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1. e e Tractor N i rN Engine Single Pump for One Wing Only Pump Mount Right Wing Pump Weldment Most Common ie w D lt TT Z I gt U U a lt e lt Driveshaft Bearing installs into pump mount weldment here Terrain Master Service Manual Pub 08 11 Page 45 Pump Mount Weldment Remove amp Replace Preparation e Items to be removed in preparation to remove pump mount weldment main pump single or tandem some hoses will need to be disconnected and or will need to be removed in order to remove the pump s The pump will need to slide back away from pump mount weldment approximately 2 Some hoses may not have enough length to the to allow the pumps to slide outward See pump remove and replace instruction section if hoses are to be disconnected see tank removal and replace section It is recommended oil be drained before disconnecting any hoses See tank remove and replace section Important Cap all hydraulic components immediately after disconnecting them do not leave hydraulic system open Do not work on hydraulic system under dirty conditions Hydraulic system must be cleaned before disconnecting hoses and or components Work area and tools must be clean at all times See Figure 1 amp 2 e There are different models of tractors which will have varying components designs Some may use spacers some may not Some will use the auxil
2. LH Wing Pump High Pressure Line LH Wing Pump Suction Line Pump Suction Cyl System Supply Figure 44 Line Pump Suction Hose Terrain Master Service Manual Pub 08 11 Page 113 Pump amp Motor Hydraulic Schematic Tank Return Filter Assembly amp Tank Return Pressure Gauge Tank Return Hose from Cylinder Control zk to Tank et Mme S Oil Level Sight Glass i Us Temperature Gauge IIe m Return Hose from Wet Tubes on LH 8 ae RH Wing Decks E Figure 43 Upper Connection Always Main Frame Cross Over from Pump To Wing Motors Bracket amp Tubes RH Side NEVER TO WET TUBES Shown note Tee Fitting in HIGH PRESSURE lower fittings _Lower Connection Always from Deck Wet Tubes to Ay Filter Tank Return Line 4 LOW PRESSURE Nut on Bulkhead Fittings Figure 44 Terrain Master Service Manual Pub 08 11 Page 114 Pump amp Motor Hydraulic Schematic Wings have a front and a rear wet tube for cooling the oil At the outer end of the decks there is a cross over hose which allows the oil to cross from the rear tube to the front tube The tubes and the cross over hose are in the oil return to tank circuit which has to be low pressure Figure 47 Tractor Remote Connecting Cylinders lt _ Hyd Outlets To Tractor Control Valve for Hydraulic Supply When the tractor hydraulics are used to supply and operate the cylinders there will not be a control valve shippe
3. ag O e O Q Z lt lt A 2 A Splined Coupler Pulley Splined Coupler Only Weldment Use w Aux Hyd Use when Tractor Hyd Pump System System is used to supply Figure 26 cylinders Terrain Master Service Manual Pub 08 11 Page 68 Auxiliary Pump Reassembly Assemble auxiliary pump See Figure 28 and 29 Note To assemble and disassemble Pump Assembly Bolts the auxiliary steps are basically the en gt same in reverse Use Disassembly And Kee Reassembly section er 1 Place pump body into vice Clamp Vice Jaw Protective Pads the pump body in a vise with at protective devices for the jaws See fr AL Figure 19 Clamp the pump body in the vice at the pump mounting flange use caution do not over tighten the vice and damage pump mounting flange r 2 Installshaftsealinto pump body the seal is installed with seal lip inward toward gears Use appropriate seal l driver to instal seal Coat the seal Figure 28 with petroleum jelly Vaseline for start up lubrication See Figure 29 3 Insert snap ring into pump body Use snap ring pliers to make certain snap ring is seated into groove in pump body See Figure 29 4 Coat the anti extrusion block with petroleum jelly and insert it into pump body make certain it is installed on the correct side of pump body The petroleum jelly will hold it in place during assembly 5 Install seal assembly The seal assembly must be installed with the sm
4. O gt O z a Z lt oc et LLI Ss Mower Repairs Rear Mower Important Clutch Adjust Information There have been three different clutches used 1 The first and earlier clutch had 6 small springs and would adjust to a length of 1 1 16 long this early clutch could be identified by the small springs which are about 1 3 16 long uncompressed 2 he next clutch had 8 springs as shown in figure 10 and spring are tightened to 1 5 16 long 3 The newest clutch has 6 springs and the springs will be tighten to 1 9 16 long when adjusted The clutch are easily identified by the springs Always check before adjusting clutch The different clutches are installed on different series universal joint drive lines and can not be interchange among drive lines When repairing the clutches the correct type must be identified to enable the correct parts be ordered a good source of identification is the Terrain Master archive manual Check All Shields Make certain any shields that were removed during assembly are reinstalled Do not Operate mower or tractor with any shields or guards missing 1 1 16 Standard D Step 9A Style Clutch with 6 Small springs shown see Step 9A for other clutches Figure 10A Terrain Master Service Manual Pub 08 11 Page 94 Friction lining plate rife ie Figure 11 Figure 10B 1 3 16 Min See Step 9A ON CH Ir 1 5 16 Standard Vegas 22 NSS 1 Spring bolt
5. m i 5 Fi i m I 1 i 4 NJ E ta NM A Y Ji E h Fk E i d u i T Lk Note Dual Wing will use both P N 002496 amp P N 002497 Wire Harness Connector to Main Harness zj Black White Connector to Wing Motor Solenoid Delivery Inspection Checklist Pre Operation Inspection Check the following items before operating the unit to assure that they are properly assembled See following page 1 4 for component location Safety Equipment Operators Manual is with Unit The Safety Decals are installed as listed in the Assembly Manual Valve operation plate is installed Operators cage or Tractor Cab is in place Deflectors are installed on the Mower Head Tractor Rops or Cab with seat belts installed properly All Foot Guards and safety switch are installed and functional Axle Plate Bolts are torqued Head Mounting Bolts tightened Frame attaching Bolts tightened Front Support Bolts are torqued Hydraulic Tank mounting Pins Bolts in place correctly All Welds inspected to insure proper welds and locations Hydraulic System Oil Level in Hydraulic Tank is within the sight gauge Item 5 page 1 4 Hose connections are tight Hoses do not have any kinks or twist in them Front Pump Shaft adapter bolts are tight Front Pump Shaft Coupler Drive Shaft is lubricated and has an anti seize compound on the Splines of Pump and Shafts The Pump Driv
6. A gt A Single Pump Disassembly amp Reassembly Single Pump Component Inspection For item numbers See Figure 17 1 Wash all parts Wash all parts in suitable clean solvent Use clean filtered compressed air to dry parts after washing Do not use compressed air to spin bearing when drying parts Do not use rags or towels that will leave lint to dry parts Parts must be kept clean at all times Work area and place parts are kept during repair process must remain clean and dust free 2 Examine needle bearings Item 16 and 17 Inspect the needle bearings in the housing Item 4 and the back plate Item 2 If the needles are free of excessive play and remain in the bearing cage there is no need to replace the bearing assembly 3 Inspect thrust washers and thrust bearings Item 5 All surfaces should be free of any signs of wear or fretting Should be no sign of distortion or flaking 4 Inspect spider Item 1B and pivot Item 1C Conical surfaces should be free of wear and score marks 5 Inspect pistons Item 1A The OD Surface should be smooth and free of scoring The shoes should be snug fit to piston The face of the shoe should be flat and free of scoring and flaking Do not lap piston shoes 6 Inspect the piston block Item 1D The bore should be free of scoring The surface that contacts the back plate should be smooth and free of grooves or metal build up 7 Inspect the cam plate insert Item 7 The surface should sh
7. d AS de Outer Front Pump P N 001841 2 77 CID P N 001733 2 28 CID Figure 12 Terrain Master Service Manual Pub 08 11 Page 62 single Pump Disassembly amp Reassembly Disassemble Single Pump For item numbers See Figure 17 1 Clamp single pump in vice with jaw protectors See Figure 15 single pump can be clamped in vice or it can be disassembled while on work bench 2 Remove back plate Item 2 The backplate is mounted with six hex head bolts Item 9 remove these six bolts lt will require a small amount of force to free the backplate loose from pump housing Use soft faced hammer tap sides of backplate This will break the backplate loose from pump housing do not hit back plate with excessive force it will damage backplate and pump housing 3 Remove O ring from backplate Remove the O ring seal Item 8 from backplate Item 2 4 Remove complete piston block assembly Item 1 from pump housing Item 4 Lift piston block assembly upward and out of pump housing it will require you to remove pump from vice and dump piston block assembly out Catch the block with hand don t let it fall out on floor or bench Do not remove the spring snap ring Item 1K from piston block assembly as spring tem 1H has compression on it this compression will require relieving before snap ring is removed this can be done later 5 Remove the Piston Assembly Item 19A from the Piston Block Item 1D The piston assembly will pull u
8. 11 1 Retaining Ring 29 1 Retaining Ring 12 2 Retaining Ring 30 2 Retaining Ring 15 4 Coupler 31 1 Bearing Backplate 14 1 Lock Ring 32 1 Bearing Housing 15 1 O Ring So 1 Roll Pin 16 1 Bearing Backplate 33A 1 Seal kit Outer Pump in Seal Kit 17 1 Bearing Housing 18 1 Roll Pin 18A 1 Seal kit Inner Pump in Seal Kit Refer To Pump ID Numbers Stamped In Flange To Identify Pump Flange No Asy No Description 73498 LAA 01 N 001840 Inner Pump Section 2 77 CID Closest to Engine 73425 LAA 01 001 734 Inner Pump Section 2 28 CID Closest to Engine 73428 LAG Bees 001841 0uter Pump Section 2 77 CID Furthermost from Engine 73425 LAB 01 re 001733 0uter Pump Section 2 28 CID Furthermost from Engine Terrain Master Service Manual Pub 08 11 Page 73 U lt U gt Z O lt O e O JJ Tandem Pump Disassembly amp Reassembly Tools Required For Pump Disassembly And Reassembly 1 Ea Ratchet wrench 1 ea 1 2 Socket 1 Ea Seal driver or similar tool1 ea Torque wrench 68 n m 50 ft Ibs 1 Ea Soft face hammer1 ea Petroleum jelly Vaseline 1 Ea Internal snap ring pliers straight 2 3mm 090 In Tip 1 Ea External snap ring pliers straight 1 8mm 070 In tip Tandem Pump Disassembly Inner Rear Pump The following instruction are based on the presumption the pumps have been disconnected from tractor unit and are ready for the work bench All ports and pump ope
9. 2 4 104768 A Rubber Bushing Support Base 5 104767 A Rubber Bushing Compression Ring 6 104765 A Rubber Bushing Expander f Ford amp Kubota Tractor 7 104766 A Rubber Bushing Expander f Case H MF amp Case Tractors 8 104769 A Drive Shaft Installation Collar 9 104770 A Rubber Bushing Installation Plug 10 103741 A Seal Installation amp Seating Tool 000802 S Hyd Pressure Gauge 3000 PSI A Denotes special tools designed by Alamo S Denotes std tools equipment available on market Terrain Master Service Manual Pub 08 11 Page 102 Hydraulic Pump Testing Hydraulic Pump Testing A Connect your flow meter with adjustable restriction valve and pressure gage in the pressure line of the pump that is in question B Open Restriction Valve on the meter completely open C Fill any porting or prime with oil if necessary D Start tractor with no load allow engine to run until oil is warmed to 100 F E Set engine RPM to 540 PTO F With engine at 540 close restriction valve at 500 RPM increments from 500 to 3000 psi and record flow reading G If pump has less than 90 of its original capability when new it is due for rebuild or replacement H If pump has better than 90 of its original capability and the machine still has poor cutting performance the main relief should be tested for proper operation If not the main relief check to see if oil bypassing motor due to disfunctional logic valve I After pump r
10. A H with nut a Wie Style Clutch with 8 large springs shown see Step 9A for other clutches 1 9 16 Standard See Step 9A a LC SkA lt KL CH Wi Style Clutch with 6 large springs shown see Step 9A for other clutches Gearbox amp Extended Shaft Asy Rear Mower shaft bearing removed this is for illustration only and will not need to be removed to remove gearbox and extension shaft asy Figure 25 Item Qty Description I NOOR WONMNN MD a a DP eck sch sch RJ sch ech Gearbox amp Extension Shaft Asy Gearbox Asy 08 90 amp Down Gearbox Asy 09 90 amp Up Spline Coupler Asy w Grease Fitting Counter Bore Screw Lockwasher Extension Shaft Extension Shaft Hsg Bevel Ring Snap Ring Bearing A Hsg Asy w Items below Bearing Only Bearing Housing Only Lubricap Terrain Master Service Manual Pub 08 11 Page 95 7 4 4 7 5 4 Gearbox amp Extension Shaft Asy Item Qty Description 1 sch sch sch sch sch sch zech 4 Bolt Nut Bearing Retaining Ring Pulley Shim Use Qty As Needed Pulley Top Shaft Drive Drive Belt Key Heavy Flat Washer Lockwasher Bolt Idler Brg Extn shaft Mount Plate Idler Pulley Arm Idler Pulley Belt Guard Shield YHAMOW ONIM ANY dVsad Gearbox amp Extended Shaft Asy Rear Mower Gearbox and Extension Shaft Assemb
11. If the area under this cover is dirty it must be cleaned before any dissembling starts this will include all metal surfaces hoses and hose fittings See Figure 2 TI C lt U gt Z O lt O O JJ Figure 2 Terrain Master Service Manual Pub 08 11 Page 57 Tandem Pump w Tank amp Aux Pump on O e gt a Z lt 0 2 A Item Qty Description 1 1 Hydraulic Tank and Pump Cover Weldment 2 1 Tandem Pump Asy Outer Half LH Wing Inner Half RH Wing 3 1 Auxillary Pump Asy 4 1 Suction Hose F Tank to LH Wing Pump 5 1 Suction Hose F Tank to RH Wing Pump 6 1 Case Drain Hose F LH Wing Pump to Tank r 1 Case Drain Hose F RH Wing Pump to Tank 8 1 Pressure Hose to LH Wing Motor 9 1 Pressure Hose to RH Wing Motor 10 1 Suction Hose to Auxilliary Pump 11 1 Pressure Hose F Auxillairy Pump to Cyl Control Valve 12 1 Return Hose F Cylinder Control valve to Tank Return Filter 15 1 Return Hose F Wing Motors to Tank Return Filter 14 1 Hydraulic Tank Temperature Gauge 15 1 Hydraulic Oil Level Sight Glass 16 1 Hydraulic Tank Breather Filler Cap 17 1 Hydraulic Tank Filler Cap 18 1 Hydraulic Oil Return Pressure Gauge 19 1 Hydraulic Oil Return Filter Asy Figure 4 Terrain Master Service Manual Pub 08 11 Page 58 Single Pump w Tank amp Aux Pump TI C lt U gt Z O lt O O JJ Item Qty Description 1 1 Hydraulic Tank and Pump Cover Weldment 2 1 Single Pump Asy RH Wing 3 1 Auxillary Pump
12. OD Flat washer lea 3 8 NC X 3 1 4 Bolt Hex Head lea 3 8 NC Hex Nut 7 Place one flat washer over 3 8 x 3 1 4 bolt place this through center of piston block Place other flat washer over bolt and let it rest on the three pins Item 1F Screw nut on to compress spring inside piston block Use Terrain Master Service Manual Pub 08 11 Page 64 single Pump Disassembly amp Reassembly snap ring pliers to install internal snap ring Item 1K Install internal snap ring Item 1k make certain it is seated into snap ring groove in piston block Unscrew bolt nut and two washers this will release pressure on spring Item 1H allowing it to seat against snap ring Item 1K Never remove snap ring in piston block with out compressing spring first 8 Install pivot Item 1C spider Item 1B and piston assembly Item 1A Sit pivot Item 1C down onto piston block with taper rounded side up See figure 17 Sit spider tem 1B down over pivot noting concave hole in center of spider will sit over rounded edge of pivot align holes in the spider with holes in piston block Lower piston assemblies tem 1A through spider holes and into piston block piston assembly can be installed one at a time 9 Install cam plate insert Item 7 Lubricate cam plate insert Item 7 well and install it into pump housing Item 4 until it is seated down into housing This is best done with pump housing lying on its side on work bench 10 Install piston bloc
13. Tandem Pump Tandem Pump Outer Front Pump Tandem Pump Connecting Bolts Inner Rear Pump Outer Front Pump Inner Rear Pump Figure 13 Figure 14 Terrain Master Service Manual Pub 08 11 Page 74 Tandem Pump Disassembly amp Reassembly shaft or it may have stayed in backplate Item 2 of inner pump Check for coupler and remove it 3 Remove O ring seal Item 15 it seals between the outer and inner pump it will be on back plate and should be removed now 4 Remove lock ring Item 14 Remove lock ring from backplate 5 Remove back plate Item 2 The backplate is bolted on with six hex head bolts Item 9 remove these six bolts It may require a small amount of force to free the backplate loose from pump housing If needed use a small plastic mallet to tap the sides of the backplate This will break the backplate loose from the pump housing do not hit backplate with excessive force as it will damage backplate and pump housing 6 Remove O ring from backplate Remove the O ring seal Item 8 from backplate Item 2 7 Remove complete piston block assembly Item 1 from pump housing Item 4 Lift the piston block assembly upward and out of the pump housing it may require you to remove pump from vice and dump the piston block assembly out If you do catch the block with you hand dont let it fall out on the floor or bench Do not remove the spring snap ring tem 1K from the piston bloc
14. e CHECK SMV sign reflectors and warning lights for proper operation and visibility behind unit e CHECK that your driving vision is not impaired by tractor cab or implement while seated in tractor seat e ADJUST your operating position mirrors and implement transport for clear vision for traveling and traffic conditions PREPARE IMPLEMENT FOR TRANSPORTING OR TOWING ENGAGE TRANSPORT LOCKS AND SAFETY CHAINS e RAISE MOWER and ENGAGE center axle cylinder transport stops or pins e RAISE WINGS and ENGAGE TRANSPORT LOCKS or pins e ATTACH implement SAFETY CHAIN to tractor e REMOVE any cut material collected on mower deck DETERMINE STOPPING CHARACTERISTICS OF TRACTOR AND IMPLEMENT FOR TRANSPORTING OR TOWING BRAKING TESTS e INSTALL center axle cylinder transport stops or pins e Observe STOPPING distances increases with increased speeds e DETERMINE the maximum safe transport speed that does not exceed 20 mph DETERMINE MAXIMUM TURING SPEED BEFORE OPERATING ON ROADS OR UNEVEN GROUND e TEST equipment in slowly increasing speed in turns to determine it can be operated at higher speeds e USE REDUCED turning speeds in sharp turns to avoid equipment turning over WHEN TOWING OR TRANSPORTING EQUIPMENT e Always WEAR SEAT BELT when operating or transporting mower e USE low speeds to avoid overturn with raised wings e USE low speeds and gradual steering on curves hills rough or uneven surfaces and on wet roads e TURN ON tractor FLA
15. roll pin should not be more that 173 Higher than surface of back plate This alignment is important and must be correct Make certain the roll pin is in the back plate Lower the back plate ltem 2 down onto the pump housing tem 4 aligning the back plate down over driveshaft until the sealing O ring tem 8 inserts into pump housing Back plate should slide down until it is inside of pump housing if back plate can not be pushing completely down without a lot of force check it for something wrong Do not use excessive force or use the bolts to pull back plate down 14 Install 6 retaining bolts Item 9 into pump housing Item 4 to fasten back plate Item 2 Inspect the bolts make certain all threads are in a the bolts need to be installed in a staggered pattern alternating from one side to the other until snug These bolts must be torqued to 15 to 18 ft lbs Do this in increment and staggered pattern also 15 Fill pump case with oil when connecting rebuilt or new pump The pump should be filled half full with oil this can be done by pouring clean oil through the ports of pump When pump is installed on mower connect pump pressure hose pump case drain hose and install pump suction elbow fitting into pump Pour oil into the elbow fitting this will put oil into pump so it will not be started dry TI C lt U gt Z O lt O O JJ 4 39 173 Roll Pin amp Bearing Installation Figure 18A Terrain Master Servi
16. through the spider holes and into the piston block the piston assembly can be installed one at time 9 Install cam plate insert Item 7 Lubricate the cam plate insert Item 7 well and install it into the pump housing Item 4 until it is seated down into the housing This is best done with the pump housing lying on its side on the work bench 10 Install piston block assembly liem 1 The piston block assembly all assembled needs to be coated with oil Slide the piston block assembly into the end of the pump housing aligning the id of it over driveshaft Push piston block assembly into housing and over driveshaft until piston shoes are in contact with the cam plate insert it may require the driveshaft to be turned as the piston block assembly is being slid in to align the splines of the shaft with the spline of the components of the piston block assembly Do not use excessive force to install piston block assembly if it will not slide together with the force of your hand there is something wrong 11 Install needle bearing Item 17 into back plate assembly Item 2 The needle bearings will install into the center opening of the back plate coat this bearing with oil as you slide it into the back plate Install bearings into back plate with number end of bearing up and visible Bearing will be slightly higher 09 Than back plate 12 Back plate Item 2 and sealing O ring Item 8 The back plate is sealed with an O ring that is inserted int
17. Asy 4 1 Suction Hose F Tank to RH Wing Pump 7 1 Case Drain Hose F RH Wing Pump to Tank 9 1 Pressure Hose to RH Wing Motor 10 1 Suction Hose to Auxilliary Pump 11 1 Pressure Hose F Auxillairy Pump to Cyl Control Valve 12 1 Return Hose F Cylinder Control valve to Tank Return Filter 13 1 Return Hose F Wing Motors to Tank Return Filter 14 1 Hydraulic Tank Temperature Gauge 15 1 Hydraulic Oil Level Sight Glass 16 1 Hydraulic Tank Breather Filler Cap 17 1 Hydraulic Tank Filler Cap 18 1 Hydraulic Oil Return Pressure Gauge 19 1 Hydraulic Oil Return Filter Asy Figure 5 Terrain Master Service Manual Pub 08 11 Page 59 Tandem amp Single Pump Remove Replace Important Warning Once the pump removal process is started tractor cannot be started unless both pumps and pump driveshaft is removed It is the responsibility of the repair technician to secure the tractor to where is safely secure before beginning any repairs It is recommended that the battery cables be disconnected and a note DO NOT START be place in the tractor operators compartment to prevent others from stating it IF the tractor is started with pumps partially disconnected or drive shaft left in the tractor when tractor is started it will damage the tractor and or other components Remove Pump Pump For Motor Supply See Figure 4 through 16 If both pumps are to be removed for this repair remove both pumps together and disassemble them on the work bench is best If only the
18. Bag 16 Red to Switched Power Suppl 12 Brown Line Connector to starter Solenoid Terrain Master Service Manual Pub 08 11 Page 119 Solenoid Connector at Cutter Valve Wing Wire Harness RH Wing Single Wing Cap Connector Note RH Wing Only Single Wing will used on RH use P N 002496 Wire Harness only Only Wing JUL ei To LH Wing Main Harness or Plugged La lm ISCH to Main Harness Yellow Outer Connector Connects to White Wire Wires connect to wing magnet switch Black White Connector to Wing Motor Black White Solenoid Inner Connector Connects to Black Wire Connector to Wing Motor Solenoid Connector Gasket Connector Fastening Screw E A Terrain Master Service Manual Pub 08 11 Page 120 Wing Wire Harness LH amp RH Wing Dual Wing Connector to Main Harness White Quter Connector Connects to White Wire Wires connect to wing magnet switch Black White Inner Connector Connects to Black Wire Connector to Wing Motor Solenoid Connector Fastening Screw Terrain Master Service Manual Pub 08 11 Page 121 d JI NA m La e a CN E D a a e a A p m ala A a a Li MI A a FL f LO LL T A y i Ki CG d d s E d Ri l BORG
19. Bolt SWS w Nut E W VV Mnt FL 0003 Seasonal Clutch Maintenance It is important that the clutch lining plates slip when an obstacle or load heavier than the clutch setting is encountered Therefore if the machine sits outside longer than 30 days and is exposed to rain and or humid air it is important to make sure that the clutch lining plates are not rusted corroded together Before using the mower use the following procedure to make sure the clutch will slip and give the overload protection required 1 Loosen nuts on springs until the springs can freely rotate yet remain secure on bolts 2 Attach mower to tractor and start the tractor Set the engine speed at 1200 RPM 3 Mark outer plates as shown above 4 Engage the PTO approximately one second and then quickly disengage it The friction lining plates should break loose check the mark 5 Turn tractor off and tighten the nuts on the springs to their original position of 1 5 16 compressed spring length Terrain Master Service Manual Pub 08 11 Page 53 Terrain Master Service Manual Pub 08 11 Page 54 Section 3 Hydraulic Pump and Motor Repair and Replace Terrain Master Service Manual Pub 08 11 Page 55 Tandem amp Single Pump Repair Replace Recommended Gauges For Diagnostics A Inlet Vacuum 30 PSI to 30 in Mercury 207 bar to 0 bar B System Pressure Gauge 6 000 PSI 700 bar C Charge Pressure Gauge 0 to 500 PSI 0 to 25 bar Power C
20. GLASSES when servicing hot components e AVOID CONTACT with hot hydraulic oil tanks pumps motors valves and hose connection surfaces e SECURELY support or BLOCK UP raised implement framework and lifted components before working underneath equipment STOP any implement movements and SHUT OFF TRACTOR engine before doing any work procedures USE ladder or raised stands to reach high equipment areas inaccessible from ground ENSURE good footing by standing on solid flat surfaces when getting on implement to perform work FOLLOW manufacturer s instructions in handling oils solvents cleansers and other chemical agents DO NOT change any factory set hydraulic calibrations to avoid component or equipment failures DO NOT modify or alter implement functions or components DO NOT WELD or repair rotating mower components These may cause vibrations and component failures being thrown from mower PERFORM SERVICE REPAIRS LUBRICATION AND MAINTENANCE OUTLINED IN IMPLEMENT MAINTENANCE SECTION e INSPECT for loose fasteners worn or broken parts leaky or loose fittings missing or broken cotter keys and washers on pins and all moving parts for wear REPLACE any worn or broken parts with authorized service parts LUBRICATE unit as specified by lubrication schedule NEVER lubricate adjust or remove material while it is running or in motion TORQUE all bolts and nuts as specified BLADE INSPECTION e REPLACE bent damage cracked or broken blades immediately wit
21. Master Service Manual Pub 08 11 Page 43 single Pump amp Driveshaft Asy w Aux Pump Typical drive amp power assembly with Driven Drive splined straight shaft and carrier Aux Hyd Pump Shield Cyl Circuit Pulley Belt bearing Another variation may have u joint and telescopic driveline instead Pulley adapter may differ with different gt driveline and tractor model m gt LLI Pulley Adapter U Locknut Mounting Bolts A e Tractor Engine LL H Pulley Z Driveshaft lt Mounting Tractor Specific Bolt amp Washer Bearing f LLI Collar gt Pump ae Mount a Plate Je Drive Pulley amp Pulley Adapter Splined Sleeve Driveshaft e Weldment Bearing Tractor Specific Small Cyl Hyd Pump Mount Plate mounts here N Single Pump for One Wing N Pump Mount Only Weldment Tractor Specific Right Wing Pump Most Common Driveshaft Bearing installs into pump mount weldment here Terrain Master Service Manual Pub 08 11 Page 44 single Pump amp Driveshaft Asy w o Aux Pump Typical drive amp power assembly with splined straight shaft and carrier bearing Another variation may have u joint and telescopic driveline instead Pulley adapter may differ with different driveline and tractor model Pulley Adapter Mounting Bolts 17 N Splined Sleeve Driveshaft Pulley Bearing Driveshaft Adapter E Collar Bearing
22. Observe the rules of safety and common sense 4 DANGER FAILING TO FOLLOW SAFETY MESSAGES AND OPERATING INSTURCTIONS CAN CAUSE SERIOUS BODILY INJURY OR EVEN DEATH TO OPERATORAND OTHERS IN THE AREA 2 NO RIDERS NO CHILDREN 3 USE SAFETY SHOES HARD 4 BLOCK UP SECURELY OPERATORS HAT SAFETY GLASSES BEFORE WORKING UNDER SEAT BELTS amp ROPS NOK RZS Ome 1 Study and understand Operator s Manuals Safety Signs and Instructional Decals for tractor amp flail mower to prevent misuse abuse amp accidents Practice before operating mower in a confined area or near passersby Learn howto stop engine suddenly in an emergency Be alert for passersby and especially children 2 Allow no children on or near implement or tractor Allow no riders on tractor or implement Falling off can cause serious injury or death from being runover by tractor or mower or contact with Flail Mower Blades 3 Operate only with tractor having Roll Over Protective Structure ROPS and with seatbelt fastened securely and snugly to prevent injury and possible death from falling off or tractor overturn Personal Protective Equipment such as Hard Hat Safety Glasses Safety Shoes and Ear Plugs are recommended 4 Block up or Support raised machine and all lifted components securely before putting hands or feet under or working underneath any lifted componentto prevent crushing injury or death from sudden dropping or inadvertent operation of controls Make cer
23. Pin d 1 Housing Not Furnished as Parts 18A 1 Seal kit Inner Pump in Seal Kit 1 Thrust Race amp Bearing Refer To Pump ID Numbers Stamped In Flange To Identify Pump lange No Asy No Description 3428 LAF 1 1 221111 00755650 Single Pump 2 77 CID 3425 LAC 11111 1 001827 Single Pump 2 28 CID NOTE When Replaceing Pump Assembly Complete it is important to Know which Pump CID is being orked on the best way to tell is look at the stamped number in the pump flange Most of the parts on the inner and the outer pump are the same the parts on the 2 28 CID pump and the 2 77 CID pump are the same except or item number 4 the pump housing Item number 4 determines which CID pump you have also item number 4 s not avalable as a replacement part If the housing needed to be replaced it would require the pump assembly to be replace as an assembly This is when it is so importanrt to identify the pump by checking the number stamped n the pump flange Terrain Master Service Manual Pub 08 11 Page 81 an O gt a Z lt A gt A Motor Removal amp Replace Motor Removal From Wing Deck Secure tractor and mowers Lower wing and rear mowers down until they are resting on the ground do not make repairs with mowers lifted or folded Secure tractor as to tractors manufactures specification for parking tractor Secure tractor so it cannot be started alamo industrial recommends that battery ca
24. Tandem Pump Es Suction Lines Hydraulic Tank Tractor Hyd Pressure Gauge by Pump Case Drain Lines SC Terrain Master Service Manual Pub 08 11 Page 108 Hydraulic Schematic W O Auxiliary Pump RH Wing Motor Return Hose Terrain Master Service Manual Pub 08 11 Page 109 Cyl Control Valve Motor Case Drain Cooling Tube Motor Return Hose amp Deck Cooling Tanks Tank Return Filter amp Return Pressure Gauge Hydraulic Tank Hydraulic Schematic W O Auxiliary Pump Dual Wing LH Wing RH Wing Tilt Cyl Tilt Cyl Cyl Valve Pressure Cyl Valve Pressure Line Aux Cyl Pump Tank Return Filter amp Return Pressure Gauge Tandem Pump Aux Cyl Pump p Suction Lines Suction Line Hydraulic Tank Terrain Master Service Manual Pub 08 11 Page 110 Pump amp Motor Hydraulic Schematic RH Wing Only Pressure hose from pump has a 90 fitting connects here Pressure hose motor has a 90 fitting connects here NOTE The pressure hose will always be connected to the top fitting and the return will always connect to the bottom Return hose to tank return filter has a 90 fitting connects here Return hose from cutter head cooling tanks has a 45 fitting connects here Main frame w hose bulkhead fitting Rh side of tractor looking from front to rear of tractor Single wing shown dual wing has metal cross over pipe with a tee in it for the
25. adjusting steps and procedure Terrain Master Service Manual Pub 08 11 Page 29 oo a T an a Z lt x T e gt am Ti Se Roller Bearing Roller Bearing Replacement See Figure 19 1 Securely support mower before beginning any repairs or service to mower all mower must be lowered and resting on ground or supports and not lifted by hydraulic system Secure tractor as directed by tractor manufactures instruction for parking Secure tractor to prevent it from being started while being repaired 2 Remove roller and both bearing and bracket assemblies from mower Lift the mower only high enough to remove the roller assembly If installing a roller with pre assembled bearing and bracket assemblies remove the old roller proceed to step 12 3 Slide bearing and bracket assemblies off each end of roller If replacing with new bearing and bracket assemblies proceed to step 10 4 Remove roller bearing and housing assembly attaching hardware Remove assembly from bracket Inspect seal between assembly and bracket for brittleness cracks wear and tear Replace if necessary If replacing with new roller bearing and housing assemblies proceed to step 9 5 Remove grease fitting from the top of bearing housing 6 Remove bearing form housing By rotating bearing 90 sideways and line up with notches in bearing housing then pull out Roller Mounting Height Adjusting Bracket p sj s R
26. amp Heplace EE 46 Drvene LAU CAO ORNE 49 ES SUMS omel KE 49 To Disassemble Universal Joint siceicsicinnchncsvececevscancsceascetaesnedveawieacexseveesnenidanaewendeacnavnesunsvecadewndebaciaedetveevancensvens 50 To Reassemble Universal Jomt u ueuuuaeaeaeaaaaawaa aaa aaa aaa aaa kaza aaa aaa aa aaaaaiazaa aaa aaa aranna erarnan erann anean n annann 51 Table of Contents MO CI et sa cee sce car eae sciasenecensussecentces E A sasessea pone E E A E E doses to 53 Seasonal Clutch Maintenant E asc e EE S EEE CZ E EEE a a adaa aa E a REN 53 Hydraulic Pump and Motor Repair and Replace cccssscceeseceeseeeeseenseeeeseeenseeenneeeaneneas 54 Tandem A Single Pump Repair Hepnlace aaa aaa aaa a aaa aa aaa aaa aaa zaaaaaazaaaaaa a aaaaaaaaaaaaaaazaaaaaaaazaaaaeaa 55 Recommended Gauges TRUE Lenert 55 FOF lee D 55 FUN OG EN 35 Pump Configurations Used E 30 DOENMYARUIEROSOMAILUSEG WEE 56 Drain Hydraulic ee 56 Tand m Pump w Tank amp Aux PUMP E 57 Single Pump wi Tank 8 Aux PUMP 00 0 0cs0c0 ccceseecereesceeeneeeeecceesseeceestesseeeceesseesseneeescceeseseeeeencuseeereesceeesenersteces 58 Remove Pump Pump For Motor ele AE 59 Remove Outer and Inner Pump From Mower Tractor 59 Replace Outer and Inner Pump to Mower Tractor cccccsseececceeescecccaeecececeasececeuueceeessageceeseaeeeesaaaeeessaaess 60 Single and Tandem PUMP E 60 Tandem Pump Disassembly amp Heassembhy e saaua aaa aaa aaa aa aa aaa aaa aa aaaaaaaaaaaa a aaaaaaaa
27. fill filter canister with oil as the filter is on the supply return line Do not operate system with out a filter and do not operate with incorrect filter Use only the correct micron size filter that is designed for this system See Figure 16 4 Reinstall filter spring and filter cover Drop spring in on top of new filter See Figure 17 5 Replace filter cover Sit the filter cover down onto the spring Push cover down and turn counter clockwise until the three bolts slide into the slots See Figure 18 6 Replace bolt in filter cover and tighten the 4 bolts Replace the one bolt that was removed previously See figure 19 tighten the four bolts in increments until the cover is seated evenly all the way around do not force cover down with bolts if it offers resistance Tighten the bolts in an even manner See Figure 20 7 Check and fill oil system It is recommended that only proper type oil be added or installed and that all oil be installed using a filtered buggy system these system are available on the market See Figure 21 or a OI an a Z lt q LLI O gt an Ti N Figure 16 EOZ Figure 17 Figure 18 S l 19 Figure 20 e Figure 21 Terrain Master Service Manual Pub 08 11 Page 40 Section 2 Driveline Assembly Terrain Master Service Manual Pub 08 11 Page 41 Tandem Pump amp Driveshaft Asy w Aux Pump Aux Hyd Pump Driven Drive Shieg Typical drive A power assembly with eer Pulley La sp
28. following procedure should be used if the spring has been removed from the piston block The spring Item 1H will have to be compressed The following parts will be needed to assemble the piston block 2 Ea 3 8 ID x 1 1 8 OD flat washer 1 Ea 3 8 NC x 3 1 4 bolt hex head 1 Ea 3 8 NC hex nut 7 Place one of the flat washers over the 3 8 x 3 1 4 bolt and place this through the center of the piston block Place the other flat washer over the bolt and let it rest on the three pins tem 1F Screw the nut on and compress the spring inside the piston block Use a pair of snap ring pliers and install the internal snap ring Item 1K Install the Terrain Master Service Manual Pub 08 11 Page 76 Tandem Pump Disassembly amp Reassembly internal snap ring Item 1K and make certain it is seated into the snap ring groove in the piston block Unscrew the bolt nut and two washers this will release pressure on spring Item 1H and allow it seat against snap ring Item 1K Never remove snap ring in piston block with out compressing spring 8 Install pivot Item 1C spider Item 1B and piston assembly Item 1A Sit the pivot Item 1C down onto the piston block with the taper rounded side up See Figure 12 Sit the spider tem 1B down over the pivot noting the concave hole in the center of the spider will sit over the rounded edge of the pivot align the holes in the spider with the holes in the piston block Lower the piston assemblies Item 1A
29. in a folded back position e Remove such foreign objects and be sure all knives are free to swing to the extended position 2 Knives are missing or broken e Replace missing or broken knives 3 Knife hanger lugs are broken off shaft e This condition usually results from continued operation in contact with large hard objects where the knife hanger lugs themselves are hitting the hard objects Lugs should be replaced using arc welding equipment so as not to direct too much heat in one area of the shaft 4 Cutter shaft ball bearings are worn enough to have radial play in them e Replace ball bearing and other worn parts to eliminate play 5 Shaft is bent e Shafts are straight within a couple of thousandths of an inch when they are made It is possible that they will become bent in use such as if the shaft is hooked on a stump while the tractor is moving forward at a good speed 6 Shafts are operated at improper speed e Rotating shafts have what is known as a natural period of vibration The same is true of the cutter shafts on the Flail Mowers The actual speed at which the harmonic will occur will vary with each mower and each installation To avoid this harmonic vibration when operating the mower it may be necessary to adjust the engine speed of the tractor up or down Some units have a harmonic which occurs below the nominal operating speed On these units it will be noticed that there is always a little vibration at a particula
30. is sent already assembled with driveline tied to it See Figure 1 3 Connect lower hitch pins Lower hitch pins connect to lift arms of the tractor with click pins pins are furnished with mower See Figure 5 amp 7 It s best to connect lower arms of three point first You will use the lower arms of tractor 4 Connect upper hitch pin Upper hitch pin will connect to top three point adjustable link with pin and click pin Top link is furnished with tractor not with mower Top link is adjustable in length and is used to level the mower See Figure 8 5 Connect driveline Driveline is tied to the mower See Figure 6 amp 9 Cut the ties loose from mower Connect the clutch end of the driveline to the mower the clutch is retained to the gearbox input shaft by a clamp yoke on clutch hub Slip the clutch onto the input shaft until holes in clamp yoke are aligned with the grooves in the input shaft Install and tighten the two bolts and nuts The QD yoke end connect to the tractor PTO 6 Leveling the rear mower The rear mower is leveled with the top three point link The cutting height is adjusted by moving the roller up or down by change the bearing bracket mounting hole There is a decal on the deck next the operators parts manual canister See Figure 10 amp 11 7 Rear mower completely connected With the rear mower completely connected Check all oil levels and grease mower components See Figure 14 before running mower Also do
31. not start tractor if the rest of the assembly to the Terrain Master is not done Make certain that all hoses components wiring is completed and oil tank for Terrain Master has been filled with oil Slip clutch is incorporated in the PTO driveline It is Figure 3 or LLI O gt O z a Z lt or et LLI Ss Figure 5 Terrain Master Service Manual Pub 08 11 Page 92 Mower Repairs Rear Mower designed to slip absorb the shock load and protect the driveline It is important that the clutch lining plates slip when an obstacle or load heavier than clutch setting is encountered Therefore ifthe machine sits outside longer than 30 days and is exposed to rain and or humid air it is important to make sure that the clutch lining plates are not rusted corroded together Before using the mower use the following procedure to make sure the clutch will slip and give the overload protection required See Figure 13 this is a required step because the driveline has been sitting and may be stuck e Loosen nuts on springs until the springs can freely rotate yet remain secure on bolts e Attach mower to tractor and start the tractor Set the engine speed at 1200 rpm e Mark outer plates with marker paint or any form that will work for you to tell if the components of the clutch slipped e Engage the PTO approximately one second and then quickly disengage it The friction lin
32. outer pump is to be removed it can be removed and the inner pump left mounted NOTE When Unit was originally assembled the technician may have used a pipe sealer in the NPT fitting Use caution when Item 8 Figure 4 atthe pump Cap all hoses and pump ports immediately D Remove the two bolts which attach the outer pump ltem 2 figure 4 to the inner pump flange Remove the outer pump by pulling outward on it Once outer pump is removed cover the opening between the two pumps to keep it clean i U E If repairing pump go to pump repair section Wing Bouction Port for pump repair procedures Ifinstallinganew Mmmm M Pressure Out Port pump or rebuilt pump lightly oil new O ring Figure 10 ec Tae To LH Wing Motor and place on inner pump flange Install the new pump rebuilt pump with the pump drain r ports facing Hydraulic Tank Right hand side Case AMB Small Pump E ank Suction of tractor With your hands push the outer Drain To GP ieee Port see Port Small pump into the inner pump until the two pump __ Tank a UMP flanges are touching align the two flange S d bolt holes and install the retaining bolts CAUTION When working with aluminum Pressure a Out Port ASS EAN Leave Capped xX removing these that the sealer doesn t fall into the hydraulic system or any of it ports Clean all oil spills at once Cap O all hoses immediately to prevent contamination of the hydraulic system a Remove Outer and Inne
33. pressure Allow oil to cool before removing cap Relieve oil pressure before removing cap slowly Stay away from hot oil that may spray from tank PN HPFM 01 Terrain Master Service Manual Pub 08 11 Page 16 Safety ELECTRICAL amp FIRE HAZARDS ALAAVS Wing contacting overhead Strike and explosion Hazard Do not operate near fires electrical lines Blades Contacting Utility or Keep mower deck clear of Gas Lines debris A DANGER TO AVOID SERIOUS INJURY OR DEATH FROM ELECTRICAL CONTACT WHEN WORKING AROUND ELECTRICAL POWER LINES GAS LINES AND UTILITY LINES e INSPECT mowing area for overhead or underground electrical power lines obstructions gas lines cables and Utility Municipal or other type structure e KEEP all raised wings at a 10 feet or greater distance from all power lines and overhead obstructions e DO NOT allow mower to contact with any Utility Municipal or type of structures and obstructions e CALL 811 and 1 800 258 0808 for identify buried utility lines FIRE PREVENTION GUIDELINES while Operating Servicing and Repairing Mower and Tractor to reduce equipment and grass fire Risk e EQUIP Tractor with a FIRE EXTINGUISHER e DO NOT OPERATE mower on a tractor equipped with under frame exhaust e DONOT SMOKE or have open flame near Mower or Tractor e DO NOT DRIVE into burning debris or freshly burnt area e AVOID FIRE IGNITION by not allowing mower blade to contact solid objects like metal or rock e ADJUS
34. safety switch Cause 3 B Electrical Malfunction Solution 3 B Check electric circuit magnetic switches and push pull switch Cause 3 C Bad Solenoid Solution 3 C Check solenoid replace as needed 4 Possible Failure Insufficient cutting power or low cutter shaft speed Cause 4 A Drive belts slipping Solution 4 A Check for correct belts condition of belts check idler pulley and spring tension system for idler pulley replace and or repair as needed Cause 4 B Bound cutter shaft Solution 4 B Free up cutter shaft Cause 4 C Hydraulic Pressure relief stuck open or setting to low Solution 4 C Check setting and condition of hydraulic relief valve Repair replace as needed Cause 4 D Solenoid Spool will not shift completely Solution 4 D Replace solenoid valve cartridge Cause 4 E Worn Pump or Motor Solution 4 E Check pump and motor repair or replace as needed Terrain Master Service Manual Pub 08 11 Page 22 Failure Cause Solution Mower Function Troubleshooting 5 Possible Failure Hydraulic oil over heating mower free to rotate Cause 5 A Low oil level in hydraulic system Solution 5 A Fill to proper oil level U Cause 5 B Relief valve setting too low m Solution 5 B Check relief valve setting repair and o
35. should be rewashed and cleaned 2 Install snap rings item 6 and thrust race and bearing ltem 5 on driveshaft Install inner snap ring Item 12 onto driveshaft from input end Install one thrust race Part of item 5 onto driveshaft sliding it down against snap ring Install thrust bearing Part of item 5 onto driveshaft until it is against thrust race Install second thrust race Part of item 5 onto driveshaft until it is against thrust bearing Install second snap ring ltem 4 onto driveshaft until seated in snap ring groove of driveshaft and seated against thrust race 3 Replace needle bearing Item 9 into pump housing Item 11 Install needle bearing assembly into the pump housing If necessary install driveshaft tem 7 into pump housing tem 17 and install washer tem 3 4 Install input seal seal adapter kit Replace the O ring seal Item 2A on seal adapter Item 2C Install input seal Item 2B into seal adapter Coat the id of shaft seal Item 2B and O ring Item 2A of seal adapter Press seal adapter assembly into the pump housing Item 11 Install the outer snap ring Item 10 into pump housing until it is seated into snap ring groove of housing 5 Install pin keeper Item 1E and pins Item 1F into spline area of piston block Item 1D Compress pin keeper and install it in the splined area of the piston block Install the three pins in the special grooves of the spline area of the piston block with the head end of pin t
36. sight gauge If no oil is seen add oil to bring the level up to the sight gauge Note Do not fill the tank with oil above the level of the sight gauge Over filling the tank with oil after the initial filling may result in oil being discharged through the air filter on top of the hydraulic tank Start the tractor and run it for 2 minutes and then turn it off Again check the oil level in the sight gauge If the oil level is in the sight gauge the unit is ready to run If no oil is seen add oil to bring the level up to the sight gauge Sea AL A BP w Terrain Master Service Manual Pub 08 11 Page 104 Torque Chart Hose End Fitting Torque Specification Hose End Type 37 Degree Angle End Steel Hose End Fittings Se Size orque ft lbs 20 900 eeng Threads do not always seal better when higher torgues are used Too much torque causes distortion and may lead to leakage DO NOT over torque fittings and DO NOT allow any contaminants to enter system through fittings when installing them i JIG Go II T ON Go Go i LA LA Torque Values Bolts Maximum Torque per Bolt Size and Grade Ft lbs amp Nm IMPORTANT Listed below IS BOLT TORQUE and NOT APPLICATION TORQUE ComponentApplication Torque will vary depending on what is bolted down and the type material Metal that is being bolted together Thread condition and lubrication will vary Torque settings Proper Torque Val
37. suction port that is in the tank exclusively for the small pump The suction hose will need to be cut to length Make certain suction hose is not kinked See Figure 37 and 38 which shows these ports Make certain the elbow Pressure port of outer tandem pump See Figure 37 38 and 39 is installed and tightened pointing to the rear of the pump this is the pressure port to the cylinder control valve 9 Reinstall any engine guards and or screens that were removed to gain access to any component Some tractor and or mower models may have guards in place replace any of these that may have been removed See Figure 40 as example Out Pressure Ratch W otteo Adjusting Hole E Pe WS en E In Suction Figure 35 Ce A i g ABE A Side Terrain Master Service Manual Pub 08 11 Page 71 U C lt U gt Z O lt O O JJ Auxiliary Pump Removal Repair amp Replace Hydraulic Schematics See Hydraulic and Electric Schematic Figure 41 thru 44 on next pages Figure 41 Hydraulic Schematic Single Pump for single Wing with Auxiliary hydraulic pump for cylinder control Figure 42 Hydraulic Schematic Dual Pump for Dual Wing with Auxiliary hydraulic pump for cylinder control Figure 43 Hydraulic Schematic Single Pump for single Wing using tractor hydraulic pump for cylinder control Figure 44 Hydraulic Schematic Dual Pump for Dual Wing using tractor hydraulic pump for cylinder control ONS Tandem Pum
38. te GNV S0IAdSS Motor Drive Pulley Adjusting Cutting Height eg Figure 14 15 16 amp 17 N Lower cutter unit and roller to ground and place control gt a Idler Pulley valve levers in FLOAT position NA 2 Place lifting device scissors jack hydraulic jack under center of cutter housing or use an over head hoist When a Cuttershaft lifting mower deck always use jack stands to support the GK A Pulley object being lifted When working under a mower always AT use safety glasses allt 3 Removehexnuts washers and carriage bolts from bracket ZNA Idler at each end of roller Make certain that roller bracketis free i SEH Adjusting to move up and down once the fasteners are removed Spring A stuck roller could drop suddenly and cause an injury While lifting deck roller should be slid down or pushed up to change mowing height Do not lift mower very high with bolts removed from roller mounting bracket a stuck roller could drop suddenly and cause an injury 4 Use lifting device to reposition cutter housing to desired cutting height Align bracket holes with cutter housing holes then reinstall fasteners Refer to cutting height decal on mower or safety section 5 Lower cutter unit to ground then remove lifting device jack or hoist 6 When adjusting cutting height on Terrain Master chose the desired hole by reading the decal Shown in figure 50 which should be on the mower decks of the Terrain Master showing the
39. the driveshaft Slide the trust race and bearing Item 5 from the driveshaft Remove the second snap ring Item 12 from the driveshaft using snap ring pliers Terrain Master Service Manual Pub 08 11 Page 75 an O gt a Z lt A gt A Tandem Pump Disassembly amp Reassembly Inner Rear Pump Component Inspection For item numbers see figure 12 1 Wash all parts Wash all parts in suitable clean solvent Use clean filtered compressed air to dry parts after washing Do not use compressed air to spin bearing when drying parts Do not use rags or towels that will leave lint to dry parts Parts must be kept clean at all times Work area and place parts are kept during repair process must remain clean and dust free 2 Examine needle bearings Item 16 and 17 Inspect the needle bearings in the housing Item 4 and the back plate Item 2 If the needles are free of excessive play and remain in the bearing cage there is no need to replace the bearing assembly 3 Inspect thrust washers and thrust bearings Item 5 All surfaces should be free of any signs of wear or fretting Should be no sign of distortion or flaking 4 Inspect spider Item 1B and pivot Item 1C Conical surfaces should be free of wear and score marks 5 Inspect pistons Item 1A The OD surface should be smooth and free of scoring The shoes should be snug fit to piston The face of the shoe should be flat and free of scoring and flaking Do not lap
40. to Motor Figure 2 to Rear wettube Control Block Motor Drive Belt and f Pulley Pump Drive Pulley Figure 3 Wire Harness Figure 3 Terrain Master Service Manual Pub 08 11 Page 82 Motor Removal amp Replace flange will pull off front of motor If motor mount plate was unbolted from mower with the drive pulley attached to motor Motor pulley will need removal before mount plate can be removed 7 Motor replace or repair The motor is being replace continue to next step If motor is being repaired go to motor repair disassembly assembly section in next pages 8 Reinstall motor mount plate The motor mount plate bolts to the motor flange Motor mount plate bolts to deck of mower The mount plate will not require any adjustment as it bolts to deck in predetermined holes See Figure 4 9 Install motor drive pulley Insert motor key into motor shaft Slide the drive pulley onto motor shaft Insert taper lock pulley hub onto motor shaft and into drive pulley The pulley on motor will require alignment with the idler and cutter shaft pulley This may require moving and tightening pulley more than once Align motor pulley with other two pulleys as close as possible The taper lock mounting bolts will pull the pulley into the lock hub and sometimes may misalign the pulley if this happens loosen taper lock hub and reposition it and try again When pulley is aligned and taper lock hub tighten the three pulleys should be aligne
41. washers over 3 8 x 3 1 4 bolt place this through center of piston block Place other flat washer over the bolt and let it rest on the three pins Item 1F Screw the nut on and compress the spring inside piston block Use snap ring pliers and remove the internal snap ring Item 1K Unscrew bolt nut and two washers this will release pressure on spring Item 1H Remove spring Item 1K three pins Item 1F and the pin keeper Item 1E 9 Remove snap ring Item 10 Using internal snap ring pliers remove internal snap ring Item 10 from front side of housing Item 11 Seal adapter Item 2C has an O ring around the OD of it and may make it difficult to remove The motor shaft can be pushed from the back plate side of housing to push the seal adapter out 10 Remove input seal Item 2B seal adapter Item 2C The input seal will be remove from the adapter from the back side of the seal adapter Use caution when removing the input seal so you don t scratch or damage the interior seal seat area of the seal adapter 11 Remove seal washer tem 3 which is located behind input seal adapter It may require to lift the housing and dump the washer out 12 Remove driveshaft Item 7 from housing Item 11 The driveshaft must be pulled out of housing to the front side The driveshaft will have the retaining rings ltem 4 amp 6 and thrust race and bearing ltem 5 still on it when it is pulled out of housing 13 Remove snap ring ltem 4 and thrus
42. working length exposing unshielded driveline areas and entanglement hazards BEFORE REMOVING WING RETAINING LOCKS e FILL Wing Cylinders with oil Refer to Instructions in Operation Section e KEEP bystanders clear of area before operating wings e LOWER WINGS slowly and carefully DO NOT connect the Mower to a tractor with the PTO directly connected to the Tractor transmission PN CDFM 03 Terrain Master Service Manual Pub 08 11 Page 10 Safety THROWN OBJECTS HAZARDS ALAAVS Mower Thrown Raised Mower Inspect Area Do not let blades Objects Hazard Thrown remove foreign contact solid Objects objects objects ROTARY MOWERS CAN THROW OBJECTS 300 FEET OR MORE UNDER ADVERSE DANGER CONDITIONS TO AVOID SERIOUS INJURY OR DEATH TO OPERATOR OR BYSTANDERS FROM THROWN OBJECTS e KEEP bystanders 300 feet away STOP MOWING IF PASSERSBY ARE WITHIN 300 FEET UNLESS e All THROWN OBJECT SHIELDING including Front and Rear Deflectors Steel Guards Bands Side Skirts and Skid Shoes in place and in good condition when mowing e Mower sections or wing are adjusted to be close and parallel to ground without exposing blades e MOWING AREA has been inspected and foreign materials and debris have been removed e PASSERSBY are inside enclosed vehicle INSPECT AREA FOR POTENTIAL THROWN OBJECTS BEFORE MOWING e REMOVE debris rocks wire cable metal objects and other foreign material from area Wire cable rope chains and metal objects ca
43. 0 psi and is not adjustable B Oil high pressure port fitting This is a hose fitting that will screw directly into the manifold block for inlet pressure high pressure supply to motor C Control solenoid assembly The solenoid will consist multiple components that may D Machine access port plug This porthas no function other than itwas required during the manufacturing process and should always remain plugged E Oil return port fitting This is a hose fitting that will screw directly into the manifold block and is for oil leaving the motor This is a low pressure line F Motor case drain port fitting This is a hose fitting that will screw directly into the manifold block and is for case drain of the motor This is a low pressure line G High pressure test port plug This port is to enable technician to connect gauge to test the high pressure from the pump This portis to always remain plugged and only used when testing pressure Do not install a pressure gauge here and leave tt H Manifold mounting bolts There are four mounting bolts that are inserted into the manifold these bolts will go through the motor back plate and screw into the motor housing The torque of these four bolts are critical These bolts must be torqued at 15 to 18 ft Ibs 10 Reinstall motor and manifold assembly to mower deck See the previous section for instructions on how to connect motor and manifold assembly to mower Use extreme caution Do not connect the hig
44. 32 Cutter Shaft REpIaceme b a ze iGO ces PW EEE PAPAE PEP K W kw Gw EA PGE SOA steams 33 Culierohal Replacement ssrin nnn iR EER OEE E a EEEE SNERRE 33 Replacing Cutter Blades hntvesl ea aaa aaa aaa aanaa aaa aazaaa az zaaaaa aaa zaaaaazaazaa aa aazakaazzazaaaaaazaazazzaaaaEaa ia 33 Kaile WAS EA Eet VE 34 For ej cisi ROTAT EE EE 34 For Reverse Rotation EE 34 Changing Mower Cutter Shaft Rotation to Forward or Heverse aaa aaa aaa aaa aaa aaa aaaaaaaaaaaazzaaanai 34 MANG NOWO ae A OOO O OO OOO OTO AA 34 SR le EPE PCN 34 Check Relief Valve Pressure 35 Checking Relief Valve breseure 35 FAG IMAC lande 36 TANK FILLING kan CART LEE 36 Hydraulic Tank Repair Information E 37 Replacement of Return Filter Pressure Gauge aaa aaa aaa aa aa aa aa aaa aaa aaaaaaaaaaa aa aaaaaazaaaaazaaaaaaaazaaaziaaaaa 38 Remove Old Hydraulic System E E 39 Reinstall New Hydraulic System Eiter 40 Driveline Assembly EE 41 Tandem Pump amp Driveshaft Asy w Aux Pump cccccceeecceceessececceeeeeeecasecessuaeseeesaeuseeeseaseeeesaaeeeessaseessagees 42 Tandem Pump amp Driveshaft Asy w o Aux Pump 43 Single Pump amp Driveshaft Asy w Aux Pump ccceeccceeeeeeseeeeeeeeeeseeeeeeeeeeaeuseeeeesaaeeeeeeesssaeeseeeeessaeeeseeeeeaaas 44 Single Pump amp Driveshaft Asy w o Aux Pump ccecccccceeeeeseeeeeeeeceeeeeeeeeeseeeeeeeeeeeseeeeeeeeessaeeseeeessasaaeeeeeesaaas 45 Pump Mount Weldment Remove 8 Henlace AE 46 Eegeregie 46 Pump Mount Weldment Removal
45. 4 4 Remove front tank bumper weldment The front bumper weldment bolts to the tank mounting rails See Figure 5 Remove the front bumper 5 Remove tank Use an overhead hoist to support the hydraulic tank while it is being unbolted In figure 6 below the main and auxiliary pumps are not installed This is for illustration only the pumps can be left mounted to the tractor Remove the bolts on the side of the tank on both sides See Figure 6 With the tank supported by the overhead hoist slide the tank outward away from the pumps and then upward 6 Replace tank To replace the tank reverse the disassembly procedure and hose connections Refill hydraulic tank with new clean oil using a filtered oil buggy system is recommended U o JJ lt O O gt pa UO JJ Li gt JJ Return Hose from 4 Return Return Tank Return Filter Pipe Tee Sy Reducer Spool Control valve Hose from Pressure vs Fitting r A yf d C 8 e SECH A Port Marked T Ving Motor ee Oil Level sight Glass z or Ip e Elbow Oil Temperature PA m 73 Z ma PH Fitting ge Kaes ga N E Oil Level Figure 4 ez 4 Sight Glass Front Bumper Weldment Figure 6 Terrain Master Service Manual Pub 05 11 Page 37 Hydraulic Tank Repair Information Replacement of Return Filter Pressure Gauge 1 Return filter pressure gauge The return filter pressure gauge See Figure 8 amp 9 is a glycerin filled gauge which gi
46. 40 and Output Seal 001779 Inspect all opening for seals to make sure there are no Burrs or Scratches to damage seals when installed Always coat ID of Seals with light coat of grease this helps to prevent damage to ID of seals when being installed 10 Fill Gearbox with Oil till Oil flows out of Oil Level hole Install Oil Level plug and Oil Fill Plug Check all Seals and Gasket areas for leaks After Running Mower for 1 2 to 1 hour recheck oil level looking for any leaks HELP This later gearbox 702673 will only have a large 8 bolt cover on rear of gearbox without the small cover in center of it There is a ball bearing on front of input shaft the old style had all roller bearings input seals are different older gearbox seal is a bit larger than the later the later type used a snap ring behind seal to hold bearings in where the earlier type had bolt on covers If you have these bolt on covers see G B 700493 These gearboxes did not use vent plugs at all or LLI O gt O z a Z lt or et LLI Ss Terrain Master Service Manual Pub 08 11 Page 98 Section 5 Index Terrain Master Service Manual Pub 08 11 Page 99 Specifications Base Unit Specifications Overall Cutting Vd 16 5 18 5 or 209 Overall Cutting Widths Frame Construction asian oco GEE Full Length Welded Tubular Frame With Transport Lock Reservoir Capacity essoaaaaaaaassaaa nna 25 Gallon Reservoir PILE BO owce AEO
47. 9 Install pivot Item 1C spider Item 1B and piston assembly Item 1A Sit pivot Item 1C down onto piston block with taper rounded side up See figure 11 Sit spider Item 1B down over pivot noting concave hole in center of spider will sit over rounded edge of pivot align holes in the spider with holes in piston block Lower piston assemblies tem 1A through spider holes and into piston block piston assembly can be installed one at a time 10 Install piston block assembly ltem 1 The piston block assembly needs to be coated with oil Slide piston block assembly into end of pump housing aligning id of it over driveshaft Push piston block assembly into housing and over driveshaft until piston shoes are in contact with cam plate insert it may require driveshaft to be turned as piston block assembly is being slid in to align splines of shaft with spline of the components of piston block assembly Do not use excessive force to install piston block assembly if it will not slide together with the force of your hand there is something wrong 11 Install needle bearing tem 13 into back plate assembly tem 15 The needle bearings will install into center opening of back plate coat this bearing with oil as you slide it into back plate Install bearings into back plate with number end of bearing up and visible Bearing will be slightly higher 09 Than back plate See figure 13 12 Back plate Item 15 and sealing O ring Item 12 The bac
48. Cutting center of cutter shaft to support cutter shaft when Height Adjustment removing cutter shaft bearing Securely support cutter shaft Note the cutter shaft must remain supported while changing bearings 3 Remove outboard fender Figure 18 Instruction Grease hole in bearing must be DETAIL OF in line with hole in ROLLER BEARING housing to insure correct placement of grease fitting Figure 19 Terrain Master Service Manual Pub 08 11 Page 31 alia mta GNV S0IAdSS or a OI an a Z lt q LLI e gt am T T Cutter Shaft Bearing 1 2 3 Si E SCHER Remove fasteners securing bearing and housing assembly to cutter housing then remove bearing and housing assembly See Figure 14 Note There are two tapped holes in the housing which can be used to pull bearing and housing assembly out by using special tool no 701627 Using a jack to align parts install bearing and housing assembly to cutter unit and make certain that bearing setscrew If Used is located in keyway on cutter shaft Grease bearing and install cap over fitting If only the outboard bearing and housing assembly is to be replaced proceed as follows e Remove jack and check shaft rotation e Reinstall Knives which were removed e Reinstall outboard fender e Remove supports lower unit to ground and test unit If the inboard drive bearing is to be replaced proceed to step 6 Drive End Cuttershaft Bearing S
49. ES disengage PTO and wait for blade to stop rotating before raising mower deck or wings e STOP LOOK and LISTEN before approaching the mower to make sure all rotating motion has stopped PN MBFM 01 ALAAVS Terrain Master Service Manual Pub 08 11 Page 15 SAFETY Safety HIGH PRESSURE OIL LEAK HAZARD High pressure oil High pressure oil Using cardboard to Tank contents under penetrating skin eroding skin check pressure Allow oil to for oil leaks cool before slowly removing cap TO AVOID SERIOUS INJURY OR DEATH FROM HIGH PRESSURE HYDRAULIC OIL LEAKS DANGER PENERATING SKIN DO NOT OPERATE equipment with oil or fuel leaks KEEP all hydraulic hoses lines and connections in GOOD CONDITION and TIGHT before applying system pressure RELIEVE HYDRAULIC PRESSURE before disconnecting lines or working on the system REMOVE and replace hose if you suspect it leaks Have dealer test it for leaks HIGH PRESSURE FLUID LEAKS CAN BE INVISIBLE WHEN CHECKING FOR HYDRAULIC LEAKS AND WORKING AROUND HYDRAULIC SYSTEMS ALWAYS WEAR safety glasses and impenetrable gloves USE paper or cardboard to search for leaks DO NOT USE hands or body parts to search for leak KEEP hands and body AWAY from pin holes and nozzles ejecting hydraulic fluid Hydraulic fluid may cause gangrene if not surgically removed immediately by a doctor familiar with this form of injury Use Caution when removing Hydraulic Tank cap Tank content maybe under
50. Extended Shaft Asy Rear Mower cccccccccceesseseceeeeeeeeeeceeeeeeeeeeeeeesaeeeeeeeeessaeeeeeeesssaeeeeeeeesaaas 94 Gearbox 8 Extended Shaft Asy Rear Mower cccccccccceesseeeeeeeeeeseeceeeceaaeeeeeeesaeeeeeeeesseeeeeeeeeesseaaeeeeeseaaas 95 Gearbox and Extension Shaft Assembly Remove Repair and Replace ccccccccesceeceeeeeeeseeeesneeeeseeeeeas 95 Gearbox Asy P N 700493 ania io EEEE E TEAR EE EE EEEE E EREE ETENE 96 Gearbox Asy P N 700493 Asy Instructions cccccceeeeecceeeeeeeeeeceeeeeeeeeceeeeeeeeesseeeeessaeeeceeesssaeeseeeeessseaeseeeesaaas 97 Assembly Instructions Gearbox 700493 csecsscesaesnesceevennnceseewegecnccecusnevacdanaenseiceepededecansiccetacasoecsenewveencceeeieass 97 Gearbox Asy Ee 98 Gearbox Asy P N 702673 Asy ee 99 Assembly Instructions Gearbox 702673 Used Feb 1991 amp Uni 99 Je E 100 BaSe ee CM CONS cca ccc EC A De EAC Ci dE WY A OC dE c 101 Wing Mower Specifications kasia OE OGAE EEE OPEC wia zawiercie e cyi 101 Rear MOWELCSPECNICANONS E 101 CAT I Implement Hitch Gpechcaton 102 CAT Il Implement Hitch Specification saski RANE ACE KA OWE JA OPACZ 102 Special Tools AV alll DI E 103 ODEGALIGOSANGNAOJE E 103 Hydrauli Pump TESTING smecnsesiahasciancadhcnteneiamaasneu duane nnnestanvania wxbdiveesalentaanasueeniaecnsaiaGesnanaiouisediendasionsacunmniinexiecetaivut 104 Ay AUN Pump LOSING E 104 Test Equipment Needed zes OEG esas inne vancesaccsnccaveaneceaaonasesoeesencaeieacnte
51. Readjust the Auxiliary pump drive belt if model uses auxiliary pump Reinstall all guards that were removed Do not leave guards off when running mower or tractor U C lt U gt Z O lt O O JJ Single and Tandem Pump The single pump is used on single wing Terrain Masters only The pump can be identified by the location of the inlet and outlet port they are located in the end plate facing outward See figure 10 the dual pump inner and outer pump will have the inlet and outlet ports to the sides of the pump See figure 11 The inner pumps end plate has a flange built on to it to allow the outer pump to bolt to the inner pump The disassembly process for the inner and outer pump is basically the same for the inner outer tandem and the single pump The large difference is in the end plates and the shafts for the tandem pump The single and the tandem pump has two different cu In Sizes It will be required to know which pump before ordering parts for them this is important as the wrong pump used will cause problems because of oil volume Terrain Master Service Manual Pub 08 11 Page 61 Tandem Pump Disassembly amp Reassembly Tandem Pump Dual Wing Model Pump ID Reference No is Stamped Here Inner Rear Pump P N 001840 2 77 CID P N 001734 2 28 CID p 7 Om AW GAR we A R W A f Se SN SE E k g Pump ID Reference No is Stamped Here T PUMP AND MOTOR
52. SHING WARNING LIGHTS e ALLOW clearance for implement swing while turning KEEP all raised wings at 10 feet or greater distance from all power lines and overhead obstructions PN TH01 Terrain Master Service Manual Pub 08 11 Page 18 Safety HAZARDS WITH MAINTENANCE OF IMPLEMENT ALAAVS Periodically inspect Stop engine Block up all moving parts remove key implement before cylinder Blades for lubricate drivelines before servicing Use transport damage or and tighten all conducting large blocks on locks cracks fasteners maintenance soft or wet soil AVOID SERIOUS INJURY OR DEATH FROM COMPONENT FAILURE BY KEEPING IMPLEMENT IN AWARN ING GOOD OPERATING CONDITION IN PERFORMING PROPER SERVICE REPAIRS AND MAINTENANCE BEFORE PERFORMING SERVICE REPAIRS AND MAINTENANCE ON THE IMPLEMENT e STOP ENGINE AND PTO engage parking brake lower implement allow all moving parts to stop and remove key before dismounting from tractor e PLACE implement on ground or securely block up raised equipment Use large blocks on soft or wet soil e PUSH and PULL Remote Hydraulic Cylinder lever to relieve hydraulic pressure e DISCONNECT IMPLEMENT driveline from tractor PTO SHAFT WEAR SAFETY GLASSES PROTECTIVE GLOVES and follow SAFETY PROCEDURES when performing service repairs and maintenance on the implement e Always WEAR protective GLOVES when handling blades knives cutting edges or worn component with sharp edges e Always WEAR GLOVES and SAFETY
53. T SLIP CLUTCHES to avoid excessive slippage and clutch plate heating e CLEAR any grass clippings or debris buildup around mower drivelines slip clutches and gearboxes e SHUT OFF ENGINE while refueling e Do not operate if oil is leaking Repair oil leak and remove all accumulated oil before operating e CLEAR any grass clippings or debris buildup around mower hydraulic pumps valves or tanks PN EFFM 01 Terrain Master Service Manual Pub 08 11 Page 17 gt LLI LL lt Y Use SMV signs Loss of Control Loss of Control Use Safety Tow Engage Transport and Flashing Stopping Speeding Chain Tractor to Locks Lights Hazard Hazard Implement TO AVOID SERIOUS INJURY AND DEATH WHEN TOWING OR TRANSPORTING EQUIPMENT AWARNING e KEEP transport speed BELOW 20 mph to maintain control of equipment e REDUCE SPEED on inclines on turns and in poor towing conditions e DO NOT TOW with trucks or other vehicles e USE only properly sized and equipped tractor for towing equipment e FOLLOW all local traffic regulations TRACTOR REQUIREMENTS FOR TOWING OR TRANSPORTING IMPLEMENTS e ONLY TRANSPORT with tractor with ROPS in the raised position e USE properly sized and equipped tractor that exceeds implement weight by at least 20 e KEEP 20 of tractor weight on front wheels to maintain safe steering BEFORE TRANSPORTING OR TOWING IMPLEMENT TRACTOR INSPECTION e CHECK steering and braking for proper operation and in good condition
54. Terrain King rm 1502 E WALNUT ST SEGUIN TX 78155 5202 800 882 5756 Engineering Practical Solutions Pub 08 11 Part No 3XXXXXXXXX Terrain Master Flail King Service Manual WE RL wr Fa K E re AU BOB A LE bk E EE MEMBER OF THE 3 e l ALWAYS OH THE CUTTING EDGE K ee el ben RT rt ee ATENCION AE An Operator s Manual was shipped with the equipment in the Manual p Canister This Operator s Manual is an integral part of the safe operation ja of this machine and must be maintained with the unit at all times READ UNDERSTAND and FOLLOW the SAFETY and Operation Instructions ma contained in this manual before operating the equipment If the Operator s Que Se Lo Lea Para Que le Manual is not with the equipment contact your dealer or Terrain King 800 Traduzca Las i Medidas de Seguridad 882 5756 to obtain a Free copy before operating the equipment Si No Lee Ingles Pida Ayuda a Alguien 2011 Terrain King TO THE OWNER OPERATOR DEALER All implements with moving parts are potentially hazardous There is no substitute for a cautious safe minded opera tor who recognizes the potential hazards and follows reasonable safety practices The manufacturer has designed this implement to be used with all its safety equipment properly attached to minimize the chance of accidents BEFORE YOU START Read the safety messages on the implement and shown in your manual
55. Tube Port Manifold Return Oil Port Machining Port Manifold Mounting Hiah Pressure to Deck Cooling Tubes Plugged Bolt Holes qty 4 Relief Valve Port a e Inlet Port High Pressure Low Pressure Motor High Pressure Test Manifold to Motor Manifold Oil Return Case Port Plugged Relief End Inlet EF from Motor Port Drain y Control d Solenoid O Top Port Motor gt Case Drain CH je Q Control Pressure O Manifold Return Oil Port Solenoid niet Port to Deck Cooling Tubes Port Figure 8 High Pressure Re Manifold Mounting Solenoid gu Manifold Inlet Port Bolt Holes qty 4 Port Plugged Control Terrain Master Service Manual Pub 08 11 Page 84 Motor Manifold Remove Repair amp Replace 7 Installing new manifold block Always wash a new manifold block with clean solvent the same as when reinstalling an existing one Dry the manifold block using filtered compressed air to remove all solvent This cleaning is critical to make certain the passage ways and ports are cleaned 8 Holding manifold for reassembly If manifold is clamped in a vise extreme caution must be taken to not damage aluminum manifold block with vise It is recommended that the manifold be bolted to the motor after it has been bolted to the deck or while motor is still clamped in vise See Figure 9 9 Reassembly of manifold With manifold secure re install components to the manifold See Figure 7 8 amp 9 A Pressure relief this is preset at 400
56. WAYS REPLACE GUARDS that have been removed for service or maintenance e Do Not use PTO or PTO guard as a step TO AVOID broken driveline during operations e CHECK driveline for proper length between PTO shaft and implement gearbox shaft Refer to Instructions in Operation Section e Drivelines too short can pull apart or disengage e Drivelines too long can bottom out Bottoming driveline telescoping assembly will stop sliding and become solid e Driveline bottoming can push through support bearings and break off PTO shaft e AVOID sharp turns or lift mower to heights to cause driveline knocking e Lubricate driveshaft telescoping components weekly CONTACT DEALER if implement driveline does not match Tractor PTO shaft e DO NOT USE PTO ADAPTER Using a PTO adapter can cause excessive vibration thrown objects blade and implement failures by doubling operating speed Increased working length exposing unshielded driveline areas PN PE01 Terrain Master Service Manual Pub 08 11 Page 14 Safety MOWER BLADE CONTACT HAZARDS eg Do not put fingers Do not put foot underneath stop Tractor Remove Key underneath mower mower Read Manual KEEP AWAY FROM ROTATING BLADES TO AVOID SERIOUS INJURY OR DEATH FROM DANGER BLADE CONTACT e STAY AWAY and KEEP HANDS FEET and BODY AWAY from rotating blades drivelines and parts until all moving elements have stopped e DO NOT put hands or feet under mower decks e STOP rotating BLAD
57. aceeene Gad Ed worki WE EYE 104 AUD PTO COUS E 105 initial Start Up PROC CONC PANA 105 TOS GV GE 106 Hose End Fitting Torque Specification ccccccccsscccesccceececeececeuceceuceceucessuseceueeceaeeeseeesaeeesaueesaueesaueesueeseaees 106 MIOUEVIIUES BOIS aaa WER WG WON AE AZ AO AO TAA Z A A 106 Torg e WIJE lt TA 107 Hydraulic Schematic WI Auxiliary Pump RH Wing n00nnnnaannnnnannnnnnnnnonnnnnnnnnnnnsnnnnnsnnnnnssnrnnsrnnenssnrresenneenne 108 Hydraulic Schematic WI Auxiliary Pump Dual Wing cccccceseeeeeccaeeeeeeceeeeeeeeseeseeesseeeeeeesseeseesseaeeeessaaaeess 109 Hydraulic Schematic W O Auxiliary Pump RH Wing ccccccssseeeccecceeeeeceeeeceeeeeeceeeeseeeeeeeeeeeseaeeeeeeesesseeeeees 110 Hydraulic Schematic W O Auxiliary Pump Dual Wing cceccccccceeseeeceeeeceeeeeeeeeeeseeeeeseeeeeseeeeeeeeeesaaeeeees 111 Pump amp Motor Hydraulic Schematic RH Wing On 112 Pump amp Motor Hydraulic Schematic Dual Wing esa sseaaeee aaa aaa aaa aaa aaaaaaaaaaaaaaaaaaaaaaaaaaaaaaazaaaaaaeaaa aaa 113 P mp amp Motor e ele ee 114 Valve to Cylinder Hose Connections Cab A HOPE 117 Wiring Harness Schematic CAB amp ROPS ccccecccccccsssseeeeeeceeeeeeeeeeeseeeeeeeeeeeseeeeeeeeeseaaeeeeseeeaaeeeeesessaaaees 118 Motor Control Switch Dual Wing E 119 Motor Control Switeh RA WINO ON E 120 Wing Wire Harness RH Wing Single Wgl 121 Wing Wire Harness LH amp RH Wing Dual VWumg E 122 De
58. adapter mounting point of torque wrench to center of hex slot 9320 ft lbs torque desired torque at end of extension Unknown setting to set torque wrench for 320 ft lbs of torque A 22 57 22 57 or 320 x 320 xX 222 ft lbs A B 22 57 10 0 32 57 UOU gt l U I 9 x lt Your Answer D is a setting of 222 ft Ibs on the torque wrench will give 320 ft Ibs of torque at the bolt By using the above formula an accuracy of or 6 of the desired torque will result at the end of the adapter due to length change during grip adjustment Terrain Master Service Manual Pub 08 11 Page 106 Hydraulic Schematic W Auxiliary Pump RH Wing Motor Return Hose Ces Cooling Tube Sea Cyl Control Valve Cyl Valve Return Line Cyl Valve Pressure Line Cooling Tube Motor Return Hose amp Deck Cooling Tanks Suction Line Tank Return Filter amp Return Pressure Gauge Hydraulic Tank Terrain Master Service Manual Pub 08 11 Page 107 Hydraulic Schematic W Auxiliary Pump Dual Wing LH Wing RH Wing Tilt Cyl Tilt Cyl RH Wing Lift Cyl i Cyl Control Valve Cooling Tube Motor Return Hose amp i Deck Cooling Tanks RH SEs oo Af Cooling Tube Pump LH Wing Cyl Valve Cyl Valve Tank Return Pump ee Ge Filter amp Return aaa GOKU eh Hyd
59. ades be removed for disassembly and reassembly 1 Place mower units resting on the ground or securely support at a convenient height 2 Remove cutter shaft bearing and housing assemblies as outlined in paragraph cutter shaft bearing repair replace section on previous pages After removing both inboard and outboard bearing assemblies the cutter shaft can be removed and a new one installed It may be necessary to remove two sets of knives nearest the drive end of cutter shaft to allow cutter shaft to slide inward far enough for other end to drop down 3 Install new bearing and housing assemblies as outlined in inboard and outboard bearing repair on previous pages Replacing Cutter Blades Knives The cutter knives are attached to the cutter shaft in three different ways depending on the cutter shaft application there is fine cut and course cut These cutter shafts use different types of blades and different type blade hangers To remove existing knives remove and replace hanger components See Figure 23 A Type A is used on fine cut cutter shaft and is the standard fine cut knife It is retained with a hardened nut and hardened bolt These pin must be installed with the head and cotter pins a certain way see below for installing pin depending on cutter shaft rotation B Type B is used on fine cut cutter shaft and is the standard fine cut knife It is retained with a hardened pin and hardened cotter pin These pin must be installed
60. aft until later Make certain that auxiliary pump drive belt is installed on pulley f auxiliary pump is used F Ifthe pump is to be repaired see pump repair section If pump is being replaced bolt the inner and outer pump together on the bench or bolt inner pump to pump mount plate and then bolt the two pumps together Dual wings with tandem pump Install new pump to inner pump making certain both case drain ports are facing hydraulic reservoir RH Side of Tractor G Reconnecting hoses to the two pumps Or single pump single wing Connect the case drain hose and the pump pressure hose first The suction hose port will have an elbow connected to it Fill this elbow with new clean hydraulic oil before connecting the hose this will prevent pump from starting dry when tractor is started later H Fill the hydraulic system with oil to the correct level always use a 10 micron max filter system to install oil Filter buggy system are commercially available Inspect oil sight gauge and temperature gauge to make certain they are not damaged Start Tractor and run system checking for leaks I Return Filter pressure gauge watch the return filter gauge When the oil is cold the gauge may show in the red and as oil gets up to normal operating temperature the gauger should drop to the green zone If gauge pressure doesn t drop to green zone check filter for being plugged and or check all hoses to make certain they are not crimped shut or in a bind J
61. after assembly is completed Terrain Master Service Manual Pub 08 11 Page 52 Slip Clutch Slip Clutch A slip clutch is incorporated in the PTO driveline It is designed to slip absorb the shock load and protect the driveline After the first hour of operation the slip clutch should be checked for overheating After this first check the slip clutch should be checked weekly or anytime there is overheating To adjust the slip clutch tighten the spring bolts 1 8 maximum turn at a time Bolts should NEVER be adjusted to the point where the springs are compressed solid Minimum spring compression length is 1 1 4 The slip clutch should be checked periodically and adjusted to compensate for wear The lining plates are 1 8 thick when new Replace after 1 32 wear If the mower has been idle for an extended period of time or in wet weather before operating check to be sure the friction lining plates are not frozen or rusted together Should this freezing occur refer to the procedure described in the Seasonal Clutch Maintenance section on the next page Mark all plates to determine rotation during seasonal clutch procedure 1 5 16 Standard 1 1 4 Min Compression O D lt TT Z TI gt U U 0 lt e lt 5 O et A Friction aN ACIS Lining WAVY VAY LR Vi Plates NNZ SANA E ANY pas Qa N WWW J U Z me J W slip Clutch Maintenance a e V d Spring
62. all hole over the anti extrusion block The grooved side of seal must be installed to the opposite side as the anti extrusion block See Figure 29 6 Install wear plate The wear plate is also referred to as other thrust plate The wear plate will have one side that is bronze this bronze side must face the gears for proper wear and performance See Figure 29 7 Install drive gear and driven gear Check the input shaft of the drive gear around the keyway slot to make certain there are no burrs or sharp edges that will cut the seal Coat the input shaft of drive gear with Vaseline at seal wear area Install the drive gear into the pump body using caution when pushing through the input seal Install the driven gear coat the driven gear shaft with coat of Vaseline and insert the gear into the pump body Inspect gears the upper edge of the gears should be even if they are not check components already installed to make gt Shaft Seal Pump Mounting Flange Anti Extrusion Block Snap Ring TI C lt U gt Z O lt O O JJ Gasket Insert Pump Body X Bridging Insert M Cover Seal Assembly Suction Side o Wear Plate Bronze si Pump LH Side Side Toward Gears O ring TE when sitting o tractor facing Figure 29 Pressure Side of Pump RH ac when forward sitting on tractor facing forward ss Terrain Master Service Manual Pub 08 11 Page 69 an O gt a Z lt A gt A Auxiliary Pump Reassem
63. and outer pumps must be removed from tractor Follow same procedure as for outer pump above plus instruction for inner pump below NOTE Clean spills at once Cap all hoses immediately to prevent contamination of the hydraulic system B Separate the outer pump from the inner This is done by disconnecting hoses to inner pump ltem 5 7 and 9 Figure 4 and 5 Remove the tow bolts holding the outer pump the inner pump or they can be left together and unbolted on the work bench Remove the two retaining bolts that mount the pump pumps to the pump mount plate C The pump will slide out of the pump mount plate the driveshaft may slide back with it or it may stay in tractor the splined coupler that connects the pump to the driveshaft may stay on driveshaft or it may stay on pump D Check driveshaft crankshaft pulley adapter and splined coupler for wear and condition If any of these parts are to be changed it is important to check the length of the new and old part to make certain they are the same Do not use coupler pulley adapter or driveshaft that is worn or damaged do not use driveshaft that is to long or to short E Make certain that driveshaft is installed into crankshaft pulley adapter correctly Make certain drive shaft is inserted through driveshaft bearing and lock collar correctly Make certain spline coupler or splined coupler pulley weldment with auxiliary pump is installed correctly Note do not tighten auxiliary pump pulley to drivesh
64. and present a safety hazard Use genuine Terrain King mower parts for economy and safety SPTk 1 SAFETY SEE YOUR TERRAIN KING DEALER Terrain Master Service Manual Pub 08 11 Page 20 Section 1 General Mower Service and Repairs Terrain Master Service Manual Pub 08 11 Page 21 Failure Cause Solution Mower Function Troubleshooting 1 Possible Failure Mower will note rotate Cause 1 A ln line fuse on Wire harness failed Solution 1 A Replace fuse as required D Lause 1 B Magnetic Safety Switch not making contact T Solution 1 B Adjust or replace switch as required LLI Cause 1 C Broken or worn drive belts LC Solution 1 C Replace drive belts as needed a Z Cause 1 D ON OFF Switch defective or broken Es Solution 1 D Inspect test switch and replace as required LU Cause 1 E Insufficient Voltage through solenoid O Solution 1 E Check solenoid coil and wiring replace repair as needed gt ag Cause 1 F Solenoid Spool will not shift completely LLI Solution 1 F Clean or replace solenoid cartridge I 2 Possible Failure Mower will not stop Cause 2 A Solenoid Spool will not shift Solution 2 A Clean or replace solenoid cartridge 3 Possible Failure Intermittent mowing power Cause 3 A Safety switch maladjustment Solution 3 A Adjust
65. arings 8 Hours 2 3 Telescoping Tube 8 Hours 6 8 Shield Bearings 50 Hours 1 2 Yoke Hub 20 Hours 1 2 Terrain Master Service Manual Pub 08 11 Page 49 Driveline To Disassemble Universal Joint 1 Remove all snap rings 2 Position joint in loose vice strike top arm of unsupported yoke to drive the top cup up Repeat on opposite side 3 SS LI N Ze lt q LI lt LI gt ag O 3 Ifyou cannot grip the loosened cap per Step 4 use a pointed tool to tip a needle them repeat Step 2 4 Grip loosened cup in vise strike yoke arm to drive yoke off cup Repeat on opposite cup 5 Support cross in loose vise and strike yoke arm Repeat Step 4 to remove remaining two Cups Terrain Master Service Manual Pub 08 11 Page 50 Driveline To Reassemble Universal Joint 1 Smear grease into bearings and check for dirt CAUTION Make sure all needle bearings are seated properly 2 Insert cup and cross Drive in with spacer w D lt TT Z I gt U U a lt e lt 3 Insert snap ring 4 Insert second cup and hold cross into cup Drive cup flush with arm Terrain Master Service Manual Pub 08 11 Page 51 Driveline 5 Drive cup down with spacer and insert snap ring 6 To loosen cross strike yoke arm and check cross for free rotation a 0 gt LI Se Ze lt q LI lt LI gt ag O 7 Position second yoke on cross Repeat Steps 2 to 6 8 Grease Kit
66. ate Remove the O ring seal tem 8 from backplate ltem 26 4 Remove complete piston block assembly Item 19 f oump housing Item 22 Lift the piston block assembly upward and out of the pump housing it may require you to remove pump from vice and dump the piston block assembly out If you do catch the block with you hand dont let it fall out on the floor or bench Do not remove the spring snap ring Item 19K from the piston block assembly as the spring Item 19H has compression on it this compression will require relieving before snap ring is removed this can be done later 5 Remove the piston assembly Item 19A from the piston block Item 19D The piston assembly will pull upward and out of piston block 6 Remove spider Item 19B and pivot Item 19C The spider Item 19B will be left lying on the piston block when the piston assembly is removed The pivot tem 19C will also be left on the piston block and can be removed 7 Piston block disassembly Item 19D The piston block assembly need not be disassembled unless the pins Item 19F or the spring Item 19H is damaged Caution The following procedure should be used if the spring is to be removed from the piston block The spring Item 19H is highly compressed and the snap ring Item 19K should not be removed without compressing the spring The following parts will be needed to disassemble the piston block 2 Ea 3 8 Id x 1 1 8 OD flat washer 1 Ea 3 8 Nc x 3 1 4 bo
67. auxiliary pump in vice Clamp the pump in a vise with protective devices for the jaws Clamp the pump in the vice at the pump mounting flange use caution do not over tighten the vice and damage pump mounting flange See Figure 28 5 Unbolt the pump assembly bolts that hold the two pump halves together See Figure 28 6 Remove the cover half of the pump will lift up and off with out to much resistance do not hammer on pump housing Drive gear and driven gear should remain in lower pump body half Look for any components that may stay in pump cover half or fell out onto the floor Such as items 2 7 8 see figure 29 7 Pull the drive gear and the driven gear form pump body half Note gear set is not shown Take notice of items 3 4 5 when pulling gear set from pump body See Figure 29 If item 3 4 and 5 stay in the pump body half when gear set is removed it is OK Remove them now by pulling them upwards out of pump body 8 Remove pump shaft input seal Using the appropriate snap ring pliers remove the seal retaining snap ring Using a seal removing tool remove the input seal use caution not to damage the pump body housing when removing seal 9 Clean all pump components Clean the pump components with clean solvent do not use any abrasive cleaning pads or powders as these would damage pump housing components Completely dry all pump components with clean compressed air Do not dry parts with rags or towels that will leave lent or fuzz on compo
68. bles be disconnected from tractor battery 1 Remove drive belt cover on wing mowers Remove drive belt cover See Figure 1 which will allow access to the motor drive belt and pulley See Figure 2 2 Disconnect hoses from wing motor The hoses on the wing will need to be disconnected from motor Cap plug Motor Drive Belt and E these hoses and all openings in motor immediately when Pulley Cover you disconnect them See Figure 2 d E i 3 Disconnectwire harness from motor control block Unplug wire harness connection at the motor solenoid on the motor control block It will not require that wire harness be completely removed only unplugged and lay it aside See Figure 3 4 Remove motor drive pulley on wing mower The drive pulley is retained with a taper lock pulley Remove the bolts and start them in the other holes in the hub This will force the pulley inward off the tapered hub Hub should pull off the pump shaft See Figure 4 Figure 1 5 Remove motor asy from wing mowers Remove bolts retaining motor mount plate to deck and lift motor off and away from deck 6 Remove motor mount plate from motor Motor mount plate bolts to motor flange Remove these bolts and mount Motor amp Motor Mount Plate Return f front wet tubeg to hydraulic Tank High Pressure Hose qj a Leg Motor Return Si e Pump Drive Pulley to rear Wet es Taper Lock Hub Case Drain H Pump Return f Motor Motor
69. bly amp Reinstall certain they are seated correctly Do not attempt to continue assembly if gears are not even in height Install gasket insert and bridging insert The pump cover will have the bridging insert and the gasket insert installed into it See Figure 29 Coat the bridging insert with a coat of Vaseline Insert the bridging insert as shown in figure 29 with the lip toward cover and the square edge toward the center Coat the gasket insert with Vaseline and install it into the pump cover making certain that it seats against the bridging insert Install O ring into pump cover Coat O ring with Vaseline which will hold the O ring in the pump cover for assembly Insert it in grooved space around hole in pump cover apposite where bridging insert installs See Figure 29 Install the pump cover to pump body Install pump cover over the gear set make certain that the O ring gasket insert and bridging insert don t slip out The pump cover should slid down over the gear set until the pump body and the pump cover are touching If the pump cover and pump body has a gap between them there is something 10 1 wrong do not install bolts or try to force them together as it will cause damage Recheck the assembly to see what is preventing them from sliding together See Figure 29 Bolt pump cover and pump body together There are four bolts and lock washer used to bolt the pump together These bolts screw into the aluminum pump body Do not over
70. ce Manual Pub 08 11 Page 65 Auxiliary Pump Remove amp Repair Single Pump and Single Wing The pump for the RH wing only single pump has one pressure hose The rear a closest to tractor engine it the supply lt kx VAE 7 Pump for the RH wing motor The LH fitting is lpi x alee the motor pressure supply The hose for the RH wing should be marked with a red Pressure N plastic tie on it connect these two hoses Out Port d ew ae Leave Capped at the pump now See figure 19 When To RH gt ke ie me on RH Only single wing there will only one suction port Wing Motor o d Model of tank used leave a cap on the other port See figure 19 Case Small Pump Elli Tank Suction Drain To seam Pressure Port Port Small Case Tandem Pump and Dual Wings Drain From Se The pump for the dual wing is a tandem Pump pump and will be connected different than the single wing The tandem pump has two Port suction hoses two case drain hoses and From two pressure hoses See figure 20 Figure 19 Tank Suction Suction Hoses From Motor Supply Pumps The suction hose is used for each pump section Single or dual as shown When single pump is used one of the suction ports of the pump will remain plugged See figure 5 and 19 an O gt a Z lt A gt A Auxiliary Pump Operation The auxiliary pump is used to supply hydraulics to the cylinder control valve This pump is powered by the tractor
71. ch pins for the hitch category being used For a Cat hitch 7 8 lower and 3 4 upper diameter hitch pins are used and Cat II hitches require 1 1 8 lower and 1 upper diameter hitch pins Top Link Attaches Here CAT Implement Hitch Specification Width from outside to outside A frame 26 7 8 Quick Hitch width inside lug to lug 27 1 8 gt 0 p Height from bottom hitch pin to top pin 18 aS s i Lower pin dameter aaa aaa 7 8 Lift Arms Upper pin diameter 0 cccceeecceeeeeseeeeeeseeeees 3 4 a Attach Here Linch pin diameter cccccccsseeeesseeeseeeeeees 15 32 Height from bottom hitch pin to top pin 19 CAT Il Implement Hitch Specification Ti pin ee Bee Wed tte na 39 3 8 Kaen pin alee ZE aa Quick Hitch width inside lug to lug 33 5 8 ynch pin diameter auuaaaaaaaaaaasaaa nana Terrain Master Service Manual Pub 05 11 Page 101 Special Tools Available Special Tools Available Special tools for installing and servicing Terrain Master kits are illustrated on the below Drawings for these tools are available on request If desired tools may be obtained from Alamo on a made to order basis Prices will be furnished on request Figure 1 p Item PartNo Code Description 1 701628 S Lift Frame Asy Suspension Chain 2 701627 A Cuttershaft Brg Puller 3 104764 A Lift Frame Alignment Pin
72. ction depending on the inlet port used An arrow on the flat surface of the motor housing at both ports indicate the direction of rotation To change rotation remove the four bolts that mount the manifold block to the motor Remove the case drain hose at the motor but leave it attached in present location at the manifold block Leave all other plumbing as presently installed at the manifold block Remove the two mounting bolts at the motor mounting plate and rotate the motor 180 this changes the present inlet port into the outlet port of the motor Reinstall manifold block but do not change the position Install case drain hose Rear Mower To change direction of cutter shaft rotation for the rear mover three left hand parts are required A belt guard an outboard bearing plate and a idler pulley arm Consult parts book for these part numbers Remove the cutter shaft and turn 180 remove the gearbox cutter shaft drive pulley and outboard bearing plate using the proper bearing plate mount the plate to opposite side of mower housing Remove the four bolts that mounts the gearbox and rotate gearbox 180 to new position Install cutter shaft pulley gearbox output pulley idler arm pulley assembly and belt Replace existing belt guard with proper guard Terrain Master Service Manual Pub 08 11 Page 34 Check Relief Valve Pressure Checking Relief Valve Pressure 1 To check the relief valve pressure setting remove inlet hose atthe control valv
73. curs shims not furnished must be welded to axle pivot stop or steering arm to limit the movement enough to avoid interference Tractors with an adjustable front axle may require an outward adjustment of the wheels 6 To fill the Terrain Master reservoir with new clean hydraulic oil follow the steps below Refer to the operation and maintenance section for specifications See Figure 16 e With a hydraulic jack raise the right side of the tractor This will tilt the tank and allow only a minimum amount of air when filling e Avoid hydraulic contamination by filtering the hydraulic oil while filling the hydraulic tank e Filter buggies or carts are commercially available for hydraulic system cleanup These consist of a high efficiency high capacity filter a circulating pump a drive motor and hoses for connecting the overhauled machine s hydraulic system e After the first 10 hours of operation replace the hydraulic filter with a new one An extra filter element is provided for you Refer to the operation and maintenance section for instruction 7 After the Terrain Master mower is completely assembled to the tractor and with the wings on the ground fill the mower hydraulic tank above the oil level sight gauge approximately 5 or 1 below the top of the tank 8 With mower on off switches in ON position and tractor fuel cut off crank engine for about 30 to 45 seconds to allow oil to fill pumps and motors Check the oil level in the
74. d Check alignment with a straight edge sighting across the three pulleys 10 Install drive belts Drive belts should be a matched set of belts Check to make certain belts are in serviceable condition The drive belts install over the top drive pulley and then idler pulley this will leave the belts hanging Using a bar to pry the idler pulley back slip the belts over the cutter shaft pulley Release pressure on the idler pulley belt tension is self adjusting through the idler pulley spring See Figure 4 11 Reinstall belt cover Install the belt cover back onto the end of the mower deck and reinstall the retaining bolts Do not operate any mower with shields or guard damaged or missing See Figure 1 through 4 12 Motor control manifold The motor control manifold bolts to the top of the motor If manifold was removed it will Deck Tube Cross Over Hose need to be installed before the hoses can be connected for Oil return through deck Always use new O ring on manifold Manifold must be tubes outer end of Deck orientated as shown in figure 6 in order for hoses to e ETZ NET connect correctly S Ne 13 Reconnect hoses and wire harness The cross over hose at the outer end of deck should not have been removed check it for condition and make certain it is still connected Reconnect the hoses to motor Caution make certain that you do not connect the high pressure hose to deck tubes The high pressure will damage tubes on deck only the ret
75. d gearbox and cutter shaft be removed as an assembly this will keep oil from being spilled on mower deck and component drive pulleys and belts Remove the bolts that connect the cutter shaft bearing housing ltem 7 2 to the idler bearing extension shaft mount plate Item 16 is may be easier to remove these bolts by removing the upper drive pulley Item 10 and drive belt Item 11 To remove drive pulley Item 10 remove the pulley retaining bolt Item 15 lock washer Item 14 flat washer Item 13 Pull the drive pulley off note the pulley key Item 12 may come off with pulley or stay in shaft Remove key now so as not to lose it Note how many shims washers ltem 9 are on the extension shaft behind the pulley quantity can vary so it is best to count them and use the same amount when reassembling the shaft With the bearing housing bolts removed go to the gearbox end and remove the 4 bolts mounting the gearbox ltem 1 to the A frame mounting plate This will allow the gearbox extension shaft assembly to be lifted up off the deck Bearing housing ltem 7 2 should slide off extension shaft 5 Remove bearing retaining ring Remove bearing retaining ring tem 8 from the extension shaft This can be done with external snap ring pliers 6 Remove extension shaft housing Extension shaft housing tem 4 is mounted to the gearbox with 4 mounting bolts removing these four bolts will allow the housing to be slid away from gearbox Note The exten
76. d with the mower The hydraulic cylinders will connect direct to the tractors remote outlets and the tractor controls will be used See Figure 14 When using the Auxiliary front pump for the cylinder hydraulic system there will be acontrol valve and components shipped See the section for installing the auxiliary pump and control valve Plug Make certain lift control spacer was installed on Lift cyl See Figure 12 amp 13 ocooooooooooo000000 Hoses for the Lift and Tilt cylinders are the same size Qty 3 of Hose P N 02905100 4 4FJX 4FJX X 114 Long RH Wing RH Wing Tilt Cylinder Lift Cylinder Figure 48 Terrain Master Service Manual Pub 08 11 Page 115 Valve to Cylinder Hose Connections Cab amp ROPS P Pressure Port T Tank Retum Port H Vent Plug gt gt RH Wing Only Use with Aux Pump RH Wing RH Wing Tilt Cylinder Lift Cylinder P Pressure Port T Tank Return Port 510208 leen pn pt pt hl WI E LL LL Vent Vent EJ Plug Plug Dual Wing gt Use with c Aux Pump RH Wing RH Wing LH Wing LH Wing Tilt Cylinder Lift Cylinder Lift Cylinder Tilt Cylinder Terrain Master Service Manual Pub 08 11 Page 116 Wiring Harness Schematic CAB amp ROPS Left z z Right Switch Switch DOUBLE WING MOWER SHOWN Single Wings have only the Right Wing Motor Solenoid Valve har ness 3 Terminal Connector Right Wing Motor L
77. der They will use the same hydraulic tank and not all ports on the hydraulic tank will be used The porting depends on the configuration A Tandem Pump with Auxiliary Hydraulic Pump The Tandem Pump is used for the dual wing model mower and the auxiliary pump is used to supply the hydraulic cylinders and cylinder control valve See Hydraulic Schematic at end of this section B Tandem Pump without Auxiliary Hydraulic Pump The Tandem Pump is used for the dual wing model mower and the tractors hydraulics are used to supply the hydraulic cylinders and cylinder control valve See Hydraulic Schematic at end of this section C Single Pump with Auxiliary Hydraulic Pump The Single Pump is used for the Single wing model mower and the auxiliary pump is used to supply the hydraulic cylinders and cylinder control valve See Hydraulic Schematic at end of this section D Single Pump without Auxiliary Hydraulic Pump The Single Pump is used for the dual wing model mower and the tractors hydraulics are used to supply the hydraulic cylinders and cylinder control valve See Hydraulic Schematic at end of this section E Pumps with different Cubic Inch Displacement CID There are two size pumps used a 2 28 CID pump anda 2 7 CID pump The Higher 2 77 CID pump is used on tractors that operate with a lower RPM engine speed 2000 RPM and below to achieve PTO Speed Tractor using 2000 RPM and above use the larger 2 77 CID Pump are tractor that use a High Engin
78. driveline replace the u joint before it causes severe damage to the driveline Monthly Mnt R 0352 8 Hours U D lt TT Z TI gt U U a lt e lt Driveline Shields The driveline integral shields should not become dented or otherwise damaged The integral shield assembly has a nylon bearing at each end and should turn freely This nylon bearing should require lubrication every 8 hours To remove the integral shields for replacement or repair turn the three nylon nuts 1 4 turn in the shield slots of the cone and tube and remove them Slip the shield cone assembly off inner section of the driveline Install the new or repaired shield on the driveline Place the split nylon bearing over the driveline housing of shaft against the yoke and in the bearing groove Install shield over the housing so the nylon bearing fits into the shield bearing retainer Align a slot in the shield cone with one of the slots in the shield Put one of the nylon nuts back in through the aligned slots and turn until it is perpendicular to the slots Add the other two nylon nuts Make certain that the driveline integral shields are free to telescope and rotate around the driveline without binding SLIP CLUTCH DRIVELINE SHIELD GREASE NYLON a e FITTING BEARING Rear an fe O LQG LL III all GH ID I O j p RC SJ SI SD Lon NYLON TELESCOPING Mnt R 0162 BOLTS TUBES Extended Lever Location Lube Interval Action Pumps Cross amp Be
79. e 7 D Worn or damaged cylinder Solution 7 D Check cylinder repair or replace as needed Cause 7 E Worn or damaged control valve Solution 7 E Check valve sections and repair or replace as needed Terrain Master Service Manual Pub 08 11 Page 23 Failure Cause Solution Mower Function Troubleshooting 1 Possible Failure Motor turns but in wrong direction Cause Motor manifold block is installed wrong on motor Solution Motor manifold block must be refitted to motor to achieve correct rotation See motor aa change rotation page 34 in mower repair section T 2 Possible Failure Motor fails to engage when electric switch activated TT Cause Electrical connection failure Switch solenoid or wire harness Wa Solution Test Switch for current and activation test solenoid coil for current and activation a Cause Pump driveshaft malfunction E Solution Inspect pump driveshaft for damage to splines or drive components Make certain pump ef is turning if not inspect splined coupler at pump and drive shaft Repair as required LJ Cause Lack of sufficient hydraulic pressure and volume O Solution Perform a pressure and flow test on hydraulic system an 3 Possible Failure Motor turns but cutter shaft will not LL Cause Broken drive belts pulley keys or pulley retaining hardware U So
80. e Install a tee fitting and reconnect the hose to a pressure gauge 2 Check for proper tension on front drive belts 1 4 inch play at midpoint 3 Start engine and run at low idle 4 Raise the Tilt cylinder and note the pressure when the cylinder bottoms 5 The pressure should be the same on both circuits 1200 psi If the pressure is 1200 psi on one and not on the other the relief valve and the pump are working fine Problem would be somewhere else 6 If pressure is low on both circuits adjust relief valve Remove hex cap loosen lock nut if present and turn adjusting screw clockwise 7 Ifthe pressure does not increase remove the relief valve and inspect it If the valve is good the gear pump is worn Control valve is only used to raise and lower the wing mowers only the rear mower will be lifted and lowered by the tractors three point hydraulic system Figure 57 Shows ROPS Tractor mounting with the control handles connected direct to the valve within the operators reach Figure 58 Shows Cab Tractor with the valve mounted in a remote location out side the tractor cab The valve is operated by remote cables mounted to remote handle assemblies which are mounted in cab U o JJ lt O O gt pa UO JJ Li gt JJ Terrain Master Service Manual Pub 08 11 Page 35 Tank Filling Instructions TANK FILLING INSTRUCTIONS USE Tractor Hydraulic Oil only A double wing Terrain Master with 74 wing mowers
81. e RPM above 2000 RPM to achieve the PTO Speed will us the lower 2 28 CID pump DO NOT use the 2 77 CID pump on tractors with higher than 2000 RPM engine speed Terrain Master Service Manual Pub 08 11 Page 56 Tandem amp Single Pump Repair Replace Type Hydraulic Reservoir Used The Hydraulic reservoir for the Terrain Master is the same for the Tandem Pump Dual Wing Model or the Single Pump Single Wing Model When the Single Pump is being used some of the ports on the tank are not used and will remained plugged Drain Hydraulic Reservoir Secure Tractor so it cannot be started while repairing the pump It will require the oil to be drained form the system and the tractor must never be started without proper level of oil in the system To drain the tank it is recommended that only a filter buggy be used if you intend on reusing the oil Filter buggies or carts are commercially available for hydraulic system clean up These consist of a high efficiency high capacity filter a circulating pump a drive motor and hoses for connecting the overhauled machine s hydraulic system See Figure 3 When disposing of or storing removed oil make certain oil to be used is properly stored to keep it clean and in aclean container Make certain Oil that is to be disposed of is done by following your local regulations and laws Remove Pump Cover Remove the Pump Cover by unscrewing the four thumb screws which hold it in place lift cover upward and off
82. e Shaft has correct alignment Suction Hose has no leaks or kinks Flail Mower Head Skid Shoe Bolts are torqued to 120 ft lbs Motor Bolts are torqued to 120 ft lbs Belt Alignment amp tension adjustment is correct Cutter shaft bearings are properly lubricated Roller bearings are properly lubricated Blades swing freely All Pins and Clips for Rear Mower are installed Clutch on Rear Mower has been checked for proper adjustment and conditions per parts book requirements All Belt guards are installed correctly Terrain Master Service Manual Pub 08 11 Page 122 Delivery Inspection Checklist Pre Operation Inspection Check the following items before operating the unit to assure that they are properly assembled See following page 1 4 for component location Tractor Mower Operation Inspection Using all Safety precautions operate the Tractor and Mower unit for 30 minutes and while the unit is running check the following items Note Only make adjustments after the mower has been turned off and all motion has stopped and all hydraulic pressure has been relieved Check for Hydraulic oil leaks at the hose connections Operate the boom and mower head throughout its full range of motion and check for hose s rub bing pinching or kinking Make sure the Return Filter Gauge is reading in the Green after Oil is warm Check the function of the Mower Head On Off Valve and switch for proper function Make sure that the tractor w
83. ed above The extension shaft housing tem 4 has a hole in the tube part of it This hole will always be at the gearbox end and will be installed to the rear so you can use a grease gun to grease the splined coupler inside Make certain that all snap rings ltem 6 amp 8 are installed on shaft and seated into snap ring grooves of shaft Make certain that the shims tem 9 are installed these shims are to align the drive pulley with the cutter shaft and idler pulley Remove or add shims as needed or LLI O gt O z a Z lt or et LLI Ss Terrain Master Service Manual Pub 08 11 Page 96 Gearbox Asy P N 702673 a eof EOG U AQQ Les A SE D EE NN NOTY GE DN CR Z ALLA 2 AL BZ Kn SC We EI ce SS EN Ta eg N Z C I N k Lk N Wty 72224 IX ZZ J er KA d amp i E zzz S K i D gt Z GU D 3 z 20 aD Hy HY U lil G Item PartNo Qty Description Item Part No Qty Description 702673 Gearbox Asy 11 001724 1 Seal 1 001718 1 Pinion 12 001725 1 Shaft amp Gear U 2 001719 1 Seal 13 00754459 1 Bearing Ball 3 001717 1 Nut 14 001708 8 _ Bolt 4 001720 1 Spring Washer 15 001710 1 Cover 5 00754757 2 Bearing Roller 16 00755633 2 Plug 6 001716 1 Spacer 17 000055 2 Plug Drain r 00754752 2 Circlip Internal 18 002516 1 Housing 8 001722 1 Bearing Roller 19 00769800 1 Gasket See NOTE 9 00753222 2 Shim 10 00754761 1 Shim Note Some models
84. ee Figure 20 21 amp 22 Remove spring from idler arm Remove motor mounting bracket fasteners at the cutter housing Pivot motor mounting bracket assembly and remove drive belts Remove fasteners that secure pulley to cutter shaft See Figure 21 item 2 Remove pulley and key See Figure 21 and item 2 Remove fasteners securing inboard bearing and housing assembly to cutter housing then remove bearing and housing assembly Refer to illustration 9 Note there are two tapped holes in the housing which can be used to pull bearing and housing assembly out by using special tool p n 701627 Using a jack to align parts install inboard bearing and housing assembly to cutter unit Grease bearing and install cap over fitting Reinstall key and pulley Secure with cutter shaft fasteners Remove jack and check shaft rotation Reinstall knives which were removed Reinstall drive belts then secure motor mounting bracket to cutter housing Reinstall idler arm spring Reinstall belt guard Remove supports lower unit to ground and test unit Reinstall outboard fender if not already installed Figure 20 Terrain Master Service Manual Pub 08 11 Page 32 Cutter Shaft Replacement Cutter Shaft Replacement Note It is recommended that cutter shaft bearing and housing assemblies be replaced when replacing cutter shaft Use caution when changing cutter shaft it is heavy and the cutting blades on it can be sharp It is recommended that bl
85. eft Wing Motor Solenoid Valve Solenoid Valve White Yellow z Brown Start Terminal Brown Starter Solenoid 3 Terminal Red to Accessory Terminal Connector Tech h Black Ground Tractor Starter DOO White Yellow Left Wing Safety Cut off Switch Right Wing Safety Cut off Switch to o f po Y t White White Left Wing Right Wing Motor Solenoid Motor Solenoid Valve 2 2 Valve Terrain Master Service Manual Pub 08 11 Page 117 Motor Control Switch Dual Wing LH Wing Push Pull Switch RH Wing Push Pull Switch 16 Red ON Off Switch Plug 16 Yellow 16 White LH Wing We Cep Fuse Holder with Fuse starter Solenoid Wire Starter Solenoid Wire switched Power Supply Ground 16 Black White ff 12 Brown Line Connector to Starter Solenoid Connectors Shipped Loose in Separate Plastic zy mme 16 Red 3 Eegen L ns Valve A mni H T wmrgeeggmnh White i 16 Yellow Plug Solenoid Connector at Cutter Valve Terrain Master Service Manual Pub 08 11 Page 118 Motor Control Switch RH Wing Only 16 Red ON Off Switch Pluc Push Pull Switch zem Fuse Holder with Fuse 10 Amp Fuse Starter Solenoid Wire Starter Solenoid Wire Switched Power Supply Ground 16 Black Solenoid Connector Ring Connecto to Ground Connectors Shipped Loose in Separate Plastic
86. ege 10 micron with a 75 gpm capacity ele Ee Oll DZA Chevron THF 1000 or equivalent Pump Type a Rating Dual Wing Tandem Piston Pumps Rated 48 GPM 3800 PSI CE Single Wing Tandem Piston Pump Rated 24 GPM 3800 PSI Auxillary DUM wau zi A AE Aa Gear 2000 psi continuous 4000 RPM max Cylinder Control Valve Dual Wing 4 Spool Valve with Detent Position 1280 psi relief w handle or cable OC Single Wing 2 Spool Valve with Detent Position 1280 psi relief w handle or cable Beete 3 bore with an 8 stroke capable of 14 horizontal lift Un Le E 3 1 2 bore with a 9 stroke 40 downward and 57 upward NOT OY PEREZ Piston 52 HP 2 48 cubic inch 3600 max RPM 5000 psi max allowable Motor circuit Heite 4000 PSI El Ronex MP or equiv Multi purpose Lithium Complex NLGI Grade 2 ISO 150 Wing Mower Specifications Wing Mower cutting Width Options 62 74 or 88 Cutting Widths Cutter Housing Construction 1 10 Gauge Unitized Cutter Housing Deck End PlatesS ssssaaaaaaassaa anna 1 2 Inboard amp 5 16 Outboard Thick Side Plates Skid Shoe Type waski Eo EEEE A ZA AE EA Bolt On Replaceable Skid Shoes Cuttershaft SZEGO GAGA 4 1 2 x 5 16 Wall Cuttershaft Bearing Size 8 Type onannnnnnnnnannnnnnnannnnnn 1 5 16 Bore Greasable Self Aligning Cuttershaft Bearings Motor Type amp Ge sa azanascc 53 HP Pis
87. elt when operating tractor and equipment e ONLY OPERATE tractor and equipment while seated in tractor seat e NEVER ALLOW RIDERS on tractor or implement WHEN MOUNTING AND DISMOUNTING TRACTOR e ONLY mount or dismount when tractor and moving parts are stopped e STOP ENGINE AND PTO engage parking brake lower implement allow all moving parts to stop and remove key before dismounting from tractor PNRoo1 Terrain Master Service Manual Pub 08 11 Page 13 PTO ENTANGLEMENT HAZARDS PTO Barra Gitatoria BOTTOMING OUT SAFETY Entanglement hazard Make sure PTO shaft DO NOT Operate if Make sure PTO Do Not approach or is securely attached PTO shields are shafts are proper touch a rotating PTO Do Not Use PTO damaged or missing length driveshaft Adapter KEEP AWAY FROM ROTATING DRIVELINES AND ELEMENTS TO AVOID SERIOUS INJURY OR DANGER DEATH STAY AWAY and KEEP hands feet and body AWAY from rotating blades drivelines and parts until all moving elements have stopped e STOP LOOK and LISTEN before approaching the mower to make sure all rotating motion has stopped e ROTATING COMPONENTS CONTINUE to ROTATE after the PTO is shut off PTO SHIELDING TO AVOID SERIOUS INJURY OR DEATH FROM ENTANGLEMENT WHEN OPERATING IMPLEMENT e KEEP PTO shields integral driveline shields and input shields installed e DO NOT OPERATE mower without shields and guards in place or missing e REPAIR OR REPLACE if damage broken or missing e AL
88. em 12 onto driveshaft until seated in snap ring groove of driveshaft and seated against thrust race 3 Replace needle bearing Item 16 into pump housing Item 4 Install needle bearing assembly into the pump housing If necessary install driveshaft Item 3 into pump housing Item 4 and install washer Item 10 Coat the ID of shaft seal Item 6 and press it into the pump housing Item 4 Install the outer snap ring Item 11 into pump housing until it is seated into snap ring groove of housing 4 Install pin keeper Item 1E and pins Item 1F into spline area of piston block Item 1D Compress pin keeper and install it in the splined area of the piston block Install the three pins in the special grooves of the spline area of the piston block with the head end of pin toward inside of block 5 Install washers Item 1G and 1J and spring Item 19H into piston block Item 7D Install washer Item 1G or 1J are the same into the piston block install spring Item 19H into piston block and against washer Item 1G Install second washer Item 1J into piston block and against spring Caution See step 6 for spring compression instructions 6 Compress spring Item 7H and install retaining snap ring Item 1k Caution The following procedure should be used if the spring has been removed from the piston block The spring Item 1H will have to be compressed The following parts will be needed to assemble the piston block 2ea 3 8 ID X 1 1 8
89. engine through a pulley and belt system off of the driveshaft to the main pumps See figure 4 5 6 8 20 and 21 If the model you have was set up to utilize the tractor hydraulic system to operate the hydraulic cylinder circuit you will not have this pump See figure 7 and 9 Remove Auxiliary Pump Hoses And Belt Guard SA Case HE A Tank Suction Pressure Remove the suction hose and the pressure hose a Drain To e Port Small Out Port from the auxiliary pump See figure 22 Make z LEM Pump To RH certain to cap Plug all hydraulic opening when sy BR d di N Wing Motor hoses and fittings are disconnected The belt es A guard is retained by the same bolts that retain the auxiliary pump mount plate to the main pump mount plate There are two bolts remove the belt adjusting bolt first then the pump plate mounting bolt The pump will remain bolted to the pump mounting plate See figure 23 and 24 Figure S b A 24 shows the auxiliary pump with out the tank AG installed for illustration only the tank will not Dual require removal to remove the auxiliary pump Wing one When auxiliary pump is removed the spline drive emm nft a ort Pressure Out Port coupler and pulley weldment will remain on the C re 20 I From aa LH Wing Motor main pump driveshaft See figure 25 and 26 gu Tank Terrain Master Service Manual Pub 08 11 Page 66 Auxiliary Pump Remove amp Replace Remove Auxiliary Pump Remove the
90. eplacement the same procedure A F can be followed to ensure the replacement is operating properly Test Equipment Needed 1 Flow Meter The Flow meter should have components to measure Gauge to Measure the Oil Temperature Gauge to Measure Oil Pressure PSI Load and No Load Gauge to Measure Oil Flow in G P M A Valve to load system to check operating Pressure PSI Assortment of Connections to connect to Hydraulic System mOO Wp 2 Electrical Volt Meter with variable settings and Ohm Meter 3 Electrical Test Light 4 Wrenches Torque Wrench Socket Wrenches Open and Boxed End Wrenches Terrain Master Service Manual Pub 08 11 Page 103 Start Up Procedure Initial Start Up Procedure 1 Check all nuts and hex head bolts to ensure all are tight and all lock washers are fully compressed 2 Check all hoses and hydraulic connections Make certain they are secure 3 Inspect all moving parts and make certain that no wires or hoses will be caught or pinched when the tractor or the Terrain Master is in operation Tie down loose wires and hoses 4 Thoroughly grease the Terrain Master and install a lubricap on each grease fitting Refer to the operation and maintenance section 5 Jack front of tractor up enough to allow axle to pivot through its full range While turning wheels through their limits right and left swing them up and down Look for interference between tires and any part of the Terrain Master If interference oc
91. ers are operating in mowing area e ADJUST mower sections or wing close and parallel to ground without exposing blades e ADJUST cutting HEIGHT to AVOID BLADE CONTACT with solid objects like wire rocks posts curbs guard rails and fixed obstructions e DO NOT operate mower when mower is raised or in transport position e STOP MOWING immediately if blades strike heavy objects fixed structures metal guard rails and con crete structures 1 BLADES CAN FAIL from impact and objects can be thrown with great velocity 2 INSPECT and REPLACE any damaged blades 3 CHECK blade carrier balance and REPLACE if damaged e DO NOT mow in standing water TO AVOID possible BLADE FAILURE e AVOID MOWING in reverse 1 STOP PTO and back up mower 2 LOWER mower engage PTO and mow forward e STOP PTO and BLADES when raising the mower to transport position e DO NOT ENGAGE PTO with mower in transport position e STOP mowing when EXCESSIVE VIBRATION occurs 1 STOP PTO and tractor ENGINE 2 INSPECT mower for vibration source 3 REPLACE any damage parts and bent or damaged BLADES PN TOFM 02 Terrain Master Service Manual Pub 08 11 Page 12 Safety RUN OVER HAZARDS ALAAVS TO AVOID SERIOUS INJURY OR DEATH FROM FALLING OFF TRACTOR OR DANGER EQUIPMENT RUN OVER e USE ROPS and SEAT BELT equipped tractors for mowing operations e KEEP ROPS locked in UP position e ONLY start tractor while seated in tractor seat e ALWAYS BUCKLE UP seat b
92. ff Case Drain g Aux Out Pressure Side Suction Hoses i Hoses 9 Pump Elbow pointing to rear aag Pressure 7 A Hose LH Wing ae ama Pressure DE AUX Hose i l mas Z Pump W A 42 A Suction 4 Hose R RH Wing a Pressure oe WK In Suction Hose I Side an e gt a Z lt A gt A To Control Valve Pressure Line P Port on Valve Suction Line Terrain Master Service Manual Pub 08 11 Page 72 Tandem Pump Disassembly amp Reassembly Inner Front Pump Assembly P N 001840 2 77 Cu In Disp P N 001734 2 28 Cu In Disp Items 1 Thru 18 Quter Front Pump Assembly P N 001841 2 77 Cu In Disp P N 001733 2 28 Cu In Disp Items 19 Thru 33 Item Qty Description Item PartNo Qty Description 1 1 Rotating Kit Asy 19 1 Rotating Kit Asy IA 1 Piston Asy 19A 1 Piston Asy 1B 1 Spider 19B 1 Spider 1C 1 Pivot 19C 1 Pivot 1D 1 Piston Block 19D 1 Piston Block 1E 1 Pin Keeper 19E 1 Pin Keeper IF 3 Pin 19F 3 Pin 1G 1 Washer 19G 1 Washer 1H 1 Spring 19H 1 Spring 1J 1 Washer 19J 1 Washer 1K 1 Snap Ring 19K 1 Snap Ring 2 1 Back Up Plate Asy w Brg 20 1 Back Up Plate Asy w Brg 3 1 Driveshaft 21 1 Driveshaft 4 1 Housing Not Furnished as Parts 22 1 Housing Not Furnished as Parts 5 1 Thrust Race amp Bearing 23 1 Thrust Race amp Bearing 6 1 Shaft Seal 24 1 Shaft Seal 7 1 Cam Plate Insert 25 1 Cam Plate Insert 8 1 O Ring 26 1 O Ring 9 6 Bolt 27 6 Bolt 10 1 Washer 28 1 Washer
93. g into the opening of the back plate and onto the driveshaft This snap ring prevents the spline coupler Item 13 from moving around This step will only apply to the tandem pump this single pump will not use these 16 Install O ring Item 15 seal into back plate Item 2 The O ring will fit into a groove cut into id of back plate pump mounting flange Item 2 Make certain groove is clean in back plate Insert O ring Item 15 into groove in id of back plate Coat O ring with coating of oil or Vaseline U C lt U gt Z O lt O O JJ Terrain Master Service Manual Pub 08 11 Page 77 Tandem Pump Disassembly amp Reassembly Disassemble Outer Front Pump For item numbers See Figure 12 1 Clamp outer front pump in vice with Pressure Port Suction Port jaw protectors See Figure 15 outer front pump can be clamped in vice Vice Jaw Protective Pads for disassembly but it can also be nin o disassembled while on the work bench oT 2 Remove back plate ltem 20 The Bench Vice backplate is bolted on with six hex head bolts item 27 remove these six bolts lt require a small amount of force to free the backplate loose from pump housing If needed use small plastic mallet to Figure 15 tap the sides of the backplate This will break the backplate loose from the pump housing do not hit back plate with excessive force as it will damage backplate and pump housing 3 Remove O ring from backpl
94. g seal Item 12 from backplate O ring groove Item 15 5 Remove complete piston block assembly Item 1 from motor housing Item 11 Lift piston block assembly upward and out of pump housing it will require you to remove pump from vice and dump piston block assembly out Catch the block with hand don t let it fall out on floor or bench Do not remove the spring snap ring Item 1k from piston block assembly as spring Item 1H has compression on it this compression will require relieving before snap ring is removed this can be done later 6 Remove the piston assembly Item 1A from the piston block Item 1D The piston assembly will pull upward and out of piston block 7 Remove spider Item 1B and pivot Item 1C The spider Item 1B will be left lying on the piston block when the piston assembly is removed The pivot tem 1C will also be left on the piston block and can be removed 8 Piston block disassembly Item 1D The piston block assembly need not be disassembled unless the pins Item 19F or the spring Item 1H is damaged Caution The following procedure should be used if the spring is to be removed from the piston block The spring Item 1H is highly compressed and the snap ring Item 1K should not be removed without compressing the spring The following parts will be needed to disassemble the piston block 2 ea 3 8 Id x 1 1 8 OD flat washer 1 ea 3 8 Nc x 3 1 4 bolt hex head amp 1 ea 3 8 NC hex nut Place one flat
95. h new blades e AVOID blade failures and thrown broken blades DO NOT straighten weld or weld hard facing blades SAFETY SHIELDS GUARDS AND SAFETY DEVICES INSPECTION e KEEP all Deflectors Steel Guards Gearbox Shields and PTO integral shields Bands Side Skirts and Skid Shoes in place and in good condition e REPLACE any missing broken or worn safety shields guards and safety devices e Engine Exhaust some of its constituents and certain vehicle components contain or emit chemicals known to the state of California to cause cancer birth defects or other reproductive harm e Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the state of California to cause cancer birth defects or other reproductive harm e DISCONNECT Pump solenoid valve or PTO driveline connection before servicing mower head e FOLLOW INSTRUCTIONS in maintenance section when replacing hydraulic cylinders to prevent component falling PN HMFM 02 Terrain Master Service Manual Pub 08 11 Page 19 PARTS INFORMATION PARTS INFORMATION Terrain King mowers use balanced and matched system components for blade carriers blades cuttershatts Knives knife hangers rollers drivetrain components and bearings These parts are made and tested to Terrain King specifications Non genuine will fit parts do not consistently meet these specifications The use of will fit parts may reduce mower performance void mower warranties
96. h pressure hose to the cooling tubes of the deck the high pressure will damage these tubes they will expand from the high pressure and in some cases crack and leak Only the return hose from the motor return outlet port can be connected to the cooling tubes as the return line is low pressure 11 Reconnect wire harness When reconnecting wire harness make certain the wire harness is routed and tied so it will not catch or rub on anything while being operated or folded for transport Pressure Test Port Motor Manifold Motor Case Drain Port Relief Valve 4000 psi Mounting Bolt qty 4 Y Oil Return Port 7 SE Machining Access Port w Pressure Port Manifold Mounting O Rings qty 2 OSTRY Vice Jaw Protective Pads TI C lt U gt Z O lt O e O JJ Figure 9 Wing Motor Assembly Terrain Master Service Manual Pub 08 11 Page 85 ag O a O gt a Z lt lt A 2 A Motor Disassembly amp Reassembly Qty sch sch sch sch zeck zeck sch sch sch sch sch Descrition Rotating Kit Asy Items 1A thru 1K Piston Asy Spider Pivot Piston Block Pin Keeper Pin Washer Spring Washer Snap Ring High Pressure Seal Kit Items 2A thru 2C O Ring High Pressure Seal Seal Adapter Washer Figure 11 Terrain Master Service Manual Pub 08 11 Page 86 Item Qty Descrition ee BM Nal ee ee ee A a A ko Ak A 4 lt k Snap Ri
97. he auxiliary pump mount plate to the main pump mount plate Do not tighten the mounting bolts yet See Figure 34 Adjust drive belt on small auxiliary pump The small pump mount plate has a 3 8 square hole that is designed to be used with a 3 8 drive ratchet or breaker bar to ad just the belt Snug the pump mounting bolts and put a 3 8 drive ratchet into the hole Pull up until belt has about the same tension as an automotive belt Tighten the mounting adjusting bolts See Figure 32 and 35 Terrain Master Service Manual Pub 08 11 Page 70 1 Pump Mount m bolts to Aux Pump flange Auxiliary Pump drive oulley amp Belt i z AR l P i gt ih Figure 30 SE EJ Lig Aux Pump Plate Mounting Bolts p veel V SZ n Pe Oil Level Y ANA Temperature Figure 31 ABBE Gauge Remove Pump Belt g Adjusting Bolt first Auxiliary Pump Removal Repair amp Replace 7 Recheck all bolts and components that have been installed The bolts and components that have been installed should be checked before moving on the next step Make certain that all bolts have been tighten It is a good practice to mark the bolts and nuts with some mark such as a dab of paint from a paint marker or anyway that you want so you will know that bolt has been tightened 8 he small cylinder hydraulic supply pump will have a short hose that connects to the small pump and to the tank
98. hed to tractor length TO AVOID SERIOUS INJURY OR DEATH FROM BEING CRUSHED BY TRACTOR OR DANGER IMPLEMENT WHEN BACKING tractor to implement hitch e DO NOT ALLOW BYSTANDERS between tractor and implement BEFORE connecting and disconnecting implement hitch e STOP TRACTOR ENGINE place transmission into park engage parking brake and remove key WHEN connecting and disconnecting implement hitch e DO NOT crawl or walk under raised mower or wing WHEN CONNECTING IMPLEMENT DRIVELINE TO AVOID implement driveline coming loose during operation e LUBRICATE yoke spring locking collar to ensure it freely slides on PTO shaft SECURELY seat yoke locking balls in PTO shaft groove e PUSH and PULL DRIVELINE on both the tractor and implement PTO SHAFTS to ensure it is SECURELY ATTACHED TO AVOID broken driveline during operations e CHECK driveline for proper length between PTO shaft and implement gearbox shaft Refer to Instructions in Operation Section Drivelines too short can pull apart or disengage Drivelines too long can bottom out Bottoming driveline telescoping assembly will stop sliding and become solid Driveline bottoming can push through support bearings and break off PTO shaft CONTACT DEALER if implement driveline does not match Tractor PTO shaft e DO NOT USE PTO ADAPTER Using a PTO adapter can cause e Excessive vibration thrown objects blade and implement failures by doubling operating speed e Increased
99. iary pump and some will not When possible consult the assembly instructions and or assembly manual that was shipped with the unit to match the tractor model you have Pump Mount Weldment Removal aoi Case Small Pump ERIE Tank Suction The hoses and pump will require ni A being unbolted from the pump mount Drain To P gt Pressure Port gt Port Smal weldment use the steps in the pump N AF 7 ak Pump repair replacement section p2 NR Sa a KT 2 The pumps removed the model using the auxiliary pump will have the drive Pressure 3 SS gt LI Se Ze lt q LI lt LI gt ag O pulley and belt still on the driveshaft Out Port 1 TR SRANIE Leave Capped Model that do not have the auxiliary To RH m R I on RH Only pump will have a spline coupler See Wing Motor Model Figure 3 3 The drive pulley weldment or splined i 1 Y ECH weng coupler will slide off of driveshaft Case gt ep through the hole for the main pump Drain From EE See Figure 4 Pump 4 The drive shaft has carrier bearing Suction and locking collar on it This locking Port collar locks down onto the driveshaft From To remove the pump mount weldment Figure 1 Tank it will not require the removal of the bearing and collar The driveshaft can be removed with the pump mount plate Case SS Tank Suction J Pressure or the driveshaft can be removed now If Drain To g Se Port Small Out Port you are repairi
100. il when connecting rebuilt or new pump The pump should be filled half full with oil this can be done by pouring clean oil through the ports of pump When pump is installed on mower connect pump pressure hose pump case drain hose and install pump inner Rear Pump L suction elbow fitting into pump Pour oil into the elbow gt fitting this will put oil into pump so it will not be started dry an O gt a Z lt A gt A Tandem Pump Tandem Pump Connecting Bolts Vice Jaw Protective Pads gt Bench Vice Figure 16 Terrain Master Service Manual Pub 08 11 Page 80 single Pump Disassembly amp Reassembly Single Pump Single Wing Model Pump ID Reference No is Stamped Here Figure 17 Single Pump P N 00755650 2 77 CID P N 001827 2 28 CID Single Pump Assembly P N 00755650 2 77 Cu In Disp Tractor P N 001827 2 28 Cu In Disp TI C lt U gt Z O lt O O JJ Engine 1 Items 1 Thru 18 This End tem Qty Description Item Qty Description 1 Rotating Kit Asy 6 1 Shaft Seal A 1 Piston Asy 7 1 Cam Plate Insert B 1 Spider 8 1 O Ring C 1 Pivot 9 6 Bolt D 1 Piston Block 10 1 Washer E 1 Pin Keeper 11 1 Retaining Ring F 63S Pin 12 2 Retaining Ring G 1 Washer H 1 Spring 14 1 Lock Ring J 1 Washer 15 1 O Ring K 1 Snap Ring 16 1 Bearing Backplate 2 1 Back Up Plate Asy w Brg 17 1 Bearing Housing 6 1 Driveshaft 18 1 Roll
101. ill not start with the mower on off switch in the on position Check the Blade Rotation for the Rotary Mower Head to make sure it is turning Clockwise look ing from the top of the mower deck Make sure the control valve boom movements agree with the valve operation decal Make Sure Boom Movement operates as expected and is smooth and under control no air in the control system Look for any unusual or excessive noise or vibrations Make sure the left rear wheel of the tractor stays on the ground when the boom is fully extended horizontally with 200 lbs placed on the outside of the mower head Post Operation Inspection Check that the oil in the hydraulic tank has not turned milky in color or has foam on top Check that there are no loose fasteners or hardware Operator Customer Orientation Details discussed with operator customer any variance pointed out and discussed Operator customer aware of all aspects of repairs Notes Terrain Master Service Manual Pub 08 11 Page 123 ZE A TERRAINKING Engineering Practical Solutions Sm Terrain Master Service Manual Pub 08 11
102. ing in system Make certain all work areas and tools are cleaned 3 Clamp pump and manifold in vise Clamp the motor and manifold in vise with protective caps on jaws of vise See Figure 9 with the manifold up 4 Remove manifold from motor Remove the four manifold mounting bolts See Figure 9 Pressure Relief Motor Case Drain Port Lift the manifold up off of motor There are 4000 psi High Pressure two O rings between manifold and motor Inlet Port make certain these O rings did not stick to Wire Harness to motor back plate or to the manifold Locate Control Solenoid these O rings and remove them now 5 Repairmanifold The motor control manifold will not have a lot of components that will ag O e O Q Z lt lt A 2 A need repairing The most important thing Manifold a LCA A LI about manifold is cleaning and inspecting ee ke P Motor Control This is best done by removing all the LIF gt Solenoid components from the manifold Wash the e bare manifold in clean solvent and blow dry with filtered compressed air Inspect manifold for any debris or damage to block Motor Case ZNA ac replace as needed Drain Port W AN Low Pressure 6 Motor disassembly and or repair If the Return Oil motor is to be disassembled go on motor Pressure Test Port oo from Deck repair section and return to here when itis Low Pressure Return Tube to Tank time to reinstall manifold block assembly Figure 7 Oil to Deck
103. ing plates should break loose Check the mark e Turn tractor off and tighten the nuts on the springs to their original position of 1 5 16 compressed spring length Slip clutch is incorporated in the PTO driveline It is designed to slip absorb the shock load and protect the driveline After the first hour of operation the slip clutch should be checked for overheating After this first check the slip clutch should be checked weekly or anytime there is overheating To adjust the slip clutch tighten the spring bolts 1 8 maximum turn at a time Bolts should never be adjusted to the point where the springs are compressed solid The slip clutch should be checked periodically and adjusted to compensate for wear The lining plates are 1 8 thick when new Replace after 1 32 wear If the mower has been idle for an extended period of time or in wet weather before operating check to be sure the friction lining plates are not frozen or rusted together Should this freezing occur refer to the procedure described in the seasonal clutch maintenance on the next page There are 4 friction disc the slip clutch These should be checked weekly for oil or grease wear and moisture which could cause corrosion on the drive plates See step 8 Note Above information is listed as a reference and is listed in the operators manual as well Terrain Master Service Manual Pub 08 11 Page 93 Figure 9 YHAMOW ONIM ANY dVsd or LLI
104. ipment can fall from mechanical or hydraulic failure or inadvertent Control Lever movement TO AVOID EQUIPMENT FALLING while working near or under lifted wings components and 4WARN ING implements raised by 3 Pointed tractor hitch SECURELY SUPPORT or block up raised equipment wings and components BLOCK UP and securely support equipment before putting hands feet or body under raised equipment or lifted compo nents e KEEP BYSTANDERS CLEAR of folded wings until wings are blocked or locked up WHEN PARKING Implement and Tractor LOWER implement LOCK or BLOCK lifted parts before leaving equipment NEVER leave implement unattended in a raised position TO AVOID CHILDREN FALLING OFF OR BEING CRUSHED BY EQUIPMENT AWARNING NEVER ALLOW children to play on or around Tractor or Implement WHEN UNHITCHING IMPLEMENT LOWER implement LOCK or BLOCK lifted parts before leaving equipment BEFORE REMOVING Wing Retaining Lock ATTACH hoses to tractor FILL Wing Cylinders with oil Refer to Instructions in Operation Section KEEP bystanders away before operating wings LOWER WINGS slowly and carefully PN CHFM 03 Terrain Master Service Manual Pub 08 11 Page 9 Safety CONNECTING OR DISCONNECTING IMPLEMENT SAFETY SAFETY Stop Tractor Crushing injury Crushing injury Make sure PTO Make sure PTO Remove Key between tractor wing falling shaft is securely shaft are proper Read Manual and implement attac
105. ircuit The pump unit assembly is made up of the oil reservoir and hydraulic pump The pump is driven by the engine crankshaft through a drive shaft Therefore oil is being pumped whenever the engine is running When the mower is off oil is directed to the reservoir by the solenoid motor control valve and does not flow to the cutter motor Cooling is provided by patented in frame cooling tubes in the wing mowers Pump Type The pump unit for the wing mower rotor shaft drive power circuit is a piston fixed displacement pump see pump repair and is engine driven It is mounted on the front of the tractor above the hydraulic reservoir There is a separate pump for each wing By following the hose routing the operator can determine each wing mower s supply source Each pump has a case drain to eliminate excessive fluid in the pump All excess fluid in the pump is routed back to the hydraulic reservoir through the case drain Hydraulic reservoir There is a separate pump for each wing Tandem for dual wings and single pump for single wings By following the hose routing the operator can determine each wing mower s supply source Each pump has a case drain to eliminate excessive fluid in the pump All excess fluid in the pumps is routed back to the reservoir through the case drain PUMP AND MOTOR Pump Configurations Used There are different pump configurations available that power the flail heads motor circuit and operate the hydraulic cylin
106. k assembly tem 1 The piston block assembly all assembled needs to be coated with oil Slide piston block assembly into end of pump housing aligning id of it over driveshaft Push piston block assembly into housing and over driveshaft until piston shoes are in contact with cam plate insert it may require driveshaft to be turned as piston block assembly is being slid in to align splines of shaft with spline of the components of piston block assembly Do not use excessive force to install piston block assembly if it will not slide together with the force of your hand there is something wrong 11 Install needle bearing ltem 17 into back plate assembly ltem 2 The needle bearings will install into center opening of back plate coat this bearing with oil as you slide it into back plate Install bearings into back plate with number end of bearing up and visible Bearing will be slightly higher 09 Than back plate See figure 18A 12 Back plate tem 2 and sealing O ring Item 8 The back plate is sealed with an O ring that is inserted into a groove on back plate fem 2 make certain this O ring is seated into this groove lubricate the OD of O ring to aid inserting of back plate into pump housing 13 Back plate assembly tem 2 roll pin and alignment The backplate has a roll pin installed into it This roll pin Item 18 is to align back plate on pump housing so front flange of housing and back plate ports will be in the correct orientation
107. k assembly as the spring tem 1H has compression on It this compression will require relieving before snap ring is removed this can be done later 8 Remove the piston assembly Item 1A from the piston block Item 1D The piston assembly will pull upward and out of piston block 9 Remove spider Item 1B and pivot Item 1C The spider Item 7B will be left lying on the piston block when the piston assembly is removed The pivot tem 1C will also be left on the piston block and can be removed 10 Piston block disassembly tem 1D The piston block assembly need not be disassembled unless the pins tem 1F or the spring Item 1H is damaged 11 Caution The following procedure should be used if the spring is to be removed from the piston block The spring Item 71H is highly compressed and the snap ring Item 1K should not be removed without compressing the spring The following parts will be needed to disassemble the piston block 2 Ea 3 8 ID x 1 1 8 OD flat washer 1 Ea 3 8 NC x 3 1 4 bolt hex head 1 Ea 3 8 NC hex nut U C lt U gt Z O lt O O JJ 12 Place one of the flat washers over the 3 8 x 3 1 4 bolt and place this through the center of the piston block Place the other flat washer over the bolt and let it rest on the three pins tem 1F Screw the nut on and compress the spring inside the piston block Use a pair of snap ring pliers and remove the internal snap ring Item 1K Un
108. k plate is sealed with an O ring that is inserted into a groove on back plate Item 15 make certain this O ring is seated into this groove lubricate the OD of O ring to aid inserting of back plate into motor housing tem 11 13 Back plate assembly Item 15 roll pin Item 14 and alignment The backplate has a roll pin installed into it This roll pin Item 14 is to align back plate on pump housing so front flange of housing and back plate ports will be in the correct orientation roll pin should not be more that 173 Higher than surface of back plate This alignment is important and must be correct Make certain the roll pin is in the back plate Lower the back plate ltem 15 down onto the pump housing Item 11 aligning the back plate down over driveshaft until the sealing O ring Item 12 inserts into pump housing Back plate should slide down until it is inside of pump housing if back plate can not be pushing completely down without a lot of force check it for something wrong Do not use excessive force or use the bolts to pull back plate down 14 Install 2 retaining bolts Item 16 into motor housing Item 11 to fasten back plate Item 15 Inspect the bolts make certain all threads are good condition The bolts need to be installed in same holes they were removed from Tighten these 2 bolts from one side to the other until snug These bolts must be torqued to 15 to 18 ft Ibs Do this in increment and staggered pattern also 15 Reinsta
109. l level stabilizes at the level of the sight gauge o a Ti an a L lt LLI e gt an LLI Se Terrain Master Service Manual Pub 08 11 Page 36 Hydraulic Tank Repair Information 1 Clean the entire area around the hydraulic tank hoses pumps and any other component that is going to be worked on do not disconnect any hydraulic system in any way before completely cleaning the area and all tools to be used Keeping every thing clean work area tools drain pans and components to be repaired is very important 2 To remove the hydraulic tank will require the removal disconnection of hydraulic lines and fittings All hoses fittings and ports must be capped sealed immediately after they are disconnected No hydraulic component should be left open this would allow contamination of the hydraulic system which will damage the system 3 Disconnect oil tank return hoses The oil return hoses from the wing s motor s and the cylinder control valve system is returned on the rh side of the tractor to the front and to through the oil return filter If the Terrain Master was ordered as model to use the tractor hydraulic oil system for supply to the control valve for the cylinders there will be no return hose from the cylinder control valve see the hydraulic schematic for system using tractor hydraulics See Figure 3 the fittings at the hydraulic tank for the return hoses will not need to be removed to remove the hydraulic tank See Figure
110. lined straight shaft and carrier bearing Cyl Circuit vn Kc Another variation may have u joint and telescopic driveline instead Pulley adapter may differ with different driveline gt and tractor model m TT Pulley Adapt knut UNEI AGAPE U Mounting Bolts SEH Engine 2 d Pulley LLI Driveshaft Z Mounting ge Bolt amp Washer Bearing Tractor Specific LLI Pump C llar gt Mount ag Drive Pulley 8 Pulley Adapter Splined Sleeve Driveshaft Tractor Specific i Weldment Bearing Small Cyl Hyd Pump Mount Plate mounts here be KS Tandem Pump for Dual Wings NE Pump Mount Weldment Tractor Specific NU Left Wing Pump Right Wing Pump Driveshaft Bearing installs into pump mount weldment here Terrain Master Service Manual Pub 08 11 Page 42 Tandem Pump amp Driveshaft Asy w o Aux Pump Typical drive amp power assembly with splined straight shaft and carrier bearing Another variation may have u joint and telescopic driveline instead Pulley adapter may differ with different driveline and tractor model Pulley Adapter Mounting Bolts Driveshaft Tractor Engine Pulley Bearing J Collar I Pulley a Tractor Specific Driveshaft Bearing U D lt TT Z D gt U U a lt e lt Tandem Pump for Dual Wings Pump Mount Weldment Left Wing Pump Right Wing Pump Driveshaft Bearing installs into pump mount weldment here Terrain
111. livery Inspection Checklet A 123 Pre OD SF AON INSPECCION ME 123 SCENA e T NID T A E T E E E iw EA GEO cae ebacuacieen EG PELE 123 Si 123 FAV OFAUNC SY AIZ EEE 123 BEAN E e EE 123 Delivery Inspection Checklet A 124 Tractor Mower Operation Inspection lt cccccncse2ecercaceseexesaziccenvecntstinesbexnendcasseaseanersiecesoeeusioendeseweeiecesaessecsceneedass 124 Post Operation Inspection E 124 Operator Customer Orientation EE 124 Safety GENERAL SAFETY INSTRUCTIONS AND PRACTICES A careful operator is the best operator Safety is of primary importance to the manufacturer and should be to the owner operator Most accidents can be avoided by being aware of your equipment your surroundings and observing certain precautions The first section of this manual includes a list of Safety Messages that if followed will help protect the operator and bystanders from injury or death Read and understand these Safety Messages before assembling operating or servicing this Implement This equipment should only be operated by those persons who have read the manual who are responsible and trained and who know how to do so responsibly SAFETY The Safety Alert Symbol combined with a Signal Word as seen below is used throughout this manual and on decals which are attached to the equipment The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED The Symbol and Signal Word are intended to warn the owner operator of i
112. ll motor manifold now The motor manifold installation is shown in previous pages under pump manifold section When installing motor manifold always install the two O ring between manifold and motor with new O rings Use petroleum jelly to hold O rings in position during mounting of manifold to motor 16 Fill motor case with oil when connecting rebuilt or new motor The pump should be filled half full with oil this can be done by pouring clean oil through the pressure port of motor manifold When motor is installed on mower connect motor high pressure hose motor case drain hose to motor manifold and install motor return hose TI C lt U gt Z O lt O O JJ Terrain Master Service Manual Pub 08 11 Page 89 Terrain Master Service Manual Pub 08 11 Page 90 Section 4 Rear and Wing Mower Service and Repair Terrain Master Service Manual Pub 08 11 Page 91 Mower Repairs Rear Mower Rear Three Point Mower Connection 1 Install rear lift chains option Rear lift chains will replace three pointliftlinks using the same pins you removed from lift links These chains allow mower to float with contour of the ground These are optional equipment and may or may not have been ordered See Figure 1 2 amp 3 Note shown below is a New Holland tractor in figure 1 2 and 3 The John Deere check chains will mount the same 2 he rear mower is a standard three point hitch mounted mower that is PTO driven through driveline It
113. lt hex head 1 Ea 3 8 Nc hex nut Place one of the flat washers over the 3 8 x 3 1 4 bolt and place this through the center of the piston block Place the other flat washer over the bolt and let it rest on the three pins Item 19F Screw the nut on and compress the spring inside the piston block Use a pair of snap ring pliers and remove the internal snap ring tem 19K Unscrew the bolt nut and two washers this will release pressure on spring Item 19H Remove the spring Item 19K the three pins ltem 19F and the pin keeper liem 19E 8 Remove cam plate insert Item 25 from housing ltem 22 The cam plate Item 25 should be lying inside the housing Item 22 Reach into the housing and the cam plate Item 25 should pull out without much effort In some cases because of the oil creating suction it may require that housing be tilted up and cam plate dumped out of housing if this is the case catch the cam plate do not let it drop 9 Remove snap ring Item 29 Using internal snap ring pliers remove internal snap ring Item 29 from front side of housing ltem 22 10 Remove input seal Item 24 from housing Item 22 The input seal will be remove from the housing using a seal puller Use caution when removing the input seal so you don t scratch or damage the interior seal seat area 11 Remove seal washer Item 28 which is located behind input seal It may require to lift the housing and dump the washer out 12 Remove driveshaft l
114. lution Inspect belts keys pulley and mounting hardware replace repair as required 4 Possible Failure Motor turns if unloaded slows down or stops as load is applied Cause A Scored back plate Solution A Remove back plate and examine surface condition of flat area if scored replace back plate DO NOT LAP back plate Cause B Scored or worn piston shoes Solution B Disassemble motor examine condition of shoes on pistons replace pistons as a complete set if necessary DO NOT LAP Cause C Low relief valve pressure Solution C Check relief valve for proper pressure setting adjust or replace relief valve 5 Possible Failure Motor will not turn Cause A Severely scored back plate Solution A Disassemble motor completely Inspect all parts clean all parts replace all worn parts and flush hydraulic system 6 Possible Failure Motor free wheels Cause A Oil flow and pressure shut off going to motor Solution A When the hydraulic system is shut off either by shutting off the engine on a closed loop system or returning the control valve spool to neutral on an open center system the motor will free wheel after it has leaked off This is inherent in the design Ona closed loop or propulsion system the motor will not free wheel as long as charge pres sure is maintained to and from the mot
115. ly Remove Repair and Replace See Figure 25 for component location and identification 1 Offset models are offset to right to id forward rotation drive belt is to the left side reverse rotation drive belt is on right side standing behind unit looking toward tractor Item 4 3 and 4 lengths are from end to end item 4 includes welded on round flanges on ends in measurement to id which unit you have measure the extension shafts or housings see Terrain Master archive parts manual for lengths of shafts and housings 2 Gearbox assembly and extension shaft assembly identification The rear mowers are mechanical driven through a driveline and gearbox assembly The gearbox has a extension shaft connected to it These shafts will not all be the same they will be different lengths depending on the size Width of the mower the cutter shaft rotation Forward or reverse and the amount and direction of the offset of the A frame on the mower The mower will need to be identified before ordering shaft tube See Terrain Master archive parts manual for extension shaft ID There were two different gearbox assemblies used See gearbox repair in next pages to ID gearbox 3 Remove drive belt guard Remove the drive belt guard tem 19 it is retained by two bolts One bolt to the front and one to the rear of the deck Set the belt cover aside as it will not be need until repair is finished 4 Remove gearbox and extension shaft as an assembly It is recommende
116. m rate of speed However if the ends are not parallel the uneven rotation effect may be multiplied resulting in a speeding up and slowing down of the entire mower system gear box extension shaft pulleys belt and cutter shaft during each revolution This effect can be readily noticed if the mower while running is raised to an extreme height on the tractor lift For smoothest operation the tilt of the mower should be adjusted on a 3 point hitch by adjusting the length of the top link between the tractor and the mower so that the ends of the drive shaft are parallel when the mower is down in operating position Raising the mower while running to extreme heights on the lift should be avoided To check where the vibration is originating first be sure the ends of the universal drive shaft are parallel Then if vibration is still present remove the drive belt and run the mower If vibration is still present it most likely is coming from and caused by a bent drive shaft If so the shaft should be replaced or straightened If the vibration is gone the drive portion of the mower is running smoothly Then the vibration is probably coming from the cutter shaft t could be a pulley out of balance or a faulty belt with a varying cross section but this is not likely oo a TI an a FA ei T e gt am Ti N The cutter shaft will run out of balance if 1 Wire rope string rags etc around the cutter shaft are holding the knives
117. manufactures instructions Never work on or repair mowers with tractor running and mowers supported by hydraulic system 2 Mowing is accomplished by a series of knives which rotate at high speed on a shaft On wing mowers the shaft is driven by a hydraulic motor through a set of drive belts Belt tension is maintained by a spring loaded idler pulley drive belts Belt tension is maintained by a spring loaded idler pulley 3 he cutter unit is mounted to the lift frame by two mounting pins and held in place by a hydraulic cylinder this cylinder is used to tilt the cutter unit to allow mowing on an angle and tilting to the vertical position for transporting Another hydraulic cylinder is mounted to the lift frame and the lift cylinder support This cylinder is used to raise the cutter unit via the lift frame 4 The cutter unit rides on a large roller assembly The position of this roller is adjustable and will determine the cutting height of the knives Replace Drive Belts Note belts must be replaced as a matched set Do not replace just one belt See figure 12 amp 14 1 Place unit on ground or support securely 2 Remove belt guard 3 Remove idler arm spring 4 Remove motor mounting bracket front bolt and loosen rear bolt 5 Pivot motor mounting bracket assembly Remove old belts and install new ones 6 Reinstall front mounting bolt then secure motor mounting bracket to unit 7 Reinstall idler arm spring and belt guard aliam
118. mber of the Machine is recorded on the Warranty Card and on the Warranty Form that you retain mg TERRAINKING Engineering Practical Solutions Sls Dear Valued Customer Everyone at Alamo Group TX Inc would like to thank you for your recent equipment purchase We strive to offer you industry leading performance and technology with safety and cost in mind You can be confident in your purchase knowing that your product is designed built and serviced by people who care greatly about the product they produce and how it performs for you We have been producing roadside mowing equipment for more than 30 years and we maintain the highest level of experience Knowledge and expertise in our industry to provide the service and support necessary to make your time of ownership a pleasant one Youre product is covered with a full manufacturer supported warranty We design our equipment with the expectation that it will provide you increased productivity less downtime and lower maintenance costs Our Sales Customer Service and Warranty teams are readily available to offer information or advice on any questions that you may have regarding the safety operation or maintenance of your mowing equipment We are here to help you at 800 356 6286 Again we thank you and we greatly appreciate your decision to invest your resources in a world class organization that has your expectations in mind It is our goal to achieve 100 customer satisfac
119. mbly Inner Rear Humpe 73 Unbolt Outer Pump From Inner PUMP occie SGO o AE Ee PAG wes daauineuedeyuuebaeseasenboansed Fw as w 73 Disassemble Inner CEI UMD E 73 Inner Rear Pump Component INSPECTION ccecccccsseececceeseeeccaeueeeecceueeeesaeaeeeesaueeeessageeeesseageeessseueeessaaess 75 measSse mole nner Roa PUMP EE 75 Disassemble Outer Front Pump aaa zzaaaaaa aaa zzaaaaaaa aa zaaaaaaaaazzaaaaaaaaazzaia 77 Outer Front Pump Component Inspection zawa y A AAAA A EE GA KE WK AEO 78 neassembie Outer Front PUMP BE 78 Bolt Inner Rear TO Outer Front FEDER eet deeg Eegenen 79 Single Pump Disassembly 8 Reassembly cccccceeseeccceeeeeseeeeeeeseeeseeceeeeeeeeseceeeesaeeeeeeesseaaeeeeeeesssaaeeeeeeeaaas 80 NOLOPREMOWALE Ira E 81 Motor Removal From le Lee 81 Motor Manifold Remove Repair amp Hepnlace A 83 Motor control manifold remove repair and replace AE 83 Motor Disassembly 8 Reassembly E 85 Disassemble enee 86 Motor Component INMSpecHO EE 87 ReassembDle MOTOT EE 87 Table of Contents Rear and Wing Mower Service and Repail cscccsssecccesseeccesseeseenseesenssessenseeseoeseessoaes 90 Mower Repairs Rear MOWE ea eaaae aaa aaaa aaa aaaaaa aaa aaaaaa aaa aaaaaaaaaaaa aaa aa aaa aaaaaa a zaaaaaaaaaaaaaaaaaaaaaa a aaaaaGaa ii 91 Rear Three Poi iM w rcCo neEcio eegene Eege GO AEG OE OAK 91 Important Clutch Adjust Information D 93 Check AlS a 6 ae e E ree ETE A ETETE EE AEE 93 Gearbox 8
120. moved only the driveshaft will remain showing if it was left in bolster Below figure 9 amp 10 show the pump mount plate removed Figure 9 shows where ATAWASSV ANI TSAIEC a Ve be Driveshaft Bearing amp Figure 4 Lock Collar Figure 5 Pump Mount Weldment Mounting Bolts 4 f LT KH F E Terrain Master Service Manual Pub 08 11 Page 47 Pump Mount Weldment Remove amp Replace 1 Driveshaft runs under batter through the tractors front bolster Figure 10 shows with the battery for this model tractor removed this is for illustration only The battery or battery tray will not have to be removed to remove the driveshaft Driveshaft will be sticking out under battery tray as shown in figure 9 2 Crankshaft pulley adapter The crankshaft pulley will have a pulley adapter bolted to it This adapter will have a splined center that the driveshaft will slide into If the pulley adapter is to be removed or replace make certain that the bolts and washers that are removed are replaced with the same length as the old ones If longer bolts are used the crankshaft pulley as well as the tractor engine will be damaged Do not modify this adapter unless instructed to do so by alamo industrial See Figure 17 3 Pump mount weldment replacement The procedure to replace the pump mount weldment will be the reverse of the disassembly procedure Important notes e Make certain driveshaft is seated into the splined p
121. mpending hazards and the degree of possible injury faced when operating this equipment Practice all usual and customary safe working precautions and above all remember safety is up to YOU Only YOU can prevent serious injury or death from unsafe practices NOTE dentifies points of particular interest for more efficient and convenient operation or repair A Indicates an imminently hazardous situation that if not avoided WILL result in DEATH OR DANGER VERY SERIOUS INJURY A Indicates an imminently hazardous situation that if not avoided COULD result in DEATH WARNING oR SERIOUS INJURY Indicates an imminently hazardous situation that if not avoided MAY result in MINOR A CAUTION INJURY Identifies special instructions or procedures that if not strictly observed could result in damage to or destruction of the machine attachments or the environment READ UNDERSTAND and FOLLOW the following Safety Messages Serious injury or death may occur unless care is taken to follow the warnings and instructions stated in this Manual and in the Safety Messages on the implement Always follow the instruction in this manual and use good common sense to avoid hazards NOTE f you want a translation of this safety section in one of the following Languages please contact Translations at 1502 E Walnut Street Seguin TX 78155 Fax 830 372 9529 Safety Section Translations are available in Spanish Portuguese French Germa
122. n Russian PN Gso1 Terrain Master Service Manual Pub 08 11 Page 7 SAFETY OPERATOR SAFETY Never use Drugs or Alcohol when operating equipment TO AVOID SERIOUS INJURY OR DEATH DO THE FOLLOWING AWARNING e READ UNDERSTAND and FOLLOW Operator s Manual instructions Warnings and Safety Messages e WEAR SAFETY GLASSES safety shoes hard hat hearing protection and gloves when operating or repairing equipment e WEAR appropriate breathing respirator when operating in dusty conditions to avoid respiratory diseases e DO NOT WEAR loose clothing or jewelry to avoid rotating parts entanglement injury e DO NOT USE DRUGS or ALCOHOL before or while operating equipment e DO NOT ALLOW anyone to operate equipment under the influence of drug or alcohol e CONSULT medical professional for medication impairment side effects e STAY ALERT prolonged operation can cause fatigue STOP and REST GENERAL OPERATING SAFETY VISIBILITY CONDITIONS WHEN MOWING e OPERATE IN DAYLIGHT or with lights that gives at least 100 yards clear visibility e BE ABLE TO SEE and identify passersby steep slopes ditches drop offs overhead obstructions power lines debris and foreign objects GROUND SPEED WHEN MOWING e NORMAL SPEED range is between 2 to 5mph e ADJUST MOWING SPEED for terrain conditions and grass type density and cut height e REDUCE MOWING SPEED when near steep slopes ditches drop offs overhead obstructions power lines a
123. n be thrown or swing outside deck with great velocity 1 MARK objects that cannot removed 2 AVOID these objects when mowing HIGH GRASS and WEED AREA INSPECTION e INSPECT for and REMOVE any hidden large debris e MOW at Intermediate height e INSPECT and remove remaining debris e MOW at final height MOWER THROWN OBJECT SHIELDING e KEEP all thrown object shielding including Front and Rear Deflectors Steel Guards Bands Side Skirts and Skid Shoes in place and in good condition when mowing e DO NOT OPERATE with any thrown object shielding missing damaged or removed RIGHT OF WAY Highway MOWING e No shielding is 100 effective in preventing thrown objects To Reduce Possibility of Injury 1 MAINTAIN MOWER SHIELDING side skirts skid shoes and blades in good operational condition 2 RAISE CUTTING HEIGHT to 6 INCHES minimum 3 INSPECT AREA thoroughly before mowing to REMOVE potential THROWN OBJECT HAZARDS 4 NEVER ALLOW BLADES to CONTACT SOLID OBJECTS like wire rocks post curbs guardrails or ground while mowing PN TOFM 01 Terrain Master Service Manual Pub 08 11 Page 11 Safety THROWN OBJECTS HAZARD CONTINUED SAFETY Mower Thrown Raised Mower Inspect Area Do not let blades Objects Hazard Thrown remove foreign contact solid Objects objects objects MOWER OPERATION e DO NOT exceed mower s rated Cutting Capacity or cut non vegetative material e USE ENCLOSED TRACTOR CABS when two or more mow
124. nd 19J and spring Item 19H into piston block Item 19D Install washer Item 19G or 19J are the same into the piston block install spring Item 19H into piston block and against washer Item 19G Install second washer Item 19J into piston block and against spring Caution See step 6 for spring compression instructions 6 Compress spring Item 19H andinstall retaining snap ring Item 19K Caution The following procedure should be used if the spring has been removed from the piston block The spring Item 19H will have to be compressed The following parts will be needed to assemble the piston block 2Ea 3 8 ID X 1 1 8 OD Flat Washer 1 Ea 3 8 NC X 3 1 4 Bolt Hex Head 1 Ea 3 8 NC Hex Nut Place one flat washer over 3 8 x 3 1 4 bolt place this through center of piston block Place other flat washer over bolt and let it rest on the three pins Item 19F Screw nut on to compress spring inside piston block Use snap ring pliers to install internal snap ring Item 1K Install internal snap ring Item 19K make certain it is seated into snap ring groove in piston block Unscrew bolt nut and two washers this will release pressure on spring Item 19H allowing it to seat against snap ring Item 19K Never remove snap ring in piston block without compressing spring first U C lt U gt Z w lt O O JJ Terrain Master Service Manual Pub 08 11 Page 79 Tandem Pump Disassembly amp Reassembly 7 Install
125. nd to avoid debris and foreign objects INSECT INFESTATION e Do Not operate in areas where bees or insects may attack unless you WEAR PROTECTIVE CLOTHING or use enclosed tractor cab PTO SPEED e DO NOT EXCEED IMPLEMENT RATED PTO SPEED e AVOID exceeding rated PTO speeds that may result in broken drivelines or blade failures SAFETY SIGNS e REPLACE missing damaged or unreadable safety signs immediately PN oso1 Read and Always wear Wear Hard understand Safety Hat Safety Operator s Manual Glasses Shoes VVear Safety Vest when operating on or near roads Terrain Master Service Manual Pub 08 11 Page 8 CRUSHING HAZARDS ALAAVS Crushing injury Lock ROPS in Always wear Crushing injury Crushing injury wing from roll over up position seatbelt implement falling falling TO AVOID SERIOUS INJURY OR DEATH FROM FALLING OFF TRACTOR EQUIPMENT RUN OVER 4 DANGER ROLLOVER AND CRUSHING BY FALLING WING OR IMPLEMENT e USE ROPS and SEAT BELT equipped tractors for mowing operations KEEP ROPS lock in up position e ALWAYS BUCKLE UP seat belt when operating tractor and equipment ONLY OPERATE tractor and equipment while seated in tractor seat WHEN RAISING OR LOWERING WINGS Raise or lower ONLY WHILE SEATED in tractor seat with seat belt buckled e KEEP BYSTANDERS CLEAR of area TO AVOID crushing KEEP sufficient clearance around implement and wings TO AVOID contacting buildings or overhead power lines LIFTED Equ
126. ndition The bolts need to be installed in a staggered pattern alternating from side to side until snug These bolts must be torqued to 15 to 18 ft lbs Do this in increment and staggered pattern also Bolt Inner Rear To Outer Front Pump 1 Clamp inner Rear pump in vice See Figure 16 with inner Front pump pointing downward See Figure 16 Make certain splined coupler tem 13 is installed into rear of the inner pump also make certain sealing O ring Item 15 is installed on inside of inner pump backplate Item 2 Coat sealing O ring with oil or Vaseline Lower outer pump down into inner pump aligning outer pump driveshaft with spline coupler Item 13 Inner and outer pump must be aligned do this by making certain ports are aligned the same The larger port will be suction port See Figure 16 when tandem pumps are bolted together these ports must be on same side Install tandem pump connecting bolts See Figure 16 It may require a small amount of force to push outer pump in inner pump but no more than pushing it together with hands If it will not push together by hand check for alignment problem Do not use bolts to force the two pump halves together this will damage pumps With inner and outer pump bolted together you are finished with pump rebuild repair See figure 13 2 Continued with reinstalling pump onto mower tractor See step 14 and 15 of reassemble tandem inner pump Outer Front Domp 3 Fill pump case with o
127. nents If cleaned parts are going to be left for long period before Reassembly parts should be coated with hydraulic oil to prevent rust and stored in such a way as not to allow dust and dirt it contaminate them When these parts are assembled it is recommended that they be washed and cleaned again 10 You pump components for inspection Lay all the components of the pump out on a clean dry surface this will include all seals gaskets O rings bolts washer or any other component that is part of the auxiliary pump It is very important that all components be inspected for wear and or damage All replacement parts should be laid out and compared to the old parts to make certain they are the same Some components cannot be replaced as parts they can only be replaced as complete pump assembly Check the pump body and pump cover for wear and or damage this pump will not have shaft bearings that are replaceable it shaft and or gear wear surface is damaged or worn the pump will need to be replaced as an assembly Check the mating edges of the pump body and cover with a straight edge to make certain the edges are flat and not warped The gear set the pump body and pump cover are not replaceable as parts these will only be replaceable by replacing the complete pump assembly The shaft seal seal plate O ring seal assembly anti extrusion block wear plate gasket insert bridging insert are available as replacement parts in the form of a pump repair kit
128. ng Thrust Race 8 Bearing Snap Ring Motor Shaft Keyed Key Needle Bearing f Housing Snap reing Housing Not Furnished As Parts O Ring Needle Bearing f Backplate Roll Pin Backplate Asy w Bearing Bolt Short Bolt Bolt Long Bolt Cam Plate Insert Seal kit in Seal Kit Motor Disassembly amp Reassembly Disassemble Motor for item numbers see figure 11 1 Motor disassembly w o manifold Manifold should already be removed before starting to disassemble motor See previous section for instruction to remove and replace motor manifold block 2 Clamp single motor in vice with jaw protectors Motor can be clamped in vice with protective covers for vise jaws See Figure 12 or it can be disassembled while on work bench 3 Remove backplate Item 15 The backplate is mounted with 6 hex head bolts Item 16 4 of these bolts will already be removed as they mounted the manifold block It is important to note which holes these last two bolts come out of as they must go back in same holes when reassembled Remove remaining two bolts It may require a small amount of force to free backplate loose from pump housing Use soft faced hammer tap sides of backplate This will break backplate loose from pump housing do not hit backplate with excess force it will damage backplate and pump housing Lift backplate up and out of motor housing Remove the needle bearing tem 13 4 Remove O ring from backplate Remove the O rin
129. ng the crankshaft pulley lo RH or pulley adapter you can loosen the EV e SC 67A P Wing Motor locking collar and pull driveshaft out or AA W you can remove the four bolts in the pump mount weldment and pull the driveshaft out with the pump mount weldment See Figure 5 5 The pump mount weldment has four mounting bolts These bolt screw into the front bolster of the tractor See Figure 6 amp 7 Figure 6 show with Dual driveshaft removed and figure 7 show with driveshaft left in carrier bearing Wing Kl mech Removal can be either way Remove an Suction oz Pressure Out the four mounting bolts for the pump saa Port From Port To LH Wing mountweldment use caution when all Figure 2 o Tank Motor Terrain Master Service Manual Pub 08 11 Page 46 Pump Mount Weldment Remove amp Replace bolts are removed mount weldment will drop if it is not secured Some tractor models will have spacer blocks SSi Driveshaft Bearing installed between pump mount weldment and tractor amp Lock Collar bolster If your model has spacer blocks this should be noted and spacer blocks should be identified and marked Pump mount weldmentwith spacer blocks will used longer bolts than model that do not have spacer blocks See Figure 7 Pull pump mount weldment away from tractor bolster If the carrier bearing was removed the driveshaft should stay through bolster See Figure 8 amp 9 6 The pump mount weldment re
130. nings are still capped plugged The inner rear pump and the outer front pump have not been unbolted and separated For replacement part numbers to repair or replace these pumps see the parts manual for the Terrain Master For a specific tractor mounting components see the assembly manual and or the assembly instruction that were shipped with unit Unbolt Outer Pump From Inner Pump Clean the outside of pump assembly thoroughly if this was not done before it was removed from tractor Make certain all pump openings are sealed during cleaning Make certain work area and all tools are clean Clamp pump in vice with jaw protectors with the outer front pump pointing upward See Figure 13 Remove the two connecting bolts connecting outer pump to inner pump See Figure 14 It may require a small amount of force to free outer pump from inner pump if needed use a soft faced hammer to tap sides of outer pump This will break outer pump loose from inner pump do not hit pump with excessive force it will damage pump housing and pump With inner and outer pump separated set outer pump aside for now See Figure 14 Disassemble Inner Rear Pump For item numbers see figure 12 1 Clamp inner pump in vice with jaw protectors See Figure 14 inner pump can be left clamped in vice for disassembly 2 Remove inner pump to outer pump coupler Pump shaft coupler tem 13 may have stayed on outer pump input an e gt a Z lt A gt A
131. o a groove on the back plate Item 2 make certain this O ring is seated into this groove lubricate the OD of the O ring to aid the inserting of the back plate into the pump housing 13 Back plate assembly tem 2 roll pin and alignment The backplate has a roll pin installed into it This roll pin Item 18 is to align the back plate on the pump housing so front flange of housing and back plate ports will be in the correct orientation roll pin should not be more that 173 High than surface of back plate This alignment is important and must be correct Make certain the roll pin is in the back plate Lower the back plate fem 2 down onto the pump housing tem 4 aligning the back plate down over driveshaft until the sealing O ring tem 8 inserts into pump housing Back plate should slide down until it is inside of pump housing if back plate can not be pushing completely down without a lot of force check it for something wrong Do not use excessive force or use the bolts to pull back plate down 14 Install 6 retaining bolts Item 9 into pump housing ltem 4 to fasten back plate Item 2 Inspect bolts make certain threads are in good condition The bolts need to be installed in a staggered pattern alternating from one side to the other until snug These bolts must be torqued to 15 to 18 ft Ibs Do this in increment and staggered pattern also 15 Install snap ring Item 14 and spline coupler Item 13 into back plate Install the snap rin
132. oller Roller Bearing A e Bearing 8 Housing y a j J Assembly al Ie Figure 15 Terrain Master Service Manual Pub 08 11 Page 30 Cutter Shaft Bearing 7 Install new bearing into housing Bearing must be installed with grease hole in bearing aligned with grease fitting hole in housing 8 Reinstall grease fitting to housing Grease fitting must be tight and seated in grease hole in bearing to prevent bearing from rotating in housing 9 Attach roller bearing and housing assembly to bracket with seal between housing and bracket 10 Slide bearing and bracket assemblies on each end of roller 11 Check bearing for proper installation in housing by gently rocking bearing and bracket assembly in end of roller Play should be slight to none at all 12 Install roller and bearing and bracket assemblies on mower 13 Lubricate roller bearing until lubricant can be seen coming out between roller and bearing housing 14 When reinstalling roller bearing and mount bracket make certain to bolt at the desired height Desired height will normally be the same bolt holes as before the repair See previous pages for adjust roller height Non Drive End Cuttershaft Bearing See Figure 20 21 amp 22 1 Lift cutter unit to maximum horizontal height then securely support ends of cutter housing with jack stands or strong blocks do not use just a jack or hoist 2 Remove enough knives to place a floor jack under P N 002023
133. or 7 Possible Failure Excessive case drain flow Cause A Excessive internal wear in motor Solution A Disassemble motor inspect parts and replace as necessary Case drain flow should not exceed 1 5 GPM at full pressure Terrain Master Service Manual Pub 08 11 Page 24 Failure Cause Solution Mower Function Troubleshooting 8 Possible Failure System will not operate in either direction Cause A Oil supply low Solution A Check oil level and fill as needed Cause B Oil filter clogged Solution B Replace filter element U Cause C Oil too heavy lt Solution C Use proper viscosity oil O MI Cause D Drive coupling broken gt Solution D Inspect coupling for sheared spline or key Z O 9 Possible Failure System noisy Cause A Airin system due to low oil level JJ Solution A Fill in reservoir to sight glass TI U Cause B Loose suction line gt Solution B Tighten fittings JJ Cause C Clogged suction filter Solution C Replace filter element Cause D Internal pump or motor damage Solution D Disassemble inspect and repair 10 Possible Failure Sluggish response to acceleration or deceleration Cause A Air in system Solution A Check oil level and fill Check for loose suction line and o
134. ould be free of wear and score marks 5 Inspect pistons Item 1A The OD surface should be smooth and free of scoring The shoes should be snug fit to piston The face of the shoe should be flat and free of scoring and flaking Do not lap piston shoes 6 Inspect the piston block Item 1D The bore should be free of scoring The surface that contacts the back plate should be smooth and free of grooves or metal build up 7 Inspect the cam plate insert Item 17 The surface should show no signs of scoring or grooves 8 Inspect the flat surface on the back plate Item 15 The back plate surface should be free of excessive scoring or metal build up 9 Inspect the drive shaft Item 7 Inspect for fretting in the bearing areas Check keyed area for twisted broken or worn spots Check for chips and or cracks in shaft Reassemble Motor For item numbers See Figure 11 1 Coat moving parts for reassembly All moving parts should be coated with lubricant before and during reassembly If pump is to used immediately after assembly the recommend hydraulic oil for Terrain Master will work If pump is to set aside for use at latter date pumps moving components should be coating with something that will withstand the time pump is sitting Petroleum jelly Vaseline which can be purchased local This will work excellent for this as it will stick to the pump components while spare pump is sitting on parts shelf If parts are to be assembled later the parts
135. ow no signs of scoring or grooves 8 Inspect the flat surface on the back plate Item 2 The back plate surface should be free of excessive scoring or metal build up 9 Inspect the drive shaft Item 3 Inspect for fretting in the bearing areas Check spline area for twisted broken or worn splines Check for chips and or cracks in shaft Reassemble Outer Front Pump For item numbers See Figure 17 1 Coat moving parts for reassembly All moving parts should be coated with lubricant before and during reassembly If pump is to used immediately after assembly the recommend hydraulic oil for Terrain Master will work If pump is to set aside for use at latter date pumps moving components should be coating with something that will withstand the time pump is sitting Petroleum jelly Vaseline which can be purchased local This will work excellent for this as it will stick to the pump components while spare pump is sitting on parts shelf If parts are to be assembled later the parts should be rewashed and cleaned 2 Install snap rings Item 12 and thrust race and bearing on driveshaft Install inner snap ring Item 12 onto driveshaft from input end Install one thrust race Part of item 5 onto driveshaft sliding it down against snap ring Install thrust bearing Part of item 5 onto driveshaft until it is against thrust race Install second thrust race Part of item 5 onto driveshaft until it is against thrust bearing Install second snap ring lt
136. oward inside of block 6 Install washers Item 1g amp 1J and spring Item 19H into piston block Item 1D Install washer Item 1g or 1j are the samE into the piston block install spring Item 19H into piston block and against washer Item 1G Install second washer tem 1J into piston block and against spring Caution See step 7 for spring compression instructions 7 Compress spring Item 1H and install retaining snap ring Item 1K Caution The following procedure should be used if the spring has been removed from the piston block and is being reinstalled The spring Item 1H will have to be compressed The following parts will be needed to assemble the piston block 2Ea 3 8 ID X 1 1 8 OD Flat Washer 1 Ea 3 8 NC X 3 1 4 Bolt Hex Head 1 Ea 3 8 NC Hex Nut Terrain Master Service Manual Pub 08 11 Page 88 Motor Disassembly amp Reassembly 8 Place one flat washer over 3 8 x 3 1 4 bolt place this through center of piston block Place other flat washer over bolt and let it rest on the three pins liem 1F Screw nut on to compress spring inside piston block Use snap ring pliers to install internal snap ring Item 1K Install internal snap ring Item 1K make certain it is seated into snap ring groove in piston block Unscrew bolt nut and two washers this will release pressure on spring Item 1H allowing it to seat against snap ring Item 1K Never remove snap ring in piston block with out compressing spring first
137. p ring Install the thrust bearing part of item 5 onto driveshaft until it is against the thrust race Install second thrust race part of item 5 onto driveshaft until it is against thrust bearing Install second snap ring tem 12 onto driveshaft until seated in snap ring groove of driveshaft and seated against thrust race 3 Replace needle bearing Item 16 into pump housing Item 4 Install needle bearing assembly into the pump housing If necessary install driveshaft Item 3 into pump housing Item 4 and install washer Item 10 Coat the ID of shaft seal Item 6 and press it into the pump housing Item 4 Install the outer snap ring Item 11 into pump housing until it is seated into snap ring groove of housing 4 Install pin keeper Item 1E and pins Item 1F into spline area of piston block Item 1D Compress pin keeper and install it in the splined area of the piston block Install the three pins in the special grooves of the spline area of the piston block with the head end of pin toward inside of block 5 Install washers Item 1G and 1J and spring Item 7H into piston block Item 1D Install washer Item 1G or 1J are the same into the piston block install spring Item 1H into piston block and against washer Item 1G Install second washer ltem 1J into piston block and against spring Caution See step 6 for spring compression instructions 6 Compress spring Item 1H and install retaining snap ring Item 1K Caution The
138. petroleum jelly which is Vaseline Purchased locaL will work excellent for this as it will stick to the pump components while spare pump is sitting on parts shelf 2 Install snap rings Item 30 and thrust race and bearing on driveshaft Install the inner snap ring Item 30 onto driveshaft from the input end Install one thrust race Part of item 23 onto driveshaft sliding it down against snap ring Install the thrust bearing Part of item 23 onto driveshaft until it is against the thrust race Install second thrust race Part of item 23 onto driveshaft until it is against thrust bearing Install second snap ring Item 30 onto driveshaft until seated in snap ring groove of driveshaft and seated against thrust race 3 Replace needle bearing Item 31 into pump housing Item 22 Install needle bearing assembly into the pump housing If necessary install driveshaft Item 27 into pump housing Item 22 and install washer Item 28 Coat the ID Of shaft seal Item 24 and drive it into the pump housing Item 22 Install the outer snap ring Item 29 into pump housing until it is seated into snap ring groove of housing 4 Install pin keeper Item 19E and pins Item 19F into spline area of piston block Item 19D Compress pin keeper and install it in the splined area of the piston block Install the three pins in the special grooves of the spline area of the piston block with the head end of pin toward inside of block 5 Install washers Item 19G a
139. piston shoes 6 Inspect the piston block Item 1D The bore should be free of scoring The surface that contacts the back plate should be smooth and free of grooves or metal build up 7 Inspect the cam plate insert Item 7 The surface should show no signs of scoring or grooves 8 Inspect the flat surface on the back plate Item 2 The back plate surface should be free of excessive scoring or metal build up 9 Inspect the drive shaft Item 3 Inspect for fretting in the bearing areas Check spline area for twisted broken or worn splines Check for chips and or cracks in shaft Reassemble Inner Rear Pump For item numbers See Figure 12 1 Coatmoving parts for reassembly Itis recommended that all moving parts be coated before and during reassembly If pump is to used immediately after assembly the recommend hydraulic oil for the Terrain Master will work If pump is to set aside for a use at a latter date it is required that pumps moving components by coating with something that will withstand the time pump is sitting STP or petroleum jelly which is vaseline purchased from your preferred supplier will work excellent for this as it will stick to the pump components while spare pump is sitting on parts shelf 2 Install snap rings Item 12 and thrust race and bearing on driveshaft Install the inner snap ring Item 12 onto driveshaft from the input end Install one thrust race part of item 5 onto driveshaft sliding it down against sna
140. pivot Item 19C spider Item 19B and piston assembly Item 19A Sit the pivot Item 19C down onto the piston block with the taper rounded side up See figure 12 Sit the spider Item 1B down over the pivot noting the concave hole in the center of the spider will sit over the rounded edge of the pivot align the holes in the spider with the holes in the piston block Lower the piston assemblies tem 19A through the spider holes and into the piston block the piston assembly can be installed one at time 8 Install cam plate insert Item 25 Lubricate cam plate insert Item 25 well and install it into pump housing Item 22 until it seats down into housing This is best done with pump housing lying on its side on work bench 9 Install piston block assembly tem 19 Coat piston block assembly with oil Slide piston block assembly into end of pump housing aligning id of it over driveshaft Push piston block assembly into housing over driveshaft until piston shoes are in contact with cam plate insert it may require driveshaft to be turned as the piston block assembly is being slid in to align splines of shaft with spline of the components of piston block assembly Do not use excessive force to install piston block assembly if it will not slide together with force of your hand there is something wrong 10 Install needle bearing ltem 32 into back plate assembly tem 20 The needle bearings will install into center opening of back plate coat thi
141. pward and out of piston block 6 Remove Spider Item 1B and Pivot Item 1C The spider Item 1B will be left lying on the piston block when the piston assembly is removed The Pivot tem 1C will also be left on the piston block and can be removed 7 Piston Block Disassembly Item 1D The Piston block assembly need not be disassembled unless the pins tem 19F or the Spring Item 1H is damaged CAUTION The following procedure should be used if the spring is to be removed from the piston block The spring Item 19H is highly compressed and the snap ring Item 1k should not be removed without compressing the spring The following parts will be needed to disassemble the piston block 2 ea 3 8 ID X 1 1 8 OD Flat Washer 1 ea 3 8 NC X 3 1 4 Bolt Hex Head lea 3 8 NC Hex Nut 8 Place one flat washers over 3 8 x 3 1 4 bolt place it through the center of piston block Place other flat washer over the bolt and let it rest on the three pins Item 1F screw the nut on and compress the spring inside piston block Use snap ring pliers and remove the internal snap ring Item 1K Unscrew bolt nut and two washers this will release pressure on spring Item 1H remove spring Item 1K three pins Item 1f and the pin keeper Item 1E 9 Remove cam plate insert Item 7 from housing Item 4 the cam plate Item 7 should be lying inside the housing Item 4 reach into the housing and the cam plate tem 7 should pull out withou
142. r Pump From Mower Tractor gt A Disconnect the outer Pump Suction Hose tem 4 Figure 4 this hose is retained with hose clamps It is easier to remove the fitting at the pump than the O hose clamp Cap all hoses and pump ports gt Case ie Tank Suction Pressure Z immediately SH Drain To Fotz Port Small Out Port ef B Disconnect the Outer Pump Case Drain a Tank a Pump To RH all Hose tem 6 Figure 4 at the pump fittings Ter sd deck WT a Wing Motor Cap all hoses and pump ports immediately ef WE C Disconnect the Outer Pump pressure hose Y GJ LL o _ castings do not force these pumps together L a with the bolt it will damage the pumps To RH on RH Only F Reinstall hydraulic hoses Item 4 6 and Wing Motor Model 8 Figure 4 Tighten hose fittings to their SE RZ ay SA proper torque Refer to Torque Chart In Case d WA i f geg specifications section g ed s 3 G If only the outer pump is being replace or gh From ES Wy repaired fill system with proper type and Up Suction amount of oil Run Unit and check for leaks Port Reinstall Pump Cover and tighten the four From thumb screws securely Figure 11 Tank Terrain Master Service Manual Pub 05 11 Page 60 Tandem amp Single Pump Remove Replace Replace Outer and Inner Pump to Mower Tractor See Figure 4 through 16 A To replace or rebuild inner pump both inner
143. r fittings Check for clogged suction filter and replace as needed Oil to heavy change to proper viscosity oil Cause B Internal pump or motor wear or damage Solution B Disassemble inspect and repair Terrain Master Service Manual Pub 08 11 Page 25 Mower Repairs Wing Mower Decks Information On Flail Mower Vibration Excessive Vibration Vibration is a MONSTER and if allowed to continue unchecked can cause the complete break up of a machine ina very short time A properly operated Flail Mower will produce very little vibration If vibration does occur the mower should be STOPPED IMMEDIATELY and THE PROBLEM CORRECTED Note Warranty does not cover failures resulting from continued operation after something happens to cause the mower to vibrate excessively Vibration is caused by a rotating part which is out of balance This could be the cutter shaft or on those models rear Mower having a universal slip joint assembly drive shaft from the drive shaft If the two extreme ends of the drive shaft the splined yokes which fit on the tractor power take off shaft and on the mower gear box driven shaft are not parallel vibration will be evident This is because of the mechanics of a universal drive wherein the rotational speed through a universal joint is not uniform If the ends of a universal drive shaft are parallel the uneven rotation effect is cancelled out and the machine being driven will be driven at a unifor
144. r replace as needed U Cause 5 C Obstruction in power circuit extra or wrong parts installed in pump or motor lt Solution 5 C Find and remove obstruction Check if components have been reassembled O lately if they have check for being assembled wrong reinstalled wrong or wrong BI parts used Make certain the correct and standard parts were used as replacement gt parts Z O 6 Possible Failure Pump making load noise Cause 6 A Low oil level in hydraulic system JJ Solution 6 A Fill to proper oil level TI U Cause 6 B Vacuum in Reservoir gt Solution 6 B Check Clean or replace reservoir vent plug JJ Cause 6 C Clogged oil filter or wrong filter installed Solution 6 C Check filter for condition and type replace as needed with original type and size filter Cause 6 D Worn or damaged pump Solution 6 D Check Pump condition and operation repair replace as needed 7 Possible Failure Mower will not raise or raises slowly Wing Mowers Cause 7 A Slow gear pump speed Solution 7 A Check gear pump speed pulleys belts and adjustments Cause 7 B Relief valve setting to low or stuck open Solution 7 B Check relief valve setting repair or replace as needed Cause 7 C Worn Gear Pump Solution 7 C Check pump pressure and flow repair or replace as needed Caus
145. r rom as the mower is being sped up to operating speed This occurs as the shaft passes through its normal harmonic vibration point As long as the mower is opened at the proper speed then harmonic vibration will not be an issue Terrain Master Service Manual Pub 08 11 Page 26 Mower Component Location Tractor Mower Component Location For Check List Pumps Hyd Tank amp Cover Ee Ee EE EE Bessssssssseesnen fssnssnsssssssssseh H umunununumunj e Cee eee e tem fennnsnnnsnsnne Left Wing ki f Right Wing Flail ke 2 see Flail alia mte GNV S0IAdSS Lift Fold Control Valve Lh ede OF S e a ene eee oe d WE Rh Side Of Tractor ZN RANEK AZ Tractor Rear Mower Driveline Rear Center Flail Terrain Master Service Manual Pub 08 11 Page 27 Lubrication Points D E T an a L lt LLI e gt am TI Se LUBRICATE ALL POINTS EVERY 8 HOURS OF OPERATION D Use NLG1 with Lithium Grease A LIFT FRAME POVOT PIN G REAR MOWER IDLERARM B WING MOWER BELT IDLERARM H BANJO BEARING c CUTTERSHAFT BEARINGS BANJO COUPLING D TILT CYLINDER ROD END J DRIVELINE YOKE E LIFT CYLINDER ROD END K DRIVELINE SHAFT F ROLLER BEARING L SLIP CLUTCH Mnt FL 0001 Terrain Master Service Manual Pub 05 11 Page 28 Drive Belt Cutting Height General 1 Mower should be in the lowered position Mowers resting on the ground Tractor shut down and parked safely according to tractor
146. return Note 45 elbow on BW bulkhead fitting that the hose connects to ii Terrain Master Service Manual Pub 08 11 Page 111 Pump amp Motor Hydraulic Schematic Dual Wing Return to tractor from wet tubes of Rh wing wet tubes of Lh wing Return Line Left Wing E EE Hose sleevin oo a We lt OUT mJ aj FH i Ar n ees aon HH SE EE e i BE g E Mrs chef print l O AHHH i OE papae ipe a H Hone Too AE EES ir ME W JOO i E F ALT gt SEET SE EE EES EENEE EE sipit IiE V GE L t ret eh Pressure from pump to Lh wing motor OUT WALL ege ere 1 sree p ara arya he bjm pe Ka Tractor Rh Side Tractor Lh Side Return to tank from wet Pressure from pump to Lh wing motor tubes of Rh amp Lh wing Pressure from pump to Rh wing motor Terrain Master Service Manual Pub 08 11 Page 112 Pump amp Motor Hydraulic Schematic RH WING ONLY HYDRAULIC MOTOR SHOWN Case Drain from Return from Motor Motor to Motor to Rear Wet Tube and on to Tank 3 NEVER CONNECT HIGH POZY PZD WYJ PRESSURE HOSE TO RR N AR gt WET TUBES ON DECK Za Ze Return from Front Figure 43 Wet Tube to Tank Tandem Pump Inner Pump for RH Wing Pump Case amp Outer Pump for LH Wing RH Wing LH Wing Only has a single pump Pump Case iz Drain Pump High Pressure Line Hose i TA Sleeving
147. rshaft Drive Belt Driven f Gearbox to Cuttershaft Automatic Spring Tension Cutter Shaft Drive Bet V Belt w Kevlar Construction CUtiershaiLBEArNJS aaa EOKA greaseable sealed self aligning 1 15 16 id rated 3 300 Ibs Bearing Size 8 Type aaa nn22 1 5 16 Bore Greasable Self Aligning Cuttershaft Bearings Cuttershaft Drtve eeeeeeeeeceeeeeceeeeeeeaeees 60 HP Gearbox Shielded Driveline Driven Gearbox Drive cccccccccceceeeeeeeeeeeeeeeeeeeeees Cat IV Shielded Driveline PTO Driven Gearbox Driveline Connection Adjustable Torque Limiter Clutch Rear Roller LE Seege ege Steel Tube Construction w Bell Ends amp Hex Shaft Rear Roller Bearings 222 11111 Greasable Sealed w Housing and Hex ID Rear Roller Adiustmenmt 6 Adjustable Rear Roller Cutting Height Adjustment 11 1 2 Down to 6 Up Cutting Height Rear Roller Knife ODUOMS E Available in Fine or Coarse Cut Safety Deflectors AE Front and Rear Safety Deflectors Standard Rear Mower Cut On Tractor PTO Controls Controlled By Tractor Operator Rear Mower to Tractor Connection CAT or CAT II Three Point Hitch COON OR EA In frame cooling with pressure relief valves for each wing Terrain Master Service Manual Pub 08 11 Page 100 Specifications fit or raise properly Consult an authorized dealer for possible modification procedures to mount nonconforming hitches Use the correct hit
148. s of rolling Torque When Bearing Pre Load is correct DON T BEND Locking Washer Tabs into Notches on Locking Nut and DON T INSTALL OUTPUT SEAL AT THIS TIME this is important 4 Install Inout Shaft and Gear into Main Housing 4 002516 5 Install front Bearing 400754459 into Main Housing 002516 Using Shims 00754761 quantity as required try same quantity as taken out install Snap ring 00754752 into Main Housing DO NOT INSTALL INPUT SEALAT THIS TIME this is important 6 6 lnstall Inout Shaft and Gear Assembly 001725 into rear of Main Housing and through front input Bearing Install Rear Bearing Cone 400754757 Cup amp Cone onto back of input Shaft Install Rear Bearing Cup 400754757 Cup amp Cone into Rear Housing Cover 001710 make sure cup is bottomed out in Cover Install Rear Cover using Gasket Sealer onto Main Housing and Tighten Bolts Some rear covers may use a Gasket some sealed with Sealer If Gasket wanted Gasket 00769800 will fit and can be used for rear cover 7 Set Bearing Pre load on Input Shaft to remove end Play Only this is because outer Bearing is a Ball Bearing Do this by adding or removing Shims between Front input Bearing and Snap Ring 8 Set Gear Back Lash with Shims on output shaft next to output Pinion Gear Add or remove shims Gear Back Lash should be from 016 to 019 This is very critical After Gear Back Lash is correct reset Bearing Pre Load on Output shaft 9 Install Inout Seal 400172
149. s bearing with oil as you slide it into back plate Install bearings into back plate with number end of bearing up and visible Bearing will be slightly higher 09 Than back plate 11 Back plate Item 20 and sealing O ring Item 26 The back plate is sealed with an O ring that is inserted into a groove on back plate Item 20 make certain this O ring is seated into this groove lubricate OD of O ring to aid the inserting of the back plate into the pump housing 12 Back plate assembly tem 2 roll pin and alignment The backplate has a roll pin installed into it This roll pin Item 33 is to align the back plate on the pump housing so front flange of housing and back plate ports will be in the correct orientation roll pin should not be more that 173 Higher than surface of back plate This alignment is important and must be correct Make certain the roll pin is in the back plate Lower the back plate ltem 20 down onto the pump housing ltem 22 aligning the back plate down over driveshaft until the sealing O ring Item 26 inserts into pump housing Back plate should slide down until it is inside of pump housing if back plate can not be pushing completely down without a lot of force check it for something wrong Do not use excessive force or use the bolts to pull back plate down 13 Install 6 retaining bolts Item 27 into pump housing Item 22 to fasten back plate Item 20 Inspect bolts make certain all threads of bolts are in good co
150. screw the bolt nut and two washers this will release pressure on spring Item 1H Remove the spring Item 1K the three pins Item 1E and the pin keeper Item 1E 13 Remove cam plate insert Item 7 from housing Item 4 The cam plate Item 7 should be lying inside the housing Item 4 Reach into the housing and the cam plate Item 7 should pull out without much effort In some cases because of the oil creating suction it may require that housing be tilted up and cam plate dumped out of housing if this is the case catch the cam plate do not let it drop 14 Remove snap ring Item 11 Using internal snap ring pliers remove internal snap ring Item 11 from front side of housing ltem 4 15 Remove input seal Item 6 from housing Item 4 The input seal will be remove from the housing using a seal puller Use caution when removing the input seal so you dont scratch or damage the interior seal seat area 16 Remove seal washer Item 10 which is located behind input seal It may require to lift the housing and dump the washer out 17 Remove driveshaft Item 3 from housing Item 4 The driveshaft must be pulled out of housing to the front side The driveshaft will have the retaining rings Item 12 and thrust race and bearing Item 5 still on it when it is pulled out of housing 18 Remove snap ring tem 12 and thrust race and bearing tem 5 from drive shaft Use snap ring pliers to remove the outer snap ring Item 12 from the end of
151. se any pressure Make certain tractor has been shut down and sit long enough that all pressure is relieved Remove one bolt from the filter to aid in removing the filter cover loosen the other three bolts See Figure 12 amp 13 4 Push the filter cover down and slowly twist the filter cover clockwise to lift it off and up lift it up slowly as there is a spring under this cover See Figure 14 5 Remove filter spring Pull the filter spring up out of filter housing See Figure 15 Pull old filter up and out of filter housing Use caution the housing may still have oil in it See Figure 16 U o JJ lt O O gt pa U JJ Li gt JJ RETURN OIL FILTER Return Filter p RETURN OIL FILTER Assembl ONY Figure 10 Vd Figure 11 7 Figure 12 a Figure 13 Figure 14 amp Figure 15 Terrain Master Service Manual Pub 08 11 Page 39 Hydraulic Tank Repair Information Reinstall New Hydraulic System Filter 1 Remove filter Inspect material trapped by the filter It can indicate parts wear in the system See Figure 16 2 Clean filter canister If filter canister needs cleaning it can not be done with any type of solvent as it would run into oil tank It cleaning is something that cannot be done with lint free towels the filter assembly will need to be removed from tank assembly for cleaning 3 Install the new filter Install the new filter into the filter canister See Figure 16 It will not be required to
152. sion housing can be removed from gearbox with the extension shaft inside housing and bearing Item 7 left on shaft The extension shaft tem 3 will be removed out of extension shaft housing on the gearbox end The best way to do this is to hold the housing up and drop the shaft down on to apiece of wood lying on the work bench This will force the shaft back up into the housing and at the same time push the bearing down the shaft If extension shaft is removed the snap ring Item 6 and bevel ring Item 5 must be replaced in the same order as removed when reassembled 7 Remove splined coupler The splined coupler Item 2 that connects extension shaft to gearbox will slide off There is a grease fitting in this coupler that allows the coupler to be greased 8 Clean and inspect all parts Clean all the parts removed except the bearing Item 7 Caution must be taken when cleaning bearing ltem 7 be careful not to use any cleaner or cleaning method that will damaged the seals in the bearing as this is a sealed bearing Inspect the splined coupler and grease fitting make certain the splines in the coupler on the shaft and on the gearbox shaft are in good conditions 9 Rebuild gearbox assembly See gearbox rebuild steps in this section for gearbox assembly instruction and gearbox identification Next pages 10 Reassemble gearbox extension shaft assembly To reassemble gearbox extension shaft assembly to deck reverse the disassembly steps list
153. t much effort In some cases because of the oil creating suction it may require that housing be tilted up and cam plate dumped out of housing if this is the case catch the cam plate do not let it drop 10 Remove snap ring Item 11 using internal snap ring pliers remove internal snap ring Item 11 from front side of housing Item 4 11 Remove input seal tem 6 from housing tem 4 The input seal will be remove from the housing using a seal puller Use caution when removing the input seal so you dont scratch or damage the interior seal seat area 12 Remove seal washer Item 10 which is located behind input seal It may require to lift the housing and dump the washer out 13 Remove driveshaft Item 3 from housing Item 4 The driveshaft must be pulled out of housing to the front side The driveshaft will have the retaining rings Item 12 and thrust race and bearing Item 5 still on it when it is pulled out of housing i 14 Remove snap ring tem 12 and thrust race and bearing ltem 5 from drive shaft Use snap ring pliers to remove the outer snap ring Item 12 from the end of the driveshaft Slide the trust race and bearing tem 5 from the driveshaft Remove the second snap ring Item 12 from the driveshaft using snap ring pliers U C lt U gt Z O lt O O JJ Vice Jaw Protective Pads Figure 18 Terrain Master Service Manual Pub 08 11 Page 63 an O gt a Z lt
154. t race and bearing ltem 5 from drive shaft Use snap ring pliers to remove the outer snap ring tem 4 from the end of the driveshaft Slide the trust race and bearing ltem 5 from the driveshaft Remove the second snap ring ltem 6 from the driveshaft using snap ring pliers U C lt U gt Z O lt O O JJ 4 39 173 Roll Pin 26 Roll Pin amp Bearing Installation Figure 13 Terrain Master Service Manual Pub 08 11 Page 87 an O gt a Z lt A gt A Motor Disassembly amp Reassembly Motor Component Inspection For item numbers See Figure 11 1 Wash all parts Wash all parts in suitable clean solvent Use clean filtered compressed air to dry parts after washing Do not use compressed air to spin bearing when drying parts Do not use rags or towels that will leave lint to dry parts Parts must be kept clean at all times Work area and place parts are kept during repair process must remain clean and dust free 2 Examine needle bearings Item 9 and 13 Inspect the needle bearings in the housing Item 11 and the back plate Item 15 If the needles are free of excessive play and remain in the bearing cage there is no need to replace the bearing assembly 3 Inspect thrust washers and thrust bearings Item 5 All surfaces should be free of any signs of wear or fretting Should be no sign of distortion or flaking 4 Inspect spider Item 1B and pivot Item 1C Conical surfaces sh
155. tain that area is clear before lowering or folding 5 Before transporting put Lift Lever in detent or full lift position Install Transport Safety Devices securely on folding implements Slow down when turning and on hillsides a nstall Restrictor in folding circuit to slow down lowering and unfolding if action is fasterthan is desirable 6 Make certain that SMV sign Warning Lights and Reflectors are clearly visible Follow local traffic codes 7 Never operate with Flail Mower or Folding Section raised if passersby bystanders or traffic are in the area to reduce possibility of injury or death form objects thrown by Blades under Shields orimplement structure 8 Before dismounting secure flail mower in transport position orlowerto ground 7 Put tractor in park or set brake disengage PTO stop engine remove key and wait until noise of rotation has ceased to prevent entanglementin rotating parts which may cause injury ordeath lt Nevermountordismounta moving vehicle Crushing from runover may cause injury or death 5 TRANSPORT SAFELY 6 USE SMV LIGHTS 8 7 DO NOT OPERATE WITH 8 DO NOT MOUNT OR LOCK UP REFLECTORS MOWER OR WING RAISED DISMOUNT WHILE MOVING gt lle Vi WI na 002369 WARRANTY INFORMATION Read and understand the complete Warranty Statement found in this Manual Fill outthe Warranty Registration Form in full and return it to within 30 Days Make certain the Serial Nu
156. tem 21 from housing ltem 22 The driveshaft must be pulled out of housing to the front side The driveshaft will have the retaining rings ltem 30 and thrust race and bearing tem 23 still on it when it is pulled out of housing 13 Remove snap ring Item 30 and thrust race and bearing Item 23 from drive shaft Use snap ring pliers to remove the outer snap ring ltem 30 from the end of the driveshaft Slide the trust race and bearing tem 23 from the driveshaft Remove the second snap ring Item 30 from the driveshaft using snap ring pliers ag O a O gt a Z lt lt A 2 A Terrain Master Service Manual Pub 08 11 Page 78 Tandem Pump Disassembly amp Reassembly Outer Front Pump Component Inspection For item numbers See Figure 12 1 Wash all parts Wash all parts in suitable clean solvent Use clean filtered compressed air to dry parts after washing Do not use compressed air to spin bearing when drying parts Do not use rags or towels that will leave lint to dry parts Parts must be kept clean at all times Work area and place parts are kept during repair process must remain clean and dust free 2 Examine needle bearings ltem 31 and 32 Inspect the needle bearings in the housing ltem 22 and the back plate Item 20 If the needles are free of excessive play and remain in the bearing cage there is no need to replace the bearing assembly 3 Inspect thrust washers and thrust bearings Item 23 All s
157. tighten these bolts Reinstall Auxiliary Pump Reinstall pump mount plate The pump mount plate will be install with the two retaining bolts through the pump mount flange that was removed during disassembly Do notover tighten these bolts they are through the aluminum pump flange and excessive tightening will damage the pump flange and pump See Figure 30 Install auxiliary pump drive pulley Install drive pulley on auxiliary pump using the key that was removed Do not tighten pulley onto the pump shaft as it will have to slide later to align the pump pulley with the drive shaft coupler pulley Bolt pump mount plate to main pump mounting plate The auxiliary pump mount plate installs with two mount bolts and nuts See Figure 31 The hole on the rh sitting on tractor seat has a slotted hole for adjustment of the drive belt Make certain to install a flat washer on the bolt that goes through the slotted hole See Figure 32 Align auxiliary pump drive pulley With the auxiliary pump mount plate firmly tightened and the drive belt on the pulley but not adjusted tight Slide the pump drive pulley but not adjusted tight Slide the pump drive pulley on the pump shaft until the upper pulley is aligned with the lower one Once the pulleys are aligned tighten the retaining set screw in the upper pulley to secure it to the pump shaft See Figure 33 Install auxiliary pump belt cover The belt cover will mount on the same two bolts that mounts t
158. tion and that your new piece of equipment exceeds your expectations Be Safe sincerely lan Burden President Alamo Group TX Table of Contents Elle 1 dei vlt CT CHE 4 ROY AAE E EE EE 7 General Safety Instructions and Practices cccccseesccccsseceeceeseceeeeeseceeeseeeeeeeeeseeeeseuecessaeaeeeesaaeeeeeseneeeeteas 7 Equipment Operation Safety Instructions and Prachces aaa aa aaa aa aaa aaa aaaa aaa aaaaaa a aaaaaaaaazanakaw aa 10 Connecting or Disconnecting Implement Safety Instructions and Hrachces 15 Transporting Safety Instructions and Prachces aaa aaa aaa aaa aaa aaaaa aaa aaaaaa a aaaaaaa aa aaaaaaaazaaaaaazaaaawaca 16 Maintenance and Service Safety Instructions and Practices aaa aaa aaa aaa aaa aa aaaaa aa aaaaaaaazaaaiia ania 18 Concluding Safety Instructions and Drachces 20 General Mower Service and Repairs cccccssseeccsssecceenseeceesseccenseeeenseeseessesseessessonseesees 21 F alure Cause AE Uu e p EEN 22 Mower Function Troubleshooting ara ARG JE AREA OO EJ oe R odd 22 Information On Flail Mower ia e E 26 Hee EE 26 The cutter shaft will run out of balance 26 Mower Component LOC AOI ane ki A A i AE A EAC EENE EEE ERARE OO 27 LUDIC UON g a OPPA 28 Ra Cunmg VO E 29 E EE 29 Roplace Dive BOI arowej EE ak OWO Or ik OOO EO OK 29 Adjusting Cutting Height E 29 Beleg Ell o EE 30 Roller Bearing Heplacement E 30 SZ Shat AS lee CEZ CH 31 Non Drive End Cuttershaft D 31 Drive End Cuttershait BERNA EE
159. ton Motor Cutter Shaft Drive aaaaaaaaaaa aa aaaaaancce Belt Drive F Motor to Cuttershaft w Automatic Spring Tension Cutter Shaft Drive Belt V Belt w Kevlar Construction Cuttershaft Beangs greaseable sealed self aligning 1 15 16 id rated 3 300 Ibs Rear Roller Tvpe aaa aaaaaasazainai Steel Tube Construction w Bell Ends amp Hex Shaft Rear Roller Bearings 22s 111111 Greasable Sealed w Housing and Hex ID Rear Roller Adiustmenmt 6 Adjustable Rear Roller Cutting Height Adjustment 11 1 2 Down to 6 Up Cutting Height Rear Roller Kite QPUONS serisinin Available in Fine or Coarse Cut Safety Deflectors wccicascccszacancncnsentedcensecic tweens Front and Rear Safety Deflectors Standard Wing Motor Cut Zwitch Automatic Cut Off Switch When Wings Raised Lift Cylinder Capaciby Lift Cylinder Capable of 14 Vertical Lift Tilt Cylinder Capaciy Tilt Cylinder Capable of 45 Degrees Down amp 90 Degrees Up RO OMNIA WE In frame cooling with pressure relief valves for each wing Rear Mower Specifications Rear Mower cutting Width Options 88 or 96 Cutting Width Configuration Dependant Cutter Housing Construction 10 Guage Unitized Cutter Housing Riesen 5 16 Thick Side Plates Both Ends Skid Shoe Type oso a GEE Bolt On Replaceable Skid Shoes Cuttershaft Gze aaa aaa aaa aaaaanacce 4 1 2 x 5 16 Wall Cuttershaft Cutte
160. two auxiliary pump mount plate bolts See figure 24 and 25 this will release the adjustment to the V belt Slip the V belt off of the auxiliary pump pulley and leave the belt hanging on the spline coupler pulley weldment See figure 17 and 18 below pump The hoses for the auxiliary pump should be disconnected now if they have not been make certain to cap all hoses and pump ports immediately when opened To Control Valve Pressure tte Suction gt Line Remove Pump Belt Adjusting Bolt first V Aux Pump Plate ez Mounting Bolts CS 7 A Za a z ri p d A i lt f w f ke j 1 d M d F i D d U a 4 l d b b T A R ST 4 WS i l a A Oil Level Ws BOR 3 4 Temperature Figure 25 j Gauge Belt Guard Pump Mount Plate Mounting Bolts Terrain Master Service Manual Pub 08 11 Page 67 Splined coupler aux pump drive pulley weldment and drive belt remains on driveshaft when auxiliary pump is removed YHOLOW ANY dWAd Auxiliary Pump Disassembly Disassemble Auxiliary Pump See Figure 28 and 29 1 Remove auxiliary pump drive pulley loosen set screw in pulley and slide it off of pump shaft 2 Remove pump from pump mount plate bracket There are two bolts that mount the pump to the mounting plate bracket remove these two bolts 3 Remove drive key from pump input shaft before beginning the disassembly of pump See Figure 28 4 Secure
161. ues for Standard Bolts Proper Torque Values for Metric Bolts Bolt Diameter Head Marking Head Marking Head Marking Head Marking Three Lines Six Lines 4 6 8 8 or 9 8 Grade Five Grade Eight Diameter To get Newton Meters multiply pound foot of torque by 1 356 30mm es La 1312 1353 Mnt B 0005 Terrain Master Service Manual Pub 08 11 Page 105 Torque Multiplier How To Compute Torque When Using An Adapter LOAD MUST BE APPLIED AT CENTER OF KNURLED GRIP HANDLE AT ALL TIMES Figure1 Typical Torque Wrench Shown lf an adapter is attached to the drive of a torque wrench the wrench will not give actual torque in dicated by the setting of the handle A simple formula however allows you to figure out what the setting should be to deliver a predetermined amount of torque at the end of any adapter to the fastener The following letters are defined as Length of the torque wrench when set at the middle scale setting inches Length of adapter inches from center hex bolt to center of torque wrench square shaft Desired torque at end of extrusion Setting for accuracy within or 6 UOU gt Here is a typical problem You have an adapter that adds 10 0 inches to a torque wrench length dimension B What should the setting be to obtain 320 ft lbs of torque at the end of the adapter 22 57 inches length from adapter mounting point torque wrench to center of grip handle 10 0 inches Length from
162. ulley adapter e Coat driveshaft with anti seize compound where it goes through the carrier bearing e Make certain to install drive pulley splined coupler weldment w drive belt on models w auxiliary pump or splined coupler on the end of driveshaft Do these before installing pump e It is recommended that the main pump shaft and the auxiliary pump shaft be coated with anti seize compound before installation See Figure 12 a SS gt LI Se Ze lt q Lu lt LI gt ag O Figur Battery shown removed for illustration only it is not required to remove battery or battery tray to remove driveshaft Coat pump shafts with anti seize compound Ar a Figure 12 Terrain Master Service Manual Pub 08 11 Page 48 Driveline Driveline Lubrication The drivelines and u joints should be inspected each time before the mower is started The u joint on the driveline undergo extreme forces when the unit Is turning It is important that the u joints be greased each time before the unit is started The u joints are located at each end of the drivelines The u joint assemblies are accessible by rotating the driveline safety shield until the hole in the shield matches up with the grease fitting Use 2 bearing grease for lubrication Inspect the u joint for wear by holding the shaft on one side of the u joint while trying to rotate the shaft on the other side of the u joint If there is noticeable movement in the
163. urfaces should be free of any signs of wear or fretting Should be no sign of distortion or flaking 4 Inspect spider Item 19B and pivot Item 19C Conical surfaces should be free of wear and score marks 5 Inspect pistons Item 19A The OD surface should be smooth and free of scoring The shoes should be snug fit to piston The face of the shoe should be flat and free of scoring and flaking Do not lap piston shoes 6 Inspect the piston block Item 19D The bore should be free of scoring The surface that contacts the back plate should be smooth and free of grooves or metal build up 7 Inspect the cam plate insert Item 25 The surface should show no signs of scoring or grooves 8 Inspect the flat surface on the back plate Item 20 The back plate surface should be free of excessive scoring or metal build up 9 Inspect the drive shaft Item 21 Inspect for fretting in the bearing areas Check spline area for twisted broken or worn splines Check for chips and or cracks in shaft Reassemble Outer Front Pump For item numbers See Figure 12 1 Coat moving parts for reassembly It is recommended that all moving parts be coated before and during reassembly If pump is to used immediately after assembly the recommend hydraulic oil for the Terrain Master will work If pump is to set aside for a use at a latter date it is required that pumps moving components by coating with something that will withstand the time pump is sitting STP or
164. urn pressure from motor can be run through the deck tubes See Figure 6 U C lt U gt Z O lt O O JJ RH WING ONLY HYDRAULIC MOTOR SHOWN Case Drain from Return from Motor Motor to Motor to Rear Wet Tube and on to Tank NEVER CONNECT HIGH PRESSURE HOSE TO TUBES ON DECK Motor Control Manifold High Pressure from Pump to Motor f Return from Front Figure 5 e Wet Tube to Tank Terrain Master Service Manual Pub 08 11 Page 83 Motor Manifold Remove Repair amp Replace Motor control manifold remove repair and replace 1 Motor control manifold Motor control manifold components can be replace d block test port plug machining port plug pressure relief valve solenoid valve and or solenoid valve components Reference to parts manual for replacement part numbers See Figure 7 8 amp 9 The motor manifold can be removed and or replace without removing motor or it can be removed with the motor The procedure to remove repair and or replace will be the same For illustration it will be assumed the manifold was removed with the motor 2 Remove hoses from manifold If hoses are still connected to manifold and only manifold is being removed see step 3 in previous section Make certain all motor components and area around motor have been cleaned before disconnecting any components Make certain to cap or plug all opened hydraulic connections immediately after opened to prevent contamination from gett
165. used gaskets Currently all models use sealant or form A Gasket This gearbox assembly P N 702673 Can replace earlier style P N 700493 as an assembly but parts will not interchange between them The easiest way to tell which gearbox you have is by looking were the shaft goes through the gearbox housing the old style had bolt on caps here and the new style will not Terrain Master Service Manual Pub 08 11 Page 97 Gearbox Asy P N 702673 Asy Instructions A Instructions Gearbox 702673 Install Output Shaft and Pinion Gear into Main Housing 002516 5 Install Snap Ring 00754752 into Main Housing 002516 Install Shims 00753222 on Output Shaft next to Gear Install Inner Output Bearing Cone 001722 Cup amp Cone on Output Shaft 001718 Install Inner Bearing Cup 001722 Cup amp Cone down over Bearing Cone Slide out put shaft into housing Insert Snap Ring 00754752 into Main Housing Slide Bearing Spacer 001716 in till it bottoms out against Snap Ring 3 Insert Outer Bearing Cup 00754757 Cup amp Cone into Main Housing till itis against Bearing Spacer Slide Outer Bearing Cone 00754757 Cup amp Cone over Shaft till it seats against Outer Cup Install Tabbed Lock Washer 001720 onto output shaft next to outer Bearing Cone Make sure Inner Tab of locking washer is in keyway of Shaft Install Notched Locking Nut 001717 by screwing it onto Output Shaft Tighten Nut till Bearing Pre Load is set at 14 to 16 lb
166. ve ita smother movement The gauge is color coded green O psi To 15 psi Red 16 psi To 60 psi The return pressure when oil is warm and at operating temperature should not move out of the green area It is not unusual for pressure to be high when oil is cold If pressure is in the read at operating temperature 700 F above ambient temperature check the return filter it may need changing Red Area Vent Cut Off Top ES T LLI CC a Replace Filter Ed 16 psi to 60 SE O LLI O gt an LLI 09 Green Area Good 0 psi to 15 psi 1 4 NPT P N 02962963 Figure 10 Return Pressure Gauge Figure 9 Terrain Master Service Manual Pub 08 11 Page 38 Hydraulic Tank Repair Information Remove Old Hydraulic System Filter 1 Hydraulic return filter A large capacity filter is located on top of the hydraulic oil reservoir figure 2 The filter will trap particles which are 001 Inch or larger The filter needs to be changed after the first 10 hours of operation and every 200 hours thereafter 2 Clean the filter cover and all components around filter assembly This is to prevent dirt or other contamination from entering filter and tank See Figure 10 amp 11 3 Loosen the four bolts on the filter cover Never loosen these four bolt until you have made certain all hydraulic pressure has been relieved from system Make certain no hydraulic cylinders are supporting any weight work the control valves to relea
167. will require approximately 26 gallons of oil to fill the hydraulic tank hoses cylinders and cooling tubes in the mower deck An Terrain Master with 60 wings will require less oil and with 88 wings will require more oil The Hydraulic tank only holds 15 gallons of oil and you can not add enough oil to the tank the first time to completely fill the system Therefore the following filling instructions must be carefully followed to prevent pump cavitation and instant pump failure 1 After the Terrain Master mower is completely assembled to the tractor and with the wings on the ground fill the mower hydraulic tank above the oil level sight gauge approximately 5 or 1 below the top of the tank Use Tractor Hydraulic Oil only 2 Start the tractor and run it for 30 to 45 seconds and then turn it off 3 Check the oil level in the sight gauge If no oil is seen add oil to bring the level up to the sight gauge NOTE Do not fill the tank with oil above the level of the sight gauge after the first filling Overfilling the tank with oil after the initial filling may result in oil being discharged through the air filter on top of the hydraulic tank 4 Start the tractor and run it for 2 minutes and then turn it off 5 Again check the oil level in the sight gauge If the oil level is in the sight gauge the unit is ready to run If no oil is seen add oil to bring the level up to the sight gauge 6 Repeat steps 4 and 5 as required until the oi
168. with the head and cotter pins a certain way see below for installing pin depending on cutter shaft rotation See following page Non Drive End Bearing Fine Cut Cutter Shaft Drive End Bearing Figure 22 Terrain Master Service Manual Pub 08 11 Page 33 U ITT JJ lt O TT gt pa UO JJ Li gt JJ Knife Installation For Forward Rotation On the right wing and rear unit all knife pins must be installed with their heads facing away form the cutter shaft pulley On the left wing the heads of the knife pins must face the cutter shaft pulley For Reverse Rotation On the right wing and rear unit all knife pins must be installed with their heads facing toward the cutter shaft pulley On the left wing and rear unit the heads of the knife pins must face away from the cutter shaft pulley Note Rotation is the direction of the cutter shaft in relation to the direction of travel of the mower The blades will not Tractor Direction of Travel need to be reversed as they are double sided and designed Forward Rotation to cut on either side i Cutter Shaft Rotation RM l l l Tractor Direction of Travel Reverse Rotation o a Ti an a A lt LLI e gt an LLI Se Cutter Shaft Rotation A B Figure 23 Figure 24 Changing Mower Cutter Shaft Rotation to Forward or Reverse Wing Mowers The hydraulic wing motors are dual rotation motors which means they will rotate in either dire
169. zaaaaaaaaaaaaa a zaaaaeac 61 Single Pump Disassembly A Reassembly ccccccceeeescceeeeeeeeeeeeeeeeeseeceeeeseeeseeeeeesaeeseeeeeeseaeeeeeeessaeeeseeeesaaas 62 Disassemble Single lr e ee een A ER A A S OJA AEO 62 Single Pump Component Inspection eeee ee aaaaaa aaa aaa aaa aa aaa aa aaaaaaaaa aaa aaa aaa aaa aa aaa kawa zaaaaaa aaa zzaaaaaa aaa zzaaaaie 63 Reassembie Outer Front UNI gente c WAR A RE PZ O OE YA R 63 Auxiliary Pump Remove 8 Repair E 65 omgle Pump and Single e asaaen ai a O EEEE ZEE APES SZEW sacs 65 Tandem Pump and Dual Wings zaatai EG ciostceaeudecceannsseeSetcuetuntusaacn staieeaneaiancotans see ecacencicaesansnmeeovaeee ioe 65 EE PUI OPE AON E 65 Remove Auxiliary Pump Hoses And Belt Guard aaa aa nana aaa aaa aaaaaaaa aaa aaa aaaaaaazaaaaaaaaaazzaaaaaaaaaaziaa 65 Romov Auxiliary PUMP asian O O Kida dziad id y 66 Auxiliary Pump Eeer 67 Disassemble Auxa F WMD E 67 Assemble auxiliary pUMp E 68 Auxiliary Pump Reassembly amp Hemstal 69 Reinstall Auxiliary PUMP aanita ii CZ OEG e O A R OGC dw G wnyk 69 Auxiliary Pump Removal Repair amp Replace cccccccsscecceseeecesseeccseeeceuseeceeseeseageeseeseeseeeessageesseneessegseeses 71 Al UN 71 Tandem Pump Disassembly amp Reassembly e saaae aaa nana aa aaa aa aaa aaa aaaaaaaaaaaa a aaaaaa aa zaaaaaaanaaaaa a zaaaaeac 72 Tools Required For Pump Disassembly And Heassemblv aa aaaa aaa aaa aaa aa aaaaaa aa aaaaaaaazaaaaaazaaaaaaca 6 Tandem Pump Disasse

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