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Toro 03708 Service Manual

Toro 03708 Service Manual

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Form No. 11185SL Rev D
®
Reelmaster
7000
(Model 03708)
Original Instructions (EN)

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  • Page 1 Form No. 11185SL Rev D ® Reelmaster 7000 (Model 03708) Original Instructions (EN)

  • Page 2: Revision History

    THE TORO COMPANY 2018 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

    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 The Toro Company reserves the right to change product 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.
  • Page 6 This page is intentionally blank. Reelmaster 7000−D (Model 03708)
  • Page 7 9 − 5 Service and Repairs ......DANFOSS STEERING UNIT TYPE OSPM SERVICE MANUAL Reelmaster 7000−D (Model 03708)
  • Page 8 This page is intentionally blank. Reelmaster 7000−D (Model 03708)
  • Page 9 ..... . . 11 − 6 Wire Harness Drawings ....Reelmaster 7000−D (Model 03708)
  • Page 10 This page is intentionally blank. Reelmaster 7000−D (Model 03708)

  • Page 11: Table Of Contents

    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

    7. Before disconnecting or performing any work on the timum performance and continued safety certification of hydraulic system, all pressure in system must be re- the machine, use genuine Toro replacement parts and lieved by stopping engine and lowering cutting units to accessories. Replacement parts and accessories made the ground.

  • 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. Reelmaster 7000 Page 1 - - 5 Safety...
  • Page 16 This page is intentionally blank. Safety Page 1 - - 6 Reelmaster 7000...

  • 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 Reelmaster 7000 Page 2 - - 2...

  • Page 19: Torque Specifications

    For critical applications, as determined reduced by 25% for lubricated fasteners to achieve 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 Steel Fasteners (Metric Series)

    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 Thread Size Regular Height Nuts Regular Height Nuts Regular Height Nuts Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts) M5 X 0.8...

  • Page 22: Other Torque Specifications

    Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Thread Size Square Head Hex Socket 7/16 -- 20 UNF 65 + 10 ft--lb 88 + 14 N--m Grade 5 1/4 -- 20 UNC 140 + 20 in--lb...

  • Page 23: Kubota Diesel Engine

    Chapter 3 Kubota Diesel Engine Table of Contents SPECIFICATIONS ......GENERAL INFORMATION .

  • Page 24: 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 25: General Information

    Kubota Workshop Manual, Diesel En- gine, 03--M--DI--E3B. Service and repair parts for Kubota engines are sup- plied through your Authorized Toro Distributor. If no Most repairs and adjustments require tools which are parts list is available, be prepared to provide your distrib- commonly available in many service shops.

  • Page 26: Service And Repairs

    Service and Repairs Air Filter System RIGHT 12 to 15 in- -lb FRONT (1.4 to 1.6 N- -m) Vacuator Direction Figure 1 1. Battery support 10. Cap screw (2 used) 19. Cap screw (2 used) 2. Bracket 11. Air cleaner assembly 20.
  • Page 27 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 using Figure 1 as a guide. Installation (Fig.

  • Page 28: Exhaust System

    Exhaust System RIGHT FRONT Figure 4 1. Muffler 6. RH engine mount 11. Engine 2. Flange head screw (2 used) 7. Flat washer 12. Muffler bracket 3. Flange head screw (4 used) 8. Cap screw 13. Flange nut (2 used) 4.
  • Page 29 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. To 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 30: Fuel System

    Fuel System RIGHT FRONT Figure 5 1. Fuel suction tube 10. Cap screw (2 used) 19. Flange nut (2 used) 2. Fuel line clamp (2 used) 11. Clamp (2 used) 20. Fuel/water separator 3. Fuel hose (supply) 12. Flange nut (2 used) 21.

  • Page 31: 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 32: Radiator

    Radiator RIGHT FRONT 9 to 11 ft- -lb (12.3 to 14.9 N- -m) Figure 6 1. 90 hydraulic fitting (2 used) 17. Flat washer (8 used) 32. Washer (2 used) 2. Oil cooler 18. Flange head screw (11 used) 33. Oil cooler top bracket 3.
  • Page 33 Removal (Fig. 6) 2. Carefully position radiator and recirculation barriers (items 24 and 25) to the radiator mount. Secure radiator 1. Park machine on a level surface, lower cutting units, and barriers in place with four (4) flange head screws stop engine, engage parking brake and remove key and flange nuts.

  • Page 34: Engine

    Engine RIGHT FRONT Figure 8 1. Muffler 13. Rebound washer (4 used) 24. Lock washer 2. Flange head screw 14. LH front engine mount 25. Spacer (2 used) 3. Flange head screw (4 used) 15. Lock washer (4 used) 26. Hardened washer (2 used) 4.

  • Page 35: Engine Removal

    Engine Removal (Fig. 8) 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 the Service and Repairs section of Chapter 7 -- Chas- sis).

  • Page 36: Engine Installation

    11. Remove fan motor and fan assembly (Fig. 11). A. To prevent contamination of hydraulic system, thoroughly clean exterior of fan motor and fittings. B. Disconnect hydraulic hoses from cooling fan mo- tor. Put caps or plugs on fittings and hoses to prevent contamination.
  • Page 37 8. Install fan motor and fan assembly (Fig. 11). C. The alternator (Fig. 10). A. Carefully position fan motor, fan and motor brack- D. The glow plug connection. et assembly to radiator. E. Wire harness connector to engine ground har- B.

  • Page 38: Pump Adapter Plate

    Pump Adapter Plate RIGHT FRONT 29 to 33 ft- -lb Loctite #242 (40 to 44 N- -m) Boss Figure 12 1. Bolt 4. Hardened washer (14 used) 6. Bolt (6 used) 2. Lock washer 5. Spring coupler 7. Cap screw (8 used) 3.
  • Page 39 Coupler Removal (Fig. 12) 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 the Ser- vice and Repairs section of Chapter 4 -- Hydraulic System).
  • Page 40 This page is intentionally blank. Kubota Diesel Engine Page 3 - - 18 Reelmaster 7000...
  • Page 41 Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS ......Flush Hydraulic System ..... GENERAL INFORMATION .
  • Page 42 This page is intentionally blank. Hydraulic System Page 4 - - 2 Reelmaster 7000...

  • Page 43: Specifications

    Specifications Item Description Piston (Traction) Pump Eaton variable displacement piston pump (Model 72400) Maximum Displacement (per revolution) 2.48 in (40.6 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 Eaton fixed displacement piston motors (Model 74315)

  • Page 44: General Information

    4WD/2WD control manifold test port (G). Toro part numbers 95- -8843 (hydraulic hose), 95- -0985 (coupler fitting) (2 required) and 340- -77 (hydraulic fitting) (2 required) are needed for this connection.

  • Page 45: Relieving Hydraulic System Pressure

    If a component in the traction circuit should fail, de- during operation. Because the Toro high flow filter is bi-- bris and contamination from the failed component will directional, the traction circuit can be operated in both circulate throughout the traction circuit.

  • Page 46: 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 47: 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 48: Hydraulic Fitting Installation

    Hydraulic Fitting Installation (SAE Straight Thread O- -Ring Fitting into Component Port) Non- -Adjustable Fitting (Fig. 6) 5. If a torque wrench is not available, or if space at the port prevents use of a torque wrench, an alternate meth- 1.
  • Page 49 Adjustable Fitting (Fig. 8) 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.

  • Page 50: Hydraulic Schematic

    Hydraulic Schematic Hydraulic System Page 4 - - 10 Reelmaster 7000...
  • Page 51 This page is intentionally blank. Reelmaster 7000 Page 4 - - 11 Hydraulic System...

  • Page 52: Hydraulic Flow Diagrams

    Hydraulic Flow Diagrams Hydraulic System Page 4 - - 12 Reelmaster 7000...

  • Page 53: Traction Circuit: Mow Speed (4Wd)

    Traction Circuit: Mow Speed (4WD) The traction circuit piston pump is a variable displace- Forward Direction ment pump that is directly coupled to the engine fly- When the mow speed limiter is in the mow speed (4WD) wheel. Pushing the traction pedal engages a hydraulic position and the traction pedal is pushed in the forward servo valve which controls the variable displacement direction, oil from the piston pump is directed to the front...
  • Page 54 Hydraulic System Page 4 - - 14 Reelmaster 7000...

  • Page 55: Traction Circuit: Transport Speed (2Wd)

    Traction Circuit: Transport Speed (2WD) 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 transport speed (2WD) wheel. Pushing the traction pedal engages a hydraulic position, solenoid valve (SV) in the 4WD/2WD control servo valve which controls the variable displacement manifold is energized.
  • Page 56 Hydraulic System Page 4 - - 16 Reelmaster 7000...

  • Page 57: Lower Cutting Units

    Lower Cutting Units A four section gear pump is coupled to the piston (trac- Because cutting unit weight assists in extending the lift tion) pump. Gear pump section P3 supplies hydraulic cylinders when lowering the cutting units, less hydraulic flow to both the lift control manifold and the steering con- pressure is necessary during the cutting unit lowering trol valve.
  • Page 58 Hydraulic System Page 4 - - 18 Reelmaster 7000...

  • Page 59: Raise Cutting Units

    Raise Cutting Units A four section gear pump is coupled to the piston (trac- tion) pump. Gear pump section P3 supplies hydraulic flow to both the lift control manifold and the steering con- trol valve. Hydraulic flow from this pump section is deliv- ered to the circuits through a proportional flow divider located in the fan control manifold.
  • Page 60 Hydraulic System Page 4 - - 20 Reelmaster 7000...

  • Page 61: Mow Circuit

    Mow Circuit Hydraulic flow for the mow circuit is supplied by two (2) When the reels are shut off, the over--running inertia sections of the gear pump (P1 and P2). Gear pump sec- load of the reels keeps driving the reel motors and can tion P1 supplies hydraulic flow to cutting units 1, 4 and turn them into pumps.
  • Page 62 Hydraulic System Page 4 - - 22 Reelmaster 7000...

  • Page 63: Steering Circuit

    Steering Circuit A four section gear pump is coupled to the piston (trac- the cylinder is proportional to the amount of the turning tion) pump. The gear pump section P3 supplies hydrau- on the steering wheel. Fluid leaving the cylinder flows lic flow to the steering control valve and the lift control back through the spool valve then through the T port and manifold.
  • Page 64 Hydraulic System Page 4 - - 24 Reelmaster 7000...

  • Page 65: Engine Cooling Fan Circuit

    Engine Cooling Fan Circuit A four section gear pump is coupled to the piston (trac- Reverse Direction Fan Operation (Fig. 18) tion) pump. The gear pump section P4 (farthest from the The TEC controller can reverse the cooling fan to clean piston pump) supplies hydraulic flow for the hydraulic debris from the rear intake screen.

  • Page 66: 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 67: Gpm Hydraulic Tester (Pressure And Flow)

    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 21 NOTE: This tester does not include hydraulic hoses (see Hydraulic Hose Kit TOR6007 below).

  • Page 68: High Flow Hydraulic Filter Kit

    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 enable you to connect test gauges into the system.
  • Page 69 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 27 Reelmaster 7000 Page 4 - 29...

  • Page 70: 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 Problem Possible Cause...

  • Page 71: Traction Circuit Problems

    Traction Circuit Problems NOTE: When troubleshooting traction circuit problems, exists in mow speed (4WD) but not in transport speed if a problem exists in both mow speed (4WD) and trans- (2WD), consider a problem in the 4WD traction system port speed (2WD), consider a faulty component that af- (e.g.

  • Page 72: Pto Problems

    PTO Problems Problem Possible Cause None of the cutting units will oper- Cutting units are not fully lowered to ground. ate. Operator seat is unoccupied. NOTE: Cutting units have to be fully Mow speed limiter is in transport (2WD) position. lowered and traction speed needs to be in mow speed (4WD) for cutting Electrical problem exists that prevents mow control manifold sole-...

  • Page 73: Steering Circuit Problems

    PTO Problems (Continued) Problem Possible Cause All cutting units operate slowly. Engine RPM is low. Cutting unit motor is damaged. Gear pump section (P1 or P2) is worn or damaged. Cutting unit stops under load. Relief valve in mow control manifold is bypassing. Cutting conditions (e.g.

  • Page 74: Lift/Lower Circuit Problems

    Lift/Lower Circuit Problems Problem Possible Cause Cutting units will not raise. Operator seat is unoccupied. NOTE: Operator must be in seat in Hydraulic oil level in reservoir is low. order to raise the cutting units. Electrical problem exists that prevents lift control manifold solenoid valve operation (see Chapter 5 -- Electrical System).

  • Page 75: Engine Cooling Fan Circuit Problems

    Engine Cooling Fan Circuit Problems Problem Possible Cause Cooling fan runs only in forward di- Fan control manifold solenoid cartridge valve (S1) is faulty. rection (fan does not run in reverse Electrical problem exists that prevents fan control manifold solenoid direction).

  • Page 76: Testing

    Testing The most effective method for isolating problems in the Precautions for Hydraulic Testing hydraulic system is by using hydraulic test equipment 1. Clean machine thoroughly before disconnecting or such as pressure gauges and flow meters in the circuits disassembling any hydraulic components. Always keep during various operational checks (See the Special in mind the need for cleanliness when working on hy- Tools section in this chapter).
  • Page 77 Which Hydraulic Tests Are Necessary? 3. If a lift/lower circuit problem exists, consider perform- ing one or more of the following tests: Lift/Lower Circuit Before beginning any hydraulic test, identify if the prob- Relief Pressure, Lift Cylinder Internal Leakage and/or lem is related to the traction circuit, mow circuit, lift/lower Gear Pump P3 Flow.

  • Page 78: Traction Circuit Charge Pressure Test

    Traction Circuit Charge Pressure Test (Using Pressure Gauge) FROM STEERING AND LIFT CIRCUITS (CHARGE CIRCUIT) FORWARD DIRECTION TEST SHOWN PRESSURE GAUGE Working Pressure Low Pressure Return or Suction Flow TO DECK CONTROL MANIFOLD TO DECK CONTROL MANIFOLD TO STEERING AND LIFT CIRCUITS (CHARGE CIRCUIT) TO FAN CIRCUIT FROM DECK MOTORS...
  • Page 79 NOTE: The traction charge circuit is designed to re- 9. Also, with the pressure gauge still connected to the place loss of hydraulic fluid from the closed loop traction charge pressure test port, monitor the gauge reading circuit. while operating the machine in forward and reverse. Start the engine and put throttle at full engine speed Procedure for Traction Circuit Charge Pressure Test (2850 RPM).

  • Page 80: Traction Circuit Relief Pressure Test

    Traction Circuit Relief Pressure Test (Using Pressure Gauge) FROM STEERING AND LIFT CIRCUITS (CHARGE CIRCUIT) FORWARD DIRECTION TEST SHOWN PRESSURE GAUGE Working Pressure Low Pressure Return or Suction Flow TO DECK CONTROL MANIFOLD TO DECK CONTROL MANIFOLD TO STEERING AND LIFT CIRCUITS (CHARGE CIRCUIT) TO FAN CIRCUIT FROM DECK MOTORS...
  • Page 81 Procedure for Traction Circuit Relief Pressure Test NOTE: Seal leakage across pilot directional valves PD1 and PD2 in 4WD/2WD control manifold can also 1. Make sure hydraulic oil is at normal operating tem- cause low forward traction pressure with reverse pres- perature by operating the machine for approximately ten sure meeting specifications.

  • Page 82: Traction Circuit Reducing Valve (Pr) Pressure Test

    Traction Circuit Reducing Valve (PR) Pressure Test (Using Pressure Gauge) FROM STEERING PRESSURE AND LIFT CIRCUITS (CHARGE CIRCUIT) GAUGE Working Pressure Low Pressure Return or Suction Flow TO DECK CONTROL MANIFOLD TO DECK CONTROL MANIFOLD TO STEERING AND LIFT CIRCUITS (CHARGE CIRCUIT) TO FAN CIRCUIT FROM DECK MOTORS...
  • Page 83 NOTE: When in reverse, pressure reducing valve (PR) limits the pressure to the rear axle motor to 450 PSI (31 bar) so the rear wheels will not scuff the turf. Procedure for Traction Circuit Pressure Reducing Valve (PR) Pressure Test 1.
  • Page 84 Rear Traction Circuit Relief (RV) Pressure Test (Using Pressure Gauge) FROM STEERING PRESSURE AND LIFT CIRCUITS (CHARGE CIRCUIT) GAUGE Working Pressure Low Pressure Return or Suction Flow TO DECK CONTROL MANIFOLD TO DECK CONTROL MANIFOLD TO STEERING AND LIFT CIRCUITS (CHARGE CIRCUIT) TO FAN CIRCUIT FROM DECK MOTORS...
  • Page 85 NOTE: Adjustable relief valve (RV) in the 4WD/2WD NOTE: Rear traction circuit relief (RV) pressure should control manifold reduces rear axle motor pressure be at least 100 PSI (7 bar) higher than traction circuit re- created in down hill, dynamic braking conditions to pre- ducing (PR) pressure.

  • Page 86: Piston (Traction) Pump Flow Test

    Piston (Traction) Pump Flow Test (Using Tester with Pressure Gauges and Flow Meter) FROM STEERING AND LIFT CIRCUITS (CHARGE CIRCUIT) TESTER Working Pressure Low Pressure Return or Suction Flow TO DECK CONTROL MANIFOLD TO DECK CONTROL MANIFOLD TO STEERING AND LIFT CIRCUITS (CHARGE CIRCUIT) TO FAN CIRCUIT FROM DECK MOTORS...
  • Page 87 Procedure for Piston (Traction) Pump Flow Test 7. Start engine and run at low idle speed. Check for any hydraulic leakage from tester and hose connections. This test measures piston (traction) pump output (flow). Correct any leaks before proceeding. During this test, pump load is created at the flow meter using the adjustable load valve on the tester.
  • Page 88 Mow Circuit Pressure Test (Using Pressure Gauge) TO RESERVOIR CONTROL TEST FOR FRONT MANIFOLD CUTTING UNITS SHOWN PRESSURE GAUGE FROM FAN CONTROL TO STEERING AND LIFT CIRCUITS TO FAN CIRCUIT ENGINE SPEED PISTON PUMP 2850/1550 GEAR PUMP BYPASS VALVE 5000 .071 .091 2.48...

  • Page 89: Mow Circuit Pressure Test

    Procedure for Mow Circuit Pressure Test 9. Disengage cutting units and shut off engine. Record test results. 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately ten 10.After testing is complete, disconnect pressure gauge (10) minutes.
  • Page 90 Mow Circuit Relief Pressure Test (Using Tester with Pressure Gauges and Flow Meter) TO RESERVOIR TESTER CONTROL MANIFOLD TEST FOR PUMP Working Pressure SECTION P1 SHOWN Low Pressure Return or Suction Flow FROM FAN CONTROL TO STEERING AND LIFT CIRCUITS TO FAN CIRCUIT ENGINE SPEED PISTON PUMP...

  • Page 91: Mow Circuit Relief Pressure Test

    The mow circuit relief pressure test should be performed to make sure that the mow circuit relief pressures are CAUTION correct. Procedure for Mow Circuit Relief Pressure Test Cutting reel blades will rotate when lowered with PTO switch in ON position. Keep away from cut- 1.

  • Page 92: Cutting Unit Motor Case Drain Leakage Test

    Cutting Unit Motor Case Drain Leakage Test (Using Tester with Pressure Gauges and Flow Meter) TO RESERVOIR STEEL TESTER MEASURING CONTAINER CONTROL MANIFOLD TEST FOR #4 CUTTING UNIT MOTOR SHOWN Working Pressure Low Pressure Return or Suction Flow FROM FAN CONTROL FROM GEAR FROM GEAR TO OIL COOLER...
  • Page 93 Procedure for Cutting Unit Motor Case Drain Leak- age Test CAUTION NOTE: Over a period of time, a cutting unit motor can wear internally. A worn motor may bypass oil to its case Cutting reel blades will rotate when lowered with drain causing the motor to be less efficient.

  • Page 94: Gear Pump P1 And P2 Flow (Mow Circuits) Test (Using Tester With Pressure Gauges And

    Gear Pump P1 and P2 Flow (Mow Circuits) Test (Using Tester with Pressure Gauges and Flow Meter) TO RESERVOIR CONTROL MANIFOLD TEST FOR GEAR PUMP SECTION P1 SHOWN FROM FAN CONTROL TO STEERING AND LIFT CIRCUITS TO FAN CIRCUIT ENGINE SPEED PISTON PUMP 2850/1550 GEAR...
  • Page 95 The gear pump P1 and P2 flow tests should be per- 7. Move throttle to high idle speed (2850 RPM). Do not formed to make sure that the mow circuits have ade- engage the cutting units. quate hydraulic flow. IMPORTANT: Do not fully restrict oil flow through NOTE: Gear pump P1 supplies hydraulic flow to cutting tester.
  • Page 96 Steering Circuit Relief Pressure Test (Using Pressure Gauge) CONTROL MANIFOLD CONTROL MANIFOLD TO LIFT MANIFOLD ENGINE SPEED 2850/1550 PISTON PUMP GEAR PUMP BYPASS VALVE 5000 .071 .091 2.48 1.03 1.03 .071 5000 STEERING WHEEL TURNED FOR RIGHT TURN 5 PSI STEERING 207 PSI CYLINDER...

  • Page 97: Steering Circuit Relief Pressure Test

    The steering circuit relief pressure test should be per- 9. If steering relief pressure is incorrect, inspect steer- formed to make sure that the steering circuit relief pres- ing relief valve located in the steering control valve (see sure is correct. Steering Control Valve Service in the Service and Re- pairs section of this chapter).

  • Page 98: Steering Cylinder Internal Leakage

    Steering Cylinder Internal Leakage Test STEERING CYLINDER FULLY LOOK FOR EXTENDED STEERING WHEEL LEAKAGE TURNED FOR RIGHT TURN STEEL PLUG 1050 TO FILTRATION MANIFOLD TO CHARGE CIRCUIT Hydraulic System Page 4 - - 58 Reelmaster 7000...
  • Page 99 The steering cylinder internal leakage test should be 7. After testing is completed, remove plug from the hy- performed if a steering problem is identified. This test draulic hose. Connect hose to the steering cylinder fit- will determine if the steering cylinder is faulty. ting.

  • Page 100: Lift/Lower Circuit Relief Pressure Test

    Lift/Lower Circuit Relief Pressure Test (Using Pressure Gauge) FROM STEERING CONTROL VALVE TO CHARGE CIRCUIT PRESSURE GAUGE Working Pressure Low Pressure Return or Suction Flow Hydraulic System Page 4 - - 60 Reelmaster 7000...
  • Page 101 The lift/lower circuit relief pressure test should be per- 9. If specification is not met, clean or adjust relief valve formed to make sure that the cutting unit lift and lower RV1 located in the lift control manifold (see Lift Control circuit relief pressure is correct.

  • Page 102: Gear Pump P3 Flow (Steering And Lift/Lower Circuits) Test (Using Tester With Pressure

    Gear Pump P3 Flow (Steering and Lift/Lower Circuits) Test (Using Tester with Pressure Gauges and Flow Meter) TO MOW CONTROL TO MOW CONTROL MANIFOLD (P2 PORT) MANIFOLD (P1 PORT) TESTER TO STEERING AND LIFT CIRCUITS TO FAN CIRCUIT ENGINE SPEED PISTON PUMP 2850/1550 GEAR...
  • Page 103 The gear pump P3 flow test should be performed to IMPORTANT: The pump is a positive displacement make sure that the steering, lift and traction charge cir- type. If pump flow is completely restricted or cuits have adequate hydraulic flow. stopped, damage to the pump, tester or other com- ponents could occur.

  • Page 104: Cooling Fan Circuit Test

    Cooling Fan Circuit Test (Using Pressure Gauge and Phototac) CONTROL MANIFOLD CONTROL MANIFOLD TO LIFT MANIFOLD PRESSURE GAUGE ENGINE SPEED 2850/1550 PISTON PUMP GEAR PUMP BYPASS VALVE 5000 .071 .091 2.48 1.03 1.03 .071 5000 5 PSI STEERING CYLINDER 207 PSI 1050 Working Pressure Low Pressure...
  • Page 105 The cooling fan circuit test should be performed to make 8. If pressure rises to approximately 3000 PSI (207 sure that the engine cooling fan circuit has the correct bar) but fan speed is low, consider that the fan motor is system pressure and fan speed.

  • Page 106: Gear Pump P4 Flow (Cooling Fan Circuit) Test (Using Tester With Pressure Gauges And

    Gear Pump P4 Flow (Cooling Fan Circuit) Test (Using Tester with Pressure Gauges and Flow Meter) TO MOW CONTROL TO MOW CONTROL MANIFOLD (P2 PORT) MANIFOLD (P1 PORT) TO STEERING AND LIFT CIRCUITS TO FAN CIRCUIT ENGINE SPEED PISTON PUMP 2850/1550 TESTER GEAR...
  • Page 107 The gear pump P4 flow test should be performed to IMPORTANT: The gear pump is a positive displace- make sure that the engine cooling fan circuit has ade- ment type. If pump flow is completely restricted or quate hydraulic flow. stopped, damage to the pump, tester or other com- ponents could occur.

  • Page 108: Adjustments

    Adjustments Adjust Control Manifold Relief Valves 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 109: 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 110: 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 111: Flush Hydraulic System

    Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time 8. Disconnect wire harness connector from engine run there is a severe component failure or the system is solenoid to prevent the engine from starting. contaminated (oil appears milky, black or contains 9.

  • Page 112: Filtering Closed- Loop Traction Circuit

    IMPORTANT: If using a filter that is not the bi- -direc- 2. Raise and support machine so all wheels are off the tional Toro high flow filter, do not press the traction ground (see Jacking Instructions in Chapter 1 -- Safety).

  • Page 113: Charge Hydraulic System

    Charge Hydraulic System NOTE: When initially starting the hydraulic system with 11. 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 114: Gear Pump

    Gear Pump 77 to 93 ft- -lb (105 to 126 N- -m) RIGHT 103 to 118 ft- -lb FRONT (140 to 160 N- -m) Figure 51 1. Flat washer (2 used) 9. Coupler 17. Spacer 2. Cap screw (2 used) 10.
  • Page 115 7. Support gear pump assembly to prevent it from fal- ling. RIGHT 8. Remove two (2) cap screws and washers securing FRONT gear pump to piston pump. Remove gear pump, coupler (item 9), spacer (item 17) and O--rings (item 16) from machine.

  • Page 116: Gear Pump Service

    Gear Pump Service 33 ft- -lb (45 N- -m) Figure 53 1. Dust seal 10. Seal (8 used) 19. Body (section P2) 2. Retaining ring 11. Idler gear 20. Body (section P3) 3. Flange washer 12. Drive shaft 21. Drive gear 4.
  • Page 117 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 118: Piston (Traction) Pump

    Piston (Traction) Pump 77 to 93 ft- -lb (105 to 126 N- -m) RIGHT 103 to 118 ft- -lb FRONT (140 to 160 N- -m) Figure 55 1. Flat washer (2 used) 9. Coupler 17. Spacer 2. Cap screw (2 used) 10.
  • Page 119 7. Remove gear pump from machine (see Gear Pump 9. Connect engine run solenoid electrical connector, Removal in this section). start the engine and check for proper operation. 8. Support the piston pump to prevent it from falling 10.Properly fill hydraulic system (see Charge Hydraulic while removing two (2) cap screws and washers retain- System).

  • Page 120: Piston (Traction) Pump Service

    Piston (Traction) Pump Service 40 to 48 in- -lb 4 to 6 ft- -lb (4.5 to 5.4 N- -m) (5 to 8 N- -m) 100 to 110 ft- -lb 40 to 48 in- -lb 25 to 28 ft- -lb (136 to 149 N- -m) (4.5 to 5.4 N- -m) (34 to 38 N- -m) 27 to 31 ft- -lb...
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  • Page 122: 4Wd/2Wd And Filtration/Charge Control Manifolds

    4WD/2WD and Filtration/Charge Control Manifolds RIGHT FRONT Figure 59 1. Filtration/charge control manifold 5. Flange head screw (3 used) 9. Flange head screw (2 used) 2. Hydraulic oil filter 6. Flange nut (2 used) 10. Flat washer (2 used) 3. 4WD/2WD control manifold 7.
  • Page 123 Removal (Fig. 59) 75 ft- -lb 25 ft- -lb (101 N- -m) NOTE: The ports on the manifolds are marked for easy (34 N- -m) identification of components. Refer to the Hydraulic Schematic in Chapter 9 -- Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each port.

  • Page 124: 4Wd/2Wd Control Manifold Service

    4WD/2WD Control Manifold Service 50 ft- -lb 20 ft- -lb (68 N- -m) (27 N- -m) 25 ft- -lb (34 N- -m) 25 ft- -lb (34 N- -m) 20 to 26 ft- -lb (27 to 35 N- -m) 20 ft- -lb 35 ft- -lb 20 ft- -lb (27 N- -m)
  • Page 125 NOTE: The ports on the manifold are marked for easy IMPORTANT: A flow control orifice (item 3) is lo- identification of components (e.g. P1 is a piston pump cated beneath the plug in 4WD/2WD control man- connection port and SV is the location for the solenoid ifold ports OR1 and OR2.

  • Page 126: Filtration/Charge Control Manifold Service

    Filtration/Charge Control Manifold Service 25 ft- -lb (34 N- -m) 35 ft- -lb (47 N- -m) 50 ft- -lb (68 N- -m) 25 ft- -lb (34 N- -m) 50 ft- -lb (68 N- -m) 25 ft- -lb (34 N- -m) 35 ft- -lb (47 N- -m) 25 ft- -lb...

  • Page 127: 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 128: Rear Axle Motor

    Rear Axle Motor Arrows on side of motor case point up RIGHT FRONT Figure 64 1. Axle motor 5. O- -ring 8. 90 hydraulic fitting 2. O- -ring 6. Hydraulic fitting 9. Cap screw (2 used) 3. Pinion gear 7. O- -ring 10.
  • Page 129 Removal (Fig. 64) Installation (Fig. 64) 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 130: Front Wheel Motors

    Front Wheel Motors 75 to 85 ft- -lb (102 to 115 N- -m) 23 24 75 to 85 ft- -lb (102 to 115 N- -m) Arrows on side of 75 to 85 ft- -lb motor case point up (102 to 115 N- -m) RIGHT 85 to 100 ft- -lb (116 to 135 N- -m)
  • Page 131 Removal (Fig. 65) 2. Position wheel motor to brake assembly making sure that arrows on the side of motor case point upward. 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key 3.

  • Page 132: Rear Axle And Front Wheel Motor Service

    Rear Axle and Front Wheel Motor Service 15 to 18 ft- -lb (20 to 24 N- -m) FRONT WHEEL MOTOR SHOWN Figure 66 1. Drive shaft 8. Shaft seal (front motor only) 15. Roll pin 2. Backplate 9. Retaining ring 16.

  • Page 133: Cutting Reel Motor

    Cutting Reel Motor The hydraulic reel motors used on all cutting units are 4. Install the cap screws for the reel drive motor into the the same. cutting unit side plate and leave approximately 1/2 inch (12.7 mm) of threads exposed on each screw. Removal 5.

  • Page 134: Cutting Reel Motor Service

    Cutting Reel Motor Service 33 ft- -lb (45 N- -m) 19 ft- -lb (25 N- -m) 19 ft- -lb (25 N- -m) Figure 68 1. Dust seal 7. Back- -up gasket 13. O- -ring 2. Retaining ring 8. Front wear plate 14.
  • Page 135 4. Loosen cap screws from the rear cover. 4. Inspect wear plates for the following: 5. Remove motor from the vise. Turn motor so that the A. Bearing areas should not have excessive wear or shaft end is facing down. Remove cap screws. scoring.
  • Page 136 Assembly (Fig. 68) 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 138: Mow Control Manifold

    Mow Control Manifold RIGHT FRONT Figure 72 1. Mow control manifold 3. Filter head 5. Lift control manifold 2. Flange head screw (4 used) 4. Hydraulic oil filter 6. Fan control manifold Hydraulic System Page 4 - - 98 Reelmaster 7000...
  • Page 139 Removal (Fig. 72) 4. Connect wire harness electrical connectors to the solenoid valve coils and backlap switches. NOTE: The ports on the manifold are marked for easy identification of components. Example: P1 is the gear 5. Lower and secure hood. pump connection port (see Hydraulic Schematic in 6.

  • Page 140: Mow Control Manifold Service

    Mow Control Manifold Service 25 ft- -lb (34 N- -m) 25 ft- -lb (34 N- -m) 20 ft- -lb 25 ft- -lb (27 N- -m) (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 141 Mow/Backlap Spool Service (Fig. 74) Manifold Plugs (Fig. 75) 1. To remove backlap spool (item 17) from mow man- NOTE: The mow control manifold uses several zero ifold: leak plugs. These plugs have a tapered sealing surface on the plug head that is designed to resist vibration in- A.

  • Page 142: 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 76 1. Steering wheel cover 6. Flange head screw (4 used) 11.
  • Page 143 7. Position steering column brace (item 12) to machine and secure with four (4) flange head screws. CAUTION 8. Slide rubber bellows to bottom of steering column. Before opening hydraulic system, operate all hy- 9. Position shroud in place and secure with removed draulic controls to relieve system pressure and fasteners (Fig.

  • Page 144: Steering Control Valve Service

    Steering Control Valve Service 20 to 24 ft- -lb (27 to 33 N- -m) Figure 79 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 146: Steering Cylinder

    Steering Cylinder RIGHT 100 to 125 ft- -lb FRONT (136 to 169 N- -m) Figure 80 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 147 Removal (Fig. 80) Installation (Fig. 80) 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 148: Steering Cylinder Service

    Steering Cylinder Service 50 to 60 ft- -lb (68 to 81 N- -m) Loctite #271 Figure 81 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.
  • Page 149 Disassembly (Fig. 81) Assembly (Fig. 81) 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 150: Engine Cooling Fan Motor

    Engine Cooling Fan Motor RIGHT 27 to 33 ft- -lb FRONT (37 to 44 N- -m) 16 17 12 to 14 ft- -lb (17 to 18 N- -m) Figure 82 1. Hydraulic fan motor 8. Washer 15. Hydraulic hose 2. O- -ring 9.
  • Page 151 5. Remove four (4) cap screws and washers used to se- IMPORTANT: Make sure to not damage the radiator cure fan (item 13) to fan hub. Remove fan. or other machine components while installing the fan motor and bracket assembly. IMPORTANT: Make sure to not damage the radiator or other machine components while loosening and 5.

  • Page 152: Engine Cooling Fan Motor Service

    Engine Cooling Fan Motor Service 33 ft- -lb (45 N- -m) Figure 84 1. Flange washer 7. Shaft seal 12. Idler gear 2. O- -ring 8. Backup gasket 13. Cap screw (4 used) 3. Front flange 9. Pressure seal 14. Dowel (2 used) 4.
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  • Page 154: Fan Control Manifold

    Fan Control Manifold RIGHT FRONT Figure 85 1. Fan control manifold 3. Filter head 5. Lift control manifold 2. Flange head screw (2 used) 4. Hydraulic oil filter 6. Mow control manifold Hydraulic System Page 4 - - 114 Reelmaster 7000...
  • Page 155 Removal (Fig. 85) 2. Install hydraulic manifold to the frame using Figure 85 as guide. NOTE: The ports on the manifold are marked for easy identification of components. Example: P1 is the gear 3. Remove caps and plugs from fittings and hoses. pump connection port (see Hydraulic Schematic in Properly connect hydraulic lines to manifold (see Hy- Chapter 9 -- Foldout Drawings to identify the function of...

  • Page 156: Fan Control Manifold Service

    Fan Control Manifold Service 60 in- -lb 60 in- -lb 50 ft- -lb (6.8 N- -m) (6.8 N- -m) (68 N- -m) 25 ft- -lb (34 N- -m) 25 ft- -lb (34 N- -m) 25 ft- -lb (34 N- -m) 25 ft- -lb (34 N- -m) 20 ft- -lb...
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  • Page 158: Lift Control Manifold

    Lift Control Manifold RIGHT FRONT Figure 88 1. Lift control manifold 4. Hydraulic oil filter 6. Flange head screw (2 used) 2. Filter mount bracket 5. Valve mount bracket 7. Mow control manifold 3. Filter head Removal (Fig. 88) 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- NOTE: The ports on the manifold are marked for easy ning of the Service and Repairs section of this chapter.
  • Page 159 2. Install hydraulic manifold to the frame using Figure 88 as guide. WARNING 3. Remove caps and plugs from fittings and hoses. Properly connect hydraulic lines to manifold (see Hy- Make sure that cutting units are fully lowered be- draulic Hose and Tube Installation in the General Infor- fore loosening hydraulic lines from lift manifold.

  • Page 160: Lift Control Manifold Service

    Lift Control Manifold Service 60 in- -lb 60 in- -lb (6.8 N- -m) (6.8 N- -m) 20 ft- -lb (27 N- -m) 20 ft- -lb 20 ft- -lb (27 N- -m) (27 N- -m) 60 in- -lb (6.8 N- -m) 20 ft- -lb (27 N- -m) 20 ft- -lb...
  • Page 161 For cartridge valve service procedures, see Control Manifold Cartridge Valve Service in this section. Refer to Figure 90 for cartridge valve and plug installation torque. IMPORTANT: A flow control orifice is placed be- neath the hydraulic fittings in lift control manifold ports C2, C3 and C4.

  • Page 162: Lift Circuit Junction Manifold

    Lift Circuit Junction Manifold RIGHT FRONT Figure 91 1. Filtration/charge control manifold 5. Flange head screw (3 used) 9. Flange head screw (2 used) 2. Hydraulic oil filter 6. Flange nut (2 used) 10. Flat washer (2 used) 3. 4WD/2WD control manifold 7.
  • Page 163 Removal (Fig. 91) 1. If fittings were removed from junction manifold, lubri- cate and place new O--rings onto fittings. Install fittings NOTE: The ports on the lift circuit junction manifold are into manifold openings making sure that orifice is cor- marked for easy identification of components (e.g.

  • Page 164: Front Lift Cylinders

    Front Lift Cylinders RIGHT FRONT 19 15 Figure 93 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. Cylinder pin 25. Lift arm (cutting unit #5) 4.
  • Page 165 Removal (Fig. 93) Installation (Fig. 93) 1. Park machine on a level surface, lower cutting units, 1. If fittings were removed from lift cylinder, lubricate stop engine, engage parking brake and remove key and place new O--rings onto fittings. Install fittings into from the ignition switch.

  • Page 166: Rear Lift Cylinders

    Rear Lift Cylinders RIGHT FRONT Figure 95 1. Flange nut (2 used) 13. Lock nut 24. Lock nut 2. Bulkhead bracket 14. Straight hydraulic fitting 25. Flat washer 3. Hydraulic tee fitting 15. Cylinder pin 26. Washer (2 per pin) 4.
  • Page 167 Removal (Fig. 95) 2. Position cylinder barrel clevis to frame and insert cyl- inder pin (item 15) with one (1) retaining ring installed 1. Park machine on a level surface, lower cutting units, through the frame and cylinder clevis. Secure pin with stop engine, engage parking brake and remove key second retaining ring.

  • Page 168: Lift Cylinder Service (Serial Number Below 314000200)

    Lift Cylinder Service (Serial Number Below 314000200) 35 to 45 ft- lb (48 to 61 N- m) Loctite #271 Figure 97 1. Barrel 7. Piston 13. Head seal 2. Lock nut 8. Buffer seal 14. Support washer 3. Wear band 9.
  • Page 169 Disassembly (Fig. 97) Assembly (Fig. 97) 1. Remove oil from lift cylinder into a drain pan by slowly 1. Make sure all cylinder components are clean before pumping the cylinder shaft. Plug both ports and clean assembly. the outside of the cylinder. 2.

  • Page 170: Lift Cylinder Service (Serial Number Above 314000200)

    Lift Cylinder Service (Serial Number Above 314000200) 35 to 45 ft- lb (48 to 61 N- m) Loctite #271 11 12 Figure 98 1. Barrel 6. Piston 11. Back- up 2. Lock nut 7. Rod 12. Retaining ring 3. Wear ring 8.
  • Page 171 Disassembly (Fig. 98) Assembly (Fig. 98) 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 172: 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 99 1. Hydraulic reservoir 9. Clamp (2 used) 16.
  • Page 173 Removal (Fig. 99) 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 174: Hydraulic Oil Cooler

    Hydraulic Oil Cooler RIGHT FRONT Figure 100 1. Oil cooler 7. Plenum 12. Hydraulic hose (2 used) 2. Mount plate (2 used) 8. Flange nut (4 used) 13. Cap screw (2 used) 3. Flange head screw (8 used) 9. O- ring 14.
  • Page 175 Removal (Fig. 100) 2. Install oil cooler using Figures 100, 101 and 102 as guides. See Hydraulic Hose and Tube Installation in the General Information section of this chapter for hydraulic CAUTION hose installation information. 3. Check oil level in hydraulic reservoir and add correct oil if necessary.
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  • Page 177 ....... Toro Electronic Controllers (TEC) ....

  • Page 178: 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 179: Electrical Drawings

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

  • Page 180: 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 181: Diagnostic Display

    Toro Electronic Controllers (TEC) inputs and outputs can be checked using the Diagnostic Display. Toro Part Number for Diagnostic Display: 85- 4750 Toro Part Number for Overlay (English): 120- 1679 NOTE: Diagnostic Display overlays are available in several languages for your Reelmaster.

  • Page 182: Troubleshooting

    Reelmaster. Diagnostic Display Reelmaster 7000 machines are equipped with a Toro Verify Diagnostic Display Input Functions Electronic Controller (TEC) which controls machine 1. Park machine on a level surface, lower the cutting electrical functions.
  • Page 183 5. The “inputs displayed” LED, on lower right column of the Diagnostic Display, should be illuminated. If “outputs displayed” LED is illuminated, press the toggle button on OVERLAY the Diagnostic Display to change to “inputs displayed” LED. 6. The Diagnostic Display will illuminate the LED associated with each of the inputs when that input switch is closed.
  • Page 184 Diagnostic Display Inputs Diagnostic Display LED Operation P BRAKE OFF Parking brake released: LED ON Parking brake applied: LED OFF DECKS DOWN Cutting units lowered: LED ON Cutting units raised: LED OFF NEUTRAL Traction pedal in neutral: LED ON Traction pedal in forward or reverse: LED OFF SEAT SWITCH Operator seat occupied: LED ON Operator seat empty: LED OFF...

  • Page 185: Verify Diagnostic Display Output Functions

    The Diagnostic Display also has the ability to detect correctly illuminated, this indicates a TEC controller which output solenoids or relays are energized by the problem. If this occurs, contact your Toro Distributor TEC controller(s). This is a quick way to determine if a for assistance.

  • Page 186: Starting Problems

    Starting 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 F3--1 (2 amp) is faulty (open). The ignition switch or circuit wiring is faulty. Starter solenoid clicks, but starter will not crank.

  • Page 187: General Run & Transport Problems

    Starting Problems (continued) Problem Possible Causes Engine cranks, but does not start. Fuel tank is empty. Engine is not cranking fast enough. Engine and/or fuel may be too cold. Fuse F5--1 (40 amp) is faulty (open). Glow relay, glow plugs or fuse M1 (60 amp) are faulty. Engine run solenoid or circuit wiring is faulty.

  • Page 188: Cutting Unit Operating Problems

    Cutting Unit Operating Problems Cutting units run, but should not, when raised. Cutting The cutting unit position switch or circuit wiring is units shut off with PTO switch. faulty. Wire harness connections are incorrectly connected to hydraulic solenoid valve coils on hydraulic mow control manifold.

  • Page 189: 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 190: Check Operation Of Interlock Switches

    Replace any malfunctioning switches before op- NOTE: Use the Diagnostic Display (see Special Tools erating the machine. in this chapter) to test Toro Electronic Controller inputs and outputs before further troubleshooting of an electri- cal problem on your Reelmaster. Electrical System...

  • Page 191: Adjustments

    Adjustments Mow/Transport Sensor The mow/transport sensor is a normally open proximity sensor that closes when the mow speed limiter is placed in the transport position. The sensor mounts to a bracket on the footrest platform (Fig. 12). The sensing plate for the mow/transport sensor is a tab on the mow speed lim- iter.

  • Page 192: Cutting Unit Position Sensor

    Cutting Unit Position Sensor The cutting unit position sensor is a normally open prox- imity sensor that is located on the front carrier frame (Fig. 13). The sensing plate that closes the sensor is a gusset on the front right cutting unit (#5) lift arm. When the cutting units are lowered, the gusset on the lift arm is located near the position sensor and the sensor closes.

  • Page 193: 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 Kubota Workshop Manual, Diesel Engine, 03--M-- that power to the circuit has been disconnected.

  • Page 194: Fuses

    Fuses Your Reelmaster 7000 uses numerous fuses for circuit Fuse Testing protection. The fuses are located in two (2) areas of the 1. Make sure that ignition switch is OFF and key is re- machine. Most of the fuses reside in the power center moved from switch.

  • Page 195: Indicator Lights

    Indicator Lights Charge Indicator Light The charge indicator light should come on when the igni- tion switch is in ON with the engine not running or with an improperly operating charging circuit while the en- gine is running. To test the charge indicator light and circuit wiring, ground the white wire attached to alternator.

  • Page 196: Hour Meter

    Hour Meter The hour meter is located on the outside of the console arm. Hobbs 1. Connect the positive (+) terminal of a 12 VDC source QUARTZ to the positive (+) terminal of the hour meter. 0 0 0 0 HOURS 2.

  • Page 197: Pto Switch

    PTO Switch The PTO switch is located on the console arm (Fig. 23). 7. After testing is completed, connect the wire harness The PTO switch is pulled up to engage the PTO and connector to the PTO switch. pushed in to disengage the PTO. 8.

  • Page 198: Cutting Unit Lift Switch

    Cutting Unit Lift Switch The cutting unit lift switch is used as an input for the TEC 7. After testing is completed, connect wire harness controller to raise or lower the cutting units. When the lift connector to the lift switch. switch paddle is depressed and held, the cutting units 8.

  • Page 199: Headlight Switch

    Headlight Switch The headlight switch is located on the operator side of the console arm (Fig. 28). This two (2) position rocker switch allows the headlights to be turned on and off. Testing 1. Make sure ignition switch is OFF. Remove key from ignition switch.

  • Page 200: Engine Cooling Fan Switch

    Engine Cooling Fan Switch The engine cooling fan switch is located on the outside of the console arm (Fig. 30). This two (2) position rocker switch allows the engine cooling fan to run in the normal, automatic mode or in the manual reverse (momentary) direction.

  • Page 201: Seat Switch

    Seat Switch The seat switch is normally open and closes when the operator is on the seat. The seat switch and its electrical connector are located in the seat assembly. If the trac- tion system or PTO switch is engaged when the operator raises out of the seat, the engine will stop.

  • Page 202: Parking Brake Switch

    Parking Brake Switch The parking brake switch is a normally open proximity switch. The parking brake switch is attached to the bot- tom of the RH brake pedal (Fig. 33). When the parking brake is not applied, the parking brake detent is positioned near the target end of the parking brake switch so the switch is closed.

  • Page 203: Mow/Transport Sensor

    Mow/Transport Sensor The mow/transport sensor is a normally open proximity 4. If the mow/transport sensor tests correctly and a cir- sensor that closes when the mow speed limiter is placed cuit problem still exists, check wire harness (see Electri- in the transport (2WD) position. The sensor mounts to cal Schematic and Wire Harness Drawings in Chapter a bracket on the footrest platform.

  • Page 204: Cutting Unit Position Sensor

    Cutting Unit Position Sensor The cutting unit position sensor is a normally open prox- 5. If the cutting unit position sensor tests correctly and imity sensor that is located on the traction unit frame a circuit problem still exists, check wire harness (see (Fig.

  • Page 205: Backlap Switches

    When a backlap lever is in the backlap position, the switch closes. The backlap switches are attached to the hydraulic mow control man- ifold located under the hood (Fig. 38). The Toro Elec- tronic Controller (TEC) uses the backlap switches as inputs.

  • Page 206: Glow And Main Power Relays

    Glow and Main Power Relays The glow and main power relays are located at the pow- 7. Disconnect voltage and test leads from the relay ter- er center behind the operator seat (Fig. 40). These re- minals. lays are attached to the wire harness with a four (4) wire 8.

  • Page 207: Start Relay

    Start Relay The start relay is located at the power center behind the 10.Secure relay to mounting bracket and connect wire operator seat (Fig. 42). This relay is attached to the wire harness connector to relay. Install cover to power center. harness with a five (5) wire connector (Fig.

  • Page 208: Reel Speed Potentiometer

    Reel Speed Potentiometer The reel speed potentiometer controls the cutting reel speed. The TEC controller uses the potentiometer set- ting as an input to determine the necessary voltage out- put for the hydraulic mow control manifold proportional valves (SP1 and SP2) for correct cutting reel speed. The reel speed potentiometer is located under the operator seat (Fig.

  • Page 209: Hydraulic Solenoid Valve Coils

    Hydraulic Solenoid Valve Coils Numerous hydraulic solenoid valve coils are used on 5. If solenoid coil resistance is incorrect, replace sole- the hydraulic control manifolds of Reelmaster 7000 ma- noid (see Hydraulic Solenoid Valve Coil Removal and chines. When energized by the TEC controller, these Installation in the Service and Repairs section of this coils provide hydraulic circuit control.

  • Page 210: Traction Neutral Switch

    Traction Neutral Switch The traction neutral switch is closed when the traction See Piston Pump Control Assembly in Chapter 4 -- Hy- pedal is in the neutral position and opens when the pedal draulic Systems for disassembly and assembly proce- is depressed in either direction.

  • Page 211: Toro Electronic Controller (Tec)

    Toro Electronic Controller (TEC) The Reelmaster 7000 uses a Toro Electronic Controller (TEC) to monitor the condition of various switches (in- puts) and then directs power output to allow certain ma- chine functions. The controller is located under the operator seat (Fig. 49). The handheld Diagnostic Dis-...

  • Page 212: Engine Coolant And Hydraulic Oil Temperature Senders

    Engine Coolant and Hydraulic Oil Temperature Senders Two (2) identical temperature senders are used as in- 7. After allowing the sender to cool, install sender: puts for the TEC controller to identify if either the engine A. Install new O--ring on sender and thread sender coolant or hydraulic oil temperature has reached an ex- into port.

  • Page 213: Fuel Pump

    Fuel Pump The fuel pump is energized by the TEC controller when the ignition switch is either in the START or ON position. The fuel pump is attached to the left side frame rail. IMPORTANT: When testing fuel pump, make sure that pump is not operated without fuel.

  • Page 214: Fuel Stop Solenoid

    Fuel Stop Solenoid The fuel stop solenoid used on your Reelmaster must be energized for the diesel engine to run. The solenoid is mounted to the injection pump on the engine (Fig. 55). The TEC controller monitors the operation of the fuel stop solenoid.

  • Page 215: Engine Temperature Sender

    Engine Temperature Sender The engine temperature sender is located near the al- 5. Install sender to the water flange. ternator on the water flange attached to the engine cylin- A. Clean threads of water flange and sender thor- der head (Fig. 57). There is a gray wire attached to the oughly.

  • Page 216: Oil Pressure Switch

    Oil Pressure Switch The engine oil pressure switch is located on the engine above the starter motor (Fig. 59). The oil pressure switch is a normally closed switch that opens with pres- sure. The oil pressure switch should open at approximately 8 PSI (0.56 kg/cm The TEC controller monitors the operation of the oil pressure switch.

  • Page 217: Service And Repairs

    Service and Repairs NOTE: For more component repair information, see the Kubota Workshop Manual, Diesel Engine, 03--M-- DI--E3B. 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 218: 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 219: 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 220: 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 221: 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. 61) 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 222 This page is intentionally blank. Electrical System Page 5 - - 46 Reelmaster 7000...

  • Page 223: Axles, Planetaries And Brakes

    ......Pinion Gear to Ring Gear Engagement ..Page 6 − 1 Reelmaster 7000−D (Model 03708) Axles, Planetaries and Brakes...

  • Page 224: Specifications

    Capacity (each wheel) 16 to 20 fl oz (0.47 to 0.59 L) Rear axle lubricant SAE 85W−140 wt. gear lube Rear axle gear lube capacity 80 fl oz (2.37 l) Page 6 − 2 Axles, Planetaries and Brakes Reelmaster 7000−D (Model 03708)

  • Page 225: General Information

    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. Page 6 − 3 Reelmaster 7000−D (Model 03708) Axles, Planetaries and Brakes...

  • Page 226: Adjustments

    2. Chock rear wheels and jack up front of machine (see Jacking Instructions in Chapter 1 − Safety). Support ma- chine with jack stands. Page 6 − 4 Axles, Planetaries and Brakes Reelmaster 7000−D (Model 03708)
  • Page 227 This page is intentionally blank. Page 6 − 5 Reelmaster 7000−D (Model 03708) Axles, Planetaries and Brakes...

  • Page 228: Service And Repairs

    18. RH brake assembly 7. Spring plate 13. Piston motor (2 used) 19. Gasket 8. Compression spring 14. Flat washer (2 per motor) 20. Brake cable (LH shown) Page 6 − 6 Axles, Planetaries and Brakes Reelmaster 7000−D (Model 03708)
  • Page 229 75 to 85 ft−lb (101 to 115 N−m). (Fig. 2). 8. Install wheel assembly. 1. Install splined brake shaft into brake assembly. Make sure that splines engage rotating discs in brake assem- bly. Page 6 − 7 Reelmaster 7000−D (Model 03708) Axles, Planetaries and Brakes...
  • Page 230 12.Remove jack stands and lower machine to ground. 10.Test planetary drive operation. Tighten wheel lug nuts in a crossing pattern from 85 to 100 ft−lb (116 to 135 N−m). Page 6 − 8 Axles, Planetaries and Brakes Reelmaster 7000−D (Model 03708)
  • Page 231 This page is intentionally left blank. Page 6 − 9 Reelmaster 7000−D (Model 03708) Axles, Planetaries and Brakes...

  • Page 232: Brake Inspection And Repair

    Install a new seal (item 2). 4. Remove extension springs (item 12). 9. Use a new gasket (item 10) when installing brake as- sembly to machine. Page 6 − 10 Axles, Planetaries and Brakes Reelmaster 7000−D (Model 03708)
  • Page 233 This page is intentionally blank. Page 6 − 11 Reelmaster 7000−D (Model 03708) Axles, Planetaries and Brakes...

  • Page 234: Planetary Drive Assembly

    (see Plane- tary Wheel Drive Service in this section). Use the following procedure to remove and install the planetary wheel drive assembly from machine. Page 6 − 12 Axles, Planetaries and Brakes Reelmaster 7000−D (Model 03708)
  • Page 235 9. Remove jack stands and lower machine to ground. Tighten wheel lug nuts in a crossing pattern from 85 to 100 ft−lb (116 to 135 N−m). Page 6 − 13 Reelmaster 7000−D (Model 03708) Axles, Planetaries and Brakes...

  • Page 236: Oph−2 Series Planetary Drive Service

    26. Primary carrier assembly 8. Lock washer (16 used) 18. Plug (2 used) 27. Secondary gear 9. Housing 19. O−ring (2 used) 28. Secondary carrier assembly 10. Dowel pin (2 used) Page 6 − 14 Axles, Planetaries and Brakes Reelmaster 7000−D (Model 03708)
  • Page 237 Remove ring gear and two (2) dowel pins B. Set inner bearing cone (item 4) into inner bearing (item 10) from housing. cup. Page 6 − 15 Reelmaster 7000−D (Model 03708) Axles, Planetaries and Brakes...
  • Page 238 If required, remove retaining ring and install a thrust washer of different thickness to adjust endplay. L. Install new O−ring (item 13) into groove in hous- ing. Page 6 − 16 Axles, Planetaries and Brakes Reelmaster 7000−D (Model 03708)
  • Page 239 This page is intentionally blank. Page 6 − 17 Reelmaster 7000−D (Model 03708) Axles, Planetaries and Brakes...

  • Page 240: Va02 Series Planetary Drive Service

    17. Plug 26. Drive shaft 8. Lock washer (8) 18. O−ring 27. Primary carrier assembly 9. Housing 19. Plug (2) 28. Secondary carrier assembly 10. Dowel pin (4) Page 6 − 18 Axles, Planetaries and Brakes Reelmaster 7000−D (Model 03708)
  • Page 241 C. Remove the O−ring from the housing bore and and secure ring gear to housing with lock washers discard. and socket head screws. Tighten screws to 27 ft−lb (37 N−m). Page 6 − 19 Reelmaster 7000−D (Model 03708) Axles, Planetaries and Brakes...
  • Page 242 F. Loosen the lock nut completely, then tighten to 90 Tighten wheel lug nuts in a crossing pattern from 85 to ft−lb (122 N−m). 100 ft−lb (116 to 135 N−m). Page 6 − 20 Axles, Planetaries and Brakes Reelmaster 7000−D (Model 03708)
  • Page 243 This page is intentionally blank. Page 6 − 21 Reelmaster 7000−D (Model 03708) Axles, Planetaries and Brakes...

  • Page 244: Rear Axle Assembly

    Rear Axle Motor in the Service and Repairs section of Chapter 4 − Hydraulic System). may result in personal injury. 6. Remove hydraulic hoses from steering cylinder. Page 6 − 22 Axles, Planetaries and Brakes Reelmaster 7000−D (Model 03708)
  • Page 245 2. Bevel gear case (LH) WARNING Failure to maintain proper wheel lug nut torque could result in failure or loss of wheel and may result in personal injury. Page 6 − 23 Reelmaster 7000−D (Model 03708) Axles, Planetaries and Brakes...

  • Page 246: Rear Axle Service

    Rear Axle Service Figure 12 Page 6 − 24 Axles, Planetaries and Brakes Reelmaster 7000−D (Model 03708)
  • Page 247 64. O−ring NOTE: Figure 12 illustrates the rear axle used on the Reelmaster 7000. Service procedures for the rear axle is on the following pages of this section. Page 6 − 25 Reelmaster 7000−D (Model 03708) Axles, Planetaries and Brakes...

  • Page 248: Bevel Gear Case And Axle Case

    (Fig. 15). Compound 57 to 67 ft−lb (77 to 91 N−m) Figure 15 1. Axle case 3. Screw (2 used) 2. Axle case support 4. Support shim Page 6 − 26 Axles, Planetaries and Brakes Reelmaster 7000−D (Model 03708)
  • Page 249 0.984 to 0.987 inch (25.00 to 25.08 mm) Figure 17 2. Inspect all gears, shafts, bearings, cases and covers 1. Knuckle pin 2. Axle case support for damage and wear. Replace components as neces- sary. Page 6 − 27 Reelmaster 7000−D (Model 03708) Axles, Planetaries and Brakes...
  • Page 250 Figure 19 1. Axle case cover 5. Upper bevel gear 2. Lower bevel gear 6. Collar 3. Bevel gear shaft 7. Upper bearing 4. Lower bearing 8. Knuckle pin Page 6 − 28 Axles, Planetaries and Brakes Reelmaster 7000−D (Model 03708)
  • Page 251 (0.1 mm), 0.008 inch (0.2 mm) and 0.020 inch (0.5 mm) thickness. Figure 22 1. Axle cover assembly 4. Dial indicator 2. Lower bevel gear 5. Axle bearing shims 3. Axle gear Page 6 − 29 Reelmaster 7000−D (Model 03708) Axles, Planetaries and Brakes...

  • Page 252: Differential Shafts

    Bevel Gear Case/Axle Case Assembly in this section of Figure 24 this manual). 1. Retaining ring 4. Bearing 2. Bevel gear 5. Bearing shims 3. Differential shaft 6. O-ring Page 6 − 30 Axles, Planetaries and Brakes Reelmaster 7000−D (Model 03708)

  • Page 253: Axle Shafts

    20 ft-lb (23 to 27 N−m). 1. Bearing 4. Spacer 2. Bevel gear 5. Retaining ring 3. Shims Figure 27 1. Axle shaft seal 3. Bearing 2. Axle cover 4. Axle shaft Page 6 − 31 Reelmaster 7000−D (Model 03708) Axles, Planetaries and Brakes...

  • Page 254: Input Shaft/Pinion Gear

    6. Inspect all gears, shafts, bearings, spacers and 4. Coat new O-ring with grease. Install O-ring in the oil cases for damage and wear. Replace components as seal collar and install the collar. necessary. Page 6 − 32 Axles, Planetaries and Brakes Reelmaster 7000−D (Model 03708)
  • Page 255 1. Axle case 3. Dial indicator 2. Screwdriver 4. Input shaft/pinion gear 16.Use a new gasket and install the cover plate. Use a new O-ring and install the drive motor. Page 6 − 33 Reelmaster 7000−D (Model 03708) Axles, Planetaries and Brakes...

  • Page 256: Differential Gear

    Figure 34 1. Differential pinion shaft 5. Side gear shims 2. Pinion gear 6. Ring gear 3. Pinion washer 7. Differential case 4. Side gear 8. Bolt/washer (8 used) Page 6 − 34 Axles, Planetaries and Brakes Reelmaster 7000−D (Model 03708)
  • Page 257 0.551 to 0.552 inch (13.10 to 14.02 mm) 3. Inspect all gears, shafts, bearings, cases and covers for damage and wear. Replace components as neces- sary. Figure 36 1. Pinion shaft 2. Pinion gear Page 6 − 35 Reelmaster 7000−D (Model 03708) Axles, Planetaries and Brakes...
  • Page 258 11. After backlash and tooth contact have been ad- justed, align the hole in the differential pinion shaft with the hole in the differential case and install a new spring pin. Page 6 − 36 Axles, Planetaries and Brakes Reelmaster 7000−D (Model 03708)

  • Page 259: Pinion Gear To Ring Gear Engagement

    2. Bearing case shims shims readjust backlash to the correct specification before 3. Differential gear case checking the contact pattern. Page 6 − 37 Reelmaster 7000−D (Model 03708) Axles, Planetaries and Brakes...
  • Page 260 B. Install thicker or additional differential bearing shim(s) to move ring gear forward. Figure 43 C. Repeat until proper tooth contact and pinion gear to ring gear backlash are correct. Page 6 − 38 Axles, Planetaries and Brakes Reelmaster 7000−D (Model 03708)
  • Page 261 Chapter 7 Chassis Table of Contents GENERAL INFORMATION ..... Operator’s Manual ......Cutting Unit Identification .

  • Page 262: 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 are identified as shown in Figure 1.
  • Page 263 This page is intentionally blank. Reelmaster 7000 Page 7 - - 3 Chassis...

  • Page 264: 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 used) 9.
  • Page 265 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 266: Console Arm

    Console Arm RIGHT FRONT Figure 5 1. Console arm frame 16. Flange head screw (2 used) 31. Screw (2 used) 2. LH cover 17. Flange nut (2 used) 32. Foam seal 3. RH cover 18. Ignition switch 33. Power point 4.
  • Page 267 Disassembly (Fig. 5) 1. Park machine on a level surface, lower cutting units, stop engine and engage parking brake. Remove key from ignition switch. 2. Remove two (2) flange head screws (item 8) and then cover plate (item 7) from outside of console arm. Locate and retrieve two (2) flange spacers (item 37).

  • Page 268: 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 269 Removal (Fig 7) 4. Position lift cylinder rod clevis to lift arm 1. Park machine on a level surface, lower cutting units, 5. Make sure that one (1) retaining ring and washer are stop engine, engage parking brake and remove key installed on cylinder pin (item 4).

  • Page 270: Lift Arms For Rear Cutting Units (#2 And #3)

    Lift Arms for Rear Cutting Units (#2 and #3) RIGHT FRONT Figure 9 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 271 CAUTION CAUTION Be careful when applying tension to the torsion Be careful when removing tension from the tor- spring on the rear lift arms. The spring is under sion spring on the rear lift arms. The spring is un- heavy load and may cause personal injury. der heavy load and may cause personal injury.

  • Page 272: Operator Seat

    Operator Seat RIGHT FRONT Figure 12 1. Seat frame 13. Flat washer (2 used) 25. Flange nut (10 used) 2. Seat plate 14. Flange head screw (4 used) 26. Cap screw 3. Torsion spring 15. Flange nut (4 used) 27. Hex nut 4.
  • Page 273 Removal (Fig. 12) A. Secure support bracket (item 21) and support channel (item 19) with flange nut (item 25) and car- 1. Park machine on a level surface, lower cutting units, riage screw (item 24). stop engine, apply parking brake and remove key from the ignition switch.

  • Page 274: Operator Seat Service

    Operator Seat Service Figure 14 1. Backrest cushion 12. Cap screw (2 used) 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 used) 25.
  • Page 275 Disassembly (Fig. 14) Assembly (Fig. 14) 1. Remove seat from machine for service (see Opera- 1. Assemble operator seat using Figure 14 as a guide. tor Seat Removal in this section). 2. Install seat to machine (see Operator Seat Installa- 2.

  • Page 276: Operator Seat Suspension

    Operator Seat Suspension RIGHT FRONT Figure 15 1. Cover 14. Washer (2 used) 27. Clamp (2 used) 2. Cover 15. Tether 28. Hose nipple 3. Level control 16. Rivet (2 used) 29. Screw 4. Air control valve 17. Washer (4 used) 30.
  • Page 277 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 278: Hood

    Hood RIGHT FRONT Figure 17 1. Screen 12. Rubber bumper (2 used) 23. LH hood frame tube 2. Latch keeper 13. Flange nut (2 used) 24. Hood frame tube 3. Pop rivet (2 used) 14. Bulb seal (2 used) 25. Flange head screw (26 used) 4.
  • Page 279 Removal (Fig. 17) Installation (Fig. 17) 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 using Figure 17 as a guide. from the ignition switch. 2.
  • Page 280 This page is intentionally blank. Chassis Page 7 - - 20 Reelmaster 7000...
  • Page 281 ....(cutting units with aluminum side plates) ..Reel Assembly (cutting units with painted side plates) ..Page 8 − 1 Reelmaster 7000−D (Model 03708) DPA Cutting Units...

  • Page 282: Specifications

    Height−of−Cut (HOC): Cutting height is adjusted on the front roller by two (2) vertical screws. Effective HOC may vary depending on turf conditions, type of bedknife, roller type and installed attachments. Page 8 − 2 Reelmaster 7000−D (Model 03708) DPA Cutting Units...

  • Page 283: General Information

    (e.g. rear roller brush), the installation instructions for the kit includes set−up and operation information. Refer to those publications for additional information when servicing the cutting units. Page 8 − 3 Reelmaster 7000−D (Model 03708) DPA Cutting Units...

  • Page 284: 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 285: Plastic Plug

    Figure 6 Spline Insert Tool Toro Part Number: TOR4074 (9 tooth) Use the spline insert tool for rotating the cutting reel when hydraulic motor is removed. Also, use this tool for installation of threaded inserts into the cutting reel shaft.

  • Page 286: Diameter/Circumference Measuring Tape

    This tool should be used with the Toro Guide to Evaluation Reel Mower Performance and Using the TurfEvaluator (Toro part no. 97931SL).
  • Page 287 Figure 13 Pulley Alignment Tool Toro Part Number: 114−5446 Use pulley alignment tool to verify alignment of groomer and/or rear roller brush drive and driven pulleys. Figure 14 Page 8 − 7 Reelmaster 7000−D (Model 03708) DPA Cutting Units...

  • Page 288: Bedknife Top Angle Indicator And Mount

    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. Since there can be variations in the mounting surface of the bedbar, it is necessary to grind the bedknife after installing it to the bedbar.

  • Page 289: 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 290 Use correct number of reel blades for clip frequency and optimum height−of−cut range. Cutting unit alignment and carrier frame ground Check carrier frames and lift arms for damage, binding following conditions or bushing wear. Repair if necessary. Page 8 − 10 Reelmaster 7000−D (Model 03708) DPA Cutting Units...
  • Page 291 Cutting unit accessories A variety of cutting unit accessories are available that can be used to enhance aftercut appearance. Refer to Operator’s Manual for a listing of available accessories. Page 8 − 11 Reelmaster 7000−D (Model 03708) DPA Cutting Units...

  • Page 292: Adjustments

    In addition, the rear roller positioning system allows for various height-of-cut ranges and aggressiveness of cut selections. Page 8 − 12 Reelmaster 7000−D (Model 03708) DPA Cutting Units...

  • Page 293: Reel Bearing Adjustment (Cutting Units With Painted Side Plates)

    Chapter 9 − Belt Driven Groomer for information on groomer. See Rear Roller Brush in the Service and Repairs section of this chapter for information on rear roller brush. Page 8 − 13 Reelmaster 7000−D (Model 03708) DPA Cutting Units...

  • Page 294: Leveling Rear Roller

    Use the shim on one side of the rear roller and install it between the rear roller bracket and roller shim (Fig. 19). 8. After leveling rear roller, complete cutting unit set−up and adjustment sequence. Page 8 − 14 Reelmaster 7000−D (Model 03708) DPA Cutting Units...
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  • Page 296: Service And Repairs

    Slide motor shaft into reel insert. 4. Rotate the motor counter−clockwise until the motor flanges are encircling the cap screws. Tighten two (2) cap screws to secure reel motor to cutting unit. Page 8 − 16 Reelmaster 7000−D (Model 03708) DPA Cutting Units...

  • Page 297: 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 298: Bedbar Assembly

    4. Loosen the lock nuts (item 10) on each bedbar pivot bolt. 5. Remove two (2) bedbar pivot bolts (item 9), two (2) metal washers and four (4) plastic washers from the cut- ting unit side plates. Page 8 − 18 Reelmaster 7000−D (Model 03708) DPA Cutting Units...
  • Page 299 The plastic washer be- tween the bedbar and side plate should be loose. Page 8 − 19 Reelmaster 7000−D (Model 03708) DPA Cutting Units...

  • Page 300: Bedknife Replacement And Grinding

    # TOR510880 7. After installing bedknife to bedbar, grind bedknife. 1st − 10 in−lb (1 N−m) 8 10 2nd − 200 to 250 in−lb (23 to 28 N−m) Figure 27 Page 8 − 20 Reelmaster 7000−D (Model 03708) DPA Cutting Units...
  • Page 301 Low HOC Figure 31 Lead −in Chamfer Standard Bedknife Low HOC 1. Use Toro General Service Training Book, Reel Mow- Extended EdgeMax Low HOC er Basics (part no. 09168SL) and grinder manufactur- 0.19” er’s instructions for bedknife grinding information. (4.8 mm)

  • Page 302: Bedbar Adjuster Service

    DPA cutting units (Fig. 32 B) include a lock nut on shaft is very similar. the end of the bedbar adjuster shaft. Upgrading to the Page 8 − 22 Reelmaster 7000−D (Model 03708) DPA Cutting Units...
  • Page 303 Tighten cap screw from 14 to 16 ft−lb (19 to 21 N−m). 7. Adjust cutting unit (see Cutting Unit Operator’s Manual). Page 8 − 23 Reelmaster 7000−D (Model 03708) DPA Cutting Units...

  • Page 304: Reel Assembly

    NOTE: Refer to Reel Assembly Service later in this sec- tion for information on replacing cutting reel grease seals, bearings and spline inserts. Page 8 − 24 Reelmaster 7000−D (Model 03708) DPA Cutting Units...
  • Page 305 Use heavy gloves when installing the cutting reel. 11. Inspect and service cutting reel assembly as re- quired (see Reel Assembly Service in this section). Page 8 − 25 Reelmaster 7000−D (Model 03708) DPA Cutting Units...
  • Page 306 After torquing nut, check that reel rolling torque does not exceed 10 in−lb (1.1 N−m). 19.Install cutting unit to the machine. Page 8 − 26 Reelmaster 7000−D (Model 03708) DPA Cutting Units...
  • Page 307 This page is intentionally blank. Page 8 − 27 Reelmaster 7000−D (Model 03708) DPA Cutting Units...

  • Page 308: Reel Assembly Service (Cutting Units With Painted Side Plates)

    B. To remove or install threaded spline inserts, use correct spline insert tool (see Special Tools). C. Check the service limit of the reel diameter (see Preparing a Reel for Grinding in this section). Page 8 − 28 Reelmaster 7000−D (Model 03708) DPA Cutting Units...
  • Page 309 XHP−222 grease or equivalent. grease or lubricant applied to ID of seal. IMPORTANT: The grease seal should installed so the metal side of the seal is toward the bearing location. Page 8 − 29 Reelmaster 7000−D (Model 03708) DPA Cutting Units...

  • Page 310: Reel Assembly

    The right bearings. side plate does not have to be removed from the frame. Page 8 − 30 Reelmaster 7000−D (Model 03708) DPA Cutting Units...
  • Page 311 See Chapter 9 − Belt Driven Groomer or Chapter moval and Rear Roller Removal in this chapter). 10 − Universal Groomer for more information. See Rear Roller Brush in this chapter for more information. Page 8 − 31 Reelmaster 7000−D (Model 03708) DPA Cutting Units...
  • Page 312 12.Install front and rear rollers (see Front Roller Installa- tion and Rear Roller Installation in this section). 13.Adjust cutting unit (see Cutting Unit Operator’s Manual). Page 8 − 32 Reelmaster 7000−D (Model 03708) DPA Cutting Units...
  • Page 313 14.Install accessories if equipped. See Chapter 9 − Belt Driven Groomer or Chapter 10 − Universal Groomer in this manual for additional Groomer information. See Rear Roller Brush in this chapter for information on rear roller brush. Page 8 − 33 Reelmaster 7000−D (Model 03708) DPA Cutting Units...

  • Page 314: Reel Assembly Service (Cutting Units With Aluminum Side Plates)

    (see Special Tools in this chapter). B. Check the reel blades for bending or cracking. C. Check the service limit of the reel diameter (see Preparing a Reel for Grinding in this section). Page 8 − 34 Reelmaster 7000−D (Model 03708) DPA Cutting Units...
  • Page 315 Flocked seals and bearings should bottom on reel shaft shoulder. 6. Fill threaded insert splines with high temp Mobil XHP−222 grease or equivalent. Page 8 − 35 Reelmaster 7000−D (Model 03708) DPA Cutting Units...

  • Page 316: 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.
  • Page 317 This page is intentionally blank. Page 8 − 37 Reelmaster 7000−D (Model 03708) DPA Cutting Units...

  • Page 318: Front Roller

    3. If both front height−of−cut (roller) brackets were re- moved from cutting unit side plate, position one of the brackets to side plate. Secure bracket to side plate with carriage screw and flange lock nut. Page 8 − 38 Reelmaster 7000−D (Model 03708) DPA Cutting Units...

  • Page 319: Rear Roller

    Install two (2) carriage screws and flange nuts to retain bracket in position. Do not fully tight- en flange nuts. Page 8 − 39 Reelmaster 7000−D (Model 03708) DPA Cutting Units...

  • Page 320: Roller Service

    7. Outer seal 3. Inner oil seal 8. Retaining ring 3. Discard removed seals and bearings. 4. Grease fitting 9. Outer oil seal 5. Ball bearing 10. Roller washer Page 8 − 40 Reelmaster 7000−D (Model 03708) DPA Cutting Units...
  • Page 321 C. Put roller in a vertical position and support shaft and installed bearing with tool TOR4067. D. Use tool TOR4067 to install second bearing. 3. Use tool TOR4068 to install inner seal. Page 8 − 41 Reelmaster 7000−D (Model 03708) DPA Cutting Units...

  • Page 322: Roller Service

    1. Roller tube 3. Bearing seal making sure to not crush the installed outer seal. 2. Inner seal 4. Bearing/outer seal tool Again, make sure that bearing still freely rotates. Page 8 − 42 Reelmaster 7000−D (Model 03708) DPA Cutting Units...
  • Page 323 7. If grease fittings were removed from end of roller 1. Roller tube 4. Bearing shaft, install fittings in shaft. 2. Roller shaft 5. Outer seal 3. Inner seal 6. Bearing/outer seal tool Page 8 − 43 Reelmaster 7000−D (Model 03708) DPA Cutting Units...

  • Page 324: Rear Roller Brush − Optional (Cutting Units With Painted Side Plates)

    Use those Instructions along with this nents used when the brush drive is on the left side of the Service Manual when servicing the rear roller brush. cutting unit. Page 8 − 44 Reelmaster 7000−D (Model 03708) DPA Cutting Units...
  • Page 325 1. Bearing housing 6. Snap ring 2. Drive shaft 7. O−ring 3. Ball bearing 8. Side plate 4. Grease seal 9. Socket head screw 5. Retaining ring 10. Grommet Page 8 − 45 Reelmaster 7000−D (Model 03708) DPA Cutting Units...
  • Page 326 15 to 19 ft−lb (20 to 25 N−m). F. Position excluder seals on brush shaft so that seals just touch bearing housings. Figure 59 1. Drive pulley 3. Idler pulley 2. Driven pulley 4. Drive belt Page 8 − 46 Reelmaster 7000−D (Model 03708) DPA Cutting Units...
  • Page 327 Wipe excess grease Figure 60 from seals and fittings. 1. Drive pulley 3. Straight edge 2. Driven pulley Figure 61 1. Rear roller brush 3. Light contact 2. Rear roller Page 8 − 47 Reelmaster 7000−D (Model 03708) DPA Cutting Units...

  • Page 328: Rear Roller Brush − Optional (Cutting Units With Aluminum Side Plates)

    (see Rear Roller Brush Drive System in this move key from the ignition switch. section). 2. To remove roller brush from brush shaft: Page 8 − 48 Reelmaster 7000−D (Model 03708) DPA Cutting Units...
  • Page 329 5. Lubricate grease fittings on brush housings until grease purges past inboard seals. Wipe excess grease from seals and fittings. 0.060” (1.5 mm) Clearance to Light Contact Figure 65 1. Rear roller brush 2. Rear roller Page 8 − 49 Reelmaster 7000−D (Model 03708) DPA Cutting Units...
  • Page 330 2. Remove cover (item 20) to access rear roller brush B. Loosen and remove drive shaft from cutting reel. drive components. 3. Remove roller brush drive components as neces- sary using Figure 66 as a guide. Page 8 − 50 Reelmaster 7000−D (Model 03708) DPA Cutting Units...
  • Page 331 Figure 69 1. Driven pulley 3. Straight edge 2. Drive pulley Page 8 − 51 Reelmaster 7000−D (Model 03708) DPA Cutting Units...
  • Page 332 5. Install cover (item 20).There should not be a set screw installed in the bottom of the cover. 6. Lubricate grease fittings on brush housings until grease purges past inboard seals. Wipe excess grease from seals and fittings. Page 8 − 52 Reelmaster 7000−D (Model 03708) DPA Cutting Units...

  • Page 333: Belt Driven Groomer (Optional)

    ......Height Adjuster Assembly ....16 Page 9 − 1 Reelmaster 7000−D (Model 03708) Belt Driven Groomer (Optional)

  • Page 334: Grooming Performance

    9. The overall turf management program − irrigation, fertilizing, weed control, coring, overseeding, sand dressing, disease control and pest control. 10.Stress periods for turf − high temperatures, high hu- midity, unusually high traffic. Page 9 − 2 Belt Driven Groomer (Optional) Reelmaster 7000−D (Model 03708)

  • Page 335: Troubleshooting

    Adjust depth if necessary. Check both ends of groomer reel. and adjust cutting unit set up (level bedknife to reel, level rear roller to reel, set height−of−cut, etc.). Page 9 − 3 Reelmaster 7000−D (Model 03708) Belt Driven Groomer (Optional)

  • Page 336: Adjustments

    5. Repeat step 4 on the opposite end of the groomer. Then, recheck setting on the first side of groomer. Height setting on both ends of groomer should be identi- cal. Page 9 − 4 Belt Driven Groomer (Optional) Reelmaster 7000−D (Model 03708)

  • Page 337: Service And Repairs

    5. Install groomer cover and secure with two (2) flange nuts. Figure 3 1. Drive pulley 3. Driven pulley 2. Idler pulley 4. Groomer drive belt Page 9 − 5 Reelmaster 7000−D (Model 03708) Belt Driven Groomer (Optional)

  • Page 338: Groomer Plate Assembly

    Roller Brush (Optional) in the Service and Repairs sec- tion of Chapter 8 − Cutting Units). hold groomer shaft. Page 9 − 6 Belt Driven Groomer (Optional) Reelmaster 7000−D (Model 03708)
  • Page 339 2. Shoulder bolt C. Install grease seals so that seal lips are posi- tioned toward the groomer blade location. Seals should be flush with surface of groomer plate. Page 9 − 7 Reelmaster 7000−D (Model 03708) Belt Driven Groomer (Optional)
  • Page 340 H. Slide driven pulley onto groomer shaft and se- cure with flange nut. Torque flange nut from 17 to 21 ft−lb (23 to 28 N−m). Page 9 − 8 Belt Driven Groomer (Optional) Reelmaster 7000−D (Model 03708)
  • Page 341 This page is intentionally blank. Page 9 − 9 Reelmaster 7000−D (Model 03708) Belt Driven Groomer (Optional)

  • Page 342: Groomer Reel

    If desired, remove cutting unit from machine plate assemblies for wear or damage. Replace compo- (see Traction Unit Operator’s Manual). nents as needed (see Groomer Plate Assembly in this section). Page 9 − 10 Belt Driven Groomer (Optional) Reelmaster 7000−D (Model 03708)
  • Page 343 NOTE: After greasing groomer bearings, operate groomer for 30 seconds, stop machine and wipe excess Figure 10 grease from groomer shaft and seals. 1. Groomer plate 2. Excluder seal Page 9 − 11 Reelmaster 7000−D (Model 03708) Belt Driven Groomer (Optional)

  • Page 344: Groomer Reel Service

    Figure 13 tered on shaft. 1. Groomer reel shaft 4. Lock nut (2 used) 2. Groomer blade (42 used) 5. Excluder seal 3. Spacer (43 used) Page 9 − 12 Belt Driven Groomer (Optional) Reelmaster 7000−D (Model 03708)
  • Page 345 7. Install O−ring on non−drive end of groomer shaft. 8. Install groomer reel back on cutting unit (see Groom- er Reel Installation in this section). Figure 14 1. Groomer shaft 2. Broomer strap Page 9 − 13 Reelmaster 7000−D (Model 03708) Belt Driven Groomer (Optional)

  • Page 346: Groomer Pivot Hub

    Figure 15 shows components used when the groomer reel drive is on the left side of the cutting unit. Page 9 − 14 Belt Driven Groomer (Optional) Reelmaster 7000−D (Model 03708)
  • Page 347 6. Slide idler plate onto pivot hub and secure with re- taining ring (item 4). 7. Install pivot hub and idler plate assembly to cutting unit (see Groomer Plate Assembly Installation in this section). Page 9 − 15 Reelmaster 7000−D (Model 03708) Belt Driven Groomer (Optional)

  • Page 348: Height Adjuster Assembly

    A. If bushing (item 10) was removed from upper position (handle toward rear of cutting unit). ramp, press new bushing into housing fully to the shoulder in the bore. Page 9 − 16 Belt Driven Groomer (Optional) Reelmaster 7000−D (Model 03708)
  • Page 349 ....Height Adjuster Assembly ....Page 10 − 1 Reelmaster 7000−D (Model 03708) Universal Groomer (Optional)

  • Page 350: Grooming Performance

    9. The overall turf management program − irrigation, fertilizing, weed control, coring, over−seeding, sand dressing, disease control and pest control. 10.Stress periods for turf − high temperatures, high hu- midity, unusually high traffic. Page 10 − 2 Universal Groomer (Optional) Reelmaster 7000−D (Model 03708)

  • Page 351: Troubleshooting

    Grooming depth is not equal on Adjust depth if necessary. Check both ends of groomer reel. and adjust cutting unit set up (level bedknife to reel, level rear roller to reel, set height−of−cut, etc.). Page 10 − 3 Reelmaster 7000−D (Model 03708) Universal Groomer (Optional)

  • Page 352: Service And Repairs

    Always stop the engine, remove the key from the ignition switch and wait for all machine movement to stop before working on the groomer. Page 10 − 4 Universal Groomer (Optional) Reelmaster 7000−D (Model 03708)
  • Page 353 This page is intentionally left blank. Page 10 − 5 Reelmaster 7000−D (Model 03708) Universal Groomer (Optional)

  • Page 354: Gear Box Assembly

    3. Safely prevent reel from rotating by blocking the cut- ting reel with piece of wood near one of the reel spiders. Page 10 − 6 Universal Groomer (Optional) Reelmaster 7000−D (Model 03708)
  • Page 355 Turn the input shaft coun- C. Continue to unscrew the input shaft and remove terclockwise to remove the gear box. the gear box from the cutting unit. Page 10 − 7 Reelmaster 7000−D (Model 03708) Universal Groomer (Optional)
  • Page 356 43. Retaining ring (2) 13. O−ring 29. Bushing 44. Bearing (4) 14. Knob 30. Ring gear 45. Idler gear (2) 15. O−ring 16. O−ring 31. Bearing 46. Cap screw (2) Page 10 − 8 Universal Groomer (Optional) Reelmaster 7000−D (Model 03708)
  • Page 357 85 to 95 in−lb (9 to 11 N−m). 6. Lubricate planet gear and sun gear pins in gear box housing with gear oil and install planet, ring and sun gears. Page 10 − 9 Reelmaster 7000−D (Model 03708) Universal Groomer (Optional)
  • Page 358 C. Tighten the input shaft from 90 to 100 ft−lb (122 to 153 N−m). 4. Install the rear roller brush drive shield if previously removed. Page 10 − 10 Universal Groomer (Optional) Reelmaster 7000−D (Model 03708)
  • Page 359 This page is intentionally left blank. Page 10 − 11 Reelmaster 7000−D (Model 03708) Universal Groomer (Optional)

  • Page 360: Idler Assembly

    6. Inspect shields, bearing and bushing in idler assem- Hydraulic Reel Motor Removal in Chapter 8 − Cutting bly. Remove and discard damaged or worn compon- Units in this manual). ents. Page 10 − 12 Universal Groomer (Optional) Reelmaster 7000−D (Model 03708)
  • Page 361 5. Install hydraulic reel motor to cutting unit (see Hy- draulic Reel Motor Installation in Chapter 8 − Cutting Units in this manual). Page 10 − 13 Reelmaster 7000−D (Model 03708) Universal Groomer (Optional)

  • Page 362: Groomer Reel

    4. Check groomer reel height and mower height−of−cut 2. Carefully remove the four (4) jam nuts, cap screws settings. Adjust as needed. and shaft clamps securing the groomer reel to the output and stub shafts. Page 10 − 14 Universal Groomer (Optional) Reelmaster 7000−D (Model 03708)

  • Page 363: Groomer Reel Service

    (18 in. reel = 31) (18 in. Reel = 32) (22 in. Reel = 39) (11 in. Reel = 40) 4. 1/4” (6.3 mm) Spacer (2) 5. Lock nut (2) Page 10 − 15 Reelmaster 7000−D (Model 03708) Universal Groomer (Optional)
  • Page 364 6. Install O−ring on non−drive end of groomer shaft. 7. Install groomer reel back on cutting unit (see Groomer Reel Installation in this section). Figure 12 1. Strap 2. Brush Page 10 − 16 Universal Groomer (Optional) Reelmaster 7000−D (Model 03708)

  • Page 365: Grooming Brush (Optional)

    (see Groomer Reel in this chapter). The grooming brush element or shaft can be serviced separately (Fig. 13). Figure 13 1. Brush element 3. Roll pin (2) 2. Shaft Page 10 − 17 Reelmaster 7000−D (Model 03708) Universal Groomer (Optional)

  • Page 366: Height Adjuster Assembly

    Discard cotter pins. 3. Loosen the two (2) height adjustment bolt lock nuts. 4. Loosen the two (2) front roller pinch bolt lock nuts and cap screws. Page 10 − 18 Universal Groomer (Optional) Reelmaster 7000−D (Model 03708)
  • Page 367 5. Adjust the cutting unit height of cut (see Cutting Unit Operators Manual). 6. Check groomer reel height and adjust as needed. Page 10 − 19 Reelmaster 7000−D (Model 03708) Universal Groomer (Optional)
  • Page 368 This page is intentionally left blank. Page 10 − 20 Universal Groomer (Optional) Reelmaster 7000−D (Model 03708)
  • Page 369 ....Power Center Wire Harness ....Page 11 − 1 Reelmaster 7000−D (Model 03708) Foldout Drawings...

  • Page 370: 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 371: Hydraulic Schematic

    VALVE 5000 .071 550 PSI .091 2.48 2.48 1.03 1.03 2.01 2.01 REAR AXLE .071 FRONT MOTOR 5000 WHEEL MOTORS .052 450 PSI 5 PSI 207 PSI 1050 STEERING CYLINDER Reelmaster 7000−D (Model 03708 Hydraulic Schematic Page 11 − 3...

  • Page 372: Electrical Schematic

    Reelmaster 7000−D (Model 03708) Electrical Schematic Sheet 1 of 2 All relays and solenoids are shown as de−energized. All ground wires are black. Page 11 − 4...
  • Page 373 FAN SPEED (PRV) REAR REELS (S5) RAISE REELS (S2) ENABLE (S1) LOWER REELS (S3) RANGE 2WD/4WD (SV) Reelmaster 7000−D (Model 03708) Electrical Schematic Sheet 2 of 2 All relays and solenoids are shown as de−energized. All ground wires are black.

  • Page 374: Main Wire Harness

    Reelmaster 7000−D (Model 03708) Main Wire Harness Page 11 − 6...
  • Page 375 ORANGE BLACK BLUE PINK/BLACK GRAY/BLUE BLACK ORANGE BLACK BLACK BLACK BROWN PINK WHITE/BLACK BLACK RED/WHITE BLACK/WHITE RED/BLACK BLACK BLACK BLACK BLACK BLACK BLACK PINK BLACK BLACK BLACK BLACK BLACK Reelmaster 7000−D (Model 03708 Main Wire Harness Page 11 − 7...

  • Page 376: Seat And Console Wire Harness

    Reelmaster 7000−D (Model 03708) Seat and Console Wire Harness Page 11 − 8...
  • Page 377 RED/WHITE BLACK/WHITE BLACK PINK PINK BLACK BLACK BLACK BLACK BLACK Reelmaster 7000−D (Model 03708) Seat and Console Wire Harness Page 11 − 9...

  • Page 378: Power Center Wire Harness

    Reelmaster 7000−D (Model 03708) Power Center Wire Harness Page 11 − 10...
  • Page 379 VIOLET BLACK BLUE PINK/BLACK BLACK ORANGE/WHITE ORANGE BLACK BLACK WHITE/YELLOW BLUE BROWN PINK RED/BLUE RED/GREEN WHITE/BLACK BROWN/BLACK TAN/BLACK GRAY/BLACK Reelmaster 7000−D (Model 03708 Power Center Wire Harness Page 11 − 11...

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Reelmaster 7000

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