reels should come on. Pull back on the lift lever, the reels should stop when fully raised. Correct the problem if this does not happen. Note: The machine is equipped with an interlock switch on the parking brake. The engine will stop if the traction pedal is depressed with the parking brake engaged. Figure 12 1.
Operating Instructions OPERATING CHARACTERISTICS 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 rise off the ground. If this should happen, the operator or any bystanders can be seriously injured or killed in a rollover.
Operating Instructions overhang, allowing you to trim closer to the edge of traps and other obstacles while keeping the tractor tires as far away from the edge of traps or water hazards as possible. If an obstacle is in the way, shift the cutting units to easily mow around it. CAUTION: This product may exceed noise levels of 85 dB(A) at the operator position. Ear protectors are recommended for prolonged exposure to reduce the potential of permanent hearing damage.
Operating Instructions 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. Note: The higher the number, the higher the speed. 2-1/4 2—1/8 2 1-7/8 1-3/4 1-5/8 1-1/2 1-3/8 1-1/4 1-1/8 1 7/8 3/4 5/8 1/2 3/8 2.25 3* 2.13 3* 2.00 3* 1.88 3* 1.75 3* 1.63 3* 1.50 3 1.38 3 1.25 4 1.13 4 1.00 5 0.88 5 0.75 7 0.63 11 0.50 11 0.
Maintenance Maintenance Schedule Maintenance Procedure Inspect the air filter, Dust Cup and Every 50 Burp Valve hours Lubricate all grease fittings Change the engine oil Check battery fluid level Check battery cable connections ✝Check alternator fan belt tension Maintenance Interval & Service Every 100 hours Every 200 hours Every 400 hours Every 800 hours ✝Change the engine oil and filter Inspect the Traction Belt Replace the air filter ✝Replace the hydraulic filter ✝Torque the wheel lug nuts Replace t
Maintenance LUBRICATION GREASING BEARINGS AND BUSHINGS (Fig. 15-26) The traction unit has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. If you operate the machine 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.
Maintenance Figure 20 Figure 24 Figure 21 Figure 25 Figure 22 Figure 26 Figure 23 23
Maintenance CAUTION Before servicing or making adjustments to the machine, stop the engine and remove the key from the switch. SERVICING THE AIR CLEANER (Fig. 28 & 29) 1. Release the latches securing the air cleaner cover to the air cleaner body. Separate the cover from the body. Clean the inside of the air cleaner cover. HOOD REMOVAL (Fig. 27) The hood may be easily removed to ease maintenance procedures in the engine area of the machine. 1. 2 Unlatch and raise the hood. 1 2.
Maintenance with clear water. Maximum water pressure must not exceed 276 kPa to prevent damage to the filter element. Rinse the filter from the clean side to the dirty side. 3. Add oil to the crankcase, refer to Check The Engine Oil. C. Dry the filter element using warm, flowing air (71° C) max), or allow the element to air dry. Do not use a light bulb to dry the filter element because damage could result. Compressed Air Method A.
Maintenance separator (Fig. 32) daily, 1. Place a clean container under the fuel filter. 2. Loosen the drain plug on the bottom of the filter canister. Tighten the plug after draining. Figure 33 1. Fuel Pre Filter 2. Hose Clamps 1 4. 2 Figure 32 DANGER 1. Water Separator 2. Drain Plug Replace the filter canister after every 400 hours of operation. 1. Clean the area where the filter canister mounts. 2. Remove the filter canister and clean the mounting surface. 3.
Maintenance C. Unlatch the oil cooler and pivot it rearward. Clean both sides of the oil cooler and radiator area thoroughly with water or compressed air. Pivot the oil cooler back into position. 1 Figure 34 1. Fuel Injectors (3) 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 solid flow is observed. Figure 36 D. Install access panel and close the hood. 4.
Maintenance ADJUSTING THE THROTTLE (Fig. 39) 1 1. Position the throttle lever rearward so that it stops against the control panel slot. 2. Loosen the throttle cable connector on the lever arm at the injection pump. Figure 37 1. Alternator/tan Belt Hydrostat Drive Belt Replacement (Fig. 38) 1. Insert a nut driver or small piece of tubing onto the end of the belt-tensioning spring. 1 WARNING Figure 39 1. Injection Pump Lever Arm Use caution when releasing spring tension—it is under a heavy load.
Maintenance CHANGING HYDRAULIC FLUID (Fig. 40–42) 1 Change hydraulic fluid after every 400 operating hours in normal conditions. If the 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 the engine off and raise the hood. 2. Disconnect hydraulic line or remove hydraulic filter and let hydraulic fluid flow into a drain pan. Reinstall the line after hydraulic fluid stops draining.
Maintenance 4. Lubricate a new filter gasket and fill the filter with hydraulic fluid. 5. Ensure the filter mounting area is clean. Screw the filter on until the gasket contacts the mounting plate. Then tighten the filter one-half turn. 6. Start the engine and let run it for about two minutes to purge air from the system. Stop the engine and check for leaks. 1 Figure 43 1.
Maintenance BATTERY CARE WARNING The engine must be running so final adjustment of the traction adjustment cam can be performed. To guard against possible personal injury, keep hands, feet, face and other parts of the body away from the muffler, other hot parts of the engine, and other rotating parts. 4. Start the engine and turn the cam hex in both directions to determine the mid position of the neutral span. 5. Tighten the locknut securing adjustment. 6. Stop the engine. 7.
Maintenance 7. cables (positive cable first) and coat the terminals with petroleum jelly. 3. Always disconnect battery ground cable (–) first, to prevent possible wiring damage from short outs whenever working with the electrical system. Note: The seat switch is bypassed when the backlap knob 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. Turn the backlap knob to the backlap position.
Maintenance 8. When backlap operation is completed, stop the engine, turn the backlap knob to the MOW position, set the reel speed controls to the desired mowing setting and wash all lapping compound off the cutting units. NOTE: Additional instructions and procedures on Backlapping are available in the TORO Sharpening Reel & Rotary Mowers Manual Form No. 80-300SL. Grafo 112X skin-over grease (Toro Part No. 505-47) or petroleum jelly to prevent corrosion. D.
Maintenance correct information and replacement parts are obtained. Note: Do not order by reference number if a parts catalog is being used; use the part number. To order replacement parts from an Authorized TORO Service Dealer, supply the following information: 1. Model and serial numbers of the mower. 2. Part number, description and quantity of part(s) desired.
