Page 1 Form No. 19241SL Rev B ProLine H800 (Models 31050, 31050TE and 31051) © 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. 06/2020 7/2021 Add model 31051 and optional slope sensor information. Revision History Page 2 ProLine H800 19241SL Rev B...
Page 3 Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.com.
Page 4 NOTES: NOTES: Page 4 ProLine H800 19241SL Rev B...
Page 5 Operator’s Manuals and Parts Catalog for your machine. Additional copies of the Operator’s Manuals and Parts Catalogs are available at www.toro.com. The Toro Company reserves the right to change the product specifications or this publication without notice. DANGER This safety symbol means danger.
Page 6 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 7: Table Of Contents
Table of Contents Preface ........................ 5 Chapter 1: Safety .................... 1–1 Safety Instructions ..................1–2 Jacking Instructions ..................1–7 Safety and Instructional Decals ..............1–9 Chapter 2: Specifications and Maintenance ............ 2–1 Specifications ....................2–2 Torque Specifications ................... 2–7 Shop Supplies .................... 2–13 Special Tools ....................
Page 8: Preface
Additional Reference Materials Yanmar 3TNV76 Service Manual Yanmar 3TNV80F Service Manual Danfoss DDC20 Axial Piston Pump Service Manual Parker Torqmotor Service Procedure (TF, TG, TH, and TL Series) Grammer Seats Repair Manual Preface Page 8 ProLine H800 19241SL Rev B...
Page 9 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........................1–5 Jacking Instructions ..........................1–7 Raising the Front of the Machine......................1–7 Raising the Rear of the Machine ......................
Page 10: Safety Instructions
Safety Instructions The ProLine H800 machines are tested and certified by Toro for compliance with existing safety standards and specifications. Although hazard control and accident prevention are partially dependent upon the design and configuration of the machine, hazard control and accident prevention are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance and storage of the machine.
Page 11: Before Operating The Machine
Become familiar with the controls and know how to stop the machine and engine quickly. Additional copies of the Operator’s Manuals are available at www.toro.com. • Never allow children to operate the machine. Never allow adults to operate the machine without proper instructions.
Page 12: While Operating The Machine
While Operating the Machine • Sit on the seat when starting and operating the machine. • Anytime you park the machine (short or long term), lower the cutting deck to the ground. IMPORTANT When you lower the cutting deck to the ground, the pressure from the hydraulic lift circuit releases and prevents the cutting deck from accidentally lowering.
Page 13: Maintenance And Service
Jacking Instructions (page 1–7). • If major repairs are necessary, contact your Authorized Toro Distributor. ProLine H800 Page 1–5 Safety: Safety Instructions 19241SL Rev B...
Page 14 At the time of manufacture, the machine conformed to the safety standards for riding mowers. To ensure the optimum performance and continued safety certification of the machine, use genuine Toro replacement parts and accessories. The replacement parts and accessories of other manufacturers can result in non-conformance with the safety standards and can void the warranty.
Page 15: Jacking Instructions
Jacking Instructions CAUTION Failing to properly support the machine with appropriate jack stands can cause the machine to move or fall and can result in personal injury. When changing the attachments, tires, or performing other services, do the following steps: •...
Page 16 Raising the Front of the Machine (continued) g216339 Figure 2 Bolt Fuel-tank bracket 3. Access left side of the engine as follows: A. Remove the bolt from the left side of the fuel-tank bracket (Figure B. Rotate the fuel tank to access the left side of the engine (Figure g224454 Figure 3...
Page 17: Safety And Instructional Decals
Numerous safety and instruction decals are affixed to the traction unit and cutting deck of your ProLine H800. If any decal becomes illegible or damaged, install a new decal. Decal part numbers are listed in your Parts Catalog. Order replacement decals from Authorized Toro Distributor. ProLine H800 Page 1–9...
Page 18 Safety: Safety and Instructional Decals Page 1–10 ProLine H800 19241SL Rev B...
Page 19 Specifications and Maintenance Table of Contents Specifications ............................2–2 Overall Dimensions..........................2–2 Engine - ProLine H800 (for Model 31050) ..................2–3 Engine - ProLine H800 (for Model 31050TE and 31051) ..............2–4 Hydraulic System ..........................2–5 Chassis .............................. 2–6 Torque Specifications ........................... 2–7 Identifying the Fastener........................
Page 20: Specifications
Specifications Overall Dimensions g288868 Figure 6 Specifications and Maintenance: Specifications Page 2–2 ProLine H800 19241SL Rev B...
Page 21: Engine - Proline H800 (For Model 31050)
Engine - ProLine H800 (for Model 31050) g288869 Figure 7 (Yanmar 3TNV80F - Shown) Alternator Flywheel Item Description Make/Designation Yanmar 3TNV76-XGZ: 4-cycle, 3 cylinder water cooled diesel. EPA Tier 3 compliant. Bore 76 mm (3 inches) Stroke 82 mm (3.2 inches)
Page 22: Engine - Proline H800 (For Model 31050Te And 31051)
Engine - ProLine H800 (for Model 31050TE and 31051) Item Description Make/Designation Yanmar 3TNV80-NXDGZ: 4-cycle, 3 cylinder water cooled diesel. EPA Tier 4 compliant. Bore 80 mm (3.15 inches) Stroke 84 mm (3.31 inches) Total displacement 1,267 cm³ (77.31 in³) Firing order 1 (flywheel end) - 3 (fan end) - 2 Compression Ratio...
Page 23: Hydraulic System
Hydraulic System Item Description Piston Pump Danfoss DDC20 Displacement (per revolution) 20 cm³ (1.22 in³) Relief Pressure 280 bar (4060 psi) Charge Pressure 7 bar (101.5 psi) Front Wheel Motors Parker TL Displacement (per revolution) 238 cm³ (14.5 in³) Rear Wheel Motors Parker TL Displacement (per revolution) 169 cm³...
Page 24: Chassis
Chassis Item Description Blades screws torque 50 N·m (37 ft-lb) Blades disc torque 53 N·m (40 ft-lb) Electro-magnetic clutch mid-screw torque 50 N·m (37 ft-lb) Wheels bolts torque 85 N·m (63 ft-lb) Engine-hydrostat bolt troque 350 N·m (258 ft-lb) Specifications and Maintenance: Specifications Page 2–6 ProLine H800 19241SL Rev B...
Page 25: Torque Specifications
Torque Specifications The recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual.
Page 26 Toro recommends replacing fasteners with a locking feature once they have been removed because the effectiveness of the locking feature diminishes with each reuse. If it is necessary to reuse a fastener with a locking feature; apply a thread locking compound (Loctite for example) to the fastener during installation.
Page 27: Calculating The Torque Values When Using A Drive-Adapter Wrench
Calculating the Torque Values When Using a Drive-Adapter Wrench g211753 Figure 10 Drive-adapter wrench Torque wrench Effective length of torque wrench Effective length of torque wrench + drive-adapter wrench Using a drive-adapter wrench (e.g., crowfoot wrench) in any position other than 90°...
Page 28: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Inch)
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch) 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 Thread sealant Used to seal threaded fittings and sensors from air, fuel, and oil pressure leaks and prevent galling and seizure between threaded parts. A thread sealant in paste firm is preferred over sealant tape. The sealant should remain semi-pliable to allow for component removal with standard tools. Some thread sealants may require the use of a cleaner or primer before use.
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 K-Line 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 2–16). Note: The replacement filter element is Toro Part No. TOR6012. The filter element canister tightening torque is 34 N∙m (25 ft-lb). Wheel Hub Puller...
Page 37 Remote Starter Switch (purchased) switch connector for circuit protection. A remote stater switch can also be constructed using Toro switch #106−2027, a length of 14 gauge wire, a 20 amp in−line fuse, two (2) alligator clips and necessary connectors. Connecting the...
Page 38 This excess current can damage the circuits that are not designed to carry it. Battery Terminal Protector Toro Part No. 107-0392 Use this aerosol spray on the battery terminals, ring terminals, and fork terminals to reduce corrosion problems. Apply the...
Page 39 Chapter 3 Troubleshooting Table of Contents GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems ......3–2 General Hydraulic System Problems ..................... 3–3 Steering Circuit Problems ........................3–5 The Height Of Cut Circuit Problems....................... 3–6 The Cutting Deck Lift Circuit Problems ....................3–7 The Hopper Lift Circuit...........................
Page 40: Gears - The Systematic Approach To Defining, Diagnosing And Solving Problems
GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems 1. Gather Information • Information reported by the customer • Information observed by you • Establish the what, where and when of the issue 2. Evaluate Potential Causes • Consider possible causes of the problem to develop a hypothesis •...
Page 41: General Hydraulic System Problems
General Hydraulic System Problems Problem Possible Cause Corrective Action Hydraulic fluid is leaking from the The fitting(s), hose(s), or tube(s) are Secure or replace loose or damaged system. loose or damaged. hydraulic connections. The O-ring(s) or seal(s) are missing or Install a new O-ring(s) or seal(s).
Page 42 General Hydraulic System Problems (continued) Problem Possible Cause Corrective Action The traction response is sluggish. The hydraulic fluid is very cold. Allow the hydraulic fluid to warm by safely operating the machine at rest. The hydraulic fluid level in the hydraulic Adjust the hydraulic fluid level.
Page 43: Steering Circuit Problems
Steering Circuit Problems Problem Possible Cause Corrective Action The steering is inoperative or sluggish. Engine RPM is too low. Increase the engine RPM. The hydraulic fluid level in the hydraulic Adjust the hydraulic fluid level. tank is low. Repair or replace the components. The steering components (e.g., tie rods, steering cylinder ends) are worn or binding.
Page 44: The Height Of Cut Circuit Problems
The Height Of Cut Circuit Problems Problem Possible Cause Corrective Action The height of cut will not lift or lift slowly. Engine RPM is too low. Increase the engine RPM. The hydraulic fluid level in the hydraulic Adjust the hydraulic fluid level. tank is low.
Page 45: The Cutting Deck Lift Circuit Problems
The Cutting Deck Lift Circuit Problems Problem Possible Cause Corrective Action The cutting deck lift circuit will not lift Engine RPM is too low. Increase the engine RPM. or lift slowly. The hydraulic fluid level in the hydraulic Adjust the hydraulic fluid level. tank is low.
Page 46: The Hopper Lift Circuit
The Hopper Lift Circuit Problem Possible Cause Corrective Action The hopper will not lift or lift slowly. Engine RPM is too low. Increase the engine RPM. The hydraulic fluid level in the hydraulic Adjust the hydraulic fluid level. tank is low. The hopper lift cylinders is binding.
Page 47: The Hopper Tilt Circuit
The Hopper Tilt Circuit Problem Possible Cause Corrective Action The hopper will not tilt or tilts slowly. Engine RPM is too low. Increase the engine RPM. The hydraulic fluid level in the hydraulic Adjust the hydraulic fluid level. tank is low. The hopper tilt cylinders is binding.
Page 48 Troubleshooting: The Hopper Tilt Circuit Page 3–10 ProLine H800 19241SL Rev B...
Page 49 Chapter 4 Engine Table of Contents General Information ..........................4–2 Traction Unit Operator’s Manual ......................4–2 Yanmar Service Manuals ........................4–2 Service and Repairs ..........................4–3 Air Cleaner Assembly......................... 4–3 Exhaust System ..........................4–5 Radiator ............................. 4–7 Fuel System ............................. 4–11 Engine..............................
Page 50: General Information
Service and repair parts for the Yanmar engines are supplied through your Authorized Toro Distributor. If the parts list is not available, provide your distributor with the Toro model and serial number of your machine as well as the Yanmar engine model and serial numbers.
Page 51: Chapter 4: Engine
Service and Repairs Air Cleaner Assembly g288944 Figure 11 Washer Air cleaner indicator Clamp 90º Hose Bolt Prefilter U-Bolt Washer Air cleaner hose Clamp Engine Hose Bolt Bracket Air cleaner Removing the Air Cleaner Assembly 1. Park the machine on a level surface, lower the cutting deck, stop the engine, engage the parking brake and remove the key from the key switch.
Page 52 Installing the Air Cleaner Assembly IMPORTANT Any leaks in the air cleaner system will allow the dirt into the engine and will cause serious engine damage. Ensure that all air cleaner components are in good condition and are properly secured during installation.
Page 53: Exhaust System
Exhaust System g288973 Figure 13 Bolt Spacer Clamp Washer Exhaust pipe Shock absorber Muffler Engine Removing the Exhaust System CAUTION A hot engine and exhaust system can cause burns. Allow the engine and the exhaust system to cool before working on or near them.
Page 54 Removing the Exhaust System (continued) 3. Allow engine and exhaust system to cool before doing any disassembly of exhaust system components. Get the access to exhaust system components. 4. Raise and lock the hopper assembly; refer to Operator’s Manual. 5. Remove the top engine cover and rear engine cover assemblies (refer to Frame Assembly (page 7–19)) and get access to exhaust pipe.
Page 55: Radiator
Radiator g289021 Figure 14 Hose Washer Clamp Plate Bracket Hose Cable guard Collar Washer Bolt Washer Gasket Debris screen Knob Washer Bracket Thread insert Tank Hose Washer Clamp Bolt Bushing Washer Gasket Bracket Washer Bolt Blower Spring Shock absorber Grommet Fan shroud Washer Radiator...
Page 56 Removing the Radiator 1. Park machine on a level surface, lower cutting deck, shut off the engine, engage parking brake, and remove key from the key switch. 2. Raise and lock the hopper assembly; refer to Operator’s Manual. DANGER If the radiator or engine is hot, pressurized hot coolant can escape and cause burns.
Page 57 Removing the Radiator (continued) g289054 Figure 16 Oil cooler Bracket Hydraulic hose Bolt Hydraulic hose Washer CAUTION Before opening the hydraulic system, operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic fluid. 7. Read the General Precautions for Removing and Installing the Hydraulic System Components (page 5–63).
Page 58 Removing the Radiator (continued) 20. If necessary, separate the oil cooler from the radiator as follows (Figure 16): A. Remove the 4 nuts, bolts and washers that attach the oil cooler to the radiator. B. Separate the oil cooler from the radiator. C.
Page 59: Fuel System
Fuel System g289096 Figure 17 Hose Float Clamp Water separator assembly Clamp Clamp Washer Screw Hose Bolt Hose Hose Hose Clamp Engine Fuel tank Fuel filter element Hose Fuel tank cap Fuel filter assembly ProLine H800 Page 4–11 Engine: Service and Repairs 19241SL Rev B...
Page 60 DANGER Diesel fuel is highly flammable and explosive. A fire or a 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 61 Removing the Fuel Tank g289124 Figure 19 Bolt Bolt Washer Fuel tank support Cross rail Rubber grommet Fuel tank Washer Bolt 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2.
Page 62 Removing the Fuel Tank (continued) 8. Cover or plug the fuel hoses or fitting openings to prevent contamination from entering the fuel system. 9. Remove the fuel tank as shown in Figure Installing the Fuel Tank 1. Install the fuel tank to the frame as shown in Figure 2.
Page 63: Engine
Engine g289256 Figure 20 Engine Bolt Flange Hose Bolt Bolt Clamp Clamp Washer Bolt Joint Washer Washer Support Bolt Clamp Bolt Washer Bolt Engine support Engine support Bolt Shock absorber Engine support Removing the Engine 1. Park machine on a level surface, lower cutting deck, stop engine, apply parking brake and remove key from the key switch.
Page 64 Removing the Engine (continued) 3. Remove the hopper assembly from the machine; refer to Removing the Hopper Assembly (page 9–3). 4. Remove the chute assembly from the machine; refer to Operator’s Manual. CAUTION Do not open radiator cap or drain coolant if the radiator or engine is hot.
Page 65 Removing the Engine (continued) 13. Disconnect the wires and/or electrical connections from the following engine electrical components: A. Alternator connector and stud. B. Oil pressure switch located near the engine oil filter. C. Connector and positive battery cable from the starter motor. D.
Page 66 Installing the Engine IMPORTANT Ensure that all parts removed from the engine during maintenance or overhaul are correctly installed on the engine. 1. Park the machine on a level surface and remove the key from the key switch. Block the wheels with chocks to prevent the machine from moving. 2.
Page 67 Installing the Engine (continued) H. PTO clutch wire connector. 8. Using the notes that you recorded during removal, secure the wires with cable ties in proper locations. 9. Install the electric clutch onto the engine; refer to Installing the Electric Clutch (page 8–16).
Page 68 Engine: Service and Repairs Page 4–20 ProLine H800 19241SL Rev B...
Page 69 Chapter 5 Hydraulic System Table of Contents General Information ..........................5–3 Checking the Hydraulic Fluid ......................5–3 Pushing or Towing the Traction Unit ....................5–4 Releasing Pressure from the Hydraulic System ................. 5–5 Traction Circuit Component Failure....................5–6 Hydraulic Hoses..........................5–7 Installing the Hydraulic Hoses and Tubes ..................
Page 70 Height Of Cut Cylinder ........................5–124 Chute Cleaning Cylinder ........................ 5–127 Oil Cooler ............................5–130 Additional Reference Materials Danfoss DDC20 Axial Piston Pump Service Manual Parker Torqmotor Service Procedure (TF, TG, TH, and TL Series) Hydraulic System: Service and Repairs Page 5–2 ProLine H800 19241SL Rev B...
Page 71: General Information
General Information The Operator's Manual provides information regarding the operation, general maintenance procedures, and maintenance intervals for your machine. Refer to the Operator's Manual for additional information when servicing the machine. Checking the Hydraulic Fluid g295950 Figure 21 The hydraulic system on your machine is designed to operate on high quality hydraulic fluid.
Page 72: Pushing Or Towing The Traction Unit
Pushing or Towing the Traction Unit IMPORTANT If towing limits are exceeded, severe damage to the hydraulic pump may occur. g231794 Figure 22 g215176 Figure 23 Front of the machine Control knob (bypass valve) Hydraulic pump If it becomes necessary to tow or push the machine, tow or push at a speed of 3 to 5 km/h (2 to 3 mph), and for a very short distance.
Page 73: Releasing Pressure From The Hydraulic System
Releasing Pressure from the Hydraulic System Follow the steps below to release all pressure in the hydraulic system prior to starting any service procedures. There must be no pressure in the hydraulic system. Releasing the Hydraulic Pressure from the Traction Circuit Note: If you park the machine on an inclined or sloped surface, the pressure in the traction circuit will not release.
Page 74: Traction Circuit Component Failure
The recommended method to remove contamination from the traction circuit is to temporarily install a Toro high flow hydraulic-fluid filter into the circuit; refer Special Tools (page 2–15). Use a high flow hydraulic-fluid filter when you connect hydraulic test gauges in order to test the traction circuit components or after you replace a failed traction circuit component (e.g., hydraulic pump or...
Page 75: Hydraulic Hoses
For more hydraulic hose information; refer to Hydraulic Hose Servicing of the Toro Basics Series Training Books (Part No. 94813SL) found on the Service Reference Set available from your Authorized Toro Distributor.
Page 76: Installing The Hydraulic Hoses And Tubes
Installing the Hydraulic Hoses and Tubes g221221 Figure 24 Tube or hose Swivel nut O-ring Fitting body 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 77 Installing the Hydraulic Hoses and Tubes (continued) 4. If a torque wrench is not available or if space at the swivel nut prevents the use of a torque wrench, use the alternative procedure Flats From Wrench Resistance (FFWR) given below: Flats From Wrench Resistance Table FFWR Size...
Page 78: Installing The Hydraulic Fittings
Installing the Hydraulic Fittings IMPORTANT The hydraulic fittings used in this machine may have BSPP (British Standard Parallel Pipe) threads or ORFS (O-Ring Face Seal) threads for the hose connections, and SAE or BSPP threads for the component connections. Pay close attention to the fitting thread type and the type of seal used when replacing the hydraulic tank fittings and seals, or component damage and leakage may occur.
Page 79 Installing an Adjustable Fitting g221224 Figure 27 Locknut Back-up washer O-ring g221225 Figure 28 Step 1: clearance the lock nut Step 3: align the fitting Step 2: seat the back-up washer Step 4: tighten the lock nut 1. Ensure that all the threads, the sealing surfaces of fitting, and the component port are free of burrs, nicks, scratches, or unwanted material.
Page 80 Installing an Adjustable Fitting (continued) 7. Tighten the fitting lock nut (Step 4 in Figure 28): A. Hold the fitting in the correct alignment with a wrench and use a torque wrench and tighten the fitting to the recommended torque value within the specified range of torque values;...
Page 81: Hydraulic Schematic
Hydraulic Schematic The hydraulic schematic for the PLH800 machine is located in Appendix A (page A–1). ProLine H800 Page 5–13 Hydraulic System: Hydraulic Schematic 19241SL Rev B...
Page 82: Hydraulic Flow Diagrams
Hydraulic Flow Diagrams Traction Circuit Hydraulic system pressure is generated by a piston-driven pump coupled to the engine flywheel. This variable-displacement pump provides hydraulic flow under regulated pressure to the front and rear wheel motors, and changes its fluid flow rate with an internal swash plate. The swash plate angle is controlled by the traction pedal through a linkage system.
Page 83 Forward Direction g292001 Figure 29 ProLine H800 Page 5–15 Hydraulic System: Hydraulic Flow Diagrams 19241SL Rev B...
Page 84 Forward Direction (continued) The forward traction pressure is limited to 280 bar (4,061 psi). The fluid flowing from the motor returns to the variable displacement pump and is continuously pumped through the closed loop circuit as long as the traction pedal is pressed. The piston pump is equipped with a case drain to allow normal internal leakage to be removed.
Page 85 Reverse Direction g292002 Figure 30 ProLine H800 Page 5–17 Hydraulic System: Hydraulic Flow Diagrams 19241SL Rev B...
Page 86 Reverse Direction (continued) The traction circuit operates essentially the same in reverse as it does when moving forward. The primary difference is that the direction of fluid flow through the circuit is reversed when the bottom of the traction pedal is pushed. The reverse traction pressure is likewise limited to 280 bar (4,061 psi).
Page 87: Steering Circuit
Steering Circuit g292117 Figure 31 The charge pump supplies the fluid flow for the steering circuit, height of cut control, and the auxiliary control circuit. The pump output flows first to the steering control valve before reaching the height of cut valve, so that the steering circuit has priority.
Page 88 Right Turn g292116 Figure 32 When a right turn is made with the engine running, the turning of the wheel positions the steering control spool valve so flow passes through the top of the spool. The fluid flow entering the steering control valve at the P port passes through the rotary meter, and is directed out through the R port.
Page 89 Left Turn g292115 Figure 33 When a left turn is made with the engine running, the turning of the wheel positions the steering control spool valve so that the flow passes through the bottom of the spool. The fluid flow entering the steering control valve at the P port passes through the rotary meter, and is directed out the L port.
Page 90: Height Of Cut Circuit
Height Of Cut Circuit g292157 Figure 34 The charge pump supplies fluid pressure to the steering circuit, height of cut circuit and auxiliary circuit. The charge pump is fed through a filter from the hydraulic tank. The pump output flows to the steering control valve first before reaching the height of cut circuit.
Page 91 Raising the Height Of Cut g292158 Figure 35 When the height of cut switch is moved to the RAISE position, the solenoid valve inside the control valve is energized to cause the valve to shift, allowing fluid flow from the P port to the A port. This extends the piston, causing the height of cut to raise.
Page 92 Lowering the Height Of Cut g292156 Figure 36 When the height of cut switch is moved to the LOW position, the solenoid valve inside the control valve is energized to cause the valve to shift, allowing fluid flow from the P port to the B port. This retracts the piston, causing the height of cut to lower.
Page 93: Auxiliary Control Circuit
Auxiliary Control Circuit g296061 Figure 37 The charge pump supplies fluid pressure to the steering circuit, the height of cut circuit, and the auxiliary control valve. The charge pump takes its suction through a filter from the hydraulic tank. The pump output flows to the steering control valve and height of cut valve before reaching the auxiliary control valve.
Page 94 Raising the Cutting Deck g292091 Figure 38 When the cutting deck lift lever is moved to the RAISE position, hydraulic fluid flow is directed to the deck lift cylinders. The hydraulic pressure against the cylinder pistons retracts the lift cylinders, lifting the cutting deck. When the deck lift cylinders reach the end of their stroke (or if the lift arms are prevented from raising any further), the relief valve in the steering control valve opens and directs the hydraulic flow back to the pump until the lift lever is returned to the neutral...
Page 95 Lower the Cutting Deck g292092 Figure 39 When the cutting deck lift lever is moved to the LOWER position, hydraulic fluid flows through the auxiliary control valve manifold and opens a path for fluid trapped in the lift cylinder piston to escape through the open port in the auxiliary control valve.
Page 96 Raising the Hopper g292201 Figure 40 When the hopper lift lever is moved to the RAISE position, hydraulic fluid flow is directed to the hopper lift cylinders. The hydraulic pressure extends the lift cylinders and the hopper goes up. When the hopper lift cylinders reach the end of their stroke, the relief valve in the steering control valve opens and directs the hydraulic flow to the pump until the lift lever is returned to the neutral position.
Page 97 Lowering the Hopper g292202 Figure 41 When the hopper lift lever is moved to the LOWER position, hydraulic fluid flow is directed to the hopper lift cylinders. The hydraulic pressure in the rod side of the cylinder causes the piston to retract and lowers the hopper. When the lift cylinders reach the end of their stroke, the relief valve in the steering control valve opens and directs the hydraulic flow to the pump until the lift lever is returned to the neutral position.
Page 98 Tilting the Hopper g292218 Figure 42 When the hopper tilt lever is moved to the TILT position, hydraulic fluid flow is directed to the hopper tilt cylinders. The hydraulic pressure extends the cylinders and tilts the hopper. When the tilt cylinders reach the end of their stroke, the relief valve in the steering control valve opens and directs the hydraulic flow to the pump until the tilt lever is returned to the neutral position.
Page 99 Leveling the Hopper g292217 Figure 43 When the hopper lift lever is moved to the LOWER position, hydraulic fluid flow is directed to the hopper lift cylinders. The hydraulic pressure in the rod side of the cylinder causes the piston to retract and lowers the hopper. When the lift cylinders reach the end of their stroke, the relief valve in the steering control valve opens and directs the hydraulic flow to the pump until the lift lever is returned to the neutral position.
Page 100: Testing The Hydraulic System
Testing the Hydraulic System The most effective procedure to isolate the problems in the hydraulic system is to use hydraulic test equipment, such as pressure gauges and flow meters in the circuits during different operational checks; refer to Special Tools (page 2–15).
Page 101 IMPORTANT Use 2 people to perform all the tests, with 1 person in the seat and the other to read and record the test results. 1. Use the following resources to assist with hydraulic system troubleshooting: • The Hydraulic Schematic in Appendix A (page A–1).
Page 102: Testing The Traction Circuit - Charge Pressure
Testing the Traction Circuit - Charge Pressure g292481 Figure 44 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 hydraulic pump. Continued unit operation can generate excessive heat, cause damage to seals and other components in the hydraulic system, and affect overall machine performance.
Page 103 Testing the Traction Circuit - Charge Pressure (continued) CAUTION Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 5–5).
Page 104 Testing the Traction Circuit - Charge Pressure (continued) g292480 Figure 46 Hydraulic pressure test port Radiator Hydraulic fluid filter 7. Gain access to the charge pressure test port (Figure 46). 8. Clean the charge pressure test port. Loosen and remove the cap from the test port.
Page 105 Testing the Traction Circuit - Charge Pressure (continued) 18. After you complete the charge pressure testing, release hydraulic system pressure; refer to Releasing Pressure from the Hydraulic System (page 5–5). Remove the pressure gauges and install the hydraulic pressure test ports. 19.
Page 106: Testing The Wheel Motors Efficiency
Testing the Wheel Motors Efficiency g292862 Figure 47 The wheel motor efficiency test evaluates the traction circuit performance. Hydraulic fluid flow of 2.8 LPM (0.74 GPM) or more through a stationary rear wheel motor under load indicates an internal leak in the wheel motor. Fluid flow of 3.4 LPM (0.9 GPM) or more through a stationary front wheel motor under load indicates an internal leak in the wheel motor.
Page 107 Special equipment required: • Flow meter with pressure gauge that has at least an 68 LPM (18 GPM) capacity. • Phototach (non-contact tachometer). Rear Left Wheel Motor Test Procedure The hydraulic fluid flows through the rear left and bypasses all other motors by masking the hydraulic connections (Figure 47).
Page 108 Rear Left Wheel Motor Test Procedure (continued) 10. Chock the rear left wheel being tested to prevent from rotation. CAUTION Use extreme caution when performing this test. The wheel motor being tested will be trying to move the machine forward. 11.
Page 109 Front Left Wheel Motor Test Procedure If the front left wheel motor requires testing, repeat the steps through 19; refer Figure Note: The flow meter reading should be less than 3.4 LPM (0.9 GPM) for the tested wheel motor. If the specification is not met, repair or replace the wheel motor.
Page 110 Front Right Wheel Motor Test Procedure If the front right wheel motor requires testing, repeat steps 2through 19; refer toFigure Note: The flow meter reading should be less than 3.4 LPM (0.9 GPM) for the tested wheel motor. If the specification is not met, repair or replace the wheel motor.
Page 111 Rear Right Wheel Motor Test Procedure If the rear right wheel motor requires testing, repeat the steps through 19; refer toFigure Note: The flow meter reading should be less than 2.8 LPM (0.74 GPM) for the tested wheel motor. If the specification is not met, repair or replace the wheel motor.
Page 112: Testing The Traction Circuit - Hydraulic Pump Flow And Relief Pressure
Testing the Traction Circuit - Hydraulic Pump Flow and Relief Pressure g292558 Figure 51 The hydraulic pump flow test is the third in a series of tests recommended to determine the traction circuit performance. This test compares fluid flow at no load with the fluid flow under load.
Page 113 Test Procedure 1. Once the test equipment is properly connected, you can run the engine and pump to warm the hydraulic fluid to operating temperature. Any test procedure that requires an open or uncapped line (like a case drain leak check) would not apply. In those rare situations, the hydraulic fluid should be warmed before disconnecting the lines.
Page 114 Test Procedure (continued) 5. Access the hydraulic pump from left side. Remove the bolt (item 1) from the bracket (tem 2) and rotate the fuel tank to the right to access the hydraulic pump. Note: You must have the steering wheel rotated to the fully left locked position to rotate the fuel tank fully.
Page 115 Test Procedure (continued) IMPORTANT Ensure that the fluid flow indicator arrow on the flow meter is showing that the fluid will flow from the pump, through the tester, and into the disconnected hydraulic hose. 9. Place a steel cap on T fitting to block the hydraulic fluid flow to front right and rear right wheel motors (Figure 54).
Page 116 Test Procedure (continued) E. Release the traction pedal, open the flow control valve fully, move the throttle to low speed, and shut off the engine. 17. If the relief pressure can not be met or is greater than specified, the traction relief valve is damaged and should be replaced.
Page 117: Testing The Steering Circuit - Steering Control Valve, Relief Valve Pressure And Steering Cylinder
Testing the Steering Circuit - Steering Control Valve, Relief Valve Pressure and Steering Cylinder g292611 Figure 55 Steering unit performance will be impacted by incorrect rear tire pressure, binding in the hydraulic steering cylinder, extra weight on the vehicle, and/or binding of the steering spindle.
Page 118 Test Procedure (continued) A. There should be no shaking or vibration in the steering wheel or rear wheels. B. The steering wheel movements should be followed immediately by a corresponding rear wheel movement without the steering wheel continuing to turn. 3.
Page 119 Test Procedure (continued) 5. The steering circuit relief valve located in the steering control valve can be tested with the pressure gauge installed in the same location as the steering cylinder test (step 4) as follows: A. Start the engine and run it at low-idle speed. Check for hydraulic-fluid leaks from the test connections and correct before continuing the test.
Page 120: Testing The Steering Circuit - Charge Pump Flow
Testing the Steering Circuit - Charge Pump Flow g292668 Figure 57 The charge pump is designed to satisfy the steering cylinder needs (at full speed). The charge pump 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 121 Test Procedure g292669 Figure 58 Hose Hydraulic filter Extension Fitting 90º fitting Hydraulic tank One direction valve Plug Hydraulic tank filter O-ring Filter assembly O-ring 90º adaptor Washer Filter support Fitting Reducer Washer Adaptor 90º adaptor Oil cooler Charge pump Hose Hose Adaptor...
Page 122 Test Procedure (continued) 1. Park the machine on a level surface with the PTO switch off, lower the cutting deck, shut off the engine, and set the parking brake. 2. Read all Warning, Cautions, and precautions listed at the beginning of this section.
Page 123 Test Procedure (continued) 11. Verify the pump flow under load as follows: CAUTION Do not close the tester valve fully when performing this test. In this test, the hydraulic tester is positioned in an unprotected part of the steering circuit. Pump damage can occur if the fluid flow is fully restricted by fully closing the tester flow control valve.
Page 124: Testing The Auxiliary Control Circuit - Cutting Deck Lift Cylinder Internal Leakage
Testing the Auxiliary Control Circuit - Cutting Deck Lift Cylinder Internal Leakage g292724 Figure 59 Perform a cutting deck lift cylinder internal leakage test if you identify a cutting deck raise and lower problem. This test determines if the lift cylinder being tested is damaged.
Page 125 Test Procedure Note: When performing the lift cylinder internal leakage test, the cutting deck should be attached to the lift arms and the cutting deck should be in raise position. 1. Park the machine on a level surface with the PTO switch off, shut off the engine, and set the parking brake.
Page 126: Testing The Auxiliary Control Circuit - Hopper Lift Cylinder Internal Leakage
Testing the Auxiliary Control Circuit - Hopper Lift Cylinder Internal Leakage g292780 Figure 60 Perform a hopper lift cylinder internal leakage test if a raise/lower problem exists. This test determines if the lift cylinder is damaged. Each hopper lift cylinder must be tested individually.
Page 127 Test Procedure (continued) IMPORTANT When capping the hopper lift cylinder fitting and hydraulic hose end, use a steel cap and plug to ensure that there is no fluid leakage. The plastic plugs cannot hold the hydraulic pressure that is developed during this test procedure.
Page 128: Testing The Auxiliary Control Circuit - Hopper Tilt Cylinder Internal Leakage
Testing the Auxiliary Control Circuit - Hopper Tilt Cylinder Internal Leakage g292781 Figure 61 Perform a hopper tilt cylinder internal leakage test if you identify a hopper tilt and lower problem. This test determines if a hopper tilt cylinder being tested is damaged.
Page 129 Test Procedure (continued) IMPORTANT When capping the hopper tilt cylinder fitting and hydraulic hose end, use a steel cap and plug to ensure that there is no fluid leakage. The plastic plugs cannot hold the hydraulic pressure that is developed during this test procedure.
Page 130: Testing The Height Of Cut Cylinder Internal Leakage
Testing the Height Of Cut Cylinder Internal Leakage The block valve in the height of cut circuit should hold the cylinder piston in correct position all the time. If the height of cut piston lowers the height of cut itself, replace the height of cut cylinder;...
Page 131: Service And Repairs
Service and Repairs General Precautions for Removing and Installing the Hydraulic System Components Before Repairing or Replacing the Components 1. Before removing any parts from the hydraulic system, park the machine on a level surface, lower the cutting deck, turn the engine OFF, set the parking brake, and remove the key from the key switch.
Page 132 After Repairing or Replacing the Components (continued) 4. Use proper tightening procedures when installing the hydraulic hoses and fittings; refer to Installing the Hydraulic Hoses and Tubes (page 5–8) Installing the Hydraulic Fittings (page 5–10). 5. After you complete the repairs, check the control linkages or cables for proper adjustment, binding, or broken parts.
Page 133: Checking The Hydraulic Lines And Hoses
Checking the 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 134: Flushing The Hydraulic System
Flushing the Hydraulic System IMPORTANT Flush the hydraulic system whenever there is a severe component failure or the system is contaminated (for example, the fluid appears milky, black, or contains metal particles). IMPORTANT If a component failure occurs in the traction circuit; refer to the Traction Circuit Component Failure (page 5–6) for information regarding the importance of removing contamination from the...
Page 135 Flushing the Hydraulic System (continued) 6. Drain the complete hydraulic system. Drain all the hoses, tubes, and components while the system is warm. Flush the hoses and tubes to remove any contamination. 7. Ensure that the mounting surface of the hydraulic-fluid filter is clean. Apply clean hydraulic fluid to the gasket on new filter.
Page 136: Filtering The Closed-Loop Traction Circuit
To effectively remove the contamination from the closed-loop circuit, use the Toro high flow hydraulic filter and hydraulic hose kits (refer to Special Tools (page 2–15)).
Page 137 5 more minutes. IMPORTANT If you are using a filter that is not the Toro high flow filter that is bi-directional, do not press the traction pedal in the reverse direction. If the flow is reversed when using a filter that is not bi-directional, unwanted material from the filter will again enter the traction circuit.
Page 138: Priming The Hydraulic Pump
Priming the Hydraulic Pump When the hydraulic system is flushed or charged or the hydraulic components are installed, it is important to properly prime the hydraulic pumps. The hydraulic pump priming ensures that the hydraulic pumps have sufficient fluid during initial start-up and running.
Page 139 Priming the Hydraulic Pump (continued) Note: A blue wire connects to the starter motor solenoid B+ terminal (Figure 64). It is necessary to remove this blue wire from the solenoid terminal for hydraulic pump priming. 4. Connect the remote starter switch electrical leads to the starter motor solenoid B+ terminal and positive post of the battery.
Page 140: Charging The Hydraulic System
Charging the Hydraulic System Note: When initially starting the hydraulic system with new or rebuilt components such as hydraulic pump, hydraulic motor, or lift cylinders, it is important that the hydraulic system is charged properly. Remove the air from the system and its components to reduce the chance of damage.
Page 141 Charging the Hydraulic System (continued) 15. Ensure that the traction pedal returns to the NEUTRAL position when released from the forward or reverse direction and adjust if necessary; refer to the Operator’s Manual. 16. Check the operation of the traction interlock switches; refer to Checking the Operation of the Interlock Switches (page 6–5).
Page 142: Hydraulic Tank
Hydraulic Tank g293230 Figure 65 Bolt Knob Washer Washer Auxiliary valve lever Clamp Spring Auxiliary control valve Band clamp Puller knob Auxiliary control valve support Band clamp Bolt Spring Hydraulic tank Auxiliary valve lever Washer Operator platform Connector Washer Auxiliary valve lever Washer Bolt Hydraulic System: Service and Repairs...
Page 143 g292669 Figure 66 Hose Hydraulic filter Extension Fitting 90º fitting Hydraulic tank One direction valve Plug Hydraulic tank filter O-ring Filter assembly O-ring 90º adaptor Washer Filter support Fitting Reducer 90º adaptor Washer Adaptor Oil cooler Charge pump Hose Hose Adaptor Fitting Hose...
Page 144 Remove the Hydraulic Tank 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Drain the hydraulic fluid from the tank into a suitable container; refer to Operator’s Manual.
Page 145 Installing the Hydraulic Tank (continued) 9. Check the hydraulic fluid level and adjust if necessary; refer to Operator’s Manual. 10. Install the right console onto the machine; refer to Assembling the Body Assembly (page 7–7). ProLine H800 Page 5–77 Hydraulic System: Service and Repairs 19241SL Rev B...
Page 146: Auxiliary Control Valve
Auxiliary Control Valve g293274 Figure 67 Knob Auxiliary valve lever Washer Bolt Washer Band clamp Spring Puller knob Auxiliary valve lever Band clamp Spring Auxiliary control valve Washer Auxiliary valve lever Auxiliary control valve support Connector Bolt Remove the Auxiliary Control Valve 1.
Page 147 Remove the Auxiliary Control Valve (continued) g293275 Figure 68 Adaptor Bolt Bolt O-ring Hose O-ring Fitting nipple Auxiliary control valve Hose Hose Fitting nipple 6. Remove the hydraulic connections from the auxiliary control valve and discard the O-rings from the fittings (Figure 68).
Page 148 Installing the Auxiliary Control Valve (continued) 6. Operate the machine and check for the hydraulic leaks near the components and fittings. Tighten any loose connections. 7. Check the hydraulic fluid level and adjust if necessary; refer to Operator’s Manual. 8. Install the right console onto the machine; refer to Assembling the Body Assembly (page 7–7).
Page 149: Traction Neutral Arm Assembly
Traction Neutral Arm Assembly g293470 Figure 69 Hydraulic pump Washer Traction cable Socket head screw Bolt Retaining ring Washer Bolt Return spring Gear pump Washer Traction neutral arm Socket head screw Washer Hydrostat neutral shaft Bracket Washer Removing the Traction Neutral Arm Assembly 1.
Page 150: Hydraulic Pump Assembly
Hydraulic Pump Assembly g293493 Figure 70 Hydraulic piston pump Bolt Return spring Bolt Traction neutral arm Socket head screw Washer Washer Socket head screw Gear pump Hydrostat neutral shaft Engine Washer Washer Washer Bracket Traction cable Bolt Washer Retaining ring Hydraulic System: Service and Repairs Page 5–82 ProLine H800...
Page 151 Removing the Hydraulic Pump Assembly CAUTION Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 5–5). 1. Park the machine on a level surface, set the parking brake, lower the cutting deck, shut off the engine, and remove the key from the key switch.
Page 152 Removing the Hydraulic Pump Assembly (continued) g293494 Figure 72 Fitting T-fitting One direction valve Adaptor O-ring Gear pump Washer 90º adaptor Hydraulic pump Fitting 6. Disconnect the hoses and tubes from the fittings on the hydraulic pump. Allow the hydraulic lines to drain into a suitable container. 7.
Page 153 Installing the Hydraulic Pump Assembly (continued) IMPORTANT Ensure that you do not damage the machine components while installing the hydraulic pump. 4. Carefully position the hydraulic pump assembly onto the engine. 5. Secure the hydraulic pump assembly to the engine with the 2 washers and 2 bolts.
Page 154: Servicing The Hydraulic Piston Pump
Servicing the Hydraulic Piston Pump g293588 Figure 73 Hydraulic System: Service and Repairs Page 5–86 ProLine H800 19241SL Rev B...
Page 155 Servicing the Hydraulic Piston Pump (continued) Figure 73 (continued) Retaining ring Needle bearing O-ring Swash plate O-ring Body Thrust plate Plug Inner race End cap gasket O-ring Lip seal Cylinder block kit O-ring Plug Valve plate Plug Hydraulic pump housing Plug Back-up ring Driveshaft...
Page 156: Servicing The Gear Pump
Servicing the Gear Pump g293600 Figure 74 Retaining ring Drive shaft Bolt Driven gear Shaft seal O-ring seal Front cover Dowel pin Dowel pin Back-up ring Body Half thrust block Seal Rear cover Half thrust block Washer Disassembling the Gear Pump Note: The gear pump must be replaced as a complete assembly.
Page 157 Disassembling the Gear Pump (continued) g293847 Figure 75 Marker line 2. Use a marker to make a diagonal line across the front flange, body and rear cover for assembly purposes (Figure 75). IMPORTANT Use caution when clamping the gear pump in a vise to avoid distorting any pump components.
Page 158 Inspecting the Gear Pump 1. Remove any nicks and burrs from all the gear pump parts with emery cloth. 2. Clean all the gear pump parts with solvent and dry them with compressed air. g293634 Figure 76 Gear shaft spline Gear teeth Gear face edge Gear shaft...
Page 159 Assembling the Gear Pump Note: When assembling the gear pump, check the marker line made during the disassembly to ensure that the parts are properly aligned during the assembly. 1. Apply clean hydraulic fluid to all the parts before you assemble them. Note: The pressure seals and back-up rings fit in the grooves machined into the thrust plates.
Page 160: Front Wheel Motors
Front Wheel Motors g293656 Figure 77 Front Left Wheel (shown) Bolt Locknut Washer Hydraulic motor Bolt Brake cable bracket Left brake assembly Washer Brake drum Removing the Front Wheel Motors CAUTION Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid;...
Page 161 Removing the Front Wheel Motors (continued) 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Block the rear wheels with chocks to prevent the machine from moving. 3.
Page 162 Removing the Front Wheel Motors (continued) g293687 Figure 78 Hydraulic filter Differential valve Hose O-ring O-ring Fitting Hose Fitting Adaptor Hose Hydraulic pump T-fitting T-fitting Front left wheel motor Fitting Plug Front right wheel motor 12. Hose Rear right wheel motor Rear left wheel motor Fitting Bolt...
Page 163 Removing the Front Wheel Motors (continued) 9. Loosen and remove the hydraulic tubes from the fittings on the wheel motor. Allow the tubes to drain the hydraulic fluid into a suitable container. 10. Install the clean caps or plugs on the hydraulic tubes and fittings to prevent system contamination.
Page 164: Rear Wheel Motors
Rear Wheel Motors g293711 Figure 79 Bolt Washer Washer Hydraulic motor Bolt Spindle Flange Spindle Woodruff key Removing the Rear Wheel Motor CAUTION Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid;...
Page 165 Removing the Rear Wheel Motor (continued) 6. Remove the rear wheel from the machine; refer to Removing the Wheels (page 7–3). 7. Remove wheel hub from the rear wheel motor as follows: IMPORTANT Do not hit the wheel hub, wheel-hub puller, or wheel motor with a hammer while removing or installing.
Page 166 Removing the Rear Wheel Motor (continued) g293687 Figure 80 Hydraulic filter Differential valve Hose O-ring O-ring Fitting Hose Fitting Adaptor Hose Hydraulic pump T-fitting T-fitting Front left wheel motor Fitting Plug Front right wheel motor 12. Hose Rear right wheel motor Rear left wheel motor Fitting Bolt...
Page 167 Removing the Rear Wheel Motor (continued) 10. Loosen and remove the hydraulic tubes from the fittings on the wheel motor. Allow the hoses to drain into a suitable container. 11. Install clean caps or plugs on the hydraulic hoses and fittings to prevent system contamination.
Page 168 Installing the Rear Wheel Motor (continued) 10. After you complete the assembly, ensure that the hydraulic hoses and fittings do not contact anything through the full range of axle motion. Also, check for any hydraulic-fluid leaks. 11. Check the hydraulic-fluid level in the hydraulic tank and add correct quantity of fluid;...
Page 169: Servicing The Hydraulic Wheel Motor
Servicing the Hydraulic Wheel Motor g186199 Figure 81 Dirt and water seal Thrust bearing Commutator ring Outer bearing Coupling shaft Manifold Housing Thrust bearing Stator Back-up ring Drive link Vane Back-up washer Bolt Wear plate Shaft seal End cover Rotor Inner bearing Body seal Commutator ring...
Page 170 Servicing the Hydraulic Wheel Motor (continued) Note: The wheel motors used in this machine are the Parker Torqmotor™ motors of the same basic design with minor differences. The 2 front wheel motors displace 238 cm³/rev (14.5 in³/rev) and the 2 rear wheel motors displace 195 cm³/rev (11.8 in³/rev).
Page 171: Differential Valve
Differential Valve g293779 Figure 82 Differential valve Chassis Washer Washer Differential valve solenoid Bolt Removing the Differential Valve 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. CAUTION Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the...
Page 172 Removing the Differential Valve (continued) 4. For assembly purposes, label all the hydraulic connections. Clean the hydraulic connections before loosening the hydraulic lines. g293687 Figure 83 Hydraulic filter Differential valve Hose O-ring O-ring Fitting Hose Fitting Adaptor Hose Hydraulic pump T-fitting T-fitting Front left wheel motor...
Page 173 Removing the Differential Valve (continued) 5. Disconnect the hydraulic hoses and tubes from the fittings in the differential valve. Allow the lines to drain into a suitable container. Remove and discard the O-rings from the fittings. 6. Install clean caps or plugs on the hydraulic lines and fittings to prevent system contamination.
Page 174: Height Of Cut Valve
Height Of Cut Valve g293797 Figure 84 Bracket Bolt Washer Washer Operators platform Bolt Height of cut valve Removing the Height Of Cut Valve 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. CAUTION Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the...
Page 175 Removing the Height Of Cut Valve (continued) g293798 Figure 85 Quick disconnect coupler Bolt Hose O-ring Fitting Hose Bracket Height of cut valve Auxiliary control valve Hose Bolt Steering control valve 5. Disconnect the hydraulic hoses and tubes from the fittings in the height of control valve.
Page 176 Installing the Height Of Cut Valve 1. If the hydraulic fittings were removed from the height of cut valve, lubricate new O-rings with clean hydraulic fluid, position the O-rings to the fittings, and install the fittings into the height of cut valve; refer to Installing the Hydraulic Fittings (page 5–10).
Page 177: Lift Cylinder
Lift Cylinder g293858 Figure 86 Washer Grease fitting Lift cylinder Support Breather cap LH lift arm Washer Washer Removing the Lift Cylinder 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2.
Page 178 Removing the Lift Cylinder (continued) WARNING Ensure that the cutting deck is fully lowered before loosening the hydraulic lines from the lift cylinders. If the cutting deck is not fully lowered as the hydraulic lines are loosened, the cutting deck may drop unexpectedly. g293859 Figure 87 Auxiliary control valve...
Page 179 Installing the Lift Cylinder 1. If the hydraulic fittings were removed from the lift cylinder, lubricate the new O-rings with clean hydraulic fluid, position the O-rings to the fittings, and install the fittings into the lift cylinder ports; refer to Installing the Hydraulic Fittings (page 5–10).
Page 180: Steering Control Valve
Steering Control Valve g289357 Figure 88 Steering wheel Steering column Connecting rod Bolt Dashboard Bracket Spacer Washer Socket head screw Thread insert Washer Bolt Washer Washer Bushing Support Bolt Socket head screw Bushing Bracket Steering control valve Washer Electronic control unit Shaft key Washer Washer...
Page 181 Removing the Steering Control Valve 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Remove the steering column components to get access to the steering control valve;...
Page 182 Installing the Steering Control Valve 1. If the hydraulic fittings were removed from the steering control valve, lubricate new O-rings with clean hydraulic fluid, position the O-rings to the fittings, and install the fittings to the steering control valve; refer to Installing the Hydraulic Fittings (page 5–10).
Page 183: Steering Cylinder
Steering Cylinder g293908 Figure 90 Bolt Steering cylinder Washer Bolt Left spindle Bolt Right spindle Retaining ring Washer Spacer Tie rod end Rear axle Thrust washer Removing the Steering Cylinder 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch.
Page 184 Removing the Steering Cylinder (continued) CAUTION Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 5–5). 3. For assembly purposes, label all the hydraulic hoses and tubes that are connected to the fittings on the steering cylinder.
Page 185 Installing the Steering Cylinder 1. If the hydraulic fittings were removed from the steering cylinder, lubricate new O-rings with clean hydraulic fluid, position the O-rings to the fittings, and install the fittings into the steering cylinder ports; refer to Installing the Hydraulic Fittings (page 5–10).
Page 186: Hopper Lift Cylinder
Hopper Lift Cylinder g293959 Figure 92 LH Hopper Lift Cylinder (shown) Bolt Grease fitting Washer Ball joint Spring Snap ring Snap ring Bushing Safety handle LH Bracket Bolt Hydraulic lift cylinder Removing the Hopper Lift Cylinder 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch.
Page 187 Removing the Hopper Lift Cylinder (continued) CAUTION Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 5–5). 3. For assembly purposes, label all the hydraulic hoses and tubes that are connected to the fittings on the hopper lift cylinder.
Page 188 Installing the Hopper Lift Cylinder 1. If the hydraulic fittings were removed from the hopper lift cylinder, lubricate new O-rings with clean hydraulic fluid, position the O-rings to the fittings, and install the fittings into the hopper lift cylinder ports; refer to Installing the Hydraulic Fittings (page 5–10).
Page 189: Hopper Tilt Cylinder
Hopper Tilt Cylinder g294039 Figure 94 RH Hopper Tilt Cylinder (shown) Hopper frame Grease fitting Washer Bolt Hydraulic cylinder Support Support frame Bolt Removing the Hopper Tilt Cylinder 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch.
Page 190 Removing the Hopper Tilt Cylinder (continued) g294041 Figure 95 Female quick coupler Hose Bracket Hose Hose Bolt Bolt Hydraulic cylinder O-ring Auxiliary control valve Hose Hose WARNING Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid;...
Page 191 Removing the Hopper Tilt Cylinder (continued) 9. If the hydraulic fittings are to be removed from the hopper tilt cylinder, mark the fitting orientation for assembly purposes. Remove the fittings from the hopper tilt cylinder and discard the O-rings from the fittings. Installing the Hopper Tilt Cylinder 1.
Page 192 Height Of Cut Cylinder g294075 Figure 96 Bolt Retaining ring Washer Support Hydraulic cylinder Cutting deck Grease fitting Grease fitting Removing the Height Of Cut Cylinder 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch.
Page 193 Removing the Height Of Cut Cylinder (continued) g294074 Figure 97 Female quick coupler 90º elbow fitting Hydraulic cylinder O-ring Cutting deck Block valve Hose Hose Bolt Fitting Hose CAUTION Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid;...
Page 194 Removing the Height Of Cut Cylinder (continued) WARNING Ensure that the cutting deck is fully lowered before loosening the hydraulic lines from the height of cut cylinder. 4. Disconnect the hydraulic hoses from the fittings in the height of cut cylinder that is to be removed.
Page 195 Chute Cleaning Cylinder g294112 Figure 98 Cutting deck Bronze bushing Bolt Hydraulic cylinder Scraper Washer Split pin Lever Fork Removing the Chute Cleaning Cylinder 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2.
Page 196 Removing the Chute Cleaning Cylinder (continued) g294113 Figure 99 Female quick coupler Hydraulic cylinder O-ring O-ring Hose Bolt Cutting deck CAUTION Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid;...
Page 197 Installing the Chute Cleaning Cylinder 1. If the hydraulic fittings were removed from the chute cleaning cylinder, lubricate new O-rings with clean hydraulic fluid, position the O-rings to the fittings, and install the fittings into the chute cleaning cylinder ports; refer to Installing the Hydraulic Fittings (page 5–10).
Page 198 Oil Cooler g289021 Figure 100 Hose Washer Clamp Plate Bracket Hose Cable guard Collar Gasket Washer Bolt Washer Debris screen Knob Washer Bracket Thread insert Tank Hose Washer Clamp Bolt Bushing Washer Gasket Bracket Washer Bolt Blower Spring Shock absorber Grommet Fan shroud Washer...
Page 199 g289054 Figure 101 Oil cooler Bracket Hydraulic hose Bolt Hydraulic hose Washer Removing the Oil Cooler The radiator and oil cooler must be removed from the machine as an assembly; refer to Removing the Radiator (page 4–8). Inspecting the Oil Cooler 1.
Page 200 Hydraulic System: Service and Repairs Page 5–132 ProLine H800 19241SL Rev B...
Page 201 Chapter 6 Electrical System Table of Contents General Information ..........................6–2 Electrical Schematics and Wire Harness Drawings/Diagrams............6–2 Electronic Control Unit (ECU) ......................6–2 Electrical System Quick Checks ......................6–3 Testing the Battery (Open Circuit Test)....................6–3 Testing the Charging System ......................6–4 Testing the Glow Plug System......................
Page 202: General Information
General Information The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your machine. Refer to the Operator’s Manual for additional information when servicing the machine. Electrical Schematics and Wire Harness Drawings/Diagrams Refer to the Electrical Schematics and Wire Harness Drawings/Diagrams in Appendix A (page A–1).
Page 203: Chapter 6: Electrical System
Electrical System Quick Checks Testing the Battery (Open Circuit Test) Use a multimeter to measure the voltage between the battery terminals; refer to Battery Test Table (page 6–3). Set the multimeter to the DC volts settings. The battery must be at a temperature of 16°C to 38°C (60°F to 100°F).
Page 204: Testing The Charging System
Testing the Charging System This is a simple test that determines if a charging system is functioning. It tells you if the charging system has an output, but not its capacity. Tool required: Digital multimeter to set DC volts. Test instructions: Connect the positive (+) multimeter lead to the positive battery post and negative (-) multimeter lead to the negative battery post.
Page 205: Testing The Glow Plug System
Testing the Glow Plug System This is a fast, simple test that helps to determine the integrity and operation of the glow plug system. Perform this test when you find hard starting (cold engine) on a diesel engine equipped with a glow plug system. Tool(s) required: Digital multimeter and/or inductive Ammeter (AC/DC Current Transducer).
Page 206: Testing The Electrical Components
Testing the Electrical Components 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 of the switch). Note: Electrical troubleshooting of any 12 V power connection can be performed through voltage drop tests without disconnecting the component.
Page 207: Fuses
Fuses g217872 Figure 103 Fuse block The electrical system is protected by fuses. It requires no maintenance, however, if a fuse blows check the component/circuit for a malfunction or short. The fuse blocks and fuses are located on the left console next to the operator’s seat (Figure 103).
Page 208 Identification and Function (continued) g224646 Figure 105 Figure 105 to identify each individual fuse and its correct amperage. Each fuse has the following function: 1. 3 A: Right steady light and plate light circuit. 2. 3 A: Left steady light circuit. 3.
Page 209 Testing the Fuses 1. Turn the key switch to the ON position (do not start the engine) and remove the cap for the fuse block. With the fuse installed in the fuse block, use a multimeter to check that 12 VDC exists at both of the terminal test points on the fuse.
Page 210: Key Switch
Key Switch g214136 Figure 107 OFF position ON/PREHEAT position LIGHTS ON position START position The key switch is located on right side of the steering column. The key switch has 4 positions: OFF, LIGHTS ON, ON/PREHEAT, and START (Figure 107). When the key switch is turned from OFF position to LIGHTS ON position, the work lights illuminate.
Page 211 Testing the Key Switch (continued) g294638 Figure 108 5. The key switch terminals are identified in Figure 108 and the circuitry of the key switch is shown in the Circuit Logic Table (page 6–11). With the use of a multimeter (ohms setting), test the switch functions to determine if the continuity exists between the various terminals for each switch position.
Page 212: Pto Switch
PTO Switch g294680 Figure 109 PTO switch The PTO switch is located on right side of the steering column. Pull it out the PTO switch to engage the PTO electric clutch. The electronic control unit (ECU) monitors the position of the PTO switch (up or down).
Page 213 Testing the PTO Switch (continued) 1. Park the machine on a level surface, lower the cutting deck, set the parking brake, and shut off the engine. 2. Disconnect the battery negative (-) cable at the battery. 3. Remove the steering column covers and get access to rear of the PTO switch;...
Page 214: Hazard Light Switch
Hazard Light Switch g294693 Figure 111 Hazard- light switch The hazard light switch is located on the dash panel (Figure 111). The hazard light switch controls the operation of the hazard lights. Testing the Hazard Light Switch g294694 Figure 112 1.
Page 215 Testing the Hazard Light Switch (continued) 5. The hazard light switch terminals are identified in Figure 112 and the circuitry of the hazard light switch is shown in the Circuit Logic Table (page 6–15). With the use of a multimeter (ohms setting), test the switch functions to determine if the continuity exists between the various terminals for each switch position.
Page 216: Differential Lock Switch
Differential Lock Switch g294695 Figure 113 Differential lock switch The differential lock switch is located on the dash panel (Figure 113). The differential lock switch controls the operation of the differential lock. Testing the Differential Lock Switch g294694 Figure 114 1.
Page 217 Testing the Differential Lock Switch (continued) 5. The differential lock switch terminals are identified in Figure 114 and the circuitry of the differential lock switch is shown in the Circuit Logic Table (page 6–17). With the use of a multimeter (ohms setting), test the switch functions to determine if the continuity exists between the various terminals for each switch position.
Page 218: Radiator Fan Reversal Switch
Radiator Fan Reversal Switch g294696 Figure 115 Radiator fan reversal switch The radiator fan reversal switch is located on the dash panel (Figure 115). The radiator fan reversal switch controls the direction of airflow through the radiator fan. Testing the Radiator Fan Reversal Switch g294694 Figure 116 1.
Page 219 Testing the Radiator Fan Reversal Switch (continued) 5. The radiator fan reversal switch terminals are identified in Figure 116 and the circuitry of the radiator fan reversal switch is shown in the Circuit Logic Table (page 6–19). With the use of a multimeter (ohms setting), test the switch functions to determine if the continuity exists between the various terminals for each switch position.
Page 220: Beacon Light Switch
Beacon Light Switch g294707 Figure 117 Beacon light switch The beacon light switch is located on the dash panel (Figure 117). The beacon light switch controls the operation of the beacon light. Testing the Beacon Light Switch g294694 Figure 118 1.
Page 221 Testing the Beacon Light Switch (continued) 5. The beacon light reversal switch terminals are identified in Figure 118 and the circuitry of the beacon light switch is shown in the Circuit Logic Table (page 6–21). With the use of a multimeter (ohms setting), test the switch functions to determine if the continuity exists between the various terminals for each switch position.
Page 222: Indicator Lights
Indicator Lights g294708 Figure 119 Battery charge indicator Raised hopper indicator Air filter restriction indicator Glow plug indicator Work light indicator Parking brake indicator Oil pressure warning indicator Road light indicator The indicator lights are located on the dash panel. Battery Charge Indicator Light The battery charge indicator light should illuminate when the key switch is in the ON position with the engine not running.
Page 223 Oil Pressure Warning Indicator Light (continued) To test the oil pressure light and circuit wiring, ground the wire attached to oil pressure switch located on the engine near the oil filter. Turn the key switch to the ON position; the engine oil pressure light should illuminate indicating correct operation of the indicator light and circuit wiring.
Page 224: Height Of Cut Switch
Height Of Cut Switch g294710 Figure 121 Height of cut switch The height of cut switch is used to adjust the mower deck cutting height. The switch is located on the left console. The engine must be running to allow the height of cut to be raised or lowered. The height of cut switch controls the solenoid valve coils on the height of cut control valve.
Page 225 Testing the Height Of Cut Switch (continued) 5. The switch terminals are identified in Figure 122 and the circuitry of the switch is shown in the Circuit Logic Table (page 6–25). With the use of a multimeter (ohms setting), test the switch functions to determine if continuity exists between the various terminals for each switch position.
Page 226: Seat Switch
Seat Switch g289939 Figure 123 Bellows Cable ties Blind rivet Spring pack Blind rivet Switching bracket Seat level indicator housing Seat switch with cable Backrest frame Cover Bushing Switch plate Compression springs The seat switch 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 227 Testing the Seat Switch (continued) g289938 Figure 124 Operator seat Seat switch connector Seat switch wire harness 3. Unplug the machine wire harness electrical connector from the seat switch (Figure 124). 4. Connect a multimeter (ohms setting) across the seat switch harness connector terminals to check the continuity of the seat switch.
Page 228: Hour Meter
Hour Meter g213963 Figure 125 Fuel gauge Hour meter/service due indicator Engine-temperature gauge Throttle lever Height-of-cut switch The hour meter records and displays the accumulated hours of the engine operation. The service due indicator displays the number of hours until the next engine oil and filter change.
Page 229 Testing the Hour Meter 1. Park the machine on a level surface, lower the cutting deck, set the parking brake, and shut off the engine. 2. Ensure that the key switch is in the OFF position. Locate the hour meter and disconnect the wire harness electrical connector from the hour meter.
Page 230: Traction Neutral Switch
Traction Neutral Switch g294807 Figure 127 Neutral switch The neutral switch sends signals to the Electronic Control Unit (ECU) about the traction pedal position. The ECU takes the inputs from neutral switch and allows the engine to start. The neutral switch is located under the operator’s platform. Testing the Traction Neutral Switch 1.
Page 231: Traction Reverse Switch
Traction Reverse Switch g294810 Figure 128 Reverse switch The reverse switch sends signals to the Electronic Control Unit (ECU) about the traction pedal position. The ECU takes the inputs from reverse switch and activates the warning buzzer. The reverse switch is located under the operator’s platform. Testing the Traction Reverse Switch 1.
Page 232: Parking Brake Switch
Parking Brake Switch g294832 Figure 129 Parking brake switch The parking brake switch is a normally open switch. The Electronic Control Unit (ECU) monitors the operation of the parking brake switch. The parking brake switch located under the operator’s platform. When the parking brake is not set, the parking brake bracket is away from the target end of the parking brake switch so that the switch is open.
Page 233: Oil Pressure Switch
Oil Pressure Switch g294844 Figure 130 Oil pressure switch The engine oil pressure switch is located on the engine near the oil filter (Figure 130). The oil pressure switch is a normally closed switch that opens with oil pressure. The oil pressure switch should open at approximately 0.6 bar (8.8 PSI). IMPORTANT If the oil pressure indicator light is illuminated with the engine running, shut off the engine immediately.
Page 234 Testing the Oil Pressure Switch (continued) 1. Park the machine on a level surface, lower the cutting deck, set the key switch to the OFF position and remove the key from the key switch. 2. Locate the engine oil pressure switch on the engine and disconnect the wire harness connector from the switch.
Page 235: Pto Electric Clutch
PTO Electric Clutch g290631 Figure 131 Bolt Woodruff key Washer Bolt Bushing Washer Bracket Drive shaft Spring Engine Electric clutch An electric clutch is used to engage the PTO. The electric clutch is mounted on the engine crankshaft and engages when current is applied to the clutch. The clutch also incorporates a magnetic brake to stop the clutch rotation when the clutch is de-energized.
Page 236 Testing the PTO Electric Clutch (continued) g294909 Figure 132 PTO electric clutch Lock nut Access slot 3. Unplug the clutch electrical connector from the machine wire harness. Note: For accurate clutch resistance measuring, the clutch should be at approximately 21°C (70°F). Note: Before taking small resistance readings with a digital multimeter, short the multimeter test leads together.
Page 237: Fuel Stop Solenoid
Fuel Stop Solenoid g294911 Figure 133 Fuel stop solenoid The fuel stop solenoid must be energized for the diesel engine to run. The solenoid is mounted to the injection pump on the engine (Figure 133). Testing the Fuel Stop Solenoid (In Place) Note: Before taking the small resistance readings with a digital multimeter, short the multimeter test leads together.
Page 238 Testing the Fuel Stop Solenoid (In Place) (continued) 4. Use a digital multimeter, touch 1 test lead to the hold coil terminal and the other test lead to the fuel stop solenoid frame (ground). The resistance of the hold coil should be approximately 15 ohms. 5.
Page 239: Relays
Relays g294973 Figure 134 Start relay (5 terminals) Forward fan relay (4 terminals) Key relay (4 terminals) Glow relay (4 terminals) Reverse fan relay (4 terminals) The machines use a number of electrical relays. Some of the relays have four (4) terminals and some have five (5) terminals.
Page 240 • The two (2) reverse fan relays are attached to the battery support plate under the operator seat. When energized, the reverse fan relays allow the electrical current to the radiator fan. • The key relay is attached inside the left arm console above the battery. When energized, the key relay allow the electrical current to the machine.
Page 241 Testing the Relays with 4 Terminals (continued) 11. Install and secure the relay onto the mounting bracket. Connect the wire harness electrical connectors to the relay. 12. Connect the positive (+) cable to the battery and then connect the negative (-) cable to the battery;...
Page 242 Testing the Relays with 5 Terminals (continued) 9. Replace the relay if testing determines that the relay is damaged. 10. If the relay testing is correct and a circuit problem still exists, check the main wire harness; refer to the Electrical Schematics and Wire Harness Drawings/Diagrams in Appendix A (page A–1).
Page 243: Diode Assembly
Diode Assembly g295056 Figure 137 End of the diode body Male terminal Diode assembly Female terminal The diode assembly is used in the main wire harness. The diode can be identified by their black color and diode symbol on the end of the diode body. The diode assembly is used to protect the PTO clutch from reverse polarity in the electrical circuit.
Page 244: Slope Sensor (Optional)
Slope Sensor (Optional) g365064 Figure 138 Slope sensor module Flange nut (2 each) Cap screw (2 each) The optional slope sensor module is located under the battery cover. Once installed and calibrated, the optional slope sensor module monitors the angle of the machine during operation, and notifies the operator of a potentially dangerous condition via an LED light on the dashboard and an audible alarm.
Page 245 Calibrating the Slope Sensor (continued) g364991 Figure 139 Plug Calibration connectors 4. Set the key switch to the O position, but do not start the engine. 5. The LED light on the dashboard should blink as the sensor calibrates. 6. When the LED light on the dashboard stops blinking, set the key switch to the O position.
Page 246 Removing and Installing the Slope Sensor Module (continued) 6. When installing the slope sensor module, tighten the fasteners that secure the sensor module to the plate to 4 N·m (37 in-lb). 7. Connect the wire harness and calibrate the slope sensor; refer to Calibrating the Slope Sensor (page 6–44).
Page 247 Testing the Slope Sensor Alarm g365076 Figure 141 Audible alarm Wire harness During operation, the audible alarm sounds to notify the operator when the machine is operating on a steep slope and should proceed to a more shallow slope. Electrical current for the alarm is provided as an output from the slope sensor module.
Page 248 Testing the Slope Sensor Alarm (continued) g355655 Figure 142 Front view Positive (+) terminal Rear view Negative (−) terminal 5. Reconnect the machine wire harness to the alarm, install the steering tower cover before returning the machine to service. Electrical System: Testing the Electrical Components Page 6–48 ProLine H800 19241SL Rev B...
Page 249: Service And Repairs
Service and Repairs 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; refer to Servicing the Battery (page 6–51). 2.
Page 250 (-) 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 251: 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 252 Removing and Installing the Battery (continued) g216923 Figure 143 3. Loosen and remove the negative (-) cable from the battery. After you disconnect the negative cable from the battery, loosen and remove the positive cable (+) from the battery (Figure 143).
Page 253 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 254 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 255 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 256 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 257 Chapter 7 Chassis Table of Contents General Information ..........................7–2 Service and Repairs ..........................7–3 Wheels ............................... 7–3 Body Assembly ..........................7–5 Steering Column ..........................7–8 Lift Arms............................7–10 Traction Pedal ..........................7–12 Brake Pedal ............................. 7–14 Operator Seat ..........................7–16 Servicing the Operator Seat ......................
Page 258: General Information
General Information The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your ProLine H800 machines. Refer to the Operator’s Manual for additional information when servicing the machine. Chassis: General Information Page 7–2 ProLine H800 19241SL Rev B...
Page 259: Service And Repairs
Service and Repairs Wheels g289305 Figure 144 Rear wheel hub Rear wheel assembly Front wheel hub Rear wheel lug bolt Front wheel assembly Washer Front wheel lug nut Removing the Wheels 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch.
Page 260 Installing the Wheels 1. Install the wheel to the machine with the wheel-lug nuts or bolts. 2. Lower the machine to the ground. g034007 Figure 145 WARNING Failure to maintain proper torque could result in failure or loss of wheel and may result in personal injury. Maintain the proper torque of the wheel-lug nuts or bolts.
Page 261: Body Assembly
Body Assembly g289455 Figure 146 Steering wheel Console-left Bracket Bolt Washer Console-right Washer Column support Screw Screw Washer Thread insert Dashboard-center Fairing Screw Cover Footboard pad Socket head screw Cage nut Washer Bracket Footboard pad Cover Footboard pad Cover Bushing Washer Cover ProLine H800...
Page 262 Disassembling the Body Assembly 1. Park the machine on a level surface, set the parking brake, lower the cutting deck, shut off the engine, and remove the key from the key switch. 2. Use a punch and hammer to remove the pin (7) from the steering wheel. Discard the pin.
Page 263 Disassembling the Body Assembly (continued) g289456 Figure 148 Control-lever knob Screw Console-right 12. Remove the knobs and control levers from the auxiliary control valve (item 1 in Figure 148). 13. Remove the 2 screws (item 3 in Figure 148) that secure the right console to the fairing.
Page 264: Steering Column
Steering Column g289357 Figure 149 Steering wheel Steering column Connecting rod Bolt Dashboard Bracket Spacer Washer Socket head screw Thread insert Washer Bolt Washer Washer Bushing Support Bolt Socket head screw Bushing Bracket Steering control valve Washer Electronic control unit Shaft key Washer Washer...
Page 265 Removing the Steering Column 1. Park the machine on a level surface, set the parking brake, lower the cutting deck, shut off the engine, and remove the key from the key switch. 2. Use a punch and hammer to remove the pin (5) from the steering wheel. Discard the pin.
Page 266: Lift Arms
Lift Arms g289477 Figure 150 Washer Plate Washer Split pin Bushing Spring Bolt Lift arm RH Lift cylinder Bushing Breather cap Bushing Lift arm assembly RH Lift arm LH Lever Grease fitting Lift arm assembly LH Bolt Rubber washer Spring pin Screw Support Plastic washer...
Page 267 Removing the Lift Arms 1. Park the machine on a level surface, set the parking brake, lower the cutting deck, shut off the engine, and remove the key from the key switch. 2. Remove the cutting deck from the lift arms; refer to the Operator’s Manual. CAUTION When changing the tires or performing other service, use correct jacks and supports.
Page 268: Traction Pedal
Traction Pedal g289736 Figure 151 Washer Washer Bolt Bolt bolt Rod end Shock absorber Traction rod Spacer Linkage bellcrank Bolt Traction pedal Grease fitting Bolt Bolt Bushing Bolt Traction pedal pin Washer Washer Removing the Traction Pedal 1. Park the machine on a level surface, set the parking brake, lower the cutting deck, shut off the engine, and remove the key from the key switch.
Page 269 Removing the Traction Pedal (continued) 4. Disassemble the traction pedal as needed using the Figure 151 as a guide. When removing the pin (21), make sure to support traction pedal pin (25) to prevent damage. Installing the Traction Pedal 1. Apply a coat of grease to outer diameter of the pin (21) and bushing (7). Apply a coat of grease to inner diameter of the spacer (22), traction pedal pin (25) and linkage bellcrank (5).
Page 270: Brake Pedal
Brake Pedal g289839 Figure 152 Bushing Bolt Spring Spacer Brake pedal spring Spacer Bracket Brake pedal pin Spring pin Bolt Brake lock Cotter pin Washer Spacer Spacer Bushing Brake pedal Rubber pad Fork Bolt Column Pulley Brake pedal cap Bracket Brake cable Bolt Washer...
Page 271 Removing of Brake Pedal 1. Park the machine on a level surface, set the parking brake, lower the cutting deck, shut off the engine, and remove the key from the key switch. 2. Block the wheels with chocks to prevent the machine from moving. 3.
Page 272: Operator Seat
Operator Seat g289937 Figure 153 Seat switch connector Bushing Operator platform Seat Seat support Rubber pad Socket head screw Washer Column Washer Socket head screw Snap ring Bolt Bolt Seat hook Washer Spring Chassis: Service and Repairs Page 7–16 ProLine H800 19241SL Rev B...
Page 273 Removing the Operator Seat g289938 Figure 154 Operator seat Seat switch connector Seat switch wire harness 1. Park the machine on a level surface, set the parking brake, lower the cutting deck, shut off the engine, and remove the key from the key switch. 2.
Page 274: Servicing The Operator Seat
Servicing the Operator Seat g289939 Figure 155 Bellows Cable ties Blind rivet Spring pack Blind rivet Switching bracket Housing of the seat level indicator Seat switch with cable Backrest frame Cover Bushing Switch plate Compression springs For servicing the operator seat, see the Grammer Seats Repair Manual.
Page 275: Frame Assembly
Frame Assembly g289962 Figure 156 Operator platform Handle Plastic hinge Bolt Washer Rear engine cover Washer Screw Thread insert Rear bumper Frame Bolt Thread insert Washer Bolt Front engine cover Bracket Tow bar Screw Bolt Magnet Hood Bracket Rubber plug Screw Disassemble and assemble the frame assembly using the Figure 156...
Page 276 Chassis: Service and Repairs Page 7–20 ProLine H800 19241SL Rev B...
Page 277 Chapter 8 Axle and PTO Table of Contents General Information ..........................8–2 Service and Repairs ..........................8–3 Servicing the Brake ..........................8–3 Rear Axle assembly ........................... 8–6 Servicing the Rear Axle........................8–9 Steering Spindle..........................8–11 PTO Drive Belt ..........................8–14 Electric Clutch ..........................
Page 278: General Information
General Information The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your machine. Refer to the Operator’s Manual for additional information when servicing the machine. Axle and PTO: General Information Page 8–2 ProLine H800 19241SL Rev B...
Page 279: Service And Repairs
Service and Repairs Servicing the Brake g290036 Figure 157 Bolt Retaining ring Hydraulic motor Brake shoe Bolt Woodruff key Spring Washer Retaining ring Brake drum Camshaft Brake lever Stud Brake plate Tire Washer Bushing Wheel rim Brake cable bracket Brake caliper Valve Washer Wheel lug nut...
Page 280 Disassembling the Brakes (continued) 4. Loosen, but do not remove the locknut (19) securing the wheel hub to the motor shaft. 5. Ensure that the parking brake is disengaged. 6. Remove the clevis pin that secures the brake cable to the brake lever (5). Position the brake cable away from the brake lever.
Page 281 Assembling the Brakes (continued) WARNING Failure to maintain proper torque could result in failure or loss of the wheel and may result in personal injury. Maintain the proper torque of the wheel-lug nuts. 15. Torque tighten the nut (19) that secure the brake drum (13) onto the wheel motor shaft (2) to 350 N·m (258 ft-lb).
Page 282: Rear Axle Assembly
Rear Axle assembly g290134 Figure 158 Bolt Thrust washer Thrust washer Washer Tie rod end Flange Retaining ring Grease fitting Woodruff key Spacer Bolt RH spindle Rear axle Washer Washer Bolt Steering cylinder Bolt Washer Washer Bolt Bolt Rear hydraulic motor LH spindle Removing the Rear Axle 1.
Page 283 Removing the Rear Axle (continued) 3. Remove the hopper assembly; refer to Removing the Hopper Assembly (page 9–3). 4. Jack up the machine (just ahead of the rear wheels) until clearance exists to allow rear axle removal. Support the machine with the jack stands or appropriate load holding device to prevent it from falling;...
Page 284 Installing the Rear Axle (continued) 13. Check and adjust the steering stops; refer to Operator’s Manual. 14. Lower the machine and install the hopper assembly; refer to Installing the Hopper Assembly (page 9–4). 15. Check the hydraulic-fluid level in the hydraulic tank and add correct quantity of fluid if necessary;...
Page 285: Servicing The Rear Axle
Servicing the Rear Axle g290147 Figure 159 Bolt Grease fitting Washer Flange bushing Bushing Bolt Rear axle Rear Axle Pivot Bushing The rear axle must be held in place snugly by the axle pivot pin. Excessive movement of the axle, which is characterized by erratic steering, might indicate worn axle pivot bushing (8).
Page 286 Rear Axle Housing Bushings The rear axle steering spindle shafts must fit snugly in the rear axle. Excessive movement of the steering spindle shaft in the axle might indicate that the flange bushings (5) are worn or damaged and must be replaced as below: 1.
Page 287: Steering Spindle
Steering Spindle g290134 Figure 160 Bolt Thrust washer Thrust washer Washer Tie rod end Flange Retaining ring Grease fitting Woodruff key Spacer Bolt RH spindle Rear axle Washer Washer Bolt Steering cylinder Bolt Washer Washer Bolt Bolt Rear hydraulic motor LH spindle Removing the Steering Spindle 1.
Page 288 Removing the Steering Spindle (continued) 3. Remove the hopper assembly; refer to Removing the Hopper Assembly (page 9–3). 4. Remove the rear wheel; refer to Removing the Wheels (page 7–3). 5. Loosen, but not remove the locknut (24) that securing the wheel flange (2) to the motor shaft (22).
Page 289 Installing the Steering Spindle (continued) 6. Connect the tie-rod end to the steering spindle and secure with the washer (10) and nut (28). 7. Lubricate the spindle through the grease fitting on the axle. Grease should purge from the ends of the steering spindle shaft identifying that the grease cavity is completely filled.
Page 290: Pto Drive Belt
PTO Drive Belt g290202 Figure 161 Retaining ring Spring Spring Ball bearing Electric clutch Belt tension indicator Shaft Engine Nylon guide Dust flange Drive shaft Shaft key Washer Fork Pulley Bolt Cotter pin Belt tension lever Bushing Bushing Washer Retaining ring Bolt Flange bushing Bearing...
Page 291: Electric Clutch
Electric Clutch g290631 Figure 162 Bolt Spring Washer Washer Electric clutch Drive shaft Bushing Woodruff key Engine Bracket Bolt Removing the Electric Clutch 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2.
Page 292 Installing the Electric Clutch 1. If removed, install the drive shaft (10) onto the engine (11) and secure with the 3 bolts (8) and washers (9). 2. Clean the drive shaft (10) and position the woodruff (7) into the drive shaft slot.
Page 293: Pto Driveshaft
PTO Driveshaft g290234 Figure 163 Retaining ring Pulley Bracket Bearing Socket head screw Shaft Washer Socket head screw Dust flange Washer Shaft key Bolt Bushing Drive shaft Fork Washer Flange bushing Washer Bracket Grease fitting Bracket Bolt Polyethylene tube protector ProLine H800 Page 8–17 Axle and PTO: Service and Repairs...
Page 294 WARNING Do not start the engine and engage the PTO switch when the PTO driveshaft is disconnected from the cutting deck. If you start the engine and the PTO shaft is allowed to rotate, serious personal injury and machine damage could result. Disconnect the PTO electric clutch electrical connector whenever the PTO driveshaft is disconnected from the cutting deck.
Page 295 Installing the PTO Driveshaft IMPORTANT If the driveshaft tube and shaft were separated, ensure that the slip shaft yoke and slip tube yoke are aligned when the tube and shaft are assembled. Misalignment of the yokes will result in shortened driveshaft life and will cause unnecessary vibration when the cutting deck is operated.
Page 296: Servicing The Driveshaft
Servicing the Driveshaft g290288 Figure 165 End yoke Grease fitting Slip tube yoke Universal joint kit (cross and Slip shaft yoke End yoke bearing) Disassembling the Driveshaft 1. Remove the PTO driveshaft from the machine; refer to Removing the PTO Driveshaft (page 8–18).
Page 297 Assembling the PTO Driveshaft 1. Install the new cross and bearings as follows: A. Apply a thick layer of grease to the bearing bores in the end yoke and shaft yoke. B. Press 1 bearing partially into the yoke. C. Insert the cross into the yoke and bearing. D.
Page 298: Pto Shaft Assembly
PTO Shaft Assembly g290337 Figure 167 Retaining ring Electric clutch Nylon guide Ball bearing Engine Shaft Drive shaft Fork Dust flange Washer Cotter pin Shaft key Bolt Pulley Bushing Belt tension lever Washer Flange bushing Bushing Bolt Grease fitting Retaining ring Bolt Washer Bearing...
Page 299 WARNING Do not start the engine and engage the PTO switch when the PTO driveshaft is disconnected from the cutting deck. If you start the engine and the PTO shaft is allowed to rotate, serious personal injury and machine damage could result. Disconnect the PTO electric clutch electrical connector whenever the PTO driveshaft is disconnected from the cutting deck.
Page 300: Servicing The Pto Shaft Assembly
Servicing the PTO Shaft Assembly g290368 Figure 168 Retaining ring Bushing Bolt Ball bearing Retaining ring Shaft Bearing Flange bushing Dust flange Pulley Grease fitting Shaft key Washer Pulley Washer Bolt Bolt Belt tension lever Washer Disassembling the PTO Shaft Assembly 1.
Page 301 Disassembling the PTO Shaft Assembly (continued) 7. Remove the bolt (17), nut (22) and washer (21) that secures the belt tension lever (8) to the dust flange (4). Remove the belt tension lever from the dust flange. 8. Remove the retaining rings (1) that secures the bearings (2) and shaft (3) into the dust flange (4).
Page 302: Servicing The Gearbox Assembly
Servicing the Gearbox Assembly g290508 Figure 169 Plug Cover Spacer Bearing Spacer Retaining ring Spacer Spacer Spacer Retaining ring Gear Retaining ring Bearing Bearing Spacer Spacer Shaft Shaft Gear Shaft key Shaft key Spacer Spacer Cover Retaining ring Retaining ring Seal Gearbox housing Retaining ring...
Page 303 g290529 Figure 170 Gearbox assembly Spacer Washer Shaft key Pulley Bolt Remove the bolt (6) and washer (5) that secures the pulley (3) to the gearbox (1). Use a puller and remove the pulley (3) and spacer (4) from the gearbox (1). Locate and retrieve the shaft key (2).
Page 304 Assembling the Gearbox 1. Position the spacer (19), gear (18), spacer (17), new bearing (16) and retaining ring (15) into the gearbox housing (21). 2. Install the spacer (14) and bearing (13) into the gearbox housing (21). 3. Install the shaft (7) into the gearbox housing (21). 4.
Page 305 Chapter 9 Hopper Assembly Table of Contents General Information ..........................9–2 Service and Repairs ..........................9–3 Hopper Assembly..........................9–3 Hopper Frame Assembly ........................9–5 Hopper ............................... 9–8 Hopper Lift Frame Assembly......................9–10 Chute Assembly..........................9–13 ProLine H800 Page 9–1 Hopper Assembly 19241SL Rev B...
Page 306: General Information
General Information The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your machine. Refer to the Operator’s Manual for additional information when servicing the machine. Hopper Assembly: General Information Page 9–2 ProLine H800 19241SL Rev B...
Page 307: Service And Repairs
Service and Repairs Hopper Assembly g291254 Figure 171 Bolt Washer Bolt Washer Flange bushing Bolt Hydraulic cylinder Removing the Hopper Assembly 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake and remove the key from the key switch. 2.
Page 308 Removing the Hopper Assembly (continued) 5. Remove the bolt (1) and washer (2) that secures the pin (3) to the machine frame. 6. Support the hopper assembly before removing the pin (8). 7. Slide and remove the pin (3) that secures the hopper assembly to the machine frame.
Page 309: Hopper Frame Assembly
Hopper Frame Assembly g291154 Figure 172 Hopper assembly Knob Support Decal Hook Screw Decal support Washer Guide Front grass catcher screen Washer Grass catcher screen Washer Plate Spring pin Rivet Inside grass catcher screen Washer Bracket Bolt Rivet Carriage bolt Cross rail Chain Washer...
Page 310 g291155 Figure 173 Washer Grommet Rivet Hinge Washer Plate Bolt Washer Rivet Hinge Grease fitting Spring Socket head screw Hinge Frame Bolt Hook Hopper cover Washer Flange bushing Washer Spacer Screw Support Washer Decal Spring Bolt Screw Washer Bolt Washer Split pin Connecting rod Handle...
Page 311 Disassembling the Hopper Frame Assembly 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake and remove the key from the key switch. 2. Remove the hopper assembly from the machine; refer to Removing the Hopper Assembly (page 9–3).
Page 312: Hopper
Hopper g291403 Figure 174 Bolt Washer Motor Bracket Cover Spring Sensor support Spacer Washer Microswitch Bracket Screw Bolt Connector pin Screw Thread insert Connector Manifold Bolt Washer Connector pin Washer Eye end Connector Bearing Washer Wire harness Spreader support Body Connecting rod Union fitting Spacer...
Page 313 Disassembling the Hopper 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake and remove the key from the key switch. 2. Remove the hopper assembly from the machine; refer to Removing the Hopper Assembly (page 9–3).
Page 314: Hopper Lift Frame Assembly
Hopper Lift Frame Assembly g291439 Figure 175 Hopper Assembly: Service and Repairs Page 9–10 ProLine H800 19241SL Rev B...
Page 315 Figure 175 (continued) Tube cap Collar Tube Hopper hinge Clamp Socket head screw Ball joint Washer RH Bracket Washer LH Bracket Bolt Bolt Snap ring Washer Support frame Bracket Screw Washer Thread insert Support Plate Bolt Chassis Magnet Cable Safety handle Knob Grease fitting Snap ring...
Page 316 Assembling the Hopper Lift Frame Assembly 1. Clean the pin (24). Inspect the pin (24) for wear or damage and replace if necessary. 2. Assemble the hopper lift frame assembly using the Figure 175 Figure as a guide. 3. Remove the caps or plugs that were installed to the hydraulic hoses and fitting during the disassembly process.
Page 317: Chute Assembly
Chute Assembly g291632 Figure 177 Chute Bracket Washer Handle Chute rubber seal Screw Bracket Screw Chute bracket Plate Disassembling the Chute Assembly 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake and remove the key from the key switch. 2.
Page 318 Hopper Assembly: Service and Repairs Page 9–14 ProLine H800 19241SL Rev B...
Page 319 Chapter 10 Cutting Unit Table of Contents General Information ..........................10–2 Service and Repairs ........................... 10–3 Idler Assembly ..........................10–4 Blade Spindle........................... 10–7 Servicing the Blade Spindle ......................10–9 Caster Wheel and Flat Frame Assembly ..................10–12 Cutting Deck Rollers and Skids...................... 10–14 Height Of Cut Linkage........................
Page 320: General Information
General Information The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your machine. Refer to the Operator’s Manual for additional information when servicing the machine. Cutting Unit: General Information Page 10–2 ProLine H800 19241SL Rev B...
Page 321: Service And Repairs
Service and Repairs WARNING Do not start the engine and engage the PTO switch when the PTO driveshaft is disconnected from the cutting deck. If you start the engine and the PTO shaft is allowed to rotate, serious personal injury and machine damage could result.
Page 322: Idler Assembly
Idler Assembly g290658 Figure 178 Cutting Unit: Service and Repairs Page 10–4 ProLine H800 19241SL Rev B...
Page 323 Figure 178 (continued) Bolt Bronze bushing Spring Washer Scraper Belt tension indicator Retaining ring Bolt Bolt Fork Bearing Plate nut Bolt Fork Pulley Bracket Washer Flange bushing Bushing Cutting deck fairing Cutting deck belt tightener Washer Bolt Bolt Bolt Washer Clamp Bolt Socket head screw...
Page 324 Installing the Idler Assembly (continued) 6. Attach the PTO driveshaft and install the cutting deck covers; refer to Operator’s Manual. Cutting Unit: Service and Repairs Page 10–6 ProLine H800 19241SL Rev B...
Page 325: Blade Spindle
Blade Spindle g290708 Figure 179 Blade spindle Bolt Center blade spindle Washer Central blade disc RH blade disc Central blade Washer RH blade Bolt Socket head screw Bevel washer LH blade Bronze bushing Cover LH blade disc Scraper Washer Oil seal Bolt ProLine H800 Page 10–7...
Page 326 Removing the Blade Spindle 1. Park the machine on a level surface, raise the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. Support the cutting deck so that it cannot fall accidentally. 2.
Page 327: Servicing The Blade Spindle
Servicing the Blade Spindle g290843 Figure 180 Grease fitting Shaft key Oil seal Bolt LH spindle shaft Retaining ring Seal Pulley Thrust washer Washer Center spindle shaft Pulley Spindle hub RH spindle shaft Cover Spacer Socket head screw Bearing Bearing Disassembling the Blade Spindle 1.
Page 328 Disassembling the Blade Spindle (continued) 6. Remove the retaining ring (16) and oil seal (15) from the spindle hub. 7. Use a press to remove the spindle shaft from the spindle hub. 8. Use a press and carefully remove the bearings (7 and 14) and spacer (13) from the spindle hub.
Page 329 Assembling the Blade Spindle (continued) IMPORTANT Pneumatic grease guns can produce air pockets when filling large cavities and therefore, are not recommended to be used for proper greasing of spindle housings. 13. Attach a hand pump grease gun to grease fitting on housing and fill housing cavity with grease.
Page 330: Caster Wheel And Flat Frame Assembly
Caster Wheel and Flat Frame Assembly g290949 Figure 182 Washer Bolt Retaining ring Footrest Bearing Plate Flat frame assembly Bolt Retaining ring Split pin Washer Caster fork Flange bushing Cutting deck Caster wheel Disassembling the Caster Wheel and Flat Frame Assembly 1.
Page 331 Assembling the Caster Wheel and Flat Frame Assembly 1. Assemble the flat frame assembly using the Figure 182 as a guide. 2. Assemble the caster wheel using the Figure 182 as a guide. 3. Check and level the cutting deck; refer to Operator’s Manual. ProLine H800 Page 10–13 Cutting Unit: Service and Repairs...
Page 332: Cutting Deck Rollers And Skids
Cutting Deck Rollers and Skids g290972 Figure 183 Bolt LH skid Roller Washer Washer Washer Washer Bolt Carriage bolt RH skid Roller shaft Cutting deck Roller Roller pin Bolt Bearing Removing the Cutting Deck Rollers and Skids 1. Park the machine on a level surface, raise the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch.
Page 333 Installing the Cutting Deck Rollers and Skids (continued) 2. Install the cutting deck rollers to the cutting deck using the Figure 183 as a guide. Tighten the nut (4) until the roller will not rotate, then loosen the nut only enough to allow the roller to rotate freely. Ensure to install the cutting deck rollers in the same mounting hole height position (lower or upper).
Page 334: Height Of Cut Linkage
Height Of Cut Linkage g291013 Figure 184 Cutting Unit: Service and Repairs Page 10–16 ProLine H800 19241SL Rev B...
Page 335 Figure 184 (continued) Frame Bolt Hydraulic cylinder Bolt Unhooking pin Bracket Retaining ring Fork Bolt Spring Washer Lever Bolt Plate Washer Bracket Block Washer Washer Washer Bolt Lever Bolt Split pin Washer HOC indicator Split pin Eye end Plate Plate Fork HOC rod Bolt...
Page 336: Cutting Deck Covers
Cutting Deck Covers g291066 Figure 185 Bracket Quarter turn fastener Collar Cover Rubber guard Plate Washer Cutting deck cover Washer Quarter turn fastener Washer Bolt Pulley cover Plastic hinge Rivet Washer Screw Hose protector Bolt Rivet Cutting deck Disassembling the Cutting Deck Covers 1.
Page 337 Assembling the Cutting Deck Covers 1. Assemble the cutting deck covers using the Figure 185 as a guide. 2. Install the cutting deck covers onto the cutting deck; refer to Operator’s Manual. ProLine H800 Page 10–19 Cutting Unit: Service and Repairs 19241SL Rev B...
Page 338 Cutting Unit: Service and Repairs Page 10–20 ProLine H800 19241SL Rev B...
Page 339 Appendix A Foldout Drawings Table of Contents Electrical Drawing Designations......................A–2 Hydraulic Schematic ..........................A–3 Electrical Schematic - Main........................A–5 Electrical Schematic - Lights ......................A–6 Wire Harness Diagram - Main ......................A–7 Wire Harness Diagram - Lights ......................A–8 Wire Harness – Slope Sensor (Optional) ...................A–9 ProLine H800 Page A–1 Foldout Drawings...
Page 340: 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 341: Hydraulic Schematic
Hydraulic Schematic g295174 ProLine H800, Drawing Rev , Sheet 1 of 1 19241SL Rev B Page A–3...
Page 342 Page A–4 19241SL Rev B , Drawing Rev , Sheet...
Page 343: Electrical Schematic - Main
Electrical Schematic - Main g295173 ProLine H800, Drawing 122-1361 Rev A, Sheet 1 of 2 19241SL Rev B Page A–5...
Page 344: Electrical Schematic - Lights
Electrical Schematic - Lights g295813 Page A–6 19241SL Rev B ProLine H800, Drawing 122-1361 Rev A, Sheet 2 of 2...
Page 345: Wire Harness Diagram - Main
Wire Harness Diagram - Main g295223 ProLine H800, Drawing Rev , Sheet 1 of 2 19241SL Rev B Page A–7...
Page 346: Wire Harness Diagram - Lights
Wire Harness Diagram - Lights g295814 Page A–8 19241SL Rev B ProLine H800, Drawing Rev , Sheet 2 of 2...
Page 347: Wire Harness - Slope Sensor (Optional
Wire Harness – Slope Sensor (Optional) g364132 model 02950, Drawing 122-1652 Rev B, Sheet 1 of 1 19241SL Rev B Page A–9...

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