Part No. 91772SL, Rev. C Service Manual Reelmaster® 335-D/3500-D Preface This publication provides the service technician with information for troubleshooting, testing, and repair of m a jo r s y s t e m s a nd c o m po ne nt s o n t he Reelmaster 335-D/3500-D REFER TO THE TRACTION UNIT AND CUTTING UNIT OPERATOR’S MANUALS FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS.
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Table Of Contents Chapter 1 - Safety Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1 Chapter 2 - Product Records and Manuals Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 Equivalents and Conversions . . . . . . . . . . . . . . . . 2 - 2 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . 2 - 3 Maintenance Interval Charts . . . . . . . . . . . . . . . . .
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Chapter 1 Safety Table of Contents While Doing Maintenance, Troubleshooting, Testing, Adjustments or Repairs . . . . . . . . . . . . . 3 SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . 1 Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . 1 While Operating. . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety Instructions The Reelmaster 335-D has been tested and verified for compliance with the B71.
. Make sure interlock switches are adjusted correctly so engine cannot be started unless traction pedal is in NEUTRAL and cutting units are DISENGAGED. 8. Since diesel fuel is flammable, handle it carefully: A. Use an approved fuel container. B. Do not remove fuel tank cap while engine is hot or running. C. Do not smoke while handling fuel. D. Fill fuel tank outdoors and only to within an inch (25 mm) from the top of the tank, not the filler neck. Do not overfill. E. Wipe up any spilled fuel. 7.
23. Before getting off of the seat: A. Set parking brake. B. Move traction pedal to neutral and wait for reels to stop. C. Disengage cutting units and wait for reels to stop. D. Stop engine and remove key from switch. E. Do not park on slopes unless wheels are chocked or blocked. 24. Use only a rigid tow bar if it becomes necessary to tow machine. Use trailer for normal transport. While Doing Maintenance, Troubleshooting, Testing, Adjustments or Repairs 25.
Safety Instructions Page 1 - 4 Reelmaster® 335-D
Chapter 2 Product Records and Manuals Table of Contents 1 2 2 2 3 3 3 MAINTENANCE CHARTS . . . . . . . . . . . . . . . . . . . . 4 2 Wheel Drive Quick Reference Aid . . . . . . . . . . 4 4 Wheel Drive Quick Reference Aid . . . . . . . . . . 5 EQUIPMENT OPERATION AND SERVICE HISTORY REPORT FORM Record information about your machine on the Product Record Form. Use this information when referring to your machine.
Equivalents and Conversions Decimal and Millimeter Equivalents ___________________________________________________________________________________________________ Fractions Decimals mm Fractions Decimals mm ___________________________________________________________________________________________________ 1/64 0.015625 1/32 ––––– 0.03125 3/64 0.046875 1/16 –––––––––––– 0.0625 5/64 0.078125 3/32 ––––– 0.9375 7/64 0.109275 1/8 ––––––––––––– 0.1250 9/64 0.140625 5/32 ––––– 0.15625 11/64 0.
Torque Specifications Use these torque values when specific torque values are not given. DO NOT use these values in place of specified values. The torque values listed below are for lubricated threads. Plated threads are considered to be lubricated. Capscrew Markings and Torque Values - U.S.
Maintenance Charts Maintenance Charts Page 2 - 4 Rev.
Reelmaster® 335-D Page 2 - 5 Rev.
Maintenance Charts Page 2 - 6 Rev.
EQUIPMENT OPERATION AND SERVICE HISTORY REPORT for REELMASTER® 335-D and 3500-D TORO Model and Serial Number:__________-__________ Engine Numbers: ____________________ Transaxle Numbers: ____________________ Cutting Unit Numbers: ____________________ _______________________ ____________________ _______________________ Date Purchased: ____________________ Warranty Expires__________ Purchased From: ____________________ ____________________ ____________________ Contacts: Parts ____________________
REELMASTER® 335-D and 3500-D Maintenance Schedule Minimum Recommended Maintenance Intervals: Maintenance Procedure Inspect Air Filter, Dust Cup, and Baffle Lubricate All Grease Fittings Maintenance Interval & Service Type: Every 50hrs A Level Service Every 100hrs Every 200hrs Every 400hrs Every 800hrs ‡ Change Engine Oil & Filter Check Battery Level and Connections Inspect Cooling System Hoses B Level Service Service Air Cleaner Filter Element Inspect Cutting Unit Reel Drive Belts C Level Service
REELMASTER® 335-D and 3500-D Daily Maintenance Check List Unit Designation:__________ Daily Maintenance:(duplicate this page for routine use) TORO ID#:_______-_______ Daily Maintenance Check For Week Of _____________ Maintenance Check Item MON TUES WED THURS FRI SAT SUN _____HRS _____HRS _____HRS _____HRS _____HRS _____HRS _____HRS Safety Interlock Operation Brake Operation Engine Oil Level Fuel Level Cooling System Fluid Level Drain Water/Fuel Separator Optional Air Filter Precleaner Radiator & Screen fo
A B C D E Other Service to perform (circle): ____________-____________ TORO I.D.
Chapter 3 Engine Table of Contents INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 IDENTIFICATION AND SPECIFICATIONS . . . . . . . 3 General Specifications . . . . . . . . . . . . . . . . . . . . 3 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Cylinder Head Gasket . . . . . . . . . . . . . . . . . . . . . 4 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction The following pages give information about specifica tions, maintenance, troubleshooting, testing and repair of the diesel engine used in the Reelmaster® 335-D and 3500-D mowers. Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Special Tools section.
Identification and Specifications General Specifications Item Specification ___________________________________________________________________________________________ Engine Type Peugeot XUD9AI, 4 cycle, water cooled, 4 cylinder, vertical in-line cylinders, single overhead cam, indirect injection, naturally aspirated. ________________________________________________________________________________________________________________________ ________________________________ Compression ratio 23.
Cylinder Head Cylinder head height h is measured with the camshaft in place fitted with two bearing caps. h is measured on the oil seal lip contact diameter (the largest diameter). h nominal: 157.40 to 157.75 mm Maximum permissible bow on bottom of cylinder head: 0.07 mm (camshaft must turn freely). Maximum permissible gasket face machining: 1.4 mm in rela tion to the measured h nominal.
Camshaft Camshafts with 0.5 mm oversize bearings* are iden tified by a yellow paint ring (d) between the cams of No. 1 cylinder. * NOTE: These camshafts are installed only on ex change engines, and can be obtained on special order. Figure 4 Valves Units: mm Intake Min. Length l +0 Exhaust 112.2 8.005 7.985 øb ± 0.1 38.5 33 a 90° 90° øa – 0.015 Intake: Faces x and y can machined a maximum of 0.2 mm Exhaust: No machining is permissible.
Valve Springs Units: mm Spring ød 29 P1: daN e1 18 42.4 Figure 7 Valve Guides Units: mm øf øg h j øk Tolerance 0 – 0.011 + 0.032 0 ± 0.25 ± 0.50 0 + 0.2 Production 14.02 14.13 13.981 14.051 Repair 1 14.29 14.211 52.00 36.50 8.02 Repair 2 14.59 14.511 øk is obtained by machining after fitting in the cylinder head Figure 8 Engine Page 3 - 6 Rev.
Valve Seats Units: mm Intake øa øb c d Tolerance 0 – 0.025 ± 0.025 0 – 0.1 ± 0.15 Production 40.161 40.361 40 40.2 6.25 6.45 8.267 8.467 Repair 1 40.461 40.3 6.45 8.467 Repair 2 40.661 40.5 6.45 8.467 Units: mm Exhaust øa øb c d Tolerance 0 – 0.025 ± 0.025 0 – 0.1 ± 0.15 Production 34.137 34.337 34 34.2 6.05 6.25 8.15 8.35 Repair 1 34.437 34.3 6.25 8.35 Repair 2 34.637 34.5 6.25 8.
Cylinder / Piston Matching Units: mm Identification (x) CYLINDER øa Tolerance: + 0.018 – 0 PISTON øb Tolerance: ± 0.009 None 83 82.93 A1 83.03 82.96 Repair 1 R1 83.20 83.13 Repair 2 R2 83.50 83.43 Repair 3 R3 83.80 83.73 Production NOTE: The piston øb must be measured at dimension c. C 25.00 NOTE: The repair dimension (x) is stamped on the cylinder block and pistons. Figure 11 Piston Pin Units: mm ø external 24.994 to 25 ø internal 13.8 to 14.1 Engine Page 3 - 8 Rev.
Crankshaft Units: mm Crank Pins and Journals øa b øc d Tolerance –0 – 0.016 ± 0.003 –0 – 0.019 ± 0.003 Production 50.00 1.827 60.00 1.842 Repair 1 49.70 1.977 59.70 1.992 NOTE: Repair 1 size connecting rod and main bearing shells can be identified by white paint (1) on the edge of the shell. Units: mm End Float No. 2 Journal Half Shell Thickness e f Tolerance + 0.05 0 ± 0.025 Production 26.60 2.305 Repair 1 26.80 2.405 Repair 2 26.90 2.455 Repair 3 27.00 2.
Tightening Torques Part Nm Kgm ft-lb __________________________________________________________________________________________ Connecting rod end caps 50 5 37 ________________________________________________________________________________________________________________________ ________________________________ Camshaft bearing caps 17.5 1.
Special Tools NOTE: Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Some tools may be l isted in the Reelmaster 335-D or 3500-D Parts Catalog. Some tools may also be available from a local supplier. TOR4033 Overhaul Tool Set This tool kit includes tools required for overhauling the engine. TOR4035 Tune-Up Set will also be required if overhauling the engine. TOR80504A1 Extension (Fig. 24) TOR80110H Indicator Holder (Fig.
TOR2437T Dial Indicator This dial indicator may be used with TOR80110H, TOR80117AM and TOR80504A2 to accomplish any of the following tasks: for checking the protrusion of the swirl chambers, valve recess and measurement for cylinder head gasket selection, adjusting the timing of the injection pump and for checking the crankshaft and float. Figure 16 TOR4024T Valve Spring Compressor This tool is used to compress valves for removal.
TOR70153C Rear Main Seal Installer Used with a small hammer to install new rear main oil seal. Figure 20 TOR70153D Front Cover Seal Installer Used with a small hammer to install new front crankshaft seal. Figure 21 TOR70153N Flywheel T.D.C. Locator Pin Used to set injection pump timing. Figure 22 TOR80110DZ 2mm Shim Cut Off Gauge With Cut Off Shim Used to gage and gut off new side seals to 2mm height. Figure 23 Reelmaster 335-D/3500-D Page 3 - 13 Rev.
TOR80110GY Extension Rod and Adapter Used with TOR 80504A1 and TOR80504A2 to check crankshaft end float. Figure 24 TOR80110H Indicator Holder Block used to hold dial indicator to check protrusion of swirl chambers, valve recess and measurement for cylinder head gasket selection. Figure 25 TOR80117AM Timing Tool Kit For Roto Diesel DPC Pump Used with dial indicator to adjust timing of injection pump.
TOR80149 Injector Socket Used to remove and install fuel injectors. Figure 28 TOR80504A1 Extension Used with TOR 80110GY and TOR 80504A2 to check crankshaft end float. Figure 29 TOR 80504A2 Indicator Holder Used with TOR80110GY and TOR 80504A1 to check crankshaft end float. Figure 30 TOR976697 Camshaft Seal Installer Used to install camshaft seal. Figure 31 Reelmaster 335-D/3500-D Page 3 - 15 Rev.
.0149 - Cylinder Head Separating Levers (Make Locally) Used to remove cylinder head (qty. 2 required). Units: mm Figure 32 TOR70153H Injector Pump Gear Puller Loosen the nut on the injector pump gear, then use this tool to loosen the pulley from the tapered shaft on the injector pump. TOR70153H Figure 33 Engine Page 3 - 16 Rev.
Adjustments Valve Clearance Adjustment (See Valve Clearance Adjustment in the Engine Over haul Section.) Engine Speed Adjustments Maximum fuel flow and speed adjustments are sealed and should only be unsealed by a CAV Lucas ROTODIESEL service dealer. Throttle Cable Adjustments The throttle control lever at the operator’s station must not touch the end of the slot during full range of motion from idle (SLOW) to full engine RPM (FAST).
Troubleshooting Alternator Problem Possible Causes Alternator is not charging. Alternator belt loose. Charging circuit defective. Energizing circuit defective. Brushes worn or seized. Rotor winding defective. Stator winding defective. Regulator defective. Output low or irregular. Alternator belt loose. Charging circuit defective. Energizing circuit defective. Brushes worn or seized. Rotor winding defective. Stator winding defective. Regulator defective. Rotor partially short-circuited.
Fuel Injectors Problem Possible Cause Correction Bad spray pattern Carbon deposit around the orifice Clean Scored nozzle seat Replace injector Needle damaged Replace injector Foreign matter jammed between nozzle seat and needle Clean Nozzle seat out-of-true Replace injector Water in fuel Drain water and flush fuel feed system (1) Copper gasket not replaced Replace gasket at each repair Injector nut too tight on injector body Tighten injector nut (1) Leaking injector Needle seized or sho
Fuel Injection Pump Problem Possible Cause Correction Engine has no power Defective fuel supply Check filter cartridge and pipes Incorrect pump timing Correct timing Incorrect spray, or injector pressure out of adjustment Check, clean and adjust injectors Air intake restriction Check hoses and air cleaner Insufficient automatic advance Have pump repaired Discharge rates too low Have pump repaired Idling stop out of adjustment Adjust stop and fast idling control Throttle cable out of adjust
Problem Possible Cause Correction Engine will not start No preheating Check glow plugs and relay No fuel supply Make sure tank is not empty Check filter element and pipes Check system bleeding Irregular engine speed Noisy engine Engine stalls at idling Vibrating engine Engine will not stop Reelmaster 335-D/3500-D Defective solenoid valve Check electric stop solenoid Seized pump plunger Have pump repaired Discharge valve blocked in “stop” position Have pump repaired Seized feed pump Drai
Low Power Problem Possible Causes Engine does not give full power Injection pump timing Seized piston rings Defective injector(s) Air intake restricted Valve leaks Clogged fuel filter Injection pipe restriction due to excessive tightening of unions Defective injection pump Irregular idling Defective injection pump Air getting into fuel system Idling stop out of adjustment Leaky injection pipe unions Speed fall-Off Clogged fuel filter Defective injection pump Engine speed rises to maximum Defective
Noisy Engine Problem Possible Causes Knocking Loose main bearings Broken part Leakage return collector clogged Lifters out of adjustment Foreign matter in a cylinder Seized injector Injection pump timing Sheared glow plug Timing out of adjustment Whistling, blowing Leaking cylinder head gasket Leaky glow plug Valve seats Leaky injector Reelmaster 335-D/3500-D Page 3 - 23 Rev.
Pre-heating Problem Possible Causes Glow plug does not glow red hot Faulty glow plug Faulty glow plug relay Damaged wiring or connector All four glow plugs burnt out / ends melted – injection pump timing out of adjustment (engine overheating) See Chapter 5 - Electrical System Engine Page 3 - 24 Rev.
Smoke During Operation Problem Possible Causes Black Defective injector Injection pump out of adjustment Injection pump timing Air intake restricted Inlet chambers clogged Not enough advance Grey Defective injector Injection pump timing Air intake restricted Not enough advance Blue-Grey Defective injector Injection pump timing Too much oil Blue Too much oil Wear White Injection pump timing Cylinder head gasket Cold engine Reelmaster 335-D/3500-D Page 3 - 25 Rev.
Starting Problems Problem Possible Causes Engine will not start and emits black smoke Air intake obstructed Defective injectors Lack of compression (seized rings, damaged or worn valve seats, or general wear) Injection pump timing Engine will not start and emits white smoke Leaking cylinder head gasket Engine will not start and does not emit any smoke Frozen fuel Injection pump does not work Leaking injection pipe unions Injection valve blocked No preheating Empty fuel tank Feed pipe obstructed Air g
Testing and Inspection Injection Pump Timing (See Timing of Injection Pump in the Engine Overhaul section.) Glow Plug Test CAUTION Be careful while handling or testing glow plugs. Glow plugs become extremely hot. Ac cidental contact with the heated plug tip could cause personal injury. 1. Disconnect the wire lead(s) to the glow plug. 2. Remove the glow plug. 3. Inspect the glow plug for signs of a burnt glow plug end tube.
Compression Test Minimum cylinder compression is 20 bar (290 psi) at 200 rpm (normal cranking speed). The engine should be warm - coolant temperature of 50o C (120o F). IMPORTANT: DO NOT put oil into the combustion chamber before performing a compression test. Damage may result because of “hydraulic” forces acting upon the piston and connecting rod. 1. Remove the glow plug lead wires and glow plugs from all four cylinders. 2. Insert a compression gauge adapter into the glow plug hole. 3.
Injector Tests There are several tests to examine the condition of the injection nozzles. These tests require the use of a nozzle tester and nozzle tester adapter. defective, damaged or adjusted incorrectly, starting failures, low power output, or engine knocking can occur. 1. Securely fasten the nozzle to the adapter. CAUTION 2. Pump the handle several times to purge air from the nozzle mechanism. The nozzle tester forces fuel from the nozzle under extremely high pressure.
Nozzle Leakage Test A nozzle that leaks fuel from the nozzle orifice must be replaced. 1. Securely fasten the nozzle to the adapter. 2. Wipe all fuel from the nozzle. 3. Operate the pump until the pressure is approximately 20 bar or kg/cm2 (280 psi) below opening pressure. Maintain this pressure to the nozzle. Good 4. Watch for leaks where the threaded nozzle body threads into the retaining nut. Leaks in this area would indicate a bad seat between the distance piece and/or the body or nozzle assembly.
Injection Pump Testing Calibration of fuel delivery volumes, pressure and dis tribution between pump barrels should be performed by a professional diesel engine service shop. Special test fixtures and equipment are required. It is possible to determine if the fuel injection pump requires service through a process of elimination using other fuel system tests. The following test procedure will help isolate fuel system difficulties. 1. Make sure that fuel is being supplied to the injector pump. 2.
Thermostat Test If the engine overheats or runs too cool, and a faulty thermostat is suspected, the thermostat should be tested. 1. Remove the thermostat. 2. Put the thermostat in a container of water with a thermometer and heat the water. Starts to open at: 81o C (178o F) 7 mm (0.28 in.) full open at 88o C (190o F) 3. If the thermostat fails to open, only partially opens, or sticks, it should be replaced. Figure 37 Engine Page 3 - 32 Rev.
Fuel System Service Priming Fuel System 1. Stop the engine. Unlatch and raise the hood 2. Fill the fuel tank. 3. Install a 3/16" hose over bleed screw. Put other end of hose into a container to catch fuel (Fig. 38). 4. Pump priming plunger until resistance is felt. Try to start engine. If engine does not start, go to step 5. 5.Loosen bleed screw a few turns. Pump priming plunger until a steady stream of fuel comes out of hole in bleed screw.
Injector Service NOTE: If injectors need to be inspected or repaired it is recommended that it be done by an authorized CAV Lucas ROTO DIESEL service dealer - especially during the warranty period. Repairs by non-authorized dealers WILL void the warranty on the injectors. 1 Removal 8 2 1. Clean top of cylinder head and injection pipes. 2. Remove injection pipes (Fig. 57, Item 12). 3 3. Disconnect injector leakage pipe. 4 4. Remove the injectors (Fig.
Assembly 1. Check all parts for condition and cleanliness. Oil parts before reassembly. 2. Secure the injector body in a “V” type injector holder. 3. Install the adjusting shims, spring, push rod, spacer and injector (Fig. 40, Items 2, 3, 4, 5, 6). 4. Install the injector holder nut (Fig. 28, Item 7) and tighten by hand. 5. Tighten injector nut to a torque of 10 Nm. Tighten the nut an additional 22° of rotation.
Timing Belt Replacement Timing Belt Removal IMPORTANT: Never install a used belt. When the timing belt is removed a NEW timing belt must be installed. SPECIAL TOOLS REQUIRED: Tune-Up Tool Set TOR 4035 1 ea. M8 x 125 x 40 Metric Bolt 2 ea. M8 x 125 x 35 Metric Bolt TOR 70153N 1. Slowly turn the crankshaft in the operating direction (clockwise as viewed from the timing belt end) until the TDC Lock Pin tool (TOR 70153N) goes into the hole in the flywheel (Fig. 42). Figure 42 2.
7. Loosen the nut (Fig. 45, Item 8) and the bolt (Item 9), securing the roller tensioner bracket (Item 10). 8. Rotate the roller tensioner bracket square (Item A) to compress the spring (Item 11). A 9. Re-tighten the bolt (Item 9). 10. Remove the timing belt. Figure 45 Reelmaster 335-D/3500-D Page 3 - 37 Rev.
Timing Belt Installation IMPORTANT: Never install a used belt. When the timing belt is removed a NEW timing belt must be installed. C A 1. Install the new timing belt, with the runs taut, in the following order (Fig. 46): Crankshaft gear (Item 13) Fixed roller (Item 11) Injection pump gear (Item B) Camshaft gear (Item C) Tensioner roller (Item 17) Coolant pump gear (Item 10). B Figure 46 A 2. Loosen the bolt (Fig. 47, Item 18) and nut (Item 19) to release the tensioner roller.
4. Remove the three gear locking bolts and TDC Lock Pin tool. A 5. Turn the crankshaft two revolutions (clockwise). 6. Re-install the TDC Lock Pin tool TOR 70153 N and the three gear locking bolts. IMPORTANT: If you can not install any one of the locking devices, repeat the Timing Belt Installation procedures from the beginning. 7. Loosen the bolt (Fig. 48, Item 18) and nut (Item 19) to release the tensioner roller. 8. Re-tighten the bolt (Item 18) then the nut (Item 19) to a torque of 17.5 Nm (13 ft-lb).
Injection Pump Timing Timing of Injection Pump (Pump Mounted on Engine) b The adjustment position for start of injection varies on each pump (manufacturing tolerances). The adjustment position is given by measurement “X.XX” in one of three places on the pump (Fig. 51): a a. Tag on pump lever. b. Bar code label c. Inspection cap NOTE: “PMH” in French = “TDC” in English. 1. Remove the cover attachment nut, cover clips and timing belt covers. Figure 51 2.
6. Clean the area around the pump timing plug (Fig. 54, Item d). Remove the pump timing plug. d b a 7. Use Timing Tool Assembly TOR 80117 AM. Lubricate the timing rod (Fig. 55, Item 1) with Diesel fuel, then install the timing rod in the pump timing hole (Item d). Check to see that the rod moves freely in the bore. 8. Install the dial indicator (metric) on the indicator bracket (Item 2). 9. Install the indicator bracket with dial indicator on the plug boss. Set the dial indicator to “0.00 mm”.
Preparation For Engine Repair 1. Before cleaning and disassembly, carefully check for problems that cannot be found after the engine has been cleaned or disassembled (e.g. oil leaks from cracked components, gaskets or loose fittings, damaged air cleaner or breather hoses that could cause cylinder wear, etc.). Make a note of any problems that you find. 2. Clean or wash the engine exterior thoroughly before disassembly. IMPORTANT: Do not spray water on a hot engine.
Engine Removal and Installation 1. Put machine on a level surface and engage parking brake. Turn engine OFF and remove key from ignition switch. Allow engine and radiator to cool. 2. Open the hood. Disconnect hood stop cable from engine. Lower the hood. Remove left and right hinge plates. Lift hood off chassis. 7. Loosen hose clamp and disconnect PCV hose from engine.8.
Installing the Engine 1. To install the engine, perform steps 2- 14 of Removing the Engine in reverse order. 2. After disassembling or overhauling the engine, install a new oil filter. Replace this filter after the first 20 to 50 hours of operation. 3. Fill the engine with the correct oil. Fill the cooling system with a 50/50 solution of ethylene glycol anti freeze, and clean, soft water. Check for oil and coolant leaks and repair as necessary. Peugeot recommended Coolant/Antifreeze is available in 1 U.S.
Engine Overhaul Disassembly of External Components 1. Remove TDC sensor and clutch housing center ing pin. 2. Mount the engine on a stand. 3. Lock the flywheel with TOR FD86 tool. 4. Remove exhaust manifold and inlet manifold. 5. Remove the coolant manifold. 6. Remove the alternator and belt. 7. Remove the oil filter (Fig. 57, Item 10). 8. Remove the injector pipes (Item 12). 9. Remove the glow plug leads. 10. Remove the crankcase breather pipes/oil filter/filter pipe assembly (Item 13). 11.
12. Remove the thermostat housing cover (Fig. 58, Item 17). TOR 80149 13. Remove the thermostat housing (Item 18). 14. Remove the injectors (Item 19) and retrieve the copper washer (Item 20), and flame trap washer (Item 21). 15. Remove the glow plugs (Item 22). Figure 58 Injection Pump Removal 1. Remove the timing belt. 2. Use injector pump gear puller TOR70153H, remove injector pump gear (Fig. 58a, Item 5). to TOR70153H Figure 58a 3. Remove the injection pump (Fig. 58b, Item 19). 4.
Cylinder Head Removal 1. Remove the cylinder head cover. 2. Use a Torx head T55 tool to loosen the cylinder head bolts, working in a spiral from the outside. Remove the cylinder head bolts. IMPORTANT: DO NOT pry at gasket surface to loosen cylinder head from block. 3. Use levers (0.0149) to release the cylinder head from the block. 4. Remove the cylinder head and gasket. Figure 59 Oil Pump Removal 1.
Crankshaft and Piston Removal 1. Remove flywheel locking tool. 2. Remove the connecting rod end caps (Fig. 62, Item 8), marking each cap for re-installation in the same location. NOTE: Connecting rods and end caps are not num bered. Once they are removed there is no way of knowing the correct location for installation unless you mark them for re-installation. 3. Remove the flywheel. 4. Remove the main bearing caps (Item 9) (marks are cast-in). Figure 62 5. Retrieve end float washers with No. 2 cap. 5.
Cylinder Head Overhaul 1. Progressively slacken the camshaft bearing caps (Fig. 65, Item 1). 2. Remove the bearing caps (Item 1), oil seals (Item 2), camshaft (Item 3), tappets (Item 4) and adjustment shims (Item 5). Mark adjustment shims and tappets so they will be re-installed in the same location – #1 intake, #1 exhaust, #2 intake, #2 exhaust, etc. NOTE: The shims are small and can stick to the tappets. Figure 65 3. Use a valve compressor to remove the eight valves (Fig. 66). 4.
8. Check the protrusion of the swirl chambers (Fig. 68, A). Protrusion: 0 to 0.03 mm Achieve this dimension by machining faces (a) and (b). 9. Check the valve recess (B). Exhaust: 0.9 to 1.45 mm Inlet: 0.5 to 1.05 mm Achieve this dimension by machining the valve seats. Figure 68 10. Lap in the valves. 11. Re-install the valves. IMPORTANT: If the cyl ind er head has been machined, fit compensating washers under the valve springs. (See Identification and Specifications section.) 12.
Crankshaft Installation 1. Put thread lock Loctite on the oil gallery plugs and install them in the cylinder block. 2. Install the grooved main bearing shells. (See Crankshaft in the Inspection and Specifications section for main bearing shell thickness.) Figure 71 3. Install the crankshaft. 4. Install the no. 3, 4 and 5 main bearing caps. 5. Install the two end float half-washers (Fig. 72, Item 1), with the anti-friction faces towards the crankshaft. Figure 72 6. Install the no. 2 main bearing cap (Fig.
7. Check crankshaft end float (Fig. 74): A . I n s t al l t he dia l i ndi c a t o r , usi ng to ols TOR 80110G1, TOR 80504 A1 and A2. TOR 80110G1 B. End float must be between 0.07 and 0.32 mm. NOTE: For choice of half-washer thickness see Crankshaft in the Identification and Specifications section. 8. Apply a thin coat of Formetanch or Permatex No. 2 sealant to surface of block where bearing cap will mate (Fig. 73, Item a). TOR 80504 A1-A2 Figure 74 9. Install the two new side seals (Fig.
13. Tighten the bearing cap bolts to a torque of 70 Nm (52 ft-lb). 14. Using shim TOR 80110DZ, cut off the side seals so that they protrude 2 mm. 15. Check that the crankshaft rotates without tight spots. TOR 80110DZ Figure 76 Pistons and Connecting Rod Assembly 1. Assemble the connecting rods and pistons with the bearing shell tab recess (Fig. 77, Item a) on the same side as the piston crown recess (Item b). 2.
3. Oil the piston and tighten the piston ring clamp (Fig. 78, Item 4). 4. Remove the connecting rod end caps. 5. Install the pistons in the bores, matching the markings made when removed, and aligning the crown recess (Item a) on the oil filter side of the block. 6. Install the connecting rod end caps. Tighten the nuts to a torque of 50 Nm (37 ft-lb). NOTE: For choice of bearing shell thickness, see Crankcase in Identification and Specifications section. Figure 78 Oil Seal Installation 1.
3. Install the special shoulder bolt (Fig. 81, Item 1) to center the pump in the proper location. 4. Install the other bolts and tighten the bolts (Item 1, 2, 3) to a torque of 20 Nm (15 ft-lb). 5. Install the seal carrier plate and a new gasket (Item 4) and tighten the bolts to a torque of 15 Nm (11 ft-lb). 6. Put a new oil seal on tool TOR 70153 D. 7. Install the seal by tapping it fully home with a mallet. TOR 70153D 8. Apply Formetanch or Permatex No. 2 sealant as shown (Item a). 9.
Cylinder Head Gasket Selection 1. Install the dial indicator on support TOR 80110 H and zero it on a surface plate. 2. Turn the crankshaft and measure the protrusion of each piston at TDC. 3. Note the maximum protrusion (Fig. 82, Item d). 4. Select a cylinder head gasket of suitable thickness. TOR 80110H Units: mm Piston protrusion (d) Thickness identification 0.56 to 0.71 2 notches 0.71 to 0.75 3 notches 0.75 to 0.79 4 notches 0.79 to 0.83 5 notches Figure 82 Cylinder Head Installation 1.
Cylinder Head Tightening 1. Install new washers on the bolts. 2. Pre-tighten the bolts in the order shown (Fig. 84) to a torque of 30 Nm (22 ft-lb). 3. Tighten the bolts in the order shown to a torque of 70 Nm 52 ft-lb). 4. Tighten each bolt in the order shown an additional 120° ± 2°. NOTE: The special cylinder head bolts (Item B) do not require re-tightening. The bolts can be removed and re-installed 5 times before replacing with new bolts.
3. Remove the camshaft gear (Fig. 86, Item 1). 4. Remove the camshaft bearing caps (Item 2). 5. Remove the camshaft (Item 3). 6. Remove the tappets (Item 4). 7. Remove the basic shims (Item 5). 8. Determine the shim thickness to be fitted for each valve. Example: Units: mm No. 1 Intake valve Specified clearance 0.15 Clearance measured 0.25 Difference Shim installed Figure 86 + 0.10 2.425 * Shim to be installed 2.50 Clearance obtained 0.175 * Basic shim 9.
11. Apply a thin coat of Formetanch or Permatex No. 2 sealant to each end of the bearing housing at (Fig. 87, Item a). 12. Apply MOLYKOTE G RAPID to the bearing surfaces on the camshaft. 13. Install the camshaft (Item 3) with the DIST marking at the timing gear end. 14. Install the camshaft bearing caps (Item 2) as shown by cast-in markings. 15. Progressively tighten the bearing caps to 17.5 Nm (13 ft-lb). Figure 87 TOR 976697 16.
Assembly of External Components 1. Install new fire ring washers (Fig. 89, Item 1), convex surface facing up. 2. Install new copper washers (Item 2). 3. Install the injectors and tighten to a torque of 90 Nm (66 ft-lb). 4. Install the pre-heat plugs (Item 4) and tighten to a torque of 22 Nm (16 ft-lb). 5. Install the thermostat housing (Item 5) and cover (Item 6), fitted with a new thermostat and gasket. 6. Install the cylinder head cover (Item 7), and tighten to a torque of 10 Nm (7 ft-lb). Figure 89 7.
Break-in Engine After Overhaul After disassembling or overhauling the engine, install the a new oil filter. Replace this filter with a new filter after the first 20 to 50 hours of operation. Reelmaster 335-D/3500-D Page 3 - 61 Rev.
Engine Page 3 - 62 Rev.
Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 3 Hydraulic Hose and Fitting Information . . . . . . . . 3 HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . 5 Two (2) Wheel Drive . . . . . . . . . . . . . . . . . . . . . . 5 Four (4) Wheel Drive . . . . . . . . . . . . . . . . . . . . . . 6 HYDRAULIC FLOW DIAGRAMS . . . . . . . . . . . . . . . 7 General Charge Pump Flow . . . .
Specifications Item Description __________________________________________________________________________________________ Traction/Reel Drive Pump (Sundstrand-Sauer) Traction relief pressure Mow relief pressure Charge pressure (remote charge relief valve) Sundstrand-Sauer, tandem in-line variable axial piston pump 5000 ± 100 PSI 2540 ± 100 PSI 100 ± 25 PSI ____________________________________________________________________________________________________________________________________________________
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 condi tions or mishandling during operation or maintenance. These conditions can cause damage or premature de terioration. Some hoses, such as reel motor hoses, are more susceptible to these conditions than others. In spect the hoses frequently for signs of deterioration or damage.
SAE Straight Thread O-Ring Port - Non-adjustable (Fig. 4) 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. 3. Lubricate the O-ring with a light coating of oil. O-Ring 4. Install the fitting into the port and tighten it down full length until finger tight. 5. Tighten the fitting to the correct flats from finger tight (F.F.F.T.). Size 4 (1/4 in.
2500/1600 RPM 2000 PSI (138 BAR) TEST PORT Hydraulic Schematic - Two (2) Wheel Drive
12.
Reelmaster® 335-D Page 4 - 7 No. 2 Lift Cylinder No. 2 Reel Motor Steering Orbitrol No. 3 Lift Cylinder No. 3 Reel Motor Check Valve Flow Suction Return Pressure No. 1 Lift Cylinder Traction Motor No. 1 Reel Motor Reservoir Check Valve Aux. Pump 2 1 3 Reel Pump Oil Cooler Traction Motor General Charge Pump Flow Filter ENGINE Steer Cylinder With all controls in neutral and the engine running, oil is drawn from the reservoir by the auxiliary pump.
Hydraulic Flow Diagrams Page 4 - 8 Reelmaster® 335-D Traction Motor Flow Suction Return Pressure Charge Relief Valve Oil Cooler Traction Motor Traction Circuit – Forward Filter ENGINE When the top of the traction pedal is pushed down, a variable displacement hydrostatic piston pump creates a flow of oil to a fixed displacement piston motor mounted on the two-speed axle to drive the machine forward.
Reelmaster® 335-D Page 4 - 9 Hydraulic Flow Diagrams No. 2 Reel Motor No. 3 Reel Motor Flow Suction Return Pressure No. 1 Reel Motor Reservoir Aux. Pump Charge Relief Valve Filter Oil Cooler Mowing Circuit ENGINE Oil flows from a variable displacement hydrostatic piston pump through a solenoid valve on each of three gear-type motors which are connected in series. The oil then continues back to the pump in a closed loop.
Hydraulic Flow Diagrams Page 4 - 10 Reelmaster® 335-D No. 2 Lift Cylinder No. 3 Lift Cylinder Flow Suction Return Pressure No. 1 Lift Cylinder Filter ENGINE Oil Cooler Lift/Lower Circuit – Lifting Cutting Units Charge Relief Valve Lift Valve Counter Balance Valve Oil from the secondary pressure port of the auxiliary gear type pump goes to the three-spool valve, then through the counterbalance valve, oil cooler, filter, and back to reservoir.
Reelmaster® 335-D Page 4 - 11 Hydraulic Flow Diagrams Steering Orbitrol Check Valve Flow Suction Return Pressure Reservoir Check Valve Aux. Pump Steering Circuit – R.H. Turn Filter Oil Cooler Oil flows from the priority pressure port of the gear type auxiliary pump to the power steering valve, then through the oil cooler, filter, and back to reservoir.
Special Tools NOTE: Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Some tools may be listed in the Reelmaster 335-D Parts Catalog. Some tools may also be available from a local supplier. Hydraulic Pressure Test Kit Used 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.
Hydraulic Tester - With Pressure and Flow Capabilities Load Valve Low Pressure Gauge Outlet Hose Flow Meter Gauge Protector Valve High Pressure Gauge Inlet Hose Figure 8 You must have o-ring face seal (ORFS) adapter fittings for this tester to use it on the Reelmaster 335-D. 1. INLET HOSE: Hose connected from the system circuit to the inlet side of the hydraulic tester. 2. LOAD VALVE: If required, upon turning the valve to restrict flow, a simulated working load is created in the circuit. 4.
Troubleshooting The cause of an improperly functioning hydraulic sys tem is best diagnosed with the use of proper testing equipment and a thorough understanding of the com plete hydraulic system. A hydraulic system with an excessive increase in heat or noise is a potential 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.
Traction Response Is Sluggish Cause Correction ___________________________________________________________________________________________ Brakes dragging. Inspect brakes and adjust or repair if necessary. ________________________________________________________________________________________________________________________________________________________ Charge pressure low - TEST NO. 8. NOTE: Counterbalance pressure will also be affected. Inspect charge relief valve and adjust or repair if necessary.
Four Wheel Drive Does Not Engage Cause Correction __________________________________________________________________________________________ Front axle shift lever in “HI” (forward) position. Front axle shift lever must be in “LOW” (rear) position for four wheel drive to engage. ________________________________________________________________________________________________________________________________________________________ Electrical problem.
No Cutting Units Operate Cause Correction ___________________________________________________________________________________________ Front axle shift lever in “HI” (forward) position. Front axle shift lever must be in “LOW” (rear) position for cutting units to engage. ________________________________________________________________________________________________________________________________________________________ Hydraulic oil level too low. Fill to proper level.
All Cutting Units Operate Slowly Cause Correction __________________________________________________________________________________________ Low engine RPM. Adjust engine rpm - use tachometer. ________________________________________________________________________________________________________________________________________________________ Hydraulic oil level too low. Fill to proper level.
One Cutting Unit Does Not Operate Cause Correction ___________________________________________________________________________________________ Reel drive belt damaged or loose. Inspect and adjust or replace belt. ________________________________________________________________________________________________________________________________________________________ Key on reel motor shaft sheared. Replace key. Inspect for damaged pulley or motor shaft.
Cutting Unit(s) Do Not Lift or Lift Too Slowly Cause Correction __________________________________________________________________________________________ Hydraulic oil level too low. Fill to proper level. ________________________________________________________________________________________________________________________________________________________ Low engine RPM. Adjust engine rpm - use tachometer.
Cutting Units Will Not Drop or Follow Ground Contours Cause Correction ___________________________________________________________________________________________ Low engine RPM. Adjust engine rpm - use tachometer. ________________________________________________________________________________________________________________________________________________________ Lift arm or cylinder pivots binding. Lubricate bushings. Inspect for damage. Repair or re place damaged parts.
Cutting Unit(s) Lower or Raise Too Quickly Cause Correction __________________________________________________________________________________________ Missing or improperly installed cylinder port orifice. Properly install orifice between fitting and lift port of hydraulic lift cylinder(s). NOTE: Orifice must be in stalled at least 10 - 12 revolutions to avoid interfer ence with adapter fitting.
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 the 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. 2.
TEST NO. 1: Checking Traction Circuit Working Pressure or Relief Pressure WORKING Pressure Check: 1. Make sure hydraulic oil is at normal operating tem perature by operating machine for approximately 10 mines. 2 2. Lower cutting units, engage parking brake and stop the engine. 1 3. Raise seat to get access to hydraulic test fittings. Remove access cover from in front of auxiliary pump. 4.
TEST NO. 2: Checking Counterbalance Pressure 1. Make sure hydraulic oil is at normal operating temperature by operating machine for approximately 10 minutes. 1 2. Lower cutting units, engage parking brake and stop the engine. 3. Remove access cover from in front of auxiliary pump. 4. Install a 1000 PSI gauge into the counterbalance quick disconnect fitting. 5. Start the engine, move throttle to full speed (2500 rpm) and observe gauge.
TEST NO. 3: Checking Mowing Circuit Working Pressure or Relief Pressure WORKING Pressure Check: 1. Make sure hydraulic oil is at normal operating temperature by operating machine for approximately 10 minutes. 2. Lower cutting units, engage parking brake and stop the engine. 1 3. Raise seat to get access to hydraulic test fittings. Remove access cover from in front of auxiliary pump. 4. Install a 5000 PSI gauge onto mow circuit quick disconnect fitting.
TEST NO. 4: Checking Mowing Circuit Flow 1. Make sure hydraulic oil is at normal operating temperature by operating machine for approximately 10 minutes. 2. Start the engine and lower the center cutting unit to the ground. 3. Turn the engine OFF. 4. Disconnect inlet hose at reel motor of center cutting unit. 5. Install tester in series between disconnected hose and reel motor (flow direction is from hose to motor). Make sure gate valve of tester is OPEN. Figure 15 6.
TEST NO. 5: Checking Reel Motor Efficiency 1. Make sure hydraulic oil is at normal operating temperature by operating machine for approximately 10 minutes. 2. Start the engine and lower the cutting unit to be checked. 3. Turn the engine OFF and engage the parking brake. 4. Use a substantial hardwood block inserted between the reel blades of reel to be checked to prevent rotation. 5. Disconnect inlet hose at reel motor. 6.
TEST NO. 6: Checking Steering Circuit Working Pressure or Relief Pressure WORKING Pressure Check: 1. Make sure hydraulic oil is at normal operating temperature by operating machine for approximately 10 mines. 1 2. Lower cutting units, engage parking brake and stop the engine. 3. Remove access cover from in front of auxiliary pump. 4. Install a 5000 PSI gauge onto steering quick discon nect fitting. 5. Operate machine while monitoring gauge. Figure 17 RANGE OF TESTER READINGS 0 - 1300 PSI. 1.
TEST NO. 7: Checking Lift Circuit Working Pressure or Relief Pressure WORKING Pressure Check: 1. Make sure hydraulic oil is at normal operating tem perature by operating machine for approximately 10 minutes. 1 2. Lower cutting units, engage parking brake and stop the engine. 3. Raise seat to get access to hydraulic test fittings. Remove access cover from in front of auxiliary pump. 4. Install a 5000 PSI gauge onto lift circuit quick discon nect fitting.
TEST NO. 8: Checking Charge Pressure for Traction and Mowing Circuits 1. Make sure hydraulic oil is at normal operating tem perature by operating machine for approximately 10 mines. 2. Lower cutting units, engage parking brake and stop the engine. 1 3. Raise seat to get access to hydraulic test fittings. Remove access cover from in front of auxiliary pump. 4. Install a 1,000 PSI gauge with extension hose onto the charge pressure quick disconnect fitting.
TEST NO. 9: Checking Traction Circuit Rear Motor Pressure (4WD Only) WORKING Pressure Check: 1. Make sure hydraulic oil is at normal operating tem perature by operating machine for approximately 10 mines. 1 2. Lower cutting units, engage parking brake and stop the engine. 3. Raise seat to get access to hydraulic test fittings. Remove access cover from in front of auxiliary pump. 4. Install a 10,000 PSI gauge with extension hose onto the rear drive motor quick disconnect fitting.
Adjustments Traction Pump Neutral Adjustment The machine must not “creep” when traction pedal is released. If it does creep, an adjustment is required. 1. Park machine on a level surface and shut engine off. Make sure transaxle is engaged in HI position. Depress only the right brake pedal and engage the parking brake. 2. Jack up left side of machine until front tire is off the shop floor. Support machine with jack stands to prevent it from falling accidentally. 1 3.
Reel Speed Control Adjustment 1. Operate machine with cutting units engaged to make sure hydraulic oil is at normal operating temperature. 2. Park machine on a level surface and engage parking brake. Raise center and left-hand cutting units, then lock in position with transport latches. Lower right-hand cut ting unit. 1 CAUTION Engine must be running and cutting unit en gaged so final adjustment of reel speed can be performed.
Repairs Removing Hydraulic System Components 1. Thoroughly clean the machine before disconnecting, removing or disassembling any hydraulic components. Always keep in mind the need for cleanliness when working on hydraulic equipment. 2. Put caps or plugs on any hydraulic lines or fittings left open or exposed. 3. Put labels on disconnected hydraulic lines and hoses for proper installation after repairs are completed. After Repair or Replacement of Components 1.
Sundstrand Tandem Pump Repairs Shaft Seal Replacement 2 4 1 3 Figure 28 1. Retaining ring 2. O-ring 3. Seal carrier 1. Park machine on a level surface, lower cutting units, engage parking brake and stop the engine. 4. Lip seal 6. Put seal carrier in an arbor press and press out old seal. Use a properly sized pipe spacer or socket wrench for a press tool. The seal cannot be used again. 2. Remove pump assembly from machine. 7. Inspect seal carrier, new seal and o-ring for damage.
Trunnion Seal Replacement 5 2 1 6 4 3 Figure 29 1. Hex tapping screw (4) 2. Trunnion seal cover 3. O-ring 4. Seal 1. Park the machine on a level surface, lower cutting units, engage parking brake and stop the engine. 2. Remove control linkage from swashplate control shaft on transmission (see Transmission Control Removal). 3. Remove hex tapping screws retaining trunnion seal cover to transmission housing (Fig. 29). 4. Remove trunnion seal cover with lip seal and o-ring. 5.
Check and High Pressure Relief Valves 1 2 1 2 Figure 30 1. Traction check/high pressure relief valve 2. Reel check/high pressure relief valve 1. Park the machine on a level surface, lower cutting units, engage parking brake and stop the engine. 2. Remove the check/high pressure relief valve hex plug (Fig 30). 3. Remove the valve cartridge assembly. Inspect the valve and mating seat in the housing for damage or foreign material. It will be necessary to replace the center section if the seat is damaged.
Charge Pressure Relief Valve 1 Figure 31 1. Charge pressure relief valve 1. Park the machine on a level surface, lower cutting units, engage parking brake and stop the engine. 5. Inspect the poppet and mating seat in the end cap for damage or foreign material. 2. Remove the charge relief valve hex plug (Fig. 31). 6. Reinstall the poppet, spring and plug (with shims and o-ring) into the housing. Tighten the plug to a torque of 30 to 70 ft-lb. 3. Remove the spring and poppet from the housing. 4.
Disassembly of Sundstrand Tandem Pump 1 2 11 18 17 16 14 12 10 13 10 15 4 25 23 7 24 24 5 9 7 6 11 8 19 15 20 21 13 6 22 23 12 3 14 2 1 Figure 32 1. Capscrew 2. Washer 3. Pump housing 4. Pump housing 5. Center section 6. Gasket 7. Alignment pin 8. Valve plate (L.H.) 9. Valve plate (R.H.) 10. Valve plate pin 11. Cylinder block assembly 12. Pistons 13. Slipper guide 14. Piston block 15. Thrust plate 16.
5. Carefully remove valve plates from center section. It may be necessary to pry valve plates off with a small screwdriver. Inspection and Replacement of Parts 17. After disassembly, thoroughly clean all parts in a suitable solvent. Replace all o-rings, gaskets and seals. 6. Remove valve plate pins from center section. 7. Lay each pump section on its side and remove cylinder block assembly from housing. 8. Remove the slipper guide and piston assemblies from cylinder blocks. 9.
Assembly of Sundstrand Tandem Pump 1 2 11 18 17 16 14 12 10 13 10 15 4 25 23 7 24 24 5 9 7 6 11 8 19 15 20 21 13 6 22 23 12 3 14 2 1 Figure 33 1. Capscrew 2. Washer 3. Pump housing 4. Pump housing 5. Center section 6. Gasket 7. Alignment pin 8. Valve plate (R.H.) 9. Valve plate (L.H.) 10. Valve plate pin 11. Cylinder block assembly 12. Pistons 13. Slipper guide 14. Piston block 15. Thrust plate 16. Drive shaft 1. Clean and lightly oil parts before assembly.
10. Assemble each cylinder block kit by installing piston assemblies into the slipper guide. Lubricate pistons and cylinder block bores. Install assembled guide and pis tons into cylinder block by inserting pistons into cylinder block bores. The pistons and bores are not selectively fitted, so no specific piston and bore orientation is required. 11. Lay the pump on its side and install cylinder block kits into the housing. 12. Install valve plate locating pins into center section. 15.
Sundstrand Tandem Pump Repairs Page 4 - 44 Reelmaster® 335-D
Chapter 5 Electrical System Table of Contents WIRING SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . 2 Engine Crank and Start Circuit . . . . . . . . . . . . . . 2 Engine Run Circuit . . . . . . . . . . . . . . . . . . . . . . . 3 Engine Run and Mowing Circuits . . . . . . . . . . . . 4 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 7 Starting Problems . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Schematics Engine Crank and Start Circuit Wiring Schematics Page 5 - 2 Reelmaster® 335-D
Engine Run Circuit Reelmaster® 335-D Page 5 - 3 Wiring Schematics
Engine Run and Mow Circuits Wiring Schematics Page 5 - 4 Reelmaster® 335-D
Special Tools NOTE: Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Some tools may be available from a local supplier. Continuity Tester Battery powered test lamp which is helpful in testing for continuity of circuits and electrical components when the current is off. Figure 1 Volt - Ohm - Amp Meter The meter can test electrical components and circuits for current, resistance, or voltage draw.
Skin-Over Grease Special non-conductive grease which forms a light pro tective skin to help waterproof electrical switches and contacts.
Troubleshooting Study the operating characteristics preceding the elec trical failure to help identify the area of difficulty. Try to isolate the failure to a specific functional system; then check that area, repairing one component at a time. Attempting to repair more than one system at one time will lead to confusion. CAUTION Remove all jewelry, especially rings and watches, before doing any electrical trou bleshooting or testing.
Starting Problems (continued) Condition Possible Cause Correction __________________________________________________________________________________________ Nothing happens when start attempt is made. Troubleshooting Battery is dead. Charge battery. Replace battery if it will not hold a charge. Loose or corroded battery cables. Loose or corroded ground. Clean and tighten or repair as necessary. “Run” fuse open. Check fuse and replace if fuse is open.
Starting Problems (continued) Condition Possible Cause Correction ___________________________________________________________________________________________ Engine cranks, but does not start (if engine cranks, cause of prob lem is not in interlock system). Injection pump ETR solenoid wiring loose or corroded. Clean and tighten or repair as necessary. Injection pump ETR solenoid faulty. Test solenoid. Replace if faulty. Glow relay faulty. Test glow relay. Replace if faulty.
General Run and Transport Problems Condition Possible Cause Correction __________________________________________________________________________________________ Engine continues to run (but should not) when traction pedal is depressed with no operator on seat. Seat switch plunger depressed with no operator on seat. Check for seat support spring that is broken, missing or stuck in down position. Check for binding seat pivot hinge. Check for waterlogged seat. Seat switch faulty or out of adjust ment.
General Run and Transport Problems (continued) Condition Possible Cause Correction ___________________________________________________________________________________________ 4WD does not engage. Axle in Hi range. Axle must be in Low range for 4WD to engage. Axle HI/Low switch faulty. Test HI/Low switch. Replace switch if faulty. Make sure switch is screwed all the way in. Axle Hi/Low switch wiring loose, corroded or damaged. Repair wiring. 4WD solenoid valve faulty. Test 4WD solenoid valve.
Cutting Unit Operation Problems Condition Possible Cause Correction __________________________________________________________________________________________ Engine continues to run (but should not) when PTO switch is ON with no operator on the seat. Seat switch plunger depressed with no operator on seat. Check for seat support spring that is broken, missing or stuck in down position. Check for binding seat pivot hinge. Check for waterlogged seat. Seat switch faulty or out of adjustment.
Cutting Unit Operation Problems (continued) Condition Possible Cause Correction ___________________________________________________________________________________________ No cutting units engage. Reelmaster® 335-D Axle in Hi range. Axle must be in Low range for cut ting units to operate. “Reel” fuse open. Check fuse and replace if fuse is open. If fuse burns out often, find and correct cause. Cutting unit relay faulty. Test relay. Replace relay if faulty.
Verify Interlock System Operation The purpose of the interlock system is to prevent the engine from cranking or starting unless the traction pedal is in NEUTRAL and the cutting unit engagement switch is DISENGAGED. In addition, the engine will stop when the cutting unit engagement switch is engaged or traction pedal is depressed with the operator off the seat. 3. Sit on seat. Depress traction pedal in forward and reverse directions while trying to start engine.
Testing This section will define components, and the tests that can be performed on those components, when those parts are disconnected from the electrical system. CAUTION For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the seat switch connector before doing a continuity check).
Seat Switch, Relay and Time Delay Capacitor The seat switch is a normally open (N.O.) switch that closes when the operator is on the seat. With no opera tor on the seat, there is an open circuit to the time delay capacitor and relay coil. If the PTO switch or traction switch is open and the operator raises off the seat, the engine will stop after a delay of 1 to 2 seconds. 3 1 2 Seat Switch Test 1. Raise the seat to get access to the seat switch wiring connector. 2.
Traction (Neutral) Switch The traction switch is a normally closed and opens when traction pedal is depressed in either direction. IMPORTANT: The traction switch has three (3) ter minals. Make sure the wires are connected to the “COMMON” and “N.O.” terminals. Test the switch by disconnecting the wires from the switch terminals and connecting a continuity tester across the COMMON and N.O. terminals.
Axle Hi/Low Switch The axle hi/low switch is normally open (N.O.) when the transaxle is in neutral or hi range. This prevents the cutting units or 4WD from engaging while the transaxle is neutral or hi range. The switch closes when the axle shift rod is moved to low range, which pushes the switch button in. 1. Disconnect the switch wire connector and install a continuity tester or ohm meter between the two leads of the switch. 1 2.
PTO Switch To test the PTO switch independent of wiring harness, disconnect wire connector from the switch terminals. When the switch is ON, there should be continuity between terminals A – B only. When the switch is OFF, terminals C – D and B – E should show continuity. 1 Figure 13 1. PTO switch Figure 14 1.
Start, Cutting Unit and High Temp. Relays To test the relay, disconnect the relay wire connector and install a continuity tester between the relay termi nals (terminals 30 and 87). The relay should make and break continuity at terminals 30 and 87 as 12 V.D.C. is connected and disconnected to terminal 85 with termi nal 86 connected to ground. 1 Figure 15 1. Start relay 2 1 Figure 16 1. Cutting unit relay 2. High temp.
Glow Relay and Glow Plugs 1. Attach an amp meter to glow plug circuit. Turn ignition switch to ON. Meter may have an initial reading as high as 100 amps. A. If amp meter shows a reading for 5 to 12 seconds, the glow relay is operating. If there is no reading, go to step 2. 1 B. Turn ignition switch OFF, then ON again. A read ing of 48 amps should be observed. Go to step 3. 2. To test the circuit: A. Check with a test light at buss bar connection for glow plugs at cylinder head.
Battery Use a hydrometer to test the battery. Charge the battery if necessary (see Battery Service). Electrolyte specific gravity Fully charged: 1.250 - 1.280 Discharged: less than 1.240 Figure 20 Injection Pump (ETR) Solenoid The Reelmaster® 335-D has an energize-to-run (ETR) fuel stop solenoid. The solenoid will stop injector pump fuel delivery with any electrical failure in the RUN circuit. 1. Disconnect the wire from the solenoid. 1 2. Remove the solenoid from the injector pump. 3.
Gauges and Indicator Lights Oil Pressure Light Temperature Light Oil pressure lamp should come on when the ignition key switch is in the RUN position with the engine not running or if the oil pressure switch closes during operation - oil pressure below 7 psi (0.5 kg/cm2). The temperature light should come on only if the high temperature shut-down switch and relay has stopped the engine - coolant temperature above 221o F (105oC).
High Temperature Shut-Down Switch 1. Lower the coolant level in the engine and remove the high temperature shut-down switch. 2. Put the switch in a container of oil with a thermometer and heat the oil. 1 3. The switch is normally open (N.O.) and should close at approximately 221o F (105o C). 2 CAUTION Handle hot oil with special care to prevent personal injury or fire. Figure 22 1. High temperature shut-down switch 2. Temperature gauge sender Figure 23 Temperature Gauge Sender 1.
Engine Oil Pressure Switch The switch is normally closed (NC) and opens with pressure. The switch opens at approximately 8 psi. 1. Turn ignition key switch ON. Oil pressure lamp should be on. If bulb is not on: 1 1. Disconnect wire from switch and touch wire to a good ground, such as the engine block. 2. If lamp comes on, replace switch. 3. If lamp does not come on check wiring between lamp and switch for continuity. Figure 25 1. Engine oil pressure switch If lamp is on with engine running: 1.
Reel Motor Solenoids 1. Disconnect the wire connector. 2. Connect a 12 volt battery so the positive (+) battery terminal is connected to lead of the wiring connector and the negative (–) battery terminal to the other lead. The valve spool should retract completely as 12 V.D.C is applied between leads. 3. If valve spool does not retract check for binding or damage in valve. 4. If valve operates smoothly, but does not retract when 12 V.D.C is applied to solenoid leads, replace solenoid coil. 5.
Repairs IMPORTANT: Before welding on the machine, dis connect both battery cables from the battery and disconnect the terminal connector from the alterna tor to prevent damage to the electrical system. Battery Service IMPORTANT: To prevent damage to electrical com ponents, do not operate the engine with the battery cables disconnected. Electrolyte Specific Gravity Keep the terminals and entire battery case clean. To clean the battery, wash the entire case with a solution of baking soda and water.
Fuses The electrical system is protected by twelve (4) fuses located under the control panel to the operator’s right. NOTE: It is not always possible to see if a fuse is faulty. It is recommended that you check for faulty fuses with a continuity tester, not visually. 2 1 The starter circuit is also protected by a 30 amp in-line fuse between the start relay and starter solenoid. 4 3 Figure 31 1. ACC fuse 2. RELAY fuse 3. REEL fuse 4. RUN fuse FUSES Repairs 1. ACC 5A 2. RELAY 5A 3. REEL 30A 4.
Traction (Neutral) Switch Replacement 1. Remove the two wires that are connected to the traction switch. 2. Have a helper push the traction pedal down into either the FORWARD or REVERSE position; this will take the switch arm tension off of the switch. Loosen two (2) screws and remove the switch. 1 3. Install new switch. DO NOT over-tighten screws as the switch case could break. NOTE: Have a helper hold the traction pedal down while installing the switch. 4. Reconnect the two wires to the new switch.
Reel Motor Solenoid Coil Replacement 1. Park machine on a level surface, engage parking brake, lower the cutting units and turn engine OFF. 2. Disconnect solenoid electrical connector. 3. Remove nut from solenoid. 4. Remove cover and solenoid coil. 5. Install new solenoid coil and secure with nut. Apply “Locktite 242" or equivalent to threads on end of stem tube before installing nut. Tighten nut to a torque of 15 in-lb. Over-tightening may cause the solenoid valve to malfunction. 1 Figure 35 6.
Chapter 6 Axles and Brakes Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . Four-Matic™ 4WD Operation . . . . . . . . . . . . . . . ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . Rear Axle Toe-In Adjustment . . . . . . . . . . . . . . . . Transaxle Shift Linkage Adjustment . . . . . . . . . .
Specifications Item Specification __________________________________________________________________________________________ Tire pressure 15 - 20 PSI front and rear ________________________________________________________________________________________________________________________________________________________ Wheel bolt torque 45 - 55 ft-lb ________________________________________________________________________________________________________________________________________________________ Fr
General Information TM Four-Matic 4WD Over-Running Clutch Operation There are two hydraulic drive motors on the Reelmaster 335-D, 4WD; one for the front axle and one for the rear axle. The drive for the rear axle incorporates an OVERRUNNING (ROLLER) CLUTCH THAT TRANSMITS POWER ONLY IN THE FORWARD DIRECTION (Fig. 3A).
Adjustments Brake Adjustment Adjust service brakes when there is more than 1.5 in. “free travel” of brake pedal, or when brakes do not work effectively. Free travel is the distance the brake pedal moves before braking resistance is felt. To reduce free travel of brake pedals, tighten nut on brake rod adjuster, 1/2 turn at a time, until you get desired “free travel” in pedal. 1 Figure 5 1. Brake rod adjuster Rear Axle Toe-in Adjustment 1.
Transaxle Shift Linkage Adjustment 1. Remove steering tower cover. Raise and securely lock the front cutting unit in raised transport position. Measure from end of shaft to edge of transaxle. 2. Move axle shift lever forward to transport (high speed) position. Measure shaft dimension from side of transaxle case to end of shaft (Fig. 7). Adjust upper linkage length at top eye rod if necessary to get proper dimension (Fig. 8). Low position 1.2 - 1.3 in. (30 - 33 mm) 3.
Repairs Wheel Bearing Service (2WD Rear Axle) 7. Use No. 2 general purpose lithium base grease containing E.P. additive. Pack both bearings with grease. Install one bearing into the cup on inboard side of wheel hub. Lubricate the inside of the new lip seal and press it into the wheel hub. 1. Jack up rear of machine until tire is off the floor. Support machine with jack stands or blocks to prevent it from falling. 2. Remove dust cap from end of wheel spindle.
Adjusting Rear Wheel Bearings 1. Remove dust cap from end of wheel spindle. Remove cotter pin retaining slotted nut in place. 2. Rotate the wheel by hand and tighten the slotted nut until the bearing binds SLIGHTLY. Then, loosen the nut until the nearest slot and hole in the spindle line up. Reinstall the cotter pin to retain the slotted nut in place. NOTE: The correct end play of the adjusted assembly is 0.002 - 0.005 inches. 1 3. Remove jack stands or blocks and lower machine to floor. 4.
Front Axle Removal and Disassembly Figure 11 Special bearing - crack in race must face down Figure 12 Repairs Page 6 - 8 Reelmaster® 335-D
with a mallet from inside out. A pressed on, sealed ball bearing (Item 24) will be on end of axle. Front Axle Removal 1. Drain oil from transaxle. 8. Do steps 2 - 7 for axle housing on other side. 2. Jack up front of machine and support chassis frame with jack stands. 3. Remove front wheels. Remove nuts (Fig. 12, Item 20). Use a puller to pull wheel hubs (Item 14) off of shaft. 4. Clean all exterior surfaces of axle and transaxle. 5. Disconnect hydraulic motor (Fig. 11, Item 27) from transaxle.
Transaxle Service NOTE: This illustration shows a differ ent hydrostatic drive mounting surface and differential than what is used on the Toro Reelmaster 335-D.
Transaxle Disassembly Transaxle Assembly 1. Clean all exterior surfaces of transaxle. Reverse steps 1 - 8 under Transaxle Disassembly, watching out for the following: 2. Put the transaxle on a work bench with cover side up. Remove screws. Lift cover (Fig. 14, Item 16) off and discard gasket (Item 4). 1. After shift rod is in position, install ball, then spring and bolt. Turn bolt in until head of bolt contacts case. 3. Remove differential assembly and thrust washers (Item 8A and 9). 2.
Rear 4WD Axle Service Axle Housing (A) Axle Housing (B) Figure 17 Figure 18 Repairs Page 6 - 12 Reelmaster® 335-D
Disassembly The two gear cases, right and left can be removed from the housing without requiring the entire axle to be dis assembled. 3 1. Remove tie rod by disconnecting rod end ball joint on each end. Disconnect hydraulic cylinder rod end from drag link arm. 2. Remove bolts (Fig. 17, Item 23 and 21) securing gear case to axle housing and pull gear case complete with final drive case.
Install seal with garter spring facing towards hydraulic motor Figure 23 4. Pull out differential shaft (Fig. 17, Item 14) from housing (B). Disassembling Axle Housing 1. Remove axle from machine before disassembling: A. Jack up rear of machine and support from frame with jack stands. B. Remove wheels from axle. C. Remove hydraulic motor. Do not disconnect hy draulic lines from motor. D. Support axle with a jack, then remove axle pivot pin to separate axle from frame. E.
Inspection Clean the disassembled parts by washing in cleaning solvent. Inspect gears and pinions to be sure their teeth are in good condition. Check to be sure that each bearing rotates smoothly. Examine housings for cracks. Reassembly Replace damaged or worn parts as necessary. Oil or grease the surfaces of rotating or sliding parts before assembling. Grease oil seals and o-rings before installing. Assembling Pinion Shaft 1.
Adjusting Pinion Shaft Cone Center “Cone Center” is the distance from the mating face of axle housing to end face of pinion (Fig. 25A). This distance can be increased or decreased by installing removing shims. Cone center specification 43 ± 0.05mm (1.69 ± 0.002 in.) Shim stock for this adjustment is available in the follow ing thicknesses: Thickness Part No. Shim set 77-4010 0.1 mm (0.004 in.) 76-7410 0.2 mm (0.008 in.) 76-7420 0.4 mm (0.016 in.
Adjusting Backlash Backlash specification 0.25 ∼ 0.35 mm (0.010 ∼ 0.014 in.) Adjust shim thickness (between bearing housing of axle housing (A) and bearing) to get specified backlash. Shim stock for this adjustment is available in these thicknesses: Thickness Part No. Shim set 77-4000 0.1 mm (0.004 in.) 76-7290 0.2 mm (0.008 in.) 76-7300 0.4 mm (0.016 in.) 76-7310 Figure 27 Shim Between Differential and Axle Housing (B) After obtaining specified backlash, determine amount of shims needed: 1.
Assembling Axle Housing 1. Coat mating faces of two housings (A) and (B) with sealant and attach selected shim to face of housing (B). Put the two housings together and fasten them by tightening bolts to following torque value: Torque specification 2.5 ∼ 3.0 kg-m (18 ∼ 22 ft-lb) 2. Fit ball bearings to out end of each differential shaft, then mount pinion (14T) and retain pinion by installing circlip. The ball bearings have a groove cut in the end faces of the inner and outer races.
Installing Drag Link and Tie Rod Arm 1. Carefully insert bushing into arm. 2. Put arm into position over holder, fitting it to final case and secure to case with bolts. 3. Check thrust clearance. Proper thrust clearance is 0 to 0.2 mm (0.008in.). If necessary reduce clearance to specification by shimming. Shim stock for this adjust ment is available in the following thicknesses: Shim Part No. TIE ROD ARM Shim Part No. DRAG LINK ARM Shim set 77-4050 77-4040 0.8 mm (0.03 in.) 76-7820 76-7700 1.
4. After obtaining proper pinion backlash, grease o-ring and fit it to mating face of axle housing. Secure gear case to housing by tightening bolts to the following torque value: Torque specification 5.0 ∼ 6.0 kg-m (36 ∼ 43 ft-lb) Reassembling Wheel Shaft 1. Grease oil seal and fit it to bearing holder. 2. Insert shaft into holder. Install ball bearing and retain bearing by installing circlip. Figure 34 3. Mount bevel gear (29T) on splined end of shaft. 4.
Installing Axle on Machine 1. Support axle under machine with a jack. 2. Install axle pivot pin to secure axle to frame. Make sure to install thrust washers between axle pivot and frame. 3. Install hydraulic motor to adaptor housing. 4. Install wheels to axle. Tighten lug nuts to a torque of 45 - 55 ft-lb. 5. Fill axle with SAE 80-90W EP gear lube. Lubricant capacity is approximately 80 oz. (2.5 U.S. qt.). 6. Check rear wheel toe-in and adjust if necessary. Rear wheel toe-in Reelmaster® 335-D 0.25 in.
Repairs Page 6 - 22 Reelmaster® 335-D
Chapter 7 Cutting Units Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting Reel to Bedknife Contact. . . . . . . . . . . Height of Cut Adjustment (Floating Cutting Unit) Quick Method for Changing Height of Cut After Initial Set Up of a Floating Cutting Unit . . Height of Cut Adjustment (Fixed Cutting Unit) . .
Specifications Bedknife to Reel Adjustment: Two lockable lead screw adjusters at each side of the frame adjust the reel to bedknife contact. Rear Roller: 3-1/2 in. (89 mm) diameter steel roller has greaseable tapered roller bearings. A double lip oil seal and wear sleeve isolates grit and moisture from the bearings. Height-of-Cut: 5 Blade - 1 to 3 in. (25 to 76 mm). 7 Blade - 1/2 to 1-3/4 in. (9.5 to 45 mm). 1 1 Blade - 3/8 to 3/4 in. (9.5 to 19 mm).
Special Tools Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Some tools may be listed in the Reelmaster 335-D Parts Catalog. Some tools may also be available from a local supplier. Gauge Bar Assembly Use gauge bar to set final height of cut (floating cutting unit with front roller only). Figure 2 Handle Assembly For applying lapping compound to cutting units while keep hands a safe distance from the rotating reel.
Bedknife Screw Tool Fits Toro bedknife attaching screws. Use with torque wrench to secure bedknife to bedbar. With clean bedbar threads and new screws, tighten to a torque of 250 in-lb. NOTE: Remove all rust, scale and corrosion from bed bar surface before installing bedknife. DO NOT use and air impact wrench with this tool.
Adjustments CAUTION Never install or work on the cutting units or lift arms with the traction unit engine running. Always stop the engine and remove the key first. Adjusting Reel to Bedknife Contact Before adjusting height-of-cut and each day before operating, check reel to bedknife contact, regardless if quality of cut had previously been acceptable. NOTE: A 3/4" wrench is required for making the reel to bedknife adjustment. A.
Height-of-Cut Adjustment (Floating Cutting Unit) Overview of Procedure: 1. Adjust reel to bedknife contact 2. Level rear roller to reel 3. Final height-of-cut adjustment using gauge bar. STEP 1 - Adjust Reel to Bedknife Contact A. Adjust reel to bedknife contact on all cutting units. (Refer to Adjusting Reel To Bedknife Contact). STEP 2 - Level Rear Roller to Reel B. Start engine and lower the cutting units onto a flat surface such as a piece of 3/4" or 1 “ plywood (at least 20" x 30" in size).
STEP 3 - Final Gauge Bar Height-of-Cut Adjustment Using F. Raise cutting units and lock in the transport posi tion. Shut off the engine and remove the key. G. Use gauge bar (Toro Part No. 59-7900) to set final height-of-cut by adjusting front roller only. H. Loosen the gauge bar jam nut and adjust the screw to set dimension between underside of screw head and gauge bar for desired height-of-cut. (Fig. 9). Tighten the jam nut to secure the adjust ment.
Quick Method For Changing Height-of-Cut After Initial Set Up of a Floating Cutting Unit If the reel to bedknife adjustment has been set (STEP 1) and the rear roller leveled to the reel (STEP 2), the 335-D cutting unit may be quickly changed from one height-of-cut to another by using the gauge bar (Part #59-7900) and adjusting the front roller only. In many cases, an entire machine can be done quickly by using the gauge bar to set the front roller of one cutting unit.
Repairs CAUTION Never install or work on the cutting units or lift arms with the traction unit engine running. Always stop the engine and remove the key first. Backlapping the machine with the long handled brush. Backlap the #2 and #3 cutting units from the front of the machine. DANGER C. Wait for 2nd person’s instruction to engage reels in BACKLAP mode, then pull up on reel switch and move it to ENGAGE position. DURING BACKLAP OPERATION REELS ARE UNDER POWER.
D. When it becomes necessary to adjust the reel to the bedknife, instruct the operator to disengage the reel, stop the engine and remove the key from the ignition switch. Then proceed with the adjustment only after the reels have stopped rotating. of water to remove all lapping material. Allow the reel to dry and lubricate the grease fittings. G. Check sharpness of the reel and bedknife with strips of newspaper.
3. Insert the two (2) reel drive motor mounting bolts (heads on inside of the drive housing - flat washer on top bolt) through the reel motor flange holes. Thread the locknuts onto the bolts. Rotate reel motor upward in the slotted hole in the housing to tension the drive belt and tighten the fasteners (Fig. 14) to approx. 25 ft-lbs (34 Nm). NOTE: Proper belt tension is achieved when belt deflects approximately 1/8" (3 mm) at mid-point when 7 lbs. force is applied. (Fig. 14).
Servicing the Bedknife/Bedbar Assembly NOTE: The bedbar on each 335-D cutting unit has a precision ground mounting surface to provide an excel lent fit with a bedknife. Backlapping of replacement bedknives is often sufficient to achieve an excellent cutting edge with minimum material removed. Bedknife/Bedbar Removal: 1. Remove the shoulder bolts,bushings and spacers from each end of the unit and remove the bedbar/bedknife assembly (Fig. 16). 2.
Servicing the Reel Assembly Disassembly: 1. Remove the guards from each end of the cutting unit and the front and rear roller assemblies (Fig. 19). 2. Remove the shoulder bolts, bushings and spacers from each end of the unit and remove the bedbar/bedknife assembly (Fig. 20). 3. Remove the inboard locknut from the adjuster pin, the fasteners for the bracket and remove the adjusting handle assembly from the side plate (Fig. 20). Figure 19 1. Guard 4. Adjusting assembly 2. Mounting fasteners 5. Dust cap 3.
4. Disassemble the cone nut from the shoulder bolt securing the bearing housing to the side plate, remove the belleville washer and bolt and slide the bearing housing off the reel shaft (Fig. 21). 5. Disassemble the cover from the drive housing and remove the drive belt from the housing (Fig. 22). 6. Remove the reel capscrew, toothed washer and pulley washer from the reel shaft (Fig. 22). (Note: Cap screw is assembled with a thread locking compound). 7.
9. Install the woodruff key in the drive housing end of the reel shaft and install the driven pulley onto the shaft. Assembly: 1. Inspect the flange bushings in the mounting holes for the drive housing and bearing housing for wear (Fig. 20). Replace, if necessary. 2. Assemble the outer seal (lip facing in to retain grease) into the drive housing using Loctite 242 retaining com pound on the outer diameter.
Roller Removal and Installation 1. Remove the fasteners securing the guard and roller adjustment housing to the side plate (Fig. 24) or un screw the upper cone nut and drop the threaded rod out of the adjustment housing (Fig. 25). 2. The threaded rod and collar assembly can be re moved from the roller by sliding it off the shaft at both ends (Fig. 25).
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