Toro Reelmaster 3100-D Service Manual
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Toro Reelmaster 3100-D Service Manual

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See also: Operator's Manual , Instruction and Installation Manual
Form No. 99024SL Rev J
®
Reelmaster
3100-D
Original Instructions (EN)

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  • Page 1 Form No. 99024SL Rev J ® Reelmaster 3100-D Original Instructions (EN)
  • Page 2 THE TORO COMPANY 2018 This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies). No intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be...
  • Page 3 Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.com...
  • Page 4 NOTES...

  • Page 5: Service Manual

    IMPORTANT: The IMPORTANT notice will give im- specifications or this publication without notice. portant instructions which must be followed to pre- vent damage to systems or components on the machine. E The Toro Company − 1999, 2002, 2003, 2005, 2007, 2009, 2011, 2012, 2018...
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  • Page 7: Table Of Contents

    Table Of Contents Chapter 1 − Safety Chapter 5 − Electrical System Safety Instructions ......1 −...
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  • Page 9: Safety Instructions

    ..General Safety Instructions The REELMASTER 3100--D was tested and certified by TORO for compliance with national and international WARNING standards as specified in the Operator’s Manual. Al- though hazard control and accident prevention are de-...

  • Page 10: While Operating

    20 degrees or less the risk of a rol- lover is low. As the slope angle increases to a Toro rec- 22.Raise the cutting units when driving from one work ommended maximum limit of 25 degrees the risk of a area to another.
  • Page 11 32.Before disconnecting or performing any work on the void the product warranty of The Toro Company. hydraulic system, all pressure in system must be re- lieved by stopping engine and lowering cutting units to the ground.

  • Page 12: Jacking Instructions

    Jacking Instructions CAUTION When changing attachments, tires, or performing other service, use correct blocks, hoists, and jacks. Make sure machine is parked on a solid lev- el floor such as a concrete floor. Prior to raising machine, remove any attachments that may inter- fere with the safe and proper raising of the ma- chine.

  • Page 13: Safety And Instruction Decals

    Numerous safety and instruction decals are affixed to the Reelmaster 3100−D. If any decal becomes illegible or damaged, install a new decal. Part numbers for re- placement decals are listed in your Parts Catalog. Order replacement decals from your Authorized Toro Distribu- tor. Reelmaster 3100−D Safety...
  • Page 14 This page is intentionally blank. Safety Reelmaster 3100−D Page 1 − 6...
  • Page 15 Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS ......MAINTENANCE ....... EQUIVALENTS AND CONVERSIONS .

  • Page 16: Product Records

    Equivalents and Conversions 0.09375 Product Records and Maintenance Reelmaster 3100−D Page 2 − 2...

  • Page 17: Torque Specifications

    For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.
  • Page 18 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Grade 1, 5, & SAE Grade 1 Bolts, Screws, Studs, & SAE Grade 5 Bolts, Screws, Studs, & SAE Grade 8 Bolts, Screws, Studs, & Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts...
  • Page 19 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws, and Studs with Class 10.9 Bolts, Screws, and Studs with Thread Size Thread Size Regular Height Nuts Regular Height Nuts Regular Height Nuts Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts) M5 X 0.8...

  • Page 20: Fasteners (Inch Series)

    Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Thread Size Square Head Hex Socket 7/16 − 20 UNF 65 + 10 ft−lb 88 + 14 N−m Grade 5 1/4 −...

  • Page 21: Adjustments

    Lubrication Traction Unit CAUTION Before servicing or making adjustments to the machine, stop engine, lower cutting, set parking brake, and remove key from the ignition switch. The traction unit has grease fittings that must be lubri- cated regularly with No. 2 General Purpose Lithium Figure 5 Base Grease.
  • Page 22 Figure 12 Figure 8 Figure 13 Figure 9 Figure 14 Figure 10 Figure 15 (See Note) Figure 11 Product Records and Maintenance Reelmaster 3100−D Page 2 − 8...
  • Page 23 Cutting Units Each cutting unit has (6) grease fittings (with optional front roller installed) that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. The grease fitting locations and quantities areas follows: Bedknife adjuster (2), every 50 hours (Fig. 17); Reel bearings (2) and front and rear rollers (2 ea.) (Fig.
  • Page 24 C. Coat cable terminals and battery posts with Grafo expected minimum temperature in your area (see 112X skin−over grease (Toro Part No. 505-47) or pe- Check Cooling System in Chapter 3 − Kubota Diesel En- troleum jelly to prevent corrosion.

  • Page 25: Service And Repairs

    Chapter 3 Kubota Diesel Engine Table of Contents Water/Fuel Separator ..... . . INTRODUCTION ......SPECIFICATIONS .

  • Page 26: Introduction

    Service and repair parts for Kubota engines are sup- commonly available in many service shops. Special plied through your Authorized Toro Distributor. If no tools are described in the Kubota Workshop Manual, parts list is available, be sure to provide your distributor Diesel Engine, 05 Series.

  • Page 27: Specifications

    Specifications Item Description Make / Designation Kubota, 4−Cycle, 3 Cylinder, Water Cooled, Diesel Engine Horse Power 21.5 HP @ 2500 RPM Bore mm (in.) 78.0 (3.07) Stroke mm (in.) 78.4 (3.09) Total Displacement cc (cu. in.) 1123 (68.53) Torque N−m (ft−lb) 67.3 (49.6) @ 2000 RPM Firing Order 1−2−3...

  • Page 28: General Information

    General Information Check Engine Oil The engine is shipped with oil in the crankcase. Howev- er, oil level must be checked before and after the engine is first started. Crankcase holds about 4.0 qts. (3.8 l) with filter. IMPORTANT: Check level of oil every 5 operating hours or daily.

  • Page 29: Fill Fuel Tank

    Fill Fuel Tank DANGER Because diesel fuel is highly flammable, use cau- tion when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot, or when machine is in an enclosed area.

  • Page 30: Adjustments

    Adjustments Adjust Throttle Cable 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Position throttle control lever all the way to the SLOW position so it stops against the control panel slot (Fig. 6). 3.

  • Page 31: Adjust Alternator/Fan Belt

    Adjust Alternator/Fan Belt Condition and tension of all belts should be checked af- ter the first 10 hours of operation and every 100 operat- ing hours thereafter. 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch.

  • Page 32: Service And Repairs

    Service and Repairs Change Engine Oil and Filter Change oil and filter initially after the first 50 hours of op- eration, thereafter change oil every 50 hours and filter every 100 hours. 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch.

  • Page 33: Bleed Fuel System

    Bleed Fuel System 1. Park machine on a level surface, lower cutting units, stop engine, and engage parking brake. 2. Make sure fuel tank is at least half full. Gain access to the engine. DANGER Because diesel fuel is highly flammable, use cau- tion when storing or handling it.

  • Page 34: Muffler And Air Cleaner

    Muffler and Air Cleaner Figure 15 1. Air inlet hose (upper) 9. Air cleaner body 17. Plug 2. Air inlet hose (lower) 10. Not used 18. Filter cover 3. Flange nut 11. Hex nut 19. Burp valve 4. Flange head screw 12.

  • Page 35: Muffler Removal

    Muffler Removal CAUTION The muffler and exhaust pipe may be hot. To avoid possible burns, allow the engine and ex- haust system to cool before working on the muf- fler. 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch.

  • Page 36: Check Air Filter, Dust Cup, & Burp Valve

    Check Air Filter, Dust Cup, & Burp Valve The air cleaner body, air filter, dust cup, and burp valve should be check daily prior to operation. 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch.

  • Page 37: Water/Fuel Separator

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

  • Page 38: Fuel System

    Fuel System Figure 22 1. Cap screw 14. Flange hex nut 27. Flange nut 2. Fuel tank 15. Lock washer 28. Seat support strap 3. Fuel hose strap 16. Flat washer 29. Foam 4. Cap screw 17. Tee fitting 30. Hex flange head screw 5.

  • Page 39: Fuel Tank Removal

    Fuel Tank Removal (Fig. 22) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Siphon fuel from the tank into a suitable container. 3. Remove seat and seat support straps from the frame.

  • Page 40: Radiator

    Radiator Figure 26 1. Drain cock valve 15. Clip spring 29. Barb fitting 2. Flange head screw 16. Philips pan head screw 30. Hose clamp 3. Flange nut 17. Pop rivet 31. Cable tie 4. Carriage bolt 18. Lock nut 32.

  • Page 41: Installation

    3. Place a suitable container under the radiator to col- Installation lect the coolant. Open drain cock valve, and completely 1. Remove any plugs from the oil cooler used during the drain the radiator. removal procedures. 4. Remove glow plug relay from the radiator assembly. 2.

  • Page 42: Clean Radiator And Oil Cooler

    Clean Radiator and Oil Cooler (Fig. 4) The radiator and oil cooler should be checked for dirt and debris daily, and hourly if conditions are extremely dusty and dirty. 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch.
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  • Page 44: Engine

    Engine Figure 29 1. Kubota engine 15. Engine mounting bracket (RH) 28. Lock nut 2. Engine mount 16. Cap screw 29. Lock washer 30. Flat washer 3. Engine mount 17. Pulley 18. Bolt 31. Flange head screw 4. Flange nut 19.
  • Page 45 8. Disconnect wire harness and electrical wires from the following: A. Engine grounds to the battery and wire harness (Fig. 30). B. Glow plug bus and fuel stop solenoid (Fig. 31). C. High temperature warning switch (Fig. 32). D. High temperature shutdown switch, alternator, and low oil pressure switch (Fig.

  • Page 46: Installation

    B. Remove five cap screws, four washers, and five spacers securing the pump mount plate to the en- gine (Fig. 34). C. Remove four cap screws and hardened washers securing the right engine mounting bracket and hy- drostat to the engine. Installation 1.
  • Page 47 Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS ......Check Hydraulic Lines and Hoses .

  • Page 48: Specifications

    Specifications Item Description Piston Pump (Hydrostat) Variable displacement piston pump Maximum Operating Pressure 3000 PSI (207 bar) Charge Pressure 100 to 150 PSI (6.9 to 10.0 bar) Traction Circuit Relief Pressure (Forward Only) 3000 PSI (207 bar) Gear Pump 2 stage positive displacement gear type pump Maximum Operating Pressure 3000 PSI (207 bar) Wheel Motors (Front)

  • Page 49: General Information

    General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure WARNING to weather, sun, chemicals, very warm storage condi- tions, or mishandling during operation or maintenance. Before disconnecting or performing any work These conditions can cause damage or premature dete- on hydraulic system, relieve all pressure in rioration.
  • Page 50 SAE Straight Thread O−Ring Port − Non−adjustable 1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material. 2. Always replace the O−ring seal when this type of fit- ting shows signs of leakage. O−Ring 3.

  • Page 51: Towing Traction Unit

    Towing Traction Unit In case of emergency, the Reelmaster can be towed for a short distance. However, Toro does not recommend this as a standard procedure. IMPORTANT: Do not tow the machine faster than 2 to 3 mph because drive system may be damaged. If ma- chine must be moved a considerable distance (more than a few feet), transport it on a truck or trailer.

  • Page 52: Relieving Hydraulic System Pressure

    Relieving Hydraulic System Pressure Before disconnecting or performing any work on the Re- which will energize the solenoid valve on hydraulic man- elmaster 3100−D hydraulic system, all pressure in the ifold to relieve circuit pressure. Move PTO switch to dis- hydraulic system must be relieved.
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  • Page 54: Hydraulic Schematics

    Hydraulic Schematics Hydraulic System Page 4 − 8 Reelmaster 3100−D...
  • Page 55 Hydraulic System Reelmaster 3100−D Page 4 − 9...
  • Page 56 Hydraulic System Page 4 - - 9.1 Reelmaster 3100--D...

  • Page 57: Reelmaster 3100--D (Model 03207 And 03171)

    Reelmaster 3100--D Hydraulic System Page 4 - - 9.2...

  • Page 58: Hydraulic Flow Diagrams

    Hydraulic Flow Diagrams Hydraulic System Reelmaster 3100−D Page 4 − 10...

  • Page 59: Traction Circuits

    Traction Circuits Forward the loss of hydraulic fluid from the closed loop circuit that must be replenished. The traction circuit of the hydraulic system consists of a hydrostat connected in a closed loop circuit to three or- The charge pump (P2) is a fixed displacement gear bital vane wheel motors.
  • Page 60 Hydraulic System Reelmaster 3100−D Page 4 − 12...

  • Page 61: Reel Circuit

    Reel Circuit REEL CIRCUIT SCHEMATIC FOR MACHINES WITH SERIAL NUMBERS BELOW 230000000 The gear pump (P1) is directly coupled to the the hydros- TO MANIFOLD tat which is driven by the engine. Taking its suction di- D1 PORT rectly from the hydraulic tank, the gear pump supplies oil flow to the manifold block and to the reel motors.
  • Page 62 Hydraulic System Reelmaster 3100−D Page 4 − 14...

  • Page 63: Lift Circuit (Up)

    Lift Circuit (Up) Raise Cutting Units When the cutting units are to be raised, the 2−spool valve is positioned by moving the cutting unit shift lever The gear pump (P2) is directly coupled to the hydrostat to RAISE. Flow is directed to cap ends of the lift cylin- through gear pump (P1).
  • Page 64 Hydraulic System Reelmaster 3100−D Page 4 − 16...

  • Page 65: Lift Circuit (Down)

    Lift Circuit (Down) Lower Cutting Units shift the pilot valve in the 2−spool valve. This shifting of the pilot valve allows hydraulic pressure to relieve from Circuit operation for lowering the cutting units is similar the cap end of the lift cylinders. Flow from the cap end to raising them.
  • Page 66 Hydraulic System Reelmaster 3100−D Page 4 − 18...

  • Page 67: Sidewinder Circuit

    Sidewinder Circuit The gear pump (P2) is directly coupled to the hydrostat and hydraulic manifold, and to the hydrostat. When the through gear pump (P1). It supplies hydraulic pressure cutting unit shift lever is released, spring action returns (charge pressure) for raising and lowering the cutting the valve to its original position and by−passes flow back to the hydrostat and stopping cylinder movement.
  • Page 68 Hydraulic System Reelmaster 3100−D Page 4 − 20...

  • Page 69: Steering Circuit

    Steering Circuit The gear pump (P2) is directly coupled to the hydrostat. steering wheel. Fluid leaving the cylinder flows back It supplies hydraulic pressure to the power steering through the spool valve then through the OUT port and valve for turning the rear wheel and maintaining 100 to to the hydrostat.

  • Page 70: Special Tools

    Special Tools Order these special tools from your Toro Distributor. Hydraulic Pressure Test Kit Toro Part Number: TOR47009 Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings.

  • Page 71: Measuring Container

    Figure 13 O- -Ring Kit Toro Part Number: 16- -3799 The kit includes O--rings in a variety of sizes for face seal and port seal hydraulic connections. It is recommended that O--rings be replaced whenever a hydraulic connec- tion is loosened.
  • Page 72 NOTE: Replacement filter element is Toro part number TOR6012. Filter element cannister tightening torque is NOTE: This kit does not include hydraulic hoses (see 25 ft- -lb (34 N- -m).
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  • Page 74: Troubleshooting

    Troubleshooting The charts that follow contain information to assist in Refer to the Testing section of this Chapter for precau- troubleshooting. There may possibly be more than one tions and specific test procedures. cause for a machine malfunction. Á Á Á Á Á Á Á Á Á Á Á Á Á Á...

  • Page 75: Testing

    Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Problem Possible Cause Á Á Á Á Á Á Á Á Á Á Á Á Á Á...
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  • Page 77: Testing

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

  • Page 78: Traction Circuit Working Pressure Test

    Traction Circuit Working Pressure Test (Using Pressure Gauge) TRACTION WHEEL MOTORS TOP PORT LOWER UPPER DUMP VALVE PORT PORT 3000 psi TRACTION RELIEF 100 to 150 psi FROM HYDRAULIC MANIFOLD (CHG) PORT PISTON PUMP (HYDROSTAT) High Pressure TO GEAR PUMP SUCTION Low Pressure THROUGH CASE DRAIN Return or Suction...
  • Page 79 Procedure for Traction Circuit Working Pressure Test: 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off. 3.
  • Page 80 Piston Pump (P3) Flow and Traction Relief Pressure Test (Using Tester with Pressure Gauges and Flow Meter) TRACTION WHEEL MOTORS TOP PORT LOWER UPPER DUMP VALVE PORT PORT 3000 psi TRACTION RELIEF 100 to 150 psi FROM HYDRAULIC MANIFOLD (CHG) PORT PISTON PUMP (HYDROSTAT) High Pressure...

  • Page 81: Relief Pressure Test

    Procedure for Piston Pump (P3) Flow and Traction Relief Pressure Test: 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. 2. Park machine on a level surface with the cutting units lowered and off.

  • Page 82: Charge Relief Valve Pressure Test

    Charge Relief Valve Pressure Test (Using Pressure Gauge) TRACTION WHEEL MOTORS TOP PORT LOWER UPPER DUMP VALVE PORT PORT TO HYDRAULIC MANIFOLD (P1) PORT 3000 psi FROM HYDRAULIC MANIFOLD (CHG) PORT 100 to 150 psi CHARGE RELIEF TO STEERING CONTROL VALVE (IN) PORT ENGINE HYDROSTAT...

  • Page 83: Service And Repairs

    Procedure for Charge Relief Valve Pressure Test: 9. A dynamic charge pressure test can be performed as follows: 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 A. With T−connector and pressure gauge still con- minutes.

  • Page 84: Gear Pump (P2) Flow Test

    Gear Pump (P2) Flow Test (Using Tester with Pressure Gauges and Flow Meter) TO HYDRAULIC MANIFOLD (P1) PORT TO STEERING CONTROL TO TOTO VALVE (IN) PORT ENGINE FROM HYDROSTAT CASE DRAIN GEAR PUMP High Pressure STRAINER Low Pressure Return or Suction Flow Hydraulic System Reelmaster 3100−D...
  • Page 85 Procedure for Gear Pump (P2) Test: 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged.

  • Page 86: Wheel Motor Efficiency Test

    Wheel Motor Efficiency Test (Using Tester with Pressure Gauges and Flow Meter) FRONT WHEEL MOTOR TESTING SHOWN TRACTION WHEEL MOTORS TOP PORT LOWER UPPER DUMP PORT PORT VALVE 3000 psi TRACTION RELIEF 100 to 150 psi FROM HYDRAULIC MANIFOLD (CHG) PORT PISTON PUMP High Pressure (HYDROSTAT)
  • Page 87 Procedure for Wheel Motor Efficiency Test: 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting units lowered and off.

  • Page 88: Reel Circuit Pressure Test

    Reel Circuit Pressure Test (Using Pressure Gauge) FROM REEL MOTOR CASE DRAINS TO INITIAL FROM FINAL REEL MOTOR REEL MOTOR TO HYDRAULIC TANK HYDRAULIC MANIFOLD BLOCK BACKLAPPING VALVE LOGIC REEL SPEED VALVE CONTROLLER REEL ON−OFF VALVE REEL RELIEF 3000 psi TO OIL COOLER PLUG...
  • Page 89 Procedure for Reel Circuit Pressure Test: 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged.

  • Page 90: Gear Pump (P1) Flow Test

    Gear Pump (P1) Flow Test (Using Tester with Pressure Gauges and Flow Meter) TO HYDRAULIC MANIFOLD (P1) PORT TO STEERING CONTROL VALVE (IN) PORT TO TOTO ENGINE FROM HYDROSTAT CASE DRAIN GEAR PUMP STRAINER High Pressure Low Pressure Return or Suction Flow Hydraulic System Reelmaster 3100−D...
  • Page 91 Procedure for Gear Pump (P1) Flow Test: IMPORTANT: In this test, the hydraulic tester is positioned before the manifold relief valve. Pump NOTE: Over a period of time, the gears and wear plates damage can occur if the oil flow is fully restricted by in the pump can wear down.

  • Page 92: Manifold Relief Valve (R1) Pressure Test (Using Tester With Pressure Gauges And Flow

    Manifold Relief Valve (R1) Pressure Test (Using Tester with Pressure Gauges and Flow Meter) FROM REEL MOTOR CASE DRAINS TO INITIAL REEL MOTOR FROM FINAL REEL MOTOR TO HYDRAULIC TANK HYDRAULIC MANIFOLD BLOCK BACKLAPPING VALVE LOGIC REEL SPEED VALVE CONTROLLER REEL ON−OFF VALVE...
  • Page 93 Procedure for Manifold Relief Valve (R1) Pressure 10.System pressure should be from 2700 to 3300 PSI Test: as the relief valve lifts. 1. Make sure hydraulic oil is at normal operating tem- A. If specification is not met, shut off engine and ad- perature by operating the machine for approximately 10 just relief valve (see Adjusting Manifold Relief Valve).

  • Page 94: Reel Motor Efficiency -- Case Drain Test

    Flow MANIFOLD PORT (M2) BOTTOM Toro # TOR4077 NOTE: Over a period of time, a reel motor can wear in- NOTE: One way to find a possibly bad reel motor is to ternally. A worn motor may by−pass oil to its case drain have another person observe the machine while mow- causing the motor to be less efficient.
  • Page 95 Procedure for Reel Motor Efficiency: Case Drain Test: 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting units lowered and off.

  • Page 96: Reel Motor Cross--Over Relief Pressures Test

    Reel Motor Cross−over Relief Pressures Test (Using Pressure Gauge) TO HYDRAULIC MANIFOLD PORT (D1) FROM HYDRAULIC MANIFOLD PORT (M1) INITIAL REEL MOTOR BOTTOM RIGHT FRONT REEL MOTOR BOTTOM FINAL REEL MOTOR BOTTOM TO HYDRAULIC MANIFOLD PORT (M2) High Pressure Low Pressure Return or Suction Flow Figure 29...
  • Page 97 Procedure for Cross−over Relief Pressures Test: 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Make sure machine is parked on a level surface with the cutting units lowered and off.
  • Page 98 12.Make sure backlap knob on the hydraulic manifold is 14.Engage cutting units. System pressure should be in the backlap position. from 1350 to 1650 PSI as the relief valve lifts. 13.One person should sit on the seat and operate the 15.Disengage cutting units and stop engine.
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  • Page 100: Lift And Steering Control Valve Relief Pressure Test

    Lift and Steering Control Valve Relief Pressure Test (Using Pressure Gauge) TO HYDRAULIC MANIFOLD (ST) PORT TO LIFT VALVE POWER (IN) PORT STEERING VALVE 1000 psi TO HYDRAULIC MANIFOLD LEFT TURN SHOWN GEAR PUMP ENGINE STRAINER High Pressure Low Pressure FROM HYDROSTAT Return or Suction INTERNAL CASE DRAIN...
  • Page 101 Procedure for Lift and Steering Control Valve Relief Pressure Test: 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. 2. Make sure machine is parked on a level surface with the cutting units lowered and off.

  • Page 102: Steering Control Valve Test

    Steering Control Valve Test STEERING CYLINDER OPEN FITTING PLUG POWER STEERING VALVE (LEFT TURN) High Pressure Low Pressure Return or Suction Flow Hydraulic System Reelmaster 3100−D Page 4 − 54...
  • Page 103 Procedure for Steering Control Valve Test: B. Turn the steering wheel all the way to the left (counterclockwise) so the steering cylinder rod is ful- 1. Make sure hydraulic oil is at normal operating tem- ly extended. perature by operating the machine for approximately 10 minutes.

  • Page 104: Adjustments

    Adjustments Adjust Traction Drive for Neutral 1. Park the machine on a level surface and turn the en- gine off. WARNING One front wheel and rear wheel must be raised off the ground or the machine will move during adjustment. Make sure machine is supported so it will not accidentally fall injuring anyone under machine.

  • Page 105: Adjust Manifold Relief Valve (R1)

    Adjust Manifold Relief Valve (R1) The hydraulic reel circuit is equipped with a relief valve. This valve is preset at the factory to 3000 PSI. However, an adjustment may be required if the setting proves to be incorrect after testing (see TESTING). If an adjust- ment is required proceed as follows: WARNING Never adjust the relief valve with the hydraulic...

  • Page 106: Service And Repairs

    Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components After Repair or Replacement of Components 1. Before removing any parts from the hydraulic sys- 1. Check oil level in the hydraulic reservoir and add cor- tem, park machine on a level surface, engage parking rect oil if necessary.

  • Page 107: Change Hydraulic Fluid

    Change Hydraulic Fluid Change hydraulic fluid after every 400 operating hours, under normal conditions. If fluid becomes contami- nated, the system must be flushed. Contaminated fluid looks milky or black when compared to clean oil. 1. Turn engine off and raise hood. 2.

  • Page 108: Replace Hydraulic Oil Filter

    200 hours of operation or yearly, whichever comes first. The hydraulic oil must be changed every 400 hours of operation or yearly, whichever comes first. Use a genuine Toro oil filter for replacement. IMPORTANT: Use of any other filter may void the warranty on some components.

  • Page 109: Replace Traction Belt

    Replace Traction Belt 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Insert nut driver or small piece of pipe onto the end of the torsion spring of the idler pulley. CAUTION Be careful when removing or applying tension from or to the torsion spring of the idler pulley.

  • Page 110: Reelmaster 3100--D

    Ing from petroleum base hydraulic fluid to a biode- draulic System Fluid. If changing to biodegradable fluid, gradable fluid such as Toro Biodegradable use Toro Biodegradable Hydraulic Fluid for this step. Hydraulic Fluid. Operate machine under normal op- Other fluids may cause system damage.

  • Page 111: Charge Hydraulic System

    Charge Hydraulic System NOTE: When initially starting the hydraulic system with 11. After the hydraulic system starts to show signs of fill, new or rebuilt components such as motors, pumps, or actuate lift control lever until the lift cylinder rod moves lift cylinders, it is important that the hydraulic system be in and out several times.

  • Page 112: Hydraulic Tank And Hydraulic Oil Filter

    Hydraulic Tank and Hydraulic Oil Filter LATER MODELS 16 to 18 ft−lb (22 to 24 N−m) Hydraulic Thread Sealant Hydraulic Thread Sealant 14 to 16 ft−lb (19 to 22 N−m) Anti−seize lubricant 30 to 60 in−lb (3.4 to 6.8 N−m) Figure 40 1.
  • Page 113 Hydraulic Tank Removal 1. Drain hydraulic tank (see Change Hydraulic Fluid). 2. Remove hydraulic tank from machine using Figures 40 and 41 as guides. Hydraulic Tank Inspection 1. Clean hydraulic tank and suction strainer with sol- vent. 2. Inspect hydraulic tank for leaks, cracks, or other damage.

  • Page 114: Front Wheel Motors

    Front Wheel Motors RIGHT FRONT Figure 42 1. Lock nut 5. Frame 8. O−ring 2. Spacer 6. Hydraulic tube 9. Hydraulic fitting 3. Socket head screw 7. Hydraulic tube 10. O−ring 4. Hydraulic motor Hydraulic System Reelmaster 3100−D Page 4 − 66...
  • Page 115 Removal Installation 1. Install wheel motor to frame using Figure 42 as guide. WARNING 2. Install wheel shield, brake bracket, and brake as- Before jacking up the machine, review and follow sembly to the frame. Install brake drum, wheel hub, and Jacking Instructions in Chapter 1 −...

  • Page 116: Rear Wheel Motor

    Rear Wheel Motor 45 to 65 ft−lb 61 to 88 N−m 200 to 400 ft−lb 271 to 542 N−m Figure 43 1. Lug nut 6. Hydraulic hose 11. Hydraulic motor 2. Drive stud 7. O−ring 12. Rear fork 3. Tire and rim 8.
  • Page 117 Rear Wheel Removal Rear Wheel Installation 1. Park machine on a level surface, lower cutting units, 1. If hydraulic fittings were removed, install fittings to stop engine, engage parking brake, and remove key reel motor using marks made during the removal pro- from the ignition switch.

  • Page 118: Wheel Motor Service

    Wheel Motor Service Figure 45 1. Dirt seal 11. Coupling shaft 20. Vane 2. Bearing 12. Thrust bearing 21. Stator 3. Housing 13. Drive link 22. Manifold 4. Back- -up washer 14. Cap screw 23. Commutator ring 5. Seal rings 15.
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  • Page 120: Reel Motors

    Reel Motors 30 to 40 ft−lb (41 to 54 N−m) 30 to 40 ft−lb (41 to 54 N−m) Figure 45 1. Hydraulic motor (front) 8. Hydraulic straight fitting 15. Hydraulic straight fitting 2. Hydraulic motor (rear) 9. Hydraulic hose 16. O−ring 3.
  • Page 121 Removal Installation NOTE: Note position of hydraulic fittings when remov- 1. If hydraulic fittings were removed, install fittings to ing from the reel motors. Position is critical to properly reel motor using marks made during the removal pro- reconnecting hydraulic hoses. cess to properly orientate fittings.

  • Page 122: Reel Motor Service (Eaton)

    Reel Motor Service (Eaton) 25 to 28 ft- -lb (34 to 38 N- -m) 10 to 12 ft- -lb (13.6 to 16.3 N- -m) Figure 46 1. Plug 8. Idler gear assembly 14. Frontplate 2. O- -ring 9. Drive gear assembly 15.
  • Page 123 Inspection (Fig. 46) 12.Replace body if the inside diameter of the gear pock- ets exceeds 1.713 in. (43.5 mm). 1. Remove all nicks and burrs from all parts with an emery cloth. 13.Make sure both plugs are secure if they or the back- plate is not being replaced.

  • Page 124: Reel Motor Service (Casappa)

    Reel Motor Service (Casappa) 33 ft- -lb (45 N- -m) 19 ft- -lb (25 N- -m) 19 ft- -lb (25 N- -m) Figure 46.1 1. Dust seal 7. Back- -up gasket 13. O- -ring 2. Retaining ring 8. Front wear plate 14.
  • Page 125 4. Loosen cap screws from the rear cover. 4. Inspect wear plates for the following: 5. Remove motor from the vise. Turn motor so that the A. Bearing areas should not have excessive wear or shaft end is facing down. Remove cap screws. scoring.
  • Page 126 1. Lubricate O--rings, pressure seals, back--up gaskets 8. Install rear wear plate with pressure seal side up and and wear plate grooves with a thin coat of petroleum jel- open side of the pressure seal pointing to the inlet side ly.
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  • Page 128: Oil Cooler

    Oil Cooler Removal CAUTION The radiator and oil cooler may be hot. To avoid possible burns, allow the engine and cooling systems to cool before working on the oil cooler. 1. Remove oil cooler using Figures 47 and 48 as guides.

  • Page 129: Hydraulic Manifold

    Hydraulic Manifold RIGHT FRONT Figure 49 1. Hose clamp 11. Hydraulic manifold 21. Hydraulic tube 2. Micro switch 12. Hydraulic hose 22. O−ring 3. Barb fitting 13. Hydraulic hose 23. Hose 4. Flange head screw 14. Hose clamp 24. Hydraulic hose 5.

  • Page 130: Hydraulic Manifold Service

    Hydraulic Manifold Service HYDRAULIC MANIFOLD USED ON MACHINES WITH SERIAL NUMBERS Loctite 242 BELOW 250999999 2 to 5 ft−lb (2.7 to 6.8 N−m) 30 to 35 ft−lb (41 to 47 N−m) 42 to 45 ft−lb (57 to 61 N−m) 30 to 35 ft−lb (41 to 47 N−m) 30 to 35 ft−lb (41 to 47 N−m)
  • Page 131 48 to 60 in- -lb (5.4 to 6.7 N- -m) HYDRAULIC MANIFOLD USED ON MACHINES WITH SERIAL NUMBERS ABOVE 260000000 40 ft- -lb (54 N- -m) 25 ft- -lb 20 ft- -lb (34 N- -m) (27 N- -m) 120 in- -lb (13.5 N- -m) 41 ft- -lb (55 N- -m)
  • Page 132 Solenoid Operated, Relief and Logic Control Car- 6. Reinstall the cartridge valve into the manifold: tridge Valves A. Lubricate new O-rings and backup rings of seal 1. Make sure the manifold is clean before removing the kit with clean hydraulic oil and install on cartridge. cartridge valve and seal kit.
  • Page 133 3. Make sure manifold is clean before removing the D. Center one detent plate hole over a locating plate rotary cartridge valve. Remove the valve and seal kit. indentation. Drop a ball into each hole, then drop a spring into each hole. 4.

  • Page 134: Reelmaster 3100--D (Model 03200)

    8. Install rotary handle (Fig. 52) (manifold shown in Fig. D. Pull spool up and out of manifold. Remove O-- 51) : rings and back--up ring from spool. A. Place handle base on flow control valve and posi- E. Discard removed O--rings and back--up rings. tion alignment mark on base with number 1 on man- 2.
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  • Page 136: Control Valve (Models 03200, 03206 And 03170)

    Control Valve (Models 03200, 03206 and 03170) Figure 55 1. Straight hydraulic fitting 8. Shoulder bolt 14. Hydraulic hose 2. 90 hydraulic fitting 9. Valve lever assembly 15. Hydraulic hose 3. Hydraulic fitting 10. Link (2 used) 16. Hydraulic tube 4.
  • Page 137 Removal WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved. See Relieving Hy- draulic System Pressure in the General Infor- mation section. 1. Remove control valve from the frame using Figures 54 and 55 as guides.

  • Page 138: Reelmaster 3100--D (Model 03201)

    Control Valve Service (Models 03200, 03206 and 03170) 30 to 42 ft- -lb 10 to 12 ft- -lb (41 to 57 N- -m) (14 to 16 N- -m) 30 to 35 ft- -lb (41 to 48 N- -m) 30 to 35 ft- -lb (41 to 48 N- -m) 20 to 25 ft- -lb (27 to 34 N- -m)
  • Page 139 Figure 57 1. Check poppet 11. Valve body 21. Not used 2. Plunger 12. O−ring 22. Plunger detent 3. Spacer 13. Retaining ring 23. Spring 4. Spool 14. Washer 24. O−ring 25. O−ring 5. Seat 15. Not used 6. Plug (solid) 16.
  • Page 140 Disassembly Assembly 1. Plug all ports and clean the outside of the valve thor- IMPORTANT: Do not wipe parts with paper towels or oughly. rags. Lint free cloth must be used to prevent lint from causing damage to the hydraulic system. 2.
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  • Page 142: Control Valve (Models 03201, 03207 And 03171)

    Control Valve (Models 03201, 03207 and 03171) Figure 59 1. Control valve (2- -spool) 10. Cotter pin 19. Carriage screw (2 used) 2. Hydraulic fitting (straight) 11. Valve lever 20. O- -ring 3. 90 hydraulic fitting 12. Valve actuator trunnion 21.
  • Page 143 Removal WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved. See Relieving Hy- draulic System Pressure in the General Infor- mation section. 1. Remove control valve from the frame using Figures 58 and 59 as guides.

  • Page 144: Control Valve Service (Models 03201, 03207 And 03171)

    Control Valve Service (Models 03201, 03207 and 03171) 10 to 12 ft- -lb 30 to 35 ft- -lb (41 to 48 N- -m) (14 to 16 N- -m) 30 to 42 ft- -lb (41 to 57 N- -m) 30 to 35 ft- -lb (41 to 48 N- -m) 20 to 25 ft- -lb (27 to 34 N- -m)
  • Page 145 Figure 61 21. Plunger 1. Check poppet 11. Valve body 2. Grooved plunger 12. O−ring 22. Plunger detent 3. Spacer 13. Retaining ring 23. Detent spring 4. Spool 14. Washer 24. O−ring 15. Seat retaining plug 25. O−ring 5. Seat 6.
  • Page 146 Disassembly Assembly 1. Plug all ports and clean the outside of the valve thor- IMPORTANT: Do not wipe parts with paper towels or oughly. rags. Lint may cause damage to the hydraulic sys- tem. IMPORTANT: Match mark spools to their associat- ed bores.
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  • Page 148: Piston Pump

    Piston Pump Antiseize Lubricant Antiseize Lubricant 27 to 31 ft−lb (37 to 42 N−m) RIGHT FRONT 90 to 120 in−lb (10.2 to 13.6 N−m) Figure 62 1. Piston pump 20. Idler pulley 39. V−belt 2. Straight hydraulic fitting 21. Spacer 40.
  • Page 149 Neutral Arm Assembly EARLY MODELS 34 33 33 34 Figure 63 1. Philips head screw 13. Spacer 25. Ball bearing 2. Flat washer 14. Traction stud 26. Rod end 3. Micro switch 15. Traction control cable 27. Lock nut 4. Keps nut 16.
  • Page 150 C. Disconnect traction control cable from the pump lever. D. Remove both flange head screws securing the neutral bracket to the piston pump. Remove flange nut and flange head screw securing the neutral bracket to the pump mount plate. E. Remove cap screw and flat washer securing the pump lever to the piston pump trunnion.
  • Page 151 Piston Pump Installation (Fig. 62) 10.Install neutral arm assembly to the piston pump as follows (Figs. 63 and 64): 1. If hydraulic fittings were removed, install fittings to pump using marks made during the removal process to A. Position neutral bracket to the mount plate, and properly orientate fittings.

  • Page 152: Piston Pump Service

    Piston Pump Service EATON MODEL 70160−LAA−01 Figure 66 1. Key 19. Spring 37. Bleed−off spring 2. Drive shaft 20. Seat 38. O−ring 3. Bearing 21. Dump valve 39. Cam plate insert 22. Cap screw 4. Cap screw (3 used per cover plate) 40.

  • Page 153: Piston Pump Crush Ring Replacement

    Piston Pump Crush Ring Replacement 29 ft−lb (39 N−m) Figure 67 Crush ring Cam plate (control shaft) Seal Shims Bearing cone Washer (3 used) Cover plate Bearing cup 10. Cap screw (3 used) Housing NOTE: The shims replace the crush ring in the piston 5.

  • Page 154: Sidewinder (Models 03201, 03207 And 03171)

    Sidewinder (Models 03201, 03207 and 03171) Figure 69 1. Plastic bushing 12. Lock nut 22. Hydraulic hose 2. Scissor link 13. Welded pin 23. 90 hydraulic fitting 3. Scissor mount 14. Flange head screw 24. Hydraulic hose 4. Cap screw 15.
  • Page 155 Removal WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved. See Relieving Hy- draulic System Pressure in the General Infor- mation section. 1. Remove hydraulic cylinder from the frame using Fig- ure 68 as guide.

  • Page 156: Steering Control Valve

    5. Cap screw 19. Hydraulic Fitting 33. Flat washer 6. Pivot hub 20. Steering wheel nut 34. Not used 7. Steering cover 21. Toro decal 35. Not used 8. Cap screw 22. Hydraulic hose 36. O−ring 9. Toro decal 23. Hydraulic hose 37.
  • Page 157 Removal WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved. See Relieving Hy- draulic System Pressure in the General Infor- mation section. 1. Remove steering control valve from the steering col- umn using Figures 70, 71, and 72 as guides.

  • Page 158: Steering Control Valve Service (Serial Numbers 90101 To 230999999)

    Steering Control Valve Service (Serial Numbers 90101 to 230999999) Figure 73 1. Nut 18. Socket head screw 35. Not used 2. Port cover 19. Commutator seal 36. Retaining plate 3. Seal ring 20. Commutator cover 37. Upper cover & jacket assembly 4.

  • Page 159: Steering Control Valve Service (Serial Numbers 240000001 And Up)

    Steering Control Valve Service (Serial Numbers 240000001 and up) 20 to 24 ft−lb (27 to 33 N−m) Figure 74 1. Sleeve 9. Dust seal ring 16. Outer gearwheel 2. Cross pin 10. Housing 17. End cover 18. O−ring (5 used) 3.

  • Page 160: Gear Pump

    Gear Pump 27 to 31 ft−lb (37 to 42 N−m) Figure 75 1. Piston pump 7. O−ring 12. Cap screw 2. Gear pump 8. O−ring 13. Flat washer 3. Hydraulic hose (tank suction) 9. Hydraulic barb fitting 14. O−ring 4. Hydraulic hose (hydraulic manifold) 10.
  • Page 161 Removal Installation 1. Remove muffler from the engine to gain access to 1. If hydraulic fittings were removed, install fittings to the gear pump (see Muffler Removal in Chapter 3 − Ku- motor using marks made during the removal process to bota Diesel Engine).

  • Page 162: Gear Pump Service

    Gear Pump Service 25 to 28 ft−lb (34 to 38 N−m) Figure 76 15. Not used 1. Front plate 8. Back−up gasket 2. Back plate 9. Wear plate 16. Drive gear 3. Front body 10. Pressure seal 17. Washer 4. Rear body 11.
  • Page 163 Disassembly (Fig. 76) MARKER LINE 1. Plug pump ports and clean the outside of the pump thoroughly. After cleaning, remove plugs and drain any oil out of the pump. 2. Make sure key is removed from the shaft of the drive gear.
  • Page 164 D. Gears should be free of excessive scoring and wear. E. Make sure drive and idler gears have their snap rings in the grooves on each side. F. Break sharp edges of gear teeth with emery cloth. G. Gear width on the drive gear and front idler gear should not be less than 0.384 inch (9.75 mm).
  • Page 165 IMPORTANT: Do not dislodge seals during installa- 15.Install new O−ring into the groove of the back plate. tion. 16.Align marker line on the back plate and body. Install 12.Install wear plate into the gear pocket of back body back plate onto the body and gear shafts. with the pressure seal and back−up gasket against the 17.Secure pump together with cap screws and new adapter plate.

  • Page 166: Front Lift Cylinder

    Front Lift Cylinder Figure 80 1. 90 hydraulic fitting 15. LIft arm pivot shaft 28. External retaining ring 2. Hydraulic cylinder 16. Roll pin 29. Bulkhead nut 3. Carrier assembly 17. Pivot shaft link 30. Hydraulic tube 4. Flange nut 18.
  • Page 167 Removal 1. Remove front lift cylinder from the frame and lift arm using Figure 80 as guide. 2. If hydraulic fittings are to be removed from lift cylin- der, mark fitting orientation to allow correct assembly. Installation 1. If hydraulic fittings were removed, install fittings to cylinder using marks made during the removal process to properly orientate fittings.

  • Page 168: Rear Lift Cylinder

    Rear Lift Cylinder Figure 82 1. Hydraulic tube 21. Flat washer 40. Not used 2. Lock nut 22. Cap screw 41. Lock washer 3. Hydraulic T−fitting 23. Lock nut 42. Guard 4. Hydraulic hose 24. Rear pivot shaft 43. Cap screw 5.
  • Page 169 Removal Installation 1. Remove rear lift cylinder from the frame and lift arm 1. If hydraulic fittings were removed, install fittings to lift using Figure 82 as guide. cylinder using marks made during the removal process to properly orientate fittings. 2.

  • Page 170: Lift Cylinder Service

    Lift Cylinder Service 24 to 30 ft−lb (33 to 41 N−m) Figure 83 1. Grease fitting 6. O−ring 11. Internal collar 2. Barrel with clevis 7. O−ring 12. Dust seal 3. Nut 8. Back−up ring 13. Shaft 4. Uni−ring 9. Rod seal 14.
  • Page 171 Disassembly Assembly 1. Remove oil from lift cylinder into a drain pan by slowly 1. Make sure all parts are clean before reassembly. pumping the cylinder shaft. Plug both ports and clean 2. Coat new O−rings, Uni−rings, rod seal, back−up the outside of the cylinder.

  • Page 172: Steering Cylinder

    Steering Cylinder No. 2 General Purpose Grease No. 2 General Purpose Grease 65 to 85 ft−lb (88 to 115 N−m) 65 to 85 ft−lb (88 to 115 N−m) Figure 84 9. Jam nut 1. Hydraulic hose 5. O−ring 2. Hydraulic hose 6.
  • Page 173 Removal 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. NOTE: The rear tire must be removed to allow sufficient clearance to remove the steering cylinder from the ma- chine.

  • Page 174: Steering Cylinder Service

    Steering Cylinder Service 24 to 30 ft−lb (33 to 41 N−m) Figure 87 1. Barrel 5. O−ring 9. O−ring 2. Lock nut 6. Piston rod 10. Back−up ring 3. Piston 7. Rod seal 11. Retaining ring 4. Uni−ring 8. Cylinder gland 12.
  • Page 175 Disassembly Reassembly 1. Remove oil from the steering cylinder into a drain pan 1. Make sure all parts are clean before reassembly. by slowly pumping the cylinder shaft. Plug both ports 2. Coat new O−rings, Uni−ring, rod seal, and back−up and clean the outside of the cylinder.
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  • Page 177: Electrical Schematics And Diagrams

    Chapter 5 Electrical System Table of Contents ELECTRICAL SCHEMATICS AND DIAGRAMS . . . ELECTRICAL SYSTEM QUICK CHECKS ..Reelmaster 3100--D Electrical Schematic Battery Test (Open Circuit) ....(Serial Numbers 90101 to 90150) .
  • Page 178 Electrical Schematics and Diagrams Electrical Systems Page 5 − 2 Reelmaster 3100−D...
  • Page 179 Electrical Systems Reelmaster 3100−D Page 5 − 3...
  • Page 180 Electrical Systems Page 5 − 4 Reelmaster 3100−D...
  • Page 181 Electrical Systems Reelmaster 3100−D Page 5 − 5...
  • Page 182 Electrical Systems Page 5 − 6 Reelmaster 3100−D...
  • Page 183 Electrical Systems Reelmaster 3100−D Page 5 − 7...
  • Page 184 Electrical Systems Page 5 − 8 Reelmaster 3100−D...
  • Page 185 WIRE IDENTIFICATION WIRE IDENTIFICATION ROUTE ROUTE LABEL COLOR FROM LABEL COLOR FROM P23−3 RED/BLACK P2−3 (2) P23−1 P16−1 RED/BLACK P2−3 (2) J15 (2) ORANGE P16−2 P14−4 RED/BLACK J15 (2) J9 (2) BLUE P16−4 NOT USED YELLOW P16−5 GREEN P17−B J20 (2) VIOLET P9−1 P16−6 (2)
  • Page 186 Electrical Systems Page 5 − 10 Reelmaster 3100−D...
  • Page 187 Electrical Systems Reelmaster 3100−D Page 5 − 11...
  • Page 188 Electrical Systems Page 5 − 12 Reelmaster 3100−D...
  • Page 189 Electrical Systems Reelmaster 3100−D Page 5 − 13...
  • Page 190 Electrical Systems Page 5 − 14 Reelmaster 3100−D...
  • Page 191 Electrical Systems Reelmaster 3100−D Page 5 − 15...
  • Page 192 Electrical Systems Page 5 − 16 Reelmaster 3100−D...
  • Page 193 WIRE IDENTIFICATION WIRE IDENTIFICATION ROUTE ROUTE LABEL COLOR FROM LABEL COLOR FROM RED/BLACK P2−3 (2) P23−3 RED/BLACK P2−3 (2) J15 (2) P23−1 P16−1 RED/BLACK J15 (2) J9 (2) ORANGE P16−2 P14−4 NOT USED BLUE P16−4 GREEN P17−B J20 (2) YELLOW P16−5 J18 (2) P6−B...
  • Page 194 Electrical Systems Page 5 − 18 Reelmaster 3100−D...
  • Page 195 Electrical Systems Reelmaster 3100−D Page 5 − 19...
  • Page 196 Electrical Systems Page 5 - - 20 Reelmaster 3100--D...
  • Page 197 Reelmaster 3100--D Page 5 - - 21 Electrical Systems...
  • Page 198 Electrical Systems Page 5 - - 22 Reelmaster 3100--D...
  • Page 199 Page 5 - - 22.1 Electrical System Reelmaster 3100--D...
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  • Page 201: Special Tools

    Multimeter The meter can test electrical components and circuits for current, resistance, or voltage. NOTE: Toro recommends the use of a DIGITAL Volt− Ohm−Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital me- ter in the voltage mode will make sure that excess cur- rent is not allowed through the meter.

  • Page 202: Troubleshooting

    Troubleshooting For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and CAUTION components used on this machine (see Electrical Sche- matics and Diagrams section of this chapter). Remove all jewelry, especially rings and If the machine has any interlock switches by−passed, watches, before doing any electrical trouble- shooting or testing.
  • Page 203 Starting Problems (continued) Problem Possible Causes Engine cranks, but does not start. Wiring in the crank circuit (see Electrical Schematics) is loose, corroded, or damaged. Engine run solenoid or fuel pump faulty. The fuel tank is empty. An engine or fuel system problem exists.
  • Page 204 General Run and Transport Problems Engine kills during operation (operator sitting on seat). Operator moved too far forward on seat (seat switch is not depressed). The engine overheated. The parking brake was engaged or the parking brake switch No. 1 failed. The seat relay or seat switch failed.

  • Page 205: Cutting Unit Operating Problems

    Cutting Unit Operating Problems The cutting units will not run with the transport mow Wiring to the reel drive circuit is (see Electrical switch in MOW and the reel on/off switch in ON with Schematics) is loose, corroded, or damaged. the cutting units lowered.

  • Page 206: Electrical System Quick Checks

    Electrical System Quick Check Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the Voltage Measured Battery Charge Level battery terminals. 12.68 V (or higher) Fully charged (100%) Set multimeter to the DC volts setting. The battery 12.45 V 75% charged should be at a temperature of 60 to 100...

  • Page 207: Check Operation Of Interlock Switches

    Check Operation of Interlock Switches 2. With operator on the seat, the engine must not start with either the reel switch engaged or the traction pedal CAUTION engaged. Correct problem if not operating properly. 3. With operator on the seat, the traction pedal in neu- Do not disconnect safety switches.

  • Page 208: Component Testing

    Component Testing For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the CAUTION circuit (e.g. unplug the ignition switch connector before doing a continuity check). When testing electrical components for continu- NOTE: For more component testing information, see ity with a multimeter (ohms setting), make sure the Kubota Workshop Manual, Diesel Engine, 05 Se- that power to the circuit has been disconnected.

  • Page 209: Glow Relay

    Glow Relay The glow relay is attached to the radiator assembly. When energized, the glow relay allows electrical current to the engine glow plugs. Two styles of glow relays have been used on the Reel- master 3100−D. On machines with serial numbers be- low 240000000, two of the four relay connections are secured with screws (Fig.

  • Page 210: Hour Meter

    Hour Meter 1. Connect the positive (+) terminal of a 12 VDC source to the positive terminal of the hour meter. Hobbs 2. Connect the negative (−) terminal of the voltage QUARTZ source to the other terminal of the hour meter. 0 0 0 0 HOURS 3.

  • Page 211: High Temperature Warning And Shutdown Switches

    High Temperature Warning and Shutdown Switches The high temperature warning and shut down switches are located on the water pump, which is located on the rear end of the engine block. The high temperature shut- down switch is on the alternator side of the engine (Fig. 11).

  • Page 212: Diode Assemblies

    Diode Assemblies The diode D1 and D2 provide logic for the interlock switches. Diode D3 is used for circuit protection from in- ductive voltage spikes when the interlock relay is deen- ergized. Machines equipped with the standard control module (serial numbers above 240000000) use only one diode.

  • Page 213: Warning Light Cluster (Serial Numbers Below 240000000)

    Warning Light Cluster (Serial Numbers Below 240000000) Note: Individual light bulbs can be tested by removing Battery Light them from the lighting cluster and applying 12 VDC to The battery light should come on when the ignition their wiring terminals. switch is in ON with the engine not running, or with an Oil Pressure Light improperly operating charging circuit while the engine is...

  • Page 214: Indicator Lights (Serial Numbers Above 240000000)

    Indicator Lights (Serial Numbers Above 240000000) Charge Indicator Light The charge indicator light should come on when the igni- tion switch is in the ON position with the engine not run- ning. Also, it should illuminate with an improperly operating charging circuit while the engine is running. Engine Oil Pressure Light The engine oil pressure light should come on when the ignition switch is in the ON position with the engine not...

  • Page 215: Fuel Pump

    Fuel Pump The fuel pump is attached to the frame just outboard of the fuel injection pump. Operational Test 1. Park machine on a level surface, lower cutting units, stop engine, and engage parking brake. 2. Disconnect electrical connector from the fuel stop solenoid to prevent the engine from firing.

  • Page 216: Fuel Stop Solenoid (Solenoid With 3 Wire Connector)

    Fuel Stop Solenoid (Solenoid With 3 Wire Connector) The fuel stop solenoid must be energized for the engine to run. It is mounted on the engine block near the injec- tion pump (Fig. 20). The fuel stop solenoid includes two coils for operation: the pull coil and the hold coil.

  • Page 217: Fuel Stop Solenoid (Solenoid With 2 Wire Connector)

    Fuel Stop Solenoid (Solenoid With 2 Wire Connector) The fuel stop solenoid used on the Reelmaster 3100−D must be energized for the diesel engine to run. The sole- noid is mounted to the injection pump on the engine (Fig. 22). The fuel stop solenoid includes two coils for operation: the pull coil and the hold coil.

  • Page 218: Glow Controller

    Glow Controller The controller is located under the right lower corner of the instrument panel. Note: Refer to Electrical Schematics and Diagrams at the beginning of the chapter when troubleshooting the controller. Controller Operation 1. When the ignition switch is placed in the RUN posi- tion, the controller energizes the glow plugs and lights up the glow lamp for 10 seconds.

  • Page 219: Standard Control Module

    Standard Control Module Reelmaster 3100−D machines with Serial Numbers above 240000000 are equipped with a Standard Control Module to monitor and control electrical components re- quired for safe operation. This Module is attached to the back of the instrument panel. Inputs from the neutral, parking brake, PTO, start (igni- tion), backlap, and high temperature switches are moni- tored by the Module.

  • Page 220: Service And Repairs

    Service and Repairs NOTE: For more component repair information, see the Kubota Workshop Manual, Diesel Engine, 05 Se- ries. Battery Storage If the machine will be stored for more than 30 days: 4. Store battery in a cool atmosphere to avoid quick de- terioration of the battery charge.

  • Page 221: Battery Service

    Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extend. Additionally, battery and electrical component failure can be prevented. CAUTION When working with batteries, use extreme cau- tion to avoid splashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes.
  • Page 222 2. Conduct a hydrometer test of the battery electrolyte. D. Measure the temperature of the center cell. IMPORTANT: Make sure the area around the cells is E. Connect a battery load tester to the battery termi- clean before opening the battery caps. nals following the manufacturer’s instructions.
  • Page 223 6. Apply a light coat of grease on all battery posts and Battery Battery Charge Level cable connectors to reduce corrosion after connections Reserve (Percent of Fully Charged) are made. Capacity Capacity (Minutes) 7. Connect a digital multimeter (set to amps) between 80 or less 3.8 hrs 7.5 hrs...
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  • Page 225: Specifications

    Chapter 6 Wheels, Brakes, and Miscellaneous Table of Contents SPECIFICATIONS ......Deluxe Seat .

  • Page 226: Specifications

    Specifications Item Description Tire pressure 14 to 18 PSI (0.97 to 1.24 bar) Wheel lug nut torque 45 to 65 ft−lb (61 to 88 N−m) Special Tools Wheel Hub Puller Part Number: TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors.

  • Page 227: Adjustments

    Adjustments Adjust Brake C. If brakes can not be adjusted properly, repair or replace brake components as necessary. CAUTION D. After adjustment is complete, install front wheel assemblies to the machine (see Front Brake and Before and after adjusting the brakes, always Wheel Installation in the Service and Repairs sec- check the brakes in a wide open area that is flat tion).

  • Page 228: Service And Repairs

    Service and Repairs Standard Seat Figure 5 1. Seat (incl. 4 thru 7, 14, &15) 7. Seat shell 13. Seat adjuster 2. Cap screw 8. Seat belt 14. Cap screw 3. Spring lock washer 9. Seat adjuster with latch 15. Seat switch 4.

  • Page 229: Deluxe Seat

    Deluxe Seat 39 40 Figure 6 1. Plate 18. Washer 35. Screw 2. Rivet 19. Nut 36. Cover 3. Screw 20. Swing arm assembly (incl. 28 & 42) 37. Clamp 4. Wear parts kit (incl. 8 thru 11) 21. Adjusting rail (RH) 38.

  • Page 230: Front Wheel And Brake

    Front Wheel and Brake RIGHT FRONT Figure 7 23. Spacer 1. Lug nut 12. Brake lever 2. Drive stud 13. Lock nut 24. Wheel shield 3. Wheel rim 14. Cap screw 25. Cotter pin 4. Tire 15. Brake bracket 26. Clevis pin 5.
  • Page 231 IMPORTANT: Do not hit wheel hub, wheel hub puller E. Position both brake shoes on the backing plate so or wheel motor with a hammer during removal or that the concave heels attach to the anchor pin. installation. Hammering may cause damage to the F.

  • Page 232: Rear Fork And Wheel

    Rear Fork and Wheel Figure 9 14. Drive stud 1. Hydraulic cylinder 27. Hex flange head screw 2. Ball joint 15. Wheel hub 28. Bushing 3. External retaining ring 16. Lock nut 29. Cap screw 4. Grease fitting 17. 45 hydraulic fitting 30.
  • Page 233 Installation WARNING 1. Position rear fork through the frame. 2. Install lock washer, thrust washer, and cap screw to Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 − Safety. the rear fork shaft. Torque cap screw from 60 to 80 ft−lb (81.4 to 108.5 N−m).

  • Page 234: Brake Linkages

    Brake Linkages Figure 10 1. Pop rivet 14. Hex socket flat head screw 26. Brake pivot shaft 2. Control panel cover 15. Parking brake link 27. Clevis pin 16. Clevis pin 28. Flange bushing 3. Cover bracket 4. Flange nut 17.

  • Page 235: Adjustments

    1. Park machine on a level surface, lower cutting units, 3. Remove and replace parts as necessary to repair stop engine, engage parking brake, and remove key brake linkages. from the ignition switch. 4. Install control panel cover to the machine. 2.

  • Page 236: Steering Column

    32. Lock nut 5. Cap screw 19. Hydraulic fitting 33. Flat washer 6. Pivot hub 20. Steering wheel nut 34. Not used 21. Toro decal 35. Not used 7. Steering cover 8. Cap screw 22. Hose assembly 36. O−ring 9. Toro decal 23.
  • Page 237 Disassembly Assembly 1. Park machine on a level surface, lower cutting units, 1. Make sure lever and friction discs are properly as- stop engine, engage parking brake, and remove key sembled to the steering control valve bracket using Fig- from the ignition switch. ure 11 as a guide.
  • Page 238 Wheels, Brakes, and Miscellaneous Page 6 − 14 Reelmaster 3100−D...

  • Page 239: Service And Repairs

    Chapter 7 SPA Cutting Units Table of Contents SPECIFICATIONS ......SERVICE AND REPAIRS .

  • Page 240: Specifications

    Specifications Figure 1 MOUNTING: All cutting units are supported by equal CLIP FREQUENCY: With variable speed set to maxi- length independent lift arms and are interchangeable to mum rpm: all three cutting unit positions. 5 blade at 1040 reel rpm moving at 5 mph (8.1 km/h) CONSTRUCTION: 5 or 8 blades of 7 inches (18 cm) di- 1 inch (25.4 mm) clip.

  • Page 241: Special Tools

    TORO parts. Some tools may also be avail- able from a local supplier. Gauge Bar Assembly Use gauge bar to verify height of cut (Toro Part No. 13−8199). Gauge Bar Figure 2 Handle Assembly −...
  • Page 242 Bedknife Screw Tool − TOR510880 This screwdriver type bit is made to fit Toro bedknife at- taching screws. Use this bit with a torque wrench to se- cure the bedknife to the bedbar. IMPORTANT: Do not use and air or manual impact wrench with this tool.

  • Page 243: Troubleshooting

    It is important to remember that the lower the troubleshooting, see Aftercut Appearance Trouble- height of cut, the more critical these factors are. shooting Aid (Toro part no. 00076SL) Remember that the “effective” or actual height of cut de- pends on cutting unit weight and turf conditions. Effec- tive height of cut will be different than the bench set height of cut.
  • Page 244 Factor Possible Problem/Correction 6. Bedknife to reel adjustment. Check bedknife to reel contact daily. Bedknife must have light contact all across the reel. No contact will cause cutting edges to become dull. Excessive contact accelerates wear; quality of cut may be adversely affected.

  • Page 245: Adjustments

    Adjustments CAUTION Never install or work on the cutting units or lift arms with the engine running. Always stop en- gine and remove key first. Characteristics The single knob (SPA) bedknife−to−reel adjustment If a cutting unit is expected to be out of adjustment, use system incorporated in this cutting unit simplifies the ad- the following procedures in the specified order to adjust justment procedure needed to deliver optimum mowing...

  • Page 246: Adjust Bedknife Parallel To Reel

    Adjust Bedknife Parallel to Reel NOTE: A 3/4−inch (19 mm) wrench will be needed to ro- tate the bedknife adjustment knob (Fig. 7). IMPORTANT: Do not allow cutting unit to rest on the bedknife adjusting screw. The setting of the bed- knife will be changed.

  • Page 247: Set Height−Of−Cut And Level Both Rollers

    Set Height−of−Cut and Level Both Rollers Note: Both floating and fixed cutting units can use this method for making height−of−cut adjustments and lev- 5/8 inch eling both front and back rollers. 1. Position cutting unit on a flat level table or board. 2.

  • Page 248: Verify Height−Of−Cut And Front Roller Level

    Verify Height−of−Cut and Front Roller Level NOTE: Gauge bar (Toro Part No. 13−8199) may be ob- tained from your local Toro Distributor. IMPORTANT: Height−of−cut must be set and both rollers leveled before performing this adjustment (see Set Height−of−Cut and Level Both Rollers).

  • Page 249: Adjust Front Lift Arms

    Adjust Front Lift Arms 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. IMPORTANT: Keep front cutting units on the lift arms when performing this adjustment. 2. Raise front lift arms. Make sure clearance between each lift arm and floor plate bracket is 0.18 to 0.32 inch (4.6 to 8.1 mm) (Fig.

  • Page 250: Adjust Rear Lift Arm

    Adjust Rear Lift Arm 1. Park machine on a level surface and engage parking brake. IMPORTANT: This adjustment must be performed with the rear cutting unit attached to the rear lift arm. 2. Raise lift arms. Make sure clearance between wear strap on the top of the rear cutting unit wear bar and bumper strap is 0.020 to 0.100 inch (0.508 to 2.54 mm) (Fig.

  • Page 251: Service And Repairs

    Service and Repairs Greasing Bearings, Bushings, and Pivot Points Each cutting unit has 9 grease fittings (with an optional front roller installed) that must be lubricated regularly with No. 2 general purpose lithium base grease. Grease Fitting Locations and Quantities Each bedknife adjuster has 1 fitting (Fig.

  • Page 252: Backlapping

    Note: Additional instructions and procedures on 1. Backlap knob 2. Reel speed knob backlapping are available in the Toro General Service Training Book, Reel Mower Basics (part no. 09168SL). 7. To make an adjustment to the cutting units while backlapping, turn off the reels by pushing in the reels 1.

  • Page 253: Cutting Unit Removal And Installation

    Cutting Unit Removal and Installation Removal 1. Position machine on a clean, level surface. Lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. On the front cutting units, detach chain from the cut- ting unit carrier frame by removing the lock nut and cap screw (Fig.

  • Page 254: Reel Motor Removal And Installation

    Reel Motor Removal and Installation RIGHT FRONT Figure 26 1. Reel 15. Side plate (LH) 29. Reel coupler (RH) 2. Cap screw 16. Washer 30. Spider coupler 3. Not used 17. Spacer 31. Not used 4. Cap screw 18. Link 32.

  • Page 255: Reel Removal And Bearing Replacement

    Reel Removal and Bearing Replacement Remove Reel (Fig. 26) 4. Clean inside of the bearing housing before installing. Install bearing into bearing housing as follows: 1. Remove hydraulic motor from the cutting unit (see Hydraulic Motor Removal and Installation). Remove A.

  • Page 256: Bedbar Removal And Installation

    Bedbar Removal and Installation Figure 27 1. Rubber bushing 13. Adjuster spacer 25. Carriage bolt 2. Flanged bushing 14. Not used 26. Not used 3. Jam nut 15. Bedbar pivot 27. Bedbar washer 4. Compression spring 16. Grease fitting 28. Bedbar housing 5.
  • Page 257 Bedbar Installation (Fig. 27) 1. Inspect flanged bushings and bushing for wear; re- place if necessary. 2. Clean and apply anti−seize lubricant to both bedbar pivots. Install bedbar washer on the bedbar. 3. Install bedbar adjusting housing and bedbar housing on the bed bar.

  • Page 258: Bedknife Replacement And Grinding

    Bedknife Replacement and Grinding Bedknife Removal 27” Cutting Unit Shown 1. Remove bedbar from cutting unit (see Bedbar Re- moval in this chapter). NOTE: 27” cutting units use 10 screws to secure bed- knife to bedbar. 32” cutting units use 12 screws to secure bedknife to bedbar.
  • Page 259 Figure 31 Figure 34 Bedknife Lead −in Chamfer 1. Use Toro General Service Training Book, Reel Mow- er Basics (part no. 09168SL) and grinder manufactur- er’s instructions for bedknife grinding information. 2. A lead−in chamfer is ground into all new bedknives (Fig.

  • Page 260: Roller Removal And Installation

    Roller Removal and Installation Note: This section can be used for both the front and rear rollers. Roller Removal 1. Remove both height−of−cut pins and hairpin cotters from each roller bracket. 2. Remove both locknuts from the capscrews securing each angle bracket to the cutting unit. 3.
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  • Page 262: Roller Bearing And Seal Replacement

    Roller Bearing and Seal Replacement Figure 36 1. Full roller 5. Bearing cone (outer) 9. Wiehle roller 2. Roller shaft 6. Outer seal 10. Sectional roller shaft 3. Grease seal 7. Adjustment nut 11. Bearing cone (inner) 4. Bearing cup 8.
  • Page 263 Install New Seals and Bearings on Full or Wiehle Install New Seals and Bearings on Sectional Roller Roller 1. Make sure all parts are clean prior to installing bear- 1. Make sure all parts are clean prior to installing bear- ings and seals.

  • Page 264: Prepare Reel For Grinding

    Land Width Range 0.050 to 0.090 inch (1.3 to 2.3 mm) 3. Refer to Toro General Service Training Book, Reel Maximum Reel Taper 0.060 inch (1.5 mm) Mower Basics (part no. 09168SL) for reel grinding infor- mation.

  • Page 265: Fixed Side Plate Installation

    Fixed Side Plate Installation 1. Remove pop rivets and rear height−of−cut plates from both sides of the cutting unit (Fig. 38). 2. Remove lock nuts, capscrews, washers, and both links from the cutting unit (Fig. 38). 3. Align fixed side plate with holes on the cutting unit (Fig.

  • Page 266: Front Lift Arms

    Front Lift Arms RIGHT FRONT Figure 40 1. 90 hydraulic fitting 15. Lift arm pivot shaft 28. External retaining ring 2. Hydraulic cylinder 16. Roll pin 29. Bulkhead nut 3. Carrier assembly 17. Pivot shaft link 30. Hydraulic tube 4. Flange nut 18.
  • Page 267 Removal 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Remove cutting unit from the pivot shaft of the front lift arm (see Cutting Unit Removal). NOTE: Remove both spacers from the hydraulic cylin- der shaft clevis when removing the right, front lift arm.

  • Page 268: Rear Lift Arm

    Rear Lift Arm 200 to 250 Ft−lb (271 to 339 N−m) Figure 44 1. External retaining ring 9. Jam nut 17. Pin 2. Thrust washer 10. Washer 18. Carrier assembly 3. Rear lift arm 11. Lynch pin 19. Hex nut 4.
  • Page 269 3. Secure hydraulic cylinder clevis to the lift cylinder 5. Adjust lift arms to proper clearance (see Adjust Rear shaft of the rear lift arm with the thrust washer and exter- Lift Arm). nal retaining ring. 6. Grease front lift arm. 4.

  • Page 270: Skid Kit Installation

    Skid Kit Installation 1. Remove front roller from the cutting unit (see Roller Removal and Installation). 2. Align skid slots with the angle bracket holes on the cutting unit. 3. Secure skid to the cutting unit with both flange head screws, flat washers, and lock nuts.

  • Page 271: General Information

    Chapter 8 DPA Cutting Units Table of Contents SPECIFICATIONS ......Reel Assembly GENERAL INFORMATION .

  • Page 272: Specifications

    Specifications Figure 1 Frame Construction: Precision machined die cast alu- Bedknife: Replaceable, single edged, high carbon minum cross member with bolt−on cast ductile iron or steel bedknife is fastened to a machined cast iron bed- aluminum side plates. bar with screws. Optional bedknives are available. Reel Construction: Reels are 27 inches (69 cm) or 32 Bedknife Adjustment: Dual screw adjustment to the inches (81 cm) in length and 7 inch (18 cm) in diameter.

  • Page 273: General Information

    General Information Cutting Unit Operator’s Manual The Cutting Unit Operator’s Manual provides informa- tion regarding the operation, general maintenance and maintenance intervals for the DPA cutting units on your Reelmaster machine. Additionally, if optional kits have been installed on the cutting units (e.g. rear roller brush), the installation instructions for the kit includes set−up and operation information.

  • Page 274: Special Tools

    Figure 2 Bedknife Screw Tool Toro Part Number: TOR510880 This screwdriver−type bit is made to fit Toro bedknife at- taching screws. Use this bit with a torque wrench to se- cure the bedknife to the bedbar. IMPORTANT: To prevent damage to the bedbar, DO NOT use an air or manual impact wrench with this tool.
  • Page 275 Figure 6 Spline Insert Tool Toro Part Number: TOR4074 (9 tooth) Use the spline insert tool for rotating the cutting reel when hydraulic motor is removed. Also, use this tool for installation of threaded inserts into the cutting reel shaft.
  • Page 276 This tool should be used with the Toro Guide to Evaluation Reel Mower Performance and Using the TurfEvaluator (Toro part no. 97931SL).
  • Page 277 Reel Bearing Installation Tool (cutting units with painted side plates) Toro Part Number: 117−0975 Use the reel bearing installation tool to keep the reel bearing aligned as the cutting unit side plate is installed on the bearing. Figure 11 Cutting Reel Shim Toro Part Number: 125−5611...
  • Page 278 Because the top grind angle on bedknives is critical for edge retention, and therefore after− cut appearance, Toro has developed these service tools for accurately measuring the top grind angle on all bedknives. Since there can be variations in the mounting surface of the bedbar, it is necessary to grind the bedknife after installing it to the bedbar.

  • Page 279: Factors That Can Affect Cutting Performance

    Note: For additional information regarding cutting unit cutting unit. It is important to remember that the lower troubleshooting, see Aftercut Appearance Trouble- the height−of−cut, the more critical these factors are. shooting Aid (Toro part no. 00076SL). Factor Possible Problem/Correction Tire pressure Check tire pressure of all traction unit tires.
  • Page 280 Factor Possible Problem/Correction Reel and bedknife sharpness A reel and/or bedknife that has rounded cutting edges or “rifling” (grooved or wavy appearance) cannot be NOTE: After grinding the reel and/or bedknife, check corrected by tightening the bedknife to reel contact. the reel to bedknife contact again after cutting two (2) Grind cutting reel to remove taper and/or rifling.
  • Page 281 Factor Possible Problem/Correction Roller condition and roller type Make sure rollers rotate freely. Repair roller bearings as necessary. See Roller Service in the Service and Repairs section of this chapter. Refer to Cutting Unit Operator’s Manual for roller options. Cutting unit accessories A variety of cutting unit accessories are available that can be used to enhance aftercut appearance.

  • Page 282: Adjustments

    Adjustments Characteristics If a cutting unit is determined to be out of adjustment, CAUTION complete the following procedures in the specified order to adjust the cutting unit properly. 1. Adjust the bedknife parallel to the reel. Never install or work on the cutting units or lift arms with the engine running.

  • Page 283: Reel Bearing Adjustment (Cutting Units With Painted Side Plates)

    Reel Bearing Adjustment (cutting units with painted side plates) NOTE: Cutting units that have aluminum side plates do not require reel bearing adjustment. 12 to 15 in−lb (1.4 to 1.7 N−m) To insure cut quality and long life of the cutting reel bear- ings, periodically check reel bearing adjustment.

  • Page 284: Leveling Rear Roller

    Leveling Rear Roller The precision machined components of the cutting unit frame keep the rear roller and cutting reel in alignment (parallel). If the side plates are disassembled or as the cutting reel wears, a limited amount of side plate adjust- ment is possible to make sure that the cutting unit is properly aligned.
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  • Page 286: Service And Repairs

    Service and Repairs Hydraulic Reel Motor IMPORTANT: When performing maintenance pro- cedures on the cutting units, carefully position the cutting unit reel motors to prevent damage to the motors or hydraulic hoses. Removal 1. Park machine on a clean and level surface, lower cutting units completely to the ground, stop engine, en- FRONT gage parking brake and remove key from the ignition...

  • Page 287: Backlapping

    (see Special Tools). Never use a short edges that may have built up on the cutting edge. handled brush to apply lapping compound. NOTE: Additional instructions and procedures on backlapping are available in the Toro General Service CAUTION Training Book, Reel Mower Basics (part no. 09168SL).

  • Page 288: Bedbar Assembly

    Bedbar Assembly 27 to 33 ft−lb (37 to 44 N−m) RIGHT FRONT Antiseize Lubricant Figure 24 1. Bedbar assembly 5. Plastic washer (4 used) 8. Metal washer (2 used) 2. Lock nut (2 used) 6. Rubber bushing (2 used) 9. Bedbar pivot bolt (2 used) 3.
  • Page 289 Bedbar Installation (Fig. 24) 9. Tighten the lock nut (item 2) on each bedbar adjuster assembly until the adjuster spring is fully compressed, 1. If rubber bushing was removed from either cutting then loosen lock nut 1/2 turn. unit side plate, install a new bushing. The bushing should be installed flush with the inside of the side plate 10.Adjust cutting unit (see Cutting Unit Operator’s (Fig.

  • Page 290: Bedknife Replacement And Grinding

    Bedknife Replacement and Grinding Bedknife Removal 27” Cutting Unit Shown 1. Remove bedbar from cutting unit (see Bedbar Re- moval in this chapter). NOTE: 18” cutting units use 6 screws to secure bed- knife to bedbar. 22” cutting units use 8 screws to secure bedknife to bedbar.
  • Page 291 Low HOC Figure 31 Standard Bedknife Lead −in Chamfer Low HOC 1. Use Toro General Service Training Book, Reel Mow- Extended EdgeMax er Basics (part no. 09168SL) and grinder manufactur- Low HOC 0.19” er’s instructions for bedknife grinding information. (4.8 mm)

  • Page 292: Bedbar Adjuster Service

    Bedbar Adjuster Service Left Hand Threads Antiseize Lubricant Loctite #243 14 to 16 ft−lb (19 to 21 N−m) Antiseize Lubricant Left Hand Threads Antiseize Lubricant Loctite #243 14 to 16 ft−lb (19 to 21 N−m) Antiseize Lubricant RIGHT FRONT 15 to 20 ft−lb (21 to 27 N−m) Figure 32 1.
  • Page 293 Removal (Fig. 32) 2. If flange bushings (item 5) were removed, apply anti- seize lubricant to bore of cutting unit frame. Align key on 1. Remove lock nut (item 3), compression spring and bushing to slot in frame and install bushings into frame. washer from bedbar adjuster screw (item 4).
  • Page 294 Reel Assembly (cutting units with painted side plates) Grease OD surface 27 to 33 ft−lb (37 to 44 N−m) RIGHT See text for tightening procedure Grease bore FRONT and threads Antiseize Lubricant 27 to 33 ft−lb (37 to 44 N−m) Figure 33 1.
  • Page 295 Reel Assembly Removal (Fig. 33) 15 to 19 ft−lb 1. Position machine on a clean and level surface, lower (20 to 25 N−m) cutting units, stop engine, engage parking brake and re- move key from the ignition switch. 2. Remove the cutting unit from the machine and place on a flat work area.
  • Page 296 IMPORTANT: During cutting reel installation, keep IMPORTANT: Over tightening reel bearing adjuster inner and outer bearing races aligned. If bearing nut may damage reel bearings. races are not aligned, binding will occur and reel 11. Make sure that set screw (item 21) is loose in LH side installation may cause bearing damage.
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  • Page 298: Reel Assembly Service (Cutting Units With Painted Side Plates)

    Reel Assembly Service (cutting units with painted side plates) Loctite #243 Clean Threads 85 to 95 ft−lb (115 to 128 N−m) (Right Hand Threads) RIGHT Left Hand Threads FRONT Loctite #243 85 to 95 ft−lb (115 to 128 N−m) Figure 35 1.
  • Page 299 C. To install spline insert into cutting reel, clean B. Press grease seals onto reel shaft with metal side threads of insert and cutting reel shaft. Apply Loctite orientated toward bearing location. Final position of #243 (or equivalent) to threads of insert, thread in- seal should be flush to 0.060”...
  • Page 300 Reel Assembly (cutting units with aluminum side plates) 27 to 33 ft−lb (37 to 44 N−m) Antiseize Lubricant (Bearing OD) Pack with Grease (both ends) RIGHT FRONT Antiseize Lubricant Antiseize (Bearing OD) Lubricant Figure 36 1. Bedbar assembly 7. Lock nut (2 used) 13.
  • Page 301 27 to 33 ft−lb 15 to 19 ft−lb (37 to 44 N−m) (20 to 25 N−m) 27 to 33 ft−lb (37 to 44 N−m) 27 to 33 ft−lb (37 to 44 N−m) 15 to 19 ft−lb (20 to 25 N−m) 27 to 33 ft−lb (37 to 44 N−m) Figure 37...
  • Page 302 7. Remove flange head screw and flange nut that se- cures frame spacer and carrier frame to LH side plate. NOTE: The reel bearings and grease seals are press fit on the cutting reel shaft and should remain on the reel when removing the LH side plate.
  • Page 303 15.If counterweight was removed from cutting unit, install new O−ring on counter weight. Secure counter weight to cutting unit side plate with two (2) flange nuts. Torque screws from 27 to 33 ft-lbs (37 to 44 N−m). 16.Install cutting unit to the machine. Reelmaster 3100−D Page 8 −...

  • Page 304: Reel Assembly Service (Cutting Units With Aluminum Side Plates)

    Reel Assembly Service (cutting units with aluminum side plates) Loctite #243 85 to 95 ft−lb (115 to 128 N−m) (Right Hand Threads) Loctite #243 RIGHT FRONT 85 to 95 ft−lb (115 to 128 N−m) (Left Hand Threads − Groove in Face) Figure 39 1.
  • Page 305 Reel Assembly 1. If removed, install new reel shaft plugs into cutting reel shaft. For cutting unit serial no. prior to 315000001, make sure plastic plug is pressed flush into end of threaded insert. For cutting unit serial no. 315000001 & Up, make sure plastic plug is pressed unto reel shaft 1.63 to 1.37 in.

  • Page 306: Preparing Reel For Grinding

    Specifications chart below). Additional reel grinding in- formation can be found in your Cutting Unit Operator’s Manual. An additional resource is the Toro Basics Se- ries Training Book, Reel Mower Basics (part no. 09168SL) found on the Service Reference Set available from your Authorized Toro Distributor.

  • Page 307: Front Roller

    Front Roller Removal (Fig. 43) Loctite #242 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and re- Antiseize move key from the ignition switch. Lubricant 2. Remove the cutting unit from the machine and place on a level working surface.

  • Page 308: Rear Roller

    Rear Roller Removal (Fig. 44) 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and re- move key from the ignition switch. 2. Remove the cutting unit from the machine and place on a level working surface.

  • Page 309: Roller Service

    Roller Service Disassembly (Fig. 45) 50 to 60 ft−lb 1. Remove bearing lock nut from each end of roller (68 to 81 N−m) shaft. 2. Loosely secure roller assembly in bench vise and lightly tap one end of roller shaft until outer seals and bearing are removed from opposite end of roller tube.
  • Page 310 3. From the roller tube end with only the inner seal NOTE: After roller is installed to cutting unit, lubricate installed, carefully install the roller shaft into the roller roller grease fittings, rotate roller to properly distribute tube. Make sure that seals are not damaged as shaft is grease in bearings and clean excess grease from roller installed.
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  • Page 312: Rear Roller Brush − Optional

    Rear Roller Brush − Optional (cutting units with painted side plates) Antiseize Lubricant 27 to 33 ft−lb (37 to 44 N−m) 15 to 19 ft−lb (20 to 25 N−m) Loctite #243 15 to 19 ft−lb (20 to 25 N−m) Grease Grommet ID Loctite #243 RIGHT...
  • Page 313 Disassembly (Fig. 51) 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and re- move key from the ignition switch. 2. To remove roller brush from brush shaft: A. Remove the non−driven brush bearing assembly 20 to 25 in−lb (item 30) from cutting unit.
  • Page 314 3. If drive bearing housing was disassembled, install CAUTION new components noting proper orientation as shown in Figures 54 and 55. A. Install bearing on shaft by pressing equally on the Contact with the reel or other cutting unit parts inner and outer bearing races.
  • Page 315 5. Check alignment of pulleys with a straight edge CHECK placed along the outer face of the driven pulley (Fig. 57). ALIGNMENT The outer faces of the driven and drive pulleys (not the idler pulley) should be in line within 0.030” (0.76 mm). If necessary to align pulleys, remove driven pulley from brush shaft and add or remove hardened washer(s) (item 9) until drive and driven pulleys are aligned within...

  • Page 316: Rear Roller Brush − Optional

    Rear Roller Brush − Optional (cutting units with aluminum side plates) Grease Seal Lip 20 to 25 in−lb (2.3 to 2.8 N−m) Antiseize Lubricant Grease Seal Lip Grease RIGHT Seal Lip FRONT 27 to 33 ft−lb (37 to 44 N−m) Figure 59 1.
  • Page 317 Rear Roller Brush Assembly (Fig. 51) 6. Once all rear roller brush service is completed, plug the 48 VDC battery disconnect back in before operating 1. If seals or bearings were removed from brush bear- the machine. ing housings, install new components noting proper ori- entation as shown in Figure 53.
  • Page 318 Drive System Disassembly (Fig. 63) Loctite #243 15 to 19 ft−lb (20 to 25 N−m) 10 to 15 ft−lb (14 to 20 N−m) Grease Grommet ID Loctite #243 15 to 19 ft−lb (20 to 25 N−m) RIGHT Loctite #243 FRONT 35 to 40 ft−lb (48 to 54 N−m) Figure 63...
  • Page 319 Drive System Assembly (Fig. 63) 85 to 95 ft−lb 1. Install drive shaft if it was removed: (115 to 128 N−m) IMPORTANT: If rear roller brush drive is on left side of cutting unit, drive shaft has left hand threads and can be identified by a groove on the flange.
  • Page 320 3. After assembly (including drive belt installation), check alignment of pulleys with a straight edge placed 27 to 33 ft−lb along the outer face of the drive pulley (Fig. 57). (37 to 44 N−m) A. The outer faces of the drive and driven pulleys (not the idler pulley) should be in−line within 0.030”...
  • Page 321 Chapter 9 Universal Groomer − DPA Cutting Units (Optional) Table of Contents GROOMING PERFORMANCE ....TROUBLESHOOTING ......Groomer Reel Mechanical Problems .

  • Page 322: Grooming Performance

    Grooming Performance There are a number of factors that can affect the per- formance of grooming. These factors vary for different golf courses and from fairway to fairway. It is important to inspect the turf frequently and vary the grooming practice with turf needs.

  • Page 323: Troubleshooting

    Troubleshooting Groomer Reel Mechanical Problems Problem Possible Causes Correction No rotation of the groomer reel. The groomer drive is in Neutral. Engage groomer drive to Forward or Reverse. Damaged or seized groomer drive Repair groomer drive. gears. The turf is damaged or has uneven The groomer reel blades are bent, Repair or replace blades if neces- grooming.

  • Page 324: Service And Repairs

    Service and Repairs RIGHT FRONT Figure 1 1. Gear box assembly 4. Height adjuster assembly (2) 6. Weights 2. Idler assembly 5. Plate 7. Button head screw (2) 3. Groomer reel NOTE: The Groomer Operator’s Manual provides in- formation regarding the installation, set−up, operation CAUTION and maintenance of the universal groomer on your Reelmaster machine.
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  • Page 326: Gear Box Assembly

    Gear Box Assembly RIGHT FRONT 90 to 100 ft−lb (122 to 135 N m) Figure 2 1. Gear box assembly 3. Cotter pin 5. Input shaft 2. Rear roller brush drive shield 4. Clevis pin NOTE: The groomer gear box assembly is located on NOTE: If cutting unit is equipped with an optional pow- the opposite side of the cutting unit from the cutting unit ered rear roller brush, remove the rear roller brush cov-...
  • Page 327 4. If installed, remove the rear roller brush drive shield 5. To detach the gear box from the cutting unit: from the gear box. A. Turn the input shaft in the correct direction to IMPORTANT: Groomer gear boxes installed on the loosen it from the reel.
  • Page 328 Disassembly (Fig. 3) 115 to 125 ft−lb (156 to 169 N−m) 85 to 95 in−lb (9 to 11 N−m) 32 to 42 in−lb Tighten to Specified Torque (see text) (4 to 5 N−m) Figure 3 1. Threaded adapter 17. Bushing (2) 32.
  • Page 329 CAUTION Use the 1−3/8” flats on the input shaft to prevent the input shaft from rotating during adapter re- moval. DO NOT use the 1/2” hex on the input shaft to secure the shaft during adapter removal or input shaft damage may occur. 1.
  • Page 330 NOTE: If cutting unit is equipped with an optional pow- ered rear roller brush, install the rear roller brush drive CAUTION housing assembly, drive belt and cover (see Roller Brush (Optional) in Chapter 8 − Cutting Units in this manual for additional information). Use the 1−3/8”...
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  • Page 332: Idler Assembly

    Idler Assembly Loctite #242 85 to 95 ft−lb (115 to 129 N−m) Antiseize Lubricant 27 to 33 ft−lb (37 to 45 N−m) 24 to 30 ft−lb (33 to 41 N−m) Figure 5 1. Socket head screw (2) 6. Cotter pin 10.
  • Page 333 Installation (Fig. 5) 1. If shields, bearing or bushing was removed from idler arm, install new components. A. Press bushing into groomer plate until the bush- ing is centered in the idler arm bore. B. Press bearing into idler arm so that bearing con- tact shoulder in idler arm bore and install bearing re- taining ring.

  • Page 334: Groomer Reel

    Groomer Reel 45 to 60 in−lb (5 to 7 N−m) 45 to 60 in−lb (5 to 7 N−m) Figure 7 1. Groomer reel 3. Cap screw (4) 4. Jam nut (4) 2. Shaft clamp (4) Remove the groomer reel to replace individual groomer 3.

  • Page 335: Groomer Reel Service

    Groomer Reel Service Inspect groomer reel blades frequently for damage and wear. Straighten bent blades. Either replace worn MIDPOINT blades or reverse the individual blades to put the sharpest blade edge forward (Fig. 8). Blades that are rounded to the midpoint of the blade tip must be re- versed or replaced for best groomer performance.
  • Page 336 5. If groomer reel is equipped with broomer kit: A. Loosen the groomer blade retaining nuts on each end of the groomer shaft. 31 to 35 ft−lb (42 to 48 N−m) B. Slide a brush into each groove around the full length of the groomer reel (Fig.
  • Page 337 Grooming Brush (Optional) Service The optional grooming brush is removed and installed from the groomer in the same manner as the groomer reel (see Groomer Reel in this chapter). The grooming brush element or shaft can be serviced separately (Fig. 13). Figure 13 1.

  • Page 338: Height Adjuster Assembly

    Height Adjuster Assembly Antiseize Lubricant Antiseize Lubricant Figure 14 1. Height of cut bracket 8. Clevis pin 14. Pinch bolt (front roller) 2. Height adjustment bolt 9. Button head screw 15. Lock nut 3. Washer (2) 10. Detent spring 16. Washer (2) 4.
  • Page 339 Assembly (Fig. 14) 1. Apply antiseize lubricant to upper threads of adjust- ment rod and lower threads of height adjusters. Assem- ble height adjuster assembly as shown. 2. If both height adjusters were removed, fit one height adjuster assembly to the cutting unit side plate and se- cure with carriage bolt and flange nut.
  • Page 340 This page is intentionally left blank. Universal Groomer (Optional) Page 9 − 20 Reelmaster 3100−D...
  • Page 342 Commercial Products E The Toro Company − 1999...

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