Form No. 3364-812 Rev B Reelmaster® 3100-D Traction Unit Model No. 03206—Serial No. 290000401 and Up Model No. 03207—Serial No. 290000468 and Up Model No. 03220 Model No. 03221 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............................................... 44 Servicing the Air Cleaner .................................... 44 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 03207 – 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 Measured vibration level for right hand = .41 m/s2 Uncertainty Value (K) = 0.5 m/s2 Sound Pressure Level Measured values were determined according to the procedures outlined in EN 836.
104-5181 CE only 1. Warning—read the Operator’s Manual. 2. Tipping hazard—do not drive on slopes greater than 15 degrees and, if the roll bar is installed, wear the seat belt. 3. Thrown object hazard—keep bystanders a safe distance from the machine. 4. Cutting hazard of hand or foot—stay away from moving parts. 5. Warning—lock the parking brake, stop the engine, and remove the ignition key before leaving the machine. 99-3558 CE only 1. Warning—read the Operator’s Manual. 2.
4-5192 Model 03207 only 1. Engage the power take off (PTO). 2. Disengage the power take off (PTO). 3. Lower the cutting units. 4. Move the cutting units to the right. 5. Raise the cutting units. 9. Engine—run 6. Move the cutting units to 10. Engine—start the left. 7. Move rear ward to lock the 11. Fast lift lever. 8. Engine—stop 12. Continuous variable setting 10 13.
104-5193 Model 03206 only 1. Engage the power take off (PTO). 2. Disengage the power take off (PTO). 3. Lower the cutting units. 4. Move the cutting units to the right. 5. Raise the cutting units. 9. Engine—run 13. Slow 6. Move the cutting units to 10. Engine—start the left. 7. Move rear ward to lock the 11. Fast lift lever. 8. Engine—stop 12.
117-5104 Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 2. No fire, open flame, or smoking. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 5. Read the Operator’s Manual. 6. Keep bystandersa safe distance from the battery. 7. Wear eye protection; explosive gases can cause blindness and other injuries 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 10. Contains lead; do not discard.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 4 5 6 7 8 9 10 11 12 Description Use Qty.
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 video 1 View before operating the machine. Pre-delivery check list 1 Check to ensure that the machine has been properly set up. Certificate of compliance 1 Ensure CE compliance.
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. No Parts Required 5. Install the filler caps and connect a 3 to 4 amp battery charger to the battery posts.
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.
9 Installing the Carrier Frames to the Cutting Units No Parts Required Procedure 1. Remove the cutting units from the cartons. Adjust them as described in the Cutting Unit Operator’s Manual. 2. Position a front carrier frame (Figure 17) onto each front cutting unit. Align the mounting holes with the mounting links as shown in Figure 19. Figure 18 1. Rear carrier frame 4. Secure each mounting link to the carrier frame with a bolt (3/8 x 2-1/4 inch), 2 flat washers, and a locknut, as shown in Figure 19.
10 Mounting the Cutting Units No Parts Required Procedure 1. Slide a thrust washer onto each front lift arm pivot rod. 2. Slide the cutting unit carrier frame onto the pivot rod and secure it with a lynch pin (Figure 20). Note: On rear cutting unit, position the thrust washer between the rear of the carrier frame and the lynch pin. Figure 21 4. Route a tipper chain up through the slot on the end of each carrier frame.
12 Adjusting the Lift Arms No Parts Required Procedure 1. Start the engine, raise the lift arms, and check to ensure that the clearance between each lift arm and the floor plate bracket is 0.18 to 0.32 inches (5 to 8 mm) (Figure 25). Figure 23 1. Weights 2. Gasket 3. Remove the plug from the bearing housing on the outside end of the right hand cutting unit and install the weights and gasket. 4. Locate the spider coupling (Figure 24) shipped in the bearing housing.
Figure 29 1. Rear cylinder Figure 27 1. Front cylinder 2. Jam nut 2. Adjusting nut B. Grasp the cylinder rod close to the nut with a pliers and rag and rotate the rod. C. Remove the pin from the rod end and rotate the clevis. C. Raise the cutting units and check the clearance. D. Install the pin and check the clearance. D. Repeat steps A through C if necessary. E. Repeat steps A through D if necessary. E. Tighten the clevis jam nut.
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 2. Reverse traction pedal 3.
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 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.
Specifications Note: Specifications and design are subject to change without notice. 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.
Note: Toro Premium Engine oil is available from a distributor in either 15W-40 or 10W-30 viscosity. See the parts catalog for part numbers. gauge. Engine failure may occur as a result of over filling or under filling the engine oil. Filling the Fuel Tank Note: The best time to check the engine oil is when the engine is cool before it has been started for the day. If it has already been run, allow the oil to drain back down to the sump for at least 10 minutes before checking.
• Painted surfaces may be damaged by biodiesel blends. • Use B5 (biodiesel content of 5%) or lesser blends in cold weather. • Monitor seals, hoses, gaskets in contact with fuel as they may be degraded over time. • Fuel filter plugging may be expected for a time after converting to biodiesel blends. • Contact a distributor for more information on biodiesel blended fuel. 1. Clean the area around the fuel tank cap (Figure 37). Figure 38 1. Access panel 2. Radiator 3.
Note: With a cold engine, the coolant level should be approximately midway between the marks on the side of the tank. 2. If the coolant level is low, remove the expansion tank cap and replenish the system. Do not overfill. 3. Install the expansion tank cap. Checking the Hydraulic System This is vegetable-oil based biodegradable oil tested and approved by Toro for this model.
light goes out (approximately 7 seconds); then rotate the key to the Start position to engage the starter motor. Release the key when the engine starts. DANGER Low tire pressure decreases machine side hill stability. This could cause a rollover, which may result in personal injury or death. Note: The key will move automatically to the On/Run position. Do not under-inflate the tires. Important: To prevent overheating of the starter motor, do not engage the starter longer than 15 seconds.
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 03207 • 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 03206 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.
Important: If the reel speed is too slow, you may notice visible clip marks. If the reel speed is too fast, the cut may have a fuzzy appearance. Adjust the clip rate (reel speed) as follows: 1. Verify the height-of-cut setting on the cutting units. Use the column of the chart listing either 5 or 8 reels, and find the height-of-cut listing nearest the actual height-of-cut setting. Look across the chart to find the number that corresponds to that height of cut.
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.
Service Interval Chart Figure 45 Premaintenance Procedures Lubrication Greasing the Bearings And Bushings Removing the Hood Service Interval: Every 50 hours (Lubricate all bearings and bushings daily when conditions are dusty and dirty.) The hood may be easily removed to ease maintenance procedures in the engine area of the machine. 1. Unlatch and raise the hood. Every 500 hours/Yearly (whichever comes first) 2. Remove the cotter pin that secures the hood pivot to the mounting brackets (Figure 46).
Figure 47 Figure 50 • Front cutting unit pivot (Figure 48) • Rear lift arm pivot and lift cylinder (2) (Figure 51) Figure 48 • SideWinder cylinder ends (2; model 03206 only) (Figure 49) Figure 51 • Left front lift arm pivot and lift cylinder (2) (Figure 52) Figure 49 Figure 52 • Steering pivot (Figure 50) • Right front lift arm pivot and lift cylinder (2) (Figure 53) 42
Figure 53 Figure 56 • Neutral adjust mechanism (Figure 54) • Steering cylinder (Figure 57). Figure 54 • Mow/transport slide (Figure 55) Figure 57 Note: If desired, install an additional grease fitting in the other end of the steering cylinder. Remove the tire, install the fitting, grease the fitting, remove the fitting, and install the plug (Figure 58).
Engine Maintenance Sealed Bearings Bearings rarely fail from defects in materials or workmanship. The most common reason for failure is moisture and contamination working its way past the protective seals. Bearings that are greased will rely upon regular maintenance to purge harmful debris from the bearing area. Sealed bearings rely on an initial fill of special grease and a robust integral seal to keep contaminants and moisture out of the rolling elements.
Figure 61 1. Engine oil drain plug Figure 60 1. Primary filter 2. Remove the oil filter (Figure 62). 5. Inspect the new filter for shipping damage and check the sealing end of the filter and the body. Do not use a damaged element. 6. Insert the new filter by applying pressure to the outer rim of the element to seat it in the canister. Do not apply pressure to the flexible center of the filter. 7. Clean the dirt ejection port located in the removable cover. 8.
Fuel System Maintenance 2 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. 1 3 G009880 • 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 63 1. Water separator/filter canister 2. Vent plug • Do not fill the fuel tank completely full.
Electrical System Maintenance 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. Caring for the Battery 4. Tighten the pipe connector securely. 5. Repeat this procedure on the remaining nozzles. Service Interval: Every 25 hours—Check the electrolyte level. (If machine is in storage, check every 30 days.
Drive System Maintenance 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. Adjusting the Traction Drive for Neutral The battery cables must be tight on the terminals to provide good electrical contact. If the machine moves when the traction pedal is in the neutral position, adjust the traction cam.
Cooling System Maintenance 6. Pivot the oil cooler back into position. 7. Install the access panel and close the hood. Cleaning the Engine Cooling System Service Interval: Before each use or daily Remove debris from the oil cooler and radiator daily. Clean them more frequently in dirty conditions. 1. Turn the engine off and raise the hood. 2. Clean the engine area thoroughly of all debris. 3. Remove the access panel (Figure 66). Figure 66 1. Access panel 2. Oil cooler 3. Radiator 4.
Brake Maintenance Belt Maintenance Adjusting the Parking Brake Servicing the Engine Belts Service Interval: Every 200 hours—Check the parking brake adjustment. Service Interval: After the first 10 hours—Check the condition and tension of all belts. 1. Loosen the set screw that secures the knob to the parking brake lever (Figure 68). Every 100 hours—Check the condition and tension of all belts. Tensioning the Alternator/Fan Belt 1. Open the hood. 2.
Controls System Maintenance 2. Push down and forward on the spring end (Figure 70) to unhook it from the bracket and release tension on the spring. Adjusting the Throttle 1. Position the throttle lever rearward so that it stops against the control panel slot. 2. Loosen the throttle cable connector on the injection pump lever arm (Figure 71). Figure 70 1. Hydrostat drive belt 2. Spring end 3. Replace the belt. 4. Reverse the procedure to tension the spring. Figure 71 1. Injection pump lever arm 3.
Hydraulic System Maintenance Important: Use only the hydraulic fluids specified. Other fluids could damage the hydraulic system. Changing the Hydraulic Fluid 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. 1. Turn the engine off and raise the hood. 2.
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 (Rev.
Notes: 58
Notes: 59
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).
