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Toro Reelmaster 335-D, Service Manual

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Toro Reelmaster 335-D Service Manual Download Page 19

Chapter 3

Engine 

Table of Contents 

INTRODUCTION  . . . . . . . . . . . . . . . . . . . . . . . . . . .  2
IDENTIFICATION AND SPECIFICATIONS  . . . . . . .  3

General Specifications  . . . . . . . . . . . . . . . . . . . .  3
Cylinder Head  . . . . . . . . . . . . . . . . . . . . . . . . . . .  4
Cylinder Head Gasket  . . . . . . . . . . . . . . . . . . . . . 4
Camshaft  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Valves  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5
Valve Recess . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Valve Springs  . . . . . . . . . . . . . . . . . . . . . . . . . . .  6
Valve Guides  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Valve Seats  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Swirl Chambers  . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cylinder / Piston Matching  . . . . . . . . . . . . . . . . .  8
Piston Pin  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  8
Crankshaft  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Tightening Torques  . . . . . . . . . . . . . . . . . . . . . .  10

SPECIAL TOOLS  . . . . . . . . . . . . . . . . . . . . . . . . . . .11
ADJUSTMENTS  . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Valve Clearance Adjustment  . . . . . . . . . . . . . . . 17
Engine Speed Adjustments  . . . . . . . . . . . . . . . . 17
Throttle Cable Adjustments  . . . . . . . . . . . . . . . . 17

TROUBLESHOOTING  . . . . . . . . . . . . . . . . . . . . . . 18

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . 20
Low Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Noisy Engine  . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Pre-heating  . . . . . . . . . . . . . . . . . . . . . . . . . . . .  24
Smoke During Operation . . . . . . . . . . . . . . . . . . 25
Starting Problems  . . . . . . . . . . . . . . . . . . . . . . .  26

TESTING AND INSPECTION  . . . . . . . . . . . . . . . .  27

Injection Pump Timing . . . . . . . . . . . . . . . . . . . . 27
Glow Plug Test  . . . . . . . . . . . . . . . . . . . . . . . . .  27
Compression Test  . . . . . . . . . . . . . . . . . . . . . . .  28

Injector Tests  . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Injection Pump Fuel Delivery Test  . . . . . . . . . . . 31
Thermostat Test . . . . . . . . . . . . . . . . . . . . . . . . . 32

FUEL SYSTEM SERVICE  . . . . . . . . . . . . . . . . . . .  33

Priming the Fuel System  . . . . . . . . . . . . . . . . . . 33
Injection Pump Removal  . . . . . . . . . . . . . . . . . .  33
Injection Pump Repair  . . . . . . . . . . . . . . . . . . . . 33
Injector Service  . . . . . . . . . . . . . . . . . . . . . . . . .  34

TIMING BELT REPLACEMENT  . . . . . . . . . . . . . . .  36

Timing Belt Removal  . . . . . . . . . . . . . . . . . . . . .  36
Timing Belt Installation  . . . . . . . . . . . . . . . . . . .  38

INJECTION PUMP TIMING  . . . . . . . . . . . . . . . . . .  40

Timing of Injection Pump  . . . . . . . . . . . . . . . . . . 40

PREPARATION FOR ENGINE REPAIR . . . . . . . . . 42

Cylinder and Cylinder Block  . . . . . . . . . . . . . . .  42

ENGINE REMOVAL AND INSTALLATION  . . . . . . . 43
ENGINE OVERHAUL  . . . . . . . . . . . . . . . . . . . . . . . 45

Disassembly of External Components . . . . . . . . 45
Injection Pump Removal  . . . . . . . . . . . . . . . . . .  46
Cylinder Head Removal . . . . . . . . . . . . . . . . . . .  47
Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . .  47
Crankshaft and Piston Removal  . . . . . . . . . . . .  48
Cylinder Head Overhaul  . . . . . . . . . . . . . . . . . .  49
Crankshaft Installation  . . . . . . . . . . . . . . . . . . . . 51
Pistons and Connecting Rod Assembly . . . . . . . 53
Oil Seal Installation  . . . . . . . . . . . . . . . . . . . . . .  54
Oil Pump Installation  . . . . . . . . . . . . . . . . . . . . .  54
Flywheel Installation  . . . . . . . . . . . . . . . . . . . . .  55
Cylinder Head Gasket Selection  . . . . . . . . . . . .  56
Cylinder Head Installation  . . . . . . . . . . . . . . . . .  56
Cylinder Head Tightening  . . . . . . . . . . . . . . . . .  57
Valve Clearance Adjustment  . . . . . . . . . . . . . . .  57
Assembly of External Components  . . . . . . . . . . 60

Reelmaster 335-D/3500-D 

Page 3 - 1  Rev. B 

Engine 

Summary of Contents for Reelmaster 335-D

Page 1: ...te Model and Serial Number of traction unit and cutting unit to The Toro Company 8111 Lyndale Avenue South Minneapolis MN 55420 The Toro Company reserves the right to change product specifications or this publication without notice see This safety symbol means DANGER WARN ING or CAUTION PERSONAL SAFETY IN STRUCTION When you this symbol carefully read the instructions that follow Failure to obey th...

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Page 3: ...rams 4 7 Special Tools 4 12 Troubleshooting 4 14 Testing 4 23 Adjustments 4 33 Repairs 4 35 Sundstrand Tandem Pump Repairs 4 36 EATON PROPULSION PISTON PUMPS REPAIR INFORMATION Traction Mow Pump EATON GEAR PUMP REPAIR INFORMATION Aux Steering Pump SUNDSTRAND SAUER 15 SERIES AXIAL PISTON MOTOR SERVICE MANUAL Front Traction Motor EATON FIXED AXIAL PISTON MOTOR REPAIR INFORMATION Rear Axle 4WD Motor ...

Page 4: ...This page is blank ...

Page 5: ...ne Become familiar with the controls and know how to stop the machine and engine quickly Replacement Operator s Manuals are available by sending complete Model and Serial Number of traction unit and cutting units to The Toro Company 8111 Lyndale Avenue South Minneapolis MN 55420 Use the Model and Serial Number when referring to your machine If you have questions about this Service Infor mation ple...

Page 6: ...ight or when there is good artificial light B Drive slowly C Watch for holes or other hidden hazards D Look behind machine before backing up E Do not drive close to a sand trap ditch creek or other hazard F Reduce speed when making sharp turns and turning on a hillside G Avoid sudden stops and starts 15 Traverse slopes carefully Do not start or stop sud denly when traveling uphill or downhill Neve...

Page 7: ...must be re lieved by lowering cutting units to the ground and stop ping the engine 30 If major repairs are ever need or assistance is desired contact an Authorized Toro Distributor 31 To reduce potential fire hazard keep engine area free of excessive grease grass leaves and dirt Clean protective screen on back of machine frequently 32 If engine must be running to perform maintenance or an adjustme...

Page 8: ...Safety Instructions Page 1 4 Reelmaster 335 D ...

Page 9: ... Torque Values Metric 3 Product Records Record information about your machine on the Product Record Form Use this information when referring to your machine MAINTENANCE CHARTS 4 2 Wheel Drive Quick Reference Aid 4 4 Wheel Drive Quick Reference Aid 5 EQUIPMENT OPERATION AND SERVICE HISTORY REPORT FORM Insert the Operator s Manuals and Parts Catalogs for your Reelmaster 335 D or 3500 D at the end of...

Page 10: ...15 478 1 8 0 1250 3 175 5 8 0 6250 15 875 9 64 0 140625 3 572 41 64 0 640625 16 272 5 32 0 15625 3 969 21 32 0 65625 16 669 11 64 0 171875 4 366 43 64 0 671875 17 066 3 16 0 1875 4 762 11 16 0 6875 17 462 13 64 0 203125 5 159 45 64 0 703125 17 859 7 32 0 21875 5 556 23 32 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64 0 76562...

Page 11: ...______________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________...

Page 12: ...Maintenance Charts Maintenance Charts Page 2 4 Rev A Reelmaster 335 D ...

Page 13: ...Reelmaster 335 D Page 2 5 Rev A Maintenance Charts ...

Page 14: ...Maintenance Charts Page 2 6 Rev A Reelmaster 335 D ...

Page 15: ...EELMASTER 335 D and 3500 D TORO Model and Serial Number __________ __________ Engine Numbers ____________________ Transaxle Numbers ____________________ Cutting Unit Numbers ____________________ _______________________ Date Purchased ____________________ Warranty Expires__________ Purchased From ____________________ Contacts Parts Phone Service Phone Sales Phone See your TORO Distributor Dealer fo...

Page 16: ...ect Fuel Lines and Connections D Level Check Engine RPM idle and full throttle Service Inspect Engine Fan Belt Inspect Engine Timing Belt see note below Drain and Clean Fuel Tank Change Hydraulic Oil Replace Hydraulic Oil Filter Change Front Transaxle Oil Pack Rear Axle Bearings 2WD Change Rear Axle Oil 4WD E Level Check Rear Wheel Toe in Service Initial break in at 10 hours Initial break in at 50...

Page 17: ...iator Screen for Debris 1 Unusual Engine Noises 2 Unusual Operating Noises Hydraulic System Oil Level Hydraulic Hoses for Damage Fluid Leaks Tire Pressure Instrument Operation Reel to Bedknife Adjustment Height of Cut Adjustment Lubricate All Grease Fittings 3 Touch up damaged paint 1 Use only low pressure compressed air for debris removal Do not use water 2 Check Glow Plugs and Injector Nozzles i...

Page 18: ...nation TORO I D Remarks ____________ ____________ Service to perform circle A B C D E Other Technician A Service every 50 hours B Service every 100 hours C Service every 200 hours Inspect Air Filter Dust Cup and Baffle Check Battery Level and Connections Inspect Cutting Unit Reel Drive Belts Inspect Cooling System Hoses Torque Wheel Lug Nuts A Service required A and B Service required D Service ev...

Page 19: ...ump Fuel Delivery Test 31 Thermostat Test 32 FUEL SYSTEM SERVICE 33 Priming the Fuel System 33 Injection Pump Removal 33 Injection Pump Repair 33 Injector Service 34 TIMING BELT REPLACEMENT 36 Timing Belt Removal 36 Timing Belt Installation 38 INJECTION PUMP TIMING 40 Timing of Injection Pump 40 PREPARATION FOR ENGINE REPAIR 42 Cylinder and Cylinder Block 42 ENGINE REMOVAL AND INSTALLATION 43 ENGI...

Page 20: ...t and the specialized nature of some repairs may dictate that the work be done at a qualified diesel engine repair facility Service and repair parts for the Peugeot engine used in the Reelmaster 335 D and 3500 D are supplied through TORO Distributors Repair parts may be ordered by TORO Part Number If no parts list is available be sure to provide your dealer or distributor with the TORO Model Numbe...

Page 21: ..._______________ ________________________________ ________________________________________________________________________________________________________________________ ________________________________ ________________________________________________________________________________________________________________________ ________________________________ ___________________________________________...

Page 22: ...e following operations must be done 1 Valve seat machining to re establish correct recess see Valve Recess in this section 2 Replacement of swirl chambers by repair dimen sion and correction of their protrusion see Swirl Chambers in this section 3 Fitting of 0 4 mm thick compensation washers under the valve springs to match cylinder head machining Cylinder heads manufactured with oversize camshaft...

Page 23: ... change engines and can be obtained on special order Figure 4 Valves Units mm Intake Exhaust Min Length l 112 2 øa 0 0 015 8 005 7 985 øb 0 1 38 5 33 a 90 90 Intake Faces x and y can machined a maximum of 0 2 mm Exhaust No machining is permissible Figure 5 Valve Recess Units mm Intake Exhaust 0 5 to 1 05 0 9 to 1 45 Figure 6 Reelmaster 335 D 3500 D Page 3 5 Rev B Engine ...

Page 24: ...nits mm øf øg h j øk Tolerance 0 0 011 0 032 0 0 25 0 50 0 0 2 Production 14 02 13 981 14 13 14 051 Repair 1 14 29 14 211 52 00 36 50 8 02 Repair 2 14 59 14 511 øk is obtained by machining after fitting in the cylinder head Figure 8 Engine Page 3 6 Rev B Reelmaster 335 D 3500 D ...

Page 25: ...8 35 Repair 1 34 437 34 3 6 25 8 35 Repair 2 34 637 34 5 6 25 8 35 After fitting valve seats into the cylinder head machine them according to drawings Fig 9 Figure 9 Swirl Chambers Units mm øe øf g h Tolerance 0 099 0 060 0 039 0 0 020 0 025 0 02 0 04 Production 32 05 32 25 32 32 2 4 4 1 3 9 4 Repair 1 32 45 32 4 4 2 4 1 Repair 2 32 65 32 6 4 3 4 2 The protrusion j must be between 0 and 0 03 mm Di...

Page 26: ... 83 03 82 96 Repair 1 R1 83 20 83 13 Repair 2 R2 83 50 83 43 Repair 3 R3 83 80 83 73 NOTE The piston øb must be measured at dimension c 25 00 NOTE The repair dimension x is stamped on the cylinder block and pistons Figure 11 Piston Pin Units mm ø external 24 994 to 25 ø internal 13 8 to 14 1 Engine Page 3 8 Rev B Reelmaster 335 D 3500 D ...

Page 27: ...d and main bearing shells can be identified by white paint 1 on the edge of the shell Units mm Units mm Figure 13 End Float No 2 Journal Half Shell Thickness e f Tolerance 0 05 0 0 025 Production 26 60 2 305 Repair 1 26 80 2 405 Repair 2 26 90 2 455 Repair 3 27 00 2 505 Oil Seal Contact Surface øg Tolerance 0 0 087 Production 90 00 Repair 1 89 80 Reelmaster 335 D 3500 D Page 3 9 Rev B Engine ...

Page 28: ..._______________ ________________________________ ________________________________________________________________________________________________________________________ ________________________________ ________________________________________________________________________________________________________________________ ________________________________ ___________________________________________...

Page 29: ...ig 23 TOR80504A2 Indicator Holder Fig 30 TOR80110GY Extension Rod Adapter Fig 24 TOR70153A1 Main Seal Installer Fig 18 TOR70153A2 Main Seal Installer Shims Fig 19 TOR70153C Rear Main Seal Installer Fig 20 TOR70153D Front Cover Seal Installer Fig 21 TOR4035 Tune Up Set This tool kit includes tools required for doing timing belt replacement injection pump timing injector removal and camshaft seal re...

Page 30: ...head gasket selection adjusting the timing of the injection pump and for checking the crankshaft and float Figure 16 TOR4024T Valve Spring Compressor This tool is used to compress valves for removal Figure 17 TOR70153A1 Main Seal Installer Used to install the two side seals to the no 1 main bearing cap Figure 18 TOR70153A2 Shim Set Used with main seal installer TOR70153A1 Figure 19 Engine Page 3 1...

Page 31: ...eal Installer Used with a small hammer to install new front crankshaft seal Figure 21 TOR70153N Flywheel T D C Locator Pin Used to set injection pump timing Figure 22 TOR80110DZ 2mm Shim Cut Off Gauge With Cut Off Shim Used to gage and gut off new side seals to 2mm height Figure 23 Reelmaster 335 D 3500 D Page 3 13 Rev B Engine ...

Page 32: ...ck protrusion of swirl chambers valve recess and measurement for cylinder head gasket selection Figure 25 TOR80117AM Timing Tool Kit For Roto Diesel DPC Pump Used with dial indicator to adjust timing of injection pump Figure 26 TOR80117EZ Crankshaft Rotating Wrench Used with a 1 2 drive ratchet wrench to turn the crankshaft Figure 27 Engine Page 3 14 Rev B Reelmaster 335 D 3500 D ...

Page 33: ...ed with TOR 80110GY and TOR 80504A2 to check crankshaft end float Figure 29 TOR 80504A2 Indicator Holder Used with TOR80110GY and TOR 80504A1 to check crankshaft end float Figure 30 TOR976697 Camshaft Seal Installer Used to install camshaft seal Figure 31 Reelmaster 335 D 3500 D Page 3 15 Rev B Engine ...

Page 34: ...nder head qty 2 required Units mm Figure 32 TOR70153H Injector Pump Gear Puller Loosen the nut on the injector pump gear then use this tool to loosen the pulley from the tapered shaft on the injector pump TOR70153H Figure 33 Engine Page 3 16 Rev B Reelmaster 335 D 3500 D ...

Page 35: ...er Throttle Cable Adjustments The throttle control lever at the operator s station must not touch the end of the slot during full range of motion from idle SLOW to full engine RPM FAST Adjust throttle cable at injection pump so throttle lever on injection pump operates at full range of motion without throttle control lever at operator s station touch ing end of slot at either FAST or SLOW position...

Page 36: ...t defective Energizing circuit defective Brushes worn or seized Rotor winding defective Stator winding defective Regulator defective Rotor partially short circuited Stator partially short circuited Rectifier diode defective Rectifier diode short circuited Battery voltage too high In line diode defective Regulator defective Poor connections Alternator noisy Rectifier diode short circuited Belt worn...

Page 37: ... Replace gasket at each repair Injector nut too tight on injector body Tighten injector nut 1 Leakage collector fills too quickly Leak between upper bearing face of nozzle and bearing face of injector body Foreign matter between bearing faces Clean Unevenness Replace injector Blue needle point Incorrect injection pump timing Replace injector and adjust pump timing again End of injector body corrod...

Page 38: ...p repaired Jammed discharged valve Have pump repaired Blocked pump governor Have pump repaired Engine will not accelerate Defective fuel supply Check filter cartridge and pipes Seized pump plunger Have pump repaired Broken pump plunger spring Have pump repaired Hard discharge valve Have pump repaired Seized feed pump Drain water from tank pipes and filter have pump repaired Accelerator linkage def...

Page 39: ... pipes Check clean and adjust injectors Have pump repaired Have pump repaired Noisy engine Engine stalls at idling Incorrect pump timing Blocked automatic advance Automatic advance to far advanced Air getting into fuel system Idling stop out of adjustment Jammed discharge rate Correct timing Have pump repaired Have pump repaired Check gaskets and pipes Adjust idling stop Have pump repaired Vibrati...

Page 40: ... pipe restriction due to exce of unions ssive tightening Defective injection pump Irregular idling Defective injection pump Air getting into fuel system Idling stop out of adjustment Leaky injection pipe unions Speed fall Off Clogged fuel filter Defective injection pump Engine speed rises to maximum Defective injection pump Throttle cable jammed Engine Page 3 22 Rev B Reelmaster 335 D 3500 D ...

Page 41: ...n collector clogged Lifters out of adjustment Foreign matter in a cylinder Seized injector Injection pump timing Sheared glow plug Timing out of adjustment Whistling blowing Leaking cylinder head gasket Leaky glow plug Valve seats Leaky injector Reelmaster 335 D 3500 D Page 3 23 Rev B Engine ...

Page 42: ...ow red hot Faulty glow plug Faulty glow plug relay Damaged wiring or connector All four glow plugs burnt out ends melted injection pump timing out of adjustment engine overheating See Chapter 5 Electrical System Engine Page 3 24 Rev B Reelmaster 335 D 3500 D ...

Page 43: ...ke restricted Inlet chambers clogged Not enough advance Grey Defective injector Injection pump timing Air intake restricted Not enough advance Blue Grey Defective injector Injection pump timing Too much oil Blue Too much oil Wear White Injection pump timing Cylinder head gasket Cold engine Reelmaster 335 D 3500 D Page 3 25 Rev B Engine ...

Page 44: ...der head gasket Engine will not start and does not emit any smoke Frozen fuel Injection pump does not work Leaking injection pipe unions Injection valve blocked No preheating Empty fuel tank Feed pipe obstructed Air getting in pipes Tank vent plugged Injection pump needs re priming Shutdown control jammed in stop position Starter does not crank or cranks slowly Battery discharged Oil too thick Eng...

Page 45: ... Remove the glow plug 3 Inspect the glow plug for signs of a burnt glow plug end tube NOTE If the metal of the glow plug end is melted it is a sign of cylinder overheating 4 Connect the positive battery terminal to the glow plug terminal and the negative battery terminal to the plug body Fig 34 If the glow plug glows red hot in 9 to 12 seconds the glow plug is operating correctly DO NOT leave on m...

Page 46: ...ressure compression gauge to the adapter 4 Disconnect the fuel stop solenoid electrical connector or hold the fuel stop lever in the stop position to prevent fuel delivery during the compression test This will prevent wash down of the cylinders and inaccurate readings 5 Crank the engine with the starter motor until you get a stable gauge reading 6 If the pressure is less than 20 bar 290 psi it wil...

Page 47: ...on chamber at a precise point in the compres sion stroke The point at which this fuel injection occurs is determined by the injection timing If the nozzle is defective damaged or adjusted incorrectly starting failures low power output or engine knocking can occur 1 Securely fasten the nozzle to the adapter 2 Pump the handle several times to purge air from the nozzle mechanism 3 Allow pressure to d...

Page 48: ...ile pressure is being applied watch for an ac cumulation of fuel at the tip of the nozzle Fig 35 A small amount of fuel may be present due to a previous chattering test this would be normal If the fuel accumu lates and drips down during the test about ten seconds the nozzle assembly is defective and must be replaced Spray Test For proper combustion the nozzle must effectively atomize the injected ...

Page 49: ... the tip of the nozzle is pointed away from the engine Tighten the fitting securely D Put the throttle control in the FAST position Turn the ignition key to the START position to crank the engine Observe the nozzle j j A j The in ection pump forces fuel from the noz zle under extremely high pressure Always point the nozzle tip away from yourself and any other personnel Contact with the fuel stream...

Page 50: ...ted 1 Remove the thermostat 2 Put the thermostat in a container of water with a thermometer and heat the water Starts to open at 81o C 178o F 7 mm 0 28 in full open at 88o C 190o F 3 If the thermostat fails to open only partially opens or sticks it should be replaced Figure 37 Engine Page 3 32 Rev B Reelmaster 335 D 3500 D ...

Page 51: ...39 and pump priming plunger until a steady stream of fuel comes out of fitting When fuel stops foaming tighten the fitting during the down stroke of the priming plunger Wipe up any spilled fuel NOTE The high pressure fuel system is self bleeding It is not necessary to open the high pressure lines Injection Pump Removal See Injection Pump Removal in the Engine Overhaul section Figure 38 1 Primer pl...

Page 52: ...ning 1 Secure the injector body in a V type injector holder 2 Remove the injector holder nut 3 Remove the injector spacer push rod pressure setting spring adjusting shims and body 4 Dip all parts in clean diesel fuel 5 Clean nozzle and needle in clean diesel fuel 6 De carbon injector nozzle using a wooden spatula Never use metallic objects emery cloth or rags Do not attempt to grind the needle on ...

Page 53: ...ine new washers must be installed Fire ring washer is installed with convex surface up 1 Install new fire ring washers Fig 58 Item 21 convex surface facing up 2 Install new copper washers Fig 58 Item 20 3 Install the injectors and tighten to a torque of 90 Nm 66 ft lb 1 Install new flame arrestor steel washer and copper gasket 2 Install injector in cylinder head 3 Install injection pipe unions on ...

Page 54: ... covers Item 2 3 and 4 in the numbered order 4 Re install the crankshaft bolt Fig 44 Item 1 and the washer 5 Lock the camshaft gear Item 6 in position by install ing an M8 x 125 x 40 bolt Tighten finger tight 6 Lock the injection pump gear Item 7 in position with two M8 x 125 x 35 bolts Tighten finger tight IMPORTANT To prevent damage to the face of the injector pump housing and future timing prob...

Page 55: ...em 9 securing the roller tensioner bracket Item 10 8 Rotate the roller tensioner bracket square Item A to compress the spring Item 11 9 Re tighten the bolt Item 9 10 Remove the timing belt A Figure 45 Reelmaster 335 D 3500 D Page 3 37 Rev B Engine ...

Page 56: ...ion pump gear Item B Camshaft gear Item C Tensioner roller Item 17 Coolant pump gear Item 10 2 Loosen the bolt Fig 47 Item 18 and nut Item 19 to release the tensioner roller DO NOT use Item A to set tension Tension on belt is only to be set by the spring Fig 46 Item 15 when tensioner plate is free to rotate 3 Re tighten the bolt Item 18 then the nut Item 19 when the belt is tensioned B C A Figure ...

Page 57: ...hten the bolt Item 18 then the nut Item 19 to a torque of 17 5 Nm 13 ft lb 9 Remove the three gear locking bolts 10 Install the covers Fig 49 Item 2 3 and 4 cover clips and cover attachment nut Item 5 5 Figure 49 11 Install the pulley A Clean with a brush and de grease the threads of the bolt Fig 50 Item 1 the bearing faces of the washer Item 2 and the head of the bolt Item 1 B Coat the threads of...

Page 58: ...3 Item 6 in position with a M8 x 125 x 40 bolt Tighten finger tight B Lock the injection pump gear Item 7 in position with two M8 x 125 x 35 bolts Tighten finger tight NOTE If the locking bolts cannot be installed be cause the holes in the gears and engine block do not align remove the TDC Lock Pin tool and rotate the engine clockwise one revolution Install the TDC Lock Pin then install the bolts ...

Page 59: ...go to far and the reading is passed stop Again rotate the pump away from the engine then rotate the pump toward the engine in one smooth motion 12 After obtaining the correct reading be careful to keep the pump in position and tighten the pump bolts 13 Remove the TDC Lock Pin tool TOR 70153 N 14 Turn the crankshaft 1 4 to 1 3 turn in the opposite direction of running counterclockwise as viewed fro...

Page 60: ...aul Before removing any parts disassembly or overhaul of the Peugeot engine it is very important to understand the nature and probable cause of the problem that made an overhaul necessary When the engine trouble is caused by worn cylinders rings or valves one or more of the following symptoms will occur 1 Low engine power and a decrease in compression pressure 2 Increased fuel consumption 3 Increa...

Page 61: ... 8 Disconnect and tag electrical wires that attach to the engine or engine components alternator starter motor and solenoid ground cable oil pressure switch tem perature gauge sender thermoswitch fuel stop ETR solenoid glow plugs 9 Disconnect hydraulic piston pump assembly from flywheel end of engine 10 Remove upper fan shroud from radiator 11 Disconnect throttle cable from speed control lever on ...

Page 62: ...ll the engine with the correct oil Fill the cooling system with a 50 50 solution of ethylene glycol anti freeze and clean soft water Check for oil and coolant leaks and repair as necessary Peugeot recommended Coolant Antifreeze is available in 1 U S Gallon containers under Toro Part No 93 7213 IMPORTANT The anti freeze should contain no Borate and have a Ph of 7 to 8 5 4 Adjust the throttle linkag...

Page 63: ...e exhaust manifold and inlet manifold 5 Remove the coolant manifold 6 Remove the alternator and belt 7 Remove the oil filter Fig 57 Item 10 8 Remove the injector pipes Item 12 9 Remove the glow plug leads 10 Remove the crankcase breather pipes oil filter filter pipe assembly Item 13 11 Remove the oil pressure switch Item 14 Figure 57 Reelmaster 335 D 3500 D Page 3 45 Rev B Engine ...

Page 64: ...mp gear Fig 58a Item 5 TOR70153H Figure 58a 3 Remove the injection pump Fig 58b Item 19 4 Remove bracket Item 20 NOTE If the pump needs to be inspected or repaired it is recommended that is be done by an authorized CAV Lucas ROTO DIESEL service dealer especially during the warranty period Repairs by non authorized dealers WILL void the pump warranty IMPORTANT Clean the injection pump and the area ...

Page 65: ...l Pump Removal 1 Remove the oil pan and gasket IMPORTANT Use solvent and a wood or plastic scraper to remove the silicone gasket material Be careful not to damage the sealing face of the block 2 Remove the bolts Fig 60 Item 1 2 and 3 3 Remove the seal carrier plate Item 4 IMPORTANT The bolt Item 1 is a special bolt that centers the pump in the correct location Figure 60 4 Remove the pump Fig 61 It...

Page 66: ...cap 5 Remove the oil seal Fig 63 Item 10 6 Remove the end float washers Item 11 7 Remove the crankshaft 8 Remove the main bearing shells 9 Remove the piston connecting rod assemblies mark ing each piston and connecting rod for re installation in the same location Figure 62 Figure 63 NOTE Connecting rods and end caps are not num bered Once they are removed there is no way of knowing the correct loc...

Page 67: ... to remove the swirl chambers from the injector orifices if necessary NOTE Swirl chambers do not need to be removed unless cylinder head is to be machined or replaced 5 Clean the cylinder head Use a wooden scraper and gasket stripping solvent to clean the gasket face DO NOT use a metal scraper 6 Check the gasket face for bow flatness Check corner to corner and side to side Fig 67 Maximum bow 0 7 m...

Page 68: ...2 Install the shims as removed in step 2 If replacing cylinder head or if cylinder head has been machined install a basic shim Fig 69 Item 6 2 425 mm thick to each valve stem and check that each shim is higher than the spring cup Item c If a shim is not higher than the cup grind the top of the cup Item c 13 Re install the tappets 14 Oil the camshaft bearings 15 Install the camshaft with the DIST m...

Page 69: ... main bearing shell thickness Figure 71 3 Install the crankshaft 4 Install the no 3 4 and 5 main bearing caps 5 Install the two end float half washers Fig 72 Item 1 with the anti friction faces towards the crankshaft Figure 72 6 Install the no 2 main bearing cap Fig 73 Item 2 with its two end float half washers with the anti friction faces towards the crankshaft Figure 73 Reelmaster 335 D 3500 D P...

Page 70: ... main bearing cap 10 Using a bolt and washer Item 5 attach tool 80153 fitted with shims A2 to no 1 main bearing cap Item 4 11 Adjust the height x of the shims x 0 5 mm above flat on side of rear main cap 12 Oil the shims and the housing IMPORTANT To avoid stretching the side seals fit the cap as follows A Engage it in its housing at 45 B Straighten it C Lower it slowly D Tighten the two bearing ca...

Page 71: ... 1 Assemble the connecting rods and pistons with the bearing shell tab recess Fig 77 Item a on the same side as the piston crown recess Item b 2 Use a piston rings pliers to install the piston rings NOTE The marked face of the tapered ring must be towards the combustion chamber 1 scraper ring 2 tapered ring 3 domed chrome ring Space the ring gaps at 120 in relation to the scraper ring gap Item c F...

Page 72: ...or choice of bearing shell thickness see Crankcase in Identification and Specifications section Figure 78 Oil Seal Installation 1 Put a new oil seal on tool TOR 70153 C 2 Install seal with lip toward the inside of the engine block to keep the oil in Fit the seal by tapping fully home with a mallet 3 Withdraw the tool with a twisting movement TOR 70153C Figure 79 Oil Pump Installation 1 Install the...

Page 73: ...ne sealant to the oil pan using the pattern shown in Figure 81a Wait 10 minutes before installing the oil pan to allow partial hardening of the gasket material 10 Install the oil pan Item 5 11 Install the bolts Item b NOTE The two shorter bolts are installed into the main bearing cap 12 Tighten the bolts Item b to a torque of 20 Nm 15 ft lb 13 Wait a minimum of 1 hour for the oil pan gasket to har...

Page 74: ...tches 0 75 to 0 79 4 notches 0 79 to 0 83 5 notches TOR 80110H Figure 82 Cylinder Head Installation 1 Turn the crankshaft to put the pistons at mid stroke with damper pulley key Fig 83 Item 6 at the 9 o clock position 2 Clean the tapped holes in the cylinder block 12 x 150 thread 3 Install the centralizing dowel Item 7 4 Install a new head gasket dry 5 Install the cylinder head 6 Carefully clean t...

Page 75: ...alled 5 times before replacing with new bolts Valve Clearance Adjustment NOTE If all valve parts are re installed in their original location it should not be necessary to adjust valve clearance unless the head has been machined or val ves ground 1 Install the camshaft gear Fig 85 Item 1 2 Check the valve clearance Units mm Running Clearance Inlet 0 15 Exhaust 0 30 Tolerance 0 04 Set on the rock In...

Page 76: ...m 5 8 Determine the shim thickness to be fitted for each valve Example Units mm Figure 86 No 1 Intake valve Specified clearance 0 15 Clearance measured 0 25 Difference 0 10 Shim installed 2 425 Shim to be installed 2 50 Clearance obtained 0 175 Basic shim 9 Install the shims as determined in step 8 10 Install the tappets Engine Page 3 58 Rev B Reelmaster 335 D 3500 D ...

Page 77: ...arking at the timing gear end 14 Install the camshaft bearing caps Item 2 as shown by cast in markings 15 Progressively tighten the bearing caps to 17 5 Nm 13 ft lb Figure 87 16 Install a new oil seal on tool TOR 976697 on the side where the inner flange is the farthest away Fig 88 17 Use a camshaft gear or pulley bolt to install the two camshaft oil seals TOR 976697 Figure 88 Reelmaster 335 D 350...

Page 78: ...t lb Figure 89 7 Install the pre heat plug wires 8 Install the breather pipe assembly with oil filler pipes and filler orifice Fig 90 Item 13 9 Install the injector pipes Item 12 10 Install the oil pressure switch Item 14 and tighten to a torque of 27 5 Nm 20 ft lb 11 Install a new oil filter Item 10 See Break in Engine After Overhaul 12 Install the alternator and alternator belt 13 Install the wa...

Page 79: ...After Overhaul After disassembling or overhauling the engine install the a new oil filter Replace this filter with a new filter after the first 20 to 50 hours of operation Reelmaster 335 D 3500 D Page 3 61 Rev B Engine ...

Page 80: ...Engine Page 3 62 Rev B Reelmaster 335 D 3500 D ...

Page 81: ...essure or Relief Pressure 24 Test No 2 Checking Counterbalance Pressure 25 Test No 3 Checking Mowing Circuit Working Pressure or Relief Pressure 26 Test No 4 Checking Mowing Circuit Flow 27 Test No 5 Checking Reel Motor Efficiency 28 Test No 6 Checking Steering Circuit Working Pressure or Relief Pressure 29 Test No 7 Checking Lift Circuit Working Pressure or Relief Pressure 30 Test No 8 Checking C...

Page 82: ..._______ ________________________________________________________________________________________________________________________________________________________ Specifications Item Description Traction Reel Drive Pump Sundstrand Sauer Sundstrand Sauer tandem in line variable axial piston pump Traction relief pressure 5000 100 PSI Mow relief pressure 2540 100 PSI Charge pressure remote charge relie...

Page 83: ... coating of oil 4 Put the tube and nut squarely into position on the face seal end of the fitting and tighten the nut until finger tight 5 Mark the nut and fitting body Hold the body with a wrench Use another wrench to tighten the nut to the correct flats from finger tight F F F T The markings on the nut and fitting body will verify that the connection has been tightened Size F F F T 4 1 4 in nomi...

Page 84: ...s or any foreign material 2 Always replace the O ring seal when this type of fitting shows signs of leakage Lock Nut 3 Lubricate the O ring with a light coating of oil Back Up Washer 4 Turn back the jam nut as far as possible Make sure O Ring the back up washer is not loose and is pushed up as far as possible Step 1 5 Install the fitting into the port and tighten finger tight Figure 5 until the wa...

Page 85: ...Hydraulic Schematic Two 2 Wheel Drive TEST PORT 2000 PSI 138 BAR 2500 1600 RPM ...

Page 86: ...Hydraulic Schematic Four 4 Wheel Drive TEST PORT 2000 PSI 138 BAR 2500 1600 RPM 12 6 1 ...

Page 87: ...arge Relief ve Filter ENGINE Traction Pump Pump Reel Pump General Charge Pump Flow With all controls in neutral and the engine running oil is drawn from the reservoir by the auxiliary pump This gear type pump has a flow divider cover Priority flow goes to the steering valve then through the oil cooler filter and back to reservoir Secondary flow goes to the lift valve then through the counterbalanc...

Page 88: ...units this flow returns Flow to the traction pump and continues to operate in a closed loop Four wheel drive units have another piston motor connected in series with the front motor and mounted to the steerable rear axle On these units flow is from the pump to the front motor through a solenoid valve then to the rear motor and back to the pump continuing in a closed loop An interlock switch on the...

Page 89: ... Motor Pump Pump cutting unit engagement switch is on with the front axle in low gear and cutting units lowered the solenoid valve on each cutting unit motor will allow oil to flow through the motor to turn the reel An interlock switch on the front axle allows the electric solenoid valves to engage the reel motors only when the axle is in low gear An interlock switch in each lift arm causes the el...

Page 90: ...nterbalance valve oil cooler filter and back Flow to reservoir Each lift valve spool controls a separate lift cylinder Check valves in each spool section hold the cutting units in the raised position When a lift lever is moved to the lift position the valve spool moves to direct oil flow to the lift cylinder lifting the cutting unit An orifice in the lift port of each cylinder limits the speed of ...

Page 91: ... of the gear type auxiliary pump to the power steering valve then through the oil cooler filter and back to reservoir Turning the steering wheel to the right clockwise moves the control spool in the steering valve to meter oil to the steering cylinder for a right turn Turning the steering wheel to the left counterclockwise has the opposite effect Cylinder movement forces oil out the other end of t...

Page 92: ...al supplier Hydraulic Pressure Test Kit Used to take various pressure readings for diagnostic tests Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools A high pressure hose is provided for remote readings Contains one each 1000 5000 and 10000 PSI gauges Use gauges as recommended in Testing section of this chapter Figure 7 Special Tools Page 4 1...

Page 93: ...ing load is created in the circuit 3 LOW PRESSURE GAUGE Low range gauge to provide accurate reading at low pressure 0 1000 PSI This gauge has a protector valve which cuts out when pressure is about to exceed the normal range for the gauge The cutout pressure is adjustable 4 HIGH PRESSURE GAUGE High range gauge to accommodate pressure beyond the capacity of the low pressure gauge 0 5000 PSI 5 FLOW ...

Page 94: ...n excessive increase in heat or noise is a potential failure Should either of these conditions be noticed immediately stop the machine turn off the engine locate the cause of the trouble and correct it before allowing the machine to be used again Continued use of an improperly functioning hydraulic System Operates Hot system could lead to extensive internal component damage The charts that follow ...

Page 95: ..._____________________________________________________________________________________________________________________________ Traction Response Is Sluggish Cause Correction Brakes dragging Inspect brakes and adjust or repair if necessary Charge pressure low TEST NO 8 Inspect charge relief valve and adjust or repair if nec NOTE Counterbalance pressure will also be essary affected Inspect auxiliary ...

Page 96: ..._______________________________________________________ ________________________________________________________________________________________________________________________________________________________ Four Wheel Drive Does Not Engage Cause Correction Front axle shift lever in HI forward position Front axle shift lever must be in LOW rear position for four wheel drive to engage Electrical p...

Page 97: ...________________________ No Cutting Units Operate Cause Correction Front axle shift lever in HI forward position Front axle shift lever must be in LOW rear position for cutting units to engage Hydraulic oil level too low Fill to proper level Reel speed control linkage damaged or out of adjust Repair control linkage ment Electrical problem Check for faulty front axle HI LOW switch cutting unit enga...

Page 98: ...______________________________________________________________________________________________________________________________ All Cutting Units Operate Slowly Cause Correction Low engine RPM Adjust engine rpm use tachometer Hydraulic oil level too low Fill to proper level Bedknife to reel contact too tight Adjust bedknife to reel contact Reel speed control linkage damaged or out of Repair or adju...

Page 99: ...____________________________________________________________________________________________________________________________________________________ One Cutting Unit Does Not Operate Cause Correction Reel drive belt damaged or loose Inspect and adjust or replace belt Key on reel motor shaft sheared Replace key Inspect for damaged pulley or motor shaft Bedknife to reel contact too tight Adjust bedk...

Page 100: ...____________________________________ Cutting Unit s Do Not Lift or Lift Too Slowly Cause Correction Hydraulic oil level too low Fill to proper level Low engine RPM Adjust engine rpm use tachometer Lift arm or cylinder pivots binding Lubricate bushings Inspect for damage Repair or re place damaged parts Lift cylinder damaged Check lift cylinder s Repair or replace if necessary Low counterbalance pr...

Page 101: ...________________________________ ________________________________________________________________________________________________________________________________________________________ Cutting Units Will Not Drop or Follow Ground Contours Cause Correction Low engine RPM Adjust engine rpm use tachometer Lift arm or cylinder pivots binding Lubricate bushings Inspect for damage Repair or re place da...

Page 102: ...oid interfer ence with adapter fitting Steering Loss Cause Correction Steering linkage or cylinder pivots damaged worn Lubricate bushings Inspect for damage Repair or re or binding place damaged parts Low steering pressure TEST NO 6 Check for restriction in pump intake line or strainer and repair if necessary Check steering cylinder for internal leakage and re pair or replace if necessary Clean re...

Page 103: ... be surgically removed within a few hours by a doctor familiar with this type of injury or gan grene may result WARNING 1 Thoroughly clean the machine before disconnecting or disassembling any hydraulic components Always keep in mind the need for cleanliness when working on hydraulic equipment 2 Put caps or plugs on any hydraulic lines left open or exposed during testing or removal of components 3...

Page 104: ...t of auxiliary pump so gauge can be observed while sitting on seat 5 Operate machine while monitoring gauge RANGE OF TESTER READINGS 100 5100 PSI RELIEF Pressure Check Move machine to an open area away from people and obstructions CAUTION 6 Set traction pedal stop for minimum ground speed 1 mph 7 Start the engine and move throttle to full speed 2500 rpm 8 Release parking brake 9 Engage the tractio...

Page 105: ... of lift control valve NORMAL SETTING 300 400 PSI oil at normal operating temperature MAXIMUM QUALITY OF CUT 300 PSI oil at normal operating temperature j j j j When ad usting counterbalance relief valve do not unscrew relief valve ad uster too far Watch pressure gauge while ad usting valve Stop unscrewing valve ad uster when pres sure no longer decreases CAUTION 7 If necessary adjust the relief v...

Page 106: ...l pressure during operation is 1500 2000 PSI Gauge may spike higher during initial engagement of cutting units RELIEF Pressure Check 6 Lower center cutting unit to the ground 7 Turn the engine OFF 8 Use a substantial hardwood block inserted between reel blades of center cutting unit to prevent rotation Center cutting unit motor is first in series from pump Stand clear of the reels during the follo...

Page 107: ...on is from hose to motor Make sure gate valve of tester is OPEN 6 Position reel speed control knob at neutral N posi tion Make sure cutting unit engagement switch is OFF 7 Start engine and move throttle to full speed 2500 rpm 8 Gradually move reel speed control knob to maximum speed position while monitoring tester flow gauge NOTE It is not necessary to engage the cutting units to measure flow in ...

Page 108: ...ies between disconnected hose and reel motor flow direction is from hose to motor Make sure gate valve of tester is OPEN 7 Position reel speed control knob at MINIMUM speed 8 Start engine and move throttle to idle speed 1500 rpm NOTE Front axle shift lever must be in LO position for cutting units to operate Stand clear of the reels during the following procedures CAUTION 9 Move the cutting unit en...

Page 109: ...0 PSI gauge onto steering quick discon nect fitting 5 Operate machine while monitoring gauge Figure 17 RANGE OF TESTER READINGS 0 1300 PSI 1 Steering circuit test port S N 39999 below RELIEF Pressure Check 6 With engine running turn the steering wheel until heavy resistance is felt indicating that the cylinder has reached maximum stroke 7 Momentarily hold steering wheel against resistance and read...

Page 110: ...liary pump so gauge can be observed Figure 18 while sitting on seat 1 1 Lift circuit test port 5 Raise each cutting unit while monitoring gauge RANGE OF TESTER READINGS 300 1800 PSI when counterbalance setting is 300 PSI NOTE Changes in counterbalance setting will affect the lift circuit relief pressure RELIEF Pressure Check 6 With engine running at full speed engage control lever into the LIFT po...

Page 111: ... from in front of auxiliary pump 4 Install a 1 000 PSI gauge with extension hose onto the charge pressure quick disconnect fitting Put gauge and hose through opening below seat in front of auxiliary pump so gauge can be observed while sitting on seat 5 Start the engine and position throttle at idle 1500 rpm TESTER READING TO BE 100 25 PSI 1 Figure 19 Eaton pump 1 Charge pressure test port 1 Figure...

Page 112: ...e rear drive motor quick disconnect fitting Put gauge and hose through opening below seat in front of auxiliary pump so gauge can be observed while sitting on seat 5 Operate machine while monitoring gauge NOTE Front axle must be in LO position for 4wd to en gage 6 When operating in conditions that would cause the front wheels to begin to slip pressure should increase as four wheel drive automatica...

Page 113: ...ent cam Fig 22 or 23 Engine must be running so final adjustment of traction adjustment cam can be performed To guard against possible personal injury keep hands feet face and other parts of body away from rotating parts CAUTION 4 Start engine and run at low idle 5 Rotate cam hex in either direction until raised wheel is not rotating 6 Tighten locknut to secure adjustment 7 Stop the engine Remove j...

Page 114: ...des and other ro tating parts CAUTION 3 Start engine and run at maximum speed 4 Rotate reel speed control knob clockwise until reel on right hand cutting unit just starts to rotate 5 Measure RPM of right hand cutting unit If necessary adjust pump lever linkage so reel speed is 450 550 RPM 6 Rotate reel speed knob clockwise until reel speed reaches 1100 1200 RPM Set maximum stop bolt 7 Check RPM at...

Page 115: ... or system is contaminated 2 After repairs check control linkage for proper adjust ment binding or broken parts 3 If a pump was disconnected or removed prime system before operating Disconnect fuel stop solenoid electrical connector on engine to prevent fuel delivery to engine cylinders Turn ignition switch to engage starter for ten 10 seconds to prime pumps Repeat cranking procedure again Connect...

Page 116: ...s removed the cylinder block could move out of place making shaft installation difficult 5 Remove o ring from seal carrier 4 Lip seal 6 Put seal carrier in an arbor press and press out old seal Use a properly sized pipe spacer or socket wrench for a press tool The seal cannot be used again 7 Inspect seal carrier new seal and o ring for damage Inspect sealing surface on shaft for rust wear or con t...

Page 117: ...rea on shaft for rust wear or contamination Polish sealing area on shaft if necessary 6 Spacer shim bearing 7 Using an arbor press press seal into position from inside of seal cover until it bottoms out in its bore Be careful not to damage the seal 8 Install o ring onto seal cover and retain with petro leum jelly 9 Use a seal installer tool or wrap end of swashplate control shaft with thin plastic...

Page 118: ...high pressure relief valve 4 The valve cartridge is retained in the special plug by a circlip The check valve spring may be removed from the special plug by pulling out at a slight angle When reassembling install the check valve spring into the special plug with its larger diameter toward the plug and snap the valve cartridge into position in the plug 5 Reinstall the valve cartridges with o rings ...

Page 119: ... and thick ness of shims is installed when reassembling the parts unless shims need to be added or removed to adjust the pressure setting 5 Inspect the poppet and mating seat in the end cap for damage or foreign material 6 Reinstall the poppet spring and plug with shims and o ring into the housing Tighten the plug to a torque of 30 to 70 ft lb 7 Before starting the engine check the oil level in th...

Page 120: ...n two parts should be coated with a film of clean hydraulic oil This will assure that these surfaces will be lubricated during start up It is recommended that all gaskets o rings and seals be replaced Lightly lubricate all o rings with clean petro leum jelly before assembly All gasket sealing surfaces must be cleaned before installing new gaskets 1 Before performing major repairs on the pump remov...

Page 121: ... Tilt and lift swashplate from housing Inspection and Replacement of Parts 17 After disassembly thoroughly clean all parts in a suitable solvent Replace all o rings gaskets and seals 18 Inspect all parts for damage nicks or unusual wear patterns Replace all parts having unusual or excessive wear or discoloration 19 If scratches which can be felt with a pencil lead can be found on bronze surface of...

Page 122: ...ousing note marks made during disassembly Install swash plate bearings into housing and onto swashplate trun nions 3 Install trunnion cover with o ring and trunnion bear ing into housing and over swashplate trunnion 4 Use an arbor press to press a new seal into trunnion seal cover Outer face of seal should be pressed flush with outer surface of seal cover Be careful not to damage the seal 5 Instal...

Page 123: ...ing splines while assembling When the sections are properly as sembled cylinder block spring will hold center section away from housing approximately 1 8 in 16 Install the four 4 screws and washers that retain rear housing to center section and evenly tighten to a torque of 45 to 54 ft lb IMPORTANT Be sure all parts are properly aligned Do not force center section into position on housing 17 Assem...

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Page 185: ...witch 17 Lift Arm Reel Switches 17 Axle Hi Low Switch 18 Backlap Mow Variable Control Switch 19 PTO Switch 20 Start Cutting Unit and High Temp Relays 20 Glow Relay and Glow Plugs 21 Battery 22 Injection Pump ETR Solenoid 22 Gauges and Indicator Lights 23 High Temperature Shut Down Switch 24 Temperature Gauge Sender 24 Engine Oil Pressure Switch 25 Fuel Gauge Sender 25 Reel Motor Solenoids 26 4WD S...

Page 186: ...Wiring Schematics Engine Crank and Start Circuit Wiring Schematics Page 5 2 Reelmaster 335 D ...

Page 187: ...Engine Run Circuit Reelmaster 335 D Page 5 3 Wiring Schematics ...

Page 188: ...Engine Run and Mow Circuits Wiring Schematics Page 5 4 Reelmaster 335 D ...

Page 189: ...from a local supplier Continuity Tester Battery powered test lamp which is helpful in testing for continuity of circuits and electrical components when the current is off Volt Ohm Amp Meter The meter can test electrical components and circuits for current resistance or voltage draw Figure 1 Figure 2 Reelmaster 335 D Page 5 5 Special Tools ...

Page 190: ...Skin Over Grease Special non conductive grease which forms a light pro tective skin to help waterproof electrical switches and contacts Figure 3 Special Tools Page 5 6 Reelmaster 335 D ...

Page 191: ...g one component at a time Attempting to repair more than one system at one time will lead to confusion Possible Causes and Corrections in the troubleshooting charts should be checked in the order in which they are listed If the machine being repaired has any interlock switches by passed they must be reconnected for proper trou bleshooting and safety Condition Possible Cause Correction Starter sole...

Page 192: ...ed or damaged In line 30 amp starter solenoid fuse open Starter solenoid wiring loose cor roded or damaged Starter solenoid faulty Charge battery Replace battery if it will not hold a charge Clean and tighten or repair as necessary Check fuse and replace if fuse is open If fuse burns out often find and correct cause Replace fusible link Test temp switch and relay Re place if faulty Repair wiring T...

Page 193: ...r repair as if engine cranks cause of prob ing loose or corroded necessary lem is not in interlock system Injection pump ETR solenoid faulty Test solenoid Replace if faulty Glow relay faulty Test glow relay Replace if faulty Glow relay glow plug wiring loose Check wiring and connections corroded or damaged Clean tighten or repair as neces sary Glow plugs faulty Test glow plugs and replace if fault...

Page 194: ...Time delay relay faulty Test relay Replace if faulty Engine kills when traction pedal is depressed or PTO switch is turned ON Operator sitting too far forward on seat seat switch not depressed Seat hinge support pin or spring binding preventing seat switch from closing Instruct operator Repair seat pivot and support Seat switch is faulty or out of ad justment Test seat switch Adjust or re place if...

Page 195: ...ty Test HI Low switch Replace switch if faulty Make sure switch is screwed all the way in Axle Hi Low switch wiring loose Repair wiring corroded or damaged 4WD solenoid valve faulty Test 4WD solenoid valve Re place if faulty 4WD solenoid wiring loose cor Repair wiring roded or damaged Problem is not electrical See Troubleshooting section of Chapter 4 Hydraulic System Battery does not charge Loose ...

Page 196: ... switch faulty or out of adjust Test seat switch Adjust or re ment place if faulty Time delay relay faulty Test relay Replace if faulty Cutting unit runs but should not Lift arm Reel switch faulty Test reel switch Replace if faulty when raised but shuts off with Make sure switch is screwed in PTO switch all the way Check for damaged pivot shaft or bushings and repair if damaged Reel solenoid valve...

Page 197: ... justment not closing Hi Low switch essary in Low range Axle Hi Low switch faulty Test switch Replace if faulty Make sure switch is screwed all the way in Axle Hi Low switch wiring loose Repair wiring corroded or damaged PTO switch faulty Test switch Replace if faulty PTO switch wiring loose corroded Repair wiring or damaged Variable reel control in neutral N Check control and linkage Adjust posit...

Page 198: ...iately If engine does not crank cutting unit engagement PTO switch is operating correctly Proceed to step 3 3 Sit on seat Depress traction pedal in forward and reverse directions while trying to start engine If engine cranks while pedal is in forward or reverse position there may be a malfunction in interlock system Repair immediately If engine does not crank traction neutral switch is operating c...

Page 199: ... the component When testing electrical components for con tinuity with a volt ohm meter or continuity tester make sure that power to the circuit has been disconnected CAUTION Ignition Key Switch The ignition key switch has three positions OFF RUN and START The terminals are marked as shown The circuitry of the ignition switch is shown in the chart With the use of a continuity tester the switch fun...

Page 200: ...ch 3 Lower the seat The continuity tester should show no continuity NOTE Make sure the compression spring and pin holds the seat up off the seat switch when there is no operator on the seat 4 Have the operator sit on the seat slowly depressing the seat switch The continuity tester should show con tinuity as the seat approaches the bottom of its travel Relay Test To test the relay disconnect the re...

Page 201: ...for replacement and adjustment procedures NOTE Apply Loctite 271 or equivalent to threads of switch screws before installing 1 Figure 8 1 Traction neutral switch Eaton pump 1 Figure 9 1 Traction neutral switch Sundstrand pump Reel Switches The reel switches are normally closed N C switches that open when the lift arm is raised which pushes the switch ball in 1 Disconnect the switch wire connector ...

Page 202: ...ion 1 Figure 11 1 Axle Hi Low switch Backlap Mow Variable Control Switch The backlap mow variable reel speed control switch is normally open N O with the variable reel speed con trol in neutral position This prevents the cutting units from engaging with the variable speed control set to neutral The switch closes when the variable reel speed control is moved to the mow or backlap position which pus...

Page 203: ...wire connector from the switch terminals When the switch is ON there should be continuity between terminals A B only When the switch is OFF terminals C D and B E should show continuity 1 Figure 13 1 PTO switch Figure 14 1 PTO switch terminals Reelmaster 335 D Page 5 19 Testing ...

Page 204: ...ween the relay termi nals terminals 30 and 87 The relay should make and break continuity at terminals 30 and 87 as 12 V D C is connected and disconnected to terminal 85 with termi nal 86 connected to ground 1 Figure 15 1 Start relay 1 2 Figure 16 1 Cutting unit relay 2 High temp relay Figure 17 Testing Page 5 20 Reelmaster 335 D ...

Page 205: ...r from bat tery If the light glows check for power from ignition switch by moving to terminal 3 4 Glow plug test A Warm up the glow plugs then check for total draw of all four 4 glow plugs if draw is 48 amps all four 4 are OK if draw is 36 amps then one 1 is faulty if draw is 24 amps then two 2 are faulty if draw is 12 amps then three 3 are faulty if draw is 0 amps then all are faulty if draw is m...

Page 206: ...e solenoid 2 Remove the solenoid from the injector pump 3 Connect a 12 volt battery so that a wire from positive battery terminal is connected to switch terminal Touch a wire from the negative battery terminal to solenoid body The plunger should retract NOTE You can also test operation without removing the solenoid from the injector pump Listen for an audible click as the solenoid extends and retr...

Page 207: ...h is turned ON Test the lamp by disconnecting the wires and applying 12 V D C between the lamp wiring terminals Temperature Light The temperature light should come on only if the high temperature shut down switch and relay has stopped the engine coolant temperature above 221o F 105o C Test the lamp and relay by disconnecting the wire from high temperature shut down switch and grounding it against ...

Page 208: ...fire Figure 22 CAUTION 1 High temperature shut down switch 2 Temperature gauge sender Figure 23 Temperature Gauge Sender 1 Lower the coolant level in the engine and remove the temperature gauge sender 2 Put the switch in a container of oil with a thermometer and heat the oil 3 With an Ohm meter connected as shown the follow ing resistance readings should be indicated 90 5 117 5 ohm at 160o F 70o C...

Page 209: ...ring 4 Install test gauge in engine oil pressure switch port Start engine and check for 30 psi minimum at 1500 rpm If engine pressure is good replace switch If engine pressure is low DO NOT operate the engine 1 Figure 25 1 Engine oil pressure switch Fuel Gauge Sender 1 Disconnect wire and remove the fuel gauge sender from the fuel tank 2 Install an ohm meter between the terminal and base 3 With ar...

Page 210: ...es not retract after replacing solenoid coil replace the valve 1 Reel motor solenoid 4WD Solenoid 1 Disconnect the wire connector 2 Connect a 12 volt battery so the positive battery terminal is connected to colored solenoid lead Connect the negative battery terminal to black lead The valve spool should retract completely as 12 V D C is applied between leads 3 If valve spool does not operate proper...

Page 211: ...but above the plates inside the battery add water so the level is to the bottom of the cap tubes If the level is below the plates add water only until the plates are covered and then charge the battery After charging fill the battery to the proper level o F 16o tery posts Do not charge a frozen battery because it can explode and cause injury Let the battery warm to 60 C before connecting to a char...

Page 212: ... fuse is faulty It is recommended that you check for faulty fuses with a continuity tester not visually The starter circuit is also protected by a 30 amp in line fuse between the start relay and starter solenoid 1 2 3 4 Figure 31 1 ACC fuse 3 REEL fuse 2 RELAY fuse 4 RUN fuse FUSES 1 ACC 5A 2 RELAY 5A 3 REEL 30A 4 RUN 15A Repairs Page 5 28 Reelmaster 335 D ...

Page 213: ... terminal IMPORTANT The traction switch has three 3 ter minals If the two 2 wires are not connected to the COMMON and NORMALLY OPEN N O termi nals the engine will be unable to start and the safety interlock circuit will not function properly NOTE Apply Loctite 271 or equivalent to threads of switch screws before installing If the wires are not correctly installed to the switch the engine could sta...

Page 214: ...oid valve to malfunction 1 Figure 35 6 Connect electrical connector 1 Reel motor solenoid 4WD Solenoid Coil Replacement 1 Park machine on a level surface engage parking brake lower the cutting units and turn engine OFF 2 Disconnect solenoid electrical connector 3 Remove coil nut 4 Remove coil assembly 5 Install new coil assembly and secure with coil nut Apply Locktite 242 or equivalent to threads ...

Page 215: ...MATION 3 Wheel Bearing Service 6 Four Matic 4WD Operation 3 Front Axle Removal and Disassembly 8 ADJUSTMENTS 4 Transaxle Service 10 Brake Adjustment 4 Rear 4WD Axle Service 12 Rear Axle Toe In Adjustment 4 Transaxle Shift Linkage Adjustment 5 Reelmaster 335 D Page 6 1 Table of Contents ...

Page 216: ..._ ________________________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________ ____________________________________________________________________________________________...

Page 217: ...his causes the rear axle shaft 49 RPM 50 RPM 49 RPM 49 RPM Rear Axle Unlocked Locked Motor Shaft Rear Shaft speed to slow down As soon as the rear axle shaft is turning the same speed as the rear motor the roller clutch will engage and power will be transmitted from the rear motor to the rear wheels four wheel drive Fig 3A When the traction unit is turning the rear wheels swing out in a larger arc...

Page 218: ...uster 1 2 turn at a time until you get desired free travel in pedal 1 Figure 5 1 Brake rod adjuster Rear Axle Toe in Adjustment 1 Measure center to center distance at axle height at front and rear of steering tires Front measurement must be 1 4 in less than rear measurement 2 To adjust loosen clamps at both ends of tie rods 3 Rotate tie rod to move front of tire inward or outward 4 Tighten tie rod...

Page 219: ...roper dimension 4 Move axle shift lever forward to transport high speed position and verify that the dimension is correct 5 Move axle shift lever rearward to mow low speed position Start the engine and lower one cutting unit Turn on reel speed control and cutting unit engagement switch The cutting unit should engage When axle shift lever is moved to N or transport position the cutting unit should ...

Page 220: ...st the shoulder 2 7 Use No 2 general purpose lithium base grease containing E P additive Pack both bearings with grease Install one bearing into the cup on inboard side of wheel hub Lubricate the inside of the new lip seal and press it into the wheel hub IMPORTANT The lip seal must be pressed in so it is flush with the end of the hub The lip of the seal must be toward the bearing 8 Pack inside of ...

Page 221: ...n the nut until the nearest slot and hole in the spindle line up Reinstall the cotter pin to retain the slotted nut in place NOTE The correct end play of the adjusted assembly is 0 002 0 005 inches 3 Remove jack stands or blocks and lower machine to floor Figure 10 4 Put a coating of grease on the inside of the dust cap Install dust cap on end of wheel spindle 1 Cotter pin and slotted nut Reelmast...

Page 222: ...Front Axle Removal and Disassembly Figure 11 Special bearing crack in race must face down Figure 12 Repairs Page 6 8 Reelmaster 335 D ...

Page 223: ...te Item 1 and transaxle spacer Item 38 7 To remove axle from housing remove retaining ring Item 23 from outboard end of housing then tap lightly with a mallet from inside out A pressed on sealed ball bearing Item 24 will be on end of axle 8 Do steps 2 7 for axle housing on other side Front Axle Assembly Reverse steps 1 8 under Front Axle Disassembly IMPORTANT Outboard axle support bearings Fig 12 ...

Page 224: ...xle Service NOTE This illustration shows a differ ent hydrostatic drive mounting surface and differential than what is used on the Toro Reelmaster 335 D Figure 13 Figure 14 Repairs Page 6 10 Reelmaster 335 D ...

Page 225: ...if binding seems excessive 8 Check shift detent spring for tension and ball for wear 9 Check shifter rod grooves for wear Be sure snap ring sharp edges go away from shifter fork 10 Inspect shifter fork for straightness and wear 11 Check differential for loose or damaged parts 12 Check differential carrier ball bearings for wear and smoothness of rotation and replace if necessary Transaxle Assembly...

Page 226: ...Rear 4WD Axle Service l A B Ax e Housing Axle Housing Figure 17 Figure 18 Repairs Page 6 12 Reelmaster 335 D ...

Page 227: ...lder will come out together with the wheel shaft Item 21 2 Pull draglink arm or tie rod arm off final drive case Be sure to recover the thrust washer 3 Remove the bolts securing top cover Item 4 to gear case and remove the cover to expose the top end of final drive shaft Item 2 Drive lightly on the exposed shaft Figure 20 end so that the final drive case will slide off the gear case 4 Remove botto...

Page 228: ... for thrust washers between axle pivot and frame 2 Remove bolts Fig 23 Item 5 securing adapter to axle housing and remove adapter 3 Separate axle housing by removing bolts 4 Pull out differential shaft Fig 17 Item 14 from housing B 5 Remove differential gear assembly Fig 17 Items 3 11 from axle housing A 6 Pull out differential shaft from housing A Disassembling Sleeve Assembly 1 Remove sleeve Ite...

Page 229: ...way against the pinion shoulder Oil seal flush with case face Sleeve lock nut Sleeve Tapered roller Bearings Pinion shaft 3 Insert pinion shaft into sleeve Fit other inner race to shaft and install oil seal bushing Pinion shaft is now securely installed inside the sleeve Oil seal 4 Grease oil seal and install it between sleeve and bushing with garter spring facing toward hydraulic motor Make outer...

Page 230: ...the required thickness of shim by proceeding as follows 1 Apply grease to o rings Install o rings to sleeve then install sleeve assembly into adapter case 2 Put a straightedge on end of pinion shaft and measure distance between bottom of straightedge and face of adaptor case Fig 25B Subract 43 mm 1 69 in from measured distance Select shim s closest to result Figure 25B Example 43 18 mm measured di...

Page 231: ...4 mm 0 016 in 76 7310 Shim Between Differential and Axle Housing B After obtaining specified backlash determine amount of shims needed 1 Put the straightedge flat on the ball bearing Fig 28A 2 Read clearance A between axle housing A and straightedge 3 Put straightedge on axle housing B and read clear ances C and D Subtract D from C The difference between D and C is clearance B Fig 28B Figure 27 4 ...

Page 232: ...g sure the seal is properly aligned NOTE The steel part of this oil seal is so thin that the seal can distort at the time of installation 3 Insert final drive shaft into gear case bringing its large diameter end to top side and fitting pinion 14T onto splined end Install inner race of upper tapered roller bearing as shown 4 Fit bearing out race into gear case Apply sealant to mating face of holder...

Page 233: ...nal case by tighten reamer bolts to following torque value Torque specification 8 5 9 5 kg m 61 69 ft lb Installing Gear Case Assembly to Axle Housing 1 To check backlash between pinions 14T one on final drive shaft and one on differential shaft tempo rarily fit gear case to axle housing and tighten two bolts diametrically opposite DO NOT use black reamer bolt for this temporary assembly 2 Install...

Page 234: ...T and pinion 15T by installing dial indicator on tip of wheel shaft Adjust shim between bevel gear 29T and ball bearing if reading is outside of specification Bevel gear 29T backlash 0 2 0 4 mm 0 008 0 016 in Shim stock for this adjustment is available in the follow ing thicknesses Figure 35 6 After obtaining proper backlash remove bearing holder and install inner ball bearing on shaft Apply Figur...

Page 235: ...ers between axle pivot and frame 3 Install hydraulic motor to adaptor housing 4 Install wheels to axle Tighten lug nuts to a torque of 45 55 ft lb 5 Fill axle with SAE 80 90W EP gear lube Lubricant capacity is approximately 80 oz 2 5 U S qt 6 Check rear wheel toe in and adjust if necessary Rear wheel toe in 0 25 in Reelmaster 335 D Page 6 21 Repairs ...

Page 236: ...Repairs Page 6 22 Reelmaster 335 D ...

Page 237: ...ing the Bedknife Bedbar Assembly 12 Height of Cut Adjustment Floating Cutting Unit 6 Servicing the Reel Assembly 13 Quick Method for Changing Height of Cut Roller Removal and Installation 16 After Initial Set Up of a Floating Cutting Unit 8 Height of Cut Adjustment Fixed Cutting Unit 8 Adjusting Skids and Front Roller Fixed Head Cutting Unit 8 Reelmaster 335 D Page 7 1 Table of Contents ...

Page 238: ...4 vibration isolation bushings Bedknife to Reel Adjustment Two lockable lead screw adjusters at each side of the frame adjust the reel to bedknife contact Rear Roller 3 1 2 in 89 mm diameter steel roller has greaseable tapered roller bearings A double lip oil seal and wear sleeve isolates grit and moisture from the bearings Height of Cut 5 Blade 1 to 3 in 25 to 76 mm 7 Blade 1 2 to 1 3 4 in 9 5 to...

Page 239: ... D Parts Catalog Some tools may also be available from a local supplier Gauge Bar Assembly Use gauge bar to set final height of cut floating cutting unit with front roller only Figure 2 Handle Assembly For applying lapping compound to cutting units while keep hands a safe distance from the rotating reel Figure 3 Reelmaster 335 D Page 7 3 Special Tools ...

Page 240: ...ecure bedknife to bedbar With clean bedbar threads and new screws tighten to a torque of 250 in lb NOTE Remove all rust scale and corrosion from bed bar surface before installing bedknife DO NOT use and air impact wrench with this tool Figure 4 Special Tools Page 7 4 Reelmaster 335 D ...

Page 241: ...ht contact is felt and heard between the reel and bedknife Final adjustment should always be in the tightening clockwise direction D Tighten adjuster locking nuts when completed IMPORTANT Adjusted correctly the reel will cut paper approx 003 thick across its entire length The Reelmaster 335 D cutting units will provide opti mum mowing performance when adjusted and main tained correctly Keeping a p...

Page 242: ...m long Fig 8 and approximately 1 8 3 mm thicker than the desired height of cut under the reel and up against the bedknife cutting edge Fig 8 The reel not bedknife must contact the bar stock along its full length NOTE Using a bar 1 8 3 mm thicker than height of cut provides proper bedknife attitude heeled up in back required for excellent low height of cut perform ance D Loosen rear roller jam nuts...

Page 243: ...and position bar against bottom of front roller Fig 10 I Loosen front roller nuts and adjust both ends of the front roller until it contacts gauge bar at both ends With the gauge bar held firmly against the bottom of the rollers adjust the front roller so the screw head just slips over the lip of the bedknife Fig 10 Tighten front roller nuts IMPORTANT Set properly front and rear rollers will conta...

Page 244: ...fe 6 Adjust rear roller adjustment knobs and jam nuts until full length of the rear roller contacts the flat surface and the full length of the reel not bedknife contacts the bar stock Tighten rear roller knobs and jam nuts Figure 11 Adjusting Skids and Front Roller Fixed Head Cutting Unit After skid kit or front rollers are installed installation instructions are included with each option make th...

Page 245: ...nimum throttle Lower either 1 the center cutting unit 1 or 2 the left hand 2 cutting unit or 3 the right hand 3 cutting unit With the 2 3 cutting units up and latched automatically shut off and the 1 cutting unit down backlap the center 1 cutting unit from the rear of the machine with the long handled brush Backlap the 2 and 3 cutting units from the front of the machine C Wait for 2nd person s ins...

Page 246: ...eld onto the reel drive motor flange Fig 12 Be sure the widest portion of the shield is at the top NOTE Check to see that motor pulley set screws are tight on motor shaft before installing motor onto cutting unit Fig 13 2 Insert the reel drive motor pulley through the housing and slip the cutting unit drive belt over the pulley Fig 13 of water to remove all lapping material Allow the reel to dry a...

Page 247: ...otors have been mounted to the cutting units make sure hydraulic hoses lay flat and do not contact the frame of the machine when the cutting units are in the raised position There should also be sufficient slack SO hoses are above and not in contact with the floata tion kit If hoses appear twisted once the hydraulic motors have been mounted and the belts tightened loosen swivel nuts at the motor a...

Page 248: ...al on the mounting face of the bedbar that will affect a good match up with the bedknife 2 Before installation apply a coating of Never Seez or any material that will ease future disassembly of the bedknife mounting screws to the threads before instal lation 3 Use a torque wrench and special bedknife screw tool to complete tightening of the screws Fig 18 Tighten the screws to a torque of 250 in lb...

Page 249: ...ove the bedbar bed knife assembly Fig 20 3 Remove the inboard locknut from the adjuster pin the fasteners for the bracket and remove the adjusting handle assembly from the side plate Fig 20 Figure 19 1 Guard 4 Adjusting assembly 2 Mounting fasteners 5 Dust cap 3 Bedbar mounting assembly Figure 20 1 Locknut 4 Bearing housing 2 Belleville washer 5 Reel shaft 3 Shoulder bolt 6 Flange bushing Reelmast...

Page 250: ...bly and cone nut belleville washer and shoulder bolt securing the housing to the side plate Fig 22 Remove the housing 9 Slide the reel assembly out of the slots in the side Figure 21 plates 1 Drive housing cover removed 10 To remove the bearing and seals from the drive 2 Drive belt housing remove the retaining ring from inside the hous ing Pry the outer seal out of the belt drive case side Press t...

Page 251: ...le washer and rear housing mounting hole Slide the bolt through the side plate mounting hole Fig 20 Install the cone nut locknut onto the bolt Tighten the cone nut to 45 55 ft lbs 8 Align the drive pinon the reel shaft with the notch in the bearing inner race and slide the bearing housing over the opposite end of the reel shaft Insert the shoul der bolt and belleville washer through the rear beari...

Page 252: ... by sliding it off the shaft at both ends Fig 25 IMPORTANT When assembling a new roller to the cutting unit mount the roller so that the roller shaft locknut is on the right side of the cutting unit Fig 25 As viewed by the operator sitting on seat of machine This prevents the lock nut from loos ening during operation Figure 24 1 Guard 2 Roller adjustment housing 3 Side plate 4 Mounting fasteners F...

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Page 254: ...Commercial Products The Toro Company ...

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