Form No.
Revision History Revision Date Description -- 1999 Initial Issue. A 2002 Updated Engine chapter. B 2003 Updated Hydraulics chapter. C 2005 Updated Hydraulics chapter. D 2007 Updated Engine chapter. E 2009 Updated Engine chapter. F 2011 Updated Hydraulics chapter. G 2012 Updated DPA Cutting Units. H 02/2018 Added revision history. J 04/2018 Revised bedknife installation procedures, added Universal Groomer chapter. K 03/2019 Updated Engine and Wheels & Brakes chapters.
Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.
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PART NO. 99024SL Rev. M Service Manual ReelmasterR 3100--D Preface The purpose of this publication is to provide the service technician with information for troubleshooting, testing, and repair of major systems and components on the Reelmaster 3100--D. REFER TO THE TRACTION UNIT AND CUTTING UNIT OPERATOR’S MANUALS FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. Space is provided in Chapter 2 of this book to insert the Operator’s Manuals and Parts Catalogs for your machine.
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Chapter 1 -- Safety Chapter 5 -- Electrical System Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -- 1 Jacking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 1 -- 4 Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 -- 5 Electrical Schematics and Diagrams . . . . . . . . . . 5 -- 2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 31 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Safety Table of Contents GENERAL SAFETY INSTRUCTIONS . . . . . . . . . . . . 1 Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Maintenance and Service . . . . . . . . . . . . . . . . . . . . 3 JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . 4 SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
While Operating 1. Do not run the engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and could be deadly. 2. Sit on the seat when starting and operating the machine. 3. Check interlock switches daily for proper operation (see Chapter 5 - Electrical System). Do not rely entirely on safety switches: shut off engine before getting off seat. If a switch fails, replace it before operating the machine. The interlock system is for your protection, so do not bypass it. 4.
1. Before servicing or making adjustments to the machine, stop the engine and remove key from switch to prevent accidental starting of the engine. 2. Check performance of all interlock switches daily. Do not defeat interlock system. It is for your protection. 3. To ensure entire machine is in good operating condition, frequently check and keep all nuts, bolts, screws and hydraulic fittings tight. 4.
Jacking Instructions CAUTION When changing attachments, tires, or performing other service, use correct blocks, hoists, and jacks. Make sure machine is parked on a solid level floor such as a concrete floor. Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels. Used jack stands or solid wood blocks to support the raised machine.
Safety and Instruction Decals Safety Numerous safety and instruction decals are affixed to the Reelmaster 3100−D. If any decal becomes illegible or damaged, install a new decal. Part numbers for replacement decals are listed in your Parts Catalog. Order replacement decals from your Authorized Toro Distributor.
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Chapter 2 Product Records and Maintenance Table of Contents 1 1 2 2 2 3 3 Product Records and Maintenance PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . Fastener Identification . .
Equivalents and Conversions 0.
Torque Specifications These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Service Manual.
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, 5, & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs, & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in−lb in−lb N−cm 10 + 2 13 + 2 147 + 23 # 6 − 32 UNC # 6 − 40 UNF # 8 − 32 UNC 13 + 2 25 + 5 # 10 − 24 UNC 30 + 5 SAE Grade 8 Bolts, Screws, Studs, & Sems with Regular Height Nuts (SAE J995 Grade 5 or Stronger Nuts) in−lb N−cm in−lb N−cm 15 + 2 170 + 20 23 + 2 260 +
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws, and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws, and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 + 5 in−lb 640 + 60 N−cm 78 + 7 in−lb 885 + 80 N−cm M6 X 1.0 96 + 9 in−lb 1018 + 100 N−cm 133 + 13 in−lb 1500 + 150 N−cm M8 X 1.25 19 + 2 ft−lb 26 + 3 N−m 27 + 2 ft−lb 36 + 3 N−m M10 X 1.
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Square Head Hex Socket 1/4 − 20 UNC 140 + 20 in−lb 73 + 12 in−lb 5/16 − 18 UNC 215 + 35 in−lb 145 + 20 in−lb 3/8 − 16 UNC 35 + 10 ft−lb 18 + 3 ft−lb 1/2 − 13 UNC 75 + 15 ft−lb 50 + 10 ft−lb 7/16 − 20 UNF Grade 5 65 + 10 ft−lb 88 + 14 N−m 1/2 − 20 UNF Grade 5 80 + 10 ft−lb 108 + 14 N−m M12 X 1.25 Class 8.
Lubrication Traction Unit CAUTION 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.
(2) Figure 12 Figure 8 Figure 13 Figure 9 Figure 14 Figure 10 Figure 15 (See Note) Figure 11 Product Records and Maintenance Page 2 − 8 Reelmaster 3100−D
Cutting Units Each cutting unit has (6) grease fittings (with optional front roller installed) that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. The grease fitting locations and quantities areas follows: Bedknife adjuster (2), every 50 hours (Fig. 17); Reel bearings (2) and front and rear rollers (2 ea.) (Fig. 16). IMPORTANT: Lubricating cutting units immediately after washing. This helps to purge water out of bearings and increases bearing life. 1.
Preparation for Seasonal Storage Traction Unit Traction Unit 1. Clean traction unit, cutting units, and the engine thoroughly. 1. Drain engine oil from the oil pan and replace the drain plug. 2. Check tire pressure. Inflate all tires to 14 to 18 psi (0.97 to 1.24 Bar). 2. Remove and discard oil filter. Install a new oil filter. 3. Check all fasteners for looseness; tighten as necessary. 4. Lubricate all grease fittings and pivot points (see Lubrication). 3. Refill oil pan with approximately 4.
Chapter 3 Kubota Diesel Engine INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4 Check Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fill Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Check Cooling System . . . . . . . . . . . . . . . . . . . . . . . 5 ADJUSTMENTS . . . . . . . . . . . . . . . . . .
Introduction This Chapter gives information about specifications, maintenance, troubleshooting, testing, and repair of the diesel engine used in the Reelmaster 3100−D. test equipment and the specialized nature of some repairs may dictate that the work be done at an engine repair facility. Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Kubota Workshop Manual, Diesel Engine, 05 Series.
Specifications Item Description Make / Designation Kubota, 4−Cycle, 3 Cylinder, Water Cooled, Diesel Engine Horse Power 21.5 HP @ 2500 RPM Bore mm (in.) 78.0 (3.07) Stroke mm (in.) 78.4 (3.09) Total Displacement cc (cu. in.) 1123 (68.53) Torque N−m (ft−lb) 67.3 (49.6) @ 2000 RPM Firing Order 1−2−3 Spherical Type Fuel No. 2 Diesel Fuel (ASTM D975) Fuel Capacity liters (gallons) 28.4 (7.
General Information Check Engine Oil The engine is shipped with oil in the crankcase. However, oil level must be checked before and after the engine is first started. 2 1 Crankcase holds about 4.0 qts. (3.8 l) with filter. IMPORTANT: Check level of oil every 5 operating hours or daily. Change oil after every 50 hours of operation. 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1. Dipstick 2.
Fill Fuel Tank DANGER 1 IMPORTANT: Use No, 2 diesel fuel only for the engine. The fuel tank capacity is about 7.5 gallons (28.4 l). 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2 Figure 3 1. Fuel tank cap 2. Fuel tank filler neck 3. Fill fuel tank to the bottom of the filler neck. Do not overfill. Install cap to the neck. 4. Wipe up any fuel that may have spilled to prevent a fire hazard. 2.
Adjustments Adjust Throttle Cable 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 4 2. Position throttle control lever all the way to the SLOW position so it stops against the control panel slot (Fig. 6). 3 1 3. Loosen cap screw securing the throttle cable to the swivel enough to loosen the cable (Fig. 7). 4. Hold speed control lever on the injection pump against the low idle stop.
Adjust Alternator/Fan Belt Condition and tension of all belts should be checked after the first 10 hours of operation and every 100 operating hours thereafter. 2 3 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 4 1 2. Open hood. 3. Check belt tension by depressing belt midway between the alternator and crankshaft pulleys with 22 lb. of force (98 N). Belt should deflect 7/16 inch (11 mm).
Service and Repairs Change Engine Oil and Filter Change oil and filter initially after the first 50 hours of operation, thereafter change oil every 50 hours and filter every 100 hours. 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2 1 2. Remove either drain plug and let oil flow into drain pan. When oil stops flowing, install the drain plug. 3. Remove oil filter.
Bleed Fuel System 1. Park machine on a level surface, lower cutting units, stop engine, and engage parking brake. 2. Make sure fuel tank is at least half full. Gain access to the engine. 2 DANGER 3. Open air bleed screw on the fuel injection pump. 1 Figure 13 1. Air bleed screw 2. Injection pump 4. Turn key in ignition switch to the ON position. The electric fuel pump will begin operation and force air out around the air bleed screw.
Muffler and Air Cleaner 8 14 1 4 3 21 8 13 4 18 11 7 12 6 22 23 19 4 17 3 5 9 24 15 2 3 Figure 15 1. 2. 3. 4. 5. 6. 7. 8. Air inlet hose (upper) Air inlet hose (lower) Flange nut Flange head screw Flat washer Cap screw Air filter bracket Hose clamp Kubota Diesel Engine 9. 10. 11. 12. 13. 14. 15. 16. Air cleaner body Not used Hex nut Lock washer Mounting band assembly Muffler Muffler bracket Not used Page 3 − 10 17. 18. 19. 20. 21. 22. 23. 24.
Muffler Removal CAUTION 2 The muffler and exhaust pipe may be hot. To avoid possible burns, allow the engine and exhaust system to cool before working on the muffler. 4 3 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1 2. Open engine hood to gain access to engine. Figure 16 1. Flange head nut 2. Flange head screw 4. Remove four hex nuts and lock washers from the exhaust manifold studs.
Check Air Filter, Dust Cup, & Burp Valve 1 The air cleaner body, air filter, dust cup, and burp valve should be check daily prior to operation. 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2 2. Check air cleaner body for damage that could cause possible air leaks. Make sure dust cup seals completely to the air cleaner body. 3 3. Check burp valve and dust cup for damage. 4.
Water/Fuel Separator DANGER Because diesel fuel is highly flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot, or when machine is in an enclosed area. Always fill fuel tank outside and wipe up any spilled diesel fuel before starting the engine. Store fuel in a clean, safety−approved container and keep cap in place. Use diesel fuel for the engine only; not for any other purpose. 1 2 Figure 20 1. Filter element 2.
Fuel System 22 10 7 31 33 22 20 24 28 22 8 30 39 32 34 1 27 9 22 3 5 35 35 32 25 26 22 14 16 18 21 36 15 37 33 22 13 19 38 17 12 22 11 43 23 4 2 4 6 22 31 Figure 22 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Cap screw Fuel tank Fuel hose strap Cap screw Fuel cap Tank support Fuel gauge Grommet Connector fitting Stand pipe R−clamp Barb fitting Cap screw 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
Fuel Tank Removal (Fig. 22) 4 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2 2. Siphon fuel from the tank into a suitable container. 3. Remove seat and seat support straps from the frame. Disconnect seat switch from the electrical harness (Fig. 23). 1 3 4. Remove fuel hose strap and both fuel hoses from the fuel tank. Pull tank from the machine (Fig. 24). Figure 23 Drain and clean the fuel tank every 2 years.
Radiator 19 16 22 15 41 8 9 21 36 5 4 33 34 25 24 18 15 2 10 38 40 3 13 17 29 31 30 26 37 30 32 27 28 30 27 6 9 12 36 35 2 14 2 1 23 25 39 20 7 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Drain cock valve Flange head screw Flange nut Carriage bolt Radiator Fan shroud (top) Fan shroud (bottom) Flange head screw Hose clamp Radiator frame Not used Radiator seal Flange head screw Reservoir bracket 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.
Installation 1. Remove any plugs from the oil cooler used during the removal procedures. 4. Remove glow plug relay from the radiator assembly. position relay away from the radiator. 2. Position radiator carefully to the radiator frame. Note: Allow hydraulic components and hoses to drain into a suitable container. Plug all hydraulic tubes, hoses, and openings to prevent contamination. 3. Secure radiator assembly to the radiator frame with four carriage bolts and lock nuts.
Clean Radiator and Oil Cooler (Fig. 4) 3 The radiator and oil cooler should be checked for dirt and debris daily, and hourly if conditions are extremely dusty and dirty. 1 2 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 4 CAUTION Figure 27 If engine has been running, the radiator may be hot and cause burns. Work on radiator only when the engine and radiator are cool. 1. Oil cooler 2. Radiator 3. Clip 4.
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Engine 5 15 39 37 38 2 37 1 9 32 8 16 11 34 5 21 40 6 23 35 22 9 24 13 11 5 14 25 10 11 18 11 36 17 12 19 31 33 29 27 11 16 26 9 30 16 8 6 3 2 4 7 4 25 26 28 8 Figure 29 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Kubota engine Engine mount Engine mount Flange nut Cap screw Hex flange head screw External lock washer Lock nut Washer Machine screw Hardened washer Cap screw Engine mounting bracket (front) Engine mounting bracket (LH) 15. 16. 17. 18. 19. 20. 21. 22.
8. Disconnect wire harness and electrical wires from the following: 4 A. Engine grounds to the battery and wire harness (Fig. 30). 6 5 3 B. Glow plug bus and fuel stop solenoid (Fig. 31). 2 C. High temperature warning switch (Fig. 32). 1 D. High temperature shutdown switch, alternator, and low oil pressure switch (Fig. 33). 9. Disconnect throttle cable from the support and swivel on the speed control lever (Fig. 30). Figure 30 1. Battery ground 2. Wire harness ground 3. Throttle cable 4.
B. Remove five cap screws, four washers, and five spacers securing the pump mount plate to the engine (Fig. 34). 1 2 C. Remove four cap screws and hardened washers securing the right engine mounting bracket and hydrostat to the engine. 2 4 Installation 3 1. Install hydrostat and pump mount plate to the engine as follows: 2 1 A. Secure right engine mounting bracket and hydrostat to the engine four hardened washers and cap screws.
Chapter 4 Hydraulic System SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic Fitting Installation . . . . . . . . . . . . . . . . . . . 3 Towing Traction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Check Hydraulic System Fluid . . . . . . . . . . . . . . . . . 5 Relieving Hydraulic System Pressure . . . . . . . . . . .
Specifications Item Description Piston Pump (Hydrostat) Maximum Operating Pressure Charge Pressure Traction Circuit Relief Pressure (Forward Only) Variable displacement piston pump 3000 PSI (207 bar) 100 to 150 PSI (6.9 to 10.
General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage conditions, or mishandling during operation or maintenance. These conditions can cause damage or premature deterioration. Some hoses are more susceptible to these conditions than others. Inspect the hoses frequently for signs of deterioration or damage.
SAE Straight Thread O−Ring Port − Non−adjustable 1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material. 2. Always replace the O−ring seal when this type of fitting shows signs of leakage. O−Ring 3. Lubricate the O−ring with a light coating of oil. 4. Install the fitting into the port and tighten it down full length until finger tight. Figure 3 5. Tighten the fitting to the correct flats from finger tight (F.F.F.T.). Size 4 (1/4 in.
Towing Traction Unit In case of emergency, the Reelmaster can be towed for a short distance. However, Toro does not recommend this as a standard procedure. 2 IMPORTANT: Do not tow the machine faster than 2 to 3 mph because drive system may be damaged. If machine must be moved a considerable distance (more than a few feet), transport it on a truck or trailer. 1 1. Locate by−pass valve on pump and rotate it 90o. 2. Before starting engine, close by−pass valve by rotating it 90o.
Relieving Hydraulic System Pressure Before disconnecting or performing any work on the Reelmaster 3100−D hydraulic system, all pressure in the hydraulic system must be relieved. Park machine on a level surface with the cutting units lowered and off. Turn key switch to OFF and allow engine to stop. To relieve hydraulic pressure in traction circuit, move traction lever to both forward and reverse directions. To relieve hydraulic pressure in steering and lift circuits, rotate steering wheel in both directions.
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Hydraulic System LOWER PORT FORWARD Page 4 − 8 100−150 psi 3000 psi UPPER PORT HYDROSTAT M6 TOP PORT INTERNAL CASE DRAIN P3 DUMP VALVE M4 M5 TRACTION WHEEL MOTORS All solenoids are shown as de−energized Reelmaster 3100−D (Model 03200) Hydraulic Schematic OIL FILTER ENGINE RPM OIL COOLER T1 FC1 REEL SPEED CONTOLLER G1 T2 D1 P1 P1 GEAR PUMP CHG S1 M2 REEL ON−OFF VALVE ST LC2 REEL RELIEF 3000 psi R1 LC1 LOGIC VALVE MD1 BACKLAPPING VALVE STRAINER P2 M1 IN AUX OUT LV
FORWARD Page 4 − 9 100 to 150 psi 3000 psi DUMP VALVE P3 INTERNAL CASE DRAIN LOWER PORT M4 UPPER PORT M6 TOP PORT HYDROSTAT TRACTION WHEEL MOTORS M5 All solenoids are shown as de−energized Reelmaster 3100−D (Model 03201) Hydraulic Schematic OIL FILTER OIL COOLER ENGINE RPM T1 REEL SPEED CONTROLLER G1 T2 D1 P1 STRAINER P2 GEAR PUMP CHG R1 REEL ON−OFF VALVE M2 ST LC2 (OPTIONAL) REEL RELIEF 3000 psi S1 LC1 LOGIC VALVE MD1 BACKLAPPING VALVE Hydraulic System P1 FC1 M1 A
Hydraulic System Page 4 -- 9.
Reelmaster 3100--D Page 4 -- 9.
Hydraulic System FORWARD Page 4 − 10 100 to 150 psi 3000 psi DUMP VALVE P3 INTERNAL CASE DRAIN LOWER PORT M4 UPPER PORT M6 TOP PORT HYDROSTAT TRACTION WHEEL MOTORS M5 High Pressure Low Pressure (Charge) Return or Suction Flow OIL FILTER OIL COOLER RPM ENGINE T1 REEL SPEED CONTROLLER G1 T2 D1 P1 P1 FC1 CHG STRAINER R1 REEL ON−OFF VALVE M2 ST LC2 (OPTIONAL) REEL RELIEF 3000 psi S1 LC1 LOGIC VALVE MD1 BACKLAPPING VALVE GEAR PUMP P2 M1 AUX OUT IN LV PLUG 1000 psi
Traction Circuits the loss of hydraulic fluid from the closed loop circuit that must be replenished. The traction circuit of the hydraulic system consists of a hydrostat connected in a closed loop circuit to three orbital vane wheel motors. The engine drives traction pump (P3) indirectly through pulleys and a V−belt. The traction pump is a variable displacement piston pump. The traction pedal connects through a cable to the trunnion shaft and swash plate of the pump.
FORWARD Page 4 − 12 100 to 150 psi 3000 psi DUMP VALVE P3 INTERNAL CASE DRAIN LOWER PORT M4 UPPER PORT M6 TOP PORT HYDROSTAT TRACTION WHEEL MOTORS M5 High Pressure Low Pressure (Charge) Return or Suction Flow Reelmaster 3100−D Reel Circuit OIL FILTER OIL COOLER ENGINE RPM T1 REEL SPEED CONTROLLER G1 T2 D1 P1 P1 FC1 CHG STRAINER P2 R1 REEL ON−OFF VALVE M2 ST LC2 (OPTIONAL) REEL RELIEF 3000 psi S1 LC1 LOGIC VALVE MD1 BACKLAPPING VALVE GEAR PUMP M1 PLUG IN LV AUX O
Reel Circuit The gear pump (P1) is directly coupled to the the hydrostat which is driven by the engine. Taking its suction directly from the hydraulic tank, the gear pump supplies oil flow to the manifold block and to the reel motors.
FORWARD Page 4 − 14 100 to 150 psi 3000 psi DUMP VALVE P3 INTERNAL CASE DRAIN LOWER PORT M4 M6 UPPER PORT TOP PORT HYDROSTAT TRACTION WHEEL MOTORS M5 High Pressure Low Pressure (Charge) Return or Suction Flow Reelmaster 3100−D Lift Circuit (Up) OIL FILTER OIL COOLER ENGINE RPM T1 REEL SPEED CONTROLLER G1 T2 D1 P1 P1 FC1 CHG STRAINER P2 R1 REEL ON−OFF VALVE M2 ST LC2 (OPTIONAL) REEL RELIEF 3000 psi S1 LC1 LOGIC VALVE MD1 BACKLAPPING VALVE GEAR PUMP M1 AUX OUT IN L
Lift Circuit (Up) Raise Cutting Units The gear pump (P2) is directly coupled to the hydrostat through gear pump (P1). It supplies hydraulic pressure (charge pressure) for raising and lowering the cutting units, operating the sidewinder unit, and maintaining 100 to 150 PSI (6.9 to 10.0 bar) to the low pressure side of the traction circuit. The pump takes its suction from the hydraulic reservoir.
FORWARD Page 4 − 16 100 to 150 psi 3000 psi DUMP VALVE P3 INTERNAL CASE DRAIN LOWER PORT M4 UPPER PORT M6 TOP PORT HYDROSTAT TRACTION WHEEL MOTORS M5 High Pressure Low Pressure (Charge) Return or Suction Flow Reelmaster 3100−D Lift Circuit (Down) OIL FILTER OIL COOLER ENGINE RPM T1 REEL SPEED CONTROLLER G1 T2 D1 P1 P1 FC1 CHG STRAINER P2 R1 REEL ON−OFF VALVE M2 ST LC2 (OPTIONAL) REEL RELIEF 3000 psi S1 LC1 LOGIC VALVE MD1 BACKLAPPING VALVE GEAR PUMP M1 AUX OUT IN
Lift Circuit (Down) Lower Cutting Units Circuit operation for lowering the cutting units is similar to raising them. However, pressure is relieved from the lift cylinders, and this action allows them to lower. During conditions of not lifting or lowering cutting units, flow from the gear pump is by−passed through the power steering valve, 2−spool valve, and hydraulic manifold directly to the hydrostat and the charge relief valve. Flow then returns to the hydraulic tank.
Page 4 − 18 FORWARD 100 to 150 psi 3000 psi DUMP VALVE P3 INTERNAL CASE DRAIN LOWER PORT M4 UPPER PORT M6 TOP PORT HYDROSTAT TRACTION WHEEL MOTORS M5 High Pressure Low Pressure (Charge) Return or Suction Flow Reelmaster 3100−D Sidewinder Circuit (Extend Right) OIL FILTER OIL COOLER ENGINE RPM T1 REEL SPEED CONTROLLER G1 T2 D1 P1 P1 FC1 CHG STRAINER P2 R1 REEL ON−OFF VALVE M2 ST LC2 (OPTIONAL) REEL RELIEF 3000 psi S1 LC1 LOGIC VALVE MD1 BACKLAPPING VALVE GEAR PUMP M1
Sidewinder Circuit The gear pump (P2) is directly coupled to the hydrostat through gear pump (P1). It supplies hydraulic pressure (charge pressure) for raising and lowering the cutting units, operating the sidewinder unit, and maintaining 100 to 150 PSI (6.9 to 10.0 bar) to the low pressure side of the traction circuit. The pump takes its suction from the hydraulic reservoir. and hydraulic manifold, and to the hydrostat.
Hydraulic System Page 4 − 20 Reelmaster 3100−D 100 to 150 psi 3000 psi DUMP VALVE P3 M4 UPPER PORT M6 TOP PORT HYDROSTAT TRACTION WHEEL MOTORS M5 High Pressure Low Pressure (Charge) Return or Suction Flow Reelmaster 3100−D Steering Circuit (Right Turn) INTERNAL CASE DRAIN LOWER PORT FORWARD OIL FILTER OIL COOLER ENGINE RPM T1 REEL SPEED CONTROLLER G1 T2 D1 P1 P1 FC1 CHG STRAINER P2 R1 REEL ON−OFF VALVE M2 ST LC2 (OPTIONAL) REEL RELIEF 3000 psi S1 LC1 LOGIC VALVE MD1
Steering Circuit With the steering wheel in the neutral position (rear wheel positioned straight ahead), the engine running, and the spool valve is in the center position, flow enters the steering control valve at the IN port and goes through the spool valve by−passing the rotary meter (V1) and steering cylinder. Flow leaves the control valve through the OUT port to the hydrostat.
Special Tools Order these special tools from your Toro Distributor. Hydraulic Pressure Test Kit Toro Part Number: TOR47009 Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings. Contains one each: 1000 PSI (70 Bar), 5000 PSI (350 Bar) and 10000 PSI (700 Bar) gauges. Use gauges as recommended in Testing section of this chapter.
Hydraulic Test Fitting Kit Toro Part Number: TOR4079 This kit includes a variety of O--ring Face seal fittings to enable you to connect test gauges into the system. The kit includes: tee’s, unions, reducers, plugs, caps, and male test fittings. Figure 12 Measuring Container Toro Part Number: TOR4077 Hydraulic System Use this container for doing hydraulic motor efficiency testing (motors with case drain lines only).
Wheel Hub Puller Toro Part Number: TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors. Figure 15 High Flow Hydraulic Filter Kit Toro Part Number: TOR6011 The high flow hydraulic filter kit is designed with large flow (40 GPM/150 LPM) and high pressure (5000 PSI/345 bar) capabilities. This kit provides for bi--directional filtration which prevents filtered debris from being allowed back into the circuit regardless of flow direction.
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Troubleshooting The charts that follow contain information to assist in troubleshooting. There may possibly be more than one cause for a machine malfunction. Refer to the Testing section of this Chapter for precautions and specific test procedures.
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Testing Before Performing Hydraulic Tests IMPORTANT: All obvious areas such as oil supply, filter, binding linkages, loose fasteners, or improper adjustments must be checked before assuming that a hydraulic component is the source of the problem. Precautions for Hydraulic Testing CAUTION Failure to use gauges with recommended pressure (psi) rating as listed in test procedures could result in damage to the gauge and possible personal injury from leaking hot oil.
Traction Circuit Working Pressure Test (Using Pressure Gauge) FORWARD M5 TRACTION WHEEL MOTORS M4 TOP PORT M6 LOWER PORT UPPER PORT DUMP VALVE 3000 psi TRACTION RELIEF 100 to 150 psi FROM HYDRAULIC MANIFOLD (CHG) PORT P3 PISTON PUMP (HYDROSTAT) High Pressure TO GEAR PUMP SUCTION THROUGH CASE DRAIN Low Pressure Return or Suction Flow Hydraulic System Page 4 − 30 Reelmaster 3100−D
Procedure for Traction Circuit Working Pressure Test: 2 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off. 3. Read Precautions for Hydraulic Testing. 4. Make sure that traction pedal is adjusted to the neutral position (see Adjust Traction Drive for Neutral in the Adjustments Section). 1 Figure 17 1. Test port 2.
Piston Pump (P3) Flow and Traction Relief Pressure Test (Using Tester with Pressure Gauges and Flow Meter) M5 FORWARD TRACTION WHEEL MOTORS M4 TOP PORT M6 LOWER PORT UPPER PORT DUMP VALVE 3000 psi TRACTION RELIEF 100 to 150 psi FROM HYDRAULIC MANIFOLD (CHG) PORT P3 PISTON PUMP (HYDROSTAT) High Pressure TO GEAR PUMP SUCTION THROUGH CASE DRAIN Low Pressure Return or Suction Flow Hydraulic System Page 4 − 32 Reelmaster 3100−D
Procedure for Piston Pump (P3) Flow and Traction Relief Pressure Test: 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off. 2 3. Read Precautions for Hydraulic Testing. 1 WARNING One front wheel and the rear wheel will be off the ground during testing.
Charge Relief Valve Pressure Test (Using Pressure Gauge) M5 TRACTION WHEEL MOTORS M4 FORWARD TOP PORT LOWER PORT M6 UPPER DUMP VALVE PORT TO HYDRAULIC MANIFOLD (P1) PORT 3000 psi FROM HYDRAULIC MANIFOLD (CHG) PORT 100 to 150 psi CHARGE RELIEF TO STEERING CONTROL VALVE (IN) PORT P3 ENGINE P1 P2 RPM HYDROSTAT GEAR PUMP STRAINER INTERNAL CASE DRAIN High Pressure Low Pressure Return or Suction Flow Hydraulic System Page 4 − 34 Reelmaster 3100−D
Procedure for Charge Relief Valve Pressure Test: 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged. 9. A dynamic charge pressure test can be performed as follows: A. With T−connector and pressure gauge still connected, sit in the operator seat and press the traction pedal to forward. B.
Gear Pump (P2) Flow Test (Using Tester with Pressure Gauges and Flow Meter) TO HYDRAULIC MANIFOLD (P1) PORT TO STEERING CONTROL TO TOTO VALVE (IN) PORT ENGINE P1 P2 RPM FROM HYDROSTAT CASE DRAIN GEAR PUMP High Pressure STRAINER Low Pressure Return or Suction Flow Hydraulic System Page 4 − 36 Reelmaster 3100−D
Procedure for Gear Pump (P2) Test: 2 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged. 1 3. Read Precautions for Hydraulic Testing. WARNING RIGHT Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved.
Wheel Motor Efficiency Test (Using Tester with Pressure Gauges and Flow Meter) FORWARD M5 FRONT WHEEL MOTOR TESTING SHOWN TRACTION WHEEL MOTORS M4 TOP PORT M6 LOWER PORT UPPER PORT DUMP VALVE 3000 psi TRACTION RELIEF 100 to 150 psi FROM HYDRAULIC MANIFOLD (CHG) PORT P3 PISTON PUMP (HYDROSTAT) TO GEAR PUMP SUCTION THROUGH CASE DRAIN High Pressure Low Pressure Return or Suction Flow Figure 21 NOTE: Over a period of time, a wheel motor can wear internally.
Procedure for Wheel Motor Efficiency Test: 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged. 2 3. Read Precautions for Hydraulic Testing. 1 Figure 22 1. Lower hydraulic fitting 5.
Reel Circuit Pressure Test (Using Pressure Gauge) FROM REEL MOTOR CASE DRAINS TO INITIAL REEL MOTOR M1 D1 FROM FINAL REEL MOTOR M2 TO HYDRAULIC TANK T2 HYDRAULIC MANIFOLD BLOCK MD1 BACKLAPPING VALVE G1 LC1 LOGIC VALVE REEL SPEED CONTROLLER S1 FC1 REEL ON−OFF VALVE R1 REEL RELIEF 3000 psi T1 TO OIL COOLER PLUG CR TO REAR LIFT CYLINDER (OPTIONAL) LC2 TO FRONT LIFT CYLINDER CF G2 P1 TO HYDROSTAT CHARGE CIRCUIT ST CHG GEAR PUMP LV FROM LIFT VALVE (OUT) PORT TO STEERING CONTROL VALVE (IN) P
Procedure for Reel Circuit Pressure Test: 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged. 2 3. Read Precautions for Hydraulic Testing. 1 WARNING Figure 23 Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved.
Gear Pump (P1) Flow Test (Using Tester with Pressure Gauges and Flow Meter) TO HYDRAULIC MANIFOLD (P1) PORT TO STEERING CONTROL VALVE (IN) PORT TO TOTO ENGINE P1 P2 RPM FROM HYDROSTAT CASE DRAIN GEAR PUMP STRAINER High Pressure Low Pressure Return or Suction Flow Hydraulic System Page 4 − 42 Reelmaster 3100−D
Procedure for Gear Pump (P1) Flow Test: NOTE: Over a period of time, the gears and wear plates in the pump can wear down. A worn pump will by pass oil and make the pump less efficient. Eventually, enough oil loss will occur to cause the reel motors to stall under heavy cutting conditions. Continued operation with a worn, inefficient pump can generate excessive heat and cause damage to the seals and other components in the hydraulic system.
Manifold Relief Valve (R1) Pressure Test (Using Tester with Pressure Gauges and Flow Meter) FROM REEL MOTOR CASE DRAINS TO INITIAL REEL MOTOR D1 M1 FROM FINAL REEL MOTOR M2 TO HYDRAULIC TANK T2 HYDRAULIC MANIFOLD BLOCK G1 MD1 BACKLAPPING VALVE LC1 LOGIC VALVE REEL SPEED CONTROLLER S1 FC1 REEL ON−OFF VALVE R1 REEL RELIEF 3000 psi T1 TO OIL COOLER PLUG CR TO REAR LIFT CYLINDER (OPTIONAL) LC2 TO FRONT LIFT CYLINDER CF G2 P1 TO HYDROSTAT CHARGE CIRCUIT ST CHG GEAR PUMP LV FROM LIFT VALVE
Procedure for Manifold Relief Valve (R1) Pressure Test: 10.System pressure should be from 2700 to 3300 PSI as the relief valve lifts. 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. A. If specification is not met, shut off engine and adjust relief valve (see Adjusting Manifold Relief Valve). Return to Step 6. 2. Park machine on a level surface with the cutting units lowered and off.
Reel Motor Efficiency − Case Drain Test (Using Tester with Pressure Gauges and Flow Meter) TO HYDRAULIC MANIFOLD PORT (D1) IN FROM HYDRAULIC MANIFOLD PORT (M1) INITIAL REEL MOTOR BOTTOM TOP RIGHT FRONT REEL MOTOR BOTTOM IN TO HYDRAULIC MANIFOLD PORT (M2) FINAL REEL MOTOR MEASURING CONTAINER High Pressure Low Pressure Return or Suction Flow BOTTOM Toro # TOR4077 NOTE: Over a period of time, a reel motor can wear internally.
Procedure for Reel Motor Efficiency: Case Drain Test: 1 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged. 3. Read Precautions for Hydraulic Testing. NOTE: The reel motors are connected in series.
Reel Motor Cross−over Relief Pressures Test (Using Pressure Gauge) TO HYDRAULIC MANIFOLD PORT (D1) FROM HYDRAULIC MANIFOLD PORT (M1) IN INITIAL REEL MOTOR BOTTOM TOP RIGHT FRONT REEL MOTOR BOTTOM IN FINAL REEL MOTOR BOTTOM TO HYDRAULIC MANIFOLD PORT (M2) High Pressure Low Pressure Return or Suction Flow Figure 29 NOTE: One way to find a possibly bad reel motor is to have another person observe the machine while mowing in dense turf.
Procedure for Cross−over Relief Pressures Test: 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 1 1 2. Make sure machine is parked on a level surface with the cutting units lowered and off. Make sure engine is off and parking brake is engaged. Back bedknives off all reels.
12.Make sure backlap knob on the hydraulic manifold is in the backlap position. 14.Engage cutting units. System pressure should be from 1350 to 1650 PSI as the relief valve lifts. 13.One person should sit on the seat and operate the machine while another person reads the gauge. Start engine and move the throttle to full speed (2650 + 50 RPM). 15.Disengage cutting units and stop engine. If specifications are not met, the cross−over relief needs replacing.
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Lift and Steering Control Valve Relief Pressure Test (Using Pressure Gauge) TO HYDRAULIC MANIFOLD (ST) PORT TO LIFT VALVE (IN) PORT POWER STEERING VALVE L V1 OUT 1000 psi STEERING IN R AUX TO HYDRAULIC MANIFOLD LEFT TURN SHOWN GEAR PUMP ENGINE P1 P2 RPM STRAINER High Pressure Low Pressure FROM HYDROSTAT INTERNAL CASE DRAIN Return or Suction Flow Hydraulic System Page 4 − 52 Reelmaster 3100−D
Procedure for Lift and Steering Control Valve Relief Pressure Test: 2 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 2. Make sure machine is parked on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged. 1 3. Read Precautions for Hydraulic Testing. RIGHT WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved.
Steering Control Valve Test STEERING CYLINDER OPEN FITTING PLUG AUX OUT IN 1000 psi V1 L R POWER STEERING VALVE (LEFT TURN) High Pressure Low Pressure Return or Suction Flow Hydraulic System Page 4 − 54 Reelmaster 3100−D
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 2. Perform the Lift and Steering Control Valve Relief Pressure and Gear Pump (P2) Flow tests to make sure that pump and relief valve are functioning correctly. NOTE: This steering test procedure will be affected by incorrect rear tire pressure, binding in the hydraulic steering cylinder, extra weight on the vehicle, and/or binding of the steering fork assembly.
Adjustments Adjust Traction Drive for Neutral 1. Park the machine on a level surface and turn the engine off. WARNING One front wheel and rear wheel must be raised off the ground or the machine will move during adjustment. Make sure machine is supported so it will not accidentally fall injuring anyone under machine. 1 2 2. Raise one front wheel and rear wheel off floor and place support blocks under frame. Figure 33 3. Loosen locknut on traction adjustment cam. 1. Adjustment cam 2.
Adjust Manifold Relief Valve (R1) The hydraulic reel circuit is equipped with a relief valve. This valve is preset at the factory to 3000 PSI. However, an adjustment may be required if the setting proves to be incorrect after testing (see TESTING). If an adjustment is required proceed as follows: 1 WARNING Never adjust the relief valve with the hydraulic system pressurized. Hydraulic oil may spray out of the valve with the cap off. Personal injury may result.
Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components After Repair or Replacement of Components 1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking brake, lower cutting units or attachments, and stop engine. Remove key from the ignition switch. 1. Check oil level in the hydraulic reservoir and add correct oil if necessary.
Change Hydraulic Fluid Change hydraulic fluid after every 400 operating hours, under normal conditions. If fluid becomes contaminated, 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 2. Disconnect hydraulic hose from filter head or remove hydraulic filter and let hydraulic fluid flow into drain pan. When hydraulic fluid stops draining, connect the hydraulic hose or install new hydraulic filter. 3.
Replace Hydraulic Oil Filter The hydraulic system filter must be changed initially, after the first 10 hours of operation, and thereafter every 200 hours of operation or yearly, whichever comes first. The hydraulic oil must be changed every 400 hours of operation or yearly, whichever comes first. 1 Use a genuine Toro oil filter for replacement. IMPORTANT: Use of any other filter may void the warranty on some components. 2 1.
Replace Traction Belt 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 3 1 2. Insert nut driver or small piece of pipe onto the end of the torsion spring of the idler pulley. 4 5 6 CAUTION Be careful when removing or applying tension from or to the torsion spring of the idler pulley. The spring is under heavy load and may cause personal injury. 4. Remove V−belt from the engine flywheel and hydrostat pulleys. 5.
Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time there is a severe component failure or the system is contaminated (oil appears milky, black, or contains metal particles). 5. Inspect and clean hydraulic oil tank (see Hydraulic Tank Inspection). 6. Reconnect all hydraulic hoses, lines, and components that were disconnected while draining system.
Charge Hydraulic System NOTE: When initially starting the hydraulic system with new or rebuilt components such as motors, pumps, or lift cylinders, it is important that the hydraulic system be charged properly. Air must be purged from the system and its components to reduce the chance of damage. IMPORTANT: Change hydraulic oil filter whenever hydraulic components are repaired or replaced. 1. Park machine on a level surface, and turn the engine off. 11.
Hydraulic Tank and Hydraulic Oil Filter LATER MODELS 29 32 14 18 31 8 23 30 16 16 to 18 ft−lb (22 to 24 N−m) 6 4 25 7 20 28 21 11 Hydraulic Thread Sealant 22 30 15 9 Hydraulic Thread Sealant 24 14 to 16 ft−lb (19 to 22 N−m) 19 12 8 26 13 10 17 22 3 1 7 Anti−seize lubricant 30 to 60 in−lb (3.4 to 6.8 N−m) 20 5 2 Figure 40 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Hydraulic Tank Removal 1 1. Drain hydraulic tank (see Change Hydraulic Fluid). 2. Remove hydraulic tank from machine using Figures 40 and 41 as guides. Hydraulic Tank Inspection 1. Clean hydraulic tank and suction strainer with solvent. 2 2. Inspect hydraulic tank for leaks, cracks, or other damage. Figure 41 Hydraulic Tank Installation 1. Gear pump 2. Suction hose 1.
Front Wheel Motors 5 7 3 8 9 6 10 8 4 9 10 RIGHT FRONT 2 1 Figure 42 1. 2. 3. 4. Lock nut Spacer Socket head screw Hydraulic motor Hydraulic System 5. Frame 6. Hydraulic tube 7. Hydraulic tube Page 4 − 66 8. O−ring 9. Hydraulic fitting 10.
Installation Removal 1. Install wheel motor to frame using Figure 42 as guide. WARNING Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 − Safety. 1. Remove tire and wheel rim, wheel hub, and brake drum from the hydraulic motor. Remove brake assembly, brake bracket, and wheel shield from the frame (see Front Wheel and Brake Removal in Chapter 6 − Wheels, Brakes, and Miscellaneous). 2. Install wheel shield, brake bracket, and brake assembly to the frame.
Rear Wheel Motor 1 45 to 65 ft−lb 61 to 88 N−m 16 2 200 to 400 ft−lb 271 to 542 N−m 5 7 8 13 3 6 7 8 13 4 14 12 9 11 10 Figure 43 1. 2. 3. 4. 5. Lug nut Drive stud Tire and rim Wheel hub Hydraulic hose Hydraulic System 6. 7. 8. 9. 10. Hydraulic hose O−ring 45o hydraulic fitting Lock nut Socket head screw Page 4 − 68 11. 12. 13. 14.
Rear Wheel Removal Rear Wheel Installation 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1. If hydraulic fittings were removed, install fittings to reel motor using marks made during the removal process to properly orientate fittings. 2. Thoroughly clean wheel motor shaft and wheel hub taper. WARNING Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 − Safety. 2.
Wheel Motor Service 13 12 11 10 3 1 4 5 6 7 8 9 8 14 27 2 15 16 17 28 26 25 24 28 27 23 22 21 19 20 18 Figure 45 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Dirt seal Bearing Housing Back--up washer Seal rings Back--up washer Inner seal Thrust washer Thrust bearing Bearing 11. 12. 13. 14. 15. 16. 17. 18. 19.
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Reel Motors 10 20 14 15 12 17 18 13 17 16 3 13 9 19 4 16 5 8 17 10 12 6 16 1 3 4 2 14 18 30 to 40 ft−lb (41 to 54 N−m) 7 7 5 17 7 30 to 40 ft−lb (41 to 54 N−m) 6 16 9 19 11 19 9 5 Figure 45 1. 2. 3. 4. 5. 6. 7. Hydraulic motor (front) Hydraulic motor (rear) Reel motor coupler Flange nut Hydraulic hose 90o hydraulic fitting Hydraulic hose Hydraulic System 8. 9. 10. 11. 12. 13. 14.
Removal Installation NOTE: Note position of hydraulic fittings when removing from the reel motors. Position is critical to properly reconnecting hydraulic hoses. 1. If hydraulic fittings were removed, install fittings to reel motor using marks made during the removal process to properly orientate fittings. 1. Remove reel motor from the cutting unit (see Reel Motor Removal and Installation in Chapter 7 − Cutting Units). 2.
Reel Motor Service (Eaton) 7 5 3 4 2 1 8 6 9 25 to 28 ft--lb (34 to 38 N--m) 10 11 12 11 13 14 15 19 10 to 12 ft--lb (13.6 to 16.3 N--m) 13 18 17 16 Figure 46 1. 2. 3. 4. 5. 6. 7. Plug O--ring Shim Spring Ball Relief valve seal Backplate 8. 9. 10. 11. 12. 13. Idler gear assembly Drive gear assembly Key O--ring Body Alignment pin Disassembly (Fig. 46) 1. Make sure key is removed from the drive gear shaft. 2. Matchmark frontplate, body, and backplate to assure proper reassembly. 3.
12.Replace body if the inside diameter of the gear pockets exceeds 1.713 in. (43.5 mm). Inspection (Fig. 46) 1. Remove all nicks and burrs from all parts with an emery cloth. 13.Make sure both plugs are secure if they or the backplate is not being replaced. Reassembly (Fig. 46) Use eye protection such as goggles when using compressed air. 2. Clean all parts with solvent. Dry all parts with compressed air. 3. Inspect drive gear shaft for a broken or chipped keyway. 4.
Reel Motor Service (Casappa) 18 33 ft--lb (45 N--m) 19 ft--lb (25 N--m) 17 16 14 13 6 7 11 9 7 6 2 14 3 15 19 ft--lb (25 N--m) 12 10 9 8 4 5 1 Figure 46.1 1. 2. 3. 4. 5. 6. Dust seal Retaining ring Flange washer Shaft seal Front flange Pressure seal 7. 8. 9. 10. 11. 12. Back--up gasket Front wear plate Dowel pin Idler gear Drive shaft Rear wear plate 13. 14. 15. 16. 17. 18. O--ring Relief valve Body Washer (4 used) Lock washer (4 used) Cap screw (4 used) Disassembly (Fig. 46.1) 1.
4. Loosen cap screws from the rear cover. 4. Inspect wear plates for the following: 5. Remove motor from the vise. Turn motor so that the shaft end is facing down. Remove cap screws. A. Bearing areas should not have excessive wear or scoring. 6. Carefully remove body. Lift body straight up to remove. Make sure the rear wear plate remains on the drive and idler gear shafts. Remove and discard O-rings from the body. Locate and retrieve dowel pins. B.
1. Lubricate O--rings, pressure seals, back--up gaskets and wear plate grooves with a thin coat of petroleum jelly. Lubricate all other internal parts freely with clean hydraulic oil. 2. Install new seals into front flange (Fig. 46.3): A. Press shaft seal into front flange until it reaches the bottom of the bore. B. Install flange washer into front flange and then install retaining ring into the groove of the front flange. C. Install new dust seal into front flange. 3.
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Oil Cooler Removal 2 CAUTION The radiator and oil cooler may be hot. To avoid possible burns, allow the engine and cooling systems to cool before working on the oil cooler. 1 1. Remove oil cooler using Figures 47 and 48 as guides. Inspection Figure 47 1. OIl cooler CAUTION 2. Clip 2 Use eye protection such as goggles when using compressed air. 1. Back flush oil cooler with cleaning solvent. After cooler is clean, make sure all solvent is drained from the cooler. 1 8 3 9 5 2.
Hydraulic Manifold 28 18 9 22 16 15 2 10 14 29 27 25 6 5 12 20 6 19 20 13 18 19 26 5 17 24 7 11 18 8 17 18 7 17 17 23 18 1 Hydraulic System 3 RIGHT FRONT 21 4 Figure 49 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Hose clamp Micro switch Barb fitting Flange head screw Straight hydraulic fitting Straight hydraulic fitting 90o hydraulic fitting 45o hydraulic fitting Straight hydraulic fitting Barb fitting 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Hydraulic Manifold Service 22 HYDRAULIC MANIFOLD USED ON MACHINES WITH SERIAL NUMBERS BELOW 250999999 Loctite 242 2 to 5 ft−lb (2.7 to 6.8 N−m) 21 23 12 24 20 5 18 19 24 30 to 35 ft−lb (41 to 47 N−m) 42 to 45 ft−lb (57 to 61 N−m) 22 17 3 8 4 32 30 to 35 ft−lb (41 to 47 N−m) 13 11 30 to 35 ft−lb (41 to 47 N−m) 16 21 2 26 19 6 18 10 25 27 10 11 25 30 to 35 ft−lb (41 to 47 N−m) 29 7 28 25 11 9 31 11 11 RIGHT 30 1 FRONT 15 14 30 11 31 14 Figure 50 1. 2. 3. 4. 5. 6. 7.
6 48 to 60 in--lb (5.4 to 6.7 N--m) 4 7 HYDRAULIC MANIFOLD USED ON MACHINES WITH SERIAL NUMBERS ABOVE 260000000 40 ft--lb (54 N--m) 25 ft--lb (34 N--m) 20 ft--lb (27 N--m) 120 in--lb (13.5 N--m) 3 8 5 41 ft--lb (55 N--m) 9 120 in--lb (13.5 N--m) 2 10 11 1 12 15 ft--lb (20 N--m) 14 22 13 220 in--lb (25 N--m) 16 21 RIGHT FRONT 18 90 in--lb (10.1 N--m) 17 198 in--lb (22 N--m) 19 20 25 ft--lb (34 N--m) Figure 51 1. 2. 3. 4. 5. 6. 7. 8.
Solenoid Operated, Relief and Logic Control Cartridge Valves 1. Make sure the manifold is clean before removing the cartridge valve and seal kit. Note: On manifold shown in Figure 50, solenoid coil has an O--ring on each side of the coil. 2. If solenoid valve is to be removed from manifold, remove nut securing solenoid to the cartridge valve. Carefully slide solenoid and O-rings (if equipped) off the valve. IMPORTANT: Use care when removing cartridge valves.
3. Make sure manifold is clean before removing the rotary cartridge valve. Remove the valve and seal kit. D. Center one detent plate hole over a locating plate indentation. Drop a ball into each hole, then drop a spring into each hole. 4. Visually inspect the manifold port and cartridge valve for damage to sealing surfaces, damaged threads, and contamination. E. On the 2-position directional valve cartridge, place indicator plate over the detent plate.
8. Install rotary handle (Fig. 52) (manifold shown in Fig. 51) : A. Place handle base on flow control valve and position alignment mark on base with number 1 on manifold. Secure base with two (2) set screws. Apply a light coating of grease to chamfer on top of base to ease seal installation. B. Make sure that sleeve bearing is in handle cap. If necessary, press sleeve bearing into cap. Install lip seal on cap with seal lip facing down. C. Place bushing onto cartridge valve stem.
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Control Valve (Models 03200, 03206 and 03170) 13 9 11 8 10 11 12 7 5 7 18 14 17 8 19 2 17 3 1 18 15 17 17 6 4 16 Figure 55 1. 2. 3. 4. 5. 6. 7. Straight hydraulic fitting 90o hydraulic fitting Hydraulic fitting 90o hydraulic fitting Control valve (single spool) Carriage screw (2 used) Flange nut Hydraulic System 8. 9. 10. 11. 12. 13. Shoulder bolt Valve lever assembly Link (2 used) Bolt Lock nut (2 used) Knob Page 4 -- 84 14. 15. 16. 17. 18. 19.
Removal 1 4 WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved. See Relieving Hydraulic System Pressure in the General Information section. 3 2 1. Remove control valve from the frame using Figures 54 and 55 as guides. 2. If hydraulic fittings are to be removed from control valve, mark fitting orientation to allow correct assembly. Figure 55 1. Spool Valve 2. Magnet support bracket 3. Flange head screws 4. Frame Installation 1.
Control Valve Service (Models 03200, 03206 and 03170) 30 to 42 ft--lb (41 to 57 N--m) 18 19 10 to 12 ft--lb (14 to 16 N--m) 6 26 25 28 24 30 to 35 ft--lb (41 to 48 N--m) 17 9 23 29 30 to 35 ft--lb (41 to 48 N--m) 22 30 7 12 11 4 2 5 27 1 12 8 20 to 25 ft--lb (27 to 34 N--m) 14 16 3 13 10 Figure 57 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Check poppet Plunger Spacer Spool Seat Plug (solid) Seat retaining plug Bushing Check spring Spool cap Hydraulic System 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
6 26 25 11 2 1 27 5 9 29 30 7 17 18 19 23 25 22 28 24 12 8 Hydraulic System 26 6 14 11 16 11 13 4 12 3 10 Figure 57 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Check poppet Plunger Spacer Spool Seat Plug (solid) Seat retaining plug Bushing Check spring Spool cap Reelmaster 3100−D 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Valve body O−ring Retaining ring Washer Not used Spool spring Disc Plug Detent plug Not used Page 4 − 87 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.
Disassembly Assembly 1. Plug all ports and clean the outside of the valve thoroughly. IMPORTANT: Do not wipe parts with paper towels or rags. Lint free cloth must be used to prevent lint from causing damage to the hydraulic system. 2. Remove spool cap and slide the spool assembly from its bore. CAUTION 3. Remove O−ring and bushing from the spool assembly. 4. Remove O−ring from the spool bore end that is opposite the spool cap. Use eye protection such as goggles when using compressed air.
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Control Valve (Models 03201, 03207 and 03171) 14 13 25 1 6 17 12 9 5 11 17 7 21 26 25 15 27 5 10 8 14 5 16 9 21 7 20 25 21 4 2 18 21 21 23 25 24 22 19 3 21 Figure 59 1. 2. 3. 4. 5. 6. 7. 8. 9. Control valve (2--spool) Hydraulic fitting (straight) 90o hydraulic fitting Hydraulic fitting (straight) Flange nut Knob 90o hydraulic fitting Valve actuator bracket Shoulder bolt Hydraulic System 10. 11. 12. 13. 14. 15. 16. 17. 18.
Removal 4 1 WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved. See Relieving Hydraulic System Pressure in the General Information section. 3 2 1. Remove control valve from the frame using Figures 58 and 59 as guides. 2. If hydraulic fittings are to be removed from control valve, mark fitting orientation to allow correct assembly. Figure 59 1. Spool valve 2. Magnet support bracket 3. Flange head screws 4. Frame Installation 1.
Control Valve Service (Models 03201, 03207 and 03171) 10 to 12 ft--lb (14 to 16 N--m) 30 to 42 ft--lb (41 to 57 N--m) 18 25 28 26 30 to 35 ft--lb (41 to 48 N--m) 15 9 1 5 27 19 12 17 30 to 35 ft--lb (41 to 48 N--m) 20 23 9 22 29 24 30 7 4 26 6 25 4 5 27 11 21 20 to 25 ft--lb (27 to 34 N--m) 10 1 5 2 27 1 20 to 25 ft--lb (27 to 34 N--m) 12 8 9 14 29 16 13 10 3 30 to 35 ft--lb (41 to 48 N--m) 30 7 Figure 61 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
6 26 25 1 27 5 9 1 7 15 9 26 25 17 19 18 21 23 1 27 5 29 30 22 24 4 14 12 16 13 20 12 8 3 Figure 61 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Check poppet Grooved plunger Spacer Spool Seat Solid plug Seat retaining plug with port Bushing Check spring Spool cap Reelmaster 3100−D 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Valve body O−ring Retaining ring Washer Seat retaining plug Spool spring Disc Plug Detent plug Wiper seal Page 4 − 93 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.
Disassembly Assembly 1. Plug all ports and clean the outside of the valve thoroughly. IMPORTANT: Do not wipe parts with paper towels or rags. Lint may cause damage to the hydraulic system. IMPORTANT: Match mark spools to their associated bores. Spools must be reinstalled to the bore from which they were removed. 2. Remove both spool caps and slide the spool assemblies from their bores. 3. Remove O−ring and bushing from each spool assembly. 4.
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Piston Pump 26 10 27 28 25 45 50 49 25 53 54 12 9 47 24 7 44 8 1 44 43 5 42 32 29 45 56 Antiseize Lubricant 48 30 57 3 33 40 13 55 27 Antiseize Lubricant 6 4 10 18 31 38 51 27 to 31 ft−lb (37 to 42 N−m) 40 34 37 41 2 41 11 20 10 RIGHT 30 36 21 35 90 to 120 in−lb (10.2 to 13.6 N−m) 39 22 19 16 FRONT 52 23 17 52 15 14 19 Figure 62 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
Neutral Arm Assembly 30 EARLY MODELS 5 22 36 6 7 7 4 3 9 32 2 12 23 1 8 24 31 11 18 21 34 33 10 9 14 29 20 12 13 25 17 35 28 27 16 33 34 19 Figure 63 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Philips head screw Flat washer Micro switch Keps nut Neutral bracket Flange nut Flange head nut Neutral arm Flange bushing Thrust washer 90o grease fitting Lock nut 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36.
C. Disconnect traction control cable from the pump lever. 9 6 D. Remove both flange head screws securing the neutral bracket to the piston pump. Remove flange nut and flange head screw securing the neutral bracket to the pump mount plate. 2 8 13 14 12 11 5 E. Remove cap screw and flat washer securing the pump lever to the piston pump trunnion. 10 7 7 F. Separate pump lever from pump trunnion and neutral bracket from mount plate. 1 4.
10.Install neutral arm assembly to the piston pump as follows (Figs. 63 and 64): 1. If hydraulic fittings were removed, install fittings to pump using marks made during the removal process to properly orientate fittings. 2. Place key into pump shaft slot. Slide taper lock bushing onto the piston pump shaft with bushing flange toward pump housing. 3. Make sure that tapered surfaces of pulley and taper lock bushing are thoroughly clean (no oil, grease, dirt, rust, etc.). 4.
Piston Pump Service 22 19 27 48 47 42 21 46 18 45 44 22 38 17 16 23 43 13 4 15 12 28 11 5 20 39 6 29 19 10 17 24 26 15 8 18 36 14 49 41 37 9 EATON MODEL 70160−LAA−01 8 3 26 6 2 7 1 25 28 31 35 34 33 30 31 30 50 4 32 51 40 52 53 Figure 66 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
Piston Pump Crush Ring Replacement 4 5 8 7 29 ft−lb (39 N−m) 2 v 3 9 10 Hydraulic System 6 1 Figure 67 1. 2. 3. 4. Crush ring Shims Cover plate Housing 5. 6. 7. Cam plate (control shaft) Bearing cone Bearing cup NOTE: The shims replace the crush ring in the piston pump cover plate on Reelmaster 3100−D machines with serial numbers above 90775.
Sidewinder (Models 03201, 03207 and 03171) 18 26 17 19 19 14 14 13 26 13 1 13 25 9 11 1 20 15 31 2 1 10 7 12 3 16 6 28 5 21 27 4 22 24 1 8 28 30 23 29 27 Figure 69 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Plastic bushing Scissor link Scissor mount Cap screw Flat washer Lock nut Scissor frame Hydraulic cylinder Spacer Flat washer Cap screw Hydraulic System 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
Removal WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved. See Relieving Hydraulic System Pressure in the General Information section. 4 3 2 1. Remove hydraulic cylinder from the frame using Figure 68 as guide. 1 2. If hydraulic fittings are to be removed from cylinder, mark fitting orientation to allow correct assembly. Figure 69 1. Scissor frame 2. Lower frame Installation 3. Sidewinder carrier 4. Gaps 1.
Steering Control Valve 17 21 8 9 39 40 14 20 7 10 20 to 26 ft−lb (27.1 to 35.3 N−m) 32 11 27 33 28 12 2 4 6 36 5 19 19 38 18 36 22 18 24 29 23 3 1 25 19 2 37 26 15 2 16 31 13 30 8 41 3 Figure 70 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Steering arm Flange nut Flange head screw Steering valve bracket Cap screw Pivot hub Steering cover Cap screw Toro decal Ball knob Lever Steering control valve Tilt bracket Cap screw Hydraulic System 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.
Removal 2 1 WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved. See Relieving Hydraulic System Pressure in the General Information section. 1. Remove steering control valve from the steering column using Figures 70, 71, and 72 as guides. 3 4 6 Installation 5 8 7 1. Install steering control valve to the steering column using Figures 70, 71, and 72 as guides. Figure 71 1. 2. 3. 4. 5. 6. 7. 8.
Steering Control Valve Service (Serial Numbers 90101 to 230999999) 1 2 2 49 5 3 4 17 8 3 9 18 3 34 6 12 19 14 20 48 13 21 3 22 10 11 36 11 23 33 15 11 24 7 3 25 16 26 27 37 28 38 29 39 31 32 40 41 Figure 73 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Nut Port cover Seal ring O−ring Relief valve cartridge Plug Push nut Port manifold Spring Drive assembly Alignment pin Valve ring Valve plate Spring Isolation manifold Drive link Metering ring 18. 19. 20. 21.
Steering Control Valve Service (Serial Numbers 240000001 and up) 8 9 7 6 10 5 4 3 2 11 1 12 22 13 14 15 21 13 16 20 17 18 20 to 24 ft−lb (27 to 33 N−m) 19 Figure 74 1. 2. 3. 4. 5. 6. 7. 8. Sleeve Cross pin Ring Spool Bearing assembly Shaft seal Ball stop Ball 9. 10. 11. 12. 13. 14. 15. Dust seal ring Housing Cardan shaft Spacer O−ring Distribution plate Inner gearwheel 16. 17. 18. 19. 20. 21. 22.
Gear Pump 8 5 4 11 7 1 14 16 10 15 2 12 13 27 to 31 ft−lb (37 to 42 N−m) 14 3 6 9 Figure 75 1. 2. 3. 4. 5. 6. Piston pump Gear pump Hydraulic hose (tank suction) Hydraulic hose (hydraulic manifold) Hydraulic hose (steering valve) Hose clamp Hydraulic System 7. 8. 9. 10. 11. O−ring O−ring Hydraulic barb fitting 90o hydraulic fitting 90o hydraulic fitting Page 4 − 108 12. 13. 14. 15. 16.
Removal Installation 1. Remove muffler from the engine to gain access to the gear pump (see Muffler Removal in Chapter 3 − Kubota Diesel Engine). 1. If hydraulic fittings were removed, install fittings to motor using marks made during the removal process to properly orientate fittings. 2. Drain hydraulic oil from hydraulic tank (see Change Hydraulic Fluid in this section). IMPORTANT: Position gear pump to the piston pump so that the gear pump suction port is facing down. 2.
Gear Pump Service 11 17 1 18 12 8 10 25 to 28 ft−lb (34 to 38 N−m) 9 19 20 5 3 12 6 14 16 13 12 2 8 10 9 7 4 12 Figure 76 1. 2. 3. 4. 5. 6. 7. Front plate Back plate Front body Rear body Drive gear Idler gear Idler gear Hydraulic System 8. 9. 10. 11. 12. 13. 14. Back−up gasket Wear plate Pressure seal Cap screw O−ring Adapter Plate Key Page 4 − 110 15. 16. 17. 18. 19. 20.
Disassembly (Fig. 76) MARKER LINE 1. Plug pump ports and clean the outside of the pump thoroughly. After cleaning, remove plugs and drain any oil out of the pump. 2. Make sure key is removed from the shaft of the drive gear. 3. Use a marker to make a diagonal line across the front plate, front body, adapter plate, rear body, and back plate for assembly purposes (Fig. 77). IMPORTANT: Avoid using excessive clamping pressure on the pump housing to prevent distorting the housing. Figure 77 4.
D. Gears should be free of excessive scoring and wear. 2 E. Make sure drive and idler gears have their snap rings in the grooves on each side. F. Break sharp edges of gear teeth with emery cloth. G. Gear width on the drive gear and front idler gear should not be less than 0.384 inch (9.75 mm). Gear width on the back gear and back idler gear should not be less than 0.244 inch (6.20 mm). 2 1 4. Inspect body for the following: Figure 78 A. Gear pockets should be free of excessive scoring and wear. 1.
IMPORTANT: Do not dislodge seals during installation. 12.Install wear plate into the gear pocket of back body with the pressure seal and back−up gasket against the adapter plate. Make sure mid section cut−away of the wear plate is on the suction side of the pump. 13.Lubricate back gear with clean hydraulic oil. Install gear onto the drive gear shaft and key. 15.Install new O−ring into the groove of the back plate. 16.Align marker line on the back plate and body.
Front Lift Cylinder 9 29 6 3 29 12 7 16 30 4 5 28 15 29 31 21 13 20 23 26 24 17 28 21 38 18 22 34 39 11 20 41 26 27 10 33 32 37 40 37 14 25 13 8 24 35 19 36 1 2 1 Figure 80 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 11. 12. 13. 14.
Removal 2 1. Remove front lift cylinder from the frame and lift arm using Figure 80 as guide. 3 2. If hydraulic fittings are to be removed from lift cylinder, mark fitting orientation to allow correct assembly. Installation 1. If hydraulic fittings were removed, install fittings to cylinder using marks made during the removal process to properly orientate fittings. IMPORTANT: With lift arms raised fully, hydraulic hoses should be routed as shown in Figure 81.
Rear Lift Cylinder 55 3 58 16 12 13 11 6 5 48 37 21 41 39 56 10 29 24 28 36 30 46 54 2 2 4 48 13 38 17 15 5 18 4 53 57 47 9 14 22 35 46 31 27 21 57 44 1 7 48 8 32 45 2 20 34 49 33 48 3 48 48 23 50 25 26 2 43 42 1 19 7 Figure 82 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Removal Installation 1. Remove rear lift cylinder from the frame and lift arm using Figure 82 as guide. 1. If hydraulic fittings were removed, install fittings to lift cylinder using marks made during the removal process to properly orientate fittings. 2. If hydraulic fittings are to be removed from lift cylinder, mark fitting orientation to allow correct assembly. 2. Install rear lift cylinder to the frame and lift arm using Figure 82 as guide. Hydraulic System 3.
Lift Cylinder Service 2 3 4 5 1 6 7 8 9 10 11 12 13 14 24 to 30 ft−lb (33 to 41 N−m) 15 1 1 2 9 12 13 3 5 4 6 7 8 10 11 14 15 1 Figure 83 1. 2. 3. 4. 5. Grease fitting Barrel with clevis Nut Uni−ring Piston Hydraulic System 6. 7. 8. 9. 10. O−ring O−ring Back−up ring Rod seal Head Page 4 − 118 11. 12. 13. 14. 15.
Disassembly Assembly 1. Remove oil from lift cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder. 1. Make sure all parts are clean before reassembly. 2. Mount lift cylinder in a vice. Remove internal collar with a spanner wrench. 3. Extract shaft, head, and piston by carefully twisting and pulling on the shaft. IMPORTANT: Do not clamp vise jaws against the shaft surface. Protect shaft surface before mounting in a vice. 4.
Steering Cylinder 7 8 3 1 6 4 5 8 5 No. 2 General Purpose Grease 2 7 10 3 No. 2 General Purpose Grease 9 4 65 to 85 ft−lb (88 to 115 N−m) 12 9 11 65 to 85 ft−lb (88 to 115 N−m) Figure 84 1. 2. 3. 4. Hydraulic hose Hydraulic hose O−ring Hydraulic fitting Hydraulic System 5. 6. 7. 8. O−ring Steering cylinder Ball joint Retaining ring Page 4 − 120 9. 10. 11. 12.
Removal 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2 1 NOTE: The rear tire must be removed to allow sufficient clearance to remove the steering cylinder from the machine. Figure 85 WARNING 1. Steering cylinder 2. Jam nuts Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 − Safety. 3 2. Jack or lift rear wheel off the ground. 2 3.
Steering Cylinder Service 1 11 12 10 9 8 7 6 5 4 3 2 2 24 to 30 ft−lb (33 to 41 N−m) 3 4 1 5 8 6 9 10 11 7 12 Figure 87 1. 2. 3. 4. Barrel Lock nut Piston Uni−ring Hydraulic System 5. 6. 7. 8. O−ring Piston rod Rod seal Cylinder gland Page 4 − 122 9. 10. 11. 12.
Disassembly Reassembly 1. Remove oil from the steering cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder. 1. Make sure all parts are clean before reassembly. IMPORTANT: Prevent damage when clamping the hydraulic cylinder into a vise; clamp on the clevis only. 2. Mount clevis end of steering cylinder in a vice. Remove retaining ring. 3. Extract shaft, head, and piston by carefully twisting and pulling on the shaft.
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Chapter 5 Electrical System Table of Contents Reelmaster 3100--D ELECTRICAL SYSTEM QUICK CHECKS . . . . . . . Battery Test (Open Circuit) . . . . . . . . . . . . . . . . . . Charging System Test . . . . . . . . . . . . . . . . . . . . . . Glow Plug System Test . . . . . . . . . . . . . . . . . . . . . Check Operation of Interlock Switches . . . . . . . . COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glow Relay . . .
Page 5 -- 2 OR 1 GN OR PK BLUE BROWN FUSIBLE LINK BN BK D2 PINK I Y X A B S W VIO T R WHITE VIOLET TAN RED (+) F4 5A OR BK (--) SP R/BK Y BU PK F3 5A SPLICE RED/BLACK YELLOW PK W HOUR HR METER (+) IGNITION SW.
Page 5 -- 3 OR PK BROWN FUSIBLE LINK GN BLUE BN OR 1 BK D2 PINK I Y X A B S W VIO T R WHITE VIOLET TAN RED (+) W F4 5A OR BK (--) HOUR HR METER (+) SP R/BK Y BU PK F3 5A GY PK SPLICE RED/BLACK YELLOW PK IGNITION SW.
Page 5 -- 4 OR PK BROWN FUSIBLE LINK GN BLUE BN OR 1 BK D2 PINK I Y S X A B W VIO T R Y WHITE VIOLET TAN RED (+) F4 5A OR BK (--) SP R/BK Y BU PK F3 5A GY PK SPLICE RED/BLACK YELLOW PK W HOUR HR METER (+) IGNITION SW.
Page 5 -- 5 OR PK FUSIBLE LINK BU BROWN GN BN OR D2 PINK I Y X A B Y W VIO T R WHITE VIOLET TAN RED (+) F4 5A OR BK (--) SP R/BK Y BU PK F3 5A GY PK SPLICE RED/BLACK YELLOW PK W HOUR HR METER (+) IGNITION SW.
Page 5 -- 6 OR PK BROWN FUSIBLE LINK GN BLUE BN OR D2 PINK I Y S X A Y W VIO T R WHITE VIOLET TAN RED (+) F4 5A OR BK (--) SP R/BK Y BU PK F3 5A GY PK SPLICE RED/BLACK YELLOW PK W HOUR HR METER (+) IGNITION SW.
Page 5 -- 7 OR PK BROWN FUSIBLE LINK GN BLUE BN OR D2 PINK I Y S X A Y W VIO T R WHITE VIOLET TAN RED (+) F4 5A OR BK (--) SP R/BK Y BU PK F3 5A GY PK SPLICE RED/BLACK YELLOW PK W HOUR HR METER (+) IGNITION SW.
ENGINE GROUND J3 HOUR P22 METER (+) A B (--) C 1 2 3 4 5 30 85 NTERLOCK P10 87A RELAY 87 86 J18 1 2 3 4 5 6 I P14 1 2 3 4 5 TEMP GLOW GND GAUGE CLUSTER P11 (+) BATTERY OIL PRESS IGNTION SWITCH X Y A B S W54 W21 W22 W64 W63 W25 W62 W16 W23 W17 W18 W64 W13 W20 W21 W5 W15 W16 W26 J16 J17 DIODE D2 W55 SP2 W57 W8 W3 SP6 W14 P9 HIGH TEMP SHUT DOWN RELAY P2 RUN SOLENOID J4 W22 W32 J6 W63 J12 W33 W57 W58 SP3 P15 W34 W62 W60 A B W40 W40 SP1 W52 1 2 3 W56 W26 W1
LABEL COLOR ROUTE FROM TO LABEL COLOR ROUTE FROM TO W1 RED P23--3 J7 W33 RED/BLACK J12 P2--3 (2) W2 RED P23--1 P16--1 W34 RED/BLACK P2--3 (2) J15 (2) W3 ORANGE P16--2 P14--4 W35 RED/BLACK J15 (2) J9 (2) W4 BLUE P16--4 J13 W36 NOT USED W5 YELLOW P16--5 J18 W37 GREEN P17--B J20 (2) W6 VIOLET P9--1 P16--6 (2) W38 TAN P6--B J19 (2) W7 VIOLET P16--6 (2) P9--2 W39 R 66465 P20 SP1 (2) W8 WHITE P16--7 P14--3 W40 WHITE SP1 (2) P2--1 W9 PINK P16--8
PK Page 5 -- 10 B+ G Start OR 1 OR PK BROWN FUSIBLE LINK BN GY GN BLUE ENGINE D2 PINK ORANGE GREEN 2 Y (+) W VIOLET WHITE W TAN T VIO RED R PK F4 5A SP R/BK Y BU IGNITION SWITCH F3 5A OR BK (--) HR BATTERY STOP -------- NONE RUN -------- B+I+A; X+Y START ------ B+I+S I Y X A S Y (--) GY FUEL PUMP ENGINE GROUND SP W B FRAME GROUND GRAY OPTIONAL LIGHT KIT BU OR BLACK F2 F1 15 A OR BK (PULL) (HOLD) ENG LOW OIL PRESSURE STARTER BK R (CLOSES AT
PK Page 5 -- 11 OR 1 OR PK BROWN FUSIBLE LINK GN BLUE BN GY D2 PINK ORANGE GREEN 2 X Y Y S (+) W VIOLET WHITE W TAN T VIO RED R PK F4 5A SP R/BK Y BU IGNITION SWITCH F3 5A OR BK (--) HR BATTERY STOP -------- NONE RUN -------- B+I+A; X+Y START ------ B+I+S I A Y (--) GY FUEL PUMP ENGINE GROUND SP W B FRAME GROUND GRAY OPTIONAL LIGHT KIT BU OR BU F2 F1 15 A OR ENGINE STARTER BLACK R BK (PULL) (HOLD) ENG LOW OIL PRESSURE B+ G Start (CLOSES AT
PK Page 5 -- 12 B+ G Start OR 1 OR PK BROWN FUSIBLE LINK BN GY GN BLUE BK ENGINE D2 PINK ORANGE GREEN 2 Y (+) W VIOLET WHITE W TAN T VIO RED R PK F4 5A SP R/BK Y BU IGNITION SWITCH 5A F3 OR BK (--) HR BATTERY STOP -------- NONE RUN -------- B+I+A; X+Y START ------ B+I+S I Y X A S Y (--) GY FUEL PUMP ENGINE GROUND SP W B FRAME GROUND GRAY OPTIONAL LIGHT KIT BU OR BLACK F2 F1 15 A OR (PULL) (HOLD) ENG LOW OIL PRESSURE STARTER BK R (CLOSES AT
PK Page 5 -- 13 OR 1 OR PK BROWN FUSIBLE LINK BN GY GN BLUE ENGINE D2 PINK ORANGE GREEN 2 Y (+) W VIOLET WHITE W TAN T VIO RED R PK F4 5A SP R/BK Y BU IGNITION SWITCH F3 5A OR BK (--) HR BATTERY STOP -------- NONE RUN -------- B+I+A; X+Y START ------ B+I+S I Y X A S Y (--) GY FUEL PUMP ENGINE GROUND SP W B FRAME GROUND GRAY OPTIONAL LIGHT KIT BU OR BLACK F2 F1 15 A OR STARTER BK R BK ENG LOW OIL PRESSURE B+ G Start (CLOSES AT 105oC) (CLOSES A
PK Page 5 -- 14 B+ G Start OR 1 OR PK BROWN FUSIBLE LINK BN GY GN BLUE ENGINE D2 PINK ORANGE GREEN 2 Y (+) W VIOLET WHITE W TAN T VIO RED R PK F4 5A SP R/BK Y BU IGNITION SWITCH F3 5A OR BK (--) HR BATTERY STOP -------- NONE RUN -------- B+I+A; X+Y START ------ B+I+S I Y X A S Y (--) GY FUEL PUMP ENGINE GROUND SP W B FRAME GROUND GRAY OPTIONAL LIGHT KIT BU OR BLACK F2 F1 15 A OR BK (PULL) (HOLD) ENG LOW OIL PRESSURE STARTER BK R (CLOSES AT
PK Page 5 -- 15 OR 1 OR PK BROWN FUSIBLE LINK GN BLUE BN GY ENGINE D2 PINK ORANGE GREEN 2 X Y Y S (+) W VIOLET WHITE W TAN T VIO RED R PK F4 5A SP R/BK Y BU IGNITION SWITCH F3 5A OR BK (--) HR BATTERY STOP -------- NONE RUN -------- B+I+A; X+Y START ------ B+I+S I A Y (--) GY FUEL PUMP ENGINE GROUND SP W B FRAME GROUND GRAY OPTIONAL LIGHT KIT BU OR BU F2 F1 15 A OR STARTER BLACK R BK (PULL) (HOLD) ENG LOW OIL PRESSURE B+ G Start (CLOSES AT
P22 J3 HOUR METER ENGINE GROUND (--) W54 A B C W5 W26 SP2 W3 J16 J17 DIODE D2 W55 W63 W22 W25 W62 (+) P10 W16 W23 1 2 3 4 5 30 85 87A 87 86 W5 W8 W15 W16 W17 W18 W64 W13 W20 W21 1 2 3 4 5 W4 1 2 3 4 5 6 I X Y A B S J13 HIGH TEMP GLOW GROUND (+) BATTERY OIL PRESS J18 P14 INTERLOCK RELAY P11 GAUGE CLUSTER IGNITION SWITCH (OPTIONAL LIGHT) W8 W56 W57 W9 W7 P9 HIGH TEMP SHUT DOWN RELAY P2 RUN SOLENOID 1 2 3 W40 W40 SP1 1 2 3 4 5 W6 W27 W32 W10 W6 W14 W25 W26 W39
LABEL COLOR ROUTE FROM TO LABEL COLOR ROUTE FROM TO W1 RED P23--3 J7 W33 RED/BLACK J12 P2--3 (2) W2 RED P23--1 P16--1 W34 RED/BLACK P2--3 (2) J15 (2) W3 ORANGE P16--2 P14--4 W35 RED/BLACK J15 (2) J9 (2) W4 BLUE P16--4 J13 W36 NOT USED W5 YELLOW P16--5 J18 (2) W37 GREEN P17--B J20 (2) W6 VIOLET P9--1 P16--6 (2) W38 TAN P6--B J19 (2) W7 VIOLET P16--6 (2) P13--3 (2) W39 R 66465 P20 SP1 (2) W8 YELLOW P16--7 J18 (2) W40 WHITE SP1 (2) P2--1 W9 P
Electrical Systems Page 5 -- 18 Reelmaster 3100--D P1 J2 J1 GLOW RELAY J4 OIL SWITCH P8 J7 ALTERNATOR P23 START SOLENOID P19 START SOLENOID P20 G J12 FUEL PUMP P17 J6 D2 TEMP SWITCH GLOW PLUG NEUTRAL SWITCH J5 P2 FUEL SOLENOID J3 ENGINE GROUND P4 SEAT SWITCH D3 SEAT SWITCH P5 P6 P21 PARKING BRAKE P18 TRANSPORT/MOW SWITCH D1 J8 J9 BACKLAP SWITCH P7 P8 SEAT RELAY REEL UP/DOWN SWITCH FUSE BLOCK P16 P9 OVERTEMP RELAY J10 Serial Numbers 90151 to 230999999 P11
R PK Page 5 -- 19 1F 2 10 A 1F 1 15 A W I X BU B+ G Start A Y BU OR B S FL FL FL R/BK X B OFF RUN Y A S I T START IGNITION SW STOP -------- NONE RUN -------- B+I+A; X+Y START ------ B+I+S FRAME GROUND Y OR (+) BK 1F 4 10 A W 1F 3 10 A BATTERY (--) ENGINE ENGINE GROUND SP FUSIBLE LINK R GLOW PLUGS (3) FUEL PUMP GN GY R/BK BU/W 110C OVER TEMP SHUTDOWN ENGINE OIL PRESSURE 105C OVER TEMP WARNING W GLOW RELAY (PULL) 87 30 85 K4 VIO 86 R R L PK PK VIO R/BK
GRAY PINK PINK GREEN PINK YELLOW ORANGE BLUE WHITE TAN RED/BLACK WHITE BLUE/WHITE BLACK FUSIBLE LINK WHITE BLUE PINK Page 5 -- 20 RED RED RED VIOLET BLACK ORANGE RED/BLACK PINK BLUE Electrical Systems Reelmaster 3100--D GREEN BLACK VIOLET WHITE/BLACK BLUE BLACK PINK PINK BROWN BLACK (SERIAL NUMBERS FROM 260000001 TO 270999999) BLACK BLACK YELLOW BLACK BLACK YELLOW GREEN ORANGE PINK GRAY BLACK (SERIAL NUMBERS FROM 240000001 TO 270999999) Serial Numbers 240000
Reelmaster 3100--D Page 5 -- 21 Electrical Systems Electrical System (SERIAL NUMBERS FROM 260000001 TO 270999999) (SERIAL NUMBERS FROM 240000001 TO 270999999) Serial Numbers 240000001 to 270999999 Reelmaster 3100--D Harness Diagram
GRAY PINK PINK PINK GREEN YELLOW ORANGE BLUE WHITE PINK Page 5 -- 22 TAN WHITE PINK RED/BLACK BLUE/WHITE BLACK BLACK ORANGE RED/BLACK PINK VIOLET BLUE FUSIBLE LINK WHITE RED RED GREEN BLACK VIOLET WHITE/BLACK BLUE BLACK PINK PINK BLACK BLACK Serial Numbers 280000001 to 314000000 YELLOW GREEN ORANGE PINK ORANGE Reelmaster 3100--D Wiring Diagram BLACK BLACK BLACK BLACK TAN BROWN BROWN BLACK BLUE GRAY Electrical Systems Reelmaster 3100--D BLACK PINK BLACK
Reelmaster 3100--D Page 5 -- 23 Electrical Systems Electrical System Serial Numbers 280000001 to 314000000 Reelmaster 3100--D Harness Diagram
Electrical Systems Page 5 -- 24 Reelmaster 3100--D 122--0260 Rev.
Reelmaster 3100--D Page 5 -- 25 Electrical Systems Electrical System 122--0258 Rev.
Electrical Systems Page 5 -- 26 Reelmaster 3100--D CV Electrical System 122--0258 Rev.
Reelmaster 3100--D Page 5 -- 27 Electrical Systems Electrical System 122--1522 Rev.
Electrical Systems Page 5 -- 28 Reelmaster 3100--D 122--1523 Rev.
Reelmaster 3100--D Page 5 -- 29 Electrical Systems CV Electrical System 122--1523 Rev.
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Special Tools Order special tools from your Toro Distributor. Some tools may also be available from a local supplier. Multimeter The meter can test electrical components and circuits for current, resistance, or voltage. NOTE: Toro recommends the use of a DIGITAL Volt-Ohm--Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode will make sure that excess current is not allowed through the meter.
Troubleshooting For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components used on this machine (see Electrical Schematics and Diagrams section of this chapter). CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage.
Starting Problems (continued) Problem Possible Causes Engine cranks, but does not start. Wiring in the crank circuit (see Electrical Schematics) is loose, corroded, or damaged. Engine run solenoid or fuel pump faulty. The fuel tank is empty. An engine or fuel system problem exists. The glow circuit does not operate properly. The glow circuit does not operate properly. Wiring in the glow circuit (see Electrical Schematics) is loose, corroded, or damaged. The glow relay or glow plug controller is faulty.
General Run and Transport Problems Engine kills during operation (operator sitting on seat). Operator moved too far forward on seat (seat switch is not depressed). The engine overheated. The parking brake was engaged or the parking brake switch No. 1 failed. The seat relay or seat switch failed. The high temperature shutdown relay failed. Fuse F1 or F3 failed. The run solenoid or fuel pump failed. Wiring in the run circuit (see Electrical Schematics) broke or disconnected.
Cutting Unit Operating Problems The cutting units will not run with the transport mow switch in MOW and the reel on/off switch in ON with the cutting units lowered. Wiring to the reel drive circuit is (see Electrical Schematics) is loose, corroded, or damaged. Fuse F4 is faulty or blown. The coil to solenoid valve S1 on the hydraulic manifold is faulty or the valve is stuck. The reels on/off is faulty. The reels up limit or transport/mow switch is faulty or misadjusted.
Electrical System Quick Check Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the battery terminals. Set multimeter to the DC volts setting. The battery should be at a temperature of 60 to 100oF (16 to 38oC). The ignition key should be off and all accessories turned off. Connect the positive (+) meter lead to the positive battery post and the negative (--) meter lead the the negative battery post. Voltage Measured Battery Charge Level 12.
Check Operation of Interlock Switches 2. With operator on the seat, the engine must not start with either the reel switch engaged or the traction pedal engaged. Correct problem if not operating properly. CAUTION Do not disconnect safety switches. They are for the operator’s protection. Check the operation of the interlock switches daily for proper operation. Replace any malfunctioning switches before operating the machine. Note: The machine is equipped with an interlock switch on the parking brake.
Component Testing For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before doing a continuity check). NOTE: For more component testing information, see the Kubota Workshop Manual, Diesel Engine, 05 Series. CAUTION When testing electrical components for continuity with a multimeter (ohms setting), make sure that power to the circuit has been disconnected.
Glow Relay The glow relay is attached to the radiator assembly. When energized, the glow relay allows electrical current to the engine glow plugs. Two styles of glow relays have been used on the Reelmaster 3100--D. On machines with serial numbers below 240000000, two of the four relay connections are secured with screws (Fig. 6). Machines with serial numbers above 240000000 are connected to the wire harness with a four wire connector (Fig. 7). 86 87 85 30 87 85 30 86 Figure 6 1.
Hour Meter 1. Connect the positive (+) terminal of a 12 VDC source to the positive terminal of the hour meter. Hobbs 2. Connect the negative (--) terminal of the voltage source to the other terminal of the hour meter. QUARTZ 00001 HOURS 3. The hour meter should move a 1/10 of an hour in six minutes. 1 10 + 4. Disconnect the voltage source from the hour meter. BACK Figure 9 Reel Drive Solenoid Note: Prior to taking small resistance readings with a digital multimeter, short the test leads together.
High Temperature Warning and Shutdown Switches The high temperature warning and shut down switches are located on the water pump, which is located on the rear end of the engine block. The high temperature shutdown switch is on the alternator side of the engine (Fig. 11). 2 1 CAUTION Make sure engine is cool before removing the temperature switch. 1. Lower coolant level in the engine and remove the temperature switch. 2. Put switch in a container of oil with a thermometer and slowly heat the oil (Fig.
Diode Assemblies The diode D1 and D2 provide logic for the interlock switches. Diode D3 is used for circuit protection from inductive voltage spikes when the interlock relay is deenergized. Machines equipped with the standard control module (serial numbers above 240000000) use only one diode. Two types of diodes have been used on the Reelmaster 3100--D: 1. On early production machines, the diodes are located within the main wiring harness that lies under the hydraulic tank and control console (Fig. 13).
Warning Light Cluster (Serial Numbers Below 240000000) Note: Individual light bulbs can be tested by removing them from the lighting cluster and applying 12 VDC to their wiring terminals. Oil Pressure Light The oil pressure light should come on when the ignition switch is in the ON position with the engine not running. Also, it should light with the engine running when the oil pressure drops below 4 PSI (0.3 kg/cm2).
Indicator Lights (Serial Numbers Above 240000000) Charge Indicator Light 2 3 The charge indicator light should come on when the ignition switch is in the ON position with the engine not running. Also, it should illuminate with an improperly operating charging circuit while the engine is running. 4 1 Engine Oil Pressure Light The engine oil pressure light should come on when the ignition switch is in the ON position with the engine not running.
Fuel Pump The fuel pump is attached to the frame just outboard of the fuel injection pump. 2 4 Operational Test 1 1. Park machine on a level surface, lower cutting units, stop engine, and engage parking brake. 2. Disconnect electrical connector from the fuel stop solenoid to prevent the engine from firing. 3. Disconnect fuel hose (pump discharge) from the fuel filter. Figure 19 1. Fuel pump 2. Fuel hose (discharge) 3. Fuel filter 4. Fuel stop solenoid 5.
Fuel Stop Solenoid (Solenoid With 3 Wire Connector) The fuel stop solenoid must be energized for the engine to run. It is mounted on the engine block near the injection pump (Fig. 20). 2 The fuel stop solenoid includes two coils for operation: the pull coil and the hold coil. When the ignition switch is turned to START, the fuel stop solenoid is initially energized and the pull coil retracts the solenoid plunger.
Fuel Stop Solenoid (Solenoid With 2 Wire Connector) The fuel stop solenoid used on the Reelmaster 3100--D must be energized for the diesel engine to run. The solenoid is mounted to the injection pump on the engine (Fig. 22). The fuel stop solenoid includes two coils for operation: the pull coil and the hold coil. When the ignition switch is turned to START, the fuel stop solenoid is initially energized and the pull coil retracts the solenoid plunger.
Glow Controller The controller is located under the right lower corner of the instrument panel. 2 Note: Refer to Electrical Schematics and Diagrams at the beginning of the chapter when troubleshooting the controller. 3 6 2 5 Controller Operation 1 4 1. When the ignition switch is placed in the RUN position, the controller energizes the glow plugs and lights up the glow lamp for 10 seconds.
Standard Control Module Reelmaster 3100--D machines with Serial Numbers above 240000000 are equipped with a Standard Control Module to monitor and control electrical components required for safe operation. This Module is attached to the back of the instrument panel. Inputs from the neutral, parking brake, PTO, start (ignition), backlap, and high temperature switches are monitored by the Module.
Service and Repairs NOTE: For more component repair information, see the Kubota Workshop Manual, Diesel Engine, 05 Series. Battery Storage If the machine will be stored for more than 30 days: 1. Remove the battery and charge it fully (see Battery Service). 4. Store battery in a cool atmosphere to avoid quick deterioration of the battery charge. 5. To help prevent the battery from freezing, make sure it is fully charged (see Battery Service). 2. Either store battery on a shelf or on the machine. 3.
Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extend. Additionally, battery and electrical component failure can be prevented. 2 CAUTION When working with batteries, use extreme caution to avoid splashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes. Always wear safety goggles and a face shield when working with batteries. 1 Figure 26 Electrolyte Specific Gravity Fully charged: 1.
2. Conduct a hydrometer test of the battery electrolyte. D. Measure the temperature of the center cell. IMPORTANT: Make sure the area around the cells is clean before opening the battery caps. E. Connect a battery load tester to the battery terminals following the manufacturer’s instructions. Connect a digital multimeter to the battery terminals. A. Measure the specific gravity of each cell with a hydrometer.
6. Apply a light coat of grease on all battery posts and cable connectors to reduce corrosion after connections are made. 7. Connect a digital multimeter (set to amps) between the negative battery post and the negative (ground) cable connector. The reading should be less than 0.1 amp. If the reading is 0.1 amp or more, the unit’s electrical system should be tested and repaired. 8. Connect negative (ground) cable connector to the negative battery post. Tighten cap screw and lock nut with two wrenches.
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Chapter 6 Wheels, Brakes, and Miscellaneous Table of Contents 2 2 3 3 4 4 Deluxe Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Front Wheel and Brake . . . . . . . . . . . . . . . . . . . . . . 6 Rear Fork and Wheel . . . . . . . . . . . . . . . . . . . . . . . . 8 Brake Linkages . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Wheels, Brakes, and Miscellaneous SPECIFICATIONS . . . . . . . . . . .
Specifications Item Description Tire pressure 14 to 18 PSI (0.97 to 1.24 bar) Wheel lug nut torque 45 to 65 ft−lb (61 to 88 N−m) Special Tools Wheel Hub Puller Part Number: TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors.
Adjustments Adjust Brake C. If brakes can not be adjusted properly, repair or replace brake components as necessary. CAUTION D. After adjustment is complete, install front wheel assemblies to the machine (see Front Brake and Wheel Installation in the Service and Repairs section). Before and after adjusting the brakes, always check the brakes in a wide open area that is flat and free of other persons and obstructions. E. Lower front wheels to the ground. 1.
Service and Repairs Standard Seat 8 3 2 4 5 1 6 7 8 3 2 15 14 9 13 16 12 11 16 10 10 17 16 Figure 5 1. 2. 3. 4. 5. 6. Seat (incl. 4 thru 7, 14, &15) Cap screw Spring lock washer Edging clip Edging Seat cushion (repair kit) 7. 8. 9. 10. 11. 12. Seat shell Seat belt Seat adjuster with latch Flange hex nut Cap screw Lock washer 13. Seat adjuster 14. Cap screw 15. Seat switch 16. Hex flange head screw 17. Seat support strap Removal Installation 1.
Deluxe Seat 39 3 4 42 40 41 7 32 8 9 5 6 1 2 43 38 44 45 12 10 37 36 33 35 34 23 31 24 5 30 29 28 27 26 25 11 14 22 13 19 21 49 20 50 16 50 15 18 48 47 17 45 44 43 49 46 Plate Rivet Screw Wear parts kit (incl. 8 thru 11) Tension spring set Handle grip Adjusting lever Cover Bumper Bushing Pad Backrest cushion Hex head machine screw Arm rests Bottom cushion Adjusting rail (LH) Screw 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34.
Front Wheel and Brake 33 31 9 25 26 11 29 30 27 22 7 32 18 28 14 17 23 24 16 8 3 10 20 41 12 13 15 21 19 2 17 5 RIGHT FRONT 4 1 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Lug nut Drive stud Wheel rim Tire Wheel hub Lock nut Hydraulic motor Brake drum Woodruff key Cotter pin Adjustment rod 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Figure 7 Brake lever Lock nut Cap screw Brake bracket Return spring Brake shoe Backing plate Cam shaft Retainer Clip Lock nut Cap screw Removal (Fig. 7) 1.
IMPORTANT: Do not hit wheel hub, wheel hub puller or wheel motor with a hammer during removal or installation. Hammering may cause damage to the hydraulic wheel motor. 5. Using hub puller (see Special Tools), loosen wheel hub from wheel motor. 6. Remove lock nut, hub, and brake drum from motor shaft. Locate and retrieve woodruff key. a complete brake assembly, secure backing plate to the brake bracket with four cap screws and lock washers. Tighten fasteners. 4. Attach adjustment rod to the brake lever.
Rear Fork and Wheel 35 2 34 25 33 4 3 6 1 21 8 27 10 9 36 16 25 28 29 24 4 22 23 26 30 6 14 28 19 17 11 20 38 32 17 31 7 37 12 15 2 39 13 3 18 5 Figure 9 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Hydraulic cylinder Ball joint External retaining ring Grease fitting Grease fitting plug Jam nut Rear fork Cap screw Lock washer Thrust washer Tire Hex socket head screw Lock nut 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
Installation WARNING 1. Position rear fork through the frame. Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 − Safety. 4. Jack up rear wheel enough to allow the removal of the rear fork. 5. Remove lug nuts from drive studs. Remove tire with wheel rim from wheel hub. 6. Remove four lock nuts and hex socket head screws securing the hydraulic motor to the rear fork. Remove motor from the fork and position it away from the fork. 2.
Brake Linkages 2 1 3 3 9 9 19 24 23 25 7 8 21 22 8 20 5 6 18 4 7 12 15 11 17 10 15 13 12 26 16 27 14 28 29 35 12 30 36 37 31 34 32 33 Figure 10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Pop rivet Control panel cover Cover bracket Flange nut Hex flange head screw Magnet support Hex washer head screw Strike bracket Magnetic catch Flat washer Lock nut Cotter pin Bumper pad Wheels, Brakes, and Miscellaneous 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.
1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 3. Remove and replace parts as necessary to repair brake linkages. 4. Install control panel cover to the machine. 2. Remove control panel cover from the machine. IMPORTANT:Always check and adjust the brakes anytime brake linkages are disassembled or repaired. 5. Adjust brake linkages (see Brake Adjustment).
Steering Column 8 9 21 17 39 40 14 20 7 10 20 to 26 ft−lb (27.1 to 35.3 N−m) 32 11 27 33 28 12 6 36 19 2 4 5 19 38 18 36 22 18 24 29 3 1 23 25 19 2 37 26 15 2 16 31 30 13 8 2 3 41 Figure 11 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Steering arm Flange hex nut Hex flange head screw Steering control valve bracket Cap screw Pivot hub Steering cover Cap screw Toro decal Ball knob Lever Steering control valve Tilt bracket Cap screw Wheels, Brakes, and Miscellaneous 15. 16. 17.
Disassembly Assembly 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1. Make sure lever and friction discs are properly assembled to the steering control valve bracket using Figure 11 as a guide. 2. Remove philips pan head screws and steering wheel cap from the steering wheel. 2. Position steering control bracket to the steering control valve and steering arm.
Wheels, Brakes, and Miscellaneous Page 6 − 14 Reelmaster 3100−D
Chapter 7 SPA Cutting Units Table of Contents SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . Greasing Bearings, Bushings, and Pivot Points Backlapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cutting Unit Removal and Installation . . . . . . . . . Reel Motor Removal and Installation . . . . . . . . . . Reel Removal and Bearing Replacement . . . . . . Bedbar Removal and Installation . . . . . . . . . . . . . Bedknife Replacement and Grinding . . . . . . . . . .
Specifications Figure 1 MOUNTING: All cutting units are supported by equal length independent lift arms and are interchangeable to all three cutting unit positions. CONSTRUCTION: 5 or 8 blades of 7 inches (18 cm) diameter welded to stamped steel spiders. Reels are mounted on greaseable self−aligning ball bearings. A cutting unit has a reel of either 27 inches (69 cm) in length or 32 inches (81 cm) in length. HEIGHT OF CUT RANGE: Floating Cutting Unit − 1/4 to 1−3/4 inches (6.4mm to 44.4mm).
Special Tools Order special tools from your Toro Distributor. Some tools may have been supplied with your machine or available as TORO parts. Some tools may also be available from a local supplier. Gauge Bar Assembly Use gauge bar to verify height of cut (Toro Part No. 13−8199). Gauge Bar Figure 2 Handle Assembly − TOR299100 SPA Cutting Units For applying lapping compound to cutting units while keeping hands a safe distance from the rotating reel.
Bedknife Screw Tool − TOR510880 This screwdriver type bit is made to fit Toro bedknife attaching screws. Use this bit with a torque wrench to secure the bedknife to the bedbar. IMPORTANT: Do not use and air or manual impact wrench with this tool.
Troubleshooting There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions. Turf conditions such as excessive thatch, “sponginess” or attempting to cut off too much grass height may not always be overcome by adjusting the machine. It is important to remember that the lower the height of cut, the more critical these factors are. Remember that the “effective” or actual height of cut depends on cutting unit weight and turf conditions.
Factor Possible Problem/Correction 6. Bedknife to reel adjustment. Check bedknife to reel contact daily. Bedknife must have light contact all across the reel. No contact will cause cutting edges to become dull. Excessive contact accelerates wear; quality of cut may be adversely affected. Slightly dull cutting edges may be corrected by backlapping, Excessively dull cutting edges must be corrected by grinding the reel and bedknife. 7. Front roller position.
Adjustments CAUTION Never install or work on the cutting units or lift arms with the engine running. Always stop engine and remove key first. Characteristics The single knob (SPA) bedknife−to−reel adjustment system incorporated in this cutting unit simplifies the adjustment procedure needed to deliver optimum mowing performance. The precise adjustment possible with the single knob/bedbar design gives the necessary control to provide a continual self−sharpening action.
Adjust Bedknife Parallel to Reel NOTE: A 3/4−inch (19 mm) wrench will be needed to rotate the bedknife adjustment knob (Fig. 7). IMPORTANT: Do not allow cutting unit to rest on the bedknife adjusting screw. The setting of the bedknife will be changed. 1 1. Remove any reel contact by turning the bedknife adjustment knob counterclockwise (Fig. 7). Tip cutting unit to gain access to the reel and bedknife (Fig. 8). 2.
Set Height−of−Cut and Level Both Rollers Note: Both floating and fixed cutting units can use this method for making height−of−cut adjustments and leveling both front and back rollers. 5/8 inch 1. Position cutting unit on a flat level table or board. 2. Loosen nut slightly that secures each roller bracket to the angle bracket. 3. For the front roller, adjust support cap screw to achieve a 1 inch + 1/16 (25.4 mm + 1.
Verify Height−of−Cut and Front Roller Level NOTE: Gauge bar (Toro Part No. 13−8199) may be obtained from your local Toro Distributor. IMPORTANT: Height−of−cut must be set and both rollers leveled before performing this adjustment (see Set Height−of−Cut and Level Both Rollers). 1. On the gauge bar, set head of the screw to the desired Height−of−Cut. This measurement is from the bar face to the underside of the screw head. 4 2 3 5 2.
Adjust Front Lift Arms 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2 1 IMPORTANT: Keep front cutting units on the lift arms when performing this adjustment. 3 2. Raise front lift arms. Make sure clearance between each lift arm and floor plate bracket is 0.18 to 0.32 inch (4.6 to 8.1 mm) (Fig. 12). 3. If the clearance is not in this range, attain proper clearance as follows: A.
Adjust Rear Lift Arm 1. Park machine on a level surface and engage parking brake. IMPORTANT: This adjustment must be performed with the rear cutting unit attached to the rear lift arm. 2 2. Raise lift arms. Make sure clearance between wear strap on the top of the rear cutting unit wear bar and bumper strap is 0.020 to 0.100 inch (0.508 to 2.54 mm) (Fig. 15). 1 3. If the clearance is not in this range, attain proper clearance by adjusting the rear hydraulic cylinder as follows (Fig. 16): A.
Service and Repairs Greasing Bearings, Bushings, and Pivot Points Each cutting unit has 9 grease fittings (with an optional front roller installed) that must be lubricated regularly with No. 2 general purpose lithium base grease. Grease Fitting Locations and Quantities Each bedknife adjuster has 1 fitting (Fig. 17). Each reel bearing housing has 2 fittings. Each front and rear roller has 2 fittings, one on each end of the roller (Fig. 18).
Backlapping DANGER Note: Additional instructions and procedures on backlapping are available in the Toro General Service Training Book, Reel Mower Basics (part no. 09168SL). 1. Position machine on a clean, level surface. Lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Remove console cover to expose the controls. 3. Rotate backlap knob on the manifold block clockwise to the BACKLAP position. Rotate reel speed knob to position 1 (Fig. 20). 4.
Cutting Unit Removal and Installation Removal 1. Position machine on a clean, level surface. Lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2 2. On the front cutting units, detach chain from the cutting unit carrier frame by removing the lock nut and cap screw (Fig. 23). 3 1 3. Remove hydraulic motor from the cutting unit (see Reel Motor Removal). 4. Remove lynch pin from pivot shaft (Fig. 24 and 25). 5.
Reel Motor Removal and Installation 2 5 4 38 10 2 5 2 7 9 RIGHT 11 13 FRONT 39 41 38 40 8 34 35 30 12 29 8 28 27 6 26 16 14 17 18 19 1 16 20 21 36 2 26 22 15 25 30 27 34 37 27 28 24 33 41 Figure 26 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Reel Cap screw Not used Cap screw Lock washer Side plate (RH) Roll pin Lock nut Hex nut Waring decal Front grass guard Frame assembly Rear grass guard Flange nut 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.
Reel Removal and Bearing Replacement 1. Remove hydraulic motor from the cutting unit (see Hydraulic Motor Removal and Installation). Remove cutting unit from the machine (see Cutting Unit Removal and Installation). 2. Remove bedbar assembly from the cutting unit (see Bedbar Removal and Installation). 3. Remove front roller from the cutting unit (see Roller Removal and Installation). Note: A 3/8−inch drive ratchet with an extension will fit into the square hole of the coupling. 4.
Bedbar Removal and Installation 1 2 3 5 4 5 17 32 24 15 2 1 25 31 30 29 28 20 8 13 9 16 19 27 36 33 19 20 21 35 34 22 23 24 25 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Rubber bushing Flanged bushing Jam nut Compression spring Washer Not used Not used Spring arm Bedbar adjuster Not used Not used Not used 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
Bedbar Installation (Fig. 27) 1. Inspect flanged bushings and bushing for wear; replace if necessary. 2. Clean and apply anti−seize lubricant to both bedbar pivots. Install bedbar washer on the bedbar. 3. Install bedbar adjusting housing and bedbar housing on the bed bar. Reinstall spacer, flat washer, lock washer, and cap screw on the bedbar. 1 4. Install bedbar assembly on the cutting unit. 5. Secure bedbar housing to the cutting unit with both carriage bolts and nuts. 3 6.
Bedknife Replacement and Grinding Bedknife Removal 27” Cutting Unit Shown 1. Remove bedbar from cutting unit (see Bedbar Removal in this chapter). NOTE: 27” cutting units use 10 screws to secure bedknife to bedbar. 32” cutting units use 12 screws to secure bedknife to bedbar. 2 2. Remove screws from bedbar using a socket wrench and bedknife screw tool (see Special Tools in this chapter). Discard screws. Remove bedknife from the bedbar (Fig. 29). 3 Antiseize Lubricant 3.
Bedknife Grinding Since there can be variations in the mounting surface of the bedbar, it is necessary to grind the bedknife after installing it to the bedbar. Follow the bedknife grinding specifications provided and grind only enough to make sure the top surface of the bedknife is true (Fig. 31 and 32). IMPORTANT: Do Not grind the bedknife below it’s service limit (Fig. 33).
Roller Removal and Installation Note: This section can be used for both the front and rear rollers. Roller Removal 1. Remove both height−of−cut pins and hairpin cotters from each roller bracket. 2 2. Remove both locknuts from the capscrews securing each angle bracket to the cutting unit. 1 3. Remove capscrews from both angle brackets and the cutting unit. 5 4. Separate roller assembly, roller brackets, and angle brackets from the cutting unit. 6 7 5. Remove roller brackets from the roller assembly.
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Roller Bearing and Seal Replacement 1 2 3 4 5 6 7 8 9 2 4 5 6 7 8 10 11 6 4 7 8 12 4 5 1. 2. 3. 4. Full roller Roller shaft Grease seal Bearing cup 5. 6. 7. 8. Figure 36 Bearing cone (outer) Outer seal Adjustment nut Grease fitting 9. 10. 11. 12. Wiehle roller Sectional roller shaft Bearing cone (inner) Sectional roller Remove Seals and Bearings 5. Remove outer seals. 1. Clean inside of roller around both adjusting nuts and roller shaft ends. Both areas should be free of dirt and debris.
Install New Seals and Bearings on Full or Wiehle Roller 1. Make sure all parts are clean prior to installing bearings and seals. 2. On the full roller, make sure cupped side of the inner seal faces the inside of the roller. Press an inner seal into each end of the roller. 3. Make sure narrow end of the taper on the bearing cup faces the inside of the roller. Press a cup into each end of the roller. 4. Keep roller level and secured roller in a vise. 5.
Prepare Reel for Grinding Note: Check to make sure reel bearings are in good condition and properly adjusted before grinding reel. 4. After completing grinding process: A. Install front roller and brackets (see Roller Removal and Installation). 1. Remove bedbar assembly (see Bedbar Removal and Installation). B. Install bedbar assembly (see Bedbar Removal and Installation). 2. Remove front roller and brackets (see Roller Removal and Installation).
Fixed Side Plate Installation 1. Remove pop rivets and rear height−of−cut plates from both sides of the cutting unit (Fig. 38). 2 6 2. Remove lock nuts, capscrews, washers, and both links from the cutting unit (Fig. 38). 3. Align fixed side plate with holes on the cutting unit (Fig. 39). 4 1 4. Attach new capscrews, washers, and flanged lock nuts to the fixed side plate and the cutting unit (Fig. 39). 5. Tighten lock nuts and capscrews. 3 6.
Front Lift Arms 9 29 RIGHT 6 FRONT 3 29 12 7 16 30 4 5 28 15 29 31 21 13 20 23 26 38 28 24 17 21 18 22 34 39 11 28 41 10 33 32 37 40 37 35 90o hydraulic fitting Hydraulic cylinder Carrier assembly Flange nut Flange head screw Hydraulic hose Centering wire Hydraulic hose Hydraulic hose Hydraulic hose Clamp bracket (Model 03200) Slide bracket (Model 03201) Flange nut (Model 03201) Plastic slide Flange head screw SPA Cutting Units 14 25 13 8 24 36 19 2 1 1. 2. 3. 4.
Removal 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Remove cutting unit from the pivot shaft of the front lift arm (see Cutting Unit Removal). NOTE: Remove both spacers from the hydraulic cylinder shaft clevis when removing the right, front lift arm. 3. Disconnect hydraulic cylinder from the front lift arm by removing external retaining rings and pin. 4.
Rear Lift Arm 23 24 19 2 1 21 5 20 6 11 7 8 22 4 12 13 8 3 1 14 15 16 17 10 9 1 200 to 250 Ft−lb (271 to 339 N−m) 18 Figure 44 1. 2. 3. 4. 5. 6. 7. 8. External retaining ring Thrust washer Rear lift arm Rear hydraulic cylinder Flange head screw Thrust washer Rear pivot shaft Bushing 9. 10. 11. 12. 13. 14. 15. 16. Removal 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2.
3. Secure hydraulic cylinder clevis to the lift cylinder shaft of the rear lift arm with the thrust washer and external retaining ring. 6. Grease front lift arm. SPA Cutting Units 4. Install rear cutting unit to the pivot shaft of the rear lift arm (see Cutting Unit Removal). 5. Adjust lift arms to proper clearance (see Adjust Rear Lift Arm).
Skid Kit Installation 1. Remove front roller from the cutting unit (see Roller Removal and Installation). 2. Align skid slots with the angle bracket holes on the cutting unit. 3. Secure skid to the cutting unit with both flange head screws, flat washers, and lock nuts. 4 4. Repeat steps 1 through 3 on the other side of the cutting unit. 3 5. Adjust skid height as necessary by loosening lock nuts and flange head screws, then retighten fasteners. 2 5 1 Figure 45 1. Skid 2. Angle bracket holes 3.
Chapter 8 DPA Cutting Units Table of Contents Reel Assembly (cutting units with painted side plates) . . . . . . . . Reel Assembly Service (cutting units with painted side plates) . . . . . . . . Reel Assembly (cutting units with aluminum side plates) . . . . . . Reel Assembly Service (cutting units with aluminum side plates) . . . . . . Preparing Reel for Grinding . . . . . . . . . . . . . . . . . Front Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Roller . . . . . . . . . . .
Specifications Figure 1 Frame Construction: Precision machined die cast aluminum cross member with bolt--on cast ductile iron or aluminum side plates. Bedknife: Replaceable, single edged, high carbon steel bedknife is fastened to a machined cast iron bedbar with screws. Optional bedknives are available. Reel Construction: Reels are 27 inches (69 cm) or 32 inches (81 cm) in length and 7 inch (18 cm) in diameter. High strength, low alloy steel blades are thru hardened and impact resistant.
General Information Cutting Unit Operator’s Manual DPA Cutting Units The Cutting Unit Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for the DPA cutting units on your Reelmaster machine. Additionally, if optional kits have been installed on the cutting units (e.g. rear roller brush), the installation instructions for the kit includes set--up and operation information.
Special Tools Special tools for servicing Toro Commercial Products are available from your Toro Distributor. Some tools may have been supplied with your machine or are available as TORO parts. Gauge Bar Assembly Toro Part Number: 108--6715 Use gauge bar to verify height--of--cut adjustment. Used for Height--of-Cut adjustment Figure 2 Bedknife Screw Tool Toro Part Number: TOR510880 This screwdriver--type bit is made to fit Toro bedknife attaching screws.
Plastic Plug Toro Part Number: 94--2703 This plug is used for placement into the side plate bearing housing when the hydraulic reel motor is removed. It prevents dirt and debris from entering the cutting reel bearing area. Figure 5 Cutting Unit Kickstand Toro Part Number: 119--8010--03 The cutting unit kickstand is used to prop up the rear of the cutting unit during service. Use of this tool prevents the bedbar adjusting screws from resting on the work surface.
Diameter/Circumference Measuring Tape Toro Part Number: TOR6023 Spring steel measuring tape for accurately measuring the circumference and outside diameter of cutting reel and other spherical components. Tape calibration is in fixed inch readings (no adjustments). Figure 8 Roller Rebuild Kit Toro Part Number: 115--0803 Bearing Installation Washer This tool kit is used to assemble the cutting unit rollers.
Reel Bearing Installation Tool (cutting units with painted side plates) Toro Part Number: 117--0975 Use the reel bearing installation tool to keep the reel bearing aligned as the cutting unit side plate is installed on the bearing. Figure 11 Cutting Reel Shim Toro Part Number: 125--5611 The cutting reel shim (0.002”) is used to help parallel the bedknife and cutting reel.
Bedknife Top Angle Indicator and Mount Toro Part Numbers: 131--6828 and 131--6829 1 Because the top grind angle on bedknives is critical for edge retention, and therefore after-- cut appearance, Toro has developed these service tools for accurately measuring the top grind angle on all bedknives. 2 3 Since there can be variations in the mounting surface of the bedbar, it is necessary to grind the bedknife after installing it to the bedbar. 1.
Factors That Can Affect Cutting Performance There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions. Turf conditions such as excessive thatch, “sponginess” or attempting to cut off too much grass height may not always be overcome by adjusting the cutting unit. It is important to remember that the lower the height--of--cut, the more critical these factors are.
Factor Possible Problem/Correction Reel and bedknife sharpness A reel and/or bedknife that has rounded cutting edges or “rifling” (grooved or wavy appearance) cannot be corrected by tightening the bedknife to reel contact. Grind cutting reel to remove taper and/or rifling. Grind bedknife to sharpen and/or remove rifling. NOTE: After grinding the reel and/or bedknife, check the reel to bedknife contact again after cutting two (2) fairways.
Factor Possible Problem/Correction Roller condition and roller type Make sure rollers rotate freely. Repair roller bearings as necessary. See Roller Service in the Service and Repairs section of this chapter. Refer to Cutting Unit Operator’s Manual for roller options. A variety of cutting unit accessories are available that can be used to enhance aftercut appearance. Refer to Operator’s Manual for a listing of available accessories.
Adjustments Characteristics If a cutting unit is determined to be out of adjustment, complete the following procedures in the specified order to adjust the cutting unit properly. CAUTION Never install or work on the cutting units or lift arms with the engine running. Always stop engine and remove key first. The dual knob bedknife--to--reel adjustment system incorporated in this cutting unit simplifies the adjustment procedure needed to deliver optimum mowing performance.
Reel Bearing Adjustment (cutting units with painted side plates) NOTE: Cutting units that have aluminum side plates do not require reel bearing adjustment. 4 12 to 15 in--lb (1.4 to 1.7 N--m) To insure cut quality and long life of the cutting reel bearings, periodically check reel bearing adjustment. 1 Check Reel Bearing Adjustment 1. Remove hydraulic reel motor from cutting unit (see Hydraulic Reel Motor Removal in the Service and Repairs section of this chapter). 15 to 17 in--lb (1.7 to 1.
Leveling Rear Roller The precision machined components of the cutting unit frame keep the rear roller and cutting reel in alignment (parallel). If the side plates are disassembled or as the cutting reel wears, a limited amount of side plate adjustment is possible to make sure that the cutting unit is properly aligned. 3 2 4 1 1. Place the assembled cutting unit on a surface plate. 4 2. Make sure that bedknife is properly adjusted to cutting reel. 3.
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Service and Repairs Hydraulic Reel Motor IMPORTANT: When performing maintenance procedures on the cutting units, carefully position the cutting unit reel motors to prevent damage to the motors or hydraulic hoses. 2 Removal 1. Park machine on a clean and level surface, lower cutting units completely to the ground, stop engine, engage parking brake and remove key from the ignition switch. 2. Loosen two (2) cap screws that secure the hydraulic reel motor to the cutting unit side plate.
Backlapping DANGER 1 TO AVOID PERSONAL INJURY OR DEATH: D Never place hands or feet in the reel area while the engine is running. D When backlapping, run engine at idle speed only. D While backlapping, the reels may stall and then restart. D Do not attempt to restart reels by hand or foot. D Do not adjust reels while the engine is running. D If a reel stalls, stop engine before attempting to clear the reel. D Reel motors are connected in series: rotating one motor causes rotation in other motors.
Bedbar Assembly 2 3 4 1 27 to 33 ft--lb (37 to 44 N--m) 6 5 7 5 8 9 RIGHT FRONT 10 Antiseize Lubricant Figure 24 1. 2. 3. 4. Bedbar assembly Lock nut (2 used) Compression spring (2 used) Washer (2 used) 5. Plastic washer (4 used) 6. Rubber bushing (2 used) 7. Flange bushing (2 used) Bedbar Removal (Fig. 24) 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2.
Bedbar Installation (Fig. 24) 1. If rubber bushing was removed from either cutting unit side plate, install a new bushing. The bushing should be installed flush with the inside of the side plate (Fig. 25). 2. If removed, install the flange bushings with flange facing outward. Apply antiseize lubricant to inside of flange bushing. 9. Tighten the lock nut (item 2) on each bedbar adjuster assembly until the adjuster spring is fully compressed, then loosen lock nut 1/2 turn. 10.
Bedknife Replacement and Grinding Bedknife Removal 27” Cutting Unit Shown 1. Remove bedbar from cutting unit (see Bedbar Removal in this chapter). 2 NOTE: 18” cutting units use 6 screws to secure bedknife to bedbar. 22” cutting units use 8 screws to secure bedknife to bedbar. 2. Remove screws from bedbar using a socket wrench and bedknife screw tool (see Special Tools in this chapter). Discard screws. Remove bedknife from the bedbar (Fig. 26). 3. See bedknife grinding information on the following pages.
Bedknife Grinding Top Surface Since there can be variations in the mounting surface of the bedbar, it is necessary to grind the bedknife after installing it to the bedbar. Follow the bedknife grinding specifications provided and grind only enough to make sure the top surface of the bedknife is true (Fig. 28 and 29). Remove Burr (without dulling sharp corner) Top Angle IMPORTANT: Do Not grind the bedknife below it’s service limit (Fig. 30).
Bedbar Adjuster Service Antiseize Lubricant Loctite #243 14 to 16 ft--lb (19 to 21 N--m) 6 Left Hand Threads 11 2 3 4 5 7 Antiseize Lubricant 8 5 9 1 10 Antiseize Lubricant A Loctite #243 14 to 16 ft--lb (19 to 21 N--m) 6 7 Left Hand Threads 5 RIGHT FRONT 12 1 13 5 10 2 3 4 Antiseize Lubricant B 11 14 15 to 20 ft--lb (21 to 27 N--m) Figure 32 1. 2. 3. 4. 5. Bedbar assembly Compression spring Lock nut Bedbar adjuster screw Flange bushing 6. 7. 8. 9. 10.
Removal (Fig. 32) 1. Remove lock nut (item 3), compression spring and washer from bedbar adjuster screw (item 4). 2. Remove bedbar assembly (see Bedbar Assembly Removal in this section). 3. Remove bedbar adjuster screw (left hand threads) from the bedbar adjuster shaft (item 10). 4. Remove adjuster shaft from cutting unit frame: A. On early production cutting units (Fig. 32 A), remove retaining ring and wave washer from adjuster shaft. Slide adjuster shaft from cutting unit frame. B.
Reel Assembly (cutting units with painted side plates) 21 12 22 Grease OD surface 1 27 to 33 ft--lb (37 to 44 N--m) 15 16 8 14 4 13 3 2 17 4 5 18 6 19 7 20 RIGHT See text for tightening procedure FRONT 9 Grease bore and threads 12 10 11 27 to 33 ft--lb (37 to 44 N--m) Antiseize Lubricant Figure 33 1. 2. 3. 4. 5. 6. 7. 8.
Reel Assembly Removal (Fig. 33) 3 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 115 to 128 Nm (85 to 95 ft---lb) 1 2. Remove the cutting unit from the machine and place on a flat work area. 3. If cutting unit is equipped with a weight on LH side plate (as shown in Figure 33), remove the two (2) cap screws securing the weight to the side plate. Remove weight from the cutting unit.
7. Loosen fasteners that secure front and rear rollers to LH side plate (see Front Roller Removal and Rear Roller Removal in this section). 8. Remove cap screw and flat washer that secure rear grass shield to LH side plate (Fig. 35). 9. Remove flange head screw that secures support tube, frame spacer and carrier frame to LH side plate (Fig. 35). Note: The reel bearings and grease seals are press fit on the cutting reel shaft and should remain on the reel when removing the LH side plate. 10.
13.Apply Loctite #243 (or equivalent) to threads of set screw and secure bearing adjuster nut in place with set screw. Torque set screw from 12 to 15 in--lb (1.4 to 1.7 N--m). 3 115 to 128 Nm (85 to 95 ft---lb) 1 14.Adjust cutting unit (see Cutting Unit Operator’s Manual). Note: The parallel position of the rear roller to the cutting reel is controlled by the precision machined frame and side plates of the cutting unit.
Reel Assembly Service (cutting units with painted side plates) 8 10 7 Loctite #243 9 5 4 3 2 Clean Threads 85 to 95 ft--lb (115 to 128 N--m) (Right Hand Threads) 1 10 RIGHT 6 3 Left Hand Threads Loctite #243 85 to 95 ft--lb (115 to 128 N--m) FRONT 4 5 Figure 37 1. 2. 3. 4. Cutting reel Threaded insert (RH thread) Retaining ring Grease seal 5. Bearing 6. Threaded insert (LH thread) 7. Retaining ring groove Inspection of Cutting Reel (Fig. 37) 1.
C. To install spline insert into cutting reel, clean threads of insert and cutting reel shaft. Apply Loctite #243 (or equivalent) to threads of insert, thread insert into reel shaft and torque from 85 to 95 ft--lb (115 to 128 N--m). Assembly of Cutting Reel (Fig. 37) 1. If seals and/or bearings were removed from reel shaft, discard removed components and replace. 2. Make sure that the two (2) retaining rings are fully seated into the grooves on the cutting reel shaft. 3.
Reel Assembly (cutting units with aluminum side plates) 1 17 18 8 15 2 13 4 27 to 33 ft--lb (37 to 44 N--m) 16 Antiseize Lubricant (Bearing OD) 3 4 7 5 6 14 Pack with Grease (both ends) RIGHT FRONT 9 12 Antiseize Lubricant (Bearing OD) 10 11 Antiseize Lubricant Figure 38 1. 2. 3. 4. 5. 6. Bedbar assembly Cutting unit frame Flange bushing (2 used) Plastic washer (4 used) Metal washer (2 used) Bedbar pivot bolt (2 used) 7. 8. 9. 10. 11. 12.
27 to 33 ft--lb (37 to 44 N--m) 15 to 19 ft--lb (20 to 25 N--m) 7 4 5 3 1 6 12 2 27 to 33 ft--lb (37 to 44 N--m) 10 27 to 33 ft--lb (37 to 44 N--m) 4 6 11 10 9 12 27 to 33 ft--lb (37 to 44 N--m) 8 4 15 to 19 ft--lb (20 to 25 N--m) Figure 39 5. 6. 7. 8. Rear grass shield Flange nut (6) Special screw Flat washer Reel Assembly Removal 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2.
4. Loosen the spline inserts: 3 A. Tip the cutting unit to access the bottom of the reel. 115 to 128 Nm (85 to 95 ft---lb) 1 B. Insert a long--handled pry bar (3/8 x 12 inch with screwdriver handle recommended) through the bottom of the cutting unit. The pry bar should pass between the top of the reel shaft and the backs of the reel blades so that the reel will not move.
3. The cutting unit has O--rings in the reel bearing bore of each side plate. Make sure the O--rings are in good condition and properly installed in the side plates. 115 to 128 Nm (85 to 95 ft---lb) 3 1 4. Apply a thin coat of antiseize lubricant to the reel bearing bore of each side plate (Fig. 41). CAUTION Contact with the reel, bedknife or other cutting unit parts can result in personal injury. Use heavy gloves when installing the cutting reel. 4 5. Make sure that flat wire spring (item 14 in Fig.
Reel Assembly Service (cutting units with aluminum side plates) Loctite #243 9 10 11 1 12 2 7 6 5 85 to 95 ft--lb (115 to 128 N--m) (Right Hand Threads) 4 3 Loctite #243 10 3 4 5 RIGHT 6 7 FRONT 8 85 to 95 ft--lb (115 to 128 N--m) (Left Hand Threads -- Groove in Face) Figure 43 1. 2. 3. 4. Cutting reel Threaded insert (RH thread) Plastic plug (2) Retaining ring 5. 6. 7. 8. Special washer Flocked seal Sealed bearing Threaded insert (LH thread) Reel Assembly Inspection 1.
Reel Assembly 1. If removed, install new reel shaft plugs into cutting reel shaft. For cutting unit serial no. prior to 315000001, make sure plastic plug is pressed flush into end of threaded insert. For cutting unit serial no. 315000001 & Up, make sure plastic plug is pressed unto reel shaft 1.63 to 1.37 in. (41 to 35 mm) below the end of the shaft (Fig. 44) 1 2 NOTE: One insert has LH threads and the other insert has RH threads. The insert with LH threads has a groove on the insert face.
Preparing Reel for Grinding Three (3) types of reel designs are used in Reelmaster cutting units: scalloped radial reel, tapered radial reel and tapered forward swept reel (Fig. 45). The radial reel designs have blades that are placed in line with the center of the reel shaft. The rear of the blades either have a scalloped relief or a tapered relief. The forward swept reel have blades that have a slight forward slant. The rear of the forward swept reel blades have a tapered relief.
Front Roller Removal (Fig. 47) 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 1 Loctite #242 Antiseize Lubricant 2. Remove the cutting unit from the machine and place on a level working surface. Use cutting unit kickstand (see Special Tools) to raise front roller from work surface. 2 15 to 19 ft--lb (20 to 26 N--m) 3 3.
Rear Roller Removal (Fig. 48) 4 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 1 2. Remove the cutting unit from the machine and place on a level working surface. Place support blocks under bedbar to raise rear roller from work surface. 5 3. Loosen two (2) flange nuts that secure the rear roller shaft to each rear roller bracket. 6 2 4.
Roller Service Disassembly (Fig. 49) 2 1. Remove bearing lock nut from each end of roller shaft. 50 to 60 ft--lb (68 to 81 N--m) 3 4 2. Loosely secure roller assembly in bench vise and lightly tap one end of roller shaft until outer seals and bearing are removed from opposite end of roller tube. Remove second set of outer seals and bearing from roller tube by tapping on opposite end of shaft. Remove shaft from roller tube. 5 6 7 1 2 4 3 5 3.
3. From the roller tube end with only the inner seal installed, carefully install the roller shaft into the roller tube. Make sure that seals are not damaged as shaft is installed. 4. Install new bearing and outer seals into second end of roller tube: NOTE: After roller is installed to cutting unit, lubricate roller grease fittings, rotate roller to properly distribute grease in bearings and clean excess grease from roller ends. A properly assembled roller should rotate with less than 5 in--lb (0.
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Rear Roller Brush -- Optional (cutting units with painted side plates) 26 27 30 6 31 Antiseize Lubricant 1 27 to 33 ft--lb (37 to 44 N--m) 29 15 to 19 ft--lb (20 to 25 N--m) 6 29 7 3 8 9 10 11 12 27 2 26 13 Loctite #243 15 to 19 ft--lb (20 to 25 N--m) 17 16 14 33 16 28 Grease Grommet ID RIGHT FRONT 5 32 18 15 2 24 23 4 34 25 22 Loctite #243 15 to 19 ft--lb (20 to 25 N--m) 21 35 to 40 ft--lb (47 to 54 N--m) 20 16 19 15 to 19 ft--lb (20 to 25 N--m) 3 Figure 55 1. 2. 3. 4.
Disassembly (Fig. 55) 2 1 3 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. To remove roller brush from brush shaft: A. Remove the non--driven brush bearing assembly (item 30) from cutting unit. B. Slide excluder seal (item 6) from roller brush shaft. C. Remove lock nut and J--bolt from both ends of the brush (Fig. 56). 20 to 25 in--lb (2.3 to 2.8 N--m) 4 Figure 56 1. Roller brush shaft 2.
3. If drive bearing housing was disassembled, install new components noting proper orientation as shown in Figures 58 and 59. A. Install bearing on shaft by pressing equally on the inner and outer bearing races. Install the bearing so that the bearing seal is closest to the shoulder on the shaft. Install snap ring (Fig. 58, item 6) onto shaft to retain bearing. B. Install new grease seal into housing with the lip of the seal toward the drive shaft splines. Apply grease to lip of seal. C.
5. Check alignment of pulleys with a straight edge placed along the outer face of the driven pulley (Fig. 61). The outer faces of the driven and drive pulleys (not the idler pulley) should be in line within 0.030” (0.76 mm). If necessary to align pulleys, remove driven pulley from brush shaft and add or remove hardened washer(s) (item 9) until drive and driven pulleys are aligned within 0.030” (0.76 mm). CHECK ALIGNMENT 6. Check that roller brush is parallel to rear roller with 0.060” (1.
Rear Roller Brush -- Optional (cutting units with aluminum side plates) 20 9 Grease Seal Lip 1 3 22 21 20 to 25 in--lb (2.3 to 2.8 N--m) 4 15 8 Antiseize Lubricant 7 6 14 v 5 6 5 Grease Seal Lip 16 19 17 7 18 10 11 12 18 Grease Seal Lip RIGHT FRONT 2 8 27 to 33 ft--lb (37 to 44 N--m) 9 13 Figure 63 1. 2. 3. 4. 5. 6. 7. 8.
Rear Roller Brush Assembly (Fig. 55) 1. If seals or bearings were removed from brush bearing housings, install new components noting proper orientation as shown in Figure 57. 6. Once all rear roller brush service is completed, plug the 48 VDC battery disconnect back in before operating the machine. 2 1 3 A. Pack bearings with high temp Mobil XHP--222 grease (or equivalent) before installation. B. Press bearing into bearing housing so that bearing contacts shoulder in housing bore. C.
Drive System Disassembly (Fig. 67) Loctite #243 15 to 19 ft--lb (20 to 25 N--m) 2 4 1 5 6 9 10 to 15 ft--lb (14 to 20 N--m) 10 6 2 Grease Grommet ID 11 3 Loctite #243 RIGHT v 13 15 5 14 6 15 to 19 ft--lb (20 to 25 N--m) 19 7 20 18 8 17 16 Loctite #243 FRONT 22 6 21 12 35 to 40 ft--lb (48 to 54 N--m) Figure 67 1. 2. 3. 4. 5. 6. 7. 8. Carriage screw (2 used) Carriage screw (3 used) Brush plate Cap screw (2 used) Flat washer (4 used) Lock nut (6 used) Idler arm Idler spacer 9. 10.
Drive System Assembly (Fig. 67) 85 to 95 ft--lb (115 to 128 N--m) 1. Install drive shaft if it was removed: IMPORTANT: If rear roller brush drive is on left side of cutting unit, drive shaft has left hand threads and can be identified by a groove on the flange. If the rear roller brush drive is on right side of cutting unit, drive shaft has right hand threads and does not have a groove on the flange (Fig. 69). 2 4 Loctite #243 A. Apply Loctite #243 (or equivalent) to threads of drive shaft.
3. After assembly (including drive belt installation), check alignment of pulleys with a straight edge placed along the outer face of the drive pulley (Fig. 61). 27 to 33 ft--lb (37 to 44 N--m) A. The outer faces of the drive and driven pulleys (not the idler pulley) should be in--line within 0.030” (0.76 mm). 4 3 B. If necessary to align pulleys, remove driven pulley from brush shaft and add or remove flat washer(s) until drive and driven pulleys are correctly aligned (Fig. 71). C.
Chapter 9 Universal Groomer -- DPA Cutting Units (Optional) Table of Contents Reelmaster 3100--D Page 9 -- 1 Universal Groomer (Optional) Universal Groomer (Optional) GROOMING PERFORMANCE . . . . . . . . . . . . . . . . . . 2 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 3 Groomer Reel Mechanical Problems . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Gear Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 6 Idler Assembly . .
Grooming Performance There are a number of factors that can affect the performance of grooming. These factors vary for different golf courses and from fairway to fairway. It is important to inspect the turf frequently and vary the grooming practice with turf needs. IMPORTANT: Improper or overaggressive use of the groomer (e.g. too deep or too frequent grooming) may cause unnecessary stress on the turf leading to severe turf damage. Use the groomer carefully.
Troubleshooting Problem Possible Causes Correction No rotation of the groomer reel. The groomer drive is in Neutral. Engage groomer drive to Forward or Reverse. Damaged or seized groomer drive gears. Repair groomer drive. The groomer reel blades are bent, damaged or missing. Repair or replace blades if necessary. The groomer reel shaft is bent or damaged. Replace groomer reel shaft. Grooming depth is not equal on both ends of groomer reel. Adjust depth if necessary.
Service and Repairs 6 2 5 7 3 1 4 RIGHT 4 FRONT Figure 1 1. Gear box assembly 2. Idler assembly 3. Groomer reel 4. Height adjuster assembly (2) 5. Plate CAUTION Never work on the groomer with the engine running. Always stop the engine, remove the key from the ignition switch and wait for all machine movement to stop before working on the groomer. Universal Groomer (Optional) 6. Weights 7.
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Gear Box Assembly RIGHT FRONT 90 to 100 ft--lb (122 to 135 N m) 5 2 3 4 1 Figure 2 1. Gear box assembly 2. Rear roller brush drive shield 3. Cotter pin 4. Clevis pin NOTE: The groomer gear box assembly is located on the opposite side of the cutting unit from the cutting unit hydraulic motor. Removal (Fig. 2) 5.
4. If installed, remove the rear roller brush drive shield from the gear box. 6 5 4 3 IMPORTANT: Groomer gear boxes installed on the left side of the cutting unit use a left hand thread. Turn the input shaft (rear roller brush drive shaft) clockwise to remove the gear box. Groomer gear boxes installed on the right side of the cutting unit use a right hand thread. Turn the input shaft counterclockwise to remove the gear box. 5.
F. Slide the groomer housing assembly from the drive shaft. 5 4 3 1 G. Tip up the cutting unit to access the bottom of the reel to remove the drive shaft assembly. H. Insert a long--handled pry bar (3/8 x 12 inch with screwdriver handle recommended) through the bottom of the cutting unit. The pry bar should pass between the top of the reel shaft and the backs of the reel blades so that the reel will not move.
Disassembly (Fig. 6) 1 115 to 125 ft--lb (156 to 169 N--m) 2 3 4 13 5 12 6 7 11 8 10 9 14 40 16 15 39 38 18 37 33 36 35 34 32 26 31 41 30 19 29 42 25 17 28 20 27 43 44 18 45 44 43 21 46 85 to 95 in--lb (9 to 11 N--m) 18 24 23 22 Tighten to Specified Torque (see text) 32 to 42 in--lb (4 to 5 N--m) Figure 6 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
CAUTION Use the 1--3/8” flats on the input shaft to prevent the input shaft from rotating during adapter removal. DO NOT use the 1/2” hex on the input shaft to secure the shaft during adapter removal or input shaft damage may occur. 1. Remove input shaft adapter (item 1) if necessary. 2. Remove the drain/fill plug and drain the oil from the gear box. 3. Remove four (4) socket head cap screws (item 22) and separate the gear box cover and housing. 4. Remove and discard the cover gasket. Figure 7 7.
Installation (Fig. 2) 6 1. Park machine on a clean and level surface, lower cutting units completely to the ground, stop engine, engage parking brake and remove key from the ignition switch. 5 4 122 to 153 Nm (90 to 100 ft---lb) CAUTION 2 Contact with the reel or other cutting unit parts can result in personal injury. Use heavy gloves when handling the cutting reel. 3 2. Safely prevent reel from rotating by blocking the cutting reel with piece of wood near one of the reel spiders.
Idler Assembly Loctite #242 85 to 95 ft--lb (115 to 129 N--m) 5 Antiseize Lubricant 4 3 2 1 27 to 33 ft--lb (37 to 45 N--m) 6 8 9 7 12 9 10 11 13 24 to 30 ft--lb (33 to 41 N--m) Figure 9 1. 2. 3. 4. 5. Socket head screw (2) Pivot hub Idler arm Bushing Threaded insert 6. 7. 8. 9. Cotter pin Clevis pin Stub shaft and shield Bearing shield (2) NOTE: The groomer idler assembly is located on the same side of the cutting unit as the cutting unit hydraulic motor. Removal (Fig. 9) 1.
Installation (Fig. 9) 1. If shields, bearing or bushing was removed from idler arm, install new components. 1 A. Press bushing into groomer plate until the bushing is centered in the idler arm bore. B. Press bearing into idler arm so that bearing contact shoulder in idler arm bore and install bearing retaining ring. C. Install bearing shields with flocked side of shield toward bearing. D. Verify idler arm orientation (LH or RH cutting unit) and insert stub shaft through shields and bearing.
Groomer Reel 3 4 45 to 60 in--lb (5 to 7 N--m) 2 1 2 4 3 45 to 60 in--lb (5 to 7 N--m) Figure 11 1. Groomer reel 2. Shaft clamp (4) 3. Cap screw (4) Remove the groomer reel to replace individual groomer blades or replace the shaft. The groomer reel can be reversed to provide additional blade life. Removal (Fig. 11) 1. Park machine on a clean and level surface, lower cutting units completely to the ground, stop engine, engage parking brake and remove key from the ignition switch.
Groomer Reel Service Inspect groomer reel blades frequently for damage and wear. Straighten bent blades. Either replace worn blades or reverse the individual blades to put the sharpest blade edge forward (Fig. 12). Blades that are rounded to the midpoint of the blade tip must be reversed or replaced for best groomer performance. 2 1 MIDPOINT Disassembly (Fig. 13) 3 1.
5. If groomer reel is equipped with broomer kit: A. Loosen the groomer blade retaining nuts on each end of the groomer shaft. 1 31 to 35 ft--lb (42 to 48 N--m) B. Slide a brush into each groove around the full length of the groomer reel (Fig. 14). Make sure brushes are seated in groomer blade slots (Fig. 15) 2 IMPORTANT: The straps must be wrapped around the groomer blade and brush assembly in the correct direction. C. Loosely wrap the straps around the groomer reel shaft and brushes as shown (Fig. 14).
Grooming Brush (Optional) Service The optional grooming brush is removed and installed from the groomer in the same manner as the groomer reel (see Groomer Reel in this chapter). 3 The grooming brush element or shaft can be serviced separately (Fig. 17). 1 3 2 Figure 17 Reelmaster 3100--D Page 9 -- 17 3. Roll pin (2) Universal Groomer (Optional) Universal Groomer (Optional) 1. Brush element 2.
Height Adjuster Assembly 9 Antiseize Lubricant 10 2 3 4 11 5 12 13 6 14 7 15 1 8 16 17 Antiseize Lubricant 18 16 19 Figure 18 1. 2. 3. 4. 5. 6. 7. Height of cut bracket Height adjustment bolt Washer (2) Lock nut Carriage bolt Flange nut Cotter pin 8. 9. 10. 11. 12. 13. Clevis pin Button head screw Detent spring Groomer height adjuster knob Quick up cover Quick up lever Disassembly (Fig. 18) 1.
Assembly (Fig. 18) 1. Apply antiseize lubricant to upper threads of adjustment rod and lower threads of height adjusters. Assemble height adjuster assembly as shown. 2. If both height adjusters were removed, fit one height adjuster assembly to the cutting unit side plate and secure with carriage bolt and flange nut. Do Not tighten the flange nut at this time. Ensure the height adjustment bolt and one (1) washer is above slot in side plate and one (1) washer and lock nut is below slot in side plate. 3.
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Commercial Products The Toro Company − 1999
