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−DPage 7 − 20Axles, Planetaries and Brakes
4. If previously removed, press bearing cups into hous-
ing. Cups should be pressed fully to shoulder of the
housing bore.
5. Fit inner bearing cone onto spindle. Make sure inner
bearing cone seats fully against spindle shoulder. If in-
ner bearing is not seated fully, lightly tap bearing cone
on inner hub until it seats properly.
6. Make sure that seal bore in housing is thoroughly
cleaned. If OD of seal is not rubber or does not have a
sealant coating, apply a light coating of silicone sealant
to seal bore in housing.
Install seal into housing so it is
flush with housing face.
7. Install boot seal. Cover surface of lip seal and boot
seal with grease.
8. Lightly oil bearing cups then place housing assembly
over spindle and inner bearing cone. Take care to not
damage seals or spindle during installation.
9. Fit outer bearing cone onto spindle.
10.Align key on spacer and install spacer onto spindle
shaft.
11. Align key on locking washer and install locking wash-
er onto spindle shaft.
IMPORTANT: .Perform the following steps without
interruption. Once the thread locking compound is
applied, you have only a few minutes before the cur-
ing process will influence the bearing lock nut
torque.
12.Install the bearing lock nut:
A. Apply high strength thread locking compound
(Loctite 263 or equivalent) and install the lock nut.
B. Tighten the lock nut to 110 ft−lb (150 N−m).
C. Rotate the housing on the spindle a few revolu-
tions to align the bearings.
D. Tighten the lock nut to 150 ft−lb (200 N−m).
E. Rotate the housing on the spindle a few revolu-
tions to seat the bearings.
IMPORTANT If installing the bearing nut with
the spindle installed on machine, have an assis-
tant hold the housing firmly in position during
the following step.
F. Loosen the lock nut completely, then tighten to 90
ft−lb (122 N−m).
IMPORTANT: Continue to tighten the lock nut
until it aligns with one of the locking washer tabs.
Do Not loosen the lock nut to align it with the
locking washer tabs.
G. Secure the lock nut by bending one of the locking
washer tabs into a slot in the lock nut.
13.Install secondary carrier and primary carrier making
sure that carrier gear teeth align with ring gear and
spline on spindle shaft.
14.If primary gear (item 25) was removed from drive
shaft, slide gear onto shaft and secure with retaining
rings.
15.Install drive shaft assembly (items 24−26) making
sure that drive shaft spline aligns with carrier gears.
16.Cover the outer face of the thrust plate with grease
and fit thrust plate onto end cap. Make sure that thrust
plate tabs are captive in end cap.
17.Apply a light coat of grease to a new O−ring and in-
stall it in the ring gear bore. Avoid pinching or cutting the
O−ring and install the end cap. Use a soft mallet to fully
seat the end cap.
18.Secure the end cap with the retaining ring. Make sure
the retaining ring is fully seated in the ring groove.
NOTE: If the planetary drive is not installed on the ma-
chine, check operation of planetary drive by hand. With
a constant turning force applied, rotation of the plane-
tary should be consistent. If there is more drag at certain
points, gears are not rolling freely and the planetary
should be examined for improper assembly or damaged
components.
19.Install wheel assembly.
20.Fill planetary drive with gear lube; refer to traction
unit Operator’s Manual. A portion of the gear lube will
pass into the brake assembly automatically.
21.Test planetary drive operation.
Failure to maintain proper wheel lug nut torque
could result in failure or loss of wheel and may
result in personal injury.
WARNING
22.Remove jack stands and lower machine to ground.
Tighten wheel lug nuts in a crossing pattern from 85 to
100 ft−lb (116 to 135 N−m).