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Toro Reelmaster 335-D Service Manual
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Toro Reelmaster 335-D Service Manual

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Preface
This publication provides the service technician with
information for troubleshooting, testing, and repair of
m a jo r
s y s t e m s
a nd
Reelmaster 335-D/3500-D
REFER TO THE TRACTION UNIT AND CUTTING
UNIT OPERATOR'S MANUALS FOR OPERATING,
MAINTENANCE AND ADJUSTMENT INSTRUC-
TIONS. Space is provided at the end of Chapter 2 in this
publication to insert the Operator's Manuals and Parts
Catalogs for your machine. Replacement Operator's
Manuals are available by sending complete 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.
Reelmaster
c o m po ne nt s
o n
t he
© The Toro Company - 1991, 1994, 1996, 2002
®
335-D/3500-D
This safety symbol means DANGER, WARN-
ING, or CAUTION, PERSONAL SAFETY IN-
STRUCTION. When you
carefully read the instructions that follow.
Failure to obey the instructions may result in
personal injury.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing or
repair of the machine.
IMPORTANT: The IMPORTANT notice will give im­
portant instructions which must be followed to
prevent damage to systems or components on the
machine.
Part No. 91772SL, Rev. C
Service Manual
see
this symbol,

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Summary of Contents for Toro Reelmaster 335-D

  • Page 1 Minneapolis, MN 55420 portant instructions which must be followed to prevent damage to systems or components on the The Toro Company reserves the right to change product machine. specifications or this publication without notice. © The Toro Company - 1991, 1994, 1996, 2002...
  • Page 2 This page is blank.

  • Page 3: Table Of Contents

    Table Of Contents Chapter 1 - Safety EATON PROPULSION PISTON PUMPS REPAIR INFORMATION (Traction/Mow Pump) Safety Instructions ......1 - 1 EATON GEAR PUMP REPAIR INFORMATION (Aux./Steering Pump) Chapter 2 - Product Records and Manuals...
  • Page 4 This page is blank.

  • Page 5: Chapter 1 - Safety

    While Operating......2 Safety Instructions The Reelmaster 335-D has been tested and verified for compliance with the B71.4-1984 specifications of the...
  • Page 6 6. Make sure interlock switches are adjusted correctly 8. Since diesel fuel is flammable, handle it carefully: so engine cannot be started unless traction pedal is in NEUTRAL and cutting units are DISENGAGED. A. Use an approved fuel container. B. Do not remove fuel tank cap while engine is hot 7.
  • Page 7 Fluid accidentally injected into the skin must be surgically removed within a few hours by a 36. Toro recommends that two people be used to back ­ doctor familiar with this form of injury or gangrene may lap reels. Each person has specific duties and must result.
  • Page 8 ® Safety Instructions Page 1 - 4 Reelmaster 335-D...

  • Page 9: Product Records

    Product Records Record information about your machine on the Product Insert the Operator’s Manuals and Parts Catalogs for Record Form. Use this information when referring to your Reelmaster 335-D or 3500-D at the end of this your machine. section. ®...

  • Page 10: Equivalents And Conversions

    Equivalents and Conversions Decimal and Millimeter Equivalents ___________________________________________________________________________________________________ Fractions Decimals Fractions Decimals ___________________________________________________________________________________________________ 1/64 0.015625 — 0.397 33/64 0.515625 — 13.097 1/32 ––––– 0.03125 — 0.794 17/32 –––– 0.53125 — 13.494 3/64 0.046875 — 1.191 35/64 0.546875 — 13.891 1/16 –––––––––––– 0.0625 —...

  • Page 11: Torque Specifications

    Torque Specifications Use these torque values when specific torque values The torque values listed below are for lubricated are not given. DO NOT use these values in place of threads. Plated threads are considered to be lubricated. specified values. Capscrew Markings and Torque Values - U.S. Customary SAE Grade Number ________________________________________________________________________________________________________________________________________________________ Capscrew Head Markings...

  • Page 12: Maintenance Interval Charts

    Maintenance Charts ® Page 2 - 4 Rev. A Maintenance Charts Reelmaster 335-D...
  • Page 13 ® Page 2 - 5 Rev. A Reelmaster 335-D Maintenance Charts...
  • Page 14 ® Page 2 - 6 Rev. A Maintenance Charts Reelmaster 335-D...
  • Page 15 ____________________ _______________________ ____________________ _______________________ Date Purchased: ____________________ Warranty Expires__________ Purchased From: ____________________ ____________________ ____________________ Contacts: Parts ____________________ Phone __________________ Service ____________________ Phone __________________ Sales ____________________ Phone __________________ See your TORO Distributor/Dealer for other Publications, Manuals, and Videos from The TORO Company.
  • Page 16 REELMASTER® 335-D and 3500-D Maintenance Schedule Minimum Recommended Maintenance Intervals: Maintenance Procedure Maintenance Interval & Service Type Every Every Every Every 800hrs Every 400hrs 200hrs Inspect Air Filter, Dust Cup, and Baffle 100hrs 50hrs A Level Lubricate All Grease Fittings Service ‡...
  • Page 17 REELMASTER® 335-D and 3500-D Daily Maintenance Check List Unit Designation:__________ Daily Maintenance: TORO ID#:_______-_______ (duplicate this page for routine use) Daily Maintenance Check For Week Of _____________ TUES THURS _____ _____ _____ _____ _____ _____ _____ Maintenance Check Item Safety Interlock Operation...
  • Page 19 Assembly of External Components ..60 Compression Test ..... . . 28 Page 3 - 1 Rev. B Reelmaster 335-D/3500-D Engine...

  • Page 20: Introduction

    335-D and TORO Distributors. Repair parts may be ordered by 3500-D mowers. TORO Part Number. If no parts list is available be sure to provide your dealer or distributor with the TORO Most repairs and adjustments require tools which are Model Number and Serial Number.

  • Page 21: Identification And Specifications

    1 - 3 - 4 - 2 ________________________________________________________________________________________________________________________ ________________________________ Electrical System 12 volt, negative ground, 55 AMP alternator with integral regulator. 12 volt - 1.4 Kw starter motor with integral solenoid, pinion shaft type. Page 3 - 3 Rev. B Reelmaster 335-D/3500-D Engine...

  • Page 22: Cylinder Head

    (+0.5) are stamped 1 in the area (a) Cylinder Head Gasket Thickness identification: Units: mm Identification (c) Identification (b) Thickness No notch 2 notches 1.48 3 notches 1.52 4 notches 1.58 5 notches 1.62 Figure 3 Page 3 - 4 Rev. B Engine Reelmaster 335-D/3500-D...

  • Page 23: Camshaft

    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 Page 3 - 5 Rev. B Reelmaster 335-D/3500-D Engine...

  • Page 24: Valve Springs

    + 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 Page 3 - 6 Rev. B Engine Reelmaster 335-D/3500-D...

  • Page 25: Valve Seats

    32.2 Repair 1 32.45 32.4 Repair 2 32.65 32.6 The protrusion j must be between 0 and 0.03 mm Dimension j is obtained by machining faces (x) and (y) Figure 10 Page 3 - 7 Rev. B Reelmaster 335-D/3500-D Engine...

  • Page 26: Cylinder / Piston Matching

    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 24.994 to 25 ø external ø 13.8 to 14.1 internal Page 3 - 8 Rev. B Engine Reelmaster 335-D/3500-D...

  • Page 27: Crankshaft

    Repair 1 26.80 2.405 Repair 2 26.90 2.455 Repair 3 27.00 2.505 Units: mm Oil Seal Contact Surface Figure 13 øg Tolerance – 0 – 0.087 Production 90.00 Repair 1 89.80 Page 3 - 9 Rev. B Reelmaster 335-D/3500-D Engine...

  • Page 28: Tightening Torques

    ________________________________________________________________________________________________________________________ ________________________________ Manifold screws ________________________________________________________________________________________________________________________ ________________________________ Alternator bracket * NOTE: 40 + 60° is tighten to 40 Nm then an additional 60° (60 degrees) of rotation (one flat of bolt head) Page 3 - 10 Rev. B Engine Reelmaster 335-D/3500-D...

  • Page 29: Special Tools

    Special Tools NOTE: Order special tools from the TORO SPECIAL Reelmaster 335-D or 3500-D Parts Catalog. Some tools TOOLS AND APPLICATIONS GUIDE (COMMERCIAL may also be available from a local supplier. PRODUCTS) . Some tools may be l isted in the...
  • Page 30 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 Page 3 - 12 Rev. B Engine Reelmaster 335-D/3500-D...
  • Page 31 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 Page 3 - 13 Rev. B Reelmaster 335-D/3500-D Engine...
  • Page 32 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 Page 3 - 14 Rev. B Engine Reelmaster 335-D/3500-D...
  • Page 33 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 Page 3 - 15 Rev. B Reelmaster 335-D/3500-D Engine...
  • Page 34 TOR70153H Injector Pump Gear Puller Loosen the nut on the injector pump gear, then use this TOR70153H tool to loosen the pulley from the tapered shaft on the injector pump. Figure 33 Page 3 - 16 Rev. B Engine Reelmaster 335-D/3500-D...

  • Page 35: Adjustments

    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 3 - 17 Rev. B Reelmaster 335-D/3500-D Engine...

  • Page 36: Troubleshooting

    Rectifier diode defective. Rectifier diode short-circuited. Battery voltage too high. In­line diode defective. Regulator defective. Poor connections. Alternator noisy. Rectifier diode short-circuited. Belt worn. Alternator mounting loose. Alternator pulley loose. Worn bearings. Page 3 - 18 Rev. B Engine Reelmaster 335-D/3500-D...

  • Page 37: Fuel Injectors

    End of injector body corroded Running temperature of engine Check thermostat too low Intermittent operation Run machine longer. Do not start and stop engine. (1) In these cases, replace the injector Page 3 - 19 Rev. B Reelmaster 335-D/3500-D Engine...

  • Page 38: Fuel Injection Pump

    Incorrect spray, or injectors out of Check, clean and adjust injectors adjustment Insufficient automatic advance Have pump repaired Discharge rates too high Have pump repaired Air intake restriction Check hoses and air cleaner Page 3 - 20 Rev. B Engine Reelmaster 335-D/3500-D...
  • Page 39 Check fuel lines and clamps Defective fuel injector Check injectors Jammed discharge valve Have pump repaired Engine will not stop Key switch defective Replace key switch Defective electric stop solenoid Check electric stop solenoid Page 3 - 21 Rev. B Reelmaster 335-D/3500-D Engine...

  • Page 40: Low Power

    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 Page 3 - 22 Rev. B Engine Reelmaster 335-D/3500-D...

  • Page 41: Noisy Engine

    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 Page 3 - 23 Rev. B Reelmaster 335-D/3500-D Engine...

  • Page 42: Pre-Heating

    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 Page 3 - 24 Rev. B Engine Reelmaster 335-D/3500-D...

  • Page 43: Smoke During Operation

    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 Page 3 - 25 Rev. B Reelmaster 335-D/3500-D Engine...

  • Page 44: Starting Problems

    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 Engine seized Faulty starter Faulty wiring Page 3 - 26 Rev. B Engine Reelmaster 335-D/3500-D...

  • Page 45: Testing And Inspection

    (Fig. 34). If the glow plug glows red-hot in 9 to 12 seconds, the glow plug is operating correctly. DO NOT leave on more than 20 seconds. 5. Replace any glow plugs that do not operate correctly. Page 3 - 27 Rev. B Reelmaster 335-D/3500-D Engine...

  • Page 46: Compression Test

    7. Repeat the test for the other three cylinders. Dif­ ference between cylinders should be no more than 5 bar (70 psi). 8. Connect the fuel stop solenoid electrical connector. 9. Install the glow plugs. Page 3 - 28 Rev. B Engine Reelmaster 335-D/3500-D...

  • Page 47: Injector Tests

    The point at which this fuel injection occurs is determined by the injection timing. If the nozzle is Page 3 - 29 Rev. B Reelmaster 335-D/3500-D Engine...
  • Page 48 (Fig. 36). straight 3. If the nozzle fails to spray properly, it must be cleaned, Figure 36 repaired or replaced. Page 3 - 30 Rev. B Engine Reelmaster 335-D/3500-D...

  • Page 49: Injection Pump Fuel Delivery Test

    C. Connect the fuel delivery pipe to the nozzle as- sembly so the tip of the nozzle is pointed away from 5. Repeat the test for the other cylinders. the engine. Tighten the fitting securely. Page 3 - 31 Rev. B Reelmaster 335-D/3500-D Engine...

  • Page 50: Thermostat Test

    Starts to open at: 81 C (178 7 mm (0.28 in.) full open at 88 C (190 3. If the thermostat fails to open, only partially opens, or sticks, it should be replaced. Figure 37 Page 3 - 32 Rev. B Engine Reelmaster 335-D/3500-D...

  • Page 51: Fuel System Service

    Lucas ROTO DIESEL service dealer - especially during vicing it. DO NOT spray water onto a hot injection the warranty period. Repairs by non-authorized dealers pump. WILL void the pump warranty. Page 3 - 33 Rev. B Reelmaster 335-D/3500-D Engine...

  • Page 52: Injector Service

    Clean each 9. Injector holder nut injector separately to matched parts are not mixed up. 10. Thread The needle should slide freely and fall in the nozzle by its own weight. Page 3 - 34 Rev. B Engine Reelmaster 335-D/3500-D...
  • Page 53 4. Moderately tighten each union, 25 Nm (18 ft-lb) max., on pump and injector. Over-tightening will distort the end of the injector line. 5. Connect fuel return pipe. Page 3 - 35 Rev. B Reelmaster 335-D/3500-D Engine...

  • Page 54: Timing Belt Replacement

    TDC Lock Pin tool and rotate the engine (clockwise) one revolution. Install the TDC Lock Pin, then install the bolts as instructed in steps 5 and 6. Figure 44 Page 3 - 36 Rev. B Engine Reelmaster 335-D/3500-D...
  • Page 55 (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. Figure 45 Page 3 - 37 Rev. B Reelmaster 335-D/3500-D Engine...

  • Page 56: Timing Belt Installation

    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. Figure 47 Page 3 - 38 Rev. B Engine Reelmaster 335-D/3500-D...
  • Page 57 LOCTITE. Install the bolt (Item 1) and washer (Item 2) and tighten to a torque of 40 Nm (30 ft-lb). C. Tighten the bolt 60° further (one flat). Figure 50 Page 3 - 39 Rev. B Reelmaster 335-D/3500-D Engine...

  • Page 58: Injection Pump Timing

    5. Remove the TDC Lock Pin tool TOR 70153N, then turn the crankshaft 1/4 to 1/3 turn in the opposite direc­ tion of running (counterclockwise as viewed from the timing belt end). Figure 53 Page 3 - 40 Rev. B Engine Reelmaster 335-D/3500-D...
  • Page 59 19. Remove TDC Lock Pin tool, three lock bolts, in­ TOR 70153N dicator and indicator bracket. Install pump cover plug. 20. Tighten injector lines. Figure 56 21. Install timing belt covers, clips and attachment nut. Page 3 - 41 Rev. B Reelmaster 335-D/3500-D Engine...

  • Page 60: Preparation For Engine Repair

    5. Loud noises in the engine. It is important to find the cause of the engine failure before beginning repair. Symptoms 2 and 4 in the above Page 3 - 42 Rev. B Engine Reelmaster 335-D/3500-D...

  • Page 61: Engine Removal And Installation

    Plug end of fuel line to prevent fuel 14. Remove muffler, brackets, coolant expansion tank leakage. Disconnect injector return hose. and accessories from engine as necessary. Drain oil from engine and remove engine oil filter. Page 3 - 43 Rev. B Reelmaster 335-D/3500-D Engine...
  • Page 62 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.

  • Page 63: Engine Overhaul

    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 Page 3 - 45 Rev. B Reelmaster 335-D/3500-D Engine...

  • Page 64: Injection Pump Removal

    WILL void the pump warranty. IMPORTANT: Clean the injection pump and the area around the injection pump before removing or ser­ vicing it. DO NOT spray water onto a hot injection pump. Figure 58b Page 3 - 46 Rev. B Engine Reelmaster 335-D/3500-D...

  • Page 65: Cylinder Head Removal

    Figure 60 4. Remove the pump (Fig. 61, Item 5) / drive chain / crankshaft sprocket (Item 7) assembly. NOTE: Item 6 ­ spacer is not used on engines used in TORO machines. Figure 61 Page 3 - 47 Rev. B...

  • Page 66: Crankshaft And Piston Removal

    10. Remove the piston pin circlips and separate the pistons from the connecting rods. 11. Remove the plugs (Fig. 63 and 64, Item 12) from the oil galleries. Figure 64 Page 3 - 48 Rev. B Engine Reelmaster 335-D/3500-D...

  • Page 67: Cylinder Head Overhaul

    Maximum bow: 0.7 mm. 7. Check the condition of the valve seats and guides, valve, valve springs, swirl chambers, camshaft, cam­ shaft bearings and all tapped holes. (See Identification and Specifications section.) Figure 67 Page 3 - 49 Rev. B Reelmaster 335-D/3500-D Engine...
  • Page 68 15. Install the camshaft, with the DIST mark at the timing gear end. 16. Progressively tighten the bearing caps to a torque of 17.5 Nm (13 ft-lb). The bearing caps have cast-in markings for correct installation. Figure 70 Page 3 - 50 Rev. B Engine Reelmaster 335-D/3500-D...

  • Page 69: Crankshaft Installation

    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 Page 3 - 51 Rev. B Reelmaster 335-D/3500-D Engine...
  • Page 70 C. Lower it slowly. D. Tighten the two bearing cap bolts (Item 6) finger tight. E. Remove the capscrew securing the tool to the main bearing cap and withdraw the tool horizontally. Figure 75 Page 3 - 52 Rev. B Engine Reelmaster 335-D/3500-D...

  • Page 71: Pistons And Connecting Rod Assembly

    (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). Figure 77 Page 3 - 53 Rev. B Reelmaster 335-D/3500-D Engine...

  • Page 72: Oil Seal Installation

    3. Withdraw the tool with a twisting movement. Figure 79 Oil Pump Installation 1. Install the key (Fig. 80, Item 6). 2. Install the pump (Item 7), drive chain and sprocket (Item 8) assembly. Figure 80 Page 3 - 54 Rev. C Engine Reelmaster 335-D/3500-D...

  • Page 73: Flywheel Installation

    1. Install the flywheel. Put Locket thread lock on the flywheel mounting bolts. 2. Install a TORFD86 flywheel locking tool. 3. Tighten the flywheel bolts to a torque of 50 Nm (37 ft-lb). 4. Remove the flywheel locking tool. Page 3 - 55 Rev. B Reelmaster 335-D/3500-D Engine...

  • Page 74: Cylinder Head Gasket Selection

    5. Install the cylinder head. 6. Carefully clean the threads of the cylinder head bolts with a brush. 7. Coat the bolt threads and washer contact faces with MOLYKOTE G RAPID. Figure 83 Page 3 - 56 Rev. B Engine Reelmaster 335-D/3500-D...

  • Page 75: Cylinder Head Tightening

    Set “on the rock” Inlet 4, Exhaust 4 Inlet 1, Exhaust 1 Check Inlet 1, Exhaust 1 Inlet 4, Exhaust 4 Inlet 2, Exhaust 3 Inlet 3, Exhaust 2 Figure 85 Page 3 - 57 Rev. B Reelmaster 335-D/3500-D Engine...
  • Page 76 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. Page 3 - 58 Rev. B Engine Reelmaster 335-D/3500-D...
  • Page 77 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. Figure 88 Page 3 - 59 Rev. B Reelmaster 335-D/3500-D Engine...

  • Page 78: Assembly Of External Components

    14. Install the exhaust manifold with new seals. 15. Install the intake manifold. 16. Remove the engine from the stand. 17. Install the clutch housing centering pin. Figure 90 18. Install the TDC sensor. Page 3 - 60 Rev. B Engine Reelmaster 335-D/3500-D...
  • Page 79 Break-in Engine 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. Page 3 - 61 Rev. B Reelmaster 335-D/3500-D Engine...
  • Page 80 Page 3 - 62 Rev. B Engine Reelmaster 335-D/3500-D...
  • Page 81 Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS ......2 TESTING ....... . 23 GENERAL INFORMATION .

  • Page 82: Specifications

    Specifications Item Description __________________________________________________________________________________________ Traction/Reel Drive Pump (Sundstrand-Sauer) Sundstrand-Sauer, tandem in-line variable axial piston pump 5000 ± 100 PSI Traction relief pressure 2540 ± 100 PSI Mow relief pressure 100 ± 25 PSI Charge pressure (remote charge relief valve) ________________________________________________________________________________________________________________________________________________________ Traction/Reel Drive Pump (Eaton) Eaton tandem in-line variable axial piston pump 5500 ±...

  • Page 83: General Information

    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 CAUTION tions or mishandling during operation or maintenance. These conditions can cause damage or premature de ­ Before disconnecting or performing any work terioration.
  • Page 84 SAE Straight Thread O-Ring Port - Non-adjustable (Fig. 4) 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 fitting shows signs of leakage. 3.
  • Page 85 Hydraulic Schematic - Two (2) Wheel Drive...
  • Page 86 Hydraulic Schematic - Four (4) Wheel Drive...

  • Page 87: Hydraulic Flow Diagrams

    Hydraulic Flow Diagrams ® Reelmaster 335-D Page 4 - 7 Hydraulic Flow Diagrams...
  • Page 88 ® Hydraulic Flow Diagrams Page 4 - 8 Reelmaster 335-D...
  • Page 89 ® Reelmaster 335-D Page 4 - 9 Hydraulic Flow Diagrams...
  • Page 90 ® Hydraulic Flow Diagrams Page 4 - 10 Reelmaster 335-D...
  • Page 91 ® Reelmaster 335-D Page 4 - 11 Hydraulic Flow Diagrams...
  • Page 92 NOTE: Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS) . Some tools may be listed in the Reelmaster 335-D Parts Catalog. Some tools may also be available from a local supplier. Hydraulic Pressure Test Kit Used to take various pressure readings for diagnostic tests.
  • Page 93 You must have o-ring face seal (ORFS) adapter fittings 4. HIGH PRESSURE GAUGE: High range gauge to for this tester to use it on the Reelmaster 335-D. accommodate pressure beyond the capacity of the low pressure gauge, 0 - 5000 PSI.
  • Page 94 Troubleshooting The cause of an improperly functioning hydraulic sys­ system could lead to extensive internal component tem is best diagnosed with the use of proper testing damage. equipment and a thorough understanding of the com ­ plete hydraulic system. The charts that follow contain detailed information to assist in troubleshooting.
  • 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.
  • 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 problem. Check for faulty front axle HI/LOW switch, four wheel drive solenoid or wiring and repair if necessary.

  • Page 97: Mowing Circuit

    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.
  • 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 adjust control linkage as necessary.
  • 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 bedknife to reel contact.
  • 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.
  • 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 damaged parts. ________________________________________________________________________________________________________________________________________________________ Lift cylinder damaged.

  • Page 102: Steering Loss

    Cutting Unit(s) Lower or Raise Too Quickly Cause Correction __________________________________________________________________________________________ Missing or improperly installed cylinder port orifice. Properly install orifice between fitting and lift port of hydraulic lift cylinder(s). NOTE: Orifice must be in­ stalled at least 10 - 12 revolutions to avoid interfer­ ence with adapter fitting.

  • Page 103: Testing

    Testing The most effective method for isolating problems in the 1. Thoroughly clean the machine before disconnecting hydraulic system is by using hydraulic test equipment or disassembling any hydraulic components. Always such as pressure gauges and flow meters in the circuits keep in mind the need for cleanliness when working on during various operational checks.
  • Page 104 TEST NO. 1: Checking Traction Circuit Working Pressure or Relief Pressure WORKING Pressure Check: 1. Make sure hydraulic oil is at normal operating tem­ perature by operating machine for approximately 10 mines. 2. Lower cutting units, engage parking brake and stop the engine.

  • Page 105: Test No. 2: Checking Counterbalance Pressure

    TEST NO. 2: Checking Counterbalance Pressure 1. Make sure hydraulic oil is at normal operating temperature by operating machine for approximately 10 minutes. 2. Lower cutting units, engage parking brake and stop the engine. 3. Remove access cover from in front of auxiliary pump. 4.
  • Page 106 TEST NO. 3: Checking Mowing Circuit Working Pressure or Relief Pressure WORKING Pressure Check: 1. Make sure hydraulic oil is at normal operating temperature by operating machine for approximately 10 minutes. 2. Lower cutting units, engage parking brake and stop the engine.

  • Page 107: Test No. 3: Checking Mowing Circuit

    TEST NO. 4: Checking Mowing Circuit Flow 1. Make sure hydraulic oil is at normal operating temperature by operating machine for approximately 10 minutes. 2. Start the engine and lower the center cutting unit to the ground. 3. Turn the engine OFF. 4.
  • Page 108 TEST NO. 5: Checking Reel Motor Efficiency 1. Make sure hydraulic oil is at normal operating temperature by operating machine for approximately 10 minutes. 2. Start the engine and lower the cutting unit to be checked. 3. Turn the engine OFF and engage the parking brake. 4.
  • Page 109 TEST NO. 6: Checking Steering Circuit Working Pressure or Relief Pressure WORKING Pressure Check: 1. Make sure hydraulic oil is at normal operating temperature by operating machine for approximately 10 mines. 2. Lower cutting units, engage parking brake and stop the engine.
  • Page 110 TEST NO. 7: Checking Lift Circuit Working Pressure or Relief Pressure WORKING Pressure Check: 1. Make sure hydraulic oil is at normal operating tem­ perature by operating machine for approximately 10 minutes. 2. Lower cutting units, engage parking brake and stop the engine.
  • Page 111 TEST NO. 8: Checking Charge Pressure for Traction and Mowing Circuits 1. Make sure hydraulic oil is at normal operating tem­ perature by operating machine for approximately 10 mines. 2. Lower cutting units, engage parking brake and stop the engine. 3.

  • Page 112: Test No. 9: Checking Traction Circuit Rear Motor Pressure (4Wd Only)

    TEST NO. 9: Checking Traction Circuit Rear Motor Pressure (4WD Only) WORKING Pressure Check: 1. Make sure hydraulic oil is at normal operating tem­ perature by operating machine for approximately 10 mines. 2. Lower cutting units, engage parking brake and stop the engine.

  • Page 113: Adjustments

    Adjustments Traction Pump Neutral Adjustment The machine must not “creep” when traction pedal is released. If it does creep, an adjustment is required. 1. Park machine on a level surface and shut engine off. Make sure transaxle is engaged in HI position. Depress only the right brake pedal and engage the parking brake.

  • Page 114: Reel Speed Control Adjustment

    Reel Speed Control Adjustment 1. Operate machine with cutting units engaged to make sure hydraulic oil is at normal operating temperature. 2. Park machine on a level surface and engage parking brake. Raise center and left-hand cutting units, then lock in position with transport latches.

  • Page 115: Repairs

    Repairs Removing Hydraulic System Components 1. Thoroughly clean the machine before disconnecting, 3. If a pump was disconnected or removed, prime removing or disassembling any hydraulic components. system before operating. Disconnect fuel stop solenoid Always keep in mind the need for cleanliness when electrical connector on engine to prevent fuel delivery working on hydraulic equipment.

  • Page 116: Sundstrand Tandem Pump Repairs

    Sundstrand Tandem Pump Repairs Shaft Seal Replacement Figure 28 1. Retaining ring 3. Seal carrier 4. Lip seal 2. O-ring 1. Park machine on a level surface, lower cutting units, 6. Put seal carrier in an arbor press and press out old engage parking brake and stop the engine.

  • Page 117: Trunnion Seal Replacement

    Trunnion Seal Replacement Figure 29 1. Hex tapping screw (4) 3. O-ring 5. Swashplate control shaft 2. Trunnion seal cover 4. Seal 6. Spacer, shim & bearing 1. Park the machine on a level surface, lower cutting 7. Using an arbor press, press seal into position from units, engage parking brake and stop the engine.

  • Page 118: Check And High Pressure Relief Valves

    Check and High Pressure Relief Valves Figure 30 1. Traction check/high pressure relief valve 2. Reel check/high pressure relief valve 1. Park the machine on a level surface, lower cutting 4. The valve cartridge is retained in the special plug by units, engage parking brake and stop the engine.

  • Page 119: Charge Pressure Relief Valve

    Charge Pressure Relief Valve Figure 31 1. Charge pressure relief valve 1. Park the machine on a level surface, lower cutting 5. Inspect the poppet and mating seat in the end cap for units, engage parking brake and stop the engine. damage or foreign material.

  • Page 120: Disassembly Of Sundstrand Tandem Pump

    Disassembly of Sundstrand Tandem Pump Figure 32 1. Capscrew 9. Valve plate (R.H.) 17. Bearing 2. Washer 10. Valve plate pin 18. Retaining ring 3. Pump housing 11. Cylinder block assembly 19. Drive shaft 4. Pump housing 12. Pistons 20. Bearing 5.
  • Page 121 5. Carefully remove valve plates from center section. It Inspection and Replacement of Parts may be necessary to pry valve plates off with a small screwdriver. 17. After disassembly, thoroughly clean all parts in a suitable solvent. Replace all o-rings, gaskets and seals. 6.

  • Page 122: Assembly Of Sundstrand Tandem Pump

    Assembly of Sundstrand Tandem Pump Figure 33 1. Capscrew 9. Valve plate (L.H.) 17. Bearing 2. Washer 10. Valve plate pin 18. Retaining ring 3. Pump housing 11. Cylinder block assembly 19. Drive shaft 4. Pump housing 12. Pistons 20. Bearing 5.
  • Page 123 10. Assemble each cylinder block kit by installing piston 15. Assemble rear pump section onto center section assemblies into the slipper guide. Lubricate pistons and (with valve plate installed). Align drive coupling splines cylinder block bores. Install assembled guide and pis­ while assembling.
  • Page 124 ® Sundstrand Tandem Pump Repairs Page 4 - 44 Reelmaster 335-D...
  • Page 185 Chapter 5 Electrical System Table of Contents WIRING SCHEMATICS ..... . 2 Start, Cutting Unit and High Temp. Relays ..20 Engine Crank and Start Circuit .

  • Page 186: Wiring Schematics

    Wiring Schematics Engine Crank and Start Circuit ® Wiring Schematics Page 5 - 2 Reelmaster 335-D...

  • Page 187: Engine Run Circuit

    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: Special Tools

    Special Tools NOTE: Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS) . Some tools may be available 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.
  • 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: Troubleshooting

    Troubleshooting Study the operating characteristics preceding the elec­ trical failure to help identify the area of difficulty. Try to isolate the failure to a specific functional system; then CAUTION check that area, repairing one component at a time. Attempting to repair more than one system at one time Remove all jewelry, especially rings and will lead to confusion.
  • Page 192 Starting Problems (continued) Condition Possible Cause Correction __________________________________________________________________________________________ Nothing happens when start at- Battery is dead. Charge battery. Replace battery if tempt is made. it will not hold a charge. Loose or corroded battery cables. Clean and tighten or repair as Loose or corroded ground.
  • Page 193 Starting Problems (continued) Condition Possible Cause Correction ___________________________________________________________________________________________ Engine cranks, but does not start Injection pump ETR solenoid wir- Clean and tighten or repair as (if engine cranks, cause of prob ­ ing loose or corroded. necessary. lem is not in interlock system). Injection pump ETR solenoid faulty.

  • Page 194: General Run And Transport Problems

    General Run and Transport Problems Condition Possible Cause Correction __________________________________________________________________________________________ Engine continues to run (but Seat switch plunger depressed Check for seat support spring should not) when traction pedal with no operator on seat. that is broken, missing or stuck in depressed with no operator on down position.
  • Page 195 General Run and Transport Problems (continued) Condition Possible Cause Correction ___________________________________________________________________________________________ 4WD does not engage. Axle in Hi range. Axle must be in Low range for 4WD to engage. Axle HI/Low switch faulty. Test HI/Low switch. Replace switch if faulty. Make sure switch is screwed all the way in.
  • Page 196 Cutting Unit Operation Problems Condition Possible Cause Correction __________________________________________________________________________________________ Engine continues to run (but Seat switch plunger depressed Check for seat support spring should not) when PTO switch is with no operator on seat. that is broken, missing or stuck in ON with no operator on the seat.
  • Page 197 Cutting Unit Operation Problems (continued) Condition Possible Cause Correction ___________________________________________________________________________________________ No cutting units engage. Axle in Hi range. Axle must be in Low range for cut­ ting units to operate. “Reel” fuse open. Check fuse and replace if fuse is open.
  • Page 198 Verify Interlock System Operation The purpose of the interlock system is to prevent the 2. Sit on seat. Move cutting unit engagement (PTO) engine from cranking or starting unless the traction switch to ON position. Try to start engine. If engine pedal is in NEUTRAL and the cutting unit engagement cranks, there may be a malfunction in interlock system.

  • Page 199: Testing

    Testing This section will define components, and the tests that can be performed on those components, when those parts are disconnected from the electrical system. CAUTION For accurate resistance and/or continuity checks, When testing electrical components for con­ electrically disconnect the component being tested from tinuity with a volt-ohm meter or continuity the circuit (e.g.

  • Page 200: Seat Switch, Relay And Time Delay Capacitor

    Seat Switch, Relay and Time Delay Capacitor The seat switch is a normally open (N.O.) switch that closes when the operator is on the seat. With no opera ­ tor on the seat, there is an open circuit to the time delay capacitor and relay coil.

  • Page 201: Traction (Neutral) Switch

    Traction (Neutral) Switch The traction switch is a normally closed and opens when traction pedal is depressed in either direction. IMPORTANT: The traction switch has three (3) ter ­ minals. Make sure the wires are connected to the “COMMON” and “N.O.” terminals. Test the switch by disconnecting the wires from the switch terminals and connecting a continuity tester across the COMMON and N.O.

  • Page 202: Axle Hi/Low Switch

    Axle Hi/Low Switch The axle hi/low switch is normally open (N.O.) when the transaxle is in neutral or hi range. This prevents the cutting units or 4WD from engaging while the transaxle is neutral or hi range. The switch closes when the axle shift rod is moved to low range, which pushes the switch button in.

  • Page 203: Pto Switch

    PTO Switch To test the PTO switch independent of wiring harness, disconnect 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. Figure 13 1.

  • Page 204: Start, Cutting Unit And High Temp. Relays

    Start, Cutting Unit and High Temp. Relays To test the relay, disconnect the relay wire connector and install a continuity tester between 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...

  • Page 205: Glow Relay And Glow Plugs

    Glow Relay and Glow Plugs 1. Attach an amp meter to glow plug circuit. Turn ignition switch to ON. Meter may have an initial reading as high as 100 amps. A. If amp meter shows a reading for 5 to 12 seconds, the glow relay is operating.

  • Page 206: Battery

    Battery Use a hydrometer to test the battery. Charge the battery if necessary (see Battery Service). Electrolyte specific gravity Fully charged: 1.250 - 1.280 Discharged: less than 1.240 Figure 20 Injection Pump (ETR) Solenoid ® The Reelmaster 335-D has an energize-to-run (ETR) fuel stop solenoid.

  • Page 207: Gauges And Indicator Lights

    Gauges and Indicator Lights Oil Pressure Light Temperature Light Oil pressure lamp should come on when the ignition key The temperature light should come on only if the high switch is in the RUN position with the engine not running temperature shut-down switch and relay has stopped or if the oil pressure switch closes during operation - oil the engine - coolant temperature above 221...

  • Page 208: High Temperature Shut-Down Switch

    High Temperature Shut-Down Switch 1. Lower the coolant level in the engine and remove the high temperature shut-down switch. 2. Put the switch in a container of oil with a thermometer and heat the oi 3. The switch is normally open (N.O.) and should close at approximately 221 F (105 C).

  • Page 209: Engine Oil Pressure Switch

    Engine Oil Pressure Switch The switch is normally closed (NC) and opens with pressure. The switch opens at approximately 8 psi. 1. Turn ignition key switch ON. Oil pressure lamp should be on. If bulb is not on: 1. Disconnect wire from switch and touch wire to a good ground, such as the engine block.

  • Page 210: Reel Motor Solenoids

    Reel Motor Solenoids 1. Disconnect the wire connector. 2. Connect a 12 volt battery so the positive (+) battery terminal is connected to lead of the wiring connector and the negative (–) battery terminal to the other lead. The valve spool should retract completely as 12 V.D.C is applied between leads.

  • Page 211: Repairs

    Repairs IMPORTANT: Before welding on the machine, dis ­ connect both battery cables from the battery and disconnect the terminal connector from the alterna ­ tor to prevent damage to the electrical system. Battery Service Electrolyte Specific Gravity IMPORTANT: To prevent damage to electrical com ­ ponents, do not operate the engine with the battery Fully charged: 1.250 - 1.280 cables disconnected.

  • Page 212: Fuses

    Fuses The electrical system is protected by twelve (4) fuses located under the control panel to the operator’s right. NOTE: It is not always possible to see if a fuse is faulty. It is recommended that you check for faulty fuses with a continuity tester, not visually.

  • Page 213: Traction (Neutral) Switch Replacement

    Traction (Neutral) Switch Replacement 1. Remove the two wires that are connected to the traction switch. 2. Have a helper push the traction pedal down into either the FORWARD or REVERSE position; this will take the switch arm tension off of the switch. Loosen two (2) screws and remove the switch.

  • Page 214: Reel Motor Solenoid Coil Replacement

    Reel Motor 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 nut from solenoid. 4. Remove cover and solenoid coil. 5. Install new solenoid coil and secure with nut. Apply “Locktite 242"...
  • Page 215 Chapter 6 Axles and Brakes Table of Contents SPECIFICATIONS ......2 REPAIRS ....... . . 6 GENERAL INFORMATION .

  • Page 216: Specifications

    Specifications Item Specification __________________________________________________________________________________________ Tire pressure 15 - 20 PSI front and rear ________________________________________________________________________________________________________________________________________________________ Wheel bolt torque 45 - 55 ft-lb ________________________________________________________________________________________________________________________________________________________ Front axle hub nut torque 300 - 350 ft-lb ________________________________________________________________________________________________________________________________________________________ Transaxle adapter plate screw torque 65 ft-lb ________________________________________________________________________________________________________________________________________________________ Front axle housing cap screw torque 100 ft-lb ________________________________________________________________________________________________________________________________________________________...

  • Page 217: General Information

    General Information Four-Matic 4WD Over-Running Clutch Operation There are two hydraulic drive motors on the Reelmaster 335-D, 4WD; one for the front axle and one for the rear Locked 49 RPM axle. The drive for the rear axle incorporates an OVER- Unlocked RUNNING (ROLLER) CLUTCH THAT TRANSMITS POWER...

  • Page 218: Adjustments

    Adjustments Brake Adjustment Adjust service brakes when there is more than 1.5 in. “free travel” of brake pedal, or when brakes do not work effectively. Free travel is the distance the brake pedal moves before braking resistance is felt. To reduce free travel of brake pedals, tighten nut on brake rod adjuster, 1/2 turn at a time, until you get desired “free travel”...

  • Page 219: Transaxle Shift Linkage Adjustment

    Transaxle Shift Linkage Adjustment 1. Remove steering tower cover. Raise and securely lock the front cutting unit in raised transport position. Measure from end of shaft to edge of transaxle. 2. Move axle shift lever forward to transport (high speed) position.

  • Page 220: Repairs

    Repairs Wheel Bearing Service (2WD Rear Axle) 1. Jack up rear of machine until tire is off the floor. 7. Use No. 2 general purpose lithium base grease Support machine with jack stands or blocks to prevent containing E.P. additive. Pack both bearings with it from falling.
  • Page 221 Adjusting Rear Wheel Bearings 1. Remove dust cap from end of wheel spindle. Remove cotter pin retaining slotted nut in place. 2. Rotate the wheel by hand and tighten the slotted nut until the bearing binds SLIGHTLY. Then, loosen the nut until the nearest slot and hole in the spindle line up.

  • Page 222: Front Axle Removal And Disassembly

    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 Front Axle Removal with a mallet from inside out. A pressed on, sealed ball bearing (Item 24) will be on end of axle. 1. Drain oil from transaxle. 8. Do steps 2 - 7 for axle housing on other side. 2.

  • Page 224: Transaxle Service

    Transaxle 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 Transaxle Disassembly Transaxle Assembly 1. Clean all exterior surfaces of transaxle. Reverse steps 1 - 8 under Transaxle Disassembly, watching out for the following: 2. Put the transaxle on a work bench with cover side up. Remove screws. Lift cover (Fig. 14, Item 16) off and 1.

  • Page 226: Rear 4Wd Axle Service

    Rear 4WD Axle Service Ax e Housing ( Axle Housing ( Figure 17 Figure 18 ® Repairs Page 6 - 12 Reelmaster 335-D...
  • Page 227 Disassembly The two gear cases, right and left can be removed from the housing without requiring the entire axle to be dis­ assembled. 1. Remove tie rod by disconnecting rod end ball joint on each end. Disconnect hydraulic cylinder rod end from drag link arm.
  • Page 228 Install seal with garter spring facing towards hydraulic motor Figure 23 Disassembling Axle Housing 4. Pull out differential shaft (Fig. 17, Item 14) from housing (B). 1. Remove axle from machine before disassembling: 5. Remove differential gear assembly (Fig. 17, Items A.
  • Page 229 Inspection Clean the disassembled parts by washing in cleaning solvent. Inspect gears and pinions to be sure their teeth are in good condition. Check to be sure that each bearing rotates smoothly. Examine housings for cracks. Reassembly Replace damaged or worn parts as necessary. Oil or grease the surfaces of rotating or sliding parts before assembling.
  • Page 230 Adjusting Pinion Shaft Cone Center “Cone Center” is the distance from the mating face of axle housing to end face of pinion (Fig. 25A). This distance can be increased or decreased by installing removing shims. 43 ± 0.05mm Cone center specification (1.69 ±...
  • Page 231 Adjusting Backlash 0.25 ∼ 0.35 mm Backlash specification (0.010 ∼ 0.014 in.) Adjust shim thickness (between bearing housing of axle housing (A) and bearing) to get specified backlash. Shim stock for this adjustment is available in these thicknesses: Thickness Part No. Shim set 77-4000 0.1 mm (0.004 in.)
  • Page 232 Assembling Axle Housing 1. Coat mating faces of two housings (A) and (B) with sealant and attach selected shim to face of housing (B). Put the two housings together and fasten them by tightening bolts to following torque value: 2.5 ∼ 3.0 kg-m Torque specification (18 ∼...
  • Page 233 Installing Drag Link and Tie Rod Arm 1. Carefully insert bushing into arm. 2. Put arm into position over holder, fitting it to final case and secure to case with bolts. 3. Check thrust clearance. Proper thrust clearance is 0 to 0.2 mm (0.008in.). If necessary reduce clearance to specification by shimming.
  • Page 234 4. After obtaining proper pinion backlash, grease o-ring and fit it to mating face of axle housing. Secure gear case to housing by tightening bolts to the following torque value: 5.0 ∼ 6.0 kg-m Torque specification (36 ∼ 43 ft-lb) Reassembling Wheel Shaft 1.
  • Page 235 Installing Axle on Machine 1. Support axle under machine with a jack. 2. Install axle pivot pin to secure axle to frame. Make sure to install thrust washers between axle pivot and frame. 3. Install hydraulic motor to adaptor housing. 4.
  • Page 236 ® Repairs Page 6 - 22 Reelmaster 335-D...
  • Page 237 Chapter 7 Cutting Units Table of Contents SPECIFICATIONS ......2 REPAIRS ....... . . 9 SPECIAL TOOLS .

  • Page 238: Specifications

    Specifications 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.

  • Page 239: Special Tools

    Special Tools Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS) Some tools may be listed in the Reelmaster 335-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).
  • Page 240 Bedknife Screw Tool Fits Toro bedknife attaching screws. Use with torque wrench to secure 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...

  • Page 241: Adjustments

    (approx. .003" thick) across its entire length. quality of cut had previously been acceptable. The Reelmaster 335-D cutting units will provide opti­ NOTE: A 3/4" wrench is required for making the reel to mum mowing performance when adjusted and main ­...

  • Page 242: Height Of Cut Adjustment (Floating Cutting Unit)

    Height-of-Cut Adjustment (Floating Cutting Unit) Overview of Procedure: 1. Adjust reel to bedknife contact 2. Level rear roller to reel 3. Final height-of-cut adjustment using gauge bar. STEP 1 - Adjust Reel to Bedknife Contact A. Adjust reel to bedknife contact on all cutting units. (Refer to Adjusting Reel To Bedknife Contact).
  • Page 243 F. Raise cutting units and lock in the transport posi­ tion. Shut off the engine and remove the key. G. Use gauge bar (Toro Part No. 59-7900) to set final height-of-cut by adjusting front roller only. H. Loosen the gauge bar jam nut and adjust the screw to set dimension between underside of screw head and gauge bar for desired height-of-cut.

  • Page 244: Quick Method For Changing Height Of Cut After Initial Set Up Of A Floating Cutting Unit

    Quick Method For Changing Height-of-Cut After Initial Set Up of a Floating Cutting Unit If the reel to bedknife adjustment has been set (STEP 1) and the rear roller leveled to the reel (STEP 2), the 335-D cutting unit may be quickly changed from one height-of-cut to another by using the gauge bar (Part #59-7900) and adjusting the front roller only.

  • Page 245: Repairs

    INJURY. to retain the deflector in the raised position. 1st persons duties (Operator): B. Dip 3 in. (76 mm) paint brush attached to Toro Part No. 29-9200 Handle Assembly into lapping A. Sit on the seat and engage parking brake.

  • Page 246: Hydraulic Motor Installation

    F. Upon completion, stop the reel and turn off the engine. Remove the key from the ignition switch. NOTE: See the Toro Sharpening Manual (Part #80-300) Wash the unit thoroughly with a low pressure stream for additional backlapping/sharpening information.
  • Page 247 3. Insert the two (2) reel drive motor mounting bolts (heads on inside of the drive housing - flat washer on top bolt) through the reel motor flange holes. Thread the locknuts onto the bolts. Rotate reel motor upward in the slotted hole in the housing to tension the drive belt and tighten the fasteners (Fig.

  • Page 248: Servicing The Bedknife/Bedbar Assembly

    Servicing the Bedknife/Bedbar Assembly NOTE: The bedbar on each 335-D cutting unit has a precision ground mounting surface to provide an excel ­ lent fit with a bedknife. Backlapping of replacement bedknives is often sufficient to achieve an excellent cutting edge with minimum material removed. Bedknife/Bedbar Removal: 1.

  • Page 249: Servicing The Reel Assembly

    Servicing the Reel Assembly Disassembly: 1. Remove the guards from each end of the cutting unit and the front and rear roller assemblies (Fig. 19). 2. Remove the shoulder bolts, bushings and spacers from each end of the unit and remove the bedbar/bed- knife assembly (Fig.
  • Page 250 4. Disassemble the cone nut from the shoulder bolt securing the bearing housing to the side plate, remove the belleville washer and bolt and slide the bearing housing off the reel shaft (Fig. 21). 5. Disassemble the cover from the drive housing and remove the drive belt from the housing (Fig.
  • Page 251 Assembly: 9. Install the woodruff key in the drive housing end of the reel shaft and install the driven pulley onto the shaft. 1. Inspect the flange bushings in the mounting holes for the drive housing and bearing housing for wear 10.

  • Page 252: Roller Removal And Installation

    Roller Removal and Installation 1. Remove the fasteners securing the guard and roller adjustment housing to the side plate (Fig. 24) or un ­ screw the upper cone nut and drop the threaded rod out of the adjustment housing (Fig. 25). 2.
  • Page 253 This page is blank.
  • Page 254 Commercial Products © The Toro Company...

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