Page 1 Form No. 19241SL Rev A ProLine H800 (Models 31050 and 31050TE) © 2020—The Toro® Company Original Instructions (EN) 8111 Lyndale Avenue South Contact us at www.Toro.com. Bloomington, MN 55420 All Rights Reserved...
Page 2 Revision History Revision Date Description Initial issue. 06/2020 Revision History Page 2 ProLine H800 19241SL Rev A...
Page 3 Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.com.
Page 4 NOTES: NOTES: Page 4 ProLine H800 19241SL Rev A...
Page 5 Operator’s Manuals and Parts Catalog for your machine. Additional copies of the Operator’s Manuals and Parts Catalogs are available at www.toro.com. The Toro Company reserves the right to change the product specifications or this publication without notice. DANGER This safety symbol means danger.
Page 6 Operator’s Manual. Note: Refer to the service decal on the machine and the machine Operator’s Manual for commonly used fluid specifications and capacities. Preface Page 6 ProLine H800 19241SL Rev A...
Page 7: Table Of Contents
Hydraulic Schematic ..................A–3 Electrical Schematic - Main ................A–5 Electrical Schematic - Lights .................A–6 Wire Harness Diagram - Main ...............A–7 Wire Harness Diagram - Lights ..............A–8 Additional Reference Materials Yanmar 3TNV76 Service Manual ProLine H800 Page 7 Preface 19241SL Rev A...
Page 8: Preface
Yanmar 3TNV80F Service Manual Danfoss DDC20 Axial Piston Pump Service Manual Parker Torqmotor Service Procedure (TF, TG, TH, and TL Series) Grammer Seats Repair Manual Preface Page 8 ProLine H800 19241SL Rev A...
Page 9 While Operating the Machine ......................1–4 Maintenance and Service........................1–5 Jacking Instructions ..........................1–7 Raising the Front of the Machine......................1–7 Raising the Rear of the Machine ......................1–9 Safety and Instructional Decals ......................1–9 ProLine H800 Page 1–1 Safety 19241SL Rev A...
Page 10: Safety Instructions
Safety Instructions The ProLine H800 machines are tested and certified by Toro for compliance with existing safety standards and specifications. Although hazard control and accident prevention are partially dependent upon the design and configuration of the machine, hazard control and accident prevention are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance and storage of the machine.
Page 11: Before Operating The Machine
Become familiar with the controls and know how to stop the machine and engine quickly. Additional copies of the Operator’s Manuals are available at www.toro.com. • Never allow children to operate the machine. Never allow adults to operate the machine without proper instructions.
Page 12: While Operating The Machine
2. Lower and disengage the cutting deck and wait for all moving parts to stop. 3. Set the parking brake. 4. Shut off the engine and remove the key from the key switch. Safety: Safety Instructions Page 1–4 ProLine H800 19241SL Rev A...
Page 13: Maintenance And Service
Jacking Instructions (page 1–7). • If major repairs are necessary, contact your Authorized Toro Distributor. ProLine H800 Page 1–5 Safety: Safety Instructions 19241SL Rev A...
Page 14 At the time of manufacture, the machine conformed to the safety standards for riding mowers. To ensure the optimum performance and continued safety certification of the machine, use genuine Toro replacement parts and accessories. The replacement parts and accessories of other manufacturers can result in non-conformance with the safety standards and can void the warranty.
Page 15: Jacking Instructions
A. Push the latch on the radiator inward toward the radiator (Figure B. Using the handle on the side of the radiator, rotate the radiator to access right side of the engine (Figure ProLine H800 Page 1–7 Safety: Jacking Instructions 19241SL Rev A...
Page 16 Frame tube on the left side of the machine 4. Position the jack securely under the frame tube directly under the ROPS tube or as close as possible (Figure 3 Figure Safety: Jacking Instructions Page 1–8 ProLine H800 19241SL Rev A...
Page 17: Safety And Instructional Decals
Safety and Instructional Decals Numerous safety and instruction decals are affixed to the traction unit and cutting deck of your ProLine H800. If any decal becomes illegible or damaged, install a new decal. Decal part numbers are listed in your Parts Catalog. Order replacement decals from Authorized Toro Distributor.
Page 18 Safety: Safety and Instructional Decals Page 1–10 ProLine H800 19241SL Rev A...
Page 19 Specifications and Maintenance Table of Contents Specifications ............................2–2 Overall Dimensions..........................2–2 Engine - ProLine H800 (for Model 31050) ..................2–3 Engine - ProLine H800 (for Model 31050TE)..................2–4 Hydraulic System ..........................2–5 Chassis .............................. 2–6 Torque Specifications ........................... 2–7 Identifying the Fastener........................
Page 20: Specifications
Specifications Overall Dimensions g288868 Figure 6 Specifications and Maintenance: Specifications Page 2–2 ProLine H800 19241SL Rev A...
Page 21: Engine - Proline H800 (For Model 31050)
Engine - ProLine H800 (for Model 31050) g288869 Figure 7 (Yanmar 3TNV80F - Shown) Alternator Flywheel Item Description Make/Designation Yanmar 3TNV76-XGZ: 4-cycle, 3 cylinder water cooled diesel. EPA Tier 3 compliant. Bore 76 mm (3 inches) Stroke 82 mm (3.2 inches)
Page 22: Engine - Proline H800 (For Model 31050Te)
Engine - ProLine H800 (for Model 31050TE) Item Description Make/Designation Yanmar 3TNV80-NXDGZ: 4-cycle, 3 cylinder water cooled diesel. EPA Tier 4 compliant. Bore 80 mm (3.15 inches) Stroke 84 mm (3.31 inches) Total displacement 1,267 cm³ (77.31 in³) Firing order...
Page 23: Hydraulic System
Steering Control Valve Ognibene (Italian) Relief Pressure 120 bar (1740 psi) Lift/Lower Circuit Relief Pressure 120 bar (1740 psi) Hydraulic Tank 5 L (5.3 qt) Hydraulic Oil See Operator’s Manual ProLine H800 Page 2–5 Specifications and Maintenance: Specifications 19241SL Rev A...
Page 24: Chassis
Blades disc torque 53 N·m (40 ft-lb) Electro-magnetic clutch mid-screw torque 50 N·m (37 ft-lb) Wheels bolts torque 85 N·m (63 ft-lb) Engine-hydrostat bolt troque 350 N·m (258 ft-lb) Specifications and Maintenance: Specifications Page 2–6 ProLine H800 19241SL Rev A...
Page 25: Torque Specifications
Torque Specifications The 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 specified in this Service Manual.
Page 26 Toro recommends replacing fasteners with a locking feature once they have been removed because the effectiveness of the locking feature diminishes with each reuse. If it is necessary to reuse a fastener with a locking feature; apply a thread locking compound (Loctite for example) to the fastener during installation.
Page 27: Calculating The Torque Values When Using A Drive-Adapter Wrench
If the listed torque recommendation for a fastener is 103 to 127 N∙m (76 to 94 ft-lb), the proper torque when using this torque wrench with a drive-adapter wrench would be 98 to 121 N∙m (72 to 89 ft-lb). ProLine H800 Page 2–9 Specifications and Maintenance: Torque Specifications...
Page 28: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Inch)
75% of the minimum proof load specified in SAE J429. The tolerance is approximately ± 10% of the nominal torque value. The thin height nuts include jam nuts. Specifications and Maintenance: Torque Specifications Page 2–10 ProLine H800 19241SL Rev A...
Page 29: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Metric Fasteners)
Note: The nominal torque values listed above are based on 75% of the minimum proof load specified in SAE J1199. The tolerance is approximately ± 10% of the nominal torque value. ProLine H800 Page 2–11 Specifications and Maintenance: Torque Specifications...
Page 30: Other Torque Specifications
Conversion Factors in-lb X 11.2985 = N∙cm N∙cm X 0.08851 = in-lb ft-lb X 1.3558 = N∙m N∙m X 0.7376 = ft-lb Specifications and Maintenance: Torque Specifications Page 2–12 ProLine H800 19241SL Rev A...
Page 31: Shop Supplies
Used to secure a variety of components immediately prior to assembly. May be recommended for installing new components or when reusing a component that had a pre-applied adhesive such as hood seals, mouldings, and weather-stripping. ProLine H800 Page 2–13 Specifications and Maintenance: Shop Supplies...
Page 32 Standard silicone sealants are designed to perform in temperatures from -51°F to 232°C (-60°F to 400°F), while high temperature variants can preform in temperatures up to 343°C (650°F). Specifications and Maintenance: Shop Supplies Page 2–14 ProLine H800 19241SL Rev A...
Page 33: Special Tools
Special Tools You can order these special tools from your Toro Distributor. Some tools may also be available from a local tool supplier. Hydraulic Pressure Testing Kit K-Line Part No. TOR47009 Use this kit to take various pressure readings for diagnostic tests. Quick...
Page 34 20 to 150 LPM (4 to 40 GPM). Note: This tester does not include any hydraulic hoses or fittings; refer to Hydraulic Hose Kit Toro Part No. TOR6007 and Hydraulic Test Fitting Kit Tor Part No. TOR4079. Hydraulic O-Ring Kit Toro Part No.
Page 35 8 ORFS (13/16–16) TOR4079–21 10 ORFS (1–14) TOR4079–1 TEST CONNECTOR – FEMALE THREAD (2 each) 4 SAE-ORB (7/16–20) TOR4079–22 1/8 NPTF TOR4079–23 TEST CONNECTOR – MALE THREAD (2 each) ProLine H800 Page 2–17 Specifications and Maintenance: Special Tools 19241SL Rev A...
Page 36 Note: This kit does not include the hydraulic hoses; refer to Hydraulic Hose Kit (page 2–16). Note: The replacement filter element is Toro Part No. TOR6012. The filter element canister tightening torque is 34 N∙m (25 ft-lb). Wheel Hub Puller...
Page 37 Remote Starter Switch (purchased) switch connector for circuit protection. A remote stater switch can also be constructed using Toro switch #106−2027, a length of 14 gauge wire, a 20 amp in−line fuse, two (2) alligator clips and necessary connectors. Connecting the...
Page 38 This excess current can damage the circuits that are not designed to carry it. Battery Terminal Protector Toro Part No. 107-0392 Use this aerosol spray on the battery terminals, ring terminals, and fork terminals to reduce corrosion problems. Apply the...
Page 39 General Hydraulic System Problems ..................... 3–3 Steering Circuit Problems ........................3–5 The Height Of Cut Circuit Problems....................... 3–6 The Cutting Deck Lift Circuit Problems ....................3–7 The Hopper Lift Circuit........................... 3–8 The Hopper Tilt Circuit ........................... 3–9 ProLine H800 Page 3–1 Troubleshooting 19241SL Rev A...
Page 40: Gears - The Systematic Approach To Defining, Diagnosing And Solving Problems
Return the unit to service by repairing, rebuilding or replacing. Solution Confirmation • Did the issue go away? • Was the root cause of the issue correctly repaired? • Are there any other new symptoms? Troubleshooting: The Hopper Tilt Circuit Page 3–2 ProLine H800 19241SL Rev A...
Page 41: General Hydraulic System Problems
Verify the charge pressure. The hydrostat/hydraulic pump is worn Verify the traction pump operation and or damaged. replace if necessary. Engine RPM is too low. Increase the engine RPM. ProLine H800 Page 3–3 Troubleshooting: General Hydraulic System Problems 19241SL Rev A...
Page 42 Test and replace the valve solenoid if solenoid valve circuit. necessary. Solenoid valve in the differential valve Clean the solenoid valve is leaking or faulty. and replace the seals. Replace solenoid valve if necessary. Troubleshooting: General Hydraulic System Problems Page 3–4 ProLine H800 19241SL Rev A...
Page 43: Steering Circuit Problems
Clean the relief valve and replace the control valve is stuck or damaged. seals. The steering cylinder leaks internally. Repair or replace the steering cylinder. The charge pressure is low. Verify the charge pressure. ProLine H800 Page 3–5 Troubleshooting: Steering Circuit Problems 19241SL Rev A...
Page 44: The Height Of Cut Circuit Problems
The height of cut control valve is worn Repair or replace the height of cut or damaged. control valve. The charge pressure is low. Verify the charge pressure. Troubleshooting: The Height Of Cut Circuit Problems Page 3–6 ProLine H800 19241SL Rev A...
Page 45: The Cutting Deck Lift Circuit Problems
The cutting deck lift control valve Repair or replace the cutting deck lift (auxiliary control valve) is worn or control valve. damaged. The charge pressure is low. Verify the charge pressure. ProLine H800 Page 3–7 Troubleshooting: The Cutting Deck Lift Circuit Problems 19241SL Rev A...
Page 46: The Hopper Lift Circuit
The hopper lift control valve (auxiliary Repair or replace the hopper lift control control valve) is worn or damaged. valve. The charge pressure is low. Verify the charge pressure. Troubleshooting: The Hopper Lift Circuit Page 3–8 ProLine H800 19241SL Rev A...
Page 47: The Hopper Tilt Circuit
The hopper tilt control valve (auxiliary Repair or replace the hopper tilt control control valve) is worn or damaged. valve. The charge pressure is low. Verify the charge pressure. ProLine H800 Page 3–9 Troubleshooting: The Hopper Tilt Circuit 19241SL Rev A...
Page 48 Troubleshooting: The Hopper Tilt Circuit Page 3–10 ProLine H800 19241SL Rev A...
Page 49 Service and Repairs ..........................4–3 Air Cleaner Assembly......................... 4–3 Exhaust System ..........................4–5 Radiator ............................. 4–7 Fuel System ............................. 4–11 Engine.............................. 4–15 Additional Reference Materials Yanmar 3TNV76 Service Manual Yanmar 3TNV80F Service Manual ProLine H800 Page 4–1 Engine 19241SL Rev A...
Page 50: General Information
Service and repair parts for the Yanmar engines are supplied through your Authorized Toro Distributor. If the parts list is not available, provide your distributor with the Toro model and serial number of your machine as well as the Yanmar engine model and serial numbers.
Page 51: Chapter 4: Engine
6. Examine the air cleaner assembly (item 12 in Figure 11) for wear and damage that could cause possible air leaks. 7. Examine the air hoses for wear or damage and replace the hoses if necessary. ProLine H800 Page 4–3 Engine: Service and Repairs 19241SL Rev A...
Page 52 2. After air cleaner has been properly installed, install and secure the engine covers. 3. Unlock and lower the hopper assembly; refer to Operator’s Manual. Engine: Service and Repairs Page 4–4 ProLine H800 19241SL Rev A...
Page 53: Exhaust System
1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Block the wheels with chocks to prevent the machine from moving. ProLine H800 Page 4–5 Engine: Service and Repairs...
Page 54 3. After exhaust system components are properly installed, install and secure the top engine cover and rear engine cover assemblies (refer to Frame Assembly (page 7–19)). 4. Unlock and lower the hopper assembly; refer to Operator’s Manual. Engine: Service and Repairs Page 4–6 ProLine H800 19241SL Rev A...
Page 55: Radiator
Washer Gasket Bracket Washer Bolt Blower Spring Shock absorber Grommet Fan shroud Washer Radiator Gasket Bolt Hose Frame Washer Bracket Clamp Bolt Shock absorber Bolt Bolt Washer Washer Clamp ProLine H800 Page 4–7 Engine: Service and Repairs 19241SL Rev A...
Page 56 5. Drain coolant from the radiator; refer to the Operator’s Manual. IMPORTANT Follow all local codes and regulations when recycling or disposing engine coolant. 6. Remove the screen from machine; refer to the Operator’s Manual. Engine: Service and Repairs Page 4–8 ProLine H800 19241SL Rev A...
Page 57 17. Remove the 2 nuts and 2 bushings that secure the radiator to the radiator support. 18. Carefully pull the radiator assembly from the machine. Plug the radiator and hose opening to prevent contamination. 19. If necessary, disassemble the radiator (Figure 14). ProLine H800 Page 4–9 Engine: Service and Repairs 19241SL Rev A...
Page 58 17. Continue to run the engine to obtain the operating temperature. Check the coolant and hydraulic fluid levels and adjust as necessary. Engine: Service and Repairs Page 4–10 ProLine H800 19241SL Rev A...
Page 59: Fuel System
Hose Float Clamp Water separator assembly Clamp Clamp Washer Screw Hose Bolt Hose Hose Hose Clamp Engine Fuel tank Fuel filter element Hose Fuel tank cap Fuel filter assembly ProLine H800 Page 4–11 Engine: Service and Repairs 19241SL Rev A...
Page 60 At the left side of the engine, operate the lever of the fuel pump until you fill the fuel-filter bowl. Engine: Service and Repairs Page 4–12 ProLine H800 19241SL Rev A...
Page 61 7. Loosen the hose clamps and carefully disconnect the fuel hoses from the fuel tank float on top of the fuel tank. Note: Before removing the fuel hoses from the fuel tank, label the hoses for assembly purposes. ProLine H800 Page 4–13 Engine: Service and Repairs 19241SL Rev A...
Page 62 8. Check the fuel hoses and fittings for leaks. Note: Repair all fuel leaks before returning the machine to service. 9. Unlock and lower the hopper assembly; refer to Operator’s Manual. Engine: Service and Repairs Page 4–14 ProLine H800 19241SL Rev A...
Page 63: Engine
2. Disconnect the battery negative cable from the battery terminal and then disconnect the positive cable from the battery; refer to Servicing the Battery (page 6–46). ProLine H800 Page 4–15 Engine: Service and Repairs 19241SL Rev A...
Page 64 Record the location of all cable ties that are removed from the machine during the engine removal so that they can be properly replaced during the engine installation. Engine: Service and Repairs Page 4–16 ProLine H800 19241SL Rev A...
Page 65 16. Carefully raise the engine and remove from the machine. 17. If necessary, remove the engine brackets from the engine (Figure 20). ProLine H800 Page 4–17 Engine: Service and Repairs 19241SL Rev A...
Page 66 D. High temperature shut down switch and temperature sender located on the water pump housing. E. Fuel stop solenoid on the injector pump. F. Battery negative cable to the injector pump. G. Glow plug strip. Engine: Service and Repairs Page 4–18 ProLine H800 19241SL Rev A...
Page 67 24. Start the engine and operate the hydraulic controls to properly fill the hydraulic and engine coolant systems; refer to Charging the Hydraulic System (page 5–72) and refer to proper coolant fill procedure. ProLine H800 Page 4–19 Engine: Service and Repairs 19241SL Rev A...
Page 68 Engine: Service and Repairs Page 4–20 ProLine H800 19241SL Rev A...
Page 69 Differential Valve ..........................5–103 Height Of Cut Valve........................5–106 Lift Cylinder ............................ 5–109 Steering Control Valve ........................5–112 Steering Cylinder ........................... 5–115 Hopper Lift Cylinder ........................5–118 Hopper Tilt Cylinder ........................5–121 ProLine H800 Page 5–1 Hydraulic System 19241SL Rev A...
Page 70 Chute Cleaning Cylinder ........................ 5–127 Oil Cooler ............................5–130 Additional Reference Materials Danfoss DDC20 Axial Piston Pump Service Manual Parker Torqmotor Service Procedure (TF, TG, TH, and TL Series) Hydraulic System: Service and Repairs Page 5–2 ProLine H800 19241SL Rev A...
Page 71: General Information
5.0 L (5.3 qt) of hydraulic fluid (Figure 21). Refer to the Operator's Manual for the procedure on checking the hydraulic-fluid level and hydraulic fluid recommendations. IMPORTANT Check the hydraulic-fluid level daily. ProLine H800 Page 5–3 Hydraulic System: General Information 19241SL Rev A...
Page 72: Pushing Or Towing The Traction Unit
22). Using a socket wrench with a 17 mm socket, rotate the control knob 3 turns counterclockwise (Figure 23). Refer to Operator’s Manual for pushing or towing procedures. IMPORTANT Do not rotate the control knob more that 3 turns. Hydraulic System: General Information Page 5–4 ProLine H800 19241SL Rev A...
Page 73: Releasing Pressure From The Hydraulic System
3. Operate the height of cut switch in both directions for 5 to 10 times. 4. Turn the key switch to the O position. ProLine H800 Page 5–5 Hydraulic System: General Information 19241SL Rev A...
Page 74: Traction Circuit Component Failure
Traction Circuit Component Failure The traction circuit of the ProLine H800 is a closed loop system that includes the hydraulic pump and hydraulic motor. If a component failure occurs in the traction circuit, unwanted material and contamination from the damaged component will circulate throughout the traction circuit.
Page 75: Hydraulic Hoses
For more hydraulic hose information; refer to Hydraulic Hose Servicing of the Toro Basics Series Training Books (Part No. 94813SL) found on the Service Reference Set available from your Authorized Toro Distributor.
Page 76: Installing The Hydraulic Hoses And Tubes
82 to 100 N∙m (60 to 74 ft-lb) 12 ORFS 1-3/16–12 116 to 142 N∙m (85 to 105 ft-lb) 16 ORFS 1-7/16–12 150 to 184 N∙m (110 to 136 ft-lb) Hydraulic System: General Information Page 5–8 ProLine H800 19241SL Rev A...
Page 77 C. Use a second wrench to tighten the nut to the correct Flats From Wrench Resistance (FFWR); refer to the Flats From Wrench Resistance Table (page 5–9). ProLine H800 Page 5–9 Hydraulic System: General Information 19241SL Rev A...
Page 78: Installing The Hydraulic Fittings
Flats From Finger Tight (FFFT) procedure given below: A. Install the fitting into the port and tighten the fitting down full length until finger-tight. Hydraulic System: General Information Page 5–10 ProLine H800 19241SL Rev A...
Page 79 6. If the adjustable fitting needs to align with another component, rotate the fitting counterclockwise until it is aligned to the desired position (Step 3 in Figure 28). Do not rotate the adjustable fitting more than 1 turn counterclockwise. ProLine H800 Page 5–11 Hydraulic System: General Information 19241SL Rev A...
Page 80 1.50 ± 0.25 3/8 BSPP 6 SAE 1.50 ± 0.25 8 SAE 1.50 ± 0.25 10 SAE 1.50 ± 0.25 1.50 ± 0.25 12 SAE 16 SAE 1.50 ± 0.25 Hydraulic System: General Information Page 5–12 ProLine H800 19241SL Rev A...
Page 81: Hydraulic Schematic
Hydraulic Schematic The hydraulic schematic for the PLH800 machine is located in Appendix A (page A–1). ProLine H800 Page 5–13 Hydraulic System: Hydraulic Schematic 19241SL Rev A...
Page 82: Hydraulic Flow Diagrams
The closed loop traction circuit includes 2 rear wheel motors, 2 front wheel motors, and a differential valve. Hydraulic System: Hydraulic Flow Diagrams Page 5–14 ProLine H800 19241SL Rev A...
Page 83 Forward Direction g292001 Figure 29 ProLine H800 Page 5–15 Hydraulic System: Hydraulic Flow Diagrams 19241SL Rev A...
Page 84 The charge pressure is limited to 7 bar (101 psi) by a dedicated pressure relief valve in the hydraulic pump. Hydraulic System: Hydraulic Flow Diagrams Page 5–16 ProLine H800 19241SL Rev A...
Page 85 Reverse Direction g292002 Figure 30 ProLine H800 Page 5–17 Hydraulic System: Hydraulic Flow Diagrams 19241SL Rev A...
Page 86 The charge circuit functions the same in reverse as it does in the forward direction. Hydraulic System: Hydraulic Flow Diagrams Page 5–18 ProLine H800 19241SL Rev A...
Page 87: Steering Circuit
P port and bypasses both the rotary meter and steering cylinder. Flow leaves the steering control valve through the E port, and is directed to the height of cut control valve. ProLine H800 Page 5–19 Hydraulic System: Hydraulic Flow Diagrams...
Page 88 The fluid leaving the steering cylinder flows back through the spool valve, then out the T port and returns to the pump. Hydraulic System: Hydraulic Flow Diagrams Page 5–20 ProLine H800 19241SL Rev A...
Page 89 The rotary meter ensures that the fluid flow to the cylinder is proportional to amount of steering wheel rotation. The fluid leaving the steering cylinder flows back through the spool valve, then out the T port and returns to the pump. ProLine H800 Page 5–21 Hydraulic System: Hydraulic Flow Diagrams...
Page 90: Height Of Cut Circuit
When the height of cut is not being adjusted higher or lower, fluid flow enters the height of cut control valve manifold at the P port and exits from the T port. Hydraulic System: Hydraulic Flow Diagrams Page 5–22 ProLine H800 19241SL Rev A...
Page 91 T port. The block valve (located between the height of cut control valve and the cylinder) holds the fluid pressure in the height of cut cylinder to maintain the correct level of cut until the next adjustment. ProLine H800 Page 5–23 Hydraulic System: Hydraulic Flow Diagrams...
Page 92 T port. The block valve (located between the height of cut control valve and cylinder) holds the fluid pressure in the height of cut cylinder to maintain correct level of cut until the next adjustment. Hydraulic System: Hydraulic Flow Diagrams Page 5–24 ProLine H800 19241SL Rev A...
Page 93: Auxiliary Control Circuit
When the auxiliary controls are being adjusted to raise or lower, fluid flow enters the auxiliary control valve manifold at the P port and exits from the T port. ProLine H800 Page 5–25 Hydraulic System: Hydraulic Flow Diagrams...
Page 94 Note: If the cutting deck lift lever is moved to the RAISE position while the steering wheel is being turned, the cutting deck lift speed will be reduced. Hydraulic System: Hydraulic Flow Diagrams Page 5–26 ProLine H800 19241SL Rev A...
Page 95 The weight of the cutting deck causes the cylinders to extend and the cutting deck lowers. ProLine H800 Page 5–27 Hydraulic System: Hydraulic Flow Diagrams...
Page 96 Hydraulic System: Hydraulic Flow Diagrams Page 5–28 ProLine H800 19241SL Rev A...
Page 97 ProLine H800 Page 5–29 Hydraulic System: Hydraulic Flow Diagrams...
Page 98 Pressure in the rod side of the cylinder causes the piston to retract the deck cleaning cylinder and operate the blade assembly simultaneously. Hydraulic System: Hydraulic Flow Diagrams Page 5–30 ProLine H800 19241SL Rev A...
Page 99 Pressure in the rod side of the cylinder causes the piston to retract the deck cleaning cylinder and operate the blade assembly simultaneously. ProLine H800 Page 5–31 Hydraulic System: Hydraulic Flow Diagrams...
Page 100: Testing The Hydraulic System
Before performing the hydraulic tests, check all obvious areas, such as fluid supply, filter, binding linkages, loose fasteners, or improper adjustments before you assume that a hydraulic component is the source of the problem. Hydraulic System: Testing the Hydraulic System Page 5–32 ProLine H800 19241SL Rev A...
Page 101 13. Record the results of all hydraulic tests performed. 14. After a hydraulic test procedure has been completed, check the hydraulic fluid level in the hydraulic tank before returning the machine to service. ProLine H800 Page 5–33 Hydraulic System: Testing the Hydraulic System...
Page 102: Testing The Traction Circuit - Charge Pressure
Any test procedure that requires an open or uncapped line (like a case drain leak check) would not apply. In those rare situations, the hydraulic fluid should be warmed before disconnecting the lines. Hydraulic System: Testing the Hydraulic System Page 5–34 ProLine H800 19241SL Rev A...
Page 103 5. Push the latch (item 2) inward toward the radiator (Figure 45). 6. Using the handle (item 1), rotate the radiator to access the hydraulic fluid filter (Figure 45). ProLine H800 Page 5–35 Hydraulic System: Testing the Hydraulic System 19241SL Rev A...
Page 104 Testing the Traction Circuit - Hydraulic Pump Flow and Relief Pressure (page 5–44). 17. Release the traction pedal, move the throttle to low speed position, and shut off the engine. Hydraulic System: Testing the Hydraulic System Page 5–36 ProLine H800 19241SL Rev A...
Page 105 20. Start the engine, check for hydraulic fluid leaks, repair any leaks as required, and fill the hydraulic tank with the correct quantity of new hydraulic fluid before returning the machine to service. ProLine H800 Page 5–37 Hydraulic System: Testing the Hydraulic System...
Page 106: Testing The Wheel Motors Efficiency
For this reason, the test procedure includes checking hydraulic flow through the motor after rotating the wheel to 3 different positions to get multiple readings. Hydraulic System: Testing the Hydraulic System Page 5–38 ProLine H800 19241SL Rev A...
Page 107 47). Connect the hydraulic lines each other that are removed from the left front wheel motor to complete the closed loop circuit. Cap the ports in the left front wheel motor to prevent contamination. ProLine H800 Page 5–39 Hydraulic System: Testing the Hydraulic System...
Page 108 Pressure from the Hydraulic System (page 5–5). 19. Disconnect the tester from the pump outlet fitting and hydraulic hose and connect the pump outlet to the hydraulic hoses. Hydraulic System: Testing the Hydraulic System Page 5–40 ProLine H800 19241SL Rev A...
Page 109 Note: The flow meter reading should be less than 3.4 LPM (0.9 GPM) for the tested wheel motor. If the specification is not met, repair or replace the wheel motor. g292860 Figure 48 ProLine H800 Page 5–41 Hydraulic System: Testing the Hydraulic System 19241SL Rev A...
Page 110 Note: The flow meter reading should be less than 3.4 LPM (0.9 GPM) for the tested wheel motor. If the specification is not met, repair or replace the wheel motor. g292861 Figure 49 Hydraulic System: Testing the Hydraulic System Page 5–42 ProLine H800 19241SL Rev A...
Page 111 Note: The flow meter reading should be less than 2.8 LPM (0.74 GPM) for the tested wheel motor. If the specification is not met, repair or replace the wheel motor. g292863 Figure 50 ProLine H800 Page 5–43 Hydraulic System: Testing the Hydraulic System 19241SL Rev A...
Page 112: Testing The Traction Circuit - Hydraulic Pump Flow And Relief Pressure
Special Equipment Required: • Flow meter with pressure gauge that has at least a 144 L/min (30 GPM) capacity. • Phototach (non-contact tachometer). Hydraulic System: Testing the Hydraulic System Page 5–44 ProLine H800 19241SL Rev A...
Page 113 A. Push the latch (item 2) inward toward the radiator (Figure 52). B. Using the handle (item 1), rotate the radiator to access the hydraulic pump (Figure 52). ProLine H800 Page 5–45 Hydraulic System: Testing the Hydraulic System 19241SL Rev A...
Page 114 8. Clean the junction of the hydraulic hose and left side of the fitting on bottom of the hydraulic pump (Figure 54), and disconnect the hose from the fitting. Hydraulic System: Testing the Hydraulic System Page 5–46 ProLine H800 19241SL Rev A...
Page 115 Note: The relief valve setting is 285 bar (4133 psi). An additional 5 bar (70 psi) is necessary to overcome system charge pressure before the relief valve opens. ProLine H800 Page 5–47 Hydraulic System: Testing the Hydraulic System 19241SL Rev A...
Page 116 21. Rotate the fuel tank into position and secure it with the bolt. 22. Start the engine, check for hydraulic leaks, and make repairs as required. Properly service the system quantity before returning the machine to service. Hydraulic System: Testing the Hydraulic System Page 5–48 ProLine H800 19241SL Rev A...
Page 117: Testing The Steering Circuit - Steering Control Valve, Relief Valve Pressure And Steering Cylinder
1. Ensure that the hydraulic fluid is at normal operating temperature by operating the machine for at least 10 minutes. 2. Drive the machine slowly in a figure eight on a flat level surface. ProLine H800 Page 5–49 Hydraulic System: Testing the Hydraulic System...
Page 118 If the hydraulic fluid comes out of the fitting while turning the steering wheel to the left, the steering cylinder has internal leakage and should be repaired or replaced. Hydraulic System: Testing the Hydraulic System Page 5–50 ProLine H800 19241SL Rev A...
Page 119 8. Start the engine, check for hydraulic-fluid leaks, repair any leaks as required, and fill the hydraulic tank with the correct quantity of new hydraulic fluid before returning the machine to service. ProLine H800 Page 5–51 Hydraulic System: Testing the Hydraulic System...
Page 120: Testing The Steering Circuit - Charge Pump Flow
Special Equipment Required: • Flow meter with pressure gauge that has at least a 19 LPM (5 GPM) capacity. • Phototach (non−contact tachometer). Hydraulic System: Testing the Hydraulic System Page 5–52 ProLine H800 19241SL Rev A...
Page 121 Washer Filter support Fitting Reducer Washer Adaptor 90º adaptor Oil cooler Charge pump Hose Hose Adaptor Fitting Hose T fitting Washer Hose Hose O-ring Hose Piston pump ProLine H800 Page 5–53 Hydraulic System: Testing the Hydraulic System 19241SL Rev A...
Page 122 10. Verify the pump flow at no load as follows: A. Record the tester pressure and flow readings at no load. B. Unrestricted pump output should be approximately 15 LPM (4 GPM). Hydraulic System: Testing the Hydraulic System Page 5–54 ProLine H800 19241SL Rev A...
Page 123 16. Start the engine, check for hydraulic-fluid leaks, repair any leaks as required, and fill the hydraulic tank with the correct quantity of new hydraulic fluid before returning the machine to service. ProLine H800 Page 5–55 Hydraulic System: Testing the Hydraulic System...
Page 124: Testing The Auxiliary Control Circuit - Cutting Deck Lift Cylinder Internal Leakage
The lift cylinder can potentially bind, there may be extra weight on the cutting deck, and/or the lift components can be hampered during operation. Inspect these components for proper function before continuing with the lift cylinder internal leakage test. Hydraulic System: Testing the Hydraulic System Page 5–56 ProLine H800 19241SL Rev A...
Page 125 17. If necessary, repeat the steps through for other lift cylinders. 18. Check and fill the hydraulic tank with the correct quantity of new hydraulic fluid before returning the machine to service. ProLine H800 Page 5–57 Hydraulic System: Testing the Hydraulic System 19241SL Rev A...
Page 126: Testing The Auxiliary Control Circuit - Hopper Lift Cylinder Internal Leakage
4. Clean the area around the hydraulic hoses end at the barrel end of the hopper lift cylinder. Disconnect the hydraulic hoses from the hopper lift cylinder barrel end fitting. Hydraulic System: Testing the Hydraulic System Page 5–58 ProLine H800 19241SL Rev A...
Page 127 15. Check and fill the hydraulic tank with the correct quantity of new hydraulic fluid before returning the machine to service. ProLine H800 Page 5–59 Hydraulic System: Testing the Hydraulic System 19241SL Rev A...
Page 128: Testing The Auxiliary Control Circuit - Hopper Tilt Cylinder Internal Leakage
4. Clean the area around the hydraulic hoses end at the barrel end of the hopper tilt cylinder. Disconnect the hydraulic hoses from the hopper tilt cylinder barrel end fitting. Hydraulic System: Testing the Hydraulic System Page 5–60 ProLine H800 19241SL Rev A...
Page 129 15. Check and fill the hydraulic tank with the correct quantity of new hydraulic fluid before returning the machine to service. ProLine H800 Page 5–61 Hydraulic System: Testing the Hydraulic System 19241SL Rev A...
Page 130: Testing The Height Of Cut Cylinder Internal Leakage
If the height of cut piston lowers the height of cut itself, replace the height of cut cylinder; refer to Height Of Cut Cylinder (page 5–124). Hydraulic System: Testing the Hydraulic System Page 5–62 ProLine H800 19241SL Rev A...
Page 131: Service And Repairs
2. Lubricate the O-rings and seals with clean hydraulic fluid before installing the hydraulic components. 3. Remove all the caps or plugs from the hydraulic tubes, hydraulic fittings, and components before connecting them again. ProLine H800 Page 5–63 Hydraulic System: Service and Repairs 19241SL Rev A...
Page 132 Charging the Hydraulic System (page 5–72). 8. Check for hydraulic-fluid leaks. Shut off the engine and repair leaks if necessary. Hydraulic System: Service and Repairs Page 5–64 ProLine H800 19241SL Rev A...
Page 133: Checking The Hydraulic Lines And Hoses
Check the hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration, and chemical deterioration. Repair the damaged hydraulic equipment before operating the machine. ProLine H800 Page 5–65 Hydraulic System: Service and Repairs 19241SL Rev A...
Page 134: Flushing The Hydraulic System
Follow all local codes and regulations when recycling or disposing the hydraulic fluid and filters. 5. Clean the area around the mounting area of the hydraulic-fluid filter. Remove and replace the hydraulic-fluid filter. Hydraulic System: Service and Repairs Page 5–66 ProLine H800 19241SL Rev A...
Page 135 17. When the hydraulic fluid is free from contamination, assume normal operation and follow the recommended maintenance intervals. ProLine H800 Page 5–67 Hydraulic System: Service and Repairs 19241SL Rev A...
Page 136: Filtering The Closed-Loop Traction Circuit
To effectively remove the contamination from the closed-loop circuit, use the Toro high flow hydraulic filter and hydraulic hose kits (refer to Special Tools (page 2–15)).
Page 137 5 more minutes. IMPORTANT If you are using a filter that is not the Toro high flow filter that is bi-directional, do not press the traction pedal in the reverse direction. If the flow is reversed when using a filter that is not bi-directional, unwanted material from the filter will again enter the traction circuit.
Page 138: Priming The Hydraulic Pump
Note: You must have the steering wheel rotated to the fully locked position to rotate the fuel tank out fully. g293122 Figure 64 Starter motor B+ terminal Starter solenoid Hydraulic System: Service and Repairs Page 5–70 ProLine H800 19241SL Rev A...
Page 139 6. Disconnect the remote starter switch leads from the starter motor solenoid terminal and positive post of the battery. 7. Connect the wire harness electrical connector to the fuel solenoid terminal. ProLine H800 Page 5–71 Hydraulic System: Service and Repairs...
Page 140: Charging The Hydraulic System
If the wheels rotate in the wrong direction, shut off the engine, inspect the hydraulic line placement at the hydraulic pump and hydraulic motor. Correct the hydraulic line installation before you proceed. Hydraulic System: Service and Repairs Page 5–72 ProLine H800 19241SL Rev A...
Page 141 19. Stop the machine. Check the hydraulic-fluid level in the hydraulic tank and add correct quantity of fluid if necessary; refer to the Operator’s Manual. 20. Check the hydraulic components for leaks and tighten any loose connections. ProLine H800 Page 5–73 Hydraulic System: Service and Repairs...
Page 142: Hydraulic Tank
Auxiliary control valve Band clamp Puller knob Auxiliary control valve support Band clamp Bolt Spring Hydraulic tank Auxiliary valve lever Washer Operator platform Connector Washer Auxiliary valve lever Washer Bolt Hydraulic System: Service and Repairs Page 5–74 ProLine H800 19241SL Rev A...
Page 143 90º adaptor Washer Filter support Fitting Reducer 90º adaptor Washer Adaptor Oil cooler Charge pump Hose Hose Adaptor Fitting Hose Washer T fitting Hose Hose O-ring Hose Piston pump ProLine H800 Page 5–75 Hydraulic System: Service and Repairs 19241SL Rev A...
Page 144 7. Fill the hydraulic tank with the correct quantity of new hydraulic fluid. 8. Operate the machine and check for the hydraulic leaks near the components and fittings. Tighten any loose connections. Hydraulic System: Service and Repairs Page 5–76 ProLine H800 19241SL Rev A...
Page 145 9. Check the hydraulic fluid level and adjust if necessary; refer to Operator’s Manual. 10. Install the right console onto the machine; refer to Assembling the Body Assembly (page 7–7). ProLine H800 Page 5–77 Hydraulic System: Service and Repairs 19241SL Rev A...
Page 146: Auxiliary Control Valve
4. Clean the hydraulic hose ends and fittings on the hydraulic tank to prevent contaminants from entering into the hydraulic system. 5. For assembly purposes, label all the hydraulic hoses and fittings. Hydraulic System: Service and Repairs Page 5–78 ProLine H800 19241SL Rev A...
Page 147 Installing the Hydraulic Fittings (page 5–10). 5. Fill the hydraulic tank with the correct quantity of new hydraulic fluid; refer to Operator’s Manual. ProLine H800 Page 5–79 Hydraulic System: Service and Repairs 19241SL Rev A...
Page 148 7. Check the hydraulic fluid level and adjust if necessary; refer to Operator’s Manual. 8. Install the right console onto the machine; refer to Assembling the Body Assembly (page 7–7). Hydraulic System: Service and Repairs Page 5–80 ProLine H800 19241SL Rev A...
Page 149: Traction Neutral Arm Assembly
Installing the Traction Neutral Arm Assembly 1. Install the traction neutral arm components to the hydraulic pump (Figure 69). 2. Check and adjust the traction neutral position; refer to Operator’s Manual. ProLine H800 Page 5–81 Hydraulic System: Service and Repairs 19241SL Rev A...
Page 150: Hydraulic Pump Assembly
Bolt Traction neutral arm Socket head screw Washer Washer Socket head screw Gear pump Hydrostat neutral shaft Engine Washer Washer Washer Bracket Traction cable Bolt Washer Retaining ring Hydraulic System: Service and Repairs Page 5–82 ProLine H800 19241SL Rev A...
Page 151 5. For assembly purposes, label all the hydraulic connections. g292559 Figure 71 Hydraulic pump Hose O-ring Hydraulic motor Fitting Fitting T fitting adaptor Hose Pressure port plug Hose ProLine H800 Page 5–83 Hydraulic System: Service and Repairs 19241SL Rev A...
Page 152 2. If the hydraulic fittings are removed from the pump, lubricate and install the new O-rings to the fittings. 3. Install the fittings into the pump; refer to Installing the Hydraulic Fittings (page 5–10). Hydraulic System: Service and Repairs Page 5–84 ProLine H800 19241SL Rev A...
Page 153 9. Operate the machine functions slowly until air is out of system; refer to Charging the Hydraulic System (page 5–72). 10. Check and adjust the traction rod for neutral; refer to Operator’s Manual. ProLine H800 Page 5–85 Hydraulic System: Service and Repairs 19241SL Rev A...
Page 154: Servicing The Hydraulic Piston Pump
Servicing the Hydraulic Piston Pump g293588 Figure 73 Hydraulic System: Service and Repairs Page 5–86 ProLine H800 19241SL Rev A...
Page 155 IMPORTANT If a hydraulic pump failure occurs; refer to the Traction Circuit Component Failure (page 5–6) for information regarding the importance of removing contamination from the traction circuit. ProLine H800 Page 5–87 Hydraulic System: Service and Repairs 19241SL Rev A...
Page 156: Servicing The Gear Pump
1. Plug the pump ports and clean the outer surface of the pump with cleaning solvent. Ensure that the work area is clean. Hydraulic System: Service and Repairs Page 5–88 ProLine H800 19241SL Rev A...
Page 157 The pump efficiency may be affected if the teeth are not installed in the same position during assembly. ProLine H800 Page 5–89 Hydraulic System: Service and Repairs...
Page 158 4. Inspect the front flange and body for damage or wear. 5. Replace the entire pump assembly if the internal parts are excessively worn or damaged. Hydraulic System: Service and Repairs Page 5–90 ProLine H800 19241SL Rev A...
Page 159 3. After the pump has been assembled, tighten the bolts by hand. Rotate the driveshaft to check for binding. Protect the shaft if you use pliers. 4. Torque the bolts evenly to 45 N∙m (33 ft-lb) in a crossing pattern. ProLine H800 Page 5–91 Hydraulic System: Service and Repairs...
Page 160: Front Wheel Motors
Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 5–5). Hydraulic System: Service and Repairs Page 5–92 ProLine H800 19241SL Rev A...
Page 161 5. Lift the machine with a jack to remove the front wheel, support the machine with jack stands. 6. Remove the front wheel, brake drum, wheel hub, and brake assembly from the machine; refer to Servicing the Brake (page 8–3). ProLine H800 Page 5–93 Hydraulic System: Service and Repairs 19241SL Rev A...
Page 162 7. Clean the hydraulic tube ends and fittings on the wheel motor to prevent contaminants from entering into the hydraulic system. 8. For assembly purposes, label all the hydraulic connections at the wheel motor. Hydraulic System: Service and Repairs Page 5–94 ProLine H800 19241SL Rev A...
Page 163 11. Start the engine, check for hydraulic-fluid leaks, repair any leaks as necessary, and fill the hydraulic tank with the correct quantity of new hydraulic fluid before returning the machine to service. ProLine H800 Page 5–95 Hydraulic System: Service and Repairs...
Page 164: Rear Wheel Motors
Before lifting the machine with a jack, review and follow Jacking Instructions (page 1–7). 5. Lift the machine with a jack to remove the rear wheel, support the machine with jack stands. Hydraulic System: Service and Repairs Page 5–96 ProLine H800 19241SL Rev A...
Page 165 C. Remove the locknut and wheel hub from the motor shaft. Discard the locknut. D. Locate and retrieve the woodruff key (item 4 in Figure 79) from the wheel motor shaft. ProLine H800 Page 5–97 Hydraulic System: Service and Repairs 19241SL Rev A...
Page 166 8. Clean the hydraulic hose ends and fittings on the wheel motor to prevent contaminants from entering into the hydraulic system. 9. For assembly purposes, label all the hydraulic connections at the wheel motor. Hydraulic System: Service and Repairs Page 5–98 ProLine H800 19241SL Rev A...
Page 167 Figure 79). 8. Ensure to torque the locknut to 350 N∙m (258 ft-lb). 9. Install the rear wheel to the machine; refer to Installing the Wheels (page 7–4). ProLine H800 Page 5–99 Hydraulic System: Service and Repairs 19241SL Rev A...
Page 168 13. Start the engine, check for hydraulic-fluid leaks, repair any leaks as necessary, and fill the hydraulic tank with the correct quantity of new hydraulic fluid before returning the machine to service. Hydraulic System: Service and Repairs Page 5–100 ProLine H800 19241SL Rev A...
Page 169: Servicing The Hydraulic Wheel Motor
Housing Thrust bearing Stator Back-up ring Drive link Vane Back-up washer Bolt Wear plate Shaft seal End cover Rotor Inner bearing Body seal Commutator ring Thrust washer Commutator ProLine H800 Page 5–101 Hydraulic System: Service and Repairs 19241SL Rev A...
Page 170 Series). Note: If a wheel motor fails; refer to the Traction Circuit Component Failure (page 5–6) for information regarding the importance of removing contamination from the traction circuit. Hydraulic System: Service and Repairs Page 5–102 ProLine H800 19241SL Rev A...
Page 171: Differential Valve
General Precautions for Removing and Installing the Hydraulic System Components (page 5–63). 3. Locate the Differential valve that is attached to front of the chassis (between the two front wheel motors) (Figure 82). ProLine H800 Page 5–103 Hydraulic System: Service and Repairs 19241SL Rev A...
Page 172 T-fitting Front left wheel motor Fitting Plug Front right wheel motor 12. Hose Rear right wheel motor Rear left wheel motor Fitting Bolt Hose Hose Hose O-ring Hose Hydraulic System: Service and Repairs Page 5–104 ProLine H800 19241SL Rev A...
Page 173 9. Start the engine, check for hydraulic fluid leaks, repair any leaks as necessary, and service the hydraulic tank with the correct quantity of new fluid before returning the machine to service. ProLine H800 Page 5–105 Hydraulic System: Service and Repairs...
Page 174: Height Of Cut Valve
3. Locate the height of cut valve that is attached to operator platform under the operator seat (Figure 84). 4. For assembly purposes, label all the hydraulic connections. Clean the hydraulic connections before loosening the hydraulic lines. Hydraulic System: Service and Repairs Page 5–106 ProLine H800 19241SL Rev A...
Page 175 8. Remove the height of control valve from the machine. 9. If necessary, remove the hydraulic fitting from the height of cut valve. Discard the O-rings that were removed. ProLine H800 Page 5–107 Hydraulic System: Service and Repairs 19241SL Rev A...
Page 176 9. Start the engine, check for hydraulic-fluid leaks, repair any leaks as necessary, and fill the hydraulic tank with the correct quantity of new hydraulic fluid before returning the machine to service. Hydraulic System: Service and Repairs Page 5–108 ProLine H800 19241SL Rev A...
Page 177: Lift Cylinder
Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 5–5). ProLine H800 Page 5–109 Hydraulic System: Service and Repairs 19241SL Rev A...
Page 178 9. If the hydraulic fittings are to be removed from the lift cylinder, mark the fitting orientation for assembly purposes. Remove the fittings from the lift cylinder and discard the O-rings from the fittings. Hydraulic System: Service and Repairs Page 5–110 ProLine H800 19241SL Rev A...
Page 179 11. Start the engine, check for hydraulic-fluid leaks, repair any leaks as necessary, and fill the hydraulic tank with the correct quantity of new hydraulic fluid before returning the machine to service. ProLine H800 Page 5–111 Hydraulic System: Service and Repairs...
Page 180: Steering Control Valve
Socket head screw Bushing Bracket Steering control valve Washer Electronic control unit Shaft key Washer Washer Hinge Nylon bushing Bolt Thread insert Operator platform Handle Support Bushing Bolt Hydraulic System: Service and Repairs Page 5–112 ProLine H800 19241SL Rev A...
Page 181 8. Remove the steering control valve from the steering column by using the Figure 88 as a guide. 9. If necessary, remove the hydraulic fittings from the steering control valve. 10. Remove and discard the O-rings from the fittings. ProLine H800 Page 5–113 Hydraulic System: Service and Repairs 19241SL Rev A...
Page 182 9. Start the engine, check for hydraulic-fluid leaks, repair any leaks as necessary, and fill the hydraulic tank with the correct quantity of new hydraulic fluid before returning the machine to service. Hydraulic System: Service and Repairs Page 5–114 ProLine H800 19241SL Rev A...
Page 183: Steering Cylinder
2. Read the General Precautions for Removing and Installing the Hydraulic System Components (page 5–63). ProLine H800 Page 5–115 Hydraulic System: Service and Repairs 19241SL Rev A...
Page 184 11. If the hydraulic fittings are to be removed from the steering cylinder, mark the fitting orientation for assembly purposes. Remove the fittings from the steering cylinder and discard the O-rings from the fittings. Hydraulic System: Service and Repairs Page 5–116 ProLine H800 19241SL Rev A...
Page 185 12. Check that the steering cylinder does not contact the axle or frame as the steering cylinder moves from one direction to another. 13. Check and adjust the steering stops; refer to the Operator’s Manual. ProLine H800 Page 5–117 Hydraulic System: Service and Repairs...
Page 186: Hopper Lift Cylinder
2. Read the General Precautions for Removing and Installing the Hydraulic System Components (page 5–63). Hydraulic System: Service and Repairs Page 5–118 ProLine H800 19241SL Rev A...
Page 187 10. If the hydraulic fittings are to be removed from the hopper lift cylinder, mark the fitting orientation for assembly purposes. Remove the fittings from the hopper lift cylinder and discard the O-rings from the fittings. ProLine H800 Page 5–119 Hydraulic System: Service and Repairs...
Page 188 11. Operate and check that the hopper lift cylinder does not contact the bracket or arm as the hopper moves up and down. Hydraulic System: Service and Repairs Page 5–120 ProLine H800 19241SL Rev A...
Page 189: Hopper Tilt Cylinder
General Precautions for Removing and Installing the Hydraulic System Components (page 5–63). 3. For assembly purposes, label all the hydraulic connections. Clean the hydraulic connections before loosening the hydraulic lines from the hopper tilt cylinder. ProLine H800 Page 5–121 Hydraulic System: Service and Repairs 19241SL Rev A...
Page 190 7. Remove the bolt (10), washer (9) and pin (8) that secures the hopper tilt cylinder (7) to the support frame (11). 8. Remove the hopper tilt cylinder from the machine. Hydraulic System: Service and Repairs Page 5–122 ProLine H800 19241SL Rev A...
Page 191 12. Operate and check that the hopper tilt cylinder does not contact the frame or arm as the hopper tilts forward and reverse. ProLine H800 Page 5–123 Hydraulic System: Service and Repairs 19241SL Rev A...
Page 192 System Components (page 5–63). 3. For assembly purposes, label all the hydraulic connections. Clean the hydraulic connections before loosening the hydraulic lines from the height of cut cylinder. Hydraulic System: Service and Repairs Page 5–124 ProLine H800 19241SL Rev A...
Page 193 Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 5–5). ProLine H800 Page 5–125 Hydraulic System: Service and Repairs 19241SL Rev A...
Page 194 Charging the Hydraulic System (page 5–72). 11. Start the engine, check for hydraulic-fluid leaks, repair any leaks as necessary, and fill the hydraulic tank with the correct quantity of new hydraulic fluid. Hydraulic System: Service and Repairs Page 5–126 ProLine H800 19241SL Rev A...
Page 195 General Precautions for Removing and Installing the Hydraulic System Components (page 5–63). 3. For assembly purposes, label all the hydraulic connections. Clean the hydraulic connections before loosening the hydraulic lines from the chute cleaning cylinder. ProLine H800 Page 5–127 Hydraulic System: Service and Repairs 19241SL Rev A...
Page 196 8. If the hydraulic fittings are to be removed from the chute cleaning cylinder, mark the fitting orientation for assembly purposes. Remove the fittings from the chute cleaning cylinder and discard the O-rings from the fittings. Hydraulic System: Service and Repairs Page 5–128 ProLine H800 19241SL Rev A...
Page 197 Charging the Hydraulic System (page 5–72). 9. Start the engine, check for hydraulic-fluid leaks, repair any leaks as necessary, and fill the hydraulic tank with the correct quantity of new hydraulic fluid. ProLine H800 Page 5–129 Hydraulic System: Service and Repairs 19241SL Rev A...
Page 198 Gasket Bracket Washer Bolt Blower Spring Shock absorber Grommet Fan shroud Washer Radiator Gasket Bolt Hose Frame Washer Bracket Clamp Bolt Shock absorber Bolt Clamp Bolt Washer Washer Hydraulic System: Service and Repairs Page 5–130 ProLine H800 19241SL Rev A...
Page 199 Installing the Oil Cooler The radiator and oil cooler must be installed into the machine as an assembly; refer to Installing the Radiator (page 4–10). ProLine H800 Page 5–131 Hydraulic System: Service and Repairs 19241SL Rev A...
Page 200 Hydraulic System: Service and Repairs Page 5–132 ProLine H800 19241SL Rev A...
Page 201 PTO Electric Clutch.......................... 6–35 Fuel Stop Solenoid........................... 6–37 Relays .............................. 6–39 Diode Assembly ..........................6–43 Service and Repairs ........................... 6–44 Battery Storage ..........................6–44 Battery Care............................. 6–44 Servicing the Battery ........................6–46 ProLine H800 Page 6–1 Electrical System 19241SL Rev A...
Page 202: General Information
ON position, you must test the switch, fuses and circuit wiring. The ECM does not connect to an external computer or hand held device, cannot be re-programmed and does not record intermittent fault data. Electrical System: General Information Page 6–2 ProLine H800 19241SL Rev A...
Page 203: Chapter 6: Electrical System
Voltage Measured Battery Charge Level 12.68 V (or higher) Fully charged (100%) 12.45 V 75% charged 12.24 V 50% charged 12.06 V 25% charged 11.89 V 0% charged ProLine H800 Page 6–3 Electrical System: Electrical System Quick Checks 19241SL Rev A...
Page 204: Testing The Charging System
At least 0.50 V over the initial battery voltage Initial battery voltage = 12.30 V Battery voltage after 3 minutes charge = 12.85 V Difference = +0.55 V Electrical System: Electrical System Quick Checks Page 6–4 ProLine H800 19241SL Rev A...
Page 205: Testing The Glow Plug System
The interlock system used on this machine includes the key switch, PTO switch, seat switch, traction neutral sensor and parking brake switch. Testing of the individual interlock switches is included in the Testing the Electrical Components (page 6–6). ProLine H800 Page 6–5 Electrical System: Electrical System Quick Checks 19241SL Rev A...
Page 206: Testing The Electrical Components
Service Manual Yanmar 3TNV80F Service Manual. IMPORTANT When testing the electrical components for continuity with a multimeter (ohms setting), ensure that you disconnect the power to the circuit. Electrical System: Testing the Electrical Components Page 6–6 ProLine H800 19241SL Rev A...
Page 207: Fuses
6. 5 A: Alternator and dashboard circuit. 7. 15 A: Work lights, brake lights, full-beam lights, and light control unit circuit. 8. 30 A: Pull and hazard light switch, spark plugs, and key switch circuit. ProLine H800 Page 6–7 Electrical System: Testing the Electrical Components...
Page 208 There are 2 fuses of 40 A that protect the main machine wire harness. These 2 fuses are located to the left side of the machine and between the roller bar strut and fuel tank (Figure 106). Electrical System: Testing the Electrical Components Page 6–8 ProLine H800 19241SL Rev A...
Page 209 D. Replace the fuse if testing determines that it is damaged. E. After you complete the fuse testing, install the fuse cap. ProLine H800 Page 6–9 Electrical System: Testing the Electrical Components 19241SL Rev A...
Page 210: Key Switch
Disassembling the Body Assembly (page 7–6). 4. Disconnect the wire harness connector from the key switch and remove the key switch from the steering column cover. Electrical System: Testing the Electrical Components Page 6–10 ProLine H800 19241SL Rev A...
Page 211 9. Install the steering column cover to the steering column; refer to Assembling the Body Assembly (page 7–7). 10. Connect the battery negative (-) cable to the battery. ProLine H800 Page 6–11 Electrical System: Testing the Electrical Components 19241SL Rev A...
Page 212: Pto Switch
Testing the PTO Switch g227536 Figure 110 COM B terminal COM C terminal NO B terminal NO C terminal NC B terminal NC C terminal Electrical System: Testing the Electrical Components Page 6–12 ProLine H800 19241SL Rev A...
Page 213 9. Install the steering column cover to the steering column; refer to Assembling the Body Assembly (page 7–7). 10. Connect the battery negative (-) cable to the battery. ProLine H800 Page 6–13 Electrical System: Testing the Electrical Components 19241SL Rev A...
Page 214: Hazard Light Switch
Disassembling the Body Assembly (page 7–6). 4. Disconnect the wire harness connector from the hazard light switch and remove the hazard light switch from the dash panel. Electrical System: Testing the Electrical Components Page 6–14 ProLine H800 19241SL Rev A...
Page 215 9. Install the dash panel to the steering column; refer to Assembling the Body Assembly (page 7–7). 10. Connect the battery negative (-) cable to the battery. ProLine H800 Page 6–15 Electrical System: Testing the Electrical Components 19241SL Rev A...
Page 216: Differential Lock Switch
Disassembling the Body Assembly (page 7–6). 4. Disconnect the wire harness connector from the differential lock switch and remove the differential lock switch from the dash panel. Electrical System: Testing the Electrical Components Page 6–16 ProLine H800 19241SL Rev A...
Page 217 9. Install the dash panel to the steering column; refer to Assembling the Body Assembly (page 7–7). 10. Connect the battery negative (-) cable to the battery. ProLine H800 Page 6–17 Electrical System: Testing the Electrical Components 19241SL Rev A...
Page 218: Radiator Fan Reversal Switch
Disassembling the Body Assembly (page 7–6). 4. Disconnect the wire harness connector from the radiator fan reversal switch and remove the radiator fan reversal switch from the dash panel. Electrical System: Testing the Electrical Components Page 6–18 ProLine H800 19241SL Rev A...
Page 219 9. Install the dash panel to the steering column; refer to Assembling the Body Assembly (page 7–7). 10. Connect the battery negative (-) cable to the battery. ProLine H800 Page 6–19 Electrical System: Testing the Electrical Components 19241SL Rev A...
Page 220: Beacon Light Switch
Disassembling the Body Assembly (page 7–6). 4. Disconnect the wire harness connector from the beacon light switch and remove the beacon light switch from the dash panel. Electrical System: Testing the Electrical Components Page 6–20 ProLine H800 19241SL Rev A...
Page 221 9. Install the dash panel to the steering column; refer to Assembling the Body Assembly (page 7–7). 10. Connect the battery negative (-) cable to the battery. ProLine H800 Page 6–21 Electrical System: Testing the Electrical Components 19241SL Rev A...
Page 222: Indicator Lights
Also, it will illuminate when the engine oil pressure drops below a safe level. IMPORTANT If the oil pressure indicator light is illuminated with the engine running, shut off the engine immediately. Electrical System: Testing the Electrical Components Page 6–22 ProLine H800 19241SL Rev A...
Page 223 Electrical Schematics and Wire Harness Drawings/Diagrams in Appendix A (page A–1). 8. Install the dash panel to the steering column; refer to Assembling the Body Assembly (page 7–7). ProLine H800 Page 6–23 Electrical System: Testing the Electrical Components 19241SL Rev A...
Page 224: Height Of Cut Switch
3. Remove the left arm control panel and get access to rear of the switch; refer Disassembling the Body Assembly (page 7–6). 4. Disconnect the wire harness connector from the height of cut switch. g223017 Figure 122 Electrical System: Testing the Electrical Components Page 6–24 ProLine H800 19241SL Rev A...
Page 225 8. After you complete the testing, connect the wire harness connector to the switch. 9. Install the left arm control panel to the machine; refer to Assembling the Body Assembly (page 7–7). ProLine H800 Page 6–25 Electrical System: Testing the Electrical Components 19241SL Rev A...
Page 226: Seat Switch
1. Park the machine on a level surface, lower the cutting deck, set the parking brake, and shut off the engine. 2. Ensure that the key switch is in the OFF position. Locate the switch for testing. Electrical System: Testing the Electrical Components Page 6–26 ProLine H800 19241SL Rev A...
Page 227 Appendix A (page A–1). 7. After you complete the seat switch testing, connect the machine wire harness connector to the seat switch. Check the operation of the seat switch. ProLine H800 Page 6–27 Electrical System: Testing the Electrical Components 19241SL Rev A...
Page 228: Hour Meter
1. Push the button until you reach the desired screen. 2. Push and hold the button for 6 seconds until the indicator stops flashing. Note: You cannot reset the total working hours of the machine. Electrical System: Testing the Electrical Components Page 6–28 ProLine H800 19241SL Rev A...
Page 229 6. Disconnect the voltage source from the hour meter. 7. Replace the hour meter if necessary. 8. Connect the wire harness electrical connector to the hour meter. ProLine H800 Page 6–29 Electrical System: Testing the Electrical Components 19241SL Rev A...
Page 230: Traction Neutral Switch
Electrical Schematics and Wire Harness Drawings/Diagrams in Appendix A (page A–1). 6. After you complete the neutral switch testing, connect the switch connector to the machine wire harness. Electrical System: Testing the Electrical Components Page 6–30 ProLine H800 19241SL Rev A...
Page 231: Traction Reverse Switch
Electrical Schematics and Wire Harness Drawings/Diagrams in Appendix A (page A–1). 6. After you complete the reverse switch testing, connect the switch connector to the machine wire harness. ProLine H800 Page 6–31 Electrical System: Testing the Electrical Components 19241SL Rev A...
Page 232: Parking Brake Switch
Electrical Schematics and Wire Harness Drawings/Diagrams in Appendix A (page A–1). 6. After you complete the reverse switch testing, connect the switch connector to the machine wire harness. Electrical System: Testing the Electrical Components Page 6–32 ProLine H800 19241SL Rev A...
Page 233: Oil Pressure Switch
Testing the Oil Pressure Switch Note: Refer to the Yanmar 3TNV76 Service Manual Yanmar 3TNV80F Service Manual for information regarding engine lubrication system and testing. ProLine H800 Page 6–33 Electrical System: Testing the Electrical Components 19241SL Rev A...
Page 234 5. If the switch tests correctly and a circuit problem still exists, check the machine wire harness; refer to Appendix A (page A–1). 6. After testing, connect the engine wire harness to the switch before returning the machine to service. Electrical System: Testing the Electrical Components Page 6–34 ProLine H800 19241SL Rev A...
Page 235: Pto Electric Clutch
1. Park the machine on a level surface, lower the cutting deck, set the parking brake, shut off the engine, and remove the key from the key switch. 2. Locate the PTO electric clutch on the engine crankshaft (Figure 131). ProLine H800 Page 6–35 Electrical System: Testing the Electrical Components 19241SL Rev A...
Page 236 7. If the clutch removal is necessary; refer to Electric Clutch (page 8–15). 8. After you complete the PTO electric clutch testing, connect the clutch electrical connector to the machine wire harness. Electrical System: Testing the Electrical Components Page 6–36 ProLine H800 19241SL Rev A...
Page 237: Fuel Stop Solenoid
3. Use a digital multimeter, touch 1 test lead to the pull coil terminal and the other test lead to the fuel stop solenoid frame (ground). The resistance of the pull coil should be less than 1 ohm (but not zero). ProLine H800 Page 6–37 Electrical System: Testing the Electrical Components...
Page 238 7. Remove positive (+) voltage from the hold coil terminal. The solenoid should release. 8. Replace the fuel stop solenoid if the testing determines that it is damaged. 9. Connect the wire harness connector to the fuel stop solenoid. Electrical System: Testing the Electrical Components Page 6–38 ProLine H800 19241SL Rev A...
Page 239: Relays
The two (2) forward fan relays are attached to the battery support plate under the operator seat (Figure 134). When energized, the forward fan relays allow the electrical current to the radiator fan. ProLine H800 Page 6–39 Electrical System: Testing the Electrical Components 19241SL Rev A...
Page 240 86 (Figure 135). 8. Disconnect the voltage and leads from the relay terminals. 9. Replace the relay if testing determines that the relay is damaged. Electrical System: Testing the Electrical Components Page 6–40 ProLine H800 19241SL Rev A...
Page 241 30 and 87 as +12 VDC is applied and removed from terminal 85. 7. Disconnect voltage from terminal 85 and multimeter lead from terminal 87. ProLine H800 Page 6–41 Electrical System: Testing the Electrical Components...
Page 242 (-) cable to the battery; refer to Servicing the Battery (page 6–46). 13. If removed, install the operator seat onto the machine; refer to Installing the Operator Seat (page 7–17). Electrical System: Testing the Electrical Components Page 6–42 ProLine H800 19241SL Rev A...
Page 243: Diode Assembly
4. If testing determines that diode is faulty, replace diode assembly. 5. After diode testing is complete, make sure that diode is fully installed into wire harness connector and secured to harness with cable tie. ProLine H800 Page 6–43 Electrical System: Testing the Electrical Components...
Page 244: Service And Repairs
(refer to Special Tools (page 2–15)) or petroleum jelly to prevent corrosion. 3. Tighten the battery cables on the battery terminals to provide a good electrical contact. Electrical System: Service and Repairs Page 6–44 ProLine H800 19241SL Rev A...
Page 245 (-) cable first. Clean the cable clamps and terminals separately. Connect the cables with the positive (+) cable first. Apply a layer of terminal protector (Toro Part No. 107-0392) or a light coat of petroleum jelly to the terminals to reduce corrosion after you make the connections.
Page 246: Servicing The Battery
1. Park machine on a level surface, lower cutting deck, shut off the engine, and engage parking brake. 2. Remove the left console and get access to the battery; refer to Disassembling the Body Assembly (page 7–6). Electrical System: Service and Repairs Page 6–46 ProLine H800 19241SL Rev A...
Page 247 A. If the reading is 0.1 A or more, the electrical system of the machine should be tested for short circuits or damaged components and repaired. 7. Install the left console onto the machine; refer to Assembling the Body Assembly (page 7–7). ProLine H800 Page 6–47 Electrical System: Service and Repairs 19241SL Rev A...
Page 248 D. Charge at the rate and time given in Charging the Battery (page 6–50) or until all cells specific gravity is 1.225 or greater with the difference in Electrical System: Service and Repairs Page 6–48 ProLine H800 19241SL Rev A...
Page 249 If the test voltage is below the minimum, replace the battery. If the test voltage is at or above the minimum, return the battery to service. 4. After you make the connections, apply terminal protector (Toro Part No. 107-0392) or a light layer of grease on all the battery posts and cable connectors to reduce corrosion.
Page 250 5.8 hrs 11.5 hrs 17.3 hrs 23 hrs 171 to 250 6 hrs 12 hrs 18 hrs 24 hrs above 250 10 A 10 A 10 A 10 A Electrical System: Service and Repairs Page 6–50 ProLine H800 19241SL Rev A...
Page 251 Note: 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 3 consecutive readings. ProLine H800 Page 6–51 Electrical System: Service and Repairs...
Page 252 Electrical System: Service and Repairs Page 6–52 ProLine H800 19241SL Rev A...
Page 253 Lift Arms............................7–10 Traction Pedal ..........................7–12 Brake Pedal ............................. 7–14 Operator Seat ..........................7–16 Servicing the Operator Seat ......................7–18 Frame Assembly ..........................7–19 Additional Reference Materials Grammer Seats Repair Manual ProLine H800 Page 7–1 Chassis 19241SL Rev A...
Page 254: General Information
General Information The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your ProLine H800 machines. Refer to the Operator’s Manual for additional information when servicing the machine. Chassis: General Information Page 7–2 ProLine H800 19241SL Rev A...
Page 255: Service And Repairs
4. Lift the machine with a jack until the wheel to be removed is off the ground. Support the machine with appropriate jack stands. 5. Remove the wheel-lug nuts or bolts that attach the wheel to the machine, and remove the wheel. ProLine H800 Page 7–3 Chassis: Service and Repairs 19241SL Rev A...
Page 256 3. Torque the wheel-lug nuts or bolts evenly to 85 to 90 N∙m (62 to 66 ft-lb) in a crossing pattern (Figure 140). 4. Check and adjust the tire pressures; refer to Operator’s Manual. Chassis: Service and Repairs Page 7–4 ProLine H800 19241SL Rev A...
Page 257: Body Assembly
Column support Screw Screw Washer Thread insert Dashboard-center Fairing Screw Cover Footboard pad Socket head screw Cage nut Washer Bracket Footboard pad Cover Footboard pad Cover Bushing Washer Cover ProLine H800 Page 7–5 Chassis: Service and Repairs 19241SL Rev A...
Page 258 9. Remove the throttle lever knob (item 2 in Figure 142). 10. Remove the 3 screws (item 1 in Figure 142) that secures the left console to the fairing. 11. Lift the console and set it aside. Chassis: Service and Repairs Page 7–6 ProLine H800 19241SL Rev A...
Page 259 8. Install the bushing (8) onto the steering control valve and secure with the washer (6) and socket head screw (5). 9. Install the washer (2) and steering wheel (1) onto the steering column and secure with a new pin (7). ProLine H800 Page 7–7 Chassis: Service and Repairs 19241SL Rev A...
Page 260: Steering Column
Bolt Socket head screw Bushing Bracket Steering control valve Washer Electronic control unit Shaft key Washer Washer Hinge Nylon bushing Bolt Thread insert Operator platform Handle Support Bushing Bolt Chassis: Service and Repairs Page 7–8 ProLine H800 19241SL Rev A...
Page 261 8. Install the bushing (6) onto the steering control valve and secure with the washer (4) and socket head screw (3). 9. Install the washer (7) and steering wheel (1) onto the steering column and secure with a new pin (5). ProLine H800 Page 7–9 Chassis: Service and Repairs 19241SL Rev A...
Page 262: Lift Arms
Lift cylinder Bushing Breather cap Bushing Lift arm assembly RH Lift arm LH Lever Grease fitting Lift arm assembly LH Bolt Rubber washer Spring pin Screw Support Plastic washer Chassis: Service and Repairs Page 7–10 ProLine H800 19241SL Rev A...
Page 263 7. After assembly is completed, raise and lower the cutting deck to verify that the hydraulic hoses and fittings do not contact anything. 8. Check the height-of-cut and leveling of mover deck; refer to the Operator’s Manual. ProLine H800 Page 7–11 Chassis: Service and Repairs 19241SL Rev A...
Page 264: Traction Pedal
Operator’s Manual. 3. For assembly purposes, label the electrical wire harness connectors. Disconnect the machine wire harness connectors from the micro switches. Chassis: Service and Repairs Page 7–12 ProLine H800 19241SL Rev A...
Page 265 Operator’s Manual. Make sure that the traction rod does not contact anything through both forward and reverse directions. 7. Connect positive battery cable from battery terminal and then connect negative cable to battery; refer to Operator’s Manual. ProLine H800 Page 7–13 Chassis: Service and Repairs 19241SL Rev A...
Page 266: Brake Pedal
Cotter pin Washer Spacer Spacer Bushing Brake pedal Rubber pad Fork Bolt Column Pulley Brake pedal cap Bracket Brake cable Bolt Washer Snap ring Bolt Operator platform Solenoid valve Camshaft Chassis: Service and Repairs Page 7–14 ProLine H800 19241SL Rev A...
Page 267 Manual. Make sure that the brake pedal does not contact anything through both forward and reverse directions. 6. Connect positive battery cable from battery terminal and then connect negative cable to battery; refer to Operator’s Manual. ProLine H800 Page 7–15 Chassis: Service and Repairs 19241SL Rev A...
Page 268: Operator Seat
Figure 148 Seat switch connector Bushing Operator platform Seat Seat support Rubber pad Socket head screw Washer Column Washer Socket head screw Snap ring Bolt Bolt Seat hook Washer Spring Chassis: Service and Repairs Page 7–16 ProLine H800 19241SL Rev A...
Page 269 (5), washers (10) and nuts (11). 3. Connect the seat electrical connector to the machine wire harness (Figure 149). 4. Connect the battery negative cable from the battery; refer to Operator’s Manual. ProLine H800 Page 7–17 Chassis: Service and Repairs 19241SL Rev A...
Page 270: Servicing The Operator Seat
Housing of the seat level indicator Seat switch with cable Backrest frame Cover Bushing Switch plate Compression springs For servicing the operator seat, see the Grammer Seats Repair Manual. Chassis: Service and Repairs Page 7–18 ProLine H800 19241SL Rev A...
Page 271: Frame Assembly
Washer Bolt Front engine cover Bracket Tow bar Screw Bolt Magnet Hood Bracket Rubber plug Screw Disassemble and assemble the frame assembly using the Figure 151 as a guide. ProLine H800 Page 7–19 Chassis: Service and Repairs 19241SL Rev A...
Page 272 Chassis: Service and Repairs Page 7–20 ProLine H800 19241SL Rev A...
Page 273 Electric Clutch ..........................8–15 PTO Driveshaft ..........................8–17 Servicing the Driveshaft ........................8–20 PTO Shaft Assembly........................8–22 Servicing the PTO Shaft Assembly ....................8–24 Servicing the Gearbox Assembly ..................... 8–26 ProLine H800 Page 8–1 Axle and PTO 19241SL Rev A...
Page 274: General Information
The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your machine. Refer to the Operator’s Manual for additional information when servicing the machine. Axle and PTO: General Information Page 8–2 ProLine H800 19241SL Rev A...
Page 275: Service And Repairs
2. Block the wheels with chocks to prevent the machine from moving. 3. Remove the front wheel; refer to Removing the Wheels (page 7–3). Make sure that the machine is raised and supported with appropriate jack stands. ProLine H800 Page 8–3 Axle and PTO: Service and Repairs 19241SL Rev A...
Page 276 12. Install the wheel assembly; refer to Installing the Wheels (page 7–4). 13. Check and adjust the brakes; refer to the Operator’s Manual. 14. Lower the machine to the ground. Axle and PTO: Service and Repairs Page 8–4 ProLine H800 19241SL Rev A...
Page 277 1. Bring the machine to full speed and apply the brakes to rapidly stop the machine without skidding or locking up the wheels. 2. Repeat this procedure 10 times. To avoid the overheating the brakes, wait 1 minute between each stop. ProLine H800 Page 8–5 Axle and PTO: Service and Repairs 19241SL Rev A...
Page 278: Rear Axle Assembly
1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Block the front wheels with chocks to prevent the machine from moving. Axle and PTO: Service and Repairs Page 8–6 ProLine H800 19241SL Rev A...
Page 279 10. Lubricate all the grease fittings in the rear axle assembly. 11. Check and adjust the rear wheel alignment; refer to Operator’s Manual. 12. Check and adjust the rear wheel toe-in; refer to Operator’s Manual. ProLine H800 Page 8–7 Axle and PTO: Service and Repairs...
Page 280 Adjust if necessary. 17. Operate the machine and check for hydraulic-fluid leaks, repair any leaks as necessary. Axle and PTO: Service and Repairs Page 8–8 ProLine H800 19241SL Rev A...
Page 281: Servicing The Rear Axle
5. Press the new bushings (8) into the rear axle (6). Bushing (6) must be flush with the axle tube after installation. 6. Install the rear axle onto the machine; refer to Installing the Rear Axle (page 8–7). ProLine H800 Page 8–9 Axle and PTO: Service and Repairs 19241SL Rev A...
Page 282 5. Press the bushings (5) into the rear axle (6) bore. Press the bushing (6) into the bore until the flange shoulder bottoms on the bore. 6. Install the rear axle onto the machine; refer to Installing the Rear Axle (page 8–7). Axle and PTO: Service and Repairs Page 8–10 ProLine H800 19241SL Rev A...
Page 283: Steering Spindle
1. Park the machine on a level surface, lower the cutting deck, shut off the engine, and remove the key from the key switch. 2. Block the wheels with chocks to prevent the machine from moving. ProLine H800 Page 8–11 Axle and PTO: Service and Repairs...
Page 284 Ensure that the tapers are free from grease, oil, rust, and dirt. Do not use anti-seize lubricant, when you install the tie rod end. Axle and PTO: Service and Repairs Page 8–12 ProLine H800 19241SL Rev A...
Page 285 Adjust if necessary. 16. Operate the machine and check for hydraulic-fluid leaks, repair any leaks as necessary. ProLine H800 Page 8–13 Axle and PTO: Service and Repairs 19241SL Rev A...
Page 286: Pto Drive Belt
Flange bushing Bearing Bolt Grease fitting Pulley Washer PTO belt Bracket Spring guide Note: Refer to Operator’s Manual for information regarding PTO drive belt removal, installation and adjustment. Axle and PTO: Service and Repairs Page 8–14 ProLine H800 19241SL Rev A...
Page 287: Electric Clutch
6. Locate and retrieve the woodruff key (7). 7. If required, remove the drive shaft (10) from the engine (11) by removing the 3 bolts (8) and washers (9). ProLine H800 Page 8–15 Axle and PTO: Service and Repairs 19241SL Rev A...
Page 288 6. Check the PTO belt tension; refer to Operator’s Manual. 7. Check and adjust the electric clutch gap; refer to Operator’s Manual. 8. Connect the machine wire harness to the electric clutch. Axle and PTO: Service and Repairs Page 8–16 ProLine H800 19241SL Rev A...
Page 289: Pto Driveshaft
Shaft Washer Socket head screw Dust flange Washer Shaft key Bolt Bushing Drive shaft Fork Washer Flange bushing Washer Bracket Grease fitting Bracket Bolt Polyethylene tube protector ProLine H800 Page 8–17 Axle and PTO: Service and Repairs 19241SL Rev A...
Page 290 4. Remove the PTO drive shaft (16) with polyethylene tube protector (20) from the machine. 5. If necessary, remove the PTO drive shaft (16) from the polyethylene tube protector (20) using the Figure 158 as a guide. Axle and PTO: Service and Repairs Page 8–18 ProLine H800 19241SL Rev A...
Page 291 8. Close the universal joint cover (item 1 in Figure 159) and secure with the quarter turn fastener. 9. Lubricate the PTO driveshaft grease fittings; refer to Operator’s Manual. ProLine H800 Page 8–19 Axle and PTO: Service and Repairs 19241SL Rev A...
Page 292: Servicing The Driveshaft
4. Clean the driveshaft yoke (5) and end yoke (1). 5. Inspect the driveshaft yoke (5) and end yoke (1) for wear, pitting or other noticeable damage. Replace the parts that are worn or damaged. Axle and PTO: Service and Repairs Page 8–20 ProLine H800 19241SL Rev A...
Page 293 If binding continues, disassemble the joint to identify the source of binding. 3. Install the PTO driveshaft onto the machine; refer to Installing the PTO Driveshaft (page 8–19). ProLine H800 Page 8–21 Axle and PTO: Service and Repairs 19241SL Rev A...
Page 294: Pto Shaft Assembly
Belt tension lever Washer Flange bushing Bushing Bolt Grease fitting Retaining ring Bolt Washer Bearing Pulley PTO belt Spring guide Washer Bracket Spring Washer Spring Belt tension indicator Bolt Axle and PTO: Service and Repairs Page 8–22 ProLine H800 19241SL Rev A...
Page 295 7. Check and adjust the PTO belt tension; refer to Operator’s Manual. 8. Install the PTO driveshaft to machine; refer to Installing the PTO Driveshaft (page 8–19). ProLine H800 Page 8–23 Axle and PTO: Service and Repairs 19241SL Rev A...
Page 296: Servicing The Pto Shaft Assembly
6. Remove the retaining ring (10) that secures the bearing (11) to the pulley (12). Use a press to remove the bushing (9) and bearing (11) from the pulley (12). Discard the bearing (11). Axle and PTO: Service and Repairs Page 8–24 ProLine H800 19241SL Rev A...
Page 297 7. Install the pulley (12) onto the belt tension lever (8) and secure with the bolt (7), washer (14) and nut (13). 8. Install the PTO shaft assembly onto the machine; refer to Installing the PTO Shaft Assembly (page 8–23). ProLine H800 Page 8–25 Axle and PTO: Service and Repairs 19241SL Rev A...
Page 298: Servicing The Gearbox Assembly
Cover Retaining ring Retaining ring Seal Gearbox housing Retaining ring Bearing Cover Note: For removing and installing the gearbox from the machine, refer to the Operator’s Manual. Axle and PTO: Service and Repairs Page 8–26 ProLine H800 19241SL Rev A...
Page 299 18. Discard the bearings, seals, caps and covers of the gearbox assembly. 19. Clean the gearbox components and inspect for wear or damage. Replace the components that are worn or damaged. ProLine H800 Page 8–27 Axle and PTO: Service and Repairs...
Page 300 15. Install the new caps (2 and 32) and new covers (1 and 33) onto the gearbox housing (21). 16. Fill the gearbox with the gearbox oil; refer to Operator’s Manual. Axle and PTO: Service and Repairs Page 8–28 ProLine H800 19241SL Rev A...
Page 301 Table of Contents General Information ..........................9–2 Service and Repairs ..........................9–3 Hopper Assembly..........................9–3 Hopper Frame Assembly ........................9–5 Hopper ............................... 9–8 Hopper Lift Frame Assembly......................9–10 Chute Assembly..........................9–13 ProLine H800 Page 9–1 Hopper Assembly 19241SL Rev A...
Page 302: General Information
General Information The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your machine. Refer to the Operator’s Manual for additional information when servicing the machine. Hopper Assembly: General Information Page 9–2 ProLine H800 19241SL Rev A...
Page 303: Service And Repairs
3. Support the hydraulic actuators (8) before loosening the mounting fasteners. 4. Remove the nut (10) and bolt (9) that secures the hydraulic cylinder to the hopper assembly. ProLine H800 Page 9–3 Hopper Assembly: Service and Repairs 19241SL Rev A...
Page 304 9. Lubricate the grease fittings; refer to Operator’s Manual. 10. Check for correct operation of the hopper assembly and adjust the hopper assembly sensor; refer to Operator’s Manual. Hopper Assembly: Service and Repairs Page 9–4 ProLine H800 19241SL Rev A...
Page 305: Hopper Frame Assembly
Grass catcher screen Washer Plate Spring pin Rivet Inside grass catcher screen Washer Bracket Bolt Rivet Carriage bolt Cross rail Chain Washer Hopper screen gasket Washer Grass catcher plastic panel ProLine H800 Page 9–5 Hopper Assembly: Service and Repairs 19241SL Rev A...
Page 306 Flange bushing Washer Spacer Screw Support Washer Decal Spring Bolt Screw Washer Bolt Washer Split pin Connecting rod Handle Plastic cap Frame Rivet Collar Rivet Bracket Grass catcher screen Hopper Assembly: Service and Repairs Page 9–6 ProLine H800 19241SL Rev A...
Page 307 5. Lubricate the grease fittings; refer to Operator’s Manual. 6. Check for correct operation of the hopper assembly and adjust the hopper assembly sensor; refer to Operator’s Manual. ProLine H800 Page 9–7 Hopper Assembly: Service and Repairs 19241SL Rev A...
Page 308: Hopper
Manifold Bolt Washer Connector pin Washer Eye end Connector Bearing Washer Wire harness Spreader support Body Connecting rod Union fitting Spacer Bolt Plastic nut Retaining ring Support Screw Hopper Assembly: Service and Repairs Page 9–8 ProLine H800 19241SL Rev A...
Page 309 5. Lubricate the grease fittings; refer to Operator’s Manual. 6. Check for correct operation of the hopper assembly and adjust the hopper assembly sensor; refer to Operator’s Manual. ProLine H800 Page 9–9 Hopper Assembly: Service and Repairs 19241SL Rev A...
Page 310: Hopper Lift Frame Assembly
Hopper Lift Frame Assembly g291439 Figure 170 Hopper Assembly: Service and Repairs Page 9–10 ProLine H800 19241SL Rev A...
Page 311 5. Disassemble the hopper lift frame assembly using the Figure 170 Figure as a guide. g291460 Figure 171 LH Bracket Bolt Chassis Washer ProLine H800 Page 9–11 Hopper Assembly: Service and Repairs 19241SL Rev A...
Page 312 8. Check the hydraulic fluid level in the hydraulic tank; refer to Operator’s Manual. 9. Check for correct operation of the hopper lift frame assembly. 10. Check the hydraulic cylinder connections for leaks. Hopper Assembly: Service and Repairs Page 9–12 ProLine H800 19241SL Rev A...
Page 313: Chute Assembly
Assembling the Chute Assembly 1. Assemble the chute assembly using the Figure 172 as a guide. 2. Install the chute assembly onto the machine; refer to Operator’s Manual. ProLine H800 Page 9–13 Hopper Assembly: Service and Repairs 19241SL Rev A...
Page 314 Hopper Assembly: Service and Repairs Page 9–14 ProLine H800 19241SL Rev A...
Page 315 Blade Spindle........................... 10–7 Servicing the Blade Spindle ......................10–9 Caster Wheel and Flat Frame Assembly ..................10–12 Cutting Deck Rollers and Skids...................... 10–14 Height Of Cut Linkage........................10–16 Cutting Deck Covers ........................10–18 ProLine H800 Page 10–1 Cutting Unit 19241SL Rev A...
Page 316: General Information
General Information The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your machine. Refer to the Operator’s Manual for additional information when servicing the machine. Cutting Unit: General Information Page 10–2 ProLine H800 19241SL Rev A...
Page 317: Service And Repairs
Do not work on the cutting deck or lift arms with the engine running. Always shut off the engine and remove the key from the key switch before working on the cutting deck. ProLine H800 Page 10–3 Cutting Unit: Service and Repairs...
Page 318: Idler Assembly
Idler Assembly g290658 Figure 173 Cutting Unit: Service and Repairs Page 10–4 ProLine H800 19241SL Rev A...
Page 319 Be careful when installing the idler spring. The spring is under heavy load and may cause personal injury. 4. Install the drive belt pulley; refer to Operator’s Manual. 5. Lubricate the idler arm grease fitting; refer to Operator’s Manual. ProLine H800 Page 10–5 Cutting Unit: Service and Repairs 19241SL Rev A...
Page 320 Installing the Idler Assembly (continued) 6. Attach the PTO driveshaft and install the cutting deck covers; refer to Operator’s Manual. Cutting Unit: Service and Repairs Page 10–6 ProLine H800 19241SL Rev A...
Page 321: Blade Spindle
Central blade disc RH blade disc Central blade Washer RH blade Bolt Socket head screw Bevel washer LH blade Bronze bushing Cover LH blade disc Scraper Washer Oil seal Bolt ProLine H800 Page 10–7 Cutting Unit: Service and Repairs 19241SL Rev A...
Page 322 Operator’s Manual. 7. Install the covers and PTO drive shaft onto the cutting deck; refer to Operator’s Manual. Cutting Unit: Service and Repairs Page 10–8 ProLine H800 19241SL Rev A...
Page 323: Servicing The Blade Spindle
17) to the spindle shaft. 3. Slide and remove the pulley from the spindle shaft. 4. Locate and retrieve the shaft key (8). 5. Remove the cover (6) from the spindle hub. ProLine H800 Page 10–9 Cutting Unit: Service and Repairs 19241SL Rev A...
Page 324 11. Secure the pulley (5 or 17) with the thrust washer (4), seal (3) and bolt (2). 12. Install the grease fitting (1) onto the bolt (2). Cutting Unit: Service and Repairs Page 10–10 ProLine H800 19241SL Rev A...
Page 325 13. Attach a hand pump grease gun to grease fitting on housing and fill housing cavity with grease. 14. Rotate the spindle shaft to make sure that it turns freely. ProLine H800 Page 10–11 Cutting Unit: Service and Repairs 19241SL Rev A...
Page 326: Caster Wheel And Flat Frame Assembly
2. Disassemble the caster wheel as needed using the Figure 177 as a guide. 3. Disassemble the flat frame assembly as needed using the Figure 177 a guide. Cutting Unit: Service and Repairs Page 10–12 ProLine H800 19241SL Rev A...
Page 327 Figure 177 as a guide. 2. Assemble the caster wheel using the Figure 177 as a guide. 3. Check and level the cutting deck; refer to Operator’s Manual. ProLine H800 Page 10–13 Cutting Unit: Service and Repairs 19241SL Rev A...
Page 328: Cutting Deck Rollers And Skids
1. Install the skids to the cutting deck using the Figure 178 as a guide. Ensure to install the skids in the same mounting hole height position (lower or upper). Cutting Unit: Service and Repairs Page 10–14 ProLine H800 19241SL Rev A...
Page 329 Ensure to install the cutting deck rollers in the same mounting hole height position (lower or upper). 3. Check and adjust the level of the cutting deck; refer to Operator’s Manual. ProLine H800 Page 10–15 Cutting Unit: Service and Repairs...
Page 330: Height Of Cut Linkage
Height Of Cut Linkage g291013 Figure 179 Cutting Unit: Service and Repairs Page 10–16 ProLine H800 19241SL Rev A...
Page 331 2. Lubricate the grease fittings. 3. Check and adjust the level of the cutting deck; refer to Operator’s Manual. 4. Check and adjust the Height Of Cut pointer; refer to Operator’s Manual. ProLine H800 Page 10–17 Cutting Unit: Service and Repairs...
Page 332: Cutting Deck Covers
2. Remove the cutting deck covers from the cutting deck; refer to Operator’s Manual. 3. Disassemble the cutting deck covers using the Figure 180 as a guide. Cutting Unit: Service and Repairs Page 10–18 ProLine H800 19241SL Rev A...
Page 333 Assembling the Cutting Deck Covers 1. Assemble the cutting deck covers using the Figure 180 as a guide. 2. Install the cutting deck covers onto the cutting deck; refer to Operator’s Manual. ProLine H800 Page 10–19 Cutting Unit: Service and Repairs 19241SL Rev A...
Page 334 Cutting Unit: Service and Repairs Page 10–20 ProLine H800 19241SL Rev A...
Page 335 Foldout Drawings Table of Contents Electrical Drawing Designations......................A–2 Hydraulic Schematic ..........................A–3 Electrical Schematic - Main........................A–5 Electrical Schematic - Lights ......................A–6 Wire Harness Diagram - Main ......................A–7 Wire Harness Diagram - Lights ......................A–8 ProLine H800 Page A–1 Foldout Drawings 19241SL Rev A...
Page 336: Electrical Drawing Designations
Y or YE YELLOW Numerous harness wires used on the Toro machines include a line with an alternate color. These wires are identified with the wire color and line color with either a / or _ separating the color abbreviations listed above (e.g., R/BK is a red wire with a black line, OR_BK is an orange wire with a black line).
Page 337: Hydraulic Schematic
Hydraulic Schematic g295174 ProLine H800, Drawing Rev , Sheet 1 of 1 19241SL Rev A Page A–3...
Page 338 Page A–4 19241SL Rev A , Drawing Rev , Sheet...
Page 339: Electrical Schematic - Main
Electrical Schematic - Main g295173 ProLine H800, Drawing 122-1361 Rev A, Sheet 1 of 2 19241SL Rev A Page A–5...
Page 340: Electrical Schematic - Lights
Electrical Schematic - Lights g295813 Page A–6 19241SL Rev A ProLine H800, Drawing 122-1361 Rev A, Sheet 2 of 2...
Page 341: Wire Harness Diagram - Main
Wire Harness Diagram - Main g295223 ProLine H800, Drawing Rev , Sheet 1 of 2 19241SL Rev A Page A–7...
Page 342: Wire Harness Diagram - Lights
Wire Harness Diagram - Lights g295814 Page A–8 19241SL Rev A ProLine H800, Drawing Rev , Sheet 2 of 2...

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Toro ProLine H800 Service Manual

Table of Contents

Chapter 1 :Safety

Table of Contents

Chapter 2 :Specificationsandmaintenance

Table of Contents

Chapter 3 :Troubleshooting

General Information/Service and Repairs

Chapter 4: Engine

Table of Contents

Chapter 5 :Hydraulicsystem

Table of Contents

Chapter 6: Electrical System

General Information/Service and Repairs

Chapter 7 :Chassis

General Information/Service and Repairs

Chapter 8 :Axleandpto

General Information/Service and Repairs

Chapter 9 :Hopperassembly

Chapter 10 :Cuttingunit

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Summary of Contents for Toro ProLine H800