99024sl.pdf Reelmaster 3100-D (Rev D) Dec, 2007

PART NO. 99024SL (Rev. D)

Service Manual

Reelmaster� 3100−D

Preface

The purpose of this publication is to provide the servicetechnician with information for troubleshooting, testing,and repair of major systems and components on theReelmaster 3100−D.

REFER TO THE TRACTION UNIT AND CUTTINGUNIT OPERATOR’S MANUALS FOR OPERATING,MAINTENANCE AND ADJUSTMENT INSTRUC-TIONS. Space is provided in Chapter 2 of this book toinsert the Operator’s Manuals and Parts Catalogs foryour machine. Replacement Operator’s Manuals areavailable by sending complete Model and Serial Num-ber to:

The Toro Company8111 Lyndale Avenue SouthBloomington, MN 55420−1196

The Toro Company reserves the right to change productspecifications or this publication without notice.

This safety symbol means DANGER, WARNING,or CAUTION, PERSONAL SAFETY INSTRUC-TION. When you see this symbol, carefully readthe instructions that follow. Failure to obey theinstructions may result in personal injury.

NOTE: A NOTE will give general information about thecorrect operation, maintenance, service, testing, or re-pair of the machine.

IMPORTANT: The IMPORTANT notice will give im-portant instructions which must be followed to pre-vent damage to systems or components on themachine.

� The Toro Company − 1999, 2002, 2003, 2005, 2007

Reelmaster 3100−D

Rev. DReelmaster 3100−D

Table Of Contents

Chapter 1 − Safety

Safety Instructions 1 − 1. . . . . . . . . . . . . . . . . . . . . . . . . . Jacking Instructions 1 − 4. . . . . . . . . . . . . . . . . . . . . . . . . Safety and Instruction Decals 1 − 5. . . . . . . . . . . . . . . .

Chapter 2 − Product Records and Manuals

Product Records 2 − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . Equivalents and Conversions 2 − 2. . . . . . . . . . . . . . . . Torque Specifications 2 − 3. . . . . . . . . . . . . . . . . . . . . . . Lubrication 2 − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preparation for Seasonal Storage 2 − 10. . . . . . . . . . . .

Chapter 3 − Kubota Diesel Engine

Introduction 3 − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications 3 − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information 3 − 4. . . . . . . . . . . . . . . . . . . . . . . . Adjustments 3 − 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service and Repairs 3 − 8. . . . . . . . . . . . . . . . . . . . . . . . KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,

05 SERIES

Chapter 4 − Hydraulic System

Specifications 4 − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information 4 − 3. . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Schematics 4 − 8. . . . . . . . . . . . . . . . . . . . . . . Hydraulic Flow Diagrams 4 − 10. . . . . . . . . . . . . . . . . . . Special Tools 4 − 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 4 − 26. . . . . . . . . . . . . . . . . . . . . . . . . . . Testing 4 − 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustments 4 − 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service and Repairs 4 − 58. . . . . . . . . . . . . . . . . . . . . . .

ROSS TORQMOTOR TM MG, MF, ME, AND MJ SE-RIES SERVICE PROCEDURE

EATON MEDIUM DUTY PISTON PUMP REPAIR IN-FORMATION MODEL 70160 VARIABLE DISPLACE-MENT PISTON PUMP

ROSS HYDRAGUIDE TM HYDROSTATIC STEERINGSYSTEM HGF SERIES SERVICE PROCEDURE

SAUER/DANFOSS STEERING UNIT TYPE OSPMSERVICE MANUAL

Chapter 5 − Electrical System

Electrical Schematics and Diagrams 5 − 2. . . . . . . . . . Special Tools 5 − 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 5 − 24. . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical System Quick Checks 5 − 28. . . . . . . . . . . . . Component Testing 5 − 30. . . . . . . . . . . . . . . . . . . . . . . . Service and Repairs 5 − 42. . . . . . . . . . . . . . . . . . . . . . .

Chapter 6 − Wheels, Brakes, and Miscellaneous

Specifications 6 − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools 6 − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustments 6 − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service and Repairs 6 − 4. . . . . . . . . . . . . . . . . . . . . . . .

Chapter 7 −Cutting Units

Specifications 6 − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools 6 − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 6 − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustments 6 − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service and Repairs 6 − 13. . . . . . . . . . . . . . . . . . . . . . .

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Reelmaster 3100−D

Reelmaster 3100−D Page 1 − 1 Safety

Chapter 1

SafetyTable of ContentsGENERAL SAFETY INSTRUCTIONS 1. . . . . . . . . . . .

Before Operating 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance and Service 3. . . . . . . . . . . . . . . . . . . . JACKING INSTRUCTIONS 4. . . . . . . . . . . . . . . . . . . . . SAFETY AND INSTRUCTION DECALS 5. . . . . . . . . .

General Safety InstructionsThe REELMASTER 3100−D was tested and certified byTORO to be in compliance with the B71.4-1990 specifi-cations of the American National Standards Institute. Al-though hazard control and accident prevention aredependent partially upon the design and configurationof the machine, these factors are also dependent uponthe awareness, concern, and proper training of the per-sonnel involved in the operation, transport, mainte-nance, and storage of the machine. Improper use ormaintenance by the operator or owner of the machinecan result in injury. To reduce the potential for any injury,comply with the following safety instructions.

WARNINGTo reduce the potential for injury or death,comply with the following safety instructions.

Supervisor’s Responsibilities

1. Make sure operators are thoroughly trained and fa-miliar with the Operator’s Manual, Operator’s Video,and all the operating and safety decals on the machine.

2. Be sure to establish your own special proceduresand work rules for unusual operating conditions (e.g.slopes to steep for machine operation). Survey mow-ing site completely to determine which hills can beoperated on safely. When performing this site survey,always use common sense and take into consideration

the turf condition and the rollover risk. To determinewhich hills or slopes may be safely operated on, use theinclinometer provided with each machine. To perform asite survey, lay a 4 foot long, 2 by 4 inch piece of woodon the slope surface and measure the angle of the slope.The piece of wood will average the slope but will not takeinto consideration dips or holes. THE MAXIMUM SIDEHILL ANGLE SHOULD NOT BE GREATER THAN 25DEGREES.

Before Operating

3. Operate machine only after reading and understand-ing the contents of the Operator’s Manual and viewingthe Operator’s Video. A replacement manual is avail-able by sending complete model and serial number to:

The Toro Company8111 Lyndale Avenue SouthMinneapolis, Minnesota 55420−1196

4. Only trained operators who are skilled in slope op-eration and who have read the Operator’s Manual andviewed the Operator’s Video should operate the ma-

chine. Never allow children to operate the machine oradults to operate it without proper instructions.

5. Become familiar with the controls and know how tostop the machine and engine quickly.

6. Do not carry passengers on the machine. Keep ev-eryone, especially children and pets, away from theareas of operation.

7. Keep all shields, safety devices and decals in place.Repair or replace damaged, malfunctioning, or illegibleshield, safety device, or decal before operating the ma-chine.

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Reelmaster 3100−DPage 1 − 2Safety

8. Always wear substantial shoes. Do not operate ma-chine while wearing sandals, tennis shoes or sneakers.Do not wear loose fitting clothing because it could getcaught in moving parts and possibly cause personal in-jury.

9. Wearing safety glasses, safety shoes, long pantsand a helmet is advisable and required by some local or-dinances and insurance regulations.

10.Make sure the work area is clear of objects whichmight be picked up and thrown by the reels.

11.Fill fuel tank with diesel fuel before starting engine.Avoid spilling any fuel. Since fuel is highly flammable,handle it carefully.

A. Use an approved fuel container.

B. Do not remove cap from fuel tank when engine ishot or running.

C. Do not smoke while handling diesel fuel.

D. Fill fuel tank outdoors and not over one inch fromthe top of the tank, (bottom of the filler neck). Do notoverfill.

While Operating

12.Do not run the engine in a confined area without ade-quate ventilation. Exhaust fumes are hazardous andcould be deadly.

13.Sit on the seat when starting and operating the ma-chine.

14.Check interlock switches daily for proper operation(Chapter 5 − Electrical System). Do not rely entirely onsafety switches -shut off engine before getting off seat.If a switch fails, replace it before operating the machine.The interlock system is for your protection, so do not by-pass it. Replace all interlock switches every two years.

15.Operator must be skilled and trained in how to driveon hillsides. Failure to use caution on slopes or hills maycause vehicle to tip or roll, possibly resulting in personalinjury or death. Always wear your seat belt.

16.This triplex mower has a unique drive system for su-perior traction on hills. The uphill wheel will not spin outand limit traction like conventional triplexes. If operatedon a side hill that is too steep, rollover will occur beforelosing traction.

17.The slope angle at which the machine will tip is de-pendent on many factors. Among these are mowingconditions such as wet or undulating turf, speed (espe-cially in turns), position of the cutting units (with side-winder), tire pressure and operator experience. At sidehill slope angles of 20 degrees or less the risk of a rol-lover is low. As the slope angle increases to a Toro rec-ommended maximum limit of 25 degrees the risk of arollover increases to a moderate level. DO NOT EX-CEED A 25 DEGREE SIDE HILL ANGLE BECAUSETHE RISK OF A ROLLOVER AND SERIOUS INJURYOR DEATH IS VERY HIGH. Stay alert for holes in terrainand other hidden hazards. Use extreme caution whenoperating close to sand traps, ditches, creeks, steep hill-sides or other hazards. Reduce speed when makingsharp turns. Do not turn on hills. Avoid sudden stops and

starts. Use reverse pedal for braking. Cutting units mustbe lowered when going down slopes for steering control.

18.When starting the engine:

A. Engage parking brake.

B. Be sure traction pedal is in neutral and reel driveis in disengage position.

C. After engine starts, release parking brake andkeep foot off traction pedal. Machine must not move.If movement is evident, the neutral control linkage isincorrectly adjusted: therefore, shut engine off andadjust until machine does not move when tractionpedal is released (see Adjust Transmission for Neu-tral).

19.Before backing up, look to the rear and assure noone is behind the machine. Watch out for traffic whennear or crossing roads. Always yield the right of way.

20.Keep hands, feet and clothing away from movingparts and the reel discharge area. Grass baskets, if soequipped, must be in place during reel operation formaximum safety.

21.This product may exceed noise levels of 85 dB(A) atthe operator position. Ear protectors are recommendedfor prolonged exposure to reduce the potential of per-manent hearing damage.

22.Raise the cutting units when driving from one workarea to another.

23.Do not touch engine, muffler, exhaust pipe or hydrau-lic tank while engine is running or soon after it hasstopped because these areas could be hot enough tocause burns.

Reelmaster 3100−D Page 1 − 3 Safety

24.If a cutting unit strikes a solid object or vibrates ab-normally, stop immediately. Turn engine off, wait for allmotion to stop and inspect for damage. A damaged reelor bedknife must be repaired or replaced before opera-tion is continued.

25.Before getting off the seat:

A. Move traction pedal to neutral.

B. Set the parking brake.

C. Disengage the cutting units and wait for the reelsto stop spinning.

D. Stop the engine and remove key from the ignitionswitch.

26.Whenever machine is left unattended, make surereels are not spinning, key is removed from ignitionswitch and parking brake is set.

Maintenance and Service

27.Before servicing or making adjustments to the ma-chine, stop the engine and remove key from switch toprevent accidental starting of the engine.

28.Check performance of all interlock switches daily. Donot defeat interlock system. It is for your protection.

29.To ensure entire machine is in good operating condi-tion, frequently check and keep all nuts, bolts, screwsand hydraulic fittings tight.

30.Make sure all hydraulic line connectors are tight, andall hydraulic hoses and lines are in good condition be-fore applying pressure to the system.

31.Keep body and hands away from pin hole leaks ornozzles that eject hydraulic fluid under high pressure.Use paper or cardboard, not hands, to search for leaks.Hydraulic fluid escaping under pressure can have suffi-cient force to penetrate skin and do serious damage. lffluid is injected into the skin it must be surgically re-moved within a few hours by a doctor familiar with thisform of injury or gangrene may result.

32.Before disconnecting or performing any work on thehydraulic system, all pressure in system must be re-lieved by stopping engine and lowering cutting units tothe ground.

33.If major repairs are ever needed or if assistance isdesired, contact an Authorized Toro Distributor.

34.To reduce potential fire hazard, keep the engine areafree of excessive grease, grass, leaves and accumula-tion of dirt.

35.If the engine must be running to perform a mainte-nance adjustment, keep hands, feet, clothing, and anyother parts of the body away from the cutting units andany moving parts. Keep everyone away.

36.Do not overspeed the engine by changing governorsettings. To assure safety and accuracy, have an Autho-rized Toro Distributor check maximum engine speedwith a tachometer.

37.Engine must be shut off before checking oil or addingoil to the crankcase.

38.To insure optimum performance and safety, use gen-uine TORO replacement parts and accessories. Re-placement parts and accessories made by othermanufacturers could be dangerous, and such use couldvoid the product warranty of The Toro Company.

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Jacking Instructions

CAUTIONWhen changing attachments, tires, or performingother service, use correct blocks, hoists, andjacks. Make sure machine is parked on a solid lev-el floor such as a concrete floor. Prior to raisingmachine, remove any attachments that may inter-fere with the safe and proper raising of the ma-chine. Always chock or block wheels. Used jackstands or solid wood blocks to support the raisedmachine. If the machine is not properly sup-ported by blocks or jack stands, the machine maymove or fall, which may result in personal injury.

Use the following positions when jacking up the ma-chine:

Jacking the Front End

1. If the front wheel motor is to be removed, positionjack securely under the square tube of the lower frameas closely to the side plate as possible (Fig. 1).

2. If the front tire is to be removed, position the jack se-curely under the front wheel motor.

3. Use jack stands or hardwood blocks under thesquare tube or wheel motors to support the machine(Fig. 1).

Jacking the Rear End

1. The preferred method of lifting the rear end of themachine for removing the rear fork or the rear wheel mo-tor:

A. Secure a chain fall or hoist to the rear casting (Fig2).

B. Chock both front tires. Lift rear tire off the ground.

C. Use jack stands or hardwood blocks under theframe to support the machine (Fig. 3).

2. If the rear of the machine can not be lifted from above(Fig. 3),

IMPORTANT: Make sure jack is as close to the rearfork as possible when jacking the rear wheel.

A. Place jack securely under the rear wheel motor.

B. Chock both front tires. Jack rear tire off theground.

C. Use jack stands or blocks under the frame to se-cure the machine.

1. Square tube 2. Side plate

Figure 1

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1. Rear tire 2. Rear casting

Figure 2

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1. Frame2. Rear wheel motor

3. Rear fork

Figure 3

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Rev. DReelmaster 3100−D Page 1 − 5 Safety

Safety and Instruction Decals

Numerous safety and instruction decals are affixed tothe Reelmaster 3100−D. If any decal becomes illegibleor damaged, install a new decal. Part numbers for re-placement decals are listed in your Parts Catalog. Orderreplacement decals from your Authorized Toro Distribu-tor.

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Rev. D


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Rev. D

Reelmaster 3100−D Page 2 − 1 Product Records and Maintenance

Chapter 2

Product Records and Maintenance

Table of Contents

PRODUCT RECORDS 1. . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS 2. . . . . . . . . . .

Decimal and Millimeter Equivalents 2. . . . . . . . . . . . U.S. to Metric Conversions 2. . . . . . . . . . . . . . . . . . .

TORQUE SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . . Capscrew Markings and Torque Values − U.S. 3. . Capscrew Markings and Torque Values − Metric 3

LUBRICATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tractor Unit 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cutting Units 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PREPARATION FOR SEASONAL STORAGE 10. . . .

Product Records

Insert Operator’s Manual and Parts Catalog for yourReelmaster 3100−D at the end of this chapter. Addition-ally, if any optional equipment or accessories have beeninstalled to your machine, insert the Installation Instruc-tions, Operator’s Manuals and Parts Catalogs for thoseoptions at the end of this chapter.

Maintenance

Maintenance procedures and recommended service in-tervals for the Reelmaster 3100−D are covered in theOperator’s Manual. Refer to that publication when per-forming regular equipment maintenance.

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Reelmaster 3100−DPage 2 − 2Product Records and Maintenance

Equivalents and Conversions


Torque SpecificationsRecommended fastener torque values are listed in thefollowing tables. For critical applications, as determinedby Toro, either the recommended torque or a torque thatis unique to the application is clearly identified and spe-cified in this Service Manual.

These Torque Specifications for the installation andtightening of fasteners shall apply to all fasteners whichdo not have a specific requirement identified in this Ser-vice Manual. The following factors shall be consideredwhen applying torque: cleanliness of the fastener, useof a thread sealant (Loctite), degree of lubrication on thefastener, presence of a prevailing torque feature, hard-ness of the surface underneath the fastener’s head, orsimilar condition which affects the installation.

As noted in the following tables, torque values should bereduced by 25% for lubricated fasteners to achievethe similar stress as a dry fastener. Torque values mayalso have to be reduced when the fastener is threadedinto aluminum or brass. The specific torque valueshould be determined based on the aluminum or brassmaterial strength, fastener size, length of thread en-gagement, etc.

The standard method of verifying torque shall be per-formed by marking a line on the fastener (head or nut)and mating part, then back off fastener 1/4 of a turn.Measure the torque required to tighten the fastener untilthe lines match up.

Fastener Identification

Grade 1 Grade 5 Grade 8

Inch Series Bolts and Screws

Class 8.8 Class 10.9

Metric Bolts and Screws

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Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)

Thread SizeGrade 1, 5, &

8 with ThinHeight Nuts

SAE Grade 1 Bolts, Screws, Studs, &Sems with Regular Height Nuts

(SAE J995 Grade 2 or Stronger Nuts)





in−lb in−lb N−cm in−lb N−cm in−lb N−cm

# 6 − 32 UNC10 + 2 13 + 2 147 + 23

15 + 2 170 + 20 23 + 2 260 + 20

# 6 − 40 UNF10 + 2 13 + 2 147 + 23

17 + 2 190 + 20 25 + 2 280 + 20

# 8 − 32 UNC13 + 2 25 + 5 282 + 30

29 + 3 330 + 30 41 + 4 460 + 45

# 8 − 36 UNF13 + 2 25 + 5 282 + 30

31 + 3 350 + 30 43 + 4 485 + 45

# 10 − 24 UNC18 + 2 30 + 5 339 + 56

42 + 4 475 + 45 60 + 6 675 + 70

# 10 − 32 UNF18 + 2 30 + 5 339 + 56

48 + 4 540 + 45 68 + 6 765 + 70

1/4 − 20 UNC 48 + 7 53 + 7 599 + 79 100 + 10 1125 + 100 140 + 15 1580 + 170

1/4 − 28 UNF 53 + 7 65 + 10 734 + 113 115 + 10 1300 + 100 160 + 15 1800 + 170

5/16 − 18 UNC 115 + 15 105 + 17 1186 + 169 200 + 25 2250 + 280 300 + 30 3390 + 340

5/16 − 24 UNF 138 + 17 128 + 17 1446 + 192 225 + 25 2540 + 280 325 + 30 3670 + 340

ft−lb ft−lb N−m ft−lb N−m ft−lb N−m

3/8 − 16 UNC 16 + 2 16 + 2 22 + 3 30 + 3 41 + 4 43 + 4 58 + 5

3/8 − 24 UNF 17 + 2 18 + 2 24 + 3 35 + 3 47 + 4 50 + 4 68 + 5

7/16 − 14 UNC 27 + 3 27 + 3 37 + 4 50 + 5 68 + 7 70 + 7 95 + 9

7/16 − 20 UNF 29 + 3 29 + 3 39 + 4 55 + 5 75 + 7 77 + 7 104 + 9

1/2 − 13 UNC 30 + 3 48 + 7 65 + 9 75 + 8 102 + 11 105 + 10 142 + 14

1/2 − 20 UNF 32 + 3 53 + 7 72 + 9 85 + 8 115 + 11 120 + 10 163 + 14

5/8 − 11 UNC 65 + 10 88 + 12 119 + 16 150 + 15 203 + 20 210 + 20 285 + 27

5/8 − 18 UNF 75 + 10 95 + 15 129 + 20 170 + 15 230 + 20 240 + 20 325 + 27

3/4 − 10 UNC 93 + 12 140 + 20 190 + 27 265 + 25 359 + 34 375 + 35 508 + 47

3/4 − 16 UNF 115 + 15 165 + 25 224 + 34 300 + 25 407 + 34 420 + 35 569 + 47

7/8 − 9 UNC 140 + 20 225 + 25 305 + 34 430 + 45 583 + 61 600 + 60 813 + 81

7/8 − 14 UNF 155 + 25 260 + 30 353 + 41 475 + 45 644 + 61 660 + 60 895 + 81

Note: Reduce torque values listed in the table aboveby 25% for lubricated fasteners. Lubricated fastenersare defined as threads coated with a lubricant such asoil, graphite, or thread sealant such as Loctite.

Note: Torque values may have to be reduced wheninstalling fasteners into threaded aluminum or brass.The specific torque value should be determined based

on the fastener size, the aluminum or base materialstrength, length of thread engagement, etc.

Note: The nominal torque values listed above forGrade 5 and 8 fasteners are based on 75% of the mini-mum proof load specified in SAE J429. The tolerance isapproximately + 10% of the nominal torque value. Thinheight nuts include jam nuts.


Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners)

Thread SizeClass 8.8 Bolts, Screws, and Studs with

Regular Height NutsClass 10.9 Bolts, Screws, and Studs with

Regular Height NutsThread Size Regular Height Nuts(Class 8 or Stronger Nuts)

Regular Height Nuts(Class 10 or Stronger Nuts)

M5 X 0.8 57 + 5 in−lb 640 + 60 N−cm 78 + 7 in−lb 885 + 80 N−cm

M6 X 1.0 96 + 9 in−lb 1018 + 100 N−cm 133 + 13 in−lb 1500 + 150 N−cm

M8 X 1.25 19 + 2 ft−lb 26 + 3 N−m 27 + 2 ft−lb 36 + 3 N−m

M10 X 1.5 38 + 4 ft−lb 52 + 5 N−m 53 + 5 ft−lb 72 + 7 N−m

M12 X 1.75 66 + 7 ft−lb 90 + 10 N−m 92 + 9 ft−lb 125 + 12 N−m

M16 X 2.0 166 + 15 ft−lb 225 + 20 N−m 229 + 22 ft−lb 310 + 30 N−m

M20 X 2.5 325 + 33 ft−lb 440 + 45 N−m 450 + 37 ft−lb 610 + 50 N−m

Note: Reduce torque values listed in the table aboveby 25% for lubricated fasteners. Lubricated fastenersare defined as threads coated with a lubricant such asoil, graphite, or thread sealant such as Loctite.

Note: Torque values may have to be reduced wheninstalling fasteners into threaded aluminum or brass.The specific torque value should be determined based

on the fastener size, the aluminum or base materialstrength, length of thread engagement, etc.

Note: The nominal torque values listed above arebased on 75% of the minimum proof load specified inSAE J1199. The tolerance is approximately + 10% of thenominal torque value.

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Other Torque Specifications

SAE Grade 8 Steel Set Screws

Thread SizeRecommended Torque

Thread SizeSquare 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. 10 − 24 UNC 38 + 7 in−lb

1/4 − 20 UNC 85 + 15 in−lb

5/16 − 18 UNC 110 + 20 in−lb

3/8 − 16 UNC 200 + 100 in−lb

Wheel Bolts and Lug Nuts

Thread Size Recommended Torque**

7/16 − 20 UNFGrade 5

65 + 10 ft−lb 88 + 14 N−m

1/2 − 20 UNFGrade 5

80 + 10 ft−lb 108 + 14 N−m

M12 X 1.25Class 8.8

80 + 10 ft−lb 108 + 14 N−m

M12 X 1.5Class 8.8

80 + 10 ft−lb 108 + 14 N−m

** For steel wheels and non−lubricated fasteners.

Thread Cutting Screws(Zinc Plated Steel)

ThreadSize

Threads per InchBaseline Torque*Size

Type A Type BBaseline Torque*

No. 6 18 20 20 + 5 in−lb

No. 8 15 18 30 + 5 in−lb

No. 10 12 16 38 + 7 in−lb

No. 12 11 14 85 + 15 in−lb

* Hole size, material strength, material thickness & finishmust be considered when determining specific torquevalues. All torque values are based on non−lubricatedfasteners.

Conversion Factors

in−lb X 11.2985 = N−cm N−cm X 0.08851 = in−lbft−lb X 1.3558 = N−m N−m X 0.7376 = ft−lb


LubricationTraction Unit

CAUTION

Before servicing or making adjustments to themachine, stop engine, lower cutting, set parkingbrake, and remove key from the ignition switch.

The traction unit has grease fittings that must be lubri-cated regularly with No. 2 General Purpose LithiumBase Grease. If machine is operated under normalconditions, lubricate bearings and bushings after every50 hours of operation. Bearings and bushings must belubricated daily when operating conditions are extreme-ly dusty and dirty. Dusty and dirty operating conditionscould cause dirt to get into the bearings and bushings,resulting in accelerated wear. Lubricate bearings andbushings immediately after every washing, regardlessof the interval listed.

The traction unit bearings and bushings that must be lu-bricated are: rear cutting unit pivot (Fig. 4), front cuttingunit pivot (Fig. 5), sideWinder cylinder ends (2) (model03201 only) (Fig. 6), steering pivot (Fig. 7), rear lift armpivot and lift cylinder (2) (Fig. 8), left front lift arm pivotand lift cylinder (2) (Fig. 9), right front lift arm pivot and liftcylinder (2) (Fig. 10), neutral arm assembly (Fig. 11),mow/transport slide (Fig. 12), belt tension pivot (Fig. 13)steering cylinder (Fig. 14).

Note: If desired, an additional grease fitting may beinstalled in other end of steering cylinder. Tire must beremoved, fitting installed, greased, fitting removed andplug installed (Fig. 15).

IMPORTANT: Do not lubricate Sidewinder (model03201) cross tube, bearing blocks are self lubri-cated.

Figure 4

Figure 5

Figure 6

(2)

Figure 7

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Figure 8

(2)

Figure 9

Figure 10

Figure 11

Figure 12

Figure 13

Figure 14

Figure 15 (See Note)


Cutting Units

Each cutting unit has (6) grease fittings (with optionalfront roller installed) that must be lubricated regularlywith No. 2 General Purpose Lithium Base Grease.

The grease fitting locations and quantities areas follows:Bedknife adjuster (2), every 50 hours (Fig. 17); Reelbearings (2) and front and rear rollers (2 ea.) (Fig. 16).

Note: Lubricate only one reel bearing grease fitting oneach end of cutting unit.

IMPORTANT: Lubricating cutting units immediatelyafter washing. This helps to purge water out of bear-ings and increases bearing life.

1. Wipe each grease fitting with a clean rag.

IMPORTANT: Do not apply too much pressure orgrease seals will be permanently damaged.

2. Apply grease until pressure is felt against handle.

3. Wipe excess grease away.

Figure 17Grease every 50 operating hours.

Figure 18Grease every 8 operating hours.

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Preparation for Seasonal StorageTraction Unit

1. Clean traction unit, cutting units, and the engine thor-oughly.

2. Check tire pressure. Inflate all tires to 14 to 18 psi(0.97 to 1.24 Bar).

3. Check all fasteners for looseness; tighten as neces-sary.

4. Lubricate all grease fittings and pivot points (see Lu-brication).

5. Cover entire length of the Sidewinder (Model 03201)cross tube with a light oil to prevent rust. After storage,wipe off all oil.

6. Lightly sand and use touch−up paint on paintedareas that are scratched, chipped, or rusted. Repair anydents in the metal body.

7. Service battery and cables as follows:

A. Remove battery terminals from the battery posts(see Battery Service in Chapter 5 − Electrical Sys-tem).

B. Clean battery, terminals, and posts with a wirebrush and baking soda solution.

C. Coat cable terminals and battery posts with Grafo112X skin−over grease (Toro Part No. 505-47) or pe-troleum jelly to prevent corrosion.

D. Every 30 days, check battery electrolyte levelsand fill battery as necessary (see Battery Care inChapter 5 − Electrical System).

E. Every 60 days, recharge battery slowly for 24hours to prevent sulfate from forming on the batteryplates (see manufacturer’s instructions for batterycharger).

Traction Unit

1. Drain engine oil from the oil pan and replace the drainplug.

2. Remove and discard oil filter. Install a new oil filter.

3. Refill oil pan with approximately 4.0 quarts (3.8 l) ofSAE10W-30 motor oil.

4. Start engine and run at idle speed for approximatelytwo minutes.

5. Stop engine.

6. Drain all fuel thoroughly from the fuel tank, fuel lines,and water/fuel separator (see Water/Fuel Separatorand Fuel System in Chapter 3 − Kubota Diesel Engine).

7. Flush the fuel tank with fresh, clean diesel fuel (seeFuel System in Chapter 3 − Kubota Diesel Engine).

8. Re−secure all fuel system fittings.

9. Clean and service the air cleaner assembly (see Ser-vice Air Filter, Dust Cup, and Burp Valve in Chapter 3 −Kubota Diesel Engine).

10.Seal air cleaner inlet and the exhaust outlet withweatherproof tape.

11.Check anti−freeze protection and add as needed forexpected minimum temperature in your area (seeCheck Cooling System in Chapter 3 − Kubota Diesel En-gine).

Reelmaster 3100−D Page 3 − 1 Kubota Diesel Engine

Chapter 3

Kubota Diesel EngineTable of ContentsINTRODUCTION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 4. . . . . . . . . . . . . . . . . . . . .

Check Engine Oil 4. . . . . . . . . . . . . . . . . . . . . . . . . . . Fill Fuel Tank 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check Cooling System 5. . . . . . . . . . . . . . . . . . . . . . .

ADJUSTMENTS 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust Throttle Cable 6. . . . . . . . . . . . . . . . . . . . . . . . Adjust Alternator/Fan Belt 7. . . . . . . . . . . . . . . . . . . .

SERVICE AND REPAIRS 8. . . . . . . . . . . . . . . . . . . . . . Change Engine Oil and Filter 8. . . . . . . . . . . . . . . . . Replace Traction Belt 8. . . . . . . . . . . . . . . . . . . . . . . . Bleed Fuel System 9. . . . . . . . . . . . . . . . . . . . . . . . . . Bleed Air from Fuel Injectors 9. . . . . . . . . . . . . . . . . . Muffler and Air Cleaner 10. . . . . . . . . . . . . . . . . . . . .

Muffler Removal 11. . . . . . . . . . . . . . . . . . . . . . . . . . . Muffler Installation 11. . . . . . . . . . . . . . . . . . . . . . . . . Check Air Filter, Dust Cup, & Burp Valve 12. . . . . Service Air Filter, Dust Cup, & Burp Valve 12. . . .

Water/Fuel Separator 13. . . . . . . . . . . . . . . . . . . . . . . Fuel System 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Fuel Lines and Connections 14. . . . . . . . . Fuel Tank Removal 15. . . . . . . . . . . . . . . . . . . . . . . Drain and Clean Fuel Tank 15. . . . . . . . . . . . . . . . . Fuel Tank Installation 15. . . . . . . . . . . . . . . . . . . . . . Replace Fuel Prefilter 15. . . . . . . . . . . . . . . . . . . . .

Radiator 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean Radiator and Oil Cooler 18. . . . . . . . . . . . . .

Engine 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,05 SERIES K

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Reelmaster 3100−DPage 3 − 2Kubota Diesel Engine

IntroductionThis Chapter gives information about specifications,maintenance, troubleshooting, testing, and repair of thediesel engine used in the Reelmaster 3100−D.

Most repairs and adjustments require tools which arecommonly available in many service shops. Specialtools are described in the Kubota Workshop Manual,Diesel Engine, 05 Series. The use of some specializedtest equipment is explained. However, the cost of the

test equipment and the specialized nature of some re-pairs may dictate that the work be done at an engine re-pair facility.

Service and repair parts for Kubota engines are sup-plied through your Authorized Toro Distributor. If noparts list is available, be sure to provide your distributorwith the Toro model and serial number.


Specifications

Item Description

Make / Designation Kubota, 4−Cycle, 3 Cylinder,Water Cooled, Diesel Engine

Horse Power 21.5 HP @ 2500 RPM

Bore mm (in.) 78.0 (3.07)

Stroke mm (in.) 78.4 (3.09)

Total Displacement cc (cu. in.) 1123 (68.53)

Torque N−m (ft−lb) 67.3 (49.6) @ 2000 RPM

Firing Order 1−2−3

Combustion Chamber Spherical Type

Fuel No. 2 Diesel Fuel (ASTM D975)

Fuel Capacity liters (gallons) 28.4 (7.5)

Fuel Injection Pump Bosch MD Type Mini Pump

Governor Centrifugal Mechanical

Low Idle (no load) 1400 + 50 RPM

High Idle (no load) 2650 + 50 RPM

Direction of Rotation Counterclockwise (Viewed from Flywheel)

Compression Ratio 22:1

Injection Nozzles Mini Nozzle (DNOPD)

Engine Oil 10W30 Detergent (API CD, CE, CF, CF−4, or CG−4)

Oil Pump Trochoid Type

Crankcase Oil Capacity liters (U.S. qt.) 3.8 (4.0) with Filter

Starter 12 VDC, 1 KW

Alternator/Regulator 12 VDC 40 AMP

Dry Weight kilograms (U.S. lbs) 93.0 (205.0)

Coolant Capacity liters (U.S. qt.) 5.7 (6.0) with 0.9 (1.0) Reservoir

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General Information

Check Engine Oil

The engine is shipped with oil in the crankcase. Howev-er, oil level must be checked before and after the engineis first started.

Crankcase holds about 4.0 qts. (3.8 l) with filter.

IMPORTANT: Check level of oil every 5 operatinghours or daily. Change oil after every 50 hours of op-eration.

1. Park machine on a level surface, lower cutting units,stop engine, engage parking brake, and remove keyfrom the ignition switch.

2. Remove dipstick and wipe it with a clean rag. Pushdipstick down into dipstick tube and make sure it isseated fully. Pull dipstick out and check oil level. If oil lev-el is low, add enough oil to raise level to the FULL markon the dipstick.

3. If oil level is low, remove oil fill cap and gradually addsmall quantities of oil, checking level frequently, until theoil level reaches the FULL mark on the dipstick.

4. The engine uses any high−quality 10W30 detergentoil having the American Petroleum Institute − API − “ser-vice classification” CD, CE, CF CF−4 or CG−4.

5. Install oil fill cap and close hood.

Figure 11. Dipstick 2. Oil fill cap

21

Figure 21. Oil fill cap 2. Injection pump

2 1


Fill Fuel Tank

DANGERBecause diesel fuel is highly flammable, use cau-tion when storing or handling it. Do not smokewhile filling the fuel tank. Do not fill fuel tankwhile engine is running, hot, or when machine isin an enclosed area. Always fill fuel tank outsideand wipe up any spilled diesel fuel before start-ing the engine. Store fuel in a clean, safety−ap-proved container and keep cap in place. Use die-sel fuel for the engine only; not for any other pur-pose.

IMPORTANT: Use No, 2 diesel fuel only for the en-gine. The fuel tank capacity is about 7.5 gallons(28.4 l).


2. Clean area around the fuel tank cap. Remove capfrom the tank.

Figure 31. Fuel tank cap 2. Fuel tank filler neck

1

2

3. Fill fuel tank to the bottom of the filler neck. Do notoverfill. Install cap to the neck.

4. Wipe up any fuel that may have spilled to prevent afire hazard.

Check Cooling System

The cooling system is filled with a 50/50 solution of waterand permanent ethylene glycol anti−freeze. Check levelof coolant at the beginning of each day before startingthe engine. System capacity is about 6 quarts (5.7 l) with1 quart (0.9 l) reservoir.


CAUTION

If engine has been running, pressurized hot cool-ant can escape when the radiator cap is removedand cause burns. Open radiator cap only whenthe radiator and engine are cold (Fig. 4).

2. Check level of coolant in the expansion tank. Coolantlevel should be between the marks on the side of tank.

3. If coolant level is low, remove expansion tank capand replenish the system. Do not overfill.

4. Install expansion tank cap.

Figure 41. Radiator cap2. Radiator

3. Oil cooler

1

2

3

Figure 51. Expansion tank 2. Cap

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Adjustments

Adjust Throttle Cable


2. Position throttle control lever all the way to the SLOWposition so it stops against the control panel slot (Fig. 6).

3. Loosen cap screw securing the throttle cable to theswivel enough to loosen the cable (Fig. 7).

4. Hold speed control lever on the injection pumpagainst the low idle stop. Tighten cable to the swivel withcap screw (Fig. 7).

5. Loosen screws securing throttle control lever to thecontrol panel (Fig. 6).

6. Push throttle control lever all the way to the FASTposition. Slide stop plate until it contacts throttle controllever, and tighten screws securing throttle control tocontrol panel (Fig. 6).

Note: Attach spring scale where the throttle cable isattached to the control lever (Fig. 8).

7. If throttle control lever does not stay in position duringoperation, torque lock nut and cap screw used to tightenthe friction disc from 40 to 55 in−lb (4.5 to 6.2 N−m). Theforce required to operate the throttle control lever shouldbe from 30 to 45 lb (133 to 200 N). Torque fasteners asnecessary (Fig. 8).

Figure 61. Throttle control lever2. Screws

3. Stop plate

2

3

1

Figure 71. Throttle cable2. Swivel

3. Speed control lever4. Low idle stop

1

2

3

4

Figure 81. Control lever2. Lock nut3. Cap screw

4. Friction disc5. Spring scale6. Throttle cable

5

3

1

2

4

6


Adjust Alternator/Fan Belt

Condition and tension of all belts should be checked af-ter the first 10 hours of operation and every 100 operat-ing hours thereafter.


2. Open hood.

3. Check belt tension by depressing belt midway be-tween the alternator and crankshaft pulleys with 22 lb.of force (98 N). Belt should deflect 7/16 inch (11 mm). Ifdeflection is incorrect, proceed to step 4. If correct, con-tinue operation.

4. Loosen bolt securing brace to engine and bolt secur-ing alternator to brace.

5. Insert pry bar between alternator and engine. Posi-tion alternator out from engine to increase belt tension.

Figure 91. Belt2. Bolt

3. Bolt4. Alternator

2

1

3

4

6. When proper tension is achieved, tighten alternatorand brace bolts to secure the adjustment.

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Service and Repairs

Change Engine Oil and Filter

Change oil and filter initially after the first 50 hours of op-eration, thereafter change oil every 50 hours and filterevery 100 hours.


2. Remove either drain plug and let oil flow into drainpan. When oil stops flowing, install the drain plug.

3. Remove oil filter. Apply light coat of clean oil to thenew filter seal before screwing filter on. Do not over−tighten filter.

4. Add oil to crankcase (see Check Engine Oil).

Figure 101. Drain plug 2. Drain pan

1 2

Figure 111. Oil filter 2. Alternator

21

Replace Traction Belt


2. Insert nut driver or small piece of pipe onto the endof the torsion spring of the idler pulley.

CAUTIONBe careful when removing or applying tensionfrom or to the torsion spring of the idler pulley.The spring is under heavy load and may causepersonal injury.

3. Push down and forward on the spring end to unhookthe spring from the pump mounting plate.

4. Remove V−belt from the engine flywheel and hy-drostat pulleys.

5. Install new V−belt onto the engine flywheel and hy-drostat pulleys.

Figure 121. Torsion spring2. Idler pulley3. Pump mounting plate

4. V−belt5. Fly wheel pulley6. Hydrostat pulley

1

4

3

2

6

5


7. Push down and back on the spring end to get thespring under the pump mounting plate notch. Then re-lease on the spring slowly to lock it into place.


Bleed Fuel System

1. Park machine on a level surface, lower cutting units,stop engine, and engage parking brake.

2. Make sure fuel tank is at least half full. Gain accessto the engine.


3. Open air bleed screw on the fuel injection pump.

IMPORTANT: The engine should normally start af-ter the above bleeding procedures are followed.However, if the engine does not start, air may betrapped between injection pump and injectors (seeBleed Air from Fuel Injectors).

Figure 131. Air bleed screw 2. Injection pump

1

2

4. Turn key in ignition switch to the ON position. Theelectric fuel pump will begin operation and force air outaround the air bleed screw. Leave key in the ON positionuntil a solid stream of fuel flows out around the air bleedscrew. Tighten screw and turn key to OFF.

Bleed Air from Fuel Injectors

IMPORTANT: This procedure should be used only ifthe fuel system has been purged of air through nor-mal priming procedures (see Bleed Fuel System)and engine will not start.



2. Loosen pipe connection to the No. 1 injector nozzleand holder assembly.

Figure 141. No. 1 injector nozzle2. No. 2 injector (behind

hose)3. No. 3 injector nozzle

3

2

1

3. Move throttle to FAST position.

4. Turn ignition switch to START and watch fuel flowaround connector. Turn key to OFF when solid flow isobserved. Tighten pipe connector securely to the injec-tor nozzle.

5. Repeat steps on the remaining injector nozzles.

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Muffler and Air Cleaner

Figure 151. Air inlet hose (upper)2. Air inlet hose (lower)3. Flange nut4. Flange head screw5. Flat washer6. Cap screw7. Air filter bracket8. Hose clamp

9. Air cleaner body10. Not used11. Hex nut12. Lock washer13. Mounting band assembly14. Muffler15. Muffler bracket16. Not used

17. Plug18. Filter cover19. Burp valve20. Filter element (inside 9 & 18)21. Lock nut22. Compression spring23. Bolt24. Gasket

1

2

3

4

56

7

8

9

4

11

12

13

14

15

8

4

3

3

19

18

17

21

22

23

24


Muffler Removal

CAUTIONThe muffler and exhaust pipe may be hot. Toavoid possible burns, allow the engine and ex-haust system to cool before working on the muf-fler.


2. Open engine hood to gain access to engine.

3. Remove both flange head nuts and screws securingthe muffler plate to the muffler bracket (Fig. 16).

4. Remove four hex nuts and lock washers from the ex-haust manifold studs. Separate muffler flange from theexhaust manifold. Remove muffler from the machine(Fig. 17).

5. Remove gasket from exhaust manifold or mufflerflange. Replace gasket if damaged or torn (Fig. 15).

Muffler Installation

Note: If a new gasket is to be installed, make suremuffler flange and exhaust manifold sealing surfacesare free of debris or damage that may prevent a tightseal.

1. Place gasket on the exhaust manifold (Fig. 15).

2. Secure muffler flange to the exhaust manifold withfour lock washers and hex nuts (Fig. 17).

IMPORTANT: Finger tighten all nuts before secur-ing the muffler plate to the muffler bracket so thereis no preload on the exhaust manifold.

3. Secure muffler plate to the muffler bracket with bothflange head screws and nuts (Fig. 16).

4. Close engine hood.

Figure 161. Flange head nut2. Flange head screw

3. Muffler plate4. Muffler bracket

3

2

4

1

Figure 171. Hex nut & lock washer2. Stud

3. Muffler flange4. Exhaust manifold

21

4 3

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Check Air Filter, Dust Cup, & Burp Valve

The air cleaner body, air filter, dust cup, and burp valveshould be check daily prior to operation.


2. Check air cleaner body for damage that could causepossible air leaks. Make sure dust cup seals completelyto the air cleaner body.

3. Check burp valve and dust cup for damage.

4. Make sure air hoses connecting the air cleaner to theengine and radiator are secured tightly and free of pos-sible air leaks.

Service Air Filter, Dust Cup, & Burp Valve

The air cleaner filter should be serviced ever 50 hours,and more frequently in extreme dusty conditions.


2. Release latches securing air cleaner cover to aircleaner body. Separate cover from body. Clean inside ofair cleaner cover.

3. Gently slide filter out of air cleaner body to reduce theamount of dust dislodged. Avoid knocking filter againstair cleaner body.

4. Inspect filter and discard if damaged. Do not wash orreuse a damaged filter.

IMPORTANT: Do not over service the air filter ele-ment; damage may result.

Washing Method

A. Prepare a solution of filter cleaner and water.Soak filter element about 15 minutes. Refer to direc-tions on filter cleaner carton for complete informa-tion.

B. After soaking filter for 15 minutes, rinse it withclear water. Maximum water pressure must not ex-ceed 40 psi to prevent damage to the filter element.Rinse filter from clean side to dirty side.

C. Dry filter element using warm, flowing air (160oFmaximum), or allow element to air−dry. Do not use alight bulb to dry the filter element because damagecould result.

Figure 181. Latch2. Dust cup

3. Burp valve

2

1

3

Figure 191. Filter element 2. Body

2 1

Compressed Air Method

A. Blow compressed air from inside to the outside ofdry filter element. Do not exceed 100 psi to preventdamage to the element.

B. Keep air hose nozzle at least 2 inches (5 cm) fromthe filter. Move nozzle up and down while rotating thefilter element. Inspect for holes and tears by lookingthrough the filter toward a bright light.

5. Inspect new filter for shipping damage. Check seal-ing end of filter. Do not install a damaged filter.

6. Insert new filter properly into air cleaner body. Makesure filter is sealed properly by applying pressure to out-er rim of filter when installing. Do not press on flexiblecenter of filter.

7. Reinstall cover and secure latches. Make sure coveris positioned with TOP side up.


Water/Fuel Separator


Draining

Drain water and other contaminants from the water/fuelseparator daily.


2. Place a suitable container under the fuel/water sepa-rator.

3. Loosen drain valve on the bottom of the separatorbase.

4. Allow all water and contaminants to drain from theseparator. Tighten drain valve.

Filter Element Replacement


2. Clean area where filter element mates with base andfilter head.

3. Place a suitable container under the fuel/water sepa-rator.

4. Unscrew filter element from base and filter head.Discard element.

5. Lubricate gasket on new filter element and O−ringwith clean diesel fuel.

6. Screw filter element onto base by hand until the gas-ket contacts the mounting surface. Rotate element anadditional 1/2 turn.

7. Screw filter element and base onto filter head byhand until the gasket contacts the mounting surface.Rotate element and base an additional 1/2 turn.

Figure 201. Filter element 2. Drain valve

1

2

Figure 211. Filter head2. Filter element (spin on)3. O−ring4. Base5. Plug

6. O−ring7. O−ring8. Plug9. Pipe plug10. Drain valve

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2

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4

5

6

7

89

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Fuel System

Figure 221. Cap screw2. Fuel tank3. Fuel hose strap4. Cap screw5. Fuel cap6. Tank support7. Fuel gauge8. Grommet9. Connector fitting10. Stand pipe11. R−clamp12. Barb fitting13. Cap screw

14. Flange hex nut15. Lock washer16. Flat washer17. Tee fitting18. Barb fitting19. Barb fitting20. Bushing21. Spacer22. Hose clamp23. Fuel prefilter24. Water/fuel separator25. Fuel fitting26. Flange head screw

27. Flange nut28. Seat support strap29. Foam30. Hex flange head screw31. Fuel hose32. Fuel hose33. Fuel hose34. Fuel hose35. Fuel hose36. Fuel pump37. Hose38. Threaded insert39. Seat support strap

2526

27

28

30

2

3

4

5

7

8 9

10

16

20

21

23

11

13

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24

22

1

12

17

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18

6

4

15

22 31

3222

33

34

2235

35

37

3322

2243

3122

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32

38

36

39


Check Fuel Lines and Connections

Check fuel lines and connections every 400 hours oryearly, whichever comes first.


2. Check lines for deterioration, damage, leaking, orloose connections. Replace hoses, clamps, and con-nections as necessary.


Fuel Tank Removal (Fig. 22)


2. Siphon fuel from the tank into a suitable container.

3. Remove seat and seat support straps from theframe. Disconnect seat switch from the electrical har-ness (Fig. 23).

4. Remove fuel hose strap and both fuel hoses from thefuel tank. Pull tank from the machine (Fig. 24).

Drain and Clean Fuel Tank (Fig. 22)

Drain and clean the fuel tank every 2 years. Also, drainand clean the fuel tank if the fuel system becomes con-taminated or if the machine is to be stored for an ex-tended period.

1. Remove fuel tank from the machine (see Fuel TankRemoval).

2. Flush fuel tank out with clean diesel fuel. Make suretank is free of contaminates and debris.

3. Install fuel tank to the machine (see Fuel Tank Instal-lation).

Fuel Tank Installation (Fig. 22)

1. Position fuel tank into the machine.

2. Connect both fuel hoses to the tank and secure withhose clamps and fuel hose strap.

3. Connect seat switch to the electrical harness. Se-cure seat support straps and seat to the frame with hexflange head screws.

4. Fill fuel tank (see Fill Fuel Tank).

Replace Fuel Prefilter (Fig. 25)

Replace fuel prefilter after every 400 operating hours oryearly, whichever occurs first. The prefilter is located onthe inside of the frame just below the water/fuel separa-tor.


2. Remove cap screw securing the prefilter to frame.

3. Clamp both fuel hoses to the prefilter to prevent fuelspillage.

4. Loosen hose clamps at each end of the prefilter. Pullfuel hoses from the filter.

Figure 231. Seat support strap2. Seat

3. Hex flange head screw4. Electrical harness

1

4

3

2

Figure 241. Fuel hose strap2. Fuel hoses

3. Fuel tank

2

1

3

Figure 251. Cap screw2. Prefilter

3. Hose clamp4. Fuel hose

3

3

4

1

4

2

5. Secure new filter to fuel hoses with hose clamps.Make sure arrow on the side of the prefilter points to-wards the injection pump.

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Radiator

Figure 261. Drain cock valve2. Flange head screw3. Flange nut4. Carriage bolt5. Radiator6. Fan shroud (top)7. Fan shroud (bottom)8. Flange head screw9. Hose clamp10. Radiator frame11. Not used12. Radiator seal13. Flange head screw14. Reservoir bracket

15. Clip spring16. Philips pan head screw17. Pop rivet18. Lock nut19. Lanyard20. Screen frame (lower)21. Magnetic catch22. Oil cooler23. Radiator hose (upper)24. Radiator hose (lower)25. Hose clamp26. Hydraulic tube27. Hydraulic tube28. Hydraulic hose

29. Barb fitting30. Hose clamp31. Cable tie32. Grommet33. Glow plug relay34. Thread forming screw35. Sleeve36. Coolant hose (reservoir)37. Hose38. Lock nut39. Flange nut40. Reservoir41. Radiator cap

31

32

3334

12

3

45

6

7

8

9

10

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

12

13

14

15

15

30

27

2

39

25

9

36

3037

35

40

36

38

41

2

Removal


2. Open and remove engine hood from the machine.

CAUTIONDo not open radiator cap or drain coolant if theradiator or engine is hot. Pressurized, hot cool-ant can escape and cause burns. Ethylene−gycolantifreeze is poisonous. Dispose of coolantproperly, or store it in a properly labeled contain-er away from children and pets.


3. Place a suitable container under the radiator to col-lect the coolant. Open drain cock valve, and completelydrain the radiator.

4. Remove glow plug relay from the radiator assembly.position relay away from the radiator.

Note: Allow hydraulic components and hoses to draininto a suitable container. Plug all hydraulic tubes, hoses,and openings to prevent contamination.

5. Clean and disconnect the following connections:

A. Hydraulic hose and clamp on the lower left cornerof the radiator leading to the hydraulic manifold.

B. Hydraulic tube from the oil cooler at the hydraulicoil filter head. Do not lose O−ring.

6. Remove oil cooler from the radiator assembly usingFigure 26 as a guide.

7. Disconnect following hoses from the radiator:

A. Upper radiator hose to the water pump.

B. Lower radiator hose to the engine block.

C. Coolant hose to the reservoir.

D. Air hose to the air cleaner.

8. Remove reservoir and bracket from the top fanshroud.

9. Remove both fan shrouds from radiator assembly.

10.Remove flange head screws securing the top andbottom of the radiator frame to the radiator. Remove fourcarriage bolts and lock nuts securing the radiator to theradiator frame.

11.Remove oil cooler from the radiator. Pull radiatorcarefully from the radiator frame.

12.Plug any openings to prevent contamination.

Installation

1. Remove any plugs from the oil cooler used during theremoval procedures.

2. Position radiator carefully to the radiator frame.

3. Secure radiator assembly to the radiator frame withfour carriage bolts and lock nuts. Secure top and bottomof radiator to frame with flange head screws.

4. Secure both fan shrouds to the radiator assemblywith flange head screws. Install oil cooler to the radiator.

5. Secure reservoir bracket and reservoir to the top fanshroud with both flange head screws and flange nuts.

6. Connect following hoses to the radiator:

A. Upper radiator hose to the water pump.

B. Lower radiator hose to the engine block.

C. Coolant hose to the reservoir.

D. Air hose to the air cleaner.

7. Remove all plugs from hydraulic tubes, hoses, andopenings used during the removal procedures.

A. Install O−ring to the fitting on the hydraulic oil filterhead. Connect hydraulic tube from the oil cooler tothe filter head.

B. Secure hydraulic hose leading to the hydraulicmanifold with the clamp to the lower left corner of theradiator.

8. Install oil cooler to the radiator assembly using Fig-ure 26 as a guide.

9. Secure glow plug relay to the radiator assembly withboth thread forming screws.

10.Make sure drain cock valve is closed. Fill radiatorwith fluid (see Check Cooling System).

11. Install engine hood to the machine and close.

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Clean Radiator and Oil Cooler (Fig. 4)

The radiator and oil cooler should be checked for dirtand debris daily, and hourly if conditions are extremelydusty and dirty.


CAUTION

If engine has been running, the radiator may behot and cause burns. Work on radiator only whenthe engine and radiator are cool.

2. Open engine hood.

3. Clean engine area thoroughly of all dirt and debris.

4. Remove lower shield. Unsnap oil cooler from springclip. Pivot cooler out.

5. Clean both sides of oil cooler and radiator area thor-oughly with water or compressed air.

6. Pivot oil cooler back and snap into position. Installlower shield. Close hood.

Figure 271. Oil cooler2. Radiator

3. Clip4. Lower shield

2

1

3

4

Figure 281. Oil cooler2. Radiator

3. Clip

12

3



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Engine

Figure 291. Kubota engine2. Engine mount3. Engine mount4. Flange nut5. Cap screw6. Hex flange head screw7. External lock washer8. Lock nut9. Washer10. Machine screw11. Hardened washer12. Cap screw13. Engine mounting bracket (front)14. Engine mounting bracket (LH)

15. Engine mounting bracket (RH)16. Cap screw17. Pulley18. Bolt19. Flange nut20. Not used21. Throttle & filter support22. Throttle cable filter23. Lock nut24. Slotted hex head screw25. Throttle cable clamp26. Cap screw27. R−clamp

28. Lock nut29. Lock washer30. Flat washer31. Flange head screw32. Flat washer33. R−clamp34. Lock washer35. Hex nut36. Wire harness37. Hose clamp38. Radiator hose (upper)39. Radiator hose (lower)40. Spacer

3234

35

36

37

38

39

1

2

3

4

5

6

7

8

9

10

16

1718

19

21

2223

24

25 26

27

28

29

30

11

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14

15 37

11

11

40

11

4

8

9

2

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1611

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26

25

33

8

9

5

Removal


2. Open and remove engine hood from the machine.Slide seat all the way forward.

3. Disconnect air hose from the air cleaner and radiator.Remove air cleaner from the engine.

4. Disconnect both battery cables at the battery (seeBattery Service in Chapter 5 − Electrical system).

5. Remove muffler from the exhaust manifold and muf-fler bracket (see Muffler Removal).

6. Drain radiator from the drain cock valve into a suit-able container (see Radiator Removal). Disconnectcoolant hoses from the water pump and engine block.

7. Remove reservoir and bracket from the top fanshroud. Remove top fan shroud from the radiator (seeRadiator Removal).


8. Disconnect wire harness and electrical wires fromthe following:

A. Engine grounds to the battery and wire harness(Fig. 30).

B. Glow plug bus and fuel stop solenoid (Fig. 31).

C. High temperature warning switch (Fig. 32).

D. High temperature shutdown switch, alternator,and low oil pressure switch (Fig. 33).

9. Disconnect throttle cable from the support and swiv-el on the speed control lever (Fig. 30).

10.Disconnect fuel hose from the water/fuel separatorFig. 30) and front injector nozzle (Fig. 31).

11.Remove traction control cable from the neutral armassembly on the piston pump. Remove all hydraulichoses from the piston an gear pumps (see Piston PumpRemoval in Chapter 4− Hydraulic System).

12.Remove cable ties securing the wire harness to thefront lift tab and other engine parts (Fig. 31). Connecthoist or lift to the front and rear lift tabs (Fig. 31 and 32).

CAUTIONMake sure lift or hoist can support the totalweight of the engine before removing the capscrews from the rear bracket and engine.

13.Remove flange nut, cap screw, and washer securingthree engine mounts to the engine mounting brackets.

CAUTIONOne person should operate lift or hoist while theother person guides the engine out of the ma-chine.

IMPORTANT: Make sure not to damage the engine,fuel and hydraulic lines, electrical harness, or otherparts while removing the engine.

14.Remove engine slowly from the machine.

15.Separate hydrostat and pump mount plate from theengine as follows:

Note: The cap screw next to the torsion spring doesnot have a flat washer with it.

A. Remove traction belt from the engine fly wheeland hydrostat pulleys (see Traction Belt Replace-ment).

Figure 301. Battery ground2. Wire harness ground3. Throttle cable

4. Support bracket5. Speed control lever6. Fuel hose

2

1

3

4

65

Figure 311. Glow plug wire2. Fuel stop solenoid

3. Fuel hose4. Front lift tab

123

4

Figure 321. Temp. warning switch 2. Rear lift tab

21

Figure 331. Temp. shutdown switch2. Alternator

3. Low oil press. switch

1

3

2

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B. Remove five cap screws, four washers, and fivespacers securing the pump mount plate to the en-gine (Fig. 34).

C. Remove four cap screws and hardened washerssecuring the right engine mounting bracket and hy-drostat to the engine.

Installation

1. Install hydrostat and pump mount plate to the engineas follows:

A. Secure right engine mounting bracket and hy-drostat to the engine four hardened washers and capscrews.

Note: Do not install flat washer with cap screw nearthe torsion spring to prevent the spring from binding.

B. Secure pump mount plate to the engine with fivespacers, four washers, and five cap screws (Fig. 34).

C. Install traction belt to the engine fly wheel and hy-drostat pulleys (see Traction Belt Replacement).

2. Connect hoist or lift to the front and rear lift tabs (Fig.31 and 32).

CAUTIONOne person should operate lift or hoist while theother person guides the engine into the machine.

IMPORTANT: Make sure not to damage the engine,fuel and hydraulic lines, electrical harness, or otherparts while installing the engine.

3. Position engine slowly into the machine.

4. Secure all three engine mounts to the engine mount-ing brackets with cap screw, washer, and flange nut.

5. Secure wire harness to the front lift tab and the en-gine with cable ties (Fig. 31).

6. Install all hydraulic hoses to the piston and gearpumps. Install traction control cable to the neutral armassembly on the piston pump (see Piston Pump Installa-tion in Chapter 4− Hydraulic System).

7. Connect fuel hose to the water/fuel separator (Fig.30) and front injector nozzle (Fig. 31).

8. Install top fan shroud to the radiator. Install reservoirand bracket to the top fan shroud (see Radiator Installa-tion).

Figure 341. Cap screw2. Spacer

3. Torsion spring4. Pump mount plate

2

2

2

1

3

1

4

9. Connect wire harness and electrical wires to the fol-lowing:

A. Engine grounds to the battery and wire harness(Fig. 30).

B. Glow plug bus and fuel stop solenoid (Fig. 31).

C. High temperature warning switch (Fig. 32).

D. High temperature shutdown switch, alternator,and low oil pressure switch (Fig. 33).

10.Connect coolant hoses to the water pump and en-gine block. Make sure drain cock valve is closed. Fill ra-diator with coolant (see Check Cooling System).

11. Install muffler to the exhaust manifold and mufflerbracket (see Muffler Installation).

12.Connect throttle cable to the support and swivel onthe speed control lever (Fig. 30).

13.Connect both battery cables at the battery (see Bat-tery Service in Chapter 5 − Electrical system).

14.Install air cleaner to the engine. Connect air hose toair cleaner and radiator.

15.Adjust throttle cable (see Adjust Throttle Cable).

16.Bleed fuel system (see Bleed Fuel System).

17.Install engine hood to the machine. Close and latchhood.

18.Adjust traction drive for neutral (see Adjust tractionDrive for Neutral in Chapter 4− Hydraulic System).

Rev. DReelmaster 3100−D Hydraulic System (Rev. C)Page 4 − 1

Chapter 4

Hydraulic System

Table of ContentsSPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 3. . . . . . . . . . . . . . . . . . . . .

Hydraulic Hoses 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Fitting Installation 3. . . . . . . . . . . . . . . . . . . Towing Traction Unit 5. . . . . . . . . . . . . . . . . . . . . . . . . Check Hydraulic System Fluid 5. . . . . . . . . . . . . . . . . Relieving Hydraulic System Pressure 6. . . . . . . . . . . Traction Circuit (Closed Loop) Component Failure 6

HYDRAULIC SCHEMATICS 8. . . . . . . . . . . . . . . . . . . . Reelmaster 3100−D (Model 03200) 8. . . . . . . . . . . . Reelmaster 3100−D (Model 03201) 9. . . . . . . . . . . . Reelmaster 3100−D (Model 03206) 9.1. . . . . . . . . . . Reelmaster 3100−D (Model 03207) 9.2. . . . . . . . . . .

HYDRAULIC FLOW DIAGRAMS 10. . . . . . . . . . . . . . . Traction Circuits 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . Reel Circuit 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift Circuit (Up) 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift Circuit (Down) 16. . . . . . . . . . . . . . . . . . . . . . . . . . . Sidewinder Circuit 18. . . . . . . . . . . . . . . . . . . . . . . . . . Steering Circuit 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Pressure Test Kit 22. . . . . . . . . . . . . . . . . . . Hydraulic Tester (Pressure and Flow) 22. . . . . . . . . . Hydraulic Test Fitting Kit 23. . . . . . . . . . . . . . . . . . . . . Measuring Container 23. . . . . . . . . . . . . . . . . . . . . . . . O−Ring Kit 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel Hub Puller 24. . . . . . . . . . . . . . . . . . . . . . . . . . . High Pressure Hydraulic Oil Filter 24. . . . . . . . . . . . .

TROUBLESHOOTING 26. . . . . . . . . . . . . . . . . . . . . . . . TESTING 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Traction Circuit Working Pressure Test 30. . . . . . . . Piston Pump (P3) Flow & Traction

Relief Pressure Test 32. . . . . . . . . . . . . . . . . . . . . Charge Relief Valve Pressure Test 34. . . . . . . . . . . . Gear Pump (P2) Flow Test 36. . . . . . . . . . . . . . . . . . . Wheel Motor Efficiency Test 38. . . . . . . . . . . . . . . . . . Reel Circuit Pressure Test 40. . . . . . . . . . . . . . . . . . . Gear Pump (P1) Flow Test 42. . . . . . . . . . . . . . . . . . . Manifold Relief Valve (R1) Pressure Test 44. . . . . . . Reel Motor Efficiency − Case Drain Test 46. . . . . . . Reel Motor Cross−over Relief Pressures Test 48. . Lift and Steering Control Valve Relief

Pressure Test 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Control Valve Test 54. . . . . . . . . . . . . . . . . .

ADJUSTMENTS 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust Traction Drive for Neutral 56. . . . . . . . . . . . . . Adjust Manifold Relief Valve (R1) 57. . . . . . . . . . . . .

SERVICE AND REPAIRS 58. . . . . . . . . . . . . . . . . . . . . General Precautions for Removing and

Installing Hydraulic System Components 58. . . Change Hydraulic Fluid 59. . . . . . . . . . . . . . . . . . . . . . Replace Hydraulic Oil Filter 60. . . . . . . . . . . . . . . . . . Replace Traction Belt 61. . . . . . . . . . . . . . . . . . . . . . . Check Hydraulic Lines and Hoses 61. . . . . . . . . . . . . Flush Hydraulic System 62. . . . . . . . . . . . . . . . . . . . . . Charge Hydraulic System 63. . . . . . . . . . . . . . . . . . . . Hydraulic Tank and Hydraulic Oil Filter 64. . . . . . . . . Front Wheel Motors 66. . . . . . . . . . . . . . . . . . . . . . . . . Rear Wheel Motor 68. . . . . . . . . . . . . . . . . . . . . . . . . . Wheel Motor Service 70. . . . . . . . . . . . . . . . . . . . . . . . Reel Motors 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reel Motor Service 74. . . . . . . . . . . . . . . . . . . . . . . . . . Oil Cooler 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Manifold 77. . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Manifold Service 78. . . . . . . . . . . . . . . . . . . Control Valve (Model 03200) 84. . . . . . . . . . . . . . . . . Control Valve Service (Model 03200) 86. . . . . . . . . . Control Valve (Model 03201) 90. . . . . . . . . . . . . . . . . Control Valve Service (Model 03201) 92. . . . . . . . . . Piston Pump 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Pump Service 100. . . . . . . . . . . . . . . . . . . . . . . Piston Pump Crush Ring Replacement 101. . . . . . . Sidewinder (Model 03201) 102. . . . . . . . . . . . . . . . . . Steering Control Valve 104. . . . . . . . . . . . . . . . . . . . . . Steering Control Valve Service (Serial Numbers

90101 to 230999999) 106. . . . . . . . . . . . . . . . . . . . . Steering Control Valve Service (Serial Numbers

240000001 and up) 107. . . . . . . . . . . . . . . . . . . . . . . Gear Pump 108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Pump Service 110. . . . . . . . . . . . . . . . . . . . . . . . Front Lift Cylinder 114. . . . . . . . . . . . . . . . . . . . . . . . . . Rear Lift Cylinder 116. . . . . . . . . . . . . . . . . . . . . . . . . . Lift Cylinder Service 118. . . . . . . . . . . . . . . . . . . . . . . . Steering Cylinder 120. . . . . . . . . . . . . . . . . . . . . . . . . . Steering Cylinder Service 122. . . . . . . . . . . . . . . . . . .

ROSS TORQMOTOR TM MG, MF, ME, AND MJ SE-RIES SERVICE PROCEDURE

EATON MEDIUM DUTY PISTON PUMP REPAIR IN-FORMATION MODEL 70160 VARIABLE DISPLACE-MENT PISTON PUMP

ROSS HYDRAGUIDE TM HYDROSTATIC STEERINGSYSTEM HGF SERIES SERVICE PROCEDURE

SAUER/DANFOSS STEERING UNIT TYPE OSPMSERVICE MANUAL

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Reelmaster 3100−DHydraulic System (Rev. C) Page 4 − 2

Specifications

Item Description

Piston Pump (Hydrostat) Variable displacement piston pumpMaximum Operating Pressure 3000 PSI (207 bar)Charge Pressure 100 to 150 PSI (6.9 to 10.0 bar)Traction Circuit Relief Pressure (Forward Only) 3000 PSI (207 bar)

Gear Pump 2 stage positive displacement gear type pumpMaximum Operating Pressure 3000 PSI (207 bar)

Wheel Motors (Front) Orbital rotor motorMaximum Operating Pressure 2000 PSI (138 bar)

Wheel Motors (Rear) Orbital rotor motorMaximum Operating Pressure 3000 PSI (207 bar)

Hydraulic Manifold Relief Pressure 3000 PSI (207 bar)

Reel Motor Gear motorCross−over Relief Pressure 1500 PSI (103 bar)Maximum Operating Pressure 2250 PSI (155 bar)

Steering Control Valve Distributor valve with rotary meterMaximum Operating Pressure 1800 PSI (124 bar)Implement (Steering and Lift) Relief Valve Pressure 1000 PSI (69 bar)

Hydraulic Filter 10 Micron spin−on cartridge type

Hydraulic Oil See Check Hydraulic System Fluid in General Information section

Hydraulic Reservoir 3.5 gal. U.S. (13.2 L)

Reelmaster 3100−D Hydraulic System (Rev. C)Page 4 − 3

General Information

Hydraulic Hoses

Hydraulic hoses are subject to extreme conditions suchas pressure differentials during operation and exposureto weather, sun, chemicals, very warm storage condi-tions, or mishandling during operation or maintenance.These conditions can cause damage or premature dete-rioration. Some hoses are more susceptible to theseconditions than others. Inspect the hoses frequently forsigns of deterioration or damage.

When replacing a hydraulic hose, be sure that the hoseis straight (not twisted) before tightening the fittings.This can be done by observing the imprint on the hose.Use two wrenches; hold the hose straight with one andtighten the hose swivel nut onto the fitting with the other.

WARNINGBefore disconnecting or performing any workon hydraulic system, relieve all pressure insystem. Stop engine; lower or support boxand/or other attachment(s).

Keep body and hands away from pin hole leaksor nozzles that eject hydraulic fluid under highpressure. Use paper or cardboard, not hands,to search for leaks. Hydraulic fluid escapingunder pressure can have sufficient force topenetrate the skin and cause serious injury. Iffluid is injected into the skin, it must be surgi-cally removed within a few hours by a doctorfamiliar with this type of injury. Gangrene mayresult from such an injury.

Hydraulic Fitting Installation

O−Ring Face Seal

1. Make sure both threads and sealing surfaces arefree of burrs, nicks, scratches, or any foreign material.

2. Make sure the O−ring is installed and properlyseated in the groove. It is recommended that the O−ringbe replaced any time the connection is opened.

3. Lubricate the O−ring with a light coating of oil.

4. Put the tube and nut squarely into position on theface seal end of the fitting and tighten the nut until fingertight.

5. Mark the nut and fitting body. Hold the body with awrench. Use another wrench to tighten the nut to the cor-rect flats from finger tight (F.F.F.T.). The markings on thenut and fitting body will verify that the connection hasbeen tightened.

Size F.F.F.T.

4 (1/4 in. nominal hose or tubing) 0.75 + 0.256 (3/8 in.) 0.75 + 0.258 (1/2 in.) 0.75 + 0.2510 (5/8 in.) 1.00 + 0.2512 (3/4 in.) 0.75 + 0.2516 (1 in.) 0.75 + 0.25

Figure 1

Nut

Sleeve

Seal

Body

Figure 2

Mark Nutand Body

FinalPosition

Extend LineInitialPosition

Finger Tight After Proper Tightening

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SAE Straight Thread O−Ring Port − Non−adjustable


2. Always replace the O−ring seal when this type of fit-ting shows signs of leakage.


4. Install the fitting into the port and tighten it down fulllength until finger tight.

5. Tighten the fitting to the correct flats from finger tight(F.F.F.T.).

Size F.F.F.T.


Figure 3

O−Ring

SAE Straight Thread O−Ring Port − Adjustable


2. Always replace the O−ring seal when this type of fit-ting shows signs of leakage.


4. Turn back the jam nut as far as possible. Make surethe back up washer is not loose and is pushed up as faras possible (Step 1).

5. Install the fitting into the port and tighten finger tightuntil the washer contacts the face of the port (Step 2).

6. To put the fitting in the desired position, unscrew it bythe required amount, but no more than one full turn(Step 3).

7. Hold the fitting in the desired position with a wrenchand turn the jam nut with another wrench to the correctflats from finger tight (F.F.F.T.) (Step 4).

Size F.F.F.T.


Figure 4

Lock Nut

Back−up Washer

O−Ring

Figure 5

Step 3Step 1

Step 2 Step 4


Towing Traction Unit

In case of emergency, the Reelmaster can be towed fora short distance. However, Toro does not recommendthis as a standard procedure.

IMPORTANT: Do not tow the machine faster than 2 to3 mph because drive system may be damaged. If ma-chine must be moved a considerable distance (morethan a few feet), transport it on a truck or trailer.

1. Locate by−pass valve on pump and rotate it 90o.

2. Before starting engine, close by−pass valve by rotat-ing it 90o. Do not start engine when valve is open.

1. Hydrostat 2. By−pass valve

Figure 6

1

2

Check Hydraulic System Fluid

The hydraulic system that drives the reels is designedto operate on anti−wear hydraulic fluid. The machinesreservoir is filled at the factory with approximately 3.5gallons (13.2 liters) of DTE 15M hydraulic fluid. Checklevel of the hydraulic fluid before the engine is firststarted and daily thereafter.

IMPORTANT: Use only types of hydraulic fluidsspecified. Other fluids could cause system damage.

NOTE: A red dye additive for the hydraulic system fluidis available in 2/3 oz. bottles. One bottle is sufficient for4 to 6 gallons (15 to 23 liters) of hydraulic fluid. OrderPart No. 44−2500 from your Authorized Toro Distributor.

1. Position machine on a level surface, lower cuttingunits, and stop engine.

2. Clean area around filler neck and cap of the hydraulictank. Remove cap from the filler neck.

3. Remove dipstick from the filler neck and wipe it witha clean rag. Insert dipstick into the filler neck; then re-move it and check level of the fluid. Fluid level should bewithin 1/4 inch (6 mm) of the mark on the dipstick.

4. If level is low, add appropriate fluid to raise the levelto full mark.

5. Install dipstick and cap onto the filler neck.

1. Hydraulic Tank 2. Cap

Figure 7

1

2

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Rev. D Reelmaster 3100−DHydraulic System (Rev. C) Page 4 − 6

Relieving Hydraulic System Pressure

Before disconnecting or performing any work on the Re-elmaster 3100−D hydraulic system, all pressure in thehydraulic system must be relieved. Park machine on alevel surface with the cutting units lowered and off. Turnkey switch to OFF and allow engine to stop.

To relieve hydraulic pressure in traction circuit, movetraction lever to both forward and reverse directions. Torelieve hydraulic pressure in steering and lift circuits, ro-tate steering wheel in both directions.

To relieve cutting system pressure, turn key switch toON (engine not running). Move PTO switch to engage

which will energize the solenoid valve on hydraulic man-ifold to relieve circuit pressure. Move PTO switch to dis-engage, return key switch to OFF and remove key fromthe ignition switch.

NOTE: Moving steering wheel with engine off may un-seat implement relief valve. If steering or lift circuits ap-pear weak or inoperative after machine is returned toservice, repeat relieving hydraulic system pressure pro-cedure.

Traction Circuit (Closed Loop) Component Failure

The Reelmaster 3100−D traction circuit is a closed loopsystem that includes the hydrostat and two (2) wheelmotors. If a component in the traction circuit should fail,debris and contamination from the failed component willcirculate throughout the traction circuit. This contamina-tion can damage other components in the circuit so itmust be removed to prevent additional component fail-ure.

If a component failure occurs in the traction circuit, it iscritical that the entire traction circuit be disassembled,drained and thoroughly cleaned to ensure that all con-tamination is removed from the circuit. If any debris re-mains in the traction circuit and the machine is operated,the debris can cause additional component failure.

An additional step for removing all traction circuit con-tamination would be to temporarily install a high pres-sure hydraulic oil filter (see Special Tools) into the circuit.The filter could be used when connecting hydraulic testgauges in order to test traction circuit components or af-ter replacing a failed traction circuit component (e.g. hy-drostat or wheel motor). The filter will ensure thatcontaminates are removed from the closed loop andthus, do not cause additional component damage.

Once the filter has been placed in the traction circuit,place the machine on jack stands and operate the trac-tion circuit to allow oil flow through the circuit. With themachine raised off the ground, the traction circuit willhave maximum oil flow at minimum pressure to mini-mize damage from any remaining contamination. Thefilter will remove contamination from the closed looptraction circuit during operation. Remove the filter fromthe machine after contamination has been removedfrom the traction circuit.

IMPORTANT: When operating the traction systemwith the high pressure filter installed, make surethat flow is always directed through the filter (e.g. donot press the traction pedal in the reverse directionif the filter is placed for forward direction flow). Ifflow is reversed, debris from the filter will re−enterthe traction circuit.



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P P

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TF

OR

WA

RD

TR

AC

TIO

N W

HE

EL

MO

TO

RS

3000

psi

FC

1R

EE

L S

PE

ED

CO

NT

OLL

ER

LC1

LOG

ICV

ALV

E

MD

1B

AC

KLA

PP

ING

VA

LVE

RE

EL

ON

−O

FF

VA

LVE

RE

EL

RE

LIE

F30

00 p

si

S1

R1

G1

T2

D1

M1

M2

MA

NIF

OLD

BLO

CK

T1

P1

LV

LC2

CH

G

CF

CR

ST

LEF

T

RIG

HT

RE

AR

F R

AB

OU

TIN

ST

EE

RIN

G

PO

WE

RS

TE

ER

ING

VA

LVE

IN

OU

T

AU

X

1000

psi

G2

PLG

NO

TE

: ON

MA

CH

INE

S W

ITH

SE

RIA

L N

UM

BE

RS

BE

LOW

2300

0000

0, IN

ITIA

L R

EE

LM

OT

OR

IN C

UT

TIN

G C

IRC

UIT

MO

TO

R A

ND

FIN

AL

MO

TO

R IS

RE

AR

(S

HO

WN

).

SE

RIA

L N

UM

BE

RS

AB

OV

E23

0000

000,

INIT

IAL

RE

EL

MO

TO

R IS

RE

AR

MO

TO

RA

ND

FIN

AL

RE

EL

MO

TO

RIS

LE

FT

FR

ON

T (

NO

T S

HO

WN

)

IS F

RO

NT

LE

FT

RE

EL

ON

MA

CH

INE

S W

ITH

FR

ON

T

FR

ON

T


D

M4

M5

DU

MP

VA

LVE

P3

HY

DR

OS

TAT

OIL

FIL

TE

R

P1

P2

EN

GIN

E R

PM

GE

AR

PU

MP

L R

V1

LOW

ER

PO

RT

UP

PE

RP

OR

T

M6

INT

ER

NA

L C

AS

E D

RA

IN

100

to 1

50 p

si

ST

RA

INE

R

OIL

CO

OLE

R

TO

P P

OR

T

FORWARD

TR

AC

TIO

N W

HE

EL

MO

TO

RS

3000

psi

FC

1

RE

EL

SP

EE

DC

ON

TR

OLL

ER

LC1

LOG

IC

MD

1B

AC

KLA

PP

ING

VA

LVE

RE

EL

ON

−O

FF

VA

LVE

RE

EL

RE

LIE

F30

00 p

si

S1

R1

G1

T2

D1

M1

M2

MA

NIF

OLD

BLO

CK

T1

P1

LV

LC2

CH

G

CF

CR

ST

LEF

T F

RO

NT

RIG

HT

FR

ON

T

RE

AR

FR

ON

T

RE

AR

SID

EW

IND

ER

AB

C

OU

T

IN

STEERING

PO

WE

RS

TE

ER

ING

VA

LVE

IN

OU

T

AU

X

1000

psi

G2

PLU

G

VA

LVE

RE

EL

MO

TO

R

RE

EL

MO

TO

R

RE

EL

MO

TO

R

Hyd

rau

lic S

chem

atic

Ree

lmas

ter

3100

−D

(M

odel

032

01)

All

sole

no

ids

are

sho

wn

as

de−

ener

giz

ed

(OP

TIO

NA

L)

LIF

T

LIF

TC

YLI

ND

ER

CY

LIN

DE

R

CY

LIN

DE

R

2−S

PO

OL

VA

LVEN

OT

E: O

N M

AC

HIN

ES

WIT

HS

ER

IAL

NU

MB

ER

S B

ELO

W23

0000

000,

INIT

IAL

RE

EL

MO

TO

R IN

CU

TT

ING

CIR

CU

IT

MO

TO

R A

ND

FIN

AL

MO

TO

R IS

RE

AR

(S

HO

WN

).

SE

RIA

L N

UM

BE

RS

AB

OV

E23

0000

000,

INIT

IAL

RE

EL

MO

TO

R IS

RE

AR

MO

TO

RA

ND

FIN

AL

RE

EL

MO

TO

RIS

LE

FT

FR

ON

T (

NO

T S

HO

WN

)

IS F

RO

NT

LE

FT

RE

EL

ON

MA

CH

INE

S W

ITH

Hyd

rau

lic

Syste

m

Rev. D9.1 Reelmaster 3100−DHydraulic System Page 4 −

Hyd

rau

lic S

chem

atic

Ree

lmas

ter

3100

−D

(M

odel

032

06)

All

sole

no

ids

are

sho

wn

as

de−

ener

giz

ed

MA

NIF

OLD

BLO

CK

Rev. D9.2Reelmaster 3100−D Hydraulic SystemPage 4 −

Hyd

rau

lic S

chem

atic

Ree

lmas

ter

3100

−D

(M

odel

032

07)

All

sole

no

ids

are

sho

wn

as

de−

ener

giz

ed

MA

NIF

OLD

BLO

CK

Hyd

rau

lic

Syste

m


Hydraulic Flow Diagrams

D

M4

M5

DU

MP

VA

LVE

P3

HY

DR

OS

TAT

OIL

FIL

TE

R

P1

P2

EN

GIN

E

RP

M

GE

AR

PU

MP

L R

V1

LOW

ER

PO

RT

UP

PE

RP

OR

T

M6

INT

ER

NA

L C

AS

E D

RA

IN

100

to 1

50 p

si

ST

RA

INE

R

OIL

CO

OLE

R

TO

P P

OR

T

FORWARD

TR

AC

TIO

N W

HE

EL

MO

TO

RS

3000

psi

FC

1

RE

EL

SP

EE

DC

ON

TR

OLL

ER

LC1

LOG

IC

MD

1B

AC

KLA

PP

ING

VA

LVE

RE

EL

ON

−O

FF

VA

LVE

RE

EL

RE

LIE

F30

00 p

siS1

R1

G1

T2

D1

M1

M2

MA

NIF

OLD

BLO

CK

T1

P1

LV

LC2

CH

G

CF

CR

ST

LEF

T F

RO

NT

RIG

HT

FR

ON

T

RE

AR

FR

ON

T

RE

AR

SID

EW

IND

ER

AB

C

OU

TIN

STEERING

PO

WE

RS

TE

ER

ING

VA

LVE

IN

OU

T

AU

X

1000

psi

G2

PLU

G

VA

LVE

RE

EL

MO

TO

R

RE

EL

MO

TO

R

RE

EL

MO

TO

R

(OP

TIO

NA

L)

LIF

T

LIF

TC

YLI

ND

ER

CY

LIN

DE

R

CY

LIN

DE

R

2−S

PO

OL

VA

LVE

Trac

tio

n C

ircu

its

(Fo

rwar

d)

Hig

h P

ress

ure

Low

Pre

ssur

e (

Cha

rge)

Ret

urn

or

Suc

tion

Flo

w

Ree

lmas

ter

310

0−D


Traction Circuits

Forward

The traction circuit of the hydraulic system consists of ahydrostat connected in a closed loop circuit to three or-bital vane wheel motors.

The engine drives traction pump (P3) indirectly throughpulleys and a V−belt. The traction pump is a variable dis-placement piston pump. The traction pedal connectsthrough a cable to the trunnion shaft and swash plate ofthe pump. With the engine running and the traction ped-al in the neutral position, P3 supplies no flow to thewheel motors. When the traction pedal is pressed to theforward position, the cable from the pedal positions theswash plate in the traction pump so oil flows out of thelower port. Oil flow out of the lower port goes to the wheelmotors and turns them in the forward direction. Oil flow-ing out of the wheel motors returns to upper port of thehydrostat and is continuously pumped out of the lowerport.

The rear wheel motor has a small check valve across itsports that allows the rear motor to over run during tightturns in the forward direction.

The traction pump uses a small amount of hydraulic fluidfor internal lubrication. Fluid is designed to leak acrosspump parts into the case drain. This leakage results in

the loss of hydraulic fluid from the closed loop circuit thatmust be replenished.

The charge pump (P2) is a fixed displacement gearpump. It is driven directly off the traction pump. Thepump replenishes the closed loop circuit with fluid fromthe hydraulic tank. The charge relief valve supplies suffi-cient head so that charge pump flow is guided to the lowpressure side of the traction circuit through one of twocheck valves. Pump flow in excess of replenishment re-quirements is relieved through the charge relief valveback to the gear pump inlet.

Reverse

The traction circuit operates essentially the same in re-verse as it does in forward. However, there are a few dif-ferences in operation.

When the reverse traction pedal is depressed, the cablefrom the pedal positions the swash plate in the tractionpump so oil flows out of the upper port. Oil flow out of theupper port goes to the wheel motors and turns them inthe reverse direction. Oil flowing out of the wheel motorsreturns to the lower port of the hydrostat and is continu-ously pumped out of the upper port. Oil by−passes therear motor in reverse because of the check valve insidethe rear motor.

Hyd

rau

lic

Syste

m


D

M4

M5

DU

MP

VA

LVE

P3

HY

DR

OS

TAT

OIL

FIL

TE

R

P1

P2

EN

GIN

E R

PM

GE

AR

PU

MP

L R

V1

LOW

ER

PO

RT

UP

PE

RP

OR

T

M6

INT

ER

NA

L C

AS

E D

RA

IN

100

to 1

50 p

si

ST

RA

INE

R

OIL

CO

OLE

R

TO

P P

OR

T

FORWARD

TR

AC

TIO

N W

HE

EL

MO

TO

RS

3000

psi

FC

1

RE

EL

SP

EE

DC

ON

TR

OLL

ER

LC1

LOG

IC

MD

1B

AC

KLA

PP

ING

VA

LVE

RE

EL

ON

−O

FF

VA

LVE

RE

EL

RE

LIE

F30

00 p

siS1

R1

G1

T2

D1

M1

M2

MA

NIF

OLD

BLO

CK

T1

P1

LV

LC2

CH

G

CFCR

ST

LEF

T F

RO

NT

RIG

HT

FR

ON

T

RE

AR

FR

ON

T

RE

AR

SID

EW

IND

ER

AB

C

OU

TIN

STEERING

PO

WE

RS

TE

ER

ING

IN

OU

T

AU

X

1000

psi

G2

PLU

G

VA

LVE

RE

EL

MO

TO

R

RE

EL

MO

TO

R

RE

EL

MO

TO

R

(OP

TIO

NA

L)

LIF

T

LIF

TC

YLI

ND

ER

CY

LIN

DE

R

CY

LIN

DE

R

2−S

PO

OL

VA

LVE

Ree

l Cir

cuit

Hig

h P

ress

ure

Low

Pre

ssur

e (

Cha

rge)

Ret

urn

or

Suc

tion

Flo

w

Ree

lmas

ter

310

0−D

INT

ER

NA

L C

AS

E D

RA

IN

VA

LVE


Reel Circuit

Mow

The gear pump (P1) is directly coupled to the the hydros-tat which is driven by the engine. Taking its suction di-rectly from the hydraulic tank, the gear pump supplies oilflow to the manifold block and to the reel motors.

Solenoid valve (S1) is de−energized with the enginerunning when either the reels on/off switch is OFF, thecutting units are up, or the transport/mow switch is inTRANSPORT. S1 by−passes flow from the reel motorsdirectly to the hydraulic reservoir.

Solenoid valve (S1) is energized with the engine runningwhen the reels on/off switch is ON, the cutting units aredown, and the transport/mow switch is in MOW. Flow isdiverted to the reel motors.

Oil flows from port (P1) across the logic cartridge valve(LC1). The logic cartridge valve maintains a pressuredifferential of 75 PSI (5.2 bar) across the speed controlvalve. Any excess flow above what the speed controlvalve is set for, is by−passed to the reservoir through thelogic cartridge valve. With the backlapping valve (MD1)in the mow position, oil flows through the valve, out port(M1), and to reel motors that are connected in series.

On machines with serial numbers below 230000000(Fig. 8), oil flows through the left front, right front, andthen rear reel motors as it turns the motors in the mowdirection. The oil then returns into manifold block port(M2) and then to the hydraulic tank.

On machines with serial numbers above 230000000(Fig. 9), oil flows through the rear, right front, and thenleft front reel motors as it turns the motors in the mowdirection. The oil then returns into manifold block port(M2) and then to the hydraulic tank.

Backlap

Backlapping operation is the same as mowing opera-tion, except for the position of the backlap valve (MD1).When the backlap valve is in the backlap position onmachines with serial numbers below 230000000, oilflows through the rear, right front, and then left front reelmotors (Fig. 8) as it turns the motors in the backlap direc-tion.

On machines with serial numbers above 230000000(Fig. 9), when the backlap valve is in the backlap posi-tion, oil flows through the left front, right front, and thenrear reel motors

Figure 8

TO MANIFOLD

LEFT

RIGHT

REAR

FRONT

FRONTM2 PORT

TO MANIFOLDD1 PORT

TO MANIFOLDM1 PORT

REEL CIRCUIT SCHEMATIC FOR MACHINESWITH SERIAL NUMBERS BELOW 230000000

Figure 9

TO MANIFOLD

LEFT

RIGHT

REAR

FRONT

FRONTM2 PORT

TO MANIFOLDD1 PORT

TO MANIFOLDM1 PORT

REEL CIRCUIT SCHEMATIC FOR MACHINESWITH SERIAL NUMBERS ABOVE 230000000

Hyd

rau

lic

Syste

m


D

M4

M5

DU

MP

VA

LVE

P3

HY

DR

OS

TAT

OIL

FIL

TE

R

P1

P2

EN

GIN

E R

PM

GE

AR

PU

MP

L R

V1

LOW

ER

PO

RT

UP

PE

RP

OR

T

M6

INT

ER

NA

L C

AS

E D

RA

IN

100

to 1

50 p

si

ST

RA

INE

R

OIL

CO

OLE

R

TO

P P

OR

T

FORWARD

TR

AC

TIO

N W

HE

EL

MO

TO

RS

3000

psi

FC

1

RE

EL

SP

EE

DC

ON

TR

OLL

ER

LC1

LOG

IC

MD

1B

AC

KLA

PP

ING

VA

LVE

RE

EL

ON

−O

FF

VA

LVE

RE

EL

RE

LIE

F30

00 p

siS1

R1

G1

T2

D1

M1

M2

MA

NIF

OLD

BLO

CK

T1

P1

LV

LC2

CH

G

CFCR

ST

LEF

T F

RO

NT

RIG

HT

FR

ON

T

RE

AR

FR

ON

T

RE

AR

SID

EW

IND

ER

AB

C

OU

TIN

STEERING

PO

WE

RS

TE

ER

ING

VA

LVE

IN

OU

T

AU

X

1000

psi

G2

PLU

G

VA

LVE

RE

EL

MO

TO

R

RE

EL

MO

TO

R

RE

EL

MO

TO

R

(OP

TIO

NA

L)

LIF

T

LIF

TC

YLI

ND

ER

CY

LIN

DE

R

CY

LIN

DE

R

2−S

PO

OL

VA

LVE

Lif

t C

ircu

it (

Up

)H

igh

Pre

ssur

eLo

w P

ress

ure

(C

harg

e)R

etur

n o

r S

uctio

nF

low

Ree

lmas

ter

3100

−D


Lift Circuit (Up)

Raise Cutting Units

The gear pump (P2) is directly coupled to the hydrostatthrough gear pump (P1). It supplies hydraulic pressure(charge pressure) for raising and lowering the cuttingunits, operating the sidewinder unit, and maintaining100 to 150 PSI (6.9 to 10.0 bar) to the low pressure sideof the traction circuit. The pump takes its suction fromthe hydraulic reservoir.

During conditions of not lifting or lowering cutting units,flow from the gear pump is by−passed through the pow-er steering valve, 2−spool valve, and hydraulic manifolddirectly to the hydrostat and the charge relief valve. Flowthen returns to the hydraulic tank.

When the cutting units are to be raised, the 2−spoolvalve is positioned by moving the cutting unit shift leverto RAISE. Flow is directed to cap ends of the lift cylin-ders. Hydraulic pressure against the cylinder pistonsmoves their shafts causing the cutting units to raise. Atthe same time, the pistons push the hydraulic fluid outof the lift cylinders and back through the hydraulic man-ifold to the hydrostat. When the cutting unit shift lever isreleased, spring action returns the valve to its originalposition and by−passes flow back to the hydrostat stop-ping lift cylinder movement. The cylinder position islocked in place, since there is no complete circuit of flowto and from the lift cylinders.

Hyd

rau

lic

Syste

m


D

M4

M5

DU

MP

VA

LVE

P3

HY

DR

OS

TAT

OIL

FIL

TE

R

P1

P2

EN

GIN

E R

PM

GE

AR

PU

MP

L R

V1

LOW

ER

PO

RT

UP

PE

RP

OR

T

M6

INT

ER

NA

L C

AS

E D

RA

IN

100

to 1

50 p

si

ST

RA

INE

R

OIL

CO

OLE

R

TO

P P

OR

T

FORWARD

TR

AC

TIO

N W

HE

EL

MO

TO

RS

3000

psi

FC

1

RE

EL

SP

EE

DC

ON

TR

OLL

ER

LC1

LOG

IC

MD

1B

AC

KLA

PP

ING

VA

LVE

RE

EL

ON

−O

FF

VA

LVE

RE

EL

RE

LIE

F30

00 p

siS1

R1

G1

T2

D1

M1

M2

MA

NIF

OLD

BLO

CK

T1

P1

LV

LC2

CH

G

CFCR

ST

LEF

T F

RO

NT

RIG

HT

FR

ON

T

RE

AR

FR

ON

T

RE

AR

SID

EW

IND

ER

AB

C

OU

T

IN

STEERING

PO

WE

RS

TE

ER

ING

VA

LVE

IN

OU

T

AU

X

1000

psi

G2

PLU

G

VA

LVE

RE

EL

MO

TO

R

RE

EL

MO

TO

R

RE

EL

MO

TO

R

(OP

TIO

NA

L)

LIF

T

LIF

TC

YLI

ND

ER

CY

LIN

DE

R

CY

LIN

DE

R

2−S

PO

OL

VA

LVE

Lif

t C

ircu

it (

Do

wn

)H

igh

Pre

ssur

eLo

w P

ress

ure

(C

harg

e)R

etur

n o

r S

uctio

nF

low

Ree

lmas

ter

3100

−D


Lift Circuit (Down)

Lower Cutting Units

Circuit operation for lowering the cutting units is similarto raising them. However, pressure is relieved from thelift cylinders, and this action allows them to lower.

During conditions of not lifting or lowering cutting units,flow from the gear pump is by−passed through the pow-er steering valve, 2−spool valve, and hydraulic manifolddirectly to the hydrostat and the charge relief valve. Flowthen returns to the hydraulic tank.

When the cutting units are to be lowered, the 2−spoolvalve is positioned by moving the cutting unit shift leverto LOWER. Pressure from gear pump (P2) is used to

shift the pilot valve in the 2−spool valve. This shifting ofthe pilot valve allows hydraulic pressure to relieve fromthe cap end of the lift cylinders. Flow from the cap endof the lift cylinders causes the cutting units to lower. Atthe same time, the fluid relieved from the cap end of thelift cylinders goes into the rod end of the cylinders andback through the hydraulic manifold to the hydrostat.When the cutting unit shift lever is released, spring ac-tion returns and detents the valve into the float positionwhile by−passing flow back to the hydrostat. The pilotvalve then shifts to its original position and stops lift cyl-inder movement. The cylinder position is locked in placesince there is no complete circuit of flow to and from thelift cylinders.

Hyd

rau

lic

Syste

m


D

M4

M5

DU

MP

VA

LVE

P3

HY

DR

OS

TAT

OIL

FIL

TE

R

P1

P2

EN

GIN

E R

PM

GE

AR

PU

MP

L R

V1

LOW

ER

PO

RT

UP

PE

RP

OR

T

M6

INT

ER

NA

L C

AS

E D

RA

IN

100

to 1

50 p

si

ST

RA

INE

R

OIL

CO

OLE

R

TO

P P

OR

T

FORWARD

TR

AC

TIO

N W

HE

EL

MO

TO

RS

3000

psi

FC

1

RE

EL

SP

EE

DC

ON

TR

OLL

ER

LC1

LOG

IC

MD

1B

AC

KLA

PP

ING

VA

LVE

RE

EL

ON

−O

FF

VA

LVE

RE

EL

RE

LIE

F30

00 p

siS1

R1

G1

T2

D1

M1

M2

MA

NIF

OLD

BLO

CK

T1

P1

LV

LC2

CH

G

CFCR

ST

LEF

T F

RO

NT

RIG

HT

FR

ON

T

RE

AR

FR

ON

T

RE

AR

SID

E−

AB

C

OU

T

IN

STEERING

PO

WE

RS

TE

ER

ING

VA

LVE

IN

OU

T

AU

X

1000

psi

G2

PLU

G

VA

LVE

RE

EL

MO

TO

R

RE

EL

MO

TO

R

RE

EL

MO

TO

R

(OP

TIO

NA

L)

LIF

T

LIF

TC

YLI

ND

ER

CY

LIN

DE

R

CY

LIN

DE

R

2−S

PO

OL

VA

LVE

Sid

ewin

der

Cir

cuit

(E

xten

d R

igh

t)H

igh

Pre

ssur

eLo

w P

ress

ure

(C

harg

e)R

etur

n o

r S

uctio

nF

low

Ree

lmas

ter

3100

−D

WIN

DE

R

RIG

HT

EX

TE

ND

S


Sidewinder Circuit

The gear pump (P2) is directly coupled to the hydrostatthrough gear pump (P1). It supplies hydraulic pressure(charge pressure) for raising and lowering the cuttingunits, operating the sidewinder unit, and maintaining100 to 150 PSI (6.9 to 10.0 bar) to the low pressure sideof the traction circuit. The pump takes its suction fromthe hydraulic reservoir.

During conditions of not lifting or lowering the cuttingunits, flow from the gear pump is by−passed through thepower steering valve, 2−spool valve, and hydraulicmanifold directly to the hydrostat and the charge reliefvalve. Flow then returns to the hydraulic tank.

Shift Sidewinder Right

When the sidewinder is to be shifted right, the 2−spoolvalve is positioned by moving the cutting unit shift leverto RIGHT. Flow is directed to the cap end of the side-winder cylinder. Hydraulic pressure against the cylinderpiston moves the rod causing the sidewinder cylinder toextend right. At the same time, the piston pushes the hy-draulic fluid out of the cylinder, back through the spool

and hydraulic manifold, and to the hydrostat. When thecutting unit shift lever is released, spring action returnsthe valve to its original position and by−passes flow backto the hydrostat and stopping cylinder movement. Thecylinder position is locked in place since there is no com-plete circuit of flow to and from the lift cylinders.

Shift Sidewinder Left

When the sidewinder is to be shifted left, the 2−spoolvalve is positioned by moving the cutting unit shift leverto LEFT. Flow is directed to the rod end of the sidewindercylinder. Hydraulic pressure against the cylinder pistonmoves the rod causing the sidewinder to retract left. Atthe same time, the piston pushes the hydraulic fluid outof the cylinder, back through the spool and hydraulicmanifold, and to the hydrostat. When the cutting unitshift lever is released, spring action returns the valve toits original position and by−passes flow back to the hy-drostat stopping cylinder movement. The cylinder posi-tion is locked in place since there is no complete circuitof flow to and from the lift cylinders.

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D

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Steering Circuit

The gear pump (P2) is directly coupled to the hydrostat.It supplies hydraulic pressure to the power steeringvalve for turning the rear wheel and maintaining 100 to150 PSI (6.9 to 10.0 Bar) to the low pressure side of thetraction circuit. The pump takes its suction from the hy-draulic reservoir.

With the steering wheel in the neutral position (rearwheel positioned straight ahead), the engine running,and the spool valve is in the center position, flow entersthe steering control valve at the IN port and goes throughthe spool valve by−passing the rotary meter (V1) andsteering cylinder. Flow leaves the control valve throughthe OUT port to the hydrostat.

Right Turn

When a right turn is made with the engine running, theturning of the steering wheel positions the spool valve sothat flow goes through the top of the spool. Flow enteringthe steering control valve at the IN port goes through thespool and is routed to two places. First, most of the flowthrough the valve is by−passed out the AUX port backthrough the 2−spool valve to the hydrostat. Second, theremainder of the flow is drawn through rotary meter (V1)and out port (R). Pressure retracts the piston for a rightturn. The rotary meter ensures that the oil flow to the cyl-inder is proportional to the amount of the turning on the

steering wheel. Fluid leaving the cylinder flows backthrough the spool valve then through the OUT port andto the hydrostat.

The steering control valve returns to the neutral positionwhen turning is complete.

Left Turn

When a left turn is made with the engine running, theturning of the steering wheel positions the spool valve sothat flow goes through the bottom of the spool. Flow en-tering the steering control valve at the IN port goesthrough the spool and is routed to two places. As in aright turn, most of the flow through the valve is by−passed out the AUX port back through the 2−spool valveto the hydrostat. Also like a right turn, the remainder ofthe flow is drawn through rotary meter (V1) but goes outport (L). Pressure extends the piston for a left turn. Therotary meter ensures that the oil flow to the cylinder isproportional to the amount of the turning on the steeringwheel. Fluid leaving the cylinder flows back through thespool valve then through the OUT port and to the hy-drostat.

The steering control valve returns to the neutral positionwhen turning is complete.

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Special ToolsOrder these special tools from your Toro Distributor.

Hydraulic Pressure Test Kit − TOR47009

Use to take various pressure readings for diagnostictests. Quick disconnect fittings provided attach directlyto mating fittings on machine test ports without tools. Ahigh pressure hose is provided for remote readings.Contains one each: 1000 PSI (70 Bar), 5000 PSI (350Bar) and 10000 PSI (700 Bar) gauges. Use gauges asrecommended in Testing section of this chapter.

Figure 10

Hydraulic Tester (Pressure and Flow) − TOR214678

Figure 11

This tester requires O−ring face seal (ORFS) adapter fit-tings for use on this machine.

1. INLET HOSE: Hose connected from the system cir-cuit to the inlet side of the hydraulic tester.

2. LOAD VALVE: A simulated working load is createdin the circuit by turning the valve to restrict flow.

3. LOW PRESSURE GAUGE: Low range gauge to pro-vide accurate reading at low pressure, 0 to 1000 PSI.

A protector valve cuts out when pressure is about toexceed the normal range for the gauge. The cutoutpressure is adjustable.

4. HIGH PRESSURE GAUGE: High range gaugewhich accommodates pressures beyond the capacity ofthe low pressure gauge, 0 to 5,000 PSI.

5. FLOW METER: This meter measures actual oil flowin the operating circuit with a gauge rated at 15 GPM.

6. OUTLET HOSE: A hose from the outlet side of thehydraulic tester connects to the hydraulic system circuit.


Hydraulic Test Fitting Kit − TOR4079

This kit includes a variety of O−ring Face seal fittings toenable you to connect test gauges into the system.

The kit includes: tee’s, unions, reducers, plugs, caps,and male test fittings.

Figure 12

Measuring Container − TOR4077

Use this container for doing hydraulic motor efficiencytesting (motors with case drain lines only). Measure effi-ciency of a hydraulic motor by restricting the outlet flowfrom the motor and measuring leakage from the casedrain line while the motor is pressurized by the hydraulicsystem.

Figure 13

O−Ring Kit

Toro Part Number: 16−3799

The kit includes O−rings in a variety of sizes for face sealand port seal hydraulic connections. It is recommendedthat O−rings be replaced whenever a hydraulic connec-tion is loosened.

Figure 14

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Wheel Hub Puller

Part Number: TOR4097

The wheel hub puller allows safe removal of the wheelhub from the shaft of wheel motors.

Figure 15

High Pressure Hydraulic Oil Filter

If a component failure occurs in the closed loop tractioncircuit, contamination from the failed part will remain inthe circuit until removed. When connecting hydraulictest gauges in order to test traction circuit componentsor after replacing a failed traction circuit component (e.g.piston pump or wheel motor), a high pressure hydraulicfilter can be installed in the traction circuit. The filter willensure that contaminates are removed from the closedloop and thus, do not cause additional component dam-age.

A high pressure hydraulic oil filter can be obtained local-ly.

Figure 16



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Troubleshooting

The charts that follow contain information to assist introubleshooting. There may possibly be more than onecause for a machine malfunction.

Refer to the Testing section of this Chapter for precau-tions and specific test procedures.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁProblem

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁPossible CauseÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Hydraulic oil leaks from system.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Fitting(s), hose(s), or tube(s) are loose or damaged.

O−ring(s) or seal(s) are missing or damaged.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Hydraulic fluid foams.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Oil level in reservoir is low.

Hydraulic system has wrong type of oil.

One of the pump suction lines has an air leak.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Hydraulic system operates hot.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Transmission pressure is high due to load or brakes applied.

Oil level in reservoir is low, or inlet filter is loose or clogged.

Oil is contaminated or too light.

Heat exchanger (if equipped) is damaged or plugged. By−pass re-lief is stuck open or air flow is obstructed.

Charge pressure is low.

Towing by−pass valve is open or defective.

Wheel motor(s) or reel motor(s) are worn or damaged.

Traction pump is worn or damaged.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Neutral is difficult to find, or unit op-erates in one direction only.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

External control linkage is misadjusted, disconnected, binding, ordamaged.

Traction pump is worn or damaged.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Traction response is sluggish. ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Charge pressure is low. Hydraulic oil is very cold.

Towing by−pass valve is open or worn. Brake is not released.

Traction pump or wheel motor(s) are worn or damaged.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

No traction exists in either direction.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Brake is not released.

Oil level in reservoir is low.

Towing by−pass valve is open.

Charge pressure is low.

Traction pump or wheel motor(s) are worn or damaged.

Traction pump drive belt loose or broken.


Wheel motor will not turn. ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Internal parts in wheel motor are damaged.

Brakes are binding.

Key on wheel motor shaft is sheared or missing.


ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Problem ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Possible CauseÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Wheel motor will not hold load inneutral.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Make up fluid from charge pump is not available.

Hydrostat ball check valves are damaged.


Reel motor drive pump is noisy (ca-vitation).

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Reservoir oil level is low.

Suction line is restricted.

Suction line has an air leak.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Reels will not turn.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Solenoid valve S1 is stuck open.

An electrical problem exists (See Chapter 5−Electrical System).

Relief valve R1 is stuck open.

LC1 logic valve is stuck open.

Gear pump P1 is damaged.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Reel speed is erratic.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Reel to bedknife adjustment is too tight.

Orifice for LC1 is obstructed.

Reel bearing(s) are damaged.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Reel(s) turn too slowly.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Reel section of pump (P1) is inefficient (see Testing).

Reel motor has internal leakage or malfunctioning cross−over reliefvalve (see Testing).

Reel bearing(s) are damaged.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Cutting units will not lift or lift slowly.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Engine speed is too low.

Charge (gear) pump is damaged.

Lift cylinder linkage is binding or broken.

Lift cylinder bushings are binding.

Reservoir oil level is low.

Charge pump pressure or flow is insufficient.

Implement relief valve (1000 PSI) is stuck open.

Lift cylinders leak internally.

Steering control valve is defective.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Cutting units raise, but will not stayup.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Lift cylinders leak internally.

Check valve within the lift valve leaks.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Steering Problems. ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

See Ross Troubleshooting Guide in the Hydraguide TM HydrostaticSteering System HGF Series Service Procedure at the end of thischapter.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Turning steering wheel turns ma-chine in the opposite direction.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Hoses to the steering cylinder are reversed.

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TestingThe most effective method for isolating problems in thehydraulic system is by using hydraulic test equipmentsuch as pressure gauges and flow meters in the circuitsduring various operational checks (See the SpecialTools section in this Chapter).

Before Performing Hydraulic Tests

IMPORTANT: All obvious areas such as oil supply,filter, binding linkages, loose fasteners, or improperadjustments must be checked before assuming thata hydraulic component is the source of the problem.

Precautions for Hydraulic Testing

CAUTIONFailure to use gauges with recommended pres-sure (psi) rating as listed in test procedurescould result in damage to the gauge and possiblepersonal injury from leaking hot oil.

CAUTION

All testing should be performed by two (2)people. One person should be in the seat to oper-ate the machine, and the other should read andrecord test results.

WARNINGKeep body and hands away from pin hole leaksor nozzles that eject hydraulic fluid under highpressure. Do not use hands to search forleaks; use paper or cardboard. Hydraulic fluidescaping under pressure can have sufficientforce to penetrate the skin and cause seriousinjury. If fluid is injected into the skin, it mustbe surgically removed within a few hours by adoctor familiar with this type of injury. Gan-grene may result from such an injury.

1. Clean machine thoroughly before disconnecting ordisassembling any hydraulic components. Always keepin mind the need for cleanliness when working on hy-draulic equipment. Contamination will cause excessivewear of components.

2. Put metal caps or plugs on any hydraulic lines leftopen or exposed during testing or removal of compo-nents.

WARNINGBefore disconnecting or performing any workon the hydraulic system, all pressure in thesystem must be relieved. See Relieving Hy-draulic System Pressure in the General Infor-mation section.

3. The engine must be in good operating condition. Usea phototac when performing a hydraulic test. Enginespeed can affect the accuracy of the tester readings.Check actual speed of the pump when performing flowtesting.

4. The inlet and the outlet hoses must be properly con-nected and not reversed (tester with pressure and flowcapabilities) to prevent damage to the hydraulic tester orcomponents.

5. When using tester with pressure and flow capabili-ties, open load valve completely in the hydraulic testerto minimize the possibility of damaging components.

6. Install fittings finger tight and far enough to makesure that they are not cross−threaded before tighteningthem with a wrench.

7. Position tester hoses to prevent rotating machineparts from contacting and damaging the hoses or tester.

8. Check oil level in the hydraulic tank. After connectingtest equipment, make sure tank is full.

9. Check control linkages for improper adjustment,binding,or broken parts.

10.All hydraulic tests should be made with the hydraulicoil at normal operating temperature.

11. If a traction circuit problem exists, consider perform-ing one or more of the following tests: Traction CircuitWorking Pressure, Charge Relief Valve Pressure, Pis-ton Pump (P3) Flow & Traction Relief Pressure and/orWheel Motor Efficiency Tests.

12.If a cutting circuit problem exists, consider perform-ing one or more of the following tests: Reel Circuit Pres-sure, Manifold Relief Valve (R1) Pressure, Reel MotorCross−over Relief Pressures, Gear Pump (P1) Flowand/or Reel Motor Efficiency Tests.

13.If a steering or lift circuit problem exists, consider per-forming one or more of the following tests: Lift and Steer-ing Control Valve Relief Pressure, Gear Pump (P2) Flowand/or Steering Control Valve Tests.

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Traction Circuit Working Pressure Test (Using Pressure Gauge)

High Pressure

Low Pressure

Return or Suction

Flow

M4

M5

DUMPVALVE

P3

PISTON PUMP

LOWERPORT

UPPERPORT

M6

TO GEAR PUMP SUCTION

100 to 150 psi

TOP PORT

FO

RW

AR

D

TRACTION WHEEL MOTORS

3000 psi

FROM HYDRAULICMANIFOLD (CHG) PORT

THROUGH CASE DRAIN

(HYDROSTAT)

TRACTIONRELIEF


Procedure for Traction Circuit Working PressureTest:

1. Make sure hydraulic oil is at normal operating tem-perature by operating the machine for approximately 10minutes.

2. Park machine on a level surface with the cutting unitslowered and off. Make sure engine is off.

3. Read Precautions for Hydraulic Testing.

4. Make sure that traction pedal is adjusted to the neu-tral position (see Adjust Traction Drive for Neutral in theAdjustments Section).


5. Connect test gauge with a hydraulic hose attachedto the test port. Make sure hose is long enough so theoperator can read it while driving the machine (Fig. 17).

6. Start engine and move throttle to full speed (2650 +50 RPM).

CAUTIONDo not operate sidewinder while performing test.The test gauge hose may get hit by the sidewind-er carrier and rupture, and cause personnel inju-ry.

7. Drive machine in the forward direction. Observe testgauge.

A. Pressure while transporting the machine over aflat, level surface should be about 500 PSI.

B. Pressure driving the machine up a steep hillshould be about 2500 PSI but can reach relief set-tings (3000 PSI).

C. Pressure while mowing should range between1000 to 2000 PSI and will vary with terrain.

8. Release traction pedal and turn off machine.

9. Disconnect test gauge and hose from the test port(Fig. 17).

10.If specification is not met, the hydrostat needs to berepaired or replaced as necessary.

1. Test port 2. Floor plateFigure 17

1

2

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Piston Pump (P3) Flow and Traction Relief Pressure Test (Using Tester with PressureGauges and Flow Meter)

High Pressure

Low Pressure

Return or Suction

Flow

M4

M5

DUMPVALVE

P3

PISTON PUMP

LOWERPORT

UPPERPORT

M6


100 to 150 psi

TOP PORT

FO

RW

AR

DTRACTION WHEEL MOTORS

3000 psi


THROUGH CASE DRAIN

(HYDROSTAT)

TRACTIONRELIEF


Procedure for Piston Pump (P3) Flow and TractionRelief Pressure Test:


2. Park machine on a level surface with the cutting unitslowered and off. Make sure engine is off.



WARNINGOne front wheel and the rear wheel will be off theground during testing. Make sure machine is sup-ported so it will not move and accidentally fall toprevent injuring anyone under machine.

5. Block up one front traction wheel and the rear wheeloff the floor to allow flow through the traction circuit; dis-connect brake linkage to this wheel (see Wheels andBrakes − Chapter 7).

6. Chock remaining front wheel to prevent movementof the machine. Apply parking brake.

7. Attach a heavy chain to the rear of the machine frameand something immovable in the shop.

8. Disconnect hose from the lower hydraulic fitting onthe bottom of the hydrostat.

NOTE: An alternate testing location would be at the hy-draulic hose connection to the hydraulic tube under theleft floor plate.

9. Install tester in series with the pump and the discon-nected hose. Make sure the flow control valve is fullyopen.

10.Start engine and move throttle to full speed (2650 +50 RPM).

CAUTION

Use extreme caution when taking gauge read-ings. The front tire on the ground will be trying tomove the machine forward.

11.Slowly push traction pedal fully to forward position.

1. Lower hydraulic fitting 2. Piston pumpFigure 18

1

2

12.Verify traction relief valve setting by closing flow con-trol valve. System pressure should be from 3000 to 3125PSI as the relief valve lifts. If pressure can not be met oris exceeded with traction pedal fully depressed, releasetraction pedal and open flow control valve fully.

13.If specification is not met consider the following:

A. The traction belt may be worn and slipping (seeReplace Traction Belt).

B. The relief valve leaks or is faulty and needs re-placement.

C. The hydrostat needs to be repaired or replacedas necessary.

14.If the traction relief valve tests out properly, verifypump flow as follows:

A. Push traction pedal in the forward direction untilpressure gauge reads 1000 PSI. Verify with a photo-tac that the pump speed is 2350 RPM (enginespeed approximately 2000 RPM).

B. Observe flow gauge. TESTER READING shouldbe approximately 12.5 GPM.

15.Release traction pedal and turn off machine.

NOTE: If pressure is good under no load, but drops be-low specification when under traction load, the pistonpump and/or wheel motor(s) should be suspected ofwear. When a pump and/or motor is worn or damaged,the charge pump is not able to keep up with internal leak-age in the traction circuit (See Charge Relief Valve Pres-sure Test).

16.If specifications are not met, the hydrostat needs tobe repaired or replaced as necessary.

17.Disconnect tester from hydraulic fitting and hose.Reconnect hose to pump connection.

18.Reconnect brake linkage to wheel (see Wheels andBrakes − Chapter 7).

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Charge Relief Valve Pressure Test (Using Pressure Gauge)

High Pressure

Low Pressure

Return or Suction

Flow

M4

M5

DUMP

VALVE

P3

HYDROSTAT

P1 P2

ENGINE

RPM

GEAR PUMP

LOWER

PORT

UPPER

PORT

M6

INTERNAL CASE DRAIN

100 to 150 psi

STRAINER

TOP PORT

FO

RW

AR

DTRACTION WHEEL MOTORS

3000 psi

TO HYDRAULIC

FROM HYDRAULIC

MANIFOLD (P1) PORT

MANIFOLD (CHG) PORT

TO STEERING CONTROLVALVE (IN) PORT

CHARGE RELIEF


Procedure for Charge Relief Valve Pressure Test:


2. Park machine on a level surface with the cutting unitslowered and off. Make sure engine is off and the parkingbrake is engaged.



4. Disconnect hose to the rear 90o hydraulic fitting onthe piston pump coming from the hydraulic manifold port(CHG). Connect T−connector and gauge to the fittingand hose connection.

5. Operate engine at full speed (2650 + 50 RPM).

6. Make sure that traction pedal is in neutral and theparking brake is engaged.

7. Pressure gauge should read from 100 to 150 PSI.

8. If charge relief pressure specification is not met, con-sider the following:

A. The piston pump charge relief valve is faulty. Re-pair or replace the piston pump charge relief valve(see Piston Pump Service in the Service and Repairssection).

B. Gear pump (P2) is faulty (steering and lift circuitsare also affected).

9. A dynamic charge pressure test can be performed asfollows:

A. With T−connector and pressure gauge still con-nected, sit in the operator seat and press the tractionpedal to forward.

B. While machine is moving, monitor the chargepressure reading on the pressure guage.

C. The charge pressure should drop no more than15% from initial test reading (Step 7 above). A pres-sure drop of more than 15% indicates a traction cir-cuit leak (e.g. a worn or damaged piston pumpand/or wheel motor).

10.Shut off engine.

11.Disconnect gauge and T−connection from the 90o

hydraulic fitting and hose connection. Reconnect hoseto the hydrostat.

1. Rear 90o hydraulic fitting 2. Piston pump

Figure 19

1 2

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Gear Pump (P2) Flow Test (Using Tester with Pressure Gauges and Flow Meter)

P1 P2

ENGINE

RPM

GEAR PUMP

STRAINER

TO TOTOTO STEERING CONTROLVALVE (IN) PORT

TO HYDRAULIC MANIFOLD(P1) PORT

FROM HYDROSTATCASE DRAIN

High Pressure

Low Pressure

Return or Suction

Flow


Procedure for Gear Pump (P2) Test:





4. Disconnect hose connection on the reel gear pumpleading to the steering control valve.

5. Install tester in series with reel drive pump and thedisconnected hose leading to the steering control valve.

6. Make sure the flow control valve on the tester is fullyopen.

IMPORTANT: In this test, the flow tester is posi-tioned before the relief valve. Pump damage can oc-cur if the oil flow is fully restricted. Do not closetester valve fully when performing test.

7. Start engine and move throttle to full speed (2650 +50 RPM). Do not engage the cutting units.

8. Watch pressure gauge carefully while slowly closingthe flow control valve until 800 PSI is obtained. Verifywith a phototac that the pump speed is 3100 RPM.

9. Flow indication should be 3.6 GPM minimum.

10.Shut off engine.

NOTE: If necessary, Steering and Lift Relief PressureTest can be conducted with tester as placed for this test.

11. If flow was less than 3.6 GPM or a pressure of 800PSI cannot be obtained, check for restriction in the pumpintake line. If line is not restricted, remove pump and re-pair or replace as necessary.

12.Disconnect tester from gear pump fitting and hose.Reconnect hose to the pump.

1. Gear pump 2. To steering control valveFigure 20

FRONT

RIGHT

1

2

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Wheel Motor Efficiency Test (Using Tester with Pressure Gauges and Flow Meter)

Figure 21

High PressureLow Pressure Return or Suction

Flow

M4

M5

DUMPVALVE

P3

PISTON PUMP

LOWERPORT

UPPERPORT

M6


100 to 150 psi

TOP PORT

FO

RW

AR

DTRACTION WHEEL

3000 psi


THROUGH CASE DRAIN

(HYDROSTAT)

TRACTIONRELIEF

FRONT WHEEL MOTOR TESTING SHOWN

MOTORS

NOTE: Over a period of time, a wheel motor can wearinternally. A worn motor may by−pass oil to its case draincausing the motor to be less efficient. Eventually,enough oil loss will cause the wheel motor to stall underheavy load conditions. Continued operation with a worn,inefficient motor can generate excessive heat, causedamage to seals and other components in the hydraulicsystem, and affect overall machine performance.


Procedure for Wheel Motor Efficiency Test:

1. Make sure hydraulic oil is at normal operating tem-perature by operating the machine for approximately 10minutes. Make sure the hydraulic tank is full.




5. Attach a heavy chain to the rear of the machine frameand an immovable object to prevent the machine frommoving during testing.

The rear wheel will be off the ground during frontwheel motor testing. Make sure machine is sup-ported so it will not move and accidentally fall toprevent injuring anyone under machine.

WARNING

6. Block up the rear wheel off the ground to allow flowthrough the traction circuit.

7. Chock front wheel being tested to prevent rotation ofthe wheel. Make sure parking brake is on.


8. Disconnect hydraulic lines from front wheel motorthat is not being tested. Cap disconnected hydrauliclines and plug ports in motor to prevent contamination.

9. Disconnect hose from the lower hydraulic fitting onthe bottom of the hydrostat (Fig. 22).

NOTE: An alternate testing location would be at the hy-draulic hose connection to the hydraulic tube under theleft floor plate.

10.Install flow tester in series with the pump and the dis-connected hose. Make sure the tester flow control valveis fully open.

11.Start engine and move throttle to full speed (2650 +50 RPM).

1. Lower hydraulic fitting 2. Piston pumpFigure 22

1

2

CAUTION

Use extreme caution when performing test. Thefront tire on the ground will be trying to move themachine forward.

12.Slowly push traction pedal in forward direction until1000 PSI is displayed on the pressure gauge.

13.Motor internal leakage will be shown on flow meterin GPM. Flow should be less than 1.5 GPM for thetested wheel motor.

14.If specifications are not met, the tested wheel motorneeds to be repaired or replaced as necessary.

15.If remaining front wheel motor requires testing, com-plete steps 5 to 14 for the remaining motor.

16.If rear wheel motor requires testing:

A. Both front wheel motors should have hydrauliclines connected. Block up both front wheels off theground. Release parking brake so front wheels canturn.

B. Attach a heavy chain to the rear of the machineframe and an immovable object to prevent the ma-chine from moving during testing.

C. Position rear wheel on the ground and chock rearwheel to prevent it from turning.

D. Complete steps 9 to 13.

E. If specifications are not met, check the relief valvein the rear wheel motor for damage. If relief valve isnot damaged, wheel motor needs to be repaired orreplaced.

17.Disconnect tester from hydraulic fitting and hose.Reconnect hose to pump connection.

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Reel Circuit Pressure Test (Using Pressure Gauge)

P1 P2

ENGINE RPM

GEAR PUMP

STRAINER

FC1

REEL SPEEDCONTROLLER

LC1LOGIC

MD1BACKLAPPINGVALVE

REELON−OFFVALVE

REELRELIEF

3000 psi

S1

R1

G1

T2

D1 M1 M2

MANIFOLDBLOCK

T1

P1 LV

LC2

CHG

CF

CR

STFROM LIFT VALVE

G2

PLUG

VALVE

(OPTIONAL)

FROM REEL MOTOR CASE DRAINS

FROM FINALTO INITIALREEL MOTOR

TO HYDRAULICTANK

TO OILCOOLER

TO HYDROSTATCHARGE CIRCUIT

FROM HYDROSTATINTERNAL CASE DRAIN

REEL MOTOR

FROM STEERING CONTROLVALVE (OUT) PORT


(OUT) PORT

TO REAR LIFTCYLINDER

TO FRONT LIFTCYLINDER

HYDRAULIC

High Pressure

Low Pressure

Return or Suction

Flow


Procedure for Reel Circuit Pressure Test:





4. Remove plug from hydraulic manifold test port (G1).

5. Install pressure test gauge with hydraulic hose at-tached into the test port.

6. Make sure backlap knob on the hydraulic manifold isin the mow position. Make sure reel speed knob is setfor typical mowing conditions.

CAUTION

Keep away from reels during test to prevent per-sonal injury from the rotating reel blades.

7. Start engine and move throttle to full speed (2650 +50 RPM). Engage the cutting units.

8. Watch pressure gauge carefully while mowing withthe machine.

9. Reel circuit pressure should be about 600 PSI.

10.Disengage cutting units. Shut off engine.

11.Disconnect test gauge with hose from manifoldblock. Reconnect plug to the hydraulic manifold test port(G1).

1. Hydraulic manifold 2. Test port (G1)

Figure 23

12

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Gear Pump (P1) Flow Test (Using Tester with Pressure Gauges and Flow Meter)

High Pressure

Low Pressure

Return or Suction

Flow

P1 P2

ENGINE

RPM

GEAR PUMP

STRAINER

TO TOTO


TO HYDRAULIC MANIFOLD(P1) PORT

FROM HYDROSTATCASE DRAIN


Procedure for Gear Pump (P1) Flow Test:

NOTE: Over a period of time, the gears and wear platesin the pump can wear down. A worn pump will by passoil and make the pump less efficient. Eventually, enoughoil loss will occur to cause the reel motors to stall underheavy cutting conditions. Continued operation with aworn, inefficient pump can generate excessive heat andcause damage to the seals and other components in thehydraulic system.





4. Disconnect hose connection on the reel gear pumpleading to port (P1) on the hydraulic manifold.

5. Install tester in series with reel drive pump and thedisconnected hose leading to port (P1) of the hydraulicmanifold.

6. Make sure backlap knob on the hydraulic manifold isin the mow position and reel speed is set to maximum.

7. Make sure the flow control valve on the tester is fullyopen.

8. Start engine and move throttle to full speed (2650 +50 RPM). Do not engage the cutting units.

IMPORTANT: In this test, the hydraulic tester ispositioned before the manifold relief valve. Pumpdamage can occur if the oil flow is fully restricted byfully closing the tester flow control valve. Do notclose tester valve fully when performing test.

9. Watch pressure gauge carefully while slowly closingthe flow control valve until 2000 PSI is obtained. Verifywith a phototac that the pump speed is 3100 RPM.

10.Flow indication should be 5.7 GPM minimum.

11.Shut off engine.

12.Disconnect tester from gear pump fitting and hose.Reconnect hose to the pump.

13.If flow was less than 5.7 GPM or a pressure of 2000PSI cannot be obtained, check for restriction in the pumpintake line. If line is not restricted, remove pump and re-pair or replace as necessary.

1. Gear pump 2. To manifold port (P1)

Figure 24

FRONT

RIGHT

1

2

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Manifold Relief Valve (R1) Pressure Test (Using Tester with Pressure Gauges and FlowMeter)

P1 P2

ENGINE RPM

GEAR PUMP

STRAINER

FC1

REEL SPEEDCONTROLLER

LC1LOGIC

MD1BACKLAPPINGVALVE

REELON−OFFVALVE

REELRELIEF

3000 psi

S1

R1

G1

T2

D1 M1 M2

MANIFOLDBLOCK

T1

P1 LV

LC2

CHG

CF

CR

STFROM LIFT VALVE

G2

PLUG

VALVE

(OPTIONAL)

FROM REEL MOTOR CASE DRAINS

FROM FINAL

TO INITIALREEL MOTOR

TO HYDRAULICTANK

TO OILCOOLER

TO HYDROSTATCHARGE CIRCUIT


REEL MOTOR

FROM STEERING CONTROLVALVE (OUT) PORT


(OUT) PORT

TO REAR LIFTCYLINDER

TO FRONT LIFTCYLINDER

HYDRAULIC

High Pressure

Low Pressure

Return or Suction

Flow


Procedure for Manifold Relief Valve (R1) PressureTest:




4. Make sure reel speed adjuster knob (FC1) is set tothe highest speed setting (fully open).


5. Disconnect hose connection from hydraulic fitting onmanifold port (M1).

6. Install tester in series with the hose and hydraulic fit-ting. Make sure the flow control valve on tester is fullyopen.

7. Make sure backlap knob on the hydraulic manifold isin the mow position. Make sure reel speed knob is setto maximum.

CAUTION



9. Watch pressure gauge carefully while slowly closingthe flow control valve to fully closed.

10.System pressure should be from 2700 to 3300 PSIas the relief valve lifts.

A. If specification is not met, shut off engine and ad-just relief valve (see Adjusting Manifold Relief Valve).Return to Step 6.

B. If this specification is met, go to Step 11.

11.Disengage cutting units. Shut off engine.

12.Disconnect tester from manifold and hose. Recon-nect hydraulic hose to manifold fitting for port (M1).

1. Hydraulic manifold 2. Hydraulic fitting (M1)

Figure 25

12

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Reel Motor Efficiency − Case Drain Test (Using Tester with Pressure Gauges and FlowMeter)

TO HYDRAULIC

FROM HYDRAULIC

TO HYDRAULIC

INITIAL

RIGHT FRONT

FINAL

REEL MOTOR

REEL MOTOR

REEL MOTOR

MANIFOLD PORT (D1)

MANIFOLD PORT (M1)

MANIFOLD PORT (M2)

MEASURINGCONTAINER

High Pressure

Low Pressure

Return or Suction

Flow

IN

BOTTOM

TOP

BOTTOM

IN

BOTTOM

Toro # TOR4077

NOTE: Over a period of time, a reel motor can wear in-ternally. A worn motor may by−pass oil to its case draincausing the motor to be less efficient. Eventually,enough oil loss will cause the reel motor to stall underheavy cutting conditions. Continued operation with aworn, inefficient motor can generate excessive heat,cause damage to seals and other components in the hy-draulic system, and affect quality of cut.

NOTE: One way to find a possibly bad reel motor is tohave another person observe the machine while mow-ing in dense turf. A bad motor will run slower, producefewer clippings, and may cause marcelling (or a wash-board appearance) on the turf.

NOTE: On machines with Serial Numbers below230000000, the initial reel motor in the cutting circuit isthe left front and the final reel motor drives the rear cut-ting unit. On machines with Serial Numbers above230000000, the initial motor is the rear reel motor andthe final reel motor is the left front.


Procedure for Reel Motor Efficiency: Case DrainTest:




NOTE: The reel motors are connected in series. To iso-late a faulty motor, you may have to test all three motorsin the circuit by starting with the upstream motor first.

4. For the suspected bad motor, disconnect return hosefrom the motor (Cross Over Relief Test Fig. 30 and 31).

5. Install tester in series with the motor and discon-nected return hose. Make sure the tester flow controlvalve is fully open.

6. Make sure backlap knob on the hydraulic manifold isin the mow position and reel speed is set to maximum.

7. Disconnect hose from case drain at the bulkhead T−fitting (Fig. 26, Fig. 27, and 28). Plug the T−fitting. Putcase drain hose into suitable container for collectingcase drain leakage.

8. One person should sit on the seat and operate themachine while another person reads the tester andmeasures case drain leakage. Make sure traction pedalis in NEUTRAL. Start engine and move the throttle to fullspeed (2650 + 50 RPM).

CAUTION


9. Engage reels by positioning the cutting unit driveswitch to the ENGAGE position. While watching pres-sure gauges, slowly close flow control valve until a pres-sure of 1200 PSI is obtained.

10.Collect hydraulic fluid for 15 seconds by putting thecase drain hose into a 1 quart container graduated inounces (1 liter container graduated in milliliters).

11.Stop cutting units by positioning the cutting unit driveswitch to the DISENGAGE position. Stop engine.

12.Measure amount of oil collected in the container. Di-vide number of ounces collected by 32 to get gallons perminute (Divide number of milliliters collected by 250 toget liters per minute).

1. Case drain (right motor) 2. Hydraulic T−fitting

Figure 26

1

2

1. Case drain (left motor) 2. Hydraulic T−fitting

Figure 27

12

1. Case drain (rear motor) 2. Hydraulic T−fitting

Figure 28

1

2

13.If flow was greater than 0.7 GPM (2.6 LPM), repairor replace the reel motor as necessary.

14.Disconnect tester from motor and hose. Reconnecthydraulic hoses.

15.Repeat test with other motors as needed.

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Reel Motor Cross−over Relief Pressures Test (Using Pressure Gauge)

Figure 29

High PressureLow Pressure Return or Suction

Flow

RIGHT FRONT

FINAL

REEL MOTOR

REEL MOTOR

INITIALREEL MOTOR

TO HYDRAULICMANIFOLD PORT (D1)

FROM HYDRAULICMANIFOLD PORT (M1)

TO HYDRAULICMANIFOLD PORT (M2)

IN

TOP

IN

BOTTOM

BOTTOM

BOTTOM

NOTE: One way to find a possibly bad reel motor is tohave another person observe the machine while mow-ing in dense turf. A bad motor will run slower, producefewer clippings, and may cause marcelling (or a wash-board appearance) on the turf.

NOTE: On machines with Serial Numbers below230000000, the initial reel motor in the cutting circuit isthe left front and the final reel motor drives the rear cut-ting unit. On machines with Serial Numbers above230000000, the initial motor is the rear reel motor andthe final reel motor is the left front.


Procedure for Cross−over Relief Pressures Test:


2. Make sure machine is parked on a level surface withthe cutting units lowered and off. Make sure engine is offand parking brake is engaged. Back bedknives off allreels.

CAUTION

Operate all hydraulic controls to relieve systempressure and avoid injury from pressurized hy-draulic oil.

3. Clean hydraulic fittings on suspected faulty reel mo-tor. Disconnect pressure inlet hose from fitting for themow direction of flow.

A. Top 90o fitting for the front reel motors.

B. Center fitting for the rear reel motor.

4. Install T−connector with 5000 PSI pressure gaugebetween the motor inlet fitting and the disconnectedhose.

5. Put a block of wood between the blades of the cuttingunit being tested to prevent the reel from rotating.

6. Make sure backlap knob on the hydraulic manifold isin the mow position.

7. One person should sit on the seat and operate themachine while another person reads the gauge. Startengine and set throttle to full speed (2650 + 50 RPM).

CAUTION


CAUTION

Do not allow system pressure to exceed 1800PSI. Shut off unit to prevent an over pressurecondition.

8. Engage cutting units. System pressure should befrom 1350 to 1650 PSI as the cross−over relief valvelifts.

1. Pressure inlet hose2. Left reel motor

3. Right reel motor

Figure 30

1

2

1

3

1. Rear reel motor 2. Pressure inlet hose

Figure 31

1

2

9. Disengage cutting units and stop engine. If specifica-tions are not met, replace cross−over relief. If specifica-tions are met, remove block of wood from cutting unitand repeat test on other reels in mow direction.

IMPORTANT: Each reel motor has two cross−overrelief valves. Test reliefs in the backlap directiononly if a problem is expected. After testing cross−over reliefs in the backlap direction, make sure thereel motor couplings are torqued (see Reel MotorRemoval and Installation in the Service and Repairssection of Chapter 7 − Cutting Units).

10.Clean suspected reel motor hydraulic fittings. Dis-connect pressure inlet hose from fitting for the backlapdirection of flow.

A. Bottom 90o fitting for the front reel motors.

B. Bottom 90o fitting for the rear reel motor.

11. Install T−connector with 5000 PSI pressure gaugebetween the motor fitting and the disconnected hose.

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12.Make sure backlap knob on the hydraulic manifold isin the backlap position.

13.One person should sit on the seat and operate themachine while another person reads the gauge. Startengine and move the throttle to full speed (2650 + 50RPM).

CAUTION


CAUTION

Do not allow system pressure to exceed 1800PSI. Shut off unit to prevent an over pressurecondition.

14.Engage cutting units. System pressure should befrom 1350 to 1650 PSI as the relief valve lifts.

15.Disengage cutting units and stop engine. If specifica-tions are not met, the cross−over relief needs replacing.Remove block of wood from cutting unit and repeat teston other reels in the same direction of flow.

16.Remove test gauge and reconnect hose to motor.Adjust bedknife to reel on all cutting units (see Adjust-ment section of Chapter 7 − Cutting Units).



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Lift and Steering Control Valve Relief Pressure Test (Using Pressure Gauge)

P1 P2

ENGINE

RPM

GEAR PUMP

L

R

V1

STRAINER

ST

EE

RIN

G

POWERSTEERINGVALVE

IN

OUT

AUX

1000 psi


TO HYDRAULICMANIFOLD

TO HYDRAULICMANIFOLD(ST) PORT

TO LIFT VALVE(IN) PORT

High Pressure

Low Pressure

Return or Suction

Flow

LEFT TURN SHOWN


Procedure for Lift and Steering Control Valve ReliefPressure Test:


2. Make sure machine is parked on a level surface withthe cutting units lowered and off. Make sure engine is offand the parking brake is engaged.



4. Disconnect hose connection on gear pump (P2)leading to the steering control valve (Fig.32).

5. Install T−connector with test gauge in series with thedischarge of the gear pump and the disconnected hoseleading to the steering control valve.

6. Make sure steering wheel is positioned so the rearwheel points directly ahead.


CAUTIONDo not allow pressure to exceed 1500 PSI.

IMPORTANT: Hold steering wheel at full lock onlylong enough to get a system pressure reading.Holding the steering wheel against the stop for anextended period will damage the steering controlvalve.

8. Watch pressure gauge carefully while turning thesteering wheel completely in one direction and holdingat full lock briefly.

9. System pressure should be from 845 to 995 PSI asthe relief valve lifts. Return steering wheel to the centerposition. If specification is not met, shut off engine andreplace relief valve in steering control valve (see Steer-ing Control Valve Service).

10.Disconnect T−connector with test gauge from gearpump (P2) fitting and hose. Reconnect hydraulic hoseto pump.

1. Gear pump 2. To steering control valveFigure 32

FRONT

RIGHT

1

2

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Steering Control Valve Test

L R

V1

STEERING

POWERSTEERINGVALVE (LEFT TURN)

IN

OU

T

AU

X

1000

psi

PLUG

High Pressure

Low Pressure

Return or Suction

Flow

CYLINDER

OPEN FITTING


Procedure for Steering Control Valve Test:


2. Perform the Lift and Steering Control Valve ReliefPressure and Gear Pump (P2) Flow tests to make surethat pump and relief valve are functioning correctly.

NOTE: This steering test procedure will be affected byincorrect rear tire pressure, binding in the hydraulicsteering cylinder, extra weight on the vehicle, and/orbinding of the steering fork assembly. Make sure thatthese items are checked before proceeding with any hy-draulic testing procedure.

3. Drive machine slowly in a figure eight on a flat levelsurface.

A. There should be no shaking or vibration in thesteering wheel or rear wheel.

B. Steering wheel movements should be followedimmediately by a corresponding rear wheel move-ment without the steering wheel continuing to turn.

4. Stop unit with the engine running. Turn steeringwheel with small quick movements in both directions.Let go of the steering wheel after each movement.

A. The steering wheel must go back immediately tothe neutral position.

B. The steering wheel should not continue to turn.

5. If either of these performance tests indicate a steer-ing problem, determine if the steering cylinder is faultyusing the following procedure.

A. Park machine on a level surface with the cuttingunits lowered and off. Make sure engine is off and theparking brake is engaged.

B. Turn the steering wheel all the way to the left(counterclockwise) so the steering cylinder rod is ful-ly extended.

C. Turn engine off.

D. Read Precautions for Hydraulic Testing.


E. Remove hydraulic hose from the 90o fitting on therod end of the steering cylinder. Plug the end of thehose.

F. With the engine off, continue turning the steeringwheel to the left (counterclockwise) with the steeringcylinder fully extended. Observe the open fitting onthe steering cylinder as the wheel is turned. If oilcomes out of the fitting while turning the steeringwheel to the left, the steering cylinder has internalleakage and must be repaired or replaced.

G. Remove plug from the hydraulic hose. Recon-nect hose to the steering cylinder fitting.

6. If steering problem exists and steering cylindertested acceptably, steering control requires service (seeSteering Control Valve and Steering Control Valve Ser-vice).

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Adjustments

Adjust Traction Drive for Neutral

1. Park the machine on a level surface and turn the en-gine off.

One front wheel and rear wheel must be raisedoff the ground or the machine will move duringadjustment. Make sure machine is supportedso it will not accidentally fall injuring anyoneunder machine.

WARNING

2. Raise one front wheel and rear wheel off floor andplace support blocks under frame.

3. Loosen locknut on traction adjustment cam.

Engine must be running so final adjustment ofthe traction adjustment cam can be performed.To guard against possible personal injury,keep hands, feet, face and other parts of thebody away from the muffler, other hot parts ofthe engine, and other rotating parts.

WARNING

4. Start engine and rotate cam hex in both directions todetermine mid position of neutral span.

5. Tighten locknut securing adjustment.

6. Stop engine.

7. Remove support blocks and lower the machine tothe shop floor. Test drive the machine to make sure itdoes not creep.

1. Adjustment cam 2. Lock nut

Figure 33

1 2


Adjust Manifold Relief Valve (R1)

The hydraulic reel circuit is equipped with a relief valve.This valve is preset at the factory to 3000 PSI. However,an adjustment may be required if the setting proves tobe incorrect after testing (see TESTING). If an adjust-ment is required proceed as follows:

Never adjust the relief valve with the hydraulicsystem pressurized. Hydraulic oil may spray outof the valve with the cap off. Personal injury mayresult. Always install the cap and tighten beforepressurizing the system.

WARNING

NOTE: Do not remove the relief valve from the hydrau-lic manifold for adjustment.

1. Remove cap from the relief valve with an allenwrench.

NOTE: A 1/8−turn of the adjustment socket will make ameasurable change in relief pressure.

2. To increase pressure setting, turn the adjustmentsocket inside the valve 1/8 of a turn clockwise.

3. To decrease pressure setting, turn the adjustmentsocket inside the valve 1/8 of a turn counterclockwise.

4. Install and tighten cap to valve. Retest pressure set-ting (see Testing).

Figure 341. Relief valve cap 2. Adjustment socket

1

2

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Service and Repairs

General Precautions for Removing and Installing Hydraulic System Components

Before Repair or Replacement of Components

1. Before removing any parts from the hydraulic sys-tem, park machine on a level surface, engage parkingbrake, lower cutting units or attachments, and stop en-gine. Remove key from the ignition switch.

2. Clean machine before disconnecting, removing, ordisassembling any hydraulic components. Make surehydraulic components, hoses connections, and fittingsare cleaned thoroughly. Always keep in mind the needfor cleanliness when working on hydraulic equipment.


3. Put caps or plugs on any hydraulic lines, hydraulic fit-tings, and components left open or exposed to preventcontamination.

4. Put labels on disconnected hydraulic lines andhoses for proper installation after repairs are completed.

5. Note the position of hydraulic fittings (especially el-bow fittings) on hydraulic components before removal.Mark parts if necessary to make sure they will be alignedproperly when reinstalling hydraulic hoses and tubes.

After Repair or Replacement of Components

1. Check oil level in the hydraulic reservoir and add cor-rect oil if necessary. Drain and refill hydraulic systemreservoir, and change oil filter if component failure wassevere or system is contaminated (see Flush HydraulicSystem).

2. Lubricate O−rings and seals with clean hydraulic oilbefore installing hydraulic components.

3. Make sure caps or plugs are removed from the hy-draulic tubes, hydraulic fittings, and components beforereconnecting.

4. Use proper tightening methods when installing hy-draulic hoses and fittings (see Hydraulic Fitting Installa-tion).

5. Make sure caps or plugs are removed from the hy-draulic tubes, hydraulic fittings, and components beforereconnecting.

6. After repairs, check control linkages or cables forproper adjustment, binding, or broken parts.

7. After disconnecting or replacing any hydraulic com-ponents, operate machine functions slowly until air isout of system (see Charge Hydraulic System).

8. Check for hydraulic oil leaks. Shut off engine and cor-rect leaks if necessary. Check oil level in hydraulic reser-voir and add correct oil if necessary.


Change Hydraulic Fluid

Change hydraulic fluid after every 400 operating hours,under normal conditions. If fluid becomes contami-nated, the system must be flushed. Contaminated fluidlooks milky or black when compared to clean oil.

1. Turn engine off and raise hood.

2. Disconnect hydraulic hose from filter head or removehydraulic filter and let hydraulic fluid flow into drain pan.When hydraulic fluid stops draining, connect the hy-draulic hose or install new hydraulic filter.

3. Fill hydraulic tank with approximately 3.5 gallons(13.2 liters) of hydraulic fluid. Refer to Check HydraulicFluid.

IMPORTANT: Use only recommended hydraulicfluids to fill hydraulic tank. Other fluids could causesystem damage.

4. Install hydraulic tank cap. Start engine and use all hy-draulic controls to distribute hydraulic fluid throughoutthe system. Also check for leaks. Then stop the engine.

5. Check level of fluid and add enough to raise level toFULL mark on dipstick. DO NOT OVER FILL.

1. Hydraulic hose 2. Filter head

Figure 35

1

2

1. Hydraulic oil filter 2. Rear wheel

Figure 36

1

2

1. Hydraulic tank 2. Cap

Figure 37

1

2

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Replace Hydraulic Oil Filter

The hydraulic system filter must be changed initially, af-ter the first 10 hours of operation, and thereafter every200 hours of operation or yearly, whichever comes first.The hydraulic oil must be changed every 400 hours ofoperation or yearly, whichever comes first.

Use a genuine Toro oil filter for replacement.

IMPORTANT: Use of any other filter may void thewarranty on some components.

1. Position machine on a level surface, lower the cut-ting units, stop the engine, engage the parking brakeand remove key from ignition switch.

2. Clamp hose leading to the oil filter head from the hy-draulic tank to prevent draining the hydraulic tank.

3. Clean area around filter mounting surface. Placedrain pan under filter and remove filter. Properly disposeof filter.

4. Lubricate new filter gasket and fill the filter with hy-draulic fluid.

5. Assure filter mounting area is clean. Screw filter onuntil gasket contacts mounting plate. Then tighten filterone−half turn.

1. Hydraulic oil filter 2. Rear wheel

Figure 38

1

2

6. Remove clamp from hydraulic hose. Check and ad-just hydraulic oil level in hydraulic tank.

7. Start engine and let run for about two minutes topurge air from the system. Stop the engine and check forleaks.

8. Check level of fluid and add enough to raise level toFULL mark on dipstick. DO NOT OVER FILL.


Replace Traction Belt



CAUTIONBe careful when removing or applying tensionfrom or to the torsion spring of the idler pulley.The spring is under heavy load and may causepersonal injury.

3. Push down and forward on the spring end to unhookthe spring from the pump mounting plate.

4. Remove V−belt from the engine flywheel and hy-drostat pulleys.

5. Install new V−belt onto the engine flywheel and hy-drostat pulleys.

Figure 391. Torsion spring2. Idler pulley3. Pump mounting plate

4. V−belt5. Fly wheel pulley6. Hydrostat pulley

1

2

54

3

6


7. Push down and back on the spring end to get thespring under the pump mounting plate notch. Then re-lease on the spring slowly to lock it into place.

Check Hydraulic Lines and Hoses

Keep body and hands away from pin hole leaksor nozzles that eject hydraulic fluid under highpressure. Use paper or cardboard, not hands, tosearch for leaks. Hydraulic fluid escaping underpressure can have sufficient force to penetratethe skin and cause serious injury. If fluid is in-jected into the skin, it must be surgically re-moved within a few hours by a doctor familiarwith this type of injury. Gangrene may result fromsuch an injury.

WARNINGCheck hydraulic lines and hoses daily for leaks, kinkedlines, loose mounting supports, wear, loose fittings,weather deterioration and chemical deterioration. Makeall necessary repairs before operating.

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Flush Hydraulic System

IMPORTANT: Flush the hydraulic system any timethere is a severe component failure or the system iscontaminated (oil appears milky, black, or containsmetal particles).

IMPORTANT: Flush hydraulic system when chang-Ing from petroleum base hydraulic fluid to a biode-gradable fluid such as Toro BiodegradableHydraulic Fluid. Operate machine under normal op-erating conditions for at least four (4) hours beforedraining.

IMPORTANT: If a component failure occurred in thetraction circuit, refer to Traction Circuit (ClosedLoop) Component Failure in the General Informa-tion section for information regarding the impor-tance of removing contamination from the tractioncircuit.

1. Park machine on a level surface. Lower cutting units,stop engine, and engage parking. Remove key from theignition switch.


IMPORTANT: Make sure to clean around any hy-draulic connections that will be disconnected fordraining.

2. Drain hydraulic tank (see Change Hydraulic Fluid).

3. Drain hydraulic system. Drain all hoses, tubes, andcomponents while the system is warm.

4. Change and replace oil filter (see Replace HydraulicOil Filter).

5. Inspect and clean hydraulic oil tank (see HydraulicTank Inspection).

6. Reconnect all hydraulic hoses, lines, and compo-nents that were disconnected while draining system.

NOTE: Use only hydraulic fluids specified in Check Hy-draulic System Fluid. If changing to biodegradable fluid,use Toro Biodegradable Hydraulic Fluid for this step.Other fluids may cause system damage.

7. Fill hydraulic tank with new hydraulic fluid (seeChange Hydraulic Fluid).

8. Disconnect electrical connector from fuel stop sole-noid.

9. Turn ignition key switch; engage starter for 10 se-conds to the prime hydrostat. Repeat this step again.

10.Connect electrical connector to fuel stop solenoid.

11.Start engine and let it idle at low speed (1750 + 50RPM) for a minimum of 2 minutes. Increase enginespeed to high idle (2650 + 50 RPM) for minimum of 1minute under no load.

12.Raise and lower cutting units several times. Turnsteering wheel fully left and right several times.

13.Shut off engine and check for hydraulic oil leaks.Check oil level in hydraulic tank and add correct amountof oil if necessary.

14.Operate the machine for 2 hours under normal oper-ating conditions.

15.Check condition of hydraulic oil. If the new fluidshows any signs of contamination, repeat steps 1through 15 again until oil is clean. If changing to biode-gradable fluid, repeat steps 1 through 15 again at leastonce and until the oil is clean.

16.Assume normal operation and follow recommendedmaintenance intervals.


Charge Hydraulic System

NOTE: When initially starting the hydraulic system withnew or rebuilt components such as motors, pumps, orlift cylinders, it is important that the hydraulic system becharged properly. Air must be purged from the systemand its components to reduce the chance of damage.

IMPORTANT: Change hydraulic oil filter wheneverhydraulic components are repaired or replaced.

1. Park machine on a level surface, and turn the engineoff.

2. Make sure all hydraulic connections, lines, and com-ponents are secured tightly.

3. If component failure was severe or the system is con-taminated, flush and refill hydraulic system and tank(see Flush Hydraulic System).

4. Make sure hydraulic tank is full. Add correct oil if nec-essary (see Change Hydraulic Fluid).

5. Disconnect fuel stop solenoid lead to prevent the en-gine from starting.

6. Check control cable to the hydrostat for proper ad-justment, binding, or broken parts.

7. Make sure traction pedal and the lift control lever arein the neutral position. Turn ignition key switch; engagestarter for fifteen (15) seconds to prime the traction andcharge pumps.

8. Reconnect fuel stop solenoid lead.

WARNINGBefore jacking up the machine, review and followJacking Instructions in Chapter 1 − Safety.

9. Raise one front and rear wheel off the floor, and placesupport blocks under the frame. Chock remaining wheelto prevent movement of the machine.

10.Make sure traction pedal and lift control lever are inneutral. Start engine and run it at low idle of 1800 RPM.The charge pump should pick up oil and fill the hydraulicsystem. If there is no indication of fill in 30 seconds, stopthe engine and determine the cause.

11.After the hydraulic system starts to show signs of fill,actuate lift control lever until the lift cylinder rod movesin and out several times. If the cylinder rod does notmove after 10 to 15 seconds, or the pump emits abnor-mal sounds, shut the engine off immediately and deter-mine cause or problem. Inspect for the following:

A. Loose filter or suction lines.

B. Loose or faulty coupler on the pump.

C. Blocked suction line.

D. Faulty charge relief valve.

E. Faulty charge pump.

12.If cylinder moves in 10 to 15 seconds, proceed tostep 13.

13.Operate the traction pedal in the forward and reversedirections. The wheel off the floor should rotate in theproper direction.

A. If the wheel rotates in the wrong direction, stopengine, remove lines from rear of pump, and reversethe connections.

B. If the wheel rotates in the proper direction, stopengine and adjust the spring adjusting pin lock nut.

14.Adjust traction pedal to the neutral position (see Ad-just Traction Drive for Neutral).

15.Check operation of the traction interlock switch (seeCheck Interlock System in Chapter 5 − Electrical Sys-tems).

16.Lower machine to ground. Remove chocks fromfront wheel.

17.If the traction pump or a wheel motor was replacedor rebuilt, run the traction unit so all wheels turn slowlyfor 10 minutes.

18.Operate traction unit by gradually increasing its workload to full over a 10 minute period.

19.Stop the machine. Check hydraulic tank and fill ifnecessary. Check hydraulic components for leaks andtighten any loose connections.

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Hydraulic Tank and Hydraulic Oil Filter

1. Grommet (4 used)2. Flange head screw (4 used)3. Barb fitting4. Barb fitting5. Flat washer (4 used)6. Hydraulic tank7. Hose clamp8. Hose clamp9. Hydraulic fitting (straight)10. Flange head screw (2 used)11. Hydraulic fitting (straight)

12. Hydraulic fitting (suction)13. Oil filter element14. Shoulder screw15. Suction strainer16. Dipstick17. Filter head18. Hydraulic tank cap19. Hose clamp20. Hydraulic hose21. O−ring22. O−ring

23. Tether24. O−ring25. O−ring26. Hose27. Not used28. Hydraulic tube29. Plug30. Suction hose31. Suction strainer32. O−ring

Figure 40

1

2

3

4

5

6

7

8

9

10

16

17

18

19

11

12

13

14

15

7

20

28

21

22

22

20

26

29

23

24

25

30

16 to 18 ft−lb(22 to 24 N−m)

14 to 16 ft−lb(19 to 22 N−m)

Anti−seize lubricant30 to 60 in−lb

(3.4 to 6.8 N−m)

Thread Sealant

ThreadSealant

Hydraulic

Hydraulic

LATER MODELS

831

32

30


Hydraulic Tank Removal

1. Drain hydraulic tank (see Change Hydraulic Fluid).

2. Remove hydraulic tank from machine using Figures40 and 41 as guides.

Hydraulic Tank Inspection

1. Clean hydraulic tank and suction strainer with sol-vent.

2. Inspect hydraulic tank for leaks, cracks, or otherdamage.

Hydraulic Tank Installation

1. On early production machines, assemble suctionstrainer and fitting:

NOTE: When applying hydraulic thread sealant to thethreads of fitting and the suction strainer, do not applysealant to the first thread.

A. Apply hydraulic thread sealant to the threads ofthe hydraulic fitting (suction). Secure fitting to thesuction strainer.

B. Apply hydraulic thread sealant to the threads ofthe suction strainer.

2. Apply anti−seize lubricant to four flange headscrews. Secure hydraulic tank to machine with flangehead screws. Torque flange head screws from 30 to 60in−lb (3.4 to 6.8 N−m).

3. Using a wrench, turn suction strainer into tank port atleast 1−1/2 to 2 full turns beyond finger tight.

4. Complete hydraulic tank installation using Figures40 and 41 as guides.

1. Gear pump 2. Suction hose

Figure 41

1

2

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Front Wheel Motors

1. Lock nut2. Spacer3. Socket head screw4. Hydraulic motor

5. Frame6. Hydraulic tube7. Hydraulic tube

8. O−ring9. Hydraulic fitting10. O−ring

Figure 42

FRONT

RIGHT

5

3

6

8

9

10

7

8

9

4

2

1

10


Removal


1. Remove tire and wheel rim, wheel hub, and brakedrum from the hydraulic motor. Remove brake assem-bly, brake bracket, and wheel shield from the frame (seeFront Wheel and Brake Removal in Chapter 6 − Wheels,Brakes, and Miscellaneous).

2. Remove wheel motor from frame using Figure 42 asguide.

Installation

1. Install wheel motor to frame using Figure 42 asguide.

2. Install wheel shield, brake bracket, and brake as-sembly to the frame. Install brake drum, wheel hub, andtire and wheel rim to the hydraulic motor (see FrontWheel and Brake Installation in Chapter 6 − Wheels,Brakes, and Miscellaneous).

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Rear Wheel Motor

1. Lug nut2. Drive stud3. Tire and rim4. Wheel hub5. Hydraulic hose

6. Hydraulic hose7. O−ring8. 45o hydraulic fitting9. Lock nut10. Socket head screw

11. Hydraulic motor12. Rear fork13. O−ring14. Woodruff key

Figure 43

13

7

12

16

8

11

5

6

1

3

10

2

4

8

7

13

14

9

200 to 400 ft−lb271 to 542 N−m

45 to 65 ft−lb61 to 88 N−m


Rear Wheel Removal



2. Jack up rear of machine enough to allow the removalof the rear wheel.

3. Remove rear tire and rim assembly from machine.

4. Remove rear wheel motor with wheel hub attachedfrom the rear fork using Figure 43 as guide.

5. Secure wheel hub in a vise. Loosen but do not re-move lock nut that secures wheel hub to wheel motor.

IMPORTANT: DO NOT hit wheel hub, wheel hubpuller or wheel motor with a hammer during wheelhub removal or installation. Hammering may causedamage to the wheel motor.

6. Using hub puller (see Special Tools), loosen wheelhub from wheel motor.

7. Remove wheel hub and motor from vise. Removelock nut and hub from motor shaft. Locate and retrievewoodruff key.

8. If hydraulic fittings are to be removed from wheel mo-tor, mark fitting orientation to allow correct assembly.

Rear Wheel Installation

1. If hydraulic fittings were removed, install fittings toreel motor using marks made during the removal pro-cess to properly orientate fittings.

2. Thoroughly clean wheel motor shaft and wheel hubtaper.

3. Clamp wheel hub in a vise. Install woodruff key intothe wheel motor shaft. Slide motor shaft into hub and se-cure with lock nut. Torque lock nut from 250 to 350 ft−lb(339 to 474 N−m). Remove wheel motor and hub fromvise.

4. Install wheel motor to the rear fork using Figure 43 asguide.

5. Install tire and rim assembly to machine.

6. Lower the machine to the ground.

7. Torque rear wheel lug nuts from 45 to 65 ft−lb (61 to88 N−m).

8. Make sure hydraulic tank is full. Add correct oil if nec-essary (see Operator’s Manual).

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Wheel Motor Service

1. Dirt seal2. Bearing3. Housing4. Back−up washer5. Seal rings6. Back−up washer7. Inner seal8. Thrust washer9. Thrust bearing10. Bearing

11. Coupling shaft12. Thrust bearing13. Drive link14. Cap screw15. Commutator seal16. Commutator17. Woodruff key18. Wear plate19. Rotor

20. Vane21. Stator22. Manifold23. Commutator ring24. End cover25. Ball26. Spring27. Plug28. O−ring

Figure 44

1 2

3 45

67

89

10

1617

18

1920

21

22

23

24

11

1213

14

15

8

25

26

28

27

2728

NOTE: The wheel motor featured in Figure 44 is therear motor. The three wheel motors are identical inconstruction except for some minor differences. Theright front and rear wheel motors have reverse timedmanifolds, and the front left motor does not. The endcover of the rear motor has a check valve consisting ofa ball and spring, and both front motors lack this feature.

IMPORTANT: If a wheel motor failure occurred, referto Traction Circuit (Closed Loop) Component Fail-ure in the General Information section for informa-tion regarding the importance of removingcontamination from the traction circuit.

NOTE: For repair of the wheel motors, see the RossTorqmotor TM MG, MF, ME, and MJ Series Service Pro-cedure at the end of this chapter.



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Reel Motors

1. Hydraulic motor (front)2. Hydraulic motor (rear)3. Reel motor coupler4. Flange nut5. Hydraulic hose6. 90o hydraulic fitting7. Hydraulic hose

8. Hydraulic straight fitting9. Hydraulic hose10. Hydraulic hose11. Hydraulic tee fitting12. Hydraulic hose13. Hydraulic straight fitting14. Hydraulic hose

15. Hydraulic straight fitting16. O−ring17. O−ring18. O−ring19. O−ring20. O−ring

Figure 45

1

2

34

5

6

7

89

10

16

17

18

19

20

9

11

12

13

1415

12

17

16

13

10

14

16

17

616

17

18

919

19 5

57

7

3

4

30 to 40 ft−lb(41 to 54 N−m)

30 to 40 ft−lb(41 to 54 N−m)


Removal

NOTE: Note position of hydraulic fittings when remov-ing from the reel motors. Position is critical to properlyreconnecting hydraulic hoses.

1. Remove reel motor from the cutting unit (see ReelMotor Removal and Installation in Chapter 7 − CuttingUnits).


2. Remove hydraulic hoses from reel motors using Fig-ure 45 as a guide.

3. If hydraulic fittings are to be removed from reel mo-tor, mark fitting orientation to allow correct assembly.

Installation

1. If hydraulic fittings were removed, install fittings toreel motor using marks made during the removal pro-cess to properly orientate fittings.

2. Install reel motor to the cutting unit (see Cutting UnitRemoval and Installation in Chapter 7− Cutting Units).

3. Install hydraulic hoses to reel motors using Figure 45as a guide.

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Reel Motor Service

1. Plug2. O−ring3. Shim4. Spring5. Ball6. Relief valve seal7. Backplate

8. Idler gear assembly9. Drive gear assembly10. Key11. O−ring12. Body13. Alignment pin

14. Frontplate15. Cap screw16. Retaining ring17. Oil seal18. Backup washer19. Relief valve assembly (items 1 thru 6)

Figure 46

1 2 3 4 56

7

89

10

1617

18

19

1112

1314

15

11

13

25 to 28 ft−lb(34 to 38 N−m)

10 to 12 ft−lb(13.6 to 16.3 N−m)

Disassembly (Fig. 46)

1. Make sure key is removed from the drive gear shaft.

2. Matchmark frontplate, body, and backplate to assureproper reassembly.

3. Secure the motor in a vise with the drive shaft up.

4. Remove all cap screws used to assemble motor.

5. Remove the motor from the vise. Remove the front-plate from the body. A wooden block or soft face ham-mer might be used to gently tap the motor when freeingthe frontplate.

6. Remove alignment pin from the body. Remove drivegear and idler gear from the body.

7. Remove body from the backplate. Remove O−ringsfrom the body and backplate.

8. Remove alignment pin from the backplate.

9. Remove retaining ring, oil seal, and backup washerfrom the frontplate.

IMPORTANT: Do not remove the relief valve as-sembly unless testing shows it to be faulty. The re-lief valve assembly must be replaced as a completeunit. Both relief valve seals are sealed in place withthread sealant; do not remove them.

10.Remove plug, O−ring, shim, spring, and ball from thebackplate.


Inspection (Fig. 46)

1. Remove all nicks and burrs from all parts with anemery cloth.

CAUTION

Use eye protection such as goggles when usingcompressed air.

2. Clean all parts with solvent. Dry all parts with com-pressed air.

3. Inspect drive gear shaft for a broken or chipped key-way.

4. Inspect drive gear and idler gear shafts at the bush-ing points and seal area for rough surfaces and exces-sive wear.

5. Replace drive gear or idler gear if the shaft diameterin the bushing area measures less than 0.748 in. (19.0mm). A single gear may be replaced separately.

6. The drive gear and idler gear face should be free ofexcessive scoring and wear.

7. Replace drive gear or idler gear if gear width is lessthan 1.140 in. (29.96 mm).

8. Make sure that retaining rings are in the grooves onboth sides of the gear for both the drive gear and idlergear.

9. Break sharp edges of gear teeth with emery cloth.

10.Replace backplate and frontplate if bushing insidediameters exceed 0.755 in. (19.2 mm). The bushingsare not available as replacement items.

11.The face of the backplate and frontplate should befree of excessive scoring. Replace if scoring a depth of0.0015 in. (0.038 mm).

12.Replace body if the inside diameter of the gear pock-ets exceeds 1.713 in. (43.5 mm).

13.Make sure both plugs are secure if they or the back-plate is not being replaced.

Reassembly (Fig. 46)

1. If replacing the relief valve assembly, install ball,spring, shim, O−ring, and plug into the backplate. Handtighten plug and then torque from 10 to 12 ft−lb (13.6 to16.3 N−m).

2. Coat O−ring lightly with petroleum jelly and install ingroove on the front plate.

3. Apply a thin coat of petroleum jelly to both gear pock-ets of the body. Install alignment pin into body.

4. Align matchmarks and slip body onto front plate untilalignment pin is engaged.

5. Dip idler gear and drive gear into clean hydraulic oiland slip into front plate bushings.

6. Coat O−ring lightly with petroleum jelly and install ingroove on the back plate.

7. Install alignment pin into back plate.

8. Align matchmarks and slip back plate over gearshafts onto body until alignment pin is engaged.

9. Hand tighten cap screws. Torque cap screws in acrisscross pattern from 25 to 28 ft−lb (33.9 to 38.0 N−m).

10.Place washer over the drive shaft into the front platehousing. Apply a liberal coat of hydraulic oil to the oilseal. Install oil seal over the drive shaft being careful notto cut the rubber seal lips.

11.Place 1−1/16 inch O.D. sleeve over the drive shaftand press in the oil seal until the retaining ring grooveappears.

12.Press retaining ring into the housing using the sleeveuntil it seats in the groove.

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Oil Cooler

Removal

CAUTION

The radiator and oil cooler may be hot. To avoidpossible burns, allow the engine and coolingsystems to cool before working on the oil cooler.

1. Remove oil cooler using Figures 47 and 48 asguides.

Inspection

CAUTION


1. Back flush oil cooler with cleaning solvent. After cool-er is clean, make sure all solvent is drained from thecooler.

2. Dry inside of oil cooler using compressed air in theopposite direction of the oil flow.

3. Plug both ends of oil cooler. Clean exterior of cooler.Make sure fins are clear of dirt and debris.

4. The oil cooler should be free of corrosion, crackedtubes, and excessive pitting of tubes.

Installation

1. If removed, apply hydraulic thread sealant to thebarb fitting threads before installing.

2. Install oil cooler using Figures 47 and 48 as guides.

1. OIl cooler 2. Clip

Figure 47

2

1

1. Oil cooler2. Lanyard3. Barb fitting4. Hydraulic hose5. Hose clamp

6. Hydraulic tube7. Hydraulic tube8. Flow to filter9. Flow from manifold

Figure 48

21

7

4

5

5

6

4

3

5

5

FRONT

RIGHT

9

8

THREAD SEALANTHYDRAULIC

3


Hydraulic Manifold

1. Hose clamp2. Micro switch3. Barb fitting4. Flange head screw5. Straight hydraulic fitting6. Straight hydraulic fitting7. 90o hydraulic fitting8. 45o hydraulic fitting9. Straight hydraulic fitting10. Barb fitting

11. Hydraulic manifold12. Hydraulic hose13. Hydraulic hose14. Hose clamp15. Spacer16. Philips pan head screw17. O−ring18. O−ring19. O−ring20. O−ring

21. Hydraulic tube22. O−ring23. Hose24. Hydraulic hose25. Hydraulic hose26. Hydraulic hose27. Hydraulic hose28. Hydraulic hose29. Hose

Figure 49

1

2

3

4

9

6

7

8

1016

11

1415

5

5

7

6

17

18

18

17

24

2527

2619

20

28 18 22 29

12

20

1318

17

18

17

23

21

19

FRONT

RIGHT

Removal

NOTE: The ports on the manifold are marked for easyidentification of components. Example: R1 is the reel cir-cuit relief valve and P1 is the gear pump connection port(See Hydraulic Schematics to identify the function of thehydraulic lines and cartridge valves at each port loca-tion).

1. Remove hydraulic manifold from the machine usingFigure 49 as guide.

2. If hydraulic fittings are to be removed from manifold,mark fitting orientation to allow correct assembly.

Installation

1. If hydraulic fittings were removed, install fittings tomanifold using marks made during the removal processto properly orientate fittings.

2. Install hydraulic manifold to the frame using Figure49 as guide.

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Hydraulic Manifold Service

1. Manifold body2. Relief valve cartridge3. Solenoid operated cartridge valve4. Rotary cartridge valve (directional)5. Solenoid coil6. Logic control cartridge7. Rotary cartridge valve (flow control)8. Cartridge cavity plug9. Orifice plug10. Plug (SAE−2)11. Plug (SAE−4)

12. Indicator plate13. Indicator plate14. Plug (SAE−6)15. Plug16. Seal kit17. Locating plate18. Set screw19. Detent plate20. Compression spring21. Jam nut

22. Knob23. Nut24. O−ring25. Seal kit26. Compression spring27. Locating plate28. Seal kit29. O−ring30. O−ring31. O−ring

Figure 50

31

28

1

2

3

4

5

6

7

8

9

10

16

17

1819

20

21

22

23

24

25

26

27

32

29

30

11

12

13

14

15

24

25

22

21

19

1810

14

11

11

11

11

11

31

30

25

FRONT

RIGHT

30 to 35 ft−lb(41 to 47 N−m)

30 to 35 ft−lb(41 to 47 N−m)

42 to 45 ft−lb(57 to 61 N−m)

30 to 35 ft−lb(41 to 47 N−m)

Loctite 2422 to 5 ft−lb

(2.7 to 6.8 N−m)

30 to 35 ft−lb(41 to 47 N−m)

HYDRAULIC MANIFOLD USED ONMACHINES WITH SERIAL NUMBERS

BELOW 250999999


1. Manifold body2. Plug (Zero Leak #8)3. Rotary cartridge valve (flow control)4. Rotary handle assembly5. Solenoid relief cartridge valve6. Nut7. Solenoid coil8. Logic control cartridge

9. Plug (Zero Leak #4) (10 used)10. Spring pin (2 used)11. Plug (SAE #4)12. Mow/backlap spool13. Ball14. Dowel pin15. O−ring

16. Ball switch (N.C.)17. Plug (Zero Leak #2) (2 used)18. Orifice (.020)19. Plug (Zero Leak #6)20. Check valve21. Plug (SAE #6) (2 used)22. Orifice (.073)

Figure 51

5

9

2

1

6

4

3

7

8

10

12

11

1314

16

15

17

18

19 20

21

25 ft−lb(34 N−m)

48 to 60 in−lb(5.4 to 6.7 N−m)

20 ft−lb(27 N−m)

120 in−lb(13.5 N−m)

25 ft−lb(34 N−m)

25 ft−lb(34 N−m)

41 ft−lb(55 N−m)

220 in−lb(25 N−m)

120 in−lb(13.5 N−m)

15 ft−lb(20 N−m)

90 in−lb(10.1 N−m)

198 in−lb(22 N−m)

22

FRONT

RIGHT

HYDRAULIC MANIFOLD USED ONMACHINES WITH SERIAL NUMBERS

ABOVE 260000000

NOTE: The ports on the hydraulic manifold are markedfor easy identification of components. Example: FC1 isthe flow control valve and P1 is the gear pump connec-tion port (See Hydraulic Schematics to identify the func-tion of the hydraulic lines and cartridge valves at eachport location).

NOTE: The hydraulic manifold shown in Figure 51 usesseveral zero leak plugs. These plugs have a taperedsealing surface on the plug head that is designed to re-sist vibration induced plug loosening. The zero leakplugs also have an O−ring to provide a secondary seal.If zero leak plug removal is necessary, lightly rap theplug head using a punch and hammer before using anallen wrench to remove the plug: the impact will allowplug removal with less chance of damage to the sockethead of the plug. When installing plugs into the manifold,torque plugs to the values identified in Figure 51.

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Solenoid Operated, Relief and Logic Control Car-tridge Valves

1. Make sure the manifold is clean before removing thecartridge valve and seal kit.

Note: On manifold shown in Figure 50, solenoid coilhas an O−ring on each side of the coil.

2. If solenoid valve is to be removed from manifold, re-move nut securing solenoid to the cartridge valve. Care-fully slide solenoid and O-rings (if equipped) off thevalve.

IMPORTANT: Use care when handling the cartridgevalve. Slight bending or distortion of the stem tubecan cause binding and malfunction.

3. Remove cartridge valve from manifold with a deepsocket wrench. Remove seal kit from valve.

4. Visually inspect the manifold port and cartridge valvefor damage to sealing surfaces, damaged threads, andcontamination.

A. Contamination may cause valves to stick or hangup. Contamination can become lodged in small valveorifices or seal areas causing valve malfunction.

B. If valve sealing surfaces appear pitted or dam-aged, the hydraulic system may be overheating orthere may be water in the system.

CAUTION


5. Cleaning cartridge valves:

A. For non−solenoid operated valves:Submerge valve in clean mineral spirits to flush outcontamination. If valve design allows, use a probe topush the internal spool in and out 20 to 30 times toflush out contamination. Particles as fine as talcumpowder can affect the operation of high pressure hy-draulic valves. Clean and dry cartridge with com-pressed air.

B. For solenoid operated valves:Temporarily install solenoid on cartridge valve andconnect a 12 volt power source to the solenoid. Whileenergized, flush out any contamination with a non-flammable aerosol brake cleaner. De-energize thesolenoid. Repeat the flush while energized proce-dure 5 or 6 times. Particles as fine as talcum powdercan affect the operation of high pressure hydraulicvalves. Remove solenoid from cartridge.

6. Reinstall the cartridge valve into the manifold:

A. Lubricate new O-rings and backup rings of sealkit with clean hydraulic oil and install on cartridge.The O-rings and backup rings must be arrangedproperly on the cartridge valve for proper operationand sealing.


B. Thread cartridge valve carefully into correct man-ifold port. The valve should go in easily without bind-ing.

C. Torque cartridge valve using a deep socket tospecification shown in manifold illustration.

Note: On manifold shown in Figure 50, solenoid coilhas an O−ring on each side of the coil. Also, on this man-ifold, apply Loctite 242 or equivalent to the threads of thevalve before installing the coil nut.

7. For solenoid valve, install solenoid coil and O-rings(if equipped) to the cartridge valve. Torque nut to specifi-cation shown in manifold illustration.

8. If problems still exist, remove valve and clean againor replace valve.

Rotary Cartridge Valves

1. Remove knob assembly (manifold shown in Fig. 50):

A. Unscrew and remove knob. Remove both jamnuts.

B. Slide off indicator plate being careful not to losesprings. Remove spring.

C. Loosen set screw and slide detent plate off thecartridge valve stem.

D. Remove locating plate with pin from the cartridgevalve stem and manifold.

2. Remove rotary handle (manifold shown in Fig. 51)(Fig. 52):

A. Loosen two (2) set screws that secure handlecap.

B. Remove screw and then lift handle cap fromvalve.

C. Locate and retrieve detent pin, compressionspring, bushing and lip seal. The sleeve bearingshould stay in the cap.

D. Loosen two (2) set screws that secure handlebase to flow control valve and remove base.


3. Make sure manifold is clean before removing therotary cartridge valve. Remove the valve and seal kit.

4. Visually inspect the manifold port and cartridge valvefor damage to sealing surfaces, damaged threads, andcontamination.

A. Contamination may cause valves to stick or hangup, it can become lodged in small valve orifices orseal areas causing valve malfunction.

B. If sealing surfaces appear pitted or damaged, thehydraulic system may be overheating or there maybe water in the system.

CAUTION


5. If necessary, clean cartridge valve using clean min-eral spirits. Submerge valve in clean mineral spirits toflush out contamination. Particles as fine as talcum pow-der can affect the operation of high pressure hydraulicvalves. Clean and dry with compressed air.

6. Reinstall rotary cartridge valve into manifold port:

A. Lubricate new O-rings and backup rings of sealkit with clean hydraulic oil and install. The O-ringsand backup rings of seal kit must be arranged prop-erly on the cartridge valve for proper operation andsealing.


B. Thread rotary cartridge valve carefully into themanifold port. The valve should go in easily withoutbinding. Torque valve to specification shown in man-ifold illustration.

7. Install knob assembly (manifold shown in Fig. 50):

A. Install locating plate so that the pin seats into thelocating hole.

B. Turn the threaded cartridge valve stem carefullyclockwise until it stops.

C. Face detent plate counterbore down. Thread det-ent plate down onto the valve stem until it is stoppedby the locating plate. Turn detent plate back counter-clockwise 1/4 turn.

D. Center one detent plate hole over a locating plateindentation. Drop a ball into each hole, then drop aspring into each hole.

1. Handle Base2. Handle Cap3. Detent Pin4. Compression Spring5. Bushing6. Set Screw (2 used)

7. Set Screw (2 used)8. Screw9. Lip Seal10. Sleeve Bearing11. Flow Control Valve

Figure 52

6

5

4

7

9

10

3

2

8

1

11

E. On the 2-position directional valve cartridge,place indicator plate over the detent plate. Make surethe arrow points directly at the number 1 on the locat-ing plate.

F. On flow control cartridge valve cartridge, place in-dicator plate over the detent plate. Make sure the ar-row points to the right at 45�.

G. While pushing down on the indicator plate andcompressing the springs, thread down a jam nut.While tightening the set screw, tighten jam nut at thesame time using a 7/16 - inch wrench.

H. Thread second jam nut all the way down the valvestem. Apply ”Loctite 242” or equivalent to the valvestem threads. Screw knob all the way down until itcontacts the upper jam nut.

I. On 2-position directional cartridge valve car-tridge, turn knob counterclockwise so the arrow is90� with the back of the manifold. Simultaneouslytighten upper jam nut and turn knob so it is tight andthe arrow is pointing 45� to the right in line with theindicator plate.

J. On flow control valve cartridge, turn knob coun-terclockwise until the arrow points at the number ”5”.Simultaneously tighten upper jam nut and turn knobso it is tight and the arrow is pointing at the number”1” on the locating plate.

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8. Install rotary handle (manifold shown in Fig. 51) (Fig.52):

A. Place handle base on flow control valve and posi-tion alignment mark on base with number 1 on man-ifold. Secure base with two (2) set screws. Apply alight coating of grease to chamfer on top of base toease seal installation.

B. Make sure that sleeve bearing is in handle cap. Ifnecessary, press sleeve bearing into cap. Install lipseal on cap with seal lip facing down.

C. Place bushing onto cartridge valve stem. Use asmall amount of grease to keep bushing toward thetop of the valve stem.

D. Place compression spring and detent pin intohandle cap. Use a small amount of grease to holddetent pin in place.

E. Make sure that flow control valve is closed by ro-tating valve stem fully clockwise. During handleinstallation, DO NOT rotate valve stem or speed ad-justment will be incorrect.

F. Press handle cap onto valve stem with arrow oncap pointing to number 9 on manifold. Make sure thatdetent pin and spring stay positioned in cap.

G. While pressing on the cap to keep the lip seal inplace, rotate cap in a clockwise direction until the ar-row on the cap aligns with number 1 on the manifold.By rotating the cap clockwise, the valve will remainclosed. Install screw to retain cap.

H. Make sure that alignment marks on cap and baseare in line and that arrow on cap is pointing to number1 on manifold. Tighten two (2) set screws to securehandle cap.

Mow/Backlap Spool (Reel Manifold Shown in Fig.51) (Fig. 53)

1. Remove spool from mow manifold:

A. Remove backlap switch from mow manifold be-fore removing mow/backlap spool. Remove dowelpin and ball from manifold port after switch is re-moved. Remove and discard O−ring from switch.

B. Remove lower retaining ring from mow/backlapspool. Raise mow/backlap spool to allow access toretaining ring on upper end of spool. Remove upperretaining ring.

C. Push spool down until O−ring and back−up ringare exposed on bottom of mow manifold. Removelower O−ring and back−up ring from spool.

D. Pull spool up and out of manifold. Remove O−rings and back−up ring from spool.

E. Discard removed O−rings and back−up rings.

2. Visually inspect the spool and manifold port for dam-age to the sealing surfaces and contamination.

3. Install spool into mow manifold:

A. Install O−rings and back−up ring to uppergrooves on spool. Apply a light coating of grease toO−rings.

B. Carefully push spool down into mow manifoldport until lower O−ring and back−up ring groove isexposed on bottom of manifold. Install lower O−ringand back−up ring to spool. Apply a light coating ofgrease to O−ring.

C. Carefully raise mow/backlap spool until upper re-taining ring groove on spool is exposed on top ofmanifold. Install upper retaining ring.

D. Push mow/backlap spool down and install lowerretaining ring to spool.

E. If handle was removed from spool, position spoolso handle location of spool is between stop pins. Ap-ply Loctite 603 Retaining Compound (or equivalent)to threads on handle and install handle into spool.

F. Place ball and dowel pin in backlap switch man-ifold port. Install new O−ring onto backlap switch.Thread backlap switch into port and torque 15 ft−lb(20 N−m).

1. Retaining ring2. O−ring3. Back−up ring

4. O−ring5. Spool handle6. Rotary spool

Figure 53

12

3

45

6

13

4

Loctite 603



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Control Valve (Model 03200, 03206)

1. Straight hydraulic fitting2. 90o hydraulic fitting3. Hydraulic fitting4. 90o hydraulic fitting5. Control valve (single spool)6. Carriage screw (2 used)7. Flange nut

8. Shoulder bolt9. Valve lever assembly10. Link (2 used)11. Bolt12. Lock nut (2 used)13. Knob

14. Hydraulic hose15. Hydraulic hose16. Hydraulic tube17. O−ring18. O−ring19. O−ring

Figure 54

4

3 2

7

5

8

6

8

7 12

9

11

11

10

13

1

15

14

16

17

18

17

18

17

19

17


Removal


1. Remove control valve from the frame using Figures54 and 55 as guides.

2. If hydraulic fittings are to be removed from controlvalve, mark fitting orientation to allow correct assembly.

Installation

1. If hydraulic fittings were removed, install fittings tocontrol valve using marks made during the removal pro-cess to properly orientate fittings.

2. Install control valve to the frame using Figures 54and 55 as guides.

1. Spool Valve2. Magnet support bracket

3. Flange head screws4. Frame

Figure 55

2

14

3

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Control Valve Service (Model 03200, 03206)

3

4

6

8

10

16

17

18

19

2

22

23

11

12

13

14

7

5

1

30

29

24

28

2526

12

9

27

1. Check poppet2. Plunger3. Spacer4. Spool5. Seat6. Plug (solid)7. Seat retaining plug8. Bushing9. Check spring10. Spool cap

11. Valve body12. O−ring13. Retaining ring14. Washer15. Not used16. Spool spring17. Disc18. Plug19. Detent plug20. Not used

21. Not used22. Plunger detent23. Spring24. O−ring25. O−ring26. Back−up washer27. O−ring28. O−ring29. O−ring30. Back−up washer

Figure 56

20 to 25 ft−lb(27 to 34 N−m)

30 to 35 ft−lb(41 to 48 N−m)

30 to 42 ft−lb

30 to 35 ft−lb(41 to 48 N−m)

(41 to 57 N−m)10 to 12 ft−lb

(14 to 16 N−m)


6 26 25 2 1 27 5 9 29 730

1917

23

24

25

266

18

4 12

12 8 14

16

13

3 10

28 22

1. Check poppet2. Plunger3. Spacer4. Spool5. Seat6. Plug (solid)7. Seat retaining plug8. Bushing9. Check spring10. Spool cap

11. Valve body12. O−ring13. Retaining ring14. Washer15. Not used16. Spool spring17. Disc18. Plug19. Detent plug20. Not used

21. Not used22. Plunger detent23. Spring24. O−ring25. O−ring26. Back−up washer27. O−ring28. O−ring29. O−ring30. Back−up washer

Figure 57

11

11

11

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Disassembly

1. Plug all ports and clean the outside of the valve thor-oughly.

2. Remove spool cap and slide the spool assemblyfrom its bore.

3. Remove O−ring and bushing from the spool assem-bly.

4. Remove O−ring from the spool bore end that is oppo-site the spool cap.

NOTE: Disassemble spool assembly only if the retain-ing ring, spacer, spring, or washer need replacing.

5. Remove seat retaining plug, back−up washer, O−ring, and check spring from the valve body.

6. Remove check poppet, seat, O−ring, and plungerfrom the valve body.

7. Remove solid plug, back−up washer, and O−ringfrom the opposite end of the plunger.

8. Remove plug and O−ring from the top of the valvebody next to the detent plug.

9. Remove detent plug and O−ring from the valve body.Remove disc spring, and detent plunger from the body.

Inspection

1. Inspect spool and spool bore for wear. If wear is ex-cessive, replace valve with new one.

2. Inspect springs and replace as necessary.

3. Inspect plunger, detent plunger, and check poppetfor wear. Replace as necessary.

4. Inspect seat, spacer, and bushing for wear. Replaceas necessary.

5. Inspect disc and washer. Replace as necessary.

6. Inspect cap and plugs for damaged threads and O−ring sealing surfaces. Replace as necessary.

Assembly

IMPORTANT: Do not wipe parts with paper towels orrags. Lint free cloth must be used to prevent lintfrom causing damage to the hydraulic system.

CAUTION


1. Clean all metal parts with solvent and blow dry withcompressed air.

2. Replace check poppet, O−rings, and back−up wash-ers with new ones.

3. Install new O−rings into the valve body.

4. Slide bushing and new O−ring over the spool.

5. If the spool was disassembled, install washer, spoolspring, spacer, and retaining ring to the spool.

6. Lubricate spool liberally with clean hydraulic fluidand install into its proper bore.

7. Install spool cap into valve body. Torque cap from 20to 25 ft−lb (27 to 34 N−m).

8. Install O−ring, back−up washer, and solid plug intothe bore on the opposite end of the plunger. Torque plugfrom 30 to 35 ft−lb (41 to 48 N−m).

9. Lubricate plunger liberally with clean hydraulic fluidand install into its valve body bore.

10.Install new O−ring, seat, check poppet, and checkspring into the plunger bore.

11. Install O−ring, back−up washer, and seat retainingplug into the plunger bore. Torque plug from 30 to 35 ft−lb (41 to 48 N−m).

12.Install O−ring and plug into the top of the valve bodynext to the detent plug bore. Torque plug from 10 to 12ft−lb (14 to 16 N−m).

13.Lubricate plunger detent, spring, and disc liberallywith clean hydraulic fluid and install into its valve bodybore.

14.Install O−ring and detent plug into its proper bore.Torque plug from 30 to 42 ft−lb (41 to 57 N−m).



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Control Valve (Model 03201, 03207)

1. Control valve (2−spool)2. Hydraulic fitting (straight)3. 90o hydraulic fitting4. Hydraulic fitting (straight)5. Flange nut6. Knob7. 90o hydraulic fitting8. Valve actuator bracket9. Shoulder bolt

10. Cotter pin11. Valve lever12. Valve actuator trunnion13. Shoulder bolt14. Link (4 used)15. Bolt16. Lock nut17. Push nut18. Hydraulic fitting

19. Carriage screw (2 used)20. O−ring21. O−ring22. Hydraulic tube23. Hydraulic tube24. Hydraulic hose25. O−ring26. Hydraulic hose27. Hydraulic tube

Figure 58

1

2

3

4

5

6

7

8

9

10

16

17

18

19

20

21

22

23

24

25

26 27

1112

13

14

15

14

17

25

7

21

25

21

21

25

21

21

5

5

9


Removal


1. Remove control valve from the frame using Figures58 and 59 as guides.

2. If hydraulic fittings are to be removed from controlvalve, mark fitting orientation to allow correct assembly.

Installation

1. If hydraulic fittings were removed, install fittings tocontrol valve using marks made during the removal pro-cess to properly orientate fittings.

2. Install control valve to the frame using Figures 58and 59 as guides.

1. Spool valve2. Magnet support bracket

3. Flange head screws4. Frame

Figure 59

2

14

3

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Control Valve Service (Model 03201, 03207)

1. Check poppet2. Grooved plunger3. Spacer4. Spool5. Seat6. Solid plug7. Seat retaining plug with port8. Bushing9. Check spring10. Spool cap

11. Valve body12. O−ring13. Retaining ring14. Washer15. Seat retaining plug16. Spool spring17. Disc18. Plug19. Detent plug20. Wiper seal

21. Plunger22. Plunger detent23. Detent spring24. O−ring25. O−ring26. Back−up washer27. O−ring28. O−ring29. O−ring30. Back−up washer

Figure 60

1

2

3

4

5

6

15

8

9

10

16

17

18

19

20

21

22

23

11

12

13

14

7

51

3029

24

2825

26

27

2526

12

9

27

275

1

7

30

29

9

10

4

30 to 42 ft−lb(41 to 57 N−m)

10 to 12 ft−lb(14 to 16 N−m)

30 to 35 ft−lb(41 to 48 N−m)

30 to 35 ft−lb(41 to 48 N−m)

30 to 35 ft−lb(41 to 48 N−m)

20 to 25 ft−lb(27 to 34 N−m)

20 to 25 ft−lb(27 to 34 N−m)


1. Check poppet2. Grooved plunger3. Spacer4. Spool5. Seat6. Solid plug7. Seat retaining plug with port8. Bushing9. Check spring10. Spool cap

11. Valve body12. O−ring13. Retaining ring14. Washer15. Seat retaining plug16. Spool spring17. Disc18. Plug19. Detent plug20. Wiper seal

21. Plunger22. Plunger detent23. Detent spring24. O−ring25. O−ring26. Back−up washer27. O−ring28. O−ring29. O−ring30. Back−up washer

Figure 61

20

12 8 3

13

1614124

18

28

2224

23

15

9

26 25 27 305

1

27 292119

175 1

6 26 25 1 9 7

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Disassembly

1. Plug all ports and clean the outside of the valve thor-oughly.

IMPORTANT: Match mark spools to their associat-ed bores. Spools must be reinstalled to the borefrom which they were removed.

2. Remove both spool caps and slide the spool assem-blies from their bores.

3. Remove O−ring and bushing from each spool as-sembly.

4. Remove wiper seals O−rings from the spool boreends that are opposite the spool caps.

NOTE: Disassemble spool assemblies only if the re-taining ring, spacer, spring, or washer need replacing.

5. Remove seat retaining plugs, back−up washers, O−rings, and check springs from the valve body.

6. Remove check poppets, seats, O−rings, and plung-ers from the valve body.

7. Remove solid plug, back−up washer, and O−ringfrom the opposite end of the plunger.

8. Remove plug and O−ring from the top of the valvebody next to the detent plug.

9. Remove detent plug and O−ring from the valve body.Remove disc spring, and detent plunger from the body.

Inspection

1. Inspect spools and spool bores for wear. If wear isexcessive, replace valve with new one.

2. Inspect springs and replace as necessary.

3. Inspect plunger, detent plunger, and check poppetfor wear. Replace as necessary.

4. Inspect seat, spacer, and bushing for wear. Replaceas necessary.

5. Inspect disc and washer. Replace as necessary.

6. Inspect cap and plugs for damaged threads and O−ring sealing surfaces. Replace as necessary.

Assembly

IMPORTANT: Do not wipe parts with paper towels orrags. Lint may cause damage to the hydraulic sys-tem.

CAUTIONUse eye protection such as goggles when usingcompressed air.

1. Clean all metal parts with solvent and blow dry withcompressed air.

2. Replace check poppets, O−rings, and back−upwashers with new ones.

3. Install new O−rings into the valve body.

4. Slide bushings and new O−rings over the spools.

5. If a spool was disassembled, install washer, spoolspring, spacer, and retaining ring to the spool.

6. Lubricate spools liberally with clean hydraulic fluidand install into their proper bore.

7. Install spool caps into valve body. Torque caps from20 to 25 ft−lb (27 to 34 N−m).

8. Lubricate both plungers liberally with clean hydraulicfluid and install into their proper bore.

9. Install new O−rings, seats, check poppets, andcheck springs into the plunger bores.

10.Install O−rings, back−up washers, and seat retainingplugs into their plunger bores. Torque both plugs from 30to 35 ft−lb (41 to 48 N−m).

11. Install new O−ring, back−up washer, and solid pluginto the bore with the grooved plunger. Torque plug from30 to 35 ft−lb (41 to 48 N−m).

12.Install new O−ring, seat, check poppet, check spring,new O−ring, back−up washer, and seat retaining pluginto the bore with the plunger. Torque plug from 30 to 35ft−lb (41 to 48 N−m).

13.Install O−ring and plug into the top of the valve bodynext to the detent plug bore. Torque plug from 10 to 12ft−lb (14 to 16 N−m).

14.Lubricate plunger detent, spring, and disc liberallywith clean hydraulic fluid and install into its valve bodybore.

15.Install O−ring and detent plug into its proper bore.Torque plug from 30 to 42 ft−lb (41 to 57 N−m).



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Piston Pump

1. Piston pump2. Straight hydraulic fitting3. Cap screw4. Lock nut5. 90o hydraulic fitting6. 90o hydraulic fitting7. 90o hydraulic fitting8. 90o hydraulic fitting9. 90o hydraulic fitting10. Washer11. Hydraulic hose12. Suction hose13. Flange nut14. Idler pivot pin15. Grease fitting16. Flange nut17. Retaining ring18. Cap screw19. Thrust washer

20. Idler pulley21. Spacer22. Torsion spring23. Idler arm24. Hose clamp25. Flange nut26. Cap screw27. Flange head screw28. Pump support29. Spacer30. Cap screw31. Flat washer32. Spacer33. Pump mount plate34. Pump mount spacer35. Pulley36. Cap screw37. Lock washer38. Taper lock bushing

39. V−belt40. O−ring41. O−ring42. O−ring43. O−ring44. O−ring45. O−ring46. O−ring47. O−ring48. Hydraulic hose49. Hydraulic hose50. Hydraulic hose51. Hydraulic hose52. Bushing53. Gear pump54. O−ring55. Flat washer56. Socket head screw57. Set screw

Figure 62

31

32

33

34

35

36

3738

39

1

2

3

4

5

6

78

9

10

16

17

18

19

20

2122

23

24

25

26 2728

29

30

11

12

13

1415

25

10

10

27

48

47

45

44

4950

43

45

44

42

51

40

40

41

41

52

52

5354

55

56

30

57

19 FRONT

RIGHT

AntiseizeLubricant

AntiseizeLubricant

27 to 31 ft−lb(37 to 42 N−m)

90 to 120 in−lb(10.2 to 13.6 N−m)

IMPORTANT: If a piston pump failure occurred, re-fer to Traction Circuit (Closed Loop) ComponentFailure in the General Information section for infor-mation regarding the importance of removing con-tamination from the traction circuit.


Neutral Arm Assembly

1. Philips head screw2. Flat washer3. Micro switch4. Keps nut5. Neutral bracket6. Flange nut7. Flange head nut8. Neutral arm9. Flange bushing10. Thrust washer11. 90o grease fitting12. Lock nut

13. Spacer14. Traction stud15. Traction control cable16. Isolator stud17. Flat washer18. Extension spring19. Cap screw20. Flat washer21. Pump lever22. Flange nut23. Flange head screw24. Cable support bracket

25. Ball bearing26. Rod end27. Lock nut28. Screw29. Cap screw30. Pump mount plate31. Spring dampener32. Adjuster bracket33. Flat washer34. Isolation mount35. Lock nut36. Piston pump

Figure 63 16

17

23 24

7

15

18

22

5

6

4 3

7

2

9

1 12

8

11

10 9

14

12

21

13

25

19

20

26 27

28

29

31

32

33 34

34 33

35

30

36

EARLY MODELS

Piston Pump Removal (Fig. 62)

1. Remove traction belt from the pulley (see ReplaceTraction Belt).

2. Remove pulley from the taper lock bushing:

A. Remove cap screws securing pulley to the taperlock bushing.

IMPORTANT: Excessive or unequal pressure on thecap screws can break the bushing flange.

B. Insert cap screws into threaded removal holes ofthe pulley. Tighten screws progressively and evenlyuntil the pulley is loose on the bushing. Removepulley from the bushing.

CAUTIONThe extension spring is under tension and maycause personal injury during removal. Use cau-tion when removing spring from the pump lever.

3. Remove neutral arm assembly from the piston pumpas follows (Figs. 63 and 64):

A. Disconnect electrical connector from the microswitch (early models).

B. Remove extension spring from the cable supportbracket and pump lever.

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C. Disconnect traction control cable from the pumplever.

D. Remove both flange head screws securing theneutral bracket to the piston pump. Remove flangenut and flange head screw securing the neutralbracket to the pump mount plate.

E. Remove cap screw and flat washer securing thepump lever to the piston pump trunnion.

F. Separate pump lever from pump trunnion andneutral bracket from mount plate.

4. Drain hydraulic oil from hydraulic tank (see ChangeHydraulic Fluid in this section).


5. Disconnect all hydraulic hoses connected to the hy-draulic fittings on the piston and gear pumps. Allowhoses to drain into a suitable container.

CAUTIONSupport piston and gear pumps when removingthem from the pump support and pump mountplate to prevent them from falling and causingpersonal injury.

6. Remove both cap screws, washers, and spacers se-curing the piston pump to the pump support.

7. Remove both lock nuts, cap screws, and washerssecuring the piston pump to the pump mount plate. Pullpumps from the machine.

8. Remove both socket head screws and flat washerssecuring gear pump to the piston pump. Separate gearpump and O−ring from the piston pump. Plug openingsof gear pump to prevent contamination.

9. Remove hydraulic fittings and O−rings from the pis-ton pump.

10.Remove taper lock bushing from the piston pumpshaft.

11. If hydraulic fittings are to be removed from pump,mark fitting orientation to allow correct assembly.

1. Extension spring2. Cable support bracket3. Pump lever4. Traction control cable5. Neutral bracket6. Pump mount plate7. Flange head screw

8. Flange nut9. Piston pump10. Flange head screw11. Flange nut12. Flat washer13. Cap screw14. Pump lever hub

Figure 64

13

6

5

7

9

12

8

10

7

11

2

1

3

4

14

LATER MODELS

Figure 651. Gear pump 2. Suction port

2

1


Piston Pump Installation (Fig. 62)

1. If hydraulic fittings were removed, install fittings topump using marks made during the removal process toproperly orientate fittings.

2. Place key into pump shaft slot. Slide taper lock bush-ing onto the piston pump shaft with bushing flange to-ward pump housing.

3. Make sure that tapered surfaces of pulley and taperlock bushing are thoroughly clean (no oil, grease, dirt,rust, etc.).

4. Position pulley to taper lock bushing and align non−threaded holes of pulley with threaded holes of bushing.Loosely install three (3) cap screws with lock washers tobushing and pulley.

5. Install O−rings and hydraulic fittings to their originalpositions on the piston pump.

NOTE: If installing a new gear pump to the piston pump,make sure to remove the plug from the suction port ofthe gear pump (Fig. 65). The gear pump suction fittingmust be on the same side as the trunnion of the pistonpump.

6. Remove plugs from the gear pump. Secure O−ringand gear pump to the piston pump with both flat washersand socket head screws. Torque fasteners from 27 to 31ft−lb (37 to 42 N−m).

CAUTIONSupport piston and gear pumps when installingthem to the pump mount plate and pump supportto prevent them from falling and causing person-al injury.

7. Position piston pump to the pump mount plate. Se-cure pump to the mount plate with both flat washers, capscrews, and lock nuts. Do not fully tighten fasteners.

8. Secure piston pump to the pump support with bothspacers, washers, and cap screws. Tighten fastenerssecuring the piston pump to the pump mount plat andpump support.

9. Remove plugs from hydraulic hoses. Connect all hy-draulic hoses as follows:

A. Secure O−rings and hoses to the gear pump.

B. Connect hydraulic suction hose from the hydrau-lic tank to the barb fitting with hose clamp.

C. Secure O−rings and hydraulic hoses to the pistonpump.

10.Install neutral arm assembly to the piston pump asfollows (Figs. 63 and 64):

A. Position neutral bracket to the mount plate, andthen pump lever to the pump trunnion.

B. Secure pump lever to the piston pump trunnionwith flat washer and cap screw.

C. Secure neutral bracket to the pump mount platewith flange head screw and flange nut. Secure neu-tral bracket to the piston pump with both flange headscrews.

D. Connect traction control cable to the pump lever.

CAUTIONThe extension spring is under tension and maycause personal injury during installation. Usecaution when installing the spring to the pumplever.

E. Install extension spring to the cable supportbracket and pump lever.

F. Connect electrical connector to the micro switch(early models).

11. Install traction belt to the pump pulley (see ReplaceTraction Belt).

12.Using a straight edge across the lower face of thepump pulley, verify traction belt alignment across engineand pump pulleys. Slide pulley and taper lock bushingon pump shaft so that traction belt and straight edge arealigned indicating correct position of pump pulley. Se-cure taper lock bushing in position with set screw.

IMPORTANT: When tightening bushing cap screws,tighten in three equal steps and in a circular pattern.

13.Secure taper lock bushing by tightening three (3) capscrews to a torque from 90 to 120 in−lb (10.2 to 13.6N−m) in three equal steps and in a circular pattern to se-cure pulley and taper lock bushing.

14.Check that belt alignment is still correct. If needed,loosen and re−adjust pulley and taper lock bushing loca-tion on pump shaft to allow for correct belt alignment.

15.Fill hydraulic tank with new hydraulic fluid (see Trac-tion Unit Operator’s Manual).

16.Adjust traction drive for neutral (see Adjust tractionDrive for Neutral).

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Piston Pump Service

1. Key2. Drive shaft3. Bearing4. Cap screw (3 used per cover plate)5. Cover plate6. Seal7. Shim kit8. Bearing cone9. Key10. Cam plate11. Rotating kit12. Gasket13. Valve plate14. Bearing15. Dowel pin16. Back plate17. O−ring18. Plug

19. Spring20. Seat21. Dump valve22. Cap screw23. Cap screw24. Roll pin25. Cover plate26. Bearing cup27. Relief valve28. Washer (3 used per cover plate)29. Housing30. Retaining ring31. Bearing race32. Thrust bearing33. Washer34. Shaft seal35. Retaining ring36. Bleed−off valve poppet

37. Bleed−off spring38. O−ring39. Cam plate insert40. Shaft seal41. O−ring42. Coupler43. Retaining ring44. Washer45. Charge relief spring46. Charge relief poppet47. Charge relief housing48. O−ring49. Cartridge50. Shim (Model 70160−LAA−01)51. Cover plate (70160−LAA−01)52. Shaft seal (70160−LAA−01)53. Retaining ring (70160−LAA−01)

Figure 66

3132

3334

35

1

2

3

18

1927

21

22

23

20

1718

19

3130

30

38

4

4

40

257

5

6

6

8

8

29

1617

24

11

12

13

14

15

15

39

10

9

22

42

28

26

26

43

4647

4445

48

49

28

53

70160−LAA−01

4137

36

50

51 52

EATON MODEL

NOTE: For repair of the piston pump, see the EatonMedium Duty Piston Pump Repair Information Model70160 Variable Displacement Piston Pump at the end ofthis chapter.

NOTE: Reelmaster 3100−D machines with serial num-bers below 90775 were equipped with an Eaton model70160−LAA−01 piston pump. This pump included somedifferences in the trunnion shaft design (Items 50 − 53in Figure 66).

IMPORTANT: If a piston pump failure occurred, re-fer to Traction Circuit (Closed Loop) ComponentFailure in the General Information section for infor-mation regarding the importance of removing con-tamination from the traction circuit.


Piston Pump Crush Ring Replacement

1. Crush ring2. Shims3. Cover plate4. Housing

5. Cam plate (control shaft)6. Bearing cone7. Bearing cup

8. Seal9. Washer (3 used)10. Cap screw (3 used)

Figure 67

v

6

4

5

8

7

2

3

910

1

29 ft−lb(39 N−m)

NOTE: The shims replace the crush ring in the pistonpump cover plate on Reelmaster 3100−D machines withserial numbers above 90775. If the cam plate, coverplate, or housing is replaced during servicing of thepump, replace the original crush ring with shims to makesure of proper preload.

1. Remove crush ring from the cover plate. Measurethickness of crush ring.

2. Stack shims to the thickness of the crush ring.

3. Insert shims into the cover plate in the same locationthat the crush ring was removed from.

4. Assemble housing, cam plate, bearing cone, bear-ing cup, and cover plate (see Eaton Medium Duty PistonPump Repair Information Model 70160 Variable Dis-placement Piston Pump at the end of this chapter).

5. Install washers and cap screws to the cover plateand housing. Torque cap screws to 29 ft−lbs (39 N−m).

6. Check torque required to rotate control shaft.Torque should be 5 to 15 in−lbs (0.6 to 1.7 N−m).

A. If torque is too low, add additional shims and re-peat steps 3 through 6 until the specified torque isachieved.

B. If torque is too high, remove shims and repeatsteps 3 through 6 until the specified torque isachieved.

7. Complete assembly of the pump (see Eaton RepairInformation at the end of this chapter).

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Sidewinder (Model 03201)

1. Plastic bushing2. Scissor link3. Scissor mount4. Cap screw5. Flat washer6. Lock nut7. Scissor frame8. Hydraulic cylinder9. Spacer10. Flat washer11. Cap screw

12. Lock nut13. Welded pin14. Flange head screw15. Lock nut16. Spacer17. Hydraulic tube18. Hydraulic tube19. 90o hydraulic fitting20. Bulkhead lock nut21. Straight hydraulic fitting

22. Hydraulic hose23. 90o hydraulic fitting24. Hydraulic hose25. Pinch point decal26. O−ring27. O−ring28. O−ring29. Retaining ring30. Lower frame (LH)31. Frame

Figure 68

1

2

3

4

56

7

8

9

10

16

17

18

19

20

21

22

23

24

25

26

27

28

29

11

12

13

14

15

26

19

1

2728

1

13

14

13

1

30

31


Removal


1. Remove hydraulic cylinder from the frame using Fig-ure 68 as guide.

2. If hydraulic fittings are to be removed from cylinder,mark fitting orientation to allow correct assembly.

Installation

1. If hydraulic fittings were removed, install fittings tocylinder using marks made during the removal processto properly orientate fittings.

2. Install hydraulic cylinder to the frame using Figure 68as guide.

3. Adjust scissors mount as follows:

A. Shift sidewinder fully to the left (fully retract cylin-der).

B. Loosen four cap screws securing mount to lowerframe.

C. The gap between the scissor frame and lowerframe and the gap between the scissor frame andthe sidewinder carrier must be equal distances with-in 0.060 inch (1.5 mm).

D. Tighten four cap screws and lock nuts.

1. Scissor frame2. Lower frame

3. Sidewinder carrier4. Gaps

Figure 69

2

1

34

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Steering Control Valve

1. Steering arm2. Flange nut3. Flange head screw4. Steering valve bracket5. Cap screw6. Pivot hub7. Steering cover8. Cap screw9. Toro decal10. Ball knob11. Lever12. Steering control valve13. Tilt bracket14. Cap screw

15. Flat washer16. Flange nut17. Steering wheel18. Hydraulic fitting19. Hydraulic Fitting20. Steering wheel nut21. Toro decal22. Hydraulic hose23. Hydraulic hose24. Hydraulic hose25. Hydraulic hose26. Hydraulic hose27. Tilt steering boss28. Friction disc

29. Friction disc30. Flat washer31. Jam nut32. Lock nut33. Flat washer34. Not used35. Not used36. O−ring37. O−ring38. O−ring39. Philips head screw40. Steering wheel cap41. Steering shield

Figure 70

31

32

33

36

37

39

40

1

2

3

4

56

7

89

10

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

11

12

13

14

152

38

1919

2

3

36

41

8

18

20 to 26 ft−lb(27.1 to 35.3 N−m)


Removal


1. Remove steering control valve from the steering col-umn using Figures 70, 71, and 72 as guides.

Installation

1. Install steering control valve to the steering columnusing Figures 70, 71, and 72 as guides.

1. Tilt bracket2. Steering valve bracket3. Jam nut4. Flat washer

5. Friction disc6. Lever7. Steering arm8. Friction disc

Figure 71

7

3

2

5

4

1

6

8

1. Cap screw2. Flange nuts3. Steering valve bracket

4. Steering arm5. Steering control valve6. Friction disc

Figure 72

41

3

6

5

2

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Steering Control Valve Service (Serial Numbers 90101 to 230999999)

1. Nut2. Port cover3. Seal ring4. O−ring5. Relief valve cartridge6. Plug7. Push nut8. Port manifold9. Spring10. Drive assembly11. Alignment pin12. Valve ring13. Valve plate14. Spring15. Isolation manifold16. Drive link17. Metering ring

18. Socket head screw19. Commutator seal20. Commutator cover21. Commutator ring22. Commutator23. Drive link spacer24. Rotor25. Stator26. Drive plate27. Thrust bearing spacer28. Thrust bearing29. Face seal30. Not used31. Seal spacer32. Upper cover plate33. Input shaft34. Retaining ring

35. Not used36. Retaining plate37. Upper cover & jacket assembly38. Bushing39. Seal40. Special bolt41. Nut42. Not used43. Not used44. Not used45. Not used46. Not used47. Not used48. Seal ring (white)49. Coil spring50. Not used51. Spacer

Figure 73

31

32

33

34

36

37

3839

40

41

1

2

3

4

5

6

89

10

16

17

18

1920

21

22

23

24

2526

27

2829

11

12

13

14

15

3

3

113

3

11

48

492

7

NOTE: For repair of the steering control valve, see theRoss Hydraguide TM Hydrostatic Steering System HGFSeries Service Procedure at the end of this chapter.


Steering Control Valve Service (Serial Numbers 240000001 and up)

1. Sleeve2. Cross pin3. Ring4. Spool5. Bearing assembly6. Shaft seal7. Ball stop8. Ball

9. Dust seal ring10. Housing11. Cardan shaft12. Spacer13. O−ring14. Distribution plate15. Inner gearwheel

16. Outer gearwheel17. End cover18. O−ring (5 used)19. Screw/fitting (ports L, R, T)20. Screw/fitting (ports P and E)21. P port check ball22. Spring set

Figure 74

1

23

11

13

17

12

14

16

15

4

5

6

89

10

7

13

13

18

19

20

21

22

20 to 24 ft−lb(27 to 33 N−m)

NOTE: For service of the steering control valve, see theSauer/Danfoss Steering Unit Type OSPM ServiceManual at the end of this chapter.

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Gear Pump

1. Piston pump2. Gear pump3. Hydraulic hose (tank suction)4. Hydraulic hose (hydraulic manifold)5. Hydraulic hose (steering valve)6. Hose clamp

7. O−ring8. O−ring9. Hydraulic barb fitting10. 90o hydraulic fitting11. 90o hydraulic fitting

12. Cap screw13. Flat washer14. O−ring15. O−ring16. O−ring

Figure 75

11

7 16

8

10141

3 69

14

2

45

12

13

15

27 to 31 ft−lb(37 to 42 N−m)


Removal

1. Remove muffler from the engine to gain access tothe gear pump (see Muffler Removal in Chapter 3 − Ku-bota Diesel Engine).

2. Drain hydraulic oil from hydraulic tank (see ChangeHydraulic Fluid in this section).


3. Remove gear pump from the piston pump using Fig-ure 75 as guide.

4. If hydraulic fittings are to be removed from gearpump, mark fitting orientation to allow correct assembly.

Installation

1. If hydraulic fittings were removed, install fittings tomotor using marks made during the removal process toproperly orientate fittings.

IMPORTANT: Position gear pump to the pistonpump so that the gear pump suction port is facingdown.

2. Install gear pump to the piston pump using Figure 75as guide.

3. Fill hydraulic tank with new hydraulic fluid (see Trac-tion Unit Operator’s Manual).

4. Install muffler to the engine (see Muffler Installationin Chapter 3 − Kubota Diesel Engine).

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Gear Pump Service

1. Front plate2. Back plate3. Front body4. Rear body5. Drive gear6. Idler gear7. Idler gear

8. Back−up gasket9. Wear plate10. Pressure seal11. Cap screw12. O−ring13. Adapter Plate14. Key

15. Not used16. Drive gear17. Washer18. Plug19. Shaft seal20. Washer

Figure 76

11171

18

8

10

9

5

6

3

12

16

14

2

4

7

13

1920

12

8

10

12

12

9

25 to 28 ft−lb(34 to 38 N−m)


Disassembly (Fig. 76)

1. Plug pump ports and clean the outside of the pumpthoroughly. After cleaning, remove plugs and drain anyoil out of the pump.

2. Make sure key is removed from the shaft of the drivegear.

3. Use a marker to make a diagonal line across thefront plate, front body, adapter plate, rear body, and backplate for assembly purposes (Fig. 77).

IMPORTANT: Avoid using excessive clampingpressure on the pump housing to prevent distortingthe housing.

4. Clamp pump in a vise with the the shaft end up.

5. Remove cap screws and washers from the frontplate.

6. Remove pump from the vise. Turn pump so that theshaft end is facing down.

7. Remove back plate from the rear body by tappingwith a soft face hammer. Remove and discard O−ringfrom the back plate.

8. Loosen rear body from the adapter plate by tappingwith a soft face hammer. Lift body straight up to remove.

9. Remove idler gear from the wear and adapter plates.Remove drive gear from the drive gear shaft.

IMPORTANT: Note position of the open and closedside of the wear plate before removing from theadapter plate.

10.Remove wear plate and O−ring from the adapterplate.

11.Remove key from the drive gear shaft using a pencilmagnet.

12.Remove O−ring from the adapter plate using an O−ring pick.

13.Loosen adapter plate from the from the front bodyusing a soft face hammer. Remove plate from the body.Turn plate over and remove O−ring using an O−ringpick.

14.Remove front pump body from the front plate.

15.Remove idler gear and drive gear from the frontplate.

IMPORTANT: Note position of the open and closedside of the wear plate before removing from thefront plate.

Figure 77

MARKER LINE

16.Remove wear plate from front plate. Remove O−ringfrom front plate using O−ring pick.

17.Remove back−up gasket and pressure seal fromboth wear plates.

IMPORTANT: Make sure not to damage the counterbore when removing the shaft seal from the frontplate.

18.Remove shaft seal from the front plate using a driftpunch.

IMPORTANT: Do not remove the plug from the frontplate unless rotation of the pump is changed.

Inspection (Fig. 76)

1. Remove all nicks and burrs from all parts with anemery cloth.

CAUTION


2. Clean all parts with solvent. Dry all parts with com-pressed air.

3. Inspect gear, drive gear, and idler gears for the fol-lowing:

A. Drive gear shaft spline should be free of twisted orbroken teeth.

B. Gear shafts should be free of rough surfaces andexcessive wear at bushing points and sealing areas.

C. Gear shaft diameter in the bushing area shouldnot be less than 0.748 inch (19.0 mm).

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D. Gears should be free of excessive scoring andwear.

E. Make sure drive and idler gears have their snaprings in the grooves on each side.

F. Break sharp edges of gear teeth with emery cloth.

G. Gear width on the drive gear and front idler gearshould not be less than 0.384 inch (9.75 mm). Gearwidth on the back gear and back idler gear should notbe less than 0.244 inch (6.20 mm).

4. Inspect body for the following:

A. Gear pockets should be free of excessive scoringand wear.

B. Inside diameter of gear pockets should not ex-ceed 1.719 inches (43.7mm).

5. Inspect front plate, back plate, and adapter plate asfollows:

A. Inside diameter of all bushings should not exceed0.755 inch (19.2 mm).

B. Bushings in the front plate should extend 0.126inch (3.20 mm) from the plate surface.

C. Bushings on the wear plate side of the adapterplate should extend 0.126 inch (3.20 mm) from theplate surface.

D. Scoring on the face of the back plate or the backplate side of the adapter plate should not exceed0.0015 inch (0.038 mm).

E. The oil groove in the bushings of the front plateshould be opposite each other and in line with withthe dowel pin holes. The oil groove in the bushings ofthe back plate should be about 37o to the pressureport (Fig. 78 and 79).

Reassembly (Fig. 76)

NOTE: When reassembling the pump, check the mark-er line on each part to make sure the parts are properlyaligned during reassembly.

1. Lubricate new O−rings, pressure seals, back−upgaskets, and wear plates with a thin coat of petroleumjelly. Lubricate all other internal parts freely with cleanhydraulic oil.

2. Install O−ring into the groove of the front plate.

3. Lubricate gear pockets of front body with a thin coatof petroleum jelly. Place front body onto front plate so thehalf moon port cavities face away from the front plate.

Figure 78

2

2

1. Front plate 2. Oil groove

1

Figure 791. Back plate 2. Oil groove

2

1

2

4. Install new pressure seal and back−up gasket intoboth new wear plates. The flat section in the middle ofthe back−up gasket must face away from the wear plateinside the seal.

5. Install wear plate into the gear pocket with the pres-sure seal and back−up gasket against the front plate.Make sure mid section cut−away of the wear plate is onthe suction side of the pump.

6. Dip drive gear and front idler gear into clean hydrau-lic oil. Install gear shafts into the front plate bushings sothat the gears set inside the gear pockets.

7. Install new O−ring into the groove of the adapterplate on the side with the bushings below the surface.

8. Align marker line on the body and adapter plate.Install adapter plate onto the body and gear shafts.

9. Install second new O−ring to the other side of theadapter plate.

10.Coat key lightly with petroleum jelly to hold it in place.Install key into the slot in the drive gear shaft.

11.Align marker line on back body and adapter plate.Install body onto adapter plate and drive gear shaft.


IMPORTANT: Do not dislodge seals during installa-tion.

12.Install wear plate into the gear pocket of back bodywith the pressure seal and back−up gasket against theadapter plate. Make sure mid section cut−away of thewear plate is on the suction side of the pump.

13.Lubricate back gear with clean hydraulic oil. Installgear onto the drive gear shaft and key.

14.Lubricate back idler gear with clean hydraulic oil.Install idler gear into the gear pocket of back body andthe adapter plate.

15.Install new O−ring into the groove of the back plate.

16.Align marker line on the back plate and body. Installback plate onto the body and gear shafts.

17.Secure pump together with cap screws and newwashers on cap screws external of the flange cavity.Torque cap screws in a criss−cross pattern from 25 to 28ft−lb (34 to 38 N−m).

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Front Lift Cylinder

1. 90o hydraulic fitting2. Hydraulic cylinder3. Carrier assembly4. Flange nut5. Flange head screw6. Hydraulic hose7. Centering wire8. Hydraulic hose9. Hydraulic hose10. Hydraulic hose11. Clamp bracket (model 03200)11. Slide bracket (model 03201)12. Flange nut13. Plastic slide14. Flange head screw

15. LIft arm pivot shaft16. Roll pin17. Pivot shaft link18. Flange head screw19. Cap screw20. Clamp (model 03200)20. Bearing cap (model 03201)21. Jam nut22. Cap screw23. Lock nut24. Hardened washer25. Slide support bar26. Pin27. Spacer

28. External retaining ring29. Bulkhead nut30. Hydraulic tube31. Bulkhead nut32. Hose rod (model 03201)33. Flange head screw (model 03201)34. Flange nut (model 03201)35. O−ring36. O−ring37. Flange head screw38. Link clip39. Hex nut40. Straight link chain41. Flat washer

Figure 80

31

3233

34

35

361

2

3

45

6

7

8

9

10

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

11

12

13

14

29

2915

28

1

26

20

24

1321

40

39

3737

38

41


Removal

1. Remove front lift cylinder from the frame and lift armusing Figure 80 as guide.

2. If hydraulic fittings are to be removed from lift cylin-der, mark fitting orientation to allow correct assembly.

Installation

1. If hydraulic fittings were removed, install fittings tocylinder using marks made during the removal processto properly orientate fittings.

IMPORTANT: With lift arms raised fully, hydraulichoses should be routed as shown in Figure 81. Makesure clearance between hydraulic hose and lift armis from 0.040 to 0.120 inches (1.0 to 3.0 mm).

2. Install front lift cylinder to the frame and lift arm usingFigure 80 as guide.

3. Adjust front lift arm (see Adjust Front Lift Arm inChapter 7 − Cutting Units).

1. Lift cylinder2. Hydraulic hoses

3. Clearance

Figure 81

1

32

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Rear Lift Cylinder

1. Hydraulic tube2. Lock nut3. Hydraulic T−fitting4. Hydraulic hose5. 90o hydraulic fitting6. Hydraulic hose7. Hydraulic tube8. 90o hydraulic fitting9. Push button switch10. Hydraulic cylinder11. Thrust washer12. Hydraulic hose13. Bulkhead nut14. Hydraulic fitting15. Hydraulic hose16. Hydraulic hose17. Hydraulic tube18. Hydraulic tube19. Hydraulic tube20. Tube clamp

21. Flat washer22. Cap screw23. Lock nut24. Rear pivot shaft25. Jam nut26. Washer27. Lift arm assembly28. Flange head screw29. Thrust washer30. Grease fitting31. Cutting unit pivot shaft32. Cap screw33. Cap screw34. Rebound washer35. Washer36. Lynch pin37. Switch bracket38. Carriage screw39. Nut

40. Not used41. Lock washer42. Guard43. Cap screw44. Cap screw45. Lock nut46. External retaining ring47. Pin48. O−ring49. Hydraulic hose50. Hydraulic hose51. Not used52. Not used53. O−ring54. Hydraulic hose55. Hydraulic hose56. Hydraulic hose57. O−ring58. Hydraulic hose

Figure 82

31

32

3334

35

36

37

38

3941

4243

44

45

46

47

48

49

50

1

7

53

54

55 56

57

1

3

4

5

6

78

9

10

16

17

18

19

20

2122

23

24

2526

27

2829

30

11

12

13

14

15

4

4848

2

57

2

22

3

13

48

5

21

46

48

48

58


Removal

1. Remove rear lift cylinder from the frame and lift armusing Figure 82 as guide.

2. If hydraulic fittings are to be removed from lift cylin-der, mark fitting orientation to allow correct assembly.

Installation

1. If hydraulic fittings were removed, install fittings to liftcylinder using marks made during the removal processto properly orientate fittings.

2. Install rear lift cylinder to the frame and lift arm usingFigure 82 as guide.

3. Adjust rear lift arm (see Adjust Rear Lift Arm in Chap-ter 7 − Cutting Units).

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Lift Cylinder Service

1. Grease fitting2. Barrel with clevis3. Nut4. Uni−ring5. Piston

6. O−ring7. O−ring8. Back−up ring9. Rod seal10. Head

11. Internal collar12. Dust seal13. Shaft14. Jam nut15. Clevis

Figure 83

1

2

3

45

6

78

910

1

11

1213

14

15

1 2 9 12

13

3 5 4 6 7 8 10 11 14 15 1

24 to 30 ft−lb(33 to 41 N−m)


Disassembly

1. Remove oil from lift cylinder into a drain pan by slowlypumping the cylinder shaft. Plug both ports and cleanthe outside of the cylinder.

IMPORTANT: Prevent damage when clamping thehydraulic cylinder into a vise; clamp on the clevisonly.

2. Mount lift cylinder in a vice. Remove internal collarwith a spanner wrench.

3. Extract shaft, head, and piston by carefully twistingand pulling on the shaft.

IMPORTANT: Do not clamp vise jaws against theshaft surface. Protect shaft surface before mount-ing in a vice.

4. Mount shaft securely in a vise by clamping on the cle-vis of the shaft. Remove lock nut and piston from theshaft. Slide head off the shaft.

5. Remove Uni−ring and O−ring from the piston. Re-move O−ring, back−up ring, rod seal, and dust seal fromthe head.

Assembly

1. Make sure all parts are clean before reassembly.

2. Coat new O−rings, Uni−rings, rod seal, back−upring, and dust seal with with clean hydraulic oil.

A. Install Uni−ring and O−ring to the piston.

B. Install dust seal, O−ring, back−up ring, and dustseal to the head.


3. Mount shaft securely in a vise by clamping on the cle-vis of the shaft.

A. Coat shaft with with clean hydraulic oil.

B. Slide head onto the onto the shaft. Install rod sealonto shaft and into head.

C. Install piston and nut onto the shaft. Torque nutfrom 24 to 30 ft−lb (33 to 41 N−m).

D. Remove shaft from the vise.


4. Mount barrel in a vice.

5. Coat all internal parts with a light coat of clean hy-draulic oil. Slide piston, shaft, and head assembly intothe barrel being careful not to damage the seals.

6. Secure head in the barrel with internal collar using aspanner wrench. Tighten collar until snug and the outerend of the collar is flush with end of the barrel.

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Steering Cylinder

1. Hydraulic hose2. Hydraulic hose3. O−ring4. Hydraulic fitting

5. O−ring6. Steering cylinder7. Ball joint8. Retaining ring

9. Jam nut10. Frame11. Rear fork12. Rear casting

Figure 84

8

9

12

11

9

1

8

5

72 3

4

5

6

3

7

4

10

65 to 85 ft−lb(88 to 115 N−m)

No. 2 GeneralPurpose Grease

No. 2 GeneralPurpose Grease

65 to 85 ft−lb(88 to 115 N−m)


Removal

1. Park machine on a level surface, lower cutting units,stop engine, engage parking brake and remove keyfrom the ignition switch.

NOTE: The rear tire must be removed to allow sufficientclearance to remove the steering cylinder from the ma-chine.

WARNING

Before jacking up the machine, review and followJacking Instructions in Chapter 1 − Safety.

2. Jack or lift rear wheel off the ground.

3. Remove rear wheel from the drive studs and wheelhub.

4. Thoroughly clean hydraulic hose ends and fittings onsteering cylinder to prevent hydraulic system contami-nation.


5. Remove steering cylinder from the frame and rearfork using Figure 84 as guide.

6. If hydraulic fittings are to be removed from steeringcylinder, mark fitting orientation to allow correct assem-bly.

Installation

1. If hydraulic fittings were removed from steering cylin-der, install fittings to cylinder using marks made duringthe removal process to properly orientate fittings.

2. Install steering cylinder to the frame and rear fork us-ing Figure 84 as guide. When securing cylinder balljoints to machine, tighten the first jam nut from 65 to 85ft−lb (88 to 115 N−m), then tighten the second jam nutto the same specification.

3. Mount rear wheel to the machine with four (4) lugnuts. Lower machine to the ground. Torque lug nuts ina crossing pattern from 45 to 65 ft−lb (61 to 88 N−m).

4. Make sure hydraulic tank is full. Add correct oil if nec-essary (see Traction Unit Operator’s Manual).

1. Steering cylinder 2. Jam nutsFigure 85

1

2

1. Steering cylinder2. Rear fork

3. Jam nuts

Figure 86

2

3

1

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Steering Cylinder Service

1. Barrel2. Lock nut3. Piston4. Uni−ring

5. O−ring6. Piston rod7. Rod seal8. Cylinder gland

9. O−ring10. Back−up ring11. Retaining ring12. O−ring

Figure 87

1

2

3

4

5

6

7

8

9

10

12

11

2 3 4 5 8 9 10 11

1 6 7 12

24 to 30 ft−lb(33 to 41 N−m)


Disassembly

1. Remove oil from the steering cylinder into a drain panby slowly pumping the cylinder shaft. Plug both portsand clean the outside of the cylinder.


2. Mount clevis end of steering cylinder in a vice. Re-move retaining ring.

3. Extract shaft, head, and piston by carefully twistingand pulling on the shaft.


4. Mount shaft securely in a vise by clamping on the cle-vis of the shaft. Remove lock nut and piston from theshaft. Slide head off the shaft.

5. Remove Uni−ring and O−ring from the piston.

6. Remove back−up ring, O−rings, and rod seal fromthe head.

Reassembly

1. Make sure all parts are clean before reassembly.

2. Coat new O−rings, Uni−ring, rod seal, and back−upring with with clean hydraulic oil.

A. Install Uni−ring and O−ring to the piston.

B. Install O−rings, back−up ring, and rod seal to thehead.


3. Mount shaft securely in a vise by clamping on the cle-vis of the shaft.

A. Coat shaft with a light coat of clean hydraulic oil.

B. Slide head onto the onto the shaft. Install pistonand lock nut onto the shaft. Torque nut from 24 to 30ft−lb (33 to 41 N−m).

C. Remove shaft from the vise.


4. Mount clevis of the barrel in a vice.

5. Coat all internal parts with a light coat of clean hy-draulic oil. Slide piston, shaft, and head assembly intothe barrel being careful not to damage the seals.

6. Secure head in the barrel with the retaining ring.

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Reelmaster 3100−D Page 5 − 1 Electrical Systems (Rev. C)

Chapter 5

Electrical System

Table of Contents

ELECTRICAL SCHEMATICS AND DIAGRAMS 2. . . Reelmaster 3100−D Electrical Schematic

(Serial Numbers 90101 to 90150) 2. . . . . . . . . . . Glow Circuits 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crank Circuits 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Run Circuits (Transport) 5. . . . . . . . . . . . . . . . . . . . Run Circuits (Mow) 6. . . . . . . . . . . . . . . . . . . . . . . . Run Circuits (Backlap) 7. . . . . . . . . . . . . . . . . . . . . Wiring Diagram 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . Supplement to Wiring Diagram 9. . . . . . . . . . . . . .

Reelmaster 3100−D Electrical Schematic(Serial Numbers 90151 to 230999999) 10. . . . . . Glow Circuits 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crank Circuits 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . Run Circuits (Transport) 13. . . . . . . . . . . . . . . . . . . Run Circuits (Mow) 14. . . . . . . . . . . . . . . . . . . . . . . Run Circuits (Backlap) 15. . . . . . . . . . . . . . . . . . . . Wiring Diagram 16. . . . . . . . . . . . . . . . . . . . . . . . . . . Supplement to Wiring Diagram 17. . . . . . . . . . . . . Harness Diagram 18. . . . . . . . . . . . . . . . . . . . . . . . .

Reelmaster 3100−D Electrical Schematic(Serial Numbers 240000001 and Up) 19. . . . . . . Wiring Diagram 20. . . . . . . . . . . . . . . . . . . . . . . . . . . Harness Diagram 21. . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 24. . . . . . . . . . . . . . . . . . . . . . . .

Starting Problems 24. . . . . . . . . . . . . . . . . . . . . . . . . . General Run & Transport Problems 26. . . . . . . . . . . Cutting Unit Operating Problems 27. . . . . . . . . . . . .

ELECTRICAL SYSTEM QUICK CHECKS 28. . . . . . . Battery Test (Open Circuit) 28. . . . . . . . . . . . . . . . . . Charging System Test 28. . . . . . . . . . . . . . . . . . . . . . Glow Plug System Test 28. . . . . . . . . . . . . . . . . . . . . Check Operation of Interlock Switches 29. . . . . . . .

COMPONENT TESTING 30. . . . . . . . . . . . . . . . . . . . . . Ignition Switch 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glow Relay 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start, Seat, and High Temperature

Shut Down Relays 31. . . . . . . . . . . . . . . . . . . . . . . . Hour Meter 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reel Drive Solenoid 32. . . . . . . . . . . . . . . . . . . . . . . . High Temperature Warning

and Shutdown Switches 33. . . . . . . . . . . . . . . . . . . Diode Assemblies 34. . . . . . . . . . . . . . . . . . . . . . . . . . Warning Light Cluster (Serial Numbers

Below 240000000) 35. . . . . . . . . . . . . . . . . . . . . . . Indicator Lights (Serial Numbers Above

240000000) 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Pump 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Stop Solenoid (Solenoid With 3 Wire

Connector) 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Stop Solenoid (Solenoid With 2 Wire

Connector) 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glow Controller 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Control Module 41. . . . . . . . . . . . . . . . . . . .

SERVICE AND REPAIRS 42. . . . . . . . . . . . . . . . . . . . . Battery Storage 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Care 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Service 43. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ele

ctri

cal

Sys

tem

Reelmaster 3100−DPage 5 − 2Electrical Systems (Rev. C)

Electrical Schematics and Diagrams

BLA

CK

BK

BLU

EB

U

BR

OW

NB

N

FU

SIB

LE L

INK

GR

AY

GY

GN

GR

EE

N

OR

OR

AN

GE

PK

PIN

K

BU O

PT

ION

AL

LIG

HT

KIT

F2

15 AF1

R

R

12

OR

OR

D2

FR

AM

E

B S

A Y

XI

Y

BK

BA

TT

ER

Y(+)

(−)

PK

IGN

ITIO

N S

W.

BU

WP

K

VIO

5 A

F4

5 AF3

OR

RR

ED

VIOT

TAN

WH

ITE

W

VIO

LET

ST

OP

−−−

− N

ON

ER

UN

−−

−−

B+

I+A

; X+

YS

TAR

T −

−− B

+I+S

SP

LIC

ES

P

YE

LLO

WY R/B

KR

ED

/BLA

CK

R 4 5 6

1 2 3

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LOW OIL PRESS.

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30

85

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86

87a

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GAUGE CLUSTER

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LOW OIL PRESS.

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(−)

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30

85

87

86

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ON

/OF

F 65

BU

W

Y

TR

AN

SP

OR

T/M

OW

BU

RE

EL

DR

IVE

SO

LEN

OID

BK

GN

RE

EL

ON

/OF

F

PR

ES

SU

RE

GR

OU

ND

GR

OU

ND

SE

AT

SW

ITC

H

(SE

AT

EM

PT

Y)

RE

ELS

UP

SW

ITC

H

(IN

MO

W)

SW

ITC

H

SW

ITC

H

(IN

BA

CK

LAP

)

(RE

ELS

ON

)

(CLO

SE

S A

T 1

05oC

)

TE

MP.

SW

ITC

H

SW

ITC

H

(RE

ELS

ON

)

Ru

n C

ircu

its

(Bac

klap

)P

ower

Cur

rent

Con

trol

Cur

rent

Indi

catio

n C

urre

ntLo

gic

Dire

ctio

n

Ree

lmas

ter

3100

−D

STA

RT

ER

Ser

ial N

umbe

rs 9

0101

to 9

0150

Ele

ctri

cal

Sys

tem


OP

TIO

NA

L

3012 85

87A3

DIO

DE

D2

P9

J17

J16

W6W

7

W55

W26

W27W

65

W54

SP

2

P22

(−)

(+)

J3

HIG

H T

EM

PS

HU

T D

OW

N

P10

868787

A

EN

GIN

EG

RO

UN

D

HO

UR

ME

TE

R

P11

INT

ER

LOC

KR

ELA

Y

TE

MP

GLO

WG

ND (+)

BA

TT

ER

YO

IL P

RE

SS 8530

64 5321

W13

W64

W18

W21

W20

W17

21W

23W

16

CBA

W63

W64

W57

W25

543

W62

W22

W21

W59

W60

W62

W57

SP

3 W58

W63

SP

6

AB

RU

N

45

8786

AB

P2

J6J4

12

3

P18

P15

J12

PULLGND

HOLD

W42

W41

W22

W32

W34

W33

W40

W56

P14

P16

I

IGN

TIO

NS

WIT

CH

1X

CLU

ST

ER

GA

UG

E

2 3 4 5

Y A B S

13

24

56

FU

SE

BLO

CK

87

J18

J13

W2

W4

W4

W5

W5

W6 W7

W9

W3 W

8

W14

W15

W16

1

STA

RT

ER

STA

RT

2

GLO

W C

ON

TR

OLE

R

B+

ALT

ER

NA

TO

R

21R

L

W1

G

SP

1

P19

P20

P3

13

2B+

P23

J7

W2

W39

W52

W14

W25

W26

W15

W20

W40

SP

5

286GLO

W R

ELA

Y

85 13

45

6

P1

J1J2 87

30P

13

W9

W52

W10

W59

W53

W11

W18

GLO

W P

LUG

J5

W19

21P

4

W51

W29

21W

28

6543P

5W

50

853021 3

87A

P8

W30

4 587 86

W46

W49

SE

AT

SW

ITC

H

SE

AT

SW

ITC

H

SE

AT

RE

LAY

W31

W44

W43

W34

DIO

DE

D1

J15

J14

W35

W23

W31

B

P7

P12

NC

NO

54

32

1

RE

EL

ON

/OF

F

87

6A

B

W12

W13

W24

J10

J11

W50

W60

W61

SP

4W

27

W47

W38

BAP

6

W44

W30

W28

J19

J20

W45

P21

A

W35

J9J8

NO

C

W48

P17

A B

W46

W37

PA

RK

ING

BR

AK

E

NO

# 2

BA

CK

LAP

CA

PA

CIT

OR

PA

RK

ING

BR

AK

E

NC

DIO

DE

D3

NE

UT

RA

L

SW

ITC

H #

1

SW

ITC

H

SW

ITC

H

SW

ITC

H

RE

LAY

SO

LEN

OID

SW

ITC

H

ENG OIL PRESS

HIGH TEMPSHUT DOWN

SWITCH

FUEL PUMP

REEL DRIVESOLENOID

TRANSPORT/MOWSWITCH

REEL UPLIMIT SWITCH

LIG

HT

Wir

ing

Dia

gra

mR

eelm

aste

r 31

00−

D

Ser

ial N

umbe

rs 9

0101

to 9

0150


WIRE IDENTIFICATION

ROUTELABEL COLOR FROM TO

W1 RED P23−3 J7

W2 RED P23−1 P16−1

W3 ORANGE P16−2 P14−4

W4 BLUE P16−4 J13

W5 YELLOW P16−5 J18

W6 VIOLET P9−1 P16−6 (2)

W7 VIOLET P16−6 (2) P9−2

W8 WHITE P16−7 P14−3

W9 PINK P16−8 (2) P13−3 (2)

W10 PINK P13−3 (2) SP5

W11 PINK SP5 P1−1

W12 PINK SP5 P12−6 (2)

W13 PINK P12−6 (2) P11−4

W14 PINK P16−8 (2) P3−1

W15 BLUE P13−1 P14−5 (2)

W16 BLUE P14−5 (2) P10−1

W17 YELLOW P9−4 SP8 (2)

W18 ORANGE P11−2 J2 (2)

W19 ORANGE J2 (2) J5

W20 GRAY P3−2 P11−5

W21 GRAY P11−6 P22−A (2)

W22 GRAY P22−A (2) J4

W23 YELLOW P10−2 J14 (2)

W24 YELLOW J14 (2) P12−2

W25 ORANGE P10−4 P19−1 (2)

W26 ORANGE P19−1 (2) J17

W27 ORANGE P9−3 SPA (4)

W28 ORANGE SP4 (4) P5−1 (2)

W29 ORANGE P5−1 (2) P4−2

W30 TAN P8−1 J19 (2)

W31 GREEN P21−B P12−1 (2)

W32 BROWN J6 P9−5

WIRE IDENTIFICATION


W33 RED/BLACK J12 P2−3 (2)

W34 RED/BLACK P2−3 (2) J15 (2)

W35 RED/BLACK J15 (2) J9 (2)

W36 NOT USED

W37 GREEN P17−B J20 (2)

W38 TAN P6−B J19 (2)

W39 R 66465 P20 SP1 (2)

W40 WHITE SP1 (2) P2−1

W41 GREEN P15−B P18−A

W42 BLUE P18−B P7−A

W43 WHITE P7−B P12−5

W44 GREEN P12−1 (2) J20 (2)

W45 BLUE J8 P21−A

W46 RED/BLACK P8−4 J9 (2)

W47 ORANGE SP4 ( 4) P6−A

W48 ORANGE SP4 (4) P17−A

W49 GRAY P8−2 J10

W50 GRAY J10 P5−3 (2)

W51 GRAY P5−3 (2) P4−1

W52 RED J1 P23−2

W53 TAN P1−2 P13−5

W54 BLACK J3 SP2 (4)

W55 BLACK SP2 (4) J16

W56 BLACK SP2 (4) P2−2

W57 BLACK SP2 (4) SP3 (6)

W58 BLACK SP3 (6) P15−A

W59 BLACK SP3 (6) P13−6

W60 BLACK SP3 (6) J11 (2)

W61 BLACK J11 (2) P8−5

W62 BLACK SP3 (6) P10−5

W63 BLACK SP3 (6) P22−C (2)

W64 BLACK P22−C (2) P11−3

W65 YELLOW SP8 (2) P9−4

Supplement to Wiring DiagramReelmaster 3100−D

Serial Numbers 90101 to 90150

Ele

ctri

cal

Sys

tem


PIN

K

OR

AN

GE

GR

EE

N

GR

AY

FU

SIB

LE L

INK

BR

OW

N

BLU

E

BLA

CK

BK

BU

BN

GY

GN

OR

PK

OP

TIO

NA

L L

IGH

T K

IT

F2F1

D2

12

R

R

OR

OR

OR

BU

YIG

NIT

ION

ST

OP

−−−

− N

ON

ER

UN

−−

−−

B+

I+A

; X+

YS

TAR

T −

−− B

+I+S

S

X

BU

PK

F4

5 A

(+)

(−)

5 A

F3

BA

TT

ER

Y

FR

AM

E

CLUSTER GAUGE

Y

OR

BK

VIO

PK

PK

VIO

VIO

3087 86

85

R

PK

PK

VIO

LET

WH

ITE

TAN

RE

D

SP

LIC

ES

P

YE

LLO

W

RE

D/B

LAC

K

GLO

W R

ELA

Y

4 5 6

1 2 3

GLO

W P

LUG

CO

NT

RO

LER

VIO

OR

BU

R T VIO W

Y

R/B

K

EN

G L

OW

OIL

EN

GIN

E H

IGH

EN

GIN

E S

HU

T−

(HO

LD)

RU

N S

OLE

NO

ID

(PU

LL)

ALT

ER

NA

TO

R

RB L

PK

R

W

EN

GIN

E

EN

GIN

E

SP

ALTERNATOR

W

GY

W

HO

UR

ME

TE

R

(−)

HR(+

)

BK

PK

R/B

K

30

85

87

86

87A

ENGINE HIGH TEMP

GLOW

ENG LOW OIL PRESS

Y

BN

OR

(+)

(−)

6500

MF

D

OP

TIO

NA

L S

EA

T S

WIT

CH

BA

CK

LAP

CN

O P

AR

KIN

G B

RA

KE

#2

(BR

AK

E O

N)

D3

1 2

SE

AT

RE

LAY

3085

8786

87A

NE

UT

RA

L

SW

ITC

H

PA

RK

ING

BR

AK

E #

1(B

RA

KE

ON

)

(IN

NE

UT

RA

L)

(SE

AT

EM

PT

Y)

SE

AT

SW

ITC

H

OR

GNT

OR

GY

R/B

K

BU

R/B

K

BK

GLO

W P

LUG

S

BK

T

R

EE

LS U

P

LIM

IT S

WIT

CH

(RE

ELS

UP

)

TR

AN

SP

OR

T/M

OW

1

RE

ELS

ON

/OF

F

(RE

ELS

OF

F)

2 RE

EL

DR

IVE

SO

LEN

OID

56

RE

ELS

ON

/OF

F

(RE

ELS

OF

F)

INT

ER

LOC

K R

ELA

Y

3085

8786 87A

BK

Y

BU

OR

BK

WB

UG

N

BK

1 2

D1

Ele

ctri

cal S

chem

atic

Ree

lmas

ter

310

0−D

All

rela

ys a

nd

so

len

oid

s ar

e sh

ow

n a

s d

e−en

erg

ized

.

FU

EL

PU

MP

AB I

SW

ITC

H

SW

ITC

H

(IN

TR

AN

SP

OR

T)

SW

ITC

H

SW

ITC

H

(IN

MO

W)

15 A

GR

OU

ND

DO

WN

SW

ITC

H

TE

MP

SW

ITC

H PR

ES

SU

RE

Sta

rtB

+G

(CLO

SE

S A

T 1

05o C

)

(CLO

SE

S A

T 1

10o C

)

STA

RT

ER

GR

OU

ND

Ser

ial N

umbe

rs 9

0151

to

Y

OR

HIG

H T

EM

PS

HU

TD

OW

N R

ELA

Y

2309

9999

9


PIN

K

OR

AN

GE

GR

EE

N

GR

AY

FU

SIB

LE L

INK

BR

OW

N

BLU

E

BLA

CK

BK

BU

BN

GY

GN

OR

PK

OP

TIO

NA

L L

IGH

T K

IT

F2F1

D2

12

R

R

OR

OR

OR

BU

YIG

NIT

ION

ST

OP

−−−

− N

ON

ER

UN

−−

−−

B+

I+A

; X+

YS

TAR

T −

−− B

+I+S

S

X

BU

PK

F4

5 A

(+)

(−)

5 A

F3

BA

TT

ER

Y

FR

AM

E

CLUSTER GAUGE

Y

OR

BK

VIO

PK

PK

VIO

VIO

3087 86

85

R

PK

PK

VIO

LET

WH

ITE

TAN

RE

D

SP

LIC

ES

P

YE

LLO

W

RE

D/B

LAC

K

GLO

W R

ELA

Y

4 5 6

1 2 3

GLO

W P

LUG

CO

NT

RO

LER

VIO

OR

BU

R T VIO W

Y

R/B

K

EN

G L

OW

OIL

EN

GIN

E H

IGH

EN

GIN

E S

HU

T−

(HO

LD)

RU

N S

OLE

NO

ID

(PU

LL)

ALT

ER

NA

TO

R

RB L

PK

R

W

EN

GIN

E

EN

GIN

E

SP

ALTERNATOR

W

GY

W

HO

UR

ME

TE

R

(−)

HR(+

)

BK

PK

R/B

K

30

85

87

86

87A

ENGINE HIGH TEMP

GLOW

ENG LOW OIL PRESS

Y

BN

OR

(+)

(−)

6500

MF

D

OP

TIO

NA

L S

EA

T S

WIT

CH

BA

CK

LAP

CN

O P

AR

KIN

G B

RA

KE

#2

(BR

AK

E O

N)

D3

1 2

SE

AT

RE

LAY

3085

8786

87A

NE

UT

RA

L

SW

ITC

H

PA

RK

ING

BR

AK

E #

1(B

RA

KE

ON

)

(IN

NE

UT

RA

L)

(SE

AT

EM

PT

Y)

SE

AT

SW

ITC

H

OR

GNT

OR

GY

R/B

K

BU

R/B

K

BK

GLO

W P

LUG

S

BK

T

R

EE

LS U

P

LIM

IT S

WIT

CH

(RE

ELS

UP

)

TR

AN

SP

OR

T/M

OW

1

RE

ELS

ON

/OF

F

(RE

ELS

OF

F)

2 RE

EL

DR

IVE

SO

LEN

OID

56

RE

ELS

ON

/OF

F

(RE

ELS

OF

F)

INT

ER

LOC

K R

ELA

Y

3085

8786 87A

BK

Y

BU

OR

BK

WB

UG

N

BK

1 2

D1

FU

EL

PU

MP

AB I

SW

ITC

H

SW

ITC

H

(IN

TR

AN

SP

OR

T)

SW

ITC

H

SW

ITC

H

(IN

MO

W)

15 A

GR

OU

ND

DO

WN

SW

ITC

H

TE

MP

SW

ITC

H PR

ES

SU

RE

Sta

rtB

+G

(CLO

SE

S A

T 1

05o C

)

(CLO

SE

S A

T 1

10o C

)

STA

RT

ER

GR

OU

ND

Y

OR

Glo

w C

ircu

its

Pow

er C

urre

ntC

ontr

ol C

urre

ntIn

dica

tion

Cur

rent

Logi

c D

irect

ion

Ree

lmas

ter

3100

−D

HIG

H T

EM

PS

HU

TD

OW

N R

ELA

Y

Ser

ial N

umbe

rs 9

0151

to23

0999

999

Ele

ctri

cal

Sys

tem


PIN

K

OR

AN

GE

GR

EE

N

GR

AY

FU

SIB

LE L

INK

BR

OW

N

BLU

E

BLA

CK

BK

BU

BN

GY

GN

OR

PK

OP

TIO

NA

L L

IGH

T K

IT

F2F1

D2

12

R

R

OR

OR

OR

BU

YIG

NIT

ION

ST

OP

−−−

− N

ON

ER

UN

−−

−−

B+

I+A

; X+

YS

TAR

T −

−− B

+I+S

S

X

BU

PK

F4

5 A

(+)

(−)

5 A

F3

BA

TT

ER

Y

FR

AM

E

CLUSTER GAUGE

Y

OR

BK

VIO

PK

PK

VIO

VIO

3087 86

85

R

PK

PK

VIO

LET

WH

ITE

TAN

RE

D

SP

LIC

ES

P

YE

LLO

W

RE

D/B

LAC

K

GLO

W R

ELA

Y

4 5 6

1 2 3

GLO

W P

LUG

CO

NT

RO

LER

VIO

OR

BU

R T VIO W

Y

R/B

K

EN

G L

OW

OIL

EN

GIN

E H

IGH

EN

GIN

E S

HU

T−

(HO

LD)

RU

N S

OLE

NO

ID

(PU

LL)

ALT

ER

NA

TO

R

RB L

PK

R

W

EN

GIN

E

EN

GIN

E

SP

ALTERNATOR

W

GY

W

HO

UR

ME

TE

R

(−)

HR(+

)

BK

PK

R/B

K

30

85

87

86

87A

ENGINE HIGH TEMP

GLOW

ENG LOW OIL PRESS

Y

BN

OR

(+)

(−)

6500

MF

D

OP

TIO

NA

L S

EA

T S

WIT

CH

BA

CK

LAP

CN

O P

AR

KIN

G B

RA

KE

#2

(BR

AK

E O

N)

D3

1 2

SE

AT

RE

LAY

3085

8786

87A

NE

UT

RA

L

SW

ITC

H

PA

RK

ING

BR

AK

E #

1(B

RA

KE

ON

)

(IN

NE

UT

RA

L)

(SE

AT

EM

PT

Y)

SE

AT

SW

ITC

H

OR

GNT

OR

GY

R/B

K

BU

R/B

K

BK

GLO

W P

LUG

S

BK

T

R

EE

LS U

P

LIM

IT S

WIT

CH

(RE

ELS

UP

)

TR

AN

SP

OR

T/M

OW

1

RE

ELS

ON

/OF

F

(RE

ELS

OF

F)

2 RE

EL

DR

IVE

SO

LEN

OID

56

RE

ELS

ON

/OF

F

(RE

ELS

OF

F)

INT

ER

LOC

K R

ELA

Y

3085

8786 87A

BK

Y

BU

OR

BK

WB

UG

N

BK

1 2

D1

FU

EL

PU

MP

AB I

SW

ITC

H

SW

ITC

H

(IN

TR

AN

SP

OR

T)

SW

ITC

H

SW

ITC

H

(IN

MO

W)

15 A

GR

OU

ND

DO

WN

SW

ITC

H

TE

MP

SW

ITC

H PR

ES

SU

RE

Sta

rtB

+G

(CLO

SE

S A

T 1

05o C

)

(CLO

SE

S A

T 1

10o C

)

STA

RT

ER

GR

OU

ND

Y

OR

Cra

nk

Cir

cuit

sP

ower

Cur

rent

Con

trol

Cur

rent

Indi

catio

n C

urre

ntLo

gic

Dire

ctio

n

Ree

lmas

ter

3100

−D

HIG

H T

EM

PS

HU

TD

OW

N R

ELA

Y

Ser

ial N

umbe

rs 9

0151

to23

0999

999


PIN

K

OR

AN

GE

GR

EE

N

GR

AY

FU

SIB

LE L

INK

BR

OW

N

BLU

E

BLA

CK

BK

BU

BN

GY

GN

OR

PK

OP

TIO

NA

L L

IGH

T K

IT

F2F1

D2

12

R

R

OR

OR

OR

BU

YIG

NIT

ION

ST

OP

−−−

− N

ON

ER

UN

−−

−−

B+

I+A

; X+

YS

TAR

T −

−− B

+I+S

S

X

BU

PK

F4

5 A

(+)

(−)

5 A

F3

BA

TT

ER

Y

FR

AM

E

CLUSTER GAUGE

Y

OR

BK

VIO

PK

PK

VIO

VIO

3087 86

85

R

PK

PK

VIO

LET

WH

ITE

TAN

RE

D

SP

LIC

ES

P

YE

LLO

W

RE

D/B

LAC

K

GLO

W R

ELA

Y

4 5 6

1 2 3

GLO

W P

LUG

CO

NT

RO

LER

VIO

OR

BU

R T VIO W

Y

R/B

K

EN

G L

OW

OIL

EN

GIN

E H

IGH

EN

GIN

E S

HU

T−

(HO

LD)

RU

N S

OLE

NO

ID

(PU

LL)

ALT

ER

NA

TO

R

RB L

PK

R

W

EN

GIN

E

EN

GIN

E

SP

ALTERNATOR

W

GY

W

HO

UR

ME

TE

R

(−)

HR(+

)

BK

PK

R/B

K

30

85

87

86

87A

ENGINE HIGH TEMP

GLOW

ENG LOW OIL PRESS

Y

BN

OR

(+)

(−)

6500

MF

D

OP

TIO

NA

L S

EA

T S

WIT

CH

BA

CK

LAP

CN

O P

AR

KIN

G B

RA

KE

#2

(BR

AK

E O

FF

)

D3

1 2

SE

AT

RE

LAY

3085

8786

87A

NE

UT

RA

L

SW

ITC

H

PA

RK

ING

BR

AK

E #

1(B

RA

KE

OF

F)

(NO

T IN

NE

UT

RA

L)

(SE

AT

EM

PT

Y)

SE

AT

SW

ITC

H

OR

GNT

OR

GY

R/B

K

BU

R/B

K

BK

GLO

W P

LUG

S

BK

T

R

EE

LS U

P

LIM

IT S

WIT

CH

(RE

ELS

UP

)

TR

AN

SP

OR

T/M

OW

1

RE

ELS

ON

/OF

F

(RE

ELS

OF

F)

2 RE

EL

DR

IVE

SO

LEN

OID

56

RE

ELS

ON

/OF

F

(RE

ELS

OF

F)

INT

ER

LOC

K R

ELA

Y

3085

8786 87A

BK

Y

BU

OR

BK

WB

UG

N

BK

1 2

D1

FU

EL

PU

MP

AB I

SW

ITC

H

SW

ITC

H

(IN

TR

AN

SP

OR

T)

SW

ITC

H

SW

ITC

H

(IN

MO

W)

15 A

GR

OU

ND

DO

WN

SW

ITC

H

TE

MP

SW

ITC

H PR

ES

SU

RE

Sta

rtB

+G

(CLO

SE

S A

T 1

05o C

)

(CLO

SE

S A

T 1

10o C

)

STA

RT

ER

GR

OU

ND

Y

OR

Ru

n C

ircu

its

(Tra

nsp

ort

)P

ower

Cur

rent

Con

trol

Cur

rent

Indi

catio

n C

urre

ntLo

gic

Dire

ctio

n

Ree

lmas

ter

3100

−D

HIG

H T

EM

PS

HU

TD

OW

N R

ELA

Y

Ser

ial N

umbe

rs 9

0151

to23

0999

999

Ele

ctri

cal

Sys

tem


PIN

K

OR

AN

GE

GR

EE

N

GR

AY

FU

SIB

LE L

INK

BR

OW

N

BLU

E

BLA

CK

BK

BU

BN

GY

GN

OR

PK

OP

TIO

NA

L L

IGH

T K

IT

F2F1

D2

12

R

R

OR

OR

OR

BU

YIG

NIT

ION

ST

OP

−−−

− N

ON

ER

UN

−−

−−

B+

I+A

; X+

YS

TAR

T −

−− B

+I+S

S

X

BU

PK

F4

5 A

(+)

(−)

5 A

F3

BA

TT

ER

Y

FR

AM

E

CLUSTER GAUGE

Y

OR

BK

VIO

PK

PK

VIO

VIO

3087 86

85

R

PK

PK

VIO

LET

WH

ITE

TAN

RE

D

SP

LIC

ES

P

YE

LLO

W

RE

D/B

LAC

K

GLO

W R

ELA

Y

4 5 6

1 2 3

GLO

W P

LUG

CO

NT

RO

LER

VIO

OR

BU

R T VIO W

Y

R/B

K

EN

G L

OW

OIL

EN

GIN

E H

IGH

EN

GIN

E S

HU

T−

(HO

LD)

RU

N S

OLE

NO

ID

(PU

LL)

ALT

ER

NA

TO

R

RB L

PK

R

W

EN

GIN

E

EN

GIN

E

SP

ALTERNATOR

W

GY

W

HO

UR

ME

TE

R

(−)

HR(+

)

BK

PK

R/B

K

30

85

87

86

87A

ENGINE HIGH TEMP

GLOW

ENG LOW OIL PRESS

Y

BN

OR

(+)

(−)

6500

MF

D

OP

TIO

NA

L S

EA

T S

WIT

CH

BA

CK

LAP

CN

O P

AR

KIN

G B

RA

KE

#2

(BR

AK

E O

FF

)

D3

1 2

SE

AT

RE

LAY

3085

8786

87A

NE

UT

RA

L

SW

ITC

H

PA

RK

ING

BR

AK

E #

1(B

RA

KE

OF

F)

(NO

T IN

NE

UT

RA

L)

(SE

AT

OC

CU

PIE

D)

SE

AT

SW

ITC

H

OR

GNT

OR

GY

R/B

K

BU

R/B

K

BK

GLO

W P

LUG

S

BK

T

R

EE

LS U

P

LIM

IT S

WIT

CH

(RE

ELS

DO

WN

)

TR

AN

SP

OR

T/M

OW

1

RE

ELS

ON

/OF

F

(RE

ELS

ON

)

2 RE

EL

DR

IVE

SO

LEN

OID

56

RE

ELS

ON

/OF

F

(RE

ELS

ON

)

INT

ER

LOC

K R

ELA

Y

3085

8786 87A

BK

Y

BU

OR

BK

WB

UG

N

BK

1 2

D1

FU

EL

PU

MP

AB I

SW

ITC

H

SW

ITC

H

(IN

MO

W)S

WIT

CH

SW

ITC

H

(IN

MO

W)

15 A

GR

OU

ND

DO

WN

SW

ITC

H

TE

MP

SW

ITC

H PR

ES

SU

RE

Sta

rtB

+G

(CLO

SE

S A

T 1

05o C

)

(CLO

SE

S A

T 1

10o C

)

STA

RT

ER

GR

OU

ND

Y

OR

Ru

n C

ircu

its

(Mo

w)

Pow

er C

urre

ntC

ontr

ol C

urre

ntIn

dica

tion

Cur

rent

Logi

c D

irect

ion

Ree

lmas

ter

3100

−D

HIG

H T

EM

PS

HU

TD

OW

N R

ELA

Y

Ser

ial N

umbe

rs 9

0151

to23

0999

999


PIN

K

OR

AN

GE

GR

EE

N

GR

AY

FU

SIB

LE L

INK

BR

OW

N

BLU

E

BLA

CK

BK

BU

BN

GY

GN

OR

PK

OP

TIO

NA

L L

IGH

T K

IT

F2F1

D2

12

R

R

OR

OR

OR

BU

YIG

NIT

ION

ST

OP

−−−

− N

ON

ER

UN

−−

−−

B+

I+A

; X+

YS

TAR

T −

−− B

+I+S

S

X

BU

PK

F4

5 A

(+)

(−)

5 A

F3

BA

TT

ER

Y

FR

AM

E

CLUSTER GAUGE

Y

OR

BK

VIO

PK

PK

VIO

VIO

3087 86

85

R

PK

PK

VIO

LET

WH

ITE

TAN

RE

D

SP

LIC

ES

P

YE

LLO

W

RE

D/B

LAC

K

GLO

W R

ELA

Y

4 5 6

1 2 3

GLO

W P

LUG

CO

NT

RO

LER

VIO

OR

BU

R T VIO W

Y

R/B

K

EN

G L

OW

OIL

EN

GIN

E H

IGH

EN

GIN

E S

HU

T−

(HO

LD)

RU

N S

OLE

NO

ID

(PU

LL)

ALT

ER

NA

TO

R

RB L

PK

R

W

EN

GIN

E

EN

GIN

E

SP

ALTERNATOR

W

GY

W

HO

UR

ME

TE

R

(−)

HR(+

)

BK

PK

R/B

K

30

85

87

86

87A

ENGINE HIGH TEMP

GLOW

ENG LOW OIL PRESS

Y

BN

OR

(+)

(−)

6500

MF

D

OP

TIO

NA

L S

EA

T S

WIT

CH

BA

CK

LAP

CN

O P

AR

KIN

G B

RA

KE

#2

(BR

AK

E O

N)

D3

1 2

SE

AT

RE

LAY

3085

8786

87A

NE

UT

RA

L

SW

ITC

H

PA

RK

ING

BR

AK

E #

1(B

RA

KE

ON

)

(IN

NE

UT

RA

L)

(SE

AT

EM

PT

Y)

SE

AT

SW

ITC

H

OR

GNT

OR

GY

R/B

K

BU

R/B

K

BK

GLO

W P

LUG

S

BK

T

R

EE

LS U

P

LIM

IT S

WIT

CH

(RE

ELS

DO

WN

)

TR

AN

SP

OR

T/M

OW

1

RE

ELS

ON

/OF

F

(RE

ELS

ON

)

2 RE

EL

DR

IVE

SO

LEN

OID

56

RE

ELS

ON

/OF

F

(RE

ELS

ON

)

INT

ER

LOC

K R

ELA

Y

3085

8786 87A

BK

Y

BU

OR

BK

WB

UG

N

BK

1 2

D1

FU

EL

PU

MP

AB I

SW

ITC

H

SW

ITC

H

(IN

MO

W)S

WIT

CH

SW

ITC

H

(IN

BA

CK

LAP

)

15 A

GR

OU

ND

DO

WN

SW

ITC

H

TE

MP

SW

ITC

H PR

ES

SU

RE

Sta

rtB

+G

(CLO

SE

S A

T 1

05o C

)

(CLO

SE

S A

T 1

10o C

)

STA

RT

ER

GR

OU

ND

Y

OR

Ru

n C

ircu

its

(Bac

klap

)P

ower

Cur

rent

Con

trol

Cur

rent

Indi

catio

n C

urre

ntLo

gic

Dire

ctio

n

Ree

lmas

ter

3100

−D

HIG

H T

EM

PS

HU

TD

OW

N R

ELA

Y

Ser

ial N

umbe

rs 9

0151

to23

0999

999

Ele

ctri

cal

Sys

tem


3012 85

SH

UT

DO

WN

HIG

H T

EM

P

DIO

DE

D2

P9

J17

J16

W6

W55

W26

W27

W54

SP

2

W10

P22

HO

UR

ME

TE

R

J3 E

NG

INE

GR

OU

ND

P10

87A

INT

ER

LOC

K R

ELA

Y

P11

CLU

ST

ER

GA

UG

EH

IGH

TE

MP

GLO

W

BA

TT

ER

YO

IL P

RE

SS

64 5321

W13

W18

W20

W17

21W

23W

16

GR

OU

ND (+)

8530

W21

W64

CBA

W57

W25

543

W62

(−)

(+)

8687

W63

W22

W59

W60

W62

SP

3

W58

W63

W57

87A3A

B

TRANSPORT/MOW

45

8786

AB

P2

12

3

P18

P15

J12

PULLGND

HOLD

W41

W34

W40

W56

J4W21

W17

J6J2

1

HIGH TEMP

W32

W33

W32

1X

2 3 4 5

Y A B S

W3

W15

W16

P14

P16

IGN

ITIO

N

SW

ITC

H

I

(OP

TIO

NA

L LI

GH

T)

13

24

56

FU

SE

BLO

CK 7

J18

J13

W2

W4

W4 W5

W6

W7

STA

RT

8 W14

STA

RT

ER

1

B+

ALT

ER

NA

TO

R

21R

L

W1

G

SP

1

P19

P20

P3

13

2B+

P23

J7

W2

W39

W52

W14

W25

W26

W15

W20

W40

W9

W12

SP

5W

9

W22

W64

2

GLO

W C

ON

TR

OLE

R

286GLO

W R

ELA

Y

85 13

45

6

P1

J1J2

30

P13

W52

W59

W53

W11

W18

W7

W10

87

GLO

W P

LUG

J5

W19

21

W51

W29

21W

28

4 653W

50

853021 3

87A

W30

4 587 86

W46

W49

P4

P5

P8

SE

AT S

EA

T

W31

W44

W43

W34

DIO

DE

D1

J15

J14

W35

W23

W31

B

P7

P12

NC

NO

54

32

1

RE

EL

ON

/OF

F

87

6A

B

REEL UPLIMIT SWITCH

W12

W13

W24

W42

W30

W28

W27

SP

4

W44

A BW

38W

47

W50

W60

W61

W37

W46

BAW

48

C NO

W35

AW

45

J19

J20

P6

J10

J11

P17

J8 J9

P21

BA

CK

LAP

CA

PA

CIT

OR

PA

RK

ING

BR

AK

E

NC

DIO

DE

D3

NE

UT

RA

L

RU

NS

OLE

NO

ID

W8

W5

W8

RE

LAY

SW

ITC

H

SE

AT

SW

ITC

H

SW

ITC

H #

1

PA

RK

ING

BR

AK

E

NO

SW

ITC

H #

2

SW

ITC

H

SW

ITC

H

ENG OIL PRESS

HIGH TEMP

FUEL PUMP

REEL DRIVE

SHUTDOWNSWITCH

SOLENOID

SWITCH

RE

LAY

WARNINGSWITCH

SW

ITC

H

Wir

ing

Dia

gra

mR

eelm

aste

r 31

00−

D

Ser

ial N

umbe

rs 9

0151

to23

0999

999


WIRE IDENTIFICATION


W1 RED P23−3 J7

W2 RED P23−1 P16−1


W4 BLUE P16−4 J13

W5 YELLOW P16−5 J18 (2)

W6 VIOLET P9−1 P16−6 (2)

W7 VIOLET P16−6 (2) P13−3 (2)

W8 YELLOW P16−7 J18 (2)

W9 PINK P16−8 (2) SP5 (4)

W10 VIOLET P13−3 (2) P9−2

W11 PINK SP5 (4) P1−1

W12 PINK SP5 (4) P12−6 (2)

W13 PINK P12−6 (2) P11−4

W14 PINK P16−8 (2) P3−1

W15 BLUE P13−1 P14−5 (2)

W16 BLUE P14−5 (2) P10−1

W17 YELLOW P11−1 J6


W19 ORANGE J2 J5

W20 WHITE P3−2 P11−5

W21 GRAY P11−6 J4

W22 PINK P22−A SP5 (4)

W23 YELLOW P10−2 J14 (2)

W24 YELLOW J14 (2) P12−2

W25 ORANGE P10−4 P19−1 (2)

W26 ORANGE P19−1 (2) J17

W27 ORANGE P9−3 SP4 (4)

W28 ORANGE SP4 (4) P5−1 (2)

W29 ORANGE P5−1 (2) P4−2

W30 TAN P8−1 J19 (2)

W31 GREEN P21−B P12−1 (2)

W32 BROWN J6 P9−5

WIRE IDENTIFICATION


W33 RED/BLACK J12 P2−3 (2)

W34 RED/BLACK P2−3 (2) J15 (2)

W35 RED/BLACK J15 (2) J9 (2)

W36 NOT USED

W37 GREEN P17−B J20 (2)

W38 TAN P6−B J19 (2)

W39 R 66465 P20 SP1 (2)

W40 WHITE SP1 (2) P2−1

W41 GREEN P15−B P18−A

W42 BLUE P18−B P7−A

W45 WHITE P7−B P12−5

W44 GREEN P12−1 (2) J20 (2)

W45 BLUE J8 P21−A

W46 RED/BLACK P8−4 J9 (2)



W49 GRAY P8−2 J10

W50 GRAY J10 P5−3 (2)

W51 GRAY P5−3 (2) P4−1

W52 RED J1 P23−2

W53 TAN P1−2 P13−5

W54 BLACK J3 SP2 (4)

W55 BLACK SP2 (4) J16

W56 BLACK SP2 (4) P2−2

W57 BLACK SP2 (4) SP3 (6)

W58 BLACK SP3 (6) P15−A

W59 BLACK SP3 (6 )P13−6

W60 BLACK SP3 (6) J11 (2)

W61 BLACK J11 (2) P8−5

W62 BLACK SP3 (6) P10−5

W63 BLACK SP3 (6) P22−C (2)

W64 PINK P11−3 SP5 (5)

W65 NOT USED

Supplement to Wiring DiagramReelmaster 3100−D

Serial Numbers 90151 to 230999999

Ele

ctri

cal

Sys

tem


J1 P1J2

J4

P8

J7

P23

P19

P20

J12

J3

P2

J5

J6

P4

P5

P18

P7

P6

P21

J8

J9

P8

P9

P10

P22

J10

J11P

12

P13

P14

J18

P11

P15

P16

J13

P17

D2

D3

D1

FU

EL

PU

MP

SE

AT

SW

ITC

H

TR

AN

SP

OR

T/M

OW

SW

ITC

H

RE

EL

UP

/DO

WN

SW

ITC

H

OV

ER

TE

MP

RE

LAY

RE

EL

ON

/OF

FS

WIT

CH

GLO

WC

ON

TR

OLL

ER

IGN

ITIO

NS

WIT

CH

ALT

ER

NA

TO

R

GLO

WR

ELA

Y

OIL

SW

ITC

H

STA

RT

SO

LEN

OID

STA

RT

SO

LEN

OID

G

FU

EL

SO

LEN

OID

EN

GIN

EG

RO

UN

D

GLO

WP

LUG

TE

MP

SW

ITC

H

PA

RK

ING

BR

AK

EB

AC

KLA

PS

WIT

CH

SE

AT

RE

LAY

SE

AT

SW

ITC

H

FU

SE

BLO

CK

RE

EL

SO

LEN

OID

GA

UG

EC

LUS

TE

R

OP

TIO

NA

LLI

GH

T

NE

UT

RA

LS

WIT

CH

INT

ER

LOC

KR

ELA

Y

HO

UR

ME

TE

R

CA

PA

CIT

OR

Har

nes

s D

iag

ram

Ree

lmas

ter

3100

−D

Ser

ial N

umbe

rs 9

0151

to23

0999

999


Ele

ctri

cal S

chem

atic

Ree

lmas

ter

310

0−D

All

rela

ys a

nd

so

len

oid

s ar

e sh

ow

n a

s d

e−en

erg

ized

.

Ser

ial N

umbe

rs 2

4000

0001

and

up

R

I

Y

RRW

SBYA

1F 3

BK

BK

BN

13

12

Y

LOW OIL PRESSURE

OVER TEMP.

PK

W

GN

OR

BU

ORX

G

FL

FL

BU

/W

W

T

WO

PT

ION

AL

LIG

HT

SW

.

PK

OR

VIO

BU

R/B

K

LAM

P

OP

TIO

NA

L LI

GH

T

PA

RK

ING

BR

AK

E D1

NE

UT

RA

L S

WIT

CH

BA

CK

LAP

2A2F

BK

10 A

1F 2

15 A

1F 1

ALT

ER

NA

TO

R

FL

BU

FR

AM

E G

RO

UN

D

EN

GIN

E

FU

SIB

LE L

INK

SP

R

GN

10 A

1F 4

10 A

BK

K4

OR

PK

VIO

PK

PK

SO

LEN

OID

VIOGN

GY

ORB

U

BU

BKT

R/B

KBN

PK

ALTERNATOR

GLOW

GLOW RELAY

30

85 86

87

4 5 6

1 2 3KU

BO

TAG

LOW

PLU

GC

ON

TR

OLE

R

PK HR(+

)

(−)

GY

EN

GIN

E G

RO

UN

D

R/B

K

EN

GIN

E O

IL P

RE

SS

UR

E

GYR/B

K

VIO

+ 1

2V

STA

RT

PT

O S

WIT

CH

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Rev. DReelmaster 3100−D Page 5 − 23 Electrical Systems (Rev. C)

Special Tools

Order special tools from your Toro Distributor. Sometools may also be available from a local supplier.

Multimeter

The meter can test electrical components and circuitsfor current, resistance, or voltage.

NOTE: Toro recommends the use of a DIGITAL Volt−Ohm−Amp multimeter when testing electrical circuits.The high impedance (internal resistance) of a digital me-ter in the voltage mode will make sure that excess cur-rent is not allowed through the meter. This excesscurrent can cause damage to circuits not designed tocarry it.

Figure 1

Skin−Over Grease

Special non−conductive grease (Toro Part No.505−165) which forms a light protective skin which helpswaterproof electrical switches and contacts.

Figure 2

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Troubleshooting

CAUTION

Remove all jewelry, especially rings andwatches, before doing any electrical trouble-shooting or testing. Disconnect the batterycables unless the test requires battery voltage.

For effective troubleshooting and repairs, you musthave a good understanding of the electrical circuits andcomponents used on this machine (see Electrical Sche-matics and Diagrams section of this chapter).

If the machine has any interlock switches by−passed,they must be reconnected for proper troubleshootingand safety.

Starting Problems

Problem Possible Causes

Starter solenoid clicks, but starter will not crank(if solenoid clicks, problem is not in safety interlocksystem).

Low battery charge.

Loose or corroded battery cables.

Loose or corroded ground.

Faulty wiring at the starter.

Faulty starter solenoid.

Nothing happens when start attempt is made. The traction pedal is not in neutral position or theneutral switch is faulty.

Reel on/off switch is in the ON position or faulty.

The engine is too hot or the over temperature shutdown relay is faulty.

The battery is dead.

Fuse F1 or F3 is faulty or blown.

Loose or corroded battery or ground cables.

Loose or corroded ground.

Wiring in the crank circuit (see Electrical Schematics)is loose, corroded, or damaged.

The ignition switch faulty.

Starter solenoid wiring loose, corroded or damaged.

Starter solenoid faulty.

The interlock relay is faulty.


Starting Problems (continued)

Problem Possible Causes

Engine cranks, but does not start. Wiring in the crank circuit (see Electrical Schematics)is loose, corroded, or damaged.

Engine run solenoid or fuel pump faulty.

The fuel tank is empty. An engine or fuel systemproblem exists.

The glow circuit does not operate properly.

The glow circuit does not operate properly. Wiring in the glow circuit (see Electrical Schematics) isloose, corroded, or damaged.

The glow relay or glow plug controller is faulty.

Fuse F4 is blown or faulty.

Engine cranks (but should not) with the reel on/offswitch in the ON position.

The reel on/off switch is faulty or short circuited.

Short circuit in reel drive neutral switch circuit.

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General Run and Transport Problems

Engine kills during operation (operator sitting on seat). Operator moved too far forward on seat (seat switch isnot depressed).

The engine overheated.

The parking brake was engaged or the parking brakeswitch No. 1 failed.

The seat relay or seat switch failed.

The high temperature shutdown relay failed.

Fuse F1 or F3 failed.

The run solenoid or fuel pump failed.

Wiring in the run circuit (see Electrical Schematics)broke or disconnected.

Engine kills when the backlap switch is in theBACKLAP position and the parking brake is ON.

The parking brake was released or the backlap switchwas moved to MOW.

The engine overheated.

The traction pedal was moved from the neutral.

The high temperature shutdown relay failed.

Fuse F1 or F3 failed.

The run solenoid or fuel pump failed.

Wiring in the run circuit (see Electrical Schematics)broke or disconnected.

Battery does not charge. Loose or broken wire(s).

Faulty alternator.

Dead battery.

Alternator warning lamp is faulty or burned out.

Alternator warning lamp wiring loose, corroded ordamaged.


Cutting Unit Operating Problems

The cutting units will not run with the transport mowswitch in MOW and the reel on/off switch in ON withthe cutting units lowered.

Wiring to the reel drive circuit is (see ElectricalSchematics) is loose, corroded, or damaged.

Fuse F4 is faulty or blown.

The coil to solenoid valve S1 on the hydraulic manifoldis faulty or the valve is stuck.

The reels on/off is faulty. The reels up limit ortransport/mow switch is faulty or misadjusted.

There is insufficient hydraulic oil pressure to turn thereels (see Troubleshooting in Chapter − 4, HydraulicSystem).

The cutting units run, but should not run when raised. The coil to solenoid valve S1 on the hydraulic manifoldis faulty or the valve is stuck.

The reels up limit switch is stuck, faulty, ormisadjusted.

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Electrical System Quick Check

Battery Test (Open Circuit Test)

Use a multimeter to measure the voltage between thebattery terminals.

Set multimeter to the DC volts setting. The batteryshould be at a temperature of 60 to 100oF (16 to 38oC).The ignition key should be off and all accessories turnedoff. Connect the positive (+) meter lead to the positivebattery post and the negative (−) meter lead the the neg-ative battery post.

NOTE: This test provides a relative condition of the bat-tery. Load testing of the battery will provide additionaland more accurate information.

Voltage Measured Battery Charge Level

12.68 V (or higher) Fully charged (100%)

12.45 V 75% charged

12.24 V 50% charged

12.06 V 25% charged

11.89 V 0% charged

Charging System Test

This is a simple test used to determine if a charging sys-tem is functioning. It will tell you if the charging systemhas an output, but not its capacity.

Tool required: Digital multimeter set to DC volts.

Test instructions: Connect the positive (+) multimeterlead to the positive battery post and the negative (−)multimeter lead to the negative battery post. Keep thetest leads connected to the battery posts and record thebattery voltage.

NOTE: Upon starting the engine, the battery voltagewill drop and then should increase once the engine isrunning.

NOTE: Depending upon the condition of the batterycharge and battery temperature, the charging systemvoltage will increase at different rates as the batterycharges.

Start the engine and run at high idle (2650 RPM). Allowthe battery to charge for at least 3 minutes. Record thebattery voltage.

After running the engine for at least 3 minutes, batteryvoltage should be at least 0.50 volt higher than initial bat-tery voltage.

Example of a charging system that is functioning:

At least 0.50 volt over initial battery voltage.

Initial Battery Voltage = 12.30 v

Battery Voltage after 3 Minute Charge = 12.85 v

Difference = +0.55 v

Glow Plug System Test

This is a fast, simple test that can help to determine theintegrity and operation of the Reelmaster 3100−D glowplug system. The test should be run anytime hard start-ing (cold engine) is encountered on a diesel engineequipped with a glow plug system.

Tool(s) required: Digital multimeter and/or inductiveAmmeter (AC/DC Current Transducer).

Test instructions: Properly connect the ammeter to thedigital multimeter (refer to manufacturers’ instructions).

Set the multimeter to the correct scale. With the ignitionswitch in the OFF position, place the ammeter pickuparound the main glow plug power supply wire and readthe meter prior to activating the glow plug system. Adjustthe meter to read zero (if applicable). Activate the glowplug system (see Traction Unit Operator’s Manual) andrecord the multimeter results.

The Reelmaster 3100−D glow plug system should havea reading of approximately 27 Amps.

Rev. DReelmaster 3100−D Page 5 − 29 Electrical Systems (Rev. C)

Check Operation of Interlock Switches

CAUTION

Do not disconnect safety switches. They are forthe operator’s protection. Check the operation ofthe interlock switches daily for proper operation.Replace any malfunctioning switches before op-erating the machine.

Note: The machine is equipped with an interlockswitch on the parking brake. The engine will stop if thetraction pedal is depressed with the parking brake en-gaged.

1. Make sure all bystanders are away from the area ofoperation. Keep hands and feet away from cutting units.

2. With operator on the seat, the engine must not startwith either the reel switch engaged or the traction pedalengaged. Correct problem if not operating properly.

3. With operator on the seat, the traction pedal in neu-tral, the parking brake off, and the reel switch in the OFFposition, the engine should start. Lift off seat and slowlydepress traction pedal, the engine should stop in one tothree seconds. Correct problem if not operating proper-ly.

4. With operator on the seat, the engine running, thereel transport slide in mow, and the reel switch in the ONposition, lower cutting units. Reels should come on. Pullback on the lift lever, the reels should stop when fullyraised. Correct problem if not operating properly.

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Component Testing

For accurate resistance and/or continuity checks, elec-trically disconnect the component being tested from thecircuit (e.g. unplug the ignition switch connector beforedoing a continuity check).

NOTE: For more component testing information, seethe Kubota Workshop Manual, Diesel Engine, 05 Se-ries.

CAUTION

When testing electrical components for continu-ity with a multimeter (ohms setting), make surethat power to the circuit has been disconnected.

Ignition Switch

The ignition (key) switch has three positions (OFF, RUN,and START). The terminals are marked as shown. Thecircuitry of the ignition switch is shown in the chart. Withthe use of a multimeter (ohms setting), the switch func-tions may be tested to determine whether continuity ex-ists between the various terminals for each position.Verify continuity between switch terminals.

SWITCHPOSITION

NORMALCIRCUITS

OTHERCIRCUITS

OFF NONE NONE

RUN B + A + I X + Y

START B + S + I NONE

Figure 3

AY

B

I

X

S

1. Switch2. Key

3. Hex nut4. Lock washer

Figure 4

23

1 4

Figure 5

45 °

45 °RUN

START

OFF


Glow Relay

The glow relay is attached to the radiator assembly.When energized, the glow relay allows electrical currentto the engine glow plugs.

Two styles of glow relays have been used on the Reel-master 3100−D. On machines with serial numbers be-low 240000000, two of the four relay connections aresecured with screws (Fig. 6). Machines with serial num-bers above 240000000 are connected to the wire har-ness with a four wire connector (Fig. 7).

1. Verify coil resistance between terminals 86 and 85with a multimeter (ohms setting):

A. On machines with serial numbers below240000000, resistance should be from 41 to 51ohms.

B. On machines with serial numbers above240000000, resistance should be approximately 72ohms.

2. Connect multimeter (ohms setting) leads to relay ter-minals 30 and 87. Ground terminal 86 and apply +12VDC to terminal 85. The relay should make and breakcontinuity between terminals 30 and 87 as 12 VDC is ap-plied and removed from terminal 85.

3. Disconnect voltage and leads from the terminals.

Figure 6

86 87

85 30 30

87

85 86

Figure 7

86 87

85 30

85 8687

30

Start, Seat, and High Temperature Shutdown Relays

These relays are located under the control panel on ma-chines with Serial Numbers below 240000000.

1. Verify coil resistance between terminals 86 and 85with a multimeter (ohms setting). Resistance should befrom 80 to 90 ohms. There should be continuity betweenterminals 87A and 30.

2. Connect multimeter (ohms setting) leads to relay ter-minals 30 and 87. Ground terminal 86 and apply +12VDC to terminal 85. The relay should make and breakcontinuity between terminals 30 and 87 as 12 VDC is ap-plied and removed from terminal 85.

3. Disconnect voltage from terminal 85 and multimeterlead from terminal 87.

4. Connect multimeter (ohms setting) lead to relay ter-minal 30 and 87A. Apply +12 VDC to terminal 85. Therelay should make and break continuity between termi-nals 30 and 87A as 12 VDC is applied and removed fromterminal 85.

5. Disconnect voltage and multimeter leads from therelay terminals.

Figure 8

86

85

87A 87

30

8687A

30

87

85

TOP VIEW

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Hour Meter

1. Connect the positive (+) terminal of a 12 VDC sourceto the positive terminal of the hour meter.

2. Connect the negative (−) terminal of the voltagesource to the other terminal of the hour meter.

3. The hour meter should move a 1/10 of an hour in sixminutes.

4. Disconnect the voltage source from the hour meter.

Figure 9

QUARTZHobbs

HOURS10 0 0 0 1

10

+

BACK

Reel Drive Solenoid

Note: Prior to taking small resistance readings with adigital multimeter, short the test leads together. The me-ter will display a small resistance value (usually 0.5ohms or less). This resistance is due to the internal re-sistance of the meter and test leads. Subtract this valuefrom from the measured value of the component you aretesting.

1. Make sure engine is off. Disconnect solenoid valveelectrical connector.

2. Apply 12VDC source directly to the solenoid. Listenfor solenoid to switch on.

3. Remove 12VDC source from the solenoid. Listen forsolenoid to switch off.

4. Measure resistance between the two connector ter-minals. The resistance should be about 7.2 ohms.

5. Install new solenoid if necessary.

A. Make sure o−ring is installed at each end of coil.Apply ”Loctite 242” or equivalent to threads on end ofvalve stem before installing nut.

B. Tighten nut to a torque of 15 in−lb (17.3 kg−cm).Over−tightening may damage the solenoid or causethe valve to malfunction.

6. Reconnect electrical connector to the solenoid.

Figure 101. Hydraulic manifold 2. Solenoid

2

1


High Temperature Warning and Shutdown Switches

The high temperature warning and shut down switchesare located on the water pump, which is located on therear end of the engine block. The high temperature shut-down switch is on the alternator side of the engine (Fig.11).

CAUTION

Make sure engine is cool before removing thetemperature switch.

1. Lower coolant level in the engine and remove thetemperature switch.

2. Put switch in a container of oil with a thermometerand slowly heat the oil (Fig. 12).

CAUTION

Handle the hot oil with extreme care to preventpersonal injury or fire.

Note: On units with serial numbers from 90101 to90150, the high temperature shutdown switch settingsare the same as the high temperature warning switchbelow.

3. Check continuity of the switch with a multimeter(ohms setting).

A. The high temperature warning switch is normallyopen and should close between 216 to 226oF (102 to108oC).

B. The high temperature shutdown switch is normal-ly open and should close between 225 to 235oF (107to 113oC).

1. Temp. warning switch2. Temp. shutdown switch

3. Water pumpFigure 11

1

2

3

Figure 12

4. Allow oil to cool while observing temperature.

A. The high temperature warning switch shouldopen at about 208oF (98oC).

B. The high temperature shutdown switch shouldopen at about 219oF (104oC).

5. Replace switch if necessary.

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Diode Assemblies

The diode D1 and D2 provide logic for the interlockswitches. Diode D3 is used for circuit protection from in-ductive voltage spikes when the interlock relay is deen-ergized. Machines equipped with the standard controlmodule (serial numbers above 240000000) use onlyone diode.

Two types of diodes have been used on the Reelmaster3100−D:

1. On early production machines, the diodes are lo-cated within the main wiring harness that lies under thehydraulic tank and control console (Fig. 13).

2. Later production machines use diodes that plug intothe wiring harness (Fig. 14). Location of the diodes is un-der the control console.

Testing

The diodes can be individually tested using a digitalmultimeter (ohms setting) and the tables below.

1. Diodes located within the main harness (Fig. 13):

MultimeterRed Lead (+)

onTerminal Blade

MultimeterBlack Lead (−)

onTerminal Blade

Continuity

Male Female YES

Female Male NO

2. Plug−in style diodes (Fig. 14):

MultimeterRed Lead (+)on Terminal

MultimeterBlack Lead (−)

on TerminalContinuity

Female Male YES

Male Female NO

Figure 13

32

14

1. Diode2. Male terminal blade

3. Female terminal blade4. Clear PVC tubing

Figure 14

1

1. Diode2. Male terminal

3. Female terminal

3

2


Warning Light Cluster (Serial Numbers Below 240000000)

Note: Individual light bulbs can be tested by removingthem from the lighting cluster and applying 12 VDC totheir wiring terminals.

Oil Pressure Light

The oil pressure light should come on when the ignitionswitch is in the ON position with the engine not running.Also, it should light with the engine running when the oilpressure drops below 4 PSI (0.3 kg/cm2).

1. Disconnect green/blue wire from the oil pressureswitch.

2. Ground green/blue wire to the engine block.

3. Turn the ignition switch to ON; the light should comeon.

4. Turn the ignition switch to OFF. Connect green/bluewire to the oil pressure switch.

High Temperature (Water) Shutdown Light

Units with Serial Numbers from 90101 to 90150

When the coolant temperature is above 221oF (105oC),the temperature light comes on as the high temperatureshutdown switch and relay stop the engine.

Units with Serial Numbers from 90150 to230999999

When the coolant temperature is above 221oF (105oC),the temperature light comes on. However, the high tem-perature shutdown switch and relay do not stop the en-gine until the high temperature shutdown switch isabove 230oF (110oC).

Glow Light

The glow light comes on when the ignition switch isplaced in RUN prior to placing the ignition switch inSTART, and stays lit for 10 seconds while left in RUN.

Battery Light

The battery light should come on when the ignitionswitch is in ON with the engine not running, or with animproperly operating charging circuit while the engine isrunning.

1. Turn ignition switch to ON; the light should come on.

2. Turn ignition switch to OFF.

Figure 15

OIL(RED)

BATT(AMBER)

WATER(RED)

GLOW(AMBER)

FRONT

BACK

A

B

F

E

A B C D E F

Figure 16

GLOW

BATT

OIL

WATER

B

E

F

A

C

D

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Indicator Lights (Serial Numbers Above 240000000)

Charge Indicator Light

The charge indicator light should come on when the igni-tion switch is in the ON position with the engine not run-ning. Also, it should illuminate with an improperlyoperating charging circuit while the engine is running.

Engine Oil Pressure Light

The engine oil pressure light should come on when theignition switch is in the ON position with the engine notrunning. Also, it should illuminate with the engine run-ning if the engine oil pressure drops to an unsafe level.

IMPORTANT: If the oil pressure indicator light is il-luminated with the engine running, shut off the en-gine immediately.

To test the oil pressure light and circuit wiring, ground thewire attached to oil pressure switch located on the en-gine near the oil filter. Turn ignition switch to the ON posi-tion; the engine oil pressure light should come onindicating correct operation of the indicator light and cir-cuit wiring.

High Temperature Warning Light

If the engine coolant temperature reaches 221oF(105oC) (approximate), the high temperature warninglight should come on.

To test the high temperature warning light and circuit wir-ing, turn ignition switch to the ON position and groundthe wire attached to high temperature sender located onthe engine water pump housing (see TemperatureSender in this Chapter). The high temperature warninglight should illuminate.

Glow Plug Indicator Light

The glow plug light should come on when the ignitionswitch is placed in the ON position prior to placing theignition switch in START. The light should stay lit forapproximately 6 seconds while the ignition switch is leftin the ON position.

Testing Indicator Lights

1. Apply 12 VDC to terminals 1A and 2A (Fig. 18).

2. Ground terminals 1B and 2B (Fig. 18).

3. Both indicator lights should illuminate.

1. Charge indicator2. Engine oil pressure

3. High temp shutdown4. Glow plug indicator

Figure 17

3

4

1

2

Figure 181. Charge indicator2. Engine oil pressure3. High temperature

4. Glow plug indicator5. Indicator light front6. Indicator light back

1A (+)

2A (+)2B (−)

1B (−)

4

3

5

2

16


Fuel Pump

The fuel pump is attached to the frame just outboard ofthe fuel injection pump.

Operational Test


2. Disconnect electrical connector from the fuel stopsolenoid to prevent the engine from firing.

3. Disconnect fuel hose (discharge) from the fuel filter.

4. Make sure fuel hoses attached to the fuel pump arefree of obstructions.

5. Place fuel hose (discharge) into a large, graduatedcylinder sufficient enough to collect 1 liter (33.8 fluidounces).

IMPORTANT: When testing the fuel pump, DO NOTturn ignition switch to START.

6. Collect fuel in the graduated cylinder by turning igni-tion switch to the RUN position. Allow pump to run for 30seconds, then return switch to OFF.

7. Multiply amount of fuel collected in the graduatedcylinder by 2 to get the capacity of the pump. Pump ca-pacity should be about 400 cc/min (13.5 fl oz/min).

8. Replace fuel pump as necessary. Install fuel hose tothe fuel filter.

9. Reconnect electrical connector to the fuel stop sole-noid.

10.Prime fuel system.

1. Fuel pump2. Fuel hose (discharge)

3. Fuel filter4. Fuel stop solenoid

Figure 19

12

3

4

Fuel Pump Specifications

Pump Capacity 13.5 fl oz/min (400 ml/min)

Pressure 5.4 psi (37.3 kPa)

Max. CurrentDraw

1.5 amp

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Fuel Stop Solenoid (Solenoid With 3 Wire Connector)

The fuel stop solenoid must be energized for the engineto run. It is mounted on the engine block near the injec-tion pump (Fig. 20).

The fuel stop solenoid includes two coils for operation:the pull coil and the hold coil. When the ignition switchis turned to START, the fuel stop solenoid is initially ener-gized and the pull coil retracts the solenoid plunger.Once the plunger is retracted, the hold coil will keep it re-tracted for continued engine operation. When the sole-noid is de−energized, the plunger extends to shut off fuelsupply to the engine causing the engine to stop running.The fuel stop solenoid is grounded through the common(black) wire of the solenoid wire connector.

NOTE: Refer to Electrical Diagrams in this chapterwhen troubleshooting the fuel stop solenoid.

Testing

NOTE: Prior to taking small resistance readings with adigital multimeter, short the test leads together. The me-ter will display a small resistance value (usually 0.5ohms or less). This resistance is due to the internal re-sistance of the meter and test leads. Subtract this valuefrom the measured value of the component you are test-ing.

1. Make sure ignition switch is in the OFF position. Dis-connect the connector from the solenoid.

2. Using a digital multimeter, touch one test lead to thepin of the black wire and the other test lead to the pin ofthe white wire (Fig. 21). The resistance of the pull coilshould be about 0.33 ohms.

3. Using a digital multimeter, touch one test lead to thepin of the black wire and the other test lead to the pin ofthe red wire (Fig. 21). The resistance of the hold coilshould be about 12.2 ohms.

4. Connect solenoid to the wiring harness.

1. Injection pump 2. Fuel stop solenoid

Figure 20

12

1. Cap screw2. Fuel stop solenoid3. Gasket

4. Common (Black wire)5. Hold coil (Red wire)6. Pull coil (White wire)

Figure 21

2

3

1

5 4

6


Fuel Stop Solenoid (Solenoid With 2 Wire Connector)

The fuel stop solenoid used on the Reelmaster 3100−Dmust be energized for the diesel engine to run. The sole-noid is mounted to the injection pump on the engine (Fig.22).

The fuel stop solenoid includes two coils for operation:the pull coil and the hold coil. When the ignition switchis turned to START, the fuel stop solenoid is initially ener-gized and the pull coil retracts the solenoid plunger.Once the plunger is retracted, the hold coil will keep it re-tracted for continued engine operation. When the sole-noid is de−energized, the plunger extends to shut off fuelsupply to the engine causing the engine to stop running.The fuel stop solenoid is grounded through the solenoidhousing.

NOTE: Refer to Chapter 8 − Electrical Diagrams whentroubleshooting the fuel stop solenoid.

In Place Testing

NOTE: Prior to taking small resistance readings with adigital multimeter, short the test leads together. The me-ter will display a small resistance value (usually 0.5ohms or less). This resistance is due to the internal re-sistance of the meter and test leads. Subtract this valuefrom the measured value of the component you are test-ing.

1. Make sure ignition switch is in the OFF position. Dis-connect wire harness connector from fuel stop solenoid.

2. Using a digital multimeter, touch one test lead to thepull coil terminal and the other test lead to the fuel stopsolenoid frame (ground) (Fig. 23). The resistance of thepull coil should be less than 1 ohm (but not zero).

3. Using a digital multimeter, touch one test lead to thehold coil terminal and the other test lead to the fuel stopsolenoid frame (ground) (Fig. 23). The resistance of thehold coil should be approximately 15 ohms.

4. Connect solenoid to the wiring harness.

1. Fuel stop solenoid 2. Harness connector

Figure 22

2

1

1. Fuel stop solenoid2. Pull coil terminal

3. Hold coil terminal

Figure 23

2

3

1

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Glow Controller

The controller is located under the right lower corner ofthe instrument panel.

Note: Refer to Electrical Schematics and Diagrams atthe beginning of the chapter when troubleshooting thecontroller.

Controller Operation

1. When the ignition switch is placed in the RUN posi-tion, the controller energizes the glow plugs and lightsup the glow lamp for 10 seconds.

Note: On units with serial numbers from 90101 to90150, the glow controller is not in use when the ignitionswitch is turned to start.

2. When the ignition switch is held in the START posi-tion, the glow plugs will energize while the switch is heldin START and the glow lamp will not light.

3. When the ignition switch is released from START toRUN, the glow plugs will deenergize and the glow lampwill remain off.

Controller Checks

1. Make sure there is power from the battery.

2. Disconnect electrical connector to the run solenoidto prevent the engine from starting.

3. Place ignition switch in the RUN position. Verify thefollowing while in the RUN position:

A. Glow indicator lamp is on.

B. Glow relay is energized.

C. Glow plugs are energized.

D. Glow indicator lamp goes out and glow plugsdeenergize after 10 seconds.

Note: On units with serial numbers from 90101 to90150, the glow controller is not in use when the ignitionswitch is turned to start.

Note: If there is no power to terminal 1 of the glow con-troller, verify continuity of the circuitry from the ignitionswitch to the controller and perform step 4 again (seeElectrical Schematics and Diagrams in this chapter).

1. Glow controller end view2. Top view

3. Side viewFigure 24

3

2

1

6

4

5

2

3

1

4. Place ignition switch in the START position. Verifythe following while in the START position:

A. Glow indicator lamp is out.

B. Glow relay is energized.

C. Glow plugs are energized.

D. Power to terminal 1 of the glow controller.

5. If any of the conditions in step 3 are not met or powerto terminal 1 exists and any of the other conditions instep 4 are not met:

A. Verify continuity of the circuitry from the battery tothe glow relay and glow plugs (see Electrical Sche-matics and Diagrams in this chapter).

B. Verify continuity of the circuitry from the battery toignition switch, glow controller, glow lamp, glowrelay, and ground (see Electrical Schematics andDiagrams in this chapter).

C. Replace parts as necessary.

6. Connect electrical connector to the run solenoid.


Standard Control Module

Reelmaster 3100−D machines with Serial Numbersabove 240000000 are equipped with a Standard ControlModule to monitor and control electrical components re-quired for safe operation. This Module is attached to theback of the instrument panel.

Inputs from the neutral, parking brake, PTO, start (igni-tion), backlap, and high temperature switches are moni-tored by the Module. Output to the PTO (reel drivesolenoid), fuel pump, and engine run solenoid are con-trolled based on the inputs received by the Module.

The Standard Control Module does not connect to anexternal computer or hand held device, can not be re−programmed, and does not record intermittent faultdata.

The Standard Control Module can be used to check op-eration of machine switches by monitoring the LED ofthe module. If a Module LED does not illuminate (e.g. thein seat input LED does not illuminate with the seat occu-pied and the ignition switch in the run position), testingof the switch and circuit wiring would be required.

Refer to the Traction Unit Operator’s Manual for opera-tion and troubleshooting of the Standard Control Mod-ule.

1. Power input LED2. Start input LED3. Engine run output LED4. Start output LED5. PTO output LED

6. Neutral input LED7. Park brake off input LED8. PTO switch input LED9. In seat input LED10. High temp input LED11. Backlap input LED

Figure 25

1

2

3

4

5

6

7

8

9

10

11

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Service and RepairsNOTE: For more component repair information, seethe Kubota Workshop Manual, Diesel Engine, 05 Se-ries.

Battery Storage

If the machine will be stored for more than 30 days:

1. Remove the battery and charge it fully (see BatteryService).

2. Either store battery on a shelf or on the machine.

3. Leave cables disconnected if the battery is stored onthe machine.

4. Store battery in a cool atmosphere to avoid quick de-terioration of the battery charge.

5. To help prevent the battery from freezing, make sureit is fully charged (see Battery Service).

Battery Care

1. Battery electrolyte level must be properly main-tained. The top of the battery must be kept clean. lf themachine is stored in a location where temperatures areextremely high, the battery will run down more rapidlythan if the machine is stored in a location where temper-atures are cool.

WARNINGWear safety goggles and rubber gloves whenworking with electrolyte. Charge battery in awell ventilated place so gasses producedwhile charging can dissipate. Since the gasesare explosive, keep open flames and electricalsparks away from the battery; do not smoke.Nausea may result if the gases are inhaled. Un-plug charger from electrical outlet before con-necting or disconnecting charger leads to orfrom battery posts.

2. Keep top of battery clean by washing periodicallywith a brush dipped in ammonia or bicarbonate of sodasolution. Flush top surface with water after cleaning. Donot remove the fill cap while cleaning.

3. Battery cables must be tight on terminals to providegood electrical contact.

WARNINGConnecting cables to the wrong post could re-sult in personal injury and/or damage to theelectrical system.

4. If corrosion occurs at terminals, disconnect cables.Always disconnect negative (−) cable first. Scrapeclamps and terminals separately. Reconnect cableswith positive (+) cable first. Coat terminals with petro-leum jelly.

5. Check electrolyte level every 25 operating hours,and every 30 days if machine is in storage.

6. Maintain cell level with distilled or demineralized wa-ter. Do not fill cells above the fill line.


Battery Service

The battery is the heart of the electrical system. Withregular and proper service, battery life can be extend.Additionally, battery and electrical component failurecan be prevented.

CAUTION

When working with batteries, use extreme cau-tion to avoid splashing or spilling electrolyte.Electrolyte can destroy clothing and burn skin oreyes. Always wear safety goggles and a faceshield when working with batteries.

Electrolyte Specific GravityFully charged: 1.265 corrected to 80oF (26.7oC)Discharged: less than 1.240

Battery SpecificationsBCI Group Size 55:450 CCA at 0o F (−17.8o C)Reserve Capacity of 60 minutes at 80oF (26.7oC)

Dimensions (including terminal posts and caps)Length 8.90 inches (22.61 cm)Width 6.03 inches (15.31 cm)Height 8.49 inches (21.56 cm)

Removal (Fig. 26 and 27)

IMPORTANT: Be careful not to damage terminalposts or cable connectors when removing the bat-tery cables.

1. Remove battery cover from the frame. Loosen bat-tery retainer securing the back of the battery to the bat-tery support.

2. Loosen nut on ground cable (−) post first and removecable from battery. This should prevent short circuitingthe battery, other components, or the operators hands.

3. Loosen nut on positive (+) cable post and removecable from battery.

4. Make sure battery vent caps are on tightly.

5. Remove battery from the battery compartment to aservice area to allow better access for service.

Inspection, Maintenance, and Testing

1. Perform following inspections and maintenance:

A. Check for cracks. Replace battery if cracked orleaking.

B. Check battery terminal posts for corrosion. Usewire brush to clean corrosion from posts.

1. Knobs 2. Battery cover

Figure 26

2

1

1. Ground cable 2. Positive cable

Figure 27

2

1

IMPORTANT: Before cleaning the battery, tape orblock vent holes to the filler caps and make sure thecaps are on tightly.

C. Check for signs of wetness or leakage on the topof the battery which might indicate a loose or missingfiller cap, overcharging, loose terminal post, or over-filling. Also, check battery case for dirt and oil. Cleanthe battery with a solution of baking soda and water,then rinse it with clean water.

D. Check that the cover seal is not broken away. Re-place the battery if the seal is broken or leaking.

E. Check the electrolyte level in each cell. If the levelis below the tops of the plates in any cell, fill all cellswith distilled water between the minimum and maxi-mum fill lines. Charge at 15 to 25 amps for 15 min-utes to allow sufficient mixing of the electrolyte.

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2. Conduct a hydrometer test of the battery electrolyte.

IMPORTANT: Make sure the area around the cells isclean before opening the battery caps.

A. Measure the specific gravity of each cell with ahydrometer. Draw electrolyte in and out of thehydrometer barrel prior to taking a reading to warm−up the hydrometer. At the same time take the tem-perature of the cell.

B. Temperature correct each cell reading. For each10oF (5.5oC) above 80oF (26.7oC) add 0.004 to thespecific gravity reading. For each 10oF (5.5oC) be-low 80oF (26.7oC) subtract 0.004 from the specificgravity reading.

Example: Cell Temperature 100oFCell Gravity 1.245100oF minus 80oF equals 20oF(37.7oC minus 26.7oC equals 11.0oC)20oF multiply by 0.004/10oF equals 0.008(11oC multiply by 0.004/5.5oC equals 0.008)ADD (conversion above) 0.008Correction to 80oF (26.7oC) 1.253

C. If the difference between the highest and lowestcell specific gravity is 0.050 or greater or the lowestcell specific gravity is less than 1.225, charge the bat-tery. Charge at the recommended rate and time giv-en in Charging or until all cells specific gravity is1.225 or greater with the difference in specific gravitybetween the highest and lowest cell less than 0.050.If these charging conditions can not be met, replacethe battery.

3. Perform a high−discharge test with an adjustableload tester.

This is one of the most reliable means of testing a batteryas it simulates the cold−cranking test. A commercial bat-tery load tester is required to perform this test.

CAUTION

Follow the manufacturer’s instructions when us-ing a battery tester.

A. Check the voltage across the battery terminalsprior to testing the battery. If the voltage is less than12.4 VDC, recharge the battery.

B. If the battery has been charged, apply a 150 ampload for 15 seconds to remove the surface charge.Use a battery load tester following the manufactur-er’s instructions.

C. Make sure battery terminals are free of corrosion.

D. Measure the temperature of the center cell.

E. Connect a battery load tester to the battery termi-nals following the manufacturer’s instructions.Connect a digital multimeter to the battery terminals.

F. Apply a test load of one half the Cranking Perfor-mance (see Battery Specifications) rating of the bat-tery for 15 seconds.

G. Take a voltage reading at 15 seconds, then re-move the load.

H. Using the table below, determine the minimumvoltage for the cell temperature reading.

MinimumVoltage

Battery ElectrolyteTemperature

9.6 70oF (and up) 21.1oC (and up)

9.5 60oF 15.6oC

9.4 50oF 10.0oC

9.3 40oF 4.4oC

9.1 30oF −1.1oC

8.9 20oF −6.7oC

8.7 10oF −12.2oC

8.5 0oF −17.8oC

I. If the test voltage is below the minimum, replacethe battery. If the test voltage is at or above the mini-mum, return the battery to service.

Installation

IMPORTANT: To prevent possible electrical prob-lems, install only a fully charged battery.

1. Make sure ignition and all accessories are off.

2. Make sure battery compartment is clean and re-painted if necessary.

3. Make sure all battery cables and connections are ingood condition and battery retainer has been repairedor replaced.

4. Place battery in its compartment. Make sure batteryis level and flat. Connect positive cable connector ontopositive battery post. Tighten cap screw and lock nutwith two wrenches.

IMPORTANT: The nut must be on top of the batteryretainer during installation to prevent the cap screwfrom hitting hydraulic hard lines when the sidewind-er is shifted.

5. Secure battery retainer. Do not overtighten to pre-vent cracking or distorting the battery case.


6. Apply a light coat of grease on all battery posts andcable connectors to reduce corrosion after connectionsare made.

7. Connect a digital multimeter (set to amps) betweenthe negative battery post and the negative (ground)cable connector. The reading should be less than 0.1amp. If the reading is 0.1 amp or more, the unit’s electri-cal system should be tested and repaired.

8. Connect negative (ground) cable connector to thenegative battery post. Tighten cap screw and lock nutwith two wrenches.

Charging

To minimize possible damage to the battery and allowthe battery to be fully charged, the slow charging meth-od is presented here. This charging method can be ac-complished with a constant current battery chargerwhich is available in most shops.

CAUTION

Follow the manufacturer’s instructions when us-ing a battery charger.

NOTE: Using specific gravity of the battery cells is themost accurate method of determining battery condition.

1. Determine the battery charge level from either itsopen specific gravity or circuit voltage.

Battery ChargeLevel

SpecificGravity

Open CircuitVoltage

100% 1.265 12.68

75% 1.225 12.45

50% 1.190 12.24

25% 1.155 12.06

0% 1.120 11.89

2. Determine the charging time and rate using themanufacturer’s battery charger instructions or thefollowing table.

BatteryReserveCapacity

Battery Charge Level(Percent of Fully Charged)

Capacity(Minutes) 75% 50% 25% 0%

80 or less 3.8 hrs@

3 amps

7.5 hrs@

3 amps

11.3 hrs@

3 amps

15 hrs @

3 amps

81 to 125 5.3 hrs@

4 amps

10.5 hrs@

4 amps

15.8 hrs@

4 amps

21 hrs@

4 amps

126 to170

5.5 hrs @

5 amps

11 hrs @

5 amps

16.5 hrs@

5 amps

22 hrs @

5 amps

171 to250

5.8 hrs@

6 amps

11.5 hrs@

6 amps

17.3 hrs@

6 amps

23 hrs@

6 amps

above250

6 hrs@

10 amps

12 hrs@

10 amps

18 hrs@

10 amps

24 hrs@

10 amps

CAUTION

Do not charge a frozen battery because it can ex-plode and cause injury. Let the battery warm to60oF (15.5o C) before connecting to a charger.

Charge the battery in a well−ventilated place todissipate gases produced from charging. Thesegases are explosive; keep open flame and elec-trical spark away from the battery. Do not smoke.Nausea may result if the gases are inhaled. Un-plug the charger from the electrical outlet beforeconnecting or disconnecting the charger leadsfrom the battery posts.

3. Following the manufacturer’s instructions, con-nect the charger cables to the battery. Make sure a goodconnection is made.

4. Charge the battery following the manufacturer’sinstructions.

5. Occasionally check the temperature of the batteryelectrolyte. If the temperature exceeds 125oF (51.6oC)or the electrolyte is violently gassing or spewing, thecharging rate must be lowered or temporarily stopped.

6. Three hours prior to the end of the charging, mea-sure the specific gravity of a battery cell once per hour.The battery is fully charged when the cells are gassingfreely at a low charging rate and there is less than a0.003 change in specific gravity for three consecutivereadings.

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Reelmaster 3100−D Page 6 − 1 Wheels, Brakes,and Miscellaneous

Chapter 6

Wheels, Brakes, and Miscellaneous

Table of Contents

SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjust Brake 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE AND REPAIRS 4. . . . . . . . . . . . . . . . . . . . . .

Standard Seat 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Deluxe Seat 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Wheel and Brake 6. . . . . . . . . . . . . . . . . . . . . . Rear Fork and Wheel 8. . . . . . . . . . . . . . . . . . . . . . . . Brake Linkages 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Column 12. . . . . . . . . . . . . . . . . . . . . . . . . . .

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Rev. C Reelmaster 3100−DPage 6 − 2Wheels, Brakes, and Miscellaneous

SpecificationsItem Description

Tire pressure 14 to 18 PSI (0.97 to 1.24 bar)

Wheel lug nut torque 45 to 65 ft−lb (61 to 88 N−m)

Special Tools

Wheel Hub Puller

Part Number: TOR4097

The wheel hub puller allows safe removal of the wheelhub from the shaft of wheel motors.

Figure 1

Rev. CReelmaster 3100−D Page 6 − 3 Wheels, Brakes,and Miscellaneous

Adjustments

Adjust Brake

CAUTION

Before and after adjusting the brakes, alwayscheck the brakes in a wide open area that is flatand free of other persons and obstructions.

1. Park machine on a level surface, lower cutting units,stop engine, and remove key from the ignition switch.

2. Adjust parking brake lever until a force of 30 to 40 lbs(133 to 178 N) is required to actuate lever. To adjust:

A. Loosen set screw on adjustment knob (Fig. 2).

B. Turn adjustment knob clockwise to increase forceand counterclockwise to decrease force.

C. Tighten set screw after adjustment.

3. Check brake adjustment as follows:

A. Rotate by−pass valve on the piston pump 90 de-grees to allow front wheels to turn freely (Fig. 3).

CAUTIONBefore jacking up the machine, review and followJacking Instructions in Chapter 1 − Safety.

B. Chock rear wheel. Jack up both front wheels andsupport the machine with hardwood blocks.

C. With the parking brake applied, use a torquewrench on the wheel hub lock nut to identify thebreak away torque at each front wheel. The mini-mum break away torque with the parking appliedshould be 270 ft−lb (366 N−m).

4. If adjustment is necessary, adjust brakes as follows:

A. Remove both front wheel assemblies from themachine (see Front Brake and Wheel Removal in theService and Repairs section).

B. Adjust brakes by turning clevis to increase or de-crease shoe pressure on the brake drum (Fig. 4).Make sure that brake shoes do not drag againstdrums with the parking brake lever released.

C. If brakes can not be adjusted properly, repair orreplace brake components as necessary.

D. After adjustment is complete, install front wheelassemblies to the machine (see Front Brake andWheel Installation in the Service and Repairs sec-tion).

E. Lower front wheels to the ground.

F. Before starting engine, close by−pass valve onpump by rotating it 90 degrees (Fig. 3).

1. Set screw2. Adjustment knob

3. Brake leverFigure 2

1

2 3

1. Piston pump 2. By−pass valveFigure 3

21

1. Clevis2. Adjustment rod3. Brake lever

4. Wheel hub5. Cotter pin6. Jam nut

Figure 4

1

4

6

5

3

2

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Reelmaster 3100−DPage 6 − 4Wheels, Brakes, and Miscellaneous

Service and Repairs

Standard Seat

1. Seat (incl. 4 thru 7, 14, &15)2. Cap screw3. Spring lock washer4. Edging clip5. Edging6. Seat cushion (repair kit)

7. Seat shell8. Seat belt9. Seat adjuster with latch10. Flange hex nut11. Cap screw12. Lock washer

13. Seat adjuster14. Cap screw15. Seat switch16. Hex flange head screw17. Seat support strap

Figure 5

3

2

5

4

1

7

83

2

6

9

10

11

12

13

14

15

8

17

16

16

16

10

Removal


2. Remove four hex flange head screws securing theseat support straps to the frame.

3. Disconnect electrical connector from the seat switch.Separate seat from the frame.

4. Remove seat parts as necessary to make repairs us-ing Figure 5 as a guide.

Installation

1. Install any new seat parts using Figure 5 as a guide.

2. Position seat and support straps to the fuel tank andframe.

3. Connect electrical connector to the seat switch.

4. Secure seat support straps to the frame with four hexflange head screws.


Deluxe Seat

1. Plate2. Rivet3. Screw4. Wear parts kit (incl. 8 thru 11)5. Tension spring set6. Handle grip7. Adjusting lever8. Cover9. Bumper10. Bushing11. Pad12. Backrest cushion13. Hex head machine screw14. Arm rests15. Bottom cushion16. Adjusting rail (LH)17. Screw

18. Washer19. Nut20. Swing arm assembly (incl. 28 & 42)21. Adjusting rail (RH)22. Bottom trim23. Seat frame24. Screw25. Seat switch (incl. 24, 26, & 27)26. Spring washer27. Nut28. Back plate pivot29. Threaded clevis30. Nut31. Washer32. Backrest trim33. Tension spring set34. Spindle adjuster (incl. 29 thru 31, 35 & 36)

35. Screw36. Cover37. Clamp38. Shock absorber39. Nut40. Washer41. Bushing kit (incl. 39 & 40)42. Backrest plate43. Cap screw44. Lock washer45. Seat belt46. Hex flange nut47. Flat washer48. Cap screw49. Hex flange head screw50. Seat support strap

Figure 6

31

32

33

34

35

36

37

38

39 404142

1 2

3 4

5 6

78 9

10

16

1718

19

20

21

22

2324

2526

2728

2930

11

12

13

14

15

5

4344

45

46

4344454748

49

49

50

50

Removal


2. Remove four hex flange head screws securing theseat support straps to the frame.

3. Disconnect electrical connector from the seat switch.Separate seat from the frame.

4. Remove seat parts as necessary to make repairs us-ing Figure 6 as a guide.

Installation

1. Install any new seat parts using Figure 6 as a guide.

2. Position seat and support straps to the fuel tank andframe.

3. Connect electrical connector to the seat switch.

4. Secure seat support straps to the frame with four hexflange head screws.

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Rev. C Reelmaster 3100−DPage 6 − 6Wheels, Brakes, and Miscellaneous

Front Wheel and Brake

1. Lug nut2. Drive stud3. Wheel rim4. Tire5. Wheel hub6. Lock nut7. Hydraulic motor8. Brake drum9. Woodruff key10. Cotter pin11. Adjustment rod

12. Brake lever13. Lock nut14. Cap screw15. Brake bracket16. Return spring17. Brake shoe18. Backing plate19. Cam shaft20. Retainer Clip21. Lock nut22. Cap screw

23. Spacer24. Wheel shield25. Cotter pin26. Clevis pin27. Clevis28. Jam nut29. Flange bushing30. Brake pivot bracket31. Brake pivot shaft32. Hex flange head screw33. Hex flange nut

Figure 7

FRONT

RIGHT

10

28

31

3032

29

3

41

8

2

6

4

1

14

13

24

12

27

2625

11

1521

5

18

19

20

1617

17

7

23

22

33

9

Removal (Fig. 7)



2. Jack up front wheel and use wood blocks to keep therear tire off the floor.

3. Remove lug nuts from drive studs. Pull wheel fromdrive studs and wheel hub.

NOTE: The installation torque of the locknut is from 250to 400 ft−lb (339 to 542 N−m). Use impact wrench to re-move lock nut from the hydraulic motor shaft.

4. Loosen, but do not remove, lock nut from the hydrau-lic motor shaft. Release parking brake.


IMPORTANT: Do not hit wheel hub, wheel hub pulleror wheel motor with a hammer during removal orinstallation. Hammering may cause damage to thehydraulic wheel motor.

5. Using hub puller (see Special Tools), loosen wheelhub from wheel motor.

6. Remove lock nut, hub, and brake drum from motorshaft. Locate and retrieve woodruff key.

7. Remove cotter pin from the adjustment rod. Sepa-rate adjustment rod from the brake lever.

NOTE: The brake lever, backing plate, retaining clip,return springs, brake shoes, and cam shaft can be re-moved as a complete brake assembly.

8. If it is desired to remove the brake assembly fromthe brake bracket, remove four cap screws and lock nutssecuring the assembly to the bracket.

9. Disassemble brake assembly as follows (Fig. 8):

A. Remove return springs from the brake shoes. Re-move brake shoes from the backing plate.

B. Matchmark brake cam and brake lever to assureproper alignment during reassembly. Remove re-taining clip from the brake cam. Pull brake lever fromthe cam. Remove cam from backing plate.

10.The brake bracket and wheel shield can be removedas follows:

A. Remove lock nuts, spacers, and cap screws se-curing the brake bracket, wheel shield, and hydraulicmotor to the frame.

B. Separate bracket and shield from the frame.

Installation (Fig. 7)

1. Insert four cap screws through the frame, hydraulicmotor, spacers, wheel shield, and brake bracket. Se-cure with lock nuts, but do not fully tighten.

2. Assemble brake assembly as follows (Fig. 8):

A. Secure backing plate to the brake bracket withfour cap screws and lock washers.

B. Apply antiseize lubricant to cam shaft splines. In-sert cam shaft through the backing plate.

C. Attach brake lever to the cam shaft. Make surematchmarks are aligned properly. Secure lever toshaft with retaining clip.

D. Lubricate brake shoe pivot points with a lightcoating of grease.

E. Position both brake shoes on the backing plate sothat the concave heels attach to the anchor pin.

F. Insert both return springs into the holes of bothbrake shoes. Make sure shoes fit snuggly againstthe anchor pin and cam.

3. If the brake lever, backing plate, retaining clip, returnsprings, brake shoes, and cam shaft were removed asa complete brake assembly, secure backing plate to thebrake bracket with four cap screws and lock washers.Tighten fasteners.

4. Attach adjustment rod to the brake lever. Secure ad-justment rod with cotter pin.

5. Thoroughly clean wheel motor shaft and wheel hubtaper.

6. Install woodruff key to the slot on the hydraulic motorshaft. Slide wheel hub and brake drum assembly ontothe shaft.

7. Secure wheel hub and brake drum to the hydraulicmotor shaft with lock nut.

NOTE: For proper brake operation, the brake shoesand backing plate must be concentrically aligned withthe brake drum.

8. To align brake shoes and drum, apply parking brake.Then tighten four socket head screws and lock nuts thatsecure the brake bracket and wheel motor to the frame.

9. Place wheel onto drive studs and wheel hub. Securewheel with lug nuts on drive studs.

10.Lower wheel to ground. Torque lug nuts from 45 to 65ft−lb (61 to 88 N−m) in a criss−cross pattern. Torque locknut from 250 to 400 ft−lb (339 to 542 kg−m).

11.Check and adjust brakes (see Adjust Brake).

1. Return spring2. Brake shoe (toe end)3. Brake shoe (heel end)4. Backing plate

5. Retaining clip6. Cam shaft7. Anchor pin

Figure 8

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4

6

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2

5

6

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Rear Fork and Wheel

1. Hydraulic cylinder2. Ball joint3. External retaining ring4. Grease fitting5. Grease fitting plug6. Jam nut7. Rear fork8. Cap screw9. Lock washer10. Thrust washer11. Tire12. Hex socket head screw13. Lock nut

14. Drive stud15. Wheel hub16. Lock nut17. 45o hydraulic fitting18. Hydraulic motor19. Hydraulic hose20. Hydraulic hose21. Lug nut22. Clamp23. Spacer24. Case drain clamp25. Hydraulic fitting26. Rear casting

27. Hex flange head screw28. Bushing29. Cap screw30. Lock nut31. O−ring32. O−ring33. O−ring34. O−ring35. Hose assembly36. Hose assembly37. Valve stem38. Wheel rim39. Woodruff key

Figure 9

31

32

333435

36

37

38

1

2 3 4

5

6

7

8

9

10

16

17

18

19

20

21

2223

24

25

26

27

28

29

30

11

12

13

14

15

25

4

28

17

2

3

6

39

Removal


2. Remove hood from the machine (see Hood Remov-al).

3. Separate hydraulic cylinder from the rear fork as fol-lows:

A. Remove both jam nuts securing the ball joint tothe rear fork.

B. Separate ball joint from the rear fork.

C. Swing cylinder clear of the rear fork.



4. Jack up rear wheel enough to allow the removal ofthe rear fork.

5. Remove lug nuts from drive studs. Remove tire withwheel rim from wheel hub.

6. Remove four lock nuts and hex socket head screwssecuring the hydraulic motor to the rear fork. Removemotor from the fork and position it away from the fork.

CAUTIONSupport front fork to prevent its falling during re-moval and installation. Personal injury or dam-age to the fork may result from improper han-dling.

7. Remove cap screw, thrust washer, and lock washerfrom the rear fork shaft.

8. Lower rear fork from machine.

9. Check bushings for wear and damage. Replace ifnecessary.

Installation

1. Position rear fork through the frame.

2. Install lock washer, thrust washer, and cap screw tothe rear fork shaft. Torque cap screw from 60 to 80 ft−lb(81.4 to 108.5 N−m). Make sure fork turns freely.

3. Install hydraulic motor to the rear fork. Secure motorto the fork with four hex socket head screws and locknuts.

4. Secure wheel rim to the wheel hub with four lug nuts.Torque nuts from 45 to 65 ft−lb (61 to 88 N−m).

5. Lower rear wheel to the ground.

6. Secure hydraulic cylinder to the rear fork as follows:

A. Swing cylinder to the rear fork.

B. Separate ball joint to rear fork.

C. Secure ball joint to the rear fork with both jamnuts.

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Brake Linkages

1. Pop rivet2. Control panel cover3. Cover bracket4. Flange nut5. Hex flange head screw6. Magnet support7. Hex washer head screw8. Strike bracket9. Magnetic catch10. Flat washer11. Lock nut12. Cotter pin13. Bumper pad

14. Hex socket flat head screw15. Parking brake link16. Clevis pin17. Clevis pin18. Lever Assembly19. Parking brake spacer20. Slotted hex head screw21. Switch22. Switch23. Flat washer24. Lock nut25. Cap screw

26. Brake pivot shaft27. Clevis pin28. Flange bushing29. Brake pivot bracket30. Hex flange head screw31. Cotter pin32. Brake cam shaft33. Brake lever34. Retainer clip35. Adjustable clevis36. Jam nut37. Adjustment rod

Figure 10

1

2

3

4

56

7

8

9

10

16

17

18

19

20

2122

2324

25

1112

13

14

15

12

15

8

7

9

3

12

2829

30

34

3332

26

27

31

35

36

37



2. Remove control panel cover from the machine.

IMPORTANT:When removing the adjustable clevisfrom either the brake pivot shaft or adjustment rodor the brake lever from the cam shaft on the brakeassembly, make sure to matchmark both parts.Marking both parts will make reassembly and brakeadjustment easier.

3. Remove and replace parts as necessary to repairbrake linkages.

4. Install control panel cover to the machine.

IMPORTANT:Always check and adjust the brakesanytime brake linkages are disassembled or re-paired.

5. Adjust brake linkages (see Brake Adjustment).

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Rev. D Reelmaster 3100−DPage 6 − 12Wheels, Brakes, and Miscellaneous

Steering Column

1. Steering arm2. Flange hex nut3. Hex flange head screw4. Steering control valve bracket5. Cap screw6. Pivot hub7. Steering cover8. Cap screw9. Toro decal10. Ball knob11. Lever12. Steering control valve13. Tilt bracket14. Cap screw

15. Flat washer16. Flange hex nut17. Steering wheel18. Hydraulic fitting19. Hydraulic fitting20. Steering wheel nut21. Toro decal22. Hose assembly23. Hose assembly24. Hose assembly25. Hose assembly26. Hose assembly27. Tilt steering boss28. Friction disc

29. Friction disc30. Flat washer31. Jam nut32. Lock nut33. Flat washer34. Not used35. Not used36. O−ring37. O−ring38. O−ring39. Philips pan head screw40. Steering wheel cap41. Steering shield

Figure 11

31

32

33

36

37

39

40

1

2

3

4

56

7

89

10

16

17

18

19

20

21

22

23

24

25

26

2728

29

30

11

12

13

14

15

2

38

1919

2

3

36

41

8

18

2

20 to 26 ft−lb(27.1 to 35.3 N−m)

Rev. DReelmaster 3100−D Page 6 − 13 Wheels, Brakes,and Miscellaneous

Disassembly


2. Remove philips pan head screws and steering wheelcap from the steering wheel.

3. Remove steering wheel nut from the steering controlvalve. Pull steering wheel from the control valve.

4. Remove steering cover from the steering controlvalve bracket.

5. Remove four lock nuts and flat washers securing thesteering control valve to the steering control valvebracket.

6. Remove both hex flange nuts, cap screws, and pivothubs securing the steering control valve bracket to thesteering arm. Slide bracket from the steering controlvalve and steering arm.

7. Remove and replace parts as necessary to repairsteering column using Figure 11 as a guide.

Assembly

1. Make sure lever and friction discs are properly as-sembled to the steering control valve bracket using Fig-ure 11 as a guide.

2. Position steering control bracket to the steering con-trol valve and steering arm. Secure bracket to the steer-ing arm with pivot hubs, cap screws, and hex flangenuts.

3. Secure steering control valve bracket to the steeringcontrol valve studs with four flat washers and lock nuts.

4. Secure steering cover to the steering control valvebracket with cap screws.

5. Install steering wheel to the steering control valve.Secure steering wheel nut to the steering control valve.Torque steering wheel nut from 20 to 26 ft−lb (27.1 to35.3 N−m).

6. Secure steering wheel cap to the steering wheel withsix philips pan head screws.

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Reelmaster 3100−D Page 7 − 1 Cutting Units

Chapter 7

Cutting UnitsTable of ContentsSPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 5. . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Characteristics 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daily Adjustments 7. . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust Bedknife Parallel to Reel 8. . . . . . . . . . . . . . . Verify Height−of−Cut and Front Roller Level 9. . . . Set Height−of−Cut and Level Both Rollers 10. . . . . Adjust Front Lift Arms 11. . . . . . . . . . . . . . . . . . . . . . . . Adjust Rear Lift Arm 12. . . . . . . . . . . . . . . . . . . . . . . .

SERVICE AND REPAIRS 13. . . . . . . . . . . . . . . . . . . . . Greasing Bearings, Bushings, and Pivot Points 13Backlapping 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cutting Unit Removal and Installation 15. . . . . . . . . Reel Motor Removal and Installation 16. . . . . . . . . . Reel Removal and Bearing Replacement 17. . . . . . Bedbar Removal and Installation 18. . . . . . . . . . . . . Bedknife Replacement and Grinding 20. . . . . . . . . . Roller Removal and Installation 21. . . . . . . . . . . . . . Roller Bearing and Seal Replacement 22. . . . . . . . Prepare Reel for Grinding 24. . . . . . . . . . . . . . . . . . . Fixed Side Plate Installation 25. . . . . . . . . . . . . . . . . Front Lift Arms Removal and Installation 26. . . . . . Rear Lift Arm Removal and Installation 28. . . . . . . . Skid Kit Installation 30. . . . . . . . . . . . . . . . . . . . . . . . . Carrier Frame Removal and Installation 30. . . . . . .

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Reelmaster 3100−DPage 7 − 2Cutting Units

Specifications

Figure 1

MOUNTING: All cutting units are supported by equallength independent lift arms and are interchangeable toall three cutting unit positions.

CONSTRUCTION: 5 or 8 blades of 7 inches (18 cm) di-ameter welded to stamped steel spiders. Reels aremounted on greaseable self−aligning ball bearings. Acutting unit has a reel of either 27 inches (69 cm) inlength or 32 inches (81 cm) in length.

HEIGHT OF CUT RANGE:Floating Cutting Unit − 1/4 to 1−3/4 inches (6.4mm to 44.4mm).Fixed Cutting Unit − 1/2 to 2−5/8 inches (12.7 mm to 65.6 mm).

POWER: Reel motors allow easy removal from or instal-lation onto the cutting unit. Cutting units can be drivenfrom either end.

HEIGHT−OF−CUT & ROLLER ADJUSTMENT:Height−of−cut adjustment is made with the rollers by aquick locating pin and/or threaded micro−adjustment.

BEDKNIFE AND BEDBAR ADJUSTMENT: A singleknob screw adjustment for bedknife to reel is located atthe center of the bedbar.

CUTTING UNIT LIFT: Hydraulic lift has an automaticreel shut off. All units are controlled from one lever.

SUSPENSION SYSTEM: A fully floating suspensionwith hydraulic counterbalance. L−I−N−K−STM cuttingunit suspension system provides fore and aft oscillation.Main center pivot allows side−to−side oscillation. Withoptional Fixed Kit (Part No. 93−6915), cutting units canbe locked into fixed (fore/aft) position for use with skidsor anti−scalp rollers.

CLIP FREQUENCY: With variable speed set to maxi-mum rpm:

5 blade at 1040 reel rpm moving at 5 mph (8.1 km/h) 1 inch (25.4 mm) clip.

5 blade at 1040 reel rpm moving at 6 mph (9.7 km/h) 1.20 inch (30.5 mm) clip.



OPTIONAL EQUIPMENT:27−inch Cutting UnitsFull Roller Kit Model No. 03440Sectional Roller Kit Model No. 03445Wiehle Roller Kit Model No. 03450Anti−Scalp Roller Kit Model No. 03447Roller Scraper Kit Part No. 60−9560Wiehle Roller Scraper Kit Part No. 94−5082Comb Kit Part No. 67−940032−inch Cutting UnitsSectional Roller Kit Model No. 03476Wiehle Roller Kit Model No. 03475Full Roller Kit Model No. 03479Anti−Scalp Roller Kit Model No. 03477Roller Scraper Kit Model No. 03478Wiehle Roller Scraper Kit Part No. 94−5081Both Models of Cutting UnitsFixed Kit Part No. 93−6915Skid Kit Part No. 94−3664Backlapping Brush Assembly Part No. 29−9100Gauge Bar Assembly Part No. 13−8199Bedknife Screw Tool Part No. 51−0880


Special ToolsOrder special tools from the TORO SPECIAL TOOLSAND APPLICATIONS GUIDE (COMMERCIAL PROD-UCTS).

Some tools may have been supplied with your machineor available as TORO parts. Some tools may also beavailable from a local supplier.

Gauge Bar Assembly

Use gauge bar to verify height of cut (Toro Part No.13−8199).

Gauge Bar

Figure 2

Handle Assembly − TOR299100

For applying lapping compound to cutting units whilekeeping hands a safe distance from the rotating reel.

Figure 3

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Bedknife Screw Tool − TOR510880

This screwdriver type bit is made to fit Toro bedknife at-taching screws. Use this bit with a torque wrench to se-cure the bedknife to the bedbar.

IMPORTANT: Do not use and air or manual impactwrench with this tool.

Figure 4


TroubleshootingThere are a number of factors that can contribute to un-satisfactory quality of cut, some of which may be turfconditions. Turf conditions such as excessive thatch,“sponginess” or attempting to cut off too much grassheight may not always be overcome by adjusting themachine. It is important to remember that the lower theheight of cut, the more critical these factors are.

Remember that the “effective” or actual height of cut de-pends on cutting unit weight and turf conditions. Effec-tive height of cut will be different than the bench setheight of cut.

Factors That Can Affect Quality of Cut

Factor Possible Problem/Correction

1. Engine maximum governed speed. Check maximum governed engine speed. Adjustspeed to specifications if necessary. If engine is notrunning at specified maximum governed RPM, reelspeed settings may not match ground speed.

2. Reel speed and ground speed. Adjust reel speed to setting shown on REEL SPEEDSETTINGS graph for the number of reel blades (5 or 8)and the desired ground speed (see Operator’sManual).

All reels should rotate at the same speed. All cuttingunits should have equal bedknife to reel contact. Ifchecking RPM, do not run reel too long without cuttinggrass, or bedknife and/or reel may overheat and “rifle”.

See other items in Troubleshooting section of Chapter4 − Hydraulic System.

3. Tire pressure. Check each tire’s pressure. Adjust to pressuresspecified in Specifications section of Chapter 6 −Wheels and Brakes.

4. Reel bearing condition. All reels should rotate freely. Make sure bearings areproperly lubricated. Replace bearings if worn ordamaged.

5. Reel and bedknife sharpness. Reel and/or bedknife that has rounded cutting edges or“rifling” cannot be corrected by tightening bedknife toreel contact. Grind reel to remove taper and/or rifling(grooved or wavy appearance). Grind bedknife tosharpen and/or remove rifling. (Most common cause ofrifling is bedknife to reel contact that is too tight.)

NOTE: New bedknife must be ground or backlappedafter installing on bedbar.

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Factor Possible Problem/Correction

6. Bedknife to reel adjustment. Check bedknife to reel contact daily. Bedknife musthave light contact all across the reel. No contact willcause cutting edges to become dull. Excessive contactaccelerates wear; quality of cut may be adverselyaffected.

Slightly dull cutting edges may be corrected bybacklapping, Excessively dull cutting edges must becorrected by grinding the reel and bedknife.

7. Front roller position. Make sure front rollers on all cutting units are in thesame position.

8. Rear roller parallel to reel. Rear roller must be set so that it is parallel with the reelbefore setting height of cut.

9. Height−of−cut. Make sure all cutting units are set at the same heightof cut. Set units as specified in the Operator’s Manual.

10. Bedbar stability. Check bedbar end bushings, adjuster pivot bushingsand nylon flanged bushings for wear or damage.

Check adjustment knob to make sure detent holdsadjustment.

11. Number of reel blades. Use cutting unit model with the correct number ofblades for clip frequency and optimum quality of cutrange (see Specifications).

12. Cutting unit alignment and ground following. Check lift arms and cutting unit pivot linkages for wear,damage, binding, or bent pivot pins.

13. Roller condition. All rollers should rotate freely. Make sure bearings areproperly lubricated. Replace bearings if worn ordamaged.


Adjustments

CAUTION

Never install or work on the cutting units or liftarms with the engine running. Always stop en-gine and remove key first.

Characteristics

The single knob bedknife−to−reel adjustment system in-corporated in this cutting unit simplifies the adjustmentprocedure needed to deliver optimum mowing perfor-mance. The precise adjustment possible with the singleknob/bedbar design gives the necessary control to pro-vide a continual self−sharpening action. This featuremaintains sharp cutting edges, assures good quality−of−cut, and greatly reduces the need for routine back-lapping.

In addition, the rear roller positioning system permits op-timum bedknife attitude and location for varying height−of−cuts and turf conditions.

If a cutting unit is expected to be out of adjustment, usethe following procedures in the specified order to adjustthe cutting unit properly.

1. Adjust the bedknife parallel to the reel.

2. Adjust the front roller.

3. Level the rear roller.

4. Set height−of−cut.

Daily Adjustments

Prior to each day’s mowing, or as required, each cuttingunit must be checked to verify proper bedknife−to−reelcontact. This must be performed even though quali-ty of cut is acceptable.

1. Lower cutting units onto a hard, level surface. Shutoff engine and remove key from ignition.

2. Slowly rotate reel in the reverse direction while lis-tening for reel−to−bedknife contact. If no contact is evi-dent, turn bedknife adjusting knob clockwise, one clickat a time, until light contact is felt and heard.

3. If excessive contact is felt, turn bedknife adjustingknob counterclockwise, one click at a time until no con-tact is evident. Then turn bedknife adjusting knob oneclick at a time clockwise, until light contact is felt andheard.

IMPORTANT: Light contact is preferred at all times.If light contact is not maintained, bedknife and reeledges will not sufficiently self−sharpen and dull cut-ting edges will result after a period of operation. Ifexcessive contact is maintained, bedknife and reelwear will be accelerated, uneven wear can result,and quality of cut may be adversely affected.

NOTE: As the reel blades continue to run against thebedknife, a slight burr will appear on the front cuttingedge surface for the full length of the bedknife. Runninga file occasionally across the front edge to remove thisburr will improved cutting quality.

After extended running, a ridge will eventually developat both ends of the bedknife. These ridges must berounded off or filed flush with cutting edge of bedknife toassure smooth operation.

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Adjust Bedknife Parallel to Reel

NOTE: A 3/4−inch (19 mm) wrench will be needed to ro-tate the bedknife adjustment knob (Fig. 5).

IMPORTANT: Do not allow cutting unit to rest on thebedknife adjusting screw. The setting of the bed-knife will be changed.

1. Remove any reel contact by turning the bedknife ad-justment knob counterclockwise (Fig. 5). Tip cutting unitto gain access to the reel and bedknife (Fig. 6).

2. On either end of the reel, insert a long strip of drynewspaper between the reel and bedknife. While slowlyrotating reel into the bedknife, turn bedknife adjustingknob clockwise, one click at a time until the paper ispinched lightly. The pinching should result in a slightdrag when the paper is pulled.

3. Check for light contact at the other end of reel usingnewspaper as in step 2. If light contact is not evident,proceed to the next step.

4. Remove counter weights and gasket from the end ofthe cutting unit.

5. Loosen both carriage bolts on the bedbar adjuster(Fig.7).

6. Adjust nuts to move bedbar adjuster up or down untilpaper is pinched along entire bedknife surface, whenbedknife adjustment knob is adjusted to no more thantwo clicks beyond first contact of reel bedknife (Fig.7).

7. Tighten nuts and carriage bolts and verify adjust-ment.

8. Reinstall counter weights to the same ends of thecutting units that they were removed from.

Figure 51. Bedknife adjusting screw

1

Figure 6

Figure 71. Carriage bolts2. Bedbar adjuster

3. Adjustment nuts

2

1

3


Set Height−of−Cut and Level Both Rollers

Note: Both floating and fixed cutting units can use thismethod for making height−of−cut adjustments and lev-eling both front and back rollers.

1. Position cutting unit on a flat level table or board.

2. Loosen nut slightly that secures each roller bracketto the angle bracket.

3. For the front roller, adjust support cap screw toachieve a 1 inch + 1/16 (25.4 mm + 1.6) dimension be-tween both height−of−cut supports and each front rollerbracket at each end of the cutting unit.

4. For the rear roller, adjust support cap screw toachieve 5/8 inch +1/16 (15.9 mm + 1.6) dimension be-tween both height−of−cut supports and each rear rollerbracket at each end of the cutting unit.

5. For the rear roller, remove hairpin cotters securingrear height−of−cut pins. Reinstall height−of−cut pins inthe 1/2−inch setting as indicated on the rear height−of−cut plate.

6. For the front roller, remove hairpin cotters securingfront height−of−cut pins. Reinstall height−of−cut pins inthe 1/4−inch setting as indicated on the front height−of−cut plate to allow for clearance between the front rollerand table.

7. Position a 1/2−inch or thicker bar under the reelblades and against the front face of the bedknife. Makesure the bar covers the full length of reel blades.

8. Verify that the rear roller is level by attempting to in-sert a piece of paper under each end of the roller. Thepaper should not fit between the roller and table.

1. Nut2. Rear roller bracket3. Front roller bracket4. Angle bracket

5. Support capscrew6. Height−of−cut support7. Height−of−cut pins8. Height−of cut plate

Figure 8

1 inch

5/8 inch

1 2

3

4

9. Level rear roller by adjusting the appropriate supportcap screw on the rear roller supports until the roller isparallel and the entire length of roller contacts the table.A piece of paper inserted between the roller and thetable should not fit.

10.When roller is level, adjust both rollers to desiredheight−of−cut with height−of−cut pins. Tighten nuts se-curing roller brackets and replace hairpin cotters tothe height−of−cut pins.

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Verify Height−of−Cut and Front Roller Level

NOTE: Gauge bar (Toro Part No. 13−8199) may be ob-tained from your local Toro Distributor.

IMPORTANT: Height−of−cut must be set and bothrollers leveled before performing this adjustment(see Set Height−of−Cut and Level Both Rollers).

1. On the gauge bar, set head of the screw to the de-sired Height−of−Cut. This measurement is from the barface to the underside of the screw head.

2. Loosen nuts slightly that secure each front rollerbracket to the angle bracket.

3. Place gauge bar across the front and rear rollers. Ad-just both front roller support capscrews until the under-side of the head of screw on the gauge bar engages thebedknife cutting edge. Do this on both ends of reel.

4. Tighten all nuts securing the roller brackets.

5. Place cutting unit on a flat surface. Verify that frontand rear rollers contact the flat surface. ReadjustHeight−of−Cut as required (see Set Height−of−Cut andLevel Rear Roller).

Figure 91. Gauge bar2. Front roller bracket nut3. Front roller bracket4. Angle bracket

5. Front roller support cap screw

6. Bedknife

1

34

6

5

2


Adjust Front Lift Arms


IMPORTANT: Keep front cutting units on the liftarms when performing this adjustment.

2. Raise front lift arms. Make sure clearance betweeneach lift arm and floor plate bracket is 0.18 to 0.32 inch(4.6 to 8.1 mm) (Fig. 10).

3. If the clearance is not in this range, attain properclearance as follows:

A. Back off stop bolts if reducing the clearance be-tween the stop bolt and lift arm (Fig. 11).

B. Adjust front hydraulic cylinder by backing off jamnut on the cylinder, removing the pin from the clevis,and rotating the clevis (Fig. 12).

C. Install pin to clevis and check clearance. Repeatsteps A and B if necessary.

4. Make sure clearance between each lift arm and stopbolt is 0.005 to 0.040 inch (0.127 to 1.02 mm). If theclearance is not in this range, adjust stop bolts as neces-sary (Fig 11).

IMPORTANT: The lack of clearance at the frontstops can damage the lift arms.

5. Install both front cutting units to the lift arms (see Cut-ting Unit Removal and Installation).

1. Lift arm2. Floor plate bracket

3. Clearance

Figure 10

1

2

3

1. Stop bolt2. Lift arm

3. Clearance

Figure 11

1

32

1. Hydraulic cylinder 2. Jam nut

Figure 12

1

2

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Adjust Rear Lift Arm

1. Park machine on a level surface and engage parkingbrake.

IMPORTANT: This adjustment must be performedwith the rear cutting unit attached to the rear lift arm.

2. Raise lift arms. Make sure clearance between wearstrap on the top of the rear cutting unit wear bar andbumper strap is 0.020 to 0.100 inch (0.508 to 2.54 mm)(Fig. 13).

3. If the clearance is not in this range, attain properclearance by adjusting the rear hydraulic cylinder as fol-lows (Fig. 14):

A. Lower cutting units, turn engine off, and removekey from the ignition switch.

B. Back off jam nut from the rear hydraulic cylinderclevis.

IMPORTANT: Use a protective covering around thehydraulic cylinder rod when rotating the rod to pre-vent damage to the rod.

C. Grasp cylinder rod near the jam nut and rotate therod.

D. Raise cutting units and check clearance. Repeatsteps A through C as necessary. Tighten jam nut onhydraulic cylinder rod.

NOTE: If rear lift arm makes clunking noises duringtransport, the clearance can be reduced.

IMPORTANT: The lack of clearance at the rear wearbar can damage the rear lift arm.

1. Wear bar 2. Bumper strapFigure 13

1

2

1. Rear hydraulic cylinder 2. Jam nut

Figure 14

1

2


Service and Repairs

Greasing Bearings, Bushings, and Pivot Points

Each cutting unit has 9 grease fittings (with an optionalfront roller installed) that must be lubricated regularlywith No. 2 general purpose lithium base grease.

Grease Fitting Locations and Quantities

Each bedknife adjuster has 1 fitting (Fig. 15). Each reelbearing housing has 2 fittings. Each front and rear rollerhas 2 fittings, one on each end of the roller (Fig. 16).

NOTE: Lubricate only one reel bearing grease fitting oneach end of cutting unit.

IMPORTANT: Lubricate cutting units immediatelyafter washing. This helps purge water out of bear-ings and increases bearing life.

1. Wipe each grease fitting with a clean rag.

IMPORTANT: Do not apply too much pressure orgrease seals will be permanently damaged.

2. Apply grease until pressure is felt against the handle.

3. Wipe excess grease away.

Figure 15Grease every 50 hours

Figure 16

Grease every 8 hours

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Backlapping

DANGER

TO AVOID PERSONAL INJURY OR DEATH:− Never place hands or feet in reel area while theengine is running.− While backlapping, reels may stall and then re-start.− Do not attempt to restart reels by hand or foot.− Do not adjust reels while the engine is running.If the reel stalls, stop engine before attempting toclear the reel.− Reel motors are connected in series, movingone motor moves the other two.

Note: Additional instructions and procedures onbacklapping are available in the TORO Sharpening Reel& Rotary Mowers Manual (Toro Part No. 80300SL).

1. Position machine on a clean, level surface. Lowercutting units, stop engine, engage parking brake, andremove key from the ignition switch.

2. Remove console cover to expose the controls.

3. Rotate backlap knob on the manifold block clockwiseto the BACKLAP position. Rotate reel speed knob toposition 1.

4. Make initial reel to bedknife adjustments appropriatefor backlapping on all cutting units. Start engine and setengine speed to low idle.

5. Engage reels by moving mow/transport lever toMOW and depressing the reel ON/OFF switch.

CAUTION

Be careful when lapping the reel because contactwith the reel or other moving parts can result inpersonal injury.

6. Apply lapping compound with a long handled brush.

1. Backlap knob 2. Reel speed knobFigure 17

1 2

7. To make an adjustment to the cutting units whilebacklapping, turn off the reels by pushing in the reelsON/OFF switch on instrument panel to OFF position andstopping the engine. After adjustments have been com-pleted, repeat steps 4 through 6.

8. When backlap operation is completed, rotate back-lap knob counter−clockwise to the MOW position, setreel speed controls to the desired mowing setting, andwash all lapping compound off the cutting units.

Note: For a better cutting edge, run a file across thefront face of the bedknife when the lapping operation iscompleted. This will remove any burrs or rough edgesthat may have built up on the cutting edge.


Cutting Unit Removal and Installation

Removal

1. Position machine on a clean, level surface. Lowercutting units, stop engine, engage parking brake, andremove key from the ignition switch.

2. On the front cutting units, detach chain from the cut-ting unit carrier frame by removing the lock nut and capscrew (Fig. 19).

3. Remove hydraulic motor from the cutting unit (seeReel Motor Removal).

4. Remove lynch pin from pivot shaft (Fig. 20 and 21).

5. Slide cutting unit carrier frame and thrust washerfrom the pivot shaft.

Installation

1. On the front cutting units, slide thrust washer andthen cutting unit carrier frame onto pivot shaft (Fig. 20).

2. On the rear cutting unit, slide cutting unit carrierframe and then thrust washer onto pivot shaft (Fig. 21).

3. Install lynch pin onto the pivot shaft (Fig. 20 and 21).

4. Install hydraulic motor to the cutting unit (see ReelMotor Installation).

5. On front cutting units, attach chain to the cutting unitcarrier frame with cap screw and lock nut (Fig. 19).

Figure 18

1. Chain2. Cap screw & lock nut

3. Front carrier frame (RH)

Figure 19

1

2

3

1. Lynch pin2. Thrust washer

3. Pivot shaft4. Front unit carrier frame

Figure 20

2

3

1

4

1. Lynch pin2. Thrust washer

3. Pivot shaft4. Rear unit carrier frame

Figure 21

23

14

IMPORTANT: Make sure hoses are free of twists andsharp bends. Route rear cutting unit hoses asshown (Fig. 18). Raise cutting units and shift themto the left (Model 03201 only). Rear cutting unithoses must not contact the traction cable bracket.If required, reposition fittings and hoses.

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Reel Motor Removal and Installation

1. Reel2. Cap screw3. Not used4. Cap screw5. Lock washer6. Side plate (RH)7. Roll pin8. Lock nut9. Hex nut10. Waring decal11. Front grass guard12. Frame assembly13. Rear grass guard14. Flange nut

15. Side plate (LH)16. Washer17. Spacer18. Link19. Bushing20. Cap screw21. Cap screw22. Cap screw23. Not used24. Reel coupler (LH)25. Grease fitting26. Hex flange head screw27. Bearing housing28. Bearing

29. Reel coupler (RH)30. Spider coupler31. Not used32. Not used33. Cover gasket34. O−ring35. Shipping plug36. Weight (3.5 lbs)37. Weight (2.0 lbs)38. Rubber side cover39. Rubber center cover40. Rivet41. Hydraulic motor

Figure 22

33

3435

3637

1

2

4 5

6

7

8

910

1617

1819

20

21

22

24

25

26

2728

2930

11

12

13

14

15

25 2

38

38

39

40

8

1626

2728

41

FRONT

RIGHT

3034

2

4127

Removal

1. Remove two capscrews holding the hydraulic motorto the bearing housing.

2. Remove hydraulic motor and spider coupling fromthe bearing housing. Position hydraulic motor awayfrom the cutting unit prior to removing or working on thecutting unit.

Inspection

1. Inspect spider coupling for wear. Replace worn cou-pling with new one.

2. Check coupling inside bearing housing. If coupling isloose remove and check for worn threads. Replace cou-pling if threads are worn. Reinstall coupling (see ReelRemoval and Bearing Replacement).

Installation

Note: The cutting unit can be installed with the hy-draulic motor on either side. If installing on the oppositeside, remove cap screws, weights, and cover gasket; re-install them on the other bearing housing.

1. Dip spider coupling in No. 2 general purpose lithiumbase grease. Reinstall spider coupling into the bearinghousing.

2. Install O−ring on the front plate of the motor. Mounthydraulic motor to the bearing housing. Secure motorwith the two capscrews.

3. Grease bearing housing sufficiently to fill housingwith grease (see Greasing Bearings, Bushings, and Piv-ot Points).


Reel Removal and Bearing Replacement

Remove Reel (Fig. 22)

1. Remove hydraulic motor from the cutting unit (seeHydraulic Motor Removal and Installation). Removecutting unit from the machine (see Cutting Unit Removaland Installation).

2. Remove bedbar assembly from the cutting unit (seeBedbar Removal and Installation).

3. Remove front roller from the cutting unit (see RollerRemoval and Installation).

Note: A 3/8−inch drive ratchet with an extension willfit into the square hole of the coupling.

4. Unscrew reel coupler (LH) from the reel. This cou-pler is left hand threaded. Unscrew reel coupling (RH)from the reel. This coupler is right hand threaded.

IMPORTANT: Support reel to prevent it from droppingwhen the bearing housings are removed.

5. Remove cap screws from both bearing housings.Pull bearing housings and bearings from reel. Removereel from the cutting unit.

6. Rotate bearings within the bearing housings, and re-move bearings from both bearing housings through theloading grooves.

Inspect Reel (Fig. 22)

1. Replace reel if the diameter has decreased to theservice limit (see Reel Grinding Specification in Prepar-ing Reel For Grinding).

2. Replace reel if blades are bent or cracked.

3. Check for a bent reel shaft by placing the reel shaftends in V−blocks. Replace reel if the reel shaft is bent.

Install Reel (Fig. 22)

1. Inspect bearings and replace if worn or damaged.Replace both bearings as a set.

2. Make sure bearing seating surfaces and threads onreel shaft ends are clean. Apply anti−seize lubricant toboth bearing seating surfaces.

3. Align reel inside the cutting unit with the bearinghousing holes. The reel must be positioned so that thegrooved end of the shaft (left−hand threads) is on the leftside of the cutting unit.

4. Clean inside of the bearing housing before installing.Install bearing into bearing housing as follows:

A. Load bearing through loading grooves.

B. Position bearing so its outer grease holes will be90o to the loading grooves.

C. Rotate bearing inside of the housing so the ex-tended part of the inner race is facing the inside of thehousing.

5. Slide bearings and bearing housings onto the reelshaft.

6. Make sure bearing housings are installed with thegrease fittings pointing up and to the front of the cuttingunit.

7. Secure bearing housings and bearings on the reelshaft ends and cutting unit with the cap screws.

8. Remove grease from the threaded end of reel cou-plers and the reel shaft. Make sure grease is completelyremoved.

9. Apply removable Loctite 242 or equivalent to reelcoupler threads. Do not get Loctite on the bearingseal.

10.Screw reel coupler (RH) to the reel. This couplingis right hand threaded. Screw reel coupler (LH) to thereel. This coupling is left hand threaded. Torque bothcouplers from 55 to 65 Ft−lb (74.6 to 88.1 N−m).

11. Install front roller to cutting unit (see Roller Removaland Installation).

12.Install bedbar assembly to cutting unit (see BedbarRemoval and Installation).

13.Install cover gasket, weights, and cap screws to thebearing housing.

14.Complete cutting unit set−up and adjustment se-quence (see Adjustments section).

15.Grease both bearings (see Greasing Bearings,Bushings, and Pivot Points).

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Bedbar Removal and Installation

1. Rubber bushing2. Flanged bushing3. Jam nut4. Compression spring5. Washer6. Not used7. Not used8. Spring arm9. Bedbar adjuster10. Not used11. Not used12. Not used

13. Adjuster spacer14. Not used15. Bedbar pivot16. Grease fitting17. Bedbar fitting18. Not used19. Flange bushing20. Bushing21. Lock nut22. Hex nut23. Adjusting housing24. Lock nut

25. Carriage bolt26. Not used27. Bedbar washer28. Bedbar housing29. Spacer30. Flat washer31. Lock washer32. Cap screw33. Bedbar34. Bedknife35. Screw36. Bedbar yoke

Figure 23

31

32

33

3435

1 2 3 4 5

8

9

16

17

1920

2122

23

24

25

27

2829

30

1315

5

21

1920

25

24

36

Bedbar Removal

1. Turn bedbar adjuster to loosen bedknife to reel con-tact. Unscrew bedbar adjuster (left−hand threaded)while loosening jam nut from the compression springuntil the bedbar fitting is clear of the bedbar yoke.

2. Remove cap screws, weights, and cover gasket fromthe bearing housing (Fig. 22).

3. Remove capscrew, lock washer, flat washer, andspacer from the end of the bedbar.

4. Loosen both adjusting lock nuts on the adjustinghousing (Fig. 24).

5. Remove both carriage bolts and nuts from the ad-justing housing (Fig. 24).

6. Remove both carriage bolts and nuts from the bed-bar housing. Remove bedbar from the cutting unit.

7. Remove adjusting housing and bedbar housing fromthe bed bar. Remove bedbar washer.

8. Sharpen or replace bedknife as necessary (seeBedknife Replacement and Grinding).


Bedbar Installation (Fig. 23)

1. Inspect flanged bushings and bushing for wear; re-place if necessary.

2. Clean and apply anti−seize lubricant to both bedbarpivots. Install bedbar washer on the bedbar.

3. Install bedbar adjusting housing and bedbar housingon the bed bar. Reinstall spacer, flat washer, lock wash-er, and cap screw on the bedbar.

4. Install bedbar assembly on the cutting unit.

5. Secure bedbar housing to the cutting unit with bothcarriage bolts and nuts.

6. Secure adjusting housing to the cutting unit with bothcarriage bolts and nuts (Fig. 24).

7. Tighten both adjusting lock nuts on the adjustinghousing (Fig. 24).

8. Position bedbar fitting to the bedbar yoke. Screw ad-justing handle (left−hand threaded) until the bedbar fit-ting is snug against the bedbar yoke.

1. Adjusting lock nut2. Adjusting housing

3. Carriage bolt and nut

3 2

1

Figure 24

9. Adjust bedknife to reel (see Bedknife to Parallel toReel Adjustment).

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Bedknife Replacement and Grinding

1. Remove bedbar from the cutting unit (see BedbarRemoval and Installation).

2. Remove bedknife screws and bedknife.

3. Remove all rust, scale and corrosion from the bedbarsurface before installing new bedknife.

NOTE: Use a torque wrench and a bedknife screw toolto install bedknife screws.

4. Install new bedknife as follows:

A. Make sure bedbar threads are clean.

B. Use new bedknife screws. Apply anti−seize lubri-cant to the screw threads before installing.

IMPORTANT: Do not use an air or manual impactwrench to tighten bedknive screws.

C. Tighten screws to a torque of 250 to 300 in−lb(28.3 to 33.9 N−m). Tighten screws from the centertoward each end of the bedbar (Fig. 25).

5. Since there can be variations in the mounting sur-face of the bedbar, a new bedknife will not be perfectlyflat after it is installed. Because of this, it is necessary tobacklap or grind a new bedknife after installing it to thebedbar. Follow the existing angle that was ground intothe bedknife and grind only enough to make sure the topsurface is true.

Regrinding Bedknife

Remove bedbar assembly from cutting unit before at-tempting to regrind a used bedknife (see Bedbar Re-moval and Installation).

Note: When grinding, be careful to not overheat thebedknife. Remove small amounts of material with eachpass of the grinder.

Note: If the height of cut is a 1/2 inch or lower on thecutting unit, the front angle can be increased to 30o forimproved performance.

Bedknife Regrinding Specifications

Relief Angle 5o

Relief Angle Range 3o to 6o

Front Angle 15o (see Note above)

Front Angle Range 13o to 17o

1 2 4 6 83579 10

Figure 25

Relief Angle

Front Angle

Top Face

FrontFace

Figure 26


Roller Removal and Installation

Note: This section can be used for both the front andrear rollers.

Roller Removal

1. Remove both height−of−cut pins and hairpin cottersfrom each roller bracket.

2. Remove both locknuts from the capscrews securingeach angle bracket to the cutting unit.

3. Remove capscrews from both angle brackets andthe cutting unit.

4. Separate roller assembly, roller brackets, and anglebrackets from the cutting unit.

5. Remove roller brackets from the roller assembly.

Roller Installation

1. Inspect flanged bushing and bushings for wear; re-place if necessary.

Note: The flanged end of the flanged bushing mustface inside toward the roller when the roller bracket isinstalled onto the cutting unit.

Note: A soft hammer may be needed to tap the rollerbracket into position on the hex adjustment nut of theroller.

2. Insert smaller diameter roller shaft into the flangedbushing, bushing, and roller bracket. Make sure hex ofthe roller bracket mates with the hex adjustment nuton the roller.

3. Insert the other end of the roller shaft into the otherbushing and roller bracket. Make sure hex of the rollerbracket mates with the hex adjustment nut on theroller.

4. Hold one roller bracket stationary and use the otherbracket as a wrench to loosen or tighten bearing clear-ance. The roller must not exceed 5 in−lb (0.57 N−m) rol-ling torque and have no bearing end play.

5. Make sure roller brackets are aligned prior to instal-ling them onto the cutting unit. If necessary after bearingadjustment, align roller brackets as follows:

A. Remove roller bracket on the side with theflanged bushing.

B. Replace roller bracket so it is aligned to within + one hex flat of the roller adjustment nut.

C. Align both roller brackets.

2

7

103

8 9

5

6

1

11

4

1. Height−of−cut pin2. Hairpin cotter3. Roller bracket4. Lock nut5. Capscrew6. Angle bracket

7. Front roller assembly8. Flanged bushing9. Bushing10. Carriage bolt11. Lock nut

Figure 27

6. Mount roller, roller brackets, and angle brackets tothe cutting unit. Secure roller brackets and angle brack-ets to the cutting unit with capscrews.

7. Install both height−of−cut pins and hairpin cotters.

8. Install both locknuts to the capscrews, and secureeach angle bracket to the cutting unit.

9. Adjust roller level (see Height−of−Cut and LevelingBoth Rollers).

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Roller Bearing and Seal Replacement

1. Full roller2. Roller shaft3. Grease seal4. Bearing cup

5. Bearing cone (outer)6. Outer seal7. Adjustment nut8. Grease fitting

9. Wiehle roller10. Sectional roller shaft11. Bearing cone (inner)12. Sectional roller

Figure 28

1

2

3

45

10

11

12

7

8

9

4

4

5

6

2

67

8

4

56

78

Remove Seals and Bearings

1. Clean inside of roller around both adjusting nuts androller shaft ends. Both areas should be free of dirt anddebris.

2. Remove adjusting nut from one end of the rollershaft. On the sectional roller, remove both adjusting nutsfrom each end of the roller.

NOTE: When disassembling a full roller, pour the oilfrom inside the roller into a suitable container.

3. Keep roller level and slide the shaft with the remain-ing adjusting nut out of the roller. On the sectional roller,slide both sectional rollers of the shaft.

4. Secure roller in a vise.

5. Remove outer seals.

6. Remove both bearing cones. On the sectional roller,remove all four bearing cones.

Note: An electric arc welder can be used to shrink thebearing cup to simplify its removal. Only a small arc inone location on the cup is required.

7. Remove both bearing cups from the roller. Removeboth inner seals installed on the full roller. On the sec-tional roller, remove all four bearing cups.

8. Discard seals and bearings.


Install New Seals and Bearings on Full or WiehleRoller

1. Make sure all parts are clean prior to installing bear-ings and seals.

2. On the full roller, make sure cupped side of the innerseal faces the inside of the roller. Press an inner seal intoeach end of the roller.

3. Make sure narrow end of the taper on the bearingcup faces the inside of the roller. Press a cup into eachend of the roller.

4. Keep roller level and secured roller in a vise.

5. If assembling a full roller, fill the inside of roller tubewith 6 oz. (170 gm) of SAE 90 oil.

6. Pack both bearing cones with No. 2 general purposelithium base grease.

7. Install a bearing cone into the bearing cup at eachend of the roller.

8. Position outer seal to the roller with the hard surfaceof seal facing out. Press a seal onto each end of the roll-er.

9. Slide roller shaft through the bearing cones and roll-er.

10.Install remaining adjustment nut and tighten it to seatboth bearings. Roller should be rotated to seat bothbearings.

11.Back off both adjustment nuts to allow the roller tospin freely. Tighten both adjustment nuts again so thereis no bearing end play and rolling torque does not ex-ceed 5 in−lb (0.57 N−m).


Install New Seals and Bearings on Sectional Roller

1. Make sure all parts are clean prior to installing bear-ings and seals.

2. Press two bearing cups into each sectional roller.Make sure narrow end of taper faces the inside of theroller.

3. Secured sectional roller shaft in a vise. Make sureshaft is level.

4. Pack all bearing cones with No. 2 general purposelithium base grease.

NOTE: Install bearing cone with the seal into the end ofthe roller that faces the inner part of the shaft.

5. On both rollers, install a bearing cone into the bear-ing cup at each end of the roller.

6. Install outer seal onto the end of each roller. Makesure the hard surface of seal faces out.

7. Slide each roller onto the shaft.

8. Install adjustment nut onto each end of the shaft.Tighten each nut to seat both bearings of each roller.Roller should be rotated to seat both bearings.

9. Back off both adjustment nuts to allow the rollers tospin freely. Tighten both adjustment nuts again so thereis no bearing end play and rolling torque does not ex-ceed 5 in−lb (0.57 N−m).


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Prepare Reel for Grinding

Note: Check to make sure reel bearings are in goodcondition and properly adjusted before grinding reel.

1. Remove bedbar assembly (see Bedbar Removaland Installation).

2. Remove front roller and brackets (see Roller Remov-al and Installation).

Note: Most reel grinders require that the rear roller as-sembly be mounted to the cutting unit for proper supportin the reel grinder. The rear roller must be parallel to thereel shaft to remove taper when grinding, or the cuttingunit must be aligned so the grinding wheel will travel par-allel to the reel shaft. This will result in the the reel beingground to the desired cylinder shape.

Note: When grinding, be careful to not overheat thereel blades. Remove small amounts of material witheach pass of the grinder.

3. After completing grinding process:

A. Install front roller and brackets (see Roller Re-moval and Installation).

B. Install bedbar assembly (see Bedbar Removaland Installation).

C. Complete cutting unit set−up and adjustment se-quence (see Adjustments section).

Reel Grinding Specifications

Nominal Reel Diameter 7 inches (178 mm)

Service LimitReel Diameter

6.2 inches (158 mm)

Blade Relief Angle 30o

Relief Angle Range 20o to 40o

Blade Land Width 0.060 inch (1.5 mm)

Land Width Range 0.050 to 0.090 inch (1.3 to 2.3 mm)

Maximum Reel Taper 0.060 inch (1.5 mm)

REEL DIAMETER TAPER = D1 − D2

D1 D2

BLADE RELIEF ANGLE

REEL DIAMETER

BLADELAND

WIDTH

Figure 29


Fixed Side Plate Installation

1. Remove pop rivets and rear height−of−cut platesfrom both sides of the cutting unit (Fig. 30).

2. Remove lock nuts, capscrews, washers, and bothlinks from the cutting unit (Fig. 30).

3. Align fixed side plate with holes on the cutting unit(Fig. 31).

4. Attach new capscrews, washers, and flanged locknuts to the fixed side plate and the cutting unit (Fig. 31).

5. Tighten lock nuts and capscrews.

6. Fasten new height−of−cut plate to the cutting unitwith new pop rivets (Fig. 31).

7. Repeat steps 1 through 6 on the other side of the cut-ting unit.

1. Pop rivet2. Height−of−cut plate3. Lock nut

4. Capscrew5. Washer6. Link

46

1

2

5

3

Figure 30

1. Fixed side plate2. Capscrews3. Washers

4. Flanged lock nut5. Height−of−cut plate6. Pop rivet

15

6

3

2

4

Figure 31

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Front Lift Arms

1. 90o hydraulic fitting2. Hydraulic cylinder3. Carrier assembly4. Flange nut5. Flange head screw6. Hydraulic hose7. Centering wire8. Hydraulic hose9. Hydraulic hose10. Hydraulic hose11. Clamp bracket (Model 03200)11. Slide bracket (Model 03201)12. Flange nut (Model 03201)13. Plastic slide14. Flange head screw

15. Lift arm pivot shaft16. Roll pin17. Pivot shaft link18. Flange head screw19. Cap screw20. Clamp (Model 03200)20. Bearing cap (Model 03201)21. Jam nut22. Cap screw23. Lock nut24. Hardened washer25. Slide bar support26. Pin27. Spacer

28. External retaining ring29. Bulkhead nut30. Hydraulic tube31. Bulkhead nut32. Hose rod (Model 03201)33. Flange head screw (Model 03201)34. Flange nut (Model 03201)35. O−ring36. O−ring37. Flange head screw38. Link clip39. Hex nut40. Tipper chain41. Flat washer

Figure 32

31

3233

34

35

36

12

3

45

6

7

8

9

10

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

11

12

13

14

29

2915

28

1

26

20

24

13

21

40

39

37 37

38

41

FRONT

RIGHT

28

28


Removal


2. Remove cutting unit from the pivot shaft of the frontlift arm (see Cutting Unit Removal).

NOTE: Remove both spacers from the hydraulic cylin-der shaft clevis when removing the right, front lift arm.

3. Disconnect hydraulic cylinder from the front lift armby removing external retaining rings and pin.

4. Remove both flange head screws and pivot shaft linkfrom the lift arm pivot shafts (Fig. 33).

5. Slide lift arm off the lift arm pivot shaft.

6. Disassemble lift arm as necessary using Figure 34as a guide.

Installation

1. Assemble lift arm using Figure 34 as a guide.

2. Slide lift arm onto the lift arm pivot shaft.

3. Secure pivot shaft link with both flange head screwsto the lift arm pivot shafts. Torque flange head screws to70 Ft−lb (95 N−m) (Fig. 33).

NOTE: Install both spacers to the hydraulic cylindershaft clevis when installing the right, front lift arm.

4. Secure hydraulic cylinder to the lift arm with pin andexternal retaining rings.

5. Route hydraulic hoses so they clear the lift arm by0.04 to 0.12 inch (1.0 to 3.0 mm) when the lift arm is fullyraised (Fig. 35).

6. Adjust lift arms to proper clearance (see Adjust FrontLift Arms).

7. Install cutting unit to the pivot shaft of the front lift arm(see Cutting Unit Installation).

8. Grease front lift arm (see Lubrication in Chapter 2 −Product Records and Maintenance).

1. Flange head screw2. Pivot shaft link

3. Lift arm pivot shaftFigure 33

2

3

1

1. Lynch pin2. Cutting unit pivot shaft3. Carrier frame4. Thrust washer5. Lift arm (LH)6. Lift arm (RH) (not shown)

7. Cap screw8. Bushing9. Bushing10. Grease fitting11. Pinch point decal

Figure 34

2

65

7

41

3

10 9

8

912

11

8

1. Hydraulic hoses2. Hydraulic cylinder

3. Hydraulic cylinder

Figure 35

1

2 3

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Rear Lift Arm

1. External retaining ring2. Thrust washer3. Rear lift arm4. Rear hydraulic cylinder5. Flange head screw6. Thrust washer7. Rear pivot shaft8. Bushing

9. Jam nut10. Washer11. Lynch pin12. Washer13. Cutting unit pivot shaft14. Cap screw15. Rebound washer16. Cap screw

17. Pin18. Carrier assembly19. Hex nut20. Lock washer21. Flat washer22. Carriage screw23. Switch bracket24. Grease fitting

Figure 36

1

1

19

2021

8

7

6

5

11

12

16

1514

17

9

10

1

2

23

24

4

22

3

18

8 13

200 to 250 Ft−lb(271 to 339 N−m)

Removal


2. Remove cutting unit from the pivot shaft of the rearlift arm (see Cutting Unit Removal).

3. Remove external retaining ring and thrust washerfrom the lift cylinder shaft of the rear lift arm.

4. Remove flange head screw and thrust washer fromthe rear pivot shaft.

5. Slide rear lift arm from rear pivot shaft and hydrauliccylinder.

6. Disassemble lift arm as necessary using Figure 36as a guide.

Installation

1. Assemble lift arm using Figure 34 as a guide.

A. If the rear pivot shaft was removed, torque jamnut from 200 to 250 Ft−lb (271 to 339 N−m).

B. If the switch bracket was removed, make sure thelip of the switch bracket faces away from the rear liftarm when installed.

2. Slide rear lift arm onto rear pivot shaft making surethat the lift shaft of the rear lift arm slides into the clevisof the hydraulic cylinder.


3. Secure hydraulic cylinder clevis to the lift cylindershaft of the rear lift arm with the thrust washer and exter-nal retaining ring.

4. Install rear cutting unit to the pivot shaft of the rear liftarm (see Cutting Unit Removal).

5. Adjust lift arms to proper clearance (see Adjust RearLift Arm).

6. Grease front lift arm (see Lubrication in Chapter 2 −Product Records and Maintenance).

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Skid Kit Installation

1. Remove front roller from the cutting unit (see RollerRemoval and Installation).

2. Align skid slots with the angle bracket holes on thecutting unit.

3. Secure skid to the cutting unit with both flange headscrews, flat washers, and lock nuts.

4. Repeat steps 1 through 3 on the other side of the cut-ting unit.

5. Adjust skid height as necessary by loosening locknuts and flange head screws, then retighten fasteners.

1. Skid2. Angle bracket holes3. Flange head screw

4. Flat washer5. Lock nut

31

4 5

2

Figure 37

Carrier Frame

Removal

1. Make sure cutting unit and carrier frame are placedfirmly on a flat working surface.

2. Remove tipper chain from the top of the carrier frame(Fig. 38).

3. Remove lock nut, both flat washers, and large capscrew securing mounting links to the carrier frame. Re-move carrier frame from the cutting unit (Fig. 39).

Installation

1. Make sure cutting unit is placed firmly on a flat work-ing surface.

2. Position carrier frame (flat edge forward) onto thecutting while aligning mounting holes with all mountinglinks (Fig. 39).

NOTE: A flat washer must be on each side of all mount-ing links during installation.

3. Secure all four mounting links to the carrier framewith both flat washers, large cap screw, and lock nut.Torque lock nut and cap screw to 31 Ft−lb (42 N−m).

4. Route tipper chain up through the slot in each end ofthe carrier frame. Secure chain to the top of the carrierframe with washer, cap screw, and lock nut (Fig. 38).

1. Tipper chain2. Carrier frame3. Washer

4. Cap screw5. Lock nut

Figure 38

1

2

4

3

5

1. Carrier frame 2. Mounting linkFigure 39

FRONT

12

Commercial Products

� The Toro Company − 1999

99024sl.pdf Reelmaster 3100-D (Rev D) Dec, 2007

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Transcript of 99024sl.pdf Reelmaster 3100-D (Rev D) Dec, 2007