Toro Reelmaster 7000 (Models 03780, 03781) Service Repair Manual

Table of Content – Reelmaster 7000 (Models 03780, 03781)

Title Page
Revision History
Reader Comments
Preface
1 – Safety
General Safety Instructions
Before Operating
While Operating
Maintenance and Service
Jacking Instructions
Safety and Instruction Decals
2 – Product Records and Maintenance
Product Records
Maintenance
Equivalents and Conversions
Torque Specifications
Fastener Identification
Using a Torque Wrench with an Offset Wrench
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series)
Conversion Factors
3 – Yanmar Diesel Engine
Specifications
General Information
Operator’s Manuals
Yanmar Service and Troubleshooting Manuals
Stopping the Engine
Engine Electronic Control Unit (ECU)
Yanmar Engine
Service and Repairs
Air Cleaner System
Exhaust System
Fuel System
Radiator, Hydraulic Oil Cooler
Engine
Pump Adapter Plate
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4 – Kubota Diesel Engine
Specifications
General Information
Operator’s Manual
Service and Repairs
Air Filter System
Exhaust System
Fuel System
Radiator, Hydraulic Oil Cooler
Engine
Pump Adapter Plate
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5 – Hydraulic System
Specifications
General Information
Operator’s Manual
Hydraulic Component Locations
Relieving Hydraulic System Pressure
Traction Circuit Component Failure
Towing Traction Unit
Hydraulic Hoses
Hydraulic Hose and Tube Installation (O-Ring Face Seal Fitting)
Hydraulic Fitting Installation (SAE Straight Thread O-Ring Fitting into Component Port)
Hydraulic Schematic
Hydraulic Flow Diagrams
Traction Circuit: LOW Speed (Mow)
Traction Circuit: HI Speed (Transport)
Mow Circuit
Steering Circuit
Lower Cutting Units
Raise Cutting Units
Engine Cooling Fan Circuit
Special Tools
Hydraulic Pressure Test Kit
Hydraulic Tester (Pressure and Flow)
40 GPM Hydraulic Tester (Pressure and Flow)
Hydraulic Hose Kit
High Flow Hydraulic Filter Kit
Hydraulic Test Fitting Kit
Measuring Container
O-ring Kit
Remote Starter Switch
Troubleshooting
General Hydraulic System Problems
Traction Circuit Problems
Mow Circuit Problems
Steering Circuit Problems
Lift, Lower Circuit Problems
Engine Cooling Fan Circuit Problems
Testing
Traction Circuit – Charge Pressure Test
Traction Circuit – Relief Pressure Test
Traction Circuit – Piston (traction) Pump Flow Test
Traction Circuit – Front Wheel Motor Case Drain Leakage Test
Traction Circuit – Reverse Reducing Valve (PR) Pressure Test
Traction Circuit – Rear Relief Valve (RV) Pressure Test
Cutting Unit Circuit – Pressure Test
Cutting Unit Circuit – Relief Pressure Test
Cutting Unit Circuit – Cutting Unit Motor Case Drain Leakage Test
Steering, Lift Circuit – Steering Relief Pressure Test
Steering, Lift Circuit – Steering Cylinder Test
Steering, Lift Circuit – Lift Relief Pressure Test
Cooling Fan Circuit – Pressure Test
Cooling Fan Circuit – Fan Motor Case Drain Leakage Test
Gear Pump Flow Test (pump sections P2 thru P5)
Adjustments
Control Manifold Relief Valve Adjustment
Service and Repairs
General Precautions for Removing and Installing Hydraulic System Components
Check Hydraulic Lines and Hoses
Priming Hydraulic Pumps
Flush Hydraulic System
Filtering Closed-Loop Traction Circuit
Charge Hydraulic System
Gear Pump
Gear Pump Service
Piston (Traction) Pump
Piston (traction) Pump Service
Rear Traction Manifold
Rear Traction Manifold Service
HI, LOW Range Manifold
Front Wheel Motors
Rear Axle Motor
Front Wheel Motor and Rear Axle Motor Service
Cutting Unit Motor
Cutting Unit Motor Service
Mow Control Manifold
Mow Control Manifold Service
Steering Control Valve
Steering Control Valve Service
Steering Cylinder
Steering Cylinder Service
Engine Cooling Fan Motor
Engine Cooling Fan Motor Service
Fan Control Manifold
Fan Control Manifold Service
Lift Manifold
Lift Manifold Service
Control Manifold Cartridge Valve Service
Lift Junction Manifold
Front Lift Cylinders
Rear Lift Cylinders
Lift Cylinder Service
Hydraulic Reservoir
Hydraulic Oil Cooler
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6 – Electrical System
General Information
Operator’s Manual
Toro Electronic Controller (TEC)
Engine Electrical Components
Engine Electronic Control Unit (ECU) (Yanmar Diesel Engines Only)
CAN-bus Communications
Electrical Drawings
Special Tools
Multimeter
Dielectric Gel
Battery Hydrometer
Terminal Protector
InfoCenter Display
InfoCenter Display Screens
Splash Screen
Main Information Screen
Operator Advisory Screen
Main Menu Screen
Faults Screen
Service Screen
Diagnostics Screen
Settings Screen
About Screen
Troubleshooting
Operator Advisories
Using the InfoCenter Display for Troubleshooting
Fault Codes
Starting Problems
General Run and Transport Problems
Cutting Unit Operating Problems
Cutting Unit Lift, Lower Problems
Electrical System Quick Checks
Battery Test (Open Circuit Test)
Charging System Test
Glow Plug System Test
Check Operation of Interlock Switches
Adjustments
HI, LOW (transport, mow) Switch
Cutting Unit Position Switch
Component Testing
Fusible Link Harness
Fuses
Toro Electronic Controllers (TEC)
Ignition Switch
Reel Enable, Disable Switch
Engine Speed Switch (Yanmar Diesel Engine Only)
Lower, Raise Joystick Switches
Seat Switch
Traction Neutral Switch
Parking Brake Switch
HI, LOW (Transport, Mow) Switch
Cutting Unit Position Switch
Backlap Switches
Hydraulic Oil Temperature Sender
Engine Temperature Sender (Kubota Diesel Engine Only)
Relays with Four (4) Terminals
Relays with Five (5) Terminals
Hydraulic Solenoid Valve Coils
Fuel Pump (Yanmar Diesel Engine Only)
Fuel Pump (Kubota Diesel Engine Only)
Fuel Stop Solenoid (Kubota Diesel Engines Only)
CAN-bus Termination Resistor
Diode Assembly
Resistor Assembly
Worklight Switch
Service and Repairs
Battery Storage
Battery Care
Battery Service
Hydraulic Solenoid Valve Coils
Worklight Bulb Replacement
7 – Axles, Planetaries and Brakes
Specifications
General Information
Operator’s Manual
Adjustments
Planetary Drive End Play (OPH-2 series planetary drives)
Service and Repairs
Brake Assembly
Brake Inspection and Repair
Planetary Drive Assembly
OPH-2 Planetary Drive Service
VA02 Series Planetary Drive Service
Rear Axle Assembly
Rear Axle Service
Bevel Gear Case and Axle Case
Differential Shafts
Axle Shafts
Input Shaft, Pinion Gear
Differential Gear
Pinion Gear to Ring Gear Engagement
8 – Chassis
General Information
Operator’s Manual
Cutting Unit Identification
Service and Repairs
Steering Column
Console Arm
Lift Arms for Front Cutting Units (#1, #4 and #5)
Lift Arms for Rear Cutting Units (#2 and #3)
Operator Seat
Operator Seat Service
Operator Seat Suspension
Hood
9 – DPA Cutting Units
Specifications
General Information
Cutting Unit Operator’s Manual
Special Tools
Gauge Bar Assembly
Bedknife Screw Tool
Handle Assembly
Plastic Plug
Cutting Unit Kickstand
Spline Insert Tool
Diameter, Circumference Measuring Tape
Roller Rebuild Kit
Turf Evaluator Tool
Reel Bearing Installation Tool (cutting units with painted side plates)
Cutting Reel Shim
Cutting Performance Paper
Pulley Alignment Tool
Bedknife Top Angle Indicator and Mount
Factors That Can Affect Cutting Performance
Adjustments
Characteristics
Reel Bearing Adjustment (cutting units with painted side plates)
Leveling Rear Roller
Service and Repairs
Hydraulic Reel Motor
Backlapping
Bedbar Assembly
Bedknife Replacement and Grinding
Bedbar Adjuster Service
Reel Assembly (cutting units with painted side plates)
Reel Assembly Service (cutting units with painted side plates)
Reel Assembly (cutting units with aluminum side plates)
Reel Assembly Service (cutting units with aluminum side plates)
Preparing Reel for Grinding
Front Roller
Rear Roller
Roller Service
Rear Roller Brush – Optional (cutting units with painted side plates)
Rear Roller Brush – Optional (cutting units with aluminum side plates)
10 – Belt Driven Groomer (Optional)
Grooming Performance
Troubleshooting
Groomer Reel Mechanical Problems
Adjustments
Groomer Height, Depth Adjustment
Service and Repairs
Groomer Drive Belt Replacement
Groomer Plate Assembly
Groomer Reel
Groomer Reel Service
Groomer Pivot Hub
Height Adjuster Assembly
11 – Universal Groomer (Optional)
Grooming Performance
Troubleshooting
Groomer Reel Mechanical Problems
Service and Repairs
Gear Box Assembly
Idler Assembly
Groomer Reel
Groomer Reel Service
Grooming Brush (Optional) Service
Height Adjuster Assembly
12 – Foldout Drawings
Electrical Drawing Designations
Hydraulic Schematic
Electrical Schematic – Traction Unit Model 03780 – Yanmar Engine (Serial numbers below 316000000)
Electrical Schematic — Traction UnitModel 03780 — Yanmar Engine(Serial numbers 316000001 to 403350000)
Electrical Schematic — Traction UnitModel 03780 — Yanmar Engine(Serial numbers above 403350001)
Electrical Schematic – Traction Unit Model 03781 – Kubota Engine (Serial numbers below 316000000)
Electrical Schematic — Traction UnitModel 03781 — Kubota Engine(Serial numbers 316000001 to 403350000)
Electrical Schematic — Traction UnitModel 03781 — Kubota Engine(Serial numbers above 403350001)
Electrical Schematic – Cab
Main Wire Harness Drawing (Serial numbers below 316000000)
Main Wire Harness Diagram (Serial numbers below 316000000)
Main Wire Harness DrawingModel 03780 & 03781(Serial numbers 316000001 to 403350000)
Main Wire Harness DiagramModel 03780 & 03781(Serial numbers 316000001 to 403350000)
Main Wire Harness DrawingModel 03780 & 03781(Serial numbers 403350001 to 405699999)
Main Wire Harness DiagramModel 03780 & 03781(Serial numbers 403350001 to 405699999)
Main Wire Harness DrawingModel 03780 & 03781(Serial numbers above 405700000)
Main Wire Harness DiagramModel 03780 & 03781(Serial numbers above 405700000)
Engine Wire Harness Drawing – Yanmar
Engine Wire Harness Diagram – Yanmar
Engine Wire Harness Drawing – Kubota
Engine Wire Harness Diagram – Kubota
Seat and Console Wire Harness Drawing
Seat and Wire Harness Diagram
Power Center Wire Harness Drawing (Serial numbers below 403350000)
Power Center Wire Harness Diagram (Serial numbers below 403350000)
Power Center Wire Harness DrawingModel 03780 & 03781(Serial numbers above 403350001)
Power Center Wire Harness DiagramModel 03780 & 03781(Serial numbers above 403350001)