Toro 3100-D manual

P ART NO. 99024SL (Rev . G) Service Manual Reelmast er R 3100 - - D Preface The pur pose of t his public ation is to pr ovide the servic e technic ian with inf orm ation for t roubles hooting, t esting, and repair of maj or syst ems and co mponents on the Reelmast er 3100 - - D. REFE R TO T HE TRACT I ON UNI T AND CUT T ING UNIT OPE RA TOR’S M AN[...]

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Rev . F Reelmast er 3100 - - D T able Of Contents Chapter 1 - - Safety Safe ty Instruc tio ns 1 - - 1 .......................... Jackin g Instructions 1 - - 4 ......................... Safet y and I nst ruc tion Dec als 1 - - 5 ................ Cha pte r 2 - - Pr oduct Re cords a nd Manuals Produc t Records 2 - - 1 ........................... Equiv[...]

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Rev . E Reelmaster 3100 - - D Page 1 - - 1 Safety Chapter 1 Safety T able of Contents GENERAL SAFETY INSTRUCTIONS 1 ............ Before Operating 1 ............................ While Operating 2 ............................. Maintenance and Service 3 .................... JACKING INSTRUCTIONS 4 ..................... SAFETY AND INSTRUCTION DECALS 5 .[...]

Reelmaster 3100−D Page 1 − 2 Safety 8. Always wear substantial shoes. Do not operate ma- chine while wearing sandals, tennis shoes or sneakers. Do not wear loose fitting clothing because it could get caught in moving parts and possibly cause personal in- jury . 9. W earing safety glasses, safety shoes, long pants an d a helmet is advisable and [...]

Reelmaster 3100−D Page 1 − 3 Safety 24. If a cutting unit strikes a solid object or vibrates ab- normally , stop immediately . Turn engine of f, wait for all motion to stop and inspect for damage. A damaged reel or bedknife must be repaired or replaced before opera- tion is continued. 25. Before getting off the seat: A. Move traction pedal to n[...]

Reelmaster 3100−D Page 1 − 4 Safety 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 rais[...]

Rev . D Reelmaster 3100−D Page 1 − 5 Safety Safety and Instruction Decals 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 T or o Dist[...]

Rev . D Reelmaster 3100−D Page 1 − 6 Safety This page is intentionally blank.[...]

Rev . E Reelmaster 3100 - - D Page 2 - - 1 Product Records and Maintenance Chapter 2 Product Records and Maintenance T able of Contents PRODUCT RECORDS 1 ......................... MAINTENANCE 1 ............................... EQUIV ALENTS AND CONVERSIONS 2 ........... Decimal and Millimeter Equivalents 2 ............ U.S. to Metric Conversions 2 ..[...]

0.09375 Rev . D Reelmaster 3100−D Page 2 − 2 Product Records and Maintenance Equivalents and Conversions[...]

Reelmaster 3100−D Page 2 − 3 Product Records and Maintenance T orque Specifications Recommended fastener torque values are listed in the following tables. For critical applications, as determined by T oro, either the recommended torque or a torque that is unique to the application is clearly identified and spe- cified in this Service Manual. Th[...]

Reelmaster 3100−D Page 2 − 4 Product Records and Maintenance Standard T orque for Dry , Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, 5, & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs, & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) SAE Grade 5 Bolts, Screws, Studs, & Sems with R[...]

Reelmaster 3100−D Page 2 − 5 Product Records and Maintenance Standard T orque for Dry , Zinc Plated, and Steel Fasteners (Metric Fasteners) Thread Size Class 8.8 Bolts, Screws, and Studs with Regular Height Nuts Class 10.9 Bolts, Screws, and Studs with Regular Height Nuts Thread Size Regular Height Nuts (Class 8 or Stronger Nuts) Regular Height[...]

Reelmaster 3100−D Page 2 − 6 Product Records and Maintenance Other T orque Specifications SAE Grade 8 Steel Set Screws Thread Size Recommended T orque 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 + 10 ft−lb 18 + 3 ft−lb 1/2 − 13 UNC 7[...]

Reelmaster 3100−D Page 2 − 7 Product Records and Maintenance Lubrication T raction 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 Lithiu[...]

Reelmaster 3100−D Page 2 − 8 Product Records and Maintenance Figure 8 (2) Figure 9 Figure 10 Figure 1 1 Figure 12 Figure 13 Figure 14 Figure 15 (See Note )[...]

Reelmaster 3100−D Page 2 − 9 Product Records and Maintenance 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. Th e grease fitting locations and quantities areas follows: Bedknife adjuster (2), every 50 hours (Fig. 17);[...]

Reelmaster 3100−D Page 2 − 10 Product Records and Maintenance Preparation for Seasonal Storage T raction Unit 1. Clean traction unit, cutting units, and the engine thor- oughly . 2. Check tire pressure. Inflate all tires to 14 to 18 psi (0.97 to 1.24 Bar). 3. Check all fasteners for looseness; tighten as neces- sary . 4. Lubricate all grease fi[...]

Reelmaster 3100−D Page 3 − 1 Kubota Diesel Engine Chapter 3 Kubota Diesel Engine T able of Contents INTRODUCTION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICA TIONS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMA TION 4 . . . . . . . . . . . . . . . . . . . . . Check Engine Oil 4 . . . . . . .[...]

Reelmaster 3100−D Page 3 − 2 Kubota Diesel Engine Introduction This Chapter gives information about specifications, maintenance, troubleshooting, testing, and repair of the diesel engine used in the Reelmaster 3100−D. Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in [...]

Reelmaster 3100−D Page 3 − 3 Kubota Diesel Engine Specifications Item Description Make / Designation Kubota, 4−Cycle, 3 Cylinder , W ater Cooled, Diesel Engine Horse Power 21.5 HP @ 2500 RPM Bore mm (in.) 78.0 (3.07) Stroke mm (in.) 78.4 (3.09) T otal Displacement cc (cu. in.) 1 123 (68.53) T orque N−m (ft−lb) 67.3 (49.6) @ 2000 RPM Firin[...]

Reelmaster 3100−D Page 3 − 4 Kubota Diesel Engine 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 . IMPORT ANT : Check level of oil every 5 operating hours or daily . Change [...]

Reelmaster 3100−D Page 3 − 5 Kubota Diesel Engine Fill Fuel T ank 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 eng ine is running, hot, or when machine is in an enclosed area. Always fill fuel tank outside and wipe up any spilled [...]

Reelmaster 3100−D Page 3 − 6 Kubota Diesel Engine 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 i t stops against the control panel slot (Fig. 6 ). 3. Loo[...]

Reelmaster 3100−D Page 3 − 7 Kubota Diesel Engine 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 switc[...]

Reelmaster 3100−D Page 3 − 8 Kubota Diesel Engine 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 fr[...]

Reelmaster 3100−D Page 3 − 9 Kubota Diesel Engine 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. Do not smoke while[...]

Reelmaster 3100−D Page 3 − 10 Kubota Diesel Engine Muffler and Air Cleaner Figure 15 1. Air inlet hose (upper) 2. Air inlet hose (lower) 3. Flange nut 4. Flange head screw 5. Flat washer 6. Cap screw 7. Air filter bracket 8. Hose clamp 9. Air cleaner body 10. Not used 1 1. Hex nut 12. Lock washer 13. Mounting band assembly 14. Muffler 15. Muffl[...]

Reelmaster 3100−D Page 3 − 1 1 Kubota Diesel Engine Muffler Removal CAUTION The muffler and exhaust pipe may be hot. T o 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 ignitio[...]

Reelmaster 3100−D Page 3 − 12 Kubota Diesel Engine Check Air Filter , Dust Cup, & Burp V alve 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. 2. Check air[...]

Reelmaster 3100−D Page 3 − 13 Kubota Diesel Engine W ater/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 eng ine is running, hot, or when machine is in an enclosed area. Always fill fuel tank outside and wipe up any s[...]

Reelmaster 3100−D Page 3 − 14 Kubota Diesel Engine Fuel System Figure 22 1. Cap screw 2. Fuel tank 3. Fuel hose strap 4. Cap screw 5. Fuel cap 6. T ank support 7. Fuel gauge 8. Grommet 9. Connector fitting 10. Stand pipe 1 1. R−clamp 12. Barb fitting 13. Cap screw 14. Flange hex nut 15. Lock washer 16. Flat washer 17. T ee fitting 18. Barb fi[...]

Reelmaster 3100−D Page 3 − 15 Kubota Diesel Engine Fuel T ank 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. Disconnect seat switc[...]

Reelmaster 3100−D Page 3 − 16 Kubota Diesel Engine Radiator Figure 26 1. Drain cock valve 2. Flange head screw 3. Flange nut 4. Carriage bolt 5. Radiator 6. Fan shroud (top) 7. Fan shroud (bottom) 8. Flange head screw 9. Hose clamp 10. Radiator frame 1 1. Not used 12. Radiator seal 13. Flange head screw 14. Reservoir bracket 15. Clip spring 16.[...]

Reelmaster 3100−D Page 3 − 17 Kubota Diesel Engine 3. Place a suitable container under the radiator to col- lect the coolant. Open drain cock valve, and completely drain the radiator . 4. Remove glow plug relay from the radiator assembly . position relay away from the radiator . Note: Allow hydraulic components and hoses t o d ra in into a suit[...]

Reelmaster 3100−D Page 3 − 18 Kubota Diesel Engine 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 [...]

Reelmaster 3100−D Page 3 − 19 Kubota Diesel Engine This page is intentionally blank. Kubota Diesel Engine[...]

Reelmaster 3100−D Page 3 − 20 Kubota Diesel Engine Engine Figure 29 1. Kubota engine 2. Engine mount 3. Engine mount 4. Flange nut 5. Cap screw 6. Hex flange head screw 7. External lock washer 8. Lock nut 9. W asher 10. Machine screw 1 1. Hardened washer 12. Cap screw 13. Engine mounting bracket (front) 14. Engine mounting bracket (LH) 15. Engi[...]

Reelmaster 3100−D Page 3 − 21 Kubota Diesel Engine 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 pressur[...]

Reelmaster 3100−D Page 3 − 22 Kubota Diesel Engine 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. Install hydrostat and pump mount plate to t[...]

Rev . F Reelmaster 3100 - - D Hydraulic System (Rev . C) Page 4 - - 1 Chapter 4 Hydraulic System T able of Contents SPECIFICA TIONS 2 ............................. GENERAL INFORMA TION 3 ..................... Hydraulic Hoses 3 ............................. Hydraulic Fitting Installation 3 ................... T owing Traction Unit 5 ................[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 2 Specifications Item Description Piston Pump (Hydrostat) V ariable displacement piston pump Maximum Operating Pressure 3000 PSI (207 bar) Charge Pressure 100 to 150 PSI (6.9 to 10.0 bar) T raction Circuit Relief Pressure (Forward Only) 3000 PSI (207 bar) Gear Pump 2 stage positive displacem[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 3 General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather , sun, chemicals, very warm storage condi- tions, or mishandling during operation or maintenance. These conditions can cause damage [...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 4 SAE Straight Thread O−Ring Port − Non−adjustable 1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material. 2. Always replace the O−ring seal when this type of fit- ting shows signs of leakage. 3. Lubricate the O−ring with a light[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 5 T owing T raction Unit In case of emergency , the Reelmaster can be towed for a short distance. However , T oro does not recommend this as a standard procedure. IMPORT ANT : Do not tow the machine faster than 2 to 3 mph because drive system may be damaged. If ma- chine must be moved a cons[...]

Rev . D Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 6 Relieving Hydraulic System Pressure Before disconnecting or performing any work on the Re- elmaster 3100−D hydraulic system, all pressure in the hydraulic system must be relieved. Park machine on a level surface with the cutting units lowered and of f. T ur n key switch to OFF an[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 7 This page is intentionally blank. Hydraulic System[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 8 Hydraulic Schematics Hydraulic Schematic Reelmaster 3100−D (Model 03200) All solenoids are shown as de−energized M4 M5 DUMP VA LV E P3 HYDROST A T OIL FIL TER P1 P2 ENGINE RPM GEAR PUMP L R V1 LOWER PORT UPPER PORT M6 INTERNAL CASE DRAIN 100−150 psi STRAINER OIL COOLER TOP POR T FORW[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 9 D M4 M5 DUMP VA LV E P3 HYDROST A T OIL FIL TER P1 P2 ENGINE RPM GEAR PUMP L R V1 LOWER PORT UPPER PORT M6 INTERNAL CASE DRAIN 100 to 150 psi STRAINER OIL COOLER TOP POR T FORW ARD TRACTION WHEEL MOTORS 3000 psi FC1 REEL SPEED CONTROLLER LC1 LOGIC MD1 BACKLAPPING VA LV E REEL ON−OFF VA L[...]

Rev . F 9.1 Reelmaster 3100 - - D Hydraulic System Page 4 - - Hydraulic Schematic Reelmaster 3100 - - D (Models 03206 and 03170) All solenoids are shown as de - - energized MANIFOLD BLOCK[...]

Rev . F 9.2 Reelmaster 3100 - - D Hydraulic System Page 4 - - Hydraulic Schematic Reelmaster 3100 - - D (Models 03207 and 03171) All solenoids are shown as de - - energized MANIFOLD BLOCK Hydraulic System[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 10 Hydraulic Flow Diagrams D M4 M5 DUMP VA LV E P3 HYDROST A T OIL FIL TER P1 P2 ENGINE RPM GEAR PUMP L R V1 LOWER PORT UPPER PORT M6 INTERNAL CASE DRAIN 100 to 150 psi STRAINER OIL COOLER TOP POR T FORW ARD TRACTION WHEEL MOTORS 3000 psi FC1 REEL SPEED CONTROLLER LC1 LOGIC MD1 BACKLAPPING V[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 1 1 T raction Circuits Forward The traction circuit of the hydraulic system consists of a hydrostat connected in a closed loop circuit to three or- bital vane wheel motors. The engine drives traction pump (P3) indirectly through pulleys and a V−belt. The traction pump is a variable dis- pl[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 12 D M4 M5 DUMP VA LV E P3 HYDROST A T OIL FIL TER P1 P2 ENGINE RPM GEAR PUMP L R V1 LOWER PORT UPPER PORT M6 INTERNAL CASE DRAIN 100 to 150 psi STRAINER OIL COOLER TOP POR T FORW ARD TRACTION WHEEL MOTORS 3000 psi FC1 REEL SPEED CONTROLLER LC1 LOGIC MD1 BACKLAPPING VA LV E REEL ON−OFF VA [...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 13 Reel Circuit Mow Th e gear pump (P1) is directly coupled to the the hydros- tat which is driven by the engine. T aking its suction di- rectly from the hydraulic tank, the gear pump supplies oil flow to the manifold block and to the reel motors. Solenoid valve (S1) is de−energized with t[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 14 D M4 M5 DUMP VA LV E P3 HYDROST A T OIL FIL TER P1 P2 ENGINE RPM GEAR PUMP L R V1 LOWER PORT UPPER PORT M6 INTERNAL CASE DRAIN 100 to 150 psi STRAINER OIL COOLER TOP POR T FORW ARD TRACTION WHEEL MOTORS 3000 psi FC1 REEL SPEED CONTROLLER LC1 LOGIC MD1 BACKLAPPING VA LV E REEL ON−OFF VA [...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 15 Lift Circuit (Up) Raise Cutting Units The gear pump (P2) is directly coupled to the hydrostat through gear pump (P1). It supplies hydraulic pressure (charge pressure) for raising and lowering the cutting units, operating the sidewinder unit, and maintaining 10 0 to 150 PSI (6.9 to 10.0 ba[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 16 D M4 M5 DUMP VA LV E P3 HYDROST A T OIL FIL TER P1 P2 ENGINE RPM GEAR PUMP L R V1 LOWER PORT UPPER PORT M6 INTERNAL CASE DRAIN 100 to 150 psi STRAINER OIL COOLER TOP POR T FORW ARD TRACTION WHEEL MOTORS 3000 psi FC1 REEL SPEED CONTROLLER LC1 LOGIC MD1 BACKLAPPING VA LV E REEL ON−OFF VA [...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 17 Lift Circuit (Down) Lower Cutting Units Circuit operation for lowering the cutting units is similar to raising them. However , pressure is relieved from the lift cylinders, and this action allows them to lower . During conditions of not lifting or lowering cutting units, flow from the gea[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 18 D M4 M5 DUMP VA LV E P3 HYDROST A T OIL FIL TER P1 P2 ENGINE RPM GEAR PUMP L R V1 LOWER PORT UPPER PORT M6 INTERNAL CASE DRAIN 100 to 150 psi STRAINER OIL COOLER TOP POR T FORW ARD TRACTION WHEEL MOTORS 3000 psi FC1 REEL SPEED CONTROLLER LC1 LOGIC MD1 BACKLAPPING VA LV E REEL ON−OFF VA [...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 19 Sidewinder Circuit The gear pump (P2) is directly coupled to the hydrostat through gear pump (P1). It supplies hydraulic pressure (charge pressure) for raising and lowering the cutting units, operating the sidewinder unit, and maintaining 10 0 to 150 PSI (6.9 to 10.0 bar) to the low press[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 20 D M4 M5 DUMP VA LV E P3 HYDROST A T OIL FIL TER P1 P2 ENGINE RPM GEAR PUMP L R V1 LOWER PORT UPPER PORT M6 INTERNAL CASE DRAIN 100 to 150 psi STRAINER OIL COOLER TOP POR T FORW ARD TRACTION WHEEL MOTORS 3000 psi FC1 REEL SPEED CONTROLLER LC1 LOGIC MD1 BACKLAPPING VA LV E REEL ON−OFF VA [...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 21 Steering Circuit The gear pump (P2) is directly coupled to the hydrostat. It supplies hydraulic pressure to the power steering valve for turning the rear wheel and maintaining 100 to 150 PSI (6.9 to 10.0 Bar) to the low pressure side of the traction circuit. The pump takes its suction fro[...]

Rev . F Reelmaster 3100 - - D Hydraulic System (Rev . C) Page 4 - - 22 Special T ools Order these special tools from your T oro Distributor . Hydraulic Pressure T est Kit T oro 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[...]

Rev . E Reelmaster 3100 - - D Hydraulic System (Rev . C) Page 4 - - 23 Hydraulic T est Fitting Kit T oro Part Number: TOR407 9 This kit includes a variety of O- - ring Face seal fittings to enable you to connect test gauges into the system. The kit includes: tee’s, unions, reducers, plugs, caps, and male test fittings. Figure 12 Measuring Contain[...]

Rev . F Reelmaster 3100- - D Hydraulic System (Rev . C) Page 4 - - 24 Wheel Hub Puller T oro Part Number: TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors. Figure 15 High Flow Hydraulic Filter Kit T oro Part Number: TOR601 1 The high flow hydraulic filter kit is designed with large flow (40 GPM/150 LP[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 25 This page is intentionally blank. Hydraulic System[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 26 T roubleshooting The charts that follow contain information to assist in troubleshooting. There may possibly be more than one cause for a machine malfunction. Refer to the T esting section of this Chapter for precau- tions and specific test procedures. Problem Possible Cause Hydraulic oil[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 27 Problem Possible Cause Wheel motor will not hold load in neutral. Make up fluid from charge pump is not available. Hydrostat ball check valves are damaged. Reel motor drive pump is noisy (ca- vitation). Reservoir oil level is low . Suction line is restricted. Suction line has an air leak.[...]

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Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 29 T esting The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks (See the Special T ools section in this Chapter). Before Performing Hydraulic T [...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 30 T raction Circuit Working Pressure T est (Using Pressure Gauge) High Pressure Low Pressure Return or Suction Flow M4 M5 DUMP VA LV E P3 PISTON PUMP LOWER PORT UPPER PORT M6 TO GEAR PUMP SUCTION 100 to 150 psi TOP PORT FORW ARD TRACTION WHEEL MOTORS 3000 psi FROM HYDRAULIC MANIFOLD (CHG) P[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 31 Procedure for T raction Circuit Working Pressure T est: 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 of f. 3. Read Preca[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 32 Piston Pump (P3) Flow and T raction Relief Pressure T est (Using T ester with Pressure Gauges and Flow Meter) High Pressure Low Pressure Return or Suction Flow M4 M5 DUMP VA LV E P3 PISTON PUMP LOWER PORT UPPER PORT M6 TO GEAR PUMP SUCTION 100 to 150 psi TOP PORT FORW ARD TRACTION WHEEL M[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 33 Procedure for Piston Pump (P3) Flow and T raction Relief Pressure T est: 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 of[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 34 Charge Relief V alve Pressure T est (Using Pressure Gauge) High Pressure Low Pressure Return or Suction Flow M4 M5 DUMP VA LV E P3 HYDROST A T P1 P2 ENGINE RPM GEAR PUMP LOWER PORT UPPER PORT M6 INTERNAL CASE DRAIN 100 to 150 psi STRAINER TOP POR T FORW ARD TRACTION WHEEL MOTORS 3000 psi [...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 35 Procedure for Charge Relief V alve Pressure T est: 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 of f. Make sure engine is off and the parking bra[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 36 Gear Pump (P2) Flow T est (Using T ester with Pressure Gauges and Flow Meter) P1 P2 ENGINE RPM GEAR PUMP STRAINER TO TO TO TO STEERING CONTROL V AL VE (IN) PORT TO HYDRAULIC MANIFOLD (P1) PORT FROM HYDROST A T CASE DRAIN High Pressure Low Pressure Return or Suction Flow[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 37 Procedure for Gear Pump (P2) T est: 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 of f. Make sure engine is off and the parking brake is engaged. [...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 38 Wheel Motor Efficiency T est (Using T ester with Pressure Gauges and Flow Meter) Figure 21 High Pressure Low Pressure Return or Suction Flow M4 M5 DUMP VA LV E P3 PISTON PUMP LOWER PORT UPPER PORT M6 TO GEAR PUMP SUCTION 100 to 150 psi TOP PORT FORW ARD TRACTION WHEEL 3000 psi FROM HYDRAU[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 39 Procedure for Wheel Motor Efficiency T est: 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 of f. Make sure en[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 40 Reel Circuit Pressure T est (Using Pressure Gauge) P1 P2 ENGINE RPM GEAR PUMP STRAINER FC1 REEL SPEED CONTROLLER LC1 LOGIC MD1 BACKLAPPING VA LV E REEL ON−OFF VA LV E REEL RELIEF 3000 psi S1 R1 G1 T2 D1 M1 M2 MANIFOLD BLOCK T1 P1 LV LC2 CHG CF CR ST FROM LIFT V AL VE G2 PLUG VA LV E (OP[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 41 Procedure for Reel Circuit Pressure T est: 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 of f. Make sure engine is off and the parking brake is en[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 42 Gear Pump (P1) Flow T est (Using T ester with Pressure Gauges and Flow Meter) High Pressure Low Pressure Return or Suction Flow P1 P2 ENGINE RPM GEAR PUMP STRAINER TO TO TO TO STEERING CONTROL V AL VE (IN) PORT TO HYDRAULIC MANIFOLD (P1) PORT FROM HYDROST A T CASE DRAIN[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 43 Procedure for Gear Pump (P1) Flow T est: NOTE: Over a period of time, the gears and wear plates in the pump can wear down. A worn pump will by pass oi l and make the pump less ef ficient. Eventually , enough oil loss will occur to cause the reel motors to stall under heavy cutting conditi[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 44 Manifold Relief V alve (R1) Pressure T est (Using T ester with Pressure Gauges and Flow Meter) P1 P2 ENGINE RPM GEAR PUMP STRAINER FC1 REEL SPEED CONTROLLER LC1 LOGIC MD1 BACKLAPPING VA LV E REEL ON−OFF VA LV E REEL RELIEF 3000 psi S1 R1 G1 T2 D1 M1 M2 MANIFOLD BLOCK T1 P1 LV LC2 CHG CF[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 45 Procedure for Manifold Relief V alve (R1) Pressure T est: 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 of f. Make sure engine is off and the park[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 46 Reel Motor Efficiency − Case Drain T est (Using T ester with Pressure Gauges and Flow Meter) TO HYDRAULIC FROM HYDRAULIC TO HYDRAULIC INITIAL RIGHT FRONT FINAL REEL MOTOR REEL MOTOR REEL MOTOR MANIFOLD PORT (D1) MANIFOLD PORT (M1) MANIFOLD PORT (M2) MEASURING CONT AINER High Pressure Lo[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 47 Procedure for Reel Motor Efficiency: Case Drain T est: 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 of f. M[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 48 Reel Motor Cross−over Relief Pressures T est (Using Pressure Gauge) Figure 29 High Pressure Low Pressure Return or Suction Flow RIGHT FRONT FINAL REEL MOTOR REEL MOTOR INITIAL REEL MOTOR TO HYDRAULIC MANIFOLD PORT (D1) FROM HYDRAULIC MANIFOLD PORT (M1) TO HYDRAULIC MANIFOLD PORT (M2) IN[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 49 Procedure for Cross−over Relief Pressures T est: 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 [...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 50 12. Make sure backlap knob on the hydraulic manifold is in the backlap position. 13. One person should sit on the seat and operate the machine while another person reads the gauge. Start engine and move the throttle to full speed (2650 + 50 RPM) . CAUTION Keep away from reels during test [...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 51 This page is intentionally blank. Hydraulic System[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 52 Lift and Steering Control V alve Relief Pressure T est (Using Pressure Gauge) P1 P2 ENGINE RPM GEAR PUMP L R V1 STRAINER STEERING POWER STEERING VA LV E IN OUT AUX 1000 psi FROM HYDROST A T INTERNAL CASE DRAIN TO HYDRAULIC MANIFOLD TO HYDRAULIC MANIFOLD (ST) PORT TO LIFT V AL VE (IN) PORT[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 53 Procedure for Lift and Steering Control V alve Relief Pressure T est: 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. Make sure [...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 54 Steering Control V alve T est L R V1 STEERING POWER STEERING V AL VE (LEFT TURN) IN OUT AUX 1000 psi PLUG High Pressure Low Pressure Return or Suction Flow CYLINDER OPEN FITTING[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 55 Procedure for Steering Control V alve T est: 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. 2. Perform the Lift and Steering Control V alve Relief Pressure and Gear Pump (P2) Flow tests to make sure that pump and reli[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 56 Adjustments Adjust T raction Drive for Neutral 1. Park the machine on a level surface and turn the en- gine off. On e front wheel and rear wheel must be raised of f the ground or the machine will move during adjustment. Make sure machine is supported so it will not accidentally fall injur[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 57 Adjust Manifold Relief V alve (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[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 58 Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components 1. Before removing any parts from the hydraulic sys- tem, park machine on a level surface, engage parking brake, lower cutting units or attachments, a[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 59 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. T urn engine off and raise hood. 2. Disconnect hydrau[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 60 Replace Hydraulic Oil Filter The hydraulic system filter must be changed initially , af- ter the first 10 hours of operation, and thereafter every 200 hours of operation or yearly , whichever comes first. The hydraulic oil must be changed every 400 hours of operation or yearly , whichever[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 61 Replace T raction 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[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 62 Flush Hydraulic System IMPORT ANT : Flush the hydraulic system any time there is a severe component failure or the system is contaminated (oil appears milky , black, or contains metal particles). IMPORT ANT : Flush hydraulic system when chang- Ing from petroleum base hydraulic fluid to a [...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 63 Charge Hydraulic System NOTE: When initially starting the hydraulic system with new or rebuilt components such as motors, pumps, or lift cylinders, it is important that the hydraulic system be charged properly . Air must be purged from the system and its components to reduce the chance of[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 64 Hydraulic T ank and Hydraulic Oil Filter 1. Grommet (4 used) 2. Flange head screw (4 used) 3. Barb fitting 4. Barb fitting 5. Flat washer (4 used) 6. Hydraulic tank 7. Hose clamp 8. Hose clamp 9. Hydraulic fitting (straight) 10. Flange head screw (2 used) 1 1. Hydraulic fitting (straight)[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 65 Hydraulic T ank Removal 1. Drain hydraulic tank (see Change Hydraulic Fluid). 2. Remove hydraulic tank from machine using Figures 40 and 41 as guides. Hydraulic T ank Inspection 1. Clean hydraulic tank and suction strainer with sol- vent. 2. Inspect hydraulic tank for leaks, cracks, or ot[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 66 Front Wheel Motors 1. Lock nut 2. Spacer 3. Socket head screw 4. Hydraulic motor 5. Frame 6. Hydraulic tube 7. Hydraulic tube 8. O−ring 9. Hydraulic fitting 10. O−ring Figure 42 FRONT RIGHT 5 3 6 8 9 10 7 8 9 4 2 1 10[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 67 Removal W ARNING Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 − Safety . 1. Remove tire and wheel rim, wheel hub, and brake drum from the hydraulic motor . Remove brake assem- bl y , brake bracket, and wheel shield from the frame (see Front Wheel an[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 68 Rear Wheel Motor 1. Lug nut 2. Drive stud 3. Tire and rim 4. Wheel hub 5. Hydraulic hose 6. Hydraulic hose 7. O−ring 8. 45 o hydraulic fitting 9. Lock nut 10. Socket head screw 1 1. Hydraulic motor 12. Rear fork 13. O−ring 14. Woodruff key Figure 43 13 7 12 16 8 11 5 6 1 3 10 2 4 8 7 [...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 69 Rear Wheel Removal 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. W ARNING Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 − Safety . 2. Jack u p rear of machine enou[...]

Rev . F Reelmaster 3100 - - D Hydraulic System (Rev . C) Page 4 - - 7 0 Wheel Motor Service 1. Dirt seal 2. Bearing 3. Housing 4. Back - - up washer 5. Seal rings 6. Back - - up washer 7. Inner seal 8. Thrust washer 9. Thrust bearing 10. Bearing 1 1. Coupling shaft 12. Thrust bearing 13. Drive link 14. Cap screw 15. Commutator seal 16. Commutator 1[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 71 This page is intentionally blank. Hydraulic System[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 72 Reel Motors 1. Hydraulic motor (front) 2. Hydraulic motor (rear) 3. Reel motor coupler 4. Flange nut 5. Hydraulic hose 6. 90 o hydraulic fitting 7. Hydraulic hose 8. Hydraulic straight fitting 9. Hydraulic hose 10. Hydraulic hose 1 1. Hydraulic tee fitting 12. Hydraulic hose 13. Hydraulic[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 73 Removal NOTE: Note position of hydraulic fittings when remov- ing from the reel motors. Position is critical to properly reconnecting hydraulic hoses. 1. Remove reel motor from the cutting unit (see Reel Motor Removal and Installation in Chapter 7 − Cutting Units). W ARNING Before disco[...]

Rev . E Reelmaster 3100 - - D Hydraulic System (Rev . C) Page 4 - - 74 Reel Motor Service (Eaton) 1. Plug 2. O - - ring 3. Shim 4. Spring 5. Ball 6. Relief valve seal 7. Backplate 8. Idler gear assembly 9. Drive gear assembly 10. Key 11 . O - - r i n g 12. Body 13. Alignment pin 14. Frontplate 15. Cap screw 16. Retaining ring 17. Oil seal 18. Backu[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 75 Inspection (Fig. 46) 1. Remove all nicks and burrs from all parts with an emery cloth. CAUTION Use eye protection such as goggles when using compressed air . 2. Clean all parts with solvent. Dry all parts with com- pressed air . 3. Inspect drive gear shaft for a broken or chipped key- way[...]

75.1 Rev . E Reelmaster 3100- - D Hydraulic System Page 4 - - Reel Motor Service (Casappa) 1. Dust seal 2. Retaining ring 3. Flange washer 4. Shaft seal 5. Front flange 6. Pressure seal 7. Back - - up gasket 8. Front wear plate 9. Dowel pin 10. Idler gear 1 1. Drive shaft 12. Rear wear plate 13. O - - ring 14. Relief valve 15. Body 16. W asher (4 u[...]

75.2 Rev . E Reelmaster 3100 - - D Hydraulic System Page 4 - - 4. Loosen cap screws from the rear cover . 5. Remove motor from the vise. T urn motor so that the shaft end is facing down. Remove cap screws. 6. Carefully remove body . Lift body straight up to re- move. Make sure the rear wear plate remains on the drive and idler gear shafts. Remove a[...]

75.3 Rev . E Reelmaster 3100- - D Hydraulic System Page 4 - - 1. Lubricate O- - rings, pressure seals, back - - up gaskets and wear plate grooves with a thin coat of petroleum jel- ly . Lubricate all other internal parts freely with clean hy- draulic oil. 2. Install new seals into front flange (Fig. 46.3): A. Press shaft seal into front flange unti[...]

75.4 Rev . E Reelmaster 3100 - - D Hydraulic System Page 4 - - This page is intentionally blank. Hydraulic System[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 76 Oil Cooler Removal CAUTION The radiator and oil cooler may be hot. T o 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. Inspection CAUTION Use eye protection such as goggles when u[...]

Rev . D Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 77 Hydraulic Manifold 1. Hose clamp 2. Micro switch 3. Barb fitting 4. Flange head screw 5. Straight hydraulic fitting 6. Straight hydraulic fitting 7. 90 o hydraulic fitting 8. 45 o hydraulic fitting 9. Straight hydraulic fitting 10. Barb fitting 1 1. Hydraulic manifold 12. Hydrauli[...]

Rev . D Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 78 Hydraulic Manifold Service 1. Manifold body 2. Relief valve cartridge 3. Solenoid operated cartridge valve 4. Rotary cartridge valve (directional) 5. Solenoid coil 6. Logic control cartridge 7. Rotary cartridge valve (flow control) 8. Cartridge cavity plug 9. Orifice plug 10. Plug[...]

Rev . E Reelmaster 3100 - - D Hydraulic System (Rev . C) Page 4 - - 79 1. Manifold body 2. Plug (Zero Leak #8) 3. Rotary cartridge valve (flow control) 4. Rotary handle assembly 5. Solenoid relief cartridge valve 6. Nut 7. Solenoid coil 8. Logic control cartridge 9. Plug (Zero Leak #4) (10 used) 10. Spring pin (2 used) 1 1. Plug (SAE #4) 12. Mow/ba[...]

Rev . E Reelmaster 3100 - - D Hydraulic System (Rev . C) Page 4 - - 80 Solenoid Operated, Relief and Logic Control Car - tridge V alves 1. Make sure the manifold is clean before removing the cartridge valve and seal kit. Note: On manifold shown in Figure 50, solenoid coil has an O - - ring on each side of the coil. 2. If solenoid valve is to be rem[...]

Rev . E Reelmaster 3100 - - D Hydraulic System (Rev . C) Page 4 - - 81 3. Make sure manifold is clean before removing the rotary cartridge valve. Remove the valve and seal kit. 4. V isually inspect the manifold port and cartridge valve for damage to sealing surfaces, damaged threads, and contamination. A. Contamination may cause valves to stick or [...]

Rev . E Reelmaster 3100 - - D Hydraulic System (Rev . C) Page 4 - - 82 8. Install rotary handle (Fig. 52) (manifold shown in Fig. 51) : A. Place handle base on flow control valve and posi- tion alignment mark on base with number 1 on man- ifold. Secure base with two (2) set screws. Apply a light coating of grease to chamfer on top of base to ease s[...]

Rev . D Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 83 This page is intentionally blank. Hydraulic System[...]

Rev . F Reelmaster 3100 - - D Hydraulic System (Rev . C) Page 4 - - 8 4 Control V alve (Models 03200, 03206 and 03170) 1. Straight hydraulic fitting 2. 90 o hydraulic fitting 3. Hydraulic fitting 4. 90 o hydraulic fitting 5. Control valve (single spool) 6. Carriage screw (2 used) 7. Flange nut 8. Shoulder bolt 9. V alve lever assembly 10. Link (2 u[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 85 Removal W ARNING 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. 2. I[...]

Rev . F Reelmaster 3100 - - D Hydraulic System (Rev . C) Page 4 - - 8 6 Control V alve Service (Models 03200, 03206 and 03170) 3 4 6 8 10 16 17 18 19 2 22 23 11 12 13 14 7 5 1 30 29 24 28 25 26 12 9 27 1. Check poppet 2. Plunger 3. Spacer 4. Spool 5. Seat 6. Plug (solid) 7. Seat retaining plug 8. Bushing 9. Check spring 10. Spool cap 1 1. V alve bo[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 87 62 6 2 5 2 1 2 7 5 9 2 9 7 30 19 17 23 24 25 26 6 18 4 12 12 8 14 16 13 31 0 28 22 1. Check poppet 2. Plunger 3. Spacer 4. Spool 5. Seat 6. Plug (solid) 7. Seat retaining plug 8. Bushing 9. Check spring 10. Spool cap 1 1. V alve body 12. O−ring 13. Retaining ring 14. W asher 15. Not use[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 88 Disassembly 1. Plug all ports and clean the outside of the valve thor- oughly . 2. Remove spool cap and slide the spool assembly from its bore. 3. Remove O−ring and bushing from the spool assem- bly . 4. Remove O−ring from the spool bore end that is oppo- site the spool cap. NOTE: Dis[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 89 This page is intentionally blank. Hydraulic System[...]

Rev . F Reelmaster 3100 - - D Hydraulic System (Rev . C) Page 4 - - 9 0 Control V alve (Models 03201, 03207 and 03171) 1. Control valve (2 - - spool) 2. Hydraulic fitting (straight) 3. 90 o hydraulic fitting 4. Hydraulic fitting (straight) 5. Flange nut 6. Knob 7. 90 o hydraulic fitting 8. V alve actuator bracket 9. Shoulder bolt 10. Cotter pin 1 1[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 91 Removal W ARNING 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. 2. I[...]

Rev . F Reelmaster 3100 - - D Hydraulic System (Rev . C) Page 4 - - 9 2 Control V alve Service (Models 03201, 03207 and 03171) 1. Check poppet 2. Grooved plunger 3. Spacer 4. Spool 5. Seat 6. Solid plug 7. Seat retaining plug with port 8. Bushing 9. Check spring 10. Spool cap 1 1. V alve body 12. O - - ring 13. Retaining ring 14. W asher 15. Seat r[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 93 1. Check poppet 2. Grooved plunger 3. Spacer 4. Spool 5. Seat 6. Solid plug 7. Seat retaining plug with port 8. Bushing 9. Check spring 10. Spool cap 1 1. V alve body 12. O−ring 13. Retaining ring 14. W asher 15. Seat retaining plug 16. Spool spring 17. Disc 18. Plug 19. Detent plug 20.[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 94 Disassembly 1. Plug all ports and clean the outside of the valve thor- oughly . IMPORT ANT : Match mark spools to their associat- ed bores. Spools must be reinstalled to the bore from which they were removed. 2. Remove both spool caps and slide the spool assem- blies from their bores. 3. [...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 95 This page is intentionally blank. Hydraulic System[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 96 Piston Pump 1. Piston pump 2. Straight hydraulic fitting 3. Cap screw 4. Lock nut 5. 90 o hydraulic fitting 6. 90 o hydraulic fitting 7. 90 o hydraulic fitting 8. 90 o hydraulic fitting 9. 90 o hydraulic fitting 10. W asher 1 1. Hydraulic hose 12. Suction hose 13. Flange nut 14. Idler piv[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 97 Neutral Arm Assembly 1. Philips head screw 2. Flat washer 3. Micro switch 4. Keps nut 5. Neutral bracket 6. Flange nut 7. Flange head nut 8. Neutral arm 9. Flange bushing 10. Thrust washer 1 1. 90 o grease fitting 12. Lock nut 13. Spacer 14. T raction stud 15. Traction control cable 16. I[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 98 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[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 99 Piston Pump Installation (Fig. 62) 1. If hydraulic fittings were removed, install fittings to pump using marks made during the removal process to properly orientate fittings. 2. Place key into pump shaft slot. Slide taper lock bush- ing onto the piston pump shaft with bushing flange to- w[...]

Rev . D Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 100 Piston Pump Service 1. Key 2. Drive shaft 3. Bearing 4. Cap screw (3 used per cover plate) 5. Cover plate 6. Seal 7. Shim kit 8. Bearing cone 9. Key 10. Cam plate 1 1. Rotating kit 12. Gasket 13. V alve plate 14. Bearing 15. Dowel pin 16. Back plate 17. O−ring 18. Plug 19. Spri[...]

Rev . D Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 101 Piston Pump Crush Ring Replacement 1. Crush ring 2. Shims 3. Cover plate 4. Housing 5. Cam plate (control shaft) 6. Bearing cone 7. Bearing cup 8. Seal 9. W asher (3 used) 10. Cap screw (3 used) Figure 67 v 6 4 5 8 7 2 3 9 10 1 29 ft−lb (39 N−m) NOTE: The shims replace the cr[...]

Rev . F Reelmaster 3100- - D Hydraulic System (Rev . C) Page 4 - - 102 Sidewinder (Models 03201, 03207 and 03171) 1. Plastic bushing 2. Scissor link 3. Scissor mount 4. Cap screw 5. Flat washer 6. Lock nut 7. Scissor frame 8. Hydraulic cylinder 9. Spacer 10. Flat washer 1 1. Cap screw 12. Lock nut 13. Welded pin 14. Flange head screw 15. Lock nut 1[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 103 Removal W ARNING 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. 2. If[...]

Rev . D Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 104 Steering Control V alve 1. Steering arm 2. Flange nut 3. Flange head screw 4. Steering valve bracket 5. Cap screw 6. Pivot hub 7. Steering cover 8. Cap screw 9. T oro decal 10. Ball knob 1 1. Lever 12. Steering control valve 13. Tilt bracket 14. Cap screw 15. Flat washer 16. Flan[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 105 Removal W ARNING 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,[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 106 Steering Control V alve Service (Serial Numbers 90101 to 230999999) 1. Nut 2. Port cover 3. Seal ring 4. O−ring 5. Relief valve cartridge 6. Plug 7. Push nut 8. Port manifold 9. Spring 10. Drive assembly 1 1. Alignment pin 12. V alve ring 13. V alve plate 14. Spring 15. Isolation manif[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 107 Steering Control V alve Service (Serial Numbers 240000001 and up) 1. Sleeve 2. Cross pin 3. Ring 4. Spool 5. Bearing assembly 6. Shaft seal 7. Ball stop 8. Ball 9. Dust seal ring 10. Housing 1 1. Cardan shaft 12. Spacer 13. O−ring 14. Distribution plate 15. Inner gearwheel 16. Outer ge[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 108 Gear Pump 1. Piston pump 2. Gear pump 3. Hydraulic hose (tank suction) 4. Hydraulic hose (hydraulic manifold) 5. Hydraulic hose (steering valve) 6. Hose clamp 7. O−ring 8. O−ring 9. Hydraulic barb fitting 10. 90 o hydraulic fitting 1 1. 90 o hydraulic fitting 12. Cap screw 13. Flat w[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 109 Removal 1. Remove muf fler from the engine to gain access to the gear pump (see Muffler Removal in Chapter 3 − Ku- bota Diesel Engine). 2. Drain hydraulic oil from hydraulic tank (see Change Hydraulic Fluid in this section). W ARNING Before disconnecting or performing any work on the h[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 1 10 Gear Pump Service 1. Front plate 2. Back plate 3. Front body 4. Rear body 5. Drive gear 6. Idler gear 7. Idler gear 8. Back−up gasket 9. Wear plate 10. Pressure seal 1 1. Cap screw 12. O−ring 13. Adapter Plate 14. Key 15. Not used 16. Drive gear 17. W asher 18. Plug 19. Shaft seal 2[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 1 1 1 Disassembly (Fig. 76) 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 . 3. Use a marker to make a diagonal line across the front plate, front b[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 1 12 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 l ess than 0.384 inch (9[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 1 13 IMPORT ANT : D o not dislodge seals during installa- tion. 12. Install wear plate into the gear pocket of back body with the pressure seal and back−up gasket against the adapter plate. Make sure mid section cut−away of the wear plate is on the suction side of the pump. 13. Lubricate[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 1 14 Front Lift Cylinder 1. 90 o hydraulic fitting 2. Hydraulic cylinder 3. Carrier assembly 4. Flange nut 5. Flange head screw 6. Hydraulic hose 7. Centering wire 8. Hydraulic hose 9. Hydraulic hose 10. Hydraulic hose 1 1. Clamp bracket (model 03200) 1 1. Slide bracket (model 03201) 12. Fla[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 1 15 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 cyli[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 1 16 Rear Lift Cylinder 1. Hydraulic tube 2. Lock nut 3. Hydraulic T−fitting 4. Hydraulic hose 5. 90 o hydraulic fitting 6. Hydraulic hose 7. Hydraulic tube 8. 90 o hydraulic fitting 9. Push button switch 10. Hydraulic cylinder 1 1. Thrust washer 12. Hydraulic hose 13. Bulkhead nut 14. Hyd[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 1 17 Removal 1. Remove rear lift cylinder from the frame and lift arm using Figure 82 as guide. 2. If hydraulic fittings are to be removed from lift cylin- der , mark fitting orientation to allow correct assembly . Installation 1. I f hydraulic fittings were removed, install fittings to lift[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 1 18 Lift Cylinder Service 1. Grease fitting 2. Barrel with clevis 3. Nut 4. Uni−ring 5. Piston 6. O−ring 7. O−ring 8. Back−up ring 9. Rod seal 10. Head 1 1. Internal collar 12. Dust seal 13. Shaft 14. Jam nut 15. Clevis Figure 83 1 2 3 4 5 6 7 8 9 10 1 11 12 13 14 15 12 9 1 2 13 3 5[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 1 19 Disassembly 1. Remove oil from lift cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder . IMPORT ANT : Prevent damage when clamping the hydraulic cylinder into a vise; clamp on the clevis only . 2. Mount lift cylinder in [...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 120 Steering Cylinder 1. Hydraulic hose 2. Hydraulic hose 3. O−ring 4. Hydraulic fitting 5. O−ring 6. Steering cylinder 7. Ball joint 8. Retaining ring 9. Jam nut 10. Frame 1 1. Rear fork 12. Rear casting Figure 84 8 9 12 11 9 1 8 5 7 2 3 4 5 6 3 7 4 10 65 to 85 ft−lb (88 to 1 15 N−m[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 121 Removal 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. NOTE: Th e rear tire must be removed to allow suf ficient clearance to remove the steering cylinder from the ma- chine. W ARNING Before jacking up t[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 122 Steering Cylinder Service 1. Barrel 2. Lock nut 3. Piston 4. Uni−ring 5. O−ring 6. Piston rod 7. Rod seal 8. Cylinder gland 9. O−ring 10. Back−up ring 1 1. Retaining ring 12. O−ring Figure 87 1 2 3 4 5 6 7 8 9 10 12 11 23 4 5 8 9 1 0 1 1 16 7 1 2 24 to 30 ft−lb (33 to 41 N−[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 123 Disassembly 1. Remove oil from the steering cylinder into a drain pa n by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder . IMPORT ANT : Prevent damage when clamping the hydraulic cylinder into a vise; clamp on the clevis only . 2. Mount clevis en[...]

Reelmaster 3100−D Hydraulic System (Rev . C) Page 4 − 124 This page is intentionally blank.[...]

Rev . F Reelmaster 3100 - - D Page 5 - - 1 Electrical Systems (Rev . C) Chapter 5 Electrical System T able of Contents ELECTRICAL SCHEMA TICS AND DIAGRAMS 2 ... Reelmaster 3100 - - D Electrical Schematic (Serial Numbers 90101 to 90150) 2 ............ Glow Circuits 3 .............................. Crank Circuits 4 ............................. Run C[...]

Reelmaster 3100−D Page 5 − 2 Electrical Systems (Rev . C) Electrical Schematics and Diagrams BLACK BK BLUE BU BROWN BN FUSIBLE LINK GRA Y GY GN GREEN OR ORANGE PK PINK BU OPTIONAL LIGHT KIT F2 15 A F1 R R 12 OR OR D2 FRAME B S A Y X I Y BK BA TTERY (+) (−) PK IGNITION SW . BU W PK VIO 5 A F4 5 A F3 OR R RED VIO T TA N WHITE W VIOLET STOP −?[...]

Reelmaster 3100−D Page 5 − 3 Electrical Systems (Rev . C) BLACK BK BLUE BU BROWN BN FUSIBLE LINK GRA Y GY GN GREEN OR ORANGE PK PINK BU OPTIONAL LIGHT KIT F2 15 A F1 R R 12 OR OR D2 FRAME B S A Y X I Y BK BA TTERY (+) (−) PK IGNITION SW . BU W PK VIO 5 A F4 5 A F3 OR R RED VIO T TA N WHITE W VIOLET STOP −−−− NONE RUN −−−− B+I+[...]

Reelmaster 3100−D Page 5 − 4 Electrical Systems (Rev . C) BLACK BK BLUE BU BROWN BN FUSIBLE LINK GRA Y GY GN GREEN OR ORANGE PK PINK BU OPTIONAL LIGHT KIT F2 15 A F1 R R 12 OR OR D2 FRAME B S A Y X I Y BK BA TTERY (+) (−) PK IGNITION SW . BU W PK VIO 5 A F4 5 A F3 OR R RED VIO T TA N WHITE W VIOLET STOP −−−− NONE RUN −−−− B+I+[...]

Reelmaster 3100−D Page 5 − 5 Electrical Systems (Rev . C) BLACK BK BLUE BU BROWN BN FUSIBLE LINK GRA Y GY GN GREEN OR ORANGE PK PINK BU OPTIONAL LIGHT KIT F2 15 A F1 R R 12 OR OR D2 FRAME B S A Y X I Y BK BA TTERY (+) (−) PK IGNITION SW . BU W PK VIO 5 A F4 5 A F3 OR R RED VIO T TA N WHITE W VIOLET STOP −−−− NONE RUN −−−− B+I+[...]

Reelmaster 3100−D Page 5 − 6 Electrical Systems (Rev . C) BLACK BK BLUE BU BROWN BN FUSIBLE LINK GRA Y GY GN GREEN OR ORANGE PK PINK BU OPTIONAL LIGHT KIT F2 15 A F1 R R 12 OR OR D2 FRAME B S A Y X I Y BK BA TTERY (+) (−) PK IGNITION SW . BU W PK VIO 5 A F4 5 A F3 OR R RED VIO T TA N WHITE W VIOLET STOP −−−− NONE RUN −−−− B+I+[...]

Reelmaster 3100−D Page 5 − 7 Electrical Systems (Rev . C) BLACK BK BLUE BU BROWN BN FUSIBLE LINK GRA Y GY GN GREEN OR ORANGE PK PINK BU OPTIONAL LIGHT KIT F2 15 A F1 R R 12 OR OR D2 FRAME B S A Y X I Y BK BA TTERY (+) (−) PK IGNITION SW . BU W PK VIO 5 A F4 5 A F3 OR R RED VIO T TA N WHITE W VIOLET STOP −−−− NONE RUN −−−− B+I+[...]

Reelmaster 3100−D Page 5 − 8 Electrical Systems (Rev . C) OPTIONAL 30 1 2 85 87A 3 DIODE D2 P9 J17 J16 W6 W7 W55 W26 W27 W65 W54 SP2 P22 (−) (+) J3 HIGH TEMP SHUT DOWN P10 86 87 87A ENGINE GROUND HOUR METER P1 1 INTERLOCK RELA Y TEMP GLOW GND (+) BA TTERY OIL PRESS 85 30 6 4 5 3 2 1 W13 W64 W18 W21 W20 W17 2 1 W23 W16 C B A W63 W64 W57 W25 5 [...]

Reelmaster 3100−D Page 5 − 9 Electrical Systems (Rev . C) WIRE IDENTIFICA TION ROUTE LABEL COLOR FROM T O W1 RED P23−3 J7 W2 RED P23−1 P16−1 W3 ORANGE P16−2 P14−4 W4 BLUE P16−4 J13 W5 YELLOW P16−5 J18 W6 VIOLET P9−1 P16−6 (2) W7 VIOLET P16−6 (2) P9−2 W8 WHITE P16−7 P14−3 W9 PINK P16−8 (2) P13−3 (2) W10 PINK P13−3[...]

Reelmaster 3100−D Page 5 − 10 Electrical Systems (Rev . C) PINK ORANGE GREEN GRA Y FUSIBLE LINK BROWN BLUE BLACK BK BU BN GY GN OR PK OPTIONAL LIGHT KIT F2 F1 D2 12 R R OR OR OR BU Y IGNITION STOP −−−− NONE RUN −−−− B+I+A; X+Y ST ART −−− B+I+S S X BU PK F4 5 A (+) (−) 5 A F3 BA TTERY FRAME CLUSTER GAUGE Y OR BK VIO PK PK[...]

Reelmaster 3100−D Page 5 − 1 1 Electrical Systems (Rev . C) PINK ORANGE GREEN GRA Y FUSIBLE LINK BROWN BLUE BLACK BK BU BN GY GN OR PK OPTIONAL LIGHT KIT F2 F1 D2 12 R R OR OR OR BU Y IGNITION STOP −−−− NONE RUN −−−− B+I+A; X+Y ST ART −−− B+I+S S X BU PK F4 5 A (+) (−) 5 A F3 BA TTERY FRAME CLUSTER GAUGE Y OR BK VIO PK P[...]

Reelmaster 3100−D Page 5 − 12 Electrical Systems (Rev . C) PINK ORANGE GREEN GRA Y FUSIBLE LINK BROWN BLUE BLACK BK BU BN GY GN OR PK OPTIONAL LIGHT KIT F2 F1 D2 12 R R OR OR OR BU Y IGNITION STOP −−−− NONE RUN −−−− B+I+A; X+Y ST ART −−− B+I+S S X BU PK F4 5 A (+) (−) 5 A F3 BA TTERY FRAME CLUSTER GAUGE Y OR BK VIO PK PK[...]

Reelmaster 3100−D Page 5 − 13 Electrical Systems (Rev . C) PINK ORANGE GREEN GRA Y FUSIBLE LINK BROWN BLUE BLACK BK BU BN GY GN OR PK OPTIONAL LIGHT KIT F2 F1 D2 12 R R OR OR OR BU Y IGNITION STOP −−−− NONE RUN −−−− B+I+A; X+Y ST ART −−− B+I+S S X BU PK F4 5 A (+) (−) 5 A F3 BA TTERY FRAME CLUSTER GAUGE Y OR BK VIO PK PK[...]

Reelmaster 3100−D Page 5 − 14 Electrical Systems (Rev . C) PINK ORANGE GREEN GRA Y FUSIBLE LINK BROWN BLUE BLACK BK BU BN GY GN OR PK OPTIONAL LIGHT KIT F2 F1 D2 12 R R OR OR OR BU Y IGNITION STOP −−−− NONE RUN −−−− B+I+A; X+Y ST ART −−− B+I+S S X BU PK F4 5 A (+) (−) 5 A F3 BA TTERY FRAME CLUSTER GAUGE Y OR BK VIO PK PK[...]

Reelmaster 3100−D Page 5 − 15 Electrical Systems (Rev . C) PINK ORANGE GREEN GRA Y FUSIBLE LINK BROWN BLUE BLACK BK BU BN GY GN OR PK OPTIONAL LIGHT KIT F2 F1 D2 12 R R OR OR OR BU Y IGNITION STOP −−−− NONE RUN −−−− B+I+A; X+Y ST ART −−− B+I+S S X BU PK F4 5 A (+) (−) 5 A F3 BA TTERY FRAME CLUSTER GAUGE Y OR BK VIO PK PK[...]

Reelmaster 3100−D Page 5 − 16 Electrical Systems (Rev . C) 30 1 2 85 SHUT DOWN HIGH TEMP DIODE D2 P9 J17 J16 W6 W55 W26 W27 W54 SP2 W10 P22 HOUR METER J3 ENGINE GROUND P10 87A INTERLOCK RELA Y P1 1 CLUSTER GAUGE HIGH TEMP GLOW BA TTERY OIL PRESS 6 4 5 3 2 1 W13 W18 W20 W17 2 1 W23 W16 GROUND (+) 85 30 W21 W64 C B A W57 W25 5 4 3 W62 (−) (+) 8[...]

Reelmaster 3100−D Page 5 − 17 Electrical Systems (Rev . C) WIRE IDENTIFICA TION ROUTE LABEL COLOR FROM T O W1 RED P23−3 J7 W2 RED P23−1 P16−1 W3 ORANGE P16−2 P14−4 W4 BLUE P16−4 J13 W5 YELLOW P16−5 J18 (2) W6 VIOLET P9−1 P16−6 (2) W7 VIOLET P16−6 (2) P13−3 (2) W8 YELLOW P16−7 J18 (2) W9 PINK P16−8 (2) SP5 (4) W10 VIOLE[...]

Reelmaster 3100−D Page 5 − 18 Electrical Systems (Rev . C) J1 P1 J2 J4 P8 J7 P23 P19 P20 J12 J3 P2 J5 J6 P4 P5 P18 P7 P6 P21 J8 J9 P8 P9 P10 P22 J10 J1 1 P12 P13 P14 J18 P1 1 P15 P16 J13 P17 D2 D3 D1 FUEL PUMP SEA T SWITCH TRANSPORT/MOW SWITCH REEL UP/DOWN SWITCH OVERTEMP RELA Y REEL ON/OFF SWITCH GLOW CONTROLLER IGNITION SWITCH AL TERNATOR GLO[...]

Reelmaster 3100−D Page 5 − 19 Electrical Systems (Rev . C) Electrical Schematic Reelmaster 3100−D All relays and solenoids are shown as de−energized. Serial Numbers 240000001 and up R I Y R R W S B Y A 1F 3 BK BK BN 13 12 Y LOW OIL PRESSURE OVER TEMP . PK W GN OR BU OR X G FL FL BU/W W T W OPTIONAL LIGHT SW . PK OR VIO BU R/BK LAMP OPTIONAL[...]

Rev . F Reelmaster 3100 - - D Page 5 - - 20 Electrical Systems (Rev . C) Wiring Diagram Reelmaster 3100 - - D Serial Numbers 240000001 to BLACK BLACK YELLOW GREEN VIOLET WHITE/BLACK TA N ORANGE GRA Y TA N BLUE FUSIBLE LINK BLUE RED/BLACK WHITE BLUE GREEN BLACK GREEN BLACK BLACK BLACK BLUE BLACK BLACK BLACK GRA Y BROWN BLACK BLACK PINK ORANGE RED GR[...]

Rev . F Reelmaster 3100 - - D Page 5 - - 21 Electrical Systems (Rev . C) Harness Diagram Reelmaster 3100 - - D Serial Numbers 240000001 to (SERIAL NUMBERS FROM 240000001 TO 270999999) (SERIAL NUMBERS FROM 260000001 TO 270999999) 270999999 Electrical System[...]

Rev . F Reelmaster 3100 - - D Page 5 - - 22 Electrical Systems (Rev . C) Wiring Diagram Reelmaster 3100 - - D Serial Numbers 280000001 and Up BLACK YELLOW ORANGE WHITE BLACK BLUE/WHITE PINK PINK RED/BLACK GREEN PINK WHITE/BLACK GRA Y PINK VIOLET BLUE PINK PINK ORANGE BLACK GREEN RED/BLACK BLACK GREEN BLACK BLACK BLACK BLACK BLACK BLACK BLUE BLACK B[...]

Rev . F 22.1 Reelmaster 3100 - - D Hydraulic System Page 4 - - Harness Diagram Reelmaster 3100 - - D Serial Numbers 280000001 and Up[...]

Rev . F 22.2 Reelmaster 3100 - - D Hydraulic System Page 4 - - This page is intentionally blank. Electrical System[...]

Rev . D Reelmaster 3100−D Page 5 − 23 Electrical Systems (Rev . C) Special T ools Order special tools from your T oro Distributor . Some tools may also be available from a local supplier . Multimeter The meter can test electrical components and circuits for current, resistance, or voltage. NOTE: T oro recommends the use of a DIGIT AL V olt− O[...]

Reelmaster 3100−D Page 5 − 24 Electrical Systems (Rev . C) T roubleshooting CAUTION Remove all jewelry , especially rings and watches, before doing any electrical trouble- shooting or testing. Disconnect the battery cables unless the test requires battery voltage. For effective troubleshooting and repairs, you must have a good understanding of [...]

Reelmaster 3100−D Page 5 − 25 Electrical Systems (Rev . C) 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. Th[...]

Reelmaster 3100−D Page 5 − 26 Electrical Systems (Rev . C) General Run and T ransport 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 swit[...]

Reelmaster 3100−D Page 5 − 27 Electrical Systems (Rev . C) Cutting Unit Operating Problems The cutting units will not run with the transport mow switch in MOW and the reel on/off switch in ON with the cutting units lowered. Wiring to the reel drive circuit is (see Electrical Schematics) is loose, corroded, or damaged. Fuse F4 is faulty or blown[...]

Reelmaster 3100−D Page 5 − 28 Electrical Systems (Rev . C) Electrical System Quick Check Battery T est (Open Circuit T est) Use a multimeter to measure the voltage between the battery terminals. Set multimeter to the DC volts setting. The battery should be a t a temperature of 60 to 100 o F (16 to 38 o C). Th e ignition key should be off and al[...]

Rev . D Reelmaster 3100−D Page 5 − 29 Electrical Systems (Rev . C) Check Operation of Interlock Switches CAUTION Do not disconnect safety switches. They are for th e operator ’ s protection. Check the operation of th e interlock switches daily for proper operation. Replace any malfunctioning switches before op- erating the machine. Note: The [...]

Reelmaster 3100−D Page 5 − 30 Electrical Systems (Rev . C) Component T esting For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before doing a continuity check). NOTE: For more component testing information, see the Kubota Workshop M[...]

Reelmaster 3100−D Page 5 − 31 Electrical Systems (Rev . C) Glow Relay The glow relay is attached to the radiator assembly . When energized, the glow relay allows electrical current to the engine glow plugs. T wo 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 [...]

Reelmaster 3100−D Page 5 − 32 Electrical Systems (Rev . C) Hour Meter 1. Connect the positive (+) terminal of a 12 VDC source to the positive terminal of the hour meter . 2. Connect the negative (−) terminal of the voltage source to the other terminal of the hour meter . 3. Th e hour meter should move a 1/10 of an hour in six minutes. 4. Disc[...]

Reelmaster 3100−D Page 5 − 33 Electrical Systems (Rev . C) High T emperature W arning 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. 1 1). CAUTION Ma[...]

Reelmaster 3100−D Page 5 − 34 Electrical Systems (Rev . C) 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 [...]

Reelmaster 3100−D Page 5 − 35 Electrical Systems (Rev . C) W arning Light Cluster (Serial Numbers Below 240000000) Note: Individual light bulbs can be tested by removing them from the lighting cluster and applying 12 VDC to their wiring terminals. Oil Pressure Light The oil pressure light should come on when the ignition switch is i n the ON po[...]

Reelmaster 3100−D Page 5 − 36 Electrical Systems (Rev . C) Indicator Lights (Serial Numbers Above 240000000) Charge Indicator Light Th e 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 i[...]

Rev . E Reelmaster 3100 - - D Page 5 - - 37 Electrical Systems (Rev . C) Fuel Pump The fuel pump is attached to the frame just outboard of the fuel injection pump. Operational T est 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 preven[...]

Reelmaster 3100−D Page 5 − 38 Electrical Systems (Rev . C) Fuel Stop Solenoid (Solenoid With 3 W ire Connector) Th e 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. When the[...]

Reelmaster 3100−D Page 5 − 39 Electrical Systems (Rev . C) Fuel Stop Solenoid (Solenoid With 2 W ire 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: t[...]

Reelmaster 3100−D Page 5 − 40 Electrical Systems (Rev . C) 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 p[...]

Reelmaster 3100−D Page 5 − 41 Electrical Systems (Rev . C) 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 n[...]

Reelmaster 3100−D Page 5 − 42 Electrical Systems (Rev . C) 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: 1. Remove the battery and charge it fully (see Battery Service). 2. Either store battery on a[...]

Reelmaster 3100−D Page 5 − 43 Electrical Systems (Rev . C) 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 spil[...]

Reelmaster 3100−D Page 5 − 44 Electrical Systems (Rev . C) 2. Conduct a hydrometer test of the battery electrolyte. IMPORT ANT : Make sure the area around the cells i s clean before opening the battery caps. A. Measure the specific gravity of each cell with a hydrometer . Draw electrolyte in and out of the hydrometer barrel prior to taking a re[...]

Reelmaster 3100−D Page 5 − 45 Electrical Systems (Rev . C) 6. Apply a light coat of grease on all battery posts and cable connectors to reduce corrosion after connections are made. 7. Connect a digital multimeter (set to amps) between the negative battery post and the negative (ground) cable connector . The reading should be less than 0.1 amp. [...]

Reelmaster 3100−D Page 5 − 46 Electrical Systems (Rev . C) This page is intentionally blank.[...]

Reelmaster 3100−D Page 6 − 1 Wheels, Brakes,and Miscellaneous Chapter 6 Wheels, Brakes, and Miscellaneous T able of Contents SPECIFICA TIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL T OOLS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

Rev . C Reelmaster 3100−D Page 6 − 2 Wheels, Brakes, and Miscellaneous Specifications Item Description T ire 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 T ools Wheel Hub Puller Part Number: TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors[...]

Rev . C Reelmaster 3100−D Page 6 − 3 Wheels, Brakes,and Miscellaneous Adjustments Adjust Brake CAUTION Before and after adjusting the brakes, always check the brakes in a wide open area that is flat and free of other persons and obstructions. 1. Park machine on a level surface, lower cutting units, stop engine, and remove key from the ignition [...]

Reelmaster 3100−D Page 6 − 4 Wheels, Brakes, and Miscellaneous Service and Repairs Standard Seat 1. Seat (incl. 4 thru 7, 14, &15) 2. Cap screw 3. Spring lock washer 4. Edging clip 5. Edging 6. Seat cushion (repair kit) 7. Seat shell 8. Seat belt 9. Seat adjuster with latch 10. Flange hex nut 1 1. Cap screw 12. Lock washer 13. Seat adjuster[...]

Reelmaster 3100−D Page 6 − 5 Wheels, Brakes,and Miscellaneous Deluxe Seat 1. Plate 2. Rivet 3. Screw 4. Wear parts kit (incl. 8 thru 1 1) 5. T ension spring set 6. Handle grip 7. Adjusting lever 8. Cover 9. Bumper 10. Bushing 1 1. Pad 12. Backrest cushion 13. Hex head machine screw 14. Arm rests 15. Bottom cushion 16. Adjusting rail (LH) 17. Sc[...]

Rev . C Reelmaster 3100−D Page 6 − 6 Wheels, Brakes, and Miscellaneous Front Wheel and Brake 1. Lug nut 2. Drive stud 3. Wheel rim 4. Tire 5. Wheel hub 6. Lock nut 7. Hydraulic motor 8. Brake drum 9. Woodruff key 10. Cotter pin 1 1. Adjustment rod 12. Brake lever 13. Lock nut 14. Cap screw 15. Brake bracket 16. Return spring 17. Brake shoe 18. [...]

Rev . C Reelmaster 3100−D Page 6 − 7 Wheels, Brakes,and Miscellaneous IMPORT ANT : Do not hit wheel hub, wheel hub puller or wheel motor with a hammer during removal or installation. Hammering may cause damage to the hydraulic wheel motor . 5. Using hub puller (see Special T ools), loosen wheel hub from wheel motor . 6. Remove lock nut, hub, an[...]

Reelmaster 3100−D Page 6 − 8 Wheels, Brakes, and Miscellaneous Rear Fork and Wheel 1. Hydraulic cylinder 2. Ball joint 3. External retaining ring 4. Grease fitting 5. Grease fitting plug 6. Jam nut 7. Rear fork 8. Cap screw 9. Lock washer 10. Thrust washer 1 1. Tire 12. Hex socket head screw 13. Lock nut 14. Drive stud 15. Wheel hub 16. Lock nu[...]

Rev . C Reelmaster 3100−D Page 6 − 9 Wheels, Brakes,and Miscellaneous W ARNING Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 − Safety . 4. Jack up rear wheel enough to allow the removal of the rear fork. 5. Remove lug nuts from drive studs. Remove tire with wheel rim from wheel hub. 6. Remove four lock nut[...]

Reelmaster 3100−D Page 6 − 10 Wheels, Brakes, and Miscellaneous Brake Linkages 1. Pop rivet 2. Control panel cover 3. Cover bracket 4. Flange nut 5. Hex flange head screw 6. Magnet support 7. Hex washer head screw 8. Strike bracket 9. Magnetic catch 10. Flat washer 1 1. Lock nut 12. Cotter pin 13. Bumper pad 14. Hex socket flat head screw 15. P[...]

Reelmaster 3100−D Page 6 − 1 1 Wheels, Brakes,and Miscellaneous 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Remove control panel cover from the machine. IMPORT ANT : When removing the adjustable clevis from either the brake pivot shaft or adjustment rod [...]

Rev . D Reelmaster 3100−D Page 6 − 12 Wheels, Brakes, and Miscellaneous Steering Column 1. Steering arm 2. Flange hex nut 3. Hex flange head screw 4. Steering control valve bracket 5. Cap screw 6. Pivot hub 7. Steering cover 8. Cap screw 9. T oro decal 10. Ball knob 1 1. Lever 12. Steering control valve 13. Tilt bracket 14. Cap screw 15. Flat w[...]

Rev . D Reelmaster 3100−D Page 6 − 13 Wheels, Brakes,and Miscellaneous Disassembly 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Remove philips pan head screws and steering wheel cap from the steering wheel. 3. Remove steering wheel nut from the steering c[...]

Reelmaster 3100−D Page 6 − 14 Wheels, Brakes, and Miscellaneous[...]

Reelmaster 3100−D Page 7 − 1 Cutting Units Chapter 7 Cutting Units T able of Contents SPECIFICA TIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL T OOLS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 5 . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS 7 . . . . . . . . . . . . . . .[...]

Reelmaster 3100−D Page 7 − 2 Cutting Units Specifications Figure 1 MOUNTING: All cutting units are supported by equal length independent lift arms and are interchangeable to all three cutting unit positions. CONSTRUCTION: 5 or 8 blades of 7 inches (18 cm) d i- ameter welded to stamped steel spiders. Reels are mounted on greaseable self−aligni[...]

Rev . E Reelmaster 3100 - - D Page 7 - - 3 Cutting Units Special T ools Order special tools from your T oro Distributor . Some tools may have been supplied with your machine or available as TORO parts. Some t ools may also be avail- able from a local supplier . Gauge Bar Assembly Use gauge bar to verify height of cut (T oro Part No. 13 - - 8199). G[...]

Reelmaster 3100−D Page 7 − 4 Cutting Units Bedknife Screw T ool − TOR510880 This screwdriver type bit is made to fit T oro bedknife at- taching screws. Use this bit with a torque wrench to se- cure the bedknife to the bedbar . IMPORT ANT : Do not use and air or manual impact wrench with this tool. Figure 4[...]

Reelmaster 3100−D Page 7 − 5 Cutting Units T roubleshooting There are a number of factors that can contribute to un- satisfactory quality of cut, some of which may be turf conditions. T urf conditions such as excessive thatch, “sponginess” or attempting to cut off too much grass height may not always be overcome by adjusting the machine. It[...]

Reelmaster 3100−D Page 7 − 6 Cutting Units 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. Slightly dull[...]

Reelmaster 3100−D Page 7 − 7 Cutting Units 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 Th e single knob bedknife−to−reel adjustment system in- corporated in this cutting unit simplifies the adjustment procedure needed to deliv[...]

Reelmaster 3100−D Page 7 − 8 Cutting Units Adjust Bedknife Parallel to Reel NOTE: A 3/4−inch (19 mm) wrench will be needed to ro- tate the bedknife adjustment knob (Fig. 5). IMPORT ANT : Do not allow cutting unit to rest on the bedknife adjusting screw . The setting of the bed- knife will be changed. 1. Remove any reel contact by turning the [...]

Reelmaster 3100−D Page 7 − 9 Cutting Units 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- eling both front and back rollers. 1. Position cutting unit on a flat level table or board. 2. Loosen nut slightly that secures each roller brac[...]

Reelmaster 3100−D Page 7 − 10 Cutting Units V erify Height−of−Cut and Front Roller Level NOTE: Gauge bar (T oro Part No. 13−8199) may be ob- tained from your local T oro Distributor . IMPORT ANT : Height−of−cut must be set and both rollers leveled before performing this adjustment (see Set Height−of−Cut and Level Both Rollers). 1.[...]

Reelmaster 3100−D Page 7 − 1 1 Cutting Units 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. IMPORT ANT : Keep front cutting units on the lift arms when performing this adjustment. 2. Raise front lift arms. Make sure clearance between eac[...]

Reelmaster 3100−D Page 7 − 12 Cutting Units Adjust Rear Lift Arm 1. Park machine on a level surface and engage parking brake. IMPORT ANT : 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 [...]

Reelmaster 3100−D Page 7 − 13 Cutting Units 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 fit[...]

Rev . E Reelmaster 3100 - - D Page 7 - - 1 4 Cutting Units Backlapping DANGER TO A VOID PERSONAL INJUR Y OR DEA TH: - - Never place hands or feet in reel area while the engine is running. - - While backlapping, reels may stall and then re - start. - - Do not attempt to restart reels by hand or foot. - - Do not adjust reels while the engine is runni[...]

Reelmaster 3100−D Page 7 − 15 Cutting Units 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 c[...]

Reelmaster 3100−D Page 7 − 16 Cutting Units Reel Motor Removal and Installation 1. Reel 2. Cap screw 3. Not used 4. Cap screw 5. Lock washer 6. Side plate (RH) 7. Roll pin 8. Lock nut 9. Hex nut 10. W aring decal 1 1. Front grass guard 12. Frame assembly 13. Rear grass guard 14. Flange nut 15. Side plate (LH) 16. W asher 17. Spacer 18. Link 19.[...]

Reelmaster 3100−D Page 7 − 17 Cutting Units Reel Removal and Bearing Replacement Remove Reel (Fig. 22) 1. Remove hydraulic motor from the cutting unit (see Hydraulic Motor Removal and Installation). Remove cutting unit from the machine (see Cutting Unit Removal and Installation). 2. Remove bedbar assembly from the cutting unit (see Bedbar Remov[...]

Reelmaster 3100−D Page 7 − 18 Cutting Units Bedbar Removal and Installation 1. Rubber bushing 2. Flanged bushing 3. Jam nut 4. Compression spring 5. W asher 6. Not used 7. Not used 8. Spring arm 9. Bedbar adjuster 10. Not used 1 1. Not used 12. Not used 13. Adjuster spacer 14. Not used 15. Bedbar pivot 16. Grease fitting 17. Bedbar fitting 18. [...]

Reelmaster 3100−D Page 7 − 19 Cutting Units Bedbar Installation (Fig. 23) 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 . Reinstall spacer , fla[...]

Reelmaster 3100−D Page 7 − 20 Cutting Units Bedknife Replacement and Grinding 1. Remove bedbar from the cutting unit (see Bedbar Removal and Installation). 2. Remove bedknife screws and bedknife. 3. Remove all rust, scale and corrosion from the bedbar surface before installing new bedknife. NOTE: Use a torque wrench and a bedknife screw tool to[...]

Reelmaster 3100−D Page 7 − 21 Cutting Units 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. Remove c[...]

Reelmaster 3100−D Page 7 − 22 Cutting Units Roller Bearing and Seal Replacement 1. Full roller 2. Roller shaft 3. Grease seal 4. Bearing cup 5. Bearing cone (outer) 6. Outer seal 7. Adjustment nut 8. Grease fitting 9. Wiehle roller 10. Sectional roller shaft 1 1. Bearing cone (inner) 12. Sectional roller Figure 28 1 2 3 4 5 10 11 12 7 8 9 4 4 5[...]

Reelmaster 3100−D Page 7 − 23 Cutting Units Install New Seals and Bearings on Full or Wiehle Roller 1. Make sure all parts are clean prior to installing bear- ings and seals. 2. On the full roller , make sure cupped side of the inner seal faces the inside of the roller . Press an inner seal into each end of the roller . 3. Make sure narrow end [...]

Rev . E Reelmaster 3100 - - D Page 7 - - 24 Cutting Units Prepare Reel for Grinding Note: Check to make sure reel bearings are in good condition and properly adjusted before grinding reel. 1. Remove bedbar assembly (see Bedbar Removal and Installation). 2. Remove front roller and brackets (see Roller Remov- al and Installation). Note: Most reel gri[...]

Reelmaster 3100−D Page 7 − 25 Cutting Units Fixed Side Plate Installation 1. Remove pop rivets and rear height−of−cut plates from both sides of the cutting unit (Fig. 30). 2. Remove lock nuts, capscrews, washers, and both links from the cutting unit (Fig. 30). 3. Align fixed side plate with holes on the cutting unit (Fig. 31). 4. Attach new[...]

Reelmaster 3100−D Page 7 − 26 Cutting Units Front Lift Arms 1. 90 o hydraulic fitting 2. Hydraulic cylinder 3. Carrier assembly 4. Flange nut 5. Flange head screw 6. Hydraulic hose 7. Centering wire 8. Hydraulic hose 9. Hydraulic hose 10. Hydraulic hose 1 1. Clamp bracket (Model 03200) 1 1. Slide bracket (Model 03201) 12. Flange nut (Model 0320[...]

Rev . E Reelmaster 3100 - - D Page 7 - - 27 Cutting Units 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 s[...]

Reelmaster 3100−D Page 7 − 28 Cutting Units Rear Lift Arm 1. External retaining ring 2. Thrust washer 3. Rear lift arm 4. Rear hydraulic cylinder 5. Flange head screw 6. Thrust washer 7. Rear pivot shaft 8. Bushing 9. Jam nut 10. W asher 1 1. Lynch pin 12. W asher 13. Cutting unit pivot shaft 14. Cap screw 15. Rebound washer 16. Cap screw 17. P[...]

Rev . E Reelmaster 3100 - - D Page 7 - - 29 Cutting Units 3. Secure hydraulic cylinder clevis to the lift cylinder shaft of the rear lift arm with the thrust washer and exter- nal retaining ring. 4. Install rear cutting unit to the pivot shaft of the rear lift arm (see Cutting Unit Removal). 5. Adjust lift arms to proper clearance (see Adjust Rear [...]

Reelmaster 3100−D Page 7 − 30 Cutting Units 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. 4. Repeat steps 1 through 3 on t[...]

Units DP A Cutting Reelmaster 3100 - - D DP A Cutting Units (Rev . G) Page 8 - - 1 Chapter 8 DP A Cutting Units T able of Contents SPECIFICA TIONS 2 ............................. GENERAL INFORMA TION 3 ..................... Cutting Unit Operator ’s Manual 3 ................ SPECIAL TOOLS 4 ............................. F ACTORS THA T CAN AFFECT C[...]

Reelmaster 3100 - - D DP A Cutting Units (Rev G) Page 8 - - 2 Specifications Figure 1 Frame Construction: Precision machined die cast alu- minum cross member with two (2) bolt - - on cast ductile iron side plates. Reel Construction: Reels are 27 inches (69 c m) or 32 inches (81 cm) in length and 7 inch (18 cm) in diameter . High strength, low alloy[...]

Units DP A Cutting Reelmaster 3100 - - D DP A Cutting Units (Rev . G) Page 8 - - 3 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 DP A c utting units on your Reelmaster machine. Additionally , if optiona[...]

Reelmaster 3100 - - D DP A Cutting Units (Rev G) Page 8 - - 4 Special T ools Special tools for servicing T oro C ommercial Products are available from your T oro Distributor . Some tools may have been supplied with your machine or are available as TORO parts. Gauge Bar Assembly T oro Part Number: 108 - - 6715 Use gauge bar to verify height - - of -[...]

Units DP A Cutting Reelmaster 3100 - - D DP A Cutting Units (Rev . G) Page 8 - - 5 Plastic Plug T oro Part Number: 94 - - 2703 This plug is used for placement into the side plate bear- ing housing when the hydraulic reel motor is removed. It prevents dirt and debris from entering the cutting reel bearing area. Figure 5 Cutting Unit Kickstand T oro [...]

Reelmaster 3100 - - D DP A Cutting Units (Rev G) Page 8 - - 6 Reel Bearing Installation T ool T oro Part Number: 1 17 - - 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 8 Roller Rebuild Kit T oro Part Number: 1 15 - - 0803 This tool kit is used to assem[...]

Units DP A Cutting Reelmaster 3100 - - D DP A Cutting Units (Rev . G) Page 8 - - 7 This page is intentionally blank.[...]

Reelmaster 3100 - - D DP A Cutting Units (Rev G) Page 8 - - 8 Factors That Can Affect Cutting Performance There are a number of factors that can contribute to un- satisfactory quality of cut, some of which may be turf conditions. T urf conditions such as excessive thatch, “sponginess” or attempting to cut off too much grass height may not alway[...]

Units DP A Cutting Reelmaster 3100 - - D DP A Cutting Units (Rev . G) Page 8 - - 9 Factor Possible P roblem/Correction Reel and bedknife sharpness A reel and/or bedknife that has rounded cutting edges or “rifling” (grooved or wavy appearance) cannot be corrected by tightening the bedknife to reel contact. Grind cutting reel to remove taper and/[...]

Reelmaster 3100 - - D DP A Cutting Units (Rev G) Page 8 - - 10 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[...]

Units DP A Cutting Reelmaster 3100 - - D DP A Cutting Units (Rev . G) Page 8 - - 1 1 Set Up and Adjustments Characteristics CAUTION Never install or work on the cutting units or lift arms with the engine running. Always stop en- gine and remove key first. The dual knob bedknife - - to - - reel adjustment system in- corporated in this cutting unit s[...]

Reelmaster 3100 - - D DP A Cutting Units (Rev G) Page 8 - - 12 Reel Bearing Adjustment T o insure cut quality and long life of the cutting reel bear- ings, periodically check reel bearing adjustment. Check Reel Bearing Adjustment 1. Remove hydraulic reel motor from cutting unit (see Hydraulic Reel Motor Removal in the Service and Re- pairs section [...]

Units DP A Cutting Reelmaster 3100 - - D DP A Cutting Units (Rev . G) Page 8 - - 13 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 [...]

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Units DP A Cutting Reelmaster 3100 - - D DP A Cutting Units (Rev . G) Page 8 - - 15 Service and Repairs Hydraulic Reel Motor IMPORT ANT : 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 sur[...]

Reelmaster 3100 - - D DP A Cutting Units (Rev G) Page 8 - - 16 Backlapping DANGER TO A VOID PERSONAL INJUR Y OR DEA TH: D Never place hands or feet in the reel area while the engine is running. D When backlapping, run engine at idle speed only . D While backlapping, the reels may stall and then restart. D Do not attempt to restart reels by hand or [...]

Units DP A Cutting Reelmaster 3100 - - D DP A Cutting Units (Rev . G) Page 8 - - 17 9. T o make an adjustment to the cutting units while backlapping, disengage the PTO switch and turn the en- gine OFF . Wait for all machine movement to stop. After adjustments have been completed, repeat steps 5 through 8. 10. When the backlapping operation is compl[...]

Reelmaster 3100 - - D DP A Cutting Units (Rev G) Page 8 - - 18 Bedbar Assembly 1. Bedbar 2. Bedknife 3. Screw 4. Bedbar adjuster shaft (2 used) 5. Flange bushing (4 used) 6. Cap screw (2 used) 7. Detent (2 used) 8. Wave washer (2 used) 9. Retaining ring (2 used) 10. Bedbar adjuster screw (2 used) 1 1. W asher (2 used) 12. Compression spring (2 used[...]

Units DP A Cutting Reelmaster 3100 - - D DP A Cutting Units (Rev . G) Page 8 - - 19 CAUTION Contact with the reel, bedknife or other cutting unit parts can result in personal injury . Use heavy gloves when handling the bedbar . 6. Remove bedbar assembly from cutting unit. 7. Inspect flange bushings (item 15) and rubber bush- ings (item 14) in side [...]

Reelmaster 3100 - - D DP A Cutting Units (Rev G) Page 8 - - 20 Bedbar Adjuster Service Figure 21 1. Bedbar assembly 2. Compression spring 3. Lock nut 4. Bedbar adjuster shaft 5. Flange bushing 6. Cap screw 7. Detent 8. Wave washer 9. Lock nut 10. Bedbar adjuster screw 1 1. Washer 12. Flat washer 14 to 16 ft - - lb ( 1 9t o 2 1N - - m ) Antiseize Lu[...]

Units DP A Cutting Reelmaster 3100 - - D DP A Cutting Units (Rev . G) Page 8 - - 21 Removal 1. Remove lock nut (item 3), compression spring (it em 2) and washer (item 1 1) from bedbar adjuster screw (item 10). 2. Remove bedbar (see Bedbar Removal in this sec- tion). Note: Inside threads in bedbar adjuster shaft ( item 4) are left - - hand threads. [...]

Reelmaster 3100 - - D DP A Cutting Units (Rev G) Page 8 - - 22 Bedknife Replacement and Grinding Bedknife Removal 1. Remove bedbar from cutting unit (see Bedbar Re- moval in this section). 2. Remove screws from bedbar using a socket wrench and bedknife screw tool (see Special T ools). Discard screws. Remove bedknife from the bedbar (Fig. 23). Bedkn[...]

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Reelmaster 3100 - - D DP A Cutting Units (Rev G) Page 8 - - 24 Reel Assembly Removal and Installation 1. Bedbar assembly 2. Flange nut (3 used per side plate) 3. Flange bushing (2 used) 4. Plastic washer (4 used) 5. Metal washer (2 used) 6. Bedbar pivot bolt (2 used) 7. Lock nut (2 used) 8. Shoulder bolt (3 used per side plate) 9. LH side plate 10.[...]

Units DP A Cutting Reelmaster 3100 - - D DP A Cutting Units (Rev . G) Page 8 - - 25 Reel Assembly Removal (Fig. 26) 1. Position machine on a c lean 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 flat work area. 3. If cutt[...]

Reelmaster 3100 - - D DP A Cutting Units (Rev G) Page 8 - - 26 IMPORT ANT : During cutting reel installation, keep inner and outer bearing races aligned. If bearing races are not aligned, binding will occur and reel installation may cause bearing damage. Use reel bearing installation tool (#1 17 - - 0975) to help with bearing alignment during reel [...]

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Reelmaster 3100 - - D DP A Cutting Units (Rev G) Page 8 - - 28 Reel Assembly Service 1. Cutting reel 2. Threaded insert (RH thread) 3. Retaining ring 4. Grease seal 5. Bearing 6. Threaded insert (LH thread) 7. Retaining ring groove 8. Groove indicating LH threads 9. Bearing shoulder 10. Reel spider Figure 28 85 to 95 ft - - lb (1 15 to 128 N - - m)[...]

Units DP A Cutting Reelmaster 3100 - - D DP A Cutting Units (Rev . G) Page 8 - - 29 Inspection of Cutting Reel (Fig. 28) 1. Inspect reel bearings to insure that they spin freely and have minimal axial play . The bearing balls must be free of deformation and scoring. 2. Inspect the reel shaft as follows. If reel damage is de- tected, replace reel. A[...]

Reelmaster 3100 - - D DP A Cutting Units (Rev G) Page 8 - - 30 Preparing Reel for Grinding Note: Before grinding a cutting reel, make sure that all cutting unit components are in good condition. Depend- ing on type of grinder used, faulty cutting unit compo- nents can affect grinding results. Note: When grinding, be careful to not overheat the cutt[...]

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Reelmaster 3100 - - D DP A Cutting Units (Rev G) Page 8 - - 32 Front Roller Removal (Fig. 30) 1. Position machine on a c lean 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. Use cutting unit kickstan[...]

Units DP A Cutting Reelmaster 3100 - - D DP A Cutting Units (Rev . G) Page 8 - - 33 Rear Roller Removal (Fig. 31) 1. Position machine on a c lean 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. Place[...]

Reelmaster 3100 - - D DP A Cutting Units (Rev G) Page 8 - - 34 Roller Service Disassembly (Fig. 32) 1. Remove bearing lock nut from each end of roller shaft. 2. Loosely secure roller assembly in bench vise and lightly tap one end of roller shaft until outer seals and bearing are removed from opposite end of roller tube. Remove second set of outer s[...]

Units DP A Cutting Reelmaster 3100 - - D DP A Cutting Units (Rev . G) Page 8 - - 35 3. From the roller tube end with only the inner seal installed, carefully install the roller shaft into the roller tube. Make sure that seals are not damaged as shaft is installed. 4. Install new bearing and outer seals into second end of roller tube: A. Position a [...]

Reelmaster 3100 - - D DP A Cutting Units (Rev G) Page 8 - - 36 Rear Roller Brush (Optional) 1. Roller brush assembly 2. Carriage screw (3 used) 3. Flange nut 4. Flange bushing 5. Idler spring 6. Excluder seal (2 used) 7. Bearing assembly (driven) 8. Spacer 9. Hardened washer (as required) 10. Driven pulley 1 1. Flange nut 12. Carriage screw (2 used[...]

Units DP A Cutting Reelmaster 3100 - - D DP A Cutting Units (Rev . G) Page 8 - - 37 Disassembly (Fig. 38) 1. Position machine on a c lean and level surface, lower cutting units, stop engine, engage parking brake and re- move key from the ignition switch. 2. T o remove roller brush from brush shaft: A. Remove the non - - driven brush bearing assembl[...]

Reelmaster 3100 - - D DP A Cutting Units (Rev G) Page 8 - - 38 3. If drive bearing housing was disassembled, install new components noting proper orientation as shown in Figures 41 and 42. A. Install bearing on shaft by pressing equally on the inner and outer bearing races. Install the bearing so that the bearing seal is closest to the shoulder on [...]

Units DP A Cutting Reelmaster 3100 - - D DP A Cutting Units (Rev . G) Page 8 - - 39 5. Check alignment of pulleys with a straight edge placed along the outer face of the driven pulley (Fig. 44). 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 d[...]

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