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 − 25
Engine Cooling Fan Circuit
A four section gear pump is coupled to the piston (trac-
tion) pump. The gear pump section P5 (farthest from the
piston pump) supplies hydraulic flow for the hydraulic
engine cooling fan motor.
The fan control manifold controls the operation of the hy-
draulic motor that drives the engine cooling fan in addi-
tion to including the flow divider (FD) for the steering and
lift circuits. The electronically controlled proportional re-
lief valve (PRV) in the fan control manifold TS port con-
trols the oil flow to the fan motor. The fan control
manifold controls the speed and direction of the fan mo-
tor based on electrical output from the Toro Electronic
Controller (TEC).
Oil flow from the gear pump to the cooling fan motor is
controlled by the proportional relief valve (PRV) in the
fan control manifold TS port. This valve adjusts fan cir-
cuit flow based on a PWM (Pulse Width Modulation) sig-
nal from the TEC. The controller uses engine coolant
and hydraulic oil temperatures as inputs to determine
the proper PWM signal for the proportional relief valve.
The fan circuit flow determines the speed of the cooling
fan motor.
The fan motor runs at reduced speed until engine
coolant temperature reaches approximately 165F
(74C), or hydraulic oil temperature reaches 170F
(77C). The fan motor increases to full speed (approx-
imately 2800 RPM) as engine coolant temperature
reaches 180F (82C), or hydraulic oil temperature
reaches 195F (91C).
The fan motor automatically slows down and then re-
verses direction if engine coolant temperature
reaches 203F (95C) or hydraulic oil temperature
reaches 212F (100C).
If the fan motor is stalled for any reason, the manifold
proportional relief valve (PRV) has a secondary function
as a circuit relief to limit fan motor pressure to 3000 PSI
(207 bar).
When the engine is shut off, the over−running inertia
load of the fan blades keeps driving the fan motor and
turns it into a pump. The check valve (CV) in the fan con-
trol manifold will open to keep the motor circuit full of oil
so the fan motor will not cavitate (fill with air).
NOTE: If PWM current is not available to the fan control
manifold proportional relief valve (PRV), the cooling fan
motor will run at full speed in the normal (forward) direc-
tion.
Fan Operation (forward/pull)
In the forward direction, the fan pulls air from outside the
engine compartment through the radiator and oil cooler.
Oil flow from the gear pump is sent through the de−ener-
gized solenoid valve S1 to rotate the cooling fan motor.
Return flow from the motor re−enters manifold port M2,
passes through the de−energized solenoid valve S1,
out manifold port T, and then is routed through the mow
control manifold, oil cooler and return oil filter.
Fan Operation (reverse/push) (Fig. 17)
The TEC can reverse the cooling fan to push air from in-
side the engine compartment through the radiator and
oil cooler to clean debris from the rear intake screen. If
hydraulic oil and/or engine coolant temperatures in-
crease to an unsuitable level or if the engine cooling fan
switch is pressed to manual reverse, a high PWM signal
is sent to the PRV valve to slow the cooling fan and direct
pump oil flow away from the fan motor. The controller
then energizes solenoid valve S1 in the fan control man-
ifold to reverse cooling fan motor oil flow so that the mo-
tor runs in the reverse direction. A lower PWM signal is
sent to the PRV valve allowing oil flow to return to the fan
motor but in the reverse direction causing the motor and
cooling fan to run in reverse for a short time.
NOTE: The fan reversal process is designed to clean
the rear intake screen (not the radiator) of debris. Refer
to Operator’s Manual for radiator cleaning maintenance
recommendations.
Figure 17
REVERSE
DIRECTION
0.51 CID
T
TS
S1
CV
FD
P2P1
ST
L
M1
50/50 SPLIT
FAN CONTROL
MANIFOLD
G2
G1
FAN
M2
MOTOR
Hydraulic
System