Form No. 19241SL Rev B ProLine H800 (Models 31050, 31050TE and 31051) © 2021—The Toro® Company 8111 Lyndale Avenue South Bloomington, MN 55420 Original Instructions (EN) Contact us at www.Toro.com.
Revision History Revision Date A 06/2020 Initial issue. B 7/2021 Add model 31051 and optional slope sensor information.
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NOTES: NOTES: Page 4 ProLine H800 19241SL Rev B
Preface The purpose of this publication is to provide the service technician with the information for troubleshooting, testing, and repair of the major systems and components on the ProLine H800. Refer to the Operator’s Manuals for operating, maintenance, and adjustment instructions. Space is provided in Chapter 2 (page 2–1) of this book to insert the Operator’s Manuals and Parts Catalog for your machine. Additional copies of the Operator’s Manuals and Parts Catalogs are available at www.toro.com.
Service Procedure Icons The following icons appear throughout this Service Manual to bring attention to specific important details of a service procedure. Critical Process This icon is used to highlight: • Installing safety equipment (shields, guards, seat belts, brakes and R.O.P.S. components) that may have been removed. • Dimensions or settings that must be maintained for proper machine operation. • A specific fastener tightening sequence. • Component orientation that may not be obvious.
Table of Contents Preface ................................................................................................................ 5 Chapter 1: Safety ............................................................................................ 1–1 Safety Instructions ....................................................................................... 1–2 Jacking Instructions ..................................................................................... 1–7 Safety and Instructional Decals .
Additional Reference Materials Yanmar 3TNV76 Service Manual Yanmar 3TNV80F Service Manual Danfoss DDC20 Axial Piston Pump Service Manual Parker Torqmotor Service Procedure (TF, TG, TH, and TL Series) Grammer Seats Repair Manual Preface Page 8 ProLine H800 19241SL Rev B
Chapter 1 Safety Table of Contents Safety Instructions ................................................................................................................................ 1–2 Supervisor’s Responsibilities ............................................................................................................. 1–2 Before Operating the Machine ........................................................................................................... 1–3 While Operating the Machine ..........
Safety Instructions The ProLine H800 machines are tested and certified by Toro for compliance with existing safety standards and specifications. Although hazard control and accident prevention are partially dependent upon the design and configuration of the machine, hazard control and accident prevention are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance and storage of the machine.
Before Operating the Machine • Review and understand the content of the Operator’s Manuals before starting and operating the machine. Become familiar with the controls and know how to stop the machine and engine quickly. Additional copies of the Operator’s Manuals are available at www.toro.com. • Never allow children to operate the machine. Never allow adults to operate the machine without proper instructions. • Become familiar with the controls and know how to stop the machine and engine quickly.
While Operating the Machine • Sit on the seat when starting and operating the machine. • Anytime you park the machine (short or long term), lower the cutting deck to the ground. IMPORTANT When you lower the cutting deck to the ground, the pressure from the hydraulic lift circuit releases and prevents the cutting deck from accidentally lowering. • If you park the machine on a slope, block or chock the wheels. • Keep hands, feet and clothing away from moving parts and the discharge • area of an attachment.
Maintenance and Service • Before servicing or making any adjustments to the machine, lower the cutting • • • • • • • • • • • • • • • ProLine H800 19241SL Rev B deck, set the parking brake, shut off the engine, and remove the key from the key switch. Ensure that the machine is in safe operating condition by keeping all the nuts, bolts, and screws tight. Do not store the machine or a fuel container inside where there is an open flame, such as near a water heater or furnace.
Maintenance and Service (continued) • If welding on the machine is necessary, disconnect the battery negative cable to prevent electrical system damage. • Ensure to dispose of potentially harmful waste (e.g., fuel, oil, engine coolant, filters, battery) in an environmentally safe manner. Follow all local codes and regulations when recycling or disposing of waste. • At the time of manufacture, the machine conformed to the safety standards for riding mowers.
Jacking Instructions CAUTION Failing to properly support the machine with appropriate jack stands can cause the machine to move or fall and can result in personal injury. When changing the attachments, tires, or performing other services, do the following steps: • Use correct blocks, hoists, and jacks to raise and support the machine. • Park the machine on a solid level surface, such as a concrete floor.
Raising the Front of the Machine (continued) g216339 Figure 2 1. Bolt 2. Fuel-tank bracket 3. Access left side of the engine as follows: A. Remove the bolt from the left side of the fuel-tank bracket (Figure 2). B. Rotate the fuel tank to access the left side of the engine (Figure 2). g224454 Figure 3 1. Frame tube on the right side of the machine g224455 Figure 4 1. Frame tube on the left side of the machine 4.
Raising the Rear of the Machine g224613 Figure 5 1. Rear jacking points 1. Set the parking brake and block the 2 front wheels with chocks to prevent the machine from moving. 2. Position the jack securely under the frame (Figure 5). Safety and Instructional Decals Numerous safety and instruction decals are affixed to the traction unit and cutting deck of your ProLine H800. If any decal becomes illegible or damaged, install a new decal. Decal part numbers are listed in your Parts Catalog.
Safety: Safety and Instructional Decals Page 1–10 ProLine H800 19241SL Rev B
Chapter 2 Specifications and Maintenance Table of Contents Specifications ....................................................................................................................................... 2–2 Overall Dimensions............................................................................................................................ 2–2 Engine - ProLine H800 (for Model 31050) ..........................................................................................
Specifications Overall Dimensions g288868 Figure 6 Specifications and Maintenance: Specifications Page 2–2 ProLine H800 19241SL Rev B
Engine - ProLine H800 (for Model 31050) g288869 Figure 7 (Yanmar 3TNV80F - Shown) 1. Alternator 2. Item Description Make/Designation Yanmar 3TNV76-XGZ: 4-cycle, 3 cylinder water cooled diesel. EPA Tier 3 compliant. Bore 76 mm (3 inches) Stroke 82 mm (3.2 inches) Total displacement 1,116 cm3 (68.1 in3) Fuel Diesel or Biodiesel fuel (up to B7) Fuel tank capacity 41 L (10.
Engine - ProLine H800 (for Model 31050TE and 31051) Item Description Make/Designation Yanmar 3TNV80-NXDGZ: 4-cycle, 3 cylinder water cooled diesel. EPA Tier 4 compliant. Bore 80 mm (3.15 inches) Stroke 84 mm (3.31 inches) Total displacement 1,267 cm³ (77.31 in³) Firing order 1 (flywheel end) - 3 (fan end) - 2 19:1 Compression Ratio Fuel Diesel or Biodiesel fuel (up to B7) Fuel tank capacity 41 L (10.
Hydraulic System Item Description Piston Pump Danfoss DDC20 Displacement (per revolution) Relief Pressure 280 bar (4060 psi) Charge Pressure 7 bar (101.5 psi) Front Wheel Motors Parker TL Displacement (per revolution) Rear Wheel Motors 238 cm³ (14.5 in³) Parker TL Displacement (per revolution) 169 cm³ (10.3 in³) Steering Control Valve Ognibene (Italian) Relief Pressure 120 bar (1740 psi) Lift/Lower Circuit Relief Pressure 120 bar (1740 psi) Hydraulic Tank 5 L (5.
Chassis Item Description Blades screws torque 50 N·m (37 ft-lb) Blades disc torque 53 N·m (40 ft-lb) Electro-magnetic clutch mid-screw torque 50 N·m (37 ft-lb) Wheels bolts torque 85 N·m (63 ft-lb) Engine-hydrostat bolt troque Specifications and Maintenance: Specifications 350 N·m (258 ft-lb) Page 2–6 ProLine H800 19241SL Rev B
Torque Specifications The 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 the fasteners will apply to all the fasteners which do not have a specific requirement identified in this Service Manual.
Fasteners with a Locking Feature IMPORTANT If a fastener with a locking feature or previously applied thread locking compound is reused, clean the fastener threads and apply new thread locker to the fastener during installation. Locking features are designed to create friction and prevent a fastener from loosening. Locking features can be found on externally or internally threaded fasteners. Common examples are plastic inserts incorporated into the fastener and pre-applied “dry” thread locking compound.
Calculating the Torque Values When Using a Drive-Adapter Wrench g211753 Figure 10 1. Drive-adapter wrench 3. Torque wrench 2. Effective length of torque wrench 4. Effective length of torque wrench + drive-adapter wrench Using a drive-adapter wrench (e.g., crowfoot wrench) in any position other than 90° and 270° to the frame of the torque wrench will affect the torque value measured by the torque wrench because of the effective length (lever) of the torque wrench changes.
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch) Thread Size # 6 - 32 UNC # 6 - 40 UNF # 8 - 32 UNC # 8 - 36 UNF # 10 - 24 UNC # 10 - 32 UNF Grade 1, 5 and 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs, and Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in-lb in-lb N∙cm 10 ± 2 13 ± 2 147 ± 23 13 ± 2 25 ± 5 282 ± 56 18 ± 2 30 ± 5 339 ± 56 SAE Grade 5 Bolts, Screws, Studs, and Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) SAE G
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) 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 ± 6 in-lb 644 ± 68 N∙cm 78 ± 8 in-lb 881 ± 90 N∙cm M6 X 1.0 96 ± 10 in-lb 1085 ± 113 N∙cm 133 ± 14 in-lb 1503 ± 158 N∙cm M8 X 1.25 19 ± 2 ft-lb 26 ± 3 N∙m 28 ± 3 ft-lb 38 ± 4 N∙m M10 X 1.
Other Torque Specifications SAE Grade 8 Steel Set Screws 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 Thread Cutting Screws (Zinc Plated Steel) Type 1, Type 23 or Type F Thread Size Baseline Torque** No. 6 - 32 UNC 20 ± 5 in-lb No. 8 - 32 UNC 30 ± 5 in-lb No.
Shop Supplies The procedures found in this Service Manual may recommend the use of commonly used shop supplies (lubricants, sealants, and adhesives). A symbol denoting the use of a shop supply may appear in figures that support a procedure. Always refer to the written procedure for specific information regarding the type and the application of a shop supply. IMPORTANT Always follow manufacturers instructions when using or storing shop supplies.
Thread sealant Used to seal threaded fittings and sensors from air, fuel, and oil pressure leaks and prevent galling and seizure between threaded parts. A thread sealant in paste firm is preferred over sealant tape. The sealant should remain semi-pliable to allow for component removal with standard tools. Some thread sealants may require the use of a cleaner or primer before use. Gasket compound Used to create a seal between mating parts.
Special Tools You can order these special tools from your Toro Distributor. Some tools may also be available from a local tool supplier. Hydraulic Pressure Testing Kit K-Line Part No. TOR47009 Use this kit to take various pressure readings for diagnostic tests. Quick disconnect fittings are provided to attach directly to the mating fittings on the machine test ports without the tools. A high-pressure hose is given for remote readings.
150 LPM (40 GPM) Hydraulic Tester K-Line Part No. AT40002 Use this tester to test the hydraulic circuits and components for flow and pressure capacities. The tester flow measurement maximum is 151 LPM (40 GPM). This tester includes the following: Load Valve – Turn the valve to restrict the flow to create a simulated working load in the circuit. Pressure Gauge – A glycerine filled pressure gauge 0 to 34,500 kPa (0 to 5,000 psi) to provide operating circuit pressure.
Hydraulic Test Fitting Kit K-Line Part No. TOR4079 This kit includes a variety of O-ring face seal fittings to let you connect the test gauges into the system.
High Flow Hydraulic Filter Kit K-Line Part No: TOR6011 The high flow hydraulic filter kit is designed with large flow (150 LPM or 40 GPM) and high pressure (34,500 kPa or 5,000 psi) capabilities. This kit provides for bi-directional filtration which prevents filtered unwanted material from entering into the circuit regardless of the flow direction. If a component failure occurs in the closed loop traction circuit, contamination from the damaged part will remain in the circuit until you remove it.
Remote Starter Switch After flushing the hydraulic system or replacing a hydraulic component (e.g. gear pump, piston pump, drive motor), it is necessary to prime the hydraulic pumps. A remote starter switch can be used for this purpose. A remote starter switch can be purchased locally or fabricated as follows: IMPORTANT: When using a remote starter switch, it is highly recommended to include a 20 amp in−line fuse between the battery and switch connector for circuit protection.
Multimeter Obtain this tool locally The meter can test the electrical components and circuits for current, resistance, or voltage. Note: Use a digital multimeter when testing the electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode ensures that the excess current is not allowed through the meter. This excess current can damage the circuits that are not designed to carry it. Battery Terminal Protector Toro Part No.
Chapter 3 Troubleshooting Table of Contents GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems ............................. 3–2 General Hydraulic System Problems ..................................................................................................... 3–3 Steering Circuit Problems ...................................................................................................................... 3–5 The Height Of Cut Circuit Problems.................................
GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems 1. Gather Information • Information reported by the customer • Information observed by you • Establish the what, where and when of the issue 2. Evaluate Potential Causes • Consider possible causes of the problem to develop a hypothesis • Narrow down the focus of the problem 3.
General Hydraulic System Problems Problem Hydraulic fluid is leaking from the system. The hydraulic fluid foams excessively causing fluid leakage from the hydraulic tank breather. The hydraulic system operates hot. ProLine H800 19241SL Rev B Possible Cause Corrective Action The fitting(s), hose(s), or tube(s) are loose or damaged. Secure or replace loose or damaged hydraulic connections. The O-ring(s) or seal(s) are missing or damaged. Install a new O-ring(s) or seal(s).
General Hydraulic System Problems (continued) Problem The traction response is sluggish. Traction jerky when starting. Neutral is difficult to find or unit operates in one direction only. No traction exists in either direction and the engine speed remains constant. The differential lock will not engage. Possible Cause Corrective Action The hydraulic fluid is very cold. Allow the hydraulic fluid to warm by safely operating the machine at rest. The hydraulic fluid level in the hydraulic tank is low.
Steering Circuit Problems Problem The steering is inoperative or sluggish. ProLine H800 19241SL Rev B Possible Cause Corrective Action Engine RPM is too low. Increase the engine RPM. The hydraulic fluid level in the hydraulic tank is low. Adjust the hydraulic fluid level. The steering components (e.g., tie rods, steering cylinder ends) are worn or binding. Repair or replace the components. The steering cylinder is binding. Check and clear the binding of the steering cylinder.
The Height Of Cut Circuit Problems Problem The height of cut will not lift or lift slowly. Possible Cause Corrective Action Engine RPM is too low. Increase the engine RPM. The hydraulic fluid level in the hydraulic tank is low. Adjust the hydraulic fluid level. The height of cut cylinder is binding. Check and clear the binding of the height of cut cylinder. The height of cut cylinder leaks internally. Repair or replace the height of cut cylinder.
The Cutting Deck Lift Circuit Problems Problem The cutting deck lift circuit will not lift or lift slowly. ProLine H800 19241SL Rev B Possible Cause Corrective Action Engine RPM is too low. Increase the engine RPM. The hydraulic fluid level in the hydraulic tank is low. Adjust the hydraulic fluid level. The cutting deck lift cylinders is binding. Check and clear the binding of the cutting deck lift cylinder. The cutting deck lift cylinders leaks internally.
The Hopper Lift Circuit Problem The hopper will not lift or lift slowly. Troubleshooting: The Hopper Lift Circuit Possible Cause Corrective Action Engine RPM is too low. Increase the engine RPM. The hydraulic fluid level in the hydraulic tank is low. Adjust the hydraulic fluid level. The hopper lift cylinders is binding. Check and clear the binding of the hopper lift cylinder. The hopper lift cylinders leaks internally. Repair or replace the hopper lift cylinders.
The Hopper Tilt Circuit Problem The hopper will not tilt or tilts slowly. ProLine H800 19241SL Rev B Possible Cause Corrective Action Engine RPM is too low. Increase the engine RPM. The hydraulic fluid level in the hydraulic tank is low. Adjust the hydraulic fluid level. The hopper tilt cylinders is binding. Check and clear the binding of the hopper tilt cylinder. The hopper tilt cylinders leaks internally. Repair or replace the hopper tilt cylinders.
Troubleshooting: The Hopper Tilt Circuit Page 3–10 ProLine H800 19241SL Rev B
Chapter 4 Engine Table of Contents General Information .............................................................................................................................. 4–2 Traction Unit Operator’s Manual ........................................................................................................ 4–2 Yanmar Service Manuals ................................................................................................................... 4–2 Service and Repairs .....................
General Information This chapter gives information about the repair of the Yanmar diesel engines used in the ProLine H800 machine. The general maintenance procedures are described in the Operator’s Manual. Detailed information on engine troubleshooting, testing, disassembly, and assembly are identified in the Yanmar 3TNV76 Service Manual and Yanmar 3TNV80F Service Manual. Additionally, some engine repair procedures are described in this manual.
Service and Repairs Air Cleaner Assembly g288944 Figure 11 7. Washer 13. Air cleaner indicator 8. 9. 10. Bolt Washer Nut 14. 15. 16. Prefilter Nut Clamp Engine 11. Hose 17. Bolt Bracket 12. Air cleaner 1. Clamp 2. 3. 4. 90º Hose U-Bolt Air cleaner hose 5. 6. Removing the Air Cleaner Assembly 1. Park the machine on a level surface, lower the cutting deck, stop the engine, engage the parking brake and remove the key from the key switch. 2.
Installing the Air Cleaner Assembly IMPORTANT Any leaks in the air cleaner system will allow the dirt into the engine and will cause serious engine damage. Ensure that all air cleaner components are in good condition and are properly secured during installation. g288971 Figure 12 1. Air cleaner body 4. Air cleaner cover 2. Safety filter 5. Dust cap 3. Primary filter 1. Assemble the air cleaner (Figure 12). A. Ensure that the dust cap is pointed down after installation. B.
Exhaust System g288973 Figure 13 1. Bolt 4. Spacer 7. Clamp 2. Washer 5. Nut 8. Exhaust pipe 3. Shock absorber 6. Muffler 9. Engine Removing the Exhaust System CAUTION A hot engine and exhaust system can cause burns. Allow the engine and the exhaust system to cool before working on or near them. 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2.
Removing the Exhaust System (continued) 3. Allow engine and exhaust system to cool before doing any disassembly of exhaust system components. Get the access to exhaust system components. 4. Raise and lock the hopper assembly; refer to Operator’s Manual. 5. Remove the top engine cover and rear engine cover assemblies (refer to Frame Assembly (page 7–19)) and get access to exhaust pipe. 6. Remove the exhaust pipe as shown in Figure 13.
Radiator g289021 Figure 14 1. Cap 15. Hose 29. Washer 43. Nut 2. Clamp 16. Nut 30. Plate 44. Bracket 3. Hose 17. Cable guard 31. Collar 45. Nut 4. 5. 6. 7. Gasket Debris screen Thread insert Nut 18. 19. 20. 21. Washer Knob Tank Clamp 32. 33. 34. 35. Bolt Washer Hose Nut 46. 47. 48. 49. Washer Bracket Washer Bolt 8. Bushing 22. Washer 36. Gasket 50. Bracket 9. Washer 23. Bolt 37. Blower 51. Spring 10. 11. 12. 13. Shock absorber Radiator Hose Clamp 24. 25.
Removing the Radiator 1. Park machine on a level surface, lower cutting deck, shut off the engine, engage parking brake, and remove key from the key switch. 2. Raise and lock the hopper assembly; refer to Operator’s Manual. DANGER If the radiator or engine is hot, pressurized hot coolant can escape and cause burns. Do not open the radiator cap or drain the radiator when the coolant is hot. WARNING Ethylene-glycol antifreeze is poisonous. Keep the coolant away from children and pets.
Removing the Radiator (continued) g289054 Figure 16 1. 2. Oil cooler Nut 5. 6. Bracket Hydraulic hose 3. Bolt 7. Hydraulic hose 4. Washer CAUTION Before opening the hydraulic system, operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic fluid. 7. Read the General Precautions for Removing and Installing the Hydraulic System Components (page 5–63). 8. Clean the hydraulic tube ends and oil cooler fittings to prevent hydraulic contamination. 9.
Removing the Radiator (continued) 20. If necessary, separate the oil cooler from the radiator as follows (Figure 16): A. Remove the 4 nuts, bolts and washers that attach the oil cooler to the radiator. B. Separate the oil cooler from the radiator. C. If the hydraulic fittings are to be removed from the oil cooler, mark the fitting orientation for assembly. D. Remove the 2 straight fittings from the oil cooler and discard the O-rings from the fittings. 21.
Fuel System g289096 Figure 17 1. 2. Hose Clamp 8. 9. Nut Water separator assembly 15. 16. Float Clamp 3. Clamp 4. 5. Hose Hose 10. Washer 17. Screw 11. 12. Bolt Hose 18. 19. Hose Clamp 6. 7. Engine 13. Fuel tank 20. Fuel filter element Hose 14. Fuel tank cap 21.
DANGER Diesel fuel is highly flammable and explosive. A fire or a explosion from the fuel can burn you, burn other people, and damage property. • Use caution whenever you store or handle diesel fuel. • Do not smoke while filling the fuel tank. • Do not fill the fuel tank while the engine is running, while the engine is hot, or when the machine is in an enclosed area. • Always fill the fuel tank outside and wipe up any spilled diesel fuel before starting the engine.
Removing the Fuel Tank g289124 Figure 19 1. 2. Bolt Washer 5. 6. Nut Cross rail 9. 10. Bolt Fuel tank support 11. Fuel tank 3. Nut 7. Rubber grommet 4. Washer 8. Bolt 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Raise and lock the hopper assembly; refer to Operator’s Manual. 3. Remove the battery negative cable from the negative post of the battery. 4.
Removing the Fuel Tank (continued) 8. Cover or plug the fuel hoses or fitting openings to prevent contamination from entering the fuel system. 9. Remove the fuel tank as shown in Figure 19. Installing the Fuel Tank 1. Install the fuel tank to the frame as shown in Figure 19. 2. Remove the plugs from the fuel hoses or fitting openings. 3. Connect the fuel hoses to the fuel tank float on top of the fuel tank. Secure the fuel hoses with the hose clamps. 4.
Engine g289256 Figure 20 1. Engine 10. Bolt 19. Flange 2. 3. Hose Clamp 11. 12. Bolt Clamp 20. 21. Bolt Washer 4. 5. Nut Washer 13. 14. Bolt Washer 22. 23. Joint Support 6. Bolt 15. Clamp 24. Bolt 7. Washer 16. Bolt 25. Engine support 8. Engine support 17. Bolt 9. Shock absorber 18. Engine support Removing the Engine 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the key switch. 2.
Removing the Engine (continued) 3. Remove the hopper assembly from the machine; refer to Removing the Hopper Assembly (page 9–3). 4. Remove the chute assembly from the machine; refer to Operator’s Manual. CAUTION Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot coolant can escape and cause burns. Ethylene−glycol antifreeze is poisonous. Dispose of coolant properly or store it in a properly labeled container away from children and pets. 5.
Removing the Engine (continued) 13. Disconnect the wires and/or electrical connections from the following engine electrical components: A. Alternator connector and stud. B. Oil pressure switch located near the engine oil filter. C. Connector and positive battery cable from the starter motor. D. High temperature shut down switch and temperature sender located on the water pump housing. E. Fuel stop solenoid on the injector pump. F. Battery negative cable from the injector pump. G. Glow plug strip. H.
Installing the Engine IMPORTANT Ensure that all parts removed from the engine during maintenance or overhaul are correctly installed on the engine. 1. Park the machine on a level surface and remove the key from the key switch. Block the wheels with chocks to prevent the machine from moving. 2. If the engine brackets were removed from the engine, install the brackets to the engine (Figure 20).
Installing the Engine (continued) H. PTO clutch wire connector. 8. Using the notes that you recorded during removal, secure the wires with cable ties in proper locations. 9. Install the electric clutch onto the engine; refer to Installing the Electric Clutch (page 8–16). 10. Install the PTO driveshaft onto the machine; refer to Installing the PTO Driveshaft (page 8–19). 11. Install the exhaust pipe onto the engine; refer to Installing the Exhaust System (page 4–6). 12.
Engine: Service and Repairs Page 4–20 ProLine H800 19241SL Rev B
Chapter 5 Hydraulic System Table of Contents General Information .............................................................................................................................. 5–3 Checking the Hydraulic Fluid ............................................................................................................. 5–3 Pushing or Towing the Traction Unit ...................................................................................................
Height Of Cut Cylinder ................................................................................................................... 5–124 Chute Cleaning Cylinder ................................................................................................................ 5–127 Oil Cooler .......................................................................................................................................
General Information The Operator's Manual provides information regarding the operation, general maintenance procedures, and maintenance intervals for your machine. Refer to the Operator's Manual for additional information when servicing the machine. Checking the Hydraulic Fluid g295950 Figure 21 The hydraulic system on your machine is designed to operate on high quality hydraulic fluid. The hydraulic system tank is located under the right console and holds approximately 5.0 L (5.
Pushing or Towing the Traction Unit IMPORTANT If towing limits are exceeded, severe damage to the hydraulic pump may occur. g231794 Figure 22 g215176 Figure 23 1. Front of the machine 2. Hydraulic pump 3. Control knob (bypass valve) If it becomes necessary to tow or push the machine, tow or push at a speed of 3 to 5 km/h (2 to 3 mph), and for a very short distance. If you must move the machine a considerable distance (more than a few feet), transport it on a truck or trailer.
Releasing Pressure from the Hydraulic System Follow the steps below to release all pressure in the hydraulic system prior to starting any service procedures. There must be no pressure in the hydraulic system. Releasing the Hydraulic Pressure from the Traction Circuit Note: If you park the machine on an inclined or sloped surface, the pressure in the traction circuit will not release. 1. Park the machine on a level surface. 2. Lower the cutting deck. 3.
Traction Circuit Component Failure The traction circuit of the ProLine H800 is a closed loop system that includes the hydraulic pump and hydraulic motor. If a component failure occurs in the traction circuit, unwanted material and contamination from the damaged component will circulate throughout the traction circuit. This contamination can damage other components in the circuit, so remove the contamination to prevent additional component failure.
Hydraulic Hoses The hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage conditions, in addition to mishandling during operation and maintenance. These conditions can cause damage to the hose or deterioration to the hose material. Some hoses are more susceptible to these conditions than others. Examine all of the hydraulic hoses of the machine frequently and repair or replace them as necessary.
Installing the Hydraulic Hoses and Tubes g221221 Figure 24 1. Tube or hose 2. Swivel nut 3. O-ring 4. Fitting body 1. Ensure that all the threads, the sealing surfaces of the hose/tube, and the fitting are free of burrs, nicks, scratches, or unwanted material. 2. Align the hose/tube against the body of the fitting so that the face of the hose/tube sleeve fully touches the face of the fitting. Note: It may be necessary to use a drive-adapter wrench (e.g.
Installing the Hydraulic Hoses and Tubes (continued) 4. If a torque wrench is not available or if space at the swivel nut prevents the use of a torque wrench, use the alternative procedure Flats From Wrench Resistance (FFWR) given below: Flats From Wrench Resistance Table Size FFWR 3/8 BSPP 1/2 to 3/4 6 ORFS 1/2 to 3/4 8 ORFS 1/2 to 3/4 10 ORFS 1/2 to 3/4 12 ORFS 1/3 to 1/2 16 ORFS 1/3 to 1/2 A.
Installing the Hydraulic Fittings IMPORTANT The hydraulic fittings used in this machine may have BSPP (British Standard Parallel Pipe) threads or ORFS (O-Ring Face Seal) threads for the hose connections, and SAE or BSPP threads for the component connections. Pay close attention to the fitting thread type and the type of seal used when replacing the hydraulic tank fittings and seals, or component damage and leakage may occur. Installing the Non-Adjustable Fittings g221223 Figure 26 1. Fitting 2.
Installing an Adjustable Fitting g221224 Figure 27 1. Locknut 2. Back-up washer 3. O-ring g221225 Figure 28 1. Step 1: clearance the lock nut 3. Step 3: align the fitting 2. Step 2: seat the back-up washer 4. Step 4: tighten the lock nut 1. Ensure that all the threads, the sealing surfaces of fitting, and the component port are free of burrs, nicks, scratches, or unwanted material. 2. To help prevent a hydraulic leak, replace the O-ring when you open the connection. 3.
Installing an Adjustable Fitting (continued) 7. Tighten the fitting lock nut (Step 4 in Figure 28): A. Hold the fitting in the correct alignment with a wrench and use a torque wrench and tighten the fitting to the recommended torque value within the specified range of torque values; refer to the Fitting Installation Torque Table (page 5–12). This tightening procedure requires a drive-adapter wrench (e.g., crowfoot wrench); refer to Calculating the Torque Values When Using a Drive-Adapter Wrench (page 2–9).
Hydraulic Schematic The hydraulic schematic for the PLH800 machine is located in Appendix A (page A–1).
Hydraulic Flow Diagrams Traction Circuit Hydraulic system pressure is generated by a piston-driven pump coupled to the engine flywheel. This variable-displacement pump provides hydraulic flow under regulated pressure to the front and rear wheel motors, and changes its fluid flow rate with an internal swash plate. The swash plate angle is controlled by the traction pedal through a linkage system. The angle of the swash plate determines the pump flow, and ultimately the speed of the machine.
Forward Direction g292001 Figure 29 ProLine H800 19241SL Rev B Page 5–15 Hydraulic System: Hydraulic Flow Diagrams
Forward Direction (continued) The forward traction pressure is limited to 280 bar (4,061 psi). The fluid flowing from the motor returns to the variable displacement pump and is continuously pumped through the closed loop circuit as long as the traction pedal is pressed. The piston pump is equipped with a case drain to allow normal internal leakage to be removed. The hydraulic pump also includes a gerotor charge pump.
Reverse Direction g292002 Figure 30 ProLine H800 19241SL Rev B Page 5–17 Hydraulic System: Hydraulic Flow Diagrams
Reverse Direction (continued) The traction circuit operates essentially the same in reverse as it does when moving forward. The primary difference is that the direction of fluid flow through the circuit is reversed when the bottom of the traction pedal is pushed. The reverse traction pressure is likewise limited to 280 bar (4,061 psi).
Steering Circuit g292117 Figure 31 The charge pump supplies the fluid flow for the steering circuit, height of cut control, and the auxiliary control circuit. The pump output flows first to the steering control valve before reaching the height of cut valve, so that the steering circuit has priority. The steering circuit pressure is limited to a 120-125 bar (1,740-1,813 psi) by a relief valve located inside the steering control.
Right Turn g292116 Figure 32 When a right turn is made with the engine running, the turning of the wheel positions the steering control spool valve so flow passes through the top of the spool. The fluid flow entering the steering control valve at the P port passes through the rotary meter, and is directed out through the R port. Pressure then extends the steering cylinder for a right turn.
Left Turn g292115 Figure 33 When a left turn is made with the engine running, the turning of the wheel positions the steering control spool valve so that the flow passes through the bottom of the spool. The fluid flow entering the steering control valve at the P port passes through the rotary meter, and is directed out the L port. Pressure extends the steering cylinder for a left turn. The rotary meter ensures that the fluid flow to the cylinder is proportional to amount of steering wheel rotation.
Height Of Cut Circuit g292157 Figure 34 The charge pump supplies fluid pressure to the steering circuit, height of cut circuit and auxiliary circuit. The charge pump is fed through a filter from the hydraulic tank. The pump output flows to the steering control valve first before reaching the height of cut circuit. When the height of cut is not being adjusted higher or lower, fluid flow enters the height of cut control valve manifold at the P port and exits from the T port.
Raising the Height Of Cut g292158 Figure 35 When the height of cut switch is moved to the RAISE position, the solenoid valve inside the control valve is energized to cause the valve to shift, allowing fluid flow from the P port to the A port. This extends the piston, causing the height of cut to raise. The fluid displaced from the rod end of the height of cut cylinder is routed to the T port.
Lowering the Height Of Cut g292156 Figure 36 When the height of cut switch is moved to the LOW position, the solenoid valve inside the control valve is energized to cause the valve to shift, allowing fluid flow from the P port to the B port. This retracts the piston, causing the height of cut to lower. The fluid displaced from the barrel end of the height of cut cylinder is routed to the T port.
Auxiliary Control Circuit g296061 Figure 37 The charge pump supplies fluid pressure to the steering circuit, the height of cut circuit, and the auxiliary control valve. The charge pump takes its suction through a filter from the hydraulic tank. The pump output flows to the steering control valve and height of cut valve before reaching the auxiliary control valve.
Raising the Cutting Deck g292091 Figure 38 When the cutting deck lift lever is moved to the RAISE position, hydraulic fluid flow is directed to the deck lift cylinders. The hydraulic pressure against the cylinder pistons retracts the lift cylinders, lifting the cutting deck.
Lower the Cutting Deck g292092 Figure 39 When the cutting deck lift lever is moved to the LOWER position, hydraulic fluid flows through the auxiliary control valve manifold and opens a path for fluid trapped in the lift cylinder piston to escape through the open port in the auxiliary control valve. The weight of the cutting deck causes the cylinders to extend and the cutting deck lowers.
Raising the Hopper g292201 Figure 40 When the hopper lift lever is moved to the RAISE position, hydraulic fluid flow is directed to the hopper lift cylinders. The hydraulic pressure extends the lift cylinders and the hopper goes up. When the hopper lift cylinders reach the end of their stroke, the relief valve in the steering control valve opens and directs the hydraulic flow to the pump until the lift lever is returned to the neutral position.
Lowering the Hopper g292202 Figure 41 When the hopper lift lever is moved to the LOWER position, hydraulic fluid flow is directed to the hopper lift cylinders. The hydraulic pressure in the rod side of the cylinder causes the piston to retract and lowers the hopper. When the lift cylinders reach the end of their stroke, the relief valve in the steering control valve opens and directs the hydraulic flow to the pump until the lift lever is returned to the neutral position.
Tilting the Hopper g292218 Figure 42 When the hopper tilt lever is moved to the TILT position, hydraulic fluid flow is directed to the hopper tilt cylinders. The hydraulic pressure extends the cylinders and tilts the hopper. When the tilt cylinders reach the end of their stroke, the relief valve in the steering control valve opens and directs the hydraulic flow to the pump until the tilt lever is returned to the neutral position. The deck cleaning blade is controlled by the deck cleaning cylinder.
Leveling the Hopper g292217 Figure 43 When the hopper lift lever is moved to the LOWER position, hydraulic fluid flow is directed to the hopper lift cylinders. The hydraulic pressure in the rod side of the cylinder causes the piston to retract and lowers the hopper. When the lift cylinders reach the end of their stroke, the relief valve in the steering control valve opens and directs the hydraulic flow to the pump until the lift lever is returned to the neutral position.
Testing the Hydraulic System The most effective procedure to isolate the problems in the hydraulic system is to use hydraulic test equipment, such as pressure gauges and flow meters in the circuits during different operational checks; refer to Special Tools (page 2–15). WARNING Opening the hydraulic system without releasing pressure from the system will cause the hydraulic fluid to escape, causing possible injury.
IMPORTANT Use 2 people to perform all the tests, with 1 person in the seat and the other to read and record the test results. 1. Use the following resources to assist with hydraulic system troubleshooting: • The Hydraulic Schematic in Appendix A (page A–1). • Hydraulic Flow Diagrams (page 5–14). • General and system specific troubleshooting tables in Chapter 3: Troubleshooting. 2. Clean the machine fully before you disconnect or disassemble any hydraulic components. 3.
Testing the Traction Circuit - Charge Pressure g292481 Figure 44 The charge pressure test is the first in a series of tests recommended to determine traction circuit performance. A charge pressure drop of more than 20% indicates an internal leak in the hydraulic pump. Continued unit operation can generate excessive heat, cause damage to seals and other components in the hydraulic system, and affect overall machine performance.
Testing the Traction Circuit - Charge Pressure (continued) CAUTION Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 5–5). 2. Park the machine on a level surface with the PTO switch off, lower the cutting deck, shut off the engine, and set the parking brake. 3. Read all Warnings, Cautions, and precautions listed at the beginning of this section.
Testing the Traction Circuit - Charge Pressure (continued) g292480 Figure 46 1. Hydraulic pressure test port 2. Hydraulic fluid filter 3. Radiator 7. Gain access to the charge pressure test port (Figure 46). 8. Clean the charge pressure test port. Loosen and remove the cap from the test port. 9. Install a pressure gauge (below 300 psi) to the test port. 10. Install a pressure gauge (below 2000 psi) to the traction pump “A” port. 11.
Testing the Traction Circuit - Charge Pressure (continued) 18. After you complete the charge pressure testing, release hydraulic system pressure; refer to Releasing Pressure from the Hydraulic System (page 5–5). Remove the pressure gauges and install the hydraulic pressure test ports. 19. Rotate and lock the radiator in correct position. 20.
Testing the Wheel Motors Efficiency g292862 Figure 47 The wheel motor efficiency test evaluates the traction circuit performance. Hydraulic fluid flow of 2.8 LPM (0.74 GPM) or more through a stationary rear wheel motor under load indicates an internal leak in the wheel motor. Fluid flow of 3.4 LPM (0.9 GPM) or more through a stationary front wheel motor under load indicates an internal leak in the wheel motor. A worn wheel motor is less efficient.
Special equipment required: • Flow meter with pressure gauge that has at least an 68 LPM (18 GPM) capacity. • Phototach (non-contact tachometer). Rear Left Wheel Motor Test Procedure The hydraulic fluid flows through the rear left and bypasses all other motors by masking the hydraulic connections (Figure 47). 1. Once the test equipment is properly connected, you can run the engine and pump to warm the hydraulic fluid to operating temperature.
Rear Left Wheel Motor Test Procedure (continued) 10. Chock the rear left wheel being tested to prevent from rotation. CAUTION Use extreme caution when performing this test. The wheel motor being tested will be trying to move the machine forward. 11. Start the engine and run it at low idle speed. Check for the hydraulic fluid leaks from the test connections and correct before the continuing the test. 12. Set the engine speed to approximately 3,210 rpm.
Front Left Wheel Motor Test Procedure If the front left wheel motor requires testing, repeat the steps 2 through 19; refer to Figure 48. Note: The flow meter reading should be less than 3.4 LPM (0.9 GPM) for the tested wheel motor. If the specification is not met, repair or replace the wheel motor.
Front Right Wheel Motor Test Procedure If the front right wheel motor requires testing, repeat steps 2through 19; refer toFigure 49. Note: The flow meter reading should be less than 3.4 LPM (0.9 GPM) for the tested wheel motor. If the specification is not met, repair or replace the wheel motor.
Rear Right Wheel Motor Test Procedure If the rear right wheel motor requires testing, repeat the steps 2 through 19; refer toFigure 50. Note: The flow meter reading should be less than 2.8 LPM (0.74 GPM) for the tested wheel motor. If the specification is not met, repair or replace the wheel motor.
Testing the Traction Circuit - Hydraulic Pump Flow and Relief Pressure g292558 Figure 51 The hydraulic pump flow test is the third in a series of tests recommended to determine the traction circuit performance. This test compares fluid flow at no load with the fluid flow under load. A drop in flow under load of more than 12% indicates an internal leak or malfunctioning relief valve in the hydraulic pump. The final traction circuit test is verifying the hydraulic pump relief valve operation.
Test Procedure 1. Once the test equipment is properly connected, you can run the engine and pump to warm the hydraulic fluid to operating temperature. Any test procedure that requires an open or uncapped line (like a case drain leak check) would not apply. In those rare situations, the hydraulic fluid should be warmed before disconnecting the lines.
Test Procedure (continued) 5. Access the hydraulic pump from left side. Remove the bolt (item 1) from the bracket (tem 2) and rotate the fuel tank to the right to access the hydraulic pump. Note: You must have the steering wheel rotated to the fully left locked position to rotate the fuel tank fully. g216339 Figure 53 1. Bolt 2. Fuel tank bracket 6. Ensure that the traction pedal is correctly adjusted for the NEUTRAL position.
Test Procedure (continued) IMPORTANT Ensure that the fluid flow indicator arrow on the flow meter is showing that the fluid will flow from the pump, through the tester, and into the disconnected hydraulic hose. 9. Place a steel cap on T fitting to block the hydraulic fluid flow to front right and rear right wheel motors (Figure 54). Also install the steel plugs in the open end of the disconnected hose to prevent leakage or contamination. 10.
Test Procedure (continued) E. Release the traction pedal, open the flow control valve fully, move the throttle to low speed, and shut off the engine. 17. If the relief pressure can not be met or is greater than specified, the traction relief valve is damaged and should be replaced. 18. The under load test flow reading (step 15C) should not drop more than 12% when compared to the no load test flow reading (step 14B).
Testing the Steering Circuit - Steering Control Valve, Relief Valve Pressure and Steering Cylinder g292611 Figure 55 Steering unit performance will be impacted by incorrect rear tire pressure, binding in the hydraulic steering cylinder, extra weight on the vehicle, and/or binding of the steering spindle. Check for these conditions before proceeding with any steering system hydraulic testing. Note: The relief valve for the steering circuit is integrated into the steering control valve.
Test Procedure (continued) A. There should be no shaking or vibration in the steering wheel or rear wheels. B. The steering wheel movements should be followed immediately by a corresponding rear wheel movement without the steering wheel continuing to turn. 3. Stop unit with the engine running. Turn the steering wheel with small quick movements in both directions. Let go of the steering wheel after each movement. A. The steering control valve should respond to each steering wheel movement. B.
Test Procedure (continued) 5. The steering circuit relief valve located in the steering control valve can be tested with the pressure gauge installed in the same location as the steering cylinder test (step 4) as follows: A. Start the engine and run it at low-idle speed. Check for hydraulic-fluid leaks from the test connections and correct before continuing the test. B. Set the engine speed to approximately 2,000 rpm. Use a phototac to check that the engine speed is correct.
Testing the Steering Circuit - Charge Pump Flow g292668 Figure 57 The charge pump is designed to satisfy the steering cylinder needs (at full speed). The charge pump flow test compares fluid flow at no load with fluid flow under load. A drop in flow under load of more than 15% indicates the gears and wear plates in the pump have worn. Continued operation with a worn pump can generate excessive heat and cause damage to the seals and other components in the hydraulic system.
Test Procedure g292669 Figure 58 1. Cap 13. Hose 25. Hydraulic filter 2. Extension 14. Fitting 26. 90º fitting 3. Hydraulic tank 15. One direction valve 27. Plug 4. Hydraulic tank filter 16. O-ring 28. Filter assembly Washer 5. O-ring 17. 90º adaptor 29. 6. Filter support 18. Fitting 30. Reducer 7. 90º adaptor 19. Washer 31. Adaptor 8. Oil cooler 20. Charge pump 32. Hose 9. Hose 21. Adaptor 33. Fitting 10. Hose 22. T fitting 34. Washer 11.
Test Procedure (continued) 1. Park the machine on a level surface with the PTO switch off, lower the cutting deck, shut off the engine, and set the parking brake. 2. Read all Warning, Cautions, and precautions listed at the beginning of this section. CAUTION Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 5–5). 3.
Test Procedure (continued) 11. Verify the pump flow under load as follows: CAUTION Do not close the tester valve fully when performing this test. In this test, the hydraulic tester is positioned in an unprotected part of the steering circuit. Pump damage can occur if the fluid flow is fully restricted by fully closing the tester flow control valve. A. Monitor the tester pressure gauge carefully while you slowly close the flow control valve until you get 75 bar (1088 psi). B.
Testing the Auxiliary Control Circuit - Cutting Deck Lift Cylinder Internal Leakage g292724 Figure 59 Perform a cutting deck lift cylinder internal leakage test if you identify a cutting deck raise and lower problem. This test determines if the lift cylinder being tested is damaged. The lift cylinders must be tested individually. Note: The raise/lower circuit operation can be affected by several possible issues.
Test Procedure Note: When performing the lift cylinder internal leakage test, the cutting deck should be attached to the lift arms and the cutting deck should be in raise position. 1. Park the machine on a level surface with the PTO switch off, shut off the engine, and set the parking brake. 2. Read all Warning, Cautions, and precautions listed at the beginning of this section. 3. If necessary, remove the front wheel to get access to the lift cylinder; refer to Removing the Wheels (page 7–3). 4.
Testing the Auxiliary Control Circuit - Hopper Lift Cylinder Internal Leakage g292780 Figure 60 Perform a hopper lift cylinder internal leakage test if a raise/lower problem exists. This test determines if the lift cylinder is damaged. Each hopper lift cylinder must be tested individually. Note: The raise/lower circuit operation can be affected by the hopper lift cylinder binding, extra weight on the hopper, and/or binding of the lift components.
Test Procedure (continued) IMPORTANT When capping the hopper lift cylinder fitting and hydraulic hose end, use a steel cap and plug to ensure that there is no fluid leakage. The plastic plugs cannot hold the hydraulic pressure that is developed during this test procedure. 5. Install a steel cap on the open hopper lift cylinder fitting to seal the lift cylinder. Also, install a steel plug in the open end of the disconnected hose to prevent leakage or contamination. 6.
Testing the Auxiliary Control Circuit - Hopper Tilt Cylinder Internal Leakage g292781 Figure 61 Perform a hopper tilt cylinder internal leakage test if you identify a hopper tilt and lower problem. This test determines if a hopper tilt cylinder being tested is damaged. The hopper tilt cylinders must be tested individually. Note: The hopper tilt/lower circuit operation can be affected by the hopper tilt cylinder binding, extra weight on the hopper, and/or binding of the lift components.
Test Procedure (continued) IMPORTANT When capping the hopper tilt cylinder fitting and hydraulic hose end, use a steel cap and plug to ensure that there is no fluid leakage. The plastic plugs cannot hold the hydraulic pressure that is developed during this test procedure. 5. Install a steel cap on the open hopper tilt cylinder fitting to seal the tilt cylinder. Also, install a steel plug in the open end of the disconnected hose to prevent leakage or contamination. 6.
Testing the Height Of Cut Cylinder Internal Leakage The block valve in the height of cut circuit should hold the cylinder piston in correct position all the time. If the height of cut piston lowers the height of cut itself, replace the height of cut cylinder; refer to Height Of Cut Cylinder (page 5–124).
Service and Repairs General Precautions for Removing and Installing the Hydraulic System Components Before Repairing or Replacing the Components 1. Before removing any parts from the hydraulic system, park the machine on a level surface, lower the cutting deck, turn the engine OFF, set the parking brake, and remove the key from the key switch. 2. Clean the machine before you disconnect, remove, or disassemble the hydraulic components.
After Repairing or Replacing the Components (continued) 4. Use proper tightening procedures when installing the hydraulic hoses and fittings; refer to Installing the Hydraulic Hoses and Tubes (page 5–8) and Installing the Hydraulic Fittings (page 5–10). 5. After you complete the repairs, check the control linkages or cables for proper adjustment, binding, or broken parts. 6.
Checking the Hydraulic Lines and Hoses WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • Ensure that all hydraulic-fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system. • Keep your body and hands away from pinhole leaks or nozzles that eject high-pressure hydraulic fluid. • Use a piece of cardboard or paper to find hydraulic leaks.
Flushing the Hydraulic System IMPORTANT Flush the hydraulic system whenever there is a severe component failure or the system is contaminated (for example, the fluid appears milky, black, or contains metal particles). IMPORTANT If a component failure occurs in the traction circuit; refer to the Traction Circuit Component Failure (page 5–6) for information regarding the importance of removing contamination from the traction circuit. 1.
Flushing the Hydraulic System (continued) 6. Drain the complete hydraulic system. Drain all the hoses, tubes, and components while the system is warm. Flush the hoses and tubes to remove any contamination. 7. Ensure that the mounting surface of the hydraulic-fluid filter is clean. Apply clean hydraulic fluid to the gasket on new filter. Tighten the filter until the gasket contacts the mounting plate, then tighten the filter 3 quarters of a turn.
Filtering the Closed-Loop Traction Circuit Filtering a closed-loop hydraulic system after a major component failure (e.g., hydraulic pump or hydraulic motor) is necessary to prevent unwanted material from transmitting throughout the system. If a closed-loop hydraulic system filtering tool is not used to ensure the system cleanliness, repeat failures, as well as subsequent damage to other hydraulic components in the affected system will occur.
Filtering the Closed-Loop Traction Circuit (continued) 5. After you install the high-flow filter to the machine, check and fill the hydraulic tank with the correct quantity of new hydraulic fluid. 6. Start the engine and run it at low-idle speed. Check for hydraulic-fluid leaks at the filter and hose connections. Correct any leaks before you proceed. CAUTION During this procedure, all the wheels will be off the ground and rotating.
Priming the Hydraulic Pump When the hydraulic system is flushed or charged or the hydraulic components are installed, it is important to properly prime the hydraulic pumps. The hydraulic pump priming ensures that the hydraulic pumps have sufficient fluid during initial start-up and running. The pump can be primed by using a remote starter switch (refer to Special Tools (page 2–15)) to crank the engine which allows the pump to prime. Use the following procedure to prime the hydraulic pumps: 1.
Priming the Hydraulic Pump (continued) Note: A blue wire connects to the starter motor solenoid B+ terminal (Figure 64). It is necessary to remove this blue wire from the solenoid terminal for hydraulic pump priming. 4. Connect the remote starter switch electrical leads to the starter motor solenoid B+ terminal and positive post of the battery. 5. Engage the remote starter switch and crank the starter for 30 seconds to prime the hydraulic pumps.
Charging the Hydraulic System Note: When initially starting the hydraulic system with new or rebuilt components such as hydraulic pump, hydraulic motor, or lift cylinders, it is important that the hydraulic system is charged properly. Remove the air from the system and its components to reduce the chance of damage. IMPORTANT Change the hydraulic fluid filter when you repair or replace the hydraulic components. 1. Park the machine on a level surface and shut off the engine. 2.
Charging the Hydraulic System (continued) 15. Ensure that the traction pedal returns to the NEUTRAL position when released from the forward or reverse direction and adjust if necessary; refer to the Operator’s Manual. 16. Check the operation of the traction interlock switches; refer to Checking the Operation of the Interlock Switches (page 6–5). 17. If the hydraulic pump was replaced or rebuilt, operate the traction circuit so that all the wheels rotate slowly for 10 minutes. 18.
Hydraulic Tank g293230 Figure 65 1. 2. Bolt Washer 10. 11. Knob Nut 19. 20. Washer Auxiliary valve lever 3. Clamp 12. Spring 21. Auxiliary control valve 4. Band clamp 13. Puller knob 22. Auxiliary control valve support 5. Band clamp 14. Spring 23. Bolt 6. Hydraulic tank 15. Auxiliary valve lever 24. Washer 7. Operator platform 16. Connector 25. Nut 26. Washer 8. Washer 17. Auxiliary valve lever 9. Nut 18.
g292669 Figure 66 1. Cap 13. Hose 25. Hydraulic filter 2. Extension 14. Fitting 26. 90º fitting 3. Hydraulic tank 15. One direction valve 27. Plug 4. Hydraulic tank filter 16. O-ring 28. Filter assembly 5. O-ring 17. 90º adaptor 29. Washer 6. Filter support 18. Fitting 30. Reducer 7. 90º adaptor 19. Washer 31. Adaptor 8. Oil cooler 20. Charge pump 32. Hose 9. Hose 21. Adaptor 33. Fitting 10. Hose 22. T fitting 34. Washer 11. Hose 23. Hose 35.
Remove the Hydraulic Tank 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Drain the hydraulic fluid from the tank into a suitable container; refer to Operator’s Manual. 3. Remove the right console to get access to auxiliary control valve; refer to Disassembling the Body Assembly (page 7–6). 4.
Installing the Hydraulic Tank (continued) 9. Check the hydraulic fluid level and adjust if necessary; refer to Operator’s Manual. 10. Install the right console onto the machine; refer to Assembling the Body Assembly (page 7–7).
Auxiliary Control Valve g293274 Figure 67 1. Knob 8. Auxiliary valve lever 15. Washer 2. 3. Nut Spring 9. 10. Bolt Washer 16. 17. Nut Band clamp 4. Puller knob 11. Auxiliary valve lever 18. Band clamp 19. Washer 5. Spring 12. Auxiliary control valve 6. Auxiliary valve lever 13. Auxiliary control valve support 7. Connector 14. Bolt Remove the Auxiliary Control Valve 1.
Remove the Auxiliary Control Valve (continued) g293275 Figure 68 1. Adaptor 7. Bolt 2. Bolt 8. O-ring 3. Hose 4. Fitting nipple 10. Auxiliary control valve 5. 6. Hose Fitting nipple 11. Hose 9. O-ring 6. Remove the hydraulic connections from the auxiliary control valve and discard the O-rings from the fittings (Figure 68). 7. Install the clean caps or plugs on the hydraulic hoses and fittings to prevent system contamination. 8.
Installing the Auxiliary Control Valve (continued) 6. Operate the machine and check for the hydraulic leaks near the components and fittings. Tighten any loose connections. 7. Check the hydraulic fluid level and adjust if necessary; refer to Operator’s Manual. 8. Install the right console onto the machine; refer to Assembling the Body Assembly (page 7–7).
Traction Neutral Arm Assembly g293470 Figure 69 1. Hydraulic pump 2. Socket head screw 3. Washer 4. 5. 6. 7. 8. Washer 15. Traction cable 9. Bolt 16. Retaining ring 10. Bolt 17. Return spring Gear pump 11. Washer 18. Traction neutral arm Nut Washer 12. 13. Nut Nut 19. 20. Socket head screw Hydrostat neutral shaft Bracket 14. Washer Removing the Traction Neutral Arm Assembly 1.
Hydraulic Pump Assembly g293493 Figure 70 1. Hydraulic piston pump Bolt 17. Return spring 2. 3. 4. Socket head screw Washer Gear pump 10. 11. 12. Bolt Washer Nut 18. 19. 20. Traction neutral arm Socket head screw Hydrostat neutral shaft 5. Nut 13. Nut 21. Engine 6. 7. 8. Washer Bracket Washer 14. 15. 16. Washer Traction cable Retaining ring 22. 23. Washer Bolt Hydraulic System: Service and Repairs 9.
Removing the Hydraulic Pump Assembly CAUTION Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 5–5). 1. Park the machine on a level surface, set the parking brake, lower the cutting deck, shut off the engine, and remove the key from the key switch. 2.
Removing the Hydraulic Pump Assembly (continued) g293494 Figure 72 1. Fitting 6. T-fitting 2. One direction valve 7. Adaptor 3. O-ring 8. Gear pump 4. 90º adaptor 9. Washer 5. Hydraulic pump 10. Fitting 6. Disconnect the hoses and tubes from the fittings on the hydraulic pump. Allow the hydraulic lines to drain into a suitable container. 7. Install clean caps or plugs on the openings of pump and disconnected lines to prevent contamination. 8.
Installing the Hydraulic Pump Assembly (continued) IMPORTANT Ensure that you do not damage the machine components while installing the hydraulic pump. 4. Carefully position the hydraulic pump assembly onto the engine. 5. Secure the hydraulic pump assembly to the engine with the 2 washers and 2 bolts. 6.
Servicing the Hydraulic Piston Pump g293588 Figure 73 Hydraulic System: Service and Repairs Page 5–86 ProLine H800 19241SL Rev B
Servicing the Hydraulic Piston Pump (continued) Figure 73 (continued) 1. Retaining ring 14. Needle bearing 27. Pin 2. O-ring 15. Swash plate 28. O-ring 3. Body 16. Thrust plate 29. Plug 4. Inner race 17. End cap gasket 30. O-ring 5. Lip seal 18. Cylinder block kit 31. O-ring 6. Plug 19. Valve plate 32. Plug 7. Hydraulic pump housing 20. Plug 33. Back-up ring 8. Driveshaft 21. O-ring 34. O-ring 9. Ball bearing 22. Plug 35. Coupling assembly 10.
Servicing the Gear Pump g293600 Figure 74 1. Retaining ring 7. Drive shaft 13. Bolt 2. Shaft seal 8. O-ring seal 14. Driven gear 3. Front cover 9. Dowel pin 15. Dowel pin 4. Back-up ring 10. Body 16. Half thrust block 5. 6. Seal Half thrust block 11. 12. Rear cover Washer Disassembling the Gear Pump Note: The gear pump must be replaced as a complete assembly. Individual gears, housing, and thrust plates are not available separately.
Disassembling the Gear Pump (continued) g293847 Figure 75 1. Marker line 2. Use a marker to make a diagonal line across the front flange, body and rear cover for assembly purposes (Figure 75). IMPORTANT Use caution when clamping the gear pump in a vise to avoid distorting any pump components. 3. Secure the front cover of the pump in a vise with the driveshaft pointing down. 4. Loosen the 4 bolts (13) that secures the pump assembly. 5. Remove the pump from the vise and remove the bolts and washers. 6.
Inspecting the Gear Pump 1. Remove any nicks and burrs from all the gear pump parts with emery cloth. 2. Clean all the gear pump parts with solvent and dry them with compressed air. g293634 Figure 76 1. Gear shaft spline 3. Gear teeth 2. Gear face edge 4. Gear shaft 3. Inspect the drive gear and idler gear for the following (Figure 76): A. Gear shaft should be free of scoring, rough surfaces, and excessive wear at the bushing points and sealing areas. B.
Assembling the Gear Pump Note: When assembling the gear pump, check the marker line made during the disassembly to ensure that the parts are properly aligned during the assembly. 1. Apply clean hydraulic fluid to all the parts before you assemble them. Note: The pressure seals and back-up rings fit in the grooves machined into the thrust plates. The body seals fit in the grooves machined in the body faces. 2. Assemble the pump section starting at the front cover end.
Front Wheel Motors g293656 Figure 77 Front Left Wheel (shown) 1. 2. Bolt Hydraulic motor 5. 6. Locknut Bolt 3. Left brake assembly 7. Washer 4. Brake drum 8. Nut 9. 10. Washer Brake cable bracket Removing the Front Wheel Motors CAUTION Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 5–5).
Removing the Front Wheel Motors (continued) 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Block the rear wheels with chocks to prevent the machine from moving. 3. Loosen, but do not remove the locknut (item 5 in Figure Figure 77) that secures the wheel hub to the wheel motor. 4. Read the General Precautions for Removing and Installing the Hydraulic System Components (page 5–63).
Removing the Front Wheel Motors (continued) g293687 Figure 78 1. Hydraulic filter 8. Differential valve 15. Hose 22. O-ring 2. O-ring 9. Fitting 16. Hose 23. Fitting 3. Adaptor 10. Hose 17. Hydraulic pump 24. T-fitting 4. T-fitting 11. Front left wheel motor 18. Fitting 25. Plug 5. Front right wheel motor 12. Hose 19. Rear right wheel motor 26. Rear left wheel motor 6. Fitting 13. Bolt 20. Hose 27. Hose 7. Hose 14. O-ring 21. Hose 7.
Removing the Front Wheel Motors (continued) 9. Loosen and remove the hydraulic tubes from the fittings on the wheel motor. Allow the tubes to drain the hydraulic fluid into a suitable container. 10. Install the clean caps or plugs on the hydraulic tubes and fittings to prevent system contamination. 11. Support the wheel motor to prevent it from falling during removal.
Rear Wheel Motors g293711 Figure 79 1. 2. Bolt Hydraulic motor 5. 6. Washer Nut 9. 10. Washer Bolt 3. Spindle 7. Flange 11. Spindle 4. Woodruff key 8. Nut Removing the Rear Wheel Motor CAUTION Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 5–5). 1.
Removing the Rear Wheel Motor (continued) 6. Remove the rear wheel from the machine; refer to Removing the Wheels (page 7–3). 7. Remove wheel hub from the rear wheel motor as follows: IMPORTANT Do not hit the wheel hub, wheel-hub puller, or wheel motor with a hammer while removing or installing. Hammering can damage the wheel motor. A. Ensure that the locknut on the wheel motor shaft is loosened at least 2 turns. B.
Removing the Rear Wheel Motor (continued) g293687 Figure 80 1. Hydraulic filter 8. Differential valve 15. Hose 22. O-ring 2. O-ring 9. Fitting 16. Hose 23. Fitting 3. Adaptor 10. Hose 17. Hydraulic pump 24. T-fitting 4. T-fitting 11. Front left wheel motor 18. Fitting 25. Plug 5. Front right wheel motor 12. Hose 19. Rear right wheel motor 26. Rear left wheel motor 6. Fitting 13. Bolt 20. Hose 27. Hose 7. Hose 14. O-ring 21. Hose 8.
Removing the Rear Wheel Motor (continued) 10. Loosen and remove the hydraulic tubes from the fittings on the wheel motor. Allow the hoses to drain into a suitable container. 11. Install clean caps or plugs on the hydraulic hoses and fittings to prevent system contamination. 12. Support the wheel motor to prevent it from falling during removal. 13. Remove the 4 bolts (item 1 in Figure 79), washers (5) and nuts (6) that secures the wheel motor to the spindle. 14. Remove the wheel motor from the machine. 15.
Installing the Rear Wheel Motor (continued) 10. After you complete the assembly, ensure that the hydraulic hoses and fittings do not contact anything through the full range of axle motion. Also, check for any hydraulic-fluid leaks. 11. Check the hydraulic-fluid level in the hydraulic tank and add correct quantity of fluid; refer to the Operator’s Manual. 12. Operate the machine functions slowly until air is out of system; refer to Charging the Hydraulic System (page 5–72). 13.
Servicing the Hydraulic Wheel Motor g186199 Figure 81 1. Dirt and water seal 9. Thrust bearing 2. 3. Outer bearing 10. Coupling shaft 18. Manifold Housing 11. Thrust bearing 19. Stator 17. Commutator ring 4. Back-up ring 12. Drive link 20. Vane 5. Back-up washer 13. Bolt 21. Wear plate 6. 7. Shaft seal Inner bearing 14. 15. End cover Body seal 22. 23. Rotor Commutator ring 8. Thrust washer 16.
Servicing the Hydraulic Wheel Motor (continued) Note: The wheel motors used in this machine are the Parker Torqmotor™ motors of the same basic design with minor differences. The 2 front wheel motors displace 238 cm³/rev (14.5 in³/rev) and the 2 rear wheel motors displace 195 cm³/rev (11.8 in³/rev). Note: For the wheel motor repair procedures; refer to Parker Torqmotor™ Service Procedure (TF, TG, TH, and TL Series).
Differential Valve g293779 Figure 82 1. 2. 3. Nut Washer Differential valve solenoid 4. 5. 6. Differential valve Washer Bolt 7. Chassis Removing the Differential Valve 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch.
Removing the Differential Valve (continued) 4. For assembly purposes, label all the hydraulic connections. Clean the hydraulic connections before loosening the hydraulic lines. g293687 Figure 83 1. Hydraulic filter 2. O-ring 3. Adaptor 8. 15. Differential valve Hose 22. O-ring 9. Fitting 16. Hose 23. Fitting 10. Hose 17. Hydraulic pump 24. T-fitting 4. T-fitting 11. Front left wheel motor 18. Fitting 25. Plug 5. Front right wheel motor 12. Hose 19.
Removing the Differential Valve (continued) 5. Disconnect the hydraulic hoses and tubes from the fittings in the differential valve. Allow the lines to drain into a suitable container. Remove and discard the O-rings from the fittings. 6. Install clean caps or plugs on the hydraulic lines and fittings to prevent system contamination. 7. Remove the 2 bolts (item 6 in Figure 82), washers (5 and 2) and nuts (1) that secures the differential valve to the chassis. 8.
Height Of Cut Valve g293797 Figure 84 1. 2. Bracket Washer 4. 5. Bolt Washer 7. 8. 3. Bolt 6. Height of cut valve Nut Operators platform Removing the Height Of Cut Valve 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch.
Removing the Height Of Cut Valve (continued) g293798 Figure 85 1. Quick disconnect coupler 5. Bolt 2. O-ring 6. Fitting 9. Hose 10. Hose 3. Bracket 7. 4. Hose 8. Height of cut valve 11. Auxiliary control valve Bolt 12. Steering control valve 5. Disconnect the hydraulic hoses and tubes from the fittings in the height of control valve. Allow the lines to drain into a suitable container. Remove and discard the O-rings from the fittings. 6.
Installing the Height Of Cut Valve 1. If the hydraulic fittings were removed from the height of cut valve, lubricate new O-rings with clean hydraulic fluid, position the O-rings to the fittings, and install the fittings into the height of cut valve; refer to Installing the Hydraulic Fittings (page 5–10). 2. Position the height of cut valve to the operator’s platform and secure with the 2 bolts (item 4 in Figure 84) and washers (5). 3.
Lift Cylinder g293858 Figure 86 1. 2. Pin Grease fitting 6. 7. 3. Support 8. 4. 5. Washer Nut 9. 10. Nut Lift cylinder 11. 12. Washer Pin Breather cap 13. LH lift arm Washer Nut Removing the Lift Cylinder 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Read the General Precautions for Removing and Installing the Hydraulic System Components (page 5–63). 3.
Removing the Lift Cylinder (continued) WARNING Ensure that the cutting deck is fully lowered before loosening the hydraulic lines from the lift cylinders. If the cutting deck is not fully lowered as the hydraulic lines are loosened, the cutting deck may drop unexpectedly. g293859 Figure 87 1. Auxiliary control valve 6. O-ring 2. O-ring 7. Bolt 3. Lift cylinder 8. Bolt 4. Hose 9. Breather cap 5. Hose 4.
Installing the Lift Cylinder 1. If the hydraulic fittings were removed from the lift cylinder, lubricate the new O-rings with clean hydraulic fluid, position the O-rings to the fittings, and install the fittings into the lift cylinder ports; refer to Installing the Hydraulic Fittings (page 5–10). Ensure that the fittings are orientated correctly. 2. Position the lift cylinder to the chassis. Note: The lift cylinder barrel end should be attached to the machine frame. 3.
Steering Control Valve g289357 Figure 88 1. Steering wheel 12. Steering column 23. Connecting rod 34. Bolt 2. Dashboard 13. Bracket 24. Spacer 35. Washer 3. 4. Socket head screw Washer 14. 15. Thread insert Washer 25. 26. Washer Bushing 36. 37. Bolt Support 5. 6. Pin Bushing 16. 17. Socket head screw Bracket 27. 28. Nut Steering control valve 38. 39. Bolt Nut 7. Washer 18. Nut 29. Shaft key 40. Electronic control unit 8. Washer 19. Washer 30. Hinge 41.
Removing the Steering Control Valve 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Remove the steering column components to get access to the steering control valve; refer to Removing the Steering Column (page 7–9). 3. Read the General Precautions for Removing and Installing the Hydraulic System Components (page 5–63). 4. For assembly purposes, label all the hydraulic connections.
Installing the Steering Control Valve 1. If the hydraulic fittings were removed from the steering control valve, lubricate new O-rings with clean hydraulic fluid, position the O-rings to the fittings, and install the fittings to the steering control valve; refer to Installing the Hydraulic Fittings (page 5–10). 2. Install the steering control valve onto the steering column by using the Figure 88 as a guide. 3.
Steering Cylinder g293908 Figure 90 1. Bolt 7. Nut 13. Steering cylinder 2. Washer 8. Bolt 14. Left spindle 3. Cap 9. Bolt 15. Right spindle 4. Retaining ring 10. Washer 16. Nut 5. Spacer 11. Tie rod end 17. Nut 6. Rear axle 12. Thrust washer Removing the Steering Cylinder 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2.
Removing the Steering Cylinder (continued) CAUTION Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 5–5). 3. For assembly purposes, label all the hydraulic hoses and tubes that are connected to the fittings on the steering cylinder. 4. Clean the hydraulic hose ends before you disconnect the hoses from the steering cylinder.
Installing the Steering Cylinder 1. If the hydraulic fittings were removed from the steering cylinder, lubricate new O-rings with clean hydraulic fluid, position the O-rings to the fittings, and install the fittings into the steering cylinder ports; refer to Installing the Hydraulic Fittings (page 5–10). Ensure that the fittings are orientated correctly. 2. If removed, apply a coat of thread locking compound onto the threads of tie rod end. Install the tie rod end (11) onto the steering cylinder (13). 3.
Hopper Lift Cylinder g293959 Figure 92 LH Hopper Lift Cylinder (shown) 1. Bolt 8. Arm 15. Grease fitting 2. Washer 9. Ball joint 16. Pin 3. Pin 10. Nut 17. Spring 4. Snap ring 11. Nut 18. Snap ring 5. Pin 12. Bushing 19. Safety handle 6. 7. LH Bracket Arm 13. 14. Bolt Hydraulic lift cylinder Removing the Hopper Lift Cylinder 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch.
Removing the Hopper Lift Cylinder (continued) CAUTION Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 5–5). 3. For assembly purposes, label all the hydraulic hoses and tubes that are connected to the fittings on the hopper lift cylinder. g293972 Figure 93 1. Bolt 7. O-ring 2. O-ring 8. Bolt 3. Ball joint 9. Hose 4. 5. 6.
Installing the Hopper Lift Cylinder 1. If the hydraulic fittings were removed from the hopper lift cylinder, lubricate new O-rings with clean hydraulic fluid, position the O-rings to the fittings, and install the fittings into the hopper lift cylinder ports; refer to Installing the Hydraulic Fittings (page 5–10). Ensure that the fittings are orientated correctly. 2. Position the ball joint end of hopper lift cylinder (14) and safety handle (19) onto the arm (7) and secure with the bolt (13) and nut (11). 3.
Hopper Tilt Cylinder g294039 Figure 94 RH Hopper Tilt Cylinder (shown) 1. Hopper frame 5. Grease fitting 2. 3. Nut Support 6. 7. Nut Hydraulic cylinder 4. Bolt 8. Pin 9. 10. 11. Washer Bolt Support frame Removing the Hopper Tilt Cylinder 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Read the General Precautions for Removing and Installing the Hydraulic System Components (page 5–63). 3.
Removing the Hopper Tilt Cylinder (continued) g294041 Figure 95 1. Female quick coupler 7. Hose 2. 3. 4. Bracket Hose Bolt 8. 9. 10. Hose Bolt Hydraulic cylinder 5. O-ring 11. Auxiliary control valve 6. Hose 12. Hose WARNING Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 5–5). 4.
Removing the Hopper Tilt Cylinder (continued) 9. If the hydraulic fittings are to be removed from the hopper tilt cylinder, mark the fitting orientation for assembly purposes. Remove the fittings from the hopper tilt cylinder and discard the O-rings from the fittings. Installing the Hopper Tilt Cylinder 1.
Height Of Cut Cylinder g294075 Figure 96 1. Nut 5. Bolt 2. 3. Washer Support 6. 7. Nut Hydraulic cylinder 9. 4. Grease fitting 8. Grease fitting 10. 11. Retaining ring Pin Cutting deck Removing the Height Of Cut Cylinder 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Read the General Precautions for Removing and Installing the Hydraulic System Components (page 5–63). 3.
Removing the Height Of Cut Cylinder (continued) g294074 Figure 97 1. Female quick coupler 5. 90º elbow fitting 9. Hydraulic cylinder 2. O-ring 6. Cutting deck 10. Block valve 3. 4. Hose Fitting 7. 8. Hose Hose 11. 12. Bolt Nut CAUTION Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 5–5).
Removing the Height Of Cut Cylinder (continued) WARNING Ensure that the cutting deck is fully lowered before loosening the hydraulic lines from the height of cut cylinder. 4. Disconnect the hydraulic hoses from the fittings in the height of cut cylinder that is to be removed. Allow the hoses to drain into a suitable container. Remove and discard the O-rings from the fittings. 5. Install clean caps or plugs on the hydraulic hoses and fittings to prevent contamination. 6.
Chute Cleaning Cylinder g294112 Figure 98 1. Cutting deck 5. Pin 2. Bolt 6. Hydraulic cylinder 3. Washer 7. Split pin 4. Lever 8. Fork 9. 10. Bronze bushing Scraper Removing the Chute Cleaning Cylinder 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Read the General Precautions for Removing and Installing the Hydraulic System Components (page 5–63). 3.
Removing the Chute Cleaning Cylinder (continued) g294113 Figure 99 1. Female quick coupler 5. Hydraulic cylinder 2. O-ring 6. O-ring 3. 4. Hose Cutting deck 7. Bolt CAUTION Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 5–5). 4. Disconnect the hydraulic hoses from the fittings in the chute cleaning cylinder that is to be removed.
Installing the Chute Cleaning Cylinder 1. If the hydraulic fittings were removed from the chute cleaning cylinder, lubricate new O-rings with clean hydraulic fluid, position the O-rings to the fittings, and install the fittings into the chute cleaning cylinder ports; refer to Installing the Hydraulic Fittings (page 5–10). 2. Position the chute cleaning cylinder onto the lever (4). Note: The chute cleaning cylinder barrel end should be towards right side of the machine. 3.
Oil Cooler g289021 Figure 100 1. Cap 15. Hose 29. Washer 43. Nut 2. Clamp 16. Nut 30. Plate 44. Bracket 3. Hose 17. Cable guard 31. Collar 45. Nut 4. 5. 6. 7. Gasket Debris screen Thread insert Nut 18. 19. 20. 21. Washer Knob Tank Clamp 32. 33. 34. 35. Bolt Washer Hose Nut 46. 47. 48. 49. Washer Bracket Washer Bolt 8. Bushing 22. Washer 36. Gasket 50. Bracket 9. Washer 23. Bolt 37. Blower 51. Spring 10. 11. 12. 13. Shock absorber Radiator Hose Clamp 24.
g289054 Figure 101 Oil cooler Nut 5. 6. Bracket Hydraulic hose 3. Bolt 7. Hydraulic hose 4. Washer 1. 2. Removing the Oil Cooler The radiator and oil cooler must be removed from the machine as an assembly; refer to Removing the Radiator (page 4–8). Inspecting the Oil Cooler 1. Back flush the oil cooler with cleaning solvent. After cleaning the cooler, ensure that all the solvent is drained from the cooler.
Hydraulic System: Service and Repairs Page 5–132 ProLine H800 19241SL Rev B
Chapter 6 Electrical System Table of Contents General Information .............................................................................................................................. 6–2 Electrical Schematics and Wire Harness Drawings/Diagrams............................................................ 6–2 Electronic Control Unit (ECU) ............................................................................................................ 6–2 Electrical System Quick Checks ...................
General Information The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your machine. Refer to the Operator’s Manual for additional information when servicing the machine. Electrical Schematics and Wire Harness Drawings/Diagrams Refer to the Electrical Schematics and Wire Harness Drawings/Diagrams in Appendix A (page A–1). Electronic Control Unit (ECU) g294331 Figure 102 3. 1. Steering wheel 2.
Electrical System Quick Checks Testing the Battery (Open Circuit Test) Use a multimeter to measure the voltage between the battery terminals; refer to Battery Test Table (page 6–3). Set the multimeter to the DC volts settings. The battery must be at a temperature of 16°C to 38°C (60°F to 100°F). Ensure that the key is in the OFF position and all the accessories are turned off. Connect the positive (+) multimeter lead to the positive battery post and negative (-) multimeter lead to the negative battery post.
Testing the Charging System This is a simple test that determines if a charging system is functioning. It tells you if the charging system has an output, but not its capacity. Tool required: Digital multimeter to set DC volts. Test instructions: Connect the positive (+) multimeter lead to the positive battery post and negative (-) multimeter lead to the negative battery post. Keep the test leads connected to the battery posts and record the battery voltage.
Testing the Glow Plug System This is a fast, simple test that helps to determine the integrity and operation of the glow plug system. Perform this test when you find hard starting (cold engine) on a diesel engine equipped with a glow plug system. Tool(s) required: Digital multimeter and/or inductive Ammeter (AC/DC Current Transducer). Test instructions: Properly connect the ammeter to the digital multimeter (refer to the manufacturer’s instructions). Set the multimeter to the correct scale.
Testing the Electrical Components For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g., unplug the key switch connector before doing a continuity check of the switch). Note: Electrical troubleshooting of any 12 V power connection can be performed through voltage drop tests without disconnecting the component. Note: For engine component testing information; refer to Yanmar 3TNV76 Service Manual and Yanmar 3TNV80F Service Manual.
Fuses g217872 Figure 103 1. Fuse block The electrical system is protected by fuses. It requires no maintenance, however, if a fuse blows check the component/circuit for a malfunction or short. The fuse blocks and fuses are located on the left console next to the operator’s seat (Figure 103). Identification and Function g224645 Figure 104 The fuses are held in the fuse blocks. Use Figure 104 to identify each individual fuse and its correct amperage. Each fuse has the following function: 1.
Identification and Function (continued) g224646 Figure 105 Use Figure 105 to identify each individual fuse and its correct amperage. Each fuse has the following function: 1. 3 A: Right steady light and plate light circuit. 2. 3 A: Left steady light circuit. 3. 15 A: Full-beam light circuit. 4. 10 A: Headlight circuit. 5. 10 A: Warning device circuit. 6. 7.5 A: Indicator lights circuit. 7. 5 A: Rotating beacon light circuit. 8. 15 A: Hazard light switch circuit. g224476 Figure 106 1.
Testing the Fuses 1. Turn the key switch to the ON position (do not start the engine) and remove the cap for the fuse block. With the fuse installed in the fuse block, use a multimeter to check that 12 VDC exists at both of the terminal test points on the fuse. If 12 VDC exists at 1 of the fuse test points but not at the other, the fuse is damaged. 2. If necessary, remove the fuse from the fuse block for testing. The fuse should have continuity between the fuse terminals. A.
Key Switch g214136 Figure 107 1. OFF position 3. ON/PREHEAT position 2. LIGHTS ON position 4. START position The key switch is located on right side of the steering column. The key switch has 4 positions: OFF, LIGHTS ON, ON/PREHEAT, and START (Figure 107). When the key switch is turned from OFF position to LIGHTS ON position, the work lights illuminate. The key switch is an input used by electronic control unit to manage various machine functions. Testing the Key Switch 1.
Testing the Key Switch (continued) g294638 Figure 108 5. The key switch terminals are identified in Figure 108 and the circuitry of the key switch is shown in the Circuit Logic Table (page 6–11). With the use of a multimeter (ohms setting), test the switch functions to determine if the continuity exists between the various terminals for each switch position. Check the continuity between the switch terminals.
PTO Switch g294680 Figure 109 1. PTO switch The PTO switch is located on right side of the steering column. Pull it out the PTO switch to engage the PTO electric clutch. The electronic control unit (ECU) monitors the position of the PTO switch (up or down). Using the inputs from the PTO switch and other switches in the interlock system, the ECU controls the energizing of the electric PTO clutch.
Testing the PTO Switch (continued) 1. Park the machine on a level surface, lower the cutting deck, set the parking brake, and shut off the engine. 2. Disconnect the battery negative (-) cable at the battery. 3. Remove the steering column covers and get access to rear of the PTO switch; refer to Disassembling the Body Assembly (page 7–6). 4. Disconnect the wire harness connector from the PTO switch and remove the PTO switch from the steering column cover. 5.
Hazard Light Switch g294693 Figure 111 1. Hazard- light switch The hazard light switch is located on the dash panel (Figure 111). The hazard light switch controls the operation of the hazard lights. Testing the Hazard Light Switch g294694 Figure 112 1. Park the machine on a level surface, lower the cutting deck, set the parking brake, and shut off the engine. 2. Disconnect the battery negative (-) cable at the battery. 3.
Testing the Hazard Light Switch (continued) 5. The hazard light switch terminals are identified in Figure 112 and the circuitry of the hazard light switch is shown in the Circuit Logic Table (page 6–15). With the use of a multimeter (ohms setting), test the switch functions to determine if the continuity exists between the various terminals for each switch position. Check the continuity between the switch terminals. Circuit Logic Table Switch Position Closed Circuits ON 2 + 3, 5 + 6 OFF 2+ 1, 5 + 4 6.
Differential Lock Switch g294695 Figure 113 1. Differential lock switch The differential lock switch is located on the dash panel (Figure 113). The differential lock switch controls the operation of the differential lock. Testing the Differential Lock Switch g294694 Figure 114 1. Park the machine on a level surface, lower the cutting deck, set the parking brake, and shut off the engine. 2. Disconnect the battery negative (-) cable at the battery. 3.
Testing the Differential Lock Switch (continued) 5. The differential lock switch terminals are identified in Figure 114 and the circuitry of the differential lock switch is shown in the Circuit Logic Table (page 6–17). With the use of a multimeter (ohms setting), test the switch functions to determine if the continuity exists between the various terminals for each switch position. Check the continuity between the switch terminals.
Radiator Fan Reversal Switch g294696 Figure 115 1. Radiator fan reversal switch The radiator fan reversal switch is located on the dash panel (Figure 115). The radiator fan reversal switch controls the direction of airflow through the radiator fan. Testing the Radiator Fan Reversal Switch g294694 Figure 116 1. Park the machine on a level surface, lower the cutting deck, set the parking brake, and shut off the engine. 2. Disconnect the battery negative (-) cable at the battery. 3.
Testing the Radiator Fan Reversal Switch (continued) 5. The radiator fan reversal switch terminals are identified in Figure 116 and the circuitry of the radiator fan reversal switch is shown in the Circuit Logic Table (page 6–19). With the use of a multimeter (ohms setting), test the switch functions to determine if the continuity exists between the various terminals for each switch position. Check the continuity between the switch terminals.
Beacon Light Switch g294707 Figure 117 1. Beacon light switch The beacon light switch is located on the dash panel (Figure 117). The beacon light switch controls the operation of the beacon light. Testing the Beacon Light Switch g294694 Figure 118 1. Park the machine on a level surface, lower the cutting deck, set the parking brake, and shut off the engine. 2. Disconnect the battery negative (-) cable at the battery. 3.
Testing the Beacon Light Switch (continued) 5. The beacon light reversal switch terminals are identified in Figure 118 and the circuitry of the beacon light switch is shown in the Circuit Logic Table (page 6–21). With the use of a multimeter (ohms setting), test the switch functions to determine if the continuity exists between the various terminals for each switch position. Check the continuity between the switch terminals.
Indicator Lights g294708 Figure 119 1. Battery charge indicator 4. Air filter restriction indicator 7. Raised hopper indicator 8. Parking brake indicator 2. Glow plug indicator 5. Work light indicator 3. Oil pressure warning indicator 6. Road light indicator The indicator lights are located on the dash panel. Battery Charge Indicator Light The battery charge indicator light should illuminate when the key switch is in the ON position with the engine not running.
Oil Pressure Warning Indicator Light (continued) To test the oil pressure light and circuit wiring, ground the wire attached to oil pressure switch located on the engine near the oil filter. Turn the key switch to the ON position; the engine oil pressure light should illuminate indicating correct operation of the indicator light and circuit wiring. Air Cleaner Restriction Indicator Light The air cleaner restriction indicator light should illuminate when the air cleaner is clogged.
Height Of Cut Switch g294710 Figure 121 1. Height of cut switch The height of cut switch is used to adjust the mower deck cutting height. The switch is located on the left console. The engine must be running to allow the height of cut to be raised or lowered. The height of cut switch controls the solenoid valve coils on the height of cut control valve. Testing the Height Of Cut Switch 1. Park the machine on a level surface, lower the cutting deck, set the parking brake, and shut off the engine. 2.
Testing the Height Of Cut Switch (continued) 5. The switch terminals are identified in Figure 122 and the circuitry of the switch is shown in the Circuit Logic Table (page 6–25). With the use of a multimeter (ohms setting), test the switch functions to determine if continuity exists between the various terminals for each switch position. Circuit Logic Table Switch Position Closed Circuits RAISE 5 + 4 OFF None LOWER 5 + 6 Note: The switch terminals 1, 2, and 3 are not used. 6.
Seat Switch g289939 Figure 123 1. 2. Bellows Spring pack 6. 7. Cable ties Blind rivet 11. 12. Blind rivet Switching bracket 3. Seat level indicator housing 8. Seat switch with cable 13. Backrest frame 4. Cover 5. Switch plate 9. 10. Bushing Compression springs The seat switch normally open and closes when the operator is on the seat. If the traction system or PTO switch is engaged when the operator raises out of the seat, the engine shuts off.
Testing the Seat Switch (continued) g289938 Figure 124 1. Operator seat 3. 2. Seat switch wire harness Seat switch connector 3. Unplug the machine wire harness electrical connector from the seat switch (Figure 124). 4. Connect a multimeter (ohms setting) across the seat switch harness connector terminals to check the continuity of the seat switch. A. With no pressure on the seat, ensure that there is no continuity between the harness terminals of the seat switch. B.
Hour Meter g213963 Figure 125 1. Fuel gauge 4. Hour meter/service due indicator 2. Engine-temperature gauge 5. Throttle lever 3. Height-of-cut switch The hour meter records and displays the accumulated hours of the engine operation. The service due indicator displays the number of hours until the next engine oil and filter change. Note: The indicator flashes automatically with “OIL CHANGE” when you need to change the engine oil and filter.
Testing the Hour Meter 1. Park the machine on a level surface, lower the cutting deck, set the parking brake, and shut off the engine. 2. Ensure that the key switch is in the OFF position. Locate the hour meter and disconnect the wire harness electrical connector from the hour meter. g294786 Figure 126 1. Hourglass icon 3. Connect the positive (+) terminal of a 12 VDC source to the positive terminal of the hour meter. 4.
Traction Neutral Switch g294807 Figure 127 1. Neutral switch The neutral switch sends signals to the Electronic Control Unit (ECU) about the traction pedal position. The ECU takes the inputs from neutral switch and allows the engine to start. The neutral switch is located under the operator’s platform. Testing the Traction Neutral Switch 1. Park the machine on a level surface, lower the cutting deck, and shut off the engine. 2.
Traction Reverse Switch g294810 Figure 128 1. Reverse switch The reverse switch sends signals to the Electronic Control Unit (ECU) about the traction pedal position. The ECU takes the inputs from reverse switch and activates the warning buzzer. The reverse switch is located under the operator’s platform. Testing the Traction Reverse Switch 1. Park the machine on a level surface, lower the cutting deck, and shut off the engine. 2.
Parking Brake Switch g294832 Figure 129 1. Parking brake switch The parking brake switch is a normally open switch. The Electronic Control Unit (ECU) monitors the operation of the parking brake switch. The parking brake switch located under the operator’s platform. When the parking brake is not set, the parking brake bracket is away from the target end of the parking brake switch so that the switch is open.
Oil Pressure Switch g294844 Figure 130 1. Oil pressure switch The engine oil pressure switch is located on the engine near the oil filter (Figure 130). The oil pressure switch is a normally closed switch that opens with oil pressure. The oil pressure switch should open at approximately 0.6 bar (8.8 PSI). IMPORTANT If the oil pressure indicator light is illuminated with the engine running, shut off the engine immediately.
Testing the Oil Pressure Switch (continued) 1. Park the machine on a level surface, lower the cutting deck, set the key switch to the OFF position and remove the key from the key switch. 2. Locate the engine oil pressure switch on the engine and disconnect the wire harness connector from the switch. Check the switch and the harness connector for damage or corrosion and clean or repair as necessary. 3. Connect a multimeter (ohms setting) to check the continuity of the switch: A.
PTO Electric Clutch g290631 Figure 131 1. Bolt 7. Woodruff key 2. 3. Washer Bushing 8. 9. Bolt Washer 4. 5. Bracket Spring 10. 11. 6. Electric clutch Drive shaft Engine An electric clutch is used to engage the PTO. The electric clutch is mounted on the engine crankshaft and engages when current is applied to the clutch. The clutch also incorporates a magnetic brake to stop the clutch rotation when the clutch is de-energized. Testing the PTO Electric Clutch 1.
Testing the PTO Electric Clutch (continued) g294909 Figure 132 1. 2. 3. PTO electric clutch Access slot Lock nut 3. Unplug the clutch electrical connector from the machine wire harness. Note: For accurate clutch resistance measuring, the clutch should be at approximately 21°C (70°F). Note: Before taking small resistance readings with a digital multimeter, short the multimeter test leads together. The meter displays a small resistance value (usually 0.5 ohms or less).
Fuel Stop Solenoid g294911 Figure 133 1. Fuel stop solenoid The fuel stop solenoid must be energized for the diesel engine to run. The solenoid is mounted to the injection pump on the engine (Figure 133). Testing the Fuel Stop Solenoid (In Place) Note: Before taking the small resistance readings with a digital multimeter, short the multimeter test leads together. The meter will display a small resistance value (usually 0.5 ohms or less).
Testing the Fuel Stop Solenoid (In Place) (continued) 4. Use a digital multimeter, touch 1 test lead to the hold coil terminal and the other test lead to the fuel stop solenoid frame (ground). The resistance of the hold coil should be approximately 15 ohms. 5. Replace the fuel stop solenoid if the testing determines that it is damaged. 6. Connect the wire harness connector to the fuel stop solenoid. Testing the Fuel Stop Solenoid (Live) 1.
Relays g294973 Figure 134 1. Start relay (5 terminals) 3. Forward fan relay (4 terminals) 2. Glow relay (4 terminals) 4. Reverse fan relay (4 terminals) 5. Key relay (4 terminals) The machines use a number of electrical relays. Some of the relays have four (4) terminals and some have five (5) terminals. The number of terminals the relay has determines how the relay should be tested. A tag near the wire harness relay connector can be used to identify each relay; refer to Figure 134.
• The two (2) reverse fan relays are attached to the battery support plate under • the operator seat. When energized, the reverse fan relays allow the electrical current to the radiator fan. The key relay is attached inside the left arm console above the battery. When energized, the key relay allow the electrical current to the machine. Testing the Relays with 4 Terminals 1.
Testing the Relays with 4 Terminals (continued) 11. Install and secure the relay onto the mounting bracket. Connect the wire harness electrical connectors to the relay. 12. Connect the positive (+) cable to the battery and then connect the negative (-) cable to the battery; refer to Servicing the Battery (page 6–51). 13. If removed, install the operator seat onto the machine; refer to Installing the Operator Seat (page 7–17). 14.
Testing the Relays with 5 Terminals (continued) 9. Replace the relay if testing determines that the relay is damaged. 10. If the relay testing is correct and a circuit problem still exists, check the main wire harness; refer to the Electrical Schematics and Wire Harness Drawings/Diagrams in Appendix A (page A–1). 11. Install and secure the relay onto the mounting bracket. Connect the wire harness electrical connectors to the relay after you complete the testing. 12.
Diode Assembly g295056 Figure 137 1. End of the diode body 3. Male terminal 2. Diode assembly 4. Female terminal The diode assembly is used in the main wire harness. The diode can be identified by their black color and diode symbol on the end of the diode body. The diode assembly is used to protect the PTO clutch from reverse polarity in the electrical circuit. The diode assembly is used to protect the engine shut off solenoid from voltage spikes in the electrical circuit.
Slope Sensor (Optional) g365064 Figure 138 1. Slope sensor module 2. Cap screw (2 each) 3. Flange nut (2 each) The optional slope sensor module is located under the battery cover. Once installed and calibrated, the optional slope sensor module monitors the angle of the machine during operation, and notifies the operator of a potentially dangerous condition via an LED light on the dashboard and an audible alarm.
Calibrating the Slope Sensor (continued) g364991 Figure 139 1. Plug 2. Calibration connectors 4. Set the key switch to the ON position, but do not start the engine. 5. The LED light on the dashboard should blink as the sensor calibrates. 6. When the LED light on the dashboard stops blinking, set the key switch to the OFF position. 7. Disconnect the calibration connectors and install the plug onto the connectors. 8. Carefully test the slope sensor operation before returning the machine to service: A.
Removing and Installing the Slope Sensor Module (continued) 6. When installing the slope sensor module, tighten the fasteners that secure the sensor module to the plate to 4 N·m (37 in-lb). 7. Connect the wire harness and calibrate the slope sensor; refer to Calibrating the Slope Sensor (page 6–44). Testing the Slope Sensor LED g279250 Figure 140 1. LED (Light Emitting Diode) 4. Hex nut 2. Gasket 5. Red wire (+) 3. Lock washer 6.
Testing the Slope Sensor Alarm g365076 Figure 141 1. Audible alarm 2. Wire harness During operation, the audible alarm sounds to notify the operator when the machine is operating on a steep slope and should proceed to a more shallow slope. Electrical current for the alarm is provided as an output from the slope sensor module. The audible alarm is located on the steering tower in front of the operator. 1.
Testing the Slope Sensor Alarm (continued) g355655 Figure 142 1. Front view 3. Positive (+) terminal 2. Rear view 4. Negative (−) terminal 5. Reconnect the machine wire harness to the alarm, install the steering tower cover before returning the machine to service.
Service and Repairs Battery Storage If you store the machine for more than 30 days: 1. Ensure that the key switch is in the OFF position. Remove the battery and charge it fully; refer to Servicing the Battery (page 6–51). 2. Either store the battery on a shelf or on the machine. 3. Disconnect the cables if the battery is kept on the machine. 4. Store the battery in a cool atmosphere to avoid quick deterioration of the battery charge. 5.
Battery Care (continued) WARNING Connecting the cables to the wrong battery post could result in personal injury and/or damage to the electrical system. Ensure that the cables are properly connected to the correct battery posts before operating the machine. 4. If corrosion occurs at the battery terminals, disconnect the cables. Always disconnect the negative (-) cable first. Clean the cable clamps and terminals separately. Connect the cables with the positive (+) cable first.
Servicing the Battery The battery is the heart of the electrical system. With the regular and correct service, the battery life can be extended. Additionally, the battery and electrical component failure can be prevented. CAUTION Battery-electrolyte is corrosive and can burn skin and eyes and damage clothing. While working with the batteries, use extreme caution to avoid splashing or spilling of the electrolyte. Always wear the safety goggles and a face shield while working with batteries.
Removing and Installing the Battery (continued) g216923 Figure 143 3. Loosen and remove the negative (-) cable from the battery. After you disconnect the negative cable from the battery, loosen and remove the positive cable (+) from the battery (Figure 143). 4. Loosen the bolt that secures the battery retainer. 5. Carefully remove the battery from the machine. 6.
Inspecting, Maintaining, and Testing the Battery 1. Do the following inspections and maintenance: A. Check for cracks. Replace the battery if cracked or leaking. B. Check the battery terminal posts for corrosion. Use the wire brush to clean corrosion from the posts. IMPORTANT Before cleaning the battery, tape or block the vent holes of the filler caps and ensure that the caps are tight. C.
Inspecting, Maintaining, and Testing the Battery (continued) specific gravity between the highest and lowest cell is less than 0.050. If you can not meet these charging conditions, replace the battery. 3. Do a high-discharge test with an adjustable load tester. This is 1 of the most reliable means of testing a battery as it simulates the cold-cranking test. A commercial battery load tester is required to do this test. CAUTION Follow the manufacturer's instructions when using a battery load tester. A.
Charging the Battery To minimize damage to the battery and allow the battery to charge fully, do the following slow charging procedure. You can do this charging procedure with a constant current battery charger that is locally available. IMPORTANT Follow the manufacturer's instructions when using a battery charger. Note: Use specific gravity of the battery cells is the most accurate procedure of determining the battery condition. 1.
Charging the Battery (continued) CAUTION Charging a frozen battery can cause explosion and can cause personal injury. Let the battery warm to 15.5°C (60°F) before connecting to a charger. • Charge the battery in a well-ventilated place to dissipate the gases produced from the charging. • These gases are explosive; keep open flame and electrical spark away from the battery. Do not smoke. • Inhaling the battery gases can cause nausea.
Chapter 7 Chassis Table of Contents General Information .............................................................................................................................. 7–2 Service and Repairs ............................................................................................................................. 7–3 Wheels ............................................................................................................................................... 7–3 Body Assembly .....
General Information The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your ProLine H800 machines. Refer to the Operator’s Manual for additional information when servicing the machine.
Service and Repairs Wheels g289305 Figure 144 1. Rear wheel hub 4. Rear wheel assembly 2. Rear wheel lug bolt 5. Front wheel assembly 3. Washer 6. Front wheel lug nut 7. Front wheel hub Removing the Wheels 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Block the wheels that are not removed with chocks to prevent the machine from moving. 3.
Installing the Wheels 1. Install the wheel to the machine with the wheel-lug nuts or bolts. 2. Lower the machine to the ground. g034007 Figure 145 WARNING Failure to maintain proper torque could result in failure or loss of wheel and may result in personal injury. Maintain the proper torque of the wheel-lug nuts or bolts. 3. Torque the wheel-lug nuts or bolts evenly to 85 to 90 N∙m (62 to 66 ft-lb) in a crossing pattern (Figure 145). 4. Check and adjust the tire pressures; refer to Operator’s Manual.
Body Assembly g289455 Figure 146 1. Steering wheel 2. Washer 3. 4. Screw Dashboard-center 5. Socket head screw Console-left 17. Bracket 10. Console-right 18. Washer 26. Column support 11. 12. Screw Fairing 19. 20. Washer Screw 27. 28. Thread insert Cover 13. Cage nut 21. Footboard pad 29. Nut 9. 25. Bolt 6. Washer 14. Bracket 22. Footboard pad 30. Cover 7. Pin 15. Nut 23. Footboard pad 31. Cover 8. Bushing 16. Washer 24.
Disassembling the Body Assembly 1. Park the machine on a level surface, set the parking brake, lower the cutting deck, shut off the engine, and remove the key from the key switch. 2. Use a punch and hammer to remove the pin (7) from the steering wheel. Discard the pin. 3. Remove the steering wheel (1) and washer (2) from the steering column. 4. Remove the socket head screw (5) and washer (6) that secures the bushing (8) to the steering control valve.
Disassembling the Body Assembly (continued) g289456 Figure 148 1. 2. Control-lever knob Console-right 3. Screw 12. Remove the knobs and control levers from the auxiliary control valve (item 1 in Figure 148). 13. Remove the 2 screws (item 3 in Figure 148) that secure the right console to the fairing. 14. Lift the right console and set aside. Assembling the Body Assembly 1. If removed, install the right console onto the fairing and secure with the 2 screws (Figure 148.) 2.
Steering Column g289357 Figure 149 1. Steering wheel 12. Steering column 23. Connecting rod 34. Bolt 2. Dashboard 13. Bracket 24. Spacer 35. Washer 3. 4. Socket head screw Washer 14. 15. Thread insert Washer 25. 26. Washer Bushing 36. 37. Bolt Support 5. 6. Pin Bushing 16. 17. Socket head screw Bracket 27. 28. Nut Steering control valve 38. 39. Bolt Nut 7. Washer 18. Nut 29. Shaft key 40. Electronic control unit 8. Washer 19. Washer 30. Hinge 41.
Removing the Steering Column 1. Park the machine on a level surface, set the parking brake, lower the cutting deck, shut off the engine, and remove the key from the key switch. 2. Use a punch and hammer to remove the pin (5) from the steering wheel. Discard the pin. 3. Remove the steering wheel (1) and washer (7) from the steering column. 4. Remove the socket head screw (3) and washer (4) that secures the bushing (6) to the steering control valve (28).
Lift Arms g289477 Figure 150 1. 2. Nut Washer 11. 12. Washer Nut 21. 22. Plate Split pin 3. Bushing 13. Nut 23. Spring 4. Lift arm RH 14. Lift cylinder 24. Bolt 5. Bushing 15. Breather cap 25. Bushing 6. Lift arm assembly RH 16. Lift arm LH 26. Lever 7. Grease fitting 17. Lift arm assembly LH 27. Pin 8. Bolt 18. Rubber washer 28. Spring pin Pin Support 19. 20. Screw Plastic washer 29. Pin 9. 10.
Removing the Lift Arms 1. Park the machine on a level surface, set the parking brake, lower the cutting deck, shut off the engine, and remove the key from the key switch. 2. Remove the cutting deck from the lift arms; refer to the Operator’s Manual. CAUTION When changing the tires or performing other service, use correct jacks and supports. Make sure that the machine is parked on a solid, level surface such as a concrete floor.
Traction Pedal g289736 Figure 151 1. 2. 3. 4. Washer Bolt Rod end Traction rod 10. 11. 12. 13. Washer bolt Shock absorber Pin 19. 20. 21. 22. Bolt Nut Pin Spacer 5. Linkage bellcrank 14. Bolt 23. Traction pedal 6. Grease fitting 15. Bolt 24. Bolt 7. Bushing 16. Bolt 25. Traction pedal pin 8. 9. Nut Nut 17. 18. Washer Washer Removing the Traction Pedal 1.
Removing the Traction Pedal (continued) 4. Disassemble the traction pedal as needed using the Figure 151 as a guide. When removing the pin (21), make sure to support traction pedal pin (25) to prevent damage. Installing the Traction Pedal 1. Apply a coat of grease to outer diameter of the pin (21) and bushing (7). 2. Apply a coat of grease to inner diameter of the spacer (22), traction pedal pin (25) and linkage bellcrank (5). 3. Assemble the traction pedal using the Figure 151 as a guide. 4.
Brake Pedal g289839 Figure 152 1. Bushing 14. Bolt 27. Spring 2. Spacer 15. Nut 28. Brake pedal spring 3. Spacer 16. Bracket 29. Brake pedal pin 4. Spring pin 17. Bolt 30. Nut 5. Brake lock 18. Cotter pin 31. Washer 6. Spacer 19. Nut 32. Spacer 7. Bushing 20. Pin 33. Brake pedal 8. Rubber pad 21. Fork 34. Bolt 9. Column 22. Pulley 35. Brake pedal cap 10. 11. Bracket Washer 23. 24. Brake cable Snap ring 36. 37. Bolt Nut 12. Bolt 25. Pin 38.
Removing of Brake Pedal 1. Park the machine on a level surface, set the parking brake, lower the cutting deck, shut off the engine, and remove the key from the key switch. 2. Block the wheels with chocks to prevent the machine from moving. 3. Disconnect the battery negative cable from battery terminal and then disconnect positive cable from battery; refer to Operator’s Manual. 4. Disconnect the electrical wire harness connector from the parking brake switch. 5.
Operator Seat g289937 Figure 153 1. Seat switch connector 8. Bushing 15. Operator platform 2. Seat Seat support 16. Rubber pad 3. 4. 5. Socket head screw Nut Socket head screw 10. 11. 12. Washer Nut Snap ring 17. 18. 19. Column Washer Bolt 6. 7. Bolt Washer 13. 14. Seat hook Spring Chassis: Service and Repairs 9.
Removing the Operator Seat g289938 Figure 154 1. Operator seat 3. 2. Seat switch wire harness Seat switch connector 1. Park the machine on a level surface, set the parking brake, lower the cutting deck, shut off the engine, and remove the key from the key switch. 2. Disconnect the battery negative cable from the battery; refer to Operator’s Manual. 3. Disconnect the seat electrical connector from the machine wire harness (Figure 154). 4.
Servicing the Operator Seat g289939 Figure 155 1. 2. Bellows Spring pack 6. 7. Cable ties Blind rivet 11. 12. Blind rivet Switching bracket 3. Housing of the seat level indicator 8. Seat switch with cable 13. Backrest frame 4. Cover 5. Switch plate 9. 10. Bushing Compression springs For servicing the operator seat, see the Grammer Seats Repair Manual.
Frame Assembly g289962 Figure 156 Handle 21. Plastic hinge 12. Washer 22. Rear engine cover 13. 14. Screw Nut 23. 24. Thread insert Rear bumper 15. 16. 17. Bolt Washer Bracket 25. 26. 27. Nut Bolt Tow bar Screw Magnet 18. 19. Nut Hood 28. 29. Bolt Bracket Rubber plug 20. Screw 30. Nut 1. Operator platform 2. Bolt 3. 4. Washer Nut 5. 6. 7. Frame Thread insert Front engine cover 8. 9. 10. 11. Disassemble and assemble the frame assembly using the Figure 156 as a guide.
Chassis: Service and Repairs Page 7–20 ProLine H800 19241SL Rev B
Chapter 8 Axle and PTO Table of Contents General Information .............................................................................................................................. 8–2 Service and Repairs ............................................................................................................................. 8–3 Servicing the Brake ............................................................................................................................ 8–3 Rear Axle assembly .
General Information The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your machine. Refer to the Operator’s Manual for additional information when servicing the machine.
Service and Repairs Servicing the Brake g290036 Figure 157 1. Bolt 10. Retaining ring 19. Nut 2. Hydraulic motor 11. Brake shoe 20. Bolt 3. Woodruff key 12. Spring 21. Washer 4. Retaining ring 13. Brake drum 22. Camshaft 5. 6. Brake lever Brake plate 14. 15. Stud Tire 23. 24. Nut Washer 7. Bushing 16. Wheel rim 25. Brake cable bracket 8. Brake caliper 17. Valve 9. Washer 18. Wheel lug nut Disassembling the Brakes 1.
Disassembling the Brakes (continued) 4. Loosen, but do not remove the locknut (19) securing the wheel hub to the motor shaft. 5. Ensure that the parking brake is disengaged. 6. Remove the clevis pin that secures the brake cable to the brake lever (5). Position the brake cable away from the brake lever. 7. Remove the lock nut (19) from the motor shaft. 8. Slide and remove the brake drum (13) from the motor shaft. Locate and retrieve the square key (3).
Assembling the Brakes (continued) WARNING Failure to maintain proper torque could result in failure or loss of the wheel and may result in personal injury. Maintain the proper torque of the wheel-lug nuts. 15. Torque tighten the nut (19) that secure the brake drum (13) onto the wheel motor shaft (2) to 350 N·m (258 ft-lb). CAUTION After servicing the brakes, always check the brakes for proper operation in a wide open, level area that is free of other persons and obstructions. 16.
Rear Axle assembly g290134 Figure 158 1. 2. 3. Bolt Washer Cap 12. 13. 14. Thrust washer Tie rod end Pin 23. 24. 25. Thrust washer Nut Flange 4. Retaining ring 15. Grease fitting 26. Woodruff key 5. Spacer 16. Bolt 27. RH spindle 6. 7. 8. Rear axle Nut Bolt 17. 18. 19. Washer Nut Steering cylinder 28. 29. 30. Nut Washer Nut Bolt Washer Nut 20. 21. 22. Nut Bolt Rear hydraulic motor 31. 32. 33. Washer Bolt LH spindle 9. 10. 11. Removing the Rear Axle 1.
Removing the Rear Axle (continued) 3. Remove the hopper assembly; refer to Removing the Hopper Assembly (page 9–3). 4. Jack up the machine (just ahead of the rear wheels) until clearance exists to allow rear axle removal. Support the machine with the jack stands or appropriate load holding device to prevent it from falling; refer to Jacking Instructions (page 1–7). 5. Remove the rear wheels; refer to Removing the Wheels (page 7–3). 6.
Installing the Rear Axle (continued) 13. Check and adjust the steering stops; refer to Operator’s Manual. 14. Lower the machine and install the hopper assembly; refer to Installing the Hopper Assembly (page 9–4). 15. Check the hydraulic-fluid level in the hydraulic tank and add correct quantity of fluid if necessary; refer to the Operator’s Manual. 16. Ensure that there is no contact between the machine components including hydraulic hoses while the rear wheels move lock to lock. Adjust if necessary. 17.
Servicing the Rear Axle g290147 Figure 159 1. Bolt 4. Nut 7. Grease fitting 2. Washer 5. Flange bushing 8. Bushing 3. Bolt 6. Rear axle Rear Axle Pivot Bushing The rear axle must be held in place snugly by the axle pivot pin. Excessive movement of the axle, which is characterized by erratic steering, might indicate worn axle pivot bushing (8). To correct the problem, replace the bushings as below: 1. Remove the rear axle from the machine; refer to Removing the Rear Axle (page 8–6). 2.
Rear Axle Housing Bushings The rear axle steering spindle shafts must fit snugly in the rear axle. Excessive movement of the steering spindle shaft in the axle might indicate that the flange bushings (5) are worn or damaged and must be replaced as below: 1. Remove the rear axle from the machine; refer to Removing the Rear Axle (page 8–6). 2. Use a bushing removal tool to extract the flange bushings (5) from the rear axle (6). Note: Take care not to damage bore of the bore during the bushing (5) removal. 3.
Steering Spindle g290134 Figure 160 1. 2. 3. Bolt Washer Cap 12. 13. 14. Thrust washer Tie rod end Pin 23. 24. 25. Thrust washer Nut Flange 4. Retaining ring 15. Grease fitting 26. Woodruff key 5. Spacer 16. Bolt 27. RH spindle 6. 7. 8. Rear axle Nut Bolt 17. 18. 19. Washer Nut Steering cylinder 28. 29. 30. Nut Washer Nut Bolt Washer Nut 20. 21. 22. Nut Bolt Rear hydraulic motor 31. 32. 33. Washer Bolt LH spindle 9. 10. 11. Removing the Steering Spindle 1.
Removing the Steering Spindle (continued) 3. Remove the hopper assembly; refer to Removing the Hopper Assembly (page 9–3). 4. Remove the rear wheel; refer to Removing the Wheels (page 7–3). 5. Loosen, but not remove the locknut (24) that securing the wheel flange (2) to the motor shaft (22). 6. Remove the nut (28) and washer (10) that secures the steering tie rod (13) to the spindle (27 or 33). 7. Carefully pry the steering tie rod end (13) from the spindle (27 or 33) with a ball joint pickle fork. 8.
Installing the Steering Spindle (continued) 6. Connect the tie-rod end to the steering spindle and secure with the washer (10) and nut (28). 7. Lubricate the spindle through the grease fitting on the axle. Grease should purge from the ends of the steering spindle shaft identifying that the grease cavity is completely filled. Wipe up excess grease. 8. Install the wheels; refer to Installing the Wheels (page 7–4). 9. Lubricate all the grease fittings in the rear axle assembly. 10.
PTO Drive Belt g290202 Figure 161 1. Retaining ring 14. Spring 27. Spring 2. Ball bearing 15. Electric clutch 28. Belt tension indicator 3. Shaft 16. Engine 29. Nylon guide 4. Dust flange 17. Drive shaft 30. Rod 5. Shaft key 18. Washer 31. Fork 6. Pulley 19. Bolt 32. Cotter pin 7. Belt tension lever 20. Bushing 33. Pin 8. Bushing 21. Washer 34. Pin 9. Retaining ring 22. Bolt 35. Flange bushing 10. Bearing 23. Bolt 36. Grease fitting 11.
Electric Clutch g290631 Figure 162 1. Bolt 5. Spring 9. 2. 3. Washer Bushing 6. 7. Electric clutch Woodruff key 4. Bracket 8. Bolt 10. 11. Washer Drive shaft Engine Removing the Electric Clutch 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Disconnect the electrical connector from the electric clutch. 3. Remove the PTO drive belt from the machine; refer to Operator’s Manual. 4.
Installing the Electric Clutch 1. If removed, install the drive shaft (10) onto the engine (11) and secure with the 3 bolts (8) and washers (9). 2. Clean the drive shaft (10) and position the woodruff (7) into the drive shaft slot. 3. Slide and install the electric clutch (6) and bushing (3) onto the drive shaft (10). 4. Secure the electric clutch (6) with the bolt (1) and washer (2). Torque tighten the bolt (1) to 50 N·m (36.8 ft-lb). 5.
PTO Driveshaft g290234 Figure 163 1. Retaining ring 11. Pulley 21. Bracket 2. Bearing 12. Nut 22. Socket head screw 3. 4. Shaft Dust flange 13. 14. Washer Washer 23. 24. Socket head screw Nut 5. Shaft key 15. Bolt 25. Bushing 6. 7. 8. Nut Washer Flange bushing 16. 17. 18. Drive shaft Nut Washer 26. 27. 28. Fork Nut Bracket 9. Grease fitting 19. Bracket 29. Bolt Pin 20. Polyethylene tube protector 10.
WARNING Do not start the engine and engage the PTO switch when the PTO driveshaft is disconnected from the cutting deck. If you start the engine and the PTO shaft is allowed to rotate, serious personal injury and machine damage could result. Disconnect the PTO electric clutch electrical connector whenever the PTO driveshaft is disconnected from the cutting deck. Removing the PTO Driveshaft 1.
Installing the PTO Driveshaft IMPORTANT If the driveshaft tube and shaft were separated, ensure that the slip shaft yoke and slip tube yoke are aligned when the tube and shaft are assembled. Misalignment of the yokes will result in shortened driveshaft life and will cause unnecessary vibration when the cutting deck is operated. 1. If removed, install the PTO driveshaft (16) into the polyethylene tube protector (20) using the Figure 163 as a guide. 2. Position the PTO driveshaft to the machine.
Servicing the Driveshaft g290288 Figure 165 1. End yoke 3. Grease fitting 5. Slip tube yoke 2. Universal joint kit (cross and bearing) 4. Slip shaft yoke 6. End yoke Disassembling the Driveshaft 1. Remove the PTO driveshaft from the machine; refer to Removing the PTO Driveshaft (page 8–18). g290289 Figure 166 1. End yoke 4. Grease fitting 2. Cross and bearing kit 5. Shaft yoke 3. Snap ring 2. Remove the snap rings (3) that secures the cross and bearing kit in the yokes.
Assembling the PTO Driveshaft 1. Install the new cross and bearings as follows: A. Apply a thick layer of grease to the bearing bores in the end yoke and shaft yoke. B. Press 1 bearing partially into the yoke. C. Insert the cross into the yoke and bearing. D. Hold the cross in alignment and press the bearing in until it hits the yoke. E. Install the snap ring into the yoke groove to secure installed bearing. F. Place second bearing into the yoke bore and onto the cross shaft.
PTO Shaft Assembly g290337 Figure 167 1. Retaining ring 15. Electric clutch 29. Nylon guide 2. Ball bearing 16. Engine 30. Rod 3. 4. Shaft Dust flange 17. 18. Drive shaft Washer 31. 32. Fork Cotter pin 5. Shaft key 19. Bolt 33. Pin 6. Pulley 20. Bushing 34. Pin 7. Belt tension lever 21. Washer 35. Flange bushing 8. Bushing 22. Bolt 36. Grease fitting 9. Retaining ring 23. Bolt 37. Washer 10. Bearing 24. Nut 38. Nut 11. Pulley 25. Nut 39. Nut 12.
WARNING Do not start the engine and engage the PTO switch when the PTO driveshaft is disconnected from the cutting deck. If you start the engine and the PTO shaft is allowed to rotate, serious personal injury and machine damage could result. Disconnect the PTO electric clutch electrical connector whenever the PTO driveshaft is disconnected from the cutting deck. Removing the PTO Shaft Assembly 1.
Servicing the PTO Shaft Assembly g290368 Figure 168 1. Retaining ring 9. Bushing 17. Bolt 2. Ball bearing 3. Shaft 10. Retaining ring 18. Pin 11. Bearing 19. Flange bushing 4. Dust flange 12. Pulley 20. Grease fitting 5. Shaft key 13. Nut 21. Washer 6. Pulley 14. Washer 22. Nut 7. 8. Bolt Belt tension lever 15. 16. Bolt Washer Disassembling the PTO Shaft Assembly 1.
Disassembling the PTO Shaft Assembly (continued) 7. Remove the bolt (17), nut (22) and washer (21) that secures the belt tension lever (8) to the dust flange (4). Remove the belt tension lever from the dust flange. 8. Remove the retaining rings (1) that secures the bearings (2) and shaft (3) into the dust flange (4). 9. Use a press to remove the bearings (2) and PTO shaft (3) from the dust flange (4). 10. Use a press to remove the pin (18) and flange bushings (19) from the dust flange (4). 11.
Servicing the Gearbox Assembly g290508 Figure 169 1. Cover 12. Spacer 23. Plug 2. Cap 13. Bearing 24. Spacer 3. Retaining ring 14. Spacer 25. Spacer 4. Spacer 15. Retaining ring 26. Gear 5. Retaining ring 16. Bearing 27. Bearing 6. Spacer 17. Spacer 28. Shaft 7. Shaft 18. Gear 29. Shaft key 8. Shaft key 19. Spacer 30. Spacer Cover 20. Retaining ring 31. Retaining ring 10. Seal 21. Gearbox housing 32. Cap 11. Retaining ring 22. Bearing 33.
g290529 Figure 170 1. Gearbox assembly 4. Spacer 2. Shaft key 5. Washer 3. Pulley 6. Bolt Remove the bolt (6) and washer (5) that secures the pulley (3) to the gearbox (1). Use a puller and remove the pulley (3) and spacer (4) from the gearbox (1). Locate and retrieve the shaft key (2). Disassembling the Gearbox 1. Remove the plug (23) and drain the gearbox oil from the gearbox assembly. 2. Remove the cover (1) and cap (2) from the gearbox assembly. 3.
Assembling the Gearbox 1. Position the spacer (19), gear (18), spacer (17), new bearing (16) and retaining ring (15) into the gearbox housing (21). 2. Install the spacer (14) and bearing (13) into the gearbox housing (21). 3. Install the shaft (7) into the gearbox housing (21). 4. Position the shaft key (8) into the key hole between the shaft (7) and gear (18) and secure the shaft key (8) with the retaining ring (20). 5. Install the spacer (12) and retaining ring (11) into the gearbox housing (21). 6.
Chapter 9 Hopper Assembly Table of Contents General Information .............................................................................................................................. 9–2 Service and Repairs ............................................................................................................................. 9–3 Hopper Assembly...............................................................................................................................
General Information The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your machine. Refer to the Operator’s Manual for additional information when servicing the machine.
Service and Repairs Hopper Assembly g291254 Figure 171 1. 2. Bolt Washer 5. 6. Washer Flange bushing 3. 4. Pin Bolt 7. 8. Nut Hydraulic cylinder 9. 10. Bolt Nut Removing the Hopper Assembly 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake and remove the key from the key switch. 2. Disconnect the hopper micro switch connector from the machine wire harness. 3. Support the hydraulic actuators (8) before loosening the mounting fasteners. 4.
Removing the Hopper Assembly (continued) 5. Remove the bolt (1) and washer (2) that secures the pin (3) to the machine frame. 6. Support the hopper assembly before removing the pin (8). 7. Slide and remove the pin (3) that secures the hopper assembly to the machine frame. Note: Two people are required to lift the hopper assembly from the machine. 8. Lift and remove the hopper assembly from the machine. 9.
Hopper Frame Assembly g291154 Figure 172 1. Hopper assembly 12. Knob 23. Support 2. 3. Decal Decal support 13. 14. Hook Washer 24. 25. Screw Guide 4. Front grass catcher screen 15. Nut 26. Washer 5. 6. Grass catcher screen Spring pin 16. 17. Washer Nut 27. 28. Plate Rivet 7. Inside grass catcher screen 18. Washer 29. Bracket 8. Carriage bolt 19. Bolt 30. Rivet 9. 10. Cross rail Hopper screen gasket 20. 21. Chain Washer 31. Washer 11. Pin 22.
g291155 Figure 173 1. 2. Washer Hinge 16. 17. Grommet Washer 31. 32. Rivet Plate 3. 4. Bolt Nut 18. 19. Washer Hinge 33. 34. Rivet Grease fitting 5. Spring 20. Socket head screw 35. Hinge 6. 7. Nut Hook 21. 22. Frame Hopper cover 36. 37. Bolt Washer 8. Flange bushing 23. Washer 38. Rod 9. Spacer 24. Screw 39. Support 10. Washer 25. Decal 40. Spring 11. 12. Bolt Bolt 26. 27. Screw Washer 41. 42. Washer Split pin 13. Connecting rod 28. Handle 43.
Disassembling the Hopper Frame Assembly 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake and remove the key from the key switch. 2. Remove the hopper assembly from the machine; refer to Removing the Hopper Assembly (page 9–3). 3. Disassemble the hopper frame assembly using the Figure 172 and Figure 173 as a guide. 4. If required, disassemble the hopper; refer to Disassembling the Hopper (page 9–9). Assembling the Hopper Frame Assembly 1.
Hopper g291403 Figure 174 1. 2. Bolt Cover 13. 14. Washer Spring 25. 26. Motor Nut 37. 38. Bracket Sensor support 3. Spacer 15. Rod 27. Washer 39. Microswitch 4. 5. Bracket Nut 16. 17. Nut Bolt 28. 29. Screw Connector pin 40. 41. Nut Screw 6. 7. Thread insert Bolt 18. 19. Nut Washer 30. 31. Connector Connector pin 42. 43. Manifold Washer 8. Eye end 20. Nut 32. Connector 44. Bearing 9. Nut 21. Washer 33. Wire harness 45. Spreader support 10. Body 22.
Disassembling the Hopper 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake and remove the key from the key switch. 2. Remove the hopper assembly from the machine; refer to Removing the Hopper Assembly (page 9–3). 3. Disassemble the hopper using the Figure 174 as a guide. 4. Note the location of the electrical connectors for assembly purposes. Assembling the Hopper 1. Assemble the hopper using the Figure 174 as a guide. 2.
Hopper Lift Frame Assembly g291439 Figure 175 Hopper Assembly: Service and Repairs Page 9–10 ProLine H800 19241SL Rev B
Figure 175 (continued) 1. Tube cap 20. Collar 39. Pin 2. Tube 21. Hopper hinge 40. Nut 3. Clamp 22. Socket head screw 41. Ball joint 4. Cap 23. Nut 42. Arm 5. 6. 7. Washer Nut Bolt 24. 25. 26. Pin Washer Bolt 43. 44. 45. RH Bracket LH Bracket Snap ring 8. Washer 27. Support frame 46. Pin 9. 10. Bracket Thread insert 28. 29. Screw Support 47. 48. Washer Plate 11. 12. Bolt Arm 30. 31. Chassis Magnet 49. 50. Nut Cable 13. Arm 32. Safety handle 51.
Assembling the Hopper Lift Frame Assembly 1. Clean the pin (24). Inspect the pin (24) for wear or damage and replace if necessary. 2. Assemble the hopper lift frame assembly using the Figure 175 and Figure 176 as a guide. 3. Remove the caps or plugs that were installed to the hydraulic hoses and fitting during the disassembly process. 4. Use the tags that marked during disassembly to correctly connect the hydraulic hoses to the hydraulic cylinders. 5.
Chute Assembly g291632 Figure 177 1. 2. 3. 4. 5. Chute Handle Screw Bracket Pin 6. 7. 8. 9. 10. Bracket Chute rubber seal Nut Screw Plate 11. 12. 13. 14. Washer Nut Pin Chute bracket Disassembling the Chute Assembly 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake and remove the key from the key switch. 2. Remove the chute assembly from the machine; refer to Operator’s Manual. 3. Disassemble the chute assembly using the Figure 177 as a guide.
Hopper Assembly: Service and Repairs Page 9–14 ProLine H800 19241SL Rev B
Chapter 10 Cutting Unit Table of Contents General Information ............................................................................................................................ 10–2 Service and Repairs ........................................................................................................................... 10–3 Idler Assembly ................................................................................................................................. 10–4 Blade Spindle.......
General Information The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your machine. Refer to the Operator’s Manual for additional information when servicing the machine.
Service and Repairs WARNING Do not start the engine and engage the PTO switch when the PTO driveshaft is disconnected from the cutting deck. If you start the engine and the PTO shaft is allowed to rotate, serious personal injury and machine damage could result. If the PTO driveshaft is disconnected from the cutting deck, disconnect the PTO electric clutch electrical connector. CAUTION Do not work on the cutting deck or lift arms with the engine running.
Idler Assembly g290658 Figure 178 Cutting Unit: Service and Repairs Page 10–4 ProLine H800 19241SL Rev B
Figure 178 1. Nut 14. Bolt (continued) 27. Bronze bushing 40. Spring 2. Washer 15. Nut 28. Scraper 41. Belt tension indicator 3. Retaining ring 16. Bolt 29. Bolt 42. Fork 4. Bearing 17. Plate nut 30. Bolt 43. Fork 5. Pulley 18. Bracket 31. Washer 44. Flange bushing 6. Bushing 19. Cutting deck fairing 32. Nut 45. Cutting deck belt tightener 7. 8. Washer Bolt 20. 21. Bolt Washer 33. 34. Bolt Clamp 46. 47. Pin Bolt 9. 10. Socket head screw Washer 22.
Installing the Idler Assembly (continued) 6. Attach the PTO driveshaft and install the cutting deck covers; refer to Operator’s Manual.
Blade Spindle g290708 Figure 179 1. Blade spindle 9. Nut 17. Bolt 2. Center blade spindle 10. Washer 18. Central blade disc 3. 4. 5. 6. Nut Washer Socket head screw Bronze bushing 11. 12. 13. 14. RH blade disc RH blade Bevel washer Cover 19. 20. 21. 22. Central blade Bolt LH blade LH blade disc 7. Scraper 15. Washer 8. Oil seal 16.
Removing the Blade Spindle 1. Park the machine on a level surface, raise the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. Support the cutting deck so that it cannot fall accidentally. 2. Remove the PTO driveshaft, belt covers and drive belt from the cutting deck; refer to Operator’s Manual. 3. Remove the blade discs and cutting blades from the blade spindles; refer to Operator’s Manual. 4.
Servicing the Blade Spindle g290843 Figure 180 1. Grease fitting 8. Shaft key 15. Oil seal 2. 3. Bolt 9. LH spindle shaft 16. Retaining ring Seal 10. Nut 17. Pulley 4. 5. Thrust washer 11. Washer 18. Center spindle shaft Pulley 12. Spindle hub 19. RH spindle shaft 6. Cover 13. Spacer 20. Socket head screw 7. Bearing 14. Bearing Disassembling the Blade Spindle 1. Remove the grease fitting (1) from the bolt (2). 2.
Disassembling the Blade Spindle (continued) 6. Remove the retaining ring (16) and oil seal (15) from the spindle hub. 7. Use a press to remove the spindle shaft from the spindle hub. 8. Use a press and carefully remove the bearings (7 and 14) and spacer (13) from the spindle hub. 9. Thoroughly clean the parts and inspect for any damage or wear. Replace the components as necessary. Assembling the Blade Spindle 1.
Assembling the Blade Spindle (continued) IMPORTANT Pneumatic grease guns can produce air pockets when filling large cavities and therefore, are not recommended to be used for proper greasing of spindle housings. 13. Attach a hand pump grease gun to grease fitting on housing and fill housing cavity with grease. 14. Rotate the spindle shaft to make sure that it turns freely.
Caster Wheel and Flat Frame Assembly g290949 Figure 182 1. Cap 8. Washer 15. Bolt 2. Retaining ring 9. Nut 16. Footrest 3. Bearing 10. Plate 17. Flat frame assembly 4. Bolt 11. Split pin 18. Retaining ring 5. 6. Washer Caster fork 12. 13. Pin Flange bushing 19. 20. Pin Cutting deck 7. Nut 14. Caster wheel Disassembling the Caster Wheel and Flat Frame Assembly 1.
Assembling the Caster Wheel and Flat Frame Assembly 1. Assemble the flat frame assembly using the Figure 182 as a guide. 2. Assemble the caster wheel using the Figure 182 as a guide. 3. Check and level the cutting deck; refer to Operator’s Manual.
Cutting Deck Rollers and Skids g290972 Figure 183 1. 2. 3. 4. Bolt Washer Washer Nut 8. 9. 10. 11. LH skid Washer Nut Carriage bolt 15. 16. 17. 18. Roller Washer Bolt RH skid 5. Roller shaft 12. Pin 19. Cutting deck 6. Roller 13. Roller pin 7. Bolt 14. Bearing Removing the Cutting Deck Rollers and Skids 1. Park the machine on a level surface, raise the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2.
Installing the Cutting Deck Rollers and Skids (continued) 2. Install the cutting deck rollers to the cutting deck using the Figure 183 as a guide. Tighten the nut (4) until the roller will not rotate, then loosen the nut only enough to allow the roller to rotate freely. Ensure to install the cutting deck rollers in the same mounting hole height position (lower or upper). 3. Check and adjust the level of the cutting deck; refer to Operator’s Manual.
Height Of Cut Linkage g291013 Figure 184 Cutting Unit: Service and Repairs Page 10–16 ProLine H800 19241SL Rev B
Figure 184 (continued) 1. 2. Frame Bolt 19. 20. Nut Hydraulic cylinder 37. 38. Nut Bolt 3. Nut 21. Pin 39. Unhooking pin 4. Bracket 22. Retaining ring 40. Pin 5. Fork 23. Bolt 41. Spring 6. 7. 8. 9. 10. 11. Nut Bolt Bracket Washer Nut Nut 24. 25. 26. 27. 28. 29. Washer Plate Block Washer Nut Bolt 42. 43. 44. 45. 46. 47. Lever Washer Washer Bolt Lever Split pin 12. 13. Washer Split pin 30. 31. HOC indicator Eye end 48. 49. Pin Plate 14. 15. 16. 17.
Cutting Deck Covers g291066 Figure 185 1. 2. Quarter turn fastener Cover 9. 10. Bracket Rubber guard 17. 18. Collar Plate 3. Washer 11. Cutting deck cover 19. Washer 4. 5. Quarter turn fastener Nut 12. 13. Washer Nut 20. 21. Bolt Pulley cover 6. Plastic hinge 14. Rivet 22. Washer 7. Screw 15. Hose protector 23. Bolt 8. Rivet 16. Cutting deck Disassembling the Cutting Deck Covers 1.
Assembling the Cutting Deck Covers 1. Assemble the cutting deck covers using the Figure 185 as a guide. 2. Install the cutting deck covers onto the cutting deck; refer to Operator’s Manual.
Cutting Unit: Service and Repairs Page 10–20 ProLine H800 19241SL Rev B
Appendix A Foldout Drawings Table of Contents Electrical Drawing Designations.........................................................................................................A–2 Hydraulic Schematic ..........................................................................................................................A–3 Electrical Schematic - Main................................................................................................................A–5 Electrical Schematic - Lights ......
Electrical Drawing Designations Note: A splice used in a wire harness will be identified on the wire harness diagram by SP. The manufacturing number of the splice is also identified on the wire harness diagram (e.g., SP01 is splice number 1). Wire Color The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter.
Hydraulic Schematic g295174 ProLine H800, Drawing Rev , Sheet 1 of 1 19241SL Rev B Page A–3
Page A–4 19241SL Rev B , Drawing Rev , Sheet
Electrical Schematic - Main g295173 ProLine H800, Drawing 122-1361 Rev A, Sheet 1 of 2 19241SL Rev B Page A–5
Electrical Schematic - Lights g295813 Page A–6 19241SL Rev B ProLine H800, Drawing 122-1361 Rev A, Sheet 2 of 2
Wire Harness Diagram - Main g295223 ProLine H800, Drawing Rev , Sheet 1 of 2 19241SL Rev B Page A–7
Wire Harness Diagram - Lights g295814 Page A–8 19241SL Rev B ProLine H800, Drawing Rev , Sheet 2 of 2
Wire Harness – Slope Sensor (Optional) g364132 model 02950, Drawing 122-1652 Rev B, Sheet 1 of 1 19241SL Rev B Page A–9
