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Cadillac 2008 Escalade Automobile User Manual

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6. Reelmaster 4000 D Page 5 17 Electrical System Rev Component Testing 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 A CAUTION doing a continuity check When testing electrical components for continu NOTE For more component testing information see ity with a multimeter ohms setting make sure the Kubota Workshop Manual for 03 Series Diesel En that power to the circuit has been disconnected gine Ignition Switch The ignition key switch has three positions OFF RUN and START The terminals are marked as shown The circuitry of the ignition switch is shown in the chart With the use of a multimeter ohms setting the switch func tions may be tested to determine whether continuity ex ists between the various terminals for each position Verify continuity between switch terminals SWITCH NORMAL OTHER POSITION CIRCUITS CIRCUITS START NONE SWITCH LOCK WASHER Figure 5 Electrical System Rev A Page 5 18 Reelmaster 4000 D Hour Meter IMPORTANT Make sure to observe polarity on the meter label 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 ter
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8. Page2 6 Wheel Bolts and Lug Nuts Thread Size Recommended Torque 88 14 N m 7 16 20 UNF 65 10 ft lb Grade 5 80 10 ft lb B 108 14 1 2 20 UNF Grade 5 M12 X 1 25 80 10 1 0 108 14 Class 8 8 M12 X 1 5 80 10 1 0 108 14 Class 8 8 For steel wheels and non lubricated fasteners Thread Cutting Screws Zinc Plated Steel Thread Threads per Inch Size Baseline Torque 20 5 in lb 30 5 in lb 38 7 in lb 85 15 in lb Hole size material strength material thickness amp finish must be considered when determining specific torque values All torque values are based on non lubricated fasteners X 0 08851 in lb N m X 0 7376 ft lb Reelmaster 4000 D 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 points are lift arms Fig 1 rear axle Fig 2 floating or fixed head kit pivots Fig 3 and cutting unit reel and roller bearings Fig 4 Also grease fitting on reel control valve not shown located under right hand console Figure 1 Lift arms 5 fittings total Figure 2 Rear Axle 3 Fittings per side Reelmaster 4000 D Page 2 7 Note Remove plastic caps over the fittings on the
9. PRESSURE OIL STEERING ORBITROL NO 2 REEL MOTOR NO 2 LIFT CYLINDER TRACTION MOTOR LEFT TRACTION MOTOR RIGHT BB 1 i BH 2 l B8 3 MOTOR 4 5 NO 1 LIFT CYLINDER F COUNTER varvel m BALANCE m VALVE PUMP PACKAGE STEER amp LIFT LO SPEED BACKLAP NO 4 REEL MOTOR NO 4 LIFT CYLINDER NO 5 LIFT CYLINDER JI 7 TT EEN a 9 STEER CYLINDER RIGHT AXLE WHEEL Hydraulic System 4 22 Reelmaster 4000 D Reel Circuit Any Unit Backup LEGEND OIL FLOW PRESSURE FREE NG ORBITROL SES PRESSURE OIL NO 2 REEL MOTOR NO 2 LIFT CYLINDER TRACTION MOTOR RIGHT TRACTION MOTOR COUNTER BALANCE VALVE PUMP PACKAGE STEER el i LO SPEED BACKLAP NO 4 REEL MOTOR NO 4 LIFT CYLINDER NO 5 LIFT CYLINDER C JN STEER CYLINDER RIGHT AXLE WHEEL Reelmaster 4000 D Page 4 23 Hydraulic System 4WD Selector Valve Operation 4WD Forward S1 OFF Pressure Oil Pressure Free 26 8 GPM 5000 PSI Hydraulic System Page 4 24 Reelmaster 4000 D 2WD Forward S1 Pressure Oil Pressure Free Reelmaster 4000 D Page 4 25 Hydraulic System Special Tools NOTE Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUI
10. RADIATOR Part 59 8440 NEXT TO TRACTION PEDAL ON S Part No 93 9397 TEERING CONSOLE Reelmaster 4000 D Page 1 5 Safety Ad satety and Instruction Decals 2 N Zoch ON FRONT CARRIER amp TOW BAR Part No 93 9400 N ON RIGHT CONTROL PANEL Part No 93 9402 ON EXHAUST SHIELD Part No 95 0645 ON FRONT ACCESS PANEL Part No 93 9425 Safety Page 1 6 Reelmaster 4000 D TORO Table of Contents PRODUCT 85 1 EQUIVALENTS AND CONVERSIONS 2 Decimal and Millimeter Equivalents 2 U S to Metric Conversions 2 Product Records Record maintenance and repair information about your Reelmaster 4000 D on the OPERATION AND SER VICE HISTORY REPORT form Use this information when referring to your machine Reelmaster 4000 D Page 2 1 Chapter 2 Product Records and Maintenance TORQUE SPECIFICATIONS 3 Fastener Identification 3 Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series 4 Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners 5 Other Torque Specifications 6 Conversion Factors 6 LUBRICATION 7 OPERATION amp S
11. SOLENOID CARTRIDGE Torque to 35 ft Ibs S4 Torque Cartridge to 12 ft lbs 2 1inch 7 8 Inch Hex Torque Coil Retaining Nut tol5 in lbs Coil Resistance 7 2 Ohms 10 CARTRIDGE Lc 2 Torque to 65 ft lbs 1 1 2 Inch Hex Figure 18 1 Disconnect the wire connector Note Prior to taking small resistance readings with a S digital multi meter short the test leads together The me ter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal re sistance of the meter and test leads Subtract this value from from the measured value of the component you are testing 0 2 Check resistance of coil with a digital multimeter Resistance should be about 7 2 ohms a me ha 3 Connect a 12 volt battery so the positive battery terminal is connected to colored solenoid lead Connect the negative battery terminal to black lead The valve spool should retract completely as 12V DC is applied across the leads Figure 19 5 f valve operates smoothly but does not retract when 12V DC is applied to solenoid leads replace sole 4 If valve spool does not retract check for binding or noid coil damage in valve 5 9 6 still does not retract after replacing solenoid coil replace the valve Electrical System Rev A Page 5 24 Reelmaster 4000 D Fuel Stop Solenoid The solenoid must be energized for the
12. 54 Lift Control Valve 58 Priority Flow Divider 60 Lift 62 Reel Control Valve 64 Reel Shut Off Valve 66 Traction Pump 68 Front Traction Motor 74 Reel uet eege re 76 Rear Wheel Drive Motor 80 Rear Wheel Drive Valve Block 87 Steering Cylinder 88 Change Hydraulic Oil 90 Replace Hydraulic Oil Filter 91 Replace Hydraulic System Breather 91 Replace Hydraulic Lines and Hoses 91 Hydraulic System Specifications Item Description Traction Pump Traction Relief Pressure Charge Pressure Variable displacement axial piston pump 5000 5200 PSI 50 150 PSI 2WD 75 150 PSI 4WD Steering Pump Steering Relief Pressure Gear pump with flow divider 1200 1300 PSI Traction Motor front Fixed axial piston motor Traction Motor rear w 4WD Geroter type wheel motors Reel Pump Cutting Circuit Relief Pressure Gear pump 2650 2750 PSI Reel Motor Cross over Relief Pressure Gear Motor 1500 PSI Lift Control Valve Lift Relief Pressure Counterbalance Pressure Max RPM Spool type directional control valve 2650 2900 PSI Hot
13. 2219 STEER CYLINDER RIGHT AXLE WHEEL Hydraulic System Page 4 14 Reelmaster 4000 D 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 To lift the cutting units the engine must be running above half throttle The flow of oil from the steer and lift pump is used to accomplish the lift function Holding a lever in the LIFT position will direct the flow of oil to the lift cylinder and raise the cutting unit Oil pressure to the lift cylinder is monitored during LIFT by a relief at the valve inlet System pressure may be monitored at the pressure tap port on the lift valve Moving the lever forward will open a path for oil to es cape from the lift cylinder The weight of the cutting unit will push oil from the cylinders through the valve allowing the cutting unit to lower Moving the lever into LIFT Reelmaster 4000 D Page 4 15 while the cutting unit is lowering will lock the cutting unit at any position by trapping oil between the valve and inder The cylinders work against counterbalance pressure during lowering For this reason the cutting units will drop faster at slow engine speeds or low counterbal ance pressures compared to full engine speed or high counterbalance pressures The counter ba
14. Fitting s hose or tube loose or damaged Missing or damaged o ring Low engine RPM Low hydraulic oil level Open or damaged traction pump by pass valve Disengaged or damaged final drive Loose or damaged traction linkage Low charge pressure See Test No 8 Low traction pressure See Test No 1 Damaged or worn traction motors Low engine RPM Low hydraulic oil level Reel to bedknife adjustment too tight Improper reel drive motor belt adjustment Low reel shut off valves Low reel system pressure See Test No 3 Worn or damaged priority flow divider Low flow to reel motors See Test No 4 Inefficient reel motor See Test No 5 Reelmaster 4000 D Problem Steering loss Cutting units lift slowly or won t lift Cutting units won t drop or follow ground contours Reelmaster 4000 D Page 4 29 Possible Causes Thermal shock after washing NOTE Normalfunctions will return after orbital tem peratures stabilize approximately 15 minutes DO NOT ATTEMPT TO TURN STEERING WHEEL UN TIL TEMPERATURES STABILIZE WHEN THER MAL SHOCK IS NOTED Improper cylinder action Low steering relief pressure See Test No 6 Worn or damaged steering cylinder Worn or damaged steering pump Worn or damaged steering control unit Low engine RPM Low hydraulic oil level Binding lift arm pivot points or bushings Worn or damaged bushings Worn or damaged cylinders Improper counte
15. NOTE REAR OF BEDKNIFE MUST BE HEELED UP AS SHOWN FOR LOW HOC OPERATION Figure 10 Final Height of Cut Adjustment Using Gauge Bar Quick Method For Changing Height of Cut After Initial Set Up of a Floating Cutting Unit If the reel to bedknife adjustment has been set in STEP 1 of Height of Cut Adjustment Floating Cutting Unit and the rear roller leveled to the reel in STEP 2 of Height of Cut Adjustment Floating Cutting Unit the cutting unit may be quickly changed from one height of cut to another by using the gauge bar Part 59 7900 and adjusting the front roller only In many Cutting Units Page 7 6 cases an entire machine can be done quickly by using the gauge bar to set the front roller of one cutting unit The remaining cutting units can then be set by loosening their front roller jam nuts and turning each front roller ad justment knob the same number of turns and in the same direction as the first unit Reelmaster 4000 D 5 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 bedknife attitude 4 Lower cutting unit onto a flat surface such as a piece of 3 4 inch 1 9 cm plate steel of at least 20 x 30 inches 50 x 76 cm Shut off engine and
16. floating or fixed head pivots and replace caps after greasing Fig 3 Figure 3 Floating of Fixed Kit Pivots 1 fitting per head Floating Kit Shown Figure 4 Reel and Roller Bearings 2 fittings per reel amp 2 fittings per roller 1 Park machine on a level surface Stop engine Re move key from the ignition switch 2 Wipe grease fitting clean so foreign matter cannot be forced into the bearing or bushing 3 Pump grease into the bearing or bushing 4 Wipe up excess grease Product Records and Maintenance Product Records and Maintenance Page 2 8 Reelmaster 4000 D EQUIPMENT OPERATION AND SERVICE HISTORY REPORT TORO Model and Serial Number Engine Numbers Transmission Numbers Drive Axle s Numbers Date Purchased Purchased From Contacts Parts Service Sales Reelmaster 4000 D for REELMASTERR 4000 D Warranty Expires Phone Phone Phone Page 2 9 Product Records and Maintenance Reelmaster 4000 D Maintenance Schedule Minimum Recommended Maintenance Intervals Maintenance Procedure Maintenance Interval amp Service Every Every 100hrs 200hrs Lubricate Reel Control Valve Grease Fitting Every Lubricate Reel Speed Valve with Oil 50hrs Lubricate All SE Level Check Battery Condition and Connections Service Change Engine Oil and Filter Drain Water from Hydraulic Tank Check engine Fan and Alternator
17. 2 Insert camplate into housing Insert the needle bear ings 18 over the arm and slide into the housing 3 Install washers 17 and shaft seal 16 over cam piv ot bearing Install seal cover 15 and secure with screws 24 4 On the opposite side of housing install needle bearing 18 inner 20 with chambered I D inward wash er 17 O ring 21 and O ring cover 22 and secure with trunnion cover 23 and screws 24 5 Install retaining ring 28 on drive shaft 31 Install thrust race 29 thrust bearing 30 and second thrust race 29 secure with second retaining ring 28 6 Install shaft in housing and install washer 27 shaft seal 26 and retain with retaining ring 25 7 Install the pivot spider and the piston assemblies in the piston block Install rotating assembly in the housing assembly the piston shoes must be in contact with the camplate 8 Clamp pump assembly in a protected jaw vise with the open end of the housing up Reelmaster 4000 D Page 4 73 9 Install new housing gasket 10 10 Install back plate 9 11 Install ball and pin into check valve housing if remo ved Install new O ring 45 and back up washer 46 on check valve assembly 8 Install O ring nearest pin Install in back plate 9 with pin in back plate 12 Install key 35 on shaft and install gerotor gear 7 over shaft 13 Install new O ring 5 in groove in charge pump adaptor 2 hol
18. Rinse filter from clean side to dirty to side C Dry filter element using warm flowing air of not greater than 1609F 719C or allow element to air dry Do not use a light bulb to dry the filter element because damage could result Kubota Diesel Engine Page 3 8 Figure 10 1 Rear screen 2 Knob Figure 11 2 Air cleaner cover 1 Air cleaner body Compressed Air Method A Blow compressed air from inside to the outside of dry filter element Do not exceed 100 psi 6 9 Bar to prevent damage to the element B Keep air hose nozzle at least 2 inches 5 cm from filter and move nozzle up and down while rotat ing the filter element Inspect for holes and tears by looking through the filter toward a bright light 9 Inspect new filter for shipping damage Check seal ing end of filter Do not install a damaged filter 10 Insert new filter properly into air cleaner body Make sure filter is sealed properly by applying pressure to out er rim of filter when installing Do not press on flexible center of filter 11 Reinstall cover and secure latches Make sure cov er is positioned with top side up Reelmaster 4000 D 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 Removeoil filter Apply a light coat of clean oil to the new fi
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20. 2 Remove 4 bolts from motor Tie Bolts 3 Lift valve housing straight up If done carefully the pins springs balance ring assembly and valve will re main on the valve plate 4 Carefully remove 3 76 diameter seal from valve housing 5 Remove case drain plug with seal from front valve housing Figure 72 Reelmaster 4000 D Page 4 81 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 Face Seal Valve Balance Ring 10 Remove the valve plate 11 Remove the 3 76 diameter seal from valve plate 12 Remove the valve drive 13 Remove the Geroter Be sure to retain the rollers in the outer ring if they are loose 14 Remove the drive 15 Remove the 3 76 diameter seal from wear plate see Fig 75 Drive Geroler 16 Remove the wear plate Bearing Housing 17 Remove the shaft face seal from the wear plate 18 Remove the 3 76 diameter seal from bearing hous ing Shaft Face Seai Figure 76 Hydraulic System Page 4 82 Reelmaster 4000 D 19 You may need a press to remove shaft and bearing assembly from bearing housing Key must be removed before removing shaft 20 Use asmall screwdriver to remove shaft seal back up washer and exclusion seal from bearing housing see Fig 78 Do not damage bore of housing NOTE Individ
21. 5 ft lb 66 7 ft lb 90 10 N m 92 9 ft lb M16 X 2 0 166 15 ft lb 225 20 229 22 ft lb 310 30 N m M20 X 2 5 325 33 ft lb 440 45 N m 450 37 ft lb 610 50 Note Reduce torque values listed in the table above on the fastener size the aluminum or base material by 25 for lubricated fasteners Lubricated fasteners strength length of thread engagement etc are defined as threads coated with a lubricant such as oil graphite or thread sealant such as Loctite Note The nominal torque values listed above are Note Torque values may have to be reduced when based on 75 of the minimum proof load specified in installing fasteners into threaded aluminum or brass SAE J1199 The tolerance is approximately 10 ofthe The specific torque value should be determined based nominal torque value Reelmaster 4000 D Page2 5 Product Records and Maintenance Other Torque Specifications SAE Grade 8 Steel Set Screws Recommended Torque Thread Size Square Head 1 4 20 UNC 140 20 in lb 73 12 in lb 5 16 18 UNC 215 35 in lb 145 20 in Ib 3 8 16 UNC 35 10 ft lb 18 3 ft lb 1 2 13 UNC 50 10 ft lb 75 15 ft lb Thread Cutting Screws Zinc Plated Steel 10 24 UNC 38 7 in lb 1 4 20 UNC 85 15 in lb 5 16 18 UNC 110 20 3 8 16 UNC 200 100 in Ib Conversion Factors X 11 2985 ft lb X 1 3558 N m Product Records and Maintenance
22. 9 2 CHama e 1 FIONA NYL 2 x 8 8 rt E 5 2 mo ov18 q3H o KEE gt on 5 55 E 2 9 9 2 gt 5 gt 2 x g v 3LIHM m gt 9 EE 5 mm m ert 13101A yov gt 5 1 T tds Ec ama EIER ovig aas y 19 E ZS 2 2 _ ZS 5 9 2 3 x TI NZ A m L 78 4 LU OU 9d lt Ina ER JIINVYOAH LI 2 2398 iN 110 10 i 911 0 04 dW3L 83 0 031115 VNOI 140 18 15 8318715 MOTA 3 I t OND war Reelmaster 4000 D Page 5 8 Electrical System Rev WIRE IDENTIFICATION LABEL COLOR wi w2 W4 w5 W6 w8 wg W10 wit wi2 W13 W14 W15 W16 W17 W18 W19 W20 wai W22 W23 WHT TAN v RY 2 0 De SC LK WHT LK WHT LK WHT LK WHT LK WHT LK WHT POO OOo oo 0 0 w E VIO VIO GRN TAN BLK BLK BLK ROUTE P2 1 J7 P2 2 6 2 P2 3 J1 P2 4 P4 3 P2 5 6 1 P6 1 J6 P1 1 J2 P1 2 6 3 P1 3 P6 4 P1 4 P7 A P7 A P3 3 P3 3 P4 1 P4 1 P8 A P8 A J5 J5 P5 B P1 5 P3 1 P3 1 PG 5 P6 5 5 P1 6 P3 5 P3 2 P7 B P2 6 P3 6 P3 6 8 P8 C P4 2 Reelmaster 4000 D J2 4WD SWITCH FUEL GAUGE P4 KUBOTA HIGH TEMP OVERIDE 46 10
23. Ad 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 IMPORTANT Make sure not to damage the engine fuel and hydraulic lines electrical harness or other parts while installing the engine B Place gasketonto exhaust bracket to receive ex haust tube Fig 26 C Lower engine slowly into the machine 2 Secure both front brackets to the engine mounts with cap screw flat washers spring washer and hex nu Torque cap screw and hex nut from 59 to 73 ft lb 8 2 to 10 1 kg m t Fig 26 3 Secure engine to the spacers and rear brackets with three cap screws and lock washers Torque cap screws from 61 to 75 ft lb 8 4 to 10 4 kg m Fig 27 4 Secure exhaust tube and gasket to the exhaust bracket with three cap screws and lock nuts Fig 26 5 Connect hydraulic pump assembly to the engine Fig 25 A Position the pump shaft into the spring coupling B Secure pump mounting flange to the pump adapter plate with four cap screws flat washers and lock washers Torque cap screws from 60 to 80 ft lb 8 3 to 11 1 kg m C Connect damper to the bracket 6 Connect throttle control cable to the swivel lever Secure cable to engine plate with R clamp Fig 24 7 Connect wire harness and electrical wires to the en gine as follows A Connect wi
24. B If pressure is less than the specified range check reel pump output pressure TEST NO 3 Check Reel Circuit Working and Relief Pressures If reel circuit pressure is correct check reel motor cross over relief valve for damage 9 Disengage cutting units by positioning reel control lever to STOP position Stop the engine 10 Disconnect tester from motor and hose Reconnect hose to the pump Remove hardwood block from reel Hydraulic System TEST NO 6 Check Reel Motor Case Drain Flow FROM LIFT CIRCUIT CIRCUIT PRIORITY CUTTING TEST PORT B zxIP 75 OUT gt lt FROM GEAR PUMP A QUART CONTAINER TO HYDRAULIC OIL TANK Figure 20 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 2 Make sure machine is parked on a level surface Lower cutting unit to be tested Make sure engine is OFF and the parking brake is engaged 3 Read Precautions for Hydraulic Testing 4 For the suspected bad motor disconnect return hose from the motor 5 Install tester in series with the motor and return hose Make sure the flow control valve
25. Fig 21 Remove fan shroud from the machine Figure 21 1 3 screws 2 Reelmaster 4000 0 3 13 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 Figure 22 1 Injector pump suction 3 Fuel pump discharge 2 Fuel pump suction 4 Fuel solenoid 10 Disconnect wire harness and electrical wires from the engine as follows A Disconnect wire and connector from the alterna tor red cable from starter three wires from the start er wire from the oil pressure switch and wires from high temperature warning and shutdown switches Fig 20 B Disconnect electrical connector from the fuel so lenoid Fig 22 C Disconnect red black wire from the glow plug bus bar Fig 23 Figure 23 1 Injector return hose 4 Bracket 2 Glow plug wire 5 Lifttab 3 Exhaust tube 11 Disconnect throttle control cable from the swivel le ver and R clamp from the engine plate Fig 24 Figure 24 1 Throttle control cable 4 Swivel lever 2 R clamp 5 Engine plate 3 Swivel 6 Screw Kubota Diesel Engine Page 3 14 Reelmaster 4000 D 12 Separate hydraulic pump assembly from the engine Fig 25 A Disconnect damper from the bracket B Remove four cap scr
26. J9 J10 J3 P15 1 P12 8 P12 8 P8 A P15 1 P18 1 P15 2 P3 1 P17 1 P12 5 P17 2 J5 J6 7 P17 3 P16 A P17 4 J22 P17 5 J16 J16 P10 3 P18 2 P12 7 P18 3 12 4 18 4 SP5 SP5 P4 6 SP5 P1 2 SP5 P12 6 P12 6 P13 2 P18 5 P14 2 P18 6 P131 P3 2 J13 P3 3 J18 P3 4 P1 1 WIRE IDENTIFICATION LABELCOLOR AWG TYPE ROUTE W33 BRN P4 1 J20 W34 P4 2 P9 1 W35 BLU 4 3 10 1 W36 RED P4 4 J2 W37 BRN P7 2 J14 w38 VIO P11 2 J17 w39 VIO 11 2 P7 5 W40 11 1 P5 A W41 WHT 11 1 P7 3 w42 YEL P7 4 P5 C W43 7 1 P5 B W44 RED BLK 10 4 P2 A W45 NOT USED W46 NOT USED W47 NOT USED W48 NOT USED W49 NOT USED W50 BLK J4 SP3 w51 BLK SP3 P6 1 W52 BLK SP3 10 2 W53 BLK P10 2 J1 W54 BLK J1 P9 2 W55 BLK P9 2 P4 5 W56 BLK SP3 P1 3 w57 BLK J4 P2 C W58 BLK SP3 P14 1 W59 BLK SP3 SP4 W60 BLK SP4 P8 B W61 BLK SP4 17 6 W62 BLK SP4 J23 W63 BLK J23 J21 W64 BLK SP4 P16 B W65 BLK SP4 J8 Reelmaster 4000 D Supplement to Main Harness Drawing S N below 220000000 Page 5 5 Electrical System Rev A 6 5 E Ku 000000022 N S EN or HOLSIS3H op 91 GION310S 827 39nvO TAN zen 1 84 444 HOLIMS WHLAN SN
27. Loctite 242 or equiv alent to threads on end of valve stem before installing nut Tighten nut to a torque of 15 in Ib 17 3 kg cm Over tightening may damage the solenoid or cause the ij valve to malfunction Fe nm E 5 Connect wiring connector Figure 29 Reelmaster 4000 D Page 5 33 Electrical System Rev A Check Interlock System A 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 are operating properly replace them every two years to assure maximum safety 1 In a wide open area free of debris and bystanders lower cutting units to the ground Stop engine 2 Sitonthe seat and engage parking brake Turn key and try to start engine with lever in both the MOW and BACKLAP positions If engine cranks there is a malfunction that must be repaired immediate ly If engine does not crank the cutter drive switch is op erating properly Electrical System Rev A Page 5 34 3 Sit on the seat and disengage the parking brake Turn key and try to start engine with Mow Backlap lever in STOP If engine cranks there is a malfunction that must be repaired immediately If engine does not crank brake switch is operating properly 4 E
28. Remove locknut 34 washer 12 plug 14 wash ers 16 17 18 spring 19 and poppet 20 10 Remove all O rings and back up rings from all plugs and seats Inspection of Lift Control Valve 1 Remove all nicks and burns from parts and inspect for excessive wear 2 Inspect all plungers and poppet seats for burrs or roughness 3 Inspect spool springs 25 relief valve spring 19 lockout springs 31 and detent springs 3 for break age 4 f spools 13 have excessive wear the valve be comes non serviceable as the spools and spool bores are matched and damaged spools cannot be replaced 5 Inspect relief valve poppet 20 for breakage or wear Reelmaster 4000 D Page 4 59 Assembly of Lift Control Valve 1 Thoroughly clean and dry all parts Apply a light coat ing of clean hydraulic oil to parts prior to assembly NOTE All O rings back up washers wiper seals and nylon poppets should be replaced as new items 2 Install new O rings 22 in proper grooves in spool bores 3 Install relief valve components 20 19 18 17 16 with new O ring 15 on plug 14 4 Install plugs 11 with new back up washers 10 and O rings 9 5 Install plungers 37 29 IMPORTANT Check location and positioning of plungers during installation 6 Install new O rings 36 on seats 35 Install new back up washers 10 and C rings 9 on plugs 30 7 Install seats 35 new poppets 33 and plugs
29. System Kubota Diesel Engine Page 3 12 Figure 17 Rear screen 2 Knob Figure 18 Oil cooler 2 Radiator Reelmaster 4000 D 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 Pivotseat up Lift front canopy and remove from the 4 uw brackets Fig 19 gd n Figure 19 1 Canopy 2 Brackets 3 Disconnect and remove battery from the machine see Battery Service in Chapter 5 Electrical Systems If engine is hot pressurized coolant can escape and cause burns when the radiator hoses are re moved The radiator and exhaust exhaust tube may be hot Avoid possible burns allow engine radiator and exhaust system to cool before re moving radiator hoses or exhaust tube t 7 gt 4 Drain radiator Disconnect both hoses from the ra Figure 20 diator Fig 20 1 Battery 7 Starter 2 Upper radiator hose 8 Oll pressure switch 5 Remove air hose from air intake manifold Fig 20 3 Lower radiator hose 9 Alternator 4 Fan guard 10 Air hose 5 11 Hi temp warning switch 6 Remove exhaust shield from the engine Fig 20 6 Exhaust shield 12 Hi temp cutout switch 7 Remove fan guard and fan shroud from the radiator Fig 20 8 Remove fan from the fan pulley Remove fan shroud and fan from machine
30. Tighten tie rod clamps when the adjustment is cor rect Axles and Brakes Page 6 4 Figure 4 Clamp 2 Tie rod Reelmaster 4000 D Service and Repairs Rear Wheel Bearing Service 2WD Only 11 12 13 14 15 Figure 5 1 Hexflange head screw 18 Tab washer 35 Hydraulic hose 2 Spindle cap 19 Valve stem 36 Steering cylinder 3 Retaining ring 20 Bearing inner cup 37 Hydraulic hose 4 Thrust washer 21 Bearing inner cone 38 O ring 5 Flange bushing 22 Inner seal 39 Hydraulic fitting 6 Rearaxle 23 Ball joint LH or RH 40 O ring 7 Wheel spindle LH 24 Grease fitting 41 Roll pin 8 Drive screw 25 Clamp assembly 42 Pivot shaft 9 Rear wheel hub 26 Lock nut 43 Hex nut 10 Outer bearing cup 27 Tie rod assembly 44 G fitti 5 11 Outer bearing cone 28 Cap screw e iting con 12 Tire 29 Cotter pin 45 Ball joint 13 Lug nut 30 Castle nut 46 Cap screw 976 14 31 Castle nut 47 Wheel spindle RH gt M 15 Cotter pin 32 Lock nut 48 Grease decal 16 33 Flange bushing 49 Grease fitting 17 Jam nut 34 Thrust washer 50 Retaining nut Reelmaster 4000 D Page 6 5 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
31. and Testing Fig 27 1 Perform following inspections and maintenance A Check for cracks caused by overly tight hold down clamp Replace battery if cracked and leak ing Electrical System Rev A Page 5 30 MAX FILL DO NOT OVERFILL MIN FILL WO RECYCLE MADE IN U S A Figure 27 B Check battery terminal posts for corrosion Use a terminal brush or steel wool to clean corrosion from the battery terminal posts IMPORTANT Before cleaning the battery tape or block vent holes to the filler caps and make sure the caps are on tightly C Check for signs of wetness or leakage on the top of the battery which might indicate a loose or mis sing filler cap overcharging loose terminal post or overfilling Also check battery case for dirt and oil Clean the battery with a solution of baking soda and water then rinse it with clean water D Check that the cover seal is not broken away Replace the battery if the seal is broken or leaking E Check the electrolyte level in each cell If the lev el is below the tops of the plates in any cell fill all cells with distilled water between the minimum and maximum fill lines Charge at 15 to 25 amps for 15 minutes to allow sufficient mixing of the electrolyte 2 Conduct a hydrometer test of the battery electrolyte IMPORTANT Make sure
32. bearing thoroughly Both ends of the roller should be free of dirt and debris 2 Secure roller tube in a vise keeping it level 3 Remove both grease fittings before removing the bearings 4 Remove jam nut lock nut and both thrust washers from the roller shaft Pull both outer grease seals from inside the roller tube 5 Useasoft hammer to pound the shaft wear sleeve O ring and bearing cone out of the roller tube Remove wear sleeve O ring and bearing cone from the shaft 6 Pull remaining wear sleeve O ring and bearing cone from the roller 7 Pull both inner grease seals from inside the roller tube Discard all four grease seals and both O rings 8 Ifdisassembling a rear roller pour oil from the inside the roller into a suitable container Cutting Units Page 7 16 9 O ring 10 Bearing cone 11 Bearing cup 12 Inner grease seal If removing bearing cups from a rear roller with anarc welder make sure the entire roller is free of oil Clean inside and out side thoroughly Note Anelectric arc welder can be used to shrink the bearing cup to simply its removal Only a small arc in one location on the cup is required 9 Remove both bearing cups from the roller tube Installation IMPORTANT Replace both bearing cones and cups with new ones since both bearing cones and cups may be damaged during removal 1 Make sure all parts are cleaned thoroughly Inside of roller tube should be free of d
33. create undue wear on the skids or rollers Skids and front rollers used to prevent scalping should not ride on the ground 3 Adjust each skid or front roller so itis 1 8 to 1 4 in 8 to 6 mm or higher above the level surface Allow greater clearance at the higher height of cut settings A The front roller is adjusted in the same manner as the rear roller Reelmaster 4000 D 7 7 Figure 12 Cap screw 5 Skid Lock nut 6 Side plate Cap screw 7 Skid bracket Lock nut B The skid is adjusted by loosening cap screws and lock washers securing the skid to the side plate and skid braket On some units the rear of the skid may be mounted to the side plate with a spacer Fig 12 Cutting Units Service and Repairs 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 During backlap operation the reels are under power Contact with rotating reels can result in personal injury Do not adjust cutting units while the engine and reels are operating Two people are required to perform backlapping One person sits on the seat to operate the con trols operator and the other performs the back lapping operation Good communication be tween each person is necessary Instruct opera tor to stop the reels and shut the engine off when adjustment is necessary Use a good grade of medium grit 80 coarsenes
34. 20 3 cm diameters and are 29 3 4 75 5 cm wide Bedknife Bedbar Assembly A replaceable single edged alloy steel bedknife is induction hardened The bedknife is fastened with steel screws to a precision ground surface on the high strength fabricated steel bedbar The stress relieved machined bedbar is mounted with four 4 vibration isolation bushings Bedknife to Reel Adjustment Two lockable lead screw adjusters at each side of the frame adjust the reel to bedknife contact Rear Roller 3 1 2 inch 89 mm diameter steel roller has greaseable tapered roller bearings A double lip oil seal and wear sleeve isolates grit and moisture from the bearings Cutting Units Page 7 2 9 Reel 10 Optional front roller 11 Top covers Height of Cut 5 Blade 1 to 3 inches 25 to 76 mm 7 Blade 1 2 to 1 3 4 inch 9 5 to 45 mm 11 Blade 3 8 to 3 4 inch 9 5 to 19 mm Height of Cut Adjustment Quick adjustment and positive locking is provided by locking type cone nuts Gauge marks of 1 4 inch 6 3 mm are provided as a ref erence for easy changes of height of cut Clip variable to match cutting conditions 5 Blade Cutting Unit 0 176 inch per mph 0 352 inch at 2 mph to 1 32 inch at 7 5 mph 7 Blade Cutting Unit 0 1 26 inch per mph 0 252 inch at 2 mph to 0 945 inch at 7 5 mph 11 Blade Cutting Unit 0 080 inch per mph 0 16 inch at 2 mph to 0 600 inch at 7 5 mph Lubrication Easily accessible gre
35. Adjust Reel to Bedknife Contact The cutting units will provide optimum mowing perfor mance when adjusted and maintained correctly Keep ing a precise reel to bedknife adjustment light contact at each end of the cutting unit will produce a continual self sharpening action Therefore sharp cutting edges are maintained good quality of cut assured and the need for corrective re sharpening reduced Note Before adjusting height of cut and each day before operating check reel to bedknife contact regard less if previous quality of cut had been acceptable Before adjusting reel to bedknife raise and fully latch cutting units Remove key from the ignition switch Keep others off machine while adjusting cutting units Note 3 4 wrench is required for making the reel to bedknife adjustment When adjusting the cutting units wear heavy gloves and use care when turning reels by hand Sharp edges can cut or pinch hands or fingers 1 Rotate reel slowly and carefully while listening for light contact across the full length of the reel and bed knife 2 f no contact is determined loosen adjuster locking nut on each adjuster Fig 5 Turn each adjuster knob equally and clockwise until light contact is felt and heard Cutting Units 7 4 Figure 5 2 Adjustment knob 1 Adjuster locking nut IMPORTANT Adjusted correctly so that the reel will cut a piece of paper approximately 0 003 inch 0
36. D 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 the seal retainers 6 Install a seal pack into the cav ity located on the face of the port section 13 with the seal retainer pointing up 2 Place port section 13 in vise with studs 3 facing up NOTE The steps pertain to installation of front cover shaft seals 9 amp 17 Lubricate the shaft seals with Marfak grease to provide initial lubrication 3 Install inner shaft seal 17 into front cover 4 Make sure the spring loaded member of shaft seal faces the inside of pump Place the shaft seal 17 on shaft seal driver and press in place 4 Install retaining ring 18 into front cover on top of shaft seal 17 5 Place a guide over the pilot diameter of front cover 4 6 Install a new outer shaft seal 9 on the driver Make sure the spring loaded member of shaft seal faces the inside of pump 7 Insert the driver and shaft seal though the guide and press in place 8 Place wear plate 7 on port section 13 with bronze face up and notch facing inlet port 9 Lubricate bronze face of wear plate 7 Install center section 8 on top of wear plate 7 and into locating holes of port section 13 w
37. Install retaining ring 1 on end of spool 9 Hydraulic System Traction Pump Hydraulic System Figure 62 Hex Head Cap Screw Charge Pump Adapter Assembly Plug Assembly Tow Valve Assembly O Ring Needle Bearing Gerotor Gear Assembly Check Valve Assembly Back Plate Assembly Housing Gasket Dowel Pin Rotating Kit Assembly Key Camplate Seal Cover Shaft Seal Washer Needle Bearing Housing Assembly Inner Race O Ring O Ring Cover Trunnion Cover Screw Page 4 68 Retaining Ring Shaft Seal Washer Retaining Ring Thrust Ring Needle Bearing Thrust Drive Shaft Relief Valve Kit O Ring Relief Valve Assembly Key Hex Head Cap Screw Cartridge O Ring Spring Poppet Spring Poppet Spring Spring Retainer O Ring Back up Washer Bearing Bearing Reelmaster 4000 D 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 jaw vise with the body of the pump up and remove the four cap screws 1 amp 36 from the adapter plate of the pump 4 Use aplastic mallet and tap the charge pump adapter 2 to loosen it then pull the adaptor straight up until it is free 5 Remove spring retainer 44 and remove sprin
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39. Lift Circuit Working and Relief Pressure Procedure For Working 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 too low perform re lief pressure check Procedure For Relief Pressure Check 1 Hydraulic oil must be at operating temperature 2 Install 5 000 psi gauge onto the quick disconnect of the lift valve 3 Start the engine and move the throttle to full speed 2500 rpm 4 Engage the control lever into the LIFT position Mo mentarily hold the lever in the engaged position after full cylinder extension and read gauge Tester reading should be from 2650 to 2900 PSI NOTE Always set counterbalance pressure to desired amount before attempting to adjust lift pressure 5 If pressure is too high clean and adjust relief valve in lift valve by removing the required shims If pressure is too low check for restriction in pump intake line Check the lift cylinder for internal leakage If cylinder is notleak ing adjust the relief valve by adding the required shims If pressure is still too low repair or replace steering lift pump TEST NO 9 Check Charge Pressure 1 Hydraulic oil must be at operating temperature 2 Install a 1000 psi gauge onto the quick disconnect at the top of the pump package 3 Start the engine and position throttle at i
40. REEL MOTOR NO 2 LIFT CYLINDER TRACTION MOTOR LEFT TRACTION MOTOR Sew me COUNTER BALANCE VALVE PUMP PACKAGE LO SPEED BACKLAP NO 4 REEL MOTOR NO 4 LIFT CYLINDER NO SLIFTCYLINDER 73 ini STEER CYLINDER RIGHT AXLE WHEEL Hydraulic System Page 4 12 Reelmaster 4000 D 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 Turning the steering wheel to the right moves the control spool in the steering unit to direct the oil to the steering Reelmaster 4000 D Page 4 13 cylinder for a right hand turn Turning the steering wheel to the left has the opposite effect Cylinder move ment returns oil from the low pressure side back through the power steering unit to the reservoir System pressure may be monitored at pressure tap port 5 Hydraulic System Steering Right LEGEND gt OIL FLOW PRESSURE FREE PRESSURE OIL STEERING ORBITROL NO 2 REEL MOTOR NO 2 LIFT CYLINDER TRACTION TRACTION MOTOR Tli COUNTER BALANCE VALVE PUMP PACKAGE STEER CHARGE TRACTION LO SPEED BACKLAP VALVE NO 4 REEL MOTOR NO 4 LIFT CYLINDER NO 5 LIFT CYLINDER E
41. Ring Seal Gland Bushing Quad Ring X Seal Reelmaster 4000 D Page 4 47 Figure 43 Retaining Ring Teflon Seal Bushing with Ident Groove 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 IMPORTANT Clean the upper surface of the hous ing by wiping with the palm of clean hand Clean each of the flat surfaces of the meter section part in asimilar way when ready for reassembly Do notuse cloth or paper to clean surfaces 18 Install 3 diameter seal in housing see Fig 45 19 Install spacer plate Align bolt holes in spacer plate with tapped holes in housing 20 Rotate spool and sleeve assembly until pin is paral lel with port face see Fig 46 Install drive make sure you engage drive with pin To assure proper alignment mark drive as shown in Fig 48 ref B Record the rela tionship between slotted end of drive to splined end of drive when marking Drive Pin Parallel with Port Face Figure 46 Hydraulic System 4 48 Reelmaster 4000 D 21 Install 3 diameter seal in meter Meter Figure 47 22 With seal side of meter toward spacer plate align Meter Gerotor Star Valley star valleys ref A on drive ref B Record the parallel relati
42. Test Kit Hydraulic Fitting TROUBLESHOOTING Hydraulic 5 Slow Traction in Either Direction Reels Slow or Won t Steering 095 tae bebe Cutting Units Lift Slow or Won t Lift Cutting Units Won t Drop or Follow Ground Contours Reelmaster 4000 D Page 4 1 Chapter 4 Hydraulic System TESTING Precautions for Hydraulic Testing Test No 1 Check Traction Working and Relief Pressures 31 Test No 2 Check Counterbalance Oil Pressure eae e da eee 32 Test No 3 Check Reel Circuit Working and Relief Pressures 33 Test No 4 Check Reel Circuit Flow 34 Test No 5 Check Reel Motor Cross Over Relief Pressure 35 Test No 6 Check Reel Motor Case Drain Flow 36 Test No 7 Check Steering Circuit Working and Relief Pressures 37 Test No 8 Check Lift Circuit Working and Relief Pressures 38 Test No 9 Check Charge Pressure 38 SERVICE AND REPAIRS 39 Removing Hydraulic System Components 39 Steering Control 40 Add Hydraulic Fluid 51 Drain Water from Hydraulic Reservoir 51 Heel Meter 55 erates ic einen Ue ED etes 52 Steering Pump
43. and O ring 26 2 Install flow divider spool 3 plug 1 with new O ring 2 and other plug 6 with new O ring 2 3 The wear plate 20 bearing seal 18 molded O ring 17 back up gasket 19 shaft seal 12 and O rings 9 should be replaced as new parts 4 Install O ring 16 in groove of front plate 15 5 Tuck back up gasket 19 into groove in front plate with open part of V section down 6 Put molded O ring 17 in groove in front plate Put bearing seal 18 over molded O ring groove side down Reelmaster 4000 D Page 4 57 7 Apply athin coat of heavy grease to both milled faces of body 21 Slip body onto plate half moon port cavi ties in body must face away from front plate NOTE The small half moon port cavity must be on the pressure side of the pump 8 Put wear plate 20 on top of back up gasket 19 with bronze face up The side with the mid section cut away must be on suction side of pump Dip gear assemblies 10 7 into oil and slip into front plate bushings 9 Install O ring 16 in groove in back plate 22 10 Slide back plate 22 over gear shafts until dowel pins 4 are engaged Install bolts 11 and washers 13 Tighten evenly to a torque of 25 28 ft lb 11 Install washer 13 Liberally oil shaft seal 12 and carefully work over drive shaft being careful not to cut rubber sealing lip 12 Put a 1 5 16 O D sleeve over the shaft and p
44. and instruct operator to engage the reel into the backlap mode 3 Apply lapping compound evenly over the full length ofthe reel Make sure all reel blades are covered When ever noise of reel against the bedknife begins to disap pear or an uneven concentration of material appears on the reel redistribute the compound with the brush 4 When it becomes necessary to adjust the reel to the bedknife instruct operator to disengage reel stop en gine and remove key from the ignition switch Make ad justment only after the reels have stopped rotating 5 Backlap each reel until the cutting edges are sharp even on all blades Achieve a minimum of 1 32 inch 0 79 mm land area on newly sharpened reel assem blies Normally a reel need only be backlapped for approximately 3 minutes 6 Upon completion stop reel and turn off engine Re move key from the ignition switch Wash unit thoroughly with alow pressure stream of water to remove all lapping material Allow reel to dry Lubricate grease fittings 7 Checksharpness ofthe reel and bedknife with news paper strips Light reel to bedknife contact should shear the paper cleanly across the entire width If the pa per is not sheared acceptably continue backlapping 8 Proceed backlapping the remaining cutting units Note See Toro Sharpening Manual Part 80 300 1 for additional backlapping information Reelmaster 4000 D Hydraulic Motor Installation 1 Install dri
45. assembling a new roller to the cutting unit mount roller so that the roller shaft locknut is on the right side of the cutting unit As viewed by the operator sitting on seat of machine This prevents the lock nut from loosening during operation Fig 27 1 Install roller adjustment housing to the side plate Fig 26 A Install roller adjustment housings to both ends of the roller shaft B Position roller adjustment housing and guard to the side plate Make sure mounting holes are aligned properly Secure guards and housings to the side plate with mounting fasteners 2 Install collar assembly to the roller adjustment hous ing Fig 27 A Install both collar assemblies to both ends of the roller shaft B Make sure cone nut is on collar assembly with the cone facing up Slide collar assembly into each adjustment housing Reelmaster 4000 D Page 7 15 Figure 26 Guard 3 Side plate Roller adjustment housing 4 Mounting fasteners Figure 27 Cone nut 3 Lock nut Collar assembly C Thread cone nut onto each collar assembly with the cone facing down D Adjust height of cut see Adjust Height of Cut 5 Cutting Units Roller Bearing Replacement Figure 28 1 Roller tube front roller shown 5 nut 2 Roller shaft 6 Trust washer 3 Grease fitting 7 Outer grease seal 4 Lock nut 8 Wear sleeve Removal 1 Clean roller around the shaft grease fittings and
46. be evident during this operation The breakaway torque necessary to turn the drive gear must not exceed 140 in lb Hydraulic System Rear Wheel Drive Motor Figure 68 1 O Ring Seal 8 Bolt 2 Backup Washer 9 Outer Seal 3 Shaft Seal 10 Inner Seal 4 Key 11 Shaft Seal 5 Sub Shaft Assembly 12 Dust Seal 6 Pin 13 Slotted Nut 7 Spring Disassembly of the Rear Wheel Drive Motor Cleanliness is extremely important when repairing a hy draulic motor Work in a clean area Before disconnect ing the lines clean the port area of the motor thoroughly Use a wire brush to remove foreign material and debris from around the exterior joints of the motor Check the shaft and keyslot remove all nicks burrs or sharp edges that might damage the bearing housing seals when installing the shaft and bearing assembly Before start ing the disassembly procedures drain the oil from inside the motor Hydraulic System Page 4 80 Reelmaster 4000 D 1 Place the motor in 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 all drawings show the motor in a vise we recommend that you keep the motor in the vise during disassembly and reassembly Follow the clamping procedures explained throughout the manual
47. clean and re painted if necessary 3 Make sure all battery cables and connections are in good condition and battery clamp or hold down has been repaired or replaced 4 Place battery in its compartment Make sure battery is level and flat Connect positive cable connector onto positive battery post Tighten cap screw and lock nut with two wrenches 5 Secure battery retainer Do not overtighten to pre vent cracking or distorting the battery case 6 Apply a light coat of grease on all battery posts and cable connectors to reduce corrosion after connections are made Electrical System Rev A 6 7 Connect a digital multimeter to amps between the negative battery post and the negative ground cable connector The reading should be less than 0 1 amp If the reading is 0 1 amp or more the unit s electri cal system should be tested and repaired 8 Connect negative ground cable connector to the negative battery post Tighten cap screw and lock nut with two wrenches Charging To minimize possible damage to the battery and allow the battery to be fully charged the slow charging meth od is presented here This charging method can be ac complished with a constant current battery charger which is available in most shops CAUTION Follow the manufacturer s instructions when us ing a battery charger NOTE Using specific gravity of the battery cells is the most acc
48. click 5 Remove positive voltage from the pin of the white wire The solenoid should stay engaged 6 Remove positive voltage from the pin of the red wire The solenoid should release 7 Reconnect the wires to the solenoid Reelmaster 4000 D Page 5 25 Figure 20 1 Fuel stop solenoid 2 Red wire hold coil 3 White wire pull coil 4 black wire common Electrical System Rev A 6 Wu 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 the cover and remove it from the reservoir Note Float switch L1 is normally open when the tank is dry float down Float switch L2 is normally closed when the tank is dry float down 3 Position float switch L2 against its lower float stop 4 Check for continuity between electrical connector leads associated with the yellow wires J RED 5 Position float switch L2 against its upper float stop YELLOW 6 Check continuity between electrical connector e E leads associated with the yellow wires There should be 1 YELLOW no continuity between connector leads RED 7 Replace swit
49. end of the unit and remove the bedbar bedknife assembly Fig 21 3 Remove inboard locknut from the adjuster pin the fasteners for the bracket and remove the adjusting han dle assembly from the side plate Fig 21 4 Disassemble cone nut from the shoulder bolt secur ing the bearing housing to the side plate Remove belle ville washer and bolt Slide bearing housing off the reel shaft Fig 22 5 Disassemble cone nut from the shoulder bolt secur ing the bearing housing to the side plate remove the belleville washer and bolt and slide the bearing housing off the reel shaft Fig 22 Figure 20 1 Guard 3 Adjusting assembly 2 Mounting fasteners 4 Dust Figure 21 1 Lock nut 4 Bearing housing 2 Belleville washer 5 Reel shaft 3 Shoulder bolt 6 Flange housing 5 Figure 22 1 Drive housing 2 Drive belt Reelmaster 4000 D Page 7 11 Cutting Units 6 Disassemble cover from the drive housing and 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 using a puller Remove woodruff key from the reel shaft Fig 23 9 Remove adjustment assembly and cone nut belle ville washer and shoulder bolt securing the drive hous ing to the side plate Remove drive housing Fig 23 10 Slid
50. in the bearing and spline areas 14 Inspect thrust bearing 30 and thrust race 29 for wear 15 Inspect the needle bearing 6 in the housing as sembly If the needles are free of excessive play and re main in the bearing cage there is no need to replace the bearing Hydraulic System Hydraulic System Figure 64 Hex Head Cap Screw Charge Pump Adapter Assembly Plug Assembly Tow Valve Assembly O Ring Needle Bearing Gerotor Gear Assembly Check Valve Assembly Back Plate Assembly Housing Gasket Dowel Pin Rotating Kit Assembly Key Camplate Seal Cover Shaft Seal Washer Needle Bearing Housing Assembly Inner Race O Ring O Ring Cover Trunnion Cover Screw Page 4 72 Retaining Ring Shaft Seal Washer Retaining Ring Thrust Ring Needle Bearing Thrust Drive Shaft Relief Valve Kit O Ring Relief Valve Assembly Key Hex Head Cap Screw Cartridge O Ring Spring Poppet Spring Poppet Spring Spring Retainer O Ring Back up Washer Bearing Bearing Reelmaster 4000 D Reassembly of Traction 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 bearing outward
51. is fully open 6 Follow hose from reel motor case drain to the hy draulic T connector A Disconnect hose from T connector B Plug T connector to prevent drainage of fluid C Put case drain hose into suitable container for collecting case drain leakage 7 One person should sit on the seat and operate the machine while another person reads the tester and measures case drain leakage Make sure reel control le ver in NEUTRAL Start engine and move the throttle to full speed 2400 RPM Hydraulic System Page 4 36 Ad caution Keep away from reels during test to prevent per sonal injury from the rotating reel blades 8 Engage reels by positioning reel control lever to MOW position While watching pressure gauges slowly close flow control valve until a pressure of 1200 PSI is obtained 9 Collect hydraulic fluid for 15 seconds by putting the case drain hose into a 1 quart container graduated in ounces 1 liter container graduated in milliliters 10 Disengage cutting units by reel control lever to the NEUTRAL position Stop the engine 11 Measure the amount of oil collected in the container Divide the number of ounces collected by 32 to get gal lons per minute Divide the number of milliliters col lected by 250 to get liters per minute 12 Disconnect tester from motor and hose Reconnect hose to the pump 13 Remove plug from Reconnect case drain hose to the T connec
52. safety device or decal is defective or dam aged repair or replace it before operating the machine 5 Always wear substantial shoes Do not operate ma chine while wearing sandals tennis shoes sneakers or when barefoot Do not wear loose fitting clothing that could get caught in moving parts and possibly cause personal injury Reelmaster 4000 D Page 1 1 Chapter 1 Safety SAFETY AND INSTRUCTION DECALS 4 WARNING To reduce the potential for injury or death comply with the following safety instructions 6 Wearing safety glasses safety shoes long pants and a helmet is advisable and required by some local or dinances and insurance regulations 7 Make sure the work area is clear of objects which might be picked up and thrown by the reels 8 Donotcarry passengers on the machine Keep ev eryone especially children and pets away from the areas of operation 9 Since diesel fuel is highly flammable handle it care fully A Use an approved fuel container B Do not remove fuel tank cap while engine is hot or running C Do not smoke while handling fuel D Fill fuel tank outdoors and only to within an inch 25 mm from the top of the tank not the filler neck Do not overfill E Wipe up any spilled fuel Safety While Operating 10 Do not run engine in a confined area without ade quate ventilation Exhaust is hazardous and could be deadly 11 Sit the seat when start
53. shall be per formed by marking a line on the fastener head or nut and mating part then back off fastener 1 4 of a turn Measure the torque required to tighten the fastener until the lines match up Class 8 8 Class 10 9 Metric Bolts and Screws Product Records and Maintenance Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series Grade 1 5 amp 8 with Thin Height Nuts SAE Grade 1 Bolts Screws Studs amp Sems with Regular Height Nuts SAE J995 Grade 2 or Stronger Nuts SAE Grade 5 Bolts Screws Studs amp Sems with Regular Height Nuts SAE J995 Grade 2 or Stronger Nuts SAE J995 Grade 5 or Stronger Nuts inte SAE Grade 8 Bolts Screws Studs amp Thread Size Sems with Regular Height Nuts 6 32 UNC 147 23 6 40 UNF 8 32 UNC 282 30 8 36 UNF 10 24 UNC 339 56 10 32 UNF 1 4 20 UNC 53 7 599 79 1 4 28 UNF 5 5 10 734 113 5 16 18 UNC 115 15 105 17 1186 169 5 16 24 UNF 138 17 128 17 1446 192 3 8 16 UNC 16 2 3 8 24 7 16 14 UNC 27 3 7 16 20 UNF 29 3 1 2 13 UNC 30 3 N 85 8 1 2 20 32 3 s om 430 45 583 61 600 60 813 81 475 45 644 61 660 60 895 81 on the fastener size the aluminum or base material strength length of thread engagement etc 5 8 11 UNC 65
54. the area around the cells is clean before opening the battery caps A Measure the specific gravity of each cell with a hydrometer Draw electrolyte in and out of the hydrometer barrel prior to taking a reading to warm up the hydrometer At the same time take the tem perature of the cell Reelmaster 4000 D D Temperature correct each cell reading For each 10 F 5 5 C above 80 F 26 7 C add 0 004 to the specific gravity reading For each 10 F 5 5 C be low 80 F 26 7 C subtract 0 004 from the specific gravity reading Example Cell Temperature 100 F Cell Gravity 1 245 100 F minus 80 F equals 20 F 37 7 C minus 26 7 C equals 11 0 C 20 F multiply by 0 004 10 F equals 0 008 11 C multiply by 0 004 5 5 C equals 0 008 ADD conversion above 0 008 Correction to 80 F 26 7 C 1 253 the difference between the highest and lowest cell specific gravity is 0 050 or greater or the lowest cell specific gravity is less than 1 225 charge the battery Charge at the recommended rate and time given in Charging or until all cells specific gravity is 1 225 or greater with the difference in specific grav ity between the highest and lowest cell less than 0 050 If these charging conditions can not be met replace the battery 3 Perform a high discharge test with an adjustable load tester This is one of the most reliable means of testing a battery as it simulates the cold cranking test A commercial bat te
55. the ring gear It is necessary to rotate the carrier and pinion to align the sun gear teeth with the secondary pinion and primary pinions with ring gear teeth Assemble primary sun gear 13 over the input shaft Rotate sun gear to align the shaft to gear splines and gear teeth 10 Assemble small thrust washer 12 over the input shaft and against the shoulder of shaft 11 Assemble O ring 21 in the groove of the disen gage plunger 22 Assemble plunger over the end of in put shaft and against the thrust washer 12 Lubricate O ring in the groove of the engage plung er Assemble thrust washer 23 with tangs engaged with the large cover 19 Apply a bead of RTV com pound or equivalent to the end face of the ring gear As semble cover over the plunger as holes of cover and ring gear are aligned Assemble eight 5 16 18x1 inch hex head bolts Torque bolts from 20 to 25 ft lb 2 8 to 3 5 kg m 13 If the wheel is to be used to drive the vehicle as semble disengage cover 18 with the dimpled center protruding out Assemble and torque two 5 16 18x3 4 inch bolts Torque bolts from 10 to 20 1 4 to 2 8 kg m 14 Invert Power Wheel assembly Assemble coupling 1 with the counterbore out to the input shaft Reelmaster 4000 D Chapter 7 TORO Cutting Units Table of Contents SPECIFICATIONS 2 SERVICE AND REPAIRS 8 SPECIAL TOOLS 3 Ba
56. to secure lockout Raise front rollers up so they do not contact the flat surface Note Using a bar 3 8inch 9 5 mm thicker than height of cut provides the proper bedknife attitude heeled up in back which is required for excellent low height of cut performance Reelmaster 4000 D B Insert a piece of bar stock 25 to 28 inches 64 to 71 cm long and approximately 3 8 inch 9 5 mm thicker than the desired height of cut under the reel and up against the bedknife cutting edge The reel not bedknife must contact the bar stock along its full length Fig 8 C Loosen rear roller jam nuts and adjusting knobs Push roller down against the flat surface At this point the reel should contact the bar stock and the rear roller should contact the flat surface Contact should exist along the entire length of the reel and rear roller Tighten rear roller adjustment knobs and jam nuts Make sure roller and reel are both still making contact after the jam nuts have been tight ened Check roll contact by trying to slide paper be tween the roller and the flat surface D Rear roller is now leveled to the reel Figure 6 Cutting Unit Float Position 1 Lockout pin 2 Jamnut Figure 7 Cutting Unit Fixed Position 1 Lockout pin 2 Jamnut CONTACT ALONG FULL LENGTH AT AND LEVELS REAR ROLLER REEL REAR ROLLER HOC 3 8 INCH 9 5 mm 5 REF FLAT SURFACE BAR STOCK Figure 8 Lev
57. to relay terminals 30 and 87 Ground terminal 86 and apply 12 VDC to terminal 85 The relay should make and break continuity between terminals 30 and 87 as 12 VDC is ap plied and removed from terminal 85 3 Disconnect voltage from terminal 85 and multimeter lead from terminal 87 4 Connect multimeter ohms setting lead to relay ter minal 30 and 87A Apply 12 VDC to terminal 85 The relay should break and make continuity between termi nals 30 and 87A as 12 VDC is applied and removed from terminal 85 5 Disconnect voltage and multimeter leads from the relay terminals Hydraulic Oil Temperature Switch The high temperature switch is located on the the bot tom of the hydraulic reservoir with two black wires and one red wire connected to it Fig 10 A CAUTION Make sure engine is cool before removing the temperature switch 1 Drain hydraulic fluid from the hydraulic reservoir and remove high temperature switch 2 Put switch in a container of oil with a thermometer and slowly heat the oil Fig 11 CAUTION Handle the hot oil with extreme care to prevent personal injury or fire 3 Check continuity of the switch with a multimeter ohms setting The switch is normally open and should close between 186 to 194 F 86 to 90 C 4 Allow the oil to cool The switch should open below 186 F 86 C TOP VIEW Figure 9 Figure 10 1 Side view 2 End view Figure 11 Electrical Syst
58. to the reel shaft This will result in the reel being ground to the desired cylinder shape Note When grinding be careful to not overheat the reel blades Remove small amounts of material with each pass of the grinder 4 After completing the grinding process A Install parts that were removed to mount the cut ting unit onto grinder B Install bedbar assembly see Bedknife Bedbar Assembly C Do a complete cutting unit set up and adjust ment procedure see Adjustments section Reel Grinding Specifications Nominal Reel Diameter 8 in 206 mm Service Limit Reel Diameter 7 2 in 182 mm 0 060 in 1 5 mm BLADE RELIEF ANGLE III REEL DIAMETER TAPER 0 Do Figure 25 Cutting Units Page 7 14 Reelmaster 4000 D 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 roller adjustment housings to the side plate B Pull housings from roller shafts 2 Remove collar assembly from roller adjustment housing Fig 27 A Unscrew upper cone nut from the collar assemb ly B Drop collar assembly out of the adjustment housing C Separate both collar assemblies from both ends of the roller shaft Installation IMPORTANT When
59. wheel hubs immediately after towing is com pleted Remove disengage covers and reinstall so dim ple on cover is facing away from hub Ad caution Do not remove wheel blocks or towing devices until wheel hubs are securely locked Reelmaster 4000 D 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 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 Figure 11 1 Hydraulic reservoir 2 Sight glass Reelmaster 4000 D Page4 7 Hydraulic System Hydraulic Schematic Siet HOSN3S 1331 L gt ee R SYOLOW y 3JdO 1nHS 1338
60. 076mm thick across its entire length 3 Ifexcessive contact is determined turn each adjust ing knob equally and counter clockwise until no contact is noticed Then turn both adjusting knobs equally and clockwise until light contact is felt and heard between the reel and bedknife Final adjustment should always be in the tightening clockwise direction IMPORTANT Cutting units with excessive contact between the reel and bedknife are noisy consume excessive power shorten component life and result in overall poor performance Light contact between the reel and bedknife once the cutting unit is warmed up provides optimum mowing perfor mance and component life 4 Tighten adjuster locking nuts when adjustments are complete Reelmaster 4000 D 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 roller to the real A Start engine and lower the cutting unit onto a flat surface such as a piece of 3 4 inch 1 9 cm plate steel of at least 20 x 30 inches 50 x 76 cm Stop engine and remove key from ignition switch Lock cutting units in the fixed position by loosening the jam nut on the lockout pin Fig 6 and screwing the pin into the hole in pivot arm Fig 7 Tighten nut
61. 1 50 25 8 1 2 in 1 50 25 10 5 8 in 1 50 25 12 3 4 in 1 50 25 16 1 in 1 50 25 Hydraulic System Page 4 4 Figure 3 Lock Nut Back up Washer O Ring Figure 4 Figure 5 Reelmaster 4000 D Pushing or Towing Traction Unit Using Traction Pump By Pass Valve In an emergency the traction unit can be pushed or towed for a very short distance by using the traction pump by pass valve IMPORTANT Do not push or tow the traction unit faster that 2 to 3 MPH 3 to 5 Km Hr because the hy draulic system may be damaged If traction unit must be moved a considerable distance transport it on a truck or trailer 1 Remove the retainer clip from seat lock rod 2 Raise seat and support it in upright position with seat support rod Fig 6 Figure 6 1 Seat 2 Support rod 3 Lift and remove front panel Fig 7 Figure 7 1 Front panel 4 Rotate by pass valve 90 degrees Opening the opens an internal passage in the traction pump thereby by passing hydraulic oil Because oil is by passed traction unit can be moved without damaging the hy draulic system Fig 8 Reelmaster 4000 D Page 4 5 Figure 8 1 Traction pump 2 By pass valve IMPORTANT Make sure that hand brake is engaged before opening the by pass valve 5 Before starting engine close by pass valve Do not start engine when valve is open IMPORTANT Running the machine with the by pass valve
62. 10 88 12 5 8 18 UNF 75 10 95 15 129 20 3 4 10 UNC 93 12 140 20 190 27 3 4 16 115 15 165 25 224 34 7 8 9 UNC 140 20 225 25 305 34 ER e ER scm caue ESCHER lo n N a a lwo fo 13 2 7 8 14 155 25 260 30 353 41 Note Reduce torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as oil graphite or thread sealant such as Loctite Note The nominal torque values listed above for Grade 5 and 8 fasteners are based on 75 of the mini Note Torque values may have to be reduced when mum proof load specified in SAE J429 The tolerance is installing fasteners into threaded aluminum or brass The specific torque value should be determined based Product Records and Maintenance Page 2 4 approximately 10 of the nominal torque value Thin height nuts include jam nuts Reelmaster 4000 D Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners Class 8 8 Bolts Screws and Studs with Class 10 9 Bolts Screws and Studs with Thread Size Regular Height Nuts Regular Height Nuts Class 8 or Stronger Nuts Class 10 or Stronger Nuts 57 5 inb 640 60 N cm 78 7 indb 96 9 indb 1018 100 N cm 133 13 in lb 19 2 ft lb 26 4 3 N m 27 2 ft Ib 38 4 ft lb 52 5N m 53
63. 18 Slide wheel off of the spindle shaft 4 Pull seal 22 out of wheel hub 9 5 Remove bearings 11 and 21 from both sides of the wheel hub 9 Clean bearings in solvent Make sure the bearings are in good operating condition Clean inside of the wheel hub 9 Check bearing cups 10 and 20 for wear pitting or other noticeable damage Replace worn or damaged parts 6 If bearing cups 10 and 20 were removed from the wheel hub 9 press them into the hub until they seat against the shoulder 7 Use No 2 general purpose lithium base grease con taining EP additive Pack both bearings 11 and 21 with grease Install bearing 21 into the cup 20 on inboard side of wheel hub IMPORTANT The lip seal must be pressed so it is flush with the end of the hub The lip of the seal must be toward the bearing 8 Lubricate the inside of the new lip seal 22 and press it into the wheel hub 9 Pack inside of wheel hub with some grease not full Install remaining bearing 11 into bearing cup 10 10 Slide wheel onto the spindle shaft and secure it in place with the flat washer 18 nut 17 and retainer nut 50 Do not tighten nut or install the cotter pin Axles and Brakes Page 6 6 11 Adjust preload on the wheel bearings Fig 6 A Tighten jam nutfrom 75 to 80 in Ib 86 to 270 kg cm while turning the hub to seat the bearings and remove all end play B Loosen jam nut until itis away from the ta
64. 3 and 1 reel motors The oil is also available for use at the Number 4 shut off valve If the Number 1 2 and 3 cutting units are in the raised position the oil will bypass these motors and be available directly to the Number 4 shut off valve With the Number 4 cutting unit in the down and mowing position the Number 4 shut off valve will allow the oil through to drive the reel motor and then to the Number Reelmaster 4000 D Page 4 19 5 shut off valve If the Number 4 cutting unit is in the raised position the oil will bypass the Number 4 reel mo tor and be available directly to the Number 5 shut off valve With the Number 5 cutting unit in the down and mowing position the Number 5 shut off valve will allow the oil through to drive the reel motor If the Number 5 cutting unit is in the raised position the oil will bypass the Num ber 5 reel motor and return to the reel On Off valve From the reel On Off valve the oil returns to the sump tank through the drain block oil cooler and filter Backlap is provided by pulling the reel On Off valve lever up and back The backlap function requires that the lever be held in this position for safety The direction of flow in Backlap is the opposite of Mow Some units will include a low speed backlap valve in the circuit to remove some oil flow from the circuit during the backlap function The reduced oil flow results in a slower reel speed in Backlap bu
65. 30 8 Install plugs 6 with new O rings 7 9 Install detent plungers 4 springs 3 discs 2 and plugs 1 with new O rings 5 10 If retaining ring 27 has been removed to replace spool spring 25 install washer 24 spring 25 spacer 26 and secure with retaining ring 27 11 Slide bushings 23 over spools Slide new O rings 22 over spools and position next to bushings Dip spools in clean hydraulic oil and install spool assemblies in proper location 12 Install spool caps 28 and tighten to a torque of 20 25 ft lb 13 Install new wiper seals 38 Hydraulic System Priority Flow Divider Figure 58 1 Plug Assembly 11 2 O Ring 12 3 Spool 13 4 Body 14 5 O Ring 15 6 O Ring 16 7 Backup Washer 17 8 Metering Stem 18 9 Groove Pin 19 10 Shim Hydraulic System Page 4 60 Shim Shim Shim O Ring Backup Washer Metering Plug Shim Shim Spring Reelmaster 4000 D Disassembly of Priority Flow Divider 1 Plug all ports and thoroughly clean outside of valve 2 Remove plug 1 shims 17 amp 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 plug 16 4 Remove shims 10 11 12 amp 13 from metering plug 16 5 Remove O rings 5 amp 14 and back up washer 15 from metering plug 16 6 Remove groove pin 9 and remove me
66. 4 0 359375 9 128 55 64 0 859375 21 828 3 8 0 3750 9 525 7 8 0 8750 22 225 25 64 0 390625 9 922 57 64 0 890625 22 622 13 32 0 40625 10 319 29 32 0 90625 23 019 27 64 0 421875 10 716 59 64 0 921875 23 416 7 16 0 4375 11 112 15 16 0 9375 23 812 29 64 0 453125 11 509 61 64 0 953125 24 209 15 32 0 46875 11 906 31 32 0 96875 24 606 31 64 0 484375 12 303 63 64 0 984375 25 003 1 2 0 5000 12 700 1 1 000 25 400 1 0 03937 in 0 001 in 0 0254 mm U S to Metric Conversions To Convert Into Multiply By Linear Miles Kilometers 1 609 Measurement Yards Meters 0 9144 Feet Meters 0 3048 Feet Centimeters 30 48 Inches Meters 0 0254 Inches Centimeters 2 54 Inches Millimeters 25 4 Area Square Miles Square Kilometers 2 59 Square Feet Square Meters 0 0929 Square Inches Square Centimeters 6 452 Acre Hectare 0 4047 Volume Cubic Yards Cubic Meters 0 7646 Cubic Feet Cubic Meters 0 02832 Cubic Inches Cubic Centimeters 16 39 Weight Tons Short Metric Tons 0 9078 Pounds Kilograms 0 4536 Ounces Avdp Grams 28 3495 Pressure Pounds Sq In Kilopascal 6 895 Pounds Sq In Bar 0 069 Work Foot pounds Newton Meters 1 356 Foot pounds Kilogram Meters 0 1383 Inch pounds Kilogram Centimeters 1 152144 Liquid Volume Quarts Liters 0 9463 Gallons Liters 3 785 Liquid Flow Gallons Minute Liters Minute 3 785 Temperature Fa
67. 6 Shell Tellus 68 Equivalent Equivalent Hydraulic Oils Interchangeable Mobil DTE 15M Amoco Rykon Oil 68 Conoco Super Hydraulic Oil 68 Exxon Nuto H 68 Kendall Kenoil R amp 0 AW 68 Pennzoil 68 Phillips Magnus A 68 Standard Energol HLP 68 Sun Sunvis 831 WR Union Unax AW 68 Drain Water from Hydraulic Reservoir After every 100 operating hours drain water from hy draulic reservoir 1 Open drain plug one half turn and allow fluid to flow into drain pan until water is not noticed in hydraulic oil Fig 53 2 Tighten drain plug and add hydraulic oil see Add Hydraulic Oil Reelmaster 4000 D Page 4 51 Figure 51 1 Hydraulic reservoir 2 Sight glass Figure 52 1 Filler cap 2 Hydraulic reservoir Figure 53 1 Drain plug 2 Right front fender Hydraulic System Reel Motor Figure 54 1 Not used 8 Plate amp Bushing Assembly 15 Relief Valve Kit 2 Idler Gear 9 Socket Head Cap Screw 16 O Ring 3 Drive Gear 10 Set Screw 17 Plug 4 Key 11 Drive Pulley 18 Shim 5 O Ring 12 Retaining Ring 19 Spring 6 Body 13 Shaft Seal 20 Ball 7 Dowel Pin Disassembly of Reel Motor 1 Remove set screws 10 from drive pulley 11 2 Remove drive pulley 11 from drive shaft 3 Remove key 4 from drive shaft 4 Clean outside of motor thoroughly Scribe a line along front plate assembly 8 body 6 and back plate as sembly 21 to assure proper reassembly 5 Clam
68. Belt isis Inspect Cooling System Hoses Service Inspect Cutting Unit Reel Drive Belts C Level Torque Wheel Lug Nuts Service Service Air Cleaner Replace Fuel Filters Inspect Fuel Lines and Connections Check Engine RPM idle and full throttle D Level Service Drain and Clean Fuel Tank Replace Hydraulic Oil Filters Adjust Valves Replace Hydraulic Tank Breather Change Front Planetary Gear Lube Pack Rear Wheel Bearings E Level Check Rear Wheel Toe in Service Initial break in at 10 hours Initial break in at 50 hours Replace Moving Hydraulic Hoses Bacommendations Replace Safety Switches Items listed are recommended every 1500 Coolant System Flush Replace Fluid hours or 2 years whichever occurs first Change Hydraulic Oil See Operator s and Service Manual for specifications and procedures Product Records and Maintenance Page 2 10 Reelmaster 4000 D 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 Sp Maintenance Check For Week OT _ Check rues web THURS FAT sr SUN 1 dT TT A 2 e 2 Q lt Cooling System Fluid Level Drain Water Fuel Separator Air Filter Restriction Indicator Radiator Oil Cooler and Screen for D
69. D L eM 4 LM LZM LEM ZiM AM 6LM ZIM 9M z 1 9 7 2 or HO LIMS Ofrld MOT VLOSD 81d OL 41d OL SSuNHVH NIVIA OL Reelmaster 4000 D Page 5 10 Electrical System Rev A SS WIRE IDENTIFICATION lt gt LABEL COLOR ROUTE a W66 YEL BLU 5 4 16 a W67 GRN P5 3 14 W68 GRN WHT 1 5 2 J15 2 w69 P5 1 J13 W70 YEL BLU J16 P2 5 W71 GRN J14 P2 4 ch 6 W72 GRN WHT J15 P2 1 or W73 YEL 13 P2 2 5 W74 BLK WHT P2 3 P2 6 W75 BLK WHT 2 3 1 3 2 W76 BLK WHT P2 6 P3 1 T Qs W77 BLK WHT P1 3 P1 6 935 g W78 RED 1P4 4 J10 SS W79 WHT 2 J12 245 e wan BLU 1P4 3 J11 W81 BRN P4 1 J9 W82 RED J10 P1 4 W83 WHT J12 P1 5 W84 BLU J11 P1 1 5 W85 BRN 199 P1 2 W86 1 1 6 J1 SE W87 GRY 1P3 5 J2 5 wes ORG 1P3 2 J5 lt W89 GRN BLK 1317 J18 W90 GRN BLK 118 J19 W91 GRN BLK J19 J20 W92 GRN BLK 1920 J3 W93 121 22 W94 ORG 1922 J23 W95 ORG 1923 J24 W96 ORG J8 J24 amp W97 ORG J8 J5 wos YEL J6 P3 3 W99 GRY 1J2 J7 W100 GRY J7 4 101 BL
70. DE COMMERCIAL PRODUCTS Some tools may also be available from a local supplier Hydraulic Tester With Pressure and Flow Capabilities TOR214678 Figure 12 You must have o ring face seal ORFS adapter fittings for this tester to use it on Toro equipment 1 INLET HOSE Hose connected from the system cir cuit to the inlet side of the hydraulic tester 2 LOAD VALVE If required upon turning the valve to restrict flow a simulated working load is created in the circuit 3 LOW PRESSURE GAUGE Low range gauge to provide accurate reading at low pressure 0 1000 PSI This gauge has a protector valve which cuts out when pressure is about to exceed the normal range for the gauge The cutout pressure is adjustable Hydraulic System Page 4 26 4 HIGH PRESSURE GAUGE High range gauge to accommodate pressure beyond the capacity of the low pressure gauge 0 5 000 PSI 5 FLOW METER This meter measures actual oil flow in the operation circuit with a gauge rated at 15 GPM 6 OUTLET HOSE Hose from the outlet side of the hy draulic tester to be connected to the hydraulic system circuit Reelmaster 4000 D Hydraulic Pressure Test 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 850 Bar and 10000 PSI 700 Bar gauges Use gauges as recommended in Testing section of this ch
71. ERVICE HISTORY REPORTS 9 Insert Operator s Manuals and Parts Catalogs for your Reelmaster 4000 D at the end of this section Product Records and Maintenance Decimal and Millimeter Equivalents Equivalents and Conversions Fractions Decimals mm Fractions Decimals mm 1 64 0 015625 0 397 33 64 0 515625 13 097 1 32 0 03125 0 794 17 32 0 53125 13 494 3 64 0 046875 1 191 35 64 0 546875 13 891 1 16 0 0625 1 588 9 16 0 5625 14 288 5 64 0 078125 1 984 37 64 0 578125 14 684 3 32 0 9375 2 381 19 32 0 59375 15 081 7 64 0 109275 2 778 39 64 0 609375 15 478 1 8 0 1250 3 175 5 8 0 6250 15 875 9 64 0 140625 3 572 41 64 0 640625 16 272 5 32 0 15625 3 969 21 32 0 65625 16 669 11 64 0 171875 4 366 43 64 0 671875 17 066 3 16 0 1875 4 762 11 16 0 6875 17 462 13 64 0 203125 5 159 45 64 0 703125 17 859 7 32 0 21875 5 556 23 32 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64 0 765625 19 447 9 32 0 28125 7 144 25 32 0 78125 19 844 19 64 0 296875 7 541 51 64 0 796875 20 241 5 16 0 3125 7 938 13 16 0 8125 20 638 21 64 0 328125 8 334 53 64 0 828125 21 034 11 32 0 34375 8 731 27 32 0 84375 21 431 23 6
72. Electrical Sche matics and Diagrams section of this chapter Remove all jewelry especially rings and watches before doing any electrical trouble If the machine has any interlock switches by passed shooting or testing Disconnect the battery they must be reconnected for proper troubleshooting cables unless the test requires battery voltage and safety Starting Problems Starter solenoid clicks but starter will not crank Low battery charge if solenoid clicks problem is not in safety interlock system Loose or corroded battery cables Loose or corroded ground Faulty wiring at starter Faulty starter solenoid Nothing happens when start attempt is made Battery is dead Loose or corroded battery cables Loose or corroded ground Parking brake is off Mow backlap lever is engaged Circuit breaker open Traction brake switch 2 out of adjustment or faulty Traction brake switch 2 wiring loose corroded or damaged Reel drive neutral switch faulty Reel drive neutral switch wiring loose corroded or damaged Key switch faulty Key switch wiring loose corroded or damaged Starter solenoid wiring loose corroded or damaged Starter solenoid faulty Electrical System Rev A Page 5 14 Reelmaster 4000 D Starting Problems continued Engine cranks but does not start Engine run solenoid wiring loose or corroded Engine run solenoid faulty Low hydraulic oil level Hydraulic oil low lev
73. Forward test port NOTE f pressure is good in 2WD but to low in 4WD check the cartridge valve seals the 4WD valve block If 4WD pressure is low after making repairs to the valve block the rear wheel motor s should be suspected of wear and inefficiency Maximum allowable bypass for each rear wheel motor is 2 GPM Procedure for Relief Pressure Check 1 Hydraulic oil must be at operating temperature 2 Install a 10 000 psi gauge into the traction circuit quick disconnect for the function to be checked 3 Set traction pedal stop for minimum ground speed 1 mph 4 Start the engine and move throttle to full speed 2500 rpm and release the parking brake 5 Carefully drive the machine into position so it will push against a strong wall or other immovable obstacle Con tinue an attempt to go forward with the machine against the obstacle and read the pressure gauge TESTER READING TO BE APPROXIMATELY 5000 5200 PSI 6 If traction pressure is too low inspect the traction pump check valves and relief valves Clean or replace relief valve s or check valves as necessary If check valves and relief valves are in good condition the trac tion pump and or motors should be suspected of wear and inefficiency Reelmaster 4000 D Page 4 31 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 th
74. Hydraulic oil must be at operating temperature 2 Install a 5 000 psi gauge into the cutting circuit quick disconnect 3 Start the engine and lower the No 2 left front and 3 right front cutting units to the ground 4 Turn the engine OFF 5 Block the reel of the No 2 cutting unit to prevent rota tion The No 2 cutting unit motor is the first in series flow from the pump Use a substantial hardwood block in serted between the reel blades AX caution Stand clear of the reels during the following proce dures 6 Place reel speed control knob at minimum 7 Start engine and position throttle at idle 8 Ease the reel control lever into MOW while monitor ing the gauge NOTE It may be necessary to raise the throttle slightly to prevent the engine from stalling TESTER READING TO BE 2650 2750 PSI 9 If reel circuit relief pressure is above 2750 psi or below 2650 psi clean or replace relief valve in reel control valve Reelmaster 4000 D Page 4 33 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 Turn the engine OFF 4 Disconnect inlet hose at No 2 reel motor 5 Install tester in series between disconnected hose and reel motor flow direction is from hose to motor Make sure gate valve of tester is OPEN Figure 18 6 Position r
75. K WHT J1 P4 6 W102 BLK J4 P4 5 kar cha TD oF Wan SE Tio oa 5 Kai 526 46 92 o gt lt a 5 Or ese rXO 9 0 B OD Suz 0 iu D we 22 Ze Co OF Fe 95 5 FD Fo ojo TT N ezg lt gt x DS TI Reelmaster 4000 D Page 5 11 Electrical System Rev A weibeig 4 15 2 14617 WV TI SONATIS Wav Iw ualdl LOdH 8r 217 Ir 98 28 vZ8 58 0 vir eif eer 0007 4 5 F 034 2 d31S0110 LHON our oer sir ver er 91441476121 SM ZZM ZM EZM 6M 9M 8M IM 92M LEM LLM SM ZM LEM LM D 2 SEM LZM 9EM 9EM 9 ZZM AE S D SIM 5 JS v E EEM EZM LLM 9LM ELM ZM 9M 02M SZM 2M 82M OEM ZIM 8LM 61M z SZM SLM LEM 5 LEM S vM 62M 9 9 e vr er l
76. R CYLINDER RIGHT AXLE WHEEL Reelmaster 4000 D Page 4 17 Hydraulic System Lift Circuit Free Float Detent OIL FLOW PRESSURE FREE BIB PRESSURE oiL STEERING ORBITROL NO 2 REEL MOTOR NO 3 REEL MOTOR NO 2 LIFT CYLINDER NO 3 LIFT CYLINDER TRACTION TRACTION MOTOR LEFT i SS PS COUNTER BALANCE VALVE PUMP PACKAGE LO SPEED BACKLAP NO 4 REEL MOTOR NO 4 LIFT CYLINDER NO 5 LIFT CYLINDER 7 J __ 9 STEER CYLINDER RIGHT AXLE NHEEL Hydraulic System Page 4 18 Reelmaster 4000 D 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 valve The reel speed is variable and ad justable by the operator to supply a flow of oil to the reel On Off valve Oil not needed to obtain the selected reel speedis directed back to the sump tank through the drain block oil cooler and filter When the reel On Off valve lever is moved into Mow to engage the reels a spool in the valve is shifted to di rect oil to the shut off valve at the front of the unit With the Number 1 2 and 3 cutting units in mowing position the shut off valve will allow oil to flow to the Number 2
77. Rear Wheel Toe in 0 125 inch 0 32 cm Wheel Planetary Lubricant Fig 1 SAE 80 90 EP gear lube 30 oz capacity Figure 1 1 1 oe N dus 2 Planetary wheel drive Axles and Brakes Page 6 2 Reelmaster 4000 0 Adjustments Hand Brake and Traction 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 tension Adjustment affects operation of traction switches 4 Adjust four U bracket nuts so engine will start and run when hand brake is at the fourth click but will not start or run when hand brake is at second click Reelmaster 4000 D Page 6 3 Hand brake Brake cable U bracket Figure 2 4 Traction switches 5 Traction pedal Axles and Brakes o 2 x Brakes Rear Wheel Toe In After every 800 operating hours 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 at both ends of the tie rods Fig 4 3 Rotate tie rod to move the front of tire inward or out ward NOTE Make sure tie rod clamps are positioned so they do not interfere with steering linkage 4
78. Refer to Hydraulic Oil Specifications IMPORTANT Use only hydraulic oils specified Other fluids could cause system damage 3 Install reservoir cover lower seat and secure with lock pin Start engine and use all hydraulic controls to distribute hydraulic oil throughout the system Also check for leaks Then stop the engine 4 With cutting units up and oil warm look into sight glass If hydraulic oil is not even with arrows add enough to raise to proper level Do not fill full if oil is cold Fig 92 Hydraulic System Page 4 90 Figure 91 1 Drain plug 2 Right front fender Figure 92 1 Hydraulic reservoir 2 Sight glass Reelmaster 4000 D 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 the warranty on some components 1 Removeseatlock pin raise seat and hold open with support rod Also remove front panel secured with mag nets ahead of the seat 2 Clean area around filter mounting area Fig 93 Place drain pan under filter and remove filter 3 Lubricate new filter gasket and fill the filter with hy draulic oil 4 Assure filter mounting area is clean Screw filter on until gasket contacts mounting plate Then tighten filter one half turn 5 Start engine and let run for about two min
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80. TORO 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 TO THE TRACTION UNIT AND CUTTING UNIT OPERATOR S MANUALS FOR OPERATING MAINTENANCE AND ADJUSTMENT INSTRUC TIONS Space is provided in Chapter 2 of this book to insert the Operator s Manuals and Parts Catalogs for your machine Replacement Operator s Manuals are available by sending complete Model and Serial Num ber to The Toro Company 8111 Lyndale Avenue South Bloomington MN 55420 1196 The Toro Company reserves the right to change product specifications or this publication without notice PART NO 9895861 Rev Service Manual Reelmaster 4000 0 This safety symbol means DANGER WARNING or CAUTION PERSONAL SAFETY INSTRUC TION When you see this symbol carefully read the instructions that follow Failure to obey the instructions may result in personal injury NOTE A NOTE will give general information about the correct operation maintenance service testing or re pair of the machine IMPORTANT The IMPORTANT notice will give im portant instructions which must be followed to pre vent damage to systems or components on the machine The Toro Company 1998 2003 Reelmaster 4000 D Table Of Contents Chapter 1 Safety General Safety Instructions 1 1 Safety an
81. Tighten drain screw Kubota Diesel Engine Page 3 10 Reelmaster 4000 D 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 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 spilled diesel fuel before start ing the engine Store fuel in a clean safety ap proved container and keep cap in place Use die sel fuel for the engine only not for any other purpose There are 2 fuel filters on the RM 4000 D A small line filter is located on top of the fuel tank and behind the the radiator Fig 15 The fuel filter water seperator is lo cated near the left rear end of the engine Fig 16 Replace fuel filters if fuel flow becomes restricted after every 400 hours of operation or annually whichever comes first 1 Park machine on a level surface Stop engine Re move key from the ignition switch 2 Unscrew bottom filter cap from filter assembly Re move cap gaskets o ring and filter from assembly Note position of gaskets and o ring when disassembling from filter 3 Install new filter gaskets o ring with filter assembly cap 4 Prime fuel system refer to Prim
82. Timing Step 1 Locate the largest open pocket in the Geroter and mark it on the outside edge of the Geroter 33 Apply a light film of petroleum jelly to the 3 76 diam eter seal Install seal in groove of valve plate Clockwise 34 Align the notch on the outside of the valve plate with Rotation the notch on the Geroter as shown in Fig 80 Timing Step 2 Locate the slot opening in the valve plate which is in line with the largest open pocket of the Geroter Counter Clockwise Timing Step 3 Locate any one of the side openings of Rotation the valve and align this opening with the open slot of the valve plate that is in line with the largest open pocket of the Geroter Install the valve by rotating it clockwise until the spline teeth engage 1 2 spline tooth max This will rovide the proper rotation when pressurized as shown in Fig 81 Pin amp Spring Valve Housing 35 Install 2 springs and 2 pins in the holes located in the bore of the valve housing as shown in Fig 79 36 Apply a light film of petroleum jelly to the 3 76 diam eter seal Install seal in the valve housing Figure 82 Hydraulic System Page 4 84 Reelmaster 4000 D 37 Apply petroleum jelly to inner and outer face seals Install seals on balance ring as shown in Fig 83 Pin Notch Inner Seal Outer Seal IMPORTANT Install face seals in the positions shown in Fig 83 or the motor will not operate prop erly Do not for
83. ace 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 damaged air cleaner body Fig 11 4 Service the air cleaner filters when ever air cleaner indicator light illuminates and warning signal sounds or every 400 hours more frequently in extreme dusty or dirty conditions Do not over service air filter 5 Be sure cover is sealing around air cleaner body Fig 11 6 Release latches securing air cleaner cover to air cleaner body Separate cover from body Clean inside of air cleaner cover Fig 11 7 Gently slide primary filter out of air cleaner body to reduce the amount of dust dislodged Avoid knocking fil ter against air cleaner body Do not remove safety fil ter IMPORTANT Never attempt to clean a safety filter Located inside primary filter Replace the safety filter with a new one after every three primary filter services 8 Inspectprimary filter and discard if damaged Do not wash or reuse a damaged filter Washing Method A Prepare a solution of filter cleaner and water a nd soak filter element about 15 minutes Refer to directions on filter cleaner carton for complete in formation B After soaking filter for 15 minutes rinse it with clear water Maximum water pressure must not ex ceed 40 psi to prevent damage to the filter element
84. aced as an assembly 2 Remove hex plugs 1 6 flow divider spool 3 spring 9 and disk 8 Inspect Steering Pump Parts GENERAL 1 Clean and dry all parts 2 Remove all nicks and burrs from all parts with emery cloth Reelmaster 4000 D Page 4 55 GEAR ASSEMBLY 1 Check drive shaft spline for twisted or broken teeth 2 Inspect both drive gear 7 and idler gear 10 shafts at bushing points and seal area for rough surfaces and excessive wear 3 If shaft measures less than 0 748 in bushing area the gear assembly should be replaced one gear as sembly may be replaced separately shafts and gears are available as assemblies only 4 Inspect gear face for scoring and excessive wear 5 f gear width is less than 0 636 the gear assembly should be replaced 6 Be sure snap rings are in grooves on either side of drive and idler gears 7 1 edge of gear teeth are sharp break edge with emery cloth FRONT PLATE AND BACK PLATE 1 Oil groove in bushings in both front plate and back plate should be in line with dowel pin holes and 1805 apart 2 If I D of bushings in front plate 15 or back plate 22 exceed 0 755 front or back plate should be placed bushings are not available separately 3 Bushings in front plate should be flush with face of front plate 4 Check for scoring on face of back plate If wear ex ceeds 0 0015 back plate should be replaced BODY 1 Check inside gear pockets f
85. ally remains with the cover Re move plunger and O ring from the cover on the end of the input shaft 4 thrust washer 23 will usually remain in position on the thrust face of the cover 5 Remove primary sun gear 13 and thrust washer 12 from the end of the input shaft Remove primary carrier assembly 15 6 Remove secondary carrier assembly 20 It may be necessary to remove the ring gear 24 first if difficulty is encountered in removing the carrier 7 Remove input shaft 2 from the spindle 3 Re move retaining rings washers and spring from the input shaft only if replacement is required 8 Remove 6 or 12 bolts from the hub and ring gear Remove ring gear 24 It may be necessary to strike ring gear with a rubber mallet to loosen from hub NOTE Use snap ring expander tool to remove the re taining ring 9 Remove large retaining ring 28 from in front of the tapered bearing Lift hub 8 from the spindle If bearings are not a loose fit it may be necessary to press spindle from the hub 10 Remove oil seal 4 and bearing cones 5 and 9 from the hub Inspect bearing cups 6 in position and re move only if replacement is required Assembly of the Planetary Wheel Drive 1 Press a new bearing cup 6 into each side of the hub 8 2 Assemble bearing cone 5 into the cup 6 at the seal end of the hub Press a new oil seal 4 into the hub 3 Position spindle 3 upright on bench Lubricate
86. ameter seal Install seal into the bearing housing Reelmaster 4000 D Page 4 83 Bearing Housing EY Shaft amp Bearing Assembly Figure 77 Bearing Shaft Seal Housing Exclusion Back up Washer Figure 78 Shaft Face Shaft Seal Wear Plate Back up Washer ________ Seal Exclusion Shaft amp Seal Bearing Ass y Figure 79 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 film of petroleum jelly to the 3 76 diam eter seal and install seal in the wear plate 30 Install the drive into the output shaft 31 Align the notch on the outside of the Geroter with the notch on the wear plate Install the Geroter against the wear plate Be sure to retain the rollers in the outer ring if they are loose 32 Install the valve drive in the Geroter Geroler Valve Valve Plate NOTE Installation at this time involves 3 steps in the timing of the motor Timing determines the direction of rotation of the output shaft Timing parts include m x to Engage 1 Geroter Spline 2 Valve Drive Anyone of 3 Valve Plate Largest 6 Ports open 4 Valve Open Alignment to Outside Pocket Ref Only of Valve
87. amping procedure explained throughout the manual Hydraulic System Page 4 40 Reelmaster 4000 D Meter Gerotor 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 Seal Washer 2 Remove 5 16 cap screws 3 Remove end cap 4 Remove seal from end cap End Cap Cap Screw 5 Remove meter Be careful not to drop star 6 Remove seal from meter Meter Spacer s Gerotor Figure 28 Reelmaster 4000 D Page 4 41 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 11 Remove housing from vise Place housing on a clean soft cloth to protect surface finish Use a thin blade screwdriver to pry retaining ring from housing as shown in Fig 30 12 Rotate spool and sleeve until pin is horizontal Push spool and sleeve assembly forward with your thumbs just far enough to free gland bushing from housing see Fig 31 Remove bushing Seal Gland Bushing 2 Figure 31 Hydraulic System Page 4 42 Reelmaster 4000 D 13 Remove quad ring seal from seal gland bushing 14 Use a thin blade screwdriver to pry dust seal from Quad Ring seal gland bushing Do not damage bushing S
88. and body bore for excessive wear NOTE f internal leakage with the spools in spring centered position has been experienced wear is indi cated between the spool and body bore This can be corrected by replacing the spool and body as an as sembly Spools or bodies cannot be serviced separately 3 Inspect relief valve NOTE Thepilot operated cartridge type relief valve is not adjustable and is pre set at the factory However to ensure cleanliness in the system snap ring washer and screens may be removed cleaned with air and re placed 4 Inspection of O rings and back up washers is not ne cessary It is recommended that these be replaced as new parts Reelmaster 4000 D Page 4 65 5 Inspect seats in body for wear Reassembly of Reel Control Valve Assembly 1 Thoroughly clean and dry all parts Metal parts should be lightly oiled prior to assembly NOTE All O rings and back up washers should be re placed as new parts 2 Position O rings 5 32 amp 33 in body bore 3 Install O rings and back up washers on relief valve and plugs 4 Install plug 4 5 Install O ring 32 washer 31 deep washer 30 spring 29 wire washer 28 and shallow washer 27 into proper position in body casting 6 Insert spool 1 into body bore and screw spool screw 26 into spool 7 Install spring 10 pawls 11 spring 10 and detent plug 9 into detent block 25 8 Slip detent block 25
89. apter Figure 13 Hydraulic Test Fitting Kit TOR4079 This kit includes a variety of O ring Face seal fittings to Toro Test Fitting Kit e enable you to connect test gauges into the system TOR4079 Cus T Fitting Tool Number e The kit includes 5 unions reducers plugs caps es d vos M and male test fittings ex wel De T t Soste ttftt wea Figure 14 Reelmaster 4000 D Page 4 27 Hydraulic System Troubleshooting 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 of these conditions be noticed immediately stop the machine turn off the engine locate the cause of the trouble and correct it before allowing the machine to be used again Problem Hydraulic oil leak s Slow or no traction in either direction Reels slow or won t turn Hydraulic System Page 4 28 Continued use of an improperly functioning hydraulic system could lead to extensive internal component damage The charts that follow contain information to assist in troubleshooting There may possibly be more than one cause for a machine malfunction Refer to the Testing section of this Chapter for precau tions and specific test procedures Possible Causes
90. ase fittings for bear ings and all major pivot points are provided Drive The reel drive motor turns a maintenance free cog beltthat drives the reel Drive pulley and cog belt are encased in a drive housing for safety and protection from contamination Grass Deflector Shields Shields are fully adjustable Reelmaster 4000 D Special Tools Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE COMMERCIAL PROD UCTS Gauge Bar Assembly Use gauge bar to set final height of cut floating cutting units with front rollers only Handle Assembly For applying lapping compound to cutting units while keeping hands a safe distance from the rotating reel Bedknife Screw Tool Fits Toro bedknife attaching screws Use with torque wrench to secure bedknife to bedbar With clean bedbar threads and new screws tighten to a torque of 250 to 300 in lb 288 to 346 kg cm Note Remove all rust scale and corrosion from bed bar surface before installing bedknife IMPORTANT Do not use an air impact wrench with this tool Reelmaster 4000 D Page 7 3 Some tools may be listed in the Reelmaster 4000 D Parts Catalog Some tools may also be available from a local supplier Figure 2 Figure 3 Figure 4 Cutting Units 5 Adjustments 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
91. b wash er and the hub has end play Tighten jam nut from 15 to 20 in lb 17 to 23 kg cm while rotating the hub C Putretainer over the jam nut If the cotter pin hole is not aligned with a retainer slot remove retainer and reorient it until alignment occurs D Insert cotter pin Bend both legs of the cotter pin and tap out of the way Install the cap 1 Cotter pin 8 Wheel hub 2 Spindle 9 Outer bearing cup 3 Cap 10 Outer bearing cone 4 Washer 11 Washer 5 Seal 12 Retainer 6 Inner bearing cone 13 Jam nut 7 Inner bearing cup Reelmaster 4000 D Planetary Wheel Drive Figure 7 1 Coupling 11 Flat washer 21 O ring 2 Input shaft 12 Thrust washer 22 Disengage plunger 3 Spindle 13 Primary sun gear 23 Thrust washer 4 seal 14 Hex head bolt 24 Ring gear 5 Bearing cone 15 Primary carrier assembly 25 Retaining ring 6 Bearing cup 16 Pipe plug 26 Washer 7 Wheel bolt 17 Hex head bolt 27 Disengage spring 8 Hub 18 Disengage cover 28 Retaining ring kit 9 Bearing cone 19 Large cover 29 Retaining ring 10 Hex head bolt 20 Secondary carrier assembly o st 98 x m lt Reelmaster 4000 D Page6 7 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 usu
92. c motors have been mounted and the belts tightened loosen swivel nuts at the motor and reposition hoses This can greatly increase the life of the hoses With cutting units down all cutting unit hoses should have a flat natural lay and be free from twist Note Refertothe Traction Unit Operator s Manual for instructions on setting the adjustable hydraulic counter balance Reelmaster 4000 D 7 9 Figure 13 1 Drive plate shield 2 Reel drive motor flange Figure 14 1 Hydraulic motor 3 Drive belt 2 Motor pulley REDI S Figure 15 2 Drive housing 1 Mounting bolts Cutting Units 5 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 bedbar thor Figure 16 oughly of all rust and scale Remove any material on the 1 Shoulder bolt 2 back mounting face of the bedbar that will affect a good 2 Bushing match up with the bedknife 2 Before installation apply a coating of anti seize lu bricant to the threads of the bedknife mounting screws IMPORTANT Do not use an impact wrench to tight en screws into the bedbar 3 Begin with the center screw and tighten alternate screws toward each end using a tor
93. ce or bend the face seals Any dam age to these seals will affect the operation of the motor Balance Ring 38 Align pin notches in balance ring with pins in bore of valve housing Install balance ring assembly in valve housing Figure 83 39 Insert your finger through port of valve housing Ap ply pressure to side of balance ring as shown in Fig 84 Balance Hold ring in position until valve housing is in place Ring against valve plate See Fig 85 0 Housing NOTE Install face seals in the positions shown in Fig 83 or the motor will not operate properly Do not force or bend the face seals Any damage to these seals will affect the operation of the motor 40 Install the tie bolts If you use alignment studs install 2 bolts opposite the studs Finger tighten the bolts Re move the alignment studs and replace with the 2 re maining bolts Torque all 4 bolts alternately to 450 Tie Bolts Case Drain Plug with Seal 41 Install seal on case drain plug then install in valve housing Torque to 50 Ib in GNm Figure 86 Reelmaster 4000 D Page 4 85 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 Shaft and Bearing Assembly Shaft Seal Bearing Housing Shaft Face Seal Back up Washer Seal Exclusion Sea
94. ch as necessary Install switch to hy Figure 21 draulic reservoir 1 Electrical connector 4 Lower float stop 2 Level switch 5 Upper float stop 3 Float switch Bridge Rectifier Each rectifier Fig 22 contains four diodes which form a single phase bridge rectifier circuit Fig 23 The diodes are used for circuit protection from inductive volt age spikes when the alarm relay is deenergized Testing The diodes can be individually tested using a digital multimeter ohms setting and the table below Fi 22 Red Lead Black Lead igure m on Terminal on Terminal ae 1 Bottom view 2 Side view Figure 23 Electrical System Rev A Page 5 26 Reelmaster 4000 D 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 held in the START position the glow plugs will energize while the switch is held in START and the glow lamp will not light When the ignition switch is released from START to RUN the glow plugs will deenergize and the glow lamp will remain off Controller Checks 1 Make sure there is power from the battery 2 Disconnect electrical connector to the fuel solenoid to prevent the engine from starting 3 Place ig
95. cklapping 8 ADJU STMENTS ere eee tret 4 Hydraulic Motor Installation 9 Adjust Reel to Bedknife 4 Bedknife Bedbar 10 Adjust Height of Cut Floating Cutting Unit 5 oct cs pd e SC UR e RTL RI ood 11 Quick Method for Changing Height of Cut Preparing a Reel for Grinding 14 After Initial Set Up of a Floating Cutting Unit 6 Front and Rear 5 15 Adjust Height of Cut Fixed Cutting Unit 7 Roller Bearing Replacement 16 Adjust Skids and Front Roller EUbriGalion i 18 Fixed Cutting Unit 7 5 Reelmaster 4000 D Page 7 1 Cutting Units Specifications Figure 1 1 Drive housing cover 5 Rear roller adjuster both ends 2 drive housing 6 Reel to bedknife adjuster 3 Drive plate shield 7 Guard 4 Grass deflector 8 cone nut Construction The frame is welded steel The reel uses heavy duty self aligning ball bearings The heavy duty steel rear roller has tapered roller bearings The rear roller and bedbar are isolated and mounted in rubber bushings for quiet vibration free operation Adjustable deflector shields are standard Stainless steel compo nents are used at key points for added durability Reel Configuration The 5 7 and 11 blade heavy duty welded reels all have 8 inch
96. d Continuity should be 1 ohm or less D Correct any problem circuitry if necessary 3 Drain fuel filter assembly into a suitable container 4 Unscrew fuel filter bowl from the assembly Remove filter element gaskets and O ring from the assembly Store seals in a clean place 5 Reconnect connector to the sensor Fill fuel filter bowl with tap water 6 Test sensor using the following steps A Place ignition switch in RUN The red warning light should come on Turn switch OFF B Hold ignition switch in START The red warning light should come on Turn switch OFF 7 Drain water from the fuel filter bowl Test sensor us ing the following steps A Place ignition switch in RUN The red warning light should stay off Turn switch OFF B Hold ignition switch in START The red warning light should stay off Turn switch OFF Electrical System Rev A Page 5 22 Figure 15 1 Sensor 5 Filter element 2 Filter assembly 6 Gasket 3 Drain plug 7 O ring 4 Fuel filter bowl 8 Disconnect connector from sensor Reassemble fuel filter assembly Reconnect connector to sensor 9 Replace sensor with new one if necessary 10 Reconnect fuel stop solenoid to the wiring harness Reelmaster 4000 D High Temperature Warning and Cutout Switches The high temperature warning and cutout switches are located on the water return pipe above the water pump which is located on the rear end of the engine block The wa
97. d not hands to search for leaks Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and do serious damage If fluid is injected into the skin it must be surgi cally removed within a few hours by a doctor familiar with this type of injury or gangrene may result 3 If continuity across the switch indicates closed Re move and replace switch with a new one Figure 25 1 Filter head 2 Filter element Figure 26 1 Filter switch 3 Filter head 2 O rings 4 Filter element Electrical System Rev A Page 5 28 Reelmaster 4000 D 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 Service 2 Either store battery on a shelf or on the machine Battery Care 1 Battery electrolyte level must be properly main tained The top of the battery must be kept clean If the machine is stored in a location where temperatures are extremely high the battery will run down more rapidly than if the machine is stored in a location where temper atures are cool Wear safety goggles and rubber gloves when working with electrolyte Charge battery in a well ventilated place so gasses produced while charging can dissipate Since the gases are explosive keep open flames and electrical sparks away from
98. d Instruction Decals 1 4 Chapter 2 Product Records and Manuals Product Records 2 1 Equivalents and Conversions 2 2 Torque Specifications 2 3 Lubrication 2 7 Operation and Service History Reports 2 8 Chapter 3 Kubota Diesel Engine Introduction cece eee eee 3 2 Specifications 3 3 General Information 3 4 Adjustments 3 7 Service and Repairs 3 8 KUBOTA WORKSHOP MANUAL 03 SERIES DIESEL ENGINE Reelmaster 4000 D Chapter 4 Hydraulic System Specifications General Hydraulic Schematic Hydraulic Flow Diagrams 4WD Selector Valve Special Tools Troubleshooting Testing Service and Repairs Chapter 5 Electrical System Electrical Schematics and Diagrams Special Tools Troubleshooting Operation Electrical System Quick Checks Component Testing Service and Repairs Chapter 6 Axles and Brakes Specifications Adjustments Service and Repairs Chapter 7 Cutting Units Specifications Special Tools Adjustments Service and Repairs Product Records and Manuals 2 ER o E gt Electrical System Axles a
99. d in place with clean clear grease As semble adaptor on pump back plate Retain with four cap screws 36 amp 1 and torque to 27 31 ft Ibs 14 Reassemble tow valve assembly 4 by installing new O rings inserting spreader into separators plug and securing with retaining ring 15 Install tow valve assembly 4 in back plate 9 and torque 27 to 30 ft Ibs 16 Install relief valve assemblies 34 in back plate 17 Install new O ring 33 and spring 41 on plug 3 Install plugs 3 in back plate and torque 55 60 ft Ibs 18 Remove pump from vise and install poppet 42 spring 43 and spring retainer 44 Hydraulic System Front Traction Motor Figure 65 1 Hex Head Cap Screw 12 Washer 2 Hex Head Cap Screw 13 Retaining Ring 3 Plug 14 Thrust Ring 4 O Ring Seal 15 Thrust Bearing 5 Back Plate Assembly 16 Bearing 6 O Ring 17 Housing Assembly 7 Bearing 18 Camplate Assembly 8 Key 19 Rotating Assembly 9 Retaining Ring 10 Drive Shaft 11 Shaft Seal Disassembly of Traction Motor 1 Clean outside of unit thoroughly 2 Remove retaining ring 9 from housing assembly 17 3 Clamp shaft in a protected jaw vise with backplate end up 4 Remove retaining ring 21 and shaft seal 22 from backplate 5 Hydraulic System Page 4 74 20 Grass Shield 21 Retaining Ring 22 Shaft Seal 5 Remove capscrews 1 amp 2 from backplate 5 6 Use aplastic mallet and tap the backpla
100. d zur sir ur zer L H31S0T10 LHOM uv Tv 1531 Sd td ber er SSINHYH OL vd OL Reelmaster 4000 D Page 5 12 Electrical System Rev A Special Tools Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE COMMERCIAL PROD UCTS Multimeter The meter can test electrical components and circuits for current resistance or voltage NOTE Toro recommends the use of a DIGITAL Volt Ohm Amp multimeter when testing electrical circuits The high impedance internal resistance of a digital me ter in the voltage mode will make sure that excess cur rent is not allowed through the meter This excess current can cause damage to circuits not designed to carry it Skin Over Grease Special non conductive grease Toro Part No 505 47 which forms a light protective skin which helps water proof electrical switches and contacts Reelmaster 4000 D Page 5 13 Some tools may also be available from a local supplier Figure 1 Figure 2 Electrical System Rev A 6 Troubleshooting For effective troubleshooting and repairs you must have a good understanding of the electrical circuits and A CAUTION components used on this machine see
101. dle 1200 rpm Tester reading should be from 75 to 150 PSI 4 If there is no pressure or pressure is too low check for restriction in pump intake line Inspect charge relief valve and valve seat Check for sheared charge pump key Disassemble charge pump and check for internal damage or worn parts If the charge pump is in good condition no scoring scratches or excessive wear the general condition of the piston pump might be sus pected of wear and inefficiency Figure 22 1 Lift control test port 2 Lift control valve Figure 23 1 Lift control test port 2 Test gauge Figure 24 1 Charge press test port 2 Traction pump Hydraulic System Page 4 38 Reelmaster 4000 D 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 fittings left open or exposed 3 Put labels on disconnected hydraulic lines and hoses for proper installation after repairs are completed After Repair or Replacement of Components 1 Check oil level in hydraulic reservoir and add correct oil if necessary Drain and refill hydraulic system reser voir and change oil filter if component failure was severe or system is contaminated Reelmaster 4000 D Page 4 39 2 After repairs check contr
102. e engine and move throttle to full speed 2500 rpm 3 Tester reading should be within the range listed COLD OIL 600 650 PSI HOT OIL 500 550 PSI NOTE Due to special conditions or customer prefer ence the counterbalance may require setting outside 6 this recommended range However the range listed will Figure 16 be adequate for most conditions 1 Counter balance test port 2 Relief valve adjustment screw 4 If necessary adjust the relief valve screw until the de sired pressure is attained Turn the screw in to increase counterbalance pressure and turn the screw out to de crease counterbalance pressure Adjust nearer the high end of the range for improved hill climbing or nearer the low end for improved quality of cut Hydraulic System 4 32 Reelmaster 4000 D 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 low perform re lief pressure check NOTE Due to special conditions or customer prefer ence the counterbalance may require setting outside this recommended range However the range listed will be adequate for most conditions Figure 17 Procedure For Relief Pressure Check 1 Cutting circuit test port 2 Reel control valve 1
103. e housing bore until the parts are flush at the meter end or 14 hole end of housing Do not pull the spool assembly beyond this pointto prevent the cross pin from dropping into the discharge groove ofthe housing With the spool assembly in this flush position check for free rotation within the housing by turning with light finger tip force at the splined end Hydraulic System Page 4 46 Figure 39 Figure 40 Reelmaster 4000 D 11 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 wards bushing see Fig 43 14 Install the quad ring seal in seal gland bushing Smooth seal in place with your finger Do not use any seal that falls freely into pocket of bushing see Fig 43 15 Install seal gland bushing over the spool end with a twisting motion Tap the bushing in place with a rubber hammer Make sure the bushing is flush against the bearing race 16 Install retaining ring see Fig 42 and 43 in housing After installing ring tap on ring end or pry with screwdriv er around entire circumference of ring to properly seat ring in groove Needle Thrust Bearing Seal Seal Gland Bushing with seals Screwdriver Figure 41 Figure 42 Dust Seal A S Retaining
104. e hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 2 Make sure machine is parked on a level surface Lower cutting unit to be tested Make sure engine is OFF and the parking brake is engaged 3 Read Precautions for Hydraulic Testing 4 Block reel being tested to prevent rotation Use a substantial hardwood block inserted between the reel blades 5 Disconnect supply hose from the motor Install test gauge with T connector in series with the motor and dis connected supply hose 6 Disconnect return hose from the motor Install test gauge with T connector in series with the motor and dis connected return hose Reelmaster 4000 D Page 4 35 7 Position reel speed control knob to minimum speed Start engine and move throttle to low idle speed of 1200 RPM IMPORTANT Each reel motor has two cross over reliefs Test relief in the backlap direction only if a problem is expected 8 Gently ease reel control lever to MOW If testing the reel motor in the backlap direction gently ease reel con trol lever to BACKLAP Slowly raise engine speed to high idle speed of 2400 RPM while monitoring pressure The pressure difference between the two gauges should be from 1400 to 1600 PSI A If pressure is greater than the specified range stop the engine and repair or replace the reel motor
105. e reel assembly out of the slots in the side plates 11 Inspect bearings and grease seals in their housings as follows A Seals must be free of cracks and tears Replace seals as necessary B Bearing roller balls must be free of deformation and scoring Replace bearing if necessary C Bearing must spin freely and have minimal axial play Replace bearing if necessary 12 Remove retaining ring from inside the drive hous ing Pry outer seal out of the belt drive case side Press bearing and rear seal out from the outer side of the hous ing 13 Remove the dust cap Fig 20 Press the bearing and seal out of the housing Inspection 1 Inspect reel as follows A Check reel shaft for bending and distortion by placing the shaft ends in V blocks Replace reel if necessary B Check reel blades for bending or cracking Re place reel if necessary C Check service limit of reel diameter see Reel Grinding Specifications in Preparing Reel for Grind ing Cutting Units 7 12 Figure 23 5 Adjustment handle 6 Woodruff key 7 Drive housing fasteners Cap screw Pulley washer Driven pulley Drive housing Reelmaster 4000 D 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 r
106. eal Seal Dust Seal Figure 32 15 Remove 2 bearing races and the needle thrust bear rere Bearing ing from spool and sleeve assembly Beating 16 Remove spool and sleeve assembly from 14 hole end of housing see Fig 34 IMPORTANT Do not bind spool and sleeve in hou sing Rotate spool and sleeve assembly slowly when removing from housing 17 Push pin from spool and sleeve assembly Figure 34 Reelmaster 4000 D Page 4 43 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 machine screw into end of check ball seat Then by pulling on screw with a pliers lift seat out of housing see Fig 36 22 Remove 2 seals from check valve seat 23 Tip housing to remove check ball and check ball re tainer 5 8 Seal Set Screw Not used on units with integral column Hydraulic System Page 4 44 Y JS Check Check Ball Seat 7 16 Seal Ball Retainer Figure 36 Reelmaster 4000 D 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 othe
107. ebris Clean Traction Pedal Lockout Unusual Engine Noises Fuel Level Unusual Operating Noises H Hydraulic System Oil Level Instrument Operation JA JAJA z 3 alz 2 IER 5 aj 115 SO 1 IER 915 E re Ica alo n Dlo E o lk 5 Di 5 c g alo 3 3 5 Di gt Height of Cut Adjustment Lubricate All Grease Fittings Touch up Damaged Paint 1 Use only low pressure compressed air for debris removal Do not use water 2 Check glow plugs and injector nozzles if hard starting excess smoke or rough running is noted 3 Immediately after every washing regardless of the interval listed Notation for areas of concern Inspection performed by Reelmaster 4000 D Page 2 11 Product Records and Maintenance seunpeooud pue 10 enuen pue s 10jeJedo ees o21AJ0S q pue 9 v uiI 90 99UM Oe qn 10044 eBueu o231AJ0S pue g y emouu WU pue Suonoauuo pue saur 12edsu 5 Z ouneapAp JeujeaJg oineap AH eoejdeu 5 2 1uejoo2 euiBu3 eoejdeu usn J euiDu3 1sn py 5 2 eoejdou 1934 IIO eoejdeu jan4 soe
108. eel speed control knob at middle range 90 degree position 7 Start engine and move throttle to full speed 2500 rpm 8 Engage the reel control lever into the MOW position Reels will rotate when reel control lever is moved into the MOW position Keep clear of rotating reels TESTER READING TO BE APPROXIMATELY 14 15 GPM 9 If reel circuit oil flow is too low check for restriction in pump intake line If not restricted remove pump and re pair or replace as necessary Hydraulic System Page 4 34 Reelmaster 4000 D TEST 5 Check Reel Motor Cross Over Relief Pressure FROM LIFT CIRCUIT CUTTING CIRCUIT TEST PORT 2 PRIORITY FROM GEAR PUMP OUT Y 3000 PSI Eh TO HYDRAULIC OIL TANK NOTE Before testing a reel motor for possible failure make sure to inspect the affected cutting unit for pos sible causes of malfunction Eliminate such possible causes as bad reel bearings bent or damaged reel jammed debris etc It is often helpful to remove the reel motor from the unit when inspecting Check Relief Pressure NOTE The reel motor has an internal relief valve that relieves when the pressure across the motor exceeds 1500 100 PSID 1 Make sur
109. el switch is faulty Hydraulic oil low level switch wiring loose corroded or damaged Engine is overheated Engine overheat shutdown switch faulty Engine overheat shutdown switch wiring loose corroded or damaged Traction brake switch 1 out of adjustment or faulty Traction brake switch 1 wiring loose corroded or damaged Engine or fuel system problem Engine cranks but should not with parking brake off Traction brake switch 2 is faulty Short circuit in Traction brake switch circuit Engine cranks but should not with mow backlap Reel drive neutral switch faulty lever in mow or backlap Short circuit in Reel drive neutral switch circuit Reelmaster 4000 D 5 15 Electrical System Rev General Run and Transport Problems Engine continues to run but should not when parking brake is released or mow backlap lever is mow or backlap with no operator on seat Engine kills when parking brake is released or mow backlap lever is moved to mow or backlap Engine kills during operation operator sitting on seat 4WD does not engage Battery does not charge Electrical System Rev A Page 5 16 Seat switch plunger depressed with no operator on seat Seat switch faulty or out of adjustment Short circuit or by pass in seat switch circuit Operator sitting too far forward on seat seat switch not depressed Seat h
110. eling Rear Roller to Reel 7 5 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 Toro Part No 59 7900 to set fi nal height of cut by adjusting the front roller only C Loosen gauge bar jam nut and adjust screw to set dimension between underside of screw head and gauge bar for desired height of cut Fig 9 Tighten jam nut to secure the adjustment Hook screw head over cutting edge of the bedknife and position bar against bottom of front roller Fig 10 D Loosen front roller nuts and adjust both ends of the front roller until it contacts the gauge bar at both ends With the gauge bar held firmly against bot tom of the rollers adjust front roller so the screw head slips just over the lip of the bedknife Fig 10 Tighten front roller nuts IMPORTANT When set properly the front and rear rollers will contact the gauge bar and the screw head will be snug over bedknife cutting edge when checked at both ends of the reel E Loosen lockout pin so cutting unit can float freely Fig 6 ADJUST FOR FINAL HEIGHT OF i CUT SETTING GAUGE BAR ASSEMBLY 59 7900 Figure 9 Gauge Bar Assembly APPROXIMATELY 3 8 INCH 9 5 MM HEEL UP FINAL HOC SETTING FRONT ROLLER GAUGE BAR ASS Y 59 7900 ADJUST FRONT ROLLER TO CONTACT GAUGE BAR
111. em Rev A Page 5 20 Reelmaster 4000 D 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 sender Note Before taking small resistance readings with a digital multimeter short test leads together The meter Figure 12 will display a small resistance value This internal resis 1 Truss head screw 4 Gasket tance of the meter and test leads should be subtract 2 Lock washer 5 Fuel tank 3 Fuel sender from the measured value of the component A CAUTION Make sure sending unit is completely dry no fuel on it before testing Perform test away from the tank to prevent an explosion or fire from sparks 4 Check resistance of the sender with a multimeter Resistance with the float in the full position should be 27 5 to 39 5 ohms Resistance with the float in the empty position should be 240 to 260 ohms Figure 13 gt 1 Full position 2 Empty position 5 Replace sender as necessary Reinstall sender into fuel tank Connect wires Fuel Gauge Electrical System The fuel gauge can be tested using a new gauge as a substitute or by the use of a DC voltage source and a variable resistance box 1 Connect t
112. em With regular and proper service battery life can be extend Additionally battery and electrical component failure can be prevented A CAUTION When working with batteries use extreme cau tion to avoid slashing or spilling electrolyte Electrolyte can destroy clothing and burn skin or eyes Always wear safety goggles and a face shield when working with batteries Electrolyte Specific Gravity Fully charged 1 265 corrected to 80 F 26 79C Discharged less than 1 240 Battery Specifications BCI Group Size 24 650 CCA at 0 F 17 8 C Reserve Capacity of 105 minutes at 25 amp and at 809F 26 79C Dimensions not including terminal posts and caps Length 10 22 inches 25 96 cm Width 6 76 inches 17 17 cm Height 9 20 inches 23 39 Removal IMPORTANT Be careful not to damage terminal posts or cable connectors when removing the bat tery cables 1 Remove battery retainer from the battery 2 Remove lock nut and cap screw from ground cable post first and remove cable from battery This should prevent short circuiting the battery other components or the operators hands 3 Remove lock nut and cap screw from positive cable post and remove cable from battery 4 Make sure battery vent caps are on tightly 5 Remove battery from the battery compartment to a service area This will minimize possible battery dam age and allow better access for inspection and service Inspection Maintenance
113. engine to run It is 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 together The me ter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal re sistance of the meter and test leads Subtract this value from from the measured value of the component you are testing 1 Disconnect the connector from the solenoid 2 Make sure that the solenoid linkages move freely and are free of dirt debris and corrosion 3 Using a digital multimeter touch one lead to the pin of the black wire and the other lead to the pin of the white wire The resistance of the pull coil should be about 0 258 ohms 4 Using a digital multimeter touch one lead to the pin of the black wire and the other lead to the pin of the red wire The resistance of the hold coil should be about 10 91 ohms 5 Connect solenoid to the wiring harness Live testing 1 Disconnect connector from the solenoid 2 Make sure that the solenoid linkages move freely and are free of dirt debris and corrosion Note The solenoid may be removed from the engine or tested in place 3 Connect a positive test lead from a 12 VDC source to the pins of the red and white wires 4 Touch a negative test lead from the 12 VDC source to the pin of the black wire The solenoid should engage making an audible
114. ents ELECTRICAL SCHEMATICS 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 Main Harness Drawing S N below 220000000 4 Reelmaster 4000 D Supplement to Main Harness Drawing S N below 220000000 5 Reelmaster 4000 D Main Harness Wiring Diagram S N below 220000000 6 Reelmaster 4000 D Main Harness Drawing S N 220000001 and up 7 Reelmaster 4000 D Main Harness Wiring Diagram S N 220000001 and up 8 Reelmaster 4000 D Control Panel Harness 0 9 Reelmaster 4000 D Control Panel Wiring Diagram 10 Reelmaster 4000 D Light Cluster Harness 11 Reelmaster 4000 0 Light Cluster Wiring Diagram 12 SPECIALE TOOLS Aaniru ieina eR ee 13 TROUBLESHOOTING 14 Starting Problems 14 General Run amp Transport Problems 16 ELECTRICAL SYSTEM QUICK CHECKS 17 Battery Test Open Circuit 17 Reelmaster 4000 D 5 1 Chapter 5 Electrical System COMPONENT TESTING 18 Ignition Switch 18 Hour Meter 19 Glow Plug and Start Relays 19 Audio Ala
115. er parts of the body away from cutting units and other mov ing parts Keep everyone away Reelmaster 4000 D Page 1 3 34 Do not overspeed the engine by changing governor setting Maximum engine speed is 2500 rpm or 100 rpm To assure safety and accuracy have an Authorized Toro Distributor check maximum engine speed 35 Shut engine off before checking or adding oil to the crankcase 36 Disconnect battery before servicing the machine If battery voltage is required for troubleshooting or test procedures temporarily connect the battery 37 Toro recommends that two people be used to back lap reels Each person has specific duties and you must communicate with one another 38 For optimum performance and safety use genuine Toro replacement parts and accessories Replacement parts and accessories made by other manufacturers could be dangerous and may void the product warranty of The Toro Company 39 When changing attachments tires or performing other service use correct blocks hoists and jacks Make sure machine is parked on a solid level floor such as a concrete floor Prior to raising the machine remove any attachments that may interfere with the safe and proper raising of the machine Always chock or block wheels Used jack stands or solid wood blocks to sup port the raised machine If the machine is not properly supported by blocks or jack stands the machine may move or fall which may result in personal inju
116. er 26 O Ring 14 Bushing Hydraulic System Page 4 54 Reelmaster 4000 D 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 11 5 Remove pump from vise hold pump in hands and bump shaft against a wood block to separate front plate 15 from back plate 22 Body 21 will remain with ei ther front plate or back plate 6 If front plate 15 was removed first remove wear plate 20 from body gear pockets 7 Remove drive gear assembly 7 and idler gear as sembly 10 from body 21 8 To separate body 21 from plate it remains with put drive gear assembly 7 in a bushing and tap protruding end with a plastic hammer or soft mallet 9 Remove O ring 16 from front plate 15 and back plate 22 10 Remove backup up gasket 19 from front plate 15 11 Remove bearing seal 18 from front plate 15 by prying with a sharp tool 12 Remove molded O ring 17 from front plate 15 by prying with a screwdriver 13 Remove shaft seal 12 from front plate 15 by pry ing with a screwdriver Disassembly of Back Plate Assembly Flow Divider Flow Conirol Relief Valve 1 Remove relief valve 23 from back plate 22 NOTE Do not disassemble relief valve cartridge as sembly it must be repl
117. est equipment and the specialized nature of some re pairs may dictate that the work be done at an engine re pair facility Service and repair parts for Kubota diesel engines are supplied through your local Kubota dealer or distributor If no parts list is available be sure to provide your distrib utor with the Toro model and serial number Reelmaster 4000 D 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 0 3 43 Stroke mm in 92 0 3 64 Total Displacement cc cu in 2197 134 07 Fuel No 2 Diesel Fuel per ASTM D975 Fuel Capacity liters gallons 56 8 15 0 Fuel Pump Bosch Type Mini pump Governor Centrifugal flyweight Mechanical Type Low Idle no load 1250 50 RPM High Idle no load 2500 50 RPM Compression Ratio 23 0 1 Rotation Counterclockwise Facing Flywheel Injection Nozzles Bosch Throttle Type Engine Oil SAE 10W30 SF or CD Oil Pump Trochoid Type Crankcase Oil Capacity liters U S qt 7 6 8 0 with filter Starter 12 VDC 1 4 KW Alternator Regulator 12 VDC 40 AMP Weight Kg Lb 190 418 Engine Coolant Capacity liters U S qt 14 0 14 8 Ti
118. etaining compound on the outer diameter Apply a light coat of oil to the seal lips and insert the bearing assem bly through the seal from the opposite side Fig 23 3 Apply a light coating of oil to the inner seal lips and install lip facing away from the bearing and toward the reel in the housing Install retaining ring to secure the assembly in the housing Fig 23 4 Apply alight coat of oil to the seal lips of the seal for the bearing housing and install lip facing away from the bearing over the bearing assembly Fig 23 5 Insert bearing and seal in housing and install the dust cap into the housing 6 Assemble reel assembly to the frame Ensure shield washer is installed on the drive housing end of the reel shaft Align drive pin on reel shaft with slotin bearing and slide the drive housing onto the shaft 7 Insert shoulder bolt through the Belleville washer and rear housing mounting hole Slide bolt through the side plate mounting hole Fig 21 Install the cone nut locknut onto the bolt Tighten the cone nut to 45 to 55 ft lbs 6 2 to 7 6 kg m 8 Align the drive pinon the reel shaft with the notch in the bearing inner race and slide the bearing housing over the opposite end of the reel shaft Insert the shoul der bolt and belleville washer through the rear bearing housing mounting hole Slide the bolt through the side plate mounting hole Install the cone onto the bolt Tight en the cone nut to 45 to 55
119. ews 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 Figure 25 1 Damper 4 Pump adapter plate 2 Bracket 5 Spring coupling 3 Pump mounting flange 13 Remove three lock nuts and cap screws securing the upper exhaust tube to the exhaust bracket Fig 26 14 Remove hex nut spring washer cap screw and flat washers securing both front brackets to the engine mounts Fig 26 15 Connect hoist or lift to the engine Make sure lift or hoist can support the total weight of the engine before removing the cap screws from the rear bracket and engine 16 Remove three cap screws and lock washers secur 1 Cap screw 6 Cap screw ing the engine to the rear bracket and spacer Fig 27 2 Upper exhaust tube 7 Flat washer 3 Exhaust bracket 8 Flat washer 4 Hex nut 9 Front bracket 5 Spring washer 10 Engine mount One person should operate lift or hoist while the other person guides the engine out of the ma chine IMPORTANT Make sure not to damage the engine e fuel and hydraulic lines electrical harness or other E parts while removing the engine 17 Remove engine slowly from the machine Save gas ket for exhaust tube Fig 26 Figure 27 1 Rear bracket amp spacer 2 Cap screw amp lock washer Reelmaster 4000 D Page 3 15 Kubota Diesel Engine Engine Installation
120. free of scoring The surface that contacts the backplate should be smooth and free of grooves or metal build up 7 Inspect the camplate assembly 18 the surface op posite the chamfered side should show no signs of scor ing Reelmaster 4000 D Page 4 75 8 Inspect the flat surface on the backplate 5 it should be free of excessive scoring or metal build up 9 Inspect the drive shaft 10 for fretting in the bearing areas Check spline area for twisted or broken teeth If keyed shaft check for cracked or chipped keyway Reassembly of Traction Motor 1 Lubricate all critical moving parts before assembly 2 Install one retaining ring 13 in rear groove on drive shaft 10 Install one thrust race 14 thrust bearing 15 and second thrust race 14 on drive shaft 10 Install second retaining ring 13 in front groove on drive shaft 3 Replace needle bearing 16 in housing 17 if neces sary Install shaft in housing assembly 17 Install wash er 12 shaft seal 11 and retain with retaining ring 9 4 Install the pivot spider and the piston assemblies in the piston block assembly 5 Lubricate camplate assembly 18 and install in hous ing assembly with chamfered edge of race against housing surface 6 Install piston block assembly in housing assembly The piston shoes must contact the camplate assembly 18 Be sure all parts are in their proper position 7 Install new bearing 7 in bac
121. ft lbs 6 2 to 7 6 kg m Reelmaster 4000 D Page 7 13 1 SEAL LIPS FACING REEL SEAL LIPS FACING REEL Figure 24 9 Install woodruff key in the drive housing end of the reel shaft and install the driven pulley onto the shaft 10 Ensure slot in the pulley washer is aligned with the roll pin in the pulley and install the washer toothed washer and reel capscrew Fig 22 Apply a medium strength thread locking compound to the reel capscrew during assembly Torque the capscrew to 45 to 55 ft lb 6 2 to 7 6 kg m 11 Install reel adjustment assemblies to each side plate Install roll pins before tightening fasteners 12 Install bedbar bedknife assembly 13 Install front and rear roller assemblies or skids 14 Adjust reel to the bedknife see Reel to Bedknife Adjust height of cut see Adjust Height of Cut Cutting Units 5 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 mount the cutting unit into the grinder e g front roller front roller brack ets 3 Follow the grinder manufacturer s instructions for set up and operation of the grinder Note The cutting unit must be aligned so the grinding wheel will travel parallel
122. g 43 and poppet 42 from adaptor assembly 2 6 Remove the gerotor gear 7 and key 35 from the pump shaft 7 Remove the two check valve assemblies 8 from back plate 9 Pin is loose fitting Caution should be tak en when removing check valve assembly so that pin and ball are not lost 8 Use screwdriver slots in housing and pry up on back plate 9 or tap with plastic mallet loosen then pull the back plate straight up to remove Remove housing gas ket 10 Reelmaster 4000 D Page 4 69 9 Remove the tow valve 4 from back plate 9 To dis assemble tow valve remove retaining ring from spread er and pull spreader from spreader plug 10 Remove plug assembly 3 spring 41 and relief valve assembly 34 from back plate 11 Remove pump from vise and remove rotating kit as sembly 12 from housing 19 12 If pistons did not come out with piston block you may remove them spider and spider pivot IMPORTANT Do not attempt to disassemble the piston block and spring The parts are not service able separately The rotating kit 12 must be re placed as an assembly 13 Remove retaining ring 25 from housing Press drive shaft 31 from housing 19 and remove shaft seal 26 and washer 27 14 Remove retaining ring 28 from shaft and remove thrust race 29 and thrust bearing 30 15 To remove the camplate 14 from housing remove screws 24 from the sides of the housing Remove tru
123. he fuel gauge to the variable resistance and DC voltage source Fig 14 2 Adjust resistance until the gauge needle points to following test points on the gauge Fig 14 A The left edge of the red area empty the resis tance setting should be from 238 to 242 ohms VARIABLE B The right edge of the green area full the resis RESISTANCE tance setting should be from 28 to 38 ohms 3 Disconnect the voltage source gauge and variable resistance Figure 14 1 Empty position 2 Full position Reelmaster 4000 D Page 5 21 Electrical System Rev A H20 in Fuel Sensor The sensor is located on the fuel filter assembly which is 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 sure engine is OFF Disconnect fuel stop sole noid from the wiring harness 2 Disconnect connector from the sensor Verify cir cuitry to the sensor at the connector using a multimeter and the following steps A Place ignition switch in RUN Battery voltage from the pin for the yellow blue wire to chassis ground should be indicated and the red warning light should come on Turn switch OFF B Hold ignition switch in START Battery voltage from the pin for the black white wire to chassis ground should be indicated Turn switch OFF C Check continuity from the pin for the black wire to chassis groun
124. he garter spring of the seal facing towards the center of the roller Fig 30 13 Place thrust washer on each end of the roller shaft 14 Apply Loctite 271 or equivalent to the threads on the roller shaft with the shorter length Tighten jam nut all the way to the end of the threads Allow Loctite to cure before proceeding further 15 Install lock nut to the other end of the shaft Torque lock nut while rotating shaft from 20 to 25 ft lb 2 8 to 3 5 kg m to seat the bearings Back off lock nut Note Starting torque may exceed 10 ft lb 1 4 kg m when torquing the lock second time This torque 3 will fall once the nut starts to turn 2 16 Torque lock nut while rotating shaft from 10 to 15 ft E Ib 1 4 to 2 1 kg m a second time 17 Install grease fittings Lubricate each bearing with at least 1 oz 33 ml of No 2 general purpose lithium base grease Reelmaster 4000 D Page 7 17 Figure 30 D Inner grease seal 7 Wear sleeve Roller tube 8 Outer grease seal 5 Bearing cup 9 Thrust washer g Roller shaft 10 Jam nut B Bearing cones 11 Lock nut 4 O ring 12 Grease fitting DNN DZS Figure 29 Inner grease seal 7 Wear sleeve Roller tube 8 Outer grease seal Bearing cup 9 Thrust washer Roller shaft 10 Jam nut Bearing cones 11 Lock nut O ring 12 Grease fitting ES Cutting Units Lubrication Use a hand operated grease gun and No 2 ge
125. hrenheit Celsius 1 Subract 32 2 Multiply by 5 9 Product Records and Maintenance Page 2 2 Reelmaster 4000 D Torque Specifications Recommended fastener torque values are listed in the following tables For critical applications as determined by Toro either the recommended torque or a torque that is unique to the application is clearly identified and spe cified in this Service Manual These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Ser vice Manual The following factors shall be considered when applying torque cleanliness of the fastener use of athread sealant Loctite degree of lubrication on the fastener presence of a prevailing torque feature hard ness of the surface underneath the fastener s head or similar condition which affects the installation Fastener Identification Grade 1 Grade 5 Inch Series Bolts and Screws Reelmaster 4000 D 2 3 As noted in the following tables torque values should be reduced by 25 for lubricated fasteners to achieve the similar stress as a dry fastener Torque values may also have to be reduced when the fastener is threaded into aluminum or brass The specific torque value should be determined based on the aluminum or brass material strength fastener size length of thread en gagement etc The standard method of verifying torque
126. iary 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 line from the reservoir Priority output flow is di rected to the steering function Excess flow exits the secondary output of the pump and is directed to the lift valve The flow continues through the lift valve where it meets the counterbalance valve The counterbalance valve super charges the incoming oil before allowing the oil to continue on its return path back to the sump tank The counterbalance pressure may be monitored at pressure tap port 3 The oil pressure provided by the counterbalance valve will be used to reduce the cutting unit weight on the turf during the mowing function Reelmaster 4000 D Page4 9 After joining with oil returning from other functions through the drain block the oil flows through the oil cool er to dissipate heat from the hydraulic system and then through the filter to collect any particles in the hydraulic system Clean oil is collected at the filter by the charge pump This oil is used to maintain a supply of oil to the closed loop traction circuit to prevent cavitation The charge pressure is regulated by a relief internal to the traction pump The charge pressure may be monitored at the pressure tap port on top of the charge pump Oil collected by the reel pump is directed to the reel speed valve and split into two variable flows Pr
127. il a steady stream of fuel comes out of hole in in bleed screw When fuel stops foaming tighten the bleed screw during the down stroke of the priming plunger Wipe up any spilled fuel Fig 8 Note It may be necessary to bleed the air out of the fuel line between the fuel filter water separator and the injection pump To do this loosen the knob on the injec tion pump Fig 7 and repeat bleeding procedure 5 Pump priming plunger until resistance is felt Try to start engine If engine does not start repeat step 4 Kubota Diesel Engine Page 3 6 Figure 7 3 Fuel pump 4 Priming lever 1 Bleed knob 2 Injection pump Figure 8 1 Primer plunger 2 Bleed screw Reelmaster 4000 D 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 Ibs 44 4 is applied on the belt midway between both pulleys 3 If deflection is not 3 8 inch 10 mm loosen alterna tor mounting bolt Increase or decrease alternator belt tension and tighten bolt Make sure tension is correct check deflection of belt again Figure 9 1 Alternator 2 Mounting bolt Reelmaster 4000 D 3 7 Kubota Diesel Engine Service and Repairs Service Air Cleaner 1 Park machine on a level surf
128. ill 18 Operator must be skilled and trained in how to drive on hillsides Failure to use caution on slopes or hills may cause loss of control and vehicle to tip or roll possibly re sulting in personal injury or death 19 When operating 4 wheel drive machine always use the seat belt and ROPS together and have seat pivot re taining pin installed 20 If engine stalls loses headway and cannot make it to the top of a slope do not turn machine around ways back slowly straight down the slope 21 Raise cutting units and latch them securely in trans port position before driving from one work area to anoth er 22 Do not touch engine muffler or exhaust pipe while engine is running or soon after it is stopped These areas could be hot enough to cause burns 23 If cutting unit strikes a solid object or vibrates abnor mally stop immediately turn engine off set parking brake and for all motion to stop Inspect for damage If reel or bedknife is damaged repair or replace it before operating Do not attempt to free blocked cutting unit by moving Mow Backlap lever rapidly between FORWARD and BACKLAP Damage to hydraulic system may result Lever should easily return and hold in the STOP posi tion 24 Before getting off the seat A Move traction pedal to neutral B Set parking brake C Disengage cutting units and wait for reels to stop D Stop engine and remove key from switch E Do not park on slopes u
129. imary oil is directed to the reel On Off control valve With the valve in the position the oil is returned directly to the drain block The remaining oil will also return to the tank through the drain block Hydraulic System Engine Run No Functions LEGEND gt OIL FLOW PRESSURE FREE STEERING ORBITROL NB PRESSURE OIL NO 2 LIFT CYLINDER TRACTION MOTOR RIGHT TRACTION MOTOR LEFT oos COUNTER BALANCE VALVE PUMP PACKAGE LO SPEED BACKLAP VALVE 4 REEL MOTOR NO 4 LIFT CYLINDER NO SLIFT CYLINDER 73 19 STEER CYLINDER Hydraulic System Page 4 10 Reelmaster 4000 D Traction Circuit Refer to Traction Circuit Forward Flow Diagram A mechanical interlock between the traction pedal link inlet of the traction motors The oil returns from the mo age and the parking brake prevents traction pedal tor to the pump where it continues through the pump in movement unless the brake is released a closed loop circuit System pressure may be moni tored at pressure tap port 1 Depressing the top of the traction pedal will shift the trac tion pump swash plate to direct a flow of oil to the forward Reelmaster 4000 D Page 4 11 Hydraulic System Traction Circuit Forward LEGEND OIL FLOW _ PRESSURE FREE PRESSURE OIL STEERING ORBITROL NO 2
130. ing Fuel System Figure 15 1 In line fuel filter 2 Fuel tank Figure 16 1 Fuel filter water separator 3 Filter 2 Filter cap Reelmaster 4000 D Page 3 11 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 Clean engine area thoroughly of all debris 3 Remove knobs securing rear screen to frame and remove screen Fig 17 4 Lift up on oil cooler handles and pivot rearward in mounting slot Clean both sides of oil cooler radiator and rear engine area thoroughly with compressed air Fig 18 5 Pivot oil cooler back into position and install rear Screen 6 Lower engine cover and secure latches Cooling System Maintenance Capacity of the system is 3 7 gal 14 L Always protect cooling system with a 50 50 solution of water and ethy lene glycol anti freeze IMPORTANT Do not use water only Do not use al cohol methanol base coolants 1 Park machine on a level surface Stop engine Re move key from the ignition switch 2 After every 100 operating hours tighten hose con nections Replace any damaged of deteriorated hoses 3 After every 800 ooperating hours drain and flush the cooling system Add anti freeze see Check Cooling
131. ing and operating the ma chine 12 Check interlock switches daily for proper operation If a switch fails replace it before operating the machine The interlock system is for your protection so do not by pass it Replace all interlock switches every two years 13 This product may exceed noise levels of 85 dB A at the operator position Ear protectors are recom mended for prolonged exposure to reduce the potential of permanent hearing damage 14 Before starting the engine each day test lamps warning buzzer and signal lights to assure proper opera tion 15 Pay attention when using the machine To prevent loss of control A Mow only in daylight or when there is good artifi cial light B Watch for holes or other hidden hazards C Be extremely careful when operating close to sand traps ditches creeks steep hillsides or other hazards D Reduce speed when making sharp turns Avoid sudden stops and starts Use ground speed limiter lever to set pedal travel so excessive ground speed will be avoided during mowing and transport E Look to the rear to assure no one is behind the machine before backing up F Watch for traffic when near or crossing roads Al ways yield the right of way G Reduce speed when driving downhill 16 Keep hands feet andclothing away from moving parts and the reels Safety Page 1 2 17 Traverse slopes carefully Do not start or stop sud denly when traveling uphill or downh
132. inge support pin or spring binding preventing seat switch from closing Seat switch is faulty or out of adjustment Seat switch wiring loose corroded or damaged Operator moved too far forward on seat seat switch not depressed Low hydraulic oil level Engine overheated Wire broke or became disconnected 4WD selector switch faulty 4WD selector switch wiring loose corroded or damaged 4WD solenoid valve faulty 4WD solenoid wiring loose corroded or damaged Problem is not electrical Loose or broken wire s Faulty alternator Dead battery Alternator warning lamp is faulty or burned out Alternator warning lamp wiring loose corroded or damaged Reelmaster 4000 D Electrical System Quick Check Battery Test Open Circuit Test Use a multimeter to measure the voltage between the Voltage Measured Battery Charge Level battery terminals 12 68 V or higher Fully charged 100 Set multimeter to the DC volts setting The battery 12 45 V 75 charged should be at a temperature of 60 to 100 F 16 to 38 C The ignition key should off and all accessories turned E EE off Connect the positive meter lead to the positive 12 06 V 25 charged battery post and the negative meter lead the the neg 11 89 V 096 charged ative battery post NOTE This test provides a relative condition of the bat tery Load testing of the battery will provide additional and more accurate information
133. ion 7 Extend rod 3 to full out position to make sure snap ring 6 is locked 8 Cycle cylinder and check for leaks Hydraulic System Reel Control Valve 1 Spool 2 Body 3 O Ring 4 Plug 5 O Ring 6 Backup Washer 7 O Ring 8 Relief Valve 9 Detent Plug 10 Detent Spring 11 Detent Pawl 12 Locknut 13 Lock Washer 14 Circlip 15 Spring 16 Plug 17 Sleeve Hydraulic System Figure 60 Page 4 64 Plunger Micro Switch Flat Washer Machine Screw Cap Head Screw Lock Washer Grease Fitting Block Detent Screw Spool Shallow Washer Wire Washer Spring Deep Washer Washer O Ring O Ring Wiper Reelmaster 4000 D 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 amp 5 4 Remove screws 22 and lock washers 23 5 Remove detent block 25 6 Remove detent plug 9 spring 10 and pawls 11 from detent block 25 7 Remove screw spool 26 8 Remove shallow washer 27 wire washer 28 spring 29 deep washer 30 washer 31 and O ring 32 9 Remove spool 1 10 Remove all O rings and back up washers from all plugs relief valves and body bore 11 Thoroughly clean all parts Inspection of Reel Control Valve Assembly 1 Remove nicks and burrs from all parts 2 Inspect spool
134. irt and debris 2 Onthefrontroller press new inner grease seals into the roller tube with the garter spring of the seal facing away from the center of the roller Fig 29 Reelmaster 4000 D 3 Onthe 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 5 Secure roller tube in a vise so it is level 6 If assembling a rear roller fill inside of the roller tube with 6 oz 200 ml of SAE 90 oil 7 Make sure roller shaft is free of nicks and burrs that could damage the grease seals Make sure grease pas sages are clear 8 Apply antiseize lubricant to the roller shaft Insert shaft through the roller tube and grease seals making sure not to damage the seals 9 Install both bearing cones to the roller shaft and into the bearing cups 10 Apply thin coat of No 2 general purpose lithium base grease to both new O rings Install O rings to roll er shaft Install both wear sleeves to the shaft so re cessed end fits over the O ring 11 On the front roller press new outer grease seal into the roller with the garter spring of the seal facing away from the center of the roller Fig 29 12 Onthe rear wiehle and sectional rollers press new outer grease seal into the roller tube with t
135. ith major diameter facing port Reelmaster 4000 D Page 4 79 section and notch facing inlet port Make sure wear plate and center section set flush against port section 10 Tape the spline area long spline of drive gear 10 to prevent cutting shaft seal s during assembly 11 Lubricate drive gear 10 and driven gear 11 Install drive gear 10 into port section 13 with short spline to wards port section Install driven gear 11 12 Lubricate bronze face of wear plate 7 Install wear plate 7 over locating pins of center section 8 with bronze face towards center section and notch facing in let port 13 Install seal pack 5 4 6 into cavity located on face of front cover 4 Apply petroleum jelly around seal pack area on face of front cover 14 Carefully position front cover 4 over studs 3 gears 10 amp 11 and center section guide pins Gently slide front cover over the gears until it is flush against wear plate 7 15 Lubricate stud 3 threads with hydraulic fluid Install washer 2 and nuts 1 on ends of studs Cross torque nuts to 60 to 70 ft lb 16 Clamp port section 13 into vise with studs facing down Make sure port section is clamped securely 17 Install O ring 15 into groove located on face of port section 13 18 Install lubricated coupling 14 on spline of drive gear 10 19 Turn the drive gear 10 one revolution with a suit able socket wrench Not binding shall
136. jday L1 EJ EJ L1 EJ E31 F1 EI E L EJ E EJ DJ ET EJ E31 C SJeoK Z ounejp H eoejdeu jan4 pue JOUBS D s eroeds pue Jenuuy 1910 5 008 3 5 00 A p nb S8SOH 12995 BUIO JOOUUOD pue uonipuo x99u5 p nb 2 pue jeg pue uey Y29949 su peeds jeeu Eqn eqn SINN jeeuM oNespAH L1 L1 EJ EJ EJ DJ DJ DJ D L EJ E1 L1 EJ ET L1 EI E L DJ E1 L1 EJ ET L1 EI E Sag Humny 1 edsu pue euibu3 002 5 sunoy 001 g sunoy 06 Y 133940 d 94V 5 OHOL uoneubiseq esn 10 eum gadna J9p4Q 1 152 Reelmaster 4000 D 12 Page 2 Product Records and Maintenance Chapter 3 TORO K
137. kplate 5 if necessary 8 Install new O ring 6 on backplate 9 Install backplate 5 on housing 10 Install capscrew 1 amp 2 and torque 15 18 ft Ibs Hydraulic System Reel Pump 9 18 17 16 Figure 66 1 Nut 10 Spline Drive Gear 2 Lock Washer 11 Driven Gear 3 Stud 12 O Ring Seal 4 Stud 13 Rear Port Section 5 Front Cover 14 Coupling 6 Gland Seal 15 O Ring 7 Wear Plate 16 Plug 8 Center S A Section 17 Shaft Seal 9 Shaft Seal 18 Retaining Ring Hydraulic System Page 4 76 Reelmaster 4000 D 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 3 Remove eight nuts 1 and eight washers 2 4 Remove front cover 4 from wear plate 7 5 Remove seal retainer 6 and gland seal 5 from front cover 4 and discard 6 Remove wear plate 7 from center section 8 7 Remove spline drive gear 10 and driven gear 11 from center section 8 8 Removal of the center section 8 may require the use of a plastic hammer 9 Remove wear plate 7 from port section 13 10 Remove seal retainer 6 and gland seal 5 from port section 13 and discard Inspection of Reel Pump All parts must be thoroughly cleaned and kept clean dur ing in
138. l Retainer Standard Steering Control Unit 5 Check Ball Seat Figure 37 Control Spring Sleeve Slot Spring Identification Control Marks Spool Figure 38 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 Tool 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 that extended edge is down and arched center section is together In this position insert one end of en tire spring set into spring installation tool as shown in Fig 39 with spring notches facing sleeve 7 Compress extended end of centering spring set and push into spool sleeve assembly withdrawing installa tion tool at the same time 8 Center the spring set in the parts so that they push down evenly and flush with the upper surface of the spool and sleeve 9 Install pin though spool and sleeve assembly until pin become flush at both sides of sleeve 10 Position the spool and sleeve assembly so that the splined end of the spool enters the 14 hole end of hous ing first see Fig 40 IMPORTANT Be extremely careful that the parts do not tilt out of position while inserting Push parts gently into place with slight rotating action keep pin nearly horizontal Bring the spool assembly entirely within th
139. l Figure 87 Hydraulic System Page 4 86 Reelmaster 4000 D Rear Wheel Drive Valve Block RM 4500 D 4WD MANIFOLD BLOCK CHECK VALVE C 2 Torque to 35 65 CHECK VALVE C41 Torque to 35 ft lbs 1inch Hex 1inch Hex LOGIC CARTRIDGE Lc 4 Torque to 35 65 1inch Hex SOLENOID CARTRIDGE Torque Cartridge to 12 ft lbs 7 8 Inch Hex Torque Coil Retaining Nut 015 in lbs Coil Resistance 7 2 Ohms 10 NOTE If cartridge valve seals appear pitted or CARTRIDGE damaged the hydraulic system may be overheating or LC 2 there may be water in the 4 1 2 Inch Hex Figure 88 Cleaning Solenoid Actuated Cartridge Valve Use a deep socket to remove the valve cartridge Use mineral spirits to clean solenoid actuated cartridge valves Submerge the valve in clean mineral spirits and use a probe to push the internal spool in and out 20 to 30 times to flush out contamination Mineral spirits does not affect the O ring material Particles as fine as talcum powder can affect the operation of high pressure hy draulic valves NOTE Apply clean hydraulic oil to the O rings before installing the valve Use a deep socket to install the valve into the manifold block Tighten to a torque of 35 ft lb 48 Nm Install the solenoid coil Make sure there is ring at each end of the coil After putting the solenoid onto the valve stem apply Loctite 242 or equivalent to the threads on the stem before installing the n
140. lance pres sure may be monitored at pressure tap port 3 Since the lift levers are spring loaded from return to neu tral a detent plunger latches the spool in the valve to hold the spool in a Free Float position The position en ables the cutting units to follow ground contours by al lowing a two way flow between the lift valve and lift cylinders Hydraulic System Lift Circuit Lift All Units LEGEND OIL FLOW PRESSURE FREE STEERING ORBITROL PRESSURE OIL NO 2 REEL MOTOR NO 3 REEL MOTOR NO 2 LIFT CYLINDER NO 3 LIFT CYLINDER TRACTION MOTOR TRACTION MOTOR LEFT 1 82 8 3 4 5 COUNTER BALANCE VALVE PUMP PACKAGE STEER cans LO SPEED BACKLAP NO 4 REEL MOTOR NO 4 LIFT CYLINDER NO 5 LIFT CYLINDER 7 J m 9 STEER CYLINDER RIGHT AXLE WHEEL Hydraulic System Page 4 16 Reelmaster 4000 D Lift Circuit Lower All Units LEGEND OIL FLOW L____ PRESSURE FREE PRESSURE OIL STEERING ORBITROL NO 2 REE MOTOR gt NO 2 LIFT CYLINDER NO 3 REEL MOTOR NO 3 LIFT CYLINDER TRACTION MOTOR TRACTION MOTOR LEFT COUNTER BALANCE VALVE PUMP PACKAGE STEER casas spp NO 4 REEL MOTOR NO 4 LIFT CYLINDER NO 5 LIFT CYLINDER sf J 15 STEE
141. lips of oil seal 4 and lower hub onto the spindle Hub 8 should be centered as it is lowered over the spindle to prevent seal damage 4 Assemble bearing cone 9 over the spindle and into the bearing cup 6 Select thickest retaining ring 28 Axles and Brakes Page 6 8 that can be assembled into the ring grooves of the spindle shaft above the bearing cone Bearing should have from 0 000 to 0 006 inches 0 00 to 0 15mm of end play when the proper retaining ring is installed 5 Assemble retaining ring 25 in the groove opposite pilot end of the input shaft 2 Assemble washer 26 spring 27 second washer 26 second retaining ring 25 and third retaining ring 29 in the middle groove of the input shaft Some shafts have a shoulder and re quire only one retaining ring 6 Assemble splined end of the input shaft down into the spindle 7 Assemble secondary carrier splines over the splined end of spindle 8 Apply a bead of RTV compound or equivalent to the hub face that mates with ring gear 24 Assemble end of the ring gear having 6 or 12 boltholes against the hub with the bolt holes of the hub and ring gear aligned As semble six 3 8 24x1 7 8 inch hex head bolts Torque bolts from 39 to 49 ft lb 5 4 to 6 8 kg m If grade 8 bolts are used torque bolts from 52 to 60 ft lb 7 2 to 8 3 kg m Grade 8 bolts can be identified by the 6 radial lines on bolt head 9 Assemble primary carrier and sun gear into
142. lter seal before screwing iton Do not overtighten filter Fig 13 3 Add oil to crankcase see Check Engine Oil Figure 12 1 Drain plug 2 Starter Figure 13 1 Oil filter 2 Fuel filter water seperator Reelmaster 4000 D Page 3 9 Kubota Diesel Engine Drain Fuel System 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 spilled diesel fuel before start ing the engine Store fuel in a clean safety ap proved container and keep cap in place Use die sel fuel for the engine only not for any other purpose Fuel Tank Figure 14 Drain and clean fuel tank every 800 hours of operation separator 3 Priming plunger or yearly whichever comes first Also drain and clean 2 Drain screw tank if fuel system becomes contaminated or if machine is to be stored for an extended period Use clean fuel to flush out the tank Fuel Filter Water Separator Drain water or other contaminants from fuel filter water separator daily 1 Park machine on a level surface Stop engine Re move key from the ignition switch 2 Place a clean container under the fuel filter 3 Loosen drain thumb screw on the side of fuel filter Press primer plunger until only fuel is evident draining into container 4
143. minal of the voltage source to the negative terminal of the hour meter 3 The meter should move 1 10 hour in 6 minutes 4 Disconnect the voltage source from the hour meter Figure 6 Glow Plug and Start Relays These relays are located in the rear of the center con sole and below the seat Access can be gained through the front access panel to the center console 1 Verify coil resistance between terminals 86 and 85 with a multimeter ohms setting Resistance should be from 41 to 51 ohms 2 Connect multimeter ohms setting leads to relay terminals 30 and 87 Ground terminal 86 and apply 12 VDC to terminal 85 The relay should make and break continuity between terminals 30 and 87 as 12 VDC is ap Figure 7 plied and removed from terminal 85 3 Disconnect voltage and leads from the terminals Audio Alarm Electrical System 1 Isolate alarm from the circuit Connect 12VDC source to terminals Make sure to observe polarity 2 Alarm should sound Remove voltage source from the alarm Reconnect alarm to the circuit Figure 8 1 Top view 2 Side view Reelmaster 4000 D Page 5 19 Electrical System Rev 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 be from 80 to 90 ohms There should be continuity between terminals 87A and 30 2 Connect multimeter ohms setting leads
144. ming BTDC 17 to 19 Degrees Reelmaster 4000 D Page 3 3 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 to the FULL mark Fig 2 4 If oil is below FULL mark remove fill cap and add SAE 10W 30 oil until level reaches the FULL mark Do not overfill Crankcase capacity is 8 qt 7 6 L with filter Fig 3 5 Install oil fill cap and dipstick Figure 1 1 Engine cover latch 6 Close engine cover and secure with the latches Figure 2 1 Dipstick Figure 3 1 Oil fill cap Kubota Diesel Engine Page 3 4 Reelmaster 4000 D Check Cooling System Check level of coolant at the beginning of each day Ca pacity of system is 3 7 gal 14 L 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 Park machine on a level surface Stop engine Re move key from the ignition switch Figure 4 2 Carefully remove radiator cap Fig 4 and expan 1 Radiator cap 2 Rear screen sion tank cap Fig 5 3 Check level of coolant in radiator Radiator should be filled to the top of the filler neck and the expansion ta
145. n nion cover 23 seal cover 15 O ring cover 22 O ring 21 washer 17 inner race 20 and needle bearing 18 Remove shaft seal 16 washer 17 and needle bearing 18 Hydraulic System Hydraulic System Figure 63 Hex Head Cap Screw Charge Pump Adapter Assembly Plug Assembly Tow Valve Assembly O Ring Needle Bearing Gerotor Gear Assembly Check Valve Assembly Back Plate Assembly Housing Gasket Dowel Pin Rotating Kit Assembly Key Camplate Seal Cover Shaft Seal Washer Needle Bearing Housing Assembly Inner Race O Ring O Ring Cover Trunnion Cover Screw Page 4 70 Retaining Ring Shaft Seal Washer Retaining Ring Thrust Ring Needle Bearing Thrust Drive Shaft Relief Valve Kit O Ring Relief Valve Assembly Key Hex Head Cap Screw Cartridge O Ring Spring Poppet Spring Poppet Spring Spring Retainer O Ring Back up Washer Bearing Bearing Reelmaster 4000 D Inspection of Traction 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 assembly 2 It should not be scored exces sively 4 Inspect the bearing 47 inside the charge pump adap
146. nd Brakes Reelmaster 4000 D TORO Table of Contents GENERAL SAFETY INSTRUCTIONS 1 Before Operating 1 While Operating 2 Maintenance and Service 3 General Safety Instructions The Reelmaster 4000 D was tested and certified by TORO for compliance with the B71 4 1984 specifica tions of the American National Standards Institute for riding mowers when rear tires are filled with calcium chloride and two rear wheel weight kits Although haz ard control and accident prevention partially are depen dent upon the design and configuration of the machine these factors are also dependent upon the awareness concern and proper training of the personnel involved in the operation transport maintenance and storage of the machine Improper use or maintenance of the ma chine can result in injury or death Before Operating 1 Read and understand the contents of the traction unit and cutting unit operator s manuals before operat ing the machine To get replacement manuals send complete model and serial number to The Toro Company 8111 Lyndale Avenue South Minneapolis MN 55420 1196 2 Never allow children to operate the machine or adults to operate it without proper instruction 3 Become familiar with the controls and know how to stop the machine and engine quickly 4 Keepallshields safety devices and decals in place If a shield
147. neral purpose grease to lubricate the eight grease fittings IMPORTANT Before washing the machine shut off the engine and remove the key Toro recommends daily lubrication of reels and rollers immediately af ter washing the machine This helps to minimize wa ter entering the reel and roller bearings If the cutting units are washed in the raised position be sure to lower them to the ground after washing This allows water to drain from the ends of the rollers and reel bearing housings 1 Wipe each grease fitting with a clean rag before greasing IMPORTANT Applying too much pressure will ruin the seals and leaking grease could cause damage to grass 2 Lubricate reel shaft and roller bearings daily with 3 or 4 pumps of grease Daily lubrication of these fittings purges water and other contaminants increasing ser vice life and maintaining excellent quality of cut Fig 31 3 Lubricate floatation kit pivots Fig 32 and Fixed head pivots Fig 33 weekly with one pump of grease 4 Wipe excess grease from the fittings Note When greasing roller bearings grease forced from bearings will not be visible around the roller shaft Cutting Units Page 7 18 Figure 32 Figure 33 Reelmaster 4000 D TORO Commercial Products The Toro Company
148. ngage parking brake start engine and lower cut ting units Move Mow Backlap lever to MOW Raise off the seat engine should stop within a few seconds which indicates the interlock system is operating properly Also raise off the seat with lever in BACKLAP Engine should stop indicating interlock system is operating If engine does not stop there is a malfunction that must be re paired immediately 5 Engage parking brake move Mow Backlap lever to NEUTRAL start engine disengage hand brake and raise off seat If engine stops interlock system is operat ing If engine does not stop there is a malfunction that must be repaired immediately Reelmaster 4000 D Chapter 6 TORO Axles and Brakes Table of Contents SPECIFICATIONS 2 SERVICE AND REPAIRS 5 ADJUSTMENTS 3 Rear Wheel Bearings 2WD 5 Hand Brake and Traction Switches 3 Planetary Wheel Drive 7 Rear Wheel Toe In Brakes o 2 E Reelmaster 4000 D Page 6 1 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 Torque 95 110 ft lb 13 1 to 15 2 kg m
149. nition switch in the RUN position Verify the following while in the RUN position A Glow indicator lamp is on B Glow relay is energized C Glow plugs are energized D Glow indicator lamp goes out and glow plugs deenergize after 10 seconds Note If there is no power to terminal 1 of the glow con troller verify continuity of the circuitry from the ignition Switch to the controller and perform step 4 again see Electrical Schematics and Diagrams 4 Place ignition switch in the START position Verify the following while in the START position A Glow indicator lamp is out B Glow relay is energized C Glow plugs are energized D Power to terminal 1 of the glow controller Reelmaster 4000 D Page 5 27 Figure 24 1 End view 3 2 Top view Side view 5 If any of the conditions in step are not met or power to terminal 1 exists and any of the other conditions in step 4 are not met A Verify continuity of the circuitry from the battery to the glow relay and glow plugs see Electrical Schematics and Diagrams B Verify continuity of the circuitry from the battery to ignition switch glow controller glow lamp glow relay and ground see Electrical Schematics and Diagrams C Replace parts as necessary 6 Connect electrical connector to the fuel solenoid Electrical System Rev A Hydraulic Oil Filter Switch The oil filter switch is activate b
150. nk filled to the marks on its side IMPORTANT Do not use water only Do not use al cohol methanol base coolants 4 If coolant is low add a 50 50 mixture of water and ethylene glycol anti freeze 5 Install radiator cap and expansion tank cap Figure 5 1 Expansion tank cap Fill Fuel Tank 1 Park machine on a level surface Stop engine Re move key from the ignition switch 2 Remove fuel tank cap Fig 6 3 Filltank to about one inch 25 mm below bottom of filler neck with No 2 diesel fuel Then install cap Figure 6 1 Fueltank cap 2 Leftrear tire Reelmaster 4000 D Page3 5 Kubota Diesel Engine Prime Fuel System IMPORTANT The fuel system must be primed when anew 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 solenoid It can be manually primed to get fuel from fuel tank to fuel filter water separator Fig 7 1 Park machine on a level surface Stop engine Re move key from the ignition switch 2 Raise engine cover 3 Insert a 3 16 inch hose over the bleed screw and run the other end ofthe hose into a container to catch the fuel Fig 8 IMPORTANT Priming fuel filter without opening bleed screw may damage priming plunger 4 Loosenfuelfilter water separator bleed screw a few turns Pump priming plunger unt
151. nless wheels are chocked or blocked 25 Theoptional TORO tow bar is for emergency towing only Use only the special tow bar if it becomes neces sary to tow machine Use trailer for normal transport Reelmaster 4000 D 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 Assure all hydraulic hoses and lines are in good condition before applying pressure to the system 29 Keep body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid Use cardboard or paper to find hydraulic leaks Hydraulic fluid escaping under pressure can penetrate skin and cause injury Fluid accidentally injected into the skin must be surgically removed within a few hours by a doc tor or gangrene may occur 30 Before any hydraulic system maintenance stop en gine and lower cutting units to the ground so all pressure is relieved 31 For major repairs or other assistance contact your local Toro Distributor 32 To reduce potential fire hazard keep engine area free of excessive grease grass leaves and dirt Clean protective screen on back of engine frequently 33 If engine must be running to perform maintenance or an adjustment keep hands feet clothing and oth
152. of swivel lever with cable so the injector pump lever is contacting the stop in the full throttle position D Secure cable to swivel with screw 18 Prime fuel system see Prime Fuel System 19 Check traction pedal adjustment for NEUTRAL Reelmaster 4000 D TORO Table of Contents SPECIFICATIONS GENERAL INFORMATION Hydraulic Hoses Hydraulic Fitting Installation Pushing or Towing Traction Unit Check Hydraulic System Fluid HYDRAULIC SCHEMATIC HYDRAULIC FLOW DIAGRAMS General Pump Flow Engine Run No Functions Traction Circuit Traction Circuit Forward Steering Steering 14 Lift Lower Circuit Lift Circuit Lift Circuit Lower All Units Lift Circuits Free Float Detent Reel Circuit sce aos aet temer Raced eae Reel Circuit All Units Mow Free Float Reel Circuit Units 1 2 amp 3 Mow Free Float Reel Circuit Units 1 2 3 amp 5 Free Float Reel Circuit Any Unit Backlap 4WD SELECTOR VALVE OPERATION AWD Forward 2WD Forward SPECIAL TOOLS Hydraulic Tester with Pressure and Flow Capabilities Hydraulic Pressure
153. oil 500 550 PSI cold oil 600 650 PSI Hydraulic Filter Fig 1 Spin on cartridge type Hydraulic Oil Mobil DTE 26 Shell Tellus 68 or equivalent see Add Hydraulic Fluid Reservoir Fig 2 Reservoir capacity 15 gal U S System capacity approximately 18 2 gal U S Hydraulic System 4 2 Reelmaster 4000 D 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 premature dete rioration Some hoses are more susceptible to these conditions than others Inspect the hoses frequently for signs of deterioration or damage When replacing a hydraulic hose be sure that the hose is straight not twisted before tightening the fittings This can be done by observing the imprint on the hose Use two wrenches one to hold the hose straight and one to tighten the hose swivel nut onto the fitting Hydraulic Fitting Installation O Ring Face Seal 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Make sure the O ring is installed and properly seated in the groove It is recommended that the O ring be re placed any time the connection is opened 3 Lubricate the O ring with a light coating of oil 4 P
154. ol linkage for proper adjust ment binding or broken parts 3 After disconnecting or replacing any hydraulic com ponents operate machine functions slowly until air is out of system 4 Checkfor hydraulic oil leaks Shut off engine and cor rectleaks if necessary Check oil level in hydraulic reser voir and add correct oil if necessary Hydraulic System Steering Control Unit 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 Centering Spring Kit 11 Control Spool 12 Seal 13 Spacer Plate 14 Drive Disassembly Cleanliness is extremely important when repairing a steering control unit Work in a clean area Before dis connecting lines clean port area of unit thoroughly Use a wire brush to remove foreign material and debris from around exterior joints of the unit 15 Gerotor 16 End Cap 18 Cap Screw 19 Pin Kit Centering 20 Spring 21 Retainer Plug 22 Check Ball 23 Check Ball Retainer 24 Check Ball 25 Seal 26 Check Ball Seat 27 Seal 28 Set Screw NOTE Troubleshooting information defines terms and problems possible causes for problems and recom mends procedures for correcting problems Although not all drawings show the unit in a vise we rec ommend that you keep the unit in the vise during disas sembly Follow the cl
155. onship of reference lines A B C and D in Fig 48 Align bolt holes without disengaging meter from drive Marked Port Face Figure 48 Reelmaster 4000 D Page 4 49 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 Figure 49 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 sequence shown in Fig 50 Gre 4 oO oe HE Figure 50 Hydraulic System Page 4 50 Reelmaster 4000 D 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 Warm oil should be even with ar rows on sight glass If level is low add hydraulic oil Re fer to Hydraulic Oil Specifications Fig 51 1 Remove seat lock pin raise seat and hold open with support rod 2 Clean around reservoir filler cap Fig 52 Remove cover and add hydraulic oil until itis even with arrows on sight glass Fig 51 IMPORTANT To prevent contamination clean top of hydraulic oil containers before puncturing As sure pour spout and funnel are clean 3 Install reservoir cover lower seat and secure with lock pin Hydraulic Oils Specifications Interchangeable Mobil DTE 2
156. open will cause the hydraulic system to overheat Vehicle will roll with front wheel motors disen gaged Vehicle must be on level surface or wheels must be blocked There is no effective braking with wheel motors disengaged If towing with front wheel motors disengaged Tow Bar Assembly Toro part no 58 7020 must be used 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 Vehicle will roll with front wheel motors disenga ged Vehicle must be on level surface or wheels must be blocked There is no effective braking with wheel motors disengaged If towing with front wheel motors disengaged Tow Bar Assembly Toro part no 58 7020 must be used NOTE The machine can also be moved slowly a short distance by opening the by pass valve on the variable displacement hydraulic pump and pushing or towing the machine See Pushing or Towing in the General In formation section of Chapter 4 Hydraulic System 1 Block the wheels or connect the machine to a towing vehicle with a rigid towing device 2 Remove bolts securing disengage covers to both front wheel hubs Fig 9 Figure 9 Hydraulic System Page4 6 3 Install disengage covers so dimple on cover is facing intowards hub Wheel hubs are now unlocked Fig 10 Figure 10 1 Disengage cover engaged dimple facing out 4 Lockthe
157. or excessive scoring or wear 2 21 should be replaced if I D of gear pocket ex ceeds 1 713 FLOW DIVIDER FLOW CONTROL RELIEF VALVE 1 Check disk 8 for wear 2 Check spring 9 for weakness or breakage 3 Wash back plate 22 in clean solvent then direct compressed air into relief valve and flow divider cavities in back plate to remove any contamination Hydraulic System Plug includes 2 O Ring Spool Dowel Pin Plug includes 2 Drive Gear Assembly Disc Spring 10 Idler Gear Assembly 11 Hex Head Cap Screw 12 Shaft Seal 13 Washer 14 Bushing JO P h ch Hydraulic System Figure 56 Page 4 56 Front Plate Assembly O Ring Molded O Ring Bearing Seal Backup Gasket Wear Plate Body Assembly Back Plate Assembly Relief Valve Assembly O Ring Back Up Washer O Ring Reelmaster 4000 D Assembly of Steering Pump Itis important that the relationship of the back plate 22 body 21 wear plate 20 and front plate 15 is correct You 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 pressure side of the pump Side of wear plate with mid section cut out must be on suction side of pump Suction side of back plate is always side with larger port boss 1 Install relief valve 23 with new O ring 24 back up washer 25
158. orque plug from 10 to 12 ft lb 1 4 to 1 7 kg m 2 Retaining ring 12 shaft seal 13 back up washer 14 and O rings 5 should be replaced as new parts 3 Install O rings 5 in grooves of front plate 8 and body 6 4 Install body 6 in front plate assembly 8 noting posi tion of scribe line 5 Install dowel pins 7 in body 6 and front plate as sembly 8 6 Dip gear assemblies 2 amp 3 into oil and slip into body and front plate bushing 7 Install back plate assembly 21 noting position of scribe line Install cap screws 9 draw up bolts evenly and torque to 22 25 ft lbs 8 Install new back up washer 14 on drive shaft Oil shaft seal 13 liberally Work shaft seal 13 over drive shaft taking care not to cut rubber sealing lip 9 Seat shaft seal 13 by tapping with plastic hammer Install new retaining ring 12 10 Replace key 4 in drive shaft 3 11 Install drive pulley 11 on drive shaft 12 Tighten set screws 10 in drive pulley 11 Hydraulic System Steering Pump Figure 55 1 Plug includes 2 15 Front Plate Assembly 2 O Ring 16 O Ring 3 Spool 17 Molded O Ring 4 Dowel Pin 18 Bearing Seal 6 Plug includes 2 19 Backup Gasket 7 Drive Gear Assembly 20 Wear Plate 8 Disc 21 Body Assembly 9 Spring 22 Back Plate Assembly 10 Idler Gear Assembly 23 Relief Valve Assembly 11 Hex Head Cap Screw 24 O Ring 12 Shaft Seal 25 Back Up Washer 13 Wash
159. over spool screw 26 and se cure to valve body 2 with lock washers 23 and cap screws 22 9 Install relief valve 8 10 Run operational check Hydraulic System Reel Shut Valve Figure 61 1 Circlip 6 Backup Washer 2 Washer 7 O Ring 3 Spacer 8 Body 4 Spring 9 Spool 5 Wiper Hydraulic System 4 66 Reelmaster 4000 D Disassembly of Reel Shut Off Valve 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 rings 7 from spool bore Inspection of Reel Shut Off Valve Assembly 1 Thoroughly clean and dry all parts 2 Inspect the spool bore inside the body The surface should be smooth and free of deep scratches Reelmaster 4000 D Page 4 67 3 Inspect O D of spool 9 Itshould be smooth and free of nicks and burrs 4 Inspect spring 4 for breakage Reassembly of Reel Shut Off Valve Assembly 1 Install new O rings 7 and back up washers 6 in spool bore with O rings to the inside of the back up washers 2 Install new wipers 5 in spool bore 3 Install washer 2 spacer 3 spring 4 and washer 2 on spool 9 4 Dip spool 9 in oil and slide in body bore taking care not to cut O rings 7 Be sure spool is installed in the proper position 5
160. p motor in vise shaft up 6 Remove eight cap screws 9 7 Remove motor from vise hold motor in hands and bump shaft against wooden block to separate the front plate assembly 8 from the back plate assembly 21 The body 6 will remain with either the front or back plate 8 Separate body 6 from either the front or back plate 9 Remove drive gear 3 and idler gear 2 10 Remove retaining ring 12 shaft seal 13 and back up washer 14 from front plate assembly 8 Hydraulic System 14 Backup Washer Page 4 52 21 Back Plate Relief Assembly 11 Remove the two O rings 5 and two dowel pins 7 between front plate assembly 8 and body 6 and be tween body 6 and back plate assembly 21 IMPORTANT Remove relief valve kit only if testing indicates the relief valve is faulty 12 Remove plug 17 and O ring 16 from the back plate 21 Remove shim 18 spring 19 and ball 20 from the back plate Reelmaster 4000 D Inspection of Reel Motor GENERAL 1 Clean and dry all parts 2 Remove nicks and burrs from all parts with emery cloth GEAR ASSEMBLY 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 and excessive wear 3 If shaft measures less than 686 in bearing area the gear assembly should be replaced One gear assembly may be replaced separately Shafts and gears a
161. que wrench and bedknife screw tool Tighten screws to a torque of 250 to 300 in Ib 288 to 345 kg m Make sure bedknife is flat against the bedbar Fig 18 Figure 17 4 Install bedbar bedknife assembly to the cutting unit 1 Bedbar E 3 Mounting screws 2 Bedknife 4 Mounting fasteners Grinding Variations in the mounting surface of a bedbar causes a new bedknife not be perfectly flat after installation This makes it is necessary to backlap or grind a new bedknife after installation to the bedbar Follow existing angle that was ground into the bedknife Grind only enough to make sure the top surface is true Fig 19 1 Remove the bedbar from the cutting unit 2 Keep the bedknife fastened to the bedbar when grinding Figure 18 3 Follow the grinder manufacturer s instructions for 1 Torque wrench 2 Bedkhita sar witool set up and operation of the grinder Note When grinding be careful to not overheat the bedknife Remove small amounts of material with each pass of the grinder Top Face Relief Angle Remove Burr Front Face Bedknife Grinding Specifications Relief Angle 5 Front Angle Relief Angle Range Front Angle Range 13 to 17 Cutting Units Page 7 10 Reelmaster 4000 D Figure 19 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
162. r Hydraulic System 4 62 Reelmaster 4000 D 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 barrel assembly 7 5 Remove wiper seal 4 and seal 5 from 1 0 of barrel assembly Inspection of Lift Cylinder 1 It is not necessary to inspect wiper 4 seal 5 or snap ring 6 These parts should be replaced as new items and are included in the seal repair kit available for this cylinder 2 Thoroughly clean all parts and remove all nicks and burrs with emery cloth 3 Inspect I D of barrel assembly 7 for excessive wear or scoring Reelmaster 4000 D Page 4 63 4 Inspect O D of rod 3 for nicks scratches or scoring Reassembly of Lift Cylinder 1 All parts should be cleaned and dried thoroughly Met al parts should be lightly oiled prior to reassembly 2 Install new seal 5 in barrel Install new wiper 4 in barrel with lips facing outward 3 Install new snap ring 6 in deep groove of rod end 3 4 Oil outside of piston rod 3 and carefully insert rod in barrel assembly 7 5 Push rod into barrel assembly until snap ring area of rod can be seen through port 6 By using screwdriver through port pop snap ring 6 into lock posit
163. r matter can get into the hydraulic system and cause da mage Do not use a coarse grit try to file or grind these parts NOTE Lubricate all seals with clean petroleum jelly such as Vaseline Do not use excessive lubricant on seals for meter sec tion Refer to parts listing covering your steering control unit when ordering replacement parts A good service policy is to replace all old seals with new seals Control End Reassembly 1 Use a needle nose pliers to lower check ball retainer into check valve hole of housing Make sure retainer is straight not tilted on edge in housing see Fig 37 2 Install check ball in housing 3 Lubricate 5 8 diameter seal and 7 16 diameter seal Install seals on check ball seat as shown in Fig 37 4 Lubricate check ball seat and seals thoroughly before installing seat in housing When installing seat do not twist or damage seals Install check ball seat in housing insert open end of seat first see Fig 37 Push check ball seat to shoulder of hole 5 Assemble spool and sleeve carefully so that the spring slots line up at the same end Rotate spool while sliding parts together Some spool and sleeve sets have identification marks align these marks as shown in Fig 38 Test for free rotation Spool should rotate smoothly in sleeve with finger tip force applied at splined end Reelmaster 4000 D Page 4 45 Set Screw 5 8 Sed 7 16 Seal SC DA Check Bal
164. r deeper Replace if necessary DO NOT deburr the figure eight section of the center section 7 Inspect splines on the drive gear 10 and driven gear 11 for nicks or excessive wear Inspect gear journals fro scratches and discoloration Any discoloration war rants replacement Inspect gear teeth for spalling scratches and or excessive wear Replace if necessa ry Stoning teeth to remove burrs is permissible The face of the gear teeth should also be inspected for scratches 8 Inspectthe drive and driven gear bushings on the port section 13 for pickup scoring discoloration and or wear Any of the preceding conditions shall warrant re placement of the port section Inspect inlet flange for nicks and burrs Stone to remove Inspect studs 3 for cross threads cracks and burrs if studs are defective remove as follows Install a nut 1 on the stud as far as possible Then install another nut over the first one and tighten to lock in place Apply torque to the first nut and remove the stud Refer to the parts drawing for stud part numbers and installation instructions Hydraulic System 9 18 17 16 Figure 67 1 Nut 10 Spline Drive Gear 2 Lock Washer 11 Driven Gear 3 Stud 12 O Ring Seal 4 Stud 13 Rear Port Section 5 Front Cover 14 Coupling 6 Gland Seal 15 O Ring 7 Wear Plate 16 Plug 8 Center S A Section 17 Shaft Seal 9 Shaft Seal 18 Retaining Ring Hydraulic System 4 78 Reelmaster 4000
165. rate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil Controls must be operated with the ignition switch in OFF Remove key from the igni tion switch Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved Stop engine lower or support attachments Hydraulic System Page 4 30 Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Do not use hands to search for leaks use paper or cardboard Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury If fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury Gan grene may result from such an injury 1 Clean machine thoroughly before disconnecting or disassembling any hydraulic components Always keep in mind the need for cleanliness when working on hy draulic equipment Contamination will cause excessive wear of components 2 Put metal caps or plugs on any hydraulic lines left open or exposed during testing or removal of compo nents 3 The engine must be in good operating condition Use a phototac when performing a hydraulic test En gine speed can affect the accuracy of the tester read ings 4 Theinlet and the outlet hoses must be properly con nected and not reversed tester wi
166. rbalance pressure See Test No 2 Worn or damaged counterbalance valve Low lift relief pressure See Test No 7 Plugged oylinder orifice Worn or damaged lift valve Worn or damaged steering lift pump Low engine RPM Low hydraulic oil level Binding lift arm pivot points or bushings Worn or damaged bushings Worn or damaged cylinders Improper counterbalance pressure See Test No 2 Worn or damaged counterbalance valve Plugged cylinder orifice Worn or damaged spool detent in lift valve Worn or damaged lift valve Hydraulic System Testing 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 Tools section in this Chapter Before Performing Hydraulic Tests IMPORTANT All obvious areas such as oil supply filter binding linkages loose fasteners or improper adjustments must be checked before assuming that a hydraulic component is the source of the problem Precautions for Hydraulic Testing Failure to use gauges with recommended pres sure psi rating as listed in test procedures could result in damage to the gauge and possible personal injury from leaking hot oil All testing should be performed by two 2 people One person should be in the seat to oper ate the machine and the other should read and record test results Ope
167. re and connector to the alternator red cable to starter three wires to the starter wire to the oil pressure switch and wires to high tempera ture warning and shutdown switches Fig 20 B Connect electrical connector to the fuel solenoid Fig 22 Kubota Diesel Engine Page 3 16 C Connect red black wire to the glow plug bus bar Fig 23 8 Connect the following 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 C Remove clamps used to prevent drainage 9 Position fan shroud to the radiator Install fan to the fan pulley Fig 21 A Apply Loctite Blue 242 or equivalent to the ends of the cap screws B Torque cap screws from 80 to 110 in lb 92 to 127 kg cm 10 Install fan shroud and guard to the radiator Fig 20 11 Install exhaust shield to the engine Fig 20 12 Install air hose to air intake manifold Fig 20 13 Install battery the machine and connect cables see Battery Service in Chapter 5 Electrical Systems 14 Connect both hoses to the radiator Fig 20 15 Secure canopy to the brackets Fig 19 16 Fill radiator with coolant see Check Cooling Sys tem 17 Adjust control cable throttle cable Fig 24 A Push throttle lever to the FAST position B Loosen screw on swivel that secures the cable to the swivel lever C Adjust position
168. re avail able as assemblies only 4 If gear width is below 1 327 gear assembly should be replaced 5 Inspect gear face for scoring and excessive wear 6 Retaining ring 12 on shaft assemblies should be in groove 7 If edge of gear teeth are sharp break edge with emery cloth FRONT PLATE BODY BACK PLATE AND RELIEF VALVE 1 Inspect I D of bushings in front plate 8 body 6 and back plate 21 If I D exceeds 693 front plate body or back plate should be replaced Bushings are not available as separate items 2 Back plate assembly 21 should be replaced if I D of gear pocket exceeds 1 719 3 Check for scoring on face of front plate 8 body 6 and back plate 21 If wear exceeds 0015 front plate body or back plate should be replaced 4 f the relief valve kit 15 was removed inspect valve bore in the back plate 21 for dirt debris and damage Clean bore of dirt and debris Replace back plate if bore or valve seating surfaces are damaged IMPORTANT The plug 17 shim 18 spring 19 and ball 20 must be replaced as a complete unit 5 If the relief valve kit was removed inspect plug 17 shim 18 spring 19 and ball 20 for wear and dam age Replace parts as necessary Reelmaster 4000 D Page 4 53 Reassembly of Reel Motor 1 If the relief valve kit was removed install ball 20 spring 19 shim 18 new O ring 16 and plug 17 into the back plate 21 T
169. ree 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 of oil 4 Install the fitting into the port and tighten it down full length until finger tight 5 Tighten the fitting to the correct flats from finger tight F F F T Size F F F T 4 1 4 in nominal hose or tubing 1 00 25 6 3 8 in 1 50 25 8 1 2 in 1 50 25 10 5 8 in 1 50 25 12 3 4 in 1 50 25 16 1 in 1 50 25 SAE Straight Thread O Ring Port 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 of oil 4 Turn back the jam nut as far as possible Make sure the back up washer is not loose and is pushed up as far as possible Step 1 5 Install the fitting into the port and tighten finger tight until the washer contacts the face of the port Step 2 6 To put the fitting in the desired position unscrew it by the required amount but no more than one full turn Step 3 7 Hold the fitting in the desired position with a wrench and turn the jam nut with another wrench to the correct flats from finger tight F F F T Step 4 Size 4 1 4 in nominal hose or tubing 1 00 25 6 3 8 in
170. remove the key 5 Insert piece of bar stock 25 to 28 inches 64 to 71cm long with thickness equal to desired height of cut under the entire length of the reel and next to bed knife Fig 11 6 Adjustrear roller adjustment knobs and jam nuts un til the full length of the rear roller contacts the flat sur face and the full length of the reel not bedknife contacts the bar stock Tighten rear roller knobs and jam nuts CONTACT ALONG FULL LENGTH AT B AND LEVELS REAR ROLLER TO REEL REAR ROLLER HOC 3 8 INCH 9 5 REF FLAT SURFACE BEDKNIFE BAR STOCK Figure 11 Adjust Skids and Front Roller Fixed Cutting Unit If the skid kit or front rollers are installed make the fol lowing adjustments to prevent them from pushing down uncut grass or scalping on undulating terrain Note Skids are used only with the cutting unit in the fixed position Front rollers may be used with the cutting unit in either the fixed or floating position 1 Lock each cutting unit in the fixed position and ad just reel to bedknife contact and height of cut see Ad just Reel to Bedknife Contact and Adjust Height of Cut 2 Position cutting units on a flat level surface such as a piece of 3 4 inch 1 9 cm plate steel of at least 20 x 30 inches 50 x 76 cm Note Proper adjustment is achieved when the cutting unit does not scalp the grass in normal mowing condi tions and yet is set high enough not to mar the turf and
171. ress in shaft seal until flush with front surface of front plate Hydraulic System Lift Control Valve 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 Washer 11 Plug Assembly 12 Washer 13 Spool 14 Plug Assembly 15 O Ring 16 Washer 17 Washer 18 Washer 19 Spring 20 Poppet Hydraulic System Figure 57 Page 4 58 O Ring Bushing Washer Spring Spacer Retaining Ring Cap Assembly Plunger Plug Assembly Spring Eyelet Poppet Assembly Locknut Seat Assembly O Ring Plunger Seal Wiper 047 Dia Orifice 052 Dia Orifice Reelmaster 4000 D 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 spool bores are matched sets Be sure each spool is identified with the correct body spool bore 4 Remove bushings 23 and O rings 22 from spools 5 Remove plugs 11 6 Remove plugs 30 springs 31 poppets 83 seats 35 and plungers 37 29 IMPORTANT Check location and positioning of plungers when removing from body to assure prop er assembly 7 Remove plugs 6 8 Remove plugs 1 discs 2 springs 3 and detent plungers 4 9
172. rm 19 Alarm Relay 20 Hydraulic Oil Temperature Switch 20 Fuel Sender ooh Sdt Seege ere n 21 Fuel 21 H20 in Fuel Sensor 22 High Temperature Warning and Cutout Switches 23 Rear Wheel Drive Solenoid 24 Fuel Stop Solenoid 25 Hydraulic Oil Level Switch 26 Bridge Rectifier 26 Glow Controller 27 Hydraulic Oil Filter Switch 28 SERVICE AND REPAIRS 29 Battery Storage 29 Battery Care 29 Battery Service 30 Rear Wheel Drive Solenoid Replacement 33 Check Interlock System 34 Electrical System Rev A 6 yor q se splougjos pue UV 000000022 N S o9neuieuos e21u129 3 2 Reelmaster 4000 D
173. rning switch has a green white wire connected to it The cutout switch has two orange wires and a violet wire connected to it Fig 16 CAUTION Make sure engine is cool before removing the temperature switch 1 Lower coolant level in the engine and remove the high temperature switch Figure 16 2 Put switch in a container of oil with a thermometer and slowly heat the oil Fig 17 CAUTION 1 High temp warning 2 High temperature cutout Handle the hot oil with extreme care to prevent personal injury or fire 3 Check continuity of the switch with a multimeter ohms setting Figure 17 A The high temperature warning switch is normally open and should close between 216 to 226 F 102 to 1089C B The high temperature cutout switch is normally closed and should open between 225 to 235 F 107 to 11390 6 4 Allow oil to cool while observing temperature A The high temperature warning switch should open between 216 to 226 F 102 to 108 C B The high temperature cutout switch should close between 225 to 235 F 107 to 113 C Reelmaster 4000 D Page 5 23 Electrical System Rev A Rear Wheel Drive Solenoid CHECK VALVE 2 RM 4500 D 4WD Torque tp 35s MANIFOLD BLOCK CHECK VALVE cq Torque to 35 ftlbs 1inch Hex 1inch Hex LOGIC CARTRIDGE LC An Torque to 35 ft lbs 1Inch Hex CHECK VALVE
174. rod 8 Remove all seals and O rings 9 Wash part in a safe solvent Dry parts with com pressed air DO NOT wipe them dry with a cloth or paper as lint and dirt may remain 10 Carefully inspect internal surface of barrel for dam age deep scratches out of round etc Replace en tire cylinder if barrel is damaged Inspect head piston rod and piston for evidence of excessive scoring pit ting or wear Replace any damaged parts Reelmaster 4000 D 11 Use 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 Reelmaster 4000 D Page 4 89 14 Put a coating of oil on all cylinder parts to ease as sembly 15 Slide piston rod assembly into cylinder tube 16 Install head into tube Install threaded cap and tight en set screw 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 reservoir and let hydraulic oil flow into drain pan Tighten plug when hydraulic oil stops draining Fig 91 2 Fill reservoir with approximately 9 3 gallons of hy draulic oil
175. ry Safety Ad satety 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 Toro Distributor A bon C e ON PANEL IN FRONT OPERATOR S SEAT Part No 93 9408 S Ml we ON LEFT SIDE OF MACHINE Part No 93 9406 H L ON LIFT ARMS Part No 93 7331 K x ON STEERING CONSOLE Part No 93 9399 IMPORTANT THIS UNIT COMPLIES WITH ANSI B7 1 4 1990 WHEN EQUIPPED WITH REAR BALLAST PER OPERATOR S MANUAL ER ON FRAME ABOVE RIGHT REAR WHEEL Part No 88 6700 em 4WD Os z FO or UH ol J N ON RIGHT CONTROL PANEL NEXT TO LIFT LEVERS Part No 98 3830 Part No 93 9407 Safety Page 1 4 Reelmaster 4000 D Ad satety and Instruction Decals UI ON FRAME ABOVE REAR WHEELS NEAR RADIATOR FILL CAP Part No 93 9405 Part No 93 9404 UNDER SEAT NEAR OIL FILL Part No 93 8067 93 6680 NEAR FUEL TANK FILL Part No 76 9760 Part No 93 6680 93 9404 93 8067 ON FAN SHROUD Part No 93 6681
176. ry load tester is required to perform this test A CAUTION Follow the manufacturer s instructions when us ing a battery tester A Check the voltage across the battery terminals prior to testing the battery If the voltage is less than 12 4 VDC recharge the battery B If the battery has been charged apply a 150 amp load for 15 seconds to remove the surface charge Use a battery load tester following the manufactur er s instructions C Make sure the battery terminals are free of corro sion D Measure the temperature of the center cell E Connect a battery load tester to the battery ter minals following the manufacturer s instruc tions Connect a digital multimeter to the battery Reelmaster 4000 D Page 5 31 terminals F Apply a test load of one half the Cranking Perfor mance see Battery Specifications rating of the bat tery for 15 seconds G Take a voltage reading at 15 seconds then re move the load H Using the table below determine the minimum voltage for the cell temperature reading Voltage Temperature 98 Legd 216 Gndws If the test voltage is below the minimum replace the battery If the test voltage is at or above the mini mum return the battery to service Installation IMPORTANT To prevent possible electrical prob lems install only a fully charged battery 1 Make sure ignition switch and all accessories are off 2 Make sure battery compartment is
177. s lap ping compound with a water soluble carrier Mix dry lap ping compound with liquid detergent until it has a free flowing consistency Note Before starting the engine raise grass deflector on the center cutting unit and tighten fasteners to retain the deflector in the raised position Operator Duties 1 Sit on seat and engage parking brake 2 Start engine and run at minimum throttle Lower ei ther the center and two front cutting units the left hand cutting unit or the right hand cutting unit 3 When both side cutting units are up and latched au tomatically shut off with the center and front cutting units down backlap the center cutting unit from the rear of the machine with the long handled brush Backlap front cutting units from the front of the machine 4 Wait for 2nd person s instruction to engage reels in backlap mode then pull mow backlap lever to the BACKLAP position and hold 5 Follow 2nd person s instructions Be prepared to stop reels and engine quickly in case of an emergency Cutting Units 7 8 2nd Person s Duties 1 Instruct operator when to start and stop the reels Never use a short handle paint brush to apply backlapping compound A rotating reel can pull a short handle paint brush and the users hand into the reel causing serious personal injury 2 Dip 3 inch 76 mm wide paint brush attached to Toro Part No 29 9200 Handle Assembly into lapping compound Stand clear
178. spection and assembly The close tolerance of the parts makes this requirement very important Paint found on the edges of all parts must be removed Clean all removed parts using a commercial solvent that is compatible with the system fluid Compressed air may be used in cleaning but it must be filtered to remove wa ter and contamination New seal kits 5 amp 6 are required for assembly Wash the metal parts blow dry them with air and place ona clean surface Kraft paper for inspection 1 Place front cover S A 4 in a vise mounting flange up Using a screwdriver pop out the outer shaft seal 9 being careful not to raise a burr on the shaft seal bore Reelmaster 4000 D Page 4 77 2 Remove the retaining ring 18 with internal retaining ring pliers 3 Remove front cover S A 4 from vise and place on work bench with mounting flange down Using a bronze drift and hammer drive inner shaft seal 17 out through mounting flange being careful not to damage bearing 4 Inspect the drive and driven gear bushings of front cover 4 for pickup scoring discoloration or excessive wear Any of the preceding conditions shall warrant re placement of the front cover S A 4 Inspect mounting flange for nicks and burrs Remove with India stone 5 Inspect wear plates 7 for erosion pitting scratching an or scoring Replace if necessary 6 Inspectthe center S A section 8 for porosity cracks and scratches 010 o
179. t does not affect performance during Mow System pressure may be monitored at pressure tap 4 for either Mow or Backlap Hydraulic System Reel Circuit All Units Mow Free Float LEGEND OIL FLOW PRESSURE FREE STEERING ORBITROL PRESSURE OIL NO 2 REEL MOTOR NO 2 LIFT CYLINDER TRACTION MOTOR TRACTION MOTOR LEFT 1 B8 2 B 3 MOTOR Enn 4 ais 5 a H COUNTER VALVE PUMP PACKAGE LO SPEED BACKLAP VALVE oll NO 4 REEL MOTOR NO 4 LIFT CYLINDER NO 5 LIFT CYLINDER 57 J STEER CYLINDER RIGHT AXLE WHEEL Hydraulic System Page 4 20 Reelmaster 4000 D Reel Circuit Units 1 2 amp 3 Mow Free Float LEGEND OIL FLOW PRESSURE FREE STEERING ORBITROL PRESSURE OIL NO 2 REEL MOTOR NO 2 LIFT CYLINDER TRACTION MOTOR TRACTION MOTOR LEFT 1 B8 2 Bo Dap 4 5 a KEE Sa VALVE PUMP PACKAGE STEER amp LIFT CHARGE LO SPEED BACKLAP NO 4 REEL MOTOR NO 4 LIFT CYLINDER NO 5 LIFT CYLINDER sf J STEER CYLINDER RIGHT AXLE WHEEL Reelmaster 4000 D Page 4 21 Hydraulic System Reel Circuit Units 1 2 3 8 5 Mow Free Float LEGEND OIL FLOW PRESSURE FREE
180. te 5 to loos en it then pull the backplate straight out 7 Remove O ring 6 from backplate 8 Remove the complete rotating assembly 19 from the housing assembly 17 9 Remove piston assemblies spider and pivot from the rotating assembly 19 Reelmaster 4000 D IMPORTANT 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 11 Remove shaft seal 11 from housing 12 Remove washer 12 and drive shaft 10 from hous ing 13 Remove the two retaining rings 13 thrust races 14 and thrust bearing 15 from drive shaft 10 Inspection of Traction Motor 1 Wash all parts thoroughly in a suitable solvent 2 Examine bearings 16 and 7 in housing 17 and backplate 5 If the needles are free of excessive play and remain in the bearing cage there is not need to re place the bearing 3 Inspect thrust races 14 and thrust bearing 15 All surfaces should be free of any signs of wear or fretting 4 Inspect spider and pivot conical surfaces should be free of wear and score marks 5 Inspect the pistons the O D surface should be smooth and free of scoring The shoes should be snug fit to the piston The face of the shoes should be flat and free of scoring and flaking Do not lap piston shoes 6 Inspect the piston block the bores should be
181. tering stem 8 from metering plug 16 7 Remove O ring 6 and back up washer 7 from in side metering screw 16 Inspection of Priority Flow Divider 1 Thoroughly clean and dry all parts 2 Remove all nicks and burrs with emery cloth 3 Inspect the spool bore inside the body the surface should be smooth and free of deep score marks 4 Inspect O D of spool it should be smooth and free of nicks and burrs Spool should slide freely inside the body bore 5 Inspect surface of metering stem 8 for deep scratches and burrs Reelmaster 4000 D Page 4 61 Reassembly of Priority Flow Divider 1 Install new back up washer 7 inside metering plug 16 2 Install new O ring 6 inside metering plug 16 3 Oil metering stem 8 and install in metering plug 16 Secure with groove pin 9 4 Install new back up washer 15 and new O rings 5 amp 14 on metering plug 16 5 Install shims 10 11 12 amp 13 on metering plug 16 NOTE Install the same number of shims that were re moved 6 Install metering plug assembly and tighten 7 Install new O ring 2 on plug 1 and install plug 8 Install flow control spool 3 spring 19 shims 18 amp 17 NOTE Install same number of shims as were removed 9 Install new O ring 2 and plug 1 and install plug Hydraulic System Lift Cylinder Figure 59 1 Bleed Screw 5 Seal 2 Washer 6 Snap Ring 3 Rod 7 Seal Kit 4 Wipe
182. th pressure and flow capabilities to prevent damage to the hydraulic tester or components 5 When using tester with pressure and flow capabili ties open load valve completely in the hydraulic tester to minimize the possibility of damaging components 6 Install fittings finger tight and far enough to make sure that they are not cross threaded before tightening them with a wrench 7 Position tester hoses to prevent rotating machine parts from contacting and damaging the hoses or tester 8 Check oil level in the hydraulic tank After connect ing test equipment make sure tank is full 9 Check control linkages for improper adjustment binding or broken parts 10 All hydraulic tests should be made with the hydraulic oil at normal operating temperature Reelmaster 4000 D 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 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 Operate the unit while monitoring gauge RANGE OF TESTER READINGS 50 5200 PSI NOTE Typical working pressure during operation while going uphill would be approximately 4000 PSI in 2WD and 2500 PSI in 4WD ZA 3 If working pressure is too low in 2WD perform the EE Figure 15 traction circuit relief pressure check 9 Reverse test port 3
183. the battery do not smoke Nausea may result if the gases are inhaled Un plug charger from electrical outlet before con necting or disconnecting charger leads to or from battery posts 2 Keep top of battery clean by washing periodically with a brush dipped in ammonia or bicarbonate of soda solution Flush top surface with water after cleaning Do not remove the fill cap while cleaning Reelmaster 4000 D Page 5 29 3 Leave cables disconnected if the battery is stored on the machine 4 Store battery in a cool atmosphere to avoid quick deterioration of the battery charge 5 To help prevent the battery from freezing make sure it is fully charged see Battery Service 3 Battery cables must be tight on terminals to provide good electrical contact Connecting cables to the wrong post could re sult in personal injury and or damage to the electrical system 4 If corrosion occurs at terminals disconnect cables Always disconnect negative cable first Scrape clamps and terminals separately Reconnect cables with positive cable first Coat terminals with petro leum jelly 5 Check electrolyte level every 25 operating hours and every 30 days if machine is in storage 6 Maintain cell level with distilled or demineralized water Do not fill cells above the fill line Electrical System Rev A 6 Battery Service The battery is the heart of the electrical syst
184. tor 14 If flow was greater than 0 7 GPM 2 6 LPM repair or replace the reel motor as necessary Reelmaster 4000 D 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 low perform re lief pressure check Procedure For Relief Pressure Check 1 Hydraulic oil must be at operating temperature 2 Install a 5 000 psi gauge into the steering quick dis connect Figure 21 1 Steering circuit test port 2 Steering pump 3 Start the engine and move the throttle to full speed 2500 rpm 4 Turn the steering wheel until heavy resistance is felt indicating that the cylinder has reached maximum stroke 5 Momentarily hold the steering wheel against the re sistance and read gauge TESTER READING TO BE APPROXIMATELY 1200 1300 PSI 6 If pressure is too high clean and adjust relief valve in steering pump by removing the required shims If pres sure is too low check for restriction in pump intake line Check the steering cylinder for internal leakage If cylin der is not leaking adjust the relief valve by adding the required shims If pressure is still too low repair or re place steering pump Reelmaster 4000 D Page 4 37 Hydraulic System TEST NO 8 Check
185. tor assembly if the needles are free of excessive play and remain in the bearing cage there is no need to replace the bearing 5 Inspect the check valve assembly 8 make sure the ball seat is in good condition and the ball is free to move 6 Inspect the flat surfaces of the back plate 9 the fin ish on the gerotor side should show on galled surface The finish on the piston block side should be smooth and free of grooves The back plate should be replaced if it shows any of the wear characteristics outlined above The cam stop should be tight in the back plate 7 Inspect the piston block The surface that contacts the back plate should be smooth and free of grooves Reelmaster 4000 D Page 4 71 8 The pistons should move freely in the piston block bore If they are sticky in the bore examine the bore for scoring or contamination 9 Examine the O D of the pistons for finish condition they should not show wear or deep scratches The shoes should be snug fit on the ball end of the pistons The flat surfaces of the shoes should be flat and smooth DO NOTLAP THE PISTON SHOES 10 Examine the spider It should be flat no cracks and no signs of wear in the pivot area 11 Examine the pivot It should be smooth and show no signs of wear 12 The camplate 14 should be inspected for the condition of the finish of the polished shoe surface It should show no signs of scoring 13 Inspect the drive shaft 31 for fretting
186. ual parts of shaft and bearing assembly are not sold separately Replace as a unit Check all mating surfaces Replace any parts that have scratches or burns 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 lint or other matter can get in the hydraulic system and cause dam age Do not use acoarse grit or try to file or grind these parts Check around the keyway and chamfered area of the shaft for burrs nicks or sharp edges that can dam age the seals when reassembling the bearing housing NOTE Lubricate all seals prior to installation with pe troleum jelly such as Vaseline Use new seals when reassembling this motor 21 Use apress to install exclusion seal in outer bore of bearing housing Lip of seal must face outward See Fig 79 If a press is not available use a plastic or rubber ham mer being careful not to damage or cock seal in the bore 22 Place back up washer into seal bore Place shaft seal onto installation tool and press seal into seal bore of the housing 23 Clamp housing in vise see Fig 69 24 Place protective bullet over shaft Apply petroleum jelly to inside diameter of dust and shaft seal You may need a press to install shaft and bearing assembly Do not distort shaft seal Damage to this seal will cause leakage NOTE Usetape over other shafts to prevent cutting the seats 25 Apply petroleum jelly to the 3 76 di
187. ubota Diesel Engine Table of Contents INTRODUCTION m II 2 Change Engine Oil and Filter 9 SPECIFICATIONS 3 Drain Fuel System 10 GENERAL INFORMATION 4 Check Fuel Lines and Connections 11 Check Engine Oil 4 Replace Fuel Filters 11 Check Cooling System 5 Engine Cooling System 12 Fill Fuel Tank 5 ENQING a a 13 Prime Fuel System 6 Engine 13 ADJUSTMENTS 7 Engine Installation 16 Adjust Alternator Belt 7 KUBOTA WORKSHOP MANUAL 03 SERIES DIESEL SERVICE AND REPAIRS 8 ENGINE Service Air Cleaner 8 Reelmaster 4000 D Page 3 1 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 the Kubota Workshop Manual 03 Series Diesel Engine The use of some specialized test equipment is explained However the cost of the Kubota Diesel Engine Page 3 2 t
188. urate method of determining battery condition 1 Determine the battery charge level from either its open specific gravity or circuit voltage Battery Charge Specific Open Circuit Level Gravity Voltage 10096 1 265 12 68 2 Determine the charging time and rate using the manufacturer s battery charger instructions or the following table Electrical System Rev A Page 5 32 Battery Battery Charge Level Reserve Percent of Fully Charged Capacity Mines 80 or less 3 8hrs 7 5hrs 11 3hrs 15 hrs 3 amps 3amps amps 3 amps 8110125 5 3hrs 10 5 hrs 15 8 hrs 21 hrs 4amps 4amps 4amps 4 amps 126 to 5 5 hrs 11 hrs 16 5hrs 22 hrs 170 Q9 5 amps 5 amps 5 amps 5 amps 171 to 5 8hrs 11 5 hrs 17 3hrs 23 hrs 250 Q 6 amps 6 amps 6 amps 6 amps above 6 hrs 12 hrs 18 hrs 24 hrs 250 10 amps 10 amps 10 amps 10 amps A CAUTION Do not charge a frozen battery because it can ex plode and cause injury Let the battery warm to 60 F 15 5 C before connecting to a charger Charge the battery a well ventilated place to dissipate gases produced from charging These gases are explosive keep open flame and elec trical spark away from the battery Do not smoke Nausea may result if the gases are inhaled Un plug the charger from the electrical outlet before connecting or disconnecting the charger leads from the battery posts 3 Follo
189. ut Tighten the nut to a maximum torque of 15 in lb 1 7 Nm to se cure the solenoid do not over tighten Reelmaster 4000 D Page 4 87 Torque to 65 ft lbs CHECK VALVE Torque to 35 ft Ibs 1inch Hex 78 Figure 89 Hydraulic System Steering Cylinder Figure 90 1 Set Screw 10 Spacer 2 Threaded Cap 11 Servon 3 Rod 12 O Ring 4 Rod Wiper 13 Piston 5 U Cup 14 Locknut 6 Cap Head 15 Barrel Assembly 7 Backup Washer 16 Jam Nut 8 O Ring 17 Rod Tie End 9 O Ring 18 Roll Pin Steering Cylinder Repair IMPORTANT To prevent damage when clamping cylinder barrel or rod in a vise clamp only on pivotal ends 1 After removing cylinder pump oil out of cylinder in to a drain pan by SLOWLY moving rod and piston in and out of cylinder bore 2 Plug ports and clean outside of cylinder 3 Mount cylinder in a vise so piston rod end of cylinder is tilted up slightly Do not close vise so firmly that cylin der tube could become distorted 4 Loosen set screw and remove threaded cap 5 Grasp clevis end of piston rod and use a twisting and pulling motion to carefully extract piston piston rod and head from cylinder barrel Hydraulic System Page 4 88 6 Securely mount piston piston rod and head into vise and remove nut IMPORTANT Do not clamp vise jaws against smooth piston rod surface the piston rod will be come damaged 7 Remove piston Slide head off of piston
190. ut the tube and nut squarely into position on the face seal end of the fitting and tighten the nut until finger tight 5 Mark the nut and fitting body Hold the body with a wrench Use another wrench to tighten the nut to the cor rect flats from finger tight F F F T The markings on the nut and fitting body will verify that the connection has been tightened Size F F FT 4 1 4 in nominal hose or tubing 75 25 6 3 8 in 75 25 8 1 2 in 75 25 10 5 8 in 1 00 25 12 3 4 in 75 25 16 1 in 75 25 Reelmaster 4000 D Page 4 3 Before disconnecting or performing any work on hydraulic system all pressure in system must be relieved by stopping the engine and lowering or supporting the box and or other at tachment Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Use paper or cardboard not hands to search for leaks Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and do serious damage If fluid is injected into the skin it must be surgi cally removed within a few hours by a doctor familiar with this type of injury or gangrene may result Figure 1 Final Position Mark Nut and Body Initial Extend Line Position Finger Tight After Proper Tightening Figure 2 Hydraulic System SAE Straight Thread O Ring Port Non adjustable 1 Make sure both threads and sealing surfaces are f
191. utes to purge air from the system Stop the engine and check for leaks 6 Check hydraulic oil level see Check Hydraulic Sys tem Fluid Replace Hydraulic System Breather Change hydraulic system breather after every 800 oper ating hours or annually whichever comes first More often in extremely dusty or dirty conditions 1 Release latches and open engine cover 2 Clean around the breather and unscrew it with a wrench Install new breather Fig 94 3 Close engine cover and latch securely Replace Hydraulic Lines and Hoses Check hydraulic lines and hoses daily for leaks kinked lines loose mounting supports wear loose fittings Reelmaster 4000 D Page 4 91 Figure 93 1 Hydraulic oil filter 2 Steering pump NOTE Under certain conditions a bypass valve in the filter mounting plate allows oil to bypass the filter Before the filter starts to bypass a warning light on the steering console will illuminate The warning light may come on momentarily when the oil is cold If the light does not go out after the oil is warm the filter is clogged or an electri cal problem exists Correct problem before commenc ing operation B Figure 94 1 Breather 2 Exhaust shield weather deterioration and chemical deterioration Make all necessary repairs before operating Hydraulic System This Page Intentionally Left Blank Hydraulic System Page 4 92 Reelmaster 4000 D TORO Table of Cont
192. ve plate shield onto the reel drive motor flange Be sure the widest portion of the shield is at the top Fig 13 IMPORTANT Make sure motor pulley set screws are tight on the motor shaft before installing the motor onto the cutting unit Fig 14 2 Insert reel drive motor pulley through the housing and slip cutting unit drive belt over the pulley Fig 13 Note Proper belt tension is achieved when the belt deflects about 1 8 inch 3 mm at the mid point when 7 lb 31 of force is applied 3 Inserttwo 2 reel drive motor mounting bolts heads on the inside of the drive housing with flat washer on the top bolt through the reel motor flange holes Thread locknuts onto the bolts Rotate reel motor upward in the slotted hole in the housing to tension the drive belt Tighten fasteners to 25 ft lbs 34 Nm NOTE Fig 15 IMPORTANT Rotate motors by hand only Never place a bar between hose fittings on the hydraulic motors motor damage may result 4 Install gasket and drive housing cover after making sure the ends of the gasket are at the bottom of the hous ing to allow for drainage IMPORTANT When hydraulic motors have been mounted to the cutting units make sure hydraulic hoses lay flat and do not contact the frame of the machine when the cutting units are in the raised position There should also be sufficient slack so hoses are above and not in contact with the floata tion kit If hoses appear twisted once the hydrauli
193. wing the manufacturer s instructions con nect the charger cables to the battery Make sure a good connection is made 4 Charge the battery following the manufacturer s instructions 5 Occasionally check the temperature of the battery electrolyte If the temperature exceeds 125 F 51 690 or the electrolyte is violently gassing or spewing the charging rate must be lowered or temporarily stopped 6 Three hours prior to the end of the charging mea sure the specific gravity of a battery cell once per hour The battery is fully charged when the cells are gassing freely at a low charging rate and there is less than a 0 003 change in specific gravity for three consecutive readings Reelmaster 4000 D Rear Wheel Drive Solenoid Replacement CHECK VALVE 2 RM 4500 D 4WD Torque tp 35th MANIFOLD BLOCK CHECK VALVE Torque to 35 ft Ibs 1Inch Hex 1inch Hex LOGIC CARTRIDGE Ted Torque to 35 ftilbs 1Inch Hex CHECK VALVE SOLENOID CARTRIDGE Torque to 35 ft Ibs 51 Torque Cartridge to 12 ftllbs 1inch Hex 7 8 Inch Hex Torque Coil Retaining Nut tol5 in lbs Coil Resistance 7 2 Ohms CARTRIDGE Ic2 Torque to 65 ft Ibs 1 1 2 Inch Hex Figure 28 1 Disconnect solenoid electrical connector 2 Remove nut from solenoid 3 Remove solenoid coil 6 m E 4 Install new solenoid coil Make sure o ring is installed at each end of coil Apply
194. y the differential 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 differential pressure drops be tween 16 to 12 PSID the switch contact opens and the alarm and light go out The purpose of the oil filter switch warning light and alarm is to detect a clogged oil filter When the hydraulic oil is cold below 68 F 15 C the oil is thicker and causes a greater pressure drop across the filter This sit uation will cause the oil filter warning alarm and light to come on Push the silence button until the hydraulic oil warms up The warning light will stay on until the oil warms up about 5 to 15 minutes Checks 1 Turn off engine Disconnect electrical connector from the oil filter switch Check continuity across the Switch The switch should indicate open 2 If continuity across the switch indicates open the Switch is good A Check that the oil filter element or filter head is not clogged B Check circuitry to the alarm and warning light for for possible faults Before disconnecting or performing any work on hydraulic system all pressure in system must be relieved by stopping the engine and lowering or supporting the box and or other at tachment Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Use paper or cardboar

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