Page 1
Form No. 15214SL Rev E
Reelmaster® 7000-D
(Models 03780/A and 03781)
Original Instructions (EN)
Page 2
Revision History
Revision
Date
Description
--
2015
A
02/2018
Updated Engine chapter. Added revision history.
B
04/2018
C
06/2019
D
07/2020
Updated Electrical, Cutting Unit, Universal Groomer chapters and
Foldout drawing.
E
06/2021
Updated Hydraulic chapter.
©
reproduced by a third party without the express written consent of The Toro Company (and/or the appropriate affiliated company).
Initial Issue.
Added VA02 planetary drive information. Revised bedknife
installation procedure and painted/aluminum side plate cutting
unit information. Added groomer chapters.
Updated rear axle service drawings.
THE TORO COMPANY 2021
This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies). No
intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be
Page 3
Reader Comments
The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality
and usefulness of its publications. To do this effectively, we encourage user feedback.
Please comment on the completeness, accuracy, organization, usability, and readability of this manual
by an e-mail to servicemanuals@toro.com
or Mail to:
Technical Publication Manager, Commercial
The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
Phone: +1 952-887-8495
Page 4
NOTES _
Page 5
Part No. 15214SL Rev. E
Service Manual
(Models 03780/A and 03781)
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--D.
REFER TO THE TRACTION UNIT AND CUTTING
UNIT OPERATOR’S MANUALS FOR OPERATING,
MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. For reference, insert a copy of the Operator’s
Manuals and Parts Catalog for your machine into Chapter 2 of this service manual. Additional copies of the Operator’s Manuals and Parts Catalog are available on the
internet at www.Toro.com.
The Toro Company reserves the right to change product
specifications or this publication without notice.
Reelmaster
This safety symbol means DANGER, WARNING
or CAUTION, PERSONAL SAFETY INSTRUCTION. When you see this symbol, carefully read
the instructions that follow. Failure to obey the
instructions may result in personal injury.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing or repair of the machine.
IMPORTANT: The IMPORTANT notice will give important instructions which must be followed to prevent damage to systems or components on the
machine.
7000--D
R
E The Toro Company -- 2015, 2018, 2019, 2020, 2021
Page 6
This page is intentionally blank.
Reelmaster 7000--D
Page 7
Table of Contents
Chapter 1 -- Safety
General Safety Instructions 1 -- 2..................
Jacking Instructions 1 -- 4.........................
Safety and Instruction Decals 1 -- 5................
Chapter 2 -- Product Records and Maintenance
Product Records 2 -- 1...........................
Maintenance 2 -- 1...............................
Equivalents and Conversions 2 -- 2................
Torque Specifications 2 -- 3.......................
Chapter 3 -- Yanmar Diesel Engine
Specifications 3 -- 2..............................
General Information 3 -- 3........................
Service and Repairs 3 -- 9........................
YANMAR TNV (Tier 4) SERIES SERVICE MANUAL
YANMAR TNV (Tier 4) SERIES TROUBLESHOOTING
MANUAL
Chapter 4 -- Kubota Diesel Engine
Specifications 4 -- 2..............................
General Information 4 -- 3........................
Service and Repairs 4 -- 4........................
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,
03--M--DI--E3B SERIES
Chapter 5 -- Hydraulic System
Specifications 5 -- 2..............................
General Information 5 -- 3........................
Hydraulic Schematic 5 -- 11.......................
Hydraulic Flow Diagrams 5 -- 12...................
Special Tools 5 -- 26.............................
Troubleshooting 5 -- 31...........................
Tes ti ng 5 - - 38...................................
Adjustments 5 -- 86..............................
Service and Repairs 5 -- 87.......................
EATON MODEL 72400 SERVO CONTROLLED PIS-
TON PUMP REPAIR INFORMATION
DANFOSS K AND L FRAME VARIABLE MOTORS
SERVICE MANUAL
DANFOSS STEERING UNIT TYPE OSPM SERVICE
MANUAL
Chapter 6 -- Electrical System
General Information 6 -- 2........................
Electrical Drawings 6 -- 5.........................
Special Tools 6 -- 6..............................
InfoCenter Display 6 -- 8..........................
Troubleshooting 6 -- 20...........................
Electrical System Quick Checks 6 -- 31.............
Adjustments 6 -- 33..............................
Component Testing 6 -- 35........................
Service and Repairs 6 -- 63.......................
Chapter 7 -- Axles, Planetaries and Brakes
Specifications 7 -- 2..............................
General Information 7 -- 3........................
Adjustments 7 -- 4...............................
Service and Repairs 7 -- 6........................
Chapter 8 -- Chassis
General Information 8 -- 2........................
Service and Repairs 8 -- 4........................
Chapter 9 -- DPA Cutting Units
Specifications 9 -- 2..............................
General Information 9 -- 3........................
Special Tools 9 -- 4..............................
Factors That Can Affect Cutting Performance 9 -- 8
Adjustments 9 -- 11..............................
Service and Repairs 9 -- 14.......................
Chapter 10 -- Belt Driven Groomer (Optional)
Grooming Performance 10 -- 2....................
Troubleshooting 10 -- 3...........................
Adjustments 10 -- 4..............................
Service and Repairs 10 -- 5.......................
..
SafetyProduct Records
Yanmar
Kubota
Hydraulic
Electrical
Axles, Planetaries
and Maintenance
Engine
Engine
System
System
and Brakes
Reelmaster 7000--D
DPA Cutting Chassis
Belt Driven
Units
Groomer
Page 8
This page is intentionally blank.
Reelmaster 7000--D
Page 9
Table of Contents (continued)
Chapter 11 -- Universal Groomer (Optional)
Grooming Performance 1 1 -- 2....................
Troubleshooting 1 1 -- 3...........................
Service and Repairs 11 -- 4.......................
Groomer
Universal
Chapter 12 -- Foldout Drawings
Electrical Drawing Designations 12 -- 2.............
Hydraulic Schematic 12 -- 3.......................
Electrical Schematics 12 -- 4......................
Wire Harness Drawings 12 -- 11...................
Foldout
Drawings
Reelmaster 7000--D
Page 10
This page is intentionally blank.
Reelmaster 7000--D
Page 11
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..........
Chapter 1
Safety
Safety
Reelmaster 7000−D Page 1 − 1 Safety
Page 12
General Safety Instructions
The Reelmaster 7000 has been tested and certified by
TORO for compliance with existing safety standards
and specifications. Although hazard control and accident prevention partially are dependent upon the design
and configuration of the machine, these factors are also
dependent upon the awareness, concern and proper
training of the personnel involved in the operation, transport, maintenance and storage of the machine. Improper use or maintenance of the machine can result in injury
or death. To reduce the potential for injury or death, comply with the following safety instructions.
Before Operating
WARNING
To reduce the potential for injury or death,
comply with the following safety instructions.
1. Review and understand the contents of the Operator’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.
Additional copies of the Operator’s Manual are available
on the internet at www.Toro.com.
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 machine. Also tighten any loose nuts, bolts or screws to ensure machine is in safe operating condition.
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 machine.
2. Before starting the engine:
A. Engage the parking brake.
4. Since diesel fuel is flammable, handle it carefully:
A. Use an approved fuel container.
B. Do not remove fuel tank cap while engine is hot or
running.
C. Do not smoke while handling fuel.
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.
4. Do not touch engine, exhaust system components or
radiator while engine is running or soon after it is
stopped. These areas could be hot enough to cause
burns.
5. Before getting off the seat:
B. Make sure traction pedal is in neutral and the
PTO switch is OFF (disengaged).
C. After engine is started, release parking brake and
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.
3. Do not run engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and
could possibly be deadly.
A. Ensure that traction pedal is in neutral.
B. Engage parking brake.
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.
F. Do not park on slopes unless wheels are chocked
or blocked.
Reelmaster 7000−DPage 1 − 2Safety
Page 13
Maintenance and Service
1. The Traction Unit and Cutting Unit Operator’s Manuals provide information regarding the operation, general
maintenance and maintenance intervals for your Reelmaster machine. Refer to these publications for additional information when servicing the machine.
2. Before servicing or making adjustments, lower cutting units, stop engine, set parking brake and remove
key from the ignition switch.
3. Make sure machine is in safe operating condition by
keeping all nuts, bolts and screws tight.
4. Never store the machine or fuel container inside
where there is an open flame, such as near a water heater or furnace.
5. Make sure all hydraulic line connectors are tight and
all hydraulic hoses and lines are in good condition before applying pressure to the hydraulic system.
6. Keep body and hands away from pin hole leaks in hydraulic 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 doctor familiar with this form of injury or gangrene may result.
7. Before disconnecting or performing any work on the
hydraulic system, all pressure in system must be relieved by stopping engine and lowering cutting units to
the ground.
8. If major repairs are ever needed or assistance is desired, contact an Authorized Toro Distributor.
13.Disconnect battery before servicing the machine.
Disconnect negative battery cable first and positive
cable last. If battery voltage is required for troubleshooting or test procedures, temporarily connect the battery.
Reconnect positive battery cable first and negative
cable last.
IMPORTANT: Before performing welding on the machine, disconnect both positive and negative battery cables from the battery , disconnect the wire
harness connector from the TEC and disconnect
the terminal connector from the engine alternator .
These steps will prevent damage to the machine
electrical system when welding.
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.
15.Battery gases can explode. Keep cigarettes, sparks
and flames away from the battery.
16.When welding on machine, disconnect both battery
cables to prevent damage to machine electronic equipment. Disconnect negative battery cable first and positive cable last. Also, disconnect the wire harness
connector fro m t h e Toro Electronic Controller (TEC) and
disconnect the terminal connector from the alternator.
17.At the time of manufacture, the machine conformed
to the safety standards for riding mowers. To assure optimum performance and continued safety certification of
the machine, use genuine Toro replacement parts and
accessories. Replacement parts and accessories made
by other manufacturers may result in non-conformance
with the safety standards and the warranty may be
voided.
Safety
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 moving parts. Keep bystanders away.
11.Do not overspeed the engine by changing governor
setting. To assure safety and accuracy , check maximum
engine speed.
12.Shut engine off before checking or adding oil to the
engine crankcase.
Reelmaster 7000−D Page 1 − 3 Safety
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
such as a concrete floor. Prior to raising the machine, remove 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 supported by jack stands, the machine may move or fall,
which may result in personal injury (see Jacking Instructions in this chapter).
Page 14
Jacking Instructions
CAUTION
When changing attachments, tires or performing other service, use correct jacks and supports. Make sure machine is parked on a solid,
level surface such as a concrete floor . Prior to
raising machine, remove any attachments that
may interfere with the safe and proper raising of
the machine. Always chock or block wheels. Use
jack stands to support the raised machine. If the
machine is not properly supported by jack
stands, the machine may move or fall, which
may result in personal injury.
Jacking the Front End (Fig. 1)
1. Apply parking brake and chock both rear tires to prevent 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.
1
2
Figure 1
1. Frame 2. Front tire (RH shown)
2. Position jack securely under the frame, just to the inside of the front tire.
3. Jack front of machine off the ground.
4. Position appropriate jack stands under the frame as
close to the wheels as possible to support the machine.
Jacking the Rear End (Fig. 2)
1. Apply parking brake and chock both front tires to prevent 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.
1
Figure 2
1. Rear axle 2. Rear tire (RH shown)
2
Reelmaster 7000−DPage 1 − 4Safety
Page 15
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−D Page 1 − 5 Safety
Page 16
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Reelmaster 7000−DPage 1 − 6Safety
Page 17
Product Records and Maintenance
Table of Contents
Chapter 2
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
Reelmaster at the end of this chapter. 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
Product Records
and Maintenance
Maintenance procedures and recommended service intervals 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.
Refer to the Engine Operator’s Manual for additional engine specific maintenance procedures.
Reelmaster 7000−D
Page 2 − 1
Product Records and Maintenance
Page 18
Equivalents and Conversions
0.09375
Product Records and Maintenance
Page 2 − 2
Reelmaster 7000−D
Page 19
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 specified in this Service Manual.
These Torque Specifications for the installation and
tightening of fasteners shall apply to all fasteners which
do not have a specific requirement identified in this Service Manual. 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
the fastener’s head or similar condition which affects th e
installation.
Fastener Identification
As noted in the following tables, torque values should be
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 engagement, etc.
The standard method of verifying torque shall be performed 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.
Product Records
and Maintenance
Grade 1 Grade 5 Grade 8
Inch Series Bolts and Screws
Figure 1
Using a Torque Wrench with an Offset Wrench
Use of an offset wrench (e.g. crowfoot wrench) will affect
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 recommendation 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 recommendation.
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”.
The measured effective length of the torque wrench with
the offset wrench installed (distance from the center of
the handle to the center of the offset wrench) is 19”.
Class 8.8 Class 10.9
Metric Bolts and Screws
Figure 2
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.
(effective length of
torque wrench)
A
B
(effective length of torque
wrench + offset wrench)
TORQUE CONVERSION FACTOR = A / B
Torque wrenchOffset wrench
The calculated torque conversion factor for this torque
wrench with this offset wrench would be 18 / 19 = 0.947.
Reelmaster 7000−D
Page 2 − 3
Figure 3
Product Records and Maintenance
Page 20
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)
Thread Size
# 6 − 32 UNC
# 6 − 40 UNF 17 + 2 192 + 23 25 + 3 282 + 34
# 8 − 32 UNC
# 8 − 36 UNF 31 + 4 350 + 45 43 + 5 486 + 56
# 10 − 24 UNC
# 10 − 32 UNF 48 + 5 542 + 56 68 + 7 768 + 79
1/4 − 20 UNC 48 + 7 53 + 7 599 + 79 100 + 10 1130 + 113 140 + 15 1582 + 169
1/4 − 28 UNF 53 + 7 65 + 10 734 + 113 115 + 12 1299 + 136 160 + 17 1808 + 192
5/16 − 18 UNC 115 + 15 105 + 15 1186 + 169 200 + 25 2260 + 282 300 + 30 3390 + 339
5/16 − 24 UNF 138 + 17 128 + 17 1446 + 192 225 + 25 2542 + 282 325 + 33 3672 + 373
3/8 − 16 UNC 16 + 2 16 + 2 22 + 3 30 + 3 41 + 4 43 + 5 58 + 7
Grade 1, 5 &
8 with Thin
Height Nuts
in−lb in−lb N−cm in−lb N−cm in−lb N−cm
10 + 2 13 + 2 147 + 23
13 + 2 25 + 5 282 + 30
18 + 2 30 + 5 339 + 56
ft−lb ft−lb N−m ft−lb N−m ft−lb N−m
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)
15 + 2 169 + 23 23 + 3 262 + 34
29 + 3 328 + 34 41 + 5 463 + 56
42 + 5 475 + 56 60 + 6 678 + 68
SAE Grade 8 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 5 or Stronger Nuts)
3/8 − 24 UNF 17 + 2 18 + 2 24 + 3 35 + 4 47 + 5 50 + 6 68 + 8
7/16 − 14 UNC 27 + 3 27 + 3 37 + 4 50 + 5 68 + 7 70 + 7 95 + 9
7/16 − 20 UNF 29 + 3 29 + 3 39 + 4 55 + 6 75 + 8 77 + 8 104 + 11
1/2 − 13 UNC 30 + 3 48 + 7 65 + 9 75 + 8 102 + 11 105 + 11 142 + 15
1/2 − 20 UNF 32 + 4 53 + 7 72 + 9 85 + 9 115 + 12 120 + 12 163 + 16
5/8 − 11 UNC 65 + 10 88 + 12 119 + 16 150 + 15 203 + 20 210 + 21 285 + 28
5/8 − 18 UNF 75 + 10 95 + 15 129 + 20 170 + 18 230 + 24 240 + 24 325 + 33
3/4 − 10 UNC 93 + 12 140 + 20 190 + 27 265 + 27 359 + 37 375 + 38 508 + 52
3/4 − 16 UNF 115 + 15 165 + 25 224 + 34 300 + 30 407 + 41 420 + 43 569 + 58
7/8 − 9 UNC 140 + 20 225 + 25 305 + 34 430 + 45 583 + 61 600 + 60 813 + 81
7/8 − 14 UNF 155 + 25 260 + 30 353 + 41 475 + 48 644 + 65 667 + 66 904 + 89
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.
The nominal torque values listed above for Grade 5 and
8 fasteners are based on 75% of the minimum proof load
specified in SAE J429. The tolerance is approximately
+
10% of the nominal torque value. Thin height nuts in-
clude jam nuts.
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
Page 2 − 4
Reelmaster 7000−D
Page 21
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series)
Class 8.8 Bolts, Screws and Studs with
Thread Size
M5 X 0.8 57 + 6 in−lb 644 + 68 N−cm 78 + 8 in−lb 881 + 90 N−cm
M6 X 1.0 96 + 10 in−lb 1085 + 113 N−cm 133 + 14 in−lb 1503 + 158 N−cm
M8 X 1.25 19 + 2 ft−lb 26 + 3 N−m 28 + 3 ft−lb 38 + 4 N−m
M10 X 1.5 38 + 4 ft−lb 52 + 5 N−m 54 + 6 ft−lb 73 + 8 N−m
M12 X 1.75 66 + 7 ft−lb 90 + 10 N−m 93 + 10 ft−lb 126 + 14 N−m
M16 X 2.0 166 + 17 ft−lb 225 + 23 N−m 229 + 23 ft−lb 310 + 31 N−m
M20 X 2.5 325 + 33 ft−lb 440 + 45 N−m 450 + 46 ft−lb 610 + 62 N−m
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.
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.
Regular Height Nuts
(Class 8 or Stronger Nuts)
The nominal torque values listed above are based on
75% of the minimum proof load specified in SAE J1 199.
The tolerance is approximately +
torque value.
Class 10.9 Bolts, Screws and Studs with
Regular Height Nuts
(Class 10 or Stronger Nuts)
10% of the nominal
Product Records
and Maintenance
Reelmaster 7000−D
Page 2 − 5
Product Records and Maintenance
Page 22
Other Torque Specifications
SAE Grade 8 Steel Set Screws
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−lb 18 + 3 ft−lb
1/2 − 13 UNC 75 + 15 ft−lb 50 + 10 ft−lb
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23 or Type F
Thread Size Baseline Torque*
No. 6 − 32 UNC 20 + 5 in−lb
Wheel Bolts and Lug Nuts
Thread Size
7/16 − 20 UNF
Grade 5
1/2 − 20 UNF
Grade 5
M12 X 1.25
Class 8.8
M12 X 1.5
Class 8.8
** For steel wheels and non−lubricated fasteners.
Thread Cutting Screws
(Zinc Plated Steel)
Thread
Size
No. 6 18 20 20 + 5 in−lb
Threads per Inch
Type A Type B
Recommended Torque**
65 + 10 ft−lb 88 + 14 N−m
80 + 10 ft−lb 108 + 14 N−m
80 + 10 ft−lb 108 + 14 N−m
80 + 10 ft−lb 108 + 14 N−m
Baseline Torque*
No. 8 − 32 UNC 30 + 5 in−lb
No. 10 − 24 UNC 38 + 7 in−lb
1/4 − 20 UNC 85 + 15 in−lb
5/16 − 18 UNC 110 + 20 in−lb
3/8 − 16 UNC 200 + 100 in−lb
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
No. 8 15 18 30 + 5 in−lb
No. 10 12 16 38 + 7 in−lb
No. 12 11 14 85 + 15 in−lb
* Hole size, material strength, material thickness and finish must be considered when determining specific
torque values. All torque values are based on non−lubricated fasteners.
Product Records and Maintenance
Page 2 − 6
Reelmaster 7000−D
Page 23
Table of Contents
SPECIFICATIONS 2............................
GENERAL INFORMATION 3.....................
Operator’s Manuals 3.........................
Yanmar Service and Troubleshooting Manuals 3..
Stopping the Engine 3.........................
Engine Electronic Control Unit (ECU) 4..........
Yanmar Engine 5.............................
Diesel Particulate Filter (DPF) 5................
SERVICE AND REPAIRS 9......................
Air Cleaner System 9..........................
Exhaust System 11...........................
Fuel System 13...............................
Check Fuel Lines and Connections 14.........
Drain and Clean Fuel Tank 14.................
Prime the Fuel System 14....................
Fuel Tank Removal 14.......................
Fuel Tank Installation 14......................
Radiator/Oil Cooler Assembly 15................
Engine 19....................................
Engine Removal 20..........................
Engine Installation 21........................
Pump Adapter Plate 23........................
YANMAR TNV (Tier 4) SERIES SERVICE MANUAL
YANMAR TNV (Tier 4) SERIES TROUBLESHOOTING
MANUAL
Chapter 3
Yanmar Diesel Engine
MODEL 03780
Engine
Yanmar
Reelmaster 7000−D Page 3 − 1 Yanmar Diesel Engine
Page 24
Specifications
Item Description
Make / Designation Yanmar Model 4TNV86CT−DTR: 4−Cycle, 4 Cylinder,
Bore 3.386 in (86 mm)
Stroke 3.543 in (90 mm)
Total Displacement 127.5 in3 (2090 cc)
Firing Order 1 (closest to flywheel end) − 3 − 2 − 4 (farthest from flywheel)
Direction of Rotation Counterclockwise (viewed from flywheel)
Fuel Diesel or Biodiesel (up to B20) Fuel with
Fuel Capacity 22 U.S. gallons (83 liters)
Fuel Pump Yanmar Supply Pump
Fuel Injection Type Common Rail with Direct Injection
Governor Electronic All Speed
Low Idle (no load) 1200 RPM
Water Cooled, Turbocharged, Tier 4 Diesel Engine
Ultra Low Sulfur Content
High Idle (no load) 2850 RPM
Engine Oil API CJ−4 or higher
Engine Oil Viscosity See Operator’s Manual
Crankcase Oil Capacity 6 U.S. quarts (5.7 liters) with Filter
Oil Pump Trochoid Type
Coolant Capacity 9 U.S. quarts (8.5 liters)
Alternator/Regulator 12 VDC, 80 amp
Engine Weight (Dry) 496 U.S. pounds (225 kg)
Reelmaster 7000−DPage 3 − 2Yanmar Diesel Engine
Page 25
General Information
This Chapter gives information about specifications and
repair of the diesel engine used in the Reelmaster
7000−D.
General maintenance procedures are described in your
Traction Unit Operator’s Manual. Information on engine
troubleshooting, testing, disassembly and assembly is
identified in the Yanmar Workshop Manual.
Most repairs and adjustments require tools which are
commonly available in many service shops. Special
Operator’s Manuals
The Traction Unit and Yanmar Engine Operator’s Manuals provide information regarding the operation, general
maintenance and maintenance intervals for your Reelmaster machine. Refer to these publications for additional information when servicing the machine.
Yanmar Service and Troubleshooting Manuals
The engine that powers your Reelmaster machine is a
Yanmar model 4TNV86CT (Tier 4). Both the Yanmar
Service Manual and the Yanmar Troubleshooting Manual is available for this engine. Make sure that the correct
engine manuals are used when servicing the engine on
your Reelmaster.
tools are described in the Yanmar Service Manual. The
use of some specialized test equipment is explained.
However, the cost of the test equipment and the specialized nature of some repairs may dictate that the work be
done at a Yanmar engine repair facility.
Service and repair parts for Yanmar engines are supplied through your Authorized Toro Distributor. If no
parts list is available, be prepared to provide your distributor with the Toro model and serial number of your machine.
Engine
Yanmar
Stopping the Engine
IMPORTANT: Before stopping the engine after
mowing or full load operation, cool the turbo-charger by allowing the engine to run at low idle speed
for five (5) minutes. Failure to do so may lead to turbo-charger trouble.
Reelmaster 7000−D Page 3 − 3 Yanmar Diesel Engine
Page 26
Engine Electronic Control Unit (ECU)
The Yanmar engine that powers your Reelmaster uses
an Electronic Control Unit (ECU) for engine management and also to communicate with the Toro Electronic
Controller (TEC) and the operator InfoCenter display on
the machine. All wire harness electrical connectors
should be plugged into the ECU before the machine ignition switch is moved from the OFF position to either the
ON or START position.
The engine electrical components (e.g. ECU, fuel injectors, EGR, exhaust DPF) are identified and matched in
the engine ECU program. If engine electrical components are replaced on the engine, the Yanmar electronic
tool must be used to update the ECU program which will
ensure correct engine operation.
If the engine ECU identifies that an engine problem exists, the engine speed may be reduced or the engine
might stop. The Yanmar electronic tool and
troubleshooting manual should be used to provide assistance in identifying the cause of the problem and the
repairs that are necessary. Contact your Toro distributor
for assistance in Yanmar engine troubleshooting.
1
2
IMPORTANT: Do not plug or unplug the engine ECU
for a period of thirty (30) seconds after the machine
key switch is turned OFF. The ECU may remain energized even though the ignition switch is OFF.
If the engine ECU is to be disconnected for any reason,
make sure that the ignition switch is in the OFF position
with the key removed before disconnecting the engine
ECU. Also, to prevent possible ECU damage when
welding on the machine, disconnect the engine ECU
from the machine before welding.
The engine ECU is mounted to the machine using four
(4) rubber grommets. The grommets isolate the ECU
from the machine electrically, and reduce machine vibration to the ECU. Make sure the ECU mounting grommets remain soft and unbroken. Replace grommets as
necessary.
Figure 1
1. Engine 2. Engine ECU
Reelmaster 7000−DPage 3 − 4Yanmar Diesel Engine
Page 27
Yanmar Engine:
The engine used on Reelmaster is a Yanmar TNV
Series, turbocharged, diesel engine that complies with
EPA Tier 4 emission regulations. Engine features include an electronic control unit (ECU) that controls a
common rail fuel injection system with direct injection,
water−cooled exhaust gas recirculation (EGR), an electronic governor, an exhaust system diesel oxidation
catalyst (DOC) and an exhaust diesel particulate filter
(DPF) with active regeneration. Glow plugs are used to
assist starting the engine. Numerous engine sensors
are used to allow the engine ECU to monitor and control
engine operation for optimum engine performance.
During the operation of the engine, if conditions warrant,
the engine ECU may generate an engine fault. Use the
machine InfoCenter to identify the engine fault; refer to
the Yanmar Troubleshooting Manual, or contact an Authorized Toro Distributor for assistance.
Figure 2
Engine
Yanmar
Diesel Particulate Filter (DPF)
The diesel particulate filter (DPF) used on Yanmar Tier
4F compliant engines is designed to breakdown the
hazardous elements in the exhaust and prevent the discharge of unburnt fuel or oil known as particulate matter
or soot. The DPF includes a Diesel Oxidation Catalyst
(DOC), a Soot Filter (SF), 2 temperature sensors, and
a pressure differential sensor. Additional information regarding the Diesel Particulate Filter (DPF) can be found
in the Yanmar Operation Manual – Industrial Engines
TNV supplied with your machine.
Regeneration
The engine ECU monitors the exhaust pressure before
and after the soot filter in the DPF to determine if soot is
accumulating. If soot is accumulating during normal engine operation, the pressure differential will increase.
The increase in pressure will signal the engine to begin
a process called Regeneration. Regeneration increases
the exhaust temperature and the length of time the engine operates at a higher than normal exhaust temperature, incinerating the built up soot and turning it into ash.
The different types of regeneration used are listed in order based on the amount of particulate matter in the soot
filter (least to most).
Note: The user interface and InfoCenter displays for
DPF regeneration changed with machine software
122-0251E. Use the InfoCenter About screen to verify
the software installed on the machine.
− For machines with software 122-0251A thru D: Com-
plete DPF regeneration instructions can be found in the
updated traction unit Operator’s Manual for the specific
machine. Visit www.toro.com to download the updated
traction unit Operator’s Manual for the machine.
− For machines with software 122-0251E and up: Com-
plete DPF regeneration instructions can be found in the
traction unit Operator’s Manual. Visit www.toro.com to
download the traction unit Operator’s Manual with the
correct DPF regeneration instructions for the machine.
Reelmaster 7000−D Page 3 − 5 Yanmar Diesel Engine
Page 28
Types of regeneration that are performed automatically (while the machine is operating)
Type Conditions Description
Passive
Assist
Reset Occurs every 100 hours of engine
Occurs during normal operation of the
machine at high engine speed or high
engine load.
Occurs because of prolonged operation
at low engine speed, low engine load,
or when the engine ECU detects the
soot filter is becoming obstructed.
operation.
Occurs after an assist regeneration if
the engine ECU determines the assist
regeneration did not sufficiently reduce
the soot level.
The DPF processes high heat exhaust
gasses, oxidizing harmful emissions
and incinerating soot to ash.
The InfoCenter does not display an icon
during passive regeneration.
The engine ECU adjusts the exhaust
intake throttle to raise the exhaust
temperature.
For software 122-0251A thru D only:
the InfoCenter dis
regeneration icon.
The engine ECU adjusts the exhaust
intake throttle and the injector timing to
raise the exhaust temperature.
plays the assist
Note: Reset regeneration may be
temporarily delayed if high exhaust
temperatures would create an unsafe
condition (the machine is operating
indoors or outdoors around trees, brush,
tall grass, or other temperature−sensitive
plants or materials). Refer to Setting
the Inhibit Regen in the traction
unit Operators Manual for additional
information.
For all software revisions:
the InfoCenter displays the high exhaust
temperature icon.
Reelmaster 7000−DPage 3 − 6Yanmar Diesel Engine
Page 29
Type
Conditions Description
Parked
Recovery
Occurs when exhaust back pressure in
the DPF increases due to continued soot
buildup. May be caused by prolonged
operation at low engine speed, low engine
load, or the use of incorrect fuel or engine
oil.
May occur if the InfoCenter is set to inhibit
regen (preventing a Reset Regeneration)
and machine operation is continued.
Can be initiated when prompted by the
engine ECU or after a minimum of 50
hours of engine operation.
For software 122-0251E and up: if
a parked regeneration is ignored, the
machine mow function (PTO) will be
disabled approximately 2 hours after the
first notification.
Occurs when exhaust back pressure in
the DPF increases due to soot buildup
reaching a critical level.
Can only be initiated when prompted by
the engine ECU.
For software 122-0251E and up: the
machine mow function (PTO) will be
disabled at first notification.
Manually initiate a parked regeneration as
soon as possible. A parked regeneration
will take approximately 30 to 60 minutes
and should not be started with less than
1/4 tank of fuel. The machine must remain
stationary (cannot be operated) during
the entire parked regeneration process.
The engine ECU adjusts the exhaust
intake throttle to raise the exhaust
temperature.
For all software revisions: the InfoCenter
displays advisory #188 and/or the stationary
regeneration icon.
Manually initiate a recovery regeneration as
soon as possible. A recovery regeneration
will take approximately 3 hours and
should not be started with less than 1/2 tank
of fuel. The machine must remain stationary
(cannot be operated) during the entire
recovery regeneration process.
Use the InfoCenter About screen to verify
the software installed on the machine.
Engine
Yanmar
hines with software 122-0251A thru D:
• Mac
Recovery regeneration must be initiated by
an Authorized Toro Distributor service
technician using Yanmar SMARTASSISTDirect
• Machines with software 122-0251E and up:
Recovery regeneration can be initiated from
the machine InfoCenter
For software 122-0251E
D only: the InfoCenter
displays the recovery
regeneration icon.
For software 122-0251E
and up: the InfoCenter displays
advisory #190 and/or
the stationary regeneration icon.
Note: Verify the model and serial number of the
engine installed in the machine. 4TNV86CT-DTR
engines below serial number 03789 cannot run a
recovery regeneration without first reprogram
ming the engine ECU. Contact an Authorized Toro
Distributor for assistance.
thru
Reelmaster 7000−D Page 3 − 7 Yanmar Diesel Engine
Page 30
Soot Accumulation
If the types of regeneration that are performed automatically (while the machine is operating) are bypassed or not
allowed to complete before shutting off the engine, soot will continue to accumulate in the soot filter. When enough
soot accumulates, the engine ECU will generate an engine fault to prompt a parked or recovery regeneration. In addition to an engine fault appearing on the InfoCenter, the engine output power will be reduced.
Soot Accumulation Engine Faults
Fault Level Fault Code
Level 1: Engine Warning
Level 2: Engine Warning
Ash Accumulation
Ash is a result of the regeneration processes. The lighter ash is discharged through the exhaust system, while the
heavier ash collects in the soot filter. When enough ash accumulates in the soot filter, the engine ECU will generate
an engine fault to prompt servicing the DPF. In addition to an engine fault appearing on the InfoCenter, the engine
output power and speed will be reduced.
Ash Accumulation Advisories and Engine Faults
Fault Level Fault Code
Engine Power
Rating
Engine Power Rating Recommended Action
Perform a parked
De-rated to 85%
De-rated to 50%
Engine Speed
Reduction
regeneration as soon
as possible.
Perform a recovery
regeneration as soon
as possible.
Recommended Action
System Advisory
(machine software
122-0251A thru D
only)
Level 1: Engine
Warning
Level 2: Engine
Warning
Level 3: Engine
Warning
100%
De-rated to 85%
De-rated to 50%
De-rated to 50%
None
None
None
Maximum torque
+200 rpm
Plan to service the
DPF in the future.
Service DPF
Service DPF
Service DPF
Reelmaster 7000−DPage 3 − 8Yanmar Diesel Engine
Page 31
Service and Repairs
Air Cleaner System
RIGHT
1617
15
FRONT
11
18
10
14
13
Engine
Yanmar
1
3
2
12
VACUATOR
DIRECTION
19
16 to 19 in−lb
(1.8 to 2.2 N−m)
7
6
9
5
8
4
Figure 3
1. Air cleaner assembly
2. Adapter
3. Indicator
4. Air cleaner strap
5. Flat washer (2)
6. Flat washer (2)
7. Socket head screw (2)
8. Lock nut (2)
9. Spring (2)
10. Air cleaner outlet hose
11. Hose clamp
12. Hose clamp
13. Air cleaner inlet hose
14. Hose clamp
15. Plenum
16. Flange head screw (4)
17. Flange nut (4)
18. Flange nut (2)
19. Cap screw (2)
Reelmaster 7000−D Page 3 − 9 Yanmar Diesel Engine
Page 32
Removal (Fig. 3)
1. Park machine on a level surface, lower cutting units,
stop engine, apply parking brake and remove key from
the ignition switch.
2. Raise and support hood.
3. Remove air cleaner components as needed.
Installation (Fig. 3)
IMPORTANT: Any leaks in the air filter system will
cause serious engine damage. Make sure that all air
cleaner components are in good condition and are
properly secured during assembly.
1. Assemble air cleaner components.
A. If service indicator was removed from air cleaner
housing, apply thread sealant to adapter threads before installing adapter and indicator to housing
(Fig. 5). Install adapter so that grooves in adapter
hex and adapter filter element are installed toward
service indicator. Tighten indicator from 26 to 33 in−
lb (3.0 to 3.7 N−m).
B. Orientate vacuator valve on air cleaner cover toward ground.
C. Make sure that air cleaner hoses do not contact
any engine or machine components. To modify
clearance, move and/or rotate air cleaner body in air
cleaner strap. Verify that tabs in strap mesh fully with
slots in air cleaner body. Air cleaner strap should be
as close as possible to air cleaner cap. Tighten strap
screws from 16 to 19 in−lb (1.8 to 2.2 N−m).
4
5
1. Air cleaner housing
2. Safety filter element
3. Air filter element
Thread
5
4
sealant
Thread
sealant
1
2
1
3
Figure 4
4. Air cleaner cap
5. Vacuator valve
2
3
26 to 33 in−lb
(3.0 to 3.7 N−m)
2. Lower and secure hood.
1. Air cleaner assembly
2. Service indicator
3. Adapter
Figure 5
4. Groove
5. Filter element
Reelmaster 7000−DPage 3 − 10Yanmar Diesel Engine
Page 33
Exhaust System
11
5
30
33
22
19 to 29 ft−lb
(25 to 40 N−m)
16
17
18
33 to 40 ft−lb
(45 to 55 N−m)
10
15
7
40
41
39
37
8
31
29
31
26
25
28
34
32
34
35
36
38
Yanmar
Emgine
27
16
20
12
25
27
33 to 40 ft−lb
(45 to 55 N−m)
4
9
RIGHT
FRONT
1. Gasket
2. Exhaust assembly stay
3. Exhaust assembly stay
4. Exhaust assembly stay
5. Exhaust assembly stay
6. Nut
7. DOC temp sensor (inlet)
8. DOC temp sensor (outlet)
9. Nut (4)
10. DOC assembly
11. Nut (3)
12. DPF assembly
13. Nut
14. Outlet flange
15. DPF gasket (2)
16
18
1
18
23
3
Figure 6
16. Bolt (20)
17. DPF lifter
18. DPF stiffener (5)
19. DPF stiffener
20. DPF stiffener
21. DPF stiffener
22. Bolt (2)
23. Nut (20)
24. Bolt (2)
25. Pipe joint bolt (2)
26. Exhaust pressure pipe (DPF inlet)
27. Sensor gasket (4)
28. Exhaust pressure pipe (DPF outlet)
29. Exhaust hose
30. Bolt (2)
44
16
2
42
13
43
18
23
15
21
19
31. Hose clip (2)
32. Hose
33. Bolt (3)
34. Hose clip (2)
35. Pressure sensor
36. Sensor bracket
37. Bolt (2)
38. Bolt (2)
39. Clip band
40. Band
41. Connector clip (2)
42. Bolt (2)
43. Bolt (2)
44. Bolt (2)
24
6
14
18
23
Reelmaster 7000−D Page 3 − 11 Yanmar Diesel Engine
Page 34
Reelmaster 7000−D models that are powered by a diesel engine that complies with EPA Tier 4 emission regulations are equipped with an exhaust system that includes
a diesel oxidation catalyst (DOC) and a diesel particulate filter (DPF). These exhaust components require
service or component replacement at intervals identified
in your Operator’s Manual. Additionally, the exhaust assembly uses two (2) temperature sensors and a pressure differential sensor which are used as inputs for the
engine ECU to monitor the operation of the exhaust system.
The diesel particulate filter (DPF) is cleaned periodically
through a regenerative process that is controlled by the
engine ECU (see the General Information section of this
chapter). The InfoCenter display will identify the status
of DPF regeneration. At recommended intervals, DPF
reconditioning is necessary which will require exhaust
system disassembly, DPF removal and DPF reconditioning by a company that has the necessary equipment. Once the DPF has gone through the
reconditioning process, it can be re−installed in the exhaust system. Contact your Toro Distributor for information on reconditioning the DPF.
Installation (Figs. 6 and 7)
NOTE: Make sure that all exhaust system flanges and
sealing surfaces are free of debris or damage that may
prevent a tight seal.
1. Make sure to install new gaskets in place of all gaskets that were removed. Do not use any type of gasket
sealant on gasket or flange surfaces.
2. Assemble all removed exhaust system components.
A. If exhaust temperature sensors (Fig. 6 items 7
and 8) were removed, tighten sensors from 19 to 29
ft−lb (25 to 40 N−m).
B. If exhaust pressure pipes ( Fig. 6 items 26 and 28)
were removed, replace sensor gaskets (item 27) on
both sides of the pressure pipe fitting. Tighten pipe
fittings from 33 to 40 ft−lb (45 to 55 N−m).
C. If DPF stiffeners (Fig. 6 items 18, 19, 20 and 21)
were loosened or removed, tighten fasteners that secure stiffeners before tightening fasteners that secure exhaust system to DPF stays.
The diesel oxidation catalyst (DOC) has a service life expectancy and requires replacement at recommended
intervals. Replacement of the DOC will require exhaust
system disassembly, removal of the existing DOC and
installation of the new DOC.
Additional information about the diesel particulate filter
(DPF) operation and maintenance can be found in the
Yanmar Service Manual and the Yanmar Troubleshooting Manual.
Removal (Figs. 6 and 7)
NOTE: The exhaust system DPF and DOC can be re-
moved from the exhaust system without removing the
entire exhaust from the engine. Certain engine service
procedures (e.g. rocker cover removal for valve clearance adjustment) will require removal of the exhaust
system assembly.
CAUTION
The muffler and exhaust pipe may be hot. To
avoid possible burns, allow the engine and exhaust system to cool before working on the exhaust system.
11
12
13
3
7
9
1
8
10
6
2
3
4
5
1. Raise and support hood to gain access to exhaust
system. Allow engine and exhaust to cool before doing
any disassembly of exhaust system components.
2. Remove exhaust system components from the engine as necessary. Discard all gaskets removed.
1. DPF assembly
2. Tailpipe
3. Clamp assembly
4. Flange nut (4)
5. Exhaust flange
6. Exhaust gasket
7. Tailpipe support
Figure 7
8. Cap screw
9. Cap screw
10. Mount bracket − RH rear
11. Engine mount
12. Rebound washer
13. Flange nut
Reelmaster 7000−DPage 3 − 12Yanmar Diesel Engine
Page 35
Fuel System
Thread Sealant
To Engine
21
8
19
17
21
8
8
20
15
16
Engine
Yanmar
14
18
13
8
1
Return From Engine
8
4
2
23
3
5
24
7
Thread
Sealant
1. Fuel suction tube
2. Fuel line clamp (2)
3. Fuel hose (tank to pump)
4. Return fitting
5. Fuel hose (engine to tank)
6. Fuel tank cap
7. Bushing (2)
8. Hose clamp (6)
9. Fuel tank
25
26
Figure 8
10. Cap screw (2)
11. Clamp (2)
12. Flange nut (2)
13. Fuel pump
14. Cap screw
15. Fuel hose (pump to filter)
16. Fuel hose (filter to engine)
17. Cap screw (2)
18. Flange nut (4)
6
RIGHT
9
FRONT
10
22
11
12
19. Fuel/water separator
20. Filter element
21. Elbow fitting (2)
22. Flat washer (2)
23. Fuel gauge
24. Grommet
25. Hose clamp
26. Draincock
Reelmaster 7000−D Page 3 − 13 Yanmar Diesel Engine
Page 36
Fuel Tank Removal (Fig. 8)
DANGER
Because diesel fuel is highly flammable, use caution when storing or handling it. Do not smoke
while filling the fuel tank. Do not fill fuel tank
while engine is running, hot or when machine is
in an enclosed area. Always fill fuel tank outside
and wipe up any spilled diesel fuel before starting the engine. Store fuel in a clean, safety−ap-
proved container and keep cap in place. Use diesel fuel for the engine only; not for any other
purpose.
Check Fuel Lines and Connections
Check fuel lines and connections as recommended in
the Traction Unit Operator’s Manual. Check lines for deterioration, damage, leaking or loose connections. Replace hoses, clamps and connections as necessary.
Drain and Clean Fuel Tank
Drain and clean the fuel tank periodically as recommended 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 extended period. To clean fuel tank, flush tank out with
clean diesel fuel. Make sure tank is free of contaminates
and debris. Follow all local codes and regulations when
recycling or disposing of waste fuel.
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.
2. For assembly purposes, label fuel hoses at suction
and return fittings in top of tank. Disconnect fuel hoses
from fittings.
3. Use draincock on bottom of tank to empty fuel tank
into a suitable container.
4. Remove fuel tank from machine.
Fuel Tank Installation (Fig. 8)
1. Install fuel tank to frame.
2. If draincock (item 26) or fuel pump fittings (item 21)
were removed, apply thread sealant to threads of draincock and fittings before installing.
3. Using labels placed during fuel tank removal, correctly connect fuel hoses to the suction and return fittings in top of tank. Secure hoses with hose clamps.
4. Make sure that draincock in bottom of fuel tank is
closed.
5. Fill fuel tank with clean fuel.
Prime the Fuel System
The fuel system needs to be primed before starting the
engine for the first time, after running out of fuel or after
fuel system maintenance (e.g. draining the filter/water
separator, replacing a fuel hose). To prime the fuel system, make sure that the fuel tank has fuel in it. Then, turn
the ignition key to the ON position for 10 to 15 seconds
which allows the fuel pump to prime the fuel system. DO
NOT use the engine starter motor to crank the engine in
order to prime the fuel system.
Reelmaster 7000−DPage 3 − 14Yanmar Diesel Engine
Page 37
Radiator/Hydraulic Oil Cooler
20
18
21
22
16
17
15
42
43
44
41
45
14
38
13
19
1
Engine
Yanmar
45
34
3
9
37
41
44
43
42
40
2
5
33
36
39
32
8
31
30
35
RIGHT
6
5
7
7
4
6
29
21
11
10
27
24
23
FRONT
12
25
26
28
Figure 9
1. Radiator
2. Fan assembly
3. Upper radiator shroud
4. Lower radiator shroud
5. R−clamp (2)
6. Flat washer (8)
7. Flange head screw (8)
8. Flange nut (4)
9. Flange head screw (4)
10. Hose clamp (4)
11. Upper radiator hose
12. Lower radiator hose
13. Plenum
14. Bulb seal
15. Crossover plate
16. Plenum seal
17. Flange head screw (8)
18. Flange nut (8)
19. Bushing
20. Elbow fitting
21. Hose clamp (4)
22. Hose (plenum drain)
23. Coolant reservoir
24. Reservoir bracket
25. Cap screw (2)
26. Lock washer (2)
27. Flange head screw (2)
28. Flange nut (2)
29. Hose (reservoir to radiator)
30. Reservoir cap
31. Hose clamp
32. Hose (reservoir overflow)
33. Flange head screw (4)
34. Radiator cap
35. Radiator draincock
36. Bulb seal
37. Bulb seal
38. Radiator mount
39. Flange head screw (4)
40. Flange nut (4)
41. Foam seal (2)
42. Spacer (6)
43. Seal bracket (2)
44. Flange nut (4)
o
45. 90
hydraulic fitting (2)
Reelmaster 7000−D Page 3 − 15 Yanmar Diesel Engine
Page 38
Removal (Fig. 9)
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 Chapter 8 − Chassis in this manual).
3. Remove air cleaner intake hose from air cleaner.
4. Remove flange head screws and flange nuts that secure plenum (item 13) to crossover plate. Remove plenum with air cleaner hose and drain hose attached.
5. Remove flange head screws and flange nuts that secure crossover plate (item 15) to radiator mount. Remove crossover plate.
CAUTION
Do not open radiator cap or drain coolant if the
radiator or engine is hot. Pressurized, hot coolant can escape and cause burns.
Ethylene−glycol antifreeze is poisonous. Dispose of coolant properly or store it in a properly
labeled container away from children and pets.
1
3
2
1. Radiator/oil cooler
2. Hydraulic tube
3. Hydraulic tube
4. Hydraulic hose
Figure 10
5. Bulkhead nut
6. Spacer
7. O−ring
4
4
5
6
7
5
6
7
6. Remove radiator cap. Drain radiator into a suitable
container using the radiator draincock.
7. Disconnect upper and lower hoses from the radiator.
8. Disconnect coolant reservoir hose (item 29) from the
radiator.
9. Remove fasteners that secure coolant reservoir
bracket (item 24) to frame and remove reservoir and
bracket from machine.
10.Remove engine cooling fan assembly including upper radiator shroud from machine (see Engine Cooling
Fan Motor in Chapter 5 − Hydraulic System in this manual).
11.To prevent contamination of hydraulic system during
radiator/oil cooler removal, thoroughly clean junction of
hydraulic hoses and fittings on oil cooler.
12.Disconnect hydraulic hoses from radiator/oil cooler
(Fig. 10). Put caps or plugs on open hydraulic hoses and
fittings to prevent system contamination. Label the hydraulic hoses to insure correct installation.
13.Remove flange head screws and flange nuts securing the radiator/oil cooler to the radiator mount (item 38).
Carefully remove radiator/oil cooler from the machine.
Make sure that spacers (item 42) remain in hood seals.
14.Plug all radiator/oil cooler and hose openings to prevent contamination.
15.If necessary, remove draincock, coolant plug, hydraulic oil plug from radiator/oil cooler (Fig. 11).
16.If hydraulic fittings are to be removed from oil cooler,
mark fitting orientation to insure correct assembly. Remove fittings from cooler and discard O−rings.
Reelmaster 7000−DPage 3 − 16Yanmar Diesel Engine
Page 39
Installation (Fig. 9)
1. If hydraulic fittings were removed from oil cooler, lubricate and place new O−rings onto fittings. Install fit-
tings into oil cooler openings using marks made during
the removal process to properly orientate fittings
(Fig. 11). Tighten fittings (see Hydraulic Fitting Installation in Chapter 5 − Hydraulic System in this manual).
2. If hydraulic plug was removed from oil cooler, place
new O−ring on plug and install into oil cooler port
(Fig. 11).
3. If draincock or plug were removed from radiator, apply thread sealant and install draincock and plug into radiator openings (Fig. 11).
2
1
3
4
5
6
Thread
sealant
4. Carefully position radiator/oil cooler to the radiator
mount. Make sure that spacers (item 42) are positioned
in hood seals. Secure radiator/oil cooler in place with
four (4) flange head screws and flange nuts.
5. Install engine cooling fan motor assembly and upper
radiator shroud to machine (see Engine Cooling Fan
Motor in Chapter 5 − Hydraulic System in this manual).
Make sure that clearance between shrouds and fan is at
least 0.180” (4.6 mm) at all points. Tighten all upper and
lower radiator shroud fasteners.
6. Remove any plugs in radiator coolant openings or
coolant hoses.
7. Connect upper and lower radiator hoses to the radiator and secure with hose clamps.
8. Secure coolant reservoir bracket (item 24) to frame
with two (2) cap screws and lock washers.
9. Connect reservoir hose (item 29) to the radiator vent
tube.
10.Remove caps or plugs from hydraulic hoses and fittings that were installed during disassembly. Connect
hydraulic hoses to oil cooler fittings (Fig. 12). Tighten hydraulic hoses (see Hydraulic Hose and Tube Installation
in Chapter 5 − Hydraulic System in this manual).
11. Install crossover plate (item 15) to radiator mount
and secure with four (4) flange head screws and nuts.
2
8
Thread sealant
Figure 11
1. Radiator/oil cooler
2. O−ring
3. 90_ Hydraulic fitting (2)
4. O−ring
1
3
7
5. Radiator cap
6. Coolant plug
7. Draincock
8. Hydraulic plug
4
7
Engine
Yanmar
4
5
6
5
6
7
12.Install plenum assembly (item 13) to crossover plate
and secure with four (4) flange head screws and nuts.
Route plenum drain hose through clamp (item 5).
13.Install air cleaner intake hose to the air cleaner.
14.Make sure that radiator draincock is closed. Fill ra-
1. Radiator/oil cooler
2. Hydraulic tube
3. Hydraulic tube
4. Hydraulic hose
2
Figure 12
5. Bulkhead nut
6. Spacer
7. O−ring
diator with coolant.
15.Install hood on the machine (see Hood Installation in
Chapter 8 − Chassis in this manual).
Reelmaster 7000−D Page 3 − 17 Yanmar Diesel Engine
Page 40
This page is intentionally left blank.
Reelmaster 7000−DPage 3 − 18Yanmar Diesel Engine
Page 41
Engine
19
18
18
RIGHT
23
24
FRONT
14
Rear
Lift
Tab
12
13
21
20
22
6
5
4
11
6
5
9
8
2
7
10
8
9
Front
Lift Tab
15
16
17
Engine
Yanmar
7
10
11
9
3
8
11
1
5
9
8
5
6
7
6
10
9
7
10
9
Figure 13
1. Mount bracket − left front
2. Mount bracket − right front
3. Mount bracket − left rear
4. Mount bracket − right rear
5. Lock washer (16)
6. Cap screw (16)
7. Engine mount (4)
8. Flange head screw (7)
9. Flange nut (12)
10. Rebound washer (4)
11. Cap screw (3)
12. Cap screw
13. Cap screw
14. Tailpipe support
15. Hose clamp (2)
16. Fuel hose (filter to engine)
17. Fuel hose (engine to tank)
18. Clamp (2)
19. Exhaust tailpipe
20. Flange nut (4)
21. Exhaust flange
22. Exhaust gasket
23. External tooth lock washer
24. Battery ground cable
Reelmaster 7000−D Page 3 − 19 Yanmar Diesel Engine
Page 42
Engine Removal (Fig. 13)
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.
6
2. Remove hood from the machine (see Hood Removal
in Chapter 8 − Chassis in this manual).
3. Open battery box cover and disconnect negative
battery cable first and then positive battery cable.
CAUTION
Do not open radiator cap or drain coolant if the
radiator or engine is hot. Pressurized, hot coolant can escape and cause burns.
Ethylene−glycol antifreeze is poisonous. Dispose of coolant properly, or store it in a properly
labeled container away from children and pets.
4. Remove radiator cap. Drain radiator into a suitable
container using the radiator draincock.
5. Disconnect coolant reservoir hose from the radiator
(Fig. 14).
6. Remove fasteners that secure coolant reservoir
bracket to frame and remove reservoir and bracket from
machine (Fig. 14).
7. Remove air cleaner intake hose from air cleaner.
Figure 14
1. Coolant reservoir hose
2. Reservoir and bracket
3. Cap screw (2)
4. Lock washer (2)
5
7
5. Plenum
6. Flange nut (4)
7. Flange head screw (4)
2
3
4
1
8. Remove flange head screws and flange nuts that secure plenum to crossover plate (Fig. 14). Remove plenum with air cleaner hose and drain hose attached.
9. Disconnect upper and lower coolant hoses from the
radiator.
10.Remove air cleaner system from engine (see Air
Cleaner Removal in this chapter).
11. Remove engine cooling fan assembly and fan
shrouds from machine (see Engine Cooling Fan Motor
in Chapter 5 − Hydraulic System in this manual).
12.Note location of cable ties used to secure wire harness. Disconnect the following engine electrical connections:
A. The two (2) engine wire harness connectors from
the engine ECU.
B. The engine wire harness connector from the machine wire harness located just rearward of the front
left engine mount.
C. The engine wire harness connectors at the start
relay, EGR relay, and the glow relay. The relays are
located on the air cleaner support bracket.
D. The positive battery cable and fusible link harness from the engine starter motor.
E. The negative battery cable, engine wire harness
ground, and main wire harness ground wires. These
wires are secured with a cap screw and external lock
washer to the right side of the engine below the
starter motor. Record location of lock washer for assembly purposes.
Reelmaster 7000−DPage 3 − 20Yanmar Diesel Engine
Page 43
13.Disconnect fuel supply and return hoses from injection pump (item 16 and 17). Cap fuel hoses and injector
pump fittings to prevent contamination.
CAUTION
IMPORTANT: The hydraulic pump assembly can remain in machine during engine removal. To prevent
pump assembly from shifting or falling, make sure
to support pump assembly before piston (traction)
pump mounting fasteners are removed.
14.Support hydraulic pump assembly. Remove fasteners that secure piston (traction) pump assembly to engine (see Piston (Traction) Pump Assembly Removal in
Chapter 5 − Hydraulic System in this manual).
15.Make sure all cable ties securing the wire harness,
fuel lines and hydraulic hoses to the engine are removed.
16.Connect lift or hoist to the lift brackets on engine.
17.Remove flange nuts, rebound washers and cap
screws that secure the engine mount brackets to the
rubber engine mounts (item 7).
CAUTION
One person should operate lift or hoist while a
second person guides the engine out of the machine.
One person should operate lift or hoist while a
second person guides the engine into the machine.
IMPORTANT: Make sure to not damage the engine,
fuel lines, hydraulic lines, electrical harness or other parts while installing the engine.
4. Carefully lower engine into the machine. Move engine toward the hydraulic pump assembly to engage the
pump input shaft with the coupler on the engine flywheel.
5. Align engine mount brackets to the rubber engine
mounts (item 7).
Install tailpipe support and secure engine mount brackets to rubber engine mounts with cap screws, rebound
washers and flange nuts.
6. Secure hydraulic pump assembly to engine (see Piston (Traction) Pump Assembly Installation in Chapter 5
− Hydraulic System in this manual).
7. Remove caps from fuel hose and injector pump fuel
inlet that were installed during engine removal to prevent contamination. Connect fuel supply hose to injection pump. Secure hose with hose clamp.
Engine
Yanmar
IMPORTANT: Make sure to not damage the engine,
fuel lines, hydraulic lines, electrical harness or other parts while removing the engine.
18.Carefully move engine away from the hydraulic
pump assembly to disengage the pump input shaft from
the coupler on the engine flywheel. Once the engine has
cleared the hydraulic pump, carefully lift engine from the
machine.
19.If necessary, remove exhaust tailpipe (item 19) and
engine mount brackets from the engine.
Engine Installation (Fig. 13)
1. Make sure that all parts removed from the engine
during maintenance or rebuilding are installed to the engine.
2. If removed, install engine mount brackets to the engine.
3. Connect lift or hoist to the lift tabs on engine.
8. Connect wire harness connectors to the following
engine components:
A. The two (2) engine wire harness connectors at
the engine ECU.
B. The engine wire harness connector at the machine wire harness located just rearward of the front
left engine mount.
C. The engine wire harness connectors at the start
relay, EGR relay, and the glow relay. The relays are
located on the air cleaner support bracket.
D. The positive battery cable and fusible link harness at the engine starter motor.
E. The electric starter. Torque nut at starter B+ terminal from 70 to 86 in−lb (7.9 to 9.7 N−m).
F. The negative battery cable, engine wire harness
ground, and main wire harness ground wires. These
wires are secured with a cap screw and external lock
washer to the right side of the engine below the
starter motor.
Reelmaster 7000−D Page 3 − 21 Yanmar Diesel Engine
Page 44
9. Using notes taken during engine removal, secure
wires with cable ties in proper locations.
10.Install engine cooling fan assembly and fan shrouds
to machine (see Engine Cooling Fan Motor in Chapter
5 − Hydraulic System in this manual).
11. Install air cleaner assembly to the engine (see Air
Cleaner Installation in this chapter).
12.If removed, install exhaust tailpipe.
13.Connect coolant hoses to the radiator.
14.Install plenum with air cleaner hose and drain hose
attached. Use flange head screws and flange nuts to secure plenum to crossover plate (Fig.15).
6
5
7
2
1
15.Connect air cleaner intake hose to air cleaner.
16.Secure coolant reservoir bracket with reservoir to
machine frame (Fig.15).
17.Connect coolant reservoir hose to the radiator
(Fig.15).
18.Make sure radiator draincock is closed and fill radiator and reservoir with coolant.
19.Check position of wires, fuel lines, hydraulic hoses
and cables for proper clearance with rotating, high temperature and moving components.
20.Connect positive battery cable first and then negative battery cable. Secure battery cover to machine.
21.Check and adjust engine oil level as needed.
22.Check and adjust hydraulic oil level as needed.
23.Prime the fuel system (see Prime the Fuel System in
this chapter).
24.Start engine and operate hydraulic controls to properly fill hydraulic system (see Charge Hydraulic System
in Chapter 5 − Hydraulic System in this manual).
Figure 15
1. Coolant reservoir hose
2. Reservoir and bracket
3. Cap screw (2)
4. Lock washer (2)
3
4
5. Plenum
6. Flange nut (4)
7. Flange head screw (4)
25.Install hood on the machine (see Hood Installation in
Chapter 8 − Chassis in this manual).
Reelmaster 7000−DPage 3 − 22Yanmar Diesel Engine
Page 45
Pump Adapter Plate
Loctite #242 (if reused)
17 to 21 ft−lb
(23 to 28 N−m)
7
3
Engine
6
4
Yanmar
Boss
5
1. Flywheel plate
2. Hardened washer (8)
3. Spring coupler
1
2
Loctite #242 (if reused)
4. Cap screw with patch lock (8)
5. Cap screw with patch lock (8)
RIGHT
FRONT
Figure 16
6. Hardened washer (8)
7. Engine assembly
Reelmaster 7000−D Page 3 − 23 Yanmar Diesel Engine
Page 46
Coupler Removal (Fig. 16)
NOTE: The hydraulic pump assembly needs to be re-
moved from engine before coupler can be removed.
1. If engine is in machine, remove hydraulic pump assembly (see Piston (Traction) Pump in Chapter 5 − Hydraulic System in this manual).
2. Remove flywheel plate and spring coupler from engine.
Coupler Installation (Fig. 16)
1. Position spring coupler to engine flywheel and align
mounting holes. Make sure that coupling hub is toward
pump (away from engine flywheel) (Fig. 17).
Engine Side Hydraulic
Pump Side
1
2
IMPORTANT: The patch lock feature of the cap
screws used in this procedure suggest replacing
the screws after disassembly. An alternative would
be to apply Loctite #242 (or equivalent) to the
threads of the original cap screws during assembly.
2. Secure coupler to flywheel with cap screws (item 4)
and hardened washers. Tighten cap screws in a crossing pattern from 17 to 21 ft−lb (23 to 28 N−m).
3. Position flywheel plate to engine. Make sure that
boss on plate is orientated down. Secure flywheel plate
with cap screws (item 5) and hardened washers in a
crossing pattern.
4. If engine is in machine, install hydraulic pump assembly (see Piston (Traction) Pump in Chapter 5 − Hydraulic System in this manual).
1. Coupler
2. Coupler hub
3
Figure 17
3. Engine flywheel
Reelmaster 7000−DPage 3 − 24Yanmar Diesel Engine
Page 47
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.......................
Prime Fuel System 10.......................
Bleed Air From Injectors 11...................
Radiator/Hydraulic Oil Cooler 12................
Engine 16....................................
Engine Removal 17..........................
Engine Installation 18........................
Pump Adapter Plate 22........................
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,
03−M−DI−E3B SERIES
Chapter 4
Kubota Diesel Engine
MODEL 03781
Engine
Kubota
Reelmaster 7000−D Page 4 − 1 Kubota Diesel Engine
Page 48
Specifications
Item Description
Make / Designation Kubota Model V2403−M−DI−E3B
Bore 3.425” (87.0 mm)
Stroke 4.031” (102.4 mm)
Total Displacement 148.5 in3 (2434 cc)
Firing Order 1 (closest to gear case end) − 3 − 4 (closest to flywheel end) − 2
Combustion Chamber Spherical Type (E−TVCS)
Compression Ratio 23.2:1
Direction of Rotation Counterclockwise (viewed from flywheel)
Fuel Diesel or Biodiesel (up to B20) Fuel with Low or Ultra Low
Fuel Capacity 22 U.S. gallons (83 liters)
Fuel Injection Pump Denso PFR 4M Type Mini Pump
Injection Nozzle Denso OPD Mini Nozzle
4−Cycle, 4 Cylinder, Liquid Cooled, Diesel Engine
Sulfur Content
Governor Centrifugal Mechanical
Low Idle (no load) 1550 + 50 RPM
High Idle (no load) 2850 +50/−120 RPM
Engine Oil API CH−4, CI−4 or higher
Engine Oil Viscosity See Operator’s Manual
Crankcase Oil Capacity 10.0 U.S. Quarts (9.5 Liters) with Filter
Oil Pump Trochoid Type
Coolant Capacity 9 U.S. quarts (8.5 liters)
Starter 12 VDC, 2.0 kW
Alternator/Regulator 12 VDC
Alternator Output 60 amp
Engine Dry Weight 406 U.S. pounds (184 kg)
Reelmaster 7000−DPage 4 − 2Kubota Diesel Engine
Page 49
General Information
This Chapter gives information about specifications and
repair of the Kubota diesel engine used in the Reelmaster 7000−D Model 03781.
General maintenance procedures are described in your
Traction Unit Operator’s Manual. Information on engine
troubleshooting, testing, disassembly and assembly is
identified in the Kubota Workshop Manual, Diesel Engine, 03−M−DI−E3B.
Most repairs and adjustments require tools which are
commonly available in many service shops. Special
Operator’s Manual
The Traction Unit and Engine Operator’s Manuals provide information regarding the operation, general maintenance and maintenance intervals for your Reelmaster
machine. Refer to these publications for additional information when servicing the machine.
tools are described in the Kubota Workshop Manual,
Diesel Engine, 03−M−DI−E3B. The use of some specialized test equipment is explained. However, the cost
of the test equipment and the specialized nature of
some repairs may dictate that the w ork be done at an engine repair facility.
Service and repair parts for Kubota engines are supplied through your Authorized Toro Distributor. If no
parts list is available, be prepared to provide your distributor with the Toro model and serial number.
Engine
Kubota
Reelmaster 7000−D Page 4 − 3 Kubota Diesel Engine
Page 50
Service and Repairs
Air Filter System
RIGHT
FRONT
12 to 15 in−lb
(1.4 to 1.6 N−m)
11
16
10
6
1
12
Vacuator
Direction
19
15
13
8
12
14
18
17
9
7
5
1. Battery support
2. Bracket
3. Flange head screw (8)
4. Flange nut (8)
5. Support bracket
6. Cap screw (4)
7. Flange nut (4)
2
4
3
6
Figure 1
8. Air cleaner strap
9. Cap screw (2)
10. Air cleaner assembly
11. Service indicator
12. Hose clamp
13. Hose clamp
14. Flat washer (2)
15. Flange nut (2)
16. Adapter
17. Air cleaner hose
18. Plenum
19. Air intake hose
Reelmaster 7000−DPage 4 − 4Kubota Diesel Engine
Page 51
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. Raise and support hood.
3. Remove air cleaner components as needed.
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.
1. Assemble air filter system.
A. If service indicator (item 11) or adapter was re-
moved from air cleaner housing, apply thread sealant to adapter threads before installing adapter and
indicator. 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).
B. Orientate vacuator valve on air cleaner cover toward ground.
4
5
1. Air cleaner housing
2. Safety filter element
3. Air filter element
5
4
2
3
Figure 2
4. Air cleaner cover
5. Vacuator valve
1
Engine
2
3
Kubota
C. Install air cleaner so air cleaner strap (item 10) is
as close as possible to air cleaner cover.
D. Make sure that air cleaner hose (item 17) does
not contact engine valve cover or other engine components. To modify clearance, move and/or rotate air
cleaner body in air cleaner strap. Verify that tabs in
strap mesh fully with slots in air cleaner body.
2. Lower and secure hood after air cleaner installation
is complete.
1
1. Air cleaner assembly
2. Service indicator
3. Adapter
Figure 3
4. Groove
5. Filter element
Reelmaster 7000−D Page 4 − 5 Kubota Diesel Engine
Page 52
Exhaust System
5
14
9
8
13
1
12
3
7
10
4
11
6
2
RIGHT
FRONT
1. Muffler
2. Flange head screw (2)
3. Flange head screw (4)
4. Muffler clamp
5. Tailpipe
Figure 4
6. RH engine mount
7. Flat washer
8. Cap screw
9. Muffler bracket
10. Muffler gasket
11. Engine
12. Muffler bracket
13. Flange nut (2)
14. Muffler clamp
Reelmaster 7000−DPage 4 − 6Kubota Diesel Engine
Page 53
Removal (Fig. 4)
CAUTION
The muffler and exhaust pipe may be hot. T o
avoid possible burns, allow the engine and exhaust system to cool before working on the muffler.
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.
NOTE: Make sure muffler flange and exhaust manifold
sealing surfaces are free of debris or damage that may
prevent a tight seal.
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.
2. Raise and support hood.
3. Remove muffler and/or muffler bracket from the en-
gine as necessary.
1. Install new exhaust gasket if original gasket is damaged or torn.
IMPORTANT: Failure to follow the suggested exhaust system fastener sequence may result in premature muffler failure.
2. Install exhaust system components to the engine.
Hand tighten all exhaust system fasteners before fully
tightening any fastener.
3. Tailpipe should have equal clearance between frame
and engine after installation.
4. Lower and secure hood after exhaust system installation is complete.
Engine
Kubota
Reelmaster 7000−D Page 4 − 7 Kubota Diesel Engine
Page 54
Fuel System
22
16
Thread
8
Sealant
19
Thread
Sealant
22
20
8
18
21
To Engine
17
8
19
13
8
14
15
28
1
Return From Engine
8
4
2
24
3
5
25
7
Thread
Sealant
1. Fuel suction tube
2. Fuel line clamp (2)
3. Fuel hose (tank to pump)
4. Return fitting
5. Fuel hose (engine to tank)
6. Fuel tank cap
7. Bushing (2)
8. Hose clamp (6)
9. Fuel tank
10. Cap screw (2)
26
27
Figure 5
11. Clamp (2)
12. Flange nut (2)
13. Fuel pump
14. Cap screw
15. Fuel pump bracket
16. Fuel hose (pump to filter)
17. Fuel hose (filter to engine)
18. Cap screw (2)
19. Flange nut (4)
10
23
11
12
6
9
RIGHT
FRONT
20. Fuel filter/water separator
21. Filter element
22. Elbow fitting (2)
23. Flat washer (2)
24. Fuel gauge
25. Grommet
26. Hose clamp
27. Draincock
28. Cap screw
Reelmaster 7000−DPage 4 − 8Kubota Diesel Engine
Page 55
Fuel Tank Removal (Fig. 5)
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 engine is running, hot or when machine is in an enclosed area. Always fill fuel tank outside and
wipe up any spilled diesel fuel before starting the
engine. Store fuel in a clean, safety−approved
container and keep cap in place. Use diesel fuel
for the engine only; not for any other purpose.
Check Fuel Lines and Connections
Check fuel lines and connections as recommended in
the T raction Unit Operator’s Manual. Check lines for deterioration, damage, leaking or loose connections. Replace hoses, clamps and connections as necessary.
Drain and Clean Fuel Tank
Drain and clean the fuel tank periodically as recommended 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 extended period. To clean fuel tank, flush tank out with
clean diesel fuel. Make sure tank is free of contaminates
and debris. Follow all local codes and regulations when
recycling or disposing of waste fuel.
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.
2. For assembly purposes, label fuel hoses at suction
and return fittings in top of tank. Disconnect fuel hoses
from fittings.
3. Use draincock on bottom of tank to empty fuel tank
into a suitable container.
4. Remove fuel tank from machine.
Fuel Tank Installation (Fig. 5)
1. Install fuel tank to frame.
2. If draincock (item 27) or fuel pump fittings (item 22)
were removed, apply thread sealant to threads of draincock and fittings before installing.
3. Using labels placed during fuel tank removal, correctly connect fuel hoses to the suction and return fittings in top of tank. Secure hoses with hose clamps.
4. Make sure that draincock on bottom of tank is closed.
5. Fill fuel tank with clean fuel.
Engine
Kubota
Reelmaster 7000−D Page 4 − 9 Kubota Diesel Engine
Page 56
Prime Fuel System
1. Park machine on a level surface, lower cutting units,
stop engine, and engage parking brake. Make sure fuel
tank is at least half full.
2. Release hood latch and open hood.
2
1
DANGER
Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive. A fire
or explosion from fuel can burn you and others
and can cause property damage.
• Fill the fuel tank outdoors, in an open area,
when the engine is cold. Wipe up any fuel
that spills.
• Never fill the fuel tank inside an enclosed
trailer.
• Never smoke when handling fuel, and stay
away from an open flame or where fuel
fumes may be ignited by a spark.
• Store fuel in an approved container and keep
it out of the reach of children. Never buy
more than a 180-day supply of fuel.
• Do not operate machine without entire
exhaust system in place and in proper
working condition.
3. Loosen air bleed screw on the top of the fuel filter/water separator (Fig. 6).
1. Fuel filter/water
separator
1
Figure 6
2. Air bleed screw
4. Turn ignition switch to the ON position until a solid
stream of fuel flows out around the bleed screw. Turn
ignition switch to the OFF position and tighten air bleed
screw.
5. Loosen air bleed screw on the fuel injection pump
(Fig. 7).
6. Turn ignition switch to the ON position until a solid
stream of fuel flows out around the bleed screw. Turn
ignition switch to the OFF position and tighten air bleed
screw.
IMPORTANT: The engine should normally start after the above bleeding procedures are followed.
However, if the engine does not start, air may be
trapped between injection pump and injectors (see
Bleed Air from Fuel Injectors).
7. Close hood and secure latch.
2
Figure 7
1. Fuel injection pump 2. Bleed screw
Reelmaster 7000−DPage 4 − 10Kubota Diesel Engine
Page 57
Bleed Air From Injectors
IMPORTANT: This procedure should be used only if
the fuel system has been purged of air through normal priming procedures (see Priming Fuel System
in this chapter) and engine will not start.
1. Park machine on a level surface, lower cutting units,
stop engine, and engage parking brake.
DANGER
Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive. A fire
or explosion from fuel can burn you and others
and can cause property damage.
• Fill the fuel tank outdoors, in an open area,
when the engine is cold. Wipe up any fuel
that spills.
• Never fill the fuel tank inside an enclosed
trailer.
• Never smoke when handling fuel, and stay
away from an open flame or where fuel
fumes may be ignited by a spark.
• Store fuel in an approved container and keep
it out of the reach of children. Never buy
more than a 180-day supply of fuel.
• Do not operate machine without entire
exhaust system in place and in proper
working condition.
Figure 8
1. No. 1 Injector/pipe connection
1
Engine
Kubota
2. Release hood latch and open hood.
3. Loosen pipe connection to the No. 1 injector nozzle
and holder assembly (Fig. 8).
4. Move throttle to FAST position.
5. Turn ignition switch to START and watch fuel flow
around connector. Turn key to OFF when solid flow is
observed. Tighten pipe connector securely to the injector nozzle.
6. Repeat steps on the remaining injector nozzles.
7. Close hood and secure latch.
Reelmaster 7000−D Page 4 − 11 Kubota Diesel Engine
Page 58
Radiator/Hydraulic Oil Cooler
20
18
21
22
16
17
15
42
43
44
41
45
14
38
13
19
1
45
34
3
9
37
41
44
43
42
40
2
5
33
36
39
RIGHT
FRONT
1. Radiator
2. Fan assembly
3. Upper radiator shroud
4. Lower radiator shroud
5. R−clamp (2)
6. Flat washer (8)
7. Flange head screw (8)
8. Flange nut (4)
9. Flange head screw (4)
10. Hose clamp (4)
11. Upper radiator hose
12. Lower radiator hose
13. Plenum
14. Bulb seal
15. Crossover plate
32
8
31
30
35
6
5
7
6
7
4
29
21
23
11
10
27
24
28
12
25
26
Figure 9
16. Plenum seal
17. Flange head screw (8)
18. Flange nut (8)
19. Bushing
20. Elbow fitting
21. Hose clamp (4)
22. Hose (plenum drain)
23. Coolant reservoir
24. Reservoir bracket
25. Cap screw (2)
26. Lock washer (2)
27. Flange head screw (2)
28. Flange nut (2)
29. Hose (reservoir to radiator)
30. Reservoir cap
31. Hose clamp
32. Hose (reservoir overflow)
33. Flange head screw (4)
34. Radiator cap
35. Radiator draincock
36. Bulb seal
37. Bulb seal
38. Radiator mount
39. Flange head screw (4)
40. Flange nut (4)
41. Foam seal (2)
42. Spacer (6)
43. Seal bracket (2)
44. Flange nut (4)
o
45. 90
hydraulic fitting (2)
Reelmaster 7000−DPage 4 − 12Kubota Diesel Engine
Page 59
Removal (Fig. 9)
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 Chapter 8 − Chassis in this manual).
3. Remove air cleaner intake hose from air cleaner.
4. Remove flange head screws and flange nuts that secure plenum (item 13) to crossover plate. Remove plenum with air cleaner hose and drain hose attached.
5. Remove flange head screws and flange nuts that secure crossover plate (item 15) to radiator mount. Remove crossover plate.
CAUTION
Do not open radiator cap or drain coolant if the
radiator or engine is hot. Pressurized, hot coolant can escape and cause burns.
Ethylene−glycol antifreeze is poisonous. Dispose of coolant properly or store it in a properly
labeled container away from children and pets.
1
3
2
1. Radiator/oil cooler
2. Hydraulic tube
3. Hydraulic tube
4. Hydraulic hose
Figure 10
5. Bulkhead nut
6. Spacer
7. O−ring
4
4
5
6
7
5
6
7
Engine
Kubota
6. Remove radiator cap. Drain radiator into a suitable
container using the radiator draincock.
7. Disconnect upper and lower hoses from the radiator.
8. Disconnect coolant reservoir hose (item 29) from the
radiator.
9. Remove fasteners that secure coolant reservoir
bracket (item 24) to frame and remove reservoir and
bracket from machine.
10.Remove engine cooling fan assembly including upper radiator shroud from machine (see Engine Cooling
Fan Motor in Chapter 5 − Hydraulic System in this manual).
11.To prevent contamination of hydraulic system during
radiator/oil cooler removal, thoroughly clean junction of
hydraulic hoses and fittings on oil cooler.
12.Disconnect hydraulic hoses from radiator/oil cooler
(Fig. 10). Put caps or plugs on open hydraulic hoses and
fittings to prevent system contamination. Label the hydraulic hoses to insure correct installation.
13.Remove flange head screws and flange nuts securing the radiator/oil cooler to the radiator mount (item 38).
Carefully remove radiator/oil cooler from the machine.
Make sure that spacers (item 42) remain in hood seals.
14.Plug all radiator/oil cooler and hose openings to prevent contamination.
15.If necessary, remove draincock, coolant plug, hydraulic oil plug from radiator/oil cooler (Fig. 11).
16.If hydraulic fittings are to be removed from oil cooler,
mark fitting orientation to insure correct assembly. Remove fittings from cooler and discard O−rings.
Reelmaster 7000−D Page 4 − 13 Kubota Diesel Engine
Page 60
Installation (Fig. 9)
1. If hydraulic fittings were removed from oil cooler, lubricate and place new O−rings onto fittings. Install fittings into oil cooler openings using marks made during
the removal process to properly orientate fittings
(Fig. 11). Tighten fittings (see Hydraulic Fitting Installation in Chapter 5 − Hydraulic System in this manual).
2. If hydraulic plug was removed from oil cooler, place
new O−ring on plug and install into oil cooler port
(Fig. 11).
3. If draincock or plug were removed from radiator, apply thread sealant and install draincock and plug into radiator openings (Fig. 11).
4. Carefully position radiator/oil cooler to the radiator
mount. Make sure that spacers (item 42) are positioned
in hood seals. Secure radiator/oil cooler in place with
four (4) flange head screws and flange nuts.
5. Install engine cooling fan motor assembly and upper
radiator shroud to machine (see Engine Cooling Fan
Motor in Chapter 5 − Hydraulic System in this manual).
Make sure that clearance between shrouds and fan is at
least 0.180” (4.6 mm) at all points. Tighten all upper and
lower radiator shroud fasteners.
2
1
2
8
Thread sealant
Figure 11
1. Radiator/oil cooler
2. O−ring
3. 90_ Hydraulic fitting (2)
4. O−ring
3
4
5
6
Thread
sealant
7
5. Radiator cap
6. Coolant plug
7. Draincock
8. Hydraulic plug
6. Remove any plugs in radiator coolant openings or
coolant hoses.
7. Connect upper and lower radiator hoses to the radiator and secure with hose clamps.
8. Secure coolant reservoir bracket (item 24) to frame
with two (2) cap screws and lock washers.
9. Connect reservoir hose (item 29) to the radiator vent
tube.
10.Remove caps or plugs from hydraulic hoses and fittings that were installed during disassembly. Connect
hydraulic hoses to oil cooler fittings (Fig. 12) Tighten
hoses (see Hydraulic Hose and Tube Installation in
Chapter 5 − Hydraulic System in this manual).
11. Install crossover plate (item 15) to radiator mount
and secure with four (4) flange head screws and nuts.
12.Install plenum assembly (item 13) to crossover plate
and secure with four (4) flange head screws and nuts.
Route plenum drain hose through clamp (item 5).
13.Install air cleaner intake hose to the air cleaner.
14.Make sure that radiator draincock is closed. Fill radiator with coolant.
1
3
2
1. Radiator/oil cooler
2. Hydraulic tube
3. Hydraulic tube
4. Hydraulic hose
Figure 12
5. Bulkhead nut
6. Spacer
7. O−ring
4
4
5
6
7
5
6
7
15.Install hood on the machine (see Hood Installation in
Chapter 8 − Chassis in this manual).
Reelmaster 7000−DPage 4 − 14Kubota Diesel Engine
Page 61
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Engine
Kubota
Reelmaster 7000−D Page 4 − 15 Kubota Diesel Engine
Page 62
Engine
10
Rear
9
Lift
Tab
8
12
13
10
11
14
RIGHT
FRONT
15
1
3
4
7
6
2
17
24
25
18
4
16
22
23
20
21
5
6
7
3
19
1. Engine
2. Mount bracket − left rear
3. Cap screw (5)
4. Lock washer (5)
5. Mount bracket − left front
6. Lock washer (4)
7. Cap screw (4)
8. Mount bracket − right rear
9. Muffler bracket
Figure 13
10. Cap screw (4)
11. Mount bracket − right front
12. Muffler bracket
13. Flange head screw
14. Cap screw (2)
15. Hardened washer (2)
16. Spacer (2)
17. Flange head screw (8)
18. Rubber engine mount (4)
19. Flange nut (8)
20. Rebound washer (4)
21. Flange nut (4)
22. Lock washer
23. Battery ground cable
24. Lock washer
25. Cap screw
Reelmaster 7000−DPage 4 − 16Kubota Diesel Engine
Page 63
Engine Removal (Fig. 13)
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.
6
2. Remove hood from the machine (see Hood Removal
in Chapter 8 − Chassis in this manual).
3. Open battery box cover and disconnect negative
battery cable first and then positive battery cable.
CAUTION
Do not open radiator cap or drain coolant if the
radiator or engine is hot. Pressurized, hot coolant can escape and cause burns.
Ethylene−glycol antifreeze is poisonous. Dispose of coolant properly, or store it in a properly
labeled container away from children and pets.
4. Remove radiator cap. Drain radiator into a suitable
container using the radiator draincock.
5. Disconnect coolant reservoir hose from the radiator
(Fig. 14).
6. Remove fasteners that secure coolant reservoir
bracket to frame and remove reservoir and bracket from
machine (Fig. 14).
7. Remove air cleaner intake hose from air cleaner.
8. Remove flange head screws and flange nuts that secure plenum to crossover plate (Fig. 14). Remove plenum with air cleaner hose and drain hose attached.
9. Disconnect upper and lower coolant hoses from the
radiator.
CAUTION
The exhaust system may be hot. T o avoid possible burns, allow the exhaust system to cool before working on or near the muffler.
10.Remove exhaust system from engine (see Exhaust
System Removal in this chapter).
11. Remove air cleaner system from engine (see Air
Cleaner Removal in this chapter).
12.Remove engine cooling fan assembly and fan
shrouds from machine (see Engine Cooling Fan Motor
in Chapter 5 − Hydraulic System in this manual).
5
7
2
1
3
4
Figure 14
1. Coolant reservoir hose
2. Reservoir and bracket
3. Cap screw (2)
4. Lock washer (2)
5. Plenum
6. Flange nut (4)
7. Flange head screw (4)
13.Record the location of cable ties used to secure wire
harness. Disconnect the following engine electrical connections:
A. The two (2) engine wire harness connectors from
the machine wire harness located just rearward of
the front left engine mount.
B. The engine wire harness connectors at the start
relay and the glow relay. The relays are located on
the air cleaner support bracket.
C. The positive battery cable and fusible link harness from the engine starter motor.
D. The negative battery cable, engine wire harness
ground, and main wire harness ground wires. These
wires are secured with a cap screw and external lock
washer to the right side of the engine below the
starter motor. Record location of lock washer for assembly purposes.
Engine
Kubota
Reelmaster 7000−D Page 4 − 17 Kubota Diesel Engine
Page 64
14.Disconnect fuel supply and return hose from injection pump (Fig. 15). Cap fuel hoses and injector pump
fittings to prevent contamination.
15.Remove throttle cable from engine (Fig. 15):
A. Remove lock nut that secures throttle cable swiv-
el to speed control lever.
B. Loosen cable clamp and remove throttle cable
from under clamp.
C. Position throttle cable away from the engine.
IMPORTANT: The hydraulic pump assembly can remain 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.
16.Support hydraulic pump assembly. Remove fasten-
ers that secure piston (traction) pump assembly to engine (see Piston (Traction) Pump Assembly Removal in
Chapter 5 − Hydraulic System in this manual).
17.Make sure all cable ties securing the wiring harness,
fuel lines or hydraulic hoses to the engine are removed.
18.Connect lift or hoist to the lift tabs on engine.
5
1
2
3
4
Figure 15
1. Engine run solenoid
2. Throttle cable
3. Cable clamp
Engine Installation (Fig. 13)
1. Make sure that all parts removed from the engine
during maintenance or rebuilding are installed to the engine.
2. If removed, install engine mount brackets to the engine.
4. Cable swivel
5. Fuel supply hose
19.Remove flange nuts, rebound washers and cap
screws that secure the engine mount brackets to the
rubber engine mounts (item 18).
CAUTION
One person should operate lift or hoist while a
second person guides the engine out of the machine.
IMPORTANT: Make sure to not damage the engine,
fuel lines, hydraulic lines, electrical harness or other parts while removing the engine.
20.Carefully move engine away from the hydraulic
pump assembly to disengage the pump input shaft from
the coupler on the engine flywheel. Once the engine has
cleared the hydraulic pump, carefully lift engine from the
machine.
21.If necessary, remove engine mounts from the en-
gine.
3. Connect lift or hoist to the lift tabs on engine.
CAUTION
One person should operate lift or hoist while a
second person guides the engine into the machine.
IMPORTANT: Make sure to not damage the engine,
fuel lines, hydraulic lines, electrical harness or other parts while installing the engine.
4. Carefully lower engine into the machine and move
engine toward the hydraulic pump assembly to engage
the pump input shaft with the coupler on the engine flywheel.
5. Align engine mount brackets to the rubber engine
mounts (item 18). Secure engine mount brackets to rubber engine mounts with cap screws, rebound washers
and flange nuts.
6. Secure hydraulic pump assembly to engine (see Piston (Traction) Pump Assembly Installation in Chapter 5
− Hydraulic System in this manual).
Reelmaster 7000−DPage 4 − 18Kubota Diesel Engine
Page 65
7. Connect throttle cable to engine (Fig. 16):
A. Secure throttle cable swivel to speed control le-
ver with lock nut.
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 contacts the end of the slot in the control console.
D. Tighten cable clamp to secure throttle cable.
8. Remove caps from fuel hose and injector pump fuel
inlet that were installed during engine removal to prevent contamination. Connect fuel supply hose to injection pump (Fig. 16). Secure hose with hose clamp.
9. Connect wire harness connectors to the following
engine components:
A. The two (2) engine wire harness connectors at
the machine wire harness located just rearward of
the front left engine mount.
B. The engine wire harness connectors at the start
relay and the glow relay. The relays are located on
the air cleaner support bracket.
C. The positive battery cable and fusible link harness at the engine starter motor.
D. The electric starter. Torque nut at starter B+ terminal from 70 to 86 in−lb (7.9 to 9.7 N−m).
5
2
3
1. Engine run solenoid
2. Throttle cable
3. Cable clamp
6
Figure 16
4. Cable swivel
5. Fuel supply hose
1
4
Engine
Kubota
5
7
2
1
E. The negative battery cable, engine wire harness
ground, and main wire harness ground wires. These
wires are secured with a cap screw and external lock
washer to the right side of the engine below the
starter motor.
10.Using notes taken during engine removal, secure
wires with cable ties in proper locations.
11.Install engine cooling fan assembly and fan shrouds
to machine (see Engine Cooling Fan Motor in Chapter
5 − Hydraulic System in this manual).
12.Install air cleaner assembly to the engine (see Air
Cleaner Installation in this chapter).
13.Install exhaust system to machine (see Exhaust Sys-
tem Installation in this chapter).
14.Connect coolant hoses to the radiator.
15.Install plenum with air cleaner hose and drain hose
attached. Use flange head screws and flange nuts to secure plenum to crossover plate (Fig. 17).
1. Coolant reservoir hose
2. Reservoir and bracket
3. Cap screw (2)
4. Lock washer (2)
3
4
Figure 17
5. Plenum
6. Flange nut (4)
7. Flange head screw (4)
Reelmaster 7000−D Page 4 − 19 Kubota Diesel Engine
Page 66
16.Connect air cleaner intake hose to air cleaner.
22.Check and adjust engine oil level as needed.
17.Secure coolant reservoir bracket with reservoir to
machine frame (Fig. 17).
18.Connect coolant reservoir hose to the radiator
(Fig. 17).
19.Make sure radiator draincock is closed and fill radiator and reservoir with coolant.
20.Check position of wires, fuel lines, hydraulic hoses
and cables for proper clearance with rotating, high temperature and moving components.
21.Connect positive battery cable first and then negative battery cable. Secure battery cover to machine.
23.Check and adjust hydraulic oil level as needed.
24.Prime the fuel system (see Priming The Fuel System
in this chapter).
25.Start engine and operate hydraulic controls to properly fill hydraulic system (see Charge Hydraulic System
in Chapter 5 − Hydraulic System in this manual).
26.Install hood on the machine (see Hood Installation in
Chapter 8 − Chassis in this manual).
Reelmaster 7000−DPage 4 − 20Kubota Diesel Engine
Page 67
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Engine
Kubota
Reelmaster 7000−D Page 4 − 21 Kubota Diesel Engine
Page 68
Pump Adapter Plate
1
RIGHT
FRONT
Loctite #242 (if reused)
29 to 33 ft−lb
(40 to 44 N−m)
3
2
5
4
6
1. Bolt
2. Lock washer
3. Flywheel plate
Boss
4
7
Loctite #242 (if reused)
Figure 18
4. Hardened washer (14)
5. Spring coupler
6. Cap screw with patch lock (6)
7. Cap screw with patch lock (8)
Reelmaster 7000−DPage 4 − 22Kubota Diesel Engine
Page 69
Coupler Removal (Fig. 18)
NOTE: The hydraulic pump assembly needs to be re-
moved from engine before coupler can be removed.
1. If engine is in machine, remove hydraulic pump as-
sembly (see Piston (Traction) Pump Removal in Chapter 5 − Hydraulic System in this manual).
2. Remove flywheel plate and spring coupler from en-
gine.
Coupler Installation (Fig. 18)
1. Position spring coupler to engine flywheel and align
mounting holes. Make sure that coupling hub is toward
pump (away from engine flywheel) (Fig. 19).
IMPORTANT: The patch lock feature of the cap
screws used in this procedure suggest replacing
the screws after disassembly. An alternative would
be to apply Loctite #242 (or equivalent) to the
threads of the original cap screws during assembly.
2. Secure coupler to flywheel with cap screws (item 6)
and hardened washers. Tighten bolts in a crossing pattern from 29 to 33 ft−lb (40 to 44 N−m).
Engine Side Hydraulic
Pump Side
1
Figure 19
1. Coupler
2. Coupler hub
3. Engine flywheel
2
3
Engine
Kubota
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 in a
crossing pattern.
4. If engine is in machine, install hydraulic pump as-
sembly (see Piston (Traction) Pump Installation in
Chapter 5 − Hydraulic System in this manual).
Reelmaster 7000−D Page 4 − 23 Kubota Diesel Engine
Page 70
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Reelmaster 7000−DPage 4 − 24Kubota Diesel Engine
Page 71
Table of Contents
Chapter 5
Hydraulic System
SPECIFICATIONS 2............................
GENERAL INFORMATION 3.....................
Operator’s Manual 3..........................
Hydraulic Component Locations 3..............
Relieving Hydraulic System Pressure 4..........
Traction Circuit Component Failure 4............
Towing Traction Unit 5.........................
Hydraulic Hoses 6............................
Hydraulic Hose and Tube Installation 7..........
Hydraulic Fitting Installation 8..................
HYDRAULIC SCHEMATIC 11....................
HYDRAULIC FLOW DIAGRAMS 12...............
Traction Circuit: LOW Speed (Mow) 12..........
Traction Circuit: HIGH Speed (Transport) 14......
Mow Circuit 16...............................
Steering Circuit 18............................
Lower Cutting Units 20........................
Raise Cutting Units 22.........................
Engine Cooling Fan Circuit 24..................
SPECIAL TOOLS 26............................
TROUBLESHOOTING 31........................
TESTING 38...................................
Traction Circuit
Charge Pressure Test 40....................
Relief Pressure Test 44......................
Piston (traction) Pump Flow Test 46...........
Front Wheel Motor Case Drain
Leakage Test 50..........................
Reverse Reducing Valve (PR)
Pressure Test 54..........................
Rear Relief Valve (RV) Pressure Test 56.......
Cutting Unit Circuit
Pressure Test 58...........................
Relief Pressure Test 62......................
Cutting Unit Motor Case Drain
Leakage Test 66..........................
Steering/Lift Circuit
Steering Relief Pressure Test 70..............
Steering Cylinder Test 72....................
Lift Relief Pressure Test 74...................
Cooling Fan Circuit
Pressure Test 76...........................
Fan Motor Case Drain Leakage Test 78........
Gear Pump Flow Test
(pumpsectionsP2thruP5) 82................
ADJUSTMENTS 86.............................
Control Manifold Relief Valve Adjustment 86......
SERVICE AND REPAIRS 87.....................
General Precautions for Removing and
Installing Hydraulic System Components 87....
Check Hydraulic Lines and Hoses 88............
Priming Hydraulic Pumps 88...................
Flush Hydraulic System 89.....................
Filtering Closed- Loop Traction Circuit 90........
Charge Hydraulic System 91
ar Pump 92................................
Ge
Gear Pump Service 94........................
Piston (traction) Pump 96......................
Piston (traction) Pump Service 98...............
Rear Traction Manifold 100.....................
Rear Traction Manifold Service 102.............
HI/LOW Range Manifold 104...................
Front Wheel Motors 106.......................
Rear Axle Motor 108..........................
Rear Axle and Front Wheel Motor Service 110....
Cutting Unit Motor 112.........................
Cutting Unit Motor Service 114.................
Mow Control Manifold 118.....................
Mow Control Manifold Service 120..............
Steering Control Valve 122.....................
Steering Control Valve Service 124..............
Steering Cylinder 126.........................
Steering Cylinder Service 128..................
Engine Cooling Fan Motor 130..................
Engine Cooling Fan Motor Service 134..........
Fan Control Manifold 136......................
Fan Control Manifold Service 138...............
Lift Manifold 140..............................
Lift Manifold Service 142.......................
Control Manifold Cartridge Valve Service 143.....
Lift Junction Manifold 144......................
Front Lift Cylinders 146........................
Rear Lift Cylinders 148........................
Lift Cylinder Service 150.......................
Hydraulic Reservoir 152.......................
Hydraulic Oil Cooler 154.......................
EATON MODEL 72400 SERVO CONTROLLED PIS-
TON PUMP REPAIR INFORMATION
DANFOSS K AND L FRAME VARIABLE MO-
TORS SERVICE MANUAL
DANFOSS STEERING UNIT TYPE OSPM
SERVICE MANUAL
...................
System
Hydraulic
Reelmaster 7000- D Hydraulic SystemPage 5 - 1
Page 72
Specifications
Item Description
Piston (Traction) Pump Eaton servo controlled variable displacement piston pump
Maximum Displacement (per revolution) 3.00 in
System Relief Pressure: Forward 5000 PSI (345 bar)
System Relief Pressure: Reverse 5000 PSI (345 bar)
Charge Pressure 207 PSI (14.3 bar)
Front Wheel Motors Danfoss 2−Position Axial Piston Motors
Displacement (per revolution) 1.83 in
Rear Axle Motor Danfoss 2−Position Axial Piston Motor
Displacement (per revolution) 2.32 in
Gear Pump Casappa 4 section, positive displacement gear type pump
Section P1/P2 Displacement (per revolution) 1.03 in
Section P3/P4 Displacement (per revolution) 0.56 in
Steering Control Valve Danfoss Steering Unit, Series OSPM
Displacement (per revolution) 6.1 in
Steering Circuit Relief Pressure 1050 PSI (72 bar)
Lift/Lower Circuit Relief Pressure 1700 PSI (117 bar)
Cutting Unit Motors Casappa Gear Motor
Displacement (per revolution) 1.63 in
3
(30 cc) Maximum / 0.89 in3 (14.6 cc) Minimum
3
(38 cc) Maximum / 1.13 in3 (18.5 cc) Minimum
with Loop Flushing Valve
(Model 72400)
3
(49.2 cc)
3
(16.85 cc)
3
(9.16 cc)
3
(100 cc)
3
(26.7 cc)
Cutting Unit Circuit Relief Pressure 3000 PSI (207 bar)
Engine Cooling Fan Motor Casappa Gear Motor
Displacement (per revolution) 0.51 in
Engine Cooling Fan Circuit Relief Pressure 3000 PSI (207 bar)
Hydraulic Filters:
Return Filter Spin−on cartridge type
Charge Filter Spin−on cartridge type
In−line Suction Strainer 100 mesh (in reservoir)
Hydraulic Reservoir Capacity 8.25 U.S. Gallons (31.3 Liters)
Hydraulic Oil See Traction Unit Operator’s Manual
3
(8.4 cc)
NOTE: The pressure specifications listed above are
component settings. When using pressure gauges to
measure circuit pressures, values may be d ifferent than
these specifications. See the Testing section of this
chapter for hydraulic test procedures and expected test
results.
Reelmaster 7000−DHydraulic System Page 5 − 2
Page 73
General Information
Operator’s Manual
The Operator’s Manuals provide information regarding
the operation, general maintenance and maintenance
intervals for your Reelmaster machine. Refer to both the
Traction Unit Operator’s Manual and the Cutting Unit
Operator’s Manual for additional information when servicing the machine.
Hydraulic Component Locations
5
910 11 12
RIGHT
FRONT
13 14
1
2
3
4
System
Hydraulic
5678
Figure 20
1. Piston pump P1
2. Gear pump P2 − P5
3. HI/LOW range manifold
4. Rear traction manifold
5. Front wheel motor (2)
6. Lift control manifold
7. Lift junction manifold
8. Steering control valve
9. Suction strainer
10. Charge filter
Reelmaster 7000−D Hydraulic SystemPage 5 − 3
11. Return filter
12. Fan control manifold
13. Mow control manifold
14. Rear axle motor
Page 74
Relieving Hydraulic System Pressure
Before disconnecting or performing any work on the hydraulic system, pressure in all of the hydraulic circuits
must be relieved.
1. Park machine on a level surface, lower cutting units
fully, set the reel enable/disable switch to the OFF position, stop engine and apply parking brake.
Traction Circuit Component Failure
The traction circuit on Reelmaster 7000−D machines is
a closed loop system that includes the piston (traction)
pump, two (2) front wheel motors and the rear axle motor. If a component in the traction circuit should fail, debris and contamination from the failed component will
circulate throughout the traction circuit. This contamination can damage other components in the circuit so it
must be removed to prevent additional component failure.
The recommended method of removing traction circuit
contamination would be to temporarily install the Toro
high flow hydraulic filter (see Special Tools in this chapter) into the circuit. This filter should be used when connecting hydraulic test gauges in order to test traction
circuit components or after replacing a failed traction circuit component (e.g. traction (piston) pump or wheel
motor). The filter will ensure that contaminates are removed from the closed loop system and do not cause
additional component damage.
Once the Toro high flow hydraulic filter kit has been
placed in the circuit, raise and support the machine with
2. Move the traction pedal in both forward and reverse
directions (relieves pressure in traction circuit).
3. Rotate steering wheel in both directions (relieves
pressure in steering and lift circuit).
NOTE: Pressure in the mow circuit is relieved automatically when the cutting units are disengaged.
all drive wheels off the ground. Operate the traction circuit to allow oil flow throughout the circuit. The filter 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−Loop Traction Circuit in this chapter for additional information on using the Toro high flow hydraulic
filter.
The alternative to using the Toro high flow hydraulic filter
kit after a traction circuit component failure would be to
disassemble, drain and thoroughly clean all components, tubes and hoses in the traction circuit. If any debris remains in the traction circuit and the machine is
operated, the debris can cause additional circuit component failure.
NOTE: If traction circuit contamination exists, the traction pump case drain could allow contaminates to enter
other hydraulic circuits on the machine.
Reelmaster 7000−DHydraulic System Page 5 − 4
Page 75
Towing Traction Unit
r
IMPORTANT: If towing limits are exceeded, severe
damage to the piston pump may occur.
If it becomes necessary to tow (or push) the machine,
tow (or push) in a forward direction, 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 90
(Fig. 1). Do not turn bypass valve when engine is running.
IMPORTANT: If the machine must be pushed or
towed in the reverse direction, the bypass valve
needs to b e turned 90
o
, and a check valve in the rear
traction manifold must be bypassed. Do not exceed
3 mph (4.8 kph) or a distance of ¼ mile (0.4 km) when
pushing or towing the machine in reverse.
The following Toro parts are needed to bypass the check
valve:
59−7410 diagnostic fitting
354−79 diagnostic fitting cap
95−8843 hydraulic hose
95−0985 coupler fitting (2)
340−77 hydraulic fitting (2)
NOTE: The #6 zero leak plug on the rear traction manifold has a tapered sealing surface on the plug head.
Lightly rap the plug head using a punch and hammer before using an allen wrench to remove the plug. The impact will allow plug removal with less chance of damage
to the socket head of the plug.
o
for towing
Figure 1
1. Bypass valve location
12 1
1
System
Hydraulic
1. To bypass the check valve, install a diagnostic fitting
in the unmarked port located between ports M8 and P2
on the rear traction manifold (Fig. 2).
2. Connect a hydraulic hose between the diagnostic fitting installed in the rear traction manifold and the reverse traction pressure test port (Fig. 3).
1. Rear traction manifold
(behind front left wheel)
2
1
1. Reverse traction
pressure test port
Figure 2
2. Unmarked port
Figure 3
2. Hydraulic oil return filte
Reelmaster 7000−D Hydraulic SystemPage 5 − 5
Page 76
Hydraulic Hoses
r
r
-
r
Hydraulic hoses are subject to extreme conditions such
as pressure differentials during operation and exposure
to weather, sun, chemicals, very warm storage conditions or mishandling during operation and maintenance.
These conditions can cause hose damage and deterioration. Some hoses are more susceptible to these
conditions than others. 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.
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 fitting with the other wrench (See Hydraulic Hose and
Tube Installation in this section). If the hose has an elbow 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).
Keep body and hands away from pin hole leaks o
nozzles that eject hydraulic fluid under high
pressure. Use paper or cardboard, not hands, to
search for leaks. Hydraulic fluid escaping unde
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 familia
with this type of injury. Gangrene may result from
such an injury.
Reelmaster 7000−DHydraulic System Page 5 − 6
Page 77
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.
2. As a preventative measure against leakage, it is recommended that the face seal O−ring be replaced any
time the connection is opened. Make sure the O−ring is
installed and properly seated in the fitting groove. Lightly
lubricate the O−ring with clean hydraulic oil.
3. Place the hose/tube against the fitting body so that
the flat face of the hose/tube sleeve fully contacts the O−
ring in the fitting.
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 6. 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).
C. Use a second wrench to tighten the nut to the correct Flats From Wrench Resistance (F.F.W.R.). The
markings on the nut and fitting body will verify that the
connection has been properly tightened.
Size F.F.W.R.
4 (1/4 in. nominal hose or tubing) 1/2 to 3/4
6 (3/8 in.) 1/2 to 3/4
8 (1/2 in.) 1/2 to 3/4
10 (5/8 in.) 1/2 to 3/4
12 (3/4 in.) 1/3 to 1/2
16 (1 in.) 1/3 to 1/2
Swivel Nut
Tube or Hose
O−ring
Fitting Body
Figure 4
System
Hydraulic
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 Resistance (F.F.W.R.) method (Fig. 2).
Mark Nut
and Fitting
Body
Final
Position
A. Using a wrench, tighten the swivel nut onto the fitting until light wrench resistance is reached (approxi-
Extend Line
mately 30 in−lb).
B. Mark the swivel nut and fitting body. Hold the
hose/tube with a wrench to prevent it from turning.
AT WRENCH RESISTANCE
Figure 5
Fitting Dash Size Hose/Tube Side Thread Size Installation Torque
4 9/16 − 18 18 to 22 ft−lb (25 to 29 N−m)
6 11/16 − 16 27 to 33 ft−lb (37 to 44 N−m)
8 13/16 − 16 37 to 47 ft−lb (51 to 63 N−m)
10 1 − 14 60 to 74 ft−lb (82 to 100 N−m)
12 1 3/16 − 12 85 to 105 ft−lb (116 to 142 N−m)
Initial
Position
AFTER TIGHTENING
16 1 7/16 − 12 110 to 136 ft−lb (150 to 184 N−m)
20 1 11/16 − 12 140 to 172 ft−lb (190 to 233 N−m)
Figure 6
Reelmaster 7000−D Hydraulic SystemPage 5 − 7
Page 78
Hydraulic Fitting Installation (SAE Straight Thread O−Ring Fitting into Component Port)
Non−Adjustable Fitting (Fig. 7)
1. Make sure all threads and sealing surfaces of fitting
and component port are free of burrs, nicks, scratches
or any foreign material.
2. As a preventative measure against leakage, it is recommended that the O−ring be replaced any time the
connection is opened.
3. Lightly lubricate the O−ring with clean hydraulic oil.
Fitting threads should be clean with no lubricant applied.
IMPORTANT: Before installing fitting into port, determine port material. If fitting is to be installed into
an aluminum port, installation torque is reduced.
4. Install the fitting into the port. Then, use a torque
wrench and socket to tighten the fitting to the recommended installation torque shown in Figure 8.
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 conversion information.
5. If a torque wrench is not available, or if space at the
port prevents use of a torque wrench, an alternate method of assembly is the Flats From Finger Tight (F.F.F.T.)
method.
A. Install the fitting into the port and tighten it down
full length until finger tight.
B. If port material is steel, tighten the fitting to the
listed F.F.F.T. If port 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) 1.00 +
6 (3/8 in.) 1.50 +
8 (1/2 in.) 1.50 +
10 (5/8 in.) 1.50 +
12 (3/4 in.) 1.50 + 0.25
16 (1 in.) 1.50 +
Fitting
O−ring
0.25
0.25
0.25
0.25
0.25
Figure 7
Fitting
Dash Size
Fitting Port Side
Thread Size
Installation Torque Into
Steel Port
Installation Torque Into
Aluminum Port
4 7/16 − 20 15 to 19 ft−lb (21 to 25 N−m) 9 to 11 ft−lb (13 to 15 N−m)
5 1/2 − 20 18 to 22 ft−lb (25 to 29 N−m) 11 to 15 ft−lb (15 to 20 N−m)
6 9/16 − 18 34 to 42 ft−lb (47 to 56 N−m) 20 to 26 ft−lb (28 to 35 N−m)
8 3/4 − 16 58 to 72 ft−lb (79 to 97 N−m) 35 to 43 ft−lb (48 to 58 N−m)
10 7/8 − 14 99 to 121 ft−lb (135 to 164 N−m) 60 to 74 ft−lb (82 to 100 N−m)
12 1 1/16 − 12 134 to 164 ft−lb (182 to 222 N−m) 81 to 99 ft−lb (110 to 134 N−m)
14 1 3/16 − 12 160 to 196 ft−lb (217 to 265 N−m) 96 to 118 ft−lb (131 to 160 N−m)
16 1 5/16 − 12 202 to 248 ft−lb (274 to 336 N−m) 121 to 149 ft−lb (165 to 202 N−m)
20 1 5/8 − 12 247 to 303 ft−lb (335 to 410 N−m) 149 to 183 ft−lb (202 to 248 N−m)
Figure 8
Reelmaster 7000−DHydraulic System Page 5 − 8
Page 79
Adjustable Fitting (Fig. 9)
1. Make sure all threads and sealing surfaces of fitting
and component port are free of burrs, nicks, scratches
or any foreign material.
2. As a preventative measure against leakage, it is recommended that the O−ring be replaced any time the
connection is opened.
3. Lightly lubricate the O−ring with clean hydraulic oil.
Fitting threads should be clean with no lubricant applied.
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 10).
IMPORTANT: Before installing fitting into port, determine port material. If fitting is to be installed into
an aluminum port, installation torque is reduced.
Lock Nut
Back−up Washer
O−ring
Figure 9
5. Install the fitting into the port and tighten finger tight
until the washer contacts the face of the port (Step 2).
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 recommended installation torque shown in Figure 8. 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).
8. If a torque wrench is not available, or if space at the
port prevents use of a torque wrench, an alternate method of assembly is the Flats From Finger Tight (F.F.F.T.)
method. 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). If port
material is aluminum, tighten fitting to 60% of listed
F.F.F.T.
Step 3Step 1
Step 2 Step 4
Figure 10
System
Hydraulic
Size F.F.F.T.
4 (1/4 in. nominal hose or tubing) 1.00 +
6 (3/8 in.) 1.50 +
8 (1/2 in.) 1.50 +
10 (5/8 in.) 1.50 + 0.25
12 (3/4 in.) 1.50 +
16 (1 in.) 1.50 + 0.25
0.25
0.25
0.25
0.25
Reelmaster 7000−D Hydraulic SystemPage 5 − 9
Page 80
This page is intentionally blank.
Reelmaster 7000−DHydraulic System Page 5 − 10
Page 81
Hydraulic Schematic
T
207 psi
CHG
S5
C3
.040”
S3
S4
C1
C2
C4
ROD
PISTON
.030”.030” .030”
.046” .046”
.046”
FRONT
LIFT CYLINDERS
LEFT CYLINTER
EXTEND TO LOWER
CENTER CYLINDER
EXTEND
TO TURN RIGHT
CYLINDER
STEERING
UNIT
STEERING
6.1
CIR
S1
S2
RV2
500 ps i
.055”
JUNCTION
MANIFOLD
EXTEND TO LOWER
E
PT
1050 psi
3.3 GPM
RV1
1700 psi
0.89 CID
1.83 CID /
LIFT MANIFOLD
P
G
REAR
LIFT CYLINDERS
EXTEND TO LOWER
LEFT CYLINTER
EXTEND TO LOWER
3.3 GPM
L
50/50 SPLIT
ST
2
1
FD
OR8
.030”
3psi
MANIFOLD
3
HI/LOW RANGE
CHARGE FILTER
50 psi
P2
6.6 GPM
T
0.89 CID
1.83 CID /
FRONT
WHEEL
MOTORS
35.2 G PM
PISTON PUMP
AXLE
REAR
FORWARD
0.036 in
6.6 GPM
1.13 CID
2.32 CID/
MOTOR
SENSOR
150 psi
RV
CV
CH
ENGINE SPEED
TOW
VALV E
5000 psi
0.028”
0.028”
CID
3.00
CID
1.03
CID
1.03
CID
0.56
CID
0.56
GEAR
PUMP
TEMPERATURE
M8
psi
550
de- energized
PR
400 psi
OR1
T
.050”
P2
REAR
TRACTION
MANIFOLD
2850 RPM
REVERSE
5000 psi
P1
P2P3P4P5
STRAINER
BREATHER
All solenoids are shown as
Hydraulic Schematic
Reelmaster 7000- D
System
Hydraulic
FAN
MOTOR
1.6 CI D
1.6 CID
REEL
MOTORS
1.6 CID
1.6 CID
#4 #1 #5 #2 #3
1.6 CID
1450 psi
1450 psi
1450 psi
1450 psi
1450 psi
M2
0.51 CID
M1
M3M4
M2
FRONT REAR
M1
CV
PRV
P1
S1
G2
G1
MV2MV1
OR2
.040
CV2
CV1
OR1
.040
MANIFOLD
FAN CONTROL
G2
SP2
110 ps i
LC2
LC1
110 ps i
SP1
P2
RV2
3000 psi
T2
T1
3000 psi
RV1
P1
MANIFOLD
MOW CONTROL
G1
Reelmaster 7000- D Hydraulic SystemPage 5 - 11
12.1 GPM
12.1 GPM
OIL COOLER
RETURN FILTER
50 psi
NOTE: A larger hydraulic schematic is
included in Chapter 10 - Foldout Drawings
Page 82
Hydraulic Flow Diagrams
)
FRONT
LIFT CYLINDERS
C3
C1
.046” .046”
.046”
STEERING
.040”
PISTON
LEFT CYLINTER
EXTEND TO LOWER
EXTEND
TO TURN RIGHT
CYLINDER
STEERING
S4
ROD
UNIT
S5
C2
S3
S2
.055”
C4
.030”.030” .030”
JUNCTION
CENTER CYLINDER
EXTEND TO LOWER
6.1
CIR
207 psi
1700 psi
S1
RV2
500 psi
REAR
LIFT CYLINDERS
MANIFOLD
LEFT CYLINTER
EXTEND TO LOWER
E
PT
1050 psi
3.3 GPM
RV1
EXTEND TO LOWER
ST
T
CHG
LIFT MANIFOLD
P
G
50/50 SPLIT
3.3 GPM
L
1.13 CID
2.32 CID/
AXLE
MOTOR
REAR
M8
PR
OR1
.050”
REAR
TRACTION
REVERSE
5000 psi
SENSOR
TEMPERATURE
T
MANIFOLD
Flow
Return or Suction
Working Pressure
Low Pressure (Charge)
Traction Circuit: LOW Speed (forward shown
Reelmaster 7000−D
STRAINER
BREATHER
0.89 CID
FRONT
WHEEL
1.83 CID /
MOTORS
35.2 GPM
FORWARD
0.036 in
PISTON PUMP
6.6 GPM
0.89 CID
1.83 CID /
2
1
FD
OR8
.030”
3 psi
MANIFOLD
3
HI/LOW RANGE
CHARGE FILTER
50 psi
P2
6.6 GPM
T
TOW
5000 psi
0.028”
0.028”
VALVE
GEAR
150 psi
CH
3.00
1.03
1.03
0.56
0.56
PUMP
RV
CV
CID
CID
CID
CID
CID
psi
550
400 psi
P2
2850 RPM
ENGINE SPEED
P1
P2P3P4P5
REEL
MOTORS
FAN
0.51 CID
MOTOR
1.6 CID
1.6 CID
1.6 CID
1.6 CID
#4 #1 #5 #2 #3
1.6 CID
1450 psi
1450 psi
1450 psi
1450 psi
1450 psi
FRONT REAR
M2
M1
M3M4
M2
M1
MV2MV1
CV
PRV
S1
G1
OR2OR1
CV2
CV1
P1
12.1 GPM
G2
MANIFOLD
FAN CONTROL
G2
SP2
.040
110 psi
LC2
LC1
110 psi
.040
SP1
3000 psi
3000 psi
RV2
RV1
G1
P2
T2
T1
P1
MANIFOLD
MOW CONTROL
12.1 GPM
OIL COOLER
RETURN FILTER
50 psi
Reelmaster 7000−DHydraulic System Page 5 − 12
Page 83
Traction Circuit: LOW Speed (Mow)
The traction circuit piston pump is a variable displacement pump that is directly coupled to the engine flywheel. Pushing the traction pedal engages a hydraulic
servo valve which controls the variable displacement
piston pump swash plate to create a flow of oil. Traction
circuit oil is directed to the dual displacement front wheel
motors and rear axle motor. Operating pressure on the
high pressure side of the closed loop traction circuit is
determined by the amount of load developed at the
wheel motors and rear axle motor. As the traction load
increases, circuit pressure can increase to the relief
valves setting of 5000 PSI (345 bar) in forward or reverse. If traction circuit pressure exceeds the relief setting, oil flows through the piston pump relief valve to the
low pressure side of the closed loop traction circuit.
Front wheel motors and the rear axle motor are positive,
dual displacement motors. The dual displacement feature allows operation in either a LOW (mow) or HI (transport) speed range. The motors are spring biased to
maximum displacement for LOW speeds, and are hydraulically shifted to minimum displacement for HI
speeds. The rear axle motor includes a flushing valve to
help cool the traction circuit oil. The valve bleeds off a
small amount of hydraulic oil from the closed loop traction circuit letting the charge circuit replenish the oil that
is bled from the traction circuit with cooler oil from the
charge circuit.
An optional traction circuit flow divider is available that
equally splits traction pump flow between the front
wheel motors and rear axle motor to prevent excessive
circuit flow going to a spinning wheel. If equipped, the
front traction manifold which includes the flow divider is
mounted to the right side of the front frame.
The piston pump, front wheel motors and rear axle motor use small amounts of hydraulic fluid for internal lubrication. Fluid is designed to leak across traction pump
and motor components into the case drain. This leakage
results in the loss of hydraulic fluid from the closed loop
traction circuit that must be replaced. The charge circuit
is designed to replace this traction circuit leakage. The
gear pump section (P4) that supplies oil to the steering
and lift/lower circuits also provides oil for the charge circuit.
Gear pump flow for the charge circuit is directed through
the steering valve, lift manifold, oil filter, and to the low
pressure side of the closed loop traction circuit. Charge
pressure is limited to 207 PSI (14.3 bar) by a check valve
located in the lift manifold.
Forward Direction
With the mow speed limiter in the LOW speed (mow)
position, the solenoid valve in the Hi/Low range manifold
is not energized. The front wheel motors and rear axle
motor are at their maximum displacement when in LOW
speed providing a slower traction speed for mowing
conditions.
When in LOW speed (mow) position with the traction
pedal pushed in the forward direction, oil from the piston
pump is directed to the front wheel motors and rear axle
motor through a parallel system. Oil flow to the front
wheel motors drives the motors in the forward direction
and then returns to the piston pump. Oil flow to the rear
axle motor drives the motor in the forward direction. Oil
returning from the axle motor enters the rear traction
manifold at the M8 port. The majority of the return flow
bypasses the pressure reducing (PR) cartridge and
passes through a less restrictive check valve (CV), out
manifold port P2 and returns to the piston pump.
When going down a hill, the tractor becomes an over−
running load that drives the front wheel and rear axle
motors. In this condition, the rear axle motor could lock
up as the oil pumped from the motor increases pressure
as it returns to the piston pump. To prevent rear wheel
lock up, an adjustable relief valve (RV) in the rear traction manifold opens to reduce rear axle motor pressure
created in down hill, dynamic braking conditions.
Reverse Direction
The traction circuit operates essentially the same in reverse LOW speed (mow) as it does in forward LOW
speed (mow). 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 rear traction 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 rear traction manifold enters the manifold at
port P2 and flows through pressure reducing valve (PR)
which limits the down stream pressure to the rear axle
motor to 400 PSI (27.6 bar) so the rear wheels will not
scuff the turf during reverse operation. This reduced
pressure flow is directed out rear traction manifold port
M8 to drive the rear axle motor in reverse. Return oil
from the rear motor returns to the piston pump.
System
Hydraulic
Reelmaster 7000−D Hydraulic SystemPage 5 − 13
Page 84
)
T
/
207 psi
CHG
S5
C3
.040”
S3
S4
C1
C2
C4
ROD
PISTON
.030”.030” .030”
.046” .046”
.046”
.055”
S2
RV2
JUNCTION
MANIFOLD
S1
500 psi
1700 psi
REAR
LIFT CYLINDERS
RV1
EXTEND TO LOWER
LIFT MANIFOLD
P
G
0.89 CID
FRONT
WHEEL
1.83 CID /
MOTORS
35.2 GPM
0.89 CID
1.83 CID /
2
1
3 psi
OR8
.030”
MANIFOLD
3
HI/LOW RANGE
CHARGE FILTER
FORWARD
AXLE
REAR
MOTOR
TOW
5000 psi
150 psi
CV
CH
VALVE
1.13 CID
2.32 CID
RV
550
400 psi
2850 RPM
ENGINE SPEED
SENSOR
TEMPERATURE
M8
psi
PR
OR1
T
.050”
P2
REAR
TRACTION
REVERSE
5000 psi
MANIFOLD
Working Pressure
Traction Circuit: HI Speed (forwaed shown
Reelmaster 7000−D
Flow
Return or Suction
Low Pressure (Charge)
FRONT
LIFT CYLINDERS
LEFT CYLINTER
EXTEND
CYLINDER
STEERING
REEL
MOTORS
#4 #1 #5 #2 #3
EXTEND TO LOWER
TO TURN RIGHT
UNIT
STEERING
1.6 CID
1.6 CID
1.6 CID
1.6 CID
1.6 CID
CENTER CYLINDER
EXTEND TO LOWER
6.1
CIR
FAN
MOTOR
1450 psi
1450 psi
1450 psi
FRONT REAR
1450 psi
1450 psi
LEFT CYLINTER
EXTEND TO LOWER
E
PT
1050 psi
ST
3.3 GPM
M2
0.51 CID
M1
MV2MV1
M3M4
M2
M1
3.3 GPM
L
50/50 SPLIT
S1
G1
OR2OR1
CV2
CV1
12.1 GPM
0.028”
12.1 GPM
0.028”
GEAR
3.00
1.03
1.03
0.56
0.56
CID
PUMP
P1
P2P3P4P5
CID
CID
CID
CID
STRAINER
BREATHER
OIL COOLER
RETURN FILTER
50 psi
50 psi
P2
6.6 GPM
FD
T
CV
PRV
P1
G2
MANIFOLD
FAN CONTROL
G2
SP2
.040
110 psi
LC2
LC1
110 psi
.040
SP1
3000 psi
3000 psi
RV2
RV1
G1
P2
T2
T1
P1
MANIFOLD
MOW CONTROL
0.036 in
PISTON PUMP
6.6 GPM
Reelmaster 7000−DHydraulic System Page 5 − 14
Page 85
Traction Circuit: HI Speed (Transport)
The traction circuit piston pump is a variable displacement pump that is directly coupled to the engine flywheel. Pushing the traction pedal engages a hydraulic
servo valve which controls the variable displacement
piston pump swash plate to create a flow of oil. Traction
circuit oil is directed to the dual displacement front wheel
motors and rear axle motor. Operating pressure on the
high pressure side of the closed loop traction circuit is
determined by the amount of load developed at the
wheel motors and rear axle motor. As the traction load
increases, circuit pressure can increase to the relief
valves setting of 5000 PSI (345 bar) in forward or reverse. If traction circuit pressure exceeds the relief setting, oil flows through the piston pump relief valve to the
low pressure side of the closed loop traction circuit.
Front wheel motors and the rear axle motor are positive,
dual displacement motors. The dual displacement feature allows operation in either a LOW (mow) or HI (transport) speed range. The motors are spring biased to
maximum displacement for LOW speeds, and are hydraulically shifted to minimum displacement for HI
speeds. The rear axle motor includes a flushing valve to
help cool the traction circuit oil. The valve bleeds off a
small amount of hydraulic oil from the closed loop traction circuit letting the charge circuit replenish the oil that
is bled from the traction circuit with cooler oil from the
charge circuit.
An optional traction circuit flow divider is available that
equally splits traction pump flow between the front
wheel motors and rear axle motor to prevent excessive
circuit flow going to a spinning wheel. If equipped, the
front traction manifold which includes the flow divider is
mounted to the right side of the front frame.
The piston pump, front wheel motors and rear axle motor use small amounts of hydraulic fluid for internal lubrication. Fluid is designed to leak across traction pump
and motor components into the case drain. This leakage
results in the loss of hydraulic fluid from the closed loop
traction circuit that must be replaced. The charge circuit
is designed to replace this traction circuit leakage. The
gear pump section (P4) that supplies oil to the steering
and lift/lower circuits also provides oil for the charge circuit.
Gear pump flow for the charge circuit is directed through
the steering valve, lift manifold, oil filter, and to the low
pressure side of the closed loop traction circuit. Charge
pressure is limited to 207 PSI (14.3 bar) by a check valve
located in the lift manifold.
Forward Direction
With the mow speed limiter in the HI speed (transport)
position, the solenoid valve in the Hi/Low range manifold
is energized. This energized solenoid valve directs
charge pressure to shift the front wheel motors and rear
axle motor to their minimum displacement. With the motors at their minimum displacements, a faster traction
speed is available for transport.
When in HI speed (transport) position with the traction
pedal pushed in the forward direction, oil from the piston
pump oil is directed to the front wheel motors and rear
axle motor through a parallel system. Oil flow to the front
wheel motors drives the motors in the forward direction
and then returns to the piston pump. Oil flow to the rear
axle motor drives the motor in the forward direction. Oil
returning from the axle motor enters the rear traction
manifold at the M8 port. The majority of the return flow
bypasses the pressure reducing (PR) cartridge and
passes through a less restrictive check valve (CV), out
manifold port P2 and returns to the piston pump.
When going down a hill, the tractor becomes an over−
running load that drives the front wheel and rear axle
motors. In this condition, the rear axle motor could lock
up as the oil pumped from the motor increases pressure
as it returns to the piston pump. To prevent rear wheel
lock up, an adjustable relief valve (RV) in the rear traction manifold opens to reduce rear axle motor pressure
created in down hill, dynamic braking conditions.
Reverse Direction
The traction circuit operates essentially the same in reverse HI speed (transport) as it does in forward HI speed
(transport). 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 rear traction 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 rear traction manifold enters the manifold at
port P2 and flows through pressure reducing valve (PR)
which limits the down stream pressure to the rear axle
motor to 450 PSI (31 bar) so the rear wheels will not scuf f
the turf during reverse operation. This reduced pressure
flow is directed out rear traction manifold port M8 to drive
the rear axle motor in reverse. Return oil from the rear
motor returns to the piston pump.
System
Hydraulic
Reelmaster 7000−D Hydraulic SystemPage 5 − 15
Page 86
)
T
/
207 psi
CHG
S5
C3
.040”
S3
S4
C1
.055”
C2
C4
ROD
PISTON
S1
S2
RV2
500 psi
1700 psi
REAR
LIFT CYLINDERS
EXTEND TO LOWER
RV1
LIFT MANIFOLD
P
G
0.89 CID
FRONT
WHEEL
1.83 CID /
MOTORS
0.89 CID
1.83 CID /
2
1
3 psi
3
.030”
OR8
MANIFOLD
HI/LOW RANGE
AXLE
REAR
1.13 CID
2.32 CID
MOTOR
SENSOR
TEMPERATURE
M8
Flow
Return or Suction
Working Pressure
Low Pressure (Charge)
PR
Mow Circuit (reels engaged
OR1
.050”
REAR
TRACTION
T
MANIFOLD
Reelmaster 7000−D
CH
150 psi
RV
CV
psi
550
400 psi
P2
FRONT
LIFT CYLINDERS
.046”
.046”.046”
LEFT CYLINTER
EXTEND
CYLINDER
STEERING
EXTEND TO LOWER
TO TURN RIGHT
UNIT
STEERING
.030”.030” .030”
JUNCTION
MANIFOLD
CENTER CYLINDER
EXTEND TO LOWER
6.1
CIR
FAN
MOTOR
LEFT CYLINTER
EXTEND TO LOWER
E
PT
1050 psi
ST
3.3 GPM
M2
0.51 CID
M1
S1
3.3 GPM
L
50/50 SPLIT
CV
2850 RPM
TOW
5000 psi
0.028”
0.028”
VALVE
GEAR
3.00
1.03
1.03
0.56
0.56
PUMP
CID
CID
CID
CID
CID
ENGINE SPEED
REVERSE
5000 psi
P1
P2P3P4P5
STRAINER
BREATHER
35.2 GPM
FORWARD
CHARGE FILTER
50 psi
P2
6.6 GPM
FD
T
PRV
P1
0.036 in
PISTON PUMP
6.6 GPM
12.1 GPM
REEL
MOTORS
G2
G1
1.6 CID
1.6 CID
1.6 CID
1.6 CID
#4 #1 #5 #2 #3
1.6 CID
1450 psi
1450 psi
1450 psi
1450 psi
1450 psi
FRONT REAR
MV2MV1
M3M4
OR2
.040
CV2
CV1
M2
M1
OR1
.040
SP2
110 psi
110 psi
SP1
MANIFOLD
FAN CONTROL
LC2
LC1
3000 psi
3000 psi
G2
RV2
RV1
G1
P2
T2
T1
P1
MANIFOLD
MOW CONTROL
12.1 GPM
OIL COOLER
RETURN FILTER
50 psi
Reelmaster 7000−DHydraulic System Page 5 − 16
Page 87
Mow Circuit
Hydraulic flow for the mow circuit is supplied by two (2)
sections of the gear pump (P2 and P3). Gear pump section P2 supplies hydraulic flow to cutting units 1, 4 and
5 (front cutting units), while gear pump section P3
supplies cutting units 2 and 3 (rear cutting units).
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 mow circuit includes a solenoid controlled
proportional valve (SP1 and SP2), a logic cartridge (LC1
and LC2) and a circuit relief cartridge (RV1 and RV2).
All cutting reel motors are equipped with cross over relief
valves to prevent hydraulic component damage in case
a cutting reel should stall.
The Toro Electronic Controller (TEC) 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.
NOTE: The mow speed limiter must be in the LOW
speed (mow) position before the mow circuit can be engaged.
Reels Engaged
Reels Disengaged (Fig. 11)
When the reel enable/disable switch is OFF (or if the cutting units are raised), the manifold proportional valves
(SP1 and SP2) are not energized, causing 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 return filter.
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 direction reverses the rotation of the front or rear cutting
reel motors allowing the backlap operation.
REEL
#4 #1 #5 #2 #3
1.6 CID
1450 psi
1.6 CID
1450 psi
FRONT REAR
1.6 CID
1450 psi
MOTORS
1.6 CID
1450 psi
1.6 CID
1450 psi
System
Hydraulic
When the reel enable/disable switch is turned ON with
the cutting units lowered, the proportional valves (SP1
and SP2) are energized by the TEC−5002 controller.
The energized valves shift to direct pump flow toward
the cutting unit motors. Flow from the valves is proportional to current applied to the valve coil by the TEC. The
reel speed (defined by InfoCenter settings) provides the
input for the TEC to allow the appropriate current to the
proportional valve coils.
Flow through the proportional valves (SP1 and SP2) is
pressure compensated 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 oil cooler and
return filter.
Maximum mow circuit pressure is limited at each mow
manifold circuit by the relief valve (RV1 or RV2). The relief valve pressure is 3000 PSI (207 bar).
When the reels are disengaged, 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
(fill with air).
G1
MOW CONTROL
MANIFOLD
SP1
M1
.040
RV1
P1
M2
CV1
110 psi
LC1
3000 psi
T1
CV2
110 psi
LC2
3000 psi
T2 P2
OR2OR1
.040
RV2
M3M4
MV2MV1
SP2
G2
Figure 11
Reelmaster 7000−D Hydraulic SystemPage 5 − 17
Page 88
)
T
207 psi
CHG
S5
C3
.040”
S4
ROD
S3
.055”
C2
C4
C1
PISTON
S1
S2
RV2
500 psi
1700 psi
REAR
LIFT CYLINDERS
EXTEND TO LOWER
RV1
LIFT MANIFOLD
P
G
0.89 CID
FRONT
WHEEL
1.83 CID /
MOTORS
0.89 CID
1.83 CID /
2
1
3 psi
3
.030”
OR8
MANIFOLD
HI/LOW RANGE
REAR
AXLE
1.13 CID
2.32 CID/
MOTOR
SENSOR
TEMPERATURE
M8
PR
OR1
T
.050”
P2
REAR
TRACTION
MANIFOLD
Working Pressure
Steering Circuit (right turn shown
Reelmaster 7000−D
Flow
Return or Suction
Low Pressure (Charge)
CH
150 psi
RV
CV
psi
550
400 psi
FRONT
LIFT CYLINDERS
.046” .046”
.046”
EXTEND
CYLINDER
STEERING
LEFT CYLINTER
EXTEND TO LOWER
TO TURN RIGHT
UNIT
STEERING
.030”.030” .030”
JUNCTION
CENTER CYLINDER
EXTEND TO LOWER
6.1
CIR
FAN
MOTOR
MANIFOLD
LEFT CYLINTER
EXTEND TO LOWER
E
PT
1050 psi
3.3 GPM
0.51 CID
2850 RPM
TOW
5000 psi
VALVE
0.028”
0.028”
GEAR
3.00
1.03
1.03
0.56
0.56
PUMP
ENGINE SPEED
P1
CID
P2P3P4P5
CID
CID
CID
CID
REVERSE
5000 psi
STRAINER
BREATHER
35.2 GPM
FORWARD
CHARGE FILTER
50 psi
3.3 GPM
L
P2
6.6 GPM
50/50 SPLIT
ST
M2
M1
FD
T
CV
PRV
P1
S1
0.036 in
PISTON PUMP
6.6 GPM
12.1 GPM
REEL
MOTORS
#4 #1 #5 #2 #3
1.6 CID
1.6 CID
1.6 CID
1.6 CID
1.6 CID
1450 psi
1450 psi
1450 psi
1450 psi
1450 psi
FRONT REAR
G2
G1
MV2MV1
M3M4
OR2
.040
CV2
CV1
M2
M1
OR1
.040
SP2
110 psi
110 psi
SP1
MANIFOLD
FAN CONTROL
LC2
LC1
3000 psi
3000 psi
G2
RV2
RV1
G1
P2
T2
T1
P1
MANIFOLD
MOW CONTROL
12.1 GPM
OIL COOLER
RETURN FILTER
50 psi
Reelmaster 7000−DHydraulic System Page 5 − 18
Page 89
Steering Circuit
A four section gear pump is coupled to the piston (traction) pump. The gear pump section P4 supplies hydraulic flow to the steering control valve and the lift control
manifold. Gear pump hydraulic flow is delivered to the
two circuits through a proportional flow divider located
in the fan control manifold. The steering circuit receives
priority flow from the flow divider. Steering circuit pressure is limited to 1050 PSI (72 bar) by a relief valve located in the steering control valve.
With the steering wheel in the neutral position and the
engine running, pump section P4 flow enters the steering 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 E port to the traction charge circuit.
Left Turn
When a left turn is made with the engine running, turning
the steering wheel to the left positions the spool valve so
that flow goes through the top of the spool. Flow entering
the steering control valve at the P port goes through the
spool and is routed to two places. Most of the flow
through the valve is bypassed out the E port back to the
traction charge circuit. The remainder of the flow is
drawn through the rotary meter and out the L port. Pressure to the rod end of the steering cylinder retracts the
cylinder for a left turn. The rotary meter ensures that the
oil flow to the cylinder is proportional to the amount the
steering wheel is turned. Fluid leaving the cylinder flows
back through the spool valve, out the T port, and returns
to the hydraulic reservoir.
The steering control valve returns to the neutral position
when turning is completed.
Right Turn
When a right turn is made with the engine running, turning the steering wheel to the right positions the spool
valve so that flow goes through the bottom of the spool.
Flow entering the steering control valve at the P port
goes through the spool and is routed to two places. Most
of the flow through the valve is bypassed out the E port
back to the traction charge circuit. The remainder of the
flow is drawn through the rotary meter and out the R port.
Pressure to the cap end of the steering cylinder extends
the cylinder for a right turn. The rotary meter ensures
that the oil flow to the cylinder is proportional to the
amount the steering wheel is turned. Fluid leaving the
cylinder flows back through the spool valve, out the T
port, and returns to the hydraulic reservoir.
The steering control valve returns to the neutral position
when turning is completed.
System
Hydraulic
NEUTRAL POSITION
STEERING
UNIT
6.1
CIR
1050 psi
PT
STEERING
CYLINDER
LEFT TURN
STEERING
CYLINDER
RETRACT
TO TURN LEFT
STEERING
UNIT
6.1
CIR
1050 psi
E
PT
E
STEERING
UNIT
RIGHT TURN
STEERING
CYLINDER
EXTEND
TO TURN RIGHT
6.1
CIR
1050 psi
PT
E
Figure 12
Reelmaster 7000−D Hydraulic SystemPage 5 − 19
Page 90
)
T
FRONT
207 psi
CHG
S5
C3
.040”
S4
ROD
S3
.055”
C4
C2
C1
PISTON
S1
S2
RV2
500 psi
1700 psi
REAR
LIFT CYLINDERS
EXTEND TO LOWER
RV1
LIFT MANIFOLD
P
G
0.89 CID
FRONT
WHEEL
1.83 CID /
MOTORS
0.89 CID
1.83 CID /
2
1
3 psi
3
.030”
OR8
MANIFOLD
HI/LOW RANGE
REAR
AXLE
1.13 CID
2.32 CID/
MOTOR
SENSOR
TEMPERATURE
M8
PR
OR1
T
.050”
REAR
TRACTION
MANIFOLD
Flow
Return or Suction
Working Pressure
Low Pressure (Charge)
CH
150 psi
RV
CV
psi
550
400 psi
P2
.046” .046”
.046”
LIFT CYLINDERS
STEERING
LEFT CYLINTER
EXTEND TO LOWER
EXTEND
TO TURN RIGHT
CYLINDER
STEERING
UNIT
.030”.030” .030”
JUNCTION
MANIFOLD
CENTER CYLINDER
EXTEND TO LOWER
6.1
CIR
FAN
MOTOR
LEFT CYLINTER
EXTEND TO LOWER
E
PT
1050 psi
ST
3.3 GPM
M2
0.51 CID
M1
S1
3.3 GPM
L
50/50 SPLIT
CV
Lower Cutting Units (joystick in lower position
2850 RPM
TOW
5000 psi
0.028”
VALVE
0.028”
3.00
1.03
1.03
0.56
0.56
GEAR
ENGINE SPEED
CID
P2P3P4P5
CID
CID
CID
CID
PUMP
REVERSE
5000 psi
P1
35.2 GPM
FORWARD
CHARGE FILTER
50 psi
P2
6.6 GPM
FD
T
PRV
P1
0.036 in
PISTON PUMP
6.6 GPM
12.1 GPM
Reelmaster 7000−D
STRAINER
BREATHER
REEL
MOTORS
G2
G1
1.6 CID
1.6 CID
1.6 CID
1.6 CID
#4 #1 #5 #2 #3
1.6 CID
1450 psi
1450 psi
1450 psi
1450 psi
1450 psi
FRONT REAR
MV2MV1
M3M4
OR2OR1
.040
CV2
CV1
M2
M1
.040
SP2
110 psi
110 psi
SP1
MANIFOLD
FAN CONTROL
LC2
LC1
3000 psi
3000 psi
G2
RV2
RV1
G1
P2
T2
T1
P1
MANIFOLD
MOW CONTROL
12.1 GPM
OIL COOLER
RETURN FILTER
50 psi
Reelmaster 7000−DHydraulic System Page 5 − 20
Page 91
Lower Cutting Units
A four section gear pump is coupled to the piston (traction) pump. Gear pump section P4 supplies hydraulic
flow to both the lift control manifold and the steering control valve. Hydraulic flow from this pump section is delivered to the circuits through a proportional flow divider
located in the fan control manifold. Maximum lift/lower
circuit pressure is limited to 1700 PSI (117 bar) by a relief
valve (RV1) in the lift control manifold. Lift circuit pressure can be monitored at the test fitting in lift control
manifold port G.
A joystick (lower mow/raise control lever) on the console
arm is used to raise and lower the five (5) cutting units
(Fig. 13). The joystick acts as an input to the Toro Electronic Controller (TEC) which sends electrical outputs to
appropriate lift control manifold solenoid 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 section P4 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.
A flow control orifice in the lift control manifold (port C3)
controls the rear cutting unit lowering speed by providing a restriction for the return flow from the lift cylinders.
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 joystick is released, solenoid valves S1, S3,
S4 and S5 are de−energized and the lift cylinders and
cutting units are held in position.
1
2
Cutting Unit Lower
NOTE: The operator must be in the operator seat and
the mow speed limiter in the LOW speed (mow) position
in order to lower the cutting units.
When the joystick is moved to the lower position, solenoid valve S1 along with solenoid valves S3, S4 and S5
are energized by the TEC. To allow the front cutting units
to be lowered before the rear cutting units, the controller
slightly delays energizing solenoid S5 after the joystick
is moved to the lower position. The energized solenoid
valves direct gear pump oil flow to the piston end of the
lift cylinders. Hydraulic pressure causes the lift cylinder
shafts to extend, and lower the cutting units.
The flow to the front lift cylinders is restricted by a series
of control orifices in the lift junction manifold. The first set
of control orifices restricts the flow to each front lift cylinder in both the lower and raise direction. Three (3) piloted check valves in the junction manifold are shifted by
hydraulic pressure to allow return flow from the extending front lift cylinders. The return flow passes through a
second set of control orifices in the junction manifold
providing additional cylinder speed control while lowering the cutting units.
Figure 13
1. Console 2. Joystick
(lower mow/raise
control lever)
#4 #1 #5
#3#2
CUTTING UNIT LOCATIONS
Figure 14
System
Hydraulic
Reelmaster 7000−D Hydraulic SystemPage 5 − 21
Page 92
)
T
207 psi
S5
C3
.040”
S3
S4
C1
.055”
C4
C2
ROD
PISTON
S1
S2
RV2
500 psi
REAR
RV1
1700 psi
LIFT CYLINDERS
EXTEND TO LOWER
CHG
LIFT MANIFOLD
P
G
0.89 CID
FRONT
WHEEL
1.83 CID /
MOTORS
0.89 CID
1.83 CID /
2
1
3 psi
OR8
.030”
MANIFOLD
HI/LOW RANGE
3
REAR
AXLE
1.13 CID
2.32 CID/
MOTOR
SENSOR
TEMPERATURE
M8
PR
OR1
T
.050”
P2
REAR
TRACTION
MANIFOLD
Flow
Return or Suction
Working Pressure
Low Pressure (Charge)
CH
150 psi
RV
CV
psi
550
400 psi
FRONT
LIFT CYLINDERS
.046”
.046”.046”
LEFT CYLINTER
EXTEND
CYLINDER
STEERING
EXTEND TO LOWER
TO TURN RIGHT
UNIT
STEERING
.030”.030” .030”
JUNCTION
MANIFOLD
CENTER CYLINDER
EXTEND TO LOWER
6.1
CIR
FAN
MOTOR
LEFT CYLINTER
EXTEND TO LOWER
TE
PT
1050 psi
ST
3.3 GPM
M2
0.51 CID
M1
S1
3.3 GPM
L
50/50 SPLIT
CV
Raise Cutting Units (joystick in raise position
2850 RPM
TOW
5000 psi
0.028”
0.028”
VALVE
3.00
1.03
1.03
0.56
0.56
GEAR
CID
CID
CID
CID
CID
PUMP
ENGINE SPEED
REVERSE
5000 psi
P1
P2P3P4P5
35.2 GPM
FORWARD
CHARGE FILTER
50 psi
P2
6.6 GPM
FD
T
PRV
P1
0.036 in
PISTON PUMP
6.6 GPM
12.1 GPM
Reelmaster 7000−D
STRAINER
BREATHER
REEL
MOTORS
#4 #1 #5 #2 #3
1.6 CID
1.6 CID
1.6 CID
1.6 CID
1.6 CID
1450 psi
1450 psi
1450 psi
1450 psi
1450 psi
FRONT REAR
G2
G1
MV2MV1
M3M4
OR2
.040
CV2
CV1
M2
M1
OR1
.040
SP2
110 psi
110 psi
SP1
MANIFOLD
FAN CONTROL
LC2
LC1
3000 psi
3000 psi
G2
RV2
RV1
G1
P2
T2
T1
P1
MANIFOLD
MOW CONTROL
12.1 GPM
OIL COOLER
RETURN FILTER
50 psi
Reelmaster 7000−DHydraulic System Page 5 − 22
Page 93
Raise Cutting Units
A four section gear pump is coupled to the piston (traction) pump. Gear pump section P4 supplies hydraulic
flow to both the lift control manifold and the steering control valve. Hydraulic flow from this pump section is delivered to the circuits through a proportional flow divider
located in the fan control manifold. Maximum lift/lower
circuit pressure is limited to 1700 PSI (117 bar) by a relief
valve (RV1) in the lift control manifold. Lift circuit pressure can be monitored at the test fitting in lift control
manifold port G.
1
2
A joystick (lower mow/raise control lever) on the console
arm is used to raise and lower the five (5) cutting units
(Fig. 15). The joystick acts as an input to the Toro Electronic Controller (TEC) which sends electrical outputs to
appropriate lift control manifold solenoid 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 section P4 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
NOTE: The operator must be in the operator seat in or-
der to raise the cutting units.
When the joystick is moved to the raise position, sole-
noid valve S1 along with solenoid valves S2, S3, S4 and
S5 are energized by the TEC. To allow the front cutting
units to be raised before the rear cutting units, the controller slightly delays energizing solenoid S5 after the
joystick is moved to the raise position. The energized solenoid valves direct gear pump oil flow to the rod end of
the lift cylinders. The flow to the front lift cylinders passes
through the piloted check valves and bypasses the first
set of control orifices. Hydraulic pressure causes the lift
cylinder shafts to retract, and raise the cutting units.
MODEL 03780 SHOWN
Figure 15
1. Console 2. Joystick
(lower mow/raise
control lever)
#4 #1 #5
#3#2
CUTTING UNIT LOCATIONS
Figure 16
System
Hydraulic
The return flow from the retracting front lift cylinders
passes through a second set of control orifices in the
junction manifold providing cylinder speed control while
raising the cutting units.
A flow control orifice in the lift control manifold (port C4)
controls the rear cutting unit raising speed by providing
a restriction for the return flow from the lift cylinders.
When the joystick 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−D Hydraulic SystemPage 5 − 23
Page 94
)
T
207 psi
CHG
S5
C3
.040”
S4
ROD
S3
.055”
C2
C4
C1
PISTON
S1
S2
RV2
500 psi
1700 psi
REAR
LIFT CYLINDERS
EXTEND TO LOWER
RV1
LIFT MANIFOLD
P
G
0.89 CID
FRONT
WHEEL
1.83 CID /
MOTORS
0.89 CID
1.83 CID /
2
1
3 psi
OR8
.030”
MANIFOLD
3
HI/LOW RANGE
REAR
AXLE
1.13 CID
2.32 CID/
MOTOR
SENSOR
TEMPERATURE
M8
PR
OR1
T
.050”
REAR
TRACTION
MANIFOLD
CH
150 psi
RV
CV
psi
550
400 psi
P2
FRONT
LIFT CYLINDERS
.046”
.046”.046”
LEFT CYLINTER
EXTEND
CYLINDER
STEERING
EXTEND TO LOWER
TO TURN RIGHT
UNIT
STEERING
.030”.030” .030”
JUNCTION
MANIFOLD
CENTER CYLINDER
EXTEND TO LOWER
6.1
CIR
FAN
MOTOR
LEFT CYLINTER
EXTEND TO LOWER
E
PT
1050 psi
ST
3.3 GPM
M2
0.51 CID
M1
S1
3.3 GPM
L
50/50 SPLIT
CV
2850 RPM
TOW
5000 psi
GEAR
VALVE
0.028”
0.028”
3.00
1.03
1.03
0.56
0.56
PUMP
ENGINE SPEED
P1
CID
P2P3P4P5
CID
CID
CID
CID
REVERSE
5000 psi
Flow
Return or Suction
Working Pressure
Low Pressure (Charge)
Engine Cooling Fan Circuit (forward/pull direction shown
Reelmaster 7000−D
STRAINER
BREATHER
35.2 GPM
FORWARD
CHARGE FILTER
50 psi
P2
6.6 GPM
FD
T
PRV
P1
0.036 in
PISTON PUMP
6.6 GPM
12.1 GPM
REEL
MOTORS
G2
G1
1.6 CID
1.6 CID
1.6 CID
1.6 CID
#4 #1 #5 #2 #3
1.6 CID
1450 psi
1450 psi
1450 psi
1450 psi
1450 psi
FRONT REAR
MV2MV1
M3M4
OR2OR1
.040
CV2
CV1
M2
M1
.040
SP2
110 psi
110 psi
SP1
MANIFOLD
FAN CONTROL
LC2
LC1
3000 psi
3000 psi
G2
RV2
RV1
G1
P2
T2
T1
P1
MANIFOLD
MOW CONTROL
12.1 GPM
OIL COOLER
RETURN FILTER
50 psi
Reelmaster 7000−DHydraulic System Page 5 − 24
Page 95
Engine Cooling Fan Circuit
A four section gear pump is coupled to the piston (traction) pump. The gear pump section P5 (farthest from the
piston pump) supplies hydraulic flow for the hydraulic
engine cooling fan motor.
The fan control manifold controls the operation of the hydraulic motor that drives the engine cooling fan in addition to including the flow divider (FD) for the steering and
lift circuits. The electronically controlled proportional relief valve (PRV) in the fan control manifold TS port controls the oil flow to the fan motor. The fan control
manifold controls the speed and direction of the fan motor based on electrical output from the Toro Electronic
Controller (TEC).
Oil flow from the gear pump to the cooling fan motor is
controlled by the proportional relief valve (PRV) in the
fan control manifold TS port. This valve adjusts fan circuit flow based on a PWM (Pulse Width Modulation) signal from the TEC. The controller uses engine coolant
and hydraulic oil temperatures as inputs to determine
the proper PWM signal for the proportional relief valve.
The fan circuit flow determines the speed of the cooling
fan motor.
The fan motor runs at reduced speed until engine
coolant temperature reaches approximately 165F
(74C), or hydraulic oil temperature reaches 170F
(77C). The fan motor increases to full speed (approximately 2800 RPM) as engine coolant temperature
reaches 180F (82C), or hydraulic oil temperature
reaches 195F (91C).
Fan Operation (forward/pull)
In the forward direction, the fan pulls air from outside the
engine compartment through the radiator and oil cooler .
Oil flow from the gear pump is sent through the de−energized solenoid valve S1 to rotate the cooling fan motor.
Return flow from the motor re−enters manifold port M2,
passes through the de−energized solenoid valve S1,
out manifold port T, and then is routed through the mow
control manifold, oil cooler and return oil filter.
Fan Operation (reverse/push) (Fig. 17)
The TEC can reverse the cooling fan to push air from inside the engine compartment through the radiator and
oil cooler 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 reverse direction. A lower PWM signal is
sent to the PR V 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.
NOTE: The fan reversal process is designed to clean
the rear intake screen (not the radiator) of debris. Refer
to Operator’s Manual for radiator cleaning maintenance
recommendations.
System
Hydraulic
The fan motor automatically slows down and then reverses direction if engine coolant temperature
reaches 203F (95C) or hydraulic oil temperature
reaches 212F (100C).
If the fan motor is stalled for any reason, the manifold
proportional relief valve (PRV) has a secondary function
as a circuit relief to limit fan motor pressure to 3000 PSI
(207 bar).
When the engine is shut off, the over−running inertia
load of the fan blades keeps driving the fan motor and
turns it into a pump. The check valve (CV) in the fan control manifold will open to keep the motor circuit full of oil
so the fan motor will not cavitate (fill with air).
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) direction.
Reelmaster 7000−D Hydraulic SystemPage 5 − 25
FAN
MOTOR
G1
G2
0.51 CID
M1
S1
REVERSE
DIRECTION
FAN CONTROL
M2
CV
TS
T
ST
FD
MANIFOLD
50/50 SPLIT
L
P2P1
Figure 17
Page 96
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
Hydraulic Tester (Pressure and Flow)
Figure 18
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. INLET HOSE: Hose connected from the system circuit 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).
5. OUTLET HOSE: A hose from the outlet side of the
hydraulic tester connects to the hydraulic system circuit.
6. FITTINGS: An assortment of hydraulic fittings are included with this kit.
Toro Part Number: TOR214678
Figure 19
Reelmaster 7000−DHydraulic System Page 5 − 26
Page 97
40 GPM Hydraulic Tester (Pressure and Flow)
Use to test hydraulic circuits and components for flow
and pressure capacities as recommended in the Testing
section of this chapter. This tester includes the following:
1. LOAD VALVE: A simulated working load is created
in the circuit by turning the valve to restrict flow.
2. PRESSURE GAUGE: Glycerine filled 0 to 5000 PSI
gauge to provide operating circuit pressure.
3. 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
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
connect 40 GPM hydraulic tester (AT40002) or high flow
hydraulic filter kit (TOR6011) to machine hydraulic traction system components.
Toro Part Number: TOR6007
Figure 20
Figure 21
System
Hydraulic
Reelmaster 7000−D Hydraulic SystemPage 5 − 27
Page 98
High Flow Hydraulic Filter Kit
The high flow hydraulic filter kit is designed with large
flow (40 GPM/150 LPM) and high pressure (5000
PSI/345 bar) capabilities. This kit provides for bi−directional filtration which prevents filtered debris from being
allowed back into the circuit regardless of flow direction.
If a component failure occurs in the closed loop traction
circuit, contamination from the failed part will remain in
the circuit until removed. When connecting hydraulic
test gauges in order to test traction circuit components
or after replacing a failed traction circuit component (e.g.
piston (traction) pump or wheel motor), the high flow hydraulic filter can be installed in the traction circuit. The
filter will ensure that contaminates are removed from the
closed loop and thus, do not cause additional component damage.
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).
Figure 22
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 23
Reelmaster 7000−DHydraulic System Page 5 − 28
Page 99
Measuring Container
Use this container for doing hydraulic motor efficiency
testing (motors with case drain lines only). Measure efficiency of a hydraulic motor by restricting the outlet flow
from the motor and measuring leakage from the case
drain line while the motor is pressurized by the hydraulic
system.
The table in F igure 25 provides gallons per minute
(GPM) conversion for measured milliliter or ounce motor
case drain leakage.
Toro Part Number: TOR4077
Figure 24
O- ring Kit
The kit includes O- rings in a variety of sizes for face seal
and port seal hydraulic connections. It is recommended
that O- rings be replaced whenever a hydraulic connection is loosened.
Toro Part Number: 117- 2727
Figure 25
System
Hydraulic
Reelmaster 7000- D Hydraulic SystemPage 5 - 29
Figure 26
Page 100
Remote Starter Switch
After flushing the hydraulic system or replacing a hydraulic component (e.g. gear pump, piston pump, wheel
motor), it is necessary to prime the hydraulic pumps. A
remote starter switch (Fig. 27) can be used for this purpose. Obtain a remote starter switch locally.
IMPORTANT: When using a remote starter switch, it
is highly recommended to include a 20 amp in−line
fuse between the battery and switch connector for
circuit protection.
A remote stater switch can also be constructed using
Toro switch #106−2027, a length of 14 gauge wire, a 20
amp in−line fuse, two (2) alligator clips and necessary
connectors. Connecting the wire to switch terminals 1
and 2 will allow the momentary switch contacts to be
used for the remote starter switch (Fig. 28).
NOTE: For information on using the remote starter
switch to prime the hydraulic pumps, see Flush Hydraulic System in the Service and Repairs section of this
chapter.
MACHINE
BATTERY
STARTER
SOLENOID
MACHINE
STARTER
Figure 27
20 AMP
FUSE
TORO SWITCH
(#106−2027)
1. Starter motor
2. Starter solenoid
Figure 28
3
1
Figure 29
3. B+ terminal
2
Reelmaster 7000−DHydraulic System Page 5 − 30
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