Toro Reelmaster 7000, Service Manual

Page 1: ... 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 to obey the instructions may result in personal...

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Page 3: ...RS FIXED DISPLACEMENT VALVE PLATE DESIGN REPAIR INFORMATION SAUER DANFOSS STEERING UNIT TYPE OSPM SERVICE MANUAL Chapter 5 Electrical System General Information 5 2 Electrical Drawings 5 3 Special Tools 5 4 Troubleshooting 5 6 Electrical System Quick Checks 5 13 Adjustments 5 15 Component Testing 5 17 Service and Repairs 5 41 Chapter 6 Axles Planetaries and Brakes Specifications 6 2 General Inform...

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Page 5: ... 7000 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 6: ...utting 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 and...

Page 7: ...ov ing parts Keep bystanders away 11 Do not overspeed the engine by changing governor setting To assure safety and accuracy check maximum engine speed 12 Shut engine 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 p...

Page 8: ...nd 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 possi...

Page 9: ...fety 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 11: ... 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 Tracti...

Page 12: ...0 09375 Reelmaster 7000 Page 2 2 Product Records and Maintenance Equivalents and Conversions ...

Page 13: ...d 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 calibra...

Page 14: ... 2 22 3 30 3 41 4 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...

Page 15: ...90 10 N m 93 10 ft 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 NOTE Reduce torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as engine oil or thread sealant such as Loctite NOTE Torque values may have to be reduced when ...

Page 16: ...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 Size Type A Type B Baseline Torque No 6...

Page 17: ...nual 3 SERVICE AND REPAIRS 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 Radiator 10 Engine 12 Engine Removal 13 Engine Installation 14 Pump Adapter Plate 16 KUBOTA WORKSHOP MANUAL DIESEL ENGINE 03 M DI E3B SERIES Kubota Diesel Engine ...

Page 18: ...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 Crankcase ...

Page 19: ... 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 listis available be prepared to provide you...

Page 20: ... screw 2 used 11 Air cleaner assembly 12 Service indicator 13 Hose clamp 14 Hose clamp 15 Flat washer 2 used 16 Coolant reservoir 17 Reservoir bracket 18 Flange nut 8 used 19 Cap screw 2 used 20 Flange head screw 4 used 21 Flange head screw 2 used 22 Hose 23 Adapter 24 Air cleaner hose 25 Reservoir cap 26 Plenum 27 Air intake hose FRONT RIGHT 12 to 15 in lb 1 4 to 1 6 N m 1 2 3 4 10 11 12 13 14 15...

Page 21: ...sing Install adapter so 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 Installair cleaner so air cleaner strap item9 isas close as possible to air cleaner cover D Make sure that air cleaner hose item 24 does not contact engine val...

Page 22: ...fler 2 Flange head screw 2 used 3 Flange head screw 4 used 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 used 14 Muffler clamp FRONT RIGHT 1 3 4 6 10 12 5 2 7 8 9 11 13 14 ...

Page 23: ...roughly 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 muf fler fastener sequence may result in premat...

Page 24: ...10 Cap screw 2 used 11 Clamp 2 used 12 Flange nut 2 used 13 Fuel pump 14 Washer head screw 15 Fuel pump bracket 16 Fuel hose supply 17 Fuel hose supply 18 Cap screw 2 used 19 Flange nut 2 used 20 Fuel water separator 21 Elbow fitting 2 used 22 Flat washer 2 used 23 Flat washer 2 used 24 Fuel gauge 25 Grommet 26 Hose clamp 27 Draincock FRONT RIGHT 8 9 3 3 4 18 17 16 12 7 1 24 23 2 22 6 11 10 25 26 ...

Page 25: ...d clean the fuel tank periodically as recom mended in the Traction Unit Operator s Manual Also drain and clean the fuel tank if the fuel system becomes 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 Fuel Tank Removal Fig 5 1 Park machine on a level surface lower cuttin...

Page 26: ...4 used 23 Foam seal 2 used 24 Recirculation barrier 2 used 25 Recirculation barrier bracket 2 used 26 Screw 2 used 27 Oil cooler mount plate 2 used 28 Flange head screw 9 used 29 O ring 30 Clamp 2 used 31 Cap screw 2 used 32 Washer 2 used 33 Oil cooler top bracket 34 Bulb seal 35 O ring 36 R clamp 2 used 37 Bushing 38 Elbow fitting 39 Reservoir hose 40 Lower radiator hose 41 Lower radiator shroud ...

Page 27: ...ation barriers items 24 and 25 to the radiator mount Carefully remove barriers and radiator from the machine 13 Plug all radiator and hose openings to prevent con tamination Installation Fig 6 1 Remove plugs placed in radiator and hose openings during the removal procedure Make sure that radiator draincock is closed 2 Carefully position radiator and recirculation barriers items 24 and 25 to the ra...

Page 28: ...H front engine mount 15 Lock washer 4 used 16 Cap screw 4 used 17 Lock washer 5 used 18 Cap screw 5 used 19 LH rear engine mount 20 Muffler bracket 21 Ground wire harness 22 Muffler gasket 23 Cap screw 24 Lock washer 25 Spacer 2 used 26 Hardened washer 2 used 27 Lock washer 28 Alternator wire harness 29 Cap screw 30 Flat washer 31 Muffler bracket 32 Flange head screw 33 Muffler clamp 34 Cap screw ...

Page 29: ... Remove air cleaner system from engine see Air Cleaner Removal in this section 7 Note location of cable ties used to secure wire har ness Disconnect wire harness connectors from the fol lowing engine components A The engine run solenoid Fig 9 B The temperature sender Fig 10 C The alternator Fig 10 D The glow plug connection E Wire harness connector from engine ground har ness F The electric starte...

Page 30: ... should operate lift or hoist while a second person guides the engine out of the ma chine IMPORTANT Make sure to not damage the engine fuel lines hydraulic lines electrical harness or oth er parts while removing the engine 16 Carefully raise engine from the machine 17 If necessary remove engine mounts from the engine using Figure 8 as a guide Engine Installation Fig 8 1 Locate machine on a level s...

Page 31: ...e to injection pump Fig 9 Secure hose with hose clamp 12 Connect wire harness connectors to the following engine components A The engine run solenoid Fig 9 B The temperature sender Fig 10 C The alternator Fig 10 D The glow plug connection E Wire harness connector to engine ground har ness F The electric starter Torque nutatstarter B termi nal from 70 to 86 in lb 7 9 to 9 7 N m G Low oil pressure s...

Page 32: ...ta Diesel Engine Pump Adapter Plate Figure 12 1 Bolt 2 Lock washer 3 Flywheel plate 4 Hardened washer 14 used 5 Spring coupler 6 Bolt 6 used 7 Cap screw 8 used FRONT RIGHT 1 2 3 4 5 6 7 4 Loctite 242 29 to 33 ft lb 40 to 44 N m Boss ...

Page 33: ...hat coupling hub is away from engine flywheel Fig 13 2 Apply Loctite 242 or equivalent to threads of bolts item 6 Secure coupler to flywheel with six 6 bolts and hardened washers Torque bolts in a crossing pattern from 29 to 33 ft lb 40 to 44 N m 3 Position flywheel plate to engine Make sure that boss on plate is orientated down Secure flywheel plate with cap screws item 7 and hardened washers usi...

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Page 35: ...n Circuit Test 66 ADJUSTMENTS 68 Adjust Control Manifold Relief Valves 68 SERVICE AND REPAIRS 69 General Precautions for Removing and Installing Hydraulic System Components 69 Check Hydraulic Lines and Hoses 70 Flush Hydraulic System 71 Filtering Closed Loop Traction Circuit 72 Charge Hydraulic System 73 Gear Pump 74 Gear Pump Service 76 Piston Traction Pump 78 Piston Traction Pump Service 80 4WD ...

Page 36: ...Reelmaster 7000 Hydraulic System Page 4 2 This page is intentionally blank ...

Page 37: ...alve Sauer 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 61 in3 26 5 cc Cutting Unit Circuit Relief Pressure 3000 PSI 207 bar Engine Cooling Fan Motor Casappa Gear Motor Displacement per revolution 0...

Page 38: ... Fig 1 Do notturn bypassvalve whenengine isrun ning See Traction Unit Operator s Manual for additional tow ing procedures IMPORTANT If the machine must be pushed or towed in a reverse direction the check valve in the 4WD 2WD control manifold must be bypassed To bypass this check valve connect a hydraulic hose between the reverse traction pressure test port and the 4WD 2WD control manifold test por...

Page 39: ... into the circuit 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 fromthe closedloop andthus donot causeaddi tional component damage Once the Toro high flow hydraulic filter kit has been ...

Page 40: ...the 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 Boo...

Page 41: ... 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 Mar...

Page 42: ...cords 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 I...

Page 43: ...with a wrench and use a torque wrench to tighten the fitting to the rec ommended installation torque shown in Figure 7 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 low...

Page 44: ...HG S2 071 VALVE T RV1 S1 PD1 SV RV M2 550 PSI PD2 CHG M1 M1 P1 PSI BYPASS P1 091 2 48 5000 450 PSI 052 P2 G CV PR 2 01 G CR2 CR1 P1 CD2 CD1 T P2 56 56 P4 1 03 1 03 P2 P3 G 2 01 PSI 5000 071 T 5 PSI 40 PSI 207 PSI CV2 CV1 CV1 L R P PB 1050 PSI 6 1 MOW MANIFOLD FRONT MOTORS AXLE MOTOR REAR S1 PRV FD CONTROL MANIFOLD LIFT CONTROL FAN MANIFOLD CONTROL NOTE A larger hydraulic schematic is included in C...

Page 45: ...Reelmaster 7000 Hydraulic System Page 4 11 This page is intentionally blank Hydraulic System ...

Page 46: ...4 C1 S5 C3 M3 M2 C4 C1 C3 C2 S3 MV1 S4 P MV2 G M3 M4 M1 M2 CHG S2 071 VALVE T RV1 S1 PD1 SV RV M2 550 PSI PD2 CHG M1 M1 P1 PSI BYPASS P1 091 2 48 5000 450 PSI 052 P2 G CV PR 2 01 G CR2 CR1 P1 CD2 STEERING CD1 T P2 56 56 P4 2 48 1 03 1 03 P2 P3 G 2 01 PSI 5000 071 T 5 PSI 40 PSI 207 PSI CV2 CV1 CV1 L R P PB 1050 PSI 6 1 MOW MANIFOLD FRONT MOTORS AXLE MOTOR REAR S1 PRV FD CONTROL MANIFOLD LIFT CONTR...

Page 47: ...ated in the filtration charge controlmanifold Charge pressure can be measured at the charge circuit pressure test port on the filtration charge control man ifold Forward Direction When the mow speed limiter is in the mow speed 4WD position and the traction pedal is pushed in the forward direction oil from the piston pump is directed to the front wheel motors and 4WD 2WD control manifold Oil flow t...

Page 48: ...2 C4 C1 C3 C2 S3 MV1 S4 P MV2 G M3 M4 M1 M2 CHG S2 071 VALVE T RV1 S1 PD1 SV RV M2 550 PSI PD2 CHG M1 M1 P1 PSI BYPASS P1 091 2 48 5000 450 PSI 052 P2 G CV PR 2 01 G CR2 CR1 P1 CD2 STEERING CD1 T P2 56 56 P4 2 48 1 03 1 03 P2 P3 G 2 01 PSI 5000 071 T 5 PSI 40 PSI 207 PSI CV2 CV1 CV1 L R P PB 1050 PSI 6 1 MOW MANIFOLD FRONT MOTORS AXLE MOTOR REAR S1 PRV FD CONTROL MANIFOLD LIFT CONTROL FAN MANIFOLD...

Page 49: ...llows charge oil flow to the closed loop if the filter becomes plugged Charge pressure is li mited to 207 PSI 14 3 bar by a relief valve located in the filtration charge control manifold Charge pressure can be measured at the test port on the filtration charge control manifold NOTE When the mow speed limiter is in the transport 2WD position the cutting units are prevented from be ing lowered and t...

Page 50: ...C3 M3 M2 C4 C1 C3 C2 S3 MV1 S4 P MV2 G M3 M4 M1 M2 CHG S2 071 VALVE T RV1 S1 PD1 SV RV M2 550 PSI PD2 CHG M1 M1 P1 PSI BYPASS P1 091 2 48 5000 450 PSI 052 P2 G CV PR 2 01 G CR2 CR1 P1 CD2 CD1 T P2 56 56 P4 1 03 1 03 P2 P3 G 2 01 PSI 5000 071 T 5 PSI 40 PSI 207 PSI CV2 CV1 CV1 L R P PB 1050 PSI 6 1 MOW MANIFOLD FRONT MOTORS AXLE MOTOR REAR S1 PRV FD CONTROL MANIFOLD LIFT CONTROL FAN MANIFOLD CONTRO...

Page 51: ...ng with solenoid valves S3 S4 and S5 are energized by the TEC controller To allow the front cutting units to be lowered before the rear cutting units the controller slightly delays energizing solenoid S5 after the lift switch is pressed The energized sole noid valves direct gear pump oil flow to the barrel end of the lift cylinders Flow control orifices in the lift control manifold C2 and C4 are b...

Page 52: ...C3 M3 M2 C4 C1 C3 C2 S3 MV1 S4 P MV2 G M3 M4 M1 M2 CHG S2 071 VALVE T RV1 S1 PD1 SV RV M2 550 PSI PD2 CHG M1 M1 P1 PSI BYPASS P1 091 2 48 5000 450 PSI 052 P2 G CV PR 2 01 G CR2 CR1 P1 CD2 CD1 T P2 56 56 P4 1 03 1 03 P2 P3 G 2 01 PSI 5000 071 T 5 PSI 40 PSI 207 PSI CV2 CV1 CV1 L R P PB 1050 PSI 6 1 MOW MANIFOLD FRONT MOTORS AXLE MOTOR REAR S1 PRV FD CONTROL MANIFOLD LIFT CONTROL FAN MANIFOLD CONTRO...

Page 53: ...om the manifold is routed to the oil filter and traction charge circuit Raise Cutting Units NOTE The operator must be in the operator seat in or der to raise the cutting units When the lift switch is moved to the raise position sole noid valve S1 along with solenoid valves S2 S3 S4 and S5 are energized by the TEC controller To allow the front cutting units to be raised before the rear cutting unit...

Page 54: ...S4 P MV2 G M3 M4 M1 M2 CHG S2 071 VALVE T RV1 S1 PD1 SV RV M2 550 PSI PD2 CHG M1 M1 P1 PSI BYPASS P1 091 2 48 5000 450 PSI 052 P2 G CV PR 2 01 G CR2 CR1 P1 CD2 CD1 T P2 56 56 P4 1 03 1 03 P2 P3 G 2 01 PSI 5000 071 T 5 PSI 40 PSI 207 PSI CV2 CV1 CV1 L R P PB 1050 PSI 6 1 MOW MANIFOLD FRONT MOTORS AXLE MOTOR REAR S1 PRV FD CONTROL MANIFOLD LIFT CONTROL FAN MANIFOLD CONTROL PISTON PUMP GEAR PUMP ENER...

Page 55: ...l cooler and oil filter PTO Engaged When the PTO switch is turned ON with the cutting units lowered the manifold proportional valves SP1 and SP2 are energized with outputs from the TEC 5002 controller The energized valves shift to direct pump flow toward the cutting unit motors Flow from the valves is proportional to current applied to the valve coil by the TEC controller The setting of the reel s...

Page 56: ...2 C4 C1 C3 C2 S3 MV1 S4 P MV2 G M3 M4 M1 M2 CHG S2 071 VALVE T RV1 S1 PD1 SV RV M2 550 PSI PD2 CHG M1 M1 P1 PSI BYPASS P1 091 2 48 5000 450 PSI 052 P2 G CV PR 2 01 G CR2 CR1 P1 CD2 STEERING CD1 T P2 56 56 P4 2 48 1 03 1 03 P2 P3 G 2 01 PSI 5000 071 T 5 PSI 40 PSI 207 PSI CV2 CV1 CV1 L R P PB 1050 PSI 6 1 MOW MANIFOLD FRONT MOTORS AXLE MOTOR REAR S1 PRV FD CONTROL MANIFOLD LIFT CONTROL FAN MANIFOLD...

Page 57: ...ressure contracts the steering cylinder for a left turn The rotary meter ensures that the oil flow to the cylinder is proportional to the amount of the turning on the steering wheel Fluid leaving the cylinder flows back through the spool valve then through the T port and to the hydraulic reservoir The steering control valve returns to the neutral position when turning is completed Right Turn When ...

Page 58: ...S5 C3 M3 M2 C4 C1 C3 C2 S3 MV1 S4 P MV2 G M3 M4 M1 M2 CHG S2 071 VALVE T RV1 S1 PD1 SV RV M2 550 PSI PD2 CHG M1 M1 P1 PSI BYPASS P1 091 2 48 5000 450 PSI 052 P2 G CV PR 2 01 G CR2 CR1 P1 CD2 CD1 T P2 56 56 P4 1 03 1 03 P2 P3 G 2 01 PSI 5000 071 T 5 PSI 40 PSI 207 PSI CV2 CV1 CV1 L R P PB 1050 PSI 6 1 MOW MANIFOLD FRONT MOTORS AXLE MOTOR REAR S1 PRV FD CONTROL MANIFOLD LIFT CONTROL FAN MANIFOLD CON...

Page 59: ...e 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 NOTE If PWM current is not available to the fan control manifold proportional relief valve PRV the cooling fan motor will run at full speed in the normal forward direc tion Forward Direction Fan Operatio...

Page 60: ...st hydraulic circuits and components for flow and pressure capacities as recommended in the Testing section ofthis 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 P...

Page 61: ...cerine 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 21 Hydraulic Hose Kit This kit includes hydraulic fittings and hoses needed to connec...

Page 62: ...r 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 above...

Page 63: ...se drain line while the motor is pressurized by the hydraulic system The table in Figure 26 provides gallons per minute GPM conversion formeasured milliliteror ouncemotor case drain leakage Toro Part Number TOR4077 Figure 25 Figure 26 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 hyd...

Page 64: ... the cooling fan and a normal engine coolant temperature Engine RPM is too low Hydraulic reservoir oil level is low Hydraulic oil is contaminated or the wrong type Brakes are applied or sticking Piston pump bypass valve is open or damaged Cooling system is not operating properly Charge pressure is low Engine cooling fan circuit is malfunctioning see Engine Cooling Fan Circuit Problems in this sect...

Page 65: ... transport speed 2WD PD1 and PD2 pilot directional valve seals in 4WD 2WD control manifold are leaking or damaged Machine travels too far before stop ping when the traction pedal is re leased Traction linkage is out of adjustment Charge pressure is low Piston traction pump servo control valve orifices are plugged or damaged Traction pedal does not return to neutral Traction power is lost or machin...

Page 66: ...nit motor is low Cutting unit problem exists see Chapter 8 Cutting Units Spline on affected cutting unit motor is damaged Cutting unit motor relief valve is stuck or damaged Cutting unit motor is damaged NOTE If appropriate transfer a sus pected damaged motor to another cutting unit If problem follows the motor motor needs repair or replacement Several cutting units will not operate Electrical pro...

Page 67: ...mp section P1 or P2 for affected cutting units is worn or damaged Steering Circuit Problems Problem Possible Cause Steering inoperative or sluggish Steering components e g tie rods steering cylinder ends are worn or binding Steering cylinder is binding Oil level in hydraulic reservoir is low other hydraulic systems af fected as well Steering relief valve in steering control valve is stuck or damag...

Page 68: ...ffect the traction charge and steering circuits Cutting units raise but will not stay up NOTE Lift cylinders cannot provide an absolutely perfect seal The lift arms will eventually lower if left in the raised position during storage Lift circuit hydraulic lines or fittings are leaking Cartridge valve in lift control manifold is stuck open Air exists in lift circuit Lift cylinder is damaged Cutting...

Page 69: ...ot rotate Fan motor is worn or damaged Gear pump section P4 is worn or damaged Cooling fan always rotates at slow speed Fan control manifold cartridge valve seals are leaking Check valve in fan control manifold is not seating Fan control manifold proportional relief valve PRV is stuck open Hydraulic fan motor is worn or damaged Cooling fan always rotates at fast speed Fan control manifold proporti...

Page 70: ...w hours by a doctor famil iar with this type of injury Gangrene may result from such an injury WARNING Precautions for Hydraulic Testing 1 Clean machine thoroughly before disconnecting or disassembling any hydraulic components Always keep in mind the need for cleanliness when working on hy draulic equipment Hydraulic system contamination will cause excessive wear of hydraulic components 2 Put meta...

Page 71: ... and or Piston Traction Pump Flow 2 If a PTO circuit problem exists consider performing one or more of the following tests Mow CircuitPressure Mow Circuit Relief Pressure Cutting Unit Motor Case Drain Leakage and or Gear Pump P1 and P2 Flow 3 If a lift lower circuit problem exists consider perform ing one or more of the following tests Lift Lower Circuit Relief Pressure Lift Cylinder Internal Leak...

Page 72: ...052 P2 G CV PR 2 01 G CR2 CR1 P1 CD2 CD1 T P2 56 56 P4 2 48 1 03 1 03 P2 P3 G 2 01 PSI 5000 071 5 PSI 40 PSI 207 PSI CV2 CV1 CV1 FRONT MOTORS AXLE MOTOR REAR PISTON PUMP GEAR PUMP CHARGE CIRCUIT FROM STEERING AND LIFT CIRCUITS TO FAN CIRCUIT TO STEERING AND LIFT CIRCUITS TO DECK CONTROL MANIFOLD TO DECK CONTROL MANIFOLD CHARGE CIRCUIT FROM DECK CONTROL MANIFOLD FROM DECK MOTORS FROM STEERING CONTR...

Page 73: ...n in gear pump intake line B Charge relief valve in filtration and charge control manifold is leaking see Filtration Charge Control Manifold Service in the Service and Repairs section of this chapter C If necessary check for internal damage or worn parts in gear pump P3 see Gear Pump P3 Flow Test in this section NOTE Steering and lift lower circuits would also be affected if gear pump P3 is worn o...

Page 74: ...52 P2 G CV PR 2 01 G CR2 CR1 P1 CD2 CD1 T P2 56 56 P4 2 48 1 03 1 03 P2 P3 G 2 01 PSI 5000 071 5 PSI 40 PSI 207 PSI CV2 CV1 CV1 FRONT MOTORS AXLE MOTOR REAR PISTON PUMP GEAR PUMP CHARGE CIRCUIT FROM STEERING AND LIFT CIRCUITS TO FAN CIRCUIT TO STEERING AND LIFT CIRCUITS TO DECK CONTROL MANIFOLD TO DECK CONTROL MANIFOLD CHARGE CIRCUIT FROM DECK CONTROL MANIFOLD FROM DECK MOTORS FROM STEERING CONTRO...

Page 75: ...owly de press the traction pedal in the appropriate direction While pushing traction pedal identify pressure reading on gauge as relief valve opens GAUGE READING TO BE Forward 4800 to 5300 PSI 332 to 365 bar Reverse 4800 to 5300 PSI 332 to 365 bar 7 Release traction pedal and stop engine Record test results 8 If traction pressure is too low makes sure that by pass valve on traction pump is fully s...

Page 76: ...50 PSI 052 P2 G CV PR 2 01 G CR2 CR1 P1 CD2 CD1 T P2 56 56 P4 2 48 1 03 1 03 P2 P3 G 2 01 PSI 5000 071 5 PSI 40 PSI 207 PSI CV2 CV1 CV1 FRONT MOTORS AXLE MOTOR REAR PISTON PUMP GEAR PUMP CHARGE CIRCUIT FROM STEERING AND LIFT CIRCUITS TO FAN CIRCUIT TO STEERING AND LIFT CIRCUITS TO DECK CONTROL MANIFOLD TO DECK CONTROL MANIFOLD CHARGE CIRCUIT FROM DECK CONTROL MANIFOLD FROM DECK MOTORS FROM STEERIN...

Page 77: ...or hydraulic leakage and cor rect before proceeding with test 5 Move throttle to high idle speed 2850 RPM Make sure that mow speed limiter is in the mow 4WD posi tion Release parking brake 6 With seat occupied apply brakes fully and slowly de press the traction pedal in the reverse direction While pushing traction pedal carefully monitor the pressure gauge Pressure should increase until the pressu...

Page 78: ... PSI 052 P2 G CV PR 2 01 G CR2 CR1 P1 CD2 CD1 T P2 56 56 P4 2 48 1 03 1 03 P2 P3 G 2 01 PSI 5000 071 5 PSI 40 PSI 207 PSI CV2 CV1 CV1 FRONT MOTORS AXLE MOTOR REAR PISTON PUMP GEAR PUMP CHARGE CIRCUIT FROM STEERING AND LIFT CIRCUITS TO FAN CIRCUIT TO STEERING AND LIFT CIRCUITS TO DECK CONTROL MANIFOLD TO DECK CONTROL MANIFOLD CHARGE CIRCUIT FROM DECK CONTROL MANIFOLD FROM DECK MOTORS FROM STEERING ...

Page 79: ...e to high idle speed 2850 RPM Make sure that mow speed limiter is in the mow 4WD posi tion Release parking brake 7 Operate the machine in mow speed 4WD with the cutting units lowered Drive down a slope in a forward di rection and decrease pressure on the traction pedal while carefully monitoring the pressure gauge Pressure should increase until relief valve RV lifts 8 Stop engine and record test r...

Page 80: ...5000 450 PSI 052 P2 G CV PR 2 01 G CR2 CR1 P1 CD2 CD1 T P2 56 56 P4 2 48 1 03 1 03 P2 P3 G 2 01 PSI 5000 071 5 PSI 40 PSI 207 PSI CV2 CV1 CV1 FRONT MOTORS AXLE MOTOR REAR PISTON PUMP GEAR PUMP CHARGE CIRCUIT FROM STEERING AND LIFT CIRCUITS TO FAN CIRCUIT TO STEERING AND LIFT CIRCUITS TO DECK CONTROL MANIFOLD TO DECK CONTROL MANIFOLD CHARGE CIRCUIT FROM DECK CONTROL MANIFOLD FROM DECK MOTORS FROM S...

Page 81: ...t see Special Tools in this chapter to connecttester to machine Make sure thatfit ting and hose connections are properly tightened Also make sure the flow control valve on tester is fully open CAUTION All wheels will be off the ground and rotating dur ing this test Make sure machine is supported so it will not move and accidentally fall to prevent in juring anyone near the machine 7 Start engine a...

Page 82: ...SP2 LC2 LC1 RV1 M5 CV1 M1 M4 OR1 OR2 CV2 M3 M2 MV1 MV2 M3 M4 M1 M2 071 VALVE PSI BYPASS P1 091 5000 CR2 CR1 P1 CD2 CD1 T P2 56 56 P4 1 03 1 03 P2 P3 PSI 5000 071 5 PSI 40 PSI 207 PSI CV2 CV1 CV1 MOW MANIFOLD CONTROL PISTON PUMP GEAR PUMP 2 48 ENGINE SPEED 2850 1550 PRESSURE GAUGE FROM STEERING CONTROL FROM FAN CONTROL TO FAN CIRCUIT TO STEERING AND LIFT CIRCUITS TO RESERVOIR FROM REEL MOTORS G1 G2...

Page 83: ...n at low idle speed Check for hydraulic leakage and cor rect before proceeding with test 6 Move throttle to high idle speed 2850 RPM Make sure that mow speed limiter is in the mow 4WD posi tion Release parking brake CAUTION Cutting reel blades will rotate when lowered with PTO switch in ON position Keep away from cut ting units during test to prevent personal injury from rotating reel blades Do no...

Page 84: ...1 T2 T1 P2 RV2 SP1 SP2 LC2 LC1 RV1 M5 CV1 M1 M4 OR1 OR2 CV2 M3 M2 MV1 MV2 M3 M4 M1 M2 071 VALVE PSI BYPASS P1 091 5000 CR2 CR1 P1 CD2 CD1 T P2 56 56 P4 1 03 1 03 P2 P3 PSI 5000 071 5 PSI 40 PSI 207 PSI CV2 CV1 CV1 MOW MANIFOLD CONTROL PISTON PUMP GEAR PUMP 2 48 ENGINE SPEED 2850 1550 FROM STEERING CONTROL FROM FAN CONTROL TO FAN CIRCUIT TO STEERING AND LIFT CIRCUITS TO RESERVOIR FROM REEL MOTORS G...

Page 85: ...ugh the tester and into the hydraulic motor 5 Install tester with pressure gauge and flow meter in series with the disconnected hose and front motor fit ting 6 Make sure the flow control valve on the tester is fully open 7 Start engine and run at low idle speed Check for hy draulic leakage and correct before proceeding with test 8 Move throttle to high idle speed 2850 RPM Make sure that mow speed ...

Page 86: ...re Low Pressure Return or Suction Flow MEASURING CONTAINER UNIT MOTOR SHOWN TEST FOR 4 CUTTING P1 T2 T1 P2 RV2 SP1 SP2 LC2 LC1 RV1 M5 CV1 M1 M4 OR1 OR2 CV2 M3 M2 MV1 MV2 M3 M4 M1 M2 MOW MANIFOLD CONTROL FROM FAN CONTROL TO RESERVOIR TO OIL COOLER G1 G2 TESTER CAP STEEL FROM GEAR PUMP P2 FROM GEAR PUMP P1 RETURN HOSE CASE DRAIN HOSE SUPPLY HOSE FRONT ...

Page 87: ...to be tested Install tester with pressure gauge and flow meter in series with the motor and the discon nected return hose Make sure the flow control valve on tester is fully open 4 Disconnect the motor case drain hose small diame ter hose where it connects to bulkhead fitting at the frame rail not at the motor Put a steel cap on the bulk head fitting leave the case drain hose open 5 Start engine a...

Page 88: ...P1 SHOWN TEST FOR GEAR PUMP P1 T2 T1 P2 RV2 SP1 SP2 LC2 LC1 RV1 M5 CV1 M1 M4 OR1 OR2 CV2 M3 M2 MV1 MV2 M3 M4 M1 M2 071 VALVE PSI BYPASS P1 091 5000 56 56 P4 1 03 1 03 P2 P3 PSI 5000 071 MOW MANIFOLD CONTROL PISTON PUMP GEAR PUMP 2 48 ENGINE SPEED 2850 1550 FROM FAN CONTROL TO FAN CIRCUIT TO STEERING AND LIFT CIRCUITS TO RESERVOIR G1 G2 FROM RESERVOIR FROM FILTRATION MANIFOLD TO OIL COOLER TESTER ...

Page 89: ...indicator arrow on the tester is showing that the oil will flow from the gear pump fitting through the tester and into the disconnected hose 5 Install tester with pressure gauge and flow meter in series with the disconnected hose and fitting in gear pump section Make sure the flow control valve on the tester is fully open 6 After installing tester start engine and run at low idle speed Check for h...

Page 90: ...1 SP1 SP2 LC2 LC1 RV1 M5 CV1 M1 M4 OR1 OR2 CV2 M3 M2 MV1 MV2 M3 M4 M1 M2 071 VALVE PSI BYPASS P1 091 5000 CR2 CR1 P1 CD2 STEERING CD1 T P2 56 56 P4 2 48 1 03 1 03 P2 P3 PSI 5000 071 T 5 PSI 40 PSI 207 PSI CV2 CV1 CV1 L R P PB 1050 PSI 6 1 MOW MANIFOLD S1 PRV FD CONTROL FAN MANIFOLD CONTROL CYLINDER PISTON PUMP GEAR PUMP ENGINE SPEED 2850 1550 G1 G2 TO LIFT MANIFOLD CAP STEEL PRESSURE GAUGE STEERIN...

Page 91: ...e steering wheel only long enough to get a system relief pressure reading Holding the steering circuit at relief pres sure for an extended period may damage the steer ing control valve 7 Turn steering wheel to the right while monitoring the pressure gauge When steering circuit pressure reach es the relief pressure setting pressure should stabilize briefly and then may continue to increase The stee...

Page 92: ...ge 4 58 Steering Cylinder Internal Leakage Test T L R P PB 1050 PSI 6 1 PLUG STEEL CYLINDER FULLY EXTENDED LOOK FOR LEAKAGE STEERING WHEEL TURNED FOR RIGHT TURN STEERING FROM FAN CONTROL MANIFOLD TO FILTRATION MANIFOLD TO CHARGE CIRCUIT ...

Page 93: ... steel 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 turn the steering wheel for a right turn Observe the open fitting on the extended steering cylinder as the steering wheel is turned If oil comes out of the fitting while turning the steering wheel the steer ing c...

Page 94: ... Relief Pressure Test Using Pressure Gauge Working Pressure Low Pressure Return or Suction Flow C2 RV2 C5 C4 C1 S5 C3 C4 C1 C3 C2 S3 S4 P G S2 T RV1 S1 CONTROL MANIFOLD LIFT G2 FROM FAN CONTROL MANIFOLD PRESSURE GAUGE TO CHARGE FROM STEERING CIRCUIT CONTROL VALVE ...

Page 95: ...are fully retracted cutting units fully raised and the relief valve lifts the pressure gauge needle will momentarily stop System pressure asthe reliefvalve RV1opens shouldbe beapproximate ly 1700 PSI 117 bar Release lift switch to the neutral position after observing relief valve pressure NOTE If lift switch continues to be pressed after the re lief valve has opened system pressure can increase hi...

Page 96: ...low Meter Working Pressure Low Pressure Return or Suction Flow 071 VALVE PSI BYPASS P1 091 5000 56 56 P4 1 03 1 03 P2 P3 PSI 5000 071 PISTON PUMP GEAR PUMP 2 48 ENGINE SPEED 2850 1550 TO FAN CIRCUIT TO STEERING AND LIFT CIRCUITS FROM RESERVOIR FROM FILTRATION MANIFOLD TESTER TO MOW CONTROL MANIFOLD P1 PORT TO MOW CONTROL MANIFOLD P2 PORT ...

Page 97: ...sure gauges and flow meter in series with the disconnected hose and fitting in gear pump section P3 Make sure the flow control valve on the tester is fully open 6 After installing tester start engine and run at idle speed Check for hydraulic leakage and correct before proceeding with test 7 Move throttle to full speed 2850 RPM DO NOT en gage the cutting units IMPORTANT The pump is a positive displ...

Page 98: ...1 M2 T P1 SP1 SP2 LC2 LC1 RV1 M5 CV1 M1 M4 OR1 OR2 CV2 M3 M2 MV1 MV2 M3 M4 M1 M2 071 VALVE PSI BYPASS P1 091 5000 CR2 CR1 P1 CD2 STEERING CD1 T P2 56 56 P4 2 48 1 03 1 03 P2 P3 PSI 5000 071 T 5 PSI 40 PSI 207 PSI CV2 CV1 CV1 L R P PB 1050 PSI 6 1 MOW MANIFOLD S1 PRV FD CONTROL FAN MANIFOLD CONTROL CYLINDER PISTON PUMP GEAR PUMP ENGINE SPEED 2850 1550 G1 G2 TO LIFT MANIFOLD PRESSURE GAUGE ...

Page 99: ...to identify the cooling fan speed disconnect the wire harness connector white green and black wires from the proportional relief valve solenoid at fan control manifold port PRV Both fan speed and pres sure should increase and stabilize after the solenoid is disconnected PRESSURE GAUGE READING TO BE approxi mately 3000 PSI 207 bar PHOTOTAC fan speed READING TO BE approxi mately 2800 RPM 7 Stop engi...

Page 100: ...ter Working Pressure Low Pressure Return or Suction Flow 071 VALVE PSI BYPASS P1 091 5000 56 56 P4 1 03 1 03 P2 P3 PSI 5000 071 PISTON PUMP GEAR PUMP 2 48 ENGINE SPEED 2850 1550 TO FAN CIRCUIT TO STEERING AND LIFT CIRCUITS FROM RESERVOIR FROM FILTRATION MANIFOLD TESTER TO MOW CONTROL MANIFOLD P1 PORT TO MOW CONTROL MANIFOLD P2 PORT ...

Page 101: ...ow meter in series with the disconnected hose and fitting in gear pump section P4 Make sure the flow control valve on the tester is fully open 6 After installing tester start engine and run at idle speed Check for hydraulic leakage and correct before proceeding with test 7 Move throttle to full speed 2850 RPM DO NOT en gage the cutting units IMPORTANT The gear pump is a positive displace ment type...

Page 102: ...old 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 th...

Page 103: ...nd 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 ...

Page 104: ...escaping under pressure can have sufficient force to penetrate the skin and cause serious injury If fluid is in jected into the skin it must be surgically re moved within a few hours by a doctor familiar with this type of injury Gangrene may result from such an injury IMPORTANT Check hydraulic lines and hoses daily for leaks kinked lines loose mounting supports wear loose fittings or deterioration...

Page 105: ...re 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 new hydraulic fluid 8 Disconnect wire harness connector from engine run solenoid to prevent the engine from starting 9 Turn ignition key switch to start and engage starter for ten 10 seconds to prime pump Let sta...

Page 106: ...ks before proceeding CAUTION All wheels will be off the ground and rotating dur ing this procedure Make sure machine is well supported so it will not move and accidentally fall to prevent injuring anyone around machine 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 ...

Page 107: ... wheels to prevent movement of the machine 10 Make sure traction pedal is in neutral Start engine and run it at low idle 1550 RPM The pumps should pick up oil and fill the hydraulic system If there is no in dication of fill in thirty 30 seconds stop the engine and determine the cause 11 After the hydraulic system starts to show signs of fill actuate lift control switch until the lift cylinder rods...

Page 108: ... lb 105 to 126 N m 103 to 118 ft lb 140 to 160 N m Removal Fig 51 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Raise seat and secure it with prop rod to gain access to gear pump 3 Drain the hydraulic reservoir into a suitable contain er 4 To prevent contamination of hydraulic system during removal thoroughly clean ...

Page 109: ...ft into coupler Secure gear pump to piston pump with two 2 cap screws and flat washers 5 Remove caps and plugs from hydraulic hoses and fittings Install hoses to gear pump see Hydraulic Hose and Tube Installation in the General Information section of this chapter 6 Replace hydraulic filter and fill hydraulic reservoir with new hydraulic oil 7 Disconnect engine run solenoid electrical connector to ...

Page 110: ...sed 26 Washer 4 used Figure 53 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 53 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 pla...

Page 111: ...g 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 53 1 Apply c...

Page 112: ...160 N m Removal Fig 55 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 contamination of hydraulic system during removal thoroughly clean exterior of pump assembly 3 Remove traction rod from control arm on piston pump by removing lock nut and flange head screw Fig 56 4 Disconnect wire harness connector from ...

Page 113: ... to 126 N m 3 Install gear pump to piston pump see Gear Pump Installation in this section 4 Position traction rod to control arm on piston pump and secure with flange head screw and lock nut Fig 56 5 Connect wire harness connector to neutral switch on traction pump 6 Remove plugs and caps from disconnected hydrau lic hoses and open ports of the pump assembly Install fittings and hoses to correct l...

Page 114: ...mbly 36 Cap screw 4 used 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 used 45 Bushing dowel 2 used 46 Socket head screw 6 used 47 Control arm 48 Hex nut 49 Lock washer Figure 58 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 ...

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Page 116: ...ge control manifold 2 Hydraulic oil filter 3 4WD 2WD control manifold 4 Manifold bracket 5 Flange head screw 3 used 6 Flange nut 2 used 7 Cap screw 2 used 8 Lift circuit junction manifold 9 Flange head screw 2 used 10 Flat washer 2 used 11 Flange head screw 2 used Figure 59 FRONT RIGHT 3 1 2 4 6 10 5 8 7 11 9 ...

Page 117: ... new O rings onto fittings Install fittings into manifold ports using marks made during the remov al process to properly orientate fittings Tighten fittings see Hydraulic Fitting Installation in the General Infor mation section of this chapter Refer to Figure 60 or 61 for fitting installation torque 2 Install hydraulic manifold to the frame using Figure 59 as guide 3 Remove caps and plugs from fit...

Page 118: ... directional valve PD1 PD2 10 Pressure reducing valve PR 11 Relief valve RV 12 Solenoid valve SV 13 Solenoid coil 14 Zero leak plug 4 15 Temperature sensor TS Figure 62 UP UP 60 in lb 6 8 N m 20 ft lb 27 N m 25 ft lb 34 N m 50 ft lb 68 N m 1 4 6 9 11 13 12 7 3 6 10 8 5 7 5 2 50 ft lb 68 N m 20 ft lb 27 N m 25 ft lb 34 N m 50 ft lb 68 N m 20 ft lb 27 N m 14 1 35 ft lb 47 N m 25 ft lb 34 N m 15 20 t...

Page 119: ...he impact will allow plug removal with less chance of damage to the head of the plug For cartridge valve service procedures see Control Manifold Cartridge Valve Service in this section Refer to Figure 62 for 4WD 2WD Control Manifold cartridge valve and plug installation torque IMPORTANT A flow control orifice item 3 is lo cated beneath the plug in 4WD 2WD control man ifold ports OR1 and OR2 If an ...

Page 120: ...Schematic in Chapter 9 Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each port NOTE The control manifold uses several zero leak plugs These plugs have 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 neces sary lig...

Page 121: ...6 Clean cartridge valve using clean mineral spirits Submerge valve in clean mineral spirits to flush out con tamination Particles as fine as talcumpowder 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 flush out contamination Be extremely careful not to damage car tridge Use c...

Page 122: ...e Motor 1 Axle motor 2 O ring 3 Pinion gear 4 External snap ring 5 O ring 6 Hydraulic fitting 7 O ring 8 90o hydraulic fitting 9 Cap screw 2 used 10 Flat washer 2 used Figure 64 FRONT RIGHT Arrows on side of motor case point up 3 4 2 5 6 7 7 8 5 9 10 1 ...

Page 123: ... Remove fittings from motor and discard O rings Installation Fig 64 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 Hydraulic Fitting Installation in the General Information section of this chapter 2 If removed install pinion ge...

Page 124: ... 2 per motor 13 Cap screw 2 per motor 14 O ring 15 90o hydraulic fitting 16 O ring 17 90o hydraulic elbow 18 O ring 19 O ring 20 RH brake assembly 21 Gasket 22 45o hydraulic fitting 23 O ring 24 Straight hydraulic fitting 25 O ring Figure 65 FRONT RIGHT Arrows on side of motor case point up 1 2 3 4 5 6 7 8 9 11 12 13 16 17 18 19 21 10 18 22 16 2324 25 14 15 10 20 10 19 75 to 85 ft lb 102 to 115 N ...

Page 125: ... straight hydraulic fittings item 24 are installed and properly tight ened first Then install and tighten angled fittings items 17 and 22 If angled fittings are installed first straight fittings may contact angled fittings before the straight fitting is properly tightened resulting in hydraulic leakage 1 If fittings were removed from wheel motor lubricate and place new O rings onto fittings Instal...

Page 126: ... to 24 N m 7 2 11 14 3 17 15 16 12 4 5 19 20 6 1 9 10 13 9 10 8 18 FRONT WHEEL MOTOR SHOWN NOTE Thefrontwheel motors shown inFigure 66 are identical The rear axle motor is similar to the front wheel motors Service of the front and rear motors requires the same procedure NOTE The rear axle motor does not have a shaft seal item 8 The case drain from the rear axle motor pro vides lubrication for the ...

Page 127: ... and discard O rings Installation 1 If fittings were removed from reel 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 Hydraulic Fitting Installation in the General Information section of this chapter 2 Remove cover from cutting unit opening 3 Coat spline shaft of ...

Page 128: ...1 5 7 12 14 15 16 17 18 4 6 7 8 14 33 ft lb 45 N m 19 ft lb 25 N m 19 ft lb 25 N m Figure 68 Disassembly Fig 68 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 69 IMPORTANT Prevent damage when clamping the reel motor into ...

Page 129: ...70 Discard seals Inspection 1 Remove any nicks and burrs from all parts 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 71 A Gear shafts should be free of rough surfaces and excessive wear at bushing points and sealing areas Scoring rou...

Page 130: ...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 132: ... Hydraulic System Page 4 98 Mow Control Manifold FRONT RIGHT 1 Mow control manifold 2 Flange head screw 4 used 3 Filter head 4 Hydraulic oil filter 5 Lift control manifold 6 Fan control manifold Figure 72 3 4 1 6 2 5 ...

Page 133: ...tion to allow correct assem bly Fig 73 Remove fittings from manifold and discard O rings Installation Fig 72 1 If fittings were removed from control manifold lubri cate and place new O rings onto fittings Install fittings into manifold ports using marks made during the remov al process to properly orientate fittings Tighten fittings see Hydraulic Fitting Installation in the General Infor mation se...

Page 134: ...3 1 5 7 12 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 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 9 Foldout Drawings to identify th...

Page 135: ...ns 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 75 NOTE The mow control manifold uses several zero leak plugs These plugs have a tapered sealing surface o...

Page 136: ...gage parking brake and remove key from the ignition switch 2 Remove fasteners that secure shroud to front of ma chine Fig 77 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 steeri...

Page 137: ...ion section of 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 N m 4 Position stee...

Page 138: ...Sleeve 11 Spool 12 Cardan shaft 13 O ring 14 Distributor plate 15 Outer gearwheel 16 Inner gearwheel 17 End cover 18 Tube 2 used 19 Washer 5 used 20 Pin bolt 21 Cap screw 4 used 22 Ball Figure 79 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 t...

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Page 140: ...ining 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 80 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 141: ...m cylinder and discard O rings Installation Fig 80 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 into ...

Page 142: ... 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 81 50 to 60 ft lb 68 to 81 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 143: ... 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 81 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 seals O ...

Page 144: ... 14 ft lb 3 5 6 4 7 1 2 8 9 10 11 12 13 14 15 16 17 4 2 5 18 19 20 21 FRONT RIGHT Removal Fig 82 1 Park machine on a level surface lower cutting units stop engine apply parking brake and remove key from the ignition switch 2 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter 3 Unlatch and raise h...

Page 145: ...ngsusingmarksmadeduringthe removalprocess to properly orientate fittings Tighten fittings see Hy draulic Fitting Installation in the General Information section of this chapter 2 Position fan motor to fan motor bracket and secure with cap screws item 20 flat washers item 21 and lock nuts item 14 3 Thoroughly clean tapered surfaces of fan motor shaft and fan hub Place woodruff key in slot in motor ...

Page 146: ...nt wear plate 7 Shaft seal 8 Backup gasket 9 Pressure seal 10 Rear wear plate 11 Body 12 Idler gear 13 Cap screw 4 used 14 Dowel 2 used 15 Drive gear 16 Washer 4 used Figure 84 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 For disassembly inspection and assembly procedures of the cooling fan motor see Reel Motor Service in this section ...

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Page 148: ... Hydraulic System Page 4 114 Fan Control Manifold 1 Fan control manifold 2 Flange head screw 2 used 3 Filter head 4 Hydraulic oil filter 5 Lift control manifold 6 Mow control manifold Figure 85 FRONT RIGHT 3 4 1 6 2 5 ...

Page 149: ...me using Figure 85 as guide 8 If hydraulic fittings are to be removed from fan control manifold mark fitting orientation to allow correct assem bly Fig 86 Remove fittings from manifold and discard O rings Installation Fig 85 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 p...

Page 150: ...is the location of the flow divider cartridge valve See Hydrau lic Schematic in Chapter 9 FoldoutDrawings 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 section Refer to Figure 87 for cartridge valve and plug installation torque NOTE The fan control manifold inclu...

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Page 152: ...rt 1 Park machine on a level surface lower cutting units stop engine apply parking brake and remove key from the ignition switch IMPORTANT To prevent unexpected cutting unit lowering make sure that cutting units are fully low ered before loosening hydraulic lines from lift man ifold 2 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Serv...

Page 153: ...ice is flat in the base of the manifold port Manifold damage is possible if the orifice is cocked in the cavity 1 If fittings were removed from junction manifold lubri cate and place new O rings onto fittings Install fittings into manifold openings making sure that orifice is cor rectly placedbeforethreadingfittingintomanifold Tight en fittings see Hydraulic Fitting Installation in the General Inf...

Page 154: ... 60 in lb 6 8 N m 20 ft lb 27 N m 20 ft lb 27 N m NOTE The ports on the manifold are marked for easy identification of components e g P is the supply con nection port and RV1 is the location for the lift relief valve See Hydraulic Schematic in Chapter 9 Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each port location WARNING If lift manifold is attached t...

Page 155: ...d be neath the hydraulic fittings in lift control manifold ports C2 C3 and C4 If any of these fittings are re moved from the manifold make sure to remove ori fice and label its position for assembly purposes Also note location of groove in orifice for assembly purposes When installing the orifice in the man ifold make sure that the orifice is flat in the base of the port Manifold damage is possibl...

Page 156: ...iltration charge control manifold 2 Hydraulic oil filter 3 4WD 2WD control manifold 4 Manifold bracket 5 Flange head screw 3 used 6 Flange nut 2 used 7 Cap screw 2 used 8 Lift circuit junction manifold 9 Flange head screw 2 used 10 Flat washer 2 used 11 Flange head screw 2 used 3 1 2 4 6 10 5 8 7 11 9 ...

Page 157: ...d and an ori fice is in the manifold port make sure to remove ori fice and label its position 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 Fig 92 Installation Fig 91 IMPORTANT When installing orifice in manifold make sure that orifice is flat in the base of the man ifold port Manifold damage is...

Page 158: ... 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 Figure 93 FRONT RIGHT 1 2 3 4 6 7 8 9 10 12 13 1...

Page 159: ...er from 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 Installation Fig 93 1 If fittings were removed from lift cylinder lubricate and place new O rings onto fittings Install fittings into cylinder openings usingmarks madeduring theremoval process to properly orientate fittin...

Page 160: ...traight 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 Chain hoop 29 Flange nut 2 per hoop 30 Lift chain 31 O ring 32 Grease fitting 33 O ring 34 O ring Figure 95 FRONT RIGHT 34 34 1 2 4 ...

Page 161: ...draulic 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 95 1 If fittings were removed from lift cylinder lubricate and place new O rings onto fittings Install fittings into cylinder openings usingmarks madeduring theremoval process to properly orientate fittings Tighten fittings see...

Page 162: ...g ring 13 Head seal 14 Support washer 15 Retaining ring 16 Wiper 17 Rod assembly Figure 97 10 5 2 11 6 13 14 12 9 7 4 3 1 8 12 10 9 5 7 4 2 3 11 1 8 6 13 14 35 to 45 ft lb 48 to 61 N m 15 16 17 Loctite 271 15 16 17 NOTE The lift cylinders used on the Reelmaster 7000 are all very similar regardless of the location on the ma chine The disassembly and assembly procedure is the same for all lift cylin...

Page 163: ...lic system will cause damage 10 Carefully inspect internal surface of barrel for dam age deep scratches out of round etc Replace en tire cylinder if barrel is damaged Inspect rod and piston for evidence of excessive scoring pitting or wear Re place any damaged parts Assembly Fig 97 1 Make sure all cylinder components are clean before assembly 2 Coat new seal kit components with clean hydraulic oil...

Page 164: ... Flat washer 2 used 8 Flange nut 3 used 9 Clamp 2 used 10 Cap screw 2 used 11 Flat washer 2 used 12 Breather 13 Screen filter 14 Dipstick 15 Plug 16 O ring 17 Cap screw 18 O ring 19 O ring 20 O ring 2 used 21 O ring 22 O ring Figure 98 FRONT RIGHT 68 to 75 ft lb 93 to 101 N m 80 to 88 ft lb 109 to 119 N m 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 8 14 17 18 19 20 21 22 ...

Page 165: ...ttings 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 98 1 If fittings were removed from reservoir lubricate and place new O rings onto fittings Install fittings into r...

Page 166: ...crew 8 used 4 Radiator mount 5 Radiator 6 Air intake hose 7 Plenum 8 Flange nut 4 used 9 O ring 10 90o hydraulic fitting 2 used 11 O ring 12 Hydraulic hose 2 used 13 Cap screw 2 used 14 Washer 2 used 15 Wire form clamp 2 used 16 Top oil cooler bracket Figure 99 2 3 4 5 6 7 8 9 10 1 8 13 14 11 12 15 16 3 FRONT RIGHT ...

Page 167: ... protection such as goggles when using compressed air 2 Dry inside of oil cooler using compressed air in the opposite direction of the oil flow 3 Plug both ends of oil cooler Clean exterior of cooler Make sure fins are clear of dirt and debris 4 The oil cooler should be free of corrosion cracked tubes and excessive pitting of tubes Installation Fig 99 1 If fittings were removed from oil cooler lub...

Page 168: ...Reelmaster 7000 Hydraulic System Page 4 134 This page is intentionally blank ...

Page 169: ... 17 Ignition Switch 17 Fuses 18 Indicator Lights 19 Hour Meter 20 Temperature Gauge 20 PTO Switch 21 Cutting Unit Lift Switch 22 Headlight Switch 23 Engine Cooling Fan Switch 24 Seat Switch 25 Parking Brake Switch 26 Mow Transport Sensor 27 Cutting Unit Position Sensor 28 Backlap Switches 29 Glow and Main Power Relays 30 Start Relay 31 Reel Speed Potentiometer 32 Hydraulic Solenoid Valve Coils 33 ...

Page 170: ...Before performing any welding on the machine disconnect the battery cables from the battery disconnect the wire harness connectors from the Toro Electronic Controller s and discon nect the terminal connector from the alternator to prevent damage to the machine electrical system Figure 1 1 1 Toro Electronic Controller CAN bus Communications The TEC controller used on the Reelmaster 7000 can communi...

Page 171: ...eelmaster 7000 Page 5 3 Electrical System Electrical Drawings The electrical schematics and other electrical drawings for the Reelmaster 7000 are located in Chapter 9 Fold out Drawings Electrical System ...

Page 172: ...when testing electrical circuits The high impedance internalresistance ofa digitalme ter in the voltage mode will make sure that excess cur rent is not allowed through the meter This excess current can cause damage to circuits not designed to carry it Figure 2 Skin Over Grease Special non conductive grease which forms a light pro tective skin to help waterproof electrical switches and contacts Tor...

Page 173: ...uage options and part numbers IMPORTANT The Diagnostic Display must not be left connected to the machine It is not designed to withstand the environment of the machine s every day use When use of Diagnostic Display is com pleted disconnect it from the machine and recon nect loop back connector to harness connector Machine will not operate without loop back con nector installed on harness Store Dia...

Page 174: ...hine IMPORTANT The Diagnostic Display must not be left connected to the machine It is not designed to withstand the environment of the machine s every day use When use of the Diagnostic Display is com pleted disconnect it from the machine and recon nect loop back connector to harness connector The machine will not operate without the loop back connector installed on the harness Store the Diag nost...

Page 175: ...OTE When the Diagnostic Display is attached to the wire harness connector and the ignition switch is in the ON position the input LED for hydraulic temp and cool ant temp should be illuminated If the harness connector is disconnected from the sensor for either of these in puts the appropriate LED should go off after a few sec ond delay Then if the harness connector is reattached to the sensor the ...

Page 176: ...RE LOW Engine not running OR low engine oil pressure LED ON Engine oil pressure OK LED OFF FAN REVERSE Fan switch in momentary REVERSE position LED ON Fan switch in AUTO position LED OFF ALTERNATOR FAULT Engine not running or alternator faulty LED ON Alternator OK LED OFF FRONT BACKLAP Front reels in backlap position LED ON Front reels NOT in backlap position LED OFF HYDRAULIC TEMP Hydraulic tempe...

Page 177: ...everal times to per form the following step To change from inputs to out puts press toggle button once This may be done as often as required Do not press and hold toggle but ton 6 Sit on seat and attempt to operate the desired func tion of the machine The appropriate output LED s should illuminate on the Diagnostic Display to indicate that the TEC controller is turning on that function The GLOW PL...

Page 178: ...r is faulty Nothing happens when start attempt is made Control panel lights and gauges operate with the ignition switch in ON The traction pedal is not in neutral position Operator seat is unoccupied OR the parking brake is not applied The PTO switch is ON engaged Fuse F1 1 20 amp is faulty open TEC fuses F3 2 F3 3 or F3 4 are faulty The traction neutral switch or circuit wiring is faulty Seat swi...

Page 179: ...t should not when the ignition switch is turned off The engine fuel stop solenoid is stuck open Ignition switch or circuit wiring is faulty Engine continues to run but should not when the traction pedal is engaged with no operator in the seat The seat switch or circuit wiring is faulty Traction neutral switch or circuit wiring is faulty The engine stops during operation but is able to restart The ...

Page 180: ...ubleshooting Section of Chapter 4 Hydraulic System Cutting units run but should not when lowered with PTO switch in the OFF disengage position The PTO switch or circuit wiring is faulty Cutting unit s do not operate The cutting units are not fully lowered The operator seat is unoccupied Mow speed limiter is not in mow position 4WD The PTO switch or circuit wiring is faulty The cutting unit positio...

Page 181: ...ition 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 ex...

Page 182: ...ne 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 and relays is included in the Component Test ing section of this Chapter NOTE Use the Diagnostic Display see Special Tools in this chapter to test Toro Electronic Contr...

Page 183: ...jamnutsthatsecuresensor to footrest platform Position switch with jam nuts to al low correct gap between sensor and mow speed limiter Tighten jam nuts to secure adjustment Jam nuts should be torqued from 162 to 198 in lb 18 4 to 22 4 N m After jam nuts are tightened make sure that clearance between head of mow transport sensor and the mow speed limiter has not changed 3 After adjustment to the mow...

Page 184: ... sensor and lift arm gusset Jam nuts should be torqued from 162 to 198 in lb 18 4 to 22 4 N m After jam nuts are tightened make sure that gap has not changed The vertical location of the cutting unit position sensor on the sensor bracket will determine the turn around position of the cutting units Raising the sensor on the bracket will allow a higher turn around position of the cutting units Lower...

Page 185: ...ctioning correctly proceed with test 2 Make sure ignition switch is OFF Remove key from ignition switch 3 Disassemble console arm to gain access to ignition switch see Console Arm Disassembly in the Service and Repairs section of Chapter 7 Chassis 4 Disconnect wire harness electrical connector from the ignition switch 5 The ignition switch terminals are identified as shown in Figure 16 The circuit...

Page 186: ... 10 Amp protects power supply to the pow erpoint Fuse F2 4 10 Amp protects power supply to the main power circuit Fuse F3 1 2 Amp protects logic power circuit to the TEC controller Fuse F3 2 7 5 Amp protects power supply to the TEC controller outputs Fuse F3 3 7 5 Amp protects power supply to the TEC controller outputs Fuse F3 4 7 5 Amp protects power supply to the TEC controller outputs Fuse M1 6...

Page 187: ...inate indi cating correct operation of the electrical wiring to the oil pressure switch High Temperature Warning Light If the engine coolant temperature rises to approximately 220oF 105oC the high temperature light should come on and the PTO cutting units will disengage To test the high temperature shutdown light and circuit wiring start the engine and ground the gray wire at tached to the tempera...

Page 188: ...0 0 1 10 BACK Temperature Gauge The temperature gauge on the control panel indicates engine coolant temperature level during machine op eration Fig 22 The changing resistance of the engine temperature sender signals the temperature gauge The temperature gauge should display the first green segment when the ignition switch is turned to ON The first yellow segment on the gauge should display when en...

Page 189: ...and Repairs section of Chapter 7 Chassis 4 Disconnect harness electrical connector from the PTO switch 5 The switch terminals are marked as shown in Figure 24 The circuit logic of the PTO switch is shown in the chart below 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...

Page 190: ...e ignition switch is OFF Remove key from ignition switch 3 Disassemble console arm to gain access to cutting unitliftswitch see Console Arm Disassembly in the Ser vice and Repairs section of Chapter 7 Chassis 4 Disconnect harness electrical connector from the lift switch 5 The switch terminals are marked as shown in Figure 27 The circuit logic of the lift switch is shown in the chart below With th...

Page 191: ...inals for each switch position The switch terminals are marked as shown in Figure 29 The circuitry of the switch is shown in the chart below Verify continuity between switch ter minals Replace headlight switch if testing identifies a faulty switch SWITCH POSITION CIRCUIT 1 CIRCUIT 2 ON 2 3 5 6 OFF 2 1 5 4 5 If headlight switch tests correctly and circuit problem still exists check wire harness see...

Page 192: ...the en gine cooling fan switch see Console Arm Disassembly in the Service and Repairs section of Chapter 7 Chas sis 4 Disconnect harness electrical connector from the cooling fan switch 5 With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists between the various terminals for each position The switch terminals are marked as shown in Figu...

Page 193: ...h testing is necessary If however the Displaydetermines that the seat switch and circuit wiring are not functioning correctly proceed with test 2 Make sure ignition switch is OFF Remove key from ignition switch 3 Disconnect seat switch connector from the machine wire harness connector 4 Check the continuity of the switch by connecting a multimeter ohms setting across the seat switch con nector ter...

Page 194: ...however the Display determines that the brake switch and circuit wiring are not functioning correctly proceed with test 3 Make sure ignition switch is OFF Remove key from ignition switch 4 Disconnect wire harness electrical connector from the parking brake switch 5 Check the continuity of the switch by connecting a multimeter ohms setting across the connector termi nals 6 When the parking brake is...

Page 195: ...PORT 2WD posi tion The LED should not be illuminated when the limit er is in the MOW 4WD position 3 If the mow transport sensor LED did not function cor rectly A Make sure that the mow transport sensor is prop erly adjusted see Mow Transport Sensor in the Ad justments section of this chapter If necessary adjust sensor and return to step 2 above B Make sure ignition switch is OFF and disconnect the...

Page 196: ...ted when the cutting units are fully lowered The LED should not be illuminated when the cutting units are raised above the turn around position 4 If the position sensor LED did not function correctly A Make sure that the cutting unit position sensor is properly adjusted see Cutting Unit Position Sensor in the Adjustments section of this chapter If neces sary adjust sensor and return to step 2 abov...

Page 197: ...est 3 Make sure ignition switch is in the OFF position 4 Unlatch and raise hood to allow access to hydraulic mow control manifold Locate the backlap switch on the front of the manifold Disconnect the harness electrical connector from the backlap switch 5 Check the continuity of the switch by connecting a multimeter ohms setting across the switch connector terminals 6 With the ignition switch in th...

Page 198: ...nd locate relay to be tested 4 Disconnect wire harness connector from 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 va...

Page 199: ... the meter and test leads Subtract this val ue from from the measured value of the component you are testing 5 Using a multimeter verify that coil resistance be tween terminals 85 and 86 is from 71 to 88 ohms 6 Connect multimeter ohms setting leads to relay ter minals 30 and 87 Ground terminal 86 and apply 12 VDC to terminal 85 The relay should make and break continuity between terminals 30 and 87...

Page 200: ...ogether 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 5 Using a multimeter measure resistances between potentiometer terminals as follows Fig 45 A Verify that resistance between terminals B and C is approximately...

Page 201: ...nnector from coil 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 4 Using a multimeter ohms setting measu...

Page 202: ...lti meter across the two 2 switch terminals With the en gine turned off slowly push the traction pedal in a forward or reverse direction while watching the multime ter There should be indications that the traction neutral switch is opening and closing Allow the traction pedal to return to the neutral position There should be conti nuity across the switch terminals when the traction ped al is in th...

Page 203: ...ngine coolant switches are all monitored by the controller Current output to the mow circuit hydraulic valve sole noid coils lift circuit hydraulic valve solenoid coils and engine components glow plug relay start relay fuel pump and engine run solenoid are controlled based on the inputs received by the controller Because of the solid state circuitry built into the control ler there is no method to...

Page 204: ...ess connector from sender 4 Thoroughly clean area around temperature sender and remove sender 5 Put sensing end of sender in a container of oil with a thermometer and slowly heat the oil Fig 52 CAUTION Handle the hot oil with extreme care to prevent personal injury or fire NOTE Prior to taking resistance readings with a digital multimeter short the meter test leads together The me ter will display...

Page 205: ...g Fig 53 6 Place disconnected fuel hose pump discharge into a large graduated cylinder sufficient enough to collect 1 quart 0 95 liter 7 Collect fuel in the graduated cylinder by turning igni tion switch to the ON position Allow pump to run for fif teen 15 seconds then turn switch to OFF 8 The amount of fuel collected in the graduated cylin der should be approximately 16 fl oz 475 ml after fif tee...

Page 206: ...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 digital multimeter ...

Page 207: ...ON Handle the hot oil with extreme care to prevent personal injury or fire 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 is due to the internal re sistance of the meter and test leads Subtract this value from from the measured value of the component yo...

Page 208: ...e lubrication system and testing 1 Turn the ignition switch to the ON position do not start engine The oil pressure indicator light on the con trol panel should be illuminated 2 If the indicator light is not illuminated open hood to gain access to engine 3 Locate oil pressure switch on engine and disconnect the wire harness connector from the switch 4 With the ignition switch in the ON position gr...

Page 209: ...ttery do not smoke Nausea may result if thegases areinhaled Unplugchar 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 will discharge slowly A Clean battery b...

Page 210: ...gital 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 bat...

Page 211: ...ith an adjustable load tester This is one ofthe mostreliable means oftesting a battery as itsimulates the cold cranking test A commercialbat 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 re...

Page 212: ... 5 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 60oF 16oC before connecting to a charger Charge the battery in a well ventilated place to dissipate gases produced from charging These gases are ex...

Page 213: ...l 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 61 1 Slide solenoid coil onto the hydraulic valve Position coil so that connector is properly orientated 2 Install nut onto valve and torque nut 60 in lb 6 8 ...

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Page 215: ...l 3 SERVICE AND REPAIRS 4 Brake Assembly 4 Brake Inspection and Repair 6 Planetary Wheel Drive Assembly 8 Planetary Wheel Drive Service 10 Rear Axle Assembly 14 Rear Axle Service 16 Bevel Gear Case and Axle Case 18 Differential Shafts 22 Axle Shafts 23 Input Shaft Pinion Gear 24 Differential Gear 26 Pinion Gear to Ring Gear Engagement 29 Axles Planetaries and Brakes ...

Page 216: ...125 ft lb 136 to 169 N m Planetary brake housing and wheel motor 75 to 85 ft lb 102 to 115 N m mounting screw torque Rear wheel toe in 0 125 in 3 mm Tire pressure front and rear 20 psi 138 kPa Planetary gear drive lubricant SAE 85W 140 wt gear lube Planetary gear lube capacity each wheel 16 fl oz 0 47 l Rear axle lubricant SAE 85W 140 wt gear lube Rear axle gear lube capacity 80 fl oz 2 37 l ...

Page 217: ...rator 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 218: ... perform ing other service use correct blocks hoists and jacks to raise and support machine Make sure machine is parked on a solid level surface such as a concrete floor Prior to raising machine re move any attachments that may interfere with the safe and proper raising of the machine Al ways chock or block wheels Use appropriate jack stands to support the raised machine If the machine is not prop...

Page 219: ... 4 Install flange head screws item 11 to secure brake assembly to frame Tighten screws in a crossing pattern to a torque from 75 to 85 ft lb 102 to 115 N m 5 Install brake cable to pull rod on brake assembly Brake cable end should be completely threaded onto pull rod before tightening jam nut 6 Install new o ring on hydraulic wheel motor Install wheel motor see Front Wheel Motors in Service and Re...

Page 220: ...n and Repair Fig 4 1 Carefully 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 actuator assembly items 3 4 5 6 and 11 and balls item 13 6 Remove seal item 2 from brake housing 7 Wash parts in cleaning solvent Inspect co...

Page 221: ...Reelmaster 7000 Page 6 7 Axles Planetaries and Brakes This page is intentionally blank Axles Planetaries and Brakes ...

Page 222: ... Make sure machine is parked on a solid level surface such as a concrete floor Prior to raising machine re move any attachments that may interfere with the safe and proper raising of the machine Al ways chock or block wheels Use appropriate jack stands to support the raised machine If the machine is not properly supported by jack stands the machine may move or fall which may result in personal inj...

Page 223: ...to 85 ft lb 102 to 115 N m 2 Apply Loctite Gasket Sealant 2 or equivalent to sealing surfaces of new gasket item 19 Apply gasket to brake assembly 3 Install brake assembly to planetary see Brake As sembly Installation in this section 4 Installhydraulic wheelmotor see FrontWheelMotor Installation in the Service and Repairs section of Chap ter 4 Hydraulic System Failure to maintain proper wheel lug ...

Page 224: ...d 11 Outer bearing 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 used 19 O ring 2 used 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 7 118 to 144 in lb 13 3 to 16 3 N m 2 3 1 4 5 6 8 9 7 ...

Page 225: ...items 2 and 3 and O rings item 13 from housing 9 Remove inner bearing cone item 4 from housing If necessary remove bearing cups items 5 and 11 from housing 10 If wheel stud item 6 removal is necessary use press to extract stud s from housing 11 If necessary remove socket head screws item 7 with lock washers item8 thatsecure ring gear item16 to housing Remove ring gear and two 2 dowel pins item 10 ...

Page 226: ...s no endplay in assembly If required remove retaining ring and install a thrust washer of different thickness to adjust endplay L Install new O ring item 13 into groove in hous ing 4 Install secondary carrier item 28 secondary gear item 27 and primary carrier item 26 making sure that carrier gear teeth align with ring gear and spline on spindle shaft 5 If primary gear item 24 was removed from driv...

Page 227: ...Reelmaster 7000 Page 6 13 Axles Planetaries and Brakes This page is intentionally blank Axles Planetaries and Brakes ...

Page 228: ...machine is parked on a solid level surface such as a concrete floor Prior to raising machine re move any attachments that may interfere with the safe and proper raising of the machine Al ways chock or block wheels Use appropriate jack stands to support the raised machine If the machine is not properly supported by jack stands the machine may move or fall which may result in personal injury Remove ...

Page 229: ...pivot pin to secure axle to frame Make sure to install thrust washer between axle pivot and frame on both ends of the pivot With washers installed there should be from 0 002 to 0 020 inch 0 05 to 0 51 mm clearance between rear frame mount and axle mounting boss Add thrust washers if needed to adjust clearance 5 Install flat washer and lock nut onto axle pivot pin Lock nut should be tightened enoug...

Page 230: ...es and Brakes Rear Axle Service Figure 12 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 231: ... 32 Bolt 4 used per knuckle 33 Shim set 34 Dowel pin 2 used 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 used per gear case 42 Bolt 4 used 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 used per axle case 51 Axle cover 52 Screw 6 use...

Page 232: ...e case assemblies 1 2 3 4 5 6 1 Cap screw 4 used 2 Lock nut 2 used 3 Lock washer 2 used 4 Axle support 5 Bevel gear case axle case assembly 6 O ring Figure 13 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 14 1 Axle case 2 Axle cover assembly 3 Screw 6 used 4 O ring Figure 14 1 2 3 4 17 to ...

Page 233: ...gear shaft seal from axle case Fig 16 1 Knuckle pin 2 Mounting screw 4 used 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 16 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 Inspe...

Page 234: ... Fig 19 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 andinstallthebevelgear andcollar Makesurethebevel gear shaft is completely seated in the upper and lower bearings Fig 19 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 cove...

Page 235: ...move 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 a...

Page 236: ...semblies 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 23 2 Mark and pull the differential shaft assembly from the axle support 3 Remove the retaining ring and bevel gear Fig 24 4 Drive the differential shaft out of the bearings Re move the bearings and bearing shims 5 Inspect all gears shafts bearings and cas...

Page 237: ...ce components as necessary Installation 1 Coat new axle shaft seal with grease and install in axle cover as shown Fig 27 2 Press the axle cover and bearing assembly onto the axle shaft Press only on the inner race of the cover bearing Fig 27 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 axle c...

Page 238: ...gs 4 Release the 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 matche...

Page 239: ...ms 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 31 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 shim...

Page 240: ...spring pin from the differential case with a punch and hammer Discard the spring pin Fig 33 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 34 NOTE Replacement ring gears are onl...

Page 241: ...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 36 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 all...

Page 242: ... 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 38 10 Adjust side gear shims if necessary to cor...

Page 243: ...nts 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 41 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 dif...

Page 244: ... 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 43 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 g...

Page 245: ...TION 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 246: ...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 are identified as shown in Figure 1 Figure 1 CUTTING UNIT LOCATIONS 4 1 5 3 2 ...

Page 247: ...Reelmaster 7000 Page 7 3 Chassis This page is intentionally blank Chassis ...

Page 248: ...Lubricant Removal 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 ...

Page 249: ...rews item 9 and flange nuts item 10 4 Secure steering controlvalve tosteering columnwith 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 tapered surfaces of steering wheel and steering column 8 Apply antiseize lubri...

Page 250: ...ator light high temp glow plug 21 Temperature gauge 22 Indicator light 23 Button plug 24 Hour meter 25 Cap screw 2 used 26 Cutting unit lift switch 27 Hole plug 28 Engine cooling fan switch 29 Headlight switch 30 Throttle cable 31 Screw 2 used 32 Foam seal 33 Power point 34 Cap 35 PTO switch 36 Console wire harness 37 Flange spacer 2 used 38 Clip 2 used 39 Bag holder 40 Washer head screw 2 used 41...

Page 251: ...ponents from console arm as needed using Figure 5 as a guide 7 If necessary remove console panel and supports from machine using Figures 5 and 6 as guides Assembly Fig 5 1 Install all removed electrical and console arm com ponents using Figure 5 and 6 as guides 2 Position covers to console arm As LH cover item 2 is placed plug wire harness connector to headlight switch 3 Secure each cover to conso...

Page 252: ... Washer 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...

Page 253: ...lation Fig 7 1 Assemble lift arm using Figure 7 as a guide 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...

Page 254: ...nder 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 Chain hoop 29 Flange nut 2 per hoop 30 Lift chain 31 O ring 32 Grease fitting 33 O ring Removal Fig 9 1 Park machine on a level surface lower cutting units stop engi...

Page 255: ...rust 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 item 13 to secure lift arm pivot pin 5 Position lift cylinder rod clevis to lift arm 6 Make sure that one 1 retaining ring and washer are installed on cylinder pin item 17 Insert cylinder pin through the lift arm and lif...

Page 256: ...ed 15 Flange nut 4 used 16 Seat assembly 17 Seat belt 18 Cap screw 19 Support channel 20 Arm support 21 Support bracket 22 Spacer 23 Cap screw 24 Carriage screw 6 used 25 Flange nut 10 used 26 Cap screw 27 Hex nut 28 Grommet 29 Flange head screw 4 used 30 Housing cap 31 Manual tube 32 Flange nut 2 used 33 Screw 2 used 34 R clamp 2 used 35 Seat belt buckle Figure 12 FRONT RIGHT 10 17 1 2 16 10 35 2...

Page 257: ...r the seat adjustmenthandle is longer than the other three 3 screws 9 Lift seat from seat suspension and remove from ma chine Installation Fig 12 1 Carefully position seat to seat suspension 2 Secure seat to seat suspension with four 4 torx head screws Fig 13 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 th...

Page 258: ...11 Washer 12 Cap screw 2 used 13 Seat 14 Nut 15 Spring 2 used 16 Magnet 17 Seat switch 18 Rivet 4 used 19 Mounting plate 20 Return spring 21 Torx screw 5 used 22 RH adjustment rail 23 Rail stop 24 Torx screw 25 Torx screw 3 used 26 Washer 3 used 27 Handle 28 RH armrest cover 29 Flange nut 30 Carriage screw 31 Support bracket Figure 14 8 10 6 5 7 4 3 2 1 11 14 12 13 15 16 17 18 19 20 21 21 28 9 23 ...

Page 259: ...ine for service see Opera tor Seat Removal in this section 2 Disassemble operator seat as necessary using Fig ure 14 as a guide Assembly Fig 14 1 Assemble operator seat using Figure 14 as a guide 2 Install seat to machine see Operator Seat Installa tion in this section Chassis ...

Page 260: ...d 17 Washer 4 used 18 C clip 4 used 19 Pin 2 used 20 Rivet 2 used 21 Washer 3 used 22 Screw 2 used 23 Washer 24 Housing support 4 used 25 Spacer 4 used 26 Hose nipple 27 Clamp 2 used 28 Hose nipple 29 Screw 30 Handle 31 Bumper 32 Nut 33 Plastic plug 23 used 34 Screw 2 used 35 Roller 2 used 36 Screw 4 used 37 Base plate 38 Suspension frame 39 Upper plate Figure 15 FRONT RIGHT 11 8 7 30 10 15 6 12 1...

Page 261: ...seat plate Fig 16 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 using Figure 15 as a guide Assembly Fig 15 1 Install all removed seat suspension components us ing Figure 15 as a ...

Page 262: ...ed 16 Axle stop 2 used 17 Lock nut 4 used 18 Cap screw 2 used 19 Cap screw 2 used 20 RH hood frame tube 21 LH hood frame tube 22 RH hood frame tube 23 LH hood frame tube 24 Hood frame tube 25 Flange head screw 26 used 26 Flange nut 26 used 27 Pop rivet 4 used 28 Flex draw latch 2 used 29 Washer 2 used 30 Latch keeper 2 used 31 Back washer 4 used 32 Radiator mount 33 Pop rivet 4 used Figure 17 FRON...

Page 263: ...s and washers from pivot pins on ra diator frame 4 Remove hood from pivot pins and machine 5 If necessary disassemble hood using Figure 17 as a guide Installation Fig 17 1 If components were removed from hood assemble hood using Figure 17 as a guide 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 ho...

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Page 265: ...ring Adjustment 12 Leveling Rear Roller 13 SERVICE AND REPAIRS 14 Hydraulic Reel Motor 14 Cutting Unit Removal and Installation 15 Backlapping 16 Bedbar Assembly 18 Bedbar Adjuster Service 20 Bedknife Replacement and Grinding 22 Reel Assembly Removal and Installation 24 Reel Assembly Removal 25 Reel Assembly Installation 25 Reel Assembly Service 28 Preparing Reel for Grinding 30 Front Roller 32 Re...

Page 266: ...rive 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 single edged high carbon steel bedknife is fastened to a machined cast iron bed bar with screws Optional bedknifes are available Bed...

Page 267: ...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 268: ...re 2 Used for Height of Cut 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 9100 For applying lapping...

Page 269: ...Unit Kickstand Toro Part Number 110 4088 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 instal...

Page 270: ... 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 technicians in determining causes for poor ...

Page 271: ...Reelmaster 7000 DPA Cutting Units Page 8 7 This page is intentionally blank DPA Cutting Units ...

Page 272: ...t Operator s manual Governed 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 Kubota Diesel Engine in this manual Reel speed All cutting reels must rotate at the same speed within 100 r...

Page 273: ...irs 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 See Heigh...

Page 274: ...r roller bearings 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 Operator s Manual for a listing of available accessories ...

Page 275: ...arpening 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 cutting u...

Page 276: ...ntact exists between bedknife and reel 2 Remove cutting unit components on LH side plate to allow access to bearing adjuster nut If cutting unit is equipped with a rear roller brush refer to Rear Roller Brush Optional in the Service and Repairs section of this chapter 3 Loosen set screw that secures bearing adjuster nut in LH side plate of cutting unit IMPORTANT Over tightening reel bearing adjust...

Page 277: ...just 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 Reel for Gr...

Page 278: ...lastic cap see Special Tools into the hole in the cutting unit side plate to prevent debris entry into reel bearing area Installation NOTE Refer to Figure 14 for correct placement of cut ting 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 appr...

Page 279: ...g cutting unit to ma chine make sure that turf compensator spring is mounted on the same side of the cutting unit as the hydraulic reel drive motor Also make sure that cut ting unit is installed on machine with motor and weight properly orientated to machine Fig 18 1 Position cutting unit to machine 2 Install cutting unit to lift arm pivot yoke Fig 16 A Make sure that thrust washer is positioned o...

Page 280: ...ort operator seat to access the hy draulic mow control manifold NOTE When backlapping the front cutting units oper ate together and the rear cutting units operate together 4 Locate backlap levers on mow control manifold Ro tate front rear or both backlap levers to the backlap position R on the manifold 5 Start engine and run at low idle speed 1550 RPM 6 With the mow speed limiter in the mow positi...

Page 281: ... the engine OFF Wait for all machine movement to stop Run a file across the front face of the bedknife Fig 21 This will remove any burrs or rough edges that may have built up on the cut ting edge Repeat procedure on all cutting units 11 When done backlapping return the mow control manifold backlap levers to the F mow position lower and secure operator seat Wash all lapping compound from cutting un...

Page 282: ...hine on a clean and level surface lower cutting units stop engine engage parking brake and re move key from the ignition switch 2 Remove the cutting unit from the machine see Cut ting Unit Removal and Installation in this section 3 Position cutting unit on work bench Use the cutting unit kickstand to support the cutting unit see Special Tools 4 Loosen the lock nuts item 13 on the end of each bedba...

Page 283: ... of each bedbar arm is between washer item 11 and adjuster screw flange item 10 6 Position a plastic washer between bedbar and each cutting unit side plate Fig 23 7 Install the bedbar pivot bolt assemblies Make sure that plastic washers are not caught on the threads of the pivot bolts Tighten each bedbar pivot bolt from 27 to 33 ft lb 37 to 44 N m 8 Tighten both lock nuts item 19 until outside met...

Page 284: ...16 ft lb 19 to 21 N m Antiseize Lubricant Loctite 242 1 2 4 5 6 7 8 9 10 5 11 3 FRONT RIGHT 12 15 to 20 ft lb 21 to 27 N m NOTE The bedbar adjuster system for current produc tion DPA cutting units is shown in Figure 24 These cut ting units include a lock nut on the end of the bedbar adjuster shaft Early production cutting units Fig 25 used a retaining ring on the end of the bedbar adjuster shaft T...

Page 285: ...tting unit frame Align key on bushing to slot in frame and install bushings into frame 3 Install adjuster shaft to cutting unit frame A On current production cutting units Fig 24 slide wave washer onto adjuster shaft and then slide ad juster shaft into flange bushings in cutting unit frame Secure adjuster shaft with flat washer and lock nut Tighten lock nut to shoulder of adjuster shaft and then t...

Page 286: ...s in the mounting surface of the bedbar a new bedknife will not be perfectly flat after it is installed to the bedbar Because of this it is neces sary to grind a new bedknife after installing it to the bed bar Follow the existing angle that was ground into the bedknife and grind only enough to make sure the top surface of the bedknife is true Fig 28 NOTE When grinding the bedknife be careful to no...

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Page 288: ...icant FRONT RIGHT Grease OD surface See text for tightening procedure Grease bore and threads 27 to 33 ft lb 37 to 44 N m 27 to 33 ft lb 37 to 44 N m 6 7 8 9 1 4 2 5 3 4 10 11 12 13 15 16 17 18 19 14 20 21 12 22 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 RefertoRee...

Page 289: ...re the LH side plate to the cutting unit frame Remove the LH side plate from thereel shaft roll ers bedbar and cutting unit frame CAUTION Contact with the reel bedknife or other cutting unit parts can result in personal injury Use heavy gloves when removing the cutting reel 10 Carefully slide the cutting reel with bearings grease seals and splined inserts from the RH side plate 11 Inspect and serv...

Page 290: ... that the carrier frame pivots freely after assembly 8 Install cap screw and flat washer that secure rear grass shield to LH side plate Fig 30 Torque screw from 15 to 19 ft lb 20 to 25 N m 9 Secure the bedbar assembly to LH side plate see Bedbar Installation in this section 10 Secure front and rear rollers to LH side plate see Front Roller Installation and Rear Roller Installation in this section ...

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Page 292: ...g ring 4 Grease seal 5 Bearing 6 Threaded insert LH thread 7 Retaining ring groove 8 Groove indicating LH threads 9 Bearing shoulder 10 Reel spider Figure 32 85 to 95 ft lb 115 to 128 N m 85 to 95 ft lb 115 to 128 N m Loctite 242 Loctite 242 3 2 6 5 4 1 3 4 5 7 8 9 10 FRONT RIGHT Right Hand Threads Left Hand Threads 10 ...

Page 293: ...into cutting reel clean threads of insert and cutting reel shaft Apply Loctite 242 or equivalent to threads of insert thread in sertinto reelshaftand torque from85to95 ft lb 115 to 128 N m Assembly of Cutting Reel Fig 32 1 If seals and or bearings were removed from reel shaft discard removed components and replace 2 Make sure that the two 2 retaining rings are fully seated into the grooves on the ...

Page 294: ...g Specifications chart to the right Additional reel grinding information can be found in Toro General Ser vice Training Book Reel Mower Basics part no 09168SL 2 After completing the reel grinding process adjust cutting unit see Cutting Unit Operator s Manual Reel Grinding Specifications Reel Diameter New 7 060 in 179 3 mm for 7 reel Service Limit Reel Diameter 6 600 in 168 0 mm for 7 reel Reel Sha...

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Page 296: ... C Thread cap screw into height of cut roller bracket NOTE When assembling height of cut roller brack ets to side plate make sure thatcap screwhead andone 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 Secure br...

Page 297: ...rking surface NOTE Refer to Cutting Unit Operator s Manual for number of roller shims required for various height of cut settings 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 the Set up and Adjustments section of this chapter If necessary this shim would be used on one side of the rear roller and should be installed be tw...

Page 298: ...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 299: ... seal installation E Using the same process install second outer sealmaking sure to notcrush 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 Loct...

Page 300: ...rew 2 used 33 Pivot washer 34 Set screw top hole in cover Figure 42 Antiseize Lubricant FRONT RIGHT 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 2 3 6 8 9 10 11 13 1 5 7 12 14 15 16 17 18 19 20 4 21 22 23 24 25 26 27 28 29 30 6 31 16 16 26 27 29 32 3 33 34 2 27 to 33 ft lb 37 to 44 N m 15 to 19 ft lb 20 to 25 N m Loctite 242 15 to 19 ft lb 20 to 25 N m Loct...

Page 301: ...Secure 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 43 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 as shown in Figure 44 A Pack bearings with grease before installation B Pres...

Page 302: ... lb 20 to 25 N m 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 242 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 ...

Page 303: ...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 49 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 CAUTION Contact with the reel bedknife or other cutting unit parts can result in...

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Page 305: ...rawings Page 9 1 Chapter 9 Foldout Drawings Table of Contents HYDRAULIC SCHEMATIC 3 ELECTRICAL SCHEMATIC 4 WIRE HARNESS DRAWINGS Main Wire Harness 6 Seat and Console Wire Harness 8 Power Center Wire Harness 10 Foldout Drawings ...

Page 306: ...Reelmaster 7000 Foldout Drawings Page 9 2 This page is intentionally blank ...

Page 307: ...71 VALVE T RV1 S1 PD1 SV RV M2 550 PSI PD2 CHG M1 M1 P1 PSI BYPASS P1 091 2 48 5000 450 PSI 052 P2 G CV PR 2 01 G CR2 CR1 P1 CD2 STEERING CD1 T P2 56 56 P4 2 48 1 03 1 03 P2 P3 G 2 01 PSI 5000 071 T 5 PSI 40 PSI 207 PSI CV2 CV1 CV1 L R P PB 1050 PSI 6 1 MOW CONTROL MANIFOLD FRONT MOTORS AXLE MOTOR REAR S1 PRV FD LIFT CONTROL MANIFOLD CYLINDER ENGINE SPEED 2850 1550 PISTON PUMP GEAR PUMP WHEEL G1 G...

Page 308: ...Page 9 4 Electrical Schematic Reelmaster 7000 All relays and solenoids are shown as de energized All ground wires are black Sheet 1 of 2 ...

Page 309: ...0 All relays and solenoids are shown as de energized All ground wires are black Sheet 2 of 2 FAN DIRECTION S1 FRONT REELS S4 REEL ENGAGE FRONT SP1 REEL ENGAGE REAR SP2 FAN SPEED PRV REAR REELS S5 RAISE REELS S2 ENABLE S1 LOWER REELS S3 RANGE 2WD 4WD SV ...

Page 310: ...Page 9 6 Reelmaster 7000 Main Wire Harness ...

Page 311: ...CK GREEN BLACK WHITE VIOLET BLACK GREEN BLACK BROWN YELLOW PINK GREEN PINK BLACK BLACK YELLOW BLACK BLACK TAN BLACK PINK BLUE GRAY VIOLET WHITE RED YELLOW GRAY GREEN VIOLET GRAY WHITE BLACK WHITE GREEN TAN WHITE BLACK YELLOW WHITE VIOLET WHITE YELLOW VIOLET BROWN WHITE BLUE BLACK BLACK WHITE RED WHITE BLACK BLUE YELLOW BLACK BLACK BLACK PINK BROWN PINK WHITE BLACK RED BLACK BLACK BLUE PINK BLACK R...

Page 312: ...Page 9 8 Reelmaster 7000 Seat and Console Wire Harness ...

Page 313: ...WHITE BLACK PINK BLACK PINK GREEN VIOLET BLACK TAN WHITE GRAY BROWN YELLOW VIOLET WHITE GRAY WHITE ORANGE PINK BLACK WHITE RED WHITE PINK BLUE VIOLET WHITE GREEN WHITE PINK PINK BLACK BLACK RED WHITE BLACK WHITE RED WHITE BLACK WHITE GRAY PINK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK PINK BLACK BLACK ...

Page 314: ...Page 9 10 Reelmaster 7000 Power Center Wire Harness ...

Page 315: ...re Harness ORANGE WHITE BLUE RED BLACK ORANGE PINK BLACK BLUE PINK RED GREEN BROWN BLACK GRAY BLACK WHITE YELLOW BROWN RED BLUE WHITE BLACK TAN BLACK RED BLACK RED BLACK PINK RED RED RED RED RED RED RED RED RED VIOLET BLACK RED BLACK RED BLACK ...