Form No. 3354–401 Rev A Reelmaster) 3100–D Traction Unit Model No. 03207—260000001 and Up Model No. 03206—260000001 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 CAUTION, WARNING, or DANGER—“personal safety instruction.” Failure to comply with the instruction may result in personal injury or death. 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.
• Watch out for traffic when crossing or near roadways. • Thoroughly inspect the area where the equipment is to be used and remove all objects which may be thrown by the machine. • Stop the blades rotating before crossing surfaces other than grass. • Warning—Fuel is highly flammable. Take the following precautions: • When using any attachments, never direct discharge of material toward bystanders nor allow anyone near the machine while in operation.
• Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision. Toro Riding Mower Safety Maintenance and Storage The following list contains safety information specific to Toro products or other safety information that you must know that is not included in the CEN, ISO, or ANSI standard. • Keep all nuts, bolts and screws tight to be sure the equipment is in safe working condition. This product is capable of amputating hands and feet and throwing objects.
• Check all fuel lines for tightness and wear on a regular basis. Tighten or repair them as needed. • Check the safety interlock switches daily for proper operation. If a switch should fail, replace the switch before operating the machine. After every two years, replace all four interlock switches in the safety system, whether they are working properly or not.
Sound Pressure Level Vibration Level This unit has an equivalent continuous A–weighted sound pressure level at the operator ear of 83 dBA, based on measurements of identical machines per Directive 98/37/EC and amendments. This unit does not exceed a vibration level of 2.5 m/s@ at the hands based on measurements of identical machines per ISO 5349 procedures. This unit does not exceed a vibration level of .5 m/s@ at the posterior based on measurements of identical machines per ISO 2631 procedures.
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 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. 107-7801 for CE 1. Tipping hazard—do not drive on slopes greater than 15 degrees.
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 Jam nut 1 Cover 1 Screw 1 Hood lock bracket 1 Screw 1/4–20 x 1–1/2” lg.
Install Wheels 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 4. Remove filler caps from battery and slowly fill each cell until electrolyte is just above the plates. Rear tire has a narrower rim than front tires. 2. Install lug nuts and torque to 45–65 ft–Ib. Install Steering Wheel 1.
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: 4. Install oil fill cap and close hood.
2. Check level of coolant in expansion tank. With a cold engine, coolant level should be midway (approx) between the marks on side of tank. 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. 1 • 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. • Do not fill the fuel tank completely full.
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 gal (15–22 1) of hydraulic oil. Order part no.44–2500 from your authorized Toro distributor. Check Tire Pressure Biodegradable Hydraulic Fluid – Mobil 224H Important Maintain recommended pressure in all tires to assure a good quality–of–cut and proper machine performance.
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. • Replace switches every two years regardless of whether they are operating properly or not. 2.
Accidents can happen to anyone. The most common causes are excessive speed, sudden turns, terrain (with the Reelmaster 3100–D that’s knowing what slopes and hills can be mowed safely), not stopping the engine before leaving the operator’s seat, and drugs which impair your alertness. Cold capsules or prescription drugs may cause drowsiness, as can alcohol and other drugs. Stay alert and stay safe. Failure to do so could result in serious injury.
3. Operate the machine for several days, then examine the cut to ensure satisfaction with 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. When cutting off larger amounts of grass, the shields shown be positioned to just below horizontal.
Standard Control Module (SCM) Output circuits are energized by an appropriate set of input conditions. The three outputs include PTO, ETR, and START. Output LED’s monitor relay condition indicating the presence of voltage at one of three specific output terminals. The Standard Control Module is a ”potted” electronic device produced in a ”one size fits all” configuration.
Each row (across) in the logic chart below identifies input and output requirements for each specific product function. Product functions are listed in the left column. Symbols identify specific circuit condition including: energized to voltage, closed to ground, and open to ground. – Indicates a circuit closed to ground. – LED ON O Indicates a circuit open to ground or de–energized – LED OFF + Indicates an energized circuit (clutch coil, solenoid, or start input) LED ON.
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 32
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. The sealed bearings require no lubrication or short term maintenance.
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.
4. Install filter canister by hand until gasket contacts mounting surface, then rotate an additional 1/2 turn. 1 1 Figure 54 1. Engine oil filter 2 3. Add oil to crankcase, refer to Check Engine Oil. Figure 55 1. Water separator Fuel System 2. Drain plug Fuel Tank Replacing Fuel Pre Filter Drain and clean fuel tank every 2 years. Also, drain and clean tank if fuel system becomes contaminated or if machine is to be stored for an extended period. Use clean fuel to flush out the tank.
Cleaning Engine Cooling 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. Remove debris from oil cooler and radiator daily, clean more frequently in dirty conditions. • Turn engine off and raise hood. Clean engine area thoroughly of all debris. • Use a funnel and fill the fuel tank outdoors, in an open area, when the engine is off and is cold.
Servicing Engine Belts 2 Check condition and tension of all belts after first day of operation and every 100 operating hours thereafter. Alternator/fan Belt 1. Open hood. 1 2. Check tension by depressing belt midway between alternator and crankshaft pulleys with 22 lb. of force. Belt should deflect 7/16 in. If deflection is incorrect, proceed to step 3. If correct, continue operation. 3. Loosen bolt securing brace to engine and bolt securing alternator to brace. Figure 61 1. Hydrostat drive belt 4.
Changing Hydraulic Fluid 1 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. Disconnect hydraulic line or remove hydraulic filter and let hydraulic fluid flow into drain pan. Reinstall line when hydraulic fluid stops draining. Figure 65 1.
Warning Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • Make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system. • Keep your body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid. • Use cardboard or paper to find hydraulic leaks.
Battery Care 6. If corrosion occurs at terminals, disconnect cables, negative (—) cable first and scrape clamps and terminals separately. Reconnect cables, positive (+) cable first and coat terminals with petroleum jelly. Warning 7. Always disconnect battery cables, ground cable (—) first, to prevent possible wiring damage from short outs whenever working with the electrical system.
Caution Caution Do not rotate backlap knob from mow to backlap position while engine is running as damage to reels may occur. Be careful when lapping the reel because contact with the reel or other moving parts can result in personal injury. 7. To make an adjustment to the cutting units while backlapping, disengage reels and turn engine OFF. After adjustments have been completed, repeat steps 4–6. 2 8.
Electrical Schematic 45
Hydraulic Schematic FORWARD LOWER PORT M5 M4 DUMP VALVE M6 TRACTION WHEEL MOTORS 3000 psi 100–150 psi P3 TOP PORT UPPER PORT HYDROSTAT 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 L R POWER STEERING VALVE C D STEERING
Storage Engine • Drain the engine oil from the oil pan and replace the drain plug. Traction Unit • Remove and discard the oil filter. Install a new oil filter. • Thoroughly clean the traction unit, cutting units and the engine. • Refill oil pan with motor oil. • Check the tire pressure. Inflate all tires to 14–18 psi. • Start the engine and run at idle speed for approximately two minutes. • Check all fasteners for looseness; tighten as necessary. • Stop the engine.
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.
