Toro 98958SL manual

P ART NO. 98958SL, Rev . A Service Manual Reelmaster R 4000–D 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 4000–D. REFER T O THE TRACTION UNIT AND CUTTING UNIT OPERA TOR’S MANUALS FOR OPERA TING, MAINTENA[...]

Reelmaster 4000–D[...]

Reelmaster 4000–D T able Of Contents Chapter 1 – Safety General Safety Instructions 1 – 1 . . . . . . . . . . . . . . . . . . Safety and Instruction Decals 1 – 4 . . . . . . . . . . . . . . . . Chapter 2 – Product Records and Manuals Product Records 2 – 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . Equivalents and Conversions [...]

Reelmaster 4000–D[...]

Reelmaster 4000–D Page 1 – 1 Safety Chapter 1 Safety T able of Contents GENERAL SAFETY INSTRUCTIONS 1 . . . . . . . . . . . . Before Operating 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service 3 . . . . . . . . . . . . . . . . . . . . SAFET[...]

Reelmaster 4000–D Page 1 – 2 Safety While Operating 10. Do not run engine in a confined area without ade- quate ventilation. Exhaust is hazardous and could be deadly . 1 1. Sit on the seat when starting and operating the ma- chine. 12. Check interlock switches daily for proper operation. If a switch fails, replace it before operating the machin[...]

Reelmaster 4000–D Page 1 – 3 Safety Maintenance and Service 26. Before servicing or making adjustments, stop en- gine and remove key from the switch. 27. Assure entire machine is properly maintained and in good operating condition. Frequently check all nuts, bolts and screws. 28. Frequently check all hydraulic line connectors and fittings. Assu[...]

Reelmaster 4000–D Page 1 – 4 Safety Safety and Instruction Decals The following safety and instruction decals are installed on the Reelmaster 4000–D. If any become damaged or illegible, replace them. Decal part numbers are listed below and in the parts catalog. Order replacements from your Authorized T oro Distributor . ON P ANEL IN FRONT OF [...]

Reelmaster 4000–D Page 1 – 5 Safety Safety and Instruction Decals NEAR FUEL T ANK FILL CAP NEAR RADIA TOR FILL CAP (Part No. 93–6680) (Part No. 93–9404) UNDER SEA T NEAR OIL FILL CAP (Part No. 93–8067) NEXT TO TRACTION PEDAL ON STEERING CONSOLE (Part No. 93–9397) ON F AN SHROUD (Part No. 93–6681) ON FRAME ABOVE REAR WHEELS (Part No.93[...]

Reelmaster 4000–D Page 1 – 6 Safety Safety and Instruction Decals ON FRONT CARRIER & TOW BAR (Part No. 93–9400) ON RIGHT CONTROL P ANEL (Part No. 93–9402) ON EXHAUST SHIELD (Part No. 95–0645) ON FRONT ACCESS P ANEL (Part No. 93–9425)[...]

Reelmaster 4000–D Page 2 – 1 Product Records and Maintenance Chapter 2 Product Records and Maintenance T able of Contents PRODUCT RECORDS 1 . . . . . . . . . . . . . . . . . . . . . . . . . EQUIV ALENTS AND CONVERSIONS 2 . . . . . . . . . . . Decimal and Millimeter Equivalents 2 . . . . . . . . . . . . U.S. to Metric Conversions 2 . . . . . . .[...]

Reelmaster 4000–D Page 2 – 2 Product Records and Maintenance Equivalents and Conversions[...]

Reelmaster 4000–D Page 2 – 3 Product Records and Maintenance T orque Specifications Recommended fastener torque values are listed in the following tables. For critical applications, as determined by T oro, either the recommended torque or a torque that is unique to the application is clearly identified and spe- cified in this Service Manual. Th[...]

Reelmaster 4000–D Page 2 – 4 Product Records and Maintenance Standard T orque for Dry , Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, 5, & 8 with Thin Height Nuts 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 R[...]

Reelmaster 4000–D Page 2 – 5 Product Records and Maintenance Standard T orque for Dry , Zinc Plated, and Steel Fasteners (Metric Fasteners) Thread Size Class 8.8 Bolts, Screws, and Studs with Reg lar Height N ts Class 10.9 Bolts, Screws, and Studs with Reg lar Height N ts Thread Size Reg u lar Height N u ts (Class 8 or Stronger Nuts) Reg u lar [...]

Reelmaster 4000–D Page 2 – 6 Product Records and Maintenance Other T orque Specifications SAE Grade 8 Steel Set Screws Thread Size Recommended T orque Th rea d Si ze Square Head Hex Socket 1/4 – 20 UNC 140 + 20 in–lb 73 + 12 in–lb 5/16 – 18 UNC 215 + 35 in–lb 145 + 20 in–lb 3/8 – 16 UNC 35 + 10 ft–lb 18 + 3 ft–lb 1/2 – 13 UN[...]

Reelmaster 4000–D Page 2 – 7 Product Records and Maintenance Lubrication GREASING BEARINGS AND BUSHINGS The machine has grease fittings that must be lubricated after every 50 hours of operation with No. 2 General Pur- pose Lithium Base Grease. Lubricate fitting immediately after every washing regardless of interval listed. The lu- brication poi[...]

Reelmaster 4000–D Page 2 – 8 Product Records and Maintenance[...]

Reelmaster 4000–D Page 2 – 9 Product Records and Maintenance EQUIPMENT OPERA TION AND SERVICE HIST OR Y REPORT for REELMASTERR 4000–D TORO Model and Serial Number: ______________–______________ Engine Numbers: _____________________________ T ransmission Numbers: _____________________________ Drive Axle(s) Numbers: __________________________[...]

Reelmaster 4000–D Page 2 – 10 Product Records and Maintenance Reelmaster 4000–D Maintenance Schedule Minimum Recommended Maintenance Intervals Maintenance Procedure Lubricate Reel Control V alve Grease Fitting Lubricate Reel Speed V alve with Oil Lubricate All Grease Fittings Check Battery Condition and Connections  Change Engine Oil and F[...]

Reelmaster 4000–D Page 2 – 1 1 Product Records and Maintenance Reelmaster 4000–D Daily Maintenance Checklist Daily Maintenance: (duplicate this page for routine use) Check proper section of Operator ’s Manual for fluid specifications Maintenance Daily Maintenance Check For Week Of _________________ Check Item b MON TUES WED THURS FRI SA T S[...]

Reelmaster 4000–D Supervisor Maintenance Work Order Date: ________________ Unit Designation: Hours: T echnician: TORO I.D. #: __________________–__________________ Service to perform (circle): A B C D Other Remarks: (See Operator ’s and Service Manual for specifications and procedures.) A– Service (every 50 hours) B – Service (every 100 h[...]

Reelmaster 4000–D Page 3 – 1 Kubota Diesel Engine Chapter 3 Kubota Diesel Engine T able of Contents INTRODUCTION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICA TIONS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMA TION 4 . . . . . . . . . . . . . . . . . . . . . Check Engine Oil 4 . . . . . . .[...]

Reelmaster 4000–D Page 3 – 2 Kubota Diesel Engine Introduction This Chapter gives information about specifications, maintenance, troubleshooting, testing, and repair of the diesel engine used in the Reelmaster 4000–D. Most repairs and adjustments require tools, which are commonly available in many service shops. Special tools are described in[...]

Reelmaster 4000–D Page 3 – 3 Kubota Diesel Engine Specifications Item Description Make / Designation Kubota, V2203, 4–Cylinder , 4–Cycle, W ater Cooled, In–line, Spherical Chamber , OHV , Diesel Engine Horse Power 39.4 HP @ 2300 RPM T orque 103 ft–lb @ 1600 RPM Firing Order 1 – 3 – 4 – 2 Bore mm (in.) 87.0 (3.43) Stroke mm (in.) 9[...]

Reelmaster 4000–D Page 3 – 4 Kubota Diesel Engine General Information Check Engine Oil 1. Park machine on a level surface. Stop engine. Re- move key from the ignition switch. 2. Release engine cover latches. Open engine cover (Fig. 1). 3. Remove dipstick, wipe clean and reinstall dipstick into tube and pull it out again. Oil level should be up [...]

Reelmaster 4000–D Page 3 – 5 Kubota Diesel Engine Check Cooling System Check level of coolant at the beginning of each day . Ca- pacity of system is 3.7 gal. (14 L). CAUTION If engine is hot, pressurized coolant can escape and cause burns when the radiator cap is re- moved. Remove radiator cap slowly and careful- ly if engine coolant is hot. 1.[...]

Reelmaster 4000–D Page 3 – 6 Kubota Diesel Engine Prime Fuel System IMPORT ANT : The fuel system must be primed when a new engine is started for the first time, if it runs out of fuel, or if maintenance is performed on the fuel system. Note: The fuel pump, located on left side of engine, under the fuel injection pump and behind the fuel stop so[...]

Reelmaster 4000–D Page 3 – 7 Kubota Diesel Engine Adjustments Adjust Alternator Belt Check condition and tension of belt after every 100 op- erating hours (Fig. 9). 1. Park machine on a level surface. Stop engine. Re- move key from the ignition switch. 2. Proper belt tension will allow 3/8 inch (10 mm) deflection when a force of 10 lbs (44.4 N)[...]

Reelmaster 4000–D Page 3 – 8 Kubota Diesel Engine Service and Repairs Service Air Cleaner 1. Park machine on a level surface. Stop engine. Re- move key from the ignition switch. 2. Remove knobs securing rear screen to frame . Re- move rear screen (Fig. 10). 3. Check air cleaner body for damage which could possibly cause an air leak. Replace a d[...]

Reelmaster 4000–D Page 3 – 9 Kubota Diesel Engine Change Engine Oil and Filter Change oil and filter after the first 50 hours of operation and every 100 hours thereafter . 1. Remove drain plug and let oil flow into drain pan. When oil stops, install drain plug (Fig. 12). 2. Remove oil filter . Apply a light coat of clean oil to the new filter s[...]

Reelmaster 4000–D Page 3 – 10 Kubota Diesel Engine Drain Fuel System DANGER Because diesel fuel is highly flammable, use cau- tion when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot, or when machine is in an enclosed area. Always fill fuel tank outside and wipe up any spille[...]

Reelmaster 4000–D Page 3 – 1 1 Kubota Diesel Engine Check Fuel Lines and Connections Check lines and connections every 400 hours or yearly , whichever comes first. Inspect for deterioration, dam- age, or loose connections. Replace Fuel Filter DANGER Because diesel fuel is highly flammable, use cau- tion when storing or handling it. Do not smoke[...]

Reelmaster 4000–D Page 3 – 12 Kubota Diesel Engine Engine Cooling System Debris Removal Remove debris from oil cooler , radiator and rear screen daily , clean more frequently in dirty conditions. 1. Park machine on a level surface. Stop engine. Re- move key from the ignition switch. 2. Release front engine cover latches and raise engine cover .[...]

Reelmaster 4000–D Page 3 – 13 Kubota Diesel Engine Engine Engine Removal 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Pivot seat up. Lift front canopy and remove from the brackets (Fig. 19). 3. Disconnect and remove battery from the machine (see Battery S[...]

Reelmaster 4000–D Page 3 – 14 Kubota Diesel Engine 9. Clamp to prevent drainage, and disconnect the fol- lowing fuel hoses: A. Suction hose at the injector pump from the fuel filter . Suction and discharge hoses at the fuel pump (Fig. 22). B. Return hose from the fuel injectors (Fig. 23). 10. Disconnect wire harness and electrical wires from th[...]

Reelmaster 4000–D Page 3 – 15 Kubota Diesel Engine 12. Separate hydraulic pump assembly from the engine (Fig. 25). A. Disconnect damper from the bracket. B. Remove four cap screws, lock washers, and flat washers securing the pump mounting flange to the pump adapter plate. C. Support pump, and pull pump shaft from the spring coupling. 13. Remove[...]

Reelmaster 4000–D Page 3 – 16 Kubota Diesel Engine Engine Installation CAUTION One person should operate lift or hoist while the other person guides the engine into the frame. 1. Install engine to the front engine mounts and rear brackets. A. Attach a hoist or lift to the engine. IMPORT ANT : Make sure not to damage the engine, fuel and hydraul[...]

Reelmaster 4000–D Page 4 – 1 Hydraulic System Chapter 4 Hydraulic System T able of Contents SPECIFICA TIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMA TION 3 . . . . . . . . . . . . . . . . . . . . . Hydraulic Hoses 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Fitting Installation 3 . . . [...]

Reelmaster 4000–D Page 4 – 2 Hydraulic System Specifications Item Description T raction Pump V ariable displacement axial piston pump T raction Relief Pressure 5000 – 5200 PSI Charge Pressure 50 – 150 PSI (2WD) 75 – 150 PSI (4WD) Steering Pump Gear pump with flow divider Steering Relief Pressure 1200 – 1300 PSI T raction Motor (front) F[...]

Reelmaster 4000–D Page 4 – 3 Hydraulic System General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as, pressure differentials during operation and exposure to weather , sun, chemicals, very warm storage condi- tions or mishandling during operation or maintenance. These conditions can cause damage or prematu[...]

Reelmaster 4000–D Page 4 – 4 Hydraulic System SAE Straight Thread O–Ring Port – Non–adjustable 1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material. 2. Always replace the O–ring seal when this type of fit- ting shows signs of leakage. 3. Lubricate the O–ring with a light coating o[...]

Reelmaster 4000–D Page 4 – 5 Hydraulic System Pushing or T owing T raction Unit Using T raction Pump By–Pass V alve In an emergency , the traction unit can be pushed or towed for a very short distance by using the traction pump by–pass valve. IMPORT ANT : Do not push or tow the traction unit faster that 2 to 3 MPH (3 to 5 Km/Hr) because the[...]

Reelmaster 4000–D Page 4 – 6 Hydraulic System Disengaging Planetary Wheel Drives In an emergency , the Reelmaster 4500–D can be moved by unlocking the front wheel hubs and towing the machine. DANGER V ehicle will roll with front wheel motors disenga- ged. V ehicle must be on level surface or wheels must be blocked. There is no effective braki[...]

Reelmaster 4000–D Page 4 – 7 Hydraulic System Check Hydraulic System Fluid 1. Look into sight glass (Fig. 1 1). Oil level should be even with arrows when checking warm oil. Oil will be 1/4 to 1/2 inch below arrows when cold. 2. If oil level is low , add hydraulic oil to the reservoir (see Add Hydraulic Fluid). 1. Hydraulic reservoir 2. Sight gl[...]

Reelmaster 4000–D Page 4 – 8 Hydraulic System Hydraulic Schematic 2500 HI–IDLE 1 100 LO–IDLE A (FWD) INLET B (REV) TEST PORT CHARGE BA PRIORITY OUT IN S1 3000 PSI LC1 (FWD) T B A TEST PORT CUTTING (TYP) IN B A T T RIGHT SIDE 5 3 1 2 4 A B C D E F TRACTION FORWARD STEERING CIRCUIT COUNTER–BALANCE TRACTION REVERSE L R TP TEST PORTS TEST POR[...]

Reelmaster 4000–D Page 4 – 9 Hydraulic System Hydraulic Flow Diagrams (2WD Machines Only) General Pump Flow Refer to “Engine Run – No Functions” Flow Diagram The traction, reel, and auxiliary pumps are directly coupled to the engine. With all controls in neutral and the engine running, the steer–lift pump draws oil through the suction l[...]

Reelmaster 4000–D Page 4 – 10 Hydraulic System Engine Run – No Functions[...]

Reelmaster 4000–D Page 4 – 1 1 Hydraulic System T raction Circuit Refer to “T raction Circuit – Forward” Flow Diagram A mechanical interlock between the traction pedal link- age and the parking brake prevents traction pedal movement unless the brake is released. Depressing the top of the traction pedal will shift the trac- tion pump swash[...]

Reelmaster 4000–D Page 4 – 12 Hydraulic System T raction Circuit – Forward[...]

Reelmaster 4000–D Page 4 – 13 Hydraulic System Steering Circuit Refer to “Steering Right” Flow Diagram With the engine running, the priority flow of oil from the steer–lift pump is directed to the power steering unit at the base of the steering column and returns to the reser- voir . T urning the steering wheel to the right moves the cont[...]

Reelmaster 4000–D Page 4 – 14 Hydraulic System Steering Right[...]

Reelmaster 4000–D Page 4 – 15 Hydraulic System Lift/Lower Circuit Refer to “Lift Circuit” Flow Diagrams The lift cylinders are controlled by an open center valve with three spools. The number 4 and 5 cutting units are independently controlled. The center spool controls the number 1, 2, and 3 cutting units. T o lift the cutting units, the en[...]

Reelmaster 4000–D Page 4 – 16 Hydraulic System Lift Circuit – Lift All Units[...]

Reelmaster 4000–D Page 4 – 17 Hydraulic System Lift Circuit – Lower All Units Hydraulic System[...]

Reelmaster 4000–D Page 4 – 18 Hydraulic System Lift Circuit – Free Float (Detent)[...]

Reelmaster 4000–D Page 4 – 19 Hydraulic System Reel Circuit Refer to “Reel Circuit” Flow Diagrams The three reel shut–off valves in this circuit enable the cutting units to be operated in several configurations for easier control, better clearance, or closer trimming. The reel pump supplies a constant flow of oil to the reel speed control[...]

Reelmaster 4000–D Page 4 – 20 Hydraulic System Reel Circuit – All Units Mow (Free Float)[...]

Reelmaster 4000–D Page 4 – 21 Hydraulic System Reel Circuit – Units 1, 2 & 3 Mow (Free Float) Hydraulic System[...]

Reelmaster 4000–D Page 4 – 22 Hydraulic System Reel Circuit – Units 1, 2, 3 & 5 Mow (Free Float)[...]

Reelmaster 4000–D Page 4 – 23 Hydraulic System Reel Circuit – Any Unit Backup Hydraulic System[...]

Reelmaster 4000–D Page 4 – 24 Hydraulic System 4WD Selector V alve Operation 4WD Forward (“S1” OFF) Pressure Oil Pressure Free[...]

Reelmaster 4000–D Page 4 – 25 Hydraulic System 2WD Forward (“S1” ON) Pressure Oil Pressure Free Hydraulic System[...]

Reelmaster 4000–D Page 4 – 26 Hydraulic System Special T ools NOTE: Order special tools from the TORO SPECIAL TOOLS AND APPLICA TIONS GUIDE (COMMERCIAL PRODUCTS ). Some tools may also be available from a local supplier . Hydraulic T ester – With Pressure and Flow Capabilities – TOR214678 Figure 12 Y ou must have o–ring face seal (ORFS) ad[...]

Reelmaster 4000–D Page 4 – 27 Hydraulic System Hydraulic Pressure T est Kit – TOR47009 Use to take various pressure readings for diagnostic tests. A high pressure hose is provided for remote read- ings. Contains one each: 1000 PSI (70 Bar), 5000 PSI (350 Bar) and 10000 PSI (700 Bar) gauges. Use gauges as recommended in T esting section of thi[...]

Reelmaster 4000–D Page 4 – 28 Hydraulic System T roubleshooting The cause of an improperly functioning hydraulic sys- tem is best diagnosed with the use of proper testing equipment and a thorough understanding of the com- plete hydraulic system. A hydraulic system with an excessive increase in heat or noise is a potential failure. Should either[...]

Reelmaster 4000–D Page 4 – 29 Hydraulic System Problem Possible Causes Steering loss. Thermal shock after washing. NOTE: Normal functions will return after orbital tem- peratures stabilize (approximately 15 minutes). DO NOT A TTEMPT TO TURN STEERING WHEEL UN- TIL TEMPERA TURES ST ABILIZE WHEN THER- MAL SHOCK IS NOTED. Improper cylinder action. [...]

Reelmaster 4000–D Page 4 – 30 Hydraulic System T esting The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks. (See the Special T ools section in this Chapter .) Before Performing Hydraulic T ests IMP[...]

Reelmaster 4000–D Page 4 – 31 Hydraulic System TEST NO. 1: Check T raction Circuit Working and Relief Pressures Procedure for Working Pressure Check: 1. Install a 10,000 psi gauge into the quick disconnect test port for the function to be checked. NOTE: If the machine is equipped with 4WD, check working pressure in both 2WD and 4WD modes. 2. Op[...]

Reelmaster 4000–D Page 4 – 32 Hydraulic System TEST NO. 2: Check Counterbalance Oil Pressure Procedure: 1. Install a 10,000 psi gauge into the center quick dis- connect as shown. 2. Start the engine and move throttle to full speed (2500 rpm). 3. T ester reading should be within the range listed: COLD OIL: 600 – 650 PSI HOT OIL: 500 – 550 PS[...]

Reelmaster 4000–D Page 4 – 33 Hydraulic System TEST NO. 3: Check Reel Circuit Working and Relief Pressures Procedure For Working Pressure Check: 1. Install a 5,000 psi gauge into the cutting circuit quick disconnect. 2. Operate the unit while monitoring the gauge. RANGE OF TESTER READINGS 0 – 2750 PSI 3. If working pressure is too high or too[...]

Reelmaster 4000–D Page 4 – 34 Hydraulic System TEST NO. 4: Check Reel Circuit Flow Procedure: 1. Hydraulic oil must be at operating temperature. 2. Start the engine and lower the No. 2 and 3 cutting units to the ground. 3. T urn the engine OFF . 4. Disconnect inlet hose at No. 2 reel motor . 5. Install tester in series between disconnected hose[...]

Reelmaster 4000–D Page 4 – 35 Hydraulic System TEST NO. 5: Check Reel Motor Cross–Over Relief Pressure BA PRIORITY OUT IN 3000 PSI T B A TEST POR T CUTTING (TYP) B A T T G CIRCUIT FROM GEAR PUMP FROM LIFT CIRCUIT TO HYDRAULIC OIL T ANK IN Figure 19 NOTE: Before testing a reel motor for possible failure, make sure to inspect the affected cutti[...]

Reelmaster 4000–D Page 4 – 36 Hydraulic System TEST NO. 6: Check Reel Motor Case Drain Flow BA PRIORITY OUT IN 3000 PSI T B A TEST POR T CUTTING (TYP) IN B A T T G CIRCUIT FROM GEAR PUMP FROM LIFT CIRCUIT TO HYDRAULIC OIL T ANK QUART CONT AINER Figure 20 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine fo[...]

Reelmaster 4000–D Page 4 – 37 Hydraulic System TEST NO. 7: Check Steering Circuit Working and Relief Pressure Procedure For Working Pressure Check: 1. Install a 5,000 psi gauge into the steering quick dis- connect. 2. Operate the unit while monitoring the gauge. RANGE OF TESTER READINGS 0 – 1300 PSI 3. If working pressure is too high or too l[...]

Reelmaster 4000–D Page 4 – 38 Hydraulic System TEST NO. 8: Check Lift Circuit Working and Relief Pressure Procedure For W orking Pressure Check: 1. Install a 5,000 psi gauge onto the quick disconnect of the lift valve. 2. Operate the unit while monitoring the gauge. Gauge should read from 500 to 2900 PSI . 3. If working pressure is too high or [...]

Reelmaster 4000–D Page 4 – 39 Hydraulic System Service and Repairs Removing Hydraulic System Components 1. Thoroughly clean the machine before disconnecting, removing or disassembling any hydraulic components. Always keep in mind the need for cleanliness when working on hydraulic equipment. 2. Put caps or plugs on any hydraulic lines or fitting[...]

Reelmaster 4000–D Page 4 – 40 Hydraulic System Steering Control Unit 1 2 3 4 5 6 7 8 9 10 16 18 19 20 21 22 23 24 25 26 27 28 11 12 13 14 15 12 12 Figure 25 1. Seal 1” I.D. 2. Retaining Ring 3. Seal Gland Bushing 4. Seal 1.875 I.D. 5. Quad Ring Seal, 1.062 I.D. 6. Bearing Race 7. Thrust Bearing, Needle 8. Housing 9. Control Sleeve 10. Centeri[...]

Reelmaster 4000–D Page 4 – 41 Hydraulic System Meter (Gerotor) End Disassembly 1. Clamp unit in vise, meter end up. Clamp lightly on edges of mounting area, see Fig. 26. Use protective ma- terial on vise jaws. Housing distortion could result if jaws are over–tightened. 2. Remove 5/16” cap screws. 3. Remove end cap. 4. Remove seal from end c[...]

Reelmaster 4000–D Page 4 – 42 Hydraulic System 7. Remove drive spacer(s) (not used on 4.5 cu. in. dis- placement units). 8. Remove drive. 9. Remove spacer plate. 10. Remove seal from housing. Control End Disassembly 1 1. Remove housing from vise. Place housing on a clean soft cloth to protect surface finish. Use a thin– blade screwdriver to p[...]

Reelmaster 4000–D Page 4 – 43 Hydraulic System 13. Remove quad ring seal from seal gland bushing. 14. Use a thin–blade screwdriver to pry dust seal from seal gland bushing. Do not damage bushing. 15. Remove 2 bearing races and the needle thrust bear- ing from spool and sleeve assembly . 16. Remove spool and sleeve assembly from 14–hole end [...]

Reelmaster 4000–D Page 4 – 44 Hydraulic System 18. Push spool partially from control end of sleeve, then remove 6 centering springs from spool carefully by hand, see Fig. 35. 19. Push spool back through and out of sleeve, see Fig. 35. Rotate spool slowly when removing from sleeve. 20. Remove seal from housing, see Fig. 36. 21. Screw a #10–24 [...]

Reelmaster 4000–D Page 4 – 45 Hydraulic System Reassembly Check all mating surfaces. Replace any parts that have scratches or burrs that could cause leakage. Clean all metal parts in clean solvent. Blow dry with air . Do not wipe dry with cloth or paper towel because of lint or other matter can get into the hydraulic system and cause da- mage. [...]

Reelmaster 4000–D Page 4 – 46 Hydraulic System 6. Bring spring slots of both parts in line and stand parts on end of bench. Insert spring installation tool through spring slots of both parts. T ool is available from an Eaton hydraulics supplier as Eaton part no. 600057. Position 3 pairs of centering springs (or 2 sets of 3 each) on bench so tha[...]

Reelmaster 4000–D Page 4 – 47 Hydraulic System 1 1. Place housing on clean, lint free cloth. Install 2–1/8” diameter seal in housing, see Fig. 41. 12. Install 2 bearing races and the needle thrust bearing in the order shown. 13. Install 1–1/4” diameter dust seal in seal gland bush- ing, flat or smooth side of dust seal must face down to[...]

Reelmaster 4000–D Page 4 – 48 Hydraulic System 17. Clamp housing in vise, as shown in Fig. 44. Clamp lightly on edges of mounting area. Do not over–tighten jaws. NOTE: Check to insure that the spool and sleeve are flush or slightly below the 14–hole surface of the hous- ing. IMPORT ANT : Clean the upper surface of the hous- ing by wiping wi[...]

Reelmaster 4000–D Page 4 – 49 Hydraulic System 21. Install 3” diameter seal in meter . 22. With seal side of meter toward spacer plate, align star valleys (ref. A) on drive (ref. B). Record the parallel relationship of reference lines A, B, C, and D in Fig. 48. Align bolt holes without disengaging meter from drive. Figure 47 Figure 48 Hydraul[...]

Reelmaster 4000–D Page 4 – 50 Hydraulic System 23. Install drive spacer(s), when used, in meter , see Fig. 49. 24. Install 3” diameter seal in end cap. 25. Install end cap on gerotor , align holes. 26. Install 7 dry cap screws with new seal washers in end cap. Pre–tighten screws to 150 inch pounds, ten torque screws to 275 inch pounds in se[...]

Reelmaster 4000–D Page 4 – 51 Hydraulic System Add Hydraulic Fluid Capacity of the hydraulic reservoir is approximately 9.3 gal. (35.2 L). With machine on a level surface, hydraulic oil level should be 1/4 to 1/2 inch below arrows on sight glass, when oil is cold. W arm oil should be even with ar- rows on sight glass. If level is low , add hydr[...]

Reelmaster 4000–D Page 4 – 52 Hydraulic System Reel Motor 2 3 4 5 6 7 8 9 10 11 12 13 14 5 7 20 19 18 16 17 15 21    2. Idler Gear 3. Drive Gear 4. Key 5. O–Ring 6. Body 7. Dowel Pin 8. Plate & Bushing Assembly 9. Socket Head Cap Screw 10. Set Screw 1 1. Drive Pulley 12. Retaining Ring 13. Shaft Seal 14. Back[...]

Reelmaster 4000–D Page 4 – 53 Hydraulic System Inspection of Reel Motor GENERAL 1. Clean and dry all parts. 2. Remove nicks and burrs from all parts with emery cloth. GEAR ASSEMBL Y 1. Inspect drive gear assembly (3) for broken or cracked keyway . 2. Inspect both the drive gear (3) and idler gear (2) shafts at bearing point for rough surfaces a[...]

Reelmaster 4000–D Page 4 – 54 Hydraulic System Steering Pump 1 2 3 4 6 7 8 9 10 16 17 18 19 20 21 22 11 12 13 14 15 4 2 16 23 24 25 26 Figure 55 1. Plug (includes #2) 2. O–Ring 3. Spool 4. Dowel Pin 6. Plug (includes #2) 7. Drive Gear Assembly 8. Disc 9. Spring 10. Idler Gear Assembly 1 1. Hex Head Cap Screw 12. Shaft Seal 13. W asher 14. Bus[...]

Reelmaster 4000–D Page 4 – 55 Hydraulic System Disassembly of Steering Pump 1. Thoroughly clean outside of pump. 2. Use a sharp tool or marker to mark across front plate (15), body (21) and back plate (22). This will assure proper reassembly . 3. Clamp pump in a vise, with the shaft up. 4. Remove capscrews (1 1). 5. Remove pump from vise, hold [...]

Reelmaster 4000–D Page 4 – 56 Hydraulic System 1 2 3 4 6 7 8 9 10 16 17 18 19 20 21 22 11 12 13 14 15 4 2 16 23 24 25 26 Figure 56 1. Plug (includes #2) 2. O–Ring 3. Spool 4. Dowel Pin 6. Plug (includes #2) 7. Drive Gear Assembly 8. Disc 9. Spring 10. Idler Gear Assembly 1 1. Hex Head Cap Screw 12. Shaft Seal 13. W asher 14. Bushing 15. Front[...]

Reelmaster 4000–D Page 4 – 57 Hydraulic System Assembly of Steering Pump It is important that the relationship of the back plate (22), body (21), wear plate (20) and front plate (15) is correct. Y ou will note two half moon cavities in the body which must face away from the front plate. NOTE: The smaller half moon port cavity must be on the pre[...]

Reelmaster 4000–D Page 4 – 58 Hydraulic System Lift Control V alve 31 32 33 35 36 37 38 1 2 3 4 5 6 7 8 9 10 16 17 18 19 20 22 23 24 25 26 27 28 29 30 11 12 13 14 15 22 34 39 40 39 Figure 57 1. Plug Assembly 2. Disc 3. Spring 4. Detent Plunger 5. O–Ring 6. Plug Assembly 7. O–Ring 8. Body 9. O–Ring 10. Backup W asher 1 1. Plug Assembly 12.[...]

Reelmaster 4000–D Page 4 – 59 Hydraulic System Disassembly of Lift Control V alve 1. Plug all ports and clean outside of valve thoroughly . 2. Remove cap assemblies (28). Do not remove retain- ing rings (26) from spools unless spring (25) is broken. 3. Remove spools (13) from body (8). NOTE: Spools and spool bores are matched sets. Be sure each[...]

Reelmaster 4000–D Page 4 – 60 Hydraulic System Priority Flow Divider 1 2 3 4 5 6 7 8 9 10 16 17 18 19 11 12 13 14 15 2 1 Figure 58 1. Plug Assembly 2. O–Ring 3. Spool 4. Body 5. O–Ring 6. O–Ring 7. Backup Washer 8. Metering Stem 9. Groove Pin 10. Shim 1 1. Shim 12. Shim 13. Shim 14. O–Ring 15. Backup W asher 16. Metering Plug 17. Shim 1[...]

Reelmaster 4000–D Page 4 – 61 Hydraulic System Disassembly of Priority Flow Divider 1. Plug all ports and thoroughly clean outside of valve. 2. Remove plug (1), shims (17 & 18), spring (19), and flow control spool (3) from body (4). NOTE: Notice the position of the spool in relation to valve body when removing spool (3). 3. Remove metering [...]

Reelmaster 4000–D Page 4 – 62 Hydraulic System Lift Cylinder 1 2 3 4 5 6 7 Figure 59 1. Bleed Screw 2. W asher 3. Rod 4. Wiper 5. Seal 6. Snap Ring 7. Seal Kit[...]

Reelmaster 4000–D Page 4 – 63 Hydraulic System Disassembly of Lift Cylinder 1. Thoroughly clean outside of cylinder assembly . 2. Pull rod (3) out until end of rod and snap ring (6) can be seen through inlet port. 3. Insert screw driver in inlet port and slide snap ring (6) into deep groove in the rod assembly . 4. Remove rod assembly (3) from [...]

Reelmaster 4000–D Page 4 – 64 Hydraulic System Reel Control V alve 31 32 33 34 1 2 3 4 5 6 7 8 9 10 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 11 12 13 14 15 Figure 60 1. Spool 2. Body 3. O–Ring 4. Plug 5. O–Ring 6. Backup W asher 7. O–Ring 8. Relief V alve 9. Detent Plug 10. Detent Spring 1 1. Detent Pawl 12. Locknut 13. Lock W asher 1[...]

Reelmaster 4000–D Page 4 – 65 Hydraulic System Disassembly of Reel Control V alve Assembly 1. Plug all outlets and thoroughly clean outside of valve. 2. Remove plug (4) and O–ring (3). 3. Remove relief valve components (8, 7, 6, & 5). 4. Remove screws (22) and lock washers (23). 5. Remove detent block (25). 6. Remove detent plug (9), spri[...]

Reelmaster 4000–D Page 4 – 66 Hydraulic System Reel Shut Off V alve 1 2 3 4 5 6 7 8 9 1 2 5 6 7 Figure 61 1. Circlip 2. W asher 3. Spacer 4. Spring 5. Wiper 6. Backup W asher 7. O–Ring 8. Body 9. Spool[...]

Reelmaster 4000–D Page 4 – 67 Hydraulic System Disassembly of Reel Shut–Off V alve Assembly 1. Thoroughly clean outside of valve. 2. Remove retaining ring (1) from end of spool (9). 3. Remove spool (9) from valve body (8). 4. Remove washers (2), spring (4), and spacer (3) from spool (9). 5. Remove wipers (5), back–up washers (6), and O– r[...]

Reelmaster 4000–D Page 4 – 68 Hydraulic System T raction Pump 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 1 2 3 4 5 6 7 8 9 10 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 11 12 13 14 15 Figure 62 1. Hex Head Cap Screw 2. Charge Pump Adapter Assembly 3. Plug Assembly 4. T ow V alve Assembly 5. O–Ring 6. Needle Bearing 7. Gerotor Gea[...]

Reelmaster 4000–D Page 4 – 69 Hydraulic System Disassembly of T raction Pump 1. Disconnect all control linkage, hydraulic lines and re- move pump assembly from vehicle. 2. Plug all ports and thoroughly clean outside of pump. 3. Clamp the end of the drive shaft in a protected jaw vise with the body of the pump up and remove the four cap screws ([...]

Reelmaster 4000–D Page 4 – 70 Hydraulic System 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 1 2 3 4 5 6 7 8 9 10 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 11 12 13 14 15 Figure 63 1. Hex Head Cap Screw 2. Charge Pump Adapter Assembly 3. Plug Assembly 4. T ow V alve Assembly 5. O–Ring 6. Needle Bearing 7. Gerotor Gear Assembly 8. C[...]

Reelmaster 4000–D Page 4 – 71 Hydraulic System Inspection of T raction Pump 1. Inspect the charge pump relief valve seat inside the charge pump adaptor . It should be smooth and free of burrs or other defects. 2. Inspect the charge pump relief valve poppet (42) and spring (43). 3. Inspect the gerotor pocket inside the charge pump adaptor assemb[...]

Reelmaster 4000–D Page 4 – 72 Hydraulic System 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 1 2 3 4 5 6 7 8 9 10 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 11 12 13 14 15 Figure 64 1. Hex Head Cap Screw 2. Charge Pump Adapter Assembly 3. Plug Assembly 4. T ow V alve Assembly 5. O–Ring 6. Needle Bearing 7. Gerotor Gear Assembly 8. C[...]

Reelmaster 4000–D Page 4 – 73 Hydraulic System Reassembly of T raction Pump 1. Clean all parts in suitable solvent, lubricate all critical moving parts before reassembly . If necessary , install new needle bearings in the housing. The camplate pivot bearings are slip fit; the needle bearing (6) is press fit, install with numbered end of the bea[...]

Reelmaster 4000–D Page 4 – 74 Hydraulic System Front T raction Motor 1 2 6 7 21 22 19 18 17 12 11 10 9 20 8 16 13 14 15 14 13 4 3 5 Figure 65 1. Hex Head Cap Screw 2. Hex Head Cap Screw 3. Plug 4. O–Ring Seal 5. Back Plate Assembly 6. O–Ring 7. Bearing 8. Key 9. Retaining Ring 10. Drive Shaft 1 1. Shaft Seal 12. W asher 13. Retaining Ring 1[...]

Reelmaster 4000–D Page 4 – 75 Hydraulic System IMPORT ANT : Do not attempt to disassemble the piston block and spring. The parts are not service- able separately . The rotating assembly (19) must be replaced as an assembly . 10. Remove camplate assembly (18) from housing. 1 1. Remove shaft seal (1 1) from housing. 12. Remove washer (12) and dri[...]

Reelmaster 4000–D Page 4 – 76 Hydraulic System Reel Pump 1 2 3 4 5 6 7 8 9 10 16 17 18 11 12 13 14 15 12 7 Figure 66 1. Nut 2. Lock W asher 3. Stud 4. Stud 5. Front Cover 6. Gland Seal 7. Wear Plate 8. Center S/A Section 9. Shaft Seal 10. Spline Drive Gear 1 1. Driven Gear 12. O–Ring Seal 13. Rear Port Section 14. Coupling 15. O–Ring 16. Pl[...]

Reelmaster 4000–D Page 4 – 77 Hydraulic System Disassembly of Reel Pump During disassembly , pay particular attention to identifi- cation of the parts for correct assembly . 1. Clamp the port section (13) in a vise with protective jaws to avoid damage to the port section’s machined surfaces. 2. Remove gear coupling (14) from port section (13)[...]

Reelmaster 4000–D Page 4 – 78 Hydraulic System 1 2 3 4 5 6 7 8 9 10 16 17 18 11 12 13 14 15 12 7 Figure 67 1. Nut 2. Lock W asher 3. Stud 4. Stud 5. Front Cover 6. Gland Seal 7. Wear Plate 8. Center S/A Section 9. Shaft Seal 10. Spline Drive Gear 1 1. Driven Gear 12. O–Ring Seal 13. Rear Port Section 14. Coupling 15. O–Ring 16. Plug 17. Sha[...]

Reelmaster 4000–D Page 4 – 79 Hydraulic System Reassembly of Reel Pump NOTE: Coat all parts with clean hydraulic fluid to facili- tate assembly and provide initial lubrication. Use small amount of petroleum jelly to hold seal glands (5) and re- tainers (6) in place during assembly . 1. Assemble seal packs by inserting the seal glands (5) into t[...]

Reelmaster 4000–D Page 4 – 80 Hydraulic System Rear Wheel Drive Motor 1 2 3 4 5 6 7 8 9 10 11 12 13 1 1 1 Figure 68 1. O–Ring Seal 2. Backup Washer 3. Shaft Seal 4. Key 5. Sub Shaft Assembly 6. Pin 7. Spring 8. Bolt 9. Outer Seal 10. Inner Seal 1 1. Shaft Seal 12. Dust Seal 13. Slotted Nut Disassembly of the Rear Wheel Drive Motor Cleanliness[...]

Reelmaster 4000–D Page 4 – 81 Hydraulic System 1. Place the motor in a vise with the output shaft down. Clamp across the mounting flange of the motor not the housing. Excessive clamping pressure will cause distor- tion. When clamping, use some protective device on the vise, such as special soft jaws, pieces of hard rubber or board. Although not[...]

Reelmaster 4000–D Page 4 – 82 Hydraulic System 6. Remove 2 pins and 2 springs from balance ring as- sembly , see Fig. 73. 7. Remove balance ring assembly . 8. Remove inner and outer face seals from balance ring. 9. Remove the valve. 10. Remove the valve plate. 1 1. Remove the 3[76] diameter seal from valve plate. 12. Remove the valve drive. 13.[...]

Reelmaster 4000–D Page 4 – 83 Hydraulic System 19. Y ou may need a press to remove shaft and bearing assembly from bearing housing. (Key must be removed before removing shaft.) 20. Use a small screwdriver to remove shaft seal, back– up washer and exclusion seal from bearing housing, see Fig. 78. Do not damage bore of housing. NOTE: Individual[...]

Reelmaster 4000–D Page 4 – 84 Hydraulic System 26. Alignment studs can be very helpful in reassembly of the motor . If you use studs, install 2 studs diagonally opposed in the bearing housing. 27. Install the shaft face seal in the wear plate as shown in Fig. 79. Do not distort seal. 28. Install the wear plate, see Fig. 79. 29. Apply a light fi[...]

Reelmaster 4000–D Page 4 – 85 Hydraulic System 37. Apply petroleum jelly to inner and outer face seals. Install seals on balance ring as shown in Fig. 83. IMPORT ANT : Install face seals in the positions shown in Fig. 83. or the motor will not operate prop- erly . Do not force or bend the face seals. Any dam- age to these seals will affect the [...]

Reelmaster 4000–D Page 4 – 86 Hydraulic System Wheel Motor On wheel motors, a different bearing housing is used, see Fig. 87. Other than this the parts are the same as the standard motor and the same disassembly and reas- sembly procedures apply . Figure 87[...]

Reelmaster 4000–D Page 4 – 87 Hydraulic System Rear Wheel Drive V alve Block NOTE: If cartridge valve seals appear pitted or damaged, the hydraulic system may be overheating or there may be water in the Figure 88 Cleaning Solenoid Actuated Cartridge V alve Use a deep socket to remove the valve cartridge. Use mineral spirits to clean solenoid ac[...]

Reelmaster 4000–D Page 4 – 88 Hydraulic System Steering Cylinder 1 3 4 5 6 7 8 9 11 12 18 13 14 15 16 17 2 10 Figure 90 1. Set Screw 2. Threaded Cap 3. Rod 4. Rod Wiper 5. U–Cup 6. Cap Head 7. Backup Washer 8. O–Ring 9. O–Ring 10. Spacer 1 1. Servon 12. O–Ring 13. Piston 14. Locknut 15. Barrel Assembly 16. Jam Nut 17. Rod Tie, End 18. R[...]

Reelmaster 4000–D Page 4 – 89 Hydraulic System 1 1. Use a complete repair kit when rebuilding the cylin- der . Put a coating of oil on all new seals, and O–rings. Install the new seal and O–rings. 12. Install head onto piston rod. 13. Install piston onto piston rod with O–ring seal (9) and tighten hex nut. 14. Put a coating of oil on all [...]

Reelmaster 4000–D Page 4 – 90 Hydraulic System Change Hydraulic Oil Normally , change hydraulic oil after every 2 years or 1500 operating hours. If oil becomes contaminated, contact your local TORO distributor because the system must be flushed. Contaminated oil looks milky or black when compared to clean oil. 1. Remove drain plug from reservoi[...]

Reelmaster 4000–D Page 4 – 91 Hydraulic System Replace Hydraulic Oil Filter Initially , change filter after the first 50 operating hours, thereafter , every 800 operating hours, annually , or on in- dication. Use T oro replacement filter (Part No. 86–61 10). IMPORT ANT : Use of any other filter may void the warranty on some components. 1. Rem[...]

Reelmaster 4000–D Page 4 – 92 Hydraulic System This Page Intentionally Left Blank[...]

Reelmaster 4000–D Page 5 – 1 Electrical System (Rev . A) Chapter 5 Electrical System T able of Contents ELECTRICAL SCHEMA TICS AND DIAGRAMS 2 . . . Reelmaster 4000–D Electrical Schematic (S/N below 220000000) 2 . . . . . . . . . . . . . . . . . . . . Reelmaster 4000–D Electrical Schematic (S/N 220000001 and up) 3 . . . . . . . . . . . . . .[...]

Reelmaster 4000–D Page 5 – 2 Electrical System (Rev . A) Electrical Schematics and Diagrams Start B+ ST ARTER BA TTERY 12 VOL T FUSIBLE LINK FUSIBLE LINK SP Y G B L AL TERNA TOR I R W PULL OR VIO 85 86 87 30 ENGINE OVER TEMP . (OPENS A T 110 C) C NC RUN RELA Y (OPERA TOR NOT PRESENT) SP R VIO VIO SEA T SWITCH W 30 BK BK/W 87 VIO VIO GLOW RELA Y[...]

Reelmaster 4000–D Page 5 – 3 Electrical System (Rev . A) Electrical Schematic Reelmaster 4000–D All relays and solenoids are shown as de–energized. All ground wires are black. (S/N 220000001 and up) Electrical System[...]

Reelmaster 4000–D Page 5 – 4 Electrical System (Rev . A) 3 4 RUN HYDRAULIC OIL LEVEL SWITCH CAP ACITOR 4 B A 3 5 7 8 2 4 6 2 B A C 2 2 4 3 6 1 5 6 5 4 3 2 1 + P2 3 1 5 2 1 C BA + ++ 1 1 2 2 1 2 1 1 2 P10 P1 1 SEA T SWITCH J2 J1 P9 6 HYDRAULIC OIL FIL TER J3 GLOW PLUGS GROUND J4 J7 J8 P13 J9 J10 GLOW RELA Y P14 J1 1 J12 ENGINE RUN RELA Y RESISTO[...]

Reelmaster 4000–D Page 5 – 5 Electrical System (Rev . A) WIRE IDENTIFICA TION LABEL COLOR ROUTE W1. R–66467 J15, SP1 W2. RED SP1, J19 W3. R–66465 J15, SP2 W4. RED SP2, J24 W5. WHT J12, P2–B W6. RED J25, P12–1 W7. RED/BLK P12–2, P6–2 W8. RED J11, J9 W9. RED/BLK J10, J3 W10. BLU P15–1, P12–8 W1 1. BLU P12–8, P8–A W12. BLU P15?[...]

Reelmaster 4000–D Page 5 – 6 Electrical System (Rev . A) 1 W13 P1 J13 J18 ENGINE OVER TEMP 105 C ENGINE OIL PRESSURE WA TER IN FUEL (FUEL FIL TER) P15 B+ L IG ST ART J14 J19 AL TERNATOR ST ARTER J15 B+ W10 2 1 W4 SP2 SP1 W12 W13 W2 W37 W1 W3 W32 W25 W56 1 2 3 W30 W31 24 34 3 2 1 P3 W63 J21 J20 W35 W55 56 P4 W34 W36 W24 AIRFIL TER LIGHT CLUSTER [...]

Reelmaster 4000–D Page 5 – 7 Electrical System (Rev . A) Main Harness Drawing Reelmaster 4000–D (S/N 220000001 and up) Electrical System[...]

Reelmaster 4000–D Page 5 – 8 Electrical System (Rev . A) Main Harness Wiring Diagram Reelmaster 4000–D (S/N 220000001 and up) RED/BLACK W22 W22 BLACK RED GREEN BLACK/WHITE BLACK BLACK BLACK BLACK BLACK BLACK BLACK PINK TA N GRA Y VIOLET ORANGE ORANGE BLK/WH BLACK/WHITE BLACK/WHITE BLK/WH BLACK BROWN BLACK TA N ORANGE BROWN BLACK RED/BLACK BLK[...]

Reelmaster 4000–D Page 5 – 9 Electrical System (Rev . A) 5 4 12 3 1 2 3 4 6 1 5 2 3 4 A A(+) C(–) B 6 2 3 6 B A 1 2 3 KUBOT A GLOW PLUG CONTROLLER 4 5 XXXXXXX 1 P7 GLOW INDICA TOR P3 4WD SWITCH J1 J2 P4 FUEL GAUGE P6 J7 IGNITION SWITCH P2 MAIN HARNESS P1 MAIN HARNESS P5 REEL DRIVE HARNESS J5 J6 HIGH TEMP OVERIDE XXXXXXX 5 B P8 HOUR METER Cont[...]

Reelmaster 4000–D Page 5 – 10 Electrical System (Rev . A) KUBOT A GLOW PLUG CONTROLLER 4WD 1 6 5 4 3 2 P1 W19 W8 W10 MAIN TO (TO P18) W7 W9 W16 W6 W18 W17 W1 1 W8 5 4 3 2 1 W5 A IGNITION P5 REEL DRIVE HARNESS P6 J7 XYA B S I P7 GLOW INDICA TOR B A W20 W10 W2 W9 W1 W5 W3 W1 (TO P17) P2 6 5 4 3 2 1 W21 W4 W2 1 2 3 45 W16 W20 W12 W17 W1 1 W19 6 W2[...]

Reelmaster 4000–D Page 5 – 1 1 Electrical System (Rev . A) J7 J8 4 ALARM TEST 6 2 3 3 4 5 6 1 2 3 TO MAIN HARNESS 3 4 1 2 SILENCE ALARM ALARM 1 J20 J2 (+) (–) P5 P2 5 4 1 2 J21 J22 J23 J24 J3 J4 J6 J5 TO LIGHT CLUSTER 5 SILENCE ALARM J1 1 2 3 4 5 6 ALARM P3 P4 TO MAIN HARNESS J9 J10 J1 1 J12 J13 J14 J15 J16 P1 TO LIGHT CLUSTER J19 J18 J17 SWI[...]

Reelmaster 4000–D Page 5 – 12 Electrical System (Rev . A) TO MAIN HARNESS (P3) 3 2 4 1 3 2 4 5 6 1 P5 P4 TO MAIN HARNESS (P4) W16 J21 W13 W15 W14 W37 W36 W4 W2 W3 W1 (–) (+) J6 J5 ALARM LIGHT CLUSTER #2 P2 W23 W33 W32 1 2 3 45 6 W7 W8 W1 1 W9 W5 W6 W10 W20 W17 W29 J9 J10 J17 RECTIFIER #1 W28 J22 RECTIFIER #2 J1 1 J18 J12 P1 LIGHT CLUSTER #1 W[...]

Reelmaster 4000–D Page 5 – 13 Electrical System (Rev . A) Special T ools Order special tools from the TORO SPECIAL TOOLS AND APPLICA TIONS GUIDE (COMMERCIAL PROD- UCTS) . Some tools may also be available from a local supplier . Multimeter The meter can test electrical components and circuits for current, resistance, or voltage. NOTE: T oro reco[...]

Reelmaster 4000–D Page 5 – 14 Electrical System (Rev . A) T roubleshooting CAUTION Remove all jewelry , especially rings and watches, before doing any electrical trouble- shooting or testing. Disconnect the battery cables unless the test requires battery voltage. For effective troubleshooting and repairs, you must have a good understanding of t[...]

Reelmaster 4000–D Page 5 – 15 Electrical System (Rev . A) Starting Problems (continued) Problem Possible Causes Engine cranks, but does not start. Engine run solenoid wiring loose or corroded. Engine run solenoid faulty . Low hydraulic oil level. Hydraulic oil low level switch is faulty . Hydraulic oil low level switch wiring loose, corroded or[...]

Reelmaster 4000–D Page 5 – 16 Electrical System (Rev . A) General Run and T ransport Problems Engine continues to run (but should not) when parking brake is released or mow–backlap lever is in mow or backlap with no operator on seat. Seat switch plunger depressed with no operator on seat. Seat switch faulty or out of adjustment. Short circuit[...]

Reelmaster 4000–D Page 5 – 17 Electrical System (Rev . A) Electrical System Quick Check Battery T est (Open Circuit T est) Use a multimeter to measure the voltage between the battery terminals. Set multimeter to the DC volts setting. The battery should be a t a temperature of 60 to 100 o F (16 to 38 o C). Th e ignition key sh ould be off and al[...]

Reelmaster 4000–D Page 5 – 18 Electrical System (Rev . A) Component T esting For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before doing a continuity check). NOTE: For more component testing information, see the Kubota Workshop Ma[...]

Reelmaster 4000–D Page 5 – 19 Electrical System (Rev . A) Hour Meter IMPORT ANT : Make sure to observe polarity on the meter l abel when testing. Damage to the meter may result from an improper connection. 1. Connect the positive (+) terminal of a 12 VDC source to the positive terminal of the hour meter . 2. Connect the negative (–) terminal [...]

Reelmaster 4000–D Page 5 – 20 Electrical System (Rev . A) Alarm Relay The alarm relay is located inside the steering tower . 1. V erify coil resistance between terminals 86 and 85 with a multimeter (ohms setting). Resistance should be from 80 t o 9 0 ohms. There should be continuity between terminals 87A and 30. 2. Connect multimeter (ohms sett[...]

Reelmaster 4000–D Page 5 – 21 Electrical System (Rev . A) Fuel Sender The sender is located on top of the fuel tank under the rear screen. 1. Remove gray wire and black ground wire from the sender . 2. Remove truss head screws and lock washers from the sender and fuel tank. 3. Remove sender and gasket from the fuel tank. Clean any fuel from the[...]

Reelmaster 4000–D Page 5 – 22 Electrical System (Rev . A) H 2 O in Fuel Sensor The sensor is located on the fuel filter assembly , which is ins ide the center shroud area to the left side of the en- gine. It energizes a red warning light when too much w a - ter has collected in the fuel filter bowl. 1. Ma k e sure engine is OF F . Disconnect fu[...]

Reelmaster 4000–D Page 5 – 23 Electrical System (Rev . A) High T emperature W arning and Cutout Switches The high temperature warning and cutout switches are located on the water return pipe above the water pump, which is l ocated on the rear end of the engine block. The warning switch has a green/white wire connected to it. Th e cutout switch [...]

Reelmaster 4000–D Page 5 – 24 Electrical System (Rev . A) Rear Wheel Drive Solenoid Figure 18 1. Disconnect the wire connector . Note: Prior to taking small resistance readings with a digital m ulti meter , short the test leads toget her . The me- ter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to th[...]

Reelmaster 4000–D Page 5 – 25 Electrical System (Rev . A) Fuel Stop Solenoid The solenoid must be energized for the engine to run. It is mounted on the engine block near the injection pump. In Place T esting Note: Prior to taking small resistance readings with a digital m ultimeter , short the test leads together . The me - ter will display a s[...]

Reelmaster 4000–D Page 5 – 26 Electrical System (Rev . A) Hydraulic Oil Level Switch The level switch is located on top of the hydraulic reser- voir under the seat. It has an electrical connector from the wiring harness with two black, a black/white, and a orange wire. 1. Remove electrical connector from the level switch. 2. Unscrew sender from[...]

Reelmaster 4000–D Page 5 – 27 Electrical System (Rev . A) Glow Controller The controller is located under the right lower corner of the instrument panel. Controller Operation When the ignition switch is placed in the RUN position, the controller energizes the glow plugs and lights up the glow lamp for 10 seconds. When the ignition switch is hel[...]

Reelmaster 4000–D Page 5 – 28 Electrical System (Rev . A) Hydraulic Oil Filter Switch Th e oil filter switch is activate by the dif ferential pressure across the oil filter . When differential pressure is be- tween 16 to 20 PSID, a normally open contact closes. An alarm sounds and a warning light comes on at the instru- ment panel. When the dif[...]

Reelmaster 4000–D Page 5 – 29 Electrical System (Rev . A) Service and Repairs NOTE: For more component repair information, see Kubota W orkshop Manual, 03 Series, Diesel Engine . Battery Storage If the machine will be stored for more than 30 days 1. Re move the battery and charge it fully (see Battery Service). 2. Either store battery on a shel[...]

Reelmaster 4000–D Page 5 – 30 Electrical System (Rev . A) Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extend. Additionally , battery and electrical component failure can be prevented. CAUTION When working with batteries, use extreme cau- tion to avoid slashing or spilli[...]

Reelmaster 4000–D Page 5 – 31 Electrical System (Rev . A) B. T emperature correct each cell reading. For each 10 o F (5.5 o C) above 80 o F (26.7 o C) add 0.004 to the specific gravity reading. For each 10 o F (5.5 o C) be- low 80 o F (26.7 o C) subtract 0.004 from the specific gravity reading. Example: Cell T emperature 100 o F Cell Gravity 1.[...]

Reelmaster 4000–D Page 5 – 32 Electrical System (Rev . A) 7. Connect a digital multimeter (set to amps) between the negative battery post and the negative (ground) cable connector . The reading should be less than 0.1 am p. If the reading is 0.1 amp or more, the unit’s electri- cal system should be tested and repaired. 8. Connect negative (gr[...]

Reelmaster 4000–D Page 5 – 33 Electrical System (Rev . A) Rear Wheel Drive Solenoid Replacement Figure 28 1. Disconnect solenoid electrical connector . 2. Remove nut from solenoid. 3. Remove solenoid coil. 4. Install new solenoid coil. Make sure o–ring is installed a t each end of coil. Apply ”Loctite 242” or equiv- alent to threads on en[...]

Reelmaster 4000–D Page 5 – 34 Electrical System (Rev . A) Check Interlock System CAUTION The interlock switches are for the operator ’ s protection, so do not disconnect them. Check operation of the switches daily to assure inter- lock system is operating. If a switch is defective, replace it before operating properly . Even if the switches a[...]

Reelmaster 4000–D Page 6 – 1 Axles and Brakes Chapter 6 Axles and Brakes T able of Contents SPECIFICA TIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hand Brake and T raction Switches 3 . . . . . . . . . . . . . Rear Wheel T oe–In 4 . . . . . . . . . . .[...]

Reelmaster 4000–D Page 6 – 2 Axles and Brakes Specifications Item Description Front T ire Pressure 13 PSI (0.90 Bar) Rear T ire Pressure 15 PSI (1.04 Bar) Front Wheel Nut T orque 60 to 85 ft–lb (8.3 to 1 1.8 kg–m) Rear Wheel Nut T orque 30 to 35 ft–lb (4.1 to 4.8 kg–m) Wheel Planetary Mounting Cap Screw T orque 95–1 10 ft–lb (13.1 t[...]

Reelmaster 4000–D Page 6 – 3 Axles and Brakes Adjustments Hand Brake and T raction Switches Over time the hand brake cable will stretch and cause the engine not to start. If this happens, adjust the cable. 1. Pull hand brake lever to 3rd click. 2. Pull hand brake up one additional click. 3. Adjust four U–bracket nuts equally so the spring has[...]

Reelmaster 4000–D Page 6 – 4 Axles and Brakes Rear Wheel T oe–In After every 800 operating hours or annually , check rear wheel toe–in. 1. Measure center–to–center distance (at axle height) at the front and rear of the steering tires (Fig. 3). Front measurement must be 1/8 inch (0.32 cm) less than the rear measurement. 2. Loosen clamps [...]

Reelmaster 4000–D Page 6 – 5 Axles and Brakes Service and Repairs Rear Wheel Bearing Service (2WD Only) 1. Hex flange head screw 2. Spindle cap 3. Retaining ring 4. Thrust washer 5. Flange bushing 6. Rear axle 7. Wheel spindle (LH) 8. Drive screw 9. Rear wheel hub 10. Outer bearing cup 1 1. Outer bearing cone 12. Tire 13. Lug nut 14. Rim 15. Co[...]

Reelmaster 4000–D Page 6 – 6 Axles and Brakes 1. Jack up rear of machine until tire is off the. Support machine with jack stands or blocks to prevent it from fal- ling (see Jacking Instructions in Chapter 1 – Safety). 2. Remove dust cap (16) from the end of the wheel spindle. 3. Remove cotter pin (15), slotted nut, and washer (18). Slide whee[...]

Reelmaster 4000–D Page 6 – 7 Axles and Brakes Planetary Wheel Drive 1. Coupling 2. Input shaft 3. Spindle 4. Oil seal 5. Bearing cone 6. Bearing cup 7. Wheel bolt 8. Hub 9. Bearing cone 10. Hex head bolt 1 1. Flat washer 12. Thrust washer 13. Primary sun gear 14. Hex head bolt 15. Primary carrier assembly 16. Pipe plug 17. Hex head bolt 18. Dis[...]

Reelmaster 4000–D Page 6 – 8 Axles and Brakes Disassemble Planetary Wheel Drive 1. Slide coupling (1) from the splines on the input shaft (2). 2. Position assembly upright on the face of spindle (3). Remove disengage cover (18). 3. Remove bolts (17) and large cover (19). The disen- gage plunger (22) usually remains with the cover . Re- move plu[...]

Reelmaster 4000–D Page 7 – 1 Cutting Units Chapter 7 Cutting Units T able of Contents SPECIFICA TIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL T OOLS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust Reel to Bedknife Contact 4 . .[...]

Reelmaster 4000–D Page 7 – 2 Cutting Units Specifications 1 11 2 6 5 7 8 9 10 3 4 1. Drive housing cover 2. drive housing 3. Drive plate shield 4. Grass deflector 5. Rear roller adjuster (both ends) 6. Reel–to–bedknife adjuster 7. Guard 8. cone nut 9. Reel 10. Optional front roller 1 1. T op covers Figure 1 Construction: The frame is welded[...]

Reelmaster 4000–D Page 7 – 3 Cutting Units Special T ools Order special tools from the TORO SPECIAL TOOLS AND APPLICA TIONS GUIDE (COMMERCIAL PROD- UCTS) . Some tools may be listed in the Reelmaster 4000–D Parts Catalog. Some tools may also be available from a local supplier . Gauge Bar Assembly Use gauge bar to set final height–of–cut (f[...]

Reelmaster 4000–D Page 7 – 4 Cutting Units Adjustments CAUTION Never install or work on the cutting units or lift arms with the traction unit engine running. Al- ways stop the engine and remove the key first. Adjust Reel to Bedknife Contact The cutting units will provide optimum mowing perfor- mance when adjusted and maintained correctly . Keep[...]

Reelmaster 4000–D Page 7 – 5 Cutting Units Height–of–Cut Adjustment (Floating Cutting Unit) Overview of Procedure: 1. Adjust reel to bedknife contact 2. Level rear roller to reel 3. Adjust initial height–of–cut using gauge bar . 1. Adjust reel to bedknife contact on all cutting units. (see Adjust Reel to Bedknife Contact). 2. Level rear[...]

Reelmaster 4000–D Page 7 – 6 Cutting Units 3. Make final height–of–cut adjustment with gauge bar . A. Raise cutting units and lock in the transport posi- tion. Shut off the engine and remove the key from the ignition switch. B. Use gauge bar (T oro Part No. 59–7900) to set fi- nal height–of–cut by adjusting the front roller only . C. [...]

Reelmaster 4000–D Page 7 – 7 Cutting Units Adjust Height–of–Cut (Fixed Cutting Unit) 1. Adjust reel to bedknife contact ( see Adjust Reel to Bedknife Contact). 2. Loosen nuts securing skids or front roller and raise to highest position. 3. Loosen jam nuts securing rear roller . Lower roller beyond desired height–of–cut (assures proper b[...]

Reelmaster 4000–D Page 7 – 8 Cutting Units Service and Repairs CAUTION Never remove, install, or work on the cutting units or lift arms with the traction unit engine run- ning. Stop engine and remove key from ignition switch first. Backlapping CAUTION During backlap operation the reels are under power . Contact with rotating reels can result in[...]

Reelmaster 4000–D Page 7 – 9 Cutting Units Hydraulic Motor Installation 1. Install drive plate shield onto the reel drive motor flange. Be sure the widest portion of the shield is at the top (Fig. 13). IMPORT ANT : Make sure motor pulley set screws are tight on the motor shaft before installing the motor onto the cutting unit (Fig. 14). 2. Inse[...]

Reelmaster 4000–D Page 7 – 10 Cutting Units Bedknife/Bedbar Disassembly 1. Remove shoulder bolts, bushings and spacers from each end of the unit. Remove bedbar/bedknife assem- bly (Fig. 16). 2. Remove mounting screws for the bedknife. Sepa- rate bedknife from the bedbar . Discard screws (Fig. 17). Assembly 1. Clean bedknife mounting face on the[...]

Reelmaster 4000–D Page 7 – 1 1 Cutting Units Reel Assembly Disassembly 1. Remove the guards from each end of the cutting unit and the front and rear roller assemblies (Fig. 20). 2. Remove shoulder bolts, bushings and spacers from each end of the unit and remove the bedbar/bedknife assembly (Fig. 21). 3. Remove inboard locknut from the adjuster [...]

Reelmaster 4000–D Page 7 – 12 Cutting Units 6. Disassemble cover from the drive housing and re- move the drive belt from the housing (Fig. 23). Note: Reel capscrew is assembled with a thread lock- ing compound 7. Remove reel capscrew , toothed washer , and pulley washer from the reel shaft (Fig. 23). 8. Remove driven pulley from the reel shaft [...]

Reelmaster 4000–D Page 7 – 13 Cutting Units Assembly 1. Inspect flange bushings in the mounting holes of the drive housing and bearing housing for wear (Fig. 21). Replace, if necessary . 2. Assemble outer seal (lip facing in to retain grease) into the drive housing using Loctite 242 (or equivalent) retaining compound on the outer diameter . App[...]

Reelmaster 4000–D Page 7 – 14 Cutting Units Preparing a Reel for Grinding Note: Check to make sure the reel bearings are in good condition before grinding the reel. Make sure the cutting unit frame and roller brackets are true and not bent or damaged. 1. Remove the bedbar assembly (Bedknife/Bedbar Disassembly). 2. Remove parts as necessary to m[...]

Reelmaster 4000–D Page 7 – 15 Cutting Units Front and Rear Rollers Note: Front and rear rollers can be removed and installed in the same manner . Removal Note: Front and rear rollers can be removed using ei- ther of two methods. 1. Remove roller adjustment housing from side plate (Fig. 26). A. Remove mounting fasteners securing both guards and [...]

Reelmaster 4000–D Page 7 – 16 Cutting Units Roller Bearing Replacement 1. Roller tube (front roller shown) 2. Roller shaft 3. Grease fitting 4. Lock nut 5. Jam nut 6. T rust washer 7. Outer grease seal 8. Wear sleeve 9. O–ring 10. Bearing cone 1 1. Bearing cup 12. Inner grease seal Figure 28 4 7 9 11 3 6 8 10 12 1 2 6 5 12 11 10 9 8 7 Removal[...]

Reelmaster 4000–D Page 7 – 17 Cutting Units 3. On the rear , wiehle, and sectional rollers, press new inner grease seals into the roller tube with the garter spring of the seal facing towards the center of the roller (Fig. 30). 4. Press both bearing cups into the roller tube with the narrow end of the taper facing the inside of the roller tube.[...]

Reelmaster 4000–D Page 7 – 18 Cutting Units Lubrication Use a hand–operated grease gun and No. 2 general purpose grease to lubricate the eight grease fittings. IMPORT ANT : Before washing the machine, shut off the engine and remove the key . T oro recommends daily lubrication of reels and rollers immediately af- ter washing the machine. This [...]

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