Service Manual
Table Of Contents
- Title Page
- Revision History
- Reader Comments
- Preface
- Table of Contents
- 1 - Safety
- 2 - Product Records and Maintenance
- 3 - Yanmar Diesel Engine
- 4 - Kubota Diesel Engine
- 5 - Hydraulic System
- Specifications
- General Information
- Operator's Manual
- Hydraulic Component Locations
- Relieving Hydraulic System Pressure
- Traction Circuit Component Failure
- Towing Traction Unit
- Hydraulic Hoses
- Hydraulic Hose and Tube Installation (O-Ring Face Seal Fitting)
- Hydraulic Fitting Installation (SAE Straight Thread O-Ring Fitting into Component Port)
- Hydraulic Schematic
- Hydraulic Flow Diagrams
- Special Tools
- Troubleshooting
- Testing
- Traction Circuit - Charge Pressure Test
- Traction Circuit - Relief Pressure Test
- Traction Circuit - Piston (traction) Pump Flow Test
- Traction Circuit - Front Wheel Motor Case Drain Leakage Test
- Traction Circuit - Reverse Reducing Valve (PR) Pressure Test
- Traction Circuit - Rear Relief Valve (RV) Pressure Test
- Cutting Unit Circuit - Pressure Test
- Cutting Unit Circuit - Relief Pressure Test
- Cutting Unit Circuit - Cutting Unit Motor Case Drain Leakage Test
- Steering/Lift Circuit - Steering Relief Pressure Test
- Steering/Lift Circuit - Steering Cylinder Test
- Steering/Lift Circuit - Lift Relief Pressure Test
- Cooling Fan Circuit - Pressure Test
- Cooling Fan Circuit - Fan Motor Case Drain Leakage Test
- Gear Pump Flow Test (pump sections P2 thru P5)
- Adjustments
- Service and Repairs
- General Precautions for Removing and Installing Hydraulic System Components
- Check Hydraulic Lines and Hoses
- Priming Hydraulic Pumps
- Flush Hydraulic System
- Filtering Closed-Loop Traction Circuit
- Charge Hydraulic System
- Gear Pump
- Gear Pump Service
- Piston (Traction) Pump
- Piston (traction) Pump Service
- Rear Traction Manifold
- Rear Traction Manifold Service
- HI/LOW Range Manifold
- Front Wheel Motors
- Rear Axle Motor
- Front Wheel Motor and Rear Axle Motor Service
- Cutting Unit Motor
- Cutting Unit Motor Service
- Mow Control Manifold
- Mow Control Manifold Service
- Steering Control Valve
- Steering Control Valve Service
- Steering Cylinder
- Steering Cylinder Service
- Engine Cooling Fan Motor
- Engine Cooling Fan Motor Service
- Fan Control Manifold
- Fan Control Manifold Service
- Lift Manifold
- Lift Manifold Service
- Control Manifold Cartridge Valve Service
- Lift Junction Manifold
- Front Lift Cylinders
- Rear Lift Cylinders
- Lift Cylinder Service
- Hydraulic Reservoir
- Hydraulic Oil Cooler
- 6 - Electrical System
- General Information
- Electrical Drawings
- Special Tools
- InfoCenter Display
- Troubleshooting
- Electrical System Quick Checks
- Adjustments
- Component Testing
- Fusible Link Harness
- Fuses
- Toro Electronic Controllers (TEC)
- Ignition Switch
- Reel Enable/Disable Switch
- Engine Speed Switch (Yanmar Diesel Engine Only)
- Lower/Raise Joystick Switches
- Seat Switch
- Traction Neutral Switch
- Parking Brake Switch
- HI/LOW (Transport/Mow) Switch
- Cutting Unit Position Switch
- Backlap Switches
- Hydraulic Oil Temperature Sender
- Engine Temperature Sender (Kubota Diesel Engine Only)
- Relays with Four (4) Terminals
- Relays with Five (5) Terminals
- Hydraulic Solenoid Valve Coils
- Fuel Pump (Yanmar Diesel Engine Only)
- Fuel Pump (Kubota Diesel Engine Only)
- Fuel Stop Solenoid (Kubota Diesel Engines Only)
- CAN-bus Termination Resistor
- Diode Assembly
- Resistor Assembly
- Worklight Switch
- Service and Repairs
- 7 - Axles, Planetaries and Brakes
- 8 - Chassis
- 9 - DPA Cutting Units
- Table of Contents
- Specifications
- General Information
- Special Tools
- Gauge Bar Assembly
- Bedknife Screw Tool
- Handle Assembly
- Plastic Plug
- Cutting Unit Kickstand
- Spline Insert Tool
- Diameter/Circumference Measuring Tape
- Roller Rebuild Kit
- Turf Evaluator Tool
- Reel Bearing Installation Tool (cutting units with painted side plates)
- Cutting Reel Shim
- Cutting Performance Paper
- Pulley Alignment Tool
- Bedknife Top Angle Indicator and Mount
- Factors That Can Affect Cutting Performance
- Adjustments
- Service and Repairs
- Hydraulic Reel Motor
- Backlapping
- Bedbar Assembly
- Bedknife Replacement and Grinding
- Bedbar Adjuster Service
- Reel Assembly (cutting units with painted side plates)
- Reel Assembly Service (cutting units with painted side plates)
- Reel Assembly (cutting units with aluminum side plates)
- Reel Assembly Service (cutting units with aluminum side plates)
- Preparing Reel for Grinding
- Front Roller
- Rear Roller
- Roller Service
- Rear Roller Brush - Optional (cutting units with painted side plates)
- Rear Roller Brush - Optional (cutting units with aluminum side plates)
- 10 - Belt Driven Groomer (Optional)
- 11 - Universal Groomer (Optional)
- 12 - Foldout Drawings
- Electrical Drawing Designations
- Hydraulic Schematic
- Electrical Schematic - Traction Unit Model 03780 - Yanmar Engine (Serial numbers below 316000000)
- Electrical Schematic -- Traction UnitModel 03780 -- Yanmar Engine(Serial numbers 316000001 to 403350000)
- Electrical Schematic -- Traction UnitModel 03780 -- Yanmar Engine(Serial numbers above 403350001)
- Electrical Schematic - Traction Unit Model 03781 - Kubota Engine (Serial numbers below 316000000)
- Electrical Schematic -- Traction UnitModel 03781 -- Kubota Engine(Serial numbers 316000001 to 403350000)
- Electrical Schematic -- Traction UnitModel 03781 -- Kubota Engine(Serial numbers above 403350001)
- Electrical Schematic - Cab
- Main Wire Harness Drawing (Serial numbers below 316000000)
- Main Wire Harness Diagram (Serial numbers below 316000000)
- Main Wire Harness DrawingModel 03780 & 03781(Serial numbers 316000001 to 403350000)
- Main Wire Harness DiagramModel 03780 & 03781(Serial numbers 316000001 to 403350000)
- Main Wire Harness DrawingModel 03780 & 03781(Serial numbers 403350001 to 405699999)
- Main Wire Harness DiagramModel 03780 & 03781(Serial numbers 403350001 to 405699999)
- Main Wire Harness DrawingModel 03780 & 03781(Serial numbers above 405700000)
- Main Wire Harness DiagramModel 03780 & 03781(Serial numbers above 405700000)
- Engine Wire Harness Drawing - Yanmar
- Engine Wire Harness Diagram - Yanmar
- Engine Wire Harness Drawing - Kubota
- Engine Wire Harness Diagram - Kubota
- Seat and Console Wire Harness Drawing
- Seat and Wire Harness Diagram
- Power Center Wire Harness Drawing (Serial numbers below 403350000)
- Power Center Wire Harness Diagram (Serial numbers below 403350000)
- Power Center Wire Harness DrawingModel 03780 & 03781(Serial numbers above 403350001)
- Power Center Wire Harness DiagramModel 03780 & 03781(Serial numbers above 403350001)
Reelmaster 7000−DHydraulic System Page 5 − 32
Traction Circuit Problems
When troubleshooting traction circuit problems, if a
problem exists in both low (mow) and high (transport)
speeds, consider a faulty component that affects the en-
tire traction circuit (e.g. charge circuit, traction circuit re-
lief valves, piston pump). If the problem exists in LOW
speed (mow) but not in HI speed (transport), consider a
problem that only exists in mow (e.g. swashplate com-
ponents in front wheel or rear axle motor, solenoid valve
in HI/LOW range manifold).
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
Problem
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ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Possible Cause
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ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
Machine operates in one direction
only.
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Piston (traction) pump by−pass valve is open or damaged.
Traction relief valve in piston pump is leaking or faulty.
Piston (traction) pump servo control valve orifices or screens are
plugged or damaged.
Problem with TEC output to piston (traction) pump servo control
exists (see Chapter 6 − Electrical System).
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
Traction pedal reaction is sluggish.
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Traction pedal components are stuck or binding.
Traction charge pressure is low.
Piston (traction) pump servo control valve orifices are plugged or
damaged.
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
Machine travels too far before stop-
ping when the traction pedal is re-
leased.
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Traction pedal components are stuck or binding.
Traction charge pressure is low.
Piston (traction) pump servo control valve orifices are plugged or
damaged.
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
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ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
Traction power is lost or machine will
not operate in either direction.
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Hydraulic reservoir oil level is low (NOTE: Other hydraulic systems
are affected as well).
Piston (traction) pump by−pass valve is open or damaged.
Traction charge pressure is low.
Traction circuit pressure is low.
Problem with TEC output to servo control (see Chapter 6 − Electric-
al System).
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
LOW traction speed (mow) will not
engage.
NOTE: LOW (mow) will not engage
when the cutting units are lowered.
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Electrical problem exists that prevents solenoid valve in HI/LOW
range manifold from being de−energized (see Chapter 6 − Electri-
cal System).
Solenoid valve in HI/LOW range manifold is faulty.
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
LOW traction speed (mow) will not
disengage.
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Electrical problem exists that prevents solenoid valve in HI/LOW
range manifold from being energized (see Chapter 6 − Electrical
System).
Solenoid valve in HI/LOW range manifold is faulty.