Toro 98958SL - Manuals

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 andin good operating condition. Frequently check all nuts,bolts and screws. 28. Frequently check all h...

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 damagedor illegible, replace them. Decal part numbers are listed below and in the parts catalog. Order replacementsfrom your Authorized ...

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

Reelmaster 4000–D Page 2 – 1 Product Records and Maintenance Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS 1 . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS 2 . . . . . . . . . . . Decimal and Millimeter Equivalents 2 . . . . . . . . . . . ...

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

Reelmaster 4000–D Page 2 – 3 Product Records and Maintenance Torque Specifications Recommended fastener torque values are listed in thefollowing tables. For critical applications, as determinedby Toro, either the recommended torque or a torque thatis unique to the application is clearly identified a...

Reelmaster 4000–D Page 2 – 4 Product Records and Maintenance Standard Torque 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 Gra...

Reelmaster 4000–D Page 2 – 6 Product Records and Maintenance Other Torque Specifications SAE Grade 8 Steel Set Screws Thread Size 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 ...

Reelmaster 4000–D Page 2 – 7 Product Records and Maintenance Lubrication GREASING BEARINGS AND BUSHINGS The machine has grease fittings that must be lubricatedafter every 50 hours of operation with No. 2 General Pur-pose Lithium Base Grease. Lubricate fitting immediatelyafter every washing regardles...

Reelmaster 4000–D Page 2 – 9 Product Records and Maintenance EQUIPMENT OPERATION AND SERVICE HISTORY REPORT for REELMASTERR 4000–D TORO Model and Serial Number: ______________–______________ Engine Numbers: _____________________________ Transmission Numbers: _____________________________ Drive Axle(...

Reelmaster 4000–D Page 2 – 10 Product Records and Maintenance Reelmaster 4000–D Maintenance Schedule Minimum Recommended Maintenance Intervals Maintenance Procedure Lubricate Reel Control Valve Grease Fitting Lubricate Reel Speed Valve with Oil Lubricate All Grease Fittings Check Battery Condition a...

Reelmaster 4000–D Page 2 – 11 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 _________________ Che...

Reelmaster 4000–D Supervisor Maintenance W ork Order Date: ________________ Unit Designation: Hours: T echnician: T ORO I.D. #: __________________–__________________ Service to perform (circle): A B C D Other Remarks: (See Operator ’s and Service Manual for specifications and procedures.) A– Service...

Reelmaster 4000–D Page 3 – 1 Kubota Diesel Engine Chapter 3 Kubota Diesel Engine Table of Contents INTRODUCTION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 4 . . . . . . . . . . . . . . . ....

Reelmaster 4000–D Page 3 – 2 Kubota Diesel Engine Introduction This Chapter gives information about specifications,maintenance, troubleshooting, testing, and repair of thediesel engine used in the Reelmaster 4000–D. Most repairs and adjustments require tools, which arecommonly available in many serv...

Reelmaster 4000–D Page 3 – 3 Kubota Diesel Engine Specifications Item Description Make / Designation Kubota, V2203, 4–Cylinder, 4–Cycle, Water Cooled, In–line, Spherical Chamber, OHV, Diesel Engine Horse Power 39.4 HP @ 2300 RPM Torque 103 ft–lb @ 1600 RPM Firing Order 1 – 3 – 4 – 2 Bore mm (in.) 87...

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 ...

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 escapeand cause burns when the radiator cap is re-moved. Remove radiator cap slowly an...

Reelmaster 4000–D Page 3 – 6 Kubota Diesel Engine Prime Fuel System IMPORTANT: The fuel system must be primed whena new engine is started for the first time, if it runs outof fuel, or if maintenance is performed on the fuelsystem. Note: The fuel pump, located on left side of engine,under the fuel in...

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 m...

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...

Reelmaster 4000–D Page 3 – 9 Kubota Diesel Engine Change Engine Oil and Filter Change oil and filter after the first 50 hours of operationand 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 ...

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 smokewhile filling the fuel tank. Do not fill fuel tankwhile engine is running, hot, or when machine isin an enclosed area. Always fil...

Reelmaster 4000–D Page 3 – 11 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 ...

Reelmaster 4000–D Page 3 – 12 Kubota Diesel Engine Engine Cooling System Debris Removal Remove debris from oil cooler, radiator and rear screendaily, 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 en...

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 keyfrom the ignition switch. 2. Pivot seat up. Lift front canopy and remove from the brackets (Fig. 19). 3. Disconnect and r...

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 fuelfilter. Suction and discharge hoses at the fuel pump(Fig. 22). B. Return hose from the fuel injectors (Fig. 23). 10. Disconnec...

Reelmaster 4000–D Page 4 – 1 Hydraulic System Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 3 . . . . . . . . . . . . . . . . . . . . . Hydraulic Hoses 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

Reelmaster 4000–D Page 4 – 3 Hydraulic System General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions suchas, pressure differentials during operation and exposureto weather, sun, chemicals, very warm storage condi-tions or mishandling during operation or maintenance.The...

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 freeof 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...

Reelmaster 4000–D Page 4 – 5 Hydraulic System Pushing or Towing Traction Unit Using Traction Pump By–Pass Valve In an emergency, the traction unit can be pushed ortowed for a very short distance by using the tractionpump by–pass valve. IMPORTANT: Do not push or tow the traction unitfaster that 2 to ...

Reelmaster 4000–D Page 4 – 6 Hydraulic System Disengaging Planetary Wheel Drives In an emergency, the Reelmaster 4500–D can bemoved by unlocking the front wheel hubs and towing themachine. DANGER Vehicle will roll with front wheel motors disenga-ged. Vehicle must be on level surface or wheelsmust be...

Reelmaster 4000–D Page 4 – 7 Hydraulic System Check Hydraulic System Fluid 1. Look into sight glass (Fig. 11). Oil level should be even with arrows when checking warm oil. Oil will be 1/4to 1/2 inch below arrows when cold. 2. If oil level is low, add hydraulic oil to the reservoir (see Add Hydraulic...

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

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 directlycoupled to the engine. With all controls in neutral and theengine running, the steer–lift ...

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

Reelmaster 4000–D Page 4 – 11 Hydraulic System Traction Circuit Refer to “Traction Circuit – Forward” Flow Diagram A mechanical interlock between the traction pedal link-age and the parking brake prevents traction pedalmovement unless the brake is released. Depressing the top of the traction pedal w...

Reelmaster 4000–D Page 4 – 12 Hydraulic System Traction 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 thesteer–lift pump is directed to the power steering unit atthe base of the steering column and returns to the reser-voir. Turning the steerin...

Reelmaster 4000–D Page 4 – 14 Hydraulic System Steering Right

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 – 19 Hydraulic System Reel Circuit Refer to “Reel Circuit” Flow Diagrams The three reel shut–off valves in this circuit enable thecutting units to be operated in several configurations foreasier control, better clearance, or closer trimming. The reel pump supplies a constant...

Reelmaster 4000–D Page 4 – 20 Hydraulic System Reel Circuit – All Units 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 Valve Operation 4WD Forward (“S1” OFF) Pressure Oil Pressure Free

Reelmaster 4000–D Page 4 – 26 Hydraulic System Special Tools NOTE: Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIALPRODUCTS). Some tools may also be available from alocal supplier. Hydraulic Tester – With Pressure and Flow Capabilities – TOR214678 Figure 12 You must...

Reelmaster 4000–D Page 4 – 27 Hydraulic System Hydraulic Pressure Test Kit – TOR47009 Use to take various pressure readings for diagnostictests. 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 gaugesas...

Reelmaster 4000–D Page 4 – 28 Hydraulic System Troubleshooting The cause of an improperly functioning hydraulic sys-tem is best diagnosed with the use of proper testingequipment and a thorough understanding of the com-plete hydraulic system. A hydraulic system with an excessive increase in heator no...

Reelmaster 4000–D Page 4 – 30 Hydraulic System Testing The most effective method for isolating problems in thehydraulic system is by using hydraulic test equipmentsuch as pressure gauges and flow meters in the circuitsduring various operational checks. (See the SpecialTools section in this Chapter.)...

Reelmaster 4000–D Page 4 – 31 Hydraulic System TEST NO. 1: Check Traction Circuit Working and Relief Pressures Procedure for Working Pressure Check: 1. Install a 10,000 psi gauge into the quick disconnecttest port for the function to be checked. NOTE: If the machine is equipped with 4WD, checkworkin...

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. Tester reading should be within the range listed: COLD O...

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 quickdisconnect. 2. Operate the unit while monitoring the gauge. RANGE OF TESTER READINGS 0 – 2750 PS...

Reelmaster 4000–D Page 4 – 35 Hydraulic System TEST NO. 5: Check Reel Motor Cross–Over Relief Pressure B A PRIORITY OUT IN 3000 PSI T B A TEST PORT CUTTING (TYP) B A T T G CIRCUIT FROMGEAR PUMP FROMLIFT CIRCUIT TO HYDRAULICOIL TANK IN Figure 19 NOTE: Before testing a reel motor for possible failure,...

Reelmaster 4000–D Page 4 – 36 Hydraulic System TEST NO. 6: Check Reel Motor Case Drain Flow B A PRIORITY OUT IN 3000PSI T B A TEST PORT CUTTING (TYP) IN B A T T G CIRCUIT FROMGEAR PUMP FROMLIFT CIRCUIT TO HYDRAULICOIL TANK QUART CONTAINER Figure 20 1. Make sure hydraulic oil is at normal operating t...

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 ...

Reelmaster 4000–D Page 4 – 38 Hydraulic System TEST NO. 8: Check Lift Circuit Working and Relief Pressure Procedure For Working Pressure Check: 1. Install a 5,000 psi gauge onto the quick disconnect ofthe lift valve. 2. Operate the unit while monitoring the gauge. Gaugeshould read from 500 to 2900 P...

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 whenworking on hydraulic equipment. 2. Put caps...

Reelmaster 4000–D Page 4 – 40 Hydraulic System Steering Control Unit 1 2 3 45678 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 Ring3. Seal Gland Bushing4. Seal 1.875 I.D.5. Quad Ring Seal, 1.062 I.D.6. Bearing Race7. Thrust Bearing, Needle8. Hous...

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 fromseal gland bushing. Do not damage bushing. 15. Remove 2 bearing races and the needle thrust bear-ing from spool and sleeve assembly. 16. Remove spoo...

Reelmaster 4000–D Page 4 – 44 Hydraulic System 18. Push spool partially from control end of sleeve, thenremove 6 centering springs from spool carefully byhand, see Fig. 35. 19. Push spool back through and out of sleeve, seeFig. 35. Rotate spool slowly when removing fromsleeve. 20. Remove seal from h...

Reelmaster 4000–D Page 4 – 51 Hydraulic System Add Hydraulic Fluid Capacity of the hydraulic reservoir is approximately 9.3gal. (35.2 L). With machine on a level surface, hydraulicoil level should be 1/4 to 1/2 inch below arrows on sightglass, when oil is cold. Warm oil should be even with ar-rows o...

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. Key5. O–Ring6. Body7. Dowel Pin 8. Plate & Bushing Assembly9. Socket Head Cap Screw10. Set Screw11. Drive Pulley12. Retaining Ring13. Shaft Seal14. Bac...

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 emerycloth. GEAR ASSEMBLY 1. Inspect drive gear assembly (3) for broken or crackedkeyway. 2. Inspect both the drive gear (3) and idler gear (2)sha...

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–Ring3. Spool4. Dowel Pin6. Plug (includes #2)7. Drive Gear Assembly8. Disc9. Spring10. Idler Gear Assembly11. Hex Head Cap Screw1...

Reelmaster 4000–D Page 4 – 58 Hydraulic System Lift Control Valve 31 32 33 35 36 37 38 1 2 3 4 5 6 7 8 9 10 16171819 20 22 2324 25 2627 28 29 30 11 12 13 14 15 22 34 39 40 39 Figure 57 1. Plug Assembly2. Disc3. Spring4. Detent Plunger5. O–Ring6. Plug Assembly7. O–Ring8. Body9. O–Ring10. Backup Washe...

Reelmaster 4000–D Page 4 – 59 Hydraulic System Disassembly of Lift Control Valve 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...

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 Assembly2. O–Ring3. Spool4. Body5. O–Ring6. O–Ring7. Backup Washer8. Metering Stem9. Groove Pin10. Shim 11. Shim12. Shim13. Shim14. O–Ring15. Backup Washer16. Me...

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), andflow control spool (3) from body (4). NOTE: Notice the position of the spool in relation tovalve body ...

Reelmaster 4000–D Page 4 – 62 Hydraulic System Lift Cylinder 1 2 3 4 5 6 7 Figure 59 1. Bleed Screw2. Washer3. Rod4. Wiper 5. Seal6. Snap Ring7. 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) canbe seen through inlet port. 3. Insert screw driver in inlet port and slide snap ring (6)into deep groove in the rod ...

Reelmaster 4000–D Page 4 – 64 Hydraulic System Reel Control Valve 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. Spool2. Body3. O–Ring4. Plug5. O–Ring6. Backup Washer7. O–Ring8. Relief Valve9. Detent Plug10. Detent Spring11. Detent Pawl12. L...

Reelmaster 4000–D Page 4 – 65 Hydraulic System Disassembly of Reel Control Valve 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 ...

Reelmaster 4000–D Page 4 – 66 Hydraulic System Reel Shut Off Valve 1 2 3 4 5 6 7 8 9 1 2 5 6 7 Figure 61 1. Circlip2. Washer3. Spacer4. Spring5. Wiper 6. Backup Washer7. O–Ring8. Body9. Spool

Reelmaster 4000–D Page 4 – 68 Hydraulic System Traction 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 Screw2. Charge Pump Adapter Assembly3. Plug Assembly4. Tow Valve Assembly5. O–...

Reelmaster 4000–D Page 4 – 69 Hydraulic System Disassembly of Traction 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 jawvise with the body of t...

Reelmaster 4000–D Page 4 – 74 Hydraulic System Front Traction 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 Screw2. Hex Head Cap Screw3. Plug4. O–Ring Seal5. Back Plate Assembly6. O–Ring7. Bearing8. Key9. Retaining Ring10. Drive Shaft11. Shaft Seal 12...

Reelmaster 4000–D Page 4 – 75 Hydraulic System IMPORTANT: Do not attempt to disassemble thepiston block and spring. The parts are not service-able separately. The rotating assembly (19) must bereplaced as an assembly. 10. Remove camplate assembly (18) from housing. 11. Remove shaft seal (11) from ho...

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. Nut2. Lock Washer3. Stud4. Stud5. Front Cover6. Gland Seal7. Wear Plate8. Center S/A Section9. Shaft Seal 10. Spline Drive Gear11. Driven Gear12. O–Ring Seal13. Rear Port Section14...

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 protectivejaws to avoid damage to the port section’s machinedsurfaces. 2. Remove ge...

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 Seal2. Backup Washer3. Shaft Seal4. Key5. Sub Shaft Assembly6. Pin7. Spring 8. Bolt9. Outer Seal10. Inner Seal11. Shaft Seal12. Dust Seal13. Slotted Nut Disassembly of the Re...

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. 11. Remove the 3[76] diameter seal from va...

Reelmaster 4000–D Page 4 – 84 Hydraulic System 26. Alignment studs can be very helpful in reassemblyof the motor. If you use studs, install 2 studs diagonallyopposed in the bearing housing. 27. Install the shaft face seal in the wear plate as shownin Fig. 79. Do not distort seal. 28. Install the wea...

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 thestandard motor and the same disassembly and reas-sembly procedures apply. Figure 87

Reelmaster 4000–D Page 4 – 87 Hydraulic System Rear Wheel Drive Valve 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 Valve Use a deep socket to remove the valve cartrid...

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 Screw2. Threaded Cap3. Rod4. Rod Wiper5. U–Cup6. Cap Head7. Backup Washer8. O–Ring9. O–Ring 10. Spacer11. Servon12. O–Ring13. Piston14. Locknut15. Barrel Assembly16. Jam Nut...

Reelmaster 4000–D Page 4 – 89 Hydraulic System 11. 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) andtighten hex nu...

Reelmaster 4000–D Page 4 – 90 Hydraulic System Change Hydraulic Oil Normally, change hydraulic oil after every 2 years or1500 operating hours. If oil becomes contaminated,contact your local TORO distributor because the systemmust be flushed. Contaminated oil looks milky or blackwhen compared to clea...

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 Toro replacement filter (Part No.86–6110). IMPORTANT: Use of any other filter may void thewa...

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 Table of Contents ELECTRICAL SCHEMATICS AND DIAGRAMS 2 . . . Reelmaster 4000–D Electrical Schematic (S/N below 220000000) 2 . . . . . . . . . . . . . . . . . . . . Reelmaster 4000–D Electrical Schematic (S/N 22000000...

Reelmaster 4000–D Page 5 – 2 Electrical System (Rev. A) Electrical Schematics and Diagrams Start B+ ST AR TER BA TTER Y 12 VOL T FUSIBLE LINK FUSIBLE LINK SP Y G B L AL TERNA T O R I R W PULL OR VIO 85 86 87 30 ENGINE OVER TEMP . (OPENS A T 1 10 C) C NC RUN RELA Y (OPERA T OR NOT PRESENT) SP R VIO V...

Reelmaster 4000–D Page 5 – 5 Electrical System (Rev. A) WIRE IDENTIFICATION LABELCOLOR 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 W11. BLU P12...

Reelmaster 4000–D Page 5 – 9 Electrical System (Rev. A) 54 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 T O R 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...

Reelmaster 4000–D Page 5 – 11 Electrical System (Rev. A) J7 J8 4 ALARM TEST 6 2 3 3 4 5 6 1 2 3 T O 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 T O LIGHT CLUSTER 5 SILENCE ALARM J1 1 2 3 4 5 6 ALARM P3 P4 T O MAIN HARNESS J9 J10 J1 1 J12 J13 J1...

Reelmaster 4000–D Page 5 – 13 Electrical System (Rev. A) Special Tools Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PROD-UCTS) . Some tools may also be available from a local supplier. Multimeter The meter can test electrical components and circuitsfor current, ...

Reelmaster 4000–D Page 5 – 16 Electrical System (Rev. A) General Run and Transport Problems Engine continues to run (but should not) when parkingbrake is released or mow–backlap lever is in mow orbacklap with no operator on seat. Seat switch plunger depressed with no operator onseat. Seat switch fau...

Reelmaster 4000–D Page 5 – 17 Electrical System (Rev. A) Electrical System Quick Check Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between thebattery terminals. Set multimeter to the DC volts setting. The batteryshould be at a temperature of 60 to 100 o F (16 to 38 o C)....

Reelmaster 4000–D Page 5 – 18 Electrical System (Rev. A) Component Testing For accurate resistance and/or continuity checks, elec-trically disconnect the component being tested from thecircuit (e.g. unplug the ignition switch connector beforedoing a continuity check). NOTE: For more component testin...

Reelmaster 4000–D Page 5 – 20 Electrical System (Rev. A) Alarm Relay The alarm relay is located inside the steering tower. 1. Verify coil resistance between terminals 86 and 85 with a multimeter (ohms setting). Resistance should befrom 80 to 90 ohms. There should be continuity betweenterminals 87A a...

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, whichis inside the center shroud area to the left side of the en-gine. It energizes a red warning light when too much wa-ter has collected in the fuel filter bowl. 1. Make...

Reelmaster 4000–D Page 5 – 23 Electrical System (Rev. A) High Temperature Warning and Cutout Switches The high temperature warning and cutout switches arelocated on the water return pipe above the water pump,which is located on the rear end of the engine block. Thewarning switch has a green/white wi...

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 multi meter, short the test leads together. The me-ter will display a small resistance value (usually 0.5ohms ...

Reelmaster 4000–D Page 5 – 25 Electrical System (Rev. A) Fuel Stop Solenoid The solenoid must be energized for the engine to run. Itis mounted on the engine block near the injection pump. In Place Testing Note: Prior to taking small resistance readings with a digital multimeter, short the test leads...

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 fromthe wiring harness with two black, a black/white, and aorange wire. 1. Remove electrical connector fro...

Reelmaster 4000–D Page 5 – 27 Electrical System (Rev. A) Glow Controller The controller is located under the right lower corner ofthe instrument panel. Controller Operation When the ignition switch is placed in the RUN position,the controller energizes the glow plugs and lights up theglow lamp for 1...

Reelmaster 4000–D Page 5 – 28 Electrical System (Rev. A) Hydraulic Oil Filter Switch The oil filter switch is activate by the differential pressureacross the oil filter. When differential pressure is be-tween 16 to 20 PSID, a normally open contact closes. Analarm sounds and a warning light comes on ...

Reelmaster 4000–D Page 5 – 29 Electrical System (Rev. A) Service and Repairs NOTE: For more component repair information, see Kubota Workshop Manual, 03 Series, Diesel Engine . Battery Storage If the machine will be stored for more than 30 days 1. Remove the battery and charge it fully (see Battery ...

Reelmaster 4000–D Page 5 – 30 Electrical System (Rev. A) Battery Service The battery is the heart of the electrical system. Withregular and proper service, battery life can be extend.Additionally, battery and electrical component failurecan be prevented. CAUTION When working with batteries, use extr...

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 at each end of coil. Apply ”Loctite ...

Reelmaster 4000–D Page 6 – 1 Axles and Brakes Chapter 6 Axles and Brakes Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hand Brake and Traction Switches 3 . . . . . . . . . . . . . R...

Reelmaster 4000–D Page 6 – 2 Axles and Brakes Specifications Item Description Front Tire Pressure 13 PSI (0.90 Bar) Rear Tire Pressure 15 PSI (1.04 Bar) Front Wheel Nut Torque 60 to 85 ft–lb (8.3 to 11.8 kg–m) Rear Wheel Nut Torque 30 to 35 ft–lb (4.1 to 4.8 kg–m) Wheel Planetary Mounting Cap Screw ...

Reelmaster 4000–D Page 6 – 3 Axles and Brakes Adjustments Hand Brake and Traction Switches Over time the hand brake cable will stretch and causethe 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 fou...

Reelmaster 4000–D Page 6 – 4 Axles and Brakes Rear Wheel Toe–In After every 800 operating hours or annually, check rearwheel toe–in. 1. Measure center–to–center distance (at axle height) at the front and rear of the steering tires (Fig. 3). Frontmeasurement must be 1/8 inch (0.32 cm) less than there...

Reelmaster 4000–D Page 6 – 5 Axles and Brakes Service and Repairs Rear Wheel Bearing Service (2WD Only) 1. Hex flange head screw2. Spindle cap 3. Retaining ring 4. Thrust washer 5. Flange bushing 6. Rear axle 7. Wheel spindle (LH)8. Drive screw 9. Rear wheel hub10. Outer bearing cup11. Outer bearing...

Reelmaster 4000–D Page 6 – 7 Axles and Brakes Planetary Wheel Drive 1. Coupling2. Input shaft 3. Spindle4. Oil seal 5. Bearing cone 6. Bearing cup 7. Wheel bolt 8. Hub9. Bearing cone 10. Hex head bolt 11. Flat washer12. Thrust washer13. Primary sun gear14. Hex head bolt15. Primary carrier assembly16...

Reelmaster 4000–D Page 7 – 1 Cutting Units Chapter 7 Cutting Units Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

Reelmaster 4000–D Page 7 – 2 Cutting Units Specifications 1 11 2 6 5 7 8 9 10 3 4 1. Drive housing cover2. drive housing 3. Drive plate shield4. Grass deflector 5. Rear roller adjuster (both ends)6. Reel–to–bedknife adjuster 7. Guard8. cone nut 9. Reel10. Optional front roller11. Top covers Figure 1...

Reelmaster 4000–D Page 7 – 3 Cutting Units Special Tools Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PROD-UCTS). Some tools may be listed in the Reelmaster 4000–DParts Catalog. Some tools may also be available froma local supplier. Gauge Bar Assembly Use gauge ...

Reelmaster 4000–D Page 7 – 4 Cutting Units Adjustments CAUTION Never install or work on the cutting units or liftarms 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 wh...

Reelmaster 4000–D Page 7 – 5 Cutting Units Height–of–Cut Adjustment (Floating Cutting Unit) Overview of Procedure: 1. Adjust reel to bedknife contact2. Level rear roller to reel3. Adjust initial height–of–cut using gauge bar. 1. Adjust reel to bedknife contact on all cutting units. (see Adjust Reel ...

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 fromthe ignition switch. B. Use gauge bar (Toro Part No. 59–7900) to set fi-nal height–of–cut by adjust...

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 de...

Reelmaster 4000–D Page 7 – 8 Cutting Units Service and Repairs CAUTION Never remove, install, or work on the cuttingunits or lift arms with the traction unit engine run-ning. Stop engine and remove key from ignitionswitch first. Backlapping CAUTION During backlap operation the reels are underpower. ...

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 thetop (Fig. 13). IMPORTANT:Make sure motor pulley set screws aretight on the motor shaft before installing the motor...

Reelmaster 4000–D Page 7 – 11 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/bedknifeassembly (Fig. 21). ...

Reelmaster 4000–D Page 7 – 14 Cutting Units Preparing a Reel for Grinding Note: Check to make sure the reel bearings are ingood condition before grinding the reel. Make sure thecutting unit frame and roller brackets are true and notbent or damaged. 1. Remove the bedbar assembly (Bedknife/Bedbar Disa...

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...

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. Trust washer 7. Outer grease seal8. Wear sleeve 9. O–ring10. Bearing cone11. Bearing cup12. Inner grease seal Figure 28 4 7 9 11 3 6 8...

Reelmaster 4000–D Page 7 – 18 Cutting Units Lubrication Use a hand–operated grease gun and No. 2 generalpurpose grease to lubricate the eight grease fittings. IMPORTANT:Before washing the machine, shut offthe engine and remove the key. Toro recommendsdaily lubrication of reels and rollers immediatel...