Page 1 Serial No. 403430001 and Up) (Model No. 03171 Serial No. 403430001 and Up) (Model No. 03174 Serial No. 400000000 and Up) © 2021—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. 05/2021 Revision History Page 2 Reelmaster ® 3100-D/3105-D 20252SL 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 servicemanuals@toro.com...
Page 4 NOTES NOTES Page 4 Reelmaster ® 3100-D/3105-D 20252SL Rev A...
Page 5 Service Manual for reference. Additional copies of the Operator’s Manuals, Installation Instructions 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 g341979 Figure 1 Preface Page 6 Reelmaster ® 3100-D/3105-D 20252SL Rev A...
Page 7 Service Procedure Icons The following icons appear throughout this Service Manual to bring attention to specific important details of a service procedure. Critical Process This icon is used to highlight: • installing safety equipment (shields, guards, seat belts, brakes and R.O.P.S. components) that may have been removed.
Page 8: Table Of Contents
Table of Contents Preface ........................ 5 Chapter 1: Safety .................... 1–1 Safety Instructions ..................1–2 Safety and Instructional Decals ..............1–9 Chapter 2: Specifications and Maintenance ............ 2–1 Specifications ....................2–2 Torque Specifications ................... 2–5 Shop Supplies .................... 2–11 Special Tools ....................2–13 Chapter 3: Troubleshooting ................
Page 9: Preface
EATON MEDIUM DUTY PISTON PUMP REPAIR INFORMATION MODEL 70160 VARIABLE DISPLACEMENT PISTON PUMP DANFOSS STEERING UNIT TYPE OSPM SERVICE MANUAL Reelmaster ® 3100-D/3105-D Page 9 Preface 20252SL Rev A...
Page 10 Preface Page 10 Reelmaster ® 3100-D/3105-D 20252SL Rev A...
Page 11 Chapter 1 Safety Table of Contents Safety Instructions ..........................1–2 Supervisor’s Responsibilities ......................1–2 Before Operating the Machine ......................1–3 While Operating the Machine ......................1–4 Maintenance and Service........................1–6 Jacking Instructions ........................... 1–7 Safety and Instructional Decals ......................1–9 Reelmaster ®...
Page 12: Safety Instructions
Safety Instructions The Reelmaster 3100-D/3105-D (Models 03170, 03171 and 03174) machine is 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, these factors are also dependent on the awareness, concern, and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine.
Page 13: Before Operating The Machine
Become familiar with the controls and know how to stop the machine quickly. Additional copies of the Operator’s Manuals are available at www.toro.com. • Keep all the shields, safety devices, and decals in place. If a shield, safety device, or decal is illegible or damaged, repair or replace it before operating the machine.
Page 14: While Operating The Machine
While Operating the Machine 1. Do not run the engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and could be deadly. 2. Sit on the seat when starting and operating the machine. 3. Check interlock switches daily for proper operation (see Chapter 6: Electrical System (page 6–1)).
Page 15 While Operating the Machine (continued) 14. Do not touch engine, muffler, exhaust pipe or hydraulic tank while engine is running or soon after it has stopped because these areas could be hot enough to cause burns. 15. If a cutting unit strikes a solid object or vibrates abnormally, stop immediately. Turn engine off, wait for all motion to stop and inspect for damage.
Page 16: Maintenance And Service
11. Engine must be shut off before checking oil or adding oil to the crankcase. 12. To insure optimum performance and safety, use genuine TORO replacement parts and accessories. Replacement parts and accessories made by other manufacturers could be dangerous, and such use could void the product warranty of The Toro Company.
Page 17: Jacking Instructions
Jacking Instructions CAUTION When changing attachments, tires, or performing other service, use correct blocks, hoists, and jacks. Make sure machine is parked on a solid level floor such as a concrete floor. Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine.
Page 18 Jacking the Rear End (continued) g341982 Figure 4 Frame Rear fork Rear wheel motor 1. The preferred method of lifting the rear end of the machine for removing the rear fork or the rear wheel motor: A. Secure a chain fall or hoist to the rear casting (Figure B.
Page 19: Safety And Instructional Decals
Numerous safety and instruction decals are affixed to the traction unit and cutting units of your Reelmaster. 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. Reelmaster ®...
Page 20 Safety: Safety and Instructional Decals Page 1–10 Reelmaster ® 3100-D/3105-D 20252SL Rev A...
Page 21 Chapter 2 Specifications and Maintenance Table of Contents Specifications ............................2–2 Overall Dimensions..........................2–2 Engine..............................2–2 Hydraulic System ..........................2–3 Wheels and Brakes ..........................2–3 DPA Cutting Units ..........................2–4 Torque Specifications ........................... 2–5 Calculating the Torque Values When Using a Drive-Adapter Wrench ..........2–6 Identifying the Fastener........................
Page 22: Specifications
Specifications Overall Dimensions g341991 Figure 5 Engine Item Description Make / Designation Kubota, 4−Cycle, 3 Cylinder, Water Cooled, Diesel Engine Horse Power 21.5 HP @ 2500 RPM Bore mm (in.) 78.0 mm (3.07 in) Stroke mm (in.) 78.4 mm (3.09 in) Total Displacement cc (cu.
Page 23: Hydraulic System
Engine (continued) Item Description Crankcase Oil Capacity liters (U.S. 3.8 L (4.0 qt) with Filter qt.) Starter 12 VDC, 1 KW Alternator/Regulator 12 VDC 40 AMP Dry Weight kilograms (U.S. lbs) 93 kg (205 lb) Coolant Capacity liters (U.S. qt.) 5.7 L (6.0 qt) with 0.9 L (1.0 qt) Reservoir Hydraulic System Item...
Page 24: Dpa Cutting Units
69 kg (152 lb.) 32” Reel, 8 Blade 74 kg (163 lb.) Options: Refer to the Cutting Unit Parts Catalog or contact your local Authorized Toro Distributor for available cutting unit options. Specifications and Maintenance: Specifications Page 2–4 Reelmaster ®...
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: Calculating The Torque Values When Using A Drive-Adapter Wrench
Calculating the Torque Values When Using a Drive-Adapter Wrench g205924 Figure 6 Torque Conversion Factor = A / B Torque wrench A (effective length of torque wrench) Drive-adapter wrench (crowsfoot) B (effective length of torque wrench and drive-adapter wrench) Using a drive-adapter wrench (e.g., crowfoot wrench) in any position other than 90°...
Page 27: Identifying The Fastener
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 28: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Inch Series)
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, 5 SAE Grade 1 Bolts, Screws, SAE Grade 5 Bolts, Screws, SAE Grade 8 Bolts, Screws, and 8 with Studs, and Sems with Studs, and Sems with Studs, and Sems with Thin Height Regular Height Nuts...
Page 29: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Metric Fasteners)
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws, and Class 10.9 Bolts, Screws, and Thread Size Studs with Regular Height Nuts Studs with Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts) M5 X 0.8 57 ±...
Page 30: Other Torque Specifications
Other Torque Specifications SAE Grade 8 Steel Set Screws Recommended Torque Thread Size Square Head Hex Socket 1/4 - 20 UNC 140 ± 20 in-lb 73 ± 12 in-lb 5/16 - 18 UNC 215 ± 35 in-lb 145 ± 20 in-lb 3/8 - 16 UNC 35 ±...
Page 31: Shop Supplies
Shop Supplies The procedures found in this Service Manual may recommend the use of commonly used shop supplies (lubricants, sealants and adhesives). A symbol denoting the use of a shop supply may appear in figures that support a procedure. Always refer to the written procedure for specific information regarding the type and the application of a shop supply.
Page 32 GASKET COMPOUND Used to create a seal between mating parts. Gasket compounds may be used with or without the presence of a pre-formed gasket. Gasket compounds may be solvent or silicone based, and cure when exposed to air or designed to cure in an air-less environment (anaerobic). Most gasket compounds are designed to be applied to clean surfaces free of oil, chemical residue and previously used gaskets or gasket compounds.
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 Hydraulic Test Fitting Kit K-Line Part No. TOR4079 This kit includes a variety of O-ring face seal fittings to let you connect the test gauges into the system. FITTING TYPE SIZE PART NUMBER 4 ORFS (9/16–18) TOR4079–3 6 ORFS (11/16–16) TOR4079–12 8 ORFS (13–16–16) TOR4079–4...
Page 36 Note: This kit does not include the hydraulic hoses; refer to Hydraulic Hose Kit (page 2–14). Note: The replacement filter element is Toro Part No. TOR6012. The filter element canister tightening torque is 34 N∙m (25 ft-lb). Remote Starter Switch After flushing the hydraulic system or replacing a hydraulic component (e.g.
Page 37 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 38 2. Used for height-of-cut adjustment Bedknife Screw Tool K-Line Part No. TOR510880 This screwdriver-type bit is made to fit Toro bedknife attaching screws. Use this bit with a torque wrench to secure the bedknife to the bedbar. IMPORTANT Important: To prevent...
Page 39 Spindle Plug K-Line Part No. 94-2703 This spindle plug can be used to prevent contaminant entry into the cutting reel spindle assembly when the hydraulic motor is removed from the spindle. Measuring Container K-Line Part No. TOR4077 Use this container to test hydraulic motor efficiency (motors with case drain lines only).
Page 40 Cutting Unit Kickstand Toro Part No. 119-8010-03 The cutting unit kickstand is used to prop up the rear of the cutting unit during service. Use of this tool stabilizes the cutting unit and...
Page 41 This tool should be used with the Toro Guide to Evaluation Reel Mower Performance and Using the Turf Evaluator (Toro Part No. 97931SL).
Page 42 Cutting Performance Paper Toro Part No. 125–5610 (300 strips) Cutting performance paper is used to test the cutting reel performance after adjusting the reel to bedknife clearance. 10 packs (30 strips per pack) of cutting performance paper are included in this part number.
Page 43 Angle Indicator and Magnetic Mount Angle Indicator: Toro Part No. 131–6828 Magnetic Mount: Toro Part No. 131–6829 Because the top grind angle on bedknives is critical for edge retention, and therefore after-cut appearance, Toro has develop these service tools for accurately measuring the top grind angle on all bedknives.
Page 44 Specifications and Maintenance: Special Tools Page 2–24 Reelmaster ® 3100-D/3105-D 20252SL Rev A...
Page 45 Chapter 3 Troubleshooting Table of Contents GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems ......3–2 Gather Information ..........................3–2 Evaluate Potential Causes ......................... 3–2 Assess Performance.......................... 3–2 Repair ..............................3–2 Solution Confirmation......................... 3–2 General Hydraulic System Problems ..................... 3–3 General Hydraulic System Problems ....................
Page 46: Gears - The Systematic Approach To Defining, Diagnosing And Solving Problems
GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems Gather Information • Information reported by the customer • Information observed by you • Establish the what, where and when of the issue Evaluate Potential Causes • Consider possible causes of the problem to develop a hypothesis •...
Page 47: General Hydraulic System Problems
General Hydraulic System Problems The charts that follow contain suggestions that can be used to assist in diagnosing hydraulic system performance issues. The suggestions are not all−inclusive. Also, consider that there may be more than one cause for a machine problem. Review the hydraulic schematic and information on hydraulic system operation in the Hydraulic Flow Diagrams in Hydraulic System chapter.
Page 48: Traction Circuit Problems
Traction Circuit Problems Problem Possible Causes Traction response is sluggish. Bypass valve in the traction pump/hydrostat is open or defective. Charge pressure is low. Hydraulic oil is very cold. Towing by−pass valve is open or worn. Brake is not released. Traction pump or wheel motor(s) are worn or damaged.
Page 49: Steering Circuit Problems
Steering Circuit Problems Problem Possible Causes Steering inoperative or sluggish. Oil level in hydraulic reservoir is low. Note: Other hydraulic systems are affected as well. Steering components (e.g. steering fork assembly, steering cylinder ends) are worn or binding. Relief valve in steering control valve is damaged −...
Page 50: Electrical System Problems
Electrical System Problems CAUTION Remove all the jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. For the effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components that are used on this machine;...
Page 51: General Run And Transport Problems
Starting Problems (continued) Problem Possible Causes The glow circuit does not operate properly. Wiring in the glow circuit (see B Electrical Schematic (page A–6)) is loose, corroded, or damaged. The glow relay or glow plug controller is faulty. Fuse F4 is blown or faulty. Engine cranks (but should not) with the reel The reel on/off switch is faulty or short circuited.
Page 52: Cutting Unit Operating Problems
Cutting Unit Operating Problems Problem Possible Causes The cutting units will not run with the transport Wiring to the reel drive circuit is (see mow switch in MOW and the reel on/off switch Electrical Schematic (page A–6)) is loose, in ON with the cutting units lowered. corroded, or damaged.
Page 53: Factors That Can Affect Cutting Performance
Note: For additional information regarding cutting unit troubleshooting, a number of Reel Mower and Aftercut Appearance General Training Books can be found on the Service Reference Set available from your Authorized Toro Distributor. Factor Possible Problem/Correction Tire pressure Check tire pressure of all traction unit tires.
Page 54 Factor Possible Problem/Correction Height-of-cut “Effective” or actual height-of-cut depends on the cutting unit weight and turf conditions. Effective height-of-cut will be different from the bench set height-of-cut. See Height-of-Cut Adjustment in the Cutting Unit Operator’s Manual. Proper bedknife selection for height-of-cut desired If the bedknife is incorrect for effective height-of-cut, poor quality of cut will result.
Page 55: Factors Affecting Grooming
Factors Affecting Grooming There are a number of factors that can affect the performance of grooming. These factors vary for different golf courses and from green to green. It is important to inspect the turf frequently and vary the grooming practice with turf needs.
Page 56: Grooming Reel Mechanical Problems
Grooming Reel Mechanical Problems Problem Possible Causes Correction No rotation of the grooming Groomer drive gears are worn Inspect groomer drive reel. or damaged. assembly and replace damaged drive components. The groomer drive is in Engage groomer drive to Neutral. Forward or Reverse.
Page 57: Chapter 4: Engine
Chapter 4 Engine Table of Contents General Information ..........................4–2 Operator’s Manual ..........................4–2 Kubota Workshop Manual........................4–2 Service and Repairs ..........................4–3 Air Cleaner Assembly......................... 4–3 Exhaust System ..........................4–6 Fuel System ............................4–8 Radiator and Oil Cooler Assembly ....................4–11 Engine..............................
Page 58: General Information
Service and repair parts for Kubota diesel engines are supplied through your local Toro Distributor. If a parts list is not available, be sure to provide your distributor with the Toro model and serial number.
Page 59: Service And Repairs
Service and Repairs Air Cleaner Assembly g342251 Figure 11 Air inlet hose (upper) Bracket Compression spring Hose clamp (4 each) Air cleaner assembly Mounting band assembly Flange head bolt (3 each) Air inlet hose (lower) Lock nut Flange head bolt (2 each) Bolt Flange nut (2 each) Reelmaster...
Page 60 Removing the Air Cleaner Assembly The air cleaner body, air filter, filter cover, and burp valve should be checked daily, prior to operation. IMPORTANT Any leaks in the air cleaner system will cause serious engine damage. Make sure that all air cleaner components are in good condition and are properly secured during operation.
Page 61 Installing the Air Cleaner Assembly 1. If removed, install the air cleaner components; refer to Figure IMPORTANT Any leaks in the air filter system will cause serious engine damage. Make sure that all air cleaner components are in good condition and are properly secured during assembly.
Page 62: Exhaust System
Exhaust System g342260 Figure 13 Flange head bolt Flange head bolt Flange nut Muffler Muffler bracket Hardened washer Flange head bolt (2 each) Flange head bolt (4 each) Lock nut Nut (4 each) Exhaust guard Bolt (4 each) Lock washer (4 each) Bolt Washer (4 each) Gasket...
Page 63 Removing the Exhaust System CAUTION The muffler and exhaust pipe may be hot. To avoid possible burns, allow the engine and exhaust system to cool before working on the muffler. 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the key switch.
Page 64: Fuel System
Fuel System g342336 Figure 14 Fuel tank Bolt Hose clamp (2 each) Flange nut (2 each) Bolt Elbow fitting (2 each) Bolt (2 each) Bolt (3 each) Fuel hose Fuel hose strap Fitting Fuel hose Trim Flange head bolt (2 each) Hose clamp (2 each) Breather tube Fuel filter...
Page 65 DANGER Diesel fuel is highly flammable and explosive. A fire or an explosion from the fuel can burn you, burn other people, and damage property. • Use caution whenever you store or handle diesel fuel. • Do not smoke while filling the fuel tank. •...
Page 66 Installing the Fuel Tank 1. Position fuel tank into the machine. 2. Using labels placed during fuel tank removal, connect both fuel hoses to the tank and secure with the hose clamps and fuel hose strap; refer to Figure 3. Connect seat switch to the electrical harness. Secure seat support straps and seat to the frame with hex flange head screws;...
Page 67: Radiator And Oil Cooler Assembly
Radiator and Oil Cooler Assembly g342392 Figure 15 Flange head nut (4 each) Radiator cooler Hydraulic hose assembly Top fan shroud Flange head bolt (4 each) Reservoir mounting bracket Flange head bolts (6 each) Fitting Lower radiator hose Radiator frame assembly R clamp (2 each) Overflow bottle Bolt (2 each)
Page 68 Removing the Radiator and Oil Cooler Assembly DANGER If the radiator or engine is hot, pressurized hot coolant can escape and cause burns. Do not open the radiator cap or drain the radiator when the coolant is hot. WARNING • Ethylene-glycol antifreeze is poisonous. •...
Page 69 Removing the Radiator and Oil Cooler Assembly (continued) 11. Pull the radiator (13) carefully from the radiator frame (4). 12. Plug any openings to prevent contamination. Installing the Radiator and Oil Cooler Assembly 1. Remove any plugs from the radiator used during the removal procedures. 2.
Page 70: Engine
Engine g342465 Figure 16 Engine Engine mount (2 each) Lock washer Grommet Flange head nut (4 each) Clamp Fuel filter mount bracket Washer (2 each) Flange head bolt Nut (4 each) Flange nut (3 each) Pulley Throttle cable stop Lock washer Bolt (3 each) Throttle swivel Bolt...
Page 71 Removing the Engine 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the key switch. 2. Open and remove the engine hood from the machine. Slide seat all the way forward. 3.
Page 72 Removing the Engine (continued) g008918 Figure 17 Throttle cable g342501 Figure 18 Glow plug wire Fuel hose Fuel stop solenoid Front lift tab g342502 Figure 19 Temp. warning switch Rear lift tab Engine: Service and Repairs Page 4–16 Reelmaster ® 3100-D/3105-D 20252SL Rev A...
Page 73 Removing the Engine (continued) g342503 Figure 20 Temp. shutdown switch Low oil press. switch Alternator 8. Disconnect wire harness and electrical wires from the following: A. Engine grounds to the battery and wire harness. B. Glow plug bus and fuel stop solenoid; refer to Figure C.
Page 74 Removing the Engine (continued) IMPORTANT Make sure not to damage the engine, fuel and hydraulic lines, electrical harness, or other parts while removing the engine. 14. Remove engine slowly from the machine. 15. Separate hydrostat and pump mount plate from the engine as follows: Note: The cap screw next to the torsion spring does not have a flat washer with it.
Page 75 Installing the Engine (continued) CAUTION One person should operate lift or hoist while the other person guides the engine into the machine. IMPORTANT Make sure not to damage the engine, fuel and hydraulic lines, electrical harness, or other parts while installing the engine. 3.
Page 76 Installing the Engine (continued) 20. Install engine hood to the machine. Close and latch hood. 21. Adjust traction drive for neutral (see Adjust traction Drive for Neutral in Operator’s Manual). Engine: Service and Repairs Page 4–20 Reelmaster ® 3100-D/3105-D 20252SL Rev A...
Page 77 Chapter 5 Hydraulic System Table of Contents General Information ..........................5–3 Operator’s Manual ..........................5–3 Relieving Hydraulic System Pressure ....................5–3 Traction Circuit (Closed Loop) Component Failure................5–3 Hydraulic Hoses..........................5–5 Installing Hydraulic Hoses and Tubes (O-Ring Face Seal Fittings) ............. 5–6 Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings)..........
Page 78 Reel Motors............................ 5–103 Servicing the Reel Motor........................ 5–106 Hydraulic Manifold Assembly ......................5–111 Servicing the Hydraulic Manifold ....................5–113 Control Valve (Models 03170 and 03174) ..................5–119 Servicing the Control Valve (Models 03170 and 03174) ..............5–121 Control Valve (Model 03171)......................5–125 Servicing the Control Valve (Model 03171) ..................
Page 79: General Information
Once the Toro high flow hydraulic filter kit has been placed in the circuit, raise and support the machine with all wheels off the ground. Then, operate the traction circuit to allow fluid flow throughout the circuit.
Page 80 If flow is reversed, debris from the filter will re−enter the traction circuit. The alternative to using the Toro high flow hydraulic filter kit after a traction circuit component failure would be to disassemble, drain and thoroughly clean all components, hydraulic tubes and hydraulic hoses in the traction circuit.
Page 81: Hydraulic Hoses
Note: If the hose has an elbow at one end, tighten the swivel nut on the elbow end before you tighten the nut on the straight end of the hose. For more hydraulic hose information, refer to the Toro Basics Series Training Book Hydraulic Hose Servicing (Part No. 94813SL).
Page 82: Installing Hydraulic Hoses And Tubes (O-Ring Face Seal Fittings)
Installing Hydraulic Hoses and Tubes (O-Ring Face Seal Fittings) g221221 Figure 22 Tube or hose Fitting body Swivel nut O-ring 1. Ensure that all the threads, the sealing surfaces of the hose/tube, and the fitting are free of burrs, nicks, scratches, or unwanted material. 2.
Page 83 Installing Hydraulic Hoses and Tubes (O-Ring Face Seal Fittings) (continued) 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 5–7). Hose/Tube Installation Torque Table Fitting Dash Size Hose/Tube Side Thread Size Installation Torque...
Page 84: Installing The Hydraulic Fittings (Sae Straight Thread O-Ring Fittings)
Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) Installing a Non-Adjustable Fitting 1. Ensure that all the threads, the sealing surfaces of fitting, and the component port are free of burrs, nicks, scratches, or unwanted material. 2. To help prevent a hydraulic leak, replace the O-ring when you open the connection.
Page 85 Installing an Adjustable Fitting (continued) g221224 Figure 25 Locknut Back-up washer O-ring 3. Lightly lubricate the O-ring with clean hydraulic fluid. Ensure that the threads of the fitting are clean with no lubricant applied (Figure 25). g212225 Figure 26 Step 1: clearance the lock nut Step 3: align the fitting Step 2: seat the back-up washer Step 4: tighten the lock nut...
Page 86 Installing an Adjustable Fitting (continued) IMPORTANT Before tightening the fitting, determine the material used for the port the fitting is being installed in. Installing a fitting into an aluminum port requires reducing the installation torque. 7. Tighten the fitting lock nut (Step 4 in Figure 26): A.
Page 87: Hydraulic Schematic
Hydraulic Schematic g344527 Figure 27 Reelmaster ® 3100-D/3105-D Page 5–11 Hydraulic System: Hydraulic Schematic 20252SL Rev A...
Page 88 g344528 Figure 28 Hydraulic System: Hydraulic Schematic Page 5–12 Reelmaster ® 3100-D/3105-D 20252SL Rev A...
Page 89 g344526 Figure 29 Reelmaster ® 3100-D/3105-D Page 5–13 Hydraulic System: Hydraulic Schematic 20252SL Rev A...
Page 90: Hydraulic Flow Diagrams
Hydraulic Flow Diagrams g344707 Figure 30 Model 03171 (shown) Hydraulic System: Hydraulic Flow Diagrams Page 5–14 Reelmaster ® 3100-D/3105-D 20252SL Rev A...
Page 91: Traction Circuits
Traction Circuits The traction circuit of the hydraulic system consists of a hydrostat connected in a closed loop circuit to three orbital vane wheel motors. The mow/transport slide control on the machines has positions for mow and transport. The mow position allows traction pedal inputs that are appropriate for mow speeds by limiting the movement of the traction pedal and the piston pump swash plate.
Page 92 Traction Circuit Cooling The traction circuit is cooled by a bleed off circuit in the piston pump. The piston pump includes an internal bleed valve which allows a small amount of hydraulic fluid to pass from the return side of the pump while operating the traction unit in the forward direction.
Page 93: Reel Circuit
Reel Circuit g344710 Figure 31 Model 03171 (shown) Reelmaster ® 3100-D/3105-D Page 5–17 Hydraulic System: Hydraulic Flow Diagrams 20252SL Rev A...
Page 94 The gear pump (P1) is directly coupled to the hydrostat which is driven by the engine. Taking its suction directly from the hydraulic tank, the gear pump supplies fluid flow to the manifold block and to the reel motors. Solenoid valve (SV) is de−energized with the engine running when either the reels on/off switch is OFF, the cutting units are up, or the transport/mow switch is in TRANSPORT.
Page 95: Lift Circuit (Up)
Lift Circuit (Up) g344709 Figure 32 Model 03171 (shown) Reelmaster ® 3100-D/3105-D Page 5–19 Hydraulic System: Hydraulic Flow Diagrams 20252SL Rev A...
Page 96 Raise Cutting Units The gear pump (P2) is directly coupled to the hydrostat through gear pump (P1). It supplies hydraulic pressure (charge pressure) for raising and lowering the cutting units, operating the sidewinder unit, and replenishing the closed loop traction circuit (charge pressure). The pump takes its suction directly from the hydraulic tank.
Page 97: Lift Circuit (Down)
Lift Circuit (Down) g344708 Figure 33 Model 03171 (shown) Reelmaster ® 3100-D/3105-D Page 5–21 Hydraulic System: Hydraulic Flow Diagrams 20252SL Rev A...
Page 98 Lower Cutting Units The gear pump (P2) is directly coupled to the hydrostat through gear pump (P1). It supplies hydraulic pressure (charge pressure) for raising and lowering the cutting units, operating the sidewinder unit, and replenishing the closed loop traction circuit (charge pressure). The pump takes its suction directly from the hydraulic tank.
Page 99: Sidewinder Circuit
Sidewinder Circuit g344711 Figure 34 Model 03171 (shown) Reelmaster ® 3100-D/3105-D Page 5–23 Hydraulic System: Hydraulic Flow Diagrams 20252SL Rev A...
Page 100 The gear pump (P2) is directly coupled to the hydrostat through gear pump (P1). It supplies hydraulic pressure (charge pressure) for raising and lowering the cutting units, operating the sidewinder unit, and replenishing the closed loop traction circuit (charge pressure). The pump takes its suction directly from the hydraulic tank.
Page 101: Steering Circuit
Steering Circuit g344712 Figure 35 Model 03171 (shown) Reelmaster ® 3100-D/3105-D Page 5–25 Hydraulic System: Hydraulic Flow Diagrams 20252SL Rev A...
Page 102 The gear pump (P2) is directly coupled to the hydrostat. It supplies hydraulic pressure to the power steering valve for turning the rear wheel and maintaining 6.9 to 10.0 bar (100 to 150 PSI) to the low pressure side of the traction circuit. The pump takes its suction from the hydraulic tank.
Page 103: Testing
Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the various hydraulic circuits to perform various operational checks (refer to the Special Tools (page 2–13)).
Page 104 Precautions for Hydraulic Testing (continued) 1. Clean machine thoroughly before disconnecting or disassembling any hydraulic components. Always keep in mind the need for cleanliness when working on hydraulic equipment. Contamination can cause excessive wear or binding of hydraulic components. 2. Before testing, check control linkages for improper adjustment, binding or broken parts.
Page 105: Traction Circuit Testing − Charge Pressure Test
Traction Circuit Testing − Charge Pressure Test g344855 Figure 36 Model 03171 (shown) The charge pressure test is the first in a series of tests recommended to determine traction circuit performance. A charge pressure drop of more than 20% indicates an internal leak in the piston pump/hydrostat. Continued unit operation can generate excessive heat, cause damage to seals and other components in the hydraulic system, and affect overall machine performance.
Page 106 Traction Circuit Testing − Charge Pressure Test (continued) g344856 Figure 37 Hydraulic hose Piston pump tow valve 4. Disconnect the hydraulic hose at the piston pump/ hydrostat fitting near the tow valve. This hose comes from the mower manifold CHG port (Figure 37).
Page 107 Traction Circuit Testing − Charge Pressure Test (continued) 13. Record reading on pressure gauge from the mower manifold CHD port. Charge pressure (without load) should read from 10.3 to 13.8 Bar (150 to 200 PSI). If charge relief pressure specification is not met, consider the following: A.
Page 108: Traction Unit Testing − Wheel Motor Efficiency Tests
Traction Unit Testing − Wheel Motor Efficiency Tests g344969 Figure 39 Model 03171 (shown) Wheel motor efficiency is the second in a series of tests recommended to determine traction circuit performance. Hydraulic fluid flow of 5.7 LPM (1.5 GPM) or more through a stationary wheel motor under load indicates an internal leak in the wheel motor.
Page 109 1. Park machine on a level surface with the cutting units lowered and the reel engage/disengage switch is in the disengage position. The engine should be off and the parking brake engaged. 2. Read Precautions for Hydraulic Testing (page 5–27). 3.
Page 110 Front Wheel Motor Tests (continued) 8. Sit in the operators seat, release the parking brake, and set the Mow/Transport slide to the transport position. 9. Slowly depress forward traction pedal until 68.9 to 103.4 Bar (1000 to 1500 PSI) is displayed on the pressure gauge. Flow meter should read less than 5.7 LPM (1.5 GPM).
Page 111 Front Wheel Motor Tests (continued) 16. Slowly depress forward traction pedal until 68.9 to 103.4 Bar (1000 to 1500 PSI) is displayed on the pressure gauge. Flow meter should read less than 5.7 LPM (1.5 GPM). 17. Release traction pedal, shut engine off, and record test results. 18.
Page 112 Rear Wheel Motor Test: (continued) g344968 Figure 43 Rear wheel motor Upper fitting 1. Disconnect hose from the upper hydraulic fitting of the rear wheel motor (Figure 43). 2. Install flow tester between the disconnected hydraulic hose and the rear wheel motor.
Page 113: Traction Circuit Testing − Piston Pump/Hydrostat (P3) Flow And Relief Pressure Test
Traction Circuit Testing − Piston Pump/Hydrostat (P3) Flow and Relief Pressure Test g345006 Figure 44 Model 03171 (shown) The hydrostat flow test is the third in a series of tests recommended to determine traction circuit performance. The final traction circuit test is verifying the hydrostat relief valve operation.
Page 114 Traction Circuit Testing − Piston Pump/Hydrostat (P3) Flow and Relief Pressure Test (continued) WARNING Before jacking up the machine, review and follow Jacking Instructions (page 1–7). 4. Raise off the floor and support both front wheels and the rear wheel. g344857 Figure 45 Lower hydraulic fitting...
Page 115 Traction Circuit Testing − Piston Pump/Hydrostat (P3) Flow and Relief Pressure Test (continued) B. Apply an additional load of 68.9 to 103.4 Bar (1000 to 1500 PSI) by slowly closing the flow meter. The flow meter pressure gauge should read 117.2 to 144.8 Bar (1700 to 2100 PSI). C.
Page 116: Reel Circuit Testing − Pressure Test
Reel Circuit Testing − Pressure Test g345028 Figure 46 Model 03171 (shown) Reel circuit pressure test is the first in a series of tests recommended to check cutting unit circuit performance. The results from this test will help determine which component(s) are the cause of cutting unit performance issues. Special Equipment Required: •...
Page 117 Reel Circuit Testing − Pressure Test (continued) 2. Make sure backlap knob on the hydraulic manifold is in the MOW position. Make sure that the reel speed knob is set for typical mowing conditions. 3. Read Precautions for Hydraulic Testing (page 5–27).
Page 118 Reel Circuit Testing − Pressure Test (continued) B. Gear pump (P1) is faulty (see Reel Circuit Testing − Gear Pump (P1) Flow Test (page 5–52)). 13. Disconnect test equipment from hydraulic manifold. Hydraulic System: Testing Page 5–42 Reelmaster ® 3100-D/3105-D 20252SL Rev A...
Page 119: Reel Circuit Testing − Reel Motor Efficiency/Case Drain Test
Reel Circuit Testing − Reel Motor Efficiency/Case Drain Test OR4077 g345040 Figure 48 Model 03171 (shown) The reel motor efficiency/case drain test is the second in a series of tests recommended to check cutting unit circuit performance. Over a period of time, a reel motor can wear internally.
Page 120 Reel Circuit Testing − Reel Motor Efficiency/Case Drain Test (continued) 2. Park the machine on a level surface with the cutting units lowered and the PTO switch in the disable position. Make sure engine is off and the parking brake is disengaged. 3.
Page 121 (continued) 14. Hold disconnected motor case drain hose into a container graduated in ounces or milliliters (e.g. Toro #TOR4077) and collect hydraulic fluid for 30 seconds. After 30 seconds, remove hose end from container. 15. Record the amount of fluid collected in the container.
Page 122: Reel Motor Cross−Over Relief Pressures Test (Using Pressure Gauge)
Reel Motor Cross−over Relief Pressures Test (Using Pressure Gauge) g345041 Figure 50 Model 03171 (shown) Note: One way to find a faulty reel motor is to have another person observe the machine while mowing in dense turf. A faulty motor will typically run slower, produce fewer clippings and may cause clip marks (a choppy appearance) on the turf.
Page 123 Reel Motor Cross−over Relief Pressures Test (Using Pressure Gauge) (continued) Note: The reel motors are connected in series. To isolate a faulty motor, all motors in the circuit may have to be tested by starting with the first motor in the series. g345042 Figure 51 Inlet hose...
Page 124 Reel Motor Cross−over Relief Pressures Test (Using Pressure Gauge) (continued) 12. Calculate the pressure differential between the two gauges. If the pressure differential is not approximately 100 bar (1450 PSI), the cross-over relief valves on the tested motor may be leaking or damaged. Inspect relief valves in the reel motor and replace if necessary (see Servicing the Reel Motor (page...
Page 125: Reel Circuit Testing − Manifold Relief Valve (Sv) Pressure Test
Reel Circuit Testing − Manifold Relief Valve (SV) Pressure Test g345058 Figure 52 Model 03171 (shown) Test the performance of the mow control manifold relief valve (SV) to make sure that the maximum amount of fluid is available to the cutting unit motors up to the set relief pressure.
Page 126 Reel Circuit Testing − Manifold Relief Valve (SV) Pressure Test (continued) 1. Park the machine on a level surface with the cutting units lowered, reel engage/disengage switch in the disengage position, and the mow/transport switch in the MOW position. Engine should be off and the parking brake disengaged.
Page 127 Reel Circuit Testing − Manifold Relief Valve (SV) Pressure Test (continued) 10. Engage cutting units. 11. Watch pressure gauge carefully while slowly closing the flow control valve. 12. System pressure should reach 207 Bar (3000 PSI) before the relief valve opens.
Page 128: Reel Circuit Testing − Gear Pump (P1) Flow Test
Reel Circuit Testing − Gear Pump (P1) Flow Test g345072 Figure 54 Model 03171 (shown) The gear pump (P1) flow test is the last in a series of tests recommended to determine cutting unit circuit performance. This test compares fluid flow at No Load with fluid flow Under Load.
Page 129 Reel Circuit Testing − Gear Pump (P1) Flow Test (continued) g345071 Figure 55 Gear pump (P1) To manifold port (P1) 3. Disconnect the hose connection on the gear pump (P1) leading to port (P1) on the mow control manifold (Figure 55).
Page 130 Reel Circuit Testing − Gear Pump (P1) Flow Test (continued) 13. The under load test flow reading (step 11.B.) should not drop more than 15% when compared to no load test flow reading (step 10). A difference in flow of more than 15%, or the inability to achieve specified pressure may indicate: A.
Page 131: Steering/Lift/Sidewinder Circuit Testing − Gear Pump (P2) Flow Test
Steering/Lift/Sidewinder Circuit Testing − Gear Pump (P2) Flow Test g345084 Figure 56 Gear pump (P2) is designed to satisfy both steering cylinder and lift cylinder needs simultaneously (at full speed throttle). The Gear Pump (P2) Flow Test compares fluid flow at No Load with fluid flow Under Load. A drop in flow under load of more than 15% indicates the gears and wear plates in the pump have worn.
Page 132 Steering/Lift/Sidewinder Circuit Testing − Gear Pump (P2) Flow Test (continued) g345083 Figure 57 Gear pump To steering control valve WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved. See Relieving Hydraulic System Pressure (page 5–3).
Page 133 Steering/Lift/Sidewinder Circuit Testing − Gear Pump (P2) Flow Test (continued) 10. Verify pump flow Under Load as follows: A. Watch pressure gauge carefully while slowly closing the flow control valve until 55.2 bar (800 PSI) is obtained on gauge. B. Record tester pressure and flow readings under load. 11.
Page 134: Steering/Lift/Sidewinder Circuit Testing − Relief Valve Pressure Test
Steering/Lift/Sidewinder Circuit Testing − Relief Valve Pressure Test g345085 Figure 58 The relief valve for the steering, lift, and sidewinder circuits is integrated into the steering control valve. If both steering and lift operations perform poorly, perform the relief valve pressure test and gear pump (P2) flow test (see Steering/Lift/Sidewinder Circuit Testing −...
Page 135 Steering/Lift/Sidewinder Circuit Testing − Relief Valve Pressure Test (continued) g345083 Figure 59 Gear pump To steering control valve 3. Install a T−connector with a pressure gauge between the gear pump and the hydraulic hose connection on the gear pump (P2) (Figure 59).
Page 136: Steering/Lift/Sidewinder Circuit Testing − Steering Control Valve And Steering Cylinder Test
Steering/Lift/Sidewinder Circuit Testing − Steering Control Valve and Steering Cylinder Test g345086 Figure 60 Unit steering performance will be affected by incorrect rear tire pressure, binding in the hydraulic steering cylinder, extra weight on the vehicle, and/or binding of the steering fork assembly. Make sure that these conditions are checked and functioning properly before proceeding with any steering system hydraulic testing.
Page 137 Steering/Lift/Sidewinder Circuit Testing − Steering Control Valve and Steering Cylinder Test (continued) B. When steering wheel is released, steering control should return to the neutral position with no additional turning. 4. If either of these performance tests indicate a steering problem, determine if the steering cylinder is faulty using the following procedure.
Page 138: Service And Repairs
Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Hydraulic Components 1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking brake, lower cutting units and stop engine. Remove key from the key switch.
Page 139: Check Hydraulic Lines And Hoses
Check Hydraulic Lines and Hoses WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • Ensure that all hydraulic-fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system. •...
Page 140: Priming Hydraulic Pumps
Priming Hydraulic Pumps Whenever the hydraulic system is flushed, the hydraulic system is charged or hydraulic components are removed, it is important to properly prime the hydraulic pumps. Hydraulic pump priming ensures that the gear pump and piston (traction) pump have adequate fluid during initial start−up and running. The pumps can be primed by using a remote starter switch (see Special Tools (page 2–13)) to crank...
Page 141: Flush Hydraulic System
(fluid appears milky, black, or contains metal particles). IMPORTANT Flush hydraulic system when changing from petroleum base hydraulic fluid to a biodegradable fluid such as Toro Biodegradable Hydraulic Fluid. Operate machine under normal operating conditions for at least four (4) hours before draining. IMPORTANT If a component failure occurred in the traction circuit, refer to Traction Circuit (Closed Loop) Component Failure (page 5–3)
Page 142 Flush Hydraulic System (continued) 6. Reconnect all hydraulic hoses, lines, and components that were disconnected while draining system. Note: Use only hydraulic fluids specified (see Traction Unit Operator’s Manual). Other fluids may cause system damage. 7. Fill hydraulic tank with new hydraulic fluid. 8.
Page 143: Filtering Closed−Loop Traction Circuit
3. Thoroughly clean junction of hydraulic hose and lower fitting on rear wheel motor (Figure 62). Disconnect hose from lower fitting on wheel motor. 4. Connect Toro high flow hydraulic filter in series between wheel motor fitting and disconnected hose. Use hydraulic hose kit (see Special Tools (page 2–13)) to connect filter to machine.
Page 144 (5) minutes. IMPORTANT If using a filter that is not the bi−directional Toro high flow filter, do not press the traction pedal in the reverse direction. If flow is reversed when using a filter that is not bi−directional, debris from the filter will re−enter the traction circuit.
Page 145: Charge Hydraulic System
Charge Hydraulic System Note: When initially starting the hydraulic system with new or rebuilt components such as motors, pumps, or lift cylinders, it is important that the hydraulic system be charged properly. Air must be purged from the system and its components to reduce the chance of damage.
Page 146 Charge Hydraulic System (continued) 11. Check operation of the traction interlock switches (see Check Operation of Interlock Switches (page 6–4)). 12. Stop the engine and lower machine. 13. If the traction (traction) pump or a wheel motor was replaced or rebuilt, run the traction unit so all wheels turn slowly for 10 minutes.
Page 147: Hydraulic Tank And Hydraulic Fluid Filter
Hydraulic Tank and Hydraulic Fluid Filter g345326 Figure 63 Flange head bolt (4 each) O-ring Shoulder screw Flat washer (4 each) Hydraulic fitting Hydraulic tank cap Grommet (4 each) O-ring Dipstick Flange head bolt (2 each) Hydraulic tube Hydraulic tank Hose Barb fitting O-ring...
Page 148 Removing the Hydraulic Tank (Figure 1. Park the machine on a level surface. Lower cutting units, stop engine and engage parking brake. Remove key from the key switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components (page 5–62).
Page 149: Radiator And Oil Cooler Assembly
Radiator and Oil Cooler Assembly g342392 Figure 64 Flange head nut (4 each) Radiator cooler Hydraulic hose assembly Top fan shroud Flange head bolt (4 each) Reservoir mounting bracket Flange head bolts (6 each) Fitting Lower radiator hose Radiator frame assembly R clamp (2 each) Overflow bottle Bolt (2 each)
Page 150: Hydraulic Pump Assembly
Hydraulic Pump Assembly g345815 Figure 65 Piston pump Idler pulley V−belt Straight hydraulic fitting Spacer O−ring Cap screw Torsion spring O−ring Lock nut Idler arm O−ring 90º hydraulic fitting Hose clamp O−ring 90º hydraulic fitting Flange nut O−ring 90º hydraulic fitting Cap screw O−ring 90º...
Page 151 Removing the Drive Belt (Figure 1. Park machine on a level surface. Lower cutting units, stop engine and engage parking brake. Remove key from the key switch. 2. Raise and support hood. g345814 Figure 66 Pump drive belt Spring end Idler pulley Pump mount plate tab Torsion spring...
Page 152 Installing the Drive Belt (Figure 65) (continued) CAUTION Use caution when installing torsion spring end onto the pump mount plate. Applying tension to the spring may cause personal injury during installation. 4. Apply pump drive belt tension with torsion spring on idler arm (Figure 66).
Page 153 Removing the Neutral Arm g345816 Figure 67 Flange bushing Cable support bracket Cap screw Flange nut Lock nut Neutral arm Flange head bolt Hub assembly 90º grease fitting Extension spring Mount Thrust washer Hose Flat washer Traction stud Flat washer Screw Lock nut Lock nut...
Page 154 Removing the Neutral Arm (continued) 1. Park machine on a level surface. Lower cutting units, stop engine and engage parking brake. Remove key from the key switch. 2. Raise and support the hood. CAUTION The extension spring is under tension and may cause personal injury during removal.
Page 155: Piston Pump/Hydrostat
Piston Pump/Hydrostat g345815 Figure 68 Piston pump Idler pulley V−belt Straight hydraulic fitting Spacer O−ring Cap screw Torsion spring O−ring Lock nut Idler arm O−ring 90º hydraulic fitting Hose clamp O−ring 90º hydraulic fitting Flange nut O−ring 90º hydraulic fitting Flange head screw O−ring 90º...
Page 156 Removing the Piston Pump/Hydrostat 1. Park machine on a level surface. Lower cutting units, stop engine and engage parking brake. Remove key from the key switch. 2. Raise and support hood. WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved.
Page 157 Removing the Piston Pump/Hydrostat (continued) g345926 Figure 69 Piston pump/hydrostat case drain Gear pump suction port 13. Remove both socket head screws and flat washers securing gear pump to the piston pump. Separate gear pump from the piston pump. Locate and retrieve O−ring.
Page 158 Installing the Piston Pump/Hydrostat (continued) IMPORTANT A case drain exists in the piston pump/hydrostat and a suction port is near the input shaft of the gear pump (Figure 69). Before the gear pump is installed to the piston pump, make sure that plugs placed in either of these ports are removed.
Page 159 Installing the Piston Pump/Hydrostat (continued) 13. Remove caps and plugs from all fittings and hydraulic hoses. Using labels placed during pump removal, properly connect hydraulic lines to pump assembly (see Installing Hydraulic Hoses and Tubes (O-Ring Face Seal Fittings) (page 5–6)).
Page 160: Piston Pump/Hydrostat Service
Piston Pump/Hydrostat Service g345931 Figure 70 Hydraulic System: Service and Repairs Page 5–84 Reelmaster ® 3100-D/3105-D 20252SL Rev A...
Page 161 Figure 70 (continued) O–ring Shaft seal Drive shaft Plug Retaining ring Bearing Relief valve asm. Cam plate insert Cap screw (3 used per plate) Check valve asm. Retaining ring Cover plate Bypass valve asm. Washer O–ring Cap screw Charge relief spring Shim kit O–ring Charge relief poppet...
Page 162 g345932 Figure 71 Back plate assembly Retaining ring Charge relief valve Bleed off valve Bleed off valve Spring O−ring O−ring Housing Cartridge Poppet Bleed-off valve Spring Charge relief valve Washer Note: The traction circuit charge relief valve and the bleed off valve for traction circuit cooling are attached to the piston pump back plate assembly (Figure 71).
Page 163 Piston Pump/Hydrostat Crush Ring Replacement g345933 Figure 72 Crush ring Camplate (control shaft) Washer (3) Shims Bearing cone Cap screw (3) Cover plate Bearing cup Housing O−ring Note: The shims replace the crush ring in the cover plate. If the camplate, cover plate or housing is replaced during servicing of the pump, the old crush ring can not be used to make sure of proper preload.
Page 164: Gear Pump
Gear Pump g345934 Figure 73 Piston pump O−ring Flat washer Gear pump O−ring O−ring Hydraulic hose (tank suction) Hydraulic barb fitting O−ring Hydraulic hose (hydraulic manifold) 10. 90º hydraulic fitting O−ring Hydraulic hose (steering valve) 90º hydraulic fitting Hose clamp Cap screw Removing the Gear Pump 1.
Page 165 Removing the Gear Pump (continued) 4. Drain the hydraulic fluid from hydraulic tank by disconnecting the suction hose from the barbed fitting in the bottom of the gear pump. Drain tank into a suitable container. 5. Label the hydraulic hoses and fittings on gear pump for assembly purposes. g345926 Figure 74 Piston pump/hydrostat case drain...
Page 166 Installing the Gear Pump (continued) IMPORTANT A case drain exists in the piston pump/hydrostat and a suction port is near the input shaft of the gear pump (Figure 74). Before the gear pump is installed to the piston pump, make sure that the plugs placed in either of these ports are removed.
Page 167: Servicing The Gear Pump
Servicing the Gear Pump g345935 Figure 75 Front plate Back−up gasket Not used Back plate Wear plate Drive gear Front body Pressure seal Washer Rear body Cap screw Plug Drive gear O−ring Shaft seal Idler gear Adapter plate Washer Idler gear Disassembling the Gear Pump (Figure Note: The gear pump must be replaced as a complete assembly.
Page 168 Disassembling the Gear Pump (Figure 75) (continued) g345936 Figure 76 Marker line 3. Use a marker to make a diagonal line across the front plate, front body, adapter plate, rear body, and back plate for assembly purposes (Figure 76). IMPORTANT Avoid using excessive clamping pressure on the pump housing to prevent distorting the housing.
Page 169 Disassembling the Gear Pump (Figure 75) (continued) 15. Remove the idler gear and drive gear from the front plate. IMPORTANT Note position of the open and closed side of the wear plate before removing from the front plate. 16. Remove the wear plate from front plate. Remove O−ring from front plate using O−ring pick.
Page 170 Inspecting the Gear Pump (Figure 75) (continued) C. Bushings on the wear plate side of the adapter plate should extend 3.20 mm (0.126 inch) from the plate surface. D. Scoring on the face of the back plate or the back plate side of the adapter plate should not exceed 0.038 mm (0.0015 inch).
Page 171 Assembling the Gear Pump (Figure 75) (continued) 4. Install new pressure seal and back−up gasket into both new wear plates. The flat section in the middle of the back−up gasket must face away from the wear plate inside the seal. 5.
Page 172: Front Wheel Motors
Front Wheel Motors g345325 Figure 79 Hydraulic tube Lock nut Bolt O-ring Brake assembly Brake lever Hydraulic fitting Bolt Cotter pin O-ring Brake drum Adjustment rod Socket head screw Wheel hub Clevis pin Hydraulic motor assembly Wheel assembly Cotter pin Pulley deck spacer Lock nut Lock nut...
Page 173 Removing the Front Wheel (Figure 79) (continued) 2. Jack up front of machine enough to allow the removal of the front wheel. Support machine with appropriate jackstands. IMPORTANT DO NOT hit wheel hub, wheel hub puller or wheel motor with a hammer during removal or installation.
Page 174: Rear Wheel Motor
Rear Wheel Motor g345327 Figure 80 Lug nut Hydraulic hose Hydraulic motor Drive stud O−ring Rear fork Tire and rim 45º hydraulic fitting O−ring Wheel hub Lock nut Woodruff key Hydraulic hose Socket head screw Removing the Rear Wheel Motor (Figure 1.
Page 175 Removing the Rear Wheel Motor (Figure 80) (continued) 2. Jack up the rear of equipment enough to allow the removal of the rear wheel. 3. Remove the rear wheel assembly from the machine; refer to Removing the Rear Fork and Wheel (page 7–14).
Page 176 Installing the Rear Wheel Motor (Figure 80) (continued) 5. Remove caps and plugs from wheel motor fittings and hoses. Using labels placed during motor removal, properly connect hydraulic lines to motor (see Installing Hydraulic Hoses and Tubes (O-Ring Face Seal Fittings) (page 5–6)).
Page 177: Servicing The Wheel Motor
Bearing Vane Note: The three wheel motors used on the Reelmaster 3100-D and 3105-D are similar in construction but do have some differences. The right front and left front motors are the same basic design but the right side motor has a reverse timed manifold to allow correct rotation direction for forward and reverse.
Page 178 Servicing the Wheel Motor (continued) Note: For repair of the wheel motors, see the Parker Torqmotor Service Procedure (TC, TB, TE, TJ, TF, TG, TH and TL Series). Hydraulic System: Service and Repairs Page 5–102 Reelmaster ® 3100-D/3105-D 20252SL Rev A...
Page 179: Reel Motors
Reel Motors g345382 Figure 82 Hydraulic hose O-ring Hydraulic motor (rear) Hydraulic hose O-ring Hydraulic hose O-ring Hydraulic fitting 90º hydraulic fitting 45º hydraulic fitting O-ring O-ring O-ring Hydraulic hose O-ring Hydraulic motor (front) O-ring Hydraulic hose O-ring 90º hydraulic fitting Hydraulic hose 90º...
Page 180 Removing the Reel Motors (continued) 2. Read the General Precautions for Removing and Installing Hydraulic System Components (page 5–62). 3. Label all hydraulic connections for assembly purposes (Figure 82). Thoroughly clean hydraulic connections prior to loosening hydraulic lines from reel motor to prevent hydraulic system contamination. CAUTION Before opening hydraulic system, operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic...
Page 181 Installing the Reel Motors (continued) 5. Rotate the motor counter-clockwise until the motor flanges are encircling the cap screws. Tighten two (2) cap screws to secure reel motor to cutting unit (Figure 83). 6. Remove the caps or plugs from fittings and hoses. IMPORTANT When installing the hydraulic hoses, make sure that the hydraulic hoses are straight (not twisted) before tightening the hoses to the...
Page 182: Servicing The Reel Motor
Servicing the Reel Motor g345534 Figure 84 Dust seal Back-up gasket O-ring Retaining ring Front wear plate Relief valve Flange washer Dowel pin Body Shaft seal Idler gear Washer (4 each) Front flange Drive shaft Lock washer (4 each) Pressure seal Rear wear plate Cap screw (4 each) Disassembling the Reel Motor...
Page 183 Disassembling the Reel Motor (Figure 84) (continued) g345531 Figure 85 Marker line 2. Use a marker to make a diagonal line across the front flange, body and rear cover for assembly purposes (Figure 85). IMPORTANT Prevent damage when clamping the motor into a vise; use a vise with soft jaws and clamp on the front flange only.
Page 184 Disassembling the Reel Motor (Figure 84) (continued) 9. Remove and discard the back−up gaskets and pressure seals from wear plates. 10. Turn the front flange over, with seal side up. IMPORTANT Make sure to not damage the front flange counter bore when removing the seals from the front flange.
Page 185 Inspecting the Reel Motor (continued) g345533 Figure 87 Gear shaft spline Gear teeth Gear shaft Gear face edge 3. Inspect drive gears and idler gears for the following (Figure 86): A. Gear shafts should be free of rough surfaces and excessive wear at bushing points and sealing areas.
Page 186 Assembling the Reel Motor (Figure 84) (continued) 5. Apply a light coating of petroleum jelly to the exposed side of the front flange. 6. Lubricate the drive gear shaft with clean hydraulic fluid. Insert the drive end of the drive shaft through the outer wear plate with the pressure seal side down and the open side of the pressure seal pointing to the inlet side of the motor.
Page 187: Hydraulic Manifold Assembly
Hydraulic Manifold Assembly g345584 Figure 88 Flange nut (2 each) 90º hydraulic fitting O-ring Stud (2 each) O-ring 45º hydraulic fitting 90º hydraulic fitting O-ring 90º hydraulic fitting Elbow fitting Hydraulic fitting O-ring Hose clamp O-ring Tee hydraulic fitting O-ring Hydraulic manifold assembly O-ring Hydraulic hose...
Page 188 Removing the Hydraulic Manifold Assembly (continued) 1. Park the machine on a level surface. Lower cutting units, stop engine and engage parking brake. Remove key from the key switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components (page 5–62).
Page 189: Servicing The Hydraulic Manifold
Servicing the Hydraulic Manifold g345657 Figure 89 Manifold body Plug (Zero Leak #4) (10 each) Plug (Zero Leak #2) (2 each) Plug (Zero Leak #8) Spring pin (2 each) Orifice (.020) Rotary cartridge valve (flow control) 11. Plug (SAE #4) Plug (Zero Leak #6) Rotary handle assembly Mow/backlap spool...
Page 190 Note: The hydraulic manifold shown in Figure 89 uses several zero leak plugs. These plugs have a tapered sealing surface on the plug head that is designed to resist vibration induced plug loosening. The zero leak plugs also have an O-ring to provide a secondary seal.
Page 191 Solenoid Operated, Relief and Logic Control Cartridge Valves (continued) 6. Reinstall the cartridge valve into the manifold: A. Lubricate new O-rings and backup rings of seal kit with clean hydraulic fluid and install on cartridge. The O-rings and backup rings must be arranged properly on the cartridge valve for proper operation and sealing.
Page 192 Rotary Cartridge Valves (continued) C. Loosen two (2) set screws that secure handle base to flow control valve and remove base. 2. Make sure manifold is clean before removing the rotary cartridge valve. Remove the valve and seal kit. 3. Visually inspect the manifold port and cartridge valve for damage to sealing surfaces, damaged threads, and contamination.
Page 193 Rotary Cartridge Valves (continued) F. Press handle cap onto valve stem with arrow on cap pointing to number 9 on manifold. Make sure that the detent pin and spring stay positioned in cap. G. While pressing on the cap to keep the lip seal in place, rotate cap in a clockwise direction until the arrow on the cap aligns with number 1 on the manifold.
Page 194 Mow/Backlap Spool (Figure 89 Figure 91) (continued) B. Carefully push spool down into mow manifold port until lower O-ring and back-up ring groove is exposed on bottom of manifold. Install lower O-ring and back-up ring to spool. Apply a light coating of grease to O-ring. C.
Page 195: Control Valve (Models 03170 And 03174)
Control Valve (Models 03170 and 03174) g345753 Figure 92 Straight hydraulic fitting Shoulder bolt Hydraulic hose 90º hydraulic fitting Valve lever assembly Hydraulic tube Hydraulic fitting Link (2 each) O-ring 90º hydraulic fitting Bolt O-ring Control valve (single spool) Lock nut (2 each) O-ring Carriage screw (2 each) Knob...
Page 196 Removing the Control Valve (continued) g345754 Figure 93 Lift control valve Flange head screws Support bracket Frame 2. Remove control valve from the frame using Figure 92 Figure 93 guides. 3. If hydraulic fittings are to be removed from control valve, mark fitting orientation to allow correct assembly.
Page 197: Servicing The Control Valve (Models 03170 And 03174)
Servicing the Control Valve (Models 03170 and 03174) g345755 Figure 94 Check poppet Spool cap Detent plug Plunger Valve body O-ring Spacer O-ring O-ring Spool Retaining ring Detent plunger Seat Washer Spring Plug (solid) Back-up washer O-ring Seat retaining plug Spool spring O-ring Bushing...
Page 198 g345756 Figure 95 Hydraulic System: Service and Repairs Page 5–122 Reelmaster ® 3100-D/3105-D 20252SL Rev A...
Page 199 Figure 95 (continued) Detent plug Check poppet Spool cap Plunger Valve body O-ring Spacer O-ring O-ring Spool Retaining ring Detent plunger Seat Washer Spring Plug (solid) Back-up washer O-ring Seat retaining plug Spool spring O-ring Bushing Disc Back-up washer Check spring Plug O-ring Disassembling the Control Valve...
Page 200 Assembling the Control Valve (continued) 2. Replace check poppet, O−rings, and back−up washers with new ones. 3. Install new O−rings into the valve body. 4. Slide bushing and new O−ring over the spool. 5. If the spool was disassembled, install washer, spool spring, spacer, and retaining ring to the spool.
Page 201: Control Valve (Model 03171)
Control Valve (Model 03171) g345779 Figure 96 Control valve (2-spool) Cotter pin Carriage screw (2 each) Hydraulic fitting (straight) Valve lever O-ring 90º hydraulic fitting Valve actuator trunnion O-ring Hydraulic fitting (straight) Shoulder bolt Hydraulic tube Flange nut Link (4 each) Hydraulic tube Knob Bolt...
Page 202 Removing the Control Valve (continued) g345780 Figure 97 Spool valve Flange head screws Magnet support bracket Frame WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved. See Relieving Hydraulic System Pressure (page 5–3).
Page 203: Servicing The Control Valve (Model 03171)
Servicing the Control Valve (Model 03171) g345781 Figure 98 Check poppet Valve body Plunger Grooved plunger O-ring Plunger detent Spacer Retaining ring Detent spring Spool Washer O-ring Seat Seat retaining plug O-ring Solid plug Spool spring Back-up washer Seat retaining plug with port Disc O-ring Bushing...
Page 204 g345782 Figure 99 Hydraulic System: Service and Repairs Page 5–128 Reelmaster ® 3100-D/3105-D 20252SL Rev A...
Page 205 Figure 99 (continued) Valve body Plunger Check poppet Grooved plunger O-ring Plunger detent Spacer Retaining ring Detent spring Spool Washer O-ring Seat Seat retaining plug O-ring Solid plug Spool spring Back-up washer Seat retaining plug with port Disc O-ring Bushing Plug O-ring Check spring...
Page 206 Assembling the Control Valve IMPORTANT Do not wipe parts with paper towels or rags. Lint may cause damage to the hydraulic system. CAUTION Use eye protection such as goggles when using compressed air. 1. Clean all metal parts with solvent and blow dry with compressed air. 2.
Page 207: Sidewinder (Model 03171)
Sidewinder (Model 03171) g345939 Figure 100 Plastic bushing Lock nut 90º hydraulic fitting Scissor link Welded pin Hydraulic hose Scissor mount Flange head screw Pinch point decal Cap screw Lock nut O-ring Flat washer Spacer O-ring Lock nut Hydraulic tube O-ring Scissor frame Hydraulic tube...
Page 208 Removing the Sidewinder WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved. See Relieving Hydraulic System Pressure (page 5–3). The hydraulic cylinder used in the Reelmaster sidewinder assembly is a non−serviceable cylinder.
Page 209: Steering Control Valve
Steering Control Valve g344474 Figure 101 Steering arm Flange hex nut Jam nut Flange hex nut Steering wheel Flat washer Hex flange head bolt Hydraulic fitting Flange head bolt Steering control valve bracket Hydraulic fitting Bolt Bolt Steering wheel nut Washer Pivot hub Decal...
Page 210 Removing the Steering Control Valve 1. Park the machine on a level surface. Lower cutting units, stop engine and engage parking brake. Remove key from the key switch. 2. Thoroughly clean the hydraulic hose ends and fittings on steering control valve to prevent hydraulic system contamination.
Page 211: Servicing The Steering Control Valve
Servicing the Steering Control Valve g345941 Figure 103 Sleeve Dust seal ring End cover Cross pin Housing O–ring (5 used) Ring Cardan shaft Screw/fitting (ports L and R) Spool Spacer Screw/fitting (ports P, T and E) Bearing assembly O–ring P port check ball Shaft seal Distribution plate Spring set...
Page 212: Steering Cylinder
Steering Cylinder g345942 Figure 104 Hydraulic hose O−ring Flextop lock nut Hydraulic hose Steering cylinder Frame O−ring Ball joint Rear fork Hydraulic fitting Retaining ring Rear casting Removing the Steering Cylinder 1. Park the machine on a level surface. Lower cutting units, stop engine and engage parking brake.
Page 213 Removing the Steering Cylinder (continued) WARNING Before jacking up the machine, review and follow Jacking Instructions (page 1–7). 2. Jack or lift rear wheel off the ground. 3. Remove the rear wheel from the machine. 4. Thoroughly clean hydraulic hose ends and fittings on steering cylinder to prevent hydraulic system contamination.
Page 214: Servicing The Steering Cylinder
Servicing the Steering Cylinder g346049 Figure 105 Barrel with clevis Piston rod Retaining ring Lock nut Rod seal Dust seal Piston Cylinder gland Square O-ring Seal O-ring Wear ring O-ring Back−up ring Disassembling the Steering Cylinder 1. Remove the hydraulic fluid from the steering cylinder into a drain pan by slowly pumping the cylinder shaft.
Page 215 Disassembling the Steering Cylinder (continued) IMPORTANT Prevent damage when clamping the hydraulic cylinder into a vise; clamp on the clevis only. 2. Mount clevis end of steering cylinder in a vice. Remove the retaining ring. 3. Remove plugs from ports. Extract shaft, cylinder gland, and piston by carefully twisting and pulling on the shaft.
Page 216 Assembling the Steering Cylinder (continued) 5. Coat all internal parts with a light coat of clean hydraulic fluid. Slide piston, shaft, and cylinder gland assembly into the barrel being careful not to damage the seals. 6. Secure head into the barrel with the retaining ring. Hydraulic System: Service and Repairs Page 5–140 Reelmaster...
Page 217: Front Lift Cylinder
Front Lift Cylinder g346257 Figure 106 Model 03171 (shown) 45º hydraulic fitting Hex nut Spacer Hydraulic cylinder Lift arm pivot shaft External retaining ring Carrier assembly Bolt Bulkhead nut Flange nut Pivot shaft link Hydraulic tube Flange head screw Flange head screw Bulkhead nut Hydraulic hose Cap screw...
Page 218 Removing the Front Lift Cylinder 1. Park machine on a level surface. Lower cutting units, stop engine and engage parking brake. Remove key from the key switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components (page 5–62).
Page 219: Rear Lift Cylinder
Rear Lift Cylinder g346266 Figure 107 Model 03171 (shown) Reelmaster ® 3100-D/3105-D Page 5–143 Hydraulic System: Service and Repairs 20252SL Rev A...
Page 220 Figure 107 (continued) Hydraulic tube Flat washer Lock washer Lock nut Cap screw Guard Hydraulic T−fitting Lock nut Cap screw Hydraulic hose Rear pivot shaft Cap screw 90º hydraulic fitting Jam nut Lock nut Hydraulic hose Washer External retaining ring Hydraulic tube Rear lift arm assembly 90º...
Page 221 Installing the Rear Lift Cylinder 1. If fittings were removed from lift cylinder, lubricate and place new O−rings onto fittings. Install fittings into cylinder port openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) (page 5–8)).
Page 222: Servicing The Lift Cylinder
Servicing the Lift Cylinder g346324 Figure 108 Grease fitting O−ring Shaft Barrel with clevis Back−up ring Jam nut Rod seal Clevis Seal Head Wear ring Piston Internal collar O−ring Dust seal Disassembling the Lift Cylinder 1. Remove fluid from lift cylinder into a drain pan by slowly pumping the cylinder shaft.
Page 223 Disassembling the Lift Cylinder (continued) 2. Mount lift cylinder in a vice. Remove the internal collar with a spanner wrench. 3. Extract the shaft, head, and piston by carefully twisting and pulling on the shaft. IMPORTANT Do not clamp vise jaws against the shaft surface. Protect shaft surface before mounting in a vice.
Page 224 Hydraulic System: Service and Repairs Page 5–148 Reelmaster ® 3100-D/3105-D 20252SL Rev A...
Page 225: Chapter 6: Electrical System
Chapter 6 Electrical System Table of Contents General Information ..........................6–2 Operator’s Manual ..........................6–2 Electrical Drawings ..........................6–2 Standard Control Module (SCM) ......................6–2 Diesel Engine − Electrical Components ..................... 6–2 Electrical System Quick Checks......................6–3 Adjustments............................6–5 Neutral Switch............................ 6–5 Mow/Transport Switch........................
Page 226: General Information
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Reelmaster machine. Refer to the Operator’s Manual for additional information when servicing the machine. Electrical Drawings The electrical schematic and wire harness drawings for the Reelmaster 3100−D and the Reelmaster 3105−D are located in Chapter 9 −...
Page 227: Electrical System Quick Checks
Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the battery terminals. Set the multimeter to the DC volts setting. The battery should be at a temperature of 16º to 38ºC (60º to 100ºF). The key switch should be off and all accessories turned off.
Page 228 Glow Plug System Test (continued) instructions) and set the multimeter to the correct scale. With the key switch in the OFF position, place the ammeter pickup around the main glow plug power supply wire and read the meter prior to activating the glow plug system. Adjust the meter to read zero (if applicable).
Page 229: Adjustments
Adjustments Neutral Switch g346737 Figure 109 Neutral switch Switch bracket Floor plate The neutral switch is a normally open proximity switch that closes when the traction pedal is in the neutral position. The neutral switch is located under the floor plate near the traction pedal. Adjusting 1.
Page 230 Adjusting (continued) g346738 Figure 110 Neutral switch Traction pedal pin 3. When the traction pedal is in the neutral position, the pin on the traction pedal should be centered with the switch eye. With the traction pushed all the way to the right, the clearance between the pin on the traction pedal and the switch should be 0.5 to 1.5 mm (0.02 to 0.06 in) (Figure 110).
Page 231: Mow/Transport Switch
Mow/Transport Switch g346739 Figure 111 Mow/Transport switch The switch used for the mow/transport slide is a normally closed switch. The switch opens when the mow/ transport slide is in the transport position. The switch is located under the floor plate (Figure 111).
Page 232 Adjusting (continued) 3. To adjust switch, loosen fasteners that secure switch to bracket and position switch to allow correct clearance between switch and rocker arm. Tighten switch fasteners and recheck switch to rocker arm clearance. Electrical System: Adjustments Page 6–8 Reelmaster ®...
Page 233: Component Testing
Component Testing For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the key switch connector before doing a continuity check). Note: For engine component testing information (starter solenoid and motor, alternator, glow plugs) see the Kubota Workshop Manual.
Page 234: Fusible Link Harness
Fusible Link Harness g346634 Figure 113 Fusible link harness Starter motor The Reelmaster machines use 3 fusible links for the circuit protection. These fusible links are located in a harness that connects the starter B+ terminal to the wire harness (Figure 113 Figure 114).
Page 235: Fuses
Fuses g346635 Figure 115 The fuse blocks are located under the control panel (Figure 115). Identification and Function The fuses are held in the fuse blocks. Use Figure 115 to identify each individual fuse and its correct amperage. Each fuse holder has the following function. F1 (15 A): Protects main power circuit to the key switch terminal B.
Page 236: Key Switch
Key Switch g346378 Figure 116 Control panel Key switch g346370 Figure 117 The key switch is located on the control panel and has three (3) positions: OFF, RUN and START (Figure 117). The Standard Control Module (SCM) monitors the operation of the key switch and reacts to the various key switch positions. g346371 Figure 118 Switch...
Page 237 Testing 1. Park machine on a level surface, lower cutting units, engage parking brake and stop engine. Remove key from key switch. 2. Remove the cover from control panel to access key switch. 3. Make sure that the key switch is in the OFF position. Disconnect wire harness connector from key switch.
Page 238: Indicator Lights
Indicator Lights g346547 Figure 119 Charge indicator High temp shutdown Engine oil pressure Glow plug indicator Charge Indicator Light The charge indicator light should come on when the key switch is in the ON position with the engine not running. Also, it should illuminate with an improperly operating charging circuit while the engine is running.
Page 239 Testing Indicator Lights g346546 Figure 120 1. Apply 12 VDC to terminals 1A and 2A (Figure 120). 2. Ground terminals 1B and 2B (Figure 120). 3. Both indicator lights should illuminate. Reelmaster ® 3100-D/3105-D Page 6–15 Electrical System: Component Testing 20252SL Rev A...
Page 240: Hour Meter
Hour Meter g346377 Figure 121 Control panel Hour meter The hour meter (Figure 121) indicates the total hours of machine operation. The hour meter starts to function whenever the key switch is on. Testing 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the key switch.
Page 241 Testing (continued) 5. The hour meter should move 1/10 of an hour in 6 minutes. 6. Disconnect the voltage source from the hour meter. 7. Replace the hour meter if necessary. 8. Connect the wire harness connector to the hour meter. Reelmaster ®...
Page 242: Pto Switch
PTO Switch g346657 Figure 123 PTO switch Control panel The PTO switch is located on the control panel (Figure 123). This switch is pulled out to engage the cutting units and pushed in to disengage the cutting units. The Standard Control Module (SCM) monitors the position of the PTO switch (up or down).
Page 243 Testing (continued) g346656 Figure 124 COM B terminal COM C terminal NO B terminal NO C terminal NC B terminal NC C terminal 4. If the SCM determines that the PTO switch and circuit wiring are not functioning correctly, then test the PTO switch as follows: A.
Page 244: Seat Switch
Seat Switch g346743 Figure 125 Seat bottom Seat switch Flange head screws Seat belt kit Seat back Decal The seat switch is normally open and closes when the operator is on the seat. If the traction system or PTO switch is engaged when the operator raises out of the seat, the engine shuts off.
Page 245 Testing (continued) 5. Ensure that the key switch is in the OFF position. Locate the switch for testing. 6. Disconnect the machine wire harness electrical connector from the seat switch (Figure 124). 7. Connect a multimeter (ohms setting) across the seat switch harness connector terminals to check the continuity of the seat switch.
Page 246: Parking Brake Switch
Parking Brake Switch g346705 Figure 126 Magnet support Lock nut Cotter pin Washer head bolt Parking brake spacer Lock nut Strike bracket Lever assembly Flat washer Washer head bolt Flat washer Switch Magnet catch Parking brake link Slotted hex head screw Rivet Clevis pin Bolt...
Page 247 The Standard Control Module (SCM) monitors the operation of the parking brake switch. If the key switch is in the ON position and the parking brake is released, the SCM parking brake off input LED should be illuminated. Testing 1. Park the machine on a level surface, lower the cutting unit, and shut off the engine.
Page 248: Neutral Switch
Neutral Switch g346737 Figure 127 Neutral switch Switch bracket Floor plate The neutral switch is a normally open proximity switch that closes when the traction pedal is in the neutral position. The neutral switch is located under the floor plate (Figure 115).
Page 249 Testing (continued) 6. With the traction pedal in the neutral position, there should be continuity between the two (2) switch leads. 7. Slowly depress the traction pedal. The continuity tester should show no continuity as the pedal is moved to the full forward or full reverse direction. 8.
Page 250: Mow/Transport Switch
Mow/Transport Switch g346739 Figure 128 Mow/Transport switch The switch used for the mow/transport slide is a normally closed switch. The switch opens when the mow/ transport slide is in the transport position. The switch is located under the floor plate (Figure 123).
Page 251: Backlap Switch
Backlap Switch g345657 Figure 129 Manifold body Plug (Zero Leak #4) (10 each) Plug (Zero Leak #2) (2 each) Plug (Zero Leak #8) Spring pin (2 each) Orifice (.020) Rotary cartridge valve (flow control) 11. Plug (SAE #4) Plug (Zero Leak #6) Rotary handle assembly Mow/backlap spool Check valve...
Page 252 The Standard Control Module (SCM) monitors the operation of the backlap switch. If the backlap switch is in the ON position, the SCM in backlap input LED should be illuminated. Testing 1. Park vehicle on a level surface, stop engine, apply parking brake and remove key from key switch.
Page 253: High Temperature Warning Switch
High Temperature Warning Switch g342502 Figure 130 Temp. warning switch Rear lift tab The high temperature warning switch (Figure 130) is attached to the water pump housing on the engine and has a gray wire attached to it. This switch is normally open and closes when the engine coolant temperature reaches approximately 105°C (220°F).
Page 254 Testing (continued) g226814 Figure 131 5. Put the end of the switch in a container of fluid with a thermometer and then slowly heat the fluid (Figure 131). CAUTION The fluid is hot and could cause personal injury or fire. Handle the hot fluid with extreme care.
Page 255: High Temperature Shutdown Switch
High Temperature Shutdown Switch g342503 Figure 132 Temp. shutdown switch Low oil press. switch Alternator The high temperature shutdown switch (Figure 132) is attached to the water pump housing on the engine and has a blue/white wire attached to it. This switch is normally open and closes when engine coolant temperature reaches approximately 110°C (230°F).
Page 256 Testing (continued) g226814 Figure 133 5. Put the end of the switch in a container of fluid with a thermometer and then slowly heat the fluid (Figure 133). CAUTION The fluid is hot and could cause personal injury or fire. Handle the hot fluid with extreme care.
Page 257: Oil Pressure Switch
Oil Pressure Switch g346755 Figure 134 Alternator Oil pressure switch The engine oil pressure switch is located on the engine below the alternator (Figure 127). The oil pressure switch is a normally closed switch that opens with pressure. The oil pressure switch should open at approximately 8 PSI. If low engine oil pressure allows the oil pressure switch to close during engine operation, the engine oil pressure light should illuminate.
Page 258 Testing (continued) 5. If the switch testing is correct and the circuit problem still exists, check the machine wire harness; refer to the Electrical Schematics and Wire Harness Drawings/Diagrams in Appendix A (page A–1). 6. After you complete the oil pressure switch testing, connect the wire harness connector to the oil pressure switch.
Page 259: Glow Relay
Glow Relay g346376 Figure 135 Radiator assembly Glow relay The glow relay is attached to the radiator assembly (Figure 135). When energized, the glow relay allows electrical current to the engine glow plugs. Testing 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the key switch.
Page 260 Testing (continued) 5. Check the coil resistance between terminals the 85 and 86 with a multimeter (ohms setting). The resistance should be approximately 72 ohms (Figure 136). 6. Connectmultimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12 VDC to terminal 85. The relay should make and break continuity between terminals 30 and 87 as 12VDCis applied and removed from terminal 85.
Page 261: Diode Assembly
End of the diode body Male terminal Diode assembly Female terminal The diode assembly can be identified by a black color, diode symbol, and Toro Part Number on the end of the diode assembly body (Figure 137). The diode assembly can be located between the operator seat and hydraulic tank.
Page 262: Fuel Stop Solenoid
Fuel Stop Solenoid g346550 Figure 138 Fuel pump Fuel filter Fuel hose (discharge) Fuel stop solenoid The fuel stop solenoid used on the Reelmaster must be energized for the diesel engine to run. The solenoid is mounted to the injection pump on the engine (Figure 138).
Page 263 Testing the Fuel Stop Solenoid (In Place) (continued) g227148 Figure 139 Fuel stop solenoid Hold coil terminal Pull coil terminal 4. 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) (Figure 139).
Page 264: Reel Drive Solenoid
Reel Drive Solenoid g346523 Figure 140 Hydraulic manifold Solenoid The hydraulic system on the Reelmaster uses a solenoid valve coil on the hydraulic manifold (Figure 140). When the solenoid valve coil (SV) is energized, hydraulic flow is directed to the cutting decks. The standard control module provides current to the solenoid valve coil based on the position of several inputs.
Page 265: Glow Controller
Glow Controller g346552 Figure 141 Glow controller The controller is located under the right lower corner of the control panel (Figure 141). Note: Refer to the Electrical Schematics in Appendix A (page A–1) when troubleshooting the glow controller circuit. Controller Operation 1.
Page 266 Controller Checks (continued) 5. If any of the conditions in step 3 are not met or power to terminal 1 exists and any of the other conditions in step 4 are not met: A. Check the continuity of the circuitry from the battery to the glow relay and glow plugs;...
Page 267: Fuel Pump
Fuel Pump g346550 Figure 142 Fuel pump Fuel filter Fuel hose (discharge) Fuel stop solenoid The fuel pump is attached to the frame just outboard of the fuel injection pump. IMPORTANT When testing the fuel pump, ensure that the pump is not operated without fuel.
Page 268 Testing the Fuel Pump Capacity (continued) IMPORTANT When testing the fuel pump output, do not turn the key switch to the START position. 7. Turn the key switch to the ON position and collect the fuel in the graduated cylinder. Allow the pump to run for 15 seconds and then turn the switch to the OFF position.
Page 269: Standard Control Module (Scm)
Figure 143 Glow controller The Reelmaster 3100-D and 3105-D machines are equipped with a Standard Control Module (SCM) to monitor and control electrical components required for safe operation. This Module is attached to the back of the control panel (Figure 143).
Page 270 Standard Control Module (SCM) (continued) and the key switch in the run position), testing of the switch and circuit wiring would be required. Refer to the Traction Unit Operator’s Manual for operation and troubleshooting of the Standard Control Module. Electrical System: Component Testing Page 6–46 Reelmaster ®...
Page 271: Service And Repairs
Service and Repairs Note: Refer to the Kubota Workshop Manual for additional component repair information. Battery Storage If you store the machine for more than 30 days: 1. Ensure that the key switch is in the OFF position. Remove the battery and charge it fully;...
Page 272 (-) 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 273: Servicing The Battery
Servicing the Battery The battery is the heart of the electrical system. With the regular and correct service, the battery life can be extended. Additionally, the battery and electrical component failure can be prevented. CAUTION Battery-electrolyte is corrosive and can burn skin and eyes and damage clothing.
Page 274 Removing and Installing the Battery g346768 Figure 145 Knob (2) Battery retainer Battery cover Carriage screw Negative cable Battery support Positive cable Battery Lock nut Battery tray Flat washer 1. Remove battery cover from the frame. Loosen battery retainer securing the back of the battery to the battery support.
Page 275 Inspecting, Maintaining, and Testing the Battery 1. Do the following inspections and maintenance: A. Check for cracks. Replace the battery if cracked or leaking. B. Check the battery terminal posts for corrosion. Use the wire brush to clean corrosion from the posts. IMPORTANT Before cleaning the battery, tape or block the vent holes of the filler caps and ensure that the caps are tight.
Page 276 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 277 Charging the Battery To minimize damage to the battery and allow the battery to charge fully, do the following slow charging procedure. You can do this charging procedure with a constant current battery charger that is locally available. IMPORTANT Follow the manufacturer's instructions when using a battery charger. Note: Use specific gravity of the battery cells is the most accurate procedure of determining the battery condition.
Page 278 Charging the Battery (continued) CAUTION Charging a frozen battery can cause explosion and can cause personal injury. Let the battery warm to 15.5°C (60°F) before connecting to a charger. • Charge the battery in a well-ventilated place to dissipate the gases produced from the charging.
Page 279 Chapter 7 Wheels, Brakes and Chassis Table of Contents General Information ..........................7–2 Adjustments ............................7–3 Adjusting the Brake ..........................7–3 Service and Repairs ..........................7–5 Standard Seat ............................ 7–5 Deluxe Seat ............................7–7 Front Wheel and Brake ........................7–9 Rear Fork and Wheel with Hydraulic Motor ..................
Page 280: General Information
General Information The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your Reelmaster machine. Refer to the Operator’s Manual for additional information when servicing the machine. Wheels, Brakes and Chassis: General Information Page 7–2 Reelmaster ®...
Page 281: Adjustments
Adjustments Adjusting the Brake CAUTION Before and after adjusting the brakes, always check the brakes in a wide open area that is flat and free of other persons and obstructions. 1. Park machine on a level surface, lower cutting units, stop engine, and remove key from the key switch.
Page 282 Adjusting the Brake (continued) CAUTION Before jacking up the machine, review and follow Jacking Instructions (page 1–7). B. Chock rear wheel. Jack up both front wheels and support the machine with hardwood blocks. C. With the parking brake applied, use a torque wrench on the wheel hub lock nut to identify the break away torque at each front wheel.
Page 283: Service And Repairs
Service and Repairs Standard Seat g344103 Figure 149 Seat assembly Socket head screw (4 each) Lock nut (2 each) Seat belt buckle Flange head bolt (4 each) Seat belt bracket Bolt (2 each) Seat support strap (2 each) Seat belt Spacer (2 each) Flange nut (4 each) Heat shield...
Page 284 Removing the Seat 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the key switch. 2. Remove the four flange head bolts securing the seat support straps to the frame. 3.
Page 285: Deluxe Seat
Deluxe Seat g344119 Figure 150 Seat and track assembly Seat support strap (2 each) Heat shield Flange head bolt (4 each) Flange nut (4 each) Removing the Seat 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the key switch.
Page 286 Removing the Seat (continued) g344120 Figure 151 Seat assembly Mounting spacer (4 each) Arm rest Seat track g344121 Figure 152 Seat-back Seat-bottom Seat switch Flange head bolt (2 each) Seat belt Decal 4. Remove seat parts as necessary to make repairs using Figure 151 Figure 152 as a guide.
Page 287: Front Wheel And Brake
Front Wheel and Brake g344136 Figure 153 Brake pivot shaft Brake assembly (2 each) Cotter pin (2 each) Flange nut (4 each) Bolt (8 each) Adjustment rod (2 each) Flange bush (2 each) Brake drum (2 each) Clevis pin (2 each) Hydraulic motor assembly (CW) Wheel hub (2 each) Cotter pin (2 each)
Page 288 Removing the Front Wheel and Brake (continued) CAUTION Before jacking up the machine, review and follow Jacking Instructions (page 1–7). 2. Jack up front wheel and use wood blocks to keep the rear tire off the floor. 3. Remove the lug nuts (item 17 in Figure 153) from drive studs (18).
Page 289 Removing the Front Wheel and Brake (continued) g344135 Figure 154 Backing plate Retaining ring Brake shoe Cam shaft Return spring 9. Disassemble brake assembly as follows (Figure 154): A. Remove return springs (3) from the brake shoes (2). Remove brake shoes from the backing plate (1).
Page 290 Installing the Front Wheel and Brake (continued) 4. Attach adjustment (20) rod to the brake lever (22). Secure adjustment rod with cotter pin (21). 5. Thoroughly clean wheel motor shaft and wheel hub taper. 6. Install the woodruff key to the slot on the hydraulic motor shaft. Slide the wheel hub and brake drum assembly onto the shaft.
Page 291: Rear Fork And Wheel With Hydraulic Motor
Rear Fork and Wheel with Hydraulic Motor g344287 Figure 155 Tire Flange head bolt (8 each) Hydraulic fitting (2 each) Lug nut (4 each) Bushing (2 each) O-ring (2 each) Wheel rim Rear casting Ball joint Lock nut Grease fitting Bolt (2 each) Wheel hub Lock washer...
Page 292 Removing the Rear Fork and Wheel 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the key switch. 2. Remove the hood from the machine. 3. Separate the hydraulic cylinder from the rear fork as follows: A.
Page 293: Rear Fork And Wheel Without Hydraulic Motor
Rear Fork and Wheel without Hydraulic Motor g344288 Figure 156 Tire Drive studs (4 each) Grease fitting Lug nut (4 each) Oil seal Lock washer Valve stem Lock nut (4 each) Thrust washer Wheel rim Cotter pin Bolt Hub and bearing assembly Spindle Flex-top nut (2 each) Dust cap...
Page 294 Removing the Rear Fork and Wheel 1. Park the machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the key switch. 2. Remove the hood from the machine. 3. Separate the hydraulic cylinder from the rear fork as follows: A.
Page 295 Installing the Rear Fork and Wheel 1. If removed, install the bushings into the rear fork. 2. Position the rear fork through the frame. 3. Install the lock washer, thrust washer, and bolt to the rear fork shaft. Torque the bolt from 81 to 108 N·m (60 to 80 ft−lb). Make sure that the fork turns freely.
Page 296: Brake Linkages
Brake Linkages g344438 Figure 157 Wheels, Brakes and Chassis: Service and Repairs Page 7–18 Reelmaster ® 3100-D/3105-D 20252SL Rev A...
Page 297 Figure 157 (continued) Magnet support Parking brake link Flange bushing Washer head bolt Clevis pin Brake pivot bracket Strike bracket Cotter pin Cotter pin Washer head bolt Clevis pin Clevis pin Magnet catch Cotter pin Jam nut Rivet Lock nut Cotter pin Cover bracket Flat washer...
Page 298: Steering Column
Steering Column g344474 Figure 158 Steering arm Flange hex nut Jam nut Flange hex nut Steering wheel Flat washer Hex flange head bolt Hydraulic fitting Flange head bolt Steering control valve bracket Hydraulic fitting Bolt Bolt Steering wheel nut Washer Pivot hub Decal O−ring...
Page 299 Disassembling the Steering Column 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the key switch. 2. Remove the philips pan head screws and steering wheel cap from the steering wheel. 3.
Page 300 Assembling the Steering Column (continued) 5. Install steering wheel to the steering control valve. Secure steering wheel nut to the steering control valve. Torque steering wheel nut from 27.1 to 35.3 N·m (20 to 26 ft−lb). 6. Secure steering wheel cap to the steering wheel with six philips pan head screws.
Page 301: Front Lift Arms
Front Lift Arms g346349 Figure 160 Model 03171 (shown) 45º hydraulic fitting Lift arm pivot shaft Bulkhead nut Hydraulic cylinder Bolt Hydraulic tube Carrier assembly Pivot shaft link Bulkhead nut Flange nut Flange head screw Hose rod Flange head screw Cap screw Flange head screw Hydraulic hose...
Page 302 Removing the Front Lift Arms 1. Park the machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the key switch. 2. Remove the cutting units from the pivot shaft of the front lift arms (see Cutting ...
Page 303: Rear Lift Arm
Rear Lift Arm g346266 Figure 161 Model 03171 (shown) Reelmaster ® 3100-D/3105-D Page 7–25 Wheels, Brakes and Chassis: Service and Repairs 20252SL Rev A...
Page 304 Figure 161 (continued) Hydraulic tube Flat washer Lock washer Lock nut Cap screw Guard Hydraulic T−fitting Lock nut Cap screw Hydraulic hose Rear pivot shaft Cap screw 90º hydraulic fitting Jam nut Lock nut Hydraulic hose Washer External retaining ring Hydraulic tube Rear lift arm assembly 90º...
Page 305 Installing the Rear Lift Arm (continued) 4. Install the rear cutting unit to the pivot shaft of the rear lift arm (see Cutting Unit Operator s Manual). 5. Adjust the lift arm (see Traction Unit Operator s Manual). IMPORTANT Make sure hydraulic hoses are free of twists and sharp bends.
Page 306: Traction Pedal
Traction Pedal g344483 Figure 162 Wheels, Brakes and Chassis: Service and Repairs Page 7–28 Reelmaster ® 3100-D/3105-D 20252SL Rev A...
Page 307 Traction Pedal (continued) Figure 162 (continued) Bolt Rocker arm Floor plate assembly Flat washer Bolt (2 each) Carriage bolt (4 each) Flat washer (3 each) Flat washer Carriage bolt Rod end ball joint Bolt Carriage bolt Spacer Jam nut Socket head screw Grip ring Retaining ring (2 each) Bolt...
Page 308 Wheels, Brakes and Chassis: Service and Repairs Page 7–30 Reelmaster ® 3100-D/3105-D 20252SL Rev A...
Page 309: Chapter 8: Dpa Cutting Units
Chapter 8 DPA Cutting Units Table of Contents General Information ..........................8–2 Cutting Unit Operator's Manual ......................8–2 Adjustments ............................8–3 Cutting Unit Characteristics........................ 8–3 Leveling Rear Roller .......................... 8–4 Service and Repairs ..........................8–6 Hydraulic Reel Motor.......................... 8–6 Backlapping ............................8–8 Bedbar Assembly..........................
Page 310: General Information
General Information Cutting Unit Operator's Manual The Cutting Unit Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for the cutting units on your machine. Additionally, if optional kits have been installed on the cutting units (e.g. groomer), the Installation Instructions for the kit includes set-up, operation and maintenance information.
Page 311: Adjustments
Adjustments Cutting Unit Characteristics CAUTION Do not install or work on the cutting units or lift arms with the engine running. Always shut off the engine and remove the key from the key switch. The dual knob bedknife-to-reel adjustment system incorporated in this cutting unit simplifies the adjustment procedure needed to deliver optimum mowing performance.
Page 312: Leveling Rear Roller
Leveling Rear Roller The precision machined components of the cutting unit frame keep the rear roller and cutting reel in alignment (parallel). If the side plates are disassembled or as the cutting reel wears, a limited amount of side plate adjustment is possible to make sure that the cutting unit is properly aligned.
Page 313 Leveling Rear Roller (continued) g214395 Figure 164 Rear roller assembly Flange nut Rear roller bracket Roller shim Carriage screw 0.010” shim (if needed) 7. If rear roller is still not level after adjusting both side plates, check to see if cutting reel is tapered (refer to Preparing the Reel for Grinding (page 8–29)).
Page 314: Service And Repairs
Service and Repairs Hydraulic Reel Motor IMPORTANT When performing the maintenance procedures on the cutting units, carefully position the cutting unit reel motors to prevent damage to the motors or hydraulic hoses. Removing the Hydraulic Reel Motor 1. Park the machine on a clean and level surface, lower the cutting units completely to the ground, shut off the engine, set the parking brake, and remove the key from the key switch.
Page 315 Installing the Hydraulic Reel Motor (continued) g343374 Figure 166 Hydraulic reel motor Cap screw 3. Rotate the motor clockwise so the motor flanges clear the cap screws in the cutting unit side plates. Align reel motor shaft splines with cutting reel insert splines.
Page 316: Backlapping
Backlapping DANGER TO AVOID PERSONAL INJURY OR DEATH: • Never place hands or feet in the reel area while the engine is running. Stay away from the cutting reels when backlapping. • When backlapping, run engine at idle speed only. •...
Page 317 168). This will remove any burrs or rough edges that may have built up on the cutting edge. Note: Additional instructions and procedures on backlapping are available in the Toro General Service Training Book, Reel Mower Basics (part no. 09168SL). Reelmaster ®...
Page 318: Bedbar Assembly
Bedbar Assembly g343482 Figure 169 Bedbar assembly Plastic washer (4 each) Bedbar pivot bolt (2 each) Lock nut (2 each) Rubber bushing (2 each) Lock nut (2 each) Compression spring (2 each) Flange bushing (2 each) Washer (2 each) Metal washer (2 each) Removing the Bedbar Assembly CAUTION Contact with the reel, bedknife or other cutting unit parts can result...
Page 319 Removing the Bedbar Assembly (continued) 4. Loosen the lock nuts (item 10) on each bedbar pivot bolt. 5. Remove two (2) bedbar pivot bolts (item 9), two (2) metal washers and four (4) plastic washers from the cutting unit side plates. 6.
Page 320 Installing the Bedbar Assembly (continued) 7. Install the bedbar pivot bolt assemblies: A. Push each bedbar pivot bolt through the side plate and into the bedbar enough to hold the bedbar in position. IMPORTANT Do Not use a powered wrench or an impact wrench to install the bedbar pivot bolts.
Page 321: Bedknife Replacement And Grinding
Bedknife Replacement and Grinding Removing the Bedknife g214675 Figure 171 Screw (8 each) Bedbar Bedknife 1. Remove the bedbar from cutting unit (refer to Removing the Bedbar Assembly (page 8–10)). Note: 18” cutting units use 6 screws to secure bedknife to bedbar. 22” cutting units use 8 screws to secure bedknife to bedbar.
Page 322 Installing the Bedknife (continued) g251663 Figure 172 5. Using a torque wrench and bedknife screw tool, tighten the 2 outer screws to 1 N·m (10 in-lb). 6. Working from the center of the bedknife toward each end (refer to Figure 172), tighten screws from 23 to 28 N·m (200 to 250 in-lb).
Page 323 Because the top grind angle on bedknives is critical for edge retention, and therefore after-cut appearance, Toro has developed special service tools for accurately measuring the top grind angle on all bedknives; refer to the Angle Indicator and Magnetic Mount in the Special Tools (page 2–13).
Page 324 Grinding the Bedknife (continued) g214496 Figure 175 Bedknife Lead-in chamfer 1. Use Toro General Service Training Book, Reel Mower Basics (part no. 09168SL) and grinder manufacturer’s instructions for bedknife grinding information. 2. lead-in chamfer is ground into all new bedknives (Figure 175).
Page 325: Servicing The Bedbar Adjuster
Servicing the Bedbar Adjuster g343496 Figure 176 Bedbar assembly Flange bushing Flat washer Compression spring Cap screw Bedbar adjuster shaft Lock nut Detent Washer Bedbar adjuster screw Lock nut Wave washer Removing the Bedbar Adjuster 1. Remove the lock nut (item 3 in Figure 176), compression spring and washer from bedbar adjuster screw (item 4).
Page 326 Installing the Bedbar Adjuster (continued) and lock nut. Tighten lock nut to shoulder of adjuster shaft and then torque lock nut from 21 to 27 N·m (15 to 20 ft-lb). Note: Inside threads in bedbar adjuster shaft (item 4) are left-hand threads. 4.
Page 327: Reel Assembly
Reel Assembly g343551 Figure 177 Bedbar assembly Lock nut (2 each) Cutting reel assembly Cutting unit frame RH side plate Wire spring Flange bushing (2 each) LH side plate Flange nut (3 each per side plate) Plastic washer (4 each) Weight Shoulder bolt (3 each per side plate) Metal washer (2 each)
Page 328 Note: Removal of the cutting reel requires removal of the left side plate from the cutting unit frame. The right side plate does not have to be removed from the frame. g343552 Figure 178 Frame Rear grass shield Flat washer LH side plate Flange nut (6 each) Washer (2 each)
Page 329: Chapter 9: Universal Groomer (Optional)
Removing the Reel Assembly (continued) 3. If cutting unit is equipped with a counterweight or accessory on LH side plate, remove the counter weight or accessory from the cutting unit. Remove and discard O-ring from counter weight. Refer to Chapter 9: Universal Groomer (Optional) (page 9–1) for additional Groomer information.
Page 330 Removing the Reel Assembly (continued) IMPORTANT The spline insert on the left end of the cutting reel has left hand threads and the spline insert on the right end of the cutting reel has right hand threads. D. Rest the handle of the pry bar against the front roller and loosen the spline insert closest to the pry bar.
Page 331 Installing the Reel Assembly (continued) g343554 Figure 180 Side plate - RH Side plate - LH 4. Apply a thin coat of antiseize lubricant to the reel bearing bore of each side plate (Figure 180). CAUTION Contact with the reel, bedknife or other cutting unit parts can result in personal injury.
Page 332 Installing the Reel Assembly (continued) 13. Adjust the cutting unit (refer to Cutting Unit Operator’s Manual). Note: The parallel position of the rear roller to the cutting reel is controlled by the precision machined frame and side plates of the cutting unit. If necessary, the cutting unit side plates can be loosened and a slight adjustment can be made to parallel the rear roller with the cutting reel (refer to Leveling Rear...
Page 333 Installing the Reel Assembly (continued) C. Rest the handle of the pry bar against the front roller and tighten the spline insert closest to the pry bar. The spline inserts are installed with thread locking compound (Loctite #243 or equivalent). Tighten the spline insert from 115 to128 N·m (85 to 95 ft-lb).
Page 334: Reel Assembly Service
Reel Assembly Service g343570 Figure 182 Cutting reel Special washer Groove indicating LH threads Threaded insert (RH thread) Flocked seal Reel spider Plastic plug (2) Sealed bearing Retaining ring groove Retaining ring Threaded insert (LH thread) Bearing shoulder Inspecting the Cutting Reel 1.
Page 335 Inspecting the Cutting Reel (continued) B. Use correct spline insert tool to remove threaded inserts (refer to Special Tools (page 2–13)). Assembling the Cutting Reel g343571 Figure 183 Reel shaft Plastic plug (2 each) 1. If removed, install new reel shaft plugs into cutting reel shaft. For cutting unit serial no.
Page 336 Assembling the Cutting Reel (continued) 6. Fill threaded insert splines with high temp Mobil XHP-222 grease or equivalent. DPA Cutting Units: Service and Repairs Page 8–28 Reelmaster ® 3100-D/3105-D 20252SL Rev A...
Page 337: Preparing The Reel For Grinding
When grinding, be careful to not overheat the cutting reel blades. Remove small amounts of material with each pass of the grinder. Follow reel grinder manufacturer’s instructions to grind cutting reel to Toro specifications (refer to Reel Grinding Specifications Table (page 8–30)).
Page 338 Preparing the Reel for Grinding (continued) Manual. An additional resource is the Toro Basics Series Training Book, Reel Mower Basics (part no. 09168SL) found on the Service Reference Set available from your Authorized Toro Distributor. Reel Grinding Specifications Table Reel diameter (new) 179.3 mm (7.060 inches)
Page 339: Front Roller
Front Roller g214676 Figure 186 Cap screw Carriage screw Flat washer Cap screw Flange nut Flange nut HOC (roller) bracket Front roller assembly Removing the Front Roller 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and remove key from the key switch.
Page 340 Installing the Front Roller (continued) B. Apply anti-seize lubricant to cap screw threads that will extend into height-of-cut (roller) bracket. C. Thread cap screw into bracket. Note: When assembling height-of-cut (roller) brackets to side plate, make sure that the cap screw head and one washer are above adjustment flange on side plate and second washer and flange lock nut are below flange.
Page 341: Shop Roller Assembly (Model 03192)
Shop Roller Assembly (Model 03192) g348049 Figure 187 Clevis pin Washer Carriage bolt Spacer Roller Cotter hairpin Flange head nut Roller bracket Removing the Shop Roller Assembly 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and remove key from the key switch.
Page 342: Rear Roller
Rear Roller g214395 Figure 188 Rear roller assembly Flange nut (2 each) Rear roller bracket Roller shim (2 each) Carriage screw (2 each) 0.010 inch shim (if necessary) Removing the Rear Roller (Figure 188) 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and remove key from the key switch.
Page 343 Installing the Rear Roller (Figure 188) (continued) carriage screws and flange nuts to retain bracket in position. Do not fully tighten flange nuts. 3. Slide rear roller shaft into the rear roller bracket attached to the cutting unit. Slide second rear roller bracket onto the other end of roller shaft. Secure second roller bracket and shims to cutting unit side plate with two (2) carriage screws and flange nuts.
Page 344: Servicing The Roller
Servicing the Roller g195108 Figure 189 Roller tube Outer seal Roller shaft Bearing lock nut Inner seal Grease fitting Bearing Disassembling the Roller (Figure 189) 1. Remove the bearing lock nut from each end of roller shaft. 2. Loosely secure roller assembly in bench vise and lightly tap one end of roller shaft until outer seals and bearing are removed from opposite end of roller tube.
Page 345 Assembling the Roller (Figure 189) g195710 Figure 190 Roller tube Inner seal tool Inner seal 1. Install inner seals into roller tube making sure that seal lip (and garter spring) faces end of tube. Use inner seal tool (refer to Special Tools (page 2–13)) and soft face hammer to fully seat seals against roller shoulder...
Page 346 Assembling the Roller (Figure 189) (continued) g195712 Figure 192 Roller tube Outer seal Inner seal Bearing/outer seal tool Bearing C. Install first outer seal into roller tube making sure that seal lip (and garter spring) faces end of tube. Use bearing/outer seal tool (refer to Special Tools (page 2–13)) and soft face hammer to lightly seat seal against...
Page 347 Assembling the Roller (Figure 189) (continued) g252750 Figure 194 Roller tube Bearing Roller shaft Outer seal Inner seal Bearing/outer seal tool D. Carefully install first outer seal into roller tube making sure that seal lip (and garter spring) faces end of tube. Use bearing/outer seal tool (refer Special Tools (page 2–13)) and soft face hammer to lightly seat seal (Figure...
Page 348: Rear Roller Brush - Optional
Rear Roller Brush – Optional g343582 Figure 195 Brush bearing housing (non-drive) Cap screw (4 each) Grease fitting Brush bearing housing (drive) Spacer Grease seal O-ring Flat washer (for pulley alignment) Ball bearing Roller brush shaft Driven pulley Grease fitting Flange nut (4 each) Flange nut Grease seal...
Page 349 Disassembling the Rear Roller Brush (Figure 195) (continued) C. Remove lock nut and J-bolt from both ends of the brush. D. While rotating brush, slide brush from the shaft. 3. Disassemble roller brush components as necessary using Figure 195 as a guide.
Page 350 Assembling the Rear Roller Brush (Figure 195) (continued) 2. If roller brush was removed from roller shaft, slide brush onto shaft while rotating brush. Secure brush to shaft with two (2) J-bolts and lock nuts. Make sure that the J-bolts are installed with the threaded portion on the outside of the brush (Figure 196).
Page 351 Disassembling the Drive System g343595 Figure 199 Carriage screw (2 used) Idler spring Drive pulley Carriage screw (3 used) Pivot washer Spacer Brush plate Drive belt Flange bushing Cap screw (2 used) Idler pulley Cover Flat washer (4 used) Retaining ring Flange nut (2 used) Lock nut (6 used) Bearing...
Page 352 Disassembling the Drive System (continued) g230301 Figure 200 Drive housing Socket-head screw Drive shaft Grommet O-ring g228652 Figure 201 Drive shaft with right-hand threads (no Drive shaft with left-hand threads (with groove) groove) 4. Remove roller brush drive shaft if needed: A.
Page 353 Assembling the Drive System 1. Install drive shaft if it was removed: IMPORTANT If rear roller brush drive is on left side of cutting unit, drive shaft has left hand threads and can be identified by a groove on the flange. If the rear roller brush drive is on right side of cutting unit, drive shaft has right hand threads and does not have a groove on the flange...
Page 354 Assembling the Drive System (continued) A. The outer faces of the drive and driven pulleys (not the idler pulley) should be in-line within 0.76 mm (0.030 in). g214811 Figure 203 Flange nut Flat washer Driven pulley Roller brush shaft B. If necessary to align pulleys, remove driven pulley from brush shaft and add or remove flat washer( s) until drive and driven pulleys are correctly aligned (Figure...
Page 355 Chapter 9 Universal Groomer (Optional) Table of Contents General Information ..........................9–2 Installation Instructions ........................9–2 Service and Repairs ..........................9–3 Gear Box Assembly ........................... 9–5 Idler Assembly ..........................9–13 Groomer Reel ..........................9–15 Groomer Reel Service........................9–17 Grooming Brush (Optional) Service ....................9–19 Height Adjuster Assembly ........................
Page 356: General Information
General Information Installation Instructions The Installation Instructions for the groomer provides information regarding the set-up, operation, general maintenance procedures, and maintenance intervals for the groomer assembly on your Reelmaster machine. Refer to the Installation Instructions for additional information when servicing the groomer assembly. Universal Groomer (Optional): General Information Page 9–2 Reelmaster...
Page 357: Service And Repairs
Service and Repairs g343764 Figure 204 Gear box assembly Height adjuster assembly (2) Button head screw (2) Idler assembly Plate Groomer reel Weights CAUTION Never work on the groomer with the engine running. Always stop the engine, remove the key from the key switch and wait for all machine movement to stop before working on the groomer.
Page 358 Note: The Groomer Operator’s Manual provides information regarding the installation, set-up, operation and maintenance of the universal groomer on your Reelmaster machine. Refer to these instructions for additional information when servicing the groomer. Universal Groomer (Optional): Service and Repairs Page 9–4 Reelmaster ®...
Page 359: Gear Box Assembly
Gear Box Assembly g343768 Figure 205 Gear box assembly Cotter pin Input shaft Rear roller brush drive shield Clevis pin Note: The groomer gear box assembly is located on the opposite side of the cutting unit from the cutting unit hydraulic motor. Removing the Gear Box Assembly 1.
Page 360 Reel support plate Gear box assembly Pry bar 5. Install a 5/16–18 X 5/8 inch square head set screw (Toro p/n 1-803022) in the end of the drive shaft and tighten to 13 N·m (120 in-lb); refer to (Figure 206).
Page 361 Removing the Gear Box Assembly (continued) IMPORTANT You must use a 6-point socket with a heavy wall to remove the gear box from the reel. Do not use an impact wrench. Groomer gear boxes installed on the left side of the cutting unit use a left hand thread; turn the drive shaft in correct direction to remove the gear box.
Page 362 Move the pry bar against the weld side of the reel support plate closest to the drive shaft assembly. J. Use the drive shaft removal tool (Toro p/n 137-0920) on the large flats of the drive shaft assembly; refer to Figure 208.
Page 363 Disassembling the Gear Box Assembly g343772 Figure 209 Threaded adapter Bushing (2) Bushing (3) Lock nut Input shaft Drain/fill plug (4) Ball O-Ring (2) Output gear V-Ring Detent spring Bearing (2) Seal Seal Housing Bearing (2) Socket head screw (4) Seal Retaining ring Cover...
Page 364 Disassembling the Gear Box Assembly (continued) CAUTION Use the 1-3/8” flats on the input shaft to prevent the input shaft from rotating during adapter removal. DO NOT use the 1/2” hex on the input shaft to secure the shaft during adapter removal or input shaft damage may occur.
Page 365 Assembling the Gear Box Assembly (continued) 8. Fit gear box cover over dowel pins and install four (4) socket head screws. Tighten screws from 2 to 4 N·m (15 to 40 in-lb). In an alternating cross pattern, tighten four (4) socket head screws from 8 to 9 N-m (75 to 85 in-lb). 9.
Page 366 Installing the Gear Box Assembly (continued) g343774 Figure 211 Square head set screw Reel shaft Reel support plate Input shaft assembly Pry bar Gear box assembly 3. Insert a long-handled pry bar through the front of the cutting unit. The pry bar should pass between the top of the reel shaft and the backs of the reel blades so that the reel will not move.
Page 367: Idler Assembly
Idler Assembly g343775 Figure 212 Socket head screw (2) Cotter pin Retaining ring Pivot hub Clevis pin Flange nut Idler arm Stub shaft and shield Collar Bushing Bearing shield (2) Threaded insert Bearing Note: The groomer idler assembly is located on the same side of the cutting unit as the cutting unit hydraulic motor.
Page 368 Removing the Idler Assembly (continued) 6. Inspect shields, bearing and bushing in idler assembly. Remove and discard damaged or worn components. Installing the Idler Assembly 1. If shields, bearing or bushing was removed from idler arm, install new components. A. Press bushing into groomer plate until the bushing is centered in the idler arm bore.
Page 369: Groomer Reel
Groomer Reel g343766 Figure 214 Groomer reel Cap screw (4) Shaft clamp (4) Jam nut (4) Remove the groomer reel to replace individual groomer blades or replace the shaft. The groomer reel can be reversed to provide additional blade life. Removing the Groomer Reel 1.
Page 370 Installing the Groomer Reel 1. Position cutting unit on a level surface. If cutting unit is attached to traction unit, make sure to stop engine, engage parking brake and remove key from the key switch. 2. Position the groomer reel between the groomer output and stub shafts. 3.
Page 371: Groomer Reel Service
Groomer Reel Service g220506 Figure 215 Groomer reel shaft 6.3 mm (1/4 inch) spacer (2 each) Sharp edge Groomer blade (40 each) Locknut (2 each) Midpoint 31.7 mm (1–1/4 inch) spacer (39 Centered on shaft Dull (rounded) edge each) Inspect groomer reel blades frequently for damage and wear. Straighten bent blades.
Page 372 Assembling the Groomer Reel (continued) 4. Using through holes in shaft to prevent shaft from rotating, tighten second lock nut from 42 to 48 N·m (31 to 35 in-lb). After tightening lock nut, spacers should not be free to rotate and groomer blades should be centered on shaft. 5.
Page 373: Grooming Brush (Optional) Service
Grooming Brush (Optional) Service g343777 Figure 217 The optional grooming brush is removed and installed from the groomer in the same manner as the groomer reel (refer to Groomer Reel (page 9–15)). The grooming brush element or shaft can be serviced separately (Figure 217).
Page 374: Height Adjuster Assembly
Height Adjuster Assembly g343767 Figure 218 Lock nut Height of cut bracket Clevis pin Height adjustment bolt Button head screw Washer (2) Washer (2) Detent spring Outer spring Lock nut Groomer height adjuster knob Inner spring Carriage bolt Quick up cover Height adjustment rod Flange nut Quick up lever...
Page 375 Assembly of Height Adjuster Assembly 1. Apply anti-seize lubricant to upper threads of adjustment rod and lower threads of height adjusters. Assemble height adjuster assembly as shown. 2. If both height adjusters were removed, fit one height adjuster assembly to the cutting unit side plate and secure with carriage bolt and flange nut.
Page 376 Universal Groomer (Optional): Service and Repairs Page 9–22 Reelmaster ® 3100-D/3105-D 20252SL Rev A...
Page 377 Appendix A Foldout Drawings Table of Contents Electrical Drawing Designations......................A–2 Hydraulic Schematic-3100-D (Model 03170) ..................A–3 Hydraulic Schematic-3100-D (Model 03171) ..................A–4 Hydraulic Schematic-3105-D (Model 03174) ..................A–5 Electrical Schematic...........................A–6 Wire Harness Drawing ........................A–7 Wire Harness Drawing ........................A–8 Reelmaster ® 3100-D/3105-D Page A–1 Foldout Drawings 20252SL Rev A...
Page 378: 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 379: Hydraulic Schematic-3100-D (Model 03170
Hydraulic Schematic-3100-D (Model 03170) g346770 Reelmaster 3100-D (Model 03170), Drawing 110-8783 Rev D, Sheet 1 of 1 20252SL Rev A Page A–3...
Page 380: Hydraulic Schematic-3100-D (Model 03171
Hydraulic Schematic-3100-D (Model 03171) g346771 Page A–4 20252SL Rev A Reelmaster 3100-D (Model 03171), Drawing 110-8782 Rev C, Sheet 1 of 1...
Page 381: Hydraulic Schematic-3105-D (Model 03174
Hydraulic Schematic-3105-D (Model 03174) g346769 Reelmaster 3105-D (Model 03174), Drawing 136-3617 Rev B, Sheet 1 of 1 20252SL Rev A Page A–5...
Page 382: Electrical Schematic
Electrical Schematic g346835 Page A–6 20252SL Rev A Reelmaster 3100-D & 3105-D , Drawing 122-1522 Rev A, Sheet 1 of 1...
Page 383: Wire Harness Drawing
Wire Harness Drawing g346834 Reelmaster 3100-D & 3105-D, Drawing 122-1523 Rev B, Sheet 1 of 2 20252SL Rev A Page A–7...
Page 384: Wire Harness Drawing
Wire Harness Drawing g346833 Page A–8 20252SL Rev A Reelmaster 3100-D & 3105-D, Drawing 122-1523 Rev A, Sheet 2 of 2...

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Reelmaster 3105-d 03170 03171 03174

Toro Reelmaster 3100-D Service Manual

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Chapter 4: Engine

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Chapter 6: Electrical System

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Chapter 8: Dpa Cutting Units

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