Toro Reelmaster 7000 Service Repair Manual

Table of Content – Reelmaster 7000

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
Decimal and Millimeter Equivalents
US to Metric 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)
Other Torque Specifications
Conversion Factors
3 – Kubota Diesel Engine
Specifications
General Information
Operator’s Manual
Service and Repairs
Air Filter System
Exhaust System
Fuel System
Radiator
Engine
Engine Removal
Engine Installation
Pump Adapter Plate
Kubota Diesel Engine Workshop Manual
4 – Hydraulic System
Specifications
General Information
Operator’s Manual
Towing Traction Unit
Check Hydraulic Fluid
Relieving Hydraulic System Pressure
Traction Circuit Component Failure
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: Mow Speed
Traction Circuit: Transport Speed
Lower Cutting Units
Raise Cutting Units
Mow Circuit
Steering Circuit
Engine Cooling Fan Circuit
Special Tools
Troubleshooting
General Hydraulic System Problems
Traction Circuit Problems
PTO Problems
Steering Circuit Problems
Lift, Lower Circuit Problems
Engine Cooling Fan Circuit Problems
Testing
Traction Circuit Charge Pressure
Traction Circuit Relief Pressure
Traction Circuit Reducing Valve (PR) Pressure
Rear Traction Circuit Relief (RV) Pressure Test
Piston (Traction) Pump Flow Test
Mow Circuit Pressure Test
Mow Circuit Relief Pressure Test
Cutting Unit Motor Case Drain Leakage Test
Gear Pump P1 and P2 Flow (Mow Circuits) Test
Steering Circuit Relief Pressure
Steering Cylinder Internal Leakage
Lift, Lower Circuit Relief Pressure
Gear Pump P3 Flow (Steering and Lift, Lower Circuits) Test
Cooling Fan Circuit Test
Gear Pump P4 Flow (Cooling Fan Circuit) Test
Adjustments
Adjust Control Manifold Relief Valves
Service and Repairs
General Precautions for Removing and Installing Hydraulic System Components
Check Hydraulic Lines and Hoses
Flush Hydraulic System
Filtering Closed-Loop Traction Circuit
Charge Hydraulic System
Gear Pump
Gear Pump Service
Piston (Traction) Pump
Piston (Traction) Pump Service
4WD, 2WD and Filtration, Charge Control Manifolds
4WD, 2WD Control Manifold Service
Filtration, Charge Control Manifold Service
Control Manifold Cartridge Valve Service
Rear Axle Motor
Front Wheel Motors
Rear Axle and Front Wheel Motor Service
Cutting Reel Motor
Cutting Reel 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 Control Manifold
Lift Control Manifold Service
Lift Circuit Junction Manifold
Front Lift Cylinders
Rear Lift Cylinders
Lift Cylinder Service (Serial Number Below 314000200)
Lift Cylinder Service (Serial Number Above 314000200)
Hydraulic Reservoir
Hydraulic Oil Cooler
Eaton Piston Pump Repair Information
Eaton Piston Motor Repair Information
Danfoss Steering Unit Service Repair Manual
5 – Electrical System
General Information
Operator’s Manual
Toro Electronic Controller (TEC)
CAN-bus Communications
Electrical Drawings
Special Tools
Troubleshooting
Diagnostic Display
Starting Problems
General Run and Transport Problems
Cutting Unit Operating Problems
Electrical System Quick Checks
Battery Test (Open Circuit Test)
Charging System Test
Glow Plug System Test
Check Operation of Interlock Switches
Adjustments
Mowith Transport Sensor
Cutting Unit Position Sensor
Component Testing
Ignition Switch
Fuses
Indicator Lights
Hour Meter
Temperature Gauge
PTO Switch
Cutting Unit Lift Switch
Headlight Switch
Engine Cooling Fan Switch
Seat Switch
Parking Brake Switch
Mowith Transport Sensor
Cutting Unit Position Sensor
Backlap Switches
Glow and Main Power Relays
Start Relay
Reel Speed Potentiometer
Hydraulic Solenoid Valve Coils
Traction Neutral Switch
Diode Assembly
Toro Electronic Controller (TEC)
Engine Coolant and Hydraulic Oil Temperature Senders
Fuel Pump
Fuel Stop Solenoid
Engine Temperature Sender
Oil Pressure Switch
Service and Repairs
Battery Storage
Battery Care
Battery Service
Hydraulic Solenoid Valve Coils
6 – Axles, Planetaries and Brakes
Specifications
General Information
Operator’s Manual
Adjustments
Planetary Drive Assembly Endplay (OPH-2 series planetary drives)
Service and Repairs
Brake Assembly
Brake Inspection and Repair
Planetary Drive Assembly
OPH-2 Series 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
7 – 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
8 – 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 (greasable bearings with retaining ring)
Roller Service (greasable bearings with bearing nut)
Rear Roller Brush – Optional (cutting units with painted side plates)
Rear Roller Brush – Optional (cutting units with aluminum side plates)
9 – 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
10 – 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
11 – Foldout Drawings
Electrical Drawing Designations
Wire Color
Wire Size
Hydraulic Schematic
Electrical Schematic: Sheet 1 of 2
Electrical Schematic: Sheet 2 of 2
Main Wire Harness Drawing
Seat and Console Wire Harness Drawing
Power Center Wire Harness Drawing