Toro 03781 Service Manual Download

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Reelmaster 7000- D

Hydraulic System

Page 5 - 50

Traction Circuit - Front Wheel Motor Case Drain Leakage Test

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Low

Pressure

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Return

Suction

CID

550

50”

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CID

150

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30”

CID

036

8”

FOR

REVERSE

REAR

URE

SOR

TOW VA

ONT

MOT

REAR AXLE MOT

psi

SPEED

2850

RPM

MEASUR

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CONT

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RAN

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LEF

WHEEL

SHOWN

Summary of Contents for 03781

Page 1: ...Form No 15214SL Rev D Reelmaster 7000 D Models 03780 A and 03781 Original Instructions EN ...

Page 2: ... service drawings D 07 2020 Updated Electrical Cutting Unit Universal Groomer chapters and Foldout drawing THE TORO COMPANY 2020 This document and all information contained herein is the sole property of The Toro Company and or its affiliated companies No intellectual property rights are granted by the delivery of this document or the disclosure of its content This document shall not be reproduced...

Page 3: ...blications To do this effectively we encourage user feedback Please comment on the completeness accuracy organization usability and readability of this manual by an e mail to servicemanuals toro com or Mail to Technical Publication Manager Commercial The Toro Company 8111 Lyndale Avenue South Bloomington MN 55420 1196 Phone 1 952 887 8495 ...

Page 4: ...NOTES _ ...

Page 5: ...p ter 2 of this service manual Additional copies of the Op erator s Manuals and Parts Catalog are available on the internet at www Toro com The Toro Company reserves the right to change product specifications or this publication without notice This safety symbol means DANGER WARNING or CAUTION PERSONAL SAFETY INSTRUC TION When you see this symbol carefully read the instructions that follow Failure...

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Page 7: ...ERVO CONTROLLED PIS TON PUMP REPAIR INFORMATION DANFOSS K AND L FRAME VARIABLE MOTORS SERVICE MANUAL DANFOSS STEERING UNIT TYPE OSPM SERVICE MANUAL Chapter 6 Electrical System General Information 6 2 Electrical Drawings 6 5 Special Tools 6 6 InfoCenter Display 6 8 Troubleshooting 6 20 Electrical System Quick Checks 6 31 Adjustments 6 33 Component Testing 6 35 Service and Repairs 6 63 Chapter 7 Axl...

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Page 9: ...Groomer Optional Grooming Performance 11 2 Troubleshooting 11 3 Service and Repairs 11 4 Chapter 12 Foldout Drawings Electrical Drawing Designations 12 2 Hydraulic Schematic 12 3 Electrical Schematics 12 4 Wire Harness Drawings 12 11 Universal Groomer Foldout Drawings ...

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Page 11: ...7000 D Page 1 1 Safety Chapter 1 Safety Table of Contents GENERAL SAFETY INSTRUCTIONS 2 Before Operating 2 While Operating 2 Maintenance and Service 3 JACKING INSTRUCTIONS 4 SAFETY AND INSTRUCTION DECALS 5 Safety ...

Page 12: ... cutting units are DISENGAGED 4 Since diesel fuel is flammable handle it carefully A Use an approved fuel container B Do not remove fuel tank cap while engine is hot or running C Do not smoke while handling fuel D Fill fuel tank outdoors and only to within an inch of the top of the tank not the filler neck Do not overfill E Wipe up any spilled fuel While Operating 1 Sit on the seat when starting a...

Page 13: ...gine off before checking or adding oil to the engine crankcase 13 Disconnect battery before servicing the machine Disconnect negative battery cable first and positive cable last If battery voltage is required for troubleshoot ing or test procedures temporarily connect the battery Reconnect positive battery cable first and negative cable last IMPORTANT Before performing welding on the ma chine disc...

Page 14: ...and chock both rear tires to pre vent the machine from moving IMPORTANT Do not place jack jack stands or blocks under the wheel motors Wheel motors can be damaged if used for jacking or support points 2 Position jack securely under the frame just to the in side of the front tire 3 Jack front of machine off the ground 4 Position appropriate jack stands under the frame as close to the wheels as poss...

Page 15: ...afety Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Reelmaster 7000 If any decal becomes illegible or damaged install a new decal Decal part numbers are listed in your Parts Catalog Safety ...

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Page 17: ...s 6 Product Records Insert Operator s Manuals and Parts Catalog for your Reelmaster at the end of this chapter Additionally insert Installation Instructions Operator s Manuals and Parts Catalogs for any accessories that have been installed on your Reelmaster at the end of this section Maintenance Maintenance procedures and recommended service in tervals for your Reelmaster are covered in the Tract...

Page 18: ...0 09375 Reelmaster 7000 D Page 2 2 Product Records and Maintenance Equivalents and Conversions ...

Page 19: ...ad or nut and mating part then back off fastener 1 4 of a turn Measure the torque required to tighten the fastener until the lines match up Fastener Identification Figure 1 Grade 1 Grade 5 Grade 8 Inch Series Bolts and Screws Figure 2 Class 8 8 Class 10 9 Metric Bolts and Screws Using a Torque Wrench with an Offset Wrench Use of an offset wrench e g crowfoot wrench will affect torque wrench calibr...

Page 20: ...43 5 58 7 3 8 24 UNF 17 2 18 2 24 3 35 4 47 5 50 6 68 8 7 16 14 UNC 27 3 27 3 37 4 50 5 68 7 70 7 95 9 7 16 20 UNF 29 3 29 3 39 4 55 6 75 8 77 8 104 11 1 2 13 UNC 30 3 48 7 65 9 75 8 102 11 105 11 142 15 1 2 20 UNF 32 4 53 7 72 9 85 9 115 12 120 12 163 16 5 8 11 UNC 65 10 88 12 119 16 150 15 203 20 210 21 285 28 5 8 18 UNF 75 10 95 15 129 20 170 18 230 24 240 24 325 33 3 4 10 UNC 93 12 140 20 190 ...

Page 21: ...lb 126 14 N m M16 X 2 0 166 17 ft lb 225 23 N m 229 23 ft lb 310 31 N m M20 X 2 5 325 33 ft lb 440 45 N m 450 46 ft lb 610 62 N m Reduce torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are de fined as threads coated with a lubricant such as engine oil or thread sealant such as Loctite Torque values may have to be reduced when installing fasteners into th...

Page 22: ... in lb Wheel Bolts and Lug Nuts Thread Size Recommended Torque 7 16 20 UNF Grade 5 65 10 ft lb 88 14 N m 1 2 20 UNF Grade 5 80 10 ft lb 108 14 N m M12 X 1 25 Class 8 8 80 10 ft lb 108 14 N m M12 X 1 5 Class 8 8 80 10 ft lb 108 14 N m For steel wheels and non lubricated fasteners Thread Cutting Screws Zinc Plated Steel Thread Size Threads per Inch Baseline Torque Type A Type B No 6 18 20 20 5 in lb...

Page 23: ...U 4 Yanmar Engine 5 Diesel Particulate Filter DPF 5 SERVICE AND REPAIRS 9 Air Cleaner System 9 Exhaust System 11 Fuel System 13 Check Fuel Lines and Connections 14 Drain and Clean Fuel Tank 14 Prime the Fuel System 14 Fuel Tank Removal 14 Fuel Tank Installation 14 Radiator Oil Cooler Assembly 15 Engine 19 Engine Removal 20 Engine Installation 21 Pump Adapter Plate 23 YANMAR TNV Tier 4 SERIES SERVI...

Page 24: ...wise viewed from flywheel Fuel Diesel or Biodiesel up to B20 Fuel with Ultra Low Sulfur Content Fuel Capacity 22 U S gallons 83 liters Fuel Pump Yanmar Supply Pump Fuel Injection Type Common Rail with Direct Injection Governor Electronic All Speed Low Idle no load 1200 RPM High Idle no load 2850 RPM Engine Oil API CJ 4 or higher Engine Oil Viscosity See Operator s Manual Crankcase Oil Capacity 6 U...

Page 25: ...h your Authorized Toro Distributor If no parts list is available be prepared to provide your distrib utor with the Toro model and serial number of your ma chine Operator s Manuals The Traction Unit and Yanmar Engine Operator s Manu als provide information regarding the operation general maintenance and maintenance intervals for your Reel master machine Refer to these publications for addi tional i...

Page 26: ...duced or the engine might stop The Yanmar electronic tool and troubleshooting manual should be used to provide as sistance in identifying the cause of the problem and the repairs that are necessary Contact your Toro distributor for assistance in Yanmar engine troubleshooting IMPORTANT Do not plug or unplug the engine ECU for a period of thirty 30 seconds after the machine key switch is turned OFF ...

Page 27: ...ional information re garding the Diesel Particulate Filter DPF can be found in the Yanmar Operation Manual Industrial Engines TNV supplied with your machine Regeneration The engine ECU monitors the exhaust pressure before and after the soot filter in the DPF to determine if soot is accumulating If soot is accumulating during normal en gine operation the pressure differential will increase The incr...

Page 28: ... raise the exhaust temperature For software 122 0251A thru D only the InfoCenter displays the assist regeneration icon Reset Occurs every 100 hours of engine operation Occurs after an assist regeneration if the engine ECU determines the assist regeneration did not sufficiently reduce the soot level Note Reset regeneration may be temporarily delayed if high exhaust temperatures would create an unsa...

Page 29: ...installed on the machine Occurs when exhaust back pressure in the DPF increases due to continued soot buildup May be caused by prolonged operation at low engine speed low engine load or the use of incorrect fuel or engine oil May occur if the InfoCenter is set to inhibit regen preventing a Reset Regeneration and machine operation is continued Can be initiated when prompted by the engine ECU or aft...

Page 30: ...eration as soon as possible Perform a recovery regeneration as soon as possible Ash Accumulation Ash is a result of the regeneration processes The lighter ash is discharged through the exhaust system while the heavier ash collects in the soot filter When enough ash accumulates in the soot filter the engine ECU will generate an engine fault to prompt servicing the DPF In addition to an engine fault...

Page 31: ...strap 5 Flat washer 2 6 Flat washer 2 7 Socket head screw 2 8 Lock nut 2 9 Spring 2 10 Air cleaner outlet hose 11 Hose clamp 12 Hose clamp 13 Air cleaner inlet hose 14 Hose clamp 15 Plenum 16 Flange head screw 4 17 Flange nut 4 18 Flange nut 2 19 Cap screw 2 16 to 19 in lb 1 8 to 2 2 N m VACUATOR DIRECTION 1 2 3 4 6 7 8 10 11 12 13 14 15 16 17 18 19 5 9 Yanmar Engine ...

Page 32: ...so that grooves in adapter hex and adapter filter element are installed toward service indicator Tighten indicator from 26 to 33 in lb 3 0 to 3 7 N m B Orientate vacuator valve on air cleaner cover to ward ground C Make sure that air cleaner hoses do not contact any engine or machine components To modify clearance move and or rotate air cleaner body in air cleaner strap Verify that tabs in strap m...

Page 33: ... 22 Bolt 2 23 Nut 20 24 Bolt 2 25 Pipe joint bolt 2 26 Exhaust pressure pipe DPF inlet 27 Sensor gasket 4 28 Exhaust pressure pipe DPF outlet 29 Exhaust hose 30 Bolt 2 31 Hose clip 2 32 Hose 33 Bolt 3 34 Hose clip 2 35 Pressure sensor 36 Sensor bracket 37 Bolt 2 38 Bolt 2 39 Clip band 40 Band 41 Connector clip 2 42 Bolt 2 43 Bolt 2 44 Bolt 2 FRONT RIGHT 19 to 29 ft lb 25 to 40 N m 2 3 8 10 13 1 5 ...

Page 34: ...shoot ing Manual Removal Figs 6 and 7 NOTE The exhaust system DPF and DOC can be re moved from the exhaust system without removing the entire exhaust from the engine Certain engine service procedures e g rocker cover removal for valve clear ance adjustment will require removal of the exhaust system assembly CAUTION The muffler and exhaust pipe may be hot To avoid possible burns allow the engine an...

Page 35: ... Clamp 2 12 Flange nut 2 13 Fuel pump 14 Cap screw 15 Fuel hose pump to filter 16 Fuel hose filter to engine 17 Cap screw 2 18 Flange nut 4 19 Fuel water separator 20 Filter element 21 Elbow fitting 2 22 Flat washer 2 23 Fuel gauge 24 Grommet 25 Hose clamp 26 Draincock Figure 8 FRONT RIGHT 12 22 11 10 25 26 Return From Engine To Engine 1 2 3 4 5 6 7 8 9 23 24 18 13 14 15 16 17 19 20 21 21 8 8 8 8 ...

Page 36: ...osing of waste fuel Prime the Fuel System The fuel system needs to be primed before starting the engine for the first time after running out of fuel or after fuel system maintenance e g draining the filter water separator replacing a fuel hose To prime the fuel sys tem make sure that the fuel tank has fuel in it Then turn the ignition key to the ON position for 10 to 15 seconds which allows the fu...

Page 37: ...ose clamp 4 22 Hose plenum drain 23 Coolant reservoir 24 Reservoir bracket 25 Cap screw 2 26 Lock washer 2 27 Flange head screw 2 28 Flange nut 2 29 Hose reservoir to radiator 30 Reservoir cap 31 Hose clamp 32 Hose reservoir overflow 33 Flange head screw 4 34 Radiator cap 35 Radiator draincock 36 Bulb seal 37 Bulb seal 38 Radiator mount 39 Flange head screw 4 40 Flange nut 4 41 Foam seal 2 42 Spac...

Page 38: ...t secure coolant reservoir bracket item 24 to frame and remove reservoir and bracket from machine 10 Remove engine cooling fan assembly including up per radiator shroud from machine see Engine Cooling Fan Motor in Chapter 5 Hydraulic System in this manu al 11 To prevent contamination of hydraulic system during radiator oil cooler removal thoroughly clean junction of hydraulic hoses and fittings on...

Page 39: ...lugs in radiator coolant openings or coolant hoses 7 Connect upper and lower radiator hoses to the radi ator and secure with hose clamps 8 Secure coolant reservoir bracket item 24 to frame with two 2 cap screws and lock washers 9 Connect reservoir hose item 29 to the radiator vent tube 10 Remove caps or plugs from hydraulic hoses and fit tings that were installed during disassembly Connect hydraul...

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Page 41: ... 10 Rebound washer 4 11 Cap screw 3 12 Cap screw 13 Cap screw 14 Tailpipe support 15 Hose clamp 2 16 Fuel hose filter to engine 17 Fuel hose engine to tank 18 Clamp 2 19 Exhaust tailpipe 20 Flange nut 4 21 Exhaust flange 22 Exhaust gasket 23 External tooth lock washer 24 Battery ground cable FRONT RIGHT 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 5 5 5 6 6 6 7 7 7 8 8 8 9 9 9 13 9 9 10 10 10 11 11 18 1...

Page 42: ...plen um with air cleaner hose and drain hose attached 9 Disconnect upper and lower coolant hoses from the radiator 10 Remove air cleaner system from engine see Air Cleaner Removal in this chapter 11 Remove engine cooling fan assembly and fan shrouds from machine see Engine Cooling Fan Motor in Chapter 5 Hydraulic System in this manual Figure 14 1 Coolant reservoir hose 2 Reservoir and bracket 3 Ca...

Page 43: ...stall engine mount brackets to the en gine 3 Connect lift or hoist to the lift tabs on engine CAUTION One person should operate lift or hoist while a second person guides the engine into the ma chine IMPORTANT Make sure to not damage the engine fuel lines hydraulic lines electrical harness or oth er parts while installing the engine 4 Carefully lower engine into the machine Move en gine toward the...

Page 44: ...coolant reservoir hose to the radiator Fig 15 18 Make sure radiator draincock is closed and fill radia tor and reservoir with coolant 19 Check position of wires fuel lines hydraulic hoses and cables for proper clearance with rotating high tem perature and moving components 20 Connect positive battery cable first and then nega tive battery cable Secure battery cover to machine 21 Check and adjust e...

Page 45: ...re 16 1 Flywheel plate 2 Hardened washer 8 3 Spring coupler 4 Cap screw with patch lock 8 5 Cap screw with patch lock 8 6 Hardened washer 8 7 Engine assembly FRONT RIGHT 1 3 5 2 4 6 7 17 to 21 ft lb 23 to 28 N m Boss Loctite 242 if reused Loctite 242 if reused Yanmar Engine ...

Page 46: ... feature of the cap screws used in this procedure suggest replacing the screws after disassembly An alternative would be to apply Loctite 242 or equivalent to the threads of the original cap screws during assembly 2 Secure coupler to flywheel with cap screws item 4 and hardened washers Tighten cap screws in a cross ing pattern from 17 to 21 ft lb 23 to 28 N m 3 Position flywheel plate to engine Ma...

Page 47: ...S 4 Air Filter System 4 Exhaust System 6 Fuel System 8 Check Fuel Lines and Connections 9 Drain and Clean Fuel Tank 9 Fuel Tank Removal 9 Fuel Tank Installation 9 Prime Fuel System 10 Bleed Air From Injectors 11 Radiator Hydraulic Oil Cooler 12 Engine 16 Engine Removal 17 Engine Installation 18 Pump Adapter Plate 22 KUBOTA WORKSHOP MANUAL DIESEL ENGINE 03 M DI E3B SERIES Kubota Engine ...

Page 48: ...d from flywheel Fuel Diesel or Biodiesel up to B20 Fuel with Low or Ultra Low Sulfur Content Fuel Capacity 22 U S gallons 83 liters Fuel Injection Pump Denso PFR 4M Type Mini Pump Injection Nozzle Denso OPD Mini Nozzle Governor Centrifugal Mechanical Low Idle no load 1550 50 RPM High Idle no load 2850 50 120 RPM Engine Oil API CH 4 CI 4 or higher Engine Oil Viscosity See Operator s Manual Crankcas...

Page 49: ...d in the Kubota Workshop Manual Diesel Engine 03 M DI E3B The use of some spe cialized test equipment is explained However the cost of the test equipment and the specialized nature of some repairs may dictate that the work be done at an en gine repair facility Service and repair parts for Kubota engines are sup plied through your Authorized Toro Distributor If no parts list is available be prepare...

Page 50: ... 5 Support bracket 6 Cap screw 4 7 Flange nut 4 8 Air cleaner strap 9 Cap screw 2 10 Air cleaner assembly 11 Service indicator 12 Hose clamp 13 Hose clamp 14 Flat washer 2 15 Flange nut 2 16 Adapter 17 Air cleaner hose 18 Plenum 19 Air intake hose FRONT RIGHT 12 to 15 in lb 1 4 to 1 6 N m 1 2 3 4 9 10 11 12 13 14 5 6 7 8 16 6 15 17 18 19 12 Vacuator Direction ...

Page 51: ...o that grooves in adapter hex and adapter filter element are installed toward service indicator Fig 3 Torque indicator from 12 to 15 in lb 1 4 to 1 6 N m B Orientate vacuator valve on air cleaner cover to ward ground C Install air cleaner so air cleaner strap item 10 is as close as possible to air cleaner cover D Make sure that air cleaner hose item 17 does not contact engine valve cover or other ...

Page 52: ... 4 1 Muffler 2 Flange head screw 2 3 Flange head screw 4 4 Muffler clamp 5 Tailpipe 6 RH engine mount 7 Flat washer 8 Cap screw 9 Muffler bracket 10 Muffler gasket 11 Engine 12 Muffler bracket 13 Flange nut 2 14 Muffler clamp FRONT RIGHT 1 3 4 6 10 12 5 7 8 9 11 13 14 2 ...

Page 53: ...oughly clean threads in head and apply Loctite 277 or equivalent to stud threads before installing studs into head NOTE Make sure muffler flange and exhaust manifold sealing surfaces are free of debris or damage that may prevent a tight seal 1 Install new exhaust gasket if original gasket is dam aged or torn IMPORTANT Failure to follow the suggested ex haust system fastener sequence may result in ...

Page 54: ...e nut 2 13 Fuel pump 14 Cap screw 15 Fuel pump bracket 16 Fuel hose pump to filter 17 Fuel hose filter to engine 18 Cap screw 2 19 Flange nut 4 20 Fuel filter water separator 21 Filter element 22 Elbow fitting 2 23 Flat washer 2 24 Fuel gauge 25 Grommet 26 Hose clamp 27 Draincock 28 Cap screw FRONT RIGHT 12 23 11 10 26 27 Return From Engine To Engine 1 2 3 4 5 6 7 8 9 13 14 15 16 17 18 19 20 22 21...

Page 55: ...es contaminated or if the machine is to be stored for an ex tended period To clean fuel tank flush tank out with clean diesel fuel Make sure tank is free of contaminates and debris Follow all local codes and regulations when recycling or disposing of waste fuel Fuel Tank Removal Fig 5 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ign...

Page 56: ... than a 180 day supply of fuel Do not operate machine without entire exhaust system in place and in proper working condition 3 Loosen air bleed screw on the top of the fuel filter wa ter separator Fig 6 4 Turn ignition switch to the ON position until a solid stream of fuel flows out around the bleed screw Turn ignition switch to the OFF position and tighten air bleed screw 5 Loosen air bleed screw...

Page 57: ... Never fill the fuel tank inside an enclosed trailer Never smoke when handling fuel and stay away from an open flame or where fuel fumes may be ignited by a spark Store fuel in an approved container and keep it out of the reach of children Never buy more than a 180 day supply of fuel Do not operate machine without entire exhaust system in place and in proper working condition 2 Release hood latch ...

Page 58: ...ng 21 Hose clamp 4 22 Hose plenum drain 23 Coolant reservoir 24 Reservoir bracket 25 Cap screw 2 26 Lock washer 2 27 Flange head screw 2 28 Flange nut 2 29 Hose reservoir to radiator 30 Reservoir cap 31 Hose clamp 32 Hose reservoir overflow 33 Flange head screw 4 34 Radiator cap 35 Radiator draincock 36 Bulb seal 37 Bulb seal 38 Radiator mount 39 Flange head screw 4 40 Flange nut 4 41 Foam seal 2 ...

Page 59: ...e coolant reservoir bracket item 24 to frame and remove reservoir and bracket from machine 10 Remove engine cooling fan assembly including up per radiator shroud from machine see Engine Cooling Fan Motor in Chapter 5 Hydraulic System in this manu al 11 To prevent contamination of hydraulic system during radiator oil cooler removal thoroughly clean junction of hydraulic hoses and fittings on oil co...

Page 60: ... Remove any plugs in radiator coolant openings or coolant hoses 7 Connect upper and lower radiator hoses to the radi ator and secure with hose clamps 8 Secure coolant reservoir bracket item 24 to frame with two 2 cap screws and lock washers 9 Connect reservoir hose item 29 to the radiator vent tube 10 Remove caps or plugs from hydraulic hoses and fit tings that were installed during disassembly Co...

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Page 62: ... Muffler bracket 10 Cap screw 4 11 Mount bracket right front 12 Muffler bracket 13 Flange head screw 14 Cap screw 2 15 Hardened washer 2 16 Spacer 2 17 Flange head screw 8 18 Rubber engine mount 4 19 Flange nut 8 20 Rebound washer 4 21 Flange nut 4 22 Lock washer 23 Battery ground cable 24 Lock washer 25 Cap screw FRONT RIGHT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 3 4 7 6 10 21 22 23 2...

Page 63: ...oolant hoses from the radiator CAUTION The exhaust system may be hot T o avoid pos sible burns allow the exhaust system to cool be fore working on or near the muffler 10 Remove exhaust system from engine see Exhaust System Removal in this chapter 11 Remove air cleaner system from engine see Air Cleaner Removal in this chapter 12 Remove engine cooling fan assembly and fan shrouds from machine see E...

Page 64: ... damage the engine fuel lines hydraulic lines electrical harness or oth er parts while removing the engine 20 Carefully move engine away from the hydraulic pump assembly to disengage the pump input shaft from the coupler on the engine flywheel Once the engine has cleared the hydraulic pump carefully lift engine from the machine 21 If necessary remove engine mounts from the en gine Figure 15 1 Engi...

Page 65: ...usible link har ness at the engine starter motor D The electric starter Torque nut at starter B termi nal from 70 to 86 in lb 7 9 to 9 7 N m E The negative battery cable engine wire harness ground and main wire harness ground wires These wires are secured with a cap screw and external lock washer to the right side of the engine below the starter motor 10 Using notes taken during engine removal sec...

Page 66: ...r proper clearance with rotating high tem perature and moving components 21 Connect positive battery cable first and then nega tive battery cable Secure battery cover to machine 22 Check and adjust engine oil level as needed 23 Check and adjust hydraulic oil level as needed 24 Prime the fuel system see Priming The Fuel System in this chapter 25 Start engine and operate hydraulic controls to prop e...

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Page 68: ...ter Plate Figure 18 1 Bolt 2 Lock washer 3 Flywheel plate 4 Hardened washer 14 5 Spring coupler 6 Cap screw with patch lock 6 7 Cap screw with patch lock 8 FRONT RIGHT 1 2 3 4 5 6 7 4 Loctite 242 if reused Boss Loctite 242 if reused 29 to 33 ft lb 40 to 44 N m ...

Page 69: ...e of the cap screws used in this procedure suggest replacing the screws after disassembly An alternative would be to apply Loctite 242 or equivalent to the threads of the original cap screws during assembly 2 Secure coupler to flywheel with cap screws item 6 and hardened washers Tighten bolts in a crossing pat tern from 29 to 33 ft lb 40 to 44 N m 3 Position flywheel plate to engine Make sure that...

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Page 71: ...t pump sections P2 thru P5 82 ADJUSTMENTS 86 Control Manifold Relief Valve Adjustment 86 SERVICE AND REPAIRS 87 General Precautions for Removing and Installing Hydraulic System Components 87 Check Hydraulic Lines and Hoses 88 Priming Hydraulic Pumps 88 Flush Hydraulic System 89 Filtering Closed Loop Traction Circuit 90 Charge Hydraulic System 91 Gear Pump 92 Gear Pump Service 94 Piston traction Pu...

Page 72: ... 9 16 cc Steering Control Valve Danfoss Steering Unit Series OSPM Displacement per revolution 6 1 in3 100 cc Steering Circuit Relief Pressure 1050 PSI 72 bar Lift Lower Circuit Relief Pressure 1700 PSI 117 bar Cutting Unit Motors Casappa Gear Motor Displacement per revolution 1 63 in3 26 7 cc Cutting Unit Circuit Relief Pressure 3000 PSI 207 bar Engine Cooling Fan Motor Casappa Gear Motor Displace...

Page 73: ...ting Unit Operator s Manual for additional information when ser vicing the machine Hydraulic Component Locations 1 Piston pump P1 2 Gear pump P2 P5 3 HI LOW range manifold 4 Rear traction manifold 5 Front wheel motor 2 6 Lift control manifold 7 Lift junction manifold 8 Steering control valve 9 Suction strainer 10 Charge filter 11 Return filter 12 Fan control manifold 13 Mow control manifold 14 Rea...

Page 74: ...ircuit This filter should be used when con necting hydraulic test gauges in order to test traction circuit components or after replacing a failed traction cir cuit component e g traction piston pump or wheel motor The filter will ensure that contaminates are re moved from the closed loop system and do not cause additional component damage Once the Toro high flow hydraulic filter kit has been place...

Page 75: ... needed to bypass the check valve 59 7410 diagnostic fitting 354 79 diagnostic fitting cap 95 8843 hydraulic hose 95 0985 coupler fitting 2 340 77 hydraulic fitting 2 NOTE The 6 zero leak plug on the rear traction mani fold has a tapered sealing surface on the plug head Lightly rap the plug head using a punch and hammer be fore using an allen wrench to remove the plug The im pact will allow plug r...

Page 76: ...he hose Use two wrenches hold the hose straight with one wrench and tighten the hose swivel nut onto the fit ting with the other wrench See Hydraulic Hose and Tube Installation in this section If the hose has an el bow at one end tighten the swivel nut on that end before tightening the nut on the straight end of the hose For additional hydraulic hose information refer to Toro Service Training Book...

Page 77: ...h in the Torque Specifica tions section of Chapter 2 Product Records and Main tenance 5 If a torque wrench is not available or if space at the swivel nut prevents use of a torque wrench an alternate method of assembly is the Flats From Wrench Resist ance F F W R method Fig 2 A Using a wrench tighten the swivel nut onto the fit ting until light wrench resistance is reached approxi mately 30 in lb B...

Page 78: ...ecords and Maintenance to determine necessary con version information 5 If a torque wrench is not available or if space at the port prevents use of a torque wrench an alternate meth od of assembly is the Flats From Finger Tight F F F T method A Install the fitting into the port and tighten it down full length until finger tight B If port material is steel tighten the fitting to the listed F F F T ...

Page 79: ... with a wrench and use a torque wrench to tighten the fitting to the rec ommended installation torque shown in Figure 8 This tightening process will require the use of an offset wrench e g crowfoot wrench Use of an offset wrench will affect torque wrench calibration due to the effective length change of the torque wrench Tightening torque when using a torque wrench with an offset wrench will be lo...

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Page 81: ...STON 110 psi 3000 psi 040 3000 psi 040 110 psi MV2 MV1 SP1 M1 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID CV1 LC1 RV1 OR2 OR1 LIFT MANIFOLD CHG STRAINER BREATHER FORWARD REVERSE LEFT CYLINTER EXTEND TO LOWER CENTER CYLINDER EXTEND TO LOWER LEFT CYLINTER FRONT LIFT CYLINDERS REAR LIFT CYLINDERS EXTEND TO LOWER REEL EXTEND 4 1 5 2 3 MOTORS FRONT REAR M2 M2 50 psi 50 psi TRACT...

Page 82: ...6 CID 0 56 CID 1 03 CID 1 03 CID 3 00 CID STEERING CYLINDER 1 2 3 0 036 in 0 028 0 028 FAN STEERING UNIT 055 C4 1700 psi C3 040 S2 S4 207 psi ROD PISTON 110 psi 3000 psi 040 3000 psi 040 110 psi MV2 MV1 SP1 M1 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID CV1 LC1 RV1 OR2 OR1 LIFT MANIFOLD CHG STRAINER BREATHER FORWARD REVERSE LEFT CYLINTER EXTEND TO LOWER CENTER CYLINDER EXTE...

Page 83: ...lso provides oil for the charge cir cuit Gear pump flow for the charge circuit is directed through the steering valve lift manifold oil filter and to the low pressure side of the closed loop traction circuit Charge pressure is limited to 207 PSI 14 3 bar by a check valve located in the lift manifold Forward Direction With the mow speed limiter in the LOW speed mow position the solenoid valve in th...

Page 84: ...D 1 03 CID 1 03 CID 3 00 CID STEERING CYLINDER 1 2 3 0 036 in 0 028 0 028 FAN STEERING UNIT 055 C4 1700 psi C3 040 500 psi S2 S4 207 psi ROD PISTON 110 psi 3000 psi 040 3000 psi 040 110 psi MV2 MV1 SP1 M1 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID CV1 LC1 RV1 OR2 OR1 LIFT MANIFOLD CHG STRAINER BREATHER FORWARD REVERSE LEFT CYLINTER EXTEND TO LOWER CENTER CYLINDER EXTEND TO...

Page 85: ...mp flow for the charge circuit is directed through the steering valve lift manifold oil filter and to the low pressure side of the closed loop traction circuit Charge pressure is limited to 207 PSI 14 3 bar by a check valve located in the lift manifold Forward Direction With the mow speed limiter in the HI speed transport position the solenoid valve in the Hi Low range manifold is energized This e...

Page 86: ...CID 1 03 CID 3 00 CID STEERING CYLINDER 1 2 3 0 036 in 0 028 0 028 FAN STEERING UNIT 055 C4 1700 psi C3 040 500 psi S2 S4 207 psi ROD PISTON 110 psi 3000 psi 040 3000 psi 040 110 psi MV2 MV1 SP1 M1 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID CV1 LC1 RV1 OR2 OR1 LIFT MANIFOLD CHG STRAINER BREATHER FORWARD REVERSE LEFT CYLINTER EXTEND TO LOWER CENTER CYLINDER EXTEND TO LOWER ...

Page 87: ...o allow the appropriate current to the proportional valve coils Flow through the proportional valves SP1 and SP2 is pressure compensated by the logic cartridge valves LC1 and LC2 The logic cartridge valve maintains a pressure of 110 PSI 7 6 bar across the proportional valve Any excess flow is returned to the oil cooler and return filter Maximum mow circuit pressure is limited at each mow manifold ...

Page 88: ... 03 CID 1 03 CID 3 00 CID STEERING CYLINDER 1 2 3 0 036 in 0 028 0 028 FAN STEERING UNIT 055 C4 1700 psi C3 040 500 psi S2 S4 207 psi ROD PISTON 110 psi 3000 psi 040 3000 psi 040 110 psi MV2 MV1 SP1 M1 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID CV1 LC1 RV1 OR2 OR1 LIFT MANIFOLD CHG STRAINER BREATHER FORWARD REVERSE LEFT CYLINTER EXTEND TO LOWER CENTER CYLINDER EXTEND TO LO...

Page 89: ...o the rod end of the steering cylinder retracts the cylinder for a left turn The rotary meter ensures that the oil flow to the cylinder is proportional to the amount the steering wheel is turned Fluid leaving the cylinder flows back through the spool valve out the T port and returns to the hydraulic reservoir The steering control valve returns to the neutral position when turning is completed Righ...

Page 90: ...6 CID 1 03 CID 1 03 CID 3 00 CID STEERING CYLINDER 1 2 3 0 036 in 0 028 0 028 FAN STEERING UNIT 055 C4 1700 psi C3 040 500 psi S2 S4 207 psi ROD PISTON 110 psi 3000 psi 040 3000 psi 040 110 psi MV2 MV1 SP1 M1 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID CV1 LC1 RV1 OR2 OR1 LIFT MANIFOLD CHG STRAINER BREATHER FORWARD REVERSE LEFT CYLINTER EXTEND TO LOWER CENTER CYLINDER EXTEN...

Page 91: ...ting units to be lowered before the rear cutting units the controller slightly delays energizing solenoid S5 after the joystick is moved to the lower position The energized solenoid valves direct gear pump oil flow to the piston end of the lift cylinders Hydraulic pressure causes the lift cylinder shafts to extend and lower the cutting units The flow to the front lift cylinders is restricted by a ...

Page 92: ... CID 1 03 CID 1 03 CID 3 00 CID STEERING CYLINDER 1 2 3 0 036 in 0 028 0 028 FAN STEERING UNIT 055 C4 1700 psi C3 040 500 psi S2 S4 207 psi ROD PISTON 110 psi 3000 psi 040 3000 psi 040 110 psi MV2 MV1 SP1 M1 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID CV1 LC1 RV1 OR2 OR1 LIFT MANIFOLD CHG STRAINER BREATHER FORWARD REVERSE LEFT CYLINTER EXTEND TO LOWER CENTER CYLINDER EXTEND...

Page 93: ...ge circuit Raise Cutting Units NOTE The operator must be in the operator seat in or der to raise the cutting units When the joystick is moved to the raise position sole noid valve S1 along with solenoid valves S2 S3 S4 and S5 are energized by the TEC To allow the front cutting units to be raised before the rear cutting units the con troller slightly delays energizing solenoid S5 after the joystick...

Page 94: ... 0 56 CID 1 03 CID 1 03 CID 3 00 CID STEERING CYLINDER 1 2 3 0 036 in 0 028 0 028 FAN STEERING UNIT 055 C4 1700 psi C3 040 500 psi S2 S4 207 psi ROD PISTON 110 psi 3000 psi 040 3000 psi 040 110 psi MV2 MV1 SP1 M1 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID CV1 LC1 RV1 OR2 OR1 LIFT MANIFOLD CHG STRAINER BREATHER FORWARD REVERSE LEFT CYLINTER EXTEND TO LOWER CENTER CYLINDER E...

Page 95: ...engine is shut off the over running inertia load of the fan blades keeps driving the fan motor and turns it into a pump The check valve CV in the fan con trol manifold will open to keep the motor circuit full of oil so the fan motor will not cavitate fill with air NOTE If PWM current is not available to the fan control manifold proportional relief valve PRV the cooling fan motor will run at full s...

Page 96: ...st hydraulic circuits and components for flow and pressure capacities as recommended in the Testing section of this chapter This tester includes the following 1 INLET HOSE Hose connected from the system cir cuit to the inlet side of the hydraulic tester 2 LOAD VALVE A simulated working load is created in the circuit by turning the valve to restrict flow 3 PRESSURE GAUGE Glycerine filled 0 to 5000 ...

Page 97: ...ycerine filled 0 to 5000 PSI gauge to provide operating circuit pressure 3 FLOW METER This meter measures actual oil flow in the operating circuit with a gauge rated from 4 to 40 GPM 20 to 150 LPM Toro Part Number AT40002 NOTE This tester does not include hydraulic hoses see Hydraulic Hose Kit TOR6007 below Figure 20 Hydraulic Hose Kit This kit includes hydraulic fittings and hoses needed to conne...

Page 98: ...or after replacing a failed traction circuit component e g piston traction pump or wheel motor the high flow hy draulic filter can be installed in the traction circuit The filter will ensure that contaminates are removed from the closed loop and thus do not cause additional compo nent damage Toro Part Number TOR6011 NOTE This kit does not include hydraulic hoses see Hydraulic Hose Kit TOR6007 abov...

Page 99: ...e drain line while the motor is pressurized by the hydraulic system The table in Figure 25 provides gallons per minute GPM conversion for measured milliliter or ounce motor case drain leakage Toro Part Number TOR4077 Figure 24 Figure 25 O ring Kit The kit includes O rings in a variety of sizes for face seal and port seal hydraulic connections It is recommended that O rings be replaced whenever a h...

Page 100: ...ctor for circuit protection A remote stater switch can also be constructed using Toro switch 106 2027 a length of 14 gauge wire a 20 amp in line fuse two 2 alligator clips and necessary connectors Connecting the wire to switch terminals 1 and 2 will allow the momentary switch contacts to be used for the remote starter switch Fig 28 NOTE For information on using the remote starter switch to prime t...

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Page 108: ...NG CAUTION Failure to use gauges with recommended pres sure PSI rating as listed in test procedures could result in damage to the gauge and possible personal injury from leaking hot oil CAUTION All testing should be performed by two 2 people One person should be in the seat to oper ate the machine and the other should monitor testing equipment and record test results 1 Clean machine thoroughly bef...

Page 109: ...ow circuit lift lower circuit steering circuit or engine cooling fan circuit Once the faulty system has been identified perform tests that relate to that circuit 1 If a traction circuit problem exists consider perform ing one or more of the following tests Traction Circuit Charge Pressure Traction Circuit Relief Pressure Traction Circuit Reducing Valve PR Pressure Rear Traction Circuit Relief Valv...

Page 110: ...0 028 0 028 FAN STEERING UNIT 055 C4 1700 psi C3 040 500 psi S2 S4 207 psi ROD PISTON 110 psi 3000 psi 040 3000 psi 040 110 psi MV2 MV1 SP1 M1 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID CV1 LC1 RV1 OR2 OR1 LIFT MANIFOLD CHG STRAINER BREATHER FORWARD REVERSE LEFT CYLINTER EXTEND TO LOWER CENTER CYLINDER EXTEND TO LOWER LEFT CYLINTER FRONT LIFT CYLINDERS REAR LIFT CYLINDERS ...

Page 111: ...om the charge filter Fig 30 4 Install a tee fitting diagnostic fitting and a 1000 PSI 70 bar pressure gauge with hose between the piston traction pump fitting and disconnected hose The pres sure gauge hydraulic hose must be long enough to safe ly view the pressure gauge while sitting in the operator s seat 1 Piston traction pump 2 Charge circuit hose Figure 30 1 2 FRONT LEFT 5 Start engine and run...

Page 112: ... charge pressure without load recorded in step 8 If specifications are not met perform Piston traction Pump Flow Test as outlined in this chapter 11 Release traction pedal set parking brake move throttle to low speed and turn the engine off 12 Remove pressure gauge and tee fitting when testing is completed Install charge circuit hose and check for leaks ...

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Page 114: ... CID 0 56 CID 1 03 CID 1 03 CID 3 00 CID STEERING CYLINDER 1 2 3 0 036 in 0 028 0 028 FAN STEERING UNIT 055 C4 1700 psi C3 040 500 psi S2 S4 207 psi ROD PISTON 110 psi 3000 psi 040 3000 psi 040 110 psi MV2 MV1 SP1 M1 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID CV1 LC1 RV1 OR2 OR1 LIFT MANIFOLD CHG STRAINER BREATHER FORWARD REVERSE LEFT CYLINTER EXTEND TO LOWER CENTER CYLIND...

Page 115: ... engine RPM on units with Kubota diesel engines 2850 50 120 RPM 6 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately ten 10 minutes 7 Sit in the operator s seat set the mow speed limiter to the HI speed transport position release the parking brake and apply the brakes Slowly depress the traction pedal in the appropriate direction forward or rever...

Page 116: ... FAN STEERING UNIT 055 C4 1700 psi C3 040 500 psi S2 S4 207 psi ROD PISTON 110 psi 3000 psi 040 3000 psi 040 110 psi MV2 MV1 SP1 M1 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID CV1 LC1 RV1 OR2 OR1 LIFT MANIFOLD CHG STRAINER BREATHER FORWARD REVERSE LEFT CYLINTER EXTEND TO LOWER CENTER CYLINDER EXTEND TO LOWER LEFT CYLINTER FRONT LIFT CYLINDERS REAR LIFT CYLINDERS EXTEND TO L...

Page 117: ...raction pump 4 Disconnect hose from left side fitting on bottom of piston traction pump forward port Fig 33 IMPORTANT Traction circuit flow for the Reelmas ter 7000 D is approximately 35 GPM 133 LPM Use a Hydraulic Tester pressure and flow with a 40 GPM or larger capacity for this test see Special Tools in this chapter Figure 33 1 Piston traction pump 2 Left hose forward port FRONT LEFT 2 1 5 Inst...

Page 118: ...ings 13 Release traction pedal to the neutral position open flow control valve on tester and shut off engine 14 The Under Load test flow reading step 12 should not drop more than 12 when compared to the No Load test flow reading step 11 A difference of more than 12 may indicate A The piston traction pump swash plate is not be ing rotated fully traction pedal linkage is out of ad justment B The for...

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Page 120: ...1 83 CID 0 89 CID PR 400 psi RV 550 050 CV T P2 M8 CH OR1 5000 psi 5000 psi 2 32 CID 1 13 CID 150 psi 030 OR8 3 psi 1 83 CID 0 89 CID 3 00 CID 1 2 3 0 036 in 0 028 0 028 FORWARD REVERSE TRACTION REAR TEMPERATURE SENSOR TOW VALVE FRONT WHEEL MOTORS REAR AXLE MOTOR P1 psi PISTON PUMP ENGINE SPEED 2850 RPM MEASURING CONTAINER HI LOW RANGE MANIFOLD TESTING FRONT LEFT WHEEL MOTOR SHOWN ...

Page 121: ...r the right front wheel motor Fig 34 Forward traction test port faces the front 3 Connect a 10 000 PSI 700 bar pressure gauge to traction circuit test port for FORWARD operation The pressure gauge hydraulic hose must be long enough to safely view the pressure gauge while sitting in the opera tor s seat 1 FORWARD test port 2 REVERSE test port Figure 34 2 1 FRONT RIGHT 4 Attach a heavy chain to the ...

Page 122: ... than 29 oz 857 ml of hydraulic fluid in ten 10 seconds 225 GPM 0 85 LPM 14 If case drain flow is more than specification the mo tor is worn or damaged and should be repaired or re placed 15 Remove case drain test hose Remove plug from case drain tube and reconnect tube 16 Repeat test for additional front wheel motor if re quired 17 When testing is completed disconnect pressure gauge from test por...

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Page 124: ...0 56 CID 1 03 CID 1 03 CID 3 00 CID STEERING CYLINDER 1 2 3 0 036 in 0 028 0 028 FAN STEERING UNIT 055 C4 1700 psi C3 040 S2 S4 207 psi ROD PISTON 110 psi 3000 psi 040 3000 psi 040 110 psi MV2 MV1 SP1 M1 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID CV1 LC1 RV1 OR2 OR1 LIFT MANIFOLD CHG STRAINER BREATHER FORWARD REVERSE LEFT CYLINTER EXTEND TO LOWER CENTER CYLINDER EXTEND TO ...

Page 125: ...e must be long enough to safely view the pressure gauge while sitting in the opera tor s seat 4 Start engine and run at low idle speed Check for hy draulic leakage and make corrections if necessary be fore proceeding with test 5 Set throttle to high speed A Use the InfoCenter display to verify engine RPM on units with Yanmar diesel engines 2850 RPM B Use a phototach to verify engine RPM on units w...

Page 126: ... 1 03 CID 3 00 CID STEERING CYLINDER 1 2 3 0 036 in 0 028 0 028 FAN STEERING UNIT 055 C4 1700 psi C3 040 S2 S4 207 psi ROD PISTON 110 psi 3000 psi 040 3000 psi 040 110 psi MV2 MV1 SP1 M1 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID CV1 LC1 RV1 OR2 OR1 LIFT MANIFOLD CHG STRAINER BREATHER FORWARD REVERSE LEFT CYLINTER EXTEND TO LOWER CENTER CYLINDER EXTEND TO LOWER LEFT CYLINT...

Page 127: ...eat 4 Start engine and run at low idle speed Check for hy draulic leakage and make corrections if necessary be fore proceeding with test 5 Set throttle to high speed A Use the InfoCenter display to verify engine RPM on units with Yanmar diesel engines 2850 RPM B Use a phototach to verify engine RPM on units with Kubota diesel engines 2850 50 120 RPM 1 Rear traction manifold 2 Unmarked port 3 Rear ...

Page 128: ...psi 040 3000 psi 040 110 psi MV2 MV1 SP1 M1 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID CV1 LC1 RV1 OR2 OR1 STRAINER BREATHER FORWARD REVERSE REEL 4 1 5 2 3 MOTORS FRONT REAR MOW CONTROL M2 50 psi TOW VALVE P2 P3 P4 P5 P1 T1 RV2 SP2 LC2 CV2 PISTON PUMP MANIFOLD FROM FAN CONTROL TO FAN CIRCUIT FROM STEERING UNIT TO RESERVOIR FROM REEL MOTORS FROM CHARGE FILTER TO STEREING LI...

Page 129: ...its with Yanmar diesel engines 2850 RPM B Use a phototach to verify engine RPM on units with Kubota diesel engines 2850 50 120 RPM 6 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately ten 10 minutes 7 Sit in the operator s seat set the mow speed limiter to the LOW speed mow position and release the park ing brake 1 Test port G1 front cutting unit...

Page 130: ... B Relief valve RV1 front cutting units or RV2 rear cutting units is faulty see Cutting Unit Circuit Re lief Valve RV Pressure Test in this chapter C Logic Cartridge LC1 front cutting units or LC2 rear cutting units Is faulty see Control Manifold Cartridge Valve Service in this chapter D Gear pump P2 front cutting units or gear pump P3 rear cutting units is faulty see Gear Pump Flow Test in this c...

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Page 132: ...0 psi 040 3000 psi 040 110 psi MV2 MV1 SP1 M1 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID CV1 LC1 RV1 OR2 OR1 STRAINER BREATHER FORWARD REVERSE REEL 4 1 5 2 3 MOTORS MOW CONTROL M2 50 psi TOW VALVE P2 P3 P4 P5 P1 T1 RV2 SP2 LC2 CV2 PISTON PUMP MANIFOLD FROM FAN CONTROL TO FAN CIRCUIT FROM STEERING UNIT TO RESERVOIR FROM REEL MOTORS FROM CHARGE FILTER TO STEREING LIFT CHARGE...

Page 133: ...tting unit motor fitting Disconnect the supply hydraulic hose from the motor IMPORTANT Make sure that the oil flow indicator on the tester matches the flow of oil disconnected hose tester hydraulic motor 4 Install tester with pressure gauge and flow meter in series with the disconnected hose and cutting unit motor fitting The tester hydraulic hoses must be long enough to safely view the tester whi...

Page 134: ... RV1 front cutting units or RV2 rear cutting units in the mow control manifold see Adjust Control Manifold Re lief Valves in this chapter Recheck relief valve pressure setting after adjustment 12 After testing is complete disconnect tester from cut ting unit motor and hose Connect hydraulic hose to mo tor ...

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Page 136: ...psi 1 6 CID P1 G1 M3 M4 T2 P2 G2 110 psi 3000 psi 040 3000 psi 040 110 psi MV2 MV1 SP1 M1 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID CV1 LC1 RV1 OR2 OR1 REEL 4 1 5 2 3 MOTORS MOW CONTROL M2 T1 RV2 SP2 LC2 CV2 MANIFOLD TO RESERVOIR TESTER REAR CUTTING UNIT CIRCUIT FRONT CUTTING UNIT CURCUIT OIL COOLER GEAR PUMP P2 FROM GEAR PUMP P3 CONTROL MANIFOLD Working Pressure Low Pres...

Page 137: ...s disengaged The backlap levers on the mow control manifold should be in the mow F position CAUTION Prevent personal injury and or damage to equip ment Read all WARNINGS CAUTIONS and Pre cautions for Hydraulic Testing at the beginning of this section IMPORTANT Make sure that the oil flow indicator on the tester matches the flow of oil hydraulic mo tor tester disconnected hose 2 Disconnect the retu...

Page 138: ...l valve and stop the engine Record test results TEST RESULTS Case drain leakage should be less than 23 ounces 672 ml of hydraulic fluid in fifteen 15 seconds 0 7 GPM 2 7 LPM 14 If case drain flow is more than 23 ounces 672 ml in fifteen 15 seconds the reel motor is worn or dam aged and should be repaired or replaced 15 Disconnect tester from motor and hose Reconnect hose to the cutting unit motor ...

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Page 140: ...orking Pressure Low Pressure Charge Return or Suction Flow 1050 psi FD P2 L P T 50 50 SPLIT 0 56 CID 0 56 CID 1 03 CID 1 03 CID STEERING CYLINDER STEERING UNIT EXTEND 6 1 CIR P2 P3 P4 P5 TO TURN RIGHT E GEAR PUMP TO FAN CIRCUIT TO CHARGE CIRCUIT TO FRONT MOW CIRCUIT TO REAR MOW CIRCUIT TO LIFT MANIFOLD TO RESERVOIR PLUG PRESSURE GAUGE ...

Page 141: ...oceeding with test 5 Set throttle to high speed A Use the InfoCenter display to verify engine RPM on units with Yanmar diesel engines 2850 RPM B Use a phototach to verify engine RPM on units with Kubota diesel engines 2850 50 120 RPM 6 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately ten 10 minutes 1 Steering cylinder 2 Barrel end hose 3 Barrel...

Page 142: ...g Lift Circuit Steering Cylinder Test High Pressure Low Pressure Return or Suction Flow 1000 PSI P L E T R TO LIFT CONTROL MANIFOLD P PORT STEERING PLUG OPEN FITTING POWER STEERING VALVE CYLINDER FROM FLOW DIVIDER FD IN FAN CONTROL MANIFOLD TO RESERVOIR ...

Page 143: ... the fitting on the rod end of the steering cylinder Fig 41 Install a hydraulic plug in the disconnected hose 5 Remove all hydraulic oil from drain pan Make sure that empty drain pan remains under the open fitting of the steering cylinder 6 With the engine off continue turning the steering wheel to the right clockwise with the steering cylinder fully extended Observe the open fitting on the steeri...

Page 144: ...OWER P C1 G C2 RV1 S1 T 046 030 030 030 S3 055 C4 1700 psi C3 040 500 psi S2 S4 207 psi ROD PISTON LIFT MANIFOLD CHG LEFT CYLINTER EXTEND TO LOWER CENTER CYLINDER EXTEND TO LOWER LEFT CYLINTER FRONT LIFT CYLINDERS REAR LIFT CYLINDERS EXTEND TO LOWER JUNCTION MANIFOLD S5 RV2 FROM FLOW DIVIDER TO RESERVOIR FROM STEERING CONTROL VALVE PRESSURE GAUGE 046 046 ...

Page 145: ...perating tem perature by operating the machine for approximately ten 10 minutes Make sure the hydraulic tank is full 6 Lower and sit in the operator s seat Move the joy stick to raise and allow the cutting units to fully raise Mo mentarily hold the joystick with the lift cylinders fully retracted cutting units raised while looking at the pres sure gauge 1 Lift manifold 2 Test port G1 3 Relief valv...

Page 146: ...OL MANIFOLD 6 6 GPM 12 1 GPM RETURN FILTER P2 G2 G2 G1 3 3 GPM 0 56 CID 0 56 CID 1 03 CID 1 03 CID STEERING CYLINDER FAN STEERING UNIT 110 psi 3000 psi 040 3000 psi 040 110 psi MV2 MV1 SP1 M1 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID CV1 LC1 RV1 OR2 OR1 STRAINER BREATHER REEL EXTEND 4 1 5 2 3 MOTORS FRONT REAR MOW CONTROL M2 M2 50 psi 6 1 CIR P2 P3 P4 P5 MOTOR TO TURN RIG...

Page 147: ...0 RPM 5 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately ten 10 minutes Make sure the hydraulic tank is full CAUTION Cooling fan blades will rotate during the test pro cedure Keep away from cooling fan blades dur ing test to prevent personal injury from rotating blades 1 Fan control manifold 2 Test fitting port G2 3 Proportional relief valve so...

Page 148: ...Pressure Low Pressure Return or Suction Flow CASE DRAIN HOSE RETURN HOSE FRONT Working Pressure Low Pressure Charge Return or Suction Flow 0 51 CID T PRV S1 CV FD P2 P1 ST L M1 50 50 SPLIT FAN CONTROL MANIFOLD G2 G1 FAN M2 MOTOR TESTER MEASURING CONTAINER TO RESERVOIR FROM GEAR PUMP SECTION P5 FAN SHROUD ...

Page 149: ... flow of oil fan shroud up per bulkhead fitting tester fan control manifold 3 Disconnect the return tube from the fan shroud up per tube and the fan control manifold M2 port Remove the hydraulic tube and install a hydraulic tester and hose between the fan shroud bulkhead fitting and the fan con trol manifold Make sure the tester flow control valve is fully open 4 Start engine and run at low idle s...

Page 150: ...the tester flow control valve and stop the engine Record test results TEST RESULTS Case drain leakage should be less than 25 ounces 745 ml of hydraulic fluid in fifteen 15 seconds 0 8 GPM 3 LPM 14 If case drain flow is more than 25 ounces 745 ml in fifteen 15 seconds the fan motor is worn or dam aged and should be repaired or replaced 15 Remove tester and hose fan control manifold and fan shroud b...

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Page 152: ...harge Return or Suction Flow OIL 5000 psi 5000 psi RETURN 0 56 CID 0 56 CID 1 03 CID 1 03 CID 3 00 CID 0 036 in 0 028 0 028 STRAINER BREATHER FORWARD REVERSE 50 psi TOW VALVE P2 P3 P4 P5 P1 PISTON PUMP FROM FROM FROM GEAR PUMP REEL MOTORS STEERING UNIT FILTER COOLER FROM WHEEL MOTOR CASE DRAIN MOW CONTROL MANIFOLD FAN CONTROL MANIFOLD PORT P1 TO FAN CONTROL MANIFOLD PORT P2 TO MOW CONTROL MANIFOLD...

Page 153: ...ure engine is off and the parking brake is applied IMPORTANT Make sure that the oil flow indicator on the tester matches the flow of oil gear pump tester manifold 2 Determine which gear pump section is to be tested and install the hydraulic tester in series with the discon nected hose and hydraulic fitting at the appropriate loca tion A Gear Pump P2 Front Cutting Unit Circuit dis connect hydraulic...

Page 154: ...ecord tester pressure and flow readings under load 9 Open tester flow control set throttle to low speed and shut off engine PUMP SECTION CIRCUIT NO LOAD FLOW P2 Front Cutting Units 12 GPM 45 LPM P3 Rear Cutting Units 12 GPM 45 LPM P4 Steering Lift Charge 6 GPM 24 LPM P5 Engine Cooling Fan 46 GPM 24 LPM Figure 46 10 The under load test flow reading step 8 should not drop more than 15 when compared ...

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Page 156: ...nifold for adjustment 1 Locate relief valve on control manifold 2 Remove cap on relief valve with an allen wrench 3 To increase pressure setting turn the adjustment socket on the valve in a clockwise direction A 1 8 turn on the socket will make a measurable change in relief pressure 4 To decrease pressure setting turn the adjustment socket on the valve in a counterclockwise direction A 1 8 turn on...

Page 157: ...hoses for proper installation after repairs are completed 5 Note the position of hydraulic fittings especially el bow fittings on hydraulic components before removal Mark parts if necessary to make sure they will be aligned properly when installing hydraulic hoses and tubes After Repair or Replacement of Hydraulic Compo nents 1 Check oil level in the hydraulic reservoir and add cor rect oil if nec...

Page 158: ...ming ensures that the gear pump and piston traction pump have adequate oil dur ing initial start up and running The pumps can be primed by using a remote starter switch see Special Tools in this chapter to crank engine which allows the pumps to prime Use the following procedure to prime the hydraulic pumps 1 Make sure that ignition switch is in the OFF position and key is removed from switch 2 Che...

Page 159: ...nge and replace both hydraulic oil filters 5 Inspect and clean hydraulic reservoir see Hydraulic Reservoir Inspection in the Service and Repair section 6 Connect all hydraulic hoses lines and components that were disconnected while draining system NOTE Use only hydraulic fluids specified in the Trac tion Unit Operator s Manual Other fluids may cause system damage 7 Fill hydraulic reservoir with ne...

Page 160: ...lic oil as required 6 Start engine and run at idle speed Check for any hy draulic leakage from filter and hose connections Cor rect any leaks before proceeding IMPORTANT While engaging the traction circuit monitor the indicator on the high flow hydraulic fil ter If the indicator should show red either reduce pressure on the traction pedal or reduce engine speed to decrease hydraulic flow through t...

Page 161: ...t and start engine and let it idle at low speed The hydraulic pumps should pick up hydraulic fluid and fill the hydraulic system If there is no indication of fill in 30 seconds stop the engine and determine the cause 9 After the hydraulic system starts to show signs of fill actuate lift control switch until the lift cylinder rods move in and out several times If the cylinder rods do not move after...

Page 162: ...ting 2 23 O ring 2 24 O ring 25 90o hydraulic fitting 26 Straight hose fitting Figure 50 FRONT RIGHT 1 2 3 4 23 16 6 12 8 9 10 13 5 21 11 18 17 20 19 14 15 22 7 5 11 11 12 8 16 18 77 to 93 ft lb 105 to 126 N m 21 22 23 24 25 26 5 103 to 118 ft lb 140 to 160 N m Removal Fig 50 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition swi...

Page 163: ...is chapter 2 Lubricate new O rings item 16 with clean hydraulic oil Position O rings on gear pump and pump spacer flanges 3 Slide coupler item 9 onto the piston pump output shaft 4 Position pump spacer item 17 to gear pump Align gear teeth and slide gear pump input shaft into coupler Secure gear pump to piston pump with two 2 cap screws and flat washers 5 Remove caps and plugs from hydraulic hoses...

Page 164: ...sher 4 Figure 52 10 11 8 15 5 3 19 20 21 22 23 24 9 7 25 26 6 1 2 16 17 18 4 14 13 12 9 33 ft lb 45 N m 11 22 21 Disassembly Fig 52 NOTE The gear pump must be replaced as a complete assembly Individual gears housings and thrust plates are not available separately Disassemble gear pump for cleaning inspection and seal replacement only IMPORTANT Keep bodies gears flanges and thrust plates for each p...

Page 165: ...ng dye to mating teeth to retain timing Pump efficiency may be affected if the teeth are not installed in the same position during assembly Keep the parts for each pump section together do not mix parts between sections 8 Clean all parts Check all components for burrs scoring nicks and other damage 9 Replace the entire pump assembly if parts are ex cessively worn or scored Assembly Fig 52 1 Apply ...

Page 166: ...4 O ring 25 90o hydraulic fitting 26 Straight hose fitting Figure 54 FRONT RIGHT 1 2 3 4 23 16 6 12 8 9 10 13 5 21 11 18 17 20 19 14 15 22 7 5 11 11 12 8 16 18 77 to 93 ft lb 105 to 126 N m 21 22 23 24 25 26 5 103 to 118 ft lb 140 to 160 N m Removal Fig 54 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 To prevent con...

Page 167: ...allation 2 Carefully lower piston pump into the machine and position it to the engine adapter plate Support pump to prevent it from falling while installing two 2 cap screws and washers securing piston pump to engine adapter plate Torque screws from 77 to 93 ft lb 105 to 126 N m 3 Install gear pump to piston pump see Gear Pump Installation in this chapter 4 Install traction rod to control arm on p...

Page 168: ...embly 36 Cap screw 4 37 Control orifice 036 38 Backplate 39 Roll pin 40 Housing gasket 41 Rotating kit 42 Camplate 43 Servo piston follower 44 Cap screw 2 45 Bushing dowel 2 46 Socket head screw 6 47 Control arm 48 Hex nut 49 Lock washer Figure 57 31 32 33 35 36 40 41 42 1 2 3 4 5 6 7 8 9 16 18 19 20 22 24 26 27 28 29 30 11 12 13 14 15 44 10 23 25 15 37 21 39 17 43 49 38 5 6 10 12 14 27 34 46 45 4...

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Page 170: ...raulic tube 6 O ring 7 Hydraulic straight fitting 8 O ring 9 Hydraulic tube 10 O ring 3 11 Hydraulic straight fitting 12 O ring 13 Hydraulic hose 14 Hydraulic tube 15 Hydraulic tee fitting 16 O ring 17 Hydraulic hose 18 Hydraulic tube 19 O ring 2 20 Hydraulic tee fitting 21 O ring Figure 58 FRONT RIGHT 4 2 3 5 7 8 9 10 12 1 6 11 13 14 15 16 17 18 19 10 19 20 21 ...

Page 171: ...lines and fittings 5 Remove rear traction manifold from the frame 6 If hydraulic fittings are to be removed from manifold mark fitting orientation to allow correct assembly Re move fittings from manifold and discard O rings Installation Fig 58 1 If fittings were removed from manifold lubricate and place new O rings onto fittings Install fittings into man ifold ports using marks made during the rem...

Page 172: ...ave a tapered sealing surface on the plug head that is designed to resist vibration induced plug loosening The zero leak plugs also have an O ring as a secondary seal If zero leak plug removal is necessary lightly rap the plug head using a punch and hammer be fore using an allen wrench to remove the plug the im pact will allow plug removal with less chance of damage to the socket head of the plug ...

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Page 174: ...raulic tube 6 O ring 4 7 Hydraulic tube 8 Hydraulic tube 9 Hydraulic tube Figure 60 FRONT RIGHT 4 2 3 5 7 6 8 9 1 6 6 6 NOTE The ports on the HI LOW range manifold are marked for easy identification of components Refer to the Hydraulic Schematics in Chapter 10 Foldout Draw ings to identify the function of the hydraulic lines and car tridge valves at each port ...

Page 175: ...NOTE The check valve adapter used in the HI LOW range manifold allows free flow toward the manifold and prevents flow away from the manifold Fig 62 Installation Fig 60 1 If fittings were removed from manifold lubricate and place new O rings onto fittings Install fittings into man ifold ports using marks made during the removal pro cess to properly orientate fittings Tighten fittings see Hydraulic ...

Page 176: ...s 2 Raise front of machine and support with jack stands 3 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of this chapter 4 To prevent contamination of hydraulic system during wheel motor removal thoroughly clean exterior of mo tor 5 Disconnect hydraulic lines from wheel motor Put caps or plugs on lines and fittings to prevent contamina tion L...

Page 177: ... motor into brake assembly 5 Secure motor to brake assembly with cap screws and flat washers Tighten cap screws from 75 to 85 ft lbs 101 to 115 N m 6 Remove plugs from lines and fittings Attach hydrau lic lines to wheel motor see Hydraulic Hose and Tube Installation in this chapter 7 Lower machine to ground 8 Fill reservoir with hydraulic fluid as required 1 O ring 2 2 Straight fitting 2 3 O ring ...

Page 178: ...4 External snap ring 2 5 O ring 6 Hydraulic fitting 7 O ring 8 90o hydraulic fitting 9 Cap screw 2 10 Flat washer 2 11 O ring 12 90o hydraulic fitting 13 O ring 14 O ring 15 90o hydraulic fitting 16 O ring 17 Temperature sender with O ring Figure 66 FRONT RIGHT 1 3 4 13 14 2 7 8 9 10 12 5 6 11 7 15 16 17 ...

Page 179: ...ntation to allow correct assembly Remove fittings from motor and discard O rings 9 If necessary remove retaining rings and pinion gear item 3 from motor shaft Installation Fig 66 1 If fittings were removed from axle motor lubricate and place new O rings onto fittings Install fittings into motor ports using marks made during the removal pro cess to properly orientate fittings Tighten fittings see H...

Page 180: ...ing 2 Minimum angle stop 3 Bias spring 4 Servo piston 5 O ring 6 O ring 7 Socket head screw 5 8 End cap 9 Dowel 10 Dowel pin 11 Bearing 12 Gasket 13 Valve plate 14 Cylinder block kit 15 Swashplate 16 Swashplate bearing assembly 17 Output shaft 18 Housing 19 Bearing 20 Retaining ring 21 Retaining ring 2 22 Seal 23 Support washer 24 Plug with O ring 3 25 Plug with O ring 2 24 16 24 25 ...

Page 181: ...ces from the front motors Use the same procedure to service of the front wheel motors and rear axle motor see the Sauer Danfoss K and L Frame Variable Motors Service Manual for additional informa tion 1 Plug 2 O ring 3 Centering spring 4 Spring retaining washer 5 Shift spool 6 Plug 7 O ring 8 Centering spring 9 Orifice poppet 10 End cap Figure 68 2 3 6 8 9 1 5 7 4 1 2 3 4 REAR AXLE MOTOR FLUSHING ...

Page 182: ...e and remove key from the ignition switch 2 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of this chapter 3 To prevent contamination of hydraulic system during reel motor removal thoroughly clean exterior of motor 4 Disconnect hydraulic hoses from reel motor Put caps or plugs on fittings and hoses to prevent contami nation of hydraulic syste...

Page 183: ...lithium base grease 4 Oil the reel motor O ring and install it onto the motor flange 5 Install the cap screws for the reel drive motor into the cutting unit side plate and leave approximately 1 2 inch 12 7 mm of threads exposed on each screw 6 Rotate the motor clockwise so the motor flanges clear the cap screws in the cutting unit side plates Align reel motor shaft splines with cutting reel insert...

Page 184: ...16 17 14 Disassembly Fig 71 1 Plug motor ports and clean the outside of the motor thoroughly After cleaning remove plugs and drain any oil out of the motor 2 Use a marker to make a diagonal line across the front flange and body for assembly purposes Fig 72 IMPORTANT Prevent damage when clamping the reel motor into a vise clamp on the front flange only Also use a vise with soft jaws 3 Clamp front f...

Page 185: ... with emery cloth CAUTION Use eye protection such as goggles when using compressed air 2 Clean all parts with solvent Dry all parts with com pressed air 3 Inspect drive gears and idler gears for the following Fig 74 A Gear shafts should be free of rough surfaces and excessive wear at bushing points and sealing areas Scoring rough surfaces or wear on gear shafts indi cates need for replacement B Ge...

Page 186: ...open side of the pressure seal pointing to the inlet side of the mo tor Carefully install shaft into front flange 7 Lubricate the idler gear shaft with clean hydraulic oil Install idler gear shaft into the remaining position in the front wear plate Apply a light coating of clean hydraulic oil to gear faces 8 Install rear wear plate with pressure seal side up and open side of the pressure seal poin...

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Page 188: ... Flange head screw 2 7 Charge filter head 8 Charge filter element 9 Cap screw 4 Figure 75 7 8 1 3 2 5 4 6 9 NOTE The ports on the manifold are marked for easy identification of components Example P1 is the supply connection for the front cutting units see Hydraulic Schematic in Chapter 10 Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each port ...

Page 189: ...om manifold lubricate and place new O rings onto fittings Install fittings into man ifold ports using marks made during the removal pro cess to properly orientate fittings Tighten fittings see Hydraulic Fitting Installation in this chapter Refer to Figure 76 for fitting installation torque 2 Install hydraulic manifold to the frame 3 Remove caps and plugs from fittings and hoses Properly connect hy...

Page 190: ...14 15 16 17 18 4 2 3 6 8 12 15 12 15 16 15 17 18 25 ft lb 34 N m 25 ft lb 34 N m 25 ft lb 34 N m 20 ft lb 27 N m 25 ft lb 34 N m 25 ft lb 34 N m FRONT RIGHT NOTE The ports on the manifold are marked for easy identification of components e g P1 is a gear pump connection port and PRV1 is the location for a propor tional relief valve See Hydraulic Schematic in Chapter 10 Foldout Drawings to identify ...

Page 191: ...ion of spool is between stop pins in manifold Apply Loctite 603 Retaining Compound or equivalent to threads on handle and install handle into spool F Place ball and dowel pin in backlap switch man ifold port Install new O ring onto backlap switch Thread backlap switch into port and torque 20 ft lb 27 N m Manifold Plugs Fig 78 NOTE The mow control manifold uses several zero leak plugs These plugs h...

Page 192: ... engage parking brake and remove key from the ignition switch 2 Remove fasteners that secure shroud to front of ma chine Fig 80 Remove shroud from machine to allow access to steering control valve 3 Remove four 4 flange head screws that secure col umn brace item 12 to frame platform Remove brace from machine to allow access to steering column fasten ers 4 Slide rubber bellows up from bottom of ste...

Page 193: ...Hydraulic Fitting Installation in this chapter 2 Apply antiseize lubricant to splines of steering con trol valve shaft 3 Slide steering control valve shaft into steering col umn universal joint Position control valve with ports to ward front of machine Secure steering control valve to steering column with four 4 socket head screws Torque screws in a criss cross pattern from 7 to 10 ft lb 10 to 13 ...

Page 194: ... pin 10 Sleeve 11 Spool 12 Cardan shaft 13 O ring 14 Distributor plate 15 Outer gearwheel 16 Inner gearwheel 17 End cover 18 Tube 2 19 Washer 5 20 Pin bolt 21 Cap screw 4 22 Ball Figure 82 3 5 6 9 10 16 11 12 13 14 15 4 7 1 2 17 18 19 20 21 8 5 13 13 22 20 to 24 ft lb 27 to 33 N m NOTE For repair of the steering control valve see the Sauer Danfoss Steering Unit Type OSPM Service Manual at the end ...

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Page 196: ...aining ring 5 Grease fitting 6 Grease fitting 7 90o hydraulic fitting 8 O ring 9 O ring 10 Drive axle assembly 11 Ball joint spacer 12 Axle washer 13 Slotted hex nut 14 Cotter pin 15 Hydraulic hose 16 Hydraulic hose Figure 83 6 4 1 2 10 5 4 3 12 14 11 13 7 8 9 9 100 to 125 ft lb 136 to 169 N m FRONT RIGHT 7 14 15 16 ...

Page 197: ...from cylinder and discard O rings Installation Fig 83 1 If fittings were removed from steering cylinder lubri cate and place new O rings onto fittings Install fittings into cylinder ports using marks made during the removal process to properly orientate fittings Tighten fittings see Hydraulic Fitting Installation in the General Infor mation section of this chapter 2 If removed press ball joints in...

Page 198: ... 2 Lock nut 3 Wear band 4 Square ring 5 Piston seal 6 O ring 7 Piston 8 Buffer seal 9 O ring 10 Back up ring 11 Head 12 Retaining ring 13 Head seal 14 Wiper 15 Rod assembly Figure 84 40 ft lb 54 N m Loctite 271 2 3 6 8 9 10 11 13 1 5 7 12 14 15 4 2 3 6 8 9 10 11 13 1 5 7 12 14 15 4 ...

Page 199: ... for dam age deep scratches out of round etc Replace en tire cylinder if barrel is damaged Inspect piston rod and piston for evidence of excessive scoring pitting or wear Replace any damaged parts Assembly Fig 84 1 Make sure all cylinder components are clean before assembly 2 Coat new seal kit components with clean hydraulic oil A Install new seals O ring and wear band to the piston B Install new ...

Page 200: ...2 6 Bulkhead nut 3 7 Flange head screw 4 8 Flange nut 4 9 Lower fan shroud 10 Flat washer 8 11 R clamp 2 12 Flange head screw 8 13 Flange nut 6 14 Fan motor and bracket assembly 15 Flange head screw 6 16 Fan 17 Flat washer 4 18 Cap screw 4 19 Radiator oil cooler assembly Figure 85 FRONT RIGHT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 10 10 11 12 13 12 15 19 ...

Page 201: ...ydraulic tubes to prevent contamination 8 Remove fasteners that secure lower fan shroud to radiator and remove lower fan shroud from machine IMPORTANT Make sure to not damage the radiator or other machine components while loosening and removing the fan motor and bracket assembly 9 Remove six 6 cap screws item 15 and flange nuts that secure fan motor bracket to radiator Carefully re move fan motor ...

Page 202: ...ecure lower fan shroud to radiator with removed fasteners Make sure that clearance between shroud and cooling fan is at least 0 180 4 6 mm at all points 5 Install upper fan shroud Fig 85 A Place support shim item 5 on hydraulic tubes connected to fan motor B Carefully install upper shroud to machine Make sure that upper shroud mounting holes properly align with hydraulic tubes and fastener locatio...

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Page 204: ...r plate 11 Body 12 Idler gear 13 Cap screw 4 14 Dowel 2 15 Drive gear 16 Washer 4 Figure 87 8 7 4 3 2 5 6 9 10 11 9 12 13 8 14 16 15 14 1 45 N m 33 ft lb The engine cooling fan motor is similar to the cutting unit motors For disassembly inspection and assembly pro cedures of the cooling fan motor refer to Cutting Unit Motor Service in this chapter Figure 88 1 Dust seal 2 Retaining ring 3 Flange wa...

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Page 206: ...manifold 6 Flange head screw 2 7 Charge filter head 8 Charge filter element 9 Cap screw 4 Figure 89 7 8 1 3 2 5 4 6 9 NOTE The ports on the manifold are marked for easy identification of components Example P1 is the gear pump connection port see Hydraulic Schematic in Chapter 10 Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each port ...

Page 207: ... 90 Remove fittings from manifold and discard O rings Installation Fig 89 1 If fittings were removed from fan control manifold lu bricate and place new O rings onto fittings Install fit tings into manifold ports using marks made during the removal process to properly orientate fittings Tighten fittings see Hydraulic Fitting Installation in this chapter Refer to Figure 90 for fitting installation t...

Page 208: ...s the location of the flow divider cartridge valve See Hydraulic Schematic in Chapter 10 Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each port location For cartridge valve service procedures see Control Manifold Cartridge Valve Service in this chapter Refer to Figure 91 for cartridge valve and plug installation torque The fan control manifold includes s...

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Page 210: ...nifold 6 Flange head screw 2 7 Charge filter head 8 Charge filter element 9 Cap screw 4 Figure 92 7 8 1 3 2 5 4 6 9 NOTE The ports on the manifold are marked for easy identification of components Example P is the supply connection port see Hydraulic Schematic in Chapter 10 Foldout Drawings to identify the function of the hydrau lic lines and cartridge valves at each port ...

Page 211: ... its posi tion for assembly purposes Also note location of groove in orifice for assembly purposes 8 If hydraulic fittings are to be removed from lift man ifold mark fitting orientation to allow correct assembly Remove fittings from manifold and discard O rings Installation Fig 92 IMPORTANT When installing orifice in manifold port make sure that orifice is flat in the base of the manifold port Man...

Page 212: ...e function of the hydraulic lines and cartridge valves at each port location WARNING Make sure that cutting units are fully lowered be fore loosening hydraulic lines or cartridge valves from lift manifold If cutting units are raised as components are loosened cutting units may drop unexpectedly For cartridge valve service procedures see Control Manifold Cartridge Valve Service in this section Refe...

Page 213: ...ther appropriate eye protection when using compressed air for drying parts 6 Clean cartridge valve using clean mineral spirits Submerge valve in clean mineral spirits to flush out con tamination Particles as fine as talcum powder can affect the operation of high pressure hydraulic valves If car tridge design allows use a wood or plastic probe to push the internal spool in and out 20 to 30 times to...

Page 214: ...O ring 8 9 90o hydraulic fitting 10 O ring 3 11 Pilot piston 3 12 Cap screw 2 Figure 95 FRONT RIGHT 2 8 6 8 9 10 11 1 5 7 4 4 6 6 6 4 8 4 3 12 NOTE The ports on the lift junction manifold are marked for easy identification of components e g P1 is the gear pump connection port See Hydraulic Sche matic in Chapter 10 Foldout Drawings to identify the function of the hydraulic lines at each port ...

Page 215: ...s on the lift junction manifold If a fitting is removed from the lift junction manifold and an orifice is in the manifold port make sure to remove orifice and label its posi tion for assembly purposes Also note location of groove in orifice for assembly purposes 6 If necessary remove fittings from manifold and dis card O rings Installation Fig 95 IMPORTANT When installing orifice in manifold make ...

Page 216: ...2 per pin 11 Grease fitting 3 12 Pivot pin 3 13 Slotted roll pin 1 per pin 14 Thrust Washer 6 15 Lock nut 3 16 Cylinder pin 3 17 Flange head screw 3 18 Cutting unit position sensor 19 Sensor bracket 20 Flange head screw 2 21 22 23 Flange head screw 2 per hoop 24 Chain hoop 25 Lift chain 26 Washer 2 per hoop 27 Flange nut 2 per hoop 28 Front carrier frame Figure 96 FRONT RIGHT 1 2 3 4 5 6 7 8 9 10 ...

Page 217: ...rom machine 8 If hydraulic fittings are to be removed from lift cylin der mark fitting orientation to allow correct assembly Remove fittings from cylinder and discard O rings Figure 97 CUTTING UNIT LOCATIONS 4 1 5 3 2 Installation Fig 96 1 If fittings were removed from lift cylinder lubricate and place new O rings onto fittings Install fittings into cylinder openings using marks made during the re...

Page 218: ... cutting unit 3 10 Lynch pin 2 11 Flange nut 2 12 Flat washer 2 13 Flange head screw 2 14 Chain hoop 2 15 Lift chain 2 16 Cylinder pin 2 17 Thrust washer 4 18 Grease fitting 2 19 Pivot pin 2 20 Slotted roll pin 2 21 RH torsion spring 22 LH torsion spring 23 Lock nut 2 24 Spacer 2 25 Flat washer 2 26 Cap screw 2 27 Lock nut 2 Figure 98 FRONT RIGHT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 ...

Page 219: ...ydraulic fittings are to be removed from lift cylin der mark fitting orientation to allow correct assembly Remove fittings from cylinder and discard O rings Installation Fig 98 1 If fittings were removed from lift cylinder lubricate and place new O rings onto fittings Install fittings into cylinder openings using marks made during the removal process to properly orientate fittings Tighten fittings...

Page 220: ... up 12 Retaining ring 13 O Ring 14 Dust seal 15 Grease fitting Figure 100 35 to 45 ft lb 48 to 61 N m Loctite 271 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 3 4 5 6 7 2 8 9 10 11 12 14 13 15 NOTE The lift cylinders used on the Reelmaster 7000 D are all very similar regardless of the location on the machine The disassembly and assembly procedure is the same for all lift cylinders ...

Page 221: ... external sur face of rod for deep scratches out of roundness and bending 3 Inspect head and piston for excessive pitting scor ing and wear 4 Replace lift cylinder if internal components are found to be worn or damaged Assembly Fig 100 1 Make sure all lift cylinder parts are clean before as sembly 2 Coat new O rings back up washer and other seals with clean hydraulic oil A Carefully install piston...

Page 222: ...ight fitting 6 Bumper 7 Flat washer 8 Flange nut 3 9 Clamp 2 10 Cap screw 2 11 Flat washer 2 12 Breather 13 Screen filter 14 Dipstick 15 Plug 16 O ring 17 Cap screw 18 O ring 19 O ring 19 20 O ring Figure 101 FRONT RIGHT 68 to 75 ft lb 93 to 101 N m 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 8 14 17 18 19 20 19 35 to 47 ft lb 48 to 63 N m 25 to 29 ft lb 34 to 39 N m ...

Page 223: ...ngs are to be removed from reservoir mark fitting orientation to allow correct assembly Re move fittings from reservoir and discard O rings Inspection 1 Clean hydraulic reservoir and suction strainer with solvent 2 Inspect reservoir for leaks cracks or other damage Installation Fig 101 1 If fittings were removed from reservoir lubricate and place new O rings onto fittings Install fittings into res...

Page 224: ... Hose clamp 4 22 Hose plenum drain 23 Coolant reservoir 24 Reservoir bracket 25 Cap screw 2 26 Lock washer 2 27 Flange head screw 2 28 Flange nut 2 29 Hose reservoir to radiator 30 Reservoir cap 31 Hose clamp 32 Hose reservoir overflow 33 Flange head screw 4 34 Radiator cap 35 Radiator draincock 36 Bulb seal 37 Bulb seal 38 Radiator mount 39 Flange head screw 4 40 Flange nut 4 41 Foam seal 2 42 Sp...

Page 225: ...ne Model 03781 in this manual for information on removal and installation of the radiator oil cooler as sembly 1 Radiator oil cooler 2 Hydraulic tube 3 Hydraulic tube 4 Hydraulic hose 5 Bulkhead nut 6 Spacer 7 O ring Figure 103 1 4 2 3 4 5 6 7 7 6 5 1 Radiator oil cooler 2 O ring 3 90_ Hydraulic fitting 2 4 O ring 5 Radiator cap 6 Coolant plug 7 Draincock 8 Hydraulic plug Figure 104 1 3 2 4 5 6 7 ...

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Page 227: ...33 HI LOW transport mow Switch 33 Cutting Unit Position Switch 34 COMPONENT TESTING 35 Fusible Link Harness 35 Fuses 36 Toro Electronic Controller TEC 38 Ignition Switch 40 Reel Enable Disable Switch 41 Engine Speed Switch Yanmar Diesel Engine Only 42 Lower Raise Joystick Switches 43 Seat Switch 44 Traction Neutral Switch 45 Parking Brake Switch 46 HI LOW Transport Mow Switch 47 Cutting Unit Posit...

Page 228: ...rollers can be checked with the Diagnostic Dis play see Special Tools Because of the solid state circuitry built into the Toro Electronic Controller TEC there is no method to test it directly The TEC may be damaged if an attempt is made to test it with an electrical test device such as a digital multimeter IMPORTANT Before performing any welding on the machine disconnect the battery cables from th...

Page 229: ...ized even though the ignition switch is OFF Figure 1 1 Yanmar engine 2 Engine ECU 1 2 CAN bus Communications The Toro Electronic Controller TEC used on the Reel master 7000 D can communicate with other electrical components engine ECU and InfoCenter display on a CAN bus communication system The CAN bus sys tem reduces the number of electrical components and connections used on the machine and allo...

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Page 231: ...lmaster 7000 D Page 6 5 Electrical System Electrical Drawings The electrical schematics and other electrical drawings for the Reelmaster 7000 D are located in Chapter 10 Foldout Drawings Electrical System ...

Page 232: ...excess current can cause damage to circuits not designed to carry it Figure 2 Dielectric Gel Dielectric gel should be used to prevent corrosion of un sealed connection terminals To ensure complete coat ing of terminals liberally apply gel to both component and wire harness connector plug connector to compo nent unplug connector reapply gel to both surfaces and reconnect harness connector to compon...

Page 233: ...hat should be used on battery terminals ring terminals and fork terminals to reduce corrosion problems Apply battery terminal protector to the con nection after the battery cable ring terminal or fork ter minal has been secured Toro Part Number 107 0392 Figure 5 Electrical System ...

Page 234: ...AN bus system provides communication necessary for machine operation between the Toro Electronic Con troller TEC the engine ECU on machines with Yan mar diesel engines and the InfoCenter Use the InfoCenter Display to test TEC inputs and out puts when troubleshooting an electrical problem on your Reelmaster 7000 D see Using the InfoCenter Display to Test TEC Inputs and Outputs in this chapter NOTE ...

Page 235: ...ERVICE SCREEN FAULTS SCREEN DIAGNOSTICS SCREEN MAIN MENU SCREEN Setttings Units Language Backlight Contrast SETTINGS SCREEN About Model Serial No TEC SW Rev InfoCtr SW Rev ABOUT SCREEN Eng SW Rev CAN Bus No No No No No Status Eng Metric Language F B Lap RPM R B Lap RPM Protected Menus Protect Settings 1 5 1 5 On Off ENTER Auto Idle Blade Count Delay Off 5 8 11 Mow Speed HOC F Reel RPM R Reel RPM m...

Page 236: ...rator Voltmeter Hourmeter displayed for first five seconds Glow plug indicator displayed only while glow plugs are energized Tachometer displayed after five seconds After the splash screen has been displayed for ten sec onds the main information screen will be appear on the InfoCenter T 13 2V 0000 0 T 13 2V RPM 1200 1 Fault indicator 2 Voltmeter 3 Hourmeter 4 Glow plug indicator 5 Tachometer Figur...

Page 237: ... are raising Down icon appears while lift arms are lowering Operator s seat Icon appears when the operator is out of the seat and the seat must be occupied before machine operation can continue Press the Menu Back button once to expose the naviga tion pane then press the Right Left button as indicated by the in the navigation pane to toggle between the main information screen and the splash screen...

Page 238: ...er fault indicator will blink to notify the operator see Faults Screen in this chapter 1 Fault indicator 2 Advisory number code 3 Advisory description 4 Advisory qualifier Figure 11 ADVISORY 160 Start Denied or OPERATOR ADVISORY SCREEN 2 3 4 1 Main Menu Screen The main menu screen Fig 12 is accessed from the In foCenter main information screen Press the Menu Back button once to expose the navigati...

Page 239: ...return to the previous screen press the Menu Back button as indicated by the at the bottom of the screen NOTE Yanmar Diesel Engines If an engine fault oc curs during machine operation the fault indicator will il luminate and the fault will be displayed on the InfoCenter to notify the operator Fig 14 The engine fault will con tinue to appear until the offending condition is corrected Once the offen...

Page 240: ...l 250 hours by pressing the Left Right button as indicated by the at the bottom of the screen and then pressing the Down button as indicated by the Yes or at the bottom of the screen Counts provides access to the following information Starts identifies the number of times that the en gine has been started Cutting Units identifies the number of times the cutting units have been engaged Traction Con...

Page 241: ...ear solenoid S5 lower only Hi Low Range identifies the requirements necessary to allow the TEC to shift the two speed shift manifold valve from LOW to High speed range Inputs Qualifiers Outputs High Range Reqd Cutting units must be above turn around po sition Two speed shift manifold solenoid valve PTO Identifies the requirements necessary to allow the TEC to engage the cutting units Inputs Qualif...

Page 242: ...allow the TEC to engage the cutting units in the reverse direc tion for backlapping cutting units Inputs Qualifiers Outputs Front Backlap In Seat or Front Reel Engage solenoid SP1 Rear Backlap Parking Brake Rear Reel Engage solenoid SP2 Reel Enable Disable Switch Cutting Unit Down Engine Running ...

Page 243: ...o decrease or the Left Right button to in crease the InfoCenter Display contrast as indicated by the and the at the bottom of the screen F B Lap RPM Use the Left Right button as indicated by the at the bottom of the screen to select the reel speed used when backlapping the front reels Choose from five 5 preset reel speeds R B Lap RPM Use the Left Right button as indicated by the at the bottom of t...

Page 244: ...ault in dicator will illuminate and an operator advisory 176 Reel Speed Changed will appear on the InfoCenter display to confirm that the change has been record ed HOC The HOC height of cut setting should match the current cutting unit HOC The HOC setting is used by the TEC to manage cutting unit reel speed Press the Left Right button as indicated by the at the bottom of the screen then use the Do...

Page 245: ...ware is displayed and the CAN bus status will be visible Press the Down button to scroll through the screen items as indicated by the at the bottom of the screen The information found in the about screen can only be edited by your Toro Distributor To return to the previous screen press the Menu Back button as indicated by the at the bottom of the screen Figure 19 About Model SN S W Rev 03780 31500...

Page 246: ... InfoCenter Display Figs 20 and 21 Each advisory screen has three elements the advisory number code the advisory description and the advisory qualifier An advisory qualifier denotes the condition s that triggered the advisory and provides instruction on elimi nating the advisory An operator advisory may involve one or more advisory qualifier Typically an advisory can be eliminated by changing the ...

Page 247: ...art attempt already happened 171 Auto Idle Engaged Yanmar diesel engines only Engine RPM has been reduced to low idle speed as machine has been inactive for the set period of time Inactive means the traction pedal is in NEUTRAL reel enable disable switch is in DISENGAGED position joy stick is in NEUTRAL position and engine speed switch Yanmar diesel engines is not pressed Auto idle feature timing ...

Page 248: ...ngine 2 Set the ignition switch to the ON position and navi gate to the InfoCenter Diagnostic Screen 3 Select highlight the malfunctioning machine opera tion and press the Left Right button as indicated by the at the bottom of the screen For this example the PTO operation has been selected Fig 23 4 Select highlight Inputs and press the Left Right but ton as indicated by the at the bottom of the sc...

Page 249: ...sender Cutting units must be lowered below turn around position cutting unit position switch If þ and do not alternate when the qualifier condition is changed the qualifier or the circuit wiring for the quali fier is faulty and should be tested as described Figure 25 1 Qualifier items 2 Left Right button 3 Down button 4 Menu Back button DIAGNOSTICS SCREEN PTO QUALIFIERS SELECTED PTO Low Range 4 3 ...

Page 250: ...een for debris buildup Check engine cooling fan and drive belt operation Check engine coolant level 2 Excessive engine coolant temperature above 239F 115C for more than 20 seconds caused engine to stop Check radiator and screen for debris buildup Check engine cooling fan and drive belt operation Check engine coolant level 3 One of the TEC output fuse is faulty Check fuse F A1 F B1 or F C1 7 5 Amp ...

Page 251: ...tion has open or short to ground Test control manifold solenoid valve S1 coil and circuit wiring 37 Glow relay Kubota diesel engines has open or short to ground Test glow relay and circuit wiring 50 Mow control manifold proportional valve SP1 has open or short to ground Test mow control manifold proportional valve SP1 coil and circuit wiring 51 Mow control manifold proportional valve SP2 has open ...

Page 252: ...ory is displayed on InfoCenter see Operator Advisory list in this section The traction pedal is not in neutral position Operator seat is unoccupied OR the parking brake is not applied The reel enable disable switch is ENABLED The joystick is in the raise or lower position The traction neutral switch or circuit wiring is faulty Seat switch or circuit wiring is faulty Parking brake switch or circuit...

Page 253: ...ty Engine is not cranking fast enough Engine and or fuel may be too cold Glow relay glow plugs or fusible link harness at the engine starter motor is faulty Fuel pump is faulty Kubota Diesel Engine Only Fuse F5 1 40 amp is faulty open Kubota Diesel Engine Only Engine fuel stop solenoid or circuit wiring is faulty Engine or fuel system is malfunctioning see Engine Service Manual Starter cranks but ...

Page 254: ...will cause the cutting units to be disengaged and can lead to engine shutdown If excessive coolant temperature causes engine shutdown the operator can restart the en gine to allow the machine to be moved a short distance After a restart in this condition the engine will run for approximately ten 10 seconds before the engine shuts down again The operator is lifting off the seat switch while mowing ...

Page 255: ...this manual Cutting units run but should not when lowered with reel enable disable switch in the DISABLE position The reel enable disable switch or circuit wiring is faulty Cutting unit s do not operate and an Operator Advisory is displayed on InfoCenter see Operator Advisory list in this section The cutting units are not fully lowered The operator seat is lifting off the seat Mow speed limiter is...

Page 256: ...d limiter switch or circuit wiring is faulty Hydraulic valve solenoid s or circuit wiring to the lift control manifold S1 or S3 is faulty A problem in the lift lower hydraulic circuit exists see Chapter 5 Hydraulic System in this manual The TEC is faulty None of the cutting units will raise TEC fuse F B1 and or F C1 7 5 amp protecting the circuits for hydraulic valves S1 S2 and S3 are faulty The s...

Page 257: ...dition of the battery charge and battery temperature the battery voltage will increase at different rates as the battery charges Start the engine and run at high idle 2850 RPM Allow the battery to charge for at least three 3 minutes Re cord the battery voltage After running the engine for at least three 3 minutes battery voltage should be at least 0 50 volt higher than initial battery voltage An e...

Page 258: ...achine Interlock switch operation is described in the Traction Unit Operator s Manual Your Reelmaster is equipped with an Toro Electronic Controller TEC which monitors interlock switch operation Testing of individual interlock switches is included in the Component Testing section of this Chapter NOTE Use the InfoCenter Display see InfoCenter Display in this chapter to test Toro Electronic Controll...

Page 259: ...eed limiter should be from 0 040 to 0 100 1 1 to 2 5 mm 2 If gap is incorrect loosen jam nuts that secure switch to footrest platform Position switch with jam nuts to al low correct gap between switch and mow speed limiter Tighten jam nuts to secure adjustment Jam nuts should be torqued from 13 to 17 ft lb 17 6 to 23 0 N m After jam nuts are tightened make sure that clearance be tween end of HI LO...

Page 260: ...ocation with jam nuts to allow correct gap between switch and lift arm gusset Jam nuts should be torqued from 13 to 17 ft lb 17 6 to 23 0 N m After jam nuts are tightened make sure that gap has not changed The vertical location of the cutting unit position switch on the switch bracket will determine the height of the cutting unit turn around position Raising the switch on the bracket will allow a ...

Page 261: ...al fusible link information Testing 1 Park machine on a level surface lower cutting units engage parking brake and stop engine Remove key from ignition switch 2 Disconnect negative battery cable from battery ter minal and then disconnect positive cable from battery see Battery Service in the Service and Repairs section of this chapter 3 Locate and unplug fusible link connector from ma chine wire h...

Page 262: ...eelmaster 7000 D machines Fuse F B3 2 amp protects the power supply to the In foCenter display Fuse F B4 10 amp protects the power supply to the operator air ride seat circuit Fuse F C1 7 5 amp protects TEC output power supply for the glow plugs glow relay cutting unit raise and lower solenoids S1 and S3 and the HI LOW range solenoid Fuse F C2 7 5 amp is not used on Reelmaster 7000 D machines Fuse...

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Page 264: ... LOW transport mow Switch IN 6 Joystick Raise Switch IN 7 Joystick Lower Switch IN 8 Reel Enable Disable Switch IN 9 Engine Speed Switch Increase Yanmar diesel engines OR Engine Oil Pressure Kubota diesel engines IN 10 Front Backlap IN 11 Rear Backlap IN 12 Engine Speed Switch Decrease Yanmar diesel engines OR Alternator Kubota diesel engines ANALOG IN 5 Hydraulic Oil Temperature Sender ANALOG IN ...

Page 265: ...ler directly A con troller may be damaged if an attempt is made to test it with an electrical test device e g digital multimeter or test light NOTE The TEC used on the Reelmaster 7000 D is programed for correct machine operation If the TEC is replaced for any reason system software needs to be reprogrammed by your Toro Distributor IMPORTANT Before performing welding on the ma chine disconnect both...

Page 266: ...Chassis in this manual 3 Disconnect wire harness electrical connector from the ignition switch 4 The ignition switch terminals are identified as shown in Figure 35 With the use of a multimeter ohms setting the switch functions can be tested to determine whether continuity exists between the various terminals for each switch position Verify continuity between switch termi nals 5 Replace switch if t...

Page 267: ... parking brake and stop engine Remove key from ignition switch 2 Disassemble console arm to gain access to the reel enable disable switch see Console Arm in Chapter 8 Chassis in this manual 3 Disconnect harness electrical connector from the reel enable disable switch 4 The switch terminals are marked as shown in Figure 37 With the use of a multimeter ohms setting the switch functions can be tested...

Page 268: ...rk machine on a level surface lower cutting units engage parking brake and stop engine Remove key from ignition switch 2 Remove console arm covers to gain access to en gine speed switch see Console Arm in Chapter 8 Chassis 3 Disconnect wire harness electrical connector from the engine speed switch 4 The switch terminals are marked as shown in Figure 39 With the use of a multimeter ohms setting the...

Page 269: ...overs to gain access to joy stick switches see Console Arm in Chapter 8 Chassis in this manual 3 Disconnect wire harness connectors from raise and lower switches on joystick assembly 4 Check the continuity of the switches by connecting a multimeter ohms setting across the switch connector terminals as follows A With the joystick in the neutral position continuity should only exist between the comm...

Page 270: ...ing test procedure 1 Park machine on a level surface lower cutting units engage parking brake and stop engine Remove key from ignition switch 2 Disconnect seat switch connector from the machine wire harness connector 3 Check the continuity of the switch by connecting a multimeter ohms setting across the seat switch con nector terminals 4 With no pressure on the seat there should be no continuity b...

Page 271: ...lower cutting units engage parking brake and stop engine Remove key from ignition switch 2 Unlatch and raise hood to allow access to the piston traction pump Locate the neutral switch and discon nect the harness electrical connector from the neutral switch 3 Check the continuity of the switch by connecting a multimeter ohms setting across the switch connector terminals 4 Move the traction pedal to...

Page 272: ...e Remove key from ignition switch 2 Disconnect wire harness electrical connector from the parking brake switch 3 Check the continuity of the switch by connecting a multimeter ohms setting across the connector termi nals 4 When the parking brake is released brake not ap plied there should be continuity closed between the switch terminals 5 When the parking brake pedal is depressed brake applied the...

Page 273: ...er is in the LOW mow position 3 If the HI LOW transport mow switch LED did not function correctly A Make sure that the HIGH LOW switch is properly adjusted see HIGH LOW transport mow Switch in this chapter If necessary adjust switch and retest B Make sure ignition switch is OFF and disconnect the HI LOW switch from machine wire harness C Verify that the machine wire harness connector terminal for ...

Page 274: ...its are raised above the turn around position 3 If the cutting unit position switch LED did not function correctly A Make sure that the cutting unit position switch is properly adjusted see Cutting Unit Position Switch in this chapter If necessary adjust switch and retest B Make sure ignition switch is OFF and disconnect the cutting unit position switch from machine wire harness C Verify that the ...

Page 275: ...ydraulic mow control manifold Locate the backlap switches on the front of the manifold Disconnect the harness electri cal connector from the backlap switch 3 Check the continuity of the switch by connecting a multimeter ohms setting across the switch connector terminals 4 Turn the backlap lever to the backlap position while watching the multimeter Continuity should be made as the switch closes 5 T...

Page 276: ...er and slowly heat the oil Fig 51 NOTE Prior to taking resistance readings with a digital multimeter short the meter test leads together The me ter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal re sistance of the meter and test leads Subtract this value from from the measured value of the tested component 6 Check resistance of the sender with...

Page 277: ...using the radiator draincock CAUTION Handle the hot oil with extreme care to prevent personal injury or fire 3 Put sender in a container of oil or coolant with a ther mometer and slowly heat the oil Fig 53 NOTE Prior to taking resistance readings with a digital multi meter short the meter test leads together The me ter will display a small resistance value usually 0 5 ohms or less This resistance ...

Page 278: ...r cleaner mounting bracket Fig 55 and 56 On machines with Yanmar diesel engines the start relay is a four 4 terminal relay The start relay is used to pro vide current to the engine starter motor solenoid The start relay is energized and monitored by the engine ECU The start relay is located on the air cleaner mount ing bracket Fig 55 Testing 1 Park machine on a level surface lower cutting units st...

Page 279: ...the relay 9 If the relay tests correctly and a circuit problem still exists A Check wire harness see Electrical Schematic and Wire Harness Drawings in Chapter 10 Foldout Drawings in this manual B Use the InfoCenter Display to check specific TEC output operation see InfoCenter Display in this chapter 10 Secure relay to mounting bracket and connect wire harness connector to relay 11 Secure all remov...

Page 280: ...rom relay Re move relay from mounting bracket for testing NOTE Prior to taking small resistance readings with a digital multimeter short the meter test leads together The meter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal resistance of the meter and test leads Subtract this val ue from from the measured value of the component you are testing...

Page 281: ...ess Drawings in Chapter 10 Foldout Drawings in this manual B Use the InfoCenter Display to check specific TEC output operation see InfoCenter Display in this chapter 12 Secure relay to mounting bracket and connect wire harness connector to relay 13 Secure all removed components to machine 14 Connect positive cable to battery and then con nect negative cable to battery see Battery Service in this c...

Page 282: ... with a digital multimeter short the meter test leads together The meter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal resistance of the meter and test leads Subtract this val ue from from the measured value of the component you are testing 4 Using a multimeter ohms setting measure resis tance between the two 2 connector terminals on the sole...

Page 283: ...nder by turning igni tion switch to the ON position Allow pump to run for thirty 30 seconds then turn switch to OFF 6 The amount of fuel collected in the graduated cylin der should be approximately 11 8 fl oz 350 ml after thirty 30 seconds 7 Replace fuel pump if output specification is not met IMPORTANT If fuel pump is replaced make sure that replacement pump is correct for your Reelmas ter by usi...

Page 284: ...d cylinder by turning igni tion switch to the ON position Allow pump to run for fif teen 15 seconds then turn switch to OFF 6 The amount of fuel collected in the graduated cylin der should be approximately 16 fl oz 475 ml after fif teen 15 seconds 7 Replace fuel pump if output specification is not met IMPORTANT If fuel pump is replaced make sure that replacement pump is the correct for your Reel m...

Page 285: ...er moves freely and is free of dirt debris and corrosion NOTE Prior to taking small resistance readings with a digital multimeter short the test leads together The me ter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal re sistance of the meter and test leads Subtract this value from the measured value of the component you are test ing 4 Using a...

Page 286: ...e wire harness connector has a blue insert to identify the proper location for the termina tion resistor NOTE Refer to the Electrical Schematics and Wire Harness Drawings in Chapter 10 Foldout Drawings for additional information on termination resistor locations and wire connections IMPORTANT The termination resistor is required for proper electrical system operation Testing 1 The termination resi...

Page 287: ...Lead on Terminal Multimeter Black Lead on Terminal Continuity Female Male YES Male Female NO Resistor Assembly A 75 ohm resistor is necessary for proper ignition switch operation on all Reelmaster 7000 D machines The re sistor plugs into the console wire harness near the igni tion switch see seat and console wire harness drawing in Chapter 10 Foldout Drawings in this manual On machines with Yanmar...

Page 288: ...rmine whether continuity exists between the various terminals for each switch position The switch terminals are marked as shown in Figure 70 Verify continuity between switch ter minals Replace worklight switch if testing identifies a faulty switch 5 If headlight switch tests correctly and circuit problem still exists check wire harness see Electrical Schemat ics and Wire Harness Drawings in Chapte...

Page 289: ...lectrical sparks away from the battery do not smoke Nausea may result if the gases are inhaled Unplug char ger from electrical outlet before connecting or disconnecting charger leads to or from battery posts IMPORTANT Do not remove fill caps while clean ing 2 Check battery condition weekly or after every 50 hours of operation Keep terminals and entire battery case clean because a dirty battery wil...

Page 290: ...ital multimeter set to amps between the negative battery post and the negative ground cable connector The reading should be less than 0 1 amp If the reading is 0 1 amp or more the machine s electrical system should be tested for short circuits or faulty com ponents and repaired 6 Make sure that rubber boot is properly placed over positive cable end and positive battery post 7 Lower and secure batt...

Page 291: ...h an adjustable load tester This is one of the most reliable means of testing a battery as it simulates the cold cranking test A commercial bat tery load tester is required to perform this test CAUTION Follow the battery load tester manufacturer s instructions when using a load tester A Check the voltage across the battery terminals prior to testing the battery If the voltage is less than 12 4 VDC...

Page 292: ... amps 171 to 250 5 8 hrs 6 amps 11 5 hrs 6 amps 17 3 hrs 6 amps 23 hrs 6 amps above 250 6 hrs 10 amps 12 hrs 10 amps 18 hrs 10 amps 24 hrs 10 amps CAUTION Do not charge a frozen battery because it can ex plode and cause injury Let the battery warm to 60F 16C before connecting to a charger Charge the battery in a well ventilated place to dissipate gases produced from charging These gases are explos...

Page 293: ... Disconnect wire harness electrical connector from the coil that is to be removed Note orientation of electri cal connector on coil for assembly purposes 4 Remove nut that secures coil to hydraulic valve 5 Slide solenoid coil from valve 6 Clean any corrosion or dirt from valve stem Installation Fig 72 1 Slide solenoid coil onto the hydraulic valve Position coil so that connector is properly orient...

Page 294: ...orklight from wire harness at bulb and remove worklight 4 Loosen the bulb from the worklight by rotating it 1 4 turn counter clockwise Then grasp bulb base and re move bulb from the worklight CAUTION Any surface contamination can damage the halogen bulb and lead to its failure or explosion creating a serious safety hazard Halogen bulbs should be handled without touch ing the clear bulb surface Han...

Page 295: ...series planetary drives 4 SERVICE AND REPAIRS 6 Brake Assembly 6 Brake Inspection and Repair 10 Planetary Drive Assembly 12 OPH 2 Planetary Drive Service 14 VA02 Planetary Drive Service 18 Rear Axle Assembly 22 Rear Axle Service 26 Bevel Gear Case and Axle Case 28 Differential Shafts 32 Axle Shafts 33 Input Shaft Pinion Gear 34 Differential Gear 36 Pinion Gear to Ring Gear Engagement 39 Axles Plan...

Page 296: ... lb 81 N m VA02 series planetary 75 to 85 ft lb 101 to 115 N m Planetary wheel drive mounting screw torque 75 to 85 ft lb 102 to 116 N m Rear wheel toe in 0 125 in 3 mm Tire pressure front and rear 12 to 15 psi 83 to 103 kPa Planetary Drive Lubricant SAE 85W 140 wt Gear Lube Capacity each wheel 16 to 20 fl oz 0 47 to 0 59 L Rear axle lubricant SAE 85W 140 wt gear lube Rear axle gear lube capacity ...

Page 297: ...erator s Manual The Traction Unit Operator s Manual provides informa tion regarding the operation general maintenance and maintenance intervals for your Reelmaster machine Refer to this publication for additional information when servicing the machine Axles Planetaries and Brakes ...

Page 298: ...ents tires or perform ing other service use correct jacks hoists and jack stands to raise and support machine See Jacking Instructions in Chapter 1 Safety for additional information and precautions 2 Chock rear wheels raise front of machine and sup port machine with appropriate jack stands see Jacking Instructions in Chapter 1 Safety 3 Grasp front wheel and check for endplay in the plan etary asse...

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Page 300: ...assembly LH shown 11 Flange head screw 4 per brake 12 Gasket 13 Piston motor 2 14 Flat washer 2 per motor 15 Cap screw 2 per motor 16 Brake cable LH shown Figure 1 85 to 100 ft lb 116 to 135 N m 1 2 3 4 5 6 7 8 9 10 11 13 14 15 17 12 16 OPH 2 series planetary 60 ft lbs 81 N m VA02 series planetary 75 to 85 ft lbs 101 to 115 N m OPH 2 series planetary 60 ft lbs 81 N m VA02 series planetary 75 to 85...

Page 301: ... In spection and Repair in this section Brake Assembly Installation Fig 1 NOTE The stepped end of the splined brake shaft must be aligned toward the hydraulic wheel motor Fig 2 1 Install splined brake shaft into brake assembly Make sure that splines engage rotating discs in brake assem bly 1 Splined brake shaft step 2 Hydraulic motor end 3 Planetary assembly end Figure 2 3 1 2 2 Position planetary...

Page 302: ... Remove jack stands and lower machine to ground Tighten wheel lug nuts in a crossing pattern from 85 to 100 ft lb 116 to 135 N m 11 Check and adjust brake cables for proper brake op eration see machine Operator s Manual 12 Remove jack stands and lower machine to ground Tighten wheel lug nuts in a crossing pattern from 85 to 100 ft lb 116 to 135 N m ...

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Page 304: ... scrape gasket material item 10 from brake housing and planetary wheel drive mounting sur faces 2 Remove retaining ring item 9 3 Remove stationary discs item 7 and rotating discs item 8 4 Remove extension springs item 12 5 Remove pull rod assembly items 3 4 5 and 6 6 Remove actuator and balls items 11 and 13 7 Remove seal item 2 from brake housing 8 Wash parts in cleaning solvent Inspect component...

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Page 306: ...or 16 Brake cable LH shown Figure 4 85 to 100 ft lb 116 to 135 N m 1 2 3 4 5 6 7 8 9 10 11 13 14 15 17 12 16 OPH 2 series planetary 60 ft lbs 81 N m VA02 series planetary 75 to 85 ft lbs 101 to 115 N m OPH 2 series planetary 60 ft lbs 81 N m VA02 series planetary 75 to 85 ft lbs 101 to 115 N m OPH 2 series planetary VA02 series planetary FRONT RIGHT Gasket Sealer NOTE The planetary wheel drive ass...

Page 307: ...oosen and remove six 6 flange head screws that se cure planetary assembly to frame Remove planetary assembly from machine Planetary Drive Installation Fig 4 1 Position planetary assembly to machine making sure to engage splined brake shaft with planetary drive shaft Secure planetary assembly to frame with six 6 flange head screws For OPH 2 series planetary drives tighten screws to 60 ft lb 81 N m ...

Page 308: ...ng cup 12 Outer bearing cone 13 O ring 14 Thrust washer 15 Retaining ring external 16 Ring gear 17 Retaining ring internal 18 Plug 2 19 O ring 2 20 End cap 21 Thrust plug 22 Thrust washer 23 Retaining ring 24 Primary gear 25 Drive shaft 26 Primary carrier assembly 27 Secondary gear 28 Secondary carrier assembly Figure 5 118 to 144 in lb 13 3 to 16 3 N m 2 3 1 4 5 6 8 9 7 12 13 14 15 17 18 23 21 24...

Page 309: ...emove and discard seals items 2 and 3 and O rings item 13 from housing 11 Remove inner bearing cone item 4 from housing If necessary remove bearing cups items 5 and 11 from housing 12 If wheel stud item 6 removal is necessary use press to extract stud s from housing 13 If necessary remove socket head screws item 7 with lock washers item 8 that secure ring gear item 16 to housing Remove ring gear a...

Page 310: ...re taining ring starting in the center and working out to ward each end to ensure that the retaining ring is properly seated Make sure that retaining ring ID is fully seated to spindle shaft groove K After retaining ring is installed make sure that there is no endplay in assembly If required remove retaining ring and install a thrust washer of different thickness to adjust endplay L Install new O ...

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Page 312: ...n 4 11 O ring 12 Spacer 13 Locking washer 14 Lock nut 15 Ring gear 16 Retaining ring 17 Plug 18 O ring 19 Plug 2 20 O Ring 2 21 End cap 22 Thrust plate 23 O Ring 24 Retaining ring 2 25 Primary gear 26 Drive shaft 27 Primary carrier assembly 28 Secondary carrier assembly Figure 7 G248465 11 12 13 14 15 16 17 18 19 20 1 2 3 4 4 5 5 6 7 8 9 10 21 22 24 24 23 25 26 27 28 37 N m 27 ft lb Grease High St...

Page 313: ...ead locking compound was used during assembly It may be necessary to heat the ring gear near the mounting screws to release the screws A Remove socket head screws item 7 and lock washers that secure the ring gear to the housing B Remove the ring gear and retrieve the four 4 dowel pins item X from housing C Remove the O ring from the housing bore and discard 1 Spindle 2 Boot seal 3 Lip seal 4 Inner...

Page 314: ...llowing step F Loosen the lock nut completely then tighten to 90 ft lb 122 N m IMPORTANT Continue to tighten the lock nut until it aligns with one of the locking washer tabs Do Not loosen the lock nut to align it with the locking washer tabs G Secure the lock nut by bending one of the locking washer tabs into a slot in the lock nut 13 Install secondary carrier and primary carrier making sure that ...

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Page 316: ...g 18 Gear 19 External snap ring 2 20 Needle bearing 21 Cap screw 6 22 Lock washer 6 23 Cover plate 24 Dowel pin 2 25 Gasket 26 O ring 27 Plug 28 Rear wheel assembly 29 Lug nut 5 per wheel 30 Rear axle assembly 31 Steering cylinder assembly 32 Cotter pin 2 33 Slotted hex nut 2 34 Flat washer 35 Spacer 36 Slotted roll pin 37 Rear axle pivot pin 38 Machine frame 39 Lock nut 40 Thrust washer 41 Grease...

Page 317: ...steering cylinder Put caps or plugs on hoses and cylinder fittings to prevent contamination 7 Remove lock nut item 39 and thrust washer item 40 from rear axle pivot pin 8 Support rear axle to prevent it from falling Remove pivot pin from frame and rear axle Lower rear axle from machine Note location of thrust washer item 42 on both ends of axle mounting boss 9 If needed for further axle disassembl...

Page 318: ...ter 5 Hydraulic System 7 Remove caps and plugs from hydraulic hoses and steering cylinder fittings Secure hydraulic hoses to steering cylinder see Hydraulic Hose and Tube Installa tion in Chapter 5 Hydraulic System Failure to maintain proper wheel lug nut torque could result in failure or loss of wheel and may result in personal injury WARNING 8 Install wheel assemblies to rear axle Lower machine ...

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Page 320: ...ies and Brakes Rear Axle Service Figure 16 3 2 4 5 6 7 8 9 10 14 13 12 11 15 1 10 11 8 9 8 13 16 17 18 19 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 20 41 42 43 50 44 45 46 47 48 49 51 54 55 56 57 58 59 52 53 60 61 62 63 64 22 ...

Page 321: ...ing 32 Bolt 4 per knuckle 33 Shim set 34 Dowel pin 2 per axle case 35 Bushing 36 Knuckle pin 37 O ring 38 Bevel gear case LH shown 39 Bushing 40 Shaft seal 41 Stud 2 per gear case 42 Bolt 4 per cover 43 Collar 44 Bevel gear 17 tooth 45 Bevel gear shaft 46 Axle case LH shown 47 Ball bearing 48 Bevel gear 29 tooth 49 Shim set 50 Clip 2 per axle case 51 Axle cover 52 Screw 6 per cover 53 Wheel stud 5...

Page 322: ...gear case axle case assemblies 1 2 3 4 5 6 1 Cap screw 4 2 Lock nut 2 3 Lock washer 2 4 Axle support 5 Bevel gear case axle case assembly 6 O ring Figure 17 35 to 41 ft lb 47 to 56 N m 35 to 41 ft lb 47 to 56 N m 3 Remove the axle cover mounting screws Remove the axle cover from the axle case as an assembly Fig 18 1 Axle case 2 Axle cover assembly 3 Screw 6 4 O ring Figure 18 1 2 3 4 17 to 20 ft l...

Page 323: ...vel gear shaft seal from axle case Fig 20 1 Knuckle pin 2 Mounting screw 4 3 O ring 4 Bevel gear case 5 Upper bearing 6 Bevel gear shaft 7 Collar 8 Upper bevel gear 9 Lower bevel gear 10 Lower bearing 11 Axle case 12 Axle case cover 13 O ring 14 Shaft seal 15 Bushing Figure 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 to 20 ft lb 23 to 27 N m 17 to 20 ft lb 23 to 27 N m Thread locking Compound Inspec...

Page 324: ...g 23 Tighten cover screws from 17 to 20 ft lb 23 to 27 N m 3 Slide the bevel gear case over the bevel gear shaft and install the bevel gear and collar Make sure the bevel gear shaft is completely seated in the upper and lower bearings Fig 23 4 Install the knuckle pin Use medium strength thread locking compound and tighten the knuckle pin mounting screws from 17 to 20 ft lb 23 to 27 N m 1 Axle case...

Page 325: ...emove mounting screws apply heavy strength thread locking compound to screw threads reinstall screws and torque from 57 to 67 ft lb 77 to 91 N m IMPORTANT Correct engagement between bevel gears is critical to axle performance and durability 7 Temporarily install the bevel gear case axle case as sembly on the axle support Position a dial indicator at the tooths center Prevent the axle from turning ...

Page 326: ...al shaft assemblies 1 Remove the mounting screws nuts and lock wash ers Remove the bevel gear case axle case assembly and O ring from the axle support Fig 27 2 Mark and pull the differential shaft assembly from the axle support 3 Remove the retaining ring and bevel gear Fig 28 4 Drive the differential shaft out of the bearings Re move the bearings and bearing shims 5 Inspect all gears shafts beari...

Page 327: ...place components as necessary Installation 1 Coat new axle shaft seal with grease and install in axle cover as shown Fig 31 2 Press the axle cover and bearing assembly onto the axle shaft Press only on the inner race of the cover bearing Fig 31 3 Install retaining ring spacer and correct combination of bearing shims Install bevel gear and bearing 4 Coat a new O ring with grease and install the axl...

Page 328: ...he stake washer and remove the lock nut Remove and discard the stake washer 5 Drive the input shaft pinion gear out from the outer bearing cone and bearing case Remove and discard the oil seal and O ring 6 Inspect all gears shafts bearings spacers and cases for damage and wear Replace components as necessary NOTE Replacement input shaft pinion gear item 11 is only available in matched set with dif...

Page 329: ...ims on the gear case and temporarily install gear case assembly into axle case Tighten mounting nuts and screws from 35 to 41 ft lb 47 to 56 N m 10 Insert a screwdriver through the drain plug hole to hold ring gear and measure the pinion gear to ring gear backlash Fig 35 PINION GEAR TO RING GEAR BACKLASH 0 004 to 0 016 inch 0 10 to 0 40 mm 11 Adjust backlash by increasing or reducing gear case shi...

Page 330: ...le case 6 Drive the spring pin from the differential case with a punch and hammer Discard the spring pin Fig 37 NOTE Mark and arrange all components so they can be reassembled in their original position 7 Remove the differential pinion shaft pinion gears and pinion washers Remove the differential side gears and side gear shims Remove the ring gear only if it will be replaced Fig 38 NOTE Replacemen...

Page 331: ... 00 to 34 06 mm 2 Measure the differential pinion shaft O D and the pinion gear I D to determine the pinion shaft to pinion gear clearance Fig 40 Replace components as nec essary PINION SHAFT TO PINION GEAR CLEARANCE 0 001 to 0 010 inch 0 03 to 0 25 mm PINION SHAFT O D Factory Spec 0 550 to 0 551 inch 13 97 to 13 10 mm PINION GEAR I D Factory Spec 0 551 to 0 552 inch 13 10 to 14 02 mm 3 Inspect al...

Page 332: ...y over several gear teeth 8 While applying a light load to either side gear rotate either pinion gear until the side gears have made one complete revolution 9 Ideal tooth contact should cover more than 35 of each tooth surface The contact area should be in the center of each tooth and extend 1 3 to 1 2 way across each tooth from the toe small end Fig 42 10 Adjust side gear shims if necessary to co...

Page 333: ...ments to the gear contact position are made by moving the input shaft pinion gear bearing case shims or by moving the differential gear case differential bear ing shims Fig 45 NOTE Bearing case shims are available in 0 004 inch 0 10 mm and 0 008 inch 0 20 mm thickness NOTE Differential bearing shims are available in 0 004 inch 0 10 mm 0 008 inch 0 20 mm and 0 016 inch 0 40 mm thickness Study the d...

Page 334: ...rd ring gear B Install thinner or remove differential bearing shim s to move ring gear backward C Repeat until proper tooth contact and pinion gear to ring gear backlash are correct 2 If contact is toward the toe or tip of the gear Fig 47 A Install thinner or remove bearing case shim s to move pinion shaft away from ring gear B Install thicker or additional differential bearing shim s to move ring...

Page 335: ...ATION 2 Operator s Manual 2 Cutting Unit Identification 2 SERVICE AND REPAIRS 4 Steering Column 4 Console Arm 6 Lift Arms For Front Cutting Units 1 4 and 5 8 Lift Arms For Rear Cutting Units 2 and 3 10 Operator Seat 12 Operator Seat Service 14 Operator Seat Suspension 16 Hood 18 Chassis ...

Page 336: ...nformation regarding the operation general maintenance and maintenance intervals for your Reel master machine Refer to these publications for addi tional information when servicing the machine Cutting Unit Identification Cutting units on the Reelmaster 7000 D are identified as shown in Figure 1 4 1 5 3 2 Figure 1 CUTTING UNIT LOCATIONS ...

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Page 338: ...emoval Fig 2 1 Park the machine on a level surface engage the parking brake lower the cutting units and stop the en gine Remove the key from the ignition switch 2 Remove platform shroud from machine to allow ac cess to steering column fasteners Fig 3 3 Remove cover from steering wheel by carefully pry ing up on one of the cover spokes 4 Remove lock nut and flat washer that secure steer ing wheel t...

Page 339: ...ontrol valve Secure steering column in place with four 4 socket head screws item 9 and flange nuts item 10 4 Secure steering control valve to steering column with four 4 socket head screws item 5 Torque screws from 7 to 10 ft lb 10 to 13 N m 5 Slide rubber bellows to bottom of steering column 6 Position column brace item 12 in place and secure with four 4 flange head screws 7 Thoroughly clean tape...

Page 340: ...l engine 18 Arm rest 19 Knob 20 Boot 21 Plate 22 Joystick 23 Flange nut 2 24 Throttle Kubota diesel engine 25 Lock nut 2 26 Headlight switch 27 Manual tube 28 Flange head screw 2 29 Flange nut 2 30 Panel clip 2 31 Flange nut 2 32 Washer head screw 2 33 Hex head screw 34 Flange nut 2 35 Carriage screw 4 36 Foam seal 37 Grommet 38 Console arm support 39 Support channel 40 Flange nut 2 41 Flange nut ...

Page 341: ...k nut item 5 that secure console arm covers to each other 4 Remove five 5 washer head screws item 6 that secure each cover to console arm panel 5 Remove console arm covers from machine As LH cover item 3 is removed from console arm unplug wire harness connector from headlight switch 6 Remove components from console arm as needed 7 If necessary remove console panel and supports from machine Fig 6 A...

Page 342: ...asher 2 per pin 16 Washer head screw 17 Lift arm cutting unit 4 18 Flange head screw 2 per hoop 19 Retaining ring 2 per pin 20 Switch bracket 21 Cutting unit position sensor 22 Pivot yoke 23 Lynch pin 24 Front carrier frame 25 Lift arm cutting unit 5 26 Grease fitting 27 RH hose guide 28 LH hose guide 29 Flange nut 2 per hoop 30 Washer 2 per hoop 31 Chain hoop 32 Lift chain 1 2 3 4 6 7 8 9 10 12 1...

Page 343: ...ed components Installation Fig 7 1 Assemble lift arm 2 Position lift arm to frame Fit thrust washer item 10 between rear of lift arm and frame Slide pivot pin into frame and lift arm Align roll pin in pivot pin with slot in frame flange 3 Install and tighten lock nut item 11 to secure lift arm pivot pin 4 Position lift cylinder rod clevis to lift arm 5 Make sure that one 1 retaining ring and washe...

Page 344: ... arm cutting unit 2 10 Lift arm cutting unit 3 11 Retaining ring 2 per pin 12 Lift cylinder cutting units 2 and 3 13 Lock nut 14 Straight hydraulic fitting 15 Cylinder pin 16 Thrust washer 17 Cylinder pin 18 Flange head screw 2 per hoop 19 90o hydraulic fitting 20 LH torsion spring 21 RH torsion spring 22 Spacer 23 Cap screw 24 Lock nut 25 Flat washer 26 Washer 2 per pin 27 Washer 2 per hoop 28 Ch...

Page 345: ... aged components Installation Fig 8 1 Assemble lift arm 2 Place torsion spring over rear of lift arm tube Posi tion long leg of spring forward and pointing out from top of spring 3 Position lift arm to frame Fig 8 Fit thrust washer item 16 between rear of lift arm and frame Slide pivot pin into frame and lift arm Align roll pin in pivot pin with slot in frame flange 4 Install and tighten lock nut ...

Page 346: ...x head screw 8 Coupling nut 9 Flange nut 4 10 Console arm support 11 Support channel 12 Grommet or foam seal 13 Manual tube 14 Clamp 2 15 Cap screw 2 16 Flange nut 2 17 Seat belt 18 Hex head screw 19 Flange head screw 4 20 Flange nut 4 21 Seat plate 22 Seat frame 23 Latch 24 Spring 25 Cotter pin 26 Flat washer 27 Clevis pin 28 Support rod 2 29 Hair pin 4 30 Flat washer 2 31 Flange head screw 4 32 ...

Page 347: ...o seat suspension Fig 11 9 Lift seat from seat suspension and remove from ma chine Installation Fig 10 1 Carefully position seat to seat suspension 2 Secure seat to seat suspension with four 4 torx head screws Fig 11 Make sure that longer screw is positioned near the seat adjustment handle Torque screws 18 ft lb 25 N m IMPORTANT Make sure to not damage the electri cal harness control cable or othe...

Page 348: ...21 Torx screw 5 22 RH adjustment rail 23 Rail stop 24 Torx screw 25 Torx screw 3 26 Washer 3 27 Handle 28 RH armrest cover 29 Flange nut 30 Carriage screw 31 Support bracket Figure 12 8 10 6 5 7 4 3 2 1 11 14 12 13 15 16 17 18 19 20 21 21 28 9 23 24 25 26 22 27 29 30 31 Disassembly Fig 12 1 Remove seat from machine for service see Opera tor Seat Removal in this chapter 2 Disassemble operator seat ...

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Page 350: ...er 2 15 Tether 16 Rivet 2 17 Washer 4 18 C clip 4 19 Pin 2 20 Rivet 2 21 Washer 3 22 Screw 2 23 Washer 24 Housing support 4 25 Spacer 4 26 Hose nipple 27 Clamp 2 28 Hose nipple 29 Screw 30 Handle 31 Bumper 32 Nut 33 Plastic plug 23 34 Screw 2 35 Roller 2 36 Screw 4 37 Base plate 38 Suspension frame 39 Upper plate Figure 13 FRONT RIGHT 11 8 7 30 10 15 6 12 13 5 3 4 2 1 9 21 33 16 17 18 19 20 22 23 ...

Page 351: ...emoval remove seat suspension from seat plate Fig 14 A Raise and support seat plate assembly Support seat suspension to prevent it from falling B Remove four 4 flange head screws and flange nuts that secure seat suspension to seat plate C Remove seat suspension from machine 5 Remove seat suspension components as needed Assembly Fig 13 1 Install all removed seat suspension components 2 If seat susp...

Page 352: ...rame tube LH 10 Hood frame tube RH 11 Hood frame tube center 12 Hood frame tube RH 13 Hood frame tube LH 14 Flange head screw 4 15 Flange nut 4 16 Radiator frame 17 Latch hood 18 Latch frame 19 Latch lock CE 20 Rear bumper 21 Cap screw 2 22 Washer 2 23 Cap screw 2 24 Lock nut 4 Figure 15 FRONT RIGHT 1 2 3 4 5 6 7 8 9 10 11 12 8 13 14 15 16 17 18 19 20 14 21 22 23 24 ...

Page 353: ...raise hood 3 Remove hair pins and washers from pivot pins on ra diator frame 4 Remove hood from pivot pins and machine 5 If necessary disassemble hood Installation Fig 15 1 If components were removed from hood assemble hood 2 Slide hood frame onto radiator frame pivot pins 3 Secure hood to frame with hair pins and washers 4 Check hood alignment for correct operation of hood latches and dust seals ...

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Page 355: ...l Motor 16 Backlapping 17 Bedbar Assembly 18 Bedknife Replacement and Grinding 20 Bedbar Adjuster Service 22 Reel Assembly cutting units with painted side plates 24 Reel Assembly Service cutting units with painted side plates 28 Reel Assembly cutting units with aluminum side plates 30 Reel Assembly Service cutting units with aluminum side plates 34 Preparing Reel for Grinding 36 Front Roller 38 Re...

Page 356: ...ameter tube with drive inserts threaded into both ends The reel drive inserts have an internal nine 9 tooth spline Height of Cut HOC Cutting height is adjusted on the front roller by two 2 vertical screws Effective HOC may vary depending on turf conditions type of bedknife roller type and installed attachments Bedknife Replaceable tool steel EdgeMaxTM bedknife is fastened to a machined cast iron b...

Page 357: ...neral maintenance and maintenance intervals for the DPA cutting units on your Reelmaster machine Additionally if optional kits have been installed on the cutting units e g rear roller brush the installation instructions for the kit includes set up and operation information Refer to those publications for additional information when servicing the cutting units DPA Cutting Units ...

Page 358: ...f Cut HOC adjustment Used for Height of Groomer HOG adjustment Bedknife Screw Tool Toro Part Number TOR510880 This screwdriver type bit is made to fit Toro bedknife at taching screws Use this bit with a torque wrench to se cure the bedknife to the bedbar IMPORTANT To prevent damage to the bedbar DO NOT use an air or manual impact wrench with this tool Figure 3 Handle Assembly Toro Part Number 29 9...

Page 359: ... Unit Kickstand Toro Part Number 119 8010 03 The cutting unit kickstand is used to prop up the rear of the cutting unit during service Use of this tool prevents the bedbar adjusting screws from resting on the work surface Figure 6 Spline Insert Tool Toro Part Number TOR4074 9 tooth Use the spline insert tool for rotating the cutting reel when hydraulic motor is removed Also use this tool for insta...

Page 360: ...ows 115 0852 Inner Seal Tool 115 0853 Bearing Outer Seal Tool 107 8133 Bearing Installation Washer Figure 9 Inner Seal Tool Bearing Outer Seal Bearing Installation Washer Tool Turf Evaluator Tool Toro Model Number 04399 Many turf discrepancies are subtle and require closer examination In these instances the Turf Evaluator grass viewing tool is helpful It can assist turf managers and service techni...

Page 361: ... reel shim 0 002 is used to help parallel the bedknife and cutting reel Figure 12 Cutting Performance Paper Toro Part Number 125 5610 Cutting performance paper is used to test the cutting reel performance after adjusting the reel to bedknife clearance 10 packs 30 strips per pack of cutting per formance paper are included in this part number Figure 13 Pulley Alignment Tool Toro Part Number 114 5446...

Page 362: ...fe with the digital display facing you as shown Fig 15 2 Press the Alt Zero button on the angle indicator 3 Remove the angle indicator and place the angle in dicator mount on the edge of the bedknife so the face of the magnet is flat against the top of the bedknife Fig 16 4 Place the angle indicator on the mount with the digital display facing you as shown Fig 16 The angle dis played on the indica...

Page 363: ...ned engine speed For best cutting performance and appearance engine should be run at maximum governed speed during machine operation Check maximum governed engine speed Adjust engine to specifications if necessary See the traction unit Operator s Manual and Chapter 3 Yanmar Diesel Engine or Chapter 4 Kubota Diesel Engine in this manual Reel speed All cutting reels must rotate at the same speed wit...

Page 364: ...e and Repairs section of this chapter Rear roller adjustment Adjust the rear roller brackets to correct position depending on the height of cut range desired See Rear Roller Adjustment in the cutting unit Operator s Manual Height of cut Effective or actual height of cut depends on the cutting unit weight and turf conditions Effective height of cut will be different from the bench set height of cut...

Page 365: ...ngs as necessary See Roller Service in the Service and Repairs section of this chapter Refer to cutting unit Operator s Manual for roller options Cutting unit accessories A variety of cutting unit accessories are available that can be used to enhance aftercut appearance Refer to cutting unit Operator s Manual for a listing of available accessories DPA Cutting Units ...

Page 366: ...lf sharpening action This feature maintains sharp cutting edges assures good quality of cut and greatly reduces the need for routine backlapping In addition the rear roller positioning system allows for various height of cut ranges and aggressiveness of cut selections If a cutting unit is determined to be out of adjustment complete the following procedures in the specified order to adjust the cutt...

Page 367: ...move cutting unit components on LH side plate to allow access to bearing adjuster nut If cutting unit is equipped with an optional groomer or rear roller brush remove components for those options from left hand side plate of cutting unit See Service and Repairs sec tion of Chapter 10 Belt Driven Groomer for information on groomer See Rear Roller Brush in the Service and Repairs section of this cha...

Page 368: ...ig 18 5 Adjust the position of the side plate to parallel the rear roller and cutting reel Then tighten the shoulder bolts to a torque from 27 to 33 ft lb 37 to 44 N m 6 After tightening the side plate recheck the rear roller If necessary loosen and adjust second side plate 7 If rear roller is still not level after adjusting both side plates check to see if cutting reel is tapered see Pre paring R...

Page 369: ...Reelmaster 7000 D DPA Cutting Units Page 9 15 This page is intentionally blank DPA Cutting Units ...

Page 370: ...ve plastic cap see Special Tools into the hole in the cutting unit side plate to prevent debris entry into reel bearing area Installation Refer to Figure 20 for correct placement of cutting unit reel motors and weights 1 Coat spline shaft of the reel motor with No 2 multi purpose lithium base grease 2 Install the cap screws for the reel drive motor into the cutting unit side plate and leave approx...

Page 371: ...the PTO switch to the ON position Press the lift switch to start the backlapping operation on the desig nated reels 6 Apply lapping compound to cutting reels with a long handle brush see Special Tools Never use a short handled brush to apply lapping compound CAUTION Be careful when backlapping the reel because contact with the reel or other moving parts can result in personal injury 7 To make a cu...

Page 372: ...on switch 2 Remove the cutting unit from the machine Use the cutting unit kickstand to support the cutting unit see Special Tools 3 Loosen the lock nuts item 2 on the end of each bed bar adjuster assembly until washer item 2 is loose 4 Loosen the lock nuts item 10 on each bedbar pivot bolt 5 Remove two 2 bedbar pivot bolts item 9 two 2 metal washers and four 4 plastic washers from the cut ting uni...

Page 373: ...into the bedbar enough to hold the bedbar in position IMPORTANT Do Not use a powered wrench or an impact wrench to install the bedbar pivot bolts B Start threading of one of the pivot bolts into the bedbar and continue until the pivot bolt bottoms out Repeat for remaining pivot bolt C Make sure that plastic washers are not caught on the threads of the pivot bolts D Tighten each bedbar pivot bolt f...

Page 374: ... 16 18UNC 2A are clean IMPORTANT Do not use an impact wrench to tight en screws into the bedbar 3 Use new screws to secure bedknife to bedbar Apply antiseize lubricant to the threads of new screws Do not apply antiseize lubricant to the taper of the screw heads 4 Install all screws but do not tighten 5 Using a torque wrench and bedknife screw tool tighten the 2 outer screws to 10 in lb 1 N m 6 Wor...

Page 375: ...ro has developed special service tools for accurately measuring the top grind angle on all bedknives refer to the Angle Indicator and Magnetic Mount in the Special Tools section of this Chapter NOTE Some bedknives were produced with a 5_ top angle Use a 10_ top angle when regrinding all bedknives Bedknife Grinding Specifications Bedknife Lip Height Service Limit Top Angle Front Angle EdgeMax Low H...

Page 376: ...ricant Hand Threads 14 to 16 ft lb 19 to 21 N m Antiseize Lubricant Loctite 243 1 2 11 3 4 5 6 7 13 12 10 5 Left Antiseize Lubricant Hand Threads 14 15 to 20 ft lb 21 to 27 N m NOTE The bedbar adjuster system for early produc tion DPA cutting units Fig 32 A used a retaining ring on the end of the bedbar adjuster shaft Current produc tion DPA cutting units Fig 32 B include a lock nut on the end of ...

Page 377: ...19 to 21 N m 2 If flange bushings item 5 were removed apply anti seize lubricant to bore of cutting unit frame Align key on bushing to slot in frame and install bushings into frame Apply antiseize lubricant to bore of each flange bushing 3 Install adjuster shaft to cutting unit frame A On early production cutting units Fig 32 A slide bedbar adjuster shaft into flange bushings in cutting unit frame...

Page 378: ...octite 243 Grease bore and threads 27 to 33 ft lb 37 to 44 N m 27 to 33 ft lb 37 to 44 N m 12 to 15 in lb 1 4 to 1 7 N m 20 19 21 11 3 22 23 Grease bore Antiseize Lubricant NOTE This section provides the procedure for remov ing and installing the cutting reel assembly cutting reel spline inserts grease seals and bearings from the cut ting unit NOTE Refer to Reel Assembly Service later in this sec ...

Page 379: ... damage the cutting edge and or cause a high blade C Move the pry bar against the weld side of the reel support plate closest to the spline insert being loosened Use correct spline insert tool see Special Tools IMPORTANT The spline insert on the left end of the cutting reel has left hand threads and the spline in sert on the right end of the cutting reel has right hand threads D Rest the handle of...

Page 380: ...ill occur and reel installation may cause bearing damage Use reel bearing installation tool Toro part number 117 0975 to help with bearing alignment during reel installation 1 LH side plate 2 Threaded insert 3 Bearing adjuster nut 4 Set screw Figure 36 1 2 3 4 12 to 15 in lb 1 4 to 1 7 N m 15 to 17 in lb 1 7 to 1 9 N m Loctite 243 3 Using reel bearing installation tool see Special Tools in this ch...

Page 381: ...oller Brush in the Service and Repairs section of this chapter for informa tion on rear roller brush 17 Tighten the spline inserts A Insert a long handled pry bar 3 8 x 12 inch with a screwdriver handle recommended through the front of the cutting unit The pry bar should pass between the top of the reel shaft and the backs of the reel blades so that the reel will not move IMPORTANT To avoid grindi...

Page 382: ...tion and scoring 2 Inspect the reel shaft as follows If reel damage is de tected replace reel A Check the reel shaft for bending and distortion by placing the shaft ends in V blocks B Check the reel blades for bending or cracking C Check the service limit of the reel diameter see Preparing a Reel for Grinding in this section 3 Check the threaded inserts in the reel shaft for ex cessive wear or dis...

Page 383: ...grease or lubricant applied to ID of seal IMPORTANT The grease seal should be installed so the metal side of the seal is toward the bearing location B Press grease seals onto reel shaft with metal side orientated toward bearing location Final position of seal should be flush to 0 060 1 5 mm away from re taining ring on reel shaft Do not force seal against retaining ring Seal must be perpendicular ...

Page 384: ...3 used per side plate 16 Shoulder bolt 3 used per side plate 17 Cap screw 2 used 18 O ring Figure 39 Antiseize Lubricant FRONT RIGHT 2 3 6 8 9 10 11 13 1 5 7 12 14 16 17 18 4 4 27 to 33 ft lb 37 to 44 N m Antiseize Lubricant Antiseize Lubricant Bearing OD Bearing OD Pack with Grease both ends 15 NOTE Refer to Reel Assembly Service later in this sec tion for information on replacing cutting reel se...

Page 385: ...ke and re move key from the ignition switch 2 Remove the cutting unit from the machine and place on a flat work area 3 If cutting unit is equipped with a counterweight or ac cessory on LH side plate remove the counter weight or accessory Remove and discard O ring from counter weight See Chapter 10 Belt Driven Groomer or Chap ter 10 Universal Groomer for more information See Rear Roller Brush in th...

Page 386: ...e cutting reel shaft and should remain on the reel when removing the LH side plate 9 Remove three 3 shoulder bolts and flange nuts that secure the LH side plate to the cutting unit frame Re move the LH side plate from the reel shaft and cutting unit frame 10 Carefully pull the cutting reel assembly from the RH side plate 11 Inspect and service cutting reel assembly as re quired see Reel Assembly S...

Page 387: ...r for informa tion on rear roller brush 15 Tighten the spline inserts A Insert a long handled pry bar 3 8 x 12 inch with a screwdriver handle recommended through the front of the cutting unit The pry bar should pass between the top of the reel shaft and the backs of the reel blades so that the reel will not move IMPORTANT To avoid grinding the reel do not con tact the cutting edge of any blade wit...

Page 388: ...tting units prior to serial no 315000001 Reel Assembly Inspection 1 Inspect reel bearings to insure that they spin freely and have minimal axial play 2 Inspect the reel shaft as follows If reel damage is de tected replace reel A Check the reel shaft for bending and distortion by placing the shaft ends in V blocks B Check the reel blades for bending or cracking C Check the service limit of the reel...

Page 389: ...ite 243 or equivalent to threaded portion of insert Tighten threaded insert from 85 to 95 ft lb 115 to 128 N m 3 Make sure that the two 2 retaining rings are fully seated into the grooves on the cutting reel shaft 4 Carefully drive special washers onto reel shaft with tapered side of washers toward reel flat side toward bearing location Installed washers should be tight against retaining ring and ...

Page 390: ...nal resource is the Toro Basics Se ries Training Book Reel Mower Basics part no 09168SL found on the Service Reference Set available from your Authorized Toro Distributor Reel Grinding Specifications Reel Diameter New 7 060 in 179 3 mm Service Limit Reel Diameter 6 600 in 168 0 mm Reel Shaft Diameter OD 1 313 in 34 4 mm Reel Diameter Taper Fig 47 0 010 in 0 25 mm Blade Land Width 0 050 to 0 060 in...

Page 391: ...Reelmaster 7000 D DPA Cutting Units Page 9 37 This page is intentionally blank DPA Cutting Units ...

Page 392: ...ket C Thread cap screw into height of cut roller bracket NOTE When assembling height of cut roller brack ets to side plate make sure that cap screw head and one washer are above adjustment flange on side plate and second washer and flange lock nut are below flange 3 If both front height of cut roller brackets were re moved from cutting unit side plate position one of the brackets to side plate Sec...

Page 393: ...e NOTE Refer to cutting unit Operator s Manual for num ber of roller shims required for various height of cut set tings NOTE A 0 010 shim part number 107 4001 is avail able to allow for leveling of the rear roller see Leveling Rear Roller in this chapter If necessary this shim would be used on one side of the rear roller and should be installed between the rear roller bracket and roller shim 2 If ...

Page 394: ...ANT During assembly process frequently check that bearings rotate freely and do not bind If any binding is detected consider component re moval and reinstallation 2 Install new bearing and outer seals into one end of roller tube A Position a new bearing into one end of roller tube Use bearing outer seal tool see Special Tools with a soft face hammer to fully seat bearing against roller shoulder Fi...

Page 395: ... seal installation E Using the same process install second outer seal making sure to not crush the installed outer seal Again make sure that shaft and bearings still freely rotate IMPORTANT Make sure that all grease is removed from shaft threads to prevent bearing lock nut loos ening 5 Thoroughly clean threads on both ends of roller shaft NOTE If original bearing lock nut s are being used apply Lo...

Page 396: ...Hardened washer 4 28 Drive bearing housing 29 Mounting bracket 2 30 Bearing assembly non driven 31 O ring 32 Socket head screw 2 33 Pivot washer 34 Set screw top hole in cover Figure 56 Antiseize Lubricant FRONT RIGHT 15 to 19 ft lb 20 to 25 N m 15 to 19 ft lb 20 to 25 N m Grease Grommet ID 27 to 33 ft lb 37 to 44 N m 15 to 19 ft lb 20 to 25 N m Loctite 243 15 to 19 ft lb 20 to 25 N m Loctite 243 ...

Page 397: ...e brush to shaft with two 2 J bolts and lock nuts Make sure that the J bolts are installed with the threaded portion on the outside of the brush Fig 57 Torque lock nuts from 20 to 25 in lb 2 3 to 2 8 N m 2 If seals or bearings were removed from brush bear ing housings install new components noting proper ori entation Fig 58 A Pack bearings with grease before installation B Press bearing into beari...

Page 398: ... C Check that brush plate is parallel to cutting unit side plate If necessary change position of mounting bracket item 29 to allow brush plate to be parallel to side plate D Apply Loctite 243 or equivalent to threads of flange head screw item 20 that secures drive pulley to drive shaft Torque flange head screw from 35 to 40 ft lb 47 to 54 N m E Apply antiseize lubricant to splines of roller brush ...

Page 399: ... washer s item 9 until drive and driven pulleys are aligned within 0 030 0 76 mm 6 Check that roller brush is parallel to rear roller with 0 060 1 5 mm clearance to light contact with roller Fig 63 If contact is incorrect brush operation will be adversely affected 7 Lubricate grease fittings on brush housings until grease purges past inboard seals Wipe excess grease from seals and fittings 1 Drive...

Page 400: ... unit from the cutting reel motor Figure 56 shows components used when the brush drive is on the left side of the cutting unit NOTE The Installation Instructions for the rear roller brush kit has detailed information regarding assembly and adjustment Use those Instructions along with this Service Manual when servicing the rear roller brush Rear Roller Brush Disassembly Fig 56 1 Position machine on...

Page 401: ...rom roller brush shaft apply antiseize lubricant to splines of pulley bore and slide pulley onto shaft Install and tighten flange nut until pulley is seated onto shaft and then torque flange nut from 27 to 33 ft lb 37 to 44 N m Use a wrench on roller brush shaft flats to prevent shaft from rotating when tightening nut C Position excluder seals on brush shaft so that seals just touch bearing housin...

Page 402: ... when the brush drive is on the left side of the cutting unit NOTE The Installation Instructions for the rear roller brush kit has detailed information regarding assembly and adjustment Use those Instructions along with this Service Manual when servicing the rear roller brush 1 Position machine on a clean and level surface lower cutting units stop engine engage parking brake and re move key from t...

Page 403: ...ners as shown in Figure 68 B Apply a light coating of grease to inner diameter of the grommet in drive bearing housing before in stalling brush plate C Brush plate should be installed so that idler pulley assembly is toward the bottom of the plate Also the shoulder bolt item 15 should not clamp the brush plate to the drive housing during assembly D When installing drive pulley item 17 make sure th...

Page 404: ...s seated onto shaft and then torque flange nut from 27 to 33 ft lb 37 to 44 N m Use a wrench on roller brush shaft flats to prevent shaft from rotating when tightening nut IMPORTANT The roller brush shaft must nor con tact the cutting unit side plate Also heavy brush contact on the rear roller will cause premature brush wear 4 Check that brush is parallel to rear roller with 0 060 1 5 mm clearance...

Page 405: ...s GROOMING PERFORMANCE 2 TROUBLESHOOTING 3 Groomer Reel Mechanical Problems 3 ADJUSTMENTS 4 Groomer Height Depth Adjustment 4 SERVICE AND REPAIRS 5 Groomer Drive Belt Replacement 5 Groomer Plate Assembly 6 Groomer Reel 10 Groomer Reel Service 12 Groomer Pivot Hub 14 Height Adjuster Assembly 16 Belt Driven Groomer ...

Page 406: ...EFORE OPERAT ING OR TESTING GROOMER PERFORMANCE It is important to remember that factors affecting quality of cut also affect grooming performance Variables That Affect the Use and Performance of Groomers 1 The growing season and weather conditions 2 General turf conditions 3 The frequency of grooming cutting number of cut tings per week and how many passes per cutting 4 The height of cut 5 The gr...

Page 407: ...ce spring If the drive belt slips it probably is out of adjustment or worn Repair or replace drive belt if nec essary A broken or worn belt could be the result of improper belt rout ing or seized bearings in groomer assembly Change grooming depth The turf is damaged or has uneven grooming The groomer reel blades are bent damaged or missing The groomer reel shaft is bent or damaged Grooming depth i...

Page 408: ...ound stop engine en gage parking brake and remove key from the ignition switch 2 Make sure rollers are clean and cutting unit is set to the desired height of cut see Cutting Unit Operator s Manual 3 Place the groomer reel in the grooming lowered position by rotating the raise lower lever toward the front of the cutting unit Fig 1 NOTE Improper or over aggressive use of the groom er e g too deep or...

Page 409: ... is equipped with powered rear roll er brush removal of roller brush components will be necessary to replace groomer drive belt see Roller Brush Optional in the Service and Repairs section of Chapter 9 Cutting Units NOTE When removing groomer cover groomer weight does not have to be removed from cover 2 Remove two 2 flange nuts that secure groomer cover then remove cover Fig 2 3 Remove groomer bel...

Page 410: ... shows components used when the groomer reel drive is on the left side of the cutting unit Removal Fig 4 1 Park machine on a clean and level surface lower cutting units completely to the ground stop engine en gage parking brake and remove key from the ignition switch NOTE If cutting unit is equipped with powered rear roll er brush removal of roller brush components will be necessary to service gro...

Page 411: ...hat secure groomer components to cutting unit side plate C Remove pivot hub from cutting unit D Support groomer shaft to prevent it from falling Carefully slide non drive side groomer plate from groomer shaft and cutting unit 4 Inspect seals bearings and bushing in groomer plates Remove and discard damaged or worn compo nents Installation Fig 4 1 If seals bearings or bushing was removed from groom...

Page 412: ...item 4 that locate drive and driven pulleys Position keys into shaft slots NOTE To prevent cutting reel from turning when installing drive pulley block cutting reel with piece of wood G Apply Loctite 243 to threads of flange head screw that secures drive pulley to pivot hub shaft Slide drive pulley onto shaft and secure with flange head screw Torque screw from 27 to 32 ft lb 37 to 43 N m NOTE To p...

Page 413: ...Reelmaster 7000 D Belt Driven Groomer Optional Page 10 9 This page is intentionally blank Belt Driven Groomer ...

Page 414: ...de additional blade life NOTE The groomer reel drive is located on the oppo site side of the cutting unit from the reel hydraulic motor Figure 8 shows the groomer reel drive on the left side of the cutting unit Removal Fig 8 1 Park machine on a clean and level surface lower cutting units completely to the ground stop engine en gage parking brake and remove key from the ignition switch If desired r...

Page 415: ...er reel into the non drive side groomer plate assembly taking care not to damage seals in groomer plate assembly 5 Carefully install groomer plate assembly to groomer reel and groomer drive side of cutting unit see Groomer Plate Assembly Installation in this section 6 Check that excluder seals just touch groomer plate assembly Fig 10 Reposition excluder seals on groomer shaft if necessary 7 Check ...

Page 416: ... the shaft Fig 13 6 Remove spacers and blades from groomer shaft If needed remove second lock nut from shaft 7 If necessary remove groomer shaft ends from groomer shaft Assembly Fig 13 1 Install lock nut on drive end of groomer shaft Place first spacer and then first blade on shaft 2 Alternately install remaining spacers and blades making sure that all blades are separated by a spacer Additionally...

Page 417: ...e positioned between blades 1 2 14 15 28 29 and 41 42 Pull straps tight and cut off strap extension approximately 1 4 6 mm beyond retainer 6 Place excluder seals on groomer shaft 7 Install O ring on non drive end of groomer shaft 8 Install groomer reel back on cutting unit see Groom er Reel Installation in this section 1 Groomer shaft 2 Broomer strap Figure 14 1 2 2 2 2 Belt Driven Groomer ...

Page 418: ...ub 6 Retaining ring 7 Extension spring 8 Retaining ring 9 Idler plate 10 O ring 7 cutting unit only 4 3 1 2 9 10 8 5 6 7 Apply Grease to Seal Lip NOTE The groomer reel drive is located on the oppo site side of the cutting unit from the cutting reel hydraulic motor Figure 15 shows components used when the groomer reel drive is on the left side of the cutting unit ...

Page 419: ...outer bearing races Install the bearing so that the bearing seal is closest to the shoulder on the shaft Install retaining ring item 7 onto shaft to retain bearing 2 Install new grease seal into housing with the lip of the seal toward the outside of the housing Apply grease to lip of seal 3 Fill cavity between bearing location and grease seal 50 to 75 full with high temperature Mobil XHP 222 greas...

Page 420: ...ts and inspect for wear or dam age Replace all worn or damaged components Assembly Fig 17 1 Assemble height adjuster using Figure 17 as a guide noting the following items A If bushing item 10 was removed from upper ramp press new bushing into housing fully to the shoulder in the bore B If jam nuts item 4 were removed from ball joint rod apply antiseize lubricant to threads of rod where jam nuts wi...

Page 421: ...omer Optional Table of Contents GROOMING PERFORMANCE 2 TROUBLESHOOTING 3 Groomer Reel Mechanical Problems 3 SERVICE AND REPAIRS 4 Gear Box Assembly 6 Idler Assembly 12 Groomer Reel 14 Groomer Reel Service 15 Grooming Brush Optional 17 Height Adjuster Assembly 18 Universal Groomer ...

Page 422: ...RE OPERATING OR TESTING GROOMER PERFORMANCE It is important to remember that factors affecting quality of cut also affect grooming performance Variables That Affect the Use and Performance of Groomers 1 The growing season and weather conditions 2 General turf conditions 3 The frequency of grooming cutting number of cut tings per week and how many passes per cutting 4 The height of cut 5 The groomi...

Page 423: ...rive to Forward or Reverse Repair groomer drive The turf is damaged or has uneven grooming The groomer reel blades are bent damaged or missing The groomer reel shaft is bent or damaged Grooming depth is not equal on both ends of groomer reel Repair or replace blades if neces sary Replace groomer reel shaft Adjust depth if necessary Check and adjust cutting unit set up level bedknife to reel level ...

Page 424: ...ver work on the groomer with the engine running Always stop the engine remove the key from the ignition switch and wait for all machine movement to stop before working on the groomer NOTE The Groomer Operator s Manual provides in formation regarding the installation set up operation and maintenance of the universal groomer on your Reelmaster machine Refer to these instructions for ad ditional info...

Page 425: ...Reelmaster 7000 D Universal Groomer Optional Page 11 5 This page is intentionally left blank Universal Groomer ...

Page 426: ... engine en gage parking brake and remove key from the ignition switch 2 Remove the groomer reel assembly see Groomer reel in this chapter NOTE If cutting unit is equipped with an optional pow ered rear roller brush remove the rear roller brush cov er drive belt and drive housing assembly to service the groomer drive see Roller Brush Optional in Chapter 9 Cutting Units in this manual for additional...

Page 427: ... You must use a 6 point socket with a heavy wall to remove the gear box from the reel Do not use an impact wrench Groomer gear boxes in stalled on the left side of the cutting unit use a left hand thread turn the drive shaft in correct direction to remove the gear box 10 Rest the handle of the pry bar against the front roller and turn the drive shaft in correct direction to loosen it from the reel...

Page 428: ... reel support plate closest to the drive shaft assembly J Use the drive shaft removal tool Toro p n 137 0920 on the large flats of the drive shaft as sembly refer to Fig 5 K Rest the handle of the pry bar against the front roller and turn the drive shaft in correct direction to loosen it from the reel 12 Tip the cutting unit back onto its rollers 13 Clean the threads in the end of the reel shaft A...

Page 429: ...23 Cover 24 Gasket 25 Thrust washer 26 Bearing 27 Sun gear 28 O ring 29 Bushing 30 Ring gear 31 Bearing 32 Planet gear 3 33 Bushing 3 34 Lock nut 35 Output gear 36 Bearing 2 37 Housing 38 Seal 39 Output shaft 40 Shield 41 Dowel pin 2 42 Thrust washer 2 43 Retaining ring 2 44 Bearing 4 45 Idler gear 2 46 Cap screw 2 11 12 13 14 15 16 17 18 18 18 19 20 1 2 3 4 5 6 7 8 9 10 21 22 23 24 25 26 27 28 41...

Page 430: ... lips and O rings before installing shafts 5 If idler gear assemblies were removed Gear box for 7 in reel cutting units only tighten idler gear cap screw from 85 to 95 in lb 9 to 11 N m 6 Lubricate planet gear and sun gear pins in gear box housing with gear oil and install planet ring and sun gears Figure 7 7 Clean gasket surface on gear box housing and cover with solvent and install new gasket 8 ...

Page 431: ...ear box assembly and rest the handle of the pry bar against the front roller 5 Position the gear box assembly against the cutting unit and turn the drive shaft assembly in correct direction until it is seated against the reel IMPORTANT You must use a 6 point socket with a heavy wall to install the gear box to the reel Do not use an impact wrench Groomer gear boxes in stalled on the left side of th...

Page 432: ...tor Removal Fig 9 1 Park machine on a clean and level surface lower cutting units completely to the ground stop engine en gage parking brake and remove key from the ignition switch 2 Remove hydraulic reel motor from cutting unit see Hydraulic Reel Motor Removal in Chapter 9 Cutting Units in this manual 3 Remove the groomer reel assembly see Groomer reel in this chapter 4 Remove the cotter pin and ...

Page 433: ... through hole in shaft to prevent shaft from ro tating tighten flange nut from 27 to 33 ft lb 37 to 45 N m E If collar was removed from idler arm install collar and tighten from 24 to 30 ft lb 33 to 41 N m 2 Apply antisieze lubricant to the outside diameter of the pivot hub Fig 10 Position idler arm over pivot hub 3 Apply Loctite to two 2 socket head screws and se cure pivot hub and idler arm to c...

Page 434: ...t in personal injury Use heavy gloves when handling the groomer reel 2 Carefully remove the four 4 jam nuts cap screws and shaft clamps securing the groomer reel to the output and stub shafts 3 Lift the groomer reel from the cutting unit 4 Inspect seal shields bushing and bearings for wear or damage Replace components as needed see Gear Box Assembly and Idler Assembly in this section Installation ...

Page 435: ...haft If needed remove second lock nut from shaft Assembly Fig 13 1 Install lock nut on drive end of groomer shaft Place a 1 4 6 3 mm spacer on the groomer shaft followed by the first groomer blade 2 Alternately install 1 1 4 31 7 mm spacers and blades making sure that all blades are separated by a spacer 3 When all blades have been installed place remain ing 1 4 6 3 mm on shaft Thread second lock ...

Page 436: ...the following locations on the broomer shaft 18 reels between blades 2 3 11 12 21 22 and 30 31 22 reels between blades 2 3 14 15 26 27 and 38 39 Position the broomer brushes properly in the blade slots and tighten the groomer blade retaining nuts from 31 to 35 ft lb 42 to 48 N m D While holding strap buckle in place pull straps tight into the pre cut notches of each brush E Cut off strap extension...

Page 437: ...ce The optional grooming brush is removed and installed from the groomer in the same manner as the groomer reel see Groomer Reel in this chapter The grooming brush element or shaft can be serviced separately Fig 17 1 Brush element 2 Shaft 3 Roll pin 2 Figure 17 1 2 3 3 Universal Groomer ...

Page 438: ...g 18 1 Park machine on a clean and level surface lower cutting units completely to the ground stop engine en gage parking brake and remove key from the ignition switch 2 Remove the cotter pins and clevis pins securing the height adjustment rods to the groomer gear box and idler arm Discard cotter pins 3 Loosen the two 2 height adjustment bolt lock nuts 4 Loosen the two 2 front roller pinch bolt lo...

Page 439: ... plate and one 1 washer and lock nut is below slot in side plate 3 Position front roller between height adjuster assem blies and secure height adjuster assembly to cutting unit side plate with carriage bolt and flange nut Do Not tight en the flange nut at this time Ensure the height adjust ment bolt and one 1 washer is above slot in side plate and one 1 washer and lock nut is below slot in side pl...

Page 440: ...Reelmaster 7000 D Universal Groomer Optional Page 11 20 This page is intentionally left blank ...

Page 441: ...below 316000000 7 Traction Unit Model 03781 Kubota Engine Serial numbers 316000001 to 403350000 8 Traction Unit Model 03781 Kubota Engine Serial numbers above 403350001 9 Cab 10 WIRE HARNESS DRAWINGS Main Wire Harness Serial numbers below 316000000 11 Main Wire Harness Serial numbers 316000001 to 403350000 13 Main Wire Harness Serial numbers 403350001 to 405699999 15 Main Wire Harness Serial numbe...

Page 442: ... YELLOW Numerous harness wires used on Toro machines in clude a line with an alternate color These wires are iden tified with the wire color and line color with either a or _ separating the color abbreviations listed above e g R BK is a red wire with a black line OR_BK is an orange wire with a black line Wire Size The individual wires of the electrical harness diagrams in this chapter identify bot...

Page 443: ...28 0 028 FAN STEERING UNIT 055 C4 1700 psi C3 040 500 psi S2 S4 207 psi ROD PISTON 110 psi 3000 psi 040 3000 psi 040 110 psi MV2 MV1 SP1 M1 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID 1450 psi 1 6 CID CV1 LC1 RV1 OR2 OR1 LIFT MANIFOLD CHG STRAINER BREATHER FORWARD REVERSE LEFT CYLINTER EXTEND TO LOWER CENTER CYLINDER EXTEND TO LOWER LEFT CYLINTER FRONT LIFT CYLINDERS REAR LIFT CYLINDERS EXT...

Page 444: ...Schematic Traction Unit Reelmaster 7000 D Model 03780 Yanmar Engine All relays and solenoids are shown as de energized All ground wires are black CAB HARNESS CONNECTOR ALTERNATOR 80 A STANDARD Serial numbers below 316000000 ...

Page 445: ... 122 0675 Rev A Reelmaster 7000 D Electrical Schematic Traction Unit Model 03780 Yanmar Engine Serial numbers 316000001 to 403350000 All relays and solenoids are shown as de energized All ground wires are black ...

Page 446: ...12 6 122 1519 Rev A Reelmaster 7000 D Electrical Schematic Traction Unit Model 03780 Yanmar Engine Serial numbers above 403350001 All relays and solenoids are shown as de energized All ground wires are black ...

Page 447: ...Schematic Traction Unit Reelmaster 7000 D Model 03781 Kubota Engine CAB HARNESS CONNECTOR All relays and solenoids are shown as de energized All ground wires are black ALTERNATOR 60 A STANDARD Serial numbers below 316000000 ...

Page 448: ... 122 0675 Rev A Reelmaster 7000 D Electrical Schematic Traction Unit Model 03781 Kubota Engine Serial numbers 316000001 to 403350000 All relays and solenoids are shown as de energized All ground wires are black ...

Page 449: ...12 9 122 1519 Rev A Reelmaster 7000 D Electrical Schematic Traction Unit Model 03781 Kubota Engine Serial numbers above 403350001 All relays and solenoids are shown as de energized All ground wires are black ...

Page 450: ...Page 12 10 Electrical Schematic Cab Reelmaster 7000 D Model 03780 30781 All relays and solenoids are shown as de energized All ground wires are black HARNESS CONNECTOR TRACTION UNIT ...

Page 451: ...Page 12 11 Reelmaster 7000 D Main Wire Harness Drawing Model 03780 30781 Serial numbers below 316000000 ...

Page 452: ...LLOW PINK GREEN PINK BLACK BLACK BLUE BLACK RED YELLOW GRAY BROWN WHITE BLACK WHITE GREEN BLACK YELLOW WHITE VIOLET WHITE YELLOW PINK BLUE BROWN WHITE BLACK WHITE RED WHITE BLACK BLACK BLACK BLACK PINK BLACK RED BLACK PINK WHITE YELLOW WHITE BLACK ORANGE VIOLET BLACK BLUE PINK BLACK WHITE ORANGE PINK BLACK WHITE RED WHITE VIOLET WHITE BLACK PINK BLACK VIOLET BLACK WHITE BLACK RED GREEN BLACK BLACK...

Page 453: ...Page 12 13 CV 122 0666 Rev A Reelmaster 7000 D Main Wire Harness Drawing Model 03780 03781 Serial numbers 316000001 to 403350000 ...

Page 454: ...Page 12 14 122 0666 Rev A Reelmaster 7000 D Main Wire Harness Diagram Model 03780 03781 Serial numbers 316000001 to 403350000 ...

Page 455: ...Page 12 15 CV 122 1520 Rev A Reelmaster 7000 D Main Wire Harness Drawing Model 03780 03781 Serial numbers 403350001 to 405699999 ...

Page 456: ...Page 12 16 122 1520 Rev A Reelmaster 7000 D Main Wire Harness Diagram Model 03780 03781 Serial numbers 403350001 to 405699999 ...

Page 457: ...Page 12 17 CV 122 1729 Rev A Reelmaster 7000 D Main Wire Harness Drawing Model 03780 03781 Serial numbers above 405700000 ...

Page 458: ...Page 12 18 122 1729 Rev A Reelmaster 7000 D Main Wire Harness Diagram Model 03780 03781 Serial numbers above 405700000 ...

Page 459: ...Page 12 19 Reelmaster 7000 D Engine Wire Harness Drawing Model 03780 Yanmar Engin ...

Page 460: ...VIOLET RED BROWN WHITE BLACK WHITE WHITE PINK BLACK RED WHITE VIOLET BLACK WHITE BLACK WHITE RED WHITE BLACK BLACK BLACK BLACK BLACK ORANGE BROWN RED BLACK VIOLET WHITE RED WHITE BLACK RED VIOLET VIOLET VIOLET WHITE VIOLET GREEN WHITE BLUE BLUE BROWN RED GREEN RED BLUE BLACK WHITE BLACK VIOLET BLUE RED WHITE BLACK WHITE BLACK BLACK BLACK VIOLET BLACK GREEN RED BLUE BLUE BLUE BLACK BLACK RED YELLOW...

Page 461: ...Page 12 21 Reelmaster 7000 D Engine Wire Harness Drawing Model 03781 Kubota Engine ...

Page 462: ...00 D Engine Wire Harness Diagram Kubota ORANGE RED BLUE GRAY BROWN ORANGE BLACK WHITE GREEN WHITE BROWN YELLOW BROWN BLACK RED BLACK RED WHITE BLACK WHITE PINK BLACK WHITE BLACK BLACK BLUE BLUE BLACK Model 03781 Kubota Engine ...

Page 463: ...Page 12 23 Reelmaster 7000 D Seat and Console Wire Harness Drawing Model 03780 30781 ...

Page 464: ...BLACK RED GREEN RED YELLOW WHITE BLACK PINK BLACK PINK GREEN ORANGE BLACK WHITE GRAY BROWN YELLOW ORANGE WHITE WHITE ORANGE PINK BLACK WHITE RED WHITE BLUE VIOLET BLACK RED WHITE BLACK WHITE RED WHITE BLACK WHITE RED WHITE BLACK WHITE PINK BLACK RED WHITE BLACK WHITE BLACK BLACK BLACK BLACK BLACK Model 03780 30781 ...

Page 465: ...Page 12 25 Reelmaster 7000 D Power Center Wire Harness Drawing Model 03780 30781 Serial numbers below 403350000 ...

Page 466: ...N BLACK GRAY BLACK BLUE PINK BLACK VIOLET ORANGE BLACK BROWN BLACK WHITE BLACK TAN BLACK GRAY BLACK WHITE ORANGE PINK WHITE YELLOW RED GREEN ORANGE RED ORANGE ORANGE ORANGE PINK BLACK BLACK BLACK RED RED ORANGE ORANGE ORANGE BLACK RED RED RED Model 03780 30781 Serial numbers below 403350000 ...

Page 467: ...Page 12 27 CV 122 1547 Rev A Reelmaster 7000 D Power Center Wire Harness Drawing Model 03780 03781 Serial numbers above 403350001 ...

Page 468: ...Page 12 28 122 1547 Rev A Reelmaster 7000 D Power Center Wire Harness Diagram Model 03780 03781 Serial numbers above 403350001 ...

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