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99024SL - Toro Media

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8. Figure 8 1 Return spring 5 Retaining clip 2 Brake shoe toe end 6 Cam shaft 3 Brake shoe heel end 7 Anchor pin 4 Backing plate Rev C Wheels Brakes and Miscellaneous o E a and Miscellaneous Rear Fork and Wheel Figure 9 1 Hydraulic cylinder 14 Drive stud 27 Hex flange head screw 2 Ball joint 15 Wheel hub 28 Bushing 3 External retaining ring 16 Lock nut 29 Cap screw 4 Grease fitting 17 45 hydraulic fitting 30 Lock nut 5 Grease fitting plug 18 Hydraulic motor 31 O ring 6 Jamnut 19 Hydraulic hose 32 O ring 7 Rear fork 20 Hydraulic hose 33 O ring 8 Cap screw 21 Lug nut 34 O ring 9 Lock washer 22 Clamp 35 Hose assembly 10 Thrust washer 23 Spacer 36 Hose assembly 11 Tire 24 Case drain clamp 37 Valve stem 12 Hex socket head screw 25 Hydraulic fitting 38 Wheel rim 13 Lock nut 26 Rear casting 39 Woodruff key Removal 3 Separate hydraulic cylinder from the rear fork as fol lows 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key A Remove both jam nuts securing the ball joint to from the ignition switch the rear fork 2 Remove hood from the machine see Hood Remov B Separate ball joint from the rear fork al C Swing cylinder clear of the rear fork Wheels Brakes and Miscellaneous Page 6 8 Reelmaster 3100 D A WARNING
9. T33HM NOILOVH L Y uva MOsINVIN ZL lt 2 H a uoljong jo umay s ainsselg YH 11083 1331 i S HN3119 0012 Reelmaster 3100 D Page 4 10 Hydraulic System Rev C Traction Circuits Forward The traction circuit of the hydraulic system consists of a hydrostat connected in a closed loop circuit to three or bital vane wheel motors The engine drives traction pump P3 indirectly through pulleys and a V belt The traction pump is a variable dis placement piston pump The traction pedal connects through a cable to the trunnion shaft and swash plate of the pump With the engine running and the traction ped al in the neutral position P3 supplies no flow to the wheel motors When the traction pedal is pressed to the forward position the cable from the pedal positions the swash plate in the traction pump so oil flows out of the lower port Oil flow out of the lower port goes to the wheel motors and turns them in the forward direction Oil flow ing out of the wheel motors returns to upper port of the hydrostat and is continuously pumped out of the lower port The rear wheel motor has a small check valve across its ports that allows the rear motor to over run during tight turns in the forward direc
10. Y 10 Carefully remove dust seal retaining ring flange 5 washer and shaft seal from the front flange Fig 46 3 Discard seals D Figure 46 3 Inspection 1 Dustseal 4 Shaftseal 2 Retaining ring 5 Drive shaft 3 FI h 1 Remove any nicks and burrs from all parts with oc emery cloth A CAUTION Use eye protection such as goggles when using compressed air 2 Clean all parts with solvent Dry all parts with com pressed air 3 Inspect drive gears and idler gears for the following Fig 46 4 A Gear shafts should be free of rough surfaces and Figure 46 4 excessive wear at bushing points and sealing areas 1 Gear shaft spline 3 Gear teeth Scoring rough surfaces or wear on gear shafts indi 2 Gear shaft 4 Gear face edge cates need for replacement Assembly Fig 46 1 B Gear teeth should be free of excessive scoring and wear Any broken or nicked gear teeth must be NOTE When assembling the motor check the marker replaced line on each part to make sure the parts are properly aligned during assembly C Inspect gear face edge for sharpness Sharp edges of gears will mill into wear plates and thus must be replaced Reelmaster 3100 D Page 4 75 2 Rev E Hydraulic System 1 Lubricate O rings pressure seals back up gaskets and wear plate grooves with a thin coat of petroleum jel ly Lubricate all other internal parts freely with clean hy draulic oil 2
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18. Switch bracket Carriage screw Nut Page 4 116 Not used Lock washer Guard Cap screw Cap screw Lock nut External retaining ring Pin O ring Hydraulic hose Hydraulic hose Not used Not used O ring Hydraulic hose Hydraulic hose Hydraulic hose O ring Hydraulic hose Reelmaster 3100 D Removal 1 Remove rear lift cylinder from the frame and lift arm using Figure 82 as guide 2 If hydraulic fittings are to be removed from lift cylin der mark fitting orientation to allow correct assembly Reelmaster 3100 D Page 4 117 Installation 1 If hydraulic fittings were removed install fittings to lift cylinder using marks made during the removal process to properly orientate fittings 2 Install rear lift cylinder to the frame and lift arm using Figure 82 as guide 3 Adjust rear lift arm see Adjust Rear Lift Arm in Chap ter 7 Cutting Units Hydraulic System Rev C 2g E gt Lift Cylinder Service Figure 83 1 Grease fitting 6 O ring 11 Internal collar 2 Barrel with clevis 7 O ring 12 Dust seal 3 Nut 8 Back up ring 13 Shaft 4 Uni ring 9 Rod seal 14 Jam nut 5 Piston 10 Head 15 Clevis Hydraulic System Rev C Page 4 118 Reelmaster 3100 D Disassembly 1 Remove oil from lift cylinde
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25. 4 Fuel Tank Removal 15 Fill Fuel Tank 5 Drain and Clean Fuel Tank 15 Check Cooling System 5 Fuel Tank Installation 15 ADJUSTMENTS 6 Replace Fuel Prefilter 15 Adjust Throttle Cable 6 Radiator 16 Adjust Alternator Fan Belt 7 Removal RT oi Rate UR 16 SERVICE AND REPAIRS 8 Installation 17 Change Engine Oil and Filter 8 Clean Radiator and Oil Cooler 18 Replace Traction 8 pere 20 Bleed Fuel System 9 Removal REX MEX E 20 5 Bleed Air from 5 9 Installation oct em das ek bee 22 gU Muffler and Air Cleaner 10 KUBOTA WORKSHOP MANUAL DIESEL ENGINE 2 Muffler 11 05 SERIES x Muffler Installation 11 Check Air Filter Dust Cup amp Burp Valve 12 Service Air Filter Dust Cup amp Burp Valve 12 Reelmaster 3100 D Page 3 1 Kubota Diesel Engine Introduction This Chapter gives information about specifications maintenance troubleshooting tes
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27. 1 Verify coil resistance between terminals 86 and 85 with a multimeter ohms setting A On machines with serial numbers below 240000000 resistance should be from 41 to 51 ohms B On machines with serial numbers above 240000000 resistance should be approximately 72 ohms 2 Connect multimeter ohms setting leads to relay ter minals 30 and 87 Ground terminal 86 and apply 12 VDC to terminal 85 The relay should make and break continuity between terminals 30 and 87 as 12 VDC is ap plied and removed from terminal 85 3 Disconnect voltage and leads from the terminals Start Seat and High Temperature Shutdown Relays These relays are located under the control panel on ma chines with Serial Numbers below 240000000 1 Verify coil resistance between terminals 86 and 85 with a multimeter ohms setting Resistance should be from 80 to 90 ohms There should be continuity between terminals 87A and 30 2 Connect multimeter ohms setting leads to relay ter minals 30 and 87 Ground terminal 86 and apply 12 VDC to terminal 85 The relay should make and break continuity between terminals 30 and 87 as 12 VDC is ap plied and removed from terminal 85 3 Disconnect voltage from terminal 85 and multimeter lead from terminal 87 4 Connect multimeter ohms setting lead to relay ter minal 30 and 87A Apply 12 to terminal 85 The relay should make and break continuity between termi nals 30 and 87A as 12 VDC is app
28. 3 o 5 Wheels Brakes and Miscellaneous Page 6 14 Reelmaster 3100 D Chapter 7 TORO Cutting Units Table of Contents SPECIFICATIONS 2 SERVICE AND REPAIRS 13 SPEGIAE TOOLS E Xem ne i 3 Greasing Bearings Bushings and Pivot Points 13 TROUBLESHOOTING 5 Backlapping 14 ADJUSTMENTS xut nr eus 7 Cutting Unit Removal and Installation 15 Characteristics 7 Reel Motor Removal and Installation 16 Daily Adjustments 7 Reel Removal and Bearing Replacement 17 Adjust Bedknife Parallel to Reel 8 Bedbar Removal and Installation 18 Verify Height of Cut and Front Roller Level 9 Bedknife Replacement and Grinding 20 Set Height of Cut and Level Both Rollers 10 Roller Removal and Installation 21 Adjust Front Lift 11 Roller Bearing and Seal Replacement 22 Adjust Rear Lift Arm 12 Prepare Reel for Grinding 24 Fixed Side Plate Installation 25 Front Lift Arms Removal and Installation 26 Rear Lift Arm Removal and Installation 28 Skid Kit Installation 30 Carrier Frame Remov
29. 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Park machine on a level surface with the cutting units lowered and off Make sure engine is off and the parking brake is engaged 3 Read Precautions for Hydraulic Testing Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hy draulic System Pressure in the General Infor mation section 4 Disconnect hose to the rear 90 hydraulic fitting on the piston pump coming from the hydraulic manifold port CHG Connect T connector and gauge to the fitting and hose connection 5 Operate engine at full speed 2650 50 RPM 6 Make sure that traction pedal is in neutral and the parking brake is engaged 7 Pressure gauge should read from 100 to 150 PSI 8 If charge relief pressure specification is not met con sider the following A The piston pump charge relief valve is faulty Re pair or replace the piston pump charge relief valve see Piston Pump Service in the Service and Repairs section B Gear pump P2 is faulty steering and lift circuits are also affected Reelmaster 3100 D Page 4 35 9 A dynamic charge pressure test can be performed as follows A With T connector and pressure gauge still con nected sit in the operator seat and press the traction pedal to forward B While machine is movin
30. 6 Remove check poppets seats O rings and plung ers from the valve body 7 Remove solid plug back up washer and O ring from the opposite end of the plunger 8 Remove plug and O ring from the top of the valve body next to the detent plug 9 Remove detent plug and O ring from the valve body Remove disc spring and detent plunger from the body Inspection 1 Inspect spools and spool bores for wear If wear is excessive replace valve with new one 2 Inspect springs and replace as necessary 3 Inspect plunger detent plunger and check poppet for wear Replace as necessary 4 Inspect seat spacer and bushing for wear Replace as necessary 5 Inspect disc and washer Replace as necessary 6 Inspect cap and plugs for damaged threads and O ring sealing surfaces Replace as necessary Hydraulic System Rev C Page 4 94 Assembly IMPORTANT Do not wipe parts with paper towels or rags Lint may cause damage to the hydraulic sys tem M CAUTION Use eye protection such as goggles when using compressed air 1 Clean all metal parts with solvent and blow dry with compressed air 2 Replace check poppets O rings and back up washers with new ones 3 Install new O rings into the valve body 4 Slide bushings and new O rings over the spools 5 If a spool was disassembled install washer spool spring spacer and retaining ring to the spool 6 Lubricate spools liberally with clean h
31. Engine run solenoid or fuel pump faulty The fuel tank is empty An engine or fuel system problem exists The glow circuit does not operate properly The glow circuit does not operate properly Wiring in the glow circuit see Electrical Schematics is loose corroded or damaged The glow relay or glow plug controller is faulty Fuse F4 is blown or faulty Engine cranks but should not with the reel on off The reel on off switch is faulty or short circuited switch in the ON position Perdre Short circuit in reel drive neutral switch circuit T5 4 Reelmaster 3100 D Page 5 25 Electrical Systems Rev C General Run and Transport Problems Engine kills during operation operator sitting on seat Engine kills when the backlap switch is in the BACKLAP position and the parking brake is ON Battery does not charge Electrical Systems Rev C Page 5 26 Operator moved too far forward on seat seat switch is not depressed The engine overheated The parking brake was engaged or the parking brake Switch No 1 failed The seat relay or seat switch failed The high temperature shutdown relay failed Fuse F1 or F3 failed The run solenoid or fuel pump failed Wiring in the run circuit see Electrical Schematics broke or disconnected The parking brake was released or the backlap switch was moved to MOW The engine overheated The traction pedal was move
32. H3NIVHLS Y Y isd 0001 1 p IWLSOYGAH 1 2 1 PAN H wp 3 3NION3 teal A 3e gt lt 15 gel ld x Td 1 Isd 091 01001 i t H31000 rq 110 zi 3 gt M T i isd 000 isd 000 TES IMYA 1HOd JAVA 440 NO lt H is 194 JAVA Mi H3TIOH1NOO 2 91901 j 48345 133u 101 o 3NVA SNIdd V DIOva SHOLON T33HM NOILOVH L Sh 21 MO lt ld JO ainssaig YH e pueix3 5 001 lt Reelmaster 3100 D Page 4 18 Hydraulic System Rev C Sidewinder Circuit The gear pump P2 is directly coupled to the hydrostat through gear pump P1 It supplies hydraulic pressure charge pressure for raising and lowering the cutting units operating the sidewinder unit and maintaining 100 to 150 PSI 6 9 to 10 0 bar to the low pressure side of the traction circuit The pump takes its suction from the hydraulic reservoir During conditions of not lifting or lowering the cutting units flow from the gear pump is by passed through the power steering valve 2 spool valve and hydraulic manifold directly to the hydrostat and the charge relief
33. Tilt steering boss Friction disc Page4 104 Hev D 20 to 26 ft lb 27 1 to 35 3 N m A 32 29 30 31 32 33 34 35 36 37 38 39 40 41 Friction disc Flat washer Jam nut Lock nut Flat washer Not used Not used O ring O ring O ring Philips head screw Steering wheel cap Steering shield Reelmaster 3100 D Removal Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hy draulic System Pressure in the General Infor mation section 1 Remove steering control valve from the steering col umn using Figures 70 71 and 72 as guides Installation 1 Install steering control valve to the steering column using Figures 70 71 and 72 as guides Figure 71 1 Tilt bracket 5 Friction disc 2 Steering valve bracket 6 Lever 3 Jamnut 7 Steering arm 4 Flat washer 8 Friction disc 2 E gt Figure 72 1 Cap screw 4 Steering arm 2 Flange nuts 5 Steering control valve 3 Steering valve bracket 6 Friction disc Reelmaster 3100 D Page 4 105 Hydraulic System Rev C Steering Control Valve Service Serial Numbers 90101 to 230999999 Figure 73 1 Nut 18 Socket head screw 2 Port cover 19 Commutator seal 3 Sealring 20 Commutator cover 4 O ring 21 Commutator ring 5 Relief valve cartridge 22 Commutator 6 Plug 23 Drive link spacer 7 Push nut 24 Rot
34. uv3o GEN 1YLSOYQAH 4 2 1 isd 0001 1no i ONIH33IS 1 2 t 4 3NION3 NI u ame Al js ___ d eos isd 081 001 NI 29 EE 39 m 1 1 52 ISi b T ISd 0006 uo i ISd 0006 437384 T E 22 1HOd 1HOd V IMYA 3ATIVA H4AO NO 1334 Eis 214 m 1334 Q 103INVIA amva 7 91501 101 O JMA 4 H Y 1408 dOL auvMuO4 uvau Cc SA 46 NMOHS LON LNOHJ 1331 SI 133H TVNIJ ANY HOLON uvau SI HOLOW 1 1344 000000082 d SHASINNN 1VIH3S _ a S3NIHOVIN NO IN NMOHS HV3H SI HOLOW ANY HOLOW 1838 1431 11083 SI LNOYS DNILLND NI HOLOW 1331 7334 000000062 SHOIOW T33HM 1 MO138 1VIH3S S3NIHOVIN NO 310N 2 Hydraulic Schematics uMous IV oineap H 002 0 ISPOW Q 001 14eiseujeeu Reelmaster 3100 D Page4 8 Hydraulic System Rev C
35. 1vIu3s JLIMS T N 3N80 1338 Hans yas ar gd gt 4 1 8 uOLVNIBLI 440 NO 1338 L 04 ONnOMD 3NIDNJ t X 9 QION310S 18715 WALNIN 190 1 911 1 LIWII 1338 Electrical Systems Rev Rev F Page 5 21 Reelmaster 3100 D pue 00000082 SJequunw jeues wureabeig Buu C OOTE NMOGLNHS 755244 MS LINDT MON 105 dW3l 83AO0 oyiyyym 110 301983 10 30010 440 NO 1338 1334 1804SNVHl JAIXO 1338 71303 83 0 041083105 NAY Led 24 ON 14 gid Sid 4 1104 82112 8256 See le vJ le vJ ay Us x J L ie 8 Y E gt 2 o m a E 2 gt 8 N33u5 dVDOVG sel MOTI3A w E m T 8 MS
36. 29 Threaded clevis 45 Seat belt 13 Hex head machine screw 30 Nut 46 Hex flange nut 14 Arm rests 31 Washer 47 Flat washer L o 15 Bottom cushion 32 Backrest trim 48 Cap screw 5 16 Adjusting LH 33 Tension spring set 49 Hex flange head screw as 17 Screw 34 Spindle adjuster incl 29 thru 31 35 amp 36 50 Seat support strap 2 2 3 Removal Installation 1 Park machine level surface lower units 1 Install any new seat parts using Figure 6 as a guide stop engine engage parking brake and remove key from the ignition switch 2 Position seat and support straps to the fuel tank and frame 2 Remove four hex flange head screws securing the seat support straps to the frame 3 Disconnect electrical connector from the seat switch Separate seat from the frame 3 Connect electrical connector to the seat switch 4 Remove seat parts as necessary to make repairs us ing Figure 6 as a guide Reelmaster 3100 D Page6 5 4 Secure seat support straps to the frame with four hex flange head screws Wheels Brakes and Miscellaneous Front Wheel and Brake Figure 7 1 Lugnut 12 Brake lever 23 Spacer 2 Drive stud 13 Lock nut 24 Wheel shield 3 Wheel rim 14 Cap screw 25 Cotter pin 4 Tire 15 Brake bracket 26 Clevis pin 5 Wheel hub 16 Return spring 27 Clevis 6 Lock nut 17 Brake shoe 28 Jam nut 7 Hydraulic motor 18 Backing plate 29 Fla
37. FROM HYDRAULIC MANIFOLD CHG PORT l l l m l PISTON PUMP HYDROSTAT TO GEAR PUMP SUCTION High Pressure THROUGH CASE DRAIN Low Pressure Return or Suction Flow Hydraulic System Rev C Page 4 32 Reelmaster 3100 D Procedure Piston Pump Flow and Traction Relief Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Park machine on a level surface with the cutting units lowered and off Make sure engine is off 3 Read Precautions for Hydraulic Testing 4 Make sure that traction pedal is adjusted to the neu tral position see Adjust Traction Drive for Neutral in the Adjustments Section One front wheel and the rear wheel will be off the ground during testing Make sure machine is sup ported so it will not move and accidentally fall to prevent injuring anyone under machine 5 Block up one front traction wheel and the rear wheel off the floor to allow flow through the traction circuit dis connect brake linkage to this wheel see Wheels and Brakes Chapter 7 6 Chock remaining front wheel to prevent movement of the machine Apply parking brake 7 Attach a heavy chain to the rear of the machine frame and something immovable in the shop 8 Disconnect hose from the lower hydraulic fitting on the bottom of the hydrostat N
38. N gt HOLIMS 2 2 Go Wig 3JO NO 1999 9 Z N g 5 n 2 xr NO 9 d E ND 2i ONbIuvd 3SH3Adu QuvMHOd NI 15 m ER MN m SNIDNG E uamiuvis HOLIMS HOLMS 5 13 lin 5 3 T 5 35 5 ea V7 1 lt y W go ees 1 ayvua dunss3ud L d PZB Ore SNbIuvd i ANIONS Sard 5 9 00801 sas079 M Z ALdW3 1735 E ee U HOLIMS 1 SNIDNA YILIN m 80 D 0059 gt D C H LIMS 1V3S 5 SIG GION310S NOY gt Sang gt HOLVNH3LTV 5 7 Electrical Systems Rev C Reelmaster 3100 D 05106 01 10106 5 jeues 4 0012 2 4 ON HOLIMS 12 ONDIHVd 9 dV iov sr HOLIMS 474 zr ir ON L HOLIMS 9d 3 vug orr LWAS 8d HOLIMS 1785 Sd HOLIMS 1 35 2 gt weibeig 5 20 z 8 om oD on m 95 GION310S zm EI v S045 2 NDS HOLIMS 20 33O NO 1399 o9 oss zia rz om Rs 2 5 oz 81 Sid 5 v ele
39. Reelmaster 3100 D Leveling Rear Roller The precision machined components ofthe cutting unit frame keep the rear roller and cutting reel in alignment parallel If the side plates are disassembled or as the cutting reel wears a limited amountof side plate adjust ment is possible to make sure that the cutting unit is properly aligned 1 Place the assembled cutting uniton a surface plate 2 Make sure that bedknife is properly adjusted to cut ting reel 3 Using the surface plate check if rear roller is level to cutting reel by using a 0 005 0 13 mm shim at each end of rear roller If the shim will pass under the roller at one end butnotthe other a frame adjustment should be made 4 Loosen but do not remove the three 3 shoulder bolts thatsecure the side plate to the frame opposite the side thatis not level Fig 12 5 Adjust the position of the side plate to parallel the rear roller and cutting reel Then tighten the shoulder bolts to a torque from 27 to 33 ft lb 37 to 44 N m 6 After tightening the side plate recheck the rear roller If necessary loosen and adjust second side plate 7 If rear roller is still not level after adjusting both side plates check to see if cutting reel is tapered see Pre paring Reel for Grinding in the Service and Repairs sec tion of this chapter If cutting reelis nottapered and rear rolleris notlevel a 0 010 shim partnumber 107 4001 is available to allow additional r
40. cx GO Lom ST Xd lt S8 1 1 57338 c NH HOLIMS ANON 4015 LHOdSNVUL S1334 440 51884 L NO o M o oe is A re A Ly LHON vd TTA 16666 HO LIMS MOWN LHOdSNVH L HOLIMS e lt na 28 NOLLINOI JOS af ot E vs 0 1 gt gt uo SE NE Bm 4 lt IA 5 i 9 lt gt y HOLIMS HOIH E 3NION3 iq 44O NO 57838 Bla m omia E NO Ar 2 21 CIVHLO3N 29 8 S m ONS TY HOLIMS t 9 fi 2 2 ga HOLIMS qWHLNAN soi a ds Wes E dV ova eg g m 9 g 7 24 ge Av 3H 1 36 M NO gt _ t 34 VH8 ONY a MOT9N3 F 00901 536010 1 36 0 ana as HOLIMS 1V3S 3NION3 TN gt 00011 1v 535010 A HOLIMS 1nHS 3NION3 HOLIMS LVS WNOlLdO z f d GION3110S 8 Electrical Systems Rev C 666666062 01 19106 5 ulo1s S
41. 1 Use Toro General Service Training Book Reel Mower Basics part no 09168SL and grinder manufacturer s instructions for bedknife grinding in formation Bedknife Grinding Specifications see Fig 25 Bedknife Relief Angle 39 to 79 39 to 79 0 190 4 8 mm Bedknife F ront Angle Minimum Bedknife Lip Height DPA Cutting Units Rev G Page 8 22 2 After grinding bedknife check lead in chamfer on bedknife see Cutting Unit Operator s Manual 3 After bedknife grinding is complete install bedbar to cutting unit see Bedbar Installation in this section Antiseize Lubricant 200 to 250 in Ib 23 to 28 1 Lightly Oil Bedbar Surface Figure 23 1 Screw 3 Bedknife 2 Bedbar Figure 24 Remove Top Face Burr Bedknife Relief Angle Lip Height Front Face FrontAngle Figure 25 Reelmaster 3100 D This page is intentionally blank D os 5 Reelmaster 3100 D Page 8 23 DPA Cutting Units Rev G Reel Assembly Removal and Installation Grease OD surface 27 to 33 ft Ib 37 to 44 N m See text for tightening procedure Grease bore 12 and threads Antiseize 27 to 33 ft Ib Lubricant 37 to 44 N m Figure 26 1 Bedbarassembly 9 LHside plate 16 Spline insert RH thread 2 Flange nut 3 used per side plate 10 Weight 17 Retaining ring 2 used 3 Flange bushing 2 used 11 Cap screw 2 used 18 Grease seal 2 used 4 Plastic washer 4 used
42. 4 If adjustment is necessary adjust brakes as follows A Remove both front wheel assemblies from the machine see Front Brake and Wheel Removal in the Service and Repairs section B Adjust brakes by turning clevis to increase or de crease shoe pressure on the brake drum Fig 4 Make sure that brake shoes do not drag against drums with the parking brake lever released Reelmaster 3100 D Page 6 1 2 1 C If brakes not be adjusted properly repair replace brake components as necessary D After adjustment is complete install front wheel assemblies to the machine see Front Brake and Wheel Installation in the Service and Repairs sec tion E Lower front wheels to the ground F Before starting engine close by pass valve on pump by rotating it 90 degrees Fig 3 Figure 2 Set screw 3 Brake lever Adjustment knob Figure 3 Piston pump 2 By pass valve Figure 4 Clevis 4 Wheel hub Adjustment rod 5 Cotter pin Brake lever 6 Jamnut Rev C Wheels Brakes and Miscellaneous an 38 pt 32 gt Service and Repairs Standard Seat Figure 5 1 Seat incl 4 thru 7 14 amp 15 7 Seat shell 2 Cap screw 8 Seat belt 3 Spring lock washer 9 Seat adjuster with latch 4 Edging clip 10 Flange hex nut 5 Edging 11 Cap screw 6 Seat cushion repair kit 12 Lock washer Removal 1 Park machine
43. Page6 7 E Position both brake shoes on the backing plate so that the concave heels attach to the anchor pin F Insert both return springs into the holes of both brake shoes Make sure shoes fit snuggly against the anchor pin and cam 3 If the brake lever backing plate retaining clip return springs brake shoes and cam shaft were removed as a complete brake assembly secure backing plate to the brake bracket with four cap screws and lock washers Tighten fasteners 4 Attach adjustment rod to the brake lever Secure ad justment rod with cotter pin 5 Thoroughly clean wheel motor shaft and wheel hub taper 6 Install woodruff key to the slot on the hydraulic motor shaft Slide wheel hub and brake drum assembly onto the shaft 7 Secure wheel hub and brake drum to the hydraulic motor shaft with lock nut NOTE For proper brake operation the brake shoes and backing plate must be concentrically aligned with the brake drum 8 To align brake shoes and drum apply parking brake Then tighten four socket head screws and lock nuts that secure the brake bracket and wheel motor to the frame 9 Place wheel onto drive studs and wheel hub Secure wheel with lug nuts on drive studs 10 Lower wheel to ground Torque lug nuts from 45 to 65 ft lb 61 to 88 N m in a criss cross pattern Torque lock nut from 250 to 400 ft lb 339 to 542 kg m 11 Check and adjust brakes see Adjust Brake
44. 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 Reelmaster 3100 D REFER TO THE TRACTION UNIT AND CUTTING UNIT OPERATOR S MANUALS FOR OPERATING MAINTENANCE AND ADJUSTMENT INSTRUC TIONS Space is provided in Chapter 2 of this book to insert the Operator s Manuals and Parts Catalogs for your machine Additional copies of the Operator s Manual and Parts Catalog are available on the internet at www Toro com The Toro Company reserves the rightto change product specifications or this publication without notice PART NO 99024SL Rev G Service Manual Reelmaster 3100 D This safety symbol means DANGER WARNING or CAUTION PERSONAL SAFETY INSTRUC TION When you see this symbol carefully read the instructions that follow Failure to obey the instructions may result in personal injury NOTE A NOTE will give general information about the correct operation maintenance service testing or re pair of the machine IMPORTANT The IMPORTANT notice will give im portant instructions which must be followed to pre vent damage to systems or components on the machine The Toro Company 1999 2002 2003 2005 2007 2009 2011 2012 This page is intentionally blank Reelmaster 3100 D Table Of Contents Chapter 1 Safety Safety 5 5 1 1 Ja
45. Reelmaster 3100 D Page 5 43 Figure 26 1 Knobs 2 Battery cover Figure 27 2 Positive cable 1 Ground cable IMPORTANT Before cleaning the battery tape or block vent holes to the filler caps and make sure the caps are on tightly C Check for signs of wetness or leakage on the top of the battery which might indicate a loose or missing filler cap overcharging loose terminal post or over filling Also check battery case for dirt and oil Clean the battery with a solution of baking soda and water then rinse it with clean water D Check that the cover seal is not broken away Re place the battery if the seal is broken or leaking E Check the electrolyte level in each cell If the level is below the tops of the plates in any cell fill all cells with distilled water between the minimum and maxi mum fill lines Charge at 15 to 25 amps for 15 min utes to allow sufficient mixing of the electrolyte Electrical Systems Rev C 2 9 gy Lu 2 Conduct a hydrometer test of the battery electrolyte IMPORTANT Make sure the area around the cells is clean before opening the battery caps A Measure the specific gravity of each cell with a hydrometer Draw electrolyte in and out of the hydrometer barrel prior to taking a reading to warm up the hydrometer At the same time take the tem perature of the cell B Temperature correct each cell reading For each 109F 5 59C above 809F
46. 12 O ring 19 Bearing 2 used 5 Metal washer 2 used 13 Cutting reel 20 Bearing adjuster nut 6 Bedbar pivot bolt 2 used 14 Spline insert LH thread 21 Cap screw 2 used 7 Lock nut 2 used 15 RH side plate 22 Cutting unit frame 8 Shoulder bolt 3 used per side plate Note This section provides the procedure for remov Note Removalofthe cutting reel requires removal of ing and installing the cutting reel assembly cutting reel the left side plate from the cutting unit frame The right spline inserts grease seals and bearings from the cut side plate does nothave to be removed from the frame ting unit Note RefertoReelAssemblyService laterin this sec tion for information on replacing cutting reel grease seals bearings and spline inserts DPA Cutting Units Rev G Page 8 24 Reelmaster 3100 D Reel Assembly Removal Fig 26 1 Position machine on a clean and level surface lower cutting units stop engine engage parking brake and re move key from the ignition switch 2 Remove the cutting unitfrom the machine and place on a flat work area 3 If cutting unit is equipped with a weight on LH side plate as shown in Figure 26 remove the two 2 cap screws securing the weight to the side plate Remove weightfrom the cutting unit Remove and discard O ring from weight 4 If cutting unitis equipped with an optional rear roller brush remove components for those options from left hand side plate of cutting un
47. 12 Slowly push traction pedal in forward direction until 1000 PSI is displayed on the pressure gauge 13 Motor internal leakage will be shown on flow meter in GPM Flow should be less than 1 5 GPM for the tested wheel motor 14 11 specifications are not met the tested wheel motor needs to be repaired or replaced as necessary 15 If remaining front wheel motor requires testing com plete steps 5 to 14 for the remaining motor 16 11 rear wheel motor requires testing A Both front wheel motors should have hydraulic lines connected Block up both front wheels off the ground Release parking brake so front wheels can turn B Attach a heavy chain to the rear of the machine frame and an immovable object to prevent the ma chine from moving during testing C Position rear wheel on the ground and chock rear wheel to prevent it from turning D Complete steps 9 to 13 E If specifications are not met check the relief valve in the rear wheel motor for damage If relief valve is not damaged wheel motor needs to be repaired or replaced 17 Disconnect tester from hydraulic fitting and hose Reconnect hose to pump connection Hydraulic System Rev C 2 E gt Reel Circuit Pressure Test Using Pressure Gauge FROM REEL MOTOR CASE DRAINS INITIAL REEL MOTOR FROM FINAL REEL MOTOR TO HYDRAULIC HYDRAULIC MANIFOLD BLOCK REEL SPEED CONTR
48. 33H 0000000 21 3AO8V 11885 YHOLOW 1434 S3NIHOVIN NO LHOIH NMOHS uV3H SI HOLOW IWNIJ ANY HOLOIN LW 1999 1441 1 SI NI HOLOW pezib1ouo op 7334 00000002 HOLOW 1338 S UMOUS 05 1VIH3S 1 083 1331 SANIHOWW NO 3 LON oineJjp H 10260 ISPOW Q 001 Page4 9 Hydraulic System Rev C Reelmaster 3100 D A CH HOLY Nivad 3595 lVNH31N dN d 339 lt gt EN 1 1 5080 51 1 CY uu x I 4 5 T 0 an 58 091 001 NI 1 6 lt ah 4 ez sd 0005 od px T 15 E E 1404 1804 43440 985 Lj Poux PN AS c cima b 82 _ 9 Al suy Mo O Na 29 Q DT j 1804 401 Aq HX U c Wn 9 GQ IOJINVIA 2 m n 4 N H VA 3 _ SYOLOW 133HM NOIIOVUI se 5 5 5 5neuueu s 02120 pue 90260 sepon G OOTE 4 Reelmaster 3100 D Page 4 9 1 Rev F Hydraulic Syst
49. Check spring 19 Detent plug 29 O ring 10 Spool cap 20 Wiper seal 30 Back up washer Hydraulic System Rev C 4 92 Rev Reelmaster 3100 D KKK lt KK ISS id jig x ES Di B CH Jm NSS an zi Hydraulic S so Al NL L Jj 5 Ee AS xS 7 Figure 61 1 Check poppet 11 Valv 21 Plunger 2 Grooved plunger 12 O ring 22 Plunger detent 3 acer 13 Retaining ring a med nt spring 4 Spool 14 Wa 4 O ring 5 Seat 15 Seat retaining plug F O ring 6 Solid plug 16 Spool spring 2 up washer 7 Seatretaining plug with port 17 Disc 7 O ring 8 Bushing 18 Plug 2 O ring 9 heck spring 19 Deten Mpun 29 O ring 10 Spool cap 20 Wiper 30 Back up washer Reelmaster 3100 D Page 4 93 Hydraulic System Rev C Disassembly 1 Plug all ports and clean the outside of the valve thor oughly IMPORTANT Match mark spools to their associat ed bores Spools must be reinstalled to the bore from which they were removed 2 Remove both spool caps and slide the spool assem blies from their bores 3 Remove C ring and bushing from each spool as sembly 4 Remove wiper seals O rings from the spool bore ends that are opposite the spool caps NOTE Disassemble spool assemblies only if the re taining ring spacer spring or washer need replacing 5 Remove seat retaining plugs back up washers O rings and check springs from the valve body
50. No 8 X 0 08851 in Ib N m X 0 7376 ft lb Reelmaster 3100 D Lubrication Traction Unit Before servicing or making adjustments to the machine stop engine lower cutting set parking brake and remove key from the ignition switch The traction unit has grease fittings that must be lubri cated regularly with No 2 General Purpose Lithium Base Grease machine is operated under normal conditions lubricate bearings and bushings after every 50 hours of operation Bearings and bushings must be lubricated daily when operating conditions are extreme ly dusty and dirty Dusty and dirty operating conditions could cause dirt to get into the bearings and bushings resulting in accelerated wear Lubricate bearings and bushings immediately after every washing regardless of the interval listed N D 59 LJ and Maintenance The traction unit bearings and bushings that must be lu bricated are rear cutting unit pivot Fig 4 front cutting unit pivot Fig 5 sideWinder cylinder ends 2 model 03201 only Fig 6 steering pivot Fig 7 rear lift arm pivot and lift cylinder 2 Fig 8 left front lift arm pivot and lift cylinder 2 Fig 9 right front lift arm pivot and lift cylinder 2 Fig 10 neutral arm assembly Fig 11 mow transport slide Fig 12 belt tension pivot Fig 13 steering cylinder Fig 14 Note f desired an additional grease fitting may
51. P4 2 W61 BLACK J11 2 P8 5 W30 TAN P8 1 J19 2 W62 BLACK SP3 6 P10 5 W31 GREEN P21 B P12 1 2 W63 BLACK SP3 6 P22 C 2 W32 BROWN J6 P9 5 W64 BLACK P22 C 2 11 3 W65 YELLOW 5 8 2 P9 4 Reelmaster 3100 D Supplement to Wiring Diagram Serial Numbers 90101 to 90150 Reelmaster 3100 D Page5 9 Electrical Systems Rev C 666666062 01 19106 2 se Splougjos pue 9 i e21129 43 5 3901195 dS M gt G OOLE digi OIN HO NMOHH N85 MOTHA A NV lt ND gt ams lt gt re Q9 Sid 98 44768 somd 48 1 8 1HVIS dn 57838 HOLIMS SNON 4018 57934 440 57838 2 NO M o vs JIM LHOM 220 HOLIMS uS s
52. Page 7 24 Rev Reelmaster 3100 D Fixed Side Plate Installation 1 Remove pop rivets and rear height of cut plates from both sides of the cutting unit Fig 30 2 Remove lock nuts capscrews washers and both links from the cutting unit Fig 30 3 Align fixed side plate with holes on the cutting unit Fig 31 4 Attach new capscrews washers and flanged lock nuts to the fixed side plate and the cutting unit Fig 31 5 Tighten lock nuts and capscrews 6 Fasten new height of cut plate to the cutting unit with new pop rivets Fig 31 7 Repeat steps 1 through 6 on the other side of the cut ting unit Reelmaster 3100 D Page 7 25 2 Height of cut plate Figure 30 4 Capscrew 5 Washer 6 Link Figure 31 4 Flanged lock nut 5 Height of cut plate 6 Poprivet Cutting Units Front Arms 90 hydraulic fitting Hydraulic cylinder Carrier assembly Flange nut Flange head screw Hydraulic hose Centering wire Hydraulic hose Hydraulic hose 10 Hydraulic hose 11 Clamp bracket Model 03200 11 Slide bracket Model 03201 12 Flange nut Model 03201 13 Plastic slide 14 Flange head screw CEN PONS Cutting Units Figure 32 Lift arm pivot shaft Roll pin Pivot shaft link Flange head screw Cap screw Clamp Model 03200 Bearing cap Model 03201 Jam nut Cap screw Lock nut Hardened washer Slide bar support Pin Sp
53. Rev C 4 90 Rev F Reelmaster 3100 Removal Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hy draulic System Pressure in the General Infor mation section 1 Remove control valve from the frame using Figures 58 and 59 as guides 2 If hydraulic fittings are to be removed from control valve mark fitting orientation to allow correct assembly Installation 1 If hydraulic fittings were removed install fittings to control valve using marks made during the removal pro cess to properly orientate fittings 2 Install control valve to the frame using Figures 58 and 59 as guides E AION Figure 59 1 Spool valve 2 Magnet support bracket Reelmaster 3100 D Page 4 91 3 Flange head screws 4 Frame Hydraulic System Rev C E E Control Valve Service Models 03201 03207 and 03171 10 to 12 ft Ib 14 to 16 N m 18 30 to 42 ft Ib 41 to 57 N m 30 to 35 ft Ib 41 to 48 N m 20 to 25 ft lb 27 to 34 N m taa S Figure 61 1 Check poppet 11 Valve body 21 Plunger 2 Grooved plunger 12 O ring 22 Plunger detent 3 Spacer 13 Retaining ring 23 Detent spring 4 Spool 14 Washer 24 O ring 5 Seat 15 Seat retaining plug 25 O ring 6 Solid plug 16 Spool spring 26 Back up washer 7 Seat retaining plug with port 17 Disc 27 O ring 8 Bushing 18 Plug 28 O ring 9
54. Set multimeter to the DC volts setting The battery should be at a temperature of 60 to 1009F 16 to 389C The ignition key should be off and all accessories turned off Connect the positive meter lead to the positive battery post and the negative meter lead the the neg ative battery post NOTE This test provides a relative condition of the bat tery Load testing of the battery will provide additional and more accurate information Charging System Test This is a simple test used to determine if a charging sys tem is functioning It will tell you if the charging system has an output but not its capacity Tool required Digital multimeter set to DC volts Test instructions Connect the positive multimeter lead to the positive battery post and the negative multimeter lead to the negative battery post Keep the test leads connected to the battery posts and record the battery voltage NOTE Upon starting the engine the battery voltage will drop and then should increase once the engine is running NOTE Depending upon the condition of the battery charge and battery temperature the charging system voltage will increase at different rates as the battery charges Glow Plug System Test This is a fast simple test that can help to determine the integrity and operation of the Reelmaster 3100 D glow plug system The test should be run anytime hard start ing cold engine is encountered on a diesel engine equippe
55. Use jack stands or blocks under the frame to se cure the machine Safety Page 1 4 Reelmaster 3100 D Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Reelmaster 3100 D If any decal becomes illegible or damaged install a new decal Part numbers for re placement decals are listed in your Parts Catalog Order replacement decals from your Authorized Toro Distribu tor Reelmaster 3100 D Page 1 5 Safety Rev D This page is intentionally blank Safety Page 1 6 Reelmaster 3100 D Rev D Chapter 2 Product Records and Maintenance Table of Contents TORO PRODUCT RECORDS 1 MAINTENANCE 1 EQUIVALENTS AND CONVERSIONS 2 mm Decimal and Millimeter Equivalents 2 U S to Metric Conversions 2 8 TORQUE SPECIFICATIONS 3 Fastener Identification 3 E Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series 4 PE Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners 5 Other Torque Specifications 6 Conversion 6 Product Records Insert Operator s Manual and Parts Catalog for your Reelmaster 3100 D atthe end of this chapter Addition ally if any optional equipment or accessories have been installe
56. Wheel Motor Efficiency Test 38 Reel Circuit Pressure 40 Gear Pump P1 Flow Test 42 Manifold Relief Valve R 1 Pressure Test 44 Reel Motor Efficiency Case Drain Test 46 Reel Motor Cross over Relief Pressures Test 48 Lift and Steering Control Valve Relief Pressure Test iios emm aba Ret 52 Steering Control Valve 54 ADJUSTMENTS crees 56 Adjust Traction Drive for Neutral 56 Adjust Manifold Relief Valve 1 57 SERVICE AND REPAIRS 58 General Precautions for Removing and Installing Hydraulic System Components 58 Change Hydraulic Fluid 59 Replace Hydraulic Oil Filter 60 Replace Traction 61 Reelmaster 3100 D Page4 1 Rev F Chapter 4 Hydraulic System Check Hydraulic Lines and Hoses 61 Flush Hydraulic 5 62 Charge Hydraulic System 63 Hydraulic Tank and Hydraulic Oil Filter 64 Front Wheel Motors 66 Rear Wheel Motor 68 Wheel Motor Service 70 Reel Motors 72 Reel Motor Service 74 Reel Motor Service Casappa 75 1 Oil COO a UE etae m tenete ate us
57. When the sole noid is de energized the plunger extends to shut off fuel supply to the engine causing the engine to stop running The fuel stop solenoid is grounded through the common black wire of the solenoid wire connector NOTE Refer to Electrical Diagrams in this chapter when troubleshooting the fuel stop solenoid Testing NOTE Prior to taking small resistance readings with a digital multimeter short the test leads together The me ter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal re sistance of the meter and test leads Subtract this value from the measured value of the component you are test ing 1 Make sure ignition switch is in the OFF position Dis connect the connector from the solenoid 2 Using a digital multimeter touch one test lead to the pin of the black wire and the other test lead to the pin of Figure 20 1 Injection pump 2 Fuel stop solenoid Figure 21 1 Cap screw 2 Fuel stop solenoid 4 Common Black wire 5 Hold coil Red wire 4 3 Gasket 6 Pull coil White wire the white wire Fig 21 The resistance of the pull coil should be about 0 33 ohms 3 Using a digital multimeter touch one test lead to the pin of the black wire and the other test lead to the pin of the red wire Fig 21 The resistance of the hold coil should be about 12 2 ohms 4 Connect solenoid to the wiring harness Electrical Systems R
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59. from 24 to 30 ft lb 33 to 41 D Remove shaft from the vise IMPORTANT Prevent damage when clamping the hydraulic cylinder into a vise clamp on the clevis only 4 Mount barrel in a vice 5 Coat all internal parts with a light coat of clean hy draulic oil Slide piston shaft and head assembly into the barrel being careful not to damage the seals 6 Secure head in the barrel with internal collar using a spanner wrench Tighten collar until snug and the outer end of the collar is flush with end of the barrel Hydraulic System Rev C 2g 8 gt Steering Cylinder d 2 General Purpose Grease 65 to 85 ft Ib 88 to 115 N m Figure 84 1 Hydraulic hose 5 O ring 9 Jamnut 2 Hydraulic hose 6 Steering cylinder 10 Frame 3 O ring 7T Ball joint 11 Rear fork 4 Hydraulic fitting 8 Retaining ring 12 Rear casting Hydraulic System Rev C Page 4 120 Reelmaster 3100 D Removal 1 Park machine on level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch NOTE The rear tire must be removed to allow sufficient clearance to remove the steering cylinder from the ma chine A WARNING Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 2 Jack or lift rear wheel off the ground 3 Remove rear wheel from the drive studs and wheel hub 4 Thoroug
60. ing the engine Store fuel in a clean safety ap loose connections Replace hoses clamps and con proved container and keep cap in place Use die nections as necessary sel fuel for the engine only not for any other pur pose Kubota Diesel Engine Page 3 14 Reelmaster 3100 D Fuel Tank Removal Fig 22 1 Park machine on level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Siphon fuel from the tank into a suitable container 3 Remove seat and seat support straps from the frame Disconnect seat switch from the electrical har ness Fig 23 4 Remove fuel hose strap and both fuel hoses from the fuel tank Pull tank from the machine Fig 24 Drain and Clean Fuel Tank Fig 22 Drain and clean the fuel tank every 2 years Also drain and clean the fuel tank if the fuel system becomes con taminated or if the machine is to be stored for an ex tended period 1 Remove fuel tank from the machine see Fuel Tank Removal 2 Flush fuel tank out with clean diesel fuel Make sure tank is free of contaminates and debris 3 Install fuel tank to the machine see Fuel Tank Instal lation Fuel Tank Installation Fig 22 1 Position fuel tank into the machine 2 Connect both fuel hoses to the tank and secure with hose clamps and fuel hose strap 3 Connect seat switch to the electrical harness Se cure seat support straps and seat to the frame wi
61. installed so the metal side of the seal is toward the bearing location B Press grease seals onto reel shaftwith metal side orientated toward bearing location Final position of seal should be flush to 0 060 1 5 mm away from re taining ring on reel shaft Do not force seal against retaining ring Seal must be perpendicular to reel shaft after installation C Pack replacement reel bearings with Mobil High Temperature HP grease or equivalent D Press grease packed bearings fully onto reel shaft Bearings should bottom on reel shaftshoulder Press equally on inner and outer bearing race when installing bearings onto reel shaft 4 Pack bore of reel shaft with Mobil High Temperature HP or equivalent grease DPA Cutting Units Rev G c 5 amp N E Preparing Reel for Grinding Note Before grinding a cutting reel make sure thatall cutting unitcomponents are in good condition Depend ing on type of grinder used faulty cutting unit compo nents can affect grinding results Note When grinding be careful to not overheat the cutting reel blades Remove small amounts of material with each pass of the grinder 1 Follow reel grinder manufacturer s instructions to grind cutting reelto Toro specifications see Reel Grind ing Specifications chart to the right Additional reel grinding information can be found in Toro General Ser vice Training Book Reel Mower Basics part no 0916851
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63. the TO MANIFOLD cutting units are up or the transport mow switch is in TRANSPORT S1 by passes flow from the reel motors directly to the hydraulic reservoir Solenoid valve S1 is energized with the engine running when the reels on off switch is ON the cutting units are Figure 8 down and the transport mow switch is in MOW Flow is ovanan 19 REEL CIRCUIT SCHEMATIC FOR MACHINES Oil flows from port P1 across the logic cartridge valve ee A aaa ABONE 230000000 LC1 The logic cartridge maintains a pressure differential of 75 PSI 5 2 bar across the speed control valve Any excess flow above what the speed control TO MANIFOLD valve is set for is by passed to the reservoir through M1 PORT EM logic cartridge valve With the backlapping valve MD1 in the position oil flows through the valve out port M2 PORT M1 and to reel motors that are connected in series On machines with serial numbers below 230000000 Fig 8 oil flows through the left front right front and then rear reel motors as it turns the motors in the mow direction The oil then returns into manifold block port M2 and then to the hydraulic tank 2 gt 3 gt Figure 9 On machines with serial numbers above 230000000 Fig 9 oil flows through the rear right front and then left front reel motors as it tu
64. 03200 03206 and 03170 30 to 42 ft Ib 700 10 to 12 ft Ib 14to 16N m 5 20 to 25 ft Ib 27 to 34 N m Figure 57 1 Check poppet 11 Valve body 21 Not used 2 Plunger 12 O ring 22 Plunger detent 3 Spacer 13 Retaining ring 23 Spring 4 Spool 14 Washer 24 O ring 5 Seat 15 Not used 25 O ring 6 Plug solid 16 Spool spring 26 Back up washer 7 Seat retaining plug 17 Disc 27 O ring 8 Bushing 18 Plug 28 O ring 9 Check spring 19 Detent plug 29 O ring 10 Spool cap 20 Not used 30 Back up washer Hydraulic System Rev C 4 86 Rev F Reelmaster 3100 D 277077 DOG ANIS KS Y L Ted Disassembly 1 Plug all ports and clean the outside of the valve thor oughly 2 Remove spool cap and slide the spool assembly from its bore 3 Remove O ring and bushing from the spool assem bly 4 Remove O ring from the spool bore end that is oppo site the spool cap NOTE Disassemble spool assembly only if the retain ing ring spacer spring or washer need replacing 5 Remove seat retaining plug back up washer O ring and check spring from the valve 6 Remove check poppet seat O ring and plunger from the valve 7 Remove solid plug back up washer and O ring from the opposite end of the plunger 8 Remove plug and O ring from the top of the valve body next to the detent plug 9 Remove detent plug and O ring from the valve bod
65. 10 2 Remove bedbar see Bedbar Removal in this sec tion Note Inside threads in bedbar adjuster shaft item 4 are left hand threads 3 Unscrew bedbar adjuster screw item 10 from the bedbar adjuster shaft item 4 4 Remove adjuster shaft from cutting unit frame A On current production cutting units Fig 21 re move lock nut and flat washer from adjuster shaft Slide adjuster shaft and wave washer from cutting unit frame B On early production cutting units Fig 22 re move retaining ring and wave washer from adjuster shaft Slide adjuster shaft from cutting unit frame 5 Inspectflange bushings item 5 in cutting unitframe and remove if necessary 6 If detent item 7 is damaged remove itfrom cutting unit side plate by removing the cap screw item 6 Installation 1 If detent item 7 was removed apply Loctite 242 or equivalent to threads of cap screw item 6 and se cure detent to cutting unit side plate with cap screw Torque cap screw from 14 to 16 ft Ib 19 to 21 N m 2 Ifflange bushings item 5 were removed apply anti seize lubricantto bore of cutting unitframe Align key on bushing to slot in frame and install bushings into frame 3 Install adjuster shaft to cutting unit frame A Oncurrentproduction cutting units Fig 21 slide wave washer onto adjuster shaft and then slide ad juster shaft into flange bushings in cutting unitframe Secure adjuster shaft with flat washer and
66. 117 0975 Use the reel bearing installation tool to keep the reel bearing aligned as the cutting unitside plate is installed on the bearing Figure 8 Roller Rebuild Kit Toro Part Number 115 0803 Bearnginstallation This tool kitis used to assemble the cutting unit rollers Tools in this kitare also available individually as follows 115 0852 Inner Seal Tool 115 0853 Bearing Outer Seal Tool 107 8133 Bearing Installation Washer T 2 7S Inner Seal Bearing Outer Seal Tool Tool Figure 9 Turf Evaluator Tool Toro Model Number 04399 Many turf discrepancies are subtle and require closer examination In these instances the Turf Evaluator grass viewing tool is helpful It can assist turf managers and service technicians in determining causes for poor reel mower performance and in comparing the effective height of cut of one mowed surface to another This tool should be used with the Toro Guide to Evaluation Reel Mower Performance and Using the TurfE valuator Toro part no 9793151 Figure 10 DPA Cutting Units Rev G Page8 6 Reelmaster 3100 D This page is intentionally blank D os 5 Reelmaster 3100 D 8 7 DPA Cutting Units Rev G Factors That Can Affect Cutting Performance There are a number of factors that can contribute to un satisfactory quality of cut some of which may be turf conditions Turf conditions such as excessive thatch sponginess or attempting to cut off
67. 12 3 4 in 0 75 0 25 16 1 in 0 75 0 25 Reelmaster 3100 D 4 3 Before disconnecting or performing any work on hydraulic system relieve all pressure in system Stop engine lower or support box and or other attachment s Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Use paper or cardboard not hands to search for leaks Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury If fluid is injected into the skin it must be surgi cally removed within a few hours by a doctor familiar with this type of injury Gangrene may result from such an injury Nut Sleeve Figure 1 Final Position Mark Nut and Body Initial Extend Line Position Finger Tight After Proper Tightening Figure 2 Hydraulic System Rev C Hydraulic System SAE Straight Thread O Ring Port Non adjustable 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Always replace the O ring seal when this type of fit ting shows signs of leakage 3 Lubricate the O ring with a light coating of oil 4 Install the fitting into the port and tighten it down full length until finger tight 5 Tighten the fitting to the correct flats from finger tight F F F T o N 4 4 1 4 in nominal hose or tubing 1 00 0 25 6 3
68. 12 24 12 06 50 1 190 25 1 155 120 2 Determine the charging time and rate using the manufacturer s battery charger instructions or the following table Reelmaster 3100 D Page 5 45 Battery Battery Charge Level Reserve Percent of Fully Charged Capacity its 80 or less 3 8hrs 7 5hrs 11 3 hrs 15 hrs 3 amps 3amps 3amps 3 amps 81 125 5 3hrs 10 5 hrs 15 8 hrs 21 hrs 4 4amps 4 amps 4 amps 126 to 5 5 hrs 11 hrs 16 5hrs 22 hrs 170 5 amps 5 5 5 amps 17110 5 8hrs 11 5 hrs 17 3 hrs 23 hrs 250 6 amps 6 amps 6 amps above 6 hrs 12 hrs 18 hrs 24 hrs 250 10 amps 10 amps 10 amps 10 amps A CAUTION Do not charge a frozen battery because it can ex plode and cause injury Let the battery warm to 60 F 15 5 C before connecting to a charger Charge the battery in a well ventilated place to dissipate gases produced from charging These gases are explosive keep open flame and elec trical spark away from the battery Do not smoke Nausea may result if the gases are inhaled Un plug the charger from the electrical outlet before connecting or disconnecting the charger leads from the battery posts 3 Following the manufacturer s instructions con nect the charger cables to the battery Make sure a good connection is made 4 Charge the battery following the manufacturer s
69. 2 After completing the reel grinding process adjust cutting unit see Cutting Unit Operator s Manual Reel Grinding Specifications Reel Diameter New 7 060 in 179 3 mm for 7 reel Service Limit Reel 6 600 in 168 0 mm for 7 reel Blade Relief Angle Range 259 to 359 Blade Land Width 0 060 in 1 5 mm Blade Land Width Range 0 050 to 0 070 in 1 3 to 1 8 mm Service Limit Reel Diameter Taper 0 010 in 0 25 mm Reel Diameter Taper D D Figure 29 DPA Cutting Units Rev G Page 8 30 Reelmaster 3100 D This page is intentionally blank D os 5 Reelmaster 3100 D 8 31 DPA Cutting Units Rev Front Roller Removal Fig 30 1 Position machine on a clean and level surface lower cutting units stop engine engage parking brake and re move key from the ignition switch 2 Remove the cutting unitfrom the machine and place on a level working surface Use cutting unit kickstand see Special Tools to raise front roller from work sur face 3 Loosen flange nut and cap screw securing the front roller shaft to each front height of cut roller bracket 4 ofthe height of cut roller brackets A Remove flange lock nut and carriage screw that secure bracket to the cutting unit side plate B Remove the height of cut roller bracket from the cutting unit 5 Slide the front roller assembly from the remaining height of cut roller bracket on t
70. 26 79C add 0 004 to the specific gravity reading For each 109F 5 59C be low 809F 26 79C subtract 0 004 from the specific gravity reading Example Cell Temperature 1009F Cell Gravity 1 245 1009F minus 809F equals 209F 37 790 minus 26 7 C equals 11 09C 20 F multiply by 0 004 109F equals 0 008 110C multiply by 0 004 5 5 C equals 0 008 ADD conversion above 0 008 Correction to 809F 26 79C 1 253 C If the difference between the highest and lowest cell specific gravity is 0 050 or greater or the lowest cell specific gravity is less than 1 225 charge the bat tery Charge at the recommended rate and time giv en in Charging or until all cells specific gravity is 1 225 or greater with the difference in specific gravity between the highest and lowest cell less than 0 050 If these charging conditions can not be met replace the battery 3 Perform a high discharge test with an adjustable load tester This is one of the most reliable means of testing a battery as it simulates the cold cranking test A commercial bat tery load tester is required to perform this test A CAUTION Follow the manufacturer s instructions when us ing a battery tester A Check the voltage across the battery terminals prior to testing the battery If the voltage is less than 12 4 VDC recharge the battery B If the battery has been charged apply a 150 load for 15 seconds to remove the surface charge Use a battery load teste
71. 5 ISd 000 HE s Jariau i ed lE H 2 7334 SES D pe EM 1HOd INVA 1HOd H3QNITAO H3ddn H3MO1 JAVA SaS 25 x 33O NO 6 1 IS 193 i EATUR m U3TIOHINOO 2 91901 y 43345 133u D HANITA d 1809 dOL 2 y 238 M SYOLOW 133HM NOILOVYL LOIN G102INVI YHOLOW cL MO 4 lt 1NOH4 1H IH YOLOW 133H 1331 wo uogongJo ejnsseJjg uang 19619 Buueeis 4 0012 JeisEu eeH Reelmaster 3100 D Page 4 20 Hydraulic System Rev C Steering Circuit The gear pump P2 is directly coupled to the hydrostat It supplies hydraulic pressure to the power steering valve for turning the rear wheel and maintaining 100 to 150 PSI 6 9 to 10 0 Bar to the low pressure side of the traction circuit The pump takes its suction from the hy draulic reservoir With the steering wheel in the neutral position rear wheel positioned straight ahead the engine running and the spool valve is in the center position flow enters the steering control valve at the IN port and goes through the spool valve by passing the rotary meter V1 and steering cylinder Flow leaves the control valve through the OUT port to the hydrostat Right Turn
72. 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 SAE Straight Thread O Ring Port Adjustable 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Always replace the O ring seal when this type of fit ting shows signs of leakage 3 Lubricate the O ring with a light coating of oil 4 Turn back the jam nut as far as possible Make sure the back up washer is not loose and is pushed up as far as possible Step 1 5 Install the fitting into the port and tighten finger tight until the washer contacts the face of the port Step 2 6 To put the fitting in the desired position unscrew it by the required amount but no more than one full turn Step 3 7 Hold the fitting in the desired position with a wrench and turn the jam nut with another wrench to the correct flats from finger tight F F F T Step 4 N m m 4 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 Hydraulic System Rev C Page 4 4 Figure 3 Lock Nut Back up Washer O Ring Figure 4 Figure 5 Reelmaster 3100 D Towing Traction Unit In case of emergency the Reelmaster can be towed for a short distance However Toro does not recommend this as a standard procedure IMPORT
73. Arm 1 Park machine on a level surface and engage parking brake IMPORTANT This adjustment must be performed with the rear cutting unit attached to the rear lift arm 2 Raise lift arms Make sure clearance between wear strap on the top of the rear cutting unit wear bar and bumper strap is 0 020 to 0 100 inch 0 508 to 2 54 mm Fig 13 3 If the clearance is not in this range attain proper clearance by adjusting the rear hydraulic cylinder as fol lows Fig 14 A Lower cutting units turn engine off and remove key from the ignition switch B Back off jam nut from the rear hydraulic cylinder clevis IMPORTANT Use a protective covering around the hydraulic cylinder rod when rotating the rod to pre vent damage to the rod C Grasp cylinder rod near the jam nut and rotate the rod D Raise cutting units and check clearance Repeat steps A through C as necessary Tighten jam nut on hydraulic cylinder rod NOTE If rear lift arm makes clunking noises during transport the clearance can be reduced IMPORTANT The lack of clearance at the rear wear bar can damage the rear lift arm Figure 13 1 Wear bar 2 Bumper strap Figure 14 1 Rear hydraulic cylinder 2 Jamnut Cutting Units Page 7 12 Reelmaster 3100 D Service and Repairs Greasing Bearings Bushings and Pivot Points Each cutting unit has 9 grease fittings with an optional front roller installed that must be lubricated regularly with N
74. Bearing Replacement Cutting Units Page 7 16 Note The cutting unit can be installed with the hy draulic motor on either side If installing on the opposite Side remove cap screws weights and cover gasket re install them on the other bearing housing 1 Dip spider coupling in No 2 general purpose lithium base grease Reinstall spider coupling into the bearing housing 2 Install O ring on the front plate of the motor Mount hydraulic motor to the bearing housing Secure motor with the two capscrews 3 Grease bearing housing sufficiently to fill housing with grease see Greasing Bearings Bushings and Piv ot Points Reelmaster 3100 D Reel Removal and Bearing Replacement Remove Reel Fig 22 1 Remove hydraulic motor from the cutting unit see Hydraulic Motor Removal and Installation Remove cutting unit from the machine see Cutting Unit Removal and Installation 2 Remove bedbar assembly from the cutting unit see Bedbar Removal and Installation 3 Remove front roller from the cutting unit see Roller Removal and Installation Note 3 8 drive ratchet with an extension will fit into the square hole of the coupling 4 Unscrew reel coupler LH from the reel This cou pler is left hand threaded Unscrew reel coupling RH from the reel This coupler is right hand threaded IMPORTANT Support reel to prevent it from dropping when the bearing housings are removed 5 Remove cap screws
75. Circuits 6 Ignition Switch eein eenean a 30 Run Circuits 7 Glow 31 Wiring Diagram 8 Start Seat and High Temperature Supplement to Wiring Diagram 9 Shut Down Relays 31 Reelmaster 3100 D Electrical Schematic 32 Serial Numbers 90151 to 230999999 10 Reel Drive Solenoid 32 Glow Clrcults ssim e Ro ER 11 High Temperature Warning Crank trece hri ete 12 and Shutdown Switches 33 Run Circuits Transport 13 Diode Assemblies 34 Run Circuits 14 Warning Light Cluster Serial Numbers Run Circuits 15 Below 240000000 35 Wiring 16 Indicator Lights Serial Numbers Above Supplementto Wiring Diagram 17 240000000 36 Harness Diagram 18 PUMP ii ernir eeens ni i 37 Reelmaster 3100 D Electrical Schematic Fuel Stop Solenoid Solenoid With 3 Wire Serial Numbers 240000001 and Up 19 Connector ack er Ce Ea en 38 Wiring Diagram Serial Numbers 240000001 Fuel Stop Solenoid Solenoid With 2 Wire to 2709
76. 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 Reelmaster 3100 D Torque Specifications Recommended fastener torque values are listed in the following tables For critical applications as determined by Toro either the recommended torque or a torque that is unique to the application is clearly identified and spe cified in this Service Manual These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Ser vice Manual The following factors shall be considered when applying torque cleanliness of the fastener use of a thread sealant Loctite degree of lubrication on the fastener presence of a prevailing torque feature hard ness of the surface underneath the fastener s head or similar condition which affects the installation Fastener Identification Grade 1 Grade 5 Inch Series Bolts and Screws Reelmaster 3100 D Page 2 3 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 alu
77. P9 2 aa BENE MBSE W11 PINK SP5 4 P1 1 W45 WHITE P7 B P12 5 W12 PINK SP5 4 P12 6 2 W44 GREEN P12 1 2 J20 2 W13 PINK P12 6 2 11 4 W45 BLUE J8 P21 A Wi4 PINK P16 8 2 P3 1 W46 RED BLACK 8 4 J9 2 W15 BLUE P13 1 14 5 2 W47 ORANGE 5 4 4 6 W16 BLUE P14 5 2 P10 1 W48 ORANGE 5 4 4 P17 A W17 YELLOW 11 1 J6 We GRAY Rone J10 W18 ORANGE P1i 2 13 2 W50 GRAY J10 P5 3 2 Wi9 ORANGE J2 J5 W51 GRAY P5 3 2 4 1 W20 WHITE P3 2 11 5 W52 RED J1 P23 2 W21 GRAY P11 6 4 W53 TAN P1 2 P13 5 W22 PINK P22 A 5 5 4 W54 BLACK J3 SP2 4 5 W23 YELLOW 10 2 J14 2 W55 BLACK 2 4 J16 W24 YELLOW 4J14 2 12 2 W56 BLACK SP2 4 P2 2 W25 ORANGE P10 4 19 1 2 W57 BLACK SP2 4 SP3 6 W26 ORANGE P19 1 2 J17 W58 BLACK SP3 6 15 W27 ORANGE P9 3 SP4 4 W59 BLACK SP3 6 13 6 W28 ORANGE SP4 4 P5 1 2 W60 BLACK SP3 6 _ 2 W29 ORANGE P5 1 2 4 2 W61 BLACK J11 2 P8 5 W30 TAN P8 1 J19 2 W62 BLACK SP3 6 10 5 W31 GREEN P21 B 12 1 2 W63 BLACK SP3 6 22 2 W32 BROWN J6 P9 5 W64 PINK P11 3 5 5 5 W65 USED Reelmaster 3100 0 Supplement to Wiring Diagram Serial Numbers 90151 to 230999999 Reelmaster 3100 D Page 5 17 Electrical Systems Rev C 666666022 01 19106 eues weibeig 7 0012 Je1seu 99H
78. Tools Discard screws Remove bedknife from the bedbar Fig 23 Bedknife Installation 1 Use scraper to remove all rust scale and corrosion from bedbar surface and lightly oil surface before instal ling bedknife 2 Make sure that screw threads 5 16 18UNC 2 are clean Apply antiseize lubricant to the threads of new screws Take care to keep anti seize lubricant from taper on screw heads IMPORTANT Do notuse an impact wrench to tight en screws into the bedbar 3 Usenew screws to secure bedknife to bedbar Install all screws but do not tighten fully Then using a torque wrench and bedknife screw tool torque screws from 200 to 250 in Ib 23 to 28 N m Use a torquing pattern working from the centertoward each end ofthe bedknife Fig 24 4 After installing bedknife to bedbar grind bedknife Bedknife Grinding Since there can be variations in the mounting surface of the bedbar a new bedknife will notbe perfectly flat after itis installed to the bedbar Because ofthis itis neces sary to grind a new bedknife after installing itto the bed bar Follow the existing angle that was ground into the bedknife and grind only enough to make sure the top surface of the bedknife is true Fig 25 Note When grinding the bedknife be careful to not overheatthe bedknife Remove small amounts of mate rial with each pass ofthe grinder Also clean and dress grinding stone often during the grinding process
79. When a right turn is made with the engine running the turning of the steering wheel positions the spool valve so that flow goes through the top of the spool Flow entering the steering control valve at the IN port goes through the spool and is routed to two places First most of the flow through the valve is by passed out the AUX port back through the 2 spool valve to the hydrostat Second the remainder of the flow is drawn through rotary meter V1 and out port R Pressure retracts the piston for a right turn The rotary meter ensures that the oil flow to the cyl inder is proportional to the amount of the turning on the Reelmaster 3100 D Page 4 21 steering wheel Fluid leaving the cylinder flows back through the spool valve then through the OUT port and to the hydrostat The steering control valve returns to the neutral position when turning is complete Left Turn When a left turn is made with the engine running the turning of the steering wheel positions the spool valve so that flow goes through the bottom of the spool Flow en tering the steering control valve at the IN port goes through the spool and is routed to two places As in a right turn most of the flow through the valve is by passed out the AUX port back through the 2 spool valve to the hydrostat Also like a right turn the remainder of the flow is drawn through rotary meter V1 but goes out port L Pressure extends the piston for a left turn The rotary me
80. accelerates wear quality of cut may be adversely affected Slightly dull cutting edges may be corrected by backlapping Excessively dull cutting edges must be corrected by grinding the reel and bedknife 7 Front roller position Make sure front rollers on all cutting units are in the same position 8 Rear roller parallel to reel Rear roller must be set so that it is parallel with the reel before setting height of cut 9 Height of cut Make sure all cutting units are set at the same height of cut Set units as specified in the Operator s Manual 10 Bedbar stability Check bedbar end bushings adjuster pivot bushings and nylon flanged bushings for wear or damage Check adjustment knob to make sure detent holds adjustment 11 Number of reel blades Use cutting unit model with the correct number of blades for clip frequency and optimum quality of cut range see Specifications 12 Cutting unit alignment and ground following Check lift arms and cutting unit pivot linkages for wear damage binding or bent pivot pins 13 Roller condition rollers should rotate freely Make sure bearings are properly lubricated Replace bearings if worn or damaged Cutting Units Page 7 6 Reelmaster 3100 D Adjustments Never install or work on the cutting units or lift arms with the engine running Always stop en gine and remove key first Characteristics The single knob bedknife to reel adjustment system in corp
81. and remove key from the ignition switch 26 Whenever machine is left unattended make sure reels are not spinning key is removed from ignition switch and parking brake is set 33 If major repairs are ever needed or if assistance is desired contact an Authorized Toro Distributor 34 To reduce potential fire hazard keep the engine area free of excessive grease grass leaves and accumula tion of dirt 35 If the engine must be running to perform a mainte nance adjustment keep hands feet clothing and any other parts of the body away from the cutting units and any moving parts Keep everyone away 36 Do not overspeed the engine by changing governor settings To assure safety and accuracy have an Autho rized Toro Distributor check maximum engine speed with a tachometer 37 Engine must be shut off before checking oil or adding oil to the crankcase 38 To insure optimum performance and safety use gen uine TORO replacement parts and accessories Re placement parts and accessories made by other manufacturers could be dangerous and such use could void the product warranty of The Toro Company Safety Jacking Instructions When changing attachments tires or performing other service use correct blocks hoists and jacks Make sure machine is parked on a solid lev el floor such as a concrete floor Prior to raising machine remove any attachments that may inter fere with the safe and proper raising of the ma ch
82. body Align marker line on the body and front flange IMPORTANT Do not dislodge seals during installa tion 11 Gently slide the body onto the assembly Firm hand pressure should be sufficient to engage the dowel pins 12 Install the four 4 cap screws with washers and hand tighten IMPORTANT Prevent damage when clamping the reel motor in a vise clamp on the front flange only Also use a vise with soft jaws 13 Place front flange of the motor into a vise with soft jaws and alternately torque the cap screws 33 ft lb 45 N m 14 Remove motor from vise 15 Place a small amount of clean hydraulic oil inthe inlet ofthe motor and rotate the drive shaft away from the inlet one revolution If any binding is noted disassemble the motor and check for assembly problems Reelmaster 3100 D EX Hydraulic This page is intentionally blank Reelmaster 3100 D Page 4 75 4 Rev E Hydraulic System Cil Cooler Removal The radiator and oil cooler may be hot To avoid possible burns allow the engine and cooling systems to cool before working on the oil cooler 1 Remove oil cooler using Figures 47 and 48 as guides Inspection Figure 47 1 Oll cooler 2 Clip Use eye protection such as goggles when using compressed air 1 Back flush oil cooler with cleaning solvent After cool er is clean make sure all solvent is drained from the cooler 2 Dry inside of oil cooler using compressed air in the HYDRA
83. compression spring and detent pin into handle cap Use a small amount of grease to hold detent pin in place E Make sure that flow control valve is closed by ro tating valve stem fully clockwise During handle installation DO NOT rotate valve stem or speed ad justment will be incorrect F Press handle cap onto valve stem with arrow on cap pointing to number 9 on manifold Make sure that detent pin and spring stay positioned in cap G While pressing on the cap to keep the lip seal in place rotate cap in a clockwise direction until the ar row on the cap aligns with number 1 on the manifold By rotating the cap clockwise the valve will remain closed Install screw to retain cap H Make sure that alignment marks on cap and base areinline andthat arrow on capis pointing to number 1 on manifold Tighten two 2 set screws to secure handle cap Mow Backlap Spool Fig 53 Reel Manifold Shown in Fig 51 1 Hydraulic System Rev C Remove spool from mow manifold A Remove backlap switch from mow manifold be fore removing mow backlap spool Remove dowel pin and ball from manifold port after switch is re moved Remove and discard O ring from switch B Remove lower retaining ring from mow backlap spool Raise mow backlap spool to allow access to retaining ring on upper end of spool Remove upper retaining ring C Push spool down until O ring and back up ring are exposed on bottom of mow manifold Remove lower O ri
84. dipstick 4 The engine uses any high quality 10W30 detergent oil having the American Petroleum Institute API ser vice classification CD CE CF CF 4 or CG 4 5 Install oil fill cap and close hood Kubota Diesel Engine Page3 4 Y Figure 1 1 Dipstick 2 Oilfill cap 4 Figure 2 1 Oil fill cap 2 Injection pump Reelmaster 3100 D Fill Fuel Tank Because diesel fuel is highly flammable use cau tion when storing or handling it Do not smoke while filling the fuel tank Do not fill fuel tank while engine is running hot or when machine is in an enclosed area Always fill fuel tank outside and wipe up any spilled diesel fuel before start ing the engine Store fuel in a clean safety ap proved container and keep cap in place Use die sel fuel for the engine only not for any other pur pose IMPORTANT Use No 2 diesel fuel only for the en gine The fuel tank capacity is about 7 5 gallons 28 4 I 1 Park machine on level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Clean area around the fuel tank cap Remove cap from the tank Check Cooling System The cooling system is filled with a 50 50 solution of water and permanent ethylene glycol anti freeze Check level of coolant at the beginning of each day before starting the engine System capacity is about 6 quarts 5 7 with 1 quart 0 9 reservoir 1 Park ma
85. from both bearing housings Pull bearing housings and bearings from reel Remove reel from the cutting unit 6 Rotate bearings within the bearing housings and re move bearings from both bearing housings through the loading grooves Inspect Reel Fig 22 1 Replace reel if the diameter has decreased to the service limit see Reel Grinding Specification in Prepar ing Reel For Grinding 2 Replace reel if blades are bent or cracked 3 Check for a bent reel shaft by placing the reel shaft ends in V blocks Replace reel if the reel shaft is bent Install Reel Fig 22 1 Inspect bearings and replace if worn or damaged Replace both bearings as a set 2 Make sure bearing seating surfaces and threads on reel shaft ends are clean Apply anti seize lubricant to both bearing seating surfaces 3 Align reel inside the cutting unit with the bearing housing holes The reel must be positioned so that the grooved end of the shaft left hand threads is on the left side of the cutting unit Reelmaster 3100 D Page 7 17 4 Clean inside of the bearing housing before installing Install bearing into bearing housing as follows A Load bearing through loading grooves B Position bearing so its outer grease holes will be 90 to the loading grooves C Rotate bearing inside of the housing so the ex tended part of the inner race is facing the inside of the housing 5 Slide bearings and bearing housings onto the reel sha
86. gear pump to the piston pump using Figure 75 as guide 3 Fill hydraulic tank with new hydraulic fluid see Trac tion Unit Operator s Manual 4 Install muffler to the engine see Muffler Installation in Chapter 3 Kubota Diesel Engine Hydraulic System Rev C 2g E gt Gear Pump Service Front plate Back plate Front body Rear body Drive gear Idler gear Idler gear gt Hydraulic System Rev Figure 76 Back up gasket Wear plate Pressure seal Cap screw O ring Adapter Plate Key Page 4 110 Not used Drive gear Washer Plug Shaft seal Washer 25 to 28 ft Ib 34 to 38 N m Reelmaster 3100 D Disassembly Fig 76 1 Plug pump ports and clean the outside of the pump thoroughly After cleaning remove plugs and drain any oil out of the pump 2 Make sure key is removed from the shaft of the drive gear 3 Use a marker to make a diagonal line across the front plate front body adapter plate rear body and back plate for assembly purposes Fig 77 IMPORTANT Avoid using excessive clamping pressure on the pump housing to prevent distorting the housing 4 Clamp pump in a vise with the the shaft end up 5 Remove cap screws and washers from the front plate 6 Remove pump from the vise Turn pump so that the shaft end is facing down 7 Remove back plate from the rear body by tapping with a soft face hammer Remov
87. idle stop Tighten cable to the swivel with cap screw Fig 7 5 Loosen screws securing throttle control lever to the Figure 7 1 Throttle cable 3 Speed control lever control panel Fig 6 2 Swivel 4 Low idle stop 6 Push throttle control lever all the way to the FAST position Slide stop plate until it contacts throttle control lever and tighten screws securing throttle control to control panel Fig 6 Note Attach spring scale where the throttle cable is attached to the control lever Fig 8 7 If throttle control lever does not stay in position during operation torque lock nut and cap screw used to tighten the friction disc from 40 to 55 in Ib 4 5 to 6 2 The force required to operate the throttle control lever should be from 30 to 45 Ib 133 to 200 N Torque fasteners as necessary Fig 8 Figure 6 1 Throttle control lever 3 Stop plate 2 Screws Figure 8 1 Control lever 4 Friction disc 2 Lock nut 5 Spring scale 3 Cap screw 6 Throttle cable Kubota Diesel Engine Page 3 6 Reelmaster 3100 D Adjust Alternator Fan Condition and tension of all belts should be checked af ter the first 10 hours of operation and every 100 operat ing hours thereafter 1 Park machine on level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Open hood 3 Check belt tension by
88. is contaminated oil appears milky black or contains metal particles IMPORTANT Flush hydraulic system when chang Ing from petroleum base hydraulic fluid to a biode gradable fluid such as Toro Biodegradable Hydraulic Fluid Operate machine under normal op erating conditions for at least four 4 hours before draining IMPORTANT If a component failure occurred in the traction circuit refer to Traction Circuit Closed Loop Component Failure in the General Informa tion section for information regarding the impor tance of removing contamination from the traction circuit 1 Park machine on a level surface Lower cutting units stop engine and engage parking Remove key from the ignition switch Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hy draulic System Pressure in the General Infor mation section IMPORTANT Make sure to clean around any hy draulic connections that will be disconnected for draining 2 Drain hydraulic tank see Change Hydraulic Fluid 3 Drain hydraulic system Drain all hoses tubes and components while the system is warm 4 Change and replace oil filter see Replace Hydraulic Filter Hydraulic System Rev C Page 4 62 5 Inspect and clean hydraulic oil tank see Hydraulic Tank Inspection 6 Reconnect all hydraulic hoses lines and compo nents that were disconnected while draini
89. motor with wheel hub attached from the rear fork using Figure 43 as guide 5 Secure wheel hub in a vise Loosen but do not re move lock nut that secures wheel hub to wheel motor IMPORTANT DO NOT hit wheel hub wheel hub puller or wheel motor with a hammer during wheel hub removal or installation Hammering may cause damage to the wheel motor 6 Using hub puller see Special Tools loosen wheel hub from wheel motor 7 Remove wheel hub and motor from vise Remove lock nut and hub from motor shaft Locate and retrieve woodruff key 8 If hydraulic fittings are to be removed from wheel mo tor mark fitting orientation to allow correct assembly Reelmaster 3100 D Page 4 69 Rear Wheel Installation 1 If hydraulic fittings were removed install fittings to reel motor using marks made during the removal pro cess to properly orientate fittings 2 Thoroughly clean wheel motor shaft and wheel hub taper 3 Clamp wheel hub in a vise Install woodruff key into the wheel motor shaft Slide motor shaft into hub and se cure with lock nut Torque lock nut from 250 to 350 ft lb 339 to 474 Remove wheel motor and hub from vise 4 Install wheel motor to the rear fork using Figure 43 as guide 5 Install tire and rim assembly to machine 6 Lower the machine to the ground 7 Torque rear wheel lug nuts from 45 to 65 ft Ib 61 to 88 N m 8 Make sure hydraulic tank is full Add correct oil if nec essary see
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91. on level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Remove four hex flange head screws securing the seat support straps to the frame 3 Disconnect electrical connector from the seat switch Separate seat from the frame 4 Remove seat parts as necessary to make repairs us ing Figure 5 as a guide Wheels Brakes and Miscellaneous Page 6 4 13 Seat adjuster 14 Cap screw 15 Seat switch 16 Hex flange head screw 17 Seat support strap Installation 1 Install any new seat parts using Figure 5 as a guide 2 Position seat and support straps to the fuel tank and frame 3 Connect electrical connector to the seat switch 4 Secure seat support straps to the frame with four hex flange head screws Reelmaster 3100 D Deluxe Seat Pa T a gon 45 44 43 14 13 Figure 6 1 Plate 18 Washer 35 Screw 2 Rivet 19 Nut 36 Cover 3 Screw 20 Swing arm assembly incl 28 amp 42 37 Clamp 4 Wear parts kit incl 8 thru 11 21 Adjusting rail RH 38 Shock absorber 5 Tension spring set 22 Bottom trim 39 Nut 6 Handle grip 23 frame 40 Washer 7T Adjusting lever 24 Screw i n 8 Cover 25 Seat switch incl 24 26 amp 27 EM ee 9 26 Spring washer 43 Cap screw 10 Bushing 27 Nut d 11 Pad 28 Back plate pivot 7 EOC Wasner 12
92. or rebuilt run the traction unit so all wheels turn slowly for 10 minutes 18 Operate traction unit by gradually increasing its work load to full over a 10 minute period 19 Stop the machine Check hydraulic tank and fill if necessary Check hydraulic components for leaks and tighten any loose connections Hydraulic System Rev C 2g 8 gt Hydraulic Tank and Hydraulic Oil Filter Anti seize lubricant 30 to 60 in Ib 3 4 to 6 8 N m Grommet 4 used Flange head screw 4 used Barb fitting Barb fitting Flat washer 4 used Hydraulic tank Hose clamp Hose clamp Hydraulic fitting straight 10 Flange head screw 2 used 11 Hydraulic fitting straight Hydraulic System Rev 16 to 18 ft lb 22 to 24 N m Thread Sealant 55 S Thread Figure 40 Hydraulic fitting suction filter element Shoulder screw Suction strainer Dipstick Filter head Hydraulic tank cap Hose clamp Hydraulic hose O ring O ring Page 4 64 LATER MODELS Tether O ring O ring Hose Not used Hydraulic tube Plug Suction hose Suction strainer O ring Reelmaster 3100 D 1 Drain hydraulic tank see Change Hydraulic Fluid 2 Remove hydraulic tank from machine using Figures 40 and 41 as guides Hydraulic Tank Inspection 1
93. rotating parts 4 Start engine and rotate cam hex in both directions to determine mid position of neutral span 5 Tighten locknut securing adjustment 6 Stop engine 7 Remove support blocks and lower the machine to the shop floor Test drive the machine to make sure it does not creep Hydraulic System Rev C Page 4 56 Reelmaster 3100 D Adjust Relief Valve R1 The hydraulic reel circuit is equipped with a relief valve This valve is preset at the factory to 3000 PSI However an adjustment may be required if the setting proves to be incorrect after testing see TESTING If an adjust ment is required proceed as follows Never adjust the relief valve with the hydraulic system pressurized Hydraulic oil may spray out of the valve with the cap off Personal injury may result Always install the cap and tighten before pressurizing the system NOTE Do not remove the relief valve from the hydrau lic manifold for adjustment 1 Remove cap from the relief valve with an allen wrench NOTE A 1 8 turn of the adjustment socket will make a Figure 34 measurable change in relief pressure 1 Relief valve cap 2 Adjustment socket 2 To increase pressure setting turn the adjustment socket inside the valve 1 8 of a turn clockwise 2g E gt 3 To decrease pressure setting turn the adjustment socket inside the valve 1 8 of a turn counterclockwise 4 Install and tighten cap t
94. s Manual are available on the internet at www Toro com 4 Only trained operators who are skilled in slope op eration and who have read the Operator s Manual and viewed the Operator s Video should operate the ma chine Never allow children to operate the machine or adults to operate it without proper instructions Reelmaster 3100 D 1 1 Chapter 1 S afety Maintenance and Service 3 JACKING INSTRUCTIONS 4 SAFETY AND INSTRUCTION DECALS 5 WARNING To reduce the potential for injury or death com ply with the following safety instructions the turf condition and the rollover risk To determine which hills or slopes may be safely operated on use the inclinometer provided with each machine To perform a site survey lay a 4 foot long 2 by 4 inch piece of wood onthe slope surface and measurethe angle ofthe slope The piece of wood will average the slope but will nottake into consideration dips or holes THE MAXIMUM SIDE HILL ANGLE SHOULD NOT BE GREATER THAN 25 DEGREES 5 Become familiar with the controls and know how to stop the machine and engine quickly 6 Do not carry passengers on the machine Keep ev eryone especially children and pets away from the areas of operation 7 Keep all shields safety devices and decals in place Repair or replace damaged malfunctioning or illegible shield safety device or decal before operating the ma chine
95. see Piston Pump Installa tion in Chapter 4 Hydraulic System 7 Connect fuel hose to the water fuel separator Fig 30 and front injector nozzle Fig 31 8 Install top fan shroud to the radiator Install reservoir and bracket to the top fan shroud see Radiator Installa tion Kubota Diesel Engine Page 3 22 Figure 34 3 Torsion spring 4 Pump mount plate 1 Cap screw 2 Spacer 9 Connect wire harness and electrical wires to the fol lowing A Engine grounds to the battery and wire harness Fig 30 B Glow plug bus and fuel stop solenoid Fig 31 C High temperature warning switch Fig 32 D High temperature shutdown switch alternator and low oil pressure switch Fig 33 10 Connect coolant hoses to the water pump and en gine block Make sure drain cock valve is closed Fill ra diator with coolant see Check Cooling System 11 Install muffler to the exhaust manifold and muffler bracket see Muffler Installation 12 Connect throttle cable to the support and swivel the speed control lever Fig 30 13 Connect both battery cables at the battery see Bat tery Service in Chapter 5 Electrical system 14 Install air cleaner to the engine Connect air hose to air cleaner and radiator 15 Adjust throttle cable see Adjust Throttle Cable 16 Bleed fuel system see Bleed Fuel System 17 Install engine hood to the machine Close and latch hood 18 Adjust traction driv
96. slip back plate over gear shafts onto body until alignment pin is engaged 9 Hand tighten cap screws Torque cap screws in a crisscross pattern from 25 to 28 ft lb 33 9 to 38 0 10 Place washer over the drive shaft into the front plate housing Apply a liberal coat of hydraulic oil to the oil seal Install oil seal over the drive shaft being careful not to cut the rubber seal lips 11 Place 1 1 16 inch O D sleeve over the drive shaft and press in the oil seal until the retaining ring groove appears 12 Press retaining ring into the housing using the sleeve until it seats in the groove Hydraulic System Rev C 2g 5 gt Reel Motor Service Casappa 33 ft lb 7 18 45 N m 45 Figure 46 1 1 Dustseal 7 Back up gasket 13 O ring 2 Retaining ring 8 Front wear plate 14 Relief valve 3 Flange washer 9 Dowel pin 15 Body 4 Shaftseal 10 Idler gear 16 Washer 4 used 5 Frontflange 11 Drive shaft 17 Lock washer 4 used 6 Pressure seal 12 Rear wear plate 18 Cap screw 4 used Disassembly Fig 46 1 1 Plug motor ports and clean the outside of the motor thoroughly After cleaning remove plugs and drain any oil out of the motor 2 Use a marker to make a diagonal line across the frontflange and body for assembly purposes Fig 46 2 IMPORTANT Prevent damage when clamping the reel motor into a vise clamp on the frontflangeonly Also use a vise with soft jaws 3 Cla
97. switch 2 Open engine hood to gain access to engine 3 Remove both flange head nuts and screws securing the muffler plate to the muffler bracket Fig 16 4 Remove four hex nuts and lock washers from the ex haust manifold studs Separate muffler flange from the exhaust manifold Remove muffler from the machine Fig 17 5 Remove gasket from exhaust manifold or muffler flange Replace gasket if damaged or torn Fig 15 Muffler Installation Note new gasket is to be installed make sure muffler flange and exhaust manifold sealing surfaces are free of debris or damage that may prevent a tight seal 1 Place gasket on the exhaust manifold Fig 15 2 Secure muffler flange to the exhaust manifold with four lock washers and hex nuts Fig 17 IMPORTANT Finger tighten all nuts before secur ing the muffler plate to the muffler bracket so there is no preload on the exhaust manifold 3 Secure muffler plate to the muffler bracket with both flange head screws and nuts Fig 16 4 Close engine hood Figure 16 1 Flange head nut 3 Muffler plate 2 Flange head screw 4 Muffler bracket E 2 E x Figure 17 1 Hexnut amp lock washer 3 Muffler flange 2 Stud 4 Exhaust manifold Reelmaster 3100 D Page 3 11 Kubota Diesel Engine Check Air Filter Dust 8 Burp Valve The air cleaner body air filter dust cup and burp valve should be check daily prior to operat
98. the adapter plate should extend 0 126 inch 3 20 mm from the plate surface D Scoring on the face of the back plate or the back plate side of the adapter plate should not exceed 0 0015 inch 0 038 mm E The oil groove in the bushings of the front plate should be opposite each other and in line with with the dowel pin holes The oil groove in the bushings of the back plate should be about 37 to the pressure port Fig 78 and 79 Reassembly Fig 76 NOTE When reassembling the pump check the mark er line on each part to make sure the parts are properly aligned during reassembly 1 Lubricate new O rings pressure seals back up gaskets and wear plates with a thin coat of petroleum jelly Lubricate all other internal parts freely with clean hydraulic oil 2 Install O ring into the groove of the front plate 3 Lubricate gear pockets of front body with a thin coat of petroleum jelly Place front body onto front plate so the half moon port cavities face away from the front plate Hydraulic System Rev C Page 4 112 Figure 78 2 Oil groove 1 Front plate Figure 79 1 Back plate 2 Oilgroove 4 Install new pressure seal and back up gasket into both new wear plates The flat section in the middle of the back up gasket must face away from the wear plate inside the seal 5 Install wear plate into the gear pocket with the pres sure seal and back up gasket against the front plate Make sure mid secti
99. the bedbar 4 Install bedbar assembly on the cutting unit 5 Secure bedbar housing to the cutting unit with both carriage bolts and nuts 6 Secure adjusting housing to the cutting unit with both carriage bolts and nuts Fig 24 7 Tighten both adjusting lock nuts on the adjusting housing Fig 24 8 Position bedbar fitting to the bedbar yoke Screw ad justing handle left hand threaded until the bedbar fit ting is snug against the bedbar yoke Reelmaster 3100 D Page 7 19 Figure 24 3 Carriage bolt and nut 1 Adjusting lock nut 2 Adjusting housing 9 Adjust bedknife to reel see Bedknife to Parallel to Reel Adjustment Cutting Units Bedknife Replacement and Grinding 1 Remove bedbar from the cutting unit see Bedbar Removal and Installation 2 Remove bedknife screws and bedknife 3 Remove all rust scale and corrosion from the bedbar surface before installing new bedknife NOTE Use a torque wrench and a bedknife screw tool to install bedknife screws 4 nstall new bedknife as follows A Make sure bedbar threads are clean B Use new bedknife screws Apply anti seize lubri cant to the screw threads before installing IMPORTANT Do not use an air or manual impact wrench to tighten bedknive screws Figure 25 C Tighten screws to a torque of 250 to 300 in Ib 28 3 to 33 9 Tighten screws from the center toward each end of the bedbar Fig 25 Top Face 5 Since
100. the piston pump NOTE If installing a new gear pump to the piston pump make sure to remove the plug from the suction port of the gear pump Fig 65 The gear pump suction fitting must be on the same side as the trunnion of the piston pump 6 Remove plugs from the gear pump Secure O ring and gear pump to the piston pump with both flat washers and socket head screws Torque fasteners from 27 to 31 ft lb 37 to 42 Support piston and gear pumps when installing them to the pump mount plate and pump support to prevent them from falling and causing person al injury 7 Position piston pump to the pump mount plate Se cure pump to the mount plate with both flat washers cap Screws and lock nuts Do not fully tighten fasteners 8 Secure piston pump to the pump support with both spacers washers and cap screws Tighten fasteners securing the piston pump to the pump mount plat and pump support 9 Remove plugs from hydraulic hoses Connect all hy draulic hoses as follows A Secure O rings and hoses to the gear pump B Connect hydraulic suction hose from the hydrau lic tank to the barb fitting with hose clamp C Secure O rings and hydraulic hoses to the piston pump Reelmaster 3100 D Page 4 99 10 Install neutral arm assembly to the piston pump as follows Figs 63 and 64 A Position neutral bracket to the mount plate and then pump lever to the pump trunnion B Secure pump lever to the piston pu
101. there can be variations in the mounting sur Relief Angle face of the bedbar a new bedknife will not be perfectly flat after it is installed Because of this it is necessary to backlap or grind a new bedknife after installing it to the bedbar Follow the existing angle that was ground into the bedknife and grind only enough to make sure the top surface is true Front Angle Regrinding Bedknife Figure 26 Remove bedbar assembly from cutting unit before at tempting to regrind a used bedknife see Bedbar Re moval and Installation Note When grinding be careful to not overheat the bedknife Remove small amounts of material with each pass of the grinder Note Ifthe height of cut is a 1 2 inch or lower on the cutting unit the front angle can be increased to 30 for improved performance Bedknife Regrinding Specifications Relief Angle Front Angle 15 see Note above Front Angle Range 13 to 179 Cutting Units Page 7 20 Reelmaster 3100 D Roller Removal and Installation Note This section can be used for both the front and rear rollers Roller Removal 1 Remove both height of cut pins and hairpin cotters from each roller bracket 2 Remove both locknuts from the capscrews securing each angle bracket to the cutting unit 3 Remove capscrews from both angle brackets and the cutting unit 4 Separate roller assembly roller brackets and angle brackets from the cutting unit 5 Remove roller brackets f
102. too much grass height may not always be overcome by adjusting the cutting unit It is important to remember that the lower the height of cut the more critical these factors are Refer to the Cutting Units Operator s Manual for de tailed cutting unit adjustment procedures For cutting unit repair information refer to the Service and R epairs section of this chapter Note Foradditional information regarding cutting unit troubleshooting see Aftercut Appearance Trouble shooting Aid part 0007651 Tire pressure Governed engine speed Reel speed Reel bearing condition Bedknife to reel adjustment DPA Cutting Units Rev G Page8 8 Check tire pressure of all traction unit tires Adjust tire pressure as necessary See the Traction Unit O perator s manual For best cutting performance and appearance engine should be run at maximum governed speed during machine operation Check maximum governed engine speed Adjust engine to specifications if necessary See the Traction Unit Operator s Manual and Chapter 3 Kubota Diesel Engine in this manual All cutting reels must rotate atthe same speed within 100 rpm see Troubleshooting in Chapter 4 Hydraulic S ystem in this manual All cutting units must have equal bedknife to reel and height of cut adjustments Make sure that reel speed selection is correct see Clip Chart Traction Unit Operator s Manual Check reel bearings for wear and replace
103. valve Flow then returns to the hydraulic tank Shift Sidewinder Right When the sidewinder is to be shifted right the 2 spool valve is positioned by moving the cutting unit shift lever to RIGHT Flow is directed to the cap end of the side winder cylinder Hydraulic pressure against the cylinder piston moves the rod causing the sidewinder cylinder to extend right At the same time the piston pushes the hy draulic fluid out of the cylinder back through the spool Reelmaster 3100 D Page 4 19 and hydraulic manifold and to the hydrostat When the cutting unit shift lever is released spring action returns the valve to its original position and by passes flow back to the hydrostat and stopping cylinder movement The cylinder position is locked in place since there is no com plete circuit of flow to and from the lift cylinders Shift Sidewinder Left When the sidewinder is to be shifted left the 2 spool valve is positioned by moving the cutting unit shift lever to LEFT Flow is directed to the rod end of the sidewinder cylinder Hydraulic pressure against the cylinder piston moves the rod causing the sidewinder to retract left At the same time the piston pushes the hydraulic fluid out of the cylinder back through the spool and hydraulic manifold and to the hydrostat When the cutting unit shift lever is released spring action returns the valve to its original position and by passes flow back to the hy drostat stopping cylind
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106. 100 D Procedure for Lift and Steering Control Valve Relief Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Make sure machine is parked on a level surface with the cutting units lowered and off Make sure engine is off and the parking brake is engaged 3 Read Precautions for Hydraulic Testing Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hy draulic System Pressure in the General Infor mation section 4 Disconnect hose connection on gear pump P2 leading to the steering control valve Fig 32 5 Install T connector with test gauge in series with the discharge of the gear pump and the disconnected hose leading to the steering control valve 6 Make sure steering wheel is positioned so the rear wheel points directly ahead 7 Start engine and move throttle to full speed 2650 50 RPM Engage the cutting units M CAUTION Do not allow pressure to exceed 1500 PSI IMPORTANT Hold steering wheel at full lock only long enough to get a system pressure reading Holding the steering wheel against the stop for an extended period will damage the steering control valve 8 Watch pressure gauge carefully while turning the steering wheel completely in one direction and holding at full lock briefly 9 System pressure should be from 845 to 995 P
107. 138 17 128 17 er EN A EN Co N N N N 16 2 7 16 14 UNC 27 3 1 2 20 UNF 32 3 115 11 120 10 163 14 5 8 11 65 10 88 12 119 16 150 15 203 20 210 20 285 27 5 8 18 75 10 95 15 129 20 170 15 230 20 240 20 325 27 3 4 10 UNC 93 12 140 20 190 27 265 25 359 34 375 35 508 47 3 4 16 UNF 115 15 165 25 224 34 300 25 407 34 420 35 569 47 7 8 9 UNC 140 20 225 25 305 34 430 45 583 61 600 60 813 81 7 8 14 UNF 155 25 260 30 353 41 475 45 644 61 660 60 895 81 Note Reduce torque values listed in the table above on the fastener size the aluminum or base material by 25 for lubricated fasteners Lubricated fasteners strength length of thread engagement etc are defined as threads coated with a lubricant such as graphite or thread sealant such Loctite Note The nominal torque values listed above for Grade 5 and 8 fasteners are based on 75 of the mini Note Torque values may have to be reduced when mum proof load specified in SAE J429 The tolerance is installing fasteners into threaded aluminum or brass approximately 1096 of the nominal torque value Thin The specific torque value should be determined based height nuts in
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109. 2 Remove cutting unit from the pivot shaft of the rear lift arm see Cutting Unit Removal 3 Remove external retaining ring and thrust washer from the lift cylinder shaft of the rear lift arm 4 Remove flange head screw and thrust washer from the rear pivot shaft 5 Slide rear lift arm from rear pivot shaft and hydraulic cylinder Cutting Units Page 7 28 as a guide Installation 1 Assemble lift arm using Figure 34 as a guide A If the rear pivot shaft was removed torque jam nut from 200 to 250 Ft Ib 271 to 339 B If the switch bracket was removed make sure the lip of the switch bracket faces away from the rear lift arm when installed 2 Slide rear lift arm onto rear pivot shaft making sure that the lift shaft of the rear lift arm slides into the clevis of the hydraulic cylinder Reelmaster 3100 D 3 Secure hydraulic cylinder clevis to the lift cylinder 5 Adjustlift arms to proper clearance see Adjust Rear shaftofthe rear lift arm with the thrust washer and exter Lift Arm nal retaining ring 6 Grease front lift arm 4 Install rear cutting unit to the pivot shaft of the rear lift arm see Cutting Unit Removal Reelmaster 3100 D Page 7 29 Rev E Cutting Units Skid Kit Installation 1 Remove front roller from the cutting unit see Roller Removal and Installation 2 Align skid slots with the angle bracket holes on the cutting unit 3 Secure skid to the cutting unit with both flang
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111. 9 447 9 32 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 7 988 13 16 0 8125 20 638 21 64 0 328125 8 334 53 64 0 828125 21 034 11 32 0 34875 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 7 16 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 in 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 Kilometers 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 Grams 28 3495 Pressure Pounds Sq In Kilopascal 6 895 Pounds Sq In Bar 0 069 Work
112. 99999 20 Connector ined as Sse eh aad 39 Harness Diagram Serial Numbers 240000001 Glow Controller 40 to 270999999 21 Standard Control Module 41 Wiring Diagram Serial Numbers 280000001 SERVICE AND REPAIRS 42 arid Up per hey Peel 22 Battery Storage 42 Harness Diagram Serial Numbers 280000001 Battery senec ses uer pere urere 42 and LER Hb t 98 22 1 Battery Service 43 SPECIAL TOOLS ied 23 TROUBLESHOOTING 24 Starting Problems 24 General Run amp Transport Problems 26 Cutting Unit Operating Problems 27 Reelmaster 3100 D 5 1 Electrical Systems Rev C Rev 09106 01 10106 S1equinN 5 se pue Reelmaster 3100 D
113. ANT Do not tow the machine faster than 2 to 3 mph because drive system may be damaged If ma chine must be moved a considerable distance more than a few feet transport it on a truck or trailer 1 Locate by pass valve on pump and rotate it 909 2 Before starting engine close by pass valve by rotat ing it 909 Do not start engine when valve is open Check Hydraulic System Fluid The hydraulic system that drives the reels is designed to operate on anti wear hydraulic fluid The machines reservoir is filled at the factory with approximately 3 5 gallons 13 2 liters of DTE 15M hydraulic fluid Check level of the hydraulic fluid before the engine is first started and daily thereafter IMPORTANT Use only types of hydraulic fluids specified Other fluids could cause system damage NOTE A red dye additive for the hydraulic system fluid is available in 2 3 oz bottles One bottle is sufficient for 4 to 6 gallons 15 to 23 liters of hydraulic fluid Order Part No 44 2500 from your Authorized Toro Distributor 1 Position machine on a level surface lower cutting units and stop engine 2 Clean area around filler neck and cap of the hydraulic tank Remove cap from the filler neck 3 Remove dipstick from the filler neck and wipe it with a clean rag Insert dipstick into the filler neck then re move it and check level of the fluid Fluid level should be within 1 4 inch 6 mm of the mark on the dipstick 4 f level is low a
114. Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 4 Jack up rear wheel enough to allow the removal of the rear fork 5 Remove lug nuts from drive studs Remove tire with wheel rim from wheel hub 6 Remove four lock nuts and hex socket head screws securing the hydraulic motor to the rear fork Remove motor from the fork and position it away from the fork Ad CAUTION Support front fork to prevent its falling during re moval and installation Personal injury or dam age to the fork may result from improper han dling 7 Remove cap screw thrust washer and lock washer from the rear fork shaft 8 Lower rear fork from machine 9 Check bushings for wear and damage Replace if necessary Reelmaster 3100 D Page 6 9 Installation 1 Position rear fork through the frame 2 Install lock washer thrust washer and cap screw to the rear fork shaft Torque cap screw from 60 to 80 ft lb 81 4 to 108 5 N m Make sure fork turns freely 3 Install hydraulic motor to the rear fork Secure motor to the fork with four hex socket head screws and lock nuts 4 Secure wheel rim to the wheel hub with four lug nuts Torque nuts from 45 to 65 ft lb 61 to 88 5 Lower rear wheel to the ground 6 Secure hydraulic cylinder to the rear fork as follows A Swing cylinder to the rear fork B Separate ball joint to rear fork C Secure ball joint to the rear fork wi
115. Clean hydraulic tank and suction strainer with sol vent 2 Inspect hydraulic tank for leaks cracks or other damage Figure 41 Hydraulic Tank Installation 1 Gear pump 2 Suction hose 1 On early production machines assemble suction strainer and fitting NOTE When applying hydraulic thread sealant to the threads of fitting and the suction strainer do not apply sealant to the first thread A Apply hydraulic thread sealant to the threads of the hydraulic fitting suction Secure fitting to the suction strainer B Apply hydraulic thread sealant to the threads of the suction strainer 2 Apply anti seize lubricant to four flange head screws Secure hydraulic tank to machine with flange head screws Torque flange head screws from 30 to 60 in Ib 3 4 to 6 8 2 gt 3 Using wrench turn suction strainer into tank port at least 1 1 2 to 2 full turns beyond finger tight 4 Complete hydraulic tank installation using Figures 40 and 41 as guides Reelmaster 3100 D Page 4 65 Hydraulic System Rev C Front Wheel Motors Figure 42 1 Locknut 5 Frame 8 O ring 2 Spacer 6 Hydraulic tube 9 Hydraulic fitting 3 Socket head screw 7 Hydraulic tube 10 O ring 4 Hydraulic motor Hydraulic System Rev C Page 4 66 Reelmaster 3100 D Removal A WARNING Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 1 Remove tire and whee
116. Components 1 Check oil level in the hydraulic reservoir and add cor rect oil if necessary Drain and refill hydraulic system reservoir and change oil filter if component failure was Severe or system is contaminated see Flush Hydraulic System 2 Lubricate O rings and seals with clean hydraulic oil before installing hydraulic components 3 Make sure caps or plugs are removed from the hy draulic tubes hydraulic fittings and components before reconnecting 4 Use proper tightening methods when installing hy draulic hoses and fittings see Hydraulic Fitting Installa tion 5 Make sure caps or plugs are removed from the hy draulic tubes hydraulic fittings and components before reconnecting 6 After repairs check control linkages or cables for proper adjustment binding or broken parts 7 After disconnecting or replacing any hydraulic com ponents operate machine functions slowly until air is out of system see Charge Hydraulic System 8 Check for hydraulic oil leaks Shut off engine and cor rect leaks if necessary Check oil level in hydraulic reser voir and add correct oil if necessary Reelmaster 3100 D Change Hydraulic Fluid Change hydraulic fluid after every 400 operating hours under normal conditions If fluid becomes contami nated the system must be flushed Contaminated fluid looks milky or black when compared to clean oil 1 engine off and raise hood 2 Disconnect hydraulic hose f
117. D Page 5 33 Figure 11 1 Temp warning switch 3 Water pump 2 Temp shutdown switch 4 Allow oil to cool while observing temperature A The high temperature warning switch should open at about 208 F 98 C B The high temperature shutdown switch should open at about 219 F 10490 5 Replace switch if necessary Electrical Systems Rev C SE Diode Assemblies The diode D1 and D2 provide logic for the interlock switches Diode 03 is used for circuit protection from in ductive voltage spikes when the interlock relay is deen ergized Machines equipped with the standard control module serial numbers above 240000000 use only one diode Two types of diodes have been used on the Reelmaster 3100 D 1 On early production machines the diodes are lo cated within the main wiring harness that lies under the hydraulic tank and control console Fig 13 2 Later production machines use diodes that plug into the wiring harness Fig 14 Location of the diodes is un der the control console Testing The diodes can be individually tested using a digital multimeter ohms setting and the tables below 1 Diodes located within the main harness Fig 13 Multimeter Black Lead Multimeter Red Lead Continuity 2 Plug in style diodes Fig 14 Multimeter Black Lead on Terminal Multimeter Red Lead on Terminal Continuity Electrical Systems
118. Infor mation section 4 Disconnect hose connection on the reel gear pump leading to the steering control valve 5 Install tester in series with reel drive pump and the disconnected hose leading to the steering control valve 6 Make sure the flow control valve on the tester is fully open IMPORTANT In this test the flow tester is posi tioned before the relief valve Pump damage can oc cur if the oil flow is fully restricted Do not close tester valve fully when performing test 7 Start engine and move throttle to full speed 2650 50 RPM Do not engage the cutting units 8 Watch pressure gauge carefully while slowly closing the flow control valve until 800 PSI is obtained Verify with a phototac that the pump speed is 3100 RPM 9 Flow indication should be 3 6 GPM minimum 10 Shut off engine NOTE If necessary Steering and Lift Relief Pressure Test can be conducted with tester as placed for this test 11 If flow was less than 3 6 GPM or a pressure of 800 PSI cannot be obtained check for restriction in the pump intake line If line is not restricted remove pump and re pair or replace as necessary 12 Disconnect tester from gear pump fitting and hose Reconnect hose to the pump 2 H ERE NNKSS 2 28S TES RIGHT OK FRONT Figure 20 1 Gear pump 2 To steering control valve 2 EI gt Reelmaster 3100 D Page 4 37 Hydraulic System Rev C Wheel M
119. Install new seals into front flange Fig 46 3 A Press shaft seal into front flange until it reaches the bottom of the bore B Install flange washer into front flange and then install retaining ring into the groove of the front flange C Install new dust seal into front flange 3 Place front flange seal side down on a flat surface 4 Install the pressure seals flat side outward into the grooves in the wear plates Follow by carefully placing the backup gaskets flat side outward between the pressure seals and the grooves in the wear plate 5 Apply alight coating of petroleum jelly to the exposed side of the front flange 6 Lubricate the drive shaft with clean hydraulic oil In sert the drive end of the drive shaft through the wear plate with the pressure seal side down andthe open side of the pressure seal pointing to the inlet side of the mo tor Carefully install shaft into front flange 7 Lubricate the idler gear shaft with clean hydraulic oil Install idler gear shaft into the remaining position in the front wear plate Apply a light coating of clean hydraulic oil to gear faces Hydraulic System Page 4 75 3 Rev E 8 Install rear wear plate with pressure seal side up and open side of the pressure seal pointing to the inlet side of the motor 9 Apply alightcoating of petroleum jelly to new O ring and O ring groove in the body Install new O ring to the 10 Install locating pins in
120. M LHOTT m i VNOLLdO 1 MOW 1HOdSNVH L 44O NO 1434 ens Y NOLLINSI GION310S I 3AIBQ 1434 Y ver bn LI 08 gt gt lt gt 8 RIA uo 1 58 98 Ha as r4 Wu E usua C 57888 EE 1 ERN S4 NMOGLNHS gt gt o 3 3 I gt HO LIMS E 57 440 NO 57984 issu diN3 L 5 al gr ml x x 3NION3 T dY TAY NI z ONY Wd ND 5 81g ge m 3NI N3 enone H ON 5 lt f 9 2 E HOLIMS HOLIMS a dS dv biova WANN efi 8 2 889 VS je p 15 98 lt a gt y m D 22 Avia vas lt 1 M 28 Ht ONY a gt 316 MOTONS id Lg ro lt X5 Bor E qa 20901 1v 538010 98 AASS Alana 139 x pokes 9 53501 HOLIMS HOLIMS 1v3S Hol ANIONS 1 200 LY 595010 AO 1 1 TA e 5390 HOLIMS ch 5 3NION3 HOLIMS 1v3S INNOLLdO 5666 J gt ee ee oe GION310S 8 gt HOLVNH3LTV Reelmaster 3100 D 666666062 01 19106 5
121. Mud MOW LHOdSNVu L 44O NO 57334 HOLIMS ens 2 GION3IOS 3AIBG 1338 us Tm KU 300 1831NI 8 vs o 4 uo A S8 rvvy 98 AEST 2 L uo 440 51834 Sa b ed lt a gt 1 920 2 NMOGLNHS GIA amp o Qu HOLIMS diN3 L HOIH E 457 330 0 57838 Gier ANIONS T EN NO 3 ivug 5 5 2 215 AVY ONDIUVd a Q m uxiuvis iH 9 95 gt _ 0 a 5 2 gt ON HOLIMS I gt HOLIMS WHLNAN 5 dS cs EIS E dV MOva v 99 gt D g v YO lt L gt lt gt e M 3unss3ud 8 a 10 MOT NI m RNC L4 ONDIHVd Hoc 1 00901 1Y 536012 98 58 ALda 1 36 dio A A M HOLIMS lt HOLIMS 19 35 20011 1 535010 AD Sar gn 49 eo HOLIMS E 1 5 M 11 nS 9 HOLIMS 1v3S i mna GH m un weer ag GION310S 8 HOIVNH3LlV Reelmaster 3100 D Page 5 10 Electrical Systems Rev C 666666062 01 19106 SJequinN 6 21501 lt queuing jueuno Ud TOHLNOO MOTO
122. OLLER RELIEF Ti 3000 psi COOLER OPTIONAL CYLINDER LC2 TO FRONT LIFT CYLINDER CHG TO HYDROSTAT FROM LIFT VALVE CHARGE CIRCUIT OUT PORT TO STEERING CONTROL gus VALVE IN PORT FROM STEERING CONTROL VALVE OUT PORT High Pressure FROM HYDROSTAT INTERNAL CASE DRAIN STRAINER Low Pressure Return or Suction Flow Hydraulic System Rev C Page 4 40 Reelmaster 3100 D Procedure for Reel Circuit Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Park machine on a level surface with the cutting units lowered and off Make sure engine is off and the parking brake is engaged 3 Read Precautions for Hydraulic Testing Figure 23 Before disconnecting or performing any work 1 Hydraulic manifold 2 Test port G1 on the hydraulic system all pressure in the system must be relieved See Relieving Hy draulic System Pressure in the General Infor mation section 4 Remove plug from hydraulic manifold test port G1 5 Install pressure test gauge with hydraulic hose at tached into the test port 6 Make sure backlap knob on the hydraulic manifold is in the mow position Make sure reel speed knob is set
123. OSS STEERING UNIT TYPE OSPM SERVICE MANUAL Hydraulic System Rev C 2 3S SE 55 gt Specifications Item Description Piston Pump Hydrostat Maximum Operating Pressure Charge Pressure Traction Circuit Relief Pressure Forward Only Variable displacement piston pump 3000 PSI 207 bar 100 to 150 PSI 6 9 to 10 0 bar 3000 PSI 207 bar Gear Pump Maximum Operating Pressure 2 stage positive displacement gear type pump 3000 PSI 207 bar Wheel Motors Front Maximum Operating Pressure Orbital rotor motor 2000 PSI 138 bar Wheel Motors Rear Maximum Operating Pressure Orbital rotor motor 3000 PSI 207 bar Hydraulic Manifold Relief Pressure 3000 PSI 207 bar Reel Motor Cross over Relief Pressure Maximum Operating Pressure Gear motor 1500 PSI 103 bar 2250 PSI 155 bar Steering Control Valve Maximum Operating Pressure Implement Steering and Lift Relief Valve Pressure Distributor valve with rotary meter 1800 PSI 124 bar 1000 PSI 69 bar Hydraulic Filter 10 Micron spin on cartridge type Hydraulic Oil See Check Hydraulic System Fluid in General Information section Hydraulic Reservoir 3 5 gal U S 13 21 Hydraulic System Rev C Page 4 2 Reelmaster 3100 D General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure t
124. OTE An alternate testing location would be at the hy draulic hose connection to the hydraulic tube under the left floor plate 9 Install tester in series with the pump and the discon nected hose Make sure the flow control valve is fully open 10 Start engine and move throttle to full speed 2650 50 RPM Use extreme caution when taking gauge read ings The front tire on the ground will be trying to move the machine forward 11 Slowly push traction pedal fully to forward position Reelmaster 3100 D Page 4 33 igure 18 1 Lower hydraulic fitting 2 Piston pump 12 Verify traction relief valve setting by closing flow con trol valve System pressure should be from 3000 to 3125 PSI as the relief valve lifts If pressure can not be met or is exceeded with traction pedal fully depressed release traction pedal and open flow control valve fully 13 If specification is not met consider the following A The traction belt may be worn and slipping see Replace Traction Belt B The relief valve leaks or is faulty and needs re placement C The hydrostat needs to be repaired or replaced as necessary 14 If the traction relief valve tests out properly pump flow as follows A Push traction pedal in the forward direction until pressure gauge reads 1000 PSI Verify with a photo tac that the pump speed is 2350 RPM engine speed approximately 2000 RPM B Observe flow gauge TESTER READING should b
125. Operator s Manual Hydraulic System Rev C 2g gt Wheel Motor Service Figure 45 l Dirtseal 11 Coupling shaft 20 Vane 2 Bearing 12 Thrust bearing 21 Stator 3 Housing 13 Drive link 22 Manifold 4 Back up washer 14 Cap screw 23 Commutator ring 5 Sealrings 15 Commutator seal 24 End cover 6 Back up washer 16 Commutator 25 Ball 7 Inner seal 17 Woodruff key 26 Spring 8 Thrust washer 18 Wear plate 27 Plug 9 Thrust bearing 19 Rotor 28 O ring 10 Bearing NOTE The three wheel motors used on the Reelmas ter 3100 D similarin construction butdo have some differences The right front and left front motors are the same basic design butthe rightside motorhas a reverse timed manifold to allow correct rotation direction for for ward and reverse The end cover of the rear motor has a check valve consisting of a ball and spring and both front motors lack this feature The wheel motor shown in Figure 45 is a rear motor IMPORTANT If a wheel motor failure occurred refer to Traction Circuit Closed Loop Component Fail ure in the General Information section for informa tion regarding the importance of removing contamination from the traction circuit Hydraulic System Rev C Page 4 70 Rev F NOTE Machines with serial numbers below 260999999 use a Ross Torqmotor in all three posi tions Machines with serial numbers above 270000000 use a Ross Torqmotor in the rear and tw
126. PM Service Manual at the end of this chapter Reelmaster 3100 D Page 4 107 Hydraulic System Rev C Gear Pump 27 to 31 ft lb 37 to 42 N m Figure 75 1 Piston pump 7 O ring 12 Cap screw 2 Gear pump 8 O ring 13 Flat washer 3 Hydraulic hose tank suction 9 Hydraulic barb fitting 14 O ring 4 Hydraulic hose hydraulic manifold 10 90 hydraulic fitting 15 O ring 5 Hydraulic hose steering valve 11 90 hydraulic fitting 16 O ring 6 Hose clamp Hydraulic System Rev C Page 4 108 Reelmaster 3100 D Removal 1 Remove muffler from the engine to gain access to the gear pump see Muffler Removal in Chapter 3 Ku bota Diesel Engine 2 Drain hydraulic oil from hydraulic tank see Change Hydraulic Fluid in this section Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hy draulic System Pressure in the General Infor mation section 3 Remove gear pump from the piston pump using Fig ure 75 as guide 4 f hydraulic fittings are to be removed from gear pump mark fitting orientation to allow correct assembly Reelmaster 3100 D Page 4 109 Installation 1 If hydraulic fittings were removed install fittings to motor using marks made during the removal process to properly orientate fittings IMPORTANT Position gear pump to the piston pump so that the gear pump suction port is facing down 2 Install
127. Pack bearings with grease before installation B Press bearing into bearing housing so that bear ing contacts shoulder in housing bore C Install grease seals so that seal lips are posi tioned toward the brush location Press inner seals into housing so that seal contacts bore shoulder Press outer seals into housing until inner sealis con tacted 20 to 25 in Ib 2 3 to 2 8 N m Figure 39 1 Roller brush shaft 3 Roller brush 2 J bolt 4 Lock nut Figure 40 4 Housing non driven 5 Housing driven Bearing Inner grease seal Outer grease seal UJ Figure 41 1l Bearing housing 6 Snap ring 2 Drive shaft 7 O ring 3 Ball bearing 8 Side plate 4 Grease seal 9 Sockethead screw 5 Retaining ring 10 Grommet Reelmaster 3100 D Page 8 37 DPA Cutting Units Rev G c 5 amp N E 3 If drive bearing housing was disassembled install new components noting proper orientation as shown in Figures 41 and 42 4 A Install bearing on shaftby pressing equally onthe inner and outer bearing races Install the bearing so thatthe bearing sealis closestto the shoulderon the shaft Install snap ring Fig 41 item 6 onto shaftto retain bearing B Install new gre
128. QNITAO uaddn H3MO1 S gt Li SANA 41440 0 715 i53 H3QNIAO gn 9 14 SMA 2 uvau 43895 1888 31907 y 1 mE a o 131 4 1HOd dOL 1 YIN INVA 1 v YHOLOW pa 7 SHOLON 133HM ui uv3u Han i 0018 rococo 3 19 1 G O4INVIN i i 133H W vote mE 1 1 1 t d cw wl 1 2 era gt 10 i ead einssejd 1NOHJ 1331 YIH lt lt 1n24I2 LI G OOLE NIVHG 3SVO Reelmaster 3100 D Page 4 12 Hydraulic System Rev C Reel Circuit Mow REEL CIRCUIT SCHEMATIC FOR MACHINES NES WITH SERIAL NUMBERS BELOW 230000000 The gear pump P1 is directly coupled to the the hydros TO MANIFOLD tat which is driven by the engine Taking its suction di ba PORT rectly from the hydraulic tank the gear pump supplies oil flow to the manifold block and to the reel motors TO MANIFOLD M1 PORT Solenoid valve 51 is de energized with the engine running when either the reels on off switch is OFF
129. Rev C Page 5 34 Figure 13 3 Female terminal blade 4 Clear PVC tubing 1 Diode 2 Male terminal blade Figure 14 3 Female terminal 1 Diode 2 Male terminal Reelmaster 3100 D Warning Light Cluster Serial Numbers Below 240000000 Note Individual light bulbs can be tested by removing them from the lighting cluster and applying 12 VDC to their wiring terminals Cil Pressure Light The oil pressure light should come on when the ignition switch is in the ON position with the engine not running Also it should light with the engine running when the oil pressure drops below 4 PSI 0 3 kg cm 1 Disconnect green blue wire from the oil pressure switch 2 Ground green blue wire to the engine block 3 Turn the ignition switch to ON the light should come on 4 Turn the ignition switch to OFF Connect green blue wire to the oil pressure switch High Temperature Water Shutdown Light Units with Serial Numbers from 90101 to 90150 When the coolant temperature is above 2219F 1059C the temperature light comes on as the high temperature shutdown switch and relay stop the engine Units with Serial Numbers from 90150 to 230999999 When the coolant temperature is above 2219F 1059C the temperature light comes on However the high tem perature shutdown switch and relay do not stop the en gine until the high temperature shutdown sw
130. S 1 Before Operating 1 While Operating 2 General Safety Instructions The REELMASTER 3100 D was tested and certified by TORO for compliance with national and international standards as specified in the Operator s Manual Al though hazard control and accident prevention are de pendent partially upon the design and configuration of the machine these factors are also dependent upon the awareness concern and proper training of the person nel involved in the operation transport maintenance and storage of the machine Improper use or mainte nance by the operator or owner of the machine can re sult in injury To reduce the potential for any injury comply with the following safety instructions Supervisor s Responsibilities 1 Make sure operators are thoroughly trained and fa miliar with the Operator s Manual Operator s Video and all the operating and safety decals on the machine 2 Be sure to establish your own special procedures and work rules for unusual operating conditions e g slopes to steep for machine operation Survey mow ing site completely to determine which hills can be operated on safely When performing this site survey always use common sense and take into consideration Before Operating 3 Operate machine only after reading and understand ing the contents of the Operator s Manual and viewing the Operator s Video Copies of the Operator
131. SI as the relief valve lifts Return steering wheel to the center position If specification is not met shut off engine and replace relief valve in steering control valve see Steer ing Control Valve Service 10 Disconnect T connector with test gauge from gear pump P2 fitting and hose Reconnect hydraulic hose to pump Se UZO GES TES RIGHT Lote FRONT Figure 32 1 Gear pump 2 steering control valve 2 EI gt Reelmaster 3100 D Page 4 53 Hydraulic System Rev C Steering Control Valve Test STEERING CYLINDER OPEN FITTING PLUG POWER STEERING VALVE LEFT TURN Hydraulic System Rev C High Pressure Low Pressure Return or Suction Flow Page4 54 Reelmaster 3100 D Procedure Steering Control Valve Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Perform the Lift and Steering Control Valve Relief Pressure and Gear Pump P2 Flow tests to make sure that pump and relief valve are functioning correctly NOTE This steering test procedure will be affected by incorrect rear tire pressure binding in the hydraulic steering cylinder extra weight on the vehicle and or binding of the steering fork assembly Make sure that these item
132. Safety Rev E 8 Always wear substantial shoes Do not operate chine while wearing sandals tennis shoes or sneakers Do not wear loose fitting clothing because it could get caught in moving parts and possibly cause personal in jury 9 Wearing safety glasses safety shoes long pants and a helmet is advisable and required by some local or dinances and insurance regulations 10 Make sure the work area is clear of objects which might be picked up and thrown by the reels While Operating 12 Do not run the engine in a confined area without ade quate ventilation Exhaust fumes are hazardous and could be deadly 13 Sit on the seat when starting and operating the ma chine 14 Check interlock switches daily for proper operation Chapter 5 Electrical System Do not rely entirely on safety switches shut off engine before getting off seat If a switch fails replace it before operating the machine The interlock system is for your protection so do not by pass it Replace all interlock switches every two years 15 Operator must be skilled and trained in how to drive on hillsides Failure to use caution on slopes or hills may cause vehicle to tip or roll possibly resulting in personal injury or death Always wear your seat belt 16 This triplex mower has a unique drive system for su perior traction on hills The uphill wheel will not spin out and limit traction like conventional triplexes If operated on a side
133. This pump included some differences in the trunnion shaft design Items 50 53 in Figure 66 Hydraulic System Rev C Page4 100 Rev D IMPORTANT If a piston pump failure occurred re fer to Traction Circuit Closed Loop Component Failure in the General Information section for infor mation regarding the importance of removing con tamination from the traction circuit Reelmaster 3100 D Piston Pump Crush Ring Replacement Figure 67 Cam plate control shaft 1 Crush ring 5 2 Shims 6 Bearing cone 3 Cover plate 7 Bearing cup 4 Housing NOTE The shims replace the crush ring in the piston pump cover plate on Reelmaster 3100 D machines with serial numbers above 90775 If the cam plate cover plate or housing is replaced during servicing of the pump replace the original crush ring with shims to make sure of proper preload 1 Remove crush ring from the cover plate Measure thickness of crush ring 2 Stack shims to the thickness of the crush ring 3 Insert shims into the cover plate in the same location that the crush ring was removed from 4 Assemble housing cam plate bearing cone bear ing cup and cover plate see Eaton Medium Duty Piston Pump Repair Information Model 70160 Variable Dis placement Piston Pump at the end of this chapter Reelmaster 3100 D Page 4 101 Rev D 8 Seal 9 Washer 3 used 10 Cap screw 3 used 5 Install washers and cap screws to the cover plate and housi
134. ULIC opposite direction of the oil flow THREAD SEALANT 3 Plug both ends of oil cooler Clean exterior of cooler Make sure fins are clear of dirt and debris 4 The oil cooler should be free of corrosion cracked tubes and excessive pitting of tubes Installation 1 If removed apply hydraulic thread sealant to the barb fitting threads before installing Figure 48 2 Install oil cooler using Figures 47 and 48 as guides 1 Oil cooler 6 Hydraulic tube 2 Lanyard 7 Hydraulic tube 3 Barb fitting 8 Flow to filter 4 Hydraulic hose 9 Flow from manifold 5 Hose clamp Hydraulic System Rev C Page 4 76 Reelmaster 3100 D Hydraulic Manifold Figure 49 1 Hose clamp 11 Hydraulic manifold 21 Hydraulic tube 2 Micro switch 12 Hydraulic hose 22 O ring 3 Barb fitting 13 Hydraulic hose 23 Hose 4 Flange head screw 14 Hose clamp 24 Hydraulic hose 5 Straight hydraulic fitting 15 Spacer 25 Hydraulic hose 6 Straight hydraulic fitting 16 Philips pan head screw 26 Hydraulic hose 7 909 hydraulic fitting 17 O ring 27 Hydraulic hose 8 45 hydraulic fitting 18 O ring 28 Hydraulic hose 9 Straight hydraulic fitting 19 O ring 29 Hose 10 Barb fitting 20 O ring Removal 2 If hydraulic fittings are to be removed from manifold NOTE The ports on the manifold are marked for easy identification of components Example 1 is the reel cir cuit relief valve and P1 is the gear pump connection port See Hydraulic S
135. acer Page 7 26 External retaining ring Bulkhead nut Hydraulic tube Bulkhead nut Hose rod Model 03201 Flange head screw Model 03201 Flange nut Model 03201 O ring O ring Flange head screw Link clip Hex nut Tipper chain Flat washer Reelmaster 3100 D Removal 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Remove cutting unit from the pivot shaft of the front lift arm see Cutting Unit Removal NOTE Remove both spacers from the hydraulic cylin der shaft clevis when removing the right front lift arm 3 Disconnect hydraulic cylinder from the front lift arm by removing external retaining rings and pin 4 Remove both flange head screws and pivot shaft link from the lift arm pivot shafts Fig 33 5 Slide lift arm off the lift arm pivot shaft 6 Disassemble lift arm as necessary using Figure 34 as a guide Installation 1 Assemble lift arm using Figure 34 as a guide 2 Slide lift arm onto the lift arm pivot shaft 3 Secure pivot shaft link with both flange head screws to the lift arm pivot shafts Torque flange head screws to 70 Ft Ib 95 N m Fig 33 NOTE Install both spacers to the hydraulic cylinder shaft clevis when installing the right front lift arm 4 Secure hydraulic cylinder to the lift arm with pin and external retain
136. acket at tached to the cutting unit Slide second rear roller brack etonto the other end of roller shaft Secure second roller bracketand shims to cutting unit side plate with two 2 carriage screws and flange nuts Do not fully tighten flange nuts 4 Center rear roller to the cutting reel and secure in place by tightening four 4 flange nuts 5 Lubricate rear roller 6 Adjust cutting unit see Cutting Unit Operator s Manual DPA Cutting Units Rev G c 5 amp N E Roller Service Disassembly Fig 32 1 Remove bearing lock nut from each end of roller shaft 2 Loosely secure roller assembly in bench vise and lightly tap one end of roller shaft until outer seals and bearing are removed from opposite end of roller tube Remove second setofouterseals and bearing from roll er tube by tapping on opposite end of shaft Remove shaft from roller tube 3 Carefully remove inner seal from both ends of roller tube taking care to not damage tube surfaces 4 Discard removed seals and bearings 5 Clean rollershaftand allsurfaces on the inside ofthe roller tube Inspect components for wear or damage Also carefully inspect seating surface and threads of bearing lock nuts Replace all damaged components Assembly Fig 32 1 Install inner seals into roller tube making sure that seal lip and garter spring faces end of tube Use inner seal tool see Tools and softface ham
137. aftercut appearance R efer to Operator s Manual for a listing of available accessories DPA Cutting Units Rev G Page 8 10 Reelmaster 3100 D Set Up and Adjustments Characteristics Never install or work on the cutting units or lift arms with the engine running Always stop en gine and remove key first The dual knob bedknife to reel adjustment system in corporated in this cutting unit simplifies the adjustment procedure needed to deliver optimum mowing perfor mance The precise adjustment possible with this de sign gives the necessary control to provide a continual self sharpening action This feature maintains sharp cutting edges assures good quality of cut and greatly reduces the need for routine backlapping In addition the rear roller positioning system allows for various height of cut ranges and aggressiveness of cut selections If a cutting unit is determined to be out of adjustment complete the following procedures in the specified order to adjust the cutting unit properly 1 Adjustthe bedknife parallel to the reel 2 Determine desired height of cut range and install rear roller mounting shim s accordingly 3 Adjustthe height of cut See Cutting Unit Operator s Manual for cutting unit ad justment procedures for your R eelmaster 32 25 amp Reelmaster 3100 0 8 11 DPA Cutting Units Rev Reel Bearing Adjustment To insure cut quality and long life ofthe cut
138. ages 4 Install control panel cover to the machine IMPORTANT Always check and adjust the brakes anytime brake linkages are disassembled or re paired 5 Adjust brake linkages see Brake Adjustment Wheels Brakes and Miscellaneous S 2 pt 2 Steering Column Steering arm Flange hex nut Hex flange head screw Steering control valve bracket Cap screw Pivot hub Steering cover Cap screw Toro decal 10 Ball knob 11 Lever 12 Steering control valve 13 Tilt bracket 14 Cap screw LON Oo PONS Wheels Brakes and Miscellaneous Figure 11 Flat washer Flange hex nut Steering wheel Hydraulic fitting Hydraulic fitting Steering wheel nut Toro decal Hose assembly Hose assembly Hose assembly Hose assembly Hose assembly Tilt steering boss Friction disc 6 12 Rev D 29 30 31 32 33 34 35 36 37 38 39 40 41 20 to 26 ft Ib 27 1 to 35 3 N m Friction disc Flat washer Jam nut Lock nut Flat washer Not used Not used O ring O ring O ring Philips pan head screw Steering wheel cap Steering shield Reelmaster 3100 D Disassembly 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Remove philips pan head screws and steering wheel cap from the steering wheel 3 Remove steering wheel nu
139. al The sleeve bearing should stay in the cap C Loosen two 2 set screws that secure handle base to flow control valve and remove base Reelmaster 3100 D 3 Make sure manifold is clean before removing the rotary cartridge valve Remove the valve and seal kit 4 Visually inspectthe manifold port and cartridge valve for damage to sealing surfaces damaged threads and contamination A Contamination may cause valves to stick or hang up it can become lodged in small valve orifices or seal areas causing valve malfunction Ifsealing surfaces appear pitted or damaged the hydraulic system may be overheating or there may be water in the system A CAUTION Use eye protection such as goggles when using compressed air 5 If necessary clean cartridge valve using clean min eral spirits Submerge valve in clean mineral spirits to flush out contamination Particles as fine as talcum pow der can affect the operation of high pressure hydraulic valves Clean and dry with compressed air 6 Reinstall rotary cartridge valve into manifold port A Lubricate new O rings and backup rings of seal kit with clean hydraulic oil and install The O rings and backup rings of seal kit must be arranged prop erly on the cartridge valve for proper operation and sealing IMPORTANT Use care when installing cartridge valves Slight bending or distortion ofthe stem tube can cause binding and malfunction Make sure that deep well socket ful
140. al and Installation 30 Reelmaster 3100 D Page 7 1 Cutting Units Specifications Figure 1 MOUNTING All cutting units are supported by equal length independent lift arms and are interchangeable to all three cutting unit positions CONSTRUCTION 5 or 8 blades of 7 inches 18 cm di ameter welded to stamped steel spiders Reels are mounted on greaseable self aligning ball bearings A cutting unit has a reel of either 27 inches 69 cm in length or 32 inches 81 cm in length HEIGHT OF CUT RANGE Floating Cutting Unit 1 4 to 1 3 4 inches 6 4mm to 44 4mm Fixed Cutting Unit 1 2 to 2 5 8 inches 12 7 mm to 65 6 mm POWER Reel motors allow easy removal from or instal lation onto the cutting unit Cutting units can be driven from either end HEIGHT OF CUT amp ROLLER ADJUSTMENT Height of cut adjustment is made with the rollers by a quick locating pin and or threaded micro adjustment BEDKNIFE AND BEDBAR ADJUSTMENT A single knob screw adjustment for bedknife to reel is located at the center of the bedbar CUTTING UNIT LIFT Hydraulic lift has an automatic reel shut off All units are controlled from one lever SUSPENSION SYSTEM A fully floating suspension with hydraulic counterbalance L I N K S cutting unit Suspension system provides fore and aft oscillation Main center pivot allows side to side oscillation With optional Fixed Kit Part No 93 6915 cutting units can be locked into fi
141. al operating tem perature by operating the machine for approximately 10 minutes 2 Park machine on a level surface with the cutting units lowered and off Make sure engine is off and the parking brake is engaged 3 Read Precautions for Hydraulic Testing Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hy draulic System Pressure in the General Infor mation section 4 Disconnect hose connection on the reel gear pump leading to port P1 on the hydraulic manifold 5 Install tester in series with reel drive pump and the disconnected hose leading to port P1 of the hydraulic manifold 6 Make sure backlap knob on the hydraulic manifold is in the mow position and reel speed is set to maximum 7 Make sure the flow control valve on the tester is fully open 8 Start engine and move throttle to full speed 2650 50 RPM Do not engage the cutting units Reelmaster 3100 D Page 4 43 IMPORTANT In this test the hydraulic tester is positioned before the manifold relief valve Pump damage can occur if the oil flow is fully restricted by fully closing the tester flow control valve Do not close tester valve fully when performing test 9 Watch pressure gauge carefully while slowly closing the flow control valve until 2000 PSI is obtained Verify with a phototac that the pump speed is 3100 RPM 10 Flow indication should be 5 7 GPM minimu
142. alue Product Records and Maintenance Product Records i gt Other Torque Specifications SAE Grade 8 Steel Set Screws Recommended Torque Thread Size 1 4 20 UNC 140 20 in Ib 73 12 in Ib 5 16 18 UNC 215 35 in Ib 145 20 in Ib 3 8 16 UNC 35 10 ft lb 18 3 ft lb 75 15 ft lb 50 10 ft lb 1 2 13 UNC 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 in lb 5 16 18 UNC 110 20 in lb 3 8 16 UNC 200 100 in Ib No 10 24 UNC 38 7 in lb Conversion Factors in lb X 11 2985 N cm ft lb X 1 3558 N m Product Records and Maintenance Page2 6 Wheel Bolts and Lug Nuts Thread Size Recommended Torque 88 14 N m 7 16 20 UNF 65 10 ft lb Grade 5 1 2 20 UNF 80 10 ft lb B 108 14 Grade 5 M12 X 1 25 80 10 ft lb B 108 14 Class 8 8 M12 X 1 5 80 10 ft lb 108 14 Class 8 8 For steel wheels and non lubricated fasteners Thread Cutting Screws Zinc Plated Steel Threads per Inch Size Baseline Torque Type A Type B No E Hole size material strength material thickness amp finish must be considered when determining specific torque values All torque values are based on non lubricated fasteners
143. and lock nut with two wrenches IMPORTANT The nut must be on top of the battery retainer during installation to prevent the cap screw from hitting hydraulic hard lines when the sidewind er is shifted 5 Secure battery retainer Do not overtighten to pre vent cracking or distorting the battery case Reelmaster 3100 D 6 Apply a light coat of grease on all battery posts and cable connectors to reduce corrosion after connections are made 7 Connect a digital multimeter set to amps between the negative battery post and the negative ground cable connector The reading should be less than 0 1 amp If the reading is 0 1 amp or more the unit s electri cal system should be tested and repaired 8 Connect negative ground cable connector to the negative battery post Tighten cap screw and lock nut with two wrenches Charging To minimize possible damage to the battery and allow the battery to be fully charged the slow charging meth od is presented here This charging method can be ac complished with a constant current battery charger which is available in most shops A CAUTION Follow the manufacturer s instructions when us ing a battery charger NOTE Using specific gravity of the battery cells is the most accurate method of determining battery condition 1 Determine the battery charge level from either its open specific gravity or circuit voltage Level Gravity Voltage 100 1 265 12 68 75 1 225 12 45
144. ap screws four washers and five spacers securing the pump mount plate to the en gine Fig 34 C Remove four cap screws and hardened washers securing the right engine mounting bracket and hy drostat to the engine Installation 1 Install hydrostat and pump mount plate to the engine as follows A Secure right engine mounting bracket and hy drostat to the engine four hardened washers and cap Screws Note Do not install flat washer with cap screw near the torsion spring to prevent the spring from binding B Secure pump mount plate to the engine with five spacers four washers and five cap screws Fig 34 C Install traction belt to the engine fly wheel and hy drostat pulleys see Traction Belt Replacement 2 Connect hoist or lift to the front and rear lift tabs Fig caution 31 and 32 One person should operate lift or hoist while the other person guides the engine into the machine IMPORTANT Make sure not to damage the engine fuel and hydraulic lines electrical harness or other parts while installing the engine 3 Position engine slowly into the machine 4 Secure all three engine mounts to the engine mount ing brackets with cap screw washer and flange nut 5 Secure wire harness to the front lift tab and the en gine with cable ties Fig 31 6 Install all hydraulic hoses to the piston and gear pumps Install traction control cable to the neutral arm assembly on the piston pump
145. ar width is less than 1 140 in 29 96 mm 8 Make sure that retaining rings are in the grooves on both sides of the gear for both the drive gear and idler gear 9 Break sharp edges of gear teeth with emery cloth 10 Replace backplate and frontplate if bushing inside diameters exceed 0 755 in 19 2 mm The bushings are not available as replacement items 11 The face of the backplate and frontplate should be free of excessive scoring Replace if scoring a depth of 0 0015 in 0 038 mm Reelmaster 3100 D Page 4 75 12 Replace if the inside diameter of the gear pock ets exceeds 1 713 in 43 5 mm 13 Make sure both plugs are secure if they or the back plate is not being replaced Reassembly Fig 46 1 If replacing the relief valve assembly install ball spring shim O ring and plug into the backplate Hand tighten plug and then torque from 10 to 12 ft Ib 13 6 to 16 3 2 Coat O ring lightly with petroleum jelly and install in groove on the front plate 3 Apply a thin coat of petroleum jelly to both gear pock ets of the body Install alignment pin into body 4 Align matchmarks and slip body onto front plate until alignment pin is engaged 5 Dip idler gear and drive gear into clean hydraulic oil and slip into front plate bushings 6 Coat C ring lightly with petroleum jelly and install in groove on the back plate 7 Install alignment pin into back plate 8 Align matchmarks and
146. ase seal into housing with the lip of the sealtoward the drive shaftsplines Apply grease to lip of seal C Fill cavity between bearing location and grease seal 5096 to 7596 full with high temperature Mobil XHP 222 grease or equivalent D Carefully slide shaft and bearing fully into hous ing bore taking care to not damage the grease seal Install retaining ring Fig 41 item 5 to secure bear ing in housing Assemble roller brush components using Figure 38 as a guide DPA Cutting Units Rev G A Apply a light coating of grease to inner diameter of the grommet in drive bearing housing B Apply Loctite 242 or equivalent to threads of cap screws item 13 that secure brush plate to driv en bearing housing assembly Torque cap screws from 15 to 19 ft Ib 20 to 25 N m C Check that brush plate is parallel to cutting unit side plate If necessary change position of mounting bracket item 29 to allow brush plate to be parallel to side plate D Apply Loctite 242 or equivalent to threads of flange head screw item 20 thatsecures drive pulley to drive shaft Torque flange head screw from 35 to 40 ft Ib 47 to 54 N m E Apply antiseize lubricantto splines of roller brush shaft before sliding hardened washer s item 9 and driven pulley item 10 onto shaft Torque flange nut item 11 that secures driven pulley to roller brush shaft from 15 to 19 ft Ib 20 to 25 N m F Position excluder seals on brush shaf
147. aster 3100 D Rev F Chapter 5 Electrical System Electrical Schematics and Diagrams 5 2 Special Tools 5 23 Troubleshooting 5 24 Electrical System Quick Checks 5 28 Component Testing 5 30 Service and Repairs 5 42 Chapter 6 Wheels Brakes and Miscellaneous S p cifiCatioris ix os acus 6 2 Special Tools 6 2 Adjustments 6 3 Service and Repairs 6 4 Chapter 7 Cutting Units S ere mero e Ei eet eee 7 2 Special Tools eee 7 3 Troubleshooting 7 5 Adjustments and 7 7 Service and Repairs 7 13 Chapter 8 DPA Cutting Units ke x eR General Information Special Tools ER Factors That Can Affect Cutting Performance Set up and Adjustments Service and Repairs Product Records and Manuals Kubota Diesel Engine System gt Electrical System and Miscellaneous Wheels Brakes DPA Cutting Units This page is intentionally blank Reelmaster 3100 D TORO Table of Contents GENERAL SAFETY INSTRUCTION
148. aulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Park machine on a level surface with the cutting units lowered and off Make sure engine is off and the parking brake is engaged 3 Read Precautions for Hydraulic Testing 4 Make sure reel speed adjuster knob FC1 is set to the highest speed setting fully open Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hy draulic System Pressure in the General Infor mation section 5 Disconnect hose connection from hydraulic fitting on manifold port M1 6 Install tester in series with the hose and hydraulic fit ting Make sure the flow control valve on tester is fully open 7 Make sure backlap knob on the hydraulic manifold is in the mow position Make sure reel speed knob is set to maximum CAUTION Keep away from reels during test to prevent per sonal injury from the rotating reel blades 8 Start engine and move throttle to full speed 2650 50 RPM Engage the cutting units 9 Watch pressure gauge carefully while slowly closing the flow control valve to fully closed Reelmaster 3100 D Page 4 45 10 System pressure should be from 2700 to 3300 PSI as the relief valve lifts A If specification is not met shut off engine and ad just relief valve see Adjusting Manifold Relief Valve Return to Step 6 B If th
149. bar Wheel lug nut torque 45 to 65 ft lb 61 to 88 N m Special Tools Wheel Hub Puller Part Number TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors Figure 1 Wheels Brakes and Miscellaneous Page6 2 Rev Reelmaster 3100 D Adjustments Adjust Brake Before and after adjusting the brakes always check the brakes in a wide open area that is flat and free of other persons and obstructions 1 Park machine on level surface lower cutting units stop engine and remove key from the ignition switch 2 Adjust parking brake lever until a force of 30 to 40 Ibs 13310 178 N is required to actuate lever To adjust A Loosen set screw on adjustment knob Fig 2 B Turn adjustment knob clockwise to increase force and counterclockwise to decrease force C Tighten set screw after adjustment 3 Check brake adjustment as follows A Rotate by pass valve on the piston pump 90 de grees to allow front wheels to turn freely Fig 3 caution Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety B Chock rear wheel Jack up both front wheels and support the machine with hardwood blocks C With the parking brake applied use a torque wrench on the wheel hub lock nut to identify the break away torque at each front wheel The mini mum break away torque with the parking applied should be 270 ft Ib 366
150. be installed in other end of steering cylinder Tire must be removed fitting installed greased fitting removed and plug installed Fig 15 IMPORTANT Do not lubricate Sidewinder model 03201 cross tube bearing blocks are self lubri cated a Figure 7 JA Figure 4 Reelmaster 3100 D Page 2 7 Product Records and Maintenance 55 3 a 4 t gt Figure 15 See Note Figure 11 Product Records and Maintenance Page 2 8 Reelmaster 3100 D Cutting Units Each cutting unit has 6 grease fittings with optional front roller installed that must be lubricated regularly with No 2 General Purpose Lithium Base Grease The grease fitting locations and quantities areas follows Bedknife adjuster 2 every 50 hours Fig 17 Reel bearings 2 and front and rear rollers 2 ea Fig 16 Note Lubricate only one reel bearing grease fitting on each end of cutting unit IMPORTANT Lubricating cutting units immediately after washing This helps to purge water out of bear ings and increases bearing life 1 Wipe each grease fitting with a clean rag Product Records i gt IMPORTANT Do not apply too much pressure grease seals will be permanently damaged Figure 17 Grease every 50 operating hours 2 Apply grease until pressure is felt agai
151. c 5 amp N E Rear Roller Brush Optional Antiseize Lubricant 27 to 33 ft Ib 37 to 44 N m 15 to 19 ft Ib 20 to 25 N m Loctite 242 15 to 19 ft lb 20 to 25 N m Grease 24 NS Grommet ID 23 Loctite 242 NN 4 RIGHT 15 to 19 ft Ib 20 to 25 N m 35 to 40 ft lb 20 FRONT 47 to 54 N m 15 to 19 ft Ib 20 to 25 N m Figure 38 1 Roller brush assembly 13 Cap screw 2 used 24 Brush plate 2 Carriage screw 3 used 14 Idler spacer 25 Idler plate 3 Flange nut 15 Idler pulley assembly 26 Cap screw 4 used 4 Flange bushing 16 Lock nut 27 Hardened washer 4 used 5 Idler spring 17 Flat washer 4 used 28 Drive bearing housing 6 Excluder seal 2 used 18 Drive belt 29 Mounting bracket 2 used 7 Bearing assembly driven 19 Brush cover 30 Bearing assembly non driven 8 Spacer 20 Flange head screw 31 O ring 9 Hardened washer as required 21 Drive pulley 32 Socket head screw 2 used 10 Driven pulley 22 Spacer 33 Pivot washer 11 Flange nut 23 Shoulder bolt 34 Set screw top hole in cover 12 Carriage screw 2 used Note Drive components for the rear roller brush are Note The Installation Instructions for the rear roller located on the opposite side ofthe cutting unitfrom the brush kit has detailed information regarding assembly cutting reel hydraulic motor Figure 38 shows compo and adjustment Use those Instructions along with thi
152. cal Sche matics and Diagrams section of this chapter Remove all jewelry especially rings and watches before doing any electrical trouble If the machine has any interlock switches by passed shooting or testing Disconnect the battery they must be reconnected for proper troubleshooting cables unless the test requires battery voltage and safety Starting Problems Starter solenoid clicks but starter will not crank Low battery charge if solenoid clicks problem is not in safety interlock system Loose or corroded battery cables Loose or corroded ground Faulty wiring at the starter Faulty starter solenoid Nothing happens when start attempt is made The traction pedal is not in neutral position or the neutral switch is faulty Reel on off switch is in the ON position or faulty The engine is too hot or the over temperature shut down relay is faulty The battery is dead Fuse F1 or is faulty or blown Loose or corroded battery or ground cables Loose or corroded ground Wiring in the crank circuit see Electrical Schematics is loose corroded or damaged The ignition switch faulty Starter solenoid wiring loose corroded or damaged Starter solenoid faulty The interlock relay is faulty Electrical Systems Rev C Page 5 24 Reelmaster 3100 D Starting Problems continued Engine cranks but does not start Wiring in the crank circuit see Electrical Schematics is loose corroded or damaged
153. cau tion to avoid splashing or spilling electrolyte Electrolyte can destroy clothing and burn skin or eyes Always wear safety goggles and a face shield when working with batteries Electrolyte Specific Gravity Fully charged 1 265 corrected to 80 F 26 7 C Discharged less than 1 240 Battery Specifications BCI Group Size 55 450 CCA at 0 F 17 8 C Reserve Capacity of 60 minutes at 80 F 26 7 C Dimensions including terminal posts and caps Length 8 90 inches 22 61 cm Width 6 03 inches 15 31 cm Height 8 49 inches 21 56 Removal Fig 26 and 27 IMPORTANT Be careful not to damage terminal posts or cable connectors when removing the bat tery cables 1 Remove battery cover from the frame Loosen bat tery retainer securing the back of the battery to the bat tery support 2 Loosen nut on ground cable post first and remove cable from battery This should prevent short circuiting the battery other components or the operators hands 3 Loosen nut on positive cable post and remove cable from battery 4 Make sure battery vent caps are on tightly 5 Remove battery from the battery compartment to a service area to allow better access for service Inspection Maintenance and Testing 1 Perform following inspections and maintenance A Check for cracks Replace battery if cracked or leaking B Check battery terminal posts for corrosion Use wire brush to clean corrosion from posts
154. chematics to identify the function of the hydraulic lines and cartridge valves at each port loca tion 1 Remove hydraulic manifold from the machine using Figure 49 as guide Reelmaster 3100 D Page4 77 Rev D mark fitting orientation to allow correct assembly Installation 1 If hydraulic fittings were removed install fittings to manifold using marks made during the removal process to properly orientate fittings 2 Install hydraulic manifold to the frame using Figure 49 as guide Hydraulic System Rev C Hydraulic Hydraulic Manifold Service 42 to 45 ft lb 57 to 61 N 4 Me 30 to 35 ft lb 41 to 47 Manifold body Relief valve cartridge Solenoid operated cartridge valve Rotary cartridge valve directional Solenoid coil Logic control cartridge Rotary cartridge valve flow control Cartridge cavity plug Orifice plug 10 Plug SAE 2 11 Plug SAE 4 Hydraulic System Rev 30 to 35 ft Ib to 47 N m S Loctite 242 2 to 5 ft lb 2 7 to 6 8 N m er es 2 Figure 50 Indicator plate Indicator plate Plug SAE 6 Plug Seal kit Locating plate Set screw Detent plate Compression spring Jam nut Page 4 78 Rev D HYDRAULIC MANIFOLD USED ON MACHINES WITH SERIAL NUMBERS BELOW 250999999 30 to 35 1 16 P to 47 N 285 26 19 Ge CEP 18 CON E 25 e 30 to 35 ft lb 41 t
155. chine on level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch M CAUTION If engine has been running pressurized hot cool ant can escape when the radiator cap is removed and cause burns Open radiator cap only when the radiator and engine are cold Fig 4 2 Check level of coolant in the expansion tank Coolant level should be between the marks on the side of tank 3 If coolant level is low remove expansion tank cap and replenish the system Do not overfill 4 Install expansion tank cap Reelmaster 3100 D Page3 5 Figure 3 2 Fueltank filler neck 1 Fuel tank cap 3 Fill fuel tank to the bottom of the filler neck Do not overfill Install cap to the neck 4 Wipe up any fuel that may have spilled to prevent a fire hazard E 2 E x Figure 4 1 Radiator cap 3 Oil cooler 2 Radiator Figure 5 1 Expansion tank 2 Cap Kubota Diesel Engine Adjustments Adjust Throttle Cable 1 Park machine on level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Position throttle control lever all the way to the SLOW position so it stops against the control panel slot Fig 6 3 Loosen cap screw securing the throttle cable to the Swivel enough to loosen the cable Fig 7 4 Hold speed control lever on the injection pump against the low
156. cking Instructions 1 4 Safety and Instruction Decals 1 5 Chapter 2 Product Records and Manuals ProductRecords 2 1 Equivalents and Conversions 2 2 Torque Specifications 2 3 Chapter 3 Kubota Diesel Engine Introduction 3 2 Specifications usce teet ce 3 3 General Information 3 4 Adj stmeris x 2 RERO 3 6 Service Repairs 3 8 WORKSHOP MANUAL DIESEL ENGINE 05 SERIES Chapter 4 Hydraulic System SpeeifiCationis cet tee esce ea 4 2 General Information 4 3 Hydraulic Schematics 4 8 Hydraulic Flow Diagrams 4 10 Special Tools it 4 22 Troubleshooting 4 26 Testing isc Als ee al bed Ae 4 29 Adjustments 4 56 Service Repairs 4 58 ROSS TORQMOTOR MG MF AND MJ 5 RIES SERVICE PROCEDURE PARKER TORQMOTOR SERVICE PROCEDURE TC TB TE TJ TF TG TH AND TL SERIES EATON MEDIUM DUTY PISTON PUMP REPAIR IN FORMATION MODEL 70160 VARIABLE DISPLACE MENT PISTON PUMP ROSS HYDRAGUIDE HYDROSTATIC STEERING SYSTEM HGF SERIES SERVICE PROCEDURE SAUER DANFOSS STEERING UNIT TYPE OSPM SERVICE MANUAL Reelm
157. clude jam nuts Product Records and Maintenance Page 2 4 Reelmaster 3100 D Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners Class 8 8 Bolts Screws and Studs with Thread Size Regular Height Nuts Class 8 or Stronger Nuts M6 X 1 0 M10 X 1 5 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 oil graphite or thread sealant such as Loctite Note Torque values may have to be reduced when installing fasteners into threaded aluminum or brass The specific torque value should be determined based Reelmaster 3100 D 640 60 N cm 26 3 38 4 ft lb 52 5 53 5 ft lb 72 7 N m Page2 5 Class 10 9 Bolts Screws and Studs with Regular Height Nuts Class 10 or Stronger Nuts 78 7 in Ib 885 80 N cm 133 13 in Ib 96 9 in lb 1018 100 N cm 1934 13inb 1500 150 27 2 ft lb 36 3 N m 66 7 ft lb 90 10 N m 92 9 ft lb 125 12 N m 166 15 ft lb 225 20 N m 229 22 ft lb 310 30 N m 325 33 ft lb 440 45 N m 450 37 ft lb 610 50 N m on the fastener size the aluminum or base material strength length of thread engagement etc Note The nominal torque values listed above are based on 75 of the minimum proof load specified in SAE J1199 The tolerance is approximately 1096 of the nominal torque v
158. ct brush operation will be adversely affected 7 Lubricate grease fittings on brush housings until grease purges pastinboard seals Wipe excess grease Figure 44 from seals and fittings 1 Drive pulley 3 Straight edge 2 Driven pulley Contact with the reel bedknife or other cutting unit parts can result in personal injury Use heavy gloves when handling the cutting reel Figure 45 1 Rearroller brush 3 Light contact 2 Rear roller 58 25 amp Reelmaster 3100 D Page 8 39 DPA Cutting Units Rev G This page is intentionally blank DPA Cutting Units Rev G Page 8 40 Reelmaster 3100 D TORO Commercial Products The Toro Company 1999
159. cts the table A piece of paper inserted between the roller and the table should not fit 10 When roller is level adjust both rollers to desired height of cut with height of cut pins Tighten nuts se curing roller brackets and replace hairpin cotters to the height of cut pins Cutting Units Verify Height of Cut and Front Roller Level NOTE Gauge bar Toro Part No 13 8199 may be ob tained from your local Toro Distributor IMPORTANT Height of cut must be set and both rollers leveled before performing this adjustment see Set Height of Cut and Level Both Rollers 1 On the gauge bar set head of the screw to the de sired Height of Cut This measurement is from the bar face to the underside of the screw head 2 Loosen nuts slightly that secure each front roller bracket to the angle bracket 3 Place gauge bar across the front and rear rollers Ad just both front roller support capscrews until the under side of the head of screw on the gauge bar engages the bedknife cutting edge Do this on both ends of reel 4 Tighten all nuts securing the roller brackets 5 Place cutting unit on a flat surface Verify that front Figure 9 1 5 Front roller support and rear rollers contact the flat surface Readjust 2 Front roller bracket nut mn Height of Cut as required see Set Height of Cut and 3 Frontroller bracket 6 Bedknife 4 Angle bracket Level Rear Roller Cutting Units Page 7 10 Re
160. cure pump together with cap screws and new washers on cap screws external of the flange cavity Torque cap screws in a criss cross pattern from 25 to 28 ft lb 34 to 38 N m Hydraulic System Rev C 2g E gt Front Lift Cylinder 90 hydraulic fitting Hydraulic cylinder Carrier assembly Flange nut Flange head screw Hydraulic hose Centering wire Hydraulic hose Hydraulic hose Hydraulic hose Clamp bracket model 03200 Slide bracket model 03201 Flange nut Plastic slide Flange head screw OND m i mh mh Hydraulic System Rev Figure 80 Lift arm pivot shaft Roll pin Pivot shaft link Flange head screw Cap screw Clamp model 03200 Bearing cap model 03201 Jam nut Cap screw Lock nut Hardened washer Slide support bar Pin Spacer Page 4 114 External retaining ring Bulkhead nut Hydraulic tube Bulkhead nut Hose rod model 03201 Flange head screw model 03201 Flange nut model 03201 O ring O ring Flange head screw Link clip Hex nut Straight link chain Flat washer Reelmaster 3100 D Removal 1 Remove front lift cylinder from the frame and lift arm using Figure 80 as guide 2 If hydraulic fittings are to be removed from lift cylin der mark fitting orientation to allow correct assembly Installation 1 If hydraulic fittings were r
161. d Maintenance Page 2 10 Traction Unit 1 Drain engine oil from the oil pan and replace the drain plug 2 Remove and discard oil filter Install a new oil filter 3 Refill oil pan with approximately 4 0 quarts 3 8 of SAE10W 30 motor oil 4 Start engine and run at idle speed for approximately two minutes 5 Stop engine 6 Drain all fuel thoroughly from the fuel tank fuel lines and water fuel separator see Water Fuel Separator and Fuel System in Chapter 3 Kubota Diesel Engine 7 Flush the fuel tank with fresh clean diesel fuel see Fuel System in Chapter 3 Kubota Diesel Engine 8 Re secure all fuel system fittings 9 Clean and service the air cleaner assembly see Ser vice Air Filter Dust Cup and Burp Valve in Chapter 3 Kubota Diesel Engine 10 Seal air cleaner inlet and the exhaust outlet with weatherproof tape 11 Check anti freeze protection and add as needed for expected minimum temperature in your area see Check Cooling System in Chapter 3 Kubota Diesel gine Reelmaster 3100 D Chapter 3 TORO Kubota Diesel Engine Table of Contents 2 Water Fuel Separator 13 SPECIFICATIONS 3 Fuel System 14 GENERAL INFORMATION 4 Check Fuel Lines and Connections 14 Check Engine Oil
162. d from the neutral The high temperature shutdown relay failed Fuse F1 or F3 failed The run solenoid or fuel pump failed Wiring in the run circuit see Electrical Schematics broke or disconnected Loose or broken wire s Faulty alternator Dead battery Alternator warning lamp is faulty or burned out Alternator warning lamp wiring loose corroded or damaged Reelmaster 3100 D Cutting Unit Operating Problems The cutting units will not run with the transport mow Wiring to the reel drive circuit is see Electrical switch in MOW and the reel on off switch in ON with Schematics is loose corroded or damaged the cutting units lowered Fuse F4 is faulty or blown The coil to solenoid valve S1 on the hydraulic manifold is faulty or the valve is stuck The reels on off is faulty The reels up limit or transport mow switch is faulty or misadjusted There is insufficient hydraulic oil pressure to turn the reels see Troubleshooting in Chapter 4 Hydraulic System The cutting units run but should not run when raised The coil to solenoid valve S1 on the hydraulic manifold is faulty or the valve is stuck The reels up limit switch is stuck faulty or misadjusted 4 Reelmaster 3100 D Page 5 27 Electrical Systems Rev C Electrical System Quick Check Battery Test Open Circuit Test Use a multimeter to measure the voltage between the battery terminals
163. d outerseal Again make sure thatshaft and bearings still freely rotate IMPORTANT Make sure that all grease is removed from shaft threads to prevent bearing lock nutloos ening 5 Thoroughly clean threads on both ends of roller shaft NOTE If original bearing lock nut s are being used apply Loctite 242 or equivalent to threads of lock nut s 6 Install bearing lock nut onto each end of the roller shaft Make sure that outer seals are not damaged dur ing nut installation Torque lock nuts from 50 to 60 ft Ib 68 to 81 N m 7 If grease fittings were removed from end of roller shaft install fittings in shaft Reelmaster 3100 D Page 8 35 NOTE After roller is installed to cutting unit lubricate roller grease fittings rotate roller to properly distribute grease in bearings and clean excess grease from roller ends A properly assembled roller should rotate with less than 5 in Ib 0 68 N m resistance Figure 35 1 Roller tube 4 Outer seal 2 Inner seal 5 Bearing outer seal tool 3 Bearing Figure 36 1 Roller tube 4 Bearing 2 Roller shaft 5 Washer 3 Inner seal 6 Bearing outer seal tool Figure 37 1 Roller tube 4 Bearing 2 Roller shaft 5 Outer seal 3 Inner seal 6 Bearing outer seal tool DPA Cutting Units Rev G
164. d to your machine insert the Installation Instruc tions Operator s Manuals and Parts Catalogs for those options at the end of this chapter Maintenance Maintenance procedures and recommended service in tervals for the Reelmaster 3100 D are covered in the Operator s Manual Refer to that publication when per forming regular equipment maintenance Reelmaster 3100 D Page2 1 Product Records and Maintenance Rev E Decimal and Millimeter Equivalents Equivalents and Conversions Rev D 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 1416 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 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 1
165. d wipe up any spilled diesel fuel before start ing the engine Store fuel in a clean safety ap proved container and keep cap in place Use die sel fuel for the engine only not for any other pur pose Draining Drain water and other contaminants from the water fuel separator daily 1 Park machine on level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Place a suitable container under the fuel water sepa rator 3 Loosen drain valve on the bottom of the separator base 4 Allow all water and contaminants to drain from the separator Tighten drain valve Filter Element Replacement 1 Park machine on level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Clean area where filter element mates with base and filter head 3 Place a suitable container under the fuel water sepa rator 4 Unscrew filter element from base and filter head Discard element 5 Lubricate gasket on new filter element and O ring with clean diesel fuel 6 Screw filter element onto base by hand until the gas ket contacts the mounting surface Rotate element an additional 1 2 turn 7 Screw filter element and base onto filter head by hand until the gasket contacts the mounting surface Rotate element and base an additional 1 2 turn 1 Reelmaster 3100 0 3 13 Figure 20 Fi
166. d with a glow plug system Tool s required Digital multimeter and or inductive Ammeter AC DC Current Transducer Test instructions Properly connect the ammeter to the digital multimeter refer to manufacturers instructions Electrical Systems Rev C Page 5 28 Voltage Measured 12 68 V or higher 12 45 V 12 24 V 50 charged 12 06 V 25 charged 11 89 V 096 charged Battery Charge Level Fully charged 100 7596 charged Start the engine and run at high idle 2650 RPM Allow the battery to charge for at least 3 minutes Record the battery voltage After running the engine for at least 3 minutes battery voltage should be at least 0 50 volt higher than initial bat tery voltage Example of a charging system that is functioning At least 0 50 volt over initial battery voltage 12 30 12 85 40 55v Initial Battery Voltage Battery Voltage after 3 Minute Charge Difference Set the multimeter to the correct scale With the ignition switch in the OFF position place the ammeter pickup around the main glow plug power supply wire and read the meter prior to activating the glow plug system Adjust the meter to read zero if applicable Activate the glow plug system see Traction Unit Operator s Manual and record the multimeter results The Reelmaster 3100 D glow plug system should have a reading of approximately 27 Amps Reelmaster 3100 D Check Operation of Interlock Switches Do not
167. dd appropriate fluid to raise the level to full mark 5 Install dipstick and cap onto the filler neck Figure 6 1 Hydrostat 2 By pass valve 2 E LE Figure 7 1 Hydraulic Tank 2 Cap Reelmaster 3100 D Page4 5 Hydraulic System Rev C Relieving Hydraulic System Pressure Before disconnecting or performing any work on the Re elmaster 3100 D hydraulic system all pressure in the hydraulic system must be relieved Park machine on a level surface with the cutting units lowered and off Turn key switch to OFF and allow engine to stop To relieve hydraulic pressure in traction circuit move traction lever to both forward and reverse directions To relieve hydraulic pressure in steering and lift circuits ro tate steering wheel in both directions To relieve cutting system pressure turn key switch to ON engine not running Move PTO switch to engage which will energize the solenoid valve on hydraulic man ifold to relieve circuit pressure Move PTO switch to dis engage return key switch to OFF and remove key from the ignition switch NOTE Moving steering wheel with engine off may un seat implement relief valve If steering or lift circuits ap pear weak or inoperative after machine is returned to service repeat relieving hydraulic system pressure pro cedure Traction Circuit Closed Loop Component Failure The Reelmaster 3100 0 traction circuit is a closed loop system that includes the hy
168. depressing belt midway be tween the alternator and crankshaft pulleys with 22 Ib of force 98 N Belt should deflect 7 16 inch 11 mm If deflection is incorrect proceed to step 4 If correct con tinue operation 4 Loosen bolt securing brace to engine and bolt secur ing alternator to brace 5 Insert pry bar between alternator and engine Posi tion alternator out from engine to increase belt tension Reelmaster 3100 D 3 7 Figure 9 1 Belt 3 Bolt 2 Bolt 4 Alternator 6 When proper tension is achieved tighten alternator and brace bolts to secure the adjustment Kubota Diesel Engine e o E 2 E x Service and Repairs Change Engine Oil and Filter Change oil and filter initially after the first 50 hours of op eration thereafter change oil every 50 hours and filter every 100 hours 1 Park machine on level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Remove either drain plug and let oil flow into drain pan When oil stops flowing install the drain plug 3 Remove oil filter Apply light coat of clean oil to the new filter seal before screwing filter on Do not over tighten filter 4 Add oil to crankcase see Check Engine Oil Replace Traction Belt 1 Park machine on level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Insert nut d
169. disconnect safety switches They are for the operator s protection Check the operation of the interlock switches daily for proper operation Replace any malfunctioning switches before op erating the machine Note The machine is equipped with an interlock switch on the parking brake The engine will stop if the traction pedal is depressed with the parking brake en gaged 1 Make sure all bystanders are away from the area of operation Keep hands and feet away from cutting units Reelmaster 3100 D Page 5 29 2 With operator on the seat the engine must not start with either the reel switch engaged or the traction pedal engaged Correct problem if not operating properly 3 With operator on the seat the traction pedal in neu tral the parking brake off and the reel switch in the OFF position the engine should start Lift off seat and slowly depress traction pedal the engine should stop in one to three seconds Correct problem if not operating proper ly 4 With operator on the seat the engine running the reel transport slide in mow and the reel switch in the ON position lower cutting units Reels should come on Pull back on the lift lever the reels should stop when fully raised Correct problem if not operating properly Electrical Systems Rev C Rev D 0 4 Lu Component Testing For accurate resistance and or continuity checks elec trically di
170. distortion of the stem tube can cause binding and malfunction Make sure that deep well socket fully engages the valve base B Lubricate threads on cartridge valve with clean hydraulic oil Thread cartridge valve carefully into correct manifold port The valve should go in easily without binding C Torque cartridge valve using a deep well socket to specification shown in manifold illustration Note On manifold shown in Figure 50 solenoid coil has an O ring on each side of the coil Also on this man apply Loctite 242 or equivalent to the threads of the valve before installing the coil nut 7 For solenoid valve install solenoid coil and O rings if equipped to the cartridge valve Torque nut specifi cation shown in manifold illustration 8 If problems still exist remove valve and clean again or replace valve Rotary Cartridge Valves 1 Remove knob assembly manifold shown in Fig 50 A Unscrew and remove knob Remove both jam nuts B Slide off indicator plate being careful not to lose springs Remove spring C Loosen set screw and slide detent plate off the cartridge valve stem D Remove locating plate with pin from the cartridge valve stem and manifold 2 Remove rotary handle manifold shown in Fig 51 Fig 52 A Loosen two 2 set screws that secure handle cap Remove screw and then lift handle cap from valve B Locate and retrieve detent pin compression spring bushing and lip se
171. draulic tank with new hydraulic fluid see Trac tion Unit Operator s Manual 16 Adjust traction drive for neutral see Adjust traction Drive for Neutral Hydraulic System Rev C 2g E gt Piston Pump Service EATON MODEL 70160 LAA 01 Figure 66 1 Key 19 Spring 37 Bleed off spring 2 Drive shaft 20 Seat 38 O ring 3 Bearing 21 Dump valve 39 Cam plate insert 4 Cap screw 3 used per cover plate 22 Cap screw 40 Shaft seal 5 Cover plate 23 Cap screw 41 O ring 6 Seal 24 Roll pin 42 Coupler 7 Shim kit 25 Cover plate 43 Retaining ring 8 Bearing cone 26 SEM 44 Washer 9 Key 27 Relief valve 10 Cam plate 28 Washer 3 used per cover plate 2 E 11 Rotating kit 29 Housing AT Gh 9 44 12 Gasket 30 Retaining ring Gnarge re ier housing 13 Valve plate 31 Bearing race 48 O ring 14 Bearing 32 Thrust bearing 49 Cartridge 15 Dowel pin 33 Washer 50 Shim Model 70160 LAA 01 16 Back plate 34 Shaft seal 51 Cover plate 70160 LAA 01 17 O ring 35 Retaining ring 52 Shaft seal 70160 LAA 01 18 Plug 36 Bleed off valve poppet 53 Retaining ring 70160 LAA 01 NOTE For repair of the piston pump see the Eaton Medium Duty Piston Pump Repair Information Model 70160 Variable Displacement Piston Pump at the end of this chapter NOTE Reelmaster 3100 0 machines with serial num bers below 90775 were equipped with an Eaton model 70160 LAA 01 piston pump
172. drostat and two 2 wheel motors If a component in the traction circuit should fail debris and contamination from the failed component will circulate throughout the traction circuit This contamina tion can damage other components in the circuit so it must be removed to prevent additional component fail ure If a component failure occurs in the traction circuit it is critical that the entire traction circuit be disassembled drained and thoroughly cleaned to ensure that all con tamination is removed from the circuit If any debris re mains in the traction circuit and the machine is operated the debris can cause additional component failure An additional step for removing all traction circuit con tamination would be to temporarily install a high pres sure hydraulic oil filter see Special Tools into the circuit The filter could be used when connecting hydraulic test gauges in order to test traction circuit components or af ter replacing a failed traction circuit component e g hy drostat or wheel motor The filter will ensure that contaminates are removed from the closed loop and thus do not cause additional component damage Hydraulic System Rev C Page4 6 Rev D Once the filter has been placed in the traction circuit place the machine on jack stands and operate the trac tion circuit to allow oil flow through the circuit With the machine raised off the ground the traction circuit will have maximum oil flow at minimu
173. e Lubricant Antiseize Lubricant Figure 19 1 Bedbar 8 Wave washer 2 used 14 Rubber bushing 2 used 2 Bedknife 9 Retaining ring 2 used 15 Flange bushing 2 used 3 Screw 10 Bedbar adjuster screw 2 used 16 Plastic washer 4 used 4 Bedbar adjuster shaft 2 used 11 Washer 2 used 17 Metal washer 2 used 5 Flange bushing 4 used 12 Compression spring 2 used 18 Bedbar pivot bolt 2 used 6 Cap screw 2 used 13 Lock nut 2 used 19 Lock nut 2 used 7 Detent 2 used Bedbar Removal Fig 19 1 Position machine on a clean and level surface lower cutting units stop engine engage parking brake and re move key from the ignition switch 2 Remove the cutting unit from the machine Use the cutting unit kickstand to support the cutting unit see Special Tools 3 Loosen the lock nuts item 13 on the end of each bedbar adjuster assembly until washer item 11 is loose DPA Cutting Units Rev G Page 8 18 4 Loosen the lock nuts item 19 on each bedbar pivot bolt item 18 5 Remove two 2 bedbar pivot bolts item 18 two 2 metal washers item 17 and four 4 plastic washers item 16 from the cutting unit side plates Reelmaster 3100 D Contact with the reel bedknife or other cutting unit parts can result in personal injury Use heavy gloves when handling the bedbar 6 Remove bedbar assembly from cutting unit 7 Inspectflange bushings item 15 and rubber bush ings item 14 i
174. e 68 as guide 2 If hydraulic fittings are to be removed from cylinder mark fitting orientation to allow correct assembly Figure 69 1 Scissor frame 3 Sidewinder carrier Installation 2 Lower frame 4 Gaps 1 If hydraulic fittings were removed install fittings to cylinder using marks made during the removal process to properly orientate fittings 2 Install hydraulic cylinder to the frame using Figure 68 as guide 3 Adjust scissors mount as follows A Shift sidewinder fully to the left fully retract cylin der B Loosen four cap screws securing mount to lower frame 2 E gt C The gap between the scissor frame and lower frame and the gap between the scissor frame and the sidewinder carrier must be equal distances with in 0 060 inch 1 5 mm D Tighten four cap screws and lock nuts Reelmaster 3100 D Page 4 103 Hydraulic System Rev C Steering Control Valve O mh BON Steering arm Flange nut Flange head screw Steering valve bracket Cap screw Pivot hub Steering cover Cap screw Toro decal Ball knob Lever Steering control valve Tilt bracket Cap screw Hydraulic System Rev C Figure 70 Flat washer Flange nut Steering wheel Hydraulic fitting Hydraulic Fitting Steering wheel nut Toro decal Hydraulic hose Hydraulic hose Hydraulic hose Hydraulic hose Hydraulic hose
175. e and discard O ring from the back plate 8 Loosen rear body from the adapter plate by tapping with a soft face hammer Lift body straight up to remove 9 Remove idler gear from the wear and adapter plates Remove drive gear from the drive gear shaft IMPORTANT Note position of the open and closed side of the wear plate before removing from the adapter plate 10 Remove wear plate and O ring from the adapter plate 11 Remove key from the drive gear shaft using a pencil magnet 12 Remove O ring from the adapter plate using ring pick 13 Loosen adapter plate from the from the front body using a soft face hammer Remove plate from the body Turn plate over and remove O ring using an O ring pick 14 Remove front pump body from the front plate 15 Remove idler gear and drive gear from the front plate IMPORTANT Note position of the open and closed side of the wear plate before removing from the front plate Reelmaster 3100 D Page 4 111 Figure 77 16 Remove wear plate from front plate Remove O ring from front plate using O ring pick 17 Remove back up gasket and pressure seal from both wear plates IMPORTANT Make sure not to damage the counter bore when removing the shaft seal from the front plate 18 Remove shaft seal from the front plate using a drift punch IMPORTANT Do not remove the plug from the front plate unless rotation of the pump is changed Inspection Fig 76 1 Remo
176. e approximately 12 5 GPM 15 Release traction pedal and turn off machine NOTE If pressure is good under no load but drops be low specification when under traction load the piston pump and or wheel motor s should be suspected of wear When a pump and or motor is worn or damaged the charge pump is not able to keep up with internal leak age in the traction circuit See Charge Relief Valve Pres sure Test 16 If specifications are not met the hydrostat needs to be repaired or replaced as necessary 17 Disconnect tester from hydraulic fitting and hose Reconnect hose to pump connection 18 Reconnect brake linkage to wheel see Wheels and Brakes Chapter 7 Hydraulic System Rev C 2 E gt Charge Relief Valve Pressure Test Using Pressure Gauge TRACTION WHEEL MOTORS e m FORWARD TOP PORT 5 e UPPER PORT 3000 psi L 100 to 150 psi CHARGE RELIEF I Tho Hydraulic System Rev C Page 4 34 TO HYDRAULIC MANIFOLD P1 PORT f N FROM HYDRAULIC MANIFOLD CHG PORT gt TO STEERING CONTROL VALVE IN PORT GEAR PUMP High Pressure Low Pressure Return or Suction Flow Reelmaster 3100 D Procedure Charge Relief Valve Pressure Test
177. e for neutral see Adjust traction Drive for Neutral in Chapter 4 Hydraulic System Reelmaster 3100 D TORO Table of Contents SPECIFICATIONS 4 rene eee tres 2 GENERAL INFORMATION 3 Hydraulic Hoses 3 Hydraulic Fitting Installation 3 Towing Traction 5 Check Hydraulic System Fluid 5 Relieving Hydraulic System Pressure 6 Traction Circuit Closed Loop Component Failure 6 HYDRAULIC SCHEMATICS 8 Reelmaster 3100 D Model 03200 8 Reelmaster 3100 D Model 03201 9 Reelmaster 3100 D Model 03206 and 03170 9 1 Reelmaster 3100 D Model 03207 and 03171 9 2 HYDRAULIC FLOW DIAGRAMS 10 Traction Circuits 10 Reel Circuit eet s ee tee 12 Lift Circuit Up uen Decree deer cen 14 Lift Circuit Down 16 Sidewinder 18 Steering Circuit 0 00 eee eee eee 20 SPECIAL TOOLS eer te 22 TROUBLESHOOTING 26 TESTING beana yaoi 29 Traction Circuit Working Pressure Test 30 Piston Pump P3 Flow amp Traction Relief Pressure Test 32 Charge Relief Valve Pressure Test 34 Gear Pump P2 Flow Test 36
178. e head screws flat washers and lock nuts 4 Repeat steps 1 through 3 on the other side of the cut ting unit 5 Adjust skid height as necessary by loosening lock nuts and flange head screws then retighten fasteners Carrier Frame Removal 1 Make sure cutting unit and carrier frame are placed firmly on a flat working surface 2 Remove tipper chain from the top of the carrier frame Fig 38 3 Remove lock nut both flat washers and large cap screw securing mounting links to the carrier frame Re move carrier frame from the cutting unit Fig 39 Installation 1 Make sure cutting unit is placed firmly on a flat work ing surface 2 Position carrier frame flat edge forward onto the cutting while aligning mounting holes with all mounting links Fig 39 NOTE A flat washer must be on each side of all mount ing links during installation 3 Secure all four mounting links to the carrier frame with both flat washers large cap screw and lock nut Torque lock nut and cap screw to 31 Ft lb 42 4 Route tipper chain up through the slot in each end of the carrier frame Secure chain to the top of the carrier frame with washer cap screw and lock nut Fig 38 Figure 37 1 Skid 4 Flat washer 2 Angle bracket holes 5 Locknut 3 Flange head screw Figure 38 1 Tipper chain 4 screw 2 Carrier frame 5 Locknut 3 Washer Figure 39 1 Carrier frame 2 Mounting link Cutting U
179. e of 1800 RPM The charge pump should pick up oil and fill the hydraulic system If there is no indication of fill in 30 seconds stop the engine and determine the cause Reelmaster 3100 D Page 4 63 11 After the hydraulic system starts to show signs of fill actuate lift control lever until the lift cylinder rod moves in and out several times If the cylinder rod does not move after 10 to 15 seconds or the pump emits abnor mal sounds shut the engine off immediately and deter mine cause or problem Inspect for the following A Loose filter or suction lines B Loose or faulty coupler on the pump C Blocked suction line D Faulty charge relief valve E Faulty charge pump 12 If cylinder moves in 10 to 15 seconds proceed to step 13 13 Operate the traction pedal in the forward and reverse directions The wheel off the floor should rotate in the proper direction A If the wheel rotates in the wrong direction stop engine remove lines from rear of pump and reverse the connections B If the wheel rotates in the proper direction stop engine and adjust the spring adjusting pin lock nut 14 Adjust traction pedal to the neutral position see Ad just Traction Drive for Neutral 15 Check operation of the traction interlock switch see Check Interlock System in Chapter 5 Electrical Sys tems 16 Lower machine to ground Remove chocks from front wheel 17 If the traction pump or a wheel motor was replaced
180. eals into the RH side plate Make sure thatbearing is fully seated into side plate 4 On LH side plate loosen set screw item 21 and back off loosen bearing adjuster nut item 20 one complete turn 5 Usingreelbearing installation tool see S pecialTools in this chapter to keep reel bearing aligned carefully slide the LH side plate onto the cutting reel assembly frontroller and rear roller Make sure thatreel end in RH side plate does not shift in position 6 Install shoulder bolts item 8 and flange nuts item 24 that secure the LH side plate to the cutting unit frame Torque the shoulder bolts from 27 to 33 ft Ib 37 to 44 N m 7 Apply Loctite 242 or equivalent to threads of flange head screw that secures support tube frame spacer and carrier frame to LH side plate Fig 27 Install screw and torque from 27 to 33 ft Ib 37 to 44 N m After tightening screw check the clearance be tween the carrier frame and side plate If clearance is more than 0 090 2 3 mm remove flange head screw and position shim s part number 67 9410 between carrier frame and side plate so that clearance is less than 0 090 2 3 mm Make sure that the carrier frame pivots freely after assembly 8 Install cap screw and flat washer that secure rear grass shield to LH side plate Fig 27 Torque screw from 15 to 19 ft Ib 20 to 25 N m 9 Secure the bedbar assembly to LH side plate see Bedbar Installation in this section 10 Sec
181. ear roller adjustment Use the shim on one side ofthe rear roller and install it between the rear roller bracketand roller shim F ig 13 8 Afterleveling rearroller complete cutting unitset up and adjustment sequence Reelmaster 3100 D Page 8 13 IND O toro t 1 S Figure 12 3 Spring tension lock nut 4 Shoulder bolt 1 Bedbar 2 Bedbar adjuster screw Figure 13 1 Rearroller assembly 2 Rear roller bracket 3 Carriage screw 4 Flange nut 5 Roller shim 6 0 010 shim if needed DPA Cutting Units Rev G c 5 amp N E This page is intentionally blank DPA Cutting Units Rev G Page 8 14 Reelmaster 3100 D Service and Repairs Hydraulic Reel Motor IMPORTANT When performing maintenance pro cedures on the cutting units carefully position the cutting unit reel motors to prevent damage to the motors or hydraulic hoses Removal 1 Park machine on a clean and level surface lower cutting units completely to the ground stop engine en gage parking brake and remove key from the ignition switch 2 Loosen two 2 cap screws thatsecure the hydraulic reel motor to the cutting unit side plate Rotate motor clockwise and remove motor from cutting unit 3 Inspectreelinsertsplines for wear Replace if neces sary see Reel Removal and Installation in the Service and Repairs section of this chapte
182. ebuilt components such as motors pumps or lift cylinders it is important that the hydraulic system be charged properly Air must be purged from the system and its components to reduce the chance of damage IMPORTANT Change hydraulic oil filter whenever hydraulic components are repaired or replaced 1 Park machine on a level surface and turn the engine off 2 Make sure all hydraulic connections lines and com ponents are secured tightly 3 If component failure was severe or the system is con taminated flush and refill hydraulic system and tank see Flush Hydraulic System 4 Make sure hydraulic tank is full Add correct oil if nec essary see Change Hydraulic Fluid 5 Disconnect fuel stop solenoid lead to prevent the en gine from starting 6 Check control cable to the hydrostat for proper ad justment binding or broken parts 7 Make sure traction pedal and the lift control lever are in the neutral position Turn ignition key switch engage starter for fifteen 15 seconds to prime the traction and charge pumps 8 Reconnect fuel stop solenoid lead A WARNING Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 9 Raise one front and rear wheel off the floor and place support blocks under the frame Chock remaining wheel to prevent movement of the machine 10 Make sure traction pedal and lift control lever are in neutral Start engine and run it at low idl
183. ed to gently tap the motor when freeing the frontplate 6 Remove alignment pin from the body Remove drive gear and idler gear from the body Hydraulic System Rev C Page 4 74 Rev 7 Remove body from the backplate Remove O rings from the body and backplate 8 Remove alignment pin from the backplate 9 Remove retaining ring oil seal and backup washer from the frontplate IMPORTANT Do not remove the relief valve as sembly unless testing shows itto be faulty The re lief valve assembly must replaced as a complete unit Both relief valve seals are sealed in place with thread sealant do not remove them 10 Remove plug O ring shim spring and from the backplate Reelmaster 3100 D Inspection Fig 46 1 Remove all nicks and burrs from all parts with an M CAUTION emery cloth Use eye protection such as goggles when using compressed air 2 Clean all parts with solvent Dry all parts with com pressed air 3 Inspect drive gear shaft for a broken or chipped key 4 Inspect drive gear and idler gear shafts at the bush ing points and seal area for rough surfaces and exces sive wear 5 Replace drive gear or idler gear if the shaft diameter in the bushing area measures less than 0 748 in 19 0 mm A single gear may be replaced separately 6 The drive gear and idler gear face should be free of excessive scoring and wear 7 Replace drive gear or idler gear if ge
184. elmaster 3100 D Adjust Front Lift Arms 1 Park machine on level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch IMPORTANT Keep front cutting units on the lift arms when performing this adjustment 2 Raise front lift arms Make sure clearance between each lift arm and floor plate bracket is 0 18 to 0 32 inch 4 6 to 8 1 mm Fig 10 3 If the clearance is not in this range attain proper clearance as follows Figure 10 A Back off stop bolts if reducing the clearance be 1 Liftarm 3 Clearance tween the stop bolt and lift arm Fig 11 2 Floor plate bracket B Adjust front hydraulic cylinder by backing off jam nut on the cylinder removing the pin from the clevis and rotating the clevis Fig 12 C Install pin to clevis and check clearance Repeat steps A and B if necessary 4 Make sure clearance between each lift arm and stop bolt is 0 005 to 0 040 inch 0 127 to 1 02 mm If the clearance is not in this range adjust stop bolts as neces sary Fig 11 IMPORTANT The lack of clearance at the front stops can damage the lift arms 5 Install both front cutting units to the lift arms see Cut ting Unit Removal and Installation 1 Stop bolt 3 Clearance 2 Lift arm 4 9 D i 74 2 w d SS E Figure 12 A 1 Hydraulic cylinder 2 Jam nut o Reelmaster 3100 D Page 7 11 Cutting Units Adjust Rear Lift
185. elt from the engine flywheel and hy drostat pulleys 5 Install new V belt onto the engine flywheel and hy drostat pulleys 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 Reelmaster 3100 D Page 4 61 Figure 39 4 V belt 5 Fly wheel pulley 6 Hydrostat pulley 1 Torsion spring 2 Idler pulley 3 Pump mounting plate 6 Insert nut driver or small piece of pipe onto the end of the torsion spring of the idler pulley 7 Push down and back on the spring end to get the spring under the pump mounting plate notch Then re lease on the spring slowly to lock it into place Check hydraulic lines and hoses daily for leaks kinked lines loose mounting supports wear loose fittings weather deterioration and chemical deterioration Make all necessary repairs before operating Hydraulic System Rev C 2 E gt gt N gt 7 Flush Hydraulic System IMPORTANT Flush the hydraulic system any time there is a severe component failure or the system
186. em oineJp H NIVYG 3590 JAVA MOd RY 4 T U3NIVHIS lo Fy T beg J dNNd 8 39 O Singal sd 0001 110 9N133318 A 1 dm gt ER yt IN Z 1 19 T J c 1 isd 061 00 811002 Feci LNO 0 gt Q 5 2 190 000 PA PS 52 4 D L 15 1 ld z lt E 2 1808 2 8 JAWA TE LT c M m 1 Gu 1 A 1904 401 MA A gt X90194 8 pe TH 1 2 a SEOIOK NOTIOVEL pezibueue op se UMOUS inejp AH pue 70460 5 G OOTE Je1seuu oa Hydraulic System Page 4 9 2 Rev F Reelmaster 3100 D Hydraulic Flow Diagrams
187. emoved install fittings to cylinder using marks made during the removal process to properly orientate fittings IMPORTANT With lift arms raised fully hydraulic hoses should be routed as shown in Figure 81 Make sure clearance between hydraulic hose and lift arm is from 0 040 to 0 120 inches 1 0 to 3 0 mm 2 Install front lift cylinder to the frame and lift arm using Figure 80 as guide 3 Adjust front lift arm see Adjust Front Lift Arm in Chapter 7 Cutting Units Reelmaster 3100 D Page 4 115 Figure 81 1 Lift cylinder 3 Clearance 2 Hydraulic hoses Hydraulic System Rev C 2 E gt N gt 7 Rear Lift Cylinder Hydraulic tube Lock nut Hydraulic T fitting Hydraulic hose 90 hydraulic fitting Hydraulic hose Hydraulic tube 90 hydraulic fitting Push button switch Hydraulic cylinder Thrust washer Hydraulic hose Bulkhead nut Hydraulic fitting Hydraulic hose Hydraulic hose Hydraulic tube Hydraulic tube Hydraulic tube Tube clamp Naas anna SOON OARWN Hydraulic System Rev C 56 37 21 41 39 Figure 82 Flat washer Cap screw Lock nut Rear pivot shaft Jam nut Washer Lift arm assembly Flange head screw Thrust washer Grease fitting Cutting unit pivot shaft Cap screw Cap screw Rebound washer Washer Lynch
188. eneral Infor mation section 2 Remove hydraulic hoses from reel motors using Fig ure 45 as a guide 3 If hydraulic fittings are to be removed from reel mo tor mark fitting orientation to allow correct assembly Reelmaster 3100 D Page 4 73 Installation 1 If hydraulic fittings were removed install fittings to reel motor using marks made during the removal pro cess to properly orientate fittings 2 Install reel motor to the cutting unit see Cutting Unit Removal and Installation in Chapter 7 Cutting Units 3 Install hydraulic hoses to reel motors using Figure 45 as a guide Hydraulic System Rev C 2g E gt Reel Motor Service Eaton 10 to 12 ft Ib 13 6 to 16 3 N m 25 to 28 ft lb 34 to 38 N m Figure 46 1 Plug 8 Idler gear assembly 14 Frontplate 2 O ring 9 Drive gear assembly 15 Cap screw 3 Shim 10 Key 16 Retaining ring 4 Spring 11 O ring 17 Oil seal 5 Ball 12 Body 18 Backup washer 6 Relief valve seal 13 Alignment pin 19 Relief valve assembly items 1 thru 6 7 Backplate Disassembly Fig 46 1 Make sure key is removed from the drive gear shaft 2 Matchmark frontplate body and backplate to assure proper reassembly 3 Secure the motor in a vise with the drive shaft up 4 Remove all cap screws used to assemble motor 5 Remove the motor from the vise Remove the front plate from the body A wooden block or soft face ham mer might be us
189. er Service 24 to 30 ft Ib 33 to 41 N m Figure 87 1 Barrel 5 O ring 9 O ring 2 Locknut 6 Piston rod 10 Back up ring 3 Piston 7 Rod seal 11 Retaining ring 4 Uni ring 8 Cylinder gland 12 O ring Hydraulic System Rev C Page 4 122 Reelmaster 3100 D Disassembly 1 Remove oil from the steering cylinder into a drain pan by slowly pumping the cylinder shaft Plug both ports and clean the outside of the cylinder IMPORTANT Prevent damage when clamping the hydraulic cylinder into a vise clamp on the clevis only 2 Mount clevis end of steering cylinder in a vice Re move retaining ring 3 Extract shaft head and piston by carefully twisting and pulling on the shaft IMPORTANT Do not clamp vise jaws against the shaft surface Protect shaft surface before mount ing in a vice 4 Mount shaft securely in a vise by clamping on the cle vis of the shaft Remove lock nut and piston from the shaft Slide head off the shaft 5 Remove Uni ring and O ring from the piston 6 Remove back up ring O rings and rod seal from the head Reelmaster 3100 D Page 4 123 Reassembly 1 Make sure all parts are clean before reassembly 2 Coat new O rings Uni ring rod seal and back up ring with with clean hydraulic oil A Install Uni ring and O ring to the piston B Install O rings back up ring and rod seal to the head IMPORTANT Do not clamp vise jaws against the shaft
190. er movement The cylinder posi tion is locked in place since there is no complete circuit of flow to and from the lift cylinders Hydraulic System Rev C 2g 8 gt ANIWA SNIH33IS 1 xnv S1ovuldu Se Se Y RES sees ae Seis Ss J NIVHG ISVO TWNHALNI D 4 IWLSOHGAH a T 3 ONIH33IS 5 i 3NION3 i gt _1 lt 10048 2 1no SS gt lt pr IN zo Im 15 owl I E ISd 091 01 001 H 431009 r3 cua L E QIYNOILdO T M e 17 I P lt 4 i d
191. est lead to the fuel stop solenoid frame ground Fig 23 The resistance of the pull coil should be less than 1 ohm but not zero 3 Using a digital multimeter touch one test lead to the hold coil terminal and the other test lead to the fuel stop solenoid frame ground Fig 23 The resistance of the hold coil should be approximately 15 ohms 4 Connect solenoid to the wiring harness 1 Fuel stop solenoid 1 Fuel stop solenoid 2 Pull coil terminal Reelmaster 3100 D Page 5 39 _ Figure 2 2 Harness connector Figure 23 3 Hold coil terminal Electrical Systems Rev C 9 Glow Controller The controller is located under the right lower corner of the instrument panel Note Refer to Electrical Schematics and Diagrams at the beginning of the chapter when troubleshooting the controller Controller Operation 1 When the ignition switch is placed in the RUN posi tion the controller energizes the glow plugs and lights up the glow lamp for 10 seconds Note On units with serial numbers from 90101 to 90150 the glow controller is not in use when the ignition switch is turned to start 2 When the ignition switch is held in the START posi tion the glow plugs will energize while the switch is held in START and the glow lamp will not light 3 When the ignition switch is released from START to RUN the glow plugs will deenergize and the glow lamp will remain off Con
192. ev C WIRE IDENTIFICATION WIRE IDENTIFICATION ROUTE ROUTE LABEL COLOR FROM TO LABEL COLOR FROM TO wi RED P23 3 J7 W33 RED BLACK J12 P2 3 2 W2 RED P23 1 P16 1 W34 RED BLACK P2 3 2 J15 2 W3 ORANGE P16 2 14 4 W35 RED BLACK J15 2 J9 2 W4 BLUE P16 4 13 W36 NOT USED W5 YELLOW P16 5 J18 W37 GREEN P17 B J20 2 We P9 1 P16 6 2 W38 TAN 6 19 2 W7 VIOLET P16 6 2 9 2 W39 R 66465 P20 5 1 2 W8 WHITE P16 7 P14 3 W40 WHITE SP1 2 P2 1 W9 PINK P16 8 2 13 3 2 W41 GREEN 15 18 W10 PINK P13 3 2 _ SP5 W42 BLUE P18 B P7 A Wii SP5 P1 1 W43 WHITE P7 B P12 5 W12 SP5 12 6 2 W44 GREEN P12 1 2 J20 2 W13 P12 6 2 11 4 W45 BLUE J8 P21 A W14 PINK 16 8 2 1 W46 RED BLACK 8 4 19 2 Wi5 BLUE P13 1 14 5 2 W47 ORANGE 5 4 4 P6 A Wi6 BLUE 14 5 2 P10 1 W48 ORANGE SP4 4 17 W17 YELLOW P9 4 5 8 2 W49 GRAY P8 2 J10 W18 ORANGE P11 2 J2 2 W50 GRAY J10 P5 3 2 W19 ORANGE J2 2 J5 W51 GRAY P5 3 2 P4 1 W20 GRAY P3 2 11 5 W52 RED Jt P23 2 W21 GRAY 11 6 22 2 W53 1 2 P13 5 Be W22 GRAY P22 A 2 J4 W54 BLACK J8 SP2 4 E 8 W23 YELLOW P10 2 J14 2 W55 BLACK SP2 4 J16 a W24 YELLOW J14 2 12 2 W56 BLACK SP2 4 P2 2 W25 ORANGE P10 4 P19 1 2 W57 BLACK SP2 4 SP3 6 W26 ORANGE P19 1 2 J17 W58 BLACK SP3 6 P15 A W27 ORANGE P9 3 SPA 4 W59 BLACK SP3 6 P13 6 W28 ORANGE 5 4 4 P5 1 2 W60 BLACK SP3 6 J11 2 W29 ORANGE P5 1 2
193. ev C Page 5 38 Reelmaster 3100 D Fuel Stop Solenoid Solenoid With 2 Wire Connector The fuel stop solenoid used on the Reelmaster 3100 D must be energized for the diesel engine to run The sole noid is mounted to the injection pump on the engine Fig 22 The fuel stop solenoid includes two coils for operation the pull coil and the hold coil When the ignition switch is turned to START the fuel stop solenoid is initially ener gized and the pull coil retracts the solenoid plunger Once the plunger is retracted the hold coil will keep it re tracted for continued engine operation When the sole noid is de energized the plunger extends to shut off fuel supply to the engine causing the engine to stop running The fuel stop solenoid is grounded through the solenoid housing NOTE Refer to Chapter 8 Electrical Diagrams when troubleshooting the fuel stop solenoid In Place Testing NOTE Prior to taking small resistance readings with a digital multimeter short the test leads together The me ter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal re sistance of the meter and test leads Subtract this value from the measured value of the component you are test ing 1 Make sure ignition switch is in the OFF position Dis connect wire harness connector from fuel stop solenoid 2 Using a digital multimeter touch one test lead to the pull coil terminal and the other t
194. ever Hydraulic System Rev C 2 EI gt D N gt 7 Disconnect traction control cable from the pump lever D Remove both flange head screws securing the neutral bracket to the piston pump Remove flange nut and flange head screw securing the neutral bracket to the pump mount plate E Remove cap screw and flat washer securing the pump lever to the piston pump trunnion F Separate pump lever from pump trunnion and neutral bracket from mount plate 4 Drain hydraulic oil from hydraulic tank see Change Hydraulic Fluid in this section Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hy draulic System Pressure in the General Infor mation section 5 Disconnect all hydraulic hoses connected to the hy draulic fittings on the piston and gear pumps Allow hoses to drain into a suitable container Support piston and gear pumps when removing them from the pump support and pump mount plate to prevent them from falling and causing personal injury 6 Remove both cap screws washers and spacers se curing the piston pump to the pump support 7 Remove both lock nuts cap screws and washers securing the piston pump to the pump mount plate Pull pumps from the machine 8 Remove both socket head screws and flat washers securing gear pump to the piston pump Separate gear pump and O ring from the pi
195. ex ceed 40 psi to prevent damage to the filter element Rinse filter from clean side to dirty side C Dry filter element using warm flowing air 1609F maximum or allow element to air dry Do not use a light bulb to dry the filter element because damage could result Kubota Diesel Engine Page 3 12 Figure 18 1 Latch 3 Burp valve 2 Dustcup Figure 19 2 Body 1 Filter element Compressed Air Method A Blow compressed air from inside to the outside of dry filter element Do not exceed 100 psi to prevent damage to the element B Keep air hose nozzle at least 2 inches 5 cm from the filter Move nozzle up and down while rotating the filter element Inspect for holes and tears by looking through the filter toward a bright light 5 Inspect new filter for shipping damage Check seal ing end of filter Do not install a damaged filter 6 Insert new filter properly into air cleaner body Make sure filter is sealed properly by applying pressure to out er rim of filter when installing Do not press on flexible center of filter 7 Reinstall cover and secure latches Make sure cover is positioned with TOP side up Reelmaster 3100 D Water Fuel Separator Because diesel fuel is highly flammable use cau tion when storing or handling it Do not smoke while filling the fuel tank Do not fill fuel tank while engine is running hot or when machine is in an enclosed area Always fill fuel tank outside an
196. ff both adjustment nuts to allow the roller to spin freely Tighten both adjustment nuts again so there is no bearing end play and rolling torque does not ex ceed 5 in lb 0 57 12 Grease both bearings see Greasing Bearings Bushings and Pivot Points Reelmaster 3100 D Page 7 23 Install New Seals and Bearings on Sectional Roller 1 Make sure all parts are clean prior to installing bear ings and seals 2 Press two bearing cups into each sectional roller Make sure narrow end of taper faces the inside of the roller 3 Secured sectional roller shaft in a vise Make sure shaft is level 4 Pack all bearing cones with No 2 general purpose lithium base grease NOTE Install bearing cone with the seal into the end of the roller that faces the inner part of the shaft 5 On both rollers install a bearing cone into the bear ing cup at each end of the roller 6 Install outer seal onto the end of each roller Make sure the hard surface of seal faces out 7 Slide each roller onto the shaft 8 Install adjustment nut onto each end of the shaft Tighten each nut to seat both bearings of each roller Roller should be rotated to seat both bearings 9 Back off both adjustment nuts to allow the rollers to spin freely Tighten both adjustment nuts again so there is no bearing end play and rolling torque does not ex ceed 5 in lb 0 57 10 Grease both bearings see Greasing Bearings Bushings and Pivot P
197. for typical mowing conditions M CAUTION 2g E gt Keep away from reels during test to prevent per sonal injury from the rotating reel blades 7 Start engine and move throttle to full speed 2650 50 RPM Engage the cutting units 8 Watch pressure gauge carefully while mowing with the machine 9 Reel circuit pressure should be about 600 PSI 10 Disengage cutting units Shut off engine 11 Disconnect test gauge with hose from manifold block Reconnect plug to the hydraulic manifold test port G1 Reelmaster 3100 D Page 4 41 Hydraulic System Rev C Gear Pump P1 Flow Test Using Tester with Pressure Gauges Flow Meter TO HYDRAULIC MANIFOLD P1 PORT TO STEERING CONTROL VALVE IN PORT ENGINE FROM HYDROSTAT CASE DRAIN GEAR PUMP STRAINER High Pressure Low Pressure Return or Suction Flow Hydraulic System Rev C Page 4 42 Reelmaster 3100 D Procedure Gear Pump P1 Flow Test NOTE Over a period of time the gears and wear plates in the pump can wear down A worn pump will by pass oil and make the pump less efficient Eventually enough oil loss will occur to cause the reel motors to stall under heavy cutting conditions Continued operation with a worn inefficient pump can generate excessive heat and cause damage to the seals and other components in the hydraulic system 1 Make sure hydraulic oil is at norm
198. ft 6 Make sure bearing housings are installed with the grease fittings pointing up and to the front of the cutting unit 7 Secure bearing housings and bearings on the reel shaft ends and cutting unit with the cap screws 8 Remove grease from the threaded end of reel cou plers and the reel shaft Make sure grease is completely removed 9 Apply removable Loctite 242 or equivalent to reel coupler threads Do not get Loctite on the bearing seal 10 Screw reel coupler RH to the reel This coupling is right hand threaded Screw reel coupler LH to the reel This coupling is left hand threaded Torque both couplers from 55 to 65 Ft lb 74 6 to 88 1 11 Install front roller to cutting unit see Roller Removal and Installation 12 Install bedbar assembly to cutting unit see Bedbar Removal and Installation 13 Install cover gasket weights and cap screws to the bearing housing 14 Complete cutting unit set up and adjustment se quence see Adjustments section 15 Grease both bearings see Greasing Bearings Bushings and Pivot Points Cutting Units Bedbar Removal and Installation Figure 23 1 Rubber bushing 13 Adjuster spacer 25 Carriage bolt 2 Flanged bushing 14 Not used 26 Not used 3 Jamnut 15 Bedbar pivot 27 Bedbar washer 4 Compression spring 16 Grease fitting 28 Bedbar housing 5 Washer 17 Bedbar fitting 29 Spacer 6 Notused 18 Not used 30 Flat washer 7 Not used 19 Flange bush
199. fter fifteen 15 seconds 7 Replace fuel pump as necessary Install fuel hose pump discharge to the fuel filter 8 Reconnect electrical connector to the fuel stop sole noid 9 Prime fuel system Reelmaster 3100 D Page 5 37 Figure 19 3 Fuel filter 4 Fuel stop solenoid 1 Fuel pump 2 Fuel hose discharge Fuel Pump Specifications Fuel pump specifications for machines with serial num bers below 240000000 are as follows Pump Capacity 13 5 fl oz min 400 ml min Fuel pump specifications for machines with serial num bers from 240000000 to 270999999 are as follows Pump Capacity Pressure Current Draw 23 5 fl oz min 700 ml min 3 3 PSI 22 8 kPa Fuel pump specifications for machines with serial num bers above 280000000 are as follows Pump Capacity 64 fl oz min 1 9 liters min 7 PSI 48 3 kPa Pressure Current Draw Electrical Systems Rev C Rev E Fuel Stop Solenoid Solenoid With 3 Wire Connector The fuel stop solenoid must be energized for the engine to run It is mounted on the engine block near the injec tion pump Fig 20 The fuel stop solenoid includes two coils for operation the pull coil and the hold coil When the ignition switch is turned to START the fuel stop solenoid is initially ener gized and the pull coil retracts the solenoid plunger Once the plunger is retracted the hold coil will keep it re tracted for continued engine operation
200. g monitor the charge pressure reading on the pressure guage C The charge pressure should drop no more than 1596 from initial test reading Step 7 above A pres sure drop of more than 15 indicates a traction cir cuit leak e g a worn or damaged piston pump and or wheel motor 10 Shut off engine 11 Disconnect gauge and T connection from the 90 hydraulic fitting and hose connection Reconnect hose to the hydrostat Figure 19 1 Rear 90 hydraulic fitting 2 Piston pump Hydraulic System Rev C 2 E gt Gear Pump P2 Flow Test Using Tester with Pressure Gauges Flow Meter TO HYDRAULIC MANIFOLD P1 PORT TO STEERING CONTROL VALVE IN PORT ENGINE RPM 1 FROM HYDROSTAT CASE DRAIN GEAR PUMP STRAINER High Pressure Low Pressure Return or Suction Flow Hydraulic System Rev C 4 36 Reelmaster 3100 D Procedure Gear Pump P2 Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Park machine on a level surface with the cutting units lowered and off Make sure engine is off and the parking brake is engaged 3 Read Precautions for Hydraulic Testing 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
201. g clip return springs brake shoes and cam shaft can be re moved as a complete brake assembly 8 If itis desired to remove the brake assembly from the brake bracket remove four cap screws and lock nuts securing the assembly to the bracket 9 Disassemble brake assembly as follows Fig 8 A Remove return springs from the brake shoes Re move brake shoes from the backing plate B Matchmark brake cam and brake lever to assure proper alignment during reassembly Remove taining clip from the brake cam Pull brake lever from the cam Remove cam from backing plate 10 The brake bracket and wheel shield be removed as follows A Remove lock nuts spacers and cap screws se curing the brake bracket wheel shield and hydraulic motor to the frame B Separate bracket and shield from the frame Installation Fig 7 1 Insert four cap screws through the frame hydraulic motor spacers wheel shield and brake bracket Se cure with lock nuts but do not fully tighten 2 Assemble brake assembly as follows Fig 8 A Secure backing plate to the brake bracket with four cap screws and lock washers B Apply antiseize lubricant to cam shaft splines In sert cam shaft through the backing plate C Attach brake lever to the cam shaft Make sure matchmarks are aligned properly Secure lever to shaft with retaining clip D Lubricate brake shoe pivot points with a light coating of grease Reelmaster 3100 D
202. g unit Slide second height of cut roller bracket onto the other end of roller shaft Secure second bracket to cutting unit side plate with carriage screw and flange nut 5 Apply Loctite 242 or equivalent 0 exposed threads of cap screw item 1 between flange of side plate and position of flange lock nut item 3 on cap screw Tighten flange lock nut on cap screw and then loosen 1 4 to 1 2 turn Cap screw should rotate freely with little if any endplay after lock nut installation 6 Apply Loctite 242 or equivalent to threads of two 2 cap screws item 6 Center front roller to the cutting reeland secure in place with two 2 cap screws Torque cap screws from 15 to 19 ft Ib 20 to 26 N m Secure cap screws with flange nuts 7 Lubricate front roller 8 Adjust cutting unit see Cutting Unit Operator s Manual Reelmaster 3100 D Rear Roller Removal Fig 31 1 Position machine on a clean and level surface lower cutting units stop engine engage parking brake and re move key from the ignition switch 2 Remove the cutting unitfrom the machine and place on a level working surface Place support blocks under bedbar to raise rear roller from work surface 3 Loosen two 2 flange nuts that secure the rear roller shaft to each rear roller bracket 4 ofthe rear roller brackets Note cutting units equipped with optional High Height of Cut Kit there will be additional roller shims instal
203. g units stop engine engage parking brake and remove key from the ignition switch 2 Remove console cover to expose the controls 3 Rotate backlap knob on the manifold block clockwise to the BACKLAP position Rotate reel speed knob to position 1 4 Make initial reel to bedknife adjustments appropriate for backlapping on all cutting units Start engine and set engine speed to low idle 5 Engage reels by moving mow transport lever to MOW and depressing the reel ON OFF switch Becareful when lapping the reel because contact with the reel or other moving parts can result in personal injury 6 Apply lapping compound with a long handled brush Cutting Units 7 14 Rev Figure 17 2 Reel speed knob 1 Backlap knob 7 To make an adjustment to the cutting units while backlapping turn off the reels by pushing in the reels ON OFF switch on instrument panel to OFF position and stopping the engine After adjustments have been com pleted repeat steps 4 through 6 8 When backlap operation is completed rotate back lap knob counter clockwise to the MOW position set reel speed controls to the desired mowing setting and wash all lapping compound off the cutting units Note For a better cutting edge run a file across the front face of the bedknife when the lapping operation is completed This will remove any burrs or rough edges that may have built up on the cutting edge Reelmaster 3100 D Cutti
204. ged Traction response is sluggish Charge pressure is low Hydraulic oil is very cold Towing by pass valve is open or worn Brake is not released Traction pump or wheel motor s are worn or damaged No traction exists in either direction Brake is not released Cil level in reservoir is low Towing by pass valve is open Charge pressure is low Traction pump or wheel motor s are worn or damaged Traction pump drive belt loose or broken Wheel motor will not turn Internal parts in wheel motor are damaged Brakes are binding Key on wheel motor shaft is sheared or missing Hydraulic System Rev C Page 4 26 Reelmaster 3100 D Problem Wheel motor will not hold load in neutral Reel motor drive pump is noisy ca vitation Reels will not turn Reel speed is erratic Reel s turn too slowly Cutting units will not lift or lift slowly Cutting units raise but will not stay up Steering Problems Possible Cause Make up fluid from charge pump is not available Hydrostat ball check valves are damaged Reservoir oil level is low Suction line is restricted Suction line has an air leak Solenoid valve S1 is stuck open An electrical problem exists See Chapter 5 Electrical System Relief valve R1 is stuck open LC1 logic valve is stuck open Gear pump P1 is damaged Reel to bedknife adjustment is too tight Orifice for LC1 is obstructed Reel bearing s are damaged Reel
205. gine is running e reel stalls stop engine before attempting to clear the reel e Reel motors are connected in series rotating one motor causes rotation in other motors Note Additional instructions and procedures on backlapping are available in the Toro General Service Training Book Reel Mower Basics part no 09168SL 1 Position the machine on a level surface lower the cutting units stop the engine and engage the parking brake 2 Remove the console cover to expose controls 3 Locate the reel speed selector knob and backlap le ver on the hydraulic manifold Fig 16 Rotate the reel speed selector knob to position 1 and the backlap lever to the R backlap position 4 Make initial reel to bedknife adjustments appropriate for backlapping on all cutting units which are to be back lapped 5 Start engine and run at idle speed 6 Engage the reels by engaging the PTO switch on the control panel IMPORTANT To prevent damage to the reel do not rotate the backlap lever from the backlap position to the mow position while the engine is running DPA Cutting Units Rev G Page 8 16 Figure 16 1 Reel Speed Selector Knob 2 Backlap Lever Figure 17 1 Long Handle Brush 7 Apply lapping compound with a long handle brush see Special Tools Fig 17 Neveruse a shorthandled brush to apply lapping compound Reels may stall while backlapping Do not attempt to restart reels by
206. haft ends in V blocks B Check the reel blades for bending or cracking C Check the service limit of the reel diameter see Preparing a Reel for Grinding in this section 3 Check the threaded inserts in the reel shaft for ex cessive wear or distortion Replace inserts if damage is evident A The threaded inserts are installed with thread locking compound Loctite 242 or equivalent One insert has LH threads and the other RH threads The insertwith LH threads has an identification groove on the flange face A groove on the reel shaft approxi mately 2 fromthe end identifies the reel end thathas LH threads see illustration in Fig 28 B To remove or install threaded spline inserts use correct spline insert tool see Special Tools C To install spline insert into cutting reel clean threads of insert and cutting reel shaft Apply Loctite 242 or equivalent to threads of insert thread in sertinto reel shaftand torque from 85to 95 ft Ib 115 to 128 N m Reelmaster 3100 D Page 8 29 Assembly of Cutting Reel Fig 28 1 If seals and or bearings were removed from reel shaft discard removed components and replace 2 Make sure that the two 2 retaining rings are fully seated into the grooves on the cutting reel shaft 3 If bearings and seals were removed from reel shaft A Make sure that bore of seals are clean with no grease or lubricant applied to ID of seal IMPORTANT grease seal should
207. hand or touch reels while backlapping Stop engine and turn reel speed adjustment knob one position toward no 8 If reels stall or become erratic while backlapping stop backlapping by disengaging the PTO switch Once the reels have stopped move the reel speed selector knob one position closer to 9 R esume backlapping by engaging the PTO switch Reelmaster 3100 D 9 To make an adjustment to the cutting units while backlapping disengage the PTO switch and turn the en Top Face gine OFF Wait for all machine movement to stop After Relief Angle Remove adjustments have been completed repeat steps 5 Burr through 8 10 When the backlapping operation is completed runa Eie file across the frontface ofthe bedknife This will remove FrontAngle any burrs or rough edges that may have built up on the cutting edge 11 R epeat procedure for all cutting units to be backlap Figure 18 ped 12 When backlap operation has been completed return the backlap leverto the F mow position setreel speed knob to desired speed install console cover and wash alllapping compound off cutting units Adjustcutting unit reel to bedknife as needed Note If the backlap lever is not returned to the F mow position after backlapping the cutting units will not function properly 32 25 amp Reelmaster 3100 0 8 17 DPA Cutting Units Rev Bedbar Assembly 27 to 33 ft lb 37 to 44 N m VA Antiseiz
208. he cutting unit 6 Ifnecessary remove the second height of cut roll er bracket from the cutting unit Installation Fig 30 1 Placecutting uniton a level working surface and use cutting unitkickstand see S pecial Tools to supportcut ting unit 2 Inspect condition of cap screws item 1 in both height of cut roller brackets Replace cap screw s if necessary A Place two 2 flat washers on cap screw and thread flange lock nut onto cap screw to a position 0 750 19 mm from screw head B Apply antiseize lubricant to cap screw threads that will extend into height of cut roller bracket C Thread cap screw into bracket Note When assembling height of cut roller brack ets to side plate make surethatcap screw head and one washer are above adjustment flange on side plate and second washer and flange lock nut are below flange 3 If both front height of cut roller brackets were re moved from cutting unit side plate position one of the brackets to side plate Secure bracketto side plate with carriage screw and flange lock nut DPA Cutting Units Rev G Page 8 32 e Loctite 242 3 Antiseize P gt Lubricant 15 to 19 ft Ib 20 to 26 N m Loctite 242 Figure 30 1 Cap screw 5 Carriage screw 2 Flat washer 6 Capscrew 3 Flangelock nut 7 Flange nut 4 HOC roller bracket 8 Frontroller assembly 4 Slide front roller shaft into bracket attached to the cuttin
209. her components in the hy draulic system and affect quality of cut Hydraulic System Rev C Page 4 46 NOTE One way to find a possibly bad reel motor is to have another person observe the machine while mow ing in dense turf A bad motor will run slower produce fewer clippings and may cause marcelling or a wash board appearance on the turf NOTE On machines with Serial Numbers below 230000000 the initial reel motor in the cutting circuit is the left front and the final reel motor drives the rear cut ting unit On machines with Serial Numbers above 230000000 the initial motor is the rear reel motor and the final reel motor is the left front Reelmaster 3100 D Procedure for Reel Motor Efficiency Case Drain Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 2 Park machine on a level surface with the cutting units lowered and off Make sure engine is off and the parking brake is engaged 3 Read Precautions for Hydraulic Testing NOTE The reel motors are connected in series To iso late a faulty motor you may have to test all three motors in the circuit by starting with the upstream motor first 4 For the suspected bad motor disconnect return hose from the motor Cross Over Relief Test Fig 30 and 31 5 Install tester in series with the motor and discon nected return hose Make sure
210. hill that is too steep rollover will occur before losing traction 17 The slope angle at which the machine will tip is de pendent on many factors Among these are mowing conditions such as wet or undulating turf speed espe cially in turns position of the cutting units with side winder tire pressure and operator experience At side hill slope angles of 20 degrees or less the risk of a rol lover is low As the slope angle increases to a Toro rec ommended maximum limit of 25 degrees the risk of a rollover increases to a moderate level DO NOT EX CEED A 25 DEGREE SIDE HILL ANGLE BECAUSE THE RISK OF A ROLLOVER AND SERIOUS INJURY OR DEATH IS VERY HIGH Stay alert for holes in terrain and other hidden hazards Use extreme caution when operating close to sand traps ditches creeks steep hill sides or other hazards Reduce speed when making sharp turns Do not turn on hills Avoid sudden stops and Safety Page 1 2 11 Fill fuel tank with diesel fuel before starting engine Avoid spilling any fuel Since fuel is highly flammable handle it carefully A Use an approved fuel container B Do not remove cap from fuel tank when engine is hot or running C Do not smoke while handling diesel fuel D Fill fuel tank outdoors and not over one inch from the top of the tank bottom of the filler neck Do not overfill starts Use reverse pedal for braking Cutting units must be lowered when going down slopes for steering contr
211. hly clean hydraulic hose ends and fittings on steering cylinder to prevent hydraulic system contami nation Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hy draulic System Pressure in the General Infor mation section 5 Remove steering cylinder from the frame and rear fork using Figure 84 as guide 6 If hydraulic fittings are to be removed from steering cylinder mark fitting orientation to allow correct assem bly Installation 1 If hydraulic fittings were removed from steering cylin der install fittings to cylinder using marks made during the removal process to properly orientate fittings 2 Install steering cylinder to the frame and rear fork us ing Figure 84 as guide When securing cylinder ball joints to machine tighten the first jam nut from 65 to 85 ft lb 88 to 115 then tighten the second jam nut to the same specification 3 Mount rear wheel to the machine with four 4 lug nuts Lower machine to the ground Torque lug nuts in crossing pattern from 45 to 65 ft lb 61 to 88 4 Make sure hydraulic tank is full Add correct oil if nec essary see Traction Unit Operator s Manual Figure 85 1 Steering cylinder 2 Jamnuts 1 Steering cylinder 3 nuts 2 Rear fork 2 E gt Reelmaster 3100 D Page 4 121 Hydraulic System Rev C Steering Cylind
212. hydrostat through gear pump P1 It supplies hydraulic pressure charge pressure for raising and lowering the cutting units operating the sidewinder unit and maintaining 100 to 150 PSI 6 9 to 10 0 bar to the low pressure side of the traction circuit The pump takes its suction from the hydraulic reservoir During conditions of not lifting or lowering cutting units flow from the gear pump is by passed through the pow er steering valve 2 spool valve and hydraulic manifold directly to the hydrostat and the charge relief valve Flow then returns to the hydraulic tank Reelmaster 3100 D Page 4 15 When the cutting units are to be raised the 2 spool valve is positioned by moving the cutting unit shift lever to RAISE Flow is directed to cap ends of the lift cylin ders Hydraulic pressure against the cylinder pistons moves their shafts causing the cutting units to raise At the same time the pistons push the hydraulic fluid out of the lift cylinders and back through the hydraulic man ifold to the hydrostat When the cutting unit shift lever is released spring action returns the valve to its original position and by passes flow back to the hydrostat stop ping lift cylinder movement The cylinder position is locked in place since there is no complete circuit of flow to and from the lift cylinders Hydraulic System Rev C 2g 8 22
213. ic System 12 Remove cable ties securing the wire harness to the front lift tab and other engine parts Fig 31 Connect hoist or lift to the front and rear lift tabs Fig 31 and 32 Make sure lift or hoist can support the total weight of the engine before removing the cap screws from the rear bracket and engine 13 Remove flange nut cap screw and washer securing three engine mounts to the engine mounting brackets One person should operate lift or hoist while the other person guides the engine out of the ma chine IMPORTANT Make sure not to damage the engine fuel and hydraulic lines electrical harness or other parts while removing the engine 14 Remove engine slowly from the machine 15 Separate hydrostat and pump mount plate from the engine as follows Note The cap screw next to the torsion spring does not have a flat washer with it A Remove traction belt from the engine fly wheel and hydrostat pulleys see Traction Belt Replace ment Figure 30 1 Battery ground 4 Support bracket 2 Wire harness ground 5 Speed control lever 3 Throttle cable 6 Fuel hose 2 h 2 E Figure 31 1 Glow plug wire 3 Fuel hose 2 Fuel stop solenoid 4 Front lift tab Figure 32 1 Temp warning switch 2 Rear lift tab anm Figure 33 1 Temp shutdown switch 3 Low oil press switch 2 Alternator Reelmaster 3100 D Page 3 21 Kubota Diesel Engine B Remove five c
214. if necessary See Reel Assembly Service in the Service and Repairs section of this chapter Check bedknife to reel contact daily The bedknife must have light contact across the entire reel No contact will dull the cutting edges Excessive contact accelerates wear of both edges Quality of cut is adversely affected by both conditions see Bedknife to Reel Adjustment in the Cutting Unit Operator s Manual Reelmaster 3100 D Reel and bedknife sharpness A reel and or bedknife that has rounded cutting edges or rifling grooved or wavy appearance cannot be corrected by tightening the bedknife to reel contact Grind cutting reel to remove taper and or rifling Grind bedknife to sharpen and or remove rifling The most common cause of rifling is bedknife to reel contact that is too tight Dull cutting edges must be corrected by grinding the bedknife and cutting reel see Preparing Reel for Grinding in the Service and Repairs section of this chapter A new bedknife must be ground flat within 0 002 after installation to the bedbar Backlapping may be required to properly mate the reel and bedknife after installation into the cutting unit Note On cutting units equipped with optional bedknives slightly dull cutting edges may be corrected by backlapping see Backlapping in the Service and Repairs section of this chapter Rear roller adjustment Adjust the rear roller brackets to correct position depending on the height of cu
215. ine Always chock or block wheels Used jack stands or solid wood blocks to support the raised machine If the machine is not properly sup ported by blocks or jack stands the machine may move or fall which may result in personal injury m 1 Square tube 2 Side plate Use the following positions when jacking up the ma chine Jacking the Front End 1 If the front wheel motor is to be removed position jack securely under the square tube of the lower frame as closely to the side plate as possible Fig 1 2 If the front tire is to be removed position the jack se curely under the front wheel motor 3 Use jack stands or hardwood blocks under the square tube or wheel motors to support the machine Fig 1 Jacking the Rear End 1 Reartire 2 Rear casting 1 The preferred method of lifting the rear end of the machine for removing the rear fork or the rear wheel mo tor A Secure a chain fall or hoist to the rear casting Fig 2 B Chock both front tires Lift rear tire off the ground C Use jack stands or hardwood blocks under the frame to support the machine Fig 3 2 If the rear of the machine can not be lifted from above Fig 3 IMPORTANT Make sure jack is as close to the rear fork as possible when jacking the rear wheel Figure 3 1 Frame 3 Rear fork A Place jack securely under the rear wheel motor 2 Rear wheel motor B Chock both front tires Jack rear tire off the ground C
216. ing 2 Flat washer 14 Traction stud 26 Rod end 3 Micro switch 15 Traction control cable 27 Lock nut 4 Keps nut 16 Isolator stud 28 Screw 5 Neutral bracket 17 Flat washer 29 Cap screw 6 Flange nut 18 Extension spring 30 Pump mount plate 7 Flange head nut 19 Cap screw 31 Spring dampener 8 Neutral arm 20 Flat washer 32 Adjuster bracket 9 Flange bushing 21 Pump lever 33 Flat washer 10 Thrust washer 22 Flange nut 34 Isolation mount 11 909 grease fitting 23 Flange head screw 35 Lock nut 12 Lock nut 24 Cable support bracket 36 Piston pump Piston Pump Removal Fig 62 1 Remove traction belt from the pulley see Replace Traction Belt 2 Remove pulley from the taper lock bushing A Remove cap screws securing pulley to the taper lock bushing IMPORTANT Excessive or unequal pressure on the cap screws can break the bushing flange B Insert cap screws into threaded removal holes of the pulley Tighten screws progressively and evenly until the pulley is loose on the bushing Remove pulley from the bushing Reelmaster 3100 D Page 4 97 The extension spring is under tension and may cause personal injury during removal Use cau tion when removing spring from the pump lever 3 Remove neutral arm assembly from the piston pump as follows Figs 63 and 64 A Disconnect electrical connector from the micro switch early models B Remove extension spring from the cable support bracket and pump l
217. ing 31 Lock washer 8 Spring arm 20 Bushing 32 Cap screw 9 Bedbar adjuster 21 Lock nut 33 Bedbar 10 Not used 22 Hex nut 34 Bedknife 11 Not used 23 Adjusting housing 35 Screw 12 Not used 24 Lock nut 36 Bedbar yoke Bedbar Removal 1 Turn bedbar adjuster to loosen bedknife to reel con tact Unscrew bedbar adjuster left hand threaded while loosening jam nut from the compression spring until the bedbar fitting is clear of the bedbar yoke 2 Remove cap screws weights and cover gasket from the bearing housing Fig 22 3 Remove capscrew lock washer flat washer and spacer from the end of the bedbar 4 Loosen both adjusting lock nuts on the adjusting housing Fig 24 Cutting Units Page 7 18 5 Remove both carriage bolts and nuts from the justing housing Fig 24 6 Remove both carriage bolts and nuts from the bed bar housing Remove bedbar from the cutting unit 7 Remove adjusting housing and bedbar housing from the bed bar Remove bedbar washer 8 Sharpen or replace bedknife as necessary see Bedknife Replacement and Grinding Reelmaster 3100 D Bedbar Installation Fig 23 1 Inspect flanged bushings and bushing for wear re place if necessary 2 Clean and apply anti seize lubricant to both bedbar pivots Install bedbar washer on the bedbar 3 Install bedbar adjusting housing and bedbar housing on the bed bar Reinstall spacer flat washer lock wash er and cap screw on
218. ing rings 5 Route hydraulic hoses so they clear the lift arm by 0 04 to 0 12 inch 1 0to 3 0 mm when the lift arm is fully raised Fig 35 6 Adjustlift arms to proper clearance see Adjust Front Lift Arms 7 Install cutting unitto the pivot shaft ofthe front lift arm see Cutting Unit Installation 8 Grease front lift arm Reelmaster 3100 D 1 2 Figure 33 Flange head screw 3 Liftarm pivot shaft Pivot shaft link 1 2 7 27 Rev Figure 34 Lynch pin 7 screw Cutting unit pivot shaft 8 Bushing Carrier frame 9 Bushing Thrust washer 10 Grease fitting Liftarm LH 11 Pinch point decal Liftarm RH notshown Figure 35 3 Hydraulic cylinder Hydraulic hoses Hydraulic cylinder Cutting Units Rear Lift Arm 200 to 250 Ft Ib 271 to 339 N m Figure 36 1 External retaining ring 9 Jamnut 17 Pin 2 Thrust washer 10 Washer 18 Carrier assembly 3 Rear lift arm 11 Lynch pin 19 Hex nut 4 Rear hydraulic cylinder 12 Washer 20 Lock washer 5 Flange head screw 13 Cutting unit pivot shaft 21 Flat washer 6 Thrust washer 14 Cap screw 22 Carriage screw 7 Rear pivot shaft 15 Rebound washer 23 Switch bracket 8 Bushing 16 Cap screw 24 Grease fitting Removal 6 Disassemble lift arm as necessary using Figure 36 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch
219. instructions 5 Occasionally check the temperature of the battery electrolyte If the temperature exceeds 125 F 51 6 C or the electrolyte is violently gassing or spewing the charging rate must be lowered or temporarily stopped 6 Three hours prior to the end of the charging mea sure the specific gravity of a battery cell once per hour The battery is fully charged when the cells are gassing freely at a low charging rate and there is less than a 0 003 change in specific gravity for three consecutive readings Electrical Systems Rev C 0 4 This page is intentionally blank Electrical Systems Rev C Page 5 46 Reelmaster 3100 D Chapter 6 TORO Wheels Brakes and Miscellaneous Table of Contents SPECIFICATIONS 2 Del xe Seat cereum i 5 SPECIAL TOOLS iiie RE 2 Front Wheel and Brake 6 ADJUSTMENTS 3 Rear Fork and Wheel 8 Adjust Brake 3 Brake Linkages 10 SERVICE AND REPAIRS 4 Steering Column 12 Standard Seat 4 S 2 25 pt 2 Reelmaster 3100 D Page 6 1 Wheels Brakes and Miscellaneous Specifications Item Description Tire pressure 14 to 18 PSI 0 97 to 1 24
220. into the rod end of the cylinders and back through the hydraulic manifold to the hydrostat When the cutting unit shift lever is released spring ac tion returns and detents the valve into the float position while by passing flow back to the hydrostat The pilot valve then shifts to its original position and stops lift cyl inder movement The cylinder position is locked in place since there is no complete circuit of flow to and from the lift cylinders Hydraulic System Rev C 2g 8 22 15 15 _ H3QNITAO oi LJ M HOLON 1334 uvad HOLON 1939 1NOHUH 1H9IH HOLON 1939 1331 xnv poe mee aes SS z gt NIVHO 3SVO TVNH3INI
221. ion 1 Park machine on level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Check air cleaner body for damage that could cause possible air leaks Make sure dust cup seals completely to the air cleaner 3 Check burp valve and dust cup for damage 4 Make sure air hoses connecting the air cleaner to the engine and radiator are secured tightly and free of pos sible air leaks Service Air Filter Dust Cup amp Burp Valve The air cleaner filter should be serviced ever 50 hours and more frequently in extreme dusty conditions 1 Park machine on level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Release latches securing air cleaner cover to air cleaner body Separate cover from body Clean inside of air cleaner cover 3 Gently slide filter out of air cleaner body to reduce the amount of dust dislodged Avoid knocking filter against air cleaner body 4 Inspect filter and discard if damaged Do not wash or reuse a damaged filter IMPORTANT Do not over service the air filter ele ment damage may result Washing Method A Prepare a solution of filter cleaner and water Soak filter element about 15 minutes Refer to direc tions on filter cleaner carton for complete informa tion B After soaking filter for 15 minutes rinse it with clear water Maximum water pressure must not
222. ion Precision machined die castalu minum cross member with two 2 bolt on cast ductile iron side plates Reel Construction Reels are 27 inches 69 cm or 32 inches 81 cm in length and 7 inch 18 cm in diameter High strength low alloy steel blades are thru hardened and impact resistant 27 inch reels are available in 5 8 and 11 blade configurations 32 inch reels have 8 blades Reel Bearings Two 2 double row self aligning ball bearings support the reel shaft with inboard seal for protection Reel bearing adjustmentis maintained by an adjuster nut in the left side plate of the cutting unit Reel Drive The reel weldment shaft is a 1 5 16 inch 33 3 mm diameter tube with drive inserts threaded into both ends The reel drive inserts have an internal nine 9 tooth spline Height of Cut HOC Cutting height is adjusted on the front roller by two 2 vertical screws Effective HOC may vary depending on turf conditions type of bedknife roller type and installed attachments DPA Cutting Units Rev G Page 8 2 Bedknife Replaceable single edged high carbon steel bedknife is fastened to a machined cast iron bed bar with screws Optional bedknives are available Bedknife Adjustment Dual screw adjustment to the reel detents corresponding to 0 0009 inch 0 023 mm bedknife movement for each indexed position Front and Rear Rollers Greaseable through shaft front and rear rollers are used with these cutting units Al
223. is specification is met go to Step 11 11 Disengage cutting units Shut off engine 12 Disconnect tester from manifold and hose Recon nect hydraulic hose to manifold fitting for port M1 XT Figure 25 1 Hydraulic manifold 2 Hydraulic fitting M1 Hydraulic System Rev C 2 E gt N gt 7 Reel Motor Efficiency Case Drain Test Using Tester with Pressure Gauges and Flow Meter TO HYDRAULIC MANIFOLD PORT D1 FROM HYDRAULIC MANIFOLD PORT 1 gt RIGHT FRONT REEL MOTOR lt FINAL TO HYDRAULIC MANIFOLD PORT M2 gt INITIAL REELMOTOR 9 MEASURING CONTAINER High Pressure Low Pressure A Return or Suction REEL MOTOR lt Milliliters in 15 sec Ounces in 15 sec 95 3 2 189 6 4 284 9 6 378 12 8 473 16 0 568 19 2 662 22 4 756 25 6 852 28 8 lalis fo 946 32 0 NOTE Over a period of a reel motor can wear in ternally A worn motor may by pass oil to its case drain causing the motor to be less efficient Eventually enough oil loss will cause the reel motor to stall under heavy cutting conditions Continued operation with a worn inefficient motor can generate excessive heat cause damage to seals and ot
224. it See RearRoller Brush in the Service and Repairs section of this chapter for infor mation on rear roller brush 5 Remove the bedbar pivot bolt and washers from the LH side plate 6 Loosen fasteners thatsecure frontand rear rollers to LH side plate see FrontR oller R emovaland R earRoller Removal in this section 7 Remove cap screw and flat washer that secure rear grass Shield to LH side plate Fig 27 8 Remove flange head screw that secures support tube frame spacer and carrier frame to LH side plate Fig 27 Note Thereel bearings and grease seals are press fit on the cutting reel shaft and should remain on the reel when removing the LH side plate 9 Remove shoulder bolts item 8 and flange nuts item 24 that secure the LH side plate to the cutting unit frame Remove the LH side plate from the reel shaft roll ers bedbar and cutting unit frame Contact with the reel bedknife or other cutting unit parts can result in personal injury Use heavy gloves when removing the cutting reel 10 Carefully slide the cutting reel with bearings grease seals and splined inserts from the RH side plate 11 1 5 and service cutting reel assembly as re quired see Reel Assembly Service in this section Reelmaster 3100 D Page 8 25 15 to 19 ft Ib 20 to 25 N m Loctite 242 27 to 33 ft lb 7 37 to 44 N m 15 to 19 16 20 to 25 N m Figure 27 1 RH side plate 6 Capscrew 2 Cen
225. it Toro bedknife at taching screws Use this bit with a torque wrench to se cure the bedknife to the bedbar IMPORTANT To prevent damage to the bedbar DO NOT use an air or manual impact wrench with this tool Handle Assembly Toro PartNumber 29 9100 For applying lapping compound to cutting units while keeping hands a Safe distance from the rotating reel DPA Cutting Units Rev G 8 4 2 CS Ss 7 Used for Height of e Cut adjustment Figure 2 oe Figure 3 Figure 4 Reelmaster 3100 D Plastic Plug Toro Part Number 94 2703 This plug is used for placement into the side plate bear ing housing when the hydraulic reel motor is removed It prevents dirt and debris from entering the cutting reel bearing area Figure 5 Cutting Unit Kickstand Toro Part Number 110 4088 03 The cutting unit kickstand is used to prop up the rear of the cutting unit during service Use ofthis tool prevents the bedbar adjusting screws from resting on the work surface Figure 6 Spline Insert Tool Part Number TOR4074 9 tooth Use the spline insert tool for rotating the cutting reel when hydraulic motor is removed Also use this tool for installation ofthreaded inserts into the cutting reel shaft Figure 7 58 5 amp Reelmaster 3100 0 8 5 DPA Cutting Units Rev Reel Bearing Installation Tool Toro Part Number
226. itch is above 2309F 1109C Glow Light The glow light comes on when the ignition switch is placed in RUN prior to placing the ignition switch in START and stays lit for 10 seconds while left in RUN Reelmaster 3100 D Page 5 35 Battery Light The battery light should come on when the ignition switch is in ON with the engine not running or with an improperly operating charging circuit while the engine is running 1 Turn ignition switch to ON the light should come on 2 Turn ignition switch to OFF GLOW AMBER AMBER Figure 16 Electrical Systems Rev C Pr Indicator Lights Serial Numbers Above 240000000 Charge Indicator Light The charge indicator light should come on when the igni tion switch is in the ON position with the engine not run ning Also it should illuminate with an improperly operating charging circuit while the engine is running Engine Oil Pressure Light The engine oil pressure light should come on when the ignition switch is in the ON position with the engine not running Also it should illuminate with the engine run ning if the engine oil pressure drops to an unsafe level IMPORTANT If the oil pressure indicator light is il luminated with the engine running shut off the en gine immediately To test the oil pressure light and circuit wiring ground the wire attached to oil pressure switch located on the en gine near the oil fil
227. just speed to specifications if necessary If engine is not running at specified maximum governed RPM reel speed settings may not match ground speed Adjust reel speed to setting shown on REEL SPEED SETTINGS graph for the number of reel blades 5 or 8 and the desired ground speed see Operator s Manual reels should rotate at the same speed All cutting units should have equal bedknife to reel contact If checking RPM do not run reel too long without cutting grass or bedknife and or reel may overheat and rifle See other items in Troubleshooting section of Chapter 4 Hydraulic System Check each tire s pressure Adjust to pressures specified in Specifications section of Chapter 6 Wheels and Brakes All reels should rotate freely Make sure bearings are properly lubricated Replace bearings if worn or damaged Reel and or bedknife that has rounded cutting edges or rifling cannot be corrected by tightening bedknife to reel contact Grind reel to remove taper and or rifling grooved or wavy appearance Grind bedknife to sharpen and or remove rifling Most common cause of rifling is bedknife to reel contact that is too tight NOTE New bedknife must be ground or backlapped after installing on bedbar Cutting Units 6 Bedknife to reel adjustment Check bedknife to reel contact daily Bedknife must have light contact all across the reel No contact will cause cutting edges to become dull Excessive contact
228. ket 9 Bushing 4 Lock nut 10 Carriage bolt 5 Capscrew 11 Lock nut 6 Angle bracket 6 Mount roller roller brackets and angle brackets to the cutting unit Secure roller brackets and angle brack ets to the cutting unit with capscrews 7 Install both height of cut pins and hairpin cotters 8 Install both locknuts to the capscrews and secure each angle bracket to the cutting unit 9 Adjust roller level see Height of Cut and Leveling Both Rollers Cutting Units Roller Bearing and Seal Replacement 4 O 1 5 Figure 28 Full roller Roller shaft Grease seal Bearing cup ONO Remove Seals and Bearings 1 Clean inside of roller around both adjusting nuts and roller shaft ends Both areas should be free of dirt and debris 2 Remove adjusting nut from one end of the roller shaft On the sectional roller remove both adjusting nuts from each end of the roller NOTE When disassembling a full roller pour the oil from inside the roller into a suitable container 3 Keep roller level and slide the shaft with the remain ing adjusting nut out of the roller On the sectional roller slide both sectional rollers of the shaft 4 Secure roller in a vise Cutting Units Bearing cone outer Outer seal Adjustment nut Grease fitting Page 7 22 9 Wiehle roller 10 Sectional roller shaft 11 Bearing cone inner 12 Sectional roller 5 Remove outer seals 6 Remove both bearing co
229. l in the Service and Repairs section of this chapter 3 Loosen set screw that secures bearing adjuster nut in LH side plate of cutting unit IMPORTANT Over tightening reel bearing adjuster nut may damage reel bearings DPA Cutting Units Rev G Page 8 12 4 With the cutting unit and reel in a horizontal position use a 1 3 8 socketand torque wrench to overtighten the bearing adjuster nutto 40 to 45 in Ib 4 5 to 5 1 N m 5 Loosen the bearing adjuster nut and then torque bearing adjuster nut from 15 to 17 in Ib 1 7 to 1 9 N m 6 Using a suitable torque wrench and spline insert tool see Special Tools check that reel rolling torque does not exceed 10 in Ib 1 1 N m Also check if reel bear ing endplay exists If endplay exists after bearing adjust er nut is properly torqued replace the cutting reel bearings and seals see Reel Assembly and Reel As sembly Service in the Service and Repairs section of this chapter 7 Apply Loctite 242 or equivalent to threads of set screw and secure bearing adjuster nutin place with set screw Torque set screw from 12 to 15 in Ib 1 4 to 1 7 N m 8 Afterreel bearing adjustment install all removed cut ting unit components to cutting unit a 4 152 7 12t 15 in Ib L4 to 1 7 N m 15 to 17in lb 1 7 to 1 9 N m Figure 11 1 LH side plate 2 Threaded insert 3 Bearing adjuster nut 4 Setscrew
230. l Infor mation section 3 The engine must be in good operating condition Use a phototac when performing a hydraulic test Engine speed can affect the accuracy of the tester readings Check actual speed of the pump when performing flow testing 4 The inlet and the outlet hoses must be properly con nected and not reversed tester with pressure and flow capabilities to prevent damage to the hydraulic tester or components 5 When using tester with pressure and flow capabili ties open load valve completely in the hydraulic tester to minimize the possibility of damaging components 6 Install fittings finger tight and far enough to make sure that they are not cross threaded before tightening them with a wrench 7 Position tester hoses to prevent rotating machine parts from contacting and damaging the hoses or tester 8 Check oil level in the hydraulic tank After connecting test equipment make sure tank is full 9 Check control linkages for improper adjustment binding or broken parts 10 All hydraulic tests should be made with the hydraulic oil at normal operating temperature 11 If a traction circuit problem exists consider perform ing one or more of the following tests Traction Circuit Working Pressure Charge Relief Valve Pressure Pis ton Pump P3 Flow amp Traction Relief Pressure and or Wheel Motor Efficiency Tests 12 If a cutting circuit problem exists consider perform ing one or more of the followi
231. l rim wheel hub and brake drum from the hydraulic motor Remove brake assem bly brake bracket and wheel shield from the frame see Front Wheel and Brake Removal in Chapter 6 Wheels Brakes and Miscellaneous 2 Remove wheel motor from frame using Figure 42 as guide Reelmaster 3100 D Page4 67 Installation 1 Install wheel motor to frame using Figure 42 as guide 2 Install wheel shield brake bracket and brake as sembly to the frame Install brake drum wheel hub and tire and wheel rim to the hydraulic motor see Front Wheel and Brake Installation in Chapter 6 Wheels Brakes and Miscellaneous Hydraulic System Rev C 2g 8 22 Rear Wheel Motor 200 to 400 ft lb 271 to 542 N m Figure 43 1 Lugnut 6 Hydraulic hose 11 Hydraulic motor 2 Drive stud 7 O ring 12 Rear fork 3 Tire and rim 8 45 hydraulic fitting 13 O ring 4 Wheel hub 9 Lock nut 14 Woodruff key 5 Hydraulic hose 10 Socket head screw Hydraulic System Rev C Page 4 68 Reelmaster 3100 D Rear Wheel Removal 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch A WARNING Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 2 Jack up rear of machine enough to allow the removal of the rear wheel 3 Remove rear tire and rim assembly from machine 4 Remove rear wheel
232. l rollers use the same heavy duty ball bearings Counterbalance Weight A cast iron weight mounted opposite to the hydraulic drive motor balances the cut ting unit Cutting Unit Weight 27 Reel 5 Blade 27 Reel 8 Blade 27 Reel 11 Blade 32 Reel 8 Blade 148 Ib 67 kg 153 Ib 69 kg 167 Ib 76 kg 158 Ib 72 kg Options Refer to Cutting UnitO perator s Manual for available op tions for your Reelmaster DPA cutting unit Reelmaster 3100 D General Information Cutting Unit Operator s Manual The Cutting Unit Operator s Manual provides informa tion regarding the operation general maintenance and maintenance intervals for the DPA cutting units on your Reelmaster machine Additionally if optional kits have been installed on the cutting units e g rearroller brush the installation instructions for the kit includes set up and operation information Refer to those publications for additional information when servicing the cutting units 32 25 amp Reelmaster 3100 0 8 3 DPA Cutting Units Rev Special Tools Special tools for servicing Toro Commercial P roducts are available from your Toro Distributor Some tools may have been supplied with your machine or are available as TORO parts Gauge Bar Assembly Toro Part Number 108 6715 Use gauge bar to verify height of cut adjustment Bedknife Screw Tool Toro Part Number TOR510880 This screwdriver type bitis made to f
233. lb 41 to 48 9 Lubricate plunger liberally with clean hydraulic fluid and install into its valve body bore 10 Install new O ring seat check poppet and check spring into the plunger bore 11 Install O ring back up washer and seat retaining plug into the plunger bore Torque plug from 30 to 35 ft Ib 41 to 48 12 Install O ring and plug into the top of the valve body next to the detent plug bore Torque plug from 10 to 12 ft lb 14 to 16 13 Lubricate plunger detent spring and disc liberally with clean hydraulic fluid and install into its valve body bore 14 Install O ring and detent plug into its proper bore Torque plug from 30 to 42 ft lb 41 to 57 Reelmaster 3100 D 2g 5 8 22 gt This page is intentionally blank Reelmaster 3100 D Page 4 89 Hydraulic System Rev C Control Valve Models 03201 03207 and 03171 Figure 59 1 Control valve 2 spool 10 Cotter pin 19 Carriage screw 2 used 2 Hydraulic fitting straight 11 Valve lever 20 O ring 3 90 hydraulic fitting 12 Valve actuator trunnion 21 O ring 4 Hydraulic fitting straight 13 Shoulder bolt 22 Hydraulic tube 5 Flange nut 14 Link 4 used 23 Hydraulic tube 6 Knob 15 Bolt 24 Hydraulic hose 7 90 hydraulic fitting 16 Lock nut 25 O ring 8 Valve actuator bracket 17 Push nut 26 Hydraulic hose 9 Shoulder bolt 18 Hydraulic fitting 27 Hydraulic tube Hydraulic System
234. led between rear roller bracket and cutting unit side plate A Remove flange nuts and carriage screws thatse cure rear roller bracketand roller shims to the cutting unit side plate B Remove the roller bracket and roller shims from the rear roller and cutting unit 5 Slide the rear roller assembly from the remaining rear roller bracket on the cutting unit 6 If necessary remove the second rear roller bracket and roller shims from the cutting unit Installation Fig 31 1 Place cutting unit on a level working surface Note Refer to Cutting Unit Operator s Manual number of roller shims required for various height of cut settings Note A0 010 shim partnumber 107 4001 is avail able to allow for leveling of the rear roller see Leveling Rear Roller in the Set up and Adjustments section of this chapter If necessary this shim would be used on one side of the rear roller and should be installed be tween the rear roller bracket and roller shim 2 Ifbothrearrollerbrackets were removed from cutting unit side plate position brackets and rollershims to one of the side plates Install two 2 carriage screws and flange nuts to retain bracketin position Do not fully tight en flange nuts Reelmaster 3100 D Page 8 33 Figure 31 1 Rear roller assembly 2 Rear roller bracket 3 Carriage screw 4 Flange nut 5 Roller shim 6 0 010 shim if needed 3 Slide rear roller shaft into the rear roller br
235. lic System Rev C 4 48 Reelmaster 3100 D Procedure for Cross over Relief Pressures Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 2 Make sure machine is parked on a level surface with the cutting units lowered and off Make sure engine is off and parking brake is engaged Back bedknives off all reels CAUTION Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil 3 Clean hydraulic fittings on suspected faulty reel mo tor Disconnect pressure inlet hose from fitting for the mow direction of flow A Top 909 fitting for the front reel motors B Center fitting for the rear reel motor 4 Install T connector with 5000 PSI pressure gauge between the motor inlet fitting and the disconnected hose 5 Puta block of wood between the blades of the cutting unit being tested to prevent the reel from rotating 6 Make sure backlap knob on the hydraulic manifold is in the mow position 7 One person should sit on the seat and operate the machine while another person reads the gauge Start engine and set throttle to full speed 2650 50 RPM Keep away from reels during test to prevent per sonal injury from the rotating reel blades Do not allow system pressure to exceed 1800 PSI Shut off unit to prevent an over pressure condition 8 E
236. lied and removed from terminal 85 5 Disconnect voltage and multimeter leads from the relay terminals Reelmaster 3100 D Page 5 31 Figure 7 Electrical System Figure 8 Electrical Systems Rev C Hour Meter 1 Connect the positive terminal of a 12 VDC source to the positive terminal of the hour meter 2 Connect the negative terminal of the voltage Hobbs 1 source to the other terminal of the hour meter 10 3 The hour meter should move a 1 10 of an hour in six HOURS minutes Bre t Figure 9 4 Disconnect the voltage source from the hour meter Reel Drive Solenoid Note Prior to taking small resistance readings with a digital multimeter short the test leads together The me ter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal re sistance of the meter and test leads Subtract this value from from the measured value of the component you are testing 1 Make sure engine is off Disconnect solenoid valve electrical connector 2 Apply 12VDC source directly to the solenoid Listen for solenoid to switch on 3 Remove 12VDC source from the solenoid Listen for Figure 10 solenoid to switch off 1 Hydraulic manifold 2 Solenoid 4 Measure resistance between the two connector ter minals The resistance should be about 7 2 ohms 5 Install new solenoid if necessary A Make sure o ri
237. lock nut Tighten lock nut to shoulder of adjuster shaft and then torque lock nut from 15 to 20 ft Ib 21 to 27 N m B On early production cutting units Fig 22 slide bedbar adjuster shaft into flange bushings in cutting unit frame Secure adjuster shaft with wave washer and retaining ring Reelmaster 3100 D Page 8 21 Note Inside threads in bedbar adjuster shaft item 4 are left hand threads 4 Apply antiseize lubricantto threads of bedbar adjust erscrew item 10 thatfitinto adjuster shaft Thread bed bar adjuster screw into adjuster shaft item 4 5 Install bedbar see Bedbar Installation in this sec tion 6 Install washer item 11 compression spring item 2 and lock nut item 3 onto adjuster screw Tighten the lock nut on each bedbar adjuster assembly until the compression spring is fully compressed then loosen lock nut 1 2 turn 7 Adjust cutting unit see Cutting Unit Operator s Manual Loctite 4242 14 to 16 ft Ib 19 to 21N m 5 Antiseize Lubricant Figure 22 Bedbar adjuster screw Retaining ring Wave washer Flange bushing 5 screw 6 Detent 7 Bedbar adjuster shaft PUNE DPA Cutting Units Rev G c 5 lt a N E Bedknife Replacement and Grinding Bedknife Removal 1 Remove bedbar from cutting unit see Bedbar Re moval in this section 2 Remove screws from bedbar using a socket wrench and bedknife screw tool see Special
238. low in the operating circuit with a gauge rated from 1 to 15 GPM 5 to 55 LPM 5 OUTLET HOSE A hose from the outlet side of the hydraulic tester connects to the hydraulic system circuit 6 FITTINGS Anassortmentof hydraulic fittings are in cluded with this kit Hydraulic System Rev C Page 4 22 Figure 10 Figure 11 Rev F Reelmaster 3100 D Hydraulic TestFitting Kit f Toro Part Number 4079 Toro Test Fitting Kit ze X VR TOR4079 lees This kit includes a variety of O ring Face seal fittings to Fitting sie bd enable you to connect test gauges into the system j m WS zi Ron The kit includes tee s unions reducers plugs caps and male test fittings e te Si 5 Xi ftit Figure 12 Measuring Container Toro Part Number TOR4077 Use this container for doing hydraulic motor efficiency testing motors with case drain lines only Measure effi ciency of a hydraulic motor by restricting the outlet flow from the motor and measuring leakage from the case drain line while the motor is pressurized by the hydraulic system 2 E I Figure 13 O Ring Kit Toro Part Number 16 3799 The kit includes O rings in a variety of sizes for face seal and port seal hydraulic connections It is recommended that O rings be replaced whenever a hydraulic connec tion is loosened Fig
239. lter element Filter head Filter element spin on O ring Base Plug 2 Drain valve O ring O ring Plug Pipe plug Drain valve Kubota Diesel Engine Kubota Diesel Engine Fuel System Figure 22 1 Cap screw 14 Flange hex nut 27 Flange nut 2 Fuel tank 15 Lock washer 28 Seat support strap 3 Fuel hose strap 16 Flat washer 29 Foam 4 Cap screw 17 Tee fitting 30 Hex flange head screw 5 Fuel 18 Barb fitting 31 Fuel hose 6 Tank support 19 Barb fitting 32 Fuel hose 7 Fuel gauge 20 Bushing 33 Fuel hose 8 Grommet 21 Spacer 34 Fuel hose 9 Connector fitting 22 Hose clamp 35 Fuel hose 10 Stand pipe 23 Fuel prefilter 36 Fuel pump 11 R clamp 24 Water fuel separator 37 Hose 12 Barb fitting 25 Fuel fitting 38 Threaded insert 13 Cap screw 26 Flange head screw 39 Seat support strap Check Fuel Lines and Connections Check fuel lines and connections every 400 hours or yearly whichever comes first Because diesel fuel is highly flammable use cau tion when storing or handling it Do not smoke 1 Park machine on a level surface lower cutting units while filling the fuel tank Do not fill fuel tank stop engine engage parking brake and remove key while engine is running hot or when machine is from the ignition switch in an enclosed area Always fill fuel tank outside and wipe up any spilled diesel fuel before start 2 Check lines for deterioration damage leaking or
240. ly engages the valve base B Lubricate threads on cartridge valve with clean hydraulic oil Thread rotary cartridge valve carefully into the manifold port The valve should go in easily without binding Torque valve with deep well socket to specification shown in manifold illustration 7 Install knob assembly manifold shown in Fig 50 A Install locating plate so that the pin seats into the locating hole B Turn the threaded cartridge valve stem carefully clockwise until it stops C Face detent plate counterbore down Thread det ent plate down onto the valve stem until it is stopped by the locating plate detent plate back counter clockwise 1 4 turn Reelmaster 3100 D Page 4 81 Rev E SY Or ir NES D Center one detent plate hole over a locating plate indentation Drop a ball into each hole then drop a spring into each hole E On the 2 position directional valve cartridge place indicator plate overthe detent plate Make sure the arrow points directly at the number 1 on the locat ing plate F Onflow control cartridge valve cartridge place in dicator plate over the detent plate Make sure the ar row points to the right at 459 G While pushing down on the indicator plate and compressing the springs thread down a jam nut While tightening the set screw tighten jam nut at the same time using a 7 16 inch wrench H Thread second jam nutall the way downthe valve stem Apply Loctite 242 or equi
241. m 20 mr Piston pump Straight hydraulic fitting Cap screw Lock nut 90 hydraulic fitting 90 hydraulic fitting 90 hydraulic fitting 909 hydraulic fitting 909 hydraulic fitting Washer Hydraulic hose Suction hose Flange nut Idler pivot pin Grease fitting Flange nut Retaining ring Cap screw Thrust washer Figure 62 Idler pulley Spacer Torsion spring Idler arm Hose clamp Flange nut Cap screw Flange head screw Pump support Spacer Cap screw Flat washer Spacer Pump mount plate Pump mount spacer Pulley Cap screw Lock washer Taper lock bushing IMPORTANT If a piston pump failure occurred re fer to Traction Circuit Closed Loop Component Failure in the General Information section for infor mation regarding the importance of removing con tamination from the traction circuit Hydraulic System Rev C Page 4 96 39 V belt 40 O ring 41 O ring 42 O ring 43 O ring 44 O ring 45 O ring 46 O ring 47 O ring 48 Hydraulic hose 49 Hydraulic hose 50 Hydraulic hose 51 Hydraulic hose 52 Bushing 53 Gear pump 54 O ring 55 Flat washer 56 Socket head screw 57 Set screw Reelmaster 3100 D Neutral Arm Assembly EARLY MODELS 21 34 33 Figure 63 1 Philips head screw 13 Spacer 25 Ball bear
242. m 11 Shut off engine 12 Disconnect tester from gear pump fitting and hose Reconnect hose to the pump 13 If flow was less than 5 7 GPM or a pressure of 2000 PSI cannot be obtained check for restriction in the pump intake line If line is not restricted remove pump and re pair or replace as necessary Figure 24 2 To manifold port P1 1 Gear pump Hydraulic System Rev C 2g gt Manifold Relief Valve R1 Pressure Test Using Tester with Pressure Gauges and Flow Meter FROM REEL MOTOR CASE DRAINS TO INITIAL REEL MOTOR FROM FINAL D1 REEL MOTOR TO HYDRAULIC TANK HYDRAULIC MANIFOLD G1 BLOCK REEL SPEED CONTROLLER a RELIEE 3000 psi 4 Ti TOOIL q COOLER TO REAR LIFT OPTIONAL CYLINDER Lue TO FRONT LIFT CYLINDER TO HYDROSTAT FROM LIFT VALVE CHARGE CIRCUIT OUT PORT TO STEERING CONTROL ENGINE E VALVE IN PORT FROM STEERING CONTROL VALVE OUT PORT gt 22 High Pressure Low Pressure FROM HYDROSTAT INTERNAL CASE DRAIN STRAINER Return or Suction Flow Hydraulic System Rev C Page 4 44 Reelmaster 3100 D Procedure for Manifold Relief Valve R1 Pressure Test 1 Make sure hydr
243. m pressure to mini mize damage from any remaining contamination The filter will remove contamination from the closed loop traction circuit during operation Remove the filter from the machine after contamination has been removed from the traction circuit IMPORTANT When operating the traction system with the high pressure filter installed make sure that flow is always directed through the filter e g do not press the traction pedal in the reverse direction if the filter is placed for forward direction flow If flow is reversed debris from the filter will re enter the traction circuit Reelmaster 3100 D 2g 5 8 22 gt This page is intentionally blank Reelmaster 3100 D Page4 7 Hydraulic System Rev C 3SVO TIVNH3LNI ANWA ONIH33IS H3NIVHIS Mo xnv S VA
244. machine frame and an immovable object to prevent the machine from moving during testing The rear wheel will be off the ground during front wheel motor testing Make sure machine is sup ported so it will not move and accidentally fall to prevent injuring anyone under machine 6 Block up the rear wheel off the ground to allow flow through the traction circuit 7 Chock front wheel being tested to prevent rotation of the wheel Make sure parking brake is on Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hy draulic System Pressure in the General Infor mation section 8 Disconnect hydraulic lines from front wheel motor that is not being tested Cap disconnected hydraulic lines and plug ports in motor to prevent contamination 9 Disconnect hose from the lower hydraulic fitting on the bottom of the hydrostat Fig 22 NOTE An alternate testing location would be at the hy draulic hose connection to the hydraulic tube under the left floor plate 10 Install flow tester in series with the pump and the dis connected hose Make sure the tester flow control valve is fully open 11 Start engine and move throttle to full speed 2650 50 RPM Reelmaster 3100 D Page 4 39 1 Lower hydraulic fitting 2 Piston pump Use extreme caution when performing test The front tire on the ground will be trying to move the machine forward
245. mentfilter elementis Toro part number TOR6012 Filter element cannister tightening torque is 25 ft lb 34 N m Figure 17 Reelmaster 3100 D 2g 5 8 22 gt This page is intentionally blank Reelmaster 3100 D Page 4 25 Hydraulic System Rev C Troubleshooting The charts that follow contain information to assist in Refer to the Testing section of this Chapter for precau troubleshooting There may possibly be more than one tions and specific test procedures cause for a machine malfunction Problem Possible Cause Hydraulic oil leaks from system Fitting s hose s or tube s are loose or damaged O ring s or seal s are missing or damaged Hydraulic fluid foams Cil level in reservoir is low Hydraulic system has wrong type of oil One of the pump suction lines has an air leak Hydraulic system operates hot Transmission pressure is high due to load or brakes applied Cil level in reservoir is low or inlet filter is loose or clogged Oil is contaminated or too light Heat exchanger if equipped is damaged or plugged By pass re lief is stuck open or air flow is obstructed Charge pressure is low Towing by pass valve is open or defective Wheel motor s or reel motor s are worn or damaged Traction pump is worn or damaged Neutral is difficult to find or unit op External control linkage is misadjusted disconnected binding or erates in one direction only damaged Traction pump is worn or dama
246. mer to ful ly seat seals against roller shoulder Fig 33 Apply a smallamountof grease around the lip of both innerseals after installation IMPORTANT During assembly process frequently check that bearings rotate freely and do not bind If any binding is detected consider component re moval and reinstallation 2 Install new bearing and outer seals into one end of roller tube A Position new bearing into one end of roller tube Use bearing outer seal tool see Special Tools with a softface hammer to fully seat bearing againstroller shoulder Fig 34 After bearing installation make sure that it rotates freely with no binding B Apply a small amount of grease around the lip of both outer seals C Install first outer seal into roller tube making sure that seal lip and garter spring faces end of tube Use bearing outer seal tool see Special Tools and soft face hammer to lightly seat seal against roller shoulder Fig 35 Make sure that bearing still freely rotates after seal installation 50 to 60 ft Ib 68 to 81 N m Figure 32 1 Roller tube 5 Outer seal 2 Roller shaft 6 Bearing lock nut 3 Inner seal 7 Grease fitting 4 Bearing Figure 33 Roller tube 3 Inner seal Inner seal tool Figure 34 D Using the same process install second o
247. minum 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 Product Records and Maintenance Product Records i 5 gt Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series Grade 1 5 amp 5 Grade 1 Bolts Screws Studs amp SAE Grade 5 Bolts Screws Studs amp SAE Grade 8 Bolts Screws Studs amp Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts Height Nuts SAE J995 Grade 2 or Stronger Nuts SAE J995 Grade 2 or Stronger Nuts SAE J995 Grade 5 or Stronger Nuts ae vorm 250 29 147 23 282 30 339 56 599 79 100 10 1125 100 140 15 1580 170 734 113 115 10 1300 100 160 15 1800 170 1186 169 200 25 2250 280 300 30 3390 340 1446 192 225 25 2540 280 325 30 3670 340 6 32 UNC 6 40 UNF 8 32 UNC 8 36 UNF 10 24 UNC 10 32 UNF 1 4 20 UNC 53 7 1 4 28 65 10 5 16 18 115 15 105 17 5 16 24 UNF
248. mp front flange of motor in a vise with soft jaws with the shaft end down Figure 46 2 Hydraulic System Page 4 75 1 Rev E Reelmaster 3100 D 4 Loosen screws from the rear cover 4 Inspect wear plates for the following 5 Remove motor from the vise Turn motor so that the A Bearing areas should not have excessive wear or shaft end is facing down Remove cap screws scoring 6 Carefully remove body Lift body straight up to re B Face of wear plates that are in contact with gears move Make sure the rear wear plate remains on the should be free of wear roughness or scoring drive and idler gear shafts Remove and discard O rings from the body Locate and retrieve pins C Thickness of wear plates should be equal IMPORTANT Note position of the open and closed 5 Inspect front flange and rear cover for damage or side of the wear plates before removing Also iden wear tify wear plates front and rear with a marker for proper assembly 7 Carefully remove rear wear plate idler gear drive shaft and front wear plate from the front flange 8 Remove and discard back up gaskets and pressure seals from wear plates 9 Turn front flange over with seal side up IMPORTANT Make sure to not damage the front flange counter bore when removing the seals from the front flange
249. mp trunnion with flat washer and cap screw C Secure neutral bracket to the pump mount plate with flange head screw and flange nut Secure neu tral bracket to the piston pump with both flange head Screws D Connect traction control cable to the pump lever The extension spring is under tension and may cause personal injury during installation Use caution when installing the spring to the pump lever E Install extension spring to the cable support bracket and pump lever F Connect electrical connector to the micro switch early models 11 Install traction belt to the pump pulley see Replace Traction Belt 12 Using a straight edge across the lower face of the pump pulley verify traction belt alignment across engine and pump pulleys Slide pulley and taper lock bushing on pump shaft so that traction belt and straight edge are aligned indicating correct position of pump pulley Se cure taper lock bushing in position with set screw IMPORTANT When tightening bushing cap screws tighten in three equal steps and in a circular pattern 13 Secure taper lock bushing by tightening three 3 cap screws to a torque from 90 to 120 in Ib 10 2 to 13 6 N m in three equal steps and in a circular pattern to se cure pulley and taper lock bushing 14 Check that belt alignment is still correct If needed loosen and re adjust pulley and taper lock bushing loca tion on pump shaft to allow for correct belt alignment 15 Fill hy
250. n side plates for wear or damage Re move bushings and replace if necessary Bedbar Installation Fig 19 1 If rubber bushing was removed from either cutting unit side plate install a new bushing The bushing should be installed flush with the inside ofthe side plate Fig 20 2 If removed install the flange bushings item 15 with flange facing outward Apply antiseize lubricantto inside of flange bushing 3 Apply antiseize lubricant to the bedbar threads and the shoulder area of each bedbar pivot bolt 4 Slide one metal washer item 17 and one plastic washer item 16 onto each bedbar pivot bolt Contact with the reel bedknife or other cutting unit parts can result in personal injury Use heavy gloves when handling the bedbar 6 Position a plastic washer between bedbar and each cutting unit side plate Fig 20 7 Install the bedbar pivot bolt assemblies Make sure thatplastic washers are notcaughton the threads ofthe pivot bolts Tighten each bedbar pivot boltfrom 27 to 33 ft lb 37 to 44 N m 8 Tighten both lock nuts item 19 until outside metal washer just stops rotating Do notover tighten the lock nuts as this can distort the side plates and affect reel bearing adjustment The plastic washer between the bedbar and side plate should be loose 9 Tighten the lock nut item 13 on each bedbar adjust er assembly until the adjuster spring is fully com pressed then loosen lock nut 1 2 turn 10 Adju
251. nate e g the in seat input LED does not illuminate with the seat occu pied and the ignition switch in the run position testing of the switch and circuit wiring would be required 11 Backlap input LED Refer to the Traction Unit Operator s Manual for opera tion and troubleshooting of the Standard Control Mod ule 0 4 Reelmaster 3100 D Page 5 41 Electrical Systems Rev C Service and Repairs NOTE For more component repair information see the Kubota Workshop Manual Diesel Engine 05 Se ries Battery Storage If the machine will be stored for more than 30 days 1 Remove the battery and charge it fully see Battery Service 2 Either store battery on a shelf or on the machine 3 Leave cables disconnected if the battery is stored on the machine Battery Care 1 Battery electrolyte level must be properly main tained The top of the battery must be kept clean If the machine is stored in a location where temperatures are extremely high the battery will run down more rapidly than if the machine is stored in a location where temper atures are cool Wear safety goggles and rubber gloves when working with electrolyte Charge battery in a well ventilated place so gasses produced while charging can dissipate Since the gases are explosive keep open flames and electrical sparks away from the battery do not smoke Nausea may result if the gases are inhaled Un plug charge
252. nes On the sectional roller remove all four bearing cones Note An electric arc welder can be used to shrink the bearing cup to simplify its removal Only a small arc in one location on the cup is required 7 Remove both bearing cups from the roller Remove both inner seals installed on the full roller On the sec tional roller remove all four bearing cups 8 Discard seals and bearings Reelmaster 3100 D Install New Seals and Bearings on Full or Wiehle Roller 1 Make sure all parts are clean prior to installing bear ings and seals 2 Onthe full roller make sure cupped side of the inner seal faces the inside of the roller Press an inner seal into each end of the roller 3 Make sure narrow end of the taper on the bearing cup faces the inside of the roller Press a cup into each end of the roller 4 Keep roller level and secured roller in a vise 5 If assembling a full roller fill the inside of roller tube with 6 oz 170 gm of SAE 90 oil 6 Pack both bearing cones with No 2 general purpose lithium base grease 7 Install a bearing cone into the bearing cup at each end of the roller 8 Position outer seal to the roller with the hard surface of seal facing out Press a seal onto each end of the roll er 9 Slide roller shaft through the bearing cones and roll er 10 Install remaining adjustment nut and tighten it to seat both bearings Roller should be rotated to seat both bearings 11 Back o
253. ng Torque cap screws to 29 ft lbs 39 6 Check torque required to rotate control shaft Torque should be 5 to 15 in Ibs 0 6 to 1 7 A If torque is too low add additional shims and re peat steps 3 through 6 until the specified torque is achieved B If torque is too high remove shims and repeat steps 3 through 6 until the specified torque is achieved 7 Complete assembly of the pump see Eaton Repair Information at the end of this chapter Hydraulic System Rev C 2 E gt Sidewinder Models 03201 03207 and 03171 Figure 69 1 Plastic bushing 12 Lock nut 22 Hydraulic hose 2 Scissor link 13 Welded pin 23 90 hydraulic fitting 3 Scissor mount 14 Flange head screw 24 Hydraulic hose 4 Capscrew 15 Lock nut 25 Pinch point decal 5 Flat washer 16 Spacer 26 O ring 6 Lock nut 17 Hydraulic tube 27 O ring 7 Scissor frame 18 Hydraulic tube 28 O ring 8 Hydraulic cylinder 19 90 hydraulic fitting 29 Retaining ring 9 Spacer 20 Bulkhead lock nut 30 Lower frame LH 10 Flat washer 21 Straight hydraulic fitting 31 Frame 11 Cap screw Hydraulic System Rev C Page4 102 Rev F Reelmaster 3100 D Removal Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hy draulic System Pressure in the General Infor mation section 1 Remove hydraulic cylinder from the frame using Fig ur
254. ng Unit Removal and Installation Removal 1 Position machine on a clean level surface Lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Onthe front cutting units detach chain from the cut ting unit carrier frame by removing the lock nut and cap screw Fig 19 3 Remove hydraulic motor from the cutting unit see Reel Motor Removal 4 Remove lynch pin from pivot shaft Fig 20 and 21 5 Slide cutting unit carrier frame and thrust washer from the pivot shaft Figure 19 1 Chain 3 Front carrier frame RH Installation 2 Cap screw amp lock nut 1 On the front cutting units slide thrust washer and then cutting unit carrier frame onto pivot shaft Fig 20 2 On the rear cutting unit slide cutting unit carrier frame and then thrust washer onto pivot shaft Fig 21 3 Install lynch pin onto the pivot shaft Fig 20 and 21 4 Install hydraulic motor to the cutting unit see Reel Motor Installation 5 On front cutting units attach chain to the cutting unit carrier frame with cap screw and lock nut Fig 19 Figure 20 1 Lynch pin 3 Pivot shaft 2 Thrust washer 4 Front unit carrier frame Figure 21 n 1 Lynch 3 Pivot shaft gt 2 Thrust washer 4 Rear unit carrier frame 2 5 o IMPORTANT Make sure hoses are free of twists and sharp bends Route rear cutting unit hoses as shown Fig 18 Raise cutting units and shift them to
255. ng and back up ring from spool 2 D Pull spool up and out of manifold Remove O rings and back up ring from spool E Discard removed O rings and back up rings Visually inspect the spool and manifold port for dam age to the sealing surfaces and contamination 3 Page4 82 Rev Install spool into mow manifold A Install O rings and back up ring to upper grooves on spool Apply a light coating of grease to O rings B Carefully push spool down into mow manifold port until lower O ring and back up ring groove is exposed on bottom of manifold Install lower O ring and back up ring to spool Apply a light coating of grease to O ring C Carefully raise mow backlap spool until upper re taining ring groove on spool is exposed on top of manifold Install upper retaining ring D Push mow backlap spool down and install lower retaining ring to spool E If handle was removed from spool position spool so handle location of spool is between stop pins Ap ply Loctite 603 Retaining Compound or equivalent to threads on handle and install handle into spool F Place ball and dowel pin in backlap switch man ifold port Install new O ring onto backlap switch Thread backlap switch into port and torque 15 ft Ib 20 N m Loctite 603 1 gt D Figure 53 1 Retaining ring 4 O ring 2 O ring 5 Spool handle 3 Back up ring 6 Rotary spool Reelmaster 3100 D 2g 5 8 22 gt This
256. ng brake and remove key from ignition switch 2 Clamp hose leading to the oil filter head from the hy draulic tank to prevent draining the hydraulic tank 3 Clean area around filter mounting surface Place drain pan under filter and remove filter Properly dispose of filter 4 Lubricate new filter gasket and fill the filter with hy draulic fluid 5 Assure filter mounting area is clean Screw filter on until gasket contacts mounting plate Then tighten filter one half turn Hydraulic System Rev C Page 4 60 Figure 38 2 Rear wheel 1 Hydraulic oil filter 6 Remove clamp from hydraulic hose Check and ad just hydraulic oil level in hydraulic tank 7 Start engine and let run for about two minutes to purge air from the system Stop the engine and check for leaks 8 Check level of fluid and add enough to raise level to FULL mark on dipstick DO NOT OVER FILL Reelmaster 3100 D Replace Traction Belt 1 Park machine on level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Insert nut driver or small piece of pipe onto the end of the torsion spring of the idler pulley Be careful when removing or applying tension from or to the torsion spring of the idler pulley The spring is under heavy load and may cause personal injury 3 Push down and forward on the spring end to unhook the spring from the pump mounting plate 4 Remove V b
257. ng is installed at each end of coil Apply Loctite 242 or equivalent to threads on end of valve stem before installing nut B Tighten nut to a torque of 15 in Ib 17 3 kg cm Over tightening may damage the solenoid or cause the valve to malfunction 6 Reconnect electrical connector to the solenoid Electrical Systems Rev C Page 5 32 Reelmaster 3100 D High Temperature Warning and Shutdown Switches The high temperature warning and shut down switches are located on the water pump which is located on the rear end of the engine block The high temperature shut down switch is on the alternator side of the engine Fig 11 A CAUTION Make sure engine is cool before removing the temperature switch 1 Lower coolant level in the engine and remove the temperature switch 2 Put switch in a container of oil with a thermometer and slowly heat the oil Fig 12 CAUTION Handle the hot oil with extreme care to prevent personal injury or fire Note On units with serial numbers from 90101 to 90150 the high temperature shutdown switch settings are the same as the high temperature warning switch below 3 Check continuity of the switch with a multimeter ohms setting A The high temperature warning switch is normally open and should close between 216 to 226 F 102 to 108 C B The high temperature shutdown switch is normal ly open and should close between 225 to 235 F 107 to 113 C Reelmaster 3100
258. ng system NOTE Use only hydraulic fluids specified in Check Hy draulic System Fluid If changing to biodegradable fluid use Toro Biodegradable Hydraulic Fluid for this step Other fluids may cause system damage 7 Fill hydraulic tank with new hydraulic fluid see Change Hydraulic Fluid 8 Disconnect electrical connector from fuel stop sole noid 9 Turn ignition key switch engage starter for 10 se conds to the prime hydrostat Repeat this step again 10 Connect electrical connector to fuel stop solenoid 11 Start engine and let it idle at low speed 1750 50 RPM for a minimum of 2 minutes Increase engine speed to high idle 2650 50 RPM for minimum of 1 minute under no load 12 Raise and lower cutting units several times Turn steering wheel fully left and right several times 13 Shut off engine and check for hydraulic oil leaks Check oil level in hydraulic tank and add correct amount of oil if necessary 14 Operate the machine for 2 hours under normal oper ating conditions 15 Check condition of hydraulic oil If the new fluid shows any signs of contamination repeat steps 1 through 15 again until oil is clean If changing to biode gradable fluid repeat steps 1 through 15 again at least once and until the oil is clean 16 Assume normal operation and follow recommended maintenance intervals Reelmaster 3100 D Charge Hydraulic System NOTE When initially starting the hydraulic system with new or r
259. ng tests Reel Circuit Pres sure Manifold Relief Valve R1 Pressure Reel Motor Cross over Relief Pressures Gear Pump P1 Flow and or Reel Motor Efficiency Tests 13 If a steering or lift circuit problem exists consider per forming one or more of the following tests Lift and Steer ing Control Valve Relief Pressure Gear Pump P2 Flow and or Steering Control Valve Tests Hydraulic System Rev C 2g E gt Traction Circuit Working Pressure Test Using Pressure Gauge TRACTION WHEEL MOTORS Y FORWARD TOP PORT 3000 psi TRACTION RELIEF FROM HYDRAULIC MANIFOLD CHG PORT I I l RA l E PISTON PUMP HYDROSTAT High Pressure TO GEAR PUMP SUCTION EIES THROUGH CASE DRAIN Return or Suction Flow Hydraulic System Rev C Page 4 30 Reelmaster 3100 D Procedure for Traction Circuit Working Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Park machine on a level surface with the cutting units lowered and off Make sure engine is off 3 Read Precautions for Hydraulic Testing 4 Make sure that traction pedal is adjusted to the neu tral position see Adjust Traction Drive for Neutral in the Adjustments Section Figure 17 1 Test port 2 Floor plate Before disconnecting or pe
260. ngage cutting units System pressure should be from 1350 to 1650 PSI as the cross over relief valve lifts Reelmaster 3100 D Page 4 49 Figure 30 1 Pressure inlet hose 3 Right reel motor 2 Left reel motor Figure 31 1 Rear reel motor 2 Pressure inlet hose 9 Disengage cutting units and stop engine If specifica tions are not met replace cross over relief If specifica tions are met remove block of wood from cutting unit and repeat test on other reels in mow direction IMPORTANT Each reel motor has two cross over relief valves Test reliefs in the backlap direction only if a problem is expected After testing cross over reliefs in the backlap direction make sure the reel motor couplings are torqued see Reel Motor Removal and Installation in the Service and Repairs section of Chapter 7 Cutting Units 10 Clean suspected reel motor hydraulic fittings Dis connect pressure inlet hose from fitting for the backlap direction of flow A Bottom 909 fitting for the front reel motors B Bottom 90 fitting for the rear reel motor 11 Install T connector with 5000 PSI pressure gauge between the motor fitting and the disconnected hose Hydraulic System Rev C E E 12 Make sure backlap knob on the hydraulic manifold is in the backlap position 13 One person should sit on the seat and operate the machine while another person reads the gauge Start engine and move the thro
261. nge bushing 8 Brake drum 19 Cam shaft 30 Brake pivot bracket 9 Woodruff key 20 Retainer Clip 31 Brake pivot shaft 10 Cotter pin 21 Lock nut 32 Hex flange head screw 11 Adjustment rod 22 Cap screw 33 Hex flange nut Removal Fig 7 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety Page 6 6 Wheels Brakes and Miscellaneous 2 Jack up front wheel and use wood blocks to keep the rear tire off the floor 3 Remove lug nuts from drive studs Pull wheel from drive studs and wheel hub NOTE The installation torque of the locknut is from 250 to 400 ft lb 339 to 542 Use impact wrench to re move lock nut from the hydraulic motor shaft 4 Loosen but do not remove lock nut from the hydrau lic motor shaft Release parking brake Rev C Reelmaster 3100 D IMPORTANT Do not hit wheel hub wheel hub puller or wheel motor with a hammer during removal or installation Hammering may cause damage to the hydraulic wheel motor 5 Using hub puller see Special Tools loosen wheel hub from wheel motor 6 Remove lock nut hub and brake drum from motor shaft Locate and retrieve woodruff key 7 Remove cotter pin from the adjustment rod Sepa rate adjustment rod from the brake lever NOTE The brake lever backing plate retainin
262. nit properly 1 Adjust the bedknife parallel to the reel 2 Adjust the front roller 3 Level the rear roller 4 Set height of cut IMPORTANT Light contact is preferred at all times If light contact is not maintained bedknife and reel edges will not sufficiently self sharpen and dull cut ting edges will result after a period of operation If excessive contact is maintained bedknife and reel wear will be accelerated uneven wear can result and quality of cut may be adversely affected NOTE As the reel blades continue to run against the bedknife a slight burr will appear on the front cutting edge surface for the full length of the bedknife Running a file occasionally across the front edge to remove this burr will improved cutting quality After extended running a ridge will eventually develop at both ends of the bedknife These ridges must be rounded off or filed flush with cutting edge of bedknife to assure smooth operation Cutting Units Adjust Bedknife Parallel to Reel NOTE A 3 4 inch 19 mm wrench will be needed to ro tate the bedknife adjustment knob Fig 5 IMPORTANT Do not allow cutting unit to rest on the bedknife adjusting screw The setting of the bed knife will be changed 1 Remove any reel contact by turning the bedknife ad justment knob counterclockwise Fig 5 Tip cutting unit to gain access to the reel and bedknife Fig 6 2 On either end of the reel insert a long strip of dry ne
263. nits Page 7 30 Reelmaster 3100 D TORO Table of Contents SPECIFICATIONS wc sc yaaa eae 2 GENERAL INFORMATION 3 Cutting Unit Operator s 3 SPECIAL TOOLS 4 FACTORS THAT CAN AFFECT CUTTING PERFORMANCE 8 SET UP AND ADJUSTMENTS 11 5 lt 11 Reel Bearing Adjustment 12 Leveling Rear Roller 13 SERVICE AND REPAIRS 15 Hydraulic Reel Motor 15 Backlapping 16 Reelmaster 3100 D Page8 1 Chapter 8 DPA Cutting Units Bedbar Assembly 18 Bedbar Adjuster Service 20 Bedknife Replacement and Grinding 22 Reel Assembly Removal and Installation 24 Reel Assembly Removal 25 Reel Assembly Installation 25 Reel Assembly Service 28 Preparing Reel for Grinding 30 Front Roler nada tease TELS 32 33 Roller Service 34 Rear Roller Brush Optional 36 DPA Cutting Units Rev G c 5 amp N E Specifications Figure 1 Frame Construct
264. nst handle 3 Wipe excess grease away Figure 18 Grease every 8 operating hours Reelmaster 3100 D Page2 9 Product Records and Maintenance Preparation for Seasonal Storage Traction Unit 1 Clean traction unit cutting units and the engine thor oughly 2 Check tire pressure Inflate all tires to 14 to 18 psi 0 97 to 1 24 Bar 3 Check all fasteners for looseness tighten as neces sary 4 Lubricate all grease fittings and pivot points see Lu brication 5 Cover entire length of the Sidewinder Model 03201 cross tube with a light oil to prevent rust After storage wipe off all oil 6 Lightly sand and use touch up paint on painted areas that are scratched chipped or rusted Repair any dents in the metal body 7 Service battery and cables as follows A Remove battery terminals from the battery posts see Battery Service in Chapter 5 Electrical Sys tem B Clean battery terminals and posts with a wire brush and baking soda solution C Coat cable terminals and battery posts with Grafo 112X skin over grease Toro Part No 505 47 or pe troleum jelly to prevent corrosion D Every 30 days check battery electrolyte levels and fill battery as necessary see Battery Care in Chapter 5 Electrical System E Every 60 days recharge battery slowly for 24 hours to prevent sulfate from forming on the battery plates see manufacturer s instructions for battery charger Product Records an
265. o 2 general purpose lithium base grease Grease Fitting Locations and Quantities Each bedknife adjuster has 1 fitting Fig 15 Each reel bearing housing has 2 fittings Each front and rear roller has 2 fittings one on each end of the roller Fig 16 NOTE Lubricate only one reel bearing grease fitting on each end of cutting unit IMPORTANT Lubricate cutting units immediately Gon 50 hours after washing This helps purge water out of bear ings and increases bearing life 1 Wipe each grease fitting with a clean rag IMPORTANT Do not apply too much pressure or grease seals will be permanently damaged 2 Apply grease until pressure is felt against the handle 3 Wipe excess grease away Figure 16 Grease every 8 hours Reelmaster 3100 D Page 7 13 Cutting Units Backlapping TO AVOID PERSONAL INJ URY OR DEATH Never place hands or feet in reel area while the engine is running While backlapping reels may stall and then re start Do notattemptto restart reels by hand or foot Do notadjustreels while the engine is running Ifthe reel stalls stop engine before attempting to clear the reel Reel motors are connected in series moving one motor moves the other two Note Additional instructions and procedures on backlapping are available in the Toro General Service Training Book Reel Mower Basics part 09168501 1 Position machine on a clean level surface Lower cuttin
266. o 47 N m 22 Knob 23 Nut 24 O ring 25 Seal kit 26 Compression spring 27 Locating plate 28 Seal kit 29 O ring 30 O ring 31 O ring Reelmaster 3100 D 48 to 60 6 5 4 to 6 7 N m HYDRAULIC MANIFOLD USED ON MACHINES WITH SERIAL NUMBERS ABOVE 260000000 120 in Ib 13 5 N m 54 N m 90 in Ib 10 1 N m 17 220 in Ib 25 N m 198 __ 19 22 Figure 51 1 Manifold body 9 Plug Zero Leak 74 10 used 16 Ball switch N C 2 Plug Zero Leak 8 10 Spring pin 2 used 17 Plug Zero Leak 22 2 used 3 Rotary cartridge valve flow control 11 Plug SAE 44 18 Orifice 020 4 Rotary handle assembly 12 Mow backlap spool 19 Plug Zero Leak 6 5 Solenoid relief cartridge valve 13 Ball 20 Check valve 6 Nut 14 Dowel pin 21 Plug SAE 76 2 used 7 Solenoid coil 15 O ring 22 Orifice 073 8 Logic control cartridge NOTE The ports on the hydraulic manifold are marked for easy identification of components Example FC1 is the flow control valve and P1 is the gear pump connec tion port See Hydraulic Schematics to identify the func tion of the hydraulic lines and cartridge valves at each port location Reelmaster 3100 D 4 79 Rev NOTE The hydraulic manifold shown in Figure 51 uses several zero leak plugs These plugs have a tapered sealing surface on the plug head that is designed to re sist vib
267. o P arker Torq motors in the front positions For repair of Ross wheel motors see the Ross Torqmotor MG MF ME and MJ Series Service P rocedure atthe end ofthis chapter For repair of Parker wheel motors see the Parker Torqmo tor Service Procedure TC TB TE TJ TF TG TH and TL Series atthe end of this chapter Reelmaster 3100 D 2g 5 8 22 gt This page is intentionally blank Hydraulic System Rev C Reelmaster 3100 D Page 4 71 Reel Motors 30 to 40 ft Ib 16 4110 54 N m Hydraulic motor front Hydraulic motor rear Reel motor coupler Flange nut Hydraulic hose 90 hydraulic fitting Hydraulic hose Hydraulic System Rev Figure 45 Hydraulic straight fitting Hydraulic hose Hydraulic hose Hydraulic tee fitting Hydraulic hose Hydraulic straight fitting Hydraulic hose Page 4 72 30 to 40 ft lb 41 to 54 Hydraulic straight fitting O ring O ring O ring O ring O ring Reelmaster 3100 D Removal NOTE Note position of hydraulic fittings when remov ing from the reel motors Position is critical to properly reconnecting hydraulic hoses 1 Remove reel motor from the cutting unit see Reel Motor Removal and Installation in Chapter 7 Cutting Units 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 G
268. o valve Retest pressure set ting see Testing Reelmaster 3100 D Page 4 57 Hydraulic System Rev C Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components 1 Before removing any parts from the hydraulic sys tem park machine on a level surface engage parking brake lower cutting units or attachments and stop en gine Remove key from the ignition switch 2 Clean machine before disconnecting removing or disassembling any hydraulic components Make sure hydraulic components hoses connections and fittings are cleaned thoroughly Always keep in mind the need for cleanliness when working on hydraulic equipment Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hy draulic System Pressure in the General Infor mation section 3 Put caps or plugs on any hydraulic lines hydraulic fit tings and components left open or exposed to prevent contamination 4 Put labels on disconnected hydraulic lines and hoses for proper installation after repairs are completed 5 Note the position of hydraulic fittings especially el bow fittings on hydraulic components before removal Mark parts if necessary to make sure they will be aligned properly when reinstalling hydraulic hoses and tubes Hydraulic System Rev C Page 4 58 After Repair or Replacement of
269. o weather sun chemicals very warm storage condi tions or mishandling during operation or maintenance These conditions can cause damage or premature dete rioration Some hoses are more susceptible to these conditions than others Inspect the hoses frequently for signs of deterioration or damage When replacing a hydraulic hose be sure that the hose is straight not twisted before tightening the fittings This can be done by observing the imprint on the hose Use two wrenches hold the hose straight with one and tighten the hose swivel nut onto the fitting with the other Hydraulic Fitting Installation O Ring Face Seal 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Make sure the O ring is installed and properly seated in the groove It is recommended that the O ring be replaced any time the connection is opened 3 Lubricate the O ring with a light coating of oil 4 Put the tube and nut squarely into position on the face seal end of the fitting and tighten the nut until finger tight 5 Mark the nut and fitting body Hold the body with a wrench Use another wrench to tighten the nut to the cor rect flats from finger tight F F F T The markings on the nut and fitting body will verify that the connection has been tightened Size F F FT 4 1 4 in nominal hose or tubing 0 75 0 25 6 3 8 in 0 75 0 25 8 1 2 in 0 75 0 25 10 5 8 in 1 00 0 25
270. of the hose F With the engine off continue turning the steering wheel to the left counterclockwise with the steering cylinder fully extended Observe the open fitting on the steering cylinder as the wheel is turned If oil comes out of the fitting while turning the steering wheel to the left the steering cylinder has internal leakage and must be repaired or replaced G Remove plug from the hydraulic hose Recon nect hose to the steering cylinder fitting 6 If steering problem exists and steering cylinder tested acceptably steering control requires service see Steering Control Valve and Steering Control Valve Ser vice Hydraulic System Rev C 2g gt Adjustments Adjust Traction Drive for Neutral 1 Park the machine on a level surface and turn the en gine off One front wheel and rear wheel must be raised off the ground or the machine will move during adjustment Make sure machine is supported 50 it will not accidentally fall injuring anyone under machine 2 Raise one front wheel and rear wheel off floor and place support blocks under frame Figure 33 1 Adjustment cam 2 Locknut 3 Loosen locknut on traction adjustment cam Engine must be running so final adjustment of the traction adjustment cam can be performed To guard against possible personal injury keep hands feet face and other parts of the body away from the muffler other hot parts of the engine and other
271. oints Cutting Units Prepare Reel for Grinding Note Check to make sure reel bearings are in good condition and properly adjusted before grinding reel 1 Remove bedbar assembly see Bedbar Removal and Installation 2 Remove front roller and brackets see Roller Remov al and Installation Note Most reel grinders require that the rear roller as sembly be mounted to the cutting unit for proper support in the reel grinder The rear roller must be parallel to the reel shaft to remove taper when grinding or the cutting unit must be aligned so the grinding wheel will travel par allel to the reel shaft This will result in the the reel being ground to the desired cylinder shape Note When grinding be careful to not overheat the reel blades Remove small amounts of material with each pass of the grinder 3 Refer to Toro General Service Training Book Reel Mower Basics part no 09168SL for reel grinding infor mation 4 After completing grinding process A Install front roller and brackets see Roller Re moval and Installation B Install bedbar assembly see Bedbar Removal and Installation C Complete cutting unit set up and adjustment se quence see Adjustments section Reel Grinding Specifications Nominal Reel Diameter 7 inches 178 mm Service Limit 6 2 inches 158 mm Reel Diameter BLADE RELIEF ANGLE LLL LT REEL DIAMETER TAPER D Do Figure 29 Cutting Units
272. ol 18 When starting the engine A Engage parking brake B Be sure traction pedal is in neutral and reel drive is in disengage position C After engine starts release parking brake and keep foot off traction pedal Machine must not move If movement is evident the neutral control linkage is incorrectly adjusted therefore shut engine off and adjust until machine does not move when traction pedal is released see Adjust Transmission for Neu tral 19 Before backing up look to the rear and assure no one is behind the machine Watch out for traffic when near or crossing roads Always yield the right of way 20 Keep hands feet and clothing away from moving parts and the reel discharge area Grass baskets if so equipped must be in place during reel operation for maximum safety 21 This product may exceed noise levels of 85 dB A at the operator position Ear protectors are recommended for prolonged exposure to reduce the potential of per manent hearing damage 22 Raise the cutting units when driving from one work area to another 23 Do not touch engine muffler exhaust pipe or hydrau lic tank while engine is running or soon after it has stopped because these areas could be hot enough to cause burns Reelmaster 3100 D 24 a cutting unit strikes a solid object or vibrates ab normally stop immediately Turn engine off wait for all motion to stop and inspect for damage A damaged reel or bedknife must be repaired o
273. oller Brush in the Service and Repairs section ofthis chapter for informa tion on rear roller brush 16 If weight was removed from cutting unit install new O ring item 12 on weight Secure weight to cutting unit side plate with two 2 cap screws Torque screws from 27 to 33 ft Ib 37 to 44 N m 17 Lubricate cutting unit grease fittings until grease purges from relief valves in side plates Initial greasing may require several pumps of a hand grease gun 18 Install cutting unitto the machine Reelmaster 3100 D This page is intentionally blank D os 5 Reelmaster 3100 D Page 8 27 DPA Cutting Units Rev G Reel Assembly Service Loctite 242 5 d p 4 Loctite 242 85 to 95 ft lb 115 to 128 N m Right Hand Threads N 85 to 95 ft Ib P di 115 to 128 N m Left Hand Threads Figure 28 1 Cutting reel 5 Bearing 8 Groove indicating LH threads 2 Threaded insert RH thread 6 Threaded insert LH thread 9 Bearing shoulder 3 Retaining ring 7 Retaining ring groove 10 Reel spider 4 Grease seal DPA Cutting Units Rev G Page 8 28 Reelmaster 3100 D Inspection of Cutting Reel Fig 28 1 Inspect reel bearings to insure that they spin freely and have minimal axial play The bearing balls mustbe free of deformation and scoring 2 Inspectthe reelshaftas follows If reel damage is de tected replace reel A Checkthe reelshaftfor bending and distortion by placing the s
274. om Flywheel Compression Ratio 22 1 Injection Nozzles Mini Nozzle DNOPD Engine Oil 10W30 Detergent API CD CE CF CF 4 or CG 4 Oil Pump Trochoid Type Crankcase Oil Capacity liters U S qt 3 8 4 0 with Filter Starter 12 VDC 1 KW Alternator Regulator 12 VDC 40 AMP Dry Weight kilograms U S 165 93 0 205 0 Coolant Capacity liters U S qt 5 7 6 0 with 0 9 1 0 Reservoir Reelmaster 3100 D Page 3 3 Kubota Diesel Engine E gt 2 x General Information Check Engine Oil The engine is shipped with oil in the crankcase Howev er oil level must be checked before and after the engine is first started Crankcase holds about 4 0 qts 3 8 1 with filter IMPORTANT Check level of oil every 5 operating hours or daily Change oil after every 50 hours of op eration 1 Park machine on level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Remove dipstick and wipe it with a clean rag Push dipstick down into dipstick tube and make sure it is seated fully Pull dipstick out and check oil level If oil lev el is low add enough oil to raise level to the FULL mark on the dipstick 3 If oil level is low remove oil fill cap and gradually add small quantities of oil checking level frequently until the oil level reaches the FULL mark on the
275. om spring clip Pivot cooler out 5 Clean both sides of oil cooler and radiator area thor oughly with water or compressed air 6 Pivot oil cooler back and snap into position Install lower shield Close hood Kubota Diesel Engine Page 3 18 Figure 27 1 Oil cooler 3 Clip 2 Radiator 4 Lower shield Figure 28 1 Oil cooler 3 Clip 2 Radiator Reelmaster 3100 D E o Lo 2 3 This page is intentionally blank Reelmaster 3100 D Page 3 19 Kubota Diesel Engine Kubota engine Engine mount Engine mount Flange nut Cap screw Hex flange head screw External lock washer Lock nut Washer Machine screw Hardened washer Cap screw Engine mounting bracket front Engine mounting bracket LH oo o mk Removal Figure 29 Engine mounting bracket RH Cap screw Pulley Bolt Flange nut Not used Throttle amp filter support Throttle cable filter Lock nut Slotted hex head screw Throttle cable clamp Cap screw R clamp 28 29 30 31 32 33 34 35 36 37 38 39 40 Lock nut Lock washer Flat washer Flange head screw Flat washer R clamp Lock washer Hex nut Wire harness Hose clamp Radiator hose upper Radiator hose lower Spacer 4 Disconnect both battery cables at the battery see Battery Service in Chapter 5 Electrical system 1 Pa
276. on cut away of the wear plate is on the suction side of the pump 6 Dip drive gear and front idler gear into clean hydrau lic oil Install gear shafts into the front plate bushings so that the gears set inside the gear pockets 7 Install new O ring into the groove of the adapter plate on the side with the bushings below the surface 8 Align marker line on the body and adapter plate Install adapter plate onto the body and gear shafts 9 Install second new O ring to the other side of the adapter plate 10 Coat key lightly with petroleum jelly to hold it in place Install key into the slot in the drive gear shaft 11 Align marker line on back body and adapter plate Install body onto adapter plate and drive gear shaft Reelmaster 3100 D IMPORTANT Do not dislodge seals during installa tion 12 Install wear plate into the gear pocket of back body with the pressure seal and back up gasket against the adapter plate Make sure mid section cut away of the wear plate is on the suction side of the pump 13 Lubricate back gear with clean hydraulic oil Install gear onto the drive gear shaft and key 14 Lubricate back idler gear with clean hydraulic oil Install idler gear into the gear pocket of back body and the adapter plate Reelmaster 3100 D Page 4 113 15 Install new O ring into the groove of the back plate 16 Align marker line on the back plate and bogy Install back plate onto the body and gear shafts 17 Se
277. or 8 Port manifold 25 Stator 9 Spring 26 Drive plate 10 Drive assembly 27 Thrust bearing spacer 11 Alignment pin 28 Thrust bearing 12 Valve ring 29 Face seal 13 Valve plate 30 Not used 14 Spring 31 Seal spacer 15 Isolation manifold 32 Upper cover plate 16 Drive link 33 Input shaft 17 Metering ring 34 Retaining ring NOTE For repair of the steering control valve see the Ross Hydraguide Hydrostatic Steering System HGF Series Service Procedure at the end of this chapter Hydraulic System Rev C Page 4 106 35 36 37 38 39 40 41 Not used 43 44 45 46 47 48 49 50 51 Not used Retaining plate Upper cover amp jacket assembly Bushing Seal Special bolt Nut Not used Not used Not used Not used Not used Seal ring white Coil spring Not used Spacer Reelmaster 3100 D Steering Control Valve Service Serial Numbers 240000001 and 20 to 24 ft Ib 27 to 33 N m 2g 8 2a Figure 74 1 Sleeve 9 Dust seal ring 16 Outer gearwheel 2 Cross pin 10 Housing 17 End cover 3 Ring 11 Cardan shaft 18 O ring 5 used 4 Spool 12 Spacer 19 Screw fitting ports L R T 5 Bearing assembly 13 O ring 20 Screw fitting ports P and E 6 Shaft seal 14 Distribution plate 21 P port check ball 7T Ball stop 15 Inner gearwheel 22 Spring set 8 Ball NOTE For service of the steering control valve see the Sauer Danfoss Steering Unit Type OS
278. orated in this cutting unit simplifies the adjustment procedure needed to deliver optimum mowing perfor mance The precise adjustment possible with the single knob bedbar design gives the necessary control to pro vide a continual self sharpening action This feature maintains sharp cutting edges assures good quality of cut and greatly reduces the need for routine back lapping In addition the rear roller positioning system permits op timum bedknife attitude and location for varying height of cuts and turf conditions Daily Adjustments Prior to each day s mowing or as required each cutting unit must be checked to verify proper bedknife to reel contact This must be performed even though quali ty of cut is acceptable 1 Lower cutting units onto a hard level surface Shut off engine and remove key from ignition 2 Slowly rotate reel in the reverse direction while lis tening for reel to bedknife contact If no contact is evi dent turn bedknife adjusting knob clockwise one click at a time until light contact is felt and heard 3 If excessive contact is felt turn bedknife adjusting knob counterclockwise one click at a time until no con tact is evident Then turn bedknife adjusting knob one click at a time clockwise until light contact is felt and heard Reelmaster 3100 D Page7 7 If a cutting unit is expected to be out of adjustment use the following procedures in the specified order to adjust the cutting u
279. otor Efficiency Test Using Tester with Pressure Gauges and Flow Meter FRONT WHEEL MOTOR TESTING SHOWN TRACTION WHEEL Y MOTORS TOP PORT FORWARD 100 to 150 psi p met A sce Ls S lt 4 High Pressure Low Pressure Return or Suction Flow Figure 21 NOTE Over a period of time a wheel motor can wear internally A worn motor may by pass oil to its case drain causing the motor to be less efficient Eventually enough oil loss will cause the wheel motor to stall under heavy load conditions Continued operation with a worn inefficient motor can generate excessive heat cause damage to seals and other components in the hydraulic system and affect overall machine performance Hydraulic System Rev C Page 4 38 Reelmaster 3100 D Procedure for Wheel Motor Efficiency Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 2 Park machine on a level surface with the cutting units lowered and off Make sure engine is off and the parking brake is engaged 3 Read Precautions for Hydraulic Testing 4 Make sure that traction pedal is adjusted to the neu tral position see Adjust Traction Drive for Neutral in the Adjustments Section 5 Attach a heavy chain to the rear of the
280. page is intentionally blank Reelmaster 3100 D Page 4 83 Rev D Hydraulic System Rev C Control Valve Models 03200 03206 and 03170 Figure 55 1 Straight hydraulic fitting 8 Shoulder bolt 14 Hydraulic hose 2 90 hydraulic fitting 9 Valve lever assembly 15 Hydraulic hose 3 Hydraulic fitting 10 Link 2 used 16 Hydraulic tube 4 909 hydraulic fitting 11 Bolt 17 O ring 5 Control valve single spool 12 Lock nut 2 used 18 O ring 6 Carriage screw 2 used 13 Knob 19 O ring 7 Flange nut Hydraulic System Rev C Page 4 84 Rev F Reelmaster 3100 D Removal Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hy draulic System Pressure in the General Infor mation section 1 Remove control valve from the frame using Figures 54 and 55 as guides 2 If hydraulic fittings are to be removed from control valve mark fitting orientation to allow correct assembly Installation 1 If hydraulic fittings were removed install fittings to control valve using marks made during the removal pro cess to properly orientate fittings 2 Install control valve to the frame using Figures 54 and 55 as guides Figure 55 1 Spool Valve 2 Magnet support bracket Reelmaster 3100 D Page 4 85 3 Flange head screws 4 Frame Hydraulic System Rev C E E Control Valve Service Models
281. pe up any spilled diesel fuel before start ing the engine Store fuel in a clean safety ap proved container and keep cap in place Use die sel fuel for the engine only not for any other pose 3 Open air bleed screw on the fuel injection pump IMPORTANT The engine should normally start af ter the above bleeding procedures are followed However if the engine does not start air may be trapped between injection pump and injectors see Bleed Air from Fuel Injectors Bleed Air from Fuel Injectors IMPORTANT This procedure should be used only if the fuel system has been purged of air through nor mal priming procedures see Bleed Fuel System and engine will not start 1 Park machine on level surface lower cutting units stop engine and engage parking brake Because diesel fuel is highly flammable use cau tion when storing or handling it Do not smoke while filling the fuel tank Do not fill fuel tank while engine is running hot or when machine is in an enclosed area Always fill fuel tank outside and wipe up any spilled diesel fuel before start ing the engine Store fuel in a clean safety ap proved container and keep cap in place Use die sel fuel for the engine only not for any other pur pose 2 Loosen pipe connection to the No 1 injector nozzle and holder assembly Figure 13 1 Air bleed screw 2 Injection pump 4 Turn key in ignition switch to the ON position The electric fuel p
282. r 4 Place protective plastic cap see Special Tools into the hole in the cutting unit side plate to prevent debris entry into reel bearing area Installation Note Referto Figure 14 for correct placement of cut ting unit reel motors and weights 1 Coatspline shaft of the reel motor with No 2 multi purpose lithium base grease 2 Installthe cap screws forthe reel drive motor into the cutting unitside plate and leave approximately 1 2 inch 12 7 mm of threads exposed on each screw 3 Rotate the motor clockwise so the motor flanges clear cap screws in the cutting unit side plates Align reel motor shaft splines with cutting reel insert splines Slide motor shaft into reel insert 4 Rotate the motor counter clockwise until the motor flanges are encircling the cap screws Tighten two 2 cap screws to secure reel motor to cutting unit 1 2 FRONT TON Figure 14 1 Reel motor location 1 Hydraulic reel motor Reelmaster 3100 D Page 8 15 Figure 15 2 Weightlocation 2 screw DPA Cutting Units Rev G c 5 amp N D Backlapping TO AVOID PERSONAL INJ URY OR DEATH e Never place hands or feet in the reel area while the engine is running e When backlapping run engine at idle speed only e While backlapping the reels may stall and then restart e Do not attempt to restart reels by hand or foot e Do notadjust reels while the en
283. r following the manufactur er s instructions C Make sure battery terminals are free of corrosion Electrical Systems Rev C Page 5 44 D Measure the temperature of the center cell E Connect a battery load tester to the battery termi nals following the manufacturer s instructions Connect a digital multimeter to the battery terminals F Apply a test load of one half the Cranking Perfor mance see Battery Specifications rating of the bat tery for 15 seconds G Take a voltage reading at 15 seconds then re move the load H Using the table below determine the minimum voltage for the cell temperature reading Voltage Temperature 96 70 F and 21 19C and up 9 5 60 F 15 6 C 50 F 10 0 C 40 F 4 4 C ENS IE NN 12 29C 17 89C l If the test voltage is below the minimum replace the battery If the test voltage is at or above the mini mum return the battery to service sr Installation IMPORTANT To prevent possible electrical prob lems install only a fully charged battery 1 Make sure ignition and all accessories are off 2 Make sure battery compartment is clean and re painted if necessary 3 Make sure all battery cables and connections are in good condition and battery retainer has been repaired or replaced 4 Place battery in its compartment Make sure battery is level and flat Connect positive cable connector onto positive battery post Tighten cap screw
284. r from electrical outlet before con necting or disconnecting charger leads to or from battery posts 2 Keep top of battery clean by washing periodically with a brush dipped in ammonia or bicarbonate of soda solution Flush top surface with water after cleaning Do not remove the fill cap while cleaning Electrical Systems Rev C Page 5 42 4 Store battery in a cool atmosphere to avoid quick de terioration of the battery charge 5 To help prevent the battery from freezing make sure it is fully charged see Battery Service 3 Battery cables must be tight on terminals to provide good electrical contact Connecting cables to the wrong post could re sult in personal injury and or damage to the electrical system 4 If corrosion occurs at terminals disconnect cables Always disconnect negative cable first Scrape clamps and terminals separately Reconnect cables with positive cable first Coat terminals with petro leum jelly 5 Check electrolyte level every 25 operating hours and every 30 days if machine is in storage 6 Maintain cell level with distilled or demineralized wa ter Do not fill cells above the fill line Reelmaster 3100 D Battery Service The battery is the heart of the electrical system With regular and proper service battery life can be extend Additionally battery and electrical component failure can be prevented A CAUTION When working with batteries use extreme
285. r into a drain pan by slowly pumping the cylinder shaft Plug both ports and clean the outside of the cylinder IMPORTANT Prevent damage when clamping the hydraulic cylinder into a vise clamp on the clevis only 2 Mount lift cylinder in a vice Remove internal collar with a spanner wrench 3 Extract shaft head and piston by carefully twisting and pulling on the shaft IMPORTANT Do not clamp vise jaws against the shaft surface Protect shaft surface before mount ing in a vice 4 Mount shaft securely in a vise by clamping on the cle vis of the shaft Remove lock nut and piston from the shaft Slide head off the shaft 5 Remove Uni ring and O ring from the piston Re move C ring back up ring rod seal and dust seal from the head Reelmaster 3100 D Page 4 119 Assembly 1 Make sure all parts are clean before reassembly 2 Coat new O rings Uni rings rod seal back up ring and dust seal with with clean hydraulic oil A Install Uni ring and O ring to the piston B Install dust seal O ring back up ring and dust seal to the head IMPORTANT Do not clamp vise jaws against the shaft surface Protect shaft surface before mount ing in a vice 3 Mount shaft securely in a vise by clamping on the cle vis of the shaft A Coat shaft with with clean hydraulic oil B Slide head onto the onto the shaft Install rod seal onto shaft and into head C Install piston and nut onto the shaft Torque nut
286. r replaced before opera tion is continued 25 Before getting off the seat A Move traction pedal to neutral B Set the parking brake Maintenance and Service 27 Before servicing or making adjustments to the ma chine stop the engine and remove key from switch to prevent accidental starting of the engine 28 Check performance of all interlock switches daily Do not defeat interlock system It is for your protection 29 ensure entire machine is in good operating condi tion frequently check and keep all nuts bolts screws and hydraulic fittings tight 30 Make sure all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition be fore applying pressure to the system 31 Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Use paper or cardboard not hands to search for leaks Hydraulic fluid escaping under pressure can have suffi cient force to penetrate skin and do serious damage If fluid is injected into the skin it must be surgically re moved within a few hours by a doctor familiar with this form of injury or gangrene may result 32 Before disconnecting or performing any work on the hydraulic system all pressure in system must be re lieved by stopping engine and lowering cutting units to the ground Reelmaster 3100 D Page 1 3 C Disengage the cutting units and wait for the reels to stop spinning D Stop the engine
287. rame lower 34 Thread forming screw 7 Fan shroud bottom 21 Magnetic catch 35 Sleeve 8 Flange head screw 22 Oil cooler 36 Coolant hose reservoir 9 Hose clamp 23 Radiator hose upper 37 Hose 10 Radiator frame 24 Radiator hose lower 38 Lock nut 11 Not used 25 Hose clamp 39 Flange nut 12 Radiator seal 26 Hydraulic tube 40 Reservoir 13 Flange head screw 27 Hydraulic tube 41 Radiator cap 14 Reservoir bracket 28 Hydraulic hose Removal 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch Do not open radiator cap or drain coolant if the radiator or engine is hot Pressurized hot cool ant can escape and cause burns Ethylene gycol antifreeze is poisonous Dispose of coolant properly or store it in a properly labeled contain er away from children and pets 2 Open and remove engine hood from the machine Kubota Diesel Engine Page 3 16 Reelmaster 3100 D 3 Place a suitable container under the radiator to col lect the coolant Open drain cock valve and completely drain the radiator 4 Remove glow plug relay from the radiator assembly position relay away from the radiator Note Allow hydraulic components and hoses to drain into a suitable container Plug all hydraulic tubes hoses and openings to prevent contamination 5 Clean and disconnect the following connections A Hydraulic hose and clamp on the lower left co
288. ration induced plug loosening The zero leak plugs also have an O ring to provide a secondary seal If zero leak plug removal is necessary lightly rap the plug head using a punch and hammer before using an allen wrench to remove the plug the impact will allow plug removal with less chance of damage to the socket head ofthe plug When installing plugs into the manifold torque plugs to the values identified in Figure 51 Hydraulic System Rev C Hydraulic System Solenoid Operated Relief and Logic Control tridge Valves 1 Make sure the manifold is clean before removing the cartridge valve and seal kit Note On manifold shown in Figure 50 solenoid coil has an O ring on each side of the coil 2 If solenoid valve is to be removed from manifold re move nut securing solenoid to the cartridge valve Care fully slide solenoid and O rings if equipped off the valve IMPORTANT Use care when removing cartridge valves Slight bending or distortion ofthe stem tube can cause binding and malfunction Make sure that deep well socket fully engages the valve base 3 Remove cartridge valve from manifold with a deep well socket wrench Remove seal kit from valve 4 Visually inspectthe manifold port and cartridge valve for damage to sealing surfaces damaged threads and contamination A Contamination may cause valves to stick or hang up Contamination can become lodged in small valve orifices or seal areas causing val
289. re 27 1 Case drain left motor 2 Hydraulic T fitting 2 E gt Figure 28 1 Case drain rear motor 2 Hydraulic T fitting 13 If flow was greater than 0 7 GPM 2 6 LPM repair or replace the reel motor as necessary 14 Disconnect tester from motor and hose Reconnect hydraulic hoses 15 Repeat test with other motors as needed Reelmaster 3100 D Page 4 47 Hydraulic System Rev C Reel Motor Cross over Relief Pressures Test Using Pressure Gauge TO HYDRAULIC ag MANIFOLD PORT Dt 7 77 FROM HYDRAULIC MANIFOLD PORT M1 gt INITIAL REEL MOTOR RIGHT FRONT REEL MOTOR REEL MOTOR HYDRAULIC MANIFOLD PORT M2 BOTTOM High Pressure Low Pressure Return or Suction Flow Figure 29 NOTE One way to find a possibly bad reel motor is to have another person observe the machine while mow ing in dense turf A bad motor will run slower produce fewer clippings and may cause marcelling or a wash board appearance on the turf NOTE On machines with Serial Numbers below 230000000 the initial reel motor in the cutting circuit is the left front and the final reel motor drives the rear cut ting unit On machines with Serial Numbers above 230000000 the initial motor is the rear reel motor and the final reel motor is the left front Hydrau
290. re assuming that a hydraulic component is the source of the problem Precautions for Hydraulic Testing Failure to use gauges with recommended pres sure psi rating as listed in test procedures could result in damage to the gauge and possible personal injury from leaking hot oil 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 1 Clean machine thoroughly before disconnecting or disassembling any hydraulic components Always keep in mind the need for cleanliness when working on hy draulic equipment Contamination will cause excessive wear of components 2 Put metal caps or plugs on any hydraulic lines left open or exposed during testing or removal of compo nents Reelmaster 3100 D Page 4 29 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 Genera
291. rforming any work on the hydraulic system all pressure in the system must be relieved See Relieving Hy draulic System Pressure in the General Infor mation section 5 Connect test gauge with a hydraulic hose attached to the test port Make sure hose is long enough so the operator can read it while driving the machine Fig 17 6 Start engine and move throttle to full speed 2650 50 RPM 2 E gt Do not operate sidewinder while performing test The test gauge hose may get hit by the sidewind er carrier and rupture and cause personnel inju ry 7 Drive machine in the forward direction Observe test gauge A Pressure while transporting the machine over a flat level surface should be about 500 PSI B Pressure driving the machine up a steep hill should be about 2500 PSI but can reach relief set tings 3000 PSI C Pressure while mowing should range between 1000 to 2000 PSI and will vary with terrain 8 Release traction pedal and turn off machine 9 Disconnect test gauge and hose from the test port Fig 17 10 If specification is not met the hydrostat needs to be repaired or replaced as necessary Reelmaster 3100 D Page 4 31 Hydraulic System Rev C Piston Pump P3 Flow and Traction Relief Pressure Test Using Tester with Pressure Gauges and Flow Meter TRACTION WHEEL MOTORS Y TOP PORT FORWARD
292. river or small piece of pipe onto the end of the torsion spring of the idler pulley Be careful when removing or applying tension from or to the torsion spring of the idler pulley The spring is under heavy load and may cause personal injury 3 Push down and forward on the spring end to unhook the spring from the pump mounting plate 4 Remove V belt from the engine flywheel and hy drostat pulleys 5 Install new V belt onto the engine flywheel and hy drostat pulleys Kubota Diesel Engine 3 8 Figure 10 1 Drain plug Figure 11 1 Oil filter 2 Alternator Figure 12 4 V belt 5 Fly wheel pulley 6 Hydrostat pulley 1 Torsion spring 2 Idler pulley 3 Pump mounting plate 6 Insert nut driver or small piece of pipe onto the end of the torsion spring of the idler pulley 7 Push down and back on the spring end to get the spring under the pump mounting plate notch Then re lease on the spring slowly to lock it into place Reelmaster 3100 D Bleed Fuel System 1 Park machine on level surface lower cutting units stop engine and engage parking brake 2 Make sure fuel tank is at least half full Gain access to the engine Because diesel fuel is highly flammable use cau tion when storing or handling it Do not smoke while filling the fuel tank Do not fill fuel tank while engine is running hot or when machine is in an enclosed area Always fill fuel tank outside and wi
293. rk machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Open and remove engine hood from the machine Slide seat all the way forward 5 Remove muffler from the exhaust manifold and muf fler bracket see Muffler Removal 6 Drain radiator from the drain cock valve into a suit able container see Radiator Removal Disconnect coolant hoses from the water pump and engine block 3 Disconnect air hose from the air cleaner and radiator Remove air cleaner from the engine Kubota Diesel Engine 7 Remove reservoir and bracket from the top fan shroud Remove top fan shroud from the radiator see Radiator Removal Page 3 20 Reelmaster 3100 D 8 Disconnect wire harness and electrical wires from the following A Engine grounds to the battery and wire harness Fig 30 B Glow plug bus and fuel stop solenoid Fig 31 C High temperature warning switch Fig 32 D High temperature shutdown switch alternator and low oil pressure switch Fig 33 9 Disconnect throttle cable from the support and swiv el on the speed control lever Fig 30 10 Disconnect fuel hose from the water fuel separator Fig 30 and front injector nozzle Fig 31 11 Remove traction control cable from the neutral arm assembly on the piston pump Remove all hydraulic hoses from the piston an gear pumps see Piston Pump Removal in Chapter 4 Hydraul
294. rner of the radiator leading to the hydraulic manifold B Hydraulic tube from the oil cooler at the hydraulic oil filter head Do not lose O ring 6 Remove oil cooler from the radiator assembly using Figure 26 as a guide 7 Disconnect following hoses from the radiator A Upper radiator hose to the water pump B Lower radiator hose to the engine block C Coolant hose to the reservoir D Air hose to the air cleaner 8 Remove reservoir and bracket from the top fan shroud 9 Remove both fan shrouds from radiator assembly 10 Remove flange head screws securing the top and bottom of the radiator frame to the radiator Remove four carriage bolts and lock nuts securing the radiator to the radiator frame 11 Remove oil cooler from the radiator Pull radiator carefully from the radiator frame 12 Plug any openings to prevent contamination Reelmaster 3100 D Page 3 17 Installation 1 Remove any plugs from the oil cooler used during the removal procedures 2 Position radiator carefully to the radiator frame 3 Secure radiator assembly to the radiator frame with four carriage bolts and lock nuts Secure top and bottom of radiator to frame with flange head screws 4 Secure both fan shrouds to the radiator assembly with flange head screws Install oil cooler to the radiator 5 Secure reservoir bracket and reservoir to the top fan shroud with both flange head screws and flange nuts 6 Connect following hose
295. rns the motors in the mow direction The oil then returns into manifold block port M2 and then to the hydraulic tank Backlap Backlapping operation is the same as mowing opera tion except for the position of the backlap valve MD1 When the backlap valve is in the backlap position on machines with serial numbers below 230000000 oil flows through the rear right front and then left front reel motors Fig 8 as it turns the motors in the backlap direc tion On machines with serial numbers above 230000000 Fig 9 when the backlap valve is in the backlap posi tion oil flows through the left front right front and then rear reel motors Reelmaster 3100 D Page 4 13 Hydraulic System Rev C 3ATVA rad ONIH33IS H3MOd xnv z 3SVO IVNH3INI d
296. rom filter head or remove hydraulic filter and let hydraulic fluid flow into drain pan When hydraulic fluid stops draining connect the hy draulic hose or install new hydraulic filter 3 Fill hydraulic tank with approximately 3 5 gallons 13 2 liters of hydraulic fluid Refer to Check Hydraulic Fluid IMPORTANT Use only recommended hydraulic fluids to fill hydraulic tank Other fluids could cause system damage 4 Install hydraulic tank cap Start engine and use all hy draulic controls to distribute hydraulic fluid throughout the system Also check for leaks Then stop the engine 5 Check level of fluid and add enough to raise level to FULL mark on dipstick DO NOT OVER FILL Figure 35 1 Hydraulic hose 2 Filter head 2 cs gt Figure 36 1 Hydraulic oil filter 2 Rear wheel Figure 37 1 Hydraulic tank 2 Cap Reelmaster 3100 D Page 4 59 Hydraulic System Rev C Replace Hydraulic Oil Filter The hydraulic system filter must be changed initially af ter the first 10 hours of operation and thereafter every 200 hours of operation or yearly whichever comes first The hydraulic oil must be changed every 400 hours of operation or yearly whichever comes first Use a genuine Toro oil filter for replacement IMPORTANT Use of any other filter may void the warranty on some components 1 Position machine on a level surface lower the cut ting units stop the engine engage the parki
297. rom the roller assembly Roller Installation 1 Inspect flanged bushing and bushings for wear re place if necessary Note The flanged end of the flanged bushing must face inside toward the roller when the roller bracket is installed onto the cutting unit Note A soft hammer may be needed to tap the roller bracket into position on the hex adjustment nut of the roller 2 Insert smaller diameter roller shaft into the flanged bushing bushing and roller bracket Make sure hex of the roller bracket mates with the hex adjustment nut on the roller 3 Insert the other end of the roller shaft into the other bushing and roller bracket Make sure hex of the roller bracket mates with the hex adjustment nut on the roller 4 Hold one roller bracket stationary and use the other bracket as a wrench to loosen or tighten bearing clear ance The roller must not exceed 5 0 57 rol ling torque and have no bearing end play 5 Make sure roller brackets are aligned prior to instal ling them onto the cutting unit If necessary after bearing adjustment align roller brackets as follows A Remove roller bracket on the side with the flanged bushing B Replace roller bracket so it is aligned to within one hex flat of the roller adjustment nut C Align both roller brackets Reelmaster 3100 D Page 7 21 Figure 27 1 Height of cut pin 7 Front roller assembly 2 Hairpin cotter 8 Flanged bushing 3 Roller brac
298. rs 76 Hydraulic Manifold 71 Hydraulic Manifold Service 78 Control Valve Models 03200 03206 and 03170 84 Control Valve Service Models 03200 03206 and 03170 rr d Rud 86 Control Valve Models 03201 03207 and 03171 90 Control Valve Service Models 03201 03207 and 0317 ci ex deese ue CR e s ice eta 92 Piston P rmp sister LR bn 96 Piston Pump Service 100 Piston Pump Crush Ring Replacement 101 Sidewinder Models 03201 03207 and 03171 102 Steering Control Valve 104 Steering Control Valve Service Serial Numbers 90101 to 230999999 106 Steering Control Valve Service Serial Numbers 240000001 107 GearPump rt ke la 108 Gear Pump Service 110 Front Lift 114 Rear Lift Cylinder 116 Lift Cylinder Service 118 Steering Cylinder 120 Steering Cylinder Service 122 ROSS TORQMOTOR 7 MG MF ME AND MJ SE RIES SERVICE PROCEDURE PARKER TORQMOTOR SERVICE PROCEDURE TC TB TE TJ TF TG TH AND TL SERIES EATON MEDIUM DUTY PISTON PUMP REPAIR IN FORMATION MODEL 70160 VARIABLE DISPLACE MENT PISTON PUMP ROSS HYDRAGUIDE HYDROSTATIC STEERING SYSTEM HGF SERIES SERVICE PROCEDURE SAUER DANF
299. s if 8 aalay LS 628 L ttd 83110841802 MOS 105 INYO 1338 Sid 01083105 NAY Zd 340 0 7338 zd 0 0089 ANIONS MS 1735 MOW LYOdSNVUL Bld MS LIMIT dn 1338 Ld Page 4 22 1 Reelmaster 3100 D Hydraulic System Rev F This page is intentionally blank b EX Reelmaster 3100 D Page 4 22 2 Hydraulic System Rev F Special Tools Order special tools from your Toro Distributor Some tools may also be available from a local supplier Multimeter The meter can test electrical components and circuits for current resistance or voltage NOTE Toro recommends the use of a DIGITAL Volt Ohm Amp multimeter when testing electrical circuits The high impedance internal resistance of a digital me ter in the voltage mode will make sure that excess cur rent is not allowed through the meter This excess current can cause damage to circuits not designed to carry it Figure 1 Skin Over Grease Special non conductive grease Toro Part 505 165 which forms a light protective skin which helps waterproof electrical switches and contacts gt Figure 2 9 Reelmaster 3100 D Page 5 23 Electrical Systems Rev C Rev D Troubleshooting For effective troubleshooting and repairs you must have a good understanding of the electrical circuits and A CAUTION components used on this machine see Electri
300. s nents used when the brush drive is on the leftside ofthe Service Manual when servicing the rear roller brush cutting unit DPA Cutting Units Rev G Page 8 36 Reelmaster 3100 D Disassembly Fig 38 1 Position machine on a clean and level surface lower cutting units stop engine engage parking brake and re move key from the ignition switch 2 To remove roller brush from brush shaft A Remove the non driven brush bearing assembly item 30 from cutting unit B Slide excluder seal item 6 from roller brush shaft C Remove lock nutandJ boltfrom both ends of the brush Fig 39 D While rotating brush slide brush from the shaft Contact with the reel or other cutting unit parts can result in personal injury Use heavy gloves when handling the cutting reel 3 To remove roller brush drive belt rotate the cutting reel and carefully pry the belt off the drive pulley 4 Disassemble roller brush components as necessary using Figures 38 as a guide Assembly Fig 38 1 If brush was removed from shaft slide brush onto shaftwhile rotating brush Secure brush to shaftwith two 2 J bolts and lock nuts Make sure thatthe J bolts are installed with the threaded portion on the outside of the brush Fig 39 Torque lock nuts from 20 to 25 in Ib 2 3 to 2 8 N m 2 If seals or bearings were removed from brush bear ing housings install new components noting proper ori entation as shown in Figure 40 A
301. s are checked before proceeding with any hy draulic testing procedure 3 Drive machine slowly in a figure eight on a flat level surface A There should be no shaking or vibration in the steering wheel or rear wheel B Steering wheel movements should be followed immediately by a corresponding rear wheel move ment without the steering wheel continuing to turn 4 Stop unit with the engine running Turn steering wheel with small quick movements in both directions Let go of the steering wheel after each movement A The steering wheel must go back immediately to the neutral position B The steering wheel should not continue to turn 5 If either of these performance tests indicate a steer ing problem determine if the steering cylinder is faulty using the following procedure A Park machine on a level surface with the cutting units lowered and off Make sure engine is off and the parking brake is engaged Reelmaster 3100 D Page 4 55 B Turn the steering wheel all the way to the left counterclockwise so the steering cylinder rod is ful ly extended C Turn engine off D Read Precautions for Hydraulic Testing Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hy draulic System Pressure in the General Infor mation section E Remove hydraulic hose from the 909 fitting on the rod end of the steering cylinder Plug the end
302. s to the radiator A Upper radiator hose to the water pump B Lower radiator hose to the engine block C Coolant hose to the reservoir D Air hose to the air cleaner 7 Remove all plugs from hydraulic tubes hoses and openings used during the removal procedures A Install O ring to the fitting on the hydraulic oil filter head Connect hydraulic tube from the oil cooler to the filter head B Secure hydraulic hose leading to the hydraulic manifold with the clamp to the lower left corner of the radiator 8 Install oil cooler to the radiator assembly using Fig ure 26 as a guide 9 Secure glow plug relay to the radiator assembly with both thread forming screws 10 Make sure drain cock valve is closed Fill radiator with fluid see Check Cooling System 11 Install engine hood to the machine and close Kubota Diesel Engine e o E e gt 2 3 x Clean Radiator and Oil Cooler Fig 4 The radiator and oil cooler should be checked for dirt and debris daily and hourly if conditions are extremely dusty and dirty 1 Park machine on level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch If engine has been running the radiator may be hot and cause burns Work on radiator only when the engine and radiator are cool 2 Open engine hood 3 Clean engine area thoroughly of all dirt and debris 4 Remove lower shield Unsnap oil cooler fr
303. sconnect the component being tested from the circuit e g unplug the ignition switch connector before A CAUTION doing a continuity check When testing electrical components for continu NOTE For more component testing information see ity with a multimeter ohms setting make sure the Kubota Workshop Manual Diesel Engine 05 Se that power to the circuit has been disconnected ries Ignition Switch The ignition key switch has three positions OFF RUN and START The terminals are marked as shown The circuitry of the ignition switch is shown in the chart With the use of a multimeter ohms setting the switch func tions may be tested to determine whether continuity ex ists between the various terminals for each position Verify continuity between switch terminals SWITCH NORMAL OTHER POSITION CIRCUITS CIRCUITS START NONE Figure 4 1 Switch 3 Hex nut 2 Key 4 Lock washer Figure 5 Electrical Systems Rev C Page 5 30 Reelmaster 3100 D Glow Relay The glow relay is attached to the radiator assembly When energized the glow relay allows electrical current to the engine glow plugs Two styles of glow relays have been used on the Reel master 3100 D On machines with serial numbers be low 240000000 two of the four relay connections are secured with screws Fig 6 Machines with serial num bers above 240000000 are connected to the wire har ness with a four wire connector Fig 7
304. section of pump P1 is inefficient see Testing Reel motor has internal leakage or malfunctioning cross over relief valve see Testing Reel bearing s are damaged 2 E LE Engine speed is too low Charge gear pump is damaged Lift cylinder linkage is binding or broken Lift cylinder bushings are binding Reservoir oil level is low Charge pump pressure or flow is insufficient Implement relief valve 1000 PSI is stuck open Lift cylinders leak internally Steering control valve is defective Lift cylinders leak internally Check valve within the lift valve leaks See Ross Troubleshooting Guide in the Hydraguide Hydrostatic Steering System HGF Series Service Procedure at the end of this chapter Turning steering wheel turns ma Hoses to the steering cylinder are reversed chine in the opposite direction Reelmaster 3100 D Page 4 27 Hydraulic System Rev C This page is intentionally blank Hydraulic System Rev C Page 4 28 Reelmaster 3100 D Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks See the Special Tools section in this Chapter Before Performing Hydraulic Tests IMPORTANT obvious areas such as oil supply filter binding linkages loose fasteners or improper adjustments must be checked befo
305. st cutting unit see Cutting Unit Operator s Manual 11 Install cutting unitto machine Antiseize Lubricant 1 5 Position bedbar into cutting unit Make sure that Figure 20 1 Cutting unit sideplate 5 Metal washer top ofeach bedbararm is between washer item 11 and 2 R bherBushing 5 Bedbar adjuster screw flange item 10 3 Flange bushing 7 Bedbar pivot bolt 4 Plastic washer 8 Lock nut Reelmaster 3100 D Page 8 19 DPA Cutting Units Rev G 32 95 amp Bedbar Adjuster Service Loctite 242 14 to 16 ft Ib 15 to 20 ft Ib 19 to 21 N m 21 to 27 N m Antiseize Lubricant Figure 21 1 Bedbarassembly 5 Flange bushing 9 Locknut 2 Compression spring 6 Capscrew 10 Bedbar adjuster screw 3 Lock nut 7 Detent 11 Washer 4 Bedbar adjuster shaft 8 Wave washer 12 Flat washer NOTE The bedbaradjuster system for current produc tion DPA cutting units is shown in Figure 21 These cut ting units include a lock nut on the end of the bedbar adjuster shaft Early production cutting units Fig 22 used a retaining ring on the end ofthe bedbar adjuster shaft The service procedures for either style of adjuster shaft is very similar DPA Cutting Units Rev G Page 8 20 Reelmaster 3100 D Removal 1 Remove lock nut item 3 compression spring item 2 and washer item 11 from bedbar adjuster screw item
306. ston pump Plug openings of gear pump to prevent contamination 9 Remove hydraulic fittings and O rings from the pis ton pump 10 Remove taper lock bushing from the piston pump shaft 11 If hydraulic fittings are to be removed from pump mark fitting orientation to allow correct assembly LATER MODELS 1 Gear pump Hydraulic System Rev C Page 4 98 Figure 64 1 Extension spring 8 2 Cable support bracket 9 3 Pump lever 10 4 Traction control cable 11 5 Neutral bracket 12 6 Pump mount plate 13 7 Flange head screw 14 Figure 65 2 Suction port Flange nut Piston pump Flange head screw Flange nut Flat washer Cap screw Pump lever hub Reelmaster 3100 D Piston Pump Installation Fig 62 1 If hydraulic fittings were removed install fittings to pump using marks made during the removal process to properly orientate fittings 2 Place key into pump shaft slot Slide taper lock bush ing onto the piston pump shaft with bushing flange to ward pump housing 3 Make sure that tapered surfaces of pulley and taper lock bushing are thoroughly clean no oil grease dirt rust etc 4 Position pulley to taper lock bushing and align non threaded holes of pulley with threaded holes of bushing Loosely install three 3 cap screws with lock washers to bushing and pulley 5 Install O rings and hydraulic fittings to their original positions on
307. surface Protect shaft surface before mount ing in a vice 3 Mount shaft securely in a vise by clamping on the cle vis of the shaft A Coat shaft with a light coat of clean hydraulic oil B Slide head onto the onto the shaft Install piston and lock nut onto the shaft Torque nut from 24 to 30 ft lb 33 to 41 C Remove shaft from the vise IMPORTANT Prevent damage when clamping the hydraulic cylinder into a vise clamp on the clevis only 4 Mount clevis of the barrel in a vice 5 Coat all internal parts with a light coat of clean hy draulic oil Slide piston shaft and head assembly into the barrel being careful not to damage the seals 6 Secure head in the barrel with the retaining ring Hydraulic System Rev C 2g 5 8 gt This page is intentionally blank Hydraulic System Rev C Page 4 124 Reelmaster 3100 D TORO Chapter 5 Electrical System Table of Contents ELECTRICAL SCHEMATICS AND DIAGRAMS 2 ELECTRICAL SYSTEM QUICK CHECKS 28 Reelmaster 3100 D Electrical Schematic Battery Test Open Circuit 28 Serial Numbers 90101 to 90150 2 Charging System Test 28 Glow Circuits ie cis nce cone REDI 3 Glow Plug System Test 28 Crank Gircuils nete 4 Check Operation of Interlock Switches 29 Run Circuits Transport 5 COMPONENT TESTING 30 Run
308. t from the steering control valve Pull steering wheel from the control valve 4 Remove steering cover from the steering control valve bracket 5 Remove four lock nuts and flat washers securing the steering control valve to the steering control valve bracket 6 Remove both hex flange nuts cap screws and pivot hubs securing the steering control valve bracket to the steering arm Slide bracket from the steering control valve and steering arm 7 Remove and replace parts as necessary to repair steering column using Figure 11 as a guide Reelmaster 3100 D Page 6 13 Rev D Assembly 1 Make sure lever and friction discs are properly as sembled to the steering control valve bracket using Fig ure 11 as a guide 2 Position steering control bracket to the steering con trol valve and steering arm Secure bracket to the steer ing arm with pivot hubs cap screws and hex flange nuts 3 Secure steering control valve bracket to the steering control valve studs with four flat washers and lock nuts 4 Secure steering cover to the steering control valve bracket with cap screws 5 Install steering wheel to the steering control valve Secure steering wheel nut to the steering control valve Torque steering wheel nut from 20 to 26 ft lb 27 1 to 35 3 6 Secure steering wheel to the steering wheel with six philips pan head screws Wheels Brakes and Miscellaneous E a
309. t range desired See Rear Roller Adjustment in the Cutting Unit Operator s Manual Height of cut Effective or actual height of cut depends on the cutting unit weight and turf conditions Effective height of cut will be different from the bench set height of cut See Height of Cut Adjustment in the Cutting Unit Operator s Manual Proper bedknife selection for height of cut desired If the bedknife is incorrect for effective height of cut poor quality of cut will result See Cutting Unit Operator s Manual for bedknife options Stability of bedbar Make sure bedbar pivot bolts are seated securely Check condition of the bushings in the side plates See Bedbar Removal and Installation in the Service and Repairs section of this chapter Number of reel blades Use correct number of reel blades for clip frequency and optimum height of cut range Cutting unit alignment and carrier frame ground Check carrier frames and lift arms for damage binding following conditions or bushing wear Repair if necessary Reelmaster 3100 D Page 8 9 DPA Cutting Units Rev 32 5 amp Roller condition and roller type Make sure rollers rotate freely Repair roller bearings as necessary See Roller Service in the Service and Repairs section of this chapter Refer to Cutting Unit Operator s Manual for roller options Cutting unit accessories A variety of cutting unit accessories are available that can be used to enhance
310. t so that seals just touch bearing housings Page 8 38 Contact with the reel or other cutting unit parts can result in personal injury Use heavy gloves when handling the cutting reel G To install drive belt loop beltaround driven pulley andoverthe top ofthe idler pulley While rotating the cutting reel carefully guide belt onto drive pulley Af ter belt installation make sure that belt and pulley grooves are aligned and that belt is centered in idler pulley Fill cavity 50 to 75 full with grease o Figure 42 4 Grease seal 5 Retaining ring 6 Snap ring 1 Bearing housing 2 Drive shaft 3 Ball bearing Figure 43 1 Drive pulley 3 Idler pulley 2 Driven pulley 4 Drive belt Reelmaster 3100 D 5 Check alignment of pulleys with a straight edge placed along the outer face ofthe driven pulley Fig 44 The outer faces of the driven and drive pulleys not the idler pulley should be in line within 0 030 0 76 mm If necessary to align pulleys remove driven pulley from brush shaft and add or remove hardened washer s item 9 until drive and driven pulleys are aligned within 0 030 0 76 mm CHECK ALIGNMENT 6 Check that roller brush is parallel to rear roller with 0 060 1 5 mm clearance to light contact with roller Fig 45 If contact is incorre
311. ter Turn ignition switch to the ON posi tion the engine oil pressure light should come on indicating correct operation of the indicator light and cir cuit wiring High Temperature Warning Light If the engine coolant temperature reaches 2219F 1059C approximate the high temperature warning light should come on To test the high temperature warning light and circuit wir ing turn ignition switch to the ON position and ground the wire attached to high temperature sender located on the engine water pump housing see Temperature Sender in this Chapter The high temperature warning light should illuminate Glow Plug Indicator Light The glow plug light should come on when the ignition switch is placed in the ON position prior to placing the ignition switch in START The light should stay lit for approximately 6 seconds while the ignition switch is left in the ON position Testing Indicator Lights 1 Apply 12 VDC to terminals and 2 Fig 18 2 Ground terminals 1B and 2B Fig 18 3 Both indicator lights should illuminate Electrical Systems Rev C Page 5 36 Figure 17 3 High temp shutdown 4 Glow plug indicator 1 Charge indicator 2 Engine oil pressure Figure 18 1 Charge indicator 4 Glow plug indicator 2 Engine oil pressure 5 Indicator light front 3 High temperature 6 Indicator light back Reelmaster 3100 D Fuel Pump The fuel pump is attached
312. ter ensures that the oil flow to the cylinder is proportional to the amount of the turning on the steering wheel Fluid leaving the cylinder flows back through the spool valve then through the OUT port and to the hy drostat The steering control valve returns to the neutral position when turning is complete Hydraulic System Rev C 2g gt Special Tools Order these special tools from your Toro Distributor Hydraulic Pressure Test Kit Toro Part Number TORA7009 Use to take various pressure readings for diagnostic tests Quick disconnect fittings provided attach directly to mating fittings on machine test ports withouttools A high pressure hose is provided for remote readings Contains one each 1000 PSI 70 Bar 5000 PSI 350 Bar and 10000 PSI 700 Bar gauges Use gauges as recommended in Testing section of this chapter Hydraulic Tester Pressure and Flow Toro Part Number TOR214678 Use to test hydraulic circuits and components for flow and pressure capacities as recommended in the Testing section of this chapter This testerincludes the following 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 PRESSURE GAUGE Glycerine filled 0 to 5000 PSI gauge to provide operating circuit pressure 4 FLOW METER This meter measures actual oil f
313. ter frame 7 Flange head screw 3 Support tube 8 Rear grass shield 4 Sockethead screw 9 LH side plate 5 Flatwasher Reel Assembly Installation Fig 26 1 Thoroughly clean side plates and other cutting unit components Inspect side plates for wear or damage and replace if needed Note Check that grease seals on cutting reel shaft are flush to 0 060 1 5 mm away from retaining ring on reel shaft If necessary adjust position of grease seals to allow proper clearance 2 Make sure that grease seals and bearings are prop erly greased and positioned on cutting reel see Reel Assembly Service in this section Apply thin coat of grease to outside of grease seals and bearings on cut ting reel to ease reel installation Also apply grease to bearing bores and threads in side plates Contact with the reel bedknife or other cutting unit parts can result in personal injury Use heavy gloves when installing the cutting reel DPA Cutting Units Rev G DPA Cutting Units IMPORTANT During cutting reel installation keep inner and outer bearing races aligned If bearing races are not aligned binding will occur and reel installation may cause bearing damage Use reel bearing installation tool 7117 0975 to help with bearing alignment during reel installation 3 Using reel bearing installation tool see S pecialTools in this chapter to keep reel bearing aligned carefully slide the cutting reel with bearings and grease s
314. th both jam nuts Wheels Brakes and Miscellaneous S 2 pt 2 Brake Linkages Pop rivet Control panel cover Cover bracket Flange nut Hex flange head screw Magnet support Hex washer head screw Strike bracket Magnetic catch Flat washer Lock nut Cotter pin Bumper pad fme mom O ON Wheels Brakes and Miscellaneous 14 15 16 18 19 Slotted hex head screw 21 22 23 24 25 Figure 10 Hex socket flat head screw Parking brake link Clevis pin Clevis pin Lever Assembly Parking brake spacer Switch Switch Flat washer Lock nut Cap screw Page 6 10 Brake pivot shaft Clevis pin Flange bushing Brake pivot bracket Hex flange head screw Cotter pin Brake cam shaft Brake lever Retainer clip Adjustable clevis Jam nut Adjustment rod Reelmaster 3100 D 1 Park machine on level surface lower units stop engine engage parking brake and remove key from the ignition switch 2 Remove control panel cover from the machine IMPORTANT When removing the adjustable clevis from either the brake pivot shaft or adjustment rod or the brake lever from the cam shaft on the brake assembly make sure to matchmark both parts Marking both parts will make reassembly and brake adjustment easier Reelmaster 3100 D Page 6 11 3 Remove and replace parts as necessary to repair brake link
315. th hex flange head screws 4 Fill fuel tank see Fill Fuel Tank Replace Fuel Prefilter Fig 25 Replace fuel prefilter after every 400 operating hours or yearly whichever occurs first The prefilter is located on the inside of the frame just below the water fuel separa tor 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Remove cap screw securing the prefilter to frame 3 Clamp both fuel hoses to the prefilter to prevent fuel spillage 4 Loosen hose clamps at each end of the prefilter Pull fuel hoses from the filter Reelmaster 3100 D Page 3 15 Figure 23 3 Hex flange head screw 4 Electrical harness 1 Seat support strap 2 Seat Figure 24 1 Fuel hose strap 3 Fuel tank 2 Fuel hoses Figure 25 1 Cap screw 2 Prefilter 3 Hose clamp 4 Fuel hose 5 Secure new filter to fuel hoses with hose clamps Make sure arrow on the side of the prefilter points to wards the injection pump Kubota Diesel Engine E e 2 E x o D Radiator Figure 26 1 Drain cock valve 15 Clip spring 29 Barb fitting 2 Flange head screw 16 Philips pan head screw 30 Hose clamp 3 Flange nut 17 Pop rivet 31 Cable tie 4 Carriage bolt 18 Lock nut 32 Grommet 5 Radiator 19 Lanyard 33 Glow plug relay 6 Fan shroud top 20 Screen f
316. the left Model 03201 only Rear cutting unit 2 T hoses must not contact the traction cable bracket Figure 18 If required reposition fittings and hoses Reelmaster 3100 D Page 7 15 Cutting Units Reel Motor Removal and Installation Figure 22 1 Reel 15 Side plate LH 29 Reel coupler RH 2 screw 16 Washer 30 Spider coupler 3 Notused 17 Spacer 31 Not used 4 screw 18 Link 32 Not used 5 Lock washer 19 Bushing 33 Cover gasket 6 Side plate RH 20 Cap screw 34 O ring 7 Roll pin 21 Cap screw 35 Shipping plug 8 Lock nut 22 Cap screw 36 Weight 3 5 Ibs 9 Hex nut 23 Not used 37 Weight 2 0 Ibs 10 Waring decal 24 Reel coupler LH 38 Rubber side cover 11 Front grass guard 25 Grease fitting 39 Rubber center cover 12 Frame assembly 26 Hex flange head screw 40 Rivet 13 Rear grass guard 27 Bearing housing 41 Hydraulic motor 14 Flange nut 28 Bearing Removal Installation 1 Remove two capscrews holding the hydraulic motor to the bearing housing 2 Remove hydraulic motor and spider coupling from the bearing housing Position hydraulic motor away from the cutting unit prior to removing or working on the cutting unit Inspection 1 Inspect spider coupling for wear Replace worn cou pling with new one 2 Check coupling inside bearing housing If coupling is loose remove and check for worn threads Replace cou pling if threads are worn Reinstall coupling see Reel Removal and
317. the tester flow control valve is fully open 6 Make sure backlap knob on the hydraulic manifold is in the mow position and reel speed is set to maximum 7 Disconnect hose from case drain at the bulkhead fitting Fig 26 Fig 27 and 28 Plug the T fitting Put case drain hose into suitable container for collecting case drain leakage 8 One person should sit on the seat and operate the machine while another person reads the tester and measures case drain leakage Make sure traction pedal is in NEUTRAL Start engine and move the throttle to full speed 2650 50 RPM M CAUTION Keep away from reels during test to prevent per sonal injury from the rotating reel blades 9 Engage reels by positioning the cutting unit drive switch to the ENGAGE position While watching pres sure gauges slowly close flow control valve until a pres sure of 1200 PSI is obtained 10 Collect hydraulic fluid for 15 seconds by putting the case drain hose into a 1 quart container graduated in ounces 1 liter container graduated in milliliters 11 Stop cutting units by positioning the cutting unit drive switch to the DISENGAGE position Stop engine 12 Measure amount of oil collected in the container Di vide number of ounces collected by 32 to get gallons per minute Divide number of milliliters collected by 250 to get liters per minute iw Iam md 1 Figure 26 1 Case drain right motor 2 Hydraulic T fitting Figu
318. ting and repair of the diesel engine used in the Reelmaster 3100 D Most repairs and adjustments require tools which are commonly available in many service shops Special tools are described in the Kubota Workshop Manual Diesel Engine 05 Series The use of some specialized test equipment is explained However the cost of the Kubota Diesel Engine Page 3 2 test equipment and the specialized nature of some re pairs may dictate that the work be done at an engine re pair facility Service and repair parts for Kubota engines are sup plied through your Authorized Toro Distributor If no parts list is available be sure to provide your distributor with the Toro model and serial number Reelmaster 3100 D Specifications Item Description Make Designation Kubota 4 3 Cylinder Water Cooled Diesel Engine Horse Power 21 5 HP 2500 RPM Bore in 78 0 3 07 Stroke mm in 78 4 3 09 Total Displacement cc cu in 1123 68 53 Torque N m ft lb 67 3 49 6 2000 RPM Firing Order 1 2 3 Combustion Chamber Spherical Type Fuel No 2 Diesel Fuel ASTM D975 Fuel Capacity liters gallons 28 4 7 5 Fuel Injection Pump Bosch MD Type Mini Pump Governor Centrifugal Mechanical Low Idle no load 1400 50 RPM High Idle no load 2650 50 RPM Direction of Rotation Counterclockwise Viewed fr
319. ting reel bear ings periodically check reel bearing adjustment Check Reel Bearing Adjustment 1 Remove hydraulic reel motor from cutting unit see Hydraulic Reel Motor R emoval in the Service and Re pairs section of this chapter 2 Loosen bedknife to reel adjustment until no contact exists see Cutting Unit Operator s Manual Contact with the reel bedknife or other cutting unit parts can result in personal injury Use heavy gloves when handling the cutting reel 3 Hold on to the reel shaftand try to move the reel as sembly side to side If reel end play exists side to side movement will be detected 4 Using suitable torque wrench and spline inserttool see Special Tools measure the rolling resistance of the cutting reel Cutting reelrolling torque should notex ceed 10 in Ib 1 1 N m 5 Ifreelhas end play orifrolling torque is incorrect per form reel bearing adjustment see below 6 Afterchecking or adjusting reel bearings adjust cut ting unit see Cutting Unit Operator s Manual 7 Install hydraulic reel motor to cutting unit see Hy draulic Reel Motor Installation in the Service and Re pairs section of this chapter Reel Bearing Adjustment Fig 11 1 Make sure that no contact exists between bedknife and reel 2 Remove cutting unitcomponents on LH side plate to allow access to bearing adjuster nut If cutting unit is equipped with a rear roller brush refer to Rear Roller Brush Optiona
320. tion The traction pump uses a small amount of hydraulic fluid for internal lubrication Fluid is designed to leak across pump parts into the case drain This leakage results in Reelmaster 3100 D Page 4 11 the loss of hydraulic fluid from the closed loop circuit that must be replenished The charge pump P2 is a fixed displacement gear pump It is driven directly off the traction pump The pump replenishes the closed loop circuit with fluid from the hydraulic tank The charge relief valve supplies suffi cient head so that charge pump flow is guided to the low pressure side of the traction circuit through one of two check valves Pump flow in excess of replenishment re quirements is relieved through the charge relief valve back to the gear pump inlet Reverse The traction circuit operates essentially the same in re verse as it does in forward However there are a few dif ferences in operation When the reverse traction pedal is depressed the cable from the pedal positions the swash plate in the traction pump so oil flows out of the upper port Oil flow out of the upper port goes to the wheel motors and turns them in the reverse direction Oil flowing out of the wheel motors returns to the lower port of the hydrostat and is continu ously pumped out of the upper port by passes the rear motor in reverse because of the check valve inside the rear motor Hydraulic System Rev C 2g Ez gt
321. to the frame just outboard of the fuel injection pump Operational Test 1 Park machine on a level surface lower cutting units stop engine and engage parking brake 2 Disconnect electrical connector from the fuel stop solenoid to prevent the engine from firing 3 Disconnectfuel hose pump discharge from the fuel filter 4 Make sure fuel hoses attached to the fuel pump are free of obstructions 5 Placefuel hose pump discharge into a large grad uated cylinder sufficient enough to collect 1 liter 33 8 fluid ounces IMPORTANT When testing the fuel pump DO NOT turn ignition switch to START Note Machines that are equipped with a Biodiesel Conversion Kit will have the same fuel pump as ma chines with serial numbers above 280000000 6 Collectfuel in the graduated cylinder by turning igni tion switch to the RUN position Allow pump to run for time listed below then return switch to OFF A For machines with serial numbers below 230999999 the amount of fuel collected in the grad uated cylinder should be approximately 6 8 fl oz 200 ml after thirty 30 seconds B For machines with serial numbers from 240000000 to 270999999 the amount of fuel col lected in the graduated cylinder should be approxi mately 11 8 fl oz 350 ml afterthirty 30 seconds C machines with serial numbers above 280000000 the amount of fuel collected in the grad uated cylinder should be approximately 16 fl oz 475 ml a
322. troller Checks 1 Make sure there is power from the battery 2 Disconnect electrical connector to the run solenoid to prevent the engine from starting 3 Place ignition switch in the RUN position Verify the following while in the RUN position A Glow indicator lamp is on B Glow relay is energized C Glow plugs are energized D Glow indicator lamp goes out and glow plugs deenergize after 10 seconds Note On units with serial numbers from 90101 to 90150 the glow controller is not in use when the ignition switch is turned to start Note If there is no power to terminal 1 of the glow con troller verify continuity of the circuitry from the ignition switch to the controller and perform step 4 again see Electrical Schematics and Diagrams in this chapter Electrical Systems Rev C Page 5 40 A 0 WADE IN JAPAN NGK DEL 16 701 ICE SPARL PLIS CO LTO i Figure 24 1 Glow controller end view 3 Side view 2 Top view 4 Place ignition switch in the START position Verify the following while in the START position A Glow indicator lamp is out B Glow relay is energized C Glow plugs are energized D Power to terminal 1 of the glow controller 5 If any of the conditions in step are not met or power to terminal 1 exists and any of the other conditions in step 4 are not met A Verify continuity of the circuitry from the battery to the glow rela
323. ttle to full speed 2650 50 RPM A CAUTION Keep away from reels during test to prevent per sonal injury from the rotating reel blades Do not allow system pressure to exceed 1800 PSI Shut off unit to prevent an over pressure condition Hydraulic System Rev C Page 4 50 14 Engage cutting units System pressure should be from 1350 to 1650 PSI as the relief valve lifts 15 Disengage cutting units and stop engine If specifica tions are not met the cross over relief needs replacing Remove block of wood from cutting unit and repeat test on other reels in the same direction of flow 16 Remove test gauge and reconnect hose to motor Adjust bedknife to reel on all cutting units see Adjust ment section of Chapter 7 Cutting Units Reelmaster 3100 D 2g 5 8 22 gt This page is intentionally blank Hydraulic System Rev C Reelmaster 3100 D Page 4 51 Lift and Steering Control Valve Relief Pressure Test Using Pressure Gauge TO HYDRAULIC MANIFOLD ST PORT ____ TO LIFT VALVE IN PORT POWER STEERING STEERING I 1000 psi TO HYDRAULIC MANIFOLD LEFT TURN SHOWN GEAR PUMP ENGINE STRAINER PNE NN High Pressure T Low Pressure FROM HYDROSTAT INTERNAL CASE DRAIN Return or Suction Flow Hydraulic System Rev C Page 4 52 Reelmaster 3
324. uge Bar Assembly Use gauge bar to verify height of cut Toro Part No 13 8199 Gauge Bar Figure 2 Handle Assembly TOR299100 For applying lapping compound to cutting units while keeping hands a safe distance from the rotating reel Figure 3 Reelmaster 3100 D Page7 3 Rev E Cutting Units Bedknife Screw Tool TOR510880 This screwdriver type bit is made to fit Toro bedknife at taching screws Use this bit with a torque wrench to se cure the bedknife to the bedbar IMPORTANT Do not use and air or manual impact 52 Figure 4 Cutting Units Page 7 4 Reelmaster 3100 D Troubleshooting There are a number of factors that can contribute to un satisfactory quality of cut some of which may be turf conditions Turf conditions such as excessive thatch sponginess or attempting to cut off too much grass height may not always be overcome by adjusting the machine It is important to remember that the lower the height of cut the more critical these factors are Remember that the effective or actual height of cut de pends on cutting unit weight and turf conditions Effec tive height of cut will be different than the bench set height of cut Factors That Can Affect Quality of Cut 1 Engine maximum governed speed 2 Reel speed and ground speed 3 Tire pressure 4 Reel bearing condition 5 Reel and bedknife sharpness Reelmaster 3100 D Page7 5 Check maximum governed engine speed Ad
325. ump will begin operation and force air out around the air bleed screw Leave key in the ON position until a solid stream of fuel flows out around the air bleed screw Tighten screw and turn key to OFF e o E 2 E x Figure 14 1 No 1 injector nozzle hose 2 No 2 injector behind 3 No injector nozzle 3 Move throttle to FAST position 4 Turn ignition switch to START and watch fuel flow around connector Turn key to OFF when solid flow is observed Tighten pipe connector securely to the injec tor nozzle 5 Repeat steps on the remaining injector nozzles Reelmaster 3100 D Page3 9 Kubota Diesel Engine Muffler and Air Cleaner Figure 15 1 Air inlet hose upper 9 Air cleaner body 17 Plug 2 Airinlet hose lower 10 Not used 18 Filter cover 3 Flange nut 11 Hex nut 19 Burp valve 4 Flange head screw 12 Lock washer 20 Filter element inside 9 amp 18 5 Flat washer 13 Mounting band assembly 21 Lock nut 6 screw 14 Muffler 22 Compression spring 7 Air filter bracket 15 Muffler bracket 23 Bolt 8 Hose clamp 16 Not used 24 Gasket Kubota Diesel Engine Page 3 10 Reelmaster 3100 D Muffler Removal The muffler and exhaust pipe may be hot To avoid possible burns allow the engine and ex haust system to cool before working on the muf fler 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition
326. ure 14 Reelmaster 3100 D Page 4 23 Rev E Hydraulic System Rev C Wheel Hub Puller Toro Part Number 4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors High Flow Hydraulic Filter Kit Part Number TOR6011 The high flow hydraulic filter kit is designed with large flow 40 GPM 150 LPM and high pressure 5000 PS1 345 bar capabilities This kit provides for bi direc tional filtration which prevents filtered debris from being allowed back into the circuitregardless offlow direction If a componentfailure occurs in the closed loop traction circuit contamination from the failed part will remain in the circuit until removed When connecting hydraulic test gauges in order to test traction circuit components orafterreplacing a failed traction circuit component e g hydrostat or wheel motor the high flow hydraulic filter can be installed in the traction circuit The filter will en sure that contaminates are removed from the closed loop and thus do notcause additional componentdam age NOTE This kit does not include hydraulic hoses see Hydraulic Hose Kit TOR 6007 above Hydraulic Hose Kit Toro Part Number TOR6007 This kit includes hydraulic fittings and hoses needed to connect high flow hydraulic filter kit TOR 6011 to ma chine hydraulic traction system components Hydraulic System Rev C Page4 24 Figure 15 Figure 16 NOTE Replace
327. ure front and rear rollers to LH side plate see Front Roller Installation and Rear Roller Installation in this section DPA Cutting Units Rev G Page 8 26 IMPORTANT Over tightening reel bearing adjuster nut may damage reel bearings 11 Make sure thatsetscrew item 21 is loose in LH side plate to allow bearing adjuster nut movement With the cutting unit and reel in a horizontal position torque the bearing adjuster nut item 20 25 in Ib 2 8 N m to re move cutting reel end play 12 Loosen the bearing adjuster nut Then torque bear ing adjuster nut from 15 to 17 in Ib 1 7 to 1 9 N m Aftertorquing nut check thatreel rolling torque does not exceed 10 in Ib 1 1 N m 13 Apply Loctite 242 or equivalent to threads of set screw and secure bearing adjuster nutin place with set screw Torque set screw from 12 to 15 1 4 to 1 7 N m 14 Adjust cutting unit see Cutting Unit Operator s Manual Note The parallel position ofthe rear roller to cut ting reel is controlled by the precision machined frame and side plates ofthe cutting unit If necessary the cut ting unitside plates can be loosened and a slight adjust ment can be made to parallel the rear roller with the cutting reel see Leveling Rear Roller in the Set Up and Adjustments section of this Chapter 15 If cutting unit is equipped with optional rear roller brush install components for those options to left hand side plate of cutting unit See Rear R
328. uter 1 Roller tube 4 Washer sealmaking sure to notcrush the installed outer seal 2 Inner seal 5 Bearing outer seal tool Again make sure that bearing still freely rotates 2 Beanng DPA Cutting Units Rev G Page 8 34 Reelmaster 3100 D 3 From the roller tube end with only the inner seal installed carefully install the roller shaft into the roller tube Make sure that seals not damaged as shaft is installed 4 Install new bearing and outer seals into second end of roller tube A Position a second new bearing to roller shaft and tube Position washer see Special Tools on bearing to allow pressing on both inner and outer bearing races simultaneously B Use washer and bearing outer seal tool see Special Tools with a soft face hammer to fully seat bearing Fig 36 After bearing installation make sure that shaft freely rotates and that no binding is detected If necessary lightly tap bearing and or shaft ends to align shaft and bearings Remove washer from roller C Apply a small amount of grease around the lip of both outer seals D Carefully install first outer seal into roller tube making sure that seal lip and garter spring faces end oftube Use bearing outer sealtool see S pecial Tools and softface hammerto lightly seatseal F ig 37 Make sure that shaft and bearings still freely ro tate after seal installation E Using the same process install second outer sealmaking sure to notcrush the installe
329. valent to the valve stem threads Screw knob all the way down until it contacts the upper jam nut l On 2 position directional cartridge valve car tridge turn knob counterclockwise so the arrow is 90 with the back of the manifold Simultaneously tighten upper jam nut and turn knob so it is tight and the arrow is pointing 45 to the right in line with the indicator plate J On flow control valve cartridge turn knob coun terclockwise until the arrow points at the number 5 Simultaneously tighten upper jam nut and turn knob so it is tight and the arrow is pointing at the number 1 on the locating plate Figure 52 Handle Base 7 SetScrew 2 used Handle Cap 8 Screw Detent Pin 9 Lip Seal Compression Spring 10 Sleeve Bearing Bushing 11 Flow Control Valve Set Screw 2 used Hydraulic System Rev C wo 52 gt 8 Install rotary handle Fig 52 manifold shown in Fig 51 A Place handle base on flow control valve and posi tion alignment mark on base with number 1 on man ifold Secure base with two 2 set screws Apply a light coating of grease to chamfer on top of base to ease seal installation B Make sure that sleeve bearing is in handle cap If necessary press sleeve bearing into cap Install lip seal on cap with seal lip facing down C Place bushing onto cartridge valve stem Use a small amount of grease to keep bushing toward the top of the valve stem D Place
330. ve a 1 inch 1 16 25 4 mm 1 6 dimension be tween both height of cut supports and each front roller bracket at each end of the cutting unit 4 For the rear roller adjust support cap screw to achieve 5 8 inch 1 16 15 9 mm 1 6 dimension be tween both height of cut supports and each rear roller bracket at each end of the cutting unit 5 For the rear roller remove hairpin cotters securing rear height of cut pins Reinstall height of cut pins in the 1 2 inch setting as indicated on the rear height of cut plate 6 For the front roller remove hairpin cotters securing front height of cut pins Reinstall height of cut pins the 1 4 inch setting as indicated on the front height of cut plate to allow for clearance between the front roller and table 7 Position a 1 2 inch or thicker bar under the reel blades and against the front face of the bedknife Make sure the bar covers the full length of reel blades 8 Verify that the rear roller is level by attempting to in Sert a piece of paper under each end of the roller The paper should not fit between the roller and table Reelmaster 3100 D Page7 9 Nut 5 Support capscrew Rear roller bracket 6 Height of cut support Front roller bracket 7 Height of cut pins Angle bracket 8 Height of cut plate BON 9 Level rear roller by adjusting the appropriate support cap screw on the rear roller supports until the roller is parallel and the entire length of roller conta
331. ve all nicks and burrs from all parts with an emery cloth M CAUTION Use eye protection such as goggles when using compressed air 2 Clean all parts with solvent Dry all parts with com pressed air 3 Inspect gear drive gear and idler gears for the fol lowing A Drive gear shaft spline should be free of twisted or broken teeth B Gear shafts should be free of rough surfaces and excessive wear at bushing points and sealing areas C Gear shaft diameter in the bushing area should not be less than 0 748 inch 19 0 mm Hydraulic System Rev C 2 E gt D Gears should be free of excessive scoring and wear E Make sure drive and idler gears have their snap rings in the grooves on each side F Break sharp edges of gear teeth with emery cloth G Gear width on the drive gear and front idler gear should not be less than 0 384 inch 9 75 mm Gear width on the back gear and back idler gear should not be less than 0 244 inch 6 20 mm 4 Inspect body for the following A Gear pockets should be free of excessive scoring and wear B Inside diameter of gear pockets should not ex ceed 1 719 inches 43 7mm 5 Inspect front plate back plate and adapter plate as follows A Inside diameter of all bushings should not exceed 0 755 inch 19 2 mm B Bushings in the front plate should extend 0 126 inch 3 20 mm from the plate surface C Bushings on the wear plate side of
332. ve 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 A CAUTION Use eye protection such as goggles when using compressed air 5 Cleaning cartridge valves A For non solenoid operated valves Submerge valve in clean mineral spirits to flush out contamination If valve design allows use a probe to push the internal spool in and out 20 to 30 times to flush out contamination Particles as fine as talcum powder can affect the operation of high pressure hy draulic valves Clean and dry cartridge with com pressed air B For solenoid operated valves Temporarily install solenoid on cartridge valve and connect a 12 volt power source to the solenoid While energized flush out any contamination with a non flammable aerosol brake cleaner De energize the solenoid Repeat the flush while energized proce dure 5 or 6 times Particles as fine as talcum powder can affect the operation of high pressure hydraulic valves Remove solenoid from cartridge Hydraulic System Rev C 4 80 Rev 6 Reinstall the cartridge valve into the manifold A Lubricate new O rings and backup rings of seal kit with clean hydraulic oil and install on cartridge The O rings and backup rings must be arranged properly on the cartridge valve for proper operation and sealing IMPORTANT Use care when installing cartridge valves Slight bending or
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334. wspaper between the reel and bedknife While slowly rotating reel into the bedknife turn bedknife adjusting knob clockwise one click at a time until the paper is pinched lightly The pinching should result in a slight drag when the paper is pulled 3 Check for light contact at the other end of reel using newspaper as in step 2 If light contact is not evident proceed to the next step 4 Remove counter weights and gasket from the end of the cutting unit 5 Loosen both carriage bolts on the bedbar adjuster Fig 7 6 Adjust nuts to move bedbar adjuster up or down until paper is pinched along entire bedknife surface when bedknife adjustment knob is adjusted to no more than two clicks beyond first contact of reel bedknife Fig 7 7 Tighten nuts and carriage bolts and verify adjust ment 8 Reinstall counter weights to the same ends of the cutting units that they were removed from Figure 5 1 Bedknife adjusting screw Figure 7 1 Carriage bolts 3 Adjustment nuts 2 Bedbar adjuster Cutting Units Page 7 8 Reelmaster 3100 D Set Height of Cut and Level Both Rollers Note Both floating and fixed cutting units can use this method for making height of cut adjustments and lev eling both front and back rollers 1 Position cutting unit on a flat level table or board 2 Loosen nut slightly that secures each roller bracket to the angle bracket 3 For the front roller adjust support cap screw to achie
335. xed fore aft position for use with skids or anti scalp rollers Cutting Units Page 7 2 CLIP FREQUENCY With variable speed set to maxi mum rpm 5 blade at 1040 reel rpm moving at 5 mph 8 1 km h 1 inch 25 4 mm clip 5 blade at 1040 reel rpm moving at 6 mph 9 7 km h 1 20 inch 30 5 mm clip 8 blade at 1040 reel rpm moving at 5 mph 8 1 km h 0 63 inch 16 0 mm clip 8 blade at 1040 reel rpm moving at 6 mph 9 7 km h 0 76 inch 19 3 mm clip OPTIONAL EQUIPMENT 27 inch Cutting Units Full Roller Kit Sectional Roller Kit Wiehle Roller Kit Anti Scalp Roller Kit Roller Scraper Kit Wiehle Roller Scraper Kit Comb Kit 32 inch Cutting Units Sectional Roller Kit Wiehle Roller Kit Full Roller Kit Anti Scalp Roller Kit Roller Scraper Kit Wiehle Roller Scraper Kit Both Models of Cutting Units Fixed Kit Skid Kit Backlapping Brush Assembly Gauge Bar Assembly Bedknife Screw Tool Model No 03440 Model No 03445 Model No 03450 Model No 03447 Part No 60 9560 Part No 94 5082 Part No 67 9400 Model No 03476 Model No 03475 Model No 03479 Model No 03477 Model No 03478 Part No 94 5081 Part No 93 6915 Part No 94 3664 Part No 29 9100 Part No 13 8199 Part No 51 0880 Reelmaster 3100 D Special Tools Order special tools from your Toro Distributor Some tools may have been supplied with your machine or available as TORO parts Some tools may also be avail able from a local supplier Ga
336. y Remove disc spring and detent plunger from the body Inspection 1 Inspect spool and spool bore for wear If wear is ex cessive replace valve with new one 2 Inspect springs and replace as necessary 3 Inspect plunger detent plunger and check poppet for wear Replace as necessary 4 Inspect seat spacer and bushing for wear Replace as necessary 5 Inspect disc and washer Replace as necessary 6 Inspect cap and plugs for damaged threads and ring sealing surfaces Replace as necessary Hydraulic System Rev C Page 4 88 Assembly IMPORTANT Do not wipe parts with paper towels or rags Lint free cloth must be used to prevent lint from causing damage to the hydraulic system Ad CAUTION Use eye protection such as goggles when using compressed air 1 Clean all metal parts with solvent and blow dry with compressed air 2 Replace check poppet O rings and back up wash ers with new ones 3 Install new O rings into the valve body 4 Slide bushing and new O ring over the spool 5 If the spool was disassembled install washer spool spring spacer and retaining ring to the spool 6 Lubricate spool liberally with clean hydraulic fluid and install into its proper bore 7 Install spool cap into valve body Torque cap from 20 to 25 ft lb 27 to 34 8 Install O ring back up washer and solid plug into the bore on the opposite end of the plunger Torque plug from 30 to 35 ft
337. y and glow plugs see Electrical Sche matics and Diagrams in this chapter B Verify continuity of the circuitry from the battery to ignition switch glow controller glow lamp glow relay and ground see Electrical Schematics and Diagrams in this chapter C Replace parts as necessary 6 Connect electrical connector to the run solenoid Reelmaster 3100 D Standard Control Module Reelmaster 3100 D machines with Serial Numbers above 240000000 are equipped with a Standard Control Module to monitor and control electrical components re quired for safe operation This Module is attached to the back of the instrument panel Inputs from the neutral parking brake PTO start igni tion backlap and high temperature switches are moni tored by the Module Output to the PTO reel drive solenoid fuel pump and engine run solenoid are con trolled based on the inputs received by the Module The Standard Control Module does not connect to an external computer or hand held device can not be re programmed and does not record intermittent fault data Figure 25 1 Power input LED 6 Neutral input LED 2 Start input LED 7T Park brake off input LED The Standard Control Module can be used to check op 3 Encino rn output LED 8 PTO switch DU LED eration of machine switches by monitoring the LED of 4 Start output LED 9 In seat input LED 5 PTO output LED 10 High temp input LED the module If a Module LED does not illumi
338. ydraulic fluid and install into their proper bore 7 Install spool caps into valve body Torque caps from 20 to 25 ft lb 27 to 34 8 Lubricate both plungers liberally with clean hydraulic fluid and install into their proper bore 9 Install new O rings seats check poppets and check springs into the plunger bores 10 Install O rings back up washers and seat retaining plugs into their plunger bores Torque both plugs from 30 to 35 ft lb 41 to 48 11 Install new O ring back up washer and solid plug into the bore with the grooved plunger Torque plug from 30 to 35 ft lb 41 to 48 12 Install new O ring seat check poppet check spring new O ring back up washer and seat retaining plug into the bore with the plunger Torque plug from 30 to 35 ft lb 41 to 48 13 Install O ring and plug into the top of the valve body next to the detent plug bore Torque plug from 10 to 12 ft lb 14 to 16 14 Lubricate plunger detent spring and disc liberally with clean hydraulic fluid and install into its valve body bore 15 Install O ring and detent plug into its proper bore Torque plug from 30 to 42 ft lb 41 to 57 Reelmaster 3100 D 2g 5 8 22 gt This page is intentionally blank Reelmaster 3100 D Page 4 95 Hydraulic System Rev C Antiseize Lubrican Antiseize Lubricant 27 to 31 ft lb to 42 11 10 2 to 13 6 N

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