John Deere Lightweight Fairway Mower 3215 3215A 3215B 3225B 3235 3235A & 3235B Technical Manual – PDF DOWNLOAD
DESCRIPTION:
John Deere Lightweight Fairway Mower 3215 3215A 3215B 3225B 3235 3235A & 3235B Technical Manual – PDF DOWNLOAD
Manual Description :
This technical manual is written for an experienced technician and contains sections that are specifically for
this product. It is a part of a total product support program. The manual is organized so that all the information on a particular system is kept together. The order of grouping is
as follows:
• Table of Contents
• Specifications and Information
• Identification Numbers
• Tools and Materials
• Component Location
• Schematics and Harnesses
• Theory of Operation
• Operation and Diagnostics
• Diagnostics
• Tests and Adjustments
• Repair
• Other
TABLE OF CONTENTS:
John Deere Lightweight Fairway Mower 3215 3215A 3215B 3225B 3235 3235A & 3235B Technical Manual – PDF DOWNLOAD
TM1534 – 3215, 3215A, 3215B, 3225B, 3235, 3235A and 3235B Lightweight Fairway Mower…………………………… 1
Introduction………………………………………………………………………………………. 3
Manual Description……………………………………………………………………………… 3
Safety……………………………………………………………………………………………. 5
Recognize Safety Information…………………………………………………………………….. 5
Replace Safety Signs……………………………………………………………………………. 5
Handle Fluids Safely – Avoid Fires……………………………………………………………….. 5
Use Care in Handling and Servicing Batteries………………………………………………………. 5
Use Care Around High-Pressure Fluid Lines…………………………………………………………. 6
Use Safe Service Procedures……………………………………………………………………… 6
Service Tires Safely……………………………………………………………………………. 8
Avoid Injury from Rotating Blades and Drive Shafts…………………………………………………. 8
Service Cooling System Safely……………………………………………………………………. 9
Handle Chemical Products Safely………………………………………………………………….. 9
Specifications and Information………………………………………………………………………. 11
Table of Contents………………………………………………………………………………. 11
General Information…………………………………………………………………………….. 13
Metric Fastener Torque Values………………………………………………………………… 13
Metric Fastener Torque Values – Grade 7……………………………………………………….. 14
Inch Fastener Torque Values………………………………………………………………….. 15
Face Seal Fittings with Inch Stud Ends Torque………………………………………………….. 16
Face Seal Fittings with Metric Stud Ends Torque………………………………………………… 17
O-Ring Face Seal Fittings……………………………………………………………………. 18
O-Ring Boss Fittings………………………………………………………………………… 18
Diesel Fuel – North America………………………………………………………………….. 19
Diesel Fuel – Europe………………………………………………………………………… 19
Diesel Fuel Lubricity……………………………………………………………………….. 19
Diesel Fuel Storage…………………………………………………………………………. 20
4-Cycle Diesel Engine Oil – North America……………………………………………………… 20
4-Cycle Diesel Engine Oil – Europe……………………………………………………………. 21
Break-In Diesel Engine Oil – North America…………………………………………………….. 22
Break-In Diesel Engine Oil – Europe…………………………………………………………… 23
Hydrostatic Transmission and Hydraulic Oil…………………………………………………….. 24
Biodegradable Oil…………………………………………………………………………… 24
Anti-Corrosion Grease……………………………………………………………………….. 25
Grease – North America………………………………………………………………………. 26
Grease – Europe…………………………………………………………………………….. 27
Alternative Lubricants………………………………………………………………………. 27
Synthetic Lubricants………………………………………………………………………… 27
Lubricant Storage…………………………………………………………………………… 27
Mixing of Lubricants………………………………………………………………………… 27
Oil Filters………………………………………………………………………………… 28
Diesel Engine Coolant – North America…………………………………………………………. 28
Diesel Engine Coolant Drain Interval – North America……………………………………………. 29
Diesel Engine Coolant – Europe……………………………………………………………….. 29
Diesel Engine Coolant Drain Interval – Europe………………………………………………….. 29
Identification Numbers………………………………………………………………………….. 30
Serial Number Location………………………………………………………………………. 30
Mower Identification Number………………………………………………………………….. 30
Engine Serial Number………………………………………………………………………… 30
Cutting Unit Serial Numbers………………………………………………………………….. 30
Engine – Diesel……………………………………………………………………………………. 31
Table of Contents………………………………………………………………………………. 31
Specifications…………………………………………………………………………………. 33
3TNE78A and 3TNE82A Engines………………………………………………………………….. 33
3TNE84 Engine………………………………………………………………………………. 39
Torque Specifications (All Engines)…………………………………………………………… 45
Tools and Materials…………………………………………………………………………….. 46
Tools……………………………………………………………………………………… 46
Component Location……………………………………………………………………………… 47
Alternator Components……………………………………………………………………….. 47
Starter Components………………………………………………………………………….. 48
Theory of Operation…………………………………………………………………………….. 49
Fuel and Air System Operation………………………………………………………………… 49
Cooling System Operation…………………………………………………………………….. 50
Lubrication System Operation…………………………………………………………………. 51
Diagnostics……………………………………………………………………………………. 51
Diesel Engine Troubleshooting………………………………………………………………… 51
Tests and Adjustments…………………………………………………………………………… 60
Test Cylinder Compression……………………………………………………………………. 60
Adjust Throttle Lever……………………………………………………………………….. 61
Adjust Fuel Shutoff Solenoid…………………………………………………………………. 61
Adjust Slow Idle……………………………………………………………………………. 62
Adjust Fast Idle 3TNE78A (Engine S.N.-13510) and 3TNE84 (Engine S.N. -011149)……………………… 62
Adjust Fast Idle 3TNE78A (Engine S.N. 013511-), 3TNE82A (All) and 3TNE84 (Engine S.N. 011150-)………. 63
Adjust Torque Capsule……………………………………………………………………….. 63
Adjust Injection Pump Timing (3TNE78A- RJFE and 3TNE84-JFE)……………………………………… 63
Adjust Injection Pump Static Timing (3TNE78A-RJFE and 3TNE84-JFE)………………………………… 64
Adjust Injection Pump Static Timing (3TNE78A-ERJFE, 3TNE82A-EJF and 3TNE84- EJFE)………………….. 65
Adjust Valve Clearance………………………………………………………………………. 65
Check Valve Lift……………………………………………………………………………. 67
Check Connecting Rod Side Play……………………………………………………………….. 67
Check Connecting Rod Bearing Clearance………………………………………………………… 68
Check Crankshaft End Play……………………………………………………………………. 69
Check Crankshaft Main Bearing Clearance……………………………………………………….. 69
Check Camshaft End Play……………………………………………………………………… 70
Check Timing Gear Backlash…………………………………………………………………… 71
Test Fuel Injection Nozzles………………………………………………………………….. 71
Test Thermostat Opening……………………………………………………………………… 73
Adjust Fan/Alternator Drive Belt……………………………………………………………… 74
Test Cylinder Leakdown………………………………………………………………………. 74
Test Cooling System Pressure…………………………………………………………………. 75
Test Radiator Pressure Cap…………………………………………………………………… 75
Test Engine Oil Pressure…………………………………………………………………….. 76
Test Air Intake System Leakage……………………………………………………………….. 76
Adjust Throttle Cable……………………………………………………………………….. 77
Test Fuel System Leakage…………………………………………………………………….. 77
Bleed Fuel System…………………………………………………………………………… 77
Test Coolant Temperature Switch………………………………………………………………. 78
Repair………………………………………………………………………………………… 78
Remove Engine………………………………………………………………………………. 78
Remove and Install Rocker Cover………………………………………………………………. 79
Remove and Install Rocker Arm Assembly………………………………………………………… 80
Inspect Rocker Arm Assembly………………………………………………………………….. 81
Remove and Install Cylinder Head and Valves……………………………………………………. 82
Disassemble and Assemble Cylinder Head and Valves………………………………………………. 83
Inspect Cylinder Head and Valves……………………………………………………………… 84
Remove and Install Exhaust Manifold…………………………………………………………… 87
Remove and Install Intake Manifold……………………………………………………………. 87
Grind Valve Seats…………………………………………………………………………… 88
Lap Valves…………………………………………………………………………………. 88
Measure Piston-to-Cylinder Head Clearance……………………………………………………… 89
Remove and Install Piston and Connecting Rod…………………………………………………… 89
Disassemble and Assemble Piston and Connecting Rod……………………………………………… 91
Inspect Piston and Connecting Rod…………………………………………………………….. 92
Inspect Cylinder Bore……………………………………………………………………….. 96
Inspect Cylinder Bore Taper and Out-of- Round………………………………………………….. 97
Remove and Install Crankcase Extension Housing…………………………………………………. 98
Replace Crankshaft Rear Oil Seal……………………………………………………………… 98
Replace Crankshaft Front Oil Seal…………………………………………………………….. 98
Remove and Install Crankshaft and Main Bearings………………………………………………… 98
Inspect Crankshaft and Main Bearings…………………………………………………………..100
Remove and Install Crankshaft Gear…………………………………………………………….101
Remove and Install Flywheel…………………………………………………………………..101
Remove and Install Camshaft…………………………………………………………………..102
Inspect Camshaft…………………………………………………………………………….103
Remove and Install Camshaft Gear………………………………………………………………105
Remove and Install Cam Followers………………………………………………………………105
Inspect Cam Followers………………………………………………………………………..105
Remove and Install Timing Gear Cover…………………………………………………………..106
Remove and Install Idler Gear…………………………………………………………………107
Inspect Idler Gear…………………………………………………………………………..107
Remove and Install Timing Gear Cover Mounting Plate……………………………………………..107
Remove and Install Oil Pan and Strainer………………………………………………………..108
Remove and Install Oil Pump…………………………………………………………………..108
Disassemble and Assemble Oil Pump……………………………………………………………..108
Inspect Oil Pump…………………………………………………………………………….108
Remove and Install Oil Pressure Regulating Valve………………………………………………..110
Remove and Install Optional Oil Cooler…………………………………………………………110
Remove and Install Thermostat and Housing – 3TNE84………………………………………………111
Remove and Install Coolant Pump……………………………………………………………….111
Inspect Coolant Pump…………………………………………………………………………112
Disassemble and Assemble Fuel Filter Assembly…………………………………………………..113
Remove Fuel Injection Pump (For 3TNE78RJFE and 3TNE84JFE Only)……………………………………113
Remove Fuel Injection Pump (For 3TNE78- ERJFE, 3TNE82A-EJF and 3TNE84-EJFE Only)……………………115
Install Fuel Injection Pump (For 3TNE78-RJFE and 3TNE84-JFE Only)…………………………………117
Install Fuel Injection Pump (For 3TNE78- ERJFE, 3TNE82A-EJF and 3TNE84-EJFE Only)…………………..118
Remove and Install Fuel Injection Nozzles………………………………………………………119
Disassemble and Assemble Fuel Injection Nozzles…………………………………………………120
Disassemble and Assemble Starter Motor…………………………………………………………122
Inspect and Test Starting Motor……………………………………………………………….124
Disassemble and Assemble Starter Gear Train…………………………………………………….125
Disassemble, Inspect and Assemble Starter Solenoid………………………………………………127
Disassemble, Inspect and Assemble Alternator……………………………………………………128
Electrical…………………………………………………………………………………………131
Table of Contents……………………………………………………………………………….131
Specifications………………………………………………………………………………….133
General Specifications……………………………………………………………………….133
Tools………………………………………………………………………………………134
General Information……………………………………………………………………………..134
Theory of Operation Information……………………………………………………………….134
Diagnostic Information……………………………………………………………………….134
Common Circuit Tests…………………………………………………………………………135
Reading Electrical Schematics…………………………………………………………………136
Wire Color Abbreviation Chart…………………………………………………………………138
Control Module………………………………………………………………………………138
LED Legend………………………………………………………………………………….138
Component Location………………………………………………………………………………139
Operator Controls and Indicators………………………………………………………………139
Component Location – 3215 and 3235…………………………………………………………….141
Component Location – 3215A, 3215B, 3225B, 3235A and 3235B………………………………………..144
Schematics and Harnesses…………………………………………………………………………147
Main Electrical Schematic…………………………………………………………………….147
Main Wiring Harness (W1)……………………………………………………………………..159
Control Module Resistor Wiring Harness…………………………………………………………162
Fuel Shutoff Solenoid Wiring Harness…………………………………………………………..162
Down Pressure Solenoid Wiring Harness………………………………………………………….162
Down Pressure Relay Wiring Harness…………………………………………………………….163
Radiator Fan Motor Wiring Harness……………………………………………………………..164
Wiring Harness:Seat Wire Harness, 3215B, 3225B, and 3235B;Seat Wire Harness, 3215B, 3225B, and 3235B….165
Fan Wire Harness – 3215B (Serial No. -020243), 3225B (Serial No. -010402), 3235B 2WD (Serial No. …….165
Operation and Diagnostics………………………………………………………………………..166
Cranking Circuit (Operator Off Seat) Operation………………………………………………….166
Cranking Circuit (Operator Off Seat) Schematic………………………………………………….167
Cranking Circuit (Operator Off Seat) Diagnosis………………………………………………….168
Cranking Circuit (Operator On Seat) Operation…………………………………………………..170
Cranking Circuit (Operator On Seat) Schematic – 3215, 3215A, 3235 and 3235A………………………..171
Cranking Circuit (Operator On Seat) Schematic – 3215B, 3225B and 3235B…………………………….172
Cranking Circuit (Operator On Seat) Diagnosis…………………………………………………..173
Seat Switch Relay Circuit Operation – 3215B, 3225B and 3235B……………………………………..175
Seat Switch Relay Circuit Schematic – 3215B, 3225B and 3235B……………………………………..175
Seat Switch Relay Circuit Diagnosis – Models 3215B, 3225B and 3235B……………………………….176
Run Circuit (Operator Off Seat) Operation………………………………………………………177
Run Circuit (Operator Off Seat) Schematic………………………………………………………178
Run Circuit (Operator Off Seat) Diagnosis………………………………………………………179
Run Circuit (Operator Off Seat for Service or Backlapping) Operation………………………………180
Run Circuit (Operator Off Seat for Service or Backlapping) Schematic………………………………181
Run Circuit (Operator Off Seat for Service or Backlapping) Diagnosis………………………………182
Normal Run Circuit (Operator On Seat and Park Lock Off) Operation…………………………………183
Normal Run Circuit (Operator On Seat and Park Lock Off) Schematic – 3215, 3215A, 3235 and 3235A………184
Normal Run Circuit (Operator On Seat and Park Lock Off) Schematic – 3215B, 3225B and 3235B…………..185
Normal Run Circuit (Operator On Seat and Park Lock Off) Diagnosis…………………………………186
Primary Run Circuit (Operator On Seat in Neutral) Operation………………………………………187
Primary Run Circuit (Operator On Seat in Neutral) Schematic – 3215, 3215A, 3235 and 3235A……………188
Primary Run Circuit (Operator On Seat in Neutral) Schematic – 3215B, 3225B and 3235B………………..189
Primary Run Circuit (Operator On Seat in Neutral) Diagnosis………………………………………190
Mow Circuit Operation………………………………………………………………………..192
Mow Circuit Schematic – 3215, 3215A, 3235 and 3235A……………………………………………..193
Mow Circuit Schematic – 3215B, 3225B and 3235B………………………………………………….194
Mow Circuit Diagnosis………………………………………………………………………..195
Backlapping Circuit Operation…………………………………………………………………196
Backlapping Circuit Schematic…………………………………………………………………197
Backlapping Circuit Diagnosis…………………………………………………………………198
Raise Lift Arms Circuit Operation……………………………………………………………..199
Raise Lift Arms Circuit Schematic……………………………………………………………..200
Raise Lift Arms Circuit Diagnosis……………………………………………………………..201
Radiator Fan Motor Circuit – 3215B, 3225B and 3235B……………………………………………..202
Radiator Fan Motor Circuit Schematic – 3215B, 3225B and 3235B…………………………………….202
Radiator Fan Motor Circuit Diagnosis – 3215B, 3225B and 3235B…………………………………….203
Radiator Fan Motor Circuit – 3215B, 3225B and 3235B……………………………………………..203
Radiator Fan Motor Circuit Schematic – 3215B, 3225B and 3235B…………………………………….204
Radiator Fan Motor Circuit Diagnosis – 3215B, 3225B and 3235B…………………………………….205
Tests and Adjustments……………………………………………………………………………206
Test Indicating Lights Circuits……………………………………………………………….206
Test Control Module AMT767 Auxiliary Harness……………………………………………………207
Test Diode Pack AMT386……………………………………………………………………….207
Test Diode Pack AMT477……………………………………………………………………….208
Test Battery………………………………………………………………………………..208
Charge Battery………………………………………………………………………………209
Test Battery Load……………………………………………………………………………210
Test Regulated Amperage and Voltage……………………………………………………………211
Test Starter Loaded Amperage Draw……………………………………………………………..212
Test Starter No-Load Amperage and RPM………………………………………………………….212
Test Starter Solenoid………………………………………………………………………..214
Bench Test Electrical Switches………………………………………………………………..214
Test Electrical Relays……………………………………………………………………….216
Test Fuel Shut-Off Solenoid – 3TNE78A and 3TNE84 Engines…………………………………………217
Test Fuel Shutoff Solenoid – 3TNE82A Engines……………………………………………………218
Test Fuse…………………………………………………………………………………..219
Test Mow Valve Solenoid Coil………………………………………………………………….219
Test Lift Valve Solenoid Coil…………………………………………………………………220
Test Fuel Level Sensor……………………………………………………………………….220
Repair…………………………………………………………………………………………221
Remove and Install Fan – 3215B, 3225B, and 3235B………………………………………………..221
WEATHER PACK………………………………………………………………………………..221
Replace WEATHER PACK…………………………………………………………………………222
Remove METRI-PACK……………………………………………………………………………223
Replace METRI-PACK…………………………………………………………………………..224
Hydrostatic Power Train……………………………………………………………………………..227
Table of Contents……………………………………………………………………………….227
Specifications………………………………………………………………………………….229
General Specifications……………………………………………………………………….229
Repair Specifications………………………………………………………………………..230
Tools and Materials……………………………………………………………………………..231
Tools………………………………………………………………………………………231
Materials…………………………………………………………………………………..232
Component Location………………………………………………………………………………232
Component Location – 3215, 3215A, 3215B, 3225B and 3235………………………………………….232
Component Location – 3235A and 3235B…………………………………………………………..233
Hydrostatic Pump – 3215, 3215A, 3215B, 3225B and 3235……………………………………………234
Hydrostatic Pump – 3235A and 3235B…………………………………………………………….236
Hydrostatic Pump Backplates – 3235A and 3235B…………………………………………………..238
Manual Servo Control Basic Assembly – 3235A and 3235B……………………………………………239
Hydrostatic Motor……………………………………………………………………………240
Transmission Linkage – 3215, 3215A, 3215B, 3225B, and 3235……………………………………….241
Transmission Linkage – 3235A and 3235B…………………………………………………………242
Forward and Reverse Pedals and Linkage…………………………………………………………244
Schematics……………………………………………………………………………………..246
Hydrostatic Schematic – 3215, 3215A, 3215B, 3225B and 3235……………………………………….246
Hydrostatic Schematic – 3235A and 3235B (S.N. TC3235T010001-TC3235T020000) (S.N. TC3235F010001-TC…….248
Hydrostatic Schematic – 3235B (S.N. TC3235T020001-) (S.N. TC3235F020001-)………………………….250
Forward Without Four Wheel Drive – 3215, 3215A, 3215B, 3225B and 3235……………………………..252
Forward With Four Wheel Drive – 3215, 3215A, 3215B, 3225B and 3235………………………………..253
Forward With Four Wheel Drive and Rear Wheels Freewheeling – 3215, 3215A, 3215B, 3225B and 3235………254
Forward Without Four Wheel Drive – 3235A and 3235B (S.N. TC3235T010001-TC3235T020000) (S.N. TC323…….255
Forward With Four Wheel Drive – 3235A and 3235B (S.N. TC3235T010001-TC3235T020000) (S.N. TC3235F0…….256
Forward With Four Wheel Drive and Rear Wheels Freewheeling – 3235A and 3235B (S.N. TC3235T010001-…….257
Forward Without Four Wheel Drive – 3235B (S.N. TC3235T020001-) (SN TC3235F020001-)………………….258
Forward With Four Wheel Drive – 3235B (S.N. TC3235T020001-) (S.N. TC3235F020001-)…………………..259
Forward With Four Wheel Drive and Rear Wheels Freewheeling – 3235B (S.N. TC3235T020001-) (S.N. TC…….260
Theory of Operation……………………………………………………………………………..262
Hydrostatic Transmission……………………………………………………………………..262
Diagnostics…………………………………………………………………………………….264
Troubleshooting Hints………………………………………………………………………..264
Hydrostatic Power Train Troubleshooting………………………………………………………..264
Tests And Adjustments……………………………………………………………………………266
Test Hydrostatic Transmission Flow – 3235A and 3235B…………………………………………….266
Test Hydrostatic Transmission Flow – 3215, 3215A, 3215B, 3225B, and 3235…………………………..268
Test Hydro Relief Valve (Reverse)……………………………………………………………..270
Test Hydro Relief Valve (Forward)……………………………………………………………..271
Test Charge Pressure – 3215, 3215A, 3215B, 3225B, 3235 and 3235B (S.N.TC3235T020001) (S.N. TC32…….272
Test Charge Pressure – 3235A and 3235B (S.N.TC3235T010001-TC3235T020000) (S.N.TC3235F010001-TC3…….274
Adjust Transmission Neutral Position – 3215, 3215A, 3215B, 3225B, and 3235…………………………275
Adjust Transmission Neutral Position – 3235A and 3235B…………………………………………..276
Repair…………………………………………………………………………………………277
Remove Hydrostatic Pump – 3215, 3215A, 3215B, 3225B, and 3235…………………………………….277
Disassemble Hydrostatic Pump – 3215, 3215A, 3215B, 3225B, and 3235………………………………..278
Inspect Hydrostatic Pump – 3215, 3215A, 3215B, 3225B, and 3235……………………………………280
Assemble Hydrostatic Pump – 3215, 3215A, 3215B, 3225B, and 3235…………………………………..282
Install Hydrostatic Pump – 3215, 3215A, 3215B, 3225B, and 3235……………………………………285
Remove Hydrostatic Pump – 3235A and 3235B………………………………………………………287
Disassemble Hydrostatic Pump – 3235A and 3235B………………………………………………….288
Inspect Hydrostatic Pump – 3235A and 3235B……………………………………………………..293
Assemble Hydrostatic Pump – 3235A and 3235B…………………………………………………….295
Install Hydrostatic Pump – 3235A and 3235B……………………………………………………..302
Remove Front Wheel Motor……………………………………………………………………..302
Disassemble Front and Rear Wheel Motor…………………………………………………………303
Inspect Front and Rear Wheel Motors……………………………………………………………305
Assemble Front and Rear Wheel Motors…………………………………………………………..305
Install Front Wheel Motor…………………………………………………………………….308
Remove Rear Wheel Motor – Four-Wheel Drive Only…………………………………………………310
Install Rear Wheel Motor – Four- WheelDriveOnly……………………………………………….310
Start-Up Procedure…………………………………………………………………………..310
Hydraulics…………………………………………………………………………………………311
Table of Contents……………………………………………………………………………….311
Specifications………………………………………………………………………………….313
General Specifications……………………………………………………………………….313
Test and Adjustment Specifications…………………………………………………………….313
Repair Specifications………………………………………………………………………..314
Tools and Materials……………………………………………………………………………..315
Tools………………………………………………………………………………………315
Component Location………………………………………………………………………………316
Reel Drive Component Location…………………………………………………………………316
Backlapping Valve Assembly……………………………………………………………………318
Lift System Component Location………………………………………………………………..319
Schematics……………………………………………………………………………………..320
Reel Drive Hydraulic Schematic – 3215, 3215A, 3235, 3235A, 3215B (S.N. -TC3215B010278), 3225B (S……..320
Reel Drive Hydraulic Schematic – 3215B (S.N. TC3215B010279-), 3225B (S.N. TC3225T010033-) and 323…….321
Lift System Hydraulic Schematic……………………………………………………………….322
Operation and Diagnostics………………………………………………………………………..323
Reel Drive System Theory of Operation………………………………………………………….323
Lift System Theory of Operation……………………………………………………………….324
Reel Drive Troubleshooting……………………………………………………………………325
Lift System Troubleshooting…………………………………………………………………..326
Tests and Adjustments……………………………………………………………………………327
Test Front Reel Motors Pressure Relief…………………………………………………………327
Test Rear Reel Motors Pressure Relief………………………………………………………….329
Test Front Reel Pump Flow…………………………………………………………………….330
Test Rear Reel Pump Flow……………………………………………………………………..332
Test Rear Reel Motors Case Drain………………………………………………………………333
Test Front Reel Motors Case Drain……………………………………………………………..334
Test Lift System Relief Valve Pressure…………………………………………………………335
Test Optional Down Pressure Valve……………………………………………………………..336
Repair…………………………………………………………………………………………337
Remove Lift Valve……………………………………………………………………………337
Disassemble Lift Valve……………………………………………………………………….337
Inspect Lift Valve…………………………………………………………………………..338
Assemble Lift Valve………………………………………………………………………….339
Install Lift Valve…………………………………………………………………………..340
Remove Lift Arm……………………………………………………………………………..341
Remove Lift Arm Bushing………………………………………………………………………341
Install Lift Arm Bushing……………………………………………………………………..341
Install Lift Arm…………………………………………………………………………….342
Remove and Install Lift Cylinder………………………………………………………………342
Remove and Install Rear Lift Cylinder Flow Restrictor……………………………………………342
Remove and Install Front Center Lift Cylinder Flow Restrictor…………………………………….342
Remove and Install Rear Lift Cylinder Lost Motion Linkage………………………………………..343
Remove Triple Pump…………………………………………………………………………..343
Disassemble Triple Pump – 3215, 3235, 3215A and 3235A……………………………………………344
Disassemble Triple Pump – 3215B, 3225B, and 3235B……………………………………………….347
Assemble Triple Pump – 3215, 3235, 3215A, and 3235A……………………………………………..348
Assemble Triple Pump – 3215B, 3225B, and 3235B………………………………………………….351
Install Triple Pump………………………………………………………………………….353
Repair Reel Motor – Medium Duty (YB Series)…………………………………………………….354
Repair Reel Motor – Medium Duty (2500M)………………………………………………………..355
Repair Reel Motor – Heavy Duty (YC Series)……………………………………………………..359
Backlapping Valve……………………………………………………………………………361
Steering…………………………………………………………………………………………..365
Table of Contents……………………………………………………………………………….365
Specifications………………………………………………………………………………….367
General Specifications……………………………………………………………………….367
Test and Adjustment Specifications…………………………………………………………….367
Repair Specifications………………………………………………………………………..367
Tools and Materials……………………………………………………………………………..368
Tools………………………………………………………………………………………368
Component Location………………………………………………………………………………369
Steering Components………………………………………………………………………….369
Theory of Operation……………………………………………………………………………..370
Steering System……………………………………………………………………………..370
Diagnostics…………………………………………………………………………………….371
Steering System Troubleshooting……………………………………………………………….371
Tests and Adjustments……………………………………………………………………………374
Test Steering System Leakage………………………………………………………………….374
Test Steering Control Unit (SCU) Leakage……………………………………………………….374
Test Steering and Lift System Relief Valve Pressure……………………………………………..375
Repair…………………………………………………………………………………………376
Remove Steering Control Unit (SCU)…………………………………………………………….376
Disassemble Steering Control Unit (SCU)………………………………………………………..377
Assemble Steering Control Unit (SCU)…………………………………………………………..378
Install Steering Control Unit (SCU)……………………………………………………………381
Brakes…………………………………………………………………………………………….383
Table of Contents……………………………………………………………………………….383
Specifications………………………………………………………………………………….385
General…………………………………………………………………………………….385
Torque Specifications………………………………………………………………………..385
Theory of Operation……………………………………………………………………………..386
Brake System………………………………………………………………………………..386
Diagnostics…………………………………………………………………………………….387
Brake System Troubleshooting………………………………………………………………….387
Tests and Adjustments……………………………………………………………………………388
Adjust Brakes……………………………………………………………………………….388
Adjust Brake Pedal Switch…………………………………………………………………….388
Repair…………………………………………………………………………………………389
Replace Brake Pad……………………………………………………………………………389
Attachments………………………………………………………………………………………..391
Table of Contents……………………………………………………………………………….391
Specifications………………………………………………………………………………….393
Cutting Units……………………………………………………………………………….393
General Specifications – 22-In. Standard and 22-In. Heavy Duty……………………………………393
Repair Specifications – 22-In. Standard and 22-In . Heavy Duty……………………………………393
Adjustment Specifications – 2500M……………………………………………………………..394
Repair Specifications – 2500M…………………………………………………………………394
Tools and Materials……………………………………………………………………………..395
Special or Essential Tools……………………………………………………………………395
Dealer Fabricated Tools………………………………………………………………………395
Other Materials……………………………………………………………………………..395
Component Location………………………………………………………………………………396
22-In. Standard Cutting Unit………………………………………………………………….396
22-In. Heavy Duty Cutting Unit………………………………………………………………..397
2500M Cutting Unit…………………………………………………………………………..398
2500M with Fairway Tender Conditioner (FTC)…………………………………………………….399
2500M Vertical Cutting Unit…………………………………………………………………..400
Theory of Operation……………………………………………………………………………..401
Reel and Bed Knife Grinding…………………………………………………………………..401
Vertical Cutting Unit………………………………………………………………………..403
Rollers…………………………………………………………………………………….403
Performance Variables………………………………………………………………………..403
Diagnostics…………………………………………………………………………………….404
Attachments Troubleshooting…………………………………………………………………..404
Tests and Adjustments……………………………………………………………………………406
Backlapping and Bed Knife-to-Reel……………………………………………………………..406
Adjust Reel-to-Bed Knife – 22-In. Standard……………………………………………………..406
Backlapping Procedure – 22-In. Standard………………………………………………………..406
Adjust Height-of-Cut (HOC) – 22-In. Standard……………………………………………………408
Adjust Cutting Unit Shield – 22-In. Standard……………………………………………………410
Adjust Reel-to-Bed Knife – 22-In. Heavy Duty……………………………………………………410
Backlapping Procedure – 22-In. Heavy Duty………………………………………………………411
Adjust Height-of-Cut (HOC) – 22-In. Heavy Duty………………………………………………….412
Adjust Depth-of-Cut – Vertical Cutting Unit (22-In. Heavy Duty)…………………………………..415
Adjust Reel-to-Bed Knife – 2500M………………………………………………………………416
Backlapping Procedure – 2500M…………………………………………………………………417
Adjust Height-of-Cut Range – 2500M…………………………………………………………….419
Adjust Front Roller – 2500M…………………………………………………………………..420
Adjust Height-of-Cut (HOC) – 2500M…………………………………………………………….422
Adjust Fairway Tender Conditioner (FTC) – 2500M…………………………………………………424
Adjust Cutting Shield – 2500M…………………………………………………………………425
Adjust Depth-of-Cut – Vertical Cutting Units (2500M)…………………………………………….426
Adjust Power Brush…………………………………………………………………………..426
Repair…………………………………………………………………………………………427
Prepare Cutting Units for Service……………………………………………………………..427
Remove Front Roller – 22-In. Standard………………………………………………………….430
Remove Roller Bracket – 22-In. Standard………………………………………………………..430
Install Roller Bracket – 22-In. Standard……………………………………………………….430
Disassemble Roller – 22-In. Standard…………………………………………………………..431
Assemble Roller – 22-In. Standard……………………………………………………………..432
Install Front Roller – 22-In. Standard…………………………………………………………432
Remove Bed Knife/Support – 22-In. Standard……………………………………………………..433
Install Bed Knife/Support – 22-In. Standard…………………………………………………….433
Remove Reel – 22-In. Standard…………………………………………………………………434
Disassemble and Inspect Pivot Arm – 22-In. Standard……………………………………………..434
Assemble Pivot Arm – 22-In. Standard…………………………………………………………..434
Install Reel – 22-In. Standard………………………………………………………………..435
Inspect Reel and Bed Knife – 22-In. Standard……………………………………………………436
Install Reel Adjustment Washers – 22-In. Standard……………………………………………….436
Remove Front Roller – 22-In. Heavy Duty………………………………………………………..437
Disassemble and Inspect Roller – 22-In. Heavy Duty………………………………………………437
Assemble Roller – 22-In. Heavy Duty……………………………………………………………437
Install Roller – 22-In. Heavy Duty…………………………………………………………….438
Remove Bed Knife/Support – 22-In. Heavy Duty……………………………………………………438
Install Bed Knife/Support – 22-In. Heavy Duty…………………………………………………..438
Remove Reel – 22-In. Heavy Duty……………………………………………………………….439
Disassemble and Inspect Pivot Arm – 22-In. Heavy Duty……………………………………………440
Assemble Pivot Arm – 22-In. Heavy Duty…………………………………………………………441
Install Reel – 22-In. Heavy Duty………………………………………………………………441
Inspect Reel and Bed Knife – 22-In. Heavy Duty………………………………………………….442
Install Reel Adjustment Washers – 22-In. Heavy Duty……………………………………………..442
Remove Fairway Tender Conditioner – 22-In. Heavy Duty……………………………………………443
Install Fairway Tender Conditioner – 22-In. Heavy Duty…………………………………………..444
Disassemble and Inspect FTC – 22-In. Heavy Duty…………………………………………………446
Remove Power Brush – 22-In. Heavy Duty…………………………………………………………448
Install Power Brush – 22-In. Heavy Duty………………………………………………………..450
Disassemble and Inspect Power Brush – 22-In. Heavy Duty………………………………………….451
Remove Reel Assembly – Vertical Cutting Unit (22-In. Heavy Duty)………………………………….452
Install Reel Assembly – Vertical Cutting Unit (22-In. Heavy Duty)…………………………………452
Disassemble and Inspect Reel Assembly – Vertical Cutting Unit (22-In. Heavy Duty)…………………..453
Assemble Reel – Vertical Cutting Unit (22-In. Heavy Duty)………………………………………..453
Replace Roller Bearing – Vertical Cutting Unit (22-In. Heavy Duty)………………………………..454
Inspect Reel and Bed Knife – 2500M…………………………………………………………….455
Remove and Install Cutting Unit – 2500M………………………………………………………..456
Remove Reel – 2500M………………………………………………………………………….456
Install Reel – 2500M…………………………………………………………………………457
Disassemble and Inspect Bearing Housing – 2500M…………………………………………………458
Assemble Bearing Housing – 2500M………………………………………………………………458
Remove Bed Knife – 2500M……………………………………………………………………..459
Install Bed Knife – 2500M…………………………………………………………………….460
Remove and Install Front Roller – 2500M………………………………………………………..460
Remove Rear Roller – 2500M……………………………………………………………………461
Install Rear Roller – 2500M…………………………………………………………………..461
Disassemble and Assembly Roller – 2500M………………………………………………………..462
Remove Fairway Tender Conditioner – 2500M………………………………………………………464
Install Fairway Tender Conditioner – 2500M……………………………………………………..466
Disassemble and Inspect Fairway Tender Conditioner – 2500M……………………………………….469
Remove Power Brush – 2500M……………………………………………………………………471
Install Power Brush – 2500M…………………………………………………………………..472
Disassemble and Inspect Power Brush – 2500M…………………………………………………….474
Remove and Install Vertical Cutting Unit – 2500M………………………………………………..474
Remove Reel Assembly – Vertical Cutting Unit (2500M)…………………………………………….474
Install Reel Assembly – Vertical Cutting Unit (2500M)……………………………………………475
Disassemble and Inspect Reel Assembly – Vertical Cutting Unit (2500M)……………………………..476
Assemble Reel – Vertical Cutting Unit (2500M)…………………………………………………..476
Disassemble and Inspect Bearing Housing – Vertical Cutting Unit (2500M)……………………………477
Assemble Bearing Housing – Vertical Cutting Unit………………………………………………..478
Remove and Install Front Roller – Vertical Cutting Unit (2500M)…………………………………..478
Remove Rear Roller – Vertical Cutting Unit (2500M)………………………………………………479
Install Rear Roller – Vertical Cutting Unit (2500M)……………………………………………..480
Replace Roller Bearing – Vertical Cutting Unit (2500M)…………………………………………..480
Index……………………………………………………………………………………………..483
Numerics……………………………………………………………………………………….483
A……………………………………………………………………………………………..484
B……………………………………………………………………………………………..484
C……………………………………………………………………………………………..484
D……………………………………………………………………………………………..485
E……………………………………………………………………………………………..486
F……………………………………………………………………………………………..486
G……………………………………………………………………………………………..486
H……………………………………………………………………………………………..487
I……………………………………………………………………………………………..487
L……………………………………………………………………………………………..487
M……………………………………………………………………………………………..488
O……………………………………………………………………………………………..488
P……………………………………………………………………………………………..488
R……………………………………………………………………………………………..488
S……………………………………………………………………………………………..489
T……………………………………………………………………………………………..490
V……………………………………………………………………………………………..490
W……………………………………………………………………………………………..491
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