Toro 11185SL User Manual

Page 1

Part No. 11 185SL (Rev. A)

Service Manual

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.

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 ManualsandPartsCatalogfor yourmachineintoChapter 2ofthis service manual. Additional copiesof theOperator’sManuals andPartsCatalog are available onthe internet at www.Toro.com.

TheToroCompany reserves the rightto changeproduct 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: ANOTE will give general information about the

correct operation, maintenance, service, testing or repair of the machine.

IMPORTANT: The IMPORTANT notice will give importantinstructionswhichmustbefollowed to prevent damage to systems or components on the machine.

7000

E The Toro Company -- 2011, 2012

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This page is intentionally blank.

Reelmaster 7000

Page 3

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 -- Kubota Diesel Engine

Specifications 3 -- 2..............................

General Information 3 -- 3........................

Service and Repairs 3 -- 4........................

KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,

03--M--DI--E3BSERIES

Chapter 4 -- Hydraulic System

Specifications 4 -- 3..............................

General Information 4 -- 4........................

Hydraulic Schematic 4 -- 10.......................

Hydraulic Flow Diagrams 4 -- 12...................

Special Tools 4 -- 26.............................

Troubleshooting 4 -- 30...........................

Testing 4 - - 36...................................

Adjustments 4 -- 68..............................

Service and Repairs 4 -- 69.......................

EATON MODEL 72400 SERVO CONTROLLED PIS-

TON PUMP REPAIR INFORMATION

EATONMODEL 74318 and 74348 PISTONMOTORS:

FIXED DISPLACEMENT, VALVE PLATE DESIGN REPAIR INFORMATION

SAUER--DANFOSS STEERING UNIT TYPE OSPM

SERVICE MANUAL

Chapter 5 -- Electrical System

General Information 5 -- 2........................

Electrical Drawings 5 -- 3.........................

Special Tools 5 -- 4..............................

Troubleshooting 5 -- 6............................

Electrical System Quick Checks 5 -- 13.............

Adjustments 5 -- 15..............................

Component Testing 5 -- 17........................

Service and Repairs 5 -- 41.......................

Chapter 6 -- Axles, Planetaries and Brakes

Specifications 6 -- 2..............................

General Information 6 -- 3........................

Service and Repairs 6 -- 4........................

Chapter 7 -- Chassis

General Information 7 -- 2........................

Service and Repairs 7 -- 4........................

Chapter 8 -- DPA Cutting Units

Specifications 8 -- 2..............................

General Information 8 -- 3........................

Special Tools 8 -- 4..............................

Factors That Can Affect Cutting Performance 8 -- 8..

Set Up and Adjustments 8 -- 11....................

Service and Repairs 8 -- 14.......................

Chapter 9 -- Foldout Drawings

Hydraulic Schematic 9 -- 3........................

Electrical Schematic 9 -- 4........................

Wire Harness Drawings 9 -- 6.....................

SafetyProduct Records

and Maintenance

Kubota

Diesel Engine

System

Hydraulic

System

Electrical

Axles, Planetaries

and Brakes

Reelmaster 7000

Units

DPACutting Chassis

Foldout

Drawings

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Reelmaster 7000

Page 5

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

Reelmaster 7000 Page 1 -- 1 Safety

Page 6

General Safety Instructions

TheReelmaster 7000have beentested andcertified by TORO for compliance with existing safety standards and specifications. Although hazard control and accidentpreventionpartiallyaredependentupon the design andconfiguration ofthe machine,these factorsare also dependent upon the awareness, concern and proper trainingofthe personnel involvedintheoperation,transport,maintenance and storage ofthe machine. Improperuseormaintenanceofthemachinecanresultininjury ordeath.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 operatingthe vehicle. Becomefamiliar with thecontrols and know how to stop the vehicle and engine quickly. AdditionalcopiesoftheOperator’sManualareavailable on the internet at www.Toro.com.

2. Keep allshields, safety devices and decals in place. Ifa shield,safetydevice ordecal isdefective, illegibleor damaged, repair or replace it before operating the machine.Alsotighten any loosenuts,bolts orscrewsto 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. Donotremovefueltank capwhileengineishotor

running. C. Do not smoke w hile handling fuel. D. Fillfuel tankoutdoorsandonly towithinan inch of

the top of the tank, not the filler neck. Do not overfill. E. Wipe up any spilled fuel.

4. Donottouchengine,exhaustsystemcomponentsor

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. Afterengine is started,releaseparkingbrakeand keepfoot offtractionpedal. Machinemust notmove. 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 c onfined 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 notpark on slopesunlesswheelsarechocked or blocked.

Reelmaster 7000Page 1 -- 2Safety

Page 7

Maintenance and Service

1. TheTractionUnit andCutting Unit Operator’s Manualsprovideinformation regardingtheoperation,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 suremachine is in safe operating condition by keeping all nuts, bolts and screws tight.

4. Never store the machine or fuel container inside wherethereisanopenflame,suchasnearawaterheater or furnace.

5. Make sure all hydraulic line connectors are tightand all hydraulic hoses and lines are in good condition before applying pressure to the hydraulic system.

6. Keepbodyandhandsawayfrompinholeleaksinhydrauliclines thatejecthigh pressurehydraulic 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 mustbe surgically removedwithin afew hoursby adoctor 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 everneeded or assistanceis desired, contact an Authorized Toro Distributor.

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 enginemustbe runningtoperform maintenanceor an adjustment, keep hands, feet, clothing and other partsofthe body awayfromcutting unitsandother moving parts. Keep bystanders away.

11.Do not overspeed the engine by changing governor setting.To assuresafetyandaccuracy,checkmaximum engine speed.

12.Shut engine off before checking or adding oil to the engine crankcase.

13.Disconnect battery before servicing the machine. Disconnect negative battery cable first and positive cablelast. If batteryvoltage isrequired fortroubleshooting or test procedures, temporarily connect the battery. Reconnect positive battery cable first and negative cable last.

14.Battery acid is poisonous and can cause burns. Avoidcontact with skin, eyes and clothing. Protectyour 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 connectorfrom themachine TECcontroller anddisconnect the terminal connector from the alternator.

17.At the time of manufacture, the machine conformed tothe safetystandards for riding mowers. Toassureoptimumperformanceand continued safetycertificationof the machine, use genuine Toro replacement parts and accessories.Replacementpartsandaccessoriesmade by other manufacturers may result in non-conformance with the safety standards and the warranty may be voided.

18.When changing attachments, tires or performing other service, use correct blocks, hoists and jacks. Make sure machine is parked on a solid level surface suchasaconcretefloor.Priortoraisingthemachine,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, whichmayresultinpersonal injury(seeJackingInstructions in this chapter).

Safety

Reelmaster 7000 Page 1 -- 3 Safety

Page 8

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 thesafe and properraising of themachine.Alwayschockorblockwheels.Use jackstands to support the raisedmachine. Ifthe 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. Applyparking brakeand chockboth reartires toprevent 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.

Figure 1

1. Frame 2. Front tire (RH shown)

2. Position jack securely underthe frame,just tothe 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 themachine.

Jacking the Rear End (Fig. 2)

1. Applyparkingbrakeand chock bothfronttirestoprevent 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.

Figure 2

1. Rear axle 2. Rear tire (RH shown)

Reelmaster 7000Page 1 -- 4Safety

Page 9

Safety and Instruction Decals

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

Safety

Reelmaster 7000 Page 1 -- 5 Safety

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Reelmaster 7000Page 1 -- 6Safety

Page 11

Product Records and Maintenance

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..........................

Chapter 2

Product Records

and Maintenance

Product Records

Insert Operator’s Manuals and Parts Catalog for your Reelmasterattheendofthischapter.Additionally,insert Installation Instructions, Operator’s Manuals and Parts Catalogs for any accessories that have been installed on your Reelmaster at the end of this section.

Maintenance

Maintenanceproceduresandrecommended serviceintervals for your Reelmaster are covered in the Traction Unit and Cutting Unit Operator’s Manuals. Refer to those publications when performing regular equipment maintenance. Several maintenance procedures have break--in intervals identified in the Operator’s Manuals. RefertotheEngineOperator’sManual foradditionalengine specific maintenance procedures.

Reelmaster 7000

Page 2 -- 1

Product Records and Maintenance

Page 12

Equivalents and Conversions

0.09375

Product Records and Maintenance

Page 2 -- 2

Reelmaster 7000

Page 13

Torque Specifications

Recommended fastener torque values are listed in the followingtables. Forcritical applications,as determined byToro,eitherthe recommendedtorqueor atorquethat 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 toall fasteners which donot have aspecific requirement identified in thisService Manual. The following factors shall be considered when applying torque: cleanliness of the fastener, use of a thread sealant (e.g. Loctite), degree of lubrication on the fastener,presence of a prevailing torque feature (e.g. Nylock nut), hardness of the surface underneath thefastener’sheador similar conditionwhichaffectsthe installation.

Fastener Identification

Asnotedinthefollowing tables, torquevaluesshouldbe 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. Measurethe torque requiredto tightenthe fasteneruntil 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

Useofanoffsetwrench(e.g.crowfootwrench) will affect torquewrench calibration dueto theeffective changeof torquewrench length.Whenusing atorque 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”.

Themeasuredeffectivelengthofthetorquewrenchwith 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)

(effective length of torque

wrench + offset wrench)

TORQUE CONVERSION FACTOR = A / B

Torque wrenchOffset wrench

The calculated torque conversion factor for this torque wrenchwith thisoffsetwrench would be18 /19 =0.947.

Reelmaster 7000

Page 2 -- 3

Figure 3

Product Records and Maintenance

Page 14

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)

Thread Size

# 6 -- 32 UNC

# 6 -- 40 UNF

# 8 -- 32 UNC

# 8 -- 36 UNF

#10--24UNC

#10--32UNF

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 &

8withThin

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

17 + 2 192 + 23 25 + 3 282 + 34

29 + 3 328 + 34 41 + 5 463 + 56

31 + 4 350 + 45 43 + 5 486 + 56

42 + 5 475 + 56 60 + 6 678 + 68

48 + 5 542 + 56 68 + 7 768 + 79

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

NOTE: Reduce torque values listed in the table above by 25% for lubricated fasteners. Lubricated fasteners are defined as threads coated with a lubricant such as engine oil or thread sealant such as Loctite.

NOTE: The nominal torque values listed above for Grade 5 and 8 fasteners are based on 75% of the minimumproof load specifiedin SAE J429. The toleranceis approximately +

10% of the nominal torque value. Thin

height nuts include jam nuts. NOTE: Torque values may have to be reduced when installing fasteners into threaded aluminum or brass. The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc.

Product Records and Maintenance

Page 2 -- 4

Reelmaster 7000

Page 15

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series)

Class 8.8 Bolts, Screws and Studs with

Thread Size Regular Height Nuts

(Class 8 or Stronger Nuts)

Class 10.9 Bolts, Screws and Studs with

Regular Height Nuts

(Class 10 or Stronger Nuts)

M5 X 0.8 57 + 6in--lb 644 + 68 N--cm 78 + 8in--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 + 2ft--lb 26 + 3N--m 28 + 3ft--lb 38 + 4N--m M10 X 1.5 38 + 4ft--lb 52 + 5N--m 54 + 6ft--lb 73 + 8N--m

M12 X 1.75 66 + 7ft--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

NOTE: The nominal torque values listed above are based on 75% of the minimum proof load specified in SAEJ1199.Thetoleranceisapproximately+ nominal torque value.

NOTE: Torque values may have to be reduced when installing fasteners into threaded aluminum or brass. The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc.

10%ofthe

Product Records

and Maintenance

Reelmaster 7000

Page 2 -- 5

Product Records and Maintenance

Page 16

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 + 3ft--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 + 5in--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 + 5in--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

Baseline Torque

No. 8 -- 32 UNC 30 + 5in--lb

No. 10 -- 24 UNC 38 + 7in--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 + 5in--lb No. 10 12 16 38 + 7in--lb No. 12 11 14 85 + 15 in--lb

*Holesize,materialstrength,materialthickness andfinish must be considered when determining specific torquevalues.Alltorquevalues arebasedonnon--lubricated fasteners.

Product Records and Maintenance

Page 2 -- 6

Reelmaster 7000

Page 17

SPECIFICATIONS 2.............................

GENERAL INFORMATION 3.....................

Operator’s Manual 3..........................

SERVICE AND REPAIRS 4......................

Air Filter System 4............................

Exhaust System 6............................

Fuel System 8................................

Check Fuel Lines and Connections 9...........

Drain and Clean Fuel Tank 9..................

Fuel Tank Removal 9........................

Fuel Tank Installation 9.......................

Radiator 10..................................

Engine 12....................................

Engine Removal 13..........................

Engine Installation 14........................

Pump Adapter Plate 16........................

KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,

03--M--DI--E3B SERIES

Chapter 3

Kubota Diesel Engine

Kubota

Diesel Engine

Reelmaster 7000 Page 3 -- 1 Kubota Diesel Engine

Page 18

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 13 U.S. Quarts (12.3 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 7000Page 3 -- 2Kubota Diesel Engine

Page 19

General Information

ThisChaptergives informationaboutspecificationsand repairofthe dieselengineused in theReelmaster7000.

Generalmaintenance procedures aredescribed inyour TractionUnit Operator’s Manual. Information onengine 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 provideinformation regarding the operation,general maintenanceandmaintenanceintervals foryourReelmaster machine.Refertothesepublicationsfor additionalinformation 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 somerepairsmaydictatethattheworkbedoneatanengine repair facility.

Service and repair parts for Kubota engines are supplied through your Authorized Toro Distributor. If no partslistisavailable, bepreparedtoprovideyourdistributor with the Toro model and serial number.

Kubota

Diesel Engine

Reelmaster 7000 Page 3 -- 3 Kubota Diesel Engine

Page 20

Service and Repairs

Air Filter System

RIGHT

FRONT

12 to 15 in--lb

(1.4 to 1.6 N--m)

Vacuator

Direction

1. Battery support

2. Bracket

3. Flange head screw (8 used)

4. Flange nut (8 used)

5. Support bracket

6. Cap screw (4 used)

7. Flange nut (4 used)

8. Fan drive manifold

9. Air cleaner strap

10. Cap screw (2 used)

11. Air cleaner assembly

12. Service indicator

13. Hose clamp

14. Hose clamp

15. Flat washer (2 used)

16. Coolant reservoir

17. Reservoir bracket

18. Flange nut (8 used)

Figure 1

19. Cap screw (2 used)

20. Flange head screw (4 used)

21. Flange head screw (2 used)

22. Hose

23. Adapter

24. Air cleaner hose

25. Reservoir cap

26. Plenum

27. Air intake hose

Reelmaster 7000Page 3 -- 4Kubota Diesel Engine

Page 21

Removal (Fig. 1)

1. Park machineon a levelsurface, lower cuttingunits, stop engine, apply parking brake and remove key from the ignition switch.

2. Raise and support hood.

3. Remove air cleaner components as needed using Figure 1 as a guide.

Installation (Fig. 1) IMPORTANT: Any leaks in the air filter system will

causeserious enginedamage. Make sure that allair cleaner components are in good condition and are properly secured during assembly.

1. Assemble air filter systemusing Figure 1as aguide. A. If service indicator (item 12) was removed from

air cleaner housing, apply thread sealant to adapter threads before installing adapter and indicator to housing. Install adapter so that grooves in adapter hex and adapter filter element are installed toward serviceindicator (Fig.3).Torqueindicator from12 to 15 in--lb (1.4 to 1.6 N--m).

1. Air cleaner housing

2. Safety filter element

3. Air filter element

Figure 2

4. Air cleaner cover

5. Vacuator valve

Kubota

Diesel Engine

B. Orientate vacuator valve on air cleaner cover toward ground.

C. Installaircleanersoaircleanerstrap(item9)isas close as possible to air cleaner cover.

D. Make sure that air cleaner hose (item 24) does notcontact engine valve coveror other engine components.Tomodify clearance, moveand/or rotateair cleaner body in air cleaner strap. Verify that tabs in strap mesh fully with slots in air cleaner body.

2. After air cleaner installation is completed, lower and

secure hood.

1. Air cleaner assembly

2. Service indicator

3. Adapter

Figure 3

4. Groove

5. Filter element

Reelmaster 7000 Page 3 -- 5 Kubota Diesel Engine

Page 22

Exhaust System

RIGHT

FRONT

1. Muffler

2. Flange head screw (2 used)

3. Flange head screw (4 used)

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 used)

14. Muffler clamp

Reelmaster 7000Page 3 -- 6Kubota Diesel Engine

Page 23

Removal (Fig. 4)

CAUTION

The muffler and exhaust pipe may be hot. To avoid possible burns, allow the engine and exhaust system to cool before working on themuffler.

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: Makesure mufflerflange and exhaustmanifold

sealing surfaces are free of debris or damage that may prevent a tight seal.

1. Park machineon a levelsurface, lower cuttingunits,

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 using Figure 4 as a guide.

1. Install new exhaust gasket if original gasket is damaged or torn.

IMPORTANT: Failure to follow the suggested mufflerfastenersequence may resultin premature muffler failure.

2. Installexhaustsystemcomponents to theengineusingFigure4 asa guide. Handtighten allexhaustsystem fasteners before fully tightening any fastener.

3. Tailpipeshouldhaveequalclearancebetweenframe and engine after installation.

4. Afterexhaustsystem installation iscompleted,lower and secure hood.

Kubota

Diesel Engine

Reelmaster 7000 Page 3 -- 7 Kubota Diesel Engine

Page 24

Fuel System

RIGHT

FRONT

2 7

1. Fuel suction tube

2. Fuel line clamp (2 used)

3. Fuel hose (supply)

4. Return fitting

5. Fuel hose (return)

6. Fuel tank cap

7. Bushing (2 used)

8. Hose clamp (6 used)

9. Fuel tank

Figure 5

10. Cap screw (2 used)

11. Clamp (2 used)

12. Flange nut (2 used)

13. Fuel pump

14. Washer head screw

15. Fuel pump bracket

16. Fuel hose (supply)

17. Fuel hose (supply)

18. Cap screw (2 used)

19. Flange nut (2 used)

20. Fuel/water separator

21. Elbow fitting (2 used)

22. Flat washer (2 used)

23. Flat washer (2 used)

24. Fuel gauge

25. Grommet

26. Hose clamp

27. Draincock

Reelmaster 7000Page 3 -- 8Kubota Diesel Engine

Page 25

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 wipeupany spilled dieselfuelbefore startingthe 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 theTractionUnitOperator’sManual.Check linesfordeterioration, damage, leaking or loose connections. R eplace 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, drainand clean thefuel tankif the fuelsystem becomes contaminatedor if themachine is tobe stored for an extended period. To clean fuel tank, flush tank out with cleandieselfuel.Make suretankisfree ofcontaminates and debris.

1. Park machineon a levelsurface, lower cuttingunits, stop engine, engage parking brake and remove key from the ignition switch.

2. Disconnectfuelhosesfromthe suctionandreturnfittings in top of tank.

3. Use draincock on bottom of tank to empty fuel tank into a suitable container.

4. Remove fuel tank from machine using Figure 5 as a guide.

Fuel Tank Installation (Fig. 5)

1. Install fuel tank to frame using Figure 5 as a guide.

2. Connect fuel hoses to the suction and return fittings in top of tank.

3. Makesurethatdraincockonbottomoftankisclosed.

4. Fill fuel tank with clean fuel.

Kubota

Diesel Engine

Reelmaster 7000 Page 3 -- 9 Kubota Diesel Engine

Page 26

Radiator

RIGHT

FRONT

15 22

9to11ft--lb

(12.3 to 14.9 N--m)

1. 90ohydraulic fitting (2 used)

2. Oil cooler

3. Flange nut (4 used)

4. Radiator mount

5. Bulb seal

6. Air cleaner hose

7. Plenum

8. Radiator

9. Hose

10. Hose clamp (3 used)

11. Radiator cap

12. Upper radiator shroud

13. Clamp (4 used)

14. Upper radiator hose

15. Flange nut (12 used)

16. Temperature sender

Figure 6

17. Flat washer (8 used)

18. Flange head screw (11 used)

19. Rubber grommet (2 used)

20. Rubber grommet

21. Flange head screw (4 used)

22. Flange nut (4 used)

23. Foam seal (2 used)

24. Recirculation barrier (2 used)

25. Recirculation barrier bracket (2 used)

26. Screw (2 used)

27. Oil cooler mount plate (2 used)

28. Flange head screw (9 used)

29. O--ring

30. Clamp (2 used)

31. Cap screw (2 used)

32. Washer (2 used)

33. Oil cooler top bracket

34. Bulb seal

35. O--ring

36. R--clamp (2 used)

37. Bushing

38. Elbow fitting

39. Reservoir hose

40. Lower radiator hose

41. Lower radiator shroud

42. Pipe plug

43. Flange head screw (8 used)

44. Flange head screw (4 used)

45. Bulb seal

46. Spacer

Reelmaster 7000Page 3 -- 10Kubota Diesel Engine

Page 27

Removal (Fig. 6)

1. Park machineon a levelsurface, lower cuttingunits,

stop engine, engage parking brake and remove key from the ignition switch.

2. Removehoodfromthemachine(seeHoodRemoval

inthe Serviceand Repairs section of Chapter7 -- Chassis).

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.

3. Remove radiator cap. Drain radiator into a suitable

container using the radiator draincock.

4. Disconnectupper andlowerhoses fromtheradiator.

5. Remove air cleaner hose (item 6).

2. Carefully position radiator and recirculation barriers (items24 and 25) to theradiator mount.Secure radiator and barriers in place with four (4) flange head screws and flange nuts.

3. Positionlower radiator shroudandfan motor bracket assembly to the radiator. Make sure that hydraulic hoses are correctly positioned in grommets in lower radiator shroud.

4. Secure fan motor bracket to radiator withsix (6) cap screws and flange nuts (Fig. 7).

5. Secure lower radiator shroud to radiator with removed fasteners.

6. Position upper radiator shroud to lower radiator shroud and radiator.Secure shrouds with removed fasteners.Make sure that clearance between shrouds and fan is at least 0.180” (4.6 mm) at all points.

7. Connectreservoir hose(item 39)to theradiator vent tube.

8. Connect upper and lower hoses to the radiator.

9. Install plenum (item 7) to radiator mount and secure with flange head screws and flange nuts.

Kubota

Diesel Engine

6. Removefour (4)flange headscrewsand flangenuts

that secure plenum (item 7) to radiator mount. Remove

10.Install aircleaner hose(item 6)to theair cleaner and plenum.

plenum.

11.Fill radiator with coolant.

7. Disconnectreservoirhose(item39)from theradiator

vent tube.

12.Install hoodon the machine(see HoodInstallation in the Service and Repairs section of Chapter 7 -- C has-

8. Detach upper radiator shroud from the radiator and

sis).

lower radiator shroud. Remove upper shroud from machine.

9. Removefasteners thatsecure lowerradiator shroud

to radiator.

10.Remove six (6) cap screws and flange nuts that se-

cure fan motor bracket to radiator (Fig. 7).

11.Position lowerradiatorshroud and fanmotorbracket

assembly away from radiator.

12.Remove four(4) flangeheadscrews andflange nuts

securingtheradiatorandrecirculationbarriers(items24 and25) totheradiator mount.Carefully removebarriers and radiator from the machine.

13.Plug all radiator and hose openings to prevent con-

tamination.

Installation (Fig. 6)

1. Removeplugs placed in radiator andhose openings

1. Fan

2. Fan motor bracket

3. Fan motor

Figure 7

4. Cap screw (6 used)

5. Flange nut (6 used)

6. Radiator

during the removal procedure. Make sure that radiator draincock is closed.

Reelmaster 7000 Page 3 -- 11 Kubota Diesel Engine

Page 28

Engine

RIGHT

FRONT

1. Muffler

2. Flange head screw

3. Flange head screw (4 used)

4. Muffler clamp

5. Tailpipe

6. RH rear engine mount

7. Cap screw (3 used)

8. RH front engine mount

9. Engine

10. Flange head screw (10 used)

11. Engine mount (4 used)

12. Flange nut (15 used)

Figure 8

13. Rebound washer (4 used)

14. LH front engine mount

15. Lock washer (4 used)

16. Cap screw (4 used)

17. Lock washer (5 used)

18. Cap screw (5 used)

19. LH rear engine mount

20. Muffler bracket

21. Ground wire harness

22. Muffler gasket

23. Cap screw

24. Lock washer

25. Spacer (2 used)

26. Hardened washer (2 used)

27. Lock washer

28. Alternator wire harness

29. Cap screw

30. Flat washer

31. Muffler bracket

32. Flange head screw

33. Muffler clamp

34. Cap screw (2 used)

Reelmaster 7000Page 3 -- 12Kubota Diesel Engine

Page 29

Engine Removal (Fig. 8)

1. Park machineon a levelsurface, lower cuttingunits,

stop engine, engage parking brake and remove key from the ignition switch.

2. Removehoodfromthemachine(seeHoodRemoval

inthe Serviceand Repairs section of Chapter7 -- Chassis).

3. Remove battery cover. 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. Drain coolant from radiator into a suitable container

(seeRadiatorRemovalinthissection).Disconnectcoolant hoses from the radiator.

1. Engine run solenoid

2. Throttle cable

3. Cable clamp

Figure 9

4. Cable swivel

5. Fuel supply hose

Kubota

Diesel Engine

CAUTION

The exhaust system may be hot. To avoid possibleburns, allow the exhaust system to coolbefore working on or near the muffler.

5. Remove exhaust system from engine (see Exhaust

System Removal in this section).

6. Remove air cleaner system from engine (see Air

Cleaner Removal in this section).

7. Note location of cable ties used to secure wire har-

ness. Disconnect wire harness connectors from the following engine components:

A. The engine run solenoid (Fig. 9). B. The temperature sender (Fig. 10). C. The alternator (Fig. 10). D. The glow plug connection. E. Wireharness connectorfrom engineground har-

ness. F. The electric starter motor.

Figure 10

1. Temperature sender

2. Harness connector

3. Battery cable

8. Disconnect fuel supply hose from injection pump (Fig.9).Capfuelhoseandinjectorpumpfuelinlettoprevent contamination.

9. Remove throttle cable from engine (Fig. 9): A. Removelocknut thatsecuresthrottle cableswiv-

el to speed control lever. B. Loosen cable clamp and remove throttle cable

from under clamp. C. Position throttle cable away from the engine.

10.Remove fasteners that secure the upper radiator

shroud to the lower shroud and radiator (see Radiator Removalinthissection).Removeupperradiator shroud from machine.

G. Low oilpressureswitchlocatedonalternator side of engine (above electric starter).

Reelmaster 7000 Page 3 -- 13 Kubota Diesel Engine

Page 30

11.Remove fan motor and fan assembly (Fig. 11). A. To prevent contamination of hydraulic system,

thoroughly clean exterior of fan motor and fittings. B. Disconnecthydraulic hosesfrom coolingfan mo-

tor.Putcaps orplugsonfittings andhosestoprevent contamination. Label hydraulic lines for proper assembly.

C. Remove six (6) cap screws and flange nuts that secure fan motor bracket to radiator.

D. Carefullyremove fanmotor,fan andmotorbracket assembly from machine.

IMPORTANT: The hydraulic pump assembly canremain in machine during engine removal. Toprevent pump assembly from shifting or falling, make sure to support pump assembly before pump mounting fasteners are removed.

12.Support hydraulic pump assembly.Remove fasten-

ers that secure piston (traction) pump assembly to engine(see Piston (Traction) PumpAssembly Removal in theService and Repairssection of Chapter4 -- Hydraulic System).

Figure 11

1. Fan

2. Fan motor bracket

3. Fan motor

4. Cap screw (6 used)

5. Flange nut (6 used)

6. Radiator

2. Make sure that all parts removed from the engine duringmaintenanceor rebuildingareinstalled totheengine.

13.Make sureall cableties securingthe wiringharness,

fuellines or hydraulic hoses to the engineare removed.

14.Connect lift or hoist to the lift tabs on engine.

15.Remove flange nuts, rebound washers and cap

screws that secure the engine mount brackets to the rubber engine mounts.

CAUTION

One person should operate lift or hoist while a second person guides the engine 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.

16.Carefully raise engine from the machine.

17.Ifnecessary,removeenginemountsfrom the engine

using Figure 8 as a guide.

Engine Installation (Fig. 8)

3. Ifremoved,installengine mountstotheengineusing Figure 8 as a guide.

4. 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.

5. Carefully lower engine into the machine.

6. Align engine to the rubber engine mounts and hydraulic pump input shaft. Secure engine to engine mounts with cap screws, rebound washers and flange nuts.

7. Securehydraulicpumpassemblytoengine(seePiston(Traction)Pump AssemblyInstallationintheService and Repairs section of Chapter 4 -- Hydraulic System).

1. Locatemachine ona levelsurfacewith keyremoved

from the ignition switch. Chock wheels to keep the machine from moving.

Reelmaster 7000Page 3 -- 14Kubota Diesel Engine

Page 31

8. Install fan motor and fan assembly (Fig. 11).

C. The alternator (Fig. 10).

A. Carefullypositionfanmotor,fanandmotorbracket assembly to radiator.

B. Secure fan motor bracket to radiator with six (6) cap screws and flange nuts.

C. Remove caps and plugs placed in hoses and fittings during removal to prevent contamination.

D. Connect hydraulic hoses to cooling fan motor (see Hydraulic Hose and Tube Installation in the GeneralInformationsectionofChapter4 -- Hydraulic System).

9. Position upperradiator shroud to the radiator.Secureshroud to the radiator and lower radiatorbracket with removedfasteners(seeRadiator Installationinthissection).Makesure thatclearancebetweenshroud andfan is at least 0.180” (4.6 mm) at all points.

10.Connect throttle cable to engine (Fig. 9): 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 boltat the same time that the throttle levercontacts the end of the slot in the control console.

D. Tighten cable clamp to secure throttle cable.

11.Remove caps from fuel hose and injector pump fuel

inlet that were placed during engine removal to prevent contamination. Connect fuel supply hose to injection pump (Fig. 9). Secure hose with hose clamp.

12.Connect wire harness connectors to the following

engine components:

A. The engine run solenoid (Fig. 9). B. The temperature sender (Fig. 10).

D. The glow plug connection. E. Wire harness connector to engine ground har-

ness. F. Theelectricstarter.TorquenutatstarterB+termi-

nal from 70 to 86 in--lb (7.9 to 9.7 N--m). G. Low oilpressureswitchlocatedonalternator side

of engine (above electric starter).

13.Using notes taken during engine removal, secure wires with cable ties in proper locations.

14.Install air cleaner assembly to the engine (see Air Cleaner Installation in this section).

15.Installexhaustsystemtomachine(seeExhaustSystem Installation in this section).

16.Connect coolanthosesto theradiator.Make sureradiatordraincockisclosed.Fillradiatorandreservoirwith coolant.

17.Check position of wires, fuel lines, hydraulic hoses andcables for proper clearance withrotating, high temperature and moving components.

18.Connect positive battery cable first and then negative battery cable. Secure battery cover to machine.

19.Check and adjust engine oil level as needed.

20.Check and adjust hydraulic oil level as needed.

21.Bleed fuel system.

22.Operate hydraulic controls to properly fill hydraulic system (see Charge Hydraulic System in the Service andRepairs sectionof Chapter4 -- HydraulicSystems).

23.Install hoodon the machine(see HoodInstallation in the Service and Repairs section of Chapter 7 -- C hassis).

Kubota

Diesel Engine

Reelmaster 7000 Page 3 -- 15 Kubota Diesel Engine

Page 32

Pump Adapter Plate

RIGHT

FRONT

29 to 33 ft--lb

(40to44N--m)

Boss

Loctite #242

1. Bolt

2. Lock washer

3. Flywheel plate

Figure 12

4. Hardened washer (14 used)

5. Spring coupler

6. Bolt (6 used)

7. Cap screw (8 used)

Reelmaster 7000Page 3 -- 16Kubota Diesel Engine

Page 33

Coupler Removal (Fig. 12) 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(seePiston(Traction)PumpRemovalintheService and Repairs section of Chapter 4 -- Hydraulic System).

2. Remove flywheel plate and spring coupler from en-

gine using Figure 12 as a guide.

Coupler Installation (Fig. 12)

1. Position spring coupler to engine flywheel and align

mounting holes. Make sure that coupling hub is away from engine flywheel (Fig. 13).

2. Apply Loctite #242 (orequivalent) to threads of bolts

(item6).Securecouplertoflywheel withsix(6)boltsand hardened washers. Torque bolts in a crossing pattern from 29 to 33 ft--lb (40 to 44 N--m).

3. Position flywheel plate to engine. Make sure that

boss on plate is orientated down. Secure flywheel plate with cap screws (item 7) and hardened washers using a crossing pattern tightening procedure.

Engine Side Hydraulic

Pump Side

Figure 13

1. Coupler

2. Coupler hub

3. Engine flywheel

Kubota

Diesel Engine

4. If engine is in machine, install hydraulic pump as-

sembly (see Piston (Traction) Pump Installation in the Service and Repairs section of Chapter 4 -- Hydraulic System).

Reelmaster 7000 Page 3 -- 17 Kubota Diesel Engine

Page 34

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Reelmaster 7000Page 3 -- 18Kubota Diesel Engine

Page 35

Chapter 4

Hydraulic System

SPECIFICATIONS 3............................

GENERAL INFORMATION 4.....................

Operator’s Manual 4..........................

Towing Traction Unit 4.........................

Check Hydraulic Fluid 4.......................

Relieving Hydraulic System Pressure 5..........

Traction Circuit Component Failure 5............

Hydraulic Hoses 6............................

Hydraulic Hose and Tube Installation 7..........

Hydraulic Fitting Installation 8..................

HYDRAULIC SCHEMATIC 10....................

HYDRAULIC FLOW DIAGRAMS 12...............

Traction Circuit: Mow Speed (4WD) 12..........

Traction Circuit: Transport Speed (2WD) 14......

Lower Cutting Units 16........................

Raise Cutting Units 18.........................

Mow Circuit 20...............................

Steering Circuit 22............................

Engine Cooling Fan Circuit 24..................

SPECIAL TOOLS 26............................

TROUBLESHOOTING 30........................

TESTING 36...................................

Traction Circuit Charge Pressure Test 38.........

Traction Circuit Relief Pressure Test 40..........

Traction Circuit Reducing Valve (PR)

Pressure Test 42............................

Rear Traction Circuit Relief (RV) Pressure Test 44

Piston (Traction) Pump Flow Test 46............

Mow Circuit Pressure Test 48...................

Mow Circuit Relief Pressure Test 50.............

Cutting Unit Motor Case Drain Leakage Test 52... Gear Pump P1 and P2 Flow (Mow Circuits) Test 54

Steering Circuit Relief Pressure Test 56..........

Steering Cylinder Internal Leakage 58...........

Lift/Lower Circuit Relief Pressure Test 60........

Gear Pump P3 Flow (Steering and Lift/Lower

Circuits) Test 62.............................

Cooling Fan Circuit Test 64.....................

Gear Pump P4 Flow (Cooling Fan Circuit) Test 66.

ADJUSTMENTS 68.............................

Adjust Control Manifold Relief Valves 68.........

SERVICE AND REPAIRS 69.....................

General Precautions for Removing and

Installing Hydraulic System Components 69....

Check Hydraulic Lines and Hoses 70............

Flush Hydraulic System 71.....................

Filtering Closed--Loop Traction Circuit 72........

Charge Hydraulic System 73...................

Gear Pump 74................................

Gear Pump Service 76........................

Piston (Traction) Pump 78.....................

Piston (Traction) Pump Service 80..............

4WD/2WD and Filtration/Charge Control

Manifolds 82.....

4WD/2WD Control Manifold Service 84..........

Filtration/Charge Control Manifold Service 86.....

Control Manifold Cartridge Valve Service 87......

Rear Axle Motor 88...........................

Front Wheel Motors 90........................

Rear Axle and Front Wheel Motor Service 92.....

Cutting Reel Motor 93.........................

Cutting Reel Motor Service 94..................

Mow Control Manifold 98......................

Mow Control Manifold Service 100..............

Steering Control Valve 102.....................

Steering Control Valve Service 104..............

Steering Cylinder 106.........................

Steering Cylinder Service 108..................

Engine Cooling Fan Motor 110..................

Engine Cooling Fan Motor Service 112..........

Fan Control Manifold 114......................

Fan Control Manifold Service 116...............

Lift Control Manifold 118.......................

Lift Control Manifold Service 120................

Lift Circuit Junction Manifold 122................

Front Lift Cylinders 124........................

Rear Lift Cylinders 126........................

Lift Cylinder Service 128.......................

Hydraulic Reservoir 130.......................

Hydraulic Oil Cooler 132.......................

EA TON MODEL 72400 SERVO CONTROLLED PIS-

TON PUMP REPAIR INFORMATION

EATON MODEL 74318 and 74348 PISTON MOTORS:

FIXED DISPLACEMENT, VALVE PLATE DESIGN REPAIR INFORMATION

SAUER--DANFOSS STEERING UNIT TYPE OSPM

SERVICE MANUAL

.......

....................

System

Hydraulic

Reelmaster 7000 Hydraulic SystemPage 4 -- 1

Rev. A

Page 36

This page is intentionally blank.

Reelmaster 7000Hydraulic System Page 4 -- 2

Page 37

Specifications

Item Description

Piston (Traction) Pump Eaton variable displacement piston pump

Maximum Displacement (per revolution) 2.48 in System Relief Pressure: Forward 5000 PSI (345 bar) System Relief Pressure: Reverse 5000PSI (345 bar)

Charge Pressure 207 PSI (14.3 bar)

Front Wheel Motors Eaton fixed displacement piston motors

Displacement (per revolution) 2.01 in

Rear Axle Motor Eaton fixed displacement piston motor

Displacement (per revolution) 2.48 in

Gear Pump Casappa 4 section, positive displacement gear type pump

Section P1/P2 Displacement (per revolution) 1.03in Section P3/P4 Displacement (per revolution) 0.56 in

Steering Control Valve Sauer--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) 1.61 in

(Model 72400)

(40.6 cc)

(Model 74315)

(32.9 cc)

(Model 74318)

(40.6 cc)

(16.85 cc)

(9.16 cc)

(100 cc)

(26.5 cc)

System

Hydraulic

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 Spin--on cartridge type

In--line S uction Strainer 100 mesh (in reservoir)

Hydraulic Reservoir Capacity 8.25 U.S. Gallons (31.3 Liters)

Hydraulic Oil See Traction Unit Operator’s Manual

(8.4 cc)

NOTE: The pressure specifications listed above are component settings. When using pressure gauges to measurecircuit pressures,values may bedifferent than these specifications. See the Testing section of this chapterfor hydraulic test proceduresand expected test results.

Reelmaster 7000 Hydraulic SystemPage 4 -- 3

Page 38

General Information

Operator’s Manual

The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Reelmaster machine. Refer to that publicationforadditional information whenservicingthe machine.

Towing Traction Unit

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 only, at a speed

below3 mph(4.8 kph) andfor adistance lessthan 1/4 mile (0.4 km). The piston (traction) pump is equipped

witha bypass valve thatneeds to be turned90 ing(Fig.1).Donotturnbypassvalvewhenengineisrunning.

fortow-

See Traction Unit Operator’s Manual for additional towing procedures.

IMPORTANT: If the machine must be pushed or towed in a reverse direction, the check valve in the 4WD/2WD control manifold must be bypassed. To bypass this check valve, connect a hydraulic hose between the reverse traction pressure test port and the 4WD/2WD control manifold test port (G). Toro part numbers 95--8843 (hydraulic hose), 95--0985 (coupler fitting) (2 required) and 340--77 (hydraulic fitting) (2 required) are needed for this connection.

Check Hydraulic Fluid

The Reelmaster 7000 hydraulic systems are designed to operate on anti --wear hydraulic fluid. The reservoir holdsapproximately8.25U.S.gallons (31.3 liters)ofhydraulic fluid. Check level of hydraulic fluid daily.

Figure 1

1. Bypass valve location

Figure 2

1. Hydraulic reservoir 2. Reservoir cap

Reelmaster 7000Hydraulic System Page 4 -- 4

Page 39

Relieving Hydraulic System Pressure

Beforedisconnecting orperforming any workon thehydraulic system, all pressure in the hydraulic system mustbe relieved.Parkmachineonalevelsurface,lower cutting units fully,stop engine and apply parking brake.

To relieve hydraulic pressure in traction circuit, move tractionpedal to bothforward andreverse directions.To relieve hydraulic pressure in steering circuit, rotate steering wheel in both directions.

Traction Circuit Component Failure

The traction circuit on Reelmaster 7000 machines is a closed loop system that includes the piston (traction) pump, two (2) front wheel motors and the rear axle motor.If a component in the traction circuit should fail, debris and contamination from the failed component will circulatethroughoutthetraction circuit.Thiscontamination 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 circuitcomponentsorafterreplacing a failedtractioncircuit component (e.g. traction (piston) pump or wheel motor). The filter will ensure that contaminates are removedfromtheclosedloop andthus,donotcauseadditional component damage.

Once the Toro high flow hydraulic filter kit has been placedin the circuit,raise and support the machinewith

Systempressureinmow circuit isrelievedwhen the cuttingunits are disengaged(PTO switchin OFF position).

To relieve hydraulicpressure in lift circuit, fullylower the cutting units to the ground. Turn ignition switch to OFF.

all drive wheels off the ground. Then, operate the tractioncircuit toallow oil flowthroughout thecircuit. The filter will remove contamination from the traction circuit duringoperation. Because the Torohigh flowfilter is bi-directional, the traction circuit can be operated in both the forward and reverse direction. The filter should be removed from the machine after contamination has been removed from the traction circuit. See Filtering Closed--LoopTractionCircuitintheServiceandRepairs section of this chapter for additional information on using the Toro high flow hydraulic filter.

Thealternativetousingthe Torohighflow 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,thedebriscancauseadditionalcircuitcomponent failure.

NOTE: If traction circuit contamination exists, the traction pump case drain could allow contaminates to enter other hydraulic circuits on the machine.

System

Hydraulic

Reelmaster 7000 Hydraulic SystemPage 4 -- 5

Page 40

Hydraulic Hoses

Hydraulichoses are subjectto extremeconditions such aspressure differentialsduring operation andexposure to weather, sun, chemicals, very warm storage conditionsormishandlingduringoperationand 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

Beforedisconnecting orperforming anywork on hydraulic system, relieve all pressure in system (seeRelieving HydraulicSystem 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 thehose. Usetwowrenches; holdthe hosestraight 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 elbowatoneend, tightentheswivelnut on thatendbefore 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).

Keepbodyandhands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar withthistypeof injury.Gangrenemayresultfrom such an injury.

Reelmaster 7000Hydraulic System Page 4 -- 6

Page 41

Hydraulic Hose and Tube Installation (O--Ring Face Seal Fitting)

1. Makesure threadsand sealingsurfacesof thehose/ tube and the fitting are free of burrs, nicks, scratches or any foreign material.

2. Asa preventativemeasure againstleakage,it isrecommended that the face seal O--ring be replaced any time the connection is opened. Make sure the O--ring is installedandproperlyseatedin the fitting groove.Lightly lubricate the O--ring with clean hydraulic oil.

3. Place the hose/tube against the fitting body so that theflatfaceofthehose/tubesleevefullycontacts 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 5. This tightening process will require the use of an offset wrench ( e.g. crowfoot wrench). Use of an offset wrench will affect torque wrench calibration due to the effective length change of the torque wrench. Tightening torque when usingatorque wrenchwithanoffsetwrenchwillbelower than the listed installation torque (see Using a Torque Wrench with an Offset Wrenchin the Torque Specificationssection of Chapter 2 -- Product Recordsand Maintenance).

C. Usea secondwrenchtotighten the nuttothecorrect Flats From Wrench Resistance (F.F.W.R.). The markingsonthenutand fitting body willverifythatthe 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 3

System

Hydraulic

5. If a torque wrench is not available or if space at the swivelnutprevents useofa torquewrench, 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. Usingawrench,tightenthe swivelnutontothefittinguntillightwrenchresistanceis 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 4

Fitting Dash Size Hose/Tube Side Thread Size Installation Torque

4 9/16 -- 18 18to22ft--lb(25to29N--m) 6 11/16 - - 16 27to33ft--lb(37to44N--m)

8 13/16 -- 16 37to47ft--lb(51to63N--m) 10 1--14 60 to 74 ft--lb (82 to 100 N--m) 12 13/16--12 85 to 105 ft--lb (116 to 142 N--m)

Initial Position

AFTER TIGHTENING

16 17/16--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 5

Reelmaster 7000 Hydraulic SystemPage 4 -- 7

Page 42

Hydraulic Fitting Installation (SAE Straight Thread O--Ring Fitting into Component Port)

Non--Adjustable Fitting (Fig. 6)

1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material.

2. Asa preventativemeasure againstleakage,it isrecommended that the O--ring be replaced any time the connection is opened.

3. Lightly lubricate the O--ring with clean hydraulic oil. Fittingthreadsshouldbecleanwithnolubricantapplied.

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 7.

NOTE: Useof 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 RecordsandMaintenancetodetermine necessaryconversion information.

5. If a torque wrench is not available, or if space at the portpreventsuseofatorque wrench, analternatemethod 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(3/8in.) 1.50+ 8(1/2in.) 1.50+ 10 (5/8 in.) 1.50 + 12 (3/4 in.) 1.50 + 16 (1 in.) 1.50 +

Fitting

O--ring

0.25

Figure 6

Fitting

Dash Size

Fitting Port Side

Thread Size

Installation Torque Into

Steel Port

Installation Torque Into

Aluminum Port

4 7/16 -- 20 15to19ft--lb(21to25N--m) 9to11ft--lb(13to15N--m) 5 1/2 -- 20 18to22ft--lb(25to29N--m) 11to15ft--lb(15to20N--m) 6 9/16 -- 18 34to42ft--lb(47to56N--m) 20to26ft--lb(28to35N--m)

8 3/4 -- 16 58to72ft--lb(79to97N--m) 35to43ft--lb(48to58N--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 11/16--12 134 to 164 ft--lb (182 to 222 N--m) 81 to 99 ft--lb (110to 134 N--m) 14 13/16--12 160 to 196 ft--lb (217 to 265 N--m) 96 to 118 ft--lb (131 to 160 N--m) 16 15/16--12 202 to 248 ft--lb (274 to 336 N--m) 121 to 149 ft--lb (165 to 202 N--m) 20 15/8--12 247 to 303 ft--lb (335 to 410 N--m) 149 to 183 ft--lb (202 to 248 N--m)

Figure 7

Reelmaster 7000Hydraulic System Page 4 -- 8

Page 43

Adjustable Fitting (Fig. 8)

1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material.

2. Asa preventativemeasure againstleakage,it isrecommended that the O--ring be replaced any time the connection is opened.

3. Lightly lubricate the O--ring with clean hydraulic oil. Fittingthreadsshouldbecleanwithnolubricantapplied.

4. Turnback the lock nutas far as possible. Make sure the back up washer is not looseand is pushed upas far as possible (Step 1 in Figure 9).

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 8

5. Install the fitting into the port and tighten finger tight until the washer contacts the face of the port (Step 2).

6. Toputthe fittingin thedesiredposition, unscrewitby 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 7. This tightening process will require the use of an offset wrench (e.g. crowfoot wrench). Use of an offsetwrench 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 portpreventsuseofatorque wrench, analternatemethod 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 withasecondwrench tothelistedF.F.F.T(Step 4).Ifport material is aluminum, tighten fitting to 60% of listed F.F.F.T.

Step 3Step 1

Step 2 Step 4

Figure 9

System

Hydraulic

Size F.F.F.T.

4 (1/4 in. nominal hose or tubing) 1.00 + 6(3/8in.) 1.50+ 8(1/2in.) 1.50+ 10 (5/8 in.) 1.50 + 12 (3/4 in.) 1.50 + 16 (1 in.) 1.50 +

0.25

Reelmaster 7000 Hydraulic SystemPage 4 -- 9

Page 44

Hydraulic Schematic

CONTROL

MANIFOLD

LIFT

RV1

AXLE

MOTOR

CHG M1

PD1

REAR

2.48

Reelmaster 7000

de--energized

All solenoids are shown as

Hydraulic Schematic

PSI

CHG

.091

P2P3

2.48

2.01

1.031.03

.56.56

PD2

FRONT

MOTORS

PSI

5000

.071

.052

450 PSI

CR2

CR1

CD1T

CV1

207 PSI

CV2

5 PSI

CV1

PSI

NOTE: A larger hydraulic

schematic is included in

P1 CD2

Chapter 9 -- Foldout

Drawings.

RV2

W MO

CONTROL

M3M2

MANIFOLD

MV2

M3M4M1 M2

OR2

CV2

CV1

OR1

MV1

SP2

LC2LC1

SP1

RV2

T1 P2

RV1

P1 T2

PISTON PUMP

2850/1550

ENGINE SPEED

550 PSI

VALVE

BYPASS

5000

.071

FAN

MANIFOLD

CONTROL

M1 M2

G1 G2

LP2

TP1

PRV

GEAR

PUMP

1050

PSI

6.1

CYLINDER

STEERING

Reelmaster 7000Hydraulic System Page 4 -- 10

Page 45

This page is intentionally blank.

System

Hydraulic

Reelmaster 7000 Hydraulic SystemPage 4 -- 11

Page 46

Hydraulic Flow Diagrams

CONTROL

MANIFOLD

LIFT

RV1

CHG M1

PD1

AXLE

MOTOR

REAR

2.48

PSI

CHG

.091

P2P3

2.48

2.01

1.031.03

.56.56

FRONT

.071

5000

PD2

.052

450 PSI

Traction Circuit: Mow Speed (Forward Shown)

Reelmaster 7000

MOTORS

CR2

CR1

CD1T

PSI

CV1

207 PSI

CV2

5 PSI

CV1

P1 CD2

PSI

Working Pressure

Low Pressure (Charge)

Flow

Return or Suction

RV2

MOW

MANIFOLD

M3M2

CONTROL

MV2

M3M4M1 M2

OR2

CV2

CV1

OR1

MV1

SP2

LC2LC1

SP1

RV2

T1 P2

RV1

P1 T2

PISTON PUMP

2850/1550

ENGINE SPEED

550 PSI

VALVE

BYPASS

5000

.071

FAN

MANIFOLD

CONTROL

M1 M2

G1 G2

LP2

TP1

PRV

GEAR

PUMP

1050

PSI

6.1

CYLINDER

STEERING

Reelmaster 7000Hydraulic System Page 4 -- 12

Page 47

Traction Circuit: Mow Speed (4WD)

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. This oil isdirectedtothefrontwheel and rearaxlemotors.Operating pressure on the high pressure side of the closed traction circuit loop is determined by the amount of load developedatthefixeddisplacementwheelandaxlemotors. As the load increases, circuit pressure can increasetoreliefvalvesettings:5000PSI(345bar)inboth forward and reverse. If pressure exceeds the relief setting,oil flows throughthe reliefvalve tothe lowpressure sideoftheclosedlooptractioncircuit.Thetractioncircuit providesoperation ineither mowspeed (4WD)or transport speed (2WD).

Traction circuit pressure (forward and reverse) can be measuredat test ports located onthe traction circuithydraulic tubes of the machine.

The traction circuit pump and motors use a small amount ofhydraulic fluid for internal lubrication. Fluid is designed to leak across traction pump and motor components into the case drain. This leakage results in the lossofhydraulicfluidfromtheclosedlooptractioncircuit thatmust be replaced.The charge circuitis designed to replace this traction circuit leakage.

The gear pump section that supplies oil to the steering andlift/lower circuits also providesoil for thecharge circuit. This gear pump is driven directly off the traction pump. It provides a constant supply of charge oil to make up for oil that is lost due to internal leakage in the traction pump and motors.

Pump flow for the charge circuit is directed through the oil filter and to the low pressure side of the closed loop traction circuit. A filter bypass valve allows charge oil flow to the closed loop if the filter becomes plugged. Chargepressure islimited to207 PSI(14.3 bar) by a reliefvalvelocatedin thefiltration/chargecontrolmanifold. Chargepressure can be measuredat the chargecircuit pressure test port on the filtration/charge control manifold.

Forward Direction

Whenthemow speedlimiter is inthe mowspeed(4WD) position and the traction pedal is pushed in the forward direction,oilfrom thepiston pump isdirected tothefront wheel motors and 4WD/2WD control manifold. Oil flow to the front wheel motors drives the motors in the forward direction and then returns to the piston pump. Oil flowtothe4WD/2WD controlmanifoldenterstheP1port and then is directed to the PD1 cartridge and out of the manifold M1 port to drive the rear axle motor in the forward direction. Oil returning from the rear motor re--entersthe 4WD/2WDcontrolmanifold atthe M2port.Flow passes through the PD2 cartridge, through the check valve (CV), out manifold port P2 and back to the piston pump.

Whengoingdown a hill,the machine becomesanover-running load that drives the wheel and axle motors. In this condition, the rear axle motor could lock up as the oil pumped from the motor increases pressure as it returns to the piston pump. To preventrear wheel lockup, an adjustable relief valve (RV) in the 4WD/2WD control manifold reduces rear axle motor pressure created in down hill, dynamic braking conditions.

Reverse Direction

The traction circuit operates essentially the same in reverse4WD as it does inthe forward direction. However, theflow through the circuitis reversed. Oilflow from the piston pump is directed to the front wheel motors and also to the 4WD/2WD control manifold. The oil to the front wheel motors drives them in the reverse direction and then returns to the piston pump. The oil to the 4WD/2WD control manifold enters the manifold at port P2 and flows through pressure reducing valve (PR) which limits the down stream pressure to the rear axle motorto450PSI(31bar)sotherearwheelswillnotscuff theturfduringreverseoperation.Thisreducedpressure flows through the PD2 cartridge and out port M2 to the rearaxlemotor.Returnoil from therearmotor re--enters the 4WD/2WD control manifold at port M1, flows through the PD1 cartridge, exits the manifold at port P1 and returns to the piston pump.

System

Hydraulic

Reelmaster 7000 Hydraulic SystemPage 4 -- 13

Page 48

CONTROL

MANIFOLD

LIFT

RV1

CHG M1

PD1

2.48

AXLE

REAR

MOTOR

CHG

.091

P2P3

2.48

2.01

1.031.03

.56.56

.071

FRONT

5000

PD2

.052

450 PSI

Traction Circuit: Transport Speed (Forward Shown)

Reelmaster 7000

MOTORS

CR2

CR1

CD1T

PSI

CV1

207 PSI

CV2

5 PSI

CV1

P1 CD2

PSI

Working Pressure

Low Pressure (Charge)

Flow

Return or Suction

RV2

CONTROL

MOW

M3M2

MANIFOLD

MV2

M3M4M1 M2

OR2

CV2

CV1

OR1

MV1

SP2

LC2LC1

SP1

RV2

T1 P2

RV1

P1 T2

PISTON PUMP

2850/1550

ENGINE SPEED

(ENERGIZED)

550 PSI

VALVE

BYPASS

PSI

5000

.071

FAN

MANIFOLD

CONTROL

M1 M2

G1 G2

LP2

TP1

PRV

GEAR

PUMP

1050

PSI

6.1

CYLINDER

STEERING

Reelmaster 7000Hydraulic System Page 4 -- 14

Page 49

Traction Circuit: Transport Speed (2WD)

Traction circuit pressure (forward and reverse) can be measuredat test ports located onthe traction circuithydraulic tubes of the machine.

The gear pump section that supplies oil to the steering and lift/lower circuits also provides charge oil for the traction circuit. This gear pump is driven directly off the tractionpump.Itprovidesaconstantsupplyofchargeoil to the traction circuit to make upfor oil that is lost dueto internal leakage in the traction pump and motors.

Chargepump flowis directedthrough theoil filterand to the low pressure side of the closed loop traction circuit. A filter bypass valve allows chargeoil flow to theclosed loopif thefilter becomes plugged.Charge pressureis limited to 207 PSI (14.3 bar) by a relief valve located in the filtration/charge control manifold. Charge pressure canbe measured at thetest port onthe filtration/charge control manifold.

Forward Direction

Withthemowspeedlimiterinthetransportspeed(2WD) position, solenoid valve (SV) in the 4WD/2WD control manifoldisenergized. Thesolenoidvalve spoolshiftsto directchargepressure thatshiftsthe PD1and PD2control valve spools. The shifted PD1 and PD2 valves prevents hydraulic flow from the piston pump to the rear axle motor.With flow blocked to the rear axle motor,all pistonpump flowis directed tothe frontwheel motors to allow a higher transport speed in the forward direction.

Without flow to the rear axle motor, the rotating rear wheels drive the axle motor so it acts like a pump. Inlet oilto the axlemotor isprovided by acheck valve thatallowscharge circuitoil into therear axlemotor circuit. Oil leaving the axle motor enters the 4WD/2WD control manifold at port M2 and isdirected back to the axlemotor through the shifted PD1 cartridge and manifold port M1.Toallowfor rearwheelloop coolingwhen inforward transport speed operation, a small amount of oil exits throughthe shiftedPD1and PD2cartridges thatreturns to the reservoir.

Reverse Direction

The traction circuit operates essentially the same in reversetransportspeedasit doesintheforward direction. However, the flow through the circuit is reversed. The shifted solenoid valve (SV) and directional valves PD1 andPD2in the 4WD/2WDmanifoldpreventoil flowfrom the rear axle motor. Oil flow from the piston pump is thereforedirectedtoonlythe front wheelmotors.Thisoil drives the front wheel motors in the reverse direction and then returns to the piston pump. Oil circulation through the rear axle motor loop is the same as in the 2WD forward direction.

System

Hydraulic

NOTE: When the mow speed limiter is in the transport

(2WD)position, thecutting unitsare preventedfrom being lowered and the mow circuit cannot be engaged.

Reelmaster 7000 Hydraulic SystemPage 4 -- 15

Page 50

CONTROL

LIFT

MANIFOLD

RV2

RV1

PISTON PUMP

CHG M1

PD1

BYPASS

AXLE

MOTOR

REAR

2.48

550 PSI

CHG

VALVE

2.01

PD2

FRONT

MOTORS

PSI

5000

.052

450 PSI

Flow

Return or Suction

Working Pressure

Reelmaster 7000

CR2

CR1

CD1T

Low Pressure (Charge)

Lower Cutting Units (Lift Switch Pressed to Lower)

CV1

PSI

GEAR

PUMP

5000

.071

.091

2.48

P2P3

1.031.03

.56.56

.071

CV2

CONTROL

M3M2

MANIFOLD

OR2

CV2

CV1

OR1

MANIFOLD

CONTROL

M1 M2

SP2

LC2LC1

SP1

MV2

M3M4M1 M2

MV1

FAN

2850/1550

ENGINE SPEED

RV2

T1 P2

RV1

P1 T2

G1 G2

LP2

TP1

PRV

207 PSI

P1 CD2

5 PSI

CV1

PSI

1050

6.1

CYLINDER

STEERING

Reelmaster 7000Hydraulic System Page 4 -- 16

Page 51

Lower Cutting Units

A four section gear pump is coupled to the piston (traction) pump. Gear pump section P3 supplies hydraulic flowtoboththe lift controlmanifoldandthesteering controlvalve.Hydraulic flowfrom thispumpsection isdelivered to the circuits through a proportional flow divider located in the fan control manifold. Maximum lift/lower circuitpressureis limited to 1700PSI(117bar)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 single lift switch on the console arm is used to raise and lower the five (5) cutting units (Fig. 10). The lift switch acts as an input to the TEC controller to send electrical outputs to appropriate lift control manifold 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 sectionP3 bypasses the lift cylinders through the lift control manifoldsolenoidvalve S1(de--energized).Returnflow from the manifold is routed to the oil filter and traction charge circuit.

Cutting Unit Lower

Because cutting unit weight assists in extending the lift cylinderswhen loweringthe cuttingunits, lesshydraulic 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: Adjustmentof liftcircuit lower reliefvalve (RV2) is not recommended.

Whenthe liftswitch is released, solenoid valvesS1, S3, S4 and S5 are de--energized and the lift cylinders and cutting units are held in position.

System

Hydraulic

NOTE: Theoperator mustbe in theoperator seat inor-

der to lower the cutting units. Also, when in transport speed (2WD), the cutting units will not lower.

When the lift switch is pressed to the lower position, solenoid valve S1 along with solenoid valves S3, S4 and S5 are energized by the TEC controller. To allow the front cutting units to be lowered before the rear cutting units, the controller slightly delays energizing solenoid S5 after the lift switch is pressed. The energized solenoidvalves direct gear pump oilflow to thebarrel endof the lift cylinders. Flow control orifices in the lift control manifold (C2 and C4) are bypassed when lowering the cutting units.

Hydraulic pressure causes the lift cylinder shafts to extend, and lower the cutting units. The three (3) piloted check valves in the junction manifold are shifted by hydraulic pressure to allow return flow from the extending lift cylinders for the front cutting units. Flow control orifices in the junction manifold control the front cutting unit lowering speed by providing a restriction for the return flow from the front lift cylinders. Rear cutting unit lowering speed is controlled by a flow control orifice in the lift control manifold (port C3).

Figure 10

1. Console 2. Lift switch

#4 #1 #5

CUTTING UNIT LOCATIONS

Figure 11

Reelmaster 7000 Hydraulic SystemPage 4 -- 17

Page 52

CONTROL

LIFT

MANIFOLD

RV2

RV1

PISTON PUMP

CHG M1

PD1

BYPASS

AXLE

MOTOR

REAR

2.48

550 PSI

CHG

VALVE

2.01

PD2

FRONT

MOTORS

PSI

5000

.052

Flow

Return or Suction

Raise Cutting Units (Lift Switch Pressed to Raise)

Reelmaster 7000

Working Pressure

Low Pressure (Charge)

450 PSI

CR2

CR1

CD1T

CV1

PSI

GEAR

PUMP

5000

.071

.091

P2P3

2.48

1.031.03

.56.56

.071

CV2

CONTROL

MANIFOLD

M3M2

OR2

CV2

CV1

OR1

MANIFOLD

CONTROL

M1 M2

SP2

LC2LC1

SP1

MV2

M3M4M1 M2

MV1

FAN

2850/1550

ENGINE SPEED

RV2

T1 P2

RV1

P1 T2

G1 G2

LP2

TP1

PRV

207 PSI

P1 CD2

5 PSI

CV1

PSI

1050

6.1

CYLINDER

STEERING

Reelmaster 7000Hydraulic System Page 4 -- 18

Page 53

Raise Cutting Units

Figure 12

1. Console 2. Lift switch

Raise Cutting Units NOTE: Theoperator mustbe in theoperator seat inor-

der to raise the cutting units. When the lift switch is moved to the raise position, sole-

noidvalveS1 alongwith solenoidvalvesS2, S3,S4and S5 are energized by the TEC controller. To allow the front cutting units to be raised before the rear cutting units, the controller slightly delays energizing solenoid S5 after the lift switch is pressed. The energized solenoidvalvesdirectgearpumpoil flow totherodendofthe lift cylinders. The flow control orifice in the lift control manifold port C3 is bypassed when raising the cutting units.

Hydraulic pressure causes the lift cylinder shafts to retract,andraisethecutting units. Theflowcontrolorifices in the junction manifold are bypassed when raising the cuttingunits. Flow control orificesin the lift control manifold (ports C2 and C4) control the cutting unit raising speed by providing a restriction for the return flow from the lift cylinders.

#4 #1 #5

#3#2

CUTTING UNIT LOCATIONS

Figure 13

System

Hydraulic

Whenthe liftswitch is released, solenoid valvesS1, S2, S3, S4 and S5 are de--energized and the lift cylinders and cutting units are held in position.

Reelmaster 7000 Hydraulic SystemPage 4 -- 19

Page 54

CONTROL

MANIFOLD

LIFT

RV1

CHG M1

PD1

AXLE

MOTOR

REAR

2.48

Mow Circuit

Reelmaster 7000

Working Pressure

Low Pressure (Charge)

Flow

Return or Suction

RV2

W MO

MANIFOLD

M3M4M1 M2

CONTROL

MV2

MV1

FAN

OR2

CV2

CV1

OR1

MANIFOLD

CONTROL

M1 M2

M3M2

(ENERGIZED)

SP2

SP1

RV2

T1 P2

RV1

P1 T2

(ENERGIZED)

G1 G2

LP2

TP1

PRV

LC2LC1

PISTON PUMP

2850/1550

ENGINE SPEED

550 PSI

VALVE

BYPASS

5000

.071

GEAR

PUMP

PSI

CHG

.091

2.48

P2P3

2.01

1.031.03

.56.56

PD2

FRONT

MOTORS

PSI

5000

.071

.052

450 PSI

CR2

CR1

CD1T

CV1

207 PSI

CV2

5 PSI

CV1

P1 CD2

PSI

1050

6.1

CYLINDER

STEERING

Reelmaster 7000Hydraulic System Page 4 -- 20

Page 55

Mow Circuit

Hydraulic flow for the mow circuit is supplied by two (2) sectionsof thegearpump (P1and P2).Gear pumpsection P1 supplies hydraulic flow to cutting units 1, 4 and 5 (front cutting units), while gear pump section P2 supplies cutting units 2 and 3 (rear cutting units).

A single mow control manifold is used to control flow from the two (2) pump sections. The manifold includes cartridge valves for control of each of the two (2) pump circuits. Each manifold circuit is equipped with a solenoidcontrolled,proportionalvalve (SP1 and SP2), alogic cartridge (LC1 and LC2) and a circuit relief cartridge (RV1 and RV2).

Allcuttingreelmotorsareequippedwithcrossoverrelief valves to prevent hydraulic componentdamage in case a cutting reel should stall.

The TEC controller uses inputs from various machine switchestodetermine whensolenoid proportional valve (SP1 and SP2) are to be energized. The controller also provides a slight delay in activation of the rear cutting units.

NOTE: When the mow speed limiter is in the transport (2WD) position, the mow circuit cannot be engaged.

When the reels are shut off, the over--running inertia load of the reels keeps driving the reel motors and can turnthem intopumps. The checkvalves (CV1and CV2) in the mow control manifold will open to keep the reel motor circuit full of oil so the motors will not cavitate.

Backlap

Wheneitherof themowcontrol manifoldbacklapvalves arerotated 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.

#4 #1 #5

#3#2

System

Hydraulic

PTO Disengaged (Fig. 15)

When the PTO switch is OFF (or if the cutting units are raised),themanifoldproportional valves(SP1andSP2) are not energized, which causes a pressure increase thatshiftsthe logiccartridges(LC1 andLC2).The pump flow is routed through theshifted logic cartridge and out manifoldportT1.Return oilfromthemanifold isdirected to the oil cooler and oil filter.

PTO Engaged

Whenthe PTOswitchis turnedON withthecutting units lowered, the manifold proportional valves (SP1 and SP2) are energized with outputs from the TEC--5002 controller.Theenergizedvalvesshifttodirectpumpflow toward the cutting unit motors. Flow from the valves is proportional to current applied to the valve coil by the TECcontroller.The settingofthereel speedcontrolprovides the input for the TEC controller to allow the appropriate current to the valve coil.

Flow through the speed control valve 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 hydraulic reservoir.

CUTTING UNIT LOCATIONS

Figure 14

M1M4

M3M4M1 M2

MV1

CV1

LC1

RV1

CV2

LC2

RV2

OR2

OR1

SP1

P1 T2 T1 P2

FROM GEAR

PUMP P1

MV2

SP2

FROM GEAR PUMP P2

M3M2

MOW CONTROL MANIFOLD

Maximum mow circuit pressure is limited at each mow manifoldcircuit bythe relief valve (RV1or RV2).The relief valve pressure is 3000 PSI (207 bar). Reelmaster 7000 Hydraulic SystemPage 4 -- 21

Figure 15

Page 56

CONTROL

MANIFOLD

LIFT

RV2

RV1

CHG M1

PD1

AXLE

MOTOR

REAR

2.48

550 PSI

Flow

Return or Suction

Working Pressure

Low Pressure (Charge)

PD2

.052

450 PSI

Steering Circuit (Right Turn Shown)

Reelmaster 7000

GEAR

BYPASS

PUMP

CHG

VALVE

PSI

5000

.071

PISTON PUMP

MOW

MANIFOLD

M3M2

CONTROL

OR2

CV2

CV1

OR1

SP2

LC2LC1

SP1

MV2

M3M4M1 M2

MV1

2850/1550

ENGINE SPEED

RV2

T1 P2

RV1

P1 T2

G1 G2

.091

P2P3

2.48

2.01

1.031.03

.56.56

FRONT

5000

.071

MOTORS

CR2

CR1

CD1T

PSI

CV1

207 PSI

CV2

5 PSI

CV1

P1 CD2

PSI

FAN

CONTROL

M1 M2

MANIFOLD

LP2

PSI

1050

TP1

PRV

6.1

CYLINDER

STEERING

Reelmaster 7000Hydraulic System Page 4 -- 22

Page 57

Steering Circuit

A four section gear pump is coupled to the piston (traction)pump. Thegear pumpsection P3supplies 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 P3 flow enters the steering control valve at the P port and goes through the steeringcontrol spoolvalve, bypassingthe rotarymeter and steering cylinder. Flow leaves the control valve through the PB port to the oil filter and traction charge circuit.

Left Turn

When a left turn is made with the engine running, the turningofthe steeringwheelpositions the spool valve so thatflowgoesthroughthetopofthespool.Flowentering thesteering control valve atthe P port goes through the spool and is routed to two places. First, most of theflow throughthevalveisbypassedout thePBportbacktothe oil filter and traction charge circuit.Second, the remainderof theflow isdrawn throughthe rotarymeter andout the L port. Pressure contracts the steering cylinder for a left turn. The rotary meter ensures that the oil flow to

the cylinder is proportional to the amount of the turning on the steering wheel. Fluid leaving the cylinder flows backthroughthespoolvalvethenthroughtheTportand to the hydraulic reservoir.

Thesteering controlvalve returns tothe neutralposition when turning is completed.

Right Turn

When a right turn is made with the engine running, the turningofthe steeringwheelpositions the spool valve so thatflow goes throughthe bottom ofthe spool. Flowentering the steering control valve at the P port goes throughthespool andis routed totwo places.Asin aleft turn, most of the flow through the valve is bypassed out the PB port back to the oil filter and traction charge circuit. Also like a left turn, the remainder of the flow is drawn through rotary meter but goes out port R. Pressure extends the steering cylinder for a right turn. The rotary meter ensures that the oil flow to the cylinder is proportionalto theamount of the turning on the steering wheel.Fluid leaving the cylinderflows back through the spool valve then through the T port and to the hydraulic reservoir.

Thesteering controlvalve returns tothe neutralposition when turning is completed.

System

Hydraulic

NEUTRAL POSITION

PPB

1050

PSI

NO CYLINDER

MOVEMENT

LEFT TURN

STEERING CONTROL VALVE

6.1

STEERING CYLINDER

PPB

1050

PSI

6.1

STEERING CONTROL VALVE

STEERING CYLINDER

RIGHT TURN

PPB

1050

PSI

STEERING CONTROL

VALVE

6.1

STEERING CYLINDER

Figure 16

Reelmaster 7000 Hydraulic SystemPage 4 -- 23

Page 58

CONTROL

MANIFOLD

LIFT

RV1

CHG M1

PD1

AXLE

MOTOR

REAR

2.48

PSI

CHG

.091

P2P3

2.48

2.01

1.031.03

.56.56

PD2

FRONT

MOTORS

PSI

5000

.071

.052

450 PSI

Engine Cooling Fan Circuit (Forward Fan Direction Shown)

CR2

CR1

CD1T

CV1

207 PSI

CV2

5 PSI

CV1

Reelmaster 7000

P1 CD2

PSI

Working Pressure

Low Pressure (Charge)

Flow

Return or Suction

RV2

W MO

MANIFOLD

M3M2

CONTROL

MV2

M3M4M1 M2

OR2

CV2

CV1

OR1

MV1

SP2

SP1

RV2

T1 P2

RV1

P1 T2

LC2LC1

PISTON PUMP

2850/1550

ENGINE SPEED

550 PSI

VALVE

BYPASS

5000

.071

FAN

MANIFOLD

CONTROL

M1 M2

G1 G2

LP2

TP1

PRV

GEAR

PUMP

1050

PSI

6.1

CYLINDER

STEERING

Reelmaster 7000Hydraulic System Page 4 -- 24

Page 59

Engine Cooling Fan Circuit

A four section gear pump is coupled to the piston (traction)pump.The gear pumpsectionP4 (farthest fromthe piston pump) supplies hydraulic flow for the hydraulic engine cooling fan motor (Fig. 17).

Thefancontrolmanifoldcontrolstheoperationofthehydraulic motor that drives the engine cooling fan in additiontoincludingtheflow divider (FD)forthesteeringand liftcircuits. The electronically controlled proportionalreliefvalve(PRV)inthemanifoldcontrolsthe oilflowtothe fan motor. The fan control manifold controls the speed anddirection ofthe fanmotor based on electrical output from the TEC controller.

Oil flow from the gear pump to the cooling fan motor is controlled by the proportional relief valve (PRV) in the fan control manifold. This valve adjusts fan circuit flow based on a PWM (Pulse Width Modulation) signal from the TEC controller. The controller uses engine coolant and hydraulic oil temperatures as inputs to determine theproperPWMsignal forthePRVvalve.Thefancircuit flow determines the speed of the cooling fan motor.

The fan motor runs at reduced speed until coolant

reachesapproximately 165

F(74oC).Thefan motor

increases to full speed (approximately 2800 RPM)

as coolant reaches 180

F(82oC).

Thefanmotorautomaticallyslowsdownandthenre-

verses direction if coolant reaches 203

hydraulic oil reaches 212

F (100oC).

F(95oC) or

Reverse Direction Fan Operation (Fig. 18)

The TEC controller can reverse the cooling fan to clean debrisfrom therear intakescreen. If hydraulicoil and/or engine coolant temperatures increase to an unsuitable level or if the engine cooling fan switch is pressed to manual reverse, a high PWM signal is sent to the PRV valve to slow the cooling fan and direct pump oil flow away from the fan motor. The controller then energizes solenoid valve S1 in the fan control manifold to reverse cooling fan motor oil flow so that the motor runs in the reversedirection.AlowerPWMsignalissenttothePRV valveallowingoilflow toreturntothe fan motorbutinthe reverse direction causing the motor and cooling fan to run in reverse for a short time.

NOTE: The fan reversal process is not designed to cleanthe radiator of debris.Refer to Operator’s Manual for radiator cleaning maintenance recommendations.

System

Hydraulic

If the fan motor is stalled for any reason, the manifold proportionalreliefvalve(PRV)hasasecondary 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

1. Gear pump

2. Fan control manifold

load of the fan blades keeps driving the fan motor and turnsitintoa pump. Thecheckvalve(CV) inthefancontrol manifold will open to keep the motor circuit full of oil so the fan motor will not cavitate.

DIRECTION

NOTE: IfPWMcurrentis not availabletothe fancontrol

manifoldproportional relief valve (PRV), the coolingfan motorwill runat full speed in thenormal (forward)direction.

Forward Direction Fan Operation

Oilflowfromthegearpump issentthroughthede--energized solenoid valve S1 to rotate the cooling fan motor. Return flow from the motor re--enters the manifold (port M2),throughthede--energizedsolenoidvalveS1,outof themanifold(portT) andthenisrouted throughthemow control manifold, oil cooler and oil filter.

Reelmaster 7000 Hydraulic SystemPage 4 -- 25

REVERSE

TO RESERVOIR

G2 G1

FROM GEAR

PUMP (P4)

Figure 17

3. Fan circuit supply hose

4. Hydraulic fan motor

PRV

Figure 18

TO STEERING CIRCUIT

FROM GEAR PUMP (P3)

TO OIL COOLER

TO LIFT/LOWER CIRCUIT

Page 60

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 19

Use to test hydraulic circuits and components for flow andpressurecapacitiesasrecommendedin the Testing sectionofthis chapter.Thistesterincludesthefollowing:

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(5to55LPM).

5. OUTLET HOSE: A hose from the outlet side of the hydraulictesterconnectstothehydraulic systemcircuit.

6. FITTINGS:Anassortment ofhydraulicfittings areincluded with this kit.

Toro Part Number: TOR214678

Figure 20

Reelmaster 7000Hydraulic System Page 4 -- 26

Page 61

40 GPM Hydraulic Tester (Pressure and Flow)

Use to test hydraulic circuits and components for flow andpressurecapacitiesasrecommendedin the Testing sectionofthis chapter.Thistesterincludesthefollowing:

1. LOAD VALVE: A simulated working load is created in the circuit by turning the valve to restrict flow.

2. PRESSURE GAUGE: Glycerine filled 0 to 5000 PSI gauge to provide operating circuit pressure.

3. FLOW METER: This meter measures actual oil flow in the operating circuit with a gauge rated from 4 to 40 GPM (20 to 150 LPM).

Toro Part Number: AT40002 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 connect40GPMhydraulictester (AT40002)orhighflow hydraulic filter kit (TOR6011)to machinehydraulic traction system components.

Toro Part Number: TOR6007

Figure 21

Figure 22

System

Hydraulic

Reelmaster 7000 Hydraulic SystemPage 4 -- 27

Page 62

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--directionalfiltration which prevents filtered debris from being allowedback intothecircuit regardlessof flow direction.

If acomponent failure occurs in the closed looptraction 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 orafterreplacingafailedtractioncircuit component(e.g. piston(traction) pumpor wheelmotor), thehigh flow hydraulic filter can be installed in the traction circuit. The filterwillensurethatcontaminatesareremovedfromthe 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: Replacementfilter elementis Toro part number

TOR6012. Filter element cannister tightening torque is 25 ft--lb (34 N-- m).

Figure 23

Hydraulic Test Fitting Kit

This kit includes a varietyof O--ringFace Seal fittings to enable you to connect test gauges into the system.

The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings.

Toro Part Number: TOR4079

Figure 24

Reelmaster 7000Hydraulic System Page 4 -- 28

Page 63

Measuring Container

Use this container for doing hydraulic motor efficiency testing(motorswith casedrain lines only).Measure efficiency of a hydraulic motor by restricting the outlet flow from the motor and measuring leakage from the case drainlinewhile themotoris pressurized bythehydraulic system.

The table in Figure 26 provides gallons per minute (GPM)conversionformeasured milliliterorouncemotor case drain leakage.

Toro Part Number: TOR4077

Figure 25

System

Hydraulic

O --ring Kit

ThekitincludesO--ringsinavarietyofsizesforfaceseal andport seal hydraulicconnections. Itis recommended thatO--ringsbe replacedwhenever ahydraulic connection is loosened.

Toro Part Number: 16--3799

Figure 26

Figure 27

Reelmaster 7000 Hydraulic SystemPage 4 -- 29

Page 64

Troubleshooting

Thechartsthat follow containinformationto assist inhydraulic system troubleshooting. There may possibly be more than one cause for a machine malfunction.

General Hydraulic System Problems

Problem Possible Cause

Hydraulic system operates hot. NOTE: An indication that the hy-

draulic system is operating at excessive temperatures would be frequent reversing of the cooling fan and a normal engine coolant temperature.

Engine RPM is too low. Hydraulic reservoir oil level is low. Hydraulic oil is contaminated or the wrong type. Brakes are applied or sticking. Piston pump bypass valve is open or damaged. Cooling system is not operating properly. Charge pressure is low. Engine cooling fan circuit is malfunctioning (see Engine Cooling Fan

Circuit Problems in this section).

Refer to the Testing section of this Chapter for precautions and specific testing procedures.

Traction circuit pressure is incorrect. Pump(s) or motor(s) are damaged.

Hydraulic oil in reservoir foams. Hydraulic reservoir oil level is low.

Wrong type of oil is in the hydraulic system. Air is leaking in suction line.

Hydraulic oil leak(s). Fitting(s), hose or tube loose or damaged.

Missing or damaged O-ring in fitting.

Reelmaster 7000Hydraulic System Page 4 -- 30

Page 65

Traction Circuit Problems

NOTE: Whentroubleshootingtractioncircuitproblems,

ifa problem existsin both mowspeed (4WD) and transport speed (2WD), consider a faulty component that affects the entire traction circuit (e.g. charge circuit, relief valves,piston pump,front wheelmotors). Ifthe problem

Problem Possible Cause

Machine operates in one direction only.

Traction pedal reaction is sluggish when in either mow speed (4WD) or transport speed (2WD).

Traction pedal reaction is sluggish when in mow speed (4WD). Pedal reaction is normal when in transport speed (2WD).

Machine travels too far before stopping when the traction pedal is released.

Traction control linkage is faulty. Traction relief valve is defective.

Traction control linkage is stuck or binding. Charge pressure is low. Piston (traction) pump servo control valve orifices are plugged or

damaged. PD1 and PD2 pilot directional valve seals in 4WD/2WD control

manifold are leaking or damaged.

Traction linkage is out of adjustment. Charge pressure is low.

exists in mow speed (4WD) but not in transport speed (2WD), consider a problem in the 4WD traction system (e.g.rearaxlemotor,cartridgevalvesin 4WD/2WDcontrol manifold).

System

Hydraulic

Piston (traction) pump servo control valve orifices are plugged or damaged.

Traction pedal does not return to neutral.

Traction power is lost or machine will not operate in either direction.

Mow speed (4WD) will not engage. Electrical problem exists (see Chapter 5 -- Electrical System).

Mow speed (4WD) will not disengage.

Hydraulic reservoir oil level is low. Piston pump bypass valve is open or damaged. Charge pressure is low. Traction circuit pressure is low. Front wheel motor couplers are damaged. If traction is lost in mow speed (4WD) but is normal in transport

speed (2WD), rear axle motor or rear axle motor drive may be faulty.

Solenoid valve SV in 4WD/2WD control manifold is faulty. Cartridge valve(s) in 4WD/2WD control manifold is (are) faulty.

Electrical problem exists (see Chapter 5 -- Electrical System). Cutting units are fully lowered. Cartridge valve in 4WD/2WD control manifold is damaged or sticking.

Reelmaster 7000 Hydraulic SystemPage 4 -- 31

Page 66

PTO Problems

Problem Possible Cause

None of the cutting units will operate.

NOTE: Cutting units have to be fully lowered and traction speed needs to be in mow speed (4WD) for cutting units to operate.

One cutting unit will not operate. System pressure to the affected cutting unit motor is low.

Several cutting units will not operate. Electrical problem exists that prevents mow control manifold sole-

Cutting units are not fully lowered to ground. Operator seat is unoccupied. Mow speed limiter is in transport (2WD) position. Electrical problem exists that prevents mow control manifold sole-

noid valve operation (see Chapter 5 -- Electrical System). Gear pump sections P1 and P2 are damaged. Gear pump coupler is damaged (other hydraulic circuits will be af-

fected as well).

Cutting unit problem exists (see Chapter 8 -- Cutting Units). Spline on affected cutting unit motor is damaged. Cutting unit motor relief valve is stuck or damaged. Cutting unit motor is damaged. NOTE: If appropriate, transfer a sus-

pected damaged motor to another cutting unit. If problem follows the motor, motor needs repair or replacement.

noid valve operation (see Chapter 5 -- Electrical System). Cutting units are not fully lowered to ground. Mow control manifold proportional valve (SP1 or SP2) for affected

cutting units is faulty. Mow control manifold logic cartridge valve (LC1 or LC2) for af-

fected cutting units is stuck or damaged. Mow control manifold check valve (CV1 or CV2) for affected cutting

units is stuck or damaged. Gear pump section (P1 or P2) is worn or damaged.

Reelmaster 7000Hydraulic System Page 4 -- 32

Page 67

PTO Problems (Continued)

Problem Possible Cause

All cutting units operate slowly. Engine RPM is low.

Cutting unit motor is damaged. Gear pump section (P1 or P2) is worn or damaged.

Cutting unit stops under load. Relief valve in mow control manifold is bypassing.

Cutting conditions (e.g. very tall or wet grass) exceed cutting unit capacity.

Cutting unit motor relief valve is stuck or damaged. Cutting unit motor has internal leakage (bypassing oil). Gear pump section (P1 or P2) for affected cutting units is worn or

damaged.

Steering Circuit Problems

System

Hydraulic

Problem Possible Cause

Steering inoperative or sluggish. Steering components (e.g. tie rods, steering cylinder ends) are

worn or binding. Steering cylinder is binding. Oil level in hydraulic reservoir is low (other hydraulic systems af-

fected as well). Steering relief valve in steering control valve is stuck or damaged. Flow divider (FD) in fan control manifold is faulty. Steering cylinder leaks internally. Steering control valve is worn or damaged. Gear pump section (P3) is worn or damaged (NOTE: A worn or

damaged gear pump section (P3) will also affect the traction (charge) and lift circuits).

Reelmaster 7000 Hydraulic SystemPage 4 -- 33

Page 68

Lift/Lower Circuit Problems

Problem Possible Cause

Cutting units will not raise. NOTE: Operator must be in seat in

order to raise the cutting units.

Cutting units raise, but will not stay up.

NOTE: Lift cylinders cannot provide an absolutely perfect seal. The lift arms will eventually lower if left in the raised position during storage.

Operator seat is unoccupied. Hydraulic oil level in reservoir is low. Electrical problem exists that prevents lift control manifold solenoid

valve operation (see Chapter 5 -- Electrical System). Lift cylinder(s) is (are) damaged. Lift arm pivots are binding. Lift/lower circuit relief valve (RV1) in lift control manifold is stuck

open. Solenoid valve(s) in lift control manifold is damaged or sticking. Flow divider (FD) in fan control manifold is faulty. Gear pump section (P3) is worn or damaged (NOTE: A worn or dam-

aged gear pump section (P3) will also affect the traction (charge) and steering circuits).

Lift circuit hydraulic lines or fittings are leaking. Cartridge valve in lift control manifold is stuck open. Air exists in lift circuit. Lift cylinder is damaged.

Cutting units will not lower. NOTE: Operator must be in seat

and traction system must be in mow speed (4WD) in order to lower the cutting units.

Operator seat is unoccupied. Mow speed limiter is in transport (2WD) position. Electrical problem exists that prevents lift control manifold solenoid

valve operation (see Chapter 5 -- Electrical System). Lift arm pivots are binding. Lift cylinder(s) is (are) is damaged. Lower circuit relief valve (RV2) in lift control manifold is stuck open. Solenoid valve(s) in lift control manifold is damaged or sticking.

Reelmaster 7000Hydraulic System Page 4 -- 34

Page 69

Engine Cooling Fan Circuit Problems

Problem Possible Cause

Cooling fan runs only in forward direction (fan does not run in reverse direction).

Cooling fan does not rotate. Fan motor is worn or damaged.

Cooling fan always rotates at slow speed.

Cooling fan always rotates at fast speed.

Fan control manifold solenoid cartridge valve (S1) is faulty. Electrical problem exists that prevents fan control manifold solenoid

valve (S1) operation (see Chapter 5 -- Electrical System).

Gear pump section (P4) is worn or damaged. Fan control manifold cartridge valve seals are leaking.

Check valve in fan control manifold is not seating. Fan control manifold proportional relief valve (PRV) is stuck open. Hydraulic fan motor is worn or damaged.

Fan control manifold proportional relief valve (PRV) is faulty. Electrical problem exists that prevents fan control manifold propor-

tional relief valve (PRV) operation (see Chapter 5 -- Electrical System).

System

Hydraulic

Reelmaster 7000 Hydraulic SystemPage 4 -- 35

Page 70

Testing

The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment suchas pressuregauges and flowmeters in the circuits during various operational checks (See the Special Tools section in this chapter).

IMPORTANT: All obvious areas such as oil supply, filter,binding linkages, loose fasteners or improper adjustmentsmustbecheckedbeforeassumingthat ahydrauliccomponentisthe source oftheproblem.

WARNING

Beforedisconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved and all rotating machine parts must be stopped. See Relieving Hydraulic System Pressure in the General Information section.

CAUTION

Precautions for Hydraulic Testing

1. Clean machine thoroughly before disconnecting or disassemblinganyhydraulic components.Always keep in mind the need for cleanliness when working on hydraulic equipment. Hydraulic system contamination will cause excessive wear of hydraulic components.

2. Put metal caps or plugs on all hydraulic lines left open or exposed during testing or removal of components.

3. Theenginemustbeingoodoperatingcondition. Use aphototac todetermine engine speed when performing ahydraulictest. Enginespeedwill affecttheaccuracyof the tester readings.

4. When using hydraulic tester with pressure and flow capabilities,the inletand theoutlet hoses mustbe properly connected and not reversed to prevent damage to the hydraulic tester or machine components.

5. When using hydraulic tester with pressure and flow capabilities, open load valve completely in the tester to minimize the possibility of damaging components.

Failure to use gauges with recommended pressure (PSI) rating as listed in test procedures couldresultindamageto the gauge andpossible personal injury from leaking hot oil.

CAUTION

All testing should be performed by two (2) people.Onepersonshould be intheseattooperate the machine and the other should monitor testing equipment and record test results.

WARNING

Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Do not use hands to search for leaks; use paper or cardboard. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. If fluidisinjectedintotheskin, it mustbesurgicallyremoved withina fewhours by a doctor familiar with this type of injury. Gangrene may result from such an injury.

6. Install fittings finger tight and far enough to make sure that they are not cross--threaded before tightening them with a wrench.

7. Position tester hoses to prevent rotating machine partsfromcontacting anddamagingthe hosesortester.

8. Check oil level in the hydraulic reservoir. After connectingtestequipment,makesurehydraulicreservoir is full.

9. Check control linkages for improper adjustment, binding or broken parts.

10.All hydraulictests shouldbe madewith thehydraulic oil at normal operating temperature.

11.Before returning machineto use, makesure that hydraulic reservoir has correct fluid level.

Reelmaster 7000Hydraulic System Page 4 -- 36

Page 71

Which Hydraulic Tests Are Necessary?

Before beginning any hydraulic test, identify if the problemisrelatedto thetractioncircuit,mowcircuit, lift/lower circuit, steering circuit or engine cooling fan circuit. Once the faulty system has been identified, perform tests that relate to that circuit.

1. If atraction circuit problem exists,consider performing one or more of the following tests: Traction Circuit ChargePressure,TractionCircuitReliefPressure,Rear

Traction Circuit Relief (RV) Pressure, Traction Circuit Reducing Valve (PR) Pressure and/or Piston(Traction) Pump Flow.

2. If a PTO circuit problem exists, consider performing oneormoreofthefollowingtests:MowCircuitPressure, Mow Circuit Relief Pressure, Cutting Unit Motor Case Drain Leakage and/or Gear Pump P1 and P2 Flow.

3. Ifalift/lowercircuitproblemexists,consider performing one or more of the following tests: Lift/Lower Circuit Relief Pressure, Lift Cylinder Internal Leakage and/or Gear Pump P3 Flow.

4. Ifasteering circuitproblemexists,consider performing one or more of the following tests: Steering Circuit Relief Pressure, Steering Cylinder Internal Leakage and/or Gear Pump P3 Flow.

5. If an engine cooling fan circuit problem exists, consider performing one or more of the following tests: Cooling Fan Circuit and/or Gear Pump P4 Flow.

System

Hydraulic

Reelmaster 7000 Hydraulic SystemPage 4 -- 37

Page 72

Traction Circuit Charge Pressure Test (Using Pressure Gauge)

FROM STEERING

AND LIFT CIRCUITS

(CHARGE CIRCUIT)

CHG M1

2.48

REAR

AXLE

MOTOR

FORWARD DIRECTION

TEST SHOWN

Working Pressure Low Pressure Return or Suction

Flow

PISTON PUMP

.052

450 PSI

PRESSURE

PD1

550 PSI

PD2

GAUGE

CHG

2.01

VALVE

BYPASS

FRONT

5000

MOTORS

CR2

CD1T

PSI

CR1

TO DECK CONTROL MANIFOLD

TO STEERING AND LIFT CIRCUITS

(CHARGE CIRCUIT)

TO FAN CIRCUIT

2850/1550

ENGINE SPEED

GEAR

PUMP

PSI

5000

.091

.071

2.48

1.031.03

P2P3

.56.56

FROM DECK MOTORS

.071

CV1

207 PSI

CV2

5 PSI

CV1

P1 CD2

PSI

FROM STEERING CONTROL VALVE

FROM DECK CONTROL MANIFOLD

Reelmaster 7000Hydraulic System Page 4 -- 38

Page 73

NOTE: The traction charge circuit is designed to replaceloss of hydraulicfluid fromtheclosed looptraction circuit.

ProcedureforTractionCircuitChargePressureTest

1. Make sure hydraulic oil is at normal operating temperaturebyoperatingthemachineforapproximatelyten (10) minutes. Make sure the hydraulic tank is full.

2. Parkmachineona level surfacewiththecuttingunits loweredand off.Makesure engine isoffand theparking brake is engaged.

3. Raise and support operator seat to access charge pressure test port.

CAUTION

9. Also, with the pressure gauge still connected to the charge pressure test port, monitor the gauge reading while operating the machine in forward and reverse. Start the engine and put throttle at full engine speed (2850 RPM). Apply the brakes and push the traction pedal forward, then reverse.

GAUGE READING TO BE within 20% of no--load charge pressure measured in step 4 above (e.g. if charge pressure in step 4 is 250 PSI (17.2 bar), charge pressure in forward or reverse should be from 200 to 250 PSI (13.8 to 17.2 bar)

10.If charge pressure is good under no load, but drops belowspecification whenunder traction load, the piston (traction)pump,frontwheel motorsand/orrearaxle motor s hould be suspected of wear andinefficiency.When thepumpand/ortractionmotor(s)arewornordamaged, thechargepumpisnotable tokeepupwithinternalleakage in traction circuit components.

Prevent personal injury and/ordamage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

4. Connect a 1000 PSI (70 bar) pressure gauge onto chargepressuretest port.Testportislocatedonhydraulic tube near hydraulic oil filter (Fig. 28).

5. After installingpressure gauge, start engineand run at low idle speed. Check for hydraulic leakage and correct before proceeding with test.

6. Move throttle to high idle speed (2850 RPM) with no load on the hydraulic system. Identify charge pressure reading on gauge:

GAUGEREADINGTOBE210 to 300 PSI (14.5 to

20.6 bar)

7. Stop engine and record test results.

8. If there is no pressure or pressure is low, check for the following:

11.When testing is completed, disconnect pressure gaugefrommanifoldtest port.Installdustcaptotestport fitting. Lower and secure operator seat.

Figure 28

1. Operator seat

2. Oil filter

3. Test port location

System

Hydraulic

A. Restriction in gear pump intake line. B. Chargereliefvalve infiltrationand chargecontrol

manifold is leaking (see Filtration/Charge Control Manifold Service in the Service and Repairs section of this chapter).

C. If necessary, check for internal damage or worn partsin gear pumpP3 (seeGear Pump P3Flow Test inthissection).NOTE: Steeringandlift/lowercircuits would also be affected if gear pump P3 is worn or damaged.

Reelmaster 7000 Hydraulic SystemPage 4 -- 39

Page 74

Traction Circuit Relief Pressure Test (Using Pressure Gauge)

FROM STEERING

AND LIFT CIRCUITS

(CHARGE CIRCUIT)

CHG M1

2.48

REAR

AXLE

MOTOR

FORWARD DIRECTION

TEST SHOWN

PRESSURE

Working Pressure Low Pressure Return or Suction

Flow

GAUGE

PISTON PUMP

.052

450 PSI

CR2

CV1

CR1

207 PSI

CD1T

PD1

.091

2.01

FRONT

5000

PD2

MOTORS

PSI

550 PSI

CHG

VALVE

BYPASS

PSI

5000

TO DECK CONTROL MANIFOLD

TO STEERING AND LIFT CIRCUITS

(CHARGE CIRCUIT)

TO FAN CIRCUIT

2850/1550

ENGINE SPEED

GEAR

PUMP

.071

2.48

1.031.03

P2P3

.56.56

FROM DECK MOTORS

CV2

5 PSI

CV1

P1 CD2

PSI

FROM STEERING CONTROL VALVE

FROM DECK CONTROL MANIFOLD

Reelmaster 7000Hydraulic System Page 4 -- 40

Page 75

Procedure for Traction Circuit Relief Pressure Test

1. Make sure hydraulic oil is at normal operating temperaturebyoperatingthemachineforapproximatelyten (10) minutes. Make sure the hydraulic tank is full.

CAUTION

Movemachinetoanopenarea,awayfrompeople and obstructions.

2. Drive machine to an open area, lower cutting units, turn the engine off and apply parking brake.

CAUTION

Prevent personal injury and/ordamage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

NOTE: Seal leakage across pilot directional valves

PD1 and PD2 in 4WD/2WD control manifold can also cause low forward traction pressure with reverse pressure meeting specifications.

NOTE: Forwardand reverse reliefvalves are identical. Relief valves can be switched in piston (traction) pump to help in identifying a faulty relief valve.

9. When testing is completed, disconnect pressure gauge from test port. Install dust cap to test port fitting.

3. Connect a 10,000 PSI (700 bar) pressure gauge to traction circuit test port for function to be checked (forward or reverse) (Fig. 29). Test ports are located on hydraulic lines toward the front of machine. Forward

traction port faces the front and reverse port faces rearward.

4. After installingpressure gauge, start engineand run at low idle speed. Check for hydraulic leakage and correct before proceeding with test.

5. Move throttle to high idle speed (2850 RPM).Make sure that mow speed limiter is in the transport (2WD) position. Release parking brake.

6. Withseatoccupied,applybrakes fullyandslowlydepress the traction pedal in the appropriate direction. While pushing traction pedal, identify pressure reading on gauge as relief valve opens:

GAUGE READING TO BE:

Forward: 4800 to 5300 PSI (332 to 365 bar) Reverse: 4800 to 5300 PSI (332 to 365 bar)

7. Release traction pedal andstop engine. Recordtest results.

Figure 29

1. Forward traction port (faces forward)

2. Reverse traction port (faces rearward)

RIGHT

FRONT

Figure 30

1. Forward relief valve

2. Reverse relief valve

3. Traction pump

System

Hydraulic

8. If traction pressure is too low, makes sure that bypass valve on traction pump is fully seated and then inspect traction pump relief valves in piston (traction) pump (Fig. 30). Clean or replace valves as necessary. These cartridge type valves are factory set and are not adjustable. If relief valves are in good condition, piston (traction) pump, wheel motors and/or rear axle motor should be suspected of wear and inefficiency.

Reelmaster 7000 Hydraulic SystemPage 4 -- 41

Page 76

Traction Circuit Reducing Valve (PR) Pressure Test (Using Pressure Gauge)

FROM STEERING AND LIFT CIRCUITS (CHARGE CIRCUIT)

AXLE

MOTOR

REAR

CHG M1

2.48

PRESSURE

GAUGE

Working Pressure Low Pressure Return or Suction

Flow

.052

450 PSI

CR2

CD1T

CR1

CV1

207 PSI

PD1

.091

2.01

PD2

FRONT

MOTORS

PSI

5000

PISTON PUMP

550 PSI

CHG

VALVE

BYPASS

PSI

5000

TO DECK CONTROLMANIFOLD

TO STEERING AND LIFT CIRCUITS

(CHARGE CIRCUIT)

TO FAN CIRCUIT

ENGINE SPEED

.071

2850/1550

GEAR

PUMP

.071

2.48

1.031.03

P2P3

.56.56

FROM DECK MOTORS

Rev. A

PSI

P1 CD2

FROM STEERING CONTROL VALVE

FROM DECK CONTROL MANIFOLD

CV2

5PSI

CV1

Reelmaster 7000Hydraulic System Page 4 -- 42

Page 77

NOTE: Whenin reverse, pressure reducingvalve (PR) limits the pressureto the rear axle motor to 450 PSI (31 bar) so the rear wheels will not scuff the turf.

Procedure for Traction Circuit Pressure Reducing Valve(PR)PressureTest

1. Make sure hydraulic oil is at normal operating temperaturebyoperatingthemachineforapproximatelyten (10) minutes. Make sure the hydraulic tank is full.

2. Parkmachineona levelsurfacewiththecutting units loweredand off.Makesure engineis offand theparking brake is engaged.

CAUTION

Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

3. Connect a 1000 PSI (70 bar) pressure gauge to test fitting(portG)onrearsideof4WD/2WDcontrolmanifold under front of machine (Figs. 31 and 32).

4. After installing pressure gauge, start engineand run at low idle speed. Check for hydraulic leakage and correct before proceeding with test.

RIGHT

FRONT

Figure 31

1. 4WD/2WD manifold 2. Reducing valve (PR)

System

Hydraulic

5. Move throttle to high idle speed (2850 RPM).Make sure that mow speed limiter is in the mow (4WD) position. Release parking brake.

6. Withseat occupied,applybrakesfully and slowlydepress the traction pedal in the reverse direction. While pushing traction pedal, carefully monitor the pressure gauge. Pressure should increase until the pressure reducing valve opens.

GAUGE READING TO BE 420 to 470 PSI (29 to 32 bar).

7. Release traction pedal, stop engine and record test results.

8. If specification is not met, clean or adjust pressure reducing valve (port PR) located on the right side of the 4WD/2WDcontrolmanifold(Fig.33)(seeAdjustControl ManifoldRelief Valvesin theAdjustments sectionof this chapterforvalveadjustmentprocedure).Recheckreducing valve pressure after adjustment.

9. When testing is completed, disconnect pressure gauge from test port. Install dust cap to test port fitting.

Figure 32

1. 4WD/2WD manifold 2. Test fitting (port G)

FRONT

Figure 33

1. 4WD/2WD manifold 2. Reducing valve (PR)

Reelmaster 7000 Hydraulic SystemPage 4 -- 43

Rev. A

Page 78

Rear Traction Circuit Relief (RV) Pressure Test (Using Pressure Gauge)

FROM STEERING

AND LIFT CIRCUITS

(CHARGE CIRCUIT)

CHG M1

AXLE

MOTOR

REAR

2.48 M2

PRESSURE

GAUGE

Working Pressure Low Pressure Return or Suction

Flow

PD1

PISTONPUMP

550 PSI

CHG

VALVE

BYPASS

PSI

5000

PD2

2.01

FRONT

MOTORS

2.01

PSI

5000

.091

.052

450 PSI

CR2

CV1

CR1

207 PSI

CD1T

TO DECK CONTROL MANIFOLD

TO STEERING AND LIFT CIRCUITS

(CHARGE CIRCUIT)

TO FAN CIRCUIT

ENGINE SPEED

.071

2850/1550

GEAR

PUMP

.071

2.48

1.031.03

P2P3

.56.56

FROM DECK MOTORS

Rev. A

PSI

P1 CD2

FROM STEERING CONTROL VALVE

FROM DECK CONTROL MANIFOLD

CV2

5PSI

CV1

Reelmaster 7000Hydraulic System Page 4 -- 44

Page 79

NOTE: Adjustable relief valve (RV) in the 4WD/2WD control manifold reduces rear axle motor pressure created in down hill, dynamic braking conditions to prevent rear wheel lock up.

ProcedureforRearTractionCircuitRelief(RV)Pressure Test

1. Make sure hydraulic oil is at normal operating temperaturebyoperatingthemachineforapproximatelyten (10) minutes. Make sure the hydraulic tank is full.

2. Parkmachineona levelsurfacewiththecutting units loweredand off.Makesure engineis offand theparking brake is engaged.

CAUTION

Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

NOTE: Rear traction circuit relief (RV) pressure should

beat least100 PSI(7 bar)higher thantraction circuitreducing (PR) pressure. If the difference in these pressures is less than 100 PSI (7 bar), reverse traction performance may be affected.

10.If specification is not met, clean or adjustrelief valve (RV) which is located on the left side of the 4WD/2WD controlmanifoldintheRVport(Fig.34)(seeAdjust ControlManifold Relief Valves inthe Adjustments section of this chapter for valve adjustment procedure). Recheck relief (RV) pressure after adjustment.

11.When testing is completed, disconnect pressure gauge from test port. Install dust cap to test port fitting.

RIGHT

FRONT

3. Measure and record traction circuit pressure reducing valve (PR) pressure (see Traction Circuit Pressure Reducing Valve (PR) Pressure Test in this section).

4. Connect a 1000 PSI (70 bar) pressure gauge to test fitting(portG)onrearsideof4WD/2WDcontrolmanifold under front of machine (Figs. 34 and 35). This is the samepressure gauge positionas used tomeasure traction circuit pressure reducing valve (PR) pressure.

5. After installing pressure gauge, start engineand run at low idle speed. Check for hydraulic leakage and correct before proceeding with test.

6. Move throttle to high idle speed (2850 RPM).Make sure that mow speed limiter is in the mow (4WD) position. Release parking brake.

7. Operate the machine in mow speed (4WD) with the cuttingunitslowered.Drivedownaslopeinaforwarddirection and decrease pressure on the traction pedal whilecarefullymonitoringthepressure gauge.Pressure should increase until relief valve (RV) lifts.

8. Stop engine and record test results.

Figure 34

1. 4WD/2WD manifold 2. Relief valve (RV)

System

Hydraulic

9. Relief (RV) pressure should be at least 100 PSI (7 bar) higher than the traction circuit pressure reducing valve (PR) pressure and also be between 520 and570 PSI (36to39 bar) (e.g.if thepressure reducing

valve(PR)pressureis450 PSI(31bar),relief (RV)pressure should be from 550 to 570 PSI (38 to 39 bar)).

Reelmaster 7000 Hydraulic SystemPage 4 -- 45

Figure 35

1. 4WD/2WD manifold 2. Test fitting (port G)

Rev. A

Page 80

Piston (Traction) Pump Flow Test (Using Tester with Pressure Gauges and Flow Meter)

FROM STEERING AND LIFT CIRCUITS (CHARGE CIRCUIT)

CHG M1

2.48

AXLE

MOTOR

REAR

Working Pressure Low Pressure Return or Suction

Flow

TESTER

PISTON PUMP

.052

450 PSI

CR2

CV1

CR1

207 PSI

CD1T

PD1

.091

2.01

FRONT

5000

PD2

MOTORS

PSI

550 PSI

CHG

VALVE

BYPASS

PSI

5000

TO DECK CONTROL MANIFOLD

TO STEERING AND LIFT CIRCUITS

(CHARGE CIRCUIT)

TO FAN CIRCUIT

2850/1550

ENGINE SPEED

GEAR

PUMP

.071

2.48

1.031.03

P2P3

.56.56

FROM DECK MOTORS

CV2

5 PSI

CV1

P1 CD2

PSI

FROM STEERING CONTROL VALVE

FROM DECK CONTROL MANIFOLD

Reelmaster 7000Hydraulic System Page 4 -- 46

Page 81

Procedure for Piston (Traction) Pump Flow

Thistest measures piston(traction) pump output(flow). During this test, pump load is created at the flow meter using the adjustable load valve on the tester.

IMPORTANT: Traction circuit flow for the Reelmaster 7000 is approximately 30 GPM (113.5 LPM). Use 40 GPM Hydraulic Tester #AT40002 (pressure and flow)for thistest (seeSpecial Toolsin this chapter).

1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes.Make sure the hydraulic tank is full.

2. Parkmachineona level surfacewiththecuttingunits raised and off. Make sure that the mow speed limiter is in the transport speed (2WD) position to ensure that traction pedal can move piston (traction) pump to full stroke. Shut off engine.

Test

CAUTION

Prevent personal injury and/ordamage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

3. Make sure that traction pedal is adjusted to the neutral position. Also, ensure that piston (traction) pump is atfull stroke when tractionpedal is pushed into fully forward position.

7. Startengineand runatlow idlespeed.Check forany hydraulic leakage from tester and hose connections. Correct any leaks before proceeding.

8. Move throttleso engine is runningat high idlespeed (2850 RPM).

9. Slowly push traction pedal to fully forward position. Keep pedal fully depressed in the forward position.

10.Havesecondpersoncarefullywatchpressuregauge ontester while slowly closingthe flow controlvalve until 1000PSI(69bar)isobtained. Verifywithaphototacthat the engine speed is still 2850 RPM.

NOTE: Ifengine speed drops below 2850 RPM, piston pump flow will decrease.

11.Observe flowgauge. Ifpiston pumpis ingood condition, flow indication should be approximately 29 GPM (110 LPM).

12.Release traction pedal to the neutral position, open flow control valve on tester and shut off engine. Record test results.

13.If flow is less than 26 GPM (98 LPM), consider the following:

A. Thepistonpump swashplate isnot beingrotated fully(e.g. mowspeedlimiter isnot intransportspeed (2WD)position, traction pedallinkage may needadjustment).

B. The piston (traction) pump needs to be repaired or replaced as necessary.

System

Hydraulic

4. Raise and support machine so all wheels are off the ground(see JackingInstructionsin Chapter1 -- Safety).

5. Thoroughly cleanjunction of hydraulic hoseand left sidefitting on bottomof piston pump(forward port) (Fig.

36). Disconnect hose from left side pump fitting.

6. Install 40 GPM Hydraulic Tester #AT40002 (pressureand flow)in series between piston pumpfitting and disconnected hose to allow flow from piston pump to tester.Use hydraulic hose kit (see Special Tools in this chapter)toconnecttestertomachine. Make sure thatfittingand hose connections areproperly tightened. Also, make sure the flow control valve on tester is fully open.

14.Makenecessary repairs beforeperforminganyadditional tests.

15.When testing is complete, disconnect tester and hose kit from pump fitting and machine hydraulic hose. Connect machine hydraulic hose to pump fitting. Lower machine to ground.

CAUTION

Allwheelswillbe off thegroundand rotating during this test. Make sure machine is supported so itwillnotmoveand accidentally fall topreventinjuring anyone near the machine.

1. Piston (traction) pump 2. LH fitting (forward port)

Reelmaster 7000 Hydraulic SystemPage 4 -- 47

RIGHT FRONT

Figure 36

Page 82

Mow Circuit Pressure Test (Using Pressure Gauge)

M1M4

TO RESERVOIR

TEST FOR FRONT

CUTTING UNITS SHOWN

MV1

OR1

CV1

CV2

OR2

M3M2

M3M4M1 M2

MOW

MV2

CONTROL MANIFOLD

PRESSURE

GAUGE

FROM FAN CONTROL TO STEERING AND LIFT CIRCUITS

TO FAN CIRCUIT

FROM REEL MOTORS

RV1

P2P3

LC2LC1

RV2

1.031.03

SP1

G1 G2

P1 T2 T1 P2

GEAR PUMP

.56.56

2.48

SP2

ENGINE SPEED

2850/1550

.071

.091

5000

PSI

PISTON PUMP

BYPASS

VALVE

5000 PSI

Working Pressure Low Pressure Return or Suction

Flow

FROM STEERING CONTROL

PSI

CV1 40

CV2

5 PSI

207 PSI

P1 CD2

CV1

CD1T

CR2 CR1

Reelmaster 7000Hydraulic System Page 4 -- 48

Page 83

Procedure for Mow Circuit Pressure Test

1. Make sure hydraulic oil is at normal operating temperaturebyoperatingthemachineforapproximatelyten (10) minutes. Make sure the hydraulic tank is full.

2. Parkmachineona level surfacewiththecuttingunits loweredand off.Makesure engine isoffand theparking brake is engaged.

3. Raisehood toallow accessto mow controlmanifold.

CAUTION

Prevent personal injury and/ordamage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

9. Disengage cutting units and shut offengine. Record test results.

10.Aftertestingiscomplete,disconnectpressuregauge frommanifoldtestport.Installdustcap to testportfitting. If necessary, repeat test for other mow circuit.

11.Lowerand secure hood afterall mowc ircuit pressure testing is completed.

4. Install 5000 PSI (350 bar) pressure gauge with hydraulic hose attached to mow control manifold test port for the mow circuit (front or rear cutting units) to be tested(Fig.37).Manifoldtest port G1shouldbeusedfor the front reel circuit and G2 should be used for the rear reel circuit.

5. After installingpressure gauge, start engineand run at low idle speed. Check for hydraulic leakage and correct before proceeding with test.

6. Move throttle to high idle speed (2850 RPM).Make sure that mow speed limiter is in the mow (4WD) position. Release parking brake.

CAUTION

Cuttingreel blades will rotate when lowered with PTO switch in ON position. Keep away from cutting units during test to prevent personal injury fromrotating reelblades. Donot standin front of the machine during test.

FRONT

Figure 37

1. Test port G1 (front cutting units)

2. Test port G3 (rear cutting units)

#4 #1 #5

#3#2

System

Hydraulic

7. With seat occupied, engage the mow circuit. Watch pressure gauge carefully while mowing with the machine.

8. Mow circuit pressure should be from 1000 to 3000 PSI (69 to 207 bar) and will vary depending on mowing conditions.

Reelmaster 7000 Hydraulic SystemPage 4 -- 49

CUTTING UNIT LOCATIONS

Figure 38

Page 84

Mow Circuit Relief Pressure Test (Using Tester with Pressure Gauges and Flow Meter)

M1M4

TO RESERVOIR

M3M2

TEST FOR PUMP

SECTION P1 SHOWN

FROM FAN CONTROL TO STEERING AND LIFT CIRCUITS

TO FAN CIRCUIT

TESTER

MV1

OR1

SP1

G1 G2

P1 T2 T1 P2

GEAR PUMP

.56.56

RV1

P2P3

CV1

CV2

LC2LC1

RV2

1.031.03

M3M4M1 M2

OR2

SP2

2.48

MV2

ENGINE SPEED

2850/1550

.071

MOW CONTROL MANIFOLD

5000

PSI

.091

Working Pressure Low Pressure Return or Suction

Flow

PISTON PUMP

BYPASS

VALVE

5000 PSI

FROM REEL MOTORS

FROM STEERING CONTROL

PSI

CV1 40

CV2

5 PSI

207 PSI

P1 CD2

CV1

CD1T

CR2 CR1

Reelmaster 7000Hydraulic System Page 4 -- 50

Page 85

Themowcircuit reliefpressuretestshouldbeperformed to make sure that the mow circuit relief pressures are correct.

CAUTION

Procedure for Mow Circuit Relief Pressure Test

1. Make sure hydraulic oil is at normal operating temperaturebyoperatingthemachineforapproximatelyten (10) minutes. Make sure the hydraulic tank is full.

2. Parkmachineona level surfacewiththecuttingunits loweredand off.Makesure engine isoffand theparking brakeis engaged.Also, make surethat thebacklap leverson themow control manifoldare inthe mow position (F on the manifold).

CAUTION

Prevent personal injury and/ordamage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

3. Determine mow manifold relief pressure to be tested:

A. For pump section (P1), mow manifold relief is tested at the forward direction supply hose (front hose) to the cutting unit #4 motor (Fig. 39).

B. For pump section (P2), mow manifold relief is tested at the forward direction supply hose (front hose) to the cutting unit #2 motor (Fig. 39).

9. With seat occupied, engage the cutting units.

10.Have a second person carefully watch tester pressuregaugewhileslowlyclosingtheflow controlvalveon tester.

11.As the relief valve lifts, system pressure should be from 2800 to 3200 PSI (193 to 220 bar).

12.After noting the relief pressure, open the tester flow control valve, disengage cutting units and stop the engine. Record test results.

13.If specificationis not met,clean oradjust reliefvalve (RV1 or RV2) in the mow control manifold. See Adjust Control Manifold Relief Valves in the Adjustments section of this chapter for valve adjustment procedure. Recheck relief valve pressure setting after adjustment.

14.After testing iscomplete, disconnect testerfrom cuttingunitmotor andhose.Connect hydraulic hosetomotor.

#4 #1 #5

System

Hydraulic

4. Thoroughly clean junction of appropriate hydraulic supply hose and cutting unit motor fitting. Disconnect the supply hydraulic hose from the motor.

IMPORTANT: Make sure that the oil flow indicator arrow on the tester is showing that the oil will flow fromthe disconnected hose, through the tester and into the hydraulic motor.

5. Install tester with pressure gauge and flow meter in series with the disconnected hose and front motor fitting.

6. Make surethe flow control valve on the testeris fully open.

7. Startengine and runat lowidle speed.Check for hydraulicleakage andcorrectbefore proceedingwith test.

8. Move throttle to high idle speed (2850 RPM).Make sure that mow speed limiter is in the mow (4WD) position. Release parking brake.

Reelmaster 7000 Hydraulic SystemPage 4 -- 51

CUTTING

UNIT

LOCATIONS

RETURN

HOSE

#2 #3

Figure 39

FRONT

Figure 40

SUPPLY

HOSE

Page 86

Cutting Unit Motor Case Drain Leakage Test (Using Tester with Pressure Gauges and Flow Meter)

TO RESERVOIR

STEEL

CAP

MEASURING CONTAINER

TEST FOR #4 CUTTING

UNIT MOTOR SHOWN

TESTER

M1M4

G1 G2

MV1

SP1

OR1

CV1

RV1

CV2

LC2LC1

RV2

M3M4M1 M2

OR2

SP2

M3M2

MV2

MOW CONTROL MANIFOLD

RETURN

HOSE

Working Pressure Low Pressure Return or Suction

Flow

CASE

DRAIN

HOSE

FROM FAN CONTROL

TO OIL COOLER

SUPPLY

HOSE

FRONT

P1 T2 T1 P2

FROM GEAR

PUMP P1

FROM GEAR PUMP P2

Reelmaster 7000Hydraulic System Page 4 -- 52

Page 87

Procedure for Cutting Unit Motor Case Drain Leakage Test

NOTE: Over a period of time, a cutting unit motor can

wear internally.A worn motor may bypass oil to its case drain causing the motor to be less efficient. Eventually, enoughoil losswill cause themotor tostall underheavy cutting conditions. Continued operation with a worn, inefficient motor can generate excessive heat, cause damageto seals and other componentsin thehydraulic system and affect quality of cut.

NOTE: One method to find a failing or malfunctioning cuttingunit motoris tohave another personobserve the machinewhilemowingindense turf.Abadmotorwillrun slower,produce fewerclippings andmay cause a different appearance on the turf.

1. Make sure hydraulic oil is at normal operating temperaturebyoperatingthemachineforapproximatelyten (10) minutes. Make sure the hydraulic tank is full.

CAUTION

6. Move throttle to high idle speed (2850 RPM).Make sure that mow speed limiter is in the mow (4WD) position. With seat occupied, release the parking brake and engage the cutting units.

7. While watching tester pressure gauge, slowly close flow control valve on tester until a pressure of 1200 PSI

(83 bar) is obtained. NOTE: Use a graduated container, special tool

TOR4077, to measure case drain leakage.

2. Parkmachineona level surfacewiththecuttingunits loweredand off.Makesure engine isoffand theparking brake is engaged.

CAUTION

Prevent personal injury and/ordamage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

NOTE: Thecuttingunitmotors are connectedinseries.

To isolate a faulty motor, all motors in the circuit may have to be tested by starting with the first motor in the circuit (see Hydraulic Schematic).

IMPORTANT: Make sure that the oil flow indicator arrow on the tester is showing that the oil will flow from the motor fitting, through the tester and into the disconnected hose.

3. Disconnect hydraulic return hose (rear hose) from themotortobetested. Install testerwithpressuregauge and flow meter in series with the motor and the disconnectedreturn hose. Makesure the flowcontrol valve on tester is fully open.

8. Have a second person measure flow from the case drain line for fifteen (15) seconds, then move the PTO switch to OFF, open the tester flow control valve and stop the engine. Record test results.

TESTRESULTS:Case drain leakageshouldbe less than22.4ounces(662ml) ofhydraulic fluidinfifteen (15) seconds (0.7 GPM / 2.7 LPM).

9. Ifcase drainflow is more than 22.4 ounces (662ml) in fifteen (15) seconds, the reel motor is worn or damaged and should be repaired or replaced.

10.Disconnect tester from motor and hose. Reconnect hose to the cutting unit motor. Remove cap from bulkhead fitting and reconnect case drain hose.

11.Repeat test for additional reel motors if required.

#4 #1 #5

#3#2

System

Hydraulic

4. Disconnectthe motor case drain hose(small diameter hose) where it connects to bulkhead fitting at the framerail (not at themotor). Put asteel cap onthe bulkhead fitting; leave the case drain hose open.

5. Startengine and runat lowidle speed.Check for hydraulicleakage andcorrectbefore proceedingwith test.

Reelmaster 7000 Hydraulic SystemPage 4 -- 53

CUTTING UNIT LOCATIONS

Figure 41

Page 88

Gear Pump P1 and P2 Flow (Mow Circuits) Test (Using Tester with Pressure Gauges and Flow Meter)

M1M4

TO RESERVOIR

M3M4M1 M2

MV1

MV2

M3M2

MOW CONTROL MANIFOLD

TEST FOR GEAR PUMP

SECTION P1 SHOWN

FROM FAN CONTROL TO STEERING AND LIFT CIRCUITS

TO FAN CIRCUIT

TO OIL COOLER

OR1

SP1

RV1

G1 G2

P1 T2 T1 P2

CV1

CV2

LC2LC1

RV2

OR2

SP2

TESTER

ENGINE SPEED

2850/1550

GEAR PUMP

.071

.56.56

P2P3

2.48

1.031.03 .071

.091

5000

PSI

PISTON PUMP

BYPASS

VALVE

5000 PSI

Working Pressure Low Pressure Return or Suction

Flow

FROM RESERVOIR FROM FILTRATION MANIFOLD

Reelmaster 7000Hydraulic System Page 4 -- 54

Page 89

The gear pump P1 and P2 flow tests should be performed to make sure that the mow circuits have adequate hydraulic flow.

NOTE: GearpumpP1supplieshydraulic flow tocutting units 1, 4 and 5. Gear pump P2 supplies flow to cutting units 2 and 3.

7. Movethrottle tohigh idlespeed (2850 RPM). Do not

engage the cutting units. IMPORTANT: Do not fully restrict oil flow through

tester. In this test, the flow tester is positioned beforethecircuit reliefvalve.Pump damage canoccur if the oil flow is fully restricted.

Procedure for Gear Pump P1 and P2 Flow Test NOTE: Overa periodoftime,thegearsandwearplates

inthe gearpump can wear.A worn pump will bypass oil andmakethepumplessefficient.Eventually,enoughoil losswilloccurtocausethecuttingunit motors to stallunder heavy cutting conditions. Continued operation with a worn, inefficient pump can generate excessive heat and cause damage to the seals and other components in the hydraulic system.

1. Make sure hydraulic oil is at normal operating temperaturebyoperatingthemachineforapproximatelyten (10) minutes. Make sure the hydraulic tank is full.

2. Parkmachineona level surfacewiththecuttingunits loweredand off.Makesure engine isoffand theparking brake is engaged.

3. Raiseand supporthood to allow access topump assembly.

CAUTION

8. Watch tester pressure gauge carefully while slowly closing the flow control valve on tester until 2000 PSI

(138bar) is obtained. Verifywith a phototac thatthe engine speed is 2850 RPM.

9. For a pump in good condition, flowindication should be approximately 12 GPM (45.4 LPM).

10.Fully open flow control valve on tester and thenshut engine off. Record test results.

11.If measured flow is less than 10.8 GPM (40.8 LPM) orapressure of2000 PSI (138bar) cannot beobtained, checkfor restriction inthe pumpintakeline (includingoil filterand oil cooler). Ifline is notrestricted, remove gear pump and repair or replace as necessary.

12.After testing is complete, disconnect tester from hydraulic hose and fitting. Connecthose to thegear pump fitting.

13.Repeat test for second pump section if required.

14.Lower and secure hood after testing is completed.

System

Hydraulic

Prevent personal injury and/ordamage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

4. Locate gear pump section to be tested (P1 or P2). Thoroughlycleanjunctionof appropriatehydraulichose and gear pump fitting. Disconnect hydraulic hose from hydraulic fitting in gear pump (Fig. 42).

IMPORTANT: Make sure that the oil flow indicator arrow on the tester is showing that the oil will flow from the gear pump fitting, through the tester and into the disconnected hose.

5. Install tester with pressure gauge and flow meter in series with the disconnected hose and fitting in gear pump section. Make sure the flow control valve on

the tester is fully open.

6. After installingtester,start engineand run atlow idle speed. Check for hydraulic leakage and correct before proceeding with test.

RIGHT

FRONT

1. Gear pump

2. Pump section P1 hose

Figure 42

3. Pump section P2 hose

Reelmaster 7000 Hydraulic SystemPage 4 -- 55

Page 90

Steering Circuit Relief Pressure Test (Using Pressure Gauge)

M1M4

MV1

CV1

RV1

CV2

LC2LC1

RV2

OR2

OR1

SP1

G1 G2

P1 T2STT1 P2

G2 G1

M1 M2

PRV

FAN CONTROL MANIFOLD

TP1

LP2

M3M4M1 M2

MV2

SP2

M3M2

MOW CONTROL MANIFOLD

TO LIFT MANIFOLD

STEERING WHEEL TURNED

FOR RIGHT TURN

STEERING CYLINDER

STEEL

CAP

ENGINE SPEED

2850/1550

GEAR PUMP

.071

1050

PSI

6.1 PB

P2P3

.56.56

2.48

1.031.03

CV2

5 PSI

CV1 40

PSI

.091

.071

P1 CD2

5000

PSI

207 PSI

CV1

PISTON PUMP

BYPASS

VALVE

5000 PSI

CD1T

CR2 CR1

PRESSURE

GAUGE

Working Pressure Low Pressure Return or Suction

Flow

Reelmaster 7000Hydraulic System Page 4 -- 56

Page 91

The steering circuit relief pressure test should be performed to make sure that thesteering circuit relief pressure is correct.

Procedure for Steering Circuit Relief Pressure Test

1. Make sure hydraulic oil is at normal operating temperaturebyoperatingthemachineforapproximatelyten (10) minutes. Make sure the hydraulic tank is full.

9. If steering relief pressure is incorrect, inspect steeringrelief valve locatedin the steeringcontrol valve (see Steering Control Valve Service in the Service and Repairs section of this chapter). If relief valve is operating properly and if lift/lower problems alsoexist, gear pump P3 should be suspected of wear or damage. If steering wheel continues to turn at end of cylinder travel (with lower than normal effort), steering cylinder or steering control valve may be worn or damaged.

2. Parkmachineona level surfacewiththecuttingunits loweredand off.Makesure engine isoffand theparking brake is engaged.

CAUTION

Prevent personal injury and/ordamage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

3. Thoroughly clean junction of hydraulic hose and steering cylinder fitting at the barrel end of the steering cylinder (Fig. 43). Disconnect hose from fitting in barrel end of steering cylinder.

4. Install 5000 PSI (350 bar) pressure gauge with hydraulichoseattachedtodisconnectedhose.Installsteel cap on steering cylinder fitting to prevent any leakage from cylinder.

5. After installingpressure gauge, start engineand run at low idle speed. Check for hydraulic leakage and correct before proceeding with test.

6. Move throttle to full engine speed (2850 RPM).

IMPORTANT: While testing, rotate steering wheel only long enough to get a system relief pressure reading. Holding the steering circuit at relief pressure for an extended period may damage the steering control valve.

10.Whentestingiscomplete,turnsteeringwheeltoboth the right and the left with the engine not running to relievesteering circuitpressure.Remove pressuregauge fromhydraulichoseand steel capfromsteeringcylinder fitting. Connect hydraulic hose to steering cylinder fitting.

RIGHT

FRONT

Figure 43

1. Steering cylinder

2. Barrel end hose

3. Barrel end fitting

4. Rear axle

System

Hydraulic

7. Turnsteering wheel to the right while monitoring the pressure gauge. When steering circuit pressure reaches the relief pressure setting, pressure should stabilize briefly and then may continue toincrease. The steering circuit relief pressure is the gauge reading when pressure stabilizes.

GAUGEREADINGTOBE1150TO 1500 PSI (80 to

103 bar)

8. Stop the engine. Record test results.

Reelmaster 7000 Hydraulic SystemPage 4 -- 57

Page 92

Steering Cylinder Internal Leakage Test

STEERING

CYLINDER FULLY

EXTENDED

LOOK FOR

LEAKAGE

STEERING WHEEL

TURNED FOR

RIGHT TURN

FROM FAN CONTROL MANIFOLD

STEEL

PLUG

6.1

1050

PSI

TO FILTRATION MANIFOLD

TO CHARGE CIRCUIT

Reelmaster 7000Hydraulic System Page 4 -- 58

Page 93

The steering cylinder internal leakage test should be performed if a steering problem is identified. This test will determine if the steering cylinder is faulty.

7. After testing is completed, remove plug from the hydraulic hose. Connect hose to the steering cylinder fitting.

Procedure for Steering Cylinder Internal Leakage Test

NOTE: Steering circuit operation will be affected by

rear tire pressure, binding of steering cylinder, extra weightonthe vehicle and/or binding of rear axle steering components. Make sure that these items are checked before proceeding with steering cylinder internal leakage test.

1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes.Make sure the hydraulic tank is full.

2. Parkmachineona level surfacewiththecuttingunits lowered and off. Turn the steering wheel for a right turn so that the steering cylinder is fully extended. Turn engine off and apply the parking brake.

CAUTION

Prevent personal injury and/ordamage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

8. Ifa steering problemexists andthe steering cylinder tested acceptably, consider the following:

A. Gear pump section P3 (steering, lift/lower and chargecircuits)iswornordamaged(seeGearPump P3 Flow Test in this section).

NOTE: If gear pump P3 is worn or damaged, charge, steering and lift circuits will all be affected.

B. Theflow dividerinthefandrivecontrolmanifoldis faulty(see FanDrive Manifold Servicein theService and Repairs section of this chapter).

C. The steering control valve requires service (see Steering Control Valve and Steering Control Valve Service in the Service and Repairs section of this chapter).

9. Check oil level in hydraulic reservoir and adjust if needed.

System

Hydraulic

3. Thoroughlycleantheareaaroundthe hydraulichose at the rod end of the steering cylinder.

4. Place a drain pan under the steering cylinder. Removehydraulichosefromthefittingontherodendofthe steeringcylinder.Installa steelplugin thedisconnected hose.

5. Remove all hydraulic oil from drain pan. Make sure that empty drain pan remains under the open fitting of the steering cylinder.

6. Withthe engineoff,turnthe steeringwheel for aright turn. Observe the open fitting on the extended steering cylinder as the steering wheel is turned.If oil comes out of the fitting while turning the steering wheel, the steering cylinder has internal leakage and must be repaired (seeSteering Cylinder andSteering Cylinder Servicein the Service and Repairs section of thischapter). Check drain pan for any evidence ofoil that would indicatecylinder leakage.

Figure 44

1. Steering cylinder 2. Rod end fitting

Reelmaster 7000 Hydraulic SystemPage 4 -- 59

Page 94

Lift/Lower Circuit Relief Pressure Test (Using Pressure Gauge)

CONTROL

MANIFOLD

LIFT

RV2

RV1

FROM STEERING

CONTROL VALVE

TO CHARGE

CIRCUIT

PRESSURE

GAUGE

FROM FAN CONTROL MANIFOLD

Working Pressure

Low Pressure Return or Suction

Flow

Reelmaster 7000Hydraulic System Page 4 -- 60

Page 95

The lift/lower circuit relief pressure test should be performed to make sure that the cutting unit lift and lower circuit relief pressure is correct.

Procedure for Lift/Lower Circuit Relief Pressure Test

1. Make sure hydraulic oil is at normal operating temperaturebyoperatingthemachineforapproximatelyten (10) minutes. Make sure the hydraulic tank is full.

2. Parkmachineona level surfacewiththecuttingunits fully lowered. Apply the parking brake and stop engine.

CAUTION

9. If specification is not met, clean oradjust relief valve RV1 located in the lift control manifold (see Lift Control Manifold Service in the Service and Repairs section of this chapter).

A. If pressure is too high, adjust relief valve RV1 to reduce lift/lower circuit relief pressure (see Adjust Control Manifold Relief Valves in the Adjustments section of this chapter).

B. Ifpressure is too low, check for restriction ingear pump intake line. Check the lift cylinders for internal leakage. If pump intake line is not restricted and lift cylinders are not leaking, adjust relief valve RV1 to increase lift/lower circuit relief pressure (see Adjust Control Manifold Relief Valves in the Adjustments section of this chapter).

Prevent personal injury and/ordamage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

3. Raise and support hood to gain access to lift control manifold (Fig. 45). Connect a 5000 PSI (350 bar) pressure gauge with hydraulic hose attached to lift manifold testport G. Routegauge hoseto allowhoodto besafely lowered.

4. After installingpressure gauge, start engineand run at low idle speed. Check for hydraulic leakage and correct before proceeding with test.

5. Move throttle to full engine speed (2850 RPM).

6. Whilesitting onthe seat,movelift switchtoraise and allowthecuttingunitstofullyraise. Momentarily holdthe switch with the lift cylinders fully retracted while looking at the pressure gauge.

7. When the lift cylinders are fully retracted (cutting units fully raised) and the relief valve lifts, the pressure gauge needle will momentarily stop. System pressure asthe reliefvalveRV1opensshouldbebeapproximately 1700 PSI (117 bar). Release lift switch to the neutral position after observing relief valve pressure.

C. If pressure is still too low after relief valve adjustment,lift cylinder(s) orgear pump P4 should besuspected of wear or damage.

10.After testing is completed, remove pressure gauge frommanifoldtestport.Installdustcap to testportfitting. Lower and secure hood.

Figure 45

1. Testport G1 2. Relief valve RV1

System

Hydraulic

NOTE: Ifliftswitchcontinues tobe pressed afterthe relief valve has opened, system pressure can increase higher than relief pressure.

8. Stop the engine and record test results.

Reelmaster 7000 Hydraulic SystemPage 4 -- 61

Page 96

Gear Pump P3 Flow (Steering and Lift/Lower Circuits) Test (Using Tester with Pressure Gauges and Flow Meter)

TO STEERING AND LIFT CIRCUITS

TO FAN CIRCUIT

TO MOW CONTROL

MANIFOLD (P2 PORT)

TESTER

GEAR PUMP

TO MOW CONTROL MANIFOLD (P1 PORT)

ENGINE SPEED

2850/1550

.091

5000

PSI

.071

.56.56

P2P3

2.48

1.031.03 .071

PISTON PUMP

BYPASS

VALVE

5000 PSI

FROM RESERVOIR FROM FILTRATIONMANIFOLD

Working Pressure Low Pressure Return or Suction

Flow

Reelmaster 7000Hydraulic System Page 4 -- 62

Page 97

The gear pump P3 flow test should be performed to make sure that the steering, lift and traction charge circuits have adequate hydraulic flow.

NOTE: GearPumpP3 suppliesoilflow forthe steering, lift and traction charge circuits.

Procedure for Gear Pump P3 Flow Test

1. Make sure hydraulic oil is at normal operating temperaturebyoperatingthemachineforapproximatelyten (10) minutes. Make sure the hydraulic tank is full.

IMPORTANT: The pump is a positive displacement type. If pump flow is completely restricted or stopped, damage to the pump, tester or other components could occur.

8. While watching pressure gauges, slowly close flow control valve on tester until 1000 PSI (69 bar) is obtained on pressure gauge. Verify engine speed continues to be correct (2850 RPM).

9. For a pump in good condition, flowindication should be approximately 6.5 GPM (24.6 LPM).

2. Parkmachineona level surfacewiththecuttingunits loweredand off.Makesure engine isoffand theparking brake is engaged.

3. Raise hood to allow access to pump assembly.

CAUTION

Prevent personal injury and/ordamage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

4. Thoroughly clean junction of hydraulic hose and fitting in gear pump section P3 (Fig. 46). Disconnect hydraulic hose from fitting.

IMPORTANT: Make sure that the oil flow indicator arrow on the tester is showing that the oil will flow from the gear pump fitting, through the tester and into the disconnected hose.

5. Install testerwith pressure gaugesand flow meter in series with the disconnected hose and fitting in gear pumpsectionP3. Makesurethe flow controlvalveon

the tester is fully open.

10.Fully open flow control valve on tester and thenshut engine off. Record test results.

11.If the flowis lower than5.8GPM(22LPM)or apres- sure of 1000 PSI (69 bar) could not be obtained, check for restriction in pump intake line. If intake line is not restricted, remove gear pump and repair or replace as necessary.

12.After testing is complete, disconnect tester from hydraulic hose and fitting. Connecthose to thegear pump fitting. Lower and secure hood.

RIGHT

FRONT

System

Hydraulic

6. After installing tester, start engine and run at idle speed. Check for hydraulic leakage and correct before proceeding with test.

7. Movethrottle tofull speed(2850 RPM).DO NOTengage the cutting units.

Reelmaster 7000 Hydraulic SystemPage 4 -- 63

1. Gear pump section P3 2. Pump section P3 hose

Figure 46

Page 98

Cooling Fan Circuit Test (Using Pressure Gauge and Phototac)

G2 G1

PRESSURE

GAUGE

M1 M2

PRV

M1M4

FAN CONTROL MANIFOLD

TP1

LP2

MV1

CV1

RV1

P2P3

OR2

CV2

LC2LC1

RV2

2.48

1.031.03

OR1

SP1

G1 G2

P1 T2STT1 P2

GEAR PUMP

.56.56

M3M4M1 M2

MV2

SP2

ENGINE SPEED

2850/1550

M3M2

MOW CONTROL MANIFOLD

.071

.091

5000

PSI

TO LIFT MANIFOLD

PISTON PUMP

BYPASS

VALVE

5000 PSI

STEERING CYLINDER

CV2

5 PSI

CV1 40

PSI

6.1

1050

PSI

P1 CD2

CV1

207 PSI

CD1T

CR2 CR1

Working Pressure Low Pressure Return or Suction

Flow

Reelmaster 7000Hydraulic System Page 4 -- 64

Page 99

Thecoolingfancircuit testshouldbeperformed to make sure that the engine cooling fan circuit has the correct system pressure and fan speed.

Procedure for Cooling Fan Circuit Test

8. If pressure rises to approximately 3000 PSI (207 bar) but fan speed is low,consider that the fan motor is

worn or damaged. If pressure and fan speed are both low, consider that gear pump P4 is worn or damaged (see Gear Pump P4 Flow Test in this section).

1. Make sure hydraulic oil is at normal operating temperaturebyoperatingthemachineforapproximatelyten (10) minutes. Make sure the hydraulic tank is full.

2. Parkmachineona level surfacewiththecuttingunits loweredand off.Makesure engine isoffand theparking brake is applied.

CAUTION

Prevent personal injury and/ordamage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

3. Raiseand supporthoodto gainaccess tofancontrol manifold(Fig.47).Connecta 5,000 PSI(345bar)gauge with hydraulic hose attached to test fitting in port G2 on rear of manifold.

4. After installing tester, start engine and run at idle speed. Check for hydraulic leakage and correct before proceeding with test.

NOTE: Ifpressureandfan speed arebothlowand gear pump P4 flow proves to be correct (see Gear Pump P4 Flow Test in this section), suspect that seals in fan controlmanifold areleaking orfaulty (seeFan Control Manifold Service in the Service and Repairs section of this chapter) or that fan motor is worn or damaged.

9. When testing is complete, remove pressure gauge from manifold fitting and reconnect wire harness to proportionalreliefvalvesolenoid.Installdustcaptotestport fitting. Lower and secure hood.

System

Hydraulic

5. Move throttle to full speed (2850 RPM).

6. While monitoring the pressure gauge and using a phototac to identify the cooling fan speed, disconnect the wire harness connector (white/green and black wires) from the proportional relief valve solenoid at fan control manifold (port PRV). Both fan speed and pressure should increase and stabilize after the solenoid is disconnected.

PRESSURE GAUGE READING TO BE approximately 3000 PSI (207 bar)

PHOTOTAC (fan speed) READING TO BE approximately 2800 RPM

7. Stop engine and record test results.

1. Fan control manifold

2. Test fitting (port G2)

Figure 47

3. PRV solenoid

Reelmaster 7000 Hydraulic SystemPage 4 -- 65

Page 100

Gear Pump P4 Flow (Cooling Fan Circuit) Test (Using Tester with Pressure Gauges and Flow Meter)

TO STEERING AND LIFT CIRCUITS

TO FAN CIRCUIT

TESTER

TO MOW CONTROL

MANIFOLD (P2 PORT)

GEAR PUMP

TO MOW CONTROL MANIFOLD (P1 PORT)

ENGINE SPEED

2850/1550

.091

5000

PSI

.071

P2P3

.56.56

2.48

1.031.03 .071

PISTON PUMP

BYPASS

VALVE

5000 PSI

FROM RESERVOIR FROM FILTRATIONMANIFOLD

Working Pressure Low Pressure Return or Suction

Flow

Reelmaster 7000Hydraulic System Page 4 -- 66

Toro 11185SL User Manual

Preface

Table Of Contents

Table of Contents

General Safety Instructions

Before Operating

While Operating

Maintenance and Service

Jacking Instructions

Safety and Instruction Decals

Table of Contents

Product Records

Maintenance

Equivalents and Conversions

Torque Specifications

Fastener Identification

Using a Torque Wrench with an Offset Wrench

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series)

Other Torque Specifications

Conversion Factors

Table of Contents

Specifications

General Information

Operator’s Manual

Service and Repairs

Air Filter System

Exhaust System

Fuel System

Radiator

Engine

Pump Adapter Plate

Table of Contents

Specifications

General Information

Operator’s Manual

Towing Traction Unit

Check Hydraulic Fluid

Relieving Hydraulic System Pressure

Traction Circuit Component Failure

Hydraulic Hoses

Hydraulic Hose and Tube Installation (O--Ring Face Seal Fitting)

Hydraulic Fitting Installation (SAE Straight Thread O--Ring Fitting into Component Port)

Hydraulic Schematic

Hydraulic Flow Diagrams

Mow Circuit

Special Tools

Troubleshooting

General Hydraulic System Problems

Traction Circuit Problems

PTO Problems

Steering Circuit Problems

Lift/Lower Circuit Problems

Engine Cooling Fan Circuit Problems

Testing