Toro 7000 - Manual

Reelmaster 7000 Page 1 -- 2 Safety 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- dent prevention partially are dependent upon the design and configuration of t...

Reelmaster 7000 Page 1 -- 3 Safety 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 whe...

Reelmaster 7000 Page 1 -- 5 Safety Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Reelmaster 7000. If any decal becomes illegible or damaged, install a new decal. Decal part numbers are listed in your Parts Catalog. Safety

Reelmaster 7000 Page 2 -- 1 Product Records and Maintenance Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS 1 . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS 2 . . . ...

0.09375 Reelmaster 7000 Page 2 -- 2 Product Records and Maintenance Equivalents and Conversions

Reelmaster 7000 Page 2 -- 3 Product Records and Maintenance 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...

Reelmaster 7000 Page 2 -- 6 Product Records and Maintenance Other Torque Specifications SAE Grade 8 Steel Set Screws Thread Size Recommended Torque Thread Size Square Head Hex Socket 1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb 5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb 3/8 -- 16 UNC 35 + 10 ft-...

Reelmaster 7000 Page 3 -- 1 Kubota Diesel Engine Chapter 3 Kubota Diesel Engine Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 3 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 3 . . . . . . . . . . . . . . . . . . . . . ....

Reelmaster 7000 Page 3 -- 2 Kubota Diesel Engine Specifications Item Description Make / Designation Kubota Model V2403--M--DI--E3B 4--Cycle, 4 Cylinder, Liquid Cooled, Diesel Engine Bore 3.425” (87.0 mm) Stroke 4.031” (102.4 mm) Total Displacement 148.5 in 3 (2434 cc) Firing Order 1 (closest to gear...

Reelmaster 7000 Page 3 -- 3 Kubota Diesel Engine General Information This Chapter gives information about specifications and repair of the diesel engine used in the Reelmaster 7000. General maintenance procedures are described in your Traction Unit Operator’s Manual. Information on engine troublesho...

Reelmaster 7000 Page 3 -- 4 Kubota Diesel Engine Service and Repairs Air Filter System Figure 1 1. Battery support 2. Bracket 3. Flange head screw (8 used) 4. Flange nut (8 used) 5. Support bracket 6. Cap screw (4 used) 7. Flange nut (4 used) 8. Fan drive manifold 9. Air cleaner strap 10. Cap screw ...

Reelmaster 7000 Page 3 -- 6 Kubota Diesel Engine Exhaust System Figure 4 1. Muffler 2. Flange head screw (2 used) 3. Flange head screw (4 used) 4. Muffler clamp 5. Tailpipe 6. RH engine mount 7. Flat washer 8. Cap screw 9. Muffler bracket 10. Muffler gasket 11. Engine 12. Muffler bracket 13. Flange ...

Reelmaster 7000 Page 3 -- 7 Kubota Diesel Engine Removal (Fig. 4) 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. 1. Park machine on a level surface, lower cutting units, stop engine, engage park...

Reelmaster 7000 Page 3 -- 8 Kubota Diesel Engine Fuel System Figure 5 1. Fuel suction tube 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 10. Cap screw (2 used) 11. Clamp (2 used) 12. ...

Reelmaster 7000 Page 3 -- 9 Kubota Diesel Engine DANGER 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 an...

Reelmaster 7000 Page 3 -- 10 Kubota Diesel Engine Radiator Figure 6 1. 90 o hydraulic fitting (2 used) 2. Oil cooler 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...

Reelmaster 7000 Page 3 -- 11 Kubota Diesel Engine Removal (Fig. 6) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove hood from the machine (see Hood Removal in the Service and Repairs section of Chapter 7 -- ...

Reelmaster 7000 Page 3 -- 12 Kubota Diesel Engine Engine 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. ...

Reelmaster 7000 Page 3 -- 16 Kubota Diesel Engine Pump Adapter Plate Figure 12 1. Bolt 2. Lock washer 3. Flywheel plate 4. Hardened washer (14 used) 5. Spring coupler 6. Bolt (6 used) 7. Cap screw (8 used) FRONT RIGHT 1 2 3 4 5 6 7 4 Loctite #242 29 to 33 ft--lb (40 to 44 N--m) Boss

Rev. A Reelmaster 7000 Hydraulic System Page 4 -- 1 Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 4 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 4 . . . . . . . . . . . . . . . . . . . . . . . ...

Reelmaster 7000 Hydraulic System Page 4 -- 3 Specifications Item Description Piston (Traction) Pump Eaton variable displacement piston pump (Model 72400) Maximum Displacement (per revolution) 2.48 in 3 (40.6 cc) System Relief Pressure: Forward 5000 PSI (345 bar) System Relief Pressure: Reverse 5000 ...

Reelmaster 7000 Hydraulic System Page 4 -- 4 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 ma...

Reelmaster 7000 Hydraulic System Page 4 -- 5 Relieving Hydraulic System Pressure Before disconnecting or performing any work on the hy- draulic system, all pressure in the hydraulic system must be relieved. Park machine on a level surface, lower cutting units fully, stop engine and apply parking bra...

Reelmaster 7000 Hydraulic System Page 4 -- 6 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- tions or mishandling during operation and maintenance. These conditions can...

Reelmaster 7000 Hydraulic System Page 4 -- 10 Hydraulic Schematic Hydraulic Schematic Reelmaster 7000 All solenoids are shown as de --energized P1 T 2 ST T1 P 2 CV RV 2 G1 G2 L P2 M1 M2 T P1 SP1 SP2 LC2 LC1 RV 1 M5 CV1 M1 C2 M4 RV 2 OR1 OR2 CV2 C5 C4 C1 S5 C3 M3 M2 C4 C1 C3 C2 S3 MV1 S4 P MV2 G M3 M...

Reelmaster 7000 Hydraulic System Page 4 -- 12 Hydraulic Flow Diagrams Traction C ircuit: M ow Speed (Forward Shown) W ork in g P res su re Low Pressure (Charge) Return or Suction Fl ow Reelmaster 7000 P1 T 2 ST T1 P 2 CV RV 2 G1 G2 L P2 M1 M2 T P1 SP1 SP2 LC2 LC1 RV 1 M5 CV1 M1 C2 M4 RV 2 OR1 OR2 CV...

Reelmaster 7000 Hydraulic System Page 4 -- 17 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 lift control manifold and the steering con- trol valve. Hydraulic flow from this pump section is deliv- ered...

Reelmaster 7000 Hydraulic System Page 4 -- 19 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 lift control manifold and the steering con- trol valve. Hydraulic flow from this pump section is deliv- ered...

Reelmaster 7000 Hydraulic System Page 4 -- 21 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 uni...

Reelmaster 7000 Hydraulic System Page 4 -- 23 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 circuit...

Reelmaster 7000 Hydraulic System Page 4 -- 25 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). The fan control manifol...

Reelmaster 7000 Hydraulic System Page 4 -- 26 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 port...

Reelmaster 7000 Hydraulic System Page 4 -- 27 40 GPM Hydraulic Tester (Pressure and Flow) Use to test hydraulic circuits and components for flow and pressure capacities as recommended in the Testing section of this chapter. This tester includes the following: 1. LOAD VALVE: A simulated working load ...

Reelmaster 7000 Hydraulic System Page 4 -- 28 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...

Reelmaster 7000 Hydraulic System Page 4 -- 29 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 lin...

Reelmaster 7000 Hydraulic System Page 4 -- 30 Troubleshooting The charts that follow 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 t...

Reelmaster 7000 Hydraulic System Page 4 -- 31 Traction Circuit Problems NOTE: When troubleshooting traction circuit problems, 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 v...

Reelmaster 7000 Hydraulic System Page 4 -- 32 PTO Problems Problem Possible Cause None of the cutting units will oper- ate. NOTE: Cutting units have to be fully lowered and traction speed needs to be in mow speed (4WD) for cutting units to operate. Cutting units are not fully lowered to ground. Oper...

Reelmaster 7000 Hydraulic System Page 4 -- 33 PTO Problems (Continued) Problem Possible Cause All cutting units operate slowly. Engine RPM is low. Cutting unit motor is damaged. Gear pump section (P1 or P2) is worn or damaged. Cutting unit stops under load. Relief valve in mow control manifold is by...

Reelmaster 7000 Hydraulic System Page 4 -- 34 Lift/Lower Circuit Problems Problem Possible Cause Cutting units will not raise. NOTE: Operator must be in seat in order to raise the cutting units. Operator seat is unoccupied. Hydraulic oil level in reservoir is low. Electrical problem exists that prev...

Reelmaster 7000 Hydraulic System Page 4 -- 35 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 con...

Reelmaster 7000 Hydraulic System Page 4 -- 38 Traction Circuit Charge Pressure Test (Using Pressure Gauge) Working PressureLow PressureReturn or Suction Flow PRESSURE GAUGE CHG .071 VA LV E PD1 SV RV M2 550 PSI PD2 CHG M1 M1 P1 PSI BYP ASS P1 .091 2.48 5000 450 PSI .052 P2 G CV PR 2.01 G CR2 CR1 P1 ...

Reelmaster 7000 Hydraulic System Page 4 -- 39 NOTE: The traction charge circuit is designed to re- place loss of hydraulic fluid from the closed loop traction circuit. Procedure for Traction Circuit Charge Pressure Test 1. Make sure hydraulic oil is at normal operating tem- perature by operating the...

Reelmaster 7000 Hydraulic System Page 4 -- 40 Traction Circuit Relief Pressure Test (Using Pressure Gauge) Working PressureLow PressureReturn or Suction Flow PRESSURE GAUGE CHG .071 VA LV E PD1 SV RV M2 550 PSI PD2 CHG M1 M1 P1 PSI BYP ASS P1 .091 2.48 5000 450 PSI .052 P2 G CV PR 2.01 G CR2 CR1 P1 ...

Reelmaster 7000 Hydraulic System Page 4 -- 46 Piston (Traction) Pump Flow Test (Using Tester with Pressure Gauges and Flow Meter) Working PressureLow PressureReturn or Suction Flow CHG .071 VA LV E PD1 SV RV M2 550 PSI PD2 CHG M1 M1 P1 PSI BYP ASS P1 .091 2.48 5000 450 PSI .052 P2 G CV PR 2.01 G CR2...

Reelmaster 7000 Hydraulic System Page 4 -- 48 Mow Circuit Pressure Test (Using Pressure Gauge) Working PressureLow PressureReturn or Suction Flow CUTTING UNITS SHOWN TEST FOR FRONT P1 T2 T1 P2 RV2 SP1 SP2 LC2 LC1 RV1 M5 CV1 M1 M4 OR1 OR2 CV2 M3 M2 MV1 MV2 M3 M4 M1 M2 .071 VALVE PSI BYPASS P1 .091 50...

Reelmaster 7000 Hydraulic System Page 4 -- 50 Mow Circuit Relief Pressure Test (Using Tester with Pressure Gauges and Flow Meter) Working PressureLow PressureReturn or Suction Flow SECTION P1 SHOWN TEST FOR PUMP P1 T2 T1 P2 RV2 SP1 SP2 LC2 LC1 RV1 M5 CV1 M1 M4 OR1 OR2 CV2 M3 M2 MV1 MV2 M3 M4 M1 M2 ....

Reelmaster 7000 Hydraulic System Page 4 -- 52 Cutting Unit Motor Case Drain Leakage Test (Using Tester with Pressure Gauges and Flow Meter) Working PressureLow PressureReturn or Suction Flow MEASURINGCONTAINER UNIT MOTOR SHOWN TEST FOR #4 CUTTING P1 T2 T1 P2 RV2 SP1 SP2 LC2 LC1 RV1 M5 CV1 M1 M4 OR1 ...

Reelmaster 7000 Hydraulic System Page 4 -- 56 Steering Circuit Relief Pressure Test (Using Pressure Gauge) Working PressureLow PressureReturn or Suction Flow FOR RIGHT TURN P1 T2 ST T1 P2 CV RV2 G1 G2 L P2 M1 M2 T P1 SP1 SP2 LC2 LC1 RV1 M5 CV1 M1 M4 OR1 OR2 CV2 M3 M2 MV1 MV2 M3 M4 M1 M2 .071 VALVE P...

Reelmaster 7000 Hydraulic System Page 4 -- 58 Steering Cylinder Internal Leakage Test T L R P PB 1050 PSI 6.1 PLUG STEEL CYLINDER FULLY EXTENDED LOOK FOR LEAKAGE STEERING WHEEL TURNED FOR RIGHT TURN STEERING FROM FA N C ONTROL M A NIFOLD TO FILTRATION MANIFOLD TO CHARGE CIRCUIT

Reelmaster 7000 Hydraulic System Page 4 -- 60 Lift/Lower Circuit Relief Pressure Test (Using Pressure Gauge) Working PressureLow PressureReturn or Suction Flow C2 RV 2 C5 C4 C1 S5 C3 C4 C1 C3 C2 S3 S4 P G S2 T RV 1 S1 CONTROL MA NI FO LD LIFT G2 FROM FA N C ONTROL M A NIFOLD PRESSURE GAUGE TO CHARGE...

Reelmaster 7000 Hydraulic System Page 4 -- 62 Gear Pump P3 Flow (Steering and Lift/Lower Circuits) Test (Using Tester with Pressure Gauges and Flow Meter) Working PressureLow PressureReturn or Suction Flow .071 VALVE PSI BYPASS P1 .091 5000 .56 .56 P4 1.03 1.03 P2 P3 PSI 5000 .071 PISTON PUMP GEARPU...

Reelmaster 7000 Hydraulic System Page 4 -- 64 Cooling Fan Circuit Test (Using Pressure Gauge and Phototac) Working PressureLow PressureReturn or Suction Flow P1 T2 ST T1 P2 CV RV2 G1 G2 L P2 M1 M2 T P1 SP1 SP2 LC2 LC1 RV1 M5 CV1 M1 M4 OR1 OR2 CV2 M3 M2 MV1 MV2 M3 M4 M1 M2 .071 VALVE PSI BYPASS P1 .0...

Reelmaster 7000 Hydraulic System Page 4 -- 68 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 ...

Reelmaster 7000 Hydraulic System Page 4 -- 70 Check Hydraulic Lines and Hoses WARNING Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have suffi...

Reelmaster 7000 Hydraulic System Page 4 -- 71 Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time there is a severe component failure or the system is contaminated (oil appears milky, black or contains metal particles). IMPORTANT: Flush hydraulic system when chang- Ing from petrole...

Reelmaster 7000 Hydraulic System Page 4 -- 73 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 c...

Reelmaster 7000 Hydraulic System Page 4 -- 74 Gear Pump 1. Flat washer (2 used) 2. Cap screw (2 used) 3. 90 o hydraulic fitting 4. Hydraulic tee fitting 5. O--ring 6. Gear pump assembly 7. Piston pump assembly 8. 90 o hydraulic fitting 9. Coupler 10. 90 o hydraulic fitting 11. O--ring 12. O--ring 13...

Reelmaster 7000 Hydraulic System Page 4 -- 76 Gear Pump Service 1. Dust seal 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) 10. Seal (8 used) 11. Idler gear 12. Drive shaft 13. Back--up gasket 14. Pr...

Reelmaster 7000 Hydraulic System Page 4 -- 80 Piston (Traction) Pump Service 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 ...

Reelmaster 7000 Hydraulic System Page 4 -- 82 4WD/2WD and Filtration/Charge Control Manifolds 1. Filtration/charge control manifold 2. Hydraulic oil filter 3. 4WD/2WD control manifold 4. Manifold bracket 5. Flange head screw (3 used) 6. Flange nut (2 used) 7. Cap screw (2 used) 8. Lift circuit junct...

Reelmaster 7000 Hydraulic System Page 4 -- 84 4WD/2WD Control Manifold Service 1. Manifold body 2. Nut 3. Orifice (0.050) 4. Orifice disc (0.030) 5. Zero leak plug (#4) (4 used) 6. Zero leak plug (#6) (2 used) 7. Zero leak plug (#8) (4 used) 8. Check valve (CV) 9. Pilot directional valve (PD1 & ...

Reelmaster 7000 Hydraulic System Page 4 -- 86 Filtration/Charge Control Manifold Service 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) Figure 63 25 ft--lb (34 N--m) 50 ft--lb (68 N--m) ...

Reelmaster 7000 Hydraulic System Page 4 -- 87 Control Manifold Cartridge Valve Service 1. Make sure the control manifold is clean before re- moving the cartridge valve from the control manifold. 2. If cartridge valve is solenoid operated, remove nut securing solenoid coil to the cartridge valve. Car...

Reelmaster 7000 Hydraulic System Page 4 -- 88 Rear Axle Motor 1. Axle motor 2. O--ring 3. Pinion gear 4. External snap ring 5. O--ring 6. Hydraulic fitting 7. O--ring 8. 90 o hydraulic fitting 9. Cap screw (2 used) 10. Flat washer (2 used) Figure 64 FRONT RIGHT Arrows on side of motor case point up ...

Reelmaster 7000 Hydraulic System Page 4 -- 90 Front Wheel Motors 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 7. LH brake assembly 8. Flange head screw (4 per brake) 9. Plug 10. O--ring 11. Piston whe...

Reelmaster 7000 Hydraulic System Page 4 -- 92 Rear Axle and Front Wheel Motor Service 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...

Reelmaster 7000 Hydraulic System Page 4 -- 93 Cutting Reel Motor The hydraulic reel motors used on all cutting units are the same. Removal 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 Precautio...

Reelmaster 7000 Hydraulic System Page 4 -- 94 Cutting Reel Motor Service 1. Dust seal 2. Retaining ring 3. Flange washer 4. Shaft seal 5. Front flange 6. Pressure seal 7. Back--up gasket 8. Front wear plate 9. Dowel pin 10. Idler gear 11. Drive shaft 12. Rear wear plate 13. O--ring 14. Relief valve ...

Reelmaster 7000 Hydraulic System Page 4 -- 98 Mow Control Manifold FRONT RIGHT 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 Figure 72 3 4 1 6 2 5

Reelmaster 7000 Hydraulic System Page 4 -- 100 Mow Control Manifold Service 1. Manifold body 2. Proportional valve (SP1 & SP2) 3. Solenoid coil (2 used) 4. Relief valve (RV1 & RV2) 5. Pressure compensator (LC1 & LC2) 6. Check valve (CV1 & CV2) 7. Nut 8. Backlap switch (2 used) 9. O--...

Reelmaster 7000 Hydraulic System Page 4 -- 102 Steering Control Valve 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 ...

Reelmaster 7000 Hydraulic System Page 4 -- 104 Steering Control Valve Service 1. Relief valve assembly 2. Dust seal ring 3. Steering valve housing 4. Shaft seal 5. Thrust washer 6. Bearing race 7. Ring 8. Spring set 9. Cross pin 10. Sleeve 11. Spool 12. Cardan shaft 13. O--ring 14. Distributor plate...

Reelmaster 7000 Hydraulic System Page 4 -- 106 Steering Cylinder 1. Steering cylinder 2. Ball joint 3. Ball joint 4. Retaining ring 5. Grease fitting 6. Grease fitting 7. 90 o hydraulic fitting 8. O--ring 9. O--ring 10. Drive axle assembly 11. Ball joint spacer 12. Axle washer 13. Slotted hex nut 14...

Reelmaster 7000 Hydraulic System Page 4 -- 108 Steering Cylinder Service 1. Barrel 2. Lock nut 3. Wear band 4. Square ring 5. Piston seal 6. O--ring 7. Piston 8. Buffer seal 9. O--ring 10. Back--up ring 11. Head 12. Retaining ring 13. Head seal 14. Wiper 15. Rod assembly Figure 81 50 to 60 ft--lb (6...

Reelmaster 7000 Hydraulic System Page 4 -- 110 Engine Cooling Fan Motor 1. Hydraulic fan motor 2. O--ring 3. Bracket 4. 45 o hydraulic fitting 5. O--ring 6. Hydraulic hose 7. Fan hub 8. Washer 9. Hex nut 10. Engine 11. Cap screw (4 used) 12. Washer (4 used) 13. Fan 14. Lock nut (2 used) 15. Hydrauli...

Reelmaster 7000 Hydraulic System Page 4 -- 112 Engine Cooling Fan Motor Service 1. Flange washer 2. O--ring 3. Front flange 4. Dust seal 5. Retaining ring 6. Front wear plate 7. Shaft seal 8. Backup gasket 9. Pressure seal 10. Rear wear plate 11. Body 12. Idler gear 13. Cap screw (4 used) 14. Dowel ...

Reelmaster 7000 Hydraulic System Page 4 -- 114 Fan Control Manifold 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 Figure 85 FRONT RIGHT 3 4 1 6 2 5

Reelmaster 7000 Hydraulic System Page 4 -- 116 Fan Control Manifold Service 1. Manifold body 2. Zero leak plug (#6) (3 used) 3. Zero leak plug (#4) (2 used) 4. Check valve (port CV) 5. Flow divider cartridge (port FD) 6. Solenoid coil (2 used) 7. Nut 8. Solenoid valve (port S1) 9. Proportional relie...

Reelmaster 7000 Hydraulic System Page 4 -- 118 Lift Control Manifold 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 Figure 88 FRONT RIGHT 3 4 7 1 6 2 5 8 Removal (Fig. 88) NOTE: The ...

Reelmaster 7000 Hydraulic System Page 4 -- 120 Lift Control Manifold Service 1. Manifold body 2. Relief valve (port RV2) 3. Solenoid valve (port S1) 4. Solenoid coil (5 used) 5. Solenoid valve (port S2) 6. Solenoid valve (ports S4 and S5) 7. Coil spacer (2 used) 8. Nut 9. Solenoid valve (port S3) 10...

Reelmaster 7000 Hydraulic System Page 4 -- 122 Lift Circuit Junction Manifold Figure 91 FRONT RIGHT 1. Filtration/charge control manifold 2. Hydraulic oil filter 3. 4WD/2WD control manifold 4. Manifold bracket 5. Flange head screw (3 used) 6. Flange nut (2 used) 7. Cap screw (2 used) 8. Lift circuit...

Reelmaster 7000 Hydraulic System Page 4 -- 124 Front Lift Cylinders 1. O--ring 2. Flange nut 3. Lift arm (cutting unit #1) 4. Cylinder pin 5. Flange head screw 6. 90 o hydraulic fitting (2 per cylinder) 7. O--ring 8. Lift cylinder (cutting units #4 and #5) 9. Lift cylinder (cutting unit #1) 10. Thru...

Reelmaster 7000 Hydraulic System Page 4 -- 126 Rear Lift Cylinders 1. Flange nut (2 used) 2. Bulkhead bracket 3. Hydraulic tee fitting 4. Flange head screw (2 used) 5. Slotted roll pin 6. Pivot pin 7. Pivot yoke 8. Lynch pin 9. Lift arm (cutting unit #2) 10. Lift arm (cutting unit #3) 11. Retaining ...

Reelmaster 7000 Hydraulic System Page 4 -- 128 Lift Cylinder Service 1. Barrel 2. Lock nut 3. Wear band 4. Square ring 5. Piston seal 6. O--ring 7. Piston 8. Buffer seal 9. O--ring 10. Back--up seal 11. Head 12. Retaining ring 13. Head seal 14. Support washer 15. Retaining ring 16. Wiper 17. Rod ass...

Reelmaster 7000 Hydraulic System Page 4 -- 130 Hydraulic Reservoir 1. Hydraulic reservoir 2. Tank strainer 3. Clamp 4. Hydraulic fitting 5. Hydraulic tee fitting 6. Bumper 7. Flat washer (2 used) 8. Flange nut (3 used) 9. Clamp (2 used) 10. Cap screw (2 used) 11. Flat washer (2 used) 12. Breather 13...

Reelmaster 7000 Hydraulic System Page 4 -- 132 Hydraulic Oil Cooler 1. Oil cooler 2. Mount plate (2 used) 3. Flange head screw (8 used) 4. Radiator mount 5. Radiator 6. Air intake hose 7. Plenum 8. Flange nut (4 used) 9. O--ring 10. 90 o hydraulic fitting (2 used) 11. O--ring 12. Hydraulic hose (2 u...

Reelmaster 7000 Page 5 -- 1 Electrical System Chapter 5 Electrical System Table of Contents GENERAL INFORMATION 2 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 2 . . . . . . . . . . . . . . . . . . . . . . . . . . Toro Electronic Controllers (TEC) 2 . . . . . . . . . . . . . . CAN--bus...

Reelmaster 7000 Page 5 -- 3 Electrical System Electrical Drawings The electrical schematics and other electrical drawings for the Reelmaster 7000 are located in Chapter 9 -- Fold- out Drawings. Electrical System

Reelmaster 7000 Page 5 -- 4 Electrical System 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 to...

Reelmaster 7000 Page 5 -- 6 Electrical System Troubleshooting CAUTION 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. For effective troubleshooting and repairs, there m...

Reelmaster 7000 Page 5 -- 10 Electrical System 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 ignitio...

Reelmaster 7000 Page 5 -- 11 Electrical System 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 ...

Reelmaster 7000 Page 5 -- 12 Electrical System Cutting Unit Operating Problems Cutting units run, but should not, when raised. Cutting units shut off with PTO switch. The cutting unit position switch or circuit wiring is faulty. Wire harness connections are incorrectly connected to hydraulic solenoi...

Reelmaster 7000 Page 5 -- 13 Electrical System Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the battery terminals. Set multimeter to the DC volts setting. The battery should be at a temperature of 60 o to 100 o F (16 o to 38 o C). Th...

Reelmaster 7000 Page 5 -- 14 Electrical System Check Operation of Interlock Switches CAUTION Do not disconnect safety switches. They are for the operator’s protection. Check the operation of the interlock switches daily for proper operation. Replace any malfunctioning switches before op- erating the...

Reelmaster 7000 Page 5 -- 15 Electrical System Adjustments Mow/Transport Sensor The mow/transport sensor is a normally open proximity sensor that closes when the mow speed limiter is placed in the transport position. The sensor mounts to a bracket on the footrest platform (Fig. 12). The sensing plat...

Reelmaster 7000 Page 5 -- 16 Electrical System 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....

Reelmaster 7000 Page 5 -- 17 Electrical System 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). NOTE: For engine co...

Reelmaster 7000 Page 5 -- 18 Electrical System 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 ...

Reelmaster 7000 Page 5 -- 19 Electrical System Indicator Lights Charge Indicator Light The charge indicator light should come on when the igni- tion switch is in ON with the engine not running or with an improperly operating charging circuit while the en- gine is running. To test the charge indicato...

Reelmaster 7000 Page 5 -- 20 Electrical System Hour Meter The hour meter is located on the outside of the console arm. 1. Connect the positive (+) terminal of a 12 VDC source to the positive (+) terminal of the hour meter. 2. Connect the negative (--) terminal of the voltage source to the other term...

Reelmaster 7000 Page 5 -- 21 Electrical System PTO Switch The PTO switch is located on the console arm (Fig. 23). The PTO switch is pulled up to engage the PTO and pushed in to disengage the PTO. NOTE: To engage the PTO, the seat has to be occu- pied, traction speed has to be in low range (4WD) and ...

Reelmaster 7000 Page 5 -- 22 Electrical System 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 ...

Reelmaster 7000 Page 5 -- 23 Electrical System 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. Testing 1. Make sure ignition switch is OFF. Remove key from ignition ...

Reelmaster 7000 Page 5 -- 24 Electrical System Engine Cooling Fan Switch The engine cooling fan switch is located on the outside of the console arm (Fig. 30). This two (2) position rocker switch allows the engine cooling fan to run in the normal, automatic mode or in the manual reverse (momentary) d...

Reelmaster 7000 Page 5 -- 25 Electrical System 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- tion system or PTO switch is engaged when the operator raises out of th...

Reelmaster 7000 Page 5 -- 26 Electrical System 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). When the parking brake is not applied, the parking brake detent is positioned near t...

Reelmaster 7000 Page 5 -- 29 Electrical System 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 switches are atta...

Reelmaster 7000 Page 5 -- 30 Electrical System 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). The glow relay is used to provide c...

Reelmaster 7000 Page 5 -- 31 Electrical System Start Relay The start relay is located at the power center behind the operator seat (Fig. 42). This relay is attached to the wire harness with a five (5) wire connector (Fig. 43). The start relay is used to provide current to the engine starter motor wh...

Reelmaster 7000 Page 5 -- 32 Electrical System 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...

Reelmaster 7000 Page 5 -- 33 Electrical System 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. Two (2) different sole...

Rev. A Reelmaster 7000 Page 5 -- 36 Electrical System 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 coo...

Reelmaster 7000 Page 5 -- 37 Electrical System 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. IMPORTANT: When testing fuel pump, make sure that pump is not operated with...

Reelmaster 7000 Page 5 -- 38 Electrical System Fuel Stop Solenoid The fuel stop solenoid used on your Reelmaster must be energized for the diesel engine to run. The solenoid is mounted to the injection pump on the engine (Fig. 55). The TEC controller monitors the operation of the fuel stop solenoid....

Reelmaster 7000 Page 5 -- 39 Electrical System Engine Temperature Sender The engine temperature sender is located near the al- ternator on the water flange attached to the engine cylin- der head (Fig. 57). There is a gray wire attached to the terminal of the sender. The resistance of the temperature...

Reelmaster 7000 Page 5 -- 40 Electrical System 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....

Reelmaster 7000 Page 5 -- 41 Electrical System Service and Repairs NOTE: For more component repair information, see the Kubota Workshop Manual, Diesel Engine, 03--M-- DI--E3B. Battery Storage If the machine will be stored for more than 30 days: 1. Remove the battery and charge it fully (see Battery ...

Reelmaster 7000 Page 5 -- 42 Electrical System 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. CAUTION When working with batteries, use extreme c...

Reelmaster 7000 Page 5 -- 45 Electrical System Hydraulic Solenoid Valve Coils A solenoid valve coil on a hydraulic control manifold can be replaced without opening the hydraulic system. Removal (Fig. 61) 1. Park machine on a level surface, lower cutting units, stop engine and engage parking brake. R...

Reelmaster 7000 Page 6 -- 1 Axles, Planetaries and Brakes Chapter 6 Axles, Planetaries and Brakes Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 3 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 3 . . . . . . . . . . . . ....

Reelmaster 7000 Page 6 -- 3 Axles, Planetaries and Brakes 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 info...

Reelmaster 7000 Page 6 -- 4 Axles, Planetaries and Brakes Service and Repairs Brake Assembly 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 7. Spring plate 8. Compression spring ...

Reelmaster 7000 Page 6 -- 6 Axles, Planetaries and Brakes Brake Inspection and Repair 1. Brake housing (LH shown) 2. Seal 3. Pull rod 4. Clevis pin (2 used) 5. Link (2 used) 6. Hitch pin (2 used) 7. Stationary disc (4 used) 8. Rotating disc (3 used) 9. Retaining ring 10. Gasket 11. Rotating actuator...

Reelmaster 7000 Page 6 -- 8 Axles, Planetaries and Brakes Planetary Wheel Drive Assembly 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 7. Spring plate 8. Compression spring 9. J...

Reelmaster 7000 Page 6 -- 10 Axles, Planetaries and Brakes Planetary Wheel Drive Service 1. Spindle 2. Boot seal 3. Oil seal 4. Inner bearing cone 5. Inner bearing cup 6. Wheel stud (8 used) 7. Socket head screw (16 used) 8. Lock washer (16 used) 9. Housing 10. Dowel pin (2 used) 11. Outer bearing c...

Reelmaster 7000 Page 6 -- 14 Axles, Planetaries and Brakes Rear Axle Assembly 1. Steering cylinder 2. Needle bearing 3. External snap ring 4. External snap ring 5. Thrust washer 6. Flat washer 7. Lock nut 8. Grease fitting 9. Cap screw (2 used) 10. Flat washer (2 used) 11. Rear axle motor 12. O--rin...

Reelmaster 7000 Page 6 -- 16 Axles, Planetaries and Brakes Rear Axle Service Figure 12 3 2 4 5 6 7 8 9 10 14 13 12 11 15 1 10 11 8 9 8 13 16 17 18 19 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 20 41 42 43 50 44 45 46 47 48 49 51 54 55 56 57 58 59 52 53 60 61 62 63 64 22

Reelmaster 7000 Page 6 -- 17 Axles, Planetaries and Brakes 1. LH axle support 2. Flange bushing (2 used) 3. Axle vent 4. Filter 5. Vent extension 6. Cap screw (4 used per gear case) 7. Shim set 8. Seal washer 9. Plug 10. Lock nut 11. Lock washer 12. Grease fitting 13. Ball bearing 14. Screw (2 used ...

Reelmaster 7000 Page 6 -- 18 Axles, Planetaries and Brakes Bevel Gear Case and Axle Case The following procedures assume the rear axle assem- bly has been removed from the machine. Removal 1. Remove the mounting screws, nuts and lock wash- ers. Remove the bevel gear case/axle case assembly and O-rin...

Reelmaster 7000 Page 6 -- 19 Axles, Planetaries and Brakes 5. Remove the knuckle pin mounting screws and the knuckle pin. Remove the gasket and any remaining gas- ket material from either mating surface (Fig. 16). 6. While holding the bevel gear case, tap the upper end of the bevel gear shaft out of...

Reelmaster 7000 Page 6 -- 22 Axles, Planetaries and Brakes 9. Remove the bevel gear case/axle case assembly from the axle support. Coat a new O-ring with grease and temporarily install the axle cover assembly. Position a dial indicator at the tooths center. Prevent the axle from turning and measure ...

Reelmaster 7000 Page 6 -- 23 Axles, Planetaries and Brakes Axle Shafts The following procedures assume the rear axle assem- bly has been removed from the machine. Removal 1. Remove the axle cover mounting screws. Remove the axle cover from the axle case as an assembly (Fig. 25). 2. Use a bearing pul...

Reelmaster 7000 Page 6 -- 24 Axles, Planetaries and Brakes Input Shaft/Pinion Gear Figure 28 1 1. Nut (2 used) 2. Lock washer (2 used) 3. Stud (2 used) 4. Lock nut 5. Stake washer 6. Oil seal 7. O-ring 8. Seal collar 9. Bearing 10. O-ring 11. Input shaft/pinion gear 12. Bearing case 13. Shim 14. Scr...

Reelmaster 7000 Page 6 -- 26 Axles, Planetaries and Brakes Differential Gear The following procedures assume the rear axle assem- bly has been removed from the machine. Removal 1. Remove bevel gear case/axle case assemblies (see Bevel Gear Case/Axle Case Assembly in this section of this manual). IMP...

Reelmaster 7000 Page 6 -- 27 Axles, Planetaries and Brakes Inspection 1. Measure the differential side gear O.D. and the dif- ferential case I.D. to determine the side gear to case clearance (Fig. 35). Replace components as necessary. SIDE GEAR TO CASE CLEARANCE: 0.002 to 0.012 inch (0.05 to 0.30 mm...

Reelmaster 7000 Page 6 -- 29 Axles, Planetaries and Brakes Pinion Gear to Ring Gear Engagement The final position of the pinion gear is verified by using the gear contact pattern method as described in the fol- lowing procedure. GEAR TOOTH DEFINITIONS (Fig. 39): Toe -- the portion of the tooth surfa...

Reelmaster 7000 Page 7 -- 1 Chassis Chapter 7 Chassis Table of Contents GENERAL INFORMATION 2 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 2 . . . . . . . . . . . . . . . . . . . . . . . . . . Cutting Unit Identification 2 . . . . . . . . . . . . . . . . . . . . . SERVICE AND REPAIRS ...

Reelmaster 7000 Page 7 -- 2 Chassis General Information Operator’s Manual The Traction Unit and Cutting Unit Operator’s Manuals provide information regarding the operation, general maintenance and maintenance intervals for your Reel- master machine. Refer to these publications for addi- tional infor...

Reelmaster 7000 Page 7 -- 4 Chassis Service and Repairs Steering Column 1. Steering wheel cover 2. Lock nut 3. Steering wheel 4. Flat washer 5. Socket head screw (4 used) 6. Flange head screw (4 used) 7. Steering column 8. Steering control valve 9. Socket head screw (4 used) 10. Flange nut (4 used) ...

Reelmaster 7000 Page 7 -- 6 Chassis Console Arm 1. Console arm frame 2. LH cover 3. RH cover 4. Washer head screw (10 used) 5. Phillips head screw 6. Lock nut (3 used) 7. Cover plate 8. Flange head screw (2 used) 9. Mount 10. U--nut (5 used) 11. Flange head screw (5 used) 12. Switch panel 13. Rivet ...

Reelmaster 7000 Page 7 -- 12 Chassis Operator Seat 1. Seat frame 2. Seat plate 3. Torsion spring 4. Seat plate latch 5. Clevis pin 6. Flat washer 7. Cotter pin 8. Hair pin (4 used) 9. Seat frame rod (2 used) 10. Flat washer (3 used) 11. Hair pin 12. Seat pivot shaft 13. Flat washer (2 used) 14. Flan...

Reelmaster 7000 Page 7 -- 14 Chassis Operator Seat Service 1. Backrest cushion 2. Seat cushion 3. LH armrest cover 4. LH armrest 5. Bushing (2 used) 6. Backrest 7. Plug (2 used) 8. Cable tie (3 used) 9. LH adjustment rail 10. Bumper (2 used) 11. Washer 12. Cap screw (2 used) 13. Seat 14. Nut 15. Spr...

Reelmaster 7000 Page 7 -- 15 Chassis Disassembly (Fig. 14) 1. Remove seat from machine for service (see Opera- tor Seat Removal in this section). 2. Disassemble operator seat as necessary using Fig- ure 14 as a guide. Assembly (Fig. 14) 1. Assemble operator seat using Figure 14 as a guide. 2. Instal...

Reelmaster 7000 Page 7 -- 16 Chassis Operator Seat Suspension 1. Cover 2. Cover 3. Level control 4. Air control valve 5. Shock absorber 6. Air spring 7. Air tube assembly 8. Wire harness 9. Compressor 10. Bellows 11. Stop 12. Bumper set (2 used) 13. Roller (4 used) 14. Washer (2 used) 15. Tether 16....

Reelmaster 7000 Page 7 -- 18 Chassis Hood 1. Screen 2. Latch keeper 3. Pop rivet (2 used) 4. Hood 5. Plastic plug (20 used) 6. Hood screen 7. Bulb seal (2 used) 8. Adjustable latch 9. Hair pin (2 used) 10. Rear bumper 11. Pop rivet (2 used) 12. Rubber bumper (2 used) 13. Flange nut (2 used) 14. Bulb...

Reelmaster 7000 DPA Cutting Units Page 8 -- 1 Chapter 8 DPA Cutting Units Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 3 . . . . . . . . . . . . . . . . . . . . . Cutting Unit Operator’s Manual 3 . . . . . . . . . . . . . . . . SPEC...

Reelmaster 7000 DPA Cutting Units Page 8 -- 2 Specifications Figure 1 Frame Construction: Precision machined die cast alu- minum cross member with two (2) bolt--on cast ductile iron side plates. Reel Construction: Reels are 27 inches (69 cm) in length and 7 inch (18 cm) in diameter. High strength, l...

Reelmaster 7000 DPA Cutting Units Page 8 -- 3 General Information Cutting Unit Operator’s Manual The Cutting Unit Operator’s Manual provides informa- tion regarding the operation, general maintenance and maintenance intervals for the DPA cutting units on your Reelmaster machine. Additionally, if opt...

Reelmaster 7000 DPA Cutting Units Page 8 -- 4 Special Tools Special tools are available from your Toro Distributor. Some tools may have been supplied with your machine or are available as TORO parts. Gauge Bar Assembly Toro Part Number: 108--6715 Use gauge bar to verify height--of--cut adjustment. F...

Reelmaster 7000 DPA Cutting Units Page 8 -- 5 Plastic Plug Toro Part Number: 94--2703 This plug is used for placement into the side plate bear- ing housing when the hydraulic reel motor is removed. It prevents dirt and debris from entering the cutting reel bearing area. Figure 5 Cutting Unit Kicksta...

Reelmaster 7000 DPA Cutting Units Page 8 -- 6 Reel Bearing Installation Tool Toro Part Number: 117--0975 Use the reel bearing installation tool to keep the reel bearing aligned as the cutting unit side plate is installed on the bearing. Figure 8 Roller Rebuild Kit Toro Part Number: 115--0803 This to...

Reelmaster 7000 DPA Cutting Units Page 8 -- 8 Factors That Can Affect Cutting Performance There are a number of factors that can contribute to un- satisfactory quality of cut, some of which may be turf conditions. Turf conditions such as excessive thatch, “sponginess” or attempting to cut off too mu...

Reelmaster 7000 DPA Cutting Units Page 8 -- 11 Set Up and Adjustments Characteristics CAUTION Never install or work on the cutting units or lift arms with the engine running. Always stop en- gine and remove key first. The dual knob bedknife--to--reel adjustment system in- corporated in this cutting ...

Reelmaster 7000 DPA Cutting Units Page 8 -- 12 Reel Bearing Adjustment To insure cut quality and long life of the cutting reel bear- ings, periodically check reel bearing adjustment. Check Reel Bearing Adjustment 1. Remove hydraulic reel motor from cutting unit (see Hydraulic Reel Motor Removal in t...

Reelmaster 7000 DPA Cutting Units Page 8 -- 13 Leveling Rear Roller The precision machined components of the cutting unit frame keep the rear roller and cutting reel in alignment (parallel). If the side plates are disassembled or as the cutting reel wears, a limited amount of side plate adjust- ment...

Reelmaster 7000 DPA Cutting Units Page 8 -- 14 Service and Repairs Hydraulic Reel Motor IMPORTANT: When performing maintenance pro- cedures on the cutting units, carefully position the cutting unit reel motors to prevent damage to the motors or hydraulic hoses. Removal 1. Park machine on a clean and...

Reelmaster 7000 DPA Cutting Units Page 8 -- 15 Cutting Unit Removal and Installation Cutting Unit Removal 1. Park machine on a clean and level surface, lower cutting units completely to the ground, stop engine, en- gage parking brake and remove key from the ignition switch. 2. If front outside cutti...

Reelmaster 7000 DPA Cutting Units Page 8 -- 16 Backlapping DANGER TO AVOID PERSONAL INJURY OR DEATH: D Never place hands or feet in the reel area while the engine is running. Stay away from the cutting reels when backlapping. D When backlapping, run engine at idle speed only. D While backlapping, th...

Reelmaster 7000 DPA Cutting Units Page 8 -- 18 Bedbar Assembly 1. Bedbar 2. Bedknife 3. Screw 4. Bedbar adjuster shaft (2 used) 5. Flange bushing (4 used) 6. Cap screw (2 used) 7. Detent (2 used) 8. Wave washer (2 used) 9. Retaining ring (2 used) 10. Bedbar adjuster screw (2 used) 11. Washer (2 used...

Reelmaster 7000 DPA Cutting Units Page 8 -- 20 Bedbar Adjuster Service Figure 24 1. Bedbar assembly 2. Compression spring 3. Lock nut 4. Bedbar adjuster shaft 5. Flange bushing 6. Cap screw 7. Detent 8. Wave washer 9. Lock nut 10. Bedbar adjuster screw 11. Washer 12. Flat washer 14 to 16 ft--lb (19 ...

Reelmaster 7000 DPA Cutting Units Page 8 -- 22 Bedknife Replacement and Grinding Bedknife Removal 1. Remove bedbar from cutting unit (see Bedbar Re- moval in this section). 2. Remove screws from bedbar using a socket wrench and bedknife screw tool (see Special Tools). Discard screws. Remove bedknife...

Reelmaster 7000 DPA Cutting Units Page 8 -- 24 Reel Assembly Removal and Installation 1. Bedbar assembly 2. Flange nut (3 used per side plate) 3. Flange bushing (2 used) 4. Plastic washer (4 used) 5. Metal washer (2 used) 6. Bedbar pivot bolt (2 used) 7. Lock nut (2 used) 8. Shoulder bolt (3 used pe...

Reelmaster 7000 DPA Cutting Units Page 8 -- 28 Reel Assembly Service 1. Cutting reel 2. Threaded insert (RH thread) 3. Retaining ring 4. Grease seal 5. Bearing 6. Threaded insert (LH thread) 7. Retaining ring groove 8. Groove indicating LH threads 9. Bearing shoulder 10. Reel spider Figure 32 85 to ...

Rev. A Reelmaster 7000 DPA Cutting Units Page 8 -- 30 Preparing Reel for Grinding NOTE: Before grinding a cutting reel, make sure that all cutting unit components are in good condition. Depend- ing on type of grinder used, faulty cutting unit compo- nents can affect grinding results. NOTE: When grin...

Reelmaster 7000 DPA Cutting Units Page 8 -- 32 Front Roller Removal (Fig. 34) 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and re- move key from the ignition switch. 2. Remove the cutting unit from the machine and place on a level working s...

Reelmaster 7000 DPA Cutting Units Page 8 -- 33 Rear Roller Removal (Fig. 35) 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and re- move key from the ignition switch. 2. Remove the cutting unit from the machine and place on a level working su...

Reelmaster 7000 DPA Cutting Units Page 8 -- 34 Roller Service Disassembly (Fig. 36) 1. Remove bearing lock nut from each end of roller shaft. 2. Loosely secure roller assembly in bench vise and lightly tap one end of roller shaft until outer seals and bearing are removed from opposite end of roller ...

Reelmaster 7000 DPA Cutting Units Page 8 -- 37 Disassembly (Fig. 42) 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and re- move key from the ignition switch. 2. To remove roller brush from brush shaft: A. Remove the non--driven brush bearing...

Reelmaster 7000 Foldout Drawings Page 9 - 1 Chapter 9 Foldout Drawings Table of Contents HYDRAULIC SCHEMATIC 3 . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SCHEMATIC 4 . . . . . . . . . . . . . . . . . . . . . WIRE HARNESS DRAWINGS Main Wire Harness 6 . . . . . . . . . . . . . . . . . . . . ...

Page 9 -- 4 Electrical Schematic Reelmaster 7000 All relays and solenoids are shown as de-- energized.All ground wires are black. Sheet 1 of 2

Page 9 -- 8 Reelmaster 7000 Seat and Console Wire Harness

Page 9 -- 10 Reelmaster 7000 Power Center Wire Harness