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1. mE 8 R BK R RUN SOLENOID ALTERNATOR 1A 20 w 9 7e ENGINE OIL PRESSURE SW 2E w 2 R OVER TEMP SHUTDOWN SW 2A PK GLOW PLUGS 3 12 OR OR e PK g Ww GY BU W OR GN DAIHATSU 52 9 GLOW PLUG amp z CONTROLLER H o o uv B E 5 5 5 9 1 4 x 8 5 o IE gt 2 5 HR HOUR METER o 9 e 5 6 C 75 OHM R BK A FL va V Rer p fms PK 1 jstot q BK t BK BU PK 2B 2 A START 442v 1 BU lt gt 2 8 OVER TEMP SHUTDOWN PTO COL 1 B BU W gt BN 2F 2A 2 C IGN SW RUN 1 C W BK lt gt R BK 1B 2 0 PARKING BRAKE sw 1 D ENGINE o o OR lt gt a ENGINE GROUND PARKING BRAKE SW 25 2 BACKLAP OVER TEMP WARNING 1 E o Y 2 SEAT SW GROUND 1 F GY GY lt gt SEAT SW es 2 6 NEUTRAL SW 2 GN lt R oe NEUTRAL SW 2 H IGN SW 75 SCM FRAME GROUND 1 lt BATTERY 2H 2 OPTIONAL SEAT SW 1 D lt BK STOP NONE x RUN B I A X Y GN o o BN START 8 5 REEL UP REEL DRIVE LIMIT SW x SOLENOID D3 IN UP POSITION 1 2 IGNITION SW 7 GN OFF RUN START 15 1F 4 10A P 4 TN BN OR Y 3 W
2. P18 WARNING LIGHTS P32 RESISTOR P3 GLOW CONTROLLER SEAT SW 42 A 8 3 02 lt 4 6 gt 64013 Sid giz P12 FUSE BLOCK SP5 P7 COIL SP7 P21 SEAT SW Ph STARTER B P20 NEUTRAL SW P1 PARKING BRAKE Reelmaster 2000 D Main Wire Harness Serial Number Above 230000000 Page 8 13 Rev ALTERNATOR B FUEL SOL HIGH TEMP SW OIL PRESSURE SW STARTER GLOW PLUGS GROUND P8 J3 P23 J6 P2 P3 JI J4 R L z xi RED BLACK j BACKLAP pa YELLOW m im 8 BLACK I 5 z lt x m tr G 0 tr ORANGE R a START Cite TEMP P33 OIL INTERCONNECT L t x FUEL F BACK L
3. NOT SUPPLIED F3 104 gt ES Y BU w OPTIONAL LIGHT T REELS ON OFF IN OFF ee BE _ 8 6 Rev A ar GLOW PLUGS 3 PK as fYYY GLOW PLUS GLOW RELAY DAIHATSU E icu EE VIO 1 h 5 6 BK B R BK R RUN SOLENOID L ALTERNATOR HOUR METER OVER TEMP SHUTDOWN BU W ENGINE DIL PRESSURE 2 Gy GY A euw GN 5 amp a rd e tt 8 i 5 START MY A o mE ed PK HIGH TEMP SW PTO COIL TER di g i 2 IGN SW 717 RUN REEL UP E i i OPTIONAL SEAT SW gt REEL DRIVE gt PARKING BRAKE ENGAGED i Bc PARKING BRAKE LIMIT SW 03 SOLENOID ENGINE 1 2 or 2 B IN UP POSITION E BACKLAP IN OFF 25 BACKLAP NOT USED ENGINE GROUND bee mem dgcecc Bo Y amp E z gt y VEA it A 24 stat sw GROUND PK NEUTRAL SW 2 NEUTRAL SW ERR SEAT SW EE UNOCCUPIED IN NEUTRAL 2 H IGN SW 75 BN e BK ee 3WD 1 BK Bk SOLENOID FRAME GROUND BATTER IF EQU
4. FROM LEFT WHEEL MOTOR T2 HYDRAULIC MANIFOLD Working Pressure Low Pressure Charge Return or Suction Flow Figure 17 Hydraulic System Page 4 22 Reelmaster 2000 D Procedure for Mow Circuit Working Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Park machine on a level surface with the cutting units lowered and off Make sure engine is off 3 Read Precautions For Hydraulic Testing 4 Connect pressure test gauge with a hydraulic hose attached to the reel circuit test port on the hydraulic man ifold Fig 18 Make sure gauge hose is long enough so the operator can read gauge while driving the machine 5 Make sure backlap knob on the hydraulic manifold is Figure 18 in the mow position Adjust reel speed knob for typical 1 Hydraulic manifold 2 Test port mowing conditions A CAUTION Keep away from reels during test to prevent per sonal injury from the rotating reel blades 6 Start engine and move throttle to full speed 3200 50 RPM Engage the cutting units 7 Watch pressure gauge carefully while mowing with the machine 2 2 gt lt 8 Reel circuit pressure should be about 600 PSI 9 Disengage cutting units Shut off engine 10 Disconnect test gauge with hose from manifold test port Reelmaster 2000 D Page 4 23 Hyd
5. P18 WARNING LIGHTS P20 NEUTRAL SW P32 P12 RESISTOR FUSE BLOCK P13 R GLOW CONTROLLER A 3 2 1 B EA 9 5r CZ CJ C8 C8 o o C3 CX 4 PL STARTER B m gt 6 3 5 5 PT 3 coi SP7 A PA Goa 1 PARKING BRAKE P21 Reelmaster 2000 D ee Main Wire Harness 0 Serial Number Below 230000000 5 Page 8 11 Rev INTERCONNECT STARTER B REELS ON IGNITION SWITCH P33 P4 P35 Je P6 X YA BS B D E F 6 H J Ae 76 IB 2A 28 1 i 23 4 5 GREEN RED PARKING BLACK ORANGE 2 BRAKE SW ORANGE 3 5 BLUE 4 FUSE BLOCK e TAN 5 6 NEUTRAL SW 12 YELLOW BLACK nz PI
6. 1 Diode 2 Male terminal Electrical System Page 5 24 Figure 28 3 Female terminal Reelmaster 2000 D Service and Repairs NOTE See the Briggs amp Stratton Daihatsu Engine Re pair Manual for more component repair information Battery Storage If the machine will be stored for more than 30 days 1 Remove the battery and charge it fully see Battery Service 2 Either store battery on a shelf or on the machine 3 Leave cables disconnected if the battery is stored on the machine Battery Care 1 Battery electrolyte level must be properly main tained The top of the battery must be kept clean If the machine is stored in a location where temperatures are extremely high the battery will run down more rapidly than if the machine is stored in a location where temper atures are cool Wear safety goggles and rubber gloves when working with electrolyte Charge battery in a well ventilated place so gasses produced while charging can dissipate Since the gases are explosive keep open flames and electrical sparks away from the battery do not smoke Nausea may result if the gases are inhaled Un plug charger from electrical outlet before con necting or disconnecting charger leads to or from battery posts IMPORTANT Do not remove battery fill caps while cleaning 2 Check battery condition weekly or after every 50 hours of operation Keep terminals and entire batt
7. a 21 8111081 02 03395 1338 A 3100 10 83538 S81 5 7 33 138 1411 C did AYD 4 34 100 1 08 NI Nid WW 10045 381 9 390 FATWA MOSH JHL 51835244284 108845 5161 23108 1331 40104 1334M E Gun Gun NOUS MY04 358 3438 lt gt 142 14H 14055444 398 2 WON NON2IW Ol 401 43100 AINN 11084 142 131 IMYA 1081002 1317 1338 eet un 2 F L amp T 8149 8 gol INYA SSvd A8 W01109 8u3M0T V V 401 3ATVA 3SH3A38 aay M303 1 918 80104 1433H M Page 4 8 Reelmaster 2000 D Hydraulic System Traction Circuit Forward Direction The traction pump is driven by the engine through the pulleys and pump drive belt The traction circuit of the hydraulic system acts essentially as a closed loop Tak ing its suction directly from the return side of the wheel motors of the traction circuit the traction pump supplies oil flow to the wheel motors through the supply side of the traction circuit With the engine running and the traction pedal in the neutral position the traction pump supplies no flow to the wheel motors When the traction pedal is pressed to the forward position the linkage from the pedal posi tions the swash plate in the traction pump so
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9. Figure 3 1 Speedcontrol lever 3 Cable clamp 2 Throttle control cable 4 High speed screw Figure 4 1 Speedcontrol lever 3 Locknut 2 High speed screw 3 2 1 FN an G o IN gt Figure 5 1 Speed control lever 3 Lock nut 2 Idle speed screw Reelmaster 2000 D Page 3 5 Engine Service and Repairs Fuel System Thread locking 30 to 60 in Ib 3 4 to 6 8 Figure 6 1 Fueltank 6 Fuel shut off 11 Washer 2 Fuelcap 7 Hose clamp 12 Cap screw 3 Hose clamp 8 Fuel hose 13 Fuel fitting 4 Fuel hose 9 Return fuel hose from injector pump 14 Fuel filter water separator 5 Fuel hose to injector pump 10 Tank mount grommet 15 Fuel fitting Engine Page 3 6 Reelmaster 2000 D Because diesel fuel is highly flammable use caution when storing or handling it Do not smoke while filling the fuel tank Do not fill fuel tank while engine is running hot or when ma chine is in an enclosed area Always fill fuel tank outside and wipe up any spilled diesel fuel be fore starting the engine Store fuel in a clean safety approved container and keep cap in place Use diesel fuel for the engine only not for any other purpose Check Fuel Lines and Connections Check fuel lines and connections periodically as recom mended in the Traction Unit Operator
10. 14 Adjust Throttle Control 5 Engine Installation 17 Adjust Engine Speed 5 Engine PTO Beet nha aces 19 BRIGGS amp STRATTON DAIHATSU ENGINE REPAIR MANUAL Reelmaster 2000 D Page 3 1 Engine Introduction This Chapter gives information about specifications troubleshooting testing and repair of the Briggs amp Stratton Daihatsu diesel engine used in the Reelmaster 2000 D Most repairs and adjustments require tools which are commonly available in many service shops Special tools are described in the Special Tools section The use of some specialized test equipment is explained How Engine Page 3 2 ever the cost of the test equipment and the specialized nature of some repairs may dictate that the work be done at an engine repair facility Service and repair parts for Briggs amp Stratton Daihatsu diesel engines are supplied through your local Toro Dis tributor If no parts list is available be sure to provide your distributor with the Toro model and serial number Reelmaster 2000 D Specifications Item Description Make Designation Briggs amp Stratton Daihatsu 4 stroke Liquid Cooled OHV Diesel Number of Cylinders Bore x Stroke mm in 68 x 78 2 68 x 3 07 Total Displacement cc cu in 850 51 9 Compression Ratio 24 5 1 Firing Order 1 2 3 Dry We
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12. N gt gt N T 3 Lubricate the O ring with a light coating of oil CSS Back up Washer 4 Turn back the jam nut as far as possible Make sure the back up washer is not loose and is pushed up as far as possible Step 1 O Ring 5 Install the fitting into the port and tighten finger tight Figure 4 until the washer contacts the face of the port Step 2 6 To put the fitting in the desired position unscrew it by the required amount but no more than one full turn Step 3 7 Hold the fitting in the desired position with a wrench and turn the jam nut with another wrench to the correct Flats From Finger Tight F F F T Step 4 Size F F F T 4 1 4 in nominal hose or tubing 1 00 0 25 6 3 8 in 1 50 0 25 8 1 2 in 1 50 0 25 10 5 8 in 1 50 0 25 12 3 4 in 1 50 0 25 16 1 in 1 50 0 25 Figure 5 Reelmaster 2000 D Page 4 5 Hydraulic System Towing Traction Unit IMPORTANT If towing limits are exceeded severe damage to the piston pump may occur If it becomes necessary to tow or push the machine tow or push at a speed below 3 mph 4 8 kph and for a distance less than 1 4 mile 0 4 km The piston trac tion pump is equipped with a by pass valve that needs to be turned 90 for towing See Traction Unit Operator s Manual for Towing Procedures Check Hydraulic Fluid The Reelmaster 2000 0 hydraulic system is designed to operate on anti wear hydraulic fluid Th
13. 95 189 32 6 4 284 378 9 6 12 8 473 568 16 0 19 2 662 22 4 756 25 6 852 28 8 o 946 32 0 Reelmaster 2000 D Page 4 15 Figure 13 Hydraulic System 2 2 gt Troubleshooting The cause of an improperly functioning hydraulic sys tem is best diagnosed with the use of proper testing equipment and a thorough understanding of the com plete hydraulic system A hydraulic system with an excessive increase in heat or noise has a potential for failure Should either of these conditions be noticed immediately stop the machine turn off the engine locate the cause of the trouble and correct it before allowing the machine to be used again Continued use of an improperly functioning hydraulic system could lead to extensive internal component damage The charts that follow contain information to assist in troubleshooting There may possibly be more than one cause for a machine malfunction Refer to the Testing section of this Chapter for precau tions and specific test procedures Hydraulic oil leaks Hydraulic system operates hot Hydraulic System Page 4 16 Reelmaster 2000 D Reelmaster 2000 D Page 4 17 Hydraulic System S 5 gt lt System Problem Possible Cause Cutting units will not lift or lift slowly Engine speed is too low
14. 4 462 gt SEAT SW pt NEUTRAL SW 2 NEUTRAL SW a e Bk OCCUPIED 1 NEUTRAL 2 IGN sw 757 BN f YYYY VIO 3WD BK SOLENOID ie IF EQUIPPED FRAME GROUND EP 1 15 OHM Y STANDARD CONTROL MODULE 1 A H REELS ON OFF IN OFF 6 8 gag R p BK ee uer es TP iq STOP NONE EJ E RUN X Y START 8 15 T IGNITION SW OFF RUN START FL 704 gt 10 T VIO F2 10A 5 Y BU 1 o OPTIONAL LIGHT INOT SUPPLIED 10 P vB GLOW PLUGS 3 8s NTRI R aw PLUS GLOW RELAY DAIHATSU T vio H Li BK d 5 BK Reelmaster 2000 D Run Transport Circuit Serial Number Below 230000000 Shown Power Current Control Current Indicator Gauge Current Logic Direction Page8 7 Rev a lt R BK lt R TE RUN SOLENOID L ALTERNATOR gt 1 i HOUR METER D Y OVER TEMP SHUTDOWN 1 s BU W 1 ENGINE OIL PRESSURE e GY z Y R PK ES Ir I E a
15. 1 2 8 HIGH TEMP SW Coll q D G QQ i BS IGN SW 717 RUN 2 PN y REEL DRIVE 1 2 SW 1 1 DPTIONAL SEAT SW M 1 8 d enne E RENE eto swine LIMIT SW 03 SOLENOID 1 1 1 3 OR 2 2 f ORANE 025 5 T LIN UP POSITION 2 1 ENGINE E 1 BACKLAP IN OFF 2 BACKLAP NOT USED cs Uv Y E T 2 iS SEAT SW BK BK oY oY S PK ETW NEUTRAL SW oi 2j NEUTRAL SW Wi 9 S BK UNOCCUPIED IN NEUTRAL 22 IGN SW 757 BN WD d 8K SOLENOID FRAME GROUND BATTERY 15 OHM IF EQUIPPED STANDARD CONTROL MODULE REELS ON OFF IN OFF 1 4 T DE BK o a STOP NONE RUN 1 X Y START 84155 IGNITION SW OFF RUN START B OSA Fe 10A B 1 OR Y jos e F3 104 F2 10 L x Y 9 o OPTIONAL LIGHT NOT SUPPLIED 30 R iin GLOW PLUGS 3 1 85 86 CONTROLLER GLOW GLOW RELAY DAIHATSU 10 H e BK ME 5 BK Reelmaster 2000 D Electrical Schematic Serial Number Below 230000000 All relays and solenoids are shown as de energized All ground wires are black Page 8 Rev A
16. 10 Remove air cleaner see Air Cleaner Removal 11 Remove throttle cable from injector pump Fig 12 A Loosen swivel clamp cap screw enough to sepa rate the throttle cable from the swivel clamp on the injector pump speed control lever B Loosen cable clamp screw Remove throttle cable from the injector pump C Position throttle cable away from the engine Engine Page 3 14 Figure 10 1 Left fender 5 Leftfootrest 2 Leftfender bracket 6 Clinch nut 3 Cap screw 7 Flange head screw 4 Flange nut 8 Grass shield Figure 11 3 Brake lever 1 Cotter pin 2 Brake rod Reelmaster 2000 D 12 Close fuel tank shut off valve 13 Disconnect hoses from engine A Loosen clamps and disconnect upper and lower radiator hoses from the engine B At injector pump loosen hose clamp and discon nect fuel hose from the fuel filter water separator Fig 12 Plug hose to prevent leakage and contami nation C At injector pump loosen hose clamp and discon nect the return to tank fuel hose Fig 12 Plug hose to prevent leakage and contamination Figure 12 14 Disconnect electrical connections 1 Injector pump 4 Fuelline from filter 2 Swivel clamp and screw 5 Fuelline return to tank 3 Cable clamp 6 Fuel line injector return NOTE Label all electrical leads for reassembly pur poses A Unplug connector with pink and white wires fro
17. 25 003 1 2 0 5000 12 700 1 1 000 25 400 1 mm 0 03937 in 0 001 in 0 0254 mm U S to Metric Conversions To Convert Into Multiply By Linear Miles Kilometers 1 609 Measurement Yards Meters 0 9144 Feet Meters 0 3048 Feet Centimeters 30 48 Inches Meters 0 0254 Inches Centimeters 2 54 Inches Millimeters 25 4 Area Square Miles Square Kilometers 2 59 Square Feet Square Meters 0 0929 Square Inches Square Centimeters 6 452 Acre Hectare 0 4047 Volume Cubic Yards Cubic Meters 0 7646 Cubic Feet Cubic Meters 0 02832 Cubic Inches Cubic Centimeters 16 39 Weight Tons Short Metric Tons 0 9078 Pounds Kilograms 0 4536 Ounces Grams 28 3495 Pressure Pounds Sq In Kilopascal 6 895 Pounds Sq In Bar 0 069 Work Foot pounds Newton Meters 1 356 Foot pounds Kilogram Meters 0 1383 Inch pounds Kilogram Centimeters 1 152144 Liquid Volume Quarts Liters 0 9463 Gallons Liters 3 785 Liquid Flow Gallons Minute Liters Minute 3 785 Temperature Fahrenheit Celsius 1 Subract 32 2 Multiply by 5 9 Product Records and Maintenance Page2 2 Rev A Reelmaster 2000 D Torque Specifications Recommended fastener torque values are listed in the following tables For critical applications as determined by Toro either the recommended torque or a torque that is unique to the application is clearly identified and spe cified in this Service Manual These Torque Specifications for the install
18. 6 5 n am PTO K x 3 z tr BROWN Al p28 GREEN g REEL UP LIMIT SW 5 2 2 tH z A B 5 P29 9 REEL DRIVE SOL A BC A B Reelmaster 2000 0 DIODE Engine Wire Harness Page 8 14 Rev GROUND 28 REEL UP LIMIT SW I P23 FUEL SOL P3 STARTER P34 P33 INTERCONNECT INTERCONNECT J6 HIGH PRESSURE SW P29 IUE pec n z REEL DRIVE SOL L 9 A GLOW PLUGS P24 BACKLAP A 9 ALTERNATOR J3 4 gt ALTERNATOR B 1 2 P2 OIL PRESSURE SW Reelmaster 2000 D Engine Wire Harness Page 8 15 Rev A This page is intentionally blank Page 8 16 Rev A
19. LD22 1 IN UP POSITION Mi come idem IN OFF 2j BACKLAP NOT USED Kl D wa 2 8 SEAT SW GROUND MF GY lt gt SEAT SW NEUTRAL SW 25 NEUTRAL SW 5 GN lt YY UNOCCUPIED IN NEUTRAL 2j 16N sw s BN VIO 3 WD Li lt 1 8 SOLENOID 1 IF EQUIPPED FRAME GROUND WF 15 OHM STANDARD CONTROL MODULE Y Y REELS ON OFF IN OFF ola a 4 T EM MS ak R i 5 R l _ STOP NONE 1 ach r RUN XeY START 1 5 7 IGNITION SW OFF RUN START Al 15A 8 F4 10 a Sel Reelmaster 2000 D Glow Plug Circuit Serial Number Below 230000000 Shown Power Current Control Current Indicator Gauge Current Logic Direction 8 5 SS STOP NONE RUN 1 X Y START BeleS IGNITION SW OFF RUN START F1 o
20. Page 5 28 3 Following the manufacturer s instructions con nect the charger cables to the battery Make sure a good connection is made 4 Charge the battery following the manufacturer s instructions 5 Occasionally check the temperature of the battery electrolyte If the temperature exceeds 1259F 51 690 or the electrolyte is violently gassing or spewing the charging rate must be lowered or temporarily stopped 6 Three hours prior to the end of the charging mea sure the specific gravity of a battery cell once per hour The battery is fully charged when the cells are gassing freely at a low charging rate and there is less than a 0 003 change in specific gravity for three consecutive readings Reelmaster 2000 D Solenoid Valve Coil The solenoid valve coil on the reel drive Fig 30 and 3WD hydraulic manifold if equipped Fig 31 can be easily replaced without opening the hydraulic system Removal 1 Disconnect the electrical connector 2 Remove the nut from the spool assembly 3 Slide the coil assembly and o rings from the spool assembly Discard the coil assembly and o rings 4 Clean any corrosion or dirt from the spool assembly Installation 1 Slide new coil assembly onto the spool assembly making sure that o ring is installed at each end of coil Align the coil assembly evenly with the manifold body 2 Apply medium strength thread locking compound to the threads of the spool Install the nut o
21. 1 Plug motor ports and clean the outside of the motor thoroughly After cleaning remove plugs and drain any oil out of the motor 2 Use a marker to make a diagonal line across the front flange and body for assembly purposes Fig 44 2 IMPORTANT Prevent damage when clamping the reel motor into a vise clamp on the front flange only Also use a vise with soft jaws 3 Clamp front flange of motor in a vise with soft jaws with the shaft end down Figure 44 2 Hydraulic System Page 4 57 1 Rev A Reelmaster 2000 D 4 Loosen screws from the rear cover 5 Remove motor from the vise Turn motor so that the shaft end is facing down Remove cap screws 6 Carefully remove body Lift body straight up to re move Make sure the rear wear plate remains on the drive and idler gear shafts Remove and discard O rings from the body Locate and retrieve dowel pins IMPORTANT Note position of the open and closed side of the wear plates before removing Also iden tify wear plates front and rear with a marker for proper assembly 7 Carefully remove rear wear plate idler gear drive shaft and front wear plate from the front flange 8 Remove and discard back up gaskets and pressure seals from wear plates 9 Turn front flange over with seal side up IMPORTANT Make sure to not damage the front flange counter bore when removing the seals from the front flange 10 Carefully remove dust seal retaining ring flange
22. Cutting Reel 55 to 65 ft lb 75 to 88 N m THREAD LOCKING COMPOUND BIGHT ANTI SEIZE LUBRICANT FRONT 55 to 65 ft Ib 27 28 75 to 88 N m 24 THREAD LOCKING COMPOUND 34 Figure 14 1 Hydraulic motor 13 Cutting reel 25 Grease fitting 2 Cap screw 14 Flange nut 26 Flange head screw 3 O ring 15 Side plate LH 27 Bearing housing 4 screw 16 Washer 28 Bearing 5 Lock washer 17 Spacer 29 Reel coupler RH 6 Side plate RH 18 Link 30 Spider coupler 7 Roll pin 19 Bushing 31 Rubber side cover 8 Lock nut 20 Cap screw 32 Rubber center cover 9 Washer head screw 21 Cap screw 33 Rivet 10 Frame assembly 22 Cap screw 34 Cover gasket 11 Front grass guard 23 Shipping plug 35 Cover 12 Rear grass guard 24 Reel coupler LH 36 Seal guard 8 amp 11 blade reels Remove Cutting Reel Fig 14 1 Remove hydraulic motor from the cutting unit see Hydraulic Reel Motor Removal Remove cover and gasket from the opposite end of the cutting unit 2 Remove cutting unit from the machine see Traction Unit Operator s Manual 3 Remove bedbar assembly from the cutting unit see Bedbar Removal 4 Remove front roller from the cutting unit see Roller Removal NOTE A 3 8 amp inch drive ratchet with an extension will fit into the square hole of the reel coupler Cutting Units Page 7 16 5 Unscrew reel coupler LH from the reel This cou pler has left hand threads Unscrew reel coupler RH from
23. 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 2000 D REFER TO THE TRACTION UNIT AND CUTTING UNIT OPERATOR S MANUALS FOR OPERATING MAINTENANCE AND ADJUSTMENT INSTRUC TIONS Space is provided in Chapter 2 of this book to insert the Operator s Manuals and Parts Catalogs for your machine Additional copies of the Operator s Manual and Parts Catalog are available on the internet at www Toro com The Toro Company reserves the rightto change product specifications or this publication without notice Part No 02103SL Rev A Service Manual Reelmaster 2000 D This safety symbol means DANGER WARNING or CAUTION PERSONAL SAFETY INSTRUC TION When you see this symbol carefully read the instructions that follow Failure to obey the instructions may result in personal injury NOTE A NOTE will give general information about the correct operation maintenance service testing or re pair of the machine IMPORTANT The IMPORTANT notice will give im portant instructions which must be followed to pre vent damage to systems or components on the machine The Toro Company 2002 2009 This page is intentionally blank Reelmaster 2000 D Table Of Contents Chapter 1 Safety Chapter 5 Electrical System Safety Instructions 1 2 Electrical Schemati
24. Reelmaster 2000 D Temperature correct each cell reading For each G Take a voltage reading at 15 seconds then re 109F 5 59C above 809F 26 79C add 0 004 to the move the load specific gravity reading For each 109F 5 59C be low 809F 26 79C subtract 0 004 from the specific H Using the table below determine the minimum gravity reading voltage for the cell temperature reading Example Cell Temperature 1009F Cell Gravity 1 245 Minimum Battery Electrolyte 1009F minus 809F equals 209F Voltage Temperature 37 79C minus 26 79 equals 11 09C 96 709F and up 21 19C and up 209F multiply by 0 004 109F equals 0 008 11 C multiply by 0 004 5 5 C equals 0 008 Correction to 809F 26 79C 1 253 9 3 1496 C If the difference between the highest and lowest cell specific gravity is 0 050 or greater or the lowest 209F 6 7 cell specific gravity is less than 1 225 charge the bat tery Charge at the recommended rate and time giv 12 29C en in Charging or until all cells specific gravity is 17 89C 1 225 or greater with the difference in specific gravity between the highest and lowest cell less than 0 050 n If these charging conditions can not be met replace If the test voltage is below the minimum replace the battery the battery If the test voltage is at or above the mini mum return the battery to service 3 Perform a high discharge test with an adjustable load tester Charging This is one
25. tion backlap and high temperature switches are moni tored by the Module Output to the PTO reel drive solenoid electric starter motor and engine run sole noid are controlled based on the inputs received by the Module The Standard Control Module does not connect to an external computer or hand held device can not be programmed and does not record intermittent fault data The Standard Control Module can be used to check op eration of machine switches by monitoring the LED of the module If a Module LED does not illuminate e g the in seat input LED does not illuminate with the seat occu pied and the ignition switch in the run position testing of the switch and circuit wiring would be required Refer to the Traction Unit Operator s Manual for opera tion and troubleshooting of the Standard Control Mod ule 1 Figure 19 Instrument panel 2 Standard control module Figure 20 1 Power input LED 6 Neutral input LED 2 Start input LED Park brake off input LED 3 Engine run output LED 8 PTO switch input LED 4 Start output LED 9 In seat input LED 5 PTO output LED 10 High temp input LED 11 Backlap input LED Electrical System Page 5 18 Reelmaster 2000 D Traction Neutral Switch The traction neutral switch is a normally open proximity Switch that closes when the traction pedal is in the neu tral position The traction arm that is pinned to the trac tion lever acts as the sensing plate for
26. Bushing 25 Seat switch incl 24 26 amp 27 39 Nut 11 Pad 26 Spring washer 40 12 Backrest cushion 27 Nut 41 Bushing kit incl 39 amp 40 13 Hex head machine screw 28 Back plate pivot 42 Backrest plate 14 Arm rests 29 Threaded clevis 43 Hex flange nut 15 Bottom cushion 30 Nut 44 Cap screw Removal Installation 1 Park machine on a level surface lower cutting units 1 Install any new seat parts using Figure 6 as a guide stop engine engage parking brake and remove key from the ignition switch 2 Position seat to the machine frame 2 Remove four cap screws and lock nuts securing the 3 Connect electrical connector to the seat switch seat to the frame Separate seat from the frame 4 Secure seat to the frame with cap screws and lock 3 Disconnect electrical connector from the seat switch nuts 4 Remove seat parts as necessary to make repairs us ing Figure 6 as a guide Reelmaster 2000 D Page 6 11 Chassis Steering Assembly Steering wheel Steering wheel cover Lock nut Flat washer Dust cover Bushing Steering column Lock nut Flat washer 0 Steering shaft amp gear Chassis Figure 7 Cap screw Grease fitting Sector gear Jam nut Thrust washer Flange bushing Flat washer Lock nut Cap screw Page 6 12 60 to 80 ft Ib 81 to 108 Thrust washer Lock washer Flange
27. SPECIAL TOOLS Hydraulic Pressure Test Kit Hydraulic Tester Pressure and Flow Hydraulic Test Fitting Measuring Container TROUBLESHOOTING TESTING Test No 1 Traction Circuit Working Pressure Test No 2 Mow Circuit Working Pressure Test No 3 Traction Pump Flow Test No 4 Charge Pump Flow and Lift Relief Pressure Test No 5 Charge Pump Relief Pressure Test No 6 Reel Gear Pump Flow Test No 7 Manifold Relief Valve Pressure Test No 8 Cross over Relief Pressures Test No 9 Reel Motor Case Drain Test 10 Wheel Motor Case Drain Reelmaster 2000 D Page 4 1 Chapter 4 Hydraulic System SERVICE AND REPAIRS 40 General Precautions for Removing and Installing Hydraulic System Components 40 Check Hydraulic Lines and Hoses 40 Flush Hydraulic System 41 Hydraulic System Start up 42 Hydraulic Pump Drive 43 Traction Charge Pump 44 Traction Charge Pump Service 48 Reel Gear Pump 49 Reel Gear Pump Service Barnes 50 Reel Gear Pump Service Casappa 51 1 Wheel 52 Wheel Motor Service 54 Cutting Reel M
28. TO LIFT CYLINDER VALVE TOP IN FRONT BOTTOM FROM LIFT CYLINDER OUT REAR BOTTOM REEL LIFT CONTROL VALVE CHARGE RELIEF LIFT RELIEF FILTER CHARGE PUMP lt Na lt gt BOTTOM a RESERVOIR TRACTION PUMP FRONT j COOLER REEL MOTOR GEAR PUMP RETURN FROM MANIFOLD TO MANIFOLD Ems 4 Working Pressure Low Pressure Charge Return or Suction Flow Figure 22 Hydraulic System Page 4 28 Reelmaster 2000 D Procedure for Charge Pump Relief Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Park machine on a level surface with the cutting units lowered Make sure engine is off and the parking brake is engaged 3 Read Precautions For Hydraulic Testing Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil 4 Disconnect hose from the front fitting of the charge pump returning from the control valve Fig 23 Connect T connector and pressure gauge to the pump and hose fitting Make sure that all hoses are free of the flywheel after installation 5 Make sure that traction pedal and lift valve are in neu tral and the parking brake is engaged 6 Operate engine at full speed 3200 50 RPM 7 Pressure gauge should read from 100 to 150
29. The nominal torque values listed above are based 75 of the minimum proof load specified in SAE J1199 The tolerance is approximately 1096 of the nominal torque value Product Records and Maintenance Product Records i i 5 gt Other Torque Specifications SAE Grade 8 Steel Set Screws Recommended Torque Thread Size Square Head 1 4 20 UNC 140 20 in lb 73 12 in lb 5 16 18 UNC 215 35 in lIb 145 20 in Ib 3 8 16 UNC 35 10 ft 18 3 ft lb 1 2 13 UNC Ib b 75 15 ft lb 50 10 ft Thread Cutting Screws Zinc Plated Steel No 10 24 UNC 38 7 in lb 1 4 20 UNC 85 15 in lb 5 16 18 UNC 110 20 in lb 3 8 16 UNC 200 100 in lb Conversion Factors in lb X 11 2985 ft lb X 1 3558 N m Product Records and Maintenance Page2 6 Wheel Bolts and Lug Nuts Thread Size Recommended Torque 7 16 20 UNF 65 10 ft lb Grade 5 1 2 20 UNF 80 10 ft lb 108 14 Grade 5 M12 X 1 25 80 10 ft lb 108 14 55 8 8 M12 X 1 5 80 10 ft lb 108 14 Class 8 8 For steel wheels and non lubricated fasteners 88 14 Thread Cutting Screws Zinc Plated Steel Thread Threads per Inch Size Baseline Torque Type A Type B 85 15 in lb Hole size material strength material thickness amp finish must be considered when determining specific torque value
30. Tool s required Digital multimeter and or inductive Ammeter AC DC Current Transducer Test instructions Properly connect the ammeter to the digital multimeter refer to manufacturer s instructions Electrical System Page 5 8 Voltage Measured Battery Charge Level 12 68 v or higher Fully charged 10096 12 45 v 7596 charged 5096 charged 2596 charged 096 charged 12 24 v 12 06 v 11 89 v Start the engine and run at 3200 RPM Allow the battery to charge for at least 3 minutes Record the battery volt age Test results should be example At least 0 50 volt over initial battery voltage Initial Battery Voltage 12 30 v Battery Voltage after 3 Minute Charge 12 80 Set the multimeter to the correct scale With the key in the OFF position place the ammeter pickup around the main glow plug power supply wire and read the meter prior to activating glow plug system Adjust the meter to read zero if applicable Cycle the glow plug system at least two times per instructions in Traction Unit Opera tor s Manual and record the final results The Reelmaster 2000 D glow plug system should a reading of about 27 Amps Reelmaster 2000 D Starting System Test This is an excellent test to use when a slow crank no start problem is encountered It will determine if the problem is due to an electrical open short or high resis tance in the starter circuit NOTE The battery condition a
31. far enough to insure that they are not cross threaded before tightening with a wrench 8 Position the tester hoses so that rotating machine parts will not make contact with them and result in hose or tester damage 9 Check and adjust the oil level in the reservoir after connecting hydraulic test equipment 10 Check the control linkage for improper adjustment binding or broken parts 11 hydraulic tests should be made with the hydraulic oil at normal operating temperature Hydraulic System 2 5 L7 EE gt TEST 1 Traction Circuit Working Pressure Using Pressure Gauge WHEEL MOTOR RIGHT TEST GAUGE FORWARD TEST GAUGE 3 REVERSE FORWARD FRONT REAR LINE LINE WHEEL MOTOR LEFT Hydraulic System FORWARD REVERSE CHARGE PUMP TRACTION PUMP TO HYDRAULIC MANIFOLD PORT T2 Figure 14 Page 4 20 TO REAR WHEEL MOTOR OPTIONAL 3WD KIT FROM REAR WHEEL MOTOR OPTIONAL 3WD KIT FROM LIFT CONTROL VALVE FRONT gt LIFT CONTROL VALVE FROM RESERVOIR TO RESERVOIR Working Pressure Low Pressure Charge Return or Suction Flow Reelmaster 2000 D Procedure for Traction Circuit Working Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Park machine on a level surface with the cutting units lo
32. 11 that secure lower end of pump support 3 Loosen lower jam nut and lock nut that secure adjust ing bolt to front engine frame 4 Pivot pump support to allow drive belt to be removed from pulleys Drive Belt Installation 1 Pivot pump support and install drive belt to pulleys Reelmaster 2000 D Page 4 43 2 Tighten lock nut on adjusting bolt to tension drive belt A used drive belt should deflect 0 120 3 mm with 11 to 13 pounds 5 to 5 9 kg pressure applied midway in the span of the belt If drive belt is being replaced a new drive belt should deflect 0 120 3 mm with 15 to 17 pounds 6 8 to 7 7 kg pressure 3 Tighten lower jam nut on adjusting bolt to secure belt adjustment 4 Torque lock nut 13 from 60 to 70 ft Ib 81 to 95 to secure pump support Hydraulic System Sg E gt Traction Charge Pump Taper lock bushing Hydraulic pump drive belt Pump pulley Lock nut Thrust washer Cap screw Pump support Traction charge pump Hardened washer Lock nut Hydraulic hose 90 hydraulic fitting Hydraulic adapter Lock washer Hose clamp gr po NE i Hydraulic System 16 17 18 19 20 21 22 Return hydraulic hose 24 25 Cap screw 27 28 29 30 37 Anti seize lubricant Figure 35 90 hydraulic fitting 90 hydraulic fitting Hydraulic hose Reel drive pump O ring
33. 133HM Reelmaster 2000 D Page 4 12 Hydraulic System Mow Circuit The reel motor drive pump is directly coupled to the trac tion pump which is belt driven by the engine Taking its suction directly from the reservoir the reel motor drive pump supplies oil flow to the hydraulic manifold block and to the reel motors With the engine running and the cutting unit switch in the DISENGAGED position oil flows into inlet port P1 and through deenergized solenoid valve S1 bypassing the reel motors Oil then flows directly back to the reservoir through the oil cooler When the cutting unit switch is the ENGAGED posi tion with the engine running solenoid valve 51 is ener gized and shifted hydraulic system pressure builds up and flow is diverted to the reel motors Cil flow from port P1 flows through the 11 position reel speed control valve Flow across the speed control valve is pressure Reelmaster 2000 D Page 4 13 compensated by the logic cartridge valve LC1 Any ex cess flow above what the speed control valve is set for is bypassed to the reservoir through the logic cartridge valve With the backlap valve MD1 in the MOW posi tion oil flows through the valve and reel motors which are connected in series Oil flows through the right cen ter and then left reel motor as it turns the motors in the mow direction The oil then returns to the reservoir Relief valve R1 limits system pressure and is set at
34. 3 If engine frames or channel were removed from the engine reinstall them as follows Fig 15 A For front engine frame secure frame to the en gine with six cap screws and washers B For rear engine frame secure RH frame bracket closest to flywheel to the engine with three cap screws and washers Secure LH frame bracket with cap screw and washer in the lower RH hole Fig 16 Lower LH hole in LH bracket is location for electrical ground connections Mount alternator bracket using longer cap screws use hardened washer and flat washer as spacers between alternator bracket and engine block Fig 15 C For engine channel secure channel to the front and rear engine frames with four flange head screws and flange nuts 4 Reinstall engine to machine A Attach short section of chain between lift tabs lo cated on each end of the cylinder head B Connect a hoist or chain fall at the center of the short section of chain Apply enough tension on the short chain so that the engine can be supported One person should operate lift or hoist while the other person guides the engine out of the ma chine IMPORTANT Make sure not to damage the engine fuel hoses hydraulic lines electrical harness or other parts while removing the engine C Reinstall engine to the machine Make sure fas tener holes of the engine frames and channel are aligned with the holes in the engine mounts D Secure engine with frames and channel t
35. 3000 PSI 207 bar When the valve opens oil is di verted back to the reservoir Backlapping operation is the same as mowing opera tion except for the position of the backlap valve MD1 When the backlap valve is the BACKLAP position oil flow is directed through the left center and then right reel motor as it turns the motors in the backlap direction Hydraulic System 5 amp gt Special Tools Order these special tools from your Toro Distributor Hydraulic Pressure Test Kit Toro Part Number TOR47009 Use to take various pressure readings for diagnostic tests Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools A high pressure hose is provided for remote readings Contains one each 1000 PSI 70 Bar 5000 PSI 350 Bar and 10000 PSI 700 Bar gauges Use gauges as recommended in Testing section of this chapter Hydraulic Tester Pressure and Flow Toro Part Number TOR214678 This tester requires O ring Face Seal ORFS adapter fittings for use on this machine see Hydraulic Test Fit ting Kit 4079 in this section 1 INLET HOSE Hose connected from the system cir cuit to the inlet side of the hydraulic tester 2 LOAD VALVE A simulated working load is created in the circuit by turning the valve to restrict flow 3 LOWPRESSURE GAUGE Low range gauge to pro vide accurate reading at low pressure 0 to 1000 PSI A
36. 5 amp SAE Grade 1 Bolts Screws Studs amp SAE Grade 5 Bolts Screws Studs amp SAE Grade 8 Bolts Screws Studs amp Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts Height Nuts SAE J995 Grade 2 or Stronger Nuts SAE J995 Grade 2 or Stronger Nuts SAE J995 Grade 5 or Stronger Nuts 15 2 170 20 260 20 147 23 339 56 599 79 100 10 1125 100 140 15 1580 170 65 10 734 113 115 10 1300 100 160 15 1800 170 105 17 1186 169 200 25 2250 280 300 30 3390 340 128 17 1446 192 225 25 2540 280 325 30 3670 340 6 32 UNC 6 40 UNF 8 32 UNC 8 36 UNF 10 24 UNC 10 32 UNF 1 4 20 UNC 48 7 1 4 28 5 16 18 UNC 115 15 5 16 24 UNF 138 17 10 2 13 2 e 3 8 16 UNC 1642 NOTE Reduce torque values listed in the table above NOTE The nominal torque values listed above for by 25 for lubricated fasteners Lubricated fasteners Grade 5 and 8 fasteners are based on 75 of the mini are defined as threads coated with a lubricant such as mum proof load specified in SAE J429 The tolerance is oil graphite or thread sealant such as Loctite approximately 10 of the nominal torque value Thin height nuts include jam nuts NOTE Torque values may have to be reduced when installing fas
37. 909 hydraulic fitting 909 hydraulic fitting Hydraulic fitting Hose clamp Hardened washer Adjusting bolt full thread Jam nut Hydraulic hose Page 4 44 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 90 to 120 in Ib 10 2 to 13 6 N m Thread locking Compound Cap screw Protective sleeve Cap screw Top spherical washer Bottom spherical washer Socket head set screw O ring O ring O ring O ring O ring Suction hose Hydraulic hose Suction hose Front engine frame Reelmaster 2000 D Neutral Arm Assembly 2 SF gt Figure 36 1 Extension spring 11 Thrust washer 20 Flange nut 2 Hose 12 Traction stud 21 Flat washer 3 Neutral bracket 13 Grease fitting 22 Lock nut 4 Pump lever 14 Cap screw 23 Screw 5 Screw 15 Lock nut 24 Bearing spacer 6 Washer 16 Bearing 25 Flange bushing 7 Locknut 17 Cap screw 26 Traction charge pump 8 Mount 18 Lock nut 27 Pump support 9 Hub 19 Carriage screw 28 Traction control rod 10 Neutral arm Removal Fig 35 2 Install plug into the hydraulic reservoir to prevent draining the reservoir 1 Park the machine on a level surface engage parking brake lower cutting units and stop engine Remove key 3 Remove traction belt from the pump pulley see Hy from the ignition switch draulic Pump Drive Belt IMPORTANT Mark position of the taper lock bush ing on the piston pu
38. Ib 72 kg Model 03213 32 8 blade 167 Ib 76 kg Reelmaster 2000 D This page is intentionally blank Reelmaster 2000 D Page 7 3 Cutting Units Special Tools Order Special Tools from your Toro Distributor Some tools may have been supplied with your machine or are available as Toro parts Gauge Bar Assembly Use gauge bar to verify height of cut and bedknife atti tude Toro Part Number 98 1852 Gunman Figure 2 Handle Assembly For applying lapping compound to cutting units while keeping hands a safe distance from the rotating reel Toro Part Number TOR299100 Figure 3 Bedknife Screw Tool This screwdriver type bit is made to fit Toro bedknife at taching screws Use this bit with a torque wrench to se cure the bedknife to the bedbar IMPORTANT Do not use an air or manual impact wrench with this tool Toro Part Number TOR510880 SS Figure 4 Cutting Units Page7 4 Rev Reelmaster 2000 D Angle Indicator Use with Gauge Bar Assembly to verify bedknife atti tude Toro Part Number 99 3503 Figure 5 Turf Evaluator Tool Many turf discrepancies are subtle and require closer examination In these instances the Turf Evaluator grass viewing tool is helpful It can assist turf managers and service technicians in determining causes for poor reel mower performance and in comparing the effective height of cut of one mowed surface to another This tool should be used with t
39. One person should sit on the seat and operate the machine while another person holds the hose and reads the tester Start engine and move the throttle to full speed 3200 50 RPM 9 Engage cutting units by pulling the reel engage knob on the instrument panel out While watching pressure gauges slowly close flow control valve until a pressure of 1200 PSI is obtained 10 Collect hydraulic fluid for 15 seconds by putting case drain hose into 1 quart container graduated in ounces 1 liter container graduated in milliliters 11 After 15 seconds push knob on the instrument panel in to disengage cutting units Stop the engine 12 Measure the amount of oil collected in the container Divide the number of ounces collected by 32 to get gal lons per minute divide the number of milliliters col lected by 250 to get liters per minute See chart in Figure 30 13 If flow was greater than 0 7 GPM 2 6 LPM repair or replace the reel motor as necessary 14 Disconnect tester from motor and hose Reconnect hose to the motor 15 Remove cap from manifold port Reconnect case drain hose to the manifold block Hydraulic System 5 EE gt TEST 10 Wheel Motor Case Drain Using Tester With Pressure Gauges and Flow Meter WHEEL MOTOR RIGHT FORWARD TO REAR WHEEL MOTOR OPTIONAL 3WD KIT REVERSE FROM REAR WHEEL MOTOR OPTIONAL 3WD KIT REELS DISENGAGED TO PREVENT FLOW TO REAR WHEEL TESTER TEST C
40. Pump pulley drive belt is loose Charge pump is damaged Lift valve control linkage is binding or broken Lift cylinder bushings are binding Reservoir oil level is low Inlet filter is loose or clogged Charge pump pressure or flow is insufficient Implement relief valve is stuck open Lift control valve is damaged Lift cylinders leak internally Cutting units raise but will not stay Lift cylinders leak internally up Lift valve leaks Hydraulic System Page 4 18 Reelmaster 2000 D Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks See Special Tools section in this Chapter Failure to use gauges with recommended pres sure psi rating as listed in test procedures could result in damage to gauge and possible personal injury from leaking hot oil Before Performing Hydraulic Tests All obvious areas such as oil supply filter binding link age loose fasteners or improper adjustments must be checked before assuming that a hydraulic component is the source of the problem being experienced Precautions For Hydraulic Testing Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved by stopping the engine and lowering or supporting the cutting units or other implements Keep body and hands away from pi
41. Set the multimeter to the DC volts setting The battery should be at a temperature of 60 to 100 F 16 to 389 C The ignition key should be in the OFF position and all accessories turned off Connect the positive me ter lead to the positive battery post and the negative meter lead to the negative battery post NOTE This test provides a relative condition of the bat tery Load testing of the battery will provide additional and more accurate information Charging System Test This is a simple test used to determine if a charging sys tem is functioning It will tell you if a charging system has an output but not its capacity Tool required Digital multimeter set to DC volts Test instructions Connect the positive meter lead to the positive battery post and the negative meter lead to the negative battery post Leave the test leads con nected and record the battery voltage NOTE Upon starting the engine the battery voltage will drop and then should increase once the engine is running NOTE Depending upon the condition of the battery charge and battery temperature the charging system voltage will increase at different rates as the battery charges Glow Plug System Test This is a fast simple test that can help to determine the integrity and operation of the glow plug system The test should be run anytime hard starting cold is encoun tered on a diesel engine equipped with a glow plug sys tem
42. Y GN gt ifs E po wee 1 IE a g Ia g d Es y 2A START 42 y i SUM 2 3 sw Pro IG i REEL UP OPTIONAL SEAT SW ota REEL DRIVE PARKING BRAKE DISENGAGED gt lt LIMIT SW D SOLENOID 1 3 lt 22 PARKING BRAKE PTO SW 1 0 REELS LOWERED DS a ENGINE i Le IN OFF m T hi 21 BACKLAP NOT ER ENGINE GROUND Peces Se SSS Sst t Y lt LEA 2 SEAT SW GROUND M M iy 4 4272 E Tm SEAT SW s NEUTRAL SW ai d o i BK OCCUPIED NOT IN NEUTRAL 236 IGN 757 gt 5 442 i ak SOLENOID BATTERY IF EQUIPPED FRAME GROUND D D STANDARD CONTROL MODULE H REELS ON OFF IN ON ole ieu Momie ae 5 BK gt Ss R lt lt STOP NONE El E RUN BeloA XoY START 8 155 Y IGNITION SW OFF RUN START Fe 10A OR gt 104 T VIO o P F2 10A X BU 1 o OPTIONAL LIGHT NOT SUPPLIED R 0 n GLOW PLUGS 3 1 oR i 85 Y Y Y a6 CONTROLLER GLOW PLUG GLOW RELAY DAIHATSU Ex PE m vio 4 d BK 5 Reelmaster 2000 0 Run Mow Circuit Serial Number Below 230000000
43. as goggles when using compressed air 1 Wash all cylinder components in solvent Dry parts with compressed air 2 Inspect internal surface of barrel for deep scratches out of roundness and bending Replace if worn or damaged 3 Inspect head shaft and piston for excessive pitting scoring and wear Replace any worn or damaged parts Reelmaster 2000 D Reassembly Fig 54 1 Coat new dust seal uni ring backup washer and all O rings lightly with hydraulic oil Install new O ring and uni ring to the piston Install O rings and backup wash er to the head Press dust seal into head IMPORTANT Do not clamp vise jaws against shaft surface Protect shaft surface before mounting in vise 2 Mount shaft securely in a vise Adjust clevis and jam nut so the number of threads exposed between the jam nut and the smooth surface of the shaft is the same as noted during disassembly The jam nut must be tight against rod clevis for this adjustment 3 Coat shaft lightly with hydraulic oil Slide head onto the shaft being careful not to damage O ring and dust seal Reelmaster 2000 D Page 4 75 4 Install piston onto the shaft being careful not to dam age O ring Install locknut onto the shaft and tighten 5 Remove shaft from vise IMPORTANT Prevent damage when clamping the barrel into a vise clamp on the pivot end only Do not close vise enough to distort barrel 6 Mount barrel in a vise so that the shaft en
44. bracket 12 Vacuator valve 3 Flange head screw 8 Cap screw 13 Plug 4 Flange nut 9 Lock nut 14 Air cleaner body 5 Intake air hose 10 Filter element Removal Installation 1 Remove air cleaner components as needed using IMPORTANT Any leaks in the air filter system will Figure 7 as a guide cause serious engine damage Make sure that all air cleaner components are in good condition and are properly secured during reassembly 1 Reassemble air cleaner system using Figure 7 asa guide 2 See Traction Unit Operator s Manual for air cleaner service procedures Engine Page 3 8 Reelmaster 2000 D This page is intentionally blank Reelmaster 2000 D Page3 9 Engine Exhaust System 7 bis 200 in Ib 22 6 Figure 8 1 Muffler 6 Rubber isolator 11 Flat washer 2 Exhaust gasket 7 Clamp 12 Spacer 3 Muffler header 8 Coupler spring 13 Cap screw 4 Tailpipe 9 Flange nut 14 Carriage screw 5 Rubber hanger 10 Lock nut Engine Page 3 10 Reelmaster 2000 D Removal Fig 8 The muffler and exhaust pipe may be hot To avoid possible burns allow the engine and ex haust system to cool before working on the ex haust system 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Remove the hood see Traction Unit Operator s Manual 3 Loosen clamp that secures tailpipe to muffler 4 Remove lock nut washers a
45. brackets and angle brackets from the cutting unit 5 Remove height of cut brackets from the roller as sembly Roller Installation 1 Inspect bushings in height of cut bracket for wear replace if necessary NOTE The flanged end of the flanged bushing must face inside toward the roller when the height of cut bracket is installed onto the cutting unit NOTE A soft hammer may be needed to tap the height of cut bracket into position on the hex adjust ment nut of the roller 2 Insert smaller diameter roller shaft into the height of cut bracket with flanged bushing and bushing Insert the other end of the roller shaft into the other height of cut bracket with bushing Make sure that hex of the height of cut brackets mate with the hex adjust ment nut on the roller Hold one height of cut bracket stationary and use the other bracket as a wrench to loosen or tighten bear ing clearance The roller must not exceed 5 0 57 N m rolling torque and have no bearing end play 4 Make sure height of cut brackets are aligned prior to installing them onto the cutting unit If necessary after bearing adjustment align height of cut brackets as fol lows A Remove height of cut bracket on the side with the flanged bushing B Adjust height of cut bracket so it is aligned to within one hex flat of the roller adjustment nut C Align both height of cut brackets Reelmaster 2000 D Page 7 13
46. bushing Rear wheel fork Jam nut LH thread Ball joint Steering tube Jam nut Ball joint Reelmaster 2000 D Disassembly Assembly 1 Park machine on a level surface lower cutting units 1 Assemble steering assembly using Figure 7 as a stop engine engage parking brake and remove key guide from the ignition switch 2 Disassemble steering assembly as needed using Figure 7 as a guide 2 A Shim steering shaft with gear and sector gear with thrust washers as needed to align gear tops Gears should not contact flange bushings B Adjust steering tube ball joints equally so that steering sector gear and rear wheel fork are perpen dicular to the frame C If rear wheel fork was removed secure fork to frame with washers and cap screw Torque cap screw from 60 to 80 1 81 to 108 Make sure that fork rotates freely after cap screw has been tight ened After assembly is complete make sure that steering components do not contact hoses or wires Reelmaster 2000 D Page 6 13 Chassis Front Lift Arms Figure 8 1 Lift arm LH shown 11 Chain 21 Cap screw 2 Lock washer 12 Shackle 22 Reinforcement plate 3 Cap screw 13 Clevis pin 23 Lift arm pivot shaft 4 Thrust washer 14 Spring 24 Spring tension arm 5 Cutting unit pivot shaft 15 Chain if used 25 Spacer 6 Flat washer 16 Shackle 26 Cap screw 7 Flange head screw 17 Clevis pin 27 Self tapping screw 8 Greas
47. from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Use paper or cardboard not hands to search for leaks Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury If fluid is in jected into the skin it must be surgically re moved within a few hours by a doctor familiar with this type of injury Gangrene may result from such an injury Hydraulic System Page 4 40 After Repair Replacement of Components 1 Check oil level in the hydraulic reservoir and add cor rect oil if necessary Drain and refill hydraulic system reservoir and change oil filter if component failure was severe or system is contaminated see Flush Hydraulic System 2 Lubricate O rings and seals with clean hydraulic oil before installing hydraulic components 3 Make sure caps or plugs are removed from the hy draulic tubes hydraulic fittings and components before reconnecting 4 Use proper tightening methods when installing hy draulic hoses and fittings see Hydraulic Fitting Installa tion 5 After repairs check control linkages and cables for proper adjustment binding or broken parts 6 After disconnecting or replacing any hydraulic com ponents operate machine functions slowly until air is out of system see Hydraulic System Start Up 7 Check for hydraulic oil leaks Shut off engine and cor rect leaks if necessary Check oil level in hydr
48. gear pump shaft with traction pump shaft 6 Secure reel gear pump to traction pump with cap screws Torque cap screws from 27 to 33 ft lb 37 to 44 N m Reelmaster 2000 D Page 4 49 27 to 33 ft lb 37 to 44 N m Y PUMP INLET 10 PORT Figure 38 1 Reel gear pump 7 O ring 2 Hose clamp 8 O ring 3 Hose 9 O ring 4 909 hydraulic fitting 10 Cap screw 5 Hose 11 O ring 6 Elbow fitting 12 Traction pump 7 Remove caps or plugs from any hydraulic lines or fit tings that were installed during disassembly process In spect threads and sealing surfaces of connectors Replace any damaged or worn connectors 8 Install O rings 8 and 9 Install fitting 4 and elbow fitting 6 and use matchmarks to correctly orient fittings 9 Secure hose 3 to connector and tighten hose clamp Secure hose 5 to elbow fitting and tighten hose connector 10 Remove plug from hydraulic reservoir 11 Follow Hydraulic System Start up procedures Hydraulic System 2 53 gt lt Reel Gear Pump Service Barnes INLET PORT SIDE OUTLET PORT 40 ft Ib 54 Figure 39 1 Retaining ring 6 O ring 11 Drive gear 2 Shaft seal 7 Dowel pin 12 Idler gear 3 Mounting flange 8 End cover 13 Rear bearing block 4 Backup ring 9 Bolt 14 Front bearing block 5 E seal 10 Gear housing Disassembly Fig 39 5 Remove the gear housing ensuring the rear bearing block 13 front bearing block 14 d
49. hose be sure that the hose is straight not twisted before tightening the fittings This can be done by observing the imprint on the hose Use two wrenches hold the hose straight with one wrench and tighten the hose swivel nut onto the fitting with the other wrench Hydraulic Fitting Installation O Ring Face Seal 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Make sure the O ring is installed and properly seated in the groove It is recommended that the O ring be replaced any time the connection is opened 3 Lubricate the O ring with a light coating of oil 4 Put the tube and nut squarely into position on the face seal end of the fitting and tighten the nut until finger tight 5 Mark the nut and fitting body Hold the body with a wrench Use another wrench to tighten the nut to the cor Before disconnecting or performing any work on hydraulic system relieve all pressure in system Stop engine lower or support all at tachment s Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Use paper or cardboard not hands to search for leaks Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury If fluid is injected into the skin it must be surgi cally removed within a few hours by a doctor familiar with this type of injury Gangrene may result fro
50. if threads are worn Reinstall reel cou pler see Cutting Reel Installation Fig 7 NOTE The cutting unit can be installed with the hy draulic motor on either side If installing on the opposite side remove cap screws cover and cover gasket rein stall them on the other bearing housing 1 Dip spider coupler in No 2 general purpose lithium base grease Reinstall spider coupler into the bearing housing 2 Install o ring on the front plate of the motor Mount hydraulic motor to the bearing housing Secure motor with two cap screws 3 Grease bearing housing sufficiently to fill housing with grease see Cutting Unit Operator s Manual Figure 7 1 Reel motor 3 O ring 2 Cap screw 4 Spider coupler Reelmaster 2000 D Page 7 9 Cutting Units Bedbar dli LUBRICANT 250 to 300 28 to 34 N m Figure 8 1 Rubber bushing 12 Flange bushing 23 Flat washer 2 Flanged bushing 13 Bushing 24 Lock washer 3 Jam nut 14 Adjusting lock nut 25 Cap screw 4 Compression spring 15 Adjusting nut 26 Bedbar 5 Washer 16 Adjusting housing 27 Bedknife 6 Bedbar fitting 17 Lock nut 28 Bedknife screw 7 Adjuster spacer 18 Carriage bolt 29 Reel frame 8 Spring arm 19 Bedbar yoke 30 Weight Models 03213 and 03214 9 Bedbar adjuster 20 Bedbar washer 31 Cap screw 10 Bedbar pivot 21 Bedbar housing 32 Lock nut 11 Grease fitting 22 Spacer Removal 1 Turn bedbar adjuster to loosen bedknife to
51. is not able to keep up with internal leak age in the traction circuit See Test 3 18 If specifications not met the traction pump needs to be repaired or replaced as necessary Figure 20 2 Hose traction forward 1 Traction pump Hydraulic System 2 gt TEST NO 4 Charge Pump Flow and Lift Relief Pressure Using Tester With Pressure Gauges and Flow Meter TO WHEEL MOTORS BOTTOM TO WHEEL MOTORS TO LIFT CYLINDER piim 1 Y FROM LIFT CYLINDER CHARGE PUMP CHARGE RELIEF TRACTION PUMP TO MANIFOLD REEL LIFT CONTROL VALVE IN FRONT OUT REAR RESERVOIR REEL MOTOR GEAR PUMP T RETURN FROM MANIFOLD Working Pressure Low Pressure Charge Return or Suction Flow Hydraulic System Figure 21 Page 4 26 COOLER Reelmaster 2000 D Procedure for Charge Pump Flow Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Park machine on a level surface with the cutting units lowered Make sure engine is off and the parking brake is engaged 3 Read Precautions For Hydraulic Testing Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil 4 Disconnect outside top hose from the discharge fit ting of the charge
52. kills during operation operator sitting on seat Electrical System Page 5 6 Possible Causes Seat switch is faulty out of adjustment or short circuited Traction neutral switch is out of adjustment faulty or short circuited Operator is lifting off the seat seat switch not depressed Parking brake is on Seat switch is faulty or out of adjustment Seat switch wiring is loose corroded or damaged Wiring to the charging circuit components is loose corroded or damaged see Wiring Schematics Fusible link to the battery is faulty Alternator is faulty Battery is dead Operator is lifting off the seat seat switch not depressed Seat switch is faulty or out of adjustment Seat switch wiring is loose corroded or damaged Engine overheated Ignition switch is faulty Wiring to the run circuit components are damaged or disconnected see Wiring Schematics Standard Control Module is faulty Reelmaster 2000 D Cutting Unit Operating Problems Engine Continues to run but should not when the reel engage switch is ON with no operator in the seat Cutting units run but should not when raised However they shut off with the reel engage switch Cutting units shut off when raised However they do not shut off with the reel engage switch Cutting units do not engage Cutting units do not engage in Backlap direction Reelmaster 2000 D Page Possible Causes Backlap switch is in the back
53. manifold IMPORTANT Make sure oil flow indicator arrow on the flow gauge is showing that the oil will flow from the hose through the tester and into the motor 5 Install flow tester with pressure gauges in series with the hose and motor Make sure the flow control valve on the tester is fully open 6 Make sure backlap knob on the valve block is in the mow position Make sure reel speed knob is set to posi tion 9 or greater CAUTION Keep away from reels during test to prevent per sonal injury from the rotating reel blades 7 Start engine and move throttle to full speed 3200 50 RPM Engage the cutting units 8 Watch pressure gauge carefully while slowly closing the flow control valve until the manifold relief opens 9 System pressure should be from 2700 to 3300 PSI as the relief valve opens A If specification is not met adjust relief valve step 10 B If this specification is met go to step 11 Reelmaster 2000 D Page 4 33 NOTE Do not remove relief valve from the hydraulic manifold for adjustment 10 Adjust the relief valve pressure as follows A Remove the cap from the relief valve Fig 28 B To increase the relief valve pressure setting use an allen wrench and turn adjustment socket slightly clockwise A 1 8 turn on the socket will make a mea surable change in relief pressure C To decrease the relief valve pressure setting use an allen wrench and turn adjustment socket slightl
54. normal operating tem perature by operating the machine for approximately 10 minutes 2 Park machine on a level surface with the cutting units lowered Make sure engine is off and the parking brake is engaged 3 Read Precautions For Hydraulic Testing Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil 4 Clean hose connection and reel gear pump Discon nect hose connection on the reel gear pump leading to port P1 on the hydraulic manifold Fig 25 IMPORTANT Make sure oil flow indicator arrow on the flow gauge is showing that the oil will flow from the pump through the tester and into the valve block 5 Install flow tester with pressure gauges in series with reel gear pump and the disconnected hose leading to port P1 of the hydraulic manifold Make sure the flow control valve on the tester is fully open 6 Make sure backlap knob on the valve block is in the mow position 7 Start engine and move throttle to full speed 3200 50 RPM Do not engage the cutting units 8 Watch pressure gauge carefully while slowly closing the flow control valve until 1500 PSI is obtained Verify with a phototac that the pump speed is 2825 RPM 9 Flow indication should be approximately 5 9 GPM 10 Shut off engine 11 Disconnect tester from manifold and hose Recon nect hose to the pump 12 If flow was less than 5 9 GPM or a pressure of 1500 PSI cannot be obtained che
55. of the most reliable means of testing a battery To minimize possible damage to the battery and allow as it simulates the cold cranking test A commercial bat the battery to be fully charged the slow charging meth tery load tester is required to perform this test od is presented here This charging method can be ac A CAUTION complished with a constant current battery charger which is available in most shops A CAUTION Follow the manufacturer s instructions when us ing a battery charger Follow the manufacturer s instructions when us ing a battery tester A Check the voltage across the battery terminals prior to testing the battery If the voltage is less than 12 4 VDC recharge the battery NOTE Using specific gravity of the battery cells is the most accurate method of determining battery condition 6 To m 4 B If the battery has been charged apply a 150 1 load for 15 seconds to remove the surface charge 1 Determine the battery charge level from either its Use a battery load tester following the manufactur specific gravity or open circuit voltage er s instructions C Make sure battery terminals are free of corrosion tius Gay ee D Measure the temperature of the center cell 100 1 265 12 68 E Connect a battery load tester to the battery termi ioe vee nals following the manufacturer s instructions 50 1 190 12 24 Connect a digital multimeter to
56. oil flows out the top port of the pump Oil flow out of the top port goes to the wheel motors and turns them in the forward direc tion flowing out of the wheel motors returns to the bottom port of the traction pump and is continuously pumped out the top port A small amount of hydraulic oil leaves the traction circuit through the bi directional shuttle valve in the front left wheel motor This oil is cooled as it flows through the oil cooler and returns to the reservoir Filtered hydraulic oil is supplied to the traction circuit from the charge pump through the lift control valve and back through the charge circuit check valves This fil tered oil replaces oil losses from flow through the shuttle valve and small amounts of pump and motor leakage The charge pump and shuttle valve circuits allow for in direct cooling and filtering of the traction circuit If the optional 3 Wheel Drive Kit has been installed the 3WD selector valve allows forward flow to the rear wheel only when the Reel Engagement switch is in the ON position When the reels are switched on the solenoid in the 3WD selector valve is energized and shifted di recting hydraulic flow to the rear wheel motor Reelmaster 2000 D Page4 9 Reverse Direction The traction circuit operates essentially the same in re verse as it does in the forward direction However the flow through the circuit is reversed When the traction pedal is pressed to the reverse posit
57. plates from both sides of the cutting unit Fig 16 2 Remove lock nuts cap screws washers and both links from the cutting unit Fig 16 3 Align fixed side plate with holes on the cutting unit Fig 17 4 Attach fixed side plate to the cutting unit with cap screws washers and flanged lock nuts Fig 17 5 Tighten lock nuts and cap screws 6 Fasten new height of cut plate to the cutting unit with pop rivets Fig 17 7 Repeat steps 1 through 6 on the other side of the cut ting unit Reelmaster 2000 D Page 7 19 Height of cut plate Figure 16 4 Cap screw 5 Washer 6 Link Figure 17 4 Flanged lock nut 5 Height of cut plate 6 Poprivet Cutting Units Skid Kit Installation 1 Remove front roller from the cutting unit see Roller Removal 2 Align skid slots with the angle bracket holes on the cutting unit 3 Secure skid to the cutting unit with both flange head screws flat washers and lock nuts 4 Repeat steps 1 through 3 on the other side of the cut ting unit 5 Adjust skid height as necessary by loosening lock nuts and flange head screws After skid height adjust ment retighten fasteners Cutting Units Page 7 20 Figure 18 1 Skid 4 Flat washer 2 Angle bracket holes 5 Locknut 3 Flange head screw Reelmaster 2000 D Chapter 8 TORO Electrical Diagrams Table of Contents ELECTRICAL SCHEMATICS 3 Serial Numbe
58. pump Fig 21 Connect gauge end of flow tester with pressure gauges to the pump dis charge fitting 5 Connect the other end of the tester to the discon nected hose Make sure that all hoses are free of the flywheel after tester installation 6 Make sure that traction pedal and lift valve are in neu tral and the parking brake is engaged 7 Start and operate engine at full speed 3200 50 RPM 8 Watch flow and pressure gauges carefully while slowly closing the flow control valve until pressure gauge reads 500 PSI 9 Minimum flow gauge reading should be 2 5 GPM If specification is not met repair or replace charge pump Procedure for Lift Relief Pressure Check Do not allow charge pressure to exceed 650 PSI 1 Fully open control valve on the tester 2 Make sure hydraulic oil is at operating temperature Reelmaster 2000 D Page 4 27 3 Operate engine at full speed 3200 50 RPM 4 Watch pressure gauge carefully Make sure lift lever is in the neutral position Record the pressure 5 While holding the lift lever in the raised position watch the pressure gauge Record pressure when the relief valve opens 6 Return lift lever to neutral position Shut off engine 7 Subtract the relief valve closed pressure from the re lief valve open pressure see example below The dif ference should be from 450 to 500 PSI A If this specification is not met adjust lift relief valve B If th
59. reel con tact Unscrew bedbar adjuster left hand threaded while loosening jam nut from the compression spring until the bedbar fitting is clear of the bedbar yoke 2 Remove capscrew lock washer flat washer and spacer from the right end of the bedbar 3 Loosen adjustment nuts on the adjusting housing Fig 9 4 Remove both carriage bolts and nuts from the ad justing housing Fig 9 Cutting Units Page 7 10 5 Remove both carriage bolts and nuts from the bed bar housing Remove bedbar from the cutting unit 6 Remove adjusting housing and bedbar housing from the bed bar Remove bedbar washer 7 If necessary Models 03213 and 03214 remove cap screws and lock nuts to allow removal of weights from bedbar Cap screws have permanent thread locking compound applied and may be difficult to remove 8 Sharpen or replace bedknife as necessary see Bed knife Replacement and Grinding Reelmaster 2000 D Installation 1 Inspect flanged bushings and bushing for wear re place if necessary 2 Clean and apply anti seize lubricant to both bedbar pivots Install bedbar washer on the bedbar 3 Install bedbar adjusting housing and bedbar housing on the bedbar Reinstall spacer flat washer lock wash er and cap screw to the right end of the bedbar 4 Position bedbar assembly to the cutting unit 5 Secure bedbar housing to the cutting unit with both carriage bolts and nuts 6 Secure adjusting housing
60. source to the other terminal of the hour meter 3 The hour meter should move a 1 10 of an hour in six minutes 4 Disconnect the voltage source from the hour meter Reels On Indicator Light The reels on indicator light should illuminate when the reels are engaged Testing Indicator Light 1 Apply 12 VDC to terminal 1A Fig 9 2 Ground terminals 1B Fig 9 3 Indicator light should illuminate Reel Engage Switch The reel engage switch is mounted on the instrument panel and is pulled to engage the cutting reels The Re elmaster 2000 D uses only two of the six switch termi nals When the switch knob is pulled switch terminals 1 COM C and 4 should have continuity Fig 12 When the switch knob is pushed in switch terminals 1 COM C and 4 should not have continuity The Standard Control Module monitors the operation of the reel engage switch If the ignition switch is in the ON position and the reel engage switch is pulled the Module PTO switch input LED should be illuminated Reelmaster 2000 D Page 5 13 1 Hobbs QUARTZ 00001 HOURS Figure 10 B 10 BACK OF LIGHT Figure 11 Figure 12 Terminal 1 COM C 2 Terminal 4 Electrical System Electrical System Glow Relay The glow relay is attached to the instrument panel When energized the glow relay allows electrical current to the glow plugs NOTE Prior to taking small resistance readings
61. spline 2 Gear shaft 4 Gear face edge Assembly Fig 44 1 NOTE When assembling the motor check the marker line on each part to make sure the parts are properly aligned during assembly Hydraulic System 2 5 3 gt 1 Lubricate O rings pressure seals back up gaskets and wear plate grooves with a thin coat of petroleum jel ly Lubricate all other internal parts freely with clean hy draulic oil 2 Install new seals into front flange Fig 44 3 A Press shaft seal into front flange until it reaches the bottom of the bore B Install flange washer into front flange and then install retaining ring into the groove of the front flange C Install new dust seal into front flange 3 Place front flange seal side down on a flat surface 4 Install the pressure seals flat side outward into the grooves in the wear plates Follow by carefully placing the backup gaskets flat side outward between the pressure seals and the grooves in the wear plate 5 Apply alight coating of petroleum jelly to the exposed side of the front flange 6 Lubricate the drive shaft with clean hydraulic oil In sert the drive end of the drive shaft through the wear plate with the pressure seal side down andthe open side ofthe pressure seal pointing to the inlet side of the mo tor Carefully install shaft into front flange 7 Lubricate the idler gear shaft with clean hydraulic oil Install idler gear shaft into the re
62. stem D Place compression spring and detent pin into handle cap Use a small amount of grease to hold detent pin in place E Make sure that flow control cartridge is closed by rotating valve stem fully clockwise During handle installation DO NOT rotate valve stem or speed ad justment will be incorrect F Press handle cap onto valve stem with arrow on cap pointing to number 9 on manifold Make sure that detent pin and spring stay positioned in cap G While pressing on the cap to keep the lip seal in place rotate cap in a clockwise direction until the ar row on the cap aligns with number 1 on the manifold By rotating the cap clockwise the valve will remain closed Install screw to retain cap H Make surethat alignment marks on cap and base areinline and that arrow on capis pointing to number 1 on manifold Tighten two 2 set screws to secure handle cap Reelmaster 2000 D gt 77 This page is intentionally blank E gt 4 63 4 Rev A Hydraulic System Reelmaster 2000 D 3 Wheel Drive Selector Valve Figure 47 1 Forward hydraulic tube 6 90 hydraulic fitting 2 Reverse hydraulic tube 7 screw 3 Locknut 8 Flat washer 4 3WD selector valve 9 Tube clamp 5 Hydraulic fitting 10 Cap screw Hydraulic System Page 4 64 11 O ring 12 O ring 13 Hydraulic hose 14 Frame skirt Reelmaster 2000 D If the optional 3 Wheel Drive Kit has
63. there can be variations in the mounting sur Relief Angle face of the bedbar a new bedknife will not be perfectly flat after it is installed It is therefore necessary to back lap or grind a new bedknife after installing it to the bed bar Follow the existing angle that was ground into the bedknife and grind only enough to make sure the top Ji Front Angle E J Front Face surface is true 6 Install bedbar to the cutting unit see Bedbar Installa tion Figure 11 Regrinding Bedknife Remove bedbar assembly from cutting unit before at tempting to regrind a used bedknife see Bedbar Re moval NOTE When grinding be careful to not overheat the bedknife Remove small amounts of material with each pass of the grinder NOTE If the height of cut is 1 2 inch 13mm or lower on the cutting unit the front angle can be increased to 309 for improved performance Bedknife Regrinding Specifications Relief Angle Front Angle 15 see NOTE above Front Angle Range 13 to 179 Cutting Units Page 7 12 Reelmaster 2000 D Front and Rear Rollers NOTE This section can be used for both the front and rear rollers Roller Removal 1 Remove both height of cut pins and hairpin cotters from each roller bracket 2 Remove both locknuts from the cap screws securing each angle bracket to the cutting unit 3 Remove cap screws from both angle brackets and the cutting unit 4 Separate roller assembly height of cut
64. to deliver optimum mowing perfor mance The precise adjustment possible with the single knob bedbar design gives the necessary control to pro vide a continual self sharpening action This feature maintains sharp cutting edges assures good quality of cut and greatly reduces the need for routine backlap ping In addition the rear roller positioning system permits op timum bedknife attitude and location for varying height of cuts and turf conditions Cutting Units 7 8 If a cutting unit is determined to be out of adjustment complete the following procedures in the specified order to adjust the cutting unit properly 1 Adjust the bedknife parallel to the reel 2 Set height of cut and level the rear roller Verify height of cut and level the front roller 4 Verify reel to bedknife clearance Refer to the Cutting Unit Operator s Manual for adjust ment procedures Reelmaster 2000 D Service and Repairs Hydraulic Reel Motor Removal Fig 7 1 Remove two cap screws holding the hydraulic motor to the bearing housing 2 Remove hydraulic motor o ring and spider coupler from the bearing housing Position hydraulic motor away from the cutting unit prior to removing or working on the cutting unit Inspection 1 Inspect spider coupler for wear Replace spider cou pler if worn 2 Check reel coupler inside bearing housing If reel coupler is loose remove and check for worn threads Replace coupler
65. washer to allow removal of wheel hub and bearings Pull wheel hub with bearings and seal from machine 5 If necessary remove seal and bearings from wheel hub 6 Inspect bearing cups in wheel hub for wear or dam age If bearing cups are damaged replace the wheel hub Reelmaster 2000 D 6 5 Installation Fig 1 1 If seal and inner bearing were removed from the wheel hub place greased bearing cone into inner bear ing cup Install new seal 2 Slide wheel hub onto machine Position greased out er bearing and tab washer onto shaft 3 Install jam nut onto shaft and tighten Back off jam nut and then while rotating wheel hub torque nut from 15 to 20 ft lb 20 to 27 4 Install lock nut retainer cotter pin and dust cap 5 Install wheel and secure with lug nuts 6 Tighten lug nuts evenly in a crossing pattern to a torque of 45 to 65 ft lb 61 to 88 Chassis Rear Wheel Optional 3 Wheel Drive 250 to 400 ft lb 339 to 542 N m 45 to 65 ft lb 61 to 88 N m Figure 2 1 Rear wheel fork 4 Key 7 Wheel assembly 2 Steering tube assembly 5 Drive stud 8 Lock nut 3 Rear wheel motor 6 Wheel hub 9 Lugnut Chassis Page 6 6 Reelmaster 2000 0 Removal Fig 2 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Chock front wheels Raise rear wheel using a jack or hoist Block rear of
66. 0 1 Coat all O rings uni ring and backup washer lightly with hydraulic oil Install new O ring and uni ring to the piston Install O rings and backup washer to the head IMPORTANT Do not clamp vise jaws against shaft surface Protect shaft surface before mounting in vise 2 Mount shaft securely in a vise by clamping vise on the ends of the shaft Slide head onto the shaft Install piston and locknut onto the shaft and tighten lock nut 3 Remove shaft from vise IMPORTANT Prevent damage when clamping the barrel into a vise clamp on the pivot end only Do not close vise enough to distort barrel 4 Mount barrel in a vise so that the shaft end tilts up slightly 5 Coat all internal lift cylinder parts with a light coat of hydraulic oil Slide piston shaft and head assembly into barrel being careful not to damage the seals 6 Secure head in barrel by installing retaining ring Align key slot in head with the access groove in the bar rel Rotate head clockwise as far as the retaining ring will allow The offset end of the retaining ring will be against the left side of the barrel groove as shown in Figure 52 Spanner wrench Retaining ring Offset end against left side of barrel groove after installing Figure 52 Reelmaster 2000 D Page 4 71 Hydraulic System 2 5 amp gt Rear Lift Cylinder 0 Cotter pin Tension spr
67. 345 1338 9 9739 JILYWJHJS YOLOW 1338 831003 11084 Gun Gun 21095 MY04 dhind NOILIVAL 810 83538 80123135 QME 0MZ WO1108 12 141 YY B 34055344 MOT dHfd 398VHJ o WON NONJIW OL 83 ba 2n 83170 YANNI aio cn A 150 051 001 10083 2 a 4331734 308vH 2 131 pasate nore ine 4 IMYA 1081802 1311 1338 1 Pe Ee vem 0 3 0 E H 8 3 i i S DEDI 1 401 WOLLOG 8 38 100 PN SANASSVd Ad LNG 1 8 H0LIOS X3M01 Y AOLOW 1338M KUADAN IWA 1 108 401 RS Nid WYD 10095 JHL A8 H 1 8240 3 32382 FHL I 51815284328 108415 SIHL 310N 24 1 ISAW M04 14914 133HM Hydraulic System 4 7 Reelmaster 2000 D Hydraulic Flow Diagrams JO uinjeH eunsseJg wo HUOM UMOUS 0002 80123145 QME MZ uvis WOION 133HM uy 1894M reuondo 3NIVA 1041802 IMYA ONIdd DID V8 LOW 150 0006 331138 gt lt 1
68. 5 Backlap switch Installation Fig 45 1 Secure hydraulic manifold to the cylinder support bracket and the mounting bracket with three flange head screws 2 Make sure all hydraulic connections ports and fit tings are clean 3 Remove caps or plugs that were put on any hydraulic lines or fittings during disassembly 4 Correctly connect hydraulic lines to the manifold Tighten all hydraulic fittings and connections 5 Reconnect solenoid valve and backlap switch elec trical connectors 6 Install hood 7 Follow Hydraulic System Start up procedures Reelmaster 2000 D 9 5 N UO gt gt N T This page is intentionally blank Reelmaster 2000 D Page 4 59 Hydraulic System Hydraulic Manifold Service Serial Number Below 290000000 35 ft Ib 15in Ib 7 33 6 47 N m DD 25 009 Thread locking gt GJ Compound de e Mi 955 990 5 17 35 ft lb 7 7 p vw na 47 N m E RES Thread locking 11 4 Compound 8 25523 A E PLUG TORQUE SAE 2 60 in Ib 6 8 N m SAE 4 135 in Ib 15 3 N m SAE 6 18 ft Ib 24 4 N m SAE 8 45 ft Ib 61 N m Figure 46 1 Logic cartridge port LC1 12 O ring 23 Manifold body 2 Seal kit 13 Reel relief cartridge port R1 24 Ball 3 Plug SAE 4 14 Seal kit 25 Spring 4 O ring 15 Reel speed cartridge port FC1 26 Knob 5 Plug SAE 8 16 Seal kit 27 Jam
69. 7 f major repairs are ever needed or assistance is de sired contact an Authorized Toro Distributor 8 Use care when checking the cutting reels Wear gloves and use caution when servicing them 9 To reduce potential fire hazard keep engine area free of excessive grease grass leaves and dirt Clean protective screen on machine frequently 10 If engine must be running to perform maintenance or an adjustment keep hands feet clothing and other parts of the body away from cutting units and other mov ing parts Keep bystanders away Reelmaster 2000 D Page 1 3 F Do not park on slopes unless wheels are chocked or blocked 11 Do not overspeed the engine by changing governor setting To assure safety and accuracy check maximum engine speed 12 Shut engine off before checking or adding oil to the crankcase 13 Disconnect battery before servicing the machine Disconnect negative battery cable first and positive cable last If battery voltage is required for troubleshoot ing or test procedures temporarily connect the battery Reconnect positive cable first and negative cable last 14 Battery acid is poisonous and can cause burns Avoid contact with skin eyes and clothing Protect your face eyes and clothing when working with a battery 15 Battery gases can explode Keep cigarettes sparks and flames away from the battery 16 At the time of manufacture the machine conformed to the safety standards for riding mow
70. 88 9 16 0 5625 14 288 5 64 0 078125 1 984 37 64 0 578125 14 684 3 32 0 09375 2 381 19 32 0 59375 15 081 7 64 0 109275 2 778 39 64 0 609375 15 478 1 8 0 1250 8 175 5 8 0 6250 15 875 9 64 0 140625 3 572 41 64 0 640625 16 272 5 32 0 15625 3 969 21 32 0 65625 16 669 11 64 0 171875 4 366 43 64 0 671875 17 066 3 16 0 1875 4 762 11 16 0 6875 17 462 13 64 0 203125 5 159 45 64 0 703125 17 859 7 32 0 21875 5 556 2332 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64 0 765625 19 447 9 32 0 28125 7 144 25 32 0 78125 19 844 19 64 0 296875 7 541 51 64 0 796875 20 241 5 6 0 3125 7 938 13 16 0 8125 20 638 21 64 0 328125 8 334 53 64 0 828125 21 034 11 32 0 34375 8 731 27 32 0 84375 21 431 23 64 0 359375 9 128 55 64 0 859375 21 828 3 8 0 3750 9 525 7 8 0 8750 22 225 25 64 0 390625 9 922 57 64 0 890625 22 622 13 32 0 40625 10 319 29 32 0 90625 23 019 27 64 0 421875 10 716 59 64 0 921875 23 416 7 6 0 4375 11 112 15 16 0 9375 23 812 29 64 0 453125 11 509 61 64 0 953125 24 209 15 32 0 46875 11 906 31 32 0 96875 24 606 31 64 0 484375 12 303 63 64 0 984375
71. Cutting Units Prepare Reel for Grinding NOTE Check to make sure reel bearings are in good condition and properly adjusted before grinding reel 1 Remove bedbar assembly see Bedbar Removal and Installation 2 Remove front roller and brackets see Roller Remov al and Installation NOTE Most reel grinders require that the rear roller as sembly be mounted to the cutting unit for proper support in the reel grinder The rear roller must be parallel to the reel shaft to remove taper when grinding or the cutting unit must be aligned so the grinding wheel will travel par allel to the reel shaft This will result in the the reel being ground to the desired cylinder shape NOTE When grinding be careful to not overheat the reel blades Remove small amounts of material with each pass of the grinder 3 After completing grinding process A Install front roller and brackets see Roller Re moval and Installation B Install bedbar assembly see Bedbar Removal and Installation C Complete cutting unit set up and adjustment se quence see Cutting Unit Operator s Manual Reel Grinding Specifications Nominal Reel Diameter 7 inches 178 mm Service Limit 6 2 inches 158 mm Reel Diameter 0 060 inch 1 5 mm BLADE RELIEF ANGLE REEL DIAMETER TAPER D Figure 15 Cutting Units Page 7 18 Reelmaster 2000 D Fixed Side Plate Installation 1 Remove pop rivets and rear height of cut
72. D SOLENOID 7 a OI 1 3 10A is T o T VIO Em T C put Reelmaster 2000 D X Y REELS ON OFF SW 1 1 BU o w Electrical Schematic OPTIONAL LIGHT Serial Number Above 230000000 All relays and solenoids are shown as de energized All ground wires are black Page8 4 Rev a gt RUN SOLENOID SY R BK o T v gt F2 10 BU NOT SUPPLIED chance ER CONTROLLER GLOW PLUG DAIHATSU 5 ge GLOW PLUGS 3 rH ee wt ALTERNATOR HOUR METER OVER TEMP SHUTDOWN BU W 2 ENGINE DIL PRESSURE w S9 r J gt 1 D R t GN GY S GN 5 a bese 5 i 5 x 4 4 1 2 4 START AV Aum dci 2 v A p 2 HIGH TEMP SW PTO COIL 14 C ide 59 IGN SW I RUN p a i Men i i OPTIONAL SEAT SW TNR REEL UP REEL DRIVE 4 D 6 a PARKING BRAKE ENGAGED PN 25 PARKING BRAKE em sw hu LIMIT SW 03 SOLENOID ENGINE H OR lt
73. Donotparkonslopes unless wheels are chocked or blocked Reelmaster 2000 D D Stop engine and remove key from ignition switch E Anytime the machine is parked short or long term the cutting units should be lowered to the ground This relieves pressure from the lift circuit and eliminates the risk of cutting units accidentally lowering to the ground Maintenance and Service 1 Before servicing or making adjustments lower decks stop engine set parking brake and remove key from the switch 2 Make sure machine is in safe operating condition by keeping all nuts bolts and screws tight 3 Never store the machine or fuel container inside where there is an open flame such as near a water heat er or furnace 4 Make sure all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition be fore applying pressure to the system 5 Keep body and hands away from pin hole leaks in hy draulic lines that eject high pressure hydraulic fluid Use cardboard or paper to find hydraulic leaks Hydraulic fluid escaping under pressure can penetrate skin and cause injury Fluid accidentally injected into the skin must be surgically removed within a few hours by a doc tor familiar with this form of injury or gangrene may re sult 6 Before disconnecting or performing any work on the hydraulic system all pressure in system must be re lieved by stopping engine and lowering cutting units to the ground
74. Figure 12 1 Height of cut pin 6 Angle bracket 2 Hairpin cotter 7 Front roller assembly 3 Height of cut bracket 8 Flanged bushing 4 Locknut 9 Bushing 5 screw 10 Carriage bolt 5 Mount roller height of cut brackets and angle brackets to the cutting unit Secure height of cut brack ets and angle brackets to the cutting unit with cap Screws 6 Install both height of cut pins and hairpin cotters 7 Install locknuts to the cap screws and secure each angle bracket to the cutting unit 8 Adjust roller level see Cutting Unit Operator s Manu al Cutting Units Roller Service See assembly process for tightening procedure Figure 13 Full roller Roller shaft Grease seal Bearing cup Disassembly 1 Clean inside of roller around both adjustment nuts and roller shaft ends Both areas should be free of dirt and debris 2 Remove adjustment nut from one end of the roller shaft On the sectional roller remove adjustment nuts from each end of the roller 3 Keep roller level and slide the shaft with the remain ing adjustment nut out of the roller On the sectional roll er slide both sectional rollers off the shaft 4 Secure roller in a vise 5 Remove outer seals Cutting Units Bearing cone outer Outer seal Adjustment nut Grease fitting Page 7 14 9 Wiehle roller 10 Sectional roller shaft 11 Bearing cone inner 12 Sectional roller 6 Remov
75. Handle assembly 8 Solenoid relief valve port SV 15 8 zero leak plug with O ring 2 Flow control cartridge port FC 9 Solenoid coil 16 Spring pin 3 4 zero leak plug with O ring 10 Nut 17 Retaining ring 4 Orifice 0 076 port OR2 11 Backlap switch 18 Check valve 5 Orifice port OR1 12 Dowel pin 19 Back up ring 6 Pilot directional element port EP 13 Ball 20 Spool 7 6 zero leak plug with O ring 14 O ring 21 O ring NOTE The ports on the manifold are marked for easy identification of components Example P1 is the gear pump connection port and SV is the location for the sole noid cartridge See Hydraulic Schematics to identify the function of the hydraulic lines and cartridge valves at each port Hydraulic System Page 4 63 1 Rev A NOTE The hydraulic manifold shown in Figure 46 1 uses several zero leak plugs These plugs have a ta pered sealing surface on the plug head that is designed to resist vibration induced plug loosening The zero leak plugs also have an O ring as a secondary seal If zero leak plug removal is necessary lightly rap the plug head using a punch and hammer before using an allen wrench to remove the plug the impact will allow plug re moval with less chance of damage to the socket head of the plug Reelmaster 2000 D Hydraulic Manifold Service 1 Make surethe manifold is thoroughly cleaned before removing any cartridge valve 2 If solenoid cartridge valve is being serviced remove
76. IPPED A 15 OHM STANDARD CONTROL MODULE NOTE The engine will crank with either the parking brake engaged or the seat occupied Reelmaster 2000 D Crank Circuit Serial Number Below 230000000 Shown Power Current Control Current Indicator Gauge Current Logic Direction 5 lt R BK E R gt RUN SOLENOID L ALTERNATOR lt gt 8 HOUR METER Y OVER TEMP SHUTDOWN 1 t ENGINE DIL PRESSURE 27 GY Y P 1 GN 0 GY amp BUW T GN E wo EISE E 3 E 1 5 i e y START 12 V KA ION ONION ON N 5 HIGH TEMP SW pro con lea Y C C C BU W xS i gt gt it GN C l GN SW 717 RUN ii REEL UP E Uia PARKING BRAKE DISENGAGED A lt SS a LIMIT Sw REEE BRIVE 1 1 i 1 3 E 2 1 PARKING BRAKE SW c 0 LENOIO ENGINE P f Ge a mro Bi 1551 IN UP POSITION P pia ENGINE GROUND t 4 4 4 BACKLAP IN OFF Y 22 BACKLAP NOT USED Si 24 SEAT SW GROUND 1 BK 5 BK eee jy ee
77. NK 8 Him SEAT sw GRAY 2 PINK PINK 2 P5 HOUR METER u SP BLACK 3 2 BLACK WHITE 5 OPTIONAL LIGHT 3 BLACK SEAT SW 2 o Sp PINK 5 BLACK PINK I oil press D SP6 GRAY 2 PIs WARNING LIGHTS X WHITE 2 alt z WHITE _ 5 p32 150 RESISTOR x 8 dE RED 2 zx 3 5 BLACK 5 I over temp e BLUE WHITE mm E pig WARNING LIGHTS Sp B glow REEL ENGAGE SW 5 x Sa 6 c T E BLACK RONN P 3 WD COIL _ VIOLET z VIOLET z 5 ORANGE 5 z 8 ui z ux i gt 5 2 2 5 lt 2 0 lt tr a tc I 5 a z m B C DEF 8 b E F 1022 12345 222 254 58 76 3085 8786 5 GLOW P30 P36 P34 P22 PI3 STANDARD CONTROL MODULE F5 INTERCONNECT GLOW RELAY GLOW CONTROLLER Reelmaster 2000 D ae Main Wire Harness HOLDER Serial Number Above 230000000 Page 8 12 Rev A P5 HOUR METER p19 WARNING LIGHTS P35 REELS ON P30 STANDARD CONTROL MODULE P31 STANDARD CONTROL MODULE P22 GLOW RELAY J5 OPTIONAL LIGHT F5 SINGLE FUSE HOLDER p25 REEL ENGAGE SW P34 INTERCONNEC T 33 INTERCONNEC T
78. ONNECTION FOR R H WHEEL MOTOR SHOWN lt CHARGE RELIEF 0 FROM LIFT CONTROL VALVE gt LIFT CONTROL VALVE CHARGE PUMP FROM RESERVOIR REVERSE TRACTION PUMP FRONT LINE TO RESERVOIR TO HYDRAULIC MANIFOLD PORT T2 WHEEL MOTOR Return or Suction Working Pressure 7 Low Pressure Charge Flow Figure 31 NOTE Over a period of time a wheel motor can wear internally A worn motor may by pass oil to its case drain causing the motor to be less efficient Eventually enough oil loss will cause the wheel motor to stall under heavy load conditions Continued operation with a worn inefficient motor can generate excessive heat cause damage to seals and other components in the hydraulic system and affect overall machine performance Hydraulic System Page 4 38 Reelmaster 2000 D Procedure for Wheel Motor Case Drain Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 2 Park machine on a level surface with the cutting units lowered and off Make sure engine is off and the parking brake is engaged 3 Read Precautions For Hydraulic Testing 4 Make sure that traction pedal is adjusted to the neu tral position see Traction Unit Operator s Manual 5 Attach a heavy chain between the rear of the ma chine frame and an immovable object
79. PINK 5 BLACK PINK 5 6 w GRAY z WHITE 28 V WHITE m A A z gt SN amp 4 RED gat PINK x 5 zz PINK n Q gt BLACK IA BLUE WHITE SP 3 PINK 2A 4 28 5 Y TON n 2 1 tc A 8 BLACK A BROWN 8 VIOLET 2 VIOLET tr MEM E 5 ORANGE I am T 2 Im 2 Reelmaster 2000 D B E F BC F 6 H A Bc 12325 345 6 3085 81786 S GLOW Main Wire Harness P30 P3I P34 Pe2 INTERCONNECT GLOW RELAY GLOW CONTROLLER P35 P19 REELS ON WARNING LIGHTS 2 SoS 4 OPTIONAL LIGHT i ue P34 2 5 INTERCONNECT 2 iT P5 HOUR METER 1 1 e P22 GLOW RELAY X 5 S2 3 RA 5 2 RO P P25 4 IGNITION SW REEL ENGAGE SW CONTROL MODULE SP3 P33 INTERCONNECT P30 STANDARD P31 1 STANDARD CONTROL MODULE J2 IGNITION SW I
80. PSI If specification is not met inspect charge relief valve in traction pump 8 A dynamic charge pressure test can be performed as follows A With and pressure gauge still con nected sit in the operator seat and press the traction pedal to forward B While machine is moving monitor the charge pressure reading on the pressure gauge do not acti vate the lift control while monitoring charge pres Sure C The charge pressure should drop no more than 1596 from initial test reading Step 7 above A pres sure drop of more than 15 indicates a traction cir cuit leak e g a worn or damaged piston pump and or wheel motor 9 Shut off engine 10 Disconnect gauge and T connection from the pump and hose Reconnect hose to the pump Figure 23 1 Traction pump 2 Hose from lift control 2 gt Reelmaster 2000 D Page 4 29 Hydraulic System TEST 6 Reel Gear Pump Flow Using Tester With Pressure Gauges and Flow Meter FILTER p TO CHARGE PUMP tue RESERVOIR TO TRACTION PUMP Y GEAR PUMP resteR FROM LEFT WHEEL MOTOR HYDRAULIC MANIFOLD Working Pressure Low Pressure Charge Return or Suction Flow Figure 24 Hydraulic System Page 4 30 Reelmaster 2000 D Procedure for Reel Gear Pump Flow Test 1 Make sure hydraulic oil is at
81. RTANT Use care when handling the valve cartridge Slight bending or distortion of the stem tube can cause binding and malfunction B Thread cartridge valve carefully into correct man ifold port The valve should go in easily without bind ing C Torque cartridge valve using a deep socket to 35 ft lb 47 9 If solenoid cartridge was removed carefully install solenoid coil to the cartridge valve making sure that seal is placed on both sides of the coil Apply medium strength thread locking compound to the threads of the valve Torque nut to 15 in Ib 1 7 10 If reel speed control cartridge valve or backlap car tridge valve was removed reinstall knob assembly to cartridge stem A Install locating plate so that the pin seats into the locating hole B Turn the threaded spool valve stem carefully clockwise until it stops C Place detent plate counterbore down and thread detent plate down onto the valve stem until it is stopped by the locating plate Turn detent plate back counterclockwise 1 4 turn D Center one detent plate hole over a locating plate indentation Drop a ball into each hole and then drop a spring into each hole E Place indicator plate over the detent plate On backlap valve make sure the arrow points to the right at 459 On reel speed control valve make sure the arrow points directly at the number 1 on the locating plate F While pushing down on the indicator plate and compressi
82. Seat Figure 5 1 Seat incl 2 thru 7 6 Seat cushion 2 Seat switch 7 Seat shell 3 screw 8 Seat adjuster 4 Edging clip 9 5 Edging 10 Flange hex nut Removal 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Remove four cap screws and lock nuts securing the seat to the machine frame 3 Disconnect electrical connector from the seat switch Separate seat from the frame 4 Remove seat parts as necessary to make repairs us ing Figure 5 as a guide Chassis Page 6 10 11 Cap screw 12 Lock washer 13 Seat stop Seat adjuster with latch 14 Cap screw 15 Flange nut Installation 1 2 3 4 loc Install any new seat parts using Figure 5 as a guide Position seat to the machine frame Connect electrical connector to the seat switch Secure seat to the frame with four cap screws and k nuts Reelmaster 2000 D Suspension Seat Figure 6 1 Plate 16 Adjusting rail LH 31 Washer 2 Rivet 17 Screw 32 Backrest trim 3 Screw 18 Washer 33 Tension spring set 4 Wear parts kit incl 8 thru 11 19 Nut 34 Spindle adjuster incl 29 thru 5 Tension spring set 20 Swing arm assembly incl 28 amp 42 35 Screw 6 Handle grip 21 Adjusting rail RH 36 Cover 7 Adjusting lever 22 Bottom trim 37 Clam 8 Cover 23 Seat frame 38 Shock absorb 9 Bumper 24 Screw 10
83. Shown Power Current Control Current Indicator Gauge Current gt Logic Direction Page8 8 Rev A This page is intentionally blank Page 8 9 Rev A PARKING BRAKE NEUTRAL SW P20 SEAT SW P21 SEAT SW 2 REEL ENGAGE SW P25 Page 8 10 Rev A STANDARD CONTROL MODULE PI2 P5 J5 FUSE BLOCK HOUR METER OPTIONAL LIGHT oil press PIS alt over 19 glow WARNING LIGHTS 15 Q RESISTOR temp WARNING LIGHTS 3 WD COIL Serial Number Below 230000000 INTERCONNECT STARTER B REELS ON IGNITION SWITCH 33 4 P35 Je P6 X Y ABS F G H 28226 IA 1B 2A 28 j 35 GREEN RED BLACK ORANGE 2 8 ORANGE V BLUE 4 9 5 Y E A YELLOW 1 8 J BLACK in 5 GRAY m 21 2 2 SP BLACK 3 2 BLACK WHITE BLACK us SPI
84. Traction Unit Operator s Manual 7 Install hood on the machine Engine Engine Removal 1 Park machine on a level surface lower cutting units stop engine and remove key from the ignition switch Chock wheels to keep the machine from moving 2 Disconnect positive and then negative battery cables at the battery 3 Gain access to the engine A Open and remove hood from the machine see Traction Unit Operator s Manual B Remove right side panel to gain access to the traction pump drive belt C Remove left rear panel radiator side which sup ports the instrument panel 4 Remove left fender and fender bracket from the ra diator side of the frame Fig 10 A Remove cap screw and flange nut holding the left footrest to the left fender B Remove remaining cap screws and flange nuts securing the left fender to the fender bracket and frame Remove fender from the frame C Remove both flange head screws and left fender bracket from the frame 5 Remove cotter pin from brake rod Disconnect brake rod from brake lever Fig 11 6 Remove cap screws and flange nut securing the left footrest to the frame Fig 10 Remove the left foot rest from the machine 7 Drain and remove radiator see Radiator removal 8 Drain and remove hydraulic reservoir see Hydraulic Reservoir in Service and Repair section of Chapter 4 Hydraulic System 9 Remove exhaust system see Exhaust System Re moval
85. Y 331134 131 Nid WYD 10045 381 AG 32382 JHL 10885 5141 310N 831113 3NIVA 1041502 20055349 M01 WON NONJIW OL WOLLOS gt 0112 81 39 2 150 06 00 331134 30NVH2 1331 801084 133HM 01109 55 4 C NIT ayaa M304 3Sd3A38 14 1894M reuondo _ guy M304 C 1H918 80104 133HM N11 11083 3S83A38 142 141 11083 1411 Reelmaster 2000 D Page 4 10 Hydraulic System Lift Circuit The charge pump is part of the traction pump and is di rectly coupled to it It supplies hydraulic pressure for raising and lowering cutting units and maintaining 100 to 150 PSI to the low pressure side of the traction circuit piston pump The charge pump takes its suction through a filter from the reservoir During conditions of not lifting or lowering cutting units flow from the charge pump goes to the lift control valve and is by passed Fig 8 directly to the suction of the piston pump and the charge relief valve Maximum lift lower circuit pressure 475 PSI is limited by a relief valve in the lift relief manifold located near the lift control valve Raise Cutting Units When the cutting units are to be raised the contr
86. al interlock switches is included in the Component Testing section of this Chapter Electrical System 6 To p E 9g Adjustments Neutral Switch 1 Adjust the neutral switch so that the switch opens when the traction pedal is moved forward 1 inch 2 5 cm measured at the top of pedal Figure 3 1 Traction pedal 3 Traction arm 2 Neutral switch Parking Brake Switch 1 Adjust parking brake switch so switch opens within two 2 clicks of parking brake lever movement Figure 4 1 Parking brake lever 2 Brake switch Electrical System Page 5 10 Reelmaster 2000 D Component Testing For accurate resistance and or continuity checks elec trically disconnect the component being tested from the circuit e g unplug the ignition switch connector before doing a continuity check NOTE Electrical troubleshooting of any 12 Volt power connection can be performed through voltage drop tests without disconnecting the component Ignition Switch The ignition key switch has three positions OFF ON and START The terminals are marked as shown The circuit wiring of the ignition switch is shown in the chart With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists between the various terminals for each position Verify continuity between switch terminals POSITION CIRCUIT B l A X Y START The Standard Control Module monitors the o
87. alve should go in easily without bind ing C Torque cartridge valve using a deep socket from 35 to 40 ft lb 47 to 54 8 If solenoid cartridge was removed A Carefully install solenoid coil to the cartridge valve making sure that seal is placed on both sides of the coil B Apply medium strength thread locking com pound to the threads of the valve C Torque nut from 4 to 6 ft lb 5 4 to 8 1 9 After reassembly if problems still exist remove valve and clean again or replace valve Hydraulic System 2 5 amp gt Front Lift Cylinder HYDRAULIC FITTING SIDE Hydraulic hose Hydraulic hose Hydraulic hose Hydraulic hose Hydraulic tee fitting O ring O ring Hydraulic System INSTALL FLANGE BUSHINGS 18 FROM THE INSIDE Figure 49 8 Lift cylinder 9 Cotter pin 10 Clevis pin 11 Flange head screw 12 Lift hub 13 Cotter pin Page 4 68 14 Clevis pin 15 Lift chain clevis 16 Cylinder guide pin 17 Cylinder support bracket 18 Flange bushing 19 Valve mount bracket Reelmaster 2000 D Removal Fig 49 1 Park the machine on level surface engage the parking brake lower the cutting units and stop the en gine Remove the key from the ignition switch Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil 2 Remove cutting units from front lift ar
88. and lift cylinder 6 Rotate lift cylinder while swinging the lift cylinder down from the frame so the hydraulic fittings 11 and 12 clear the exhaust system 7 Remove cotter pin 1 and flat washer 14 from cle vis pin 15 Support lift cylinder and slide clevis pin with second flat washer out of the lift arm Remove lift cylin der from machine 8 Remove hydraulic fittings 11 and 12 and O rings from the lift cylinder Reelmaster 2000 D Page 4 73 Installation Fig 53 1 Coat new O rings lightly with clean hydraulic oil Install hydraulic fittings with new O rings to the lift cylin der 2 Position lift cylinder inside frame pivot supports Install ram pivot pin and washer head screw 3 Swing the lift cylinder up so the clevis is positioned at the lift arm slot Slide a flat washer onto the clevis pin Slide clevis pin through the lift cylinder clevis and the lift arm slot Install remaining flat washer and then cotter pin onto the clevis pin 4 Remove caps or plugs from disconnected hoses Install hose connections onto hydraulic fittings Tighten hydraulic hose fittings 5 Install cutting unit to rear lift arm see Traction Unit Operator s Manual 6 Check and adjust rear carrier frame height see Trac tion Unit Operator s Manual 7 Follow Hydraulic System Start up procedures Hydraulic System 2 gt gt lt Rear Lift Cylinder Service Figure 54 Disassembly Fi
89. and remove key from pump trunnion 6 Disconnect all hydraulic hoses connected to the hy draulic fittings on the piston and reel drive pumps Allow hoses to drain into a suitable container Cap or plug openings of pumps and hoses to prevent contamination Support piston and gear pumps when removing them from the pump support to prevent them from falling and causing personal injury 7 Remove both cap screws hardened washers and lock nuts securing the piston pump to the pump support Pull pump assembly from the machine Hydraulic System Page 4 46 8 Remove reel drive pump from the piston pump see Reel Drive Pump Removal 9 Remove hydraulic fittings and O rings from the pumps as required 10 If necessary loosen socket head set screw in taper lock bushing and remove bushing from the piston pump shaft Locate and remove key from piston pump shaft Piston Pump Installation Fig 35 1 Make sure the inside of the taper lock bushing is clean Apply anti seize lubricant to both the piston pump shaft and the inside of the taper lock bushing Position key to pump shaft Slide bushing onto shaft 2 Apply medium strength thread locking compound to bushing socket head set screw Secure taper lock bush ing to the marked position on the piston pump shaft with set screw 3 Remove caps and plugs that were placed during dis assembly from pumps Install O rings and hydraulic fit tings to their original positions on the pist
90. apscrew 13 Flange head screw 23 Engine mount Flat washer 14 Flange nut 24 Cap screw Bushing 15 Cap screw 25 Cap screw Pulley 16 Flat washer 26 Cap screw Key 17 Lock nut 27 Lock nut Hardened washer 18 Upper alternator bracket 28 Cap screw Lower alternator bracket 19 Alternator 29 Lock washer 0 Front engine frame 20 Cap screw Remove engine from machine Fig 15 A Attach short section of chain between lift tabs lo cated on each end of the cylinder head B Connect a hoist or chain fall at the center of the short section of chain Apply enough tension on the short chain so that the engine will be supported as the engine mount brackets are removed C Remove cap screws snubbing washers and lock nuts that secure the engine with frames and channel to the engine mounts One person should operate lift or hoist while the other person guides the engine out of the ma chine IMPORTANT Make sure not to damage the engine fuel hoses hydraulic lines electrical harness or other parts while removing the engine D Remove engine with engine frames and chan nel from the machine Page 3 16 Reelmaster 2000 D Engine Installation 1 Locate machine on a level surface with cutting units lowered and key removed from the ignition switch Chock wheels to keep the machine from moving 2 Make sure that all parts removed from the engine during maintenance or rebuilding are reinstalled to the engine
91. art up procedure be used This procedure reduces the chance of damag ing the system or its components from not purging the system of air 1 After the hydraulic system components have been properly installed and if the traction pump was rebuilt or replaced make sure traction pump housing is at least half full of clean hydraulic oil 2 Make sure all hydraulic connections and lines are se cured tightly 3 Make sure hydraulic reservoir is full Add correct oil if necessary see Traction Unit Operators Manual Drain flush and refill hydraulic system reservoir and change oil filter if component failure was severe or sys tem is contaminated 4 Disconnect electrical connector to the fuel stop sole noid to prevent engine from starting 5 After repairs check control linkage for proper adjust ment binding or broken parts 6 Make sure traction pedal is in neutral and the cutting unit switch is off Turn ignition key switch to start en gage starter for fifteen 15 seconds to prime pump 7 Attach electrical connector to the fuel stop solenoid 8 Make sure traction pedal is in neutral and the cutting unit switch is off Start engine and run it at low idle The charge pump should pick up oil and fill the hydraulic sys tem If there is no indication of fill in 30 seconds stop the engine and determine the cause Hydraulic System Page 4 42 Be careful when operating the cutting unit reels Contact with the reel or ot
92. ation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Ser vice Manual The following factors shall be considered when applying torque cleanliness of the fastener use of a thread sealant e g Loctite degree of lubrication on the fastener presence of a prevailing torque feature hardness of the surface underneath the fastener s head or similar condition which affects the installation Fastener Identification Grade 5 Inch Series Bolts and Screws Figure 1 Reelmaster 2000 D Page2 3 As noted in the following tables torque values should be reduced by 25 for lubricated fasteners to achieve the similar stress as a dry fastener Torque values may also have to be reduced when the fastener is threaded into aluminum or brass The specific torque value should be determined based on the aluminum or brass material strength fastener size length of thread en gagement etc The standard method of verifying torque shall be per formed by marking a line on the fastener head or nut and mating part then back off fastener 1 4 of a turn Measure the torque required to tighten the fastener until the lines match up Class 8 8 Class 10 9 Metric Bolts and Screws Figure 2 Product Records and Maintenance Product Records i gt Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series Grade 1
93. attery and electrical component failure can be prevented A CAUTION When working with batteries use extreme cau tion to avoid slashing or spilling electrolyte Electrolyte can destroy clothing and burn skin or eyes Always wear safety goggles and a face shield when working with batteries Electrolyte Specific Gravity Fully charged 1 265 corrected to 80 F 26 79C Discharged less than 1 240 Battery Specifications BCI Group Size 55 585 CCA at 0 F 18 C Reserve Capacity of 95 minutes at 80 F 27 C Dimensions including terminal posts and handle Length 9 0 inches 22 9 cm Width 6 0 inches 15 2 cm Height 8 5 inches 21 6 cm Removal and Installation Fig 29 1 Loosen and remove negative cable from battery Af ter negative cable is removed loosen and remove posi tive cable 2 Loosen flange nuts that secure battery bracket Slide bracket away from battery 3 Carefully remove battery from machine 4 Install battery in reverse order making sure to con nect positive cable to battery before connecting nega tive cable NOTE Before connecting the negative ground cable connect a digital multimeter set to amps between the negative battery post and the negative ground cable connector The reading should be less than 0 1 amp If the reading is 0 1 amp or more the unit s electrical sys tem should be tested and repaired Inspection Maintenance and Testing 1 Perform following inspections a
94. aulic fluids specified in Traction Unit Oper ator s Manual Other fluids could cause system dam age 5 Fill hydraulic reservoir 6 Disconnect electrical connector to the fuel stop sole noid to prevent engine from starting 7 Turn ignition key switch to start engage starter for ten 10 seconds to prime hydraulic pump Repeat this step again 8 Attach electrical connector to the fuel stop solenoid 9 Start engine and let it idle at low speed for a minimum of two 2 minutes 10 Increase engine speed to high idle for minimum of one 1 minute under no load 11 Raise and lower cutting units several times Reelmaster 2000 D Page 4 41 Figure 32 1 Hydraulic reservoir cap 2 Sight gauge Figure 33 1 Hydraulic filter 2 Footrest 12 Shut off engine and check for hydraulic oil leaks Check oil level in hydraulic reservoir and add correct oil if necessary 13 Operate the machine for two 2 hours under normal operating conditions 14 Check condition of hydraulic oil If the fluid shows any signs of contamination or if you are changing to biode gradable fluid repeat steps 1 through 14 again 15 Resume normal operation and follow recommended maintenance intervals Hydraulic System 2 gt gt lt Hydraulic System Start up NOTE When initially starting the hydraulic system with new or rebuilt components such as motors pumps or lift cylinders it is important that this st
95. aulic reser voir and add correct oil if necessary Check hydraulic lines and hoses daily for leaks kinked lines loose mounting supports wear loose fittings weather deterioration and chemical deterioration Make all necessary repairs before operating Reelmaster 2000 D Flush 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 con tains metal particles IMPORTANT Flush hydraulic system when chang Ing from petroleum base hydraulic fluid such as Mobil DTE 15M to biodegradable fluid such as Mo bil EAL 224H Operate machine under normal oper ating conditions for at least four 4 hours before draining 1 Park machine on a level surface Lower cutting units stop engine engage parking brake and remove key from ignition switch 2 Clean area around filter mounting area Remove fil ter and drain reservoir into a suitable container Drain hydraulic system Drain all hoses tubes and compo nents while the system is warm Discard filter 3 Inspect and clean reservoir see Inspecting Reser voir Parts 4 Make sure filter mounting surface is clean Apply hy draulic oil to gasket on the new filter Screw filter on until gasket contacts mounting plate then tighten filter half a turn NOTE Use biodegradable fluid such as Mobil EAL 224H for this step if you are changing to this type of fluid Use only hydr
96. b 47 N m Figure 43 1 Flange nut 3 Reel motor 2 Coupling 4 Key 7 Place O ring on face seal of hydraulic fitting Secure hydraulic fitting to the reel motor ensuring that the matchmarks are aligned Repeat this step for the re maining hydraulic fittings 8 Inspect threads and sealing surfaces of hose con nections Replace any damaged or worn connections 9 Secure hose connection to the hydraulic fitting Re peat this step for the remaining hydraulic fittings 10 Install reel motor to cutting unit see Repair section of Chapter 7 Cutting Units 11 Follow Hydraulic System Start up procedures Hydraulic System 2 3 gt Cutting Reel Motor Service Serial Number Below 290000000 10 to 12 ft Ib 14 to 16 N m 25 to 28 ft Ib 13 34 to 38 N m MED 15 Figure 44 1 Relief valve plug 8 Idler gear assembly 14 Frontplate 2 O ring 9 Drive gear assembly 15 Screw 3 Shim 10 Key 16 Retaining ring 4 Spring 11 O ring 17 Oil seal 5 Ball 12 Body 18 Backup washer 6 Relief valve seat 13 Alignment pin 19 Relief valve assembly 1 thru 5 7 Backplate The front cutting reel motors are identical The rear cut ting reel motor has a different back plate than the front motors Service for front and rear reel motors is identi cal Disassembly Fig 44 1 Make sure key is removed from the drive gear shaft 2 Matchmark frontplate body and backplate to assure pr
97. been installed the 3WD selector valve removal and installation procedure is as follows Removal Fig 47 1 Park the machine on a level surface engage the parking brake lower the cutting units and stop the en gine Remove the key from the ignition switch Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil 2 Clean selector valve and hydraulic fittings 3 Put caps or plugs on any hydraulic lines or fittings left open or exposed Put labels on disconnected hydraulic lines and hoses for proper reassembly 4 Loosen lock nut and cap screw that secure tube clamp so the hydraulic tubes can be moved 5 Disconnect two hydraulic hoses and two hydraulic tubes from hydraulic fittings on selector valve Allow hy draulic oil to drain from hoses and tubes into a suitable container 6 Disconnect electrical connector from solenoid valve on selector valve 7 Remove cap screws and flat washers that secure se lector valve to frame skirt 8 Remove selector valve from machine 9 Remove fittings and O rings from selector valve Discard O rings Reelmaster 2000 D Page 4 65 Installation Fig 47 1 Install hydraulic fittings and new O rings into selec tor valve 2 Position selector valve to the machine Secure se lector valve to the frame skirt with two cap screws and flat washers 3 Remove caps or plugs that were put on any hydraulic lines or fitt
98. ck for restriction in the pump suction hose If suction hose is not restricted remove reel gear pump and repair or replace as necessary Figure 25 Reel gear pump 3 Suction hose 2 Hose to manifold P1 2 gt gt Figure 26 1 Disconnected hose 3 O ring 2 Reel gear pump Reelmaster 2000 D Page 4 31 Hydraulic System TEST NO 7 Manifold Relief Valve Pressure Using Tester With Pressure Gauges and Flow Meter G1 FROM REEL DRIVE PUMP gt FROM CARTRIDGE VALVES AND LEFT WHEEL MOTOR HYDRAULIC MANIFOLD Working Pressure Low Pressure Charge Return or Suction Flow Install tester in series between fitting hose at the motor right hand motor shown Figure 27 Hydraulic System Page 4 32 Reelmaster 2000 D Procedure for Manifold Relief Valve Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Park machine on a level surface with the cutting units lowered Make sure engine is off and the parking brake is engaged 3 Read Precautions For Hydraulic Testing Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil 4 Clean hose connections of right hand reel motor Disconnect the hose leading from the right hand reel motor to port M2 on the hydraulic
99. ck off both adjustment nuts to allow the roller to spin freely Tighten both adjustment nuts again so there is no bearing end play and rolling torque does not ex ceed 5 in lb 0 57 11 Grease bearings see Cutting Unit Operator s Manu al Reelmaster 2000 D Page 7 15 Sectional Roller Assembly 1 Make sure all parts are clean prior to installing bear ings and seals 2 Press two bearing cups into each sectional roller Make sure narrow end of taper faces the inside of the roller 3 Secure sectional roller shaft in a vise Make sure shaft is level 4 Pack all bearing cones with No 2 general purpose lithium base grease NOTE Install the bearing cone with the seal into the end of the roller that faces the inner part of the shaft 5 On both rollers install a bearing cone into the bear ing cup at each end of the roller 6 Grease outer seal lips and install seal into the end of each roller Make sure the hard surface of seal faces out 7 Slide each roller onto the shaft 8 Install adjustment nut onto each end of the shaft Tighten each nut to seat both bearings of each roller Roller should be rotated to seat both bearings 9 Back off both adjustment nuts to allow the rollers to spin freely Tighten both adjustment nuts again so there is no bearing end play and rolling torque does not ex ceed 5 in Ib 0 57 10 Grease bearings see Cutting Unit Operator s Manu al Cutting Units
100. cross the switch with the lift cylinder extended cutting units raised 4 Connect switch electrical connector Backlap Switch The backlap switch is attached to the hydraulic man ifold It is normally open and is closed when the backlap knob is turn clockwise to the backlap position The Standard Control Module monitors the operation of the backlap switch If the ignition switch is in the ON position and the backlap knob is turned to the backlap position the Module backlap input LED should be illumi nated Backlap Switch Test 1 Locate backlap switch on hydraulic manifold Dis connect the backlap switch electrical connector 2 Check the continuity of the switch by connecting a multimeter ohms setting across the connector termi nals 3 With the engine off turn the backlap knob clockwise to the backlap position while watching the multimeter Continuity should be made as the switch closes 4 Turn the backlap knob counterclockwise to the mow position while watching the multimeter Continuity should be broken as the switch opens 5 Reconnect the electrical connector Figure 24 1 Cutting unit interlock switch 2 Hydraulic manifold Figure 25 1 Backlap switch 3 Backlap knob 2 Connector Electrical System Page 5 22 Reelmaster 2000 D Fuses The fuse block is located on the back of the instrument panel Fig 26 Identification Function and Wiring The fuses are held in the fuse block Use F
101. cs and Electrical Harness Jacking Instructions 1 4 Connector Drawings Safety and Instruction Decals 1 4 Special Tools Troubleshooting PET Chapter 2 Product Records and Maintenance Electrical System Quick Checks Adjustments of Product Records 2 1 Component Testing 2 Maintenance eee ee nennen 2 1 Service and Repairs 5 Equivalents and Conversions 2 2 52 Torque Specifications 2 9 Chapter 6 Chassis Chapter 3 Engine Specifications Service and Repairs Introduction eee 3 2 Specifications 3 3 Chapter 7 Cutting Units General Information 3 4 Adjustments ee ee Vee 3 5 Specifications Service and Repairs 3 6 Special ToolS esie ire ik eR I pees BRIGGS amp STRATTON DIAHATSU ENGINE REPAIR Troubleshooting MANUAL Adjustments eripe sen RUE EE DE YR Sex Service and Repairs Chapter 4 Hydraulic System 5 Chapter 8 Electrical Diagrams Specificatio
102. d malfunction 4 Remove cartridge valve with a deep socket wrench Note correct location for o rings sealing rings and backup rings Remove and discard seal kit 5 Visually inspect the manifold port for damage to the sealing surfaces damaged threads and contamination 6 Visually inspect cartridge valve for damaged sealing surfaces and contamination A Contamination may cause valves to stick or hang up Contamination can become lodged in small valve orifices or seal areas causing malfunction B If valve sealing surfaces appear pitted or dam aged the hydraulic system may be overheating or there may be water in the system A CAUTION Use eye protection such as goggles when using compressed air 7 Clean cartridge valve using clean mineral spirits Submerge valve in clean mineral spirits to flush out con tamination Particles as fine as talcum powder can affect the operation of high pressure hydraulic valves If car tridge design allows use a wood or plastic probe to push the internal spool in and out 20 to 30 times to flush out contamination Be extremely careful not to damage car tridge Use compressed air for cleaning Reelmaster 2000 D Page 4 61 8 Reinstall the cartridge valve A Lubricate new seal kit components with clean hy draulic oil and install on valve The o rings sealing rings and backup rings must be arranged properly on the cartridge valve for proper operation and seal ing IMPO
103. d slip body onto frontplate until alignment pin is engaged Dip idler gear and drive gear into clean hydraulic oil and slip into frontplate bushings 6 Coat new O ring lightly with petroleum jelly and install in groove on the backplate 7 Install alignment pin into backplate 8 Align matchmarks and slip backplate over gear shafts onto body until alignment pin is engaged 9 Install and hand tighten cap screws Torque in a crisscross pattern from 25 to 28 ft lb 34 to 38 10 Place washer 18 over the drive shaft into the front plate housing Apply a liberal coat of hydraulic oil to the oil seal Install oil seal over the drive shaft being careful not to cut the rubber seal lips 11 Place a 1 1 16 inch O D sleeve over the drive shaft and press the oil seal into the frontplate housing until the retaining ring groove appears 12 Install retaining ring into the frontplate housing using the sleeve until the ring seats in the groove Hydraulic System 2g Ez 52 gt Cutting Reel Motor Service Serial Number Above 290000000 33 ft lb 7 18 45 N m t Figure 44 1 1 Dust seal 7 Back up gasket 13 O ring 2 Retaining ring 8 Front wear plate 14 Relief valve 3 Flange washer 9 Dowel pin 15 Body 4 Shaft seal 10 Idler gear 16 Washer 4 used 5 Front flange 11 Drive shaft 17 Lock washer 4 used 6 Pressure seal 12 Rear wear plate 18 Cap screw 4 used Disassembly Fig 44 1
104. d tilts up slightly 7 Coat all internal lift cylinder parts with a light coat of hydraulic oil Slide piston shaft and head assembly into barrel being careful not to damage the seals 8 Secure head in barrel by installing retaining ring into barrel groove Hydraulic System 2 5 L7 amp gt Control and Lift Relief Valves 27 RETURN nS Figure 55 1 Control valve 11 Hydraulic hose 20 Relief valve cartridge 2 Locknut 12 O ring 21 Hydraulic tube 3 Hydraulic hose 13 Lock nut 22 Hydraulic adapter 4 screw 14 Sponge 23 Hydraulic tube 5 Valve lever 15 Spring 24 O ring 6 Knob 16 Flat washer 25 O ring 7 Hydraulic tee fitting 17 Flat washer 26 O ring 8 90 hydraulic fitting 18 Hydraulic tube 27 Relief valve body 9 Hydraulic hose 19 Straight hydraulic fitting 28 Connecting link 10 Hydraulic hose 1 Park the machine on a level surface engage the Control Valve Removal Fig 55 parking brake lower the cutting units and stop the en gine Remove the key from the ignition switch 1 Disconnect hose connections 3 9 and 11 from hy draulic fittings 7 and 19 and tube connection 23 from fitting 22 Allow hoses to drain into a suitable container 2 Remove lock nut 13 that secures valve lever to ma chine Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy 3 Remove two lock nuts 2 Slid
105. de will make sure that excess cur rent is not allowed through the meter This excess current can cause damage to circuits not designed to carry it Figure 1 Skin Over Grease Special non conductive grease Toro Part Number 505 165 which forms a light protective skin to help wa terproof electrical switches and contacts 291230 91869 96 IE Figure 2 Reelmaster 2000 D 5 3 Rev Electrical System Troubleshooting For effective troubleshooting and repairs you must have a good understanding of the electrical circuits and A CAUTION components used on this machine see Chapter 8 Electrical Diagrams Remove all jewelry especially rings and watches before doing any electrical trouble If the machine has any interlock switches by passed shooting or testing Disconnect the battery they must be reconnected for proper troubleshooting cables unless the test requires battery voltage and safety Starting Problems Starter solenoid clicks but starter will not crank Battery charge is low if solenoid clicks problem is not in safety interlock system Battery cables are loose or corroded Battery ground to frame is loose or corroded Wiring at starter is faulty Starter solenoid is faulty Starter mounting bolts are loose or not supplying a sufficient ground for solenoid Starter is faulty Nothing happens when start attempt is made either Reel engage switch is ON pull
106. e elmaster at the end of this chapter Refer to Operator s Manual for recommended maintenance intervals Addi tionally insert Installation Instructions Operator s Manuals and Parts Catalogs for any accessories that have been installed on your Reelmaster at the end of this section Maintenance Maintenance procedures and recommended service in tervals for your Reelmaster are covered in the Opera tor s Manual Refer to that publication when performing regular equipment maintenance Several maintenance procedures have break in intervals identified in the Op erator s Manual Refer to the Engine Operator s Manual for additional engine specific maintenance procedures Chapter 2 Product Records and Maintenance Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series 4 Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners 5 Other Torque Specifications 6 Conversion Factors 6 Reelmaster 2000 D 2 1 Rev Product Records and Maintenance Product Records i 2 G cs Decimal and Millimeter Equivalents Equivalents and Conversions Fractions Decimals mm Fractions Decimals mm 1 64 0 015625 0 397 33 64 0 515625 13 097 1 32 0 03125 0 794 17 32 0 53125 13 494 3 64 0 046875 1 191 35 64 0 546875 13 891 1 16 0 0625 1 5
107. e Run Solenoid 16 Solenoid Valve 17 Standard Control Module 18 Traction Neutral Switch 19 Seat Switch 20 Parking Brake Switch 21 Cutting Unit Interlock Switch 22 Backlap Switch 22 FUSOS lt i stam bre YD E Regu V x ot ies 23 Diode Assembly 24 SERVICE AND REPAIRS 25 Battery Storage 25 Battery 25 Battery Service 26 Solenoid Valve 29 Electrical System Electrical Schematics and Electrical Harness Connectors Drawings The electrical schematics and other electrical drawings for the Reelmaster 2000 D are located in Chapter 8 Electrical Diagrams Electrical System Page 5 2 Reelmaster 2000 D Special Tools Order these special tools from your Toro Distributor Some tools may also be available from a local supplier Multimeter The multimeter can test electrical components and cir cuits for current resistance or voltage NOTE Toro recommends the use of a DIGITAL Volt Ohm Amp multimeter when testing electrical circuits The high impedance internal resistance of a digital me ter in the voltage mo
108. e both bearing cones On the sectional roller remove all four bearing cones NOTE An electric arc welder can be used to shrink the bearing cup to simplify its removal Only a small arc in one location on the cup is required 7 Remove both bearing cups from the roller On the full roller remove both inner seals On the sectional roller remove all four bearing cups 8 Discard seals and bearings that were removed from roller Reelmaster 2000 D Full or Wiehle Roller Assembly 1 Make sure all parts are clean prior to installing bear ings and seals 2 Ona full roller grease inner seal lips and install inner seal into each end of the roller Make sure that cupped side of the seal faces the inside of the roller 3 Make sure narrow end of the taper on the bearing cup faces the inside of the roller Press a cup into each end of the roller 4 Secure roller in a vise in a level position 5 Pack both bearing cones with No 2 general purpose lithium base grease 6 Install a bearing cone into the bearing cup at each end of the roller 7 Position outer seal to the roller with the hard surface of seal facing out Grease seal lips and press a seal into each end of the roller 8 Slide roller shaft with adjustment nut installed on one end through the bearing cones seals and roller 9 Install remaining adjustment nut onto shaft and tight en it to seat both bearings Roller should be rotated to seat bearings 10 Ba
109. e cap screws 4 and draulic oil washer 17 from the control valve 1 4 Slide control valve 1 from the support bracket and 2 Remove side panels Lift hood to gain access to the remove from the unit control valve and relief valve Hydraulic System Page 4 76 Reelmaster 2000 D 5 Unsnap remove connecting link assembly 28 Remove valve lever 5 from the control valve 1 6 Disconnect tube 21 from hydraulic fitting 7 Dis connect tube 18 from 90 hydraulic fitting 8 7 Remove hydraulic fittings 7 8 19 and 22 and O rings from the control valve 1 Control Valve Installation Fig 55 1 Install hydraulic fittings 7 8 19 and 22 and new rings to the control valve 1 2 Install tube 21 to hydraulic fitting 7 Connect tube 18 to 90 hydraulic fitting 8 3 Install valve lever 5 to the control valve 1 by snap ping the connecting link assembly 28 to the valve lever and control valve 4 Position control valve 1 to machine and slide valve lever onto support bracket pin 5 Slide cap screw 4 with flat washer into control valve 1 Secure control valve with lock nuts 2 and valve le ver with lock nut 13 6 Connect hose connections 3 9 and 11 to hydraulic fittings 7 and 19 and tube connection 23 to fitting 22 Tighten connections Lift Relief Valve Removal Fig 55 NOTE This procedure may be used if only the lift relief valve needs remo
110. e fitting 18 Cotter pin 28 Cap screw 9 Bushing 19 Lock nut 29 Chain 10 Cotter pin 20 Flat washer Disassembly Assembly 1 Remove cutting unit from lift arm see Traction Unit 1 Install front lift arm components to machine using Operator s Manual Figure 8 as a guide Mount cutting unit to lift arm see Traction Unit Operator s Manual 2 Remove front lift arm components from machine us ing Figure 8 as a guide 2 See Operator s Manual for adjustment procedures Chassis Page 6 14 Reelmaster 2000 D Rear Lift Arm Figure 9 1 Lift arm 9 Thrust washer 17 2 Bushing 10 Flat washer 18 3 Grease fitting 11 Flange head screw 19 4 Cap screw 12 Lift arm pivot shaft 20 5 Lock washer 13 Cap screw 21 6 Flat washer 14 Self tapping screw 22 7 Cap screw 15 Cap screw 23 8 Cutting unit pivot shaft 16 Reinforcement plate 24 Disassembly Assembly 1 Remove cutting unit from lift arm see Traction Unit Operator s Manual 2 Remove rear lift arm components from machine us ing Figure 9 as a guide Spacer Spring tension arm Lock nut Clevis pin Shackle Cotter pin Sleeve Spring 1 Install rear lift arm components to machine using Fig ure 9 as a guide Mount cutting unit to lift arm see Trac tion Unit Operator s Manual 2 See Traction Unit Operator s Manual for adjustment procedures Reelmaster 2000 D Page 6 15 Chassis This page is intentionally blank Chassis Page 6 16 Reel
111. e reservoir holds about 3 3 gallons 12 5 liters of hydraulic fluid Check level of hydraulic fluid daily See Traction Unit Operator s Manual for fluid level checking procedure and oil recommendations Hydraulic System Page 4 6 Figure 6 1 By pass valve location Figure 7 Hydraulic reservoir cap 2 Sight gauge Reelmaster 2000 D Hydraulic Schematic 5 6 oynejp H 1081NO JILVWSHIS 40106 133HM 1431 14 eaud I99UM reuondo 7 182 0006 se 5 5 1 440 NO 331134 1 1 105 Iv H z0 t z 42 ril M 0002 T Y 5 DM genitus 3AWA 8 hi A 21901 311L0HS cH 9NIddV DDVG Ww LOW od 2 ve gt Ha m 1431 2 124 gt 80100 133HM Sd 005 i ZW uand ssoud ih 82711041802 03
112. e top fitting straight back and bottom fitting 459 down 4 Install hydraulic hoses to fittings and secure with hose clamps 5 Install hood on the machine Reelmaster 2000 D TORO Table of Contents ELECTRICAL SCHEMATICS and ELECTRICAL HARNESS and CONNECTOR DRAWINGS 2 SPECIAL TOOLS td eerte 3 TROUBLESHOOTING 4 Starting Problems 4 General Run and Transport Problems 6 Cutting Unit Operating Problems 7 ELECTRICAL SYSTEM QUICK CHECKS 8 Battery Test Open Circuit Test 8 Charging System Test 8 Glow Plug System Test 8 Starting System Test 9 Check Operation of Interlock Switches 9 ADJUSTMENTS vce ees E RR 10 Neutral Switch 10 Parking Brake 10 COMPONENT TESTING 11 Ignition Switch 11 Indicator Lights 12 Hour Meter 13 Reelmaster 2000 D 5 1 Chapter 5 Electrical System Reels On Indicator Light 13 Reel Engage 13 Glow 14 High Temperature Shutdown Switch 15 Oil Pressure Switch 16 Engin
113. e type 16 to 20 PSI 1 1 to 1 38 bar Front and rear wheel lug nut torque 45 to 65 ft Ib 61 to 88 N m Front hub nut torque 250 to 400 ft lb 339 to 542 3WD rear hub nut torque 250 to 400 ft lb 339 to 542 Chassis Page 6 2 Reelmaster 2000 D This page is intentionally blank Reelmaster 2000 D Page 6 3 Chassis Service and Repairs Rear Wheel Standard 2 Wheel Drive 60 to 80 ft lb gt 21 1 81 to 108 20 19 45 to 65 ft lb 61 to 88 N m 5 i51020ft b 20 to 27 N m See text for tightening procedure Figure 1 1 Lugnut 10 Drive stud 19 Lock washer 2 Wheel assembly 11 Seal 20 Thrust washer 3 Dust 12 Lock nut 21 Cap screw 4 Locknutretainer 13 Cotter pin 22 Ball joint 5 Jamnut 14 Rear wheel fork 23 Jam nut left hand thread 6 Tab washer 15 Hub 24 Jam nut 7 Bearing cone 16 Socket head screw 25 Ball joint 8 Bearing cup 17 Jam nut 26 Steering tube 9 Wheel hub 18 Grease fitting Chassis 6 4 Reelmaster 2000 0 Removal Fig 1 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Chock front wheels Raise rear wheel using a jack or hoist Block rear of machine 3 Remove lug nuts and remove rear wheel 4 Remove dust cap from hub Remove cotter pin lock nut retainer jam nut and tab
114. ear Pump Removal Fig 38 1 Park the machine on a level surface engage the parking brake lower the cutting units and stop the en gine Remove the key from the ignition switch Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil 2 Clean reel gear pump and hydraulic connections Install plug into the hydraulic reservoir Label all hose connections for reassembly purposes Matchmark fit tings and pump to allow correct reassembly Put caps or plugs on any hydraulic lines or fittings left open or ex posed 3 Loosen hose clamp 2 and remove hose 3 from fit ting Allow hydraulic oil to drain from hose into a suitable container 4 Disconnect hose 5 from elbow fitting 6 Allow hy draulic oil to drain from hose into a suitable container 5 Remove fittings and O rings from the pump 6 Support reel drive pump and remove two cap screws Separate reel gear pump and O ring 11 from the traction pump Installation Fig 38 1 Make sure mounting and O ring sealing surfaces on reel gear pump and traction pump are clean 2 Remove caps or plugs that were put on any hydraulic lines or fittings during disassembly 3 Replace all O rings with new ones Apply clean hy draulic oil to all O rings 4 Place O ring 11 on reel gear pump 5 Position reel gear pump to traction pump the inlet port on the reel gear pump should be facing up Align splines on reel
115. ear or idler gear if the shaft in the bushing area diameter measures less than 0 748 in 19 0 mm A single gear may be replaced separately 6 The drive gear and idler gear face should be free of excessive scoring and wear 7 Replace drive gear or idler gear if gear width is less than 1 140 in 29 96 mm 8 Make sure that retaining rings are in the grooves on both sides of the gear for both the drive gear and idler gear 9 Break sharp edges of gear teeth with emery cloth 10 Replace backplate 7 and frontplate 14 if bushing inside diameters exceed 0 755 in 19 2 mm The bush ings are not available as replacement items Reelmaster 2000 D Page 4 57 11 The face of the backplate and frontplate should be free of excessive scoring Replace if any scoring exists to a depth of 0 0015 in 0 088 mm 12 Replace body 12 if the inside diameter of the gear pockets exceeds 1 713 in 43 5 mm 13 Make sure that both relief valve plugs are secure if they or the backplate are not being replaced Reassembly Fig 44 1 If replacing the relief valve assembly 19 install ball spring shim O ring and plug into the backplate Hand tighten plug and then torque from 10 to 12 ft lb 14 to 16 N m 2 Coat new O ring lightly with petroleum jelly and install in groove on the frontplate Apply a thin coat of petroleum jelly to both gear pock ets of the body Install alignment pin into body 4 Align matchmarks an
116. ed out or is faulty seat switch OR parking brake must be engaged for successful start Battery cables are loose or corroded Battery ground to frame is loose or corroded Battery is dead Engine fuse 15 amp is open Fusible link is open Wiring to start circuit components is loose corroded or damaged see Wiring Schematics Traction neutral switch out of adjustment or faulty Ignition switch is faulty Fuse block is faulty High temperature shutdown switch is faulty Starter solenoid is faulty Standard Control Module is faulty Electrical System Page 5 4 Reelmaster 2000 D Starting Problems continued Engine cranks but does not start Engine run solenoid is faulty Glow plugs are faulty Engine or fuel system is malfunctioning see Chapter 3 Engine Engine and or fuel may be too cold Standard Control Module is faulty Engine cranks but should not with the traction pedal Traction neutral switch is out of adjustment or faulty out of the neutral position Traction neutral switch wiring is faulty 6 m Reelmaster 2000 0 5 5 Electrical System General Run and Transport Problems Engine continues to run but should not when the traction pedal is depressed with no operator on the seat Engine kills when the traction pedal is depressed or the reel engage switch is pulled ON with the operator in the seat Battery does not charge Engine
117. eel blades 5 or 8 and the desired ground speed see Traction Unit Operator s Manual reels should rotate at the same speed All cutting units should have equal bedknife to reel contact If checking RPM do not run reel too long without cutting grass or bedknife and or reel may overheat and rifle See other items in Troubleshooting section of Chapter 4 Hydraulic System Check each tire s pressure Adjust to pressures specified in Specifications section of Chapter 6 Chassis All reels should rotate freely Make sure bearings are properly lubricated Replace bearings if worn or damaged Reel and or bedknife that has rounded cutting edges or rifling cannot be corrected by tightening bedknife to reel contact Grind reel to remove taper and or rifling grooved or wavy appearance Grind bedknife to sharpen and or remove rifling Most common cause of rifling is bedknife to reel contact that is too tight NOTE New bedknife must be ground or backlapped after installing on bedbar Reelmaster 2000 D 6 Bedknife to reel adjustment Check bedknife to reel contact daily Bedknife must have light contact all across the reel No contact will cause cutting edges to become dull Excessive contact accelerates wear quality of cut may be adversely affected Slightly dull cutting edges may be corrected by backlapping Excessively dull cutting edges must be corrected by grinding the reel and bedknife 7 Front r
118. em Start up procedures D Install extension spring and hose to the neutral arm and pump support 8 Install pulley to the taper lock bushing A Place pulley to the bushing Align non threaded holes of pulley with threaded holes of bushing B Secure pulley to bushing with cap screws and lock washers Torque cap screws from 90 to 120 in Ib 10 2 to 13 6 in a circular pattern C Verify alignment across engine and pump pulley faces with a straight edge The gap between both faces must not exceed 0 030 0 8 mm 9 5 N UO LR gt N T Reelmaster 2000 D Page 4 47 Hydraulic System Traction Charge Pump Service Figure 37 1 Drive shaft 13 Camplate insert 2 End cover 14 Washer 3 Housing 15 Bearing 4 Rotating kit 16 Camplate shaft seal 5 Camplate 17 Cap screw 6 Washer 18 Bypass valve 7 Snapring 19 Plug 8 Retaining ring 20 Check valve 9 Thrust bearing 21 Valve plate 10 Thrust washer 22 Bearing cone 11 Drive shaft seal 23 Cover plate 12 Housing gasket 24 Cover plate NOTE For repair of the traction charge pump see the Eaton Medium Duty Piston Pump Repair Information Model 70160 Variable Displacement Piston Pump at the end of this chapter Hydraulic System Page 4 48 Washer Dowel pin Cap screw Cap screw Key Key O ring Shim kit Bearing cup Geroter and coupler assembly O ring Charge pump adapter Reelmaster 2000 D Reel G
119. ents with clean hy draulic oil and install on valve The O rings sealing rings and backup rings must be arranged properly on the cartridge valve for proper operation and sealing IMPORTANT Use care when installing cartridge valves Slight bending or distortion of the stem tube can cause binding and malfunction Make sure that deep well socket fully engages the valve base Hydraulic System Page 4 63 3 Rev A B Lubricate threads of cartridge valve with clean hydraulic oil Thread cartridge valve carefully into correct manifold port The valve should go in easily without binding C Torque cartridge valve using a deep well socket to values identified in Figure 46 1 11 If solenoid coil was removed install coil onto sole noid valve A Carefully install coil onto the cartridge valve B Install nut and torque nut to 5 ft lb 6 7 N m 12 If flow control cartridge valve was removed install rotary handle to valve stem Fig 46 2 A Place handle base flow control valve and posi tion alignment mark on base with number 1 on man ifold Secure base with two 2 set screws Apply a light coating of grease to chamfer on top of base to ease seal installation B Make sure that sleeve bearing is in handle cap If necessary press sleeve bearing into cap Install lip seal on cap with seal lip facing down C Place bushing onto cartridge valve stem Use a small amount of grease to keep bushing toward the top of the valve
120. erging valve in clean mineral spirits to flush out contamination Particles as fine as talcum powder can affect the operation of high pressure hydraulic valves If cartridge design allows use a wood or plastic probe to push the internal spool in and out 20 to 30 times to flush out contamination Be ex tremely careful not to damage cartridge Use com pressed air for cleaning 9 If mow backlap spool was removed from mow man ifold install spool A Install O rings and back up ring to upper grooves on spool Apply a light coating of grease to O rings B Carefully push spool down into mow manifold port until lower O ring and back up ring groove is exposed on bottom of manifold Install lower O ring and back up ring to spool Apply a light coating of grease to O ring C Carefully raise mow backlap spool until upper re taining ring groove on spool is exposed on top of manifold Install upper retaining ring D Push mow backlap spool down and install lower retaining ring to spool E If handle was removed from spool position spool so handle location of spool is between stop pins Ap ply Loctite 603 Retaining Compound or equivalent to threads on handle and install handle into spool F Place ball and dowel pin in backlap switch man ifold port Install new O ring onto backlap switch Thread backlap switch into port and torque 15 ft Ib 20 N m 10 Reinstall cartridge valve into manifold A Lubricate new seal kit compon
121. ers To assure op timum performance and continued safety certification of the machine use genuine Toro replacement parts and accessories Replacement parts and accessories made by other manufacturers may result in non conformance with the safety standards and the warranty may be voided 17 When changing attachments tires or performing other service use correct blocks hoists and jacks Make sure machine is parked on a solid level floor such as a concrete floor Prior to raising the machine remove any attachments that may interfere with the safe and proper raising of the machine Always chock or block wheels Use jack stands or solid wood blocks to support the raised machine If the machine is not properly sup ported by blocks or jack stands the machine may move or fall which may result in personal injury see Jacking Instructions Safety Jacking Instructions When changing attachments tires or perform ing other service use correct blocks hoists and jacks Make sure machine is parked on a solid level surface such as a concrete floor Prior to raising machine remove any attach ments that may interfere with the safe and prop er raising of the machine Always chock or block wheels Use jack stands or solid wood blocks to support the raised machine If the ma chine is not properly supported by blocks or jack stands the machine may move or fall which may result in personal injury Jacking the Front End 1 Set pa
122. ery case clean because a dirty battery will discharge slowly A Clean battery by washing entire case with a solu tion of baking soda and water Rinse with clear water B Coat battery posts and cable connectors with skin over grease Toro Part No 505 47 or petro leum jelly to prevent corrosion Reelmaster 2000 D Page 5 25 4 Store battery in a cool atmosphere to avoid quick de terioration of the battery charge 5 To help prevent the battery from freezing make sure it is fully charged see Battery Service 3 Battery cables must be tight on terminals to provide good electrical contact Connecting cables to the wrong post could re sult in personal injury and or damage to the electrical system 4 If corrosion occurs at terminals disconnect cables Always disconnect negative cable first Clean clamps and terminals separately Reconnect cables with positive cable first Coat battery posts and cable connectors with skin over grease Toro Part No 505 47 or petroleum jelly to prevent corrosion 5 Check electrolyte level every 25 operating hours and every 30 days if machine is in storage 6 Maintain cell level with distilled or demineralized wa ter Do not fill cells above the fill line Electrical System Wu Battery Service The battery is the heart of the electrical system With regular and proper service battery life can be extended Additionally b
123. faces of the brake drum for excessive wear Replace wm Figure 4 any worn or damaged parts or S 9 YOKE pin Installation 1 If brake lever was removed from brake cam shaft apply anti seize lubricant to splines of cam shaft before installing brake lever 2 Secure flat washers 7 brake grass shield 15 and backing plate 29 to the brake bracket with the cap screws 9 and lock nuts 6 Tighten fasteners 3 Connect brake lever 22 to the yoke 23 Install yoke pin 21 through the brake lever and yoke Install and lock cotter pin 28 into the yoke pin Fig 4 4 Install brake shoes 32 onto the backing plate 29 Install brake return springs 31 into the holes on each end of the brake shoes Springs should be installed in opposite directions of each other 5 Mount key 34 in the wheel motor shaft then install the wheel hub 11 and brake drum 12 onto the wheel motor shaft 6 Install the lock nut 14 onto the wheel motor shaft and torque from 250 to 400 1 339 to 542 7 Check and adjust brakes see Traction Unit Opera tor s Manual 8 Check operation of brake switch see Traction Unit Operator s Manual Adjust brake switch if necessary see Adjustments in Chapter 5 Electrical System 9 Install wheel assembly and secure with lug nuts Tighten lug nuts evenly in a crossing pattern to a torque from 45 to 65 ft lb 61 to 88 Reelmaster 2000 D Page 6 9 Chassis Standard
124. for damage to the sealing surfaces damaged threads and contamination 5 Visually inspect cartridge valve for damaged sealing surfaces and contamination A Contamination may cause valves to stick or hang up Contamination can become lodged in small valve orifices or seal areas causing malfunction B If valve sealing surfaces appear pitted or dam aged the hydraulic system may be overheating or there may be water in the system A CAUTION Use eye protection such as goggles when using compressed air 6 Clean cartridge valve using clean mineral spirits Submerge valve in clean mineral spirits to flush out con tamination Particles as fine as talcum powder can affect the operation of high pressure hydraulic valves If car tridge design allows use a wood or plastic probe to push the internal spool in and out 20 to 30 times to flush out contamination Be extremely careful not to damage car tridge Use compressed air for cleaning Reelmaster 2000 D 4 67 7 Reinstall the cartridge valve A Lubricate new seal kit components with clean hy draulic oil and install on valve The o rings sealing rings and backup rings must be arranged properly on the cartridge valve for proper operation and seal ing IMPORTANT Use care when handling the car tridge valve Slight bending or distortion of the stem tube can cause binding and malfunction B Thread cartridge valve carefully into correct man ifold port The v
125. g 54 1 Remove oil from cylinder into a drain pan by slowly pumping the cylinder shaft Plug both ports and clean the outside of the lift cylinder IMPORTANT Prevent damage when clamping the lift cylinder into a vise clamp on the pivot end only Do not close vise enough to distort the barrel 2 Mount lift cylinder in a vise so that the shaft end tilts up slightly 3 Remove retaining ring 11 from the barrel 4 Grasp clevis rod 14 extract shaft 6 head 10 and piston 3 by carefully twisting and pulling the shaft out from the barrel IMPORTANT Do not clamp vise jaws against shaft surface Protect shaft surface before mounting in the vise 5 Mount shaft securely in a vise Remove locknut and piston from the shaft Slide head off the shaft 6 Remove and discard uni ring 4 and O ring 5 from the piston Remove and discard dust seal 12 backup washer 9 and O rings 7 and 8 from the head Hydraulic System 1 Barrel 6 Shaft 2 Locknut 7 O ring 3 Piston 8 O ring 4 Uni ring 9 Backup washer 5 O ring 10 Head Page 4 74 11 Retaining ring 12 Dust seal 13 Jam nut 14 Clevis rod 15 Grease fitting NOTE If the clevis rod 14 is to be removed from the shaft 6 note the number of threads exposed between the jam nut 13 and the smooth surface of the shaft to help reassembly 7 Loosen jam nut and remove clevis rod if necessary A CAUTION Inspection Use eye protection such
126. g units and stop the en gine Remove the key from the ignition switch Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil 2 Remove reel motor from cutting unit see Repair sec tion of Chapter 7 Cutting Units 3 Unscrew flange nut and remove coupling from reel motor using a puller Locate and retrieve key 4 Clean motor fittings and hose connections NOTE The position of the fittings on the reel motor is critical to reconnecting hydraulic hoses 5 Label all hose connections for reassembly purposes Matchmark reel motor and all hydraulic fittings for reas sembly purposes 6 Remove hose connections from hydraulic fittings Al low hydraulic oil to drain from hose into a suitable con tainer Put caps or plugs on disconnected hoses to prevent contamination 7 Remove hydraulic fittings and O rings from reel mo tor Discard O rings Installation Fig 43 1 Position key and place coupling on reel motor shaft 2 Install flange nut and torque nut 35 ft lb 47 3 Make sure hydraulic fitting ports and O ring sealing surfaces on the reel motor are clean 4 Remove caps or plugs that were put on any hydraulic lines or fittings during disassembly 5 Apply clean hydraulic oil to all O rings 6 Inspect threads and sealing surfaces of hydraulic fit tings Replace any damaged or worn fittings Reelmaster 2000 D Page 4 55 35 ft l
127. he Toro Guide to Evaluation Reel Mower Performance and Using the TurfEvaluator Toro part no 97931SL Toro Model Number 04399 Figure 6 2 E Reelmaster 2000 D Page 7 5 Cutting Units Troubleshooting There are a number of factors that can contribute to un satisfactory quality of cut some of which may be turf conditions Turf conditions such as excessive thatch sponginess or attempting to cut off too much grass height may not always be overcome by adjusting the machine It is important to remember that the lower the height of cut the more critical these factors are Remember that the effective or actual height of cut depends on cutting unit weight and turf conditions Ef fective height of cut will be different than the bench set height of cut For additional information regarding cutting unit trouble shooting see Aftercut Appearance Troubleshooting Aid Toro part 0007651 Factors That Can Affect Quality Of Cut 1 Engine maximum governed speed 2 Reel speed and ground speed 3 Tire pressure 4 Reel bearing condition 5 Reel and bedknife sharpness Cutting Units Page 7 6 Check maximum governed engine speed Adjust speed to specifications if necessary If engine is not running at specified maximum governed RPM reel speed settings may not match ground speed Adjust reel speed to setting shown on REEL SPEED SELECTION CHART for the number of r
128. her moving parts can result in personal injury 9 After the hydraulic system starts to show signs of fill accomplish the following A If a reel motor was replaced or rebuilt run the cut ting units at the minimum speed setting under no load for 10 minutes in both directions B If a reel motor drive pump was replaced or rebuilt run the cutting units at the minimum speed setting under no load for 10 minutes C If a traction pump or a wheel motor was replaced or rebuilt run the traction unit so the wheels slowly turn for 10 minutes 10 Operate the traction unit and cutting unit by gradually increasing their work load to full over a 10 minute period 11 Stop the machine Check hydraulic reservoir and fill if necessary Check hydraulic components for leaks and tighten any loose connections Reelmaster 2000 D Hydraulic Pump Drive Belt 12 60 to 70 ft lb 134 81 to 95 N m 11 Cap screw 12 Thrust washer 13 Lock nut 14 Front engine frame Figure 34 1 Hydraulic pump drive belt 6 Adjusting bolt full thread 2 Pump pulley 7 Jamnut 3 Engine pulley 8 Top spherical washer 4 Pump support 9 Bottom spherical washer 5 Hardened washer 10 Lock nut Drive Belt Removal 1 Park the machine on a level surface engage parking brake lower cutting units and stop engine Remove key from the ignition switch 2 Loosen lock nut 13 and cap screw
129. ide of the cyl inder support bracket 3 Align lift cylinder mounting hole with holes at bottom of the valve mount bracket Slide clevis pin through holes and secure clevis pin with cotter pin 4 Align lift hub holes with the slots on the cylinder sup port bracket Apply grease to flange bushings and install bushings into the cylinder support bracket slots 5 Make sure flange bushings are aligned with the lift hub holes Slide cylinder guide pin through the cylinder support bracket flange bushings and lift hub 6 Align hole in cylinder guide pin to lift hub hole Secure guide pin by installing flanged head screw fully 7 Secure lift chain clevis 15 to the cylinder guide pin with clevis pin and cotter pin 8 Remove caps and plugs from disconnected hoses and fittings 9 Install O rings and hydraulic fittings into the lift cylin der 10 Connect hydraulic hoses to hydraulic fittings on lift cylinder Tighten hose connections 11 Install hood 12 Install cutting units to front lift arms see Traction Unit Operator s Manual 13 Follow Hydraulic System Start up procedures Hydraulic System e 5 amp gt Front Lift Cylinder Service Figure 50 1 Retaining ring 5 O ring 9 Uni ring 2 O ring 6 Shaft 10 Lock nut 3 Head 7 O ring 11 Barrel 4 Backup washer 8 Piston 12 Dust seal Disassembly Fig 50 1 Remove oil from the cylinder into a drain pan by slowly pu
130. ight approximate kg 72 159 Fuel Grade No 2 diesel fuel ASTM specification Fuel Injection Pump VE Bosch type Fuel Injector Nozzle Bosch throttle type Fuel Tank Capacity liter U S gal 25 6 5 Governor Mechanical Idle Speed no load 1540 50 RPM High Idle no load 3200 50 RPM Engine Oil SAE 10W30 API CF or better Oil Pump Gear driven trochoid type Crankcase Oil Capacity liter U S qt 3 3 3 5 with filter Water Pump Belt driven centrifugal type Cooling System Capacity liter U S qt 4 7 5 0 Starter 12 VDC 1 2 KW Alternator Regulator 12 VDC 40 AMP Reelmaster 2000 D Page 3 3 Engine General Information Fuel Shutoff Valve This valve Fig 1 should be shut when removing the fuel tank or engine from the machine or when placing the unit in long term storage Adding Oil to Engine When adding oil to the engine maintain clearance be tween the oil fill device and the oil fill opening in the valve cover Fig 2 This clearance is necessary to allow vent ing when adding engine oil which will prevent oil from running into the breather tube and intake system Figure 1 1 Fuel shutoff valve under the fuel tank Note Clearance M amp Note zs Figure 2 Page3 4 Reelmaster 2000 D Adjustments Adjust Throttle Control Proper throttle
131. igure 27 to identify each individual fuse and its correct amperage Each fuse holder has the following functions and wire connected to it Fuse 1 15 Amp A Supplies power to igniti itch terminal B 9 pplies ignition switch termina Figure 26 B Has orange wire and red wire battery 1 Fuse block Fuse 2 option A Supplies power to optional lights B Has blue wire and red wire C DO NOT use fuse greater than 15 amp MAXIMUM Fuse 3 10 Amp 1 8 uM A Supplies power from ignition switch terminal S B Has violet wire and tan wire Fuse 4 10 Amp A Supplies power from ignition switch terminal l B Has pink wire and yellow wire Figure 27 gt Testing E Remove fuses from the fuse block for testing Fuse should have continuity between fuse terminals Reelmaster 2000 D Page 5 23 Electrical System Diode Assembly Diode D3 is used for circuit protection from voltage spikes when the hydraulic valve solenoid is de ener gized The diode plugs into the wiring harness see Wire Harness Drawings in Chapter 8 Electrical Diagrams Diode Test The diode Fig 28 can be tested using a digital multime ter diode test or ohms setting and the table below Multimeter Multimeter Red Lead Black Lead Continuity on Terminal on Terminal
132. ing arm Cap screw Thread forming screw Washer head screw Ram pivot pin Lift arm pivot shaft Lock nut Hydraulic hose Hydraulic hose Hydraulic System Figure 53 45 hydraulic fitting Hydraulic fitting Rear lift cylinder Flat washer Clevis pin Cap screw Lock washer Cap screw Flat washer Rear lift arm Page 4 72 Thrust washer Cutting unit pivot shaft Flat washer Flange head screw Cap screw Spacer Reinforcement plate O ring O ring Grease fitting Reelmaster 2000 D Removal Fig 53 1 Park the machine on a level surface engage the parking brake lower the cutting units and stop the en gine Remove the key from the ignition switch 2 Remove cutting unit from rear lift arm see Traction Unit Operator s Manual Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil A CAUTION The rear lift cylinder is located near the muffler exhaust pipe To avoid possible burns allow the exhaust pipe to cool before working on the rear lift cylinder 3 Label all connections for reassembly Disconnect both hydraulic hoses from hydraulic fittings on lift cylin der Allow hoses to drain into a suitable container 4 Put caps or plugs on disconnected hoses and fittings to prevent contamination 5 Remove washer head screw 6 that secures ram pivot pin 6 to frame Slide ram pivot pin from frame
133. ings during disassembly 4 Install hydraulic tubes and hoses to hydraulic fittings on selector valve and tighten fittings 5 Install electrical connector to solenoid valve on se lector valve 6 Tighten lock nut and cap screw so the tube clamp will prevent movement of the hydraulic tubes 7 Follow Hydraulic System Start up procedures Hydraulic System 5 amp gt 3 Wheel Drive Selector Valve Service 5 4106 eee 5 4 to 8 1 3 35 to 40 gt A 2 3510 40 ft lb 47 to 54 N m 47 10 54 Figure 48 1 Selector Valve manifold 3 Pilot operated directional valve 5 Nut 2 Solenoid valve 4 Solenoid coil 6 O ring Hydraulic System Page 4 66 Reelmaster 2000 D If the optional 3 Wheel Drive Kit has been installed the 3WD selector valve service procedure is as follows Selector Valve Service 1 Make sure the manifold is clean before removing the cartridge valve 2 If solenoid cartridge is being serviced remove nut securing solenoid to the cartridge valve Carefully slide solenoid off the valve IMPORTANT Use care when handling the cartridge valve Slight bending or distortion of the stem tube can cause binding and malfunction 3 Remove cartridge valve with a deep socket wrench Note correct location for o rings sealing rings and backup rings Remove and discard seal kit 4 Visually inspect the manifold port
134. ion the linkage from the pedal positions the swash plate in the traction motor so oil flows out the bottom port of the pump Oil flow out of the bottom port goes to the wheel motors and turns them in the reverse direction Cil flowing out of the wheel motors returns to the top port of the traction pump and is continuously pumped out the bottom port The charge and shuttle valve circuits function the same in reverse as they did in the forward direction If the optional 3 Wheel Drive Kit has been installed the pilot directional valve in the 3WD selector valve pre vents reverse flow to the rear wheel As a result there is no 3WD in reverse Hydraulic System 5 amp gt MO 4 uonong 40 UMOM yr1 Q 0002 1 40193135 0 1 2 uvis 80104 133HM H01108 Cx 1081NO2 41 tH INVA 180 000 440 NO 431738 74 1338 1338 TA 4 Ww ri 15 813 cel NA INVA F MIVA 21901 E 9NIddY DiOV8 LOH ZYN Hy Ee gy 10 gt lt 1 13 ZW 7 83 10 1 02 03305 1338 19 Y OPS XYD e 3 331003 10 83534 581 SL
135. is 7 Follow Hydraulic System Start up procedures Reelmaster 2000 D Page 4 53 Wheel motor Hose connection Hydraulic fitting O ring Figure 41 5 6 7 8 Socket head screw Lock nut Rear wheel fork O ring Sg 3 gt Hydraulic System Wheel Motor Service LEFT WHEEL MOTOR SHOWN Figure 42 1 Coupling shaft 11 Manifold 21 Inner seal 2 Thrust bearing 12 Stator 22 Back up washer 3 Drive link 13 Vane 23 Seal ring 4 Cap screw 14 Rotor 24 Back up washer 5 O ring 15 Wear plate 25 Dirt and water seal 6 Shuttle valve 16 Commutator ring 26 Bearing 7 Ball 17 Commutator 27 Housing 8 Spring 18 Commutator seal 28 Thrust washer 9 End cover 19 Bearing 29 Thrust bearing 10 Plug 20 Woodruff key NOTE The wheel motor shown in Figure 42 is the left motor The two wheel motors are identical in construc tion except for end cover differences The end cover of the right motor lacks the shuttle valve and plugs of the left motor shown On machines equipped with the op tional 3 Wheel Drive Kit the wheel motor for the rear wheel is identical to the right motor NOTE For repair of the wheel motors see the Ross Torqmotor TM MG MF ME and MJ Series Service Pro cedure at the end of this chapter Hydraulic System Page 4 54 Reelmaster 2000 D Cutting Reel Motor Removal Fig 43 1 Park the machine on a level surface engage the parking brake lower the cuttin
136. is specification is met go to step 9 Example Calculation Relief Valve Open Lever raised Relief Valve Closed Lever in neutral Open less Closed Pressure 450 to 500 PSI NOTE Do not remove lift relief valve from the hydraulic manifold for adjustment 8 Adjust the lift relief valve pressure as follows A Remove the cap from the relief valve B To increase the relief valve pressure setting use an allen wrench and turn adjustment socket clock wise A 1 8 turn on the socket will make a measur able change in relief pressure C To decrease the relief valve pressure setting use an allen wrench and turn adjustment socket counter clockwise A 1 8 turn on the socket will make a mea surable change in relief pressure D Repeat steps 1 through 8 above until the relief valve pressure setting is correct Reinstall cap on re lief valve when valve is set properly E If the relief valve pressure setting can not be ad justed to specification go to step 9 and replace the relief valve NOTE If the pressure and flow are within specification but the cutting units do not lift or lift slowly check for me chanical binding or internal leakage of the lift cylinder 9 Disconnect tester from the pump and hose Recon nect hose to the pump Hydraulic System 2 FE 5 gt N gt 77 TEST 5 Charge Pump Relief Pressure Using Pressure Gauge TO WHEEL MOTORS TO WHEEL MOTORS
137. key 3 Remove five cap screws and flat washers that se cure stub shaft to engine flywheel Remove stub shaft from engine Assembly 1 Position stub shaft to engine flywheel and install cap screws and flat washers Torque cap screws from 17 to 21 ft lb 23 to 29 N m 2 Install three cap screws and lock washers through non threaded holes in bushing Position bushing to pulley to allow cap screws to thread into pulley Leave cap screws loose 3 Place key into stub shaft slot Slide bushing and pulley assembly onto stub shaft while aligning bushing slot to key 4 Position bushing 1 2 1 27 mm from end of stub shaft Tighten cap screws evenly three times in a rotat ing pattern to secure bushing and pulley to stub shaft 17 to 21 ft lb 23 to 29 Figure 17 1 Engine 6 Pulley 2 PTO stub shaft 7 Bushing 3 Cap screw 8 Cap screw 4 Flat washer 9 Lock washer 5 Key Reelmaster 2000 D Page 3 19 Engine This page is intentionally blank Engine Page 3 20 Reelmaster 2000 D TORO Table of Contents SPECIFICATIONS GENERAL INFORMATION Hydraulic Hoses Hydraulic Fitting Installation Towing Traction Check Hydraulic Fluid HYDRAULIC SCHEMATIC HYDRAULIC FLOW DIAGRAMS Traction Circuits ue ues Lift Circuit Mow Circuit
138. l Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components 1 Before removing any parts from the hydraulic sys tem park machine on a level surface engage parking brake lower cutting units or attachments and stop en gine Remove key from the ignition switch 2 Clean machine before disconnecting removing or disassembling any hydraulic components Make sure hydraulic components hoses connections and fittings are cleaned thoroughly Always keep in mind the need for cleanliness when working on hydraulic equipment Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil Controls must be operated with the ignition switch in RUN and the engine OFF Make sure all electrically operated control valves are actuated Return ignition switch to OFF when pressure has been relieved Remove key from the ignition switch 3 Put caps or plugs on any hydraulic lines hydraulic fit tings and components left open or exposed to prevent contamination 4 Put labels on disconnected hydraulic lines and hoses for proper installation after repairs are completed 5 Note the position of hydraulic fittings especially el bow fittings on hydraulic components before removal Mark parts if necessary to make sure they will be aligned properly when reinstalling hydraulic hoses and tubes Check Hydraulic Lines and Hoses Keep body and hands away
139. lap position Backlap switch is faulty or out of adjustment Wiring to the mow backlap circuit components is loose corroded or damaged see Wiring Schematics Seat switch is faulty out of adjustment or short circuited Cutting deck position switch or circuit wiring is faulty or out of adjustment Reel engage switch is faulty or short circuited Operator not present in seat Cutting units are not lowered System fuse 10 amp is open Fuse block is faulty Seat switch is faulty or out of adjustment Wiring to mow backlap circuit components is loose corroded or damaged see Wiring Schematics Reel engage switch is faulty Cutting unit interlock switch is faulty Cutting unit solenoid valve or coil on hydraulic manifold is faulty Cutting units are not lowered Parking Brake is not engaged System fuse 10 amp is open Fuse block is faulty Seat switch is faulty or out of adjustment Parking brake switch is faulty or out of adjustment Wiring to mow backlap circuit components is loose corroded or damaged see Wiring Schematics Reel engage switch is faulty Backlap switch is faulty or out of adjustment Cutting unit interlock switch is faulty Cutting unit solenoid valve or coil on hydraulic manifold is faulty 5 7 Electrical System Electrical System Electrical System Quick Checks Battery Test Open Circuit Test Use a multimeter to measure the voltage between the battery terminals
140. m the alternator Remove connector with red wire from alternator stud B Unplug connector with blue white wire from the high temperature shut down switch located on the water pump behind the fan C Unplug connector with red black wire from the fuel valve solenoid in the injector pump D Unplug connector with gray wire from the oil pres sure switch located near the engine oil dipstick E Remove connector with red wire from the glow plugs located on the rear side of the cylinder head F Unplug connector with white wire from the engine Figure 13 starter motor located below the exhaust manifold 1 F siblelink harness 4 Wire harness ground Remove fusible link connector and positive battery 2 Positive battery cable 5 Harness R clamp cable from the starter motor Fig 13 3 Negative battery cable G Disconnect negative battery cable and black en gine wire harness ground wire from the rear side of the cylinder block Fig 13 Remove cap screws and flat washers from R clamps Fig 14 Position wiring harness and hoses away from the engine 15 Remove hydraulic pump assembly see Service and Repairs section of Chapter 4 Hydraulic System Figure 14 1 R clamp locations on cylinder head Reelmaster 2000 D Page 3 15 Engine 1 2 3 4 5 6 7 8 9 1 16 Engine Figure 15 Engine 11 Rear engine frame 21 Lock nut Flywheel stub shaft 12 Engine channel 22 Snubbing washer C
141. m such an injury Nut Sleeve Figure 1 rect Flats From Finger Tight F F F T The markings on the nut and fitting body will verify that the connection has Final been tightened Fosition Mark Nut Size Body 4 1 4 in nominal hose or tubing 0 75 0 25 Extend Line E NUR 6 3 8 in 0 75 0 25 8 1 2 in 0 75 0 25 10 5 8 1 00 0 25 Finger Tight After Proper Tightening 12 3 4 in 0 75 0 25 16 1 in 0 75 0 25 Figure 2 Hydraulic System Page 4 4 Reelmaster 2000 D SAE Straight Thread O Ring Port Non adjustable 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Always replace the O ring seal when this type of fit ting shows signs of leakage 3 Lubricate the O ring with a light coating of oil 4 Install the fitting into the port and tighten it down full Figure 3 length until finger tight g 5 Tighten the fitting to the correct Flats From Finger Tight F F F T Size F F F T 4 1 4 in nominal hose or tubing 1 00 0 25 6 3 8 in 1 50 0 25 8 1 2 in 1 50 0 25 10 5 8 in 1 50 0 25 12 3 4 in 1 50 0 25 16 1 in 1 50 0 25 SAE Straight Thread O Ring Port Adjustable 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Always replace the O ring seal when this type of fit ting shows signs of leakage Lock Nut 9 5
142. machine 3 Remove lug nuts and remove rear wheel 4 Remove lock nut from wheel motor shaft IMPORTANT DO NOT hit wheel hub 6 with a ham mer during removal or installation Hammering may cause damage to the wheel motor 5 Use a puller to remove the wheel hub Remove the key from the wheel motor shaft 6 Remove rust from all parts with a wire brush prior to installation Clean all parts Replace any worn or dam aged components Reelmaster 2000 D Page 6 7 Installation Fig 2 1 Install key and wheel hub onto the wheel motor shaft 2 Install lock nut to wheel motor shaft and tighten to a torque of 250 to 400 ft lb 339 to 542 3 Install wheel assembly and secure the lug nuts to the drive studs 4 Tighten lug nuts evenly in a crossing pattern to a torque of 45 to 65 ft lb 61 to 88 Chassis Front Wheels and Brakes Anti seize lubricant 15 45 to 65 ft lb 61 to 88 N m 250 to 400 ft lb m we Figure 3 1 Flange nut 13 Lug nut 24 Nut 2 Brake rod 14 Lock nut 25 Adjusting rod 3 Parking brake lever 15 Wheel assembly 26 Thrust washer 4 Flange head screw 16 Drive stud 27 Brake shaft 5 Extension spring 17 Cotter pin 28 Cotter pin 6 Locknut 18 Hair pin 29 Key 7 Flat washer 19 Brake lever LH shown 30 Brake cam shaft 8 Brake grass shield 20 Roll pin 31 Return spring 9 screw 21 Yoke pin 32 Brake shoe 10 Brake assembly 22 Brake lever 33 E
143. maining position in the front wear plate Apply a light coating of clean hydraulic oil to gear faces Hydraulic System Page 4 57 3 Rev 8 Install rear wear plate with pressure seal side up and open side of the pressure seal pointing to the inlet side of the motor 9 Apply alight coating of petroleum jelly to new O ring and O ring groove in the body Install new O ring to the body 10 Install locating dowel pins in body Align marker line on the body and front flange IMPORTANT Do not dislodge seals during installa tion 11 Gently slide the body onto the assembly Firm hand pressure should be sufficient to engage the dowel pins 12 Install the four 4 cap screws with washers and hand tighten IMPORTANT Prevent damage when clamping the reel motor in a vise clamp on the front flange only Also use a vise with soft jaws 13 Place front flange of the motor into a vise with soft jaws and alternately torque the cap screws 33 ft lb 45 N m 14 Remove motor from vise 15 Place a small amount of clean hydraulic oil inthe inlet ofthe motor and rotate the drive shaft away from the inlet one revolution If any binding is noted disassemble the motor and check for assembly problems Reelmaster 2000 D SE S5 Yao Fa This page is intentionally blank Page 4 57 4 Rev A Hydraulic System Reelmaster 2000 D Hydraulic Manifold Removal Fig 45 1 Park the machine on a level surface engage the pa
144. manifold NOTE Prior to taking small resistance readings with a digital multimeter short the test leads together The me ter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal re sistance of the meter and test leads Subtract this value from from the measured value of the component you are testing NOTE The solenoid does not have to be removed from the valve for testing 1 Make sure engine is off Unplug solenoid valve elec Figure 17 trical connector 1 Reel drive hydraulic manifold 2 Solenoid valve coil 2 Apply 12VDC source directly to the solenoid Listen for solenoid to switch on 3 Remove 12VDC source from the solenoid Listen for solenoid to switch off 4 Measure resistance between the two coil connector terminals A Resistance of the reel drive solenoid should be about 7 2 ohms B Resistance of the 3 wheel drive solenoid if equipped should be about 7 5 ohms 5 Reconnect electrical connector to the solenoid Figure 18 1 3WD hydraulic manifold 2 Solenoid valve coil SE 96 9 Reelmaster 2000 D Page 5 17 Electrical System Standard Control Module The Reelmaster 2000 D is equipped with a Standard Control Module to monitor and control electrical compo nents required for safe operation This Module is at tached to the back of the instrument panel Fig 19 Inputs from the neutral parking brake PTO start igni
145. master 2000 D Chapter 7 TORO Cutting Units Table of Contents SPECIFICATIONS 2 SPECIAL TOOLS 4 TROUBLESHOOTING 6 Factors That Can Affect Quality Of Cut 6 ADJUSTMENTS EYE Ed 8 Characteristics 8 SERVICE AND REPAIRS 9 Hydraulic Reel Motor 9 BOGDAN ede iet td whe ara Rin nia dem 10 Bedknife Replacement and Grinding 12 Front and Rear 13 Roller Service 14 Cutting 16 Prepare Reel for Grinding 18 Fixed Side Plate Installation 19 Skid Kit Installation 20 Reelmaster 2000 D Page 7 1 Cutting Units Specifications Figure 1 MOUNTING All cutting units are supported by equal length independent lift arms and are interchangeable to all three cutting unit positions CONSTRUCTION 5 8 or 11 blades of 7 inches 18 cm diameter welded to stamped steel spiders Reels are mounted on greaseable self aligning ball bearings Cut ting unit reel length of either 27 inches 69 cm or 32 inches 81 cm HEIGHT OF CUT RANGE Floating Cutting Unit 1 4 to 1 3 4 inches 6mm to 44mm Fixed Cutting Unit 1 2 to 2 5 8 inches 13mm to 67mm POWER Hyd
146. mp shaft Bushing position is critical for the proper alignment of the traction belt and flywheel pulleys Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil Reelmaster 2000 D Page 4 45 Hydraulic System 4 Remove pulley from the taper lock bushing on the piston pump A Remove cap screws and lock washers securing pulley to the taper lock bushing IMPORTANT Excessive or unequal pressure on the cap screws can break the bushing flange B Insert cap screws into threaded removal holes of the pulley Tighten screws progressively and evenly until the pulley is loose on the bushing Remove pulley from the bushing 5 Remove pump lever and neutral arm assemblies Fig 36 from the piston pump as follows The extension spring is under tension and may cause personal injury during removal Use cau tion when removing spring from the neutral arm A Remove extension spring from the pump support and neutral arm B Disconnect traction control rod from the pump le ver by removing cap screw and lock nut C Remove cap screw and washer securing the neu tral bracket to the piston pump Remove flange nut and carriage screw securing the neutral bracket to the pump support D Remove cap screw and flat washer securing the pump lever to the piston pump trunnion E Separate pump lever assembly from pump trun nion and neutral bracket assembly from pump sup port Locate
147. mping the cylinder shaft 6 Plug both ports and clean the outside of the lift cylinder IMPORTANT Prevent damage when clamping the lift cylinder into a vise clamp on the pivot only Do not close vise enough to distort barrel 2 Mount lift cylinder in a vise so that the shaft end tilts up slightly Remove and discard dust seal 12 3 Rotate head 3 with a spanner wrench and remove retaining ring as shown in Figure 51 4 Grasp end of shaft extract shaft head and piston 8 by carefully twisting and pulling on the shaft IMPORTANT Do not clamp vise jaws against shaft surface Protect shaft surface before mounting in vise Hydraulic System Page 4 70 5 Mount shaft securely a vise by clamping vise on the flats of the shaft Remove locknut 10 and piston from the shaft Slide head from the shaft 6 Remove and discard O ring 7 and uni ring 9 from the piston Remove and discard both O rings 2 and 5 and backup washer 4 from the head Spanner wrench Retaining ring Figure 51 Reelmaster 2000 D Inspection A CAUTION Use eye protection such as goggles when using compressed air 1 Wash all parts in solvent Dry parts with compressed air 2 Inspect internal surface of barrel for deep scratches out of roundness and bending Replace if worn or damaged 3 Inspect head shaft and piston for excessive pitting scoring and wear Replace any worn or damaged parts Reassembly Fig 5
148. ms see Trac tion Unit Operator s Manual 3 Raise and remove hood to get access to the front lift cylinder see Traction Unit Operator s Manual Label all connections for reassembly 4 Disconnect hydraulic hoses 1 2 3 and 4 from hy draulic fittings 5 Allow hoses to drain into a suitable container 5 Put caps or plugs on disconnected hoses and fittings to prevent contamination 6 Remove hydraulic fittings 5 and O rings 7 from the lift cylinder 8 7 Remove cotter pin 9 from the clevis pin 10 Pull clevis pin from the lift cylinder and frame 8 Remove flange head screw 11 from cylinder guide pin 16 and lift hub 12 Remove cotter pin 13 and cle vis pin 14 from the lift chain clevis 15 that is on the hy draulic fitting side of the cylinder support bracket 17 9 Support lift cylinder and slide cylinder guide pin 16 from the lift hub 12 10 Reach up from the bottom and rotate lift cylinder so the bottom port comes out of the slot in the frame Drop lift cylinder down and out from the frame 11 Remove flange bushings 18 from the cylinder sup port bracket 17 12 Remove lift hub from the lift cylinder shaft Reelmaster 2000 D Page 4 69 Installation Fig 49 1 Thread lift hub onto lift cylinder and tighten fully 2 Position lift cylinder inside the cylinder support bracket and valve mount bracket Make sure the ports of the lift cylinder face the hydraulic fitting s
149. n 16 Remove test gauge and reconnect hose to motor Adjust bedknife to reel clearance on all cutting units see Cutting Unit Operator s Manual Hydraulic System Hydraulic System TEST 9 Reel Motor Case Drain Using Tester With Pressure Gauges and Flow Meter MEASURE RH CASE DRAIN FLOW HERE FROM REEL MOTOR GEAR PUMP a MD1 TO COOLER FROM CARTRIDGE VALVES AND LEFT WHEEL MOTOR HYDRAULIC MANIFOLD Milliliters in 15 sec Ounces in 15 sec Working Pressure Low Pressure Charge Return or Suction Flow 95 32 189 6 4 284 9 6 378 12 8 473 16 0 568 19 2 662 22 4 756 25 6 852 28 8 946 32 0 o Figure 30 Hydraulic System Page 4 36 Reelmaster 2000 D Procedure for Reel Motor Case Drain Test NOTE Over period of time a reel motor can wear in ternally A worn motor may by pass oil to its case drain causing the motor to be less efficient Eventually enough oil loss will cause the reel motor to stall under heavy cutting conditions Continued operation with a worn inefficient motor can generate excessive heat cause damage to seals and other components in the hy draulic system and affect quality of cut NOTE One way to find a possibly bad reel motor is to have another pers
150. n hole leaks or nozzles that eject hydraulic fluid under high pressure Use paper or cardboard not hands to search for leaks Hydraulic fluid escaping under pressure can have sufficient force to penetrate skin and cause serious injury If fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury Gangrene may result from such an injury Reelmaster 2000 D Page 4 19 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 Contamination will cause exces sive wear of hydraulic components 2 Put caps or plugs on any hydraulic lines left open or exposed during testing or removal of components 3 The engine must be in good operating condition Use a tachometer when making a hydraulic test Engine speed will affect the accuracy of the tester readings 4 Because the hydraulic pump is belt driven check for proper pump belt adjustment before performing any hy draulic test 5 To prevent damage to tester or components the inlet and the outlet hoses must be properly connected and not reversed when using tester with pressure and flow capabilities 6 To minimize the possibility of damaging compo nents completely open load valve in hydraulic tester when using tester with pressure and flow capabilities 7 Install fittings finger tight
151. nd O rings from the valve body Re move springs balls and cam pins from the valve body 4 Remove snap ring from the bottom of the valve body Remove spool snap ring spring retainer spacer and spring 5 Push and twist spool carefully out of the valve body Set spool aside 6 Remove O rings from valve body using a soft hooked scribe or a thin screwdriver taking care not to scratch the valve bore finish Control Valve Inspection Fig 56 Ad caution Use eye protection such as goggles when using compressed air 1 Wash all parts in solvent Dry parts with compressed air 2 Inspect spool for bending and flatness Signs of wear on one side of the spool may indicate damage Replace a worn or damaged spool if necessary 3 Inspect other components for wear or damage and replace damaged items as necessary Control Valve Reassembly Fig 56 1 Coat all new O rings with hydraulic oil Install new O rings into the bore of the valve body 2 Coat spool lightly with hydraulic oil Push and twist spool carefully into the valve body Avoid damaging rings 3 Install spring retainer spring spacer second spring retainer and spool snap ring onto the spool Install snap ring into the valve body Hydraulic System Page 4 78 Figure 56 1 Plug 8 Spool 2 O ring 9 O ring 3 Spring 10 Spring retainer 4 Ball 11 Spring 5 Check valve seat 12 Spacer 6 Cam pin 13 Spool snap ring 7 Control valve b
152. nd cap screw securing the tailpipe to the rubber hanger Slide tailpipe from ma chine 5 Remove coupler springs that retain muffler to head er 6 Remove flange nut that secures muffler to rubber isolator Remove muffler from machine 7 f muffler header removal is required remove four hex nuts and lock washers from the exhaust manifold studs Separate muffler header from the exhaust man ifold 8 Remove exhaust gasket Replace gasket if dam aged or torn Reelmaster 2000 D Page 3 11 Installation Fig 8 NOTE Make sure exhaust manifold and muffler head er sealing surfaces are free of debris or damage that may prevent a tight seal 1 If muffler header was removed place exhaust gas ket on the exhaust manifold Secure muffler header to the manifold with four lock washers and hex nuts IMPORTANT Finger tighten all fasteners before securing so there is no preload on exhaust compo nents 2 Position muffler to muffler header and rubber isola tor Install flange nut to rubber isolator 3 Tighten muffler flange hex nuts and then muffler plate screws and nuts 4 Place clamp on tailpipe and position tailpipe to muf fler Install cap screw washers and lock nut securing the tailpipe to the rubber hanger 5 Install coupler springs to secure muffler to header Tighten flange nut at rubber isolator 6 Torque muffler tailpipe clamp to 200 22 6 Tighten lock nut at rubber hanger t
153. nd maintenance A Check for cracks Replace battery if cracked or leaking B Check battery terminal posts for corrosion Use wire brush to clean corrosion from posts Electrical System Page 5 26 Figure 29 1 Negative battery cable 2 Positive battery cable IMPORTANT Before cleaning the battery tape or block vent holes to the filler caps and make sure the caps are on tightly C Check for signs of wetness or leakage on the top of the battery which might indicate a loose or missing filler cap overcharging loose terminal post or over filling Also check battery case for dirt and oil Clean the battery with a solution of baking soda and water then rinse it with clean water D Check that the cover seal is not broken away Re place the battery if the seal is broken or leaking E Check the electrolyte level in each cell If the level is below the tops of the plates in any cell fill all cells with distilled water between the minimum and max imum fill lines Charge at 15 to 25 amps for 15 min utes to allow sufficient mixing of the electrolyte 2 Conduct a hydrometer test of the battery electrolyte IMPORTANT Make sure the area around the cells is clean before opening the battery caps A Measure the specific gravity of each cell with a hydrometer Draw electrolyte in and out of the hydrometer barrel prior to taking a reading to warm up the hydrometer At the same time take the tem perature of the cell
154. nd state of charge must be checked before testing the starter system Tool s required Digital multimeter and or inductive Ammeter AC DC Current Transducer Test instructions Properly connect the ammeter to the digital multimeter refer to manufacturers instructions Check Operation of Interlock Switches Do not disconnect safety switches They are for the operator s protection Checkthe operation of the interlock switches daily for proper operation Replace any malfunctioning switches before op erating the machine Reelmaster 2000 D Page5 9 Rev A Set the multimeter to the correct scale With the key in the OFF position place the ammeter pickup around the main negative battery cable and read the meter prior to activating the starter system Adjustthe meterto read zero if applicable Crank the engine for at least 3 se conds and record the results Maximum starter system draw for the RM 2000 D is 140 Amps at 65 F 189 C If current draw is significantly higher than listed check for a shorted condition If current draw is significantly lower than listed check for high resistance Interlock switch operation is described in the Traction Unit Operator s Manual The Reelmaster 2000 D is equipped with a Standard Control Module which moni tors interlock switch operation Information on this Mod ule is described in the Component Testing of this Chapter and in the Traction Unit Operator s Manual Testing of individu
155. ng grooves C Rotate bearing inside the housing so the ex tended part of the inner race is facing the inside of the housing 5 Slide bearings and bearing housings onto the reel shaft 6 Make sure bearing housings are installed with the grease fittings pointing up and to the front of the cutting unit 7 Secure bearing housings to the cutting unit with flange head screws 8 Remove any grease from the threaded end of the reel couplers and the reel shaft Make sure grease is completely removed 9 Apply medium strength thread locking compound to reel coupler threads Do not get thread locking com pound on the bearing seal 10 Screw reel coupler RH to the reel This coupler has right hand threads Screw reel coupler LH to the reel This coupler has left hand threads Torque both couplers from 55 to 65 75 to 88 11 Install front roller to cutting unit see Roller Installa tion Reelmaster 2000 D Page 7 17 12 Install bedbar assembly to cutting unit see Bedbar Installation 13 Complete cutting unit set up and adjustment se quence see Cutting Unit Operator s Manual 14 Install cutting unit to machine see Traction Unit Op erator s Manual 15 Install hydraulic motor to drive end of the cutting unit see Hydraulic Reel Motor Installation Install cover gasket cover and cap screws to the other end of the cutting unit 16 Grease cutting unit see Cutting Unit Operator s Manual
156. ng the springs install a jam nut onto the valve stem While tightening the set screw tighten jam nut at the same time using a 7 16 wrench G Thread second jam nut all the way down the valve stem Apply medium strength thread locking com pound to the valve stem threads Screw knob all the way down until it contacts the upper jam nut Hydraulic System e 5 amp gt On backlap valve turn knob counterclockwise so the arrow is 909 with the back of the manifold body Simultaneously tighten upper jam nut and turn knob so it is tight and the arrow is pointing 45 to the right in line with the indicator plate On reel speed control valve turn knob counter clockwise until the arrow points at the number 5 Si multaneously tighten upper jam nut and turn knob so it is tight and the arrow is pointing at the number 1 on the locating plate 11 After reassembly if problems still exist remove valve and clean again or replace valve Hydraulic System Page 4 62 Reelmaster 2000 D 9 5 N UO gt gt N T This page is intentionally blank Reelmaster 2000 D Page 4 63 Hydraulic System Hydraulic Manifold Service Serial Number Above 290000000 N 50 ft Ib FRONT 67 N m i 25 ft Ib N 34 N m 5 ft lb 10 6 7 N m 25 ft Ib 34 N m 15 ft lb x 4 20 N m 40 ft Ib 54 N m 20 ft Ib 27 N m Figure 46 1 1
157. nge nut securing the left footrest to the frame Tighten cap screws Fig 10 18 Connect brake rod to brake arm Install and lock cot ter pin to the brake rod Fig 11 19 Reinstall fender bracket and left fender to the radia tor side of the frame Fig 10 A Secure both cap screws and left fender bracket to the frame B Reinstall remaining cap screws and flange nuts securing the fender to the fender bracket and frame C Secure cap screw and flange nut to the left foot rest and the left fender 20 Adjust hand brake see Traction Unit Operator s Manual 21 Check engine oil level see Traction Unit Operator s Manual 22 Connect negative and then positive battery cables at the battery 23 Bleed fuel system see Traction Unit Operator s Manual 24 Replace access covers to the engine A Reinstall left rear panel radiator side which sup ports the instrument panel B Reinstall right side panel which accesses the traction pump drive belt C Reinstall hood to the machine Reelmaster 2000 D Disassembly 1 Remove three cap screws and lock washers that se cure bushing to pulley IMPORTANT Excessive or unequal pressure on the cap screws can break the bushing flange 2 Insert cap screws into threaded removal holes of the bushing Tighten screws progressively and evenly until the pulley is loose on the bushing Remove bushing and pulley from stub shaft Locate and remove
158. ns 4 2 General Information 4 4 Electrical Schematics Hydraulic Schematic 4 7 Circuit Diagrams Hydraulic Flow Diagrams 4 8 Wire Harness Drawings 5 Special TOs 4 14 25 Troubleshooting race xo 4 16 9 4 19 ui Service and Repairs 4 40 EATON MEDIUM DUTY PISTON PUMP REPAIR IN FORMATION MODEL 70160 VARIABLE DISPLACE MENT PISTON PUMP ROSS TORQMOTOR MG ME AND MJ SE RIES SERVICE PROCEDURE c D 5 o Electrical Diagrams Reelmaster 2000 D Rev A This page is intentionally blank Reelmaster 2000 D Chapter 1 TORO Safety Table of Contents SAFETY INSTRUCTIONS 2 JACKING INSTRUCTIONS 4 Before Operating 2 SAFETY AND INSTRUCTION DECALS 4 While Operating 2 Maintenance and Service 3 Reelmaster 2000 D Page 1 1 Safety Safety Instructions The Reelmaster 2000 D has been tested and certified by TORO for compliance with existing safety standards and specifications as specified in the Traction Unit Op erator s Manual Although hazard control and accident prevention partially a
159. nto the spool as sembly and torque as follows do not over tighten A Torque nut for reel drive solenoid from 2 to 5 ft lb 2 7 to 6 8 B Torque nut for 3WD solenoid from 4 to 6 ft b 5 to 8 N m 3 Connect the solenoid to the machine wiring harness Reelmaster 2000 D Page 5 29 2 to 5 ft lb 2 7 to 6 8 Thread locking compound Figure 30 4 Spool assembly 5 Reel drive manifold 1 Nut 2 Coil assembly 3 O ring Thread locking compound Figure 31 1 Nut 4 Spoolassembly 2 Coil assembly 5 3WD manifold 3 O ring Electrical System This page is intentionally blank Electrical System Page 5 30 Reelmaster 2000 D TORO Table of Contents SPECIFICATIONS SERVICE AND REPAIRS Rear Wheel Standard 2 Wheel Drive Rear Wheel Optional Wheel Drive Front Wheels and Brakes Reelmaster 2000 D Page 6 1 Chapter 6 Chassis Standard Seat uus ix seseque credi 10 Suspension Seat 11 Steering Assembly 12 Front Lift ArmS 14 Rear Lift Arm eo cc rer REV C 15 Chassis Specifications Item Description Front tire pressure 20 x 10 8 4 ply tubeless 16 to 20 PSI 1 1 to 1 38 bar Rear tire pressure 20 x 8 8 4 ply tub
160. nut 6 O ring 17 Locating plate 28 Indicator plate 7 Solenoid cartridge port S1 18 Backlap cartridge port MD1 29 Detent plate 8 Seal kit 19 4 way seal kit 30 Socket head screw 9 Solenoid valve coil 20 Locating plate 31 Orifice plug 10 Solenoid seal 21 Plug SAE 6 32 Indicator plate 11 Plug SAE 2 22 O ring 33 Nut NOTE The ports on the manifold are marked for easy identification of components Example P1 is the gear pump connection port and 61 is the location for the sole noid cartridge See Hydraulic Schematics to identify the function of the hydraulic lines and cartridge valves at each port Hydraulic System 4 60 Rev A Reelmaster 2000 D Hydraulic Manifold Service 1 Make sure the manifold is clean before removing the cartridge valve 2 If solenoid cartridge is being serviced remove nut securing solenoid to the cartridge valve Carefully slide solenoid off the valve 3 If reel speed control cartridge valve or backlap car tridge valve is being serviced remove knob assembly A Unscrew and remove knob Remove both jam nuts B Slide off indicator plate being careful not to lose springs or balls Remove both springs and balls from detent plate C Loosen set screw and slide detent plate from the spool valve stem D Remove locating plate with pin from spool valve IMPORTANT Use care when handling the cartridge valve Slight bending or distortion of the stem tube can cause binding an
161. nut securing solenoid coil to the cartridge valve Careful ly slide solenoid coil off the valve 3 If flow control cartridge valve is being serviced re move rotary handle from valve stem Fig 46 2 A Loosen two 2 set screws that secure handle cap B Remove screw and then lift handle cap from valve C Locate and retrieve detent pin compression spring bushing and lip seal The sleeve bearing should stay in the cap D Loosen two 2 set screws that secure handle base to flow control valve and remove base Before opening hydraulic system operate all hy draulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil See Relieving Hydraulic System Pressure in the Gen eral Information section of this chapter IMPORTANT Use care when removing cartridge valves Slight bending or distortion of the stem tube can cause binding and malfunction Make sure that deep well socket fully engages the valve base 4 Using a deep well socket remove cartridge valve from manifold Note correct location of O rings sealing rings and backup rings Remove and discard seal kit from valve IMPORTANT Before removing mow backlap spool from mow manifold remove backlap switch dowel pin and ball 5 If necessary remove mow backlap spool from mow manifold A Remove backlap switch from mow manifold be fore removing mow backlap spool Remove dowel pin and ball from manifold port after switch is re mo
162. o 10 0 bar Implement Lift Relief Valve Implement Relief Pressure Differential area relief valve 450 525 PSI 31 1 to 36 2 bar Lift Control Valve Spool type directional control valve Reel Motor Gear Pump Maximum Operating Pressure Positive displacement gear type pump 4000 PSI 276 bar Hydraulic Manifold Relief Valve Cutting Circuit Relief Pressure Differential area relief valve 2700 to 3300 PSI 186 3 to 227 7 bar Reel Motor Maximum Operating Pressure Cross over Relief Pressure Gear motor 2250 PSI 155 bar 1350 to 1650 PSI 93 2 to 113 9 bar Hydraulic Filter 10 Micron spin on cartridge type Hydraulic Oil See Traction Unit Operator s Manual Hydraulic Reservoir Capacity 2 3 Gal U S 8 7 L Hydraulic System Page 4 2 Reelmaster 2000 D 9 5 N UO gt gt N T This page is intentionally blank Reelmaster 2000 D 4 3 Hydraulic System General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather sun chemicals very warm storage condi tions or mishandling during operation and mainte nance These conditions can cause damage or premature deterioration Some hoses are more suscep tible to these conditions than others Inspect the hoses frequently for signs of deterioration or damage When replacing a hydraulic
163. o secure tail pipe 7 Install the hood see Traction Unit Operator s Manu al Engine Radiator Radiator surge tank Surge tank bracket Top radiator shroud Flange head screw Left cover Radiator cap Top foam Flange nut Thumb screw 10 Flange head screw 11 Rear radiator bracket 12 Threaded insert 13 Cap screw Engine Figure 9 Screen Bottom radiator shield Screw Hose clamp Flange nut Carriage screw Front radiator bracket Radiator Bottom radiator shroud Flange head screw Flange nut Radiator cap decal Page 3 12 Warning decal Radiator hose Bulb seal Top radiator hose Radiator tube Flange head screw Flat washer Radiator hose Oil cooler Knob Lock nut Oil cooler bracket Reelmaster 2000 D Removal Fig 9 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Open and remove the hood see Traction Unit Oper ator s Manual Do not open radiator cap or drain coolant if the radiator or engine is hot Pressurized hot cool ant can escape and cause burns Ethylene glycol antifreeze is poisonous Dis pose of coolant properly or store it in a properly labeled container away from children and pets 3 Drain coolant from radiator A Slowly remove radiator cap from the radiator B Place d
164. o the engine mounts with cap screws snubbing washers and lock nuts Reelmaster 2000 D 5 Page 3 17 Reconnect electrical connections A Pull wiring harness and hoses into position keep ing them from contacting moving parts Route har ness and hoses through R clamps Install cap Screws with flat washers to secure R clamps to inder head Fig 14 B Install connector with pink and white wires to the alternator Secure red wire to alternator stud C Install connector with blue white wire to the high temperature shut down switch located on the water pump behind the fan D Install connector with red black wire to the fuel valve solenoid in the injector pump E Install connector with gray wire to the oil pressure Switch located near the engine oil dipstick F Install connector with red wire to the glow plugs located on the rear side of the cylinder head G Install connector with white wire to the engine starter motor located below the exhaust manifold Install fusible link connector and positive battery cable to the starter motor Fig 13 H Connect negative battery cable and black engine wire harness ground wire to the LH bracket of the rear engine frame Fig 16 Figure 16 Cap screw with washer Cap screw Flat washer Negative battery cable 5 Wire harness ground 6 Star washer 7 Alternator bracket mount Engine 6 Install hydraulic pump assembly see Service and Repairs
165. ody 14 Snap ring 4 check valve seat was damaged and removed press fit replacement into the valve body 5 Lubricate and install cam pin ball and spring Place new O ring on plug and install them into the valve body Tighten plug 6 Repeat steps 4 and 5 for the second plug assembly Reelmaster 2000 D Hydraulic Reservoir Thread locking Compound 30 to 60 in Ib 3 4 to 6 8 e 5 L7 ES gt 3 4 10 6 8 Thread locking a 30 to 60 in Ib Compound Figure 57 1 Shoulder screw 10 Tank mount grommet 19 Suction hose 2 Sight glass 11 Washer 20 Oil filter 3 Hose clamp 12 Cap screw 21 Filter head 4 Tee fitting 13 Carriage screw 22 90 hydraulic fitting 5 Nut 14 Hose clamp 23 Suction hose 6 Hydraulic reservoir cap 15 Hydraulic hose tank to filter 24 O ring 7 Screen filter 16 45 hydraulic fitting 25 O ring 8 Hydraulic tank 17 U bracket 26 Reservoir plug 9 Tank bracket 18 Flange head screw Inspecting Reservoir Parts Fig 57 4 Make sure all three tank mounting cap screws are secure loose remove cap screw apply medium 1 Clean tank and filler screen with solvent strength thread locking compound to threads and rein stall Torque cap screws from 30 to 60 in lb 3 4 to 6 8 2 Inspect tank for leaks cracks or other damage N m 3 Replace hydraulic hoses if worn or leaking 5 Make sure all bracket fasteners are tight Reelmaster 2000 D Page 4 79 H
166. ol valve spool is positioned down and flow is directed out the top LIFT CIRCUIT NEUTRAL POSITION LIFT RELIEF 475 LBS 2 3 S REEL LIFT VALVE TOP A BOTTOM B TO CHARGE RELIEF VALVE FROM CHARGE PUMP of the control valve to the lower and outer portions of the lift cylinders Hydraulic pressure against the cylinder pistons pushes the shafts out At the same time the pis tons push the hydraulic fluid in the upper and inner por tions of the lift cylinders out and through the control valve to the piston pump suction When the control valve lever is released spring action returns the spool to the center position and by passes flow back to the piston pump suction Lift cylinder movement is stopped The cylinder position is locked in place since there is no complete cir cuit of flow to and from the lift cylinders Lower Cutting Units Circuit operation for lowering the lift cylinders is similar to raising them However the control valve spool is shifted up and flow is reversed to and from the lift cylin ders Fig 8 thus moving the cutting units down LIFT CIRCUIT LOWER hcc LIFT RELIEF 475 LBS FRONT eee REEL LIFT CONTROL VALVE TO CHARGE RELIEF VALVE FROM CHARGE PUMP Figure 8 Reelmaster 2000 D Page 4 11 Hydraulic System 2 5 A amp gt
167. oller position Make sure front rollers on all cutting units are in the same position 8 Rear roller parallel to reel Rear roller must be set so that it is parallel with the reel before setting height of cut 9 Height of cut Make sure all cutting units are set at the same height of cut Set units as specified in the Cutting Unit Operator s Manual 10 Bedbar stability Check bedbar end bushings adjuster pivot bushings and nylon flanged bushings for wear or damage Check bedbar adjustment knob to make sure detent holds adjustment 11 Number of reel blades Use cutting unit model with the correct number of blades for clip frequency and optimum quality of cut range see Specifications 12 Cutting unit alignment and ground following Check lift arms and cutting unit pivot linkages for wear damage binding or bent pivot pins 13 Roller condition rollers should rotate freely Make sure roller bearings are properly lubricated Replace bearings if worn or damaged Reelmaster 2000 D Page 7 7 Cutting Units Adjustments Never install or work on the cutting units or lift arms with the engine running Always stop en gine and remove key first See Cutting Unit Operator s Manual for adjustment pro cedures for the cutting units on the Reelmaster 2000 D Characteristics The single knob bedknife to reel adjustment system in corporated in this cutting unit simplifies the adjustment procedure needed
168. on and reel drive pumps 4 Install reel drive pump to piston pump see Reel Drive Pump Installation Support piston and gear pumps when installing them to the pump support to prevent them from falling and causing personal injury 5 Position pump assembly to the pump support Se cure piston pump to the pump support with both cap screws hardened washers and lock nuts 6 Remove plugs that were placed during disassembly from hydraulic hoses Connect all hydraulic hoses that were removed during disassembly 7 Install pump lever and neutral arm assemblies Fig 36 to the piston pump as follows A Position neutral bracket assembly to the pump and pump support Secure neutral bracket to pump with cap screw and washer Secure neutral bracket to pump support with carriage screw and flange nut B Place key in pump trunnion and slide pump lever assembly onto trunnion Secure pump lever to the trunnion with flat washer and cap screw C Connect traction control rod to the pump lever with cap screw and lock nut Reelmaster 2000 D 9 Install drive belt to the pulleys see Hydraulic Pump Drive Belt 10 Check traction drive for neutral and neutral switch The extension spring is under tension and may adjustment see Traction Unit Operator s Manual cause personal injury during installation Use caution when installing the spring to the neutral 11 Remove plug from the hydraulic reservoir arm 12 Follow Hydraulic Syst
169. on observe the machine while mow ing in dense turf A bad motor will run slower produce fewer clippings and may cause marcelling or a wash board appearance on the turf 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 2 Park machine on a level surface with the cutting units lowered Make sure engine is off and the parking brake is engaged 3 Read Precautions For Hydraulic Testing Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil Position Case Drain Motor Return 4 On the suspected bad reel motor clean hose nection and disconnect return hose from motor to man ifold see table IMPORTANT Make sure oil flow indicator arrow on the flow gauge is showing that the oil will flow from the motor through the tester and into the hose Reelmaster 2000 D Page 4 37 5 Install flow tester with pressure gauges in series with the motor and the disconnected return hose Make sure the flow control valve on the tester is fully open 6 Make sure backlap knob on the valve block is in the mow position 7 Clean hose fitting and disconnect case drain hose from the manifold block see table Plug the manifold port Keep away from reels during test to prevent per sonal injury from the rotating reel blades 8
170. ontrols to relieve system pressure and avoid injury from pressurized hy draulic oil 10 Clean hose fitting and disconnect hose from the el bow connection on the top of the traction pump Fig 20 IMPORTANT Make sure oil flow indicator arrow on the flow gauge is showing that the oil will flow from the motor through the tester and into the hose 11 Install flow tester with pressure gauges in series with the motor and the disconnected hose Make sure flow control valve is fully open 12 person should sit on the seat and operate the machine while another person reads the tester Start en gine 13 Adjust engine speed so pump speed is 2400 RPM engine speed approximately 2700 RPM Verify pump speed with a phototac Reelmaster 2000 D Page 4 25 Use extreme caution when taking gauge read ings The front tire on the ground will be trying to move the machine forward 14 Slowly push traction pedal to fully forward position 15 Close flow control valve until pressure gauge reads 1000 PSI Observe flow gauge TESTER READING flow approximately 13 GPM 16 Release traction pedal and turn off machine 17 Disconnect tester from elbow connection and hose Reconnect hose to elbow connection NOTE If pressure is good under no load but drops be low specification when under traction load the piston pump and or wheel motor s should be suspected of wear When a pump and or motor is worn or damaged the charge pump
171. oper reassembly 3 Secure the motor in a vise with the drive shaft up 4 Remove all eight screws Hydraulic System Page4 56 5 Remove the motor from the vise Remove the front plate from the body A wooden block or soft face ham mer can be used to gently tap the motor when freeing the frontplate 6 Remove alignment pin from the body Remove drive gear 9 and idler gear 8 from the body 7 Remove body from the backplate Remove O rings from the body and backplate and discard 8 Remove alignment pin from the backplate 9 Remove retaining ring oil seal and backup washer from the frontplate Reelmaster 2000 D IMPORTANT Do remove the relief valve assem bly 19 unless testing shows it to be faulty The re lief valve assembly must be replaced as a complete unit Both relief valve seats 6 are sealed in place with locking compound do not remove them 10 If necessary remove relief valve plug O ring shim spring and ball from the backplate Inspection Fig 44 1 Remove all nicks and burrs from all parts with an A CAUTION emery cloth Use eye protection such as goggles when using compressed air 2 Clean all parts with solvent Dry all parts with com pressed air 3 Inspect drive gear 9 shaft for a broken or chipped keyway 4 Inspect drive gear and idler gear 8 shafts at the bushing points and seal area for rough surfaces and ex cessive wear 5 Replace drive g
172. operation is dependent upon proper ad justment of throttle control Make sure throttle control is operating properly 1 Move remote throttle control lever to FAST position 2 Check position of speed control lever on fuel injec tion pump Speed control lever should be contacting high speed screw when throttle control lever is in FAST position 3 If necessary throttle control can be adjusted by loos ening cable clamp screw and repositioning control cable until speed control lever contacts high speed screw Adjust Engine Speed 1 Allow engine to reach operating temperature before checking or adjusting engine speed Park machine on a level surface lower cutting units and engage parking brake 2 With engine running move remote throttle control le ver to FAST position 3 Using a tachometer check that engine is operating at 3200 50 RPM 4 f high idle speed is incorrect adjust high speed screw on fuel injection pump Fig 4 A Loosen lock nut on high speed screw B Adjust high speed screw to obtain 3200 50 RPM C Tighten lock nut Recheck high speed 5 Move remote throttle control lever to SLOW position 6 Using a tachometer check that engine is operating at 1540 50 RPM 7 If idle speed is incorrect adjust idle speed screw Fig 5 A Loosen lock nut on idle speed screw B Adjust idle speed screw to obtain 1540 50 RPM C Tighten lock nut Recheck idle speed
173. ops the engine To test the high temperature shutdown light and circuit wiring start the engine and ground the blue white wire attached to high temperature shutdown switch located on water pump housing see High Temperature Shut down Switch in this Chapter Warning light should illu minate and engine should stop running Glow Plug Indicator Light The glow plug light should come on when the ignition switch is placed in the ON position prior to placing the ignition switch in START The light should stay lit for approximately 5 seconds while the ignition switch is left in the ON position Charge Indicator Light The charge indicator light should come on when the igni tion switch is in the ON position with the engine not run ning or with an improperly operating charging circuit while the engine is running Testing Indicator Lights 1 Apply 12 VDC to terminals 1A and 2A Fig 9 2 Ground terminals 1B and 2B Fig 9 3 Both indicator lights should illuminate Figure 8 1 Charge indicator 3 High temp shutdown 2 Engine oil pressure 4 Glow plug indicator Figure 9 1 Charge indicator 4 Glow plug indicator 2 Engine oil pressure 5 Warning light front 3 High temp shutdown 6 Warning light back Electrical System Page 5 12 Reelmaster 2000 D Hour Meter 1 Connect the positive terminal of a 12 VDC source to the positive 4 terminal of the hour meter 2 Connect the negative terminal of the voltage
174. otor 55 Cutting Reel Motor Service Serial Number Below 290000000 56 Cutting Reel Motor Service Serial Number Above 290000000 57 1 Hydraulic Manifold 58 Hydraulic Manifold Service Serial Number Below 290000000 60 Hydraulic Manifold Service Serial Number Above 290000000 63 1 3 Wheel Drive Selector Valve 64 3 Wheel Drive Selector Valve Service 66 Front Lift Cylinder 68 Front Lift Cylinder Service 70 Rear Lift Cylinder 72 Rear Lift Cylinder Service 74 Control and Lift Relief Valves 76 Hydraulic Reservoir 79 Oil Goolet foc aude heehee rerun anaes 80 EATON MEDIUM DUTY PISTON PUMP REPAIR IN FORMATION MODEL 70160 VARIABLE DISPLACE MENT PISTON PUMP ROSS TORQMOTOR MG MF ME AND MJ SERIES SERVICE PROCEDURE Rev A Hydraulic System 2g 3 SE 52 gt Specifications Item Description Traction Pump Maximum Operating Pressure Variable displacement piston pump 3000 PSI 207 bar Wheel Motors Maximum Operating Pressure Orbital rotor motor with shuttle valve on left front motor 2000 PSI 138 bar Charge Pump Charge Pressure Gerotor pump integral in traction pump 100 to 150 PSI 6 9 t
175. p direction only if they are expected to be a problem After testing cross over reliefs in the backlap direction make sure the reel motor couplings are torqued see Hy draulic Reel Motor in the Service and Repair section of Chapter 7 Cutting Units 10 If 5 relief pressure is to be tested in the backlap direction clean left hand reel motor and its hose connection leading to manifold port M3 Discon nect hose connection and install pressure gauge with a T connection between the hose connection and the reel motor 11 Put a block of wood between the blades of the cutting unit being tested to prevent that reel from rotating 12 Make sure backlap knob on the valve block is in the backlap position 13 One person should sit on the seat and operate the machine while another person reads the gauge Start engine and move the throttle to full speed 3200 50 RPM Keep away from reels during test to prevent per sonal injury from the rotating reel blades Do not allow system pressure to exceed 1700 PSI Shut off unit to prevent an over pressure condition 14 Engage cutting units Observe pressure gauge Motor Position Right Hand Pressure Range PSI 1580 to 1680 1540 to 1640 Left Hand 1500 to 1600 15 Disengage cutting units and stop engine If specifica tions are not met the cross over relief needs replacing Remove block of wood from cutting unit and repeat test on other reels in the backlap directio
176. peration of the ignition switch If the ignition switch is in the ON posi tion the Module power input LED should be illuminated If the ignition switch is in the START position the Module start output LED should also be illuminated Reelmaster 2000 D Page 5 11 NOTE See the Briggs amp Stratton Daihatsu Engine Re pair Manual for more component testing information A CAUTION When testing electrical components for continu ity with a multimeter ohms setting make sure that power to the circuit has been disconnected Figure 6 1 Key 3 Lock washer 2 Hex nut 4 Ignition switch Figure 7 Electrical System Indicator Lights Engine Oil Pressure Light The oil pressure light should come on when the ignition switch is in the ON position with the engine not running Also it should light with the engine running if the engine oil pressure drops below 4 3 PSI 0 3 kg cm To test the oil pressure light and circuit wiring ground the gray wire attached to oil pressure switch located on the front side of engine near the oil dipstick Turn ignition Switch to the ON position the oil pressure light should come on indicating correct operation of the electrical wiring to the oil pressure switch High Temperature Shutdown Light If the engine coolant temperature rises to 238 F 1149C the high temperature light should come on as the high temperature shutdown switch st
177. perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 2 Park machine on a level surface with the cutting units lowered Make sure engine is off and parking brake is engaged Back bedknives off all reels Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil 3 Clean manifold port G1 Remove cap and install pressure gauge in manifold port G1 4 Puta block of wood between the blades of the cutting unit being tested to prevent that reel from rotating 5 Make sure backlap knob on the valve block is in the mow position 6 One person should sit on the seat and operate the machine while another person reads the tester Start en gine and set throttle to full speed 3200 50 RPM Do not allow system pressure to exceed 1700 PSI Shut off unit to prevent an over pressure condition 7 Engage cutting units Observe pressure gauge Motor Position Right Hand Pressure Range PSI 1500 to 1600 1540 to 1640 Left Hand 1580 to 1680 8 Disengage cutting units and stop engine If specifica tions are not met replace cross over relief If specifica tions are met remove block of wood from cutting unit and repeat test on other reels in mow direction Reelmaster 2000 D Page 4 35 9 Remove test gauge and put cap on manifold port G1 IMPORTANT Each reel motor has two cross over reliefs Test reliefs in the backla
178. protector valve cuts out when pressure is about to exceed the normal range for the gauge The cutout pressure is adjustable 4 HIGH PRESSURE GAUGE High range gauge which accommodates pressures beyond the capacity of the low pressure gauge 0 to 5 000 PSI 5 FLOW METER This meter measures actual oil flow in the operating circuit with a gauge rated at 15 GPM 6 OUTLET HOSE A hose from the outlet side of the hydraulic tester connects to the hydraulic system circuit Hydraulic System Page4 14 Figure 9 Figure 10 Reelmaster 2000 D Hydraulic Test Fitting Kit Toro Part Number TOR4079 This kit includes a variety of O ring Face Seal fittings to enable connection of test gauges to the system The kit includes tee s unions reducers plugs caps and male test fittings Measuring Container Toro Part Number TOR4077 Use this container for doing hydraulic motor efficiency testing motors with case drain lines only Measure effi ciency of a hydraulic motor by restricting the outlet flow from the motor and measuring leakage from the case drain line while the motor is pressurized by the hydraulic system The table in Figure 13 provides gallons per minute GPM conversion for hydraulic motor case drain leak age measured in either milliliters or ounces Toro Fitting Test Fitting Kit TOR4079 Tool Number to Vu Vane Neste Figure 12 Milliliters 15 Ounces in 15 sec
179. r Below 230000000 3 Serial Number Above 230000000 4 CIRCUIT DIAGRAMS 5 Glow Plug Circuit Diagram 5 Crank Circuit Diagram 6 Run Transport Circuit Diagram 7 Run Mow Circuit Diagram 8 WIRE HARNESS DRAWINGS 10 Main Wire Harness Drawing Serial Number Below 230000000 10 Main Wire Harness Drawing Serial Number Above 230000000 12 Engine Wire Harness Drawing 14 Ba oF ES os Reelmaster 2000 D Page8 1 Rev Electrical Diagrams This page is intentionally blank Electrical Diagrams Page 8 2 Reelmaster 2000 D B YYYY R BK R RUN SOLENOID S ALTERNATOR NR HOUR METER OVER TEMP SHUTDOWN BU W 7 ENGINE OIL PRESSURE GN 2 GY BUM GN L be t 11 1 va amp zla 4 i 5 amp 2 A START 42v tart 1 z lt
180. rain pan below the radiator drain plug lo cated on the bottom of the radiator Remove plug and allow coolant to drain 4 Loosen knobs that secure oil cooler to front radiator bracket Unhook and position oil cooler assembly away from radiator 5 Disconnect radiator hoses upper and lower from the radiator 6 Support the radiator assembly before loosening mounting fasteners 7 Remove two carriage screws and flange nuts secur ing the front radiator bracket to the frame Remove four cap screws and flange nuts securing the rear radiator bracket to the frame 8 Carefully pull radiator assembly from the machine Plug radiator and hose openings to prevent contamina tion 9 As required remove brackets and shrouds from ra diator using Figure 9 as a guide Reelmaster 2000 D Page 3 13 Installation 1 Install any removed brackets or shrouds to radiator using Figure 9 as a guide 2 Remove any plugs used during the removal proce dure 3 Carefully position radiator assembly to the frame Secure radiator with two carriage screws and flange nuts at the front radiator bracket and four cap screws and flange nuts at the rear radiator bracket 4 Position and secure oil cooler to front radiator brack et IMPORTANT Make sure lower radiator hose doesn t contact fan belt after assembly 5 Connect hoses upper and lower to the radiator 6 Make sure radiator drain plug is tight Fill radiator with coolant see
181. raulic System TEST 3 Traction Pump Flow Using Tester With Pressure Gauges and Flow Meter WHEEL MOTOR RIGHT FORWARD TO REAR WHEEL MOTOR OPTIONAL 3WD KIT REVERSE FROM REAR WHEEL MOTOR OPTIONAL 3WD KIT lt CHARGE RELIEF FROM LIFT CONTROL VALVE gt LIFT CONTROL VALVE FROM RESERVOIR REVERSE TRACTION PUMP FRONT LINE TO RESERVOIR TO HYDRAULIC MANIFOLD PORT T2 Working Pressure Low Pressure Charge WHEEL MOTOR Return or Suction LEFT Flow Figure 19 Hydraulic System Page 4 24 Reelmaster 2000 D Procedure for Traction Pump Flow Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Park machine on a level surface with the cutting units lowered and off Make sure engine is off 3 Read Precautions For Hydraulic Testing 4 Make sure that traction pedal is adjusted to the neu tral position see Traction Unit Operator s Manual 5 Make sure that pump drive belt is adjusted properly see Traction Unit Operator s Manual 6 Block one front traction wheel off the floor to allow flow through the traction circuit 7 Chock remaining wheels to prevent movement of the machine 8 Attach a heavy chain to the rear of the machine frame and something immovable in the shop 9 Make sure parking brake is off Operate all hydraulic c
182. raulic reel motors allow easy removal from or installation onto the cutting unit Cutting units can be driven from either end HEIGHT OF CUT amp ROLLER ADJUSTMENT Height of cut adjustment is made with the rollers by a quick locating pin and or threaded micro adjustment BEDKNIFE AND BEDBAR ADJUSTMENT A single knob screw adjustment for bedknife to reel is located at the center of the bedbar CUTTING UNIT LIFT Hydraulic lift has an automatic reel shut off Lift for all cutting units are controlled from one lever Cutting Units Page 7 2 SUSPENSION SYSTEM A fully floating suspension with hydraulic counterbalance L I N K S cutting unit suspension system provides fore and aft oscillation Main center pivot allows side to side oscillation With optional Fixed Kit Part No 93 6915 cutting units can be locked into fixed fore aft position for use with skids or anti scalp rollers CLIP FREQUENCY With variable speed set to maxi mum reel RPM 1040 RPM Reel Blades Ground Speed Clip Frequency 5 27 or 32 5 mph 8 km h 1 00 25mm 5 27 or 32 6mph 9 7 km h 1 20 30 5mm 8 27 32 0 63 16 8 27 32 0 76 19 11 27 only 0 46 12 11 27 only 6 mph 9 7 km h 0 55 14mm CUTTING UNIT WEIGHT Model 03210 27 5 blade 136 Ib 62 kg Model 03211 27 8 blade 143 Ib 65 kg Model 03214 27 11 blade 14910 68 kg Model 03212 32 5 blade 158
183. re dependent upon the design and configuration of the machine these factors are also de pendent upon the awareness concern and proper training ofthe personnel involved in the operation trans port maintenance and storage ofthe machine Improp eruse or maintenance ofthe machine can result in injury Before Operating 1 Read and understand the contents of the Operator s Manual before starting and operating the machine Be come familiar with the controls and know how to stop the machine and engine quickly Additional copies of the Operator s Manual are available on the internet at www Toro com 2 Keep all shields safety devices and decals in place If a shield safety device or decal is defective illegible or damaged repair or replace it before operating the machine Also tighten any loose nuts bolts or screws to ensure machine is in safe operating condition 3 Assure interlock switches are adjusted correctly so engine cannot be started unless traction pedal is in NEUTRAL and cutting units are DISENGAGED While Operating 1 Sit on the seat when starting and operating the ma chine 2 Before starting the engine A Engage the parking brake B Make sure traction pedal is in neutral and the PTO switch is OFF disengaged C After engine is started release parking brake and keep foot off traction pedal Machine must not move If movement is evident the traction pedal linkage is adjusted incorrectly therefore sh
184. ring 11 Wheel hub 23 Yoke 34 Backing plate 12 Brake drum Removal 1 Park machine on a level surface lower cutting units stop engine and remove key from the ignition switch 2 Make sure brake is disengaged 3 Lift front wheel off the ground using a jack Block front and rear of other wheels 4 Remove lug nuts 13 and wheel assembly 15 Re move lock nut 14 from wheel motor shaft Chassis Page 6 8 IMPORTANT DO NOT hit wheel hub 11 with a ham mer during removal or installation Hammering may cause damage to the wheel motor 5 Use a puller to remove the wheel hub 11 and brake drum 12 Remove the key 34 from the wheel motor shaft 6 Remove brake return springs 31 from brake shoes 82 Remove brake shoes from backing plate 29 Reelmaster 2000 D 7 Remove cotter 28 from the yoke pin 21 Re move yoke pin from the brake lever 22 and separate yoke 23 from the brake lever Fig 4 8 Remove cap screws 9 and lock nuts 6 holding the backing plate 36 and brake grass shield 8 to the brake bracket 9 Remove backing plate 29 flat washers 7 and brake grass shield 15 from the brake bracket 10 If brake lever 22 is removed from brake cam shaft 80 match mark lever and shaft before disassembly to allow for correct reassembly alignment 11 Remove rust from all parts with a wire brush prior to installation Clean all parts Inspect brake shoe contact sur
185. rive gear 11 and 1 Tape the shaft end of the drive gear 11 to prevent idler gear 12 remain together Remove the remaining damaging the shaft seal when the shaft is removed or two dowel pins from the gear housing reinstalled 6 Remove the rear bearing block from the drive and 2 Matchmark the inlet side of the gear housing 10 idler gear shafts with the mounting flange 3 and the end cover 8 for proper orientation of these three parts during reassemb 7 Remove the idler gear ly 8 Remove the drive gear shaft carefully from the 3 Position the pump with the drive end facing down mounting flange Remove the front bearing block from the drive gear shaft 4 Remove the four bolts Lift off the end cover and two dowel pins Hydraulic System 4 50 Rev A Reelmaster 2000 D Shaft Seal Replacement Fig 39 1 Place the mounting flange on a clean working sur face with the shaft seal 2 up Remove the retaining ring NOTE Avoid scratching or marring the shaft seal bore in the mounting flange Damage to the bore may cause the shaft seal to leak around the outer diameter of the seal 2 Carefully remove the shaft seal Clean any contami nation from the seal bore 3 Place a new shaft seal with the part number side up into the seal bore Apply uniform pressure to the face of the shaft seal while pressing it into the bore This method should prevent damage or misalignment of the seal in the bore 4 Install ne
186. rking brake lower the cutting units and stop the en gine Remove the key from the ignition switch Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil 2 Raise and remove hood to gain access to the hy draulic manifold NOTE The ports on the manifold are marked for easy identification of components Example R1 is the reel cir cuit relief valve and G1 is the test gauge connection port See Hydraulic Schematics to identify the function of the hydraulic lines and cartridge valves at each port loca tion 3 If necessary the hydraulic manifold can be removed Figure 45 A Disconnect solenoid valve and backlap switch electrical connectors B Clean manifold and hydraulic connections Dis connect hydraulic lines Label all connections for reassembly C Allow hydraulic lines to drain into a suitable con tainer Put caps or plugs on disconnected hoses and fittings to prevent contamination D Remove two flange head screws that secure bot tom of hydraulic manifold to the mounting bracket E Support hydraulic manifold and remove flange head screw that secures hydraulic manifold to the cylinder support bracket Remove hydraulic man ifold from the machine Hydraulic System Page 4 58 Figure 45 1 Hydraulic manifold 6 Flat washer 2 Cylinder support bracket 7 Switch bracket 3 Flange head screw 8 screw 4 Mounting bracket 9 Lock washer
187. rking brake and chock rear tire to prevent the machine from moving 2 Position jack securely under the frame just to the in side of the front tire 3 Jack front of machine off the ground 4 Position jack stands or hardwood blocks under the frame as close to the wheel as possible to support the machine Safety and Instruction Decals Numerous safety and instruction decals are affixed to the traction unit and the cutting units of the Reelmaster 2000 D If any decal becomes illegible or damaged in Safety Page1 4 Jacking the Rear End 1 Set parking brake and chock both front tires to pre vent the machine from moving 2 Place jack securely under the frame directly in front of the castor fork rear wheel 3 Jack rear of machine off the ground 4 Position jack stands or hardwood blocks under the frame to support the machine stall a new decal Part numbers are listed in your Parts Catalog Order replacement decals from your Autho rized Toro Distributor Reelmaster 2000 D TORO Table of Contents PRODUCT RECORDS 1 1 EQUIVALENTS AND CONVERSIONS 2 Decimal and Millimeter Equivalents 2 U S to Metric Conversions 2 TORQUE SPECIFICATIONS 3 Fastener Identification 3 Product Records Insert Operator s Manual and Parts Catalog for your R
188. ront wheel motor requires testing com plete steps 6 to 13 for the remaining motor 16 1 machine has 3WD kit installed and rear wheel mo tor requires testing A Both front wheel motors should have hydraulic lines disconnected Cap disconnected hoses and plug ports in wheel motor to prevent contamination B Attach a heavy chain between the rear of the ma chine frame and an immovable object to prevent the machine from moving during testing C Chock rear wheel to prevent it from turning D Clean hose fitting and disconnect hose from the elbow connection on the top of the traction pump Fig 20 E Install tester in series with the pump and the dis connected hose Make sure flow control valve is fully open F Start engine and move throttle to full speed 3200 50 RPM Use extreme caution when performing test The rear tire on the ground will be trying to move the machine forward G Slowly push traction pedal in forward direction until 1000 PSI is displayed on the pressure gauge H Wheel motor internal leakage will be shown on flow meter in GPM Flow should be less than 1 5 GPM for the tested wheel motor l If specifications are not met the wheel motor needs to be repaired or replaced 17 Disconnect tester from hydraulic fitting and hose Reconnect hose to pump connection 18 Reconnect hydraulic lines to wheel motors Hydraulic System e 5 E gt Service and Repairs Genera
189. s All torque values are based on non lubricated fasteners 0 5 in 16 7 in X 0 08851 in Ib X 0 7376 ft lb Reelmaster 2000 D Maintenance Maintenance procedures and recommended service in tion when performing regular equipment maintenance tervals for the Reelmaster 2000 D are covered in the Refer to the Engine Operator s Manual for additional en Traction Unit Operator s Manual Refer to that publica gine specific maintenance procedures Product Records i i gt Reelmaster 2000 D Page2 7 Product Records and Maintenance 5 e2iAJeg Jeuonippv 88g pue s n jeeuM 1934 oineupAH eoejdeu jan4 eoejdeu ANY 5 5 002 s s 2 L L1 DJ EJ DJ EJ EJ EI E seunpeoo4g pue suoneouioedg enuen sJ01eJed 995 oinejp H pue 5 4 pue 5 pue g 1 9 Wd 40949 juaujeA o N eBexur 19edsu jejisouueu eoejdeu sesoH 5 usn J eoe deuH Aieneg 2949 L1 EJ EJ L1 EJ E31 F1 EI E L1 E13 E13 EJ P1 P3 E31 EI E
190. s Manual Check lines for deterioration damage leaking or loose con nections Replace hoses clamps and connections as necessary Drain and Clean Fuel Tank Drain and clean the fuel tank periodically as recom mended in the Traction Unit Operator s Manual Also drain and clean the fuel tank if the fuel system becomes contaminated or if the machine is to be stored for an ex tended period To clean fuel tank flush tank out with clean diesel fuel Make sure tank is free of contaminates and debris Reelmaster 2000 D Page 3 7 Fuel Tank Removal 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Close fuel tank shut off valve Disconnect fuel hose from the shut off valve 3 Use shut off valve to empty fuel tank into a suitable container 4 Disconnect return fuel hose from fuel tank fitting 5 Remove fuel tank using Figure 6 as a guide Fuel Tank Installation 1 Install fuel tank to frame using Figure 6 as a guide Apply thread locking compound to fuel tank cap screws and torque screws from 30 to 60 in Ib 3 4 to 6 8 2 Connect fuel hose to the shut off valve Connect re turn hose to tank fitting 3 Fill fuel tank see Traction Unit Operator s Manual Engine Air Cleaner Figure 7 1 Air cleaner assembly 6 Hose clamp 11 Air cleaner cover 2 Mounting bracket 7 Air cleaner
191. section of Chapter 4 Hydraulic System 7 After engine and pump installation verify pulley alignment across engine and pump pulley faces with a straight edge The gap between both faces must not ex ceed 0 030 0 8 mm 8 Adjust traction pump belt see Traction Unit Opera tor s Manual 9 Reconnect throttle cable to injector pump A Route throttle cable to injector pump on engine B Reinstall the throttle cable into the swivel clamp on the pump speed control lever C Place cable under cable clamp D Adjust throttle control see Adjust Throttle Con trol 10 Remove plugs installed in hoses during disassem bly Connect hoses to the engine A Connect return to tank fuel hose to the injector pump fitting Fig 12 Tighten hose clamp B Connect fuel hose from the fuel filter water sepa rator Fig 12 Tighten hose clamp C Connect upper and lower radiator hoses to the engine Tighten hose clamps 11 Reinstall exhaust system see Exhaust System Installation 12 Reinstall air cleaner see Air Cleaner Installation 13 Reinstall radiator see Radiator Installation 14 Add coolant to radiator see Traction Unit Operator s Manual 15 Open fuel shut off valve under the fuel tank Engine Page 3 18 16 Fill hydraulic reservoir with hydraulic fluid see Trac tion Unit Operator s Manual Check reservoir for leaks 17 Slide the left foot rest onto the brake rod Reinstall cap screws and fla
192. starting at front cover end 3 After pump has been assembled tighten cap screws by hand Rotate the drive shaftto check for binding Pro tect the shaft if using a pliers 4 Tighten the four 4 cap screws evenly in a crossing pattern to a torque of 33 ft lb 45 N m Hydraulic System 2 3 52 gt Wheel Motor Front Wheel Motor Removal Fig 40 1 Park the machine on a level surface engage the parking brake lower the cutting units and stop the en gine Remove the key from the ignition switch Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil 2 Remove wheel and brake assembly from unit see Repair section of Chapter 6 Chassis 3 Clean wheel motor and hydraulic connections Label all tube hose connections for reassembly purposes Put caps or plugs on any hydraulic lines or fittings left open or exposed 4 Disconnect tube connections from hydraulic fittings on motor to be removed On the left hand wheel motor also disconnect hydraulic hose 4 from hydraulic fitting on motor Allow hydraulic oil to drain from tubes and hose into a suitable container 5 Support wheel motor Remove four socket head screws and lock nuts from support frame Remove brake bracket 13 grass shield 14 and spacers 15 Pull wheel motor from the support frame 6 Remove hydraulic fittings and O rings from the wheel motor Front Wheel Motor Installa
193. t come on after step 2 check the circuit wiring and indicator light Testing with the engine running 1 If the lamp is on with the engine running shut off the engine immediately 2 Disconnect the gray wire from the switch 3 Turn the ignition switch to ON The oil pressure lamp should not be illuminated 4 If the light is still on check the oil switch circuit wiring 5 Return ignition switch to OFF and connect the gray wire to the switch See the Briggs amp Stratton Daihatsu Engine Repair Manual for engine oil pressure testing procedures Engine Run Solenoid The engine run solenoid must be energized for the en gine to run The solenoid is an integral component of the injector pump and has a red black wire attached to it The Standard Control Module monitors the operation of the engine run solenoid If the ignition switch is either in the ON or START position and the correct switch inputs seat parking brake etc are received the Module en gine run output LED should be illuminated Electrical System Page 5 16 Figure 16 3 Dipstick 1 Oil pressure switch 2 Oil filter See the Briggs amp Stratton Daihatsu Engine Repair Manual for engine run solenoid testing procedures Reelmaster 2000 D Solenoid Valve Coil The hydraulic system on the Reelmaster 2000 0 uses a solenoid valve coil on the reel drive manifold and when equipped with the optional 3WD kit a second sole noid coil on the 3WD
194. t face hammer to loosen the pump sec tions Be careful to not drop parts or disengage gear mesh IMPORTANT Markthe relative positions of the gear teeth and the wear plates so they can be reassem bled inthe same position Do nottouch the gear sur faces as residue on hands may be corrosive to gear finish 7 Remove the wear plates and seals from each pump section Before removing each gear set apply marking dye to mating teeth to retain timing Pump efficiency may be affected if the teeth are not installed in the same position during assembly Discard removed seals 8 Turn front flange over with seal side up IMPORTANT Make sure to not damage the front flange counter bore when removing the seal from the front flange 9 Carefully remove retaining ring and shaft seal from the front flange Discard seal Reelmaster 2000 D 4 51 2 Rev 10 Clean all parts Check all components for burrs scoring nicks and other damage 11 Replace the entire pump assembly if parts are ex cessively worn or scored Assembly Fig 39 1 1 Lubricate O ring pressure seals back up gaskets and wear plate grooves with a thin coat of petroleum jelly to hold them in position during gear pump assembly Lu bricate all other internal parts freely with clean hydraulic oil NOTE Pressure seals and back up gaskets fit in grooves machined into wear plates The O ring seal fits in groove machined in body face 2 Assemble pump
195. t has a Switch that is mounted to the seat base under the cush ion The switch electrical connector for either seat type is located directly under the seat Testing is the same for either switch type The Standard Control Module monitors the operation of the seat switch If the ignition switch is in the ON position Figure 22 and the seat is occupied the Module in seat input LED 1 should be illuminated Electrical connector 2 Standard seat switch Seat Switch Test 1 Make sure the engine is off 2 Disconnect electrical connector from the seat switch 3 Check the continuity of the switch by connecting a multimeter ohms setting across the connector termi nals 4 With no pressure on the seat there should be no continuity between the seat switch terminals 5 Press directly onto the seat switch through the seat cushion There should be continuity as the seat cushion approaches the bottom of its travel 6 Reconnect switch connector Electrical System Page 5 20 Reelmaster 2000 D Parking Brake Switch The parking brake switch is a normally open proximity switch that is mounted on a bracket at the base of the parking brake lever Fig 23 The parking brake lever is used as the sensing plate When the parking brake is engaged the brake lever is moved away from the brake switch and the switch opens This open switch prevents the cutting units from operating The Standard Control Module monitors the operation of
196. tate the drive shaft away from the inlet one revolution If the drive shaft binds while rotating disassemble the pump and check for assembly problems and then reas semble pump Hydraulic System 2 gt Reel Gear Pump Service Casappa Figure 39 1 Disassembly Fig 39 1 NOTE The gear pump replaced as a complete assembly Individual gears body and wear plates are not available separately Disassemble gear pump for cleaning inspection and seal replacement only 1 Plug pump ports and clean the outside of the pump thoroughly After cleaning remove plugs and drain any oil out of the motor 2 Use a marker to make a diagonal line across the frontflange and body for assembly purposes Fig 39 2 IMPORTANT Use caution when clamping gear pump in a vise to avoid distorting any pump compo nents 3 Secure the front cover of the pump in a vise with the drive shaft pointing down 1 Retaining ring 6 Back up gasket 2 Shaft seal 7 Front wear plate 3 Front flange 8 Drive shaft 4 O ring 9 Idler gear 5 Pressure seal 10 Rear wear plate 11 Dowel pin 12 Body 13 Washer 4 used 14 Cap screw 4 used MARKER LINE Figure 39 2 Hydraulic System Page 4 51 1 Rev A Reelmaster 2000 D 4 Loosen the four 4 cap screws that secure pump as sembly 5 Remove pump from vise and remove fasteners 6 Supportthe pump assembly and gently tap the pump case with a sof
197. teners into threaded aluminum or brass The specific torque value should be determined based on the fastener size the aluminum or base material strength length of thread engagement etc Product Records and Maintenance Page 2 4 Reelmaster 2000 D Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners Thread Size Regular Height Nuts M5 X 0 8 57 5 in lb M6 X 1 0 96 9 in Ib 1018 100 N cm 26 3 N m M8 X 1 25 19 2 ft Class 8 or Stronger Nuts Class 8 8 Bolts Screws and Studs with 640 60 Class 10 9 Bolts Screws and Studs with Regular Height Nuts Class 10 or Stronger Nuts 78 7 in lb 885 80 N cm 133 13 in Ib 1500 150 27 2 ft lb 36 3 N m M12 X 1 75 66 7 ft 90 10 92 9 ft lb 125 12 N m M16 X 2 0 166 15 ft lb 225 20 N m 229 22 ft lb 310 30 M20 X 2 5 325 33 ft lb 440 45 450 37 ft lb 610 50 NOTE Reduce torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as oil graphite or thread sealant such as Loctite NOTE Torque values may have to be reduced when installing fasteners into threaded aluminum or brass The specific torque value should be determined based on the fastener size the aluminum or base material strength length of thread engagement etc Reelmaster 2000 D Page2 5 Ib Ib NOTE
198. the battery terminals 25 1 155 12 06 F Apply a test load of one half the Cranking Perfor 0 1 120 11 89 mance see Battery Specifications rating of the bat tery for 15 seconds Reelmaster 2000 D Page 5 27 Electrical System 2 Determine the charging time and rate using the manufacturer s battery charger instructions or the following table Battery Battery Charge Level Reserve Percent of Fully Charged Capacity Mines 80 or less 3 8hrs 7 5hrs 11 3hrs 15 hrs 2 2 2 2 3 amps 3amps amps amps 8110 125 5 3hrs 10 5 hrs 15 8 hrs 21 hrs 2 2 2 2 4amps 4amps 4amps 4 amps 126 to 5 5 hrs 11 hrs 16 5hrs 22 hrs 170 Q9 Q 2 2 5 amps 5amps 5 amps 5 amps 171 to 5 8hrs 11 5 hrs 17 3hrs 23 hrs 250 2 2 2 2 6 amps 6 amps 6 amps 6 amps above 6 hrs 12 hrs 18 hrs 24 hrs 250 10 amps 10 amps 10 amps 10 amps A CAUTION Do not charge a frozen battery because it can ex plode and cause injury Let the battery warm to 60 F 15 5 C before connecting to a charger Charge the battery in a well ventilated place to dissipate gases produced from charging These gases are explosive keep open flame and elec trical spark away from the battery Do not smoke Nausea may result if the gases are inhaled Un plug the charger from the electrical outlet before connecting or disconnecting the charger leads from the battery posts Electrical System
199. the parking brake switch If the ignition switch is in the ON position and the parking brake is not applied the Module brake off input LED should be illuminated Parking Brake Switch Test 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch Figure 23 2 Disconnect parking brake switch from machine wir 1 Parking brake lever 2 Brake switch ing harness 3 Check the continuity of the switch by connecting a multimeter ohms setting across the switch connector terminals 4 With the parking brake disengaged there should be continuity across the switch terminals 5 Apply the parking brake There should be no continu ity across the switch terminals 6 Replace switch as needed Reconnect switch 6 m Reelmaster 2000 D Page 5 21 Electrical System Cutting Unit Interlock Switch This switch is normally open and closes when the cutting units are lowered The switch and its electrical connec tor are located behind and below the hydraulic manifold on the cylinder support bracket 1 Disconnect switch electrical connector 2 With the cutting units lowered check the continuity of the switch by connecting a multimeter ohms setting across the connector terminals There should be conti nuity across the switch 3 Raise the cutting units and check the continuity of the Switch There should be no continuity a
200. the reel This coupler has right hand threads IMPORTANT Support reel to prevent it from dropping when the bearing housings are removed 6 Remove flange head screws from both bearing housings Pull bearing housings and bearings from reel Remove reel from the cutting unit 7 Rotate bearings within the bearing housings and re move bearings from both bearing housings through the loading grooves Reelmaster 2000 D Inspect Cutting Reel Fig 14 1 Replace reel if the diameter has decreased to the service limit see Reel Grinding Specification in Prepar ing Reel For Grinding 2 Replace reel if blades are bent or cracked 3 Check for a bent reel shaft by placing the reel shaft ends in V blocks Replace reel if the reel shaft is bent Install Cutting Reel Fig 14 1 Inspect reel bearings and replace if worn or dam aged Replace both bearings as a set 2 Make sure bearing seating surfaces and threads on reel shaft ends are clean Apply anti seize lubricant to both bearing seating surfaces of reel shaft 3 Position reel inside the cutting unit and align with the bearing housing holes The reel must be positioned so that the grooved end of the shaft left hand threads is on the left side of the cutting unit 4 Clean inside of the bearing housings Install bear ings into bearing housing as follows A Load bearing through loading grooves B Position bearing so its outer grease holes will be 90 to the loadi
201. the switch The Standard Control Module monitors the operation of the traction neutral switch If the ignition switch is in the ON position and the traction pedal is in the neutral posi tion the Module neutral input LED should be illumi nated Traction Neutral Switch Test 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch Figure 21 Traction pedal 3 Traction arm 2 Disconnect the electrical connector to the neutral Neutral switch switch 3 Check the continuity of the switch by connecting a multimeter ohms setting across the connector termi nals 4 With the ignition switch in the OFF position slowly push the traction pedal in the forward and reverse direc tion while watching the multimeter Continuity should be broken in both the forward and reverse directions 5 Allow the traction pedal to return to the neutral posi tion There should be continuity across the terminals 6 Reconnect the electrical connector to the switch SE 92 Reelmaster 2000 D Page 5 19 Electrical System Seat Switch The seat switch is normally open and closes when the operator is on the seat If either the neutral switch or parking brake switch is open when the operator raises out of the seat the engine will stop The standard seat uses a switch that is fastened to the underside of the seat Fig 22 The deluxe sea
202. tion Fig 40 1 Place and support wheel motor into the support frame Insert four socket head screws through the sup port frame and wheel motor 2 Slide spacers grass shield and brake bracket onto the cap screws and wheel motor Tighten lock nuts onto cap screws 3 Remove caps or plugs that were put on any hydraulic lines or fittings during disassembly 4 Install hydraulic fittings 5 and 6 onto the wheel mo tor On the left hand wheel motor also install hydraulic fitting 7 onto the wheel motor Tighten hydraulic fit tings Hydraulic System Page 4 52 Figure 40 1 Wheel motor LH shown 9 O ring LH motor 2 Tube connection 10 Socket head screw 3 Tube connection 11 Lock nut 4 Hyd hose LH motor 12 Support frame 5 Hydraulic fitting 13 Brake bracket 6 O ring LH motor 14 Grass shield 7 Hyd fitting LH motor 15 Spacer 8 O ring 16 O ring Install tube connections to hydraulic fittings on wheel motor On the left hand motor also install hose connec tion 4 to hydraulic fitting 7 Tighten connections 6 Install wheel and brake to machine see Repair sec tion of Chapter 6 Chassis 7 Follow Hydraulic System Start up procedures Reelmaster 2000 D 3WD Rear Wheel Motor Removal Fig 41 If the optional 3 Wheel Drive Kit has been installed rear wheel motor removal procedure is as follows 1 Park the machine on a level surface engage the parking brake lower the cutting
203. tion of the high temperature shutdown switch If the ignition Switch is in the ON position and the high temperature shutdown switch is closed excessive coolant tempera ture the Module Hi Temp input LED should be illumi nated High Temperature Shutdown Switch Test 1 Lower the coolant level in the engine and remove the high temperature shutdown switch Figure 14 1 Temperature switch 2 Water pump housing 2 Putthe switch in a container of oil with a thermometer and slowly heat the oil Fig 15 A CAUTION Handle the hot oil with extreme care to prevent personal injury or fire 3 Check the continuity of the switch with a multimeter ohms setting The switch is normally open and should close at 238 F 114 C Figure 15 4 Allow the oil to cool The switch should open at 232 F 111 C SE 9 5 Reelmaster 2000 D Page 5 15 Electrical System Cil Pressure Switch The engine oil pressure switch is located on the cylinder near the dipstick and oil filter It is a normally closed switch and opens with pressure The operating range for the switch is 2 9 to 5 7 PSI 0 2 to 0 4 kg cm Testing with the engine off 1 Turn the ignition switch to the ON position The oil pressure lamp should be on 2 If the lamp is not on disconnect the gray wire from the switch and ground the wire to the engine block 3 If the lamp comes on the oil pressure switch is bad 4 If the lamp does no
204. to prevent the ma chine from moving during testing 6 Chock front wheel being tested to prevent rotation of the wheel Make sure parking brake is on 7 Disconnect hydraulic lines from front wheel motor that is not being tested Cap disconnected hydraulic lines and plug ports in wheel motor to prevent contami nation 8 Clean hose fitting and disconnect hose from the el bow connection on the top of the traction pump Fig 20 IMPORTANT Make sure oil flow indicator arrow on the flow gauge is showing that the oil will flow from the motor through the tester and into the hose 9 Install flow tester with pressure gauges in series with the pump and the disconnected hose Make sure flow control valve is fully open 10 If machine has 3WD kit installed make certain that reel engage switch is pushed in disengaged to prevent hydraulic flow to the rear wheel 11 Start engine and move throttle to full speed 3200 50 RPM Use extreme caution when performing test The front tire on the ground will be trying to move the machine forward 12 Slowly push traction pedal in forward direction until 1000 PSI is displayed on the pressure gauge 13 Wheel motor internal leakage will be shown on flow meter in GPM Flow should be less than 1 5 GPM for the tested wheel motor Reelmaster 2000 D Page 4 39 14 11 specifications are not met the tested wheel motor needs to be repaired or replaced as necessary 15 If remaining f
205. to the cutting unit with both carriage bolts and nuts Fig 9 7 Tighten both adjusting nuts on the adjusting housing Fig 9 8 Position bedbar fitting to the bedbar yoke Screw ad justing handle left hand threaded until the bedbar fit ting is snug against the bedbar yoke 9 If weights were removed from bedbar Models 03213 and 03214 apply permanent thread locking com pound to cap screw threads and secure weights to bed bar with cap screws and lock nuts 10 Adjust bedknife to reel see Cutting Unit Operator s Manual 1 Adjusting lock nut 2 Adjusting nut Reelmaster 2000 D Page 7 11 Figure 9 3 Adjusting housing 4 Carriage bolt and nut Cutting Units Bedknife Replacement and Grinding 1 Remove bedbar from the cutting unit see Bedbar Removal 2 Remove bedknife screws and bedknife 3 Remove all rust scale and corrosion from the bedbar surface before installing new bedknife NOTE Use a torque wrench and a bedknife screw tool to install bedknife screws 4 Install new bedknife as follows A Make sure bedbar threads are clean B Use new bedknife screws Apply anti seize lubri cant to the screw threads before installing IMPORTANT Do not use an air or manual impact wrench to tighten bedknife screws Figure 10 Tighten screws to a torque of 250 to 300 in Ib 28 to 34 Tighten screws from the center to ward each end of the bedbar Fig 10 Top Face 5 Since
206. units and stop the en gine Remove the key from the ignition switch Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil 2 Clean wheel motor and hydraulic connection Put caps or plugs on any hydraulic lines or fittings left open or exposed 3 Remove wheel and wheel hub from unit see Repair section of Chapter 6 Chassis 4 Disconnect hose connections from hydraulic fittings Remove O rings Allow hydraulic oil to drain from the hose into a suitable container 5 Support wheel motor Remove four socket head screws and lock nuts from the rear wheel fork Pull wheel motor from the rear wheel fork 6 Remove hydraulic fittings and O rings from the wheel motor 3WD Rear Wheel Motor Installation Fig 41 If the optional 3 Wheel Drive Kit has been installed rear wheel motor installation procedure is as follows 1 Place and support wheel motor into the rear wheel fork Insert four socket head screws through the rear wheel fork and wheel motor 2 Tighten lock nuts onto socket head screws 3 Remove caps or plugs that were put on any hydraulic lines or fittings during disassembly 4 Install hydraulic fittings and O rings onto the wheel motor Tighten hydraulic fittings 5 Install O rings while connecting hose connections onto the hydraulic fittings Tighten connections 6 Install wheel and wheel hub to unit see Repair sec tion of Chapter 6 Chass
207. ut engine off and adjust traction pedal linkage until machine does not move when traction pedal is released 3 Do not run engine in a confined area without ade quate ventilation Exhaust fumes are hazardous and could possibly be deadly 4 Do not touch engine muffler or exhaust pipe while engine is running or soon after it is stopped These areas could be hot enough to cause burns Safety Page1 2 Rev A or death To reduce the potential for injury or death comply with the following safety instructions To reduce the potential for injury or death comply with the following safety instructions 4 Since diesel fuel is highly flammable handle it care fully A Store fuel in containers specifically designed for this purpose B Do not remove machine fuel tank cap while en gine is hot or running C Do not smoke while handling fuel D Fill fuel tank outdoors and only to within an inch of the top ofthe tank not the filler neck Do not overfill E Wipe up any spilled fuel 5 Before getting off the seat A Ensure that traction pedal is in neutral B Set parking brake C Disengage cutting units and wait for blades to stop D Stop engine and remove key from ignition switch E Anytime the machine is parked short or long term the cutting units should be lowered to the ground This relieves pressure from the lift circuit and eliminates the risk of cutting units accidentally lowering to the ground F
208. val from the unit Reelmaster 2000 D Page 4 77 1 Disconnect hose connection 9 from hydraulic tee fitting 7 Allow hose to drain hydraulic oil into a suitable container 2 Disconnect tube 21 from hydraulic tee fitting 7 Al low fitting to drain into a suitable container 3 Remove lift relief valve body 27 and hydraulic tee fitting 7 from tube 18 4 Remove hydraulic tee fitting 7 tube 21 and both O rings from the lift relief valve body 27 Lift Relief Valve Installation Fig 55 NOTE This procedure may be used if only the lift relief valve has been removed from the unit 1 Install hydraulic tee fitting 7 with new O ring to the lift relief valve body 27 2 Install tube 21 with new O ring to the lift relief valve body 27 3 Setlift relief valve body 27 with attached fitting and tube into the unit 4 Connect tube 21 to hydraulic tee fitting 7 5 Connect tube 18 to hydraulic tee fitting 7 6 Connect hose connection 9 to hydraulic tee fitting 7 7 Follow Hydraulic System Start up procedures Hydraulic System 2 o E gt Control Valve Disassembly Fig 56 1 Wash control valve in solvent and dry it thoroughly 2 Mount control valve into a vise so the mounting pads are against the jaws of the vice and snap ring faces up NOTE Remove check valve seat only if it needs re placement it is pressed into the valve body 3 Remove plugs a
209. ved Remove and discard O ring from switch B Remove lower retaining ring from mow backlap spool Raise mow backlap spool to allow access to retaining ring on upper end of spool Remove upper retaining ring Reelmaster 2000 D Page 4 63 2 Rev C Push spool down until O ring and back up ring are exposed on bottom of mow manifold Remove lower O ring and back up ring from spool D Pull spool up and out of mow manifold Remove O rings and back up ring from spool E Discard removed O rings and back up rings Figure 46 2 1 Handle base 7 Set screw 2 used 2 Handle cap 8 Screw 3 Detent pin 9 Lip seal 4 Compression spring 10 Sleeve bearing 5 Bushing 11 Flow control valve 6 Set screw 2 used 6 Visually inspect the manifold port for damage to the sealing surfaces damaged threads and contamination 7 Visually inspect cartridge valve for damaged sealing surfaces and contamination A Contamination may cause valves to stick or hang up Contamination can become lodged in small valve orifices or seal areas causing valve malfunction B If valve sealing surfaces appear pitted or dam aged the hydraulic system may be overheating or there may be water in the system A CAUTION Use eye protection such as goggles when using compressed air for cartridge valve cleaning Hydraulic System E 5 gt I A CAUTION stored fluid to be released suddenly 8 Clean cartridge valve by subm
210. w retaining ring into the mounting flange E seal and Backup Ring Replacement Fig 39 1 Place the front bearing block on a clean surface Re move the old backup ring and Clean any con tamination from the groove 2 Apply a light coating of petroleum jelly in the E seal groove of the front bearing block and on the flat side of the E seal to help keep the seals in place during assem bly 3 Place the E seal with its flat side up into the seal groove on the front bearing block Place the backup ring into the groove made by the E seal and bearing block Make sure the notches in the center of the backup ring and E seal line up so that the backup ring sits flush with the E seal 4 Repeat the above steps for the rear bearing block O ring Replacement Fig 39 1 Remove the old O rings from the gear housing Clean any contamination from the O ring groove 2 Apply a light coating of petroleum jelly in the O ring grooves of the gear housing Place a new O ring in each groove Reassembly Fig 39 1 Place the mounting flange with the shaft seal side down onto a clean working surface Make sure that the back side of the mounting flange is free of any contami nation Reelmaster 2000 D Page 4 51 2 Place the front bearing block with its seal side down onto the mounting flange The open side of the E seal should point toward the matchmark on the inlet side of the mounting flange 3 Appl
211. washer and shaft seal from the front flange Fig 44 3 Discard seals Inspection 1 Remove any nicks and burrs from all parts with emery cloth A CAUTION Use eye protection such as goggles when using compressed air 2 Clean all parts with solvent Dry all parts with com pressed air 3 Inspect drive gears and idler gears for the following Fig 44 4 A Gear shafts should be free of rough surfaces and excessive wear at bushing points and sealing areas Scoring rough surfaces or wear on gear shafts indi cates need for replacement B Gear teeth should be free of excessive scoring and wear Any broken or nicked gear teeth must be replaced C Inspect gear face edge for sharpness Sharp edges of gears will mill into wear plates and thus must be replaced Reelmaster 2000 D Page 4 57 2 Rev A 4 Inspect wear plates for the following A Bearing areas should not have excessive wear or scoring B Face of wear plates that are in contact with gears should be free of wear roughness or scoring C Thickness of wear plates should be equal 5 Inspect front flange and rear cover for damage or wear Figure 44 3 1 Dust seal 4 Shaft seal 2 Retaining ring 5 Drive shaft 3 Flange washer Figure 44 4 3 Gear teeth 1 Gear shaft
212. wered and off Make sure engine is off 3 Read Precautions For Hydraulic Testing 4 Make sure that traction pedal is adjusted to the neu tral position see Traction Unit Operator s Manual 5 Connect pressure test gauge with a hydraulic hose attached to the forward test port located on the hydraulic tube Fig 15 and 16 Make sure gauge hose is long enough so the operator can read gauge while driving the machine 6 Start engine and move throttle to full speed 3200 50 RPM 7 Drive machine in the forward direction Observe test gauge A Pressure while transporting the machine over a flat level surface should be about 500 PSI B Pressure while mowing should range between 1000 to 2000 PSI and will vary with terrain 8 Release traction pedal and turn off machine 9 Disconnect test gauge and hose from the test port Fig 16 10 If specification is not met the hydrostat needs to be repaired or replaced as necessary Reelmaster 2000 D Page 4 21 Forward test port RIGHT FRONT Figure 15 Hydraulic tube forward 3 Hydraulic tube reverse 2 Forward test port 4 Reverse test port 2 gt Figure 16 2 Reverse test port Hydraulic System TEST NO 2 Mow Circuit Working Pressure Using Pressure Gauge FILTER p TO CHARGE PUMP p TO TRACTION PUMP ___ lt X COOLER TEST GAUGE RESERVOIR 7
213. with a digital multi meter short the meter test leads together The meter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal resistance of the meter and test leads Subtract this val ue from from the measured value of the component you are testing NOTE The glow relay may be manufactured by one of two different manufacturers Verify manufacturer name and part number before performing the resistance check on the relay coil 1 Verify coil resistance between terminals 85 and 86 with a multimeter ohms setting Figure 13 A For the Tyco Electronics relay 48VF7 41F11 801 resistance should be approxi mately 72 ohms B For the Hella Electronics relay 87430B resist ance should be approximately 100 ohms 2 Connect multimeter ohms setting leads to relay ter minals 30 and 87 Ground terminal 86 and apply 12 VDC to terminal 85 The relay should make and break continuity between terminals 30 and 87 as 12 VDC is applied and removed from terminal 85 3 Disconnect voltage and leads from the relay termi nals Electrical System Page 5 14 Reelmaster 2000 D High Temperature Shutdown Switch The high temperature shutdown switch is located on the top of the water pump housing The water pump is on the left end of the engine inside the fan pulley assembly There is a blue white wire attached to the shutdown Switch The Standard Control Module monitors the opera
214. y counterclockwise A 1 8 turn on the socket will make a measurable change in relief pressure D Repeat steps 1 through 10 above until the relief valve pressure setting is correct Reinstall cap on re lief valve when valve is set properly E If the relief valve pressure set point cannot be ad justed to specification go to step 11 and replace the relief valve 11 Disengage cutting units Shut off engine 12 Disconnect tester from manifold and hose Recon nect hose to the pump Figure 2 1 Reel drive hydraulic manifold 2 Reelrelief valve Hydraulic System e 5 amp TEST NO 8 Cross over Relief Pressures Using Pressure Gauge TEST GAUGE LOCATION TESTING IN MOW FROM REEL DRIVE PUMP FROM CARTRIDGE VALVES AND LEFT WHEEL MOTOR HYDRAULIC MANIFOLD Figure 29 NOTE One way to find a possibly bad reel motor is to have another person observe the machine while mow ing in dense turf A bad motor will run slower produce fewer clippings and may cause marcelling or a wash board appearance on the turf Hydraulic System Page 4 34 T CONNECTION AND GAUGE LOCATION TESTING IN BACKLAP Working Pressure Low Pressure Charge Return or Suction Flow Reelmaster 2000 D Procedure for Cross over Relief Pressures Test 1 Make sure hydraulic oil is at normal operating tem
215. y a light coating of hydraulic oil to the exposed face of the front bearing block Make sure the tape is on the shaft end of the drive gear Insert the shaft end of the drive gear carefully through the front bearing block and the shaft seal being careful not to damage the shaft seal 4 Place the shaft of the idler gear into the remaining position of the front bearing block Apply a light coating of oil to the back face of the drive and idler gears 5 Place the rear bearing block with seal side up onto the drive and idler gear shaft ends Make sure that the open side of the is pointing towards the inlet of the pump 6 Install two dowel pins into the mounting flange 7 Align the matchmarks on the gear housing and mounting flange Slide the gear housing down over the gears and bearing blocks 8 Make sure the rear bearing block face sits just below the back face of the gear housing If the rear bearing block sits higher than the rear face of the gear housing remove the gear housing Check that the E seal back up ring or O ring did not shift out of place during assem bly 9 Place the remaining two dowel pins into the rear of the gear housing Align matchmarks and set end cover on the rear of the gear housing 10 Insert the four bolts through the bolt holes in the end cover and gear housing Hand tighten each bolt and then torque to 40 ft lb 54 11 Place a small amount of oil in the inlet of the pump Ro
216. ydraulic System Cil Cooler Hydraulic Sealant Figure 58 1 Oil cooler 7 Hydraulic hose from manifold 13 Front screen bracket 2 Hydraulic connector 8 Knob 14 Flat washer 3 O ring 9 Lock nut 15 Lock nut 4 Bulkhead nut 10 Protective sleeve 16 Flange head screw 5 90 hydraulic fitting 11 Hydraulic hose to reservoir 17 Left front panel 6 Hose clamp 12 Nut Removal Fig 58 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Open and remove the hood see Traction Unit Oper ator s Manual Remove the radiator screen 3 Loosen hose clamps and remove both hydraulic hoses from fittings on oil cooler Allow hoses to drain oil into a suitable container 4 Remove 90 hydraulic fittings from oil cooler assem bly Remove and discard o rings from connectors 5 Remove bulkhead nuts from oil cooler assembly 6 Pull oil cooler from screen bracket 7 f necessary remove hydraulic connectors from oil cooler Hydraulic System Page 4 80 Installation Fig 58 1 If hydraulic connectors were removed apply hydrau lic sealant to threads of connectors Install connectors to oil cooler Coat new o rings with hydraulic oil Install new o rings in connectors 2 Position and secure oil cooler to screen bracket with bulkhead nuts 3 Install 909 hydraulic fittings to oil cooler assembly Orientat

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