ProLine H800 Rotary Mower

Toro ProLine H800 Rotary Mower User manual

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FormNo.19241SLRevA
ProLineH800
(Models31050and31050TE)
©2020—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
OriginalInstructions(EN)
Contactusatwww.Toro.com.
AllRightsReserved
RevisionHistory
RevisionDateDescription
A
06/2020
Initialissue.
RevisionHistoryPage2
ProLineH800
19241SLRevA
ReaderComments
TheToroCompanyT echnicalAssistanceCentermaintainsacontinuous
efforttoimprovethequalityandusefulnessofitspublications.Todothis
effectively,weencourageuserfeedback.Pleasecommentonthecompleteness,
accuracy,organization,usability,andreadabilityofthismanualbyane-mail
orMailto:
TechnicalPublicationManager,Commercial
TheToroCompany
8111LyndaleAvenueSouth
Bloomington,MN55420-1196
Phone:+1952-887-8495
ProLineH800
Page3
ReaderComments
19241SLRevA
NOTES:
NOTES:
Page4
ProLineH800
19241SLRevA
Preface
Thepurposeofthispublicationistoprovidetheservicetechnicianwiththe
informationfortroubleshooting,testing,andrepairofthemajorsystemsand
componentsontheProLineH800.
RefertotheOperator’sManualsforoperating,maintenance,andadjustment
instructions.SpaceisprovidedinChapter2(page2–1)ofthisbooktoinsertthe
Operator’sManualsandPartsCatalogforyourmachine.Additionalcopiesofthe
Operator’sManualsandPartsCatalogsareavailableatwww.toro.com.
TheToroCompanyreservestherighttochangetheproductspeciî‚¿cationsor
thispublicationwithoutnotice.
DANGER
Thissafetysymbolmeansdanger.Whenyouseethissymbol,
carefullyreadtheinstructionsthatfollow.Failuretoobeythe
instructionscouldkillorcauseseriouspermanentinjuryordisability.
WARNING
Thissafetysymbolmeanswarning.Whenyouseethissymbol,
carefullyreadtheinstructionsthatfollow.Failuretoobeythe
instructionscanresultinseriousinjury.
CAUTION
Thissafetysymbolmeanscaution.Whenyouseethissymbol,
carefullyreadtheinstructionsthatfollow.Failuretoobeythe
instructionscanresultinminortomoderateinjury.
IMPORTANT
TheImportantnoticewillgivetheimportantinstructionswhichyou
mustfollowtopreventdamagetothesystemsorcomponentson
themachine.
Note:ANotewillgivethegeneralinformationaboutthecorrectoperation,
maintenance,service,testing,orrepairofthemachine.
ProLineH800
Page5
Preface
19241SLRevA
ServiceProcedureIcons
ThefollowingiconsappearthroughoutthisServiceManualtobringattentionto
speciî‚¿cimportantdetailsofaserviceprocedure.
CriticalProcess
Thisiconisusedtohighlight:
•Installingsafetyequipment(shields,guards,seatbelts,brakesandR.O.P .S.
components)thatmayhavebeenremoved.
•Dimensionsorsettingsthatmustbemaintainedforpropermachineoperation.
•Aspecicfastenertighteningsequence.
•Componentorientationthatmaynotbeobvious.
CriticalTorque
Thisiconisusedtohighlightanassemblytorquerequirementthatisdifferent
thanwhatisrecommendedintheStandardTorqueT ables;refertoT orque
Specications(page2–7).
FluidSpeciî‚¿cations
Thisiconisusedtohighlightuidspecicationsandcapacitiesthatareless
common,andmaynotappearonthemachineservicedecalorinthemachine
Operator’sManual.
Note:RefertotheservicedecalonthemachineandthemachineOperator’s
Manualforcommonlyuseduidspecicationsandcapacities.
Preface
Page6
ProLineH800
19241SLRevA
TableofContents
Preface................................................................................................................5
Chapter1:Safety............................................................................................1–1
SafetyInstructions.......................................................................................1–2
JackingInstructions.....................................................................................1–7
SafetyandInstructionalDecals....................................................................1–9
Chapter2:SpecicationsandMaintenance....................................................2–1
Specications...............................................................................................2–2
TorqueSpecications...................................................................................2–7
ShopSupplies............................................................................................2–13
SpecialT ools..............................................................................................2–15
Chapter3:Troubleshooting.............................................................................3–1
GEARS–TheSystematicApproachtoDening,DiagnosingandSolving
Problems......................................................................................................3–2
GeneralHydraulicSystemProblems............................................................3–3
SteeringCircuitProblems.............................................................................3–5
TheHeightOfCutCircuitProblems..............................................................3–6
TheCuttingDeckLiftCircuitProblems..........................................................3–7
TheHopperLiftCircuit..................................................................................3–8
TheHopperTiltCircuit..................................................................................3–9
Chapter4:Engine...........................................................................................4–1
GeneralInformation.....................................................................................4–2
ServiceandRepairs.....................................................................................4–3
Chapter5:HydraulicSystem...........................................................................5–1
GeneralInformation.....................................................................................5–3
HydraulicSchematic...................................................................................5–13
HydraulicFlowDiagrams............................................................................5–14
TestingtheHydraulicSystem......................................................................5–32
ServiceandRepairs...................................................................................5–63
Chapter6:ElectricalSystem...........................................................................6–1
GeneralInformation.....................................................................................6–2
ElectricalSystemQuickChecks....................................................................6–3
TestingtheElectricalComponents................................................................6–6
ServiceandRepairs...................................................................................6–44
Chapter7:Chassis..........................................................................................7–1
GeneralInformation.....................................................................................7–2
ServiceandRepairs.....................................................................................7–3
Chapter8:AxleandPTO.................................................................................8–1
GeneralInformation.....................................................................................8–2
ServiceandRepairs.....................................................................................8–3
Chapter9:HopperAssembly..........................................................................9–1
GeneralInformation.....................................................................................9–2
ServiceandRepairs.....................................................................................9–3
Chapter10:CuttingUnit................................................................................10–1
GeneralInformation...................................................................................10–2
ServiceandRepairs...................................................................................10–3
AppendixA......................................................................................................A–1
ElectricalDrawingDesignations....................................................................A–2
HydraulicSchematic.....................................................................................A–3
ElectricalSchematic-Main...........................................................................A–5
ElectricalSchematic-Lights.........................................................................A–6
WireHarnessDiagram-Main.......................................................................A–7
WireHarnessDiagram-Lights.....................................................................A–8
AdditionalReferenceMaterials
Yanmar3TNV76ServiceManual
ProLineH800
Page7
Preface
19241SLRevA
Yanmar3TNV80FServiceManual
DanfossDDC20AxialPistonPumpServiceManual
ParkerTorqmotorServiceProcedure(TF ,TG,TH,andTLSeries)
GrammerSeatsRepairManual
Preface
Page8
ProLineH800
19241SLRevA
Chapter1
Safety
TableofContents
SafetyInstructions................................................................................................................................1–2
Supervisor’sResponsibilities.............................................................................................................1–2
BeforeOperatingtheMachine...........................................................................................................1–3
WhileOperatingtheMachine.............................................................................................................1–4
MaintenanceandService...................................................................................................................1–5
JackingInstructions..............................................................................................................................1–7
RaisingtheFrontoftheMachine........................................................................................................1–7
RaisingtheRearoftheMachine........................................................................................................1–9
SafetyandInstructionalDecals............................................................................................................1–9
ProLineH800
Page1–1
Safety
19241SLRevA
SafetyInstructions
TheProLineH800machinesaretestedandcertiî‚¿edbyT oroforcompliance
withexistingsafetystandardsandspeciî‚¿cations.Althoughhazardcontroland
accidentpreventionarepartiallydependentuponthedesignandconî‚¿gurationof
themachine,hazardcontrolandaccidentpreventionarealsodependentupon
theawareness,concernandpropertrainingofthepersonnelinvolvedinthe
operation,transport,maintenanceandstorageofthemachine.Improperuseor
maintenanceofthemachinecanresultininjuryordeath.Toreducethepotential
forinjuryordeath,complywiththefollowingsafetyinstructions.
WARNING
Toreducethepotentialofinjuryordeath,complywiththefollowing
safetyinstructionsaswellasinformationfoundintheOperator’s
Manuals.
Supervisor’sResponsibilities
1.EnsurethattheoperatorsarefullytrainedandfamiliarwiththeOperator’s
Manual,alloftheoperatingandsafetydecalsonthemachineandany
operationinformationfoundintheInstallationInstructionsforaccessories
thatareinstalledonthemachine.
2.Establishyourownspecialproceduresandworkrulesforunusualoperating
conditions(e.g.,slopestoosteepformachineoperation).Surveythemowing
sitecompletelytodeterminehillsonwhichyoucanoperatesafely.When
performingthissitesurvey,alwaysunderstandandtakeintoconsideration
theturfconditionandrolloverrisk.
Safety:SafetyInstructions
Page1–2
ProLineH800
19241SLRevA
BeforeOperatingtheMachine
•ReviewandunderstandthecontentoftheOperator’sManualsbeforestarting
andoperatingthemachine.Becomefamiliarwiththecontrolsandknowhow
tostopthemachineandenginequickly.AdditionalcopiesoftheOperator’s
Manualsareavailableatwww.toro.com.
•Neverallowchildrentooperatethemachine.Neverallowadultstooperate
themachinewithoutproperinstructions.
•Becomefamiliarwiththecontrolsandknowhowtostopthemachineand
enginequickly.
•Keepalltheshields,safetydevices,anddecalsinplace.Ifashield,safety
device,ordecalisillegibleordamaged,repairorreplaceitbeforeoperating
themachine.
•Alwayswearsubstantialshoes.Donotoperatethemachinewhilewearing
sandals,tennisshoesorsneakers.Donotwearlooseî‚¿ttingclothingwhich
couldgetcaughtinmovingpartsandcausepersonalinjury.
•Wearingsafetyglasses,safetyshoes,longpantsandahelmetisadvisable
andrequiredbysomelocalsafetyandinsuranceregulations.
•Makesureworkareaisclearofobjectswhichmightbepickedupandthrown
bytheattachments.
•Keepeveryone,especiallychildrenandpets,awayfromtheareaofoperation.
•Ensurethesafetyinterlocksarefunctioningproperly.Adjustorreplace
anymalfunctioningswitchesorinterlockmechanismsbeforeoperatingthe
machine.RefertoCheckingtheOperationoftheInterlockSwitches(page
6–5)foradditionalinformation.
•Dieselfuelishighlyammable;handleitcarefully.
–Storefuelincontainersspecicallydesignedforstoringfuel.
–Donotremovethefueltankcapofthemachinewhiletheengineishot
orrunning.
–Donotsmokewhilehandlingthefuel.
–Fillthefueltankoutdoorsandonlytoalevelwithinaninchofthetopof
thetank,nottheî‚¿llerneck.Donotoverî‚¿llthefueltank.
–Afterrefuelingthemachine,installthefueltankandfuelcontainercaps.
–Ifyouspillfuel,donotattempttostarttheenginebutmovethemachine
awayfromthespill.Avoidcreatinganysourceofignitionuntilfuelvapors
havedissipated.Wipeupanyspilledfuel.
ProLineH800
Page1–3
Safety:SafetyInstructions
19241SLRevA
WhileOperatingtheMachine
•Sitontheseatwhenstartingandoperatingthemachine.
•Anytimeyouparkthemachine(shortorlongterm),lowerthecuttingdeckto
theground.
IMPORTANT
Whenyoulowerthecuttingdecktotheground,thepressurefrom
thehydraulicliftcircuitreleasesandpreventsthecuttingdeck
fromaccidentallylowering.
•Ifyouparkthemachineonaslope,blockorchockthewheels.
•Keephands,feetandclothingawayfrommovingpartsandthedischarge
areaofanattachment.
•Donottouchtheengine,muferorexhaustpipewhiletheengineisrunning
orsoonafteritisstoppedbecausetheseareascouldbehotenoughto
causeburns.
Beforestartingthemachine
DANGER
Theexhaustfumesarehazardousandhavethepotentialofinjury
ordeath.
Donotruntheengineinaconî‚¿nedareawithoutadequateventilation.
1.Settheparkingbrake.
2.EnsurethatthetractionpedalisintheNEUTRALpositionandthePTOswitch
isintheOFF(disengaged)position.
3.Afteryoustarttheengine,releasetheparkingbrakeandkeepfootoffthe
tractionpedal.Ensurethatthemachinedoesnotmove.
Note:Ifmachinemovementisevident,thetractionpedallinkageisadjusted
incorrectly;therefore,shutofftheengineandadjustthetractionpedallinkage
untilthemachinedoesnotmovewhenyoureleasethetractionpedal;referto
theOperator'sManual.
CAUTION
Runningtheenginecausestheengine,radiator,andexhaustsystem
tobecomehot.Touchingahotengine,radiator,orexhaustsystem
canburnyou.
Donottouchtheengine,radiator,orexhaustsystemwhilethe
engineisrunningorsoonafteryoustopit.
Beforestoppingthemachine
1.EnsurethatthetractionpedalisintheNEUTRALposition.
2.Loweranddisengagethecuttingdeckandwaitforallmovingpartstostop.
3.Settheparkingbrake.
4.Shutofftheengineandremovethekeyfromthekeyswitch.
Safety:SafetyInstructions
Page1–4
ProLineH800
19241SLRevA
MaintenanceandService
•Beforeservicingormakinganyadjustmentstothemachine,lowerthecutting
deck,settheparkingbrake,shutofftheengine,andremovethekeyfromthe
keyswitch.
•Ensurethatthemachineisinsafeoperatingconditionbykeepingallthe
nuts,bolts,andscrewstight.
•Donotstorethemachineorafuelcontainerinsidewherethereisanopen
ame,suchasnearawaterheaterorfurnace.
•Ensurethatallofthehydrauliclineconnectorsaretightandthatallthe
hydraulichosesandlinesareingoodconditionbeforeapplyingpressureto
thehydraulicsystem.
•Keepyourbodyandhandsawayfrompin-holeleaksinthehydrauliclines
thatejecthydraulicuidunderhighpressure.Usecardboardorpapertond
hydraulicleaks.Thehydraulicuidescapingunderpressurecanpenetrate
theskinandcauseinjury.Ifhydraulicuidisaccidentallyinjectedintothe
skin,youmusthaveitsurgicallyremovedwithinafewhoursbyadoctor
familiarwiththistypeofinjury.Otherwise,gangrenemayresult.
•Beforedisconnectingorperforminganyworkonthehydraulicsystem,
releaseallthepressureinthesystembyparkingthemachineonalevel
surface,loweringthecuttingdeckcompletely,shuttingofftheengine,and
thenusingallofthehydrauliccontrols(pressingthetractionpedal,turning
thesteeringwheel,andpressingtheliftswitchtobothraiseandlower).
•Usecarewhencheckingorservicingthecuttingdeck.Wearglovesand
usecautionwhenservicingthedeck.
•Toreducepotentialrehazards,keeptheengineareafreeofexcessive
grease,grass,leaves,anddirt.Cleantheprotectivescreenonthemachine
frequently.
•Ifyoumustruntheenginetoperformmaintenanceortomakeanadjustment,
keepyourhands,feet,clothing,andotherpartsofthebodyawayfromthe
cuttingdeckandothermovingparts.Keepbystandersaway.
•Donotoverspeedtheenginebychangingtheenginegovernorsetting.
Toensuresafetyandaccuracy,checkthemaximumenginespeedwith
aphototac.
•Shutofftheenginebeforecheckingoraddingoiltotheenginecrankcase.
•Disconnectthebatterybeforeservicingthemachine.Disconnectthebattery
negativecableandthenthepositivecable.Ifbatteryvoltageisnecessaryfor
troubleshootingortestprocedures,temporarilyconnectthebattery.Connect
thepositivebatterycableandthenthenegativecable.
•Batteryacidispoisonousandcancauseburns.Avoidacidcontactwithskin,
eyes,andclothing.Protectyourface,eyes,andclothingwhenworkingwitha
battery.
•Batterygasescanexplode.Keepcigarettes,sparks,andamesawayfrom
thebattery.
•Whenchangingtheattachments,tires,orperformingotherservice,use
correctblocks,hoists,andjackstoraiseandsupportthemachine.Ensure
thatthemachineisparkedonasolidlevelsurface,suchasaconcreteoor.
Beforeyouliftthemachine,removealltheattachmentsthatmayinterfere
withthesafeandcorrectliftofthemachine.Alwaysblockthewheelswith
chocks.Useappropriatejackstandstosupporttheraisedmachine.Failing
toproperlysupportthemachinewithappropriatejackstandscancausethe
machinetomoveorfallandcanresultinpersonalinjury;refertoJacking
Instructions(page1–7).
•Ifmajorrepairsarenecessary,contactyourAuthorizedT oroDistributor.
ProLineH800
Page1–5
Safety:SafetyInstructions
19241SLRevA
MaintenanceandService(continued)
•Ifweldingonthemachineisnecessary,disconnectthebatterynegativecable
topreventelectricalsystemdamage.
•Ensuretodisposeofpotentiallyharmfulwaste(e.g.,fuel,oil,enginecoolant,
î‚¿lters,battery)inanenvironmentallysafemanner.Followalllocalcodesand
regulationswhenrecyclingordisposingofwaste.
•Atthetimeofmanufacture,themachineconformedtothesafetystandards
forridingmowers.Toensuretheoptimumperformanceandcontinued
safetycertiî‚¿cationofthemachine,usegenuineT ororeplacementpartsand
accessories.Thereplacementpartsandaccessoriesofothermanufacturers
canresultinnon-conformancewiththesafetystandardsandcanvoidthe
warranty.
Safety:SafetyInstructions
Page1–6
ProLineH800
19241SLRevA
JackingInstructions
CAUTION
Failingtoproperlysupportthemachinewithappropriatejackstands
cancausethemachinetomoveorfallandcanresultinpersonal
injury.
Whenchangingtheattachments,tires,orperformingotherservices,
dothefollowingsteps:
•Usecorrectblocks,hoists,andjackstoraiseandsupportthe
machine.
•Parkthemachineonasolidlevelsurface,suchasaconcrete
oor.
•Beforeyouliftthemachine,removealltheattachmentsthatmay
interferewiththesafeandcorrectliftofthemachine.
•Alwaysblockthewheelswithchocks.
•Useappropriatejackstandstosupporttheraisedmachine.
•Donotusethecuttingdeckasajackingpoint.
RaisingtheFrontoftheMachine
1.Settheparkingbrakeandblockthe2rearwheelswithchockstoprevent
themachinefrommoving.
g215339
Figure1
1.Handle2.Latch
2.Accessrightsideoftheengineasfollows:
A.Pushthelatchontheradiatorinwardtowardtheradiator(Figure1).
B.Usingthehandleonthesideoftheradiator,rotatetheradiatortoaccess
rightsideoftheengine(Figure1).
ProLineH800
Page1–7
Safety:JackingInstructions
19241SLRevA
RaisingtheFrontoftheMachine(continued)
g216339
Figure2
1.Bolt2.Fuel-tankbracket
3.Accessleftsideoftheengineasfollows:
A.Removetheboltfromtheleftsideofthefuel-tankbracket(Figure2).
B.Rotatethefueltanktoaccesstheleftsideoftheengine(Figure2).
g224454
Figure3
1.Frametubeontherightsideofthemachine
g224455
Figure4
1.Frametubeontheleftsideofthemachine
4.PositionthejacksecurelyundertheframetubedirectlyundertheROPStube
orascloseaspossible(Figure3andFigure4).
Safety:JackingInstructions
Page1–8
ProLineH800
19241SLRevA
RaisingtheRearoftheMachine
g224613
Figure5
1.Rearjackingpoints
1.Settheparkingbrakeandblockthe2frontwheelswithchockstoprevent
themachinefrommoving.
2.Positionthejacksecurelyundertheframe(Figure5).
SafetyandInstructionalDecals
Numeroussafetyandinstructiondecalsareafî‚¿xedtothetractionunitand
cuttingdeckofyourProLineH800.Ifanydecalbecomesillegibleordamaged,
installanewdecal.DecalpartnumbersarelistedinyourPartsCatalog.Order
replacementdecalsfromAuthorizedT oroDistributor.
ProLineH800
Page1–9
Safety:SafetyandInstructionalDecals
19241SLRevA
Safety:SafetyandInstructionalDecals
Page1–10
ProLineH800
19241SLRevA
Chapter2
Speciî‚¿cationsandMaintenance
TableofContents
Specications.......................................................................................................................................2–2
OverallDimensions............................................................................................................................2–2
Engine-ProLineH800(forModel31050)..........................................................................................2–3
Engine-ProLineH800(forModel31050TE)......................................................................................2–4
HydraulicSystem...............................................................................................................................2–5
Chassis..............................................................................................................................................2–6
TorqueSpecications...........................................................................................................................2–7
IdentifyingtheFastener......................................................................................................................2–7
CalculatingtheT orqueValuesWhenUsingaDrive-AdapterWrench.................................................2–9
StandardTorqueforDry,ZincPlated,andSteelFasteners(Inch)....................................................2–10
StandardT orqueforDry,ZincPlated,andSteelFasteners(MetricFasteners).................................2–11
OtherTorqueSpecications.............................................................................................................2–12
ConversionFactors..........................................................................................................................2–12
ShopSupplies....................................................................................................................................2–13
SpecialTools......................................................................................................................................2–15
ProLineH800
Page2–1
Speciî‚¿cationsandMaintenance
19241SLRevA
Speciî‚¿cations
OverallDimensions
g288868
Figure6
Speciî‚¿cationsandMaintenance:Speciî‚¿cations
Page2–2
ProLineH800
19241SLRevA
/