Service Manual

ManualsBrandsToro ManualsRiding ProductsReelmaster 6500-D 2 Wheel Drive

PART NO. 95871SL Rev. D

Service Manual

Reelmaster

6500–D/6700–D

Preface

The purpose of this publication is to provide the service

technician with information for troubleshooting, testing,

and repair of major systems and components on the

Reelmaster 6500–D and 6700–D.

REFER TO THE TRACTION UNIT AND CUTTING

UNIT OPERATOR’S MANUALS FOR OPERATING,

MAINTENANCE AND ADJUSTMENT INSTRUC-

TIONS. Space is provided in Chapter 2 of this book to

insert the Operator’s Manuals and Parts Catalogs for

your machine. Replacement Operator’s Manuals are

available by sending complete Model and Serial Num-

ber to:

The Toro Company

8111 Lyndale Avenue South

Minneapolis, MN 55420

The Toro Company reserves the right to change product

specifications or this publication without notice.

This safety symbol means DANGER, WARN-

ING, or CAUTION, PERSONAL SAFETY

INSTRUCTION. When you see this symbol,

carefully read the instructions that follow.

Failure to obey the instructions may result in

personal injury.

NOTE: A NOTE will give general information about the

correct operation, maintenance, service, testing or re-

pair of the machine.

IMPORTANT: The IMPORTANT notice will give im-

portant instructions which must be followed to pre-

vent damage to systems or components on the

machine.

E The Toro Company – 1996, 1998, 1999, 2002

(With Peugeot Engine)

Summary of content (366 pages)

PAGE 1
PART NO. 95871SL Rev. D Service Manual ReelmasterR 6500–D/6700–D (With Peugeot Engine) Preface The purpose of this publication is to provide the service technician with information for troubleshooting, testing, and repair of major systems and components on the Reelmaster 6500–D and 6700–D. REFER TO THE TRACTION UNIT AND CUTTING UNIT OPERATOR’S MANUALS FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS.
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Reelmaster 6500–D/6700–D
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Chapter 1 – Safety Chapter 6 – Axles, Planetaries and Brakes Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 1 Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 – 4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Reelmaster 6500–D/6700–D
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Chapter 1 Safety Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 1 Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Maintenance and Service . . . . . . . . . . . . . . . . . . . . . 3 SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 4 Safety Instructions The REELMASTER 6500-D and 6700–D was tested and certified by TORO for compliance with the B71.
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7. Remove all debris or other objects that might be picked up and thrown by the reels or fast moving components from other attached implements. Keep all bystanders away from operating area. B. Do not remove fuel tank cap while engine is hot or running. 8. Since diesel fuel is highly flammable, handle it carefully: D. Fill fuel tank outdoors and only to within an inch of the top of the tank, not the filler neck. Do not overfill. C. Do not smoke while handling fuel. E. Wipe up any spilled fuel. A.
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22. Before servicing or making adjustments, stop engine and remove key from the switch. 28. If major repairs are ever needed or assistance is desired, contact an Authorized Toro Distributor. 23. When changing attachments, tires or performing other service, use the correct blocks, hoists and jacks. Always chock or block the wheels and use jack stands or solid wood blocks to support the raised machine.
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Safety and Instruction Decals The following safety and instruction decals are affixed to the traction unit. If any decal becomes illegible or damaged, install a new decal. Part numbers are listed below and in your Parts Catalog. UNDER FLOOR PLATE (Part No. 93–6693) WARNING: Moving Parts under floor plate IN TOOL BOX (Part No. 93–3728) Quick Reference Aid ON LEFT FENDER (Part No. 93–6680) Diesel Fuel Only INSIDE CONTROL BOX (Part No. 93–1268) Operating Instructions H.O.C.
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Safety ON TOOL BOX (Part No. 93–1262) WARNING: Read Operating & Safety Instructions ON BACKLAP BRACKET (Part No. 93–1264) WARNING: Read Backlap, Operating & Safety Instructions ON LIFT ARMS (Part No. 93–6687) Do Not Step ON TOWER (Part No. 93–6699) Mowing Speed Control ON ROLL BAR ROOF (Part No. 93–8050) (Model 03804 only) WARNING: Fasten Seat Belt ON CONSOLES (Part No. 93–6689) WARNING: No Riders ON FRAME UNDER MUFFLER (Part No.
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Safety Page 1 – 6 Reelmaster 6500–D/6700–D
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Chapter 2 Product Records and Manuals 1 2 2 2 3 3 4 Capscrew Markings and Torque Values – Metric . 5 Other Torque Specifications . . . . . . . . . . . . . . . . . . . 6 Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . . 6 QUICK REFERENCE MAINTENANCE AID . . . . . . . 7 Bearing and Bushing Lubrication . . . . . . . . . . . . . . 8 OPERATION AND SERVICE HISTORY REPORT . 11 Record information about your machine on the OPERATION AND SERVICE HISTORY REPORT form.
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Equivalents and Conversions Product Records and Manuals Page 2 – 2 Reelmaster 6500–D/6700–D
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Torque Specifications These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Service Manual.
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Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, 5, & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs, & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in–lb in–lb N–cm 10 + 2 13 + 2 147 + 23 # 6 – 32 UNC # 6 – 40 UNF # 8 – 32 UNC 13 + 2 25 + 5 # 10 – 24 UNC 30 + 5 SAE Grade 8 Bolts, Screws, Studs, & Sems with Regular Height Nuts (SAE J995 Grade 5 or Stronger Nuts) in–lb N–cm in–lb N–cm 15 + 2 170 + 20 23 + 2 260 +
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Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws, and Studs with Reg lar Height Nuts N ts Regular (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws, and Studs with Reg lar Height Nuts N ts Regular (Class 10 or Stronger Nuts) M5 X 0.8 57 + 5 in–lb 640 + 60 N–cm 78 + 7 in–lb 885 + 80 N–cm M6 X 1.0 96 + 9 in–lb 1018 + 100 N–cm 133 + 13 in–lb 1500 + 150 N–cm M8 X 1.25 19 + 2 ft–lb 26 + 3 N–m 27 + 2 ft–lb 36 + 3 N–m M10 X 1.
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Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Square Head Hex Socket 1/4 – 20 UNC 140 + 20 in–lb 73 + 12 in–lb 5/16 – 18 UNC 215 + 35 in–lb 145 + 20 in–lb 3/8 – 16 UNC 35 + 10 ft–lb 18 + 3 ft–lb 1/2 – 13 UNC 75 + 15 ft–lb 50 + 10 ft–lb 7/16 – 20 UNF Grade 5 65 + 10 ft–lb 88 + 14 N–m 1/2 – 20 UNF Grade 5 80 + 10 ft–lb 108 + 14 N–m M12 X 1.25 Class 8.
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Product Records and Manuals Reelmaster 6500–D/6700–D Page 2 – 7 Rev.
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Lubricating Bearings and Bushings CAUTION Before servicing or making adjustments to the machine, stop engine and remove key from the switch. The machine has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. If machine is operated under normal conditions, lubricate all bearings and bushings after every 50 hours of operation or immediately after every washing. Figure 3 1.
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Figure 8 Figure 9 Reelmaster 6500–D/6700–D Page 2 – 9 Rev.
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Product Records and Manuals Page 2 – 10 Rev.
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Product Records and Manuals EQUIPMENT OPERATION AND SERVICE HISTORY REPORT for REELMASTERR 6500–D AND 6700–D TORO Model and Serial Number: ______________–______________ Engine Numbers: _____________________________ Transmission Numbers: _____________________________ Drive Axle(s) Numbers: _____________________________ Date Purchased: _____________________________ Warranty Expires____________ Purchased From: _____________________________ _____________________________ _____________________________
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REELMASTER 6500–D/6700–D Maintenance Schedule Minimum Recommended Maintenance Intervals Maintenance Procedure Maintenance Interval & Service Lubricate All Grease Fittings Inspect Air Filter, Dust Cup, and Baffle Check Battery Level/Cable Connections Every 100hrs Every 50hrs A Level Service } Change Engine Oil and Filter Inspect Cooling System Hoses Every 400hrs Every 200hrs Every 800hrs B Level Service { Check Fan and Alternator Belt Tension C Level Service { Torque Wheel Lug Nuts ~ Service Air
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REELMASTER 6500–D/6700–D Daily Maintenance Check List Daily Maintenance: (duplicate this page for routine use) Check proper section of Operator’s Manual for fluid specifications Daily Maintenance Check For Week Of _________________ Maintenance Check Item b n Safety Interlock Operation n Brake Operation n Engine Oil & Fuel Level n Cooling System Fluid Level TUES WED THURS FRI SAT SUN Product Records and Manuals MON Drain Water/Fuel Separator n Air Filter Restriction Indicator n Radiator &
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Product Records and Manuals Page 2 – 14 Rev.
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Chapter 3 Engine INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 IDENTIFICATION AND SPECIFICATIONS . . . . . . . 3 General Specifications . . . . . . . . . . . . . . . . . . . . 3 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Cylinder Head Gasket . . . . . . . . . . . . . . . . . . . . . 4 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Valve Recess. . . . . . . .
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Introduction The following pages give information about specifications, maintenance, troubleshooting, testing and repair of the diesel engine used in the Reelmaster® 6500-D mower. Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Special Tools section.
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Identification and Specifications General Specifications Item Specification ___________________________________________________________________________________________ Engine Type Peugeot XUD9AI, 4 cycle, water cooled, 4 cylinder, vertical in-line cylinders, single overhead cam, indirect injection, naturally aspirated. ________________________________________________________________________________________________________________________________________________________ Compression ratio 23.
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Cylinder Head Cylinder head height h is measured with the camshaft in place fitted with two bearing caps. h is measured on the oil seal lip contact diameter (the largest diameter). h nominal: 157.40 to 157.75 mm Maximum permissible bow on bottom of cylinder head: 0.07 mm (camshaft must turn freely). Maximum permissible gasket face machining: 0.14 mm in relation to the measured h nominal.
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Camshaft Camshafts with 0.5 mm oversize bearings* are identified by a yellow paint ring (d) between the cams of No. 1 cylinder. * NOTE: These camshafts are installed only on exchange engines, and can be obtained on special order. Figure 4 Valves Intake Min. Length l øa +0 Exhaust 112.2 8.005 7.985 øb ± 0.1 38.5 33 a 90° 90° – 0.015 Engine Units: mm Intake: Faces x and y can machined a maximum of 0.2 mm Exhaust: No machining is permissible.
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Valve Springs Units: mm Spring ød 29 P1: daN e1 18 42.4 Figure 7 Valve Guides Units: mm øf øg h j øk Tolerance 0 – 0.011 + 0.032 0 ± 0.25 ± 0.50 0 + 0.2 Production 14.02 14.13 13.981 14.051 Repair 1 14.29 14.211 52.00 36.50 8.02 Repair 2 14.59 14.
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Valve Seats Units: mm Intake øa øb c d Tolerance 0 – 0.025 ± 0.025 0 – 0.1 ± 0.15 Production 40.161 40.361 40 40.2 6.25 6.45 8.267 8.467 Repair 1 40.461 40.3 6.45 8.467 Repair 2 40.661 40.5 6.45 8.467 Units: mm øa øb c d Tolerance 0 – 0.025 ± 0.025 0 – 0.1 ± 0.15 Production 34.137 34.337 34 34.2 6.05 6.25 8.15 8.35 Repair 1 34.437 34.3 6.25 8.35 Repair 2 34.637 34.5 6.25 8.
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Cylinder / Piston Matching Units: mm Identification (x) CYLINDER øa Tolerance: + 0.018 – 0 PISTON øb Tolerance: ± 0.009 None 83 82.93 A1 83.03 82.96 Repair 1 R1 83.20 83.13 Repair 2 R2 83.50 83.43 Repair 3 R3 83.80 83.73 Production NOTE: The piston øb must be measured at dimension c. C 25.00 NOTE: The repair dimension (x) is stamped on the cylinder block and pistons. Figure 11 Piston Pin Units: mm ø external 24.994 to 25 ø internal 13.8 to 14.
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Crankshaft Units: mm Crank Pins and Journals øa b øc d Tolerance –0 – 0.016 ± 0.003 –0 – 0.019 ± 0.003 Production 50.00 1.827 60.00 1.842 Repair 1 49.70 1.977 59.70 1.992 NOTE: Repair 1 size connecting rod and main bearing shells can be identified by white paint (1) on the edge of the shell. Units: mm End Float Half Shell Thickness e f Tolerance + 0.05 0 ± 0.025 Production 26.60 2.305 Repair 1 26.80 2.405 Repair 2 26.90 2.455 Repair 3 27.00 2.505 Engine No.
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Tightening Torques Part Nm Kgm ft-lb __________________________________________________________________________________________ Connecting rod end caps 50 5 37 ________________________________________________________________________________________________________________________________________________________ Camshaft bearing caps 17.5 1.
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Special Tools NOTE: Order special tools from the TO R O S P E C IA L TO O L S A N D A P P LIC AT IO N S G U ID E (C O M M E R C IA L P R O D U C T S ). Some tools may be listed in the Reelmaster 6500-D Parts Catalog. Some tools may also be available from a local supplier. TOR4033 Overhaul Tool Set This tool kit includes tools required for overhauling the engine. TOR4035 Tune-Up Set will also be required if overhauling the engine. Engine TOR80504A1 Extension (Fig. 24) TOR80110H Indicator Holder (Fig.
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TOR2437T Dial Indicator This dial indicator may be used with TOR80110H, TOR80117AM and TOR80504A2 to accomplish any of the following tasks: for checking the protrusion of the swirl chambers, valve recess and measurement for cylinder head gasket selection, adjusting the timing of the injection pump and for checking the crankshaft and float. Figure 16 TOR4024T Valve Spring Compressor This tool is used to compress valves for removal.
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TOR70153C Rear Main Seal Installer Used with a small hammer to install new rear main oil seal. Figure 20 TOR70153D Front Cover Seal Installer Engine Used with a small hammer to install new front crankshaft seal. Figure 21 TOR70153N Flywheel T.D.C. Locator Pin Used to set injection pump timing. Figure 22 TOR80110DZ 2mm Shim Cut Off Gauge With Cut Off Shim Used to gage and gut off new side seals to 2mm height.
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TOR80110GY Extension Rod and Adapter Used with TOR 80504A1 and TOR80504A2 to check crankshaft end float. Figure 24 TOR80110H Indicator Holder Block used to hold dial indicator to check protrusion of swirl chambers, valve recess and measurement for cylinder head gasket selection. Figure 25 TOR80117AM Timing Tool Kit For Roto Diesel DPC Pump Used with dial indicator to adjust timing of injection pump.
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TOR80149 Injector Socket Used to remove and install fuel injectors. Figure 28 TOR80504A1 Extension Engine Used with TOR 80110GY and TOR 80504A2 to check crankshaft end float. Figure 29 TOR 80504A2 Indicator Holder Used with TOR80110GY and TOR 80504A1 to check crankshaft end float. Figure 30 TOR976697 Camshaft Seal Installer Used to install camshaft seal.
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.0149 - Cylinder Head Separating Levers (Make Locally) Used to remove cylinder head (qty. 2 required). Units: mm Figure 32 TOR70153H Injector Pump Gear Puller Loosen the nut on the injector pump gear, then use this tool to loosen the pulley from the tapered shaft on the injector pump.
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Adjustments Valve Clearance Adjustment (See Valve Clearance Adjustment in the Engine Overhaul Section.) Engine Speed Adjustments Maximum fuel flow and speed adjustments are sealed and should only be unsealed by a CAV Lucas ROTODIESEL service dealer. Throttle Cable Adjustments Engine The throttle control lever at the operator’s station must not touch the end of the slot during full range of motion from idle (SLOW) to full engine RPM (FAST).
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Troubleshooting Alternator Problem Possible Causes Alternator is not charging. Alternator belt loose. Charging circuit defective. Energizing circuit defective. Brushes worn or seized. Rotor winding defective. Stator winding defective. Regulator defective. Output low or irregular. Alternator belt loose. Charging circuit defective. Energizing circuit defective. Brushes worn or seized. Rotor winding defective. Stator winding defective. Regulator defective. Rotor partially short-circuited.
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Fuel Injectors Possible Cause Correction Bad spray pattern Carbon deposit around the orifice Clean Scored nozzle seat Replace injector Needle damaged Replace injector Foreign matter jammed between nozzle seat and needle Clean Nozzle seat out-of-true Replace injector Water in fuel Drain water and flush fuel feed system (1) Copper gasket not replaced Replace gasket at each repair Injector nut too tight on injector body Tighten injector nut (1) Leaking injector Needle seized or showing seiz
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Fuel Injection Pump Problem Possible Cause Correction Engine has no power Defective fuel supply Check filter cartridge and pipes Incorrect pump timing Correct timing Incorrect spray, or injector pressure out of adjustment Check, clean and adjust injectors Air intake restriction Check hoses and air cleaner Insufficient automatic advance Have pump repaired Discharge rates too low Have pump repaired Idling stop out of adjustment Adjust stop and fast idling control Throttle cable out of adjust
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Problem Possible Cause Correction Engine will not start No preheating Check glow plugs and relay No fuel supply Make sure tank is not empty Check filter element and pipes Irregular engine speed Noisy engine Engine stalls at idling Vibrating engine Engine will not stop Reelmaster 6500-D/6700-D Defective solenoid valve Check electric stop solenoid Seized pump plunger Have pump repaired Discharge valve blocked in “stop” position Have pump repaired Seized feed pump Drain water from tank, pi
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Low Power Problem Possible Causes Engine does not give full power Injection pump timing Seized piston rings Defective injector(s) Air intake restricted Valve leaks Clogged fuel filter Injection pipe restriction due to excessive tightening of unions Defective injection pump Irregular idling Defective injection pump Air getting into fuel system Idling stop out of adjustment Leaky injection pipe unions Speed fall-Off Clogged fuel filter Defective injection pump Engine speed rises to maximum Defective
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Noisy Engine Problem Possible Causes Knocking Loose main bearings Broken part Leakage return collector clogged Lifters out of adjustment Foreign matter in a cylinder Seized injector Injection pump timing Engine Sheared glow plug Timing out of adjustment Whistling, blowing Leaking cylinder head gasket Leaky glow plug Valve seats Leaky injector Reelmaster 6500-D/6700-D Page 3 - 23 Engine
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Pre-heating Problem Possible Causes Glow plug does not glow red hot Faulty glow plug Faulty glow plug relay Damaged wiring or connector All four glow plugs burnt out / ends melted – injection pump timing out of adjustment (engine overheating) See Chapter 5 - Electrical System Engine Page 3 - 24 Reelmaster 6500-D/6700-D
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Smoke During Operation Problem Possible Causes Black Defective injector Injection pump out of adjustment Injection pump timing Air intake restricted Inlet chambers clogged Not enough advance Grey Defective injector Engine Injection pump timing Air intake restricted Not enough advance Blue-Grey Defective injector Injection pump timing Too much oil Blue Too much oil Wear White Injection pump timing Cylinder head gasket Cold engine Reelmaster 6500-D/6700-D Page 3 - 25 Engine
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Starting Problems Problem Possible Causes Engine will not start and emits black smoke Air intake obstructed Defective injectors Lack of compression (seized rings, damaged or worn valve seats, or general wear) Injection pump timing Engine will not start and emits white smoke Leaking cylinder head gasket Engine will not start and does not emit any smoke Frozen fuel Injection pump does not work Leaking injection pipe unions Injection valve blocked No preheating Empty fuel tank Feed pipe obstructed Air g
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Testing and Inspection Injection Pump Timing (See Timing of Injection Pump in the Engine Overhaul section.) Glow Plug Test CAUTION Engine Be careful while handling or testing glow plugs. Glow plugs become extremely hot. Accidental contact with the heated plug tip could cause personal injury. 1. Disconnect the wire lead(s) to the glow plug. 2. Remove the glow plug. 3. Inspect the glow plug for signs of a burnt glow plug end tube.
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Compression Test Minimum cylinder compression is 20 bar (290 psi) at 200 rpm (normal cranking speed). The engine should be warm - coolant temperature of 50o C (120o F). IMPORTANT: DO NOT put oil into the combustion chamber before performing a compression test. Damage may result because of “hydraulic” forces acting upon the piston and connecting rod. 1. Remove the glow plug lead wires and glow plugs from all four cylinders. 2. Insert a compression gauge adapter into the glow plug hole. 3.
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Injector Tests There are several tests to examine the condition of the injection nozzles. These tests require the use of a nozzle tester and nozzle tester adapter. sion stroke. The point at which this fuel injection occurs is determined by the injection timing. If the nozzle is defective, damaged or adjusted incorrectly, starting failures, low power output, or engine knocking can occur. 1. Securely fasten the nozzle to the adapter. CAUTION 2.
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Nozzle Leakage Test A nozzle that leaks fuel from the nozzle orifice must be replaced. 1. Securely fasten the nozzle to the adapter. 2. Wipe all fuel from the nozzle. 3. Operate the pump until the pressure is approximately 20 bar or kg/cm2 (280 psi) below opening pressure. Maintain this pressure to the nozzle. Good 4. Watch for leaks where the threaded nozzle body threads into the retaining nut. Leaks in this area would indicate a bad seat between the distance piece and/or the body or nozzle assembly.
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Injection Pump Testing Calibration of fuel delivery volumes, pressure and distribution between pump barrels should be performed by a professional diesel engine service shop. Special test fixtures and equipment are required. D. Put the throttle control in the FAST position. Turn the ignition key to the START position to crank the engine. Observe the nozzle. It is possible to determine if the fuel injection pump requires service through a process of elimination using other fuel system tests.
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Thermostat Test If the engine overheats or runs too cool, and a faulty thermostat is suspected, the thermostat should be tested. 1. Remove the thermostat. 2. Put the thermostat in a container of water with a thermometer and heat the water. Starts to open at: 81o C (178o F) 7 mm (0.28 in.) full open at 88o C (190o F) 3. If the thermostat fails to open, only partially opens, or sticks, it should be replaced.
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Fuel System Service Priming Fuel System 1. Stop the engine. Unlatch and raise the hood 2. Fill the fuel tank. 3. Install a 3/16" hose over bleed screw. Put other end of hose into a container to catch fuel (Fig. 38). 1 2 4. Pump priming plunger until resistance is felt. Try to start engine. If engine does not start, go to step 5. 5.Loosen bleed screw a few turns. Pump priming plunger until a steady stream of fuel comes out of hole in bleed screw.
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Injector Service NOTE: If injectors need to be inspected or repaired it is recommended that it be done by an authorized CAV Lucas ROTO DIESEL service dealer - especially during the warranty period. Repairs by non-authorized dealers WILL void the warranty on the injectors. 1 Removal 8 2 1. Clean top of cylinder head and injection pipes. 2. Remove injection pipes (Fig. 57, Item 12). 3 3. Disconnect injector leakage pipe. 4 4. Remove the injectors (Fig.
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Assembly 1. Check all parts for condition and cleanliness. Oil parts before reassembly. 2. Secure the injector body in a “V” type injector holder. 3. Install the adjusting shims, spring, push rod, spacer and injector (Fig. 40, Items 2, 3, 4, 5, 6). 4. Install the injector holder nut (Fig. 28, Item 7) and tighten by hand. 5. Tighten injector nut to a torque of 10 Nm. Tighten the nut an additional 22° of rotation.
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Timing Belt Replacement Timing Belt Removal IMPORTANT: Never install a used belt. When the timing belt is removed a NEW timing belt must be installed. SPECIAL TOOLS REQUIRED: Tune-Up Tool Set TOR 4035 1 ea. M8 x 125 x 40 Metric Bolt 2 ea. M8 x 125 x 35 Metric Bolt TOR 70153N 1. Slowly turn the crankshaft in the operating direction (clockwise as viewed from the timing belt end) until the TDC Lock Pin tool (TOR 70153N) goes into the hole in the flywheel (Fig. 42). Figure 42 2.
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7. Loosen the nut (Fig. 45, Item 8) and the bolt (Item 9), securing the roller tensioner bracket (Item 10). 8. Rotate the roller tensioner bracket square (Item A) to compress the spring (Item 11). A 9. Re-tighten the bolt (Item 9). Engine 10. Remove the timing belt.
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Timing Belt Installation IMPORTANT: Never install a used belt. When the timing belt is removed a NEW timing belt must be installed. C A 1. Install the new timing belt, with the runs taut, in the following order (Fig. 46): Crankshaft gear (Item 13) Fixed roller (Item 11) Injection pump gear (Item B) Camshaft gear (Item C) Tensioner roller (Item 17) Coolant pump gear (Item 10). B Figure 46 A 2. Loosen the bolt (Fig. 47, Item 18) and nut (Item 19) to release the tensioner roller.
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4. Remove the three gear locking bolts and TDC Lock Pin tool. A 5. Turn the crankshaft two revolutions (clockwise). 6. Re-install the TDC Lock Pin tool TOR 70153 N and the three gear locking bolts. IMPORTANT: If you can not install any one of the locking devices, repeat the Timing Belt Installation procedures from the beginning. 7. Loosen the bolt (Fig. 48, Item 18) and nut (Item 19) to release the tensioner roller. 8. Re-tighten the bolt (Item 18) then the nut (Item 19) to a torque of 17.5 Nm (13 ft-lb).
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Injection Pump Timing Timing of Injection Pump (Pump Mounted on Engine) b The adjustment position for start of injection varies on each pump (manufacturing tolerances). The adjustment position is given by measurement “X.XX” in one of three places on the pump (Fig. 51): a a. Tag on pump lever. b. Bar code label c. Inspection cap NOTE: “PMH” in French = “TDC” in English. 1. Remove the cover attachment nut, cover clips and timing belt covers. Figure 51 2.
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6. Clean the area around the pump timing plug (Fig. 54, Item d). Remove the pump timing plug. d b a 7. Use Timing Tool Assembly TOR 80117 AM. Lubricate the timing rod (Fig. 55, Item 1) with Diesel fuel, then install the timing rod in the pump timing hole (Item d). Check to see that the rod moves freely in the bore. 8. Install the dial indicator (metric) on the indicator bracket (Item 2). 9. Install the indicator bracket with dial indicator on the plug boss. Set the dial indicator to “0.00 mm”.
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Preparation For Engine Repair 1. Before cleaning and disassembly, carefully check for problems that cannot be found after the engine has been cleaned or disassembled (e.g. oil leaks from cracked components, gaskets or loose fittings, damaged air cleaner or breather hoses that could cause cylinder wear, etc.). Make a note of any problems that you find. 2. Clean or wash the engine exterior thoroughly before disassembly. IMPORTANT: Do not spray water on a hot engine.
PAGE 67
Engine Engine Removal and Installation Figure 57 Removing the Engine 1. Put machine on a level surface and engage parking brake. Turn engine OFF and remove key from ignition switch. Allow engine and radiator to cool. CAUTION 2. Drain oil from engine. DO NOT open radiator cap or drain coolant if engine or radiator is hot. Pressurized, hot coolant can escape and cause burns. 3. Remove the hood. 4. Disconnect positive (+) and negative (–) battery cables from battery. Remove battery. 5.
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perature gauge sender, thermoswitch, fuel stop (ETR) solenoid, glow plugs. 15. Remove fasteners securing engine to engine mounts. 11. Remove fan shroud from radiator. 16. Attach a short section of chain between the two lifting brackets on the engine. Connect hoist, or block and tackle chain at center of the short section of chain. One person should operate hoist or block and tackle and other person should help guide engine out of chassis. Remove engine from chassis.
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Engine Overhaul Disassembly of External Components 1. Remove TDC sensor and clutch housing centering pin. 2. Mount the engine on a stand. 3. Lock the flywheel with TOR FD86 tool. 4. Remove exhaust manifold and inlet manifold. 5. Remove the coolant manifold. 6. Remove the alternator and belt. 7. Remove the oil filter (Fig. 57, Item 10). Engine 8. Remove the injector pipes (Item 12). 9. Remove the glow plug leads. 10. Remove the crankcase breather pipes/oil filter/filter pipe assembly (Item 13). 11.
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12. Remove the thermostat housing cover (Fig. 58, Item 17). TOR 80149 13. Remove the thermostat housing (Item 18). 14. Remove the injectors (Item 19) and retrieve the copper washer (Item 20), and flame trap washer (Item 21). 15. Remove the glow plugs (Item 22). Figure 58 Injection Pump Removal 1. Remove the timing belt. 2. Use injector pump gear puller TOR70153H, to remove injector pump gear (Fig. 58a, Item 5). TOR70153H Figure 58a 3. Remove the injection pump (Fig. 58b, Item 19). 4.
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Cylinder Head Removal 1. Remove the cylinder head cover. 2. Use a Torx head T55 tool to loosen the cylinder head bolts, working in a spiral from the outside. Remove the cylinder head bolts. IMPORTANT: DO NOT pry at gasket surface to loosen cylinder head from block. 3. Use levers (0.0149) to release the cylinder head from the block. 4. Remove the cylinder head and gasket. Figure 59 Engine Oil Pump Removal 1.
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Crankshaft and Piston Removal 1. Remove flywheel locking tool. 2. Remove the connecting rod end caps (Fig. 62, Item 8), marking each cap for re-installation in the same location. NOTE: Connecting rods and end caps are not numbered. Once they are removed there is no way of knowing the correct location for installation unless you mark them for re-installation. 3. Remove the flywheel. 4. Remove the main bearing caps (Item 9) (marks are cast-in). Figure 62 5. Retrieve end float washers with No. 2 cap. 5.
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Cylinder Head Overhaul 1. Progressively slacken the camshaft bearing caps (Fig. 65, Item 1). 2. Remove the bearing caps (Item 1), oil seals (Item 2), camshaft (Item 3), tappets (Item 4) and adjustment shims (Item 5). Mark adjustment shims and tappets so they will be re-installed in the same location – #1 intake, #1 exhaust, #2 intake, #2 exhaust, etc. NOTE: The shims are small and can stick to the tappets. Figure 65 Engine 3. Use a valve compressor to remove the eight valves (Fig. 66). 4.
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8. Check the protrusion of the swirl chambers (Fig. 68, A). Protrusion: 0 to 0.03 mm Achieve this dimension by machining faces (a) and (b). 9. Check the valve recess (B). Exhaust: 0.9 to 1.45 mm Inlet: 0.5 to 1.05 mm Achieve this dimension by machining the valve seats. Figure 68 10. Lap in the valves. 11. Re-install the valves. IMPORTANT: If the cylinder head has been machined, fit compensating washers under the valve springs. (See Identification and Specifications section.) 12.
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Crankshaft Installation 1. Put thread lock Loctite on the oil gallery plugs and install them in the cylinder block. 2. Install the grooved main bearing shells. (See Crankshaft in the Inspection and Specifications section for main bearing shell thickness.) Figure 71 Engine 3. Install the crankshaft. 4. Install the no. 3, 4 and 5 main bearing caps. 5. Install the two end float half-washers (Fig. 72, Item 1), with the anti-friction faces towards the crankshaft. Figure 72 6. Install the no.
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7. Check crankshaft end float (Fig. 74): A . I n s t a l l t he dia l in dica to r, usin g t oo l s TOR 80110G1, TOR 80504 A1 and A2. TOR 80110G1 B. End float must be between 0.07 and 0.32 mm. NOTE: For choice of half-washer thickness see Crankshaft in the Identification and Specifications section. 8. Apply a thin coat of Formetanch or Permatex No. 2 sealant to surface of block where bearing cap will mate (Fig. 73, Item a). TOR 80504 A1-A2 Figure 74 9. Install the two new side seals (Fig.
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13. Tighten the bearing cap bolts to a torque of 70 Nm (52 ft-lb). 14. Using shim TOR 80110DZ, cut off the side seals so that they protrude 2 mm. 15. Check that the crankshaft rotates without tight spots. TOR 80110DZ Figure 76 Pistons and Connecting Rod Assembly Engine 1. Assemble the connecting rods and pistons with the bearing shell tab recess (Fig. 77, Item a) on the same side as the piston crown recess (Item b). 2.
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3. Oil the piston and tighten the piston ring clamp (Fig. 78, Item 4). 4. Remove the connecting rod end caps. 5. Install the pistons in the bores, matching the markings made when removed, and aligning the crown recess (Item a) on the oil filter side of the block. 6. Install the connecting rod end caps. Tighten the nuts to a torque of 50 Nm (37 ft-lb). NOTE: For choice of bearing shell thickness, see Crankcase in Identification and Specifications section. Figure 78 Oil Seal Installation 1.
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3. Install the special shoulder bolt (Fig. 81, Item 1) to center the pump in the proper location. 4. Install the other bolts and tighten the bolts (Item 1, 2, 3) to a torque of 20 Nm (15 ft-lb). 5. Install the seal carrier plate and a new gasket (Item 4) and tighten the bolts to a torque of 15 Nm (11 ft-lb). 6. Put a new oil seal on tool TOR 70153 D. 7. Install the seal by tapping it fully home with a mallet. TOR 70153D 8. Apply Formetanch or Permatex No. 2 sealant as shown (Item a). 9.
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Cylinder Head Gasket Selection 1. Install the dial indicator on support TOR 80110 H and zero it on a surface plate. 2. Turn the crankshaft and measure the protrusion of each piston at TDC. 3. Note the maximum protrusion (Fig. 82, Item d). 4. Select a cylinder head gasket of suitable thickness. TOR 80110H Units: mm Piston protrusion (d) Thickness identification 0.56 to 0.71 2 notches 0.71 to 0.75 3 notches 0.75 to 0.79 4 notches 0.79 to 0.83 5 notches Figure 82 Cylinder Head Installation 1.
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Cylinder Head Tightening 1. Install new washers on the bolts. 2. Pre-tighten the bolts in the order shown (Fig. 84) to a torque of 30 Nm (22 ft-lb). 3. Tighten the bolts in the order shown to a torque of 70 Nm 52 ft-lb). 4. Tighten each bolt in the order shown an additional 120° ± 2°. NOTE: The special cylinder head bolts (Item B) do not require re-tightening. The bolts can be removed and re-installed 5 times before replacing with new bolts.
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3. Remove the camshaft gear (Fig. 86, Item 1). 4. Remove the camshaft bearing caps (Item 2). 5. Remove the camshaft (Item 3). 6. Remove the tappets (Item 4). 7. Remove the basic shims (Item 5). 8. Determine the shim thickness to be fitted for each valve. Example: Units: mm No. 1 Intake valve Specified clearance 0.15 Clearance measured 0.25 Difference Shim installed Figure 86 + 0.10 2.425 * Shim to be installed 2.50 Clearance obtained 0.175 * Basic shim 9.
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11. Apply a thin coat of Formetanch or Permatex No. 2 sealant to each end of the bearing housing at (Fig. 87, Item a). 12. Apply MOLYKOTE G RAPID to the bearing surfaces on the camshaft. 13. Install the camshaft (Item 3) with the DIST marking at the timing gear end. 14. Install the camshaft bearing caps (Item 2) as shown by cast-in markings. Engine 15. Progressively tighten the bearing caps to 17.5 Nm (13 ft-lb). Figure 87 TOR 976697 16.
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Assembly of External Components 1. Install new fire ring washers (Fig. 89, Item 1), convex surface facing up. 2. Install new copper washers (Item 2). 3. Install the injectors and tighten to a torque of 90 Nm (66 ft-lb). 4. Install the pre-heat plugs (Item 4) and tighten to a torque of 22 Nm (16 ft-lb). 5. Install the thermostat housing (Item 5) and cover (Item 6), fitted with a new thermostat and gasket. 6. Install the cylinder head cover (Item 7), and tighten to a torque of 10 Nm (7 ft-lb). Figure 89 7.
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Break-in Engine After Overhaul Engine After disassembling or overhauling the engine, install the a new oil filter. Replace this filter with a new filter after the first 20 to 50 hours of operation.
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Engine Page 3 - 62 Reelmaster 6500-D/6700-D
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Chapter 4 Hydraulic System SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic Fitting Installation . . . . . . . . . . . . . . . . . . . 3 Pushing or Towing Traction Unit . . . . . . . . . . . . . . . 5 HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . . . 6 Reelmaster 6500–D 2WD . . . . . . . . . . . . . . . . . . . .
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Specifications Item Description Traction Pump Traction Relief Pressure Charge Pressure Servo controlled piston pump 3800 – 4200 PSI 150 – 210 PSI Traction Motor (front & rear w/4WD) Fixed displacement piston motor Steering/Reel Pump Steering Relief Pressure 3-section gear pump 1350 – 1450 PSI Valve Blocks Front & Rear Reel Circuit Relief Pressure Lift Relief Pressure Cartridge logic, elec./hyd.
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General Information Hydraulic Hoses When replacing a hydraulic hose, be sure that the hose is straight (not twisted) before tightening the fittings. This can be done by observing the imprint on the hose. Use two wrenches; one to hold the hose straight and one to tighten the hose swivel nut onto the fitting. WARNING Before disconnecting or performing any work on hydraulic system, all pressure in system must be relieved by stopping the engine and lowering or supporting the box and/or other attachment.
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SAE Straight Thread O–Ring Port – Non–adjustable (Fig. 4) 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 fitting shows signs of leakage. O–Ring 3. Lubricate the O–ring with a light coating of oil. 4. Install the fitting into the port and tighten it down full length until finger tight. Figure 4 5. Tighten the fitting to the correct flats from finger tight (F.F.F.T.). Size 4 (1/4 in.
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Pushing or Towing Traction Unit In an emergency, the Reelmaster 6500–D can be moved by actuating the by–pass valve in the variable displacement hydraulic pump and pushing or towing the machine. IMPORTANT: Do not push or tow the machine faster than 2–3 mph (3–4.8 km/hr) because internal transmission damage may occur. The by–pass valve must be open whenever the machine is pushed or towed. 1. By–pass valve is located on top of variable displacement pump (Fig. 7).
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G1A S2A Hydraulic System P1A S1A M4A R3 R1A R3 Page 4 – 6 Rev. B R R F R2A S5A 12:1 T2A S4A M5A D4 R3 M9 S3A R3 M5 F 12:1 M8 T1A R3 M1 PC1A VS1A R3 M4 C4 R6 C1A .040 S7A S6A C4A .060 R6 C1 C5 P4 R5 C2A P2A C5A P1 G1B P2 P3 S2B M2B P1B LH RH R7 S1B R3 R3 M2 V1 R1B R4 T1B S3B M3B PC1B R3 VS1B R3 M3 OUT IN C3B C3 .
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Reelmaster 6500–D/6700–D Page 4 – 7 Rev. B Hydraulic System G1A S2A P1A S1A M4A R3 14.1:1 12:1 R1A R3 M5A R M10 R R F M9 F S3A R3 R3 M5 M8 F T1A R3 M1 PC1A VS1A R3 M4 12:1 T2A R2A S4A S5A D4 .040 R6 C1A S7A S6A C4 C4A .060 R6 C1 C5 P4 R5 C2A P2A C5A P1 G1B P2 P1B R3 LH RH R7 S1B Hydraulic System P3 S2B M2B R3 M2 V1 R1B R4 T1B S3B M3B PC1B R3 VS1B R3 M3 OUT IN C3B C3 S4B .
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Hydraulic System Page 4 – 8 Reelmaster 6500–D/6700–D Front Valve Block G1A S2A P1A S1A M4A R3 14.1:1 12:1 R1A R3 R R M10 M9 R F R2A S5A 12:1 T2A S4A M5A D4 R3 F S3A R3 M5 M8 F T1A R3 M1 PC1A VS1A R3 M4 S7A S6A C4 R6 C1 Pump Package R6 C1A .040 C4A .060 C5 P4 R5 C2A P2A C5A P1 G1B P2 P3 S2B M2B P1B R3 LH RH R7 S1B R3 M2 V1 R1B R4 PC1B R3 VS1B R3 M3 T1B S3B M3B OUT IN C3B S4B .
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Reelmaster 6500–D/6700–D Page 4 – 9 Hydraulic System Front Valve Block G1A S2A P1A S1A M4A R3 14.1:1 12:1 R1A R3 R3 F R R M10 M9 R F M8 M5A R3 M5 S3A F T1A R3 M1 PC1A VS1A R3 M4 R2A S5A 12:1 T2A S4A D4 .040 R6 C1 Pump Package R6 C1A S7A S6A C4 C4A .060 C5 P4 R5 P1 G1B M2B P3 S2B P2 Hydraulic System C2A P2A C5A P1B LH RH R7 S1B R3 R3 M2 V1 R1B VS1B R3 R4 PC1B R3 M3 T1B S3B M3B OUT IN C3B C3 S4B .
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Hydraulic System Page 4 – 10 Reelmaster 6500–D/6700–D Front Valve Block G1A S2A P1A S1A M4A R3 14.1:1 12:1 R1A R3 R M10 R R F M9 M5A R3 F S3A R3 M5 M8 F T1A R3 M1 PC1A VS1A R3 M4 R2A S5A 12:1 T2A S4A D4 R6 C1 Pump Package R6 C1A .040 S7A S6A C4 C4A .060 C5 P4 R5 C2A P2A C5A P1 G1B P2 P3 S2B M2B P1B R3 LH RH R7 S1B R3 M2 V1 R1B R4 T1B S3B M3B PC1B R3 VS1B R3 M3 OUT IN C3B S4B .
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Reelmaster 6500–D/6700–D Page 4 – 11 Hydraulic System Front Valve Block G1A S2A P1A S1A M4A R3 14.1:1 12:1 R1A R3 R M10 R R F M9 M5A R3 F S3A R3 M5 M8 F T1A R3 M1 PC1A VS1A R3 M4 R2A S5A 12:1 T2A S4A D4 R6 C1 Pump Package R6 C1A .040 S7A S6A C4 C4A .060 C5 P4 R5 P1 G1B Hydraulic System C2A P2A C5A P2 P3 S2B M2B P1B LH RH R7 S1B R3 R3 M2 V1 R1B VS1B R3 R4 PC1B R3 M3 T1B S3B M3B C3 S4B .
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Hydraulic System Page 4 – 12 Reelmaster 6500–D/6700–D Front Valve Block G1A S2A P1A S1A M4A R3 14.1:1 12:1 R1A R3 R M10 R F R M5A M9 F S3A R3 R3 M5 M8 F T1A R3 M1 PC1A VS1A R3 M4 R2A S5A 12:1 T2A S4A D4 .040 R6 C1 Pump Package R6 C1A S7A S6A C4 C4A .
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Reelmaster 6500–D/6700–D Page 4 – 13 Hydraulic System Front Valve Block G1A S2A P1A S1A M4A R3 14.1:1 12:1 R1A R3 R R M10 M9 F R M5A R3 F S3A R3 M5 M8 F T1A R3 M1 PC1A VS1A R3 M4 R2A S5A 12:1 T2A S4A D4 .040 R6 C1 Pump Package R6 C1A S7A S6A C4 C4A .060 C5 P1 G1B Hydraulic System P4 R5 C2A P2A C5A P2 P3 S2B M2B P1B LH RH R7 S1B R3 R3 M2 V1 R1B VS1B R3 R4 PC1B R3 M3 T1B S3B M3B OUT IN C3B C3 S4B .
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Hydraulic System Page 4 – 14 Rev. B Reelmaster 6500–D/6700–D S2A P1A S1A M4A R3 14.1:1 12:1 R1A VS1A R3 M8 R F M10 R F M9 R M5A R3 M5 S3A F T1A R3 M1 R3 PC1A R3 M4 12:1 T2A R2A S4A S5A D4 R6 .040 C1A S7A S6A C4A .060 C4 R6 C1 C5 P4 R5 C2A P2A C5A S2B R7 P1B LH RH S1B S10 R3 M2 R3 M2B P1 P2 P3 G1B R3 R3 M6 R1B V1 R4 PC1B VS1B R3 R3 M3 T1B S3B M3B R3 S11 R3 M7 C3 S7B OUT IN C7 C6 S9B C2B C7B S8B S6B C2 P3B C8B C6B S5B .
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Reelmaster 6500–D/6700–D Page 4 – 15 Hydraulic System P1A S1A Front Valve Block G1A S2A M4A R3 14.1:1 12:1 R1A R3 R M8 R3 R M10 F F R M9 R2A S5A 12:1 T2A S4A M5A D4 R3 M5 S3A F T1A R3 M1 PC1A VS1A R3 M4 R6 C1A .040 R6 C1 C5 Pump Package S7A S6A C4A .060 C4 P4 R5 P1 G1B R3 S2B P2 Hydraulic System C2A P2A C5A R3 M6 P3 P1B M2B R7 LH RH S1B S10 R3 R3 M2 R1B VS1B R3 V1 R4 PC1B R3 M3 T1B S3B M3B S11 R3 R3 M7 C3 .
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Hydraulic System Page 4 – 16 Reelmaster 6500–D/6700–D P1A S1A Front Valve Block G1A S2A M4A R3 14.1:1 12:1 R1A R3 R M8 R3 F R M10 F R M9 R2A S5A 12:1 T2A S4A M5A D4 R3 M5 S3A F T1A R3 M1 PC1A VS1A R3 M4 R6 C1A .040 R6 C1 C5 Pump Package S7A S6A C4A .060 C4 P4 R5 C2A P2A C5A P1 G1B R3 P2 S2B R3 M6 P3 P1B M2B LH RH S1B S10 R7 R3 R3 M2 R1B VS1B R3 V1 R4 S3B M3B R3 T1B PC1B R3 M3 S11 R3 M7 C3 .
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Reelmaster 6500–D/6700–D Page 4 – 17 Hydraulic System P1A S1A Front Valve Block G1A S2A M4A R3 14.1:1 12:1 R1A R3 R M8 R3 R M10 F R M9 F R2A S5A 12:1 T2A S4A M5A D4 R3 M5 S3A F T1A R3 M1 PC1A VS1A R3 M4 R6 C1A .040 R6 C1 C5 Pump Package S7A S6A C4A .060 C4 P4 R5 C2A P2A C5A P2 P3 S2B P1B LH RH S1B S10 R3 M2 R7 R3 M2B Hydraulic System P1 G1B R3 R3 M6 R1B VS1B R3 V1 R4 S3B M3B R3 T1B PC1B R3 M3 S11 R3 M7 C3 .
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Special Tools NOTE: Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Some tools may also be available from a local supplier. Hydraulic Pressure Test Kit – 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.
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Figure 11 You must have o–ring face seal (ORFS) adapter fittings for this tester to use it on the Workman vehicle. 1. INLET HOSE: Hose connected from the system circuit to the inlet side of the hydraulic tester. 2. LOAD VALVE: If required, upon turning the valve to restrict flow, a simulated working load is created in the circuit. 4. HIGH PRESSURE GAUGE: High range gauge to accommodate pressure beyond the capacity of the low pressure gauge, 0 – 5,000 PSI. 5.
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Troubleshooting The cause of an improperly functioning hydraulic system is best diagnosed with the use of proper testing equipment and a thorough understanding of the complete hydraulic system. A hydraulic system with an excessive increase in heat or noise is a potential failure. Should either of these conditions be noticed, immediately stop the machine, turn off the engine, locate the cause of the trouble, and correct it before allowing the machine to be used again.
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Transmission or Hydraulic System is Operating Hot Cause Correction Oil in reservoir is below level. Fill reservoir to proper level. Contaminated oil. Drain reservoir and refill with clean oil. Oil in system too light. Drain reservoir and refill with proper viscosity oil. Heat exchanger defective. Check oil cooler for obstructed air flow.
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Transmission Response Sluggish Cause Correction Charge pressure low. TEST NO. 1. Inspect charge relief valve. Repair or replace if defective. Servo control valve faulty.
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ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Cause Correction Wheel motor(s) worn or damaged. Inspect wheel motors and repair or replace if worn or damaged. NOTE: If a motor has internal damage, it is likely that the pump and other motor are also damaged. Pump worn or damaged. Inspect pump and repair or replace if worn or damaged.
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Excessive Wheel Motor Case Drain Flow Cause Correction Excessive internal wear in wheel motor. Disassemble motor completely. Inspect parts and replace as necessary. Case drain flow should not exceed 7.6 L/m [2 gal/m] at full pressure. ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Noisy Gear Pump Caused by Cavitation Cause Correction Oil too heavy. Change to proper viscosity oil.
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Cause Correction VS1A not shifting. NOTE: Lift function will also be affected. Do electrical diagnostics to make sure that voltage is being applied to VS1A and that there is no electrical fault. See Chapter 5 – Electrical System. Do cartridge valve service procedure for valve VS1A. Interchange VS1A with VS1B and check operation. Replace VS1A if faulty.
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Front Reels Turn Too Fast Cause Correction VS1A not operating properly. Do electrical diagnostics to make sure that voltage is being applied to VS1A and that there is no electrical fault. See Chapter 5 – Electrical System. Do cartridge service procedure for VS1A. Interchange VS1A with VS1B and check operation. Replace VS1A if faulty. Front Reels Won’t Backlap (Mowing Operation OK) Cause Correction S3A not shifting.
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Front Reel Speed Erratic Cause Correction Reel bearing or bedknife to reel adjustment too tight. See Chapter 8 – Cutting Units. Electrical problem. See Chapter 5 – Electrical System. ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ REAR Cutting Unit Problems Cause Correction For problems with rear cutting unit reel operation, refer to the Correction recommended for the front cutting units.
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Cutting Units Raise, But Will Not Stay Up NOTE: Lift cylinders and check valves cannot provide an absolutly perfect seal. The lift arms will eventually lower if left in the raised position during storage. It is recommended that the machine be stored with the cutting units in the lowered position. This also prevents accidental lowering of the cutting units if the lift lever (joysitck) is bumped while the key switch is on. Cause Correction S5A leaking down (not seating properly).
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Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks. (See the Special Tools section in this Chapter.) 1. Thoroughly clean the machine before disconnecting or disassembling any hydraulic components. Always keep in mind the need for cleanliness when working on hydraulic equipment. 2.
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TEST NO. 1: Traction Circuit Charge Pressure 1. Make sure hydraulic oil is at normal operating temperature before doing test. 2. Park the machine on a level surface, engage the parking brake and stop the engine. 3. Connect a 1000 PSI gauge onto charge pressure test port. 4. Start the engine and put throttle at full engine RPM (approx. 2500 RPM for 6500–D and 2750 RPM for 6700–D) with no load on the system. 5. Also take a gauge reading while operating the ma– chine in forward and reverse.
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TEST NO. 2: Traction Circuit System Pressure 1. Make sure hydraulic oil is at normal operating temperature before doing test. 2. Drive machine to an open area, lower cutting units, and shut off the engine. 2 3. Connect a 10,000 psi gauge to traction circuit test port for function to be checked. 4. Start the engine and move throttle to full speed (approx. 2500 RPM for 6500–D and 2750 RPM for 6700–D). 1 CAUTION Move machine to an open area, away from people and obstructions. Figure 13 1.
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TEST NO. 3: Steering Circuit Pressure 1. Make sure hydraulic oil is at normal operating temperature before doing test. 2. Park the machine on a level surface, engage the parking brake and stop the engine. 3. Connect a 5000 PSI gauge onto steering pressure test port. 4. Start the engine and put throttle at full engine RPM (approx. 2500 RPM for 6500–D and 2750 RPM for 6700–D). 5. Turn steering all the way in one direction and momentarily hold the steering wheel against resistance.
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TEST NO. 4: Lift Circuit Pressure 1. Make sure hydraulic oil is at normal operating temperature before doing test. 2. Lower cutting units, engage parking brake and stop the engine. 3. Raise seat to get access to hydraulic test fittings. Remove access cover from in front of hydraulic valve block. Install a 5000 PSI gauge with extension hose onto quick disconnect fitting in port G1A. Put gauge and hose through opening in front of hydraulic valve block, then lower the seat. 1 2 4.
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TEST NO. 5: Front Mow Circuit Pressure 1. Make sure hydraulic oil is at normal operating temperature before doing test. 2. Lower cutting units, engage parking brake and stop the engine. Set HOC Selector Knob, located under the instrument panel, to position A (full speed). Make sure Backlap switch is OFF. 2 3. Raise seat to get access to hydraulic test fittings. Remove access cover from in front of hydraulic valve block.
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TEST NO. 6: Rear Mow Circuit Pressure 1. Make sure hydraulic oil is at normal operating temperature before doing test. 2. Lower cutting units, engage parking brake and stop the engine. Set HOC Selector Knob, located under the instrument panel, to position A (full speed). Make sure Backlap switch is OFF. 3. Raise hood to get access to hydraulic test fittings. Remove fiberglass access cover from behind seat. Install a 5000 PSI gauge with extension hose onto quick disconnect fitting in port G1B.
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TEST NO. 7: Reel Drive/Lift Pump Efficiency (Using Tester with Pressure Gauges and Flow Meter) M4 M1 R3 M5 R3 R3 R3 R3 R3 M4A C5 C4 C4A .060 M5A D4 M2 C5A M3 R3 R3 PC1A S2A S4A S5A R3 S6A R3 M2B M3B P2A C2 C2B P2B R2A S3A C3 .040 S4B PC1B S2B S7A S1A C3B S1B VS1A S3B R1A G1A P1A T1A T2A .040 C1A C2A C1 Front Valve Block VS1B Rear Valve Block R1B G1B T1B P1B R5 R6 12:1 F F M8 R M9 R P4 12:1 P1 P2 P3 R6 R7 R4 F 14.
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flow from the pump, through the tester and into the valve block. Reel Drive/Lift Pump Efficiency Test Over a period of time, the gears and wear plates in the pump can wear. A worn pump will by–pass oil and make the pump less efficient. Eventually, enough oil loss will occur to cause the reels to stall in heavy cutting conditions. Continued operation with a worn, inefficient pump can generate excessive heat and cause damage to seals and other components in the hydraulic system. 1.
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TEST NO. 8: Reel Drive Motor Cross Over Relief Pressure Test Use a tee fitting to install pressure gauge in inlet line of motor being tested. NOTE: Inlet is front hose. M4 M1 R3 R3 M5 R3 R3 R3 High Pressure Low Pressure R3 Flow M4A M5A D4 Front Valve Block Figure 16.1 Hydraulic System Page 4 – 37.1 Rev.
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1. Make sure hydraulic oil is at normal operating temperature before doing test. 3. Lower cutting units, engage parking brake and stop the engine. 4. Install a tee fitting between the motor inlet fitting and hose. Install a 5000 PSI pressure gauge on the tee fitting. CAUTION Keep away from reels during tests to prevent personal injury from rotating reel blades. Do not stand in front of the machine. 5. Set HOC Selector Knob, located under the instrument panel, to position A (full speed).
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TEST NO. 9: Reel Drive Motor Efficiency (Using Tester with Pressure Gauges and Flow Meter) Outlet hose Case drain hose Disconnect case drain hose (small diameter hose) at bulkhead fitting on frame. High Pressure Low Pressure Case Drain Flow M4 M1 R3 R3 M5 R3 R3 R3 R3 M4A M5A D4 Install tester in series between fitting and hose at motor outlet. NOTE: Outlet is rear hose. Front Valve Block Figure 19 Hydraulic System Page 4 – 38 Rev.
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Over a period of time, the motor can wear internally. A worn motor will by–pass oil to the case drain line and make the motor less efficient. Eventually, enough oil loss will occur to cause the motor to stall in heavy cutting conditions. Continued operation with a worn, inefficient motor can generate a lot of heat, cause damage to seals and other components in the hydraulic system and affect quality of cut. 1. Make sure hydraulic oil is at normal operating temperature before doing test. 2.
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Adjustments Traction Drive Neutral Adjustment The machine must not creep when traction pedal is released. If it does creep, an adjustment is required. 1 1. Park machine on a level surface, shut engine off and lower cutting units to the floor. Depress only the right brake pedal and engage the parking brake. 2 Adjust Length 2. Jack up left side of machine until front tire is off the shop floor. Support machine with jack stands to prevent it from falling accidentally.
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Front Outer Cutting Unit Lift Rate Adjustment The #4 (left front) and #5 (right front) cutting unit lift circuit is equipped with a adjustable valve to ensure the front cutting units lower evenly. Adjust cutting units as follows: 1 1. Locate valve under seat. 2. Loosen setscrew on valve. Rotate valve clockwise to slow down drop rate of front outside cutting units. 3. Verify lift rate adjustment by raising and lowering cutting units several times. Readjust as required. Figure 21 1.
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Repairs Removing Hydraulic System Components 1. Thoroughly clean the machine before disconnecting, removing or disassembling any hydraulic components. Always keep in mind the need for cleanliness when working on hydraulic equipment. 2. Put caps or plugs on any hydraulic lines or fittings left open or exposed. 3. Put labels on disconnected hydraulic lines and hoses for proper installation after repairs are completed. 2. After repairs, check control linkage for proper adjustment, binding or broken parts. 3.
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Servo Controlled Piston Pump (Traction Pump) 11 7 17 18 19 20 6 5 13 12 16 14 15 8 9 21 10 4 3 2 1 28 29 62 61 60 45 44 63 30 65 66 33 64 32 34 35 31 36 59 42 49 37 38 58 40 57 39 41 56 Hydraulic System 22 6 7 42 43 49 44 45 50 46 51 55 53 52 54 48 47 T–2120 Figure 22 1. Valve Plate 2. Bearing 3. Quad Ring 4. Retaining Ring 5. Dump Valve Plug 6. O–Ring 7. Relief Valve 8. Backplate Assembly 9. Lock Ring 10. Coupler 11. Molded O–Ring 12. Charge Relief Adaptor 13.
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7. Remove housing gasket (34) from housing (58) or backplate (8). Disassembly – Servo Controlled Piston Pump The following instructions apply to a single servo controlled piston pump with or without a gerotor charge pump. A tandem pump assembly should be separated into individual pumps before disassembly. 1. Position the pump into a protected jaw vise, clamping onto the outer portion of the flange, with the cap screws up.
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Housing Inspection: Check the bearing (57) (press fit) in housing (58). If needles remain in cage, move freely, and setting at the dimension shown in figure 24, removal not required. 4. Screw the cover plate (43) onto the servo piston assembly (41). Install new cover plate gasket (42) in place on housing (58). Install servo piston assembly (41) and cover plate (43) into servo piston bore in right side of housing (as shown in Figure 25). Retain cover plate with four each washers (44) and cap screws (45).
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9. Install shaft assembly into front of housing. Seat seal (54) into position with seal driver and retain with interior retaining ring (55). 10. Install servo piston follower (33) onto camplate dowel pin. Install camplate (36) carefully onto bushing (37) (coat bushing surface with hydraulic oil), aligning servo piston follower (33) with slot in servo piston assembly (41). 11. To install rotating kit assembly (35), leave housing (58) and shaft (56) in the horizontal position.
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Servo Control 1 2 3 4 5 4 14 6 10 15 13 7 12 9 11 8 16 24 23 17 22 21 18 T–2119 19 Figure 26 1. Plug 2. O–Ring 3. Retaining Ring 4. Spring Retainer 5. Spring 6. Spool Valve 7. Control Housing 8. Input Shaft 9. O–Ring 10. Wiper Seal 11. O–Ring 12. Adaptor 13. Ball 14. Pin 15. Switch 16. O–Ring 17. Set Screw 18. Set Screw 19. Pin 20. Retaining Ring 21. Link 22. Dowel Pin 23. Bell Crank 24. Set Screw Disassembly – Manual Servo Control Assembly Reassembly – Manual Servo Control Assembly 1.
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D. Leaving the control arm in the detent position, the light will remain on. Screw in the switch until the light goes off. Mark this position “B”. 5. Apply Loctite #242 or equivalent to set screw (18) and install, retaining input shaft (8). Adjust set screw until it bottoms out on input shaft and back out one–quarter turn. E. Unscrew the switch one third of the distance between “B” and “A”. Install and tighten the hex socket head set screw in one of the upper quadrants of the hex of the switch adapter.
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Wheel Motor 4 7 8 5 6 3 1 4 9 5 10 2 11 12 13 14 15 16 17 T–2117 19 Figure 28 1. Retaining Ring 2. Shaft Seal 3. Washer 4. Retaining Ring 5. Thrust Race 6. Thrust Bearing 7. Splined Drive Shaft 8. HH Screw 9. Backplate Assembly 10. O–Ring 11. Speed Pickup Sensor 12. Dowel Pin 13. Dowel Pin 14. Needle Bearing Cleanliness is extremely important when repairing these motors. Work in a clean area. Before disconnecting the lines, clean port area of motor.
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7. Remove retaining ring (4) from shaft and remove thrust washers (5) and thrust bearing (6). 4. Install shaft in housing. Install washer (3), new shaft seal (2), and retain with retaining ring (1). 8. Discard the shaft seals and o–ring, and replace with new items upon reassembly. 5. Install camplate insert (17) with the lettering side of insert to the front of the housing. Use petroleum jelly to hold in place during assembly. Inspection 1.
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4WD Rear Axle Motor 5 6 5 4 7 4 8 3 9 2 1 10 11 12 13 14 16 17 T–2118 Figure 30 1. Retaining Ring 2. Spacer 3. Straight Drive Shaft 4. Retaining Ring 5. Thrust Race 6. Thrust Bearing 7. HH Screw 8. Backplate Assembly 9. O–Ring 10. Dowel Pin 11. Dowel Pin 12. Needle Bearing 13. Valve Plate 14. Rotating Kit 15. Camplate Insert 16. Housing 17. Needle Bearing Cleanliness is extremely important when repairing these motors. Work in a clean area.
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8. Remove retaining ring (4) from shaft and remove thrust washers (5) and thrust bearing (6). 4. Install shaft in housing. Install new spacer (2), and retain with retaining ring (1). 9. Discard the shaft seals and o–ring, and replace with new items upon reassembly. 5. Install camplate insert (15) with the lettering side of insert to the front of the housing. Use petroleum jelly to hold in place during assembly. Inspection 1.
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Gear Pump 9 7 6 8 10 5 4 11 3 12 2 1 20 13 14 15 16 21 23 18 17 30 24 25 27 26 29 28 T–2138 Figure 32 1. O–Ring 2. Front body 3. Drive gear assembly 4. Wear plate 5. Balance pressure seal 6. Backup gasket 7. Plug 8. Front plate assembly 9. Copper washer 10. Cap Screw Reelmaster 6500–D/6700–D 11. Shaft seal 12. Washer 13. Idler gear assembly 14. Key 15. Gear 16. Middle body 17. Gear 18. Idler gear 19. Key 20. Front adapter plate Page 4 – 53 21. Rear adapter plate 22. O–Ring 23. Plug 24.
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14. Remove o–rings (1) from front plate (8), adapter plates (20, 21), and backplate (30). Repair Information Work in a clean area, cleanliness is extremely important when repairing hydraulic pumps. Before disconnecting the lines, clean port area of pump. Disconnect hydraulic lines, removing pump assembly from vehicle and plug ports. Thoroughly clean the outside of pump. After cleaning then remove port plugs and drain oil. 15.
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Front Plate, Backplate and Adapter Plates Inspection NOTE: The small half moon port cavity must be on the pressure side of pump. 1. Oil groove in bushings in front plate, backplate and adapter plates should be in line with dowel pin holes and 180 degrees apart. This positions the oil grooves closest to respective dowel pin holes. 7. Place wear plate (4) on top of backup gasket (6) with bronze face up. The side with the mid section cut away must be on suction side of pump. 2.
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Valve Blocks Solenoid Wire Identification Torque to 15 in–lb Solenoid Power Wire Color Function VS1A S1A S2A S3A S4A S5A S6A S7A Front Reel Speed, Front Lift Speed Front Reels On/Off, Front Lift Front Reels/Lift Selector Front Reels Mow/Backlap Selector Lift All Lower All Lift/Lower #4, #5 Lift/Lower #1 Orange/Black Black/Red Violet/Red Blue/White Orange/Blue Brown/White Yellow/Black Yellow/White 1 1 1 19 Apply Loctite 242 to threads S7A 1 1 4 5 VS1A S4A 1 7 Torque to 35 ft–lb 1 10 9 8
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Solenoid Wire Identification Torque to 15 in–lb Solenoid Power Wire Color Function VS1B S1B S2B S3B S4B Rear Reel Speed, Rear Lift Speed Rear Reels On/Off Rear Reels/Lift Selector Rear Reels Mow/Backlap Selector Lift/Lower #2, #3 Yellow/Blue Orange/Red Orange/White White/Orange Pink/Blue 1 8 16 Apply Loctite 242 to threads 1 S4B S2B VS1B 7 Torque to 35 ft–lb 9 10 1 6 5 17 4 3 S1B 4 S3B 15 11 3 12 2 6 5 R1 PC1B 6 14 12 11 Hydraulic System 5 13 Rear Valve Block (RM6500–D) Fi
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Torque to 15 in–lb Solenoid Wire Identification Solenoid Power Wire Color Function VS1B S1B S2B S3B S4B S5B S6B S7B S8B S9B Rear Reel Speed, Rear Lift Speed Rear Reels On/Off Rear Reels/Lift Selector Rear Reels Mow/Backlap Selector Lift/Lower #2, #3 Lift/Lower Selector #6, #7 Lower #6, #7 Lift/Lower #6, #7 Lift/Lower #6 Lift/Lower #7 Yellow/Blue Orange/Red Orange/White White/Orange Pink/Blue Black/Red Violet/Red Yellow/Black Orange/Blue Brown/White Apply Loctite 242 to threads S4B 13 S6B 1 Torque t
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Cartridge Valves 1. Clean valve block to prevent contamination when valve cartridge is removed. Cartridge Installation 1. Lubricate all o–rings with clean hydraulic oil. 2. Remove cartridge valve: 2. Carefully thread cartridge into the port by hand. Valve cartridge should go in easily without binding. A. Remove nut from solenoid. B. Remove solenoid coil and o–ring at each end of solenoid coil. C. Use a deep socket to remove cartridge valve.
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Reel Motor 1 3 2 4 5 6 Use seal protector tool TOR4072 when inserting shaft through seal. 7 8 NOTE: Seal protector tool is part of TOR4070 Cutting Unit Tool Kit shown in Chapter 7 – Cutting Units. T–2091 Figure 37 1. Retaining Ring 2. Shaft seal 3. Flange 4. E–Seal 5. O–Ring 6. Dowel pin Adjusting Valve (Cross–over Relief Valve) Service NOTE: The adjusting valve (8) must be replaced as a complete assembly. Disassemble parts for cleaning and inspection only. 1.
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6. Remove valve block (7). O–ring Replacement 7. Remove gear housing. Make sure rear bearing block remains on drive and idler gear shafts. 1. Remove dowel pins (6) and O–rings (5) from gear housing. Clean O–ring grooves. 8. Remove rear bearing block from drive and idler gear shafts. 2. Apply a light coating of grease or petroleum jelly to O– ring grooves in gear housing and install new O–rings in each groove. 9. Before removing gear set, apply marking dye to mating teeth to retain “timing”.
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Steering Cylinder (2WD) 1 2 3 4 5 6 7 8 9 11 10 Figure 38 1. Butt & Tube Assembly 2. Lock Nut 3. Piston 4. O–Ring 5. Teflon Seal 6. O–Ring 7. Gland 8. Wiper IMPORTANT: To prevent damage when clamping cylinder barrel or rod in a vise, clamp only on pivotal ends. 1. After removing cylinder, pump oil out of cylinder into a drain pan by SLOWLY moving rod and piston in and out of cylinder bore. 2. Plug ports and clean outside of cylinder. 3.
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Steering Cylinder (4WD) 9 8 7 2 3 10 4 5 6 11 Figure 39 1. Butt & Tube Assembly 2. Teflon Seal 3. O–Ring 4. Piston 5. O–Ring 6. U–cup 7. Gland 8. Wiper 9. Piston Rod Assembly 10. O–Ring 11. Lock Nut IMPORTANT: To prevent damage when clamping cylinder barrel or rod in a vise, clamp only on pivotal ends. 6. Wash part in a safe solvent. Dry parts with compressed air. DO NOT wipe them dry with a cloth or paper as lint and dirt may remain. 1.
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Front Lift Cylinders 1 2 3 4 5 6 7 8 9 10 11 12 13 Figure 40 1. Grease Fitting 2. Barrel Assembly 3. Locknut 4. Piston 5. O–Ring 6. Special Seal 7. O–Ring 8. Backup 9. Rod Seal 10. Head 11. Dust Seal 12. Shaft w/Clevis 13. Collar IMPORTANT: To prevent damage when clamping the cylinder barrel in a vise, clamp only on the pivot end. Do not clamp the vise jaws against the smooth shaft surface. Protect the shaft surface before mounting in the vise. 5.
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Rear Lift Cylinders 1 2 3 4 5 6 7 8 9 10 11 12 13 1. Grease Fitting 2. Barrel Assembly 3. Nut 4. Uni–Ring 5. Piston 6. O–Ring 7. Shaft w/Clevis 8. Rod Seal 9. O–Ring 10. Backup IMPORTANT: To prevent damage when clamping the cylinder barrel in a vise, clamp only on the pivot end. Do not clamp the vise jaws against the smooth shaft surface. Protect the shaft surface before mounting in the vise. 1.
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#6 and #7 Lift Cylinders (RM6700–D) 1 2 3 4 5 6 7 8 9 10 11 12 13 Figure 42 1. Grease Fitting 2. Barrel Assembly 3. Locknut 4. Piston 5. O–Ring 6. Special Seal 7. O–Ring 8. Backup 9. Rod Seal 10. Head 11. Dust Seal 12. Shaft w/Clevis 13. Collar IMPORTANT: To prevent damage when clamping the cylinder barrel in a vise, clamp only on the pivot end. Do not clamp the vise jaws against the smooth shaft surface. Protect the shaft surface before mounting in the vise. 6.
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Steering Valve (75–0600 or 92–7544) 1 2 3 1 5 21 22 6 1 7 8 9 10 11 4 12 13 14 15 5 23 1 24 25 5 16 17 20 19 18 26 41 35 40 39 34 38 33 31 30 1 37 29 28 27 92–7546 T–2062 Figure 41 1. Seal Ring 2. Valve Ring 3. Valve Plate 4. Spring 5. Alignment Pin 6. Isolation Manifold 7. Metering Ring 8. Hex Drive Assembly 9. Drive Link 10. HSH Screw 11. Commutator Seal 12. Commutator Cover 13. Commutator 14. Commutator Ring Reelmaster 6500–D/6700–D 15. Stator 16. Rotor 17.
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Steering Valve Service Before Disassembly When disassembling any of the parts, use a clean work bench. Wash all parts in solvent and dry them with compressed air. DO NOT wipe them dry with a cloth of paper as lint and dirt may remain. Keep each part separate to prevent nicks and burrs. Components of the steering valve are stacked on four bolts and held in alignment with alignment pins. The alignment pins are designed to be a slip fit into the components.
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Disassembly of Steering Valve 1. To avoid distorting or damaging the steering valve, do not clamp it directly into a vise. Clamp a service assembly fixture securely in a vise (Fig. 43). Put the steering valve, input shaft first, into the service assembly fixture. Attache the steering valve to the fixture with four (4) 5/16–24 UNF nuts (Fig. 44). NOTE: Before beginning the disassembly of the steering valve, study the relative positions of the alignment grooves on the side of the components in the assembly.
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4. Grasp the port cover assembly (four plates bonded together) and lift it from the unit. Remove and discard the four o–rings and seal ring (Fig. 47). Figure 47 5. Remove the loosened plug and o–ring assembly from the port cover. Be ready to catch the steel check ball as it falls from its cavity (Fig. 48). Discard the o–ring. 6. Inspect the port cover for port fitting sealing surface scratches and thread damage. Replace the port cover if it is damaged.
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11. Remove the valve ring (Fig. 50). Remove and discard the two seal rings (Fig. 51). The valve ring should be free of nicks and scoring. Hydraulic System Figure 50 Figure 51 12. Remove the valve plate by lifting it from the isolation manifold (Fig. 52). 13. Inspect the slot edges and ground surfaces. If the valve plate shows nicks or scoring or the edges are not sharp, it must be replaced. NOTE: The valve ring and valve plate are a matched set and must be replaced as a set.
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14. Remove three springs from the isolation manifold pockets (Fig. 53). NOTE: The unit has two different length spring sets. the set you have just removed from the isolation manifold is 1/2 in. (13 mm) long. Keep this spring set separate from the set removed from the port manifold. Figure 53 15. Inspect the springs for bent or distorted coils. If a spring is broken or deformed, all six springs in the unit must be replaced (Fig. 54). Figure 54 16. Remove the hex drive assembly from the drive link (Fig.
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18. Remove the two alignment pins that align the port manifold, valve ring and isolation manifold (Fig. 56). Figure 56 19. Remove the isolation manifold (four plates bonded together) (Fig. 57). Hydraulic System 20. Inspect the ground surfaces of the isolation manifold. You should notice a “normal” polished pattern due to the rotation of the valve plate, and on the opposite side a “normal” polished pattern due to the action of the commutator cover and commutator seal.
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22. Remove the drive link from the unit (Fig. 59). 23. Inspect each end of the drive link. the four crowned contact surfaces should not be worn or scored. Replace if wear or scoring is evident. Figure 59 24. Remove the metering ring and discard the two seal rings (Fig. 60). If the metering ring bore is scored, it should be replaced. Figure 60 25. The “metering package” components are held together with eleven hex socket head screws.
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26. Remove and discard the commutator seal from the commutator cover (Fig. 62). Figure 62 Hydraulic System 27. Remove the eleven hex socket head screws, that hold the metering package together (Fig. 63). Use a 3/32 in. Allen wrench. Inspect the screws for thread and socket damage and replace as necessary. Figure 63 28. Lift the commutator cover from the metering package (Fig. 64). 29. Inspect the ground surfaces of the commutator cover.
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30. Remove the commutator ring (Fig. 65). Inspect for cracks, burrs and scoring. IMPORTANT: Handle the commutator ring with care, as it is easily broken. Figure 65 31. Remove the commutator from the rotor (Fig. 66). IMPORTANT: To prevent damage, DO NOT use a screwdriver to remove the commutator. Use a wood dowel if necessary. 32. The commutator is made up of two round plates, pinned and bonded together as a permanent assembly that cannot be disassembled. Inspect the ground surfaces of the commutator.
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34. Remove the drive link spacer (Fig. 68). Replace it if it grooved or worn. 35. With the rotor set lying on the drive plate, the rotor should rotate and orbit freely within the stator. The commutator side of the stator face must be free of grooves or scoring. NOTE: the rotor and stator are a matched set. You must replace them as a matched set, if either is worn or damaged. Figure 68 36. Check the rotor lobe “tip” to stator lobe “tip” clearance, with a feeler gauge (Fig. 69).
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39. Inspect the thrust bearing side of the drive plate (Fig. 71) for brinelling (dents) or spalling (flaking). The flat sides of the input shaft engagement hole should not be grooved or worn. If any of these conditions in steps 38 and 39 are present, the drive plate must be replaced. Figure 71 40. Remove the face seal, backup ring, and face seal spacer from the upper cover plate (Fig. 72). Discard the face seal and backup ring. Keep the metal spacer. Figure 72 41.
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43. Remove the upper cover plate (four plates bonded together) (Fig. 74). Inspect the upper cover plate. You should notice some polishing due to the action of the seal. The plate should be free of brinelling (dents) or spalling (flaking). If it is damaged, the upper cover plate must be replaced. Figure 74 Hydraulic System 44. Slide the seal from the jacket tube (Fig. 75). If the seal is worn or damaged, it must be replaced. Figure 75 45.
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47. Remove the washer and upper cover & jacket (Fig. 77). NOTE: The retaining plate and upper cover & jacket are a matched set. If either part is worn or damaged, both must be replaced. Figure 77 48. Inspect the bushing at the top of the cover & jacket for wear or damage. If bushing replacement is necessary. put the upper cover & jacket in a vise. Use a pliers or punch to straighten the crimped areas on the bushing end of the jacket tube (Fig. 78). IMPORTANT: Hold the steering tube in a soft–jaw vise.
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50. Remove the nuts holding the four bolts to the fixture, and remove the bolts (Fig. 80). Check the bolt threads for wear or damage.
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Assembly of Steering Valve Replace all seals and o–rings with new ones. Make sure the seals and o–rings remain seated correctly when components are assembled. Before assembling the steering valve, wash all parts in clean solvent. Dry the parts with compressed air. DO NOT wipe them dry with a cloth or paper as lint and dirt may remain. 1. Put the four bolts into the fixture with the shortest threaded end of the bolts through the fixture holes (Fig. 81).
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3. Put the upper cover and jacket on the four bolts with the jacket tube pointing down through the hole in fixture (Fig. 84). Make sure the square shoulder of the bolts engage the square holes in the upper cover. 4. Apply a small amount of multi–purpose grease to the recessed face of the retainer plate and washer. Put the retainer plate into the upper cover & jacket with the recessed retainer face out. Put the washer against the recessed face of the retainer plate. Figure 84 5.
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8. Apply clean multi–purpose grease to the face of the upper cover plate, input shaft and face seal (Fig. 88). Figure 88 9. Assemble the seal backup ring and face seal onto the seal spacer (Fig. 89). Figure 89 10. Install the face seal, backup ring and spacer assembly over the end of the input shaft and onto the upper cover plate (Fig. 90).
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11. Put the drive plate on a clean lint–free surface with the eleven tapped holes facing up. Put the rotor set on top of the drive plate with the five pin holes facing up. Rotate the stator until the eleven hex socket head screw relief slots are aligned with the tapped holes in the drive plate (Fig. 91). Figure 91 Hydraulic System 12. Apply a small amount of clean multi–purpose grease to the spacer and insert it into the drive slot in the rotor (Fig. 92).
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14. Align the five holes and press the five alignment pins in place (Fig. 94). IMPORTANT: Make sure the five alignment pins are pressed below the surface of the commutator. Figure 94 15. Put a few drops of oil into each recess in the commutator (Fig. 95). Figure 95 16. Put the commutator ring (either side up) on top of the stator (Fig. 96). Align the commutator ring screw recesses with the stator screw slots.
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17. Put the commutator cover on top of the commutator ring with the flat surface towards the commutator (Fig. 97). Align the screw holes in the cover, with the screw holes in the drive plate. Figure 97 18. Screw the eleven hex socket head cap screws loosely into the metering package (Fig. 98). Hydraulic System NOTE: The commutator ring must be concentric with the drive plate within 0.005 in. (0.127 mm) total indicator reading AFTER tightening the eleven hex socket head cap screws.
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20. Put another piece of the 0.007 in. (0.18 mm) shim stock between the drive plate and each of the three pieces of shim stock already in place. Lift the metering ring and metering package and remove the wood block. Push the metering package and shims into the metering ring until the drive plate and shims are at least flush with the metering ring (Fig. 100). Figure 100 21. Reverse the metering ring and metering package as a unit on a flat surface.
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22. Insert the LARGE tang of the drive link into the slot in the rotor (Fig. 103). IMPORTANT: An incorrect (reversed) assembly of the drive link will prevent the assembly of the hex drive. Figure 103 Hydraulic System 23. Grasp the drive link and rotate the metering package by hand to make sure the parts do not bind (Fig. 104). The rotor should orbit inside the stator. If they bind, disassemble the metering package, correct the cause and repeat the assembly and concentricity procedures. Figure 104 24.
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25. Put the bearing spacer onto the face of the upper cover plate (Fig. 106). Figure 106 26. Lightly grease the roller thrust bearing and put it on the upper cover plate, inside the bearing spacer (Fig. 107). Figure 107 27. Inspect the exposed face of the drive plate making sure it is clean and lint free. Apply a small amount of clean multi–purpose grease on the drive plate (Fig. 108).
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28. Put the metering package, drive plate side first, into the metering ring (Fig. 109). Revolve the input shaft or metering package until the hole in the drive plate engages the end of the input shaft and the drive plate is seated on the thrust bearing. When properly seated, the metering package will be below the surface of the metering ring. Figure 109 Hydraulic System 29. Apply clean multi–purpose grease on the new commutator seal and put it into the commutator cover seal groove (Fig. 110).
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31. Put two alignment pins into the metering ring (Fig. 112). Figure 112 32. Stack the isolation manifold (4 plates bonded together) onto the metering ring, aligning the grooves on the side of the manifold with the grooves on the side of the upper cover plate (Fig. 113). Align the alignment pin holes with the alignment pins in the metering ring. The isolation manifold surface without the recessed slots must be toward the metering ring. Figure 113 33.
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34. Put the three 1/2 in. (13 mm) springs into the spring pockets of the isolation manifold (Fig. 115). NOTE: Two different length springs are used in the unit. Be sure to use the 1/2 in. (13 mm) length springs during this part of the assembly. Figure 115 35. Apply clean grease to a seal ring and put it in the valve ring recess that will face down when installed. Install the valve ring over the bolts and alignment pins with the seal ring facing the isolation manifold (Fig. 116).
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37. To install the valve plate correctly, first carefully study Figures 93 and 94 for positioning of the valve plate spring slots and other cavities in relation to the spring and spring recesses on the isolation manifold. Be sure to use the alignment grooves on the side of the isolation manifold for orientation. Put the valve plate with the surface that reads “shaft side” down over the hex drive assembly.
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39. Put the port manifold (three plates bonded together), valve side up, in a clean surface. Install three 3/4 in. springs into the spring pockets (Fig. 121). Figure 121 Hydraulic System 40. Apply a few drops of oil to the valve plate. Align the grooves on the side of the port manifold with the grooves on the side of the isolation manifold and assemble the port manifold with the springs toward the valve plate (Fig. 122). Be careful not to pinch a spring during installation.
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42. Apply clean multi–purpose grease to the four o– rings and seal ring. Put the new o–rings and seal ring into their proper location in the port cover (Fig. 124). Figure 124 43. Align a groove on the side of the port cover with the grooves on the side of the port manifold and put the port cover into position (Fig. 125).
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44. Install the lock nuts onto the bolts. Tighten each nut gradually until resistance is felt (Fig. 126). Tighten to a torque of 20 – 24 ft–lb (27 – 33 Nm) in the sequence shown (Fig. 127). Hydraulic System Figure 126 Figure 127 45. Tighten the plug to a torque of 8 – 12 ft–lb (11 – 16 Nm) (Fig. 128).
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46. Apply a small amount of clean multi–purpose grease on the lip of the seal. Install the seal onto the jacket tube and input shaft (Fig. 129). 47. Make a final inspection of the relative groove positions on the side of the unit (Fig. 42). Components of the steering valve with alignment grooves, must be assembled so that their alignment grooves are positioned as illustrated for the valve to function correctly (Fig. 42). Disassemble and correct the assembly if necessary. Figure 129 48.
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Hydraulic Reservoir 4 35 5 6 3 7 2 8 1 9 14 10 17 15 10 18 10 19 11 15 20 12 13 33 31 34 21 32 26 25 36 24 37 38 23 22 Hydraulic System 30 16 39 29 28 27 30–60 in–lb Figure 131 1. Hydraulic Tank 2. Flange Gasket 3. Tank Cover 4. Air Breather 5. Hex Hd. Flange Screw 6. Plastic Plug 7. O–Ring 8. Dipstick 9. Screen Filter 10. O–Ring 11. Hydraulic Fitting 12. O–Ring 13. Return Hose 14. Elbow 90_ Fitting 15. O–Ring 16. Filter Hose 17. Screw 18. Filter Head 19. Hydraulic 90_ Fitting 20.
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Flushing the Hydraulic System IMPORTANT: Flush the hydraulic system any time there is a severe component failure or the system is contaminated (oil appears milky or black or contains metal particles). IMPORTANT: Flush hydraulic system when changing from petroleum base hydraulic fluid, such as Mobil 424, to biodegradable fluid, such as Mobil EAL 224H. Operate machine under normal operating conditions for at least four (4) hours before draining. 1.
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Figure 134 then plug the ports and thoroughly clean the exterior. During repairs, always protect machined surfaces. Before Disassembly Cleanliness is extremely important when repairing steering control units. Work in a clean area. Before disconnecting the hydraulic lines, clean the port area of the steering control unit. Before disassembly, drain the oil, 1. Remove the seven capscrews and disassemble the steering control unit as shown (Fig. 134). 2. Remove the plug and manual steering check valves.
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Figure 135 3. Slide the spool and sleeve from the housing (Fig. 135). 4. Remove the trust bearing and bearing races. 5. Remove the quad seal. 6. Use a small blade screwdriver to carefully pry the dust seal from the housing. Be careful to not damage the dust seal seat. 7. Remove the pin that holds the spool and sleeve together (Fig. 136). 8. Carefully slide the spool out of the sleeve. The springs and retaining ring will stay with the spool as it is removed. Figure 136 9.
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Reassembly Check all mating surfaces. Replace any parts with scratches or burrs that could cause leakage. Wash all metal parts in clean solvent. Blow them dry with pressurized air. Do not wipe parts dry with paper towels or cloth. Lint in a hydraulic system will cause damage. NOTE: Always use new seals when reassembling the steering control unit. IMPORTANT: During reassembly, lubricate the new seals with petroleum jelly. Also lubricate machined surfaces and bearings with clean hydraulic fluid. 1.
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10. Clamp the housing in a vise (Fig. 138). Use just enough clamping force to hold the housing securely. 11. Lubricate and install a new o–ring seal in the groove in the housing. 12. Install the wear plate and align the holes in the wear plate with threaded holes in the housing. NOTE: The holes in the wear plate are symmetrical. 13. Install the drive, making sure the slot in the drive engages the pin. Figure 138 14. Lubricate and install a new o–ring seal in the groove in the wear plate. 15.
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Chapter 5 Electrical System WIRING SCHEMATICS (S/N 50001 – 59999) . . . . . . . . . 2 Reelmaster 6500–D . . . . . . . . . . . . . . . . . . . . . . . . . 2 5 Amp Fuse (Ignition Switch) Circuits . . . . . . . . . . 3 10 Amp Fuses (Controller Power) Circuits . . . . . . 4 Crank, Glow and Alt. Output Circuits . . . . . . . . . . . 5 5 Amp Fuse (Leak Detector) Circuits . . . . . . . . . . . 6 10 Amp Fuse (Optional Lights) Circuit . . . . . . . . . . 7 WIRING SCHEMATICS (S/N 60001 & Up) . . . . . . . . . . .
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ORG OPTIONAL LIGHT KIT ”J” BLK ORG BLK BLUE/WHITE 1 2 3 WATER SENSOR (FUEL) BLACK G S 1 WARNING LIGHTS #1 2 3 BLACK 4 5 6 1 2 3 4 WARNING 5 LIGHTS #2 6 RED RED STARTER B #1 RED BLACK BLK HOC POT ORG ”G” KEY SWITCH YELLOW YELLOW A VCC GREEN/RED 3M SPEED SENSOR HOC SELECTOR 3N NEUTRAL SENSOR 2D 3E 2E 1D 3G 1E 2H 1F 3H 2F GROUND 3F 3J 3L 3A 1H ALTERNATOR (W) GLOW PLUG RELAY 5 1 6 4 2 3 RESISTOR 160 OHM BLACK OUTPUT (B) 2M 1M 1L 1K 1P 1R LEAK DETECT
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ORG OPTIONAL LIGHT KIT BLK BLUE/WHITE 1 2 3 WATER SENSOR (FUEL) BLACK G S 1 WARNING LIGHTS #1 2 3 BLACK 4 5 6 BLK RED RED #1 – BLACK BLK HOC POT ORG ”G” KEY SWITCH YELLOW YELLOW Electrical System Electrical System A VCC GREEN/RED 3M SPEED SENSOR HOC SELECTOR 3N NEUTRAL SENSOR 2D 3E 2E 1D 3G 1E 2H 1F 3H 2F GROUND 3F 3J 3L 3A 1H ALTERNATOR (W) GLOW PLUG RELAY 5 1 6 4 2 3 RESISTOR 160 OHM BLACK OUTPUT (B) 2M 1M 1L 1K 1P 1R LEAK DETECTOR A B C D BLACK
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ORG OPTIONAL LIGHT KIT BLK BLUE/WHITE 1 2 3 WATER SENSOR (FUEL) BLACK G S 1 WARNING LIGHTS #1 2 3 BLACK 4 5 6 RED 1 2 3 4 WARNING 5 LIGHTS #2 6 RED STARTER B #1 RED – BLACK ORG ”G” KEY SWITCH YELLOW YELLOW A VCC GREEN/RED 3M SPEED SENSOR HOC SELECTOR 3N NEUTRAL SENSOR 2D 3E 2E 1D 3G 1E 2H 1F 3H 2F GROUND 3F 3J 3L 3A 1H ALTERNATOR (W) GLOW PLUG RELAY 5 1 6 4 2 3 RESISTOR 160 OHM BLACK OUTPUT (B) 2M 1M 1L 1K 1P 1R LEAK DETECTOR A B C D BLACK 1S OU
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ORG OPTIONAL LIGHT KIT ”J” BLK ORG BLK BLUE/WHITE 1 2 3 WATER SENSOR (FUEL) BLACK G S 1 WARNING LIGHTS #1 2 3 BLACK 4 5 6 RED 1 2 3 4 WARNING 5 LIGHTS #2 6 #1 RED STARTER B RED – BLACK ORG ”G” KEY SWITCH YELLOW YELLOW Electrical System Electrical System A VCC GREEN/RED 3M SPEED SENSOR HOC SELECTOR 3N NEUTRAL SENSOR 2D 3E 2E 1D 3G 1E 2H 1F 3H 2F GROUND 3F 3J 3L 3A 1H ALTERNATOR (W) GLOW PLUG RELAY 5 1 6 4 2 3 RESISTOR 160 OHM BLACK OUTPUT (B) 2M 1M
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ORG OPTIONAL LIGHT KIT BLK BLUE/WHITE 1 2 3 WATER SENSOR (FUEL) BLACK G S 1 WARNING LIGHTS #1 2 3 BLACK 4 5 6 RED 1 2 3 4 WARNING 5 LIGHTS #2 6 RED STARTER B #1 RED – BLACK ORG ”G” KEY SWITCH YELLOW YELLOW A VCC GREEN/RED 3M SPEED SENSOR HOC SELECTOR 3N NEUTRAL SENSOR 2D 3E 2E 1D 3G 1E 2H 1F 3H 2F GROUND 3F 3J 3L 3A 1H ALTERNATOR (W) GLOW PLUG RELAY 5 1 6 4 2 3 RESISTOR 160 OHM BLACK OUTPUT (B) 2M 1M 1L 1K 1P 1R LEAK DETECTOR A B C D BLACK 1S OUT
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ORG OPTIONAL LIGHT KIT ”J” BLK ORG BLK BLUE/WHITE 1 2 3 WATER SENSOR (FUEL) BLACK G S 1 WARNING LIGHTS #1 2 3 BLACK 4 5 6 1 2 3 4 WARNING 5 LIGHTS #2 6 RED RED STARTER B #1 RED BLACK BLK HOC POT ORG ”G” KEY SWITCH YELLOW YELLOW Electrical System Electrical System A VCC GREEN/RED 3M SPEED SENSOR HOC SELECTOR 3N NEUTRAL SENSOR 2D 3E 2E 1D 3G 1E 2H 1F 3H 2F GROUND 3F 3J 3L 3A 1H ALTERNATOR (W) GLOW PLUG RELAY 5 1 6 4 2 3 RESISTOR 160 OHM BLACK OUTPUT (B
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YELLOW BLACK BLACK WATER SENSOR (FUEL) G S BLACK ”P” 1 WARNING LIGHTS #1 2 BLACK 3 4 ”M” 5 6 Rev. C STARTER + – BATTERY 12 VOLTS RED BLACK B A #2B 7.
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YELLOW OPTIONAL LIGHT KIT G S I BLACK G S I BLACK BLUE/GREEN FUEL GAGE G S I ”H” GEAR TOOTH SENSOR G S HOC POT ”P” 1 WARNING LIGHTS #1 2 BLACK 3 ”M” 4 5 6 SPEEDO– METER Page 5 – 8.1 Rev. C STARTER + – BATTERY 12 VOLTS RED BLACK B A Electrical System Electrical System A I S #2B 7.
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This page is intentionally blank. Electrical System Page 5 – 8.2 Rev.
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YELLOW BLACK ORANGE BLACK BLACK BLUE/GREEN WATER SENSOR (FUEL) G S BLACK HOC POT ”P” 1 WARNING LIGHTS #1 2 BLACK 3 ”M” 4 5 6 STARTER + – BATTERY 12 VOLTS RED BLACK B A A #2B 7.
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YELLOW BLACK BLACK WATER SENSOR (FUEL) G S BLACK ”P” 1 WARNING LIGHTS #1 2 BLACK 3 ”M” 4 5 6 STARTER + – BATTERY 12 VOLTS RED BLACK B A A #2B 7.
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YELLOW OPTIONAL LIGHT KIT BLACK G S I BLACK BLUE/GREEN FUEL GAGE G S I ”H” GEAR TOOTH SENSOR G S HOC POT ”P” 1 WARNING LIGHTS #1 2 BLACK 3 ”M” 4 5 6 SPEEDO– METER BLACK FRONT REEL SPEED SENSOR STARTER + – BLACK BATTERY 12 VOLTS RED B A A I S #2B 7.
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YELLOW FUEL GAGE GEAR TOOTH SENSOR ”P” 1 WARNING LIGHTS #1 2 BLACK 3 4 ”M” 5 6 SPEEDO– METER WATER SENSOR (FUEL) G S STARTER + – BATTERY 12 VOLTS RED BLACK B A A #2B 7.
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YELLOW FUEL GAGE GEAR TOOTH SENSOR ”P” 1 WARNING LIGHTS #1 2 BLACK 3 ”M” 4 5 6 SPEEDO– METER WATER SENSOR (FUEL) G S STARTER + – BATTERY 12 VOLTS RED BLACK B A Electrical System RED 3M 2J 3E 1C 2E 1D 3G 1E 2H 1F 3H 2F GROUND 3F 3J 3L OUTPUT (B) 2M 1M 1L 1K 3A 1H ALTERNATOR (W) BLACK GLOW PLUG RELAY 5 1 6 4 2 3 RESISTOR 160 OHM 1G 1P 1R A B C D LEAK DETECTOR BLACK 1S OUTPUTS 1B RUN (ETR) SOLENOID 2A B BLACK BLACK CAN (–) CAN (+) A C D A E B C COMMU
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YELLOW FUEL GAGE GEAR TOOTH SENSOR ”P” 1 WARNING LIGHTS #1 2 BLACK 3 4 ”M” 5 6 SPEEDO– METER WATER SENSOR (FUEL) G S STARTER + – BATTERY 12 VOLTS RED BLACK B A A #2B 7.
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Electrical System Controller 2 Reelmaster 6700–D Reelmaster 6500–D/6700–D Page 5 – 15 Electrical System
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Electrical System Page 5 – 16 Reelmaster 6500–D/6700–D 20 Amp Fuse (Ignition Switch) Circuits Reelmaster 6700–D (Controller 2)
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Reelmaster 6500–D/6700–D Page 5 – 17 Electrical System Electrical System 15 Amp Fuse (Controller 2 Power) Circuits Reelmaster 6700–D (Controller 2)
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Main Wire Harness Connector Diagram 3B 3M 3N 2J 2B 3C 2C 2G 2D 3E 2E 3G 2H 3H 3F 2F INPUTS 3J 1A 3K 1J 1K 3L 2K 92–5720 SOLID STATE CONTROLLER GROUND BATTERY POWER 2L 1L 3P 1M 3R OUTPUTS 2M 3A 1H 2P 1N 1G 1P 1R 3S 1S 1B 1C 1D 1E 1F 2S 2A Pin Labeling on Controller Connector 1 PIN NO’S 2 3 A B C D E F G H J K 1 2 HARNESS 3 A/L B/M C/N D/P NOTE: The smaller connector is phyisically labeled A–F, but the controller diagram refers to these connections as L–S.
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Special Tools Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Some tools may be listed in the Parts Catalog for the Reelmaster 6500–D or 6700–D. Some tools may also be available from a local supplier. Digital Multimeter The meter can test electrical components and circuits for current, resistance, or voltage drop. NOTE: Toro recommends the use of a DIGITAL mutlimeter when testing electrical circuits.
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Toro Autotomated Control Electronicst Diagnostic Tools Diagnostic ACEt Display The diagnostic display (Fig. 3) is connected to the wiring harness connector located inside the R.H. console to help the user verfiy correct electrical functions of the machine. Decal Diagnostic ACE Display Figure 3 Data Logt System The data log system controller is connected to the wiring harness connector near the electronic control unit (ECU).
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Troubleshooting For all electrical problems, use of the Quick Reference Troubleshooting guide is recommended. Using the Diagnostic ACE Display allows you to quickly find the source of the electrical problem. If the machine has any interlock switches by–passed, they must be reconnected for proper troubleshooting and safety.
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toggle button, on Diagnostic ACE, to change LED to “inputs displayed”. Do not hold button down. To verify interlock switch function: 1. Park machine on a level surface, lower the cutting units, stop the engine and engage the parking brake. 2. Open control panel cover. Locate wire harness and connector. Carefully unplug loopback connector from harness connector. 3. Connect the Diagnostic ACE display connector to the harness connector. Make sure correct overlay decal is positioned on Diagnostic ACE display.
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defective electrical parts immediately. To reset a blinking LED, turn the key switch “OFF”, then back “ON”. If no output LED’s are blinking, but the correct output LED’s do not illuminate, verify that the required input switches are in the necessary positions to allow that function to occur. Verify correct switch function. If the output LED’s are on as specified, but the machine does not function properly, this indicates a non–electrical problem. Repair as necessary.
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Quick Reference Troubleshooting Guide (Reelmaster 6700–D) Diagnostic Lights The RM 6700–D is equipped with two diagnostic lights which indicate if the electronic controllers are functioning correctly. The diagnostic light for the main (#1) controller is located on the steering tower panel. When the (#1) electronic controller is functioning correctly and the key switch is moved to the ON position, the controller diagnostic light will be illuminated for approximately 6 seconds.
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Note: The red text on the overlay decal refers to input switches and the green text refers to outputs. Checking Interlock Switches The purpose of the interlock switches are to prevent the engine from cranking or starting unless the traction pedal is in NEUTRAL, the Enable/ Disable switches are in DISABLE and the Lower Mow/Raise control is in the neutral position. In addition, the engine will stop when the traction pedal is depressed with operator off the seat.
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4. Turn the key switch to the ON position, but do not start machine. switches are in the necessary positions to allow that function to occur. Verify correct switch function. Note: The red text on the overlay decal refers to input switches and the green text refers to outputs. If the output LED’s are on as specified, but the machine does not function properly, this indicates a non–electrical problem. Repair as necessary. 5.
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Leak Detector Operation The TurfDefender is an electronic hydraulic fluid leak detection device that fits inside the hydraulic tank of your machine. It is a pressure based system which requires a sealed hydraulic tank to function properly. Very small changes to the oil level in the sealed tank result in a large movement of the leak detector’s internal float. The TurfDefender’s internal microprocessor analyzes the float movement and determines if there is a leak in the system.
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Diagnostic ACE, to change LED to “Inputs displayed”. Do not hold button down. Oil too hot: Allow machine to cool and clean any debris from oil cooler. If TurfDefender is functioning normally: Air leak in system: Assure tank cap is tight or check for leak in tank. 1. When the “Inputs displayed” LED is lit, the actual Float position (1 or 2 LED’s on left row) and “Oil level OK” LED – should be displayed. Note: Only large air leaks can be detected by hand held Diagnostic ACE.
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If false alarms are observed: 1. Oil level may be low causing air to be drawn out of system. Check oil level. 2. Extremely hard left turns can cause oil to slosh to the right, exposing suction line and purging air out of system. Normal maneuvering should not cause this condition. 3. Air leak in system. Check to make sure cap is securely on tank. Contact your local authorized Toro Distributor for further assistance with air leak problem. 4.
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1 Diagnostic ACE Display Functions 1. 2. 3. 4. 2 3 Overlay decal (English shown) “Inputs Displayed” LED (Red) “Outputs Displayed” LED (Green) Toggle button 4 Figure 11c Using “Inputs Displayed” (Red Text) 1 2 a. 3 4 5 6 7 b. 1. 2. 3. 4. 5. LED lit if oil level is too high LED lit if oil level is OK LED lit if oil level is too low LED lit if oil is too hot LED lit if system air leak has been detected 6. One or two LED’s lit displaying relative position of the Turfdefender’s internal float. 7.
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Turf Defender Troubleshooting Guide The following is a quick guide to the most common problems likely to be encountered.
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Understanding the Controllers Loopback connector CAN bus Controller #2 (Secondary) – RM6700–D Only Functions: S Manages the functions of #6 and #7 cutting units ONLY. S Needs approval from controller #1 before executing an operator request. S Same part number as controller #1, but requires a different software program (on TOROPC disk). S Connected to other controller and/or leak detector by the CAN bus.
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Understanding the Diagnostic Lamps Controller #1 (Primary) Fault Identification / Operator Warning The reel control lamp (red) on the steering tower will stay ON with no flashing if: 1. The glow plugs are on. 2. Operator mowing too slow or too fast for proper ClipAce control. 3. Defective reel speed sensor (reels engaged). 4. Defective traction unit speed sensor (reels engaged – cannot sense ground speed). The reel control lamp (red) on the steering tower will flash ON and OFF if: 1.
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Starting Problems All Electrical and Gauges Are Dead ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
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Engine Starts, But Dies When Ignition Switch Is Released From Start Position Cause Correction Run solenoid faulty. Replace run solenoid. Run solenoid wiring faulty. Repair wiring. Faulty high engine water temperature shut–down switch (engine not overheated) or wiring. Check switch and wiring and replace or repair if necessary.
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General Run and Transport Problems Engine Continues To Run, But Should Not, When Ignition Key Is Off ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Cause Correction Engine fuel lever or run solenoid stuck in “on” position. Check operation of run solenoid and adjust or replace if necessary.
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Engine Kills When Traction Pedal Is Depressed Cause Correction Seat lifting off seat switch. Instruct operator to sit back in seat during operation. ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Check seat plate hinges and seat support pin and repair if faulty Seat switch circuit open.
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Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the battery terminals. Set the multimeter to the DC Volts setting. The battery should be at a temperature of 60_ to 100_ F. The ignition key should be off and all accessories turned off. Connect the positive (+) Volt meter lead to the positive battery post and the negative (–) Voltmeter lead the the negative battery post. NOTE: This test provides a relative condition of the battery.
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Glow Plug System Test This is a fast, simple test that can help you determine a Glow Plug system’s integrity and operation. The test should be run anytime hard starting (cold) is encountered on a diesel engine equipped with a Glow system. Remember – there are 2 types of Glow Plug systems that Toro uses: 1. Systems with resistors (Glow Plug Indicators) in series (Reelmaster 450/4500–D, Groundsmaster 325–D, etc.) Set multimeter on Volts scale.
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Component Identification and Testing For all electrical problems, use of the Quick Reference Troubleshooting guide is recommended. Using the Diagnostic ACE Display allows you to quickly find the source of the electrical problem. CAUTION When testing electrical components for continuity with a volt–ohm meter or continuity tester, make sure that power to the circuit has been disconnected.
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Electronic Control Unit (ECU) The Toro electronic control unit (ECU) senses the condition of various switches, such as the seat switch, cutting unit down switches, traction neutral switch, etc., and directs power output to allow certain machine functions, such as engine run, cutting units engage, etc. Because of the solid state circuitry built into the controller, there is no method to test it directly.
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Traction Neutral Switch The traction switch is normally closed and opens when traction pedal is depressed in either direction. The switch is located on the right side of the hydrostatic transmission. Test the switch by disconnecting the wires from the switch terminals and connecting a continuity tester across the two terminals that had wires connected to them. With the engine turned off, slowly push the traction pedal in a forward and reverse direction while watching the continuity tester.
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Lower–Mow/Raise Switches (Joystick) Each switch is normally open and closes when the joystick is moved. Test each switch by disconnecting the wiring connector from the switch and connecting a continuity tester across the two terminals of the switch being tested. Testing With the engine turned off, move the joystick, then allow it to return to neutral while watching the continuity tester. There should be indications that the switch is opening and closing.
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Backlap Switch The Backlap switch is a three–way switch. Test the switch by disconnecting the wires and connecting a continuity tester across terminals of switch. With the switch OFF, the tester should show no continuity across terminals 4 – 5 or 5 – 6. 1 With the switch in the FRONT position (toward keyway), tester should show continuity across terminals 4 and 5. With the switch in the REAR position (away from keyway), tester should show continuity across terminals 5 and 6.
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Glow Relay and Glow Plugs 1. Attach an amp meter to glow plug circuit. Turn ignition switch to ON. Meter may have an initial reading as high as 100 amps. A. If amp meter shows a reading for 5 to 12 seconds, the glow relay is operating. If there is no reading, go to step 2. B. Turn ignition switch OFF, then ON again. A reading of 48 amps should be observed. Go to step 3. 2. To test the circuit. A. Check with a test light at buss bar connection for glow plugs at cylinder head. Turn the ignition switch ON.
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Fuel Stop (ETR) Solenoid This engine has an energize-to-run (ETR) fuel stop solenoid. The solenoid will stop injector pump fuel delivery with any electrical failure in the RUN circuit. 1. Disconnect the wire from the solenoid. 2. Remove the solenoid from the injector pump. 1 3. Connect a 12 volt battery so that a wire from positive (+) battery terminal is connected to switch terminal. Touch a wire from the negative (–) battery terminal to solenoid body. The plunger should retract.
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Indicator Lights and Gauges Reel Control and Diagnostic Lamps Glow Light See Quick Reference Troubleshooting Guide in Troubleshooting section for explanation of diagnostic functions. The glow light should be on when the ignition switch is in the ON position. The glow system runs off of a timer relay. The REEL CONTROL lamp should come ON when the cutting units are operating with the machine not moving.
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Fuel Gauge Sender Disconnect wire and remove the fuel gauge sender from the fuel tank. 1 Install an ohm meter between the terminal and base. With arm completely down (empty position), resistance should be 240–260 ohms. With arm completely up (full position), resistance should be 29–34 ohms. NOTE: Bend float arm, if necessary, to get proper gauge reading for a 1/2 full tank. CAUTION Figure 28 1.
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Valve Block Solenoids 1. Disconnect the wire connector. 2. Connect a 12 volt battery so the positive (+) battery terminal is connected to colored solenoid lead. Connect the negative (–) battery terminal to black lead. The valve spool should retract completely as 12 V.D.C. is applied between leads. 3. If valve spool does not retract check for binding or damage in valve. 4. If valve operates smoothly, but does not retract when 12 V.D.C. is applied to solenoid leads, replace solenoid coil. 5.
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Solenoid Wire Identification Torque to 15 in–lb Solenoid Power Wire Color Function VS1A S1A S2A S3A S4A S5A S6A S7A Front Reel Speed, Front Lift Speed Front Reels On/Off, Front Lift Front Reels/Lift Selector Front Reels Mow/Backlap Selector Lift All Lower All Lift/Lower #4, #5 Lift/Lower #1 Orange/Black Black/Red Violet/Red Blue/White Orange/Blue Brown/White Yellow/Black Yellow/White 1 1 1 19 Apply Loctite 242 to threads S7A 1 1 4 1 7 5 VS1A S4A Torque to 35 ft–lb 1 10 9 8 6 S1A 12 11
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Solenoid Wire Identification Torque to 15 in–lb Solenoid Power Wire Color Function VS1B S1B S2B S3B S4B Rear Reel Speed, Rear Lift Speed Rear Reels On/Off Rear Reels/Lift Selector Rear Reels Mow/Backlap Selector Lift/Lower #2, #3 Yellow/Blue Orange/Red Orange/White White/Orange Pink/Blue 1 8 16 Apply Loctite 242 to threads 1 S4B S2B VS1B 7 Torque to 35 ft–lb 9 10 1 6 5 17 4 3 S1B 4 S3B 15 11 3 12 2 6 5 5 R1 PC1B 6 14 13 12 11 Rear Valve Block (RM6500–D) Figure 32 1.
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Torque to 15 in–lb Solenoid Wire Identification Solenoid Power Wire Color Function VS1B S1B S2B S3B S4B S5B S6B S7B S8B S9B Rear Reel Speed, Rear Lift Speed Rear Reels On/Off Rear Reels/Lift Selector Rear Reels Mow/Backlap Selector Lift/Lower #2, #3 Lift/Lower Selector #6, #7 Lower #6, #7 Lift/Lower #6, #7 Lift/Lower #6 Lift/Lower #7 Yellow/Blue Orange/Red Orange/White White/Orange Pink/Blue Black/Red Violet/Red Yellow/Black Orange/Blue Brown/White Apply Loctite 242 to threads S4B 13 S6B 1 Torque t
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#6 and #7 Reel On/Off Solenoids 1. Disconnect the wire connector. 2. Connect a 12 volt battery so the positive (+) battery terminal is connected to colored solenoid lead. Connect the negative (–) battery terminal to black lead. The valve spool should retract completely as 12 V.D.C. is applied between leads. 2 3. If valve spool does not operate properly check for binding or damage to valve. 1 4. If valve moves smoothly, but does not engage when 12 V.D.C.
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Repairs Battery Service IMPORTANT: To prevent damage to the electrical components, do not operate the engine with the battery cables disconnected. Electrolyte Specific Gravity Keep the terminals and entire battery case clean. To clean the battery, wash the entire case with a solution of baking soda and water. Rinse with clear water. Do not get the soda solution into the battery because damage to the battery will result.
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Fuses Fuses are located below the control panel. NOTE: It is not always possible to see if a fuse is faulty. It is recommended that you check for faulty fuses with a continuity tester; not visually. 1 Figure 36 1.
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Installing Optional Lighting SCHEMATIC FOR OPTIONAL LIGHTING IMPORTANT: If optional lighting is to be added to the traction unit, use the following schematic and part numbers to prevent damage to the traction unit’s electrical system. To Lights w/external ground Black 30 Red To Lights 30 Orange 85 2 3 Switch 86 Relay Switch* Toro Part No. 75–1010 Honeywell Part No. 1TL1–2 Relay Toro Part No. 70–1480 Bosch Part No. 0–332–204 Black, red and orange wires are located in control console.
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Hydraulic Valve Block Solenoid Coil Replacement 1. Remove solenoid coil: A. Remove nut from solenoid. B. Remove solenoid coil and o–ring at each end of solenoid coil. NOTE: There are two different solenoid coils used on the hydraulic valve blocks. Cartridge valves VS1A and VS1B use 28 Watt coils. All other valves use 20 Watt coils. Make sure you use the correct replacement solenoid. Figure 38 2. Install solenoid coil: A. Make sure there is an o–ring installed at each end of the coil. B.
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Speedometer Sensor Installation NOTE: It is recommended that this procedure be done with the motor removed from the machine. 1 1. Thread locknut onto speed sensor to allow full exposure of sensor threads. 2. Center a motor piston with the center of the sensor port (see Sensor Port View below). NOTE: If the motor is on the machine use a tool to feel when a motor piston is in the center of the sensor port. 3. Lubricate O–ring on sensor. 4. Thread sensor into port until sensor contacts piston.
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Reel Speed Sensor Installation See Cutting Unit Installation in Repairs section of Chapter 7 – Cutting Units. 1 Figure 42 1. Reel speed sensor Traction Neutral Switch Installation See Servo Control in Repairs section of Chapter 4 – Hydraulic System. 1 Figure 43 1.
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Chapter 6 Axles, Planetaries and Brakes Table of Contents 2 3 5 5 5 REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Rear Wheel Bearing Service (2WD) . . . . . . . . . . . . 6 Planetary Wheel Drive Service . . . . . . . . . . . . . . . . 8 Brake Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Rear 4WD Axle Service . . . . . . . . . . . . . . . . . . . . . 12 Axles, Planetaries and Brakes SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . .
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Specifications Item Specification Front wheel lug nut torque 45–55 ft–lb Rear wheel lug nut torque 85–100 ft–lb Steering cylinder bolt torque 100–125 ft–lb Rear wheel toe–in .25” Tire pressure 15–20 psi, front and rear Brake pedal free travel .12” Planetary brake housing, and wheel motor mounting cap screw torque 75–85 ft–lb Planetary gear drive oil System gear lube capacity each wheel SAE 85W–140 wt. gear lube 16 oz. (incl.
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Special Tools Order special tools from the TORO SPECIALS TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Rear 4WD Axle Tools TOR4038 – Differential Case Gauge Used to determine the number of shims required between the 4WD rear axle differential housing. Figure 3 TOR4039 – Pilot Bushing Driver Used to install the pilot bushing into ends of 4WD rear axle. Axles, Planetaries and Brakes Figure 4 TOR4040 – Pinion Nut Tool Used to remove or install the pinion (sleeve) nut on the 4WD rear axle.
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TOR4041 – Bevel Gear Remover Used to separate the bevel gears from their shafts in the ends of the 4WD rear axle. Figure 6 TOR4042 – Pinion Gauge Used to determine the number of shims required to properly position the 4WD rear axle pinion. Figure 7 TOR4043 – Oil Seal Installation Tool Used to install the oil seals in the ends of the 4WD rear axle.
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Adjustments Service Brake Adjustment Adjust the service brakes when there is more than 1 inch of “free travel” of the brake pedal, or when the brakes do not work effectively. Free travel is the distance the brake pedal moves before braking resistance is felt. 1 1. Disengage locking pin from brake pedals so both pedals work independently of each other. 2. To reduce free travel of brake pedals, tighten the brakes – loosen front nut on threaded end of brake cable.
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Repairs Rear Wheel Bearing Service (2WD) 10 56 11 12 7 8 1 14 15 16 17 18 9 6 51 52 50 49 53 47 54 57 58 59 19 20 55 48 17 46 21 22 45 6 37 13 42 43 44 8 23 28 24 25 26 37 38 27 29 6 7 39 40 41 30 31 37 32 36 T–2078 T.1–813.92–7400.16 35 34 33 Figure 11 1. Cap Hex Hd. Screw 6. Cotter Pin 7. Hose Assembly 8. Hose Assembly 9. Hex Slotted Nut 10. Axle Stop 11. Lock Nut 12. Flat Washer 13. Lock Nut 14. Hex Hd. Flange Screw 15. Spindle Cap 16. Retaining Ring 17. Thrust Washer 18.
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Disassemble, clean, repack and adjust the rear wheel bearings after each 800 hours of operation. Use No. 2 general purpose lithium base grease containing E.P. additive. If operating conditions are extremely dusty and dirty, it may be necessary to perform this maintenance more often. 10. Adjust preload on the wheel bearings. A. Tighten the jam nut to 75 – 80 in–lb (86 – 270 Kg– cm) while turning the hub to seat the bearings and remove all end play. B.
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Planetary Wheel Drive Service 1 2a 2b 3 4 5 6 7 8 2c 9 10 11 25 12 24 21 22 23 20 19 18 13 2d 17 16 14 15 T–2070 92–7415 Figure 13 1. Spindle 2. Seal kit 3. Bearing cone 4. Bearing cup 5. Wheel stud 6. Housing 7. Bearing cup 8. Bearing cone 9. Thrust washer 10. Retaining ring 11. Secondary carrier assembly 12. Primary carrier assembly 13. Pipe plug 14. Retaining ring 15. Cover plate 16. Input spacer 17. Thrust washer 18. Ring gear 19. Retaining ring 20. Sun gear 21. Sun gear 22.
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10. Use a puller to remove spindle (1) from housing (6). Remove bearing cone (8). 6. Press bearing cone (8) onto spindle and secure with thrust washer (9) and retaining ring (10). 11. Remove and discard all seals. 7. Install seal (2c), then assemble ring gear (18) to housing (6) with capscrews (25). 12. If bearings will be replaced, use a puller to remove bearing cone (3) from spindle. Remove bearing cups (4 and 7) from housing (6). 8. Install secondary carrier assembly (11). 9. Install sun gear (21).
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Brake Service 75 – 85 ft–lb 10 75 – 85 ft–lb 1 3 4 7 8 2 9 5 75 – 85 ft–lb 6 Figure 14 1. Capscrew 2. Wheel motor 3. O–ring 4. Brake cable 5. Flange head capscrew 6. Brake assembly 7. Splined shaft 8. Retaining ring 9. Planetary wheel drive 10. Flange head capscrew Remove Brake Assembly (Fig. 14) Install Brake Assembly (Fig. 14) 1. Drain oil from planetary wheel drive (9) and brake assembly (6). 1. Install splined shaft (7) into brake assembly. 2.
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3 2 1 4 5 6 7 8 9 13 10 12 11 T–2071 92–7417 Figure 15 6. Hair Cotter Pin 7. Stationary Disc 8. Rotating Disc 9. Retaining Ring 10. Gasket 11. Actuator 12. Extension Spring 13. Ball Brake Inspection and Repair (Fig. 15) 6. Remove balls (13). 1. Scrape gasket material (10) off of brake housing and planetary wheel drive mounting surfaces. 7. Wash parts in cleaning solvent. 8. Inspect parts for wear or damage. 2. Remove retaining ring (9). 3. Remove stationary discs (7) and rotating discs (8). 4.
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Rear 4WD Axle Service 21 8 13 14 11 10 9 12 10 11 6 1 5 9 8 2322 2 4 3 7 12 13 21 14 19 20 19 15 16 17 18 T–1111 Figure 16 30 5 4 3 2 10 1 12 13 26 14 15 16 17 18 19 20 21 6 7 27 8 3 9 27 26 11 28 28 T–1110 Figure 17 Axles, Planetaries and Brakes Page 6 – 12 Reelmaster 6500–D/6700–D
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Disassembly The two gear cases, right and left can be removed from the housing without requiring the entire axle to be disassembled. 1. Remove tie rod by disconnecting rod end ball joint on each end. Disconnect hydraulic cylinder rod end from drag link arm. 2. Remove bolts (Fig. 16, Item 23 and 21) securing gear case to axle housing and pull gear case complete with final drive case.
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12 5 9 8 7 10 6 1 2 3 4 Instal seal so garter spring faces hydraulic motor 2 11 Figure 22 1. Bearing 2. O–Ring 3. Shim 4. Sleeve 5. Bolt 6. Oil Seal 7. Bushing 8. Washer 9. Locknut 10. O–Ring 11. Bearing 12. Adapter 13. Nut 14. Stud Bolt 15. Washer Disassembling Axle Housing 3. Separate axle housing by removing bolts. 1. Remove axle from machine before disassembling: 4. Pull out differential shaft (Fig. 16, Item 14) from housing (B). A.
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Inspection Clean the disassembled parts by washing in cleaning solvent. Inspect gears and pinions to be sure their teeth are in good condition. Check to be sure that each bearing rotates smoothly. Examine housings for cracks. Reassembly Replace damaged or worn parts as necessary. Oil or grease the surfaces of rotating or sliding parts before assembling. Grease oil seals and o–rings before installing. Assembling Pinion Shaft 1.
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Adjusting Pinion Shaft Cone Center “Cone Center” is the distance from the mating face of axle housing to end face of pinion. This distance can be increased or decreased by installing removing shims. Cone center specification 43 ± 0.05mm (1.69 ± 0.002 in.) Shim stock for this adjustment is available in the following thicknesses: Thickness Part No. Shim set 77-4010 0.1 mm (0.004 in.) 76-7410 0.2 mm (0.008 in.) 76-7420 0.4 mm (0.016 in.
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Adjusting Backlash Backlash specification 0.25 ~ 0.35 mm (0.010 ~ 0.014 in.) Adjust shim thickness (between bearing housing of axle housing (A) and bearing) to get specified backlash. Shim stock for this adjustment is available in these thicknesses: Thickness Part No. Shim set 77-4000 0.1 mm (0.004 in.) 76-7290 0.2 mm (0.008 in.) 76-7300 0.4 mm (0.016 in.) 77-7310 Figure 26 Shim Between Differential and Axle Housing (B) After obtaining specified backlash, determine amount of shims needed: 1.
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Assembling Axle Housing 1. Coat mating faces of two housings (A) and (B) with sealant and attach selected shim to face of housing (B). Put the two housings together and fasten them by tightening bolts to following torque value: Torque specification 2.5 ~ 3.0 kg–m (18 ~ 22 ft-lb) 2. Fit ball bearings to out end of each differential shaft, then mount pinion (14T) and retain pinion by installing circlip. The ball bearings have a groove cut in the end faces of the inner and outer races.
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Installing Drag Link and Tie Rod Arm 1. Carefully insert bushing into arm. 2. Put arm into position over holder, fitting it to final case and secure to case with bolts. 3. Check thrust clearance. Proper thrust clearance is 0 to 0.2 mm (0.008in.). If necessary reduce clearance to specification by shimming. Shim stock for this adjustment is available in the following thicknesses: Thickness Shim Part No. TIE ROD ARM Part No. DRAG LINK ARM Shim set 77-4050 77-4040 0.8 mm (0.03 in.) 76-7820 76-7700 1.
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4. After obtaining proper pinion backlash, grease o–ring and fit it to mating face of axle housing. Secure gear case to housing by tightening bolts to the following torque value: Torque specification 5.0 ~ 6.0 kg–m (36 ~ 43 ft-lb) Reassembling Wheel Shaft 1. Grease oil seal and fit it to bearing holder. 2. Insert shaft into holder. Install ball bearing and retain bearing by installing circlip. Figure 33 3. Mount bevel gear (29T) on splined end of shaft. 4.
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Installing Axle on Machine 1. Support axle under machine with a jack. 2. Install axle pivot pin to secure axle to frame. Make sure to install thrust washers between axle pivot and frame. 3. Install hydraulic motor to adaptor housing. 4. Install wheels to axle. Tighten wheel bolts to a torque of 85 – 100 ft–lb. 5. Fill axle with SAE 80–90W EP gear lube. Lubricant capacity is approximately 80 oz. (2.5 U.S. qt.). 6. Check rear wheel toe–in and adjust if necessary. .25 in.
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Axles, Planetaries and Brakes Page 6 – 22 Reelmaster 6500–D/6700–D
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Chapter 7 Model 03853 Model 03854 Model 03856 Cutting Units Table of Contents Bedbar Removal and Installation . . . . . . . . . . . . . Bedknife Replacement and Grinding . . . . . . . . . . Preparing Reel for Grinding . . . . . . . . . . . . . . . . . . Reel Removal and Bearing Replacement . . . . . . Roller and Frame Service . . . . . . . . . . . . . . . . . . . . Roller Bearing and Seal Replacement . . . . . . . . . Cutting Unit Installation . . . . . . . . . . . . . . . . . . . . . .
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Specifications Figure 1 REEL CONSTRUCTION: Fairway reels. All welded. 5 or 11 blades. BEDKNIFE AND BEDBAR ADJUSTMENT: Single point adjustment mechanism. HEIGHT OF CUT RANGE: 5 Blade – 3/4” to 1–1/4” 7 Blade – 1/2” to 1–1/8” 11 Blade – 3/8” to 3/4” CLIP FREQUENCY: .375” – 1.25”. Reel speed automatically adjusts to maintain proper clip. Reel speed is continuously calculated based on the current forward speed and the pre–set reel type and height of cut. REEL DIAMETER: 7 in.
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Special Tools Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Some tools may have been supplied with your machine or available as TORO parts. Some tools may also be available from a local supplier. Gauge Bar Assembly Use gauge bar to verify height of cut. Toro P/N 59–7900 Gauge bar Figure 2 Handle Assembly – TOR299100 For applying lapping compound to cutting units while keep hands a safe distance from the rotating reel.
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Bedknife Screw Tool – TOR510880 This screwdriver–type bit is made to fit Toro bedknife attaching screws. Use this bit with a torque wrench to secure the bedknife to the bedbar. Make sure bedbar threads are clean and use new screws. Tighten screws to a torque of 250 – 300 in.lb. (288 – 345 KgCm) starting in the middle of the bedknife as shown in figure 5. NOTE: Remove all rust, scale and corrosion from bedbar surface before installing bedknife. DO NOT use and air impact wrench with this tool.
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Troubleshooting There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions. Turf conditions such as excessive thatch, “sponginess” or attempting to cut off too much grass height may not always be overcome by adjusting the machine. It is important to remember that the lower the height of cut, the more critical these factors are. Remember that the “effective” or actual height of cut depends on cutting unit weight and turf conditions.
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Factor Possible Problem/Correction 5. Bedknife to reel adjustment. Check bedknife to reel contact daily. Bedknife must have light contact all across reel. No contact will cause cutting edges to become dull. Excessive contact accelerates wear; quality of cut may be adversely affected. Adjust so you paper can be pinched between reel and bedknife without tearing when inserted from the front, and cuts cleanly when inserted at a right angle (along entire length of bedknife).
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Set–up and Adjustments IMPORTANT: Toro strongly recommends the use of a leveling plate when setting–up or adjusting any reel type cutting unit. The leveling plate will help to ensure accurate and consistent adjustments. RIGHT Note: Right and left ends of cutting unit is determined by standing in the operator’s position (Fig. 7). Use the following sequence to set–up and adjust each cutting unit: 1. Check each end of the reel for grease.
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Bedknife to Reel Adjustment 1. A 19 mm (3/4 inch) wrench will be needed to rotate bedknife adjustment knob. Each notch on the knob will move the bedknife .0005 inches (.013 mm) (Fig. 6). 1 2. On either end of reel, insert a long strip of dry newspaper between reel and bedknife. While slowly rotating reel into bedknife, turn bedknife adjusting knob clockwise, one click at a time until paper is pinched lightly, which results in a slight drag when paper is pulled. 3.
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Front Roller Adjustment and Leveling Note: Cutting units are shipped from the factory with the front roller mounted in the “C” position. The best cutting unit attitude is dependent on turf conditions and desired results. Experience in your conditions will determine the best setting to use.
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Height of Cut The Height–of–Cut adjustment is made by moving the rear roller up or down, after adjusting and leveling the front roller. This can be done by using the adjusting screw or quick height–of–cut locating pin (Fig. 13 & 13). Note: To ensure accuracy, initial rear roller set–up should be performed on a leveling plate . 1 2 A B A C X C B 3 1. Select proper rear roller position holes for desired height–of–cut (Fig. 13 & 15).
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Verify Height of Cut 1. On gauge bar, set head of screw to desired Height– of–Cut. This measurement is from bar face to underside of screw head. 2. Place the bar across the front and rear rollers and adjust the rear roller up or down until the underside of screw head engages the bedknife edge. Do this on both ends of reel. 1 Figure 16 1. Gauge bar Grass Shield and Fin Adjustment Adjust grass shield and/or shield fin angle for desired grass clippings dispersion. 1.
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Service and Repairs Backlapping Note: See traction unit Operator’s Manual for complete operating instructions. Note: Lapping is not intended to be a reconditioning process to correct severely nicked or rounded blades, rifling or taper. If, after 5 minutes of lapping, the edge is not restored, it is time to grind the reel. 5. Move enable / disable switch to enable position. Move lower mow / raise lever forward to start backlapping operation on designated reels. 6.
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Bedbar Removal and Installation 14 1 2 3 4 10 5 31 1 6 15 17 16 18 7 1117 9 8 23 20 24 25 26 47 37 45 46 44 43 36 28 29 42 27 36 30 32 1 32 10 41 40 39 38 37 35 34 33 4 Cutting Units 03853, 03854, 03856 Figure 18 Reelmaster 6500–D/6700–D Page 7 – 13 Rev.
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Remove Bedbar 1 1. Loosen bedknife adjusting knob to loosen bedknife to reel contact. 2 2. Loosen locknut on bedknife adjuster assembly and disengaging adjuster from bedbar. NOTE: On early production cutting units there is no slot in bedbar for disengaging bedknife adjuster from the bedbar; you must completely unscrew adjuster assembly from pivot on cutting unit frame. 3. Remove bedbar leveling screw and spring from L.H. side of cutting unit. 4. Remove fasteners securing L.H. and R.H.
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Bedknife Replacement and Grinding 1. Remove bedbar from cutting unit. Use a torque wrench and bedknife screw tool 2. Remove bedknife screws and remove bedknife. 3. Remove all rust, scale and corrosion from bedbar surface before installing new bedknife. 4. Install new bedknife: A. Make sure bedbar threads are clean. B. Use new screws. Apply anti–seize lubricant to screw threads before installing. C. Tighten screws to a torque of 250 – 300 in.lb.
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Preparing Reel for Grinding 1. Check to make sure reel bearings are in good condition and properly adjusted before grinding the reel. Make sure the cutting unit frame and roller brackets are true and not bent or damaged from impacts with trees, posts or cart path edges. Note: When grinding, be careful to not overheat the reel blades. Remove small amounts of material with each pass of the grinder. 4. After completing the grinding process, do a complete set–up and adjustment procedure. 2.
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Reel Removal and Bearing Replacement 1 2 27 3 4 5 NOTE: Early production units have pressed in spline inserts. 6 Use tool TOR4074 to install threaded spline insert. Apply Locite 242 to threads Tighten to 75 – 85 ft–lb (10.4 – 11.8 KgM) 15 24 13 25 Apply anti–sieze lubricant to splines 26 3 27 7 8 9 10 11 12 23 22 21 20 19 18 17 16 4 Pack bearings with No. 2 general purpose grease 15 14 29 28 Use tool TOR4064 Tighten set screw one–half turn beyond initial contact minimum Figure 24 11.
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bearing race. Remove the seals. NOTE: If bearing is removed, the seal should be replaced. Remove Reel 1. Remove weight from cutting unit. If equipped with a speed sensor, remove shaft magnet after removing weight and sensor. B. Install new seals on the reel shaft. Make sure seals are installed square to shaft. 2. Remove bedbar assembly. C. Pack bearings with No. 2 general purpose grease before installing. Install bearings on reel shaft by pressing on the inner bearing race. 3.
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Roller and Frame Service 9 10 8 20 – 30 in–lb (23 – 35 KgCm) 7 1112 13 1415 6 5 4 2 1 * Early production units only 110 – 120 in–lb (127 – 138 KgCm) Apply Loctite 242 2 13 – 17 ft–lb (1.8 – 2.4 KgM) 16 17 18 3 26 37 36 13 – 17 ft–lb (1.8 – 2.4 KgM) 37 31 28 27 75 – 85 ft–lb (10.4 – 11.8 KgM) 39 36 44 19 42 41 1 35 18 17 40 2 16 44 15 75 – 85 ft–lb (10.4 – 11.8 KgM)44 43 43 44 26 28 44 32 22 14 2 28 29 13 – 17 ft–lb (1.8 – 2.4 KgM) 21 36 34 75 – 85 ft–lb (10.
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Roller Bearing and Seal Replacement 1 2 3 5 6 7 8 9 4 Sharp edge out 7 9 8 6 5 3 2 4 1 Lip of seal facing in Figure 26 1. Roller 2. Inner oil seal 3. Bearing 4. Roller shaft 5. Inner seal 6. Outer seal 7. Retaining ring 8. Outer oil seal 9. Washer NOTE: Bearing and seal configurations are the same for both the front and rear rollers. B. Install roller shaft from opposite end of roller. Be carefull not to damage the inner oil seals. Remove Seals and Bearings C.
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Cutting Unit Installation Cutting unit models 03854 and 03856 can be installed at any of the five mounting locations on the traction unit. Figure 17 shows the orientation of the hydraulic drive motor for each of the five locations. For any of the locations requiring the motor to be mounted on the right end of the cutting unit, install a counter weight on the left end of the cutting unit.
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7. Mount the motor to the drive end of the cutting unit and secure with two capscrews provided (Fig. 30). 8. On front center and left rear cutting units, plug speed sensor wire harness connector into traction unit wire harness connector. 1 1 Figure 30 1. Motor 2. O–ring 7 9. On motor side of cutting unit, insert speed sensor end of harness into frame tube and route to counterweight. 10. Install small O–ring onto speed sensor and insert sensor into hole in counterweight. 11.
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Greasing Bearings, Bushings and Pivot Points Each cutting unit has (6) grease fittings (Fig. 32) that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. The grease fitting locations and quantities are: reel bearings (2) and front and rear rollers (2 ea.) IMPORTANT: Lubricating cutting units immediately after washing helps purge water out of bearings and increases bearing life. 1. Wipe each grease fitting with a clean rag. 2. Apply grease until pressure is felt against handle.
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Cutting Units Model 03853 Model 03854 Model 03855 Page 7 – 24 Rev.
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Model 03857, S/N 80001–80301 Model 03858, S/N 80001–81418 Model 03859, S/N 80001–81992 Chapter 8 Cutting Units Table of Contents 15 15 16 18 19 20 22 23 24 26 Cutting Units SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . Backlapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bedbar Removal and Installation . . . . . . . . . . . . . Bedknife Replacement and Grinding . . . . . . . . . . Preparing Reel for Grinding . . . . . . . . . . . . . . . . . .
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Specifications Figure 1 REEL CONSTRUCTION: Fairway reels. All welded. 5, 7 or 11 blades. BEDKNIFE AND BEDBAR ADJUSTMENT: Single point adjustment mechanism. HEIGHT OF CUT RANGE: 5 Blade – 3/4” to 1–1/2” 7 Blade – 1/2” to 1–1/8” 11 Blade – 3/8” to 3/4” CLIP FREQUENCY: .375” – 1.25”. Reel speed automatically adjusts to maintain proper clip. Reel speed is continuously calculated based on the current forward speed, reel type (number of blades) and height of cut. Note: Use bedknife Part No.
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Special Tools Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Some tools may have been supplied with your machine or available as TORO parts. Some tools may also be available from a local supplier. Gauge Bar Assembly Use gauge bar to verify height of cut and bedknife attitude. Toro P/N 98–1852 Figure 2 Handle Assembly – TOR299100 For applying lapping compound to cutting units while keep hands a safe distance from the rotating reel.
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Bedknife Screw Tool – TOR510880 This screwdriver–type bit is made to fit Toro bedknife attaching screws. Use this bit with a torque wrench to secure the bedknife to the bedbar. Make sure bedbar threads are clean and use new screws. Tighten screws to a torque of 250 – 300 in.lb. (288 – 345 KgCm) starting in the middle of the bedknife as shown in figure 5. NOTE: Remove all rust, scale and corrosion from bedbar surface before installing bedknife. DO NOT use and air impact wrench with this tool.
PAGE 305
Troubleshooting There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions. Turf conditions such as excessive thatch, “sponginess” or attempting to cut off too much grass height may not always be overcome by adjusting the machine. It is important to remember that the lower the height of cut, the more critical these factors are. Remember that the “effective” or actual height of cut depends on cutting unit weight and turf conditions.
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Factor Possible Problem/Correction 5. Bedknife to reel adjustment. Check bedknife to reel contact daily. Bedknife must have light contact all across reel. No contact will cause cutting edges to become dull. Excessive contact accelerates wear; quality of cut may be adversely affected. Adjust so you paper can be pinched between reel and bedknife without tearing when inserted from the front, and cuts cleanly when inserted at a right angle (along entire length of bedknife).
PAGE 307
Set–up and Adjustments IMPORTANT: Toro strongly recommends the use of a leveling plate when setting–up or adjusting any reel type cutting unit. The leveling plate will help to ensure accurate and consistent adjustments. RIGHT Note: Right and left ends of cutting unit is determined by standing in the operator’s position (Fig. 7). After the cutting unit is unboxed, use the following procedures to assure the cutting units are adjusted properly. 1. Check each end of the reel for grease.
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Bedknife to Reel Adjustment 1. A 19 mm (3/4 inch) wrench will be needed to rotate bedknife adjustment knob. Each notch on the knob will move the bedknife .0005 inches (.013 mm) (Fig. 8). 1 2. Tip cutting unit rearward to gain access to reel and bedknife (Fig. 9). 3. On either end of reel, insert a long strip of dry newspaper between reel and bedknife.
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Cutting Unit Set–up Guide Adjustable front and rear brackets allow infinite adjustment of cuffing unit ”attitude”. Attitude refers to the angle of the knife relative to the ground. Attitude has a significant impact on the performance of the cutting unit. All cutting units on a given machine must be set to the same attitude. In general, less aggressive attitudes are more appropriate for lower heights of cut while, higher heights of cut may require more aggressive attitudes.
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Preliminary Height of Cut and Front Roller Adjustment When setting–up a cutting unit, or if repositioning or installing a front or rear roller to the cutting unit, proceed as follows: 1. Verify reel to bedknife contact before setting height– of–cut. 2. Select initial front roller bracket setting and rear roller position holes for desired height–of–cut (Fig. 11, 12 & CHART). CONTACT ALONG FULL LENGTH AT “A” AND “B” LEVELS FRONT ROLLER TO REEL FRONT ROLLER REAR ROLLER “B” REEL “A” 3.
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Final Height of Cut Adjustment 1. Using a gauge bar, Toro part no. 98–1852 or equivalent (Fig. 15), set head of screw to desired Height–of– Cut. This measurement is from bar face to underside of screw head. FINAL HOC SETTING FRONT ROLLER 2. Place gauge bar across front and rear rollers. Verify at each end (Fig. 16). Adjust as required. IMPORTANT: Set properly, front and rear rollers will contact gauge bar and screw head will be snug over bedknife cutting edge when checked at both ends of the reel.
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Grass Shield and Fin Adjustment Adjust grass shield and/or shield fin angle for desired grass clippings dispersion. For best dispersion under most conditions 1. Position cutting unit on a flat level surface. 2. To adjust fins, unhook and move front mounting tab to the straight ahead or angled position slot. 3. To change grass shield angle, loosen flange head capscrew (Fig. 17) securing shield to left side plate, move shield to desired angle and tighten screw. 3 1 2 Figure 17 1. Shield fin 2.
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Cutting Unit Attitude Adjustment (2 Screw Gauge Bar) The cutting unit attitude may be adjusted or verified using a gauge bar, Toro part no. 98–1852. which has two screws and three hole locations. The second screw is used in the inner hole to set or verify cutting attitude. Adjust as follows: ADJUST FOR FINAL HOC SETTING “B” 1. Set front screw height to final height–of–cut setting (Fig. 18). 2. Set rear screw, distance “B”, lower than front setting (Fig. 18). Figure 18 BEDKNIFE .20” (5.3mm) .15” (3.
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Alternate Adjustments Tractors are setup at the factory appropriately for most fairway mowing applications. The following adjustments are available for fine–tuning of the machine to the application: Adjusting Cutting Unit Stop Chains The lift chain of the cuttings units may be lengthened or shortened to adjust for either ground following or ground clearance of the cutting units. Refer to the cutting unit operator manual for adjusting procedure.
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Service and Repairs Backlapping 6. Select either front or rear on the backlap switch to determine whether front or rear reels will be backlapped. DANGER: To avoid personal injury, be certain that you are clear of the cutting units before proceeding. REELS MAY STALL WHILE BACKLAPPING. DO NOT ATTEMPT TO RESTART REELS BY HAND OR TOUCH REELS WHILE BACKLAPPING. STOP ENGINE AND TURN H.O.C. KNOB ONE POSITION TOWARD ”A”. 7. Move Enable/Disable switch to Enable position.
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Bedbar Removal and Installation 14 1 2 3 4 10 5 31 1 6 15 17 16 18 7 11 17 9 8 23 20 24 25 26 37 47 45 43 36 28 29 27 30 32 1 36 32 42 10 41 40 39 37 35 34 33 4 Figure 21 1. Screw 2. Washer 3. Quad ring 4. Lock nut 5. R.H. pivot hub 6. R.H. side plate 7. Reel frame 8. Bushing assembly 9. Flange bushing 10. Flat washer 11. Grease fitting 14. Plastic bushing 15.
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Remove Bedbar 1 1. Loosen bedknife adjusting knob to loosen bedknife to reel contact. 2 2. Loosen locknut on bedknife adjuster assembly and disengaging adjuster from bedbar. 3. Remove bedbar leveling screw from L.H. side of cutting unit. 4. Remove fasteners securing L.H. and R.H. bedbar pivot hubs to frame. 5. Remove bedbar assembly. 6. Remove capscrew, washer and quad ring from R.H. end of bedbar. Figure 22 1. Bedknife adjusting knob 7. Remove R.H. and L.H. pivot hubs from bedbar. 2. Locknut 8.
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Bedknife Replacement and Grinding 1. Remove bedbar from cutting unit. Use a torque wrench and bedknife screw tool 2. Remove bedknife screws and remove bedknife. 3. Remove all rust, scale and corrosion from bedbar surface before installing new bedknife. 4. Install new bedknife: A. Make sure bedbar threads are clean. B. Use new screws. Apply anti–seize lubricant to screw threads before installing. C. Tighten screws to a torque of 250 – 300 in.lb.
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Preparing Reel for Grinding 1. Check to make sure reel bearings are in good condition and properly adjusted before grinding the reel. Make sure the cutting unit frame and roller brackets are true and not bent or damaged from impacts with trees, posts or cart path edges. Note: When grinding, be careful to not overheat the reel blades. Remove small amounts of material with each pass of the grinder. 4. After completing the grinding process, do a complete set–up and adjustment procedure. 2.
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Reel Removal and Bearing Replacement 1 2 27 3 4 5 6 Use tool TOR4074 to install threaded spline insert. Apply Locite 242 to threads Tighten to 75 – 85 ft–lb (10.4 – 11.8 KgM) 15 24 13 25 Apply anti–sieze lubricant to splines 26 3 27 7 8 9 10 11 12 23 22 21 20 19 18 17 16 4 Pack bearings with No. 2 general purpose grease 15 14 29 28 Use tool TOR4064 Tighten set–screw one–half turn beyond initial contact minimum Figure 27 1. Screw 2. R.H. bearing housing 3. Bearing 4. Grease seal 5.
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4. Inspect bearings and seals. To replace seals and bearings: Remove Reel 1. Remove weight from cutting unit. If equipped with a speed sensor, remove shaft magnet after removing weight and sensor. 2. Remove bedbar assembly. A. Use a bearing puller tool to remove the bearings. To prevent damage to bearings, pull on the inner bearing race. Remove the seals. NOTE: If bearing is removed, the seal should be replaced. 3. Remove front roller assembly. B. Install new seals on the reel shaft.
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Roller and Frame Service 9 10 8 2 1112 7 13 13 – 17 ft–lb (1.8 – 2.4 KgM) 14 6 5 4 2 1 44 15 16 17 18 22 19 3 26 37 23 20 36 21 43 42 24 40 13 – 17 ft–lb (1.8 – 2.4 KgM) 2 27 41 34 13 – 17 ft–lb (1.8 – 2.4 KgM) 22 23 36 24 35 39 2 19 1 17 2 16 15 28 29 14 30 31 37 26 13 – 17 ft–lb (1.8 – 2.4 KgM) 3 38 75 – 85 ft–lb (10.4 – 11.8 KgM) 33 32 Figure 28 1. Angle bracket 2. Lock nut 3. Snap ring 4. HOC Compression Spring 5. Rear HOC support 6. Spacer 7. HOC pin 8.
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Roller Bearing and Seal Replacement 1 2 3 5 6 7 8 9 4 Sharp edge out 7 9 8 6 5 3 2 4 1 Lip of seal facing in Figure 29 4. Roller shaft 5. Inner seal 6. Outer seal 7. Retaining ring 8. Outer oil seal 9. Washer NOTE: Bearing and seal configurations are the same for both the front and rear rollers. B. Install roller shaft from opposite end of roller. Be carefull not to damage the inner oil seals. Remove Seals and Bearings C.
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Cutting Unit Installation Cutting unit models 03857, 03858, and 03859 can be installed at any of the five mounting locations on the traction unit. Figure 1 shows the orientation of the hydraulic drive motor for each of the five locations. For any of the locations requiring the motor to be mounted on the right end of the cutting unit, install a counter weight on the left end of the cutting unit.
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6. Insert a thrust washer onto horizontal shaft of pivot knuckle as shown in figure 32. 5 7. Insert the horizontal shaft of the pivot knuckle into the mounting tube of the carrier frame (Fig. 32). 8. Secure pivot knuckle to carrier frame with a thrust washer, flat washer and a flange head capscrew (Fig. 32). 9. Insert a thrust washer onto vertical shaft of pivot knuckle (Fig. 32). 10. Insert the vertical shaft of the pivot knuckle into lift arm pivot hub (Fig. 32).
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Greasing Bearings, Bushings and Pivot Points IMPORTANT: Lubricating cutting units immediately after washing helps purge water out of bearings and increases bearing life. Each cutting unit has (6) grease fittings (Fig. 34) that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. The grease fitting locations shown in figure 34 are for each side of cutting unit. IMPORTANT: Lubricating cutting units immediately after washing helps purge water out of bearings and increases bearing life.
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Chapter 8.1 Model 03857, S/N 80302 & Up Model 03858, S/N 81419 & Up Model 03859, S/N 81993 & Up Cutting Units Table of Contents 19 19 20 20 21 21 22 24 25 26 28 29 30 32 33 Cutting Units SPA (Single Point Adjustment) Spring . . . . . . . . . Cutting Unit Lowering Rate Adjustment . . . . . . . . Lifted Height of Outer Front Cutting Units . . . . . . Travel of Front Three Cutting Units . . . . . . . . . . . SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . Backlapping . . . . . . . . . . . .
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Specifications Figure 1 Reel Construction: Fairway reels. All welded. 5, 7 or 11 blades. Height Of Cut Range: 5 Blade – 3/4” to 1–1/2” (19–38 mm) 7 Blade – 1/2” to 1–1/8” (13–29 mm) 11 Blade – 3/8” to 3/4” (10–19 mm) NOTE: Use bedknife Part No. 93–9774 for height–of– cuts below 1/2” (13 mm). Reel Diameter: 7 in. (178 mm) Power Attachment: Reel motors feature quick disconnect for removal or installation onto cutting unit. Cutting units can be driven from either end.
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Special Tools Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Some tools may have been supplied with your machine or available as TORO parts. Some tools may also be available from a local supplier. Gauge Bar Assembly Use gauge bar to verify height of cut and cutting unit attitude. Toro P/N 98–1852 Figure 2 Angle Indicator Use angle indicator to measure and set cutting unit attitude.
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Bedknife Screw Tool TOR510880 This screwdriver–type bit is made to fit Toro bedknife attaching screws. Use this bit with a torque wrench to secure the bedknife to the bedbar. Make sure bedbar threads are clean and use new screws. Tighten screws to a torque of 250 – 300 in.lb. (288 – 345 KgCm) starting in the middle of the bedknife as shown in figure 5. NOTE: Remove all rust, scale and corrosion from bedbar surface before installing bedknife. DO NOT use and air impact wrench with this tool.
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Troubleshooting There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions. Turf conditions such as excessive thatch, “sponginess” or attempting to cut off too much grass height may not always be overcome by adjusting the machine. It is important to remember that the lower the height of cut, the more critical these factors are. Remember that the “effective” or actual height of cut depends on cutting unit weight and turf conditions.
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Factor Possible Problem/Correction 5. Bedknife to reel adjustment. Check bedknife to reel contact daily. Bedknife must have light contact all across reel. No contact will cause cutting edges to become dull. Excessive contact accelerates wear; quality of cut may be adversely affected. Adjust so you paper can be pinched between reel and bedknife without tearing when inserted from the front, and cuts cleanly when inserted at a right angle (along entire length of bedknife).
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Set–up and Adjustments IMPORTANT: To insure proper setting of height–of–cut, these procedures must be followed in this order: A. Adjusting (Parallel) Bedknife To Reel NOTE: Right and left ends of cutting unit is determined by standing with the rear roller in front of you (Fig. 8). RIGHT B. Setting Cutting Unit Attitude OPERATOR C. Leveling Front Roller D. Finalizing Height–of–Cut IMPORTANT: Each cutting unit must be set consistently.
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A. Adjusting (Parallel) Bedknife to Reel IMPORTANT: The reel and bedknife must be parallel to insure the cutting unit cuts grass across the bedknife, and the reel and bedknife wear evenly. 1 NOTE: Toro recommends light contact between the reel and bedknife. However, for dry and/or sparse conditions a .001–.002” (.03–.05 mm) clearance may be required to prevent heat buildup which can cause uneven wear in the reel and bedknife. NOTE: A 3/4 inch (19 mm) wrench is needed to rotate bedknife adjustment knob.
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B. Setting Cutting Unit Attitude – New Cutting Units IMPORTANT: Cutting unit “attitude” has a significant impact on the performance of the cutting unit. Attitude refers to the angle of the knife relative to the ground (Fig. 12). Adjustable front and rear brackets allow for variable adjustment of cutting unit attitude within the height–of– cut range. All cutting units on a given machine must be set to the same attitude, if not - after cut appearance will be negatively affected.
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ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ
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3. Set the rear support bracket and side plate using the approximate dimensions given by Table 1. The rear support bracket is either in the top or bottom location, and the side plate location can be in holes 1 thru 4, with 1 being the top hole (Fig. 15). 4. With the cutting unit rotated vertical, place gauge bar across front and rear rollers. The first screw head should fit snugly over edge of bedknife and the end of second screw should contact bottom of bedknife (Fig. 16).
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B. Checking or Adjusting Attitude – Used Cutting Units NOTE: As a starting point for adjusting cutting unit attitude, the cutting unit may be set up using the dimensions from TABLE 1. However, because of wear on the bedknife and reel, either the First or Second Method must be used to insure the correct setting of the attitude. 3 FIRST METHOD (Angle Indicator): 1. Rotate cutting unit backwards to gain access to reel and bedknife. 2. Place an angle indicator, Toro part no.
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SECOND METHOD (Screw Height Difference) : 1. Rotate cutting unit backwards to gain access to reel and bedknife. 2. Using a two–screw gauge bar, Toro part no. 98–1852, set first screw to desired Height–of–Cut. 1 3. Place the gauge bar across front and rear rollers. The first screw head needs to fit snugly over edge of the bedknife, while the gauge bar contacts the front roller (Fig. 20). NOTE: The rear roller does not have to contact the gauge bar. 2 1 Figure 21 1. 1st screw 2. 2nd screw 6.
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ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ TABLE 2 - USED CUTTING UNIT SET UP GUIDE Attitude (degrees) 1 2 3 4 5 6 7 8 Screw Height Difference (in) (mm) 0.028 0.72 0.057 1.44 0.085 2.16 0.114 2.89 0.142 3.61 0.171 4.34 0.200 5.07 0.228 5.80 9. Put 1st screw back to the normal position (screw head hooks over bedknife) and set to desired height of cut (Fig. 20) 10.
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D. Finalizing Height–of–Cut IMPORTANT: Adjusting (Parallel) bedknife to reel, setting cutting unit attitude, and leveling the front roller must be completed before finalizing height of cut. 1. Using a two–screw gauge bar, Toro part no. 98–1852, set first screw to desired Height–of–Cut. This setting is from the bar face to the underside of the screw head (Fig. 25). 1 2. With the cutting unit rotated backwards, place gauge bar across front and rear rollers.
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Front Shield and Fins Adjustment Adjust front shield and/or shield fin angle for desired grass clippings dispersion. 1. Position cutting unit on a flat level surface. 2. To adjust fins (Fig. 28), unhook and move front mounting tab to the straight ahead or angled position slot. 1 3. To change front shield angle, loosen flange head capscrew securing shield to right side plate, move shield to desired angle and tighten screw. 2 3 Figure 28 1. Shield fin 2. Front grass shield 3.
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Turf Compensation Spring Adjustment The Turf Compensation Spring (Fig. 30), connecting carrier frame to cutting unit, controls the amount of fore– aft rotation available, as well as the amount of ground clearance in transport and turn around. ÇÇÇ ÇÇ ÇÇÇ ÇÇ ÇÇÇ ÇÇ “B” “C” “A” The Turf Compensation Spring also transfers weight from the front to rear roller. This helps to reduce a wave pattern in the turf, also known as bobbing.
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Reel Bearing Adjustment To insure long life of the reel bearings, periodically check if reel end play exits. The reel bearings can be checked and adjusted as follows: 1 1. Loosen reel to bedknife contact by turning the bedknife adjusting knob counter–clockwise until no contact exists. 2. Hold on to the reel shaft and try to move the reel assembly side to side. 3. If end play exists, proceeded as follows: A.
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SPA (Single Point Adjustment) Spring If single point adjustment assembly (Fig. 41) is removed for servicing, make sure spring is compressed to a length of 1.25” (32 mm). This adjustment is attained by tightening nut on SPA knob shaft. 1.25” (32mm) 2 1 Figure 34 1. Single point adjust assembly 2. Adjusting nut Cutting Unit Lowering Rate Adjustment (Outer front cutting units only – #4 and #5 The cutting unit lift circuit is equipped with a adjustable valve to ensure the front cutting units lower evenly.
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Lifted Height of Outer Front Cutting Units (Enable Position) The turnaround height of the front outer cutting units (#4 & #5) may be increased to provide additional ground clearance on contoured fairways. Contact your distributor for assistance. Travel of Front Three Cutting Units Additional downward travel of the front three cutting units may be desirable in highly contoured locations.
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Service and Repairs Backlapping DANGER REELS MAY STALL WHILE BACKLAPPING. DO NOT ATTEMPT TO RESTART REELS BY HAND OR TOUCH REELS WHILE BACKLAPPING. STOP ENGINE AND TURN H.O.C. KNOB ONE POSITION TOWARD ”A”. NOTE: When backlapping, the front units all operate together, and the rear units operate together. 1. Position the machine on a level surface, lower the cutting units, stop the engine, engage the parking brake, and move the Enable/Disable switch to disable position. 2.
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Bedbar Removal and Installation 14 1 2 3 4 10 5 31 1 6 15 17 16 18 7 11 17 9 8 23 20 24 25 26 37 47 45 43 36 28 29 27 30 32 1 36 32 42 10 41 40 39 37 35 34 33 4 Figure 39 1. Screw 2. Washer 3. Quad ring 4. Lock nut 5. R.H. pivot hub 6. R.H. side plate 7. Reel frame 8. Bushing assembly 9. Flange bushing 10. Flat washer 11. Grease fitting 14. Plastic bushing 15.
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Remove Bedbar 1 3. Loosen bedknife adjusting knob to loosen bedknife to reel contact. 2 4. Loosen locknut on bedknife adjuster assembly and disengaging adjuster from bedbar. 5. Remove bedbar leveling screw from L.H. side of cutting unit. 6. Remove fasteners securing L.H. and R.H. bedbar pivot hubs to frame. 7. Remove bedbar assembly. 8. Remove capscrew, washer and quad ring from R.H. end of bedbar. 9. Remove R.H. and L.H. pivot hubs from bedbar. Figure 40 1. Bedknife adjusting knob 2. Locknut 10.
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Bedknife Replacement and Grinding 1. Remove bedbar from cutting unit. Use a torque wrench and bedknife screw tool 2. Remove bedknife screws and remove bedknife. 3. Remove all rust, scale and corrosion from bedbar surface before installing new bedknife. 4. Install new bedknife: A. Make sure bedbar threads are clean. B. Use new screws. Apply anti–seize lubricant to screw threads before installing. C. Tighten screws to a torque of 250 – 300 in.lb.
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Preparing Reel for Grinding 1. Check to make sure reel bearings are in good condition and properly adjusted before grinding the reel. Make sure the cutting unit frame and roller brackets are true and not bent or damaged from impacts with trees, posts or cart path edges. Note: When grinding, be careful to not overheat the reel blades. Remove small amounts of material with each pass of the grinder. 4. After completing the grinding process, do a complete set–up and adjustment procedure. 2.
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Reel Removal and Bearing Replacement 1 2 27 3 4 5 6 Use tool TOR4074 to install threaded spline insert. Apply Locite 242 to threads Tighten to 75 – 85 ft–lb (10.4 – 11.8 KgM) 15 24 13 25 Apply anti–sieze lubricant to splines 26 3 27 7 8 9 10 11 12 23 22 21 20 19 18 17 16 4 Pack bearings with No. 2 general purpose grease 15 14 29 28 Use tool TOR4064 Tighten set–screw one–half turn beyond initial contact minimum Figure 45 1. Screw 2. R.H. bearing housing 3. Bearing 4. Grease seal 5.
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4. Inspect bearings and seals. To replace seals and bearings: Remove Reel 1. Remove weight from cutting unit. If equipped with a speed sensor, remove shaft magnet after removing weight and sensor. 2. Remove bedbar assembly. A. Use a bearing puller tool to remove the bearings. To prevent damage to bearings, pull on the inner bearing race. Remove the seals. NOTE: If bearing is removed, the seal should be replaced. 3. Remove front roller assembly. B. Install new seals on the reel shaft.
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Roller and Frame Service 9 10 55 8 1112 7 13 13 – 17 ft–lb (1.8 – 2.4 KgM) 14 6 5 4 2 1 15 16 17 18 53 19 3 48 26 37 44 45 51 36 20 21 43 42 24 40 13 – 17 ft–lb (1.8 – 2.4 KgM) 50 46 41 13 – 17 ft–lb (1.8 – 2.4 KgM) 34 52 36 47 50 24 54 35 48 50 49 28 19 1 17 2 16 15 29 14 30 31 37 26 38 13 – 17 ft–lb (1.8 – 2.4 KgM) 3 75 – 85 ft–lb (10.4 – 11.8 KgM) 33 32 Figure 46 1. Angle bracket 2. Lock nut 3. Snap ring 4. HOC compression spring 5. Rear HOC spacer 6.
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Roller Bearing and Seal Replacement 1 2 3 5 6 7 8 9 4 Sharp edge out 7 9 8 6 5 3 2 4 1 Lip of seal facing in Figure 47 4. Roller shaft 5. Inner seal 6. Outer seal 7. Retaining ring 8. Outer oil seal 9. Washer NOTE: Bearing and seal configurations are the same for both the front and rear rollers. B. Install roller shaft from opposite end of roller. Be carefull not to damage the inner oil seals. Remove Seals and Bearings C.
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Cutting Unit Installation IMPORTANT: All Reelmaster 6000 Series must have the on-board controller (ECU) configured for the installed cutting units, otherwise the cutting unit drive circuits will not function. Refer to configuration instrucĆ tions in this manual. Cutting unit models 03857, 03858, and 03859 can be installed at any of the five mounting locations on the traction unit. Figure 46 shows the orientation of the hydraulic drive motor for each of the five locations.
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6. Insert a thrust washer onto horizontal shaft of pivot knuckle as shown in figure 51. 5 7. Insert the horizontal shaft of the pivot knuckle into the mounting tube of the carrier frame (Fig. 51). 8. Secure pivot knuckle to carrier frame with a thrust washer, flat washer and a flange head capscrew (Fig. 51). 9. Insert a thrust washer onto vertical shaft of pivot knuckle (Fig. 51). 3 10. Insert the vertical shaft of the pivot knuckle into lift arm pivot hub (Fig. 51).
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Cutting Unit Selection The Controller must be programmed with the Blade configuration (number of Blades) on the installed cutting units in order for the ClipAceT feature to operate properly. If the Blade configuration is not set, the cutting units will not operate in the mow position. IMPORTANT: Do not sit in the seat. Closed Seat Switch will void this procedure! 1. Rotate ignition key to Off position. 2. Connect the Hand held Diagnostic Tool to the Controller Loopback Connector (remove overlays). 3.
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Greasing Bearings, Bushings and Pivot Points IMPORTANT: Lubricating cutting units immediately after washing helps purge water out of bearings and increases bearing life. Each cutting unit has (7) grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. The lubrication points are front roller (2), rear roller (2), reel bearing (2), and bedknife adjuster. (2) 1. Wipe each grease fitting with a clean rag. 2. Apply grease until pressure is felt against handle. (2) 3.
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Cutting Units Model 03857, S/N 80302 & Up Model 03858, S/N 81419 & Up Model 03859, S/N 81993 & Up Page 8.1 – 34 Rev.
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Chapter 9 Wire Harness Wire Harness Diagram Table of Contents WIRE LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 WIRE HARNESS DIAGRAM . . . . . . . . . . . . . . . . . . . . 5 Reelmaster 6500–D/6700–D Page 9 – 1 Rev.
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WIRE NO. COLOR CONNECTOR LOCATION A CONNECTOR LOCATION B 1 BLACK HARNESS GROUND SPLICE A GROUND TO FRAME 2 BLACK HARNESS GROUND SPLICE G OPTIONAL LIGHTS 3 BLACK HARNESS GROUND SPLICE A LIFT ARM SENSOR – FRONT 4 BLACK HYD. SOLENOID S5A HARNESS GROUND SPLICE A 5 BLACK HYD. SOLENOID S6A HARNESS GROUND SPLICE A 6 BLACK HYD. SOLENOID S1B HARNESS GROUND SPLICE C 7 BLACK HARNESS GROUND SPLICE A HARNESS GROUND SPLICE B 8 BLACK HYD.
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67 RED / WHITE CONTROLLER (C/N 1) BACKLAP SWITCH 68 RED / WHITE CONTROLLER (J3) (CAN +) HARNESS CAN + SPLICE 69 Not Used 70 TAN CONTROLLER (C3) SEAT SWITCH 71 VIOLET CONTROLLER (D2) JOYSTICK RAISE 72 VIOLET / RED CONTROLLER (B/M 3) KEY START (S) 73 VIOLET / RED CONTROLLER (A3) HYD.
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134 BLACK HYD. SOLENOID VS1B HARNESS GROUND SPLICE C 135 BLACK HYD.
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TEMP GAUGE 408 RANGE / DIAGNOSTIC SPEEDOMETER LIGHT IGNITION 86A 76A 97A 41B S REEL SPEED SENSOR REAR LEFT 72B B 45B F E D 110B IGNITION ”I” 96A A 112B 113B A B ”A” 4B 1A 40A 5B 7A 3A 23A 13B 12B 54B A B 125B ABC 2B FRAME GROUND 50B 59B A B 39B 97B 98B 99B REELS ENABLE 2 3 125A 124B 3 4 139A 124B 4 1 3 92B 2 4 38B 3 64B 109A 89B 124A 109A 5 6 142B 141B 143B 138B 122A 22B 5 88B WARNING 6 80B LIGHT HARNESS #1 S7A A B 90B 94A 37B 87B FUEL SENDOR17B A B A B 120B
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TEMP GAUGE 408 RANGE / DIAGNOSTIC SPEEDOMETER LIGHT IGNITION 86A 76A 97A 41B S REEL SPEED SENSOR REAR LEFT 72B B 45B F E D 110B IGNITION ”I” 96A A 112B 113B A B ”A” 4B 1A 40A 5B 7A 3A 23A 13B 12B 54B A B 125B ABC 2B FRAME GROUND 50B A B 59B REELS ENABLE 1 150A 96B 2 3 125A 124B 3 4 139A 124B 4 1 3 92B 2 4 38B 3 64B 109A 89B 124A 109A 5 6 142B 141B 143B 138B 122A 22B 5 88B WARNING 6 80B LIGHT HARNESS #1 S7A A B 90B 94A 37B 87B FUEL SENDOR17B A B A B 120B 4A 4