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 Hydraulic SystemPage 5 − 13
Traction Circuit: LOW Speed (Mow)
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. Traction
circuit oil is directed to the dual displacement front wheel
motors and rear axle motor. Operating pressure on the
high pressure side of the closed loop traction circuit is
determined by the amount of load developed at the
wheel motors and rear axle motor. As the traction load
increases, circuit pressure can increase to the relief
valves setting of 5000 PSI (345 bar) in forward or re-
verse. If traction circuit pressure exceeds the relief set-
ting, oil flows through the piston pump relief valve to the
low pressure side of the closed loop traction circuit.
Front wheel motors and the rear axle motor are positive,
dual displacement motors. The dual displacement fea-
ture allows operation in either a LOW (mow) or HI (trans-
port) speed range. The motors are spring biased to
maximum displacement for LOW speeds, and are hy-
draulically shifted to minimum displacement for HI
speeds. The rear axle motor includes a flushing valve to
help cool the traction circuit oil. The valve bleeds off a
small amount of hydraulic oil from the closed loop trac-
tion circuit letting the charge circuit replenish the oil that
is bled from the traction circuit with cooler oil from the
charge circuit.
An optional traction circuit flow divider is available that
equally splits traction pump flow between the front
wheel motors and rear axle motor to prevent excessive
circuit flow going to a spinning wheel. If equipped, the
front traction manifold which includes the flow divider is
mounted to the right side of the front frame.
The piston pump, front wheel motors and rear axle mo-
tor use small amounts of hydraulic fluid for internal lu-
brication. Fluid is designed to leak across traction pump
and motor components into the case drain. This leakage
results in the loss of hydraulic fluid from the closed loop
traction circuit that must be replaced. The charge circuit
is designed to replace this traction circuit leakage. The
gear pump section (P4) that supplies oil to the steering
and lift/lower circuits also provides oil for the charge cir-
cuit.
Gear pump flow for the charge circuit is directed through
the steering valve, lift manifold, oil filter, and to the low
pressure side of the closed loop traction circuit. Charge
pressure is limited to 207 PSI (14.3 bar) by a check valve
located in the lift manifold.
Forward Direction
With the mow speed limiter in the LOW speed (mow)
position, the solenoid valve in the Hi/Low range manifold
is not energized. The front wheel motors and rear axle
motor are at their maximum displacement when in LOW
speed providing a slower traction speed for mowing
conditions.
When in LOW speed (mow) position with the traction
pedal pushed in the forward direction, oil from the piston
pump is directed to the front wheel motors and rear axle
motor through a parallel system. Oil flow to the front
wheel motors drives the motors in the forward direction
and then returns to the piston pump. Oil flow to the rear
axle motor drives the motor in the forward direction. Oil
returning from the axle motor enters the rear traction
manifold at the M8 port. The majority of the return flow
bypasses the pressure reducing (PR) cartridge and
passes through a less restrictive check valve (CV), out
manifold port P2 and returns to the piston pump.
When going down a hill, the tractor becomes an over−
running load that drives the front wheel and rear axle
motors. In this condition, the rear axle motor could lock
up as the oil pumped from the motor increases pressure
as it returns to the piston pump. To prevent rear wheel
lock up, an adjustable relief valve (RV) in the rear trac-
tion manifold opens to reduce rear axle motor pressure
created in down hill, dynamic braking conditions.
Reverse Direction
The traction circuit operates essentially the same in re-
verse LOW speed (mow) as it does in forward LOW
speed (mow). However, the flow through the circuit is re-
versed. Oil flow from the piston pump is directed to the
front wheel motors and also to the rear traction manifold.
The oil to the front wheel motors drives them in the re-
verse direction and then returns to the piston pump. The
oil to the rear traction manifold enters the manifold at
port P2 and flows through pressure reducing valve (PR)
which limits the down stream pressure to the rear axle
motor to 400 PSI (27.6 bar) so the rear wheels will not
scuff the turf during reverse operation. This reduced
pressure flow is directed out rear traction manifold port
M8 to drive the rear axle motor in reverse. Return oil
from the rear motor returns to the piston pump.
Hydraulic
System