Form No. 3359–704 Rev A Reelmaster) 3100–D Traction Unit Model No. 03207—280000001 and Up Model No. 03206—280000001 and Up Model No. 03220 Model No.
Check Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . Check Reel To Bedknife Contact . . . . . . . . . . . . . Check Torque Of Wheel Nuts . . . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting/Stopping Engine . . . . . . . . . . . . . . . . . . . Bleeding Fuel System . . . . . . . . . . . . . . . . . . . . . . Check Operation Of Interlock Switches . . . . .
Introduction Safety Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely. This machine meets or exceeds CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.
• The owner/user can prevent and is responsible for accidents or injuries occurring to himself or herself, other people, or property. – do not stop or start suddenly when going up or downhill; – machine speeds should be kept low on slopes and during tight turns; Preparation – stay alert for humps and hollows and other hidden hazards; • While mowing, always wear substantial footwear, long trousers, hard hat, safety glasses, and hearing protection.
• Disconnect battery and remove spark plug wire before making any repairs. Disconnect the negative terminal first and the positive last. Reconnect positive first and negative last. • Keep hands and feet away from the cutting units. • Look behind and down before backing up to be sure of a clear path. • Slow down and use caution when making turns and crossing roads and sidewalks. Stop cylinders/reels if not mowing. • Use care when checking the cylinders/reels.
Maintenance and Storage • Use extreme caution when operating close to sand traps, ditches, creeks, steep hillsides or other hazards. Reduce speed when making sharp turns. Do not turn on hills. Avoid sudden stops and starts. Use reverse pedal for braking. Cutting units must be lowered when going down slopes for steering control. • Make sure all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition before applying pressure to the system.
Safety and Instruction Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. 104–5192 (Model 03207) 1. 2. 3. 4. Engage the reels. Disengage the reels. Lower the reels. Move the cutting units to the right. 5. Raise the reels. 6. Move the cutting units to the left. 7. Move rear ward to lock the lift lever. 8. Engine—stop 9. Engine—run 10. Engine=start 7 11. Fast 12.
104-5193 (Model 03206) 1. Engage the reels. 2. Disengage the reels. 3. Lower the reels. 4. Raise the reels. 5. Move rear ward to lock the lift lever. 6. Engine—stop 7. Engine—run 8. Engine=start 9. Fast 10. Continuous variable setting 11. Slow 94-3353 (Model 03206) 1. Crushing hazard of hand—keep your hands a safe distance away. 99-3558 for CE 93-6681 1. Warning—read the Operator’s Manual. 2.
104-5199 99-3496 9
0-4837 104-5181 for CE compliance 1. Warning—read the Operator’s Manual. 2. Tipping hazard—do not drive on slopes greater than 15 degrees and always wear the seat belt with ROPS. 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.
Specifications Note: Specifications and design subject to change without notice. General Specifications Engine Cooling System Electrical 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. Radiator capacity is approximately 6 qts. of 50/50 mixture of ethylene glycol anti–freeze. Remote mounted 1 qt. expansion tank.
Setup Note: Determine the left and right sides of the machine from the normal operating position. Loose Parts Chart Note: Use this chart as a checklist to ensure all parts necessary for assembly have been shipped. If any of these parts are missing, total setup cannot be completed. Description Qty. Use Wheel assembly 3 Steering wheel 1 Flat washer 21/32 1 Jam nut 1 Cover 1 Screw 1 Hood lock bracket 1 Screw 1/4–20 x 1–1/2” lg.
Install Wheels 2. Remove battery cover. 3. If Battery is not filled with electrolyte or activated, bulk electrolyte with 1.260 specific gravity must be purchased from a local battery supply outlet and added to battery. 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. 2. Install lug nuts and torque to 45–65 ft–Ib.
must not contact battery cover. Slide the rubber boot over the positive terminal to prevent possible short–out from occurring. Warning • Connecting cables to the wrong post could damage the electrical system and result in personal injury. 1 Figure 4 1. Angle indicator 3. If inclinometer does not read zero degrees, move the machine to a location where a zero degree reading is obtained. The angle indicator, mounted on machine, should now read zero degrees as well. 2 4.
Install Exhaust Guard 3. Secure fuel line vent hose to vent tube on ROPS with hose clamp. (European Compliance) Caution 1. Position exhaust guard around muffler while aligning mounting holes with holes in frame. Fuel line vent hose must be connected to vent tube prior to starting engine or fuel will flow from hose. 2. Secure exhaust guard to frame with (4) self tapping screws. Install Front Lift Arms 1. Remove (2) capscrews securing lift arm pivot shaft link to lift arm pivot shafts.
Mount Carrier Frames To Cutting Units 5. Remove rear retaining rings securing mounting pins to each end of lift cylinder. 3 1. Remove cutting units from cartons. Adjust per Cutting Unit Operator’s Manual. 2. Position a front carrier frame (Fig. 12) onto each front cutting unit. Align mounting holes with mounting links as shown in figure 14. 1 4 1 6 4 2 5 Figure 10 1. Lift arm (R.H.) 2. Lift arm (L.H.) 3. Retaining ring 4. Mounting pin 5. Lift cylinder 6. Spacer (2) 6.
4. Secure each mounting link to carrier frame with a 3/8–16 x 2–1/4” lg capscrew, (2) flatwashers and a locknut, as shown in figure 14. Position a washer on each side of link when mounting. Torque to 31 ft–lb. 1 2 3 FRONT Figure 14 1. Carrier frame 2. Mounting link 3. Plug Figure 16 Mount Cutting Units 1. Slide a thrust washer onto each front lift arm pivot rod. 4. Route a tipper chain up thru slot in end of each carrier frame.
Mount Cutting Unit Drive Motors Adjust Lift Arms 1. Start engine, raise lift arms and check to make sure clearance between each lift arm and floor plate bracket is .18” – .32” (Fig. 20). If clearance is not in this range, back off stop bolts (Fig. 22) and adjust cylinder to attain clearance. To adjust cylinder, back off the jam nut on the cylinder (Fig. 21), remove pin from rod end and rotate clevis. Install pin and check clearance. Repeat procedure if required. Tighten clevis jam nut. 1.
1 3 1 2 2 Figure 24 1. Rear cylinder Figure 22 1. Stop bolt 2. Lift arm 2. Adjusting nut 3. Clearance Important Lack of clearance at front stops or rear wear bar could damage lift arms. Note: If rear lift arm “clunks” during transport, clearance can be reduced. 2. Check to make sure clearance between each lift arm and stop bolt is .005” – .040” (Fig. 22). If clearance is not in this range, adjust stop bolts to attain clearance. 3.
Before Operating Note: Determine the left and right sides of the machine from the normal operating position. 1 Check Crankcase Oil The engine is shipped with oil in the crankcase; however, the oil level must be checked before and after the engine is first started. Figure 26 Crankcase capacity is approximately 4 qt. (2.8 l) with the filter. 1. Oil fill cap Use high-quality engine oil that meets the following specifications: Fill Fuel Tank API Classification Level Required: CH–4, CI–4 or higher.
Biodiesel Ready Check Cooling System This machine can also use a biodiesel blended fuel of up to B20 (20% biodiesel, 80% petrodiesel). The petrodiesel portion should be low or ultra low sulfur. Observe the following precautions: Clean debris off radiator and oil cooler daily (Fig. 28), hourly if conditions are extremely dusty and dirty; refer to Cleaning Radiator. 1. The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol anti–freeze.
4. Install expansion tank cap. 1. Position machine on a level surface, lower the cutting units and stop the engine. Checking the Hydraulic System 2. Clean area around filler neck and cap of hydraulic tank (Fig. 30). Remove cap from filler neck. The machines reservoir is filled at the factory with approximately 3.5 U.S. gallons (13.2 l) of high quality hydraulic fluid. Check the level of the hydraulic fluid before the engine is first started and daily thereafter.
Check Torque Of Wheel Nuts Warning Torque wheel nuts to 45-65 ft–lb 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 wheel and may result in personal injury.
Controls Note: Determine the left and right sides of the machine from the normal operating position. 1 Traction Pedals 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. Figure 32 1. Speed stop screw 4 Starter Switch 6 The starter switch, used to start, stop and preheat the engine, has three positions: OFF, ON/PREHEAT and START.
Cutting Unit Drive Switch Parking Brake The switch has two positions: ENGAGE and DlSENGAGE. Rocker switch operates a solenoid valve, on valve bank, to drive cutting units. Whenever the engine is shut off, the parking brake must be engaged to prevent accidental movement of the machine. To engage the parking brake, pull up on lever. Engine will stop if traction pedal is depressed with parking brake engaged.
Operation Bleeding Fuel System 1. Park the machine on a level surface. Make sure fuel tank is at least half full. Note: Determine the left and right sides of the machine from the normal operating position. 2. Unlatch and raise hood. Starting/Stopping Engine 3. Open the air bleed screw on the fuel injection pump (Fig. 35). Important The fuel system may have to be bled if any of the following situations have occurred: • Initial start up of a new engine. • Engine has ceased running due to lack of fuel.
Check Operation Of Interlock Switches Caution 1 If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. Figure 36 1. By–pass valve • Do not tamper with the interlock switches. • Check the operation of the interlock switches daily and replace any damaged switches before operating the machine. 2. Before starting engine, close by–pass valve by rotating it 90_. Do not start engine when valve is open. Operating Characteristics 1.
Don’t shift the units from side to side, unless the cutting units are down and the machine is moving, or the cutting units are up in the transport position. Shifting the cutting units when they are down and the machine is not moving may cause turf damage. If a person appears in or near the operating area, stop the machine, and don’t start up again until the area is cleared. The Reelmaster is a one–person machine. Never let anyone else ride on the machine with you.
2. Turn the reel speed control knob to the number setting determined in step 1. Caution • Shut engine off and wait for all moving parts to stop before opening or closing cutting unit shields 1 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 module monitors inputs including neutral, parking brake, PTO, start, backlap, and high temperature. The module energizes outputs including PTO, Starter, and ETR (energize to run) solenoid. 8 BLADE REEL REEL SPEED SELECTION CHART HEIGHT OF CUT 2–1/2 2–3/8 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 2.50 2.38 2.25 2.13 2.00 1.88 1.75 1.63 1.50 1.38 1.25 1.13 1.00 0.88 0.75 0.63 0.50 0.
4. Position input devices at appropriate position to achieve the appropriate output. Use the following logic chart to determine the appropriate input condition. 6. If specific output LED is not illuminated, check both fuses. 7. If specific output LED is not illuminated and inputs are in appropriate condition, install new SCM and determine if fault disappears. 5. If specific output LED is illuminated without appropriate output function, check output harness, connections, and component. Repair as required.
Lubrication 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. Dusty and dirty operating conditions could cause dirt to get into the bearings and bushings, resulting in accelerated wear.
Figure 46 Figure 43 Figure 44 Figure 47 Figure 45 Figure 48 33
Figure 49 (see note) Note: If desired, an additional grease fitting may be installed in other end of steering cylinder. Tire must be removed, fitting installed, greased, fitting removed and plug installed (Fig. 49). 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.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position.
Caution If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition and disconnect the wire from the spark plug before you do any maintenance. Set the wire aside so that it does not accidentally contact the spark plug. Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Maintenance Check Item Mon. Tues. Wed. Thurs. Fri.
Service Interval Chart Hood Removal 1 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. 3. Slide hood to right side, lift other side and pull out of brackets. 4. Reverse procedure to reinstall hood. Figure 50 1.
General Air Cleaner Maintenance 5. Install the cover orienting the rubber outlet valve in a downward position – between approximately 5:00 to 7:00 when viewed from the end. • Check air cleaner body for damage which could possibly cause an air leak. Replace a damaged air cleaner body. • Service the air cleaner filter every 200 hours (more frequently in extreme dusty or dirty conditions). Do not over service air filter. • Be sure cover is sealing around air cleaner body. 1 Servicing Air Cleaner 1.
Water Separator Drain water or other contaminants from water separator (Fig. 55) daily. 1. Place a clean container under fuel filter. 2. Loosen drain plug on bottom of filter canister. Tighten plug after draining. Replace filter canister after every 400 hours of operation. 1. Clean area where filter canister mounts. 1 2. Remove filter canister and clean mounting surface. Figure 54 3. Lubricate gasket on filter canister with clean oil. 1. Engine oil filter 4.
2. Move throttle to FAST position. Servicing Engine Belts 3. Turn key in key switch to START position and watch fuel flow around connector. Turn key to OFF position when solid flow is observed. Check condition and tension of all belts after first day of operation and every 100 operating hours thereafter. 4. Tighten pipe connector securely. Alternator/fan Belt 5. Repeat steps on remaining nozzles. 1. Open hood. 2.
Changing Hydraulic Fluid 2 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 1. Turn engine off and raise hood. 2. Disconnect hydraulic line or remove hydraulic filter and let hydraulic fluid flow into drain pan. Reinstall line when hydraulic fluid stops draining. Figure 60 1. Hydrostat drive belt 2.
Checking Hydraulic Lines And Hoses 1 Daily, 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. Warning Hydraulic fluid escaping under pressure can penetrate skin and cause injury.
Warning 3 1 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. 2 Figure 66 1. Parking brake lever 2. Knob 3. Set screw Battery Care 1 2 Warning Figure 65 1. Traction adjustment cam CALIFORNIA 2.
Backlapping Caution Danger Wear safety goggles and rubber gloves when working with electrolyte. Charge the battery in a well ventilated place so gasses produced while charging can dissipate. Since the gases are explosive, keep open flames and electrical spark away from the battery; do not smoke. Nausea may result if the gases are inhaled. Unplug charger from electrical outlet before connecting to or disconnecting charger leads from battery posts.
4. Make initial reel to bedknife adjustments appropriate for backlapping on all cutting units. Start engine and set engine to low idle speed. Storage 5. Engage reels by engaging PTO switch on control panel. Traction Unit 6. Apply lapping compound with long handled brush. • Thoroughly clean the traction unit, cutting units and the engine. Caution • Check the tire pressure. Inflate all tires to 14–18 psi.
Electrical Schematic 46
Hydraulic Schematic 47
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 Toro Commercial Product (“Product”) to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first.