Toro Reelmaster 7000 (Models 03780, 03781) Service Repair Manual

Table of Content – Reelmaster 7000 (Models 03780, 03781)

• Title Page
• Revision History
• Reader Comments
• Preface
• Table of Contents
• 1 – Safety
• General Safety Instructions
• Before Operating
• While Operating
• Maintenance and Service
• Jacking Instructions
• Safety and Instruction Decals
• 2 – Product Records and Maintenance
• Product Records
• Maintenance
• Equivalents and Conversions
• Torque Specifications
• Fastener Identification
• Using a Torque Wrench with an Offset Wrench
• Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)
• Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series)
• Conversion Factors
• 3 – Yanmar Diesel Engine
• Specifications
• General Information
• Operator's Manuals
• Yanmar Service and Troubleshooting Manuals
• Stopping the Engine
• Engine Electronic Control Unit (ECU)
• Yanmar Engine
• Service and Repairs
• Air Cleaner System
• Exhaust System
• Fuel System
• Radiator, Hydraulic Oil Cooler
• Engine
• Pump Adapter Plate
• YANMAR TNV (Tier 4) SERIES Service Repair Manual
• YANMAR TNV (Tier 4) SERIES TROUBLESHOOTING MANUAL
• 4 – Kubota Diesel Engine
• Specifications
• General Information
• Operator's Manual
• Service and Repairs
• Air Filter System
• Exhaust System
• Fuel System
• Radiator, Hydraulic Oil Cooler
• Engine
• Pump Adapter Plate
• KUBOTA WORKSHOP MANUAL DIESEL ENGINE 03−M−DI−E3B SERIES
• 5 – Hydraulic System
• Specifications
• General Information
• Operator's Manual
• Hydraulic Component Locations
• Relieving Hydraulic System Pressure
• Traction Circuit Component Failure
• Towing Traction Unit
• Hydraulic Hoses
• Hydraulic Hose and Tube Installation (O-Ring Face Seal Fitting)
• Hydraulic Fitting Installation (SAE Straight Thread O-Ring Fitting into Component Port)
• Hydraulic Schematic
• Hydraulic Flow Diagrams
• Traction Circuit: LOW Speed (Mow)
• Traction Circuit: HI Speed (Transport)
• Mow Circuit
• Steering Circuit
• Lower Cutting Units
• Raise Cutting Units
• Engine Cooling Fan Circuit
• Special Tools
• Hydraulic Pressure Test Kit
• Hydraulic Tester (Pressure and Flow)
• 40 GPM Hydraulic Tester (Pressure and Flow)
• Hydraulic Hose Kit
• High Flow Hydraulic Filter Kit
• Hydraulic Test Fitting Kit
• Measuring Container
• O-ring Kit
• Remote Starter Switch
• Troubleshooting
• General Hydraulic System Problems
• Traction Circuit Problems
• Mow Circuit Problems
• Steering Circuit Problems
• Lift, Lower Circuit Problems
• Engine Cooling Fan Circuit Problems
• Testing
• Traction Circuit – Charge Pressure Test
• Traction Circuit – Relief Pressure Test
• Traction Circuit – Piston (traction) Pump Flow Test
• Traction Circuit – Front Wheel Motor Case Drain Leakage Test
• Traction Circuit – Reverse Reducing Valve (PR) Pressure Test
• Traction Circuit – Rear Relief Valve (RV) Pressure Test
• Cutting Unit Circuit – Pressure Test
• Cutting Unit Circuit – Relief Pressure Test
• Cutting Unit Circuit – Cutting Unit Motor Case Drain Leakage Test
• Steering, Lift Circuit – Steering Relief Pressure Test
• Steering, Lift Circuit – Steering Cylinder Test
• Steering, Lift Circuit – Lift Relief Pressure Test
• Cooling Fan Circuit – Pressure Test
• Cooling Fan Circuit – Fan Motor Case Drain Leakage Test
• Gear Pump Flow Test (pump sections P2 thru P5)
• Adjustments
• Control Manifold Relief Valve Adjustment
• Service and Repairs
• General Precautions for Removing and Installing Hydraulic System Components
• Check Hydraulic Lines and Hoses
• Priming Hydraulic Pumps
• Flush Hydraulic System
• Filtering Closed-Loop Traction Circuit
• Charge Hydraulic System
• Gear Pump
• Gear Pump Service
• Piston (Traction) Pump
• Piston (traction) Pump Service
• Rear Traction Manifold
• Rear Traction Manifold Service
• HI, LOW Range Manifold
• Front Wheel Motors
• Rear Axle Motor
• Front Wheel Motor and Rear Axle Motor Service
• Cutting Unit Motor
• Cutting Unit Motor Service
• Mow Control Manifold
• Mow Control Manifold Service
• Steering Control Valve
• Steering Control Valve Service
• Steering Cylinder
• Steering Cylinder Service
• Engine Cooling Fan Motor
• Engine Cooling Fan Motor Service
• Fan Control Manifold
• Fan Control Manifold Service
• Lift Manifold
• Lift Manifold Service
• Control Manifold Cartridge Valve Service
• Lift Junction Manifold
• Front Lift Cylinders
• Rear Lift Cylinders
• Lift Cylinder Service
• Hydraulic Reservoir
• Hydraulic Oil Cooler
• EATON MODEL 72400 SERVO CONTROLLED PISTON PUMP REPAIR INFORMATION
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• 6 – Electrical System
• General Information
• Operator's Manual
• Toro Electronic Controller (TEC)
• Engine Electrical Components
• Engine Electronic Control Unit (ECU) (Yanmar Diesel Engines Only)
• CAN-bus Communications
• Electrical Drawings
• Special Tools
• Multimeter
• Dielectric Gel
• Battery Hydrometer
• Terminal Protector
• InfoCenter Display
• InfoCenter Display Screens
• Splash Screen
• Main Information Screen
• Operator Advisory Screen
• Main Menu Screen
• Faults Screen
• Service Screen
• Diagnostics Screen
• Settings Screen
• About Screen
• Troubleshooting
• Operator Advisories
• Using the InfoCenter Display for Troubleshooting
• Fault Codes
• Starting Problems
• General Run and Transport Problems
• Cutting Unit Operating Problems
• Cutting Unit Lift, Lower Problems
• Electrical System Quick Checks
• Battery Test (Open Circuit Test)
• Charging System Test
• Glow Plug System Test
• Check Operation of Interlock Switches
• Adjustments
• HI, LOW (transport, mow) Switch
• Cutting Unit Position Switch
• Component Testing
• Fusible Link Harness
• Fuses
• Toro Electronic Controllers (TEC)
• Ignition Switch
• Reel Enable, Disable Switch
• Engine Speed Switch (Yanmar Diesel Engine Only)
• Lower, Raise Joystick Switches
• Seat Switch
• Traction Neutral Switch
• Parking Brake Switch
• HI, LOW (Transport, Mow) Switch
• Cutting Unit Position Switch
• Backlap Switches
• Hydraulic Oil Temperature Sender
• Engine Temperature Sender (Kubota Diesel Engine Only)
• Relays with Four (4) Terminals
• Relays with Five (5) Terminals
• Hydraulic Solenoid Valve Coils
• Fuel Pump (Yanmar Diesel Engine Only)
• Fuel Pump (Kubota Diesel Engine Only)
• Fuel Stop Solenoid (Kubota Diesel Engines Only)
• CAN-bus Termination Resistor
• Diode Assembly
• Resistor Assembly
• Worklight Switch
• Service and Repairs
• Battery Storage
• Battery Care
• Battery Service
• Hydraulic Solenoid Valve Coils
• Worklight Bulb Replacement
• 7 – Axles, Planetaries and Brakes
• Table of Contents
• Specifications
• General Information
• Operator's Manual
• Adjustments
• Planetary Drive End Play (OPH-2 series planetary drives)
• Service and Repairs
• Brake Assembly
• Brake Inspection and Repair
• Planetary Drive Assembly
• OPH-2 Planetary Drive Service
• VA02 Series Planetary Drive Service
• Rear Axle Assembly
• Rear Axle Service
• Bevel Gear Case and Axle Case
• Differential Shafts
• Axle Shafts
• Input Shaft, Pinion Gear
• Differential Gear
• Pinion Gear to Ring Gear Engagement
• 8 – Chassis
• General Information
• Operator's Manual
• Cutting Unit Identification
• Service and Repairs
• Steering Column
• Console Arm
• Lift Arms for Front Cutting Units (#1, #4 and #5)
• Lift Arms for Rear Cutting Units (#2 and #3)
• Operator Seat
• Operator Seat Service
• Operator Seat Suspension
• Hood
• 9 – DPA Cutting Units
• Table of Contents
• Specifications
• General Information
• Cutting Unit Operator's Manual
• Special Tools
• Gauge Bar Assembly
• Bedknife Screw Tool
• Handle Assembly
• Plastic Plug
• Cutting Unit Kickstand
• Spline Insert Tool
• Diameter, Circumference Measuring Tape
• Roller Rebuild Kit
• Turf Evaluator Tool
• Reel Bearing Installation Tool (cutting units with painted side plates)
• Cutting Reel Shim
• Cutting Performance Paper
• Pulley Alignment Tool
• Bedknife Top Angle Indicator and Mount
• Factors That Can Affect Cutting Performance
• Adjustments
• Characteristics
• Reel Bearing Adjustment (cutting units with painted side plates)
• Leveling Rear Roller
• Service and Repairs
• Hydraulic Reel Motor
• Backlapping
• Bedbar Assembly
• Bedknife Replacement and Grinding
• Bedbar Adjuster Service
• Reel Assembly (cutting units with painted side plates)
• Reel Assembly Service (cutting units with painted side plates)
• Reel Assembly (cutting units with aluminum side plates)
• Reel Assembly Service (cutting units with aluminum side plates)
• Preparing Reel for Grinding
• Front Roller
• Rear Roller
• Roller Service
• Rear Roller Brush – Optional (cutting units with painted side plates)
• Rear Roller Brush – Optional (cutting units with aluminum side plates)
• 10 – Belt Driven Groomer (Optional)
• Table of Contents
• Grooming Performance
• Troubleshooting
• Groomer Reel Mechanical Problems
• Adjustments
• Groomer Height, Depth Adjustment
• Service and Repairs
• Groomer Drive Belt Replacement
• Groomer Plate Assembly
• Groomer Reel
• Groomer Reel Service
• Groomer Pivot Hub
• Height Adjuster Assembly
• 11 – Universal Groomer (Optional)
• Table of Contents
• Grooming Performance
• Troubleshooting
• Groomer Reel Mechanical Problems
• Service and Repairs
• Gear Box Assembly
• Idler Assembly
• Groomer Reel
• Groomer Reel Service
• Grooming Brush (Optional) Service
• Height Adjuster Assembly
• 12 – Foldout Drawings
• Electrical Drawing Designations
• Hydraulic Schematic
• Electrical Schematic – Traction Unit Model 03780 – Yanmar Engine (Serial numbers below 316000000)
• Electrical Schematic — Traction UnitModel 03780 — Yanmar Engine(Serial numbers 316000001 to 403350000)
• Electrical Schematic — Traction UnitModel 03780 — Yanmar Engine(Serial numbers above 403350001)
• Electrical Schematic – Traction Unit Model 03781 – Kubota Engine (Serial numbers below 316000000)
• Electrical Schematic — Traction UnitModel 03781 — Kubota Engine(Serial numbers 316000001 to 403350000)
• Electrical Schematic — Traction UnitModel 03781 — Kubota Engine(Serial numbers above 403350001)
• Electrical Schematic – Cab
• Main Wire Harness Drawing (Serial numbers below 316000000)
• Main Wire Harness Diagram (Serial numbers below 316000000)
• Main Wire Harness DrawingModel 03780 & 03781(Serial numbers 316000001 to 403350000)
• Main Wire Harness DiagramModel 03780 & 03781(Serial numbers 316000001 to 403350000)
• Main Wire Harness DrawingModel 03780 & 03781(Serial numbers 403350001 to 405699999)
• Main Wire Harness DiagramModel 03780 & 03781(Serial numbers 403350001 to 405699999)
• Main Wire Harness DrawingModel 03780 & 03781(Serial numbers above 405700000)
• Main Wire Harness DiagramModel 03780 & 03781(Serial numbers above 405700000)
• Engine Wire Harness Drawing – Yanmar
• Engine Wire Harness Diagram – Yanmar
• Engine Wire Harness Drawing – Kubota
• Engine Wire Harness Diagram – Kubota
• Seat and Console Wire Harness Drawing
• Seat and Wire Harness Diagram
• Power Center Wire Harness Drawing (Serial numbers below 403350000)
• Power Center Wire Harness Diagram (Serial numbers below 403350000)
• Power Center Wire Harness DrawingModel 03780 & 03781(Serial numbers above 403350001)
• Power Center Wire Harness DiagramModel 03780 & 03781(Serial numbers above 403350001)