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Toro 03206 Operator's Manual

Traction unit
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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.
Original Instructions (EN)

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Summary of Contents for Toro 03206

  • Page 1 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. Original Instructions (EN)

  • Page 2: Table Of Contents

    Authorized Service grass-covered land. Other states or federal areas Dealer or Toro Customer Service and have the model may have similar laws. and serial numbers of your product ready. Figure 1 identifies the location of the model and serial numbers on the product.

  • Page 3: Safety

    Safety Checking the Tire Pressure ......... 28 Checking the Reel-to-Bedknife Contact....29 Torquing the Wheel Nuts........29 This machine meets or exceeds CEN standard EN Starting and Stopping the Engine ......29 836:1997 (when appropriate decals applied), and Bleeding the Fuel System ........29 ANSI B71.4-2004 specifications in effect at the time Checking the Interlock System......
  • Page 4 ◊ Inadequate braking • Remember there is no such thing as a safe slope. Travel on grass slopes requires particular care. Do ◊ The type of machine is unsuitable for the task the following to guard against overturning: ◊ Lack of awareness of the effect of ground –...

  • Page 5: Toro Mower Safety

    The following list contains safety information specific to Toro products or other safety information that you • Allow the engine to cool before storing in any must know that is not included in the CEN, ISO, or enclosure.

  • Page 6: Maintenance And Storage

    mowing site to determine which hills can be safely terrain, speed (especially in turns), position of the operated on. When performing this site survey, always cutting units (with the Sidewinder), tire pressure, use common sense and take into consideration the turf and operator experience.

  • Page 7: Sound Power Level

    • Do not overspeed the engine by changing governor settings. To ensure safety and accuracy, have an Authorized Toro Distributor check the maximum engine speed with a tachometer. • The engine must be shut off before checking the oil or adding oil to the crankcase.

  • Page 8: Safety And Instructional Decals

    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.
  • Page 9 104-5181 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.
  • Page 10 104-5193 Model 03206 only 1. Engage the power take off 5. Raise the cutting units. 9. Engine—run 13. Slow (PTO). 2. Disengage the power take 6. Move the cutting units to 10. Engine—start off (PTO). the left. 3. Lower the cutting units.
  • Page 11 117-5104 Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. Keep bystanders a safe distance from the battery. 2. No fire, open flame, or 7. Wear eye protection; explosive gases can smoking. cause blindness and other injuries 8.

  • Page 12: Setup

    Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description Qty. Front wheel assemblies Install the wheels. Rear wheel assembly Steering wheel Steering wheel cap Large washer Install the steering wheel. Jam nut Screw Inclinometer Check the angle indicator.

  • Page 13: Installing The Wheels

    Media and Additional Parts Description Qty. Affix to the machine over corresponding English decals Decal, CE for European compliance. Ignition key Start the engine. Operator’s Manual Read before operating the machine. Engine Operator’s Manual Parts Catalog Use to look up and order parts. Operator video View before operating the machine.

  • Page 14: Activating, Charging, And Connecting The Battery

    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). Figure 4 Activating, Charging, and 1.

  • Page 15: Checking The Angle Indicator

    Figure 6 9. Coat both battery connections with Grafo 112X 1. Angle indicator (skin over) grease, Toro Part No. 505-47, petroleum jelly, or light grease to prevent corrosion. 3. If the inclinometer does not read zero degrees, 10. Slide the rubber boot over the positive terminal to move the machine to a location where a zero degree prevent a possible short from occurring.

  • Page 16: Installing The Hood Latch (Ce Only)

    Installing the Hood Latch (CE Installing the Exhaust Guard Only) (CE Only) Parts needed for this procedure: Parts needed for this procedure: Hood lock bracket Exhaust guard Screw, 1/4 x 1–1/2 inches Self-tapping screw Flat washer, 1/4 inch Procedure Locknut, 1/4 inch 1.

  • Page 17: Installing The Roll Bar

    Installing the Roll Bar Installing the Front Lift Arms Parts needed for this procedure: Parts needed for this procedure: Roll bar assembly Lift arms Flange head bolts Pivot rod Locknuts Bolt (5/16 x 7/8 inch) 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 Important: Never weld or modify a rollover and retain the pivot shaft link and bolts (Figure 10).

  • Page 18: Installing The Carrier Frames To The Cutting Units

    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. Note: Torque the bolts to 70 ft-lb (95 N-m). Installing the Carrier Frames to the Cutting Units No Parts Required Procedure...

  • Page 19: Mounting The Cutting Units

    (Figure 18). Raise the cutting units and shift them to the left 1. Carrier frame 2. Mounting link (model 03206). The rear cutting unit hoses must 3. Plug not contact traction cable bracket. Reposition the fittings and/or hoses, if necessary.

  • Page 20: Mounting The Cutting Unit Drive Motors

    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.

  • Page 21: Adjusting The Lift Arms

    Adjusting the Lift Arms No Parts Required Procedure Figure 24 1. Start the engine, raise the lift arms, and check to 1. Front cylinder 2. Jam nut 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).

  • Page 22: Product Overview

    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.

  • Page 23: Hour Meter

    Release the key when the engine starts. The key will ground and the machine is moving (Model 03206 only). move automatically to the On/Run position. To shut the...

  • Page 24: Fuel Gauge

    Glow Plug Indicator Fuel Gauge The glow plug indicator light (Figure 29) will glow when The fuel gauge (Figure 31) registers the amount of fuel the glow plugs are operating. in the tank. Parking Brake Whenever the engine is shut off, engage the parking brake (Figure 29) to prevent accidental movement of the machine.

  • Page 25: Specifications

    Contact your Authorized Service Dealer or Distributor or go to Checking the Engine Oil Level www.Toro.com for a list of all approved attachments and accessories. Service Interval: Before each use or daily The engine is shipped with oil in the crankcase;...

  • Page 26: Filling The Fuel Tank

    Note: Toro Premium Engine oil is available from a gauge. Engine failure may occur as a result of distributor in either 15W-40 or 10W-30 viscosity. See over filling or under filling the engine oil. the parts catalog for part numbers.

  • Page 27: Checking The Cooling System

    • 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.

  • Page 28: Checking The Hydraulic System

    Note: Maintain the recommended pressure in all tires Toro Biodegradable Hydraulic Fluid (Available in 5 gallon pails or 55 gallon drums. See parts catalog or a Toro to ensure a good quality of cut and proper machine distributor for part numbers.)

  • Page 29: Checking The Reel-To-Bedknife Contact

    3. Move the throttle lever to the 1/2 throttle position. 4. Insert the key into the switch and rotate it to the Low tire pressure decreases machine side hill On/Preheat position until the glow plug indicator stability. This could cause a rollover, which may light goes out (approximately 7 seconds);...

  • Page 30: Checking The Interlock System

    In case of an emergency, the machine can be towed for 1. Fuel injection pump bleed screw a short distance; however, Toro does not recommend this as a standard procedure. 4. Turn the key in the ignition switch to the On Important: Do not tow the machine faster than 2 position.

  • Page 31: Standard Control Module (Scm)

    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°...
  • Page 32 INPUTS OUTPUTS Function Power Start ON Brake PTO ON In Seat Hi Temp Backlap Start Neutral — — — Start — — Run (Off Unit) — — — Run (On Unit) — — — — — — — — Backlap —...

  • Page 33: Operating Tips

    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 General Tips the forward traction pedal, and carefully drive to an open area.
  • Page 34 (model 03206 only). straight toward it. • As soon as the front cutting units reach the edge of...
  • Page 35 0.50 and personal preference. 0.38 *Toro does not recommend this height-of-cut and/or mowing speed. Note: The higher the number, the higher the speed. 2. Turn the reel speed control knob (Figure 41) to the...

  • Page 36: Maintenance

    Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Maintenance Procedure Interval • Torque the wheel nuts. After the first hour • Torque the wheel nuts. • Check the condition and tension of all belts. After the first 10 hours •...

  • Page 37: Daily Maintenance Checklist

    Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Maintenance Check Item Mon. Tues. Wed. Thurs. Fri. Sat. Sun. Check the safety interlock operation. Check the brake operation. Check the fuel level. Check the engine oil level. Check the cooling system fluid level.

  • Page 38: Service Interval Chart

    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.

  • Page 39: Lubrication

    • Rear cutting unit pivot (Figure 44) Figure 47 Figure 44 • Rear lift arm pivot and lift cylinder (2) (Figure 48) • Front cutting unit pivot (Figure 45) Figure 45 • SideWinder cylinder ends (2; model 03206 only) (Figure 46)
  • Page 40 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 •...

  • Page 41: Sealed Bearings

    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.

  • Page 42: Engine Maintenance

    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.

  • Page 43: Fuel System Maintenance

    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, Figure 58 in an open area, when the engine is off and is cold.

  • Page 44: Changing The Fuel Filter Canister

    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.

  • Page 45: Electrical System Maintenance

    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 Service Interval: Every 25 hours—Check the glasses to shield your eyes and rubber gloves electrolyte level.

  • Page 46: Storing The Battery

    Drive System damage from short outs whenever working with the electrical system. Maintenance Storing the Battery Adjusting the Traction Drive If the machine will be stored more than 30 days, remove for Neutral the battery and charge it fully. Either store it on the shelf or on the machine.

  • Page 47: Cooling System Maintenance

    Cooling System 6. Pivot the oil cooler back into position. 7. Install the access panel and close the hood. Maintenance 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.

  • Page 48: Brake Maintenance

    Brake Maintenance Belt Maintenance Servicing the Engine Belts Adjusting the Parking Brake Service Interval: After the first 10 hours—Check the Service Interval: Every 200 hours—Check the parking condition and tension of all belts. brake adjustment. Every 100 hours—Check the 1. Loosen the set screw that secures the knob to the condition and tension of all belts.

  • Page 49: Controls System Maintenance

    Controls System 2. Push down and forward on the spring end (Figure 67) to unhook it from the bracket and release tension Maintenance on the spring. Adjusting the Throttle 1. Position the throttle lever rearward so that it stops against the control panel slot. 2.

  • Page 50: Hydraulic System Maintenance

    Maintenance 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.

  • Page 51: Checking The Hydraulic Lines And Hoses

    Checking the Hydraulic Lines Miscellaneous and Hoses Maintenance Service Interval: Before each use or daily Backlapping the Cutting Check hydraulic lines and hoses for leaks, kinked lines, System loose mounting supports, wear, loose fittings, weather deterioration, and chemical deterioration. Make all necessary repairs before operating.

  • Page 52: Storage

    A. Remove the battery terminals from the battery Note: Additional instructions and procedures on posts. backlapping are available in the TORO Sharpening Reel & Rotary Mowers Manual Form No. 80–300SL. B. Remove the battery. Note: For a better cutting edge, run a file across the C.
  • Page 53 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.

  • Page 54: Schematics

    Schematics G008924 Electrical Schematic (Rev. A)
  • Page 55 G008925 Hydraulic Schematic (Rev. A)
  • Page 56 Countries Other than the United States or Canada Customers who have purchased Toro products exported from the United States or Canada should contact their Toro Distributor (Dealer) to obtain guarantee policies for your country, province, or state. If for any reason you are dissatisfi ed with your Distributor’s service or have diffi culty ob- taining guarantee information, contact the Toro importer.

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032070322003221Reelmaster 3100-d

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