User manual

ManualsBrandsToro ManualsEngineLawn Mower 11185SL

Part No. 11185SL (Rev. A)

Service Manual

Reelmaster

7000

Preface

The purpose of this publication is to provide theservice

technician with information for troubleshooting, testing

and repair of major systems and components on the

Reelmaster 7000.

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

ManualsandParts Catalog for yourmachine intoChap-

ter 2ofthisservice manual. Additional copiesof theOp-

erator’s Manuals andParts Catalog areavailable onthe

internet at www.Toro.com.

TheToroCompanyreservestherighttochangeproduct

specifications or this publication without notice.

This safety symbol means DANGER, W ARNING

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 -

portantinstructionswhichmustbefollowedtopre-

vent damage to systems or components on the

machine.

E Th e Toro Company -- 2011, 2012

Summary of content (315 pages)

PAGE 1
Part No. 11185SL (Rev. A) Service Manual ReelmasterR 7000 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 7000. REFER TO THE TRACTION UNIT AND CUTTING UNIT OPERATOR’S MANUALS FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. For reference, insert a copy of the Operator’s Manuals and Parts Catalog for your machine into Chapter 2 of this service manual.
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Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equivalents and Conversions . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2 -2 -2 -2 -- 1 1 2 3 Chapter 3 -- Kubota Diesel Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 2 General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 3 Service and Repairs . .
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Safety Table of Contents GENERAL SAFETY INSTRUCTIONS . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
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General Safety Instructions The Reelmaster 7000 have been tested and certified by TORO for compliance with existing safety standards and specifications. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance and storage of the machine.
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1. The Traction Unit and Cutting Unit Operator’s Manuals provide information regarding the operation, general maintenance and maintenance intervals for your Reelmaster machine. Refer to these publications for additional information when servicing the machine. 2. Before servicing or making adjustments, lower cutting units, stop engine, set parking brake and remove key from the ignition switch. 3. Make sure machine is in safe operating condition by keeping all nuts, bolts and screws tight. 4.
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Jacking Instructions CAUTION When changing attachments, tires or performing other service, use correct jacks and supports. Make sure machine is parked on a solid, level surface such as a concrete floor. Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels. Use jack stands to support the raised machine.
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Safety Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Reelmaster 7000. If any decal becomes illegible or damaged, install a new decal. Decal part numbers are listed in your Parts Catalog.
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Product Records and Maintenance Table of Contents PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . . . . . . . . . . . . . . . .
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Equivalents and Conversions 0.
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Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual. 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.
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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 Stronger N
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Thread Size 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 + 6 in--lb 644 + 68 N--cm 78 + 8 in--lb 881 + 90 N--cm M6 X 1.0 96 + 10 in--lb 1085 + 113 N--cm 133 + 14 in--lb 1503 + 158 N--cm M8 X 1.25 19 + 2 ft--lb 26 + 3 N--m 28 + 3 ft--lb 38 + 4 N--m M10 X 1.5 38 + 4 ft--lb 52 + 5 N--m 54 + 6 ft--lb 73 + 8 N--m M12 X 1.
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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.
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Chapter 3 Kubota Diesel Engine Table of Contents Reelmaster 7000 Page 3 -- 1 Kubota Diesel Engine SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Air Filter System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Exhaust System . . . . . . . . . . . . . . . . . . . . .
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Specifications Item Description Make / Designation Kubota Model V2403--M--DI--E3B 4--Cycle, 4 Cylinder, Liquid Cooled, Diesel Engine Bore 3.425” (87.0 mm) Stroke 4.031” (102.4 mm) Total Displacement 148.5 in3 (2434 cc) Firing Order 1 (closest to gear case end) -- 3 -- 4 (closest to flywheel end) -- 2 Combustion Chamber Spherical Type (E--TVCS) Compression Ratio 23.
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General Information General maintenance procedures are described in your Traction Unit Operator’s Manual. Information on engine troubleshooting, testing, disassembly and assembly is identified in the Kubota Workshop Manual, Diesel Engine, 03--M--DI--E3B. Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Kubota Workshop Manual, Diesel Engine, 03--M--DI--E3B. The use of some specialized test equipment is explained.
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Service and Repairs Air Filter System RIGHT 27 12 to 15 in--lb (1.4 to 1.6 N--m) FRONT 26 13 13 24 12 23 11 14 Vacuator Direction 18 18 10 25 6 20 15 16 9 1 19 17 7 21 22 8 4 2 5 6 3 Figure 1 1. 2. 3. 4. 5. 6. 7. 8. 9. Battery support Bracket Flange head screw (8 used) Flange nut (8 used) Support bracket Cap screw (4 used) Flange nut (4 used) Fan drive manifold Air cleaner strap Kubota Diesel Engine 10. 11. 12. 13. 14. 15. 16. 17. 18.
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Removal (Fig. 1) 1. Park machine on a level surface, lower cutting units, stop engine, apply parking brake and remove key from the ignition switch. 2 4 2. Raise and support hood. 1 3. Remove air cleaner components as needed using Figure 1 as a guide. Installation (Fig. 1) 3 IMPORTANT: Any leaks in the air filter system will cause serious engine damage. Make sure that all air cleaner components are in good condition and are properly secured during assembly. A.
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Exhaust System 8 13 12 5 3 7 14 1 10 4 11 6 2 9 RIGHT FRONT Figure 4 1. 2. 3. 4. 5. Muffler Flange head screw (2 used) Flange head screw (4 used) Muffler clamp Tailpipe Kubota Diesel Engine 6. 7. 8. 9. 10. RH engine mount Flat washer Cap screw Muffler bracket Muffler gasket Page 3 -- 6 11. 12. 13. 14.
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Removal (Fig. 4) Installation (Fig. 4) The muffler and exhaust pipe may be hot. To avoid possible burns, allow the engine and exhaust system to cool before working on the muffler. 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Raise and support hood. 3. Remove muffler and/or muffler bracket from the engine as necessary using Figure 4 as a guide.
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Fuel System 19 16 20 21 16 13 3 18 21 14 15 8 1 8 24 17 25 4 3 8 7 23 2 7 6 5 9 10 22 RIGHT FRONT 11 26 12 27 Figure 5 1. 2. 3. 4. 5. 6. 7. 8. 9. Fuel suction tube Fuel line clamp (2 used) Fuel hose (supply) Return fitting Fuel hose (return) Fuel tank cap Bushing (2 used) Hose clamp (6 used) Fuel tank Kubota Diesel Engine 10. 11. 12. 13. 14. 15. 16. 17. 18.
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Fuel Tank Removal (Fig. 5) Because diesel fuel is flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot or when machine is in an enclosed area. Always fill fuel tank outside and wipe up any spilled diesel fuel before starting the engine. Store fuel in a clean, safety--approved container and keep cap in place. Use diesel fuel for the engine only; not for any other purpose. 1.
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Radiator 26 1 46 28 3 29 23 43 15 RIGHT 10 FRONT 7 42 39 2 11 12 3 37 38 5 15 22 6 18 4 15 40 13 18 32 31 30 33 25 24 35 44 17 8 19 14 41 28 36 17 20 34 43 27 45 10 9 16 21 9 to 11 ft--lb (12.3 to 14.9 N--m) Figure 6 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
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1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove hood from the machine (see Hood Removal in the Service and Repairs section of Chapter 7 -- Chassis). CAUTION Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot coolant can escape and cause burns. Ethylene--glycol antifreeze is poisonous.
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Engine 29 5 1 12 31 3 30 33 22 4 9 6 18 28 21 17 10 7 20 8 19 25 24 2 10 11 34 18 32 26 23 17 14 15 16 12 27 13 RIGHT 12 FRONT Figure 8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Muffler Flange head screw Flange head screw (4 used) Muffler clamp Tailpipe RH rear engine mount Cap screw (3 used) RH front engine mount Engine Flange head screw (10 used) Engine mount (4 used) Flange nut (15 used) Kubota Diesel Engine 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
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Engine Removal (Fig. 8) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 5 2. Remove hood from the machine (see Hood Removal in the Service and Repairs section of Chapter 7 -- Chassis). 1 3. Remove battery cover. Disconnect negative battery cable first and then positive battery cable. 3 2 CAUTION Do not open radiator cap or drain coolant if the radiator or engine is hot.
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11. Remove fan motor and fan assembly (Fig. 11). A. To prevent contamination of hydraulic system, thoroughly clean exterior of fan motor and fittings. 6 B. Disconnect hydraulic hoses from cooling fan motor. Put caps or plugs on fittings and hoses to prevent contamination. Label hydraulic lines for proper assembly. 3 4 1 5 C. Remove six (6) cap screws and flange nuts that secure fan motor bracket to radiator. D. Carefully remove fan motor, fan and motor bracket assembly from machine.
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8. Install fan motor and fan assembly (Fig. 11). C. The alternator (Fig. 10). A. Carefully position fan motor, fan and motor bracket assembly to radiator. D. The glow plug connection. E. Wire harness connector to engine ground harness. B. Secure fan motor bracket to radiator with six (6) cap screws and flange nuts. F. The electric starter. Torque nut at starter B+ terminal from 70 to 86 in--lb (7.9 to 9.7 N--m). C.
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Pump Adapter Plate 1 2 RIGHT FRONT 29 to 33 ft--lb (40 to 44 N--m) Loctite #242 5 6 3 4 Boss 4 7 Figure 12 1. Bolt 2. Lock washer 3. Flywheel plate Kubota Diesel Engine 4. Hardened washer (14 used) 5. Spring coupler Page 3 -- 16 6. Bolt (6 used) 7.
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Coupler Removal (Fig. 12) NOTE: The hydraulic pump assembly needs to be removed from engine before coupler can be removed. Engine Side Hydraulic Pump Side 1. If engine is in machine, remove hydraulic pump assembly (see Piston (Traction) Pump Removal in the Service and Repairs section of Chapter 4 -- Hydraulic System). 1 2. Remove flywheel plate and spring coupler from engine using Figure 12 as a guide. 1. Position spring coupler to engine flywheel and align mounting holes.
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Chapter 4 Hydraulic System SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Towing Traction Unit . . . . . . . . . . . . . . . . . . . . . . . . . 4 Check Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . 4 Relieving Hydraulic System Pressure . . . . . . . . . . 5 Traction Circuit Component Failure . . . . . . . . . . . .
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Specifications Item Description Piston (Traction) Pump Eaton variable displacement piston pump (Model 72400) 2.48 in3 (40.6 cc) 5000 PSI (345 bar) 5000 PSI (345 bar) Maximum Displacement (per revolution) System Relief Pressure: Forward System Relief Pressure: Reverse Charge Pressure 207 PSI (14.3 bar) Front Wheel Motors Eaton fixed displacement piston motors (Model 74315) 2.01 in3 (32.9 cc) Displacement (per revolution) Eaton fixed displacement piston motor (Model 74318) 2.48 in3 (40.
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General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Reelmaster machine. Refer to that publication for additional information when servicing the machine. Towing Traction Unit IMPORTANT: If towing limits are exceeded, severe damage to the piston pump may occur. 1 If it becomes necessary to tow (or push) the machine, tow (or push) in a forward direction only, at a speed below 3 mph (4.
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Relieving Hydraulic System Pressure Before disconnecting or performing any work on the hydraulic system, all pressure in the hydraulic system must be relieved. Park machine on a level surface, lower cutting units fully, stop engine and apply parking brake. To relieve hydraulic pressure in traction circuit, move traction pedal to both forward and reverse directions. To relieve hydraulic pressure in steering circuit, rotate steering wheel in both directions.
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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 and maintenance. These conditions can cause hose damage and deterioration. Some hoses are more susceptible to these conditions than others.
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Hydraulic Hose and Tube Installation (O--Ring Face Seal Fitting) 1. Make sure threads and sealing surfaces of the hose/ tube and the fitting are free of burrs, nicks, scratches or any foreign material. C. Use a second wrench to tighten the nut to the correct Flats From Wrench Resistance (F.F.W.R.). The markings on the nut and fitting body will verify that the connection has been properly tightened. 2.
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Hydraulic Fitting Installation (SAE Straight Thread O--Ring Fitting into Component Port) Non--Adjustable Fitting (Fig. 6) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 5. If a torque wrench is not available, or if space at the port prevents use of a torque wrench, an alternate method of assembly is the Flats From Finger Tight (F.F.F.T.) method. 2.
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Adjustable Fitting (Fig. 8) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 2. As a preventative measure against leakage, it is recommended that the O--ring be replaced any time the connection is opened. Lock Nut 3. Lightly lubricate the O--ring with clean hydraulic oil. Fitting threads should be clean with no lubricant applied. Back--up Washer 4. Turn back the lock nut as far as possible.
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Hydraulic System Page 4 -- 10 STEERING CYLINDER R L 6.1 G1 G2 P1 M1 T PRV CV M2 S1 1050 PSI P2 ST T PB P FD L FAN CONTROL MANIFOLD M4 GEAR PUMP G1 M1 P4 .56 T2 RV1 LC1 T1 RV2 LC2 T P1 P3 P2 .56 1.03 1.03 P1 SP1 M4 M2 CV1 40 PSI 5 PSI CV2 SP2 MV2 M3 2.48 P2 OR1 CV1 CV2OR2 M1 M2 MV1 M5 P1 P2 .071 .071 C5 CD2 207 PSI CV1 5000 PSI .
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Hydraulic System Page 4 -- 12 STEERING CYLINDER R L 6.1 G1 G2 P1 M1 T PRV CV M2 S1 1050 PSI P2 ST T PB P FD L FAN CONTROL MANIFOLD M4 GEAR PUMP G1 M1 M1 P4 .56 M4 T2 RV1 LC1 T1 RV2 LC2 T CV1 40 PSI G2 5 PSI CV2 P1 P2 .071 .071 CD2 207 PSI CV1 5000 PSI .091 C5 C1 C4 MOW CONTROL MANIFOLD M3 ENGINE SPEED 2850/1550 SP2 MV2 M3 M2 2.48 P2 OR1 CV1 CV2 OR2 M2 P1 P3 P2 .56 1.03 1.
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Traction Circuit: Mow Speed (4WD) The traction circuit piston pump is a variable displacement pump that is directly coupled to the engine flywheel. Pushing 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 the front wheel and rear axle motors.
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Hydraulic System Page 4 -- 14 Reelmaster 7000 STEERING CYLINDER R L 6.1 G1 G2 P1 M1 T PRV CV M2 S1 1050 PSI P2 ST T PB P FD L FAN CONTROL MANIFOLD M4 GEAR PUMP G1 M1 M1 P4 .56 M4 T2 RV1 LC1 T1 RV2 LC2 T CV1 40 PSI G2 5 PSI CV2 P1 P2 .071 .071 CD2 207 PSI CV1 5000 PSI .091 C5 C1 C4 MOW CONTROL MANIFOLD M3 ENGINE SPEED 2850/1550 SP2 MV2 M3 M2 2.48 P2 OR1 CV1 CV2OR2 M2 P1 P3 P2 .56 1.03 1.
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Traction Circuit: Transport Speed (2WD) Traction circuit pressure (forward and reverse) can be measured at test ports located on the traction circuit hydraulic tubes of the machine. The traction circuit pump and motors use a small amount of hydraulic fluid for internal lubrication. Fluid is designed to leak across traction pump and motor components into the case drain. This leakage results in the loss of hydraulic fluid from the closed loop traction circuit that must be replaced.
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Hydraulic System Page 4 -- 16 Reelmaster 7000 STEERING CYLINDER R L 6.1 G1 G2 P1 M1 T PRV CV M2 S1 1050 PSI P2 ST T PB P FD L FAN CONTROL MANIFOLD M4 GEAR PUMP G1 M1 P4 .56 T2 RV1 LC1 T1 RV2 LC2 T P1 P3 P2 .56 1.03 1.03 P1 SP1 M2 CV1 40 PSI G2 CV2 P1 P2 .071 .071 CD2 207 PSI CV1 5000 PSI .091 C5 C1 C4 MOW CONTROL MANIFOLD M3 ENGINE SPEED 2850/1550 5 PSI 2.
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Lower Cutting Units A four section gear pump is coupled to the piston (traction) pump. Gear pump section P3 supplies hydraulic flow to both the lift control manifold and the steering control valve. Hydraulic flow from this pump section is delivered to the circuits through a proportional flow divider located in the fan control manifold. Maximum lift/lower circuit pressure is limited to 1700 PSI (117 bar) by a relief valve (RV1) in the lift control manifold.
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Hydraulic System Page 4 -- 18 Reelmaster 7000 STEERING CYLINDER R L 6.1 G1 G2 P1 M1 T PRV CV M2 S1 1050 PSI P2 ST T PB P FD L FAN CONTROL MANIFOLD M4 GEAR PUMP G1 M1 P4 .56 T2 RV1 LC1 T1 RV2 LC2 T P1 P3 P2 .56 1.03 1.03 P1 SP1 M4 M2 CV1 40 PSI G2 5 PSI CV2 P1 P2 .071 .071 CD2 207 PSI CV1 5000 PSI .091 C5 C1 C4 MOW CONTROL MANIFOLD M3 ENGINE SPEED 2850/1550 SP2 MV2 M3 2.
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Raise Cutting Units A four section gear pump is coupled to the piston (traction) pump. Gear pump section P3 supplies hydraulic flow to both the lift control manifold and the steering control valve. Hydraulic flow from this pump section is delivered to the circuits through a proportional flow divider located in the fan control manifold. Maximum lift/lower circuit pressure is limited to 1700 PSI (117 bar) by a relief valve (RV1) in the lift control manifold.
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Hydraulic System Page 4 -- 20 Reelmaster 7000 STEERING CYLINDER R L 6.1 G1 G2 P1 M1 T PRV CV M2 S1 1050 PSI P2 ST T PB P FD L FAN CONTROL MANIFOLD M4 P4 .56 P1 SP1 RV1 LC1 T P3 P2 P1 .56 1.03 1.03 T1 RV2 LC2 M2 CV1 40 PSI CV2 5 PSI 2.48 P2 P1 P2 .071 .071 CD2 207 PSI CV1 5000 PSI .
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Mow Circuit Hydraulic flow for the mow circuit is supplied by two (2) sections of the gear pump (P1 and P2). Gear pump section P1 supplies hydraulic flow to cutting units 1, 4 and 5 (front cutting units), while gear pump section P2 supplies cutting units 2 and 3 (rear cutting units). When the reels are shut off, the over--running inertia load of the reels keeps driving the reel motors and can turn them into pumps.
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Hydraulic System Page 4 -- 22 Reelmaster 7000 STEERING CYLINDER R L 6.1 G1 G2 P1 M1 T PRV CV M2 S1 1050 PSI P2 ST T PB P FD L FAN CONTROL MANIFOLD M4 GEAR PUMP G1 M1 M1 P4 .56 M4 T2 RV1 LC1 T1 RV2 LC2 T CV1 40 PSI G2 5 PSI CV2 P1 P2 .071 .071 CD2 207 PSI CV1 5000 PSI .091 C5 C1 C4 MOW CONTROL MANIFOLD M3 ENGINE SPEED 2850/1550 SP2 MV2 M3 M2 2.48 P2 OR1 CV1 CV2 OR2 M2 P1 P3 P2 .56 1.03 1.
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Steering Circuit A four section gear pump is coupled to the piston (traction) pump. The gear pump section P3 supplies hydraulic flow to the steering control valve and the lift control manifold. Gear pump hydraulic flow is delivered to the two circuits through a proportional flow divider located in the fan control manifold. The steering circuit receives priority flow from the flow divider. Steering circuit pressure is limited to 1050 PSI (72 bar) by a relief valve located in the steering control valve.
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Hydraulic System Page 4 -- 24 Reelmaster 7000 STEERING CYLINDER R L 6.1 G1 G2 P1 M1 T PRV CV M2 S1 1050 PSI P2 ST T PB P FD L FAN CONTROL MANIFOLD M4 GEAR PUMP G1 M1 P4 .56 T2 RV1 LC1 T1 T G2 5 PSI CV2 P1 P2 .071 .071 CD2 207 PSI CV1 5000 PSI .091 C5 C1 C4 MOW CONTROL MANIFOLD M3 ENGINE SPEED 2850/1550 SP2 MV2 2.48 P2 CV1 40 PSI RV2 LC2 P3 P2 P1 .56 1.03 1.
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Engine Cooling Fan Circuit The fan control manifold controls the operation of the hydraulic motor that drives the engine cooling fan in addition to including the flow divider (FD) for the steering and lift circuits. The electronically controlled proportional relief valve (PRV) in the manifold controls the oil flow to the fan motor. The fan control manifold controls the speed and direction of the fan motor based on electrical output from the TEC controller.
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Special Tools Order the following special tools from your Toro Distributor. Hydraulic Pressure Test Kit 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. Use gauges as recommended in Testing section of this chapter.
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40 GPM Hydraulic Tester (Pressure and Flow) Use to test hydraulic circuits and components for flow and pressure capacities as recommended in the Testing section of this chapter. This tester includes the following: 1. LOAD VALVE: A simulated working load is created in the circuit by turning the valve to restrict flow. 2. PRESSURE GAUGE: Glycerine filled 0 to 5000 PSI gauge to provide operating circuit pressure. 3.
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High Flow Hydraulic Filter Kit The high flow hydraulic filter kit is designed with large flow (40 GPM/150 LPM) and high pressure (5000 PSI/345 bar) capabilities. This kit provides for bi--directional filtration which prevents filtered debris from being allowed back into the circuit regardless of flow direction. If a component failure occurs in the closed loop traction circuit, contamination from the failed part will remain in the circuit until removed.
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Measuring Container Use this container for doing hydraulic motor efficiency testing (motors with case drain lines only). Measure efficiency of a hydraulic motor by restricting the outlet flow from the motor and measuring leakage from the case drain line while the motor is pressurized by the hydraulic system. The table in Figure 26 provides gallons per minute (GPM) conversion for measured milliliter or ounce motor case drain leakage.
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Troubleshooting The charts that follow contain information to assist in hydraulic system troubleshooting. There may possibly be more than one cause for a machine malfunction. Refer to the Testing section of this Chapter for precautions and specific testing procedures. General Hydraulic System Problems Problem Possible Cause Hydraulic system operates hot. Engine RPM is too low.
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Traction Circuit Problems NOTE: When troubleshooting traction circuit problems, if a problem exists in both mow speed (4WD) and transport speed (2WD), consider a faulty component that affects the entire traction circuit (e.g. charge circuit, relief valves, piston pump, front wheel motors). If the problem exists in mow speed (4WD) but not in transport speed (2WD), consider a problem in the 4WD traction system (e.g. rear axle motor, cartridge valves in 4WD/2WD control manifold).
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PTO Problems Problem Possible Cause None of the cutting units will operate. Cutting units are not fully lowered to ground. NOTE: Cutting units have to be fully lowered and traction speed needs to be in mow speed (4WD) for cutting units to operate. Operator seat is unoccupied. Mow speed limiter is in transport (2WD) position. Electrical problem exists that prevents mow control manifold solenoid valve operation (see Chapter 5 -- Electrical System). Gear pump sections P1 and P2 are damaged.
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PTO Problems (Continued) Problem Possible Cause All cutting units operate slowly. Engine RPM is low. Cutting unit motor is damaged. Gear pump section (P1 or P2) is worn or damaged. Cutting unit stops under load. Relief valve in mow control manifold is bypassing. Cutting conditions (e.g. very tall or wet grass) exceed cutting unit capacity. Cutting unit motor relief valve is stuck or damaged. Gear pump section (P1 or P2) for affected cutting units is worn or damaged.
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Lift/Lower Circuit Problems Problem Possible Cause Cutting units will not raise. Operator seat is unoccupied. NOTE: Operator must be in seat in order to raise the cutting units. Hydraulic oil level in reservoir is low. Electrical problem exists that prevents lift control manifold solenoid valve operation (see Chapter 5 -- Electrical System). Lift cylinder(s) is (are) damaged. Lift arm pivots are binding. Lift/lower circuit relief valve (RV1) in lift control manifold is stuck open.
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Engine Cooling Fan Circuit Problems Problem Possible Cause Cooling fan runs only in forward direction (fan does not run in reverse direction). Fan control manifold solenoid cartridge valve (S1) is faulty. Cooling fan does not rotate. Fan motor is worn or damaged. Electrical problem exists that prevents fan control manifold solenoid valve (S1) operation (see Chapter 5 -- Electrical System). Gear pump section (P4) is worn or damaged. Cooling fan always rotates at slow speed.
PAGE 70
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). 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 71
Which Hydraulic Tests Are Necessary? Before beginning any hydraulic test, identify if the problem is related to the traction circuit, mow circuit, lift/lower circuit, steering circuit or engine cooling fan circuit. Once the faulty system has been identified, perform tests that relate to that circuit. 1.
PAGE 72
M2 2.48 CHG M1 G PD1 M1 (CHARGE CIRCUIT) AXLE REAR FROM STEERING AND LIFT CIRCUITS MOTOR Traction Circuit Charge Pressure Test (Using Pressure Gauge) 450 PSI P2 PRESSURE GAUGE G 2.01 G FRONT MOTORS 2.01 P1 CHG PR CV .052 550 PSI RV SV PD2 FORWARD DIRECTION TEST SHOWN CR1 P1 CD2 CV1 P3 .56 P2 1.03 T 40 PSI 5 PSI CV1 CV2 P2 .071 2.48 P1 1.03 TO DECK CONTROL MANIFOLD TO DECK CONTROL MANIFOLD 207 PSI PSI 5000 .091 .
PAGE 73
Procedure for Traction Circuit Charge Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged. 3. Raise and support operator seat to access charge pressure test port. CAUTION Prevent personal injury and/or damage to equipment.
PAGE 74
M2 2.48 CHG M1 G PD1 M1 (CHARGE CIRCUIT) AXLE REAR FROM STEERING AND LIFT CIRCUITS MOTOR Traction Circuit Relief Pressure Test (Using Pressure Gauge) 450 PSI P2 P1 CHG PR CV .052 550 PSI RV SV PD2 FORWARD DIRECTION TEST SHOWN G G CR1 CR2 CV1 40 PSI CV1 P3 .56 P2 1.03 T P1 1.03 TO DECK CONTROL MANIFOLD TO DECK CONTROL MANIFOLD 5 PSI CV2 P2 .071 2.48 P1 .091 .
PAGE 75
Procedure for Traction Circuit Relief Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. Make sure the hydraulic tank is full. CAUTION Move machine to an open area, away from people and obstructions. NOTE: Seal leakage across pilot directional valves PD1 and PD2 in 4WD/2WD control manifold can also cause low forward traction pressure with reverse pressure meeting specifications.
PAGE 76
M2 2.48 CHG M1 PRESSURE GAUGE 450 PSI P2 G CR1 P1 P3 .56 P2 1.03 T 40 PSI CV1 5 PSI CV2 P2 .071 2.48 P1 1.03 TO DECK CONTROL MANIFOLD TO DECK CONTROL MANIFOLD 207 PSI CV1 .091 .071 ENGINE SPEED 2850/1550 5000 PSI Flow CD2 PSI 5000 Return or Suction BYPASS VALVE Low Pressure CD1 PISTON PUMP Working Pressure CR2 G 2.01 G FRONT MOTORS 2.01 P1 CHG PR CV .
PAGE 77
NOTE: When in reverse, pressure reducing valve (PR) limits the pressure to the rear axle motor to 450 PSI (31 bar) so the rear wheels will not scuff the turf. Procedure for Traction Circuit Pressure Reducing Valve (PR) Pressure Test 2 1 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting units lowered and off.
PAGE 78
M2 2.48 CHG M1 PRESSURE GAUGE 450 PSI P2 G CR1 P1 P3 .56 P2 1.03 T 40 PSI CV1 5 PSI CV2 P2 .071 2.48 P1 1.03 TO DECK CONTROL MANIFOLD TO DECK CONTROL MANIFOLD 207 PSI CV1 .091 .071 ENGINE SPEED 2850/1550 5000 PSI Flow CD2 PSI 5000 Return or Suction BYPASS VALVE Low Pressure CD1 PISTON PUMP Working Pressure CR2 G 2.01 G FRONT MOTORS 2.01 P1 CHG PR CV .
PAGE 79
Procedure for Rear Traction Circuit Relief (RV) Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged. CAUTION Prevent personal injury and/or damage to equipment.
PAGE 80
M2 2.48 CHG M1 450 PSI P2 G 2.01 G FRONT MOTORS 2.01 P1 CHG PR CV .052 550 PSI RV SV PD2 G PD1 M1 (CHARGE CIRCUIT) AXLE REAR FROM STEERING AND LIFT CIRCUITS MOTOR Piston (Traction) Pump Flow Test (Using Tester with Pressure Gauges and Flow Meter) CR1 P1 CD2 207 PSI CV1 40 PSI GEAR PUMP TO FAN CIRCUIT FROM DECK MOTORS Hydraulic System Page 4 -- 46 FROM STEERING CONTROL VALVE P4 .56 TO STEERING AND LIFT CIRCUITS (CHARGE CIRCUIT) FROM DECK CONTROL MANIFOLD P3 .56 P2 1.
PAGE 81
This test measures piston (traction) pump output (flow). During this test, pump load is created at the flow meter using the adjustable load valve on the tester. IMPORTANT: Traction circuit flow for the Reelmaster 7000 is approximately 30 GPM (113.5 LPM). Use 40 GPM Hydraulic Tester #AT40002 (pressure and flow) for this test (see Special Tools in this chapter). 1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes.
PAGE 82
Mow Circuit Pressure Test (Using Pressure Gauge) M4 M1 M5 M2 M3 TO RESERVOIR M1 TEST FOR FRONT CUTTING UNITS SHOWN M2 M4 M3 OR1 SP1 PRESSURE GAUGE MOW CONTROL MANIFOLD MV2 MV1 G1 P1 CV1 CV2 OR2 LC1 LC2 RV1 RV2 T2 T1 SP2 G2 P2 FROM FAN CONTROL TO STEERING AND LIFT CIRCUITS TO FAN CIRCUIT ENGINE SPEED 2850/1550 PISTON PUMP GEAR PUMP .071 P4 .56 P3 .56 P2 P1 1.03 1.03 5000 PSI BYPASS VALVE .091 2.48 .
PAGE 83
Procedure for Mow Circuit Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged. 9. Disengage cutting units and shut off engine. Record test results. 10.After testing is complete, disconnect pressure gauge from manifold test port.
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Mow Circuit Relief Pressure Test (Using Tester with Pressure Gauges and Flow Meter) M4 M1 M5 M2 M3 TO RESERVOIR TESTER M1 M2 M4 M3 MV2 MV1 OR1 TEST FOR PUMP SECTION P1 SHOWN MOW CONTROL MANIFOLD CV1 CV2 OR2 LC1 SP1 Working Pressure LC2 Low Pressure SP2 Return or Suction Flow RV1 RV2 G1 G2 P1 T2 T1 P2 FROM FAN CONTROL TO STEERING AND LIFT CIRCUITS TO FAN CIRCUIT ENGINE SPEED 2850/1550 PISTON PUMP GEAR PUMP .071 P4 .56 P3 .56 P2 P1 1.03 1.03 5000 PSI BYPASS VALVE .091 2.
PAGE 85
The mow circuit relief pressure test should be performed to make sure that the mow circuit relief pressures are correct. Procedure for Mow Circuit Relief Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged.
PAGE 86
Cutting Unit Motor Case Drain Leakage Test (Using Tester with Pressure Gauges and Flow Meter) TO RESERVOIR STEEL CAP TESTER M4 M1 M2 M5 M1 M2 M4 M3 M3 MEASURING CONTAINER MOW CONTROL MV2 MV1 OR1 TEST FOR #4 CUTTING UNIT MOTOR SHOWN SP1 CV1 CV2 LC1 LC2 RV1 RV2 OR2 SP2 G1 Working Pressure MANIFOLD G2 P1 T2 T1 P2 Low Pressure Return or Suction Flow FROM FAN CONTROL TO OIL COOLER CASE DRAIN HOSE FROM GEAR PUMP P1 FROM GEAR PUMP P2 SUPPLY HOSE RETURN HOSE FRONT Hydraulic
PAGE 87
Procedure for Cutting Unit Motor Case Drain Leakage Test NOTE: One method to find a failing or malfunctioning cutting unit 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 a different appearance on the turf. 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. Make sure the hydraulic tank is full. 2.
PAGE 88
Gear Pump P1 and P2 Flow (Mow Circuits) Test (Using Tester with Pressure Gauges and Flow Meter) M4 M1 M5 M2 M3 TO RESERVOIR M1 M2 M4 M3 MOW CONTROL MANIFOLD MV2 MV1 OR1 OR2 CV1 CV2 LC1 LC2 SP2 SP1 RV1 RV2 G1 G2 P1 T2 T1 P2 TESTER TEST FOR GEAR PUMP SECTION P1 SHOWN FROM FAN CONTROL TO STEERING AND LIFT CIRCUITS TO FAN CIRCUIT ENGINE SPEED 2850/1550 PISTON PUMP GEAR PUMP .071 TO OIL COOLER P4 .56 P3 .56 P2 1.03 P1 1.03 5000 PSI BYPASS VALVE .091 2.48 .
PAGE 89
NOTE: Gear pump P1 supplies hydraulic flow to cutting units 1, 4 and 5. Gear pump P2 supplies flow to cutting units 2 and 3. Procedure for Gear Pump P1 and P2 Flow Test NOTE: Over a period of time, the gears and wear plates in the gear pump can wear. A worn pump will by pass oil and make the pump less efficient. Eventually, enough oil loss will occur to cause the cutting unit motors to stall under heavy cutting conditions.
PAGE 90
Steering Circuit Relief Pressure Test (Using Pressure Gauge) M4 M1 M5 M2 M1 M2 M4 M3 MV2 MV1 M1 M2 FAN CONTROL MANIFOLD ST M3 MOW CONTROL MANIFOLD OR1 CV1 CV2 OR2 S1 SP1 LC1 LC2 RV1 RV2 SP2 FD CV G2 G1 G1 PRV P1 T P2 G2 L P1 T2 T1 P2 TO LIFT MANIFOLD ENGINE SPEED 2850/1550 PISTON PUMP GEAR PUMP .071 P4 .56 P3 .56 P2 P1 1.03 1.03 BYPASS VALVE 5000 PSI .091 2.48 .
PAGE 91
Procedure for Steering Circuit Relief Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged. CAUTION 9.
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STEERING CYLINDER FULLY EXTENDED LOOK FOR LEAKAGE FROM FAN CONTROL MANIFOLD Steering Cylinder Internal Leakage Test STEERING WHEEL TURNED FOR RIGHT TURN STEEL PLUG 1050 L PSI P 6.
PAGE 93
The steering cylinder internal leakage test should be performed if a steering problem is identified. This test will determine if the steering cylinder is faulty. 7. After testing is completed, remove plug from the hydraulic hose. Connect hose to the steering cylinder fitting. Procedure for Steering Cylinder Internal Leakage Test 8.
PAGE 94
MANIFOLD FROM STEERING CONTROL VALVE RV1 TO CHARGE CIRCUIT C3 C4 C2 RV2 G P S2 S3 C1 S4 S1 T S5 C3 LIFT CONTROL Lift/Lower Circuit Relief Pressure Test (Using Pressure Gauge) FROM FAN CONTROL MANIFOLD C2 PRESSURE GAUGE C5 C1 C4 Working Pressure Low Pressure G2 Return or Suction Hydraulic System Page 4 -- 60 Flow Reelmaster 7000
PAGE 95
Procedure for Lift/Lower Circuit Relief Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting units fully lowered. Apply the parking brake and stop engine. 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.
PAGE 96
Gear Pump P3 Flow (Steering and Lift/Lower Circuits) Test (Using Tester with Pressure Gauges and Flow Meter) TO MOW CONTROL MANIFOLD (P2 PORT) TO MOW CONTROL MANIFOLD (P1 PORT) TESTER TO STEERING AND LIFT CIRCUITS TO FAN CIRCUIT ENGINE SPEED 2850/1550 PISTON PUMP GEAR PUMP .071 P4 .56 P3 .56 P2 1.03 P1 1.03 BYPASS VALVE .091 2.48 .
PAGE 97
NOTE: Gear Pump P3 supplies oil flow for the steering, lift and traction charge circuits. Procedure for Gear Pump P3 Flow Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged. 3. Raise hood to allow access to pump assembly.
PAGE 98
Cooling Fan Circuit Test (Using Pressure Gauge and Phototac) M4 M1 M5 M2 M1 M2 M4 M3 MV2 MV1 M1 M2 FAN CONTROL MANIFOLD ST M3 MOW CONTROL MANIFOLD OR1 CV1 CV2 OR2 S1 SP1 LC1 LC2 RV1 RV2 SP2 FD CV G2 G1 G1 PRV P1 T P2 G2 L P1 T2 T1 P2 TO LIFT MANIFOLD PRESSURE GAUGE ENGINE SPEED 2850/1550 PISTON PUMP GEAR PUMP .071 P4 .56 P3 .56 P2 P1 1.03 1.03 5000 PSI BYPASS VALVE .091 2.48 .071 5000 PSI P2 CV2 T CD1 5 PSI CV1 CV1 40 PSI STEERING CYLINDER 1050 PSI L 6.
PAGE 99
The cooling fan circuit test should be performed to make sure that the engine cooling fan circuit has the correct system pressure and fan speed. Procedure for Cooling Fan Circuit Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is applied. 8.
PAGE 100
Gear Pump P4 Flow (Cooling Fan Circuit) Test (Using Tester with Pressure Gauges and Flow Meter) TO MOW CONTROL MANIFOLD (P2 PORT) TO MOW CONTROL MANIFOLD (P1 PORT) TO STEERING AND LIFT CIRCUITS TO FAN CIRCUIT ENGINE SPEED 2850/1550 PISTON PUMP TESTER GEAR PUMP .071 P4 .56 P3 .56 P2 1.03 P1 1.03 BYPASS VALVE .091 2.48 .
PAGE 101
NOTE: Gear Pump P4 supplies oil flow for the engine cooling fan circuit. Procedure for Gear Pump P4 Flow Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged. 3. Raise hood to allow access to pump assembly. CAUTION Prevent personal injury and/or damage to equipment.
PAGE 102
Adjustments Adjust Control Manifold Relief Valves Several of the hydraulic control manifolds on your Reelmaster include adjustable relief valves. The following procedure can be used to adjust these relief valves. Refer to the Testing section of this chapter for information on testing relief pressure. NOTE: Do not remove relief valve from the hydraulic manifold for adjustment. 1 1. Locate relief valve on control manifold. 2. Remove cap on relief valve with an allen wrench. 3.
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Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Hydraulic Components After Repair or Replacement of Hydraulic 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 104
Check Hydraulic Lines and Hoses IMPORTANT: Check hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, wear, loose fittings or deterioration. Make all necessary repairs before operating the machine. 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.
PAGE 105
Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time there is a severe component failure or the system is contaminated (oil appears milky, black or contains metal particles). IMPORTANT: Flush hydraulic system when changIng from petroleum base hydraulic fluid to a biodegradable fluid. Operate machine under normal operating conditions for at least four (4) hours before draining. 1. Park machine on a level surface. Lower cutting units, stop engine and engage parking brake.
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Filtering Closed--Loop Traction Circuit Filtering of a closed--loop hydraulic system after a major component failure (e.g. traction (piston) pump or front wheel motor) is a requirement to prevent debris from transmitting throughout the system. If a closed--loop hydraulic system filtering tool is not used to ensure system cleanliness, repeat failures, as well as subsequent damage to other hydraulic components in the affected system, will occur.
PAGE 107
Charge Hydraulic System IMPORTANT: Change hydraulic oil filter whenever hydraulic components are repaired or replaced. 11. After the hydraulic system starts to show signs of fill, actuate lift control switch until the lift cylinder rods move in and out several times. If the cylinder rods do not move after fifteen (15) seconds or the pump emits abnormal sounds, shut the engine off immediately and determine cause or problem. Inspect for the following: A. Loose filter or suction lines. 1.
PAGE 108
Gear Pump 15 14 77 to 93 ft--lb (105 to 126 N--m) 18 13 7 3 18 11 11 8 2 1 16 16 17 9 12 5 8 4 5 12 22 23 6 19 21 RIGHT FRONT 20 11 103 to 118 ft--lb (140 to 160 N--m) 10 Figure 51 1. 2. 3. 4. 5. 6. 7. 8. Flat washer (2 used) Cap screw (2 used) 90o hydraulic fitting Hydraulic tee fitting O--ring Gear pump assembly Piston pump assembly 90o hydraulic fitting 9. 10. 11. 12. 13. 14. 15. 16.
PAGE 109
7. Support gear pump assembly to prevent it from falling. 8. Remove two (2) cap screws and washers securing gear pump to piston pump. Remove gear pump, coupler (item 9), spacer (item 17) and O--rings (item 16) from machine. 9. If hydraulic fittings are to be removed from gear pump, mark fitting orientation to allow correct assembly. Remove fittings from pump and discard O--rings. RIGHT FRONT 3 4 5 Installation (Fig. 51) 1 2. Lubricate new O--rings (item 16) with clean hydraulic oil.
PAGE 110
Gear Pump Service 18 6 9 12 10 14 13 15 17 16 5 3 19 4 11 24 21 9 11 1 2 8 7 21 26 25 23 22 33 ft--lb (45 N--m) 22 20 Figure 53 1. 2. 3. 4. 5. 6. 7. 8. 9. Dust seal Retaining ring Flange washer Shaft seal Front cover Dowel pin (16 used) Pressure seal Back--up gasket Thrust plate (8 used) 10. 11. 12. 13. 14. 15. 16. 17. 18.
PAGE 111
3. Secure the front cover of the pump in a vise with the drive shaft pointing down. 4. Loosen the four (4) cap screws that secure pump assembly. 5. Remove pump from vise and remove fasteners. 6. Support the pump assembly and gently tap the pump case with a soft face hammer to loosen the pump sections. Be careful to not drop parts or disengage gear mesh. IMPORTANT: Mark the relative positions of the gear teeth and the thrust plates so they can be reassembled in the same position.
PAGE 112
Piston (Traction) Pump 15 14 77 to 93 ft--lb (105 to 126 N--m) 13 18 7 3 18 11 11 8 2 1 16 16 17 9 12 5 8 4 5 12 22 6 23 19 21 RIGHT FRONT 20 11 103 to 118 ft--lb (140 to 160 N--m) 10 Figure 55 1. 2. 3. 4. 5. 6. 7. 8. Flat washer (2 used) Cap screw (2 used) 90o hydraulic fitting Hydraulic tee fitting O--ring Gear pump assembly Piston pump assembly 90o hydraulic fitting 9. 10. 11. 12. 13. 14. 15. 16.
PAGE 113
7. Remove gear pump from machine (see Gear Pump Removal in this section). 9. Connect engine run solenoid electrical connector, start the engine and check for proper operation. 8. Support the piston pump to prevent it from falling while removing two (2) cap screws and washers retaining pump assembly to engine adapter plate. Carefully pull pump assembly from adapter plate and raise it out of the machine. 10.Properly fill hydraulic system (see Charge Hydraulic System). 11.
PAGE 114
Piston (Traction) Pump Service 40 to 48 in--lb (4.5 to 5.4 N--m) 4 to 6 ft--lb (5 to 8 N--m) 40 to 48 in--lb (4.5 to 5.
PAGE 115
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PAGE 116
4WD/2WD and Filtration/Charge Control Manifolds 3 9 2 1 4 5 6 11 10 RIGHT FRONT 7 8 Figure 59 1. 2. 3. 4. Filtration/charge control manifold Hydraulic oil filter 4WD/2WD control manifold Manifold bracket Hydraulic System 5. 6. 7. 8. Flange head screw (3 used) Flange nut (2 used) Cap screw (2 used) Lift circuit junction manifold Page 4 -- 82 9. Flange head screw (2 used) 10. Flat washer (2 used) 11.
PAGE 117
Removal (Fig. 59) NOTE: The ports on the manifolds are marked for easy identification of components. Refer to the Hydraulic Schematic in Chapter 9 -- Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each port. 2. To prevent contamination of hydraulic system during manifold removal, thoroughly clean exterior of manifold. 12 6. If hydraulic fittings are to be removed from control manifold, mark fitting orientation to allow correct assembly (Figure 60 or 61).
PAGE 118
4WD/2WD Control Manifold Service 50 ft--lb (68 N--m) 6 20 ft--lb (27 N--m) 7 25 ft--lb (34 N--m) 25 ft--lb (34 N--m) 14 UP 1 20 to 26 ft--lb (27 to 35 N--m) 10 15 5 8 5 3 20 ft--lb (27 N--m) 35 ft--lb (47 N--m) 20 ft--lb (27 N--m) 25 ft--lb (34 N--m) 50 ft--lb (68 N--m) 50 ft--lb (68 N--m) 7 6 UP 11 9 1 4 12 13 60 in--lb (6.8 N--m) 2 20 ft--lb (27 N--m) Figure 62 1. 2. 3. 4. 5. Manifold body Nut Orifice (0.050) Orifice disc (0.
PAGE 119
NOTE: The ports on the manifold are marked for easy identification of components (e.g. P1 is a piston pump connection port and SV is the location for the solenoid valve). See Hydraulic Schematic in Chapter 9 -- Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each port. NOTE: The 4WD/2WD control manifold uses several zero leak plugs. These plugs have a tapered sealing surface on the plug head that is designed to resist vibration induced plug loosening.
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Filtration/Charge Control Manifold Service UP 25 ft--lb (34 N--m) 6 35 ft--lb (47 N--m) 2 1 UP 50 ft--lb (68 N--m) 4 25 ft--lb (34 N--m) 3 5 50 ft--lb (68 N--m) 3 35 ft--lb (47 N--m) 25 ft--lb (34 N--m) 2 25 ft--lb (34 N--m) 3 2 50 ft--lb (68 N--m) Figure 63 1. Manifold body 2. Zero leak plug (#8) 3. Zero leak plug (#6) 4. Check valve (reservoir return) NOTE: The ports on the manifold are marked for easy identification of components (e.g.
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Control Manifold Cartridge Valve Service 2. If cartridge valve is solenoid operated, remove nut securing solenoid coil to the cartridge valve. Carefully slide coil off the valve. IMPORTANT: Use care when handling the cartridge valve. Slight bending or distortion of the stem tube can cause binding and malfunction. When removing cartridge valve from manifold, make sure that deep well socket fully engages the valve base. 3. Remove cartridge valve from manifold using a deep socket wrench.
PAGE 122
Rear Axle Motor Arrows on side of motor case point up 5 6 7 7 8 4 5 2 1 10 9 3 RIGHT FRONT Figure 64 1. 2. 3. 4. Axle motor O--ring Pinion gear External snap ring Hydraulic System 5. O--ring 6. Hydraulic fitting 7. O--ring Page 4 -- 88 8. 90o hydraulic fitting 9. Cap screw (2 used) 10.
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Removal (Fig. 64) Installation (Fig. 64) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 1. If fittings were removed from axle motor, lubricate and place new O--rings onto fittings. Install fittings into motor ports using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 3.
PAGE 124
Front Wheel Motors 75 to 85 ft--lb (102 to 115 N--m) 1 2 20 15 3 14 10 18 22 16 14 15 23 24 25 19 18 6 10 19 17 16 10 9 13 10 12 11 9 75 to 85 ft--lb (102 to 115 N--m) RIGHT 8 7 Arrows on side of motor case point up 5 21 4 75 to 85 ft--lb (102 to 115 N--m) 85 to 100 ft--lb (116 to 135 N--m) FRONT Figure 65 1. 2. 3. 4. 5. 6. 7. 8. 9.
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1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Raise front of machine and support with jackstands. 3. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 4. To prevent contamination of hydraulic system during wheel motor removal, thoroughly clean exterior of motor. 5.
PAGE 126
Rear Axle and Front Wheel Motor Service 15 to 18 ft--lb (20 to 24 N--m) FRONT WHEEL MOTOR SHOWN 1 7 9 10 13 10 2 9 11 18 8 6 19 20 14 15 16 12 4 5 3 17 Figure 66 1. 2. 3. 4. 5. 6. 7. Drive shaft Backplate Housing assembly Rotating assembly Cam plate insert Retaining ring Cap screw 8. 9. 10. 11. 12. 13. 14. Shaft seal (front motor only) Retaining ring Thrust race O--ring Valve plate Thrust bearing Roll pin NOTE: The front wheel motors (shown in Figure 66) are identical.
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Cutting Reel Motor Removal 4. Install the cap screws for the reel drive motor into the cutting unit side plate and leave approximately 1/2 inch (12.7 mm) of threads exposed on each screw. 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 5. Rotate the motor clockwise so the motor flanges clear the cap screws in the cutting unit side plates. Align reel motor shaft splines with cutting reel insert splines.
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Cutting Reel Motor Service 18 33 ft--lb (45 N--m) 19 ft--lb (25 N--m) 14 17 16 13 7 6 11 9 6 7 2 14 3 15 19 ft--lb (25 N--m) 12 10 9 8 4 5 1 Figure 68 1. 2. 3. 4. 5. 6. Dust seal Retaining ring Flange washer Shaft seal Front flange Pressure seal 7. 8. 9. 10. 11. 12. Back--up gasket Front wear plate Dowel pin Idler gear Drive shaft Rear wear plate 13. 14. 15. 16. 17. 18. O--ring Relief valve Body Washer (4 used) Lock washer (4 used) Cap screw (4 used) Disassembly (Fig. 68) 1.
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4. Loosen cap screws from the rear cover. 4. Inspect wear plates for the following: 5. Remove motor from the vise. Turn motor so that the shaft end is facing down. Remove cap screws. A. Bearing areas should not have excessive wear or scoring. 6. Carefully remove body. Lift body straight up to remove. Make sure the rear wear plate remains on the drive and idler gear shafts. Remove and discard O-rings from the body. Locate and retrieve dowel pins. B.
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Assembly (Fig. 68) NOTE: When assembling the motor, check the marker line on each part to make sure the parts are properly aligned during assembly. 1. Lubricate O--rings, pressure seals, back--up gaskets and wear plate grooves with a thin coat of petroleum jelly. Lubricate all other internal parts freely with clean hydraulic oil. 2. Install new seals into front flange (Fig. 70): 7. Lubricate the idler gear shaft with clean hydraulic oil.
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PAGE 132
Mow Control Manifold 2 RIGHT FRONT 6 3 1 5 4 Figure 72 1. Mow control manifold 2. Flange head screw (4 used) Hydraulic System 3. Filter head 4. Hydraulic oil filter Page 4 -- 98 5. Lift control manifold 6.
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Removal (Fig. 72) NOTE: The ports on the manifold are marked for easy identification of components. Example: P1 is the gear pump connection port (see Hydraulic Schematic in Chapter 9 -- Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each port). 1. Park machine on a level surface, lower cutting units, stop engine, apply parking brake and remove key from the ignition switch. 4.
PAGE 134
Mow Control Manifold Service 12 18 25 ft--lb (34 N--m) 15 16 5 12 15 25 ft--lb (34 N--m) 15 16 17 15 18 6 25 ft--lb (34 N--m) 17 20 ft--lb (27 N--m) 6 25 ft--lb (34 N--m) 4 8 9 2 10 11 25 ft--lb (34 N--m) 8 3 60 in--lb (6.8 N--m) 14 7 UP 1 13 12 2 25 ft--lb (34 N--m) 3 Figure 74 1. 2. 3. 4. 5. 6. Manifold body Proportional valve (SP1 & SP2) Solenoid coil (2 used) Relief valve (RV1 & RV2) Pressure compensator (LC1 & LC2) Check valve (CV1 & CV2) 7. 8. 9. 10. 11. 12.
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Mow/Backlap Spool Service (Fig. 74) Manifold Plugs (Fig. 75) 1. To remove backlap spool (item 17) from mow manifold: NOTE: The mow control manifold uses several zero leak plugs. These plugs have a tapered sealing surface on the plug head that is designed to resist vibration induced plug loosening. The zero leak plugs also have an O--ring as a secondary seal.
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Steering Control Valve 1 RIGHT 4 2 FRONT 3 20 to 26 ft--lb (28 to 35 N--m) 7 Antiseize Lubricant 10 9 11 14 15 5 7 to 10 ft--lb (10 to 13 N--m) 13 Antiseize Lubricant 6 8 6 6 12 Figure 76 1. 2. 3. 4. 5. Steering wheel cover Lock nut Steering wheel Flat washer O--ring 6. 7. 8. 9. 10. Flange head screw (4 used) Steering column Steering control valve Socket head screw (4 used) Flange nut (4 used) Removal (Fig. 76) 1.
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7. Position steering column brace (item 12) to machine and secure with four (4) flange head screws. CAUTION 8. Slide rubber bellows to bottom of steering column. 8. Disconnect hydraulic lines from steering control valve. Allow lines to drain into a suitable container. 9. Position shroud in place and secure with removed fasteners (Fig. 77). 10.Check oil level in hydraulic reservoir and add correct oil if necessary. 11.
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Steering Control Valve Service 2 3 1 8 4 5 6 5 9 7 10 22 11 12 13 14 13 15 13 16 17 18 19 20 to 24 ft--lb (27 to 33 N--m) 20 21 Figure 79 1. 2. 3. 4. 5. 6. 7. 8. Relief valve assembly Dust seal ring Steering valve housing Shaft seal Thrust washer Bearing race Ring Spring set 9. 10. 11. 12. 13. 14. 15. Cross pin Sleeve Spool Cardan shaft O--ring Distributor plate Outer gearwheel 16. 17. 18. 19. 20. 21. 22.
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Steering Cylinder 7 6 9 15 7 4 9 8 2 16 5 4 1 3 10 12 14 11 13 14 RIGHT FRONT 100 to 125 ft--lb (136 to 169 N--m) Figure 80 1. 2. 3. 4. 5. 6. Steering cylinder Ball joint Ball joint Retaining ring Grease fitting Grease fitting Hydraulic System 7. 8. 9. 10. 11. 90o hydraulic fitting O--ring O--ring Drive axle assembly Ball joint spacer Page 4 -- 106 12. 13. 14. 15. 16.
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Removal (Fig. 80) Installation (Fig. 80) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 1. If fittings were removed from steering cylinder, lubricate and place new O--rings onto fittings. Install fittings into cylinder ports using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 3.
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Steering Cylinder Service 50 to 60 ft--lb (68 to 81 N--m) 2 3 4 1 7 9 10 5 Loctite #271 12 6 8 14 11 15 13 1 2 7 6 3 5 8 4 15 11 13 9 10 12 14 Figure 81 1. 2. 3. 4. 5. Barrel Lock nut Wear band Square ring Piston seal Hydraulic System 6. 7. 8. 9. 10. O--ring Piston Buffer seal O--ring Back--up ring Page 4 -- 108 11. 12. 13. 14. 15.
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Disassembly (Fig. 81) Assembly (Fig. 81) 1. Remove oil from steering 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 cylinder components are clean before assembly. 2. Mount steering cylinder securely in a vise by clamping on the clevis end of the barrel. Use of a vise with soft jaws is recommended. 3. Loosen head from barrel: A.
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Engine Cooling Fan Motor RIGHT FRONT 4 3 2 1 5 27 to 33 ft--lb (37 to 44 N--m) 21 6 20 7 8 2 9 4 5 19 10 18 13 14 15 16 17 12 11 12 to 14 ft--lb (17 to 18 N--m) Figure 82 1. 2. 3. 4. 5. 6. 7. Hydraulic fan motor O--ring Bracket 45o hydraulic fitting O--ring Hydraulic hose Fan hub 8. 9. 10. 11. 12. 13. 14. Washer Hex nut Engine Cap screw (4 used) Washer (4 used) Fan Lock nut (2 used) 15. 16. 17. 18. 19. 20. 21. Removal (Fig. 82) 1.
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IMPORTANT: Make sure to not damage the radiator or other machine components while loosening and removing the fan motor and bracket assembly. 6. Remove cooling fan motor and bracket assembly. A. To prevent contamination of hydraulic system, thoroughly clean exterior of fan motor and fittings. B. Disconnect hydraulic hoses from fan motor. Put caps or plugs on fittings and hoses to prevent contamination. Label hydraulic lines for proper assembly. C.
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Engine Cooling Fan Motor Service 11 10 15 6 3 1 14 7 16 13 8 9 5 4 14 8 2 12 9 33 ft--lb (45 N--m) Figure 84 1. 2. 3. 4. 5. 6. Flange washer O--ring Front flange Dust seal Retaining ring Front wear plate 7. 8. 9. 10. 11. Shaft seal Backup gasket Pressure seal Rear wear plate Body 12. 13. 14. 15. 16. Idler gear Cap screw (4 used) Dowel (2 used) Drive gear Washer (4 used) For disassembly, inspection and assembly procedures of the cooling fan motor, see Reel Motor Service in this section.
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Fan Control Manifold 2 1 3 6 5 4 RIGHT FRONT Figure 85 1. Fan control manifold 2. Flange head screw (2 used) Hydraulic System 3. Filter head 4. Hydraulic oil filter Page 4 -- 114 5. Lift control manifold 6.
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NOTE: The ports on the manifold are marked for easy identification of components. Example: P1 is the gear pump connection port (see Hydraulic Schematic in Chapter 9 -- Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each port). 1. Park machine on a level surface, lower cutting units, stop engine, apply parking brake and remove key from the ignition switch. 2.
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Fan Control Manifold Service 60 in--lb (6.8 N--m) 50 ft--lb (68 N--m) 10 5 2 25 ft--lb (34 N--m) 60 in--lb (6.8 N--m) 7 1 6 6 25 ft--lb (34 N--m) 2 9 2 25 ft--lb (34 N--m) 8 25 ft--lb (34 N--m) 3 UP 4 1 20 ft--lb (27 N--m) UP 20 ft--lb (27 N--m) Figure 87 1. 2. 3. 4. Manifold body Zero leak plug (#6) (3 used) Zero leak plug (#4) (2 used) Check valve (port CV) 5. Flow divider cartridge (port FD) 6. Solenoid coil (2 used) 7.
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Lift Control Manifold 8 RIGHT FRONT 2 3 7 4 1 5 6 Figure 88 1. Lift control manifold 2. Filter mount bracket 3. Filter head 4. Hydraulic oil filter 5. Valve mount bracket Removal (Fig. 88) NOTE: The ports on the manifold are marked for easy identification of components. Example: P is the supply connection port (see Hydraulic Schematic in Chapter 9 -- Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each port). 1.
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2. Install hydraulic manifold to the frame using Figure 88 as guide. Make sure that cutting units are fully lowered before loosening hydraulic lines from lift manifold. If cutting units are raised as hydraulic lines are loosened, cutting units may drop unexpectedly. 6. Disconnect hydraulic lines from manifold and put caps or plugs on open hydraulic lines and fittings. Label disconnected hydraulic lines for proper assembly. 7. Remove hydraulic manifold from the frame using Figure 88 as guide.
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Lift Control Manifold Service 60 in--lb (6.8 N--m) 8 8 60 in--lb (6.8 N--m) UP 4 7 9 20 ft--lb (27 N--m) 4 20 ft--lb (27 N--m) 20 ft--lb (27 N--m) 10 7 60 in--lb (6.8 N--m) 6 5 11 1 4 2 20 ft--lb (27 N--m) 20 ft--lb (27 N--m) 3 6 Figure 90 1. 2. 3. 4. Manifold body Relief valve (port RV2) Solenoid valve (port S1) Solenoid coil (5 used) 5. 6. 7. 8.
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For cartridge valve service procedures, see Control Manifold Cartridge Valve Service in this section. Refer to Figure 90 for cartridge valve and plug installation torque. Hydraulic System IMPORTANT: A flow control orifice is placed beneath the hydraulic fittings in lift control manifold ports C2, C3 and C4. If any of these fittings are removed from the manifold, make sure to remove orifice and label its position for assembly purposes. Also note location of groove in orifice for assembly purposes.
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Lift Circuit Junction Manifold 3 9 2 1 4 5 6 11 10 RIGHT 7 FRONT 8 Figure 91 1. 2. 3. 4. Filtration/charge control manifold Hydraulic oil filter 4WD/2WD control manifold Manifold bracket Hydraulic System 5. 6. 7. 8. Flange head screw (3 used) Flange nut (2 used) Cap screw (2 used) Lift circuit junction manifold Page 4 -- 122 9. Flange head screw (2 used) 10. Flat washer (2 used) 11.
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Removal (Fig. 91) NOTE: The ports on the lift circuit junction manifold are marked for easy identification of components (e.g. P1 is the gear pump connection port). See Hydraulic Schematic in Chapter 9 -- Foldout Drawings to identify the function of the hydraulic lines at each port. 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 1.
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Front Lift Cylinders RIGHT FRONT 21 5 14 20 11 16 2 24 13 5 14 12 11 6 6 7 1 1 1 8 6 12 13 2 6 7 15 10 22 26 19 15 3 8 6 7 12 10 19 7 1 1 25 15 23 6 19 10 4 10 9 19 15 22 15 27 23 1 10 4 22 15 19 4 29 30 26 19 10 26 23 18 17 32 31 28 Figure 93 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
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Removal (Fig. 93) Installation (Fig. 93) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 1. If fittings were removed from lift cylinder, lubricate and place new O--rings onto fittings. Install fittings into cylinder openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 3.
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Rear Lift Cylinders 12 15 11 22 24 16 16 21 25 23 7 26 32 11 17 5 11 10 8 26 13 1 11 6 3 34 34 4 14 16 22 2 24 19 31 31 20 9 23 25 11 33 32 11 5 17 26 29 26 RIGHT 27 6 FRONT 12 16 7 30 28 18 8 Figure 95 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
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1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 3. To prevent contamination of hydraulic system during lift cylinder removal, thoroughly clean exterior of lift cylinder.
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Lift Cylinder Service 35 to 45 ft--lb (48 to 61 N--m) 2 5 6 1 10 3 11 4 13 Loctite #271 7 16 8 9 12 17 14 15 6 2 3 4 5 7 8 1 11 9 13 17 14 10 12 15 16 Figure 97 1. 2. 3. 4. 5. 6. Barrel Lock nut Wear band Square ring Piston seal O--ring 7. 8. 9. 10. 11. 12. Piston Buffer seal O--ring Back--up seal Head Retaining ring 13. 14. 15. 16. 17.
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Disassembly (Fig. 97) Assembly (Fig. 97) 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 cylinder components are clean before assembly. 2. Mount lift cylinder securely in a vise by clamping on the clevis end of the barrel. Use of a vise with soft jaws is recommended. 2. Coat new seal kit components with clean hydraulic oil. A. Install new seals, wear band and O--ring to the piston. B.
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Hydraulic Reservoir 15 16 RIGHT 1 FRONT 14 10 13 11 68 to 75 ft--lb (93 to 101 N--m) 12 8 9 7 6 21 4 18 22 2 19 5 3 20 80 to 88 ft--lb (109 to 119 N--m) 17 8 Figure 98 1. 2. 3. 4. 5. 6. 7. 8. Hydraulic reservoir Tank strainer Clamp Hydraulic fitting Hydraulic tee fitting Bumper Flat washer (2 used) Flange nut (3 used) Hydraulic System 9. 10. 11. 12. 13. 14. 15. Clamp (2 used) Cap screw (2 used) Flat washer (2 used) Breather Screen filter Dipstick Plug Page 4 -- 130 16. 17. 18. 19.
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Removal (Fig. 98) Inspection 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 1. Clean hydraulic reservoir and suction strainer with solvent. 3. To prevent contamination of hydraulic system during hydraulic reservoir removal, thoroughly clean exterior of reservoir. 4. Disconnect one of the hydraulic tubes from the tee fitting on bottom of reservoir to allow draining of reservoir. Drain reservoir into a suitable container.
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Hydraulic Oil Cooler 12 11 10 13 RIGHT 8 9 FRONT 14 7 15 3 16 8 1 6 4 3 2 5 Figure 99 1. 2. 3. 4. 5. 6. Oil cooler Mount plate (2 used) Flange head screw (8 used) Radiator mount Radiator Air intake hose Hydraulic System 7. 8. 9. 10. 11. Plenum Flange nut (4 used) O--ring 90o hydraulic fitting (2 used) O--ring Page 4 -- 132 12. 13. 14. 15. 16.
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Removal (Fig. 99) 2. Install oil cooler using Figures 99, 100 and 101 as guides. See Hydraulic Hose and Tube Installation in the General Information section of this chapter for hydraulic hose installation information. 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. 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 3.
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Chapter 5 Electrical System Table of Contents Reelmaster 7000 Engine Cooling Fan Switch . . . . . . . . . . . . . . . . . . Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . Mow/Transport Sensor . . . . . . . . . . . . . . . . . . . . . . Cutting Unit Position Sensor . . . . . . . . . . . . . . . . . Backlap Switches . . . . . . . . . . . . . . . . . . . . . . . . . . Glow and Main Power Relays . . . . . . . . . .
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General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Reelmaster machine. Refer to the Operator’s Manual for additional information when servicing the machine. Toro Electronic Controller (TEC) Reelmaster 7000 machines use a single Toro Electronic Controller (TEC) to manage machine electrical functions.
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Electrical Drawings Electrical System The electrical schematics and other electrical drawings for the Reelmaster 7000 are located in Chapter 9 -- Foldout Drawings.
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Special Tools Order special tools from your Toro distributor. Some tools may also be available from a local supplier. Multimeter The multimeter can test electrical components and circuits for current (amps), resistance (ohms) or voltage. Obtain this tool locally. NOTE: Toro recommends the use of a DIGITAL Volt-Ohm--Amp multimeter when testing electrical circuits.
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Diagnostic Display The Diagnostic Display (Fig. 5) can be connected to the wiring harness connector located inside the console arm to verify correct electrical functions of the machine. Toro Electronic Controllers (TEC) inputs and outputs can be checked using the Diagnostic Display. Toro Part Number for Diagnostic Display: 85--4750 Toro Part Number for Overlay (English): 120--1679 NOTE: Diagnostic Display overlays are available in several languages for your Reelmaster.
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Troubleshooting For effective troubleshooting and repairs, there must be a good understanding of the electrical circuits and components used on this machine (see Chapter 9 -- Foldout Drawings). 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. If the machine has any interlock switches by--passed, reconnect the switches for proper safety and troubleshooting.
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5. The “inputs displayed” LED, on lower right column of the Diagnostic Display, should be illuminated. If “outputs displayed” LED is illuminated, press the toggle button on the Diagnostic Display to change to “inputs displayed” LED. TEC OVERLAY 6. The Diagnostic Display 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, press traction pedal, etc.
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Diagnostic Display Inputs Diagnostic Display LED Operation P BRAKE OFF Parking brake released: LED ON Parking brake applied: LED OFF DECKS DOWN Cutting units lowered: LED ON Cutting units raised: LED OFF NEUTRAL Traction pedal in neutral: LED ON Traction pedal in forward or reverse: LED OFF SEAT SWITCH Operator seat occupied: LED ON Operator seat empty: LED OFF HI RANGE Mow speed limiter is in the transport (2WD) position: LED ON Mow speed limiter is in the mow (4WD) position: LED OFF DECK RAISE
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Verify Diagnostic Display Output Functions The Diagnostic Display also has the ability to detect which output solenoids or relays are energized by the TEC controller(s). This is a quick way to determine if a machine malfunction is electrical or hydraulic. NOTE: An open output (e.g. an unplugged connector or a broken wire) cannot be detected with the Diagnostic Display. C.
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Starting Problems Problem Possible Causes No electrical power to machine (including gauges). Battery is discharged. Battery cables are loose or corroded. Ground connection on machine is loose or corroded. Fuse F3--1 (2 amp) is faulty (open). The ignition switch or circuit wiring is faulty. Starter solenoid clicks, but starter will not crank. Battery is discharged. NOTE: If the solenoid clicks, the problem is not in the in- Battery cables are loose or corroded. terlock circuit.
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Starting Problems (continued) Problem Possible Causes Engine cranks, but does not start. Fuel tank is empty. Engine is not cranking fast enough. Engine and/or fuel may be too cold. Fuse F5--1 (40 amp) is faulty (open). Glow relay, glow plugs or fuse M1 (60 amp) are faulty. Engine run solenoid or circuit wiring is faulty. Fuel pump is faulty. Engine or fuel system is malfunctioning (see Chapter 3 -- Kubota Diesel Engine). Starter cranks, but should not when the traction pedal is depressed.
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Cutting Unit Operating Problems Cutting units run, but should not, when raised. Cutting units shut off with PTO switch. The cutting unit position switch or circuit wiring is faulty. Wire harness connections are incorrectly connected to hydraulic solenoid valve coils on hydraulic mow control manifold. Cutting units run, but should not, when raised. Cutting units do not shut off with the PTO switch. The cutting unit position switch or circuit wiring AND PTO switch or circuit wiring are faulty.
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Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the battery terminals. Voltage Measured Battery Charge Level 12.68 V (or higher) Fully charged (100%) Set multimeter to the DC volts setting. The battery should be at a temperature of 60o to 100oF (16o to 38oC). The ignition key should be off and all accessories turned off.
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Check Operation of Interlock Switches CAUTION Do not disconnect safety switches. They are for the operator’s protection. Check the operation of the interlock switches daily for proper operation. Replace any malfunctioning switches before operating the machine. Electrical System Interlock switch operation is described in the Traction Unit Operator’s Manual. Your Reelmaster is equipped with an Toro Electronic Controller (TEC) which monitors interlock switch operation.
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Adjustments Mow/Transport Sensor The mow/transport sensor is a normally open proximity sensor that closes when the mow speed limiter is placed in the transport position. The sensor mounts to a bracket on the footrest platform (Fig. 12). The sensing plate for the mow/transport sensor is a tab on the mow speed limiter. 2 Adjustment 1. The gap between the mow/transport sensor and the mow speed limiter should be from 0.040” to 0.100” (1.1 to 2.5 mm). 2.
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Cutting Unit Position Sensor The cutting unit position sensor is a normally open proximity sensor that is located on the front carrier frame (Fig. 13). The sensing plate that closes the sensor is a gusset on the front right cutting unit (#5) lift arm. When the cutting units are lowered, the gusset on the lift arm is located near the position sensor and the sensor closes. This closed sensor provides an input for the TEC controller to allow the lowered cutting units to operate.
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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 checking continuity on the switch terminals). NOTE: For engine component testing information, see the Kubota Workshop Manual, Diesel Engine, 03--M-DI--E3B. CAUTION When testing electrical components for continuity with a multimeter (ohms setting), make sure that power to the circuit has been disconnected.
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Fuses Your Reelmaster 7000 uses numerous fuses for circuit protection. The fuses are located in two (2) areas of the machine. Most of the fuses reside in the power center behind the operator’s seat. An in--line fuse holder located in the wire harness near the engine starter motor holds an additional fuse (F5--1) that protects the engine run solenoid pull coil circuit. Fuse Testing Fuse Identification and Function (Figs. 17 and 18) 3. Remove fuse from fuse block for testing.
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Indicator Lights Charge Indicator Light The charge indicator light should come on when the ignition switch is in ON with the engine not running or with an improperly operating charging circuit while the engine is running. 3 2 4 To test the charge indicator light and circuit wiring, ground the white wire attached to alternator. Turn ignition switch to ON; the charge indicator light should illuminate indicating correct operation of the electrical wiring to the alternator.
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Hour Meter The hour meter is located on the outside of the console arm. 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 (6) minutes. 4. Disconnect voltage source from the hour meter.
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PTO Switch The PTO switch is located on the console arm (Fig. 23). The PTO switch is pulled up to engage the PTO and pushed in to disengage the PTO. NOTE: To engage the PTO, the seat has to be occupied, traction speed has to be in low range (4WD) and the cutting units have to be fully lowered. 7. After testing is completed, connect the wire harness connector to the PTO switch. 8. Assemble console arm (see Console Arm Assembly in the Service and Repairs section of Chapter 7 -- Chassis). Testing 1.
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Cutting Unit Lift Switch The cutting unit lift switch is used as an input for the TEC controller to raise or lower the cutting units. When the lift switch paddle is depressed and held, the cutting units will lower. When the lift switch paddle is raised and held, the cutting units will raise. The cutting units will remain in position when the switch is released. The lift switch is located on the console arm (Fig. 25). 7. After testing is completed, connect wire harness connector to the lift switch. 8.
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Headlight Switch The headlight switch is located on the operator side of the console arm (Fig. 28). This two (2) position rocker switch allows the headlights to be turned on and off. 1 Testing 1. Make sure ignition switch is OFF. Remove key from ignition switch. 2. Disassemble console arm to gain access to headlight switch (see Console Arm Disassembly in the Service and Repairs section of Chapter 7 -- Chassis). 3. Disconnect harness electrical connector from the switch.
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Engine Cooling Fan Switch The engine cooling fan switch is located on the outside of the console arm (Fig. 30). This two (2) position rocker switch allows the engine cooling fan to run in the normal, automatic mode or in the manual reverse (momentary) direction. 2 Testing 1. Before disconnecting the engine cooling fan switch for testing, the switch and its circuit wiring should be tested as a TEC input with the Diagnostic Display (see Diagnostic Display in the Troubleshooting section of this chapter).
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Seat Switch The seat switch is normally open and closes when the operator is on the seat. The seat switch and its electrical connector are located in the seat assembly. If the traction system or PTO switch is engaged when the operator raises out of the seat, the engine will stop. Testing of the switch can be done without seat removal by disconnecting the switch wire from the machine wire harness (Fig. 32). Testing 1.
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Parking Brake Switch The parking brake switch is a normally open proximity switch. The parking brake switch is attached to the bottom of the RH brake pedal (Fig. 33). When the parking brake is not applied, the parking brake detent is positioned near the target end of the parking brake switch so the switch is closed. The parking brake detent is moved away from the switch when the parking brake is applied causing the switch to open. Switch Testing 1.
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Mow/Transport Sensor The mow/transport sensor is a normally open proximity sensor that closes when the mow speed limiter is placed in the transport (2WD) position. The sensor mounts to a bracket on the footrest platform. The sensing plate for the mow/transport sensor is the mow speed limiter. The mow/transport sensor is used as an input for the TEC controller. 4.
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Cutting Unit Position Sensor The cutting unit position sensor is a normally open proximity sensor that is located on the traction unit frame (Fig. 36). The sensing plate that closes the sensor is a gusset on the front right cutting unit (#5) lift arm. 5. If the cutting unit position sensor tests correctly and a circuit problem still exists, check wire harness (see Electrical Schematic and Wire Harness Drawings in Chapter 9 -- Foldout Drawings).
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Backlap Switches The backlap switches are normally open ball switches that are in the normal, open state when the backlap levers are in the mow position. When a backlap lever is in the backlap position, the switch closes. The backlap switches are attached to the hydraulic mow control manifold located under the hood (Fig. 38). The Toro Electronic Controller (TEC) uses the backlap switches as inputs. 1 2 4 Testing 3 1.
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Glow and Main Power Relays The glow and main power relays are located at the power center behind the operator seat (Fig. 40). These relays are attached to the wire harness with a four (4) wire connector (Fig. 41). The glow relay is used to provide current to the engine glow plugs when energized by the TEC controller. The TEC controls and monitors the operation of the glow relay. 7. Disconnect voltage and test leads from the relay terminals. 8.
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Start Relay The start relay is located at the power center behind the operator seat (Fig. 42). This relay is attached to the wire harness with a five (5) wire connector (Fig. 43). The start relay is used to provide current to the engine starter motor when energized by the TEC controller. The TEC controls and monitors the operation of the start relay. 10.Secure relay to mounting bracket and connect wire harness connector to relay. Install cover to power center. 11.
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Reel Speed Potentiometer The reel speed potentiometer controls the cutting reel speed. The TEC controller uses the potentiometer setting as an input to determine the necessary voltage output for the hydraulic mow control manifold proportional valves (SP1 and SP2) for correct cutting reel speed. The reel speed potentiometer is located under the operator seat (Fig. 44). 1 Testing 1.
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Hydraulic Solenoid Valve Coils Numerous hydraulic solenoid valve coils are used on the hydraulic control manifolds of Reelmaster 7000 machines. When energized by the TEC controller, these coils provide hydraulic circuit control. 5. If solenoid coil resistance is incorrect, replace solenoid (see Hydraulic Solenoid Valve Coil Removal and Installation in the Service and Repairs section of this chapter). Two (2) different solenoid valve coils are used on the Reelmaster 7000.
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Traction Neutral Switch The traction neutral switch is closed when the traction pedal is in the neutral position and opens when the pedal is depressed in either direction. The switch is located on the right side of the piston (traction) pump (Fig. 47). See Piston Pump Control Assembly in Chapter 4 -- Hydraulic Systems for disassembly and assembly procedures for the neutral switch.
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Toro Electronic Controller (TEC) The Reelmaster 7000 uses a Toro Electronic Controller (TEC) to monitor the condition of various switches (inputs) and then directs power output to allow certain machine functions. The controller is located under the operator seat (Fig. 49). The handheld Diagnostic Display (see Special Tools in this chapter) with the correct overlay should be used when checking inputs and outputs of the controller used on your Reelmaster (see Troubleshooting in this chapter).
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Engine Coolant and Hydraulic Oil Temperature Senders Two (2) identical temperature senders are used as inputs for the TEC controller to identify if either the engine coolant or hydraulic oil temperature has reached an excessive level. The coolant temperature sender threads into the radiator (Fig. 50). The hydraulic oil temperature sender is attached to the 4WD/2WD control manifold at the front of the machine (Fig. 51). 7. After allowing the sender to cool, install sender: Testing 8.
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Fuel Pump The fuel pump is energized by the TEC controller when the ignition switch is either in the START or ON position. The fuel pump is attached to the left side frame rail. 1 3 IMPORTANT: When testing fuel pump, make sure that pump is not operated without fuel. Fuel Pump Capacity Test 1. Park machine on a level surface, lower cutting units, stop engine and engage parking brake. Remove key from ignition switch. 2 2. Raise and support hood. 3. Remove 20A fuse (F1--1) (Fig.
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Fuel Stop Solenoid The fuel stop solenoid used on your Reelmaster must be energized for the diesel engine to run. The solenoid is mounted to the injection pump on the engine (Fig. 55). The TEC controller monitors the operation of the fuel stop solenoid. The solenoid and its circuit wiring should be tested as a controller output with the Diagnostic Display before following the testing procedure listed below (see Special Tools and Troubleshooting in this chapter). 1 2 Testing 1.
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Engine Temperature Sender The engine temperature sender is located near the alternator on the water flange attached to the engine cylinder head (Fig. 57). There is a gray wire attached to the terminal of the sender. The resistance of the temperature sender reduces as the engine coolant temperature increases. The changing resistance of the temperature sender signals the console temperature gauge to indicate engine coolant temperature during machine operation. Engine Temperature Sender Test 1.
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Oil Pressure Switch The engine oil pressure switch is located on the engine above the starter motor (Fig. 59). The oil pressure switch is a normally closed switch that opens with pressure. The oil pressure switch should open at approximately 8 PSI (0.56 kg/cm2). 2 The TEC controller monitors the operation of the oil pressure switch. The switch and its circuit wiring should be tested as a controller input with the Diagnostic Display (see Special Tools and Troubleshooting in this chapter).
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Service and Repairs NOTE: For more component repair information, see the Kubota Workshop Manual, Diesel Engine, 03--M-DI--E3B. Battery Storage If the machine will be stored for more than 30 days: 1. Remove the battery and charge it fully (see Battery Service in this section). 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.
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Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can be prevented. 1 3 CAUTION 2 When working with batteries, use extreme caution to avoid splashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes. Always wear safety goggles and a face shield when working with batteries.
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Battery Testing C. Make sure battery terminals are free of corrosion. 1. Conduct a hydrometer test of the battery electrolyte. D. Measure the temperature of the center battery cell. A. Measure the specific gravity of each cell with a hydrometer. Draw electrolyte in and out of the hydrometer barrel prior to taking a reading to warm-up the hydrometer. At the same time take the temperature of the cell. B. Temperature correct each cell reading. For each 10oF (6oC) above 80oF (27oC) add 0.
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Battery 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 locations. CAUTION Follow the battery charger manufacturer’s instructions when using a battery charger. NOTE: Using specific gravity of the battery cells is the most accurate method of determining battery condition. 1.
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Hydraulic Solenoid Valve Coils A solenoid valve coil on a hydraulic control manifold can be replaced without opening the hydraulic system. 4 Removal (Fig. 61) 3 1. Park machine on a level surface, lower cutting units, stop engine and engage parking brake. Remove key from ignition switch. 60 in--lb (6.8 N--m) 2. Locate solenoid valve coil that is to be removed. 3. Disconnect wire harness electrical connector from the coil that is to be removed.
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Chapter 6 Axles, Planetaries and Brakes Table of Contents Axles, Planetaries and Brakes SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Brake Inspection and Repair . . . . . . . . . . . . . . . . . .
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Specifications Item Specification Wheel lug nut torque (front and rear) 85 to 100 ft--lb (116 to 135 N--m) Steering cylinder bolt torque 100 to 125 ft--lb (136 to 169 N--m) Planetary, brake housing and wheel motor mounting screw torque 75 to 85 ft--lb (102 to 115 N--m) Rear wheel toe--in 0.125 in (3 mm) Tire pressure (front and rear) 20 psi (138 kPa) Planetary gear drive lubricant Planetary gear lube capacity (each wheel) SAE 85W--140 wt. gear lube 16 fl oz (0.
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General Information Operator’s Manual Axles, Planetaries and Brakes The Traction Unit Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Reelmaster machine. Refer to this publication for additional information when servicing the machine.
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Service and Repairs Brake Assembly 75 to 85 ft--lb (102 to 115 N--m) 1 19 18 3 6 85 to 100 ft--lb (116 to 135 N--m) 5 2 17 17 8 9 15 RIGHT 14 20 7 16 13 12 11 10 FRONT 75 to 85 ft--lb (102 to 115 N--m) 19 4 Figure 1 1. 2. 3. 4. 5. 6. 7. Flange head screw (6 per planetary) Splined brake shaft Planetary assembly (2 used) Front wheel assembly (2 used) Lug nut (8 per wheel) Retaining ring Spring plate 8. 9. 10. 11. 12. 13. 14.
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5. Remove hydraulic wheel motor (see Front Wheel Motors in Service and Repairs section of Chapter 4 -Hydraulic System). 6. Disconnect brake cable from pull rod on brake. NOTE: Be careful to not drop splined brake shaft as brake assembly is removed. 7. Support brake assembly and remove flange head cap screws (item 11) securing brake assembly to frame. Remove brake assembly. WARNING Failure to maintain proper wheel lug nut torque could result in failure or loss of wheel and may result in personal injury. 8.
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Brake Inspection and Repair 3 2 1 4 5 6 7 8 9 15 14 10 13 12 11 Figure 4 1. 2. 3. 4. 5. Brake housing (LH shown) Seal Pull rod Clevis pin (2 used) Link (2 used) 6. 7. 8. 9. 10. Hitch pin (2 used) Stationary disc (4 used) Rotating disc (3 used) Retaining ring Gasket Brake Inspection and Repair (Fig. 4) 1. Carefully scrape gasket material (item 10) from brake housing and planetary wheel drive mounting surfaces. 11. 12. 13. 14. 15.
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Planetary Wheel Drive Assembly 75 to 85 ft--lb (102 to 115 N--m) 1 19 18 3 6 2 17 17 8 9 15 14 7 16 13 12 RIGHT FRONT 20 11 10 75 to 85 ft--lb (102 to 115 N--m) 5 19 4 85 to 100 ft--lb (116 to 135 N--m) Figure 5 1. 2. 3. 4. 5. 6. 7. Flange head screw (6 per planetary) Splined brake shaft Planetary assembly (2 used) Front wheel assembly (2 used) Lug nut (8 per wheel) Retaining ring Spring plate 8. 9. 10. 11. 12. 13. 14.
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4. Remove front wheel assembly. 5. Remove hydraulic wheel motor (see Front Wheel Motor Removal in the Service and Repairs section of Chapter 4 -- Hydraulic System). 1 6. Remove brake assembly (see Brake Assembly Removal in this section). 7. Support planetary assembly to prevent it from falling. Loosen and remove six (6) flange head screws that secure planetary assembly to frame. Remove planetary assembly from machine. 2 8. Remove and discard gasket (item 19).
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Planetary Wheel Drive Service 2 118 to 144 in--lb (13.3 to 16.3 N--m) 3 4 7 8 9 11 1 12 13 14 5 15 16 6 10 28 21 13 27 26 17 25 24 23 22 20 19 18 Figure 7 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Spindle Boot seal Oil seal Inner bearing cone Inner bearing cup Wheel stud (8 used) Socket head screw (16 used) Lock washer (16 used) Housing Dowel pin (2 used) Axles, Planetaries and Brakes 11. 12. 13. 14. 15. 16. 17. 18. 19.
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NOTE: The planetary wheel drive assembly can be serviced with the planetary installed to machine. If the spindle (item 1) needs to be removed from machine, see Planetary Wheel Drive Assembly in this section. Disassembly (Figs. 7 and 8) 1. If planetary wheel drive assembly is installed on machine: A. Park machine on a level surface, lower cutting units, stop engine and remove key from the ignition switch. B. Drain oil from planetary wheel drive/brake assembly. C.
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F. Lightly oil bearing journals on spindle shaft. Slide housing assembly onto spindle (item 1) taking care to not damage seal or spindle. Make sure that inner bearing in housing fully seats against spindle shaft shoulder. G. Install outer bearing cone (item 12) onto spindle. NOTE: The planetary shim kit includes the retaining ring and several thrust washers with thickness in incremental steps of 0.004 inch (0.10 mm). H. Measure thickness of thrust washer (item 14) that was removed during disassembly.
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Rear Axle Assembly 7 6 5 70 ft--lb (94 N--m) maximum 8 1 4 3 2 14 13 10 12 11 9 16 22 17 15 5 21 20 RIGHT 85 to 100 ft--lb (116 to 135 N--m) 19 FRONT 18 Figure 9 1. 2. 3. 4. 5. 6. 7. 8. Steering cylinder Needle bearing External snap ring External snap ring Thrust washer Flat washer Lock nut Grease fitting 9. 10. 11. 12. 13. 14. 15. Cap screw (2 used) Flat washer (2 used) Rear axle motor O--ring Pinion gear Gear Stop pin 16. 17. 18. 19. 20. 21. 22.
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7. Remove hydraulic hose from hydraulic fitting on side of input gear case. 8. Remove lock nut and flat washer from axle pivot pin. 9. Support rear axle to prevent it from falling. Remove pivot pin. Lower rear axle from machine. Note location of thrust washer on both ends of axle mounting boss. 10.If needed for further axle disassembly, remove steering cylinder from axle (see Steering Cylinder in Service and Repairs section of Chapter 4 -- Hydraulic System). 11.
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Rear Axle Service 10 11 21 20 19 17 18 24 22 2 23 16 1 25 4 13 15 12 5 26 43 6 7 8 44 45 27 46 61 62 14 3 9 47 8 33 28 29 32 30 31 10 11 48 37 50 63 64 42 22 60 51 38 41 52 8 9 35 36 49 13 34 40 53 59 54 58 39 57 56 55 Figure 12 Axles, Planetaries and Brakes Page 6 -- 16 Reelmaster 7000
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Figure 12 (Continued) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. LH axle support Flange bushing (2 used) Axle vent Filter Vent extension Cap screw (4 used per gear case) Shim set Seal washer Plug Lock nut Lock washer Grease fitting Ball bearing Screw (2 used per steering arm) Axle case support (LH shown) Bolt (2 used) Stud (2 used) Shim set Differential assembly O--ring Plug O--ring 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43.
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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. 13). 4 5 2 2. Mark both right and left bevel gear case/axle case assemblies. 3 35 to 41 ft--lb (47 to 56 N--m) IMPORTANT: Do not interchange right and left bevel gear case/axle case assemblies.
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5. Remove the knuckle pin mounting screws and the knuckle pin. Remove the gasket and any remaining gasket material from either mating surface (Fig. 16). 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. 2 1 17 to 20 ft--lb (23 to 27 N--m) 3 4 Thread--locking Compound 7. Pull the bevel gear case from the axle case and remove the upper bevel gear and collar from the gear case. 5 8.
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Installation 1. Coat new shaft seal with grease and install in axle case as shown (Fig. 18). 3 2 1 Figure 18 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. 19). Tighten cover screws from 17 to 20 ft-lb (23 to 27 N--m). 3. Shaft seal 7 8 3. Slide the bevel gear case over the bevel gear shaft and install the bevel gear and collar.
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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.
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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. 22). LOWER BEVEL GEAR BACKLASH: 0.004 to 0.016 inch (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).
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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 1. Remove the axle cover mounting screws. Remove the axle cover from the axle case as an assembly (Fig. 25). 4 3 2. Use a bearing puller to remove the bearing and bevel gear as shown (Fig. 26). 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.
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Input Shaft/Pinion Gear 35 to 41 ft--lb (47 to 56 N--m) 1 3 2 18 20 19 9 8 7 6 5 17 4 18 16 15 10 14 10 9 13 11 35 to 41 ft--lb (47 to 56 N--m) 12 Figure 28 1. 2. 3. 4. 5. 6. 7. Nut (2 used) Lock washer (2 used) Stud (2 used) Lock nut Stake washer Oil seal O-ring 8. 9. 10. 11. 12. 13. 14. Seal collar Bearing O-ring Input shaft/pinion gear Bearing case Shim Screw (2 used) The following procedures assume the rear axle assembly has been removed from the machine. Removal (Fig. 28) 1.
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5. Install a new stake washer. Install the lock nut finger tight. 6. Set the bearing preload by securing the bearing case in a vise. Thread a M12 x 1.5 hex head cap screw into the splined end of the input shaft/pinion gear and slowly tighten the lock nut until 4 to 6 in-lb (0.4 to 0.7 N--m) of force is required to rotate the input shaft/pinion gear in the bearing case. 0.040 in. (1.0 mm) 2 1 7. Secure the lock nut with the stake washer. 8.
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Differential Gear The following procedures assume the rear axle assembly has been removed from the machine. 35 to 41 ft--lb (47 to 56 N--m) 1 Removal 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. 2. Mark and pull the differential shaft assemblies from the axle support. 3. Remove input shaft/pinion gear assembly, shims and O-ring from the axle support (Fig.
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Inspection 1. Measure the differential side gear O.D. and the differential case I.D. to determine the side gear to case clearance (Fig. 35). Replace components as necessary. SIDE GEAR TO CASE CLEARANCE: 0.002 to 0.012 inch (0.05 to 0.30 mm) 1 SIDE GEAR O.D. (Factory Spec.): 1.335 to 1.337 inch (33.91 to 33.95 mm) DIFFERENTIAL CASE I.D. (Factory Spec.): 1.339 to 1.341 inch (34.00 to 34.06 mm) 2 2. Measure the differential pinion shaft O.D. and the pinion gear I.D.
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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.
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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. 39): 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.
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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. 42): A. Install thicker or additional bearing case shim(s) to move pinion shaft toward ring gear. Figure 42 B. Install thinner or remove differential bearing shim(s) to move ring gear backward. C.
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Chapter 7 Chassis Table of Contents Chassis GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Cutting Unit Identification . . . . . . . . . . . . . . . . . . . . . 2 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Console Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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General Information Operator’s Manual The Traction Unit and Cutting Unit Operator’s Manuals provide information regarding the operation, general maintenance and maintenance intervals for your Reelmaster machine. Refer to these publications for additional information when servicing the machine. Cutting Unit Identification Cutting units on the Reelmaster 7000 are identified as shown in Figure 1.
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Service and Repairs Steering Column 1 RIGHT 4 2 FRONT 3 20 to 26 ft--lb (28 to 35 N--m) 7 Antiseize Lubricant 10 9 11 7 to 10 ft--lb (10 to 13 N--m) 5 Antiseize Lubricant 6 8 6 6 12 Figure 2 1. 2. 3. 4. Steering wheel cover Lock nut Steering wheel Flat washer 5. 6. 7. 8. Socket head screw (4 used) Flange head screw (4 used) Steering column Steering control valve Removal (Fig. 2) 1. Park the machine on a level surface, engage the parking brake, lower the cutting units and stop the engine.
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7. Slide rubber bellows up steering column to allow access to fasteners that secure steering control valve and steering column to machine. 1 2 4 8. Support steering control valve to prevent it from shifting during steering column removal. 3 9. Loosen and remove four (4) socket head screws (item 5) that secure steering control valve to steering column. 4 10.Loosen and remove four (4) socket head screws (item 9) and flange nuts (item 10) that secure steering column to machine. 5 6 11.
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Console Arm 28 39 40 7 34 33 14 12 26 13 41 8 15 24 37 27 25 35 10 36 21 19 20 27 45 11 9 5 15 44 31 23 43 3 10 38 1 42 18 16 36 32 17 22 30 RIGHT 6 6 FRONT 2 4 29 Figure 5 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
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Disassembly (Fig. 5) 7 1. Park machine on a level surface, lower cutting units, stop engine and engage parking brake. Remove key from ignition switch. 8 5 11 4. Remove five (5) washer head screws (item 4) that secure each cover to console arm panel. 6. Remove electrical components from console arm as needed using Figure 5 as a guide. 7. If necessary, remove console panel and supports from machine using Figures 5 and 6 as guides. 4 12 3.
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Lift Arms for Front Cutting Units (#1, #4 and #5) RIGHT FRONT 21 5 14 11 20 2 16 24 13 5 14 12 11 6 6 1 7 8 1 1 6 12 13 2 6 7 15 10 22 15 23 7 1 10 25 3 7 12 8 6 1 19 15 10 19 26 6 19 4 27 15 10 4 22 10 9 19 15 22 23 1 15 19 4 29 30 26 19 10 26 23 18 17 32 31 28 Figure 7 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
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Removal (Fig 7) 4. Position lift cylinder rod clevis to lift arm 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 5. Make sure that one (1) retaining ring and washer are installed on cylinder pin (item 4). Insert cylinder pin through the lift arm and lift cylinder clevis. Secure pin with second washer and retaining ring. Make sure that retaining ring is fully seated in pin. 2.
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Lift Arms for Rear Cutting Units (#2 and #3) 11 25 22 24 16 12 15 16 21 23 7 26 17 11 32 8 5 11 11 10 26 1 13 6 3 4 22 9 32 24 16 2 23 25 11 5 RIGHT 6 FRONT 16 7 30 19 31 31 20 17 26 14 29 27 28 33 12 26 11 18 8 Figure 9 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
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CAUTION CAUTION Be careful when removing tension from the torsion spring on the rear lift arms. The spring is under heavy load and may cause personal injury. 4. Remove tension from torsion spring on rear of lift arm tube (Fig. 11): A. Insert nut driver or small piece of pipe onto the end of the torsion spring that is on the rear of the lift arm. B. Push down and rearward on the spring end to unhook the spring from the stop on the lift arm. 5. Loosen and remove lock nut (item 13) from lift arm pivot pin. 6.
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Operator Seat RIGHT FRONT 25 26 16 23 20 27 28 35 24 10 17 32 22 19 31 4 34 14 3 10 7 25 33 25 21 30 24 6 2 29 18 5 11 8 12 9 15 25 1 9 13 8 Figure 12 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Seat frame Seat plate Torsion spring Seat plate latch Clevis pin Flat washer Cotter pin Hair pin (4 used) Seat frame rod (2 used) Flat washer (3 used) Hair pin Seat pivot shaft Chassis 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
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Removal (Fig. 12) 1. Park machine on a level surface, lower cutting units, stop engine, apply parking brake and remove key from the ignition switch. 2. Disconnect seat electrical connector from machine wire harness. 3. Support console arm assembly to prevent it from shifting. 4. Remove flange nut (item 25) and carriage screw (item 24) that secure support bracket (item 21) to support channel (item 19). 5. Remove cap screw (item 26) that secures console arm support (item 20) to hex nut (item 27). A.
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Operator Seat Service 28 7 6 21 1 2 5 13 12 21 29 22 26 25 31 30 18 19 20 11 4 16 14 17 24 3 23 9 8 27 10 15 Figure 14 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Backrest cushion Seat cushion LH armrest cover LH armrest Bushing (2 used) Backrest Plug (2 used) Cable tie (3 used) LH adjustment rail Bumper (2 used) Washer Chassis 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
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Disassembly (Fig. 14) Assembly (Fig. 14) 1. Remove seat from machine for service (see Operator Seat Removal in this section). 1. Assemble operator seat using Figure 14 as a guide. 2. Install seat to machine (see Operator Seat Installation in this section). Chassis 2. Disassemble operator seat as necessary using Figure 14 as a guide.
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Operator Seat Suspension RIGHT 16 17 FRONT 24 22 25 23 5 18 2 19 21 33 1 20 3 39 14 12 7 35 28 30 6 15 38 27 13 31 4 36 8 29 9 10 26 33 11 34 32 37 Figure 15 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Cover Cover Level control Air control valve Shock absorber Air spring Air tube assembly Wire harness Compressor Bellows Stop Bumper set (2 used) Roller (4 used) Chassis 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
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NOTE: Most of the seat suspension components can be serviced with the seat suspension base mounted to the seat plate. If the air spring assembly (item 6) requires removal, the seat suspension base will have to be removed from the seat plate. Disassembly (Fig. 15) 5 4 1. Park machine on a level surface, lower cutting units, stop engine, apply parking brake and remove key from the ignition switch. 3 2. Remove operator seat from seat suspension (see Operator Seat Removal in this section). 3.
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Hood 5 6 RIGHT 4 26 FRONT 1 7 25 22 8 30 33 24 11 31 20 21 26 25 32 29 23 3 14 10 12 13 2 9 17 16 28 15 18 27 19 Figure 17 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Screen Latch keeper Pop rivet (2 used) Hood Plastic plug (20 used) Hood screen Bulb seal (2 used) Adjustable latch Hair pin (2 used) Rear bumper Pop rivet (2 used) Chassis 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
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Removal (Fig. 17) Installation (Fig. 17) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 1. If components were removed from hood, assemble hood using Figure 17 as a guide. 2. Release hood latches and raise hood. 3. Remove hair pins and washers from pivot pins on radiator frame. 4. Remove hood from pivot pins and machine. 2. Slide hood frame onto radiator frame pivot pins. 3.
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Chapter 8 DPA Cutting Units Table of Contents 16 18 20 22 24 25 25 28 30 32 33 34 36 Reelmaster 7000 Page 8 -- 1 DPA Cutting Units Units Backlapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bedbar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . Bedbar Adjuster Service . . . . . . . . . . . . . . . . . . . . Bedknife Replacement and Grinding . . . . . . . . . . Reel Assembly Removal and Installation . . . . . . Reel Assembly Removal . . . . . . . . . . . . . . . . . .
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Specifications Figure 1 Frame Construction: Precision machined die cast aluminum cross member with two (2) bolt--on cast ductile iron side plates. Bedknife: Replaceable, single edged, high carbon steel bedknife is fastened to a machined cast iron bedbar with screws. Optional bedknifes are available. Reel Construction: Reels are 27 inches (69 cm) in length and 7 inch (18 cm) in diameter. High strength, low alloy steel blades are thru hardened and impact resistant.
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General Information Cutting Unit Operator’s Manual Reelmaster 7000 Page 8 -- 3 DPA Cutting Units Units DPA Cutting 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. rear roller brush), the installation instructions for the kit includes set--up and operation information.
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Special Tools Special tools 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. Used for Height--of-Cut adjustment Figure 2 Bedknife Screw Tool Toro Part Number: 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.
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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.
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Reel Bearing Installation Tool Toro Part Number: 117--0975 Use the reel bearing installation tool to keep the reel bearing aligned as the cutting unit side plate is installed on the bearing. Figure 8 Roller Rebuild Kit Toro Part Number: 115--0803 Bearing Installation Washer This tool kit is used to assemble the cutting unit rollers.
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Reelmaster 7000 Page 8 -- 7 DPA Cutting Units Units DPA Cutting This page is intentionally blank.
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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.
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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.
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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. Cutting unit accessories DPA Cutting Units A variety of cutting unit accessories are available that can be used to enhance aftercut appearance. Refer to Operator’s Manual for a listing of available accessories.
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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.
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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.
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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. 2 3 1. Place the assembled cutting unit on a surface plate. 1 2. Make sure that bedknife is properly adjusted to cutting reel. 4 4 3.
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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. 1 1 2 1 4 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. Loosen two (2) cap screws that secure the hydraulic reel motor to the cutting unit side plate.
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Cutting Unit Removal and Installation Cutting Unit 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. 3 2. If front outside cutting units (#4 or #5 cutting unit) is being removed, separate hydraulic hoses from hose guide. 4 2 3. Remove hydraulic reel motor from cutting unit that is to be removed (see Hydraulic Reel Motor Removal in this section).
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Backlapping DANGER 2 TO AVOID PERSONAL INJURY OR DEATH: D Never place hands or feet in the reel area while the engine is running. Stay away from the cutting reels when backlapping. 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.
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8. If reels stall or become erratic while backlapping, increase the engine speed slightly until the reel speed stabilizes. Top Face Relief Angle 9. To make an adjustment to the cutting units while backlapping, disengage the PTO switch and turn the engine OFF. Wait for all machine movement to stop. After adjustments have been completed, repeat steps 5 through 8. 10.When the backlapping operation is completed, disengage the PTO switch and turn the engine OFF. Wait for all machine movement to stop.
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Bedbar Assembly 12 6 4 5 7 10 13 5 11 9 1 8 27 to 33 ft--lb (37 to 44 N--m) Antiseize Lubricant 3 2 16 14 15 16 17 18 19 RIGHT FRONT Antiseize Lubricant Figure 22 1. 2. 3. 4. 5. 6. 7. Bedbar Bedknife Screw 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. 22) 1.
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8. 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. 22) 1. If rubber bushing was removed from either cutting unit side plate, install a new bushing. The bushing should be installed flush with the inside of the side plate (Fig. 23). 2. If removed, install the flange bushings (item 15) with flange facing outward. Apply antiseize lubricant to inside of flange bushing. 3.
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Bedbar Adjuster Service Loctite #242 14 to 16 ft--lb (19 to 21 N--m) 15 to 20 ft--lb (21 to 27 N--m) 10 6 3 9 2 12 5 11 5 7 8 1 4 Antiseize Lubricant RIGHT FRONT Figure 24 1. 2. 3. 4. Bedbar assembly Compression spring Lock nut Bedbar adjuster shaft 5. 6. 7. 8. Flange bushing Cap screw Detent Wave washer 9. 10. 11. 12. Lock nut Bedbar adjuster screw Washer Flat washer NOTE: The bedbar adjuster system for current production DPA cutting units is shown in Figure 24.
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Removal (Fig. 24) 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). NOTE: Inside threads in bedbar adjuster shaft (item 4) are left--hand threads. 3. Unscrew bedbar adjuster screw (item 10) from the bedbar adjuster shaft (item 4). 4. Remove adjuster shaft from cutting unit frame: A. On current production cutting units (Fig. 24), remove lock nut and flat washer from adjuster shaft.
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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. 26). 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).
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Reel Assembly Removal and Installation 21 12 22 Grease OD surface 1 27 to 33 ft--lb (37 to 44 N--m) 15 16 8 14 4 13 3 4 17 2 5 18 6 19 7 20 RIGHT 9 See text for tightening procedure Grease bore 12 and threads 10 11 FRONT 27 to 33 ft--lb (37 to 44 N--m) Antiseize Lubricant Figure 29 1. 2. 3. 4. 5. 6. 7. 8.
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2. Remove the cutting unit from the machine and place on a flat work area (see Cutting Unit Removal and Installation in this section). 1 NOTE: The reel bearings and grease seals are press fit on the cutting reel shaft and should remain on the reel when removing the LH side plate. 9. Remove shoulder bolts (item 8) and flange nuts (item 24) that secure the LH side plate to the cutting unit frame. Remove the LH side plate from the reel shaft, rollers, bedbar and cutting unit frame.
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IMPORTANT: During cutting reel installation, keep inner and outer bearing races aligned. If bearing races are not aligned, binding will occur and reel installation may cause bearing damage. Use reel bearing installation tool (#117--0975) to help with bearing alignment during reel installation. 3. Using reel bearing installation tool (see Special Tools in this chapter) to keep reel bearing aligned, carefully slide the cutting reel with bearings and grease seals into the RH side plate.
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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 6 RIGHT 3 85 to 95 ft--lb (115 to 128 N--m) (Left Hand Threads) FRONT 4 5 Figure 32 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 8 -- 28 8. Groove indicating LH threads 9. Bearing shoulder 10.
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Inspection of Cutting Reel (Fig. 32) Assembly of Cutting Reel (Fig. 32) 1. Inspect reel bearings to insure that they rotate 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. A. Check the reel shaft for bending and distortion by placing the shaft ends in V--blocks. B. Check the reel blades for bending or cracking. C.
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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. Reel Shaft Diameter (OD) 1.
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Front Roller Removal (Fig. 34) 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 Loctite #242 15 to 19 ft--lb (20 to 26 N--m) 3 3.
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Rear Roller Removal (Fig. 35) 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 2 4.
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Roller Service Disassembly (Fig. 36) 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 3 3.
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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. 4. Install new bearing and outer seals into second end of roller tube: NOTE: After roller is installed to cutting unit, lubricate roller grease fittings, rotate roller to properly distribute grease in bearings and clean excess grease from roller ends. A properly assembled roller should rotate with less than 5 in--lb (0.
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Rear Roller Brush (Optional) 26 27 30 6 Antiseize Lubricant 31 1 27 to 33 ft--lb (37 to 44 N--m) 29 15 to 19 ft--lb (20 to 25 N--m) 6 29 7 3 8 9 10 11 12 27 2 26 13 Loctite #242 15 to 19 ft--lb (20 to 25 N--m) 17 16 14 33 16 28 Grease Grommet ID RIGHT 5 32 18 15 2 24 23 4 34 25 22 Loctite #242 15 to 19 ft--lb (20 to 25 N--m) 21 35 to 40 ft--lb (47 to 54 N--m) 20 16 FRONT 19 3 15 to 19 ft--lb (20 to 25 N--m) Figure 42 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
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Disassembly (Fig. 42) 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--driven brush bearing assembly (item 30) from cutting unit. B. Slide excluder seal (item 6) from roller brush shaft. C. Remove lock nut and J--bolt from both ends of the brush (Fig. 43). 20 to 25 in--lb (2.3 to 2.8 N--m) 4 Figure 43 1. Roller brush shaft 2.
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3. If drive bearing housing was disassembled, install new components noting proper orientation as shown in Figures 45 and 46. 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 (Fig. 45, item 6) onto shaft to retain bearing. G. To install drive belt, loop belt around driven pulley and over the top of the idler pulley.
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5. Check alignment of pulleys with a straight edge placed along the outer face of the driven pulley (Fig. 48). The outer faces of the driven and drive pulleys (not the idler pulley) should be in line within 0.030” (0.76 mm). If necessary to align pulleys, remove driven pulley from brush shaft and add or remove hardened washer(s) (item 9) until drive and driven pulleys are aligned within 0.030” (0.76 mm). CHECK ALIGNMENT 6. Check that roller brush is parallel to rear roller with 0.060” (1.
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Chapter 9 Foldout Drawings Table of Contents Reelmaster 7000 Page 9 - 1 Foldout Drawings Foldout Drawings HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . 3 ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . 4 WIRE HARNESS DRAWINGS Main Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Seat and Console Wire Harness . . . . . . . . . . . . . . 8 Power Center Wire Harness . . . . . . . . . . . . . . . . .
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M4 M1 M5 M2 M3 C1 C3 PISTON S4 M1 M2 M4 ROD M3 MV1 MV2 S5 C2 S3 MOW CONTROL MANIFOLD C4 S2 M1 OR1 CV1 ST M2 RV2 CV2 OR2 S1 C4 S1 SP1 SP2 LC1 LC2 FD CV C1 G2 C2 G1 RV1 G1 PRV P1 RV2 T P2 G2 L P1 T2 T1 C3 RV1 C5 LIFT CONTROL MANIFOLD G P2 ENGINE SPEED 2850/1550 P T PISTON PUMP GEAR PUMP SV .071 P4 .56 P3 .56 P2 1.03 P1 1.03 CHG M1 PD1 G P1 BYPASS VALVE 5000 PSI M1 550 PSI RV CHG .091 2.48 .071 2.48 2.01 2.
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Reelmaster 7000 Electrical Schematic Sheet 1 of 2 All relays and solenoids are shown as de-- energized. All ground wires are black.
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FAN DIRECTION (S1) FRONT REELS (S4) REEL ENGAGE FRONT (SP1) REEL ENGAGE REAR (SP2) FAN SPEED (PRV) REAR REELS (S5) RAISE REELS (S2) ENABLE (S1) LOWER REELS (S3) RANGE 2WD/4WD (SV) Reelmaster 7000 Electrical Schematic Sheet 2 of 2 All relays and solenoids are shown as de-- energized. All ground wires are black. Page 9 -- 5 Rev.
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Reelmaster 7000 Main Wire Harness Page 9 -- 6
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BLACK BLUE/YELLOW WHITE/BLACK WHITE/GREEN TAN/WHITE BLACK/YELLOW WHITE/VIOLET WHITE/YELLOW VIOLET BROWN/WHITE BLUE/BLACK BLACK/WHITE RED/WHITE RED/YELLOW GRAY/GREEN VIOLET/GRAY BLACK TAN/BLACK PINK/BLUE GRAY VIOLET/WHITE YELLOW/BLACK BLACK BROWN/YELLOW PINK/GREEN PINK/BLACK BLACK GRAY/BLACK GREEN/WHITE BROWN GRAY/BLUE BLUE/WHITE RED/GREEN YELLOW/GREEN RED/BLUE BROWN/BLACK RED/BLACK ORANGE GREEN/YELLOW YELLOW GREEN VIOLET/BLACK WHITE GREEN/BLACK ORANGE/BLACK BLACK BLUE/YELLOW BLACK PINK BLACK PINK
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Reelmaster 7000 Seat and Console Wire Harness Page 9 -- 8
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BLACK BLACK BLACK BLACK BLACK GRAY BLACK/WHITE RED/WHITE BLACK PINK BLACK PINK BLACK BLACK BLACK BLACK Reelmaster 7000 Seat and Console Wire Harness Page 9 -- 9 BLACK BLACK PINK BLACK/WHITE RED/WHITE BLACK PINK WHITE PINK GREEN WHITE VIOLET BLUE RED/WHITE BLACK/WHITE PINK WHITE/ORANGE GRAY VIOLET/WHITE BROWN/YELLOW GRAY TAN/WHITE VIOLET/BLACK PINK/GREEN PINK/BLACK WHITE/BLACK RED/YELLOW BLUE/WHITE BROWN RED/GREEN WHITE/YELLOW
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Reelmaster 7000 Power Center Wire Harness Page 9 -- 10
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RED RED RED RED VIOLET BLACK BLUE RED BLACK PINK/BLACK ORANGE/WHITE RED RED ORANGE BLACK BLACK WHITE/YELLOW BLUE BROWN PINK RED/BLUE RED/GREEN WHITE/BLACK BROWN/BLACK TAN/BLACK RED RED RED RED RED BLACK PINK BLACK RED RED GRAY/BLACK Reelmaster 7000 Power Center Wire Harness Page 9 -- 11