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--D
DPA Cutting Units
Page 9 -- 33
9. Apply Loctite #243 (or equivalent) to threads of
flange head screw that secures frame spacer and carri-
er frame to LH side plate. Install screw and torque from
27 to 33 ft-lbs (37 to 44 N--m). After tightening screw,
check the clearance between the carrier frame and side
plate. If clearance is more than 0.065” (1.6 mm),re-
move flange head screw and position shim(s) between
carrier frame and side plate so that clearance is less
than 0.065” (1.6 mm). Make sure that the carrier frame
pivots freely after assembly.
10.Install cap screw and flat washer that secure rear
grass shield to LH side plate. Torque screw from 15 to
19 ft-lbs (20 to 25 N--m).
11. Install the bedbar assembly (see Bedbar Installation
in this section).
12.Install front and rear rollers (see Front Roller Installa-
tion and Rear Roller Installation in this section).
13.Adjust cutting unit (see Cutting Unit Operator’s
Manual).
NOTE: The parallel position of the rear roller to the cut-
ting reel is controlled by the precision machined frame
and side plates of the cutting unit. If necessary, the cut-
ting unit side plates can be loosened and a slight adjust-
ment can be m ade to parallel the rear roller with the
cutting reel ( see Leveling Rear Roller in this Chapter).
14.Install accessories if equipped. See Chapter 10 --
Belt Driven Groomer or Chapter 10 -- Universal
Groomer in this manual for additional Groomer informa-
tion. See Rear Roller Brush in this chapter for informa-
tion on rear roller brush.
15.Tighten the spline inserts:
A. Insert a long--handled pry bar (3/8 x 12 inch with
a screwdriver handle recommended) through the
front of the cutting unit. The p ry bar should pass
between the top of the reel shaft and the backs of
the reel blades so that the reel will not move.
IMPORTANT: To avoid grinding the reel, do not con-
tact the cutting edge of any blade with the pry bar as
this may damage the cutting edge and/or cause a
high blade.
B. Move the pry bar against the weld side of the reel
support plate closest to the spline insert being
tightened.
IMPORTANT: The spline insert on the left end of the
cutting reel has left hand threads and the spline in-
sert on the right end of the cutting reel has right
hand threads.
C. Rest the handle of the pry bar against the front
roller and tighten the spline insert closest to the pry
bar. The spline inserts are installed with thread lock-
ing compound (Loctite #243 or equivalent). Tighten
the spline insert from 85 to 95 ft--lb (115 to
128N·m). Use correct spline insert tool (see Special
Too l s) .
1. Side plate -- RH 2. Side plate -- LH
Figure 42
12
Antiseize
Lubricant
1. Spline insert (LH)
2. Reel shaft
3. Reel support plate
4. Pry bar
Figure 43
2
4
3
(85to95ft---- l b )
115 to 128 Nm
1
(Cutting Unit 3 shown)
D. Positiontheprybarinthesamemanneronthe
opposite end of the reel and tighten the remaining
spline insert.
16.If counterweight was removed from cutting unit,
install new O--ring on counter weight. Secure counter
weight to cutting unit side plate with two (2) flange nuts.
Tor q ue s cr e ws f ro m 27 to 33 ft-lbs (37 to 44 N--m).
17.Install cutting unit to the machine.
DPA Cutting
Units