Form No. 3361-268 Rev B Reelmaster® 3100-D Traction Unit Model No. 03206—Serial No. 290000001 and Up Model No. 03207—Serial No. 290000001 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.
Warning Introduction CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage. You are responsible for operating the product properly and safely. You may contact Toro directly at www.Toro.
Safety Checking the Tire Pressure ................................. 28 Checking the Reel-to-Bedknife Contact............... 29 Torquing the Wheel Nuts.................................... 29 Starting and Stopping the Engine ........................ 29 Bleeding the Fuel System .................................... 29 Checking the Interlock System............................ 30 Towing the Traction Unit.................................... 30 Standard Control Module (SCM) ........................
◊ Inadequate braking ◊ The type of machine is unsuitable for the task ◊ Lack of awareness of the effect of ground conditions, especially slopes ◊ Incorrect hitching and load distribution • 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.
• Disengage the drive to attachments when transporting or when the machine is not in use. • Reduce the throttle setting before stopping the engine and, if the engine is provided with a fuel shut-off valve, turn the fuel off at the conclusion of mowing. • 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.
mowing site to determine which hills can be safely operated on. When performing this site survey, always use common sense and take into consideration the turf condition and the rollover risk. To determine which hills or slopes may be safely operated on, use the inclinometer provided with each machine. To perform a site survey, follow the procedure outlined in the Operation section of the this manual. The maximum side hill angle is detailed on the slope decal affixed near the angle indicator.
• • • • • • • pressure can have sufficient force to penetrate the skin and cause serious injury. If fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result. Check all fuel lines for tightness and wear on a regular basis. Tighten or repair them as needed.
Safety and Instructional 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. 93-6681 1. Cutting/dismemberment—hazard, fan-stay away from moving parts. 99-3496 93-7276 1. Explosion hazard—wear eye protection. 2. Caustic liquid/chemical burn hazard—to perform first aid, flush with water. 3. Fire hazard—no fire, open flames, or smoking. 4.
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. 104-5192 Model 03207 only 1. Engage the power take off (PTO). 2.
4-5193 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.
7-5104 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 bystanders a 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.
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 Parts needed for this procedure: • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. 1 • Always connect the positive (red) battery cable before connecting the negative (black) cable.
5 6 Installing the Hood Latch (CE Only) Installing the Exhaust Guard (CE Only) Parts needed for this procedure: Parts needed for this procedure: 1 Hood lock bracket 1 Exhaust guard 1 Screw, 1/4 x 1–1/2 inches 4 Self-tapping screw 1 Flat washer, 1/4 inch 1 Locknut, 1/4 inch Procedure 1. Position the exhaust guard around the muffler while aligning the mounting holes with the holes in the frame (Figure 8). Procedure 1. Unhook the hood latch from the hood latch bracket (Figure 7).
7 8 Installing the Roll Bar Installing the Front Lift Arms Parts needed for this procedure: Parts needed for this procedure: 1 Roll bar assembly 2 Lift arms 4 Flange head bolts 2 Pivot rod 4 Locknuts 2 Bolt (5/16 x 7/8 inch) 1 Hose clamp Procedure 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 10). Important: Never weld or modify a rollover protection system (ROPS).
4. Insert the lift arms onto the lift arm pivot shafts (Figure 12), and secure each with a lift arm pivot shaft link and bolts previously removed. 9 Note: Torque the bolts to 70 ft-lb (95 N-m). 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 14) onto each front cutting unit.
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 17). Note: On rear cutting unit, position the thrust washer between the rear of the carrier frame and the lynch pin. Figure 15 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 16.
Figure 20 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. Figure 18 4. Locate the spider coupling (Figure 21) shipped in the bearing housing. 4. Route a tipper chain up through the slot on the end of each carrier frame. Secure the tipper chain to the top of the carrier frame with a bolt, a washer, and a locknut (Figure 19). Figure 21 Figure 19 1. Spider coupling 2. Reel motor 1. Tipper chain 3.
12 Adjusting the Lift Arms No Parts Required Procedure Figure 24 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 22). 1. Front cylinder 2. Jam nut C. Remove the pin from the rod end and rotate the clevis. D. Install the pin and check the clearance. 2 E. Repeat steps 1 through 4 if necessary. F. Tighten the clevis jam nut.
Product Overview Controls Figure 26 1. Rear cylinder 2. Adjusting nut B. Grasp the cylinder rod close to the nut with a pliers and rag and rotate the rod. C. Raise the cutting units and check the clearance. D. Repeat steps 1 through 3 if necessary. E. Tighten the clevis jam nut. Figure 27 Important: Lack of clearance at the front stops or the rear wear bar could damage the lift arms. 1. Forward traction pedal 2. Reverse traction pedal 3. Mow/transport slide 4. Tilt steering lever 5. Indicator slot 6.
Tilt Steering Lever Cutting Unit Drive Switch Pull the tilt steering lever (Figure 27) back to adjust the steering wheel to the desired position, then push the lever forward to tighten. The cutting unit drive switch (Figure 29) has two positions: Engage and Disengage. The rocker switch operates a solenoid valve on the valve bank to drive the cutting units. Indicator Slot Hour Meter The slot in the operator platform (Figure 27) indicates when the cutting units are in the center position.
Glow Plug Indicator Fuel Gauge The glow plug indicator light (Figure 29) will glow when the glow plugs are operating. The fuel gauge (Figure 31) registers the amount of fuel in the tank. Parking Brake Whenever the engine is shut off, engage the parking brake (Figure 29) to prevent accidental movement of the machine. To engage the parking brake, pull up on the lever. The engine will stop if you press the traction pedal with the parking brake engaged.
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.
• The blended fuel composition should meet ASTM D975 or EN590. • 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. Figure 35 1. Access panel 2. Radiator 1.
Note: With a cold engine, the coolant level should be approximately midway between the marks on the side of the tank. Alternate fluid: Mobil EAL 224H This is vegetable-oil based biodegradable oil tested and approved by Toro for this model. This fluid is not as resistant to high temperatures as standard fluid, so install an oil cooler if required by the operator manual and follow recommended fluid change intervals with this fluid.
3. Move the throttle lever to the 1/2 throttle position. 4. Insert the key into the switch and rotate it to the On/Preheat position until the glow plug indicator 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. Low tire pressure decreases machine side hill stability. This could cause a rollover, which may result in personal injury or death. Do not under-inflate the tires.
Checking the Interlock System Service Interval: Before each use or daily 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. 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. Wipe up any spilled fuel.
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 39 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 40 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 • Start the engine and run it at half idle until it warms up. Push the throttle lever all the way forward, lift the cutting units, disengage the parking brake, press the forward traction pedal, and carefully drive to an open area. General Tips • 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.
• The Sidewinder offers up to a maximum of 13 inches (33 cm) of overhang, allowing you to trim closer to the edge of sand traps and other obstacles, while at the same time keeping the tractor tires as far away from the edge of traps or water hazards as possible. the shields too far or an excessive amount of clippings could 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.
REEL SPEED SELECTION CHART Height-of-Cut (inches) 5-Blade Reel 5 MPH 6 MPH 8-Blade Reel 5 MPH 6 MPH 2-1/2 2.50 3 3 3* 3* 2-3/8 2.38 3 4 3* 3* 2-1/4 2.25 3 4 3* 3* 2-1/8 2.13 3 4 3* 3* 2 2.00 3 4 3* 3* 1-7/8 1.88 4 5 3* 3* 1-3/4 1.75 4 5 3* 3* 1-5/8 1.63 5 6 3* 3* 1-1/2 1.50 5 7 3 4 1-3/8 1.38 5 8 3 4 1-1/4 1.25 6 9 4 4 1-1/8 1.13 8 9* 4 5 1 1.00 9 9* 5 6 7/8 0.88 9* 9* 5 7 3/4 0.75 9* 9* 7 9 5/8 0.
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.
Notation for Areas of Concern (cont'd.) Service Interval Chart Figure 42 Premaintenance Procedures Removing the Hood The hood may be easily removed to ease maintenance procedures in the engine area of the machine. 1. Unlatch and raise the hood. Figure 43 2. Remove the cotter pin that secures the hood pivot to the mounting brackets (Figure 43). 1. Cotter pin 3. Slide the hood to the right side, lift the other side, and pull it out of the brackets. Note: Reverse the procedure to install the hood.
Lubrication Greasing the Bearings And Bushings Service Interval: Every 50 hours (Lubricate all bearings and bushings daily when conditions are dusty and dirty.) Yearly Every 500 hours/Yearly (whichever comes first) The machine has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. Bearings and bushings must be lubricated daily when the operating conditions are extremely dusty and dirty.
Figure 51 • Mow/transport slide (Figure 52) Figure 48 • Left front lift arm pivot and lift cylinder (2) (Figure 49) Figure 52 • Belt tension pivot (Figure 53) Figure 49 • Right front lift arm pivot and lift cylinder (2) (Figure 50) Figure 53 • Steering cylinder (Figure 54).
Due to the operating conditions these bearing/seal packages are subject to (i.e., sand, turf chemicals, water, impacts, etc.) they are considered normal wear items. Bearings that fail due to causes other than defects in materials or workmanship are typically not covered under the warranty. Note: Bearing life can be negatively affected by improper wash-down procedures. Do not wash down the unit when it is still hot and avoid directing high-pressure or high volume spray at the bearings.
Engine Maintenance Servicing the Air Cleaner Service Interval: Every 200 hours (More frequently in extreme dusty or dirty conditions) • Check the air cleaner body for damage which could cause an air leak. Replace it if it is damaged. Check the whole intake system for leaks, damage, or loose hose clamps. • Service the air cleaner at the recommended service interval or earlier if engine performance suffers due to extremely dusty, dirty conditions.
Fuel System Maintenance 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. • 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 58 1. Engine oil drain plug • Do not fill the fuel tank completely full. Add fuel to the fuel tank until the level is 1 in. (25 mm) below the bottom of the filler neck.
2 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. 4. Tighten the pipe connector securely. 5. Repeat this procedure on the remaining nozzles. 1 3 G009880 Figure 60 1. Water separator/filter canister 2. Vent plug 3. Drain valve 3. Tighten the valve after draining. Changing the Fuel Filter Canister Service Interval: Every 400 hours 1.
Electrical System Maintenance Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns. Caring for the Battery • Do not drink electrolyte and avoid contact with skin, eyes or clothing. Wear safety glasses to shield your eyes and rubber gloves to protect your hands. Service Interval: Every 25 hours—Check the electrolyte level. (If machine is in storage, check every 30 days.) • Fill the battery where clean water is always available for flushing the skin.
Drive System Maintenance damage from short outs whenever working with the electrical system. Storing the Battery Adjusting the Traction Drive for Neutral If the machine will be stored more than 30 days, remove the battery and charge it fully. Either store it on the shelf or on the machine. Leave the cables disconnected if they are stored on the machine. Store the battery in a cool atmosphere to avoid quick deterioration of the charge in the battery.
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 63). Figure 63 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. Every 100 hours—Check the condition and tension of all belts. 1. Loosen the set screw that secures the knob to the parking brake lever (Figure 65). Tensioning the Alternator/Fan Belt 1. Open the hood. 2.
Controls System Maintenance 2. Push down and forward on the spring end (Figure 67) 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 68). Figure 67 1. Hydrostat drive belt 2. Spring end 3. Replace the belt. 4. Reverse the procedure to tension the spring. Figure 68 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. Contacting the reels may cause personal injury or death. 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.
G008925 Hydraulic Schematic (Rev.
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. This warranty is applicable to all products with the exception of Aerators (refer to separate warranty statements for these products).
