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.
This safety symbol means DANGER, WARNING
or CAUTION, PERSONAL SAFETY INSTRUC-
TION. When you see this symbol, carefully read
the instructions that follow. Failure to obey the
instructions may result in personal injury.
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
Manuals and Parts Catalog for your machine into Chap-
ter 2 of this service manual. Additional copies of the Op-
erator’s Manuals and Parts Catalog are available on the
internet at www.Toro.com.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing or re-
pair of the machine.
The Toro Company reserves the right to change product
specifications or this publication without notice.
IMPORTANT: The IMPORTANT notice will give im-
portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.
E The Toro Company - 2011, 2012
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Table Of Contents
Chapter 1 -- Safety
Chapter 5 -- Electrical System
General Safety Instructions . . . . . . . . . . . . . . . . . . 1 -- 2
Jacking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 1 -- 4
Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 -- 5
General Information . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 2
Electrical Drawings . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 6
Electrical System Quick Checks . . . . . . . . . . . . . 5 -- 13
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 15
Component Testing . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 17
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 5 -- 41
Chapter 2 -- Product Records and Maintenance
Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -- 1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -- 1
Equivalents and Conversions . . . . . . . . . . . . . . . . 2 -- 2
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2 -- 3
Chapter 6 -- Axles, Planetaries and Brakes
Chapter 3 -- Kubota Diesel Engine
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 2
General Information . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 3
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 4
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 2
General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 3
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 4
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,
03--M--DI--E3B SERIES
Chapter 7 -- Chassis
General Information . . . . . . . . . . . . . . . . . . . . . . . . 7 -- 2
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 7 -- 4
Chapter 4 -- Hydraulic System
Chapter 8 -- DPA Cutting Units
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 3
General Information . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 4
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . 4 -- 10
Hydraulic Flow Diagrams . . . . . . . . . . . . . . . . . . . 4 -- 12
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 26
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 30
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 36
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 68
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 4 -- 69
EATON MODEL 72400 SERVO CONTROLLED PIS-
TON PUMP REPAIR INFORMATION
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -- 2
General Information . . . . . . . . . . . . . . . . . . . . . . . . 8 -- 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -- 4
Factors That Can Affect Cutting Performance . . 8 -- 8
Set Up and Adjustments . . . . . . . . . . . . . . . . . . . . 8 -- 11
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 8 -- 14
Chapter 9 -- Foldout Drawings
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . 9 -- 3
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . 9 -- 4
Wire Harness Drawings . . . . . . . . . . . . . . . . . . . . . 9 -- 6
EATON MODEL 74318 and 74348 PISTON MOTORS:
FIXED DISPLACEMENT, VALVE PLATE DESIGN
REPAIR INFORMATION
SAUER--DANFOSS STEERING UNIT TYPE OSPM
SERVICE MANUAL
Reelmaster 7000
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Chapter 1
Safety
Table of Contents
GENERAL SAFETY INSTRUCTIONS . . . . . . . . . . . . 2
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Maintenance and Service . . . . . . . . . . . . . . . . . . . . 3
JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . 4
SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 5
Reelmaster 7000
Page 1 -- 1
Safety
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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 acci-
dentpreventionpartiallyaredependentupon thedesign
and configuration of the machine, these factors are also
dependent upon the awareness, concern and proper
trainingofthepersonnelinvolvedintheoperation,trans-
port, maintenance and storage of the machine. Improp-
eruseormaintenanceofthemachinecanresultininjury
ordeath. Toreducethepotentialforinjuryordeath,com-
ply with the following safety instructions.
WARNING
To reduce the potential for injury or death,
comply with the following safety instructions.
Before Operating
1. Review and understand the contents of the Opera-
tor’s Manuals and Operator’s DVD before starting and
operating the vehicle. Become familiar with the controls
and know how to stop the vehicle and engine quickly.
AdditionalcopiesoftheOperator’sManualareavailable
on the internet at www.Toro.com.
4. Since diesel fuel is flammable, handle it carefully:
A. Use an approved fuel container.
B. Do notremove fuel tank capwhile engineis hotor
running.
C. Do not smoke while handling fuel.
2. Keep all shields, safety devices and decals in place.
If a shield, safety device or decal is defective, illegible or
damaged, repair or replace it before operating the ma-
chine. Also tighten any loose nuts, bolts or screws to en-
sure machine is in safe operating condition.
D. Fill fuel tank outdoors and only to within an inch of
the top of the tank, not the filler neck. Do not overfill.
E. Wipe up any spilled fuel.
3. Assure interlock switches are adjusted correctly so
engine cannot be started unless traction pedal is in
NEUTRAL and cutting units are DISENGAGED.
While Operating
1. Sit on the seat when starting and operating the ma-
chine.
4. Donottouchengine, exhaustsystemcomponentsor
radiator while engine is running or soon after it is
stopped. These areas could be hot enough to cause
burns.
2. Before starting the engine:
A. Engage the parking brake.
5. Before getting off the seat:
A. Ensure that traction pedal is in neutral.
B. Engage parking brake.
B. Make sure traction pedal is in neutral and the
PTO switch is OFF (disengaged).
C. After engine isstarted, releaseparking brakeand
keep foot off traction pedal. Machine must not move.
If movement is evident, the traction pedal linkage is
adjusted incorrectly; therefore, shut engine off and
adjust traction pedal linkage until machine does not
move when traction pedal is released.
C. Disengage PTO and wait for cutting unit reel to
stop rotating.
D. Stop engine and remove key from switch.
E. Toro recommends that anytime the machine is
parked (short or long term), the cutting units should
be lowered to the ground. This relieves pressure
from the lift circuit and eliminates the risk of cutting
units accidentally lowering to the ground.
3. Do not run engine in a confined area without ade-
quate ventilation. Exhaust fumes are hazardous and
could possibly be deadly.
F. Donotparkonslopesunlesswheelsarechocked
or blocked.
Safety
Page 1 -- 2
Reelmaster 7000
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Maintenance and Service
1. The Traction Unit and Cutting Unit Operator’s Manu-
als provide information regarding the operation, general
maintenance and maintenance intervals for your Reel-
master machine. Refer to these publications for addi-
tional information when servicing the machine.
11.Do not overspeed the engine by changing governor
setting. To assuresafety andaccuracy, checkmaximum
engine speed.
12.Shut engine off before checking or adding oil to the
engine crankcase.
2. Before servicing or making adjustments, lower cut-
ting units, stop engine, set parking brake and remove
key from the ignition switch.
13.Disconnect battery before servicing the machine.
Disconnect negative battery cable first and positive
cable last. If battery voltage is required for troubleshoot-
ing or test procedures, temporarily connect the battery.
Reconnect positive battery cable first and negative
cable last.
3. Make sure machine is in safe operating condition by
keeping all nuts, bolts and screws tight.
4. Never store the machine or fuel container inside
wherethereisanopenflame, suchasnearawaterheat-
er or furnace.
14.Battery acid is poisonous and can cause burns.
Avoid contact with skin, eyes and clothing. Protect your
face, eyes and clothing when working with a battery.
5. Make sure all hydraulic line connectors are tight and
all hydraulic hoses and lines are in good condition be-
fore applying pressure to the hydraulic system.
15.Battery gases can explode. Keep cigarettes, sparks
and flames away from the battery.
6. Keepbodyandhandsawayfrompinholeleaksinhy-
draulic lines that eject high pressure hydraulic fluid. Use
cardboard or paper to find hydraulic leaks. Hydraulic
fluid escaping under pressure can penetrate skin and
cause injury. Fluid accidentally injected into the skin
must be surgically removed within a few hours by a doc-
tor familiar with this form of injury or gangrene may re-
sult.
16.When welding on machine, disconnect both battery
cables to prevent damage to machine electronic equip-
ment. Disconnect negative battery cable first and posi-
tive cable last. Also, disconnect the wire harness
connector from the machine TEC controller and discon-
nect the terminal connector from the alternator.
17.At the time of manufacture, the machine conformed
to the safety standards for riding mowers. To assure op-
timum performance and continued safety certification of
the machine, use genuine Toro replacement parts and
accessories. Replacementpartsandaccessoriesmade
by other manufacturers may result in non-conformance
with the safety standards and the warranty may be
voided.
7. Before disconnecting or performing any work on the
hydraulic system, all pressure in system must be re-
lieved by stopping engine and lowering cutting units to
the ground.
8. If major repairs are ever needed or assistance is de-
sired, contact an Authorized Toro Distributor.
18.When changing attachments, tires or performing
other service, use correct blocks, hoists and jacks.
Make sure machine is parked on a solid level surface
suchasaconcretefloor. Priorto raisingthe machine, re-
move any attachments that may interfere with the safe
and proper raising of the machine. Always chock or
block wheels. Use appropriate jack stands to support
the raised machine. If the machine is not properly sup-
ported by jack stands, the machine may move or fall,
which may resultin personal injury (see Jacking Instruc-
tions in this chapter).
9. To reduce potential fire hazard, keep engine area
free of excessive grease, grass, leaves and dirt. Clean
protective screen on machine frequently.
10.If engine must be running to perform maintenance or
an adjustment, keep hands, feet, clothing and other
parts of the body away from cutting units and other mov-
ing parts. Keep bystanders away.
Reelmaster 7000
Page 1 -- 3
Safety
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Jacking Instructions
CAUTION
When changing attachments, tires or perform-
ing other service, use correct jacks and sup-
ports. 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
themachine. Alwayschockorblockwheels.Use
jack stands to support the raised machine. If the
machine is not properly supported by jack
stands, the machine may move or fall, which
may result in personal injury.
1
2
Figure 1
1. Frame
2. Front tire (RH shown)
Jacking the Front End (Fig. 1)
1. Apply parking brake and chock both rear tires to pre-
vent the machine from moving.
IMPORTANT: Do not place jack, jack stands or
blocks under the wheel motors. Wheel motors can
be damaged if used for jacking or support points.
2. Position jack securely under the frame, just to the in-
side of the front tire.
3. Jack front of machine off the ground.
2
1
4. Position appropriate jack stands under the frame as
close to the wheels as possible to support the machine.
Figure 2
Jacking the Rear End (Fig. 2)
1. Rear axle
2. Rear tire (RH shown)
1. Applyparkingbrakeand chockboth fronttires topre-
vent the machine from moving.
2. Place jack securely under the center of rear axle.
3. Jack rear of machine off the ground.
4. Position appropriate jack stands under the rear axle
to support the machine.
Safety
Page 1 -- 4
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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.
Reelmaster 7000
Page 1 -- 5
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Safety
Page 1 -- 6
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Chapter 2
Product Records and Maintenance
Table of Contents
PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 1
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . 2
Decimal and Millimeter Equivalents . . . . . . . . . . . . 2
U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . 2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 3
Fastener Identification . . . . . . . . . . . . . . . . . . . . . . . 3
Using a Torque Wrench with an Offset Wrench . . 3
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Inch Series) . . . . . . . . . . . . . . . 4
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Metric Fasteners) . . . . . . . . . . . 5
Other Torque Specifications . . . . . . . . . . . . . . . . . . 6
Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Product Records
Insert Operator’s Manuals and Parts Catalog for your
Reelmasterattheendofthischapter. Additionally,insert
Installation Instructions, Operator’s Manuals and Parts
Catalogs for any accessories that have been installed
on your Reelmaster at the end of this section.
Maintenance
Maintenance procedures and recommended service in-
tervals for your Reelmaster are covered in the Traction
Unit and Cutting Unit Operator’s Manuals. Refer to
those publications when performing regular equipment
maintenance. Several maintenance procedures have
break--in intervals identified in the Operator’s Manuals.
RefertotheEngineOperator’sManualfor additionalen-
gine specific maintenance procedures.
Reelmaster 7000
Product Records and Maintenance
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Equivalents and Conversions
0.09375
Product Records and Maintenance
Reelmaster 7000
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Torque Specifications
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 spe-
cified in this Service Manual.
Asnoted inthe followingtables, torquevalues shouldbe
reduced by 25% for lubricated fasteners to achieve
the similar stress as a dry fastener. Torque values may
also have to be reduced when the fastener is threaded
into aluminum or brass. The specific torque value
should be determined based on the aluminum or brass
material strength, fastener size, length of thread en-
gagement, etc.
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 Ser-
vice Manual. The following factors shall be considered
when applying torque: cleanliness of the fastener, use
of a thread sealant (e.g. Loctite), degree of lubrication
on the fastener, presence of a prevailing torque feature
(e.g. Nylock nut), hardness of the surface underneath
thefastener’shead orsimilar conditionwhich affectsthe
installation.
The standard method of verifying torque shall be per-
formed by marking a line on the fastener (head or nut)
and mating part, then back off fastener 1/4 of a turn.
Measure the torque required to tighten the fastener until
the lines match up.
Fastener Identification
Grade 1
Grade 5
Grade 8
Class 8.8
Class 10.9
Inch Series Bolts and Screws
Figure 1
Metric Bolts and Screws
Figure 2
Using a Torque Wrench with an Offset Wrench
Useofanoffsetwrench(e.g. crowfootwrench)willaffect
torque wrench calibration due to the effective change of
torque wrench length. When using a torque wrench with
an offset wrench, multiply the listed torque recommen-
dation by the calculated torque conversion factor (Fig.
3) to determine proper tightening torque. Tightening
torque when using a torque wrench with an offset
wrench will be lower than the listed torque recommen-
dation.
If the listed torque recommendation for a fastener is
from 76 to 94 ft--lb, the proper torque when using this
torque wrench with an offset wrench would be from 72
to 89 ft--lb.
Offset wrench
Torque wrench
(effective length of
torque wrench)
A
Example: The measured effective length of the torque
wrench (distance from the center of the handle to the
center of the square drive) is 18”.
B
(effective length of torque
wrench + offset wrench)
Themeasuredeffectivelengthofthetorquewrenchwith
the offset wrench installed (distance from the center of
the handle to the center of the offset wrench) is 19”.
TORQUE CONVERSION FACTOR = A / B
Figure 3
The calculated torque conversion factor for this torque
wrench with this offset wrench would be 18 / 19 = 0.947.
Reelmaster 7000
Product Records and Maintenance
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Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)
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)
SAE Grade 5 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
SAE Grade 8 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 5 or Stronger Nuts)
Thread Size
in--lb
in--lb
N--cm
in--lb
15 + 2
N--cm
169 + 23
192 + 23
328 + 34
350 + 45
475 + 56
542 + 56
1130 + 113
1299 + 136
2260 + 282
2542 + 282
N--m
in--lb
23 + 3
N--cm
262 + 34
282 + 34
463 + 56
486 + 56
678 + 68
768 + 79
1582 + 169
1808 + 192
3390 + 339
3672 + 373
N--m
# 6 -- 32 UNC
# 6 -- 40 UNF
# 8 -- 32 UNC
# 8 -- 36 UNF
# 10 -- 24 UNC
# 10 -- 32 UNF
1/4 -- 20 UNC
1/4 -- 28 UNF
5/16 -- 18 UNC
5/16 -- 24 UNF
10 + 2
13 + 2
147 + 23
17 + 2
25 + 3
29 + 3
41 + 5
13 + 2
18 + 2
25 + 5
30 + 5
282 + 30
339 + 56
31 + 4
43 + 5
42 + 5
60 + 6
48 + 5
68 + 7
48 + 7
53 + 7
53 + 7
65 + 10
105 + 15
128 + 17
ft--lb
599 + 79
734 + 113
1186 + 169
1446 + 192
N--m
100 + 10
115 + 12
200 + 25
225 + 25
ft--lb
140 + 15
160 + 17
300 + 30
325 + 33
ft--lb
115 + 15
138 + 17
ft--lb
3/8 -- 16 UNC
3/8 -- 24 UNF
7/16 -- 14 UNC
7/16 -- 20 UNF
1/2 -- 13 UNC
1/2 -- 20 UNF
5/8 -- 11 UNC
5/8 -- 18 UNF
3/4 -- 10 UNC
3/4 -- 16 UNF
7/8 -- 9 UNC
16 + 2
16 + 2
22 + 3
30 + 3
41 + 4
43 + 5
58 + 7
17 + 2
18 + 2
24 + 3
35 + 4
47 + 5
50 + 6
68 + 8
27 + 3
27 + 3
37 + 4
50 + 5
68 + 7
70 + 7
95 + 9
29 + 3
29 + 3
39 + 4
55 + 6
75 + 8
77 + 8
104 + 11
142 + 15
163 + 16
285 + 28
325 + 33
508 + 52
569 + 58
813 + 81
904 + 89
30 + 3
48 + 7
65 + 9
75 + 8
102 + 11
115 + 12
203 + 20
230 + 24
359 + 37
407 + 41
583 + 61
644 + 65
105 + 11
120 + 12
210 + 21
240 + 24
375 + 38
420 + 43
600 + 60
667 + 66
32 + 4
53 + 7
72 + 9
85 + 9
65 + 10
75 + 10
93 + 12
115 + 15
140 + 20
155 + 25
88 + 12
95 + 15
140 + 20
165 + 25
225 + 25
260 + 30
119 + 16
129 + 20
190 + 27
224 + 34
305 + 34
353 + 41
150 + 15
170 + 18
265 + 27
300 + 30
430 + 45
475 + 48
7/8 -- 14 UNF
NOTE: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
engine oil or thread sealant such as Loctite.
NOTE: The nominal torque values listed above for
Grade 5 and 8 fasteners are based on 75% of the mini-
mum proof load specified in SAE J429. The tolerance is
approximately + 10% of the nominal torque value. Thin
height nuts include jam nuts.
NOTE: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Product Records and Maintenance
Reelmaster 7000
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Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series)
Class 8.8 Bolts, Screws and Studs with
Regular Height Nuts
Class 10.9 Bolts, Screws and Studs with
Thread Size
Regular Height Nuts
(Class 10 or Stronger Nuts)
(Class 8 or Stronger Nuts)
M5 X 0.8
M6 X 1.0
57 + 6 in--lb
96 + 10 in--lb
19 + 2 ft--lb
644 + 68 N--cm
1085 + 113 N--cm
26 + 3 N--m
78 + 8 in--lb
881 + 90 N--cm
1503 + 158 N--cm
38 + 4 N--m
133 + 14 in--lb
28 + 3 ft--lb
M8 X 1.25
M10 X 1.5
M12 X 1.75
M16 X 2.0
M20 X 2.5
38 + 4 ft--lb
52 + 5 N--m
54 + 6 ft--lb
73 + 8 N--m
66 + 7 ft--lb
90 + 10 N--m
225 + 23 N--m
440 + 45 N--m
93 + 10 ft--lb
229 + 23 ft--lb
450 + 46 ft--lb
126 + 14 N--m
310 + 31 N--m
610 + 62 N--m
166 + 17 ft--lb
325 + 33 ft--lb
NOTE: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
engine oil or thread sealant such as Loctite.
NOTE: The nominal torque values listed above are
based on 75% of the minimum proof load specified in
SAEJ1199. Thetoleranceisapproximately+10%ofthe
nominal torque value.
NOTE: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Reelmaster 7000
Product Records and Maintenance
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Other Torque Specifications
SAE Grade 8 Steel Set Screws
Wheel Bolts and Lug Nuts
Thread Size Recommended Torque**
65 + 10 ft--lb 88 + 14 N--m
Recommended Torque
Thread Size
Square Head
140 + 20 in--lb
215 + 35 in--lb
35 + 10 ft--lb
75 + 15 ft--lb
Hex Socket
73 + 12 in--lb
145 + 20 in--lb
18 + 3 ft--lb
7/16 -- 20 UNF
Grade 5
1/4 -- 20 UNC
5/16 -- 18 UNC
3/8 -- 16 UNC
1/2 -- 13 UNC
1/2 -- 20 UNF
Grade 5
80 + 10 ft--lb 108 + 14 N--m
80 + 10 ft--lb 108 + 14 N--m
80 + 10 ft--lb 108 + 14 N--m
M12 X 1.25
Class 8.8
50 + 10 ft--lb
M12 X 1.5
Class 8.8
** For steel wheels and non--lubricated fasteners.
Thread Cutting Screws
(Zinc Plated Steel)
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23 or Type F
Thread Threads per Inch
Size
Baseline Torque*
Thread Size
Baseline Torque*
20 + 5 in--lb
Type A Type B
No. 6 -- 32 UNC
No. 8 -- 32 UNC
No. 10 -- 24 UNC
1/4 -- 20 UNC
No. 6
No. 8
18
15
12
11
20
18
16
14
20 + 5 in--lb
30 + 5 in--lb
38 + 7 in--lb
85 + 15 in--lb
30 + 5 in--lb
38 + 7 in--lb
No. 10
No. 12
85 + 15 in--lb
110 + 20 in--lb
200 + 100 in--lb
5/16 -- 18 UNC
3/8 -- 16 UNC
*Holesize,materialstrength,materialthicknessandfin-
ish must be considered when determining specific
torque values. Alltorque values are based on non--lubri-
cated fasteners.
Conversion Factors
in--lb X 11.2985 = N--cm
N--cm X 0.08851 = in--lb
ft--lb X 1.3558 = N--m
N--m X 0.7376 = ft--lb
Product Records and Maintenance
Reelmaster 7000
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Chapter 3
Kubota Diesel Engine
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3
Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4
Air Filter System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Check Fuel Lines and Connections . . . . . . . . . . . 9
Drain and Clean Fuel Tank . . . . . . . . . . . . . . . . . . 9
Fuel Tank Removal . . . . . . . . . . . . . . . . . . . . . . . . 9
Fuel Tank Installation . . . . . . . . . . . . . . . . . . . . . . . 9
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . 14
Pump Adapter Plate . . . . . . . . . . . . . . . . . . . . . . . . 16
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,
03--M--DI--E3B SERIES
Reelmaster 7000
Page 3 -- 1
Kubota Diesel Engine
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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)
4.031” (102.4 mm)
Stroke
3
Total Displacement
Firing Order
148.5 in (2434 cc)
1 (closest to gear case end) -- 3 -- 4 (closest to flywheel end) -- 2
Spherical Type (E--TVCS)
Combustion Chamber
Compression Ratio
Direction of Rotation
Fuel
23.2:1
Counterclockwise (viewed from flywheel)
Diesel or Biodiesel (up to B20) Fuel with Low or Ultra Low
Sulfur Content
Fuel Capacity
22 U.S. gallons (83 liters)
Denso PFR 4M Type Mini Pump
Denso OPD Mini Nozzle
Centrifugal Mechanical
1550 + 50 RPM
Fuel Injection Pump
Injection Nozzle
Governor
Low Idle (no load)
High Idle (no load)
Engine Oil
2850 +50/--120 RPM
API CH--4, CI--4 or higher
See Operator’s Manual
10.0 U.S. Quarts (9.5 Liters) with Filter
Trochoid Type
Engine Oil Viscosity
Crankcase Oil Capacity
Oil Pump
Coolant Capacity
Starter
13 U.S. Quarts (12.3 Liters)
12 VDC, 2.0 kW
Alternator/Regulator
Alternator Output
12 VDC
60 amp
Engine Dry Weight
406 U.S. pounds (184 kg)
Kubota Diesel Engine
Page 3 -- 2
Reelmaster 7000
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General Information
This Chapter gives information about specifications and
repair of the diesel engine used in the Reelmaster 7000.
tools are described in the Kubota Workshop Manual,
Diesel Engine, 03--M--DI--E3B. The use of some spe-
cialized test equipment is explained. However, the cost
of the test equipment and the specialized nature of
somerepairsmaydictatethattheworkbedoneatanen-
gine repair facility.
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 En-
gine, 03--M--DI--E3B.
Service and repair parts for Kubota engines are sup-
plied through your Authorized Toro Distributor. If no
partslistisavailable,bepreparedtoprovideyourdistrib-
utor with the Toro model and serial number.
Most repairs and adjustments require tools which are
commonly available in many service shops. Special
Operator’s Manual
The Traction Unit and Engine Operator’s Manuals pro-
vide information regarding the operation, general main-
tenance and maintenance intervals for your Reelmaster
machine. Refer tothese publicationsfor additionalinfor-
mation when servicing the machine.
Reelmaster 7000
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Service and Repairs
Air Filter System
RIGHT
27
12 to 15 in--lb
FRONT
(1.4 to 1.6 N--m)
26
13
13
24
12
23
14
11
Vacuator
Direction
18
18
10
25
16
15
20
6
9
1
19
17
7
21
22
8
4
2
5
6
3
Figure 1
1. Battery support
2. Bracket
3. Flange head screw (8 used)
4. Flange nut (8 used)
5. Support bracket
10. Cap screw (2 used)
11. Air cleaner assembly
12. Service indicator
13. Hose clamp
19. Cap screw (2 used)
20. Flange head screw (4 used)
21. Flange head screw (2 used)
22. Hose
14. Hose clamp
23. Adapter
6. Cap screw (4 used)
7. Flange nut (4 used)
8. Fan drive manifold
9. Air cleaner strap
15. Flat washer (2 used)
16. Coolant reservoir
17. Reservoir bracket
18. Flange nut (8 used)
24. Air cleaner hose
25. Reservoir cap
26. Plenum
27. Air intake hose
Kubota Diesel Engine
Page 3 -- 4
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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.
3
Installation (Fig. 1)
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.
5
Figure 2
1. Air cleaner housing
2. Safety filter element
3. Air filter element
4. Air cleaner cover
5. Vacuator valve
1. Assemble air filter system using Figure 1 as a guide.
A. If service indicator (item 12) was removed from
air cleaner housing, apply thread sealant to adapter
threads before installing adapter and indicator to
housing. Install adapter so that grooves in adapter
hex and adapter filter element are installed toward
service indicator (Fig. 3). Torque indicator from 12 to
15 in--lb (1.4 to 1.6 N--m).
5
4
2
3
B. Orientate vacuator valve on air cleaner cover to-
ward ground.
C. Installaircleanersoaircleanerstrap(item9)isas
close as possible to air cleaner cover.
1
D. Make sure that air cleaner hose (item 24) does
not contact engine valve cover or other engine com-
ponents. Tomodifyclearance, moveand/orrotateair
cleaner body in air cleaner strap. Verify that tabs in
strap mesh fully with slots in air cleaner body.
Figure 3
1. Air cleaner assembly
2. Service indicator
3. Adapter
4. Groove
5. Filter element
2. After air cleaner installation is completed, lower and
secure hood.
Reelmaster 7000
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Kubota Diesel Engine
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Exhaust System
8
13
1
12
5
3
7
10
14
4
11
6
2
9
RIGHT
FRONT
Figure 4
1. Muffler
6. RH engine mount
7. Flat washer
8. Cap screw
9. Muffler bracket
10. Muffler gasket
11. Engine
2. Flange head screw (2 used)
3. Flange head screw (4 used)
4. Muffler clamp
12. Muffler bracket
13. Flange nut (2 used)
14. Muffler clamp
5. Tailpipe
Kubota Diesel Engine
Page 3 -- 6
Reelmaster 7000
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Removal (Fig. 4)
Installation (Fig. 4)
IMPORTANT: If exhaust studs were removed from
engine cylinder head, thoroughly clean threads in
head and apply Loctite #277 (or equivalent) to stud
threads before installing studs into head.
CAUTION
The muffler and exhaust pipe may be hot. To
avoid possible burns, allow the engine and ex-
haust system to cool before working on the muf-
fler.
NOTE: Make sure muffler flange and exhaust manifold
sealing surfaces are free of debris or damage that may
prevent a tight seal.
1. Install new exhaust gasket if original gasket is dam-
aged or torn.
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.
IMPORTANT: Failure to follow the suggested muf-
fler fastener sequence may result in premature muf-
fler failure.
2. Raise and support hood.
3. Remove muffler and/or muffler bracket from the en-
gine as necessary using Figure 4 as a guide.
2. Installexhaustsystemcomponents tothe engineus-
ing Figure 4 as a guide. Hand tighten all exhaust system
fasteners before fully tightening any fastener.
3. Tailpipeshouldhaveequalclearancebetweenframe
and engine after installation.
4. After exhaustsystem installationis completed, lower
and secure hood.
Reelmaster 7000
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Kubota Diesel Engine
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Fuel System
19
16
20
21
16
13
18
3
21
8
14
8
15
1
24
17
8
25
4
3
2
7
23
7
5
6
9
10
22
RIGHT
11
12
FRONT
26
27
Figure 5
1. Fuel suction tube
10. Cap screw (2 used)
11. Clamp (2 used)
12. Flange nut (2 used)
19. Flange nut (2 used)
20. Fuel/water separator
21. Elbow fitting (2 used)
22. Flat washer (2 used)
23. Flat washer (2 used)
24. Fuel gauge
25. Grommet
26. Hose clamp
27. Draincock
2. Fuel line clamp (2 used)
3. Fuel hose (supply)
4. Return fitting
5. Fuel hose (return)
6. Fuel tank cap
7. Bushing (2 used)
8. Hose clamp (6 used)
9. Fuel tank
13. Fuel pump
14. Washer head screw
15. Fuel pump bracket
16. Fuel hose (supply)
17. Fuel hose (supply)
18. Cap screw (2 used)
Kubota Diesel Engine
Page 3 -- 8
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Fuel Tank Removal (Fig. 5)
DANGER
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.
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 en-
gine is running, hot or when machine is in an en-
closed 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.
2. Disconnectfuelhoses fromthe suctionand returnfit-
tings in top of tank.
3. Use draincock on bottom of tank to empty fuel tank
into a suitable container.
4. Remove fuel tank from machine using Figure 5 as a
guide.
Check Fuel Lines and Connections
Fuel Tank Installation (Fig. 5)
Check fuel lines and connections as recommended in
the Traction Unit Operator’s Manual. Check lines for de-
terioration, damage, leaking or loose connections. Re-
place hoses, clamps and connections as necessary.
1. Install fuel tank to frame using Figure 5 as a guide.
2. Connect fuel hoses to the suction and return fittings
in top of tank.
3. Makesurethatdraincockonbottomoftankisclosed.
4. Fill fuel tank with clean fuel.
Drain and Clean Fuel Tank
Drain and clean the fuel tank periodically as recom-
mended in the Traction Unit Operator’s Manual. Also,
drain and clean the fuel tank if the fuel system becomes
contaminated or if the machine is to be stored for an ex-
tended period. To clean fuel tank, flush tank out with
clean diesel fuel. Make sure tank is free ofcontaminates
and debris.
Reelmaster 7000
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Radiator
26
35
1
46
31
43
32
30
33
25
28
29
3
24
23
15
RIGHT
FRONT
7
39
42
2
10
11
3
37
38
5
6
15
22
12
27
43
18
4
15
17
44
45
10
9
18
8
13
40
16
19
14
20
41
9 to 11 ft--lb
(12.3 to 14.9 N--m)
34
21
17
36
28
Figure 6
17. Flat washer (8 used)
18. Flange head screw (11 used)
19. Rubber grommet (2 used)
20. Rubber grommet
21. Flange head screw (4 used)
22. Flange nut (4 used)
o
1. 90 hydraulic fitting (2 used)
2. Oil cooler
32. Washer (2 used)
33. Oil cooler top bracket
34. Bulb seal
35. O--ring
36. R--clamp (2 used)
37. Bushing
3. Flange nut (4 used)
4. Radiator mount
5. Bulb seal
6. Air cleaner hose
7. Plenum
8. Radiator
9. Hose
10. Hose clamp (3 used)
11. Radiator cap
12. Upper radiator shroud
13. Clamp (4 used)
14. Upper radiator hose
15. Flange nut (12 used)
16. Temperature sender
23. Foam seal (2 used)
24. Recirculation barrier (2 used)
38. Elbow fitting
39. Reservoir hose
40. Lower radiator hose
41. Lower radiator shroud
42. Pipe plug
43. Flange head screw (8 used)
44. Flange head screw (4 used)
45. Bulb seal
25. Recirculation barrier bracket (2 used)
26. Screw (2 used)
27. Oil cooler mount plate (2 used)
28. Flange head screw (9 used)
29. O--ring
30. Clamp (2 used)
31. Cap screw (2 used)
46. Spacer
Kubota Diesel Engine
Page 3 -- 10
Reelmaster 7000
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Removal (Fig. 6)
2. Carefully position radiator and recirculation barriers
(items 24 and 25) to the radiator mount. Secure radiator
and barriers in place with four (4) flange head screws
and flange nuts.
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.
3. Position lower radiator shroud and fan motor bracket
assembly to the radiator. Make sure that hydraulic
hoses are correctly positioned in grommets in lower ra-
diator shroud.
2. Removehoodfromthemachine(seeHoodRemoval
in the Service and Repairs section of Chapter 7 -- Chas-
sis).
4. Secure fan motor bracket to radiator with six (6) cap
screws and flange nuts (Fig. 7).
CAUTION
5. Secure lower radiator shroud to radiator with re-
moved fasteners.
Do not open radiator cap or drain coolant if the
radiator or engine is hot. Pressurized, hot cool-
ant can escape and cause burns.
6. Position upper radiator shroud to lower radiator
shroud and radiator. Secure shrouds with removed fas-
teners. Make sure that clearance between shrouds and
fan is at least 0.180” (4.6 mm) at all points.
Ethylene--glycol antifreeze is poisonous. Dis-
pose of coolant properly or store it in a properly
labeled container away from children and pets.
7. Connect reservoir hose (item 39) to the radiator vent
tube.
3. Remove radiator cap. Drain radiator into a suitable
container using the radiator draincock.
8. Connect upper and lower hoses to the radiator.
4. Disconnect upper and lower hoses from the radiator.
5. Remove air cleaner hose (item 6).
9. Install plenum (item 7) to radiator mount and secure
with flange head screws and flange nuts.
10.Install air cleaner hose (item 6) to the air cleaner and
plenum.
6. Remove four (4) flange head screws and flange nuts
that secure plenum (item 7) to radiator mount. Remove
plenum.
11.Fill radiator with coolant.
7. Disconnectreservoirhose(item39)fromtheradiator
vent tube.
12.Install hood on the machine (see Hood Installation in
the Service and Repairs section of Chapter 7 -- Chas-
sis).
8. Detach upper radiator shroud from the radiator and
lower radiator shroud. Remove upper shroud from ma-
chine.
9. Remove fasteners that secure lower radiator shroud
to radiator.
6
3
10.Remove six (6) cap screws and flange nuts that se-
cure fan motor bracket to radiator (Fig. 7).
4
11.Position lower radiator shroud and fan motor bracket
assembly away from radiator.
5
1
12.Remove four (4) flange head screws and flange nuts
securingtheradiatorandrecirculationbarriers(items24
and 25) to the radiator mount. Carefully remove barriers
and radiator from the machine.
2
13.Plug all radiator and hose openings to prevent con-
tamination.
Figure 7
Installation (Fig. 6)
1. Fan
4. Cap screw (6 used)
2. Fan motor bracket
3. Fan motor
5. Flange nut (6 used)
6. Radiator
1. Remove plugs placed in radiator and hose openings
during the removal procedure. Make sure that radiator
draincock is closed.
Reelmaster 7000
Page 3 -- 11
Kubota Diesel Engine
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Engine
29
31
30
1
12
5
3
22
33
4
9
6
21
18
28
17
7
10
20
8
19
25
24
23
2
10
17
11
32
18
14
26
34
15
16
12
13
27
RIGHT
12
FRONT
Figure 8
1. Muffler
2. Flange head screw
3. Flange head screw (4 used)
4. Muffler clamp
5. Tailpipe
6. RH rear engine mount
7. Cap screw (3 used)
8. RH front engine mount
9. Engine
10. Flange head screw (10 used)
11. Engine mount (4 used)
12. Flange nut (15 used)
13. Rebound washer (4 used)
14. LH front engine mount
15. Lock washer (4 used)
16. Cap screw (4 used)
17. Lock washer (5 used)
18. Cap screw (5 used)
19. LH rear engine mount
20. Muffler bracket
24. Lock washer
25. Spacer (2 used)
26. Hardened washer (2 used)
27. Lock washer
28. Alternator wire harness
29. Cap screw
30. Flat washer
31. Muffler bracket
32. Flange head screw
33. Muffler clamp
21. Ground wire harness
22. Muffler gasket
23. Cap screw
34. Cap screw (2 used)
Kubota Diesel Engine
Page 3 -- 12
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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. Removehoodfromthemachine(seeHoodRemoval
in the Service and Repairs section of Chapter 7 -- Chas-
sis).
1
3. Remove battery cover. Disconnect negative battery
cable first and then positive battery cable.
2
3
4
CAUTION
Figure 9
Do not open radiator cap or drain coolant if the
radiator or engine is hot. Pressurized, hot cool-
ant can escape and cause burns.
1. Engine run solenoid
2. Throttle cable
3. Cable clamp
4. Cable swivel
5. Fuel supply hose
Ethylene--glycol antifreeze is poisonous. Dis-
pose of coolant properly, or store it in a properly
labeled container away from children and pets.
1
3
4. Drain coolant from radiator into a suitable container
(seeRadiatorRemovalinthissection).Disconnectcool-
ant hoses from the radiator.
2
CAUTION
The exhaust system may be hot. To avoid pos-
sible burns, allow the exhaust system to cool be-
fore working on or near the muffler.
Figure 10
5. Remove exhaust system from engine (see Exhaust
System Removal in this section).
1. Temperature sender
2. Harness connector
3. Battery cable
6. Remove air cleaner system from engine (see Air
Cleaner Removal in this section).
8. Disconnect fuel supply hose from injection pump
(Fig. 9). Capfuelhoseandinjectorpumpfuelinlettopre-
vent contamination.
7. Note location of cable ties used to secure wire har-
ness. Disconnect wire harness connectors from the fol-
lowing engine components:
9. Remove throttle cable from engine (Fig. 9):
A. Remove lock nut that secures throttle cable swiv-
el to speed control lever.
A. The engine run solenoid (Fig. 9).
B. The temperature sender (Fig. 10).
C. The alternator (Fig. 10).
B. Loosen cable clamp and remove throttle cable
from under clamp.
C. Position throttle cable away from the engine.
D. The glow plug connection.
10.Remove fasteners that secure the upper radiator
shroud to the lower shroud and radiator (see Radiator
Removalinthissection). Removeupperradiatorshroud
from machine.
E. Wire harness connector from engine ground har-
ness.
F. The electric starter motor.
G. Lowoilpressureswitch locatedon alternatorside
of engine (above electric starter).
Reelmaster 7000
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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 mo-
tor. Putcaps or plugs on fittings and hoses to prevent
contamination. Label hydraulic lines for proper as-
sembly.
3
4
5
1
C. Remove six (6) cap screws and flange nuts that
secure fan motor bracket to radiator.
D. Carefully remove fan motor, fan and motor brack-
et assembly from machine.
2
IMPORTANT: The hydraulic pump assembly can re-
main in machine during engine removal. To prevent
pump assembly from shifting or falling, make sure
to support pump assembly before pump mounting
fasteners are removed.
Figure 11
1. Fan
4. Cap screw (6 used)
2. Fan motor bracket
3. Fan motor
5. Flange nut (6 used)
6. Radiator
12.Support hydraulic pump assembly. Remove fasten-
ers that secure piston (traction) pump assembly to en-
gine (see Piston (Traction) Pump Assembly Removal in
the Service and Repairs section of Chapter 4 -- Hydrau-
lic System).
2. Make sure that all parts removed from the engine
during maintenance or rebuilding are installed to the en-
gine.
13.Make sure all cable ties securing the wiring harness,
fuel lines or hydraulic hoses to the engine are removed.
3. Ifremoved, install engine mounts tothe engineusing
Figure 8 as a guide.
14.Connect lift or hoist to the lift tabs on engine.
4. Connect lift or hoist to the lift tabs on engine.
15.Remove flange nuts, rebound washers and cap
screws that secure the engine mount brackets to the
rubber engine mounts.
CAUTION
One person should operate lift or hoist while a
second person guides the engine into the ma-
chine.
CAUTION
One person should operate lift or hoist while a
second person guides the engine out of the ma-
chine.
IMPORTANT: Make sure to not damage the engine,
fuel lines, hydraulic lines, electrical harness or oth-
er parts while installing the engine.
5. Carefully lower engine into the machine.
IMPORTANT: Make sure to not damage the engine,
fuel lines, hydraulic lines, electrical harness or oth-
er parts while removing the engine.
6. Align engine to the rubber engine mounts and hy-
draulic pump input shaft. Secure engine to engine
mounts with cap screws, rebound washers and flange
nuts.
16.Carefully raise engine from the machine.
17.Ifnecessary, remove engine mounts fromtheengine
using Figure 8 as a guide.
7. Securehydraulicpumpassemblytoengine(seePis-
ton(Traction)PumpAssemblyInstallationintheService
and Repairs section of Chapter 4 -- Hydraulic System).
Engine Installation (Fig. 8)
1. Locate machine on a level surface with key removed
from the ignition switch. Chock wheels to keep the ma-
chine from moving.
Kubota Diesel Engine
Page 3 -- 14
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8. Install fan motor and fan assembly (Fig. 11).
C. The alternator (Fig. 10).
D. The glow plug connection.
A. Carefullypositionfanmotor, fanandmotorbrack-
et assembly to radiator.
E. Wire harness connector to engine ground har-
ness.
B. Secure fan motor bracket to radiator with six (6)
cap screws and flange nuts.
F. Theelectricstarter.TorquenutatstarterB+termi-
nal from 70 to 86 in--lb (7.9 to 9.7 N--m).
C. Remove caps and plugs placed in hoses and fit-
tings during removal to prevent contamination.
G. Lowoilpressureswitch locatedon alternatorside
of engine (above electric starter).
D. Connect hydraulic hoses to cooling fan motor
(see Hydraulic Hose and Tube Installation in the
GeneralInformationsectionofChapter4 -- Hydraulic
System).
13.Using notes taken during engine removal, secure
wires with cable ties in proper locations.
14.Install air cleaner assembly to the engine (see Air
Cleaner Installation in this section).
9. Position upper radiator shroud to the radiator. Secu-
re shroud to the radiator and lower radiator bracket with
removed fasteners (see Radiator Installation in this sec-
tion). Make sure that clearance between shroud and fan
is at least 0.180” (4.6 mm) at all points.
15.Installexhaustsystemtomachine(seeExhaustSys-
tem Installation in this section).
16.Connect coolant hoses to the radiator. Make sure ra-
diatordraincockisclosed. Fillradiatorandreservoirwith
coolant.
10.Connect throttle cable to engine (Fig. 9):
A. Secure throttle cable swivel to speed control le-
ver with lock nut.
17.Check position of wires, fuel lines, hydraulic hoses
and cables for proper clearance with rotating, high tem-
perature and moving components.
B. Place throttle cable under cable clamp.
C. Adjust throttle cable position in cable clamp so
that engine governor lever contacts the high speed
stop bolt at the same time that the throttle lever con-
tacts the end of the slot in the control console.
18.Connect positive battery cable first and then nega-
tive battery cable. Secure battery cover to machine.
19.Check and adjust engine oil level as needed.
20.Check and adjust hydraulic oil level as needed.
21.Bleed fuel system.
D. Tighten cable clamp to secure throttle cable.
11.Remove caps from fuel hose and injector pump fuel
inlet that were placed during engine removal to prevent
contamination. Connect fuel supply hose to injection
pump (Fig. 9). Secure hose with hose clamp.
22.Operate hydraulic controls to properly fill hydraulic
system (see Charge Hydraulic System in the Service
and Repairs section of Chapter 4 -- Hydraulic Systems).
12.Connect wire harness connectors to the following
engine components:
23.Install hood on the machine (see Hood Installation in
the Service and Repairs section of Chapter 7 -- Chas-
sis).
A. The engine run solenoid (Fig. 9).
B. The temperature sender (Fig. 10).
Reelmaster 7000
Page 3 -- 15
Kubota Diesel Engine
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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
4. Hardened washer (14 used)
5. Spring coupler
6. Bolt (6 used)
7. Cap screw (8 used)
3. Flywheel plate
Kubota Diesel Engine
Page 3 -- 16
Reelmaster 7000
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Coupler Removal (Fig. 12)
NOTE: The hydraulic pump assembly needs to be re-
moved from engine before coupler can be removed.
Engine Side
Hydraulic
Pump Side
1. If engine is in machine, remove hydraulic pump as-
sembly(seePiston(Traction)PumpRemovalintheSer-
vice and Repairs section of Chapter 4 -- Hydraulic
System).
1
2. Remove flywheel plate and spring coupler from en-
gine using Figure 12 as a guide.
Coupler Installation (Fig. 12)
1. Position spring coupler to engine flywheel and align
mounting holes. Make sure that coupling hub is away
from engine flywheel (Fig. 13).
2
3
2. Apply Loctite #242 (or equivalent) to threads of bolts
(item6). Secure couplerto flywheelwith six(6) boltsand
hardened washers. Torque bolts in a crossing pattern
from 29 to 33 ft--lb (40 to 44 N--m).
Figure 13
1. Coupler
3. Engine flywheel
2. Coupler hub
3. Position flywheel plate to engine. Make sure that
boss on plate is orientated down. Secure flywheel plate
with cap screws (item 7) and hardened washers using
a crossing pattern tightening procedure.
4. If engine is in machine, install hydraulic pump as-
sembly (see Piston (Traction) Pump Installation in the
Service and Repairs section of Chapter 4 -- Hydraulic
System).
Reelmaster 7000
Page 3 -- 17
Kubota Diesel Engine
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Kubota Diesel Engine
Page 3 -- 18
Reelmaster 7000
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Chapter 4
Hydraulic System
Table of Contents
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 . . . . . . . . . . . . 5
Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic Hose and Tube Installation . . . . . . . . . . 7
Hydraulic Fitting Installation . . . . . . . . . . . . . . . . . . 8
HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . 10
HYDRAULIC FLOW DIAGRAMS . . . . . . . . . . . . . . . 12
Traction Circuit: Mow Speed (4WD) . . . . . . . . . . 12
Traction Circuit: Transport Speed (2WD) . . . . . . 14
Lower Cutting Units . . . . . . . . . . . . . . . . . . . . . . . . 16
Raise Cutting Units . . . . . . . . . . . . . . . . . . . . . . . . . 18
Mow Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Engine Cooling Fan Circuit . . . . . . . . . . . . . . . . . . 24
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 30
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Traction Circuit Charge Pressure Test . . . . . . . . . 38
Traction Circuit Relief Pressure Test . . . . . . . . . . 40
Traction Circuit Reducing Valve (PR)
Check Hydraulic Lines and Hoses . . . . . . . . . . . . 70
Flush Hydraulic System . . . . . . . . . . . . . . . . . . . . . 71
Filtering Closed--Loop Traction Circuit . . . . . . . . 72
Charge Hydraulic System . . . . . . . . . . . . . . . . . . . 73
Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Gear Pump Service . . . . . . . . . . . . . . . . . . . . . . . . 76
Piston (Traction) Pump . . . . . . . . . . . . . . . . . . . . . 78
Piston (Traction) Pump Service . . . . . . . . . . . . . . 80
4WD/2WD and Filtration/Charge Control
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Manifolds . . . . .
82
4WD/2WD Control Manifold Service . . . . . . . . . . 84
Filtration/Charge Control Manifold Service . . . . . 86
Control Manifold Cartridge Valve Service . . . . . . 87
Rear Axle Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Front Wheel Motors . . . . . . . . . . . . . . . . . . . . . . . . 90
Rear Axle and Front Wheel Motor Service . . . . . 92
Cutting Reel Motor . . . . . . . . . . . . . . . . . . . . . . . . . 93
Cutting Reel Motor Service . . . . . . . . . . . . . . . . . . 94
Mow Control Manifold . . . . . . . . . . . . . . . . . . . . . . 98
Mow Control Manifold Service . . . . . . . . . . . . . . 100
Steering Control Valve . . . . . . . . . . . . . . . . . . . . . 102
Steering Control Valve Service . . . . . . . . . . . . . . 104
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . 106
Steering Cylinder Service . . . . . . . . . . . . . . . . . . 108
Engine Cooling Fan Motor . . . . . . . . . . . . . . . . . . 110
Engine Cooling Fan Motor Service . . . . . . . . . . 112
Fan Control Manifold . . . . . . . . . . . . . . . . . . . . . . 114
Fan Control Manifold Service . . . . . . . . . . . . . . . 116
Lift Control Manifold . . . . . . . . . . . . . . . . . . . . . . . 118
Lift Control Manifold Service . . . . . . . . . . . . . . . . 120
Lift Circuit Junction Manifold . . . . . . . . . . . . . . . . 122
Front Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . 124
Rear Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . 126
Lift Cylinder Service . . . . . . . . . . . . . . . . . . . . . . . 128
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . 130
Hydraulic Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . 132
EATON MODEL 72400 SERVO CONTROLLED PIS-
TON PUMP REPAIR INFORMATION
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Rear Traction Circuit Relief (RV) Pressure Test 44
Piston (Traction) Pump Flow Test . . . . . . . . . . . . 46
Mow Circuit Pressure Test . . . . . . . . . . . . . . . . . . . 48
Mow Circuit Relief Pressure Test . . . . . . . . . . . . . 50
Cutting Unit Motor Case Drain Leakage Test . . . 52
Gear Pump P1 and P2 Flow (Mow Circuits) Test 54
Steering Circuit Relief Pressure Test . . . . . . . . . . 56
Steering Cylinder Internal Leakage . . . . . . . . . . . 58
Lift/Lower Circuit Relief Pressure Test . . . . . . . . 60
Gear Pump P3 Flow (Steering and Lift/Lower
Circuits) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Cooling Fan Circuit Test . . . . . . . . . . . . . . . . . . . . . 64
Gear Pump P4 Flow (Cooling Fan Circuit) Test . 66
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Adjust Control Manifold Relief Valves . . . . . . . . . 68
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 69
General Precautions for Removing and
EATON MODEL 74318 and 74348 PISTON MOTORS:
FIXED DISPLACEMENT, VALVE PLATE DESIGN
REPAIR INFORMATION
SAUER--DANFOSS STEERING UNIT TYPE OSPM
SERVICE MANUAL
Installing Hydraulic System Components . . . . 69
Reelmaster 7000
Page 4 -- 1
Hydraulic System
Rev. A
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Hydraulic System
Page 4 -- 2
Reelmaster 7000
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Specifications
Item
Description
Piston (Traction) Pump
Eaton variable displacement piston pump
(Model 72400)
3
Maximum Displacement (per revolution)
System Relief Pressure: Forward
System Relief Pressure: Reverse
2.48 in (40.6 cc)
5000 PSI (345 bar)
5000 PSI (345 bar)
Charge Pressure
207 PSI (14.3 bar)
Front Wheel Motors
Eaton fixed displacement piston motors
(Model 74315)
3
Displacement (per revolution)
2.01 in (32.9 cc)
Rear Axle Motor
Eaton fixed displacement piston motor
(Model 74318)
3
Displacement (per revolution)
2.48 in (40.6 cc)
Gear Pump
Section P1/P2 Displacement (per revolution)
Section P3/P4 Displacement (per revolution)
Casappa 4 section, positive displacement gear type pump
3
1.03 in (16.85 cc)
3
0.56 in (9.16 cc)
Steering Control Valve
Displacement (per revolution)
Sauer--Danfoss Steering Unit, Series OSPM
3
6.1 in (100 cc)
Steering Circuit Relief Pressure
Lift/Lower Circuit Relief Pressure
1050 PSI (72 bar)
1700 PSI (117 bar)
Casappa Gear Motor
Cutting Unit Motors
Displacement (per revolution)
3
1.61 in (26.5 cc)
Cutting Unit Circuit Relief Pressure
3000 PSI (207 bar)
Engine Cooling Fan Motor
Displacement (per revolution)
Casappa Gear Motor
3
0.51 in (8.4 cc)
Engine Cooling Fan Circuit Relief Pressure
3000 PSI (207 bar)
Hydraulic Filters
In--line Suction Strainer
Spin--on cartridge type
100 mesh (in reservoir)
Hydraulic Reservoir Capacity
Hydraulic Oil
8.25 U.S. Gallons (31.3 Liters)
See Traction Unit Operator’s Manual
NOTE: The pressure specifications listed above are
component settings. When using pressure gauges to
measure circuit pressures, values may be different than
these specifications. See the Testing section of this
chapter for hydraulic test procedures and expected test
results.
Reelmaster 7000
Page 4 -- 3
Hydraulic System
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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 (4.8 kph) and for a distance less than 1/4
mile (0.4 km). The piston (traction) pump is equipped
with a bypass valve that needs to be turned 90o for tow-
ing(Fig.1).Donotturnbypassvalvewhenengineisrun-
ning.
See Traction Unit Operator’s Manual for additional tow-
ing procedures.
IMPORTANT: If the machine must be pushed or
towed in a reverse direction, the check valve in the
4WD/2WD control manifold must be bypassed. To
bypass this check valve, connect a hydraulic hose
between the reverse traction pressure test port and
the 4WD/2WD control manifold test port (G). Toro
part numbers 95--8843 (hydraulic hose), 95--0985
(coupler fitting) (2 required) and 340--77 (hydraulic
fitting) (2 required) are needed for this connection.
Figure 1
1. Bypass valve location
Check Hydraulic Fluid
The Reelmaster 7000 hydraulic systems are designed
to operate on anti--wear hydraulic fluid. The reservoir
holdsapproximately8.25 U.S. gallons (31.3liters) ofhy-
draulic fluid. Check level of hydraulic fluid daily.
1
2
Figure 2
1. Hydraulic reservoir
2. Reservoir cap
Hydraulic System
Page 4 -- 4
Reelmaster 7000
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Relieving Hydraulic System Pressure
Before disconnecting or performing any work on the hy-
draulic system, all pressure in the hydraulic system
mustberelieved.Parkmachineonalevelsurface,lower
cutting units fully, stop engine and apply parking brake.
Systempressure in mow circuitis relieved when the cut-
ting units are disengaged (PTO switch in OFF position).
To relieve hydraulic pressure in lift circuit, fully lower the
cutting units to the ground. Turn ignition switch to OFF.
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.
Traction Circuit Component Failure
The traction circuit on Reelmaster 7000 machines is a
closed loop system that includes the piston (traction)
pump, two (2) front wheel motors and the rear axle mo-
tor. If a component in the traction circuit should fail, de-
bris and contamination from the failed component will
circulate throughout the traction circuit. This contamina-
tion can damage other components in the circuit so it
must be removed to prevent additional component fail-
ure.
all drive wheels off the ground. Then, operate the trac-
tion circuit to allow oil flow throughout the circuit. The fil-
ter will remove contamination from the traction circuit
during operation. Because the Toro high flow filter is bi--
directional, the traction circuit can be operated in both
the forward and reverse direction. The filter should be
removed from the machine after contamination has
been removed from the traction circuit. See Filtering
Closed--LoopTractionCircuitintheServiceandRepairs
section of this chapter for additional information on us-
ing the Toro high flow hydraulic filter.
The recommended method of removing traction circuit
contamination would be to temporarily install the Toro
high flow hydraulic filter (see Special Tools in this chap-
ter) into the circuit. This filter should be used when con-
necting hydraulic test gauges in order to test traction
circuitcomponentsorafterreplacing afailed tractioncir-
cuit component (e.g. traction (piston) pump or wheel
motor). The filter will ensure that contaminates are re-
movedfromtheclosedloopandthus, donotcauseaddi-
tional component damage.
The alternative tousing theToro highflow hydraulicfilter
kit after a traction circuit component failure would be to
disassemble, drain and thoroughly clean all compo-
nents, tubes and hoses in the traction circuit. If any de-
bris remains in the traction circuit and the machine is
operated, thedebriscancauseadditionalcircuitcompo-
nent failure.
NOTE: If traction circuit contamination exists, the trac-
tion pump case drain could allow contaminates to enter
other hydraulic circuits on the machine.
Once the Toro high flow hydraulic filter kit has been
placed in the circuit, raise and support the machine with
Reelmaster 7000
Page 4 -- 5
Hydraulic System
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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 condi-
tionsormishandlingduringoperation andmaintenance.
These conditions can cause hose damage and deterio-
ration. Some hoses are more susceptible to these
conditions than others. Inspect all machine hydraulic
hoses frequently for signs of deterioration or damage:
WARNING
Before disconnecting or performing any work on
hydraulic system, relieve all pressure in system
(see Relieving Hydraulic System Pressure in this
section).
Hard, cracked, cut, abraded, charred, leaking or
otherwise damaged hose.
Keepbodyandhandsawayfrompinholeleaksor
nozzles that eject hydraulic fluid under high
pressure. Use paper or cardboard, not hands, to
search for leaks. Hydraulic fluid escaping under
pressure can have sufficient force to penetrate
the skin and cause serious injury. If fluid is in-
jected into the skin, it must be surgically re-
moved within a few hours by a doctor familiar
with thistype ofinjury. Gangrenemay resultfrom
such an injury.
Kinked, crushed, flattened or twisted hose.
Blistered, soft, degraded or loose hose cover.
Cracked, damaged or badly corroded hose fittings.
When replacing a hydraulic hose, be sure that the hose
is straight (not twisted) before tightening the fittings.
This can be done by observing the imprint (layline) on
the hose. Use two wrenches; hold the hose straight with
one wrench and tighten the hose swivel nut onto the fit-
ting with the other wrench (See Hydraulic Hose and
Tube Installation in this section). If the hose has an el-
bow at one end, tighten the swivel nut on that end before
tightening the nut on the straight end of the hose.
For additional hydraulic hose information, refer to Toro
Service Training Book, Hydraulic Hose Servicing (Part
Number 94813SL).
Hydraulic System
Page 4 -- 6
Reelmaster 7000
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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 nutto the cor-
rect Flats From Wrench Resistance (F.F.W.R.). The
markingsonthenutandfittingbodywillverifythatthe
connection has been properly tightened.
2. As a preventative measure against leakage, it is rec-
ommended that the face seal O--ring be replaced any
time the connection is opened. Make sure the O--ring is
installedandproperlyseatedinthefittinggroove.Lightly
lubricate the O--ring with clean hydraulic oil.
Size
F.F.W.R.
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
1/2 to 3/4
1/2 to 3/4
1/2 to 3/4
1/2 to 3/4
1/3 to 1/2
1/3 to 1/2
3. Place the hose/tube against the fitting body so that
theflatfaceofthehose/tubesleevefullycontactstheO--
ring in the fitting.
16 (1 in.)
Swivel Nut
Fitting Body
O--ring
4. Thread the swivel nut onto the fitting by hand. While
holding the hose/tube with a wrench, use a torque
wrench to tighten the swivel nut to the recommended
installation torque shown in Figure 5. This tightening
process will require the use of an offset wrench (e.g.
crowfoot wrench). Use of an offset wrench will affect
torque wrench calibration due to the effective length
change of the torque wrench. Tightening torque when
usingatorquewrenchwithanoffsetwrenchwillbelower
than the listed installation torque (see Using a Torque
Wrench with an Offset Wrench in the Torque Specifica-
tions section of Chapter 2 -- Product Records and Main-
tenance).
Tube or Hose
Figure 3
5. If a torque wrench is not available or if space at the
swivel nut prevents use of a torque wrench, an alternate
method of assembly is the Flats From Wrench Resist-
ance (F.F.W.R.) method (Fig. 2).
Mark Nut
Final
Position
and Fitting
Body
A. Using a wrench, tighten the swivel nutonto thefit-
tinguntillightwrenchresistanceis reached(approxi-
mately 30 in--lb).
Initial
Position
Extend Line
AT WRENCH RESISTANCE
AFTER TIGHTENING
B. Mark the swivel nut and fitting body. Hold the
hose/tube with a wrench to prevent it from turning.
Figure 4
Fitting Dash Size
Hose/Tube Side Thread Size
9/16 -- 18
Installation Torque
4
6
18 to 22 ft--lb (25 to 29 N--m)
27 to 33 ft--lb (37 to 44 N--m)
37 to 47 ft--lb (51 to 63 N--m)
60 to 74 ft--lb (82 to 100 N--m)
85 to 105 ft--lb (116 to 142 N--m)
110 to 136 ft--lb (150 to 184 N--m)
140 to 172 ft--lb (190 to 233 N--m)
11/16 -- 16
8
13/16 -- 16
10
12
16
20
1 -- 14
1 3/16 -- 12
1 7/16 -- 12
1 11/16 -- 12
Figure 5
Page 4 -- 7
Reelmaster 7000
Hydraulic System
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Hydraulic Fitting Installation (SAE Straight Thread O--Ring Fitting into Component Port)
Non--Adjustable Fitting (Fig. 6)
5. If a torque wrench is not available, or if space at the
portpreventsuseofatorque wrench, an alternatemeth-
od of assembly is the Flats From Finger Tight (F.F.F.T.)
method.
1. Make sure all threads and sealing surfaces of fitting
and component port are free of burrs, nicks, scratches
or any foreign material.
A. Install the fitting into the port and tighten it down
full length until finger tight.
2. As a preventative measure against leakage, it is rec-
ommended that the O--ring be replaced any time the
connection is opened.
B. If port material is steel, tighten the fitting to the
listed F.F.F.T. If port material is aluminum, tighten fit-
ting to 60% of listed F.F.F.T.
3. Lightly lubricate the O--ring with clean hydraulic oil.
Fittingthreadsshouldbecleanwithnolubricantapplied.
Size
F.F.F.T.
IMPORTANT: Before installing fitting into port, de-
termine port material. If fitting is to be installed into
an aluminum port, installation torque is reduced.
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
1.00 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
4. Install the fitting into the port. Then, use a torque
wrench and socket to tighten the fitting to the recom-
mended installation torque shown in Figure 7.
16 (1 in.)
NOTE: Use of an offset wrench (e.g. crowfoot wrench)
will affect torque wrench calibration due to the effective
length change of the torque wrench. Tightening torque
when using a torque wrench with an offset wrench will
be less than the recommended installation torque. See
Using a Torque Wrench with an Offset Wrench in the
Torque Specifications section of Chapter 2 -- Product
Records and Maintenance to determine necessary con-
version information.
Fitting
O--ring
Figure 6
Fitting
Dash Size
Fitting Port Side
Thread Size
Installation Torque Into
Steel Port
Installation Torque Into
Aluminum Port
4
5
7/16 -- 20
1/2 -- 20
15 to 19 ft--lb (21 to 25 N--m)
18 to 22 ft--lb (25 to 29 N--m)
34 to 42 ft--lb (47 to 56 N--m)
58 to 72 ft--lb (79 to 97 N--m)
99 to 121 ft--lb (135 to 164 N--m)
134 to 164 ft--lb (182 to 222 N--m)
160 to 196 ft--lb (217 to 265 N--m)
202 to 248 ft--lb (274 to 336 N--m)
9 to 11 ft--lb (13 to 15 N--m)
11 to 15 ft--lb (15 to 20 N--m)
20 to 26 ft--lb (28 to 35 N--m)
35 to 43 ft--lb (48 to 58 N--m)
60 to 74 ft--lb (82 to 100 N--m)
81 to 99 ft--lb (110 to 134 N--m)
96 to 118 ft--lb (131 to 160 N--m)
121 to 149 ft--lb (165 to 202 N--m)
149 to 183 ft--lb (202 to 248 N--m)
6
9/16 -- 18
3/4 -- 16
8
10
12
14
16
20
7/8 -- 14
1 1/16 -- 12
1 3/16 -- 12
1 5/16 -- 12
1 5/8 -- 12
247 to 303 ft--lb (335 to 410 N--m)
Figure 7
Hydraulic System
Page 4 -- 8
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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 rec-
ommended that the O--ring be replaced any time the
connection is opened.
Lock Nut
3. Lightly lubricate the O--ring with clean hydraulic oil.
Fittingthreadsshouldbecleanwithnolubricantapplied.
Back--up Washer
4. Turn back the lock nut as far as possible. Make sure
the back up washer is not loose and is pushed up as far
as possible (Step 1 in Figure 9).
O--ring
Figure 8
IMPORTANT: Before installing fitting into port, de-
termine port material. If fitting is to be installed into
an aluminum port, installation torque is reduced.
5. Install the fitting into the port and tighten finger tight
until the washer contacts the face of the port (Step 2).
Step 1
Step 2
Step 3
Step 4
6. To put the fitting in the desired position, unscrew it by
the required amount, but no more than one full turn
(Step 3).
7. Hold the fitting in the desired position with a wrench
and use a torque wrench to tighten the fitting to the rec-
ommended installation torque shown in Figure 7. This
tightening process will require the use of an offset
wrench (e.g. crowfoot wrench). Use of an offset wrench
will affect torque wrench calibration due to the effective
length change of the torque wrench. Tightening torque
when using a torque wrench with an offset wrench will
be lower than the listed installation torque (see Using a
Torque Wrench with an Offset Wrench in the Torque
Specifications section of Chapter 2 -- Product Records
and Maintenance).
Figure 9
8. If a torque wrench is not available, or if space at the
portpreventsuseofatorque wrench, an alternatemeth-
od of assembly is the Flats From Finger Tight (F.F.F.T.)
method. Hold the fitting in the desired position with a
wrench and, if port material is steel, tighten the lock nut
with a second wrench to the listed F.F.F.T (Step 4). Ifport
material is aluminum, tighten fitting to 60% of listed
F.F.F.T.
Size
F.F.F.T.
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
1.00 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
16 (1 in.)
Reelmaster 7000
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Hydraulic Schematic
Hydraulic System
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Reelmaster 7000
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Hydraulic Flow Diagrams
Hydraulic System
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Traction Circuit: Mow Speed (4WD)
The traction circuit piston pump is a variable displace-
ment pump that is directly coupled to the engine fly-
wheel. Pushing the traction pedal engages a hydraulic
servo valve which controls the variable displacement
piston pump swash plate to create a flow of oil. This oil
isdirectedto thefrontwheeland rearaxle motors. Oper-
ating pressure on the high pressure side of the closed
traction circuit loop is determined by the amount of load
developedatthefixeddisplacementwheelandaxlemo-
tors. As the load increases, circuit pressure can in-
creasetoreliefvalvesettings:5000PSI(345bar)inboth
forward and reverse. If pressure exceeds the relief set-
ting, oil flows through the relief valve to the low pressure
sideoftheclosedlooptractioncircuit.Thetractioncircuit
provides operation in either mow speed (4WD) or trans-
port speed (2WD).
Forward Direction
When the mow speed limiter is in the mow speed (4WD)
position and the traction pedal is pushed in the forward
direction, oil from the piston pump is directed to the front
wheel motors and 4WD/2WD control manifold. Oil flow
to the front wheel motors drives the motors in the for-
ward direction and then returns to the piston pump. Oil
flowtothe4WD/2WDcontrolmanifoldenterstheP1port
and then is directed to the PD1 cartridge and out of the
manifold M1 port to drive the rear axle motor in the for-
ward direction. Oil returning from the rear motor re--en-
ters the 4WD/2WD control manifold at the M2 port. Flow
passes through the PD2 cartridge, through the check
valve (CV), out manifold port P2 and back to the piston
pump.
When going down a hill, the machine becomes an over--
running load that drives the wheel and axle motors. In
this condition, the rear axle motor could lock up as the
oil pumped from the motor increases pressure as it re-
turns to the piston pump. To prevent rear wheel lock up,
an adjustable relief valve (RV) in the 4WD/2WD control
manifold reduces rear axle motor pressure created in
down hill, dynamic braking conditions.
Traction circuit pressure (forward and reverse) can be
measured at test ports located on the traction circuit hy-
draulic 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 com-
ponents into the case drain. This leakage results in the
lossofhydraulicfluidfromtheclosedlooptractioncircuit
that must be replaced. The charge circuit is designed to
replace this traction circuit leakage.
Reverse Direction
The traction circuit operates essentially the same in re-
verse 4WD as it does in the forward direction. However,
the flow through the circuit is reversed. Oil flow from the
piston pump is directed to the front wheel motors and
also to the 4WD/2WD control manifold. The oil to the
front wheel motors drives them in the reverse direction
and then returns to the piston pump. The oil to the
4WD/2WD control manifold enters the manifold at port
P2 and flows through pressure reducing valve (PR)
which limits the down stream pressure to the rear axle
motorto450PSI(31bar)sotherearwheelswillnotscuff
theturfduringreverseoperation. Thisreducedpressure
flows through the PD2 cartridge and out port M2 to the
rear axle motor. Return oil from the rear motor re--enters
the 4WD/2WD control manifold at port M1, flows
through the PD1 cartridge, exits the manifold at port P1
and returns to the piston pump.
The gear pump section that supplies oil to the steering
and lift/lower circuits also provides oil for the charge cir-
cuit. This gear pump is driven directly off the traction
pump. It provides a constant supply of charge oil to
make up for oil that is lost due to internal leakage in the
traction pump and motors.
Pump flow for the charge circuit is directed through the
oil filter and to the low pressure side of the closed loop
traction circuit. A filter bypass valve allows charge oil
flow to the closed loop if the filter becomes plugged.
Charge pressure is limited to 207 PSI (14.3 bar) by a re-
liefvalvelocatedinthefiltration/chargecontrolmanifold.
Charge pressure can be measured at the charge circuit
pressure test port on the filtration/charge control man-
ifold.
Reelmaster 7000
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Traction Circuit: Transport Speed (2WD)
The traction circuit piston pump is a variable displace-
ment pump that is directly coupled to the engine fly-
wheel. Pushing the traction pedal engages a hydraulic
servo valve which controls the variable displacement
piston pump swash plate to create a flow of oil. This oil
isdirectedto thefrontwheeland rearaxle motors. Oper-
ating pressure on the high pressure side of the closed
traction circuit loop is determined by the amount of load
developedatthefixeddisplacementwheelandaxlemo-
tors. As the load increases, circuit pressure can in-
creasetoreliefvalvesettings:5000PSI(345bar)inboth
forward and reverse. If pressure exceeds the relief set-
ting, oil flows through the relief valve to the low pressure
sideoftheclosedlooptractioncircuit.Thetractioncircuit
provides operation in either mow speed (4WD) or trans-
port speed (2WD).
Forward Direction
Withthemowspeedlimiterinthetransportspeed(2WD)
position, solenoid valve (SV) in the 4WD/2WD control
manifold is energized. The solenoid valve spool shifts to
direct charge pressure that shifts the PD1 and PD2 con-
trol valve spools. The shifted PD1 and PD2 valves pre-
vents hydraulic flow from the piston pump to the rear
axle motor. With flow blocked to the rear axle motor, all
piston pump flow is directed to the front wheel motors to
allow a higher transport speed in the forward direction.
Without flow to the rear axle motor, the rotating rear
wheels drive the axle motor so it acts like a pump. Inlet
oil to the axle motor is provided by a check valve that al-
lows charge circuit oil into the rear axle motor circuit. Oil
leaving the axle motor enters the 4WD/2WD control
manifold at port M2 and is directed back to the axle mo-
tor through the shifted PD1 cartridge and manifold port
M1. To allow for rear wheel loop cooling when in forward
transport speed operation, a small amount of oil exits
through the shifted PD1 and PD2 cartridges that returns
to the reservoir.
Traction circuit pressure (forward and reverse) can be
measured at test ports located on the traction circuit hy-
draulic 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 com-
ponents into the case drain. This leakage results in the
lossofhydraulicfluidfromtheclosedlooptractioncircuit
that must be replaced. The charge circuit is designed to
replace this traction circuit leakage.
Reverse Direction
The traction circuit operates essentially the same in re-
verse transportspeed as itdoes in the forward direction.
However, the flow through the circuit is reversed. The
shifted solenoid valve (SV) and directional valves PD1
and PD2 in the 4WD/2WD manifold preventoil flow from
the rear axle motor. Oil flow from the piston pump is
therefore directed toonly thefrontwheelmotors. Thisoil
drives the front wheel motors in the reverse direction
and then returns to the piston pump. Oil circulation
through the rear axle motor loop is the same as in the
2WD forward direction.
The gear pump section that supplies oil to the steering
and lift/lower circuits also provides charge oil for the
traction circuit. This gear pump is driven directly off the
tractionpump. Itprovidesaconstantsupplyofchargeoil
to the traction circuit to make up for oil that is lost due to
internal leakage in the traction pump and motors.
Charge pump flow is directed through the oil filter and to
the low pressure side of the closed loop traction circuit.
A filter bypass valve allows charge oil flow to the closed
loop if the filter becomes plugged. Charge pressure is li-
mited to 207 PSI (14.3 bar) by a relief valve located in
the filtration/charge control manifold. Charge pressure
can be measured at the test port on the filtration/charge
control manifold.
NOTE: When the mow speed limiter is in the transport
(2WD) position, the cutting units are prevented from be-
ing lowered and the mow circuit cannot be engaged.
Reelmaster 7000
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Hydraulic System
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Lower Cutting Units
A four section gear pump is coupled to the piston (trac-
tion) pump. Gear pump section P3 supplies hydraulic
flow to both the liftcontrolmanifold andthe steeringcon-
trol valve. Hydraulic flow from this pump section is deliv-
ered to the circuits through a proportional flow divider
located in the fan control manifold. Maximum lift/lower
circuitpressureislimitedto1700PSI(117bar)byarelief
valve (RV1) in the lift control manifold. Lift circuit pres-
sure can be monitored at the test fitting in lift control
manifold port G.
Because cutting unit weight assists in extending the lift
cylinders when lowering the cutting units, less hydraulic
pressure is necessary during the cutting unit lowering
operation. Lift circuit lower relief valve (RV2) allows lift
circuit pressure to be limited to 500 PSI (34 bar) while
lowering the cutting units.
NOTE: Adjustment of lift circuit lower relief valve (RV2)
is not recommended.
When the lift switch is released, solenoid valves S1, S3,
S4 and S5 are de--energized and the lift cylinders and
cutting units are held in position.
A single lift switch on the console arm is used to raise
and lower the five (5) cutting units (Fig. 10). The lift
switch acts as an input to the TEC controller to send
electrical outputs to appropriate lift control manifold so-
lenoid coils in order to raise or lower the cutting units.
When the cutting units are in a stationary position (not
raising or lowering), lift circuit flow from gear pump sec-
tion P3 bypasses the lift cylinders through the lift control
manifold solenoid valve S1 (de--energized). Return flow
from the manifold is routed to the oil filter and traction
charge circuit.
2
1
Cutting Unit Lower
Figure 10
NOTE: The operator must be in the operator seat in or-
der to lower the cutting units. Also, when in transport
speed (2WD), the cutting units will not lower.
1. Console
2. Lift switch
When the lift switch is pressed to the lower position, so-
lenoid valve S1 along with solenoid valves S3, S4 and
S5 are energized by the TEC controller. To allow the
front cutting units to be lowered before the rear cutting
units, the controller slightly delays energizing solenoid
S5 after the lift switch is pressed. The energized sole-
noid valves direct gear pump oil flow to the barrel end of
the lift cylinders. Flow control orifices in the lift control
manifold (C2 and C4) are bypassed when lowering the
cutting units.
#4
#1
#5
#2
#3
Hydraulic pressure causes the lift cylinder shafts to ex-
tend, and lower the cutting units. The three (3) piloted
check valves in the junction manifold are shifted by hy-
draulic pressure to allow return flow from the extending
lift cylinders for the front cutting units. Flow control orifi-
ces in the junction manifold control the front cutting unit
lowering speed by providing a restriction for the return
flow from the front lift cylinders. Rear cutting unit lower-
ing speed is controlled by a flow control orifice in the lift
control manifold (port C3).
CUTTING UNIT LOCATIONS
Figure 11
Reelmaster 7000
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Raise Cutting Units
A four section gear pump is coupled to the piston (trac-
tion) pump. Gear pump section P3 supplies hydraulic
flow to both the liftcontrolmanifold andthe steeringcon-
trol valve. Hydraulic flow from this pump section is deliv-
ered to the circuits through a proportional flow divider
located in the fan control manifold. Maximum lift/lower
circuitpressureislimitedto1700PSI(117bar)byarelief
valve (RV1) in the lift control manifold. Lift circuit pres-
sure can be monitored at the test fitting in lift control
manifold port G.
2
1
A single lift switch on the console arm is used to raise
and lower the five (5) cutting units (Fig. 10). The lift
switch acts as an input to the TEC controller to send
electrical outputs to appropriate lift control manifold so-
lenoid coils in order to raise or lower the cutting units.
Figure 12
1. Console
2. Lift switch
#4
#1
#5
When the cutting units are in a stationary position (not
raising or lowering), lift circuit flow from gear pump sec-
tion P3 bypasses the lift cylinders through the lift control
manifold solenoid valve S1 (de--energized). Return flow
from the manifold is routed to the oil filter and traction
charge circuit.
Raise Cutting Units
#2
#3
NOTE: The operator must be in the operator seat in or-
der to raise the cutting units.
When the lift switch is moved to the raise position, sole-
noid valve S1 along with solenoid valves S2, S3, S4 and
S5 are energized by the TEC controller. To allow the
front cutting units to be raised before the rear cutting
units, the controller slightly delays energizing solenoid
S5 after the lift switch is pressed. The energized sole-
noidvalvesdirectgearpumpoilflowtotherodendofthe
lift cylinders. The flow control orifice in the lift control
manifold port C3 is bypassed when raising the cutting
units.
CUTTING UNIT LOCATIONS
Figure 13
Hydraulic pressure causes the lift cylinder shafts to re-
tract, and raisethe cuttingunits. Theflow controlorifices
in the junction manifold are bypassed when raising the
cutting units. Flow control orifices in the lift control man-
ifold (ports C2 and C4) control the cutting unit raising
speed by providing a restriction for the return flow from
the lift cylinders.
When the lift switch is released, solenoid valves S1, S2,
S3, S4 and S5 are de--energized and the lift cylinders
and cutting units are held in position.
Reelmaster 7000
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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 sec-
tion 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. The check valves (CV1 and CV2)
in the mow control manifold will open to keep the reel
motor circuit full of oil so the motors will not cavitate.
A single mow control manifold is used to control flow
from the two (2) pump sections. The manifold includes
cartridge valves for control of each of the two (2) pump
circuits. Each manifold circuit is equipped with a sole-
noidcontrolled,proportionalvalve(SP1andSP2), alog-
ic cartridge (LC1 and LC2) and a circuit relief cartridge
(RV1 and RV2).
Backlap
When either of the mow control manifold backlap valves
are rotated to the backlap (R) position, pump flow to the
cutting unit motors is reversed. This change in flow di-
rection reverses the rotation of the front or rear cutting
reel motors allowing the backlap operation.
Allcuttingreelmotorsareequippedwithcrossoverrelief
valves to prevent hydraulic component damage in case
a cutting reel should stall.
#4
#1
#5
The TEC controller uses inputs from various machine
switches to determine when solenoid proportional valve
(SP1 and SP2) are to be energized. The controller also
provides a slight delay in activation of the rear cutting
units.
#2
#3
NOTE: When the mow speed limiter is in the transport
(2WD) position, the mow circuit cannot be engaged.
PTO Disengaged (Fig. 15)
When the PTO switch is OFF (or if the cutting units are
raised), the manifold proportional valves (SP1 and SP2)
are not energized, which causes a pressure increase
that shifts the logic cartridges (LC1 and LC2). The pump
flow is routed through the shifted logic cartridge and out
manifold port T1. Return oil from the manifold is directed
to the oil cooler and oil filter.
CUTTING UNIT LOCATIONS
Figure 14
M4
M1
M5
M2
M3
PTO Engaged
When the PTO switch is turned ON with the cutting units
lowered, the manifold proportional valves (SP1 and
SP2) are energized with outputs from the TEC--5002
controller. Theenergizedvalvesshifttodirectpumpflow
toward the cutting unit motors. Flow from the valves is
proportional to current applied to the valve coil by the
TEC controller. The setting ofthe reel speed control pro-
vides the input for the TEC controller to allow the ap-
propriate current to the valve coil.
M1
M2
M4
M3
MOW
CONTROL
MANIFOLD
MV2
MV1
CV2
LC2
OR1
CV1
LC1
OR2
SP1
SP2
Flow through the speed control valve is pressure com-
pensated by the logic cartridge valves (LC1 and LC2).
The logic cartridge valve maintains a pressure of 110
PSI (7.6 bar) across the proportional valve. Any excess
flow is returned to the hydraulic reservoir.
RV1
RV2
T1
P1
T2
P2
FROM GEAR
PUMP P1
FROM GEAR
PUMP P2
Maximum mow circuit pressure is limited at each mow
manifold circuit by the relief valve (RV1 or RV2). The re-
lief valve pressure is 3000 PSI (207 bar).
Figure 15
Reelmaster 7000
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Steering Circuit
A four section gear pump is coupled to the piston (trac-
tion) pump. The gear pump section P3 supplies hydrau-
lic 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 pres-
sure is limited to 1050 PSI (72 bar) by a relief valve lo-
cated in the steering control valve.
the cylinder is proportional to the amount of the turning
on the steering wheel. Fluid leaving the cylinder flows
backthroughthespoolvalvethenthroughtheTportand
to the hydraulic reservoir.
The steering control valve returns to the neutral position
when turning is completed.
Right Turn
With the steering wheel in the neutral position and the
engine running, pump section P3 flow enters the steer-
ing control valve at the P port and goes through the
steering control spool valve, bypassing the rotary meter
and steering cylinder. Flow leaves the control valve
through the PB port to the oil filter and traction charge
circuit.
When a right turn is made with the engine running, the
turningofthesteeringwheelpositionsthespoolvalveso
that flow goes through the bottom of the spool. Flow en-
tering the steering control valve at the P port goes
through the spool and is routed to two places. As in a left
turn, most of the flow through the valve is bypassed out
the PB port back to the oil filter and traction charge cir-
cuit. Also like a left turn, the remainder of the flow is
drawn through rotary meter but goes out port R. Pres-
sure extends the steering cylinder for a right turn. The
rotary meter ensures that the oil flow to the cylinder is
proportional to the amount of the turning on the steering
wheel. Fluid leaving the cylinder flows back through the
spool valve then through the T port and to the hydraulic
reservoir.
Left Turn
When a left turn is made with the engine running, the
turningofthesteeringwheelpositionsthespoolvalveso
thatflowgoesthroughthetopofthespool. Flowentering
the steering control valve at the P port goes through the
spool and is routed to two places. First, most of the flow
throughthevalveisbypassedoutthePBportbacktothe
oil filter and traction charge circuit. Second, the remain-
der of the flow is drawn through the rotary meter and out
the L port. Pressure contracts the steering cylinder for
a left turn. The rotary meter ensures that the oil flow to
The steering control valve returns to the neutral position
when turning is completed.
NEUTRAL POSITION
LEFT TURN
RIGHT TURN
STEERING
CONTROL
VALVE
STEERING
CONTROL
VALVE
STEERING
CONTROL
VALVE
P
PB
T
P
PB
T
P
PB
T
1050
PSI
1050
PSI
1050
PSI
L
R
L
R
L
R
NO CYLINDER
MOVEMENT
STEERING
CYLINDER
STEERING
CYLINDER
STEERING
CYLINDER
Figure 16
Reelmaster 7000
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Engine Cooling Fan Circuit
A four section gear pump is coupled to the piston (trac-
tion) pump. The gear pump section P4 (farthest from the
piston pump) supplies hydraulic flow for the hydraulic
engine cooling fan motor (Fig. 17).
Reverse Direction Fan Operation (Fig. 18)
The TEC controller can reverse the cooling fan to clean
debris from the rear intake screen. If hydraulic oil and/or
engine coolant temperatures increase to an unsuitable
level or if the engine cooling fan switch is pressed to
manual reverse, a high PWM signal is sent to the PRV
valve to slow the cooling fan and direct pump oil flow
away from the fan motor. The controller then energizes
solenoid valve S1 in the fan control manifold to reverse
cooling fan motor oil flow so that the motor runs in the
reversedirection. AlowerPWMsignalissenttothePRV
valve allowing oil flow to return to the fan motor but in the
reverse direction causing the motor and cooling fan to
run in reverse for a short time.
Thefancontrolmanifoldcontrolstheoperationofthehy-
draulic motor that drives the engine cooling fan in addi-
tion toincluding theflow divider(FD) forthe steeringand
lift circuits. The electronically controlled proportional re-
liefvalve(PRV)inthemanifoldcontrolsthe oilflow tothe
fan motor. The fan control manifold controls the speed
and direction of the fan motor based on electrical output
from the TEC controller.
Oil flow from the gear pump to the cooling fan motor is
controlled by the proportional relief valve (PRV) in the
fan control manifold. This valve adjusts fan circuit flow
based on a PWM (Pulse Width Modulation) signal from
the TEC controller. The controller uses engine coolant
and hydraulic oil temperatures as inputs to determine
the proper PWM signal for the PRVvalve. The fancircuit
flow determines the speed of the cooling fan motor.
NOTE: The fan reversal process is not designed to
clean the radiator of debris. Refer to Operator’s Manual
for radiator cleaning maintenance recommendations.
4
The fan motor runs at reduced speed until coolant
reaches approximately 165oF (74oC). The fan motor
increases to full speed (approximately 2800 RPM)
as coolant reaches 180oF (82oC).
2
3
Thefanmotorautomaticallyslowsdownandthenre-
verses direction if coolant reaches 203oF (95oC) or
hydraulic oil reaches 212oF (100oC).
If the fan motor is stalled for any reason, the manifold
proportionalreliefvalve(PRV) hasa secondaryfunction
as a circuit relief to limit fan motor pressure to 3000 PSI
(207 bar).
1
Figure 17
1. Gear pump
2. Fan control manifold
3. Fan circuit supply hose
4. Hydraulic fan motor
When the engine is shut off, the over--running inertia
load of the fan blades keeps driving the fan motor and
turns itinto a pump. The check valve (CV) in the fan con-
trol manifold will open to keep the motor circuit full of oil
so the fan motor will not cavitate.
REVERSE
DIRECTION
TO STEERING
CIRCUIT
TO RESERVOIR
TO LIFT/LOWER
CIRCUIT
NOTE: If PWM current is not available to the fan control
manifold proportional relief valve (PRV), the cooling fan
motor will run at full speed in the normal (forward) direc-
tion.
Forward Direction Fan Operation
PRV
G2
G1
Oil flowfromthegear pumpis sentthrough thede--ener-
gized solenoid valve S1 to rotate the cooling fan motor.
Return flow from the motor re--enters the manifold (port
M2), throughthe de--energizedsolenoid valveS1, outof
the manifold (port T) and then is routed through the mow
control manifold, oil cooler and oil filter.
FROM GEAR
PUMP (P3)
FROM GEAR
PUMP (P4)
TO OIL COOLER
Figure 18
Reelmaster 7000
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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.
Toro Part Number: TOR47009
Figure 19
Hydraulic Tester (Pressure and Flow)
Use to test hydraulic circuits and components for flow
andpressurecapacitiesasrecommendedintheTesting
sectionofthischapter.Thistesterincludesthefollowing:
1. INLET HOSE: Hose connected from the system cir-
cuit to the inlet side of the hydraulic tester.
2. LOAD VALVE: A simulated working load is created
in the circuit by turning the valve to restrict flow.
3. PRESSURE GAUGE: Glycerine filled 0 to 5000 PSI
gauge to provide operating circuit pressure.
4. FLOW METER: This meter measures actual oil flow
in the operating circuit with a gauge rated from 1 to 15
GPM (5 to 55 LPM).
Figure 20
5. OUTLET HOSE: A hose from the outlet side of the
hydraulictesterconnectstothehydraulicsystemcircuit.
6. FITTINGS: An assortment of hydraulic fittings are in-
cluded with this kit.
Toro Part Number: TOR214678
Hydraulic System
Page 4 -- 26
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40 GPM Hydraulic Tester (Pressure and Flow)
Use to test hydraulic circuits and components for flow
andpressurecapacitiesasrecommendedintheTesting
sectionofthischapter.Thistesterincludesthefollowing:
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. FLOW METER: This meter measures actual oil flow
in the operating circuit with a gauge rated from 4 to 40
GPM (20 to 150 LPM).
Toro Part Number: AT40002
Figure 21
NOTE: This tester does not include hydraulic hoses
(see Hydraulic Hose Kit TOR6007 below).
Hydraulic Hose Kit
This kit includes hydraulic fittings and hoses needed to
connect40 GPMhydraulictester (AT40002)or highflow
hydraulic filter kit (TOR6011) to machine hydraulic trac-
tion system components.
Toro Part Number: TOR6007
Figure 22
Reelmaster 7000
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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--direc-
tional 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. When connecting hydraulic
test gauges in order to test traction circuit components
orafterreplacingafailedtractioncircuitcomponent(e.g.
piston (traction) pump or wheel motor), the high flow hy-
draulic filter can be installed in the traction circuit. The
filterwillensurethatcontaminatesareremovedfromthe
closed loop and thus, do not cause additional compo-
nent damage.
Figure 23
Toro Part Number: TOR6011
NOTE: This kit does not include hydraulic hoses (see
Hydraulic Hose Kit TOR6007 above).
NOTE: Replacement filter element is Toro part number
TOR6012. Filter element cannister tightening torque is
25 ft--lb (34 N--m).
Hydraulic Test Fitting Kit
This kit includes a variety of O--ring Face Seal fittings to
enable you to connect test gauges into the system.
The kit includes: tee’s, unions, reducers, plugs, caps
and male test fittings.
Toro Part Number: TOR4079
Figure 24
Hydraulic System
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Measuring Container
Use this container for doing hydraulic motor efficiency
testing (motors with case drain lines only). Measure effi-
ciency 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)conversionformeasuredmilliliterorouncemotor
case drain leakage.
Toro Part Number: TOR4077
Figure 25
Figure 26
O--ring Kit
ThekitincludesO--ringsinavarietyofsizesforfaceseal
and port seal hydraulic connections. It is recommended
that O--rings be replaced whenever a hydraulic connec-
tion is loosened.
Toro Part Number: 16--3799
Figure 27
Reelmaster 7000
Page 4 -- 29
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Troubleshooting
The charts thatfollow contain information to assist in hy-
draulic system troubleshooting. There may possibly be
more than one cause for a machine malfunction.
Refer to the Testing section of this Chapter for precau-
tions and specific testing procedures.
General Hydraulic System Problems
Problem
Possible Cause
Engine RPM is too low.
Hydraulic system operates hot.
NOTE: An indication that the hy-
draulic system is operating at exces-
sive temperatures would be frequent
reversing of the cooling fan and a
normal engine coolant temperature.
Hydraulic reservoir oil level is low.
Hydraulic oil is contaminated or the wrong type.
Brakes are applied or sticking.
Piston pump bypass valve is open or damaged.
Cooling system is not operating properly.
Charge pressure is low.
Engine cooling fan circuit is malfunctioning (see Engine Cooling Fan
Circuit Problems in this section).
Traction circuit pressure is incorrect.
Pump(s) or motor(s) are damaged.
Hydraulic reservoir oil level is low.
Hydraulic oil in reservoir foams.
Hydraulic oil leak(s).
Wrong type of oil is in the hydraulic system.
Air is leaking in suction line.
Fitting(s), hose or tube loose or damaged.
Missing or damaged O-ring in fitting.
Hydraulic System
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Traction Circuit Problems
NOTE: Whentroubleshootingtractioncircuitproblems,
if a problem exists in both mow speed (4WD) and trans-
port speed (2WD), consider a faulty component that af-
fects 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 con-
trol manifold).
Problem
Possible Cause
Traction control linkage is faulty.
Machine operates in one direction
only.
Traction relief valve is defective.
Traction pedal reaction is sluggish
when in either mow speed (4WD) or
transport speed (2WD).
Traction control linkage is stuck or binding.
Charge pressure is low.
Piston (traction) pump servo control valve orifices are plugged or
damaged.
Traction pedal reaction is sluggish
when in mow speed (4WD). Pedal
reaction is normal when in transport
speed (2WD).
PD1 and PD2 pilot directional valve seals in 4WD/2WD control
manifold are leaking or damaged.
Machine travels too far before stop-
ping when the traction pedal is re-
leased.
Traction linkage is out of adjustment.
Charge pressure is low.
Piston (traction) pump servo control valve orifices are plugged or
damaged.
Traction pedal does not return to neutral.
Hydraulic reservoir oil level is low.
Traction power is lost or machine will
not operate in either direction.
Piston pump bypass valve is open or damaged.
Charge pressure is low.
Traction circuit pressure is low.
Front wheel motor couplers are damaged.
If traction is lost in mow speed (4WD) but is normal in transport
speed (2WD), rear axle motor or rear axle motor drive may be faulty.
Mow speed (4WD) will not engage.
Electrical problem exists (see Chapter 5 -- Electrical System).
Solenoid valve SV in 4WD/2WD control manifold is faulty.
Cartridge valve(s) in 4WD/2WD control manifold is (are) faulty.
Electrical problem exists (see Chapter 5 -- Electrical System).
Mow speed (4WD) will not disen-
gage.
Cutting units are fully lowered.
Cartridge valve in 4WD/2WD control manifold is damaged or sticking.
Reelmaster 7000
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PTO Problems
Problem
Possible Cause
None of the cutting units will oper-
ate.
Cutting units are not fully lowered to ground.
Operator seat is unoccupied.
NOTE: Cutting units have to be fully
lowered and traction speed needs to
be in mow speed (4WD) for cutting
units to operate.
Mow speed limiter is in transport (2WD) position.
Electrical problem exists that prevents mow control manifold sole-
noid valve operation (see Chapter 5 -- Electrical System).
Gear pump sections P1 and P2 are damaged.
Gear pump coupler is damaged (other hydraulic circuits will be af-
fected as well).
One cutting unit will not operate.
System pressure to the affected cutting unit motor is low.
Cutting unit problem exists (see Chapter 8 -- Cutting Units).
Spline on affected cutting unit motor is damaged.
Cutting unit motor relief valve is stuck or damaged.
Cutting unit motor is damaged. NOTE: If appropriate, transfer a sus-
pected damaged motor to another cutting unit. If problem follows the
motor, motor needs repair or replacement.
Several cutting units will not operate.
Electrical problem exists that prevents mow control manifold sole-
noid valve operation (see Chapter 5 -- Electrical System).
Cutting units are not fully lowered to ground.
Mow control manifold proportional valve (SP1 or SP2) for affected
cutting units is faulty.
Mow control manifold logic cartridge valve (LC1 or LC2) for af-
fected cutting units is stuck or damaged.
Mow control manifold check valve (CV1 or CV2) for affected cutting
units is stuck or damaged.
Gear pump section (P1 or P2) is worn or damaged.
Hydraulic System
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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.
Relief valve in mow control manifold is bypassing.
Cutting unit stops under load.
Cutting conditions (e.g. very tall or wet grass) exceed cutting unit
capacity.
Cutting unit motor relief valve is stuck or damaged.
Cutting unit motor has internal leakage (bypassing oil).
Gear pump section (P1 or P2) for affected cutting units is worn or
damaged.
Steering Circuit Problems
Problem
Possible Cause
Steering inoperative or sluggish.
Steering components (e.g. tie rods, steering cylinder ends) are
worn or binding.
Steering cylinder is binding.
Oil level in hydraulic reservoir is low (other hydraulic systems af-
fected as well).
Steering relief valve in steering control valve is stuck or damaged.
Flow divider (FD) in fan control manifold is faulty.
Steering cylinder leaks internally.
Steering control valve is worn or damaged.
Gear pump section (P3) is worn or damaged (NOTE: A worn or
damaged gear pump section (P3) will also affect the traction
(charge) and lift circuits).
Reelmaster 7000
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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.
Solenoid valve(s) in lift control manifold is damaged or sticking.
Flow divider (FD) in fan control manifold is faulty.
Gear pump section (P3) is worn or damaged (NOTE: A worn or dam-
aged gear pump section (P3) will also affect the traction (charge) and
steering circuits).
Cutting units raise, but will not stay
up.
Lift circuit hydraulic lines or fittings are leaking.
Cartridge valve in lift control manifold is stuck open.
Air exists in lift circuit.
NOTE: Lift cylinders cannot provide
an absolutely perfect seal. The lift
arms will eventually lower if left in
the raised position during storage.
Lift cylinder is damaged.
Cutting units will not lower.
Operator seat is unoccupied.
NOTE: Operator must be in seat
and traction system must be in mow
speed (4WD) in order to lower the
cutting units.
Mow speed limiter is in transport (2WD) position.
Electrical problem exists that prevents lift control manifold solenoid
valve operation (see Chapter 5 -- Electrical System).
Lift arm pivots are binding.
Lift cylinder(s) is (are) is damaged.
Lower circuit relief valve (RV2) in lift control manifold is stuck open.
Solenoid valve(s) in lift control manifold is damaged or sticking.
Hydraulic System
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Engine Cooling Fan Circuit Problems
Problem
Possible Cause
Cooling fan runs only in forward di-
rection (fan does not run in reverse
direction).
Fan control manifold solenoid cartridge valve (S1) is faulty.
Electrical problem exists that prevents fan control manifold solenoid
valve (S1) operation (see Chapter 5 -- Electrical System).
Cooling fan does not rotate.
Fan motor is worn or damaged.
Gear pump section (P4) is worn or damaged.
Cooling fan always rotates at slow
speed.
Fan control manifold cartridge valve seals are leaking.
Check valve in fan control manifold is not seating.
Fan control manifold proportional relief valve (PRV) is stuck open.
Hydraulic fan motor is worn or damaged.
Cooling fan always rotates at fast
speed.
Fan control manifold proportional relief valve (PRV) is faulty.
Electrical problem exists that prevents fan control manifold propor-
tional relief valve (PRV) operation (see Chapter 5 -- Electrical Sys-
tem).
Reelmaster 7000
Page 4 -- 35
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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).
Precautions for Hydraulic Testing
1. Clean machine thoroughly before disconnecting or
disassembling any hydraulic components. Always keep
in mind the need for cleanliness when working on hy-
draulic equipment. Hydraulic system contamination will
cause excessive wear of hydraulic components.
IMPORTANT: All obvious areas such as oil supply,
filter, binding linkages, loose fasteners or improper
adjustmentsmustbecheckedbeforeassumingthat
ahydrauliccomponentisthesourceoftheproblem.
2. Put metal caps or plugs on all hydraulic lines left
open or exposed during testing or removal of compo-
nents.
3. Theenginemustbeingoodoperatingcondition. Use
a phototac to determine engine speed when performing
a hydraulic test. Engine speed will affect the accuracy of
the tester readings.
WARNING
Before disconnecting or performing any work on
the hydraulic system, all pressure in the system
must be relieved and all rotating machine parts
must be stopped. See Relieving Hydraulic Sys-
tem Pressure in the General Information section.
4. When using hydraulic tester with pressure and flow
capabilities, the inlet and the outlet hoses must be prop-
erly connected and not reversed to prevent damage to
the hydraulic tester or machine components.
5. When using hydraulic tester with pressure and flow
capabilities, open load valve completely in the tester to
minimize the possibility of damaging components.
CAUTION
Failure to use gauges with recommended pres-
sure (PSI) rating as listed in test procedures
couldresultindamagetothegaugeandpossible
personal injury from leaking hot oil.
6. Install fittings finger tight and far enough to make
sure that they are not cross--threaded before tightening
them with a wrench.
7. Position tester hoses to prevent rotating machine
parts from contacting and damaging the hoses or tester.
CAUTION
8. Check oil level in the hydraulic reservoir. After con-
nectingtestequipment, makesurehydraulicreservoiris
full.
All testing should be performed by two (2)
people. One person should be in theseat tooper-
ate the machine and the other should monitor
testing equipment and record test results.
9. Check control linkages for improper adjustment,
binding or broken parts.
10.All hydraulic tests should be made with the hydraulic
oil at normal operating temperature.
WARNING
11.Before returning machine to use, make sure that hy-
draulic reservoir has correct fluid level.
Keep body and hands away from pin hole leaks
or nozzles that eject hydraulic fluid under high
pressure. Do not use hands to search for leaks;
use paper or cardboard. Hydraulic fluid escap-
ing under pressure can have sufficient force to
penetrate the skin and cause serious injury. If
fluidisinjectedintotheskin, itmust besurgical-
ly removed within a few hours by a doctor famil-
iar with this type of injury. Gangrene may result
from such an injury.
Hydraulic System
Page 4 -- 36
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Which Hydraulic Tests Are Necessary?
3. Ifalift/lowercircuitproblemexists, considerperform-
ing one or more of the following tests: Lift/Lower Circuit
Relief Pressure, Lift Cylinder Internal Leakage and/or
Gear Pump P3 Flow.
Before beginning any hydraulic test, identify if the prob-
lem 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.
4. If a steering circuit problemexists, consider perform-
ing one or more of the following tests: Steering Circuit
Relief Pressure, Steering Cylinder Internal Leakage
and/or Gear Pump P3 Flow.
1. If a traction circuit problem exists, consider perform-
ing one or more of the following tests: Traction Circuit
ChargePressure, TractionCircuitReliefPressure, Rear
Traction Circuit Relief (RV) Pressure, Traction Circuit
Reducing Valve (PR) Pressure and/or Piston (Traction)
Pump Flow.
5. If an engine cooling fan circuit problem exists, con-
sider performing one or more of the following tests:
Cooling Fan Circuit and/or Gear Pump P4 Flow.
2. If a PTO circuit problem exists, consider performing
oneormoreofthefollowingtests:MowCircuitPressure,
Mow Circuit Relief Pressure, Cutting Unit Motor Case
Drain Leakage and/or Gear Pump P1 and P2 Flow.
Reelmaster 7000
Page 4 -- 37
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Traction Circuit Charge Pressure Test (Using Pressure Gauge)
FROM STEERING
AND LIFT CIRCUITS
(CHARGE CIRCUIT)
FORWARD DIRECTION
TEST SHOWN
PRESSURE
GAUGE
Working Pressure
Low Pressure
Return or Suction
Flow
TO DECK CONTROL MANIFOLD
TO DECK CONTROL MANIFOLD
TO STEERING AND LIFT CIRCUITS
(CHARGE CIRCUIT)
TO FAN CIRCUIT
FROM DECK MOTORS
Hydraulic System
Page 4 -- 38
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NOTE: The traction charge circuit is designed to re-
place loss of hydraulic fluid from the closed loop traction
circuit.
9. Also, with the pressure gauge still connected to the
charge pressure test port, monitor the gauge reading
while operating the machine in forward and reverse.
Start the engine and put throttle at full engine speed
(2850 RPM). Apply the brakes and push the traction
pedal forward, then reverse.
ProcedureforTractionCircuitChargePressureTest
1. Make sure hydraulic oil is at normal operating tem-
peraturebyoperatingthemachineforapproximatelyten
(10) minutes. Make sure the hydraulic tank is full.
GAUGE READING TO BE within 20% of no--load
charge pressure measured in step 4 above (e.g.
if charge pressure in step 4 is 250 PSI (17.2 bar),
charge pressure in forward or reverse should be
from 200 to 250 PSI (13.8 to 17.2 bar)
2. Parkmachineonalevelsurfacewiththecuttingunits
lowered and off. Make sure engine is off and the parking
brake is engaged.
10.If charge pressure is good under no load, but drops
below specification when under traction load, the piston
(traction) pump, front wheel motors and/or rear axle mo-
tor should be suspected of wear and inefficiency. When
thepumpand/ortractionmotor(s)arewornordamaged,
thechargepumpisnotabletokeepupwithinternalleak-
age in traction circuit components.
3. Raise and support operator seat to access charge
pressure test port.
CAUTION
Prevent personal injury and/or damage to equip-
ment. Read all WARNINGS, CAUTIONS and Pre-
cautions for Hydraulic Testing at the beginning
of this section.
11.When testing is completed, disconnect pressure
gaugefrommanifoldtestport.Installdustcaptotestport
fitting. Lower and secure operator seat.
4. Connect a 1000 PSI (70 bar) pressure gauge onto
chargepressuretestport.Testportislocatedonhydrau-
lic tube near hydraulic oil filter (Fig. 28).
1
5. After installing pressure gauge, start engine and run
at low idle speed. Check for hydraulic leakage and cor-
rect before proceeding with test.
3
6. Move throttle to high idle speed (2850 RPM) with no
load on the hydraulic system. Identify charge pressure
reading on gauge:
2
GAUGE READING TO BE 210 to 300 PSI (14.5 to
20.6 bar)
Figure 28
7. Stop engine and record test results.
1. Operator seat
2. Oil filter
3. Test port location
8. If there is no pressure or pressure is low, check for
the following:
A. Restriction in gear pump intake line.
B. Charge relief valve in filtration and charge control
manifold is leaking (see Filtration/Charge Control
Manifold Service in the Service and Repairs section
of this chapter).
C. If necessary, check for internal damage or worn
parts in gear pump P3 (see Gear Pump P3 Flow Test
in this section). NOTE:Steering and lift/lowercircuits
would also be affected if gear pump P3 is worn or
damaged.
Reelmaster 7000
Page 4 -- 39
Hydraulic System
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Traction Circuit Relief Pressure Test (Using Pressure Gauge)
FROM STEERING
AND LIFT CIRCUITS
(CHARGE CIRCUIT)
FORWARD DIRECTION
TEST SHOWN
PRESSURE
GAUGE
Working Pressure
Low Pressure
Return or Suction
Flow
TO DECK CONTROL MANIFOLD
TO DECK CONTROL MANIFOLD
TO STEERING AND LIFT CIRCUITS
(CHARGE CIRCUIT)
TO FAN CIRCUIT
FROM DECK MOTORS
Hydraulic System
Page 4 -- 40
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Procedure for Traction Circuit Relief Pressure Test
NOTE: Seal leakage across pilot directional valves
PD1 and PD2 in 4WD/2WD control manifold can also
cause low forward traction pressure with reverse pres-
sure meeting specifications.
1. Make sure hydraulic oil is at normal operating tem-
peraturebyoperatingthemachineforapproximatelyten
(10) minutes. Make sure the hydraulic tank is full.
NOTE: Forward and reverse relief valves are identical.
Relief valves can be switched in piston (traction) pump
to help in identifying a faulty relief valve.
CAUTION
9. When testing is completed, disconnect pressure
gauge from test port. Install dust cap to test port fitting.
Movemachinetoanopenarea,awayfrompeople
and obstructions.
2. Drive machine to an open area, lower cutting units,
turn the engine off and apply parking brake.
CAUTION
Prevent personal injury and/or damage to equip-
ment. Read all WARNINGS, CAUTIONS and Pre-
cautions for Hydraulic Testing at the beginning
of this section.
2
1
3. Connect a 10,000 PSI (700 bar) pressure gauge to
traction circuit test port for function to be checked (for-
ward or reverse) (Fig. 29). Test ports are located on hy-
draulic lines toward the front of machine. Forward
traction port faces the front and reverse port faces
rearward.
Figure 29
1. Forward traction port (faces forward)
2. Reverse traction port (faces rearward)
4. After installing pressure gauge, start engine and run
at low idle speed. Check for hydraulic leakage and cor-
rect before proceeding with test.
2
RIGHT
FRONT
5. Move throttle to high idle speed (2850 RPM). Make
sure that mow speed limiter is in the transport (2WD)
position. Release parking brake.
6. Withseatoccupied, applybrakes fullyand slowlyde-
press the traction pedal in the appropriate direction.
While pushing traction pedal, identify pressure reading
on gauge as relief valve opens:
3
1
GAUGE READING TO BE:
Forward: 4800 to 5300 PSI (332 to 365 bar)
Reverse: 4800 to 5300 PSI (332 to 365 bar)
Figure 30
1. Forward relief valve
2. Reverse relief valve
3. Traction pump
7. Release traction pedal and stop engine. Record test
results.
8. If traction pressure is too low, makes sure that by-
pass valve on traction pump is fully seated and then in-
spect traction pump relief valves in piston (traction)
pump (Fig. 30). Clean or replace valves as necessary.
These cartridge type valves are factory set and are not
adjustable. If relief valves are in good condition, piston
(traction) pump, wheel motors and/or rear axle motor
should be suspected of wear and inefficiency.
Reelmaster 7000
Page 4 -- 41
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Traction Circuit Reducing Valve (PR) Pressure Test (Using Pressure Gauge)
FROM STEERING
AND LIFT CIRCUITS
PRESSURE
GAUGE
(CHARGE CIRCUIT)
Working Pressure
Low Pressure
Return or Suction
Flow
TO DECK CONTROL MANIFOLD
TO DECK CONTROL MANIFOLD
TO STEERING AND LIFT CIRCUITS
(CHARGE CIRCUIT)
TO FAN CIRCUIT
FROM DECK MOTORS
Hydraulic System
Page 4 -- 42
Reelmaster 7000
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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 tem-
peratureby operatingthemachinefor approximatelyten
(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.
RIGHT
FRONT
CAUTION
Figure 31
Prevent personal injury and/or damage to equip-
ment. Read all WARNINGS, CAUTIONS and Pre-
cautions for Hydraulic Testing at the beginning
of this section.
1. 4WD/2WD manifold
2. Reducing valve (PR)
3. Connect a 1000 PSI (70 bar) pressure gauge to test
fitting(portG)onrearsideof4WD/2WDcontrolmanifold
under front of machine (Figs. 31 and 32).
4. After installing pressure gauge, start engine and run
at low idle speed. Check for hydraulic leakage and cor-
rect before proceeding with test.
5. Move throttle to high idle speed (2850 RPM). Make
sure that mow speed limiter is in the mow (4WD) posi-
tion. Release parking brake.
1
2
6. With seat occupied, apply brakes fully and slowly de-
press the traction pedal in the reverse direction. While
pushing traction pedal, carefully monitor the pressure
gauge. Pressure should increase until the pressure re-
ducing valve opens.
Figure 32
1. 4WD/2WD manifold
2. Test fitting (port G)
GAUGE READING TO BE 420 to 470 PSI (29 to 32
bar).
FRONT
7. Release traction pedal, stop engine and record test
results.
8. If specification is not met, clean or adjust pressure
reducing valve (port PR) located on the right side of the
4WD/2WDcontrolmanifold(Fig. 33)(seeAdjustControl
Manifold Relief Valves in the Adjustments section of this
chapterforvalveadjustmentprocedure). Recheckredu-
cing valve pressure after adjustment.
1
2
Figure 33
1. 4WD/2WD manifold
2. Reducing valve (PR)
9. When testing is completed, disconnect pressure
gauge from test port. Install dust cap to test port fitting.
Reelmaster 7000
Page 4 -- 43
Hydraulic System
Rev. A
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Rear Traction Circuit Relief (RV) Pressure Test (Using Pressure Gauge)
FROM STEERING
AND LIFT CIRCUITS
(CHARGE CIRCUIT)
PRESSURE
GAUGE
Working Pressure
Low Pressure
Return or Suction
Flow
TO DECK CONTROL MANIFOLD
TO DECK CONTROL MANIFOLD
TO STEERING AND LIFT CIRCUITS
(CHARGE CIRCUIT)
TO FAN CIRCUIT
FROM DECK MOTORS
Hydraulic System
Page 4 -- 44
Reelmaster 7000
Rev. A
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NOTE: Adjustable relief valve (RV) in the 4WD/2WD
control manifold reduces rear axle motor pressure
created in down hill, dynamic braking conditions to pre-
vent rear wheel lock up.
NOTE: Rear traction circuit relief (RV) pressure should
be at least 100 PSI (7 bar) higher than traction circuit re-
ducing (PR) pressure. If the difference in these pres-
sures is less than 100 PSI (7 bar), reverse traction
performance may be affected.
Procedure for Rear Traction Circuit Relief (RV) Pres-
sure Test
10.If specification is not met, clean or adjust relief valve
(RV) which is located on the left side of the 4WD/2WD
controlmanifoldinthe RV port(Fig. 34) (see AdjustCon-
trol Manifold Relief Valves in the Adjustments section of
this chapter for valve adjustment procedure). Recheck
relief (RV) pressure after adjustment.
1. Make sure hydraulic oil is at normal operating tem-
peratureby operatingthemachinefor approximatelyten
(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.
11.When testing is completed, disconnect pressure
gauge from test port. Install dust cap to test port fitting.
CAUTION
RIGHT
FRONT
Prevent personal injury and/or damage to equip-
ment. Read all WARNINGS, CAUTIONS and Pre-
cautions for Hydraulic Testing at the beginning
of this section.
1
3. Measure and record traction circuit pressure redu-
cing valve (PR) pressure (see Traction Circuit Pressure
Reducing Valve (PR) Pressure Test in this section).
2
4. Connect a 1000 PSI (70 bar) pressure gauge to test
fitting(portG)onrearsideof4WD/2WDcontrolmanifold
under front of machine (Figs. 34 and 35). This is the
same pressure gauge position as used to measure trac-
tion circuit pressure reducing valve (PR) pressure.
5. After installing pressure gauge, start engine and run
at low idle speed. Check for hydraulic leakage and cor-
rect before proceeding with test.
Figure 34
1. 4WD/2WD manifold
2. Relief valve (RV)
6. Move throttle to high idle speed (2850 RPM). Make
sure that mow speed limiter is in the mow (4WD) posi-
tion. Release parking brake.
7. Operate the machine in mow speed (4WD) with the
cutting units lowered. Drive down a slope in a forward di-
rection and decrease pressure on the traction pedal
while carefully monitoring the pressure gauge. Pressure
should increase until relief valve (RV) lifts.
8. Stop engine and record test results.
9. Relief (RV) pressure should be at least 100 PSI (7
bar) higher than the traction circuit pressure redu-
cing valve (PR) pressure and also be between 520
and 570 PSI (36 to 39 bar) (e.g. if the pressure reducing
valve (PR) pressure is 450 PSI (31 bar), relief (RV) pres-
sure should be from 550 to 570 PSI (38 to 39 bar)).
1
2
Figure 35
1. 4WD/2WD manifold
2. Test fitting (port G)
Reelmaster 7000
Page 4 -- 45
Hydraulic System
Rev. A
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Piston (Traction) Pump Flow Test (Using Tester with Pressure Gauges and Flow Meter)
FROM STEERING
AND LIFT CIRCUITS
(CHARGE CIRCUIT)
TESTER
Working Pressure
Low Pressure
Return or Suction
Flow
TO DECK CONTROL MANIFOLD
TO DECK CONTROL MANIFOLD
TO STEERING AND LIFT CIRCUITS
(CHARGE CIRCUIT)
TO FAN CIRCUIT
FROM DECK MOTORS
Hydraulic System
Page 4 -- 46
Reelmaster 7000
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Procedure for Piston (Traction) Pump Flow Test
7. Start engine and run at low idle speed. Check for any
hydraulic leakage from tester and hose connections.
Correct any leaks before proceeding.
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.
8. Move throttle so engine is running at high idle speed
(2850 RPM).
IMPORTANT: Traction circuit flow for the Reelmas-
ter 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).
9. Slowly push traction pedal to fully forward position.
Keep pedal fully depressed in the forward position.
10.Havesecondpersoncarefullywatchpressuregauge
on tester while slowly closing the flow control valve until
1000PSI(69bar) isobtained. Verifywithaphototacthat
the engine speed is still 2850 RPM.
1. Make sure hydraulic oil is at normal operating tem-
perature by operating the machine under load for
approximately ten (10) minutes. Make sure the hydrau-
lic tank is full.
NOTE: If engine speed drops below 2850 RPM, piston
pump flow will decrease.
2. Parkmachineonalevelsurfacewiththecuttingunits
raised and off. Make sure that the mow speed limiter is
in the transport speed (2WD) position to ensure that
traction pedal can move piston (traction) pump to full
stroke. Shut off engine.
11.Observe flow gauge. If piston pump is in good condi-
tion, flow indication should be approximately 29 GPM
(110 LPM).
12.Release traction pedal to the neutral position, open
flow control valve on tester and shut off engine. Record
test results.
CAUTION
13.If flow is less than 26 GPM (98 LPM), consider the
following:
Prevent personal injury and/or damage to equip-
ment. Read all WARNINGS, CAUTIONS and Pre-
cautions for Hydraulic Testing at the beginning
of this section.
A. The piston pump swash plate is not being rotated
fully (e.g. mow speed limiter is not in transport speed
(2WD) position, traction pedal linkage may need ad-
justment).
3. Make sure that traction pedal is adjusted to the neu-
tral position. Also, ensure that piston (traction) pump is
at full stroke when traction pedal is pushed into fully for-
ward position.
B. The piston (traction) pump needs to be repaired
or replaced as necessary.
4. Raise and support machine so all wheels are off the
ground (see Jacking Instructions in Chapter 1 -- Safety).
14.Makenecessaryrepairsbeforeperforminganyaddi-
tional tests.
5. Thoroughly clean junction of hydraulic hose and left
side fitting on bottom of piston pump (forward port) (Fig.
36). Disconnect hose from left side pump fitting.
15.When testing is complete, disconnect tester and
hose kit from pump fitting and machine hydraulic hose.
Connect machine hydraulic hose to pump fitting. Lower
machine to ground.
6. Install 40 GPM Hydraulic Tester #AT40002 (pres-
sure and flow) in series between piston pump fitting and
disconnected hose to allow flow from piston pump to
tester. Use hydraulic hose kit (see Special Tools in this
chapter)toconnecttestertomachine. Makesurethatfit-
ting and hose connections are properly tightened. Also,
make sure the flow control valve on tester is fully open.
RIGHT
FRONT
CAUTION
1
2
Allwheels willbe off the ground and rotatingdur-
ing this test. Make sure machine is supported so
itwillnotmoveandaccidentallyfalltopreventin-
juring anyone near the machine.
Figure 36
1. Piston (traction) pump
2. LH fitting (forward port)
Reelmaster 7000
Page 4 -- 47
Hydraulic System
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Mow Circuit Pressure Test (Using Pressure Gauge)
M4
M1
M5
M2
M3
TO RESERVOIR
M1 M2
M4 M3
MOW
CONTROL
MV2
MANIFOLD
MV1
TEST FOR FRONT
CUTTING UNITS SHOWN
OR1
OR2
CV2
CV1
LC1 LC2
SP2
SP1
PRESSURE
GAUGE
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
BYPASS
VALVE
5000
PSI
.071
.091
P4
P3
P2
P1
2.48
.56 .56 1.03 1.03
.071
5000
PSI
FROM REEL MOTORS
P2
Working Pressure
Low Pressure
CV2
T
CD1
5 PSI
CV1
CR2
CR1
Return or Suction
CV1
40
PSI
Flow
207 PSI
P1
CD2
FROM STEERING CONTROL
Hydraulic System
Page 4 -- 48
Reelmaster 7000
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Procedure for Mow Circuit Pressure Test
9. Disengage cutting units and shut off engine. Record
test results.
1. Make sure hydraulic oil is at normal operating tem-
peraturebyoperatingthemachineforapproximatelyten
(10) minutes. Make sure the hydraulic tank is full.
10.Aftertestingiscomplete, disconnectpressuregauge
frommanifoldtestport. Installdustcaptotestportfitting.
If necessary, repeat test for other mow circuit.
2. Parkmachineonalevelsurfacewiththecuttingunits
lowered and off. Make sure engine is off and the parking
brake is engaged.
11.Lowerandsecurehoodafterallmowcircuitpressure
testing is completed.
3. Raise hood to allow access to mow control manifold.
1
2
CAUTION
Prevent personal injury and/or damage to equip-
ment. Read all WARNINGS, CAUTIONS and Pre-
cautions for Hydraulic Testing at the beginning
of this section.
FRONT
4. Install 5000 PSI (350 bar) pressure gauge with hy-
draulic hose attached to mow control manifold test port
for the mow circuit (front or rear cutting units) to be
tested (Fig. 37). ManifoldtestportG1 shouldbe usedfor
the front reel circuit and G2 should be used for the rear
reel circuit.
Figure 37
1. Test port G1 (front cutting units)
2. Test port G3 (rear cutting units)
5. After installing pressure gauge, start engine and run
at low idle speed. Check for hydraulic leakage and cor-
rect before proceeding with test.
#4
#1
#5
6. Move throttle to high idle speed (2850 RPM). Make
sure that mow speed limiter is in the mow (4WD) posi-
tion. Release parking brake.
CAUTION
#2
#3
Cutting reel blades will rotate when lowered with
PTO switch in ON position. Keep away from cut-
ting units during test to prevent personal injury
from rotating reel blades. Do not stand in front of
the machine during test.
7. With seat occupied, engage the mow circuit. Watch
pressure gauge carefully while mowing with the ma-
chine.
CUTTING UNIT LOCATIONS
Figure 38
8. Mow circuit pressure should be from 1000 to 3000
PSI (69 to 207 bar) and will vary depending on mowing
conditions.
Reelmaster 7000
Page 4 -- 49
Hydraulic System
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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
MOW
CONTROL
MV2
MANIFOLD
MV1
OR1
OR2
CV2
CV1
TEST FOR PUMP
SECTION P1 SHOWN
Working Pressure
Low Pressure
LC1 LC2
SP2
SP1
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
BYPASS
VALVE
5000
PSI
.071
.091
P4
P3
P2
P1
2.48
.56 .56 1.03 1.03
.071
5000
PSI
FROM REEL MOTORS
P2
CV2
T
CD1
5 PSI
CV1
CR2
CR1
CV1
40
PSI
207 PSI
P1
CD2
FROM STEERING CONTROL
Hydraulic System
Page 4 -- 50
Reelmaster 7000
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Themowcircuitreliefpressuretestshouldbeperformed
to make sure that the mow circuit relief pressures are
correct.
CAUTION
Procedure for Mow Circuit Relief Pressure Test
Cutting reel blades will rotate when lowered with
PTO switch in ON position. Keep away from cut-
ting units during test to prevent personal injury
from rotating reel blades. Do not stand in front of
the machine during test.
1. Make sure hydraulic oil is at normal operating tem-
peraturebyoperatingthemachineforapproximatelyten
(10) minutes. Make sure the hydraulic tank is full.
2. Parkmachineonalevelsurfacewiththecuttingunits
lowered and off. Make sure engine is off and the parking
brake is engaged. Also, make sure that the backlap lev-
ers on the mow control manifold are in the mow position
(F on the manifold).
9. With seat occupied, engage the cutting units.
10.Have a second person carefully watch tester pres-
suregaugewhileslowlyclosingtheflowcontrolvalveon
tester.
11.As the relief valve lifts, system pressure should be
from 2800 to 3200 PSI (193 to 220 bar).
CAUTION
12.After noting the relief pressure, open the tester flow
control valve, disengage cutting units and stop the en-
gine. Record test results.
Prevent personal injury and/or damage to equip-
ment. Read all WARNINGS, CAUTIONS and Pre-
cautions for Hydraulic Testing at the beginning
of this section.
13.If specification is not met, clean or adjust relief valve
(RV1 or RV2) in the mow control manifold. See Adjust
Control Manifold Relief Valves in the Adjustments sec-
tion of this chapter for valve adjustment procedure. Re-
check relief valve pressure setting after adjustment.
3. Determine mow manifold relief pressure to be
tested:
A. For pump section (P1), mow manifold relief is
tested at the forward direction supply hose (front
hose) to the cutting unit #4 motor (Fig. 39).
14.After testing is complete, disconnect tester from cut-
ting unit motor and hose. Connect hydraulic hose to mo-
tor.
B. For pump section (P2), mow manifold relief is
tested at the forward direction supply hose (front
hose) to the cutting unit #2 motor (Fig. 39).
#4
#1
#5
CUTTING
UNIT
LOCATIONS
4. Thoroughly clean junction of appropriate hydraulic
supply hose and cutting unit motor fitting. Disconnect
the supply hydraulic hose from the motor.
#2
#3
IMPORTANT: Make sure that the oil flow indicator
arrow on the tester is showing that the oil will flow
from the disconnected hose, through the tester and
into the hydraulic motor.
5. Install tester with pressure gauge and flow meter in
series with the disconnected hose and front motor fit-
ting.
Figure 39
6. Make sure the flow control valve on the tester is fully
open.
SUPPLY
HOSE
RETURN
HOSE
7. Start engine and run at low idle speed. Check for hy-
draulic leakage and correct before proceeding with test.
8. Move throttle to high idle speed (2850 RPM). Make
sure that mow speed limiter is in the mow (4WD) posi-
tion. Release parking brake.
FRONT
Figure 40
Reelmaster 7000
Page 4 -- 51
Hydraulic System
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Cutting Unit Motor Case Drain Leakage Test (Using Tester with Pressure Gauges and
Flow Meter)
TO RESERVOIR
STEEL
CAP
M2
M3
M4
M1
M5
TESTER
M1
M2
M4
M3
MEASURING
CONTAINER
MOW
CONTROL
MANIFOLD
MV2
MV1
OR1
OR2
CV2
LC2
CV1
LC1
TEST FOR #4 CUTTING
UNIT MOTOR SHOWN
SP2
SP1
RV1
RV2
G1
G2
P1
T2
T1
P2
Working Pressure
Low Pressure
Return or Suction
Flow
FROM FAN CONTROL
FROM GEAR
PUMP P1
FROM GEAR
PUMP P2
TO OIL COOLER
CASE
DRAIN
HOSE
SUPPLY
HOSE
RETURN
HOSE
FRONT
Hydraulic System
Page 4 -- 52
Reelmaster 7000
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Procedure for Cutting Unit Motor Case Drain Leak-
age Test
CAUTION
NOTE: Over a period of time, a cutting unit motor can
wear internally. A worn motor may bypass oil to its case
drain causing the motor to be less efficient. Eventually,
enough oil loss will cause the motor to stall under heavy
cutting conditions. Continued operation with a worn, in-
efficient motor can generate excessive heat, cause
damage to seals and other components in the hydraulic
system and affect quality of cut.
Cutting reel blades will rotate when lowered with
PTO switch in ON position. Keep away from cut-
ting units during test to prevent personal injury
from rotating reel blades. Do not stand in front of
the machine during test.
6. Move throttle to high idle speed (2850 RPM). Make
sure that mow speed limiter is in the mow (4WD) posi-
tion. With seat occupied, release the parking brake and
engage the cutting units.
NOTE: One method to find a failing or malfunctioning
cutting unit motor is to have another person observe the
machinewhilemowingindenseturf.Abadmotorwillrun
slower, produce fewer clippings and may cause a differ-
ent appearance on the turf.
7. While watching tester pressure gauge, slowly close
flow control valve on tester until a pressure of 1200 PSI
(83 bar) is obtained.
1. Make sure hydraulic oil is at normal operating tem-
peraturebyoperatingthemachineforapproximatelyten
(10) minutes. Make sure the hydraulic tank is full.
NOTE: Use a graduated container, special tool
TOR4077, to measure case drain leakage.
2. Parkmachineonalevelsurfacewiththecuttingunits
lowered and off. Make sure engine is off and the parking
brake is engaged.
8. Have a second person measure flow from the case
drain line for fifteen (15) seconds, then move the PTO
switch to OFF, open the tester flow control valve and
stop the engine. Record test results.
TEST RESULTS: Case drain leakage should be less
than22.4ounces(662ml)ofhydraulicfluidinfifteen
(15) seconds (0.7 GPM / 2.7 LPM).
CAUTION
Prevent personal injury and/or damage to equip-
ment. Read all WARNINGS, CAUTIONS and Pre-
cautions for Hydraulic Testing at the beginning
of this section.
9. If case drain flow is more than 22.4 ounces (662 ml)
in fifteen (15) seconds, the reel motor is worn or dam-
aged and should be repaired or replaced.
10.Disconnect tester from motor and hose. Reconnect
hose to the cutting unit motor. Remove cap from bulk-
head fitting and reconnect case drain hose.
NOTE: The cutting unit motors are connected in series.
To isolate a faulty motor, all motors in the circuit may
have to be tested by starting with the first motor in the
circuit (see Hydraulic Schematic).
11.Repeat test for additional reel motors if required.
IMPORTANT: Make sure that the oil flow indicator
arrow on the tester is showing that the oil will flow
from the motor fitting, through the tester and into
the disconnected hose.
#4
#1
#5
3. Disconnect hydraulic return hose (rear hose) from
the motor tobe tested. Install testerwith pressuregauge
and flow meter in series with the motor and the discon-
nected return hose. Make sure the flow control valve on
tester is fully open.
#2
#3
4. Disconnect the motor case drain hose (small diame-
ter hose) where it connects to bulkhead fitting at the
frame rail (not at the motor). Put a steel cap on the bulk-
head fitting; leave the case drain hose open.
CUTTING UNIT LOCATIONS
Figure 41
5. Start engine and run at low idle speed. Check for hy-
draulic leakage and correct before proceeding with test.
Reelmaster 7000
Page 4 -- 53
Hydraulic System
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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
MV2
MANIFOLD
MV1
OR1
OR2
CV2
CV1
LC1 LC2
SP2
SP1
RV1 RV2
G1
G2
P1
T2
T1
P2
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
BYPASS
VALVE
5000
PSI
.071
TO OIL COOLER
.091
P4
.56
P3
P2
P1
2.48
.56 1.03 1.03
.071
5000
PSI
Working Pressure
Low Pressure
FROM RESERVOIR
FROM FILTRATION MANIFOLD
Return or Suction
Flow
Hydraulic System
Page 4 -- 54
Reelmaster 7000
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The gear pump P1 and P2 flow tests should be per-
formed to make sure that the mow circuits have ade-
quate hydraulic flow.
7. Move throttle to high idle speed (2850 RPM). Do not
engage the cutting units.
IMPORTANT: Do not fully restrict oil flow through
tester. In this test, the flow tester is positioned be-
fore the circuit relief valve. Pump damage can occur
if the oil flow is fully restricted.
NOTE: Gear pump P1 supplies hydraulic flow tocutting
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
8. Watch tester pressure gauge carefully while slowly
closing the flow control valve on tester until 2000 PSI
(138 bar) is obtained. Verify with a phototac that the en-
gine speed is 2850 RPM.
NOTE: Overaperiodoftime, thegearsandwearplates
in the gear pump can wear. A worn pump will by pass oil
andmakethepumplessefficient. Eventually, enoughoil
losswilloccurtocausethecuttingunitmotorstostallun-
der heavy cutting conditions. Continued operation with
a worn, inefficient pump can generate excessive heat
and cause damage to the seals and other components
in the hydraulic system.
9. For a pump in good condition, flow indication should
be approximately 12 GPM (45.4 LPM).
10.Fully open flow control valve on tester and then shut
engine off. Record test results.
11.If measured flow is less than 10.8 GPM (40.8 LPM)
or a pressure of 2000 PSI (138 bar) cannot be obtained,
check for restriction in the pump intake line (including oil
filter and oil cooler). If line is not restricted, remove gear
pump and repair or replace as necessary.
1. Make sure hydraulic oil is at normal operating tem-
peraturebyoperatingthemachineforapproximatelyten
(10) minutes. Make sure the hydraulic tank is full.
2. Parkmachineonalevelsurfacewiththecuttingunits
lowered and off. Make sure engine is off and the parking
brake is engaged.
12.After testing is complete, disconnect tester from hy-
draulic hose and fitting. Connect hose to the gear pump
fitting.
3. Raise and support hood to allow access to pump as-
sembly.
13.Repeat test for second pump section if required.
14.Lower and secure hood after testing is completed.
CAUTION
Prevent personal injury and/or damage to equip-
ment. Read all WARNINGS, CAUTIONS and Pre-
cautions for Hydraulic Testing at the beginning
of this section.
RIGHT
FRONT
2
4. Locate gear pump section to be tested (P1 or P2).
Thoroughly clean junction ofappropriate hydraulic hose
and gear pump fitting. Disconnect hydraulic hose from
hydraulic fitting in gear pump (Fig. 42).
1
IMPORTANT: Make sure that the oil flow indicator
arrow on the tester is showing that the oil will flow
from the gear pump fitting, through the tester and
into the disconnected hose.
3
5. Install tester with pressure gauge and flow meter in
series with the disconnected hose and fitting in gear
pump section. Make sure the flow control valve on
the tester is fully open.
Figure 42
1. Gear pump
3. Pump section P2 hose
2. Pump section P1 hose
6. After installing tester, start engine and run at low idle
speed. Check for hydraulic leakage and correct before
proceeding with test.
Reelmaster 7000
Page 4 -- 55
Hydraulic System
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Steering Circuit Relief Pressure Test (Using Pressure Gauge)
M4
M1
M5
M2
M3
M1 M2
M4 M3
MOW
CONTROL
MV2
MV1
MANIFOLD
FAN
CONTROL
MANIFOLD
M1
M2
ST
OR2
OR1
CV2
CV1
LC1 LC2
S1
SP1
SP2
FD
CV
G2
G1
RV1 RV2
G1
G2
PRV
P1
T
P2
L
P1
T2
T1 P2
TO LIFT MANIFOLD
ENGINE SPEED
PISTON PUMP
2850/1550
GEAR
PUMP
BYPASS
VALVE
5000
PSI
.071
.071
.091
P4
P3
P2
P1
2.48
.56 .56 1.03 1.03
5000
PSI
STEERING WHEEL TURNED
FOR RIGHT TURN
P2
CV2
T
CD1
5 PSI
CV1
207 PSI
CR2
CR1
CV1
40
PSI
STEERING
CYLINDER
1050
PSI
P1
CD2
L
P
6.1
PB
T
R
STEEL
CAP
Working Pressure
Low Pressure
PRESSURE
GAUGE
Return or Suction
Flow
Hydraulic System
Page 4 -- 56
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The steering circuit relief pressure test should be per-
formed to make sure that the steering circuit relief pres-
sure is correct.
9. If steering relief pressure is incorrect, inspect steer-
ing relief valve located in the steering control valve (see
Steering Control Valve Service in the Service and Re-
pairs section of this chapter). If relief valve is operating
properly and if lift/lower problems also exist, gear pump
P3 should be suspected of wear or damage. If steering
wheel continues to turn at end of cylinder travel (with
lower than normal effort), steering cylinder or steering
control valve may be worn or damaged.
Procedure for Steering Circuit Relief Pressure Test
1. Make sure hydraulic oil is at normal operating tem-
peraturebyoperatingthemachineforapproximatelyten
(10) minutes. Make sure the hydraulic tank is full.
2. Parkmachineonalevelsurfacewiththecuttingunits
lowered and off. Make sure engine is off and the parking
brake is engaged.
10.Whentestingiscomplete,turnsteeringwheeltoboth
the right and the left with the engine not running to re-
lieve steering circuit pressure. Remove pressure gauge
from hydraulic hose and steel cap from steering cylinder
fitting. Connect hydraulic hose to steering cylinder fit-
ting.
CAUTION
1
Prevent personal injury and/or damage to equip-
ment. Read all WARNINGS, CAUTIONS and Pre-
cautions for Hydraulic Testing at the beginning
of this section.
RIGHT
2
FRONT
3. Thoroughly clean junction of hydraulic hose and
steering cylinder fitting at the barrel end of the steering
cylinder (Fig. 43). Disconnect hose from fitting in barrel
end of steering cylinder.
3
4. Install 5000 PSI (350 bar) pressure gauge with hy-
draulichoseattachedtodisconnectedhose. Installsteel
cap on steering cylinder fitting to prevent any leakage
from cylinder.
5. After installing pressure gauge, start engine and run
at low idle speed. Check for hydraulic leakage and cor-
rect before proceeding with test.
4
Figure 43
6. Move throttle to full engine speed (2850 RPM).
1. Steering cylinder
2. Barrel end hose
3. Barrel end fitting
4. Rear axle
IMPORTANT: While testing, rotate steering wheel
only long enough to get a system relief pressure
reading. Holding the steering circuit at relief pres-
sure for an extended period may damage the steer-
ing control valve.
7. Turn steering wheel to the right while monitoring the
pressure gauge. When steering circuit pressure reach-
es the relief pressure setting, pressure should stabilize
briefly and then may continue to increase. The steering
circuit relief pressure is the gauge reading when pres-
sure stabilizes.
GAUGE READING TO BE 1150 TO 1500 PSI (80 to
103 bar)
8. Stop the engine. Record test results.
Reelmaster 7000
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Steering Cylinder Internal Leakage Test
STEERING
CYLINDER FULLY
LOOK FOR
EXTENDED
LEAKAGE
STEERING WHEEL
TURNED FOR
RIGHT TURN
STEEL
PLUG
L
1050
PSI
P
6.1
PB
T
TO FILTRATION MANIFOLD
TO CHARGE CIRCUIT
R
Hydraulic System
Page 4 -- 58
Reelmaster 7000
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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 hy-
draulic hose. Connect hose to the steering cylinder fit-
ting.
Procedure for Steering Cylinder Internal Leakage
Test
8. If a steering problem exists and the steering cylinder
tested acceptably, consider the following:
NOTE: Steering circuit operation will be affected by
rear tire pressure, binding of steering cylinder, extra
weightonthevehicleand/orbindingofrearaxlesteering
components. Make sure that these items are checked
before proceeding with steering cylinder internal leak-
age test.
A. Gear pump section P3 (steering, lift/lower and
chargecircuits)iswornordamaged(seeGearPump
P3 Flow Test in this section).
NOTE: If gear pump P3 is worn or damaged,
charge, steering and lift circuits will all be affected.
B. Theflowdividerinthefandrivecontrolmanifoldis
faulty (see Fan Drive Manifold Service in the Service
and Repairs section of this chapter).
1. Make sure hydraulic oil is at normal operating tem-
perature by operating the machine under load for
approximately ten (10) minutes. Make sure the hydrau-
lic tank is full.
C. The steering control valve requires service (see
Steering Control Valve and Steering Control Valve
Service in the Service and Repairs section of this
chapter).
2. Parkmachineonalevelsurfacewiththecuttingunits
lowered and off. Turn the steering wheel for a right turn
so that the steering cylinder is fully extended. Turn en-
gine off and apply the parking brake.
9. Check oil level in hydraulic reservoir and adjust if
needed.
CAUTION
1
Prevent personal injury and/or damage to equip-
ment. Read all WARNINGS, CAUTIONS and Pre-
cautions for Hydraulic Testing at the beginning
of this section.
3. Thoroughlycleantheareaaroundthehydraulichose
at the rod end of the steering cylinder.
2
4. Place a drain pan under the steering cylinder. Re-
movehydraulichosefromthefittingontherodendofthe
steering cylinder. Install a steel plug in the disconnected
hose.
5. Remove all hydraulic oil from drain pan. Make sure
that empty drain pan remains under the open fitting of
the steering cylinder.
Figure 44
1. Steering cylinder
2. Rod end fitting
6. With the engine off, turn the steering wheel for a right
turn. Observe the open fitting on the extended steering
cylinder as the steering wheel is turned. If oil comes out
of the fitting while turning the steering wheel, the steer-
ing cylinder has internal leakage and must be repaired
(see Steering Cylinder and Steering Cylinder Service in
the Service and Repairs section of this chapter). Check
drain pan for any evidence of oil that would indicate cyl-
inder leakage.
Reelmaster 7000
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Lift/Lower Circuit Relief Pressure Test (Using Pressure Gauge)
FROM STEERING
CONTROL VALVE
TO CHARGE
CIRCUIT
PRESSURE
GAUGE
Working Pressure
Low Pressure
Return or Suction
Flow
Hydraulic System
Page 4 -- 60
Reelmaster 7000
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The lift/lower circuit relief pressure test should be per-
formed to make sure that the cutting unit lift and lower
circuit relief pressure is correct.
9. If specification is not met, clean or adjust relief valve
RV1 located in the lift control manifold (see Lift Control
Manifold Service in the Service and Repairs section of
this chapter).
Procedure for Lift/Lower Circuit Relief Pressure
Test
A. If pressure is too high, adjust relief valve RV1 to
reduce lift/lower circuit relief pressure (see Adjust
Control Manifold Relief Valves in the Adjustments
section of this chapter).
1. Make sure hydraulic oil is at normal operating tem-
peraturebyoperatingthemachineforapproximatelyten
(10) minutes. Make sure the hydraulic tank is full.
B. If pressure is too low, check for restriction in gear
pump intake line. Check the lift cylinders for internal
leakage. If pump intake line is not restricted and lift
cylinders are not leaking, adjust relief valve RV1 to
increase lift/lower circuit relief pressure (see Adjust
Control Manifold Relief Valves in the Adjustments
section of this chapter).
2. Parkmachineonalevelsurfacewiththecuttingunits
fully lowered. Apply the parking brake and stop engine.
CAUTION
Prevent personal injury and/or damage to equip-
ment. Read all WARNINGS, CAUTIONS and Pre-
cautions for Hydraulic Testing at the beginning
of this section.
C. If pressure is still too low after relief valve adjust-
ment, lift cylinder(s) or gear pump P4 should be sus-
pected of wear or damage.
10.After testing is completed, remove pressure gauge
frommanifoldtestport. Installdustcaptotestportfitting.
Lower and secure hood.
3. Raise and support hood to gain access to lift control
manifold (Fig. 45). Connect a 5000 PSI (350 bar) pres-
sure gauge with hydraulic hose attached to lift manifold
test port G. Route gauge hose to allow hood to be safely
lowered.
1
4. After installing pressure gauge, start engine and run
at low idle speed. Check for hydraulic leakage and cor-
rect before proceeding with test.
2
5. Move throttle to full engine speed (2850 RPM).
6. While sitting on the seat, move lift switch to raise and
allowthecuttingunitstofullyraise. Momentarilyholdthe
switch with the lift cylinders fully retracted while looking
at the pressure gauge.
7. When the lift cylinders are fully retracted (cutting
units fully raised) and the relief valve lifts, the pressure
gauge needle will momentarily stop. System pressure
asthereliefvalveRV1opensshouldbebeapproximate-
ly 1700 PSI (117 bar). Release lift switch to the neutral
position after observing relief valve pressure.
Figure 45
1. Test port G1
2. Relief valve RV1
NOTE: If lift switch continues to be pressed after the re-
lief valve has opened, system pressure can increase
higher than relief pressure.
8. Stop the engine and record test results.
Reelmaster 7000
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Hydraulic System
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Gear Pump P3 Flow (Steering and Lift/Lower Circuits) Test (Using Tester with Pressure
Gauges and Flow Meter)
TO MOW CONTROL
TO MOW CONTROL
MANIFOLD (P2 PORT)
MANIFOLD (P1 PORT)
TESTER
TO STEERING AND LIFT CIRCUITS
TO FAN CIRCUIT
ENGINE SPEED
2850/1550
PISTON PUMP
GEAR
PUMP
BYPASS
VALVE
5000
PSI
.071
.091
P4
.56
P3
P2
P1
2.48
.56 1.03 1.03
.071
5000
PSI
FROM RESERVOIR
FROM FILTRATION MANIFOLD
Working Pressure
Low Pressure
Return or Suction
Flow
Hydraulic System
Page 4 -- 62
Reelmaster 7000
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The gear pump P3 flow test should be performed to
make sure that the steering, lift and traction charge cir-
cuits have adequate hydraulic flow.
IMPORTANT: The pump is a positive displacement
type. If pump flow is completely restricted or
stopped, damage to the pump, tester or other com-
ponents could occur.
NOTE: Gear Pump P3 supplies oil flow for the steering,
lift and traction charge circuits.
8. While watching pressure gauges, slowly close flow
control valve on tester until 1000 PSI (69 bar) is ob-
tained on pressure gauge. Verify engine speed contin-
ues to be correct (2850 RPM).
Procedure for Gear Pump P3 Flow Test
1. Make sure hydraulic oil is at normal operating tem-
peraturebyoperatingthemachineforapproximatelyten
(10) minutes. Make sure the hydraulic tank is full.
9. For a pump in good condition, flow indication should
be approximately 6.5 GPM (24.6 LPM).
2. Parkmachineonalevelsurfacewiththecuttingunits
lowered and off. Make sure engine is off and the parking
brake is engaged.
10.Fully open flow control valve on tester and then shut
engine off. Record test results.
11.If the flow is lower than 5.8 GPM (22 LPM) or a pres-
sure of 1000 PSI (69 bar) could not be obtained, check
for restriction in pump intake line. If intake line is not re-
stricted, remove gear pump and repair or replace as
necessary.
3. Raise hood to allow access to pump assembly.
CAUTION
12.After testing is complete, disconnect tester from hy-
draulic hose and fitting. Connect hose to the gear pump
fitting. Lower and secure hood.
Prevent personal injury and/or damage to equip-
ment. Read all WARNINGS, CAUTIONS and Pre-
cautions for Hydraulic Testing at the beginning
of this section.
RIGHT
4. Thoroughly clean junction of hydraulic hose and fit-
ting in gear pump section P3 (Fig. 46). Disconnect hy-
draulic hose from fitting.
FRONT
IMPORTANT: Make sure that the oil flow indicator
arrow on the tester is showing that the oil will flow
from the gear pump fitting, through the tester and
into the disconnected hose.
2
5. Install tester with pressure gauges and flow meter in
series with the disconnected hose and fitting in gear
pump section P3. Make sure the flow control valve on
the tester is fully open.
1
6. After installing tester, start engine and run at idle
speed. Check for hydraulic leakage and correct before
proceeding with test.
Figure 46
1. Gear pump section P3
2. Pump section P3 hose
7. Move throttle to full speed (2850 RPM). DO NOT en-
gage the cutting units.
Reelmaster 7000
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Cooling Fan Circuit Test (Using Pressure Gauge and Phototac)
M4
M1
M5
M2
M3
M1 M2
M4 M3
MOW
CONTROL
MV2
MV1
MANIFOLD
FAN
CONTROL
MANIFOLD
M1
M2
ST
OR2
OR1
CV2
CV1
LC1 LC2
S1
SP1
SP2
FD
CV
G2
G1
RV1 RV2
G1
G2
PRV
P1
T
P2
L
P1
T2
T1 P2
TO LIFT MANIFOLD
PRESSURE
GAUGE
ENGINE SPEED
PISTON PUMP
2850/1550
GEAR
PUMP
BYPASS
VALVE
5000
PSI
.071
.071
.091
P4
P3
P2
P1
2.48
.56 .56 1.03 1.03
5000
PSI
P2
CV2
T
CD1
5 PSI
CV1
207 PSI
CR2
CR1
CV1
40
PSI
STEERING
CYLINDER
1050
PSI
P1
CD2
L
P
6.1
PB
T
R
Working Pressure
Low Pressure
Return or Suction
Flow
Hydraulic System
Page 4 -- 64
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The cooling fan circuit testshould be performed to make
sure that the engine cooling fan circuit has the correct
system pressure and fan speed.
8. If pressure rises to approximately 3000 PSI (207
bar) but fan speed is low, consider that the fan motor is
worn or damaged. If pressure and fan speed are both
low, consider that gear pump P4 is worn or damaged
(see Gear Pump P4 Flow Test in this section).
Procedure for Cooling Fan Circuit Test
1. Make sure hydraulic oil is at normal operating tem-
peraturebyoperatingthemachineforapproximatelyten
(10) minutes. Make sure the hydraulic tank is full.
NOTE: If pressure and fan speed are both low and gear
pump P4 flow proves to be correct (see Gear Pump P4
Flow Test in this section), suspect that seals in fan con-
trol manifold are leaking or faulty (see Fan Control Man-
ifold Service in the Service and Repairs section of this
chapter) or that fan motor is worn or damaged.
2. Parkmachineonalevelsurfacewiththecuttingunits
lowered and off. Make sure engine is off and the parking
brake is applied.
9. When testing is complete, remove pressure gauge
from manifold fitting and reconnect wire harness to pro-
portionalreliefvalvesolenoid.Installdustcaptotestport
fitting. Lower and secure hood.
CAUTION
Prevent personal injury and/or damage to equip-
ment. Read all WARNINGS, CAUTIONS and Pre-
cautions for Hydraulic Testing at the beginning
of this section.
3
3. Raise and support hood to gain access to fan control
manifold (Fig. 47). Connecta5,000 PSI(345 bar)gauge
with hydraulic hose attached to test fitting in port G2 on
rear of manifold.
1
2
4. After installing tester, start engine and run at idle
speed. Check for hydraulic leakage and correct before
proceeding with test.
5. Move throttle to full speed (2850 RPM).
Figure 47
6. While monitoring the pressure gauge and using a
phototac to identify the cooling fan speed, disconnect
the wire harness connector (white/green and black
wires) from the proportional relief valve solenoid at fan
control manifold (port PRV). Both fan speed and pres-
sure should increase and stabilize after the solenoid is
disconnected.
1. Fan control manifold
2. Test fitting (port G2)
3. PRV solenoid
PRESSURE GAUGE READING TO BE approxi-
mately 3000 PSI (207 bar)
PHOTOTAC (fan speed) READING TO BE approxi-
mately 2800 RPM
7. Stop engine and record test results.
Reelmaster 7000
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Gear Pump P4 Flow (Cooling Fan Circuit) Test (Using Tester with Pressure Gauges and
Flow Meter)
TO MOW CONTROL
TO MOW CONTROL
MANIFOLD (P2 PORT)
MANIFOLD (P1 PORT)
TO STEERING AND LIFT CIRCUITS
TO FAN CIRCUIT
ENGINE SPEED
2850/1550
PISTON PUMP
TESTER
GEAR
PUMP
BYPASS
VALVE
5000
PSI
.071
.091
P4
.56
P3
P2
P1
2.48
.56 1.03 1.03
.071
5000
PSI
FROM RESERVOIR
FROM FILTRATION MANIFOLD
Working Pressure
Low Pressure
Return or Suction
Flow
Hydraulic System
Page 4 -- 66
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The gear pump P4 flow test should be performed to
make sure that the engine cooling fan circuit has ade-
quate hydraulic flow.
IMPORTANT: The gear pump is a positive displace-
ment type. If pump flow is completely restricted or
stopped, damage to the pump, tester or other com-
ponents could occur.
NOTE: Gear Pump P4 supplies oil flow for the engine
cooling fan circuit.
8. While watching pressure gauge on tester, slowly
close flow control valve on tester until 1000 PSI (69 bar)
is obtained on pressure gauge. Verify engine speed
continues to be correct (2850 RPM).
Procedure for Gear Pump P4 Flow Test
1. Make sure hydraulic oil is at normal operating tem-
peraturebyoperatingthemachineforapproximatelyten
(10) minutes. Make sure the hydraulic tank is full.
9. For a pump in good condition, flow indication should
be approximately 6.5 GPM (24.6 LPM).
2. Parkmachineonalevelsurfacewiththecuttingunits
lowered and off. Make sure engine is off and the parking
brake is engaged.
10.Fully open flow control valve on tester and then shut
engine off. Record test results.
11.If the flow is lower than 5.8 GPM (22 LPM) or a pres-
sure of 1000 PSI (69 bar) could not be obtained, check
for restriction in pump intake line. If intake line is not re-
stricted, remove gear pump and repair or replace as
necessary.
3. Raise hood to allow access to pump assembly.
CAUTION
12.After testing is complete, disconnect tester from hy-
draulic hose and fitting. Connect hose to the gear pump
fitting. Lower and secure hood.
Prevent personal injury and/or damage to equip-
ment. Read all WARNINGS, CAUTIONS and Pre-
cautions for Hydraulic Testing at the beginning
of this section.
4. Thoroughly clean junction of hydraulic hose and fit-
ting in gear pump section P4 (Fig. 48). Disconnect hy-
draulic hose from fitting.
RIGHT
FRONT
IMPORTANT: Make sure that the oil flow indicator
arrow on the tester is showing that the oil will flow
from the gear pump fitting, through the tester and
into the disconnected hose.
2
1
5. Install tester with pressure gauge and flow meter in
series with the disconnected hose and fitting in gear
pump section P4. Make sure the flow control valve on
the tester is fully open.
6. After installing tester, start engine and run at idle
speed. Check for hydraulic leakage and correct before
proceeding with test.
Figure 48
1. Gear pump
2. Pump section P4 hose
7. Move throttle to full speed (2850 RPM). DO NOT en-
gage the cutting units.
Reelmaster 7000
Page 4 -- 67
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Adjustments
Adjust Control Manifold Relief Valves
Several of the hydraulic control manifolds on your Reel-
master include adjustable relief valves. The following
procedure can be used to adjust these relief valves. Re-
fer 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. To increase pressure setting, turn the adjustment
socket on the valve in a clockwise direction. A 1/8 turn
on the socket will make a measurable change in relief
pressure.
2
4. To decrease pressure setting, turn the adjustment
socket on the valve in a counterclockwise direction. A
1/8 turn on the socket will make a measurable change
in relief pressure.
5. Install and tighten cap on relief valve.
Figure 49
1. Relief valve cap
2. Adjustment socket
6. Recheck relief pressure and readjust as needed.
Hydraulic System
Page 4 -- 68
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Service and Repairs
General Precautions for Removing and Installing Hydraulic System Components
Before Repair or Replacement of Hydraulic Compo-
nents
After Repair or Replacement of Hydraulic Compo-
nents
1. Before removing any parts from the hydraulic sys-
tem, park machine on a level surface, engage parking
brake, lower cutting units or attachments and stop en-
gine. Remove key from the ignition switch.
1. Checkoillevelinthehydraulicreservoirand addcor-
rect oil if necessary. Drain and refill hydraulic system
reservoir and change oil filter if component failure was
severe or system is contaminated (see Flush Hydraulic
System in this section).
2. Clean machine before disconnecting, removing or
disassembling any hydraulic components. Make sure
hydraulic components, hoses connections and fittings
are cleaned thoroughly. Always keep in mind the need
for cleanliness when working on hydraulic equipment.
2. Lubricate O--rings and seals with clean hydraulic oil
before installing hydraulic components.
3. Make sure caps or plugs are removed from the hy-
draulic tubes, hydraulic fittings and components before
reconnecting.
CAUTION
4. Use proper tightening methods when installing hy-
draulic hoses and fittings (see Hydraulic Fitting Installa-
tion in the General Information section of this chapter).
Operate all hydraulic controls to relieve system
pressure and avoid injury from pressurized hy-
draulic oil. Controls must be operated with the
ignition switch in RUN and the engine OFF. Make
sure all electrically operated control valves are
actuated. Return ignition switch to OFF when
pressure has been relieved. Remove key from
the ignition switch.
5. After repairs, check control linkages or cables for
proper adjustment, binding or broken parts.
6. After disconnecting or replacing any hydraulic com-
ponents, operate machine functions slowly until air is
out of system (see Charge Hydraulic System in this sec-
tion).
3. Putcapsorplugsonanyhydrauliclines, hydraulicfit-
tings and components left open or exposed to prevent
system contamination.
7. Checkforhydraulicoilleaks.Shutoffengineandcor-
rectleaksifnecessary.Checkoillevelinhydraulicreser-
voir and add correct oil if necessary.
4. Put labels on disconnected hydraulic lines and
hosesforproperinstallationafterrepairsarecompleted.
5. Note the position of hydraulic fittings (especially el-
bow fittings) on hydraulic components before removal.
Markpartsifnecessarytomakesuretheywillbealigned
properly when installing hydraulic hoses and tubes.
Reelmaster 7000
Page 4 -- 69
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Check Hydraulic Lines and Hoses
IMPORTANT: Checkhydraulic linesand hosesdaily
for leaks, kinked lines, loose mounting supports,
wear, loose fittings or deterioration. Make all neces-
sary 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. If fluid is in-
jected into the skin, it must be surgically re-
moved within a few hours by a doctor familiar
withthistypeofinjury. Gangrenemayresultfrom
such an injury.
Hydraulic System
Page 4 -- 70
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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).
8. Disconnect wire harness connector from engine run
solenoid to prevent the engine from starting.
9. Turn ignition key switch to start and engage starter
for ten (10) seconds to prime pump. Let starter cool and
then repeat cranking procedure again.
IMPORTANT: Flush hydraulic system when chang-
Ing from petroleum base hydraulic fluid to a biode-
gradable fluid. Operate machine under normal
operating conditions for at least four (4) hours be-
fore draining.
10.Connect wire harness connector to engine run sole-
noid.
11.Start engine and let it idle at low speed (1550 RPM)
for a minimum of two (2) minutes. Increase engine
speed to high idle (2850 RPM) for minimum of one (1)
minute under no load.
1. Park machineon alevelsurface. Lower cuttingunits,
stop engine and engage parking brake. Remove key
from the ignition switch.
12.Raise and lower cutting units several times. Turn
steering wheel fully left and right several times.
CAUTION
13.Move PTO switch to ON to engage cutting units and
let them run for several minutes. Move PTO switch to
OFF.
Operate all hydraulic controls to relieve system
pressure and avoid injury from pressurized hy-
draulic oil. Controls must be operated with the
ignition switch in OFF. Remove key from the igni-
tion switch.
14.Shut off engine and check for hydraulic oil leaks.
Check oil level in hydraulic reservoir and add correct
amount of oil if necessary.
IMPORTANT: Make sure to clean around any hy-
draulic connections that will be disconnected for
draining.
15.Operate machine for two (2) hours under normal op-
erating conditions.
16.Check condition of hydraulic oil. If the new fluid
shows any signs of contamination, repeat steps 1
through 14 again until oil is clean. If changing to biode-
gradable fluid, repeat steps 1 through 15 again at least
once and until the oil is clean.
2. Drain hydraulic reservoir into a suitable container.
3. Drain hydraulic system. Drain all hoses, tubes and
components while the system is warm.
4. Change and replace both hydraulic oil filters.
17.Assume normal operation and follow recommended
maintenance intervals.
5. Inspect and clean hydraulic reservoir (see Hydraulic
Reservoir Inspection in the Service and Repair section).
6. Connect all hydraulic hoses, lines and components
that were disconnected while draining system.
NOTE: Use only hydraulic fluids specified in the Trac-
tion Unit Operator’s Manual. Other fluids may cause
system damage.
7. Fill hydraulic reservoir with new hydraulic fluid.
Reelmaster 7000
Page 4 -- 71
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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 hy-
draulic system filtering tool is not used to ensure system
cleanliness, repeatfailures, aswellassubsequentdam-
age to other hydraulic components in the affected sys-
tem, will occur. To effectively remove contamination
from closed--loop traction circuit, use of the Toro high
flow hydraulic filter and hydraulic hose kits are recom-
mended (see Special Tools in this chapter).
7. With engine running at low idle speed, slowly move
the traction pedal to the forward direction to allow flow
through the tractioncircuitandhigh flowfilter. Keeptrac-
tion circuit engaged for five (5) minutes while gradually
increasing both forward pressure on traction pedal and
engine speed. Monitor filter indicator to make sure that
green color is showing during operation.
8. With engine running at high idle speed and traction
pedal moved to the forward direction, periodically apply
brakes to increase pressure in traction circuit. While
monitoring filter indicator, continue this process for an
additional five (5) minutes.
1. Parkmachineon alevelsurfacewith enginestopped
and key removed from ignition switch.
IMPORTANT: If using a filter that is not the bi--direc-
tional Toro high flow filter, do not press the traction
pedal in the reverse direction. If flow is reversed
when using a filter that is not bi--directional, debris
from the filter will re--enter the traction circuit.
2. Raise and support machine so all wheels are off the
ground (see Jacking Instructions in Chapter 1 -- Safety).
NOTE: If front wheel or rear axle motor was replaced,
install high flow filter to the inlet of new motor instead of
to the traction pump fitting. This will prevent system con-
tamination from entering and damaging the new motor.
9. With engine running at high idle speed, alternately
movetractionpedalfromforwardtoreverse.Whilemon-
itoring filter indicator, continue this process for an addi-
tional five (5) minutes.
3. Thoroughly clean junction of hydraulic hose and
right side fitting on bottom of traction pump (Fig. 50).
Disconnect hose from right side pump fitting.
10.Shut engine off and remove key from ignition switch.
4. Connect Toro high flow hydraulic filter in series be-
tween traction pump fitting and disconnected hose. Use
hydraulic hose kit (see Special Tools in this chapter) to
connectfiltertomachine. Makesurethatfittingandhose
connections are properly tightened.
11.Remove high flow hydraulic filter and hydraulic hose
kit from machine. Connect hydraulic hose to right side
traction pump fitting. Make sure to properly tighten hose
(see Hydraulic Hose and Tube Installation in the Gener-
al Information section of this chapter).
IMPORTANT: Use only hydraulic fluids specified in
Operator’sManual.Otherfluidscouldcausesystem
damage.
12.Lower machine to ground.
13.Check oil level in hydraulic reservoir and add correct
oil if necessary.
5. After installing high flow filter to machine, check and
fill hydraulic reservoir with new hydraulic oil as required.
1
RIGHT
6. Start engine and run at idle speed. Check for any hy-
draulic leakage from filter and hose connections. Cor-
rect any leaks before proceeding.
FRONT
CAUTION
Allwheels willbe off the ground and rotatingdur-
ing this procedure. Make sure machine is well
supported so it will not move and accidentally
fall to prevent injuring anyone around machine.
2
IMPORTANT: While engaging the traction circuit,
monitor the indicator on the high flow hydraulic fil-
ter. If the indicator should show red, either reduce
pressure on the traction pedal or reduce engine
speed to decrease hydraulic flow through the filter.
Figure 50
1. Piston (traction) pump
2. Right side fitting/hose
Hydraulic System
Page 4 -- 72
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Charge Hydraulic System
NOTE: When initially starting the hydraulic system with
new or rebuilt components such as pumps, motors or lift
cylinders, it is important that the hydraulic system be
charged properly. Air must be purged from the system
and its components to reduce the chance of damage.
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:
IMPORTANT: Change hydraulic oil filter whenever
hydraulic components are repaired or replaced.
A. Loose filter or suction lines.
B. Blocked suction line.
1. Park machineon alevelsurface. Lower cuttingunits,
stop engine and engage parking brake. Remove key
from the ignition switch.
C. Faulty charge relief valve.
D. Faulty gear pump.
2. Make sure all hydraulic connections, lines and com-
ponents are secured tightly.
12.Once lift cylinders do move, proceed to step 13.
3. Ifcomponentfailurewassevereorthesystemiscon-
taminated, flush and refill hydraulic system and tank
(see Flush Hydraulic System in this section).
13.Operatethetractionpedalintheforwardandreverse
directions. The wheels off the ground should rotate in
the proper direction.
4. Make sure hydraulic reservoir is full. Add correct hy-
draulic oil if necessary.
A. If the wheels rotate in the wrong direction, stop
engine and inspect hydraulic line placement at pis-
ton (traction) pump and wheel motors. Correct hy-
draulic line installation before proceeding.
5. Disconnect wire harness connector from engine run
solenoid to prevent the engine from starting.
B. If the wheels rotate in the proper direction, pro-
ceed with procedure.
6. Check control rod to the piston (traction) pump for
proper adjustment, binding or broken parts.
14.Adjust traction pedal to the neutral position.
15.Check operation of the traction interlock switch.
7. Make sure traction pedal is in the neutral position.
Turn ignition key switch to start and engage starter for
ten (10) seconds to prime the traction and gear pumps.
Let starter cool and then repeat cranking procedure
again.
16.Stop engine, remove blocks from frame and lower
machine. Remove chocks from remaining wheels.
8. Connect wire harness connector to engine run sole-
noid.
17.If the piston (traction) pump or a traction motor was
replaced or rebuilt, run the machine so all wheels turn
slowly for ten (10) minutes.
18.Operate machine by gradually increasing its work
load to full over a ten (10) minute period.
WARNING
Beforejackingupthemachine, reviewandfollow
Jacking Instructions in Chapter 1 -- Safety.
19.Stop the machine. Check hydraulic reservoir and fill
ifnecessary. Check hydraulic components for leaks and
tighten any loose connections.
9. Raise one front and one rear wheel off the ground
and place support blocks under the frame. Chock re-
maining wheels to prevent movement of the machine.
10.Make sure traction pedal is in neutral. Start engine
and run it at low idle (1550 RPM). The pumps should
pick up oil and fill the hydraulic system. If there is no in-
dication of fill in thirty (30) seconds, stop the engine and
determine the cause.
Reelmaster 7000
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Gear Pump
15
14
77 to 93 ft--lb
(105 to 126 N--m)
18
13
18
7
11
3
9
16
17
11
16
8
1
2
12
5
8
4
5
12
22
23
6
19
21
RIGHT
20
11
103 to 118 ft--lb
FRONT
(140 to 160 N--m)
10
Figure 51
1. Flat washer (2 used)
2. Cap screw (2 used)
3. 90 hydraulic fitting
9. Coupler
17. Spacer
18. O--ring
19. O--ring
o
10. 90 hydraulic fitting
11. O--ring
o
4. Hydraulic tee fitting
5. O--ring
12. O--ring
13. 45 hydraulic fitting
14. Cap screw
15. Washer
16. O--ring
20. Straight hose fitting
21. O--ring
22. Straight hydraulic fitting
23. O--ring
o
6. Gear pump assembly
7. Piston pump assembly
o
8. 90 hydraulic fitting
Removal (Fig. 51)
4. To prevent contamination of hydraulic system during
removal, thoroughly clean exterior of pump and fittings.
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.
5. Read the General Precautions for Removing and
Installing Hydraulic System Components at the begin-
ning of the Service and Repairs section of this chapter.
2. Raise seat and secure it with prop rod to gain access
to gear pump.
6. Disconnect hydraulic lines from gear pump and put
caps or plugs on open hydraulic lines and fittings. Label
disconnected hydraulic lines for proper assembly (Fig.
52).
3. Drain the hydraulic reservoir into a suitable contain-
er.
Hydraulic System
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7. Support gear pump assembly to prevent it from fal-
ling.
3
RIGHT
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.
4
FRONT
5
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.
Installation (Fig. 51)
1
1. If fittings were removed from gear pump, lubricate
and place new O--rings onto fittings. Install fittings into
pump ports using marks made during the removal pro-
cess to properly orientate fittings. Tighten fittings (see
Hydraulic Fitting Installation in the General Information
section of this chapter).
6
2
7
Figure 52
1. Supply hose to mow manifold P1 port
2. Supply hose to mow manifold P2 port
3. Supply hose to fan manifold P2 port
4. Supply hose to fan manifold P1 port
5. Suction hose from filter manifold
6. Suction hose from reservoir
2. Lubricate new O--rings (item 16) with clean hydraulic
oil. Position O--rings on gear pump and pump spacer
flanges.
7. Supply hose for charge circuit
3. Slide coupler (item 9) onto the piston pump output
shaft.
4. Position pump spacer (item 17) to gear pump. Align
gear teeth and slide gear pump input shaft into coupler.
Secure gear pump to piston pump with two (2) cap
screws and flat washers.
5. Remove caps and plugs from hydraulic hoses and
fittings. Install hoses to gear pump (see Hydraulic Hose
and Tube Installation in the General Information section
of this chapter).
6. Replace hydraulic filter and fill hydraulic reservoir
with new hydraulic oil.
7. Disconnect engine run solenoid electrical connector
to prevent engine from starting. Prime the hydraulic
pump by turning the ignition key switch to start and
crankingtheengineforten(10)seconds.Letstartercool
and then repeat cranking procedure again.
8. Connect engine run solenoid electrical connector,
start the engine and check for proper operation.
9. Properly fill hydraulic system (see Charge Hydraulic
System in this section).
10.Stop engine and check for hydraulic oil leaks. Check
hydraulic reservoir oil level.
11.Lower and secure seat.
Reelmaster 7000
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Gear Pump Service
18
17
16
15
13
14
12
10
9
6
5
19
4
24
3
11
21
9
11
21
7
8
2
26
1
25
23
22
33 ft--lb
(45 N--m)
22
20
Figure 53
1. Dust seal
10. Seal (8 used)
11. Idler gear
12. Drive shaft
13. Back--up gasket
14. Pressure seal
15. Front body (section P1)
16. Splined connecting shaft (3 used)
17. Flange
18. Drive gear
19. Body (section P2)
20. Body (section P3)
21. Drive gear
22. Idler gear
23. Rear body (section P4)
24. Rear cover
25. Cap screw (4 used)
26. Washer (4 used)
2. Retaining ring
3. Flange washer
4. Shaft seal
5. Front cover
6. Dowel pin (16 used)
7. Pressure seal
8. Back--up gasket
9. Thrust plate (8 used)
Disassembly (Fig. 53)
DIAGONAL LINE
NOTE: The gear pump mustbe replacedas acomplete
assembly. Individual gears, housings and thrust plates
are not available separately. Disassemble gear pump
for cleaning, inspection and seal replacement only.
IMPORTANT: Keep bodies, gears, flanges and
thrustplatesforeachpumpsectiontogether;donot
mix parts between pump sections.
1. Plug pump ports and thoroughly clean exterior of
pump with cleaning solvent. Make sure work area is
clean.
2. Use a marker to make a diagonal line across the
gear pump for assembly purposes (Fig. 54).
Figure 54
Hydraulic System
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IMPORTANT: Use caution when clamping gear
pump in a vise to avoid distorting any pump compo-
nents.
8. Clean all parts. Check all components for burrs,
scoring, nicks and other damage.
9. Replace the entire pump assembly if parts are ex-
cessively worn or scored.
3. Secure the front cover of the pump in a vise with the
drive shaft pointing down.
Assembly (Fig. 53)
4. Loosen the four (4) cap screws that secure pump as-
sembly.
1. Apply clean hydraulic oil to all pump parts before as-
sembling.
5. Remove pump from vise and remove fasteners.
NOTE: Pressure seals and back--up gaskets fit in
grooves machined into thrust plates. Body seals fit in
grooves machined in body faces.
6. Supportthepumpassemblyandgentlytapthepump
case with a soft face hammer to loosen the pump sec-
tions. Be careful to not drop parts or disengage gear
mesh.
2. Assemble pump sections starting at front cover end.
Apply grease or petroleum jelly to new section seals to
hold them in position during gear pump assembly.
IMPORTANT: Mark the relative positions of the gear
teeth and the thrust plates so they can be reassem-
bled in the same position. Do not touch the gearsur-
faces as residue on hands may be corrosive to gear
finish.
3. After pump has been assembled, tighten cap screws
and nuts by hand. Rotate the drive shaft to check for
binding. Protect the shaft if using a pliers.
4. Tighten the four (4) cap screws evenly in a crossing
pattern to a torque of 33 ft--lb (45 N--m).
7. Remove the thrust plates and seals from each pump
section. Before removing each gear set, apply marking
dye to mating teeth to retain ”timing”. Pump efficiency
may be affected if the teeth are not installed in the same
position during assembly. Keep the parts for each pump
section together; do not mix parts between sections.
Reelmaster 7000
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Piston (Traction) Pump
15
14
77 to 93 ft--lb
(105 to 126 N--m)
18
13
7
18
11
3
9
16
17
11
16
8
1
2
12
5
8
4
5
12
22
23
6
19
21
RIGHT
20
11
10
103 to 118 ft--lb
(140 to 160 N--m)
FRONT
Figure 55
1. Flat washer (2 used)
2. Cap screw (2 used)
3. 90 hydraulic fitting
9. Coupler
17. Spacer
18. O--ring
19. O--ring
o
10. 90 hydraulic fitting
11. O--ring
o
4. Hydraulic tee fitting
5. O--ring
12. O--ring
13. 45 hydraulic fitting
14. Cap screw
15. Washer
16. O--ring
20. Straight hose fitting
21. O--ring
22. Straight hydraulic fitting
23. O--ring
o
6. Gear pump assembly
7. Piston pump assembly
o
8. 90 hydraulic fitting
Removal (Fig. 55)
4. Disconnect wire harness connector from neutral
switch on traction pump (Fig. 56).
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.
5. Read the General Precautions for Removing and
Installing Hydraulic System Components at the begin-
ning of the Service and Repairs section of this chapter.
2. To prevent contamination of hydraulic system during
removal, thoroughly clean exterior of pump assembly.
6. Put a drain pan below the pump assembly. Remove
hydraulic hoses connected to piston and gear pumps.
Put plugs or caps on disconnected hydraulic hoses and
fittings to prevent contamination of the system (Fig. 57).
3. Remove traction rod from control arm on piston
pump by removing lock nut and flange head screw (Fig.
56).
Hydraulic System
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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 retain-
ing 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.Stop engine and check for hydraulic oil leaks. Check
hydraulic reservoir oil level.
9. If hydraulic fittings are to be removed from piston
pump, mark fitting orientation to allow correct assembly.
Remove fittings from pump and discard O--rings.
Installation (Fig. 55)
1
2
1. If fittings were removed from piston pump, lubricate
and place new O--rings onto fittings. Install fittings into
pump ports using marks made during the removal pro-
cess to properly orientate fittings. Tighten fittings (see
Hydraulic Fitting Installation in the General Information
section of this chapter).
3
5
IMPORTANT: To prevent spring coupler damage,
make sure that piston pump is properly supported
anddoesnotputsideloadintocouplerduringpump
installation.
4
2. Carefully lower piston pump into the machine and
position it to the engine adapter plate. Support pump to
prevent it from falling while installing two (2) cap screws
and washers securing piston pump to engine adapter
plate. Torque screws from 77 to 93 ft--lb (105 to 126
N--m).
Figure 56
1. Piston pump
2. Neutral switch
3. Traction rod
4. Flange head screw
5. Lock nut
3. Install gear pump to piston pump (see Gear Pump
Installation in this section).
3
RIGHT
FRONT
4
4. Position traction rod to control arm on piston pump
and secure with flange head screw and lock nut (Fig.
56).
5
5. Connectwire harness connector to neutral switch on
traction pump.
6. Remove plugs and caps from disconnected hydrau-
lic hoses and open ports of the pump assembly. Install
fittings and hoses to correct location on gear and piston
pumps (see Hydraulic Hose and Tube Installation in the
General Information section of this chapter).
1
6
2
7
7. Install new filter and fill hydraulic reservoir with cor-
rect oil.
Figure 57
1. Supply hose to mow manifold P1 port
2. Supply hose to mow manifold P2 port
3. Supply hose to fan manifold P2 port
4. Supply hose to fan manifold P1 port
5. Suction hose from filter manifold
6. Suction hose from reservoir
8. Disconnect engine run solenoid electrical connector
to prevent engine from starting. Prime pumps by turning
ignition key switch to crank engine for ten (10) seconds.
Repeat cranking procedure again.
7. Supply hose for charge circuit
Reelmaster 7000
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Piston (Traction) Pump Service
40 to 48 in--lb
4 to 6 ft--lb
(4.5 to 5.4 N--m)
(5 to 8 N--m)
100 to 110 ft--lb
(136 to 149 N--m)
40 to 48 in--lb
(4.5 to 5.4 N--m)
25 to 28 ft--lb
(34 to 38 N--m)
40
48
47
41
35
49
46
33
43 42
15
30
14
37
32
31
44
27 to 31 ft--lb
(37 to 42 N--m)
27
45
36
38
39
34
12
23
22
10
21
19
20
9
25
28
27
29
8
24
10
1
26
18
17
11
5
100 to 110 ft--lb
(136 to 149 N--m)
12
6
13
14
7
150 to 160 in--lb
(17 to 18 N--m)
15
16
6
40 to 48 in--lb
(4.5 to 5.4 N--m)
4
5
3
2
Figure 58
1. Drive shaft
2. Retaining ring
3. Shaft seal
4. Washer
5. Retaining ring
6. Thrust bearing race
7. Thrust bearing
8. Bearing
9. Housing
10. Seal set
11. Servo piston
12. Gasket
13. Cover plate
14. Flat washer (4 used per cover)
15. Socket head screw (4 used per cover)
16. Washer
17. Jam nut
18. Seal washer
19. Plug
20. O--ring
21. Cradle
22. Bushing
23. Screw
24. Valve plate
25. Bearing
26. Reverse relief valve
27. O--ring
28. O--ring
34. Flat washer (4 used)
35. Manual servo control assembly
36. Cap screw (4 used)
37. Control orifice (.036)
38. Backplate
39. Roll pin
40. Housing gasket
41. Rotating kit
42. Camplate
43. Servo piston follower
44. Cap screw (2 used)
45. Bushing dowel (2 used)
46. Socket head screw (6 used)
47. Control arm
29. Bypass valve
30. Forward relief valve
31. Cover plate
32. Housing gasket
48. Hex nut
49. Lock washer
33. Control orifice (.028) (2 used)
NOTE: For service of the piston (traction) pump, see
the Eaton Model 72400 Servo Controlled Piston Pump
Repair Information at the end of this chapter.
Hydraulic System
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Reelmaster 7000
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4WD/2WD and Filtration/Charge Control Manifolds
3
9
2
1
4
5
6
11
10
RIGHT
7
FRONT
8
Figure 59
1. Filtration/charge control manifold
2. Hydraulic oil filter
3. 4WD/2WD control manifold
5. Flange head screw (3 used)
6. Flange nut (2 used)
7. Cap screw (2 used)
9. Flange head screw (2 used)
10. Flat washer (2 used)
11. Flange head screw (2 used)
4. Manifold bracket
8. Lift circuit junction manifold
Hydraulic System
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Removal (Fig. 59)
4
75 ft--lb
(101 N--m)
25 ft--lb
(34 N--m)
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.
9
8
2
6
7
5
5
10
1. Read the General Precautions for Removing and
Installing Hydraulic System Components at the begin-
ning of the Service and Repairs section of this chapter.
6
50 ft--lb
(68 N--m)
11
2
2. To prevent contamination of hydraulic system during
manifold removal, thoroughly clean exterior of manifold.
12
4
3. If 4WD/2WD control manifold is being removed, la-
bel wire harness electrical connectors that attach to
manifold components. Disconnect harness electrical
connectors from the solenoid valve coil and electrical
sensors (pressure and temperature).
15
4
3
2
13
1
20 ft--lb
(27 N--m)
14
4. Disconnect hydraulic lines from manifold being re-
moved and put caps or plugs on open hydraulic lines
and fittings. Label disconnected hydraulic lines for prop-
er assembly.
Figure 60
1. 4WD/2WD manifold
2. O--ring
3. 45 fitting
9. Check fitting
10. O--ring
o
11. O--ring
4. O--ring
5. 90 fitting
6. Straight fitting
7. O--ring
12. Straight fitting
13. O--ring
14. Test fitting
15. Dust cap
5. Remove hydraulic manifold from the frame using
Figure 59 as guide.
o
8. O--ring
6. If hydraulic fittings are to be removed from control
manifold, mark fittingorientation toallow correctassem-
bly (Figure 60 or 61). Remove fittings from manifold and
discard O--rings.
75 ft--lb
(101 N--m)
50 ft--lb
(68 N--m)
Installation (Fig. 59)
6
13
75 ft--lb
(101 N--m)
1. If fittings were removed from control manifold, lubri-
cate and place new O--rings onto fittings. Install fittings
into manifold ports using marks made during the remov-
al process to properly orientate fittings. Tighten fittings
(see Hydraulic Fitting Installation in the General Infor-
mation section of this chapter). Refer to Figure 60 or 61
for fitting installation torque.
5
14
2
2
2
4
3
1
2. Install hydraulic manifold to the frame using Figure
59 as guide.
10
5
6
3. Remove caps and plugs from fittings and hoses.
Properly connect hydraulic lines to manifold (see Hy-
draulic Hose and Tube Installation in the General Infor-
mation section of this chapter).
6
9
11
7
5
25 ft--lb
(34 N--m)
8
12
4. If4WD/2WDcontrol manifoldwas removed, connect
wire harness electrical connectors to the solenoid valve
coil and electrical sensors.
Figure 61
1. Filtration manifold
2. O--ring
3. 90 fitting
8. O--ring
9. O--ring
10. Straight fitting
o
4. O--ring
5. Straight fitting (3 used)
6. O--ring
7. Straight fitting
11. O--ring
12. O--ring
13. Barb fitting
14. O--ring
5. Check oil level in hydraulic reservoir and add correct
oil if necessary.
6. Follow Hydraulic System Start--up procedures (see
Hydraulic System Start--up in this section).
Reelmaster 7000
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4WD/2WD Control Manifold Service
50 ft--lb
(68 N--m)
20 ft--lb
6
(27 N--m)
7
25 ft--lb
(34 N--m)
25 ft--lb
(34 N--m)
14
20 to 26 ft--lb
1
(27 to 35 N--m)
10
UP
15
5
8
5
3
20 ft--lb
35 ft--lb
20 ft--lb
(27 N--m)
(27 N--m)
(47 N--m)
25 ft--lb
(34 N--m)
50 ft--lb
(68 N--m)
7
50 ft--lb
(68 N--m)
6
UP
11
9
1
4
12
13
20 ft--lb
(27 N--m)
2
60 in--lb
(6.8 N--m)
Figure 62
1. Manifold body
2. Nut
3. Orifice (0.050)
6. Zero leak plug (#6) (2 used)
7. Zero leak plug (#8) (4 used)
8. Check valve (CV)
11. Relief valve (RV)
12. Solenoid valve (SV)
13. Solenoid coil
4. Orifice disc (0.030)
5. Zero leak plug (#4) (4 used)
9. Pilot directional valve (PD1 & PD2)
10. Pressure reducing valve (PR)
14. Zero leak plug (#4)
15. Temperature sensor (TS)
Hydraulic System
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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.
IMPORTANT: A flow control orifice (item 3) is lo-
cated beneath the plug in 4WD/2WD control man-
ifold ports OR1 and OR2. If an orifice is removed
from these manifold ports, make sure to label its
position for assembly purposes. When installing
the orifice in the manifold, make sure that the orifice
is properly tightened in the 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 vibra-
tion induced plug loosening. The zero leak plugs also
have an O--ring as a secondary seal. Ifzero leak plug re-
moval is necessary, lightly rap the plug head using a pin
punch and hammer before using an allen wrench to re-
move the plug: the impact will allow plug removal with
less chance of damage to the head of the plug.
IMPORTANT: An orifice disc (item 4) is located be-
neaththe4WD/2WDcontrolmanifoldsolenoidvalve
(SV). If this valve is removed from the manifold,
make sure to remove orifice and label its position
for assembly purposes. When installing the orifice
in the manifold, make sure that the orifice is flat in
the base of the port.
For cartridge valve service procedures, see Control
Manifold Cartridge Valve Service in this section. Refer
to Figure 62 for 4WD/2WD Control Manifold cartridge
valve and plug installation torque.
Reelmaster 7000
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Filtration/Charge Control Manifold Service
25 ft--lb
(34 N--m)
6
35 ft--lb
UP
2
(47 N--m)
1
UP
50 ft--lb
4
(68 N--m)
25 ft--lb
(34 N--m)
3
50 ft--lb
(68 N--m)
3
5
25 ft--lb
(34 N--m)
2
35 ft--lb
(47 N--m)
3
25 ft--lb
2
(34 N--m)
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)
5. Check valve (filter bypass)
6. Check valve (charge pressure)
NOTE: The ports on the manifold are marked for easy
identification of components (e.g. P2 is the gear pump
connection port and P1 is the connection from the oil
cooler).SeeHydraulicSchematicinChapter9 -- Foldout
Drawings to identify the function of the hydraulic lines
and cartridge valves at each port.
For cartridge valve service procedures, see Control
Manifold Cartridge Valve Service in this section. Refer
to Figure 63 for Filtration/Charge Control Manifold car-
tridge valve and plug installation torque.
NOTE: The control manifold uses several zero leak
plugs. These plugs have a tapered sealing surface on
theplugheadthatisdesigned toresistvibrationinduced
plugloosening. Thezeroleakplugsalsohave anO--ring
as a secondary seal. If zero leak plug removal is neces-
sary, lightly rap the plug head using a pin punch and
hammer before using an allen wrench to remove the
plug:the impactwill allow plug removal with less chance
of damage to the head of the plug.
Hydraulic System
Page 4 -- 86
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Control Manifold Cartridge Valve Service
1. Make sure the control manifold is clean before re-
moving the cartridge valve from the control manifold.
6. Clean cartridge valve using clean mineral spirits.
Submerge valve in clean mineral spirits to flush out con-
tamination. Particlesasfineastalcumpowdercanaffect
the operation of high pressure hydraulic valves. If car-
tridgedesignallows, useawoodorplasticprobetopush
the internal spool in and out 20 to 30 times to flush out
contamination. Be extremely careful not to damage car-
tridge. Use compressed air for cleaning.
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 remov-
ing cartridge valve from manifold, make sure that
deep well socket fully engages the valve base.
7. Install the cartridge valve into the manifold:
A. Lubricate new seal kit components with clean hy-
draulic oil and install on valve. The O--rings, sealing
ringsandbackupringsmustbearrangedproperlyon
the cartridge valve for proper operation and sealing.
3. Remove cartridge valve from manifold using a deep
socket wrench. Note correct location for O--rings, seal-
ing rings and backup rings. Remove seal kit from car-
tridge valve and discard removed seals.
B. Dip assembled cartridge into clean hydraulic oil.
4. Visually inspect the port in the manifold for damage
to the sealing surfaces, damaged threads and contami-
nation.
IMPORTANT: Use care when handling the valve
cartridge. Slight bending or distortion of the
stem tube can cause binding and malfunction.
When installing cartridge valve into manifold,
make sure that deep well socket fully engages
the valve base.
5. Visually inspect cartridge valve for damaged sealing
surfaces and contamination.
A. Contamination may cause valves to stick or hang
up.Contaminationcanbecomelodgedinsmallvalve
orifices or seal areas causing malfunction.
C. Thread cartridge valve carefully into manifold
port by hand until the top O--ring is met. The valve
should go into manifold port easily without binding.
B. If valve sealing surfaces appear pitted or dam-
aged, the hydraulic system may be overheating or
there may be water in the system.
D. Torque cartridge valve using a deep socket
wrench to value identified in control manifold illustra-
tion.
8. If cartridge valve is solenoid operated, carefully
install solenoid coil to the cartridge valve. Secure coil to
valve with nut and torque nut to 60 in--lb (6.8 N--m).
CAUTION
Use eye protection such as goggles when using
compressed air.
9. If problems still exist after assembly, remove valve
and clean again or replace valve.
Reelmaster 7000
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Rear Axle Motor
Arrows on side of
motor case point up
5
6
7
7
8
4
5
9
10
1
2
3
RIGHT
FRONT
Figure 64
o
1. Axle motor
2. O--ring
3. Pinion gear
5. O--ring
8. 90 hydraulic fitting
9. Cap screw (2 used)
10. Flat washer (2 used)
6. Hydraulic fitting
7. O--ring
4. External snap ring
Hydraulic System
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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 pro-
cess to properly orientate fittings. Tighten fittings (see
Hydraulic Fitting Installation in the General Information
section of this chapter).
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the begin-
ning of the Service and Repairs section of this chapter.
2. If removed, install pinion gear to axle motor.
3. To prevent contamination of hydraulic system during
axle motor removal, thoroughly clean exterior of motor.
3. Install O--ring onto motor. Position motor to rear axle
assembly making sure that arrows on the side of motor
case point upward. Align gear teeth and slide motor into
place.
4. Disconnect hydraulic lines from motor. Put caps or
plugs on lines and fittings to prevent contamination. La-
bel the hydraulic hoses to show their correct position on
the axle motor for assembly purposes.
4. Secure motor to axle with cap screws and flat wash-
ers.
IMPORTANT: Support axle motor to prevent motor
from falling during removal.
5. Remove plugs from lines and fittings. Attach hydrau-
lic lines to axle motor (see Hydraulic Hose and Tube
Installation in the General Information section of this
chapter).
5. Remove motor using Figure 64 as a guide.
6. If hydraulic fittings are to be removed from axle mo-
tor, mark fitting orientation to allow correct assembly.
Remove fittings from motor and discard O--rings.
6. Fill hydraulic reservoir with hydraulic fluid as re-
quired.
7. Follow Hydraulic System Start--up procedures (see
Hydraulic System Start--up in this section).
8. After assembly is completed, verify that hydraulic
hoses and fittings do not contact anything.
Reelmaster 7000
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Front Wheel Motors
75 to 85 ft--lb
(102 to 115 N--m)
1
2
20
3
14
10
15
22
23
18
16
14
15
10
24
25
6
19
17
18
19
10
13
16
9
10
9
12
11
8
5
75 to 85 ft--lb
(102 to 115 N--m)
7
21
4
Arrows on side of
motor case point up
75 to 85 ft--lb
(102 to 115 N--m)
RIGHT
85 to 100 ft--lb
(116 to 135 N--m)
FRONT
Figure 65
1. Flange head screw (6 per planetary)
2. Splined brake shaft
3. Planetary assembly
4. Wheel assembly
5. Lug nut (8 per wheel)
6. Retaining ring
10. O--ring
18. O--ring
19. O--ring
20. RH brake assembly
11. Piston wheel motor
12. Flat washer (2 per motor)
13. Cap screw (2 per motor)
14. O--ring
21. Gasket
o
22. 45 hydraulic fitting
o
15. 90 hydraulic fitting
23. O--ring
7. LH brake assembly
8. Flange head screw (4 per brake)
9. Plug
16. O--ring
17. 90 hydraulic elbow
24. Straight hydraulic fitting
25. O--ring
o
Hydraulic System
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Removal (Fig. 65)
2. Positionwheelmotortobrakeassemblymakingsure
that arrows on the side of motor case point upward.
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.
3. Align splines on motor shaft and splined brake shaft.
Slide motor into brake assembly.
2. Raise front of machine and support with jackstands.
4. Secure motor to brake assembly with cap screws
andflatwashers. Tightencapscrewsfrom75to85ft--lb
(102 to 115 N--m).
3. Read the General Precautions for Removing and
Installing Hydraulic System Components at the begin-
ning of the Service and Repairs section of this chapter.
5. Remove plugs from lines and fittings. Attach hydrau-
lic lines and tubes to wheel motor (see Hydraulic Hose
and Tube Installation in the General Information section
of this chapter).
4. To prevent contamination of hydraulic system during
wheel motor removal, thoroughly clean exterior of mo-
tor.
6. Lower machine to ground.
5. Disconnect hydraulic hoses and tubes from wheel
motor. Put caps or plugs on hoses and fittings to prevent
contamination. Label the hydraulic lines to show their
correct position on the wheel motor for assembly pur-
poses.
7. Check oil level in hydraulic reservoir and add correct
oil if necessary.
8. Follow Hydraulic System Start--up procedures (see
Hydraulic System Start--up in this section).
IMPORTANT: Support wheel motor to prevent mo-
tor from falling during removal.
6. Remove wheel motor using Figure 65 as a guide.
7. Ifhydraulicfittingsaretoberemovedfromwheelmo-
tor, mark fitting orientation to allow correct assembly.
Remove fittings from motor and discard O--rings.
Installation (Fig. 65)
IMPORTANT: If fittings were removed from wheel
motor backplate, make sure that straight hydraulic
fittings (item 24) are installed and properly tight-
ened first. Then, install and tighten angled fittings
(items 17 and 22). If angled fittings are installedfirst,
straight fittings may contact angled fittings before
the straight fitting is properly tightened resulting in
hydraulic leakage.
1. If fittings were removed from wheel motor, lubricate
and place new O--rings onto fittings. Install fittings into
motor ports using marks made during the removal pro-
cess to properly orientate fittings. Tighten fittings (see
Hydraulic Fitting Installation in the General Information
section of this chapter).
Reelmaster 7000
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Rear Axle and Front Wheel Motor Service
15 to 18 ft--lb
(20 to 24 N--m)
FRONT WHEEL MOTOR SHOWN
1
7
2
9
10
13
10
9
11
18
8
6
19
20
14
15
16
12
4
5
3
17
Figure 66
1. Drive shaft
2. Backplate
3. Housing assembly
4. Rotating assembly
5. Cam plate insert
6. Retaining ring
7. Cap screw
8. Shaft seal (front motor only)
9. Retaining ring
10. Thrust race
11. O--ring
12. Valve plate
13. Thrust bearing
14. Roll pin
15. Roll pin
16. Bearing
17. Bearing
18. Washer
19. Plug
20. O--ring
NOTE: Thefrontwheelmotors(showninFigure66)are
identical. The rear axlemotor issimilar tothe frontwheel
motors. Service ofthe frontand rear motors requires the
same procedure.
NOTE: For service of the wheel motors, see the Eaton
Model 74318 and 74348 Piston Motors: Fixed Displace-
ment, Valve Plate Design Repair Information at the end
of this chapter.
NOTE: The rear axle motor does not have a shaft seal
(item 8). The case drain from the rear axle motor pro-
vides lubrication for the input gear case of the rear axle.
Hydraulic System
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Cutting Reel Motor
The hydraulic reel motors used on all cutting units are
the same.
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.
Removal
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.
Slide motor shaft into reel insert.
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 begin-
ning of the Service and Repairs section of this chapter.
6. Rotate the motor counter--clockwise until the motor
flanges are encircling the cap screws. Tighten two (2)
cap screws to secure reel motor to cutting unit.
3. To prevent contamination of hydraulic system during
reel motor removal, thoroughly clean exterior of motor.
7. Remove caps or plugs from hydraulic fittings and
hoses. Connect hydraulic hoses to reel motor (see Hy-
draulic Hose and Tube Installation in the General Infor-
mation section of this chapter).
4. Disconnect hydraulic hoses from reel motor. Put
caps or plugs on fittings and hoses to prevent contami-
nation of hydraulic system. Label hydraulic hoses for
proper assembly.
8. After assembly is completed, verify that hydraulic
hosesandfittingsarenotcontactedbyanymovingcom-
ponents.
5. Loosen two (2) cap screws that secure the hydraulic
reel motor to the cutting unit side plate. Rotate motor
clockwise and remove motor from cutting unit.
9. Check oil level in hydraulic reservoir and add correct
oil if necessary.
6. Inspectreelinsertsplinesfor wear. Replace ifneces-
sary (see Reel Removal and Installation in the Service
and Repairs section of Chapter 7 -- DPA Cutting Units).
10.Follow Hydraulic System Start--up procedures (see
Hydraulic System Start--up in this section).
7. Place protectiveplastic cap(see SpecialTools inthis
chapter) into the hole in the cutting unit side plate to pre-
vent debris entry into reel bearing area.
8. If hydraulic fittings are to be removed from reel mo-
tor, mark fitting orientation to allow correct assembly.
Remove fittings from motor and discard O--rings.
Installation
1. If fittings were removed from reel motor, lubricate
and place new O--rings onto fittings. Install fittings into
motor ports using marks made during the removal pro-
cess to properly orientate fittings. Tighten fittings (see
Hydraulic Fitting Installation in the General Information
section of this chapter).
2
1
Figure 67
2. Remove cover from cutting unit opening.
1. Cap screw
2. Hydraulic reel motor
3. Coat spline shaft of the reel motor with No. 2 multi-
purpose lithium base grease.
Reelmaster 7000
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Cutting Reel Motor Service
18
33 ft--lb
(45 N--m)
17
19 ft--lb
(25 N--m)
14
16
13
7
6
11
9
6
7
14
3
2
15
19 ft--lb
(25 N--m)
12
10
9
8
5
4
1
Figure 68
1. Dust seal
7. Back--up gasket
8. Front wear plate
9. Dowel pin
13. O--ring
14. Relief valve
15. Body
2. Retaining ring
3. Flange washer
4. Shaft seal
10. Idler gear
16. Washer (4 used)
5. Front flange
6. Pressure seal
11. Drive shaft
12. Rear wear plate
17. Lock washer (4 used)
18. Cap screw (4 used)
Disassembly (Fig. 68)
MARKER LINE
1. Plug motor ports and clean the outside of the motor
thoroughly. After cleaning, remove plugs and drain any
oil out of the motor.
2. Use a marker to make a diagonal line across the
front flange and body for assembly purposes (Fig. 69).
IMPORTANT: Prevent damage when clamping the
reelmotorintoavise;clamponthefrontflangeonly.
Also, use a vise with soft jaws.
3. Clamp front flange of motor in a vise with soft jaws
with the shaft end down.
Figure 69
Hydraulic System
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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. Bearingareasshouldnothaveexcessive wearor
scoring.
6. Carefully remove body. Lift body straight up to re-
move. 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. Face of wear plates that are in contact with gears
should be free of wear, roughness or scoring.
C. Thickness of wear plates should be equal.
5. Inspect front flange and rear cover for damage or
wear.
IMPORTANT: Note position of the open and closed
side of the wear plates before removing. Also, iden-
tify wear plates (front and rear) with a marker for
proper assembly.
2
3
4
1
7. Carefully remove rear wear plate, idler gear, drive
shaft and front wear plate from the front flange.
5
8. Remove and discard back--up gaskets and pressure
seals from wear plates.
9. Turn front flange over, with seal side up.
IMPORTANT: Make sure to not damage the front
flange counter bore when removing the seals from
the front flange.
10.Carefully remove dust seal, retaining ring, flange
washer and shaft seal from the front flange (Fig. 70).
Discard seals.
Inspection
1. Remove any nicks and burrs from all parts with
emery cloth.
Figure 70
1. Dust seal
2. Retaining ring
3. Flange washer
4. Shaft seal
5. Drive shaft
CAUTION
3
Use eye protection such as goggles when using
compressed air.
2
2. Clean all parts with solvent. Dry all parts with com-
pressed air.
3. Inspect drive gears and idler gears for the following
(Fig. 71):
1
A. Gear shafts should be free of rough surfaces and
excessive wear at bushing points and sealing areas.
Scoring, rough surfaces or wear on gear shafts indi-
cates need for replacement.
4
Figure 71
B. Gear teeth should be free of excessive scoring
and wear. Any broken or nicked gear teeth must be
replaced.
1. Gear shaft spline
2. Gear shaft
3. Gear teeth
4. Gear face edge
C. Inspect gear face edge for sharpness. Sharp
edges of gears will mill into wear plates and, thus,
must be replaced.
Reelmaster 7000
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Assembly (Fig. 68)
7. Lubricate the idler gear shaft with clean hydraulic oil.
Install idler gear shaft into the remaining position in the
front wear plate. Apply a light coating of clean hydraulic
oil to gear faces.
NOTE: When assembling the motor, check the marker
line on each part to make sure the parts are properly
aligned during assembly.
8. Install rear wear plate with pressure seal side up and
open side of the pressure seal pointing to the inlet side
of the motor.
1. Lubricate O--rings, pressure seals, back--up gaskets
and wear plate grooves with a thin coat of petroleum jel-
ly. Lubricate all other internal parts freely with clean hy-
draulic oil.
9. Apply a light coating of petroleum jelly to new O--ring
and O--ring groove in the body. Install new O--ring to the
body.
2. Install new seals into front flange (Fig. 70):
A. Press shaft seal into front flange until it reaches
the bottom of the bore.
10.Install locating dowel pins in body. Align marker line
on the body and front flange.
B. Install flange washer into front flange and then
install retaining ring into the groove of the front
flange.
IMPORTANT: Do not dislodge seals during installa-
tion.
11.Gently slide the body onto the assembly. Firm hand
pressure should be sufficient to engage the dowel pins.
C. Install new dust seal into front flange.
3. Place front flange, seal side down, on a flat surface.
12.Installthefour(4)capscrewswithwashersandhand
tighten.
4. Install the pressure seals, flat side outward, into the
grooves in the wear plates. Follow by carefully placing
the backup gaskets, flat side outward, between the
pressure seals and the grooves in the wear plate.
IMPORTANT: Prevent damage when clamping the
reel motor in a vise; clamp on the front flange only.
Also, use a vise with soft jaws.
5. Applyalightcoatingofpetroleumjellytotheexposed
side of the front flange.
13.Place front flange of the motor into a vise with soft
jaws and alternately torque the cap screws 33 ft--lb (45
N--m).
6. Lubricate the drive shaft with clean hydraulic oil. In-
sert the drive end of the drive shaft through the wear
platewiththepressuresealsidedownandtheopenside
of the pressure seal pointing to the inlet side of the mo-
tor. Carefully install shaft into front flange.
14.Remove motor from vise.
15.Placeasmallamountofcleanhydraulicoilintheinlet
ofthemotorandrotatethedriveshaftawayfromtheinlet
one revolution. If any binding is noted, disassemble the
motor and check for assembly problems.
Hydraulic System
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Mow Control Manifold
2
RIGHT
6
FRONT
3
1
5
4
Figure 72
1. Mow control manifold
2. Flange head screw (4 used)
3. Filter head
4. Hydraulic oil filter
5. Lift control manifold
6. Fan control manifold
Hydraulic System
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Removal (Fig. 72)
4. Connect wire harness electrical connectors to the
solenoid valve coils and backlap switches.
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).
5. Lower and secure hood.
6. Check oil level in hydraulic reservoir and add correct
oil if necessary.
7. Follow Hydraulic System Start--up procedures (see
Hydraulic System Start--up in this section).
1. Park machine on a level surface, lower cutting units,
stop engine, apply parking brake and remove key from
the ignition switch.
75 ft--lb
(101 N--m)
20 ft--lb
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the begin-
ning of the Service and Repairs section of this chapter.
8
(27 N--m)
11
3. Unlatch and raise hood.
4. To prevent contamination of hydraulic system during
manifold removal, thoroughly clean exterior of manifold.
1
7
14
13
5. Label wire harness electrical connectors that attach
to manifold solenoid coils. Disconnect connectors from
the solenoid coils and backlap switches.
17
10
7
5
6. Disconnect hydraulic lines from manifold and put
caps or plugs on open hydraulic lines and fittings. Label
disconnected hydraulic lines for proper assembly.
9
8
15
7. Remove hydraulic manifold from the frame using
Figure 72 as guide.
6
2
8. If hydraulic fittings are to be removed from control
manifold, mark fittingorientation toallow correctassem-
bly (Fig. 73). Remove fittings from manifold and discard
O--rings.
14
17
16
3
12
Installation (Fig. 72)
50 ft--lb
(68 N--m)
75 ft--lb
(101 N--m)
1. If fittings were removed from control manifold, lubri-
cate and place new O--rings onto fittings. Install fittings
into manifold ports using marks made during the remov-
al process to properly orientate fittings. Tighten fittings
(see Hydraulic Fitting Installation in the General Infor-
mation section of this chapter). Refer to Figure 73 for fit-
ting installation torque.
4
Figure 73
1. Mow manifold
2. O--ring
3. Straight fitting (8 used)
4. O--ring
5. O--ring
10. O--ring
11. Test fitting
12. 45 fitting
o
13. O--ring
14. Straight fitting (4 used)
6. Straight fitting
7. O--ring
8. Dust cover
9. Test fitting
15. O--ring
16. 90 fitting
17. O--ring
2. Install hydraulic manifold to the frame using Figure
72 as guide.
o
3. Remove caps and plugs from fittings and hoses.
Properly connect hydraulic lines to manifold (see Hy-
draulic Hose and Tube Installation in the General Infor-
mation section of this chapter).
Reelmaster 7000
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Mow Control Manifold Service
25 ft--lb
(34 N--m)
12
15
18
17
16
15
5
12
15
25 ft--lb
(34 N--m)
16
15
18
6
17
20 ft--lb
25 ft--lb
(34 N--m)
(27 N--m)
6
11
10
9
8
25 ft--lb
(34 N--m)
4
25 ft--lb
(34 N--m)
2
8
3
60 in--lb
(6.8 N--m)
14
UP
1
13
12
7
2
25 ft--lb
(34 N--m)
3
Figure 74
1. Manifold body
2. Proportional valve (SP1 & SP2)
3. Solenoid coil (2 used)
7. Nut
8. Backlap switch (2 used)
9. O--ring
13. Backup ring
14. O--ring
15. O--ring
4. Relief valve (RV1 & RV2)
5. Pressure compensator (LC1 & LC2)
10. Dowel
11. Ball
16. Backup ring
17. Backlap spool (2 used)
6. Check valve (CV1 & CV2)
12. Retaining ring (2 used per spool)
18. Spool handle
NOTE: The ports on the manifold are marked for easy
identification of components (e.g. P1 is a gear pump
connection port and PRV1 is the location for a propor-
tional relief valve). See Hydraulic Schematic in Chapter
9 -- Foldout Drawings to identify the function of the hy-
draulic lines and cartridge valves at each port location.
Cartridge Valve Service
1. For cartridge valve service procedures, see Control
Manifold Cartridge Valve Service in this section. Refer
to Figure 74 for cartridge valve installation torque.
Hydraulic System
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Mow/Backlap Spool Service (Fig. 74)
Manifold Plugs (Fig. 75)
1. To remove backlap spool (item 17) from mow man-
ifold:
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 in-
duced plug loosening. The zero leak plugs also have an
O--ring as a secondary seal. If zero leak plug removal is
necessary, lightly rap the plug head using a pin punch
andhammerbeforeusinganallenwrenchtoremovethe
plug:the impactwill allow plug removal with less chance
of damage to the head of the plug.
A. Remove backlap switch (item 8) from mow man-
ifold before removing mow/backlap spool. Remove
dowel pin and ball from manifold port after switch is
removed. Remove and discard O--ring from switch.
B. Remove lower retaining ring from backlap spool.
Raise backlap spool to allow access to retaining ring
on upper end of spool. Remove upper retaining ring.
IMPORTANT: An orifice is located beneath the plug
in mow control manifold ports OR1 and OR2. If an
orifice is removed from these manifold ports, make
sure to label its position for assembly purposes.
When installing the orifice in the manifold, make
sure that the orifice is properly tightened in the port.
C. Push spool down until O--ring and back--up ring
are exposed on bottom of mow manifold. Remove
lower O--ring and back--up ring from spool.
D. Pull spool up and out of mow manifold. Remove
O--rings and back--up ring from spool.
1. RemoveplugsasneededusingFigure75asaguide.
Discard O--ring after plug removal.
E. Discard removed O--rings and back--up rings.
2. Lubricate and place new O--ring onto removed
plugs. Ifplug was removed from port OR1 or OR2, make
sure that orifice is correctly installed before threading
plug into manifold. Install plugs into manifold openings.
Torque #4 plugs to 20 ft--lb (27 N--m) and #6 plugs to 25
ft--lb (34 N--m).
2. Toinstallbacklapspool(item17)frommowmanifold:
A. Install O--rings and back--up ring to upper
grooves on backlap spool. Apply a light coating of
grease to O--rings.
B. Carefully push backlap spool down into mow
manifold port until lower O--ring and back--up ring
groove is exposed on bottom of manifold. Install low-
er O--ring and back--up ring to spool. Apply a light
coating of grease to O--ring.
20 ft--lb
(27 N--m)
2
25 ft--lb
(34 N--m)
3
2
2
C. Carefullyraisebacklapspooluntilupperretaining
ring groove on spool is exposed on top of manifold.
Install upper retaining ring.
2
3
2
D. Pushbacklapspooldownandinstalllowerretain-
ing ring to spool.
2
4
3
E. If handle was removed from spool, position spool
so handle location of spool is between stop pins in
manifold. Apply Loctite 603Retaining Compound(or
equivalent) to threads on handle and install handle
into spool.
5
2
2
4
3
3
F. Place ball and dowel pin in backlap switch man-
ifold port. Install new O--ring onto backlap switch.
Thread backlap switch into port and torque 20 ft--lb
(27 N--m).
2
1
2
20 ft--lb
(27 N--m)
Figure 75
1. Mow manifold
2. #4 zero leak plug
3. #6 zero leak plug
4. #4 zero leak plug
5. Orifice (.040)
Reelmaster 7000
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Steering Control Valve
1
RIGHT
4
3
2
FRONT
20 to 26 ft--lb
(28 to 35 N--m)
7
Antiseize
Lubricant
10
9
5
15
14
11
7 to 10 ft--lb
(10 to 13 N--m)
13
Antiseize
Lubricant
6
8
6
6
12
Figure 76
1. Steering wheel cover
2. Lock nut
3. Steering wheel
4. Flat washer
5. O--ring
6. Flange head screw (4 used)
7. Steering column
8. Steering control valve
9. Socket head screw (4 used)
10. Flange nut (4 used)
11. Tinnerman nut (4 used)
12. Column brace
13. Socket head screw (4 used)
14. O--ring
15. Straight fitting (5 used)
Removal (Fig. 76)
4. Slide rubber bellows up from bottom of steering col-
umn. Support steering column to prevent it from falling.
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.
5. Read the General Precautions for Removing and
Installing Hydraulic System Components at the begin-
ning of the Service and Repairs section of this chapter.
2. Remove fasteners that secure shroud to front of ma-
chine (Fig. 77). Remove shroud from machine to allow
access to steering control valve.
6. Thoroughly clean hydraulic connections prior to
loosening hydraulic lines.
3. Remove four (4) flange head screws that secure col-
umn brace (item 12) to frame platform. Remove brace
frommachinetoallowaccesstosteeringcolumnfasten-
ers.
7. Label all hydraulic connections for assembly pur-
poses. Note port designations on steering control valve
(Fig. 78).
Hydraulic System
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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.
Before opening hydraulic system, operate all hy-
draulic controls to relieve system pressure and
avoid injury from pressurized hydraulic oil. See
Relieving Hydraulic System Pressure in the Gen-
eral Information section of this chapter.
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.
8. Disconnect hydraulic lines from steering control
valve. Allow lines to drain into a suitable container.
11.Follow Hydraulic System Start--up procedures (see
Hydraulic System Start--up in this section).
9. Put caps or plugs on disconnected lines and fittings
to prevent contamination.
1
2
10.Loosen and remove four (4) sockethead screws and
flange nuts that secure steering column to machine.
4
11.Remove steering column assembly with steering
control valve attached from machine.
3
4
12.Loosen and remove four (4) sockethead screws that
secure steering control valve to steering column.
13.Remove steering control valve from steering col-
umn.
5
6
14.If necessary, remove fittings and O--rings from steer-
ing control valve. Discard all removed O--rings.
Figure 77
1. Roller support
2. Screw (2 used)
3. Carriage screw (2 used)
4. Headlight assembly
5. Flange nut (2 used)
6. Platform shroud
Installation (Fig. 76)
1. If fittings were removed, lubricate new O--rings with
clean hydraulic oil and install fittings to steering control
valve (see Hydraulic Fitting Installation in the General
Information section of this chapter).
T
2. Apply antiseize lubricant to splines of steering con-
trol valve shaft.
L
P
R
3. Slide steering control valve shaft into steering col-
umn universal joint. Position control valve with ports to-
ward front of machine. Secure steering control valve to
steering column with four (4) socket head screws.
Torquescrewsinacriss--crosspatternfrom7to10ft--lb
(10 to 13 N--m).
E
4. Position steering column assembly to machine. Se-
cure steering column in place with four (4) socket head
screws and flange nuts.
Figure 78
5. Remove caps and plugs from disconnected lines
and fittings.
6. Lubricate new O--rings and connect hydraulic lines
to fittings on steering control valve (see Hydraulic Hose
and Tube Installation in the General Information section
of this chapter).
Reelmaster 7000
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Steering Control Valve Service
2
3
1
8
4
5
6
5
9
7
10
11
22
12
13
14
13
15
13
16
17
18
20 to 24 ft--lb
(27 to 33 N--m)
19
20
21
Figure 79
1. Relief valve assembly
2. Dust seal ring
3. Steering valve housing
4. Shaft seal
5. Thrust washer
6. Bearing race
7. Ring
9. Cross pin
10. Sleeve
11. Spool
12. Cardan shaft
13. O--ring
14. Distributor plate
15. Outer gearwheel
16. Inner gearwheel
17. End cover
18. Tube (2 used)
19. Washer (5 used)
20. Pin bolt
21. Cap screw (4 used)
22. Ball
8. Spring set
NOTE: For repair of the steering control valve, see the
Sauer--Danfoss Steering Unit Type OSPM Service
Manual at the end of this chapter.
Hydraulic System
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Steering Cylinder
7
9
15
6
7
4
9
8
16
5
2
4
1
3
10
12
14
11
13
14
RIGHT
100 to 125 ft--lb
(136 to 169 N--m)
FRONT
Figure 80
o
1. Steering cylinder
2. Ball joint
3. Ball joint
7. 90 hydraulic fitting
8. O--ring
12. Axle washer
13. Slotted hex nut
14. Cotter pin
9. O--ring
4. Retaining ring
5. Grease fitting
6. Grease fitting
10. Drive axle assembly
11. Ball joint spacer
15. Hydraulic hose
16. Hydraulic hose
Hydraulic System
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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, lubri-
cate and place new O--rings onto fittings. Install fittings
intocylinderportsusingmarksmadeduring theremoval
process to properly orientate fittings. Tighten fittings
(see Hydraulic Fitting Installation in the General Infor-
mation section of this chapter).
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the begin-
ning of the Service and Repairs section of this chapter.
2. If removed, press ball joints into lift cylinder and se-
cure with retaining ring.
3. To prevent contamination of hydraulic system during
steering cylinder removal, thoroughly clean exterior of
steering cylinder.
3. Slide ram end ball joint through hole on steering arm.
Secure with axle washer and slotted hex nut. Slide fixed
end of cylinder through hole on axle. Install spacer onto
ball joint and secure with slotted hex nut. Torque slotted
hex nuts from 100 to 125 ft--lbs (136 to 169 N--m) prior
to inserting cotter pins.
4. Remove hydraulic hoses from steering cylinder. La-
bel the hydraulic hoses to show their correct position on
the steering cylinder for assembly purposes.
5. Remove cotter pins, slotted hex nuts, axle washer
and ball joint spacer from the threaded ends of ball
joints.Removesteeringcylinderwithballjointsfromma-
chine.
4. Install hydraulic hoses to steering cylinder (see Hy-
draulic Hose and Tube Installation in the General Infor-
mation section of this chapter).
6. If necessary, remove ball joints from steering cylin-
der.
5. Fill reservoir with hydraulic fluid as required.
6. Follow Hydraulic System Start--up procedures (see
Hydraulic System Start--up in this section).
7. If hydraulic fittings are to be removed from steering
cylinder, mark fitting orientation to allow correct assem-
bly. Remove fittings from cylinder and discard O--rings.
7. After assembly is completed, operate steering cylin-
dertoverifythathydraulichosesandfittingsarenotcon-
tacted by anything.
Reelmaster 7000
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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
6
8
13
2
14
4
11
9
10 12
15
7
3
5
Figure 81
1. Barrel
6. O--ring
7. Piston
8. Buffer seal
9. O--ring
10. Back--up ring
11. Head
2. Lock nut
3. Wear band
4. Square ring
5. Piston seal
12. Retaining ring
13. Head seal
14. Wiper
15. Rod assembly
Hydraulic System
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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. Coat new seal kit components with clean hydraulic
oil.
IMPORTANT: Prevent damage when clamping the
cylinder in a vise; clamp on the clevis only. Do not
close vise enough to distort the barrel.
A. Install new seals, O--ring and wear band to the
piston.
2. Mount steering cylinder securely in a vise by clamp-
ing on the clevis end of the barrel. Use of a vise with soft
jaws is recommended.
B. Install new seals, O--ring and back--up ring to the
head.
IMPORTANT: Do not clamp vise jaws against the
rod surface. Protect rod surface before mounting in
a vise.
3. Loosen head from barrel:
A. Use a spanner wrench to rotate head clockwise
until the edge of the retaining ring appears in the bar-
rel opening.
3. Mount rod securely in a vise by clamping on the cle-
vis of the rod.
B. Insert a screwdriver under the beveled edge of
the retaining ring to start the retaining ring through
the opening.
A. Coat rod with clean hydraulic oil.
B. Carefully slide head and piston onto the rod.
C. Rotatetheheadcounter--clockwisetoremovere-
taining ring from barrel and head.
C. Clean threads on end of rod. Apply Loctite #271
(or equivalent) to rod threads.
4. Extract rod with head and piston by carefully twisting
and pulling on the rod.
D. Secure piston to rod with lock nut. Torque locknut
from 50 to 60 ft--lb (68 to 81 N--m).
IMPORTANT: Do not clamp vise jaws against the
rod surface. Protect rod surface before mounting in
a vise.
IMPORTANT: When installing the rod assembly into
the barrel, pay careful attention to the retaining ring
slot in the barrel to insure that the piston and head
seals do not lodge in the slot.
5. Mountshaftsecurelyinavisebyclampingonthecle-
vis of the rod. Remove lock nut and piston from the rod.
Slide head off the rod.
4. Coat all internal parts with a light coat of clean hy-
draulic oil. Slide piston, rod and head assembly into the
barrel being careful not to damage the seals.
6. For assembly purposes, note location and orienta-
tion of all seals and O--rings on piston and head. Re-
move and discard all seals and O--rings from the piston
and the head.
IMPORTANT: Prevent damage when clamping the
cylinder’s barrel into a vise; clamp on the clevis
only. Do not close vise enough to distort the barrel.
7. Wash cylinder parts in clean solvent. Dry parts with
compressed air. Do not wipe parts dry with paper towels
or cloth. Lint in a hydraulic system will cause damage.
5. Mount steering cylinder in a vise with soft jaws. Se-
cure head in barrel:
A. Align retaining ring hole in the head with the ac-
cess slot in the barrel.
8. Carefully inspect internal surface of barrel for dam-
age (deep scratches, out--of--round, etc.). Replace en-
tire cylinder if barrel is damaged. Inspect piston rod and
piston for evidence of excessive scoring, pitting or wear.
Replace any damaged parts.
B. Insert the retaining ring hook into the hole and ro-
tate head clockwise until the retaining ring is com-
pletely pulled into the barrel and the ring ends are
covered.
C. Apply silicone sealer to barrel access slot.
Reelmaster 7000
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Engine Cooling Fan Motor
2
3
RIGHT
4
1
5
27 to 33 ft--lb
(37 to 44 N--m)
FRONT
21
6
20
7
8
2
9
4
5
19
10
18
16
17
15
14
13
12
11
12 to 14 ft--lb
(17 to 18 N--m)
Figure 82
1. Hydraulic fan motor
2. O--ring
8. Washer
9. Hex nut
10. Engine
11. Cap screw (4 used)
12. Washer (4 used)
13. Fan
15. Hydraulic hose
16. O--ring
17. Hydraulic fitting
3. Bracket
o
4. 45 hydraulic fitting
18. O--ring
5. O--ring
6. Hydraulic hose
7. Fan hub
19. Hydraulic hose
20. Cap screw (2 used)
21. Flat washer (2 used)
14. Lock nut (2 used)
Removal (Fig. 82)
CAUTION
1. Park machine on a level surface, lower cutting units,
stop engine, apply parking brake and remove key from
the ignition switch.
The radiator and engine may be hot. To avoid
possible burns, allow the engine and cooling
systems to cool before removing fan motor.
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the begin-
ning of the Service and Repairs section of this chapter.
4. Remove air cleaner hose and upper radiator shroud
to allow access to hydraulic fan motor (Fig. 83).
3. Unlatch and raise hood.
Hydraulic System
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5. Removefour(4)capscrewsandwashersusedtose-
cure fan (item 13) to fan hub. Remove fan.
IMPORTANT: Make sure to not damage the radiator
or other machine components while installing the
fan motor and bracket assembly.
IMPORTANT: Make sure to not damage the radiator
or other machine components while loosening and
removing the fan motor and bracket assembly.
5. Carefullyposition fanmotor andbracketassemblyto
radiator and secure with six (6) cap screws and flange
nuts.
6. Remove cooling fan motor and bracket assembly.
6. Remove caps and plugs placed in hoses and fittings
during removal to prevent contamination. Connect hy-
draulic hoses to cooling fan motor (see Hydraulic Hose
and Tube Installation in the General Information section
of this chapter).
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 con-
tamination. Label hydraulic lines for proper assemb-
ly.
7. Position fan to fan hub and secure with four (4) cap
screws and washers.
C. Remove six (6) cap screws and flange nuts that
secure fan motor bracket to radiator.
8. Install upper radiator shroud and air cleaner hose
(Fig. 83). Makesurethatclearancebetween shroudand
cooling fan is at least 0.180” (4.6 mm) at all points.
D. Carefully remove fan motor and bracket assem-
bly from machine and place on suitable work sur-
face.
9. Lower and secure hood.
10.Check oil level in hydraulic reservoir and add correct
oil if necessary.
7. Removehexnut(item9)andwasher(item8)thatse-
cure fan hub to fan motor. Use suitable puller to carefully
remove fan hub from fan motor shaft. Locate and re-
trieve woodruff key.
11.Follow Hydraulic System Start--up procedures (see
Hydraulic System Start--up in this section).
8. Remove two (2) cap screws (item 20), flat washers
(item 21) and lock nuts (item 14) that secure fan motor
to fan motor bracket. Remove fan motor from bracket.
9. If hydraulic fittings are to be removed from fan motor,
mark fitting orientation to allow correct assembly. Re-
move fittings from motor and discard O--rings.
5
2
Installation (Fig. 82)
3
4
1. If fittings were removed from fan motor, lubricate and
place new O--rings onto fittings. Install fittings into port
openingsusingmarksmadeduringtheremovalprocess
to properly orientate fittings. Tighten fittings (see Hy-
draulic Fitting Installation in the General Information
section of this chapter).
1
2. Position fan motor to fan motor bracket and secure
with cap screws (item 20), flat washers (item 21) and
lock nuts (item 14).
7
6
Figure 83
3. Thoroughly clean tapered surfaces of fan motor
shaft and fan hub. Place woodruff key in slot in motor
shaft.
1. Radiator
5. Air cleaner hose
6. Screw
2. Upper radiator shroud
3. Screw (4 used)
4. Flange nut (4 used)
7. Flat washer
4. Position fan hub onto motor shaft and secure with
washer (item 8) and hex nut (item 9). Torque nut from 27
to 33 ft--lb (37 to 44 N--m).
Reelmaster 7000
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Engine Cooling Fan Motor Service
11
10
15
6
3
14
7
1
13
16
8
9
12
33 ft--lb
9
(45 N--m)
8
2
5
14
4
Figure 84
1. Flange washer
2. O--ring
3. Front flange
4. Dust seal
5. Retaining ring
6. Front wear plate
7. Shaft seal
12. Idler gear
8. Backup gasket
9. Pressure seal
10. Rear wear plate
11. Body
13. Cap screw (4 used)
14. Dowel (2 used)
15. Drive gear
16. Washer (4 used)
For disassembly, inspection and assembly procedures
of the cooling fan motor, see Reel Motor Service in this
section.
Hydraulic System
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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)
3. Filter head
4. Hydraulic oil filter
5. Lift control manifold
6. Mow control manifold
Hydraulic System
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Removal (Fig. 85)
2. Install hydraulic manifold to the frame using Figure
85 as guide.
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).
3. Remove caps and plugs from fittings and hoses.
Properly connect hydraulic lines to manifold (see Hy-
draulic Hose and Tube Installation in the General Infor-
mation section of this chapter).
1. Park machine on a level surface, lower cutting units,
stop engine, apply parking brake and remove key from
the ignition switch.
4. Connect wire harness electrical connectors to the
solenoid valves.
5. Lower and secure hood.
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the begin-
ning of the Service and Repairs section of this chapter.
6. Check oil level in hydraulic reservoir and add correct
oil if necessary.
7. Follow Hydraulic System Start--up procedures (see
Hydraulic System Start--up in this section).
3. Unlatch and raise hood.
4. To prevent contamination of hydraulic system during
fan control manifold removal, thoroughly clean exterior
of manifold.
2
3
UP
5. Label wire harness electrical connectors that attach
to manifold solenoid coils. Disconnect connectors from
the solenoid coils.
2
1
50 ft--lb
(68 N--m)
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
7. Remove hydraulic manifold from the frame using
Figure 85 as guide.
2
6
2
8. Ifhydraulicfittingsaretoberemovedfromfancontrol
manifold, mark fittingorientation toallow correctassem-
bly (Fig. 86). Remove fittings from manifold and discard
O--rings.
2
Installation (Fig. 85)
5
4
1. If fittings were removed from fan control manifold, lu-
bricate and place new O--rings onto fittings. Install fit-
tings into manifold 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). Refer to Figure 86
for fitting installation torque.
Figure 86
1. O--ring
5. Test fitting
6. O--ring
2. Straight fitting (7 used)
3. O--ring
7. Fan control manifold
4. Dust cap
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Fan Control Manifold Service
60 in--lb
(6.8 N--m)
60 in--lb
(6.8 N--m)
50 ft--lb
(68 N--m)
10
5
2
7
25 ft--lb
1
(34 N--m)
6
6
25 ft--lb
(34 N--m)
2
9
2
8
25 ft--lb
(34 N--m)
25 ft--lb
3
(34 N--m)
UP
4
1
20 ft--lb
(27 N--m)
20 ft--lb
(27 N--m)
UP
Figure 87
1. Manifold body
5. Flow divider cartridge (port FD)
6. Solenoid coil (2 used)
7. Nut
8. Solenoid valve (port S1)
9. Proportional relief cartridge (port TS)
10. Nut
2. Zero leak plug (#6) (3 used)
3. Zero leak plug (#4) (2 used)
4. Check valve (port CV)
NOTE: The ports on the fan control manifold are
marked for easy identification of components (e.g. ST is
the supply to the steering control valve and FD is the
location ofthe flow divider cartridge valve). See Hydrau-
licSchematicinChapter9 -- FoldoutDrawingstoidentify
the function of the hydraulic lines and cartridge valves
at each port location.
NOTE: The fan control manifold includes several zero
leak plugs. These plugs have a tapered sealing surface
on the plug head that is designed to resist vibration in-
duced plug loosening. The zero leak plugs also have an
O--ring as a secondary seal. If zero leak plug removal is
necessary, lightly rap the plug head using a punch and
hammer before using an allen wrench to remove the
plug:the impactwill allow plug removal with less chance
of damage to the socket head of the plug.
For cartridge valve service procedures, see Control
Manifold Cartridge Valve Service in this section. Refer
to Figure 87 for cartridge valve and plug installation
torque.
Hydraulic System
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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
6. Flange head screw (2 used)
7. Mow control manifold
Removal (Fig. 88)
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the begin-
ning of the Service and Repairs section of this chapter.
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
-- FoldoutDrawingstoidentifythefunctionofthehydrau-
lic lines and cartridge valves at each port).
3. Unlatch and raise hood.
4. To prevent contamination of hydraulic system during
manifold removal, thoroughly clean exterior of manifold.
1. Park machine on a level surface, lower cutting units,
stop engine, apply parking brake and remove key from
the ignition switch.
5. Label wire harness electrical connectors that attach
to manifold solenoid coils. Disconnect wire harness
electrical connectors from the solenoid valve coils.
IMPORTANT: To prevent unexpected cutting unit
lowering, make sure that cutting units are fully low-
ered before loosening hydraulic lines from lift man-
ifold.
Hydraulic System
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2. Install hydraulic manifold to the frame using Figure
88 as guide.
WARNING
3. Remove caps and plugs from fittings and hoses.
Properly connect hydraulic lines to manifold (see Hy-
draulic Hose and Tube Installation in the General Infor-
mation section of this chapter).
Make sure that cutting units are fully lowered be-
fore loosening hydraulic lines from lift manifold.
If cutting units are raised as hydraulic lines are
loosened, cutting units may drop unexpectedly.
4. Connect wire harness electrical connectors to the
solenoid valve coils.
6. Disconnect hydraulic lines from manifold and put
caps or plugs on open hydraulic lines and fittings. Label
disconnected hydraulic lines for proper assembly.
5. Lower and secure hood.
6. Check oil level in hydraulic reservoir and add correct
oil if necessary.
7. Remove hydraulic manifold from the frame using
Figure 88 as guide.
7. Follow Hydraulic System Start--up procedures (see
Hydraulic System Start--up in this section).
IMPORTANT: A flow control orifice is placed be-
neath hydraulic fittings in lift control manifold ports
C2, C3 and C4 (Fig. 89). If a fitting is removed from
theliftjunctionmanifoldandanorifice isin theman-
ifold port, make sure to remove orifice and label its
position for assembly purposes. Also note location
of groove in orifice for assembly purposes.
25 ft--lb
(34 N--m)
8
2
9
8. If hydraulic fittings are to be removed from lift control
manifold, mark fittingorientation toallow correctassem-
bly (Fig. 89). Remove fittings from manifold and discard
O--rings.
5
12
Installation (Fig. 88)
4
IMPORTANT: When installing orifice in manifold
port, make sure that orifice is flat in the base of the
manifold port. Manifold damage is possible if the
orifice is cocked in the cavity.
11
10
3
5
1
12
6
25 ft--lb
(34 N--m)
7
1. If fittings were removed from junction manifold, lubri-
cate and place new O--rings onto fittings. Install fittings
into manifold openings making sure that orifice is cor-
rectlyplacedbeforethreadingfittingintomanifold.Tight-
en fittings (see Hydraulic Fitting Installation in the
General Information section of this chapter). Refer to
Figure 89 for fitting installation torque.
Figure 89
1. Lift manifold
2. Dust cap
3. Test fitting
4. O--ring
5. O--ring
7. O--ring
8. Orifice (0.040) (port C3)
9. Orifice (0.055) (port C4)
10. Orifice (0.109) (port C2)
11. O--ring
6. Straight fitting (2 used)
12. Straight fitting (4 used)
Reelmaster 7000
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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. Manifold body
5. Solenoid valve (port S2)
9. Solenoid valve (port S3)
10. Relief valve (port RV1)
11. Nut
2. Relief valve (port RV2)
3. Solenoid valve (port S1)
4. Solenoid coil (5 used)
6. Solenoid valve (ports S4 and S5)
7. Coil spacer (2 used)
8. Nut
NOTE: The ports on the manifold are marked for easy
identification of components (e.g. P is the supply con-
nection port and RV1 is the location for the lift relief
valve). See Hydraulic Schematic in Chapter 9 -- Foldout
Drawings to identify the function of the hydraulic lines
and cartridge valves at each port location.
WARNING
If lift manifold is attached to machine, make sure
that cutting units are fully lowered before loos-
ening hydraulic lines or cartridge valves from lift
manifold. If cutting units are raised as compo-
nents are loosened in manifold, cutting units
may drop unexpectedly.
Hydraulic System
Page 4 -- 120
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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.
IMPORTANT: A flow control orifice is placed be-
neath the hydraulic fittings in lift control manifold
ports C2, C3 and C4. If any of these fittings are re-
moved from the manifold, make sure to remove ori-
fice and label its position for assembly purposes.
Also note location of groove in orifice for assembly
purposes. When installing the orifice in the man-
ifold, make sure that the orifice is flat in the base of
the port. Manifold damage is possible if the orifice
is cocked in the port.
Reelmaster 7000
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Lift Circuit Junction Manifold
3
9
2
1
4
5
6
11
10
RIGHT
7
8
FRONT
Figure 91
1. Filtration/charge control manifold
2. Hydraulic oil filter
3. 4WD/2WD control manifold
5. Flange head screw (3 used)
6. Flange nut (2 used)
7. Cap screw (2 used)
9. Flange head screw (2 used)
10. Flat washer (2 used)
11. Flange head screw (2 used)
4. Manifold bracket
8. Lift circuit junction manifold
Hydraulic System
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Removal (Fig. 91)
1. If fittings were removed from junction manifold, lubri-
cate and place new O--rings onto fittings. Install fittings
into manifold openings making sure that orifice is cor-
rectlyplacedbeforethreadingfittingintomanifold.Tight-
en fittings (see Hydraulic Fitting Installation in the
General Information section of this chapter). Refer to
Figure 92 for fitting installation torque.
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 Sche-
matic 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.
2. Install hydraulic manifold to the frame using Figure
91 as guide.
3. Remove caps and plugs from fittings and hoses.
Properly connect hydraulic lines to manifold (see Hy-
draulic Hose and Tube Installation in the General Infor-
mation section of this chapter).
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the begin-
ning of the Service and Repairs section of this chapter.
3. To prevent contamination of hydraulic system during
manifold removal, thoroughly clean exterior of manifold.
4. Check oil level in hydraulic reservoir and add correct
oil if necessary.
5. Follow Hydraulic System Start--up procedures (see
Hydraulic System Start--up in this section).
WARNING
75 ft--lb
(101 N--m)
5
Make sure that cutting units are fully lowered be-
fore loosening hydraulic lines from lift circuit
junction manifold. If cutting units are raised as
hydraulic lines are loosened, cutting units may
drop unexpectedly.
25 ft--lb
(34 N--m)
10
11
4. Disconnect hydraulic lines from manifold and put
caps or plugs on open hydraulic lines and fittings. Label
disconnected hydraulic lines for proper assembly.
1
6
4
2
5. Remove hydraulic manifold from the frame using
Figure 91 as guide.
6
4
3
IMPORTANT: A flow control orifice is placed be-
neath several of the hydraulic fittings on the lift cir-
cuit junction manifold (Fig. 92). If a fitting is
removed from the lift junction manifold and an ori-
fice is in the manifold port, make sure to remove ori-
fice and label its position for assembly purposes.
Also note location of groove in orifice for assembly
purposes.
6
8
9
7
UP
6. If necessary, remove fittings from manifold and dis-
card O--rings (Fig. 92).
20 ft--lb
(27 N--m)
Installation (Fig. 91)
Figure 92
1. Manifold body
2. Orifice (0.030) (3 used)
3. O--ring
4. Straight fitting (4 used)
5. Zero leak plug (3 used)
6. O--ring
7. Check valve (3 used)
8. O--ring
9. 90 hydraulic fitting
10. O--ring
11. Pilot piston (3 used)
IMPORTANT: When installing orifice in manifold,
make sure that orifice is flat in the base of the man-
ifold port. Manifold damage is possible if the orifice
is cocked in the cavity.
o
Reelmaster 7000
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Front Lift Cylinders
RIGHT
FRONT
5
21
14
2
20
11
16
13
24
5
14
12
11
6
1
1
6
7
6
12
1
1
19
25
13
2
6
8
7
7
6
1
8
6
15
10
1
7
22
10
10
9
12
4
19
19
15
3
15
15
19
15
10
23
19
22
26
4
29
30
10
4
26
15
22
31
27
19
32
10
23
17
23
26
18
28
Figure 93
1. O--ring
2. Flange nut
3. Lift arm (cutting unit #1)
12. Pivot pin
13. Slotted roll pin
14. Cylinder pin
23. Lynch pin
24. Front carrier frame
25. Lift arm (cutting unit #5)
4. Cylinder pin
15. Washer (2 per pin)
16. Washer head screw
17. Lift arm (cutting unit #4)
18. Flange head screw (2 per hoop)
19. Retaining ring (2 per pin)
20. Switch bracket
21. Cutting unit position sensor
22. Pivot yoke
26. Grease fitting
27. RH hose guide
28. LH hose guide
29. Flange nut (2 per hoop)
30. Washer (2 per hoop)
31. Chain hoop
5. Flange head screw
o
6. 90 hydraulic fitting (2 per cylinder)
7. O--ring
8. Lift cylinder (cutting units #4 and #5)
9. Lift cylinder (cutting unit #1)
10. Thrust washer
32. Lift chain
11. Lock nut
Hydraulic System
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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
cylinderopeningsusingmarksmadeduringtheremoval
process to properly orientate fittings. Tighten fittings
(see Hydraulic Fitting Installation in the General Infor-
mation section of this chapter).
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the begin-
ning of the Service and Repairs section of this chapter.
2. Position lift cylinder barrel clevis to frame and insert
cylinder pin (item 14) into frame and clevis. Secure pin
with flange nut and flange head screw.
3. To prevent contamination of hydraulic system during
lift cylinder removal, thoroughly clean exterior of lift cyl-
inder that is to be removed from machine.
3. Position cylinder rod clevis to lift armand insertcylin-
der pin (item 4) with one (1) retaining ring and washer
installed through the lift arm and cylinder clevis. Secure
pin with second washer and retaining ring. Make sure
that retaining ring is fully seated in pin.
WARNING
Make sure that cutting units are fully lowered be-
forelooseninghydrauliclinesfromliftcylinder. If
cutting units are raised as hydraulic lines are
loosened, cutting units may drop unexpectedly.
4. Remove caps and plugs from hoses and fittings. At-
tach hydraulic hoses to lift cylinder (see Hydraulic Hose
and Tube Installation in the General Information section
of this chapter).
4. Disconnect hydraulic hoses from lift cylinder. Put
caps or plugs on open hydraulic lines and fittings to pre-
vent system contamination. Label disconnected hy-
draulic lines for proper assembly.
5. Fill reservoir with hydraulic fluid as required.
6. Follow Hydraulic System Start--up procedures (see
Hydraulic System Start--up in this section).
5. Remove one (1) retaining ring and washer from the
cylinder pin (item 4). Remove cylinder pin from the lift
arm and cylinder rod clevis which will free lift cylinder
from lift arm.
7. After assembly is completed, operate lift cylinder to
verify that hydraulic hoses and fittings are not contacted
by anything.
6. Remove flange nut and flange head screw that se-
cure the cylinder pin (item 14) to the frame. Pull pin from
frame and cylinder barrel clevis.
#4
#1
#5
7. Remove lift cylinder from machine.
8. If hydraulic fittings are to be removed from lift cylin-
der, mark fitting orientation to allow correct assembly.
Remove fittings from cylinder and discard O--rings.
#2
#3
CUTTING UNIT LOCATIONS
Figure 94
Reelmaster 7000
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Rear Lift Cylinders
12
16
15
21
11
23
25
22
24
16
7
11
26
11
32
17
5
10
8
26
13
1
11
6
3
34
34
4
19
31
14
22
16
2
24
31
20
9
23
25
11
33
32
11
5
17
18
26
12
29
27
28
26
RIGHT
6
30
FRONT
16
8
7
Figure 95
1. Flange nut (2 used)
2. Bulkhead bracket
3. Hydraulic tee fitting
4. Flange head screw (2 used)
5. Slotted roll pin
13. Lock nut
14. Straight hydraulic fitting
15. Cylinder pin
16. Thrust washer
17. Cylinder pin
24. Lock nut
25. Flat washer
26. Washer (2 per pin)
27. Washer (2 per hoop)
28. Chain hoop
6. Pivot pin
7. Pivot yoke
18. Flange head screw (2 per hoop)
19. 90 hydraulic fitting
29. Flange nut (2 per hoop)
30. Lift chain
o
8. Lynch pin
20. LH torsion spring
21. RH torsion spring
22. Spacer
31. O--ring
32. Grease fitting
33. O--ring
34. O--ring
9. Lift arm (cutting unit #2)
10. Lift arm (cutting unit #3)
11. Retaining ring (2 per pin)
23. Cap screw
12. Lift cylinder (cutting units #2 and #3)
Hydraulic System
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Removal (Fig. 95)
2. Position cylinder barrel clevis to frame and insertcyl-
inder pin (item 15) with one (1) retaining ring installed
through the frame and cylinder clevis. Secure pin with
second retaining ring. Make sure that retaining ring is
fully seated in pin.
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 begin-
ning of the Service and Repairs section of this chapter.
3. Position cylinder rod clevis to lift armand insertcylin-
der pin (item 17) with one (1) retaining ring and washer
installed through the lift arm and cylinder rod clevis. Se-
cure pin with second washer and retaining ring. Make
sure that retaining ring is fully seated in pin.
3. To prevent contamination of hydraulic system during
lift cylinder removal, thoroughly clean exterior of lift cyl-
inder.
4. Remove caps and plugs from hoses and fittings. At-
tach hydraulic hoses to lift cylinder (see Hydraulic Hose
and Tube Installation in the General Information section
of this chapter).
WARNING
5. Fill reservoir with hydraulic fluid as required.
Make sure that cutting units are fully lowered be-
forelooseninghydrauliclinesfromliftcylinder. If
cutting units are raised as hydraulic lines are
loosened, cutting units may drop unexpectedly.
6. Follow Hydraulic System Start--up procedures (see
Hydraulic System Start--up in this section).
7. After assembly is completed, operate lift cylinder to
verify that hydraulic hoses and fittings are not contacted
by anything.
4. Disconnect hydraulic hoses from lift cylinder. Put
caps or plugs on open hydraulic lines and fittings to pre-
ventsystemcontamination.Labelthehydraulichosesto
show their correct position on the lift cylinder for assem-
bly purposes.
#4
#1
#5
5. Remove one (1) retaining ring and washer from the
cylinder pin (item 17) that secures the lift cylinder rod
clevis to the lift arm. Remove pin from lift arm and cylin-
der shaft clevis.
6. Remove one (1) retaining ring from the cylinder pin
(item 15) that secures the lift cylinder barrel clevis to the
frame. Remove cylinder pin from the frame and cylinder
barrel clevis.
#2
#3
7. Remove lift cylinder from machine.
8. If hydraulic fittings are to be removed from lift cylin-
der, mark fitting orientation to allow correct assembly.
Remove fittings from cylinder and discard O--rings.
CUTTING UNIT LOCATIONS
Figure 96
Installation (Fig. 95)
1. If fittings were removed from lift cylinder, lubricate
and place new O--rings onto fittings. Install fittings into
cylinderopeningsusingmarksmadeduringtheremoval
process to properly orientate fittings. Tighten fittings
(see Hydraulic Fitting Installation in the General Infor-
mation section of this chapter).
Reelmaster 7000
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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
14
17
15
6
4
8
11 13 14
17
2
3
5
7
1
9
10 12 15
16
Figure 97
1. Barrel
7. Piston
8. Buffer seal
9. O--ring
10. Back--up seal
11. Head
12. Retaining ring
13. Head seal
2. Lock nut
3. Wear band
4. Square ring
5. Piston seal
6. O--ring
14. Support washer
15. Retaining ring
16. Wiper
17. Rod assembly
NOTE: The lift cylinders used on the Reelmaster 7000
are all very similar regardless of the location on the ma-
chine. The disassembly and assembly procedure is the
same for all lift cylinders.
Hydraulic System
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Disassembly (Fig. 97)
Assembly (Fig. 97)
1. Removeoilfromliftcylinderintoadrainpanbyslowly
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. Coat new seal kit components with clean hydraulic
oil.
IMPORTANT: Prevent damage when clamping the
cylinder in a vise; clamp on the clevis only. Do not
close vise enough to distort the barrel.
A. Install new seals, wear band and O--ring to the
piston.
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.
B. Install new seals, O--ring and back--up seal to the
head.
IMPORTANT: Do not clamp vise jaws against the
rod surface. Protect rod surface before mounting in
a vise.
3. Carefully remove wiper (item 16) from the barrel tak-
ing care to not damage barrel. Slide wiper toward rod
clevis.
3. Mount rod securely in a vise by clamping on the cle-
vis of the rod.
4. Remove retaining ring (item15) frombarrel. Slidere-
tainingringandsupportwasher(item14)towardrodcle-
vis.
A. Coat rod with clean hydraulic oil.
5. Loosen head from barrel:
B. Carefully slide wiper (item 16), retaining ring
(item 15), support washer (item 14), head assembly
and piston assembly onto the rod.
A. Use a spanner wrench to rotate head clockwise
until the edge of the retaining ring (item 12) appears
in the barrel opening.
C. Clean threads on end of rod. Apply Loctite #271
(or equivalent) to rod threads.
B. Insert a screwdriver under the beveled edge of
the retaining ring to start the retaining ring through
the opening.
D. Secure piston to rod with lock nut. Torque locknut
from 35 to 45 ft--lb (48 to 61 N--m).
C. Rotatetheheadcounter--clockwisetoremovere-
taining ring from barrel and head.
4. Lubricate head and piston with hydraulic oil. Careful-
ly slide rod assembly into cylinder barrel.
6. Extract rod assembly with head and piston by care-
fully twisting and pulling on the rod clevis.
IMPORTANT: Prevent damage when clamping the
cylinder’s barrel into a vise; clamp on the clevis
only. Do not close vise enough to distort the barrel.
IMPORTANT: Do not clamp vise jaws against the
rod surface. Protect shaft surface before mounting
in a vise.
5. Mount lift cylinder in a vise with soft jaws. Secure
head in barrel:
7. Mount rod assembly securely in a vise by clamping
on the clevis of the rod. Remove lock nut from the rod.
Slide piston, head, support washer, retaining ring and
wiper off the rod.
A. Align retaining ring hole in the head with the ac-
cess slot in the barrel.
B. Insert the retaining ring hook into the hole and ro-
tate head clockwise until the retaining ring is com-
pletely pulled into the barrel and the ring ends are
covered.
8. Remove and discard all seals and O--rings from the
piston and the head.
9. Wash cylinder parts in clean solvent. Dry parts with
compressed air. Do not wipe parts dry with paper towels
or cloth. Lint in a hydraulic system will cause damage.
C. Apply silicone sealer to barrel access slot.
6. Slide support washer to top of head and then install
retaining ring. Make sure that retaining ring is fully
seated in slot in barrel.
10.Carefully inspect internal surface of barrel for dam-
age (deep scratches, out--of--round, etc.). Replace en-
tire cylinder if barrel is damaged. Inspect rod and piston
for evidence of excessive scoring, pitting or wear. Re-
place any damaged parts.
7. Press wiper into barrel taking care to not damage
wiper.
Reelmaster 7000
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Hydraulic Reservoir
15
16
RIGHT
FRONT
10
1
14
13
68 to 75 ft--lb
(93 to 101 N--m)
11
9
12
8
7
6
21
4
18
3
22
2
19
5
20
80 to 88 ft--lb
(109 to 119 N--m)
17
8
Figure 98
1. Hydraulic reservoir
2. Tank strainer
3. Clamp
4. Hydraulic fitting
5. Hydraulic tee fitting
6. Bumper
9. Clamp (2 used)
16. O--ring
17. Cap screw
18. O--ring
19. O--ring
20. O--ring (2 used)
10. Cap screw (2 used)
11. Flat washer (2 used)
12. Breather
13. Screen filter
14. Dipstick
21. O--ring
7. Flat washer (2 used)
15. Plug
22. O--ring
8. Flange nut (3 used)
Hydraulic System
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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.
2. Inspect reservoir for leaks, cracks or other damage.
Installation (Fig. 98)
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the begin-
ning of the Service and Repairs section of this chapter.
1. If fittings were removed from reservoir, lubricate and
place new O--rings onto fittings. Install fittings into reser-
voir openings using marks made during the removal
process to properly orientate fittings. Torque fittings to
values identified in Figure 98.
3. To prevent contamination of hydraulic system during
hydraulicreservoirremoval, thoroughlycleanexteriorof
reservoir.
4. Disconnectoneofthehydraulictubesfromtheteefit-
ting on bottom of reservoir to allow draining of reservoir.
Drain reservoir into a suitable container.
2. Install reservoir using Figure 98 as a guide.
IMPORTANT: When tightening hoses to reservoir
fittings, hold fitting with wrench to prevent over--
tightening of fitting and potential reservoir damage.
5. Disconnect remaining hydraulic hoses from reser-
voir. Label the hydraulic hoses to show their correct
position on the reservoir for assembly purposes.
3. Connect hydraulic hoses to reservoir fittings (see
Hydraulic Hose and Tube Installation in the General In-
formation section of this chapter).
6. Remove hydraulic reservoir using Figure 98 as a
guide.
4. Fill reservoir with hydraulic fluid to proper level.
7. If hydraulic fittings are to be removed from reservoir,
mark fitting orientation to allow correct assembly. Re-
move fittings from reservoir and discard O--rings.
5. Follow Hydraulic System Start--up procedures (see
Hydraulic System Start--up in this section).
Reelmaster 7000
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Hydraulic Oil Cooler
12
11
10
13
RIGHT
8
9
FRONT
14
15
7
3
16
8
1
6
2
3
4
5
Figure 99
1. Oil cooler
7. Plenum
8. Flange nut (4 used)
12. Hydraulic hose (2 used)
13. Cap screw (2 used)
14. Washer (2 used)
15. Wire form clamp (2 used)
16. Top oil cooler bracket
2. Mount plate (2 used)
3. Flange head screw (8 used)
4. Radiator mount
5. Radiator
9. O--ring
o
10. 90 hydraulic fitting (2 used)
11. O--ring
6. Air intake hose
Hydraulic System
Page 4 -- 132
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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
3. Check oil level in hydraulic reservoir and add correct
oil if necessary.
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.
4. Follow Hydraulic System Start--up procedures (see
Hydraulic System Start--up in this section).
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.
1
1
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the begin-
ning of the Service and Repairs section of this chapter.
3. To prevent contamination of hydraulic system during
oil cooler removal, thoroughly clean exterior of cooler.
4. Remove oil cooler using Figures 99, 100 and 101 as
guides.
3
2
5. If hydraulic fittings are to be removed from oil cooler,
mark fitting orientation to allow correct assembly. Re-
move fittings from cooler and discard O--rings.
Figure 100
1. Wire form clamp
2. Hose to oil cooler
3. Hose from oil cooler
Inspection
1. Backflushoilcoolerwithcleaningsolvent. Aftercool-
er is clean, make sure all solvent is drained from the
cooler.
1
1
CAUTION
Use eye protection such as goggles when using
compressed air.
2
2. Dry inside of oil cooler using compressed air in the
opposite direction of the oil flow.
3. Plug both ends of oil cooler. Clean exterior of cooler.
Make sure fins are clear of dirt and debris.
Figure 101
1. Wire form clamp
2. Oil cooler
4. The oil cooler should be free of corrosion, cracked
tubes and excessive pitting of tubes.
Installation (Fig. 99)
1. If fittings were removed from oil cooler, lubricate and
placenewO--ringsontofittings. Installfittingsintocooler
openingsusingmarksmadeduringtheremovalprocess
to properly orientate fittings. Tighten fittings (see Hy-
draulic Fitting Installation in the General Information
section of this chapter).
Reelmaster 7000
Page 4 -- 133
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Hydraulic System
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Chapter 5
Electrical System
Table of Contents
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2
Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Toro Electronic Controllers (TEC) . . . . . . . . . . . . . . 2
CAN--bus Communications . . . . . . . . . . . . . . . . . . . 2
ELECTRICAL DRAWINGS . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 6
Diagnostic Display . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Verify Diagnostic Display Input Functions . . . . . 6
Verify Diagnostic Display Output Functions . . . . 9
Starting Problems . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General Run & Transport Problems . . . . . . . . . . . 11
Cutting Unit Operating Problems . . . . . . . . . . . . . 12
ELECTRICAL SYSTEM QUICK CHECKS . . . . . . . 13
Battery Test (Open Circuit) . . . . . . . . . . . . . . . . . . 13
Charging System Test . . . . . . . . . . . . . . . . . . . . . . 13
Glow Plug System Test . . . . . . . . . . . . . . . . . . . . . 13
Check Operation of Interlock Switches . . . . . . . . 14
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Mow/Transport Sensor . . . . . . . . . . . . . . . . . . . . . . 15
Cutting Unit Position Sensor . . . . . . . . . . . . . . . . . 16
COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . 17
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . 20
PTO Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Cutting Unit Lift Switch . . . . . . . . . . . . . . . . . . . . . . 22
Headlight Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Engine Cooling Fan Switch . . . . . . . . . . . . . . . . . . 24
Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . 26
Mow/Transport Sensor . . . . . . . . . . . . . . . . . . . . . . 27
Cutting Unit Position Sensor . . . . . . . . . . . . . . . . . 28
Backlap Switches . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Glow and Main Power Relays . . . . . . . . . . . . . . . . 30
Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Reel Speed Potentiometer . . . . . . . . . . . . . . . . . . . 32
Hydraulic Solenoid Valve Coils . . . . . . . . . . . . . . . 33
Traction Neutral Switch . . . . . . . . . . . . . . . . . . . . . 34
Diode Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Toro Electronic Controller (TEC) . . . . . . . . . . . . . . 35
Engine Coolant and Hydraulic Oil Temperature
Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Fuel Stop Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . 38
Engine Temperature Sender . . . . . . . . . . . . . . . . . 39
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . 40
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 41
Battery Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Battery Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Battery Specifications . . . . . . . . . . . . . . . . . . . . . 42
Battery Removal and Installation . . . . . . . . . . . . 42
Battery Inspection and Maintenance . . . . . . . . . 42
Battery Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Hydraulic Solenoid Valve Coils . . . . . . . . . . . . . . . 45
Reelmaster 7000
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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 Op-
erator’s Manual for additional information when servic-
ing the machine.
Toro Electronic Controller (TEC)
Reelmaster 7000 machines use a single Toro Electronic
Controller (TEC) to manage machine electrical func-
tions.
The controller is microprocessor controlled that senses
the condition of various machine switches (inputs) and
directs electrical power to control appropriate machine
functions (outputs) based on the state of the inputs. The
status of inputs to the controllers as well as outputs from
the controllers can be checked with the Diagnostic Dis-
play (see Special Tools).
1
Because of the solid state circuitry built into the Toro
Electronic Controller (TEC), there is no method to test
it directly. The TEC may be damaged if an attempt is
made to test it with an electrical test device, such as a
digital multimeter.
Figure 1
1. Toro Electronic Controller
IMPORTANT: Before performing any welding on the
machine, disconnect the battery cables from the
battery, disconnect the wire harness connectors
from the Toro Electronic Controller(s) and discon-
nect the terminal connector from the alternator to
prevent damage to the machine electrical system.
CAN--bus Communications
The TEC controller used on the Reelmaster 7000 can
communicate with other electrical components on a
CAN--bus communication system. The CAN--bus sys-
tem reduces the number of electrical components and
connections used on the machine and allows the num-
ber of wires in the wire harness to be reduced.
Each of the components that is controlled by the CAN--
buslinkonlyneedsfour(4)wirestooperateandcommu-
nicate to the system: CAN--high, CAN--low, B+ (power)
and ground.
IMPORTANT: The termination resistors at the ends
of the bus cables are required for proper electrical
system operation.
CAN identifies the Controller Area Network that is used
on the Reelmaster. Two (2) specially designed, twisted
cables form the bus. These wires provide the data path-
ways between machine components. The engineering
term for these two (2) cables are CAN--high and CAN--
low. At the ends of the twisted pair of bus cables are 120
ohm termination resistors.
Electrical System
Page 5 -- 2
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Electrical Drawings
The electrical schematics and other electrical drawings
fortheReelmaster 7000are locatedin Chapter9 -- Fold-
out Drawings.
Reelmaster 7000
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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 cir-
cuits 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.
Thehighimpedance(internalresistance)ofadigitalme-
ter in the voltage mode will make sure that excess cur-
rent is not allowed through the meter. This excess
current can cause damage to circuits not designed to
carry it.
Figure 2
Skin--Over Grease
Special non--conductive grease which forms a light pro-
tective skin to help waterproof electrical switches and
contacts.
Toro Part Number: TOR50547
Figure 3
Battery Hydrometer
Use the battery hydrometer when measuring specific
gravity of battery electrolyte. Obtain this tool locally.
Figure 4
Electrical System
Page 5 -- 4
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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. Refer to your
Parts Catalog for overlay language options and part
numbers.
Figure 5
IMPORTANT: The Diagnostic Display must not be
left connected to the machine. It is not designed to
withstand the environment of the machine’s every
day use. When use of Diagnostic Display is com-
pleted, disconnect it from the machine and recon-
nect loop--back connector to harness connector.
Machine will not operate without loop--back con-
nector installed on harness. Store Diagnostic Dis-
play in a dry, secure, indoor location and not on
machine.
Figure 6
Battery Terminal Protector
Aerosol spray that should be used on battery terminals
to reduce corrosion problems. Apply battery terminal
protector after the battery cable has been secured to the
battery terminal.
Toro Part Number: 107--0392
Figure 7
Reelmaster 7000
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Troubleshooting
CAUTION
For effective troubleshooting and repairs, there must be
a good understanding of the electrical circuits and com-
ponents used on this machine (see Chapter 9 -- Foldout
Drawings).
Remove all jewelry, especially rings and
watches, before doing any electrical trouble-
shooting 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 trouble-
shooting.
NOTE: Use the Diagnostic Display (see Special Tools
in this chapter) to test Electronic Control Module inputs
and outputs when troubleshooting an electrical problem
on your Reelmaster.
Diagnostic Display
Reelmaster 7000 machines are equipped with a Toro
Electronic Controller (TEC) which controls machine
electrical functions. The controller monitors various in-
put switches (e.g. ignition switch, seat switch, neutral
switch) and energizes outputs to actuate solenoids or
relays for the requested machine function.
Verify Diagnostic Display Input Functions
1. Park machine on a level surface, lower the cutting
units, stop the engine and apply the parking brake.
2. Remove plate in front of seat to allow access to wire
harness loop--back connector. Locate wire harness and
loop--back connector (Fig. 8). Carefully unplug loop--
back connector from harness connector.
For the TEC to control the machine as desired, each of
the inputs (switches and sensors) and outputs (sole-
noids and relays) must be connected and functioning
properly.
3. Connect the Diagnostic Display connector to the
wire harness connector. Make sure correct overlay de-
cal is positioned on the Diagnostic Display (Fig. 9).
The Diagnostic Display (see Special Tools in this chap-
ter)isatooltohelpthetechnicianverifycorrectelectrical
functions of the machine.
4. Turn the ignition switch to the ON position, but do not
start machine.
IMPORTANT: The Diagnostic Display must not be
left connected to the machine. It is not designed to
withstand the environment of the machine’s every
dayuse. WhenuseoftheDiagnosticDisplayiscom-
pleted, disconnect it from the machine and recon-
nect loop--back connector to harness connector.
The machine will not operate without the loop--back
connector installed on the harness. Store the Diag-
nostic Display in a dry, secure, indoor location and
not on machine.
NOTE: The red text on the Diagnostic Display overlay
decal refers to TEC inputs and the green text refers to
TEC outputs.
3
CAUTION
2
The interlock switches are for the protection of
the operator and bystanders and to ensure cor-
rect operation of the machine. Do not bypass or
disconnect switches. Check the operation of the
interlockswitchesdailyforproperoperation. Re-
place any malfunctioning switches before oper-
ating the machine.
1
Figure 8
1. Wire harness connector
2. Loop--back connector
3. TEC controller
Electrical System
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5. The “inputs displayed” LED, on lower right column of
theDiagnosticDisplay, shouldbeilluminated. If“outputs
displayed”LEDisilluminated,pressthetogglebuttonon
the Diagnostic Display to change to “inputs displayed”
LED.
TEC
OVERLAY
6. The Diagnostic Display will illuminate the LED
associatedwitheachoftheinputswhenthatinputswitch
is closed. Individually, change each ofthe switches from
open to closed (i.e., sit on seat, press traction pedal,
etc.), and note that the appropriate LED on the Diagnos-
ticDisplaywillilluminatewhenthe correspondingswitch
is closed. Repeat on each switch that is possible to be
changed by hand (see Diagnostic Display Inputs and
LED Operation chart on following page).
NOTE: When the Diagnostic Display is attached to the
wire harness connector and the ignition switch is in the
ON position, the input LED for hydraulic temp and cool-
anttempshould beilluminated. Ifthe harnessconnector
is disconnected from the sensor for either of these in-
puts, the appropriate LED should go off after a few sec-
ond delay. Then, if the harness connector is reattached
tothesensor,theinputLEDshouldagainilluminateafter
a few seconds.
Figure 9
7. If appropriate LED does not toggle on and off when
switch state is changed, check all wiring and connec-
tions to that switch and/or test switch (see Component
Testing in this chapter). Replace any defective switches
and repair any damaged wiring.
8. After input functions testing is complete, disconnect
the Diagnostic Display connector from the harness con-
nector and plug loop--back connector into wire harness.
Secure access plate to frame.
Reelmaster 7000
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Diagnostic Display Inputs
P BRAKE OFF
Diagnostic Display LED Operation
Parking brake released: LED ON
Parking brake applied: LED OFF
DECKS DOWN
NEUTRAL
Cutting units lowered: LED ON
Cutting units raised: LED OFF
Traction pedal in neutral: LED ON
Traction pedal in forward or reverse: LED OFF
SEAT SWITCH
HI RANGE
Operator seat occupied: LED ON
Operator seat empty: LED OFF
Mow speed limiter is in the transport (2WD) position: LED ON
Mow speed limiter is in the mow (4WD) position: LED OFF
DECK RAISE
Console arm lift switch in RAISE position: LED ON
Lift switch NOT in RAISE position: LED OFF
DECK LOWER
PTO ON
Console arm lift switch in LOWER position: LED ON
Lift switch NOT in LOWER position: LED OFF
PTO switch ON: LED ON
PTO switch OFF: LED OFF
OIL PRESSURE LOW
FAN REVERSE
ALTERNATOR FAULT
FRONT BACKLAP
HYDRAULIC TEMP
COOLANT TEMP
REAR BACKLAP
KEY START
Engine not running OR low engine oil pressure: LED ON
Engine oil pressure OK: LED OFF
Fan switch in momentary REVERSE position: LED ON
Fan switch in AUTO position: LED OFF
Engine not running or alternator faulty: LED ON
Alternator OK: LED OFF
Front reels in backlap position: LED ON
Front reels NOT in backlap position: LED OFF
Hydraulic temperature, switch and circuit wiring OK: LED ON
Hydraulic temperature, switch or circuit wiring faulty: LED OFF
Engine coolant temperature, switch and circuit wiring OK: LED ON
Coolant temperature, switch or circuit wiring faulty: LED OFF
Rear reels in backlap position: LED ON
Rear reels NOT in backlap position: LED OFF
Ignition switch in START: LED ON
Ignition switch in ON or OFF: LED OFF
KEY RUN
Ignition switch in ON or START: LED ON
Ignition switch in OFF: LED OFF
NOTE: When the ignition switch is in the OFF position,
all Diagnostic Display LED’s should be OFF.
Electrical System
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Verify Diagnostic Display Output Functions
C. If each input switch is in the correct position and
functioning correctly, but the output LED’s are not
correctly illuminated, this indicates a TEC controller
problem. If this occurs, contact your Toro Distributor
for assistance.
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.
7. After output functions testing is complete, discon-
nect the Diagnostic Display connector from the harness
connector and plug loop--back connector into wire har-
ness. Secure access plate to frame.
NOTE: Anopenoutput(e.g.anunpluggedconnectoror
a broken wire) cannot be detected with the Diagnostic
Display.
1. Park machine on a level surface, lower the cutting
units, stop the engine and engage the parking brake.
2. Remove plate in front of seat to allow access to wire
harness loop--back connector. Locate wire harness and
loop--back connector (Fig. 10). Carefully unplug loop--
back connector from harness connector.
3
3. ConnecttheDiagnosticDisplayconnectortothehar-
nessconnector.Makesurecorrectoverlaydecalisposi-
tioned on the Diagnostic Display (Fig. 11).
2
1
4. Turn the ignition switch to the ON position.
NOTE: The red text on the Diagnostic Display overlay
decal refers to input switches and the green text refers
to TEC outputs.
Figure 10
1. Wire harness connector
2. Loop--back connector
3. TEC controller
5. The “outputs displayed” LED, on lower right column
of the Diagnostic Display, should be illuminated. If “in-
puts displayed” LED is illuminated, press the toggle but-
ton on the Diagnostic Display to change the LED to
“outputs displayed”.
TEC
OVERLAY
NOTE: It may be necessary to toggle between “inputs
displayed” and “outputs displayed” several times to per-
form the following step. To change from inputs to out-
puts, press toggle button once. This may be done as
often as required. Do not press and hold toggle but-
ton.
6. Sit on seat and attempt to operate the desired func-
tion of the machine. The appropriate output LED’s
should illuminate on the Diagnostic Display to indicate
that the TEC controller is turning on that function. The
GLOWPLUGS, HIRANGEandOKRUNoutputscanbe
checked with the ignition switch in the ON position and
the engine not running. For testing of the solenoid out-
puts (e.g. PTO 1, ENABLE, REAR REELS), the engine
must be running.
A. IfthecorrectoutputLED’sdonotilluminate, verify
that the required input switches are in the necessary
positions to allow that function to occur.
B. If the output LED’s are on as specified, but the
machine does not function properly, suspect a failed
electrical component, an open in the tested circuit or
a non-electrical problem (e.g. hydraulic component
problem). Repair as necessary.
Figure 11
Reelmaster 7000
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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.
Battery is discharged.
Starter solenoid clicks, but starter will not crank.
NOTE: If the solenoid clicks, the problem is not in the in-
terlock circuit.
Battery cables are loose or corroded.
Ground connection on machine is loose or corroded.
Wiring at the starter is faulty.
Starter solenoid is faulty.
Starter is faulty.
Nothing happens when start attempt is made. Control
panel lights and gauges operate with the ignition
switch in ON.
The traction pedal is not in neutral position.
Operator seat is unoccupied OR the parking brake is
not applied.
The PTO switch is ON (engaged).
Fuse F1--1 (20 amp) is faulty (open).
TEC fuses (F3--2, F3--3 or F3--4) are faulty.
The traction neutral switch or circuit wiring is faulty.
Seat switch or circuit wiring is faulty.
Ignition switch or circuit wiring is faulty.
Parking brake switch or circuit wiring is faulty.
Start relay or circuit wiring is faulty.
Starter solenoid or starter motor is faulty.
TEC controller is faulty.
Engine starts, but stops when the ignition switch is
released from the START position.
The engine run solenoid or circuit wiring is faulty
(solenoid pull coil operates but hold coil is faulty).
Electrical System
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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 The traction neutral switch is out of adjustment.
is depressed.
The traction neutral switch or circuit wiring is faulty.
General Run and Transport Problems
Engine continues to run, but should not, when the
ignition switch is turned off.
The engine fuel stop solenoid is stuck open.
Ignition switch or circuit wiring is faulty.
The seat switch or circuit wiring is faulty.
Traction neutral switch or circuit wiring is faulty.
The operator is lifting off the seat.
Engine continues to run, but should not, when the
traction pedal is engaged with no operator in the seat.
The engine stops during operation, but is able to
restart.
The seat switch or circuit wiring is faulty.
The ignition switch or circuit wiring is faulty.
The engine kills when the traction pedal is depressed. The operator is lifting off the seat.
The parking brake is applied.
The seat switch or circuit wiring is faulty.
The parking brake switch or circuit wiring is faulty.
Battery does not charge.
Loose, corroded or broken wire(s) in charging circuit.
The alternator is faulty.
Battery is damaged.
Reelmaster 7000
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Cutting Unit Operating Problems
Cutting units run, but should not, when raised. Cutting The cutting unit position switch or circuit wiring is
units shut off with PTO switch.
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 The cutting unit position switch or circuit wiring AND
units do not shut off with the PTO switch.
PTO switch or circuit wiring are faulty.
A hydraulic problem exists (see Troubleshooting
Section of Chapter 4 -- Hydraulic System).
Cutting units run, but should not, when lowered with
PTO switch in the OFF (disengage) position.
The PTO switch or circuit wiring is faulty.
Cutting unit(s) do not operate.
The cutting units are not fully lowered.
The operator seat is unoccupied.
Mow speed limiter is not in mow position (4WD).
The PTO switch or circuit wiring is faulty.
The cutting unit position switch or circuit wiring to the
affected cutting unit(s) is faulty.
Hydraulic solenoid valve coil(s) or circuit wiring to the
affected cutting units is faulty.
A hydraulic problem exists (see Troubleshooting
section of Chapter 4 -- Hydraulic System).
Cutting unit(s) operation is intermittent over rough
terrain.
The cutting unit lift/lower switch or circuit wiring is
faulty.
Electrical System
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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
Fully charged (100%)
75% charged
12.68 V (or higher)
12.45 V
Set multimeter to the DC volts setting. The battery
should be at a temperature of 60o to 100oF (16o to
38oC). The ignitionkey shouldbe offand allaccessories
turned off. Connect the positive (+) meter lead to the
positive battery post and the negative (--) meter lead to
the negative battery post.
12.24 V
50% charged
12.06 V
25% charged
11.89 V
0% charged
NOTE: This testprovides a relative condition ofthebat-
tery. Load testing of the battery will provide additional
and more accurate information (see Battery Service in
the Service and Repairs section of this chapter).
Charging System Test
This is a simple test used to determine if a charging sys-
tem is functioning. It will tell you if the charging system
has an output, but not its capacity.
Start the engine and run at high idle (2850 RPM). Allow
the battery to charge for at least three (3) minutes. Re-
cord the battery voltage.
Use a digital multimeter set to DC volts. Connect the
positive (+) multimeter lead to the positive battery post
and the negative (--) multimeter lead to the negative bat-
tery post. Keep the test leads connected to the battery
posts and record the battery voltage.
After running the engine for at least three (3) minutes,
battery voltage should be at least 0.50 volt higher than
initial battery voltage.
An example of a charging system that is functioning:
NOTE: Upon starting the engine, the battery voltage
will drop and then should increase once the engine is
running.
At least 0.50 volt over initial battery voltage.
Initial Battery Voltage
Battery Voltage after 3 Minute Charge
Difference
= 12.30 v
= 12.85 v
= +0.55 v
NOTE: Depending upon the condition of the battery
charge and battery temperature, the battery voltage will
increase at different rates as the battery charges.
Glow Plug System Test
This is a fast, simple test that can help to determine the
integrity and operation of your Reelmaster glow plug
system. The test should be run anytime hard starting
(cold engine) is encountered on a diesel engine
equipped with a glow plug system.
ammeter pickup around the main glow plug power sup-
ply wire and read the meter prior to activating the glow
plug system. Adjust the meter to read zero (if applica-
ble). Activate the glow plug system by turning the igni-
tion switch to ON and record the multimeter results.
Use a digital multimeter and/or inductive Ammeter (AC/
DCCurrentTransducer). Properlyconnecttheammeter
to the digital multimeter (refer to manufacturers’ instruc-
tions) and set the multimeter to the correct scale. With
the ignition switch in the OFF position, place the
The Reelmaster glow plug system should have a read-
ing of approximately nine (9) amps per glow plug (36
amps total). If low current reading is observed, one (or
more) of the glow plugs is faulty.
Reelmaster 7000
Page 5 -- 13
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Check Operation of Interlock Switches
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. Testing of individual interlock
switches and relays is included in the Component Test-
ing section of this Chapter.
CAUTION
Do not disconnect safety switches. They are for
the operator’sprotection. Checkthe operationof
the interlock switches daily for proper operation.
Replace any malfunctioning switches before op-
erating the machine.
NOTE: Use the Diagnostic Display (see Special Tools
in this chapter) to test Toro Electronic Controller inputs
and outputs before further troubleshooting of an electri-
cal problem on your Reelmaster.
Electrical System
Page 5 -- 14
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Adjustments
Mow/Transport Sensor
The mow/transport sensor is a normally open proximity
sensorthatcloseswhenthemow speedlimiter isplaced
inthetransportposition. Thesensormountstoabracket
on the footrest platform (Fig. 12). The sensing plate for
themow/transportsensorisatabonthemowspeedlim-
iter.
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).
1
2. Ifgapisincorrect,loosenjamnutsthatsecuresensor
to footrest platform. Position switch with jam nuts to al-
low correct gap between sensor and mow speed limiter.
Tighten jam nuts to secure adjustment. Jam nuts should
be torqued from 162 to 198 in--lb (18.4 to 22.4 N--m).
After jam nuts are tightened, make sure that clearance
between head of mow/transport sensor and the mow
speed limiter has not changed.
Figure 12
1. Mow/transport sensor
2. Mow speed limiter
3. After adjustment to the mow/transport sensor, use
the Diagnostic Display (see Special Tools in this chap-
ter)toverifythatmow/transportsensorand circuitwiring
are functioning correctly (see Mow/Transport Sensor in
the Component Testing section of this chapter).
Reelmaster 7000
Page 5 -- 15
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Cutting Unit Position Sensor
The cutting unit position sensor is a normally open prox-
imity 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. ThisclosedsensorprovidesaninputfortheTEC
controller to allow the lowered cutting units to operate.
1
3
Adjustment
The gap between the cutting unit position sensor and
the lift arm gussetshould be 0.063” (1.6 mm). Ifdistance
is incorrect, loosen jam nuts that secure position sensor
to bracket. Adjust sensor location with jam nuts to allow
correct gap between sensor and lift arm gusset. Jam
nuts should be torqued from 162 to 198 in--lb (18.4 to
22.4 N--m). After jam nuts are tightened, make sure that
gap has not changed.
2
Figure 13
1. Position sensor
2. #5 lift arm
3. Gap
The vertical location of the cutting unit position sensor
on the sensor bracket will determine the turn--around
position of the cutting units. Raising the sensor on the
bracket will allow a higher turn--around position of the
cutting units. Lowering the sensor on the bracket will al-
low a lower turn--around position of the cutting units.
LED location
1
4
5
2
6
After adjustment to the position sensor, use the Diag-
nostic Display (see Special Tools in this chapter) to
verify that cutting unit position sensor and circuit wiring
are functioning correctly (see Cutting Unit Position Sen-
sor in the Component Testing section of this chapter).
3
FRONT
Figure 14
1. Position sensor
2. Sensor bracket
3. Screw (2 used)
4. Jam nut (2 used)
5. Lock washer (2 used)
6. Front carrier frame
Electrical System
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Component Testing
For accurate resistance and/or continuity checks, elec-
trically disconnect the component being tested from the
circuit (e.g. unplug the ignition switch connector before
checking continuity on the switch terminals).
CAUTION
When testing electrical components for continu-
ity with a multimeter (ohms setting), make sure
that power to the circuit has been disconnected.
NOTE: For engine component testing information, see
the Kubota Workshop Manual, Diesel Engine, 03--M--
DI--E3B.
Ignition Switch
The ignition (key) switch on the console arm has three
(3) positions (OFF, ON/PREHEAT and START).
7. After testing is completed, connect the wire harness
connector to the ignition switch.
Testing
8. Assemble console arm (see Console Arm Assembly
in the Service and Repairs section of Chapter 7 -- Chas-
sis).
1. Before disconnecting the ignition 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).
If the Diagnostic Display verifies that the ignition switch
and circuit wiring are functioning correctly, no further
switch testing is necessary. If, however, the Display de-
termines that the ignition switch and circuit wiring are
not functioning correctly, proceed with test.
2
2. Make sure ignition switch is OFF. Remove key from
ignition switch.
3. Disassemble console arm to gain access to ignition
switch (see Console Arm Disassembly in the Service
and Repairs section of Chapter 7 -- Chassis).
1
4. Disconnect wire harness electrical connector from
the ignition switch.
5. The ignition switch terminals are identified as shown
in Figure 16. The circuit logic of the ignition switch is
shown in the chart below. With the use of a multimeter
(ohms setting), the switch functions can be tested to de-
termine whether continuity exists between the various
terminals for each switch position. Verify continuity be-
tween switch terminals. Replace switch if testing identi-
fies that switch is faulty.
Figure 15
1. Console arm
2. Ignition switch
ON/PREHEAT
o
o
45
45
OFF
START
POSITION
OFF
CIRCUIT
NONE
F
A
ON/PREHEAT
START
B + C + F, D + E
A + B + C
E
B
D
C
REAR VIEW
FRONT VIEW
6. If ignition switch tests correctly and circuit problem
still exists, check wire harness (see Electrical Schemat-
ics and Wire Harness Drawings in Chapter 9 -- Foldout
Drawings).
Figure 16
Reelmaster 7000
Page 5 -- 17
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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 lo-
cated 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
1. Make sure that ignition switch is OFF and key is re-
moved from switch.
2. Remove power center cover from operator platform
to access fuses.
3. Remove fuse from fuse block for testing. Fuse
should have continuity across the terminals.
Fuse Identification and Function (Figs. 17 and 18)
Fuse F1--1 (20 Amp) protects power supply to engine
starter motor circuit.
4. After fuse testing is completed, install and secure
power center cover.
Fuse F1--2 position available for optional flow divider kit.
Fuse F1--3 position available for optional kit.
Fuse F1--4 position available for optional kit.
Fuse F2--1 (10 Amp) protects power supply to the light
circuit.
Fuse F2--2 (10 Amp) protects power supply to the oper-
ator seat circuit.
Fuse F2--3 (10 Amp) protects power supply to the pow-
erpoint.
Fuse F2--4 (10 Amp) protects power supply to the main
power circuit.
Fuse F3--1 (2 Amp) protects logic power circuit to the
TEC controller.
Figure 17
Fuse F3--2 (7.5 Amp) protects power supply to the TEC
controller outputs.
FRONT
Fuse F3--3 (7.5 Amp) protects power supply to the TEC
controller outputs.
F1
Fuse F3--4 (7.5 Amp) protects power supply to the TEC
controller outputs.
Fuse M1 (60A) protects power supply to the glow plug
circuit.
F2
Fuse M2 position available for operator cab option.
M2 (option)
F3
Fuse F5--1 (in--line 40A) protects power supply for the
engine run solenoid pull coil.
M1 (60A)
1
2
3
4
Figure 18
Electrical System
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Indicator Lights
Charge Indicator Light
Thechargeindicatorlightshouldcomeonwhentheigni-
tion switch is in ON with the engine not running or with
an improperly operating charging circuit while the en-
gine is running.
3
2
1
4
To test the charge indicator light and circuit wiring,
ground the white wire attached to alternator. Turn igni-
tionswitchtoON;thechargeindicatorlightshouldillumi-
nate indicating correct operation of the electrical wiring
to the alternator.
Engine Oil Pressure Light
The oil pressure light should come on when the ignition
switch is in the ON position with the engine not running.
Also, it should light with the engine running if the engine
oil pressure drops below 7 PSI (0.5 kg/cm2).
Totesttheoilpressurelightandcircuitwiring,groundthe
green wire attached to oil pressure switch located on
right side of engine near the starter motor. Turn ignition
switchtoON;theoilpressurelightshouldilluminateindi-
cating correct operation of the electrical wiring to the oil
pressure switch.
Figure 19
1. Charge indicator
2. Engine oil pressure
3. High temp indicator
4. Glow plug indicator
High Temperature Warning Light
2
1
3
4
If the engine coolant temperature rises to approximately
220oF (105oC), the high temperature light should come
on and the PTO (cutting units) will disengage.
To test the high temperature shutdown light and circuit
wiring, start the engine and ground the gray wire at-
tached to the temperature sender attached to water
flange on engine (see Temperature Sender in this sec-
tion). Warning light should illuminate.
5
Glow Plug Indicator Light
1B
2B
1A (+)
2A (+)
The glow plug light should come on when the ignition
switch is placed in ON/PREHEAT prior to placing the
ignition switch in START. The light should stay lit for
approximately seven (7) seconds while the ignition
switch is left in ON.
Figure 20
Testing Indicator Lights
1. Charge indicator
2. Engine oil pressure
3. High temp warning
4. Glow plug indicator
5. Warning light back
1. Apply 12 VDC to terminals 1A and 2A.
2. Ground terminals 1B and 2B.
3. Both indicator lights should light.
Reelmaster 7000
Page 5 -- 19
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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
1
10
0 0 00 1
HOURS
2. Connect the negative (--) terminal of the voltage
source to the other terminal of the hour meter.
3. The hour meter should move a 1/10 of an hour in six
(6) minutes.
+
4. Disconnect voltage source from the hour meter.
BACK
Figure 21
Temperature Gauge
The temperature gauge on the control panel indicates
engine coolant temperature level during machine op-
eration (Fig. 22). The changing resistance of the engine
temperature sender signals the temperature gauge.
2
3
The temperature gauge should display the first green
segment when the ignition switch is turned to ON. The
first yellow segment on the gauge should display when
engine coolant temperature is approximately 212oF
(100oC).
Whenenginecoolanttemperaturerisestoapproximate-
ly221oF(105oC), thetemperaturegaugeshoulddisplay
the first red segment.
1
Figure 22
1. Console arm
3. High temp indicator
2. Temperature gauge
Electrical System
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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.
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 -- Chas-
sis).
NOTE: To engage the PTO, the seat has to be occu-
pied, traction speed has to be in low range (4WD) and
the cutting units have to be fully lowered.
Testing
1. Before disconnecting the PTO switch for testing, the
switch and its circuit wiring should be tested as a TEC
input with the Diagnostic Display (see Diagnostic Dis-
playintheTroubleshootingsectionofthischapter). Ifthe
Diagnostic Display verifies that the PTO switch and cir-
cuit wiring are functioning correctly, no further switch
testingisnecessary.If,however,theDisplaydetermines
that the PTO switch and circuit wiring are not function-
ing correctly, proceed with test.
2
1
2. Make sure ignition switch is OFF. Remove key from
ignition switch.
3. Disassemble console arm to gain access to PTO
switch (see Console Arm Disassembly in the Service
and Repairs section of Chapter 7 -- Chassis).
4. Disconnect harness electrical connector from the
PTO switch.
Figure 23
1. Console arm
2. PTO switch
5. The switch terminals are marked as shown in Figure
24. The circuit logic of the PTO switch is shown in the
chartbelow. With the useofamultimeter (ohmssetting),
the switch functions can be tested to determine whether
continuity exists between the various terminals for each
switch position. Verify continuity between switch termi-
nals. Replace switch if testing identifies that switch is
faulty.
4
1
5
2
SWITCH
POSITION
CLOSED
CIRCUITS
OPEN
CIRCUITS
3
6
OFF (DOWN)
ON (UP)
COM B + NC B COM B + NO B
COM C + NC C COM C + NO C
Figure 24
COM B + NO B COM B + NC B
COM C + NO C COM C + NC C
1. COM B terminal
2. NO B terminal
3. NC B terminal
4. COM C terminal
5. NO C terminal
6. NC C terminal
6. If PTO switch tests correctly and circuit problem still
exists, check wire harness (see Electrical Schematics
and Wire Harness Drawings in Chapter 9 -- Foldout
Drawings).
Reelmaster 7000
Page 5 -- 21
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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. Assemble console arm (see Console Arm Assembly
in the Service and Repairs section of Chapter 7 -- Chas-
sis).
NOTE: Tolowerthecuttingunits, themowspeedlimiter
hastobeinmowrange(4WD). Also, toraiseorlowerthe
cutting units, the seat has to be occupied.
Testing
1. Before disconnecting the lift switch for testing, the
switch and its circuit wiring should be tested as a TEC
input with the Diagnostic Display (see Diagnostic Dis-
playintheTroubleshootingsectionofthischapter). Ifthe
Diagnostic Display verifies that the lift switch and circuit
wiring are functioning correctly, no further switch testing
is necessary. If, however, the Display determines that
the lift switch and circuit wiring are not functioning cor-
rectly, proceed with test.
1
2
Figure 25
1. Console arm
2. Lift switch
2. Make sure ignition switch is OFF. Remove key from
ignition switch.
3. Disassemble console arm to gain access to cutting
unitliftswitch(seeConsoleArmDisassemblyintheSer-
vice and Repairs section of Chapter 7 -- Chassis).
#4
#1
#5
CUTTING
UNIT
LOCATIONS
4. Disconnect harness electrical connector from the lift
switch.
5. The switch terminals are marked as shown in Figure
27. The circuit logic of the lift switch is shown in the chart
below. With the use of a multimeter (ohms setting), the
switch functions may be tested to determine whether
continuity exists between the various terminals for each
position. Verifycontinuity betweenswitch terminals. Re-
place switch if testing identifies a faulty switch.
#2
#3
Figure 26
SWITCH
POSITION
CLOSED
CIRCUITS
OPEN
CIRCUITS
LOWER
2 + 1
6 + 5
2 + 4
6 + 8
NEUTRAL
RAISE
NONE
ALL
2 + 4
6 + 8
2 + 1
6 + 5
BACK OF SWITCH
Figure 27
6. If lift switch tests correctly and circuitproblem still ex-
ists, check wire harness (see Electrical Schematics and
Wire Harness Drawings in Chapter 9 -- Foldout Draw-
ings).
NOTE: Lift switch terminals 5, 6 and 8 are not used on
Reelmaster 7000 machines.
Electrical System
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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 head-
light switch (see Console Arm Disassembly in the Ser-
vice and Repairs section of Chapter 7 -- Chassis).
3. Disconnect harness electrical connector from the
switch.
2
4. With the use of a multimeter (ohms setting), the
switch functions may be tested to determine whether
continuity exists between the various terminals for each
switch position. The switch terminals are marked as
shown in Figure 29. The circuitry of the switch is shown
in the chart below. Verify continuity between switch ter-
minals. Replace headlight switch if testing identifies a
faulty switch.
Figure 28
1. Console arm
2. Headlight switch
SWITCH
POSITION
CIRCUIT 1
2 + 3
CIRCUIT 2
5 + 6
ON
OFF
2 + 1
5 + 4
BACK OF SWITCH
Figure 29
5. If headlight switch tests correctly and circuit problem
still exists, check wire harness (see Electrical Schemat-
ics and Wire Harness Drawings in Chapter 9 -- Foldout
Drawings).
NOTE: Headlight switch terminals 1, 4, 5 and 6 are not
used on Reelmaster 7000 machines.
6. After testing is completed, connect wire harness
connector to the headlight switch.
7. Assemble console arm (see Console Arm Assembly
in the Service and Repairs section of Chapter 7 -- Chas-
sis).
Reelmaster 7000
Page 5 -- 23
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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 allowsthe enginecooling fanto runin thenormal,
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
DiagnosticDisplayintheTroubleshootingsectionofthis
chapter). If the Diagnostic Display verifies that cooling
fan switch and circuit wiring are functioning correctly, no
further switch testing is necessary. If, however, the Dis-
playdeterminesthatcoolingfanswitchandcircuitwiring
are not functioning correctly, proceed with test.
1
Figure 30
1. Console arm
2. Cooling fan switch
2. Make sure ignition switch is OFF. Remove key from
ignition switch.
3. Disassemble console arm to gain access to the en-
gine cooling fan switch (see Console Arm Disassembly
in the Service and Repairs section of Chapter 7 -- Chas-
sis).
4. Disconnect harness electrical connector from the
cooling fan switch.
BACK OF SWITCH
Figure 31
5. With the use of a multimeter (ohms setting), the
switch functions may be tested to determine whether
continuity exists between the various terminals for each
position. The switch terminals are marked as shown in
Figure 31. The circuitry of the cooling fan switch is
shown in the chart below. Verify continuity between
switch terminals.
NOTE: Cooling fan switch terminals 3, 4, 5 and 6 are
not used on Reelmaster 7000 machines.
SWITCH
POSITION
NORMAL
CIRCUITS
OTHER
CIRCUITS
AUTO
2 + 3
2 + 1
5 + 6
5 + 4
MANUAL RE-
VERSE
6. If switch tests correctly and circuit problem still ex-
ists, check wire harness (see Electrical Schematics and
Wire Harness Drawings in Chapter 9 -- Foldout Draw-
ings).
7. After testing is completed, connect wire harness
connector to the cooling fan switch.
8. Assemble console arm (see Console Arm Assembly
in the Service and Repairs section of Chapter 7 -- Chas-
sis).
Electrical System
Page 5 -- 24
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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 trac-
tionsystemorPTOswitchisengagedwhentheoperator
raises out of the seat, the engine will stop. Testing of the
switch can be done without seat removal by disconnect-
ing the switch wire from the machine wire harness (Fig.
32).
Testing
1. Before disconnecting the seat switch for testing, the
switch and its circuit wiring should be tested as a TEC
input with the Diagnostic Display (see Diagnostic Dis-
playintheTroubleshootingsectionofthischapter). Ifthe
Diagnostic Display verifies that the seat switch and cir-
cuit wiring are functioning correctly, no further switch
testingisnecessary.If,however,theDisplaydetermines
thattheseatswitchandcircuitwiringarenotfunctioning
correctly, proceed with test.
3
1
2
2. Make sure ignition switch is OFF. Remove key from
ignition switch.
Figure 32
1. Wire harness connector
2. Seat switch connector
3. Console arm
3. Disconnect seat switch connector from the machine
wire harness connector.
4. Check the continuity of the switch by connecting a
multimeter (ohms setting) across the seat switch con-
nector terminals.
5. With no pressure on the seat, there should be no
continuity between the seat switch terminals.
6. Press directly onto the seat switch through the seat
cushion. There should be continuity as the seat cushion
approaches the bottom of its travel.
7. If testing determines that seat switch is faulty, re-
place seatswitch (see Operator Seat Service in the Ser-
vice and Repairs section of Chapter 7 -- Chassis).
8. Connect seat switch connector to wire harness con-
nector after testing is complete.
Reelmaster 7000
Page 5 -- 25
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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 bot-
tom of the RH brake pedal (Fig. 33).
Whentheparkingbrakeisnotapplied,theparkingbrake
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. Park machine on a level surface, lower cutting units,
stop engine.
1
2
2. Before disconnecting the parking brake switch for
testing, the switch and its circuit wiring should be tested
as a TEC input with the Diagnostic Display (see Diag-
nostic Display in the Troubleshooting section of this
chapter). Ifthe Diagnostic Display verifies that the brake
switch andcircuitwiringare functioningcorrectly, nofur-
ther switch testing is necessary. If, however, the Display
determines that the brake switch and circuit wiring are
not functioning correctly, proceed with test.
3
6
4
5
Figure 33
3. Make sure ignition switch is OFF. Remove key from
ignition switch.
1. RH brake pedal
2. Brake detent
3. Carriage screw
4. Switch plate
5. Parking brake switch
6. Lock nut
4. Disconnect wire harness electrical connector from
the parking brake switch.
1
5. Check the continuity of the switch by connecting a
multimeter (ohms setting) across the connector termi-
nals.
2
6. When the parking brake is released (brake not ap-
plied), there should be continuity (closed) between the
switch terminals.
7. When the parking brake pedal is depressed (brake
applied), there should not be continuity (open) between
the switch terminals.
Figure 34
1. Parking brake switch
2. Switch target area
NOTE: When installing the parking brake switch to the
brake pedal, place switch plate tab into switch mounting
hole that is closest to target end of switch (Fig. 34).
8. Replace parking brake switch if testing determines
that it is faulty.
9. After testing is complete, connect wire harness elec-
trical connector to the parking brake switch.
Electrical System
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Mow/Transport Sensor
The mow/transport sensor is a normally open proximity
sensorthatcloseswhenthemow speedlimiter isplaced
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. If the mow/transport sensor tests correctly and a cir-
cuit problem still exists, check wire harness (see Electri-
cal Schematic and Wire Harness Drawings in Chapter
9 -- Foldout Drawings).
5. Make sure that mow/transport sensor is connected
to wire harness when testing is complete.
Sensor Testing
1
1. Before disconnecting the mow/transport sensor for
testing, the sensor and its circuit wiring should be tested
as a TEC controller input with the Diagnostic Display
(see Diagnostic Display in the Troubleshooting section
ofthis chapter). IftheDiagnostic Displayverifies thatthe
mow/transport sensor and circuit wiring are functioning
correctly, no further sensor testing is necessary. If, how-
ever, the Diagnostic Display determines that the mow/
transport sensor and circuit wiring are not functioning
correctly, proceed with testing procedure.
2. Turn ignition switch to the ON position (do not start
engine) and check LED on cable end of mow/transport
sensor (Fig. 35). LED should be illuminated when the
mow speed limiter is in the TRANSPORT (2WD) posi-
tion. The LED should not be illuminated when the limit-
er is in the MOW (4WD) position.
2
3
Figure 35
1. Mow speed limiter
2. Mow/transport sensor
3. Sensor cable
3. Ifthe mow/transportsensorLED didnotfunctioncor-
rectly:
A. Make sure that the mow/transport sensor is prop-
erly adjusted (see Mow/Transport Sensor in the Ad-
justments section of this chapter). If necessary,
adjust sensor and return to step 2 above.
B. Make sure ignition switch is OFF and disconnect
the mow/transport sensor connector from machine
wire harness.
C. Verify that the machine wire harness connector
terminal for black wire is closed (continuity) to
ground.
D. Turn ignition switch to the ON position (do not
start engine) and verify with a multimeter that ma-
chine wire harness connector terminal for pink wire
has system voltage (12 VDC) present.
E. If black wire is closed to ground, pink wire has
systemvoltagepresentandsensorLEDdidnotfunc-
tion, replace mow/transport sensor. Adjust sensor
after installation (see Mow/Transport Sensor in the
Adjustments section of this chapter).
Reelmaster 7000
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Cutting Unit Position Sensor
The cutting unit position sensor is a normally open prox-
imity 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).
When the cutting units are lowered, the gusset on the lift
arm is located near the position sensor and the sensor
closes. ThisclosedsensorprovidesaninputfortheTEC
controller to allow the lowered cutting units to operate.
6. Make sure that cutting unit position sensor is con-
nected to wire harness when testing is complete.
Sensor Testing
3
1. Park machine on a level surface, lower cutting units,
stop engine and engage parking brake.
1
2. Before disconnecting the cutting unit position sensor
for testing, the sensor and its circuit wiring should be
tested as a TEC input with the Diagnostic Display (see
DiagnosticDisplayintheTroubleshootingsectionofthis
chapter). If the Diagnostic Display verifies that the posi-
tion sensor and circuit wiring are functioning correctly,
no further sensor testing is necessary. If, however, the
Display determines that the position sensor and circuit
wiring are not functioning correctly, proceed with test.
2
Figure 36
1. Position sensor
2. Sensor cable
3. Lift arm (#5)
3. Turn ignition switch to the ON position and check
LED on cable end of cutting unit position sensor (Fig.
36). LED should be illuminated when the cutting units
are fully lowered. The LED should not be illuminated
when the cutting units are raised above the turn--around
position.
#4
#1
#5
4. If the position sensor LED did not function correctly:
A. Make sure that the cutting unit position sensor is
properly adjusted (see Cutting Unit Position Sensor
in the Adjustments section of this chapter). If neces-
sary, adjust sensor and return to step 2 above.
#2
#3
B. Make sure ignition switch is OFF and disconnect
the cutting unit position sensor connector from ma-
chine wire harness.
C. Verify that the machine wire harness connector
terminal for black wire is closed (continuity) to
ground.
CUTTING UNIT LOCATIONS
Figure 37
D. Turn ignition switch to the ON position (do not
start engine) and verify with a multimeter that ma-
chine wire harness connector terminal for pink wire
has system voltage (12 VDC) present.
E. If black wire is closed to ground, pink wire has
systemvoltagepresentandsensorLEDdidnotfunc-
tion, replace cutting unit position sensor. Adjust sen-
sor after installation (see Cutting Unit Position
Sensor in the Adjustments section of this chapter).
Electrical System
Page 5 -- 28
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Backlap Switches
The backlap switches are normally open ball switches
that are in the normal, open state when the backlap lev-
ers are in the mow position. When a backlap lever is in
the backlap position, the switch closes. The backlap
switchesareattachedtothehydraulicmowcontrolman-
ifold located under the hood (Fig. 38). The Toro Elec-
tronic Controller (TEC) uses the backlap switches as
inputs.
1
4
2
Testing
3
5
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.
Figure 38
2. Before disconnecting a backlap 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).
If the Diagnostic Display verifies that the backlap switch
and circuit wiring are functioning correctly, no further
switch testing is necessary. If, however, the Display de-
termines that the backlap switch and circuit wiring are
not functioning correctly, proceed with test.
1. Mow control manifold
2. Front backlap lever
3. Front backlap switch
4. Rear backlap lever
5. Rear backlap switch
1
5
4
3
3. Make sure ignition switch is in the OFF position.
4. Unlatch and raise hood to allow access to hydraulic
mow control manifold. Locate the backlap switch on the
front of the manifold. Disconnect the harness electrical
connector from the backlap switch.
2
5. Check the continuity of the switch by connecting a
multimeter (ohms setting) across the switch connector
terminals.
20 ft--lb
2
(27 N--m)
6. With the ignition switch in the OFF position, turn the
backlap lever to the backlap position while watching the
multimeter.Continuityshouldbemadeastheswitchclo-
ses.
Figure 39
1. Mow control manifold
2. Backlap switch (2 used)
3. O--ring
4. Dowel
5. Ball
7. Turn the backlap lever to the mow position while
watchingthemultimeter. Continuityshouldbebrokenas
the switch opens.
8. If backlap switch is faulty, replace switch (Fig. 39).
9. If the backlap switch tests correctly and a circuit
problem still exists, check wire harness (see Electrical
Schematic and Wire Harness Drawings in Chapter 9 --
Foldout Drawings).
10.After testing is completed, connect harness electri-
cal connector to the backlap switch. Lower and secure
hood.
Reelmaster 7000
Page 5 -- 29
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Glow and Main Power Relays
The glow and main power relays are located at the pow-
er center behind the operator seat (Fig. 40). These re-
lays are attached to the wire harness with a four (4) wire
connector (Fig. 41).
7. Disconnect voltage and test leads from the relay ter-
minals.
8. Secure relay to mounting bracket and connect wire
harnessconnectortorelay.Installcovertopowercenter.
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.
9. Connect positive (+) cable to battery and then con-
nect negative (--) cable to battery (see Battery Service
in the Service and Repairs section of this chapter).
The main power relay is used to provide current to the
TEC controllers and most of the fuse protected circuits
(headlights, operator seat, power point and optional
electric equipment). When the ignition switch is in the
ON or START position, the main power relay is ener-
gized.
3
1
1
2
Testing
4
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.
2. To make sure that machine operation does not occur
unexpectedly, disconnect negative (--) cable from bat-
tery and then disconnect positive (+) cable from battery
(see Battery Service in the Service and Repairs section
of this chapter).
5
6
3. Remove cover from power center and locate relay to
be tested.
5
Figure 40
4. Disconnect wire harness connector from relay. Re-
move relay from mounting bracket for testing.
1. Lock nut
2. Main power relay
3. Glow relay
4. Start relay
5. Flange head screw
6. Mounting bracket
NOTE: Prior to taking small resistance readings with a
digital multimeter, short the meter test leads together.
The meter will display a small resistance value (usually
0.5 ohms or less). This resistance is due to the internal
resistance of the meter and test leads. Subtract this val-
ue from from the measured value of the component you
are testing.
86
85
87
30
85
86
87
30
5. Using a multimeter, verify that coil resistance be-
tween terminals 86 and 85 is approximately 72 ohms.
6. Connectmultimeter (ohmssetting) leadsto relayter-
minals 30 and 87. Ground terminal 86 and apply +12
VDC to terminal 85. The relay should make and break
continuity between terminals 30 and 87 as +12 VDC is
applied and removed from terminal 85.
Figure 41
Electrical System
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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).
10.Secure relay to mounting bracket and connect wire
harnessconnectortorelay.Installcovertopowercenter.
11.Connect positive (+) cable to battery and then con-
nect negative (--) cable to battery (see Battery Service
in the Service and Repairs section of this chapter).
The start relay is used to provide current to the engine
startermotorwhenenergizedbytheTECcontroller. The
TEC controls and monitors the operation of the start
relay.
3
Testing
1
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.
1
2
2. To make sure that machine operation does not occur
unexpectedly, disconnect negative (--) cable from bat-
tery and then disconnect positive (+) cable from battery
(see Battery Service in the Service and Repairs section
of this chapter).
4
3. Remove cover from power center and locate start
relay.
5
4. Disconnect wire harness connector from relay. Re-
move relay from mounting bracket for testing.
6
5
NOTE: Prior to taking small resistance readings with a
digital multimeter, short the meter test leads together.
The meter will display a small resistance value (usually
0.5 ohms or less). This resistance is due to the internal
resistance of the meter and test leads. Subtract this val-
ue from from the measured value of the component you
are testing.
Figure 42
1. Lock nut
2. Main power relay
3. Glow relay
4. Start relay
5. Flange head screw
6. Mounting bracket
5. Using a multimeter, verify that coil resistance be-
tween terminals 85 and 86 is from 71 to 88 ohms.
4
3
1
6. Connectmultimeter (ohmssetting) leadsto relayter-
minals 30 and 87. Ground terminal 86 and apply +12
VDC to terminal 85. The relay should make and break
continuity between terminals 30 and 87 as +12 VDC is
applied and removed from terminal 85.
86
85
87A
87
7. Disconnect voltage from terminal 85 and multimeter
lead from terminal 87.
30
8. Connectmultimeter (ohmssetting) leadsto relayter-
minals 30 and 87A. Apply +12 VDC to terminal 85. The
relay should make and break continuity between termi-
nals 30 and 87A as +12 VDC is applied and removed
from terminal 85.
1
2
Figure 43
1. Coil terminal
2. Common terminal
3. Normally closed term.
4. Normally open terminal
9. Disconnect voltage and multimeter test leads from
the relay terminals.
Reelmaster 7000
Page 5 -- 31
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Reel Speed Potentiometer
The reel speed potentiometer controls the cutting reel
speed. The TEC controller uses the potentiometer set-
ting as an input to determine the necessary voltage out-
put for the hydraulic mow control manifold proportional
valves(SP1andSP2)forcorrectcuttingreelspeed. The
reel speed potentiometer is located under the operator
seat (Fig. 44).
1
Testing
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 operator seat to gain access to
reel speed potentiometer.
Figure 44
1. Reel speed potentiometer
3. Carefully unplug wire harness connector from reel
speed potentiometer.
4. Remove screw that secures potentiometer to ma-
chine and remove potentiometer from machine for test-
ing.
NOTE: Prior to taking small resistance readings with a
digital multimeter, short the meter test leads together.
The meter will display a small resistance value (usually
0.5 ohms or less). This resistance is due to the internal
resistance of the meter and test leads. Subtract this val-
ue from from the measured value of the component you
are testing.
5. Using a multimeter, measure resistances between
potentiometer terminals as follows (Fig. 45):
A. Verify that resistance between terminals B and C
is approximately 5000 ohms. Record measured re-
sistance.
3
2
1
Figure 45
B. Measure resistance between terminals A and C
and then measure resistance between terminals A
and B. Record these resistances. The totalofthetwo
measured resistances should be approximately
5000 ohms.
1. Terminal A
2. Terminal B
3. Terminal C
C. Rotate the reel speed potentiometer to other set-
tings and repeat step 6. The total of the two resist-
ances should consistently be approximately 5000
ohms.
D. If measured resistances are incorrect, replace
reel speed potentiometer.
6. After testing is completed, secure potentiometer to
machine frame. Secure wire harness connector to po-
tentiometer. Lower and secure seat.
Electrical System
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Hydraulic Solenoid Valve Coils
Numerous hydraulic solenoid valve coils are used on
the hydraulic control manifolds of Reelmaster 7000 ma-
chines. When energized by the TEC controller, these
coils provide hydraulic circuit control.
5. If solenoid coil resistance is incorrect, replace sole-
noid (see Hydraulic Solenoid Valve Coil Removal and
Installation in the Service and Repairs section of this
chapter).
Two(2)differentsolenoidvalvecoilsareusedontheRe-
elmaster 7000. A coil can be identified by measuring it’s
height and diameter (Fig. 46). Testing of the coils can be
done with the coil remaining on the hydraulic valve.
6. After testing is completed, connect wire harness
connector to the solenoid coil.
NOTE: To assist in troubleshooting, identical solenoid
coils can be exchanged. If the problem follows the ex-
changed coil, a problem with the coil likely exists. If the
problem remains unchanged, something other than the
solenoid coil is the problem source (e.g. switch, circuit
wiring, hydraulic problem).
Testing
COIL
DIAMETER
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.
2. Locate hydraulic valve solenoid coil to be tested.
Identify coil by measuring the coil diameter and coil
height (Fig. 46).
COIL
HEIGHT
3. Disconnect wire harness connector from coil.
NOTE: Prior to taking small resistance readings with a
digital multimeter, short the meter test leads together.
The meter will display a small resistance value (usually
0.5 ohms or less). This resistance is due to the internal
resistance of the meter and test leads. Subtract this val-
ue from from the measured value of the component you
are testing.
Figure 46
4. Using a multimeter (ohms setting), measure resis-
tance between the two (2) connector terminals on the
solenoid valve coil. The correct resistance for the sole-
noid coil is identified below:
COIL
DIAMETER
COIL
HEIGHT
COIL
RESISTANCE
1.840 inch
(46.7 mm)
1.960 inch
(49.9 mm)
7.1 ohm
1.410 inch
(35.8 mm)
1.430 inch
(36.3 mm)
8.8 ohm
NOTE: Solenoid coil resistance should be measured
with solenoid at approximately 68oF (20oC). Resistance
may be slightly different than listed at different tempera-
tures. Typically, a failed solenoid coil will either be
shorted (very low or no resistance) or open (infinite re-
sistance).
Reelmaster 7000
Page 5 -- 33
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Traction Neutral Switch
The traction neutral switch is closed when the traction
pedalisintheneutralpositionandopenswhenthepedal
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 -- Hy-
draulic Systems for disassembly and assembly proce-
dures for the neutral switch.
Testing
Before disconnecting the traction neutral switch for test-
ing, 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).
If the Diagnostic Display verifies that neutral switch and
circuit wiring are functioning correctly, no further switch
testingisnecessary.If,however,theDisplaydetermines
that neutral switch and circuit wiring are not functioning
correctly, proceed with test.
2
1
To test the traction neutral switch, make sure that the
ignition switch is in the OFF position and the key is re-
moved from the switch. Disconnect the wire harness
connector from the neutral switch and connect a multi-
meter across the two (2) switch terminals. With the en-
gine turned off, slowly push the traction pedal in a
forwardorreversedirectionwhilewatching themultime-
ter. There should be indications that the traction neutral
switch is opening and closing. Allow the traction pedal
to return to the neutral position. There should be conti-
nuity across the switch terminals when the traction ped-
al is in the neutral position.
Figure 47
1. Piston (traction) pump
2. Neutral switch
Diode Assembly
The engine wire harness contains a diode that is used
for circuit protection from voltage spikes when the en-
gine starter solenoid is de--energized. The diode plugs
into the wiring harness near the starter motor (see En-
gine Wire Harness Drawing in Chapter 9 -- Foldout
Drawings).
2
Diode Test
3
1
The diode (Fig. 48) can be individually tested using a
digital multimeter (diode test or ohms setting) and the
table to the right.
Figure 48
1. Diode
3. Female terminal
2. Male terminal
Multimeter
Red Lead (+)
on Terminal
Multimeter
Black Lead (--)
on Terminal
Continuity
Female
Male
Male
YES
NO
Female
Electrical System
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Toro Electronic Controller (TEC)
The Reelmaster 7000 uses a Toro Electronic Controller
(TEC) to monitor the condition of various switches (in-
puts) and then directs power output to allow certain ma-
chine functions. The controller is located under the
operator seat (Fig. 49). The handheld Diagnostic Dis-
play (see Special Tools in this chapter) with the correct
overlay should be used when checking inputs and out-
puts of the controller used on your Reelmaster (see
Troubleshooting in this chapter).
1
Inputs from the ignition, traction neutral, parking brake,
PTO, seat, cutting unit lift, mow/transport, engine cool-
ing fan, backlap, reel position, hydraulic temperature,
engine oil pressure and engine coolant switches are all
monitored by the controller.
Figure 49
Current output to the mow circuit hydraulic valve sole-
noid coils, lift circuit hydraulic valve solenoid coils and
engine components (glow plug relay, start relay, fuel
pump and engine run solenoid) are controlled based on
the inputs received by the controller.
1. TEC controller
Because of the solid state circuitry built into the control-
ler, there is no method to test the controller directly. The
controller may be damaged if an attempt is made to test
itwith an electricaltestdevice, such asa digitalmultime-
ter.
IMPORTANT: Before performing any welding on the
machine, disconnect both positive and negative
battery cables from the battery, disconnect the wire
harness connector from the TEC controller and dis-
connect the terminal connector from the alternator.
This will prevent damage to the electrical system of
your Reelmaster.
Reelmaster 7000
Page 5 -- 35
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Engine Coolant and Hydraulic Oil Temperature Senders
Two (2) identical temperature senders are used as in-
puts for the TEC controller to identify if either the engine
coolant or hydraulic oil temperature has reached an ex-
cessive 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:
A. Install new O--ring on sender and thread sender
into port. Torque sender to values identified incorrect
illustration (Fig. 50 or 51).
B. Connect wire harness connector to sender.
8. Check and fill system (coolant or hydraulic) to proper
level.
Testing
1. Park machine on a level surface, lower cutting units,
stop engine and engage parking brake.
9 to 11 ft--lb
(12.3 to 14.9 N--m)
2. Before disconnecting temperature sender for test-
ing, the sender 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).
If the Diagnostic Display verifies that the sender and cir-
cuit wiring are functioning correctly, no further sender
testingis necessary. If, however, the Displaydetermines
that the temperature sender and circuit wiring are not
functioning correctly, proceed with test.
1
2
3. Locate temperature sender that is to be tested. Dis-
connect wire harness connector from sender.
Figure 50
1. Radiator
2. Coolant temp sender
4. Thoroughly clean area around temperature sender
and remove sender.
20 to 26 ft--lb
(27 to 35 N--m)
5. Put sensing end of sender in a container of oil with
a thermometer and slowly heat the oil (Fig. 52).
2
CAUTION
Handle the hot oil with extreme care to prevent
personal injury or fire.
1
NOTE: Prior to taking resistance readings with a digital
multimeter, short the meter test leads together. The me-
ter will display a small resistance value (usually 0.5
ohms or less). This resistance is due to the internal re-
sistance of the meter and test leads. Subtract this value
from from the measured value of the tested component.
Figure 51
1. 4WD/2WD manifold
2. Oil temp sender
6. Check resistance of the sender with a multimeter
(ohms setting) as the oil temperature increases. Re-
place sender if specifications are not met.
OIL TEMP
SENDER RESISTANCE
11.6 to 13.5 kilo ohms
2.3 to 2.5 kilo ohms
605 to 669 ohms
o
o
68 F (20 C)
o
o
140 F (60 C)
o
o
212 F (100 C)
Figure 52
Electrical System
Page 5 -- 36
Reelmaster 7000
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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. 54) from fuse block to
prevent the engine from cranking.
Figure 53
1. Fuel/water separator
2. Pump discharge hose
3. Inlet fitting
4. Make sure fuel hoses attached to the fuel pump are
free of obstructions.
5. Disconnect fuel pump discharge hose from the fuel/
water separator inlet fitting (Fig. 53).
FRONT
6. Place disconnected fuel hose (pump discharge) into
a large, graduated cylinder sufficient enough to collect
1 quart (0.95 liter).
F1
7. Collect fuel in the graduated cylinder by turning igni-
tion switch to the ON position. Allow pump to run for fif-
teen (15) seconds, then turn switch to OFF.
F2
F3
M2 (option)
M1 (60A)
8. The amount of fuel collected in the graduated cylin-
der should be approximately 16 fl oz (475 ml) after fif-
teen (15) seconds.
9. Replace fuel pump if necessary.
Figure 54
Fuel Pump Specifications
10.Install fuel hose to the fuel/water separator. Secure
hose with hose clamp.
Pump Capacity
Pressure
64 fl oz/min (1.9 l/min)
7 PSI (48.3 kPa)
2.0 amp
11.Install 20A fuse into fuse block.
12.Bleed the fuel system.
Current Draw
13.Lower and secure hood.
Reelmaster 7000
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Fuel Stop Solenoid
ThefuelstopsolenoidusedonyourReelmastermustbe
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 Dis-
play before following the testing procedure listed below
(see Special Tools and Troubleshooting in this chapter).
1
2
Testing
1. Park machine on a level surface, lower cutting units,
stop engine, apply parking brake and remove key from
ignition switch. Open hood to gain access to engine.
2. Disconnect wire harness connector from fuel stop
solenoid.
Figure 55
1. Injection pump
2. Fuel stop solenoid
NOTE: The fuel stop solenoid may be removed from
the engine or tested in place.
2
3. If the solenoid is removed from the engine, make
sure that the solenoid plunger moves freely and is free
of dirt, debris and corrosion.
1
NOTE: Prior to taking small resistance readings with a
digital multimeter, short the test leads together. The me-
ter will display a small resistance value (usually 0.5
ohms or less). This resistance is due to the internal re-
sistance of the meter and test leads. Subtract this value
from the measured value ofthe componentyou are test-
ing.
3
Figure 56
4. Using a digital multimeter (ohms setting), touch one
test lead to the pull coil terminal and the other test lead
to the fuel stop solenoid frame (ground) (Fig. 56). The
resistance of the pull coil should be less than 1 ohm (but
not zero).
1. Fuel stop solenoid
2. Pull coil terminal
3. Hold coil terminal
5. Using a digital multimeter (ohms setting), touch one
test lead to the hold coil terminal and the other test lead
to the fuel stop solenoid frame (ground) (Fig. 56). The
resistance of the hold coil should be approximately 15
ohms.
6. If either coil resistance is incorrect, replace fuel stop
solenoid.
7. Connect wire harness connector to the fuel stop so-
lenoid.
8. Lower and secure hood.
Electrical System
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Engine Temperature Sender
The engine temperature sender is located near the al-
ternatoronthewaterflangeattachedtotheenginecylin-
der head (Fig. 57). There is a gray wire attached to the
terminal of the sender.
5. Install sender to the water flange.
A. Clean threads of water flange and sender thor-
oughly. Apply thread sealant to the threads of the
sender.
The resistance of the temperature sender reduces as
the engine coolant temperature increases. The chang-
ing resistance of the temperature sender signals the
console temperature gauge to indicate engine coolant
temperature during machine operation.
B. Screw sender into the water flange. Torque send-
er from 16 to 20 ft--lb (22 to 27 N--m).
C. Connect gray wire to sender. Apply skin--over
grease (Part Number TOR50547) to sender termi-
nal.
Engine Temperature Sender Test
6. Fill engine cooling system.
7. Close and secure hood.
1. Park machine on a level surface, lower cutting units,
stop engine, apply parking brake and remove key from
ignition switch. Open hood to gain access to engine.
1
CAUTION
Make sure engine is cool before removing the
temperature sender from engine.
2. Lower coolant level in the engine and remove the
temperature sender from water flange.
2
3. Put sender in a container of oil with a thermometer
and slowly heat the oil (Fig. 58).
Figure 57
CAUTION
1. Temperature sender
2. Alternator
Handle the hot oil with extreme care to prevent
personal injury or fire.
NOTE: Prior to taking resistance readings with a digital
multi meter, short the meter test leads together. The me-
ter will display a small resistance value (usually 0.5
ohms or less). This resistance is due to the internal re-
sistance of the meter and test leads. Subtract this value
fromfrom themeasured valueofthecomponentyouare
testing.
4. Check resistance of the sender with a multimeter
(ohms setting) as the temperature increases. Replace
sender if specifications are not met.
Figure 58
OIL TEMP
100oF (38oC)
160oF (71oC)
200oF (93oC)
221oF (105oC)
TEMP SENDER RESISTANCE
460 ohms (approximate)
140 ohms (approximate)
54 to 78 ohms
50 ohms (approximate)
Reelmaster 7000
Page 5 -- 39
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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 pres-
sure.
The oil pressure switch should open at approximately 8
PSI (0.56 kg/cm2).
2
The TEC controller monitors the operation of the oil
pressureswitch. Theswitchand itscircuitwiring should
be tested as a controller input with the Diagnostic Dis-
play (see Special Tools and Troubleshooting in this
chapter).
1
Testing
NOTE: Refer to Kubota Workshop Manual, Diesel En-
gine, 03--M--DI--E3B for information regarding engine
lubrication system and testing.
Figure 59
1. Starter motor
2. Oil pressure switch
1. Turn the ignition switch to the ON position (do not
start engine). The oil pressure indicator light on the con-
trol panel should be illuminated.
2. If the indicator light is not illuminated, open hood to
gain access to engine.
3. Locate oil pressure switch on engine and disconnect
the wire harness connector from the switch.
4. With the ignition switch in the ON position, ground
the disconnected wire to the engine block.
5. If the indicator light comes on, the oil pressure switch
is faulty.
6. If the indicator light does not come on after step 5,
check the oil pressure indicator light and circuit wiring
(see Indicator Lights in this section).
7. After testing is completed, connect the wire harness
connector to the oil pressure switch. Lower and secure
hood.
Electrical System
Page 5 -- 40
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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:
4. Store battery in a cool atmosphere to avoid quick de-
terioration of the battery charge.
1. Remove the battery and charge it fully (see Battery
Service in this section).
5. To help prevent the battery from freezing, make sure
it is fully charged (see Battery Service in this section).
2. Either store battery on a shelf or on the machine.
3. Leave cables disconnected if the battery is stored on
the machine.
Battery Care
1. Battery electrolyte level must be properly main-
tained. The top of the battery must be kept clean. lf the
machine is stored in a location where temperatures are
extremely high, the battery will discharge more rapidly
than if the machine is stored in a location where temper-
atures are cool.
3. Battery cables must be tight on battery terminals to
provide good electrical contact.
WARNING
Connecting cables to the wrong post could re-
sult in personal injury and/or damage to the elec-
trical system.
WARNING
Wear safety goggles and rubber gloves when
working with electrolyte. Charge battery in a
well ventilated place so gasses produced while
charging can dissipate. Since the gases are ex-
plosive, keep open flames and electrical sparks
away from the battery; do not smoke. Nausea
mayresultifthegasesareinhaled. Unplugchar-
ger from electrical outlet before connecting or
disconnecting charger leads to or from battery
posts.
4. If corrosion occurs at battery terminals, disconnect
cables. Always disconnect negative (--) cable first.
Clean clamps and terminals separately. Reconnect
cables with positive (+) cable first. Coat battery posts
and cable connectors with battery terminal protector
(see Special Tools in this chapter) or petroleum jelly to
prevent corrosion.
5. Checkelectrolytelevelevery25operatinghoursand
every 30 days if machine is in storage.
6. Maintain battery cell level with distilled or demineral-
ized water. Do not fill cells above the fill line.
IMPORTANT: Do not remove fill caps while clean-
ing.
2. Check battery condition weekly or after every 50
hours of operation. Keep terminals and entire battery
case clean because a dirty battery will discharge slowly.
A. Clean battery by washing entire case with a solu-
tionofbakingsodaandwater. Rinsewithclearwater.
B. Coatbatterypostsandcableconnectorswithbat-
tery terminal protector (see Special Tools in this
chapter) or petroleum jelly to prevent corrosion.
Reelmaster 7000
Page 5 -- 41
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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 cau-
tion 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.
Battery Specifications
BCI Group 24 Battery
660 Amp Cranking Performance at 0oF (--18oC)
110 minute Reserve Capacity at 80oF (27oC)
Electrolyte Specific Gravity (fully charged): from 1.250
to 1.280
Electrolyte Specific Gravity (discharged): 1.240
Battery Removal and Installation (Fig. 60)
Figure 60
1. Negative cable
2. Positive cable
3. Battery strap
1. Unlatch and raise battery storage box cover behind
the operator seat to access battery.
Battery Inspection and Maintenance
2. Loosen and remove negative cable from battery. Af-
ter negative cable is removed, loosen and remove posi-
tive cable from battery.
1. Replace battery if case is cracked or leaking.
2. Check battery terminal posts for corrosion. Use wire
brush to clean corrosion from posts.
3. Loosen strap that secures battery in storage box.
4. Carefully remove battery from machine.
IMPORTANT: Before cleaning the battery, tape or
block vent holes to the filler caps and make sure the
caps are on tightly.
5. Install battery in reverse order making sure to con-
nect and tighten positive cable to battery before con-
necting the negative cable.
3. Check for signs of wetness or leakage on the top of
the battery which might indicate a loose or missing filler
cap, overcharging, loose terminal post or overfilling.
Also, check battery case for dirt and oil. Clean the bat-
tery with a solution of baking soda and water, then rinse
it with clean water.
NOTE: Before connecting the negative (ground) cable,
connect a digital multimeter (set to amps) between the
negative battery post and the negative (ground) cable
connector. The reading should be less than 0.1 amp. If
the reading is 0.1 amp or more, the machine’s electrical
system should be tested for short circuits or faulty com-
ponents and repaired.
4. Check that the cover seal is not broken away. Re-
place the battery if the seal is broken or leaking.
6. Make sure that rubber boot is properly placed over
positive cable end and positive battery post.
5. Check the electrolyte level in each cell. If the level is
below the tops of the plates in any cell, fill all cells with
distilled water between the minimum and maximum fill
lines. Charge at 15 to 25 amps for fifteen (15) minutes
to allow sufficient mixing of the electrolyte.
7. Lower and secure battery storage box cover.
Electrical System
Page 5 -- 42
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Battery Testing
C. Make sure batteryterminals arefree ofcorrosion.
1. Conduct a hydrometer test of the battery electrolyte.
D. Measure the temperature of the center battery
cell.
IMPORTANT: Make sure the area around the cells is
clean before opening the battery caps.
E. Connect a battery load tester to the battery termi-
nals following the load tester manufacturer’s in-
structions. Connect a digital multimeter to the
battery terminals.
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 tem-
perature of the cell.
F. Applyatestloadof330amps(onehalftheCrank-
ing Performance rating of the battery) for fifteen (15)
seconds.
B. Temperature correct each cell reading. For each
10oF (6oC) above 80oF (27oC) add 0.004 to the spe-
cificgravityreading.Foreach10oF(6oC)below80oF
(27oC) subtract 0.004 from the specific gravity read-
ing.
G. Take a battery voltage reading after the load has
been applied to the battery for fifteen (15) seconds,
then remove the load. Record the voltage reading.
H. Using the table below, determine the minimum
voltage for the cell temperature reading:
o
Example: Cell Temperature
Cell Gravity
100 F
1.245
o
o
o
100 F minus 80 F equals 20 F
o
o
o
Minimum
Voltage
Battery Electrolyte
Temperature
(38 C minus 27 C equals 11 C)
o
o
20 F multiply by 0.004/10 F equals 0.008
o
o
(11 C multiply by 0.004/6 C equals 0.008)
ADD (conversion above) 0.008
1.253
9.6
9.5
9.4
9.3
9.1
8.9
8.7
8.5
70oF (and up)
21oC (and up)
16oC
60oF
50oF
40oF
30oF
20oF
10oF
0oF
o
o
Correction to 80 F (27 C)
10oC
4oC
-- 1 oC
-- 7 oC
-- 1 2 oC
-- 1 8 oC
C. If the difference between the highest and lowest
cell specific gravity is 0.050 or greater or the lowest
cellspecificgravityislessthan1.225,chargethebat-
tery. Charge at the recommended rate and time giv-
en in Battery Charging or until all cells specific
gravity is 1.225 or greater with the difference in spe-
cific gravity between the highest and lowest cell less
than 0.050. If these charging conditions can not be
met, replace the battery.
I. If the test voltage is below the minimum, replace
the battery. If the test voltage is at or above the mini-
mum, return the battery to service.
2. Perform a high--discharge test with an adjustable
load tester.
Thisisoneofthemostreliablemeansoftestingabattery
asitsimulatesthecold--crankingtest.Acommercialbat-
tery load tester is required to perform this test.
CAUTION
Follow the battery load tester manufacturer’s
instructions when using a load tester.
A. Check the voltage across the battery terminals
prior to testing the battery. If the voltage is less than
12.4 VDC, recharge the battery.
B. If the battery has been charged, apply a 150 amp
load for fifteen (15) seconds to remove the surface
charge. Use a battery load tester following the
manufacturer’s instructions.
Reelmaster 7000
Page 5 -- 43
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Battery Charging
CAUTION
To minimize possible damage to the battery and allow
the battery to be fully charged, the slow charging meth-
od is presented here. This charging method can be ac-
complished with a constant current battery charger
which is available in most locations.
Do not charge a frozen battery because it can ex-
plode and cause injury. Let the battery warm to
60oF (16oC) before connecting to a charger.
Charge the battery in a well--ventilated place to
dissipate gases produced from charging. These
gases are explosive; keep open flame and elec-
trical spark away from the battery. Do not smoke.
Nausea may result if the gases are inhaled. Un-
plug the charger from the electrical outlet before
connecting or disconnecting the charger leads
from the battery posts.
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.
3. Following the battery charger manufacturer’s
instructions, connect the charger cables to the battery.
Make sure a good connection is made.
1. Determine the battery charge level from either its
specific gravity or open circuit voltage.
4. Charge the battery following the battery charger
manufacturer’s instructions.
Battery Charge
Level
Specific
Gravity
Open Circuit
Voltage
5. Occasionally check the temperature of the battery
electrolyte. If the temperature exceeds 125oF (52oC) or
the electrolyte is violently gassing or spewing, the
charging rate must be lowered or temporarily stopped.
100%
75%
50%
25%
0%
1.265
1.225
1.190
1.155
1.120
12.68
12.45
12.24
12.06
11.89
6. Three (3)hours priorto theend ofthe charging, mea-
sure the specific gravity of a battery cell once per hour.
The battery is fully charged when the cells are gassing
freely at a low charging rate and there is less than a
0.003 change in specific gravity for three (3) consecu-
tive readings.
2. Determine the charging time and rate using the bat-
tery charger manufacturer’s instructions or the fol-
lowing table.
Battery
Reserve
Capacity
(Minutes)
Battery Charge Level
(Percent of Fully Charged)
75%
50%
25%
0%
80 or less 3.8 hrs
@
7.5 hrs 11.3 hrs 15 hrs
@
@
@
3 amps 3 amps 3 amps 3 amps
81 to 125 5.3 hrs 10.5 hrs 15.8 hrs 21 hrs
@
@
@
@
4 amps 4 amps 4 amps 4 amps
126 to
170
5.5 hrs
@
11 hrs
@
16.5 hrs 22 hrs
@
@
5 amps 5 amps 5 amps 5 amps
171 to
250
5.8 hrs 11.5 hrs 17.3 hrs 23 hrs
@
@
@
@
6 amps 6 amps 6 amps 6 amps
above
250
6 hrs
@
12 hrs
@
18 hrs
@
24 hrs
@
10 amps 10 amps 10 amps 10 amps
Electrical System
Page 5 -- 44
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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. Note orientation of electri-
cal connector on coil for assembly purposes.
2
4. Remove nut that secures coil to hydraulic valve.
5. Slide solenoid coil from valve.
6. Clean any corrosion or dirt from valve stem.
Installation (Fig. 61)
1
1. Slide solenoid coil onto the hydraulic valve. Position
coil so that connector is properly orientated.
LIFT/LOWER CONTROL MANIFOLD SHOWN
Figure 61
2. Install nut onto valve and torque nut 60 in--lb (6.8
N--m) (do not over tighten).
1. Control manifold
2. Solenoid valve
3. Solenoid coil
4. Nut
3. Connect machine wire harness connector to the so-
lenoid coil.
Reelmaster 7000
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Electrical System
Page 5 -- 46
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Chapter 6
Axles, Planetaries and Brakes
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3
Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4
Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Brake Inspection and Repair . . . . . . . . . . . . . . . . . . 6
Planetary Wheel Drive Assembly . . . . . . . . . . . . . . 8
Planetary Wheel Drive Service . . . . . . . . . . . . . . . 10
Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . 14
Rear Axle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Bevel Gear Case and Axle Case . . . . . . . . . . . . . 18
Differential Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Axle Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Input Shaft/Pinion Gear . . . . . . . . . . . . . . . . . . . . . 24
Differential Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Pinion Gear to Ring Gear Engagement . . . . . . . . 29
Reelmaster 7000
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Specifications
Item
Specification
85 to 100 ft--lb (116 to 135 N--m)
100 to 125 ft--lb (136 to 169 N--m)
75 to 85 ft--lb (102 to 115 N--m)
Wheel lug nut torque (front and rear)
Steering cylinder bolt torque
Planetary, brake housing and wheel motor
mounting screw torque
Rear wheel toe--in
0.125 in (3 mm)
20 psi (138 kPa)
Tire pressure (front and rear)
Planetary gear drive lubricant
Planetary gear lube capacity (each wheel)
SAE 85W--140 wt. gear lube
16 fl oz (0.47 l)
Rear axle lubricant
Rear axle gear lube capacity
SAE 85W--140 wt. gear lube
80 fl oz (2.37 l)
Axles, Planetaries and Brakes
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General Information
Operator’s Manual
The Traction Unit Operator’s Manual provides informa-
tion regarding the operation, general maintenance and
maintenance intervals for your Reelmaster machine.
Refer to this publication for additional information when
servicing the machine.
Reelmaster 7000
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Service and Repairs
Brake Assembly
75 to 85 ft--lb
(102 to 115 N--m)
1
19
85 to 100 ft--lb
(116 to 135 N--m)
3
18
6
5
2
17
17
20
8
7
9
16
12
15
14
13
RIGHT
11
10
FRONT
19
75 to 85 ft--lb
(102 to 115 N--m)
4
Figure 1
1. Flange head screw (6 per planetary)
2. Splined brake shaft
3. Planetary assembly (2 used)
4. Front wheel assembly (2 used)
5. Lug nut (8 per wheel)
6. Retaining ring
8. Compression spring
9. Jam nut
10. LH Brake assembly
11. Flange head screw (4 per brake)
12. Hex plug
13. Piston motor (2 used)
14. Flat washer (2 per motor)
15. Cap screw (2 per motor)
16. O--ring
17. O--ring
18. RH brake assembly
19. Gasket
20. Brake cable (LH shown)
7. Spring plate
Brake Assembly Removal (Fig. 1)
1. Park machine on a level surface and raise cutting
units to allow easier access to front brake assembly.
Stop engine, engage parking brake and remove key
from the ignition switch.
CAUTION
When changing attachments, tires or perform-
ing other service, use correct blocks, hoists and
jacks to raise and support machine. Make sure
machine is parked on a solid level surface such
as a concrete floor. Prior to raising machine, re-
move any attachments that may interfere with
the safe and proper raising of the machine. Al-
ways chock or block wheels. Use appropriate
jack stands to support the raised machine. If the
machine is not properly supported by jack
stands, the machine may move or fall, which
may result in personal injury.
2. Drain oilfromplanetarywheeldrive/brakeassembly.
3. Chock rear wheels and jack up front of machine (see
JackingInstructionsin Chapter1 -- Safety). Supportma-
chine with appropriate jack stands.
4. Remove wheel assembly.
Axles, Planetaries and Brakes
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5. Remove hydraulic wheel motor (see Front Wheel
Motors in Service and Repairs section of Chapter 4 --
Hydraulic System).
WARNING
6. Disconnect brake cable from pull rod on brake.
Failure to maintain proper wheel lug nut torque
could result in failure or loss of wheel and may
result in personal injury.
NOTE: Be careful to not drop splined brake shaft as
brake assembly is removed.
8. Lower machine to ground. Torque lug nuts from 85
to 100 ft--lb (116 to 135 N--m).
7. Support brake assembly and remove flange head
cap screws (item 11) securing brake assembly to frame.
Remove brake assembly.
9. Make sure drain plug is installed in bottom of brake
assembly (Fig. 3). Fill planetary wheel drive/brake as-
sembly with SAE 85W--140 gear lube.
8. Remove splined brake shaft.
9. Complete brake inspection and repair (see Brake In-
spection and Repair in this section).
10.Check for proper brake operation and adjust brake
cables if necessary.
Brake Assembly Installation (Fig. 1)
NOTE: The stepped end of the splined brake shaft
must be aligned toward the hydraulic wheel motor (Fig.
2).
3
2
1. Install splined brake shaft into brake assembly.
2. Apply Loctite Gasket Sealant #2 (or equivalent) to
sealing surfaces of new gasket (item 19). Apply gasket
to brake assembly.
1
Figure 2
3. Install brake assembly onto frame, aligning splined
brake shaft with input shaft on planetary wheel drive.
1. Splined brake shaft step
2. Hydraulic motor end
3. Planetary assembly end
4. Install flange head screws (item 11) to secure brake
assembly to frame. Tighten screws in a crossing pattern
to a torque from 75 to 85 ft--lb (102 to 115 N--m).
1
5. Install brake cable to pull rod on brake assembly.
Brake cable end should be completely threaded onto
pull rod before tightening jam nut.
2
6. Install new o--ring on hydraulic wheel motor. Install
wheel motor (see Front Wheel Motors in Service and
RepairssectionofChapter4 -- HydraulicSystem). Make
sure that mounting cap screws are torqued from 75 to
85 ft--lb (102 to 115 N--m).
3
7. Install wheel assembly.
Figure 3
1. Brake housing
2. Check plug
3. Drain plug
Reelmaster 7000
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Brake Inspection and Repair
3
2
1
4
5
6
7
8
9
15
10
14
13
12
11
Figure 4
1. Brake housing (LH shown)
2. Seal
3. Pull rod
4. Clevis pin (2 used)
5. Link (2 used)
6. Hitch pin (2 used)
11. Rotating actuator
7. Stationary disc (4 used)
8. Rotating disc (3 used)
9. Retaining ring
12. Extension spring (3 used)
13. Ball (3 used)
14. Plug
10. Gasket
15. O--ring
Brake Inspection and Repair (Fig. 4)
5. Remove actuator assembly (items 3, 4, 5, 6 and 11)
and balls (item 13).
1. Carefully scrape gasket material (item 10) from
brake housing and planetary wheel drive mounting sur-
faces.
6. Remove seal (item 2) from brake housing.
7. Wash parts in cleaning solvent. Inspect components
for wear or damage.
2. Remove retaining ring (item 9).
3. Remove stationary discs (item 7) and rotating discs
(item 8).
8. Reverse steps 2 -- 6 to assemble brakes, installing
new parts as necessary. Install a new seal (item 2).
4. Remove extension springs (item 12).
9. Use a new gasket (item 10) when installing brake as-
sembly to machine.
Axles, Planetaries and Brakes
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Reelmaster 7000
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Planetary Wheel Drive Assembly
75 to 85 ft--lb
(102 to 115 N--m)
1
19
3
18
6
2
17
17
20
8
7
9
16
12
15
14
13
11
5
RIGHT
10
19
75 to 85 ft--lb
(102 to 115 N--m)
FRONT
4
85 to 100 ft--lb
(116 to 135 N--m)
Figure 5
1. Flange head screw (6 per planetary)
2. Splined brake shaft
3. Planetary assembly (2 used)
4. Front wheel assembly (2 used)
5. Lug nut (8 per wheel)
6. Retaining ring
8. Compression spring
9. Jam nut
10. LH Brake assembly
11. Flange head screw
12. Hex plug
15. Cap screw (2 used per motor)
16. O--ring
17. O--ring
18. RH brake assembly
19. Gasket
20. Brake cable (LH shown)
13. Piston motor (2 used)
7. Spring plate
14. Flat washer (2 used per motor)
NOTE: Theplanetarywheeldriveassemblycanbeser-
vicedwiththeplanetaryinstalledtomachine(seePlane-
tary Wheel Drive Service in this section). Use the
following procedure to remove and install the planetary
wheel drive assembly from machine.
CAUTION
When changing attachments, tires or perform-
ing other service, use correct blocks, hoists and
jacks to raise and support machine. Make sure
machine is parked on a solid level surface such
as a concrete floor. Prior to raising machine, re-
move any attachments that may interfere with
the safe and proper raising of the machine. Al-
ways chock or block wheels. Use appropriate
jack stands to support the raised machine. If the
machine is not properly supported by jack
stands, the machine may move or fall, which
may result in personal injury.
Planetary Wheel Drive Removal (Fig. 5)
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.
2. Drain oilfromplanetarywheeldrive/brakeassembly.
3. Chock rear wheels and jack up front of machine (see
JackingInstructionsin Chapter1 -- Safety). Supportma-
chine with appropriate jack stands.
Axles, Planetaries and Brakes
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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 Re-
moval in this section).
7. Supportplanetaryassemblytopreventitfromfalling.
Loosen and remove six (6) flange head screws that se-
cure planetary assembly to frame. Remove planetary
assembly from machine.
2
8. Remove and discard gasket (item 19). Make sure
that all gasket material is removed from both brake and
planetary assemblies.
3
Figure 6
1. Brake housing
2. Check plug
3. Drain plug
Planetary Wheel Drive Installation (Fig. 5)
1. Position planetary assembly to machine. Install
flange head screws that secure planetary assembly.
Torque screws from 75 to 85 ft--lb (102 to 115 N--m).
2. Apply Loctite Gasket Sealant #2 (or equivalent) to
sealing surfaces of new gasket (item 19). Apply gasket
to brake assembly.
3. Install brake assembly to planetary (see Brake As-
sembly Installation in this section).
4. Installhydraulicwheelmotor(seeFrontWheelMotor
Installation in the Service and Repairs section of Chap-
ter 4 -- Hydraulic System).
WARNING
Failure to maintain proper wheel lug nut torque
could result in failure or loss of wheel and may
result in personal injury.
5. Install wheel assembly.
6. Lower machine to ground. Torque lug nuts from 85
to 100 ft--lb (116 to 135 N--m).
7. Make sure drain plug is installed in bottom of brake
assembly (Fig. 6). Fill planetary wheel drive/brake as-
sembly with SAE 85W--140 gear lube. Capacity is
approximately 16 oz. (0.47 l) per wheel.
8. Check for proper brake operation and adjust brake
cables if necessary.
Reelmaster 7000
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Planetary Wheel Drive Service
118 to 144 in--lb
(13.3 to 16.3 N--m)
2
3
4
7
8
9
11
1
12
13
14
15
5
16
6
10
28
21
13
27
26
17
25
24
23
22
20
19
18
Figure 7
1. Spindle
2. Boot seal
3. Oil seal
4. Inner bearing cone
5. Inner bearing cup
6. Wheel stud (8 used)
11. Outer bearing cup
12. Outer bearing cone
13. O--ring
14. Thrust washer
15. Retaining ring (external)
20. End cap
21. Thrust plug
22. Thrust washer
23. Retaining ring
24. Primary gear
25. Drive shaft
16. Ring gear
7. Socket head screw (16 used)
8. Lock washer (16 used)
9. Housing
17. Retaining ring (internal)
18. Plug (2 used)
19. O--ring (2 used)
26. Primary carrier assembly
27. Secondary gear
28. Secondary carrier assembly
10. Dowel pin (2 used)
Axles, Planetaries and Brakes
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NOTE: Theplanetarywheeldriveassemblycanbeser-
viced with the planetary installed to machine. If the
spindle(item1)needstoberemovedfrommachine, see
Planetary Wheel Drive Assembly in this section.
Disassembly (Figs. 7 and 8)
1. If planetary wheel drive assembly is installed on ma-
chine:
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 as-
sembly.
C. Chock rear wheels and jack up front of machine
(see Jacking Instructions in Chapter 1 -- Safety).
Support machine with jack stands.
D. Remove front wheel assembly.
2. Remove retaining ring (item 17).
Figure 8
Assembly (Figs. 7 and 8)
3. Remove end cap(item 20). Thrustplug(item 21)and
thrust washer (item 22) usually remain in end cap bore
and should be removed for cleaning and inspection.
1. Thoroughlycleanpartsinsolventanddrycompletely
after cleaning. Inspect parts for damage or excessive
wear and replace as necessary.
4. Remove drive shaft assembly (items 23, 24 and 25)
If necessary, remove retaining ring and primary gear
from shaft.
2. If any wheel studs were removed, use a press to
install new studs into housing. Make sure that stud
shoulder is fully pressed against housing surface.
5. Remove primary carrier (item 26), secondary gear
(item 27) and secondary carrier (item 28).
NOTE: Use new seal and shim kits when assembling
planetary wheel drive.
NOTE: Steps 6 through 10 are necessary only if in-
specting or replacing bearings and/or seals.
3. If spindle and housing were separated:
IMPORTANT: Do not reuse retaining ring (item 10)
after it has been removed.
A. Press bearing cups (items 5 and 11) into housing
(item 9). Cups should be pressed fully to shoulder of
the housing bore.
6. Remove retaining ring (item 15) and thrust washer
(item 14). Discard retaining ring.
B. Set inner bearing cone (item 4) into inner bearing
cup.
7. Carefully remove housing (item 9) from spindle (item
1). Remove outer bearing cone (item 12).
C. Make sure that seal bore in housing is thoroughly
cleaned. If OD of seal (item 3) is not rubber or does
not have a sealant coating, apply light coating of sili-
cone sealant to seal bore in housing. Install seal into
housing so it is flush with housing face. Lightly
grease seal lips.
8. Remove and discard seals (items 2 and 3) and O--
rings (item 13) from housing.
9. Remove inner bearing cone (item 4) from housing. If
necessary, remove bearing cups (items 5 and 11) from
housing.
D. Pack boot seal (item 2) with grease and install on
housing.
10.If wheel stud (item 6) removal is necessary, use
press to extract stud(s) from housing.
E. If ring gear was removed from housing, place
dowel pins (item 10) in housing. Secure ring gear to
housing with lock washers (item 8) and socket head
screws (item 7). Torque socket head screws from
118 to 144 in--lb (13.3 to 16.3 N--m).
11.If necessary, remove socket head screws (item 7)
withlockwashers(item8)thatsecureringgear(item16)
to housing. Remove ring gear and two (2) dowel pins
(item 10) from housing.
Reelmaster 7000
Page 6 -- 11
Axles, Planetaries and Brakes
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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.
4. Install secondary carrier (item 28), secondary gear
(item 27) and primary carrier (item 26) making sure that
carrier gear teeth align with ring gear and spline on
spindle shaft.
5. If primary gear (item 24) was removed from drive
shaft,slidegearontoshaftandsecurewithretainingring
(item 23).
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 in-
cremental steps of 0.004 inch (0.10 mm).
6. Install drive shaft assembly (items 25, 24 and 23)
making sure that drive shaft spline aligns with carrier
gears.
H. Measurethicknessofthrustwasher(item14)that
was removed during disassembly. Choose new
thrustwasherofequalthicknessorthenextavailable
thickness from thrust washers in the shim kit.
7. Install thrust plug (item 21) and thrust washer (item
22) into end cap (item 20). Make sure that thrust plug
and thrust washer are captive on inside of end cap (item
20).
I. Apply a light coating of oil to spindle shaft, thrust
washer (item 14) and new retaining ring (item 15).
Install thrust washer onto spindle shaft.
8. Install new O--ring (item 13) to end cap and then
install end cap. Secure cap with retaining ring (item 17).
9. Check operation of planetary wheel drive. With a
constant turning force applied, rotation of the planetary
should be consistent. If there is more drag at certain
points, gears are not rolling freely and the planetary
shouldbeexaminedforimproperassemblyordamaged
components.
WARNING
If retaining ring (item 15) is not fully installed in
spindle groove, loss of wheel and personal inju-
ry may result.
10.If planetary wheel drive assembly is installed on ma-
chine:
J. Carefully install new retaining ring (item 15) into
the spindle shaft groove taking care to not distort
ring. If the proper thrust washer has been installed,
the retaining ring should fit tightly between the thrust
washer and spindle groove. Tap the OD of the re-
taining ring starting in the center and working out to-
ward each end to ensure that the retaining ring is
properly seated into the spindle groove. Make sure
that retaining ring ID is fully seated to spindle shaft
groove.
A. Install front wheel assembly.
WARNING
Failure to maintain proper wheel lug nut torque
could result in failure or loss of wheel and may
result in personal injury.
K. After retaining ring is installed, make sure that
there is no endplay in assembly. If required, remove
retaining ring and install a thrust washer of different
thickness to adjust endplay.
B. Lower machine to ground. Torque wheel lug nuts
in a crossing pattern from 85 to 100 ft--lb (116 to 135
N--m).
C. Make sure drain plug is installed in bottom of
brake assembly. Fill planetary wheel drive/brake as-
sembly with SAE85W--140gear lubeto properlevel.
Capacity is approximately 16 oz. (0.47 l) per wheel.
L. Install new O--ring (item 13) into groove in hous-
ing.
Axles, Planetaries and Brakes
Page 6 -- 12
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Reelmaster 7000
Page 6 -- 13
Axles, Planetaries and Brakes
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Rear Axle Assembly
7
70 ft--lb (94 N--m) maximum
6
5
8
1
4
3
2
9
10
11
12
13
14
16
22
15
17
5
85 to 100 ft--lb
(116 to 135 N--m)
21
20
19
RIGHT
FRONT
18
Figure 9
1. Steering cylinder
2. Needle bearing
3. External snap ring
4. External snap ring
5. Thrust washer
6. Flat washer
9. Cap screw (2 used)
10. Flat washer (2 used)
11. Rear axle motor
12. O--ring
13. Pinion gear
14. Gear
16. Hydraulic fitting
17. Rear wheel assembly (2 used)
18. Lug nut (5 used per wheel)
19. Hex plug
20. O--ring
21. Drive axle assembly
22. Axle pivot pin
7. Lock nut
15. Stop pin
8. Grease fitting
Remove Rear Axle (Fig. 9)
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.
CAUTION
When changing attachments, tires or perform-
ing other service, use correct blocks, hoists and
jacks to raise and support machine. Make sure
machine is parked on a solid level surface such
as a concrete floor. Prior to raising machine, re-
move any attachments that may interfere with
the safe and proper raising of the machine. Al-
ways chock or block wheels. Use appropriate
jack stands to support the raised machine. If the
machine is not properly supported by jack
stands, the machine may move or fall, which
may result in personal injury.
2. Drain oil from rear axle and axle gearbox.
3. Chock front wheels and jack up rear of machine (see
JackingInstructionsin Chapter1 -- Safety). Supportma-
chine with appropriate jack stands.
4. Remove both wheels from rear axle.
5. Remove hydraulic motor from axle assembly (see
Rear Axle Motor in the Service and Repairs section of
Chapter 4 -- Hydraulic System).
6. Remove hydraulic hoses from steering cylinder.
Axles, Planetaries and Brakes
Page 6 -- 14
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