Toro 11185SL manual

Part No. 1 1 185SL (Rev . A) Service Manual Reelmast er R 7000 Preface The pur pose of t his public ation is to provide t he service technic ian with inf orm ation f or t roubles hooting, test ing and repair of maj or syst ems and co mponents on the Reelmast er 7000. REFE R TO T HE TRACT I ON UNI T AND CUT T ING UNIT OPE RA TOR’S MA NUALS FO R O [...]

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Reelmast er 7000 T able Of Contents Chapter 1 - - Safe ty Gener al Safet y I nst ruc tions 1 - - 2 .................. Jackin g Instructions 1 - - 4 ......................... Safet y and I nst ruc tion Dec als 1 - - 5 ................ Cha pter 2 - - Produc t Rec ords a nd Maint enanc e Produc t Records 2 - - 1 ........................... Maint enanc[...]

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Reelmaster 7000 Page 1 - - 1 Safety Chapter 1 Safety T able of Contents GENERAL SAFETY INSTRUCTIONS 2 ............ Before Operating 2 ............................ While Operating 2 ............................. Maintenance and Service 3 .................... JACKING INSTRUCTIONS 4 ..................... SAFETY AND INSTRUCTION DECALS 5 .......... Safe[...]

Reelmaster 7000 Page 1 - - 2 Safety General Safety Instructions The Reelmaster 7000 have been tested and certified by TORO for compliance with existing safety standards and specifications. Although hazard control and acci- dent prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon[...]

Reelmaster 7000 Page 1 - - 3 Safety Maintenance and Service 1. The T raction Unit and Cutting Unit Operator ’ s Manu- als provide information regarding the operation, general maintenance and maintenance intervals for your Reel- master machine. Refer to these publications for addi- tional information when servicing the machine. 2. Before servicing[...]

Reelmaster 7000 Page 1 - - 4 Safety 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 t[...]

Reelmaster 7000 Page 1 - - 5 Safety Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Reelmaster 7000. If any decal becomes illegible or damaged, install a new decal. Decal part numbers are listed in your Parts Catalog. Safety[...]

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Reelmaster 7000 Page 2 - - 1 Product Records and Maintenance Chapter 2 Product Records and Maintenance T able of Contents PRODUCT RECORDS 1 ......................... MAINTENANCE 1 ............................... EQUIV ALENTS AND CONVERSIONS 2 ........... Decimal and Millimeter Equivalents 2 ............ U.S. to Metric Conversions 2 ................[...]

0.09375 Reelmaster 7000 Page 2 - - 2 Product Records and Maintenance Equivalents and Conversions[...]

Reelmaster 7000 Page 2 - - 3 Product Records and Maintenance T orque Specifications Recommended fastener torque values are listed in the following tables. For critical applications, as determined by T oro, either the recommended torque or a torque that is unique to the application is clearly identified and spe- cified in this Service Manual. These [...]

Reelmaster 7000 Page 2 - - 4 Product Records and Maintenance Standard T orque for Dry , Zinc Plated and Steel Fasteners (Inch Series) Thread Size Grade 1, 5 & 8w i t hT h i n Height Nuts SAE Grade 1 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) SAE Grade 5 Bolts, Screws, Studs & Sems with Regul[...]

Reelmaster 7000 Page 2 - - 5 Product Records and Maintenance Standard T orque for Dry , Zinc Plated and Steel Fasteners (Metric Series) T h r e a d S i z e Class 8.8 Bolts, Screws and Studs with R e g u l a r H e i g h t N u t s Class 10.9 Bolts, Screws and Studs with R e g u l a r H e i g h t N u t s Thread Size Regular Height Nuts (Class 8 or Str[...]

Reelmaster 7000 Page 2 - - 6 Product Records and Maintenance Other T orque Specifications SAE Grade 8 Steel Set Screws T h r e a d S i z e Recommended T orque Thread Size Square Head Hex Socket 1/4 - - 20 UNC 140 + 20 in - - lb 73 + 12 in - - lb 5/16 - - 18 UNC 215 + 35 in - - lb 145 + 20 in - - lb 3/8 - - 16 UNC 35 + 10 ft - - lb 18 + 3f t - - l b[...]

Reelmaster 7000 Page 3 - - 1 Kubota Diesel Engine Chapter 3 Kubota Diesel Engine T able of Contents SPECIFICA TIONS 2 ............................. GENERAL INFORMA TION 3 ..................... Operator ’s Manual 3 .......................... SERVICE AND REP AIRS 4 ...................... Air Filter System 4 ............................ Exhaust Syst[...]

Reelmaster 7000 Page 3 - - 2 Kubota Diesel Engine Specifications Item Description Make / Designation Kubota Model V2403 - - M- - DI - - E3B 4 - - Cycle, 4 Cylinder, L iquid Cooled, Diesel Engine Bore 3.425” (87.0 mm) Stroke 4.031” (102.4 mm) T otal Displacement 148.5 in 3 (2434 cc) Firing Order 1 (closest to gear case end) - - 3 - - 4 (closest [...]

Reelmaster 7000 Page 3 - - 3 Kubota Diesel Engine General Information This Chapter gives information about specifications and repair of the diesel engine used in the Reelmaster 7000. General maintenance procedures are described in your T raction Unit Operator ’s Manual. Information on engine troubleshooting, testing, disassembly and assembly is i[...]

Reelmaster 7000 Page 3 - - 4 Kubota Diesel Engine Service and Repairs Air Filter System Figure 1 1. Battery support 2. Bracket 3. Flange head screw (8 used) 4. Flange nut (8 used) 5. Support bracket 6. Cap screw (4 used) 7. Flange nut (4 used) 8. Fan drive manifold 9. Air cleaner strap 10. Cap screw (2 used) 1 1. Air cleaner assembly 12. Service in[...]

Reelmaster 7000 Page 3 - - 5 Kubota Diesel Engine 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. 1) IMPORT ANT : Any leaks in the air[...]

Reelmaster 7000 Page 3 - - 6 Kubota Diesel Engine Exhaust System Figure 4 1. Muffler 2. Flange head screw (2 used) 3. Flange head screw (4 used) 4. Muffler clamp 5. T ailpipe 6. RH engine mount 7. Flat washer 8. Cap screw 9. Muffler bracket 10. Muffler gasket 1 1. Engine 12. Muffler bracket 13. Flange nut (2 used) 14. Muffler clamp FRONT RIGHT 1 3 [...]

Reelmaster 7000 Page 3 - - 7 Kubota Diesel Engine Removal (Fig. 4) CAUTION The muffler and exhaust pipe may be hot. T o avoid possible burns, allow the engine and ex - haust system to cool before working on the muf- fler . 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition swi[...]

Reelmaster 7000 Page 3 - - 8 Kubota Diesel Engine Fuel System Figure 5 1. Fuel suction tube 2. Fuel line clamp (2 used) 3. Fuel hose (supply) 4. Return fitting 5. Fuel hose (return) 6. Fuel tank cap 7. Bushing (2 used) 8. Hose clamp (6 used) 9. Fuel tank 10. Cap screw (2 used) 1 1. Clamp (2 used) 12. Flange nut (2 used) 13. Fuel pump 14. Washer hea[...]

Reelmaster 7000 Page 3 - - 9 Kubota Diesel Engine DANGER Because diesel fuel is flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while en- gine is running, hot or when machine is in an e n- closed area. Always fill fuel tank outside and wipe up any spilled diesel fuel before startin[...]

Reelmaster 7000 Page 3 - - 10 Kubota Diesel Engine Radiator Figure 6 1. 90 o hydraulic fitting (2 used) 2. Oil cooler 3. Flange nut (4 used) 4. Radiator mount 5. Bulb seal 6. Air cleaner hose 7. Plenum 8. Radiator 9. Hose 10. Hose clamp (3 used) 1 1. Radiator cap 12. Upper radiator shroud 13. Clamp (4 used) 14. Upper radiator hose 15. Flange nut (1[...]

Reelmaster 7000 Page 3 - - 1 1 Kubota Diesel Engine Removal (Fig. 6) 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). CAUTION Do not open radiator cap or[...]

Reelmaster 7000 Page 3 - - 12 Kubota Diesel Engine Engine Figure 8 1. Muffler 2. Flange head screw 3. Flange head screw (4 used) 4. Muffler clamp 5. T ailpipe 6. RH rear engine mount 7. Cap screw (3 used) 8. RH front engine mount 9. Engine 10. Flange head screw (10 used) 1 1. Engine mount (4 used) 12. Flange nut (15 used) 13. Rebound washer (4 used[...]

Reelmaster 7000 Page 3 - - 13 Kubota Diesel Engine 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). 3. Remove battery cover . Dis[...]

Reelmaster 7000 Page 3 - - 14 Kubota Diesel Engine 1 1. Remove fan motor and fan assembly (Fig. 1 1). A. T o 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. Label hydraulic lines [...]

Reelmaster 7000 Page 3 - - 15 Kubota Diesel Engine 8. Install fan motor and fan assembly (Fig. 1 1). A. Carefully position fan motor , fan and motor brack- et assembly to radiator . B. Secure fan motor bracket to radiator with six ( 6) cap screws and flange nuts. C. Remove caps and plugs placed in hoses and fit- tings during removal to prevent cont[...]

Reelmaster 7000 Page 3 - - 16 Kubota Diesel Engine Pump Adapter Plate Figure 12 1. Bolt 2. Lock washer 3. Flywheel plate 4. Hardened washer (14 used) 5. Spring coupler 6. Bolt (6 used) 7. Cap screw (8 used) FRONT RIGHT 1 2 3 4 5 6 7 4 Loctite #242 29 to 33 ft - - lb ( 4 0t o4 4N - - m ) Boss[...]

Reelmaster 7000 Page 3 - - 17 Kubota Diesel Engine Coupler Removal (Fig. 12) NOTE: The hydraulic pump assembly needs to be re- moved from engine before coupler can be removed. 1. If engine is in machine, remove hydraulic pump as- sembly (see Piston (T raction) Pump Removal in the Ser- vice and Repairs section of Chapter 4 - - Hydraulic System). 2. [...]

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Rev . A Reelmaster 7000 Hydraulic System Pa ge 4 - - 1 Chapter 4 Hydraulic System T able of Contents SPECIFICA TIONS 3 ............................ GENERAL INFORMA TION 4 ..................... Operator ’s Ma nual 4 .......................... T owing T raction Unit 4 ......................... Check Hydraulic Fluid 4 ....................... Relievi[...]

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Reelmaster 7000 Hydraulic System Page 4 - - 3 Specifications Item Description Piston (T raction) Pump Eaton variable displacement piston pump (Model 72400) Maximum Displacement (per revolution) 2.48 in 3 (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)[...]

Reelmaster 7000 Hydraulic System Page 4 - - 4 General Information Operator ’s Manual The Operator ’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Reelmaster machine. Refer to that publication for additional information when servicing the machine. T owing T raction Unit IMPORT ANT : [...]

Reelmaster 7000 Hydraulic System Page 4 - - 5 Relieving Hydraulic System Pressure Before disconnecting or performing any work on the hy- draulic system, all pressure in the hydraulic system must be relieved. Park machine on a level surface, lower cutting units fully , stop engine and apply parking brake. T o relieve hydraulic pressure in traction c[...]

Reelmaster 7000 Hydraulic System Page 4 - - 6 Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather , sun, chemicals, very warm storage condi- tions or mishandling during operation and maintenance. These conditions can cause hose damage and deterio- ration. Some hos[...]

Reelmaster 7000 Hydraulic System Page 4 - - 7 Hydraulic Hose and T ube Installation (O - - Ring Face Seal Fitting) 1. Make sure threads and sealing surfaces of the hose/ tube and the fitting are free of burrs, nicks, scratches or any foreign material. 2. As a preventative measure against leakage, it is rec- ommended that the face seal O - -r ing be[...]

Reelmaster 7000 Hydraulic System Page 4 - - 8 Hydraulic Fitting Installation (SAE Straight Thread O - - Ring Fitting into Component Port) Non - - Adjustable Fitting (Fig. 6) 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 le[...]

Reelmaster 7000 Hydraulic System Page 4 - - 9 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. 3. Lig[...]

Reelmaster 7000 Hydraulic System Page 4 - - 10 Hydraulic Schematic Hydraulic Schematic Reelmaster 7000 All solenoids are shown as de - - energized P1 T2 ST T1 P2 CV RV2 G1 G2 L P2 M1 M2 T P1 SP1 SP2 LC2 LC1 RV1 M5 CV1 M1 C2 M4 RV2 OR1 OR2 CV2 C5 C4 C1 S5 C3 M3 M2 C4 C1 C3 C2 S3 MV1 S4 P MV2 G M3 M4 M1 M2 CHG S2 .071 VA LV E T RV1 S1 PD1 SV RV M2 55[...]

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Reelmaster 7000 Hydraulic System Page 4 - - 12 Hydraulic Flow Diagrams T raction Circuit: Mow Speed (Forward Shown) Working Pressure Low Pressure (Charge) Return or Suction Flow Reelmaster 7000 P1 T2 ST T1 P2 CV RV2 G1 G2 L P2 M1 M2 T P1 SP1 SP2 LC2 LC1 RV1 M5 CV1 M1 C2 M4 RV2 OR1 OR2 CV2 C5 C4 C1 S5 C3 M3 M2 C4 C1 C3 C2 S3 MV1 S4 P MV2 G M3 M4 M1 [...]

Reelmaster 7000 Hydraulic System Page 4 - - 13 T raction Circuit: Mow Speed (4WD) The traction circuit piston pump is a variable displace- ment pump that is directly coupled to the engine fly- wheel. Pushing the traction pedal engages a hydraulic servo valve which controls the variable displacement piston pump swash plate to create a flow of oil. T[...]

Reelmaster 7000 Hydraulic System Page 4 - - 14 T raction Circuit: T ransport Speed (Forward Shown) Working Pressure Low Pressure (Charge) Return or Suction Flow Reelmaster 7000 P1 T2 ST T1 P2 CV RV2 G1 G2 L P2 M1 M2 T P1 SP1 SP2 LC2 LC1 RV1 M5 CV1 M1 C2 M4 RV2 OR1 OR2 CV2 C5 C4 C1 S5 C3 M3 M2 C4 C1 C3 C2 S3 MV1 S4 P MV2 G M3 M4 M1 M2 CHG S2 .071 VA[...]

Reelmaster 7000 Hydraulic System Page 4 - - 15 T raction Circuit: T ransport Speed (2WD) The traction circuit piston pump is a variable displace- ment pump that is directly coupled to the engine fly- wheel. Pushing the traction pedal engages a hydraulic servo valve which controls the variable displacement piston pump swash plate to create a flow of[...]

Reelmaster 7000 Hydraulic System Page 4 - - 16 Working Pressure Low Pressure (Charge) Return or Suction Flow Reelmaster 7000 Lower Cutting Units (Lift Switch Pressed to Lower) P1 T2 ST T1 P2 CV RV2 G1 G2 L P2 M1 M2 T P1 SP1 SP2 LC2 LC1 RV1 M5 CV1 M1 C2 M4 RV2 OR1 OR2 CV2 C5 C4 C1 S5 C3 M3 M2 C4 C1 C3 C2 S3 MV1 S4 P MV2 G M3 M4 M1 M2 CHG S2 .071 VA [...]

Reelmaster 7000 Hydraulic System Page 4 - - 17 Lower 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 s ection is deliv- ered to the circuits through a proportional flow div[...]

Reelmaster 7000 Hydraulic System Page 4 - - 18 Working Pressure Low Pressure (Charge) Return or Suction Flow Reelmaster 7000 Raise Cutting Units (Lift Switch Pressed to Raise) P1 T2 ST T1 P2 CV RV2 G1 G2 L P2 M1 M2 T P1 SP1 SP2 LC2 LC1 RV1 M5 CV1 M1 C2 M4 RV2 OR1 OR2 CV2 C5 C4 C1 S5 C3 M3 M2 C4 C1 C3 C2 S3 MV1 S4 P MV2 G M3 M4 M1 M2 CHG S2 .071 VA [...]

Reelmaster 7000 Hydraulic System Page 4 - - 19 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 s ection is deliv- ered to the circuits through a proportional flow div[...]

Reelmaster 7000 Hydraulic System Page 4 - - 20 Mow Circuit Working Pressure Low Pressure (Charge) Return or Suction Flow Reelmaster 7000 P1 T2 ST T1 P2 CV RV2 G1 G2 L P2 M1 M2 T P1 SP1 SP2 LC2 LC1 RV1 M5 CV1 M1 C2 M4 RV2 OR1 OR2 CV2 C5 C4 C1 S5 C3 M3 M2 C4 C1 C3 C2 S3 MV1 S4 P MV2 G M3 M4 M1 M2 CHG S2 .071 VA LV E T RV1 S1 PD1 SV RV M2 550 PSI PD2 [...]

Reelmaster 7000 Hydraulic System Page 4 - - 21 Mow Circuit Hydraulic flow for the mow circuit is supplied by two (2) sections of the gear pump (P1 and P2). Gear pump sec- tion P1 supplies hydraulic flow to cutting units 1, 4 and 5 (front cutting units), while gear pump section P2 supplies cutting units 2 and 3 (rear cutting units). A single mow con[...]

Reelmaster 7000 Hydraulic System Page 4 - - 22 Steering Circuit (Right T urn Shown) Working Pressure Low Pressure (Charge) Return or Suction Flow Reelmaster 7000 P1 T2 ST T1 P2 CV RV2 G1 G2 L P2 M1 M2 T P1 SP1 SP2 LC2 LC1 RV1 M5 CV1 M1 C2 M4 RV2 OR1 OR2 CV2 C5 C4 C1 S5 C3 M3 M2 C4 C1 C3 C2 S3 MV1 S4 P MV2 G M3 M4 M1 M2 CHG S2 .071 VA LV E T RV1 S1 [...]

Reelmaster 7000 Hydraulic System Page 4 - - 23 Steering Circuit A four section gear pump is coupled to the piston (trac- tion) pump. The gear pump section P3 supplies hydrau- lic flow to the steering control valve and the lift control manifold. Gear pump hydraulic flow is delivered to the two circuits through a proportional flow divider located in [...]

Reelmaster 7000 Hydraulic System Page 4 - - 24 Engine Cooling Fan Circuit (Forward Fan Direction Shown) Working Pressure Low Pressure (Charge) Return or Suction Flow Reelmaster 7000 P1 T2 ST T1 P2 CV RV2 G1 G2 L P2 M1 M2 T P1 SP1 SP2 LC2 LC1 RV1 M5 CV1 M1 C2 M4 RV2 OR1 OR2 CV2 C5 C4 C1 S5 C3 M3 M2 C4 C1 C3 C2 S3 MV1 S4 P MV2 G M3 M4 M1 M2 CHG S2 .0[...]

Reelmaster 7000 Hydraulic System Page 4 - - 25 Engine Cooling Fan Circuit A four section gear pump is coupled to the piston (trac- tion) pump. The gear pump section P4 (farthest from the piston pump) supplies hydraulic flow for the hydraulic engine cooling fan motor (Fig. 17). The fan control manifold controls the operation of the hy- draulic motor[...]

Reelmaster 7000 Hydraulic System Page 4 - - 26 Special T ools Order the following special tools from your T oro Distributor . Hydraulic Pressure T est 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 prov[...]

Reelmaster 7000 Hydraulic System Page 4 - - 27 40 GPM Hydraulic T ester (Pressure and Flow) Use to test hydraulic circuits and components for flow and pressure capacities as recommended in the T esting section of this chapter . This tester includes the following: 1. LOAD V AL VE: A simulated working load is created in the circuit by turning the val[...]

Reelmaster 7000 Hydraulic System Page 4 - - 28 High Flow Hydraulic Filter Kit The high flow hydraulic filter kit is designed with large flow (40 GPM/150 LPM) and high pressure (5000 PSI/345 bar) capabilities. This kit provides for bi - - direc- tional filtration which prevents filtered debris from being allowed back into the circuit regardless of f[...]

Reelmaster 7000 Hydraulic System Page 4 - - 29 Measuring Container Use this container for doing hydraulic motor efficiency testing (motors with case drain lines only). Measure ef fi- ciency of a hydraulic motor by restricting the outlet flow from the motor and measuring leakage from the case drain line while the motor is pressurized by the hydrauli[...]

Reelmaster 7000 Hydraulic System Page 4 - - 30 T roubleshooting The c harts that follow contain information to assist in hy- draulic system troubleshooting. There may possibly be more than one cause for a machine malfunction. Refer to the T esting s ection of this Chapter for precau- tions and specific testing procedures. General Hydraulic System P[...]

Reelmaster 7000 Hydraulic System Page 4 - - 31 T raction Circuit Problems NOTE: When troubleshooting traction circuit problems, if a problem exists in both mow speed (4WD) and trans- port speed (2WD), consider a faulty component that af- fects the entire traction circuit (e.g. charge circuit, relief valves, piston pump, front wheel motors). If the [...]

Reelmaster 7000 Hydraulic System Page 4 - - 32 PTO P roblems Problem Possible Cause None of the cutting units will oper- ate. NOTE: Cutting units have to be fully lowered and traction speed needs to be in mow speed (4WD) for cutting units to operate. Cutting units are not fully lowered to ground. Operator seat is unoccupied. Mow speed limiter is in[...]

Reelmaster 7000 Hydraulic System Page 4 - - 33 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. very tall or [...]

Reelmaster 7000 Hydraulic System Page 4 - - 34 Lift/Lower Circuit Problems Problem Possible Cause Cutting units will not raise. NOTE: Operator must be in seat in order to raise the cutting units. Operator seat is unoccupied. Hydraulic oil level in reservoir is low . Electrical problem exists that prev ents lift control manifold solenoid valve opera[...]

Reelmaster 7000 Hydraulic System Page 4 - - 35 Engine Cooling Fan Circuit Problems Problem Possible Cause Cooling fan runs only in forward di- rection (fan does not run in reverse direction). Fan control manifold solenoid cartridge valve (S1) is faulty . Electrical problem exists that prev ents fan control manifold solenoid valve (S1) operation (se[...]

Reelmaster 7000 Hydraulic System Page 4 - - 36 T esting The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks (See the Special T ools section in this chapter). IMPORT ANT : All obvious areas such as oil s[...]

Reelmaster 7000 Hydraulic System Page 4 - - 37 Which Hydraulic T ests Are Necessary? Before beginning any hydraulic test, identify if the prob- lem is related to the traction circuit, mow circuit, lift/lower circuit, steering circuit or engine cooling fan circuit. Once the faulty system has been identified, perform tests that relate to that circuit[...]

Reelmaster 7000 Hydraulic System Page 4 - - 38 T raction Circuit Charge Pressure T est (Using Pressure Gauge) Working Pressure Low Pressure Return or Suction Flow PRESSURE GAUGE CHG .071 VA LV E PD1 SV RV M2 550 PSI PD2 CHG M1 M1 P1 PSI BYP ASS P1 .091 2.48 5000 450 PSI .052 P2 G CV PR 2.01 G CR2 CR1 P1 CD2 CD1 T P2 .56 .56 P4 2.48 1.03 1.03 P2 P3 [...]

Reelmaster 7000 Hydraulic System Page 4 - - 39 NOTE: The traction charge circuit is designed to re- place loss of hydraulic fluid from the closed loop traction circuit. Procedure for T raction Circuit Charge Pressure T est 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately t en (10) minutes. M[...]

Reelmaster 7000 Hydraulic System Page 4 - - 40 T raction Circuit Relief Pressure T est (Using Pressure Gauge) Working Pressure Low Pressure Return or Suction Flow PRESSURE GAUGE CHG .071 VA LV E PD1 SV RV M2 550 PSI PD2 CHG M1 M1 P1 PSI BYP ASS P1 .091 2.48 5000 450 PSI .052 P2 G CV PR 2.01 G CR2 CR1 P1 CD2 CD1 T P2 .56 .56 P4 2.48 1.03 1.03 P2 P3 [...]

Reelmaster 7000 Hydraulic System Page 4 - - 41 Procedure for T raction Circuit Relief Pressure T est 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately t en (10) minutes. Make sure the hydraulic tank is full. CAUTION Move machine to an open area, away from people and obstructions. 2. Drive mac[...]

Rev . A Reelmaster 7000 Hydraulic System Page 4 - - 42 T raction Circuit Reducing V alve (PR) Pressure T est (Using Pressure Gauge) Wor king Pre ssure Low Pressure Return or Suction Flow CHG .071 VA LV E PD1 SV RV M2 550 PSI PD2 CHG M1 M1 P1 PSI BYPASS P1 .091 2.48 5000 450 PSI .052 P2 G CV PR 2.01 G CR2 CR1 P1 CD2 CD1 T P2 .56 .56 P4 2.48 1.03 1.0[...]

Rev . A Reelmaster 7000 Hydraulic System Page 4 - - 43 NOTE: When in reverse, pressure reducing valve (P R) limits the pressure to the rear axle motor to 450 PSI (31 bar) so the rear wheels will no t scuff the tur f. Procedure for T raction Circuit Pressure Reducing V a l v e( P R )P r e s s u r eT e s t 1. Make sure hydrau lic oil is at normal ope[...]

Rev . A Reelmaster 7000 Hydraulic System Page 4 - - 44 Rear T raction Cir cuit Relief (R V) Pressure T est (Using Pressure Gauge) Working Pressure Low Pressure Return or Suction Flow CHG .071 VA LV E PD1 SV RV M2 550 PSI PD2 CHG M1 M1 P1 PSI BYPASS P1 .091 2.48 5000 450 PSI .052 P2 G CV PR 2.01 G CR2 CR1 P1 CD2 CD1 T P2 .56 .56 P4 2.48 1.03 1.03 P2[...]

Rev . A Reelmaster 7000 Hydraulic System Page 4 - - 45 NOTE: Adjustable relief valve (R V) in the 4WD/2WD control manifo ld reduces rea r axle motor pressure created in down hill, dynamic braking conditions to pre- vent rear wheel lock up. Procedure for Rear T raction Circuit Relief (RV) Pres- sure T est 1. Make sure hydrau lic oil is at normal ope[...]

Reelmaster 7000 Hydraulic System Page 4 - - 46 Piston (T raction) Pump Flow T est (Using T ester with Pressure Gauges and Flow Meter) Working Pressure Low Pressure Return or Suction Flow CHG .071 VA LV E PD1 SV RV M2 550 PSI PD2 CHG M1 M1 P1 PSI BYP ASS P1 .091 2.48 5000 450 PSI .052 P2 G CV PR 2.01 G CR2 CR1 P1 CD2 CD1 T P2 .56 .56 P4 2.48 1.03 1.[...]

Reelmaster 7000 Hydraulic System Page 4 - - 47 Procedure for Piston (T raction) Pump Flow T est This test measures piston (traction) pump output (flow). During this test, pump load is created at the flow meter using the adjustable load valve on the tester . IMPORT ANT : T raction circuit flow for the Reelmas - ter 7000 is approximately 30 GPM (1 13[...]

Reelmaster 7000 Hydraulic System Page 4 - - 48 Mow Circuit Pressure T est (Using Pressure Gauge) Working Pressure Low Pressure Return or Suction Flow CUTTING UNITS SHOWN TEST FOR FRONT P1 T2 T1 P2 RV2 SP1 SP2 LC2 LC1 RV1 M5 CV1 M1 M4 OR1 OR2 CV2 M3 M2 MV1 MV2 M3 M4 M1 M2 .071 VA LV E PSI BYP ASS P1 .091 5000 CR2 CR1 P1 CD2 CD1 T P2 .56 .56 P4 1.03 [...]

Reelmaster 7000 Hydraulic System Page 4 - - 49 Procedure for Mow Circuit Pressure T est 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately t en (10) minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off[...]

Reelmaster 7000 Hydraulic System Page 4 - - 50 Mow Circuit Relief Pressure T est (Using T ester with Pressure Gauges and Flow Meter) Working Pressure Low Pressure Return or Suction Flow SECTION P1 SHOWN TEST FOR PUMP P1 T2 T1 P2 RV2 SP1 SP2 LC2 LC1 RV1 M5 CV1 M1 M4 OR1 OR2 CV2 M3 M2 MV1 MV2 M3 M4 M1 M2 .071 VA LV E PSI BYP ASS P1 .091 5000 CR2 CR1 [...]

Reelmaster 7000 Hydraulic System Page 4 - - 51 The mow circuit relief pressure test should be performed to make sure that the mow circuit relief pressures are correct. Procedure for Mow Circuit Relief Pressure T est 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately t en (10) minutes. Make sur[...]

Reelmaster 7000 Hydraulic System Page 4 - - 52 Cutting Unit Motor Case Drain Leakage T est (Using T ester with Pressure Gauges and Flow Meter) Working Pressure Low Pressure Return or Suction Flow MEASURING CONT AINER UNIT MOTOR SHOWN TEST FOR #4 CUTTING P1 T2 T1 P2 RV2 SP1 SP2 LC2 LC1 RV1 M5 CV1 M1 M4 OR1 OR2 CV2 M3 M2 MV1 MV2 M3 M4 M1 M2 MOW MANIF[...]

Reelmaster 7000 Hydraulic System Page 4 - - 53 Procedure for Cutting Unit Motor Case Drain Leak- age T est NOTE: Over a period of time, a cutting unit motor can wear internally . A worn motor may bypass oil to its case drain causing the motor to be less efficient. Eventually , enough oil loss will cause the motor to stall under heavy cutting condit[...]

Reelmaster 7000 Hydraulic System Page 4 - - 54 Gear Pump P1 and P2 Flow (Mow Circuits) T est (Using T ester with Pressure Gauges and Flow Meter) Working Pressure Low Pressure Return or Suction Flow SECTION P1 SHOWN TEST FOR GEAR PUMP P1 T2 T1 P2 RV2 SP1 SP2 LC2 LC1 RV1 M5 CV1 M1 M4 OR1 OR2 CV2 M3 M2 MV1 MV2 M3 M4 M1 M2 .071 VA LV E PSI BYP ASS P1 .[...]

Reelmaster 7000 Hydraulic System Page 4 - - 55 The gear pump P1 and P2 flow tests should be per- formed to make sure that the mow circuits have ade- quate hydraulic flow . NOTE: Gear pump P1 supplies hydraulic flow to cutting units 1, 4 and 5. Gear pump P2 supplies flow to cutting units 2 and 3. Procedure for Gear Pump P1 and P2 Flow T est NOTE: Ov[...]

Reelmaster 7000 Hydraulic System Page 4 - - 56 Steering Circuit Relief Pressure T est (Using Pressure Gauge) Working Pressure Low Pressure Return or Suction Flow FOR RIGHT TURN P1 T2 ST T1 P2 CV RV2 G1 G2 L P2 M1 M2 T P1 SP1 SP2 LC2 LC1 RV1 M5 CV1 M1 M4 OR1 OR2 CV2 M3 M2 MV1 MV2 M3 M4 M1 M2 .071 VA LV E PSI BYP ASS P1 .091 5000 CR2 CR1 P1 CD2 STEER[...]

Reelmaster 7000 Hydraulic System Page 4 - - 57 The steering circuit relief pressure test should be per- formed to make sure that the steering circuit relief pres- sure is correct. Procedure for Steering Circuit Relief Pressure T est 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately t en (10) [...]

Reelmaster 7000 Hydraulic System Page 4 - - 58 Steering Cylinder Internal Leakage T est T L R P PB 1050 PSI 6.1 PLUG STEEL CYLINDER FULL Y EXTENDED LOOK FOR LEAKAGE STEERING WHEEL TURNED FOR RIGHT TURN STEERING FROM FAN CONTROL MANIFOLD TO FIL TRA TION MANIFOLD TO CHARGE CIRCUIT[...]

Reelmaster 7000 Hydraulic System Page 4 - - 59 The steering cylinder internal leakage test should be performed if a steering problem is identified. This test will determine if the steering cylinder is faulty . Procedure for Steering Cylinder Internal Leakage T est NOTE: Steering circuit operation will be af fected by rear tire pressure, binding of [...]

Reelmaster 7000 Hydraulic System Page 4 - - 60 Lift/Lower Circuit Relief Pressure T est (Using Pressure Gauge) Working Pressure Low Pressure Return or Suction Flow C2 RV2 C5 C4 C1 S5 C3 C4 C1 C3 C2 S3 S4 P G S2 T RV1 S1 CONTROL MANIFOLD LIFT G2 FROM FAN CONTROL MANIFOLD PRESSURE GAUGE TO CHARGE FROM STEERING CIRCUIT CONTROL V ALVE[...]

Reelmaster 7000 Hydraulic System Page 4 - - 61 The lift/lower circuit relief pressure test should be per- formed to make sure that the cutting unit lift and lower circuit relief pressure is correct. Procedure for Lift/Lower Circuit Relief Pressure T est 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for app[...]

Reelmaster 7000 Hydraulic System Page 4 - - 62 Gear Pump P3 Flow (Steering and Lift/Lower Circuits) T est (Using T ester with Pressure Gauges and Flow Meter) Working Pressure Low Pressure Return or Suction Flow .071 VA LV E PSI BYP ASS P1 .091 5000 .56 .56 P4 1.03 1.03 P2 P3 PSI 5000 .071 PISTON PUMP GEAR PUMP 2.48 ENGINE SPEED 2850/1550 TO F AN CI[...]

Reelmaster 7000 Hydraulic System Page 4 - - 63 The gear pump P3 flow test should be performed to make sure that the steering, lift and traction charge cir- cuits have adequate hydraulic flow . NOTE: Gear Pump P3 supplies o il flow for the steering, lift and traction charge circuits. Procedure for Gear Pump P3 Flow T est 1. Make sure hydraulic oil i[...]

Reelmaster 7000 Hydraulic System Page 4 - - 64 Cooling Fan Circuit T est (Using Pressure Gauge and Phototac) Working Pressure Low Pressure Return or Suction Flow P1 T2 ST T1 P2 CV RV2 G1 G2 L P2 M1 M2 T P1 SP1 SP2 LC2 LC1 RV1 M5 CV1 M1 M4 OR1 OR2 CV2 M3 M2 MV1 MV2 M3 M4 M1 M2 .071 VA LV E PSI BYP ASS P1 .091 5000 CR2 CR1 P1 CD2 STEERING CD1 T P2 .5[...]

Reelmaster 7000 Hydraulic System Page 4 - - 65 The cooling fan circuit test should be performed to make sure that the engine cooling fan circuit has the correct system pressure and fan speed. Procedure for Cooling Fan Circuit T est 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately t en (10) m[...]

Reelmaster 7000 Hydraulic System Page 4 - - 66 Gear Pump P4 Flow (Cooling Fan Circuit) T est (Using T ester with Pressure Gauges and Flow Meter) Working Pressure Low Pressure Return or Suction Flow .071 VA LV E PSI BYP ASS P1 .091 5000 .56 .56 P4 1.03 1.03 P2 P3 PSI 5000 .071 PISTON PUMP GEAR PUMP 2.48 ENGINE SPEED 2850/1550 TO F AN CIRCUIT TO S TE[...]

Reelmaster 7000 Hydraulic System Page 4 - - 67 The gear pump P4 flow test should be performed to make sure that the engine cooling fan circuit has ade- quate hydraulic flow . NOTE: Gear Pump P4 supplies oil flow for the engine cooling fan circuit. Procedure for Gear Pump P4 Flow T est 1. Make sure hydraulic oil is at normal operating tem- perature [...]

Reelmaster 7000 Hydraulic System Page 4 - - 68 Adjustments Adjust Control Manifold Relief V alves 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 T esting s ection of this chapter for information on testing relief pres[...]

Reelmaster 7000 Hydraulic System Page 4 - - 69 Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Hydraulic Compo - nents 1. Before removing any parts from the hydraulic sys- tem, park machine on a level surface, engage parking brake, lower cutting units or attachments and[...]

Reelmaster 7000 Hydraulic System Page 4 - - 70 Check Hydraulic Lines and Hoses W ARNING Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause seri[...]

Reelmaster 7000 Hydraulic System Page 4 - - 71 Flush Hydraulic System IMPORT ANT : Flush the hydraulic system any time there is a severe component failure or the system is contaminated (oil appears milky , black or contains metal particles). IMPORT ANT : Flush hydraulic system when chang - Ing from petroleum base hydraulic fluid to a biode - gradab[...]

Reelmaster 7000 Hydraulic System Page 4 - - 72 Filtering Closed - - Loop T raction Circuit Filtering of a closed - - loop hydraulic system after a major component failure (e.g. traction (piston) pump or front wheel motor) is a requirement to prevent debris from transmitting throughout the system. If a closed - - loop hy- draulic system filtering to[...]

Reelmaster 7000 Hydraulic System Page 4 - - 73 Charge Hydraulic System NOTE: When initially starting the hydraulic system with new or rebuilt components such as pumps, motors or lift cylinders, it is important that the hydraulic system be charged properly . Air must be purged from the system and its components to reduce the chance of damage. IMPORT[...]

Reelmaster 7000 Hydraulic System Page 4 - - 74 Gear Pump 1. Flat washer (2 used) 2. Cap screw (2 used) 3. 90 o hydraulic fitting 4. Hydraulic tee fitting 5. O - - r ing 6. Gear pump assembly 7. Piston pump assembly 8. 90 o hydraulic fitting 9. Coupler 10. 90 o hydraulic fitting 11 . O - - r i n g 12. O - - r ing 13. 45 o hydraulic fitting 14. Cap s[...]

Reelmaster 7000 Hydraulic System Page 4 - - 75 7. Support gear pump assembly to prevent it from fal- ling. 8. Remove two (2) cap screws and washers securing gear pump to piston pump. Remove gear pump, coupler (item 9), spacer (item 17) and O - - rings (item 16) from machine. 9. If hydraulic fittings are to be removed from gear pump, mark fitting or[...]

Reelmaster 7000 Hydraulic System Page 4 - - 76 Gear Pump Service 1. Dust seal 2. Retaining ring 3. Flange washer 4. Shaft seal 5. Front cover 6. Dowel pin (16 used) 7. Pressure seal 8. Back - - up gasket 9. Thrust plate (8 used) 10. Seal (8 used) 1 1. Idler gear 12. Drive shaft 13. Back - - up gasket 14. Pressure seal 15. Front body (section P 1) 1[...]

Reelmaster 7000 Hydraulic System Page 4 - - 77 IMPORT ANT : Use caution when clamping gear pump in a vise to avoid distorting any pump compo- nents. 3. Secure the front cover of t he pump in a vise with the drive shaft pointing down. 4. Loosen the four (4) cap screws that secure pump as- sembly . 5. Remove pump from vise and remove fasteners. 6. Su[...]

Reelmaster 7000 Hydraulic System Page 4 - - 78 Piston (T raction) Pump 1. Flat washer (2 used) 2. Cap screw (2 used) 3. 90 o hydraulic fitting 4. Hydraulic tee fitting 5. O - - r ing 6. Gear pump assembly 7. Piston pump assembly 8. 90 o hydraulic fitting 9. Coupler 10. 90 o hydraulic fitting 11 . O - - r i n g 12. O - - r ing 13. 45 o hydraulic fit[...]

Reelmaster 7000 Hydraulic System Page 4 - - 79 7. Remove gear pump from machine (see Gear Pump Removal in this section). 8. Support the piston pump to prevent it from falling while removing two (2) cap screws and washers retain- ing pump assembly to engine adapter plate. Carefully pull pump assembly from adapter plate and raise it out of the machin[...]

Reelmaster 7000 Hydraulic System Page 4 - - 80 Piston (T raction) Pump Service 1. Drive shaft 2. Retaining ring 3. Shaft seal 4. W asher 5. Retaining ring 6. Thrust bearing race 7. Thrust bearing 8. Bearing 9. Housing 10. Seal set 1 1. Servo piston 12. Gasket 13. Cover plate 14. Flat washer (4 used per cover) 15. Socket head screw (4 used per cover[...]

Reelmaster 7000 Hydraulic System Page 4 - - 81 This page is intentionally blank. Hydraulic System[...]

Reelmaster 7000 Hydraulic System Page 4 - - 82 4WD/2WD and Filtration/Charge Control Manifolds 1. Filtration/charge control manifold 2. Hydraulic oil filter 3. 4WD/2WD control manifold 4. Manifold bracket 5. Flange head screw (3 used) 6. Flange nut (2 used) 7. Cap screw (2 used) 8. Lift circuit junction manifold 9. Flange head screw (2 used) 10. Fl[...]

Reelmaster 7000 Hydraulic System Page 4 - - 83 Removal (Fig. 59) NOTE: The ports on the manifolds are marked for easy 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. 1. Read the General Precautions for Removing and Ins[...]

Reelmaster 7000 Hydraulic System Page 4 - - 84 4WD/2WD Control Manifold Service 1. Manifold body 2. Nut 3. Orifice (0.050) 4. Orifice disc (0.030) 5. Zero leak plug (#4) (4 used) 6. Zero leak plug (#6) (2 used) 7. Zero leak plug (#8) (4 used) 8. Check valve (CV) 9. Pilot directional valve (PD1 & PD2) 10. Pressure reducing valve (PR) 1 1. Relief[...]

Reelmaster 7000 Hydraulic System Page 4 - - 85 NOTE: The ports on the manifold are marked for easy identification of components (e.g. P1 is a piston pump connection port and SV is the location for the solenoid valve). See Hydraulic Schematic in Chapter 9 - - Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at ea[...]

Reelmaster 7000 Hydraulic System Page 4 - - 86 Filtration/Charge Control Manifold Service 1. Manifold body 2. Zero leak plug (#8) 3. Zero leak plug (#6) 4. Check valve (reservoir return) 5. Check valve (filter bypass) 6. Check valve (charge pressure) Figure 63 25 ft - - lb (34 N - - m) 50 ft - - lb (68 N - - m) 25 ft - - lb (34 N - - m) 35 ft - - l[...]

Reelmaster 7000 Hydraulic System Page 4 - - 87 Control Manifold Cartridge V alve Service 1. Make sure the control manifold is clean before re- moving the cartridge valve from the control manifold. 2. If cartridge valve is solenoid operated, remove nut securing solenoid coil to the cartridge valve. Carefully s l i d ec o i lo f ft h ev a l v e . IMP[...]

Reelmaster 7000 Hydraulic System Page 4 - - 88 Rear Axle Motor 1. Axle motor 2. O - - r ing 3. Pinion gear 4. External snap ring 5. O - - r ing 6. Hydraulic fitting 7. O - - r ing 8. 90 o hydraulic fitting 9. Cap screw (2 used) 10. Flat washer (2 used) Figure 64 FRONT RIGHT Arrows on side of motor case point u p 3 4 2 5 6 7 7 8 5 9 10 1[...]

Reelmaster 7000 Hydraulic System Page 4 - - 89 Removal (Fig. 64) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this cha[...]

Reelmaster 7000 Hydraulic System Page 4 - - 90 Front Wheel Motors 1. Flange head screw (6 per planetary) 2. Splined brake shaft 3. Planetary assembly 4. Wheel assembly 5. Lug nut (8 per wheel) 6. Retaining ring 7. LH brake assembly 8. Flange head screw (4 per brake) 9. Plug 10. O - - r ing 1 1. Piston wheel motor 12. Flat washer (2 per motor) 13. C[...]

Reelmaster 7000 Hydraulic System Page 4 - - 91 Removal (Fig. 65) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Raise front of machine and support with jackstands. 3. Read the General Precautions for Removing and Installing Hydraulic System Components at the beg[...]

Reelmaster 7000 Hydraulic System Page 4 - - 92 Rear Axle and Front Wheel Motor Service 1. Drive shaft 2. Backplate 3. Housing assembly 4. Rotating assembly 5. Cam plate insert 6. Retaining ring 7. Cap screw 8. Shaft seal (front motor only) 9. Retaining ring 10. Thrust race 11 . O - - r i n g 12. Valve plate 13. Thrust bearing 14. Roll pin 15. Roll [...]

Reelmaster 7000 Hydraulic System Page 4 - - 93 Cutting Reel Motor The hydraulic reel motors used on all cutting units are the same. Removal 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System C[...]

Reelmaster 7000 Hydraulic System Page 4 - - 94 Cutting Reel Motor Service 1. Dust seal 2. Retaining ring 3. Flange washer 4. Shaft seal 5. Front flange 6. Pressure seal 7. Back - - up gasket 8. Front wear plate 9. Dowel pin 10. Idler gear 1 1. Drive shaft 12. Rear wear plate 13. O - - r ing 14. Relief valve 15. Body 16. Washer (4 used) 17. Lock was[...]

Reelmaster 7000 Hydraulic System Page 4 - - 95 4. Loosen cap screws from the rear cover . 5. Remove motor from the vise. T urn motor so that the shaft end is facing down. Remove cap screws. 6. Carefully remove body . Lift body straight up to re- move. Make sure the rear wear plate remains on the drive and idler gear shafts. Remove and discard O - -[...]

Reelmaster 7000 Hydraulic System Page 4 - - 96 Assembly (Fig. 68) NOTE: When assembling the motor , check the marker line on each part to make sure the parts are properly aligned during assembly . 1. Lubricate O - - rings, pressure seals, back - - up gaskets and wear plate grooves with a thin coat of petroleum jel- ly . Lubricate all other internal[...]

Reelmaster 7000 Hydraulic System Page 4 - - 97 This page is intentionally blank. Hydraulic System[...]

Reelmaster 7000 Hydraulic System Page 4 - - 98 Mow Control Manifold FRONT RIGHT 1. Mow control manifold 2. Flange head screw (4 used) 3. Filter head 4. Hydraulic oil filter 5. Lift control manifold 6. Fan control manifold Figure 72 3 4 1 6 2 5[...]

Reelmaster 7000 Hydraulic System Page 4 - - 99 Removal (Fig. 72) NOTE: The ports on the manifold are marked for easy identification of components. Example: P1 is the gear pump connection port (see Hydraulic Schematic in Chapter 9 - - Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each port). 1. Park machine[...]

Reelmaster 7000 Hydraulic System Page 4 - - 100 Mow Control Manifold Service 1. Manifold body 2. Proportional valve (SP1 & SP2) 3. Solenoid coil (2 used) 4. Relief valve (RV1 & R V2) 5. Pressure compensator (LC1 & LC2) 6. Check valve (CV1 & CV2) 7. Nut 8. Backlap switch (2 used) 9. O - - r ing 10. Dowel 11 . B a l l 12. Retaining ri[...]

Reelmaster 7000 Hydraulic System Page 4 - - 101 Mow/Backlap Spool Service (Fig. 74) 1. T o remove backlap spool (item 17) from mow man- ifold: A. Remove backlap switch (item 8) from mow man- ifold before removing mow/backlap spool. Remove dowel pin and ball from manifold port after switch is removed. Remove and discard O - - ring from switch. B. Re[...]

Reelmaster 7000 Hydraulic System Page 4 - - 102 Steering Control V alve 1. Steering wheel cover 2. Lock nut 3. Steering wheel 4. Flat washer 5. O - - r ing 6. Flange head screw (4 used) 7. Steering column 8. Steering control valve 9. Socket head screw (4 used) 10. Flange nut (4 used) 1 1. Tinnerman nut (4 used) 12. Column brace 13. Socket head scre[...]

Reelmaster 7000 Hydraulic System Page 4 - - 103 CAUTION Before opening hydraulic system, operate all hy- draulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the Gen - eral Information section of this chapter . 8. Disconnect hydraulic lines from steering control valv[...]

Reelmaster 7000 Hydraulic System Page 4 - - 104 Steering Control V alve Service 1. Relief valve assembly 2. Dust seal ring 3. Steering valve housing 4. Shaft seal 5. Thrust washer 6. Bearing race 7. Ring 8. Spring set 9. Cross pin 10. Sleeve 1 1. Spool 12. Cardan shaft 13. O - - r ing 14. Distributor plate 15. Outer gearwheel 16. Inner gearwheel 17[...]

Reelmaster 7000 Hydraulic System Page 4 - - 105 This page is intentionally blank. Hydraulic System[...]

Reelmaster 7000 Hydraulic System Page 4 - - 106 Steering Cylinder 1. Steering cylinder 2. Ball joint 3. Ball joint 4. Retaining ring 5. Grease fitting 6. Grease fitting 7. 90 o hydraulic fitting 8. O - - r ing 9. O - - r ing 10. Drive axle assembly 1 1. Ball joint spacer 12. Axle washer 13. Slotted hex nut 14. Cotter pin 15. Hydraulic hose 16. Hydr[...]

Reelmaster 7000 Hydraulic System Page 4 - - 107 Removal (Fig. 80) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this ch[...]

Reelmaster 7000 Hydraulic System Page 4 - - 108 Steering Cylinder Service 1. Barrel 2. Lock nut 3. Wear band 4. Square ring 5. Piston seal 6. O - - r ing 7. Piston 8. Buffer seal 9. O - - r ing 10. Back - - up ring 1 1. Head 12. Retaining ring 13. Head seal 14. Wiper 15. Rod assembly Figure 81 50 to 60 ft - - lb ( 6 8t o8 1N - - m ) Loctite #271 2 [...]

Reelmaster 7000 Hydraulic System Page 4 - - 109 Disassembly (Fig. 81) 1. Remove oil from s teering cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder . IMPORT ANT : Prevent damage when c lamping the cylinder in a vise; clamp on the clevis only . Do not close vise enough to distort t[...]

Reelmaster 7000 Hydraulic System Page 4 - - 1 10 Engine Cooling Fan Motor 1. Hydraulic fan motor 2. O - - r ing 3. Bracket 4. 45 o hydraulic fitting 5. O - - r ing 6. Hydraulic hose 7. Fan hub 8. W asher 9. Hex nut 10. Engine 1 1. Cap screw (4 used) 12. Washer (4 used) 13. Fan 14. Lock nut (2 used) 15. Hydraulic hose 16. O - - r ing 17. Hydraulic f[...]

Reelmaster 7000 Hydraulic System P a g e 4 - - 111 5. Remove four (4) cap screws and washers used to se- cure fan (item 13) to fan hub. Remove fan. IMPORT ANT : Make sure to not damage the radiator or other machine components while loosening and removing the fan motor and bracket assembly . 6. Remove cooling fan motor and bracket assembly . A. T o [...]

Reelmaster 7000 Hydraulic System Page 4 - - 1 12 Engine Cooling Fan Motor Service 1. Flange washer 2. O - - r ing 3. Front flange 4. Dust seal 5. Retaining ring 6. Front wear plate 7. Shaft seal 8. Backup gasket 9. Pressure seal 10. Rear wear plate 1 1. Body 12. Idler gear 13. Cap screw (4 used) 14. Dowel (2 used) 15. Drive gear 16. Washer (4 used)[...]

Reelmaster 7000 Hydraulic System Page 4 - - 1 13 This page is intentionally blank. Hydraulic System[...]

Reelmaster 7000 Hydraulic System Page 4 - - 1 14 Fan Control Manifold 1. Fan control manifold 2. Flange head screw (2 used) 3. Filter head 4. Hydraulic oil filter 5. Lift control manifold 6. Mow control manifold Figure 85 FRONT RIGHT 3 4 1 6 2 5[...]

Reelmaster 7000 Hydraulic System Page 4 - - 1 15 Removal (Fig. 85) NOTE: The ports on the manifold are marked for easy identification of components. Example: P1 is the gear pump connection port (see Hydraulic Schematic in Chapter 9 - - Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each port). 1. Park machi[...]

Reelmaster 7000 Hydraulic System Page 4 - - 1 16 Fan Control Manifold Service 1. Manifold body 2. Zero leak plug (#6) (3 used) 3. Zero leak plug (#4) (2 used) 4. Check valve (port CV) 5. Flow divider cartridge (port FD) 6. Solenoid coil (2 used) 7. Nut 8. Solenoid valve (port S1) 9. Proportional relief cartridge (port TS) 10. Nut Figure 87 7 4 6 3 [...]

Reelmaster 7000 Hydraulic System Page 4 - - 1 17 This page is intentionally blank. Hydraulic System[...]

Reelmaster 7000 Hydraulic System Page 4 - - 1 18 Lift Control Manifold 1. Lift control manifold 2. Filter mount bracket 3. Filter head 4. Hydraulic oil filter 5. V alve mount bracket 6. Flange head screw (2 used) 7. Mow control manifold Figure 88 FRONT RIGHT 3 4 7 1 6 2 5 8 Removal (Fig. 88) NOTE: The ports on the manifold are marked for easy ident[...]

Reelmaster 7000 Hydraulic System Page 4 - - 1 19 W ARNING Make sure that cutting units are fully lowered be - fore loosening hydraulic lines from lift manifold. If cutting units are raised as hydraulic lines are loosened, cutting units may drop unexpectedly . 6. Disconnect hydraulic lines from manifold and put caps or plugs on open hydraulic lines [...]

Reelmaster 7000 Hydraulic System Page 4 - - 120 Lift Control Manifold Service 1. Manifold body 2. Relief valve (port RV2) 3. Solenoid valve (port S1) 4. Solenoid coil (5 used) 5. Solenoid valve (port S2) 6. Solenoid valve (ports S4 and S5) 7. Coil spacer (2 used) 8. Nut 9. Solenoid valve (port S3) 10. Relief valve (port RV1) 11 . N u t Figure 90 UP[...]

Reelmaster 7000 Hydraulic System Page 4 - - 121 For cartridge valve service procedures, see Control Manifold Cartridge V alve Service in this section. Refer to Figure 90 for cartridge valve and plug installation torque. IMPORT ANT : A flow control orifice is placed be - neath the hydraulic fittings in lift control manifold ports C2, C3 and C4. If a[...]

Reelmaster 7000 Hydraulic System Page 4 - - 122 Lift Circuit Junction Manifold Figure 91 FRONT RIGHT 1. Filtration/charge control manifold 2. Hydraulic oil filter 3. 4WD/2WD control manifold 4. Manifold bracket 5. Flange head screw (3 used) 6. Flange nut (2 used) 7. Cap screw (2 used) 8. Lift circuit junction manifold 9. Flange head screw (2 used) [...]

Reelmaster 7000 Hydraulic System Page 4 - - 123 Removal (Fig. 91) NOTE: The ports on the lift circuit junction manifold are marked for easy identification of components (e.g. P1 is the gear pump connection port). See Hydraulic Sche- matic in Chapter 9 - - Foldout Drawings to identify the function of the hydraulic lines at each port. 1. Park machine[...]

Reelmaster 7000 Hydraulic System Page 4 - - 124 Front Lift Cylinders 1. O - - r ing 2. Flange nut 3. Lift arm (cutting unit #1) 4. Cylinder pin 5. Flange head screw 6. 90 o hydraulic fitting (2 per cylinder) 7. O - - r ing 8. Lift cylinder (cutting units #4 and #5) 9. Lift cylinder (cutting unit #1) 10. Thrust washer 1 1. Lock nut 12. Pivot pin 13.[...]

Reelmaster 7000 Hydraulic System Page 4 - - 125 Removal (Fig. 93) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this ch[...]

Reelmaster 7000 Hydraulic System Page 4 - - 126 Rear Lift Cylinders 1. Flange nut (2 used) 2. Bulkhead bracket 3. Hydraulic tee fitting 4. Flange head screw (2 used) 5. Slotted roll pin 6. Pivot pin 7. Pivot yoke 8. L ynch pin 9. Lift arm (cutting unit #2) 10. Lift arm (cutting unit #3) 1 1. Retaining ring (2 per pin) 12. Lift cylinder (cutting uni[...]

Reelmaster 7000 Hydraulic System Page 4 - - 127 Removal (Fig. 95) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this ch[...]

Reelmaster 7000 Hydraulic System Page 4 - - 128 Lift Cylinder Service 1. Barrel 2. Lock nut 3. Wear band 4. Square ring 5. Piston seal 6. O - - r ing 7. Piston 8. Buffer seal 9. O - - r ing 10. Back - - up seal 1 1. Head 12. Retaining ring 13. Head seal 14. Support washer 15. Retaining ring 16. Wiper 17. Rod assembly Figure 97 10 5 2 11 6 13 14 12 [...]

Reelmaster 7000 Hydraulic System Page 4 - - 129 Disassembly (Fig. 97) 1. Remove oil from lift cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder . IMPORT ANT : Prevent damage when c lamping the cylinder in a vise; clamp on the clevis only . Do not close vise enough to distort the ba[...]

Reelmaster 7000 Hydraulic System Page 4 - - 130 Hydraulic Reservoir 1. Hydraulic reservoir 2. T ank strainer 3. Clamp 4. Hydraulic fitting 5. Hydraulic tee fitting 6. Bumper 7. Flat washer (2 used) 8. Flange nut (3 used) 9. Clamp (2 used) 10. Cap screw (2 used) 1 1. Flat washer (2 used) 12. Breather 13. Screen filter 14. Dipstick 15. Plug 16. O - -[...]

Reelmaster 7000 Hydraulic System Page 4 - - 131 Removal (Fig. 98) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this ch[...]

Reelmaster 7000 Hydraulic System Page 4 - - 132 Hydraulic Oil Cooler 1. Oil cooler 2. Mount plate (2 used) 3. Flange head screw (8 used) 4. Radiator mount 5. Radiator 6. Air intake hose 7. Plenum 8. Flange nut (4 used) 9. O - - r ing 10. 90 o hydraulic fitting (2 used) 11 . O - - r i n g 12. Hydraulic hose (2 used) 13. Cap screw (2 used) 14. Washer[...]

Reelmaster 7000 Hydraulic System Page 4 - - 133 Removal (Fig. 99) CAUTION The radiator and oil cooler may be hot. T o avoid possible burns, allow the engine and cooling systems to cool before working on the oil cooler . 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch[...]

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Reelmaster 7000 Page 5 - - 1 Electrical System Chapter 5 Electrical System T able of Contents GENERAL INFORMA TION 2 ..................... Operator ’s Manual 2 .......................... T oro Electronic Controllers (TEC) 2 .............. CAN - - bus Communications 2 ................... ELECTRICAL DRA WINGS 3 ..................... SPECIAL TOOLS 4[...]

Reelmaster 7000 Page 5 - - 2 Electrical System General Information Operator ’s Manual The Operator ’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Reelmaster machine. Refer to the Op- erator ’s Manual for additional information when servic- ing the machine. T oro Electronic Contro[...]

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

Reelmaster 7000 Page 5 - - 4 Electrical System Special T ools Order special tools from your T oro distributor . Some tools may also be available from a local supplier . Multimeter The multimeter can test electrical components and cir- cuits for current (amps), resistance (ohms) or voltage. Obtain this tool locally . NOTE: T oro recommends the use o[...]

Reelmaster 7000 Page 5 - - 5 Electrical System Diagnostic Display The Diagnostic Display (Fig. 5) can be connected to the wiring harness connector located inside the console arm to verify correct electrical functions of the machine. T oro Electronic Controllers (TEC) inputs and outputs can be checked using the Diagnostic Display . T oro Part Number[...]

Reelmaster 7000 Page 5 - - 6 Electrical System T roubleshooting CAUTION Remove all jewelry , especially rings and watches, before doing any electrical trouble- shooting or testing. Disconnect the battery cables unless the test requires battery voltage. For effective troubleshooting and repairs, there must be a good understanding of the electrical c[...]

Reelmaster 7000 Page 5 - - 7 Electrical System 5. The “inputs displayed ” LED, on lower right column of the Diagnostic Display , should b e illuminated. If “ outputs displayed ” LED is illuminated, press the toggle button on the Diagnostic Display to change to “inputs displayed ” LED. 6. The Diagnostic Display will illuminate the LED as[...]

Reelmaster 7000 Page 5 - - 8 Electrical System 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 T raction pedal in neutral: LED ON T raction pedal in forward or reverse: LED OFF SEA T SWI[...]

Reelmaster 7000 Page 5 - - 9 Electrical System V e rify Diagnostic Display Output Functions The Diagnostic Display also has the ability to detect which output solenoids or relays are energized by the TEC controller(s). This is a quick way to determine if a machine malfunction is electrical or hydraulic. NOTE: An open output (e.g. an unplugged conne[...]

Reelmaster 7000 Page 5 - - 10 Electrical System 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[...]

Reelmaster 7000 Page 5 - - 1 1 Electrical System 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 o[...]

Reelmaster 7000 Page 5 - - 12 Electrical System Cutting Unit Operating Problems Cutting units run, but should not, when raised. Cutting units shut off with PT O switch. The cutting unit position switch or circuit wiring is faulty . Wire harness connections are incorrectly connected to hydraulic solenoid valve coils on hydraulic mow control manifold[...]

Reelmaster 7000 Page 5 - - 13 Electrical System Electrical System Quick Checks Battery T est (Open Circuit T est) Use a multimeter to measure the voltage between the battery terminals. Set multimeter to the DC volts setting. The battery should be at a temperature of 60 o to 100 o F( 1 6 o to 38 o C). The ignition key should be off and all accessori[...]

Reelmaster 7000 Page 5 - - 14 Electrical System Check Operation of Interlock Switches CAUTION Do not disconnect safety switches. They are for the operator ’ s protection. Check the operation of the interlock switches daily for proper operation. Replace any malfunctioning switches before op- erating the machine. Interlock switch operation is descr[...]

Reelmaster 7000 Page 5 - - 15 Electrical System Adjustments Mow/T ransport 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 s ensor mounts to a bracket on the footrest platform (Fig. 12). The sensing plate for the mow/transport sensor is a tab on the [...]

Reelmaster 7000 Page 5 - - 16 Electrical System 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 c utting units are lowered, the gusset [...]

Reelmaster 7000 Page 5 - - 17 Electrical System Component T esting For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before checking continuity on the switch terminals). NOTE: For engine component testing information, see the Kubota Work[...]

Reelmaster 7000 Page 5 - - 18 Electrical System Fuses Y our Reelmaster 7000 uses numerous fuses for circuit protection. The fuses are located in two (2) areas of the machine. Most of the fuses reside in the power center behind the operator ’s seat. An in- - line fuse holder lo- cated in the wire harness near the engine starter motor holds an addi[...]

Reelmaster 7000 Page 5 - - 19 Electrical System 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. T o test the charge indicator light and circuit wiring, ground the white wir[...]

Reelmaster 7000 Page 5 - - 20 Electrical System Hour Meter The hour meter is located on the outside of the console arm. 1. Connect the positive (+) terminal of a 12 VDC source to the positive (+) terminal of the hour meter . 2. Connect the negative ( - -) terminal of the voltage source to the other terminal of the hour meter . 3. The hour meter sho[...]

Reelmaster 7000 Page 5 - - 21 Electrical System PT O Switch The PTO switch is located on the console arm (Fig. 23). The PTO switch is pulled up to engage the PT O and pushed in to disengage the PTO. NOTE: T o engage the PTO, t he seat has to be occu- pied, traction speed has to be in low range (4WD) and the cutting units have to be fully lowered. T[...]

Reelmaster 7000 Page 5 - - 22 Electrical System Cutting Unit Lift Switch The c utting unit lift switch is used as an input for the TEC controller to r aise or lower the cutting units. When the lift switch paddle is depressed and held, the cutting units will lower . When the lift switch paddle is raised and held, the cutting units will raise. The cu[...]

Reelmaster 7000 Page 5 - - 23 Electrical System 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. T esting 1. Make sure igniti on switch is OFF . Remove key from ignition switch. 2. Disassemble console arm to gain acc[...]

Reelmaster 7000 Page 5 - - 24 Electrical System Engine Cooling Fan Switch The engine cooling fan switch is located on the outside of the console arm (Fig. 30). This two (2) position r ocker switch allows the engine cooling fan to run in the normal, automatic mode or in the manual reverse (momentary) direction. T esting 1. Before disconnecting the e[...]

Reelmaster 7000 Page 5 - - 25 Electrical System 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 s witch is engaged when the operator raises out of the seat, the engine will stop. T esting of the s[...]

Reelmaster 7000 Page 5 - - 26 Electrical System 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 [...]

Reelmaster 7000 Page 5 - - 27 Electrical System Mow/T ransport Sensor The mow/transport sensor is a normally open proximity sensor that closes when the mow speed limiter is placed in the transport (2WD) position. The sensor mounts to a bracket on the footrest platform. The sensing plate for the mow/transport sensor is the mow speed limiter . The mo[...]

Reelmaster 7000 Page 5 - - 28 Electrical System Cutting Unit Position Sensor The cutting unit position sensor is a normally open prox- imity sensor that is located on the traction unit frame (Fig. 36). The sensing plate that closes the sensor is a gusset on the front right cutting unit (#5) lift arm. When the c utting units are lowered, the gusset [...]

Reelmaster 7000 Page 5 - - 29 Electrical System Backlap Switches The backlap switches are normally open ball switches that are in the normal, open state w hen the backlap lev- ers are in the mow position. When a backlap lever is in the backlap position, the switch closes. The backlap switches are attached to the hydraulic mow control man- ifold loc[...]

Reelmaster 7000 Page 5 - - 30 Electrical System Glow and Main Power Relays The glow and main power relays are located at the pow- er center behind the operator seat (Fig. 40). These re- lays are attached to the wire harness with a four (4) wire connector (Fig. 41). The glow relay is used to provide current to the engine glow plugs when energized by[...]

Reelmaster 7000 Page 5 - - 31 Electrical System Start Relay The start relay is located at the power center behind the operator seat (Fig. 42). This relay is attached to the wire harness with a five (5) wire connector (Fig. 43). The start relay is used to provide current to the engine starter motor when energized by the TEC controller . The TEC cont[...]

Reelmaster 7000 Page 5 - - 32 Electrical System 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. Th[...]

Reelmaster 7000 Page 5 - - 33 Electrical System Hydraulic Solenoid V alve Coils Numerous hydraulic solenoid valve coils are used on the hydraulic control manifolds of R eelmaster 7000 ma- chines. When energized by the TEC controller , these coils provide hydraulic circuit control. T wo (2) different solenoid valve coils are used on the Re- elmaster[...]

Reelmaster 7000 Page 5 - - 34 Electrical System T raction Neutral Switch The traction neutral switch is closed when the traction pedal is in the neutral position and opens when the pedal is depressed in either direction. The switch is located on the right side of the piston (traction) pump (Fig. 47). T esting Before disconnecting the traction neutr[...]

Reelmaster 7000 Page 5 - - 35 Electrical System T oro Electronic Controller (TEC) The Reelmaster 7000 uses a T oro 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 Diagnosti[...]

Rev . A Reelmaster 7000 Page 5 - - 36 Elec trical Syste m Engine Coolant and Hydraulic Oil T emperature Sender s T wo (2) identical temperature se nders are used as in- puts for the TEC controller to id entify if either t he engine coolant or hyd raulic oil tem perature has reached an ex- cessive level. The cool ant temperature sender threads into [...]

Reelmaster 7000 Page 5 - - 37 Electrical System Fuel Pump The fuel pump is energized by the TEC controller when the ignition switch is either in the ST ART or ON position. The fuel pump is attached to the left side frame rail. IMPORT ANT : When testing fuel pump, make sure that pump is not operated without fuel. Fuel Pump Capacity T est 1. Park mac[...]

Reelmaster 7000 Page 5 - - 38 Electrical System 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. The solenoid and its circuit wiring should be te[...]

Reelmaster 7000 Page 5 - - 39 Electrical System Engine T emperature Sender The engine temperature sender is located near the al- ternator on the w ater flange attached to the engine cylin- der head (Fig. 57). There is a gray wire attached to the terminal of the sender . The resistance of the temperature sender reduces as the engine coolant temperat[...]

Reelmaster 7000 Page 5 - - 40 Electrical System 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 2 ). The TEC controller monitors the ope[...]

Reelmaster 7000 Page 5 - - 41 Electrical System 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: 1. Remove the battery and charge it fully (see Battery Service in this section). 2. Either store[...]

Reelmaster 7000 Page 5 - - 42 Electrical System 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 electrol[...]

Reelmaster 7000 Page 5 - - 43 Electrical System Battery T esting 1. Conduct a hydrometer test of the battery electrolyte. IMPORT ANT : Make sure the area around the cells is clean before opening the battery caps. A. Measure the specific gravity of each cell w ith a hydrometer . Draw electrolyte in and out of the hydrometer barrel prior to taking a [...]

Reelmaster 7000 Page 5 - - 44 Electrical System Battery Charging T o 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- complished with a constant current battery charger which is available in most locations. CAUTION Follow the battery char[...]

Reelmaster 7000 Page 5 - - 45 Electrical System Hydraulic Solenoid V alve Coils A solenoid v alve 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, stop engine and engage parking brake. Remove key from ignition switch. 2. Locate solen[...]

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Reelmaster 7000 Page 6 - - 1 Axles, Planetaries and Brakes Chapter 6 Axles, Planetaries and Brakes T able of Contents SPECIFICA TIONS 2 ............................. GENERAL INFORMA TION 3 ..................... Operator ’s Manual 3 .......................... SERVICE AND REP AIRS 4 ...................... Brake Assembly 4 ..........................[...]

Reelmaster 7000 Page 6 - - 2 Axles, Planetaries and Brakes Specifications Item Specification Wheel lug nut torque (front and rear) 85 to 100 ft - - lb (1 16 to 135 N - - m) Steering cylinder bolt torque 100 to 125 ft - - lb (136 to 169 N- - m) Planetary , brake housing and wheel motor 75 to 85 ft - - lb (102 to 1 15 N - - m) mounting screw torque R[...]

Reelmaster 7000 Page 6 - - 3 Axles, Planetaries and Brakes General Information Operator ’s Manual The T raction Unit Operator ’ s Manual provides informa- tion regarding the operation, general maintenance and maintenance intervals for your Reelmaster machine. Refer to this publication for additional information when servicing the machine. Axles[...]

Reelmaster 7000 Page 6 - - 4 Axles, Planetaries and Brakes Service and Repairs Brake Assembly 1. Flange head screw (6 per planetary) 2. Splined brake shaft 3. Planetary assembly (2 used) 4. Front wheel assembly (2 used) 5. Lug nut (8 per wheel) 6. Retaining ring 7. Spring plate 8. Compression spring 9. Jam nut 10. LH Brake assembly 1 1. Flange head[...]

Reelmaster 7000 Page 6 - - 5 Axles, Planetaries and Brakes 5. Remove hydraulic wheel motor (see Front Wheel Motors in Service and Repairs section of Chapter 4 - - Hydraulic System). 6. Disconnect brake cable from pull rod on brake. NOTE: Be careful to not drop splined brake shaft as brake assembly is removed. 7. Support brake assembly and remove fl[...]

Reelmaster 7000 Page 6 - - 6 Axles, Planetaries and Brakes Brake Inspection and Repair 1. Brake housing (LH shown) 2. Seal 3. Pull rod 4. Clevis pin (2 used) 5. Link (2 used) 6. Hitch pin (2 used) 7. Stationary disc (4 used) 8. Rotating disc (3 used) 9. Retaining ring 10. Gasket 1 1. Rotating actuator 12. Extension spring (3 used) 13. Ball (3 used)[...]

Reelmaster 7000 Page 6 - - 7 Axles, Planetaries and Brakes This page is intentionally blank. Axles, Planetaries and Brakes[...]

Reelmaster 7000 Page 6 - - 8 Axles, Planetaries and Brakes Planetary Wheel Drive Assembly 1. Flange head screw (6 per planetary) 2. Splined brake shaft 3. Planetary assembly (2 used) 4. Front wheel assembly (2 used) 5. Lug nut (8 per wheel) 6. Retaining ring 7. Spring plate 8. Compression spring 9. Jam nut 10. LH Brake assembly 1 1. Flange head scr[...]

Reelmaster 7000 Page 6 - - 9 Axles, Planetaries and Brakes 4. Remove front wheel assembly . 5. Remove hydraulic wheel motor (see Front Wheel Motor Removal in the Service and Repairs section of Chapter 4 - - Hydraulic System). 6. Remove brake assembly (see Brake Assembly Re- moval in this section). 7. Support planetary assembly to prevent it from fa[...]

Reelmaster 7000 Page 6 - - 10 Axles, Planetaries and Brakes Planetary Wheel Drive Service 1. Spindle 2. Boot seal 3. Oil seal 4. Inner bearing cone 5. Inner bearing cup 6. Wheel stud (8 used) 7. Socket head screw (16 used) 8. Lock washer (16 used) 9. Housing 10. Dowel pin (2 used) 1 1. Outer bearing cup 12. Outer bearing cone 13. O - - r ing 14. Th[...]

Reelmaster 7000 Page 6 - - 1 1 Axles, Planetaries and Brakes NOTE: The planetary wheel drive assembly can be ser- viced with the planetary installed to machine. If the spindle (item 1) needs to be removed from machine, see Planetary Wheel Drive Assembly in this section. Disassembly (Figs. 7 and 8) 1. If planetary w heel drive assembly is installed [...]

Reelmaster 7000 Page 6 - - 12 Axles, Planetaries and Brakes F . Lightly oil bearing journals on spindle shaft. Slide housing assembly onto spindle (item 1) taking care to not damage seal or spindle. Make sure that inner bearing in housing fully seats against spindle shaft shoulder . G. Install outer bearing cone (item 12) onto spindle. NOTE: The pl[...]

Reelmaster 7000 Page 6 - - 13 Axles, Planetaries and Brakes This page is intentionally blank. Axles, Planetaries and Brakes[...]

Reelmaster 7000 Page 6 - - 14 Axles, Planetaries and Brakes Rear Axle Assembly 1. Steering cylinder 2. Needle bearing 3. External snap ring 4. External snap ring 5. Thrust washer 6. Flat washer 7. Lock nut 8. Grease fitting 9. Cap screw (2 used) 10. Flat washer (2 used) 1 1. Rear axle motor 12. O - - r ing 13. Pinion gear 14. Gear 15. Stop pin 16. [...]

Reelmaster 7000 Page 6 - - 15 Axles, Planetaries and Brakes 7. Remove hydraulic hose from hydraulic fitting on side of input gear case. 8. Remove lock nut and flat washer from axle pivot pin. 9. Support rear axle to prevent it from falling. Remove pivot pin. Lower rear axle from machine. Note location of thrust washer on both ends of axle mounting [...]

Reelmaster 7000 Page 6 - - 16 Axles, Planetaries and Brakes Rear Axle Service Figure 12 3 2 4 5 6 7 8 9 10 14 13 12 11 15 1 10 11 8 9 8 13 16 17 18 19 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 20 41 42 43 50 44 45 46 47 48 49 51 54 55 56 57 58 59 52 53 60 61 62 63 64 22[...]

Reelmaster 7000 Page 6 - - 17 Axles, Planetaries and Brakes 1. LH axle support 2. Flange bushing (2 used) 3. Axle vent 4. Filter 5. V ent extension 6. Cap screw (4 used per gear case) 7. Shim set 8. Seal washer 9. Plug 10. Lock nut 1 1. Lock washer 12. Grease fitting 13. Ball bearing 14. Screw (2 used per steering arm) 15. Axle case support (LH sho[...]

Reelmaster 7000 Page 6 - - 18 Axles, Planetaries and Brakes Bevel Gear Case and Axle Case The following procedures assume the rear axle assem- bly has been removed from the machine. Removal 1. Remove the mounting screws, nuts and lock wash- ers. Remove the bevel gear case/axle case assembly and O-ring from the axle support (Fig. 13). 2. Mark both r[...]

Reelmaster 7000 Page 6 - - 19 Axles, Planetaries and Brakes 5. Remove the knuckle pin mounting screws and the knuckle pin. Remove the gasket and any remaining gas- ket material from either mating surface (Fig. 16). 6. While holding the bevel gear case, tap the upper end of the bevel gear shaft out of the upper bearing and up- per bevel gear . 7. Pu[...]

Reelmaster 7000 Page 6 - - 20 Axles, Planetaries and Brakes Installation 1. Coat new shaft seal with grease and install in axle case as shown (Fig. 18). 1. Axle case 2. Bevel gear case 3. Shaft seal Figure 18 1 2 3 2. Install the lower bevel gear and bevel gear shaft in the axle case cover . Coat a new O-ring with grease and install the axle case c[...]

Reelmaster 7000 Page 6 - - 21 Axles, Planetaries and Brakes 5. Determine necessary quantity of support shims. A. Lubricate the axle case support bushing with a thin coat of grease and slide axle case support onto knuckle pin. B. Position support shims that were removed during disassembly between axle case support and axle case. Install mounting scr[...]

Reelmaster 7000 Page 6 - - 22 Axles, Planetaries and Brakes 9. Remove the bevel gear case/axle case assembly from the axle support. Coat a new O-ring with grease and temporarily install the axle cover assembly . Position a dial indicator at the tooths center . Prevent the axle from turning and measure the lower bevel gear to axle gear backlash (Fig[...]

Reelmaster 7000 Page 6 - - 23 Axles, Planetaries and Brakes Axle Shafts The following procedures assume the rear axle assem- bly has been removed from the machine. Removal 1. Remove the axle cover mounting screws. Remove t h ea x l ec o v e rf r o mt h ea x l ec a s ea sa na s s e m b l y (Fig. 25). 2. Use a bearing puller to remove the bearing and[...]

Reelmaster 7000 Page 6 - - 24 Axles, Planetaries and Brakes Input Shaft/Pinion Gear Figure 28 1 1. Nut (2 used) 2. Lock washer (2 used) 3. Stud (2 used) 4. Lock nut 5. Stake washer 6. Oil seal 7. O-ring 8. Seal collar 9. Bearing 10. O-ring 1 1. Input shaft/pinion gear 12. Bearing case 13. Shim 14. Screw (2 used) 15. Gear case 16. Gasket 17. Cover p[...]

Reelmaster 7000 Page 6 - - 25 Axles, Planetaries and Brakes 5. Install a new stake washer . Install the lock nut finger tight. 6. Set the bearing preload by securing the bearing case in a vise. Thread a M12 x 1.5 hex head cap screw into the splined end of the input shaft/pinion gear and slowly tighten the lock nut until 4 to 6 in-lb (0.4 to 0.7 N -[...]

Reelmaster 7000 Page 6 - - 26 Axles, Planetaries and Brakes Differential Gear The following procedures assume the rear axle assem- bly has been removed from the machine. Removal 1. Remove bevel gear case/axle case assemblies (see Bevel Gear Case/Axle Case Assembly in this section of this manual). IMPORT ANT : Do not interchange right and left dif -[...]

Reelmaster 7000 Page 6 - - 27 Axles, Planetaries and Brakes Inspection 1. Measure the dif ferential side gear O.D. and the dif- ferential case I.D. to determine the side gear to case clearance (Fig. 35). Replace components as necessary . SIDE GEAR TO CASE CLEARANCE: 0.002 to 0.012 inch (0.05 to 0.30 mm) SIDE GEAR O.D. (Factory Spec.): 1.335 to 1.33[...]

Reelmaster 7000 Page 6 - - 28 Axles, Planetaries and Brakes Installation 1. If the ring gear was removed from the differential case, use medium strength Loctite thread locker and tighten the mounting screws from 22 to 25 ft-lb (30 to 34 N - - m) . 2. Apply molybdenum disulfide lubricant (Three Bond 1901 or equivalent) to the splines and bearing sur[...]

Reelmaster 7000 Page 6 - - 29 Axles, Planetaries and Brakes Pinion Gear to Ring Gear Engagement The final position of the pinion gear is verified by using the gear contact pattern method as described in the fol- lowing procedure. GEAR TOOTH DEFINITIONS (Fig. 39): To e - - the portion of the tooth surface at the end to- wards the center . Heel - - t[...]

Reelmaster 7000 Page 6 - - 30 Axles, Planetaries and Brakes Gear Pattern Movement Summary Every gear has a characteristic pattern. The illustrations show typical patterns only and explain how patterns shift as gear location is changed. 1. If contact is toward t he heel or base of the gear (Fig. 42): A. Install thicker or additional bearing case shi[...]

Reelmaster 7000 Page 7 - - 1 Chassis Chapter 7 Chassis T able of Contents GENERAL INFORMA TION 2 ..................... Operator ’s Manual 2 .......................... Cutting Unit Identification 2 ..................... SERVICE AND REP AIRS 4 ...................... Steering Column 4 ............................ Console Arm 6 ......................[...]

Reelmaster 7000 Page 7 - - 2 Chassis General Information Operator ’s Manual The T raction 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[...]

Reelmaster 7000 Page 7 - - 3 Chassis This page is intentionally blank. Chassis[...]

Reelmaster 7000 Page 7 - - 4 Chassis Service and Repairs Steering Column 1. Steering wheel cover 2. Lock nut 3. Steering wheel 4. Flat washer 5. Socket head screw (4 used) 6. Flange head screw (4 used) 7. Steering column 8. Steering control valve 9. Socket head screw (4 used) 10. Flange nut (4 used) 1 1. Tinnerman nut (4 used) 12. Column brace Figu[...]

Reelmaster 7000 Page 7 - - 5 Chassis 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 v alve to prevent it from shif- ting during steering column removal. 9. Loosen and remove four (4) socket head screws (item 5) that secure steer[...]

Reelmaster 7000 Page 7 - - 6 Chassis Console Arm 1. Console arm frame 2. LH cover 3. RH cover 4. W asher head screw (10 used) 5. Phillips head screw 6. Lock nut (3 used) 7. Cover plate 8. Flange head screw (2 used) 9. Mount 10. U - - nut (5 used) 1 1. Flange head screw (5 used) 12. Switch panel 13. Rivet (2 used) 14. Arm rest 15. Flange nut (3 used[...]

Reelmaster 7000 Page 7 - - 7 Chassis 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). 3. At[...]

Reelmaster 7000 Page 7 - - 8 Chassis Lift Arms for Front Cutting Units (#1, #4 and #5) Figure 7 FRONT RIGHT 1. O - - r ing 2. Flange nut 3. Lift arm (cutting unit #1) 4. Cylinder pin 5. Flange head screw 6. 90 o hydraulic fitting (2 per cylinder) 7. O - - r ing 8. Lift cylinder (cutting units #4 and #5) 9. Lift cylinder (cutting unit #1) 10. Thrust[...]

Reelmaster 7000 Page 7 - - 9 Chassis Removal (Fig 7) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove cutting unit assembly from lift arm (see Cut- ting Unit Removal in the Service and Repairs section of Chapter 8 - - D P A Cutting Units). 3. If lift arm fo[...]

Reelmaster 7000 Page 7 - - 10 Chassis Lift Arms for Rear Cutting Units (#2 and #3) Figure 9 FRONT RIGHT 1 2 4 5 6 7 8 9 10 11 14 15 16 17 19 20 21 22 23 24 25 26 7 8 16 26 16 16 32 17 13 11 11 11 11 32 5 6 26 26 24 22 25 23 11 12 12 3 27 28 29 30 18 31 33 31 1. Flange nut (2 used) 2. Bulkhead bracket 3. Hydraulic tee fitting 4. Flange head screw (2[...]

Reelmaster 7000 Page 7 - - 1 1 Chassis CAUTION Be careful when removing tension from the tor- sion spring on the rear lift arms. The spring is un- der heavy load and may cause personal injury . 4. Remove tension from torsion spring on rear of lift arm tube (Fig. 1 1): A. Insert nut driver or small piece of pipe onto the end of the torsion spring th[...]

Reelmaster 7000 Page 7 - - 12 Chassis Operator Seat 1. Seat frame 2. Seat plate 3. T orsion spring 4. Seat plate latch 5. Clevis pin 6. Flat washer 7. Cotter pin 8. Hair pin (4 used) 9. Seat frame rod (2 used) 10. Flat washer (3 used) 11 . H a i r p i n 12. Seat pivot shaft 13. Flat washer (2 used) 14. Flange head screw (4 used) 15. Flange nut (4 u[...]

Reelmaster 7000 Page 7 - - 13 Chassis Removal (Fig. 12) 1. Park machine on a level surface, lower cutting units, stop engine, apply parking brake and remove key from the ignition switch. 2. Disconnect seat electrical connector from machine wire harness. 3. Support console arm assembly to prevent it from shifting. 4. Remove flange nut (item 25) and [...]

Reelmaster 7000 Page 7 - - 14 Chassis Operator Seat Service 1. Backrest cushion 2. Seat cushion 3. LH armrest cover 4. LH armrest 5. Bushing (2 used) 6. Backrest 7. Plug (2 used) 8. Cable tie (3 used) 9. LH adjustment rail 10. Bumper (2 used) 1 1. Washer 12. Cap screw (2 used) 13. Seat 14. Nut 15. Spring (2 used) 16. Magnet 17. Seat switch 18. Rive[...]

Reelmaster 7000 Page 7 - - 15 Chassis Disassembly (Fig. 14) 1. Remove seat from machine for service (see Opera- tor Seat Removal in this section). 2. Disassemble operator seat as necessary using Fig- ure 14 as a guide. Assembly (Fig. 14) 1. Assemble operator seat using Figure 14 as a guide. 2. Install seat to machine (see Operator Seat Installa- ti[...]

Reelmaster 7000 Page 7 - - 16 Chassis Operator Seat Suspension 1. Cover 2. Cover 3. Level control 4. Air control valve 5. Shock absorber 6. Air spring 7. Air tube assembly 8. Wire harness 9. Compressor 10. Bellows 11 . S t o p 12. Bumper set (2 used) 13. Roller (4 used) 14. Washer (2 used) 15. T ether 16. Rivet (2 used) 17. Washer (4 used) 18. C - [...]

Reelmaster 7000 Page 7 - - 17 Chassis 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) r equires removal, the seat suspension base will have to be re- moved from the seat plate. Disassembly (Fig. 15) 1. Park machine on a level surface, lower cut[...]

Reelmaster 7000 Page 7 - - 18 Chassis Hood 1. Screen 2. Latch keeper 3. Pop rivet (2 used) 4. Hood 5. Plastic plug (20 used) 6. Hood screen 7. Bulb seal (2 used) 8. Adjustable latch 9. Hair pin (2 used) 10. Rear bumper 1 1. Pop rivet (2 used) 12. Rubber bumper (2 used) 13. Flange nut (2 used) 14. Bulb seal (2 used) 15. Flat washer (2 used) 16. Axle[...]

Reelmaster 7000 Page 7 - - 19 Chassis Removal (Fig. 17) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Release hood latches and raise hood. 3. Remove hair pins and washers from pivot pins on ra- diator frame. 4. Remove hood from pivot pins and machine. 5. If nec[...]

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Reelmaster 7000 DP A Cutting Units Page 8 - - 1 Chapter 8 DP A Cutting Units T able of Contents SPECIFICA TIONS 2 ............................. GENERAL INFORMA TION 3 ..................... Cutting Unit Operator ’s Manual 3 ................ SPECIAL TOOLS 4 ............................. F ACTORS T HA T CAN AFFECT CUTTING PERFORMANCE 8 .............[...]

Reelmaster 7000 DP A Cutting Units Page 8 - - 2 Specifications Figure 1 Frame Construction: Precision machined die c ast alu- minum cross member with two (2) bolt - - on cast ductile iron side plates. Reel Construction: Reels are 27 inches (69 cm) in length and 7 inch (18 cm) in diameter . High strength, low alloy steel blades are thru hardened and[...]

Reelmaster 7000 DP A Cutting Units Page 8 - - 3 General Information Cutting Unit Operator ’s Manual The Cutting Unit Operator ’s Manual provides informa- tion regarding the operation, general maintenance and maintenance intervals for the DP A cutting units on your Reelmaster machine. Additionally , if optional kits have been installed on the cu[...]

Reelmaster 7000 DP A Cutting Units Page 8 - - 4 Special T ools Special tools are available from your T oro Distributor . Some tools may have been supplied with your machine or are available as TORO parts. Gauge Bar Assembly T oro Part Number: 108 - - 6715 Use gauge bar to verify height - - of - - cut adjustment. Figure 2 Used for Height - - of - - [...]

Reelmaster 7000 DP A Cutting Units Page 8 - - 5 Plastic Plug T oro Part Number: 94 - - 2703 This plug is used for placement into the side plate bear- ing housing when the hydraulic reel motor is removed. It prevents dirt and debris from entering the cutting reel bearing area. Figure 5 Cutting Unit Kickstand T oro Part Number: 1 10 - - 4088 - - 03 T[...]

Reelmaster 7000 DP A Cutting Units Page 8 - - 6 Reel Bearing Installation T ool T oro Part Number: 1 17 - - 0975 Use the reel bearing installation tool to keep the reel bearing aligned as the cutting unit side plate is installed on the bearing. Figure 8 Roller Rebuild Kit T oro Part Number: 1 15 - - 0803 This tool kit is used to assemble the cuttin[...]

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Reelmaster 7000 DP A Cutting Units Page 8 - - 8 Factors That Can Affect Cutting Performance There are a number of factors that can contribute to un- satisfactory quality of cut, some of which may be turf conditions. T urf conditions such as excessive thatch, “sponginess” or attempting to cut off too much grass height may not always be overcome [...]

Reelmaster 7000 DP A Cutting Units Page 8 - - 9 Factor Possible Problem/Correction Reel and bedknife sharpness A reel and/or bedknife that has rounded cutting edges or “rifling” (grooved or wavy appearance) cannot be corrected by tightening the bedknife to reel contact. Grind cutting reel to remove taper and/or rifling. Grind bedknife to sharpe[...]

Reelmaster 7000 DP A Cutting Units Page 8 - - 10 Factor Possible Problem/Correction Roller condition and roller type Make sure rollers rotate freely . Repair roller bearings as necessary . See Roller Service in the Service and Repairs section of this chapter . Refer to Cutting Unit Operator ’s Manual for roller options. Cutting unit accessories A[...]

Reelmaster 7000 DP A Cutting Units Page 8 - - 1 1 Set Up and Adjustments Characteristics CAUTION Never install or work on the cutting units or lift arms with the engine running. Always stop en- gine and remove key first. The dual knob bedknife - - to - - reel adjustment system in- corporated in this cutting unit simplifies the adjustment procedure [...]

Reelmaster 7000 DP A Cutting Units Page 8 - - 12 Reel Bearing Adjustment T o insure cut quality and long life of the cutting reel bear- ings, periodically check reel bearing adjustment. Check Reel Bearing Adjustment 1. Remove hydraulic reel motor from cutting unit (see Hydraulic Reel Motor Removal in the Service and Re- pairs section of this chapte[...]

Reelmaster 7000 DP A Cutting Units Page 8 - - 13 Leveling Rear Roller The precision machined components of the cutting unit frame keep the rear roller and cutting reel in alignment (parallel). If the side plates are disassembled or as the cutting reel wears, a limited amount of side plate adjust- ment is possible to make sure that the cutting unit [...]

Reelmaster 7000 DP A Cutting Units Page 8 - - 14 Service and Repairs Hydraulic Reel Motor IMPORT ANT : When performing maintenance pro - cedures on the cutting units, carefully position the cutting unit reel motors to prevent damage to the motors or hydraulic hoses. Removal 1. Park machine on a clean and level surface, lower cutting units completel[...]

Reelmaster 7000 DP A Cutting Units Page 8 - - 15 Cutting Unit Removal and Installation Cutting Unit Removal 1. Park machine on a clean and level surface, lower cutting units completely to the ground, stop engine, en- gage parking brake and remove key from the ignition switch. 2. If front outside cutting units (#4 or #5 cutting unit) is being remove[...]

Reelmaster 7000 DP A Cutting Units Page 8 - - 16 Backlapping DANGER TO A VOID PERSONAL INJUR Y OR DEA TH: D Never place hands or feet in the reel area while the engine is running. Stay away from the cutting reels when backlapping. D When backlapping, run engine at idle speed only . D While backlapping, the reels may stall and then restart. D Do not[...]

Reelmaster 7000 DP A Cutting Units Page 8 - - 17 8. If reels stall or become erratic while backlapping, in- crease the engine speed slightly until the reel speed sta- bilizes. 9. T o make an adjustment to the cutting units while backlapping, disengage the PT O switch and turn the en- gine OFF . W ait for all machine movement to stop. After adjustme[...]

Reelmaster 7000 DP A Cutting Units Page 8 - - 18 Bedbar Assembly 1. Bedbar 2. Bedknife 3. Screw 4. Bedbar adjuster shaft (2 used) 5. Flange bushing (4 used) 6. Cap screw (2 used) 7. Detent (2 used) 8. W ave washer (2 used) 9. Retaining ring (2 used) 10. Bedbar adjuster screw (2 used) 1 1. Washer (2 used) 12. Compression spring (2 used) 13. Lock nut[...]

Reelmaster 7000 DP A Cutting Units Page 8 - - 19 8. Inspect flange bushings (item 15) and rubber bush- ings (item 14) in side plates for wear or damage. Re- move bushings and replace if necessary . Bedbar Installation (Fig. 22) 1. If rubber bushing was removed from either cutting unit side plate, install a new bushing. The bushing should be install[...]

Reelmaster 7000 DP A Cutting Units Page 8 - - 20 Bedbar Adjuster Service Figure 24 1. Bedbar assembly 2. Compression spring 3. Lock nut 4. Bedbar adjuster shaft 5. Flange bushing 6. Cap screw 7. Detent 8. W ave washer 9. Lock nut 10. Bedbar adjuster screw 1 1. Washer 12. Flat washer 14 to 16 ft - - lb ( 1 9t o2 1N - - m ) Antiseize Lubricant Loctit[...]

Reelmaster 7000 DP A Cutting Units Page 8 - - 21 Removal (Fig. 24) 1. Remove lock nut (item 3), compression spring (it em 2) and washer (item 1 1) from bedbar adjuster screw (item 10). 2. Remove bedbar (see Bedbar Removal in this sec- tion). NOTE: Inside threads in bedbar adjuster shaft ( item 4) are left - - hand threads. 3. Unscrew bedbar adjuste[...]

Reelmaster 7000 DP A Cutting Units Page 8 - - 22 Bedknife Replacement and Grinding Bedknife Removal 1. Remove bedbar from cutting unit (see Bedbar Re- moval in this section). 2. Remove screws from bedbar using a socket wrench and bedknife screw tool (see Special T ools). Discard screws. Remove bedknife from the bedbar (Fig. 26). Bedknife Installati[...]

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Reelmaster 7000 DP A Cutting Units Page 8 - - 24 Reel Assembly Removal and Installation 1. Bedbar assembly 2. Flange nut (3 used per side plate) 3. Flange bushing (2 used) 4. Plastic washer (4 used) 5. Metal washer (2 used) 6. Bedbar pivot bolt (2 used) 7. Lock nut (2 used) 8. Shoulder bolt (3 used per side plate) 9. LH side plate 10. Weight 1 1. C[...]

Reelmaster 7000 DP A Cutting Units Page 8 - - 25 Reel Assembly Removal (Fig. 29) 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and re- move key from the ignition switch. 2. Remove the cutting unit from the machine and place on a flat work area (see Cutting Unit Removal and Instal- lation in[...]

Reelmaster 7000 DP A Cutting Units Page 8 - - 26 IMPORT ANT : During cutting reel installation, keep inner and outer bearing races aligned. If bearing races are not aligned, binding will occur and reel installation may cause bearing damage. Use reel bearing installation tool (#1 17 - - 0975) to help with bearing alignment during reel installation. [...]

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Reelmaster 7000 DP A Cutting Units Page 8 - - 28 Reel Assembly Service 1. Cutting reel 2. Threaded insert (RH thread) 3. Retaining ring 4. Grease seal 5. Bearing 6. Threaded insert (LH thread) 7. Retaining ring groove 8. Groove indicating LH threads 9. Bearing shoulder 10. Reel spider Figure 32 85 to 95 ft - - lb (1 15 to 128 N - - m) 85 to 95 ft -[...]

Reelmaster 7000 DP A Cutting Units Page 8 - - 29 Inspection of Cutting Reel (Fig. 32) 1. Inspect reel bearings to insure that they rotate freely and have minimal axial play . The bearing balls must be free of deformation and scoring. 2. Inspect the reel shaft as follows. If reel damage is de- tected, replace reel. A. Check the reel shaft for bendin[...]

Rev . A Reelmaster 7000 DP A Cutting Units Page 8 - - 30 Preparing Reel for Grinding NOTE: Before grinding a cutting reel, make sure that all cutting unit c omponents are in good condition. Depend- ing on type of grinder used, faulty cutting unit compo- nents can affect grinding results. NOTE: When grinding, be careful to not overheat the cutting r[...]

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Reelmaster 7000 DP A Cutting Units Page 8 - - 32 Front Roller Removal (Fig. 34) 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and re- move key from the ignition switch. 2. Remove the cutting unit from the machine and place on a level working surface. Use cutting unit kickstand (see Special [...]

Reelmaster 7000 DP A Cutting Units Page 8 - - 33 Rear Roller Removal (Fig. 35) 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and re- move key from the ignition switch. 2. Remove the cutting unit from the machine and place on a level working surface. Place support blocks under bedbar to rais[...]

Reelmaster 7000 DP A Cutting Units Page 8 - - 34 Roller Service Disassembly (Fig. 36) 1. Remove bearing lock nut from each end of roller shaft. 2. Loosely secure roller assembly in bench vise and lightly tap one end of roller shaft until outer seals and bearing are removed from opposite end of roller tube. Remove second set of outer seals and beari[...]

Reelmaster 7000 DP A Cutting Units Page 8 - - 35 3. From the roller tube end with only the inner seal installed, carefully install the roller shaft into the roller tube. Make sure that seals are not damaged as shaft is installed. 4. Install new bearing and outer seals into second end of roller tube: A. Position a second new bearing to roller shaft [...]

Reelmaster 7000 DP A Cutting Units Page 8 - - 36 Rear Roller Brush (Optional) 1. Roller brush assembly 2. Carriage screw (3 used) 3. Flange nut 4. Flange bushing 5. Idler spring 6. Excluder seal (2 used) 7. Bearing assembly (driven) 8. Spacer 9. Hardened washer (as required) 10. Driven pulley 1 1. Flange nut 12. Carriage screw (2 used) 13. Cap scre[...]

Reelmaster 7000 DP A Cutting Units Page 8 - - 37 Disassembly (Fig. 42) 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and re- move key from the ignition switch. 2. T o remove roller brush from brush shaft: A. Remove the non - - driven brush bearing assembly (item 30) from cutting unit. B. Sl[...]

Reelmaster 7000 DP A Cutting Units Page 8 - - 38 3. If drive bearing housing was disassembled, install new components noting proper orientation as shown in Figures 45 and 46. A. Install bearing on shaft by pressing equally on the inner and outer bearing races. Install the bearing so that the bearing seal is closest to the shoulder on the shaft. Ins[...]

Reelmaster 7000 DP A Cutting Units Page 8 - - 39 5. Check alignment of pulleys with a straight edge placed along the outer face of the driven pulley (Fig. 48). The outer faces of the driven and drive pulleys (not the idler pulley) should be in line within 0.030” (0.76 mm). If necessary to align pulleys, remove driven pulley from brush shaft and a[...]

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Reelmaster 7000 Foldout Drawings Page 9 - 1 Chapter 9 Foldout Drawings T able of Contents HYDRAULIC SCHEMA TIC 3 ..................... ELECTRICAL SCHEMA TIC 4 ..................... WIRE HARNESS DRA WINGS Main Wire Harness 6 .......................... Seat and Console Wire Harness 8 .............. Power Center Wire Harness 10 ................. Foldo[...]

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Page 9 - - 3 Hydr aulic Sc hem atic Reelmaster 7000 P1 T2 ST T1 P2 CV RV2 G1 G2 L P2 M1 M2 T P1 SP1 SP2 LC2 LC1 RV1 M5 CV1 M1 C2 M4 RV2 OR1 OR2 CV2 C5 C4 C1 S5 C3 M3 M2 C4 C1 C3 C2 S3 MV1 S4 P MV2 G M3 M4 M1 M2 CHG S2 .071 VA L V E T RV1 S1 PD1 SV RV M2 550 PSI PD2 CHG M1 M1 P1 PSI BYP ASS P1 .091 2.48 5000 450 PSI .052 P2 G CV PR 2.01 G CR2 CR1 P1[...]

Page 9 - - 4 Electr ical Schematic Reelmaster 7000 All r elays and so lenoids are shown as de - - energized. All gr ound wir es are black. She et 1 o f 2[...]

Rev . A Page 9 - - 5 Electr ical Schematic Reelmaster 7000 All r elays and so lenoids are shown as de - - energized. All gr ound wir es are black. Sheet 2 of 2 FA N D I R E C TI ON ( S 1 ) FRO NT REELS (S4) REEL ENG AGE FRON T (SP1) REEL ENG AGE REAR (SP2) F AN SPEED (PRV) REAR REELS ( S5) RAISE REEL S (S2) ENABLE ( S1) LOWER R EELS (S3) RANGE 2WD/[...]

Page 9 - - 6 Reelmaster 7000 Ma in Wi re Ha rne s s[...]

Page 9 - - 7 Reelmaster 7000 Ma in Wi re Ha rne s s ORANGE BLACK GRA Y/BLUE BLACK BLACK BLACK BLACK BLACK VIOLET BLACK VIOLET BLACK BLACK BLACK RED/WHI TE BLACK/WHI TE BLACK BLACK BLACK BLACK BLACK BLACK BLACK PINK BLUE/YELLOW BLUE/YELLOW GRA Y PINK BLACK PINK GRA Y/BLACK GREEN/WHI TE BROWN GRA Y/BLUE BLUE/WHI TE RED/GREEN YELLOW/GREEN RED/BLUE BRO[...]

Page 9 - - 8 Reelmaster 7000 Seat and Console Wire Har ness[...]

Page 9 - - 9 Reelmaster 7000 Seat and Console Wire Har ness BLACK WHITE/ YELLOW RED/GREEN BROWN BLUE/WHI TE RED/YELLOW WHITE/ BLACK PINK/ BLACK PINK/ GREEN VIOLET/ BLACK TAN / W H I T E GRA Y BROWN/YELLOW VIOLET/ WHITE GRA Y WHITE/ ORANGE PINK BLACK/WHI TE RED/WHI TE PINK BLUE VIOLET WHITE GREEN WHITE PINK PINK BLACK BLACK RED/WHI TE BLACK/WHI TE R[...]

Page 9 - - 10 Reelmaster 7000 Power Center Wir e Harness[...]

Page 9 - - 1 1 Reelmaster 7000 P o w e rC e n t e rW i r e H a r n e s s ORANGE/WHI TE BLUE RED BLACK ORANGE PINK/ BLACK BLUE PINK RED/GREEN BROWN/BLACK GRA Y/BLACK WHITE/ YELLOW BROWN RED/BLUE WHITE/ BLACK T AN/BLACK RED BLACK RED BLACK PINK RED RED RED RED RED RED RED RED RED VIOLET BLACK RED BLACK RED BLACK[...]