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
R
E The Toro Company -- 2011, 2012
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Reelmaster 7000
Page 3

Table Of Contents

Chapter 1 -- Safety
General Safety Instructions 1 -- 2..................
Jacking Instructions 1 -- 4.........................
Safety and Instruction Decals 1 -- 5................
Chapter 2 -- Product Records and Maintenance
Product Records 2 -- 1...........................
Maintenance 2 -- 1...............................
Equivalents and Conversions 2 -- 2................
Torque Specifications 2 -- 3.......................
Chapter 3 -- 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
Page 4
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Reelmaster 7000
Page 5

Table of Contents

GENERAL SAFETY INSTRUCTIONS 2............
Before Operating 2............................
While Operating 2.............................
Maintenance and Service 3....................
JACKING INSTRUCTIONS 4.....................
SAFETY AND INSTRUCTION DECALS 5..........
Chapter 1
Safety
Safety
Reelmaster 7000 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.
1
2
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.
1
Figure 2
1. Rear axle 2. Rear tire (RH shown)
2
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

Table of Contents

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)
A
B
(effective length of torque
wrench + offset wrench)
TORQUE CONVERSION FACTOR = A / B
Torque wrenchOffset wrench
The calculated torque conversion factor for this torque 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: 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 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
80 + 10 ft--lb 108+ 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

Table of Contents

SPECIFICATIONS 2.............................
GENERAL INFORMATION 3.....................
Operator’s Manual 3..........................
SERVICE AND REPAIRS 4......................
Air Filter System 4............................
Exhaust System 6............................
Fuel System 8................................
Check Fuel Lines and Connections 9...........
Drain and Clean Fuel Tank 9..................
Fuel Tank Removal 9........................
Fuel Tank Installation 9.......................
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
8
12 to 15 in--lb
27
(1.4 to 1.6 N--m)
13
26
13
12
24
23
11
14
Vacuator
Direction
18
18
25
16
10
15
20
6
1
19
17
9
7
21
22
4
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
5
6
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)
2
3
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).
4
5
1. Air cleaner housing
2. Safety filter element
3. Air filter element
5
4
2
3
Figure 2
4. Air cleaner cover
5. Vacuator valve
1
Kubota
Diesel Engine
2
3
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
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

8
13
12
1
5
3
10
14
7
4
11
6
2
9
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

14
19
16
20
21
16
13
3
18
21
15
RIGHT
FRONT
8
8
1
8
3
4
7
2 7
24
17
25
23
6
5
9
10
22
11
26
12
27
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
13
40
18
15
18
17
12
14
28
10
42
39
26
46
25
24
28
23
15
7
29
35
1
31
33
32
30
3
43
2
11
5
37
38
6
3
15 22
27
43
10
36
17
41
20
34
19
21
16
4
44
8
9
45
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
6
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
4
1
5
3
assembly away from radiator.
12.Remove four(4) flangeheadscrews andflange nuts
securingtheradiatorandrecirculationbarriers(items24 and25) totheradiator mount.Carefully removebarriers and radiator from the machine.
2
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

29
31
5
30
12
1
3
33
20
4
22
9
6
18
21
28
17
7
10
8
19
25
24
2
10
17
11
26
32
34
14
15
23
18
16
27
12
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)
13
12
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.
5
2
3
1. Engine run solenoid
2. Throttle cable
3. Cable clamp
1
4
Figure 9
4. Cable swivel
5. Fuel supply hose
1
Kubota
Diesel Engine
3
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.
2
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).
6
3
4
1
5
2
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
1
2
FRONT
29 to 33 ft--lb
(40to44N--m)
3
Boss
Loctite #242
5
6
4
1. Bolt
2. Lock washer
3. Flywheel plate
4
7
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
1
2
3
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
This page is intentionally blank.
Reelmaster 7000Page 3 -- 18Kubota Diesel Engine
Page 35

Table of Contents

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)
3
(40.6 cc)
(Model 74315)
3
(32.9 cc)
(Model 74318)
3
(40.6 cc)
3
(16.85 cc)
3
(9.16 cc)
3
(100 cc)
3
(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
3
(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.
o
fortow-
1
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
1
2
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
0.25
0.25
0.25
0.25
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
0.25
0.25
0.25
0.25
0.25
Reelmaster 7000 Hydraulic SystemPage 4 -- 9
Page 44

Hydraulic Schematic

CONTROL
MANIFOLD
LIFT
S5
C3
S4
S3
C1
S1
S2
RV1
T
AXLE
MOTOR
P
G
CHG M1
PD1
REAR
2.48
M1
M2
G
Reelmaster 7000
de--energized
All solenoids are shown as
Hydraulic Schematic
PSI
RV
CHG
.091
P1
P2P3
P4
2.48
2.01
2.01
1.031.03
.56.56
PD2
CV
FRONT
MOTORS
PSI
5000
.071
.052
PR
450 PSI
P2
G
CR2
CR1
CD1T
CV1
207 PSI
P2
CV2
5 PSI
40
CV1
PSI
G
NOTE: A larger hydraulic
schematic is included in
P1 CD2
Chapter 9 -- Foldout
Drawings.
RV2
C2
C4
W MO
CONTROL
M3M2
M5
MANIFOLD
MV2
M3M4M1 M2
OR2
CV2
CV1
OR1
MV1
C3
C2
C4
SP2
LC2LC1
SP1
C5
C1
RV2
T1 P2
RV1
P1 T2
PISTON PUMP
2850/1550
ENGINE SPEED
SV
550 PSI
P1
G
VALVE
BYPASS
5000
.071
M1
M4
FAN
MANIFOLD
CONTROL
ST
S1
M1 M2
G1 G2
LP2
FD
CV
TP1
PRV
G1
G2
GEAR
PUMP
1050
L
T
P
PB
PSI
6.1
R
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
S5
C3
T
S4
S3
C1
S1
S2
RV1
P
G
CHG M1
PD1
AXLE
MOTOR
REAR
2.48
M1
M2
G
PSI
RV
CHG
.091
P1
P2P3
P4
2.48
2.01
2.01
1.031.03
.56.56
FRONT
.071
CV
5000
PD2
.052
PR
450 PSI
P2
Traction Circuit: Mow Speed (Forward Shown)
Reelmaster 7000
G
MOTORS
G
CR2
CR1
CD1T
PSI
CV1
207 PSI
P2
CV2
5 PSI
CV1
P1 CD2
40
PSI
Working Pressure
Low Pressure (Charge)
Flow
Return or Suction
RV2
C2
C4
MOW
MANIFOLD
M3M2
M5
CONTROL
MV2
M3M4M1 M2
OR2
CV2
CV1
OR1
MV1
C3
C2
C4
SP2
LC2LC1
SP1
C5
C1
RV2
T1 P2
RV1
P1 T2
PISTON PUMP
2850/1550
ENGINE SPEED
SV
550 PSI
P1
G
VALVE
BYPASS
5000
.071
M1
M4
FAN
MANIFOLD
CONTROL
ST
S1
M1 M2
G1 G2
LP2
FD
CV
TP1
PRV
G1
G2
GEAR
PUMP
1050
L
P
PB
T
PSI
6.1
R
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
S5
C3
T
S4
S3
C1
S1
S2
RV1
P
G
M1
CHG M1
PD1
2.48
AXLE
REAR
MOTOR
M2
G
CHG
.091
P1
P2P3
P4
2.48
2.01
2.01
1.031.03
.56.56
.071
FRONT
5000
PD2
.052
CV
PR
450 PSI
P2
Traction Circuit: Transport Speed (Forward Shown)
Reelmaster 7000
G
MOTORS
G
CR2
CR1
CD1T
PSI
CV1
207 PSI
P2
CV2
5 PSI
CV1
P1 CD2
40
PSI
Working Pressure
Low Pressure (Charge)
Flow
Return or Suction
RV2
C2
C4
CONTROL
MOW
M3M2
M5
MANIFOLD
MV2
M3M4M1 M2
OR2
CV2
CV1
OR1
MV1
C3
C2
C4
SP2
LC2LC1
SP1
C5
C1
RV2
T1 P2
RV1
P1 T2
PISTON PUMP
2850/1550
ENGINE SPEED
SV
SV
(ENERGIZED)
RV
550 PSI
P1
G
VALVE
BYPASS
PSI
5000
.071
M1
M4
FAN
MANIFOLD
CONTROL
ST
S1
M1 M2
G1 G2
LP2
FD
CV
TP1
PRV
G1
G2
GEAR
PUMP
1050
L
T
P
PB
PSI
6.1
R
CYLINDER
STEERING
Reelmaster 7000Hydraulic System Page 4 -- 14
Page 49
Traction Circuit: Transport Speed (2WD)
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 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
C3
C1
S5
T
S1
S2
S3
S4
RV2
C2
C4
RV1
P
G
C3
C2
PISTON PUMP
M1
CHG M1
PD1
SV
P1
G
BYPASS
AXLE
MOTOR
REAR
2.48
RV
550 PSI
CHG
VALVE
2.01
2.01
PD2
CV
FRONT
MOTORS
PSI
5000
M2
G
.052
PR
450 PSI
Flow
Return or Suction
Working Pressure
P2
Reelmaster 7000
G
G
CR2
CR1
CD1T
Low Pressure (Charge)
Lower Cutting Units (Lift Switch Pressed to Lower)
CV1
PSI
GEAR
PUMP
5000
.071
.091
2.48
P1
P2P3
P4
1.031.03
.56.56
.071
P2
CV2
C4
W
CONTROL
MO
M3M2
M5
M1
M4
MANIFOLD
OR2
CV2
CV1
OR1
MANIFOLD
CONTROL
ST
M1 M2
SP2
LC2LC1
SP1
S1
MV2
M3M4M1 M2
MV1
FAN
C5
C1
2850/1550
ENGINE SPEED
RV2
T1 P2
RV1
P1 T2
G1 G2
LP2
FD
CV
TP1
PRV
G1
G2
207 PSI
P1 CD2
5 PSI
40
CV1
PSI
T
P
PB
PSI
1050
6.1
L
R
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.
1
2
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
#2
#3
CUTTING UNIT LOCATIONS
Figure 11
Reelmaster 7000 Hydraulic SystemPage 4 -- 17
Page 52
CONTROL
LIFT
MANIFOLD
C3
C1
S5
T
S4
S3
C2
C4
S1
S2
RV2
RV1
P
G
C3
C2
PISTON PUMP
CHG M1
PD1
SV
P1
G
BYPASS
AXLE
MOTOR
REAR
2.48
M1
RV
550 PSI
CHG
VALVE
2.01
2.01
PD2
CV
FRONT
MOTORS
PSI
5000
M2
G
.052
Flow
Return or Suction
Raise Cutting Units (Lift Switch Pressed to Raise)
Reelmaster 7000
Working Pressure
Low Pressure (Charge)
PR
450 PSI
P2
G
G
CR2
CR1
CD1T
CV1
PSI
GEAR
PUMP
5000
.071
.091
P1
P2P3
P4
2.48
1.031.03
.56.56
.071
P2
CV2
C4
W
CONTROL
MANIFOLD
M3M2
M5
M1
M4
MO
OR2
CV2
CV1
OR1
MANIFOLD
CONTROL
ST
M1 M2
SP2
LC2LC1
SP1
S1
MV2
M3M4M1 M2
MV1
FAN
C5
C1
2850/1550
ENGINE SPEED
RV2
T1 P2
RV1
P1 T2
G1 G2
LP2
FD
CV
TP1
PRV
G1
G2
207 PSI
P1 CD2
5 PSI
40
CV1
PSI
T
P
PB
PSI
1050
6.1
L
R
CYLINDER
STEERING
Reelmaster 7000Hydraulic System Page 4 -- 18
Page 53
Raise 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.
1
2
Figure 12
1. Console 2. Lift switch
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.
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
S5
C3
T
S4
S3
C1
S1
S2
RV1
P
G
CHG M1
PD1
AXLE
MOTOR
REAR
2.48
M1
M2
G

Mow Circuit

Reelmaster 7000
Working Pressure
Low Pressure (Charge)
Flow
Return or Suction
RV2
C4
C2
W MO
MANIFOLD
M3M4M1 M2
CONTROL
MV2
MV1
FAN
OR2
CV2
CV1
OR1
MANIFOLD
CONTROL
ST
M1 M2
M3M2
M5
M1
M4
C3
C2
C4
C1
C5
(ENERGIZED)
SP2
SP1
RV2
T1 P2
RV1
P1 T2
(ENERGIZED)
G1 G2
LP2
FD
CV
TP1
PRV
G1
G2
LC2LC1
S1
PISTON PUMP
2850/1550
ENGINE SPEED
SV
550 PSI
P1
G
VALVE
BYPASS
5000
.071
GEAR
PUMP
RV
PSI
CHG
.091
2.48
P1
P2P3
P4
2.01
2.01
1.031.03
.56.56
PD2
CV
FRONT
MOTORS
PSI
5000
.071
.052
PR
450 PSI
P2
G
G
CR2
CR1
CD1T
CV1
207 PSI
P2
CV2
5 PSI
CV1
P1 CD2
40
PSI
T
P
PB
PSI
1050
6.1
L
R
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
M5
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
S5
C3
T
S4
S3
C1
C2
S1
S2
RV2
C4
RV1
P
G
C3
CHG M1
PD1
SV
AXLE
MOTOR
REAR
2.48
M1
RV
550 PSI
M2
G
Flow
Return or Suction
Working Pressure
Low Pressure (Charge)
PD2
.052
CV
PR
450 PSI
Steering Circuit (Right Turn Shown)
Reelmaster 7000
P1
GEAR
G
BYPASS
PUMP
CHG
VALVE
PSI
5000
.071
C2
PISTON PUMP
C4
MOW
MANIFOLD
M3M2
M5
M1
M4
CONTROL
OR2
CV2
CV1
OR1
SP2
LC2LC1
SP1
MV2
M3M4M1 M2
MV1
C5
C1
2850/1550
ENGINE SPEED
RV2
T1 P2
RV1
P1 T2
G1 G2
.091
P1
P2P3
P4
2.48
2.01
2.01
1.031.03
.56.56
FRONT
5000
.071
P2
G
MOTORS
G
CR2
CR1
CD1T
PSI
CV1
207 PSI
P2
CV2
5 PSI
CV1
P1 CD2
40
PSI
FAN
CONTROL
ST
M1 M2
MANIFOLD
FD
S1
CV
LP2
P
PB
T
PSI
1050
TP1
PRV
G1
G2
6.1
L
R
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
L
NO CYLINDER
MOVEMENT
LEFT TURN
STEERING CONTROL VALVE
T
6.1
R
STEERING CYLINDER
PPB
1050
PSI
6.1
L
STEERING CONTROL VALVE
T
R
STEERING CYLINDER
RIGHT TURN
PPB
1050
PSI
L
STEERING CONTROL
VALVE
T
6.1
R
STEERING CYLINDER
Figure 16
Reelmaster 7000 Hydraulic SystemPage 4 -- 23
Page 58
CONTROL
MANIFOLD
LIFT
S5
C3
T
S4
S3
C1
S1
S2
RV1
P
G
CHG M1
PD1
AXLE
MOTOR
REAR
2.48
M1
M2
G
PSI
RV
CHG
.091
P1
P2P3
P4
2.48
2.01
2.01
1.031.03
.56.56
PD2
CV
FRONT
MOTORS
PSI
5000
.071
.052
PR
450 PSI
P2
Engine Cooling Fan Circuit (Forward Fan Direction Shown)
G
CR2
CR1
CD1T
CV1
207 PSI
P2
CV2
5 PSI
40
CV1
Reelmaster 7000
G
P1 CD2
PSI
Working Pressure
Low Pressure (Charge)
Flow
Return or Suction
RV2
C2
C4
W MO
MANIFOLD
M3M2
M5
CONTROL
MV2
M3M4M1 M2
OR2
CV2
CV1
OR1
MV1
C3
C2
C4
C1
C5
SP2
SP1
RV2
T1 P2
RV1
P1 T2
LC2LC1
PISTON PUMP
2850/1550
ENGINE SPEED
SV
550 PSI
P1
G
VALVE
BYPASS
5000
.071
M1
M4
FAN
MANIFOLD
CONTROL
ST
S1
M1 M2
G1 G2
LP2
FD
CV
TP1
PRV
G1
G2
GEAR
PUMP
1050
L
T
P
PB
PSI
6.1
R
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
o
reachesapproximately 165
F(74oC).Thefan motor
increases to full speed (approximately 2800 RPM)
o
as coolant reaches 180
F(82oC).
Thefanmotorautomaticallyslowsdownandthenre-
o
verses direction if coolant reaches 203
o
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.
4
2
3
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)
1
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
M1
2.48
REAR
AXLE
MOTOR
M2
FORWARD DIRECTION
TEST SHOWN
Working Pressure Low Pressure Return or Suction
Flow
PISTON PUMP
.052
PR
G
450 PSI
PRESSURE
PD1
SV
RV
550 PSI
PD2
CV
GAUGE
P1
CHG
2.01
G
2.01
VALVE
BYPASS
FRONT
5000
P2
G
MOTORS
CR2
CD1T
PSI
CR1
TO DECK CONTROL MANIFOLD
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
P1
1.031.03
P2P3
.56.56
P4
FROM DECK MOTORS
.071
CV1
207 PSI
P2
CV2
5 PSI
40
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.
1
3
2
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
M1
2.48
REAR
AXLE
MOTOR
M2
FORWARD DIRECTION
TEST SHOWN
PRESSURE
Working Pressure Low Pressure Return or Suction
Flow
GAUGE
PISTON PUMP
.052
G
PR
450 PSI
G
G
CR2
CV1
CR1
207 PSI
CD1T
PD1
.091
2.01
2.01
FRONT
5000
PD2
CV
P2
MOTORS
PSI
SV
RV
550 PSI
P1
CHG
G
VALVE
BYPASS
PSI
5000
TO DECK CONTROL MANIFOLD
TO DECK CONTROL MANIFOLD
TO STEERING AND LIFT CIRCUITS
(CHARGE CIRCUIT)
TO FAN CIRCUIT
2850/1550
ENGINE SPEED
GEAR
PUMP
.071
.071
2.48
P1
1.031.03
P2P3
.56.56
P4
FROM DECK MOTORS
P2
CV2
5 PSI
40
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.
2
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)
2
RIGHT
FRONT
Figure 30
1. Forward relief valve
2. Reverse relief valve
1
3. Traction pump
System
Hydraulic
3
1
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
M1
M2
PRESSURE
GAUGE
Working Pressure Low Pressure Return or Suction
Flow
.052
G
PR
450 PSI
G
G
CR2
CD1T
CR1
CV1
207 PSI
PD1
.091
2.01
2.01
PD2
CV
P2
FRONT
MOTORS
PSI
5000
SV
PISTON PUMP
RV
550 PSI
P1
CHG
G
VALVE
BYPASS
PSI
5000
TO DECK CONTROLMANIFOLD
TO DECK CONTROLMANIFOLD
TO STEERING AND LIFT CIRCUITS
(CHARGE CIRCUIT)
TO FAN CIRCUIT
ENGINE SPEED
.071
2850/1550
GEAR
PUMP
.071
2.48
P1
1.031.03
P2P3
.56.56
P4
FROM DECK MOTORS
Rev. A
PSI
P1 CD2
FROM STEERING CONTROL VALVE
FROM DECK CONTROL MANIFOLD
P2
CV2
5PSI
40
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.
2
1
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.
1
2
Figure 32
1. 4WD/2WD manifold 2. Test fitting (port G)
FRONT
1
Figure 33
1. 4WD/2WD manifold 2. Reducing valve (PR)
2
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
M1
AXLE
MOTOR
REAR
2.48 M2
PRESSURE
GAUGE
Working Pressure Low Pressure Return or Suction
Flow
PD1
SV
PISTONPUMP
RV
550 PSI
P1
CHG
G
VALVE
BYPASS
PSI
5000
PD2
CV
P2
2.01
FRONT
MOTORS
2.01
PSI
5000
.091
G
.052
PR
450 PSI
G
G
CR2
CV1
CR1
207 PSI
CD1T
TO DECK CONTROL MANIFOLD
TO DECK CONTROL MANIFOLD
TO STEERING AND LIFT CIRCUITS
(CHARGE CIRCUIT)
TO FAN CIRCUIT
ENGINE SPEED
.071
2850/1550
GEAR
PUMP
.071
2.48
P1
1.031.03
P2P3
.56.56
P4
FROM DECK MOTORS
Rev. A
PSI
P1 CD2
FROM STEERING CONTROL VALVE
FROM DECK CONTROL MANIFOLD
P2
CV2
5PSI
40
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
1
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
2
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
1
2
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
M1
2.48
AXLE
MOTOR
REAR
M2
Working Pressure Low Pressure Return or Suction
Flow
TESTER
PISTON PUMP
.052
G
PR
450 PSI
G
G
CR2
CV1
CR1
207 PSI
CD1T
PD1
.091
2.01
2.01
FRONT
5000
PD2
CV
P2
MOTORS
PSI
SV
RV
550 PSI
P1
CHG
G
VALVE
BYPASS
PSI
5000
TO DECK CONTROL MANIFOLD
TO DECK CONTROL MANIFOLD
TO STEERING AND LIFT CIRCUITS
(CHARGE CIRCUIT)
TO FAN CIRCUIT
2850/1550
ENGINE SPEED
GEAR
PUMP
.071
.071
2.48
P1
1.031.03
P2P3
.56.56
P4
FROM DECK MOTORS
P2
CV2
5 PSI
40
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
1
2
Figure 36
Page 82
Mow Circuit Pressure Test (Using Pressure Gauge)
M5
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
P1
1.031.03
SP1
G1 G2
P1 T2 T1 P2
GEAR PUMP
P4
.56.56
2.48
SP2
ENGINE SPEED
2850/1550
.071
.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
P2
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.
1
2
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)
M5
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
P4
.56.56
RV1
P2P3
CV1
CV2
LC2LC1
RV2
P1
1.031.03
M3M4M1 M2
OR2
SP2
2.48
MV2
ENGINE SPEED
2850/1550
.071
.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
P2
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).
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.
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
M5
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
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.
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)
M5
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
P4
.56.56
P1
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
2
1
1. Gear pump
2. Pump section P1 hose
3
Figure 42
3. Pump section P2 hose
Reelmaster 7000 Hydraulic SystemPage 4 -- 55
Page 90
Steering Circuit Relief Pressure Test (Using Pressure Gauge)
M5
M1M4
MV1
CV1
RV1
CV2
LC2LC1
RV2
OR2
OR1
SP1
G1 G2
P1 T2STT1 P2
G2 G1
M1 M2
CV
PRV
FAN CONTROL MANIFOLD
S1
FD
TP1
LP2
M3M4M1 M2
MV2
SP2
M3M2
MOW CONTROL MANIFOLD
TO LIFT MANIFOLD
STEERING WHEEL TURNED
FOR RIGHT TURN
STEERING CYLINDER
L
R
STEEL
CAP
ENGINE SPEED
2850/1550
GEAR PUMP
.071
P4
1050
PSI
P
6.1 PB
T
P1
P2P3
.56.56
2.48
1.031.03
CV2
5 PSI
CV1 40
PSI
.091
.071
P2
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.
1
RIGHT
FRONT
3
4
2
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
L
6.1
R
1050
PSI
P
PB
T
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.
1
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.
2
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
C3
C1
S5
T
S1
S4
C2
S3
S2
RV2
C4
RV1
PG
C3
FROM STEERING
CONTROL VALVE
TO CHARGE
CIRCUIT
PRESSURE
GAUGE
C2
FROM FAN CONTROL MANIFOLD
Working Pressure
C4
C1
C5
Low Pressure Return or Suction
G2
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.
1
2
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
P4
.56.56
P1
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
2
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
1
Figure 46
Page 98
Cooling Fan Circuit Test (Using Pressure Gauge and Phototac)
M5
G2 G1
PRESSURE
GAUGE
M1 M2
CV
PRV
M1M4
FAN CONTROL MANIFOLD
S1
FD
TP1
LP2
MV1
CV1
RV1
P2P3
OR2
CV2
LC2LC1
RV2
P1
2.48
1.031.03
OR1
SP1
G1 G2
P1 T2STT1 P2
GEAR PUMP
P4
.56.56
M3M4M1 M2
MV2
SP2
ENGINE SPEED
2850/1550
M3M2
MOW CONTROL MANIFOLD
.071
.071
.091
5000
PSI
TO LIFT MANIFOLD
PISTON PUMP
BYPASS
VALVE
5000 PSI
STEERING CYLINDER
P2
CV2
5 PSI
CV1 40
PSI
L
6.1
R
1050
PSI
P
PB
T
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.
3
1
2
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
P4
TO MOW CONTROL MANIFOLD (P1 PORT)
ENGINE SPEED
2850/1550
.091
5000
PSI
.071
P1
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
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