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Toro Reelmaster 7000 Service Manual
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Toro Reelmaster 7000 Service Manual

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Preface
The purpose of this publication is to provide the service
technician with information for troubleshooting, testing
and repair of major systems and components on the
Reelmaster 7000.
REFER TO THE TRACTION UNIT AND CUTTING
UNIT OPERATOR'S MANUALS FOR OPERATING,
MAINTENANCE AND ADJUSTMENT INSTRUC-
TIONS. For reference, insert a copy of the Operator's
Manuals and Parts Catalog for your machine into Chap-
ter 2 of this service manual. Additional copies of the Op-
erator's Manuals and Parts Catalog are available on the
internet at www.Toro.com.
The Toro Company reserves the right to change product
specifications or this publication without notice.
E The Toro Company - - 2011, 2012

Service Manual

Reelmaster
This safety symbol means DANGER, WARNING
or CAUTION, PERSONAL SAFETY INSTRUC-
TION. When you see this symbol, carefully read
the instructions that follow. Failure to obey the
instructions may result in personal injury.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing or re-
pair of the machine.
IMPORTANT: The IMPORTANT notice will give im-
portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.
Part No. 11185SL (Rev. A)
R
7000

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  • Page 1: Service Manual

    The Toro Company reserves the right to change product IMPORTANT: The IMPORTANT notice will give im- specifications or this publication without notice. portant instructions which must be followed to pre- vent damage to systems or components on the machine.
  • Page 2 This page is intentionally blank. Reelmaster 7000...

  • Page 3: Table Of Contents

    ..... 9 -- 6 FIXED DISPLACEMENT, VALVE PLATE DESIGN REPAIR INFORMATION SAUER--DANFOSS STEERING UNIT TYPE OSPM SERVICE MANUAL Reelmaster 7000...
  • Page 4 This page is intentionally blank. Reelmaster 7000...

  • Page 5: General Safety Instructions 1

    ..... SAFETY AND INSTRUCTION DECALS ..Reelmaster 7000 Page 1 - - 1 Safety...

  • Page 6: General Safety Instructions

    General Safety Instructions The Reelmaster 7000 have been tested and certified by TORO for compliance with existing safety standards WARNING and specifications. Although hazard control and acci- dent prevention partially are dependent upon the design To reduce the potential for injury or death, and configuration of the machine, these factors are also comply with the following safety instructions.

  • Page 7: Maintenance And Service

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

  • Page 8: Jacking Instructions

    2. Place jack securely under the center of rear axle. 3. Jack rear of machine off the ground. 4. Position appropriate jack stands under the rear axle to support the machine. Safety Page 1 - - 4 Reelmaster 7000...

  • Page 9: Safety And Instruction Decals

    Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Reelmaster 7000. If any decal becomes illegible or damaged, install a new decal. Decal part numbers are listed in your Parts Catalog. Reelmaster 7000 Page 1 - - 5...
  • Page 10 This page is intentionally blank. Safety Page 1 - - 6 Reelmaster 7000...

  • Page 11: Product Records

    Several maintenance procedures have break--in intervals identified in the Operator’s Manuals. Refer to the Engine Operator’s Manual for additional en- gine specific maintenance procedures. Reelmaster 7000 Product Records and Maintenance Page 2 - - 1...

  • Page 12: Equivalents And Conversions

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

  • Page 13: Torque Specifications

    For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.
  • Page 14 The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc. Product Records and Maintenance Reelmaster 7000 Page 2 - - 4...
  • Page 15 The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc. Reelmaster 7000 Product Records and Maintenance Page 2 - - 5...
  • Page 16 Conversion Factors in- -lb X 11.2985 = N- -cm N- -cm X 0.08851 = in- -lb ft- -lb X 1.3558 = N- -m N- -m X 0.7376 = ft- -lb Product Records and Maintenance Reelmaster 7000 Page 2 - - 6...

  • Page 17: Specifications

    ......KUBOTA WORKSHOP MANUAL, DIESEL ENGINE, 03--M--DI--E3B SERIES Reelmaster 7000 Page 3 - - 1 Kubota Diesel Engine...

  • Page 18: Specifications

    Oil Pump Trochoid Type Coolant Capacity 13 U.S. Quarts (12.3 Liters) Starter 12 VDC, 2.0 kW Alternator/Regulator 12 VDC Alternator Output 60 amp Engine Dry Weight 406 U.S. pounds (184 kg) Kubota Diesel Engine Page 3 - - 2 Reelmaster 7000...

  • Page 19: General Information

    This Chapter gives information about specifications and tools are described in the Kubota Workshop Manual, repair of the diesel engine used in the Reelmaster 7000. Diesel Engine, 03--M--DI--E3B. The use of some spe- cialized test equipment is explained. However, the cost...

  • Page 20: Air Filter System

    7. Flange nut (4 used) 16. Coolant reservoir 25. Reservoir cap 8. Fan drive manifold 17. Reservoir bracket 26. Plenum 9. Air cleaner strap 18. Flange nut (8 used) 27. Air intake hose Kubota Diesel Engine Page 3 - - 4 Reelmaster 7000...
  • Page 21 1. Air cleaner assembly 4. Groove 2. Service indicator 5. Filter element 2. After air cleaner installation is completed, lower and 3. Adapter secure hood. Reelmaster 7000 Page 3 - - 5 Kubota Diesel Engine...

  • Page 22: Exhaust System

    12. Muffler bracket 3. Flange head screw (4 used) 8. Cap screw 13. Flange nut (2 used) 4. Muffler clamp 9. Muffler bracket 14. Muffler clamp 5. Tailpipe 10. Muffler gasket Kubota Diesel Engine Page 3 - - 6 Reelmaster 7000...
  • Page 23 Figure 4 as a guide. Hand tighten all exhaust system fasteners before fully tightening any fastener. 3. Tailpipe should have equal clearance between frame and engine after installation. 4. After exhaust system installation is completed, lower and secure hood. Reelmaster 7000 Page 3 - - 7 Kubota Diesel Engine...

  • Page 24: Fuel System

    7. Bushing (2 used) 16. Fuel hose (supply) 25. Grommet 8. Hose clamp (6 used) 17. Fuel hose (supply) 26. Hose clamp 9. Fuel tank 18. Cap screw (2 used) 27. Draincock Kubota Diesel Engine Page 3 - - 8 Reelmaster 7000...

  • Page 25: Check Fuel Lines And Connections

    To clean fuel tank, flush tank out with clean diesel fuel. Make sure tank is free of contaminates and debris. Reelmaster 7000 Page 3 - - 9 Kubota Diesel Engine...

  • Page 26: Radiator

    44. Flange head screw (4 used) 14. Upper radiator hose 30. Clamp (2 used) 45. Bulb seal 15. Flange nut (12 used) 16. Temperature sender 31. Cap screw (2 used) 46. Spacer Kubota Diesel Engine Page 3 - - 10 Reelmaster 7000...
  • Page 27 5. Flange nut (6 used) 1. Remove plugs placed in radiator and hose openings 3. Fan motor 6. Radiator during the removal procedure. Make sure that radiator draincock is closed. Reelmaster 7000 Page 3 - - 11 Kubota Diesel Engine...

  • Page 28: Engine

    10. Flange head screw (10 used) 22. Muffler gasket 33. Muffler clamp 11. Engine mount (4 used) 23. Cap screw 34. Cap screw (2 used) 12. Flange nut (15 used) Kubota Diesel Engine Page 3 - - 12 Reelmaster 7000...

  • Page 29: Engine Removal

    Removal in this section). Remove upper radiator shroud F. The electric starter motor. from machine. G. Low oil pressure switch located on alternator side of engine (above electric starter). Reelmaster 7000 Page 3 - - 13 Kubota Diesel Engine...

  • Page 30: Engine Installation

    Repairs section of Chapter 4 -- Hydraulic System). Engine Installation (Fig. 8) 1. Locate machine on a level surface with key removed from the ignition switch. Chock wheels to keep the ma- chine from moving. Kubota Diesel Engine Page 3 - - 14 Reelmaster 7000...

  • Page 31: General Information 4

    23.Install hood on the machine (see Hood Installation in the Service and Repairs section of Chapter 7 -- Chas- A. The engine run solenoid (Fig. 9). sis). B. The temperature sender (Fig. 10). Reelmaster 7000 Page 3 - - 15 Kubota Diesel Engine...

  • Page 32: Pump Adapter Plate

    (40 to 44 N- -m) Boss Figure 12 1. Bolt 4. Hardened washer (14 used) 6. Bolt (6 used) 2. Lock washer 5. Spring coupler 7. Cap screw (8 used) 3. Flywheel plate Kubota Diesel Engine Page 3 - - 16 Reelmaster 7000...
  • Page 33 4. If engine is in machine, install hydraulic pump as- sembly (see Piston (Traction) Pump Installation in the Service and Repairs section of Chapter 4 -- Hydraulic System). Reelmaster 7000 Page 3 - - 17 Kubota Diesel Engine...
  • Page 34 This page is intentionally blank. Kubota Diesel Engine Page 3 - - 18 Reelmaster 7000...

  • Page 35: Hydraulic Schematic 4

    ..... SAUER--DANFOSS STEERING UNIT TYPE OSPM General Precautions for Removing and SERVICE MANUAL Installing Hydraulic System Components ..Reelmaster 7000 Page 4 - - 1 Hydraulic System Rev. A...
  • Page 36 This page is intentionally blank. Hydraulic System Page 4 - - 2 Reelmaster 7000...
  • Page 37 When using pressure gauges to measure circuit pressures, values may be different than these specifications. See the Testing section of this chapter for hydraulic test procedures and expected test results. Reelmaster 7000 Page 4 - - 3 Hydraulic System...
  • Page 38 4WD/2WD control manifold test port (G). Toro part numbers 95- -8843 (hydraulic hose), 95- -0985 (coupler fitting) (2 required) and 340- -77 (hydraulic fitting) (2 required) are needed for this connection.
  • Page 39 Traction Circuit Component Failure The traction circuit on Reelmaster 7000 machines is a all drive wheels off the ground. Then, operate the trac- closed loop system that includes the piston (traction) tion circuit to allow oil flow throughout the circuit.

  • Page 40: Hydraulic Hoses

    Tube Installation in this section). If the hose has an el- bow at one end, tighten the swivel nut on that end before tightening the nut on the straight end of the hose. For additional hydraulic hose information, refer to Toro Service Training Book, Hydraulic Hose Servicing (Part Number 94813SL).
  • Page 41 85 to 105 ft--lb (116 to 142 N--m) 1 7/16 -- 12 110 to 136 ft--lb (150 to 184 N--m) 1 11/16 -- 12 140 to 172 ft--lb (190 to 233 N--m) Figure 5 Reelmaster 7000 Page 4 - - 7 Hydraulic System...
  • Page 42 202 to 248 ft--lb (274 to 336 N--m) 121 to 149 ft--lb (165 to 202 N--m) 1 5/8 -- 12 247 to 303 ft--lb (335 to 410 N--m) 149 to 183 ft--lb (202 to 248 N--m) Figure 7 Hydraulic System Page 4 - - 8 Reelmaster 7000...
  • Page 43 1.00 + 0.25 6 (3/8 in.) 1.50 + 0.25 8 (1/2 in.) 1.50 + 0.25 10 (5/8 in.) 1.50 + 0.25 12 (3/4 in.) 1.50 + 0.25 16 (1 in.) 1.50 + 0.25 Reelmaster 7000 Page 4 - - 9 Hydraulic System...

  • Page 44: Hydraulic Schematic

    Hydraulic Schematic Hydraulic System Page 4 - - 10 Reelmaster 7000...
  • Page 45 This page is intentionally blank. Reelmaster 7000 Page 4 - - 11 Hydraulic System...

  • Page 46: Hydraulic Flow Diagrams

    Hydraulic Flow Diagrams Hydraulic System Page 4 - - 12 Reelmaster 7000...
  • Page 47 4WD/2WD control manifold at port M1, flows pressure test port on the filtration/charge control man- through the PD1 cartridge, exits the manifold at port P1 ifold. and returns to the piston pump. Reelmaster 7000 Page 4 - - 13 Hydraulic System...
  • Page 48 Hydraulic System Page 4 - - 14 Reelmaster 7000...
  • Page 49 NOTE: When the mow speed limiter is in the transport (2WD) position, the cutting units are prevented from be- ing lowered and the mow circuit cannot be engaged. Reelmaster 7000 Page 4 - - 15 Hydraulic System...
  • Page 50 Hydraulic System Page 4 - - 16 Reelmaster 7000...
  • Page 51 Rear cutting unit lower- ing speed is controlled by a flow control orifice in the lift control manifold (port C3). Reelmaster 7000 Page 4 - - 17 Hydraulic System...
  • Page 52 Hydraulic System Page 4 - - 18 Reelmaster 7000...
  • Page 53 When the lift switch is released, solenoid valves S1, S2, S3, S4 and S5 are de--energized and the lift cylinders and cutting units are held in position. Reelmaster 7000 Page 4 - - 19 Hydraulic System...
  • Page 54 Hydraulic System Page 4 - - 20 Reelmaster 7000...

  • Page 55: Mow Circuit

    PUMP P2 Maximum mow circuit pressure is limited at each mow Figure 15 manifold circuit by the relief valve (RV1 or RV2). The re- lief valve pressure is 3000 PSI (207 bar). Reelmaster 7000 Page 4 - - 21 Hydraulic System...
  • Page 56 Hydraulic System Page 4 - - 22 Reelmaster 7000...

  • Page 57: Steering Circuit

    The rotary meter ensures that the oil flow to NEUTRAL POSITION LEFT TURN RIGHT TURN STEERING STEERING STEERING CONTROL CONTROL CONTROL VALVE VALVE VALVE 1050 1050 1050 NO CYLINDER STEERING STEERING STEERING MOVEMENT CYLINDER CYLINDER CYLINDER Figure 16 Reelmaster 7000 Page 4 - - 23 Hydraulic System...
  • Page 58 Hydraulic System Page 4 - - 24 Reelmaster 7000...

  • Page 59: Engine Cooling Fan Circuit

    FROM GEAR the manifold (port T) and then is routed through the mow PUMP (P3) FROM GEAR control manifold, oil cooler and oil filter. PUMP (P4) TO OIL COOLER Figure 18 Reelmaster 7000 Page 4 - - 25 Hydraulic System...

  • Page 60: Special Tools

    Special Tools Order the following special tools from your Toro Distributor. Hydraulic Pressure Test Kit Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings.
  • Page 61 3. FLOW METER: This meter measures actual oil flow in the operating circuit with a gauge rated from 4 to 40 GPM (20 to 150 LPM). Toro Part Number: AT40002 Figure 21 NOTE: This tester does not include hydraulic hoses (see Hydraulic Hose Kit TOR6007 below).

  • Page 62: Hydraulic Test Fitting Kit

    Toro Part Number: TOR6011 NOTE: This kit does not include hydraulic hoses (see Hydraulic Hose Kit TOR6007 above). NOTE: Replacement filter element is Toro part number TOR6012. Filter element cannister tightening torque is 25 ft- -lb (34 N- -m). Hydraulic Test Fitting Kit This kit includes a variety of O--ring Face Seal fittings to enable you to connect test gauges into the system.

  • Page 63: Measuring Container

    The kit includes O--rings in a variety of sizes for face seal and port seal hydraulic connections. It is recommended that O--rings be replaced whenever a hydraulic connec- tion is loosened. Toro Part Number: 16- -3799 Figure 27 Reelmaster 7000 Page 4 - - 29...

  • Page 64: Troubleshooting

    Wrong type of oil is in the hydraulic system. Air is leaking in suction line. Hydraulic oil leak(s). Fitting(s), hose or tube loose or damaged. Missing or damaged O-ring in fitting. Hydraulic System Page 4 - - 30 Reelmaster 7000...
  • Page 65 Mow speed (4WD) will not disen- Electrical problem exists (see Chapter 5 -- Electrical System). gage. Cutting units are fully lowered. Cartridge valve in 4WD/2WD control manifold is damaged or sticking. Reelmaster 7000 Page 4 - - 31 Hydraulic System...
  • Page 66 Mow control manifold check valve (CV1 or CV2) for affected cutting units is stuck or damaged. Gear pump section (P1 or P2) is worn or damaged. Hydraulic System Page 4 - - 32 Reelmaster 7000...
  • Page 67 Steering control valve is worn or damaged. Gear pump section (P3) is worn or damaged (NOTE: A worn or damaged gear pump section (P3) will also affect the traction (charge) and lift circuits). Reelmaster 7000 Page 4 - - 33 Hydraulic System...
  • Page 68 Lift arm pivots are binding. Lift cylinder(s) is (are) is damaged. Lower circuit relief valve (RV2) in lift control manifold is stuck open. Solenoid valve(s) in lift control manifold is damaged or sticking. Hydraulic System Page 4 - - 34 Reelmaster 7000...
  • Page 69 Fan control manifold proportional relief valve (PRV) is faulty. speed. Electrical problem exists that prevents fan control manifold propor- tional relief valve (PRV) operation (see Chapter 5 -- Electrical Sys- tem). Reelmaster 7000 Page 4 - - 35 Hydraulic System...

  • Page 70: Testing

    Gangrene may result from such an injury. Hydraulic System Page 4 - - 36 Reelmaster 7000...
  • Page 71 2. If a PTO circuit problem exists, consider performing one or more of the following tests: Mow Circuit Pressure, Mow Circuit Relief Pressure, Cutting Unit Motor Case Drain Leakage and/or Gear Pump P1 and P2 Flow. Reelmaster 7000 Page 4 - - 37 Hydraulic System...
  • Page 72 PRESSURE GAUGE Working Pressure Low Pressure Return or Suction Flow TO DECK CONTROL MANIFOLD TO DECK CONTROL MANIFOLD TO STEERING AND LIFT CIRCUITS (CHARGE CIRCUIT) TO FAN CIRCUIT FROM DECK MOTORS Hydraulic System Page 4 - - 38 Reelmaster 7000...
  • Page 73 P3 (see Gear Pump P3 Flow Test in this section). NOTE: Steering and lift/lower circuits would also be affected if gear pump P3 is worn or damaged. Reelmaster 7000 Page 4 - - 39 Hydraulic System...
  • Page 74 PRESSURE GAUGE Working Pressure Low Pressure Return or Suction Flow TO DECK CONTROL MANIFOLD TO DECK CONTROL MANIFOLD TO STEERING AND LIFT CIRCUITS (CHARGE CIRCUIT) TO FAN CIRCUIT FROM DECK MOTORS Hydraulic System Page 4 - - 40 Reelmaster 7000...
  • Page 75 These cartridge type valves are factory set and are not adjustable. If relief valves are in good condition, piston (traction) pump, wheel motors and/or rear axle motor should be suspected of wear and inefficiency. Reelmaster 7000 Page 4 - - 41 Hydraulic System...
  • Page 76 Working Pressure Low Pressure Return or Suction Flow TO DECK CONTROL MANIFOLD TO DECK CONTROL MANIFOLD TO STEERING AND LIFT CIRCUITS (CHARGE CIRCUIT) TO FAN CIRCUIT FROM DECK MOTORS Hydraulic System Page 4 - - 42 Rev. A Reelmaster 7000...

  • Page 77: Adjustments 4

    1. 4WD/2WD manifold 2. Reducing valve (PR) 9. When testing is completed, disconnect pressure gauge from test port. Install dust cap to test port fitting. Reelmaster 7000 Page 4 - - 43 Hydraulic System Rev. A...
  • Page 78 Working Pressure Low Pressure Return or Suction Flow TO DECK CONTROL MANIFOLD TO DECK CONTROL MANIFOLD TO STEERING AND LIFT CIRCUITS (CHARGE CIRCUIT) TO FAN CIRCUIT FROM DECK MOTORS Hydraulic System Page 4 - - 44 Rev. A Reelmaster 7000...
  • Page 79 (PR) pressure is 450 PSI (31 bar), relief (RV) pres- sure should be from 550 to 570 PSI (38 to 39 bar)). 1. 4WD/2WD manifold 2. Test fitting (port G) Reelmaster 7000 Page 4 - - 45 Hydraulic System Rev. A...
  • Page 80 (CHARGE CIRCUIT) TESTER Working Pressure Low Pressure Return or Suction Flow TO DECK CONTROL MANIFOLD TO DECK CONTROL MANIFOLD TO STEERING AND LIFT CIRCUITS (CHARGE CIRCUIT) TO FAN CIRCUIT FROM DECK MOTORS Hydraulic System Page 4 - - 46 Reelmaster 7000...
  • Page 81 Make sure machine is supported so it will not move and accidentally fall to prevent in- juring anyone near the machine. Figure 36 1. Piston (traction) pump 2. LH fitting (forward port) Reelmaster 7000 Page 4 - - 47 Hydraulic System...
  • Page 82 2850/1550 GEAR PUMP BYPASS VALVE 5000 .071 .091 2.48 1.03 1.03 .071 5000 FROM REEL MOTORS Working Pressure Low Pressure 5 PSI Return or Suction Flow 207 PSI FROM STEERING CONTROL Hydraulic System Page 4 - - 48 Reelmaster 7000...
  • Page 83 Figure 38 8. Mow circuit pressure should be from 1000 to 3000 PSI (69 to 207 bar) and will vary depending on mowing conditions. Reelmaster 7000 Page 4 - - 49 Hydraulic System...
  • Page 84 TO STEERING AND LIFT CIRCUITS TO FAN CIRCUIT ENGINE SPEED PISTON PUMP 2850/1550 GEAR PUMP BYPASS VALVE 5000 .071 .091 2.48 1.03 1.03 .071 5000 FROM REEL MOTORS 5 PSI 207 PSI FROM STEERING CONTROL Hydraulic System Page 4 - - 50 Reelmaster 7000...
  • Page 85 8. Move throttle to high idle speed (2850 RPM). Make sure that mow speed limiter is in the mow (4WD) posi- tion. Release parking brake. FRONT Figure 40 Reelmaster 7000 Page 4 - - 51 Hydraulic System...
  • Page 86 UNIT MOTOR SHOWN Working Pressure Low Pressure Return or Suction Flow FROM FAN CONTROL FROM GEAR FROM GEAR TO OIL COOLER PUMP P1 PUMP P2 CASE DRAIN HOSE SUPPLY HOSE RETURN HOSE FRONT Hydraulic System Page 4 - - 52 Reelmaster 7000...
  • Page 87 CUTTING UNIT LOCATIONS 5. Start engine and run at low idle speed. Check for hy- draulic leakage and correct before proceeding with test. Figure 41 Reelmaster 7000 Page 4 - - 53 Hydraulic System...
  • Page 88 PISTON PUMP 2850/1550 GEAR PUMP BYPASS VALVE 5000 .071 TO OIL COOLER .091 2.48 1.03 1.03 .071 5000 Working Pressure Low Pressure FROM RESERVOIR FROM FILTRATION MANIFOLD Return or Suction Flow Hydraulic System Page 4 - - 54 Reelmaster 7000...
  • Page 89 3. Pump section P2 hose 2. Pump section P1 hose 6. After installing tester, start engine and run at low idle speed. Check for hydraulic leakage and correct before proceeding with test. Reelmaster 7000 Page 4 - - 55 Hydraulic System...
  • Page 90 .071 .091 2.48 1.03 1.03 .071 5000 STEERING WHEEL TURNED FOR RIGHT TURN 5 PSI STEERING 207 PSI CYLINDER 1050 STEEL Working Pressure Low Pressure PRESSURE Return or Suction GAUGE Flow Hydraulic System Page 4 - - 56 Reelmaster 7000...
  • Page 91 The steering circuit relief pressure is the gauge reading when pres- sure stabilizes. GAUGE READING TO BE 1150 TO 1500 PSI (80 to 103 bar) 8. Stop the engine. Record test results. Reelmaster 7000 Page 4 - - 57 Hydraulic System...

  • Page 92: Steering Cylinder Internal Leakage Test

    Steering Cylinder Internal Leakage Test STEERING CYLINDER FULLY LOOK FOR EXTENDED STEERING WHEEL LEAKAGE TURNED FOR RIGHT TURN STEEL PLUG 1050 TO FILTRATION MANIFOLD TO CHARGE CIRCUIT Hydraulic System Page 4 - - 58 Reelmaster 7000...

  • Page 93: Service And Repairs 4

    (see Steering Cylinder and Steering Cylinder Service in the Service and Repairs section of this chapter). Check drain pan for any evidence of oil that would indicate cyl- inder leakage. Reelmaster 7000 Page 4 - - 59 Hydraulic System...
  • Page 94 Lift/Lower Circuit Relief Pressure Test (Using Pressure Gauge) FROM STEERING CONTROL VALVE TO CHARGE CIRCUIT PRESSURE GAUGE Working Pressure Low Pressure Return or Suction Flow Hydraulic System Page 4 - - 60 Reelmaster 7000...
  • Page 95 NOTE: If lift switch continues to be pressed after the re- lief valve has opened, system pressure can increase higher than relief pressure. 8. Stop the engine and record test results. Reelmaster 7000 Page 4 - - 61 Hydraulic System...
  • Page 96 TO FAN CIRCUIT ENGINE SPEED PISTON PUMP 2850/1550 GEAR PUMP BYPASS VALVE 5000 .071 .091 2.48 1.03 1.03 .071 5000 FROM RESERVOIR FROM FILTRATION MANIFOLD Working Pressure Low Pressure Return or Suction Flow Hydraulic System Page 4 - - 62 Reelmaster 7000...
  • Page 97 Check for hydraulic leakage and correct before proceeding with test. Figure 46 1. Gear pump section P3 2. Pump section P3 hose 7. Move throttle to full speed (2850 RPM). DO NOT en- gage the cutting units. Reelmaster 7000 Page 4 - - 63 Hydraulic System...
  • Page 98 ENGINE SPEED 2850/1550 PISTON PUMP GEAR PUMP BYPASS VALVE 5000 .071 .091 2.48 1.03 1.03 .071 5000 5 PSI STEERING CYLINDER 207 PSI 1050 Working Pressure Low Pressure Return or Suction Flow Hydraulic System Page 4 - - 64 Reelmaster 7000...
  • Page 99 PRESSURE GAUGE READING TO BE approxi- mately 3000 PSI (207 bar) PHOTOTAC (fan speed) READING TO BE approxi- mately 2800 RPM 7. Stop engine and record test results. Reelmaster 7000 Page 4 - - 65 Hydraulic System...
  • Page 100 ENGINE SPEED PISTON PUMP 2850/1550 TESTER GEAR PUMP BYPASS VALVE 5000 .071 .091 2.48 1.03 1.03 .071 5000 FROM RESERVOIR FROM FILTRATION MANIFOLD Working Pressure Low Pressure Return or Suction Flow Hydraulic System Page 4 - - 66 Reelmaster 7000...
  • Page 101 Check for hydraulic leakage and correct before proceeding with test. Figure 48 1. Gear pump 2. Pump section P4 hose 7. Move throttle to full speed (2850 RPM). DO NOT en- gage the cutting units. Reelmaster 7000 Page 4 - - 67 Hydraulic System...

  • Page 102: Adjustments

    1/8 turn on the socket will make a measurable change in relief pressure. 5. Install and tighten cap on relief valve. Figure 49 1. Relief valve cap Adjustment socket 6. Recheck relief pressure and readjust as needed. Hydraulic System Page 4 - - 68 Reelmaster 7000...

  • Page 103: Service And Repairs

    5. Note the position of hydraulic fittings (especially el- bow fittings) on hydraulic components before removal. Mark parts if necessary to make sure they will be aligned properly when installing hydraulic hoses and tubes. Reelmaster 7000 Page 4 - - 69 Hydraulic System...
  • Page 104 If fluid is in- jected into the skin, it must be surgically re- moved within a few hours by a doctor familiar with this type of injury. Gangrene may result from such an injury. Hydraulic System Page 4 - - 70 Reelmaster 7000...
  • Page 105 NOTE: Use only hydraulic fluids specified in the Trac- tion Unit Operator’s Manual. Other fluids may cause system damage. 7. Fill hydraulic reservoir with new hydraulic fluid. Reelmaster 7000 Page 4 - - 71 Hydraulic System...

  • Page 106: Special Tools 5

    IMPORTANT: If using a filter that is not the bi- -direc- 2. Raise and support machine so all wheels are off the tional Toro high flow filter, do not press the traction ground (see Jacking Instructions in Chapter 1 -- Safety).
  • Page 107 (1550 RPM). The pumps should pick up oil and fill the hydraulic system. If there is no in- dication of fill in thirty (30) seconds, stop the engine and determine the cause. Reelmaster 7000 Page 4 - - 73 Hydraulic System...

  • Page 108: Gear Pump

    6. Disconnect hydraulic lines from gear pump and put caps or plugs on open hydraulic lines and fittings. Label 3. Drain the hydraulic reservoir into a suitable contain- disconnected hydraulic lines for proper assembly (Fig. 52). Hydraulic System Page 4 - - 74 Reelmaster 7000...
  • Page 109 9. Properly fill hydraulic system (see Charge Hydraulic System in this section). 10.Stop engine and check for hydraulic oil leaks. Check hydraulic reservoir oil level. 11. Lower and secure seat. Reelmaster 7000 Page 4 - - 75 Hydraulic System...

  • Page 110: Gear Pump Service

    1. Plug pump ports and thoroughly clean exterior of pump with cleaning solvent. Make sure work area is clean. 2. Use a marker to make a diagonal line across the gear pump for assembly purposes (Fig. 54). Figure 54 Hydraulic System Page 4 - - 76 Reelmaster 7000...
  • Page 111 ”timing”. Pump efficiency may be affected if the teeth are not installed in the same position during assembly. Keep the parts for each pump section together; do not mix parts between sections. Reelmaster 7000 Page 4 - - 77 Hydraulic System...
  • Page 112 3. Remove traction rod from control arm on piston Put plugs or caps on disconnected hydraulic hoses and pump by removing lock nut and flange head screw (Fig. fittings to prevent contamination of the system (Fig. 57). 56). Hydraulic System Page 4 - - 78 Reelmaster 7000...
  • Page 113 5. Suction hose from filter manifold ignition key switch to crank engine for ten (10) seconds. 6. Suction hose from reservoir Repeat cranking procedure again. 7. Supply hose for charge circuit Reelmaster 7000 Page 4 - - 79 Hydraulic System...

  • Page 114: Eaton Model 72400 Servo Controlled Pis

    33. Control orifice (.028) (2 used) 49. Lock washer NOTE: For service of the piston (traction) pump, see the Eaton Model 72400 Servo Controlled Piston Pump Repair Information at the end of this chapter. Hydraulic System Page 4 - - 80 Reelmaster 7000...
  • Page 115 This page is intentionally blank. Reelmaster 7000 Page 4 - - 81 Hydraulic System...
  • Page 116 6. Flange nut (2 used) 10. Flat washer (2 used) 3. 4WD/2WD control manifold 7. Cap screw (2 used) 11. Flange head screw (2 used) 4. Manifold bracket 8. Lift circuit junction manifold Hydraulic System Page 4 - - 82 Reelmaster 7000...
  • Page 117 12. O- -ring oil if necessary. 6. O- -ring 13. Barb fitting 7. Straight fitting 14. O- -ring 6. Follow Hydraulic System Start--up procedures (see Hydraulic System Start--up in this section). Reelmaster 7000 Page 4 - - 83 Hydraulic System...
  • Page 118 4. Orifice disc (0.030) 9. Pilot directional valve (PD1 & PD2) 14. Zero leak plug (#4) 5. Zero leak plug (#4) (4 used) 10. Pressure reducing valve (PR) 15. Temperature sensor (TS) Hydraulic System Page 4 - - 84 Reelmaster 7000...
  • Page 119 For cartridge valve service procedures, see Control Manifold Cartridge Valve Service in this section. Refer to Figure 62 for 4WD/2WD Control Manifold cartridge valve and plug installation torque. Reelmaster 7000 Page 4 - - 85 Hydraulic System...
  • Page 120 Hydraulic System Page 4 - - 86 Reelmaster 7000...
  • Page 121 60 in- -lb (6.8 N- -m). Use eye protection such as goggles when using 9. If problems still exist after assembly, remove valve compressed air. and clean again or replace valve. Reelmaster 7000 Page 4 - - 87 Hydraulic System...

  • Page 122: Rear Axle Motor

    5. O- -ring 8. 90 hydraulic fitting 2. O- -ring 6. Hydraulic fitting 9. Cap screw (2 used) 3. Pinion gear 7. O- -ring 10. Flat washer (2 used) 4. External snap ring Hydraulic System Page 4 - - 88 Reelmaster 7000...
  • Page 123 Remove fittings from motor and discard O--rings. quired. 7. Follow Hydraulic System Start--up procedures (see Hydraulic System Start--up in this section). 8. After assembly is completed, verify that hydraulic hoses and fittings do not contact anything. Reelmaster 7000 Page 4 - - 89 Hydraulic System...

  • Page 124: Front Wheel Motors

    23. O- -ring 7. LH brake assembly 16. O- -ring 24. Straight hydraulic fitting 8. Flange head screw (4 per brake) 17. 90 hydraulic elbow 25. O- -ring 9. Plug Hydraulic System Page 4 - - 90 Reelmaster 7000...
  • Page 125 O--rings onto fittings. Install fittings into motor ports using marks made during the removal pro- cess to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). Reelmaster 7000 Page 4 - - 91 Hydraulic System...

  • Page 126: Eaton Model 74318 And 74348 Piston Motors

    NOTE: The rear axle motor does not have a shaft seal (item 8). The case drain from the rear axle motor pro- vides lubrication for the input gear case of the rear axle. Hydraulic System Page 4 - - 92 Reelmaster 7000...
  • Page 127 Figure 67 2. Remove cover from cutting unit opening. 1. Cap screw 2. Hydraulic reel motor 3. Coat spline shaft of the reel motor with No. 2 multi- purpose lithium base grease. Reelmaster 7000 Page 4 - - 93 Hydraulic System...

  • Page 128: Cutting Reel Motor Service

    Also, use a vise with soft jaws. 3. Clamp front flange of motor in a vise with soft jaws with the shaft end down. Figure 69 Hydraulic System Page 4 - - 94 Reelmaster 7000...
  • Page 129 Any broken or nicked gear teeth must be 2. Gear shaft 4. Gear face edge replaced. C. Inspect gear face edge for sharpness. Sharp edges of gears will mill into wear plates and, thus, must be replaced. Reelmaster 7000 Page 4 - - 95 Hydraulic System...
  • Page 130 Carefully install shaft into front flange. of the motor and rotate the drive shaft away from the inlet one revolution. If any binding is noted, disassemble the motor and check for assembly problems. Hydraulic System Page 4 - - 96 Reelmaster 7000...
  • Page 131 This page is intentionally blank. Reelmaster 7000 Page 4 - - 97 Hydraulic System...

  • Page 132: Mow Control Manifold

    Mow Control Manifold RIGHT FRONT Figure 72 1. Mow control manifold 3. Filter head 5. Lift control manifold 2. Flange head screw (4 used) 4. Hydraulic oil filter 6. Fan control manifold Hydraulic System Page 4 - - 98 Reelmaster 7000...
  • Page 133 3. Remove caps and plugs from fittings and hoses. Properly connect hydraulic lines to manifold (see Hy- draulic Hose and Tube Installation in the General Infor- mation section of this chapter). Reelmaster 7000 Page 4 - - 99 Hydraulic System...

  • Page 134: Mow Control Manifold Service

    See Hydraulic Schematic in Chapter to Figure 74 for cartridge valve installation torque. 9 -- Foldout Drawings to identify the function of the hy- draulic lines and cartridge valves at each port location. Hydraulic System Page 4 - - 100 Reelmaster 7000...
  • Page 135 Thread backlap switch into port and torque 20 ft- -lb (27 N- -m) (27 N- -m). Figure 75 1. Mow manifold 4. #4 zero leak plug 2. #4 zero leak plug 5. Orifice (.040) 3. #6 zero leak plug Reelmaster 7000 Page 4 - - 101 Hydraulic System...

  • Page 136: Steering Control Valve

    7. Label all hydraulic connections for assembly pur- umn brace (item 12) to frame platform. Remove brace poses. Note port designations on steering control valve from machine to allow access to steering column fasten- (Fig. 78). ers. Hydraulic System Page 4 - - 102 Reelmaster 7000...
  • Page 137 5. Remove caps and plugs from disconnected lines and fittings. 6. Lubricate new O--rings and connect hydraulic lines to fittings on steering control valve (see Hydraulic Hose and Tube Installation in the General Information section of this chapter). Reelmaster 7000 Page 4 - - 103 Hydraulic System...

  • Page 138: Sauer--Danfoss Steering Unit Type Ospm

    15. Outer gearwheel 22. Ball 8. Spring set NOTE: For repair of the steering control valve, see the Sauer--Danfoss Steering Unit Type OSPM Service Manual at the end of this chapter. Hydraulic System Page 4 - - 104 Reelmaster 7000...
  • Page 139 This page is intentionally blank. Reelmaster 7000 Page 4 - - 105 Hydraulic System...

  • Page 140: Steering Cylinder

    3. Ball joint 9. O- -ring 14. Cotter pin 4. Retaining ring 10. Drive axle assembly 15. Hydraulic hose 5. Grease fitting 11. Ball joint spacer 16. Hydraulic hose 6. Grease fitting Hydraulic System Page 4 - - 106 Reelmaster 7000...
  • Page 141 Remove fittings from cylinder and discard O--rings. 7. After assembly is completed, operate steering cylin- der to verify that hydraulic hoses and fittings are not con- tacted by anything. Reelmaster 7000 Page 4 - - 107 Hydraulic System...

  • Page 142: Steering Cylinder Service

    7. Piston 12. Retaining ring 3. Wear band 8. Buffer seal 13. Head seal 4. Square ring 9. O- -ring 14. Wiper 5. Piston seal 10. Back- -up ring 15. Rod assembly Hydraulic System Page 4 - - 108 Reelmaster 7000...
  • Page 143 Replace any damaged parts. pletely pulled into the barrel and the ring ends are covered. C. Apply silicone sealer to barrel access slot. Reelmaster 7000 Page 4 - - 109 Hydraulic System...

  • Page 144: Engine Cooling Fan Motor

    Service and Repairs section of this chapter. 4. Remove air cleaner hose and upper radiator shroud to allow access to hydraulic fan motor (Fig. 83). 3. Unlatch and raise hood. Hydraulic System Page 4 - - 110 Reelmaster 7000...
  • Page 145 4. Position fan hub onto motor shaft and secure with washer (item 8) and hex nut (item 9). Torque nut from 27 to 33 ft- -lb (37 to 44 N- -m). Reelmaster 7000 Page 4 - - 111 Hydraulic System...

  • Page 146: Engine Cooling Fan Motor Service

    5. Retaining ring 11. Body 16. Washer (4 used) 6. Front wear plate For disassembly, inspection and assembly procedures of the cooling fan motor, see Reel Motor Service in this section. Hydraulic System Page 4 - - 112 Reelmaster 7000...
  • Page 147 This page is intentionally blank. Reelmaster 7000 Page 4 - - 113 Hydraulic System...

  • Page 148: Fan Control Manifold

    Fan Control Manifold RIGHT FRONT Figure 85 1. Fan control manifold 3. Filter head 5. Lift control manifold 2. Flange head screw (2 used) 4. Hydraulic oil filter 6. Mow control manifold Hydraulic System Page 4 - - 114 Reelmaster 7000...
  • Page 149 3. O- -ring 7. Fan control manifold fittings (see Hydraulic Fitting Installation in the General 4. Dust cap Information section of this chapter). Refer to Figure 86 for fitting installation torque. Reelmaster 7000 Page 4 - - 115 Hydraulic System...

  • Page 150: Fan Control Manifold Service

    For cartridge valve service procedures, see Control of damage to the socket head of the plug. Manifold Cartridge Valve Service in this section. Refer to Figure 87 for cartridge valve and plug installation torque. Hydraulic System Page 4 - - 116 Reelmaster 7000...
  • Page 151 This page is intentionally blank. Reelmaster 7000 Page 4 - - 117 Hydraulic System...

  • Page 152: Lift Control Manifold

    IMPORTANT: To prevent unexpected cutting unit lowering, make sure that cutting units are fully low- ered before loosening hydraulic lines from lift man- ifold. Hydraulic System Page 4 - - 118 Reelmaster 7000...
  • Page 153 General Information section of this chapter). Refer to 4. O- -ring 10. Orifice (0.109) (port C2) Figure 89 for fitting installation torque. 5. O- -ring 11. O- -ring 6. Straight fitting (2 used) 12. Straight fitting (4 used) Reelmaster 7000 Page 4 - - 119 Hydraulic System...

  • Page 154: Lift Control Manifold Service

    If cutting units are raised as compo- nents are loosened in manifold, cutting units may drop unexpectedly. Hydraulic System Page 4 - - 120 Reelmaster 7000...
  • Page 155 When installing the orifice in the man- ifold, make sure that the orifice is flat in the base of the port. Manifold damage is possible if the orifice is cocked in the port. Reelmaster 7000 Page 4 - - 121 Hydraulic System...

  • Page 156: Lift Circuit Junction Manifold

    6. Flange nut (2 used) 10. Flat washer (2 used) 3. 4WD/2WD control manifold 7. Cap screw (2 used) 11. Flange head screw (2 used) 4. Manifold bracket 8. Lift circuit junction manifold Hydraulic System Page 4 - - 122 Reelmaster 7000...
  • Page 157 10. O- -ring ifold port. Manifold damage is possible if the orifice 5. Zero leak plug (3 used) 11. Pilot piston (3 used) is cocked in the cavity. 6. O- -ring Reelmaster 7000 Page 4 - - 123 Hydraulic System...
  • Page 158 30. Washer (2 per hoop) 9. Lift cylinder (cutting unit #1) 20. Switch bracket 31. Chain hoop 10. Thrust washer 21. Cutting unit position sensor 32. Lift chain 11. Lock nut 22. Pivot yoke Hydraulic System Page 4 - - 124 Reelmaster 7000...
  • Page 159 8. If hydraulic fittings are to be removed from lift cylin- der, mark fitting orientation to allow correct assembly. Remove fittings from cylinder and discard O--rings. CUTTING UNIT LOCATIONS Figure 94 Reelmaster 7000 Page 4 - - 125 Hydraulic System...
  • Page 160 10. Lift arm (cutting unit #3) 22. Spacer 33. O- -ring 11. Retaining ring (2 per pin) 23. Cap screw 34. O- -ring 12. Lift cylinder (cutting units #2 and #3) Hydraulic System Page 4 - - 126 Reelmaster 7000...
  • Page 161 O--rings onto fittings. Install fittings into cylinder openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Infor- mation section of this chapter). Reelmaster 7000 Page 4 - - 127 Hydraulic System...

  • Page 162: Lift Cylinder Service

    17. Rod assembly 6. O- -ring 12. Retaining ring NOTE: The lift cylinders used on the Reelmaster 7000 are all very similar regardless of the location on the ma- chine. The disassembly and assembly procedure is the same for all lift cylinders.
  • Page 163 Inspect rod and piston 7. Press wiper into barrel taking care to not damage for evidence of excessive scoring, pitting or wear. Re- wiper. place any damaged parts. Reelmaster 7000 Page 4 - - 129 Hydraulic System...

  • Page 164: Hydraulic Reservoir

    5. Hydraulic tee fitting 13. Screen filter 20. O- -ring (2 used) 6. Bumper 14. Dipstick 21. O- -ring 7. Flat washer (2 used) 15. Plug 22. O- -ring 8. Flange nut (3 used) Hydraulic System Page 4 - - 130 Reelmaster 7000...
  • Page 165 7. If hydraulic fittings are to be removed from reservoir, mark fitting orientation to allow correct assembly. Re- 5. Follow Hydraulic System Start--up procedures (see move fittings from reservoir and discard O--rings. Hydraulic System Start--up in this section). Reelmaster 7000 Page 4 - - 131 Hydraulic System...

  • Page 166: Hydraulic Oil Cooler

    14. Washer (2 used) 4. Radiator mount 10. 90 hydraulic fitting (2 used) 15. Wire form clamp (2 used) 5. Radiator 11. O- -ring 16. Top oil cooler bracket 6. Air intake hose Hydraulic System Page 4 - - 132 Reelmaster 7000...
  • Page 167 O--rings onto fittings. Install fittings into cooler openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hy- draulic Fitting Installation in the General Information section of this chapter). Reelmaster 7000 Page 4 - - 133 Hydraulic System...
  • Page 168 This page is intentionally blank. Hydraulic System Page 4 - - 134 Reelmaster 7000...

  • Page 169: Electrical System Quick Checks 5

    ....... Toro Electronic Controllers (TEC) ....

  • Page 170: General Information

    Diagnostic Dis- play (see Special Tools). Because of the solid state circuitry built into the Toro Electronic Controller (TEC), there is no method to test it directly. The TEC may be damaged if an attempt is...

  • Page 171: Electrical Drawings

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

  • Page 172: Special Tools

    The multimeter can test electrical components and cir- cuits for current (amps), resistance (ohms) or voltage. Obtain this tool locally. NOTE: Toro recommends the use of a DIGITAL Volt-- Ohm--Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital me- ter in the voltage mode will make sure that excess cur- rent is not allowed through the meter.

  • Page 173: Diagnostic Display

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

  • Page 174: Troubleshooting

    Reelmaster. Diagnostic Display Reelmaster 7000 machines are equipped with a Toro Verify Diagnostic Display Input Functions Electronic Controller (TEC) which controls machine 1. Park machine on a level surface, lower the cutting electrical functions.
  • Page 175 8. After input functions testing is complete, disconnect the Diagnostic Display connector from the harness con- nector and plug loop--back connector into wire harness. Secure access plate to frame. Reelmaster 7000 Page 5 - - 7 Electrical System...
  • Page 176 Ignition switch in ON or START: LED ON Ignition switch in OFF: LED OFF NOTE: When the ignition switch is in the OFF position, all Diagnostic Display LED’s should be OFF. Electrical System Page 5 - - 8 Reelmaster 7000...

  • Page 177: Verify Diagnostic Display Output Functions

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

  • Page 178: Starting Problems

    Engine starts, but stops when the ignition switch is The engine run solenoid or circuit wiring is faulty released from the START position. (solenoid pull coil operates but hold coil is faulty). Electrical System Page 5 - - 10 Reelmaster 7000...

  • Page 179: General Run & Transport Problems

    The seat switch or circuit wiring is faulty. The parking brake switch or circuit wiring is faulty. Battery does not charge. Loose, corroded or broken wire(s) in charging circuit. The alternator is faulty. Battery is damaged. Reelmaster 7000 Page 5 - - 11 Electrical System...

  • Page 180: Cutting Unit Operating Problems

    A hydraulic problem exists (see Troubleshooting section of Chapter 4 -- Hydraulic System). Cutting unit(s) operation is intermittent over rough The cutting unit lift/lower switch or circuit wiring is terrain. faulty. Electrical System Page 5 - - 12 Reelmaster 7000...

  • Page 181: Electrical System Quick Checks

    If low current reading is observed, one (or tions) and set the multimeter to the correct scale. With more) of the glow plugs is faulty. the ignition switch in the OFF position, place the Reelmaster 7000 Page 5 - - 13 Electrical System...

  • Page 182: Check Operation Of Interlock Switches

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

  • Page 183: Adjustments

    Diagnostic Display (see Special Tools in this chap- ter) to verify that mow/transport sensor and circuit wiring are functioning correctly (see Mow/Transport Sensor in the Component Testing section of this chapter). Reelmaster 7000 Page 5 - - 15 Electrical System...

  • Page 184: Cutting Unit Position Sensor

    Component Testing section of this chapter). FRONT Figure 14 1. Position sensor 4. Jam nut (2 used) 2. Sensor bracket 5. Lock washer (2 used) 3. Screw (2 used) 6. Front carrier frame Electrical System Page 5 - - 16 Reelmaster 7000...

  • Page 185: Component Testing

    FRONT VIEW 6. If ignition switch tests correctly and circuit problem still exists, check wire harness (see Electrical Schemat- Figure 16 ics and Wire Harness Drawings in Chapter 9 -- Foldout Drawings). Reelmaster 7000 Page 5 - - 17 Electrical System...

  • Page 186: Fuses

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

  • Page 187: Indicator Lights

    2. Engine oil pressure 5. Warning light back 1. Apply 12 VDC to terminals 1A and 2A. 3. High temp warning 2. Ground terminals 1B and 2B. 3. Both indicator lights should light. Reelmaster 7000 Page 5 - - 19 Electrical System...
  • Page 188 When engine coolant temperature rises to approximate- ly 221 F (105 C), the temperature gauge should display the first red segment. Figure 22 1. Console arm 3. High temp indicator 2. Temperature gauge Electrical System Page 5 - - 20 Reelmaster 7000...

  • Page 189: Pto Switch

    6. NC C terminal 6. If PTO switch tests correctly and circuit problem still exists, check wire harness (see Electrical Schematics and Wire Harness Drawings in Chapter 9 -- Foldout Drawings). Reelmaster 7000 Page 5 - - 21 Electrical System...

  • Page 190: Cutting Unit Lift Switch

    (see Electrical Schematics and NOTE: Lift switch terminals 5, 6 and 8 are not used on Wire Harness Drawings in Chapter 9 -- Foldout Draw- Reelmaster 7000 machines. ings). Electrical System Page 5 - - 22...

  • Page 191: Headlight Switch

    Drawings). NOTE: Headlight switch terminals 1, 4, 5 and 6 are not 6. After testing is completed, connect wire harness used on Reelmaster 7000 machines. connector to the headlight switch. 7. Assemble console arm (see Console Arm Assembly in the Service and Repairs section of Chapter 7 -- Chas- sis).

  • Page 192: Engine Cooling Fan Switch

    The switch terminals are marked as shown in NOTE: Cooling fan switch terminals 3, 4, 5 and 6 are Figure 31. The circuitry of the cooling fan switch is not used on Reelmaster 7000 machines. shown in the chart below. Verify continuity between switch terminals.

  • Page 193: Seat Switch

    (see Operator Seat Service in the Ser- vice and Repairs section of Chapter 7 -- Chassis). 8. Connect seat switch connector to wire harness con- nector after testing is complete. Reelmaster 7000 Page 5 - - 25 Electrical System...

  • Page 194: Parking Brake Switch

    (Fig. 34). 8. Replace parking brake switch if testing determines that it is faulty. 9. After testing is complete, connect wire harness elec- trical connector to the parking brake switch. Electrical System Page 5 - - 26 Reelmaster 7000...

  • Page 195: Mow/Transport Sensor

    E. If black wire is closed to ground, pink wire has system voltage present and sensor LED did not func- tion, replace mow/transport sensor. Adjust sensor after installation (see Mow/Transport Sensor in the Adjustments section of this chapter). Reelmaster 7000 Page 5 - - 27 Electrical System...

  • Page 196: Cutting Unit Position Sensor

    LED did not func- tion, replace cutting unit position sensor. Adjust sen- sor after installation (see Cutting Unit Position Sensor in the Adjustments section of this chapter). Electrical System Page 5 - - 28 Reelmaster 7000...

  • Page 197: Backlap Switches

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

  • Page 198: Glow And Main Power Relays

    30 and 87. Ground terminal 86 and apply +12 VDC to terminal 85. The relay should make and break continuity between terminals 30 and 87 as +12 VDC is applied and removed from terminal 85. Electrical System Page 5 - - 30 Reelmaster 7000...

  • Page 199: Start Relay

    30 and 87A as +12 VDC is applied and removed Figure 43 from terminal 85. 1. Coil terminal 3. Normally closed term. 2. Common terminal 4. Normally open terminal 9. Disconnect voltage and multimeter test leads from the relay terminals. Reelmaster 7000 Page 5 - - 31 Electrical System...

  • Page 200: Reel Speed Potentiometer

    D. If measured resistances are incorrect, replace reel speed potentiometer. 6. After testing is completed, secure potentiometer to machine frame. Secure wire harness connector to po- tentiometer. Lower and secure seat. Electrical System Page 5 - - 32 Reelmaster 7000...

  • Page 201: Hydraulic Solenoid Valve Coils

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

  • Page 202: Traction Neutral Switch

    Figure 48 1. Diode 3. Female terminal 2. Male terminal Multimeter Multimeter Red Lead (+) Black Lead (- -) Continuity on Terminal on Terminal Female Male Male Female Electrical System Page 5 - - 34 Reelmaster 7000...

  • Page 203: Toro Electronic Controller (Tec)

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

  • Page 204: Engine Coolant And Hydraulic Oil Temperature Senders

    OIL TEMP SENDER RESISTANCE F (20 11.6 to 13.5 kilo ohms F (60 2.3 to 2.5 kilo ohms F (100 605 to 669 ohms Figure 52 Electrical System Page 5 - - 36 Rev. A Reelmaster 7000...

  • Page 205: Fuel Pump

    Pump Capacity 64 fl oz/min (1.9 l/min) 11. Install 20A fuse into fuse block. Pressure 7 PSI (48.3 kPa) 12.Bleed the fuel system. Current Draw 2.0 amp 13.Lower and secure hood. Reelmaster 7000 Page 5 - - 37 Electrical System...

  • Page 206: Fuel Stop Solenoid

    15 ohms. 6. If either coil resistance is incorrect, replace fuel stop solenoid. 7. Connect wire harness connector to the fuel stop so- lenoid. 8. Lower and secure hood. Electrical System Page 5 - - 38 Reelmaster 7000...

  • Page 207: Engine Temperature Sender

    Figure 58 OIL TEMP TEMP SENDER RESISTANCE F (38 460 ohms (approximate) F (71 140 ohms (approximate) F (93 54 to 78 ohms F (105 50 ohms (approximate) Reelmaster 7000 Page 5 - - 39 Electrical System...

  • Page 208: Oil Pressure Switch

    (see Indicator Lights in this section). 7. After testing is completed, connect the wire harness connector to the oil pressure switch. Lower and secure hood. Electrical System Page 5 - - 40 Reelmaster 7000...

  • Page 209: Service And Repairs

    Rinse with clear water. B. Coat battery posts and cable connectors with bat- tery terminal protector (see Special Tools in this chapter) or petroleum jelly to prevent corrosion. Reelmaster 7000 Page 5 - - 41 Electrical System...

  • Page 210: Battery Service

    7. Lower and secure battery storage box cover. lines. Charge at 15 to 25 amps for fifteen (15) minutes to allow sufficient mixing of the electrolyte. Electrical System Page 5 - - 42 Reelmaster 7000...

  • Page 211: Battery Testing

    12.4 VDC, recharge the battery. B. If the battery has been charged, apply a 150 amp load for fifteen (15) seconds to remove the surface charge. Use a battery load tester following the manufacturer’s instructions. Reelmaster 7000 Page 5 - - 43 Electrical System...

  • Page 212: Battery Charging

    11.5 hrs 17.3 hrs 23 hrs 6 amps 6 amps 6 amps 6 amps above 6 hrs 12 hrs 18 hrs 24 hrs 10 amps 10 amps 10 amps 10 amps Electrical System Page 5 - - 44 Reelmaster 7000...

  • Page 213: Hydraulic Solenoid Valve Coils

    2. Install nut onto valve and torque nut 60 in- -lb (6.8 N- -m) (do not over tighten). Figure 61 1. Control manifold 3. Solenoid coil 3. Connect machine wire harness connector to the so- 2. Solenoid valve 4. Nut lenoid coil. Reelmaster 7000 Page 5 - - 45 Electrical System...
  • Page 214 This page is intentionally blank. Electrical System Page 5 - - 46 Reelmaster 7000...

  • Page 215: General Information 6

    ......Pinion Gear to Ring Gear Engagement ..Reelmaster 7000 Page 6 - - 1 Axles, Planetaries and Brakes...

  • Page 216: Specifications

    Planetary gear lube capacity (each wheel) 16 fl oz (0.47 l) Rear axle lubricant SAE 85W--140 wt. gear lube Rear axle gear lube capacity 80 fl oz (2.37 l) Axles, Planetaries and Brakes Page 6 - - 2 Reelmaster 7000...

  • Page 217: General Information

    The Traction Unit Operator’s Manual provides informa- tion regarding the operation, general maintenance and maintenance intervals for your Reelmaster machine. Refer to this publication for additional information when servicing the machine. Reelmaster 7000 Page 6 - - 3 Axles, Planetaries and Brakes...

  • Page 218: Service And Repairs

    If the 4. Remove wheel assembly. machine is not properly supported by jack stands, the machine may move or fall, which may result in personal injury. Axles, Planetaries and Brakes Page 6 - - 4 Reelmaster 7000...
  • Page 219 75 to 85 ft- -lb (102 to 115 N- -m). 7. Install wheel assembly. Figure 3 1. Brake housing 3. Drain plug 2. Check plug Reelmaster 7000 Page 6 - - 5 Axles, Planetaries and Brakes...

  • Page 220: Brake Inspection And Repair

    Install a new seal (item 2). 4. Remove extension springs (item 12). 9. Use a new gasket (item 10) when installing brake as- sembly to machine. Axles, Planetaries and Brakes Page 6 - - 6 Reelmaster 7000...
  • Page 221 This page is intentionally blank. Reelmaster 7000 Page 6 - - 7 Axles, Planetaries and Brakes...

  • Page 222: Planetary Wheel Drive Assembly

    3. Chock rear wheels and jack up front of machine (see stands, the machine may move or fall, which Jacking Instructions in Chapter 1 -- Safety). Support ma- may result in personal injury. chine with appropriate jack stands. Axles, Planetaries and Brakes Page 6 - - 8 Reelmaster 7000...
  • Page 223 (Fig. 6). Fill planetary wheel drive/brake as- sembly with SAE 85W--140 gear lube. Capacity is approximately 16 oz. (0.47 l) per wheel. 8. Check for proper brake operation and adjust brake cables if necessary. Reelmaster 7000 Page 6 - - 9 Axles, Planetaries and Brakes...

  • Page 224: Planetary Wheel Drive Service

    26. Primary carrier assembly 8. Lock washer (16 used) 18. Plug (2 used) 27. Secondary gear 9. Housing 19. O- -ring (2 used) 28. Secondary carrier assembly 10. Dowel pin (2 used) Axles, Planetaries and Brakes Page 6 - - 10 Reelmaster 7000...
  • Page 225 Remove ring gear and two (2) dowel pins screws (item 7). Torque socket head screws from (item 10) from housing. 118 to 144 in- -lb (13.3 to 16.3 N- -m). Reelmaster 7000 Page 6 - - 11 Axles, Planetaries and Brakes...
  • Page 226 L. Install new O--ring (item 13) into groove in hous- brake assembly. Fill planetary wheel drive/brake as- ing. sembly with SAE 85W--140 gear lube to proper level. Capacity is approximately 16 oz. (0.47 l) per wheel. Axles, Planetaries and Brakes Page 6 - - 12 Reelmaster 7000...
  • Page 227 This page is intentionally blank. Reelmaster 7000 Page 6 - - 13 Axles, Planetaries and Brakes...

  • Page 228: Rear Axle Assembly

    Rear Axle Motor in the Service and Repairs section of may result in personal injury. Chapter 4 -- Hydraulic System). 6. Remove hydraulic hoses from steering cylinder. Axles, Planetaries and Brakes Page 6 - - 14 Reelmaster 7000...
  • Page 229 1. Steering stop bolt 2. Bevel gear case (LH) WARNING Failure to maintain proper wheel lug nut torque could result in failure or loss of wheel and may result in personal injury. Reelmaster 7000 Page 6 - - 15 Axles, Planetaries and Brakes...

  • Page 230: Rear Axle Service

    Rear Axle Service Figure 12 Axles, Planetaries and Brakes Page 6 - - 16 Reelmaster 7000...
  • Page 231 43. Collar 64. O- -ring 22. O- -ring NOTE: Figure 12 illustrates the rear axle used on the Reelmaster 7000. Service procedures for the rear axle is on the following pages of this section. Reelmaster 7000 Page 6 - - 17...

  • Page 232: Bevel Gear Case And Axle Case

    (Fig. 15). Compound 57 to 67 ft- -lb (77 to 91 N- -m) Figure 15 1. Axle case 3. Screw (2 used) 2. Axle case support 4. Support shim Axles, Planetaries and Brakes Page 6 - - 18 Reelmaster 7000...
  • Page 233 0.984 to 0.987 inch (25.00 to 25.08 mm) Figure 17 2. Inspect all gears, shafts, bearings, cases and covers 1. Knuckle pin 2. Axle case support for damage and wear. Replace components as neces- sary. Reelmaster 7000 Page 6 - - 19 Axles, Planetaries and Brakes...
  • Page 234 Figure 19 1. Axle case cover 5. Upper bevel gear 2. Lower bevel gear 6. Collar 3. Bevel gear shaft 7. Upper bearing 4. Lower bearing 8. Knuckle pin Axles, Planetaries and Brakes Page 6 - - 20 Reelmaster 7000...
  • Page 235 (0.1 mm), 0.008 inch (0.2 mm) and 0.020 inch (0.5 mm) thickness. Figure 22 1. Axle cover assembly 4. Dial indicator 2. Lower bevel gear 5. Axle bearing shims 3. Axle gear Reelmaster 7000 Page 6 - - 21 Axles, Planetaries and Brakes...

  • Page 236: Differential Shafts

    Bevel Gear Case/Axle Case Assembly in this section of Figure 24 this manual). 1. Retaining ring 4. Bearing 2. Bevel gear 5. Bearing shims 3. Differential shaft 6. O-ring Axles, Planetaries and Brakes Page 6 - - 22 Reelmaster 7000...

  • Page 237: Axle Shafts

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

  • Page 238: Input Shaft/Pinion Gear

    6. Inspect all gears, shafts, bearings, spacers and 4. Coat new O-ring with grease. Install O-ring in the oil cases for damage and wear. Replace components as seal collar and install the collar. necessary. Axles, Planetaries and Brakes Page 6 - - 24 Reelmaster 7000...
  • Page 239 1. Axle case 3. Dial indicator 2. Screwdriver 4. Input shaft/pinion gear 16.Use a new gasket and install the cover plate. Use a new O-ring and install the drive motor. Reelmaster 7000 Page 6 - - 25 Axles, Planetaries and Brakes...

  • Page 240: Differential Gear

    Figure 34 1. Differential pinion shaft 5. Side gear shims 2. Pinion gear 6. Ring gear 3. Pinion washer 7. Differential case 4. Side gear 8. Bolt/washer (8 used) Axles, Planetaries and Brakes Page 6 - - 26 Reelmaster 7000...
  • Page 241 0.551 to 0.552 inch (13.10 to 14.02 mm) 3. Inspect all gears, shafts, bearings, cases and covers for damage and wear. Replace components as neces- sary. Figure 36 1. Pinion shaft 2. Pinion gear Reelmaster 7000 Page 6 - - 27 Axles, Planetaries and Brakes...
  • Page 242 11. After backlash and tooth contact have been ad- justed, align the hole in the differential pinion shaft with the hole in the differential case and install a new spring pin. Axles, Planetaries and Brakes Page 6 - - 28 Reelmaster 7000...

  • Page 243: Pinion Gear To Ring Gear Engagement

    2. Bearing case shims shims readjust backlash to the correct specification before 3. Differential gear case checking the contact pattern. Reelmaster 7000 Page 6 - - 29 Axles, Planetaries and Brakes...
  • Page 244 B. Install thicker or additional differential bearing shim(s) to move ring gear forward. Figure 43 C. Repeat until proper tooth contact and pinion gear to ring gear backlash are correct. Axles, Planetaries and Brakes Page 6 - - 30 Reelmaster 7000...
  • Page 245 ........Reelmaster 7000 Page 7 - - 1...

  • Page 246: General Information

    Reel- master machine. Refer to these publications for addi- tional information when servicing the machine. Cutting Unit Identification Cutting units on the Reelmaster 7000 are identified as shown in Figure 1. CUTTING UNIT LOCATIONS Figure 1...
  • Page 247 This page is intentionally blank. Reelmaster 7000 Page 7 - - 3 Chassis...

  • Page 248: Service And Repairs

    (item 12) to frame platform. Remove brace from machine to allow access to steering column fasten- 3. Remove cover from steering wheel by carefully pry- ers. ing up on one of the cover spokes. Chassis Page 7 - - 4 Reelmaster 7000...
  • Page 249 (28 to 35 N- -m). 5. Lock washer (2 used) 11. Pedal 6. Cylinder 12. Spring 10.Install steering wheel cover to steering wheel. 11. Install and secure platform shroud to machine (Fig. Reelmaster 7000 Page 7 - - 5 Chassis...

  • Page 250: Console Arm

    42. Lock washer 13. Rivet (2 used) 28. Engine cooling fan switch 43. Nut 14. Arm rest 29. Headlight switch 44. Ignition key 15. Flange nut (3 used) 30. Throttle cable 45. Arm support Chassis Page 7 - - 6 Reelmaster 7000...
  • Page 251 (item 4). Install screw (item 5) and lock nut (item 6) to secure covers at front of console arm. 4. Position cover plate and flange spacers to outside of console arm. Secure with two (2) flange head screws. Reelmaster 7000 Page 7 - - 7 Chassis...

  • Page 252: Lift Arms For Front Cutting Units (#1, #4 And #5)

    30. Washer (2 per hoop) 9. Lift cylinder (cutting unit #1) 20. Switch bracket 31. Chain hoop 10. Thrust washer 21. Cutting unit position sensor 32. Lift chain 11. Lock nut 22. Pivot yoke Chassis Page 7 - - 8 Reelmaster 7000...

  • Page 253: Chapter 8 - - Dpa Cutting Units

    Slide pivot pin into frame and lift arm. Align roll pin in pivot pin with slot in frame flange. 3. Install and tighten lock nut (item 11) to secure lift arm Figure 8 pivot pin. Reelmaster 7000 Page 7 - - 9 Chassis...

  • Page 254: Lift Arms For Rear Cutting Units (#2 And #3)

    2. Remove cutting unit from lift arm (see Cutting Unit Removal in the Service and Repairs section of Chapter 8 -- DPA Cutting Units). Chassis Page 7 - - 10 Reelmaster 7000...
  • Page 255 Secure pin with second washer and retaining ring. Make sure that Figure 11 retaining ring is fully seated in pin. 1. Torsion spring 2. Spring end Reelmaster 7000 Page 7 - - 11 Chassis...

  • Page 256: Operator Seat

    33. Screw (2 used) 10. Flat washer (3 used) 22. Spacer 34. R- -clamp (2 used) 11. Hair pin 23. Cap screw 35. Seat belt buckle 12. Seat pivot shaft 24. Carriage screw (6 used) Chassis Page 7 - - 12 Reelmaster 7000...
  • Page 257 IMPORTANT: Make sure to not damage the electri- cal harness, control cable or other parts while mov- ing the console arm assembly. 3. Position and secure console arm assembly to seat. Install all fasteners before fully tightening them. Reelmaster 7000 Page 7 - - 13 Chassis...

  • Page 258: Operator Seat Service

    8. Cable tie (3 used) 19. Mounting plate 29. Flange nut 9. LH adjustment rail 20. Return spring 30. Carriage screw 10. Bumper (2 used) 21. Torx screw (5 used) 31. Support bracket 11. Washer Chassis Page 7 - - 14 Reelmaster 7000...
  • Page 259 Seat Removal in this section). 2. Install seat to machine (see Operator Seat Installa- 2. Disassemble operator seat as necessary using Fig- tion in this section). ure 14 as a guide. Reelmaster 7000 Page 7 - - 15 Chassis...

  • Page 260: Operator Seat Suspension

    11. Stop 24. Housing support (4 used) 37. Base plate 12. Bumper set (2 used) 25. Spacer (4 used) 38. Suspension frame 13. Roller (4 used) 26. Hose nipple 39. Upper plate Chassis Page 7 - - 16 Reelmaster 7000...
  • Page 261 3. Install operator seat to seat suspension (see Opera- tor Seat Installation in this section). 4. Make sure that seat electrical connectors are se- cured to machine wire harness. Reelmaster 7000 Page 7 - - 17 Chassis...

  • Page 262: Hood

    20. RH hood frame tube 31. Back washer (4 used) 10. Rear bumper 21. LH hood frame tube 32. Radiator mount 11. Pop rivet (2 used) 22. RH hood frame tube 33. Pop rivet (4 used) Chassis Page 7 - - 18 Reelmaster 7000...
  • Page 263 4. Check hood alignment for correct operation of hood diator frame. latches and dust seals. 4. Remove hood from pivot pins and machine. 5. If necessary, disassemble hood using Figure 17 as a guide. Reelmaster 7000 Page 7 - - 19 Chassis...
  • Page 264 This page is intentionally blank. Chassis Page 7 - - 20 Reelmaster 7000...

  • Page 265: Specifications 8

    ..Rear Roller Brush (Optional) ....Reelmaster 7000 Page 8 - - 1 DPA Cutting Units...

  • Page 266: Specifications

    (2) vertical screws. Effective HOC tions for your Reelmaster DPA cutting unit. may vary depending on turf conditions, type of bedknife, roller type and installed attachments. Page 8 - - 2 Reelmaster 7000 DPA Cutting Units...

  • Page 267: General Information

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

  • Page 268: Special Tools

    Figure 2 Bedknife Screw Tool Toro Part Number: TOR510880 This screwdriver--type bit is made to fit Toro bedknife at- taching screws. Use this bit with a torque wrench to se- cure the bedknife to the bedbar. IMPORTANT: To prevent damage to the bedbar, DO NOT use an air or manual impact wrench with this tool.
  • Page 269 Figure 5 Cutting Unit Kickstand Toro Part Number: 110- -4088- -03 The cutting unit kickstand is used to prop up the rear of the cutting unit during service. Use of this tool prevents the bedbar adjusting screws from resting on the work surface.
  • Page 270 This tool should be used with the Toro Guide to Evaluation Reel Mower Performance and Using the TurfEvaluator (Toro part no. 97931SL).
  • Page 271 This page is intentionally blank. Reelmaster 7000 Page 8 - - 7 DPA Cutting Units...

  • Page 272: Factors That Can Affect Cutting Performance

    NOTE: For additional information regarding cutting unit cutting unit. It is important to remember that the lower troubleshooting, see Aftercut Appearance Trouble- the height--of--cut, the more critical these factors are. shooting Aid (Toro part no. 00076SL). Factor Possible Problem/Correction Tire pressure Check tire pressure of all traction unit tires.
  • Page 273 Use correct number of reel blades for clip frequency and optimum height--of--cut range. Cutting unit alignment and carrier frame ground Check carrier frames and lift arms for damage, binding following conditions or bushing wear. Repair if necessary. Reelmaster 7000 Page 8 - - 9 DPA Cutting Units...
  • Page 274 Cutting unit accessories A variety of cutting unit accessories are available that can be used to enhance aftercut appearance. Refer to Operator’s Manual for a listing of available accessories. Page 8 - - 10 Reelmaster 7000 DPA Cutting Units...

  • Page 275: Set Up And Adjustments

    In addition, the rear roller positioning system allows for various height-of-cut ranges and aggressiveness of cut selections. Reelmaster 7000 Page 8 - - 11 DPA Cutting Units...

  • Page 276: Reel Bearing Adjustment

    4. Set screw 3. Loosen set screw that secures bearing adjuster nut in LH side plate of cutting unit. IMPORTANT: Over tightening reel bearing adjuster nut may damage reel bearings. Page 8 - - 12 Reelmaster 7000 DPA Cutting Units...

  • Page 277: Leveling Rear Roller

    8. After leveling rear roller, complete cutting unit set--up and adjustment sequence. Figure 13 1. Rear roller assembly 4. Flange nut 2. Rear roller bracket 5. Roller shim 3. Carriage screw 6. 0.010” shim (if needed) Reelmaster 7000 Page 8 - - 13 DPA Cutting Units...

  • Page 278: Service And Repairs

    Slide motor shaft into reel insert. 4. Rotate the motor counter--clockwise until the motor flanges are encircling the cap screws. Tighten two (2) cap screws to secure reel motor to cutting unit. Page 8 - - 14 Reelmaster 7000 DPA Cutting Units...

  • Page 279: Cutting Unit Removal And Installation

    Motor Installation in this section). Figure 18 5. If front outside cutting unit (#4 or #5 cutting unit) was 1. Reel motor location 2. Weight location removed, install hydraulic hoses into hose guide. Reelmaster 7000 Page 8 - - 15 DPA Cutting Units...

  • Page 280: Backlapping

    3. Rear backlap lever NOTE: Additional instructions and procedures on 2. Front backlap lever backlapping are available in the Toro General Service Training Book, Reel Mower Basics (part no. 09168SL). 1. Position the machine on a level surface, lower the cutting units, stop the engine and engage the parking brake.
  • Page 281 Adjust cutting unit reel to bedknife as needed. NOTE: If the backlap lever is not returned to the F (mow) position after backlapping, the cutting units will not function properly. Reelmaster 7000 Page 8 - - 17 DPA Cutting Units...

  • Page 282: Bedbar Assembly

    4. Loosen the lock nuts (item 13) on the end of each heavy gloves when handling the bedbar. bedbar adjuster assembly until washer (item 11) is loose on bedbar. 7. Remove bedbar assembly from cutting unit. Page 8 - - 18 Reelmaster 7000 DPA Cutting Units...
  • Page 283 4. Plastic washer 8. Lock nut pivot bolts. Tighten each bedbar pivot bolt from 27 to 33 ft- -lb (37 to 44 N- -m). Reelmaster 7000 Page 8 - - 19 DPA Cutting Units...

  • Page 284: Bedbar Adjuster Service

    Early production cutting units (Fig. 25) used a retaining ring on the end of the bedbar adjuster shaft. The service procedures for either style of adjuster shaft is very similar. Page 8 - - 20 Reelmaster 7000 DPA Cutting Units...
  • Page 285 N- -m). B. On early production cutting units (Fig. 25), slide bedbar adjuster shaft into flange bushings in cutting unit frame. Secure adjuster shaft with wave washer and retaining ring. Reelmaster 7000 Page 8 - - 21 DPA Cutting Units...

  • Page 286: Bedknife Replacement And Grinding

    Figure 27 rial with each pass of the grinder. Also, clean and dress grinding stone often during the grinding process. Remove 1. Use Toro General Service Training Book, Reel Top Face Bedknife Burr Mower Basics (part no. 09168SL) and grinder Relief Angle manufacturer’s instructions for bedknife grinding in-...
  • Page 287 This page is intentionally blank. Reelmaster 7000 Page 8 - - 23 DPA Cutting Units...

  • Page 288: Reel Assembly Removal And Installation

    NOTE: Refer to Reel Assembly Service later in this sec- lic reel motor is on the right side of the cutting unit. tion for information on replacing cutting reel grease seals, bearings and spline inserts. Page 8 - - 24 Reelmaster 7000 DPA Cutting Units...

  • Page 289: Reel Assembly Removal

    Use 11. Inspect and service cutting reel assembly as re- heavy gloves when installing the cutting reel. quired (see Reel Assembly Service in this section). Reelmaster 7000 Page 8 - - 25 DPA Cutting Units...
  • Page 290 IMPORTANT: After cutting unit assembly, reel bear- 1. LH side plate 3. Bearing adjuster nut ings must be adjusted properly or damage to reel 2. Threaded insert 4. Set screw bearings will occur. Page 8 - - 26 Reelmaster 7000 DPA Cutting Units...
  • Page 291 This page is intentionally blank. Reelmaster 7000 Page 8 - - 27 DPA Cutting Units...

  • Page 292: Reel Assembly Service

    8. Groove indicating LH threads 2. Threaded insert (RH thread) 6. Threaded insert (LH thread) 9. Bearing shoulder 3. Retaining ring 7. Retaining ring groove 10. Reel spider 4. Grease seal Page 8 - - 28 Reelmaster 7000 DPA Cutting Units...
  • Page 293 HP (or equivalent) grease. #242 (or equivalent) to threads of insert, thread in- sert into reel shaft and torque from 85 to 95 ft- -lb (115 to 128 N- -m). Reelmaster 7000 Page 8 - - 29 DPA Cutting Units...

  • Page 294: Preparing Reel For Grinding

    1. Follow reel grinder manufacturer’s instructions to Blade Land Width Range 0.050 to 0.070 in (1.3 to 1.8 mm) grind cutting reel to Toro specifications (see Reel Grind- ing Specifications chart to the right). Additional reel Service Limit - 0.010 in (0.25 mm)
  • Page 295 This page is intentionally blank. Reelmaster 7000 Page 8 - - 31 DPA Cutting Units...

  • Page 296: Front Roller

    3. If both front height--of--cut (roller) brackets were re- moved from cutting unit side plate, position one of the brackets to side plate. Secure bracket to side plate with carriage screw and flange lock nut. Page 8 - - 32 Reelmaster 7000 DPA Cutting Units...

  • Page 297: Rear Roller

    Install two (2) carriage screws and flange nuts to retain bracket in position. Do not fully tight- en flange nuts. Reelmaster 7000 Page 8 - - 33 DPA Cutting Units...

  • Page 298: Roller Service

    1. Roller tube 3. Bearing seal making sure to not crush the installed outer seal. 2. Inner seal 4. Bearing/outer seal tool Again, make sure that bearing still freely rotates. Page 8 - - 34 Reelmaster 7000 DPA Cutting Units...
  • Page 299 7. If grease fittings were removed from end of roller 1. Roller tube 4. Bearing shaft, install fittings in shaft. 2. Roller shaft 5. Outer seal 3. Inner seal 6. Bearing/outer seal tool Reelmaster 7000 Page 8 - - 35 DPA Cutting Units...
  • Page 300 Use those Instructions along with this nents used when the brush drive is on the left side of the Service Manual when servicing the rear roller brush. cutting unit. Page 8 - - 36 Reelmaster 7000 DPA Cutting Units...
  • Page 301 1. Bearing housing 6. Snap ring 2. Drive shaft 7. O- -ring 3. Ball bearing 8. Side plate 4. Grease seal 9. Socket head screw 5. Retaining ring 10. Grommet Reelmaster 7000 Page 8 - - 37 DPA Cutting Units...
  • Page 302 F. Position excluder seals on brush shaft so that seals just touch bearing housings. CAUTION Contact with the reel or other cutting unit parts can result in personal injury. Use heavy gloves when handling the cutting reel. Page 8 - - 38 Reelmaster 7000 DPA Cutting Units...
  • Page 303 Contact with the reel, bedknife or other cutting unit parts can result in personal injury. Use heavy gloves when handling the cutting reel. Figure 49 1. Rear roller brush 3. Light contact 2. Rear roller Reelmaster 7000 Page 8 - - 39 DPA Cutting Units...
  • Page 304 This page is intentionally blank. Page 8 - - 40 Reelmaster 7000 DPA Cutting Units...

  • Page 305: Hydraulic Schematic

    ....Power Center Wire Harness ....Reelmaster 7000 Page 9 - 1 Foldout Drawings...
  • Page 306 This page is intentionally blank. Foldout Drawings Page 9 - 2 Reelmaster 7000...
  • Page 307 BYPASS VALVE 5000 .071 550 PSI .091 2.48 2.48 1.03 1.03 2.01 2.01 REAR AXLE .071 FRONT MOTOR 5000 WHEEL MOTORS .052 450 PSI 5 PSI 207 PSI 1050 STEERING CYLINDER Reelmaster 7000 Hydraulic Schematic Page 9 - - 3...

  • Page 308: Electrical Schematic 9

    Reelmaster 7000 Electrical Schematic Sheet 1 of 2 All relays and solenoids are shown as de- - energized. All ground wires are black. Page 9 - - 4...
  • Page 309 FAN SPEED (PRV) REAR REELS (S5) RAISE REELS (S2) ENABLE (S1) LOWER REELS (S3) RANGE 2WD/4WD (SV) Reelmaster 7000 Electrical Schematic Sheet 2 of 2 All relays and solenoids are shown as de- - energized. All ground wires are black.
  • Page 310 Reelmaster 7000 Main Wire Harness Page 9 - - 6...
  • Page 311 ORANGE BLACK BLUE PINK/BLACK GRAY/BLUE BLACK ORANGE BLACK BLACK BLACK BROWN PINK WHITE/BLACK BLACK RED/WHITE BLACK/WHITE RED/BLACK BLACK BLACK BLACK BLACK BLACK BLACK PINK BLACK BLACK BLACK BLACK BLACK Reelmaster 7000 Main Wire Harness Page 9 - - 7...
  • Page 312 Reelmaster 7000 Seat and Console Wire Harness Page 9 - - 8...
  • Page 313 RED/WHITE BLACK/WHITE BLACK PINK PINK BLACK BLACK BLACK BLACK BLACK Reelmaster 7000 Seat and Console Wire Harness Page 9 - - 9...
  • Page 314 Reelmaster 7000 Power Center Wire Harness Page 9 - - 10...
  • Page 315 VIOLET BLACK BLUE PINK/BLACK BLACK ORANGE/WHITE ORANGE BLACK BLACK WHITE/YELLOW BLUE BROWN PINK RED/BLUE RED/GREEN WHITE/BLACK BROWN/BLACK TAN/BLACK GRAY/BLACK Reelmaster 7000 Power Center Wire Harness Page 9 - - 11...

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