Page 1 Form No. 15214SL Rev D Reelmaster 7000-D ® (Models 03780/A and 03781) Original Instructions (EN)
Page 2 THE TORO COMPANY 2020 This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies). No intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be...
Page 3 Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.com...
Page 4 NOTES...
Page 5 IMPORTANT: The IMPORTANT notice will give im- specifications or this publication without notice. portant instructions which must be followed to pre- vent damage to systems or components on the machine. E The Toro Company - - 2015, 2018, 2019, 2020...
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Page 7: Table Of Contents
Table of Contents Chapter 1 - - Safety Chapter 6 - - Electrical System General Safety Instructions ....1 -- 2 General Information .
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Page 9 Table of Contents (continued) Chapter 11 - - Universal Groomer (Optional) Grooming Performance ....11 -- 2 Troubleshooting ......11 -- 3 Service and Repairs .
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Page 11 Chapter 1 Safety Table of Contents GENERAL SAFETY INSTRUCTIONS ... . Before Operating ......While Operating .
Page 12: General Safety Instructions
E. Toro recommends that anytime the machine is parked (short or long term), the cutting units should 3. Do not run engine in a confined area without ade- be lowered to the ground.
Page 13: Maintenance And Service
Also, disconnect the wire harness must be surgically removed within a few hours by a doc- connector from the Toro Electronic Controller (TEC) and tor familiar with this form of injury or gangrene may re- disconnect the terminal connector from the alternator.
Page 14: Jacking Instructions
Jacking Instructions CAUTION When changing attachments, tires or perform- ing other service, use correct jacks and sup- ports. Make sure machine is parked on a solid, level surface such as a concrete floor . Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine.
Page 15: Safety And Instruction Decals
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. Page 1 − 5 Safety Reelmaster 7000−D...
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Page 17: Product Records
Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS ......MAINTENANCE ......EQUIVALENTS AND CONVERSIONS .
Page 18: Equivalents And Conversions
Equivalents and Conversions 0.09375 Product Records and Maintenance Page 2 − 2 Reelmaster 7000−D...
Page 19: Torque Specifications
25% for lubricated fasteners to achieve following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.
Page 20: Standard Torque For Dry, Zinc Plated And Steel Fasteners (Inch Series)
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Grade 1, 5 & SAE Grade 1 Bolts, Screws, Studs & SAE Grade 5 Bolts, Screws, Studs & SAE Grade 8 Bolts, Screws, Studs & Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts...
Page 21: Standard Torque For Dry, Zinc Plated And
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series) Class 8.8 Bolts, Screws and Studs with Class 10.9 Bolts, Screws and Studs with Thread Size Regular Height Nuts Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts) M5 X 0.8 57 + 6 in−lb 644 + 68 N−cm...
Page 22: Specifications
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Square Head Hex Socket 7/16 − 20 UNF 65 + 10 ft−lb 88 + 14 N−m Grade 5 1/4 −...
Page 23: General Information
Chapter 3 Yanmar Diesel Engine MODEL 03780 Table of Contents SPECIFICATIONS ......GENERAL INFORMATION .
Page 24: Specifications
Specifications Item Description Make / Designation Yanmar Model 4TNV86CT−DTR: 4−Cycle, 4 Cylinder, Water Cooled, Turbocharged, Tier 4 Diesel Engine Bore 3.386 in (86 mm) Stroke 3.543 in (90 mm) Total Displacement 127.5 in (2090 cc) Firing Order 1 (closest to flywheel end) − 3 − 2 − 4 (farthest from flywheel) Direction of Rotation Counterclockwise (viewed from flywheel) Fuel...
Page 25: General Information
Authorized Toro Distributor. If no parts list is available, be prepared to provide your distrib- Most repairs and adjustments require tools which are utor with the Toro model and serial number of your ma- commonly available in many service shops. Special chine.
Page 26: Engine Electronic Control Unit (Ecu)
The Yanmar engine that powers your Reelmaster uses an Electronic Control Unit (ECU) for engine manage- ment and also to communicate with the Toro Electronic Controller (TEC) and the operator InfoCenter display on the machine. All wire harness electrical connectors...
Page 27: Yanmar Engine
Additional information re- updated traction unit Operator’s Manual for the specific garding the Diesel Particulate Filter (DPF) can be found machine. Visit www.toro.com to download the updated in the Yanmar Operation Manual – Industrial Engines traction unit Operator’s Manual for the machine.
Page 28 Types of regeneration that are performed automatically (while the machine is operating) Type Conditions Description Passive Occurs during normal operation of the The DPF processes high heat exhaust machine at high engine speed or high gasses, oxidizing harmful emissions engine load. and incinerating soot to ash.
Page 29 Note: Verify the model and serial number of the engine installed in the machine. 4TNV86CT-DTR engines below serial number 03789 cannot run a recovery regeneration without first reprogram ming the engine ECU. Contact an Authorized Toro Distributor for assistance. Reelmaster 7000−D Page 3 − 7...
Page 30 Soot Accumulation If the types of regeneration that are performed automatically (while the machine is operating) are bypassed or not allowed to complete before shutting off the engine, soot will continue to accumulate in the soot filter. When enough soot accumulates, the engine ECU will generate an engine fault to prompt a parked or recovery regeneration. In addi- tion to an engine fault appearing on the InfoCenter, the engine output power will be reduced.
Page 31: Service And Repairs
Service and Repairs Air Cleaner System RIGHT FRONT VACUATOR DIRECTION 16 to 19 in−lb (1.8 to 2.2 N−m) Figure 3 1. Air cleaner assembly 8. Lock nut (2) 14. Hose clamp 2. Adapter 9. Spring (2) 15. Plenum 3. Indicator 10.
Page 32 Removal (Fig. 3) 1. Park machine on a level surface, lower cutting units, stop engine, apply parking brake and remove key from the ignition switch. 2. Raise and support hood. 3. Remove air cleaner components as needed. Installation (Fig. 3) IMPORTANT: Any leaks in the air filter system will cause serious engine damage.
Page 33: Exhaust System
Exhaust System 19 to 29 ft−lb (25 to 40 N−m) 33 to 40 ft−lb (45 to 55 N−m) 33 to 40 ft−lb (45 to 55 N−m) RIGHT FRONT Figure 6 1. Gasket 16. Bolt (20) 31. Hose clip (2) 2. Exhaust assembly stay 17.
Page 34 C. If DPF stiffeners (Fig. 6 items 18, 19, 20 and 21) reconditioning process, it can be re−installed in the ex- were loosened or removed, tighten fasteners that se- haust system. Contact your Toro Distributor for informa- cure stiffeners before tightening fasteners that se- tion on reconditioning the DPF.
Page 35: Fuel System
Fuel System Thread Sealant To Engine Return From Engine RIGHT FRONT Thread Sealant Figure 8 1. Fuel suction tube 10. Cap screw (2) 19. Fuel/water separator 2. Fuel line clamp (2) 11. Clamp (2) 20. Filter element 3. Fuel hose (tank to pump) 12.
Page 36: Check Fuel Lines And Connections
Fuel Tank Removal (Fig. 8) DANGER 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. Because diesel fuel is highly flammable, use cau- tion when storing or handling it. Do not smoke 2.
Page 37 Radiator/Hydraulic Oil Cooler RIGHT FRONT Figure 9 1. Radiator 16. Plenum seal 31. Hose clamp 2. Fan assembly 17. Flange head screw (8) 32. Hose (reservoir overflow) 3. Upper radiator shroud 18. Flange nut (8) 33. Flange head screw (4) 4.
Page 38 Removal (Fig. 9) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove hood from the machine (see Hood Removal in Chapter 8 − Chassis in this manual). 3.
Page 39 Installation (Fig. 9) 1. If hydraulic fittings were removed from oil cooler, lu- bricate and place new O−rings onto fittings. Install fit- tings into oil cooler openings using marks made during the removal process to properly orientate fittings (Fig. 11). Tighten fittings (see Hydraulic Fitting Installa- tion in Chapter 5 −...
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Page 41: Engine
Engine RIGHT FRONT Rear Lift Front Lift Tab Figure 13 1. Mount bracket − left front 9. Flange nut (12) 17. Fuel hose (engine to tank) 2. Mount bracket − right front 10. Rebound washer (4) 18. Clamp (2) 3. Mount bracket − left rear 11.
Page 42: Engine Removal
Engine Removal (Fig. 13) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove hood from the machine (see Hood Removal in Chapter 8 − Chassis in this manual). 3.
Page 43: Engine Installation
13.Disconnect fuel supply and return hoses from injec- CAUTION tion pump (item 16 and 17). Cap fuel hoses and injector pump fittings to prevent contamination. IMPORTANT: The hydraulic pump assembly can re- One person should operate lift or hoist while a main in machine during engine removal.
Page 44 9. Using notes taken during engine removal, secure wires with cable ties in proper locations. 10.Install engine cooling fan assembly and fan shrouds to machine (see Engine Cooling Fan Motor in Chapter 5 − Hydraulic System in this manual). 11. Install air cleaner assembly to the engine (see Air Cleaner Installation in this chapter).
Page 45: Pump Adapter Plate
Pump Adapter Plate Loctite #242 (if reused) 17 to 21 ft−lb (23 to 28 N−m) RIGHT Boss FRONT Loctite #242 (if reused) Figure 16 1. Flywheel plate 4. Cap screw with patch lock (8) 6. Hardened washer (8) 2. Hardened washer (8) 5.
Page 46 Coupler Removal (Fig. 16) NOTE: The hydraulic pump assembly needs to be re- moved from engine before coupler can be removed. Engine Side Hydraulic Pump Side 1. If engine is in machine, remove hydraulic pump as- sembly (see Piston (Traction) Pump in Chapter 5 − Hy- draulic System in this manual).
Page 47: Kubota Workshop Manual, Diesel Engine, 03--M--Di--E3B Series
Chapter 4 Kubota Diesel Engine MODEL 03781 Table of Contents SPECIFICATIONS ......GENERAL INFORMATION .
Page 48: Specifications
Specifications Item Description Make / Designation Kubota Model V2403−M−DI−E3B 4−Cycle, 4 Cylinder, Liquid Cooled, Diesel Engine Bore 3.425” (87.0 mm) Stroke 4.031” (102.4 mm) Total Displacement 148.5 in (2434 cc) Firing Order 1 (closest to gear case end) − 3 − 4 (closest to flywheel end) − 2 Combustion Chamber Spherical Type (E−TVCS) Compression Ratio...
Page 49: General Information
Kubota Workshop Manual, Diesel En- Service and repair parts for Kubota engines are sup- gine, 03−M−DI−E3B. plied through your Authorized Toro Distributor. If no parts list is available, be prepared to provide your distrib- Most repairs and adjustments require tools which are utor with the Toro model and serial number.
Page 50: Service And Repairs
Service and Repairs Air Filter System RIGHT FRONT 12 to 15 in−lb (1.4 to 1.6 N−m) Vacuator Direction Figure 1 1. Battery support 8. Air cleaner strap 14. Flat washer (2) 15. Flange nut (2) 2. Bracket 9. Cap screw (2) 3.
Page 51 Removal (Fig. 1) 1. Park machine on a level surface, lower cutting units, stop engine, apply parking brake and remove key from the ignition switch. 2. Raise and support hood. 3. Remove air cleaner components as needed. Installation (Fig. 1) IMPORTANT: Any leaks in the air filter system will cause serious engine damage.
Page 52: Exhaust System
Exhaust System RIGHT FRONT Figure 4 1. Muffler 6. RH engine mount 11. Engine 2. Flange head screw (2) 7. Flat washer 12. Muffler bracket 3. Flange head screw (4) 8. Cap screw 13. Flange nut (2) 4. Muffler clamp 9.
Page 53 Removal (Fig. 4) Installation (Fig. 4) IMPORTANT: If exhaust studs were removed from CAUTION engine cylinder head, thoroughly clean threads in head and apply Loctite #277 (or equivalent) to stud threads before installing studs into head. The muffler and exhaust pipe may be hot. T avoid possible burns, allow the engine and ex- NOTE: Make sure muffler flange and exhaust manifold haust system to cool before working on the muf-...
Page 54: Fuel System
Fuel System Thread Thread Sealant Sealant To Engine Return From Engine RIGHT FRONT Thread Sealant Figure 5 1. Fuel suction tube 11. Clamp (2) 20. Fuel filter/water separator 2. Fuel line clamp (2) 12. Flange nut (2) 21. Filter element 13.
Page 55: Check Fuel Lines And Connections
Fuel Tank Removal (Fig. 5) DANGER 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. Because diesel fuel is flammable, use caution when storing or handling it. Do not smoke while 2.
Page 56: Prime Fuel System
Prime Fuel System 1. Park machine on a level surface, lower cutting units, stop engine, and engage parking brake. Make sure fuel tank is at least half full. 2. Release hood latch and open hood. DANGER Under certain conditions, diesel fuel and fuel va- pors are highly flammable and explosive.
Page 57: Bleed Air From Injectors
Bleed Air From Injectors IMPORTANT: This procedure should be used only if the fuel system has been purged of air through nor- mal priming procedures (see Priming Fuel System in this chapter) and engine will not start. 1. Park machine on a level surface, lower cutting units, stop engine, and engage parking brake.
Page 58: Radiator/Hydraulic Oil Cooler
Radiator/Hydraulic Oil Cooler RIGHT FRONT Figure 9 1. Radiator 16. Plenum seal 31. Hose clamp 2. Fan assembly 17. Flange head screw (8) 32. Hose (reservoir overflow) 3. Upper radiator shroud 18. Flange nut (8) 33. Flange head screw (4) 34.
Page 59 Removal (Fig. 9) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove hood from the machine (see Hood Removal in Chapter 8 − Chassis in this manual). 3.
Page 60 Installation (Fig. 9) 1. If hydraulic fittings were removed from oil cooler, lu- bricate and place new O−rings onto fittings. Install fit- tings into oil cooler openings using marks made during the removal process to properly orientate fittings (Fig. 11). Tighten fittings (see Hydraulic Fitting Installa- tion in Chapter 5 −...
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Page 62: Engine
Engine Rear Lift RIGHT FRONT Figure 13 1. Engine 10. Cap screw (4) 18. Rubber engine mount (4) 2. Mount bracket − left rear 11. Mount bracket − right front 19. Flange nut (8) 3. Cap screw (5) 12. Muffler bracket 20.
Page 63: Engine Removal
Engine Removal (Fig. 13) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove hood from the machine (see Hood Removal in Chapter 8 − Chassis in this manual). 3.
Page 64: Engine Installation
14.Disconnect fuel supply and return hose from injec- tion pump (Fig. 15). Cap fuel hoses and injector pump fittings to prevent contamination. 15.Remove throttle cable from engine (Fig. 15): A. Remove lock nut that secures throttle cable swiv- el to speed control lever. B.
Page 65 7. Connect throttle cable to engine (Fig. 16): A. Secure throttle cable swivel to speed control le- ver with lock nut. B. Place throttle cable under cable clamp. C. Adjust throttle cable position in cable clamp so that engine governor lever contacts the high speed stop bolt at the same time that the throttle lever con- tacts the end of the slot in the control console.
Page 66 16.Connect air cleaner intake hose to air cleaner. 22.Check and adjust engine oil level as needed. 17.Secure coolant reservoir bracket with reservoir to 23.Check and adjust hydraulic oil level as needed. machine frame (Fig. 17). 24.Prime the fuel system (see Priming The Fuel System 18.Connect coolant reservoir hose to the radiator in this chapter).
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Page 68: Pump Adapter Plate
Pump Adapter Plate RIGHT FRONT Loctite #242 (if reused) 29 to 33 ft−lb (40 to 44 N−m) Boss Loctite #242 (if reused) Figure 18 1. Bolt 4. Hardened washer (14) 6. Cap screw with patch lock (6) 2. Lock washer 5.
Page 69 Coupler Removal (Fig. 18) NOTE: The hydraulic pump assembly needs to be re- Engine Side Hydraulic moved from engine before coupler can be removed. Pump Side 1. If engine is in machine, remove hydraulic pump as- sembly (see Piston (Traction) Pump Removal in Chap- ter 5 −...
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Page 71 Chapter 5 Hydraulic System Table of Contents SPECIFICATIONS ......SERVICE AND REPAIRS ..... GENERAL INFORMATION .
Page 72: Specifications
Specifications Item Description Piston (Traction) Pump Eaton servo controlled variable displacement piston pump (Model 72400) Maximum Displacement (per revolution) 3.00 in (49.2 cc) System Relief Pressure: Forward 5000 PSI (345 bar) System Relief Pressure: Reverse 5000 PSI (345 bar) Charge Pressure 207 PSI (14.3 bar) Front Wheel Motors Danfoss 2−Position Axial Piston Motors...
Page 73: General Information
General Information Operator’s Manual The Operator’s Manuals provide information regarding the operation, general maintenance and maintenance intervals for your Reelmaster machine. Refer to both the Traction Unit Operator’s Manual and the Cutting Unit Operator’s Manual for additional information when ser- vicing the machine.
Page 74: Relieving Hydraulic System Pressure
Toro high flow hydraulic filter (see Special Tools in this chap- The alternative to using the Toro high flow hydraulic filter ter) into the circuit. This filter should be used when con- kit after a traction circuit component failure would be to...
Page 75: Towing Traction Unit
3 mph (4.8 kph) or a distance of ¼ mile (0.4 km) when 1. Bypass valve location pushing or towing the machine in reverse. The following Toro parts are needed to bypass the check valve: 59−7410 diagnostic fitting 354−79 diagnostic fitting cap 95−8843 hydraulic hose...
Page 76: Hydraulic Hoses
Tube Installation in this section). If the hose has an el- bow at one end, tighten the swivel nut on that end before tightening the nut on the straight end of the hose. For additional hydraulic hose information, refer to Toro Service Training Book, Hydraulic Hose Servicing (Part Number 94813SL).
Page 77: Hydraulic Hose And Tube Installation
Hydraulic Hose and Tube Installation (O−Ring Face Seal Fitting) 1. Make sure threads and sealing surfaces of the hose/ C. Use a second wrench to tighten the nut to the cor- tube and the fitting are free of burrs, nicks, scratches or rect Flats From Wrench Resistance (F.F.W.R.).
Page 78: Hydraulic Fitting Installation
Hydraulic Fitting Installation (SAE Straight Thread O−Ring Fitting into Component Port) Non−Adjustable Fitting (Fig. 7) 5. If a torque wrench is not available, or if space at the port prevents use of a torque wrench, an alternate meth- 1. Make sure all threads and sealing surfaces of fitting od of assembly is the Flats From Finger Tight (F.F.F.T.) and component port are free of burrs, nicks, scratches method.
Page 79 Adjustable Fitting (Fig. 9) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 2. As a preventative measure against leakage, it is rec- ommended that the O−ring be replaced any time the connection is opened.
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Page 81: Hydraulic Schematic
Hydraulic Schematic Reelmaster 7000- D Page 5 - 11 Hydraulic System...
Page 82: Hydraulic Flow Diagrams
Hydraulic Flow Diagrams Hydraulic System Page 5 − 12 Reelmaster 7000−D...
Page 83: Traction Circuit: Low Speed (Mow)
Traction Circuit: LOW Speed (Mow) The traction circuit piston pump is a variable displace- Forward Direction ment pump that is directly coupled to the engine fly- With the mow speed limiter in the LOW speed (mow) wheel. Pushing the traction pedal engages a hydraulic position, the solenoid valve in the Hi/Low range manifold servo valve which controls the variable displacement is not energized.
Page 84 Hydraulic System Page 5 − 14 Reelmaster 7000−D...
Page 85: Traction Circuit: High Speed (Transport)
Traction Circuit: HI Speed (Transport) The traction circuit piston pump is a variable displace- Forward Direction ment pump that is directly coupled to the engine fly- With the mow speed limiter in the HI speed (transport) wheel. Pushing the traction pedal engages a hydraulic position, the solenoid valve in the Hi/Low range manifold servo valve which controls the variable displacement is energized.
Page 86 Hydraulic System Page 5 − 16 Reelmaster 7000−D...
Page 87: Mow Circuit
The Toro Electronic Controller (TEC) uses inputs from various machine switches to determine when solenoid proportional valve (SP1 and SP2) are to be energized.
Page 88 Hydraulic System Page 5 − 18 Reelmaster 7000−D...
Page 89: Steering Circuit
Steering Circuit A four section gear pump is coupled to the piston (trac- oil flow to the cylinder is proportional to the amount the tion) pump. The gear pump section P4 supplies hydrau- steering wheel is turned. Fluid leaving the cylinder flows lic flow to the steering control valve and the lift control back through the spool valve, out the T port, and returns manifold.
Page 90 Hydraulic System Page 5 − 20 Reelmaster 7000−D...
Page 91: Lower Cutting Units
(5) cutting units (Fig. 13). The joystick acts as an input to the Toro Elec- When the joystick is released, solenoid valves S1, S3, tronic Controller (TEC) which sends electrical outputs to S4 and S5 are de−energized and the lift cylinders and...
Page 92 Hydraulic System Page 5 − 22 Reelmaster 7000−D...
Page 93: Raise Cutting Units
A joystick (lower mow/raise control lever) on the console MODEL 03780 SHOWN arm is used to raise and lower the five (5) cutting units (Fig. 15). The joystick acts as an input to the Toro Elec- Figure 15 tronic Controller (TEC) which sends electrical outputs to 1.
Page 94 Hydraulic System Page 5 − 24 Reelmaster 7000−D...
Page 95: Engine Cooling Fan Circuit
The fan control Fan Operation (reverse/push) (Fig. 17) manifold controls the speed and direction of the fan mo- tor based on electrical output from the Toro Electronic The TEC can reverse the cooling fan to push air from in- Controller (TEC).
Page 96: Special Tools
Special Tools Order the following special tools from your Toro Distributor. Hydraulic Pressure Test Kit Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings.
Page 97 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 Figure 20 NOTE: This tester does not include hydraulic hoses (see Hydraulic Hose Kit TOR6007 below).
Page 98 Toro Part Number: TOR6011 NOTE: This kit does not include hydraulic hoses (see Hydraulic Hose Kit TOR6007 above). NOTE: Replacement filter element is Toro part number TOR6012. Filter element cannister tightening torque is 25 ft−lb (34 N−m). Hydraulic Test Fitting Kit This kit includes a variety of O−ring Face Seal fittings to...
Page 99 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 hydraulic connec- tion is loosened. Toro Part Number: 117- 2727 Figure 26 Reelmaster 7000- D Page 5 - 29...
Page 100 Figure 27 A remote stater switch can also be constructed using Toro switch #106−2027, a length of 14 gauge wire, a 20 amp in−line fuse, two (2) alligator clips and necessary MACHINE connectors. Connecting the wire to switch terminals 1...
Page 101: Troubleshooting
Troubleshooting The charts that follow contain information to assist in hy- Refer to the Testing section of this Chapter for precau- draulic system troubleshooting. There may possibly be tions and specific testing procedures. more than one cause for a machine malfunction. General Hydraulic System Problems Á...
Page 102 Traction Circuit Problems When troubleshooting traction circuit problems, if a speed (mow) but not in HI speed (transport), consider a problem exists in both low (mow) and high (transport) problem that only exists in mow (e.g. swashplate com- speeds, consider a faulty component that affects the en- ponents in front wheel or rear axle motor, solenoid valve tire traction circuit (e.g.
Page 103 Mow Circuit Problems Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á...
Page 104 Mow Circuit Problems (Continued) Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á...
Page 105 Lift/Lower Circuit Problems Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á...
Page 106 Engine Cooling Fan Circuit Problems Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á...
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Page 108: Testing
Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment CAUTION such as pressure gauges and flow meters in the circuits during various operational checks (See the Special Tools section in this chapter). All testing should be performed by two (2) people.
Page 109 Gear Pump (P4): 100 engine RPM = 0.24 GPM or Which Hydraulic Test Are Necessary? 31 oz. (917 cc) of hydraulic fluid displaced per Before beginning any hydraulic test, identify if the prob- minute lem is related to the traction circuit, mow circuit, lift/lower Gear Pump (P4): 100 engine RPM = 0.24 GPM or circuit, steering circuit or engine cooling fan circuit.
Page 110: Traction Circuit Charge Pressure Test
Traction Circuit − Charge Pressure Test Hydraulic System Page 5 − 40 Reelmaster 7000−D...
Page 111 Traction Circuit − Charge Pressure Test The charge pressure test is one of the tests recommen- LEFT ded to determine traction circuit performance. A charge pressure drop of more than 20% indicates an internal FRONT leak in the piston (traction) pump. Continued unit opera- tion can generate excessive heat, cause damage to seals and other components in the hydraulic system, and affect overall machine performance.
Page 112 10.Record reading on pressure gauge. Charge pres- 12.Remove pressure gauge and tee fitting when testing sure (under load) should not drop more than 20% when is completed. Install charge circuit hose and check for compared to charge pressure (without load) recorded in leaks.
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Page 114 Traction Circuit − Relief Pressure Test Hydraulic System Page 5 − 44 Reelmaster 7000−D...
Page 115 Traction Circuit − Relief Pressure Test Special Equipment Required: S Pressure Gauge − 10,000 PSI (700 bar) with hose S Phototach (non−contact tachometer) for units with Kubota diesel engine CAUTION FRONT RIGHT Prevent personal injury and/or damage to equip- ment. Read all WARNINGS, CAUTIONS and Pre- cautions for Hydraulic Testing at the beginning Figure 31 of this section.
Page 116 Traction Circuit − Piston (traction) Pump Flow Test TESTER Hydraulic System Page 5 − 46 Reelmaster 7000−D...
Page 117 Traction Circuit − Piston (traction) Pump Flow Test This test compares fluid flow at No Load with fluid flow LEFT Under Load. A drop in flow under load of more than 12% FRONT indicates an internal leak or malfunctioning relief valve in the piston (traction) pump.
Page 118 11. Verify pump flow at No Load as follows: 14.The Under Load test flow reading (step 12.) should not drop more than 12% when compared to the No A. Slowly depress forward traction pedal to full for- Load test flow reading (step 11.). A difference of more ward position.
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Page 120 Traction Circuit - Front Wheel Motor Case Drain Leakage Test Hydraulic System Page 5 - 50 Reelmaster 7000- D...
Page 121: Leakage Test
Traction Circuit − Front Wheel Motor Case Drain Leakage Test Front wheel motor efficiency is one of tests recommen- ded to determine traction circuit performance. Over a period of time, a wheel motor can wear internally. A worn motor will bypass oil to its case drain causing the motor to be less efficient.
Page 122 12.Release the parking brake and apply both left and right brakes. Slowly move the traction pedal in the FOR- WARD direction until the pressure gauge reaches sys- tem relief pressure (approximately 2500- 3000 psi (172- 206 bar)). NOTE: Use a graduated container (special tool TOR4077) to measure case drain leakage.
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Page 124 Traction Circuit − Reverse Reducing Valve (PR) Pressure Test Hydraulic System Page 5 − 54 Reelmaster 7000−D...
Page 125: Pressure Test
Traction Circuit − Reverse Reducing Valve (PR) Pressure Test When in reverse, pressure reducing valve (PR) located in the rear traction manifold limits the pressure to the rear axle motor to 450 PSI (31 bar) so the rear wheels will not scuff the turf. Check the pressure reducing valve (PR) pressure if the rear wheels are scuffing the turn in reverse (setting too high) of if poor traction performance when in reverse is suspect (setting too low or too close...
Page 126 Traction Circuit − Rear Relief Valve (RV) Pressure Test Hydraulic System Page 5 − 56 Reelmaster 7000−D...
Page 127 Traction Circuit − Rear Relief Valve (RV) Pressure Test The adjustable rear relief valve (RV) in the rear traction manifold reduces rear axle motor pressure created in down hill, dynamic braking conditions to prevent rear wheel lock up. Check the rear relief valve (RV) pressure if the rear wheels lock up during dynamic braking condi- tions (setting too high) or if poor traction performance when in reverse is suspect (setting too low or too close...
Page 128: Cutting Unit Circuit Pressure Test
Cutting Unit Circuit − Pressure Test TO RESERVOIR REEL MOTORS 1.6 CID 1.6 CID 1.6 CID 1.6 CID 1.6 CID 1450 psi 1450 psi 1450 psi 1450 psi 1450 psi FRONT REAR MOW CONTROL MANIFOLD .040 .040 110 psi 110 psi PRESSURE PRESSURE GAUGE...
Page 129 Cutting Unit Circuit − Pressure Test Cutting unit circuit pressure is the first in a series of tests recommended to check cutting unit circuit performance. The results from this test will help determine which com- ponent(s) are the cause of cutting unit performance is- sues.
Page 130 12.If pressure specifications are not met, consider the following: A. Proportional valve or valve coil SP1 (front cutting units) or SP2 (rear cutting units) is faulty (see Control Manifold Cartridge Valve Service in this chapter, or Hydraulic Solenoid Valve Coils in Chapter 6 − Electri- cal System in this manual).
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Page 132 Cutting Unit Circuit − Relief Pressure Test TO RESERVOIR REEL MOTORS 1.6 CID 1.6 CID 1.6 CID 1.6 CID 1.6 CID 1450 psi 1450 psi 1450 psi 1450 psi 1450 psi FRONT CUTTING UNIT CURCUIT REAR CUTTING UNIT CIRCUIT TESTER TESTER .040 .040...
Page 133 Cutting Unit Circuit − Relief Pressure Test Two relief valves are used in the Reelmaster 7000−D cutting unit circuit. Relief valve RV1 protects the front cutting unit circuit powered by gear pump section P2, and relief valve RV2 protects the rear cutting unit circuit powered by gear pump P3.
Page 134 11. If specification is not met, clean or adjust relief valve 12.After testing is complete, disconnect tester from cut- RV1 (front cutting units) or RV2 (rear cutting units) in the ting unit motor and hose. Connect hydraulic hose to mo- mow control manifold (see Adjust Control Manifold Re- tor.
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Page 136 Cutting Unit Circuit − Cutting Unit Motor Case Drain Leakage Test TO RESERVOIR REEL MOTORS TESTER 1.6 CID 1.6 CID 1.6 CID 1.6 CID 1.6 CID 1450 psi 1450 psi 1450 psi 1450 psi 1450 psi FRONT CUTTING UNIT CURCUIT REAR CUTTING UNIT CIRCUIT MEASURING CONTAINER...
Page 137: Leakage Test
Cutting Unit Circuit − Cutting Unit Motor Case Drain IMPORTANT: Make sure that the oil flow indicator Leakage Test on the tester matches the flow of oil (hydraulic mo- tor > tester > disconnected hose). The reel motor efficiency/case drain test is the second in a series of tests recommended to check cutting unit 2.
Page 138 12.While watching tester pressure gauge, slowly close 14.If case drain flow is more than 23 ounces (672 ml) flow control valve on tester until a pressure of 2000 PSI in fifteen (15) seconds, the reel motor is worn or dam- (138 bar) is obtained.
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Page 140: Steering/Lift Circuit Steering Relief Pressure Test
Steering/Lift Circuit − Steering Relief Pressure Test STEERING WHEEL TURNED STEERING CYLINDER FOR RIGHT TURN EXTEND TO TURN RIGHT PLUG STEERING UNIT PRESSURE GAUGE 1050 psi 50/50 SPLIT TO LIFT MANIFOLD TO CHARGE CIRCUIT TO RESERVOIR TO FAN CIRCUIT TO FRONT MOW CIRCUIT TO REAR MOW CIRCUIT GEAR PUMP...
Page 141 Steering/Lift Circuit − Steering Relief Pressure Test Unit steering performance will be affected by incorrect rear tire pressure, binding in the hydraulic steering cylin- der, extra weight on the vehicle, and/or binding of the steering fork assembly. Make sure that these conditions are checked and functioning properly before proceeding with any steering system hydraulic testing.
Page 142: Steering Cylinder Test
Steering/Lift Circuit − Steering Cylinder Test STEERING CYLINDER OPEN FITTING PLUG POWER STEERING VALVE 1000 PSI FROM FLOW DIVIDER (FD) RESERVOIR LIFT CONTROL IN FAN CONTROL MANIFOLD MANIFOLD (P) PORT High Pressure Low Pressure Return or Suction Flow Hydraulic System Page 5 −...
Page 143 Steering/Lift Circuit − Steering Cylinder Test Unit steering performance will be affected by incorrect rear tire pressure, binding in the hydraulic steering cylin- der, extra weight on the vehicle, and/or binding of the steering fork assembly. Make sure that these conditions are checked and functioning properly before proceeding with any steering system hydraulic testing.
Page 144 Steering/Lift Circuit − Lift Relief Pressure Test TO RESERVOIR FROM STEERING CONTROL VALVE FROM FLOW DIVIDER PRESSURE GAUGE High Pressure Low Pressure Return or Suction Flow Hydraulic System Page 5 − 74 Reelmaster 7000−D...
Page 145 Steering/Lift Circuit− Lift Relief Pressure Test If all cutting unit lift arms perform poorly during both raise and lower operations, the lift circuit relief pressure test should be performed. If both steering and lift operations perform poorly, perform the flow test on gear pump sec- tion P4 (see Gear Pump Flow Test in this chapter).
Page 146: Cooling Fan Circuit Pressure Test
Cooling Fan Circuit − Pressure Test STEERING REEL CYLINDER MOTORS EXTEND STEERING TO TURN RIGHT 1.6 CID 1.6 CID 1.6 CID 1.6 CID 1.6 CID UNIT MOTOR 1450 psi 1450 psi 1450 psi 1450 psi 1450 psi FRONT REAR 0.51 CID 1050 psi 3.3 GPM TO CHARGE...
Page 147 Cooling Fan Circuit − Pressure Test The cooling fan circuit test should be performed to make sure that the engine cooling fan circuit has the correct system pressure, and therefore, fan speed. Special Equipment Required: S Pressure Gauge − 5000 PSI (350 bar) with hose S Phototach (non−contact tachometer) 1.
Page 148 Cooling Fan Circuit − Fan Motor Case Drain Leakage Test MOTOR 0.51 CID TESTER MEASURING CONTAINER Working Pressure 50/50 SPLIT Low Pressure (Charge) Return or Suction Flow FAN CONTROL MANIFOLD SHROUD FROM GEAR PUMP TO RESERVOIR SECTION P5 RETURN HOSE CASE DRAIN HOSE...
Page 149 Cooling Fan Circuit − Fan Motor Case Drain Leakage Test Over a period of time, the motor can wear internally. This test measures case drain volume while restricting flow across the motor ports. Case drain volume under load of more than 12% of total motor flow indicates the gears and wear plates in the motor have worn.
Page 150 TEST RESULTS: Case drain leakage should be less than 25 ounces (745 ml) of hydraulic fluid in fifteen CAUTION (15) seconds (0.8 GPM / 3 LPM). 14.If case drain flow is more than 25 ounces (745 ml) Cooling fan blades will rotate during the test pro- in fifteen (15) seconds, the fan motor is worn or dam- cedure.
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Page 152: Gear Pump Flow Test (Pump Sections P2 Thru P5)
Gear Pump Flow Test (pump sections P2 thru P5) CONTROL MANIFOLD PORT P1 TESTER FIRST GEAR PUMP SECTION P2 FLOW TEST SHOWN CONTROL MANIFOLD PORT P2 CHARGE CIRCUIT CONTROL MANIFOLD PORT P2 PISTON PUMP FROM CONTROL CONTROL MANIFOLD 0.036 in MANIFOLD PORT P1 FORWARD...
Page 153 Gear Pump Sections P2 thru P5 Flow Test A gear pump flow test should be performed to make sure a hydraulic circuit has adequate fluid flow. Four (4) gear pumps are used in the Reelmaster 7000−D to power the various hydraulic circuits (Fig. 45). Gear pump section P2 provides hydraulic flow for the front cutting units #1, #4, &...
Page 154 PUMP NO LOAD CIRCUIT CAUTION SECTION FLOW Front Cutting 12 GPM Units (45 LPM) Do not close tester valve fully when perform- Rear Cutting 12 GPM ing this test. In this test, the hydraulic tester is Units (45 LPM) positioned before the manifold relief valve. Steering/Lift/ 6 GPM Pump damage can occur if the fluid flow is fully...
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Page 156: Adjustments
Adjustments Control Manifold Relief Valve Adjustment Several of the hydraulic control manifolds on your Reel- master include adjustable relief valves. The following procedure can be used to adjust these relief valves. Re- fer to the Testing section of this chapter for information on testing relief pressure.
Page 157: Service And Repairs
Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Hydraulic Compo- After Repair or Replacement of Hydraulic Compo- nents nents 1. Before removing any parts from the hydraulic sys- 1. Check oil level in the hydraulic reservoir and add cor- tem, park machine on a level surface, engage parking rect oil if necessary.
Page 158: Check Hydraulic Lines And Hoses
Check Hydraulic Lines and Hoses IMPORTANT: Check hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, WARNING wear, loose fittings or deterioration. Make all neces- sary repairs before operating the machine. Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure.
Page 159: Flush Hydraulic System
Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time 5. Inspect and clean hydraulic reservoir (see Hydraulic there is a severe component failure or the system is Reservoir Inspection in the Service and Repair section). contaminated (oil appears milky, black or contains 6.
Page 160: Filtering Closed- Loop Traction Circuit
To effectively remove contamination 8. With engine running at high idle speed and traction from closed- loop traction circuit, use of the Toro high pedal moved to the forward direction, periodically apply flow hydraulic filter and hydraulic hose kits are recom- brakes to increase pressure in traction circuit.
Page 161: Charge Hydraulic System
Charge Hydraulic System NOTE: When initially starting the hydraulic system with 9. After the hydraulic system starts to show signs of fill, new or rebuilt components such as pumps, motors or lift actuate lift control switch until the lift cylinder rods move cylinders, it is important that the hydraulic system be in and out several times.
Page 162: Gear Pump
Gear Pump 77 to 93 ft- lb (105 to 126 N- m) 103 to 118 ft- lb (140 to 160 N- m) RIGHT FRONT Figure 50 1. Flat washer (2) 10. 90 hydraulic fitting 19. O- ring 2. Cap screw (2) 11.
Page 163 5. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this chapter. 6. Disconnect hydraulic lines from gear pump and put caps or plugs on open hydraulic lines and fittings. Label disconnected hydraulic lines for proper assembly (Fig.
Page 164: Gear Pump Service
Gear Pump Service 33 ft- lb (45 N- m) Figure 52 1. Dust seal 10. Seal (8) 19. Body (section P3) 2. Retaining ring 11. Idler gear 20. Body (section P4) 3. Flange washer 12. Drive shaft 21. Drive gear 4.
Page 165 IMPORTANT: Use caution when clamping gear 8. Clean all parts. Check all components for burrs, pump in a vise to avoid distorting any pump compo- scoring, nicks and other damage. nents. 9. Replace the entire pump assembly if parts are ex- 3.
Page 166: Piston (Traction) Pump
Piston (Traction) Pump 77 to 93 ft- lb (105 to 126 N- m) 103 to 118 ft- lb (140 to 160 N- m) RIGHT FRONT Figure 54 1. Flat washer (2) 10. 90 hydraulic fitting 19. O- ring 2. Cap screw (2) 11.
Page 167 5. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this chapter. 6. Put a drain pan below the pump assembly. Remove hydraulic hoses connected to piston and gear pumps. Put plugs or caps on disconnected hydraulic hoses and fittings to prevent contamination of the system (Fig.
Page 168: Piston (Traction) Pump Service
Piston (traction) Pump Service 4 to 6 ft- lb 40 to 48 in- lb (5 to 8 N- m) (4.5 to 5.4 N- m) 40 to 48 in- lb (4.5 to 5.4 N- m) 25 to 28 ft- lb 100 to 110 ft- lb (34 to 38 N- m) (136 to 149 N- m) 27 to 31 ft- lb...
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Page 170: Rear Traction Manifold
Rear Traction Manifold RIGHT FRONT Figure 58 1. Rear traction manifold 8. O- ring 15. Hydraulic tee fitting 2. Cap screw (2) 9. Hydraulic tube 16. O- ring 3. Flange nut (2) 10. O- ring (3) 17. Hydraulic hose 4. Lift circuit junction manifold 11.
Page 171 Removal (Fig. 58) Installation (Fig. 58) NOTE: The ports on the rear traction manifold are 1. If fittings were removed from manifold, lubricate and marked for easy identification of components. Refer to place new O- rings onto fittings. Install fittings into man- the Hydraulic Schematics in Chapter 10 - Foldout Draw- ifold ports using marks made during the removal pro- ings to identify the function of the hydraulic lines and car-...
Page 172: Rear Traction Manifold Service
Rear Traction Manifold Service 25 ft- lb 50 ft- lb (67 N- m) (34 N- m) 20 ft- lb (27 N- m) 35 ft- lb (47 N- m) 25 ft- lb (34 N- m) Figure 59 1. Rear traction manifold body 4.
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Page 174: Hi/Low Range Manifold
HI/LOW Range Manifold RIGHT FRONT Figure 60 1. HI/LOW range manifold 4. Lift circuit junction manifold 7. Hydraulic tube 2. Cap screw (2) 5. Hydraulic tube 8. Hydraulic tube 3. Flange nut (2) 6. O- ring (4) 9. Hydraulic tube NOTE: The ports on the HI/LOW range manifold are marked for easy identification of components.
Page 175 Removal (Fig. 60) 30 in- lb 1. Read the General Precautions for Removing and 25 ft- lb (3.4 N- m) (34 N- m) Installing Hydraulic System Components at the begin- ning of this chapter. 2. To prevent contamination of hydraulic system during manifold removal, thoroughly clean exterior of HI/LOW range control manifold.
Page 176: Front Wheel Motors
Front Wheel Motors 75 to 85 ft- lbs (101 to 115 N- m) RIGHT FRONT Figure 63 1. Wheel motor (2) 3. Flat washer (2 per motor) 5. Brake assembly (LH shown) 2. Cap screw (2 per motor) 4. O- ring 6.
Page 177 Installation (Fig. 63) LEFT WHEEL 1. If fittings were removed from wheel 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 (Figs. 64 and 65). Tighten fittings (see Hydraulic Fitting Installation in this chapter).
Page 178: Rear Axle Motor
Rear Axle Motor RIGHT FRONT Figure 66 1. Rear axle motor 7. O- ring 13. O- ring 2. O- ring 8. 90 hydraulic fitting 14. O- ring 3. Pinion gear 9. Cap screw (2) 15. 90 hydraulic fitting 4. External snap ring (2) 10.
Page 179 Removal (Fig. 66) Installation (Fig. 66) 1. Park machine on a level surface, lower cutting units, 1. If fittings were removed from axle motor, lubricate stop engine, engage parking brake and remove key and place new O- rings onto fittings. Install fittings into from the ignition switch.
Page 180 Front Wheel Motor and Rear Axle Motor Service Figure 67 1. Plug with O- ring 10. Dowel pin 18. Housing 2. Minimum angle stop 11. Bearing 19. Bearing 3. Bias spring 12. Gasket 20. Retaining ring 4. Servo piston 13. Valve plate 21.
Page 181 NOTE: The front wheel motors are identical (Fig. 67). REAR AXLE MOTOR FLUSHING VALVE The rear axle motor includes a flushing valve (Fig. 68) for cooling the closed loop traction circuit and therefore has some differences from the front motors. Use the same procedure to service of the front wheel motors and rear axle motor (see the Sauer- Danfoss K and L Frame Variable Motors Service Manual for additional informa-...
Page 182: Cutting Unit Motor
Cutting Unit Motor Figure 69 1. O- Ring 4. O- Ring 7. Hydraulic hose (inlet) 2. Elbow fitting 5. Straight fitting 8. Hydraulic hose (return) 3. O- Ring 6. O- Ring 9. Hydraulic hose (case drain) The hydraulic reel motors used on all cutting units are 4.
Page 183 7. Inspect reel insert splines for wear. Replace if neces- 7. Rotate the motor counter- clockwise until the motor sary (see Reel Assembly Removal and Installation in flanges are encircling the cap screws. Tighten two (2) Chapter 9 - DPA Cutting Units in this manual). cap screws to secure reel motor to cutting unit (Fig.
Page 184: Cutting Unit Motor Service
Cutting Unit Motor Service 33 ft- lb (45 N- m) 19 ft- lb (25 N- m) 19 ft- lb (25 N- m) Figure 71 1. Dust seal 7. Back- up gasket 13. O- ring 2. Retaining ring 8. Front wear plate 14.
Page 185 6. Carefully remove body. Lift body straight up to re- A. Bearing areas should not have excessive wear or move. Make sure the rear wear plate remains on the scoring. drive and idler gear shafts. Remove and discard O- B. Face of wear plates that are in contact with gears rings from the body.
Page 186 Assembly (Fig. 71) 7. Lubricate the idler gear shaft with clean hydraulic oil. Install idler gear shaft into the remaining position in the NOTE: When assembling the motor, check the marker front wear plate. Apply a light coating of clean hydraulic line on each part to make sure the parts are properly oil to gear faces.
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Page 188 Mow Control Manifold RIGHT FRONT Figure 75 1. Mow control manifold 4. Flange head screw (2) 7. Charge filter head 2. Flange head screw (4) 5. Lift manifold 8. Charge filter element 3. Fan control manifold 6. Flange head screw (2) 9.
Page 189 Removal (Fig. 75) 75 ft- lb 10 ft- lb 1. Park machine on a level surface, lower cutting units, (101 N- m) (13 N- m) 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- 20 ft- lb ning of this chapter.
Page 190: Mow Control Manifold Service
Mow Control Manifold Service 25 ft- lb (34 N- m) RIGHT FRONT 25 ft- lb (34 N- m) 20 ft- lb (27 N- m) 25 ft- lb (34 N- m) 25 ft- lb (34 N- m) 25 ft- lb (34 N- m) 60 in- lb (6.8 N- m) 25 ft- lb...
Page 191 Mow/Backlap Spool Service (Fig. 77) Manifold Plugs (Fig. 78) 1. To remove backlap spool (item 17) from mow control NOTE: The mow control manifold uses several zero manifold: leak plugs. These plugs have a tapered sealing surface on the plug head that is designed to resist vibration in- A.
Page 192: Steering Control Valve
Steering Control Valve RIGHT FRONT 20 to 26 ft- lb (28 to 35 N- m) Antiseize Lubricant 7 to 10 ft- lb (10 to 13 N- m) Antiseize Lubricant Figure 79 1. Steering wheel cover 6. Flange head screw (4) 11.
Page 193 CAUTION Before opening hydraulic system, operate all hy- draulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the Gen- eral Information section of this chapter. 8. Disconnect hydraulic lines from steering control valve.
Page 194: Steering Control Valve Service
Steering Control Valve Service 20 to 24 ft- lb (27 to 33 N- m) Figure 82 1. Relief valve assembly 9. Cross pin 16. Inner gearwheel 2. Dust seal ring 10. Sleeve 17. End cover 3. Steering valve housing 11. Spool 18.
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Page 196: Steering Cylinder
Steering Cylinder 100 to 125 ft- lb (136 to 169 N- m) RIGHT FRONT Figure 83 1. Steering cylinder 7. 90 hydraulic fitting 12. Axle washer 2. Ball joint 8. O- ring 13. Slotted hex nut 3. Ball joint 9. O- ring 14.
Page 197 Removal (Fig. 83) Installation (Fig. 83) 1. Park machine on a level surface, lower cutting units, 1. If fittings were removed from steering cylinder, lubri- stop engine, engage parking brake and remove key cate and place new O- rings onto fittings. Install fittings from the ignition switch.
Page 198: Steering Cylinder Service
Steering Cylinder Service 40 ft- lb (54 N- m) Loctite #271 Figure 84 1. Barrel 6. O- ring 11. Head 2. Lock nut 7. Piston 12. Retaining ring 3. Wear band 8. Buffer seal 13. Head seal 4. Square ring 9.
Page 199 Disassembly (Fig. 84) Assembly (Fig. 84) 1. Remove oil from steering cylinder into a drain pan by 1. Make sure all cylinder components are clean before slowly pumping the cylinder shaft. Plug both ports and assembly. clean the outside of the cylinder. 2.
Page 200: Engine Cooling Fan Motor
Engine Cooling Fan Motor RIGHT FRONT Figure 85 8. Flange nut (4) 14. Fan motor and bracket assembly 1. Plenum assembly 2. Flange nut (4) 9. Lower fan shroud 15. Flange head screw (6) 3. Flange head screw (4) 10. Flat washer (8) 16.
Page 201 Removal (Fig. 85) 1. Park machine on a level surface, lower cutting units, stop engine, apply parking brake and remove key from the ignition switch. RIGHT 2. Read the General Precautions for Removing and FRONT Installing Hydraulic System Components in this chapter. 3.
Page 202 Installation (Fig. 85) 5. Install upper fan shroud (Fig. 85): 1. If fittings were removed from fan motor, lubricate and A. Place support shim (item 5) on hydraulic tubes place new O- rings onto fittings. Install fittings into port connected to fan motor. openings.
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Page 204: Engine Cooling Fan Motor Service
Engine Cooling Fan Motor Service 33 ft- lb (45 N- m) Figure 87 1. Flange washer 7. Shaft seal 12. Idler gear 2. O- ring 8. Backup gasket 13. Cap screw (4) 3. Front flange 9. Pressure seal 14. Dowel (2) 4.
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Page 206: Fan Control Manifold
Fan Control Manifold RIGHT FRONT Figure 89 1. Mow control manifold 4. Flange head screw (2) 7. Charge filter head 2. Flange head screw (4) 5. Lift manifold 8. Charge filter element 3. Fan control manifold 6. Flange head screw (2) 9.
Page 207 Removal (Fig. 89) 4. Connect wire harness electrical connectors to the solenoid valves. 1. Park machine on a level surface, lower cutting units, stop engine, apply parking brake and remove key from 5. Lower and secure hood. the ignition switch. 6.
Page 208: Fan Control Manifold Service
Fan Control Manifold Service 50 ft- lb (68 N- m) 60 in- lb (6.8 N- m) 60 in- lb (6.8 N- m) 25 ft- lb 25 ft- lb (34 N- m) (34 N- m) 25 ft- lb (34 N- m) 25 ft- lb (34 N- m) 25 ft- lb...
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Page 210: Lift Manifold
Lift Manifold RIGHT FRONT Figure 92 1. Mow control manifold 4. Flange head screw (2) 7. Charge filter head 2. Flange head screw (4) 5. Lift manifold 8. Charge filter element 3. Fan control manifold 6. Flange head screw (2) 9.
Page 211 Removal (Fig. 92) 1. If fittings were removed from lift junction manifold, lu- bricate and place new O- rings onto fittings. Install fit- 1. Park machine on a level surface, lower cutting units, tings into manifold openings making sure that orifice is stop engine, apply parking brake and remove key from correctly placed before threading fitting into manifold.
Page 212: Lift Manifold Service
Lift Manifold Service 60 in- lb 60 in- lb (6.8 N- m) (6.8 N- m) 20 ft- lb (27 N- m) 25 ft- lb (34 N- m) 60 in- lb (6.8 N- m) 20 ft- lb (27 N- m) 20 ft- lb (27 N- m) 20 ft- lb (27 N- m)
Page 213: Control Manifold Cartridge Valve Service
Control Manifold Cartridge Valve Service 1. Make sure the control manifold is clean before re- 6. Clean cartridge valve using clean mineral spirits. moving the cartridge valve from the control manifold. Submerge valve in clean mineral spirits to flush out con- tamination.
Page 214: Lift Junction Manifold
Lift Junction Manifold FRONT RIGHT Figure 95 1. Lift junction manifold 5. Socket plug (3) 9. 90 hydraulic fitting 2. Orifice - .030” (3) 6. O- ring (8) 10. O- ring (3) 3. Orifice - .046” (3) 7. Check valve (3) 11.
Page 215 Removal (Fig. 95) IMPORTANT: A flow control orifice is placed be- neath several of the hydraulic fittings on the lift 1. Park machine on a level surface, lower cutting units, junction manifold. If a fitting is removed from the lift stop engine, engage parking brake and remove key junction manifold and an orifice is in the manifold from the ignition switch.
Page 216: Front Lift Cylinders
Front Lift Cylinders RIGHT 16 17 FRONT Figure 96 1. Pivot yoke 11. Grease fitting (3) 20. Flange head screw (2) 2. Lynch pin 12. Pivot pin (3) 3. Lift arm (cutting unit #5) 13. Slotted roll pin (1 per pin) 4.
Page 217 Removal (Fig. 96) 1. Park machine on a level surface, lower cutting units, stop engine, engage 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 this chapter.
Page 218: Rear Lift Cylinders
Rear Lift Cylinders RIGHT FRONT Figure 98 10. Lynch pin (2) 19. Pivot pin (2) 1. Lift cylinder (cutting units #2 and #3) 2. Straight hydraulic fitting (2) 11. Flange nut (2) 20. Slotted roll pin (2) 3. 90 hydraulic fitting (2) 12.
Page 219 Removal (Fig. 98) 1. Park machine on a level surface, lower cutting units, stop engine, engage 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 this chapter.
Page 220: Lift Cylinder Service
Lift Cylinder Service 35 to 45 ft- lb (48 to 61 N- m) Loctite #271 11 12 Figure 100 1. Barrel 6. Piston 11. Back- up 2. Lock nut 7. Rod 12. Retaining ring 3. Wear ring 8. Head seal 13.
Page 221 Disassembly (Fig. 100) Assembly (Fig. 100) 1. Remove oil from lift cylinder into a drain pan by slowly 1. Make sure all lift cylinder parts are clean before as- pumping the cylinder shaft. Plug both ports and clean sembly. the outside of the cylinder. 2.
Page 222: Hydraulic Reservoir
Hydraulic Reservoir RIGHT FRONT 68 to 75 ft- lb (93 to 101 N- m) 25 to 29 ft- lb (34 to 39 N- m) 35 to 47 ft- lb (48 to 63 N- m) Figure 101 1. Hydraulic reservoir 8. Flange nut (3) 15.
Page 223 Removal (Fig. 101) Inspection 1. Park machine on a level surface, lower cutting units, 1. Clean hydraulic reservoir and suction strainer with stop engine, engage parking brake and remove key solvent. from the ignition switch. 2. Inspect reservoir for leaks, cracks or other damage. 2.
Page 224: Hydraulic Oil Cooler
Hydraulic Oil Cooler RIGHT FRONT Figure 102 1. Radiator 16. Plenum seal 31. Hose clamp 2. Fan assembly 17. Flange head screw (8) 32. Hose (reservoir overflow) 3. Upper radiator shroud 18. Flange nut (8) 33. Flange head screw (4) 4.
Page 225 NOTE: The hydraulic oil cooler on your Reelmaster 7000- D is combined with the radiator. See Radiator and Oil Cooler Assembly in Chapter 3 - Yanmar Diesel En- gine (Model 03780) or Chapter 4 - Kubota Diesel En- gine (Model 03781) in this manual for information on removal and installation of the radiator/oil cooler as- sembly.
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Page 227 ......Toro Electronic Controller (TEC) ... . .
Page 228: General Information
Diagnostic Dis- play (see Special Tools). Because of the solid state circuitry built into the Toro Electronic Controller (TEC), there is no method to test it directly. The TEC may be damaged if an attempt is...
Page 229: Engine Electronic Control Unit (Ecu) (Yanmar Diesel Engines Only)
1. Yanmar engine 2. Engine ECU CAN−bus Communications The Toro Electronic Controller (TEC) used on the Reel- Each of the components that is controlled by the CAN− master 7000−D can communicate with other electrical bus link only needs four (4) wires to operate and commu- components (engine ECU and InfoCenter display) on a nicate to the system: CAN−high, CAN−low, B+ (power)
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Page 231: Electrical Drawings
Electrical Drawings The electrical schematics and other electrical drawings for the Reelmaster 7000−D are located in Chapter 10 − Foldout Drawings. Reelmaster 7000−D Page 6 − 5 Electrical System...
Page 232: Special Tools
The multimeter can test electrical components and cir- cuits for current (amps), resistance (ohms) or voltage. Obtain this tool locally. NOTE: Toro recommends the use of a DIGITAL Volt− Ohm−Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital me- ter in the voltage mode will make sure that excess cur- rent is not allowed through the meter.
Page 233 Apply battery terminal protector to the con- nection after the battery cable, ring terminal, or fork ter- minal has been secured. Toro Part Number: 107−0392 Figure 5 Reelmaster 7000−D Page 6 − 7...
Page 234: Infocenter Display
(Fig. 7). A CAN−bus system provides communication necessary for machine operation between the Toro Electronic Con- troller (TEC), the engine ECU (on machines with Yan- mar diesel engines), and the InfoCenter.
Page 235 IGNITION SWITCHED FAULTS SCREEN MAIN MENU SCREEN SPLASH SCREEN CODE DETAIL SERVICE SCREEN Hours Key On Hours Engine Run Hours Cutting Units Hours HIGH Range Hours Service Due Hours AFTER Service Reset* Hours Counts SECONDS Starts Count Cutting Units Count Traction Control Count DPF Regen*...
Page 236: Splash Screen
Splash Screen When the ignition switch is turned from the OFF position to the ON/PREHEAT or START position, the fault indica- SPLASH SCREEN tor illuminates for a few seconds to verify indicator oper- ation and the InfoCenter splash screen appears (Fig. 8). The splash screen provides the following information to the operator: Voltmeter...
Page 237: Main Information Screen
Main Information Screen The InfoCenter main information screen is displayed MAIN INFORMATION SCREEN about 10 seconds after the ignition switch has been turned from the OFF position to the ON/PREHEAT or START position (Fig. 9). The main information screen is the “default”...
Page 238: Operator's Advisory Screen
Operator Advisory Screen If one or more Toro Electronic Controller (TEC) inputs OPERATOR ADVISORY SCREEN are not in the correct position to allow certain machine operations, or are malfunctioning, the fault indicator will illuminate and an advisory screen will appear on the InfoCenter Display (Fig.
Page 239: Faults Screen
(ECU) and can only be viewed using the engine See Service Manual diagnostic tool. Engine faults are not stored in the Toro Electronic Controller (TEC) so engine fault history can- not be viewed using the InfoCenter faults screen.
Page 240: Service Screen
Service Screen The service screen (Fig. 15) contains machine opera- SERVICE SCREEN tional information including hours and counts. If the cor- rect passcode (PIN) has been entered (see Settings Screen − Protected Menus in this chapter) the service Hours screen allows access to initiate a manual DPF regener- 161.6 Hours ation, provides information on DPF ash accumulation,...
Page 241: Diagnostics Screen
Diagnostics Screen The diagnostics screen (Fig. 16) lists a variety of ma- Inputs Qualifiers Outputs chine operations and the current state of the Toro Elec- Reel Enable/Disable Low Range Front Reel tronic Controller (TEC) inputs, the qualifiers and the Switch Engage outputs required to allow the operation to proceed.
Page 242 Backlap Identifies the requirements necessary to allow the TEC to engage the cutting units in the reverse direc- tion for backlapping cutting units. Inputs Qualifiers Outputs Front Backlap In Seat or Front Reel Engage (solenoid SP1) Rear Backlap Parking Brake Rear Reel Engage (solenoid SP2)
Page 243: Settings Screen
Settings Screen The settings screen (Fig 17) allows the operator or tech- SETTINGS SCREEN nician to customize the InfoCenter display, modify a vari- ety of machine functions, and provides access to unlock various protected menus and settings. To scroll through the list of functions, view its current setting, and select Settings Units:...
Page 244 PIN has been changed and is forgotten, a temporary #176 (Reel Speed Changed) will appear on the Info- PIN can be obtained from your Toro distributor. Center display to confirm that the change has been recorded. The following settings will only be visible if Protect Set- tings is set to ON and the correct passcode (PIN) has SETTINGS SCREEN (F &...
Page 245: About Screen
The information found in the about screen can only be edited by your Toro Distributor. To return to the previous screen, press the Menu/Back button (as indicated by the at the bottom of the screen).
Page 246: Troubleshooting
If the machine has any interlock switches by−passed, reconnect the switches for proper safety and trouble- CAUTION shooting. Use the InfoCenter Display to test Toro Electronic Con- Remove all jewelry, especially rings and troller (TEC) inputs and outputs when troubleshooting watches, before doing any electrical trouble- an electrical problem on your Reelmaster 7000−D (see...
Page 247 Number/ Description Condition/Action Code Start Denied Wait to start until system functions have been initialized No operator in seat and parking brake is not engaged. Traction pedal is in FORWARD or REVERSE position Joystick is in RAISE position Joystick is in LOWER position Reel Enable/Disable switch is in ENGAGE position Engage Cutting Unit Denied No operator in seat...
Page 248: Using The Infocenter Display For Troubleshooting
Using the InfoCenter Display for Troubleshooting The diagnostics screen of the InfoCenter display can be DIAGNOSTICS SCREEN very helpful when troubleshooting machine operation is- sues (see Diagnostics Screen in this chapter). The diag- nostics screen (Fig. 22) lists a variety of machine Diagnostics operations and the current state of the inputs, the quali- Lift/Lower...
Page 249 ON. If the outputs remain OFF, the personal injury. Toro Electronic Controller (TEC) or TEC software may be damaged and require reloading or replacement. Contact your Toro Distributor for assistance. In the PTO operation example, the following qualifiers must be in the desired condition (þ) before any opera-...
Page 250: Fault Codes
The list below identifies the fault codes that are gener- Fault codes 26 through 56 identify problems with TEC ated by the Toro Electronic Controller (TEC) to identify or the outputs energized by the TEC (e.g. relays and so- an electrical system fault (malfunction) that occurred lenoids).
Page 251 Fault Fault Description Service Suggestions Code Engine speed switch (Yanmar diesel engines) is Test engine speed switch and circuit wiring faulty Alternator voltage is too low Check alternator drive belt Test engine alternator and circuit wiring Hydraulic temperature sender is faulty Test temperature sender and circuit wiring Engine coolant temperature sender is faulty Test temperature sender and circuit wiring...
Page 252: Starting Problems
Starting Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine elec- trical problems. Problem Possible Causes No electrical power to machine (including gauges). Battery is discharged. Battery cables are loose or corroded. Ground connection on machine is loose or corroded. Fuse F−D1 (2 amp) is faulty (open).
Page 253 Starting Problems (continued) Problem Possible Causes Engine starts, but stops when the ignition switch is Kubota Diesel Engine Only − The engine fuel stop released from the START position. solenoid or circuit wiring is faulty (solenoid pull coil operates but hold coil is faulty). Engine cranks, but does not start.
Page 254: General Run & Transport Problems
General Run and Transport Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine elec- trical problems. Problem Possible Causes Engine continues to run, but should not, when the Ignition switch or circuit wiring is faulty. ignition switch is turned to OFF.
Page 255: Cutting Unit Operating Problems
Cutting Unit Operating Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine elec- trical problems. Problem Possible Causes Cutting units run, but should not, when raised. Cutting The cutting unit position switch or circuit wiring is units shut off with the reel enable/disable switch.
Page 256: Cutting Unit Lift/Lower Problems
Cutting Unit Lift/Lower Problems NOTE: Check InfoCenter Display for possible operator NOTE: To lower the cutting units, the operator must be advisories or faults whenever diagnosing machine elec- in the operator seat and the speed limiter must be in the trical problems.
Page 257: Electrical System Quick Checks
Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the Voltage Measured Battery Charge Level battery terminals. 12.68 V (or higher) Fully charged (100%) Set multimeter to the DC volts setting. The battery 12.45 V 75% charged should be at a temperature of 60...
Page 258: Check Operation Of Interlock Switches
Replace any malfunctioning switches before op- NOTE: Use the InfoCenter Display (see InfoCenter erating the machine. Display in this chapter) to test Toro Electronic Controller inputs and outputs before further troubleshooting of an electrical problem on your Groundsmaster. Electrical System Page 6 −...
Page 259: Adjustments
(Fig. 26). When the speed limiter is moved to the HIGH (transport) position, a tab on the speed limiter swings in front of the switch, closing the switch. The HILOW switch provides an input for the Toro Electronic Controller (TEC) during various machine operation modes. Adjustment 1.
Page 260: Cutting Unit Position Switch
(Fig. 27). When a gusset on the front right cutting unit (#5) lift arm passes in front of the switch, the switch clos- es. The cutting unit position switch provides an input for the Toro Electronic Controller (TEC) during various ma- chine operation modes. Adjustment The gap between the cutting unit position switch and the lift arm gusset should be 0.063”...
Page 261: Component Testing
Component Testing For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the CAUTION circuit (e.g. unplug the ignition switch connector before checking continuity on the switch terminals). When testing electrical components for continu- NOTE: For engine component testing information, see ity with a multimeter (ohms setting), make sure the Yanmar Model 4TNV86CT−DTR Service Manual or that power to the circuit has been disconnected.
Page 262: Fuses
Fuses Your Reelmaster 7000−D uses numerous fuses for cir- Fuse F−D1 (2 amp) protects the logic power circuit for cuit protection. Most of the fuses reside in the power the TEC and the ignition switch. center behind the operator’s seat. An additional in−line Fuse F−D2 (2 amp) is not used on Reelmaster 7000−D fuse holder located in the wire harness near the battery machines.
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Page 264: Toro Electronic Controller (Tec)
Toro Electronic Controllers (TEC) Reelmaster 7000−D machines use a Toro Electronic Controller (TEC) to control electrical system operation. The controller contains a microcontroller that monitors the condition of various switches and senders (inputs). The controller then directs electrical power to control ap- propriate machine functions (outputs) based on the in- put conditions.
Page 265 CAN BUS programed for correct machine operation. If the TEC is replaced for any reason, system software needs to be reprogrammed by your Toro Distributor. Figure 33 IMPORTANT: Before performing welding on the ma- chine, disconnect both positive and negative bat-...
Page 266: Ignition Switch
Ignition Switch The ignition switch on the console arm has three (3) positions − OFF, ON and START (Fig. 34).The ignition switch is an input used by the Toro Electronic Controller (TEC) to manage various machine functions. Testing The ignition switch and its circuit wiring can be tested as a TEC input using the InfoCenter Display (see InfoCen- ter Display in this chapter).
Page 267: Reel Enable/Disable Switch
(switch light illuminated) and push down on the rear of the switch to disengage the cutting units. The reel en- able/disable switch is an input used by the Toro Elec- tronic Controller (TEC) to manage various machine functions.
Page 268: Engine Speed Switch
The current engine RPM will be displayed on the InfoCenter screen for five seconds when the en- gine speed switch is depressed. The engine speed switch is an input used by the Toro Electronic Controller (TEC) to manage various machine functions.
Page 269: Lower/Raise Joystick Switches
(Fig. 41). The switches are identi- cal. The Toro Electronic Controller (TEC) monitors the posi- tion of the normally open lower/raise switches. The low- er/raise joystick switches are inputs used by the TEC to manage various machine functions.
Page 270: Seat Switch
Testing of the switch can be done without seat removal by discon- necting the switch wire from the machine wire harness (Fig. 42). The seat switch is an input used by the Toro Electronic Controller (TEC) to manage various machine functions.
Page 271: Traction Neutral Switch
The switch is located on the right side of the piston (traction) pump (Fig. 43). The neutral switch is an input used by the Toro Electronic Controller (TEC) to manage various machine functions. Testing NOTE: Make sure that traction pedal is adjusted to the neutral position (see traction unit Operator’s Manual)
Page 272: Parking Brake Switch
The parking brake detent is moved away from the switch when the parking brake is applied causing the switch to open. The parking brake switch is an input used by the Toro Electronic Con- troller (TEC) to manage various machine functions. Testing...
Page 273: Hi/Low (Transport/Mow) Switch
The sensing plate for the HI/LOW (transport/mow) switch is the mow speed limiter. The HI/LOW (transport/mow) switch is an input used by the Toro Electronic Controller (TEC) to manage various machine functions. Testing...
Page 274: Cutting Unit Position Switch
The cutting unit position switch is an input used by the Toro Electronic Controller (TEC) to manage various machine functions. Testing...
Page 275: Backlap Switches
The backlap switches are attached to the hydraulic mow control man- ifold located under the hood (Fig. 48). The backlap switches are inputs used by the Toro Electronic Con- troller (TEC) to manage various machine functions. Testing...
Page 276: Hydraulic Oil Temperature Sender
Hydraulic Oil Temperature Sender A temperature sender is used as an input for the Toro Electronic Controller (TEC) to identify if the hydraulic oil temperature has reached an excessive level. The hy- draulic oil temperature sender is attached to the rear axle motor (Fig.
Page 277: Engine Temperature Sender
All Reelmaster 7000−D machines have an engine tem- perature sender. The sender is used as an input for the Toro Electronic Controller (TEC) to identify if the engine coolant temperature has reached an excessive level. For machines with Yanmar diesel engines, refer to the Yanmar Service Manual and the Yanmar Troubleshoot- ing Manual for sender testing information.
Page 278: Relays With Four (4) Terminals
Relays with Four (4) Terminals Your Reelmaster 7000−D uses a number of electrical re- lays that have four (4) terminals. A tag near the wire har- ness relay connector can be used to identify each relay. The main power relay is used to provide current to most of the fuse protected circuits (operator seat, InfoCenter display, engine electronic control unit (ECU), power point and optional electric equipment).
Page 279 5. Using a multimeter, verify that coil resistance be- tween terminals 86 and 85 is approximately 72 ohms KUBOTA DIESEL ENGINE (Fig. 57). 6. Connect multimeter (ohms setting) leads to relay ter- minals 30 and 87. Ground terminal 86 and apply +12 VDC to terminal 85.
Page 280: Relays With Five (5) Terminals
(5) terminal relay. The start relay is used to pro- vide current to the engine starter motor solenoid. The start relay is energized and monitored by the Toro Elec- tronic Controller (TEC). The start relay is located on the air cleaner mounting bracket (Fig.
Page 281 9. Disconnect voltage and test leads from the relay ter- 14.Connect positive (+) cable to battery and then con- minals. nect negative (−) cable to battery (see Battery Service in this chapter). 10.If testing determines that the relay is not functioning correctly, replace the relay.
Page 282: Hydraulic Solenoid Valve Coils
Numerous hydraulic solenoid valve coils are used on the hydraulic control manifolds of Reelmaster 7000−D machines. The solenoid valve coils are energized by the Toro Electronic Controller (TEC) to provide hydraulic cir- cuit control. Two (2) different solenoid valve coils are used on the Re- elmaster 7000−D.
Page 283: Fuel Pump (Yanmar Diesel Engine Only)
Reelmas- 2. Pump discharge hose 4. Fuel/water separator ter by using your Toro Parts Catalog. If incorrect pump is used, fuel system damage can occur Fuel Pump Specifications 8. Connect fuel pump discharge hose to fuel water sep- Pump Capacity 23.5 fl oz/min (700 ml/min)
Page 284: Fuel Pump (Kubota Diesel Engine Only)
64 fl oz/min (1.9 l/min) that replacement pump is the correct for your Reel- Pressure 7 PSI (48.3 kPa) master by using your Toro Parts Catalog. If incorrect pump is used, fuel system damage may occur. Current Draw 2.0 amp 8.
Page 285: Fuel Stop Solenoid
The solenoid is mounted to the injection pump on the en- gine (Fig. 64). The Toro Electronic Controller (TEC) monitors the op- eration of the fuel stop solenoid. The solenoid and its cir- cuit wiring should be tested as a controller output with...
Page 286: Can−Bus Termination Resistor
CAN−bus Termination Resistor System communication between electrical components on Reelmaster 7000−D machines is accomplished on a Termination CAN−bus communication system. Two (2) specially de- Resistor signed, twisted cables form the bus for the network used on the machine. These wires provide the data pathways between machine components.
Page 287: Diode Assembly
The resistor assemblies can be identified by their gray 1. Resistor assembly 2. End of resistor body color, resistor symbol and Toro part number on the end of the resistor assembly body. Testing The resistor can be tested using a digital multimeter (ohms setting).
Page 288: Worklight Switch
Worklight Switch The worklight switch is located on the operator side of the console arm (Fig. 69). This two (2) position rocker switch allows the worklights to be turned ON and OFF. Testing 1. Park machine on a level surface, lower cutting units, engage parking brake and stop engine.
Page 289: Service And Repairs
Service and Repairs NOTE: For engine component repair information, see the Yanmar Model 4TNV86CT−DTR Service Manual or Troubleshooting Manual, or the Kubota Model 03−M−DI−E3B Workshop Manual. Battery Storage If the machine will be stored for more than 30 days: 4. Store battery in a cool atmosphere to avoid quick de- terioration of the battery charge.
Page 290: Battery Service
Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can be prevented. CAUTION When working with batteries, use extreme cau- tion to avoid splashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes.
Page 291: Battery Testing
Battery Testing C. Make sure battery terminals are free of corrosion. 1. Conduct a hydrometer test of the battery electrolyte. D. Measure the temperature of the center battery cell. IMPORTANT: Make sure the area around the cells is clean before opening the battery caps. E.
Page 292: Battery Charging
Battery Charging CAUTION To minimize possible damage to the battery and allow the battery to be fully charged, the slow charging meth- od is presented here. This charging method can be ac- Do not charge a frozen battery because it can ex- complished with a constant current battery charger plode and cause injury.
Page 293: Hydraulic Solenoid Valve Coils
Hydraulic Solenoid Valve Coils A solenoid valve coil on a hydraulic control manifold can be replaced without opening the hydraulic system. Removal (Fig. 72) 1. Park machine on a level surface, lower cutting units, 60 in−lb stop engine and engage parking brake. Remove key (6.8 N−m) from ignition switch.
Page 294: Worklight Bulb Replacement
Worklight Bulb Replacement The worklights are adjustable left and right, and up and down as necessary. The worklights use a replaceable halogen bulb. CAUTION The worklights use a halogen bulb that becomes extremely hot when in operation. Handling a hot bulb can cause severe burns and personal injury.
Page 295 Chapter 7 Axles, Planetaries and Brakes Table of Contents SPECIFICATIONS ......GENERAL INFORMATION .
Page 296 Specifications Item Specification Wheel lug nut torque (front and rear) 85 to 100 ft−lb (116 to 135 N−m) Steering cylinder bolt torque 100 to 125 ft−lb (136 to 169 N−m) Planetary, Brake Assembly and Wheel Motor Mounting Screw Torque OPH−2 series planetary 60 ft−lb (81 N−m) VA02 series planetary 75 to 85 ft−lb (101 to 115 N−m)
Page 297: General Information
General Information Operator’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. Reelmaster 7000−D Page 7 − 3 Axles, Planetaries and Brakes...
Page 298: Adjustments
Adjustments Planetary Drive End Play (OPH−2 series planetary drives) A front planetary wheel drive assembly that is properly 3. Grasp front wheel and check for endplay in the plan- operating should have no endplay. Any endplay in a etary assembly as indicated by axial wheel movement. planetary assembly indicates that there are potential Make sure that there is no endplay in assembly.
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Page 300: Service And Repairs
Service and Repairs Brake Assembly OPH−2 series planetary = 60 ft−lbs (81 N−m) VA02 series planetary = 75 to 85 ft−lbs (101 to 115 N−m) Gasket OPH−2 series planetary = 60 ft−lbs (81 N−m) Sealer 85 to 100 ft−lb VA02 series planetary = 75 to 85 ft−lbs (101 to 115 N−m) (116 to 135 N−m) OPH−2 series planetary RIGHT...
Page 301 Brake Assembly Removal (Fig. 1) 1. Park machine on a level surface and raise cutting units to allow easier access to front brake assembly. Stop engine, engage parking brake and remove key from the ignition switch. 2. Drain oil from planetary drive and brake assembly; refer to traction unit Operator’s Manual.
Page 302 9. Check and adjust brake cables for proper brake op- 11. Check and adjust brake cables for proper brake op- eration (see machine Operator’s Manual). eration (see machine Operator’s Manual). 10.Remove jack stands and lower machine to ground. 12.Remove jack stands and lower machine to ground. Tighten wheel lug nuts in a crossing pattern from 85 to Tighten wheel lug nuts in a crossing pattern from 85 to 100 ft−lb (116 to 135 N−m).
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Page 304: Brake Inspection And Repair
Brake Inspection and Repair Gasket Sealant Figure 3 1. Brake housing (LH shown) 6. Hitch pin (2) 11. Rotating actuator 2. Seal 7. Stationary disc (4) 12. Extension spring (3) 3. Pull rod 8. Rotating disc (3) 13. Ball (3) 4.
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Page 306: Planetary Drive Assembly
Planetary Drive Assembly OPH−2 series planetary = 60 ft−lbs (81 N−m) VA02 series planetary = 75 to 85 ft−lbs (101 to 115 N−m) Gasket Sealer OPH−2 series planetary = 60 ft−lbs (81 N−m) 85 to 100 ft−lb VA02 series planetary = 75 to 85 ft−lbs (101 to 115 N−m) (116 to 135 N−m) OPH−2 series planetary RIGHT...
Page 307 Planetary Drive Removal (Fig. 4) Planetary Drive Installation (Fig. 4) 1. Park machine on a level surface, stop engine, en- 1. Position planetary assembly to machine making gage parking brake and remove key from the ignition sure to engage splined brake shaft with planetary drive switch.
Page 308: Oph−2 Planetary Drive Service
OPH−2 Planetary Drive Service 118 to 144 in−lb (13.3 to 16.3 N−m) OPH−2 series planetary Figure 5 1. Spindle 11. Outer bearing cup 20. End cap 2. Boot seal 12. Outer bearing cone 21. Thrust plug 3. Oil seal 13. O−ring 22.
Page 309 NOTE: The planetary wheel drive assembly can be ser- viced with the planetary installed to machine. If the spindle (item 1) needs to be removed from machine, see Planetary Wheel Drive Assembly in this section. Disassembly (Figs. 5 and 6) 1.
Page 310 C. Make sure that seal bore in housing is thoroughly L. Install new O−ring (item 13) into groove in hous- cleaned. If OD of seal (item 3) is not rubber or does ing. not have a sealant coating, apply light coating of sili- 4.
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Page 312 VA02 Series Planetary Drive Service High Strength Grease Thread Locking Compound 37 N−m (27 ft−lb) VA02 series planetary High Strength Thread Locking Compound G248465 Figure 7 1. Spindle 11. O−ring 20. O−Ring (2) 2. Boot seal 12. Spacer 21. End cap 3.
Page 313 NOTE: The planetary drive assembly is best serviced with the planetary installed to machine or the spindle firmly secured to a fixture or workbench. If the spindle (item 1) needs to be removed from machine, see Plane- tary Drive Assembly in this chapter. Disassembly 1.
Page 314 4. If previously removed, press bearing cups into hous- IMPORTANT: Continue to tighten the lock nut ing. Cups should be pressed fully to shoulder of the until it aligns with one of the locking washer tabs. housing bore. Do Not loosen the lock nut to align it with the locking washer tabs.
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Page 316: Rear Axle Assembly
Rear Axle Assembly 60 to 70 ft−lb (81 to 94 N−m) 85 to 100 ft−lb (116 to 135 N−m) RIGHT 85 to 100 ft−lb (116 to 135 N−m) FRONT Figure 9 1. Rear axle motor 15. 90 hydraulic fitting 29. Lug nut (5 per wheel) 2.
Page 317 Remove Rear Axle (Fig. 9) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Clean the area around the drain plugs and drain oil from rear axle assembly: A.
Page 318 Install Rear Axle (Fig. 9) RIGHT SIDE SHOWN 1. If removed, install steering cylinder to axle assembly (see Steering Cylinder in Chapter 5 − Hydraulic Sys- tem). 2. If removed, install the tie rod to rear axle (Fig. 12). Tighten ball joint castle nuts and install new cotter pins. 3.
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Page 320: Rear Axle Service
Rear Axle Service Figure 16 Axles, Planetaries and Brakes Page 7 - 26 Reelmaster 7000- D...
Page 321 Figure 12 (Continued) 1. LH axle support 23. RH axle support 44. Bevel gear (17 tooth) 2. Flange bushing (2) 24. Input shaft assembly 45. Bevel gear shaft 3. Axle vent 25. Bolt (8) 46. Axle case (LH shown) 4. Filter 26.
Page 322: Bevel Gear Case And Axle Case
Bevel Gear Case and Axle Case The following procedures assume the rear axle assem- 35 to 41 ft−lb bly has been removed from the machine. (47 to 56 N−m) Removal 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.
Page 323 5. Remove the knuckle pin mounting screws and the knuckle pin. Remove the gasket and any remaining gas- ket material from either mating surface (Fig. 20). 6. While holding the bevel gear case, tap the upper end 17 to 20 ft−lb (23 to 27 N−m) of the bevel gear shaft out of the upper bearing and up- per bevel gear.
Page 324 Installation 1. Coat new shaft seal with grease and install in axle case as shown (Fig. 22). Figure 22 1. Axle case 3. Shaft seal 2. Bevel gear case 2. Install the lower bevel gear and bevel gear shaft in the axle case cover.
Page 325 5. Determine necessary quantity of support shims. 57 to 67 ft−lb A. Lubricate the axle case support bushing with a (77 to 91 N−m) thin coat of grease and slide axle case support onto knuckle pin. B. Position support shims that were removed during VERTICAL disassembly between axle case support and axle ENDPLAY...
Page 326: Differential Shafts
9. Remove the bevel gear case/axle case assembly NOTE: Axle bearing shims are available in 0.008 inch from the axle support. Coat a new O-ring with grease (0.2 mm), 0.012 inch (0.3 mm) and 0.020 inch (0.5 mm) and temporarily install the axle cover assembly. Position thickness.
Page 327: Axle Shafts
Axle Shafts The following procedures assume the rear axle assem- 17 to 20 ft−lb bly has been removed from the machine. (23 to 27 N−m) Removal 1. Remove the axle cover mounting screws. Remove the axle cover from the axle case as an assembly (Fig.
Page 328: Input Shaft/Pinion Gear
Input Shaft/Pinion Gear 35 to 41 ft−lb (47 to 56 N−m) 35 to 41 ft−lb (47 to 56 N−m) Figure 32 1. Nut (2) 8. Seal collar 15. Gear case 2. Lock washer (2) 9. Bearing 16. Gasket 3. Stud (2) 10.
Page 329 5. Install a new stake washer. Install the lock nut finger tight. 6. Set the bearing preload by securing the bearing case in a vise. Thread a M12 x 1.5 hex head cap screw into the splined end of the input shaft/pinion gear and slowly tighten the lock nut until 4 to 6 in-lb (0.4 to 0.7 N−m) of 0.040 in.
Page 330: Differential Gear
Differential Gear The following procedures assume the rear axle assem- 47 to 56 Nm bly has been removed from the machine. (35 to 41 ft- lb) Removal 1. Remove bevel gear case/axle case assemblies (see Bevel Gear Case/Axle Case Assembly in this section of this manual).
Page 331 Inspection 1. Measure the differential side gear O.D. and the dif- ferential case I.D. to determine the side gear to case clearance (Fig. 39). Replace components as necessary. SIDE GEAR TO CASE CLEARANCE: 0.002 to 0.012 inch (0.05 to 0.30 mm) SIDE GEAR O.D.
Page 332 Installation 1. If the ring gear was removed from the differential case, use medium strength Loctite thread locker and tighten the mounting screws from 22 to 25 ft-lb (30 to 34 N−m). 2. Apply molybdenum disulfide lubricant (Three Bond 1901 or equivalent) to the splines and bearing surfaces of the differential pinion gears, pinion washers and side gears.
Page 333: Pinion Gear To Ring Gear Engagement
Pinion Gear to Ring Gear Engagement The final position of the pinion gear is verified by using PROFILE the gear contact pattern method as described in the fol- TOP LAND lowing procedure. GEAR TOOTH DEFINITIONS (Fig. 43): Toe - the portion of the tooth surface at the end to- LENGTHWISE wards the center.
Page 334 Gear Pattern Movement Summary Heel Contact Base Contact Every gear has a characteristic pattern. The illustrations show typical patterns only and explain how patterns shift as gear location is changed. 1. If contact is toward the heel or base of the gear (Fig.
Page 335 Chapter 8 Chassis Table of Contents GENERAL INFORMATION ..... Operator’s Manual ......Cutting Unit Identification .
Page 336: General Information
General Information Operator’s Manual The Traction Unit and Cutting Unit Operator’s Manuals provide information regarding the operation, general maintenance and maintenance intervals for your Reel- master machine. Refer to these publications for addi- tional information when servicing the machine. Cutting Unit Identification Cutting units on the Reelmaster 7000−D are identified as shown in Figure 1.
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Page 338: Service And Repairs
Service and Repairs Steering Column RIGHT FRONT 20 to 26 ft−lb (28 to 35 N−m) Antiseize Lubricant 7 to 10 ft−lb (10 to 13 N−m) Antiseize Lubricant Figure 2 1. Steering wheel cover 5. Socket head screw (4) 9. Socket head screw (4) 2.
Page 339 7. Slide rubber bellows up steering column to allow ac- cess to fasteners that secure steering control valve and steering column to machine. 8. Support steering control valve to prevent it from shif- ting during steering column removal. 9. Loosen and remove four (4) socket head screws (item 5) that secure steering control valve to steering column.
Page 340: Console Arm
Console Arm 33 34 RIGHT FRONT Figure 5 1. Console arm frame 16. Reel enable/disable switch 28. Flange head screw (2) 2. RH cover 17. Engine speed switch 29. Flange nut (2) 3. LH cover (Yanmar diesel engine) 30. Panel clip (2) 4.
Page 341 Figure 6 1. Hex head screw 7. Hex head screw 12. Grommet or foam seal 2. Spacer 8. Coupling nut 13. Manual tube 3. Seat belt buckle 9. Flange nut (4) 14. Clamp (2) 4. Flat washer 10. Console arm support 15.
Page 342: Lift Arms For Front Cutting Units (#1, #4 And #5)
Lift Arms for Front Cutting Units (#1, #4 and #5) RIGHT FRONT 19 15 Figure 7 1. O−ring 12. Pivot pin 23. Lynch pin 2. Flange nut 13. Slotted roll pin 24. Front carrier frame 3. Lift arm (cutting unit #1) 14.
Page 343 Removal (Fig 7) Installation (Fig 7) 1. Park machine on a level surface, lower cutting units, 1. Assemble lift arm. stop engine, engage parking brake and remove key 2. Position lift arm to frame. Fit thrust washer (item 10) from the ignition switch. between rear of lift arm and frame.
Page 344: Lift Arms For Rear Cutting Units (#2 And #3)
Lift Arms for Rear Cutting Units (#2 and #3) RIGHT FRONT Figure 8 1. Flange nut (2 used) 12. Lift cylinder (cutting units #2 and #3) 23. Cap screw 2. Bulkhead bracket 13. Lock nut 24. Lock nut 3. Hydraulic tee fitting 14.
Page 345 Removal (Fig. 8) 3. Position lift arm to frame (Fig. 8). Fit thrust washer (item 16) between rear of lift arm and frame. Slide pivot 1. Park machine on a level surface, lower cutting units, pin into frame and lift arm. Align roll pin in pivot pin with stop engine, engage parking brake and remove key slot in frame flange.
Page 346: Operator Seat
Operator Seat RIGHT FRONT Figure 10 1. Hex head screw 13. Manual tube 24. Spring 2. Spacer 14. Clamp (2) 25. Cotter pin 3. Seat belt buckle 15. Cap screw (2) 26. Flat washer 4. Flat washer (3) 16. Flange nut (2) 27.
Page 347 Removal (Fig. 10) 1. Park machine on a level surface, lower cutting units, stop engine, apply parking brake and remove key from the ignition switch. 2. Disconnect seat electrical connector from machine wire harness. 3. Support console arm assembly to prevent it from shifting.
Page 348: Operator Seat Service
Operator Seat Service Figure 12 1. Backrest cushion 12. Cap screw (2) 22. RH adjustment rail 2. Seat cushion 13. Seat 23. Rail stop 3. LH armrest cover 14. Nut 24. Torx screw 4. LH armrest 15. Spring (2) 25. Torx screw (3) 5.
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Page 350: Operator Seat Suspension
Operator Seat Suspension RIGHT FRONT Figure 13 1. Cover 14. Washer (2) 27. Clamp (2) 2. Cover 15. Tether 28. Hose nipple 3. Level control 16. Rivet (2) 29. Screw 4. Air control valve 17. Washer (4) 30. Handle 5. Shock absorber 18.
Page 351 NOTE: Most of the seat suspension components can be serviced with the seat suspension base mounted to the seat plate. If the air spring assembly (item 6) requires removal, the seat suspension base will have to be re- moved from the seat plate. Disassembly (Fig.
Page 352 Hood RIGHT FRONT Figure 15 1. Hood 9. Hood frame tube − LH 17. Latch − hood 2. Hood screen 10. Hood frame tube − RH 18. Latch − frame 3. Plastic plug (20) 11. Hood frame tube − center 19.
Page 353: Hood
Removal (Fig. 15) Installation (Fig. 15) 1. Park machine on a level surface, lower cutting units, 1. If components were removed from hood, assemble stop engine, engage parking brake and remove key hood. from the ignition switch. 2. Slide hood frame onto radiator frame pivot pins. 2.
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Page 355: General Information
Chapter 9 DPA Cutting Units Table of Contents SPECIFICATIONS ......Reel Assembly GENERAL INFORMATION .
Page 356: Specifications
Specifications Figure 1 Frame Construction: Precision machined die cast alu- Bedknife: Replaceable, tool steel EdgeMax bedknife minum cross member with bolt--on cast ductile iron or is fastened to a machined cast iron bedbar with 10 aluminum side plates. screws. Optional bedknives are available. Reel Construction: Reels are 27 inches (69 cm) in Bedknife Adjustment: Dual screw assemblies allow length and 7 inch (18 cm) in diameter.
Page 357: General Information
General Information Cutting Unit Operator’s Manual The cutting unit Operator’s Manual provides information regarding the operation, general 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.
Page 358: Special Tools
Figure 2 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.
Page 359 Figure 5 Cutting Unit Kickstand Toro Part Number: 119- -8010- -03 The cutting unit kickstand is used to prop up the rear of the cutting unit during service. Use of this tool prevents the bedbar adjusting screws from resting on the work surface.
Page 360 This tool should be used with the Toro Guide to Evaluation Reel Mower Performance and Using the TurfEvaluator (Toro part no. 97931SL).
Page 361 Reel Bearing Installation Tool (cutting units with painted side plates) Toro Part Number: 117- -0975 Use the reel bearing installation tool to keep the reel bearings aligned during reel installation. Figure 11 Cutting Reel Shim Toro Part Number: 125- -5611 The cutting reel shim (0.002”) is used to help parallel the...
Page 362 Bedknife Top Angle Indicator and Mount Toro Part Numbers: 131- -6828 and 131- -6829 Because the top grind angle on bedknives is critical for edge retention, and therefore after-- cut appearance, Toro has developed these service tools for accurately measuring the top grind angle on all bedknives.
Page 363: Factors That Can Affect Cutting Performance
NOTE: For additional information regarding cutting unit cutting unit. It is important to remember that the lower troubleshooting, see Aftercut Appearance Trouble- the height--of--cut, the more critical these factors are. shooting Aid (Toro part no. 00076SL). Factor Possible Problem/Correction Tire pressure Check tire pressure of all traction unit tires.
Page 364 Factor Possible Problem/Correction Reel and bedknife sharpness A reel and/or bedknife that has rounded cutting edges or “rifling” (grooved or wavy appearance) cannot be corrected by tightening the bedknife to reel contact. Grind cutting reel to remove taper and/or rifling. Grind bedknife to sharpen and/or remove rifling.
Page 365 Factor Possible Problem/Correction Roller condition and roller type Make sure rollers rotate freely. Repair 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.
Page 366: Adjustments
Adjustments Characteristics If a cutting unit is determined to be out of adjustment, CAUTION complete the following procedures in the specified order to adjust the cutting unit properly. 1. Adjust the bedknife parallel to the reel. Never install or work on the cutting units or lift arms with the engine running.
Page 367: Reel Bearing Adjustment (Cutting Units With Painted Side Plates)
Reel Bearing Adjustment (cutting units with painted side plates) NOTE: Cutting units that have aluminum side plates do not require reel bearing adjustment. 12 to 15 in- -lb (1.4 to 1.7 N- -m) To insure cut quality and long life of the cutting reel bear- ings, periodically check reel bearing adjustment.
Page 368: Leveling Rear Roller
Leveling Rear Roller The precision machined components of the cutting unit frame keep the rear roller and cutting reel in alignment (parallel). If the side plates are disassembled or as the cutting reel wears, a limited amount of side plate adjust- ment is possible to make sure that the cutting unit is properly aligned.
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Page 370: Service And Repairs
Service and Repairs Hydraulic Reel Motor IMPORTANT: When performing maintenance pro- cedures on the cutting units, carefully position the cutting unit reel motors to prevent damage to the motors or hydraulic hoses. Removal 1. Park machine on a clean and level surface, lower cutting units completely to the ground, stop engine, en- gage parking brake and remove key from the ignition switch.
Page 371: Backlapping
Be careful when backlapping the reel because NOTE: Additional instructions and procedures on contact with the reel or other moving parts can backlapping are available in the Toro General Service result in personal injury. Training Book, Reel Mower Basics (part no.
Page 372: Bedbar Assembly
Bedbar Assembly 27 to 33 ft- -lb (37 to 44 N- -m) RIGHT FRONT Antiseize Lubricant Figure 24 1. Bedbar assembly 5. Plastic washer (4 used) 8. Metal washer (2 used) 2. Lock nut (2 used) 6. Rubber bushing (2 used) 9.
Page 373 Bedbar Installation (Fig. 24) 9. Tighten the lock nut (item 2) on each bedbar adjuster assembly until the adjuster spring is fully compressed, 1. If rubber bushing was removed from either cutting then loosen lock nut 1/2 turn. unit side plate, install a new bushing. The bushing should be installed flush with the inside of the side plate 10.Adjust cutting unit (see Cutting Unit Operator’s (Fig.
Page 374: Bedknife Replacement And Grinding
Bedknife Replacement and Grinding Bedknife Removal 1. Remove bedbar assembly from cutting unit (see Bedbar Assembly in this chapter). 2. Remove screws from bedbar using a socket wrench and bedknife screw tool (see Special Tools in this chapter). Discard screws. Remove bedknife from the bedbar (Fig.
Page 375 Low HOC Figure 31 Standard Bedknife Lead - -in Chamfer Low HOC 1. Use Toro General Service Training Book, Reel Mow- Extended EdgeMax er Basics (part no. 09168SL) and grinder manufactur- Low HOC 0.19” er’s instructions for bedknife grinding information.
Page 376: Bedbar Adjuster Service
Bedbar Adjuster Service Left Hand Threads Antiseize Lubricant Loctite #243 14 to 16 ft- -lb (19 to 21 N- -m) Antiseize Lubricant Left Hand Threads Antiseize Lubricant Loctite #243 14 to 16 ft- -lb (19 to 21 N- -m) Antiseize Lubricant RIGHT FRONT...
Page 377 Removal (Fig. 32) 2. If flange bushings (item 5) were removed, apply anti- seize lubricant to bore of cutting unit frame. Align key on 1. Remove lock nut (item 3), compression spring and bushing to slot in frame and install bushings into frame. washer from bedbar adjuster screw (item 4).
Page 378: Reel Assembly
Reel Assembly (cutting units with painted side plates) Grease 27 to 33 ft- -lb bore (37 to 44 N- -m) Grease OD surface RIGHT See text for Grease bore tightening FRONT and threads procedure Antiseize Loctite #243 Lubricant 12 to 15 in- -lb 27 to 33 ft- -lb (1.4 to 1.7 N- -m) (37 to 44 N- -m)
Page 379 3. If the cutting unit is equipped with a counterweight or accessory on LH side plate, remove the counter weight 115 to 128 Nm or accessory. Remove and discard the O--ring from (85 to 95 ft- - - -lb) counter weight. 4.
Page 380 Use reel from 15 to 19 ft-lbs (20 to 25 N- -m). bearing installation tool (Toro part number 9. Secure the bedbar assembly to LH side plate (see 117- -0975) to help with bearing alignment during Bedbar Installation in this section).
Page 381 IMPORTANT: Over tightening reel bearing adjuster 115 to 128 Nm nut may damage reel bearings. (85 to 95 ft- - - -lb) 11. Make sure that set screw is loose in LH side plate to allow bearing adjuster nut movement. With the cutting unit and reel in a horizontal position, tighten the bearing adjuster nut to 25 in- -lb (2.8 N- -m) to remove cutting reel end play.
Page 382: Reel Assembly Service (Cutting Units With Painted Side Plates)
Reel Assembly Service (cutting units with painted side plates) Loctite #243 Clean Threads 85 to 95 ft- -lb (115 to 128 N- -m) (Right Hand Threads) RIGHT Left Hand Threads FRONT Loctite #243 85 to 95 ft- -lb (115 to 128 N- -m) Figure 38 1.
Page 383 C. To install spline insert into cutting reel, clean B. Press grease seals onto reel shaft with metal side threads of insert and cutting reel shaft. Apply Loctite orientated toward bearing location. Final position of #243 (or equivalent) to threads of insert, thread in- seal should be flush to 0.060”...
Page 384: Reel Assembly
Reel Assembly (cutting units with aluminum side plates) 27 to 33 ft- -lb (37 to 44 N- -m) Antiseize Lubricant (Bearing OD) Pack with Grease (both ends) RIGHT FRONT Antiseize Lubricant Antiseize (Bearing OD) Lubricant Figure 39 1. Bedbar assembly 7.
Page 385 27 to 33 ft- -lb 15 to 19 ft- -lb (37 to 44 N- -m) (20 to 25 N- -m) 15 to 19 ft- -lb (20 to 25 N- -m) 27 to 33 ft- -lb (37 to 44 N- -m) Figure 40 Frame 7.
Page 386 4. Loosen the spline inserts: 115 to 128 Nm A. Tip the cutting unit to access the bottom of the (85 to 95 ft- - - -lb) reel. B. Insert a long--handled pry bar (3/8 x 12 inch with screwdriver handle recommended) through the bot- tom of the cutting unit.
Page 387 9. Apply Loctite #243 (or equivalent) to threads of flange head screw that secures frame spacer and carri- er frame to LH side plate. Install screw and torque from 27 to 33 ft-lbs (37 to 44 N- -m). After tightening screw, check the clearance between the carrier frame and side plate.
Page 388: Reel Assembly Service (Cutting Units With Aluminum Side Plates)
Reel Assembly Service (cutting units with aluminum side plates) Loctite #243 85 to 95 ft- -lb (115 to 128 N- -m) (Right Hand Threads) Loctite #243 Loctite #243 RIGHT FRONT 85 to 95 ft- -lb (115 to 128 N- -m) (Left Hand Threads - - Groove in Face) Figure 44 1.
Page 389 Reel Assembly Cutting Unit Serial no. 315000001 & Up 1. If removed, install new reel shaft plugs into cutting reel shaft. For cutting unit serial no. prior to 315000001, make sure plastic plug is pressed flush into end of threaded insert. For cutting unit serial no. 315000001 & Up, make sure plastic plug is pressed unto reel shaft 1.63 to 1.37 in.
Page 390: Preparing Reel For Grinding
Specifications chart below). Additional reel grinding in- formation can be found in your Cutting Unit Operator’s Manual. An additional resource is the Toro Basics Se- ries Training Book, Reel Mower Basics (part no. 09168SL) found on the Service Reference Set available from your Authorized Toro Distributor.
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Page 392: Front Roller
Front Roller Removal (Fig. 48) Loctite #242 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and re- Antiseize move key from the ignition switch. Lubricant 2. Remove the cutting unit from the machine and place on a level working surface.
Page 393 Rear Roller Removal (Fig. 49) 15 to 19 ft- -lb (20 to 26 N- -m) 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and re- move key from the ignition switch. 2.
Page 394 Roller Service Disassembly (Fig. 50) 50 to 60 ft- -lb 1. Remove bearing lock nut from each end of roller (68 to 81 N- -m) shaft. 2. Loosely secure roller assembly in bench vise and lightly tap one end of roller shaft until outer seals and bearing are removed from opposite end of roller tube.
Page 395 3. From the roller tube end with only the inner seal NOTE: After roller is installed to cutting unit, lubricate installed, carefully install the roller shaft into the roller roller grease fittings, rotate roller to properly distribute tube. Make sure that seals are not damaged as shaft is grease in bearings and clean excess grease from roller installed.
Page 396 Rear Roller Brush - - Optional (cutting units with painted side plates) Antiseize Lubricant 27 to 33 ft- -lb (37 to 44 N- -m) 15 to 19 ft- -lb (20 to 25 N- -m) Loctite #243 15 to 19 ft- -lb (20 to 25 N- -m) Grease Grommet ID...
Page 397 Disassembly (Fig. 56) 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and re- move key from the ignition switch. 2. To remove roller brush from brush shaft: A. Remove the non--driven brush bearing assembly 20 to 25 in- -lb (item 30) from cutting unit.
Page 398 3. If drive bearing housing was disassembled, install CAUTION new components noting proper orientation as shown (Fig. 59 and 60). A. Install bearing on shaft by pressing equally on the Contact with the reel or other cutting unit parts inner and outer bearing races. Install the bearing so can result in personal injury.
Page 399 5. Check alignment of pulleys with a straight edge CHECK placed along the outer face of the driven pulley (Fig. 62). ALIGNMENT The outer faces of the driven and drive pulleys (not the idler pulley) should be in line within 0.030” (0.76 mm). If necessary to align pulleys, remove driven pulley from brush shaft and add or remove hardened washer(s) (item 9) until drive and driven pulleys are aligned within...
Page 400 Rear Roller Brush - - Optional (cutting units with aluminum side plates) Grease Seal Lip 20 to 25 in- -lb (2.3 to 2.8 N- -m) Antiseize Lubricant Grease Seal Lip Grease RIGHT Seal Lip FRONT 27 to 33 ft- -lb (37 to 44 N- -m) Figure 64 1.
Page 401 Rear Roller Brush Assembly (Fig. 56) 6. Once all rear roller brush service is completed, plug the 48 VDC battery disconnect back in before operating 1. If seals or bearings were removed from brush bear- the machine. ing housings, install new components noting proper ori- entation as shown in Figure 58.
Page 402 Drive System Disassembly (Fig. 68) Loctite #243 15 to 19 ft- -lb (20 to 25 N- -m) 10 to 15 ft- -lb (14 to 20 N- -m) Grease Grommet ID Loctite #243 15 to 19 ft- -lb (20 to 25 N- -m) RIGHT Loctite #243 FRONT...
Page 403 Drive System Assembly (Fig. 68) 85 to 95 ft- -lb 1. Install drive shaft if it was removed: (115 to 128 N- -m) IMPORTANT: If rear roller brush drive is on left side of cutting unit, drive shaft has left hand threads and can be identified by a groove on the flange.
Page 404 3. After assembly (including drive belt installation), check alignment of pulleys with a straight edge placed 27 to 33 ft- -lb along the outer face of the drive pulley (Fig. 62). (37 to 44 N- -m) A. The outer faces of the drive and driven pulleys (not the idler pulley) should be in--line within 0.030”...
Page 405 Chapter 10 Belt Driven Groomer (Optional) Table of Contents GROOMING PERFORMANCE ....TROUBLESHOOTING ......Groomer Reel Mechanical Problems .
Page 406: Grooming Performance
Grooming Performance There are a number of factors that can affect the perfor- mance of grooming. These factors vary for different golf courses and from fairway to fairway. It is important to in- spect the turf frequently and vary the grooming practice with turf needs.
Page 407: Troubleshooting
Troubleshooting Groomer Reel Mechanical Problems Problem Possible Causes Correction No rotation of the groomer reel. The groomer drive belt needs to be Adjust groomer drive belt. adjusted. Seized groomer reel or idler bear- Identify and replace faulty bear- ing(s) in groomer side plate(s). ing(s).
Page 408: Adjustments
Adjustments NOTE: The Groomer Installation Instructions provide information regarding the installation, set−up and op- CAUTION eration of the optional groomer on your Reelmaster ma- chine. Refer to these instructions for additional Never work on the groomer with the engine information when servicing the groomer. running.
Page 409: Service And Repairs
Service and Repairs NOTE: The Groomer Installation Instructions provide CAUTION information regarding the installation, set−up and op- eration of the optional groomer on your Reelmaster ma- chine. Refer to these instructions for additional Never work on the groomer with the engine information when servicing the groomer.
Page 410: Groomer Plate Assembly
Groomer Plate Assembly Loctite #243 Antiseize Lubricant Loctite #243 RIGHT FRONT Antiseize 17 to 21 ft−lb Loctite #243 Lubricant (23 to 28 N−m) 27 to 32 ft−lb (37 to 43 N−m) Figure 4 1. Groomer reel 9. Idler pulley assembly 17.
Page 411 C. Remove the flange nut (item 6) that secures driv- D. Press bushings into groomer plate until the bush- en pulley (item 5) to groomer shaft. Remove driven ing contacts the shoulder in the groomer plate bore. pulley from shaft. Locate and retrieve square key E.
Page 412 2. Install groomer plate assembly to groomer non− I. Check pulley alignment by laying a straight edge drive side of cutting unit: along the outer face of the drive pulley (Fig. 7). Drive and driven pulleys should be in line within 0.030” A.
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Page 414: Groomer Reel
Groomer Reel Loctite #243 Antiseize Lubricant Loctite #243 RIGHT FRONT Antiseize 17 to 21 ft−lb Loctite #243 Lubricant (23 to 28 N−m) 27 to 32 ft−lb (37 to 43 N−m) Figure 8 1. Groomer reel 9. Idler pulley assembly 17. Groomer plate (drive) 2.
Page 415 Installation (Fig. 8) 1. Position cutting unit on a level surface. If cutting unit is attached to traction unit, make sure to stop engine, en- gage parking brake and remove key from the ignition switch. 2. Apply a light coating of grease to seal lips in groomer plate assemblies.
Page 416: Groomer Reel Service
Groomer Reel Service Inspect groomer reel blades frequently for damage and wear. Straighten bent blades with a pliers. Either replace worn blades or reverse the blades to put the sharpest blade edge forward (Fig. 11). Blades that are rounded to the midpoint of the blade tip must be reversed or re- placed for best groomer performance.
Page 417 5. If groomer reel is equipped with broomer kit (Fig. 14), position broomer brushes to reel blades and secure with straps. Straps should be positioned between blades 1−2, 14−15, 28−29 and 41−42. Pull straps tight and cut off strap extension approximately 1/4” (6 mm) beyond retainer.
Page 418: Groomer Pivot Hub
Groomer Pivot Hub Apply Grease to Seal Lip Figure 15 1. Groomer drive shaft 5. Pivot hub 8. Retaining ring 2. Ball bearing 6. Retaining ring 9. Idler plate 3. Grease seal 7. Extension spring 10. O−ring (7” cutting unit only) 4.
Page 419 Disassembly (Fig. 15) Fill cavity 50 to 75% full 1. Remove pivot hub assembly (with idler plate) from with grease cutting unit (see Groomer Plate Assembly Removal in this section). 2. Remove retaining ring (item 4) that secures idler plate to pivot hub. Slide idler plate from pivot hub. 3.
Page 420: Height Adjuster Assembly
Height Adjuster Assembly Antiseize Lubricant 30 to 40 in−lb (3.4 to 4.5 N−m) Antiseize Lubricant 17 to 21 ft−lb (23 to 28 N−m) Antiseize Lubricant Figure 17 1. Groomer plate (LH drive shown) 6. Flange head screw 11. Flat washer 2.
Page 421 Chapter 11 Universal Groomer (Optional) Table of Contents GROOMING PERFORMANCE ....TROUBLESHOOTING ......Groomer Reel Mechanical Problems .
Page 422 Grooming Performance There are a number of factors that can affect the per- formance of grooming. These factors vary for different golf courses and from fairway to fairway. It is important to inspect the turf frequently and vary the grooming practice with turf needs.
Page 423 Troubleshooting Groomer Reel Mechanical Problems Problem Possible Causes Correction No rotation of the groomer reel. The groomer drive is in Neutral. Engage groomer drive to Forward or Reverse. Damaged or seized groomer drive Repair groomer drive. gears. The turf is damaged or has uneven The groomer reel blades are bent, Repair or replace blades if neces- grooming.
Page 424: Service And Repairs
Service and Repairs RIGHT FRONT Figure 1 1. Gear box assembly 3. Groomer reel 5. Weight 2. Idler assembly 4. Height adjuster assembly (2) 6. Button head screw (2) NOTE: The Groomer Operator’s Manual provides in- CAUTION formation regarding the installation, set--up, operation and maintenance of the universal groomer on your Reelmaster machine.
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Page 426 Gear Box Assembly 90 to 100 ft- -lb (122 to 135 N- -m) RIGHT FRONT Figure 2 1. Gear box assembly 3. Cotter pin 5. Input shaft 2. Rear roller brush drive shield 4. Clevis pin NOTE: The groomer gear box assembly is located on NOTE: If cutting unit is equipped with an optional pow- the opposite side of the cutting unit from the cutting unit ered rear roller brush, remove the rear roller brush cov-...
Page 427 5. Install a 5/16–18 X 5/8 inch square head set screw (Toro p/n 1--803022) in the end of the drive shaft and tighten to 13 N·m (120 in--lb); refer to Fig. 3. 13 Nm 6.
Page 428 I. Move the pry bar against the weld side of the reel support plate closest to the drive shaft assembly. J. Use the drive shaft removal tool (Toro p/n 137--0920) on the large flats of the drive shaft as- sembly; refer to Fig. 5.
Page 429 Disassembly (Fig. 6) 115 to 125 ft- -lb (156 to 169 N- -m) 85 to 95 in- -lb (9 to 11 N- -m) 32 to 42 in- -lb Tighten to Specified Torque (4 to 5 N- -m) (see text) Figure 6 1.
Page 430 CAUTION Use the 1- -3/8” flats on the input shaft to prevent the input shaft from rotating during adapter re- moval. DO NOT use the 1/2” hex on the input shaft to secure the shaft during adapter removal or input shaft damage may occur. 1.
Page 431 Installation (Fig. 2) 1. Park machine on a clean and level surface, lower cutting units completely to the ground, stop engine, en- gage parking brake and remove key from the ignition switch. CAUTION Contact with the reel or other cutting unit parts can result in personal injury.
Page 432 Idler Assembly Loctite #242 85 to 95 ft- -lb (115 to 129 N- -m) Antiseize Lubricant 27 to 33 ft- -lb (37 to 45 N- -m) 24 to 30 ft- -lb (33 to 41 N- -m) Figure 9 1. Socket head screw (2) 6.
Page 433 Installation (Fig. 9) 1. If shields, bearing or bushing was removed from idler arm, install new components. A. Press bushing into groomer plate until the bush- ing is centered in the idler arm bore. B. Press bearing into idler arm so that bearing con- tact shoulder in idler arm bore and install bearing re- taining ring.
Page 434 Groomer Reel 45 to 60 in- -lb (5 to 7 N- -m) 45 to 60 in- -lb (5 to 7 N- -m) Figure 11 1. Groomer reel 3. Cap screw (4) 4. Jam nut (4) 2. Shaft clamp (4) Remove the groomer reel to replace individual groomer 3.
Page 435 Groomer Reel Service Inspect groomer reel blades frequently for damage and wear. Straighten bent blades. Either replace worn MIDPOINT blades or reverse the individual blades to put the sharpest blade edge forward (Fig. 12). Blades that are rounded to the midpoint of the blade tip must be re- versed or replaced for best groomer performance.
Page 436 5. If groomer reel is equipped with broomer kit: A. Loosen the groomer blade retaining nuts on each end of the groomer shaft. 31 to 35 ft- -lb (42 to 48 N- -m) B. Slide a brush into each groove around the full length of the groomer reel (Fig.
Page 437 Grooming Brush (Optional) Service The optional grooming brush is removed and installed from the groomer in the same manner as the groomer reel (see Groomer Reel in this chapter). The grooming brush element or shaft can be serviced separately (Fig. 17). Figure 17 1.
Page 438 Height Adjuster Assembly Antiseize Lubricant Antiseize Lubricant Figure 18 1. Height of cut bracket 8. Clevis pin 14. Pinch bolt (front roller) 2. Height adjustment bolt 9. Button head screw 15. Lock nut 3. Washer (2) 10. Detent spring 16. Washer (2) 4.
Page 439 Assembly (Fig. 18) 1. Apply antiseize lubricant to upper threads of adjust- ment rod and lower threads of height adjusters. Assem- ble height adjuster assembly as shown. 2. If both height adjusters were removed, fit one height adjuster assembly to the cutting unit side plate and se- cure with carriage bolt and flange nut.
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Page 441 Chapter 12 Foldout Drawings Table of Contents ELECTRICAL DRAWING DESIGNATIONS ..HYDRAULIC SCHEMATIC ..... ELECTRICAL SCHEMATICS Traction Unit Model 03780 -- Yanmar Engine (Serial numbers below 316000000)
Page 442: Electrical Drawing Designations
WHITE Y or YE YELLOW Numerous harness wires used on Toro machines in- clude a line with an alternate color. These wires are iden- tified with the wire color and line color with either a / or _ separating the color abbreviations listed above (e.g.
Page 443: Hydraulic Schematic
FRONT STEERING LIFT CYLINDERS CYLINDER EXTEND STEERING TO TURN RIGHT UNIT .046” .046” .046” REEL .040” PISTON MOTORS LEFT CYLINTER 1.6 CID 1.6 CID 1.6 CID 1.6 CID 1.6 CID EXTEND TO LOWER .030” .030” .030” CENTER CYLINDER EXTEND TO LOWER .055”...
Page 444: (Serial Numbers Below 316000000)
ALTERNATOR (80 A) (STANDARD) All relays and solenoids CAB HARNESS are shown as de- - energized. CONNECTOR All ground wires are black. Reelmaster 7000--D Electrical Schematic - - Traction Unit Model 03780 -- Yanmar Engine (Serial numbers below 316000000) Page 12 - - 4...
Page 445: (Serial Numbers 316000001 To 403350000)
122- -0675 Rev A All relays and solenoids Reelmaster 7000- -D are shown as de- -energized. Electrical Schematic - - Traction Unit All ground wires are black. Model 03780 - - Yanmar Engine (Serial numbers 316000001 to 403350000) Page 12 - - 5...
Page 446: (Serial Numbers Above 403350001)
122- -1519 Rev A All relays and solenoids Reelmaster 7000- -D are shown as de- -energized. Electrical Schematic - - Traction Unit All ground wires are black. Model 03780 - - Yanmar Engine (Serial numbers above 403350001) Page 12 - - 6...
Page 447 ALTERNATOR (60 A) (STANDARD) All relays and solenoids Reelmaster 7000--D are shown as de- - energized. All ground wires are black. Electrical Schematic - - Traction Unit Model 03781 -- Kubota Engine CAB HARNESS CONNECTOR (Serial numbers below 316000000) Page 12 - - 7...
Page 448: (Serial Numbers 316000001 To 403350000)
122- -0675 Rev A All relays and solenoids Reelmaster 7000- -D are shown as de- -energized. Electrical Schematic - - Traction Unit All ground wires are black. Model 03781 - - Kubota Engine (Serial numbers 316000001 to 403350000) Page 12 - - 8...
Page 449: (Serial Numbers Above 403350001)
122- -1519 Rev A All relays and solenoids Reelmaster 7000- -D are shown as de- -energized. Electrical Schematic - - Traction Unit All ground wires are black. Model 03781 - - Kubota Engine (Serial numbers above 403350001) Page 12 - - 9...
Page 450: Cab
TRACTION UNIT HARNESS CONNECTOR All relays and solenoids are shown as de- - energized. All ground wires are black. Reelmaster 7000--D Electrical Schematic - - Cab Model 03780 & 30781 Page 12 - - 10...
Page 451 Reelmaster 7000--D Main Wire Harness Drawing Model 03780 & 30781 (Serial numbers below 316000000) Page 12 - - 11...
Page 452 VIOLET BLACK BLUE VIOLET PINK/BLACK BLACK ORANGE VIOLET BLACK BLACK BLACK PINK WHITE/YELLOW WHITE/BLACK BLACK RED/BLACK BLACK BLACK BLACK BLACK BLACK BLACK PINK BLACK BLACK BLACK BLACK BLACK Reelmaster 7000--D Main Wire Harness Diagram Model 03780 & 30781 (Serial numbers below 316000000) Page 12 - - 12...
Page 453 122- -0666 Rev A Reelmaster 7000- -D Main Wire Harness Drawing Model 03780 & 03781 (Serial numbers 316000001 to 403350000) Page 12 - - 13...
Page 454 122- -0666 Rev A Reelmaster 7000- -D Main Wire Harness Diagram Model 03780 & 03781 (Serial numbers 316000001 to 403350000) Page 12 - - 14...
Page 455 122- -1520 Rev A Reelmaster 7000- -D Main Wire Harness Drawing Model 03780 & 03781 (Serial numbers 403350001 to 405699999) Page 12 - - 15...
Page 456 122- -1520 Rev A Reelmaster 7000- -D Main Wire Harness Diagram Model 03780 & 03781 (Serial numbers 403350001 to 405699999) Page 12 - - 16...
Page 457 122- -1729 Rev A Reelmaster 7000- -D Main Wire Harness Drawing Model 03780 & 03781 (Serial numbers above 405700000) Page 12 - - 17...
Page 458 122- -1729 Rev A Reelmaster 7000- -D Main Wire Harness Diagram Model 03780 & 03781 (Serial numbers above 405700000) Page 12 - - 18...
Page 459 Reelmaster 7000--D Engine Wire Harness Drawing Model 03780 -- Yanmar Engin Page 12 - - 19...
Page 460 GREEN BLACK BLUE BLACK VIOLET ORANGE BLACK BLUE BROWN BLUE YELLOW BLUE GREEN GREEN YELLOW WHITE BLACK WHITE GREEN BLACK BROWN BLUE YELLOW ORANGE GREEN WHITE BLUE BROWN YELLOW YELLOW BLUE YELLOW VIOLET WHITE/BLUE VIOLET GREEN VIOLET VIOLET WHITE VIOLET VIOLET VIOLET VIOLET...
Page 461 Reelmaster 7000--D Engine Wire Harness Drawing Model 03781 -- Kubota Engine Page 12 - - 21...
Page 462 ORANGE BLUE GRAY/BROWN WHITE GREEN/WHITE BROWN/YELLOW BROWN/BLACK RED/BLACK RED/WHITE BLACK/WHITE PINK/BLACK Reelmaster 7000--D Engine Wire Harness Diagram - - Kubota Model 03781 -- Kubota Engine Page 12 - - 22...
Page 463: Seat And Console Wire Harness
Reelmaster 7000--D Seat and Console Wire Harness Drawing Model 03780 & 30781 Page 12 - - 23...
Page 464 RED/YELLOW BLACK BLACK PINK PINK WHITE BLACK BLACK RED/WHITE BLACK/WHITE BLACK BLACK Reelmaster 7000--D Seat and Console Wire Harness Diagram Model 03780 & 30781 Page 12 - - 24...
Page 465 Reelmaster 7000--D Power Center Wire Harness Drawing Model 03780 & 30781 (Serial numbers below 403350000 Page 12 - - 25...
Page 466: (Serial Numbers Below 403350000)
WHITE/BLACK BROWN/BLACK TAN/BLACK GRAY/BLACK BLUE PINK/BLACK ORANGE VIOLET BLACK PINK WHITE/ORANGE WHITE/YELLOW RED/GREEN WHITE/BLACK BROWN/BLACK TAN/BLACK GRAY/BLACK BLACK Reelmaster 7000--D Power Center Wire Harness Diagram Model 03780 & 30781 (Serial numbers below 403350000) Page 12 - - 26...
Page 467 122- -1547 Rev A Reelmaster 7000- -D Power Center Wire Harness Drawing Model 03780 & 03781 (Serial numbers above 403350001) Page 12 - - 27...
Page 468 122- -1547 Rev A Reelmaster 7000- -D Power Center Wire Harness Diagram Model 03780 & 03781 (Serial numbers above 403350001) Page 12 - - 28...

This manual is also suitable for:

03780 03780a 03781

Toro Reelmaster 7000-D Service Manual

This Page Is Intentionally Blank.

Chapter 1 Safety

Chapter 2 Product Records and Maintenance

Chapter 3 Yanmar Diesel Engine

Chapter 4 Kubota Diesel Engine

Chapter 5 Hydraulic System

Chapter 6 Electrical System

Chapter 7 Axles, Planetaries and Brakes

Chapter 8 Chassis

Chapter 9 Dpa Cutting Units

Chapter 10 Belt Driven Groomer (Optional)

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Toro Reelmaster 7000-D