Service Manual

ManualsBrandsToro ManualsRiding ProductsReelmaster 6700-D 4-Wheel Drive Traction Unit

NOTE:

For Machines With Serial Numbers Below 250000000: Use this book along with the Kubota Workshop Manu-

al, 05 Series Diesel Engine (Toro Part No. 01090SL) (Tier 1 Emission Engine Models).

PART NO. 01084SL (Rev. F)

Service Manual

Reelmaster

6500-D/6700-D

Preface

The purpose of this publication is to provide the service

technician with information for troubleshooting, testing,

and repair of major systems and components on the

Reelmaster 6500-D/6700-D Models 03806, 03807 &

03808.

REFER TO THE TRACTION UNIT AND CUTTING

UNIT OPERATOR’S MANUALS FOR OPERATING,

MAINTENANCE AND ADJUSTMENT INSTRUC-

TIONS. For reference, insert a copy of the Operator’s

Manual and Parts Catalog for your machine into Chap-

ter 2 of this service manual. Additional copies of the Op-

erator’s Manual and Parts Catalog are available on the

internet at www.Toro.com.

TheToroCompany reservesthe rightto changeproduct

specifications or this publication without notice.

This safety symbol means DANGER, WARNING,

or CAUTION, PERSONAL SAFETY INSTRUC-

TION. When you see this symbol, carefully read

the instructions that follow. Failure to obey the

instructions may result in personal injury.

NOTE: A NOTE will give general information about the

correct operation, maintenance, service, testing or re-

pair of the machine.

IMPORTANT: The IMPORTANT notice will give im-

portant instructions which must be followed to pre-

vent damage to systems or components on the

machine.

E The Toro Company - 2002, 2003, 2004, 2007, 2008

Summary of content (328 pages)

PAGE 1
PART NO. 01084SL (Rev. F) Service Manual ReelmasterR 6500-D/6700-D Preface NOTE: For Machines With Serial Numbers Below 250000000: Use this book along with the Kubota Workshop Manual, 05 Series Diesel Engine (Toro Part No. 01090SL) (Tier 1 Emission Engine Models). The purpose of this publication is to provide the service technician with information for troubleshooting, testing, and repair of major systems and components on the Reelmaster 6500-D/6700-D Models 03806, 03807 & 03808.
PAGE 2
This page is intentionally blank.
PAGE 3
Chapter 1 -- Safety Chapter 6 -- Axles, Planetaries and Brakes Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -- 1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 4
This page is intentionally blank.
PAGE 5
Chapter 1 Safety SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . . Safety Table of Contents 1 1 2 3 Safety Instructions The REELMASTER 6500-D and 6700-D were tested and certified by TORO for compliance with the B71.
PAGE 6
7. Remove all debris or other objects that might be picked up and thrown by the reels or fast moving components from other attached implements. Keep all bystanders away from operating area. B. Do not remove fuel tank cap while engine is hot or running. 8. Since diesel fuel is highly flammable, handle it carefully: D. Fill fuel tank outdoors and only to within an inch of the top of the tank, not the filler neck. Do not overfill. C. Do not smoke while handling fuel. E. Wipe up any spilled fuel. A.
PAGE 7
1. Before servicing or making adjustments, stop engine and remove key from the switch. 7. If major repairs are ever needed or assistance is desired, contact an Authorized Toro Distributor. 2. When changing attachments, tires or performing other service, use the correct blocks, hoists and jacks. Always chock or block the wheels and use jack stands or solid wood blocks to support the raised machine.
PAGE 8
This page is intentionally blank.
PAGE 9
Chapter 2 Product Records and Maintenance Table of Contents 1 1 2 2 2 3 3 Product Records and Maintenance PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . Fastener Identification .
PAGE 10
Equivalents and Conversions 0.09375 Product Records and Maintenance Page 2 - 2 Rev.
PAGE 11
Torque Specifications These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Service Manual.
PAGE 12
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size # 6 -- 32 UNC Grade 1, 5, & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs, & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in--lb in--lb N--cm 10 + 2 13 + 2 147 + 23 # 6 -- 40 UNF # 8 -- 32 UNC 13 + 2 25 + 5 282 + 30 # 8 -- 36 UNF # 10 -- 24 UNC 18 + 2 30 + 5 339 + 56 # 10 -- 32 UNF SAE Grade 5 Bolts, Screws, Studs, & Sems with Regular Height Nuts (SAE J995 Grade 2 or Strong
PAGE 13
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Series) Class 8.8 Bolts, Screws, and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws, and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 + 5 in--lb 640 + 60 N--cm 78 + 7 in--lb 885 + 80 N--cm M6 X 1.0 96 + 9 in--lb 1018 + 100 N--cm 133 + 13 in--lb 1500 + 150 N--cm M8 X 1.25 19 + 2 ft--lb 26 + 3 N--m 27 + 2 ft--lb 36 + 3 N--m M10 X 1.
PAGE 14
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Thread Size Square Head Hex Socket 1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb 5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb 3/8 -- 16 UNC 35 + 10 ft--lb 18 + 3 ft--lb 1/2 -- 13 UNC 75 + 15 ft--lb 50 + 10 ft--lb Recommended Torque** 7/16 -- 20 UNF Grade 5 65 + 10 ft--lb 88 + 14 N--m 1/2 -- 20 UNF Grade 5 80 + 10 ft--lb 108 + 14 N--m M12 X 1.25 Class 8.
PAGE 15
Chapter 3 Kubota Diesel Engine INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4 Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . 4 Check Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fill Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Check Cooling System . . . . . . . . . . .
PAGE 16
Introduction This Chapter gives information about specifications, maintenance, troubleshooting, testing, and repair of the diesel engine used in the Reelmaster 6500-D and 6700-D. test equipment is explained. However, the cost of the test equipment and the specialized nature of some repairs may dictate that the work be done at an engine repair facility. Most repairs and adjustments require tools which are commonly available in many service shops.
PAGE 17
Specifications Item Description Make/Designation Kubota V1505--T (E), 4-Cycle, 4 Cylinder, Turbocharged, Vertical, Water Cooled, Diesel Engine Horse Power 42.5 HP @ 3000 RPM Bore 3.07 in. (78 mm) Stroke 3.09 in. (78 mm) Total Displacement 91.4 cu. in. (1498 cc) Torque 85.8 ft-lb (119.6 N-m) @ 2000 RPM Firing Order 1-3-4-2 Combustion Chamber Spherical Type No. 2 Diesel Fuel (ASTM D975) Fuel Capacity 15 U.S. Gal. (57.
PAGE 18
General Information Stopping The Engine IMPORTANT: Before stopping the engine after mowing or full load operation, cool the turbo-charger by allowing the engine to idle at low speed for 5 minutes. Failure to do so may lead to turbo-charger trouble. Check Engine Oil 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Release hood latch and open hood. 3. Remove, wipe clean, and reinstall dipstick.
PAGE 19
Fill Fuel Tank DANGER 1 Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage. 2 Figure 4 1. Fuel Tank Cap 2. Fuel Tank Filler Neck Kubota Diesel Engine • Use a funnel and fill the fuel tank outdoors, in an open area, when the engine is off and is cold. Wipe up any fuel that spills. • Do not fill the fuel tank completely full. Add fuel to the fuel tank until the level is 1 in.
PAGE 20
Check Cooling System The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol anti-freeze. Check level of coolant at the beginning of each day before starting the engine. System capacity is about 10 quarts (9.4 l). IMPORTANT: Clean debris off the screen, oil cooler, and front of the radiator daily, and more often if conditions are extremely dusty or dirty (see Engine Cooling System). 1.
PAGE 21
Adjustments Adjust Throttle Cable 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1 2. Release hood latch and open hood. 3. Position throttle lever forward so it stops against the seat base slot. 4. At the fuel injection pump, loosen throttle cable connector on the control lever arm. 5. Hold fuel injection pump lever arm against the high idle stop screw and tighten the cable connector. 2 Figure 7 1.
PAGE 22
Adjust Alternator Belt The condition and tension of all belts should be checked periodically as recommended in the maintenance schedules in Chapter 2 - Product Records and Maintenance. 1 4 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2 5 2. Release hood latch and open hood. 3. Check tension by depressing belt midway between alternator and crankshaft pulleys with 22 lb. (9.9 Kg) of force. Belt should deflect 7/16 in.
PAGE 23
Service and Repairs Bleed Fuel System 1. Park machine on a level surface, lower cutting units, stop engine, and engage parking brake. Make sure fuel tank is at least half full. 2. Release hood latch and open hood. 1 2 DANGER Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage. Figure 9 • Use a funnel and fill the fuel tank outdoors, in an open area, when the engine is off and is cold.
PAGE 24
Bleed Air from Fuel Injectors IMPORTANT: This procedure should be used only if the fuel system has been purged of air through normal priming procedures (see Bleed Fuel System) and engine will not start. 1. Park machine on a level surface, lower cutting units, stop engine, and engage parking brake. 1 DANGER Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage.
PAGE 25
Clean Radiator and Oil Cooler Remove debris from rear screen, oil cooler and radiator daily, clean more frequently in dirty conditions. IMPORTANT: Never spray water onto a hot engine as damage to engine may occur. 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1 CAUTION Figure 14 If engine has been running, the radiator may be hot and cause burns. Work on radiator only when the engine and radiator are cool. 1.
PAGE 26
Fuel Filter/Water Separator DANGER Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage. • Use a funnel and fill the fuel tank outdoors, in an open area, when the engine is off and is cold. Wipe up any fuel that spills. • Do not fill the fuel tank completely full. Add fuel to the fuel tank until the level is 1 in. (25 mm) below the bottom of the filler neck.
PAGE 27
4. Place a suitable container under fuel/water separator, and unscrew filter element and base from the filter head. 8. Screw filter element and base onto filter head by hand until the gasket contacts the mounting surface. Rotate element and base an additional 1/2 turn. 5. Unscrew filter element from base and discard element. 9. Bleed air from fuel system (see Bleed Fuel System in this section of this manual). 6. Lubricate gasket on new filter element and O-ring with clean diesel fuel. 10.
PAGE 28
Fuel System 8 9 1 10 2 4 3 5 11 12 13 6 7 14 15 20 16 19 30 to 60 in--lb (3.4 to 6.8 N--m) Never Seez 18 17 Figure 19 1. 2. 3. 4. 5. 6. 7. Fuel Hose Cable Tie Spring Clamp Round Head Screw Lock Washer Sending Unit Gasket Kubota Diesel Engine 8. 9. 10. 11. 12. 13. 14. Fuel Hose Hose Clamp Stand Pipe Fuel Elbow Connector Grommet Tank Cap Fuel Tank Page 3 - 14 15. 16. 17. 18. 19. 20.
PAGE 29
DANGER Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage. Check Fuel Lines and Connections Check fuel lines and connections periodically as recommended in the maintenance schedules in Chapter 2 Product Records and Maintenance. 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2.
PAGE 30
Air Filter General Maintenance 1 2 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Release hood latch and open hood. 3. Check air cleaner, seals, and intake hose for damage which could cause an air leak. Be sure the air cleaner cover seals tightly around the air cleaner body. Replace damaged air cleaner components as necessary. 3 4.
PAGE 31
Kubota Diesel Engine This page is intentionally left blank.
PAGE 32
Radiator 14 13 20 11 12 19 15 21 14 16 10 17 36 9 13 14 7 8 18 1 22 2 23 24 32 35 34 24 22 25 28 33 26 3 29 28 27 4 5 31 30 6 Figure 24 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Fan Shroud RH Screw Hex Nut Flat Washer Hex Nut Fan Shroud LH Screw Flat Washer Radiator Support Screw Reservoir Bracket Locknut Kubota Diesel Engine 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
PAGE 33
Removal (Fig. 24) Installation (Fig. 24) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1. Remove any plugs used during the removal procedure. 2. Unlatch and remove rear screen. 3. Unscrew knobs and pivot oil cooler rearward. 2. Slide the radiator into the radiator support from the left of the machine. 3. Secure the top and bottom of the radiator to the radiator support. 4. Release hood latch and open hood. 5.
PAGE 34
Engine 1 2 10 3 12 13 14 15 12 16 17 18 12 19 12 16 20 21 22 4 5 28 23 6 7 24 26 25 33 8 5 9 27 36 5035 38 37 35 34 39 26 24 10 39 32 24 41 18 29 71 30 64 55 62 60 61 63 66 64 57 31 12 51 50 53 54 56 72 55 65 42 40 52 59 58 12 44 49 11 43 45 46 47 48 67 68 24 70 69 Figure 25 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
PAGE 35
Removal (Fig. 25) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1 2 2. Release hood latch and open hood. 3. Disconnect both battery cables at the battery (see Battery Service in Chapter 5 - Electrical system). CAUTION 1. Cable bracket Figure 26 2. Cable swivel The muffler and exhaust pipe may be hot. To avoid possible burns, allow the exhaust system to cool before working on or near the muffler. 2 4.
PAGE 36
C. High temperature shutdown switch (Fig. 30). Glow plug bus (Fig. 31). 2 13.Make sure all cable ties securing the wiring harness, fuel lines, or hydraulic hoses to the engine are removed. 14.Connect hoist or lift to the front and rear engine lift tabs. 1 3 15.Remove the nuts, washers, and cap screws securing the engine brackets to the engine mounts.
PAGE 37
10.Install radiator support and oil cooler. 11. Install radiator (see Radiator Installation in this section of this manual). 12.Connect air filter hose to the engine. 13.Install muffler assembly. 14.Connect both battery cables to the battery (see Battery Service in Chapter 5 - Electrical system). 15.Adjust throttle cable (see Adjust Throttle Cable in this section of this manual). 16.Bleed air from fuel system (see Bleed Fuel System in this section of this manual). 17.Start engine and check for fuel leaks.
PAGE 38
This page is intentionally left blank.
PAGE 39
Chapter 4 Hydraulic System SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic Fitting Installation . . . . . . . . . . . . . . . . . . . 3 Pushing or Towing Traction Unit . . . . . . . . . . . . . . . . 5 Check Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . 5 HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . . .
PAGE 40
Specifications Item Specification Traction Pump Traction Relief Pressure Charge Pressure Servo controlled piston pump 4000 PSI (276 bar) 250 PSI (17 bar) Reel/Steering/Lift Pump Maximum Operating Pressure Steering Relief Pressure 3 section, positive displacement gear type pump 3000 PSI (207 bar) 1500 PSI (103 bar) Hydraulic Manifold (Reel) Front Reel Circuit Relief Pressure (R1) RM 6500--D Rear Reel Circuit Relief Pressure (R2) RM 6700--D Rear Reel Circuit Relief Pressure (R2) 3000 PSI (207 bar) 2000
PAGE 41
General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage conditions, or mishandling during operation or maintenance. These conditions can cause damage or premature deterioration. Some hoses are more susceptible to these conditions than others. Inspect the hoses frequently for signs of deterioration or damage.
PAGE 42
SAE Straight Thread O-Ring Port - Non-adjustable 1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material. 2. Always replace the O-ring seal when this type of fitting shows signs of leakage. O-Ring 3. Lubricate the O-ring with a light coating of oil. 4. Install the fitting into the port and tighten it down full length until finger tight. Figure 3 5. Tighten the fitting to the correct flats from finger tight (F.F.F.T.). Size 4 (1/4 in.
PAGE 43
Pushing or Towing Traction Unit In an emergency, the machine can be moved by actuating the bypass valve in the variable displacement hydraulic pump and pushing or towing the machine. 1 IMPORTANT: Do not push or tow the machine faster than 2 to 3 MPH (3 to 4.8 km/h) because internal transmission damage may occur. The bypass valve must be open whenever the machine is pushed or towed. 1. The bypass valve is located on top of variable displacement pump (Fig. 6).
PAGE 44
Hydraulic System LH RH V1 OUT IN MOW AUX G1 12:1 FC1 P1 MOW1 R7 M1 Page 4 - 6 Rev. F R M8 F 3000 PSI BKLP1 R7 R7 M4 C.U. 1 R7 C.U. 5 R7 R1 LC1 OR1 .025 DIA MD1 R7 M5 MOW CIRCUIT C.U. 4 F R M9 12:1 T MSV1 MSV2 BACKLAP R4 R2 LC2 OR2 .025 DIA MOW C.U. 2 R6 P2 2000 PSI MD2 MOW2 R7 M2 R7 R6 FC2 BKLP2 R7 M3 G2 R5 BACKLAP R7 C.U.
PAGE 45
Reelmaster 6500-D/6700-D Page 4 - 7 Rev. F Hydraulic System LH RH V1 OUT IN MOW AUX G1 12:1 FC1 P1 MOW1 R7 M1 R M8 F 3000 PSI BKLP1 R7 R7 M4 C.U. 1 R7 C.U. 5 R7 R1 LC1 OR1 .025 DIA MD1 R7 M5 MOW CIRCUIT C.U. 4 F R M9 12:1 T MSV1 MSV2 BACKLAP R4 R2 R6 P2 2000 PSI MD2 MOW2 R7 M2 R7 R6 FC2 BKLP2 R7 M3 G2 R5 BACKLAP R7 C.U. 3 MOW CIRCUIT Hydraulic System LC2 OR2 .025 DIA MOW C.U.
PAGE 46
Hydraulic System Page 4 - 8 Rev. F Reelmaster 6500-D/6700-D SV1 SV2 G3 P3 C1 SV1 C2 #1 ST SV3 C3 #4 T C1 P C4 FD1 CD2 SV4 C2 #3 C6 CD3 C5 SV5 #2 PT LOWER RAISE All solenoids are shown as de-energized.
PAGE 47
Reelmaster 6500-D/6700-D Page 4 - 9 Rev. F Hydraulic System SV1 SV2 Hydraulic System All solenoids are shown as de-energized.
PAGE 48
Hydraulic System Page 4 - 10 Rev. F Reelmaster 6500-D/6700-D LH RH V1 OUT IN MOW AUX G1 P1 13.8:1 12:1 FC1 MOW1 R7 M1 R M8 F 3000 PSI BKLP1 R7 R7 M4 C.U. 1 R7 C.U. 5 R7 F R M10 R1 LC1 OR1 .025 DIA MD1 R7 M5 MOW CIRCUIT C.U. 4 F R M9 T 12:1 MSV1 MSV2 BACKLAP R4 R2 LC2 OR2 .025 DIA MOW C.U. 2 R6 P2 2000 PSI MD2 MOW2 R7 M2 R7 R6 FC2 BKLP2 R7 M3 G2 R5 BACKLAP R7 C.U.
PAGE 49
Reelmaster 6500-D/6700-D Page 4 - 11 Rev. F Hydraulic System LH RH V1 OUT IN MOW AUX G1 P1 13.8:1 12:1 FC1 MOW1 R7 M1 R M8 F 3000 PSI BKLP1 R7 R7 M4 C.U. 1 R7 R7 M5 C.U. 5 R7 R M10 F R1 LC1 OR1 .025 DIA MD1 MOW CIRCUIT C.U. 4 R M9 F T R4 R2 LC2 OR2 .025 DIA MOW R6 P2 2000 PSI MD2 MOW2 R7 M2 R7 R6 FC2 BKLP2 R7 M3 G2 R5 BACKLAP R7 C.U. 3 MOW CIRCUIT Hydraulic System 12:1 MSV1 MSV2 BACKLAP C.U.
PAGE 50
Hydraulic System Page 4 - 12 Rev. F Reelmaster 6500-D/6700-D SV1 SV2 G3 P3 C1 SV2 #5 ST SV3 C3 #4 T SV8 C1 P C4 FD1 CD2 SV4 C2 #3 C6 CD3 C5 SV5 #2 PT LOWER RAISE All solenoids are shown as de-energized.
PAGE 51
Reelmaster 6500-D/6700-D Page 4 - 12.1 Rev. F Hydraulic System SV1 SV2 Hydraulic System All solenoids are shown as de-energized.
PAGE 52
Hydraulic System Page 4 - 12.2 Rev. F Reelmaster 6500-D/6700-D LH RH V1 OUT IN MOW AUX G1 FC1 P1 MOW1 R7 M1 R7 M5 C.U. 5 R7 13.8:1 F R F R M10 T F R4 R 12:1 R2 LC2 P2 3000 PSI MD2 MOW2 R7 M2 R7 R6 FC2 BKLP2 R7 M3 R7 C.U. 3 MOW CIRCUIT C.U. 2 S10 OR2 .025 DIA MOW R7 M6 R7 C.U. 6 M9 MSV1 MSV2 BACKLAP M8 R1 LC1 OR1 .025 DIA MD1 12:1 3000 PSI BKLP1 R7 R7 M4 C.U. 1 R7 MOW CIRCUIT C.U. 4 R6 G2 BACKLAP S11 R7 M7 R7 C.U.
PAGE 53
Reelmaster 6500-D/6700-D Page 4 - 12.3 Rev. F Hydraulic System LH RH V1 OUT IN MOW AUX G1 FC1 P1 MOW1 R7 M1 R7 M5 C.U. 5 R7 13.8:1 F R R M10 F T F R4 R P2 3000 PSI R7 R6 FC2 BKLP2 R7 M3 Hydraulic System 12:1 R2 LC2 MD2 MOW2 R7 M2 R7 C.U. 3 MOW CIRCUIT C.U. 2 S10 OR2 .025 DIA MOW R7 M6 R7 C.U. 6 M9 MSV1 MSV2 BACKLAP M8 R1 LC1 OR1 .025 DIA MD1 12:1 3000 PSI BKLP1 R7 R7 M4 C.U. 1 R7 MOW CIRCUIT C.U. 4 R6 G2 BACKLAP S11 R7 M7 R7 C.U.
PAGE 54
Hydraulic System Page 4 - 12.4 Rev. F Reelmaster 6500-D/6700-D FLOW RATE CALCULATED AT 3000 RPM AND 98% EFFICIENCY. SV1 SV2 All solenoids are shown as de-energized.
PAGE 55
Reelmaster 6500-D/6700-D Page 4 - 13 Rev. F Hydraulic System FLOW RATE CALCULATED AT 3000 RPM AND 98% EFFICIENCY. SV1 SV2 Hydraulic System All solenoids are shown as de-energized.
PAGE 56
Hydraulic System Page 4 - 14 13.
PAGE 57
Traction Circuit The hydraulic pump assembly is driven by a coupling attached to the engine flywheel. The pump assembly consists of a three section gear pump, a gerotor charge pump, and a variable displacement piston pump. Pushing the top of the traction pedal engages a hydraulic servo valve which controls the variable displacement piston pump swash plate to create a flow of oil. This oil is directed to two fixed displacement motors.
PAGE 58
Hydraulic System Page 4 - 16 Rev. B Reelmaster 6500-D/6700-D LH RH V1 OUT IN MOW AUX G1 FC1 P1 MOW1 R7 M1 R7 M5 C.U. 5 R7 13.8:1 F R R M10 F T F R4 R 12:1 R2 LC2 P2 3000 PSI MD2 MOW2 R7 M2 R7 R6 FC2 BKLP2 R7 M3 R7 C.U. 3 MOW CIRCUIT C.U. 2 S10 OR2 .025 DIA MOW R7 M6 R7 C.U. 6 M9 MSV1 MSV2 BACKLAP M8 R1 LC1 OR1 .025 DIA MD1 12:1 3000 PSI BKLP1 R7 R7 M4 C.U. 1 R7 MOW CIRCUIT C.U. 4 R6 G2 BACKLAP S11 R7 M7 R7 C.U.
PAGE 59
Lower Cutting Units Gear pump section (P3) provides oil flow through the steering control valve and lift manifold to all cutting unit lift cylinders. Maximum circuit pressure (1500 PSI/104.0 bar) is limited by a relief valve in the gear pump (R3). When the cutting units are in the raised position, flow from the gear pump (P3) passes through the steering control valve and into the lift manifold. All lift manifold solenoid valves are de-energized and flow is directed to the hydraulic reservoir.
PAGE 60
Hydraulic System Page 4 - 18 Rev. B Reelmaster 6500-D/6700-D LH RH V1 OUT IN MOW AUX G1 FC1 P1 MOW1 R7 M1 R7 M5 C.U. 5 R7 13.8:1 F R R M10 F T F R4 R 12:1 R2 LC2 P2 3000 PSI MD2 MOW2 R7 M2 R7 R6 FC2 BKLP2 R7 M3 R7 C.U. 3 MOW CIRCUIT C.U. 2 S10 OR2 .025 DIA MOW R7 M6 R7 C.U. 6 M9 MSV1 MSV2 BACKLAP M8 R1 LC1 OR1 .025 DIA MD1 12:1 3000 PSI BKLP1 R7 R7 M4 C.U. 1 R7 MOW CIRCUIT C.U. 4 R6 G2 BACKLAP S11 R7 M7 R7 C.U.
PAGE 61
Raise Cutting Units The hydraulic pump assembly is driven by a coupling attached to the engine flywheel. The pump assembly consists of a three section gear pump, a gerotor charge pump, and a variable displacement piston pump. Gear pump section (P3) provides oil flow through the steering control valve and lift manifold to all five cutting unit lift cylinders. Maximum circuit pressure (1500 PSI/104.0 bar) is limited by a relief valve in the gear pump (R3).
PAGE 62
Hydraulic System Page 4 - 20 Rev. B Reelmaster 6500-D/6700-D LH RH V1 OUT IN MOW AUX G1 P1 13.8:1 12:1 FC1 MOW1 R7 M1 F 3000 PSI R R M10 F R1 LC1 F R M9 R7 M6 12:1 T R2 R6 LC2 R6 P2 3000 PSI MD2 MOW2 R7 M2 R7 FC2 BKLP2 R7 M3 R7 C.U. 3 MOW CIRCUIT C.U. 2 S10 OR2 .025 DIA MOW R4 R7 C.U. 6 MSV1 MSV2 BACKLAP OR1 .025 DIA MD1 R7 M5 C.U. 5 R7 BKLP1 M8 R7 R7 R7 M4 C.U. 1 MOW CIRCUIT C.U. 4 R5 G2 P4 BACKLAP S11 R7 M7 P5 R7 C.U.
PAGE 63
Mow and Backlap The reel manifold contains two independent control circuits for the front and rear cutting units. Each circuit is supplied by its own gear pump section. Gear pump section (P1) supplies hydraulic power to the front cutting units, while section (P2) supplies the the rear units. Both circuits share manifold port (T), which drains to the oil cooler, oil filter, and on to the hydraulic reservoir.
PAGE 64
Hydraulic System Page 4 - 22 Reelmaster 6500-D/6700-D 13.
PAGE 65
Right and Left Turns In addition to supplying hydraulic flow to the cutting unit lift circuits, gear pump section (P3) supplies hydraulic flow to the steering control valve for turning the rear wheels. With the the engine running and the steering wheel in the neutral position (rear wheels positioned straight ahead), the spool of the steering control valve is in the center position.
PAGE 66
Special Tools NOTE: Order special tools from your Toro Distributor. Some tools may also be available from a local supplier. Hydraulic Pressure Test Kit - TOR47009 Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings. Contains one each: 1000 PSI (70 Bar), 5000 PSI (350 Bar) and 10000 PSI (700 Bar) gauges.
PAGE 67
Hydraulic Tester - With Pressure and Flow Capabilities - TOR214678 You must have o-ring face seal (ORFS) adapter fittings for this tester to use it on the Reelmaster 6500--D and 6700--D. 4. HIGH PRESSURE GAUGE: High range gauge to accommodate pressure beyond the capacity of the low pressure gauge, 0 - 5,000 PSI. 1. INLET HOSE: Hose connected from the system circuit to the inlet side of the hydraulic tester. 5.
PAGE 68
Troubleshooting The cause of an improperly functioning hydraulic system is best diagnosed with the use of proper testing equipment and a thorough understanding of the complete hydraulic system. A hydraulic system with an excessive increase in heat or noise is a potential failure. Should either of these conditions be noticed, immediately stop the machine, turn off the engine, locate the cause of the trouble, and correct it before allowing the machine to be used again.
PAGE 69
Transmission or Hydraulic System is Operating Hot Cause Correction Oil in reservoir is below level. Fill reservoir to proper level. Contaminated oil. Drain reservoir and refill with clean oil. Oil in system too light. Drain reservoir and refill with proper viscosity oil. Heat exchanger defective. Check oil cooler for obstructed air flow. Charge pressure low. TEST NO. 1. Inspect charge relief valve R5. Repair or replace if defective. Transmission pressure high. Reduce transmission load.
PAGE 70
Transmission Response Sluggish Cause Correction Charge pressure low. TEST NO. 1. Inspect charge relief valve R5. Repair or replace if defective. Servo control valve faulty. Inspect control valve for: Plugged control orifices. Damaged mounting gasket. Misadjusted or damaged neutral return spring. Broken control connector pin. Galled or stuck control spool. Neutral switch misadjusted. Repair or replace control valve if necessary. Towing by-pass valve open. Close valve. Wheel motor(s) worn or damaged.
PAGE 71
Transmission Will Not Operate in Either Direction (Continued) Cause Correction Wheel motor(s) worn or damaged. Inspect wheel motors and repair or replace if worn or damaged. NOTE: If a motor has internal damage, it is likely that the pump and other motor are also damaged. Pump worn or damaged. Inspect pump and repair or replace if worn or damaged. Wheel Motor Turns While Unloaded, But Slows Down or Stops When Load Applied Cause Correction Scored valve plate on wheel motor.
PAGE 72
Excessive Wheel Motor Case Drain Flow Cause Correction Excessive internal wear in wheel motor. Disassemble motor completely. Inspect parts and replace as necessary. Case drain flow should not exceed 2 gal/m (7.6 L/m) at full pressure. Noisy Gear Pump Caused by Cavitation Cause Correction Oil too heavy. Change to proper viscosity oil. Suction line restricted. Check for bent or collapsed suction line. Check suction screen in reservoir for blockage - drain and clean reservoir if necessary.
PAGE 73
Front (Rear) Reels Will Not Turn (Continued) Cause Correction Relief valve R1 (R2) by-passing oil. TEST NO. 3. Adjust relief valve R1 (R2) if necessary. Do cartridge valve service procedure for valve R1 (R2). Replace faulty valve. Solenoid Valve SV10 and/or SV11 not shifting. (Reelmaster 6700-D #6 & #7 cutting units only) Do electrical diagnostics to make sure that voltage is being applied to SV10 and/or SV11 and that there is no electrical fault. See Chapter 5 - Electrical System. Test solenoid coil.
PAGE 74
Front (Rear) Reels Do Not Turn or Turn Too Slow (Continued) Cause Correction Gear pump section P1 (P2) inefficient. TEST NO. 5. Repair or replace pump. Reel motor internal leakage (by-passing oil) or malfunctioning cross-over relief valve in motor. TEST NO. 6 & 7. Repair or replace reel motor. Front (Rear) Reels Turn Too Fast Cause Correction Reel Speed Valve FC1 (FC2) improperly adjusted. Make sure FC1 (FC2) is is set to desired reel speed. Do cartridge valve service procedure for valve FC1 (FC2).
PAGE 75
Front (Rear) Reels Stop Under Load Cause Correction Relief valve R1 (R2) by-passing oil. TEST NO. 3. Adjust relief valve R1 (R2) if necessary. Do cartridge valve service procedure for valve R1 (R2). Replace faulty valve. Gear pump section P1 (P2) inefficient. TEST NO. 5. Repair or replace pump. Reel motor internal leakage (by-passing oil) or malfunctioning cross-over relief valve in motor. TEST NO. 6 & 7. Repair or replace reel motor.
PAGE 76
Cutting Units Will Not Raise (Continued) Cause Correction Engine high idle RPM too low. See Chapter 3 - Kubota Diesel Engine. See Kubota Workshop Manual. Relief valve R3 by-passing oil. TEST NO. 4. Replace faulty valve. Lift arm pivots bindings. Lubricate bushings. Inspect for damage. Repair or replace damaged parts. Electrical problem. See Chapter 5 - Electrical System. Gear pump section P3 inefficient. TEST NO. 4. Repair or replace pump. Lift cylinder(s) have internal leakage.
PAGE 77
Cutting Units Will Not Lower Cause Correction Solenoid Valve SV1 not shifting. Do electrical diagnostics to make sure that voltage is being applied to SV1 and that there is no electrical fault. See Chapter 5 - Electrical System. Test solenoid coil. Replace if faulty. See Chapter 5 Electrical System. Do cartridge valve service procedure for valve SV1. Replace faulty valve. Solenoid valve(s) SV3, SV4, or SV5 not shifting. Solenoid valve(s) SV6 or SV7 not shifting.
PAGE 78
Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks (See the Special Tools section in this Chapter.) Before Performing Hydraulic Tests IMPORTANT: All obvious areas such as oil supply, filter, binding linkages, loose fasteners, or improper adjustments must be checked before assuming that a hydraulic component is the source of the problem.
PAGE 79
TEST NO. 1: Traction Circuit Charge Pressure 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 2. Make sure machine is parked on a level surface with the cutting units lowered and off. Make sure engine is off. CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning of this section. 3. Connect a 1000 PSI gauge onto charge pressure test port (Fig. 13).
PAGE 80
TEST NO. 2: Traction Circuit Pressure 1. Make sure hydraulic oil is at normal operating temperature before doing test. 2. Drive machine to an open area, lower cutting units, and shut off the engine. 2 3. Connect a 10,000 psi gauge to traction circuit test port for function to be checked (Fig. 14). 4. Start the engine and move throttle to full speed (approx. 3200 RPM). 1 CAUTION Prevent personal injury and/or damage to equipment.
PAGE 81
TEST NO. 3: Cutting Unit Drive Circuit Pressure Note: The front cutting unit drive circuit is protected by relief valve R1 and the rear circuit by relief valve R2. See Hydraulic Flow Diagrams at the beginning of this chapter. 2 1 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 2. Make sure machine is parked on a level surface with the cutting units lowered and off. Make sure engine is off. Figure 15 CAUTION 1.
PAGE 82
TEST NO. 4: Gear Pump Section P3 Flow and Relief Valve Pressure (Using Tester with Pressure Gauges and Flow Meter) 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 1 2. Make sure machine is parked on a level surface with the cutting units lowered and off. Make sure engine is off. CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning of this section.
PAGE 83
TEST NO. 5: Gear Pump Section P1 & P2 Flow (Using Tester with Pressure and Flow Capabilities) Over a period of time, the gears and wear plates in the pump can wear. A worn pump will by-pass oil and make the pump less efficient. Eventually, enough oil can bypass to cause the reels to stall in heavy cutting conditions. Continued operation with a worn, inefficient pump can generate excessive heat and cause damage to seals and other components in the hydraulic system. 1 2 1.
PAGE 84
TEST NO. 6: Reel Drive Motor Cross-Over Relief Pressure Use a tee fitting to install pressure gauge in inlet line of motor being tested. NOTE: Inlet is front hose. R7 R7 R7 R7 R7 M4 High Pressure Low Pressure Flow R7 M1 M5 Reel Manifold Block Figure 19 Note: One way to find a bad reel motor is to have another person observe the machine while mowing in dense turf. A bad motor will run slower, produce fewer clippings, and may cause marcelling (or a washboard appearance) on the turf. 1.
PAGE 85
2. Determine which reel motor is malfunctioning. Note: The reel motors are connected in series. To isolate a faulty motor, you may have to test all three motors in the circuit by starting with the upstream motor first. 3. Lower cutting units, engage parking brake and stop the engine. 4. Install a tee fitting between the motor inlet fitting and hose. Install a 5000 PSI pressure gauge on the tee fitting (Fig. 19). 5. Set reel speed control to the full speed position.
PAGE 86
TEST NO. 7: Reel Drive Motor Efficiency (Using Tester with Pressure Gauges and Flow Meter) Outlet hose Case drain hose High Pressure Low Pressure Case Drain Flow R7 R7 R7 Install tester in series between fitting and hose at motor outlet. NOTE: Outlet is rear hose. R7 R7 M4 R7 M1 M5 Disconnect case drain hose (small diameter hose) where it connects to the traction unit. Reel Manifold Block Figure 20 Note: Over a period of time, a reel motor can wear internally.
PAGE 87
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Make sure machine is parked on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged. 3. Read Precautions for Hydraulic Testing. Note: The reel motors are connected in series.
PAGE 88
Adjustments Adjust Manifold Relief Valve (R1 and R2) The hydraulic reel circuit is equipped with a relief valve. Valve (R1) is preset at the factory to 3000 PSI. Valve (R2) on Reelmaster 6500--D is set to 2000 PSI. Valve (R2) on Reelmaster 6700--D is set to 3000 PSI. However, an adjustment may be required if the setting proves to be off after testing (see TESTING). If an adjustment is required proceed as follows: 2 WARNING Never adjust the relief valve with the hydraulic system pressurized.
PAGE 89
Adjust Traction Drive for Neutral The machine must not creep when traction pedal is released. If it does creep, an adjustment is required. 1 1. Park machine on a level surface, shut engine off and lower cutting units to the floor. Depress only the right brake pedal and engage the parking brake. 2. Jack up left side of machine until front tire is off the shop floor. Support machine with jack stands to prevent it from falling accidentally.
PAGE 90
Adjust Cutting Unit Drop Rates (Serial Numbers Below 280000000) The cutting unit lift/lower circuit is equipped with adjustable flow control valves to ensure the cutting units do not drop too quickly and damage the turf. Center (#1), Outside Front (#4 & 5) and Rear (6700-D #6 & 7) Cutting Units (Fig. 23) 1. Locate valve behind access panel above operator’s platform. 1 3 3 2 2. Loosen setscrew on valve and rotate valve approximately 1/2 turn clockwise. 3.
PAGE 91
Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components After Repair or Replacement of Components 1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking brake, lower cutting units or attachments, and stop engine. Remove key from the ignition switch 1. Check oil level in the hydraulic reservoir and add correct oil if necessary.
PAGE 92
Check Hydraulic Lines and Hoses WARNING Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result from such an injury.
PAGE 93
Charge Hydraulic System IMPORTANT: Change hydraulic oil filter whenever hydraulic components are repaired or replaced. 1. Park machine on a level surface, and turn the engine off. 2. Make sure all hydraulic connections, lines, and components are secured tightly. 3. If component failure was severe or the system is contaminated, flush and refill hydraulic system and tank (see Flush Hydraulic System). 4. Make sure hydraulic reservoir is full. Add correct oil if necessary (see Check Hydraulic System Fluid). 5.
PAGE 94
Change Hydraulic Fluid Change hydraulic fluid after every 800 operating hours, in normal conditions. If fluid becomes contaminated, contact your local TORO distributor because the system must be flushed. Contaminated fluid looks milky or black when compared to clean oil. 1 1. Turn engine off and raise hood. 2. Remove drain plug from bottom of reservoir and let hydraulic fluid flow into drain pan (Fig. 25). Reinstall and tighten plug when hydraulic fluid stops draining.
PAGE 95
Replace Hydraulic Oil Filter The hydraulic system filter head is equipped with a service indicator. With the engine running, view the indicator, it should be in the GREEN zone. When the indicator is in the RED zone, the filter element should be changed. IMPORTANT: Use only the Toro replacement filter recommended for this product (see parts catalog or service reference decal on unit). Use of any other filter may void the warranty on some components. 1 2 1.
PAGE 96
Piston Pump (Traction Pump) 20 26 30 54 24 28 27 48 44 9 12 53 56 17 19 49 40 41 35 33 34 5 36 21 38 8 57 32 58 59 45 60 61 37 54 52 56 41 55 22 17 38 42 11 6 10 23 46 47 39 23 7 51 18 14 10 13 23 44 5 25 1 15 2 31 29 3 15 3 4 16 43 Figure 28 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
PAGE 97
Disassembly (Fig. 28) 1. Position the pump into a protected jaw vise, clamping onto the outer portion of the flange, with the cap screws up. Mark the relationship of the working ports (for reassembly identification) to the servo control assembly with a scribe. Remove the four screws (19 & 20). 2. Lift the charge pump adapter assembly (32) straight up off backplate (24) and shaft (25). Remove the outer gerotor (36). 6. Lift backplate straight up off shaft and housing (47).
PAGE 98
Camplate Inspection: Bushing Inspection: ¯ The finish on the piston shoe surfaces of the camplate should show no signs of scoring. ¯ Inspect cradle bushing (23) for contamination embedment within coating of bushing surface coming in contact with camplate. ¯ Inspect camplate bushing (23) surface for wear and surface for coating transfer from bushing. 12. To remove servo piston assembly (7) from housing, start with the four each cap screws and washers (5 & 44) retaining each cover plate (13 & 9). 13.
PAGE 99
8. To assemble cradle assembly, press dowels (46) into cradle and install cradle bushing (23) onto cradle. Install screw (52). and tighten to 14 to 16 in-lbs. (1.6 to 1.8 Nm). 9. Place cradle assembly into housing making sure dowels and cradle are completely seated into housing. Apply Loctite #277 (or equivalent) to the end of threads and install two cap screws (18). Tighten cap screws to 25 to 28 ft-lbs. (34 to 38 Nm). 10.
PAGE 100
Servo Control 1 2 3 4 5 4 14 6 10 15 13 7 12 9 11 8 16 24 17 23 22 18 21 20 19 Figure 33 1. 2. 3. 4. 5. 6. 7. 8. Plug O-ring Retaining Ring Spring Retainer Spring Spool Valve Control Housing Input Shaft 9. 10. 11. 12. 13. 14. 15. 16. O-ring Wiper Seal O-ring Adapter Ball Pin Neutral Lockout Switch O-ring 17. 18. 19. 20. 21. 22. 23. 24. Set Screw Set Screw Pin Retaining Ring Link Dowel Pin Bell Crank Set Screw Disassembly (Fig. 33) Assembly (Fig. 33) 1.
PAGE 101
5. Apply Loctite #242 or equivalent to set screw (18) and install. Adjust set screw until it bottoms out on input shaft then back out one-quarter turn. 6. Install wiper seal (10) on input shaft. 7. Install new O-ring (2) onto plug (1) and install plug. Adjust plug until there is no play in the valve spool with input shaft held stationary. Install set screw (24) and tighten to 17 to 25 in-lbs. (2 to 3 Nm). Neutral Lockout Switch Disassembly 1.
PAGE 102
Gear Pump 9 7 6 8 10 5 4 11 3 12 2 1 20 13 14 15 16 21 22 23 19 18 17 30 24 25 27 26 29 28 Figure 35 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. O-ring Front Body Drive Gear Assembly Wearplate Balance Pressure Seal Backup Gasket Plug Front Plate Assembly Copper Washer Screw Hydraulic System 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Shaft Seal Washer Idler Gear Assembly Key Gear Middle Body Gear Idler Gear Key Front Adapter Plate Page 4 - 60 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.
PAGE 103
Repair Information Work in a clean area, cleanliness is extremely important when repairing hydraulic pumps. Before disconnecting the lines, clean port area of pump. Disconnect hydraulic lines, removing pump assembly from vehicle and plug ports. Thoroughly clean the outside of pump. After cleaning then remove port plugs and drain oil. Disassembly (Fig. 35) 1. Scribe a line, at an angle, across front plate (8), bodies (2, 16, 25), adapter plates (20, 21) and backplate (30). This will assure proper reassembly.
PAGE 104
Front Plate, Backplate and Adapter Plates Inspection Note: The small half moon port cavity must be on the pressure side of pump. 1. Oil groove in bushings in front plate, backplate and adapter plates should be in line with dowel pin holes and 180 degrees apart. This positions the oil grooves closest to respective dowel pin holes. 7. Place wear plate (4) on top of backup gasket (6) with bronze face up. The side with the mid section cut away must be on suction side of pump. 2.
PAGE 105
Reelmaster 6500-D/6700-D Page 4 - 63 Hydraulic System This page is intentionally blank.
PAGE 106
Wheel Motor 7 4 8 5 9 6 5 4 3 1 10 2 11 12 13 14 15 16 17 18 19 Figure 36 1. 2. 3. 4. 5. 6. 7. Retaining Ring Shaft Seal Washer Retaining Ring Thrust Race Thrust Bearing Splined Drive Shaft 8. 9. 10. 11. Screw Backplate Assembly O-ring Speed Pickup Sensor (RH wheel motor only) 12. Dowel Pin 13. Dowel Pin Cleanliness is extremely important when repairing these motors. Work in a clean area. Before disconnecting the lines, clean port area of motor.
PAGE 107
2. Inspect valve plate (15) on the bronze side next to the piston block for wear. A smooth surface is required. Do not lap valve plate bronze surface. Replace valve plate if any wear exists. 0.173 in (4.39 mm) 0.090 in (2.30 mm) 3. Inspect the piston block surface that makes contact with valve plate. This surface should be smooth and free of deep scratches. Do not lap piston block. 4. The pistons should move freely in the piston block bore.
PAGE 108
4WD Rear Axle Motor 19 20 5 5 6 4 7 4 21 19 8 3 18 9 2 1 18 10 11 12 13 14 15 16 17 Figure 38 1. 2. 3. 4. 5. 6. 7. Retaining Ring Spacer Shaft Retaining Ring Thrust Race Thrust Bearing Screw 8. 9. 10. 11. 12. 13. 14. Backplate Assembly O-ring Dowel Pin Dowel Pin Needle Bearing Valve Plate Rotating Kit 15. 16. 17. 18. 19. 20. 21.
PAGE 109
Inspection 1. Check the condition of the needle bearing (12) in backplate (8) and replace if necessary. 0.173 in (4.39 mm) 0.090 in (2.30 mm) 2. Inspect valve plate (13) on the bronze side next to the piston block for wear. A smooth surface is required. Do not lap valve plate bronze surface. Replace valve plate if any wear exists. 3. Inspect the piston block surface that makes contact with valve plate. This surface should be smooth and free of deep scratches. Do not lap piston block. 5. Examine the O.D.
PAGE 110
Reel Motor (Barnes) 1 2 3 4 12 5 6 11 40 to 45 ft--lb (54 to 61 N--m) 10 9 Use seal protector tool TOR4072 when inserting shaft through seal. 7 NOTE: Seal protector tool is part of TOR4070 Cutting Unit Tool Kit shown in Chapter 7 Cutting Units. 8 5 13 4 Figure 40 1. 2. 3. 4. 5. Retaining Ring Shaft Seal Flange E-Seal O-ring 6. 7. 8. 9. Dowel Pin Valve Block Adjusting Valve Rear Bearing Block 10. 11. 12. 13. Drive Gear Gear Housing Front Bearing Block Idler Gear Removal 1.
PAGE 111
Adjusting Valve (Cross-over Relief Valve) Service 10.Remove idler gear. Note: The adjusting valve (#8 Fig. 40) must be replaced as a complete assembly. Disassemble parts for cleaning and inspection only. 11. Remove drive gear and shaft slowly until drive end is through shaft seal. 12.Remove front bearing block. 2. Inspect adjusting valve bore and seat in valve block. 13.Wash all parts in cleaning solvent. Check all parts for burrs, scoring, nicks and other damage.
PAGE 112
Assembly (Fig. 40) 7. Carefully install gear housing over rear bearing block and slide gear housing down over the gears and front bearing block. Make sure the markings put on the flange and housing earlier line up. 1. Put flange on a flat surface with shaft seal facing down. Make sure back side of flange is free of contamination. 8. The rear bearing block should sit just below back face of gear housing.
PAGE 113
1. Plug motor ports and clean the outside of the motor thoroughly. After cleaning, remove plugs and drain any oil out of the motor. 2. Use a marker to make a diagonal line across the front flange, body and rear cover to allow correct component alignment during assembly. IMPORTANT: Avoid using excessive clamping pressure on the motor flange to prevent damage. 3. Clamp front flange of motor in a vise with the shaft end down. Use of a vise with soft jaws is recommended. 4.
PAGE 114
Hydraulic Control Manifolds 13 21 11 8 32 10 23 29 19 12 9 28 14 22 18 20 24 2 4 1 21 25 20 19 3 21 5 13 11 9 10 7 5 12 19 28 20 17 14 6 29 15 16 30 26 31 27 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Straight Hydraulic Fitting O-ring O-ring Hydraulic Tube 90_ Hydraulic Fitting O-ring O-ring Control Manifold Flat Washer Safety Switch Test Port Fitting 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
PAGE 115
Reelmaster 6700-D Only 31 26 27 30 33 42 32 34 30 30 31 30 33 31 31 43 26 31 34 44 30 31 17 31 31 29 30 27 21 29 31 18 11 29 30 8 6 22 31 10 37 35 26 16 15 17 3 7 17 5 24 20 15 16 39 25 38 10 12 13 40 94 36 30 1 19 20 27 31 28 19 31 29 41 23 18 20 26 30 15 9 4 16 Hydraulic System 14 18 45 34 31 23 19 30 30 34 31 27 2 Figure 44 (Lift Manifold) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
PAGE 116
Hydraulic Control Manifold Service 21 24 20 4 23 6 28 22 5 12 30 3 33 32 29 2 to 5 ft--lb (2.7 to 6.8 N--m) 26 25 27 38 7 35 34 36 31 37 11 10 Loctite 242 R2 FC2 9 MD2 R1 7 MS2 8 Backlap 55 to 60 ft--lb (75 to 81 N--m) FC1 P2 10 P1 3 15 Reel Speed 45 ft--lb (61 N--m) 45 ft--lb (61 N--m) MS1 MD1 G1 13 LC1 14 2 1 19 17 18 16 Figure 45 (Reel Manifold For Units With Serial No. Below 260000500) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
PAGE 117
20 48 to 60 in--lb (5.4 to 6.7 N--m) 6 23 21 5 23 24 25 ft--lb (33 N--m) 22 4 19 3 7 35 ft--lb (47 N--m) 41 ft--lb (55 N--m) 2 1 8 23 21 198 in--lb (22 N--m) 9 18 20 10 11 12 15 ft--lb (20 N--m) 16 13 20 ft--lb (27 N--m) 14 15 165 in--lb (18.6 N--m) 25 ft--lb (33 N--m) Figure 47 (Reel Manifold For Units With Serial No. Above 260000500) 1. 2. 3. 4. 5. 6. 7. 8.
PAGE 118
50 to 55 in--lb (5.7 to 6.2 N--m) 8 15 15 7 5 Loctite 242 16 6 4 5 3 30 to 35 ft--lb (41 to 47 N--m) 1 30 to 35 ft--lb (41 to 47 N--m) 2 SV5 30 to 35 ft--lb (41 to 47 N--m) SV8 SV4 13 SV3 14 SV1 SV2 10 9 P1 12 11 Figure 48 (Lift Manifold For Units With Serial No. Below 280000000 (RM6500--D Shown)) 1. Plug (unit serial no. 210000001 219999999) 2. Cartridge Valve (4 way) 3. Seal Kit 4. Cartridge Valve (N.O.) 5. Seal Kit 6. 7. 8. 9. 10. 11. Cartridge Valve (N.C.
PAGE 119
25 ft--lb (33 N--m) 2 15 9 9 9 13 48 to 60 in--lb (5.4 to 6.7 N--m) 16 9 9 2 4 10 7 20 ft--lb (27 N--m) 6 5 4 4 25 ft--lb (33 N--m) 20 ft--lb (27 N--m) 8 20 ft--lb (27 N--m) 12 11 3 1 14 12 UP Figure 49 (Lift Manifold For RM6500--D Units With Serial No. Above 280000000) 1. 2. 3. 4. 5. 6. Lift manifold block Nut NWD--6 plug Solenoid blocking valve (4 used) Solenoid valve (S3) Solenoid valve (S1) 7. 8. 9. 10. 11.
PAGE 120
20 ft--lb (27 N--m) 25 ft--lb (33 N--m) 20 ft--lb (27 N--m) 48 to 60 in--lb (5.4 to 6.7 N--m) 6 9 2 5 2 1 48 to 60 in--lb (5.4 to 6.7 N--m) 16 2 8 2 20 ft--lb (27 N--m) 13 3 2 25 ft--lb (33 N--m) 25 ft--lb (33 N--m) 4 12 5 7 20 ft--lb (27 N--m) 9 10 11 10 ft--lb (14 N--m) 14 11 6 25 ft--lb (33 N--m) 10 15 UP 10 ft--lb (14 N--m) 11 Figure 50 (Lift Manifold For RM6700--D Units With Serial No. Above 280000000) 1. 2. 3. 4. 5. 6.
PAGE 121
1. Make sure the manifold is clean before removing the cartridge valve and seal kit. Note: Solenoid valves used in mow manifold (Fig. 45) and lift manifold (Fig. 47) have an O--ring on each side of coil. 6. Reinstall the cartridge valve: A. Lubricate new O-rings and backup rings of seal kit with clean hydraulic oil and install. The O-ring and backup ring must be arranged properly on the cartridge valve for proper operation and sealing. B. Thread spool valve carefully into port.
PAGE 122
3. Make sure manifold is clean before removing the cartridge valve. Remove the valve and seal kit. 4. Visually inspect the manifold port and cartridge valve for damage to sealing surfaces, damaged threads, and contamination. 8 2 6 A. Contamination may cause valves to stick or hang up, it can become lodged in small valve orifices or seal areas causing malfunction. 9 10 11 4 B. If sealing surfaces appear pitted or damaged, the hydraulic system may be overheating or there may be water in the system.
PAGE 123
A. Place handle base on flow control valve and position alignment mark on base with number 1 on manifold. Secure base with two (2) set screws. Apply a light coating of grease to chamfer on top of base to ease seal installation. B. Make sure that sleeve bearing is in handle cap. If necessary, press sleeve bearing into cap. Install lip seal on cap with seal lip facing down. C. Place bushing onto cartridge valve stem. Use a small amount of grease to keep bushing toward the top of the valve stem. D.
PAGE 124
Lift Cylinders Removal and Installation 7 1. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 3 2. Disconnect hydraulic hoses from lift cylinder. 3. Remove/install lift cylinders. 5 6 4 Front Center (#1) 2 1 A. Remove retaining ring from the cylinder rod end pin. Remove cylinder pin with remaining retaining ring and thrust washers from the lift arm and cylinder clevis (Fig. 49). B.
PAGE 125
Rear (6700-D #6 or 7 Only) A. Remove both lock nuts and upper link plate. Remove upper link and rollers from the lift arm and cylinder clevis (Fig. 52). 4 B. Remove retaining ring from the cylinder cap end pin. Remove cylinder pin with remaining retaining ring from the frame and cylinder clevis (Fig. 52). 1 C. Install in reverse order. Use a drop of medium strength thread locking compound to secure the lock nuts. 5 2 6 3 8 7 8 Figure 52 Lock Nut Upper Link Plate Upper Link Roller 5. 6. 7. 8.
PAGE 126
Lift Cylinder Service 13 1 FRONT CENTER LIFT CYLINDER #1 2 4 5 3 7 8 6 9 FRONT LEFT AND FRONT RIGHT LIFT CYLINDER #4 & 5 10 13 11 1 12 REAR LIFT CYLINDER #2 & 3 2 4 13 5 3 1 2 3 4 13 7 8 6 9 10 5 11 6 1 7 8 12 9 10 11 2 4 REAR LIFT CYLINDER (6700-D #6 & 7 ONLY) 12 5 3 7 8 6 9 10 11 12 1. 2. 3. 4. Barrel with Clevis Nut Uni-ring Piston Hydraulic System 5. 6. 7. 8. 9. Figure 53 O-ring Rod Seal O-ring Back-up Ring Head Page 4 - 82 10. 11. 12. 13.
PAGE 127
Disassembly (Fig. 53) Assembly (Fig. 53) 1. Remove oil from lift cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder. 1. Make sure all parts are clean before Assembly. IMPORTANT: Prevent damage when clamping the cylinder’s barrel into a vise; clamp on the clevis only. Do not close vise enough to distort the barrel. 2. Mount lift cylinder into a vice. Remove collar with a spanner wrench. 3.
PAGE 128
Steering Cylinder (2WD) 4 11 12 7 2 6 10 9 8 3 5 1 1. 2. 3. 4. Barrel with Clevis Piston Rod Piston Gland Hydraulic System 5. 6. 7. 8. Figure 54 Nut Retaining Ring Dust Seal Uni--ring Page 4 - 84 Rev. E 9. 10. 11. 12.
PAGE 129
Disassembly (Fig. 54) 7. Remove piston. IMPORTANT: Prevent damage when clamping the cylinder’s barrel into a vise; clamp on the clevis only. Do not close vise enough to distort the barrel. 8. Remove all seals and O-rings. 1. After removing cylinder, pump oil out of cylinder into a drain pan by SLOWLY moving rod and piston in and out of cylinder bore. 2. Plug ports and clean outside of cylinder. 3. Mount cylinder in a vise so piston rod end of cylinder is tilted up slightly.
PAGE 130
Steering Cylinder (4WD) 9 8 7 2 3 4 10 5 6 11 1 1. 2. 3. 4. Barrel with Clevis PTFE Seal O-ring Piston Hydraulic System 5. 6. 7. 8. O-ring U-cup Gland Wiper Figure 55 Page 4 - 86 Rev. D 9. Piston Rod Assembly 10. O-ring 11.
PAGE 131
Disassembly (Fig. 55) 5. Remove all seals and O-rings. IMPORTANT: Prevent damage when clamping the cylinder’s barrel into a vise; clamp on the clevis only. Do not close vise enough to distort the barrel. 6. Wash part in a safe solvent. Dry parts with compressed air. DO NOT wipe them dry with a cloth or paper as lint and dirt may remain. 1. After removing cylinder, pump oil out of cylinder into a drain pan by SLOWLY moving rod and piston in and out of cylinder bore.
PAGE 132
Power Steering The ReelmasterR 6500-D/6700 is equipped with power steering. The power steering valve is enclosed in the steering tower at the front of the traction unit. As the steering wheel is turned, the steering valve meters hydraulic fluid to the double-acting steering cylinder on the rear axle and turns the wheels. Hydraulic fluid flow for power steering is supplied by section P3 of the hydraulic pump. The steering section of the pump has a built-in relief valve.
PAGE 133
Steering Valve Removal (Figs. 57 and 58) 3 1. Engage the parking brakes, lower the cutting units to the ground, turn the engine OFF and remove the key from the ignition switch. 4 1 2. Remove the front center cutting unit (see Chapter 7-Cutting Units in this manual). 2 3. Remove cap screws and cover from steering tower. 4. Clean outside of the steering valve and the area around the hydraulic fittings. Disconnect hydraulic lines from steering valve (Fig. 58).
PAGE 134
Steering Valve Service Figure 59 Disassembly Note: Cleanliness is extremely important when repairing steering control units. Work in a clean area. Before disconnecting the hydraulic lines, clean the port area of the steering control unit. Before disassembly, drain the oil, then plug the ports and thoroughly clean the exterior. During repairs, always protect machined surfaces. 1. Remove the seven capscrews and disassemble the steering control unit as shown (Fig. 59). 6.
PAGE 135
Figure 60 Assembly Hydraulic System Check all mating surfaces. Replace any parts with scratches or burrs that could cause leakage. Wash all metal parts in clean solvent. Blow them dry with pressurized air. Do not wipe parts dry with paper towels or cloth. Lint in a hydraulic system will cause damage. Note: Always use new seals when reassembling the steering control unit. IMPORTANT: During reassembly, lubricate the new seals with petroleum jelly.
PAGE 136
3. Install the centering springs in the spool (Fig. 61). It is best to install the two flat pieces first. Next, install the curved pieces, three at a time. 4. Fit the retaining ring over the centering springs. 5. Apply a light coating of clean hydraulic fluid to the spool and slide it into the sleeve. Be sure the centering springs fit into the notches in the sleeve. 6. Install the pin. 7. Apply a light coating of petroleum jelly to the inner edge of the dust and quad seals. Figure 63 8.
PAGE 137
Solenoid Valve SV10 and SV11 Service (RM 6700-D Only) Removal 2 Note: Solenoid valves SV10 and SV11 provide oil flow to the reel motors of cutting units #6 & 7 (see Hydraulic Schematics and Flow Diagrams in this section of this manual). 6 5 4 1 3 Note: Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 2. Disconnect the electrical connector from the solenoid valve. 3.
PAGE 138
Hydraulic Reservoir 5 7 4 8 6 9 1 2 3 10 28 29 12 11 13 14 21 19 20 24 23 30 11 15 18 17 Thread Sealant 31 16 22 35 33 39 37 34 26 41 38 34 25 27 40 32 36 30 to 60 in--lb (3.4 to 6.8 N--m) Never Seez In Engine Compartment Figure 65 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Hydraulic Reservoir Gasket Tank Cover Breather Adapter Tank Breather Capscrew Reservoir Cap O-ring Dipstick Filler Screen O-ring Hydraulic Tube O-ring Tee Hydraulic Fitting Hydraulic System 15. 16.
PAGE 139
Removal (Fig. 65) Installation (Fig. 65) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1. Install reservoir. Note: The electrical harness does not have to be disconnected to remove the right fender and control console from the frame. 2. Remove right fender with control console attached enough to allow removal of the hydraulic reservoir. 3. Drain reservoir into a suitable container (see Change Hydraulic Fluid). 4.
PAGE 140
Hydraulic Oil Cooler Removal (Fig. 66) 1 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2 CAUTION The radiator and oil cooler may be hot. To avoid possible burns, allow the engine and cooling systems to cool before working on the oil cooler. 3 8 4 2. Unlatch and remove rear screen. 6 3. Unscrew knobs and pivot oil cooler rearward. 7 4. Mark and disconnect the hydraulic hoses at the oil cooler. 3 5 5.
PAGE 141
Chapter 5 Electrical System Table of Contents Reelmaster 6500-D/6700-D Run (ETR) Solenoid (Solenoid With 3 Wire Connector) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Run (ETR) Solenoid (Solenoid With 2 Wire Connector) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Gauge Sender . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature Sender . . . . . . . . . . . . . . . . . . . . . .
PAGE 142
Special Tools Order special tools from your Toro Distributor. Some tools may be listed in the Parts Catalog for the Reelmaster 6500-D or 6700-D. Some tools may also be available from a local supplier. Digital Multimeter The meter can test electrical components and circuits for current, resistance, or voltage drop. NOTE: Toro recommends the use of a DIGITAL multimeter when testing electrical circuits.
PAGE 143
Toro Automated Control Electronicst Diagnostic Tools Diagnostic ACEt Display The diagnostic display is connected to the wiring harness connector located inside the control console to help the user verfiy correct electrical functions of the machine (Fig. 3 and 4). Overlay Diagnostic ACE Display ACE Display (Toro Part No. 85-4750) Note: ACE diagnostic display overlays may vary with specific unit model and serial numbers. Always use the overlay(s) supplied with your RM 6500-D/6700-D.
PAGE 144
Troubleshooting CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage. For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components used on this machine (see Electrical Schematics and Wire Harness and Electrical Connector Drawings in Chapter 8 -- Electrical Drawings).
PAGE 145
Fault Identification/Operator Warning: S Alerts operator to several potential problems with audible “beeps” and/or by cutting unit shut down. Diagnostics: S Do troubleshooting by connecting one of the following devices to the loopback connector: - Diagnostic ACE (with the correct overlay). - TOROPC and a personal computer (authorized Toro distributor only). Understanding the Diagnostic Lamps Red Diagnostic Lamp (located on steering tower) Functions: S ON - When glow plug circuit is energized.
PAGE 146
Using the ACEt Diagnostic Display The primary electronic controller controls most machine functions. The controller determines what function is required for various input switches (i.e. seat sensor, key switch, etc.) and energizes the outputs to actuate solenoids or relays for the requested machine function. 1 For the electronic controller to control the machine as desired, each of the inputs, outputs must be connected and functioning properly.
PAGE 147
B. The Diagnostic ACE will illuminate the LED associated with each of the inputs when that input switch is closed. Individually, change each of the switches from open to closed (i.e., sit on seat, engage traction pedal, etc.), and note that the appropriate LED on Diagnostic ACE will blink on and off when corresponding switch is closed. Repeat on each switch that is possible to be changed by hand. C.
PAGE 148
IMPORTANT: The display will show eight (8) individual records with the fault displayed on the 8th record. Each record will be displayed for 10 seconds. Be sure to have the Diagnostic Tool display on Outputs to see fault. The Problem circuit will be flashing. Records will repeat until key is turned off. Unit will not start in this mode. Clearing the Fault Memory (Diagnostic Tool not required) 1. Rotate ignition key to Off position. 2. Turn Backlap Switch to the Front or Rear Backlap position. 3.
PAGE 149
Note: See Leak Detector Troubleshooting Guide in this section of this manual for additional information. S Alarm short circuit (LED blinking): Check/replace TurfDefender alarm or wires. 1. Park machine on a level surface and engage the parking brake. 1 2. Open control panel cover. Locate leak detector harness loopback connector with hydraulic symbol tag. Carefully unplug loopback connector from harness connector. 4. The ignition key switch must be turned to the “ON” position.
PAGE 150
Note: If machine must be operable with leak detector disabled, unplug leak detector 4--pin connector from 4--pin connector of main harness. Do not unplug leak detector alarm. Note: The system will reset itself whenever the ignition key is turned to “OFF” position. The hand held Diagnostic ACE must be connected and observed during a false alarm. Once the ignition key is turned to “OFF” position, the TurfDefender will reset itself. If false alarms are observed: 1.
PAGE 151
1 Diagnostic ACE Display Functions 1. 2. 3. 4. 2 3 Overlay decal (English shown) “Inputs Displayed” LED (Red) “Outputs Displayed” LED (Green) Toggle button 4 Figure 13 Using “Inputs Displayed” (Red Text) 1 5 LED lit if oil level is too high LED lit if oil level is OK LED lit if oil level is too low LED lit if slow leak detected Target oil level - Cold oil & cutting units raised 6.
PAGE 152
Leak Detector Troubleshooting Guide The following is a quick guide to the most common problems likely to be encountered.
PAGE 153
Starting Problems Problem Possible Causes All electrical power is dead, including gauges. The battery charge is low. The ignition switch or circuit wiring is faulty. The fusible link from the battery is faulty. The 20 ampere fuse to the ignition switch is open. Starter solenoid clicks, but starter will not crank. Low battery charge. Note: If the solenoid clicks, the problem is not in the Loose or corroded battery cables. interlock circuit wiring or the ECU. Loose or corroded ground.
PAGE 154
General Run and Transport Problems Problem Possible Causes Engine continues to run, but should not, when the ignition switch is turned off. The engine run (ETR) solenoid is stuck open. Engine continues to run, but should not, when the traction pedal is engaged with no operator in the seat. The seat sensor or circuit wiring is faulty. The engine stops during operation, but is able to restart. The parking brake is engaged. Ignition switch or circuit wiring is faulty.
PAGE 155
Cutting Unit Operating Problems Problem Possible Causes The cutting units remain engaged, but should not, with no operator in the seat. The seat sensor or circuit wiring is faulty. Cutting units run, but should not, when raised. Units shut off with enable disable switch. The front reels down sensor or circuit wiring is faulty. Cutting units run, but should not, when raised. Units do Both the front reels down sensor or circuit wiring, and not shut off with the enable disable switch.
PAGE 156
Cutting Unit Operating Problems (Continued) Problem Possible Causes None of the cutting units will raise. Raise switch on joystick or circuit wiring is faulty. Solenoid SV1 or circuit wiring is faulty. Solenoid SV2 or circuit wiring is faulty. A hydraulic problem exists (see Troubleshooting section of Chapter 4 - Hydraulic System). Front center cutting unit #1 will not raise or lower, but the other cutting units will raise and lower. Solenoid SV3 or circuit wiring is faulty.
PAGE 157
Electrical System Quick Checks Battery Test (Open Circuit Test) This is a simple test used to determine the condition of the battery at rest. Tool required: Digital Multimeter - DC volts setting. Test instructions: Set the multimeter to the DC Volts setting. The battery should be at a temperature of 60_ to 100_ F. The ignition key should be off and all accessories turned off.
PAGE 158
Glow Plug System Test This is a fast, simple test that can help you determine a Glow Plug system’s integrity and operation. The test should be run anytime hard starting (cold) is encountered on a diesel engine equipped with a Glow system. Remember - there are 2 types of Glow Plug systems that Toro uses: 1. Systems with resistors (Glow Plug Indicators) in series (Reelmaster 450/4500-D, Groundsmaster 325-D, etc.). 2.
PAGE 159
Component Testing For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before doing a continuity check). NOTE: For more component testing information, see the Kubota Workshop Manual, Diesel Engine, 05 Series at the end of Chapter 3 - Kubota Diesel Engines.
PAGE 160
Glow and Start Relays The glow relay and the start relay are mounted to the right side frame member below the operator’s seat. Note: Prior to taking small resistance readings with a digital multi meter, short the test leads together. The meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal resistance of the meter and test leads. Subtract this value from from the measured value of the component you are testing.
PAGE 161
Fuses The fuse blocks are located under the control panel and inside the control console. 1 Identification, Function, and Wiring The fuses are held in two fuse blocks. Use Figure 20 to identify each individual fuse and its correct amperage. Each fuse holder has the following functions and wire connected to it. 2 Fuse 1A A. Supplies power to Primary Electronic Controller terminals 1L and 1M. B. Has blue/white wire (1L), green/black wire (1M) and red wire (battery). Figure 19 1. Fuse block A 2.
PAGE 162
Hydraulic Valve Solenoids These solenoids can be tested using the “Output Checks” feature of the ACE Diagnostic tool. 1 2 The solenoids can also be tested manually. Note: Prior to taking small resistance readings with a digital multimeter, short the test leads together. The meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal resistance of the meter and test leads. Subtract this value from the measured value of the component you are testing. 1.
PAGE 163
High Temperature Warning and Shutdown Switch The high temperature warning and shut down switch is located on the right side of the water flange that is attached to the front of the engine cylinder head. There is a green/white wire attached to the switch (Fig. 23). 2 1 CAUTION Make sure engine is cool before removing the temperature switch. 1. Lower coolant level in the engine and remove the temperature switch. 2. Put switch in a container of oil with a thermometer and slowly heat the oil (Fig. 24).
PAGE 164
Warning Light Cluster Note: Individual light bulbs can be tested by removing them from the lighting cluster and applying 14 VDC to their wiring terminals. 1 2 3 4 Testing Cluster Removed from Connector. 1. Apply 14 VDC to pin D. 5 2. Ground pins F, A, and E. 3. Lamps 1, 2, and 3 should light. 4. Apply 14 VDC to pin B. 2 1 5. Ground pin C. 6. Lamp 4 should light. 6 Oil Pressure Light The oil pressure light should come on when the ignition switch is in the ON position with the engine not running.
PAGE 165
Run (ETR) Solenoid (Solenoid With 3 Wire Connector) The solenoid must be energized for the engine to run. It is mounted on the engine block near the injection pump. 1 In Place Testing Note: Prior to taking small resistance readings with a digital multimeter, short the test leads together. The meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal resistance of the meter and test leads.
PAGE 166
Run (ETR) Solenoid (Solenoid With 2 Wire Connector) The run (ETR) solenoid must be energized for the engine to run. It is mounted on the engine block near the injection pump. 2 1 In Place Testing Note: Prior to taking small resistance readings with a digital multimeter, short the test leads together. The meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal resistance of the meter and test leads.
PAGE 167
Fuel Gauge Sender The sender is located on top of the fuel tank under the right, front fender. 1. Remove blue/green wire and black ground wire from the sender. 2 2. Remove round head screws and lock washers from the sender and fuel tank. 3. Remove sender and gasket from the fuel tank. Clean any fuel from the sender. Note: Before taking small resistance readings with a digital multimeter, short test leads together. The meter will display a small resistance value.
PAGE 168
Fuel Gauge The fuel gauge can be tested using a new gauge as a substitute or by the use of a DC voltage source and a variable resistance box. CAUTION Make sure the voltage source is turned OFF before connecting it to the electrical circuit to avoid electrical shock and prevent damaging the gauge. VARIABLE RESISTANCE 14 VDC + 0.01 VDC 1. Connect fuel gauge to the variable resistance and DC voltage source (Fig. 33).
PAGE 169
Temperature Sender The sender is located on the left side of the water flange that is attached to the front of the engine cylinder head. There is a blue/white wire attached to the terminal of the switch (Fig. 35). 1 1. Lower coolant level in the engine and remove the high temperature sender. 2. Put switch in a container of oil with a thermometer and slowly heat the oil (Fig. 36). 2 CAUTION Handle the hot oil with extreme care to prevent personal injury or fire. Figure 35 1. Temperature sender 2.
PAGE 170
Temperature Gauge The temperature gauge can be tested using a new gauge as a substitute or by the use of a DC voltage source and a variable resistance box. CAUTION Make sure the voltage source is turned OFF before connecting it to the electrical circuit to avoid electrical shock and prevent damaging the gauge. VARIABLE RESISTANCE 14 VDC + 0.01 VDC 1. Connect temperature gauge to the variable resistance and DC voltage source (Fig. 37).
PAGE 171
Hour Meter The meter is either located on the control panel or under the control panel inside the control console. Hobbs 1. Connect the positive (+) terminal of a 12 VDC source to the positive terminal of the hour meter. QUARTZ 00001 HOURS 2. Connect the negative (-) terminal of the voltage source to the other terminal of the hour meter. 1 10 + 3. The hour meter should move a 1/10 of an hour in six minutes. 4. Disconnect voltage source from the hour meter.
PAGE 172
Engine Low Oil Pressure Switch The switch is normally closed (NC) and opens with pressure. The switch opens at approximately 8 psi. 1. Turn ignition key switch ON. Oil pressure lamp should be on. 1 If lamp is not on: 1. Disconnect wire from switch and touch wire to a good ground, such as the engine block. Figure 41 2. If lamp comes on, replace switch. (shown with muffler removed) 3. If lamp does not come on check wiring between lamp and switch for continuity. 1. Engine oil low pressure switch 3.
PAGE 173
Speedometer The speedometer can be tested using a DC pulse generator. 2 1 CAUTION 3 Make sure the voltage source is turned OFF before connecting it to the electrical circuit to avoid electrical shock and prevent damaging the gauge. Pulse Generator 14 VDC + 0.01 VDC 1. Connect speedometer to the pulse generator and DC voltage source (Fig. 43). 14 VDC + 0.01 VDC 2. Take test point readings. A. Set generator to 325.2 Hertz. Apply signal to circuit. The needle should point to 4 MPH. B.
PAGE 174
Reel Backlap Switches The front and rear backlap switches are attached to the reel hydraulic manifold block (Fig. 45). When the backlap control valve (MD1 or MD2) is in the Backlap position, the switch contacts close. This feature allows only one person to backlap any of the reels. The backlap switch circuit also prevents reels from raising during backlapping. When the backlap control valve (MD1 or MD2) is in the Mow position, the switch contacts open.
PAGE 175
Seat Sensor The sensor consists of two parts. The reed switch is located on the lower bracket of the seat suspension mechanism and has a normally open contact. The switch actuator is located on the upper plate of the seat suspension mechanism and is made of a magnetic material. When the operator sits in the seat, the magnetic field of the actuator is positioned near the reed switch and the contact in the switch closes.
PAGE 176
Cutting Unit Down Sensor(s) The cutting unit down switch is a normally open (NO) reed switch located on the left front lift arm that closes when the lift arm is in the lowered position. As the lift arm is lowered, a bracket on the lift arm comes close to the switch, causing the reed switch to close and complete the circuit. This sensor can be tested using the “Input Checks” feature of the ACE Diagnostic tool. 1 The sensor can also be tested manually. 1.
PAGE 177
Service and Repairs NOTE: For more component repair information, see the Kubota Workshop Manual, Diesel Engine, 05 Series at the end of Chapter 3 - Kubota Diesel Engines. Battery Storage If the machine will be stored for more than 30 days 1. Remove the battery and charge it fully (see Battery Service). 2. Either store battery on a shelf or on the machine. 4. Store battery in a cool atmosphere to avoid quick deterioration of the battery charge. 5.
PAGE 178
Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extend. Additionally, battery and electrical component failure can be prevented. Inspection, Maintenance, and Testing 1. Perform following inspections and maintenance: A. Check for cracks. Replace battery if cracked or leaking. CAUTION B. Check battery terminal posts for corrosion. Use wire brush to clean corrosion from posts.
PAGE 179
C. If the difference between the highest and lowest cell specific gravity is 0.050 or greater or the lowest cell specific gravity is less than 1.225, charge the battery. Charge at the recommended rate and time given in Charging or until all cells specific gravity is 1.225 or greater with the difference in specific gravity between the highest and lowest cell less than 0.050. If these charging conditions can not be met, replace the battery. Minimum Voltage 3.
PAGE 180
Charging To minimize possible damage to the battery and allow the battery to be fully charged, the slow charging method is presented here. This charging method can be accomplished with a constant current battery charger which is available in most shops. Battery Reserve Capacity (Minutes) 75% 50% 25% 0% 80 or less 3.8 hrs @ 3 amps 7.5 hrs @ 3 amps 11.3 hrs @ 3 amps 15 hrs @ 3 amps 81 to 125 5.3 hrs @ 4 amps 10.5 hrs @ 4 amps 15.8 hrs @ 4 amps 21 hrs @ 4 amps 126 to 170 5.
PAGE 181
Speedometer Sensor Replacement 1. Thread locknut onto speed sensor to allow full exposure of sensor threads. 1 2. Center a motor piston with the center of the sensor port (see Sensor Port View in Figure 52 below). NOTE: Use a suitable tool to feel when a motor piston is in the center of the sensor port. 3. Lubricate O-ring on sensor. 4. Thread sensor into port until sensor contacts piston. Motor output shaft must rotate freely 360o. 5.
PAGE 182
Installing Optional Lighting (customer supplied) IMPORTANT: If optional lighting is to be added to the traction unit, use the following schematic and part numbers to prevent damage to the traction unit’s electrical system. Installation Instructions 1. Install a relay into the open connector under the control console. Relay = Toro #70-1480 (Hella #87411 B) 2. Install the light switch. Note: A punch out is provided in the control console for light switch installation. 3.
PAGE 183
Chapter 6 Axles, Planetaries and Brakes Table of Contents 2 3 3 4 5 5 6 7 7 Brake Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Rear Axle Service (2WD) . . . . . . . . . . . . . . . . . . . . 11 Rear Axle Service (4WD) . . . . . . . . . . . . . . . . . . . . 14 Bevel Gear Case and Axle Case . . . . . . . . . . . . . 16 Differential Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Axle Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 184
Specifications Item Specification Front wheel lug nut torque 85 to 100 ft-lbs. (115 to 136 Nm) Rear wheel lug nut torque 85 to 100 ft-lbs. (115 to 136 Nm) Steering cylinder bolt torque 100 to 125 ft-lbs. (136 to 169 Nm) Rear wheel toe-in 0.000 to 0.125 in. (0.0 to 3.0 mm) Tire pressure (front and rear) 10 to 15 psi. (0.69 to 1.03 Bar) Brake pedal free travel 0.5 to 1.0 in. (13 to 25 mm) Planetary brake housing and wheel motor mounting screw torque 75 to 85 ft-lbs.
PAGE 185
Maintenance Changing Planetary Gear Drive Lubricant Planetary gear drive lubricant should be changed every 800 hours of operation. There are 2 separate oil reservoirs (one for each front wheel) that require draining and refilling with SAE 85W-140 gear lube. 1. With machine on level surface, position wheel so the check/drain plug is at lowest position (Fig. 1). 1 2. Remove both plugs from the bottom of the brake housing and allow the oil to drain (Fig. 2). 3.
PAGE 186
Changing Rear Axle Lubricant Rear axle lubricant should be changed every 800 hours of operation. Rear axle lubricant should be SAE 85W-140 gear lube. 1. Position machine on a level surface. 2. Clean area around the check plugs, drain plugs, and fill/vent plug (Fig. 3, 4, & 5). 3. Remove check plugs and fill/vent plug to allow easier rear axle draining. 4. Remove drain plugs and allow axle lubricant to drain into drain pans. 1 2 5. Reinstall all drain plugs after complete axle draining. 6.
PAGE 187
Adjustments Service Brake Adjustment Adjust the service brakes when there is more than 1 inch of “free travel” of the brake pedal, or when the brakes do not work effectively. Free travel is the distance the brake pedal moves before braking resistance is felt. 1 1. Disengage locking pin from brake pedals so both pedals work independently of each other. 2. To reduce free travel of brake pedals, tighten the brakes - loosen front nut on threaded end of brake cable.
PAGE 188
Rear Wheel Toe-in Adjustment After every 800 operating hours or annually, check rear wheel toe-in. To check toe-in, rotate the steering wheel so the rear wheels point straight ahead. Measure the center-tocenter distance, at axle height, in front and rear of steering tires. Front measurement should be 1/4” (6.4 mm) less than the rear measurement. If toe-in is not within specifications, an adjustment is required. 2WD Traction Units 1 1. Loosen clamps at both ends of tie rod (Fig. 7). 2.
PAGE 189
Repairs Planetary Wheel Drive Service 1 2a 2b 3 4 5 6 7 8 2c 9 10 11 25 12 24 21 22 23 20 19 18 13 2d 17 16 14 15 Spindle Seal Kit Bearing Cone Bearing Cup Wheel Stud (8 used) Housing Bearing Cup Bearing Cone Thrust Washer 10. 11. 12. 13. 14. 15. 16. 17. Retaining Ring Secondary Carrier Assembly Primary Carrier Assembly Pipe Plug Retaining Ring Cover Plate Input Spacer Thrust Washer 18. 19. 20. 21. 22. 23. 24. 25.
PAGE 190
8. Remove capscrews (25) and remove ring gear (18). 9. Remove retaining ring (10) and thrust washer (9). 5. Install seal (2b) to housing (6). Assemble housing (6) to spindle (1). Make sure seals are installed correctly (Fig. 10). 10.Use a puller to remove spindle (1) from housing (6). Remove bearing cone (8). 6. Press bearing cone (8) onto spindle and secure with thrust washer (9) and retaining ring (10). 11. Remove and discard all seals. 7.
PAGE 191
Brake Service 10 75 to 85 ft-lbs (101 to 115 Nm) 1 75 to 85 ft-lbs (101 to 115 Nm) 3 7 Stepped End 4 8 9 2 5 75 to 85 ft-lbs (101 to 115 Nm) 6 Figure 11 Capscrew Wheel Motor O-ring Brake Cable 5. Flange Head Screw 6. Brake Assembly 7. Splined Shaft 8. Retaining Ring 9. Planetary Wheel Drive 10. Flange Head Screw Removal (Fig. 11) Installation (Fig. 11) 1. Drain oil from planetary wheel drive (9) and brake assembly (6). 1. Install splined shaft (7) into brake assembly.
PAGE 192
3 2 1 4 5 6 7 8 9 13 10 12 11 Figure 12 1. 2. 3. 4. 5. Brake Housing - LH Seal Pull Rod Clevis Pin Link 6. 7. 8. 9. Cotter Hair Pin Stationary Disc Rotating Disc Retaining Ring 10. 11. 12. 13. Gasket Actuator Extension Spring Ball Inspection and Repair (Fig. 12) 7. Remove balls (13). 1. Scrape gasket material (10) off of brake housing and planetary wheel drive mounting surfaces. 8. Wash parts in cleaning solvent. 2. Remove retaining ring (9). 3.
PAGE 193
Rear Axle Service (2WD) 1 13 2 3 10 25 to 33 ft--lbs (34 to 45 Nm) 4 5 8 9 9 6 15 14 16 12 11 17 5 19 18 20 4 7 48 49 47 50 51 10 25 to 33 ft--lbs (34 to 45 Nm) 52 22 53 20 23 24 46 25 45 41 44 43 42 54 55 21 56 57 26 28 27 29 30 41 40 39 38 31 32 33 58 59 60 34 35 37 56 85 to 100 ft--lbs (115 to 136 Nm) 36 Screw Spindle Cap Retaining Ring Thrust Washer Flange Bushing Rear Axle Assembly Spindle - RH Axle Pivot Pin Sleeve Bushing Slotted Nut Thrust Washer Gre
PAGE 194
Axle Pivot Bushings Axle Spindle Bushings The rear axle must be held in place snugly by the axle pin. Excessive movement of the axle, which is characterized by erratic steering, usually indicates worn bushings. To correct the problem, replace the bushings. The rear wheel spindles must fit snugly in the rear axle. Excessive movement of the spindle in the axle indicates that the bushings are probably worn and must be replaced. 1. Disconnect the hydraulic hoses from the steering cylinder.
PAGE 195
12.Mount the axle to the frame with the axle pin. Install washer(s) and axle pivot pin. Secure the axle pivot pin in place with the thrust washer and jamnut. 5 6 7 13.Remove the jackstands and lower the machine to the floor. 6 4 14.Lubricate the steering spindles through the grease fittings on the rear axle. 5 8 10 9 3 2 15.Install the hydraulic hoses to the steering cylinder. 1 16.Check steering cylinder hydraulic connections for leaks.
PAGE 196
Rear Axle Service (4WD) 28 29 30 14 12 11 11 12 13 16 17 8 21 18 6 22 23 24 25 26 24 37 23 33 38 20 4 42 43 3 40 41 40 44 45 2 1 35 39 7 5 35 19 8 5 34 27 14 7 33 36 15 10 9 32 31 46 47 48 61 4 49 50 60 59 54 52 58 57 56 55 51 85 to 100 ft--lbs (115 to 136 Nm) 53 Figure 15 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
PAGE 197
Removal (Fig. 15) Installation (Fig. 15) 1. Engage the parking brakes, lower the cutting units to the ground, turn the engine OFF and remove the key from the ignition switch. 1. Apply a thin coat of grease to the inside of the rear axle pivot bushings and move the rear axle assembly into position under machine frame. 2. Drain rear axle lubricant (see Changing Rear Axle Lubricant in this section of this manual). 2. Install washer(s) and axle pivot pin.
PAGE 198
Bevel Gear Case and Axle Case The following procedures assume the rear axle assembly has been removed from the machine. 35 to 41 ft--lb (47 to 56 N--m) Removal 1 6 1. Remove the mounting screws, nuts, and lock washers. Remove the bevel gear case/axle case assembly and O-ring from the axle support (Fig. 17). 4 2. Mark both right and left bevel gear case/axle case assemblies. 5 2 3 35 to 41 ft--lb (47 to 56 N--m) IMPORTANT: Do not interchange right and left bevel gear case/axle case assemblies. 1. 2.
PAGE 199
5. Remove the knuckle pin mounting screws and the knuckle pin. Remove the gasket and any remaining gasket material from either mating surface (Fig. 20). 2 6. While holding the bevel gear case, tap the upper end of the bevel gear shaft out of the upper bearing and upper bevel gear. 1 17 to 20 ft--lb (23 to 27 N--m) 3 4 7. Pull the bevel gear case from the axle case and remove the upper bevel gear, and collar from the gear case. 5 8.
PAGE 200
Installation 1. Coat new shaft seal with grease and install in axle case as shown (Fig. 22). 3 2 1 1. Axle case 2. Bevel gear case 2. Install the lower bevel gear, and bevel gear shaft in the axle case cover. Coat a new O-ring with grease and install the axle case cover (Fig. 23). Tighten cover screws to 17 to 20 ft-lbs. (23 to 27 Nm). Figure 22 3. Shaft seal 7 8 3. Slide the bevel gear case over the bevel gear shaft and install the bevel gear and collar.
PAGE 201
5. Determine necessary quantity of support shims. 4 A. Lubricate the axle case support bushing with a thin coat of grease and slide axle case support onto knuckle pin. B. Position support shims that were removed during disassembly between axle case support and axle case. Install mounting screws into axle case. Slowly tighten screws while frequently checking for clearance (vertical endplay) between axle case support and knuckle pin.
PAGE 202
9. Remove the bevel gear case/axle case assembly from the axle support. Coat a new O-ring with grease and temporarily install the axle cover assembly. Position a dial indicator at the tooths center. Prevent the axle from turning and measure the lower bevel gear to axle gear backlash (Fig. 26). LOWER BEVEL GEAR BACKLASH: 0.004 to 0.016 in. (0.10 to 0.40 mm) 10.Adjust backlash by increasing or reducing axle bearing shim thickness (see Axle Shafts in this section of this manual).
PAGE 203
Axle Shafts The following procedures assume the rear axle assembly has been removed from the machine. 17 to 20 ft--lb (23 to 27 N--m) 1 Removal 4 3 1. Remove the axle cover mounting screws. Remove the axle cover from the axle case as an assembly (Fig. 29). 2. Use a bearing puller to remove the bearing and bevel gear as shown (Fig. 30). 3. Remove the shims, spacer, and retaining ring. Drive the axle out of the bearing and cover. Remove and discard the axle shaft seal. 4.
PAGE 204
Input Shaft/Pinion Gear 3 9 7 8 6 5 2 1 19 18 4 17 16 10 11 15 10 14 12 13 Figure 32 1. 2. 3. 4. 5. 6. 7. Nut Lockwasher Stud Locknut Stake washer Oil Seal O-ring 8. 9. 10. 11. 12. 13. Seal Collar Inner Bearing O-ring Outer Bearing Input Shaft/Pinion Gear Bearing Case 14. 15. 16. 17. 18. 19. Shim Screw Gear Case Gasket Cover Plate Support Bearing The following procedures assume the rear axle assembly has been removed from the machine.
PAGE 205
5. Set the bearing preload by securing the bearing case in a vise. Thread a M12 x 1.5 hex. hd. capscrew into the splined end of the input shaft/pinion gear and slowly tighten the locknut until 4.0 to 6.0 in-lbs. (0.4 to 0.7 Nm) of force is required to rotate the input shaft/pinion gear in the bearing case. 0.04 in. (1.0 mm) 6. Secure the lock nut with the stake washer. 2 1 7.
PAGE 206
Differential Gear The following procedures assume the rear axle assembly has been removed from the machine. 5 7 Removal 35 to 41 ft--lb (47 to 56 N--m) 6 1 2 1. Remove bevel gear case/axle case assemblies (see Bevel Gear Case/Axle Case Assembly in this section of this manual). IMPORTANT: Do not interchange right and left differential shafts assemblies. 4 2. Mark and pull the differential shaft assemblies from the axle support. 3.
PAGE 207
Inspection 1. Measure the differential side gear O.D. and the differential case I.D. to determine the side gear to case clearance (Fig. 39). Replace components as necessary. SIDE GEAR TO CASE CLEARANCE: 0.002 to 0.012 in. (0.05 to 0.30 mm) 1 SIDE GEAR O.D. (Factory Spec.): 1.335 to 1.337 in. (33.91 to 33.95 mm) DIFFERENTIAL CASE I.D. (Factory Spec.): 1.339 to 1.341 in. (34.00 to 34.06 mm) 2 2. Measure the differential pinion shaft O.D. and the pinion gear I.D.
PAGE 208
Installation 3 1. If the ring gear was removed from the differential case, use medium strength Loctite thread locker and tighten the mounting screws from 22 to 25 ft-lb (30 to 34 N--m). 2 1 2. Apply molybdenum disulfide lubricant (Three Bond 1901 or equivalent) to the splines and bearing surfaces of the differential pinion gears, pinion washers and side gears. 3. Install the side gear shims and side gears in their original location in the differential case. 4.
PAGE 209
Pinion Gear to Ring Gear Engagement The final position of the pinion gear is verified by using the gear contact pattern method as described in the following procedure. PROFILE TOP LAND GEAR TOOTH DEFINITIONS (Fig. 43): Toe -- the portion of the tooth surface at the end towards the center. TOE HEEL Heel -- the portion of the gear tooth at the outer end. LENGTHWISE BEARING ARC Top Land -- top surface of tooth. 1.
PAGE 210
Gear Pattern Movement Summary Heel Contact Base Contact Every gear has a characteristic pattern. The illustrations show typical patterns only and explain how patterns shift as gear location is changed. 1. If contact is toward the heel or base of the gear (Fig. 46): A. Install thicker or additional bearing case shim(s) to move pinion shaft toward ring gear. Figure 46 B. Install thinner or remove differential bearing shim(s) to move ring gear backward. C.
PAGE 211
Chapter 7 Cutting Units Table of Contents SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . Backlapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bedbar Removal and Installation . . . . . . . . . . . . . . Bedknife Replacement and Regrinding . . . . . . . . . Preparing Reel for Regrinding . . . . . . . . . . . . . . . . Reel and Reel Bearings . . . . . . . . . . . . . . . . . . . . . . Bearing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . .
PAGE 212
Specifications Figure 1 REEL CONSTRUCTION: Fairway reels. All welded. 5, 7 or 11 blades. BEDKNIFE AND BEDBAR ADJUSTMENT: Single point adjustment mechanism. HEIGHT OF CUT RANGE: 5 Blade - 1” to 1-3/4” (25-44 mm) 7 Blade - 1/2” to 1” (13-25 mm) 11 Blade - 3/8” to 3/4” (10-19 mm) ROLLERS: Front rollers: 3” (76 mm) diameter Wiehle rollers. Optional 3“ (76 mm) diameter full rollers, Part No. 93-3040, are available for the front position. Rear rollers: 3” (76 mm) diameter full rollers.
PAGE 213
Special Tools Order special tools from your Toro distributor. Some tools may have been supplied with your machine or available as TORO parts. Some tools may also be available from a local supplier. Gauge Bar Assembly Use gauge bar to verify height of cut and bedknife attitude. Toro P/N 98-1852 Figure 2 Angle Indicator Use with Gauge Bar Assembly to verify bedknife attitude.
PAGE 214
Bedknife Screw Tool - TOR510880 This screwdriver-type bit is made to fit Toro bedknife attaching screws. Use this bit with a torque wrench to secure the bedknife to the bedbar. Make sure bedbar threads are clean and use new screws. Tighten screws to a torque of 250 - 300 in.lb. (28 - 34 Nm) starting in the middle of the bedknife (Fig. 27). Note: Remove all rust, scale and corrosion from bedbar surface before installing bedknife. DO NOT use an air impact wrench with this tool.
PAGE 215
Troubleshooting There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions. Turf conditions such as excessive thatch, “sponginess” or attempting to cut off too much grass height may not always be overcome by adjusting the machine. It is important to remember that the lower the height of cut, the more critical these factors are. Remember that the “effective” or actual height of cut depends on cutting unit weight and turf conditions.
PAGE 216
Factor Possible Problem/Correction 5. Bedknife to reel adjustment. Check bedknife to reel contact daily. Bedknife must have light contact all across reel. No contact will cause cutting edges to become dull. Excessive contact accelerates wear; quality of cut may be adversely affected. Adjust so you paper can be pinched between reel and bedknife without tearing when inserted from the front, and cuts cleanly when inserted at a right angle (along entire length of bedknife).
PAGE 217
Set-up and Adjustments IMPORTANT: Toro strongly recommends the use of a leveling plate when setting-up or adjusting any reel type cutting unit. The leveling plate will help to ensure accurate and consistent adjustments. RIGHT Note: Right and left ends of cutting unit is determined by standing in the operator’s position (Fig. 8). 1. Check each end of the reel for grease. Grease should be visibly evident in the reel bearings and internal splines of reel shaft. 2.
PAGE 218
Bedknife to Reel Adjustment IMPORTANT: The reel and bedknife must be parallel to insure the cutting unit cuts grass across the bedknife, and the reel and bedknife wear evenly. Note: Toro recommends light contact between the reel and bedknife. However, for dry and/or sparse conditions a .001-.002” (.03-.05 mm) clearance may be required to prevent heat buildup which can cause uneven wear in the reel and bedknife. Note: A 3/4 inch (19 mm) wrench is needed to rotate bedknife adjustment knob.
PAGE 219
C. Recheck reel to bedknife contact on both ends of the bedknife. If necessary, repeat step B. Note: Reel to bedknife contact may become too tight or too loose after previous adjustment; therefore, turn bedknife adjustment knob, accordingly, for light contact. D. Retighten pivot hub lock nuts. Note: Recheck if paper cuts on both ends, to insure the bedknife did not move when re--tightening the pivot hub lock nuts.
PAGE 220
Checking or Adjusting Attitude (Used Cutting Units) As a starting point for adjusting cutting unit attitude, the cutting unit may be set up using the dimensions from the New Cutting Unit Set Up Guide found in the Cutting Unit Operator’s Manual. However, because of wear to the bedknife and reel, the following procedure must be used to ensure the correct attitude setting for reels that have been used for more than just a fews hours. 1 1. Rotate cutting unit backward to gain access to reel and bedknife. 2.
PAGE 221
Leveling Front Roller IMPORTANT: Toro strongly recommends the use of a leveling plate when setting--up or adjusting any reel type cutting unit. The leveling plate will help to ensure accurate and consistent adjustments. Contact your local Toro Distributor for ordering a leveling plate. 1. Position cutting unit on a flat surface. 1 Note: The bar thickness does not affect the adjustment. The recommended bars keep the cutting unit more balanced during the adjustment.
PAGE 222
Final Height of Cut Adjustment 1. Rotate the cutting unit vertical and place the gauge bar across front and rear rollers (Fig. 18). 2. Adjust rear roller until it contacts the gauge bar on both sides. Note: Make sure gauge bar is in contact with the front roller at all times to keep desired height-of-cut. 1 3. Slide gauge bar toward the end of the cutting unit to remove. Gauge bar can now be utilized to set remaining cutting units on machine. 3 2 Figure 18 1. First Screw 2. Second Screw 3.
PAGE 223
Rear Shield Adjustment Under most conditions, best dispersion is attained when rear shield is closed (front discharge). When conditions are heavy or wet, rear shield may be opened. 1. To open rear shield, loosen flange head capscrews securing shield to right side plate, rotate shield to open position and tighten screw.
PAGE 224
Daily Adjustments Prior to each day’s mowing, or as required, each cutting unit must be checked to verify proper bedknife--to--reel contact. This must be performed even though quality of cut is acceptable. 1. Lower cutting units onto a hard surface, shut off engine and remove key from ignition. 2. Slowly rotate reel in reverse direction listening for reel--to--bedknife contact. If no contact is evident, turn bedknife adjusting knob clockwise, one click at a time, until light contact is felt and heard. 3.
PAGE 225
DANGER TO AVOID PERSONAL INJURY, NEVER PLACE HANDS OR FEET IN REEL AREA WHILE ENGINE IS RUNNING. CHANGING ENGINE SPEED WHILE BACKLAPPING MAY CAUSE REELS TO STALL. NEVER CHANGE ENGINE SPEED WHILE BACKLAPPING. ONLY BACKLAP AT IDLE ENGINE SPEED. NEVER ATTEMPT TO TURN REELS BY HAND OR FOOT WHILE ENGINE IS RUNNING. 1 Figure 22 1. Long Handle Brush 6. Select either front, rear, or both backlap knobs to determine which reels will be backlapped. 7. Move Enable/Disable switch to Enable position.
PAGE 226
Bedbar Removal and Installation 12 1 2 3 4 10 5 26 1 6 13 15 14 16 7 11 15 9 8 18 20 17 19 21 32 39 38 37 31 23 24 22 31 25 27 1 27 36 10 35 34 33 32 30 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Screw Washer Quad Ring Locknut Pivot Hub - RH Sideplate - RH Reel Frame Bushing Assembly Flange Bushing Flat Washer Grease Fitting Plastic Bushing Adjustment Screw Pivot Cutting Units 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
PAGE 227
Removal 6. Loosen bedknife adjusting knob to loosen bedknife to reel contact. 1 2 7. Loosen locknut on bedknife adjuster assembly and disengaging adjuster from bedbar (Fig. 25). 8. Remove bedbar leveling screw from L.H. side of cutting unit. 9. Remove fasteners securing L.H. and R.H. bedbar pivot hubs to frame. 10. Remove bedbar assembly. 11. Remove capscrew, washer and quad ring from R.H. end of bedbar. 12. Remove R.H. and L.H. pivot hubs from bedbar. Figure 25 1. Bedknife Adjusting Knob 2. Locknut 13.
PAGE 228
Bedknife Replacement and Regrinding 1. Remove bedbar from cutting unit. Use a torque wrench and bedknife screw tool (TOR510880) 2. Use bedknife screw tool TOR510880 to remove bedknife screws. Remove bedknife (Fig. 27). 3. Remove all rust, scale and corrosion from bedbar surface before installing new bedknife. 4. Install new bedknife: A. Make sure bedbar threads are clean. If necessary, use 5/16--18 UNC 2A tap to clean threads. B. Use new screws.
PAGE 229
Preparing Reel for Regrinding 1. Check to make sure reel bearings are in good condition and properly adjusted before regrinding the reel. Make sure the cutting unit frame and roller brackets are true and not bent or damaged from impacts with trees, posts or cart path edges. 2. Remove bedbar assembly. Note: When regrinding, be careful to not overheat the reel blades. Remove small amounts of material with each pass of the grinder. 4.
PAGE 230
Reel and Reel Bearings 1 2 17 Use tool TOR4074 to install threaded spline insert. Apply Locite 242 to threads Tighten to 75 -- 85 ft--lb (10.4 -- 11.8 KgM) 3 4 5 Cutting Unit Serial No. 220000001 & Up Apply anti--seize lubricant to internal splines 6 Apply grease to OD of seal and bearing 15 3 Apply grease to OD of seal and bearing 23 10 20 15 21 22 Apply grease to OD of seal and bearing 3 17 7 8 9 10 11 12 16 4 15 Pack bearings with No. 2 general purpose grease 1. 2. 3. 4. 5. 6.
PAGE 231
Reel Bearing Adjustment To insure long life of the reel bearings, periodically check if reel end play exists. The reel bearings can be checked and adjusted as follows: Note: Bearing and bearing housing were preset at factory as indicated with a paint mark. 1. Loosen reel to bedknife contact by turning the bedknife adjusting knob counter--clockwise until no contact exists (Fig. 32). Figure 33 2. Hold on to the reel shaft and try to move the reel assembly side to side (Fig. 33). CUTTING UNIT SERIAL NO.
PAGE 232
Reel Removal Reel Installation 1. Remove weight from cutting unit. CAUTION 2. Remove bedbar assembly. 3. Remove front roller assembly. 4. Loosen set screw and remove bearing adjustment nut from L.H. bearing housing. Contact with the reel, bedknife or other cutting unit parts can result in personal injury. Use heavy gloves when installing the cutting reel. 5. Use a hammer and punch to drive out roll pins from L.H. bearing housing. Remove L.H. bearing housing. It is not necessary to remove the R.H.
PAGE 233
Roller and Frame Service 13 -- 17 ft--lb (1.8 -- 2.4 KgM) 36 35 34 75 -- 85 ft--lb (10.4 -- 11.8 KgM) 26 33 27 22 25 13 -- 17 ft--lb (1.8 -- 2.4 KgM) 1 20 28 24 17 19 18 21 22 29 30 31 32 23 2 20 13 -- 17 ft--lb (1.8 -- 2.4 KgM) 14 12 34 4 13 16 15 36 35 3 5 9 28 6 75 -- 85 ft--lb (10.4 -- 11.8 KgM) 11 33 32 31 8 10 30 7 29 13 -- 17 ft--lb (1.8 -- 2.
PAGE 234
Roller Bearing and Seal Replacement 1 2 3 5 6 7 8 9 4 Sharp edge out 7 9 8 6 5 3 2 4 1 Lip of seal facing in 1. Roller 2. Inner Oil Seal 3. Bearing Figure 37 4. Roller Shaft 5. Inner Seal 6. Outer Seal 7. Retaining Ring 8. Outer Oil Seal 9. Washer Note: Bearing and seal configurations are the same for both the front and rear rollers. B. Install roller shaft from opposite end of roller. Be careful not to damage the inner oil seals. Removal C.
PAGE 235
Cutting Unit Installation Cutting unit models 03860, 03861, and 03862 can be installed at any of the mounting locations on the traction unit. Figure 1 shows the orientation of the hydraulic drive motor for each of the five locations. For any of the locations requiring the motor to be mounted on the right end of the cutting unit, install a counter weight on the left end of the cutting unit.
PAGE 236
12. Insert steering pin into the pivot knuckle if you wish to keep cutting units locked in a straight line during operation. If no steering pin is used, the cutting units will steer themselves as the traction unit turns (Fig. 40). 2 13. Hook spring wire around bottom of steering pin (Fig. 40). 14. Mount the motor to the drive end of the cutting unit and secure with two capscrews provided (Fig. 41). 1 Figure 41 1. Motor 2.
PAGE 237
Lubrication Each cutting unit has seven grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease (Fig. 42). D IMPORTANT: Lubricating cutting units immediately after washing helps purge water out of bearings and increases bearing life. (2) C 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. B (2) 2. The grease fitting locations and quantities are as follows: A A.
PAGE 238
This page is intentionally left blank.
PAGE 239
Chapter 7.1 Groomer Groomer Table of Contents TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 2 Factors Affecting Grooming . . . . . . . . . . . . . . . . . . . 2 Groomer Reel Mechanical Problems . . . . . . . . . . . 3 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Groomer Height/Depth Adjustment . . . . . . . . . . . . 4 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 5 Groomer Belt Replacement . . . . . . . . . . . . . . . . . . .
PAGE 240
Troubleshooting Factors Affecting Grooming There are a number of factors that can affect the performance of grooming. These factors vary for different golf courses and from fairway to fairway. It is important to inspect the turf frequently and vary the grooming practice with turf needs. It is important to remember that factors affecting quality of cut also affect grooming performance. IMPORTANT: Improper or overaggressive use of the groomer (e.g.
PAGE 241
Problem Possible Causes Correction No rotation of the groomer reel. Seized groomer reel or idler bearing(s) in groomer side plate(s). Identify and replace faulty bearing(s). Broken or damaged idler spring. Replace spring. The groomer belt is worn, broken or If the belt slips, it probably is worn damaged. and must be replaced. Repair or replace belt if necessary. A broken or worn belt could be the result of improper belt routing or seized bearings in groomer assembly.
PAGE 242
Adjustments CAUTION Never work on the groomer with the engine running. Always stop the engine and remove the key from the ignition switch before working on the groomer. Groomer Height/Depth Adjustment Note: Grooming is performed above the soil level. When adjusting groomer height/depth, groomer blades should never penetrate the soil. 1. Park machine on a clean and level surface, lower cutting units completely to the ground, stop engine, engage parking brake and remove key from the ignition switch. 1 2 2.
PAGE 243
Service and Repairs Groomer Belt Replacement 2 1 1. Park machine on a clean and level surface, lower cutting units completely to the ground, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove two (2) flange nuts that secure groomer belt cover, then remove cover (Fig. 2). 3. Lift idler pulley to relax belt tension. Slip groomer drive belt off pulleys (Fig. 3). Carefully release idler pulley. 4.
PAGE 244
Groomer Reel 21 28 32 1 26 24 26 23 2 25 22 27 3 4 5 32 29 6 20 7 15 to 19 ft--lb (20.3 to 25.7 N--m) 8 24 21 31 30 22 RIGHT 10 11 12 18 19 9 12 13 17 16 23 FRONT 10 15 Loctite #242 14 Figure 4 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Groomer reel assembly Square key Cap screw Flat washer Groomer plate Retaining plate Idler arm spacer Torsion spring Idler assembly Flange nut (3 used) Drive pulley 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
PAGE 245
6. Remove two (2) cap screws (item 26) that secure height of cut assembly (non--drive side) to the cutting unit side plates (Fig. 6). Support groomer to prevent it from falling. Slide height of cut assembly from groomer. Locate and retrieve two (2) flat washers (item 32). 7. Carefully pull the groomer reel from the height of cut assembly (drive side). 8. Inspect seals, bushings and bearings in height of cut assemblies for wear or damage (see Groomer Height of Cut Assembly in this section).
PAGE 246
Groomer Reel Service Inspect groomer reel blades frequently for damage and wear. Straighten bent blades with a pliers. Either replace worn blades or reverse the blades to put the sharpest blade edge forward (Fig. 7). Blades that are rounded to the midpoint of the blade tip must be reversed or replaced for best groomer performance. 3 2 Disassembly (Fig. 8) 4 1. Remove groomer reel from cutting unit (see Groomer Reel Removal in this section). 2. Remove seal guards from groomer reel. 3.
PAGE 247
Idler Assembly The drive side plate assembly groomer kit incorporates the idler system for tensioning the groomer drive belt. A torsion spring is used to maintain proper belt tension. 1 2 3 5 1. Remove groomer belt cover and drive belt from groomer drive side of cutting unit (see Groomer Reel Removal in this section). 6 7 8 9 10 CAUTION 11 Be careful when removing or installing the idler pulley torsion spring. The spring is under heavy load and may cause personal injury. 2.
PAGE 248
Groomer Drive 26 30 24 29 19 28 22 27 20 17 18 16 25 23 9 8 21 7 19 15 to 19 ft--lb (20.3 to 25.7 N--m) 6 14 2 4 31 13 5 4 10 15 1 1 12 11 Loctite #242 3 Figure 12 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Flange nut Groomer belt cover Groomer drive belt Flange head screw (3 used) Drive pulley Idler assembly Torsion spring Idler arm spacer Retaining plate Retaining plate spacer (2 used) Flange nut 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
PAGE 249
8. Slide drive housing assembly from cutting unit. Locate and retrieve o--ring (item 25). 9. Remove shaft and bearings from housing (Fig. 14): A. Remove retaining ring (item 18) from housing. B. Slide shaft from housing. Bearings should remain on shaft. 8. Make sure that pulley spacer (item 15) and washer (item 31) are positioned on groomer shaft. Place square key (item 28) in groomer shaft slot and slide driven pulley onto shaft.
PAGE 250
Groomer Height of Cut Assembly 4 15 6 5 7 16 17 14 3 2 1 13 4 6 5 12 5 2 17 6 3 6 7 8 17 9 10 11 5 6 Figure 15 1. 2. 3. 4. 5. 6. Groomer reel assembly Grease seal Bearing Height of Cut screw Washer Lock nut 7. 8. 9. 10. 11. 12. Grease fitting Bearing housing Grease seal Adjustment bracket Height of Cut bracket Height of Cut bracket 13. 14. 15. 16. 17.
PAGE 251
Disassembly (Fig. 15) 1 1. Remove groomer height of cut assembly from cutting unit (see Groomer Reel Removal in this section). 2. Disassemble groomer height of cut assembly using Figure 15 as a guide. 2 3 3 Groomer Assembly (Fig. 15) 1. If bearing housing were disassembled, install bearings and grease seals noting proper orientation of components as shown in Figure 16. 2. Assemble groomer height of cut assembly using Figure 15 as a guide. 7 3.
PAGE 252
Groomer (Rev. C) Page 7.
PAGE 253
Chapter 7.2 DPA Cutting Units Table of Contents Bedbar Adjuster Service . . . . . . . . . . . . . . . . . . . . Bedknife Replacement and Grinding . . . . . . . . . . Reel Assembly Removal and Installation . . . . . . Reel Assembly Removal . . . . . . . . . . . . . . . . . . Reel Assembly Installation . . . . . . . . . . . . . . . . Reel Assembly Service . . . . . . . . . . . . . . . . . . . . . Preparing Reel for Grinding . . . . . . . . . . . . . . . . . . Front Roller . . . . . . . . . . . . . . . . . .
PAGE 254
Specifications Figure 1 Frame Construction: Precision machined die cast aluminum cross member with two (2) bolt--on cast ductile iron side plates. Bedknife: Replaceable, high carbon steel EdgeMaxTM bedknife is fastened to a machined cast iron bedbar with eight (8) screws. Optional bedknives are available. Reel Construction: Reels are 22 inches (55.9 cm.) in length and 7 inch (17.8 cm) in diameter. High strength, low alloy steel blades are thru hardened and impact resistant.
PAGE 255
General Information Cutting Unit Operator’s Manual DPA Cutting Units The Cutting Unit Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for the DPA cutting units on your Reelmaster machine. Additionally, if optional kits have been installed on the cutting units (e.g. groomer, rear roller brush), the installation instructions for the kit includes set--up and operation information.
PAGE 256
Special Tools Special tools for servicing Toro Commercial Products are available from your Toro Distributor. Some tools may have been supplied with your machine or are available as TORO parts. Gauge Bar Assembly Toro Part Number: 108--6715 Use gauge bar to verify height--of--cut adjustment. Also used for depth adjustment of optional groomer.
PAGE 257
Plastic Plug Toro Part Number: 94--2703 This plug is used for placement into the side plate bearing housing when the hydraulic reel motor is removed. It prevents dirt and debris from entering the cutting reel bearing area. Figure 5 Cutting Unit Kickstand Toro Part Number: 110--4088--03 The cutting unit kickstand is used to prop up the rear of the cutting unit during service. Use of this tool prevents the bedbar adjusting screws from resting on the work surface.
PAGE 258
Cutting Unit Tool Kit Toro Part Number: TOR4070 This tool kit includes special tools required for rebuilding the cutting unit and cutting unit drive motor on the Reelmaster 6500--D/6700--D series of machines.
PAGE 259
DPA Cutting Units This page is intentionally blank. Reelmaster 6500--D/6700--D Page 7.2 -- 7 Rev.
PAGE 260
Factors That Can Affect Cutting Performance There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions. Turf conditions such as excessive thatch, “sponginess” or attempting to cut off too much grass height may not always be overcome by adjusting the cutting unit. It is important to remember that the lower the height--of--cut, the more critical these factors are.
PAGE 261
Factor Possible Problem/Correction Reel and bedknife sharpness A reel and/or bedknife that has rounded cutting edges or “rifling” (grooved or wavy appearance) cannot be corrected by tightening the bedknife to reel contact. Grind cutting reel to remove taper and/or rifling. Grind bedknife to sharpen and/or remove rifling. The most common cause of rifling is bedknife to reel contact that is too tight.
PAGE 262
Factor Possible Problem/Correction Roller condition and roller type Make sure rollers rotate freely. Repair roller bearings as necessary. See Roller Service in the Service and Repairs section of this chapter. Refer to Cutting Unit Operator’s Manual for roller options. Turf compensation spring adjustment Refer to Traction Unit Operator’s Manual for adjustment procedure. Cutting unit accessories A variety of cutting unit accessories are available that can be used to enhance aftercut appearance.
PAGE 263
Set Up and Adjustments Characteristics If a cutting unit is determined to be out of adjustment, complete the following procedures in the specified order to adjust the cutting unit properly. CAUTION Never install or work on the cutting units or lift arms with the engine running. Always stop engine and remove key first. The dual knob bedknife--to--reel adjustment system incorporated in this cutting unit simplifies the adjustment procedure needed to deliver optimum mowing performance.
PAGE 264
Reel Bearing Adjustment To insure cut quality and long life of the cutting reel bearings, periodically check reel bearing adjustment. Check Reel Bearing Adjustment 1. Remove hydraulic reel motor from cutting unit (see Hydraulic Reel Motor Removal in the Service and Repairs section of this chapter). 2. Loosen bedknife to reel adjustment until no contact exists (see Cutting Unit Operator’s Manual). CAUTION Contact with the reel, bedknife or other cutting unit parts can result in personal injury.
PAGE 265
Leveling Rear Roller The precision machined components of the cutting unit frame keep the rear roller and cutting reel in alignment (parallel). If the side plates are disassembled or as the cutting reel wears, a limited amount of side plate adjustment is possible to make sure that the cutting unit is properly aligned. 3 2 4 1 1. Place the assembled cutting unit on a surface plate. 4 2. Make sure that bedknife is properly adjusted to cutting reel. 3.
PAGE 266
This page is intentionally blank. DPA Cutting Units Page 7.2 -- 14 Rev.
PAGE 267
Service and Repairs Hydraulic Reel Motor IMPORTANT: When performing maintenance procedures on the cutting units, carefully position the cutting unit reel motors to prevent damage to the motors or hydraulic hoses. 2 1 4 1 5 Removal 1. Park machine on a clean and level surface, lower cutting units completely to the ground, stop engine, engage parking brake and remove key from the ignition switch. 2 FRONT 6 2.
PAGE 268
Backlapping DANGER 2 TO AVOID PERSONAL INJURY OR DEATH: D Never place hands or feet in the reel area while the engine is running. D When backlapping, run engine at idle speed only. D While backlapping, the reels may stall and then restart. D Do not attempt to restart reels by hand or foot. D Do not adjust reels while the engine is running. D If a reel stalls, stop engine before attempting to clear the reel. D Reel motors are connected in series: rotating one motor causes rotation in other motors.
PAGE 269
9. To make an adjustment to the cutting units while backlapping, turn reels OFF by moving the Lower Mow/ Raise lever rearward; move the Enable/Disable switch to Disable and turn the engine OFF. After adjustments have been completed, repeat steps 5--8. Top Face Relief Angle Front Face Front Angle 10.When the backlapping operation is completed, run a file across the front face of the bedknife. This will remove any burrs or rough edges that may have built up on the cutting edge. 11.
PAGE 270
Bedbar Assembly 10 6 7 11 5 4 8 12 13 9 1 5 2 16 27 to 33 ft--lb (37 to 44 N--m) 3 14 15 16 17 18 19 RIGHT FRONT Antiseize Lubricant Figure 19 1. 2. 3. 4. 5. 6. 7. Bedbar Bedknife Screw (8 used) Bedbar adjuster shaft (2 used) Flange bushing (4 used) Cap screw (2 used) Detent (2 used) 8. 9. 10. 11. 12. 13. Wave washer (2 used) Retaining ring (2 used) Bedbar adjuster screw (2 used) Washer (2 used) Compression spring (2 used) Lock nut (2 used) Bedbar Removal (Fig. 19) 1.
PAGE 271
6. Position a plastic washer (item 16) between bedbar and each cutting unit side plate (Fig. 20). CAUTION Contact with the reel, bedknife or other cutting unit parts can result in personal injury. Use heavy gloves when handling the bedbar. 6. Remove bedbar assembly from cutting unit. 7. Inspect flange bushings (item 15) and rubber bushings (item 14) in side plates for wear or damage. Remove bushings and replace if necessary. Bedbar Installation (Fig. 19) 1.
PAGE 272
Bedbar Adjuster Service Antiseize Lubricant Loctite #242 14 to 16 ft--lb (19 to 21 N--m) 8 6 5 10 3 9 2 11 7 5 1 4 RIGHT FRONT Figure 21 1. 2. 3. 4. Bedbar assembly Compression spring Lock nut Bedbar adjuster shaft 5. 6. 7. 8. Flange bushing Cap screw Detent Wave washer Removal (Fig. 21) 1. Remove lock nut (item 3), compression spring (item 2) and washer (item 11) from bedbar adjuster screw (item 10). 2. Remove bedbar (see Bedbar Removal in this section).
PAGE 273
Bedknife Replacement and Grinding Bedknife Removal 1. Remove bedbar from cutting unit (see Bedbar Removal in this section). 2. Remove screws from bedbar using a socket wrench and bedknife screw tool (see Special Tools). Discard screws. Remove bedknife from the bedbar (Fig. 22). 2. After grinding bedknife, check lead--in chamfer on bedknife (see Cutting Unit Operator’s Manual). 3. After bedknife grinding is complete, install bedbar to cutting unit (see Bedbar Installation in this section).
PAGE 274
Reel Assembly Removal and Installation 12 22 1 24 27 to 33 ft--lb (37 to 44 N--m) 15 23 16 Grease OD surface 9 8 4 2 13 14 17 18 FRONT 4 5 6 19 20 RIGHT See text for tightening procedure 3 7 21 12 Loctite #242 12 to 15 in--lb (1.4 to 1.7 N--m) Grease bore and threads 27 to 33 ft--lb (37 to 44 N--m) 11 10 Antiseize Lubricant Figure 25 1. 2. 3. 4. 5. 6. 7. 8.
PAGE 275
Reel Assembly Removal (Fig. 25) 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove the cutting unit from the machine and place on a flat work area. 8 3. If cutting unit is equipped with a counterweight on LH side plate (as shown in Figure 25), remove the two (2) cap screws securing the counter weight to the side plate. Remove counter weight from the cutting unit.
PAGE 276
3. Carefully slide the cutting reel with bearings and grease seals into the RH side plate. Make sure that bearing is fully seated into side plate. 4. On LH side plate, loosen set screw (item 21) and back--off (loosen) bearing adjuster nut (item 20) one complete turn. 5. Slide the LH side plate onto the cutting reel assembly, front roller and rear roller. Make sure that reel end in RH side plate does not shift in position. 6.
PAGE 277
DPA Cutting Units This page is intentionally blank. Reelmaster 6500--D/6700--D Page 7.2 -- 25 Rev.
PAGE 278
Reel Assembly Service 8 10 7 Loctite #242 9 5 4 3 2 Loctite #242 85 to 95 ft--lb (115 to 128 N--m) (Right Hand Threads) 1 10 RIGHT 6 3 FRONT 85 to 95 ft--lb (115 to 128 N--m) (Left Hand Threads) 4 5 Figure 27 1. 2. 3. 4. Cutting reel Threaded insert (RH thread) Retaining ring Grease seal DPA Cutting Units 5. Bearing 6. Threaded insert (LH thread) 7. Retaining ring groove Page 7.2 -- 26 Rev. E 8. Groove indicating LH threads 9. Bearing shoulder 10.
PAGE 279
Inspection of Cutting Reel (Fig. 27) Assembly of Cutting Reel (Fig. 27) 1. Inspect reel bearings to insure that they spin freely and have minimal axial play. The bearing balls must be free of deformation and scoring. 1. If seals and/or bearings were removed from reel shaft, discard removed components and replace. 2. Inspect the reel shaft as follows. If reel damage is detected, replace reel. A. Check the reel shaft for bending and distortion by placing the shaft ends in V--blocks. B.
PAGE 280
Preparing Reel for Grinding Note: Before grinding a cutting reel, make sure that all cutting unit components are in good condition. Depending on type of grinder used, faulty cutting unit components can affect grinding results. Reel Grinding Specifications Note: When grinding, be careful to not overheat the cutting reel blades. Remove small amounts of material with each pass of the grinder. Blade Relief Angle 1.
PAGE 281
DPA Cutting Units This page is intentionally blank. Reelmaster 6500--D/6700--D Page 7.2 -- 29 Rev.
PAGE 282
Front Roller Removal (Fig. 29) 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 1 Loctite #242 Antiseize Lubricant 2. Remove the cutting unit from the machine and place on a level working surface. Use cutting unit kickstand (see Special Tools) to raise front roller from work surface. 2 15 to 19 ft--lb (20 to 26 N--m) 3 3.
PAGE 283
Rear Roller Removal (Fig. 30) 4 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 1 2. Remove the cutting unit from the machine and place on a level working surface. Place support blocks under bedbar to raise rear roller from work surface. 5 3. Loosen two (2) flange nuts that secure the rear roller shaft to each rear roller bracket. 6 4.
PAGE 284
Roller Service (Greasable Bearings with Retaining Ring) v 2 5 7 9 1 10 8 3 4 6 Figure 31 1. 2. 3. 4. Roller tube (front Wiehle shown) Roller shaft Inner oil seal Grease fitting 5. Ball bearing 6. Inner seal 7. Outer seal 8. Retaining ring 9. Outer oil seal 10. Roller washer Note: Numerous front and rear rollers are available for the Reelmaster cutting units. These rollers use one of two styles of bearing and seal configurations.
PAGE 285
Removal (Figs. 31 and 32) 1. Remove retaining ring from both ends of roller. 2. Support roller assembly and press one end of roller shaft to remove seals and bearing from opposite end of roller. Press on other end of roller shaft to remove remaining seals and bearing from roller. Be careful not to drop roller shaft or tube when removing seals and bearings. 3. Discard removed seals and bearings. Installation (Figs. 31 and 32) Note: Use of a press is recommended to assemble the roller.
PAGE 286
Roller Service (Greasable Bearings with Bearing Nut) Disassembly (Fig. 33) 2 1. Remove bearing lock nut from each end of roller shaft. 50 to 60 ft--lb (68 to 81 N--m) 3 4 2. Loosely secure roller assembly in bench vise and lightly tap one end of roller shaft until outer seals and bearing are removed from opposite end of roller tube. Remove second set of outer seals and bearing from roller tube by tapping on opposite end of shaft. Remove shaft from roller tube. 5 6 7 1 2 4 3 5 3.
PAGE 287
3. From the roller tube end with only the inner seal installed, carefully install the roller shaft into the roller tube. Make sure that seals are not damaged as shaft is installed. IMPORTANT: When roller assembly is installed to cutting deck, make sure that grease groove in each roller mount aligns with the grease hole in each end of roller shaft. 4.
PAGE 288
Rear Roller Brush (Optional) 30 6 5 31 20 to 25 in--lb (2.3 to 2.8 N--m) 2 26 27 11 3 29 17 to 21 ft--lb (23 to 28 N--m) 6 1 7 4 8 Antiseize Lubricant 27 12 26 9 10 11 13 14 25 15 16 17 11 18 RIGHT FRONT 19 28 24 32 Grease Grommet ID 27 to 33 ft--lb (37 to 44 N--m) Loctite #242 23 22 21 20 11 Figure 39 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
PAGE 289
Disassembly (Fig. 39) 2 1 3 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. To remove roller brush from brush shaft: A. Remove the non--drive brush bearing housing (item 30) from cutting unit. 20 to 25 in--lb (2.3 to 2.8 N--m) 4 B. Slide excluder seal from roller brush shaft. Figure 40 C. Remove lock nut and J--bolt from both ends of the brush. D. While rotating brush, slide brush from the shaft. 3.
PAGE 290
3. If drive bearing housing was disassembled, install new components noting proper orientation as shown in Figures 42 and 43. 8 A. Install bearing on shaft by pressing equally on the inner and outer bearing races. Install the bearing so that the bearing seal is closest to the shoulder on the shaft. Install snap ring (item 6) onto shaft to retain bearing. 7 6 B. Install new grease seal into housing with the lip of the seal toward the drive shaft splines. Apply grease to lip of seal. 9 5 3 2 4 C.
PAGE 291
5. Check that roller brush has light contact with rear roller (Fig. 46). If contact is incorrect, brush operation will be adversely affected. Also make sure that brush shaft is parallel with rear roller. 2 1 6. Lubricate grease fittings on brush housings until grease purges past inboard seals. Wipe excess grease from seals and fittings. STRAIGHT EDGE 3 Figure 44 1. Driven pulley 2. Drive pulley 3. Check for alignment Figure 45 1 3 2 Figure 46 3. Light contact DPA Cutting Units 1.
PAGE 292
This page is intentionally blank. DPA Cutting Units Page 7.2 -- 40 Rev.
PAGE 293
Chapter 7.3 DPA Groomer Table of Contents DPA Groomer GROOMING PERFORMANCE . . . . . . . . . . . . . . . . . . 2 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 3 Groomer Reel Mechanical Problems . . . . . . . . . . . 3 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Groomer Height/Depth Adjustment . . . . . . . . . . . . 4 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 5 Groomer Drive Belt Replacement . . . . . . . . . . . . . .
PAGE 294
Grooming Performance There are a number of factors that can affect the performance of grooming. These factors vary for different golf courses and from fairway to fairway. It is important to inspect the turf frequently and vary the grooming practice with turf needs. IMPORTANT: Improper or overaggressive use of the groomer (e.g. too deep or too frequent grooming) may cause unnecessary stress on the turf leading to severe turf damage. Use the groomer carefully.
PAGE 295
Troubleshooting Groomer Reel Mechanical Problems Problem Possible Causes Correction No rotation of the groomer reel. The groomer drive belt needs to be adjusted. Adjust groomer drive belt. Seized groomer reel or idler bearing(s) in groomer side plate(s). Identify and replace faulty bearing(s). Broken or damaged idler spring. Replace spring. The groomer drive belt is worn, bro- If the drive belt slips, it probably is out of adjustment or worn. ken or damaged.
PAGE 296
Adjustments CAUTION Never work on the groomer with the engine running. Always stop the engine, remove the key from the ignition switch and wait for all machine movement to stop before working on the groomer. NOTE: The Groomer Installation Instructions provide information regarding the installation, set--up and operation of the optional groomer on your Reelmaster machine. Refer to those instructions for additional information when servicing the groomer.
PAGE 297
Service and Repairs CAUTION Never work on the groomer with the engine running. Always stop the engine, remove the key from the ignition switch and wait for all machine movement to stop before working on the groomer. NOTE: The Groomer Installation Instructions provide information regarding the installation, set--up and operation of the optional groomer on your Reelmaster machine. Refer to these instructions for additional information when servicing the groomer. Groomer Drive Belt Replacement 3 2 1.
PAGE 298
Groomer Plate Assembly Loctite #242 7 21 20 19 16 Antiseize Lubricant 21 22 18 17 23 Loctite #242 16 24 7 4 1 14 13 12 2 3 5 RIGHT 15 23 Antiseize Lubricant FRONT 6 7 8 9 17 to 21 ft--lb (23 to 28 N--m) 10 11 Loctite #242 27 to 32 ft--lb (37 to 43 N--m) Figure 4 1. 2. 3. 4. 5. 6. 7. 8. Groomer reel Pulley spacer Washer (as required) Square key Driven pulley Flange nut Socket head screw Idler plate 9. 10. 11. 12. 13. 14. 15. 16.
PAGE 299
B. Remove flange head screw (item 11) that retains drive pulley. Pull drive pulley from drive shaft. Locate and retrieve square key (item 4) from drive shaft. NOTE: To prevent groomer shaft from turning when removing driven pulley, use wrench on shaft flats to hold groomer shaft. C. Remove the flange nut (item 6) that secures driven pulley (item 5) to groomer shaft. Slide driven pulley from shaft. D. Slide washer (item 3) and pulley spacer (item 2) from groomer shaft. B.
PAGE 300
2. Install groomer plate assembly to groomer non-drive side of cutting unit: A. Carefully position non--drive side groomer plate onto groomer shaft and slide to cutting unit. B. Position pivot hub to cutting unit. C. Secure groomer components to cutting unit side plate with two (2) socket head screws (item 7). D. Install hydraulic reel motor to cutting unit (see Hydraulic Reel Motor Installation in the Service and Repairs section of Chapter 7.2 -- DPA Cutting Units). 3.
PAGE 301
DPA Groomer This page is intentionally blank. Reelmaster 6500--D/6700--D Page 7.3 -- 9 Rev.
PAGE 302
Groomer Reel Loctite #242 7 21 20 19 16 Antiseize Lubricant 21 22 18 17 23 Loctite #242 16 24 7 4 14 13 12 1 2 3 4 5 RIGHT 6 15 7 23 FRONT 8 9 Antiseize Lubricant 17 to 21 ft--lb (23 to 28 N--m) 10 11 Loctite #242 27 to 32 ft--lb (37 to 43 N--m) Figure 8 1. 2. 3. 4. 5. 6. 7. 8. Groomer reel Pulley spacer Washer Square key Driven pulley Flange nut Socket head screw Idler plate 9. 10. 11. 12. 13. 14. 15. 16.
PAGE 303
Installation (Fig. 8) 3 1. Position cutting unit on a level surface. If cutting unit is attached to traction unit, make sure to stop engine, engage parking brake and remove key from the ignition switch. 2. Apply a light coating of grease to seal lips in groomer plate assemblies. 3. Make sure that excluder seals (item 23) and o--ring (item 24) are positioned on groomer shaft. The excluder seal lips should be toward the end of the groomer shaft. Apply a film of grease onto seal lip. 4.
PAGE 304
Groomer Reel Service Inspect groomer reel blades frequently for damage and wear. Straighten bent blades with a pliers. Either replace worn blades or reverse the blades to put the sharpest blade edge forward (Fig. 11). Blades that are rounded to the midpoint of the blade tip must be reversed or replaced for best groomer performance. 5. If groomer reel is equipped with broomer kit (Fig. 13), position broomer brushes to reel blades and secure with straps.
PAGE 305
6. Place excluder seals on groomer shaft. 7. Install o--ring on non--drive end of groomer shaft. 2 8. Install groomer reel back on cutting unit (see Groomer Reel Installation in this section). 2 2 2 1 Figure 13 2. Broomer strap DPA Groomer 1. Groomer shaft Reelmaster 6500--D/6700--D Page 7.3 -- 13 Rev.
PAGE 306
Groomer Pivot Hub 6 2 10 5 3 4 7 8 Apply Grease to Seal Lip 1 9 Figure 14 1. 2. 3. 4. Groomer drive shaft Ball bearing Grease seal Retaining ring 5. Pivot hub 6. Retaining ring 7. Extension spring 8. Retaining ring 9. Idler plate 10. O--ring (7” cutting unit only) NOTE: The groomer reel drive is located on the opposite side of the cutting unit from the cutting reel hydraulic motor. Figure 14 shows components used when the groomer reel drive is on the left side of the cutting unit.
PAGE 307
Disassembly (Fig. 14) Fill cavity 50 to 75% full with grease 1. Remove pivot hub assembly (with idler plate) from cutting unit (see Groomer Plate Assembly Removal in this section). 4 2. Remove retaining ring (item 4) that secures idler plate to pivot hub. Slide idler plate from pivot hub. 3 3. Remove retaining ring (item 8) that retains ball bearing into pivot hub. Slide drive shaft and bearing out of hub. 4. Remove retaining ring (item 7) that retains bearing on drive shaft.
PAGE 308
Height Adjuster Assembly 11 12 10 9 8 Antiseize Lubricant 7 13 30 to 40 in--lb (3.4 to 4.5 N--m) 6 14 Antiseize Lubricant 5 4 17 to 21 ft--lb (23 to 28 N--m) 3 2 1 Antiseize Lubricant Figure 16 1. 2. 3. 4. 5. Groomer plate (LH drive shown) Shoulder bolt Ball joint rod Jam nut Compression spring 6. 7. 8. 9. 10.
PAGE 309
Chapter 8 Electrical Diagrams Table of Contents Reelmaster 6500-D/6700-D WIRE HARNESS AND ELECTRICAL CONNECTOR DRAWINGS Reelmaster 6500-D/6700-D Wire Harnesses . . . 17 Reelmaster 6500-D/6700-D Electrical Connector Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Reelmaster 6700-D Secondary (#2) Electronic Controller Harness and Electrical Connector Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 310
This page is intentionally blank.
PAGE 311
ORANGE BLACK C FUEL SENDER A IGNITION B SWITCH YELLOW 2J 3M 3B 2B 3N 2C 2G 2E 3G 2H 3H 3F 2F INPUTS 3J 1A 3K SOLID STATE CONTROLLER BLACK 2A RS232 (RX) ORANGE/RED SV4 BLACK/WHITE 2S ORANGE/BLUE 1F RED/BLUE 1E SV3 ORANGE/BLUE SV1 1D PINK/BLUE 1C 1B SV2 1S YELLOW/BLACK BROWN/WHITE 1R 3S MSV2 MSV1 #1A RELAY 1P YELLOW/WHITE RED/BLUE RUN \ ALTERNATOR BROWN/RED 1G FAULT INDICATOR LIGHT 10A #4A 1N RED/WHITE #3A 2P 1H PINK/BLACK VIOLET/RED #4B BLACK
PAGE 312
Reelmaster 6500-D Model 03806 & 03807 Serial Numbers 220000001 & Up Electrical Schematic All relays and solenoids are shown as de-energized. All ground wires are black. Reelmaster 6500-D/6700-D Page 8 - 4 Rev.
PAGE 313
#7 REEL #6 REEL SV7 SV6 HIGH TEMP SHUTDOWN SWITCH Reelmaster 6700-D Model 03808 Serial Numbers 210000001 -- 210999999 Electrical Schematic All relays and solenoids are shown as de-energized. All ground wires are black. Reelmaster 6500-D/6700-D Page 8 - 5 Rev.
PAGE 314
#7 REEL #6 REEL SV7 SV6 HIGH TEMP SHUTDOWN SWITCH Reelmaster 6700-D Model 03808 Serial Numbers 220000001 & Up Electrical Schematic All relays and solenoids are shown as de-energized. All ground wires are black. Reelmaster 6500-D/6700-D Page 8 - 6 Rev.
PAGE 315
IF EQUIPPED HIGH TEMP SHUTDOWN SWITCH Reelmaster 6500--D/6700--D Ignition Switch Circuit (20 Amp Fuse) Reelmaster 6500-D/6700-D Page 8 - 7 Rev.
PAGE 316
IF EQUIPPED HIGH TEMP SHUTDOWN SWITCH Reelmaster 6500--D/6700--D Controller #1 Power Circuit (10 Amp Fuses) Reelmaster 6500-D/6700-D Page 8 - 8 Rev.
PAGE 317
IF EQUIPPED HIGH TEMP SHUTDOWN SWITCH Reelmaster 6500-D/6700-D Controller #1 Logic Circuit (5 Amp Fuse) Reelmaster 6500-D/6700-D Page 8 - 9 Rev.
PAGE 318
IF EQUIPPED HIGH TEMP SHUTDOWN SWITCH Reelmaster 6700-D Controller #2 Power Circuit (15 Amp Fuse) Page 1 of 2 Reelmaster 6500-D/6700-D Page 8 - 10 Rev.
PAGE 319
#7 REEL #6 REEL SV7 SV6 Reelmaster 6700--D Controller #2 Power Circuit (15 Amp Fuse) Page 2 of 2 Reelmaster 6500-D/6700-D Page 8 - 11 Rev.
PAGE 320
IF EQUIPPED HIGH TEMP SHUTDOWN SWITCH Reelmaster 6500--D/6700--D Accessory Power and Controller #2 Logic Circuit (7.5 Amp Fuse) Page 1 of 2 Reelmaster 6500-D/6700-D Page 8 - 12 Rev.
PAGE 321
#7 REEL #6 REEL SV7 SV6 Reelmaster 6500--D/6700--D Accessory Power and Controller #2 Logic Circuit (7.5 Amp Fuse) Page 2 of 2 Reelmaster 6500-D/6700-D Page 8 - 13 Rev.
PAGE 322
IF EQUIPPED HIGH TEMP SHUTDOWN SWITCH Reelmaster 6500--D/6700--D Starter, Glow Plugs, and Alternator Circuits (Fusible Links) Reelmaster 6500-D/6700-D Page 8 - 14 Rev.
PAGE 323
IF EQUIPPED HIGH TEMP SHUTDOWN SWITCH Reelmaster 6500--D/6700--D Optional Lighting Circuit (10 Amp Fuse) Reelmaster 6500-D/6700-D Page 8 - 15 Rev.
PAGE 324
TO LEAK DETECTOR CONNECTOR OF MAIN HARNESS A B C D + RED/YELLOW (RED) BLACK/YELLOW ALARM -- BLACK/BLUE BLACK RED BLACK/WHITE ORANGE/BLACK RED/WHITE YELLOW A A E E B B TURF DEFENDER BLACK/ORANGE ELECTRIC PORT AND GREEN/WHITE SOLENOID COMMUNICATION VALVE LOOPBACK CONNECTOR BLACK 2D 1B 3B 2C 1E 2E 1C 3C 2A 2F 1F 3F C C TURF DEFENDER LOOPBACK I.D.
PAGE 325
P3 P4 P12 Neutral Switch Harness P18 P7 & P8 P5 J24 J25 J22 P6 P29 J21 J23 P25 P17 P45 P37 Console Harness P38 P37 P2 P19 J8 P14 J9 P39 P41 P41 P16 J17 P26 J3 P15 J2 J4 P11 P13 P40 P1 J5 P30 Main Harness J10 P28 J6 J11 P35 P10 P44 P34 J15 J20 P36 P39 J16 P24 P33 P32 P31 P21 J1 J14 P23 P38 J13 P22 P9 P43 J19 Engine Harness P20 P42 Reelmaster 6500-D/6700-D Page 8 - 17 Electrical Diagrams P27 J18 Reelmaster 6500-D/6700-D Wire Harnesses
PAGE 326
P1 P2 P3 P4 P5 P6 P9 P8 P7 4 5 3 2 A3 B3 C3 D3 E3 A2 B2 C2 D2 E2 A1 B1 C1 D1 E1 F3 G3 H3 J3 K3 F2 G2 H2 J2 K2 F1 G1 H1 J1 K1 A3 B3 C3 A2 B2 C2 A1 B1 C1 30 Pin Connector 18 Pin Connector Located under the operator’s seat Plugged into the Primary (#1) Electronic Controller P15 Located under the operator’s seat Plugged into the Primary (#1) Electronic Controller Cavity Wire F1 Red/Blue F2 White F3 Blue G1 Red/Blue G2 Orange G3 Pink H1 Pink/Black H2 Open H3 Open J1 Pink/Black J2 Gray J3 Red/Wh
PAGE 327
P30 P31 P32 P33 P34 P35 P36 P37 P38 P39 P40 P41 P42 1 2 D2 Front Reel Backlap Switch SV2 Solenoid Located on reel manifold Located on lift manifold Located on lift manifold Located on lift manifold Located on lift manifold Located on lift manifold Cavity Wire A Orange/Blue B Black Cavity Wire A Pink/Blue B Black Cavity Wire A Orange/Red B Black Cavity Wire A Yellow/Black B Black Cavity Wire A Red/Blue B Black Cavity A B Wire Blue Black SV3 Solenoid SV4 Solenoid SV1 Solenoid
PAGE 328
Secondary (#2) Electronic Controller 18 Pin Connector A3 B3 C3 D3 E3 A2 B2 C2 D2 E2 A1 B1 C1 D1 E1 F3 G3 H3 J3 K3 F2 G2 H2 J2 K2 F1 G1 H1 J1 K1 A3 B3 C3 A2 B2 C2 A1 B1 C1 30 Pin Connector Located under the operator’s seat Plugged into the Secondary (#2) Electronic Controller D3 E3 F3 D2 E2 F2 D1 E1 F1 18 Pin Connector Located under the operator’s seat Plugged into the Secondary (#2) Electronic Controller Communications Port #2 Loop--Back connector #2 Diagnostic Light #2 (Green) Located in the c