Part No. 02103SL (Rev. A) Service Manual ReelmasterR 2000--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 2000--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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Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equivalents and Conversions . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2 -2 -2 -2 -- 1 1 2 3 Chapter 3 -- Engine Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 3 General Information . . . . .
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Chapter 1 Safety Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . Reelmaster 2000–D 2 2 2 3 JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . 4 SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
Safety Instructions The Reelmaster 2000--D has been tested and certified by TORO for compliance with existing safety standards and specifications as specified in the Traction Unit Operator’s Manual. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern, and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine.
D. Stop engine and remove key from ignition switch. F. Do not park on slopes unless wheels are chocked or blocked. Safety E. Anytime the machine is parked (short or long term), the cutting units should be lowered to the ground. This relieves pressure from the lift circuit and eliminates the risk of cutting units accidentally lowering to the ground. Maintenance and Service 1. Before servicing or making adjustments, lower decks, stop engine, set parking brake, and remove key from the switch. 11.
Jacking Instructions Jacking the Rear End CAUTION When changing attachments, tires, or performing other service, use correct blocks, hoists, and jacks. Make sure machine is parked on a solid level surface 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. Use jack stands or solid wood blocks to support the raised machine.
Chapter 2 Table of Contents PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions 0.09375 Product Records and Maintenance Page 2 -- 2 Rev.
Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual. 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 +
Thread Size 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 1.5 38 + 4 ft–lb 52 + 5 N–m 53 + 5 ft–lb 72 + 7 N–m M12 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.
Maintenance tion when performing regular equipment maintenance. Refer to the Engine Operator’s Manual for additional engine specific maintenance procedures. Product Records and Maintenance Maintenance procedures and recommended service intervals for the Reelmaster 2000–D are covered in the Traction Unit Operator’s Manual.
Product Records and Maintenance Page 2 – 8 Reelmaster 2000–D R Replace Fuel Filter/Water Separator Replace Hydraulic Filter Check Traction Belt Tension Change Engine Oil A – Service required Lubricate All Grease Fittings Check Engine Belt Tension ________________________________ ________________________________ ________________________________ ________________________________ ________________________________ _______________________________ _______________________________ __________________________
Chapter 3 Engine Table of Contents 2 3 4 4 4 5 5 5 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction This Chapter gives information about specifications, troubleshooting, testing, and repair of the Briggs & Stratton/Daihatsu diesel engine used in the Reelmaster 2000–D. Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Special Tools section. The use of some specialized test equipment is explained.
Specifications Item Description Make / Designation Briggs & Stratton/Daihatsu, 4–stroke, Liquid Cooled, OHV Diesel Number of Cylinders 3 Bore x Stroke mm (in.) 68 x 78 (2.68 x 3.07) Total Displacement cc (cu. in.) 850 (51.9) Compression Ratio 24.5:1 Firing Order 1–2–3 Dry Weight (approximate) kg (lb.) 72 (159) Grade No. 2 diesel fuel (ASTM specification) Fuel Injection Pump VE (Bosch) type Fuel Injector Nozzle Bosch throttle type Fuel Tank Capacity liter (U.S. gal.) 25 (6.
General Information Fuel Shutoff Valve This valve (Fig. 1) should be shut when removing the fuel tank or engine from the machine or when placing the unit in long term storage. 1 Figure 1 1. Fuel shutoff valve (under the fuel tank) Adding Oil to Engine When adding oil to the engine, maintain clearance between the oil fill device and the oil fill opening in the valve cover (Fig. 2).
Adjustments Adjust Throttle Control Proper throttle operation is dependent upon proper adjustment of throttle control. Make sure throttle control is operating properly. 1. Move remote throttle control lever to FAST position. 2. Check position of speed control lever on fuel injection pump. Speed control lever should be contacting high speed screw when throttle control lever is in FAST position. 3 1 3.
Service and Repairs Fuel System 2 1 7 8 7 6 3 9 4 3 Thread–locking Compound 10 11 12 30 to 60 in–lb (3.4 to 6.8 N–m) 4 RIGHT 3 FRONT 3 15 13 5 14 Figure 6 1. 2. 3. 4. 5. Fuel tank Fuel cap Hose clamp Fuel hose Fuel hose (to injector pump) Engine 6. 7. 8. 9. 10. Fuel shut off Hose clamp Fuel hose Return fuel hose (from injector pump) Tank mount grommet Page 3 – 6 11. 12. 13. 14. 15.
Fuel Tank Removal 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.
Air Cleaner 2 10 ÇÇ ÇÇ 3 13 1 14 11 12 6 5 6 8 7 4 9 RIGHT FRONT Figure 7 1. 2. 3. 4. 5. Air cleaner assembly Mounting bracket Flange head screw Flange nut Intake air hose 6. 7. 8. 9. 10. Hose clamp Air cleaner bracket Cap screw Lock nut Filter element 11. 12. 13. 14. Air cleaner cover Vacuator valve Plug Air cleaner body Removal Installation 1. Remove air cleaner components as needed using Figure 7 as a guide.
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Exhaust System 14 12 11 13 10 11 12 5 11 8 10 4 3 1 2 7 9 6 200 in–lb (22.6 N–m) 9 RIGHT FRONT Figure 8 1. 2. 3. 4. 5. Muffler Exhaust gasket Muffler header Tailpipe Rubber hanger Engine 6. 7. 8. 9. 10. Rubber isolator Clamp Coupler spring Flange nut Lock nut Page 3 – 10 11. 12. 13. 14.
Removal (Fig. 8) Installation (Fig. 8) NOTE: Make sure exhaust manifold and muffler header sealing surfaces are free of debris or damage that may prevent a tight seal. The muffler and exhaust pipe may be hot. To avoid possible burns, allow the engine and exhaust system to cool before working on the exhaust system. 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Remove the hood (see Traction Unit Operator’s Manual). 1.
Radiator 9 5 31 17 26 32 7 30 27 3 25 6 23 4 22 29 17 17 24 12 11 33 RIGHT 2 23 FRONT 1 34 13 21 10 14 28 15 18 20 16 8 35 36 19 18 37 Figure 9 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Radiator surge tank Surge tank bracket Top radiator shroud Flange head screw Left cover Radiator cap Top foam Flange nut Thumb screw Flange head screw Rear radiator bracket Threaded insert Cap screw Engine 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.
Removal (Fig. 9) Installation 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1. Install any removed brackets or shrouds to radiator using Figure 9 as a guide. 2. Open and remove the hood (see Traction Unit Operator’s Manual). 2. Remove any plugs used during the removal procedure. 3. Carefully position radiator assembly to the frame.
Engine Removal 1. Park machine on a level surface, lower cutting units, stop engine, and remove key from the ignition switch. Chock wheels to keep the machine from moving. 3 3 5 1 2. Disconnect positive (+) and then negative (–) battery cables at the battery. 3 3. Gain access to the engine. A. Open and remove hood from the machine (see Traction Unit Operator’s Manual). 3 B. Remove right side panel to gain access to the traction pump drive belt. 4 C.
12.Close fuel tank shut–off valve. 1 13.Disconnect hoses from engine. 6 A. Loosen clamps and disconnect upper and lower radiator hoses from the engine. B. At injector pump, loosen hose clamp and disconnect fuel hose from the fuel filter/water separator (Fig. 12). Plug hose to prevent leakage and contamination. 5 4 C. At injector pump, loosen hose clamp and disconnect the return to tank fuel hose (Fig. 12). Plug hose to prevent leakage and contamination.
20 5 28 25 17 Lift Tab 19 9 Lift Tab 8 4 29 16 13 7 6 11 15 3 18 4 26 2 20 20 12 24 23 3 4 14 22 10 27 1 21 22 23 22 27 RIGHT FRONT Figure 15 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Engine Flywheel stub shaft Cap screw Flat washer Bushing Pulley Key Hardened washer Lower alternator bracket Front engine frame 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Engine Installation 5. Reconnect electrical connections. 2. Make sure that all parts removed from the engine during maintenance or rebuilding are reinstalled to the engine. A. Pull wiring harness and hoses into position keeping them from contacting moving parts. Route harness and hoses through R–clamps. Install cap screws with flat washers to secure R–clamps to cylinder head (Fig. 14). 3. If engine frames or channel were removed from the engine, reinstall them as follows (Fig. 15): B.
6. Install hydraulic pump assembly (see Service and Repairs section of Chapter 4 – Hydraulic System). 16.Fill hydraulic reservoir with hydraulic fluid (see Traction Unit Operator’s Manual). Check reservoir for leaks. 7. After engine and pump installation, verify pulley alignment across engine and pump pulley faces with a straight edge. The gap between both faces must not exceed 0.030” (0.8 mm). 17.Slide the left foot rest onto the brake rod.
Engine PTO Disassembly 2 8 3 4 17 to 21 ft–lb (23 to 29 N–m) 3. Remove five cap screws and flat washers that secure stub shaft to engine flywheel. Remove stub shaft from engine. 1. Position stub shaft to engine flywheel and install cap screws and flat washers. Torque cap screws from 17 to 21 ft–lb (23 to 29 N–m). 9 5 2. Insert cap screws into threaded removal holes of the bushing. Tighten screws progressively and evenly until the pulley is loose on the bushing.
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Chapter 4 Hydraulic System SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic Fitting Installation . . . . . . . . . . . . . . . . . . . 4 Towing Traction Unit . . . . . . . . . . . . . . . . . . . . . . . . . 6 Check Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . 6 HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . .
Specifications Item Description Traction Pump Maximum Operating Pressure Variable displacement piston pump 3000 PSI (207 bar) Wheel Motors Maximum Operating Pressure Orbital rotor motor (with shuttle valve on left front motor) 2000 PSI (138 bar) Charge Pump Charge Pressure Gerotor pump integral in traction pump 100 to 150 PSI (6.9 to 10.0 bar) Implement (Lift) Relief Valve Implement Relief Pressure Differential area relief valve 450 – 525 PSI (31.1 to 36.
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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 and 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 IMPORTANT: If towing limits are exceeded, severe damage to the piston pump may occur. If it becomes necessary to tow (or push) the machine, tow (or push) at a speed below 3 mph (4.8 kph), and for a distance less than 1/4 mile (0.4 km). The piston (traction) pump is equipped with a by–pass valve that needs to be turned 90o for towing. See Traction Unit Operator’s Manual for Towing Procedures. 1 Figure 6 1.
SHUTTLE VLV BY–PASS VALVE Reelmaster 2000–D Page 4 – 7 Hydraulic System All solenoids are shown as de–energized Reelmaster 2000–D Hydraulic Schematic Optional 3 Wheel Drive Kit Hydraulic Schematic Hydraulic System
BY–PASS VALVE Hydraulic System Page 4 – 8 Working Pressure Low Pressure (Charge) Return or Suction Flow Reelmaster 2000–D Traction Circuit (Forward Shown) Optional 3 Wheel Drive Kit Hydraulic Flow Diagrams Reelmaster 2000–D
Traction Circuit Forward Direction Reverse Direction The traction pump is driven by the engine through the pulleys and pump drive belt. The traction circuit of the hydraulic system acts essentially as a closed loop. Taking its suction directly from the return side of the wheel motors of the traction circuit, the traction pump supplies oil flow to the wheel motors through the supply side of the traction circuit.
Hydraulic System Page 4 – 10 Reelmaster 2000–D BY–PASS VALVE Working Pressure Low Pressure (Charge) Return or Suction Flow Reelmaster 2000–D Lift Circuit (Raise) Optional 3 Wheel Drive Kit
Lift Circuit The charge pump is part of the traction pump and is directly coupled to it. It supplies hydraulic pressure for raising and lowering cutting units and maintaining 100 to 150 PSI to the low pressure side of the traction circuit (piston pump). The charge pump takes its suction through a filter from the reservoir. During conditions of not lifting or lowering cutting units, flow from the charge pump goes to the lift control valve and is by–passed (Fig.
Hydraulic System Page 4 – 12 Reelmaster 2000–D BY–PASS VALVE Working Pressure Low Pressure (Charge) Return or Suction Flow Reelmaster 2000–D Mow Circuit (Cutting Units Engaged) Optional 3 Wheel Drive Kit
Mow Circuit The reel motor drive pump is directly coupled to the traction pump which is belt driven by the engine. Taking its suction directly from the reservoir, the reel motor drive pump supplies oil flow to the hydraulic manifold block and to the reel motors. With the engine running and the cutting unit switch in the DISENGAGED position, oil flows into inlet port (P1) and through deenergized solenoid valve (S1) bypassing the reel motors.
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 connection of test gauges to the system. The kit includes: tee’s, unions, reducers, plugs, caps, and male test fittings. Figure 11 Measuring Container Toro Part Number: TOR4077 Use this container for doing hydraulic motor efficiency testing (motors with case drain lines only).
Troubleshooting The cause of an improperly functioning hydraulic system is best diagnosed with the use of proper testing equipment and a thorough understanding of the complete hydraulic system. A hydraulic system with an excessive increase in heat or noise has a potential for failure. Should either of these conditions be noticed, immediately stop the machine, turn off the engine, locate the cause of the trouble, and correct it before allowing the machine to be used again.
Problem Possible Cause No traction in either direction Brake is not released. Oil level in reservoir is low. Traction pump by--pass valve is open. Charge pressure is low. Traction pump or wheel motor(s) are worn or damaged. Wheel motor will not turn Internal parts in wheel motor are damaged. Brakes are binding. Key on wheel motor shaft is sheared or missing. Wheel motor will not hold load in neutral Make up fluid from charge pump is not available.
Problem Possible Cause Cutting units will not lift or lift slowly Engine speed is too low. Pump pulley drive belt is loose. Charge pump is damaged. Lift valve control linkage is binding or broken. Lift cylinder bushings are binding. Reservoir oil level is low. Inlet filter is loose or clogged. Charge pump pressure or flow is insufficient. Implement relief valve is stuck open. Lift control valve is damaged. Lift cylinders leak internally.
Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks. (See Special Tools section in this Chapter.) 1. Thoroughly clean the machine before disconnecting or disassembling any hydraulic components. Always keep in mind the need for cleanliness when working on hydraulic equipment. Contamination will cause excessive wear of hydraulic components. 2.
TEST NO.
Procedure for Traction Circuit Working Pressure Test: 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 3 1 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off. 4 3. Read Precautions For Hydraulic Testing. 4. Make sure that traction pedal is adjusted to the neutral position (see Traction Unit Operator’s Manual). 2 RIGHT 5.
TEST NO.
Procedure for Mow Circuit Working Pressure Test: 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 1 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. Connect pressure test gauge with a hydraulic hose attached to the reel circuit test port on the hydraulic manifold (Fig. 18).
TEST NO.
Procedure for Traction Pump Flow 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. CAUTION Use extreme caution when taking gauge readings. The front tire on the ground will be trying to move the machine forward. 3. Read Precautions For Hydraulic Testing. 14.Slowly push traction pedal to fully forward position. 4.
TEST NO.
Procedure for Charge Pump Flow Test: 3. Operate engine at full speed (3200 + 50 RPM). 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 4. Watch pressure gauge carefully. Make sure lift lever is in the neutral position. Record the pressure. 2. Park machine on a level surface with the cutting units lowered. Make sure engine is off and the parking brake is engaged. 5.
TEST NO.
Procedure for Charge Pump Relief Pressure Test: 9. Shut off engine. 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 10.Disconnect gauge and T–connection from the pump and hose. Reconnect hose to the pump. 2. Park machine on a level surface with the cutting units lowered. Make sure engine is off and the parking brake is engaged. 3. Read Precautions For Hydraulic Testing.
TEST NO.
Procedure for Reel Gear Pump Flow 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. Make sure engine is off and the parking brake is engaged. 3. Read Precautions For Hydraulic Testing. 3 CAUTION Figure 25 1. Reel gear pump 2. Hose to manifold P1 4. Clean hose connection and reel gear pump.
TEST NO. 7: Manifold Relief Valve Pressure (Using Tester With Pressure Gauges and Flow Meter) G1 TESTER FROM REEL DRIVE PUMP M2 D1 RH MD1 M1 M5 D3 CTR M6 TO COOLER M4 LH FROM CARTRIDGE VALVES AND LEFT WHEEL MOTOR D2 M3 HYDRAULIC MANIFOLD Working Pressure Low Pressure (Charge) Return or Suction Flow Install tester in series between fitting and hose at the motor (right hand motor shown).
Procedure for Manifold Relief Valve Pressure Test: 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. NOTE: Do not remove relief valve from the hydraulic manifold for adjustment. 10.Adjust the relief valve pressure as follows: A. Remove the cap from the relief valve (Fig. 28). 2. Park machine on a level surface with the cutting units lowered. Make sure engine is off and the parking brake is engaged. 3.
TEST NO. 8: Cross–over Relief Pressures (Using Pressure Gauge) TEST GAUGE LOCATION (TESTING IN MOW) G1 FROM REEL DRIVE PUMP M2 D1 RH MD1 M1 M5 D3 CTR M6 TO COOLER M4 LH FROM CARTRIDGE VALVES AND LEFT WHEEL MOTOR D2 M3 T–CONNECTION AND GAUGE LOCATION (TESTING IN BACKLAP) HYDRAULIC MANIFOLD Working Pressure Low Pressure (Charge) 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: 9. Remove test gauge and put cap on manifold port G1. 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. IMPORTANT: Each reel motor has two cross–over reliefs. Test reliefs in the backlap direction only if they are expected to be a problem.
TEST NO. 9: Reel Motor Case Drain (Using Tester With Pressure Gauges and Flow Meter) MEASURE RH CASE DRAIN FLOW HERE G1 TEST CONNECTION FOR R.H.
NOTE: Over a period of time, a reel motor can wear internally. A worn motor may by–pass oil to its case drain causing the motor to be less efficient. Eventually, enough oil loss will cause the reel motor to stall under heavy cutting conditions. Continued operation with a worn, inefficient motor can generate excessive heat, cause damage to seals and other components in the hydraulic system, and affect quality of cut.
TEST NO. 10: Wheel Motor Case Drain (Using Tester With Pressure Gauges and Flow Meter) WHEEL MOTOR RIGHT FORWARD TO REAR WHEEL MOTOR (OPTIONAL 3WD KIT) REVERSE FROM REAR WHEEL MOTOR (OPTIONAL 3WD KIT) REELS DISENGAGED TO PREVENT FLOW TO REAR WHEEL TESTER BOTTOM TOP TEST CONNECTION FOR R.H.
14.If specifications are not met, the tested wheel motor needs to be repaired or replaced as necessary. Procedure for Wheel Motor Case Drain 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. 15.
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.
Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time there is a severe component failure or the system is contaminated (oil appears milky or black or contains metal particles). 1 IMPORTANT: Flush hydraulic system when changIng from petroleum base hydraulic fluid, such as Mobil DTE 15M, to biodegradable fluid, such as Mobil EAL 224H. Operate machine under normal operating conditions for at least four (4) hours before draining. 2 1. Park machine on a level surface.
Hydraulic System Start–up NOTE: When initially starting the hydraulic system with new or rebuilt components such as motors, pumps, or lift cylinders, it is important that this start–up procedure be used. This procedure reduces the chance of damaging the system or its components from not purging the system of air. 1. After the hydraulic system components have been properly installed and if the traction pump was rebuilt or replaced, make sure traction pump housing is at least half full of clean hydraulic oil.
Hydraulic Pump Drive Belt 6 3 5 4 2 1 7 7 8 9 60 to 70 ft–lb (81 to 95 N–m) 12 13 FRONT 9 8 11 12 10 14 Figure 34 1. 2. 3. 4. 5. Hydraulic pump drive belt Pump pulley Engine pulley Pump support Hardened washer 6. 7. 8. 9. 10. Adjusting bolt (full thread) Jam nut Top spherical washer Bottom spherical washer Lock nut Drive Belt Removal 1. Park the machine on a level surface, engage parking brake, lower cutting units, and stop engine. Remove key from the ignition switch. 2.
Traction/Charge Pump 41 16 37 17 38 11 30 31 25 39 44 32 18 13 40 37 8 39 19 90 to 120 in–lb (10.2 to 13.6 N–m) 28 27 12 7 10 6 9 20 1 40 14 33 2 21 37 Anti–seize lubricant 23 39 3 15 22 36 29 30 38 40 12 43 Thread–locking Compound 29 35 34 5 4 40 24 RIGHT FRONT 45 25 42 34 35 26 10 5 Figure 35 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Neutral Arm Assembly 26 19 18 27 7 28 9 3 2 20 21 15 25 14 1 8 10 13 25 4 17 Hydraulic System 24 11 16 12 6 23 22 5 Figure 36 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Extension spring Hose Neutral bracket Pump lever Screw Washer Lock nut Mount Hub Neutral arm 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. Thrust washer Traction stud Grease fitting Cap screw Lock nut Bearing Cap screw Lock nut Carriage screw Removal (Fig.
4. Remove pulley from the taper lock bushing on the piston pump: 8. Remove reel drive pump from the piston pump (see Reel Drive Pump Removal). A. Remove cap screws and lock washers securing pulley to the taper lock bushing. 9. Remove hydraulic fittings and O–rings from the pumps as required. IMPORTANT: Excessive or unequal pressure on the cap screws can break the bushing flange. 10.If necessary, loosen socket head set screw in taper lock bushing and remove bushing from the piston pump shaft.
9. Install drive belt to the pulleys (see Hydraulic Pump Drive Belt). CAUTION The extension spring is under tension and may cause personal injury during installation. Use caution when installing the spring to the neutral arm. 10.Check traction drive for neutral and neutral switch adjustment (see Traction Unit Operator’s Manual). 11. Remove plug from the hydraulic reservoir. 12.Follow Hydraulic System Start–up procedures. D. Install extension spring and hose to the neutral arm and pump support. 8.
Traction/Charge Pump Service 28 18 27 25 36 26 35 20 34 20 2 21 22 17 14 12 4 24 13 33 30 31 3 15 22 5 1 29 19 31 8 7 11 6 8 10 9 14 17 33 32 10 16 23 Figure 37 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Drive shaft End cover Housing Rotating kit Camplate Washer Snap ring Retaining ring Thrust bearing Thrust washer Drive shaft seal Housing gasket 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
Reel Gear Pump Removal (Fig. 38) 27 to 33 ft–lb (37 to 44 N–m) 1. Park the machine on a level surface, engage the parking brake, lower the cutting units, and stop the engine. Remove the key from the ignition switch. 6 PUMP INLET PORT 10 3 7 2 4 CAUTION 8 Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. 9 3. Loosen hose clamp (2) and remove hose (3) from fitting. Allow hydraulic oil to drain from hose into a suitable container. 4.
Reel Gear Pump Service (Barnes) 1 2 3 4 5 6 7 INLET PORT SIDE 10 7 6 11 14 5 4 8 12 13 OUTLET PORT 40 ft--lb (54 N--m) 9 Figure 39 1. 2. 3. 4. 5. Retaining ring Shaft seal Mounting flange Backup ring E--seal 6. 7. 8. 9. 10. O--ring Dowel pin End cover Bolt Gear housing Disassembly (Fig. 39) 1. Tape the shaft end of the drive gear (11) to prevent damaging the shaft seal when the shaft is removed or reinstalled. 2.
1. Place the mounting flange on a clean working surface with the shaft seal (2) up. Remove the retaining ring. NOTE: Avoid scratching or marring the shaft seal bore in the mounting flange. Damage to the bore may cause the shaft seal to leak around the outer diameter of the seal. 2. Carefully remove the shaft seal. Clean any contamination from the seal bore. 3. Place a new shaft seal with the part number side up into the seal bore.
Reel Gear Pump Service (Casappa) 12 11 10 8 3 5 6 13 6 14 5 11 33 ft--lb (45 N--m) 9 7 1 2 4 Figure 39.1 1. 2. 3. 4. 5. Retaining ring Shaft seal Front flange O--ring Pressure seal 6. 7. 8. 9. 10. Back--up gasket Front wear plate Drive shaft Idler gear Rear wear plate Disassembly (Fig. 39.1) 11. 12. 13. 14. Dowel pin Body Washer (4 used) Cap screw (4 used) MARKER LINE NOTE: The gear pump must be replaced as a complete assembly.
4. Loosen the four (4) cap screws that secure pump assembly. 10.Clean all parts. Check all components for burrs, scoring, nicks and other damage. 5. Remove pump from vise and remove fasteners. 11. Replace the entire pump assembly if parts are excessively worn or scored. 6. Support the pump assembly and gently tap the pump case with a soft face hammer to loosen the pump sections. Be careful to not drop parts or disengage gear mesh.
Wheel Motor Front Wheel Motor Removal (Fig. 40) 1. Park the machine on a level surface, engage the parking brake, lower the cutting units, and stop the engine. Remove the key from the ignition switch. 9 (LH) 4 7 (LH) 3 CAUTION 6 (LH) Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. 5 16 8 5 1 16 10 14 2 2. Remove wheel and brake assembly from unit (see Repair section of Chapter 6 – Chassis). 12 3.
3WD Rear Wheel Motor Removal (Fig. 41) If the optional 3 Wheel Drive Kit has been installed, rear wheel motor removal procedure is as follows. 1. Park the machine on a level surface, engage the parking brake, lower the cutting units, and stop the engine. Remove the key from the ignition switch. 7 1 CAUTION 2 Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. 5 3 4 8 6 2. Clean wheel motor and hydraulic connection.
Wheel Motor Service 3 LEFT WHEEL MOTOR SHOWN 2 1 19 28 27 28 5 29 10 4 26 18 20 17 6 16 8 7 21 8 22 23 9 24 5 10 25 11 12 13 14 15 Figure 42 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Coupling shaft Thrust bearing Drive link Cap screw O–ring Shuttle valve Ball Spring End cover Plug 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Manifold Stator Vane Rotor Wear plate Commutator ring Commutator Commutator seal Bearing Woodruff key 21. 22. 23. 24. 25. 26. 27. 28. 29.
Cutting Reel Motor Removal (Fig. 43) 1. Park the machine on a level surface, engage the parking brake, lower the cutting units, and stop the engine. Remove the key from the ignition switch. CAUTION 35 ft–lb (47 N–m) Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. 4 2 2. Remove reel motor from cutting unit (see Repair section of Chapter 7 – Cutting Units). 1 3 3. Unscrew flange nut and remove coupling from reel motor using a puller.
Cutting Reel Motor Service (Serial Number Below 290000000) 7 10 to 12 ft--lb (14 to 16 N--m) 1 2 3 4 5 8 9 6 10 11 12 11 13 14 25 to 28 ft--lb (34 to 38 N--m) 15 19 13 18 17 16 Figure 44 1. 2. 3. 4. 5. 6. 7. Relief valve plug O--ring Shim Spring Ball Relief valve seat Backplate 8. 9. 10. 11. 12. 13. Idler gear assembly Drive gear assembly Key O--ring Body Alignment pin 14. 15. 16. 17. 18. 19.
IMPORTANT: Do not remove the relief valve assembly (19) unless testing shows it to be faulty. The relief valve assembly must be replaced as a complete unit. Both relief valve seats (6) are sealed in place with locking compound; do not remove them. 10.If necessary, remove relief valve plug, O–ring, shim, spring, and ball from the backplate. 11. The face of the backplate and frontplate should be free of excessive scoring. Replace if any scoring exists to a depth of 0.0015 in. (0.038 mm). 12.
Cutting Reel Motor Service (Serial Number Above 290000000) 18 33 ft--lb (45 N--m) 17 16 14 13 6 7 11 9 7 6 2 14 3 15 12 10 9 8 4 5 1 Figure 44.1 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. 44.1) 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. 44.3): 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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Hydraulic Manifold Removal (Fig. 45) 6 1. Park the machine on a level surface, engage the parking brake, lower the cutting units, and stop the engine. Remove the key from the ignition switch. 5 7 8 9 CAUTION 3 Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. 4 2 2. Raise and remove hood to gain access to the hydraulic manifold. NOTE: The ports on the manifold are marked for easy identification of components.
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Hydraulic Manifold Service (Serial Number Below 290000000) 35 ft--lb (47 N--m) 33 15 in--lb (1.7 N--m) 10 9 13 10 35 ft--lb (47 N--m) 24 14 11 8 27 27 30 17 7 3 4 26 28 29 25 Thread--locking Compound 26 32 25 29 24 30 20 Thread--locking Compound 12 18 15 19 35 ft--lb 16 (47 N--m) 3 4 35 ft--lb (47 N--m) 5 35 ft--lb (47 N--m) 6 4 4 3 3 2 1 11 12 31 21 22 22 23 21 PLUG TORQUE SAE #2: 60 in--lb (6.8 N--m) SAE #4: 135 in--lb (15.3 N--m) SAE #6: 18 ft--lb (24.
8. Reinstall the cartridge valve: 1. Make sure the manifold is clean before removing the cartridge valve. 2. If solenoid cartridge is being serviced, remove nut securing solenoid to the cartridge valve. Carefully slide solenoid off the valve. 3. If reel speed control cartridge valve or backlap cartridge valve is being serviced, remove knob assembly: A. Unscrew and remove knob. Remove both jam nuts. B. Slide off indicator plate being careful not to lose springs or balls.
H. On backlap valve, turn knob counterclockwise so the arrow is 90o with the back of the manifold body. Simultaneously tighten upper jam nut and turn knob so it is tight and the arrow is pointing 45o to the right in line with the indicator plate. I. On reel speed control valve, turn knob counterclockwise until the arrow points at the number ”5”. Simultaneously tighten upper jam nut and turn knob so it is tight and the arrow is pointing at the number ”1” on the locating plate. 11.
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Hydraulic Manifold Service (Serial Number Above 290000000) 15 ft--lb (20 N--m) FRONT UP 12 9 25 ft--lb (34 N--m) 25 ft--lb (34 N--m) 40 ft--lb (54 N--m) 10 5 ft--lb (6.7 N--m) 50 ft--lb (67 N--m) 1 11 2 13 14 8 15 3 7 7 7 4 20 ft--lb (27 N--m) 25 ft--lb (34 N--m) 20 ft--lb (27 N--m) 25 ft--lb (34 N--m) 16 17 7 6 18 3 3 5 19 7 20 ft--lb (27 N--m) 20 ft--lb (27 N--m) 20 3 20 ft--lb (27 N--m) 21 16 15 UP 25 ft--lb (34 N--m) FRONT 21 50 ft--lb (67 N--m) 19 17 Figure 46.
Hydraulic Manifold Service C. Push spool down until O--ring and back--up ring are exposed on bottom of mow manifold. Remove lower O--ring and back--up ring from spool. 1. Make sure the manifold is thoroughly cleaned before removing any cartridge valve. D. Pull spool up and out of mow manifold. Remove O--rings and back--up ring from spool. 2. If solenoid cartridge valve is being serviced, remove nut securing solenoid coil to the cartridge valve. Carefully slide solenoid coil off the valve. E.
CAUTION Abrupt movement of internal spools can cause stored fluid to be released suddenly. 8. Clean cartridge valve by submerging valve in clean mineral spirits to flush out contamination. Particles as fine as talcum powder can affect the operation of high pressure hydraulic valves. If cartridge design allows, use a wood or plastic probe to push the internal spool in and out 20 to 30 times to flush out contamination. Be extremely careful not to damage cartridge. Use compressed air for cleaning. 9.
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3 Wheel Drive Selector Valve 10 8 10 8 14 RIGHT FRONT 7 4 8 6 12 9 5 11 13 11 2 1 12 8 9 11 5 12 3 3 Figure 47 1. 2. 3. 4. 5. Forward hydraulic tube Reverse hydraulic tube Lock nut 3WD selector valve Hydraulic fitting Hydraulic System 6. 7. 8. 9. 10. 90o hydraulic fitting Cap screw Flat washer Tube clamp Cap screw Page 4 – 64 11. 12. 13. 14.
If the optional 3 Wheel Drive Kit has been installed, the 3WD selector valve removal and installation procedure is as follows. Installation (Fig. 47) 1. Install hydraulic fittings and new O–rings into selector valve. Removal (Fig. 47) 1. Park the machine on a level surface, engage the parking brake, lower the cutting units, and stop the engine. Remove the key from the ignition switch. 2. Position selector valve to the machine. Secure selector valve to the frame skirt with two cap screws and flat washers.
3 Wheel Drive Selector Valve Service 5 4 to 6 ft–lb (5.4 to 8.1 N–m) 6 4 6 Thread–locking Compound 3 35 to 40 ft–lb (47 to 54 N–m) 2 35 to 40 ft–lb (47 to 54 N–m) 1 Figure 48 1. Selector Valve manifold 2. Solenoid valve Hydraulic System 3. Pilot operated directional valve 4. Solenoid coil Page 4 – 66 5. Nut 6.
If the optional 3 Wheel Drive Kit has been installed, the 3WD selector valve service procedure is as follows. 7. Reinstall the cartridge valve: 1. Make sure the manifold is clean before removing the cartridge valve. A. Lubricate new seal kit components with clean hydraulic oil and install on valve. The o–rings, sealing rings, and backup rings must be arranged properly on the cartridge valve for proper operation and sealing. 2.
Front Lift Cylinder INSTALL FLANGE BUSHINGS (18) FROM THE INSIDE 17 HYDRAULIC FITTING SIDE 14 15 11 18 13 12 1 4 6 6 18 19 14 15 5 2 7 6 16 3 8 13 10 9 Figure 49 1. 2. 3. 4. 5. 6. 7. Hydraulic hose Hydraulic hose Hydraulic hose Hydraulic hose Hydraulic tee fitting O–ring O–ring Hydraulic System 8. 9. 10. 11. 12. 13. Lift cylinder Cotter pin Clevis pin Flange head screw Lift hub Cotter pin Page 4 – 68 14. 15. 16. 17. 18. 19.
Removal (Fig. 49) Installation (Fig. 49) 1. Park the machine on a level surface, engage the parking brake, lower the cutting units, and stop the engine. Remove the key from the ignition switch. 1. Thread lift hub onto lift cylinder and tighten fully. Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. 2. Remove cutting units from front lift arms (see Traction Unit Operator’s Manual). 3.
Front Lift Cylinder Service 9 7 11 5 3 10 8 1 6 4 2 12 Figure 50 1. 2. 3. 4. Retaining ring O–ring Head Backup washer 5. 6. 7. 8. O–ring Shaft O–ring Piston Disassembly (Fig. 50) 1. Remove oil from the cylinder into a drain pan by slowly pumping the cylinder shaft (6). Plug both ports and clean the outside of the lift cylinder. IMPORTANT: Prevent damage when clamping the lift cylinder into a vise; clamp on the pivot only. Do not close vise enough to distort barrel. 9. 10. 11. 12.
Inspection CAUTION Spanner wrench Use eye protection such as goggles when using compressed air 1. Wash all parts in solvent. Dry parts with compressed air. 2. Inspect internal surface of barrel for deep scratches, out–of–roundness, and bending. Replace if worn or damaged. Retaining ring (Offset end against left side of barrel groove after installing) Figure 52 3. Inspect head, shaft, and piston for excessive pitting, scoring, and wear. Replace any worn or damaged parts. Reassembly (Fig. 50) 1.
Rear Lift Cylinder 8 FRONT 2 26 RIGHT 27 3 4 25 5 6 7 30 29 10 12 28 20 29 14 1 9 28 11 18 22 13 15 17 19 20 14 24 23 21 17 16 Figure 53 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Cotter pin Tension spring arm Cap screw Thread forming screw Washer head screw Ram pivot pin Lift arm pivot shaft Lock nut Hydraulic hose Hydraulic hose Hydraulic System 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Removal (Fig. 53) Installation (Fig. 53) 1. Park the machine on a level surface, engage the parking brake, lower the cutting units, and stop the engine. Remove the key from the ignition switch. 1. Coat new O–rings lightly with clean hydraulic oil. Install hydraulic fittings with new O–rings to the lift cylinder. 2. Remove cutting unit from rear lift arm (see Traction Unit Operator’s Manual). 2. Position lift cylinder inside frame pivot supports. Install ram pivot pin and washer head screw.
Rear Lift Cylinder Service 14 6 11 9 7 13 5 12 3 1 10 8 6 4 15 2 Figure 54 1. 2. 3. 4. 5. Barrel Lock nut Piston Uni–ring O–ring 6. 7. 8. 9. 10. Shaft O–ring O–ring Backup washer Head Disassembly (Fig. 54) 1. Remove oil from cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the lift cylinder. 11. 12. 13. 14. 15.
4. Install piston onto the shaft being careful not to damage O–ring. Install locknut onto the shaft and tighten. Reassembly (Fig. 54) 1. Coat new dust seal, uni–ring, backup washer, and all O–rings lightly with hydraulic oil. Install new O–ring and uni–ring to the piston. Install O–rings and backup washer to the head. Press dust seal into head. IMPORTANT: Do not clamp vise jaws against shaft surface. Protect shaft surface before mounting in vise. 2. Mount shaft securely in a vise.
Control and Lift Relief Valves 6 14 15 28 3 13 5 7 25 IN 16 4 24 17 1 RETURN A 2 26 B 22 24 25 21 23 26 25 11 12 19 24 7 24 20 10 9 8 24 18 27 25 24 Figure 55 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Control valve Lock nut Hydraulic hose Cap screw Valve lever Knob Hydraulic tee fitting 90o hydraulic fitting Hydraulic hose Hydraulic hose 11. 12. 13. 14. 15. 16. 17. 18. 19. Hydraulic hose O–ring Lock nut Sponge Spring Flat washer Flat washer Hydraulic tube Straight hydraulic fitting 1.
5. Unsnap and remove connecting link assembly (28). Remove valve lever (5) from the control valve (1). 6. Disconnect tube (21) from hydraulic fitting (7). Disconnect tube (18) from 90o hydraulic fitting (8). 7. Remove hydraulic fittings (7, 8, 19, and 22) and O– rings from the control valve (1). 1. Disconnect hose connection (9) from hydraulic tee fitting (7). Allow hose to drain hydraulic oil into a suitable container. 2. Disconnect tube (21) from hydraulic tee fitting (7).
Control Valve Disassembly (Fig. 56) 1. Wash control valve in solvent and dry it thoroughly. 2. Mount control valve into a vise so the mounting pads are against the jaws of the vice and snap ring faces up. 8 NOTE: Remove check valve seat only if it needs replacement; it is pressed into the valve body. 3. Remove plugs and O–rings from the valve body. Remove springs, balls, and cam pins from the valve body. 4. Remove snap ring from the bottom of the valve body.
Hydraulic Reservoir 1 6 2 7 26 24 8 Thread–locking Compound 30 to 60 in–lb (3.4 to 6.8 N–m) 23 9 24 16 3 14 14 22 20 11 12 15 25 4 15 10 5 13 5 24 21 RIGHT 24 FRONT 13 17 5 14 22 Hydraulic System 19 18 13 10 11 12 30 to 60 in–lb (3.4 to 6.8 N–m) Thread–locking Compound Figure 57 1. 2. 3. 4. 5. 6. 7. 8. 9. Shoulder screw Sight glass Hose clamp Tee fitting Nut Hydraulic reservoir cap Screen filter Hydraulic tank Tank bracket 10. 11. 12. 13. 14. 15. 16. 17. 18.
Oil Cooler 2 IN 6 5 4 3 7 8 RIGHT FRONT OUT 3 1 2 Hydraulic Sealant 9 4 17 10 11 16 6 5 12 13 14 15 Figure 58 1. 2. 3. 4. 5. 6. Oil cooler Hydraulic connector O–ring Bulkhead nut 90o hydraulic fitting Hose clamp 7. 8. 9. 10. 11. 12. Hydraulic hose (from manifold) Knob Lock nut Protective sleeve Hydraulic hose (to reservoir) Nut 13. 14. 15. 16. 17. Front screen bracket Flat washer Lock nut Flange head screw Left front panel Removal (Fig. 58) Installation (Fig. 58) 1.
Chapter 5 Electrical System Table of Contents Reels On Indicator Light . . . . . . . . . . . . . . . . . . . . Reel Engage Switch . . . . . . . . . . . . . . . . . . . . . . . . Glow Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Temperature Shutdown Switch . . . . . . . . . . Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . Engine Run Solenoid . . . . . . . . . . . . . . . . . . . . . . . Solenoid Valve Coil . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Schematics and Electrical Harness and Connectors Drawings The electrical schematics and other electrical drawings for the Reelmaster 2000–D are located in Chapter 8 – Electrical Diagrams.
Special Tools Order these special tools from your Toro Distributor. Some tools may also be available from a local supplier. Multimeter The multimeter 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 Chapter 8 – Electrical Diagrams). 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. If the machine has any interlock switches by–passed, they must be reconnected for proper troubleshooting and safety.
Starting Problems (continued) Problem Possible Causes Engine cranks, but does not start. Engine run solenoid is faulty. Glow plugs are faulty. Engine or fuel system is malfunctioning (see Chapter 3 – Engine). Engine and/or fuel may be too cold. Standard Control Module is faulty. Traction neutral switch is out of adjustment or faulty. Traction neutral switch wiring is faulty. Electrical System Engine cranks (but should not) with the traction pedal out of the neutral position.
General Run and Transport Problems Problem Possible Causes Engine continues to run (but should not) when the traction pedal is depressed with no operator on the seat. Seat switch is faulty, out of adjustment, or short circuited. Engine kills when the traction pedal is depressed or the reel engage switch is pulled ON with the operator in the seat. Operator is lifting off the seat (seat switch not depressed). Traction neutral switch is out of adjustment, faulty, or short circuited. Parking brake is on.
Cutting Unit Operating Problems Problem Possible Causes Engine Continues to run (but should not) when the reel Backlap switch is in the backlap position. engage switch is ON with no operator in the seat. Backlap switch is faulty or out of adjustment. Wiring to the mow/backlap circuit components is loose, corroded, or damaged (see Wiring Schematics). Seat switch is faulty, out of adjustment, or short circuited. Cutting units run (but should not) when raised.
Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the battery terminals. Voltage Measured Battery Charge Level 12.68 v (or higher) Fully charged (100%) Set the multimeter to the DC volts setting. The battery should be at a temperature of 60o to 100o F (16o to 38o C). The ignition key should be in the OFF position and all accessories turned off.
Starting System Test This is an excellent test to use when a “slow crank/no start” problem is encountered. It will determine if the problem is due to an electrical open, short, or high resistance in the starter circuit. NOTE: The battery condition and state of charge must be checked before testing the starter system. Tool(s) required: Digital multimeter and/or inductive Ammeter (AC/DC Current Transducer).
Adjustments Neutral Switch 1. Adjust the neutral switch so that the switch opens when the traction pedal is moved forward 1 inch (2.5 cm), measured at the top of pedal. 3 1 2 Figure 3 1. Traction pedal 2. Neutral switch 3. Traction arm Parking Brake Switch 1. Adjust parking brake switch so switch opens within two (2) clicks of parking brake lever movement. 1 2 Figure 4 1. Parking brake lever Electrical System Page 5 – 10 2.
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: Electrical troubleshooting of any 12 Volt power connection can be performed through voltage drop tests without disconnecting the component. NOTE: See the Briggs & Stratton/Daihatsu Engine Repair Manual for more component testing information.
Indicator Lights Engine 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 if the engine oil pressure drops below 4.3 PSI (0.3 kg/cm2). 2 To test the oil pressure light and circuit wiring, ground the gray wire attached to oil pressure switch located on the front side of engine near the oil dipstick.
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 10 Reels On Indicator Light The reels on indicator light should illuminate when the reels are engaged.
Glow Relay The glow relay is attached to the instrument panel. When energized, the glow relay allows electrical current to the glow plugs. 30 NOTE: Prior to taking small resistance readings with a digital multi meter, short the meter test leads together. The meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal resistance of the meter and test leads. Subtract this value from from the measured value of the component you are testing.
High Temperature Shutdown Switch The high temperature shutdown switch is located on the top of the water pump housing. The water pump is on the left end of the engine inside the fan pulley assembly. There is a blue/white wire attached to the shutdown switch. 2 The Standard Control Module monitors the operation of the high temperature shutdown switch.
Oil Pressure Switch The engine oil pressure switch is located on the cylinder near the dipstick and oil filter. It is a normally closed switch and opens with pressure. The operating range for the switch is 2.9 to 5.7 PSI (0.2 to 0.4 kg/cm2). 2 1 Testing with the engine off 1. Turn the ignition switch to the ON position. The oil pressure lamp should be on. 2. If the lamp is not on, disconnect the gray wire from the switch and ground the wire to the engine block. 3.
Solenoid Valve Coil The hydraulic system on the Reelmaster 2000–D uses a solenoid valve coil on the reel drive manifold and, when equipped with the optional 3WD kit, a second solenoid coil on the 3WD manifold. 2 NOTE: Prior to taking small resistance readings with a digital multimeter, short the test leads together. The meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal resistance of the meter and test leads.
Standard Control Module The Reelmaster 2000–D is 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 (Fig. 19). 1 Inputs from the neutral, parking brake, PTO, start (ignition), backlap, and high temperature switches are monitored by the Module.
Traction Neutral Switch The traction neutral switch is a normally open proximity switch that closes when the traction pedal is in the neutral position. The traction arm that is pinned to the traction lever acts as the sensing plate for the switch. 3 The Standard Control Module monitors the operation of the traction neutral switch. If the ignition switch is in the ON position and the traction pedal is in the neutral position, the Module neutral input LED should be illuminated.
Seat Switch The seat switch is normally open and closes when the operator is on the seat. If either the neutral switch or parking brake switch is open when the operator raises out of the seat, the engine will stop. 1 The standard seat uses a switch that is fastened to the underside of the seat (Fig. 22). The deluxe seat has a switch that is mounted to the seat base under the cushion. The switch electrical connector for either seat type is located directly under the seat.
Parking Brake Switch The parking brake switch is a normally open proximity switch that is mounted on a bracket at the base of the parking brake lever (Fig. 23). The parking brake lever is used as the sensing plate. 1 When the parking brake is engaged, the brake lever is moved away from the brake switch and the switch opens. This open switch prevents the cutting units from operating. 2 The Standard Control Module monitors the operation of the parking brake switch.
Cutting Unit Interlock Switch This switch is normally open and closes when the cutting units are lowered. The switch and its electrical connector are located behind and below the hydraulic manifold on the cylinder support bracket. 1. Disconnect switch electrical connector. 2. With the cutting units lowered, check the continuity of the switch by connecting a multimeter (ohms setting) across the connector terminals. There should be continuity across the switch. 1 2 3.
Fuses The fuse block is located on the back of the instrument panel (Fig. 26). Identification, Function, and Wiring The fuses are held in the fuse block. Use Figure 27 to identify each individual fuse and its correct amperage. Each fuse holder has the following functions and wire connected to it. 1 Fuse 1 (15 Amp) A. Supplies power to ignition switch terminal B. Figure 26 1. Fuse block B. Has orange wire and red wire (battery). Fuse 2 (option) A. Supplies power to optional lights. B.
Diode Assembly Diode D3 is used for circuit protection from voltage spikes when the hydraulic valve solenoid is de–energized. The diode plugs into the wiring harness (see Wire Harness Drawings in Chapter 8 – Electrical Diagrams). 2 Diode Test The diode (Fig. 28) can be tested using a digital multimeter (diode test or ohms setting) and the table below.
Service and Repairs NOTE: See the Briggs & Stratton/Daihatsu Engine Repair Manual for more component repair information. 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 extended. Additionally, battery and electrical component failure can be prevented. 1 CAUTION When working with batteries, use extreme caution to avoid slashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes. Always wear safety goggles and a face shield when working with batteries. Electrolyte Specific Gravity Fully charged: 1.265 corrected to 80oF (26.
G. Take a voltage reading at 15 seconds, then remove the load. B. Temperature correct each cell reading. For each 10oF (5.5oC) above 80oF (26.7oC) add 0.004 to the specific gravity reading. For each 10oF (5.5oC) below 80oF (26.7oC) subtract 0.004 from the specific gravity reading. Example: Cell Temperature 100oF Cell Gravity 1.245 100oF minus 80oF equals 20oF (37.7oC minus 26.7oC equals 11.0oC) 20oF multiply by 0.004/10oF equals 0.008 (11oC multiply by 0.004/5.5oC equals 0.008) ADD (conversion above) 0.
2. Determine the charging time and rate using the manufacturer’s battery charger instructions or the following table. Battery Reserve Capacity (Minutes) 3. Following the manufacturer’s instructions, connect the charger cables to the battery. Make sure a good connection is made. 4. Charge the battery following the manufacturer’s instructions. Battery Charge Level (Percent of Fully Charged) 75% 50% 25% 0% 80 or less 3.8 hrs @ 3 amps 7.5 hrs @ 3 amps 11.3 hrs @ 3 amps 15 hrs @ 3 amps 81 to 125 5.
Solenoid Valve Coil The solenoid valve coil on the reel drive (Fig. 30) and 3WD hydraulic manifold, if equipped, (Fig. 31) can be easily replaced without opening the hydraulic system. 3 1 Removal 2 to 5 ft–lb (2.7 to 6.8 N–m) 1. Disconnect the electrical connector. 2 2. Remove the nut from the spool assembly. 3. Slide the coil assembly and o–rings from the spool assembly. Discard the coil assembly and o–rings. 3 Thread–locking compound 4. Clean any corrosion or dirt from the spool assembly.
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Chapter 6 Chassis Table of Contents 2 4 4 6 8 Standard Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Suspension Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Steering Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 12 Front Lift Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Rear Lift Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Chassis SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications Item Description Front tire pressure (20 x 10–8, 4 ply, tubeless) 16 to 20 PSI (1.1 to 1.38 bar) Rear tire pressure (20 x 8–8, 4 ply, tube type) 16 to 20 PSI (1.1 to 1.
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Service and Repairs Rear Wheel (Standard 2 Wheel Drive) 21 60 to 80 ft–lb (81 to 108 N–m) 20 19 18 24 25 22 23 45 to 65 ft–lb (61 to 88 N–m) 26 15 17 10 9 6 2 4 16 14 RIGHT FRONT 13 12 1 11 7 8 7 5 15 to 20 ft–lb (20 to 27 N–m) (See text for tightening procedure) 3 Figure 1 1. 2. 3. 4. 5. 6. 7. 8. 9. Lug nut Wheel assembly Dust cap Lock nut retainer Jam nut Tab washer Bearing cone Bearing cup Wheel hub Chassis 10. 11. 12. 13. 14. 15. 16. 17. 18.
Removal (Fig. 1) Installation (Fig. 1) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1. If seal and inner bearing were removed from the wheel hub, place greased bearing cone into inner bearing cup. Install new seal. 2. Chock front wheels. Raise rear wheel using a jack or hoist. Block rear of machine. 2. Slide wheel hub onto machine. Position greased outer bearing and tab washer onto shaft. 3.
Rear Wheel (Optional 3 Wheel Drive) 2 250 to 400 ft–lb (339 to 542 N–m) 4 7 6 1 8 3 5 9 45 to 65 ft–lb (61 to 88 N–m) Figure 2 1. Rear wheel fork 2. Steering tube assembly 3. Rear wheel motor Chassis 4. Key 5. Drive stud 6. Wheel hub Page 6 – 6 7. Wheel assembly 8. Lock nut 9.
Removal (Fig. 2) Installation (Fig. 2) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1. Install key and wheel hub onto the wheel motor shaft. 2. Chock front wheels. Raise rear wheel using a jack or hoist. Block rear of machine. 2. Install lock nut to wheel motor shaft and tighten to a torque of 250 to 400 ft–lb (339 to 542 N–m). 3. Install wheel assembly and secure the lug nuts to the drive studs. 3.
Front Wheels and Brakes 3 18 4 5 34 2 30 31 32 33 1 20 31 32 6 7 8 10 27 9 16 26 17 25 29 12 15 45 to 65 ft–lb (61 to 88 N–m) 11 19 24 23 28 RIGHT 21 13 22 FRONT Anti–seize lubricant 250 to 400 ft–lb (339 to 542 N–m) 14 Figure 3 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Flange nut Brake rod Parking brake lever Flange head screw Extension spring Lock nut Flat washer Brake grass shield Cap screw Brake assembly Wheel hub Brake drum 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
7. Remove cotter pin (28) from the yoke pin (21). Remove yoke pin from the brake lever (22) and separate yoke (23) from the brake lever (Fig. 4). 8. Remove cap screws (9) and lock nuts (6) holding the backing plate (36) and brake grass shield (8) to the brake bracket. 9. Remove backing plate (29), flat washers (7), and brake grass shield (15) from the brake bracket. 2 10.
Standard Seat 4 5 1 6 7 14 2 3 13 9 8 12 15 11 10 Figure 5 1. 2. 3. 4. 5. Seat (incl. 2 thru 7) Seat switch Cap screw Edging clip Edging 6. 7. 8. 9. 10. Seat cushion Seat shell Seat adjuster Seat adjuster with latch Flange hex nut 11. 12. 13. 14. 15. Cap screw Lock washer Seat stop Cap screw Flange nut Removal Installation 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1.
Suspension Seat 39 3 4 42 40 41 1 2 7 32 8 9 5 6 12 38 10 37 36 33 35 34 23 5 31 24 30 29 28 27 26 25 11 14 22 13 19 21 20 16 15 18 44 43 17 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 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. Adjusting rail (LH) Screw Washer Nut Swing arm assembly (incl.
Steering Assembly 4 2 3 60 to 80 ft–lb (81 to 108 N–m) 26 1 19 20 21 27 5 28 6 22 7 8 12 13 9 11 9 6 14 15 10 25 22 24 23 16 16 17 18 12 14 RIGHT FRONT Figure 7 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Steering wheel Steering wheel cover Lock nut Flat washer Dust cover Bushing Steering column Lock nut Flat washer Steering shaft & gear Chassis 11. 12. 13. 14. 15. 16. 17. 18. 19.
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. Assemble steering assembly using Figure 7 as a guide. A. Shim steering shaft (with gear) and sector gear with thrust washers as needed to align gear tops. Gears should not contact flange bushings. 2. Disassemble steering assembly as needed using Figure 7 as a guide. B.
Front Lift Arms 19 24 10 25 13 12 11 26 27 20 23 22 10 20 21 28 29 9 1 18 10 20 2 12 19 RIGHT 3 9 17 13 8 16 4 15 FRONT 5 14 6 7 Figure 8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Lift arm (LH shown) Lock washer Cap screw Thrust washer Cutting unit pivot shaft Flat washer Flange head screw Grease fitting Bushing Cotter pin 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.
Rear Lift Arm 22 21 23 19 20 18 17 16 15 14 24 13 12 3 2 FRONT RIGHT 2 1 4 5 6 8 10 9 5 7 Chassis 11 Figure 9 1. 2. 3. 4. 5. 6. 7. 8. Lift arm Bushing Grease fitting Cap screw Lock washer Flat washer Cap screw Cutting unit pivot shaft 9. 10. 11. 12. 13. 14. 15. 16. Thrust washer Flat washer Flange head screw Lift arm pivot shaft Cap screw Self tapping screw Cap screw Reinforcement plate 17. 18. 19. 20. 21. 22. 23. 24.
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Chapter 7 Cutting Units Table of Contents Cutting Units SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 6 Factors That Can Affect Quality Of Cut . . . . . . . . . 6 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SERVICE AND REPAIRS . . . .
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, 8, or 11 blades of 7 inches (18 cm) diameter welded to stamped steel spiders. Reels are mounted on greaseable self–aligning ball bearings. Cutting unit reel length of either 27 inches (69 cm) or 32 inches (81 cm). HEIGHT OF CUT RANGE: Floating Cutting Unit – 1/4 to 1–3/4 inches (6mm to 44mm).
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Special Tools Order Special Tools from your Toro Distributor. Some tools may have been supplied with your machine or are available as Toro parts. Gauge Bar Assembly Use gauge bar to verify height--of--cut and bedknife attitude. Toro Part Number: 98-1852 Figure 2 Handle Assembly For applying lapping compound to cutting units while keeping hands a safe distance from the rotating reel.
Angle Indicator Use with Gauge Bar Assembly to verify bedknife attitude. Toro Part Number: 99–3503 Figure 5 Turf Evaluator Tool Many turf discrepancies are subtle and require closer examination. In these instances, the Turf Evaluator grass viewing tool is helpful. It can assist turf managers and service technicians in determining causes for poor reel mower performance and in comparing the effective height–of–cut of one mowed surface to another.
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. See Cutting Unit Operator’s Manual for adjustment procedures for the cutting units on the Reelmaster 2000–D. Characteristics The single knob bedknife–to–reel adjustment system incorporated in this cutting unit simplifies the adjustment procedure needed to deliver optimum mowing performance.
Service and Repairs Hydraulic Reel Motor Removal (Fig. 7) 1. Remove two cap screws holding the hydraulic motor to the bearing housing. 2. Remove hydraulic motor, o–ring, and spider coupler from the bearing housing. Position hydraulic motor away from the cutting unit prior to removing or working on the cutting unit. 3 Inspection 1. Inspect spider coupler for wear. Replace spider coupler if worn. 4 2. Check reel coupler inside bearing housing. If reel coupler is loose, remove and check for worn threads.
Bedbar 1 2 5 3 4 5 6 25 17 10 2 9 7 8 1 11 18 ANTI–SEIZE LUBRICANT 19 29 32 PERMANENT THREAD–LOCKING COMPOUND 24 23 30 22 31 21 13 12 ANTI–SEIZE LUBRICANT 20 26 ANTI–SEIZE LUBRICANT 12 13 14 28 15 16 RIGHT 27 FRONT 17 250 to 300 in–lb (28 to 34 N–m) 18 Figure 8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Rubber bushing Flanged bushing Jam nut Compression spring Washer Bedbar fitting Adjuster spacer Spring arm Bedbar adjuster Bedbar pivot Grease fitting 12. 13. 14. 15. 16. 17. 18. 19.
Installation 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 bedbar. Reinstall spacer, flat washer, lock washer, and cap screw to the right end of the bedbar. 1 4. Position bedbar assembly to the cutting unit. 2 5. Secure bedbar housing to the cutting unit with both carriage bolts and nuts. 4 3 6.
Bedknife Replacement and Grinding 1. Remove bedbar from the cutting unit (see Bedbar Removal). 2. Remove bedknife screws and bedknife. 3. Remove all rust, scale and corrosion from the bedbar surface before installing new bedknife. NOTE: Use a torque wrench and a bedknife screw tool to install bedknife screws. 4. Install new bedknife as follows: A. Make sure bedbar threads are clean. B. Use new bedknife screws. Apply anti–seize lubricant to the screw threads before installing.
Front and Rear Rollers 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 cap screws securing each angle bracket to the cutting unit. 1 3. Remove cap screws from both angle brackets and the cutting unit. 5 4. Separate roller assembly, height–of–cut brackets, and angle brackets from the cutting unit. 6 7 4 5.
Roller Service 1 2 3 4 5 6 7 8 9 2 4 5 See assembly process for tightening procedure 6 7 8 10 11 6 4 7 8 12 4 5 Figure 13 1. 2. 3. 4. Full roller Roller shaft Grease seal Bearing cup 5. 6. 7. 8. Bearing cone (outer) Outer seal Adjustment nut Grease fitting 9. 10. 11. 12. Wiehle roller Sectional roller shaft Bearing cone (inner) Sectional roller 6. Remove both bearing cones. On the sectional roller, remove all four bearing cones. Disassembly 1.
Full or Wiehle Roller Assembly Sectional Roller Assembly 1. Make sure all parts are clean prior to installing bearings and seals. 1. Make sure all parts are clean prior to installing bearings and seals. 2. On a full roller, grease inner seal lips and install inner seal into each end of the roller. Make sure that cupped side of the seal faces the inside of the roller. 2. Press two bearing cups into each sectional roller. Make sure narrow end of taper faces the inside of the roller. 3.
Cutting Reel 2 5 4 31 2 5 2 7 9 11 12 32 1 31 33 8 3 23 30 10 29 8 28 16 14 27 17 18 19 6 26 16 20 36 55 to 65 ft–lb (75 to 88 N–m) THREAD–LOCKING COMPOUND 21 35 13 RIGHT 26 ANTI–SEIZE LUBRICANT FRONT 36 22 15 55 to 65 ft–lb (75 to 88 N–m) THREAD–LOCKING COMPOUND 25 27 28 24 34 Figure 14 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
12.Install bedbar assembly to cutting unit (see Bedbar Installation). Inspect Cutting Reel (Fig. 14) 1. Replace reel if the diameter has decreased to the service limit (see Reel Grinding Specification in Preparing Reel For Grinding). 13.Complete cutting unit set–up and adjustment sequence (see Cutting Unit Operator’s Manual). 14.Install cutting unit to machine (see Traction Unit Operator’s Manual). 2. Replace reel if blades are bent or cracked. 3.
Prepare Reel for Grinding NOTE: Check to make sure reel bearings are in good condition and properly adjusted before grinding reel. 3. 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. 16). 2 6 4 2. Remove lock nuts, cap screws, washers, and both links from the cutting unit (Fig. 16). 3. Align fixed side plate with holes on the cutting unit (Fig. 17). 1 4. Attach fixed side plate to the cutting unit with cap screws, washers, and flanged lock nuts (Fig. 17). 5. Tighten lock nuts and cap screws. 3 6.
Skid Kit Installation 1. Remove front roller from the cutting unit (see Roller Removal). 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. 5 3 2 5. Adjust skid height as necessary by loosening lock nuts and flange head screws. After skid height adjustment, retighten fasteners. 1 Figure 18 1. Skid 2. Angle bracket holes 3.
Chapter 8 Electrical Diagrams Table of Contents Electrical Diagrams ELECTRICAL SCHEMATICS . . . . . . . . . . . . . . . . . . . 3 Serial Number Below 230000000 . . . . . . . . . . . . . . 3 Serial Number Above 230000000 . . . . . . . . . . . . . 4 CIRCUIT DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Glow Plug Circuit Diagram . . . . . . . . . . . . . . . . . . . . 5 Crank Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . 6 Run (Transport) Circuit Diagram . . . . . . . . . .
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(IN OFF) (UNOCCUPIED) (IN NEUTRAL) 3 WD SOLENOID (IF EQUIPPED) (IN OFF) Reelmaster 2000--D Electrical Schematic Serial Number Below 230000000 All relays and solenoids are shown as de-- energized. All ground wires are black. Page 8 -- 3 Rev.
Reelmaster 2000--D Electrical Schematic Serial Number Above 230000000 All relays and solenoids are shown as de-- energized. All ground wires are black. Page 8 -- 4 Rev.
(IN OFF) (UNOCCUPIED) (IN NEUTRAL) 3 WD SOLENOID (IF EQUIPPED) (IN OFF) Reelmaster 2000--D Glow Plug Circuit (Serial Number Below 230000000 Shown) Power Current Control Current Indicator/Gauge Current Logic Direction Page 8 -- 5 Rev.
(IN OFF) (UNOCCUPIED) (IN NEUTRAL) 3 WD SOLENOID (IF EQUIPPED) (IN OFF) NOTE: The engine will crank with either the parking brake engaged or the seat occupied. Reelmaster 2000--D Crank Circuit (Serial Number Below 230000000 Shown) Power Current Control Current Indicator/Gauge Current Logic Direction Page 8 -- 6 Rev.
(DISENGAGED) (IN OFF) (OCCUPIED) (NOT IN NEUTRAL) 3 WD SOLENOID (IF EQUIPPED) (IN OFF) Reelmaster 2000--D Run (Transport) Circuit (Serial Number Below 230000000 Shown) Power Current Control Current Indicator/Gauge Current Logic Direction Page 8 -- 7 Rev.
(DISENGAGED) (IN OFF) (OCCUPIED) (REELS LOWERED) (NOT IN NEUTRAL) 3 WD SOLENOID (IF EQUIPPED) (IN ON) Reelmaster 2000--D Run (Mow) Circuit (Serial Number Below 230000000 Shown) Power Current Control Current Indicator/Gauge Current Logic Direction Page 8 -- 8 Rev.
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GREEN RED ORANGE BLACK ORANGE BLACK YELLOW PINK BROWN RED/BLACK BLACK BLUE TAN GRAY PINK PINK BLACK WHITE BLACK BLACK PINK PINK BLACK WHITE PINK PINK RED PINK YELLOW BLACK BLACK WHITE GRAY PINK BLUE/WHITE GRAY PINK BLUE/WHITE PINK PINK RED TAN BLACK BROWN VIOLET TAN BLACK ORANGE TAN BLACK GREEN WHITE BLUE/WHITE BROWN VIOLET Reelmaster 2000--D Main Wire Harness Serial Number Below 230000000 Page 8 -- 10 Rev.
Reelmaster 2000--D Main Wire Harness Serial Number Below 230000000 Page 8 -- 11 Rev.
GREEN RED BLACK ORANGE BLACK BLUE TAN YELLOW BROWN RED/BLACK BLACK ORANGE PINK GRAY PINK PINK BLACK WHITE BLACK BLACK PINK PINK BLACK YELLOW WHITE PINK BLACK BLACK WHITE BLUE/WHITE GRAY PINK GRAY RED PINK PINK BLUE/WHITE RED PINK PINK TAN BLACK BROWN VIOLET ORANGE BLACK ORANGE ORANGE BLACK WHITE/BLACK PINK GREEN BLUE BLUE/WHITE BROWN VIOLET Reelmaster 2000--D Main Wire Harness Serial Number Above 230000000 Page 8 -- 12 Rev.
Reelmaster 2000--D Main Wire Harness Serial Number Above 230000000 Page 8 -- 13 Rev.
PINK RED BLUE/WHITE BLACK GRAY RED/BLACK WHITE YELLOW BLACK ORANGE GREEN BLACK BLACK WHITE BROWN BLACK GREEN GREEN GREEN Reelmaster 2000--D Engine Wire Harness Page 8 -- 14 Rev.
Reelmaster 2000--D Engine Wire Harness Page 8 -- 15 Rev.
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