Manuale d’uso / di manutenzione del prodotto 11185SL del fabbricante Toro
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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.
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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 .
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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 ..............
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.
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.
Reelmaster 7000 Page 1 - - 4 Safety Jacking Instructions CAUTION When changing attachments, tires or perform- ing other service, use correct jacks and sup - ports.
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.
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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 ........
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.
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.
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.
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 - .
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 .
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.
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.
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.
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.
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.
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 .
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.
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.
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.
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).
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.
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).
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 .
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.
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.
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).
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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 .
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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.
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.
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.
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.
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.
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.
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.
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 .
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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 .
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.
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 .
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.
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 .
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.
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 .
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.
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 .
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).
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 .
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.
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 .
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.
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.
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.
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.
Reelmaster 7000 Hydraulic System Page 4 - - 29 Measuring Container Use this container for doing hydraulic motor efficiency testing (motors with case drain lines only).
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.
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.
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.
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.
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 .
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 .
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).
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.
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.
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.
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.
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.
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 .
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.
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 .
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.
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 .
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 .
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 .
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.
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 .
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.
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 MEAS.
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.
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 .
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.
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 .
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.
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 TUR.
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 .
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.
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.
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 .
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.
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 .
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.
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.
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.
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.
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.
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.
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).
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.
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 .
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.
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.
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.
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 .
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.
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.
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.
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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.
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.
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.
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).
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 .
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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.
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).
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.
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.
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.
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 .
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.
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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.
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.
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.
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 .
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.
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 .
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.
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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.
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).
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.
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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.
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 .
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 .
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.
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.
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 .
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 .
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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 .
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.
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.
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.
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 .
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.
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.
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 u.
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.
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.
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).
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.
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).
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.
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.
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.
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).
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.
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.
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 .
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.
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 .
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 .
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.
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.
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.
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.
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.
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.
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.
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 .
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.
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.
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.
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.
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.
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.
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.
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 .
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.
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.
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.
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 .
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.
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.
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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 .................
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 torq.
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.
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.
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.
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.
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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.
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).
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.
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.
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 .
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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.
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.
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 3.
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.
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.
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 .
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 .
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.
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 .
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.
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.
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.
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).
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.
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) .
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.
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.
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 .......
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.
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.
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.
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.
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.
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.
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).
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
Reelmaster 7000 Page 7 - - 20 Chassis This page is intentionally blank..
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 .
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 .
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.
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.
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.
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.
Reelmaster 7000 DP A Cutting Units Page 8 - - 7 This page is intentionally blank. DP A Cutting Units.
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.
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.
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 .
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.
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.
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).
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.
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.
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 .
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 .
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.
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.
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.
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.
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).
Reelmaster 7000 DP A Cutting Units Page 8 - - 23 This page is intentionally blank. DP A Cutting Units.
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.
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.
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.
Reelmaster 7000 DP A Cutting Units Page 8 - - 27 This page is intentionally blank. DP A Cutting Units.
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.
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.
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.
Reelmaster 7000 DP A Cutting Units Page 8 - - 31 This page is intentionally blank. DP A Cutting Units.
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.
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.
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.
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.
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.
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.
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.
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.
Reelmaster 7000 DP A Cutting Units Page 8 - - 40 This page is intentionally blank..
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 .
Reelmaster 7000 Foldout Drawings Page 9 - 2 This page is intentionally blank..
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 .
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 REEL.
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 BL.
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/YE.
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/.
Un punto importante, dopo l’acquisto del dispositivo (o anche prima di acquisto) è quello di leggere il manuale. Dobbiamo farlo per diversi motivi semplici:
Se non hai ancora comprato il Toro 11185SL è un buon momento per familiarizzare con i dati di base del prodotto. Prime consultare le pagine iniziali del manuale d’uso, che si trova al di sopra. Dovresti trovare lì i dati tecnici più importanti del Toro 11185SL - in questo modo è possibile verificare se l’apparecchio soddisfa le tue esigenze. Esplorando le pagine segenti del manuali d’uso Toro 11185SL imparerai tutte le caratteristiche del prodotto e le informazioni sul suo funzionamento. Le informazioni sul Toro 11185SL ti aiuteranno sicuramente a prendere una decisione relativa all’acquisto.
In una situazione in cui hai già il Toro 11185SL, ma non hai ancora letto il manuale d’uso, dovresti farlo per le ragioni sopra descritte. Saprai quindi se hai correttamente usato le funzioni disponibili, e se hai commesso errori che possono ridurre la durata di vita del Toro 11185SL.
Tuttavia, uno dei ruoli più importanti per l’utente svolti dal manuale d’uso è quello di aiutare a risolvere i problemi con il Toro 11185SL. Quasi sempre, ci troverai Troubleshooting, cioè i guasti più frequenti e malfunzionamenti del dispositivo Toro 11185SL insieme con le istruzioni su come risolverli. Anche se non si riesci a risolvere il problema, il manuale d’uso ti mostrerà il percorso di ulteriori procedimenti – il contatto con il centro servizio clienti o il servizio più vicino.
