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07154SL - Toro Media

1. P1 M1 P2 A1 4 SOLENOID OPTIONAL SOLENOID WHEEL MOTOR O ovi B PUMP Se pl 5 4 CU IN REV q OF OF T q CHARGE RELIEF SYSTEM Us R3 RELIEF lt gt 80 PSI Ti i500 Est q d 2 10 MICRON FILTER M2 C1 AF C2 CONTROL MANIFOLD AUTO FILL BRUSH CONVEYOR Bune MOTOR MOTOR 2 3 CU IN REV 29 8 CU IN REV Topdresser 2500 Hydraulic Schematic Serial Number Below 240000000 Page 6 4 CHARGE MOTOR 813 CU IN REV OO CHARGE PUMP 232 CU IN REV 1 1 1 1 SOLENOID CV1 WHEEL MOTOR 4 oO PUMP A2 5 4 CU IN REV 52 BRAKE e e e OPTIO 2 OPTIONAL AUTO FILL R1 ISOLATION V2 c PLUG T Law 4 SYSTEM 7 RELIEF T 1325 PSI amp x 5 CHARGE RELIEF 100 PSI FIXED R2 s 1 30 PSI C1 M2 AF C2 CONTROL MANIFOLD V FTN BRUSH CONVEYOR MOTOR MOTOR 2 3 CU IN REV 29 8 CU IN REV CHARGE MOTOR p CHARGE PUMP L 813 CUIN REV 232 CU IN REV Topdresser 2500 Hydraulic Schematic Serial Number Above 240000000
2. LOO v 8 2 P35 P4 TO LOOP BACK SWITCH HARNESS TO TRAILER LOOP BACK HARNESS FUSE uL E P5 A B C A B x x a a 5 RED J BLACK J20 9 DA PA TO SWITCH HARNESS BATT ERY C JI o O J20 BATTE RY ie SWITCH Je SWITCH J J2 SWITCH WIRE HARNESS ON MACHINES WITH SERIAL NUMBERS ABOVE 250000000 EQUIPPED WITH SPADE TERMINALS BLACK BLACK WHITE WHITE D pus PINK TO BATTERY WIRE HARNESS LOOP BACK pi TO BATTERY WIRE HARNESS 2 LOOP BACK Topdresser 2500 Switch Wire Harness Page 6 9 This page is intentionally blank Page 6 10
3. Service and Repairs Chapter 6 Foldout Diagrams Hydraulic Schematics Electrical Schematic Topdresser 2500 Wire Harness Drawings Topdresser 2500 Product Records and Maintenance System 2 5 3 gt I Electrical System Diagrams This page is intentionally blank Topdresser 1800 amp 2500 Chapter 1 TORO Safety Table of Contents SAFETY INSTRUCTIONS 2 Before Operating 2 While Operating 2 Maintenance and Service 3 JACKING INSTRUCTIONS TOPDRESSER 2500 4 SECURING TOPDRESSER 2500 TO TOW VEHICLE oce eR Ra 5 SAFETY AND INSTRUCTION DECALS 5 Topdresser 1800 amp 2500 Page 1 1 Safety Safety Instructions The Topdresser is designed and tested to offer safe ser vice when operated and maintained properly Although hazard control and accident prevention partially are de pendent upon the design and configuration of the ma chine 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 of the machine can result in injury or death To re duce the potential for injury or death comply with the following safety instructions Before Operating 1 Read an
4. 6 5 HYDRAULIC SOLENOID S1 5546 X D SWITCH BATTERY WIRE WIRE B HARNESS HARNESS TRAILER re WIRE Ld BLACK ORANGE HARNESS 3 DIODE sla pu ef WHITE WHITE WHITE SWITCH zm 5 A 4 on EU BLACK BLACK LLI tr BATTERY Topdresser 2500 Electrical Schematic All ground wires are black Page 6 6 DIODE P4 TO BATTERY WIRE HARNESS P1 BIC P2 SOLENOID ea LOOP BACK P3 a DIODE 4 2 A WHITE WHITE A BATTERY ae 2 2 SOLENOID WIRE HARNESS 5 BLACK A LooP BACK D PINK Topdresser 2500 Trailer Wire Harness Page 6 7 LOOP BACK P TO TRAILER P HARNESS Topdresser 2500 Battery Wire Harness 6 8 FUSE ES en
5. 52 This page is intentionally blank Topdresser 1800 amp 2500 Page 3 37 Hydraulic System Wheel Motor Topdresser 2500 Frame O ring 45 hydraulic fitting O ring Hydraulic hose Hydraulic hose O ring 45 hydraulic fitting 2 used O ring gi Hydraulic System Figure 33 Hydraulic motor 2 used Lock nut 2 used Flat washer 2 used Square key Set screw 2 used Flat washer Cap screw Lock washer Page 3 38 Antiseize Lubricant Loctite 242 Sprocket Roller chain with master link Hydraulic hose Cradle cover Cap screw Flat washer Carriage bolt Cradle assembly Topdresser 1800 amp 2500 Removal Fig 33 1 Empty Topdresser hopper and position machine on a level surface Chock wheels to prevent machine from moving If Topdresser is attached to tow vehicle engage tow vehicle parking brake stop engine and remove key from the ignition switch 2 Loosen but do not remove two 2 lock nuts item 11 that secure wheel motor to frame 3 Remove cap screw item 16 lock washer item 17 and flat washer item 15 from wheel motor shaft 4 Loosen two 2 set screws item 14 that secure sprocket to wheel motor shaft 5 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter 6 Label all hydraulic connections
6. TION ENERGIZED SYSTEM RELIEF 1325 PSI CHARGE RELIEF 100 PSI FIXED RENE aa CONTROL MANIFOLD BRUSH CONVEYOR MOTOR MOTOR 2 3 CU IN REV 29 8 CU IN REV ATN L1 M a RT A 7 eX CHARGE MOTOR y gt CHARGE PUMP LJ 813 CU IN REV NY 232 CU IN REV AX A D D Lo Figure 23 NOTE The Brush Motor Efficiency Test pertains only to Topdresser 2500 machines Hydraulic System Page 3 26 Topdresser 1800 amp 2500 Rotation speed of the Topdresser brush can be mea sured with a rotating contact RPM indicator to see if brush motor performance is correct Before performing this test the System Flow Test should be completed to make sure that hydraulic flow from the wheel motors is correct NOTE The brush motor rotation speed will be affected by brush bearing condition and or binding of the brush assembly Make sure that these items are checked be fore proceeding with this test procedure Procedure for Brush Motor Efficiency Test 1 Perform System Flow Test to make sure that wheel motor output flow is correct IMPORTANT Make sure to thoroughly clean around all hydraulic connections that will be disassembled 2 Remove conveyor motor from the hydraulic system to allow accurate testing of the brush motor A Disconnect hydraulic hose from the straight hy draulic fitting on the brush motor Fig 24 Instal
7. 0 65625 16 669 11 64 0 171875 4 366 43 64 0 671875 17 066 3 16 0 1875 4 762 11 16 0 6875 17 462 13 64 0 203125 5 159 45 64 0 703125 17 859 7 32 0 21875 5 556 23 32 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64 0 765625 19 447 9 82 0 28125 7 144 25 32 0 78125 19 844 19 64 0 296875 7 541 51 64 0 796875 20 241 5 16 0 3125 7 938 13 16 0 8125 20 638 21 64 0 328125 8 334 53 64 0 828125 21 034 11 32 0 34375 8 731 27 32 0 84375 21 431 23 64 0 359375 9 128 55 64 0 859375 21 828 3 8 0 3750 9 525 7 8 0 8750 22 225 25 64 0 390625 9 922 57 64 0 890625 22 622 13 32 0 40625 10 319 29 32 0 90625 23 019 27 64 0 421875 10 716 59 64 0 921875 23 416 716 0 4375 11 112 15 16 0 9375 23 812 29 64 0 453125 11 509 61 64 0 953125 24 209 15 32 0 46875 11 906 31 32 0 96875 24 606 31 64 0 484375 12 303 63 64 0 984375 25 003 1 2 0 5000 12 700 1 1 000 25 400 1 mm 0 03937 0 001 in 0 0254 mm U S to Metric Conversions To Convert Into Multiply By Linear Miles Kilometers 1 609 Measurement Yards Meters 0 9144 Feet Meters 0 3048 Feet Centimeters 30 48 Inches Meters 0 0254 Inches Centimeters 2 54 Inches Millimeters 25 4 Area Square Miles Square Kilomete
8. Figure 17 1 Brush motor 3 45 hydraulic fitting 2 Hydraulic hose 5 gt HYDRAULIC MANIFOLD FROM MACHINE WITH SERIAL NUMBER BELOW 240000000 Figure 18 1 Hydraulic manifold 2 Charge relief valve R2 HYDRAULIC MANIFOLD FROM MACHINE WITH SERIAL NUMBER ABOVE 240000000 Figure 19 1 Hydraulic manifold 2 Charge relief valve R2 Topdresser 1800 amp 2500 Page 3 23 Hydraulic System System Flow Test SCHEMATIC FOR MACHINE WITH SERIAL NUMBER ABOVE 240000000 SHOWN m WHEEL MOTOR SYSTEM RELIEF 1325 PSI CONTROL MANIFOLD BRUSH CONVEYOR MOTOR MOTOR 2 3 CU IN REV 29 8 CU IN REV CHARGE MOTOR bu CHARGE PUMP 813 CU IN REV 232 CU IN REV Figure 20 NOTE The System Flow Test pertains only to Top dresser 2500 machines Hydraulic System Page 3 24 1800 amp 2500 Procedure for System Flow 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 Make sure tow ve hicle engine is off and that the parking brake is applied 3 Read and follow Precautions for Hydraulic Testing IMPORTANT Make sure to thoroughly clean around all hydraulic connections that will be disassembled 4 Disconnect hydraulic hose from 45 hydraulic fitting on the brush motor to allow hydraulic tester flo
9. 5 E E TORQUE SPECIFICATIONS 3 Other Torque Specifications 6 Fastener Identification 3 Conversion Factors 6 Product Records Insert Operator s Manual and Parts Catalog for your Topdresser at the end of this chapter Additionally if any optional equipment or accessories have been installed to your machine insert the Installation Instructions Op erator s Manuals and Parts Catalogs for those options at the end of this chapter Maintenance Maintenance procedures and recommended service in tervals for the Topdresser are covered in the Operator s Manual Refer to that publication when performing regu lar equipment maintenance Topdresser 1800 amp 2500 Page 2 1 Product Records and Maintenance Decimal and Millimeter Equivalents Equivalents and Conversions Fractions Decimals mm Fractions Decimals mm 1 64 0 015625 0 397 33 64 0 515625 13 097 1 32 0 03125 0 794 17 82 0 53125 13 494 3 64 0 046875 1 191 35 64 0 546875 13 891 1 16 0 0625 1 588 9 16 0 5625 14 288 5 64 0 078125 1 984 37 64 0 578125 14 684 3 32 0 09375 2 381 19 32 0 59375 15 081 7 64 0 109275 2 778 39 64 0 609375 15 478 1 8 0 1250 3 175 5 8 0 6250 15 875 9 64 0 140625 3 572 41 64 0 640625 16 272 5 32 0 15625 3 969 21 32
10. C Use a small screwdriver to carefully push the shim fully into the groove 7 Install the wire ring item 26 into the housing groove making sure that the ring ends are butted 8 Place the housing in an arbor press with the mount ing flange facing down Press down on the rear housing bearing until is from 0 164 to 0 205 4 2 to 5 2 mm be low the housing surface This allows room for the thrust washer and thrust bearing to be installed later in the as sembly process 9 Insert shaft up through housing and then press seal carrier assembly down into housing until the carrier is against the installed wire ring in the housing 10 Remove shaft from housing and make sure that there is from 0 080 and 0 100 2 0 to 2 5 mm clear ance between the rear thrust washer in the housing and the front bearing Fig 38 If not enough clearance ex ists bearing must be repositioned in the housing before continuing with assembly process IMPORTANT Prevent damage when clamping the motor in a vise clamp on the housing only 11 Mount the housing in a vise with the mounting flange facing down Coat shaft with clean hydraulic oil and then carefully insert shaft down through housing taking care to not damage the seals in the housing 12 Place thrust washer item 16 against the shaft end and then install thrust bearing item 15 onto washer 13 Place a body seal item 3 into the groove in the rear face of the housing 14 Insert
11. dresser 2500 Wheel motors are worn or damaged Topdresser 2500 Brush motor and or conveyor motor Hydraulic hoses to Workman vehicle are reversed Topdresser rotate in wrong direction 1800 Hydraulic hoses to brush motor and or conveyor motor are re versed 2 4 0 Et zo Hydraulic hoses reversed at control manifold or wheel motors Top dresser 2500 Topdresser 1800 amp 2500 Page 3 17 Hydraulic System This page is intentionally blank Hydraulic System Page 3 18 Topdresser 1800 amp 2500 Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges in the circuits during various operational checks see the Special Tools section in this Chapter NOTE The Workman vehicle remote hydraulic system is used to operate the Topdresser 1800 Therefore when troubleshooting a hydraulic problem on the Top dresser 1800 perform hydraulic tests on the Workman vehicle Before Performing Hydraulic Tests IMPORTANT All obvious areas such as oil supply oil filter binding linkages loose fasteners or im proper adjustments must be checked before as suming that a hydraulic component is the source of a hydraulic system problem Precautions for Hydraulic Testing Failure to use gauges with expected pressure psi rating as listed in test procedures could re sult in damage to the gauge and possible person al injury from
12. The measured effective length of the torque wrench with the offset wrench installed distance from the center of the handle to the center of the offset wrench is 19 The calculated torque conversion factor for this torque wrench with this offset wrench would be 18 19 0 947 Topdresser 1800 amp 2500 Page 2 3 If the listed torque recommendation for a fastener is from 76 to 94 ft lb the proper torque when using this torque wrench with an offset wrench would be from 72 to 89 ft lb Offset wrench i Torque wrench effective length of torque wrench A effective length of torque wrench offset wrench TORQUE CONVERSION FACTOR A B Figure 3 Product Records and Maintenance S gt 6 Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series SAE Grade 8 Bolts Screws Studs amp Sems with Regular Height Nuts SAE J995 Grade 2 or Stronger Nuts SAE J995 Grade 5 or Stronger Nuts ovum om Pinte SAE Grade 5 Bolts Screws Studs amp Sems with Regular Height Nuts SAE J995 Grade 2 or Stronger Nuts Grade 1 5 amp 8 with Thin Height Nuts SAE Grade 1 Bolts Screws Studs amp Thread Size Sems with Regular Height Nuts 6 32 UNC 147 23 6 40 UNF 8 32 UNC 8 36 UNF 10 24 UNC 339 56 10 32 UNF 1 4 20 UNC 48 7 5
13. on hydraulic components before removal Mark parts if necessary to make sure they will be aligned properly when reinstalling hydraulic hoses Check Hydraulic Lines and Hoses 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 Topdresser 1800 amp 2500 Page 3 29 After Repair or Replacement of Components 1 If component failure was severe or if hydraulic sys tem is contaminated drain entire hydraulic system Drain and flush all hoses and components Also change oil filter 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 hoses hydraulic fittings and components before reconnecting 4 Use proper tightening methods when installing hy draulic hoses and fittings see Hydraulic Fitting Installa tion in the General Information section of this chapter 5 After hydraulic repairs are completed but before op erating the Topdresser check oil level in the hydraulic reservoir and add correct oil if necessary 6 After disc
14. SERIAL NUMBER ABOVE 240000000 FRONT or 2 Figure 15 3 Charge relief valve R2 1 Hydraulic manifold 2 5 3 5 gt System Relief Valve R1 Pressure Test SCHEMATIC FOR MACHINE WITH SERIAL NUMBER ABOVE 240000000 SHOWN BRAKE OPTION N WHEEL MOTOR PUMP 5 4 CU IN REV m ENERGIZED SYSTEM RELIEF 1325 PSI CHARGE RELIEF 100 PSI FIXED BRUSH MOTOR 2 3 CU IN REV CONTROL MANIFOLD CONVEYOR MOTOR 29 8 CU IN REV N CHARGE MOTOR a a CHARGE PUMP 813 CU IN REV 232 CU IN REV Figure 16 NOTE The System Relief Valve R1 Pressure Test pertains only to Topdresser 2500 machines Hydraulic System Page 3 22 Topdresser 1800 amp 2500 Procedure for System 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 Make sure tow ve hicle engine is off and that the parking brake is applied 3 Read and follow Precautions for Hydraulic Testing NOTE If machine is equipped with optional brake kit system relief pressure can be measured with a pressure gauge installed in manifold port P1 While towing the machine with the brakes applied minimum of 3 MPH system relief pressure will be displayed on the pressure gauge see step 7 below IMPORTANT Make sure to thoroughly clean aroun
15. Screw 4 used 10 Manifold 19 2 End cover 11 Rotor assembly 20 3 Body seal 12 Drive link 21 4 Piston spring 13 Wear plate 22 5 Backup seal 14 Housing 23 6 O ring seal 15 Thrust bearing 24 7 Piston 16 Thrust washer 25 8 Commutator seal 17 Bearing 26 9 Commutator assembly 18 Bearing spacer 27 Disassembly Fig 35 1 Thoroughly clean exterior of wheel motor To aid in assembly use a marker to draw a V shaped set of lines from end cover to housing Fig 36 IMPORTANT Prevent damage when clamping the motor in a vise clamp on the housing only 50 ft Ib 67 Shaft Shaft seal Backup seal Metal backup shim Seal carrier High pressure seal Metal backup shim Wire ring Dust seal 2 With shaft facing down secure motor in a vise by clamping on the housing 3 Loosen and remove four 4 screws item 1 Hydraulic System Page 3 40 Topdresser 1800 amp 2500 4 Remove end cover taking care to not drop piston Us ing needle nose pliers lift piston item 7 from end cover Remove and discard backup seal item 5 and O ring seal item 6 from piston 5 Remove piston spring item 4 from end cover IMPORTANT When removing commutator seal item 8 be careful not to scratch or damage com mutator assembly 6 Lift commutator assembly item 9 from motor Place commutator on a flat clean surface with the seal facing up Place the tip of a small screwdriver on the seal and gently t
16. Taper lock bushing 2 Flat washer 4 used per bearing 8 Cap screw 3 used per bushing 14 Drive chain with master link 3 Cap screw 4 used per bearing 9 Lock washer 3 used per bushing 15 Sprocket 4 Lock washer 4 used per bearing 10 Set screw 16 Wheel motor 5 Flange bearing 2 used per cradle 11 Cradle assembly 2 used 17 Lock nut 2 used per motor 6 Lock nut 12 Cradle axle 18 Carriage screw Removal Fig 11 1 Position Topdresser on a level surface with hopper empty Have Topdresser attached to towing vehicle en gage vehicle parking brake stop engine and remove key from the ignition switch Chock Topdresser wheels to prevent machine from moving 2 Jack or hoist sweeper from ground and support ma chine with blocking or jack stands see Operator s Manual and Jacking Instructions in Chapter 1 Safety Chassis Page 5 14 3 Remove both wheels from cradle assembly to be serviced see Wheel Removal in this section 4 Loosen lock nuts that secure wheel motor to cradle Rotate motor to obtain slack in drive chain 5 Rotate axle until master link is located in recessed area of cradle near wheel motor Remove master link from drive chain 6 Remove lock nuts that secure wheel hubs to cradle axle Use puller to remove hubs from axle Topdresser 1800 amp 2500 7 Loosen and remove set screw from the locking collar on both flange bearings 8 Remove four 4 cap screws lock washers and flat
17. Topdresser 2500 70 to 90 ft Ib 95 to 122 Chassis Page 5 2 Topdresser 1800 amp 2500 General Information Operator s Manual The Operator s Manual provides information regarding the operation general maintenance and maintenance intervals for your Topdresser machine Refer to that publication for additional information when servicing the machine Securing Topdresser 2500 to Tow Vehicle While operating or servicing the Topdresser 2500 make sure that hitch pin is properly positioned in tow vehicle hitch and sweeper tongue Hitch pin should be secured with hairpin clip Fig 1 Figure 1 1 Hitch pin 2 Hairpin clip Topdresser 1800 amp 2500 Page 5 3 Chassis Service and Repairs Brush Guard Figure 2 1 Brush guard 8 Nylon washer 15 Hopper frame assembly 2 Socket head screw 9 Lock washer 16 Gate 3 Flat washer 10 Cap screw 17 Clevis pin 4 Flange bushing 11 Spring pin 18 Spring 5 Slide washer 12 Slide block plate 19 Cap screw 2 used 6 Knob 13 Spring pin 20 Bumper Topdresser 1800 7 Knob 14 Gate handle Chassis Page 5 4 1800 amp 2500 Removal Fig 2 1 Position Topdresser on a level surface with hopper empty Chock Topdresser wheels to prevent machine from moving 2 Remove knob item 6 from gate handle item 14 3 Push spring pin item 13 from gate handle taking care to not damage handle 4 Remove twelve 12 cap screws lock w
18. a jacking point 3 Carefully jack machine off the ground 4 Position jack stands under the skids to support the Topdresser Safety Page 1 4 Topdresser 1800 amp 2500 Securing Topdresser 2500 to Tow Vehicle While operating or servicing the Topdresser 2500 make sure that hitch pin is properly positioned in tow vehicle hitch and Topdresser tongue Hitch pin should be se cured with hairpin clip Fig 2 Figure 2 1 Hitch pin 2 Hairpin clip Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Topdresser If any decal becomes illegible or dam aged install a new decal Part numbers for replacement decals are listed in your Parts Catalog Order replace ment decals from your Authorized Toro Distributor Topdresser 1800 amp 2500 1 5 Safety This page is intentionally blank Safety Page 1 6 Topdresser 1800 amp 2500 Chapter 2 TORO Product Records and Maintenance Table of Contents PRODUCT RECORDS 1 Using a Torque Wrench with an Offset Wrench 3 5 S MAINTENANCE 1 Standard Torque for Dry Zinc Plated and 2s EQUIVALENTS AND CONVERSIONS 2 Steel Fasteners Inch Series 4 Decimal Millimeter Equivalents 2 Standard Torque for Dry Zinc Plated and U S to Metric Conversions 2 Steel Fasteners Metric Fasteners
19. bar After Serial Number 240000000 Charge Motor Pump Topdresser 2500 Motor Displacement per revolution Pump Displacement per revolution Haldex Barnes gear motor charge pump 0 831 Cubic Inches 13 6 cc 0 232 Cubic Inches 3 8 cc Charge Relief Pressure Topdresser 2500 80 PSI 5 5 bar Before Serial Number 240000000 100 PSI 6 9 bar After Serial Number 240000000 Hydraulic Tank Capacity Topdresser 2500 2 5 Gal U S 9 51 Hydraulic Filter Topdresser 2500 Spin on cartridge type Hydraulic Oil See Operator s Manual Hydraulic Schematics The hydraulic schematics for Topdresser machines are located in Chapter 6 Foldout Diagrams Hydraulic System Page 3 2 Topdresser 1800 amp 2500 General Information Operator s Manual The Operator s Manual provides information regarding the operation general maintenance and maintenance intervals for your Topdresser machine Refer to that publication for additional information when servicing the machine Securing Topdresser 2500 to Tow Vehicle While servicing the Topdresser 2500 make sure that the hitch pin is properly positioned in tow vehicle hitch and Topdresser tongue The hitch pin should be secured with a hairpin clip Fig 1 Relieving Hydraulic System Pressure AX CAUTION Operate all machine hydraulic controls to relieve system pressure and to avoid injury from pres surized hydraulic oil Before
20. by the hydraulic conveyor motor with a chain reduction Operating pressure is lim ited by the system relief valve R1 located in the control manifold Flow from the conveyor motor is directed to the charge motor pump assembly causing the charge motor to ro tate The charge motor rotation in turn rotates the charge pump which provides charge flow to fill the hy draulic system to the wheel motors Charge pressure is limited by the charge relief valve R2 located in the con trol manifold Topdresser 1800 amp 2500 Page 3 13 Because hydraulic flow is developed by the wheel mo tors the hydraulic system automatically compensates for changes in ground speed to produce even applica tion rates even though ground speed fluctuations may occur An optional brake kit is available for the Topdresser 2500 that uses a solenoid cartridge valve S2 to cause hy draulic flow to bypass the brush and conveyor motors when the brakes are applied Oil flow is directed to the main relief valve causing a pressure increase to slow the wheel motors and therefore the machine when brak ing Hydraulic System 2g E ESA Special Tools Order special tools from your Toro Distributor Hydraulic Pressure Test Kit Part Number TOR47009 Use to take various pressure readings for diagnostic tests Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools A high pressure ho
21. decal is defective illegible or damaged repair or replace it before operating the machine Also tighten any loose nuts bolts or screws to ensure machine is in safe operating condition 3 Make sure that the tow vehicle is carefully selected to assure the best performance and safe operation of the Topdresser 4 Make sure that operator is familiar with tow vehicle and Topdresser operation 6 While operating the Topdresser may exceed noise levels of 85dB A at the operator position Hearing protection is recommended for prolonged exposure to reduce the potential of permanent hearing damage 7 Before leaving the operator s position of the tow ve hicle Workman A Move equipment control to stop Topdresser brush and conveyor movement On Topdresser 2500 move hand control switch to the OFF position On Topdresser 1800 move the remote hydraulic le ver to the OFF position B Ensure that vehicle traction lever is in neutral set parking brake stop engine and remove key from ignition switch 8 Park on level surface empty hopper and chock Top dresser wheels before disconnecting the Topdresser 2500 from tow vehicle Topdresser 1800 amp 2500 Maintenance and Service 1 Before servicing or making adjustments empty hop per and position Topdresser on a level surface If Top dresser is attached to tow vehicle engage tow vehicle parking brake stop engine and remove key from the ignition switch On Topdresser 2500 choc
22. install hydraulic fittings with new O rings into the brush motor ports see Hydraulic Fitting Installa tion in the General Information section of this chapter 2 Apply antiseize lubricant to motor shaft Position woodruff key into motor shaft keyway 3 Align motor shaft with brush shaft Slide motor shaft into brush shaft and secure brush motor to frame with two 2 cap screws item 23 flat washers item 24 and lock nuts item 2 Torque lock nuts from 54 to 66 ft Ib 74 to 89 N m 4 Apply Loctite 242 or equivalent to threads of set screws item 11 Secure brush shaft to motor shaft by tightening set screws 5 Remove caps or plugs that were put on any hydraulic lines and fittings during disassembly 6 Lubricate new O rings with clean hydraulic oil and position on fittings Using labels made during removal correctly connect and secure hydraulic hoses to hydrau lic fittings on brush motor 7 Check brush adjustment Brush should be adjusted evenly across belt area with light bristle contact at top of belt cleats If necessary adjust brush 8 Install brush guard to machine see Brush Guard Installation in the Service and Repairs section of Chap ter 5 Chassis Hydraulic System E ESA EO Brush Motor Service Figure 28 1 screw 4 used 7 Bearing race 12 Drive 2 Exclusion seal 8 Thrust bearing 13 Spacer plate 3 Mounting flange 9 Output shaft 14 Geroter assembly
23. leaking hot oil 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 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 Topdresser 1800 amp 2500 Page 3 19 1 Clean machine thoroughly before disconnecting or disassembling any hydraulic component Always keep in mind the need for cleanliness when working on hy draulic equipment Contamination can cause excessive wear or binding of hydraulic components 2 Review all test steps before starting the test proce dure 3 Before testing check all control linkages for improp er adjustment binding or broken parts 4 All hydraulic tests should be made with the hydraulic oil at normal operating temperature 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 of this chapter 5 Put metal caps or plugs on any hydraulic lines left
24. made by other manufacturers may result in non conformance with the safety standards and the warranty may be voided 9 When changing tires or performing other service on the Topdresser 2500 use correct hoists and jacks Make sure machine is parked on a solid level surface such as a concrete floor with the hopper empty Have Topdresser attached to towing vehicle engage vehicle parking brake stop engine and remove key from the ignition switch Always chock or block wheels Use ap propriate jack stands to support the raised machine If the machine is not properly supported the machine may move or fall which may result in personal injury see Jacking Instructions Safety Jacking Instructions Topdresser 2500 When changing tires or performing other ser vice use correct hoists or jacks to support the Topdresser Make sure machine is parked solid level surface such as a concrete floor Al ways chock or block wheels Use appropriate jack stands to support the raised machine If the machine is not properly supported the ma chine may move or fall which may result in per Figure 1 sonal injury 1 Skid 1 Position Topdresser on a level surface with hopper empty Have Topdresser attached to towing vehicle en gage vehicle parking brake stop engine and remove key from the ignition switch Chock Topdresser wheels to prevent it from moving 2 Position jack securely under the skids Fig 1 Do not use the axle as
25. port material is aluminum tighten fitting to 6096 of listed F F F T Size F F F T 4 1 4 in nominal hose or tubing 1 00 0 25 6 3 8 in 1 50 0 25 8 1 2 in 1 50 0 25 10 5 8 in 1 50 0 25 12 3 4 in 1 50 0 25 16 1 in 1 50 0 25 Topdresser 1800 amp 2500 Page 3 7 Hydraulic System Hydraulic Flow Diagrams WORKMAN REMOTE HYDRAULIC SYSTEM FLOW RETURN FROM WORKMAN ORKMAN BRUSH MOTOR 2 3 CU IN REV Hydraulic System Page 3 8 CONVEYOR MOTOR 29 8 CU IN REV Topdresser 1800 Working Pressure Return Flow Topdresser 1800 amp 2500 Topdresser 1800 Operation Hydraulic flow for the Topdresser 1800 is provided by the Workman remote hydraulic system Hydraulic flow GPM LPM and relief pressure therefore are deter mined by the Workman When the Workman hydraulic control is in the OFF posi tion no flow is directed to the Topdresser so there is no operation of the brush or conveyor motors Topdresser 1800 amp 2500 Page 3 9 When the Workman hydraulic control is moved to the RUN position flow from the Workman is directed to the Topdresser brush motor and then to the conveyor motor Hydraulic flow causes rotation of both the brush motor and the conveyor motor which are connected in series Oil from the Topdresser returns back to the Workman The brush is driven directly by the hydraulic brush motor The conveyor belt is driven by the hydraulic conveyor motor with a chain
26. reduction Hydraulic System 2g E B5 ESA WHEEL MOTOR v PUMP J 54 CUIN REV SYSTEM RELIEF 1325 PSI Y CHARGE RELIEF BRUSH CONVEYOR MOTOR MOTOR 2 3 CU IN REV 29 8 CU IN REV We oS br 4 fu 4 N 1 Pa pe Nac Aa S di CHARGE PUMP 232 CU IN REV 1 CHARGE MOTOR LJ 813 CU IN REV D Lat Topdresser 2500 Switch Off Serial Number Above 240000000 Shown Working Pressure Charge Pressure Return or Suction Flow Hydraulic System Page 10 1800 amp 2500 Topdresser 2500 Operation Switch Off While being towed in the forward direction with the Top dresser control handle switch in the OFF position the wheel motors act as pumps to provide hydraulic flow for the system This flow from the wheel motors is directed through the control manifold and solenoid valve 51 not energized to bypass the brush and conveyor motors Flow is then directed to the charge motor pump assem bly causing the charge motor to rotate The charge mo tor rotation in turn rotates the charge pump which provides charge flow to fill the hydraulic system to the wheel motors Charge pressure is limited by the charge relief valve R2 located in the control manifold Topdresser 1800 amp 2500 Page 3 11 If the Topdresser is
27. skid plates to the frame 7 Install wheel assemblies see Wheel Installation in this section 8 Carefully lower machine to ground 9 Lubricate grease fittings on flange bearings Chassis This page is intentionally blank Chassis Page 5 18 1800 amp 2500 Chapter 6 TORO Foldout Diagrams Table of Contents HYDRAULIC SCHEMATICS 3 Topdresser 1800 3 Topdresser 2500 Serial Number Below 240000000 4 Topdresser 2500 Serial Number Above 240000000 5 ELECTRICAL SCHEMATIC TOPDRESSER 2500 6 Electrical Schematic 6 WIRE HARNESS DRAWINGS TOPDRESSER 2500 9 46 tive accra areca tiated reas 7 Trailer Wire 7 Battery Wire Harness 8 Switch Wire Harness 9 o Topdresser 1800 amp 2500 6 1 Foldout Diagrams This page is intentionally blank Foldout Diagrams Page 6 2 Topdresser 1800 amp 2500 WORKMAN TOW VEHICLE REMOTE HYDRAULIC SYSTEM FLOW FROM WORKMAN o BRUSH MOTOR 2 3 CU IN REV RETURN TO WORKMAN CONVEYOR MOTOR 29 8 CU IN REV Topdresser 1800 Hydraulic Schematic Page 6 3
28. the drive link item 12 into the shaft with the tapered end of the drive link facing up 15 Using the marker lines placed before disassembly Fig 36 for orientation place the wear plate item 13 over the drive link and onto the housing 16 Place a body seal item 3 into the groove in the face of the rotor assembly item 11 17 Align the splines of the drive link and the rotor assem bly and lower the seal side of the rotor assembly to the wear plate Hydraulic System Page 3 42 0 080 to 0 100 2 0 to 2 5 mm Figure 38 Y Og Figure 39 1 Manifold 3 Manifold groove 2 Drive link 18 Place a body seal item 3 into the groove in each face of the manifold item 10 19 Install manifold A Lift the drive link approximately 0 100 2 5 mm and place the tip of a small screwdriver under the disk shaped portion of the drive link to hold it up B With the side of the manifold with the largest holes down align the notch in the manifold with the notch in the rotor Lower the manifold toward the ro tor and engage the disk shaped portion of the drive link into the manifold groove Fig 39 C Remove the screwdriver from the drive link and fully lower the manifold to the rotor D Make sure that the end of the drive link protrudes above the surface of the manifold If not the drive lin
29. washers that secure flange bearings to cradle Slide bearing assemblies from cradle and axle 9 Remove chain from axle sprocket and pull axle as sembly from cradle 10 If necessary remove sprocket and taper lock bush ing from axle A Remove three 3 cap screws and lock washers that secure sprocket to bushing Remove sprocket from bushing B Remove set screw that secures bushing to axle Slide bushing from axle 11 Clean all parts thoroughly Replace all parts found to be worn or damaged Installation Fig 11 1 During the assembly procedure apply antiseize lu bricant to all bearing bores hubs and axle shaft prior to installing components 2 If sprocket and taper lock bushing were removed from axle A Slide taper lock bushing onto axle Position flange of bushing from 6 735 to 6 765 17 11 to 17 18 cm from end of shaft Fig 12 B Apply Loctite 242 or equivalent to threads of bushing set screw Install set screw into bushing to secure bushing to axle After tightening set screw make sure that bushing is still correctly positioned on axle C Slide sprocket onto bushing Install three 3 cap screws and lock washers to secure sprocket to bush ing 3 Install axle assembly into cradle 4 Slide bearing assemblies to axle and cradle Secure bearings to cradle with four 4 cap screws lock washers and flat washers Do not secure bearing locking collars to axle at this time 5 Fit chain t
30. 4 Backup washer 10 Housing 15 End cap 5 Pressure seal 11 Seal 3 used 16 Cap screw 5 used 6 Seal NOTE For service of the hydraulic brush motor see the Eaton Char Lynn A Series General Purpose Ger oler Motor Repair Information at the end of this chapter Hydraulic System Page 3 32 Topdresser 1800 amp 2500 e 52 This page is intentionally blank Topdresser 1800 amp 2500 Page 3 33 Hydraulic System Conveyor Motor Loctite 242 54 to 66 ft lb 74 to 89 Antiseize Lubricant Figure 29 1 Flat washer 2 used 9 Brush 17 O ring 2 Lock washer 2 used 10 Hydraulic hose 18 90 hydraulic fitting 3 Cap screw 2 used 11 Hydraulic hose 19 O ring 4 Roller chain 12 LH motor brace 20 O ring 2 used 5 Set screw 2 used 13 90 hydraulic fitting 21 Hydraulic conveyor motor 6 Sprocket 14 O ring 2 used 22 Spacer plate 7 Hydraulic brush motor 15 O ring 23 Square key 8 RH motor brace 16 90 hydraulic fitting 24 Hydraulic fitting Removal Fig 29 1 Empty Topdresser hopper and position machine on a level surface Chock wheels to prevent machine from moving If Topdresser is attached to tow vehicle engage tow vehicle parking brake stop engine and remove key from the ignition switch 2 Remove brush guard from machine to gain access to conveyor motor see Brush Guard Removal in the Service and Repairs section of Chapter 5 Chassis Hydrauli
31. 99 79 1 4 28 UNF 65 10 734 113 5 16 18 UNC 115 15 105 15 1186 169 5 16 24 UNF 138 17 128 17 1446 192 3 8 16 UNC 16 2 3 8 24 UNF 17 2 7 16 14 UNC 27 3 7 16 20 UNF 294 3 o oe c l A2 gt A 102 11 105 11 430 45 583 61 600 60 813 81 475 48 644 65 667 66 904 89 1 2 13 UNC 30 3 142 15 f 8 1 2 20 UNF 5 8 11 UNC 65 10 88 12 5 8 18 UNF 75 10 95 15 129 20 3 4 10 UNC 93 12 140 20 190 27 3 4 16 UNF 115 15 165 25 224 34 7 8 9 UNC 140 20 225 25 305 34 7 8 14 UNF 155 25 260 30 353 41 cory pb cm 9 cae s se euwo 182 2 coe ae m sce f we e zi N 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 engine oil 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 Product Records and Maintenance Page 2 4 NOTE The nominal torque values listed above
32. Figure 4 1 Handle 3 Switch harness 2 Rocker switch Topdresser 1800 amp 2500 Page 4 5 Electrical System Fuse The Topdresser 2500 uses a single 5 amp fuse for circuit protection The fuse holder is located in the battery wire harness Fig 5 Testing Remove fuse from the fuse holder for testing Fuse should have continuity between fuse terminals Diode Assembly A diode assembly Fig 6 is used in the Topdresser 2500 trailer wire harness see wire harness drawings Chap ter 6 Foldout Diagrams The diode is used for circuit protection from voltage spikes that occur when the hy draulic solenoid is de energized NOTE If the Topdresser 2500 is equipped with the op tional brake kit a second diode assembly will be used and is located in the brake kit wire harness Testing 1 Make sure the trailer wire harness is unplugged from the battery harness 2 Locate diode assembly and remove cable tie that se cures diode to wire harness 3 Unplug the diode from the wire harness for testing The diode Fig 6 can be tested using a digital multime ter diode test or ohms setting and the table to the right Fig 7 4 After testing is complete make sure that diode is fully installed into harness connector and secured to harness with cable tie 5 Connect trailer wire harness to battery harness Electrical System Page 4 6 Figure 5 3 Trailer wire harness 4 Fuse 1 Battery wire har
33. Installation Fig 29 1 If removed install hydraulic fittings with new O rings into the conveyor motor ports see Hydraulic Fitting Installation in the General Information section of this chapter 2 Position spacer plate and conveyor motor to frame Install two 2 cap screws item 3 lock washers item 2 and flat washers item 1 that secure motor to frame Do not fully tighten fasteners at this time 3 Apply antiseize lubricant to motor shaft Position square key into motor shaft slot 4 Slide sprocket onto motor shaft Make sure that hub on sprocket gear goes in toward frame 5 Position roller chain around conveyor motor sprock et and connect roller chain ends with master link 6 Slide conveyor motor sprocket on shaft to align it with driven sprocket on conveyor roller Apply Loctite 4242 or equivalent to threads of set screws item 11 and se cure sprocket to conveyor motor shaft with two 2 set screws 7 Rotate conveyor motor to take slack out of chain but not so tight that binding occurs on sprockets Torque cap screws from 54 to 66 ft lb 74 to 89 N m to secure conveyor motor to frame 8 Check that chain has 0 125 3 2 mm deflection at mid span between the sprockets If necessary reposi tion conveyor motor to allow correct chain deflection Topdresser 1800 amp 2500 Page 3 35 Topdresser 2500 Figure 30 1 Carriage screw 5 Cap screw 2 Chain guard 6 Lock washer 3 Flat was
34. L DIAGRAMS 2 SPEGIAL TOOLS c t e 3 TROUBLESHOOTING 4 COMPONENT TESTING 5 Control Handle Switch 5 EUSe Sauf apa aeui ane 6 Diode Assembly 6 Solenoid Valve 7 SERVICE AND REPAIRS 8 Solenoid Valve 8 lt Topdresser 1800 amp 2500 Page 4 1 Electrical System General Information The Topdresser 1800 uses no electrical components Information in this chapter pertains only to Topdresser 2500 machines Electrical power to the Topdresser 2500 is provided by the tow vehicle battery Three 3 wire harnesses used on the Topdresser 2500 Fig 1 The battery wire harness attaches to the tow vehicle battery The switch wire harness connects the control handle to the battery wire harness The third harness the trailer wire harness resides on the Topdresser and provides electrical power to the hydraulic manifold solenoids Electrical Diagrams The electrical schematic and wire harness drawings for Topdresser 2500 machines are located in Chapter 6 Foldout Diagrams Figure 1 1 Battery wire harness 3 Trailer wire harness 2 Switch wire harness Electrical System Page 4 2 Topdresser 1800 amp 2500 Special Tools Multimete
35. TORO Preface The purpose of this publication is to provide the service technician with information for troubleshooting testing and repair of major systems and components on the Topdresser 1800 and 2500 REFER TO THE OPERATOR S MANUAL FOR OPER ATING MAINTENANCE AND ADJUSTMENT INSTRUCTIONS Space is provided in Chapter 2 of this book to insert the Operator s Manual and Parts Catalog for your machine A replacement Operator s Manual is available on the internet at www toro com or by sending complete Model and Serial Number to The Toro Company Attn Technical Publications 8111 Lyndale Avenue South Minneapolis MN 55420 The Toro Company reserves the right to change product specifications or this publication without notice Part No 07154SL Service Manual Topdresser 1800 and 2500 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 ANOTE 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 The Toro Company 2007 This page is intentionally blank Topdresser 1800 amp 2500 Table Of Contents Chapter 1 Saf
36. Wheels Topdresser 2500 70 to 90 ft lb 95 to 122 Figure 10 1 Trailer frame 3 Wheel assembly 4 used 5 Flange bearing 2 used per cradle 2 Lug bolt 5 used per wheel 4 Cradle assembly 2 used Chassis Page 5 12 Topdresser 1800 amp 2500 Wheel Removal Fig 10 1 Position Topdresser on a level surface with hopper empty Have Topdresser attached to towing vehicle en gage vehicle parking brake stop engine and remove key from the ignition switch Chock Topdresser wheels to prevent it from moving 2 Jack or hoist sweeper from ground and support ma chine with blocking or jack stands see Operator s Manual and Jacking Instructions in Chapter 1 Safety 3 Loosen and remove five 5 lug bolts from wheel to be removed 4 Pull wheel from machine Topdresser 1800 amp 2500 Page 5 13 Wheel Installation Fig 10 1 Position wheel to wheel hub on cradle Make sure that the valve stem is facing out away from wheel hub 2 Secure wheel to sweeper with five 5 lug bolts 3 Lower machine to ground Failure to maintain proper lug bolt torque could result in failure or loss of wheel and may result in personal injury 4 Alternately torque bolts from 70 to 90 ft Ib 95 to 122 Chassis Cradle Axle Topdresser 2500 230 to 270 ft Ib 312 to 366 Loctite 242 Loctite 242 230 to 270 ft Ib 312 to 366 Figure 11 1 Wheel hub 7 Set screw 13
37. acement see Solenoid Valve Coil in the Service and Repairs section of this chapter 5 Reconnect harness electrical connector to the sole noid valve coil 6 Connect trailer wire harness to battery harness HYDRAULIC MANIFOLD FROM MACHINE WITH SERIAL NUMBER BELOW 240000000 Figure 8 1 Hydraulic manifold 2 Solenoid coil S1 HYDRAULIC MANIFOLD FROM MACHINE WITH SERIAL NUMBER ABOVE 240000000 Oe QA WY a KO Figure 9 1 Hydraulic manifold 2 Solenoid coil S1 Topdresser 1800 amp 2500 Page 4 7 Electrical System Electrical Service and Repairs Solenoid Valve Coil The solenoid valve coil S1 on the Topdresser 2500 hy draulic control manifold Fig 10 and 11 can be replaced without opening the hydraulic system NOTE If the Topdresser 2500 is equipped with the op tional brake kit a second solenoid valve coil will be in cluded on the hydraulic control manifold at port S2 Removal 1 Position machine on a level surface and chock wheels to prevent machine movement If Topdresser is attached to towing vehicle engage vehicle parking brake stop engine and remove key from the ignition switch 2 Make sure that the Topdresser switch is in the OFF position 3 Disconnect the wire harness electrical connector from the solenoid coil 4 Remove the nut from the hydraulic valve 5 Slide the coil assembly from the valve 6 Clean all corrosion or dirt from the spool assembly Installation 1 Slide
38. ap the seal until the opposite side of the seal lifts from the groove in the commutator Remove and discard the commutator seal 7 Lift manifold item 10 rotor assembly item 11 and wear plate item 13 from motor Make sure that rollers do not drop from rotor as it is removed 8 Remove drive link item 12 thrust bearing item 15 and then thrust washer item 16 from motor housing 9 From front of housing gently tap shaft item 19 up wards and remove from rear of housing 10 Remove housing from vise and place on flat clean surface with dust seal facing up Using a small thin screwdriver carefully pry dust seal item 27 from the seal carrier Discard removed seal 11 Using an arbor press and appropriate sleeve press the seal carrier item 23 down into the housing approxi mately 0 250 6 4 mm to allow access to wire ring groove in housing 12 Using a small thin screwdriver carefully pry the wire ring item 26 from the housing groove Then pry the metal backup shim item 25 and high pressure seal item 24 from the groove 13 Remove the seal carrier from the housing Carefully pry the shaft seal item 20 backup seal item 21 and metal backup shim item 22 from the seal carrier Dis card seals and shim 14 Remove two 2 thrust washers item 16 and thrust bearing item 15 from housing caution Use eye protection such as goggles when using compressed air 15 Wash all parts in solvent Dry p
39. ar as possible Step 1 in Figure 8 O ring Figure 7 IMPORTANT Before installing fitting into port de termine port material If fitting is to be installed into an aluminum port installation torque is reduced 5 Install the fitting into the port and tighten finger tight until the washer contacts the face of the port Step 2 Hydraulic 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 use a torque wrench to tighten the fitting to the rec ommended installation torque shown in Figure 6 This tightening process will require the use of an offset wrench e g crowfoot wrench Use of an offset wrench will affect torque wrench calibration due to the effective length change of the torque wrench Tightening torque when using a torque wrench with an offset wrench will be lower than the listed installation torque see Using a Torque Wrench with an Offset Wrench in the Torque Specifications section of Chapter 2 Product Records and Maintenance Figure 8 8 If a torque wrench is not available or if space at the port prevents use of a torque wrench an alternate meth od of assembly is the Flats From Finger Tight F F F T method Hold the fitting in the desired position with a wrench and if port material is steel tighten the lock nut with a second wrench to the listed F F F T Step 4 If
40. arts with compressed air Topdresser 1800 amp 2500 Page 3 41 MARKER LINE Figure 36 Figure 37 1 Dust seal 4 Backup seal 2 Sealcarrier 5 Shaft seal 3 Metal backup shim Assembly Fig 35 1 Coat new seals with clean hydraulic oil 2 Assemble seal components to seal carrier A Install metal backup shim item 22 backup seal item 21 and shaft seal item 20 into seal carrier item 23 noting orientation shown in Figure 37 B Place seal side of carrier on flat surface and press carrier down to seat seals in seal carrier C Install dust seal item 27 into seal carrier noting orientation shown in Figure 37 D Make sure that dust seal and shaft seal are coated with clean hydraulic oil to provide start up lu brication 3 With the flange side of the housing facing up place one thrust washer the thrust bearing and then the sec ond thrust washer against the bearing in the housing 4 Install the seal carrier assembly into the housing making sure that the large OD of the seal carrier faces down Hydraulic System 5 gt I 5 Install high pressure seal item 24 into the housing groove 6 Install the backup shim item 25 into the housing A Slightly squeeze the shim between thumb and forefinger to bow the shim B While maintaining the bow in the shim start the shim into the housing groove
41. ashers and flat washers that secure brush guard to frame NOTE On Topdresser 1800 machines a bumper not shown is attached to the brush guard 5 Lift brush guard from machine Topdresser 1800 amp 2500 5 5 Installation Fig 2 1 Lower brush guard to machine frame making sure that gate handle item 14 is positioned in slide block plate mounted on brush guard 2 On Topdresser 1800 machines place bumper not shown to brush guard 3 Secure brush guard to frame with twelve 12 cap screws lock washers and flat washers 4 Push spring pin item 13 into gate handle taking care to not damage handle End of spring pin should be flush with the inside of the handle 5 Install knob item 6 onto gate handle Chassis Brush OOND No Antiseize Lubricant 54 to 66 ft lb 74 to 89 N Pd Hydraulic brush motor Lock nut 2 used O ring 45 hydraulic fitting O ring Hydraulic hose Woodruff key Hydraulic hose Hydraulic fitting Loctite 242 Figure 3 RH motor brace Set screw 4 used Brush Brush shaft Flange bearing Grease fitting Locking collar Set screw To prevent personal injury make sure that brush is supported as it is removed from the machine Brush weighs approximately 26 pounds 11 8 kg Chassis Page 5 6 Loctite 242 Loctite 242 Lock nut 2 used Flat washer 4 used LH motor brace Cap sc
42. at the swivel nut prevents use of a torque wrench an alternate Mark Nut Final method of assembly is the Flats From Wrench Resist and arning Position ance F F W R method Fig 2 A Using a wrench tighten the swivel nut onto the fit Initial ting until light wrench resistance is reached approxi Extend Line Position mately 30 1 AT WRENCH RESISTANCE AFTER TIGHTENING B Mark the swivel nut and fitting body Hold the hose tube with a wrench to prevent it from turning Figure 3 Fitting Dash Size Hose Tube Side Thread Size Installation Torque 9 16 18 18 to 22 ft lb 25 to 29 N m 11 16 16 27 to 33 ft lb 37 to 44 N m 13 16 16 37 to 47 ft lb 51 to 63 N m 1 14 60 to 74 ft lb 82 to 100 13 16 12 85 to 105 ft Ib 116 to 142 N m 17 6 12 110 to 136 ft lb 150 to 184 1 11 16 12 140 to 172 ft lb 190 to 233 N m Figure 4 Topdresser 1800 amp 2500 Page 3 5 Hydraulic System Hydraulic Fitting Installation SAE Straight Thread O ring Face Seal Fitting into Compo nent Port Non Adjustable Fitting Fig 5 1 Make sure all threads and sealing surfaces of fitting and component port are free of burrs nicks scratches or any foreign material 2 As a preventative measure against leakage it is rec ommended that the O ring be replaced any time the connection is opened 3 Lightly lubricate the O ring with clean hydraulic oil Fitting threads should be clean w
43. aterial thickness amp finish must be considered when determining specific torque values All torque values are based on non lubricated fasteners Baseline Torque 20 5 in b 20 18 16 X 0 08851 in lb X 0 7376 ft lb Topdresser 1800 amp 2500 TORO Table of Contents SPECIFICATIONS 2 HYDRAULIC SCHEMATICS 2 GENERAL INFORMATION 3 Operator s Manual 3 Securing Topdresser to Tow Vehicle 3 Relieving Hydraulic System Pressure 3 Hydraulic Hoses 4 Hydraulic Hose and Tube Installation O ring Face Seal Fitting 5 Hydraulic Fitting Installation SAE Straight Thread ring Face Seal Fitting into Component Port 6 HYDRAULIC FLOW DIAGRAMS 8 Topdresser 1800 8 Topdresser 2500 Operation Switch Off 10 Topdresser 2500 Operation Switch On 12 SPECIAL TOOLS 14 Hydraulic Pressure Test Kit 14 Hydraulic Tester Pressure and Flow 14 Hydraulic Test Fitting Kit 15 Kite soie Me vie een 15 TROUBLESHOOTING 16 TESTING 19 Charge Pressure Test 20 System Relief Valve R1 P
44. c System Page 3 34 3 Remove chain guard from outside of frame Figs 30 and 31 4 Loosen but do not remove two 2 cap screws item 3 lock washers item 2 and flat washers item 1 that secure conveyor motor to frame 5 Locate and remove roller chain master link Position chain away from conveyor motor sprocket 6 Loosen two 2 set screws item 5 that secure sprocket to conveyor motor shaft Topdresser 1800 amp 2500 7 Slide sprocket from conveyor motor shaft Locate and retrieve square key from motor shaft 8 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter 9 Label all hydraulic connections for assembly pur poses Thoroughly clean hydraulic hoses and fittings prior to loosening hydraulic lines at conveyor motor 10 Disconnect hydraulic lines from fittings on conveyor motor Allow hydraulic oil to drain from lines into a suit able container Put caps or plugs on open hydraulic lines and fittings to prevent contamination Remove and dis card O rings 11 Support conveyor motor to prevent it from shifting Remove two 2 cap screws item 3 lock washers item 2 and flat washers item 1 that secure motor to frame Remove conveyor motor from the machine Remove spacer plate from between motor and frame 12 If required remove hydraulic fittings and O rings from the conveyor motor Discard O rings
45. coil assembly onto the hydraulic valve 2 Install the nut onto the spool assembly and torque nut 36 in Ib 4 1 N m do not over tighten 3 Connect the wire harness electrical connector to the solenoid coil Electrical System HYDRAULIC MANIFOLD FROM MACHINE WITH SERIAL NUMBER BELOW 240000000 Figure 10 1 Hydraulic manifold 2 Solenoid coil S1 Page 4 8 HYDRAULIC MANIFOLD FROM MACHINE WITH SERIAL NUMBER ABOVE 240000000 36 in Ib 4 1 N m p y e ico Figure 11 1 Hydraulic manifold 2 Solenoid coil S1 Topdresser 1800 amp 2500 Chapter 5 TORO Chassis Table of Contents SPECIFICATIONS 2 GENERAL INFORMATION 3 Operator s Manual 3 Securing Topdresser 2500 to Tow Vehicle 3 SERVICE AND REPAIRS 4 Brush Guard 4 Br sh on Rh 6 HOllerS ioa AE feste 8 Wheels Topdresser 2500 12 Cradle Axle Topdresser 2500 14 Cradle Assembly Topdresser 2500 16 Topdresser 1800 amp 2500 Page 5 1 Chassis Specifications Item Description Tires Topdresser 2500 Size Before Serial Number 250000000 18 x 10 5 8 4 Ply Tubeless Size After Serial Number 250000000 18 x 9 5 8 4 Ply Tubeless Pressure 20 to 30 PSI 138 to 206 kPa Wheel Lug Nut Torque
46. d Topdresser 2500 Serial Number Below 240000000 0 50 55 ft Ib 74 N m 37 ft lb 50 ft lb 67 36 in lb 19 50 Hydraulic manifold Check valve port CV2 O ring Hydraulic fitting ports A1 and A2 O ring O ring Hydraulic adapter ports C1 and C2 O ring Check valve port CV4 Hydraulic fitting Hydraulic System 50 7 74 Figure 40 O ring O ring Hydraulic fitting port M1 O ring Hydraulic fitting port M2 Hydraulic tube Relief valve port R1 Solenoid valve port 51 Solenoid coil Page 44 Rear View Front View Nut Oil filter Relief valve port R2 Filter adapter fitting Check valve ports CV1 and CV3 Hydraulic adapter Hydraulic T fitting Hydraulic adapter port AF Hydraulic adapter port T1 Topdresser 1800 amp 2500 Serial Number Above 240000000 Rear View Front View 37 ft Ib 50 N m Poa 50 ft Ib IG 67 N m 5 14 36 in Ib 4 1 Figure 41 1 Hydraulic manifold 9 O ring 16 Nut 2 O ring 10 Hydraulic fitting 2 used 17 Oil filter 3 Hydraulic fitting 5 used 11 O ring 18 Check relief valve port R2 4 O ring 12 45 hydraulic fitting 19 Check valve ports CV1 and CV3 5 O ring 13 Relief valve port R1 20 Check valve port CV2 6 Hydraulic fitting 2 used 14 Solenoid valve port S1 21 90 hydraulic fitting 7 O r
47. d all hydraulic connections that will be disassembled 4 Disconnect hydraulic hose from 45 hydraulic fitting on the brush motor to allow hydraulic tester flow meter installation Fig 17 5 Install hydraulic tester flow meter between discon nected hose and fitting Make sure that tester flow arrow points from the hose and into the fitting Fully close the flow control valve on the tester 6 Make sure hydraulic tank is full 7 Start engine on tow vehicle and move the Topdress er control handle switch to the ON position Tow the Top dresser at a minimum of 3 MPH while monitoring the pressure gauge on the hydraulic tester 8 Once system pressure builds to relief setting the pressure gauge will display system relief pressure For machines with serial number below 240000000 system relief pressure should be approximately 1500 PSI 103 bar For machines with serial number above 240000000 system relief pressure should be approximately 1325 PSI 91 bar 9 Stop tow vehicle shut off engine and record test re sults 10 If relief pressure specification is not met inspect re pair or adjust charge relief valve R1 in hydraulic control manifold Figs 18 and 19 Also consider air in the hy draulic system a leaking hydraulic manifold check valve CV1 or worn wheel motors 11 When testing is complete remove hydraulic tester Connect hydraulic hose to fitting on brush motor Make sure hydraulic tank is full
48. d understand the contents of the Operator s Manual before starting and operating the machine Be come familiar with the controls and know how to stop the Topdresser quickly A replacement Operator s Manual is available on the Internet at www Toro com or by send ing the complete model and serial number to The Toro Company Attn Technical Publications 8111 Lyndale Avenue South Bloomington Minnesota 55420 1196 While Operating 1 Operator should be in the operators position when operating the tow vehicle and Topdresser Stay away from the Topdresser when the brush and conveyor are engaged 2 When using the Topdresser 2500 make sure that hitch pin is properly positioned in tow vehicle and Top dresser Hitch pin should be secured with hairpin clip 3 Do not run tow vehicle engine in a confined area with out adequate ventilation Exhaust fumes are hazardous and could possibly be deadly 4 Do not touch tow vehicle engine muffler or exhaust pipe while engine is running or soon after it is stopped These areas could be hot enough to cause burns 5 If abnormal vibration is detected stop operation of the Topdresser immediately and determine source of vibration Correct problems before resuming the use of the Topdresser Safety Page 1 2 To reduce the potential for injury or death comply with the following safety instructions 2 Keep all shields safety devices and decals in place If a shield safety device or
49. disconnecting or performing any work on the Topdresser hydraulic system all pressure in the hydrau lic system must be relieved Topdresser 1800 amp 2500 Page 3 3 Figure 1 1 Hitch pin 2 Hairpin clip To relieve hydraulic system pressure on Topdresser 1800 machines turn tow vehicle key switch to OFF en gine not running and place the remote hydraulic valve handle in the float position For Topdresser 2500 machines turn tow vehicle key switch to OFF and allow engine to stop Make sure that Topdresser control handle switch is in the OFF position to relieve system pressure Hydraulic System E 5 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 and maintenance These conditions can cause hose damage and deterio ration Some hoses are more susceptible to these conditions than others Inspect all machine hydraulic hoses frequently for signs of deterioration or damage Hard cracked cut abraded charred leaking or otherwise damaged hose Kinked crushed flattened or twisted hose Blistered soft degraded or loose hose cover Cracked damaged or badly corroded hose fittings 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 impr
50. en troubleshooting a hydraulic problem on the Topdresser 1800 inspect the Workman hydraulic system if both brush motor and con veyor motor are malfunctioning If only one of the motors appears to be malfunctioning check that motor Hydraulic oil leaks Hydraulic fitting s or hose s are loose or damaged O ring s or seal s are missing or damaged Foaming hydraulic fluid Hydraulic oil level in hydraulic reservoir is low Hydraulic system has wrong kind of oil Hydraulic system on Workman vehicle is malfunctioning Topdress er 1800 Hydraulic system operates hot Hydraulic oil level in hydraulic reservoir is low Excessive dirt and debris on hydraulic components Hydraulic oil is contaminated or too light Brush or conveyor motor is worn or damaged Hydraulic system on Workman vehicle is malfunctioning Topdress er 1800 Optional hydraulic brakes are activated continuously Topdresser 2500 Hydraulic System Page 3 16 Topdresser 1800 amp 2500 Neither brush motor nor conveyor Hydraulic hose s to Workman vehicle are not connected Top motor will rotate dresser 1800 Hydraulic system on Workman vehicle is malfunctioning Topdress er 1800 Control manifold solenoid S1 is not being energized or cartridge is faulty Topdresser 2500 Electrical problem exists Topdresser 2500 see Chapter 4 Elec trical System Wheel motors are not turning due to chain drive problem Top
51. ety Safety 1 2 Jacking Instructions Topdresser 2500 1 4 Securing Topdresser 2500 to Tow Vehicle 1 5 Safety and Instruction Decals 1 5 Chapter 2 Product Records and Maintenance Product Records 2 1 Maintenance 2 1 Equivalents and Conversions 2 2 Torque Specifications 2 3 Chapter 3 Hydraulic System Specifications 3 2 Hydraulic Schematics 3 2 General Information 3 3 Hydraulic Flow Diagrams 3 8 Special Tools 3 14 Troubleshooting 3 16 TOSUN ee 3 19 Service and Repairs 3 29 EATON CHAR LYNN A SERIES GENERAL PUR POSE GEROLER MOTOR REPAIR INFORMATION EATON CHAR LYNN 2000 SERIES DISC VALVE GEROLER MOTOR REPAIR INFORMATION Topdresser 1800 amp 2500 Chapter 4 Electrical System General Information Electrical Diagrams Special Tools ence ceni Troubleshooting Component Testing Service and Repairs Chapter 5 Chassis Specifications General Information
52. f test gauges to the system 6 te 8 ee The kit includes tee s unions reducers plugs caps and male test fittings 10 to No No 12 10 No 8 a P Cop Ping 200 Pipe Tha Figure 11 O ring Kit Part Number 16 3799 Hydraulic The O ring kit includes O rings in a variety of sizes for face seal and port seal hydraulic connections As a pre ventative measure against leakage it is recommended that an O ring be replaced any time a hydraulic connec tion is opened Figure 12 Topdresser 1800 amp 2500 Page 3 15 Hydraulic System System Troubleshooting The cause of an improperly functioning hydraulic sys tem is best diagnosed with the use of proper testing equipment and a thorough understanding of the com plete hydraulic system A hydraulic system with an excessive increase in heat or noise has a potential for failure Should either of these conditions be noticed immediately stop the machine turn off the tow vehicle engine locate the cause of the trouble and correct it before allowing the machine to be used again Continued use of an improperly functioning hydraulic system could lead to extensive hydraulic com ponent damage The charts that follow contain information to assist in troubleshooting There may possibly be more than one cause for a machine malfunction NOTE The Workman vehicle hydraulic system is used to operate the Topdresser 1800 Wh
53. follow Precautions for Hydraulic Testing IMPORTANT Make sure to thoroughly clean around all hydraulic connections that will be disassembled 4 Locate and remove plug from the P2 port on the hy draulic control manifold Figs 14 and 15 5 Connect pressure gauge with a hydraulic hose at tached to the P2 port on the hydraulic control manifold Make sure hose is long enough so the operator can read the gauge while driving the tow vehicle 6 Start engine on tow vehicle and tow the Topdresser at a minimum of 3 MPH Leave the Topdresser control handle switch in the OFF position 7 The pressure gauge will display system charge pres sure and should read at least 50 PSI 3 4 bar Record test results 8 Stop tow vehicle shut off engine and record test re sults 9 If charge pressure specification is not met inspect repair or replace charge relief valve R2 in hydraulic control manifold Also consider a clogged oil filter air in the hydraulic system or a worn charge motor pump 10 Remove pressure gauge from hydraulic manifold and install plug into manifold port P2 Torque plug 19 ft 2 P2 port Ib 25 7 11 After testing is completed make sure hydraulic tank is full Topdresser 1800 amp 2500 Page 3 21 Hydraulic System HYDRAULIC MANIFOLD FROM MACHINE WITH SERIAL NUMBER BELOW 240000000 Figure 14 1 Hydraulic manifold 3 Charge relief valve R2 2 P2 port HYDRAULIC MANIFOLD FROM MACHINE WITH
54. 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 Topdresser 1800 amp 2500 Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners Regular Height Nuts Class 8 or Stronger Nuts Thread Size M5 X 0 8 57 6in lb 96 10 in Ib Class 8 8 Bolts Screws and Studs with Class 10 9 Bolts Screws and Studs with Regular Height Nuts Class 10 or Stronger Nuts 644 68 N cm 78 8 in lb 881 90 N cm 1085 113 133 14 in lb 1503 158 N cm M6 X 1 0 M8 X 1 25 M10 X 1 5 19 2 ft Ib 38 4 ft lb M12 X 1 75 M16 X 2 0 M20 X 2 5 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 engine oil or thread sealant such as Loctite 66 7 ft lb 166 17 ft lb 325 33 ft lb 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 Topdresser 1800 amp 2500 26 3 N m 90 10 93 10 ft lb 126 14 225 23 N m 229 23 ft lb 310 31 N m 450 46 ft Ib 610 62 N m Page 2 5 28 3 ftlb 38 4 N m NOTE The nom
55. for assembly pur poses Thoroughly clean hydraulic hoses and fittings prior to loosening hydraulic lines at wheel motor 7 Disconnect hydraulic lines from fittings on wheel mo tor Allow hydraulic oil to drain from lines into a suitable container Put caps or plugs on open hydraulic lines and fittings to prevent contamination Remove and discard O rings 8 Support wheel motor to prevent it from shifting Re move two 2 lock nuts item 11 and flat washers item 12 that secure motor to machine 9 Slide wheel motor from sprocket and machine While sliding wheel motor from sprocket insert dowel into sprocket bore to support sprocket and chain in cradle assembly Locate and retrieve square key from motor shaft 10 11 required remove hydraulic fittings and O rings from the wheel motor Discard O rings Installation Fig 33 1 If removed install hydraulic fittings with new O rings into the wheel motor ports see Hydraulic Fitting Installa tion in the General Information section of this chapter 2 Apply antiseize lubricant to wheel motor shaft Posi tion square key into motor shaft slot 5 Slide wheel motor shaft into sprocket while removing the dowel in sprocket bore that was placed during the re moval process Align motor mounting holes with car riage bolt and stud on frame Place flat washer item 12 and lock nut item 11 on carriage bolt and stud but do not fully tighten 6 Apply Loctite 242 or equivalent
56. g Fitting Port Side Installation Torque Into Dash Size Thread Size Steel Port 7 16 20 15 to 19 ftHb 21 to 25 N m 1 2 20 18 to 22 ftHb 25 to 29 9 16 18 34 to 42 ft lb 47 to 56 N m 3 4 16 58 to 72 ft lb 79 to 97 7 8 14 99 to 121 ft lb 135 to 164 1 1 16 12 134 to 164 ft lb 182 to 222 1 3 16 12 160 to 196 ft lb 217 to 265 1 5 16 12 202 to 248 ft lb 274 to 336 15 8 12 247 to 303 10 335 to 410 Figure 6 Hydraulic System Page 3 6 Installation Torque Into Aluminum Port 9 to 11 ft lb 13 to 15 11 to 15 ft lb 15 to 20 20 to 26 ft lb 28 to 35 35 to 43 ft lb 48 to 58 60 to 74 ft lb 82 to 100 81 to 99 ft lb 110 to 134 N m 96 to 118 ft lb 131 to 160 121 to 149 ftHb 165 to 202 N m 149 to 183 ft lb 202 to 248 Topdresser 1800 amp 2500 Adjustable Fitting Fig 7 1 Make sure all threads and sealing surfaces of fitting and component port are free of burrs nicks scratches or any foreign material 2 As apreventative measure against leakage it is rec ommended that the O ring be replaced any time the connection is opened Lock Nut 3 Lightly lubricate the O ring with clean hydraulic oil Fitting threads should be clean with no lubricant applied Back up Washer 4 Turn back the lock nut as far as possible Make sure the back up washer is not loose and is pushed up as f
57. her 7 Hyd conveyor motor 4 Locknut 8 Drive chain Topdresser 1800 Figure 31 1 Locknut 6 Cap screw 2 Flat washer 7 Lock washer 3 Spacer 8 Cap screw 4 Guard 9 Hyd conveyor motor 5 Chain guard 10 Drive chain 9 Remove caps or plugs that were put on any hydraulic lines and fittings during disassembly 10 Lubricate new O rings with clean hydraulic oil and position on fittings Using labels made during removal correctly connect and secure hydraulic hoses to hydrau lic fittings on conveyor motor 11 Install brush guard to machine see Brush Guard Installation in the Service and Repairs section of Chap ter 5 Chassis 12 Install chain guard to outside of frame Figs 30 and 31 Hydraulic System 2 5 gt Conveyor Motor Service Figure 32 1 Exclusion seal 9 Main drive 2 Bearing housing 10 Geroler assembly 3 Seal 11 Valve drive 4 Back up ring 12 Valve plate 5 Shaft seal 13 Valve 6 Shaft and bearing kit 14 Balance ring 7 Shaft face seal 15 Outer face seal 8 Wear plate NOTE For service of the hydraulic conveyor motor see the Eaton Char Lynn 2000 Series Disc Valve Ger oler Motor Repair Information at the end of this chapter Hydraulic System Page 3 36 16 17 18 19 20 21 22 Inner face seal Balance ring pin 2 used Compression spring 2 used Valve housing O ring Plug Cap screw 4 used Topdresser 1800 amp 2500 e
58. inal 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 Product Records and Maintenance Product Records S gt 5 6 Other Torque Specifications SAE Grade 8 Steel Set Screws Recommended Torque 140 20 inb 73 12 inb Thread Size 1 4 20 UNC 5 16 18UNC 215 35 in Ib 145 20 inb 3 8 16 UNC 1 2 13 UNC 75 15 ft lb 50 10 ft lb 35 10 ft lb 18 3 ft Ib Thread Cutting Screws Zinc Plated Steel Type 1 Type 23 or Type F Thread Size Baseline Torque No 6 32 UNC 20 5 in lb No 8 32 UNC 30 5 in lb 1 4 20 UNC 85 15 inb 5 16 18 UNC 110 20 inb 3 8 16 UNC 200 100 in Ib No 10 24 UNC 38 7 in lb Conversion Factors in lb X 11 2985 ft lb X 1 3558 Product Records and Maintenance Page 2 6 Wheel Bolts and Lug Nuts Thread Size Recommended Torque 88 14 7 16 20 UNF 65 10 ftHb Grade 5 1 2 20 UNF 80 10 ftHb 108 14 Grade 5 M12 X 1 25 80 10 ftHb f 108 14 Nom Class 8 8 M12 X 1 5 80 10 ftHb f 108 14 Class 8 8 For steel wheels and non lubricated fasteners Thread Cutting Screws Zinc Plated Steel Thread Threads per Inch Size Type A Type B 85 15 in Ib Hole size material strength m
59. ing 15 Solenoid coil 22 Check valve port CV4 8 90 hydraulic fitting Manifold Removal Figs 40 and 41 1 Empty Topdresser hopper and position machine on a level surface Chock wheels to prevent machine from moving If Topdresser is attached to tow vehicle engage tow vehicle parking brake stop engine and remove key from the ignition switch Operate all sweeper hydraulic controls to relieve system pressure and to avoid injury from pres surized hydraulic oil See Relieving Hydraulic System Pressure in the General Information sec tion of this chapter Topdresser 1800 amp 2500 Page 3 45 Hydraulic System 2 5 3 5 gt gt 170 2 Relieve sweeper hydraulic system pressure NOTE The ports on the control manifold are marked to identify hydraulic connections Example R1 is the sys tem relief valve port See Hydraulic Schematic in Chap ter 6 Foldout Diagrams to identify the function of the hydraulic lines and cartridge valves at each manifold port location 3 Label all control manifold electrical and hydraulic connections for assembly purposes 4 Disconnect wire harness electrical connector from solenoid valve on control manifold 5 Clean control manifold and manifold hydraulic con nections Disconnect hydraulic hoses from manifold fit tings 6 Allow disconnected hydraulic lines to drain into a suitable container Put caps or plugs on disconnected hoses and fit
60. int layline on the hose Use two wrenches hold the hose straight with one wrench and tighten the hose swivel nut onto the fit ting with the other wrench See Hydraulic Hose and Tube Installation in this section If the hose has an el bow at one end tighten the swivel nut on that end before tightening the nut on the straight end of the hose For additional hydraulic hose information refer to Toro Service Training Book Hydraulic Hose Servicing Part Number 9481361 Hydraulic System Page 3 4 Before disconnecting or performing any work on hydraulic system relieve all pressure in system see Relieving Hydraulic System Pressure in this section 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 Topdresser 1800 amp 2500 Hydraulic Hose and Tube Installation O Ring Face Seal Fitting 1 Make sure threads and sealing surfaces of the hose C Use a second wrench to tighten the nut to the cor tube and the fitting are free of burrs nicks scratches or rect Flats From Wrench Resistance F F W R The any foreign material marking
61. ion in this section 13 Carefully lower machine to ground 14 Lubricate grease fittings on flange bearings lt 6 735 to 6 765 17 11 to 17 18 cm Figure 12 3 Sprocket 4 Set screw 1 Cradle axle 2 Taper lock bushing Chassis Cradle Assembly Topdresser 2500 Loctite 242 Figure 13 1 Frame 9 Flat washer 2 Flange bearing 2 used per cradle 10 Lock washer 3 Flat washer 11 Cap screw 4 Lock nut 12 Lug bolt 5 used per wheel 5 Set screw 13 Skid 4 used 6 Wheel motor pump 14 Carriage screw 2 used per skid 7 Square key 15 Flat washer 2 used per skid 8 Sprocket 16 Lock nut 2 used per skid Chassis Page 5 16 Antiseize Lubricant Loctite 242 70 to 90 ft lb 95 to 122 N m Wheel 4 used Carriage screw Cradle cover Flat washer Cap screw Cradle assembly 2 used Drive chain with master link Set screw Topdresser 1800 amp 2500 Removal Fig 13 1 Position Topdresser on a level surface with hopper empty Have Topdresser attached to towing vehicle en gage vehicle parking brake stop engine and remove key from the ignition switch Chock Topdresser wheels to prevent machine from moving 2 Jack or hoist sweeper from ground and support ma chine with blocking or jack stands see Operator s Manual and Jacking Instructions in Chapter 1 Safety 3 Remove both wheels from cradle assembly to be re moved
62. ith hopper empty Chock Topdresser wheels to prevent machine from moving 2 Remove conveyor belt from machine see Opera tor s Manual A Remove conveyor chain guard and disconnect drive chain Figs 6 and 7 B Remove fasteners that secure hopper to frame Pivot hopper rearward and lean against wall or post Fig 8 Do not allow hopper to rest against rear of machine as damage may result to brush or other components IMPORTANT Make sure hopper is pivoted be yond center and secured to wall or post to pre vent it from accidentally falling on work area Fig 8 C Loosen jam nuts that tension conveyor belt D On right side of machine loosen fasteners that secure slider bed to frame On left side of machine remove fasteners that secure slider bed to frame E Remove conveyor belt from machine NOTE Normal roller rotation is clockwise as viewed from left side of machine Fig 9 3 Loosen set screw item 22 that secures bearing locking collar to roller shaft Using a punch and hammer rotate locking collar in the opposite direction of normal roller rotation to loosen collar 4 Support roller to prevent it from shifting 5 Remove four 4 screws and lock washers that se cure bearings to frame Remove roller assembly from machine 6 If rear roller was removed remove two 2 set screws that secure sprocket to roller Remove sprocket square key and sprocket spacer from roller 7 Slide bearings from ro
63. ith no lubricant applied IMPORTANT Before installing fitting into port de termine port material If fitting is to be installed into an aluminum port installation torque is reduced 4 Install the fitting into the port Then use a torque wrench and socket to tighten the fitting to the recom mended installation torque shown in Figure 6 NOTE Use of an offset wrench e g crowfoot wrench will affect torque wrench calibration due to the effective length change of the torque wrench Tightening torque when using a torque wrench with an offset wrench will be less than the recommended installation torque See Using a Torque Wrench with an Offset Wrench in the Torque Specifications section of Chapter 2 Product Records and Maintenance to determine necessary con version information 5 If atorque wrench is not available or if space at the port prevents use of a torque wrench an alternate meth od of assembly is the Flats From Finger Tight F F F T method A Install the fitting into the port and tighten it down full length until finger tight B If port material is steel tighten the fitting to the listed F F F T If port material is aluminum tighten fit ting to 60 of listed F F F T Size F F F T 4 1 4 in nominal hose or tubing 1 00 0 25 6 3 8 in 1 50 0 25 8 1 2 in 1 50 0 25 10 5 8 in 1 50 0 25 12 3 4 in 1 50 0 25 16 1 in 1 50 0 25 Fitting oS O ring Figure 5 Fittin
64. k disk is not engaged in the manifold groove and the motor will not operate Repeat manifold installation steps if necessary Topdresser 1800 amp 2500 20 Make sure that marker lines Fig 36 on installed components are aligned Also make sure that bolt holes through components are aligned If parts need re align ment make sure that drive link end still protrudes above the surface of the manifold 21 With the metal side of the commutator seal item 8 facing up use finger pressure to press the commutator seal down into the commutator The seal should be flush with the commutator surface 22 Place the commutator container onto the manifold and then place the commutator onto the protruding end of the drive link making sure that the seal side faces up 23 Install the final body seal item 3 into the groove in the face of the end cover Topdresser 1800 amp 2500 Page 3 43 24 Install the piston spring item 4 backup seal item 5 and then O ring seal item 6 into the end cover 25 Line up the piston alignment pin and then press pis ton item 7 into the end cover 26 Lower the end cover assembly onto the motor taking care to keep piston in end cover 27 Install four 4 screws to secure the motor assembly Torque screws 10 ft lb 13 6 to seat all compo nents Then torque screws a crossing pattern to 50 ft Ib 67 Hydraulic System 2g E ESA Hydraulic Control Manifol
65. k wheels to prevent it from moving 2 Make sure machine is in safe operating condition by keeping all nuts bolts and screws tight 3 Make sure all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition be fore applying pressure to the hydraulic system 4 Keep body and hands away from pin hole leaks in hy draulic lines that eject high pressure hydraulic fluid Use cardboard or paper to find hydraulic leaks Hydraulic fluid escaping under pressure can penetrate skin and cause injury Hydraulic fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result 5 Before disconnecting any hydraulic component or performing any work on the hydraulic system all pres sure in system must be relieved See Relieving Hydrau lic System Pressure in the General Information section of Chapter 3 Hydraulic System Topdresser 1800 amp 2500 Page 1 3 6 On Topdresser 2500 disconnect electrical power harness from tow vehicle before servicing the machine 7 If major repairs are ever needed or assistance is de sired contact an Authorized Toro Distributor 8 At the time of manufacture the machine conformed to all applicable safety standards To assure optimum performance and continued safety certification of the machine use genuine Toro replacement parts and ac cessories Replacement parts and accessories
66. l a clean steel plug into disconnected hose end B Disconnect hydraulic hose from the longer elbow fitting on the conveyor motor Fig 25 Install a clean steel cap onto the fitting C Pull hose that was disconnected from conveyor motor through hole in frame Connect this hose to the open fitting on brush motor to allow a complete hy draulic circuit for brush motor operation Make sure that hose is safely positioned away from the brush and other rotating machine parts 3 Start engine on tow vehicle and tow the Topdresser Turn the Topdresser control handle switch to the ON position 4 While operating the machine monitor the vehicle speed and the brush rotational speed using a rotating contact RPM indicator Brush speed is dependant on ground speed and should be as shown in the chart to the right Fig 26 5 If system flow is correct and brush RPM is low con sider that the brush motor is worn or leaking internally Topdresser 1800 amp 2500 Page 3 27 NOTE If system flow and brush RPM are correct and conveyor is not operating correctly thoroughly inspect conveyor rollers and bearings for wear or damage If conveyor components are found to be in good condition consider that the conveyor motor needs repair Figure 24 1 Brush motor 2 Hose supply to conveyor motor 3 Hose return to hydraulic manifold T ca Figure 25 1 Conveyor motor 2 Longer elbow fitting 3 Hose return to hydraulic manifo
67. lar condition which affects the installation Fastener Identification Grade 1 Grade 5 Inch Series Bolts and Screws Figure 1 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 Class 8 8 Class 10 9 Metric Bolts and Screws Figure 2 Using a Torque Wrench with an Offset Wrench Use of an offset wrench e g crowfoot wrench will affect torque wrench calibration due to the effective change of torque wrench length When using a torque wrench with an offset wrench multiply the listed torque recommen dation by the calculated torque conversion factor Fig 3 to determine proper tightening torque Tightening torque when using a torque wrench with an offset wrench will be lower than the listed torque recommen dation Example The measured effective length of the torque wrench distance from the center of the handle to the center of the square drive is 18
68. ld Brush RPM 160 180 RPM 245 270 RPM 325 360 RPM Ground Speed 2 MPH 3 2 KPH 3 MPH 4 8 KPH 4 MPH 6 4 KPH 5 MPH 8 0 KPH 405 450 RPM Figure 26 Hydraulic System 9 5 hee gt N gt 170 This page is intentionally blank Hydraulic System Page 3 28 Topdresser 1800 amp 2500 Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components 1 Before removing any parts from the hydraulic sys tem empty Topdresser hopper and position machine on a level surface 2 On Topdresser 2500 machines chock Topdresser wheels to prevent machine from moving while repairing machine If attached to tow vehicle engage tow vehicle parking brake stop engine and remove key from the ignition switch 3 Thoroughly clean Topdresser 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 4 Put caps or plugs on any hydraulic lines hydraulic fit tings or hydraulic components left open or exposed to prevent hydraulic system contamination 5 Put labels on disconnected hydraulic lines and hoses for proper installation after repairs are completed 6 Note the position of hydraulic fittings especially el bow fittings
69. ller shaft 8 Inspect conveyor belt hopper seals and gate edge for wear or damage Replace worn or torn components to insure proper operation of machine Installation Fig 5 1 Clean roller shaft ends and apply antiseize lubricant to shaft ends Slide bearing assembly onto each end of roller shaft Make sure that locking collar is orientated to ward the end of the roller Do not tighten set screws in locking collars Figure 6 1 Carriage screw 5 2 Chain guard 6 3 Flat washer 7 4 Lock nut 8 Figure 7 1 Lock nut 6 2 Flat washer 7 3 Spacer 8 4 Guard 9 5 Chain guard 10 Topdresser 2500 Cap screw Lock washer Hyd conveyor motor Drive chain Topdresser 1800 Cap screw Lock washer Cap screw Hyd conveyor motor Drive chain Figure 8 Topdresser 1800 amp 2500 Page 5 9 Chassis NOTE The rear roller has a textured surface and has a key slot for the drive sprocket 2 Position roller to frame Secure bearings to frame with four 4 screws and lock washers 3 Center roller between bearings Also make sure that pulley groove in roller aligns with slot in slider bed NOTE Normal roller rotation is clockwise as viewed from left side of machine Fig 9 4 Using a punch and hammer rotate bearing locking collars in the direction of normal roller rotation to tighten collars 5 Apply Loctite 242 or equivalent to threads of lock ing colla
70. ness 2 Switch wire harness Figure 6 1 Diode 3 Female terminal 2 Male terminal Multimeter Black Lead on Terminal Multimeter Red Lead on Terminal Continuity romeo e es was reme no Figure 7 Topdresser 1800 amp 2500 Solenoid Valve Coil The hydraulic system on the Topdresser 2500 uses a solenoid valve coil on the hydraulic control manifold at port S1 Fig 8 and 9 The coil is energized when the control handle switch is in the ON position NOTE If the Topdresser 2500 is equipped with the op tional brake kit a second solenoid valve coil will be in cluded on the hydraulic control manifold at port S2 Testing NOTE The solenoid does not have to be removed from the cartridge valve for testing 1 Make sure the Topdresser trailer wire harness is un plugged from battery harness 2 Unplug solenoid valve coil electrical connector from wire harness connector 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 3 Measure resistance between the two coil connector terminals Resistance of the solenoid coil should be approximately 10 4 ohms 4 If solenoid coil needs repl
71. o cradle axle sprocket and install master link to secure chain Make sure that cradle gusset near wheel motor is between upper and lower chain run 6 Position cradle axle in bearings so sprocket is cen tered in cradle Check sprocket alignment and if neces sary adjust position of sprocket s Topdresser 1800 amp 2500 Page 5 15 7 Apply Loctite 242 or equivalent to threads of lock ing collar set screw Install set screw into locking collar to secure collar to cradle axle After tightening set screw make sure that sprocket is still centered in cradle and sprocket alignment is correct 8 Rotate wheel motor to take slack out of chain but not so tight that binding occurs on sprockets Tighten lock nuts to secure motor to cradle 9 Check that chain has 0 125 3 2 mm deflection at mid span between sprockets If necessary reposition wheel motor to allow correct chain deflection 10 Lubricate grease fittings on bearing assemblies 11 Secure wheel hubs to cradle axle with lock nuts After starting both lock nuts on axle threads retain one lock nut with socket and torque second lock nut from 230 to 270 ft lb 312 to 366 N m Following this procedure both lock nuts should be properly tightened Check torque on both lock nuts after tightening Failure to maintain proper lug bolt torque could result in failure or loss of wheel and may result in personal injury 12 Install wheel assemblies see Wheel Installat
72. ocking collar is fitted to bearing 2 Clean brush shaft item 13 and apply antiseize lubri cant to shaft 3 Apply antiseize lubricant to shaft of brush motor Place square key in brush motor shaft 4 Position brush assembly to hopper frame 6 Slide brush shaft item 13 through flange bearing assembly and into brush until end of brush shaft is flush with bearing locking collar Do not tighten set screw in locking collar at this time 7 Tighten fasteners to secure hydraulic brush motor to hopper frame Torque lock nuts from 54 to 66 ft lb 74 to 89 8 Center brush in hopper frame 9 Check that brush is adjusted evenly across conveyor belt There should just be contact with brush bristles at top of belt cleats If necessary loosen and change posi tion of brush motor and or flange bearing to obtain prop er brush adjustment 10 Apply Loctite 2242 or equivalent to threads of set Screws item 11 Secure brush to motor shaft and brush shaft with four 4 set screws NOTE Normal brush rotation is counter clockwise as viewed from left side of Topdresser Fig 4 11 Using a punch and hammer rotate bearing locking collar counter clockwise direction of normal brush rotation to tighten collar onto brush shaft 12 Apply Loctite 242 or equivalent to locking collar set screw Secure bearing locking collar to brush shaft with set screw 13 Install brush guard to machine see Brush Guard Installation in
73. oid cartridge was removed carefully install solenoid coil onto the cartridge valve Install nut and torque nut to 36 in Ib 4 1 9 After assembly if problems still exist remove valve and clean again or replace valve Manifold Installation Figs 40 and 41 1 Lightly oil new O rings for all removed hydraulic fit tings Install hydraulic fittings to control manifold see Hydraulic Fitting Installation in the General Information section of this chapter Topdresser 1800 amp 2500 Page 3 47 2 Position hydraulic manifold to the frame mounting bracket Install four 4 cap screws and flat washers to secure manifold to machine 3 Make sure all hydraulic connections ports and fit tings are clean 4 Remove caps or plugs that were put on hydraulic lines or fittings during disassembly 5 Lightly oil new O rings for hydraulic fitting and hose locations 6 Using labels placed during the removal process cor rectly connect hydraulic lines to the manifold Properly tighten all hydraulic connections see Hydraulic Fitting Installation in the General Information section of this chapter 7 Connect wire harness electrical connector to sole noid valve Hydraulic System E ESA EO This page is intentionally blank Hydraulic System Page 3 48 Topdresser 1800 amp 2500 Chapter 4 TORO Electrical System Table of Contents GENERAL INFORMATION 2 ELECTRICA
74. onnecting or replacing any hydraulic com ponent operate machine functions slowly until air is out of system If an air lock has occurred maybe caused by partial drainage during disassembly it may be neces sary to crack open the highest point hydraulic line near the brush motor while slowly operating the unit to purge air from the closed circuit 7 Check for hydraulic oil leaks and correct leaks if found Check hydraulic hoses daily for leaks kinked lines loose mounting supports wear loose fittings weather deterioration and or chemical deterioration Make all necessary repairs before operating the Topdresser Hydraulic System 5 LU 5 gt I Brush Motor Antiseize Lubricant 54 to 66 ft lb 74 to 89 Hydraulic brush motor Lock nut 2 used O ring 45 hydraulic fitting O ring Hydraulic hose Woodruff key Hydraulic hose PN OOP ON Hydraulic System Loctite 242 Figure 27 Hydraulic fitting RH motor brace Set screw 4 used Brush Brush shaft Flange bearing Grease fitting Locking collar Page 3 30 Set screw Lock nut 2 used Flat washer 4 used LH motor brace Cap screw 2 used Hydraulic conveyor motor Cap screw 2 used Flat washer 2 used Topdresser 1800 amp 2500 Removal Fig 27 1 Empty Topdresser hopper and position machine on a level surface Chock wheels to prevent machine from moving If Topdres
75. open or exposed during testing 6 Install hydraulic fittings finger tight and far enough to make sure that they are not cross threaded before tight ening them with a wrench 7 Position tester hoses to prevent rotating machine parts from contacting and damaging the hoses or tester 8 After connecting test equipment check oil level in the hydraulic tank to make sure that oil level is correct 9 When conducting tests on the hydraulic system wear eye protection Hydraulic System Hydraulic System Charge Pressure Test SCHEMATIC FOR MACHINE WITH SERIAL NUMBER ABOVE 240000000 SHOWN PRESSURE GAUGE CAN WHEEL MOTOR w PUMP J 5 4 CUIN REV 2 ENERGIZED SYSTEM RELIEF 1325 PSI CHARGE 100 PS RELIEF CONTROL MANIFOLD CONVEYOR MOTOR 2 3 CU IN REV 29 8 CU IN REV P c e M 4 gt 4 gt P 2 2 LJ CHARGE MOTOR 813 CU IN REV Figure 13 J 4 o gt v CHARGE PUMP 232 CU IN REV NOTE The Charge Pressure Test pertains only to Top dresser 2500 machines Hydraulic System Page 3 20 Topdresser 1800 amp 2500 Procedure for Charge 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 Make sure tow ve hicle engine is off and that the parking brake is applied 3 Read and
76. r The multimeter can test electrical components and cir cuits for current amps resistance ohms or voltage NOTE Toro recommends the use of a DIGITAL Ohm Amp multimeter when testing electrical circuits The high impedance internal resistance of a digital me ter in the voltage mode will make sure that excess cur rent is not allowed through the meter This excess current can cause damage to circuits not designed to carry it Figure 2 T lt Topdresser 1800 amp 2500 Page 4 3 Electrical System Troubleshooting Remove all jewelry especially rings and watches before doing any electrical trouble shooting or testing Disconnect the trailer wire harness from the tow vehicle unless the test re quires battery voltage Brush and conveyor do not rotate when control handle Problem with power or ground from vehicle switch is turned to the ON position Fuse 5 Amp is faulty Trailer switch and or battery wire harnesses are not connected or are faulty Control handle switch or circuit wiring is faulty Solenoid valve coil S1 or circuit wiring is faulty Hydraulic problem exists see Chapter 3 Hydraulic System Electrical System 4 4 Topdresser 1800 amp 2500 Component Testing For accurate resistance and or continuity checks elec trically disconnect the component being tested from the circuit e g disconnect the switch connectors before do ing a contin
77. r hang up Contamination can become lodged in small valve orifices or seal areas causing 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 Use eye protection such as goggles when using compressed air for cartridge valve cleaning M CAUTION stored fluid to be released suddenly 6 Clean cartridge valve by submerging valve in clean mineral spirits to flush out contamination Particles as fine as talcum powder can affect the operation of high pressure hydraulic valves If cartridge design allows use a wood or plastic probe to push the internal spool in and out 20 to 30 times to flush out contamination Be ex tremely careful not to damage cartridge Use com pressed air for cleaning 7 Reinstall the cartridge valve into control manifold A Lubricate new seal kit components with clean hy draulic oil and install on valve The O rings sealing rings and backup rings must be arranged properly on the cartridge valve for proper operation and sealing Topdresser 1800 amp 2500 IMPORTANT Use care when handling the valve cartridge Slight bending or distortion of the stem tube can cause binding and malfunction B Thread cartridge valve carefully into correct man ifold port The valve should go in easily without bind ing C Torque cartridge valve using a deep socket to val ues identified in Figures 40 and 41 8 If solen
78. r set screws item 22 Install and tighten set screws to secure locking collars to roller shaft 6 Check that roller is free to rotate and no binding ex ists 7 If rear roller was removed install sprocket spacer square key and then sprocket to roller shaft Make sure that hub side of sprocket is outward away from frame and that sprocket is tight against spacer and roller Apply Loctite 242 or equivalent to threads of set screws item 3 Install set screws to secure sprocket to roller shaft 8 Install conveyor belt to machine see Operator s Manual A Install conveyor belt to machine Make sure that the guide on the underside of the belt is positioned in both roller grooves and also is routed in the slider bed frame cut out B Tighten fasteners that secure slider bed to frame C Pivot hopper down to slider bed and secure with removed fasteners D Connect conveyor drive chain to sprockets Check that conveyor drive chain has 0 125 3 2 mm deflection at mid span between sprockets If neces sary reposition conveyor motor to allow correct chain deflection E Install chain guard Figs 6 and 7 F Adjust tension on conveyor belt 9 Lubricate grease fittings on roller bearings Chassis Page 5 10 NORMAL ROTATION DIRECTION Figure 9 2 Rear conveyor roller Topdresser 1800 amp 2500 This page is intentionally blank Topdresser 1800 amp 2500 Page 5 11 Chassis
79. ressure Test 22 System Flow Test 24 Brush Motor Efficiency Test 26 Topdresser 1800 amp 2500 Page 3 1 Chapter 3 Hydraulic System SERVICE AND REPAIRS 29 General Precautions for Removing and Installing Hydraulic System Components 29 Check Hydraulic Lines and Hoses 29 Brush 30 Brush Motor Service 32 Conveyor 34 Conveyor Motor Service 36 Wheel Motor Topdresser 2500 38 Wheel Motor Service Topdresser 2500 40 Hydraulic Control Manifold Topdresser 2500 44 EATON CHAR LYNN A SERIES GENERAL PUR POSE GEROLER MOTOR REPAIR INFORMATION EATON CHAR LYNN 2000 SERIES DISC VALVE GEROLER MOTOR REPAIR INFORMATION Hydraulic System e 0 Et fo Specifications Item Description Brush Motor Displacement per revolution Eaton orbital rotor motor A Series 2 3 Cubic Inches 38 cc Conveyor Motor Displacement per revolution Eaton orbital rotor motor 2000 Series 29 8 Cubic Inches 488 cc Wheel Motor Pump Topdresser 2500 Displacement per revolution White Hydraulics orbital rotor motor HB Series 5 4 Cubic Inches 89 cc System Relief Pressure Topdresser 2500 1500 PSI 103 bar Before Serial Number 240000000 1325 PSI 91
80. rew 2 used Hydraulic conveyor motor Cap screw 2 used Flat washer 2 used Hopper frame Topdresser 1800 amp 2500 Removal Fig 3 1 Position Topdresser on a level surface with hopper empty Chock Topdresser wheels to prevent machine from moving 2 Remove brush guard from machine see Brush Guard Removal in this section 3 Loosen two 2 lock nuts that secure hydraulic brush motor to hopper frame Do not fully remove lock nuts from cap screws NOTE Normal brush rotation is counter clockwise as viewed from left side of Topdresser Fig 4 4 Loosen set screw item 17 that secures bearing locking collar to brush shaft Using a punch and ham mer rotate locking collar clockwise opposite direction of normal brush rotation to loosen collar 5 Loosen and remove four 4 set screws item 11 from brush 6 Support brush to prevent it from shifting 7 While supporting brush pull brush shaft item 13 from brush 8 Carefully slide brush motor shaft from brush until brush can be removed from brush motor shaft Remove brush from machine Retrieve square key from brush motor shaft 9 If necessary remove flange bearing assembly from hopper frame Installation Fig 3 1 If removed install flange bearing to hopper frame with cap screws flat washers and lock nuts Place cap screws from the inside of the hopper frame to the out side Make sure that bearing grease fitting is orientated up and l
81. rs 2 59 Square Feet Square Meters 0 0929 Square Inches Square Centimeters 6 452 Acre Hectare 0 4047 Volume Cubic Yards Cubic Meters 0 7646 Cubic Feet Cubic Meters 0 02832 Cubic Inches Cubic Centimeters 16 39 Weight Tons Short Metric Tons 0 9078 Pounds Kilograms 0 4536 Ounces Avdp Grams 28 3495 Pressure Pounds Sq In Kilopascal 6 895 Pounds Sq In Bar 0 069 Work Foot pounds Newton Meters 1 356 Foot pounds Kilogram Meters 0 1383 Inch pounds Kilogram Centimeters 1 152144 Liquid Volume Quarts Liters 0 9463 Gallons Liters 3 785 Liquid Flow Gallons Minute Liters Minute 3 785 Temperature Fahrenheit Celsius 1 Subract 32 2 Multiply by 5 9 Product Records and Maintenance Page 2 2 Topdresser 1800 amp 2500 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 e g Loctite degree of lubrication on the fastener presence of a prevailing torque feature hardness of the surface underneath the fastener s head or simi
82. s on the nut and fitting body will verify that the connection has been properly tightened 2 As apreventative measure against leakage it is rec ommended that the face seal O ring be replaced any Size F F W R time the connection is opened Make sure the O ring is A iain nominalhoseor tubing installed and properly seated in the fitting groove Lightly 6 3 8 in 4 2 to 3 4 lubricate the O ring with clean hydraulic oil 8 1 2 in 1 2 to 3 4 10 6 8 in 1 2 to 3 4 12 3 4 in 1 3 to 1 2 3 Place the hose tube against the fitting body so that the flat face of the hose tube sleeve fully contacts the O ring in the fitting 16 1 in 1 8 to 1 2 Swivel Nut 4 Thread the swivel nut onto the fitting by hand While holding the hose tube with a wrench use a torque wrench to tighten the swivel nut to the recommended installation torque shown in Figure 4 This tightening process will require the use of an offset wrench e g crowfoot wrench Use of an offset wrench will affect torque wrench calibration due to the effective length change of the torque wrench Tightening torque when using a torque wrench with an offset wrench will be lower than the listed installation torque see Using a Torque Wrench with an Offset Wrench in the Torque Specifica tions section of Chapter 2 Product Records and Main tenance 5 i 5 gt Figure 2 5 Ifa torque wrench is not available or if space
83. se is provided for remote readings The Pressure Test Kit contains one each 1000 PSI 70 Bar 5000 PSI 350 Bar and 10000 PSI 700 Bar gauges Use gauges as recommended in the Testing Section of this chapter Hydraulic Tester Pressure and Flow Toro Part Number TOR214678 This tester requires O ring Face Seal ORFS adapter fittings for use on this machine 1 INLET HOSE Hose connected from the system cir cuit to the inlet side of the hydraulic tester 2 LOAD VALVE A simulated working load is created in the circuit by turning the valve to restrict flow 3 LOW PRESSURE GAUGE Low range gauge to pro vide accurate reading at low pressure 0 to 1000 PSI A protector valve cuts out when pressure is about to exceed the normal range for the gauge The cutout pressure is adjustable 4 HIGH PRESSURE GAUGE High range gauge which accommodates pressures beyond the capacity of the low pressure gauge 0 to 5000 PSI 5 FLOW METER This meter measures actual oil flow in the operating circuit with a gauge rated at 15 GPM 6 OUTLET HOSE A hose from the outlet side of the hydraulic tester connects to the hydraulic system circuit Hydraulic System Page 3 14 Figure 9 Figure 10 Topdresser 1800 amp 2500 Hydraulic Test Fitting Kit Toro Part Number TOR4079 TORO TEST FITTING KIT TOR4079 This kit includes a variety of O ring face seal fittings to a LEE Swivel Nut Run Tee 2 ea Toro No enable connection o
84. see Wheel Removal in this section 4 Remove wheel motor from cradle assembly see Wheel Motor Removal in the Service and Repairs sec tion of Chapter 3 Hydraulic System 5 Remove both skid plates from the frame 6 Loosen and remove set screw from locking collar of both flange bearings 7 Support cradle assembly to keep it from shifting 8 Remove four 4 lock nuts and flat washers that se cure both flange bearings to frame 9 Slide both flange bearings from cradle assembly piv ot and studs on frame 10 Lower cradle assembly from frame and remove from machine 11 Remove components from cradle assembly as essary see Cradle Axle Removal in this section Topdresser 1800 amp 2500 Page 5 17 Installation Fig 13 1 Install all removed components to cradle assembly see Cradle Axle Installation in this section 2 Position cradle assembly under frame Raise cradle to frame and place both flange bearings to cradle as sembly pivot and studs on frame 3 Secure flange bearings to frame with four 4 lock nuts and flat washers 4 Center cradle assembly in frame between bearings Tighten bearing collar set screws to secure cradle as sembly in frame 5 Install wheel motor to cradle assembly see Wheel Motor Installation in the Service and Repairs section of Chapter 3 Hydraulic System After wheel motor instal lation make sure that drive chain is properly tensioned 6 Secure both
85. ser is attached to tow vehicle engage tow vehicle parking brake stop engine and remove key from the ignition switch 2 Remove brush guard from machine to gain access to brush motor see Brush Guard Removal in the Ser vice and Repairs section of Chapter 5 Chassis 3 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter 4 Label all hydraulic connections for assembly pur poses Thoroughly clean hydraulic hoses and fittings prior to loosening hydraulic lines at brush motor 5 Disconnect hydraulic lines from hydraulic fittings on brush motor Allow hydraulic oil to drain from lines into a suitable container Put caps or plugs on open hydraulic lines and fittings to prevent contamination Remove and discard O rings 6 Support brush to prevent it from shifting during brush motor removal 7 Loosen two 2 set screws item 11 that secure brush shaft to brush motor shaft 8 Support brush motor to prevent it from shifting Re move two 2 cap screws item 23 flat washers item 24 and lock nuts item 2 that secure motor to frame Slide brush motor from the brush shaft and remove from machine Locate and retrieve woodruff key from motor shaft 9 If required remove hydraulic fittings and O rings from the brush motor Discard O rings Topdresser 1800 amp 2500 Page 3 31 Installation Fig 27 1 If removed
86. this section 14 Lubricate grease fitting on flange bearing NORMAL ROTATION DIRECTION Figure 4 5 Slide brush motor shaft into brush Make sure that 1 Bras 2 Rear conveyor roller square key remains in motor shaft and that the key is aligned with slot in brush Topdresser 1800 amp 2500 Page 5 7 Chassis Rollers Loctite 242 Antiseize Lubricant Antiseize Lubricant Antiseize Lubricant Figure 5 1 Slider bed frame 10 Spring holder 2 used per side 2 Driven sprocket 11 Compression spring 2 used 3 Set screw 2 used 12 Spring pin 2 used 4 Sprocket spacer 13 Hex nut 3 used per side 5 Bearing 14 Screw 2 used per bearing 6 Rear roller 15 Lock washer 2 used per bearing 7 Conveyor belt 16 Lock nut 4 used per side 8 Wear plate 2 used 17 Flat washer 4 used per side 9 Pop rivet 18 used To prevent personal injury make sure that roll ers are well supported as they are removed from the machine Front roller weighs approxi mately 65 pounds 29 5 kg Rear roller weighs approximately 73 pounds 33 1 kg Chassis Page 5 8 Antiseize Lubricant Spring plate 2 used Slide washer 4 used per side Spacer 4 used per side Front roller Set screw 1 used per bearing Locking collar 1 used per bearing Square key Grease fitting 1 used per bearing Topdresser 1800 amp 2500 Removal Fig 5 1 Position Topdresser on a level surface w
87. tings to prevent contamination Discard any removed O rings 7 Support control manifold to prevent it from falling Remove four 4 cap screws and flat washers that se cure hydraulic manifold to the machine frame 8 Remove hydraulic manifold from the machine 9 Remove hydraulic fittings from manifold as needed Discard any removed O rings Hydraulic Manifold Service Figs 40 and 41 1 Make sure the control manifold is clean before re moving any cartridge valve 2 If solenoid cartridge is being serviced remove nut securing solenoid to the cartridge valve Carefully slide solenoid off the valve Operate all sweeper hydraulic controls to relieve system pressure and to avoid injury from pres surized hydraulic oil See Relieving Hydraulic System Pressure in the General Information sec tion of this chapter IMPORTANT Use care when handling the cartridge valve Slight bending or distortion of the stem tube can cause binding and malfunction 3 Remove cartridge valve with a deep socket wrench Note correct location for O rings sealing rings and backup rings Remove and discard seal kit from valve Hydraulic System Page 3 46 Figure 42 1 Hydraulic manifold 2 Drawbar 4 Visually inspect the manifold port for damage to the sealing surfaces damaged threads and contamination 5 Visually inspect cartridge valve for damaged sealing surfaces and contamination A Contamination may cause valves to stick o
88. to threads of set screws item 14 Center sprocket in cradle and secure in position with two 2 set screws Make sure that sprocket does not contact head of carriage bolt item 24 7 Apply Loctite 242 or equivalent to threads of cap screw item 16 Install cap screw lock washer item 17 and flat washer item 15 into wheel motor shaft 8 Rotate wheel motor to take slack out of chain but not so tight that binding occurs on sprockets Tighten lock nuts to secure motor to cradle 9 Check that chain has 0 125 3 2 mm deflection at mid span between sprockets If necessary reposition wheel motor to allow correct chain deflection 10 Remove caps or plugs that were put on any hydraulic lines and fittings during disassembly 11 Lubricate new O rings with clean hydraulic oil and position on fittings Using labels made during removal correctly connect and secure hydraulic hoses to hydrau lic fittings on wheel motor Antiseize Lubricant Loctite 242 3 Make sure that roller chain is positioned around Figure 34 wheel motor sprocket and that hub of sprocket is away 1 Hydraulic motor 5 Lock washer from wheel motor position 2 Square key Flat washer 3 Set screw 2 used 7 Sprocket 4 Make sure that carriage screw is placed in cradle 4 8 Drive chain hole Topdresser 1800 amp 2500 Page 3 39 Hydraulic System E ESA fo Wheel Motor Service Topdresser 2500 Figure 35 1
89. towed in the reverse direction flow from the wheel motors will reverse Check valves CV3 and CV1 however are placed in the hydraulic manifold to prevent reverse flow through the hydraulic system Hydraulic System 5 gt I 51 CV N WHEEL MOTOR gt 3 J PUMP o gt 54CUIN REV BRAKE ENERGIZED gt SYSTEM RELIEF 1325 PSI CHARGE RELIEF BRUSH CONVEYOR MOTOR MOTOR 2 3 CU IN REV 29 8 CU IN REV Nou CHARGE MOTOR NI gt L 813 CU IN REV J 232 CU IN REV Topdresser 2500 Switch On Serial Number Above 240000000 Shown Working Pressure Charge Pressure Return or Suction Flow Hydraulic System Page 3 12 Topdresser 1800 amp 2500 Topdresser 2500 Operation Switch On While being towed in the forward direction with the Top dresser control handle switch in the ON position the wheel motors act as pumps to provide hydraulic flow for the system Flow from the wheel motors is directed to the control manifold through two ports A1 Energized solenoid cartridge valve S1 diverts flow from the man ifold out port M1 to the brush motor and then to the con veyor motor Hydraulic flow causes rotation of both the brush motor and the conveyor motor which are connected in series The brush is driven directly by the hydraulic brush motor The conveyor belt is driven
90. uity check on switch When testing electrical components for continu ity with a multimeter ohms setting make sure that power to the circuit has been disconnected Control Handle Switch The control handle switch is used to activate the Top dresser 2500 brush and conveyor by energizing sole noid valve coil S1 on the hydraulic manifold When the control handle switch is in the OFF position the solenoid is not energized allowing hydraulic flow to bypass the brush and conveyor motors On machines with serial numbers below 250000000 the control handle switch is a toggle switch Fig 3 On machines with serial numbers above 250000000 the control handle switch is a rocker switch Fig 4 The function of either switch type is identical Testing lt 1 Make sure the Topdresser switch wire harness is un plugged from the battery harness 2 Disassemble control handle to gain access to control handle switch Figure 3 1 Handle 3 Switch harness 3 With the use of a multimeter ohms setting deter 2 Toggle switch mine whether continuity exists between the switch ter minals A When the switch is in the ON position there should be continuity between the two switch termi nals B When in the OFF position there should be no continuity between the switch terminals 4 Replace switch if necessary Assemble handle 5 Connect switch wire harness to battery harness
91. w meter installation Fig 17 5 Install hydraulic tester flow meter between discon nected hose and fitting Make sure that tester flow arrow Figure 21 4 Lee points from the hose and into the fitting Make sure the 12 Brush motor 3 45 hydraulic fitting 26 2 Hydraulic hose flow control valve on the tester is fully open 9 gt 6 Start engine on tow vehicle and tow the Topdresser Turn the Topdresser control handle switch to the ON Ground Ppesd hicle speed and the hydraulic tester flow gauge System 3 MPH 4 8 KPH 2 7 GPM 10 2 LPM Flow is dependant on ground speed and should be as shown in the chart to the right Fig 22 a MENG RETI S6 GEMS SEPM 5 MPH 8 0 KPH 4 5 GPM 17 0 LPM Figure 22 position While operating the machine monitor the ve 2 MPH 3 2 KPH 1 8 GPM 6 8 LPM 7 system flow is less than specified consider that one or both of the wheel motors are worn or inefficient It should be noted that if system flow is low operation of both the brush motor and the conveyor motor would be affected 8 When testing is complete remove hydraulic tester flow meter and connect hose to brush motor fitting Make sure hydraulic tank is full Topdresser 1800 amp 2500 Page 3 25 Hydraulic System Brush Motor Efficiency Test SCHEMATIC FOR MACHINE WITH SERIAL NUMBER ABOVE 240000000 SHOWN lt WHEEL MOTOR 77 PUMP J amp 4CUIN REV

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