Toro 11185SL User Manual
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
This page is intentionally blank.
Reelmaster 7000
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
This page is intentionally blank.
Reelmaster 7000
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
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
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
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
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
This page is intentionally blank.
Reelmaster 7000Page 1 -- 6Safety
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
Equivalents and Conversions
0.09375
Product Records and Maintenance
Page 2 -- 2
Reelmaster 7000
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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