The purpose of this publication is to provide the service technician with information for troubleshooting, testing, and repair of major systems and components on the Reelmaster 3100--D.

REFER TO THE TRACTION UNIT AND CUTTING

UNIT OPERATOR???S MANUALS FOR OPERATING,

MAINTENANCE AND ADJUSTMENT INSTRUC- TIONS. Space is provided in Chapter 2 of this book to insert the Operator???s Manuals and Parts Catalogs for your machine. Additional copies of the Operator???s Manual and Parts Catalog are available on the internet at www.Toro.com.

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

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

NOTE: A NOTE will give general information about the correct 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 the machine.

ROSS TORQMOTOR TM MG, MF, ME, AND MJ SE-

RIES SERVICE PROCEDURE

PARKER TORQMOTORTM SERVICE PROCEDURE (TC, TB, TE, TJ, TF, TG, TH AND TL SERIES)

EATON MEDIUM DUTY PISTON PUMP REPAIR IN-

FORMATION MODEL 70160 VARIABLE DISPLACE-

MENT PISTON PUMP

ROSS HYDRAGUIDE TM HYDROSTATIC STEERING

SYSTEM HGF SERIES SERVICE PROCEDURE

SAUER/DANFOSS STEERING UNIT TYPE OSPM

SERVICE MANUAL

Chapter 1

Safety

Table of Contents

Safety

General Safety Instructions

The REELMASTER 3100--D was tested and certified by TORO for compliance with national and international standards as specified in the Operator???s Manual. Al- though hazard control and accident prevention are de- pendent partially upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern, and proper training of the person- nel involved in the operation, transport, maintenance, and storage of the machine. Improper use or mainte- nance by the operator or owner of the machine can re- sult in injury. To reduce the potential for any injury, comply with the following safety instructions.

WARNING

To reduce the potential for injury or death, com- ply 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 procedures and work rules for unusual operating conditions (e.g. slopes to steep for machine operation). Survey mow- ing site completely to determine which hills can be operated on safely. When performing this site survey, always use common sense and take into consideration

the turf condition and the rollover risk. To determine which hills or slopes may be safely operated on, use the inclinometer provided with each machine. To perform a site survey, lay a 4 foot long, 2 by 4 inch piece of wood on the slope surface and measure the angle of the slope. The piece of wood will average the slope but will not take into consideration dips or holes. THE MAXIMUM SIDE

HILL ANGLE SHOULD NOT BE GREATER THAN 25

DEGREES.

Before Operating

3.Operate machine only after reading and understand- ing the contents of the Operator???s Manual and viewing the Operator???s Video. Copies of the Operator???s Manual are available on the internet at www.Toro.com.

4.Only trained operators who are skilled in slope op- eration and who have read the Operator???s Manual and viewed the Operator???s Video should operate the ma- chine. Never allow children to operate the machine or adults to operate it without proper instructions.

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

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

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

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 get caught in moving parts and possibly cause personal in- jury.

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

10.Make sure the work area is clear of objects which might 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 is hot or running.

C.Do not smoke while handling diesel fuel.

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

While Operating

12.Do not run the engine in a confined area without ade- quate ventilation. Exhaust fumes are hazardous and could 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 on safety switches -shut off engine before getting off seat. If a switch fails, replace it before operating the machine. The interlock system is for your protection, so do not by- pass it. Replace all interlock switches every two years.

15.Operator must be skilled and trained in how to drive on hillsides. Failure to use caution on slopes or hills may cause vehicle to tip or roll, possibly resulting in personal injury 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 out and limit traction like conventional triplexes. If operated on a side hill that is too steep, rollover will occur before losing traction.

17.The slope angle at which the machine will tip is de- pendent on many factors. Among these are mowing conditions 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 side hill 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 a rollover increases to a moderate level. DO NOT EX-

CEED A 25 DEGREE SIDE HILL ANGLE BECAUSE

THE RISK OF A ROLLOVER AND SERIOUS INJURY OR DEATH IS VERY HIGH. Stay alert for holes in terrain and other hidden hazards. Use extreme caution when operating close to sand traps, ditches, creeks, steep hill- sides or other hazards. Reduce speed when making sharp turns. Do not turn on hills. Avoid sudden stops and

starts. Use reverse pedal for braking. Cutting units must be 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 drive is in disengage position.

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

19.Before backing up, look to the rear and assure no one is behind the machine. Watch out for traffic when near or crossing roads. Always yield the right of way.

20.Keep hands, feet and clothing away from moving parts and the reel discharge area. Grass baskets, if so equipped, must be in place during reel operation for maximum safety.

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

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

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

24.If a cutting unit strikes a solid object or vibrates ab- normally, stop immediately. Turn engine off, wait for all motion to stop and inspect for damage. A damaged reel or 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 reels to stop spinning.

D.Stop the engine and remove key from the ignition switch.

26.Whenever machine is left unattended, make sure reels are not spinning, key is removed from ignition switch and parking brake is set.

Safety

Maintenance and Service

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

28.Check performance of all interlock switches daily. Do not 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, screws and hydraulic fittings tight.

30.Make sure all hydraulic line connectors are tight, and all 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 or nozzles 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. lf fluid is injected into the skin it must be surgically re- moved within a few hours by a doctor familiar with this form of injury or gangrene may result.

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

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

34.To reduce potential fire hazard, keep the engine area free 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 any other parts of the body away from the cutting units and any moving parts. Keep everyone away.

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

37.Engine must be shut off before checking oil or adding oil 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 other manufacturers could be dangerous, and such use could void the product warranty of The Toro Company.

Jacking Instructions

CAUTION

When changing attachments, tires, or performing other service, use correct blocks, hoists, and jacks. Make sure machine is parked on a solid lev- el floor such as a concrete floor. Prior to raising machine, remove any attachments that may inter- fere with the safe and proper raising of the ma- chine. Always chock or block wheels. Used jack stands or solid wood blocks to support the raised machine. If the machine is not properly sup- ported by blocks or jack stands, the machine may move 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, position jack securely under the square tube of the lower frame as 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 the square tube or wheel motors to support the machine (Fig. 1).

Jacking the Rear End

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

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

2).

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

C.Use jack stands or hardwood blocks under the frame 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 rear fork 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 the ground.

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

2

1. Square tube

2

1. Rear tire

1

1.Frame

2.Rear wheel motor

1

Figure 1

2. Side plate

1

Figure 2

2. Rear casting

3

2

Figure 3

3. Rear fork

Reelmaster 3100???D

Chapter 2

Product Records and Maintenance

Table of Contents

PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 1

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . 2

Decimal and Millimeter Equivalents . . . . . . . . . . . . 2

U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . 2

TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 3

Fastener Identification . . . . . . . . . . . . . . . . . . . . . . . 3

Standard Torque for Dry, Zinc Plated, and Steel

Fasteners (Inch Series) . . . . . . . . . . . . . . . . . . . . 4

Standard Torque for Dry, Zinc Plated, and Steel

Fasteners (Metric Fasteners) . . . . . . . . . . . . . . . . 5

Other Torque Specifications . . . . . . . . . . . . . . . . . . 6

Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Product Records

Insert Operator???s Manual and Parts Catalog for your Reelmaster 3100--D at the end of this chapter. Addition- ally, if any optional equipment or accessories have been installed to your machine, insert the Installation Instruc- tions, Operator???s Manuals and Parts Catalogs for those options at the end of this chapter.

Maintenance

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

Product Records and Maintenance

Torque Specifications

Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and spe- cified in this Service Manual.

These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Ser- vice Manual. The following factors shall be considered when applying torque: cleanliness of the fastener, use of a thread sealant (Loctite), degree of lubrication on the fastener, presence of a prevailing torque feature, hard- ness of the surface underneath the fastener???s head, or similar condition which affects the installation.

As noted in the following tables, torque values should be reduced by 25% for lubricated fasteners to achieve the similar stress as a dry fastener. Torque values may also have to be reduced when the fastener is threaded into aluminum or brass. The specific torque value should be determined based on the aluminum or brass material 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 until the lines match up.

Product Records and Maintenance

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

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

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

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

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

Product Records and Maintenance

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

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

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

Note: The nominal torque values listed above are based on 75% of the minimum proof load specified in SAE J1199. The tolerance is approximately + 10% of the nominal torque value.

Other Torque Specifications

SAE Grade 8 Steel Set Screws

Thread Cutting Screws

(Zinc Plated Steel)

Type 1, Type 23, or Type F

Wheel Bolts and Lug Nuts

** For steel wheels and non???lubricated fasteners.

Thread Cutting Screws

(Zinc Plated Steel)

* Hole size, material strength, material thickness & finish must be considered when determining specific torque values. All torque values are based on non???lubricated fasteners.

Lubrication

Traction Unit

CAUTION

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

The traction unit has grease fittings that must be lubri- cated regularly with No. 2 General Purpose Lithium Base Grease. If machine is operated under normal conditions, lubricate bearings and bushings after every 50 hours of operation. Bearings and bushings must be lubricated daily when operating conditions are extreme- ly dusty and dirty. Dusty and dirty operating conditions could cause dirt to get into the bearings and bushings, resulting in accelerated wear. Lubricate bearings and bushings immediately after every washing, regardless of the interval listed.

The traction unit bearings and bushings that must be lu- bricated are: rear cutting unit pivot (Fig. 4), front cutting unit pivot (Fig. 5), sideWinder cylinder ends (2) (model 03201 only) (Fig. 6), steering pivot (Fig. 7), rear lift arm pivot and lift cylinder (2) (Fig. 8), left front lift arm pivot and lift cylinder (2) (Fig. 9), right front lift arm pivot and lift cylinder (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 be installed in other end of steering cylinder. Tire must be removed, fitting installed, greased, fitting removed and plug installed (Fig. 15).

IMPORTANT: Do not lubricate Sidewinder (model 03201) cross tube, bearing blocks are self lubri- cated.

Figure 4

Figure 6

Figure 7

Product Records and Maintenance

Cutting Units

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

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

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

IMPORTANT: Lubricating cutting units immediately after 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 or grease seals will be permanently damaged.

2.Apply grease until pressure is felt against handle.

3.Wipe excess grease away.

Figure 17

Grease every 50 operating hours.

Figure 18

Grease every 8 operating hours.

Product Records and Maintenance

Traction 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 painted areas that are scratched, chipped, or rusted. Repair any dents 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 wire brush and baking soda solution.

C.Coat cable terminals and battery posts with Grafo 112X skin???over grease (Toro Part No. 505-47) or pe- troleum jelly to prevent corrosion.

D.Every 30 days, check battery electrolyte levels and fill battery as necessary (see Battery Care in Chapter 5 ??? Electrical System).

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

Traction Unit

1.Drain engine oil from the oil pan and replace the drain plug.

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

3.Refill oil pan with approximately 4.0 quarts (3.8 l) of SAE10W-30 motor oil.

4.Start engine and run at idle speed for approximately two minutes.

5.Stop engine.

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

7.Flush the fuel tank with fresh, clean diesel fuel (see Fuel 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 with weatherproof tape.

11. Check anti???freeze protection and add as needed for expected minimum temperature in your area (see Check Cooling System in Chapter 3 ??? Kubota Diesel En- gine).

Chapter 3

Kubota Diesel Engine

Table of Contents

Engine

Kubota Diesel

Introduction

This Chapter gives information about specifications, maintenance, troubleshooting, testing, and repair of the diesel engine used in the Reelmaster 3100???D.

Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Kubota Workshop Manual, Diesel Engine, 05 Series. The use of some specialized test 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 no parts list is available, be sure to provide your distributor with the Toro model and serial number.

Specifications

Engine

Kubota Diesel

Check Engine Oil

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

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

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

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

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

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

4.The engine uses any high???quality 10W30 detergent oil 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.

2

1

Figure 1

1. Dipstick2. Oil fill cap

21

Fill Fuel Tank

DANGER

Because diesel fuel is highly flammable, use cau- tion when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot, or when machine is in an enclosed area. Always fill fuel tank outside and wipe up any spilled diesel fuel before 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).

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

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

1

2

Figure 3

3.Fill fuel tank to the bottom of the filler neck. Do not overfill. Install cap to the neck.

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

Engine

Kubota Diesel

Check Cooling System

The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol anti???freeze. Check level of coolant at the beginning of each day before starting the engine. System capacity is about 6 quarts (5.7 l) with 1 quart (0.9 l) reservoir.

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

CAUTION

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

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

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

4.Install expansion tank cap.

2

Adjust Throttle Cable

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

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

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

4.Hold speed control lever on the injection pump against the low idle stop. Tighten cable to the swivel with cap screw (Fig. 7).

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

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

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

7. If throttle control lever does not stay in position during operation, torque lock nut and cap screw used to tighten the friction disc from 40 to 55 in???lb (4.5 to 6.2 N???m). The force required to operate the throttle control lever should be from 30 to 45 lb (133 to 200 N). Torque fasteners as necessary (Fig. 8).

3

1

4

Figure 8

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

3

1

4

Figure 9

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 filter every 100 hours.

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

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

3.Remove oil filter. Apply light coat of clean oil to the new filter seal before screwing filter on. Do not over??? tighten filter.

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

Replace Traction Belt

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

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

CAUTION

Be careful when removing or applying tension from or to the torsion spring of the idler pulley. The spring is under heavy load and may cause personal injury.

3.Push down and forward on the spring end to unhook the 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.

3

1

4

5

6

2

Figure 12

6.Insert nut driver or small piece of pipe onto the end of the torsion spring of the idler pulley.

7.Push down and back on the spring end to get the spring 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 access to the engine.

DANGER

Because diesel fuel is highly flammable, use cau- tion when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot, or when machine is in an enclosed area. Always fill fuel tank outside and wipe up any spilled diesel fuel before 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.

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 be trapped between injection pump and injectors (see Bleed Air from Fuel Injectors).

2

1

Figure 13

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

Engine

Kubota Diesel

Bleed Air from Fuel Injectors

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

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

DANGER

Because diesel fuel is highly flammable, use cau- tion when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot, or when machine is in an enclosed area. Always fill fuel tank outside and wipe up any spilled diesel fuel before 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.

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

2

1

3

Figure 14

3.Move throttle to FAST position.

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

5.Repeat steps on the remaining injector nozzles.

Muffler Removal

CAUTION

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

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

2.Open engine hood to gain access to engine.

3.Remove both flange head nuts and screws securing the 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 the exhaust manifold. Remove muffler from the machine (Fig. 17).

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

Muffler Installation

Note: If a new gasket is to be installed, make sure muffler flange and exhaust manifold sealing surfaces are free of debris or damage that may prevent a tight seal.

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

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

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

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

4.Close engine hood.

2

4

3

1

Figure 16

2

1

Engine

Kubota Diesel

Check Air Filter, Dust Cup, & Burp Valve

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

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

2.Check air cleaner body for damage that could cause possible air leaks. Make sure dust cup seals completely to the air cleaner body.

3.Check burp valve and dust cup for damage.

4.Make sure air hoses connecting the air cleaner to the engine 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.

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

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

3.Gently slide filter out of air cleaner body to reduce the amount of dust dislodged. Avoid knocking filter against air cleaner body.

4.Inspect filter and discard if damaged. Do not wash or reuse 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 with clear 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 (160oF maximum), or allow element to air???dry. Do not use a light bulb to dry the filter element because damage could result.

1

2

Figure 19

Compressed Air Method

A.Blow compressed air from inside to the outside of dry filter element. Do not exceed 100 psi to prevent damage to the element.

B.Keep air hose nozzle at least 2 inches (5 cm) from the filter. Move nozzle up and down while rotating the filter element. Inspect for holes and tears by looking through 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. Make sure filter is sealed properly by applying pressure to out- er rim of filter when installing. Do not press on flexible center of filter.

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

Water/Fuel Separator

DANGER

Because diesel fuel is highly flammable, use cau- tion when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot, or when machine is in an enclosed area. Always fill fuel tank outside and wipe up any spilled diesel fuel before 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.

Draining

Drain water and other contaminants from the water/fuel separator daily.

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

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

3.Loosen drain valve on the bottom of the separator base.

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

Filter Element Replacement

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

2.Clean area where filter element mates with base and filter 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???ring with clean diesel fuel.

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

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

1

2

Figure 20

DANGER

Because diesel fuel is highly flammable, use cau- tion when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot, or when machine is in an enclosed area. Always fill fuel tank outside and wipe up any spilled diesel fuel before 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.

Check Fuel Lines and Connections

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

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

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

Fuel Tank Removal (Fig. 22)

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

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

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

4.Remove fuel hose strap and both fuel hoses from the fuel 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, drain and 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 Tank Removal).

2.Flush fuel tank out with clean diesel fuel. Make sure tank 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 with hose clamps and fuel hose strap.

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

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

Replace Fuel Prefilter (Fig. 25)

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

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

2.Remove cap screw securing the prefilter to frame.

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

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

4

Figure 23

1

Figure 25

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.

Removal

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

2.Open and remove engine hood from the machine.

CAUTION

Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot cool- ant can escape and cause burns. Ethylene???gycol antifreeze is poisonous. Dispose of coolant properly, 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 completely drain the radiator.

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

Note: Allow hydraulic components and hoses to drain into 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 corner of the radiator leading to the hydraulic manifold.

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

6.Remove oil cooler from the radiator assembly using Figure 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 fan shroud.

9.Remove both fan shrouds from radiator assembly.

10.Remove flange head screws securing the top and bottom of the radiator frame to the radiator. Remove four carriage bolts and lock nuts securing the radiator to the radiator frame.

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

12.Plug any openings to prevent contamination.

Installation

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

2.Position radiator carefully to the radiator frame.

3.Secure radiator assembly to the radiator frame with four carriage bolts and lock nuts. Secure top and bottom of radiator to frame with flange head screws.

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

5.Secure reservoir bracket and reservoir to the top fan shroud 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, and openings used during the removal procedures.

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

B.Secure hydraulic hose leading to the hydraulic manifold with the clamp to the lower left corner of the radiator.

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

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

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

11. Install engine hood to the machine and close.

Engine

Kubota Diesel

Clean Radiator and Oil Cooler (Fig. 4)

The radiator and oil cooler should be checked for dirt and debris daily, and hourly if conditions are extremely dusty and dirty.

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

CAUTION

If engine has been running, the radiator may be hot and cause burns. Work on radiator only when the 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 spring clip. 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. Install lower shield. Close hood.

3

1

2

4

Figure 27

3

1

2

Removal

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

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 (see Battery 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). Disconnect coolant hoses from the water pump and engine block.

7.Remove reservoir and bracket from the top fan shroud. Remove top fan shroud from the radiator (see Radiator Removal).

8.Disconnect wire harness and electrical wires from the 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 separator Fig. 30) and front injector nozzle (Fig. 31).

11. Remove traction control cable from the neutral arm assembly on the piston pump. Remove all hydraulic hoses from the piston an gear pumps (see Piston Pump Removal in Chapter 4??? Hydraulic System).

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

CAUTION

Make sure lift or hoist can support the total weight of the engine before removing the cap screws from the rear bracket and engine.

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

CAUTION

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

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

14.Remove engine slowly from the machine.

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

Note: The cap screw next to the torsion spring does not have a flat washer with it.

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

4

1

2

Figure 32

1

3

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

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

Installation

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

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

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

B.Secure pump mount plate to the engine with five spacers, 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.

31and 32).

CAUTION

One person should operate lift or hoist while the other person guides the engine into the machine.

IMPORTANT: Make sure not to damage the engine, fuel and hydraulic lines, electrical harness, or other parts 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 gear pumps. Install traction control cable to the neutral arm assembly 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 reservoir and bracket to the top fan shroud (see Radiator Installa- tion).

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 muffler bracket (see Muffler Installation).

12.Connect throttle cable to the support and swivel on the 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 to air 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 latch hood.

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

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 (Eaton) . . . . . . . . . . . . . . . . . . . 74

Reel Motor Service (Casappa) . . . . . . . . . . . . . . 75.1

Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Hydraulic Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Hydraulic Manifold Service . . . . . . . . . . . . . . . . . . . 78

Control Valve (Models 03200, 03206 and 03170) 84

Control Valve Service (Models 03200, 03206 and

03170) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Control Valve (Models 03201, 03207 and 03171) 90

Control Valve Service (Models 03201, 03207 and

03171) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Piston Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Piston Pump Service . . . . . . . . . . . . . . . . . . . . . . . 100

Piston Pump Crush Ring Replacement . . . . . . . . 101

Sidewinder (Models 03201, 03207 and 03171) . 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

PARKER TORQMOTORTM SERVICE PROCEDURE

(TC, TB, TE, TJ, TF, TG, TH AND TL SERIES)

EATON MEDIUM DUTY PISTON PUMP REPAIR IN-

FORMATION MODEL 70160 VARIABLE DISPLACE-

MENT PISTON PUMP

ROSS HYDRAGUIDE TM HYDROSTATIC STEERING

SYSTEM HGF SERIES SERVICE PROCEDURE

SAUER/DANFOSS STEERING UNIT TYPE OSPM

SERVICE MANUAL

System

Hydraulic

Hydraulic Hoses

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

When replacing a hydraulic hose, be sure that the hose is 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 and tighten the hose swivel nut onto the fitting with the other.

WARNING

Before disconnecting or performing any work on hydraulic system, relieve all pressure in system. Stop engine; lower or support box and/or other attachment(s).

Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. If fluid is injected into the skin, it must be surgi- cally removed within a few hours by a doctor familiar with this type of injury. Gangrene may result from such an injury.

Hydraulic Fitting Installation

O???Ring Face Seal

Nut

Sleeve

Body

System

Hydraulic

Seal

Figure 1

Final

Position

Figure 2

SAE Straight Thread O???Ring Port ??? Non???adjustable

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

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

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

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

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

SAE Straight Thread O???Ring Port ??? Adjustable

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

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

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

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

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

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

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

O???Ring

Figure 3

Lock Nut

Back???up Washer

O???Ring

Figure 4

Figure 5

Towing Traction Unit

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

IMPORTANT: Do not tow the machine faster than 2 to 3 mph because drive system may be damaged. If ma- chine must be moved a considerable distance (more than 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.

2

1

Figure 6

Check Hydraulic System Fluid

The hydraulic system that drives the reels is designed to operate on anti???wear hydraulic fluid. The machines reservoir is filled at the factory with approximately 3.5 gallons (13.2 liters) of DTE 15M hydraulic fluid. Check level of the hydraulic fluid before the engine is first started and daily thereafter.

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

NOTE: A red dye additive for the hydraulic system fluid is available in 2/3 oz. bottles. One bottle is sufficient for 4 to 6 gallons (15 to 23 liters) of hydraulic fluid. Order Part No. 44???2500 from your Authorized Toro Distributor.

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

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

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

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

5.Install dipstick and cap onto the filler neck.

2

1

Figure 7

System

Hydraulic

Relieving Hydraulic System Pressure

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

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

To relieve cutting system pressure, turn key switch to ON (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 from the 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 to service, repeat relieving hydraulic system pressure pro- cedure.

The Reelmaster 3100???D traction circuit is a closed loop system that includes the hydrostat and two (2) wheel motors. If a component in the traction circuit should fail, debris and contamination from the failed component will circulate throughout the traction circuit. This contamina- tion can damage other components in the circuit so it must be removed to prevent additional component fail- ure.

If a component failure occurs in the traction circuit, it is critical 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 test gauges 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 that contaminates are removed from the closed loop and thus, 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 the machine raised off the ground, the traction circuit will have maximum oil flow at minimum pressure to mini- mize damage from any remaining contamination. The filter will remove contamination from the closed loop traction circuit during operation. Remove the filter from the machine after contamination has been removed from the traction circuit.

IMPORTANT: When operating the traction system with the high pressure filter installed, make sure that flow is always directed through the filter (e.g. do not press the traction pedal in the reverse direction if the filter is placed for forward direction flow). If flow is reversed, debris from the filter will re???enter the traction circuit.

This page is intentionally blank.

System

Hydraulic

T2

G1

MD1

BACKLAPPING

VALVE

LC1 LOGIC

VALVE

FC1

REEL SPEED

LEFT

FRONT

RIGHT

FRONT

REAR

MANIFOLD

BLOCK

NOTE: ON MACHINES WITH

SERIAL NUMBERS BELOW 230000000, INITIAL REEL

MOTOR IN CUTTING CIRCUIT

IS FRONT LEFT REEL

MOTOR AND FINAL

MOTOR IS REAR (SHOWN).

ON MACHINES WITH

SERIAL NUMBERS ABOVE 230000000, INITIAL REEL

MOTOR IS REAR MOTOR

AND FINAL REEL MOTOR

IS LEFT FRONT (NOT SHOWN)

F

Schematics Hydraulic

CONTOLLER

S1 REEL

ON???OFF

VALVE

R1

REEL

RELIEF 3000 psi

A B

R

3000 psi

T1

LC2

CR

PLG

CF

LV

IN

D???3100 Reelmaster

9 ??? 4 Page

Reelmaster 3100???D (Model 03201)

Hydraulic Schematic

All solenoids are shown as de???energized

3000 psi

100 to 150 psi

P3

IN

L

C) .(Rev System Hydraulic

HYDROSTAT

INTERNAL CASE DRAIN

Hydraulic

System

LEFT FRONT

REEL MOTOR

RIGHT FRONT

REEL MOTOR

REAR

REEL MOTOR

FRONT

LIFT

CYLINDER

REAR

LIFT

CYLINDER

L

STEERING

R

POWER

STEERING

VALVE

Diagrams Flow Hydraulic

Traction Circuits

Forward

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

The engine drives traction pump (P3) indirectly through pulleys and a V???belt. The traction pump is a variable dis- placement piston pump. The traction pedal connects through a cable to the trunnion shaft and swash plate of the pump. With the engine running and the traction ped- al in the neutral position, P3 supplies no flow to the wheel motors. When the traction pedal is pressed to the forward position, the cable from the pedal positions the swash plate in the traction pump so oil flows out of the lower port. Oil flow out of the lower port goes to the wheel motors and turns them in the forward direction. Oil flow- ing out of the wheel motors returns to upper port of the hydrostat and is continuously pumped out of the lower port.

The rear wheel motor has a small check valve across its ports that allows the rear motor to over run during tight turns in the forward direction.

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

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

The charge pump (P2) is a fixed displacement gear pump. It is driven directly off the traction pump. The pump replenishes the closed loop circuit with fluid from the hydraulic tank. The charge relief valve supplies suffi- cient head so that charge pump flow is guided to the low pressure side of the traction circuit through one of two check valves. Pump flow in excess of replenishment re- quirements is relieved through the charge relief valve back 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 cable from the pedal positions the swash plate in the traction pump so oil flows out of the upper port. Oil flow out of the upper port goes to the wheel motors and turns them in the reverse direction. Oil flowing out of the wheel motors returns to the lower port of the hydrostat and is continu- ously pumped out of the upper port. Oil by???passes the rear motor in reverse because of the check valve inside the rear motor.

System

Hydraulic

C) .(Rev System Hydraulic

12 ??? 4 Page

D???3100 Reelmaster

Reelmaster 3100???D

Reel Circuit

3000 psi

100 to 150 psi

P3

HYDROSTAT

INTERNAL CASE DRAIN

INTERNAL CASE DRAIN

GEAR PUMP

IN

ENGINE

RPM

P1 P2

V1

OIL

FILTER1000 psi

OUT

STRAINER

AUX

LEFT FRONT

REEL MOTOR

RIGHT FRONT

REEL MOTOR

REAR

REEL MOTOR

FRONT

LIFT

CYLINDER

REAR

LIFT

CYLINDER

2???SPOOL D

VALVE

L

STEERING

R

POWER

STEERING

VALVE

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 oil flow to the manifold block and to the reel motors.

Solenoid valve (S1) is de???energized with the engine running when either the reels on/off switch is OFF, the cutting units are up, or the transport/mow switch is in TRANSPORT. S1 by???passes flow from the reel motors directly to the hydraulic reservoir.

Solenoid valve (S1) is energized with the engine running when the reels on/off switch is ON, the cutting units are down, and the transport/mow switch is in MOW. Flow is diverted to the reel motors.

Oil flows from port (P1) across the logic cartridge valve (LC1). The logic cartridge valve maintains a pressure differential of 75 PSI (5.2 bar) across the speed control valve. Any excess flow above what the speed control valve is set for, is by???passed to the reservoir through the logic 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, and then rear reel motors as it turns the motors in the mow direction. 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 then left front reel motors as it turns the motors in the mow direction. 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 on machines with serial numbers below 230000000, oil flows through the rear, right front, and then left front reel motors (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 then rear reel motors

REEL CIRCUIT SCHEMATIC FOR MACHINES WITH SERIAL NUMBERS BELOW 230000000

TO MANIFOLD

D1 PORT

TO MANIFOLD

M2 PORTRIGHT

FRONT

REAR

Figure 8

REEL CIRCUIT SCHEMATIC FOR MACHINES WITH SERIAL NUMBERS ABOVE 230000000

TO MANIFOLD

D1 PORT

Figure 9

System

Hydraulic

C) .(Rev System Hydraulic

14 ??? 4 Page

D???3100 Reelmaster

Reelmaster 3100???D

Lift Circuit (Up)

High Pressure

Low Pressure (Charge)

Return or Suction

Lift Circuit (Up)

Raise Cutting Units

The gear pump (P2) is directly coupled to the hydrostat through gear pump (P1). It supplies hydraulic pressure (charge pressure) for raising and lowering the cutting units, operating the sidewinder unit, and maintaining 100 to 150 PSI (6.9 to 10.0 bar) to the low pressure side of the traction circuit. The pump takes its suction from the hydraulic reservoir.

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 manifold directly to the hydrostat and the charge relief valve. Flow then returns to the hydraulic tank.

When the cutting units are to be raised, the 2???spool valve is positioned by moving the cutting unit shift lever to RAISE. Flow is directed to cap ends of the lift cylin- ders. Hydraulic pressure against the cylinder pistons moves their shafts causing the cutting units to raise. At the same time, the pistons push the hydraulic fluid out of the lift cylinders and back through the hydraulic man- ifold to the hydrostat. When the cutting unit shift lever is released, spring action returns the valve to its original position and by???passes flow back to the hydrostat stop- ping lift cylinder movement. The cylinder position is locked in place, since there is no complete circuit of flow to and from the lift cylinders.

C) .(Rev System Hydraulic

16 ??? 4 Page

D???3100 Reelmaster

Reelmaster 3100???D

Lift Circuit (Down)

High Pressure

Low Pressure (Charge)

Return or Suction

LEFT FRONT

REEL MOTOR

RIGHT FRONT

REEL MOTOR

REAR

REEL MOTOR

FRONT

LIFT

CYLINDER

REAR

LIFT

CYLINDER

B C

SIDEWINDER

CYLINDER

2???SPOOL D

VALVE

L

STEERING

R

POWER

STEERING

VALVE

Lift Circuit (Down)

Lower Cutting Units

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

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

When the cutting units are to be lowered, the 2???spool valve is positioned by moving the cutting unit shift lever to LOWER. Pressure from gear pump (P2) is used to

shift the pilot valve in the 2???spool valve. This shifting of the pilot valve allows hydraulic pressure to relieve from the cap end of the lift cylinders. Flow from the cap end of the lift cylinders causes the cutting units to lower. At the same time, the fluid relieved from the cap end of the lift cylinders goes into the rod end of the cylinders and back 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 position while by???passing flow back to the hydrostat. The pilot valve then shifts to its original position and stops lift cyl- inder movement. The cylinder position is locked in place since there is no complete circuit of flow to and from the lift cylinders.

Hydraulic

Reelmaster 3100???D

Sidewinder Circuit (Extend Right)

C) .(Rev System

18 ??? 4 Page

D???3100 Reelmaster

High Pressure

Low Pressure (Charge)

Return or Suction

LEFT FRONT

REEL MOTOR

RIGHT FRONT

REEL MOTOR

Sidewinder Circuit

The gear pump (P2) is directly coupled to the hydrostat through gear pump (P1). It supplies hydraulic pressure (charge pressure) for raising and lowering the cutting units, operating the sidewinder unit, and maintaining 100 to 150 PSI (6.9 to 10.0 bar) to the low pressure side of the traction circuit. The pump takes its suction from the hydraulic reservoir.

During conditions of not lifting or lowering the cutting units, flow from the gear pump is by???passed through the power steering valve, 2???spool valve, and hydraulic manifold directly to the hydrostat and the charge relief valve. Flow then returns to the hydraulic tank.

Shift Sidewinder Right

When the sidewinder is to be shifted right, the 2???spool valve is positioned by moving the cutting unit shift lever to RIGHT. Flow is directed to the cap end of the side- winder cylinder. Hydraulic pressure against the cylinder piston moves the rod causing the sidewinder cylinder to extend 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 the cutting unit shift lever is released, spring action returns the valve to its original position and by???passes flow back to the hydrostat and stopping cylinder movement. The cylinder 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???spool valve is positioned by moving the cutting unit shift lever to LEFT. Flow is directed to the rod end of the sidewinder cylinder. Hydraulic pressure against the cylinder piston moves the rod causing the sidewinder to retract left. At the same time, the piston pushes the hydraulic fluid out of the cylinder, back through the spool and hydraulic manifold, and to the hydrostat. When the cutting unit shift lever is released, spring action returns the valve to its 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 circuit of flow to and from the lift cylinders.

System

Hydraulic

C) .(Rev System Hydraulic

20 ??? 4 Page

D???3100 Reelmaster

Reelmaster 3100???D

Steering Circuit (Right Turn)

High Pressure

Low Pressure (Charge)

Return or Suction

Steering Circuit

The gear pump (P2) is directly coupled to the hydrostat. It supplies hydraulic pressure to the power steering valve for turning the rear wheel and maintaining 100 to 150 PSI (6.9 to 10.0 Bar) to the low pressure side of the traction circuit. The pump takes its suction from the hy- draulic reservoir.

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

Right Turn

When a right turn is made with the engine running, the turning of the steering wheel positions the spool valve so that flow goes through the top of the spool. Flow entering the steering control valve at the IN port goes through the spool and is routed to two places. First, most of the flow through the valve is by???passed out the AUX port back through the 2???spool valve to the hydrostat. Second, the remainder of the flow is drawn through rotary meter (V1) and out port (R). Pressure retracts the piston for a right turn. 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 back through the spool valve then through the OUT port and to the hydrostat.

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

Left Turn

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

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

System

Hydraulic

Hydraulic Test Fitting Kit

Toro Part Number: TOR4079

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

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

Figure 12

Measuring Container

Toro Part Number: TOR4077

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

Figure 13

O-Ring Kit

Toro Part Number: 16--3799

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

Figure 14

System

Hydraulic

High Flow Hydraulic Filter Kit

Toro Part Number: TOR6011

The high flow hydraulic filter kit is designed with large flow (40 GPM/150 LPM) and high pressure (5000 PSI/345 bar) capabilities. This kit provides for bi--direc- tional filtration which prevents filtered debris from being allowed back into the circuit regardless of flow direction.

If a component failure occurs in the closed loop traction circuit, contamination from the failed part will remain in the circuit until removed. When connecting hydraulic test gauges in order to test traction circuit components or after replacing a failed traction circuit component (e.g. hydrostat or wheel motor), the high flow hydraulic filter can be installed in the traction circuit. The filter will en- sure that contaminates are removed from the closed loop and thus, do not cause additional component dam- age.

NOTE: This kit does not include hydraulic hoses (see Hydraulic Hose Kit TOR6007 above).

Figure 16

NOTE: Replacement filter element is Toro part number TOR6012. Filter element cannister tightening torque is

25 ft--lb (34 N--m).

This page is intentionally blank.

System

Hydraulic

The charts that follow contain information to assist in troubleshooting. There may possibly be more than one cause for a machine malfunction.

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

Testing

The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks (See the Special Tools section in this Chapter).

Before Performing Hydraulic Tests

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

Precautions for Hydraulic Testing

CAUTION

Failure to use gauges with recommended pres- sure (psi) rating as listed in test procedures could result in damage to the gauge and possible personal 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 and record test results.

WARNING

Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Do not use hands to search for leaks; use paper or cardboard. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury. Gan- grene may result from such an injury.

1.Clean machine thoroughly before disconnecting or disassembling any hydraulic components. Always keep in mind the need for cleanliness when working on hy- draulic equipment. Contamination will cause excessive wear of components.

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

WARNING

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

3.The engine must be in good operating condition. Use a phototac when performing a hydraulic test. Engine speed can affect the accuracy of the tester readings. Check actual speed of the pump when performing flow testing.

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

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

6.Install fittings finger tight and far enough to make sure that they are not cross???threaded before tightening them with a wrench.

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

8.Check oil level in the hydraulic tank. After connecting test 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 hydraulic oil at normal operating temperature.

11. If a traction circuit problem exists, consider perform- ing one or more of the following tests: Traction Circuit Working Pressure, Charge Relief Valve Pressure, Pis- ton Pump (P3) Flow & Traction Relief Pressure and/or Wheel 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 Motor Cross???over Relief Pressures, Gear Pump (P1) Flow and/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) Flow and/or Steering Control Valve Tests.

System

Hydraulic

Procedure for Traction Circuit Working Pressure Test:

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

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

3.Read Precautions for Hydraulic Testing.

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

WARNING

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

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

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

50RPM).

CAUTION

Do 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 test gauge.

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

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

C.Pressure while mowing should range between 1000 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 be repaired or replaced as necessary.

Reelmaster 3100???D

2

1

System

Hydraulic

Hydraulic System (Rev. C)

FORWARD

M5

TRACTION WHEEL MOTORS

M4

TOP PORT

M6

PISTON PUMP

(HYDROSTAT)

TO GEAR PUMP SUCTION

THROUGH CASE DRAIN

High Pressure

Low Pressure

Return or Suction

Flow

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

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

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

3.Read Precautions for Hydraulic Testing.

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

WARNING

One front wheel and the rear wheel will be off the ground during testing. Make sure machine is sup- ported so it will not move and accidentally fall to prevent injuring anyone under machine.

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

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

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

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

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

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

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 to move the machine forward.

11. Slowly push traction pedal fully to forward position.

2

1

Figure 18

12.Verify traction relief valve setting by closing flow con- trol valve. System pressure should be from 3000 to 3125 PSI as the relief valve lifts. If pressure can not be met or is exceeded with traction pedal fully depressed, release traction 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 (see Replace Traction Belt).

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

C.The hydrostat needs to be repaired or replaced as necessary.

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

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

B.Observe flow gauge. TESTER READING should be 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 piston pump and/or wheel motor(s) should be suspected of wear. 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 to be 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 and Brakes ??? Chapter 7).

System

Hydraulic

INTERNAL CASE DRAIN

GEAR PUMP

STRAINER

High Pressure

Low Pressure

Return or Suction

Flow

Procedure for Charge Relief Valve Pressure Test:

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

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

3.Read Precautions for Hydraulic Testing.

WARNING

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

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

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

6.Make sure that traction pedal is in neutral and the parking 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 Repairs section).

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

9. A dynamic charge pressure test can be performed as follows:

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

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

C.The charge pressure should drop no more than 15% 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 pump and/or wheel motor).

10.Shut off engine.

11. Disconnect gauge and T???connection from the 90o hydraulic fitting and hose connection. Reconnect hose to the hydrostat.

System

Hydraulic

Figure 19

1. Rear 90o hydraulic fitting 2. Piston pump

Procedure for Gear Pump (P2) Test:

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

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

3.Read Precautions for Hydraulic Testing.

WARNING

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

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

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

6.Make sure the flow control valve on the tester is fully open.

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 close tester valve fully when performing test.

7.Start engine and move throttle to full speed (2650 +

50RPM). Do not engage the cutting units.

8.Watch pressure gauge carefully while slowly closing the flow control valve until 800 PSI is obtained. Verify with 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 Pressure Test can be conducted with tester as placed for this test.

11. If flow was less than 3.6 GPM or a pressure of 800 PSI cannot be obtained, check for restriction in the pump intake 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.

Figure 20

System

Hydraulic

FORWARD

M5

FRONT WHEEL MOTOR TESTING SHOWN

TRACTION WHEEL

MOTORS

M4

TOP PORT

M6

Procedure for Wheel Motor Efficiency Test:

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

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

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 the Adjustments Section).

5.Attach a heavy chain to the rear of the machine frame and an immovable object to prevent the machine from moving during testing.

WARNING

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

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

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

WARNING

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

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

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

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

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

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

2

1

Figure 22

CAUTION

Use extreme caution when performing test. The front tire on the ground will be trying to move the machine forward.

12.Slowly push traction pedal in forward direction until 1000 PSI is displayed on the pressure gauge.

13.Motor internal leakage will be shown on flow meter in GPM. Flow should be less than 1.5 GPM for the tested wheel motor.

14.If specifications are not met, the tested wheel motor needs 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 hydraulic lines connected. Block up both front wheels off the ground. Release parking brake so front wheels can turn.

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

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

D.Complete steps 9 to 13.

E.If specifications are not met, check the relief valve in the rear wheel motor for damage. If relief valve is not damaged, wheel motor needs to be repaired or replaced.

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

System

Hydraulic

High Pressure

Low Pressure

Return or Suction

Flow

Procedure for Reel Circuit Pressure Test:

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

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

3.Read Precautions for Hydraulic Testing.

WARNING

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

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 is in the mow position. Make sure reel speed knob is set for 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 +

50RPM). Engage the cutting units.

8.Watch pressure gauge carefully while mowing with the machine.

9.Reel circuit pressure should be about 600 PSI. 10.Disengage cutting units. Shut off engine.

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

2

1

Figure 23

System

Hydraulic

Procedure for Gear Pump (P1) Flow Test:

NOTE: Over a period of time, the gears and wear plates in the pump can wear down. A worn pump will by pass oil and make the pump less efficient. Eventually, enough oil loss will occur to cause the reel motors to stall under heavy cutting conditions. Continued operation with a worn, inefficient pump can generate excessive heat and cause damage to the seals and other components in the hydraulic system.

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

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

3.Read Precautions for Hydraulic Testing.

WARNING

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

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

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

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

7.Make sure the flow control valve on the tester is fully open.

8.Start engine and move throttle to full speed (2650 +

50RPM). Do not engage the cutting units.

IMPORTANT: In this test, the hydraulic tester is positioned before the manifold relief valve. Pump damage can occur if the oil flow is fully restricted by fully closing the tester flow control valve. Do not close tester valve fully when performing test.

9. Watch pressure gauge carefully while slowly closing the flow control valve until 2000 PSI is obtained. Verify with 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 2000 PSI cannot be obtained, check for restriction in the pump intake line. If line is not restricted, remove pump and re- pair or replace as necessary.

High Pressure

Low Pressure

Return or Suction

Flow

Procedure for Manifold Relief Valve (R1) Pressure Test:

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

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

3.Read Precautions for Hydraulic Testing.

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

WARNING

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

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

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

7.Make sure backlap knob on the hydraulic manifold is in the mow position. Make sure reel speed knob is set to maximum.

CAUTION

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

8.Start engine and move throttle to full speed (2650 +

50RPM). Engage the cutting units.

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

10.System pressure should be from 2700 to 3300 PSI as 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).

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

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

NOTE: On machines with Serial Numbers below 230000000, the initial reel motor in the cutting circuit is the left front and the final reel motor drives the rear cut- ting unit. On machines with Serial Numbers above 230000000, the initial motor is the rear reel motor and the final reel motor is the left front.

Procedure for Reel Motor Efficiency: Case Drain Test:

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

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

3.Read Precautions for Hydraulic Testing.

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

4.For the suspected bad motor, disconnect return hose from 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 control valve is fully open.

6.Make sure backlap knob on the hydraulic manifold is in 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. Put case drain hose into suitable container for collecting case drain leakage.

8.One person should sit on the seat and operate the machine while another person reads the tester and measures case drain leakage. Make sure traction pedal is in NEUTRAL. Start engine and move the throttle to full speed (2650 + 50 RPM).

CAUTION

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

9. Engage reels by positioning the cutting unit drive switch 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 the case drain hose into a 1 quart container graduated in ounces (1 liter container graduated in milliliters).

11. Stop cutting units by positioning the cutting unit drive switch 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 per minute (Divide number of milliliters collected by 250 to get liters per minute).

1

2

Figure 26

1

2

Figure 27

2

1

Figure 28

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

14.Disconnect tester from motor and hose. Reconnect hydraulic hoses.

15.Repeat test with other motors as needed.

System

Hydraulic

TO HYDRAULIC

MANIFOLD PORT (D1)

FROM HYDRAULIC

MANIFOLD PORT (M1)

IN

INITIAL

REEL MOTOR

BOTTOM

TOP

RIGHT FRONT

REEL MOTOR

BOTTOM

IN

FINAL

REEL MOTOR

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

NOTE: On machines with Serial Numbers below 230000000, the initial reel motor in the cutting circuit is the left front and the final reel motor drives the rear cut- ting unit. On machines with Serial Numbers above 230000000, the initial motor is the rear reel motor and the final reel motor is the left front.

Procedure for Cross???over Relief Pressures Test:

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

2.Make sure machine is parked on a level surface with the cutting units lowered and off. Make sure engine is off and parking brake is engaged. Back bedknives off all reels.

CAUTION

Operate all hydraulic controls to relieve system pressure 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 the mow 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 gauge between the motor inlet fitting and the disconnected hose.

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

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

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

CAUTION

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

CAUTION

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

8. Engage cutting units. System pressure should be from 1350 to 1650 PSI as the cross???over relief valve lifts.

1

2

1

Figure 31

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 unit and repeat test on other reels in mow direction.

IMPORTANT: Each reel motor has two cross???over relief valves. Test reliefs in the backlap direction only if a problem is expected. After testing cross??? over reliefs in the backlap direction, make sure the reel motor couplings are torqued (see Reel Motor Removal and Installation in the Service and Repairs section of Chapter 7 ??? Cutting Units).

10.Clean suspected reel motor hydraulic fittings. Dis- connect pressure inlet hose from fitting for the backlap direction 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 gauge between the motor fitting and the disconnected hose.

System

Hydraulic

12.Make sure backlap knob on the hydraulic manifold is in the backlap position.

13.One person should sit on the seat and operate the machine while another person reads the gauge. Start engine and move the throttle to full speed (2650 + 50

RPM).

CAUTION

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

CAUTION

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

14.Engage cutting units. System pressure should be from 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 test on 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).

This page is intentionally blank.

System

Hydraulic

Procedure for Lift and Steering Control Valve Relief Pressure Test:

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

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

3.Read Precautions for Hydraulic Testing.

WARNING

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

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 the discharge of the gear pump and the disconnected hose leading to the steering control valve.

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

7.Start engine and move throttle to full speed (2650 +

50RPM). Engage the cutting units.

CAUTION

Do not allow pressure to exceed 1500 PSI.

IMPORTANT: Hold steering wheel at full lock only long enough to get a system pressure reading. Holding the steering wheel against the stop for an extended period will damage the steering control valve.

8.Watch pressure gauge carefully while turning the steering wheel completely in one direction and holding at full lock briefly.

9.System pressure should be from 845 to 995 PSI as the relief valve lifts. Return steering wheel to the center position. If specification is not met, shut off engine and

replace relief valve in steering control valve (see Steer- ing Control Valve Service).

10.Disconnect T???connector with test gauge from gear pump (P2) fitting and hose. Reconnect hydraulic hose to pump.

Figure 32

System

Hydraulic

Procedure for Steering Control Valve Test:

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

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

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

3.Drive machine slowly in a figure eight on a flat level surface.

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

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

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

A.The steering wheel must go back immediately to the 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 faulty using the following procedure.

A.Park machine on a level surface with the cutting units lowered and off. Make sure engine is off and the parking 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.

WARNING

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

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

F.With the engine off, continue turning the steering wheel to the left (counterclockwise) with the steering cylinder fully extended. Observe the open fitting on the steering cylinder as the wheel is turned. If oil comes out of the fitting while turning the steering wheel to the left, the steering cylinder has internal leakage 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 cylinder tested acceptably, steering control requires service (see Steering Control Valve and Steering Control Valve Ser- vice).

System

Hydraulic

Adjustments

Adjust Traction Drive for Neutral

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

WARNING

One front wheel and rear wheel must be raised off the ground or the machine will move during adjustment. Make sure machine is supported so it will not accidentally fall injuring anyone under machine.

1

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

2

WARNING

Never adjust the relief valve with the hydraulic system pressurized. Hydraulic oil may spray out of the valve with the cap off. Personal injury may result. Always install the cap and tighten before pressurizing the system.

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

1

2

System

Hydraulic

Before Repair or Replacement of Components

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

2.Clean machine before disconnecting, removing, or disassembling any hydraulic components. Make sure hydraulic components, hoses connections, and fittings are cleaned thoroughly. Always keep in mind the need for cleanliness when working on hydraulic equipment.

WARNING

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

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

4.Put labels on disconnected hydraulic lines and hoses 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 aligned properly 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 system reservoir, and change oil filter if component failure was severe or system is contaminated (see Flush Hydraulic System).

2.Lubricate O???rings and seals with clean hydraulic oil before installing hydraulic components.

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

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 before reconnecting.

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

7.After disconnecting or replacing any hydraulic com- ponents, operate machine functions slowly until air is out 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 fluid looks milky or black when compared to clean oil.

1.Turn engine off and raise hood.

2.Disconnect hydraulic hose from filter head or remove hydraulic filter and let hydraulic fluid flow into drain pan. When hydraulic fluid stops draining, connect the 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 Hydraulic Fluid.

IMPORTANT: Use only recommended hydraulic fluids to fill hydraulic tank. Other fluids could cause system damage.

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

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

1

2

Figure 35

2

1

Figure 37

Replace Hydraulic Oil Filter

The hydraulic system filter must be changed initially, af- ter the first 10 hours of operation, and thereafter every 200 hours of operation or yearly, whichever comes first. The hydraulic oil must be changed every 400 hours of operation or yearly, whichever comes first.

Use a genuine Toro oil filter for replacement.

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

1.Position machine on a level surface, lower the cut- ting units, stop the engine, engage the parking brake and 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. Place drain pan under filter and remove filter. Properly dispose of filter.

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

5.Assure filter mounting area is clean. Screw filter on until gasket contacts mounting plate. Then tighten filter one???half turn.

1

2

Figure 38

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 to purge air from the system. Stop the engine and check for leaks.

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

Replace Traction Belt

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

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

CAUTION

Be careful when removing or applying tension from or to the torsion spring of the idler pulley. The spring is under heavy load and may cause personal injury.

3.Push down and forward on the spring end to unhook the 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.

3

1

6

2

Figure 39

6.Insert nut driver or small piece of pipe onto the end of the torsion spring of the idler pulley.

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

Check Hydraulic Lines and Hoses

WARNING

Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the 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 familiar with this type of injury. Gangrene may result from such an injury.

Check hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration and chemical deterioration. Make all necessary repairs before operating.

System

Hydraulic

Flush Hydraulic System

IMPORTANT: Flush the hydraulic system any time there is a severe component failure or the system is contaminated (oil appears milky, black, or contains metal particles).

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

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

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

WARNING

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

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

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

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

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

5.Inspect and clean hydraulic oil tank (see Hydraulic Tank 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 (see Change 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 + 50 RPM) for a minimum of 2 minutes. Increase engine speed to high idle (2650 + 50 RPM) for minimum of 1 minute under no load.

12.Raise and lower cutting units several times. Turn steering 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 amount of oil if necessary.

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

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

16.Assume normal operation and follow recommended maintenance intervals.

Charge Hydraulic System

NOTE: When initially starting the hydraulic system with new or rebuilt components such as motors, pumps, or lift cylinders, it is important that the hydraulic system be charged properly. Air must be purged from the system and its components to reduce the chance of damage.

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

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

off.

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 are in the neutral position. Turn ignition key switch; engage starter for fifteen (15) seconds to prime the traction and charge pumps.

8.Reconnect fuel stop solenoid lead.

WARNING

Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 ??? Safety.

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

10.Make sure traction pedal and lift control lever are in neutral. Start engine and run it at low idle of 1800 RPM. The charge pump should pick up oil and fill the hydraulic system. If there is no indication of fill in 30 seconds, stop the 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 moves in and out several times. If the cylinder rod does not move 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 to step 13.

13.Operate the traction pedal in the forward and reverse directions. The wheel off the floor should rotate in the proper direction.

A.If the wheel rotates in the wrong direction, stop engine, remove lines from rear of pump, and reverse the connections.

B.If the wheel rotates in the proper direction, stop engine 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 (see Check Interlock System in Chapter 5 ??? Electrical Sys- tems).

16.Lower machine to ground. Remove chocks from front wheel.

17.If the traction pump or a wheel motor was replaced or rebuilt, run the traction unit so all wheels turn slowly for 10 minutes.

18.Operate traction unit by gradually increasing its work load to full over a 10 minute period.

19.Stop the machine. Check hydraulic tank and fill if necessary. Check hydraulic components for leaks and tighten any loose connections.

System

Hydraulic

Hydraulic Tank Removal

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

2.Remove hydraulic tank from machine using Figures

40and 41 as guides.

Hydraulic Tank Inspection

1.Clean hydraulic tank and suction strainer with sol- vent.

2.Inspect hydraulic tank for leaks, cracks, or other damage.

Hydraulic Tank Installation

1

2

Figure 41

1. On early production machines, assemble suction strainer and fitting:

NOTE: When applying hydraulic thread sealant to the threads of fitting and the suction strainer, do not apply sealant to the first thread.

A.Apply hydraulic thread sealant to the threads of the hydraulic fitting (suction). Secure fitting to the suction strainer.

B.Apply hydraulic thread sealant to the threads of the suction strainer.

2.Apply anti???seize lubricant to four flange head screws. Secure hydraulic tank to machine with flange head screws. Torque flange head screws from 30 to 60 in???lb (3.4 to 6.8 N???m).

3.Using a wrench, turn suction strainer into tank port at least 1???1/2 to 2 full turns beyond finger tight.

4.Complete hydraulic tank installation using Figures

40and 41 as guides.

System

Hydraulic

Removal

WARNING

Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 ??? Safety.

1.Remove tire and wheel rim, wheel hub, and brake drum from the hydraulic motor. Remove brake assem- bly, brake bracket, and wheel shield from the frame (see Front Wheel and Brake Removal in Chapter 6 ??? Wheels, Brakes, and Miscellaneous).

2.Remove wheel motor from frame using Figure 42 as guide.

Installation

1.Install wheel motor to frame using Figure 42 as guide.

2.Install wheel shield, brake bracket, and brake as- sembly to the frame. Install brake drum, wheel hub, and tire and wheel rim to the hydraulic motor (see Front Wheel and Brake Installation in Chapter 6 ??? Wheels, Brakes, and Miscellaneous).

Rear Wheel Removal

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

WARNING

Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 ??? Safety.

2.Jack up rear of machine enough to allow the removal of the rear wheel.

3.Remove rear tire and rim assembly from machine.

4.Remove rear wheel motor with wheel hub attached from 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 hub puller or wheel motor with a hammer during wheel hub removal or installation. Hammering may cause damage to the wheel motor.

6.Using hub puller (see Special Tools), loosen wheel hub from wheel motor.

7.Remove wheel hub and motor from vise. Remove lock nut and hub from motor shaft. Locate and retrieve woodruff 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 to reel motor using marks made during the removal pro- cess to properly orientate fittings.

2.Thoroughly clean wheel motor shaft and wheel hub taper.

3.Clamp wheel hub in a vise. Install woodruff key into the 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 from vise.

4.Install wheel motor to the rear fork using Figure 43 as guide.

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 to

88N???m).

8.Make sure hydraulic tank is full. Add correct oil if nec- essary (see Operator???s Manual).

System

Hydraulic

NOTE: The three wheel motors used on the Reelmas- ter 3100--D are similar in construction but do have some differences. The right front and left front motors are the same basic design but the right side motor has a reverse timed manifold to allow correct rotation direction for for- ward and reverse. The end cover of the rear motor has a check valve consisting of a ball and spring, and both front motors lack this feature. The wheel motor shown in Figure 45 is a rear motor.

IMPORTANT: If a wheel motor failure occurred, refer to Traction Circuit (Closed Loop) Component Fail- ure in the General Information section for informa- tion regarding the importance of removing contamination from the traction circuit.

NOTE: Machines with serial numbers below 260999999 use a Ross TorqmotorTM in all three posi- tions. Machines with serial numbers above 270000000 use a Ross Torqmotor TM in the rear and two Parker Torq- motorsTM in the front positions. For repair of Ross wheel motors, see the Ross Torqmotor TM MG, MF, ME, and MJ Series Service Procedure at the end of this chapter. For repair of Parker wheel motors, see the Parker Torqmo- torTM Service Procedure (TC, TB, TE, TJ, TF, TG, TH and TL Series) at the end of this chapter.

This page is intentionally blank.

System

Hydraulic

Removal

NOTE: Note position of hydraulic fittings when remov- ing from the reel motors. Position is critical to properly reconnecting hydraulic hoses.

1. Remove reel motor from the cutting unit (see Reel Motor Removal and Installation in Chapter 7 ??? Cutting Units).

WARNING

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

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 to reel motor using marks made during the removal pro- cess to properly orientate fittings.

2.Install reel motor to the cutting unit (see Cutting Unit Removal and Installation in Chapter 7??? Cutting Units).

3.Install hydraulic hoses to reel motors using Figure 45 as a guide.

Disassembly (Fig. 46)

1.Make sure key is removed from the drive gear shaft.

2.Matchmark frontplate, body, and backplate to assure proper reassembly.

3.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 freeing the frontplate.

6.Remove alignment pin from the body. Remove drive gear and idler gear from the body.

7.Remove body from the backplate. Remove O--rings from the body and backplate.

8.Remove alignment pin from the backplate.

9.Remove retaining ring, oil seal, and backup washer from 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 complete unit. Both relief valve seals are sealed in place with thread sealant; do not remove them.

10.Remove plug, O--ring, shim, spring, and ball from the backplate.

Inspection (Fig. 46)

1. Remove all nicks and burrs from all parts with an emery cloth.

CAUTION

Use eye protection such as goggles when using compressed 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 diameter in the bushing area measures less than 0.748 in. (19.0 mm). A single gear may be replaced separately.

6.The drive gear and idler gear face should be free of excessive scoring and wear.

7.Replace drive gear or idler gear if gear width is less than 1.140 in. (29.96 mm).

8.Make sure that retaining rings are in the grooves on both sides of the gear for both the drive gear and idler gear.

9.Break sharp edges of gear teeth with emery cloth.

10.Replace backplate and frontplate if bushing inside diameters exceed 0.755 in. (19.2 mm). The bushings are not available as replacement items.

11. The face of the backplate and frontplate should be free of excessive scoring. Replace if scoring a depth of 0.0015 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. Hand tighten plug and then torque from 10 to 12 ft???lb (13.6 to 16.3 N???m).

2.Coat O???ring lightly with petroleum jelly and install in groove 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 until alignment pin is engaged.

5.Dip idler gear and drive gear into clean hydraulic oil and slip into front plate bushings.

6.Coat O???ring lightly with petroleum jelly and install in groove on the back plate.

7.Install alignment pin into back plate.

8.Align matchmarks and slip back plate over gear shafts onto body until alignment pin is engaged.

9.Hand tighten cap screws. Torque cap screws in a crisscross pattern from 25 to 28 ft???lb (33.9 to 38.0 N???m).

10.Place washer over the drive shaft into the front plate housing. Apply a liberal coat of hydraulic oil to the oil seal. Install oil seal over the drive shaft being careful not to cut the rubber seal lips.

11. Place 1???1/16 inch O.D. sleeve over the drive shaft and press in the oil seal until the retaining ring groove appears.

12.Press retaining ring into the housing using the sleeve until it seats in the groove.

System

Hydraulic

Disassembly (Fig. 46.1)

1.Plug motor ports and clean the outside of the motor thoroughly. After cleaning, remove plugs and drain any oil out of the motor.

2.Use a marker to make a diagonal line across the front flange and body for assembly purposes (Fig. 46.2).

IMPORTANT: Prevent damage when clamping the reel motor into a vise; clamp on the front flange only. Also, use a vise with soft jaws.

3. Clamp front flange of motor in a vise with soft jaws with the shaft end down.

MARKER LINE

Figure 46.2

4.Loosen cap screws from the rear cover.

5.Remove motor from the vise. Turn motor so that the shaft end is facing down. Remove cap screws.

6.Carefully remove body. Lift body straight up to re- move. Make sure the rear wear plate remains on the drive and idler gear shafts. Remove and discard O-- rings from the body. Locate and retrieve dowel pins.

IMPORTANT: Note position of the open and closed side of the wear plates before removing. Also, iden- tify wear plates (front and rear) with a marker for proper assembly.

7.Carefully remove rear wear plate, idler gear, drive shaft and front wear plate from the front flange.

8.Remove and discard back--up gaskets and pressure seals from wear plates.

9.Turn front flange over, with seal side up.

IMPORTANT: Make sure to not damage the front flange counter bore when removing the seals from the front flange.

10.Carefully remove dust seal, retaining ring, flange washer and shaft seal from the front flange (Fig. 46.3). Discard seals.

Inspection

1. Remove any nicks and burrs from all parts with emery cloth.

CAUTION

Use eye protection such as goggles when using compressed air.

2.Clean all parts with solvent. Dry all parts with com- pressed air.

3.Inspect drive gears and idler gears for the following (Fig. 46.4):

A.Gear shafts should be free of rough surfaces and excessive wear at bushing points and sealing areas. Scoring, rough surfaces or wear on gear shafts indi- cates need for replacement.

B.Gear teeth should be free of excessive scoring and wear. Any broken or nicked gear teeth must be replaced.

C.Inspect gear face edge for sharpness. Sharp edges of gears will mill into wear plates and, thus, must be replaced.

4.Inspect wear plates for the following:

A.Bearing areas should not have excessive wear or scoring.

B.Face of wear plates that are in contact with gears should be free of wear, roughness or scoring.

C.Thickness of wear plates should be equal.

5.Inspect front flange and rear cover for damage or wear.

Figure 46.3

3

2

1

Assembly (Fig. 46.1)

NOTE: When assembling the motor, check the marker line on each part to make sure the parts are properly aligned during assembly.

System

Hydraulic

1.Lubricate O--rings, pressure seals, back--up gaskets and wear plate grooves with a thin coat of petroleum jel- ly. Lubricate all other internal parts freely with clean hy- draulic oil.

2.Install new seals into front flange (Fig. 46.3):

A.Press shaft seal into front flange until it reaches the bottom of the bore.

B.Install flange washer into front flange and then install retaining ring into the groove of the front flange.

C.Install new dust seal into front flange.

3.Place front flange, seal side down, on a flat surface.

4.Install the pressure seals, flat side outward, into the grooves in the wear plates. Follow by carefully placing the backup gaskets, flat side outward, between the pressure seals and the grooves in the wear plate.

5.Apply a light coating of petroleum jelly to the exposed side of the front flange.

6.Lubricate the drive shaft with clean hydraulic oil. In- sert the drive end of the drive shaft through the wear plate with the pressure seal side down and the open side of the pressure seal pointing to the inlet side of the mo- tor. Carefully install shaft into front flange.

7.Lubricate the idler gear shaft with clean hydraulic oil. Install idler gear shaft into the remaining position in the front wear plate. Apply a light coating of clean hydraulic oil to gear faces.

8.Install rear wear plate with pressure seal side up and open side of the pressure seal pointing to the inlet side of the motor.

9.Apply a light coating of petroleum jelly to new O--ring and O--ring groove in the body. Install new O--ring to the body.

10.Install locating dowel pins in body. Align marker line on the body and front flange.

IMPORTANT: Do not dislodge seals during installa- tion.

11.Gently slide the body onto the assembly. Firm hand pressure should be sufficient to engage the dowel pins.

12.Install the four (4) cap screws with washers and hand tighten.

IMPORTANT: Prevent damage when clamping the reel motor in a vise; clamp on the front flange only. Also, use a vise with soft jaws.

13.Place front flange of the motor into a vise with soft jaws and alternately torque the cap screws 33 ft--lb (45 N--m).

14.Remove motor from vise.

15.Place a small amount of clean hydraulic oil in the inlet of the motor and rotate the drive shaft away from the inlet one revolution. If any binding is noted, disassemble the motor and check for assembly problems.

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System

Hydraulic

Oil Cooler

Removal

CAUTION

The radiator and oil cooler may be hot. To avoid possible burns, allow the engine and cooling systems to cool before working on the oil cooler.

1. Remove oil cooler using Figures 47 and 48 as guides.

Inspection

CAUTION

Use eye protection such as goggles when using compressed air.

1.Back flush oil cooler with cleaning solvent. After cool- er is clean, make sure all solvent is drained from the cooler.

2.Dry inside of oil cooler using compressed air in the opposite 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, cracked tubes, and excessive pitting of tubes.

Installation

1.If removed, apply hydraulic thread sealant to the barb fitting threads before installing.

2.Install oil cooler using Figures 47 and 48 as guides.

2

1

Figure 47

Figure 48

Removal

NOTE: The ports on the manifold are marked for easy

identification 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 the hydraulic lines and cartridge valves at each port loca- tion).

1. Remove hydraulic manifold from the machine using Figure 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 to manifold using marks made during the removal process to properly orientate fittings.

2.Install hydraulic manifold to the frame using Figure

49as guide.

NOTE: The ports on the hydraulic manifold are marked

for easy identification of components. Example: FC1 is the 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 each port location).

NOTE: The hydraulic manifold shown in Figure 51 uses several zero leak plugs. These plugs have a tapered sealing surface on the plug head that is designed to re- sist vibration induced plug loosening. The zero leak plugs also have an O--ring to provide a secondary seal. If zero leak plug removal is necessary, lightly rap the plug head using a punch and hammer before using an allen wrench to remove the plug: the impact will allow plug removal with less chance of damage to the socket head of the plug. When installing plugs into the manifold, torque plugs to the values identified in Figure 51.

Solenoid Operated, Relief and Logic Control Car- tridge Valves

1. Make sure the manifold is clean before removing the cartridge valve and seal kit.

Note: On manifold shown in Figure 50, solenoid coil has an O--ring on each side of the coil.

2. If solenoid valve is to be removed from manifold, re- move nut securing solenoid to the cartridge valve. Care- fully slide solenoid and O-rings (if equipped) off the valve.

IMPORTANT: Use care when removing cartridge valves. Slight bending or distortion of the stem tube can cause binding and malfunction. Make sure that deep well socket fully engages the valve base.

3.Remove cartridge valve from manifold with a deep well socket wrench. Remove seal kit from valve.

4.Visually inspect the manifold port and cartridge valve for damage to sealing surfaces, damaged threads, and contamination.

A.Contamination may cause valves to stick or hang up. Contamination can become lodged in small valve orifices or seal areas causing valve malfunction.

B.If valve sealing surfaces appear pitted or dam- aged, the hydraulic system may be overheating or there may be water in the system.

6.Reinstall the cartridge valve into the manifold:

A. Lubricate new O-rings and backup rings of seal kit with clean hydraulic oil and install on cartridge. The O-rings and backup rings must be arranged properly on the cartridge valve for proper operation and sealing.

IMPORTANT: Use care when installing cartridge valves. Slight bending or distortion of the stem tube can cause binding and malfunction. Make sure that deep well socket fully engages the valve base.

B.Lubricate threads on cartridge valve with clean hydraulic oil. Thread cartridge valve carefully into correct manifold port. The valve should go in easily without binding.

C.Torque cartridge valve using a deep well socket to specification shown in manifold illustration.

Note: On manifold shown in Figure 50, solenoid coil has an O--ring on each side of the coil. Also, on this man- ifold, apply Loctite 242 or equivalent to the threads of the valve 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 again or replace valve.

Rotary Cartridge Valves

CAUTION

Use eye protection such as goggles when using compressed air.

5. Cleaning cartridge valves:

A. For non--solenoid operated valves:

Submerge valve in clean mineral spirits to flush out contamination. If valve design allows, use a probe to push the internal spool in and out 20 to 30 times to flush out contamination. Particles as fine as talcum powder 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 and connect a 12 volt power source to the solenoid. While energized, flush out any contamination with a non- flammable aerosol brake cleaner. De-energize the solenoid. Repeat the flush while energized proce- dure 5 or 6 times. Particles as fine as talcum powder can affect the operation of high pressure hydraulic valves. Remove solenoid from cartridge.

1.Remove knob assembly (manifold shown in Fig. 50):

A.Unscrew and remove knob. Remove both jam nuts.

B.Slide off indicator plate being careful not to lose springs. Remove spring.

C.Loosen set screw and slide detent plate off the cartridge valve stem.

D.Remove locating plate with pin from the cartridge valve stem and manifold.

2.Remove rotary handle (manifold shown in Fig. 51) (Fig. 52):

A.Loosen two (2) set screws that secure handle cap. Remove screw and then lift handle cap from valve.

B.Locate and retrieve detent pin, compression spring, bushing and lip seal. The sleeve bearing should stay in the cap.

C.Loosen two (2) set screws that secure handle base to flow control valve and remove base.

3.Make sure manifold is clean before removing the rotary cartridge valve. Remove the valve and seal kit.

4.Visually inspect the manifold port and cartridge valve for damage to sealing surfaces, damaged threads, and contamination.

A.Contamination may cause valves to stick or hang up, it can become lodged in small valve orifices or seal areas causing valve malfunction.

B.If sealing surfaces appear pitted or damaged, the hydraulic system may be overheating or there may be water in the system.

CAUTION

Use eye protection such as goggles when using compressed air.

5.If necessary, clean cartridge valve using clean min- eral spirits. Submerge valve in clean mineral spirits to flush out contamination. Particles as fine as talcum pow- der can affect the operation of high pressure hydraulic valves. Clean and dry with compressed air.

6.Reinstall rotary cartridge valve into manifold port:

A. Lubricate new O-rings and backup rings of seal kit with clean hydraulic oil and install. The O-rings and backup rings of seal kit must be arranged prop- erly on the cartridge valve for proper operation and sealing.

IMPORTANT: Use care when installing cartridge valves. Slight bending or distortion of the stem tube can cause binding and malfunction. Make sure that deep well socket fully engages the valve base.

B.Lubricate threads on cartridge valve with clean hydraulic oil. Thread rotary cartridge valve carefully into the manifold port. The valve should go in easily without binding. Torque valve with deep well socket to specification shown in manifold illustration.

7.Install knob assembly (manifold shown in Fig. 50):

A.Install locating plate so that the pin seats into the locating hole.

B.Turn the threaded cartridge valve stem carefully clockwise until it stops.

C.Face detent plate counterbore down. Thread det- ent plate down onto the valve stem until it is stopped by the locating plate. Turn detent plate back counter- clockwise 1/4 turn.

D.Center one detent plate hole over a locating plate indentation. Drop a ball into each hole, then drop a spring into each hole.

E.On the 2-position directional valve cartridge, place indicator plate over the detent plate. Make sure the 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 45o.

G.While pushing down on the indicator plate and compressing the springs, thread down a jam nut. While tightening the set screw, tighten jam nut at the same time using a 7/16 - inch wrench.

H.Thread second jam nut all the way down the valve stem. Apply ???Loctite 242??? or equivalent to the valve stem threads. Screw knob all the way down until it contacts the upper jam nut.

I.On 2-position directional cartridge valve car-

tridge, turn knob counterclockwise so the arrow is 90o with the back of the manifold. Simultaneously

tighten upper jam nut and turn knob so it is tight and the arrow is pointing 45o to the right in line with the indicator plate.

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 knob so it is tight and the arrow is pointing at the number ???1??? on the locating plate.

Figure 52

System

Hydraulic

8. Install rotary handle (Fig. 52) (manifold shown in Fig.

51):

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 a light coating of grease to chamfer on top of base to ease seal installation.

B.Make sure that sleeve bearing is in handle cap. If necessary, press sleeve bearing into cap. Install lip seal on cap with seal lip facing down.

C.Place bushing onto cartridge valve stem. Use a small amount of grease to keep bushing toward the top of the valve stem.

D.Place compression spring and detent pin into handle cap. Use a small amount of grease to hold detent pin in place.

E.Make sure that flow control valve is closed by ro- tating valve stem fully clockwise. During handle installation, DO NOT rotate valve stem or speed ad- justment will be incorrect.

F.Press handle cap onto valve stem with arrow on cap pointing to number 9 on manifold. Make sure that detent pin and spring stay positioned in cap.

G.While pressing on the cap to keep the lip seal in place, 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 remain closed. Install screw to retain cap.

H.Make sure that alignment marks on cap and base are in line and that arrow on cap is pointing to number 1 on manifold. Tighten two (2) set screws to secure handle cap.

Mow/Backlap Spool (Fig. 53) (Reel Manifold Shown

in Fig. 51)

1.Remove spool from mow manifold:

A.Remove backlap switch from mow manifold be- fore removing mow/backlap spool. Remove dowel pin and ball from manifold port after switch is re- moved. Remove and discard O--ring from switch.

B.Remove lower retaining ring from mow/backlap spool. Raise mow/backlap spool to allow access to retaining ring on upper end of spool. Remove upper retaining ring.

C.Push spool down until O--ring and back--up ring are exposed on bottom of mow manifold. Remove lower O--ring and back--up ring from spool.

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 upper grooves on spool. Apply a light coating of grease to O--rings.

B.Carefully push spool down into mow manifold port until lower O--ring and back--up ring groove is exposed on bottom of manifold. Install lower O--ring and back--up ring to spool. Apply a light coating of grease to O--ring.

C.Carefully raise mow/backlap spool until upper re- taining ring groove on spool is exposed on top of manifold. Install upper retaining ring.

D.Push mow/backlap spool down and install lower retaining ring to spool.

E.If handle was removed from spool, position spool so 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).

Figure 53

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System

Hydraulic

Removal

WARNING

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

1.Remove control valve from the frame using Figures

54and 55 as guides.

2.If hydraulic fittings are to be removed from control valve, mark fitting orientation to allow correct assembly.

Installation

1.If hydraulic fittings were removed, install fittings to control valve using marks made during the removal pro- cess to properly orientate fittings.

2.Install control valve to the frame using Figures 54 and 55 as guides.

1

4

2

Figure 55

System

Hydraulic

13

4 12

3 10

Figure 57

System

Hydraulic

Disassembly

1.Plug all ports and clean the outside of the valve thor- oughly.

2.Remove spool cap and slide the spool assembly from 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 plunger from the valve body.

7.Remove solid plug, back???up washer, and O???ring from the opposite end of the plunger.

8.Remove plug and O???ring from the top of the valve body 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 poppet for wear. Replace as necessary.

4.Inspect seat, spacer, and bushing for wear. Replace as 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 or rags. Lint free cloth must be used to prevent lint from causing damage to the hydraulic system.

CAUTION

Use eye protection such as goggles when using compressed air.

1.Clean all metal parts with solvent and blow dry with compressed 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, spool spring, spacer, and retaining ring to the spool.

6.Lubricate spool liberally with clean hydraulic fluid and install into its proper bore.

7.Install spool cap into valve body. Torque cap from 20 to 25 ft???lb (27 to 34 N???m).

8.Install O???ring, back???up washer, and solid plug into the bore on the opposite end of the plunger. Torque plug from 30 to 35 ft???lb (41 to 48 N???m).

9.Lubricate plunger liberally with clean hydraulic fluid and install into its valve body bore.

10.Install new O???ring, seat, check poppet, and check spring into the plunger bore.

11. Install O???ring, back???up washer, and seat retaining plug 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 body next to the detent plug bore. Torque plug from 10 to 12 ft???lb (14 to 16 N???m).

13.Lubricate plunger detent, spring, and disc liberally with clean hydraulic fluid and install into its valve body bore.

14.Install O???ring and detent plug into its proper bore. Torque plug from 30 to 42 ft???lb (41 to 57 N???m).

This page is intentionally blank.

System

Hydraulic

Removal

WARNING

1

4

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

1.Remove control valve from the frame using Figures

58and 59 as guides.

2.If hydraulic fittings are to be removed from control valve, mark fitting orientation to allow correct assembly.

Installation

1.If hydraulic fittings were removed, install fittings to control valve using marks made during the removal pro- cess to properly orientate fittings.

2.Install control valve to the frame using Figures 58 and 59 as guides.

2

Figure 59

System

Hydraulic

15

13

System

Hydraulic

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 bore from 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 bore ends 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???ring from the opposite end of the plunger.

8.Remove plug and O???ring from the top of the valve body 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 is excessive, replace valve with new one.

2.Inspect springs and replace as necessary.

3.Inspect plunger, detent plunger, and check poppet for wear. Replace as necessary.

4.Inspect seat, spacer, and bushing for wear. Replace as 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 or rags. Lint may cause damage to the hydraulic sys- tem.

CAUTION

Use eye protection such as goggles when using compressed air.

1.Clean all metal parts with solvent and blow dry with compressed air.

2.Replace check poppets, O???rings, and back???up washers 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, spool spring, spacer, and retaining ring to the spool.

6.Lubricate spools liberally with clean hydraulic fluid and install into their proper bore.

7.Install spool caps into valve body. Torque caps from

20to 25 ft???lb (27 to 34 N???m).

8.Lubricate both plungers liberally with clean hydraulic fluid and install into their proper bore.

9.Install new O???rings, seats, check poppets, and check springs into the plunger bores.

10.Install O???rings, back???up washers, and seat retaining plugs into their plunger bores. Torque both plugs from 30 to 35 ft???lb (41 to 48 N???m).

11. Install new O???ring, back???up washer, and solid plug into the bore with the grooved plunger. Torque plug from 30 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 plug into the bore with the plunger. Torque plug from 30 to 35 ft???lb (41 to 48 N???m).

13.Install O???ring and plug into the top of the valve body next to the detent plug bore. Torque plug from 10 to 12 ft???lb (14 to 16 N???m).

14.Lubricate plunger detent, spring, and disc liberally with clean hydraulic fluid and install into its valve body bore.

15.Install O???ring and detent plug into its proper bore. Torque plug from 30 to 42 ft???lb (41 to 57 N???m).

This page is intentionally blank.

System

Hydraulic

Neutral Arm Assembly

Figure 63

System

Hydraulic

Piston Pump Removal (Fig. 62)

1.Remove traction belt from the pulley (see Replace Traction Belt).

2.Remove pulley from the taper lock bushing:

A. Remove cap screws securing pulley to the taper lock bushing.

IMPORTANT: Excessive or unequal pressure on the cap screws can break the bushing flange.

B. Insert cap screws into threaded removal holes of the pulley. Tighten screws progressively and evenly until the pulley is loose on the bushing. Remove pulley from the bushing.

CAUTION

The extension spring is under tension and may cause personal injury during removal. Use cau- tion when removing spring from the pump lever.

3. Remove neutral arm assembly from the piston pump as follows (Figs. 63 and 64):

A.Disconnect electrical connector from the micro switch (early models).

B.Remove extension spring from the cable support bracket and pump lever.

C.Disconnect traction control cable from the pump lever.

D.Remove both flange head screws securing the neutral bracket to the piston pump. Remove flange nut and flange head screw securing the neutral bracket to the pump mount plate.

E.Remove cap screw and flat washer securing the pump lever to the piston pump trunnion.

F.Separate pump lever from pump trunnion and neutral bracket from mount plate.

4.Drain hydraulic oil from hydraulic tank (see Change Hydraulic Fluid in this section).

WARNING

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

5. Disconnect all hydraulic hoses connected to the hy- draulic fittings on the piston and gear pumps. Allow hoses to drain into a suitable container.

CAUTION

Support piston and gear pumps when removing them from the pump support and pump mount plate to prevent them from falling and causing personal 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 washers securing the piston pump to the pump mount plate. Pull pumps from the machine.

8.Remove both socket head screws and flat washers securing gear pump to the piston pump. Separate gear pump and O???ring from the piston pump. Plug openings of 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 pump shaft.

11. If hydraulic fittings are to be removed from pump, mark fitting orientation to allow correct assembly.

Figure 64

2

1

Figure 65

Piston Pump Installation (Fig. 62)

1.If hydraulic fittings were removed, install fittings to pump using marks made during the removal process to properly orientate fittings.

2.Place key into pump shaft slot. Slide taper lock bush- ing onto the piston pump shaft with bushing flange to- ward pump housing.

3.Make sure that tapered surfaces of pulley and taper lock 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 to bushing and pulley.

5.Install O???rings and hydraulic fittings to their original positions 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 of the gear pump (Fig. 65). The gear pump suction fitting must be on the same side as the trunnion of the piston pump.

6. Remove plugs from the gear pump. Secure O???ring and gear pump to the piston pump with both flat washers and socket head screws. Torque fasteners from 27 to 31 ft???lb (37 to 42 N???m).

CAUTION

Support piston and gear pumps when installing them to the pump mount plate and pump support to 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, cap screws, and lock nuts. Do not fully tighten fasteners.

8.Secure piston pump to the pump support with both spacers, washers, and cap screws. Tighten fasteners securing the piston pump to the pump mount plat and pump 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 piston pump.

10.Install neutral arm assembly to the piston pump as follows (Figs. 63 and 64):

A.Position neutral bracket to the mount plate, and then pump lever to the pump trunnion.

B.Secure pump lever to the piston pump trunnion with flat washer and cap screw.

C.Secure neutral bracket to the pump mount plate with flange head screw and flange nut. Secure neu- tral bracket to the piston pump with both flange head screws.

D.Connect traction control cable to the pump lever.

CAUTION

The extension spring is under tension and may cause personal injury during installation. Use caution when installing the spring to the pump lever.

E.Install extension spring to the cable support bracket and pump lever.

F.Connect electrical connector to the micro switch (early models).

11. Install traction belt to the pump pulley (see Replace Traction Belt).

12.Using a straight edge across the lower face of the pump pulley, verify traction belt alignment across engine and pump pulleys. Slide pulley and taper lock bushing on pump shaft so that traction belt and straight edge are aligned 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) cap screws to a torque from 90 to 120 in???lb (10.2 to 13.6 N???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 traction Drive for Neutral).

System

Hydraulic

37.Bleed???off spring

38.O???ring

39.Cam plate insert

40.Shaft seal

41.O???ring

42.Coupler

43.Retaining ring

44.Washer

45.Charge relief spring

46.Charge relief poppet

47.Charge relief housing

48.O???ring

49.Cartridge

50.Shim (Model 70160???LAA???01)

51.Cover plate (70160???LAA???01)

52.Shaft seal (70160???LAA???01)

53.Retaining ring (70160???LAA???01)

NOTE: For repair of the piston pump, see the Eaton Medium Duty Piston Pump Repair Information Model 70160 Variable Displacement Piston Pump at the end of this chapter.

NOTE: Reelmaster 3100???D machines with serial num- bers below 90775 were equipped with an Eaton model 70160???LAA???01 piston pump. This pump included some differences in the trunnion shaft design (Items 50 ??? 53 in Figure 66).

IMPORTANT: If a piston pump failure occurred, re- fer to Traction Circuit (Closed Loop) Component Failure in the General Information section for infor- mation regarding the importance of removing con- tamination from the traction circuit.

4

5

8

7

3

9

10

6

1

Figure 67

4.Housing

System

Hydraulic

NOTE: The shims replace the crush ring in the piston pump cover plate on Reelmaster 3100???D machines with serial numbers above 90775. If the cam plate, cover plate, or housing is replaced during servicing of the pump, replace the original crush ring with shims to make sure of proper preload.

1.Remove crush ring from the cover plate. Measure thickness of crush ring.

2.Stack shims to the thickness of the crush ring.

3.Insert shims into the cover plate in the same location that the crush ring was removed from.

4.Assemble housing, cam plate, bearing cone, bear- ing cup, and cover plate (see Eaton Medium Duty Piston Pump Repair Information Model 70160 Variable Dis- placement Piston Pump at the end of this chapter).

5.Install washers and cap screws to the cover plate and 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 is achieved.

B.If torque is too high, remove shims and repeat steps 3 through 6 until the specified torque is achieved.

7.Complete assembly of the pump (see Eaton Repair Information at the end of this chapter).

Removal

WARNING

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

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 to cylinder using marks made during the removal process to properly orientate fittings.

2.Install hydraulic cylinder to the frame using Figure 68 as 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 lower frame.

C.The gap between the scissor frame and lower frame and the gap between the scissor frame and the sidewinder carrier must be equal distances with- in 0.060 inch (1.5 mm).

D.Tighten four cap screws and lock nuts.

System

Hydraulic

Removal

WARNING

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

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 column using Figures 70, 71, and 72 as guides.

2

1

3

5

8

7

Figure 71

5

3

6

System

Hydraulic

Removal

1.Remove muffler from the engine to gain access to the gear pump (see Muffler Removal in Chapter 3 ??? Ku- bota Diesel Engine).

2.Drain hydraulic oil from hydraulic tank (see Change Hydraulic Fluid in this section).

WARNING

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

3.Remove gear pump from the piston pump using Fig- ure 75 as guide.

4.If hydraulic fittings are to be removed from gear pump, mark fitting orientation to allow correct assembly.

Installation

1. If hydraulic fittings were removed, install fittings to motor using marks made during the removal process to properly orientate fittings.

IMPORTANT: Position gear pump to the piston pump so that the gear pump suction port is facing down.

2.Install gear pump to the piston pump using Figure 75 as guide.

3.Fill hydraulic tank with new hydraulic fluid (see Trac- tion Unit Operator???s Manual).

4.Install muffler to the engine (see Muffler Installation in Chapter 3 ??? Kubota Diesel Engine).

System

Hydraulic

Disassembly (Fig. 76)

1.Plug pump ports and clean the outside of the pump thoroughly. After cleaning, remove plugs and drain any oil out of the pump.

2.Make sure key is removed from the shaft of the drive gear.

3.Use a marker to make a diagonal line across the front plate, front body, adapter plate, rear body, and back plate for assembly purposes (Fig. 77).

IMPORTANT: Avoid using excessive clamping pressure on the pump housing to prevent distorting the housing.

4.Clamp pump in a vise with the the shaft end up.

5.Remove cap screws and washers from the front plate.

6.Remove pump from the vise. Turn pump so that the shaft end is facing down.

7.Remove back plate from the rear body by tapping with a soft face hammer. Remove and discard O???ring from the back plate.

8.Loosen rear body from the adapter plate by tapping with 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 closed side of the wear plate before removing from the adapter plate.

10.Remove wear plate and O???ring from the adapter plate.

11. Remove key from the drive gear shaft using a pencil magnet.

12.Remove O???ring from the adapter plate using an O??? ring pick.

13.Loosen adapter plate from the from the front body using a soft face hammer. Remove plate from the body. Turn plate over and remove O???ring using an O???ring pick.

14.Remove front pump body from the front plate.

15.Remove idler gear and drive gear from the front plate.

IMPORTANT: Note position of the open and closed side of the wear plate before removing from the front plate.

MARKER LINE

Figure 77

16.Remove wear plate from front plate. Remove O???ring from front plate using O???ring pick.

17.Remove back???up gasket and pressure seal from both wear plates.

IMPORTANT: Make sure not to damage the counter bore when removing the shaft seal from the front plate.

18.Remove shaft seal from the front plate using a drift punch.

IMPORTANT: Do not remove the plug from the front plate unless rotation of the pump is changed.

Inspection (Fig. 76)

1. Remove all nicks and burrs from all parts with an emery cloth.

CAUTION

Use eye protection such as goggles when using compressed air.

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 or broken teeth.

B.Gear shafts should be free of rough surfaces and excessive wear at bushing points and sealing areas.

C.Gear shaft diameter in the bushing area should not be less than 0.748 inch (19.0 mm).

System

Hydraulic

D.Gears should be free of excessive scoring and wear.

E.Make sure drive and idler gears have their snap rings in the grooves on each side.

F.Break sharp edges of gear teeth with emery cloth.

G.Gear width on the drive gear and front idler gear should not be less than 0.384 inch (9.75 mm). Gear width on the back gear and back idler gear should not be less than 0.244 inch (6.20 mm).

4.Inspect body for the following:

A.Gear pockets should be free of excessive scoring and 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 as follows:

A.Inside diameter of all bushings should not exceed 0.755 inch (19.2 mm).

B.Bushings in the front plate should extend 0.126 inch (3.20 mm) from the plate surface.

C.Bushings on the wear plate side of the adapter plate should extend 0.126 inch (3.20 mm) from the plate surface.

D.Scoring on the face of the back plate or the back plate side of the adapter plate should not exceed 0.0015 inch (0.038 mm).

E.The oil groove in the bushings of the front plate should be opposite each other and in line with with the dowel pin holes. The oil groove in the bushings of the back plate should be about 37o to the pressure port (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 properly aligned during reassembly.

1.Lubricate new O???rings, pressure seals, back???up gaskets, and wear plates with a thin coat of petroleum jelly. Lubricate all other internal parts freely with clean hydraulic oil.

2.Install O???ring into the groove of the front plate.

3.Lubricate gear pockets of front body with a thin coat of petroleum jelly. Place front body onto front plate so the half moon port cavities face away from the front plate.

2

2

1

Figure 78

2

2

1

Figure 79

4.Install new pressure seal and back???up gasket into both new wear plates. The flat section in the middle of the back???up gasket must face away from the wear plate inside 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 on the 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 so that the gears set inside the gear pockets.

7.Install new O???ring into the groove of the adapter plate 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 the adapter 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 body with the pressure seal and back???up gasket against the adapter plate. Make sure mid section cut???away of the wear plate is on the suction side of the pump.

13.Lubricate back gear with clean hydraulic oil. Install gear onto the drive gear shaft and key.

14.Lubricate back idler gear with clean hydraulic oil. Install idler gear into the gear pocket of back body and the adapter plate.

15.Install new O???ring into the groove of the back plate.

16.Align marker line on the back plate and body. Install back plate onto the body and gear shafts.

17.Secure pump together with cap screws and new washers on cap screws external of the flange cavity. Torque cap screws in a criss???cross pattern from 25 to 28 ft???lb (34 to 38 N???m).

1.90o hydraulic fitting

2.Hydraulic cylinder

3.Carrier assembly

4.Flange nut

5.Flange head screw

6.Hydraulic hose

7.Centering wire

8.Hydraulic hose

9.Hydraulic hose

10.Hydraulic hose

11.Clamp bracket (model 03200)

11.Slide bracket (model 03201)

12.Flange nut

13.Plastic slide

14.Flange head screw

Removal

1.Remove front lift cylinder from the frame and lift arm using 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 to cylinder using marks made during the removal process to properly orientate fittings.

IMPORTANT: With lift arms raised fully, hydraulic hoses should be routed as shown in Figure 81. Make sure clearance between hydraulic hose and lift arm is from 0.040 to 0.120 inches (1.0 to 3.0 mm).

2.Install front lift cylinder to the frame and lift arm using Figure 80 as guide.

3.Adjust front lift arm (see Adjust Front Lift Arm in Chapter 7 ??? Cutting Units).

2 3

1

Removal

1.Remove rear lift cylinder from the frame and lift arm using 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 lift cylinder using marks made during the removal process to properly orientate fittings.

2.Install rear lift cylinder to the frame and lift arm using Figure 82 as guide.

3.Adjust rear lift arm (see Adjust Rear Lift Arm in Chap- ter 7 ??? Cutting Units).

Disassembly

1. Remove oil from lift cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder.

IMPORTANT: Prevent damage when clamping the hydraulic cylinder into a vise; clamp on the clevis only.

2.Mount lift cylinder in a vice. Remove internal collar with a spanner wrench.

3.Extract shaft, head, and piston by carefully twisting and pulling on the shaft.

IMPORTANT: Do not clamp vise jaws against the shaft surface. Protect shaft surface before 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 the shaft. 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 from the head.

Assembly

1.Make sure all parts are clean before reassembly.

2.Coat new O???rings, Uni???rings, rod seal, back???up ring, 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 dust seal to the head.

IMPORTANT: Do not clamp vise jaws against the shaft surface. Protect shaft surface before mount- ing in a vice.

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 seal onto shaft and into head.

C.Install piston and nut onto the shaft. Torque nut from 24 to 30 ft???lb (33 to 41 N???m).

D.Remove shaft from the vise.

IMPORTANT: Prevent damage when clamping the hydraulic cylinder into a vise; clamp on the clevis only.

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 into the barrel being careful not to damage the seals.

6.Secure head in the barrel with internal collar using a spanner wrench. Tighten collar until snug and the outer end of the collar is flush with end of the barrel.

System

Hydraulic

Removal

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

NOTE: The rear tire must be removed to allow sufficient clearance to remove the steering cylinder from the ma- chine.

WARNING

Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 ??? Safety.

2.Jack or lift rear wheel off the ground.

3.Remove rear wheel from the drive studs and wheel hub.

4.Thoroughly clean hydraulic hose ends and fittings on steering cylinder to prevent hydraulic system contami- nation.

WARNING

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

5.Remove steering cylinder from the frame and rear fork using Figure 84 as guide.

6.If hydraulic fittings are to be removed from steering cylinder, 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 during the 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 ball joints to machine, tighten the first jam nut from 65 to 85 ft???lb (88 to 115 N???m), then tighten the second jam nut to the same specification.

3.Mount rear wheel to the machine with four (4) lug nuts. Lower machine to the ground. Torque lug nuts in a 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).

2

1. Steering cylinder

2

1.Steering cylinder

2.Rear fork

1

Figure 85

2. Jam nuts

3

1

Figure 86

3. Jam nuts

System

Hydraulic

Hydraulic System (Rev. C)

Disassembly

1. Remove oil from the steering cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder.

IMPORTANT: Prevent damage when clamping the hydraulic cylinder into a vise; clamp on the clevis only.

2.Mount clevis end of steering cylinder in a vice. Re- move retaining ring.

3.Extract shaft, head, and piston by carefully twisting and pulling on the shaft.

IMPORTANT: Do not clamp vise jaws against the shaft surface. Protect shaft surface before 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 the shaft. 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 from the head.

Reassembly

1.Make sure all parts are clean before reassembly.

2.Coat new O???rings, Uni???ring, rod seal, and back???up ring 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 the head.

IMPORTANT: Do not clamp vise jaws against the shaft surface. Protect shaft surface before mount- ing in a vice.

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 piston and lock nut onto the shaft. Torque nut from 24 to 30 ft???lb (33 to 41 N???m).

C.Remove shaft from the vise.

IMPORTANT: Prevent damage when clamping the hydraulic cylinder into a vise; clamp on the clevis only.

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 into the barrel being careful not to damage the seals.

6.Secure head in the barrel with the retaining ring.

System

Hydraulic

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 (Serial Numbers 240000001

to 270999999) . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Harness Diagram (Serial Numbers 240000001

to 270999999) . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Wiring Diagram (Serial Numbers 280000001

and Up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Harness Diagram (Serial Numbers 280000001

and Up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.1 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

System

Electrical

.(Rev Systems Electrical

R/BK

R/BK

Electrical

C)

2 ??? 5 Page

(REELS OFF)

OR

1

D1

2

Diagrams and Schematics

R

30

87

BK

OR

GLOW PLUGS

D???3100 Reelmaster

85 86

PK

All relays and solenoids are shown as de???energized.

Serial Numbers 90101 to 90150

D???3100 Reelmaster

3 ??? 5 Page

C) .(Rev Systems Electrical

Power Current

Control Current

Indication Current

Logic Direction

Serial Numbers 90101 to 90150

Electrical

System

C) .(Rev Systems Electrical

4 ??? 5 Page

D???3100 Reelmaster

Power Current

Control Current

Indication Current

Logic Direction

Serial Numbers 90101 to 90150

D???3100 Reelmaster

5 ??? 5 Page

C) .(Rev Systems Electrical

Power Current

Control Current

Indication Current

Logic Direction

Serial Numbers 90101 to 90150

Electrical

System

C) .(Rev Systems Electrical

6 ??? 5 Page

D???3100 Reelmaster

Power Current

Control Current

Indication Current

Logic Direction

Serial Numbers 90101 to 90150

D???3100 Reelmaster

7 ??? 5 Page

C) .(Rev Systems Electrical

GLOW RELAY

T

BK

Reelmaster 3100???D

Run Circuits (Backlap)

Power Current

Control Current

Indication Current

Logic Direction

Serial Numbers 90101 to 90150

C) .(Rev Systems Electrical

8 ??? 5 Page

D???3100 Reelmaster

FUSE BLOCK

P16

1 2 3 4 5 6 7 8

W2 W4 W6 W9

W4

W5 W7 W14

W3

W8

W15

W16

W5

W17

W18

W64

W13

W20

W21

W16

W23

W25

W62

DIODE D2

P9

HIGH TEMP

SHUT DOWN

RELAY

Wiring Diagram

Serial Numbers 90101 to 90150

Reelmaster 3100???D

Supplement to Wiring Diagram

Serial Numbers 90101 to 90150

System

Electrical

C) .(Rev Systems Electrical

10 ??? 5 Page

ALTERNATOR

R/BK

(???)(+)

D???3100 Reelmaster

STOP ???????????? NONE

RUN ???????????? B+I+A; X+Y

START ????????? B+I+S

D???3100 Reelmaster

11 ??? 5 Page

C) .(Rev Systems Electrical

R

(HOLD)

Electrical

System

C) .(Rev Systems Electrical

12 ??? 5 Page

D???3100 Reelmaster

D???3100 Reelmaster

13 ??? 5 Page

C) .(Rev Systems Electrical

C) .(Rev Systems Electrical

14 ??? 5 Page

D???3100 Reelmaster

GLOW PLUG

CONTROLERSerial Numbers 90151 to 230999999

D???3100 Reelmaster

15 ??? 5 Page

C) .(Rev Systems Electrical

C) .(Rev Systems Electrical

16 ??? 5 Page

D???3100 Reelmaster

Serial Numbers 90151 to 230999999

WIRE IDENTIFICATION

WIRE IDENTIFICATION

Reelmaster 3100???D

Supplement to Wiring Diagram

Serial Numbers 90151 to 230999999

System

Electrical

C) .(Rev Systems Electrical

18 ??? 5 Page

J2

P1

GLOW

RELAY

REEL ON/OFF

SWITCH

P12

D???3100 Reelmaster

Reelmaster 3100???D

Harness Diagram

Serial Numbers 90151 to 230999999

D???3100 Reelmaster

19 ??? 5 Page

C) .(Rev Systems Electrical

B A

S Y

I X

1F 1 15 A

OR

1F 2 10 A

BU

FRAME GROUND

STOP ???????????? NONE RUN ???????????? B+I+A; X+Y START ????????? B+I+S

IGNITION SW

OFF RUN START

B I Y

A

S T

X Y

VIO

2???H IGN. SW. ???S???

Reelmaster 3100???D

Electrical Schematic

All relays and solenoids are shown as de???energized.

Serial Numbers 240000001 and up

(SERIAL NUMBERS FROM 240000001 TO 270999999)

WHITE

PINK

ORANGE

BLACK

BLACK

VIOLET

ORANGE

BLACK

RED/BLACK

BLACK

BLACK

BLACK

BLACK

BLUE/WHITE

BLACK

GREEN

BLACK

BLUE

GREEN

RED/BLACK

Reelmaster 3100--D Wiring Diagram Serial Numbers 240000001 to 270999999

PINK

WHITE

ORANGE

BLACK

BLACK

VIOLET

ORANGE

BLACK

RED/BLACK

BLACK

BLACK

BLACK

BLACK

BLUE/WHITE

BLACK

GREEN

BLACK

BLUE

GREEN

RED/BLACK

Serial Numbers 280000001 and Up

Wiring Diagram

Reelmaster 3100--D

Figure 1

Skin???Over Grease

Special non???conductive grease (Toro Part No. 505???165) which forms a light protective skin which helps waterproof electrical switches and contacts.

Figure 2

System

Electrical

Troubleshooting

CAUTION

Remove all jewelry, especially rings and watches, before doing any electrical trouble- shooting or testing. Disconnect the battery cables unless the test requires battery voltage.

For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components 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 troubleshooting and safety.

Use a multimeter to measure the voltage between the battery terminals.

Set multimeter to the DC volts setting. The battery should be at a temperature of 60 to 100oF (16 to 38oC). The ignition key should be off and all accessories turned off. Connect the positive (+) meter lead to the positive battery post and the negative (???) meter lead the the neg- ative battery post.

NOTE: This test provides a relative condition of the bat- tery. Load testing of the battery will provide additional and more accurate information.

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 system has an output, but not its capacity.

Tool required: Digital multimeter set to DC volts.

Test instructions: Connect the positive (+) multimeter lead to the positive battery post and the negative (???) multimeter lead to the negative battery post. Keep the test leads connected to the battery posts and record the battery voltage.

NOTE: Upon starting the engine, the battery voltage will drop and then should increase once the engine is running.

NOTE: Depending upon the condition of the battery charge and battery temperature, the charging system voltage will increase at different rates as the battery charges.

Start the engine and run at high idle (2650 RPM). Allow the battery to charge for at least 3 minutes. Record the battery voltage.

After running the engine for at least 3 minutes, battery voltage 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.

Glow Plug System Test

This is a fast, simple test that can help to determine the integrity and operation of the Reelmaster 3100???D glow plug system. The test should be run anytime hard start- ing (cold engine) is encountered on a diesel engine equipped with a glow plug system.

Tool(s) required: Digital multimeter and/or inductive Ammeter (AC/DC Current Transducer).

Test instructions: Properly connect the ammeter to the digital multimeter (refer to manufacturers??? instructions).

Set the multimeter to the correct scale. With the ignition switch in the OFF position, place the ammeter pickup around the main glow plug power supply wire and read the meter prior to activating the glow plug system. Adjust the meter to read zero (if applicable). Activate the glow plug system (see Traction Unit Operator???s Manual) and record the multimeter results.

The Reelmaster 3100???D glow plug system should have a reading of approximately 27 Amps.

Check Operation of Interlock Switches

CAUTION

Do not disconnect safety switches. They are for the operator???s protection. Check the operation of the interlock switches daily for proper operation. Replace any malfunctioning switches before op- erating the machine.

Note: The machine is equipped with an interlock switch on the parking brake. The engine will stop if the traction pedal is depressed with the parking brake en- gaged.

1. Make sure all bystanders are away from the area of operation. Keep hands and feet away from cutting units.

2.With operator on the seat, the engine must not start with either the reel switch engaged or the traction pedal engaged. Correct problem if not operating properly.

3.With operator on the seat, the traction pedal in neu- tral, the parking brake off, and the reel switch in the OFF position, the engine should start. Lift off seat and slowly depress traction pedal, the engine should stop in one to three seconds. Correct problem if not operating proper- ly.

4.With operator on the seat, the engine running, the reel transport slide in mow, and the reel switch in the ON position, lower cutting units. Reels should come on. Pull back on the lift lever, the reels should stop when fully raised. Correct problem if not operating properly.

Component Testing

For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before doing a continuity check).

NOTE: For more component testing information, see the Kubota Workshop Manual, Diesel Engine, 05 Se- ries.

CAUTION

When testing electrical components for continu- ity with a multimeter (ohms setting), make sure that 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. The circuitry of the ignition switch is shown in the chart. With the 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.

Y

B

S

I

A

X

Figure 3

Glow Relay

The glow relay is attached to the radiator assembly. When energized, the glow relay allows electrical current to the engine glow plugs.

Two styles of glow relays have been used on the Reel- master 3100???D. On machines with serial numbers be- low 240000000, two of the four relay connections are secured 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 85 with a multimeter (ohms setting):

A.On machines with serial numbers below 240000000, resistance should be from 41 to 51 ohms.

B.On machines with serial numbers above 240000000, resistance should be approximately 72 ohms.

2.Connect multimeter (ohms setting) leads to relay ter- minals 30 and 87. Ground terminal 86 and apply +12 VDC to terminal 85. The relay should make and break continuity 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 7

These relays are located under the control panel on ma- chines with Serial Numbers below 240000000.

1.Verify coil resistance between terminals 86 and 85 with a multimeter (ohms setting). Resistance should be from 80 to 90 ohms. There should be continuity between terminals 87A and 30.

2.Connect multimeter (ohms setting) leads to relay ter- minals 30 and 87. Ground terminal 86 and apply +12 VDC to terminal 85. The relay should make and break continuity between terminals 30 and 87 as 12 VDC is ap- plied and removed from terminal 85.

3.Disconnect voltage from terminal 85 and multimeter lead from terminal 87.

4.Connect multimeter (ohms setting) lead to relay ter- minal 30 and 87A. Apply +12 VDC to terminal 85. The relay should make and break continuity between termi- nals 30 and 87A as 12 VDC is applied and removed from terminal 85.

5.Disconnect voltage and multimeter leads from the relay terminals.

86 87A 87

87

87A

8685

30

8530

TOP VIEW

Figure 8

System

Electrical

Hour Meter

1.Connect the positive (+) terminal of a 12 VDC source to the positive terminal of the hour meter.

2.Connect the negative (???) terminal of the voltage source to the other terminal of the hour meter.

3.The hour meter should move a 1/10 of an hour in six minutes.

4.Disconnect the voltage source from the hour meter.

+

BACK

Figure 9

Reel Drive Solenoid

Note: Prior to taking small resistance readings with a digital multimeter, short the test leads together. The me- ter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal re- sistance of the meter and test leads. Subtract this value from from the measured value of the component you are testing.

1.Make sure engine is off. Disconnect solenoid valve electrical connector.

2.Apply 12VDC source directly to the solenoid. Listen for solenoid to switch on.

3.Remove 12VDC source from the solenoid. Listen for solenoid 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 of valve 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 cause the valve to malfunction.

6.Reconnect electrical connector to the solenoid.

2

1

Figure 10

The high temperature warning and shut down switches are located on the water pump, which is located on the rear end of the engine block. The high temperature shut- down switch is on the alternator side of the engine (Fig. 11).

CAUTION

Make sure engine is cool before removing the temperature switch.

1.Lower coolant level in the engine and remove the temperature switch.

2.Put switch in a container of oil with a thermometer and slowly heat the oil (Fig. 12).

2

1

CAUTION

Handle the hot oil with extreme care to prevent personal injury or fire.

Note: On units with serial numbers from 90101 to 90150, the high temperature shutdown switch settings are the same as the high temperature warning switch below.

3. Check continuity of the switch with a multimeter (ohms setting).

A.The high temperature warning switch is normally open and should close between 216 to 226oF (102 to 108oC).

B.The high temperature shutdown switch is normal- ly open and should close between 225 to 235oF (107 to 113oC).

Figure 12

4.Allow oil to cool while observing temperature.

A.The high temperature warning switch should open at about 208oF (98oC).

B.The high temperature shutdown switch should open at about 219oF (104oC).

5.Replace switch if necessary.

System

Electrical

Diode Assemblies

The diode D1 and D2 provide logic for the interlock switches. Diode D3 is used for circuit protection from in- ductive voltage spikes when the interlock relay is deen- ergized. Machines equipped with the standard control module (serial numbers above 240000000) use only one diode.

Two types of diodes have been used on the Reelmaster 3100???D:

1.On early production machines, the diodes are lo- cated within the main wiring harness that lies under the hydraulic tank and control console (Fig. 13).

2.Later production machines use diodes that plug into the wiring harness (Fig. 14). Location of the diodes is un- der the control console.

Testing

The diodes can be individually tested using a digital multimeter (ohms setting) and the tables below.

1. Diodes located within the main harness (Fig. 13):

2

3

1

Figure 14

Note: Individual light bulbs can be tested by removing them from the lighting cluster and applying 12 VDC to their wiring terminals.

Oil Pressure Light

The oil pressure light should come on when the ignition switch is in the ON position with the engine not running. Also, it should light with the engine running when the oil pressure drops below 4 PSI (0.3 kg/cm2).

1.Disconnect green/blue wire from the oil pressure switch.

2.Ground green/blue wire to the engine block.

3.Turn the ignition switch to ON; the light should come

on.

4.Turn the ignition switch to OFF. Connect green/blue wire 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 temperature shutdown switch and relay stop the engine.

Units with Serial Numbers from 90150 to 230999999

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 is above 230oF (110oC).

Glow Light

The glow light comes on when the ignition switch is placed in RUN prior to placing the ignition switch in START, and stays lit for 10 seconds while left in RUN.

Battery Light

The battery light should come on when the ignition switch is in ON with the engine not running, or with an improperly operating charging circuit while the engine is running.

1.Turn ignition switch to ON; the light should come on.

2.Turn ignition switch to OFF.

A F

B E

A B C D E F

BACK

Figure 15

C

B GLOW

E BATT

D

F OIL

System

Electrical

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 improperly operating charging circuit while the engine is running.

Engine Oil Pressure Light

The engine oil pressure light should come on when the ignition switch is in the ON position with the engine not running. 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 the wire 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 on indicating 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 warning light should come on.

To test the high temperature warning light and circuit wir- ing, turn ignition switch to the ON position and ground the wire attached to high temperature sender located on the engine water pump housing (see Temperature Sender in this Chapter). The high temperature warning light should illuminate.

Glow Plug Indicator Light

The glow plug light should come on when the ignition switch is placed in the ON position prior to placing the ignition switch in START. The light should stay lit for approximately 6 seconds while the ignition switch is left in the ON position.

4

1

Figure 17

Figure 18

Fuel Pump

The fuel pump is attached to the frame just outboard of the fuel injection pump.

Operational Test

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

2.Disconnect electrical connector from the fuel stop solenoid to prevent the engine from firing.

3.Disconnect fuel hose (pump discharge) from the fuel filter.

4.Make sure fuel hoses attached to the fuel pump are free of obstructions.

5.Place fuel hose (pump discharge) into a large, grad- uated cylinder sufficient enough to collect 1 liter (33.8 fluid ounces).

IMPORTANT: When testing the fuel pump, DO NOT turn ignition switch to START.

Note: Machines that are equipped with a Biodiesel Conversion Kit will have the same fuel pump as ma- chines with serial numbers above 280000000.

6.Collect fuel in the graduated cylinder by turning igni- tion switch to the RUN position. Allow pump to run for time listed below, then return switch to OFF.

A.For machines with serial numbers below 230999999, the amount of fuel collected in the grad- uated cylinder should be approximately 6.8 fl oz (200 ml) after thirty (30) seconds.

B.For machines with serial numbers from 240000000 to 270999999, the amount of fuel col- lected in the graduated cylinder should be approxi- mately 11.8 fl oz (350 ml) after thirty (30) seconds.

C.For machines with serial numbers above 280000000, the amount of fuel collected in the grad- uated cylinder should be approximately 16 fl oz (475 ml) after fifteen (15) seconds.

7.Replace fuel pump as necessary. Install fuel hose (pump discharge) to the fuel filter.

8.Reconnect electrical connector to the fuel stop sole- noid.

9.Prime fuel system.

2

4

1

3

Figure 19

Fuel Pump Specifications

Fuel pump specifications for machines with serial num- bers below 240000000 are as follows:

Fuel pump specifications for machines with serial num- bers from 240000000 to 270999999 are as follows:

Fuel pump specifications for machines with serial num- bers above 280000000 are as follows:

System

Electrical

The fuel stop solenoid must be energized for the engine to 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 switch is 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 fuel supply 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 chapter when troubleshooting the fuel stop solenoid.

Testing

NOTE: Prior to taking small resistance readings with a digital multimeter, short the test leads together. The me- ter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal re- sistance of the meter and test leads. Subtract this value from 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 the pin of the black wire and the other test lead to the pin of the white wire (Fig. 21). The resistance of the pull coil should be about 0.33 ohms.

3.Using a digital multimeter, touch one test lead to the pin of the black wire and the other test lead to the pin of the red wire (Fig. 21). The resistance of the hold coil should be about 12.2 ohms.

2

1

Figure 20

6

3

5 4

2

1

Figure 21

The fuel stop solenoid used on the Reelmaster 3100???D must 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 switch is 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 fuel supply to the engine causing the engine to stop running. The fuel stop solenoid is grounded through the solenoid housing.

NOTE: Refer to Chapter 8 ??? Electrical Diagrams when troubleshooting the fuel stop solenoid.

In Place Testing

NOTE: Prior to taking small resistance readings with a digital multimeter, short the test leads together. The me- ter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal re- sistance of the meter and test leads. Subtract this value from 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 the pull coil terminal and the other test lead to the fuel stop solenoid frame (ground) (Fig. 23). The resistance of the pull coil should be less than 1 ohm (but not zero).

3.Using a digital multimeter, touch one test lead to the hold coil terminal and the other test lead to the fuel stop solenoid frame (ground) (Fig. 23). The resistance of the hold coil should be approximately 15 ohms.

1

2

Figure 22

Figure 23

System

Electrical

Glow Controller

The controller is located under the right lower corner of the instrument panel.

Note: Refer to Electrical Schematics and Diagrams at the beginning of the chapter when troubleshooting the controller.

Controller Operation

1. When the ignition switch is placed in the RUN posi- tion, the controller energizes the glow plugs and lights up the glow lamp for 10 seconds.

Note: On units with serial numbers from 90101 to 90150, the glow controller is not in use when the ignition switch 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 held in START and the glow lamp will not light.

3.When the ignition switch is released from START to RUN, the glow plugs will deenergize and the glow lamp will remain off.

Controller Checks

1.Make sure there is power from the battery.

2.Disconnect electrical connector to the run solenoid to prevent the engine from starting.

3.Place ignition switch in the RUN position. Verify the following 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 plugs deenergize after 10 seconds.

Note: On units with serial numbers from 90101 to 90150, the glow controller is not in use when the ignition switch 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 ignition switch to the controller and perform step 4 again (see Electrical Schematics and Diagrams in this chapter).

2

3 6

2 5

1 4

1

3

Figure 24

2.Top view

4.Place ignition switch in the START position. Verify the 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 power to terminal 1 exists and any of the other conditions in step 4 are not met:

A.Verify continuity of the circuitry from the battery to the glow relay and glow plugs (see Electrical Sche- matics and Diagrams in this chapter).

B.Verify continuity of the circuitry from the battery to ignition switch, glow controller, glow lamp, glow relay, and ground (see Electrical Schematics and Diagrams 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 Numbers above 240000000 are equipped with a Standard Control Module to monitor and control electrical components re- quired for safe operation. This Module is attached to the back 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 drive solenoid), 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 an external computer or hand held device, can not be re??? programmed, and does not record intermittent fault data.

The Standard Control Module can be used to check op- eration of machine switches by monitoring the LED of the module. If a Module LED does not illuminate (e.g. the in seat input LED does not illuminate with the seat occu- pied and the ignition switch in the run position), testing of 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.

Battery Storage

If the machine will be stored for more than 30 days:

1.Remove the battery and charge it fully (see Battery Service).

2.Either store battery on a shelf or on the machine.

3.Leave cables disconnected if the battery is stored on the 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 sure it 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 the machine is stored in a location where temperatures are extremely high, the battery will run down more rapidly than if the machine is stored in a location where temper- atures are cool.

WARNING

Wear safety goggles and rubber gloves when working with electrolyte. Charge battery in a well ventilated place so gasses produced while charging can dissipate. Since the gases are explosive, keep open flames and electrical sparks 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 or from battery posts.

2. Keep top of battery clean by washing periodically with a brush dipped in ammonia or bicarbonate of soda solution. Flush top surface with water after cleaning. Do not remove the fill cap while cleaning.

3. Battery cables must be tight on terminals to provide good electrical contact.

WARNING

Connecting cables to the wrong post could re- sult in personal injury and/or damage to the electrical system.

4.If corrosion occurs at terminals, disconnect cables. Always disconnect negative (???) cable first. Scrape clamps and terminals separately. Reconnect cables with 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. With regular and proper service, battery life can be extend. Additionally, battery and electrical component failure can be prevented.

CAUTION

When working with batteries, use extreme cau- tion to avoid splashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes. Always wear safety goggles and a face shield when working with batteries.

Electrolyte Specific Gravity

Fully charged: 1.265 corrected to 80oF (26.7oC)

Discharged: less than 1.240

Battery Specifications

BCI 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)

Removal (Fig. 26 and 27)

IMPORTANT: Be careful not to damage terminal posts 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 remove cable from battery. This should prevent short circuiting the battery, other components, or the operators hands.

3.Loosen nut on positive (+) cable post and remove cable from battery.

4.Make sure battery vent caps are on tightly.

5.Remove battery from the battery compartment to a service 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 or leaking.

B.Check battery terminal posts for corrosion. Use wire brush to clean corrosion from posts.

2

1

Figure 26

1

2

Figure 27

IMPORTANT: Before cleaning the battery, tape or block vent holes to the filler caps and make sure the caps are on tightly.

C.Check for signs of wetness or leakage on the top of the battery which might indicate a loose or missing filler cap, overcharging, loose terminal post, or over- filling. Also, check battery case for dirt and oil. Clean the 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 level is below the tops of the plates in any cell, fill all cells with 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.

System

Electrical

2. Conduct a hydrometer test of the battery electrolyte.

IMPORTANT: Make sure the area around the cells is clean before opening the battery caps.

A.Measure the specific gravity of each cell with a hydrometer. Draw electrolyte in and out of the hydrometer 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 each 10oF (5.5oC) above 80oF (26.7oC) add 0.004 to the specific gravity reading. For each 10oF (5.5oC) be- low 80oF (26.7oC) subtract 0.004 from the specific gravity reading.

100oF minus 80oF equals 20oF (37.7oC minus 26.7oC equals 11.0oC)

20oF multiply by 0.004/10oF equals 0.008 (11oC multiply by 0.004/5.5oC equals 0.008) ADD (conversion above)0.008

1.253

C. If the difference between the highest and lowest cell specific gravity is 0.050 or greater or the lowest cell 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 is 1.225 or greater with the difference in specific gravity between the highest and lowest cell less than 0.050. If these charging conditions can not be met, replace the battery.

3. Perform a high???discharge test with an adjustable load tester.

This is one of the most reliable means of testing a battery as 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 terminals prior to testing the battery. If the voltage is less than 12.4 VDC, recharge the battery.

B.If the battery has been charged, apply a 150 amp load 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 minimum voltage for the cell temperature reading.

I. If the test voltage is below the minimum, replace the 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 in good condition and battery retainer has been repaired or replaced.

4.Place battery in its compartment. Make sure battery is level and flat. Connect positive cable connector onto positive battery post. Tighten cap screw and lock nut with two wrenches.

IMPORTANT: The nut must be on top of the battery retainer during installation to prevent the cap screw from 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 and cable connectors to reduce corrosion after connections are made.

7.Connect a digital multimeter (set to amps) between the negative battery post and the negative (ground) cable connector. The reading should be less than 0.1 amp. If the reading is 0.1 amp or more, the unit???s electri- cal system should be tested and repaired.

8.Connect negative (ground) cable connector to the negative battery post. Tighten cap screw and lock nut with two wrenches.

Charging

To minimize possible damage to the battery and allow the 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 charger which 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 the most accurate method of determining battery condition.

1. Determine the battery charge level from either its open specific gravity or circuit voltage.

2. Determine the charging time and rate using the

manufacturer???s battery charger instructions or the following table.

CAUTION

Do not charge a frozen battery because it can ex- plode and cause injury. Let the battery warm to 60oF (15.5o C) before connecting to a charger.

Charge the battery in a well???ventilated place to dissipate gases produced from charging. These gases 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 before connecting or disconnecting the charger leads from the battery posts.

3.Following the manufacturer???s instructions, con- nect the charger cables to the battery. Make sure a good connection is made.

4.Charge the battery following the manufacturer???s instructions.

5.Occasionally check the temperature of the battery electrolyte. If the temperature exceeds 125oF (51.6oC) or the electrolyte is violently gassing or spewing, the charging 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 gassing freely at a low charging rate and there is less than a 0.003 change in specific gravity for three consecutive readings.

System

Electrical

Adjust Brake

CAUTION

Before and after adjusting the brakes, always check the brakes in a wide open area that is flat and free of other persons and obstructions.

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 force and 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).

CAUTION

Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 ??? Safety.

B.Chock rear wheel. Jack up both front wheels and support the machine with hardwood blocks.

C.With the parking brake applied, use a torque wrench on the wheel hub lock nut to identify the break away torque at each front wheel. The mini- mum break away torque with the parking applied should be 270 ft???lb (366 N???m).

4.If adjustment is necessary, adjust brakes as follows:

A.Remove both front wheel assemblies from the machine (see Front Brake and Wheel Removal in the Service 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 against drums with the parking brake lever released.