27-inch or 32-inch rear roller brush kit (12 pages)
Summary of Contents for Toro Reelmaster 3100-D
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Form No. 99024SL Rev J ® Reelmaster 3100-D Original Instructions (EN)
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THE TORO COMPANY 2018 This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies). No intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be...
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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...
IMPORTANT: The IMPORTANT notice will give im- specifications or this publication without notice. portant instructions which must be followed to pre- vent damage to systems or components on the machine. E The Toro Company − 1999, 2002, 2003, 2005, 2007, 2009, 2011, 2012, 2018...
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..General Safety Instructions The REELMASTER 3100--D was tested and certified by TORO for compliance with national and international WARNING standards as specified in the Operator’s Manual. Al- though hazard control and accident prevention are de-...
20 degrees or less the risk of a rol- lover is low. As the slope angle increases to a Toro rec- 22.Raise the cutting units when driving from one work ommended maximum limit of 25 degrees the risk of a area to another.
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32.Before disconnecting or performing any work on the void the product warranty of The Toro Company. hydraulic system, all pressure in system must be re- lieved by stopping engine and lowering cutting units to the ground.
Jacking Instructions CAUTION When changing attachments, tires, or performing other service, use correct blocks, hoists, and jacks. Make sure machine is parked on a solid lev- el floor such as a concrete floor. Prior to raising machine, remove any attachments that may inter- fere with the safe and proper raising of the ma- chine.
Numerous safety and instruction decals are affixed to the Reelmaster 3100−D. If any decal becomes illegible or damaged, install a new decal. Part numbers for re- placement decals are listed in your Parts Catalog. Order replacement decals from your Authorized Toro Distribu- tor. Reelmaster 3100−D Safety...
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Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS ......MAINTENANCE ....... EQUIVALENTS AND CONVERSIONS .
For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.
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Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Grade 1, 5, & SAE Grade 1 Bolts, Screws, Studs, & SAE Grade 5 Bolts, Screws, Studs, & SAE Grade 8 Bolts, Screws, Studs, & Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts...
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Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws, and Studs with Class 10.9 Bolts, Screws, and Studs with Thread Size Thread Size Regular Height Nuts Regular Height Nuts Regular Height Nuts Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts) M5 X 0.8...
Lubrication Traction Unit CAUTION Before servicing or making adjustments to the machine, stop engine, lower cutting, set parking brake, and remove key from the ignition switch. The traction unit has grease fittings that must be lubri- cated regularly with No. 2 General Purpose Lithium Figure 5 Base Grease.
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Figure 12 Figure 8 Figure 13 Figure 9 Figure 14 Figure 10 Figure 15 (See Note) Figure 11 Product Records and Maintenance Reelmaster 3100−D Page 2 − 8...
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Cutting Units Each cutting unit has (6) grease fittings (with optional front roller installed) that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. The grease fitting locations and quantities areas follows: Bedknife adjuster (2), every 50 hours (Fig. 17); Reel bearings (2) and front and rear rollers (2 ea.) (Fig.
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C. Coat cable terminals and battery posts with Grafo expected minimum temperature in your area (see 112X skin−over grease (Toro Part No. 505-47) or pe- Check Cooling System in Chapter 3 − Kubota Diesel En- troleum jelly to prevent corrosion.
Service and repair parts for Kubota engines are sup- commonly available in many service shops. Special plied through your Authorized Toro Distributor. If no tools are described in the Kubota Workshop Manual, parts list is available, be sure to provide your distributor Diesel Engine, 05 Series.
General Information Check Engine Oil The engine is shipped with oil in the crankcase. Howev- er, oil level must be checked before and after the engine is first started. Crankcase holds about 4.0 qts. (3.8 l) with filter. IMPORTANT: Check level of oil every 5 operating hours or daily.
Fill Fuel Tank DANGER Because diesel fuel is highly flammable, use cau- tion when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot, or when machine is in an enclosed area.
Adjustments Adjust Throttle Cable 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Position throttle control lever all the way to the SLOW position so it stops against the control panel slot (Fig. 6). 3.
Adjust Alternator/Fan Belt Condition and tension of all belts should be checked af- ter the first 10 hours of operation and every 100 operat- ing hours thereafter. 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch.
Service and Repairs Change Engine Oil and Filter Change oil and filter initially after the first 50 hours of op- eration, thereafter change oil every 50 hours and filter every 100 hours. 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch.
Bleed Fuel System 1. Park machine on a level surface, lower cutting units, stop engine, and engage parking brake. 2. Make sure fuel tank is at least half full. Gain access to the engine. DANGER Because diesel fuel is highly flammable, use cau- tion when storing or handling it.
Muffler and Air Cleaner Figure 15 1. Air inlet hose (upper) 9. Air cleaner body 17. Plug 2. Air inlet hose (lower) 10. Not used 18. Filter cover 3. Flange nut 11. Hex nut 19. Burp valve 4. Flange head screw 12.
Muffler Removal CAUTION The muffler and exhaust pipe may be hot. To avoid possible burns, allow the engine and ex- haust system to cool before working on the muf- fler. 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch.
Check Air Filter, Dust Cup, & Burp Valve The air cleaner body, air filter, dust cup, and burp valve should be check daily prior to operation. 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch.
Water/Fuel Separator DANGER Because diesel fuel is highly flammable, use cau- tion when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot, or when machine is in an enclosed area. Always fill fuel tank outside and wipe up any spilled diesel fuel before start- ing the engine.
Fuel Tank Removal (Fig. 22) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Siphon fuel from the tank into a suitable container. 3. Remove seat and seat support straps from the frame.
3. Place a suitable container under the radiator to col- Installation lect the coolant. Open drain cock valve, and completely 1. Remove any plugs from the oil cooler used during the drain the radiator. removal procedures. 4. Remove glow plug relay from the radiator assembly. 2.
Clean Radiator and Oil Cooler (Fig. 4) The radiator and oil cooler should be checked for dirt and debris daily, and hourly if conditions are extremely dusty and dirty. 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch.
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8. Disconnect wire harness and electrical wires from the following: A. Engine grounds to the battery and wire harness (Fig. 30). B. Glow plug bus and fuel stop solenoid (Fig. 31). C. High temperature warning switch (Fig. 32). D. High temperature shutdown switch, alternator, and low oil pressure switch (Fig.
B. Remove five cap screws, four washers, and five spacers securing the pump mount plate to the en- gine (Fig. 34). C. Remove four cap screws and hardened washers securing the right engine mounting bracket and hy- drostat to the engine. Installation 1.
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Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS ......Check Hydraulic Lines and Hoses .
General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure WARNING to weather, sun, chemicals, very warm storage condi- tions, or mishandling during operation or maintenance. Before disconnecting or performing any work These conditions can cause damage or premature dete- on hydraulic system, relieve all pressure in rioration.
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SAE Straight Thread O−Ring Port − Non−adjustable 1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material. 2. Always replace the O−ring seal when this type of fit- ting shows signs of leakage. O−Ring 3.
Towing Traction Unit In case of emergency, the Reelmaster can be towed for a short distance. However, Toro does not recommend this as a standard procedure. IMPORTANT: Do not tow the machine faster than 2 to 3 mph because drive system may be damaged. If ma- chine must be moved a considerable distance (more than a few feet), transport it on a truck or trailer.
Relieving Hydraulic System Pressure Before disconnecting or performing any work on the Re- which will energize the solenoid valve on hydraulic man- elmaster 3100−D hydraulic system, all pressure in the ifold to relieve circuit pressure. Move PTO switch to dis- hydraulic system must be relieved.
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Traction Circuits Forward the loss of hydraulic fluid from the closed loop circuit that must be replenished. The traction circuit of the hydraulic system consists of a hydrostat connected in a closed loop circuit to three or- The charge pump (P2) is a fixed displacement gear bital vane wheel motors.
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Reel Circuit REEL CIRCUIT SCHEMATIC FOR MACHINES WITH SERIAL NUMBERS BELOW 230000000 The gear pump (P1) is directly coupled to the the hydros- TO MANIFOLD tat which is driven by the engine. Taking its suction di- D1 PORT rectly from the hydraulic tank, the gear pump supplies oil flow to the manifold block and to the reel motors.
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Lift Circuit (Up) Raise Cutting Units When the cutting units are to be raised, the 2−spool valve is positioned by moving the cutting unit shift lever The gear pump (P2) is directly coupled to the hydrostat to RAISE. Flow is directed to cap ends of the lift cylin- through gear pump (P1).
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Lift Circuit (Down) Lower Cutting Units shift the pilot valve in the 2−spool valve. This shifting of the pilot valve allows hydraulic pressure to relieve from Circuit operation for lowering the cutting units is similar the cap end of the lift cylinders. Flow from the cap end to raising them.
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Sidewinder Circuit The gear pump (P2) is directly coupled to the hydrostat and hydraulic manifold, and to the hydrostat. When the through gear pump (P1). It supplies hydraulic pressure cutting unit shift lever is released, spring action returns (charge pressure) for raising and lowering the cutting the valve to its original position and by−passes flow back to the hydrostat and stopping cylinder movement.
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Steering Circuit The gear pump (P2) is directly coupled to the hydrostat. steering wheel. Fluid leaving the cylinder flows back It supplies hydraulic pressure to the power steering through the spool valve then through the OUT port and valve for turning the rear wheel and maintaining 100 to to the hydrostat.
Special Tools Order these special tools from your Toro Distributor. Hydraulic Pressure Test Kit Toro Part Number: TOR47009 Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings.
Figure 13 O- -Ring Kit Toro Part Number: 16- -3799 The kit includes O--rings in a variety of sizes for face seal and port seal hydraulic connections. It is recommended that O--rings be replaced whenever a hydraulic connec- tion is loosened.
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NOTE: Replacement filter element is Toro part number TOR6012. Filter element cannister tightening torque is NOTE: This kit does not include hydraulic hoses (see 25 ft- -lb (34 N- -m).
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Troubleshooting The charts that follow contain information to assist in Refer to the Testing section of this Chapter for precau- troubleshooting. There may possibly be more than one tions and specific test procedures. cause for a machine malfunction. Á Á Á Á Á Á Á Á Á Á Á Á Á Á...
Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment WARNING such as pressure gauges and flow meters in the circuits during various operational checks (See the Special Before disconnecting or performing any work Tools section in this Chapter).
Traction Circuit Working Pressure Test (Using Pressure Gauge) TRACTION WHEEL MOTORS TOP PORT LOWER UPPER DUMP VALVE PORT PORT 3000 psi TRACTION RELIEF 100 to 150 psi FROM HYDRAULIC MANIFOLD (CHG) PORT PISTON PUMP (HYDROSTAT) High Pressure TO GEAR PUMP SUCTION Low Pressure THROUGH CASE DRAIN Return or Suction...
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Procedure for Traction Circuit Working Pressure Test: 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off. 3.
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Piston Pump (P3) Flow and Traction Relief Pressure Test (Using Tester with Pressure Gauges and Flow Meter) TRACTION WHEEL MOTORS TOP PORT LOWER UPPER DUMP VALVE PORT PORT 3000 psi TRACTION RELIEF 100 to 150 psi FROM HYDRAULIC MANIFOLD (CHG) PORT PISTON PUMP (HYDROSTAT) High Pressure...
Procedure for Piston Pump (P3) Flow and Traction Relief Pressure Test: 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. 2. Park machine on a level surface with the cutting units lowered and off.
Charge Relief Valve Pressure Test (Using Pressure Gauge) TRACTION WHEEL MOTORS TOP PORT LOWER UPPER DUMP VALVE PORT PORT TO HYDRAULIC MANIFOLD (P1) PORT 3000 psi FROM HYDRAULIC MANIFOLD (CHG) PORT 100 to 150 psi CHARGE RELIEF TO STEERING CONTROL VALVE (IN) PORT ENGINE HYDROSTAT...
Procedure for Charge Relief Valve Pressure Test: 9. A dynamic charge pressure test can be performed as follows: 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 A. With T−connector and pressure gauge still con- minutes.
Gear Pump (P2) Flow Test (Using Tester with Pressure Gauges and Flow Meter) TO HYDRAULIC MANIFOLD (P1) PORT TO STEERING CONTROL TO TOTO VALVE (IN) PORT ENGINE FROM HYDROSTAT CASE DRAIN GEAR PUMP High Pressure STRAINER Low Pressure Return or Suction Flow Hydraulic System Reelmaster 3100−D...
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Procedure for Gear Pump (P2) Test: 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged.
Wheel Motor Efficiency Test (Using Tester with Pressure Gauges and Flow Meter) FRONT WHEEL MOTOR TESTING SHOWN TRACTION WHEEL MOTORS TOP PORT LOWER UPPER DUMP PORT PORT VALVE 3000 psi TRACTION RELIEF 100 to 150 psi FROM HYDRAULIC MANIFOLD (CHG) PORT PISTON PUMP High Pressure (HYDROSTAT)
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Procedure for Wheel Motor Efficiency Test: 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting units lowered and off.
Reel Circuit Pressure Test (Using Pressure Gauge) FROM REEL MOTOR CASE DRAINS TO INITIAL FROM FINAL REEL MOTOR REEL MOTOR TO HYDRAULIC TANK HYDRAULIC MANIFOLD BLOCK BACKLAPPING VALVE LOGIC REEL SPEED VALVE CONTROLLER REEL ON−OFF VALVE REEL RELIEF 3000 psi TO OIL COOLER PLUG...
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Procedure for Reel Circuit Pressure Test: 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged.
Gear Pump (P1) Flow Test (Using Tester with Pressure Gauges and Flow Meter) TO HYDRAULIC MANIFOLD (P1) PORT TO STEERING CONTROL VALVE (IN) PORT TO TOTO ENGINE FROM HYDROSTAT CASE DRAIN GEAR PUMP STRAINER High Pressure Low Pressure Return or Suction Flow Hydraulic System Reelmaster 3100−D...
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Procedure for Gear Pump (P1) Flow Test: IMPORTANT: In this test, the hydraulic tester is positioned before the manifold relief valve. Pump NOTE: Over a period of time, the gears and wear plates damage can occur if the oil flow is fully restricted by in the pump can wear down.
Manifold Relief Valve (R1) Pressure Test (Using Tester with Pressure Gauges and Flow Meter) FROM REEL MOTOR CASE DRAINS TO INITIAL REEL MOTOR FROM FINAL REEL MOTOR TO HYDRAULIC TANK HYDRAULIC MANIFOLD BLOCK BACKLAPPING VALVE LOGIC REEL SPEED VALVE CONTROLLER REEL ON−OFF VALVE...
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Procedure for Manifold Relief Valve (R1) Pressure 10.System pressure should be from 2700 to 3300 PSI Test: as the relief valve lifts. 1. Make sure hydraulic oil is at normal operating tem- A. If specification is not met, shut off engine and ad- perature by operating the machine for approximately 10 just relief valve (see Adjusting Manifold Relief Valve).
Flow MANIFOLD PORT (M2) BOTTOM Toro # TOR4077 NOTE: Over a period of time, a reel motor can wear in- NOTE: One way to find a possibly bad reel motor is to ternally. A worn motor may by−pass oil to its case drain have another person observe the machine while mow- causing the motor to be less efficient.
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Procedure for Reel Motor Efficiency: Case Drain Test: 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting units lowered and off.
Reel Motor Cross−over Relief Pressures Test (Using Pressure Gauge) TO HYDRAULIC MANIFOLD PORT (D1) FROM HYDRAULIC MANIFOLD PORT (M1) INITIAL REEL MOTOR BOTTOM RIGHT FRONT REEL MOTOR BOTTOM FINAL REEL MOTOR BOTTOM TO HYDRAULIC MANIFOLD PORT (M2) High Pressure Low Pressure Return or Suction Flow Figure 29...
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Procedure for Cross−over Relief Pressures Test: 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Make sure machine is parked on a level surface with the cutting units lowered and off.
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12.Make sure backlap knob on the hydraulic manifold is 14.Engage cutting units. System pressure should be in the backlap position. from 1350 to 1650 PSI as the relief valve lifts. 13.One person should sit on the seat and operate the 15.Disengage cutting units and stop engine.
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Lift and Steering Control Valve Relief Pressure Test (Using Pressure Gauge) TO HYDRAULIC MANIFOLD (ST) PORT TO LIFT VALVE POWER (IN) PORT STEERING VALVE 1000 psi TO HYDRAULIC MANIFOLD LEFT TURN SHOWN GEAR PUMP ENGINE STRAINER High Pressure Low Pressure FROM HYDROSTAT Return or Suction INTERNAL CASE DRAIN...
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Procedure for Lift and Steering Control Valve Relief Pressure Test: 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. 2. Make sure machine is parked on a level surface with the cutting units lowered and off.
Steering Control Valve Test STEERING CYLINDER OPEN FITTING PLUG POWER STEERING VALVE (LEFT TURN) High Pressure Low Pressure Return or Suction Flow Hydraulic System Reelmaster 3100−D Page 4 − 54...
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Procedure for Steering Control Valve Test: B. Turn the steering wheel all the way to the left (counterclockwise) so the steering cylinder rod is ful- 1. Make sure hydraulic oil is at normal operating tem- ly extended. perature by operating the machine for approximately 10 minutes.
Adjustments Adjust Traction Drive for Neutral 1. Park the machine on a level surface and turn the en- gine off. WARNING One front wheel and rear wheel must be raised off the ground or the machine will move during adjustment. Make sure machine is supported so it will not accidentally fall injuring anyone under machine.
Adjust Manifold Relief Valve (R1) The hydraulic reel circuit is equipped with a relief valve. This valve is preset at the factory to 3000 PSI. However, an adjustment may be required if the setting proves to be incorrect after testing (see TESTING). If an adjust- ment is required proceed as follows: WARNING Never adjust the relief valve with the hydraulic...
Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components After Repair or Replacement of Components 1. Before removing any parts from the hydraulic sys- 1. Check oil level in the hydraulic reservoir and add cor- tem, park machine on a level surface, engage parking rect oil if necessary.
Change Hydraulic Fluid Change hydraulic fluid after every 400 operating hours, under normal conditions. If fluid becomes contami- nated, the system must be flushed. Contaminated fluid looks milky or black when compared to clean oil. 1. Turn engine off and raise hood. 2.
200 hours of operation or yearly, whichever comes first. The hydraulic oil must be changed every 400 hours of operation or yearly, whichever comes first. Use a genuine Toro oil filter for replacement. IMPORTANT: Use of any other filter may void the warranty on some components.
Replace Traction Belt 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Insert nut driver or small piece of pipe onto the end of the torsion spring of the idler pulley. CAUTION Be careful when removing or applying tension from or to the torsion spring of the idler pulley.
Ing from petroleum base hydraulic fluid to a biode- draulic System Fluid. If changing to biodegradable fluid, gradable fluid such as Toro Biodegradable use Toro Biodegradable Hydraulic Fluid for this step. Hydraulic Fluid. Operate machine under normal op- Other fluids may cause system damage.
Charge Hydraulic System NOTE: When initially starting the hydraulic system with 11. After the hydraulic system starts to show signs of fill, new or rebuilt components such as motors, pumps, or actuate lift control lever until the lift cylinder rod moves lift cylinders, it is important that the hydraulic system be in and out several times.
Hydraulic Tank and Hydraulic Oil Filter LATER MODELS 16 to 18 ft−lb (22 to 24 N−m) Hydraulic Thread Sealant Hydraulic Thread Sealant 14 to 16 ft−lb (19 to 22 N−m) Anti−seize lubricant 30 to 60 in−lb (3.4 to 6.8 N−m) Figure 40 1.
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Hydraulic Tank Removal 1. Drain hydraulic tank (see Change Hydraulic Fluid). 2. Remove hydraulic tank from machine using Figures 40 and 41 as guides. Hydraulic Tank Inspection 1. Clean hydraulic tank and suction strainer with sol- vent. 2. Inspect hydraulic tank for leaks, cracks, or other damage.
Front Wheel Motors RIGHT FRONT Figure 42 1. Lock nut 5. Frame 8. O−ring 2. Spacer 6. Hydraulic tube 9. Hydraulic fitting 3. Socket head screw 7. Hydraulic tube 10. O−ring 4. Hydraulic motor Hydraulic System Reelmaster 3100−D Page 4 − 66...
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Removal Installation 1. Install wheel motor to frame using Figure 42 as guide. WARNING 2. Install wheel shield, brake bracket, and brake as- Before jacking up the machine, review and follow sembly to the frame. Install brake drum, wheel hub, and Jacking Instructions in Chapter 1 −...
Rear Wheel Motor 45 to 65 ft−lb 61 to 88 N−m 200 to 400 ft−lb 271 to 542 N−m Figure 43 1. Lug nut 6. Hydraulic hose 11. Hydraulic motor 2. Drive stud 7. O−ring 12. Rear fork 3. Tire and rim 8.
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Rear Wheel Removal Rear Wheel Installation 1. Park machine on a level surface, lower cutting units, 1. If hydraulic fittings were removed, install fittings to stop engine, engage parking brake, and remove key reel motor using marks made during the removal pro- from the ignition switch.
Reel Motors 30 to 40 ft−lb (41 to 54 N−m) 30 to 40 ft−lb (41 to 54 N−m) Figure 45 1. Hydraulic motor (front) 8. Hydraulic straight fitting 15. Hydraulic straight fitting 2. Hydraulic motor (rear) 9. Hydraulic hose 16. O−ring 3.
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Removal Installation NOTE: Note position of hydraulic fittings when remov- 1. If hydraulic fittings were removed, install fittings to ing from the reel motors. Position is critical to properly reel motor using marks made during the removal pro- reconnecting hydraulic hoses. cess to properly orientate fittings.
Reel Motor Service (Eaton) 25 to 28 ft- -lb (34 to 38 N- -m) 10 to 12 ft- -lb (13.6 to 16.3 N- -m) Figure 46 1. Plug 8. Idler gear assembly 14. Frontplate 2. O- -ring 9. Drive gear assembly 15.
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Inspection (Fig. 46) 12.Replace body if the inside diameter of the gear pock- ets exceeds 1.713 in. (43.5 mm). 1. Remove all nicks and burrs from all parts with an emery cloth. 13.Make sure both plugs are secure if they or the back- plate is not being replaced.
Reel Motor Service (Casappa) 33 ft- -lb (45 N- -m) 19 ft- -lb (25 N- -m) 19 ft- -lb (25 N- -m) Figure 46.1 1. Dust seal 7. Back- -up gasket 13. O- -ring 2. Retaining ring 8. Front wear plate 14.
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4. Loosen cap screws from the rear cover. 4. Inspect wear plates for the following: 5. Remove motor from the vise. Turn motor so that the A. Bearing areas should not have excessive wear or shaft end is facing down. Remove cap screws. scoring.
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1. Lubricate O--rings, pressure seals, back--up gaskets 8. Install rear wear plate with pressure seal side up and and wear plate grooves with a thin coat of petroleum jel- open side of the pressure seal pointing to the inlet side ly.
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Oil Cooler Removal CAUTION The radiator and oil cooler may be hot. To avoid possible burns, allow the engine and cooling systems to cool before working on the oil cooler. 1. Remove oil cooler using Figures 47 and 48 as guides.
Hydraulic Manifold Service HYDRAULIC MANIFOLD USED ON MACHINES WITH SERIAL NUMBERS Loctite 242 BELOW 250999999 2 to 5 ft−lb (2.7 to 6.8 N−m) 30 to 35 ft−lb (41 to 47 N−m) 42 to 45 ft−lb (57 to 61 N−m) 30 to 35 ft−lb (41 to 47 N−m) 30 to 35 ft−lb (41 to 47 N−m)
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48 to 60 in- -lb (5.4 to 6.7 N- -m) HYDRAULIC MANIFOLD USED ON MACHINES WITH SERIAL NUMBERS ABOVE 260000000 40 ft- -lb (54 N- -m) 25 ft- -lb 20 ft- -lb (34 N- -m) (27 N- -m) 120 in- -lb (13.5 N- -m) 41 ft- -lb (55 N- -m)
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Solenoid Operated, Relief and Logic Control Car- 6. Reinstall the cartridge valve into the manifold: tridge Valves A. Lubricate new O-rings and backup rings of seal 1. Make sure the manifold is clean before removing the kit with clean hydraulic oil and install on cartridge. cartridge valve and seal kit.
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3. Make sure manifold is clean before removing the D. Center one detent plate hole over a locating plate rotary cartridge valve. Remove the valve and seal kit. indentation. Drop a ball into each hole, then drop a spring into each hole. 4.
8. Install rotary handle (Fig. 52) (manifold shown in Fig. D. Pull spool up and out of manifold. Remove O-- 51) : rings and back--up ring from spool. A. Place handle base on flow control valve and posi- E. Discard removed O--rings and back--up rings. tion alignment mark on base with number 1 on man- 2.
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Removal WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved. See Relieving Hy- draulic System Pressure in the General Infor- mation section. 1. Remove control valve from the frame using Figures 54 and 55 as guides.
Control Valve Service (Models 03200, 03206 and 03170) 30 to 42 ft- -lb 10 to 12 ft- -lb (41 to 57 N- -m) (14 to 16 N- -m) 30 to 35 ft- -lb (41 to 48 N- -m) 30 to 35 ft- -lb (41 to 48 N- -m) 20 to 25 ft- -lb (27 to 34 N- -m)
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Figure 57 1. Check poppet 11. Valve body 21. Not used 2. Plunger 12. O−ring 22. Plunger detent 3. Spacer 13. Retaining ring 23. Spring 4. Spool 14. Washer 24. O−ring 25. O−ring 5. Seat 15. Not used 6. Plug (solid) 16.
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Disassembly Assembly 1. Plug all ports and clean the outside of the valve thor- IMPORTANT: Do not wipe parts with paper towels or oughly. rags. Lint free cloth must be used to prevent lint from causing damage to the hydraulic system. 2.
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Removal WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved. See Relieving Hy- draulic System Pressure in the General Infor- mation section. 1. Remove control valve from the frame using Figures 58 and 59 as guides.
Control Valve Service (Models 03201, 03207 and 03171) 10 to 12 ft- -lb 30 to 35 ft- -lb (41 to 48 N- -m) (14 to 16 N- -m) 30 to 42 ft- -lb (41 to 57 N- -m) 30 to 35 ft- -lb (41 to 48 N- -m) 20 to 25 ft- -lb (27 to 34 N- -m)
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Disassembly Assembly 1. Plug all ports and clean the outside of the valve thor- IMPORTANT: Do not wipe parts with paper towels or oughly. rags. Lint may cause damage to the hydraulic sys- tem. IMPORTANT: Match mark spools to their associat- ed bores.
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Piston Pump Antiseize Lubricant Antiseize Lubricant 27 to 31 ft−lb (37 to 42 N−m) RIGHT FRONT 90 to 120 in−lb (10.2 to 13.6 N−m) Figure 62 1. Piston pump 20. Idler pulley 39. V−belt 2. Straight hydraulic fitting 21. Spacer 40.
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Neutral Arm Assembly EARLY MODELS 34 33 33 34 Figure 63 1. Philips head screw 13. Spacer 25. Ball bearing 2. Flat washer 14. Traction stud 26. Rod end 3. Micro switch 15. Traction control cable 27. Lock nut 4. Keps nut 16.
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C. Disconnect traction control cable from the pump lever. D. Remove both flange head screws securing the neutral bracket to the piston pump. Remove flange nut and flange head screw securing the neutral bracket to the pump mount plate. E. Remove cap screw and flat washer securing the pump lever to the piston pump trunnion.
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Piston Pump Installation (Fig. 62) 10.Install neutral arm assembly to the piston pump as follows (Figs. 63 and 64): 1. If hydraulic fittings were removed, install fittings to pump using marks made during the removal process to A. Position neutral bracket to the mount plate, and properly orientate fittings.
Piston Pump Crush Ring Replacement 29 ft−lb (39 N−m) Figure 67 Crush ring Cam plate (control shaft) Seal Shims Bearing cone Washer (3 used) Cover plate Bearing cup 10. Cap screw (3 used) Housing NOTE: The shims replace the crush ring in the piston 5.
Sidewinder (Models 03201, 03207 and 03171) Figure 69 1. Plastic bushing 12. Lock nut 22. Hydraulic hose 2. Scissor link 13. Welded pin 23. 90 hydraulic fitting 3. Scissor mount 14. Flange head screw 24. Hydraulic hose 4. Cap screw 15.
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Removal WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved. See Relieving Hy- draulic System Pressure in the General Infor- mation section. 1. Remove hydraulic cylinder from the frame using Fig- ure 68 as guide.
5. Cap screw 19. Hydraulic Fitting 33. Flat washer 6. Pivot hub 20. Steering wheel nut 34. Not used 7. Steering cover 21. Toro decal 35. Not used 8. Cap screw 22. Hydraulic hose 36. O−ring 9. Toro decal 23. Hydraulic hose 37.
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Removal WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved. See Relieving Hy- draulic System Pressure in the General Infor- mation section. 1. Remove steering control valve from the steering col- umn using Figures 70, 71, and 72 as guides.
Steering Control Valve Service (Serial Numbers 90101 to 230999999) Figure 73 1. Nut 18. Socket head screw 35. Not used 2. Port cover 19. Commutator seal 36. Retaining plate 3. Seal ring 20. Commutator cover 37. Upper cover & jacket assembly 4.
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Removal Installation 1. Remove muffler from the engine to gain access to 1. If hydraulic fittings were removed, install fittings to the gear pump (see Muffler Removal in Chapter 3 − Ku- motor using marks made during the removal process to bota Diesel Engine).
Gear Pump Service 25 to 28 ft−lb (34 to 38 N−m) Figure 76 15. Not used 1. Front plate 8. Back−up gasket 2. Back plate 9. Wear plate 16. Drive gear 3. Front body 10. Pressure seal 17. Washer 4. Rear body 11.
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Disassembly (Fig. 76) MARKER LINE 1. Plug pump ports and clean the outside of the pump thoroughly. After cleaning, remove plugs and drain any oil out of the pump. 2. Make sure key is removed from the shaft of the drive gear.
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D. Gears should be free of excessive scoring and wear. E. Make sure drive and idler gears have their snap rings in the grooves on each side. F. Break sharp edges of gear teeth with emery cloth. G. Gear width on the drive gear and front idler gear should not be less than 0.384 inch (9.75 mm).
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IMPORTANT: Do not dislodge seals during installa- 15.Install new O−ring into the groove of the back plate. tion. 16.Align marker line on the back plate and body. Install 12.Install wear plate into the gear pocket of back body back plate onto the body and gear shafts. with the pressure seal and back−up gasket against the 17.Secure pump together with cap screws and new adapter plate.
Front Lift Cylinder Figure 80 1. 90 hydraulic fitting 15. LIft arm pivot shaft 28. External retaining ring 2. Hydraulic cylinder 16. Roll pin 29. Bulkhead nut 3. Carrier assembly 17. Pivot shaft link 30. Hydraulic tube 4. Flange nut 18.
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Removal 1. Remove front lift cylinder from the frame and lift arm using Figure 80 as guide. 2. If hydraulic fittings are to be removed from lift cylin- der, mark fitting orientation to allow correct assembly. Installation 1. If hydraulic fittings were removed, install fittings to cylinder using marks made during the removal process to properly orientate fittings.
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Removal Installation 1. Remove rear lift cylinder from the frame and lift arm 1. If hydraulic fittings were removed, install fittings to lift using Figure 82 as guide. cylinder using marks made during the removal process to properly orientate fittings. 2.
Lift Cylinder Service 24 to 30 ft−lb (33 to 41 N−m) Figure 83 1. Grease fitting 6. O−ring 11. Internal collar 2. Barrel with clevis 7. O−ring 12. Dust seal 3. Nut 8. Back−up ring 13. Shaft 4. Uni−ring 9. Rod seal 14.
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Disassembly Assembly 1. Remove oil from lift cylinder into a drain pan by slowly 1. Make sure all parts are clean before reassembly. pumping the cylinder shaft. Plug both ports and clean 2. Coat new O−rings, Uni−rings, rod seal, back−up the outside of the cylinder.
Steering Cylinder No. 2 General Purpose Grease No. 2 General Purpose Grease 65 to 85 ft−lb (88 to 115 N−m) 65 to 85 ft−lb (88 to 115 N−m) Figure 84 9. Jam nut 1. Hydraulic hose 5. O−ring 2. Hydraulic hose 6.
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Removal 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. NOTE: The rear tire must be removed to allow sufficient clearance to remove the steering cylinder from the ma- chine.
Steering Cylinder Service 24 to 30 ft−lb (33 to 41 N−m) Figure 87 1. Barrel 5. O−ring 9. O−ring 2. Lock nut 6. Piston rod 10. Back−up ring 3. Piston 7. Rod seal 11. Retaining ring 4. Uni−ring 8. Cylinder gland 12.
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Disassembly Reassembly 1. Remove oil from the steering cylinder into a drain pan 1. Make sure all parts are clean before reassembly. by slowly pumping the cylinder shaft. Plug both ports 2. Coat new O−rings, Uni−ring, rod seal, and back−up and clean the outside of the cylinder.
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Multimeter The meter can test electrical components and circuits for current, resistance, or voltage. NOTE: Toro recommends the use of a DIGITAL Volt− Ohm−Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital me- ter in the voltage mode will make sure that excess cur- rent is not allowed through the meter.
Troubleshooting For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and CAUTION components used on this machine (see Electrical Sche- matics and Diagrams section of this chapter). Remove all jewelry, especially rings and If the machine has any interlock switches by−passed, watches, before doing any electrical trouble- shooting or testing.
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Starting Problems (continued) Problem Possible Causes Engine cranks, but does not start. Wiring in the crank circuit (see Electrical Schematics) is loose, corroded, or damaged. Engine run solenoid or fuel pump faulty. The fuel tank is empty. An engine or fuel system problem exists.
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General Run and Transport Problems Engine kills during operation (operator sitting on seat). Operator moved too far forward on seat (seat switch is not depressed). The engine overheated. The parking brake was engaged or the parking brake switch No. 1 failed. The seat relay or seat switch failed.
Cutting Unit Operating Problems The cutting units will not run with the transport mow Wiring to the reel drive circuit is (see Electrical switch in MOW and the reel on/off switch in ON with Schematics) is loose, corroded, or damaged. the cutting units lowered.
Electrical System Quick Check Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the Voltage Measured Battery Charge Level battery terminals. 12.68 V (or higher) Fully charged (100%) Set multimeter to the DC volts setting. The battery 12.45 V 75% charged should be at a temperature of 60 to 100...
Check Operation of Interlock Switches 2. With operator on the seat, the engine must not start with either the reel switch engaged or the traction pedal CAUTION engaged. Correct problem if not operating properly. 3. With operator on the seat, the traction pedal in neu- Do not disconnect safety switches.
Component Testing For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the CAUTION circuit (e.g. unplug the ignition switch connector before doing a continuity check). When testing electrical components for continu- NOTE: For more component testing information, see ity with a multimeter (ohms setting), make sure the Kubota Workshop Manual, Diesel Engine, 05 Se- that power to the circuit has been disconnected.
Glow Relay The glow relay is attached to the radiator assembly. When energized, the glow relay allows electrical current to the engine glow plugs. Two styles of glow relays have been used on the Reel- master 3100−D. On machines with serial numbers be- low 240000000, two of the four relay connections are secured with screws (Fig.
Hour Meter 1. Connect the positive (+) terminal of a 12 VDC source to the positive terminal of the hour meter. Hobbs 2. Connect the negative (−) terminal of the voltage QUARTZ source to the other terminal of the hour meter. 0 0 0 0 HOURS 3.
High Temperature Warning and Shutdown Switches The high temperature warning and shut down switches are located on the water pump, which is located on the rear end of the engine block. The high temperature shut- down switch is on the alternator side of the engine (Fig. 11).
Diode Assemblies The diode D1 and D2 provide logic for the interlock switches. Diode D3 is used for circuit protection from in- ductive voltage spikes when the interlock relay is deen- ergized. Machines equipped with the standard control module (serial numbers above 240000000) use only one diode.
Warning Light Cluster (Serial Numbers Below 240000000) Note: Individual light bulbs can be tested by removing Battery Light them from the lighting cluster and applying 12 VDC to The battery light should come on when the ignition their wiring terminals. switch is in ON with the engine not running, or with an Oil Pressure Light improperly operating charging circuit while the engine is...
Indicator Lights (Serial Numbers Above 240000000) Charge Indicator Light The charge indicator light should come on when the igni- tion switch is in the ON position with the engine not run- ning. Also, it should illuminate with an improperly operating charging circuit while the engine is running. Engine Oil Pressure Light The engine oil pressure light should come on when the ignition switch is in the ON position with the engine not...
Fuel Pump The fuel pump is attached to the frame just outboard of the fuel injection pump. Operational Test 1. Park machine on a level surface, lower cutting units, stop engine, and engage parking brake. 2. Disconnect electrical connector from the fuel stop solenoid to prevent the engine from firing.
Fuel Stop Solenoid (Solenoid With 3 Wire Connector) The fuel stop solenoid must be energized for the engine to run. It is mounted on the engine block near the injec- tion pump (Fig. 20). The fuel stop solenoid includes two coils for operation: the pull coil and the hold coil.
Fuel Stop Solenoid (Solenoid With 2 Wire Connector) The fuel stop solenoid used on the Reelmaster 3100−D must be energized for the diesel engine to run. The sole- noid is mounted to the injection pump on the engine (Fig. 22). The fuel stop solenoid includes two coils for operation: the pull coil and the hold coil.
Glow Controller The controller is located under the right lower corner of the instrument panel. Note: Refer to Electrical Schematics and Diagrams at the beginning of the chapter when troubleshooting the controller. Controller Operation 1. When the ignition switch is placed in the RUN posi- tion, the controller energizes the glow plugs and lights up the glow lamp for 10 seconds.
Standard Control Module Reelmaster 3100−D machines with Serial Numbers above 240000000 are equipped with a Standard Control Module to monitor and control electrical components re- quired for safe operation. This Module is attached to the back of the instrument panel. Inputs from the neutral, parking brake, PTO, start (igni- tion), backlap, and high temperature switches are moni- tored by the Module.
Service and Repairs NOTE: For more component repair information, see the Kubota Workshop Manual, Diesel Engine, 05 Se- ries. Battery Storage If the machine will be stored for more than 30 days: 4. Store battery in a cool atmosphere to avoid quick de- terioration of the battery charge.
Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extend. Additionally, battery and electrical component failure can be prevented. CAUTION When working with batteries, use extreme cau- tion to avoid splashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes.
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2. Conduct a hydrometer test of the battery electrolyte. D. Measure the temperature of the center cell. IMPORTANT: Make sure the area around the cells is E. Connect a battery load tester to the battery termi- clean before opening the battery caps. nals following the manufacturer’s instructions.
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6. Apply a light coat of grease on all battery posts and Battery Battery Charge Level cable connectors to reduce corrosion after connections Reserve (Percent of Fully Charged) are made. Capacity Capacity (Minutes) 7. Connect a digital multimeter (set to amps) between 80 or less 3.8 hrs 7.5 hrs...
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Specifications Item Description Tire pressure 14 to 18 PSI (0.97 to 1.24 bar) Wheel lug nut torque 45 to 65 ft−lb (61 to 88 N−m) Special Tools Wheel Hub Puller Part Number: TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors.
Adjustments Adjust Brake C. If brakes can not be adjusted properly, repair or replace brake components as necessary. CAUTION D. After adjustment is complete, install front wheel assemblies to the machine (see Front Brake and Before and after adjusting the brakes, always Wheel Installation in the Service and Repairs sec- check the brakes in a wide open area that is flat tion).
Front Wheel and Brake RIGHT FRONT Figure 7 23. Spacer 1. Lug nut 12. Brake lever 2. Drive stud 13. Lock nut 24. Wheel shield 3. Wheel rim 14. Cap screw 25. Cotter pin 4. Tire 15. Brake bracket 26. Clevis pin 5.
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IMPORTANT: Do not hit wheel hub, wheel hub puller E. Position both brake shoes on the backing plate so or wheel motor with a hammer during removal or that the concave heels attach to the anchor pin. installation. Hammering may cause damage to the F.
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Installation WARNING 1. Position rear fork through the frame. 2. Install lock washer, thrust washer, and cap screw to Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 − Safety. the rear fork shaft. Torque cap screw from 60 to 80 ft−lb (81.4 to 108.5 N−m).
1. Park machine on a level surface, lower cutting units, 3. Remove and replace parts as necessary to repair stop engine, engage parking brake, and remove key brake linkages. from the ignition switch. 4. Install control panel cover to the machine. 2.
32. Lock nut 5. Cap screw 19. Hydraulic fitting 33. Flat washer 6. Pivot hub 20. Steering wheel nut 34. Not used 21. Toro decal 35. Not used 7. Steering cover 8. Cap screw 22. Hose assembly 36. O−ring 9. Toro decal 23.
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Disassembly Assembly 1. Park machine on a level surface, lower cutting units, 1. Make sure lever and friction discs are properly as- stop engine, engage parking brake, and remove key sembled to the steering control valve bracket using Fig- from the ignition switch. ure 11 as a guide.
Specifications Figure 1 MOUNTING: All cutting units are supported by equal CLIP FREQUENCY: With variable speed set to maxi- length independent lift arms and are interchangeable to mum rpm: all three cutting unit positions. 5 blade at 1040 reel rpm moving at 5 mph (8.1 km/h) CONSTRUCTION: 5 or 8 blades of 7 inches (18 cm) di- 1 inch (25.4 mm) clip.
TORO parts. Some tools may also be avail- able from a local supplier. Gauge Bar Assembly Use gauge bar to verify height of cut (Toro Part No. 13−8199). Gauge Bar Figure 2 Handle Assembly −...
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Bedknife Screw Tool − TOR510880 This screwdriver type bit is made to fit Toro bedknife at- taching screws. Use this bit with a torque wrench to se- cure the bedknife to the bedbar. IMPORTANT: Do not use and air or manual impact wrench with this tool.
It is important to remember that the lower the troubleshooting, see Aftercut Appearance Trouble- height of cut, the more critical these factors are. shooting Aid (Toro part no. 00076SL) Remember that the “effective” or actual height of cut de- pends on cutting unit weight and turf conditions. Effec- tive height of cut will be different than the bench set height of cut.
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Factor Possible Problem/Correction 6. Bedknife to reel adjustment. Check bedknife to reel contact daily. Bedknife must have light contact all across the reel. No contact will cause cutting edges to become dull. Excessive contact accelerates wear; quality of cut may be adversely affected.
Adjustments CAUTION Never install or work on the cutting units or lift arms with the engine running. Always stop en- gine and remove key first. Characteristics The single knob (SPA) bedknife−to−reel adjustment If a cutting unit is expected to be out of adjustment, use system incorporated in this cutting unit simplifies the ad- the following procedures in the specified order to adjust justment procedure needed to deliver optimum mowing...
Adjust Bedknife Parallel to Reel NOTE: A 3/4−inch (19 mm) wrench will be needed to ro- tate the bedknife adjustment knob (Fig. 7). IMPORTANT: Do not allow cutting unit to rest on the bedknife adjusting screw. The setting of the bed- knife will be changed.
Set Height−of−Cut and Level Both Rollers Note: Both floating and fixed cutting units can use this method for making height−of−cut adjustments and lev- 5/8 inch eling both front and back rollers. 1. Position cutting unit on a flat level table or board. 2.
Verify Height−of−Cut and Front Roller Level NOTE: Gauge bar (Toro Part No. 13−8199) may be ob- tained from your local Toro Distributor. IMPORTANT: Height−of−cut must be set and both rollers leveled before performing this adjustment (see Set Height−of−Cut and Level Both Rollers).
Adjust Front Lift Arms 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. IMPORTANT: Keep front cutting units on the lift arms when performing this adjustment. 2. Raise front lift arms. Make sure clearance between each lift arm and floor plate bracket is 0.18 to 0.32 inch (4.6 to 8.1 mm) (Fig.
Adjust Rear Lift Arm 1. Park machine on a level surface and engage parking brake. IMPORTANT: This adjustment must be performed with the rear cutting unit attached to the rear lift arm. 2. Raise lift arms. Make sure clearance between wear strap on the top of the rear cutting unit wear bar and bumper strap is 0.020 to 0.100 inch (0.508 to 2.54 mm) (Fig.
Service and Repairs Greasing Bearings, Bushings, and Pivot Points Each cutting unit has 9 grease fittings (with an optional front roller installed) that must be lubricated regularly with No. 2 general purpose lithium base grease. Grease Fitting Locations and Quantities Each bedknife adjuster has 1 fitting (Fig.
Note: Additional instructions and procedures on 1. Backlap knob 2. Reel speed knob backlapping are available in the Toro General Service Training Book, Reel Mower Basics (part no. 09168SL). 7. To make an adjustment to the cutting units while backlapping, turn off the reels by pushing in the reels 1.
Cutting Unit Removal and Installation Removal 1. Position machine on a clean, level surface. Lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. On the front cutting units, detach chain from the cut- ting unit carrier frame by removing the lock nut and cap screw (Fig.
Reel Motor Removal and Installation RIGHT FRONT Figure 26 1. Reel 15. Side plate (LH) 29. Reel coupler (RH) 2. Cap screw 16. Washer 30. Spider coupler 3. Not used 17. Spacer 31. Not used 4. Cap screw 18. Link 32.
Reel Removal and Bearing Replacement Remove Reel (Fig. 26) 4. Clean inside of the bearing housing before installing. Install bearing into bearing housing as follows: 1. Remove hydraulic motor from the cutting unit (see Hydraulic Motor Removal and Installation). Remove A.
Bedbar Removal and Installation Figure 27 1. Rubber bushing 13. Adjuster spacer 25. Carriage bolt 2. Flanged bushing 14. Not used 26. Not used 3. Jam nut 15. Bedbar pivot 27. Bedbar washer 4. Compression spring 16. Grease fitting 28. Bedbar housing 5.
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Bedbar Installation (Fig. 27) 1. Inspect flanged bushings and bushing for wear; re- place if necessary. 2. Clean and apply anti−seize lubricant to both bedbar pivots. Install bedbar washer on the bedbar. 3. Install bedbar adjusting housing and bedbar housing on the bed bar.
Bedknife Replacement and Grinding Bedknife Removal 27” Cutting Unit Shown 1. Remove bedbar from cutting unit (see Bedbar Re- moval in this chapter). NOTE: 27” cutting units use 10 screws to secure bed- knife to bedbar. 32” cutting units use 12 screws to secure bedknife to bedbar.
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Figure 31 Figure 34 Bedknife Lead −in Chamfer 1. Use Toro General Service Training Book, Reel Mow- er Basics (part no. 09168SL) and grinder manufactur- er’s instructions for bedknife grinding information. 2. A lead−in chamfer is ground into all new bedknives (Fig.
Roller Removal and Installation Note: This section can be used for both the front and rear rollers. Roller Removal 1. Remove both height−of−cut pins and hairpin cotters from each roller bracket. 2. Remove both locknuts from the capscrews securing each angle bracket to the cutting unit. 3.
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Roller Bearing and Seal Replacement Figure 36 1. Full roller 5. Bearing cone (outer) 9. Wiehle roller 2. Roller shaft 6. Outer seal 10. Sectional roller shaft 3. Grease seal 7. Adjustment nut 11. Bearing cone (inner) 4. Bearing cup 8.
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Install New Seals and Bearings on Full or Wiehle Install New Seals and Bearings on Sectional Roller Roller 1. Make sure all parts are clean prior to installing bear- 1. Make sure all parts are clean prior to installing bear- ings and seals.
Land Width Range 0.050 to 0.090 inch (1.3 to 2.3 mm) 3. Refer to Toro General Service Training Book, Reel Maximum Reel Taper 0.060 inch (1.5 mm) Mower Basics (part no. 09168SL) for reel grinding infor- mation.
Fixed Side Plate Installation 1. Remove pop rivets and rear height−of−cut plates from both sides of the cutting unit (Fig. 38). 2. Remove lock nuts, capscrews, washers, and both links from the cutting unit (Fig. 38). 3. Align fixed side plate with holes on the cutting unit (Fig.
Front Lift Arms RIGHT FRONT Figure 40 1. 90 hydraulic fitting 15. Lift arm pivot shaft 28. External retaining ring 2. Hydraulic cylinder 16. Roll pin 29. Bulkhead nut 3. Carrier assembly 17. Pivot shaft link 30. Hydraulic tube 4. Flange nut 18.
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Removal 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Remove cutting unit from the pivot shaft of the front lift arm (see Cutting Unit Removal). NOTE: Remove both spacers from the hydraulic cylin- der shaft clevis when removing the right, front lift arm.
Rear Lift Arm 200 to 250 Ft−lb (271 to 339 N−m) Figure 44 1. External retaining ring 9. Jam nut 17. Pin 2. Thrust washer 10. Washer 18. Carrier assembly 3. Rear lift arm 11. Lynch pin 19. Hex nut 4.
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3. Secure hydraulic cylinder clevis to the lift cylinder 5. Adjust lift arms to proper clearance (see Adjust Rear shaft of the rear lift arm with the thrust washer and exter- Lift Arm). nal retaining ring. 6. Grease front lift arm. 4.
Skid Kit Installation 1. Remove front roller from the cutting unit (see Roller Removal and Installation). 2. Align skid slots with the angle bracket holes on the cutting unit. 3. Secure skid to the cutting unit with both flange head screws, flat washers, and lock nuts.
Specifications Figure 1 Frame Construction: Precision machined die cast alu- Bedknife: Replaceable, single edged, high carbon minum cross member with bolt−on cast ductile iron or steel bedknife is fastened to a machined cast iron bed- aluminum side plates. bar with screws. Optional bedknives are available. Reel Construction: Reels are 27 inches (69 cm) or 32 Bedknife Adjustment: Dual screw adjustment to the inches (81 cm) in length and 7 inch (18 cm) in diameter.
General Information Cutting Unit Operator’s Manual The Cutting Unit Operator’s Manual provides informa- tion regarding the operation, general maintenance and maintenance intervals for the DPA cutting units on your Reelmaster machine. Additionally, if optional kits have been installed on the cutting units (e.g. rear roller brush), the installation instructions for the kit includes set−up and operation information.
Figure 2 Bedknife Screw Tool Toro Part Number: TOR510880 This screwdriver−type bit is made to fit Toro bedknife at- taching screws. Use this bit with a torque wrench to se- cure the bedknife to the bedbar. IMPORTANT: To prevent damage to the bedbar, DO NOT use an air or manual impact wrench with this tool.
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Figure 6 Spline Insert Tool Toro Part Number: TOR4074 (9 tooth) Use the spline insert tool for rotating the cutting reel when hydraulic motor is removed. Also, use this tool for installation of threaded inserts into the cutting reel shaft.
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This tool should be used with the Toro Guide to Evaluation Reel Mower Performance and Using the TurfEvaluator (Toro part no. 97931SL).
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Reel Bearing Installation Tool (cutting units with painted side plates) Toro Part Number: 117−0975 Use the reel bearing installation tool to keep the reel bearing aligned as the cutting unit side plate is installed on the bearing. Figure 11 Cutting Reel Shim Toro Part Number: 125−5611...
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Because the top grind angle on bedknives is critical for edge retention, and therefore after− cut appearance, Toro has developed these service tools for accurately measuring the top grind angle on all bedknives. Since there can be variations in the mounting surface of the bedbar, it is necessary to grind the bedknife after installing it to the bedbar.
Note: For additional information regarding cutting unit cutting unit. It is important to remember that the lower troubleshooting, see Aftercut Appearance Trouble- the height−of−cut, the more critical these factors are. shooting Aid (Toro part no. 00076SL). Factor Possible Problem/Correction Tire pressure Check tire pressure of all traction unit tires.
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Factor Possible Problem/Correction Reel and bedknife sharpness A reel and/or bedknife that has rounded cutting edges or “rifling” (grooved or wavy appearance) cannot be NOTE: After grinding the reel and/or bedknife, check corrected by tightening the bedknife to reel contact. the reel to bedknife contact again after cutting two (2) Grind cutting reel to remove taper and/or rifling.
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Factor Possible Problem/Correction Roller condition and roller type Make sure rollers rotate freely. Repair roller bearings as necessary. See Roller Service in the Service and Repairs section of this chapter. Refer to Cutting Unit Operator’s Manual for roller options. Cutting unit accessories A variety of cutting unit accessories are available that can be used to enhance aftercut appearance.
Adjustments Characteristics If a cutting unit is determined to be out of adjustment, CAUTION complete the following procedures in the specified order to adjust the cutting unit properly. 1. Adjust the bedknife parallel to the reel. Never install or work on the cutting units or lift arms with the engine running.
Reel Bearing Adjustment (cutting units with painted side plates) NOTE: Cutting units that have aluminum side plates do not require reel bearing adjustment. 12 to 15 in−lb (1.4 to 1.7 N−m) To insure cut quality and long life of the cutting reel bear- ings, periodically check reel bearing adjustment.
Leveling Rear Roller The precision machined components of the cutting unit frame keep the rear roller and cutting reel in alignment (parallel). If the side plates are disassembled or as the cutting reel wears, a limited amount of side plate adjust- ment is possible to make sure that the cutting unit is properly aligned.
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Service and Repairs Hydraulic Reel Motor IMPORTANT: When performing maintenance pro- cedures on the cutting units, carefully position the cutting unit reel motors to prevent damage to the motors or hydraulic hoses. Removal 1. Park machine on a clean and level surface, lower cutting units completely to the ground, stop engine, en- FRONT gage parking brake and remove key from the ignition...
(see Special Tools). Never use a short edges that may have built up on the cutting edge. handled brush to apply lapping compound. NOTE: Additional instructions and procedures on backlapping are available in the Toro General Service CAUTION Training Book, Reel Mower Basics (part no. 09168SL).
Bedbar Assembly 27 to 33 ft−lb (37 to 44 N−m) RIGHT FRONT Antiseize Lubricant Figure 24 1. Bedbar assembly 5. Plastic washer (4 used) 8. Metal washer (2 used) 2. Lock nut (2 used) 6. Rubber bushing (2 used) 9. Bedbar pivot bolt (2 used) 3.
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Bedbar Installation (Fig. 24) 9. Tighten the lock nut (item 2) on each bedbar adjuster assembly until the adjuster spring is fully compressed, 1. If rubber bushing was removed from either cutting then loosen lock nut 1/2 turn. unit side plate, install a new bushing. The bushing should be installed flush with the inside of the side plate 10.Adjust cutting unit (see Cutting Unit Operator’s (Fig.
Bedknife Replacement and Grinding Bedknife Removal 27” Cutting Unit Shown 1. Remove bedbar from cutting unit (see Bedbar Re- moval in this chapter). NOTE: 18” cutting units use 6 screws to secure bed- knife to bedbar. 22” cutting units use 8 screws to secure bedknife to bedbar.
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Low HOC Figure 31 Standard Bedknife Lead −in Chamfer Low HOC 1. Use Toro General Service Training Book, Reel Mow- Extended EdgeMax er Basics (part no. 09168SL) and grinder manufactur- Low HOC 0.19” er’s instructions for bedknife grinding information. (4.8 mm)
Bedbar Adjuster Service Left Hand Threads Antiseize Lubricant Loctite #243 14 to 16 ft−lb (19 to 21 N−m) Antiseize Lubricant Left Hand Threads Antiseize Lubricant Loctite #243 14 to 16 ft−lb (19 to 21 N−m) Antiseize Lubricant RIGHT FRONT 15 to 20 ft−lb (21 to 27 N−m) Figure 32 1.
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Removal (Fig. 32) 2. If flange bushings (item 5) were removed, apply anti- seize lubricant to bore of cutting unit frame. Align key on 1. Remove lock nut (item 3), compression spring and bushing to slot in frame and install bushings into frame. washer from bedbar adjuster screw (item 4).
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Reel Assembly (cutting units with painted side plates) Grease OD surface 27 to 33 ft−lb (37 to 44 N−m) RIGHT See text for tightening procedure Grease bore FRONT and threads Antiseize Lubricant 27 to 33 ft−lb (37 to 44 N−m) Figure 33 1.
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Reel Assembly Removal (Fig. 33) 15 to 19 ft−lb 1. Position machine on a clean and level surface, lower (20 to 25 N−m) cutting units, stop engine, engage parking brake and re- move key from the ignition switch. 2. Remove the cutting unit from the machine and place on a flat work area.
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IMPORTANT: During cutting reel installation, keep IMPORTANT: Over tightening reel bearing adjuster inner and outer bearing races aligned. If bearing nut may damage reel bearings. races are not aligned, binding will occur and reel 11. Make sure that set screw (item 21) is loose in LH side installation may cause bearing damage.
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Reel Assembly Service (cutting units with painted side plates) Loctite #243 Clean Threads 85 to 95 ft−lb (115 to 128 N−m) (Right Hand Threads) RIGHT Left Hand Threads FRONT Loctite #243 85 to 95 ft−lb (115 to 128 N−m) Figure 35 1.
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C. To install spline insert into cutting reel, clean B. Press grease seals onto reel shaft with metal side threads of insert and cutting reel shaft. Apply Loctite orientated toward bearing location. Final position of #243 (or equivalent) to threads of insert, thread in- seal should be flush to 0.060”...
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Reel Assembly (cutting units with aluminum side plates) 27 to 33 ft−lb (37 to 44 N−m) Antiseize Lubricant (Bearing OD) Pack with Grease (both ends) RIGHT FRONT Antiseize Lubricant Antiseize (Bearing OD) Lubricant Figure 36 1. Bedbar assembly 7. Lock nut (2 used) 13.
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27 to 33 ft−lb 15 to 19 ft−lb (37 to 44 N−m) (20 to 25 N−m) 27 to 33 ft−lb (37 to 44 N−m) 27 to 33 ft−lb (37 to 44 N−m) 15 to 19 ft−lb (20 to 25 N−m) 27 to 33 ft−lb (37 to 44 N−m) Figure 37...
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7. Remove flange head screw and flange nut that se- cures frame spacer and carrier frame to LH side plate. NOTE: The reel bearings and grease seals are press fit on the cutting reel shaft and should remain on the reel when removing the LH side plate.
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15.If counterweight was removed from cutting unit, install new O−ring on counter weight. Secure counter weight to cutting unit side plate with two (2) flange nuts. Torque screws from 27 to 33 ft-lbs (37 to 44 N−m). 16.Install cutting unit to the machine. Reelmaster 3100−D Page 8 −...
Reel Assembly Service (cutting units with aluminum side plates) Loctite #243 85 to 95 ft−lb (115 to 128 N−m) (Right Hand Threads) Loctite #243 RIGHT FRONT 85 to 95 ft−lb (115 to 128 N−m) (Left Hand Threads − Groove in Face) Figure 39 1.
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Reel Assembly 1. If removed, install new reel shaft plugs into cutting reel shaft. For cutting unit serial no. prior to 315000001, make sure plastic plug is pressed flush into end of threaded insert. For cutting unit serial no. 315000001 & Up, make sure plastic plug is pressed unto reel shaft 1.63 to 1.37 in.
Specifications chart below). Additional reel grinding in- formation can be found in your Cutting Unit Operator’s Manual. An additional resource is the Toro Basics Se- ries Training Book, Reel Mower Basics (part no. 09168SL) found on the Service Reference Set available from your Authorized Toro Distributor.
Front Roller Removal (Fig. 43) Loctite #242 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and re- Antiseize move key from the ignition switch. Lubricant 2. Remove the cutting unit from the machine and place on a level working surface.
Rear Roller Removal (Fig. 44) 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and re- move key from the ignition switch. 2. Remove the cutting unit from the machine and place on a level working surface.
Roller Service Disassembly (Fig. 45) 50 to 60 ft−lb 1. Remove bearing lock nut from each end of roller (68 to 81 N−m) shaft. 2. Loosely secure roller assembly in bench vise and lightly tap one end of roller shaft until outer seals and bearing are removed from opposite end of roller tube.
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3. From the roller tube end with only the inner seal NOTE: After roller is installed to cutting unit, lubricate installed, carefully install the roller shaft into the roller roller grease fittings, rotate roller to properly distribute tube. Make sure that seals are not damaged as shaft is grease in bearings and clean excess grease from roller installed.
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Rear Roller Brush − Optional (cutting units with painted side plates) Antiseize Lubricant 27 to 33 ft−lb (37 to 44 N−m) 15 to 19 ft−lb (20 to 25 N−m) Loctite #243 15 to 19 ft−lb (20 to 25 N−m) Grease Grommet ID Loctite #243 RIGHT...
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Disassembly (Fig. 51) 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and re- move key from the ignition switch. 2. To remove roller brush from brush shaft: A. Remove the non−driven brush bearing assembly 20 to 25 in−lb (item 30) from cutting unit.
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3. If drive bearing housing was disassembled, install CAUTION new components noting proper orientation as shown in Figures 54 and 55. A. Install bearing on shaft by pressing equally on the Contact with the reel or other cutting unit parts inner and outer bearing races.
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5. Check alignment of pulleys with a straight edge CHECK placed along the outer face of the driven pulley (Fig. 57). ALIGNMENT The outer faces of the driven and drive pulleys (not the idler pulley) should be in line within 0.030” (0.76 mm). If necessary to align pulleys, remove driven pulley from brush shaft and add or remove hardened washer(s) (item 9) until drive and driven pulleys are aligned within...
Rear Roller Brush − Optional (cutting units with aluminum side plates) Grease Seal Lip 20 to 25 in−lb (2.3 to 2.8 N−m) Antiseize Lubricant Grease Seal Lip Grease RIGHT Seal Lip FRONT 27 to 33 ft−lb (37 to 44 N−m) Figure 59 1.
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Rear Roller Brush Assembly (Fig. 51) 6. Once all rear roller brush service is completed, plug the 48 VDC battery disconnect back in before operating 1. If seals or bearings were removed from brush bear- the machine. ing housings, install new components noting proper ori- entation as shown in Figure 53.
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Drive System Disassembly (Fig. 63) Loctite #243 15 to 19 ft−lb (20 to 25 N−m) 10 to 15 ft−lb (14 to 20 N−m) Grease Grommet ID Loctite #243 15 to 19 ft−lb (20 to 25 N−m) RIGHT Loctite #243 FRONT 35 to 40 ft−lb (48 to 54 N−m) Figure 63...
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Drive System Assembly (Fig. 63) 85 to 95 ft−lb 1. Install drive shaft if it was removed: (115 to 128 N−m) IMPORTANT: If rear roller brush drive is on left side of cutting unit, drive shaft has left hand threads and can be identified by a groove on the flange.
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3. After assembly (including drive belt installation), check alignment of pulleys with a straight edge placed 27 to 33 ft−lb along the outer face of the drive pulley (Fig. 57). (37 to 44 N−m) A. The outer faces of the drive and driven pulleys (not the idler pulley) should be in−line within 0.030”...
Grooming Performance There are a number of factors that can affect the per- formance of grooming. These factors vary for different golf courses and from fairway to fairway. It is important to inspect the turf frequently and vary the grooming practice with turf needs.
Troubleshooting Groomer Reel Mechanical Problems Problem Possible Causes Correction No rotation of the groomer reel. The groomer drive is in Neutral. Engage groomer drive to Forward or Reverse. Damaged or seized groomer drive Repair groomer drive. gears. The turf is damaged or has uneven The groomer reel blades are bent, Repair or replace blades if neces- grooming.
Service and Repairs RIGHT FRONT Figure 1 1. Gear box assembly 4. Height adjuster assembly (2) 6. Weights 2. Idler assembly 5. Plate 7. Button head screw (2) 3. Groomer reel NOTE: The Groomer Operator’s Manual provides in- formation regarding the installation, set−up, operation CAUTION and maintenance of the universal groomer on your Reelmaster machine.
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Gear Box Assembly RIGHT FRONT 90 to 100 ft−lb (122 to 135 N m) Figure 2 1. Gear box assembly 3. Cotter pin 5. Input shaft 2. Rear roller brush drive shield 4. Clevis pin NOTE: The groomer gear box assembly is located on NOTE: If cutting unit is equipped with an optional pow- the opposite side of the cutting unit from the cutting unit ered rear roller brush, remove the rear roller brush cov-...
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4. If installed, remove the rear roller brush drive shield 5. To detach the gear box from the cutting unit: from the gear box. A. Turn the input shaft in the correct direction to IMPORTANT: Groomer gear boxes installed on the loosen it from the reel.
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Disassembly (Fig. 3) 115 to 125 ft−lb (156 to 169 N−m) 85 to 95 in−lb (9 to 11 N−m) 32 to 42 in−lb Tighten to Specified Torque (see text) (4 to 5 N−m) Figure 3 1. Threaded adapter 17. Bushing (2) 32.
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CAUTION Use the 1−3/8” flats on the input shaft to prevent the input shaft from rotating during adapter re- moval. DO NOT use the 1/2” hex on the input shaft to secure the shaft during adapter removal or input shaft damage may occur. 1.
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NOTE: If cutting unit is equipped with an optional pow- ered rear roller brush, install the rear roller brush drive CAUTION housing assembly, drive belt and cover (see Roller Brush (Optional) in Chapter 8 − Cutting Units in this manual for additional information). Use the 1−3/8”...
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Idler Assembly Loctite #242 85 to 95 ft−lb (115 to 129 N−m) Antiseize Lubricant 27 to 33 ft−lb (37 to 45 N−m) 24 to 30 ft−lb (33 to 41 N−m) Figure 5 1. Socket head screw (2) 6. Cotter pin 10.
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Installation (Fig. 5) 1. If shields, bearing or bushing was removed from idler arm, install new components. A. Press bushing into groomer plate until the bush- ing is centered in the idler arm bore. B. Press bearing into idler arm so that bearing con- tact shoulder in idler arm bore and install bearing re- taining ring.
Groomer Reel Service Inspect groomer reel blades frequently for damage and wear. Straighten bent blades. Either replace worn MIDPOINT blades or reverse the individual blades to put the sharpest blade edge forward (Fig. 8). Blades that are rounded to the midpoint of the blade tip must be re- versed or replaced for best groomer performance.
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5. If groomer reel is equipped with broomer kit: A. Loosen the groomer blade retaining nuts on each end of the groomer shaft. 31 to 35 ft−lb (42 to 48 N−m) B. Slide a brush into each groove around the full length of the groomer reel (Fig.
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Grooming Brush (Optional) Service The optional grooming brush is removed and installed from the groomer in the same manner as the groomer reel (see Groomer Reel in this chapter). The grooming brush element or shaft can be serviced separately (Fig. 13). Figure 13 1.
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Assembly (Fig. 14) 1. Apply antiseize lubricant to upper threads of adjust- ment rod and lower threads of height adjusters. Assem- ble height adjuster assembly as shown. 2. If both height adjusters were removed, fit one height adjuster assembly to the cutting unit side plate and se- cure with carriage bolt and flange nut.
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Commercial Products E The Toro Company − 1999...