PART NO. 98958SL, Rev. A
Service Manual
ReelmasterR 4000–D
Preface
The purpose of this publication is to provide the service
technician with information for troubleshooting, testing,
and repair of major systems and components on the
Reelmaster 4000–D.
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.
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:
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing, or re-
pair of the machine.
The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420–1196
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 reserves the right to change product
specifications or this publication without notice.
E The Toro Company – 1998, 2003
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Table Of Contents
Chapter 1 – Safety
Chapter 4 – Hydraulic System
General Safety Instructions . . . . . . . . . . . . . . . . . . 1 – 1
Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 – 4
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 3
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . 4 – 8
Hydraulic Flow Diagrams . . . . . . . . . . . . . . . . . . . . 4 – 9
4WD Selector Valve Operation . . . . . . . . . . . . . . 4 – 24
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 26
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 28
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 30
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 4 – 39
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 5 – Electrical System
Chapter 3 – Kubota Diesel Engine
Electrical Schematics and Diagrams . . . . . . . . . . 5 – 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 14
Electrical System Quick Checks . . . . . . . . . . . . . 5 – 17
Component Testing . . . . . . . . . . . . . . . . . . . . . . . . 5 – 18
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 5 – 29
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 3
General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 – 4
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 7
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 3 – 8
KUBOTA WORKSHOP MANUAL, 03 SERIES,
DIESEL ENGINE
Chapter 6 – Axles and Brakes
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 2
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 3
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 6 – 5
Chapter 7 – Cutting Units
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 3
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 4
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 7 – 8
Reelmaster 4000–D
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Reelmaster 4000–D
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Chapter 1
Safety
Table of Contents
GENERAL SAFETY INSTRUCTIONS . . . . . . . . . . . . 1
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Maintenance and Service . . . . . . . . . . . . . . . . . . . . 3
SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 4
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.
WARNING
To reduce the potential for injury or death,
comply with the following safety instructions.
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:
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.
The Toro Company
8111 Lyndale Avenue South
Minneapolis, MN 55420–1196
8. Do not carry passengers on the machine. Keep ev-
eryone, especially children and pets, away from the
areas of operation.
2. Never allow children to operate the machine or
adults to operate it without proper instruction.
9. Since diesel fuel is highly flammable, handle it care-
fully:
3. Become familiar with the controls and know how to
stop the machine and engine quickly.
A. Use an approved fuel container.
4. Keep all shields, safety devices and decals in place.
If a shield, safety device or decal is defective or dam-
aged, repair or replace it before operating the machine.
B. Do not remove fuel tank cap while engine is hot
or running.
C. Do not smoke while handling fuel.
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.
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.
Reelmaster 4000–D
Safety
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While Operating
10. Do not run engine in a confined area without ade-
quate ventilation. Exhaust is hazardous and could be
deadly.
17. Traverse slopes carefully. Do not start or stop sud-
denly when traveling uphill or downhill.
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.
11. Sit on the seat when starting and operating the ma-
chine.
12. Check interlock switches daily for proper operation.
If a switch fails, replace it before operating the machine.
The interlock system is for your protection, so do not by-
pass it. Replace all interlock switches every two years.
19. When operating 4 wheel drive machine, always use
the seat belt and ROPS together and have seat pivot re-
taining pin installed.
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.
20. If engine stalls or loses headway and cannot make
it to the top of a slope, do not turn machine around. Al-
ways back slowly straight down the slope.
21. Raise cutting units and latch them securely in trans-
14. Before starting the engine each day, test lamps,
warningbuzzerandsignallightstoassureproperopera-
tion.
port position before driving from one work area to anoth-
er.
22. Do not touch engine, muffler or exhaust pipe while
engineisrunningorsoonafteritisstopped. Theseareas
could be hot enough to cause burns.
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.
23. If cutting unit strikes a solid object or vibrates abnor-
mally, stop immediately, turn engine off, set parking
brakeandwaitforallmotiontostop. Inspectfordamage.
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
andBACKLAP. Damage to hydraulic system may result.
Lever should easily return and hold in the STOP posi-
tion.
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.
24. Before getting off the seat:
A. Move traction pedal to neutral.
B. Set parking brake.
E. Look to the rear to assure no one is behind the
machine before backing up.
C. Disengage cutting units and wait for reels to
stop.
F. Watch for traffic when near or crossing roads. Al-
ways yield the right–of–way.
D. Stop engine and remove key from switch.
G. Reduce speed when driving downhill.
E. Do not park on slopes unless wheels are
chocked or blocked.
16. Keep hands, feet, andclothing away from moving
parts and the reels.
25. The optional 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.
Safety
Reelmaster 4000–D
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Maintenance and Service
26. Before servicing or making adjustments, stop en-
gine and remove key from the switch.
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.
27. Assure entire machine is properly maintained and
in good operating condition. Frequently check all nuts,
bolts and screws.
35. Shut engine off before checking or adding oil to the
crankcase.
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.
36. Disconnect battery before servicing the machine. If
battery voltage is required for troubleshooting or test
procedures, temporarily connect the battery.
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.
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.
30. Before any hydraulic system maintenance, stop en-
gine and lower cutting units to the ground so all pressure
is relieved.
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 injury.
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 other
parts of the body away from cutting units and other mov-
ing parts. Keep everyone away.
Reelmaster 4000–D
Safety
Page 1 – 3
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Safety and Instruction Decals
The following safety and instruction decals are installed on the Reelmaster 4000–D. If any become damaged
or illegible, replace them. Decal part numbers are listed below and in the parts catalog. Order replacements
from your Authorized Toro Distributor.
ON LIFT ARMS
(Part No. 93–7331)
ON PANEL IN FRONT OF OPERATOR’S SEAT
(Part No. 93–9408)
ON STEERING CONSOLE
(Part No. 93–9399)
ON LEFT SIDE OF MACHINE
ON FRAME ABOVE RIGHT REAR WHEEL
(Part No. 93–9406)
(Part No. 88–6700)
ON RIGHT CONTROL PANEL
(Part No. 98–3830)
NEXT TO LIFT LEVERS
(Part No. 93–9407)
Safety
Reelmaster 4000–D
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Safety and Instruction Decals
ON FRAME ABOVE REAR WHEELS
(Part No.93–9405)
NEAR RADIATOR FILL CAP
(Part No. 93–9404)
ON FAN SHROUD
(Part No. 93–6681)
UNDER SEAT NEAR OIL FILL CAP
(Part No. 93–8067)
ON CUTTING UNIT
(Part No. 76–8760)
NEAR FUEL TANK FILL CAP
(Part No. 93–6680)
ON RADIATOR CAP
(Part No. 59–8440)
NEXT TO TRACTION PEDAL ON STEERING CONSOLE
(Part No. 93–9397)
Reelmaster 4000–D
Safety
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Safety and Instruction Decals
ON FRONT CARRIER & TOW BAR
(Part No. 93–9400)
ON RIGHT CONTROL PANEL
(Part No. 93–9402)
ON EXHAUST SHIELD
(Part No. 95–0645)
ON FRONT ACCESS PANEL
(Part No. 93–9425)
Safety
Reelmaster 4000–D
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Chapter 2
Product Records and Maintenance
Table of Contents
PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 1
EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . 2
Decimal and Millimeter Equivalents . . . . . . . . . . . . 2
U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . 2
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 & SERVICE HISTORY REPORTS . . . 9
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.
Insert Operator’s Manuals and Parts Catalogs for your
Reelmaster 4000–D at the end of this section.
Reelmaster 4000–D
Product Records and Maintenance
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Equivalents and Conversions
Product Records and Maintenance
Reelmaster 4000–D
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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.
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.
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 a thread 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.
The standard method of verifying torque 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.
Fastener Identification
Grade 1
Grade 5
Grade 8
Class 8.8
Class 10.9
Inch Series Bolts and Screws
Metric Bolts and Screws
Reelmaster 4000–D
Product Records and Maintenance
Page 2 – 3
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Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)
Grade 1, 5, &
8 with Thin
SAE Grade 1 Bolts, Screws, Studs, &
Sems with Regular Height Nuts
SAE Grade 5 Bolts, Screws, Studs, &
Sems with Regular Height Nuts
SAE Grade 8 Bolts, Screws, Studs, &
Sems with Regular Height Nuts
Thread Size
Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
(SAE J995 Grade 2 or Stronger Nuts)
(SAE J995 Grade 5 or Stronger Nuts)
in–lb
in–lb
N–cm
in–lb
15 + 2
N–cm
170 + 20
190 + 20
330 + 30
350 + 30
475 + 45
540 + 45
1125 + 100
1300 + 100
2250 + 280
2540 + 280
N–m
in–lb
23 + 2
N–cm
260 + 20
280 + 20
460 + 45
485 + 45
675 + 70
765 + 70
1580 + 170
1800 + 170
3390 + 340
3670 + 340
N–m
# 6 – 32 UNC
# 6 – 40 UNF
# 8 – 32 UNC
# 8 – 36 UNF
# 10 – 24 UNC
# 10 – 32 UNF
1/4 – 20 UNC
1/4 – 28 UNF
5/16 – 18 UNC
5/16 – 24 UNF
10 + 2
13 + 2
147 + 23
17 + 2
25 + 2
29 + 3
41 + 4
13 + 2
18 + 2
25 + 5
30 + 5
282 + 30
339 + 56
31 + 3
43 + 4
42 + 4
60 + 6
48 + 4
68 + 6
48 + 7
53 + 7
53 + 7
65 + 10
105 + 17
128 + 17
ft–lb
599 + 79
734 + 113
1186 + 169
1446 + 192
N–m
100 + 10
115 + 10
200 + 25
225 + 25
ft–lb
140 + 15
160 + 15
300 + 30
325 + 30
ft–lb
115 + 15
138 + 17
ft–lb
3/8 – 16 UNC
3/8 – 24 UNF
7/16 – 14 UNC
7/16 – 20 UNF
1/2 – 13 UNC
1/2 – 20 UNF
5/8 – 11 UNC
5/8 – 18 UNF
3/4 – 10 UNC
3/4 – 16 UNF
7/8 – 9 UNC
16 + 2
16 + 2
22 + 3
30 + 3
41 + 4
43 + 4
58 + 5
17 + 2
18 + 2
24 + 3
35 + 3
47 + 4
50 + 4
68 + 5
27 + 3
27 + 3
37 + 4
50 + 5
68 + 7
70 + 7
95 + 9
29 + 3
29 + 3
39 + 4
55 + 5
75 + 7
77 + 7
104 + 9
30 + 3
48 + 7
65 + 9
75 + 8
102 + 11
115 + 11
203 + 20
230 + 20
359 + 34
407 + 34
583 + 61
644 + 61
105 + 10
120 + 10
210 + 20
240 + 20
375 + 35
420 + 35
600 + 60
660 + 60
142 + 14
163 + 14
285 + 27
325 + 27
508 + 47
569 + 47
813 + 81
895 + 81
32 + 3
53 + 7
72 + 9
85 + 8
65 + 10
75 + 10
93 + 12
115 + 15
140 + 20
155 + 25
88 + 12
95 + 15
140 + 20
165 + 25
225 + 25
260 + 30
119 + 16
129 + 20
190 + 27
224 + 34
305 + 34
353 + 41
150 + 15
170 + 15
265 + 25
300 + 25
430 + 45
475 + 45
7/8 – 14 UNF
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.
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Note: The nominal torque values listed above for
Grade 5 and 8 fasteners are based on 75% of the mini-
mum proof load specified in SAE J429. The tolerance is
approximately + 10% of the nominal torque value. Thin
height nuts include jam nuts.
Note: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
Product Records and Maintenance
Reelmaster 4000–D
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Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners)
Class 8.8 Bolts, Screws, and Studs with
Regular Height Nuts
Class 10.9 Bolts, Screws, and Studs with
Thread Size
Regular Height Nuts
(Class 10 or Stronger Nuts)
(Class 8 or Stronger Nuts)
M5 X 0.8
M6 X 1.0
57 + 5 in–lb
96 + 9 in–lb
19 + 2 ft–lb
38 + 4 ft–lb
66 + 7 ft–lb
166 + 15 ft–lb
325 + 33 ft–lb
640 + 60 N–cm
1018 + 100 N–cm
26 + 3 N–m
78 + 7 in–lb
885 + 80 N–cm
1500 + 150 N–cm
36 + 3 N–m
133 + 13 in–lb
27 + 2 ft–lb
M8 X 1.25
M10 X 1.5
M12 X 1.75
M16 X 2.0
M20 X 2.5
52 + 5 N–m
53 + 5 ft–lb
72 + 7 N–m
90 + 10 N–m
225 + 20 N–m
440 + 45 N–m
92 + 9 ft–lb
125 + 12 N–m
310 + 30 N–m
610 + 50 N–m
229 + 22 ft–lb
450 + 37 ft–lb
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.
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Note: The nominal torque values listed above are
based on 75% of the minimum proof load specified in
SAEJ1199. The tolerance is approximately +10% of the
nominal torque value.
Note: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
Reelmaster 4000–D
Product Records and Maintenance
Page 2 – 5
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Other Torque Specifications
SAE Grade 8 Steel Set Screws
Wheel Bolts and Lug Nuts
Thread Size Recommended Torque**
65 + 10 ft–lb 88 + 14 N–m
Recommended Torque
Thread Size
Square Head
140 + 20 in–lb
215 + 35 in–lb
35 + 10 ft–lb
75 + 15 ft–lb
Hex Socket
73 + 12 in–lb
145 + 20 in–lb
18 + 3 ft–lb
7/16 – 20 UNF
Grade 5
1/4 – 20 UNC
5/16 – 18 UNC
3/8 – 16 UNC
1/2 – 13 UNC
1/2 – 20 UNF
Grade 5
80 + 10 ft–lb 108 + 14 N–m
80 + 10 ft–lb 108 + 14 N–m
80 + 10 ft–lb 108 + 14 N–m
M12 X 1.25
Class 8.8
50 + 10 ft–lb
M12 X 1.5
Class 8.8
** For steel wheels and non–lubricated fasteners.
Thread Cutting Screws
(Zinc Plated Steel)
Thread Cutting Screws
(Zinc Plated Steel)
Thread Threads per Inch
Size
Type 1, Type 23, or Type F
Baseline Torque*
Type A Type B
Thread Size
Baseline Torque*
20 + 5 in–lb
No. 6
No. 8
18
15
12
11
20
18
16
14
20 + 5 in–lb
30 + 5 in–lb
38 + 7 in–lb
85 + 15 in–lb
No. 6 – 32 UNC
No. 8 – 32 UNC
No. 10 – 24 UNC
1/4 – 20 UNC
30 + 5 in–lb
No. 10
No. 12
38 + 7 in–lb
85 + 15 in–lb
110 + 20 in–lb
200 + 100 in–lb
* Hole size, material strength, material thickness & finish
must be considered when determining specific torque
values. All torque values are based on non–lubricated
fasteners.
5/16 – 18 UNC
3/8 – 16 UNC
Conversion Factors
in–lb X 11.2985 = N–cm
N–cm X 0.08851 = in–lb
ft–lb X 1.3558 = N–m
N–m X 0.7376 = ft–lb
Product Records and Maintenance
Reelmaster 4000–D
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Lubrication
Note: Remove plastic caps over the fittings on the
floating or fixed head pivots and replace caps after
greasing (Fig. 3).
GREASING BEARINGS AND BUSHINGS
The machine has grease fittings that must be lubricated
afterevery50hoursofoperationwithNo. 2GeneralPur-
poseLithiumBaseGrease. Lubricatefittingimmediately
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 3
Floating of Fixed Kit Pivots (1 fitting per head)
(Floating Kit Shown)
Figure 1
Lift arms (5 fittings total)
Figure 4
Reel and Roller Bearings
(2 fittings per reel & 2 fittings per roller)
1. Park machine on a level surface. Stop engine. Re-
move key from the ignition switch.
Figure 2
Rear Axle (3 Fittings per side)
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.
Reelmaster 4000–D
Product Records and Maintenance
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Product Records and Maintenance
Reelmaster 4000–D
Page 2 – 8
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EQUIPMENT OPERATION AND SERVICE HISTORY REPORT
for
REELMASTERR 4000–D
TORO Model and Serial Number: ______________–______________
Engine Numbers:
_____________________________
Transmission Numbers:
Drive Axle(s) Numbers:
Date Purchased:
_____________________________
_____________________________
_____________________________ Warranty Expires____________
_____________________________
Purchased From:
_____________________________
_____________________________
Contacts:
Parts
_____________________________ Phone____________________
_____________________________ Phone____________________
_____________________________ Phone____________________
Service
Sales
Reelmaster 4000–D
Product Records and Maintenance
Page 2 – 9
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Reelmaster 4000–D Maintenance Schedule
Minimum Recommended Maintenance Intervals
Maintenance Procedure
Maintenance Interval & Service
Every
800hrs
Every
400hrs
Every
200hrs
Every
100hrs
Lubricate Reel Control Valve Grease Fitting
Lubricate Reel Speed Valve with Oil
Lubricate All Grease Fittings
Every
50hrs
A Level
Service
Check Battery Condition and Connections
} Change Engine Oil and Filter
Drain Water from Hydraulic Tank
{ Check Engine Fan and Alternator Belt
Inspect Cooling System Hoses
B Level
Service
Inspect Cutting Unit Reel Drive Belts
C Level
Service
{ Torque Wheel Lug Nuts
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
Check Rear Wheel Toe–in
E Level
Service
{ Initial break in at 10 hours
} Initial break in at 50 hours
Replace Moving Hydraulic Hoses
Replace Safety Switches
Annual Recommendations:
Items listed are recommended every 1500
hours or 2 years, whichever occurs first.
Coolant System – Flush/Replace Fluid
Change Hydraulic Oil
(See Operator’s and Service Manual for specifications and procedures)
Product Records and Maintenance
Reelmaster 4000–D
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Reelmaster 4000–D Daily Maintenance Checklist
Daily Maintenance: (duplicate this page for routine use)
Check proper section of Operator’s Manual for fluid specifications
Daily Maintenance Check For Week Of _________________
Maintenance
Check Item b
MON
TUES
WED
THURS
FRI
SAT
SUN
n Safety Interlock Operation
n Parking Brake Operation
n Engine Oil Level
n Fuel Level
n Cooling System Fluid Level
Drain Water/Fuel Separator
n Air Filter Restriction Indicator
n Radiator, Oil Cooler and
1
Screen for Debris
Clean Traction Pedal Lockout
2
n Unusual Engine Noises
n Unusual Operating Noises
n Hydraulic System Oil Level
n Hydraulic Hoses for Damage
n Fluid Leaks
n Tire Pressure
n Instrument Operation
n Warning Lamps Operation
n Reel–to–Bedknife Adjustment
n Height–of–Cut Adjustment
3
Lubricate All Grease Fittings
Touch–up Damaged Paint
1
= Use only low pressure compressed air for debris removal. Do not use water.
2
3
= Check glow plugs and injector nozzles, if hard starting excess smoke or rough running is noted.
= Immediately after every washing, regardless of the interval listed.
Notation for areas of concern: Inspection performed by_____________________________
Item
Date
Information
1
2
3
4
5
6
7
8
Reelmaster 4000–D
Product Records and Maintenance
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Product Records and Maintenance
Reelmaster 4000–D
Page 2 – 12
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Chapter 3
Kubota Diesel Engine
Table of Contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4
Check Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Check Cooling System . . . . . . . . . . . . . . . . . . . . . . . 5
Fill Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Prime Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Adjust Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . 7
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 8
Service Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Change Engine Oil and Filter . . . . . . . . . . . . . . . . . 9
Drain Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . 10
Check Fuel Lines and Connections . . . . . . . . . . . . 11
Replace Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . 12
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . 16
KUBOTA WORKSHOP MANUAL, 03 SERIES, DIESEL
ENGINE
Reelmaster 4000–D
Page 3 – 1
Kubota Diesel Engine
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Introduction
This Chapter gives information about specifications,
maintenance, troubleshooting, testing, and repair of the
diesel engine used in the Reelmaster 4000–D.
test equipment and the specialized nature of some re-
pairs may dictate that the work be done at an engine re-
pair facility.
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
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 yourdistrib-
utor with the Toro model and serial number.
Kubota Diesel Engine
Reelmaster 4000–D
Page 3 – 2
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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
103 ft–lb @ 1600 RPM
1 – 3 – 4 – 2
Torque
Firing Order
Bore mm (in.)
87.0 (3.43)
Stroke mm (in.)
Total Displacement cc (cu. in.)
Fuel
92.0 (3.64)
2197 (134.07)
No. 2 Diesel Fuel per ASTM D975
56.8 (15.0)
Fuel Capacity liters (gallons)
Fuel Pump
Bosch Type Mini pump
Centrifugal flyweight Mechanical Type
1250 + 50 RPM
Governor
Low Idle (no load)
High Idle (no load)
Compression Ratio
Rotation
2500 + 50 RPM
23.0 : 1
Counterclockwise Facing Flywheel
Bosch Throttle Type
SAE 10W30 SF or CD
Trochoid Type
Injection Nozzles
Engine Oil
Oil Pump
Crankcase Oil Capacity liters (U.S. qt.)
Starter
7.6 (8.0) with filter
12 VDC 1.4 KW
Alternator/Regulator
Weight Kg (Lb.)
Engine Coolant Capacity liters (U.S. qt.)
Timing
12 VDC 40 AMP
190 (418)
14.0 (14.8)
BTDC 17 to 19 Degrees
Reelmaster 4000–D
Page 3 – 3
Kubota Diesel Engine
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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).
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.
1
Figure 2
1. Dipstick
1
Figure 3
1. Oil fill cap
Kubota Diesel Engine
Reelmaster 4000–D
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Check Cooling System
Check level of coolant at the beginning of each day. Ca-
pacity of system is 3.7 gal. (14 L).
1
CAUTION
2
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-
sion tank cap (Fig. 5).
1. Radiator cap
2. Rear screen
3. Check level of coolant in radiator. Radiator should
be filled to the top of the filler neck and the expansion
tank filled to the marks on its side.
IMPORTANT: Do not use water only. Do not use al-
cohol / methanol base coolants.
1
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. Fill tank to about one inch (25 mm) below bottom of
filler neck with No. 2 diesel fuel. Then install cap.
1
2
Figure 6
1. Fuel tank cap
2. Left rear tire
Reelmaster 4000–D
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Kubota Diesel Engine
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Prime Fuel System
IMPORTANT: The fuel system must be primed when
a new engine is started for the first time, if it runs out
of fuel, or if maintenance is performed on the fuel
system.
2
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).
3
4
1. Park machine on a level surface. Stop engine. Re-
move key from the ignition switch.
1
Figure 7
2. Raise engine cover.
1. Bleed knob
3. Fuel pump
2. Injection pump
4. Priming lever
3. Insert a 3/16–inch hose over the bleed screw, and
runtheotherendofthehoseintoacontainertocatchthe
fuel (Fig. 8).
1
IMPORTANT: Priming fuel filter without opening
bleed screw may damage priming plunger.
4. Loosen fuel filter/water separator bleed screw a few
turns. Pumpprimingplungeruntilasteadystreamoffuel
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).
2
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.
Figure 8
1. Primer plunger
2. Bleed screw
5. Pump priming plunger until resistance is felt. Try to
start engine. If engine does not start repeat step 4.
Kubota Diesel Engine
Reelmaster 4000–D
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Adjustments
Adjust Alternator Belt
Check condition and tension of belt after every 100 op-
erating hours (Fig. 9).
1
1. Park machine on a level surface. Stop engine. Re-
move key from the ignition switch.
2
2. Proper belt tension will allow 3/8 inch (10 mm)
deflection when a force of 10 lbs (44.4 N) 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
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Kubota Diesel Engine
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Service and Repairs
Service Air Cleaner
1. Park machine on a level surface. Stop engine. Re-
move key from the ignition switch.
2. Remove knobs securing rear screen to frame . Re-
move rear screen (Fig. 10).
3. Check air cleaner body for damage which could
possibly cause an air leak. Replace a damaged air
cleaner body (Fig. 11).
2
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.
1
5. Be sure cover is sealing around air cleaner body
(Fig. 11).
Figure 10
1. Rear screen
2. Knob
6. Release latches securing air cleaner cover to air
cleaner body. Separate cover from body. Clean inside of
air cleaner cover (Fig. 11).
2
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.
1
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.
Figure 11
1. Air cleaner body
2. Air cleaner cover
8. Inspectprimaryfilteranddiscardifdamaged. Donot
wash or reuse a damaged filter.
Compressed Air Method
Washing 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.
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. 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.
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.
Rinse filter from clean side to dirty to side.
9. Inspect new filter for shipping damage. Check seal-
ing end of filter. Do not install a damaged filter.
C. Dry filter element using warm, flowing air of not
o
o
greater than 160 F (71 C), or allow element to air–
dry. Do not use a light bulb to dry the filter element
because damage could result.
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.
Kubota Diesel Engine
Reelmaster 4000–D
Page 3 – 8
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Change Engine Oil and Filter
Change oil and filter after the first 50 hours of operation
and every 100 hours thereafter.
1. Remove drain plug and let oil flow into drain pan.
When oil stops, install drain plug (Fig. 12).
2. Remove oil filter. Apply a light coat of clean oil to the
newfiltersealbeforescrewingiton. Donotovertighten
filter (Fig.13).
1
2
3. Add oil to crankcase (see Check Engine Oil).
Figure 12
1. Drain plug
2. Starter
1
2
Figure 13
1. Oil filter
2. Fuel filter/water seperator
Reelmaster 4000–D
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Kubota Diesel Engine
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Drain Fuel System
3
DANGER
Becausedieselfuelishighlyflammable, usecau-
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.
1
2
Fuel Tank
Figure 14
Drain and clean fuel tank every 800 hours of operation
or yearly, whichever comes first. Also, drain and clean
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.
1. Fuel filter/water separator 3. Priming plunger
2. Drain screw
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. Tighten drain screw.
Kubota Diesel Engine
Reelmaster 4000–D
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Check Fuel Lines and Connections
Check lines and connections every 400 hours or yearly,
whichever comes first. Inspect for deterioration, dam-
age, or loose connections.
Replace Fuel Filter
DANGER
1
2
Becausedieselfuelishighlyflammable, usecau-
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.
Figure 15
1. In–line fuel filter
2. Fuel tank
There are 2 fuel filters on the RM 4000–D. A small in–
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
1. Park machine on a level surface. Stop engine. Re-
move key from the ignition switch.
3
2. Unscrew bottom filter cap from filter assembly. Re-
movecap, gaskets, o-ringandfilterfromassembly. Note
position of gaskets and o-ring when disassembling from
filter.
2
3. Install new filter, gaskets, o-ring with filter assembly
cap.
Figure 16
1. Fuel filter/water separator 3. Filter
2. Filter cap
4. Prime fuel system, refer to Priming Fuel System.
Reelmaster 4000–D
Page 3 – 11
Kubota Diesel Engine
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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
2. Releasefrontenginecoverlatchesandraiseengine
cover. Clean engine area thoroughly of all debris.
3. Remove knobs securing rear screen to frame and
remove screen (Fig. 17).
1
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).
Figure 17
1. Rear screen
2. Knob
5. Pivot oil cooler back into position and install rear
screen.
6. Lower engine cover and secure latches.
2
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
1. Park machine on a level surface. Stop engine. Re-
move key from the ignition switch.
Figure 18
1. Oil cooler
2. Radiator
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
thecoolingsystem. Addanti–freeze(seeCheckCooling
System).
Kubota Diesel Engine
Reelmaster 4000–D
Page 3 – 12
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Engine
Engine Removal
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
2. Pivot seat up. Lift front canopy and remove from the
brackets (Fig. 19).
1
2
Figure 19
1. Canopy
2. Brackets
3. Disconnect and remove battery from the machine
(see Battery Service in Chapter 5 – Electrical Systems).
5
2
11
4
10
CAUTION
6
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.
12
8
9
1
3
7
4. Drain radiator. Disconnect both hoses from the ra-
diator (Fig. 20).
Figure 20
1. Battery
7. Starter
2. Upper radiator hose
3. Lower radiator hose
4. Fan guard
5. Fan shroud
6. Exhaust shield
8. OIl pressure switch
9. Alternator
10. Air hose
11. Hi temp. warning switch
12. Hi temp. cutout switch
5. Remove air hose from air intake manifold (Fig. 20).
6. Remove exhaust shield from the engine (Fig. 20).
7. Remove fan guard and fan shroud from the radiator
(Fig. 20).
1
8. Remove fan from the fan pulley. Remove fanshroud
and fan from machine (Fig. 21). Remove fan shroud
from the machine.
2
3
Figure 21
1. Fan
3. Cap screws
2. Fan pulley
Reelmaster 4000–D
Page 3 – 13
Kubota Diesel Engine
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9. Clamp to prevent drainage, and disconnect the fol-
lowing fuel hoses:
1
A. Suction hose at the injector pump from the fuel
filter. Suction and discharge hoses at the fuel pump
(Fig. 22).
4
B. Return hose from the fuel injectors (Fig. 23).
3
2
Figure 22
1. Injector pump suction
2. Fuel pump suction
3. Fuel pump discharge
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).
2
1
B. Disconnect electrical connector from the fuel so-
lenoid (Fig. 22).
C. Disconnect red/black wire from the glow plug
bus bar (Fig. 23).
5
Figure 23
1. Injector return hose
2. Glow plug wire
3. Exhaust tube
4. Bracket
5. Lift tab
11. Disconnect throttle control cable from the swivel le-
ver and R–clamp from the engine plate (Fig. 24).
1
2
3
6
3
2
4
4
5
Figure 24
1. Throttle control cable
2. R–clamp
3. Swivel
4. Swivel lever
5. Engine plate
6. Screw
Kubota Diesel Engine
Reelmaster 4000–D
Page 3 – 14
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12. Separate hydraulic pump assembly from the engine
(Fig. 25).
3
4
A. Disconnect damper from the bracket.
B. Remove four cap screws, lock washers, and flat
washers securing the pump mounting flange to the
pump adapter plate.
1
5
C. Support pump, and pull pump shaft from the
spring coupling.
2
4
Figure 25
1. Damper
2. Bracket
4. Pump adapter plate
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).
9
4
5
14. Remove hex nut, spring washer, cap screw, and flat
washers securing both front brackets to the engine
mounts (Fig. 26).
1
3
2
15. Connect hoist or lift to the engine.
10
9
CAUTION
8
Make sure lift or hoist can support the total
weight of the engine before removing the cap
screws from the rear bracket and engine.
1
6
7
Figure 26
16. Remove three cap screws and lock washers secur-
ing the engine to the rear bracket and spacer (Fig. 27).
1. Cap screw
6. Cap screw
2. Upper exhaust tube
3. Exhaust bracket
4. Hex nut
7. Flat washer
8. Flat washer
9. Front bracket
10. Engine mount
5. Spring washer
CAUTION
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,
fuel and hydraulic lines, electrical harness, or other
parts while removing the engine.
1
2
17. Removeengineslowlyfromthemachine. Savegas-
ket for exhaust tube (Fig. 26).
Figure 27
1. Rear bracket & spacer
2. Cap screw & lock washer
Reelmaster 4000–D
Page 3 – 15
Kubota Diesel Engine
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Engine Installation
C. Connect red/black wire to the glow plug bus bar
(Fig. 23).
8. Connect the following fuel hoses:
CAUTION
A. Suction hose at the injector pump from the fuel
filter. Suction and discharge hoses at the fuel pump
(Fig. 22).
One person should operate lift or hoist while the
other person guides the engine into the frame.
B. Return hose from the fuel injectors (Fig. 23).
C. Remove clamps used to prevent drainage.
1. Install engine to the front engine mounts and rear
brackets.
9. Position fan shroud to the radiator. Install fan to the
fan pulley (Fig. 21).
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.
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).
B. Placegasket onto exhaust bracket to receive ex-
haust tube (Fig. 26).
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).
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).
13. Install battery the machine and connect cables (see
Battery Service in Chapter 5 – Electrical Systems).
3. Secureenginetothespacersandrearbracketswith
three cap screws and lock washers. Torque cap screws
from 61 to 75 ft–lb (8.4 to 10.4 kg–m) (Fig. 27).
14. Connect both hoses to the radiator (Fig. 20).
15. Secure canopy to the brackets (Fig. 19).
4. Secure exhaust tube and gasket to the exhaust
bracket with three cap screws and lock nuts (Fig. 26).
16. Fill radiator with coolant (see Check Cooling Sys-
tem).
5. Connect hydraulic pump assembly to the engine
(Fig. 25).
17. Adjust control cable throttle cable (Fig. 24).
A. Push throttle lever to the FAST position.
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).
B. Loosenscrewonswivelthatsecuresthecableto
the swivel lever.
C. Adjust position of swivel lever with cable so the
injector pump lever is contacting the stop in the full
throttle position.
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).
D. Secure cable to swivel with screw.
18. Prime fuel system (see Prime Fuel System).
19. Check traction pedal adjustment for NEUTRAL.
7. Connect wire harness and electrical wires to the en-
gine as follows:
A. Connect wire 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
Reelmaster 4000–D
Page 3 – 16
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Chapter 4
Hydraulic System
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic Fitting Installation . . . . . . . . . . . . . . . . . . . 3
Pushing or Towing Traction Unit . . . . . . . . . . . . . . . 5
Check Hydraulic System Fluid . . . . . . . . . . . . . . . . . 7
HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . 8
HYDRAULIC FLOW DIAGRAMS . . . . . . . . . . . . . . . . 9
General Pump Flow . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine Run – No Functions . . . . . . . . . . . . . . . . . . 10
Traction Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Traction Circuit – Forward . . . . . . . . . . . . . . . . . . . 12
Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Steering Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Lift/Lower Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Lift Circuit – Lift All Units . . . . . . . . . . . . . . . . . . . . . 16
Lift Circuit – Lower All Units . . . . . . . . . . . . . . . . . . 17
Lift Circuits – Free Float (Detent) . . . . . . . . . . . . . 18
Reel Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Reel Circuit – All Units Mow (Free Float) . . . . . . . 20
Reel Circuit – Units 1, 2 & 3 Mow (Free Float) . . 21
Reel Circuit – Units 1, 2, 3 & 5 (Free Float) . . . . 22
Reel Circuit – Any Unit Backlap . . . . . . . . . . . . . . 23
4WD SELECTOR VALVE OPERATION . . . . . . . . . 24
4WD Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2WD Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Hydraulic Tester with Pressure and Flow
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Precautions for Hydraulic Testing . . . . . . . . . . . . . 30
Test No. 1: Check Traction Working
and Relief Pressures . . . . . . . . . . . . . . . . . . . . . . . 31
Test No. 2: Check Counterbalance
Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Unit . . . . . . . . . . . . . . . . . . . . . . . . 40
Add Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . 51
Drain Water from Hydraulic Reservoir . . . . . . . . . 51
Reel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Lift Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Priority Flow Divider . . . . . . . . . . . . . . . . . . . . . . . . 60
Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Reel Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Reel Shut Off Valve . . . . . . . . . . . . . . . . . . . . . . . . . 66
Traction Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Front Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . 74
Reel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Hydraulic Pressure Test Kit . . . . . . . . . . . . . . . . . . 27
Hydraulic Fitting Kit . . . . . . . . . . . . . . . . . . . . . . . . . 27
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 28
Hydraulic Oil Leak(s) . . . . . . . . . . . . . . . . . . . . . . . . 28
Slow or No Traction in Either Direction . . . . . . . . 28
Reels Slow or Won’t Turn . . . . . . . . . . . . . . . . . . . . 28
Steering Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Cutting Units Lift Slow or Won’t Lift . . . . . . . . . . . 29
Cutting Units Won’t Drop
or Follow Ground Contours . . . . . . . . . . . . . . . . . 29
Reelmaster 4000–D
Hydraulic System
Page 4 – 1
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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
Gear pump
Cutting Circuit Relief Pressure
2650 – 2750 PSI
Reel Motor
Cross–over Relief Pressure
Gear Motor
1500 PSI
Lift Control Valve
Lift Relief Pressure
Spool type directional control valve
2650 – 2900 PSI
Counterbalance Pressure (Max. RPM)
Hot oil 500 – 550 PSI, cold oil 600 – 650 PSI
Hydraulic Filter (Fig. 1)
Hydraulic Oil
Spin–on cartridge type
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
Reelmaster 4000–D
Page 4 – 2
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General Information
Hydraulic Hoses
Hydraulic hoses are subject to extreme conditions such
as, pressuredifferentialsduringoperationandexposure
to weather, sun, chemicals, very warm storage condi-
tions or mishandling during operation or maintenance.
Theseconditionscancausedamageorprematuredete-
rioration. Some hoses are more susceptible to these
conditions than others. Inspect the hoses frequently for
signs of deterioration or damage.
WARNING
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.
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.
Usetwowrenches;onetoholdthehosestraightandone
to tighten the hose swivel nut onto the fitting.
Keepbodyandhandsawayfrompinholeleaks
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.
Hydraulic Fitting Installation
O–Ring Face Seal
Nut
Body
1. Make sure both threads and sealing surfaces are free
of burrs, nicks, scratches, or any foreign material.
Sleeve
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.
Seal
3. Lubricate the O–ring with a light coating of oil.
4. Put the tube and nut squarely into position on the face
seal end of the fitting and tighten the nut until finger tight.
Figure 1
5. Mark the nut and fitting body. Hold the body with a
wrench. Useanotherwrenchtotightenthenuttothecor-
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.
Final
Position
Size
F.F.F.T.
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
.75 + .25
.75 + .25
.75 + .25
1.00 + .25
.75 + .25
.75 + .25
Mark Nut
and Body
Initial
Extend Line
Position
16 (1 in.)
Finger Tight
After Proper Tightening
Figure 2
Reelmaster 4000–D
Hydraulic System
Page 4 – 3
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SAE Straight Thread O–Ring Port – Non–adjustable
1. Make sure both threads and sealing surfaces are free
of burrs, nicks, scratches, or any foreign material.
2. Always replace the O–ring seal when this type of fit-
ting shows signs of leakage.
O–Ring
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.).
Figure 3
Size
F.F.F.T.
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
1.00 + .25
1.50 + .25
1.50 + .25
1.50 + .25
1.50 + .25
1.50 + .25
16 (1 in.)
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.
Lock Nut
3. Lubricate the O–ring with a light coating of oil.
Back–up Washer
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).
O–Ring
Figure 4
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).
Step 1
Step 2
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
F.F.F.T.
Step 4
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
1.00 + .25
1.50 + 25
1.50 + .25
1.50 + .25
1.50 + .25
1.50 + .25
Figure 5
16 (1 in.)
Hydraulic System
Reelmaster 4000–D
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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.
2
1. Remove the retainer clip from seat lock rod.
1
2. Raise seat and support it in upright position with seat
support rod (Fig. 6).
Figure 8
1. Traction pump
2. By–pass valve
IMPORTANT: Make sure that hand brake is engaged
before opening the by–pass valve.
2
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 open will cause the hydraulic system to
overheat.
1
DANGER
Figure 6
1. Seat
2. Support rod
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.
3. Lift and remove front panel (Fig. 7).
If towing, with front wheel motors disengaged,
Tow Bar Assembly, Toro part no. 58–7020, must
be used.
1
Figure 7
Front panel
1.
4. Rotate by–pass valve 90 degrees. Opening the valve
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
Hydraulic System
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Disengaging Planetary Wheel Drives
3. Install disengage covers so dimple on cover is facing
in towards hub. Wheel hubs are now unlocked. (Fig. 10).
In an emergency, the Reelmaster 4500–D can be
moved by unlocking the front wheel hubs and towing the
machine.
DANGER
2
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.
Figure 10
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. Disengage cover – engaged (dimple facing out)
4. Lock the wheel hubs immediately after towing is com-
pleted. Remove disengage covers and reinstall so dim-
ple on cover is facing away from hub.
1. Block the wheels or connect the machine to a towing
vehicle with a rigid towing device.
CAUTION
2. Remove bolts securing disengage covers to both
front wheel hubs (Fig. 9).
Do not remove wheel blocks or towing devices
until wheel hubs are securely locked.
Figure 9
Hydraulic System
Reelmaster 4000–D
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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
2. If oil level is low, add hydraulic oil to the reservoir
(see Add Hydraulic Fluid).
1
Figure 11
1. Hydraulic reservoir
2. Sight glass
Reelmaster 4000–D
Hydraulic System
Page 4 – 7
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Hydraulic Schematic
P R I O R I T Y
R E A R
Hydraulic System
Reelmaster 4000–D
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Hydraulic Flow Diagrams (2WD Machines Only)
General Pump Flow
Refer to “Engine Run – No Functions” Flow Diagram
The traction, reel, and auxiliary pumps are directly
coupledtotheengine. Withallcontrolsinneutralandthe
enginerunning, thesteer–liftpumpdrawsoilthroughthe
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.
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.
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.
Oil collected by the reel pump is directed to the reel
speed valve and split into two variable flows. Primary oil
is directed to the reel “On–Off” control valve. With the
valve in the “Off” position, the oil is returned directly to
the drain block. The remaining oil will also return to the
tank through the drain block.
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
Hydraulic System
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Engine Run – No Functions
Hydraulic System
Reelmaster 4000–D
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Traction Circuit
Refer to “Traction Circuit – Forward” Flow Diagram
A mechanical interlock between the traction pedal link-
age and the parking brake prevents traction pedal
movement unless the brake is released.
inlet of the traction motors. The oil returns from the mo-
tor to the pump where it continues through the pump in
a closed–loop circuit. System pressure may be moni-
tored at pressure tap port 1.
Depressingthetopofthetractionpedalwillshiftthetrac-
tionpumpswashplatetodirectaflowofoiltotheforward
Reelmaster 4000–D
Hydraulic System
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Traction Circuit – Forward
Hydraulic System
Reelmaster 4000–D
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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.
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.
Turning the steering wheel to the right moves the control
spool in the steering unit to direct the oil to the steering
System pressure may be monitored at pressure tap port
5.
Reelmaster 4000–D
Hydraulic System
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Steering Right
Hydraulic System
Reelmaster 4000–D
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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.
while the cutting unit is lowering will lock the cutting unit
at any position by trapping oil between the valve and cyl-
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 balance pres-
sure may be monitored at pressure tap port 3.
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.
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.
Moving the lever forward will open a path for oil to es-
cape from the lift cylinder. The weight of the cutting unit
willpushoilfromthecylindersthroughthevalveallowing
the cutting unit to lower. Moving the lever into “LIFT”
Reelmaster 4000–D
Hydraulic System
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Lift Circuit – Lift All Units
Hydraulic System
Reelmaster 4000–D
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Lift Circuit – Lower All Units
Reelmaster 4000–D
Hydraulic System
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Lift Circuit – Free Float (Detent)
Hydraulic System
Reelmaster 4000–D
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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.
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.
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 speed is directed back to the sump tank through the
drain block, oil cooler, and filter.
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.
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,
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.
“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”, but does not affect performance
during “Mow”.
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
Systempressure may be monitored at pressure tap 4 for
either “Mow” or “Backlap”.
Reelmaster 4000–D
Hydraulic System
Page 4 – 19
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Reel Circuit – All Units Mow (Free Float)
Hydraulic System
Reelmaster 4000–D
Page 4 – 20
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Reel Circuit – Units 1, 2 & 3 Mow (Free Float)
Reelmaster 4000–D
Hydraulic System
Page 4 – 21
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Reel Circuit – Units 1, 2, 3 & 5 Mow (Free Float)
Hydraulic System
Reelmaster 4000–D
Page 4 – 22
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Reel Circuit – Any Unit Backup
Reelmaster 4000–D
Hydraulic System
Page 4 – 23
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4WD Selector Valve Operation
4WD Forward (“S1” OFF)
Pressure Oil
Pressure Free
Hydraulic System
Reelmaster 4000–D
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2WD Forward (“S1” ON)
Pressure Oil
Pressure Free
Reelmaster 4000–D
Hydraulic System
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Special Tools
NOTE: Order special tools from the TORO SPECIAL
TOOLS AND APPLICATIONS GUIDE (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.
4. HIGH PRESSURE GAUGE: High range gauge to
accommodate pressure beyond the capacity of the low
pressure gauge, 0 – 5,000 PSI.
1. INLET HOSE: Hose connected from the system cir-
cuit to the inlet side of the hydraulic tester.
5. FLOW METER: This meter measures actual oil flow
in the operation circuit, with a gauge rated at 15 GPM.
2. LOAD VALVE: If required, upon turning the valve to
restrict flow, a simulated working load is created in the
circuit.
6. OUTLET HOSE: Hose from the outlet side of the hy-
draulic tester to be connected to the hydraulic system
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
Reelmaster 4000–D
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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
(350 Bar) and 10000 PSI (700 Bar) gauges. Use gauges
as recommended in Testing section of this chapter.
Figure 13
Hydraulic Test Fitting Kit – TOR4079
This kit includes a variety of O–ring Face seal fittings to
enable you to connect test gauges into the system.
The kit includes: tee’s, unions, reducers, plugs, caps,
and male test fittings.
Figure 14
Reelmaster 4000–D
Hydraulic System
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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.
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.
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.
Refer to the Testing section of this Chapter for precau-
tions and specific test procedures.
Problem
Possible Causes
Hydraulic oil leak(s).
Fitting(s), hose, or tube loose or damaged.
Missing or damaged o–ring.
Low engine RPM.
Slow or no traction in either direction.
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.
Reels slow or won’t turn.
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.)
Hydraulic System
Reelmaster 4000–D
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Problem
Possible Causes
Steering loss.
Thermal shock after washing.
NOTE: Normalfunctionswillreturnafterorbitaltem-
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.
Cutting units lift slowly or won’t lift.
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.
Low lift relief pressure. (See Test No.7.)
Plugged cylinder orifice.
Worn or damaged lift valve.
Worn or damaged steering/lift pump.
Low engine RPM.
Cutting units won’t drop or follow ground contours.
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.
Reelmaster 4000–D
Hydraulic System
Page 4 – 29
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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.)
WARNING
Keepbodyandhandsawayfrompinholeleaks
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.
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
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.
CAUTION
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.
2. Put metal caps or plugs on any hydraulic lines left
open or exposed during testing or removal of compo-
nents.
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.
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.
CAUTION
4. The inlet and the outlet hoses must be properly con-
nected and not reversed (tester with pressure and flow
capabilities)to prevent damage to the hydraulic tester or
components.
Operate 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.
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.
WARNING
Before disconnecting or performing any work
on the hydraulic system, all pressure in the
system must be relieved. Stop engine; lower or
support attachments.
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. Allhydraulictestsshouldbemadewiththehydraulic
oil at normal operating temperature.
Hydraulic System
Reelmaster 4000–D
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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.
2
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
3
NOTE: Typical working pressure during operation
while going uphill, would be approximately 4000 PSI in
2WD and 2500 PSI in 4WD.
1
3. If working pressure is too low in 2WD, perform the
traction circuit relief pressure check.
Figure 15
1. Reverse test port
3. Forward test port
2. Front wheel motor (RH)
NOTE: If pressure is good in 2WD but to low in 4WD,
check the cartridge valve seals in 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. Installa10,000psigaugeintothetractioncircuitquick
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. Carefullydrivethemachineintopositionsoitwillpush
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
Hydraulic System
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TEST NO. 2: Check Counterbalance Oil Pressure
Procedure:
1. Install a 10,000 psi gauge into the center quick dis-
connect as shown.
2
1
2. Start the 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
this recommended range. However, the range listed will
be adequate for most conditions.
Figure 16
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
Reelmaster 4000–D
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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.
1
2. Operate the unit while monitoring the gauge.
2
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. 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.
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. Ifreelcircuitreliefpressureisabove2750psiorbelow
2650 psi, clean or replace relief valve in reel control
valve.
Reelmaster 4000–D
Hydraulic System
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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 reel speed control knob at middle range (90
degree position).
7. Start engine and move throttle to full speed
(2500 rpm).
8. Engagethereelcontrolleverintothe“MOW”position.
CAUTION
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
Reelmaster 4000–D
Page 4 – 34
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TEST NO. 5: Check Reel Motor Cross–Over Relief Pressure
FROM
LIFT CIRCUIT
CUTTING
T
CIRCUIT
TEST PORT
G
T
PRIORITY
B
A
IN
(TYP)
IN
FROM
GEAR PUMP
OUT
A
B
3000
PSI
T
B
A
TO HYDRAULIC
OIL TANK
Figure 19
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.
CAUTION
Keep away from reels during test to prevent per-
sonal injury from the rotating reel blades.
Check Relief Pressure
7. Position reel speed control knob to minimum
speed. Start engine and move throttle to low idle speed
of 1200 RPM.
NOTE: The reel motor has an internal relief valve that
relieves when the pressure across the motor exceeds
1500 + 100 PSID.
IMPORTANT: Each reel motor has two cross–over
reliefs. Test relief in the backlap direction only if a
problem is expected.
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.
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.
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.
A. If pressure is greater than the specified range,
stop theengineandrepairorreplacethereelmotor.
4. Block reel being tested to prevent rotation. Use a
substantial hardwood block inserted between the reel
blades.
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.
5. Disconnect supply hose from the motor. Install test
gaugewithT–connectorinserieswiththemotoranddis-
connected supply hose.
6. Disconnect return hose from the motor. Install test
gaugewithT–connectorinserieswiththemotoranddis-
connected return hose.
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.
Reelmaster 4000–D
Hydraulic System
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TEST NO. 6: Check Reel Motor Case Drain Flow
FROM
LIFT CIRCUIT
T
CUTTING
CIRCUIT
TEST PORT
G
T
PRIORITY
OUT
B
A
IN
FROM
GEAR PUMP
(TYP) IN
B
A
3000
PSI
T
QUART
CONTAINER
B
A
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.
CAUTION
Keep away from reels during test to prevent per-
sonal injury from the rotating reel blades.
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.
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.
3. Read Precautions for Hydraulic Testing.
4. For the suspected bad motor, disconnect return
hose from the motor.
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).
5. Install tester in series with the motor and return
hose. Make sure the flow control valve is fully open.
6. Follow hose from reel motor case drain to the hy-
draulic T–connector.
10. Disengage cutting units by reel control lever to the
NEUTRAL position. Stop the engine.
A. Disconnect hose from T–connector.
11. Measuretheamountofoilcollectedinthecontainer.
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).
B. Plug T–connector to prevent drainage of fluid.
C. Put case drain hose into suitable container for
collecting case drain leakage.
12. Disconnect tester from motor and hose. Reconnect
hose to the pump.
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).
13. Remove plug from T–connector. Reconnect case
drain hose to the T–connector.
14. If flow was greater than 0.7 GPM (2.6 LPM), repair
or replace the reel motor as necessary.
Hydraulic System
Reelmaster 4000–D
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TEST NO. 7: Check Steering Circuit Working and Relief Pressure
Procedure For Working Pressure Check:
2
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.
1
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
Hydraulic System
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TEST NO. 8: Check Lift Circuit Working and Relief Pressure
Procedure For Working Pressure Check:
2
1. Install a 5,000 psi gauge onto the quick disconnect of
the lift valve.
1
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:
Figure 22
1. Lift control test port
2. Lift control valve
1. Hydraulic oil must be at operating temperature.
2. Install a 5,000 psi gauge onto the quick disconnect of
the lift valve.
1
3. Start the engine and move the throttle to full speed
(2500 rpm).
2
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.
Figure 23
1. Lift control test port
2. Test gauge
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 not leak-
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.
2
3. Start the engine and position throttle at idle
(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.
1
Figure 24
1. Charge press. test port
2. Traction pump
Hydraulic System
Reelmaster 4000–D
Page 4 – 38
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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. After repairs, check control 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.
2. Put caps or plugs on any hydraulic lines or fittings left
open or exposed.
4. Check for hydraulic oil leaks. Shut off engine and cor-
rectleaksifnecessary. Checkoillevelinhydraulicreser-
voir and add correct oil if necessary.
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
Hydraulic System
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Steering Control Unit
11
12
13
28
27
12
14
26
25
24
15
23
12
16
22
21
20
18
Figure 25
1. Seal 1” I.D.
15. Gerotor
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
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
13. Spacer Plate
14. Drive
28. Set Screw
Disassembly
NOTE: Troubleshooting information defines terms and
problems, possible causes for problems, and recom-
mends procedures for correcting problems.
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.
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 clamping procedure explained
throughout the manual.
Hydraulic System
Reelmaster 4000–D
Page 4 – 40
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Meter (Gerotor) End Disassembly
1. Clamp unit in vise, meter end up. Clamp lightly on
edges of mounting area, see Fig. 26. Use protective ma-
terial on vise jaws. Housing distortion could result if jaws
are over–tightened.
Figure 26
Figure 27
Figure 28
2. Remove 5/16” cap screws.
3. Remove end cap.
4. Remove seal from end cap.
5. Remove meter. Be careful not to drop star.
6. Remove seal from meter.
Reelmaster 4000–D
Hydraulic System
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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.
Figure 29
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.
Figure 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.
Figure 31
Hydraulic System
Reelmaster 4000–D
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13. Remove quad ring seal from seal gland bushing.
14. Use a thin–blade screwdriver to pry dust seal from
seal gland bushing. Do not damage bushing.
Figure 32
15. Remove 2 bearing races and the needle thrust bear-
ing from spool and sleeve assembly.
Figure 33
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
Hydraulic System
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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.
Figure 35
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.
Figure 36
Hydraulic System
Reelmaster 4000–D
Page 4 – 44
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Reassembly
Check all mating surfaces. Replace any parts that have
scratches or burrs that could cause leakage. Clean all
metal parts in clean solvent. Blow dry with air. Do not
wipe dry with cloth or paper towel because of lint or other
matter can get into the hydraulic system and cause da-
mage. 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.
Figure 37
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.
Figure 38
Reelmaster 4000–D
Hydraulic System
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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.
Figure 39
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
gentlyintoplacewithslightrotatingaction, keeppin
nearly horizontal. Bring the spool assembly entirely
within the 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 point to prevent the
cross pin from dropping into the discharge groove
of the housing. Withthespoolassemblyinthisflush
position, check for free rotation within the housing
by turning with light finger tip force at the splined
end.
Figure 40
Hydraulic System
Reelmaster 4000–D
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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.
Figure 41
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.
Figure 42
16. Install retaining ring (see Fig. 42 and 43) in housing.
Afterinstallingring, taponringendorprywithscrewdriv-
er around entire circumference of ring to properly seat
ring in groove.
Figure 43
Reelmaster 4000–D
Hydraulic System
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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
asimilarwaywhenreadyforreassembly. Do not use
cloth or paper to clean surfaces.
Figure 44
Figure 45
Figure 46
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.
Hydraulic System
Reelmaster 4000–D
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21. Install 3” diameter seal in meter.
Figure 47
22. With seal side of meter toward spacer plate, align
star valleys (ref. A) on drive (ref. B). Record the parallel
relationship of reference lines A, B, C, and D in Fig. 48.
Align bolt holes without disengaging meter from drive.
Figure 48
Reelmaster 4000–D
Hydraulic System
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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.
Figure 50
Hydraulic System
Reelmaster 4000–D
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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).
2
1. Remove seat lock pin, raise seat and hold open with
support rod.
1
2. Clean around reservoir filler cap (Fig. 52). Remove
cover and add hydraulic oil until it is even with arrows on
sight glass (Fig.51).
Figure 51
1. Hydraulic reservoir
2. Sight glass
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.
2
1
Hydraulic Oils Specifications (Interchangeable):
Mobil DTE 26/Shell Tellus 68 Equivalent*
*Equivalent Hydraulic Oils (Interchangeable)
Mobil
DTE 15 M
Figure 52
Amoco
Conoco
Exxon
Rykon Oil #68
Super Hydraulic Oil 68
Nuto H 68
1. Filler cap
2. Hydraulic reservoir
Kendall
Pennzoil
Phillips
Kenoil R & 0 AW 68
Penreco 68
Magnus A 68
Standard Energol HLP 68
Sun
Union
Sunvis 831 WR
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).
1
2
2. Tighten drain plug and add hydraulic oil (see Add
Hydraulic Oil).
Figure 53
1. Drain plug
2. Right front fender
Reelmaster 4000–D
Hydraulic System
Page 4 – 51
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Reel Motor
21
2
3
4
5
6
5
7
8
9
15
10
7
20
19
11
18
16
17
14
13
12
Figure 54
1. Not used
2. Idler Gear
3. Drive Gear
4. Key
8. Plate & Bushing Assembly
9. Socket Head Cap Screw
10. Set Screw
15. Relief Valve Kit
16. O–Ring
17. Plug
11. Drive Pulley
18. Shim
5. O–Ring
6. Body
12. Retaining Ring
13. Shaft Seal
19. Spring
20. Ball
7. Dowel Pin
14. Backup Washer
21. Back Plate/Relief Assembly
Disassembly of Reel Motor
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).
1. Remove set screws (10) from drive pulley (11).
2. Remove drive pulley (11) from drive shaft.
3. Remove key (4) from drive shaft.
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.
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. Clamp 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
Reelmaster 4000–D
Page 4 – 52
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Inspection of Reel Motor
GENERAL
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). Torque plug from 10 to 12 ft–lb
(1.4 to 1.7 kg–m).
1. Clean and dry all parts.
2. Remove nicks and burrs from all parts with emery
cloth.
2. Retaining ring (12), shaft seal (13), back–up washer
(14), and O–rings (5) should be replaced as new parts.
GEAR ASSEMBLY
3. Install O–rings (5) in grooves of front plate (8) and
body (6).
1. Inspect drive gear assembly (3) for broken or cracked
keyway.
4. Install body (6) in front plate assembly (8) noting posi-
tion of scribe line.
2. Inspect both the drive gear (3) and idler gear (2)
shafts at bearing point for rough surfaces and excessive
wear.
5. Install dowel pins (7) in body (6) and front plate as-
sembly (8).
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 are avail-
able as assemblies only.)
6. Dip gear assemblies (2 & 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.
4. If gear width is below 1.327, gear assembly should be
replaced.
5. Inspect gear face for scoring and excessive wear.
8. Install new back–up washer (14) on drive shaft.
6. Retaining ring (12) on shaft assemblies should be in
groove.
Oil shaft seal (13) liberally. Work shaft seal (13) over
drive shaft taking care not to cut rubber sealing lip.
7. If edge of gear teeth are sharp, break edge with
emery cloth.
9. Seat shaft seal (13) by tapping with plastic hammer.
Install new retaining ring (12).
FRONT PLATE, BODY, BACK PLATE, AND RELIEF
VALVE
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).
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. If 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
Hydraulic System
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Steering Pump
7
1
2
11
12
4
13
10
3
4
14
15
16
17
18
19
20
21
16
22
26
25
9
24
8
2
6
23
Figure 55
1. Plug (includes #2)
2. O–Ring
15. Front Plate Assembly
16. O–Ring
3. Spool
4. Dowel Pin
17. Molded O–Ring
18. Bearing Seal
6. Plug (includes #2)
7. Drive Gear Assembly
8. Disc
19. Backup Gasket
20. Wear Plate
21. Body Assembly
22. Back Plate Assembly
23. Relief Valve Assembly
24. O–Ring
9. Spring
10. Idler Gear Assembly
11. Hex Head Cap Screw
12. Shaft Seal
25. Back Up Washer
26. O–Ring
13. Washer
14. Bushing
Hydraulic System
Reelmaster 4000–D
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Disassembly of Steering Pump
GEAR ASSEMBLY
1. Thoroughly clean outside of pump.
1. Check drive shaft spline for twisted or broken teeth.
2. Use a sharp tool or marker to mark across front plate
(15), body (21) and back plate (22). This will assure
proper reassembly.
2. Inspect both drive gear (7) and idler gear (10) shafts
at bushing points and seal area for rough surfaces and
excessive wear.
3. Clamp pump in a vise, with the shaft up.
4. Remove capscrews (11).
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).
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.
4. Inspect gear face for scoring and excessive wear.
5. If gear width is less than 0.636”, the gear assembly
should be replaced.
6. If front plate (15) was removed first, remove wear
plate (20) from body gear pockets.
6. Be sure snap rings are in grooves on either side of
drive and idler gears.
7. Remove drive gear assembly (7) and idler gear as-
sembly (10) from body (21).
7. If edge of gear teeth are sharp, break edge with
emery cloth.
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.
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.
9. Remove O–ring (16) from front plate (15) and back
plate (22).
10. Remove backup–up gasket (19) from front plate
(15).
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).
11. Remove bearing seal (18) from front plate (15) by
prying with a sharp tool.
3. Bushings in front plate should be flush with face of
front plate.
12. Remove molded O–ring (17) from front plate (15) by
prying with a screwdriver.
4. Check for scoring on face of back plate. If wear ex-
ceeds 0.0015”, back plate should be replaced.
13. Remove shaft seal (12) from front plate (15) by pry-
ing with a screwdriver.
BODY
Disassembly of Back Plate Assembly (Flow Divider
/ Flow Control / Relief Valve)
1. Check inside gear pockets for excessive scoring or
wear.
1. Remove relief valve (23) from back plate (22).
2. Body (21) should be replaced if I.D. of gear pocket ex-
ceeds 1.713”.
NOTE: Do not disassemble relief valve cartridge as-
sembly – it must be replaced as an assembly.
FLOW DIVIDER / FLOW CONTROL / RELIEF VALVE
1. Check disk (8) for wear.
2. Remove hex plugs (1, 6) flow divider spool (3), spring
(9) and disk (8).
2. Check spring (9) for weakness or breakage.
Inspect Steering Pump Parts
GENERAL
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.
1. Clean and dry all parts.
2. Remove all nicks and burrs from all parts with emery
cloth.
Reelmaster 4000–D
Hydraulic System
Page 4 – 55
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7
1
2
11
12
4
13
10
3
4
14
15
16
17
18
19
20
21
16
22
26
25
9
24
8
2
6
23
Figure 56
1. Plug (includes #2)
2. O–Ring
15. Front Plate Assembly
16. O–Ring
3. Spool
4. Dowel Pin
17. Molded O–Ring
18. Bearing Seal
6. Plug (includes #2)
7. Drive Gear Assembly
8. Disc
19. Backup Gasket
20. Wear Plate
21. Body Assembly
22. Back Plate Assembly
23. Relief Valve Assembly
24. O–Ring
9. Spring
10. Idler Gear Assembly
11. Hex Head Cap Screw
12. Shaft Seal
25. Back Up Washer
26. O–Ring
13. Washer
14. Bushing
Hydraulic System
Reelmaster 4000–D
Page 4 – 56
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Assembly of Steering Pump
7. Apply a thin 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.
It is 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 small half moon port cavity must be on the
pressure side of the pump.
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.
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.
1. Install relief valve (23) with new O–ring (24), back–up
washer (25), and O–ring (26).
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.
2. Install flow divider spool (3), plug (1) with new O–ring
(2), and other plug (6) with new O–ring (2).
Install bolts (11) and washers (13). Tighten evenly to a
torque of 25 – 28 ft.–lb.
3. Thewearplate(20), bearingseal(18), moldedO–ring
(17), back–up gasket (19), shaft seal (12), and O–rings
(9) should be replaced as new parts.
11. Install washer (13). Liberally oil shaft seal (12) and
carefully work over drive shaft, being careful not to cut
rubber sealing lip.
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.
12. Put a 1–5/16” O.D. sleeve over the shaft and press
in shaft seal until flush with front surface of front plate.
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
Hydraulic System
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Lift Control Valve
34
12
14
15
11
16
17
18
19
20
10
9
13
22
38
8
7
6
5
4
3
2
1
37
22
23
24
39
29
36
35
25
33
32
31
26
27
28
30
39
40
Figure 57
1. Plug Assembly
2. Disc
3. Spring
22. O–Ring
23. Bushing
24. Washer
4. Detent Plunger
5. O–Ring
25. Spring
26. Spacer
6. Plug Assembly
7. O–Ring
8. Body
27. Retaining Ring
28. Cap Assembly
29. Plunger
9. O–Ring
30. Plug Assembly
31. Spring
32. Eyelet
33. Poppet Assembly
34. Locknut
10. Backup Washer
11. Plug Assembly
12. Washer
13. Spool
14. Plug Assembly
15. O–Ring
35. Seat Assembly
36. O–Ring
16. Washer
37. Plunger
17. Washer
38. Seal Wiper
18. Washer
19. Spring
39. .047 Dia. Orifice
40. .052 Dia. Orifice
20. Poppet
Hydraulic System
Reelmaster 4000–D
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Disassembly of Lift Control Valve
Assembly of Lift Control Valve
1. Plug all ports and clean outside of valve thoroughly.
1. Thoroughly clean and dry all parts. Apply a light coat-
ing of clean hydraulic oil to parts prior to assembly.
2. Remove cap assemblies (28). Do not remove retain-
ing rings (26) from spools unless spring (25) is broken.
NOTE: All O–rings, back–up washers, wiper seals and
nylon poppets should be replaced as new items.
3. Remove spools (13) from body (8).
2. Install new O–rings (22) in proper grooves in spool
bores.
NOTE: Spools and spool bores are matched sets. Be
sure each spool is identified with the correct body spool
bore.
3. Install relief valve components (20, 19, 18, 17, 16)
with new O–ring (15) on plug (14).
4. Remove bushings (23) and O–rings (22) from spools.
5. Remove plugs (11).
4. Install plugs (11) with new back–up washers (10) and
O–rings (9).
6. Remove plugs (30), springs (31), poppets (33), seats
(35) and plungers (37, 29).
5. Install plungers (37, 29).
IMPORTANT: Check location and positioning of
plungers during installation.
IMPORTANT: Check location and positioning of
plungers when removing from body to assure prop-
er assembly.
6. Install new O–rings (36) on seats (35). Install new
back–up washers (10) and O–rings (9) on plugs (30).
7. Remove plugs (6).
7. Install seats (35), new poppets (33), and plugs (30).
8. Install plugs (6) with new O–rings (7).
8. Remove plugs (1), discs (2), springs (3) and detent
plungers (4).
9. Remove locknut (34), washer (12), plug (14), wash-
ers (16, 17, 18), spring (19) and poppet (20).
9. Install detent plungers (4), springs (3), discs (2), and
plugs (1) with new O–rings (5).
10. Remove all O–rings and back–up rings from all
plugs and seats.
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).
Inspection of Lift Control Valve
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.
1. Remove all nicks and burns from parts and inspect for
excessive wear.
2. Inspect all plungers and poppet seats for burrs or
roughness.
12. Install spool caps (28) and tighten to a torque of
20 – 25 ft–lb.
3. Inspect spool springs (25), relief valve spring (19),
lockout springs (31), and detent springs (3) for break-
age.
13. Install new wiper seals (38).
4. If 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
Hydraulic System
Page 4 – 59
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Priority Flow Divider
16
15
14
13
12
11
10
9
8
7
6
5
1
2
17
4
18
19
3
2
1
Figure 58
1. Plug Assembly
2. O–Ring
11. Shim
12. Shim
3. Spool
13. Shim
4. Body
5. O–Ring
6. O–Ring
7. Backup Washer
8. Metering Stem
9. Groove Pin
10. Shim
14. O–Ring
15. Backup Washer
16. Metering Plug
17. Shim
18. Shim
19. Spring
Hydraulic System
Reelmaster 4000–D
Page 4 – 60
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Disassembly of Priority Flow Divider
Reassembly of Priority Flow Divider
1. Plug all ports and thoroughly clean outside of valve.
1. Install new back–up washer (7) inside metering plug
(16).
2. Remove plug (1), shims (17 & 18), spring (19), and
flow control spool (3) from body (4).
2. Install new O–ring (6) inside metering plug (16).
NOTE: Notice the position of the spool in relation to
valve body when removing spool (3).
3. Oil metering stem (8) and install in metering plug (16).
Secure with groove pin (9).
3. Remove metering plug (16).
4. Install new back–up washer (15) and new O–rings (5
& 14) on metering plug (16).
4. Remove shims (10, 11, 12, & 13) from metering plug
(16).
5. Install shims (10, 11, 12, & 13) on metering plug (16).
5. Remove O–rings (5 & 14) and back–up washer (15)
from metering plug (16).
NOTE: Install the same number of shims that were re-
moved.
6. Removegroovepin(9)andremovemeteringstem(8)
from metering plug (16).
6. Install metering plug assembly and tighten.
7. Install new O–ring (2) on plug (1) and install plug.
7. Remove O–ring (6) and back–up washer (7) from in-
side metering screw (16).
8. Install flow control spool (3), spring (19) shims (18 &
17).
Inspection of Priority Flow Divider
NOTE: Installsamenumberofshimsaswereremoved.
1. Thoroughly clean and dry all parts.
2. Remove all nicks and burrs with emery cloth.
9. Install new O–ring (2) and plug (1) and install plug.
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
Hydraulic System
Page 4 – 61
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Lift Cylinder
1
2
7
6
5
4
3
Figure 59
1. Bleed Screw
2. Washer
3. Rod
5. Seal
6. Snap Ring
7. Seal Kit
4. Wiper
Hydraulic System
Reelmaster 4000–D
Page 4 – 62
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Disassembly of Lift Cylinder
4. Inspect O.D. of rod (3) for nicks, scratches or scoring.
1. Thoroughly clean outside of cylinder assembly.
Reassembly of Lift Cylinder
2. Pull rod (3) out until end of rod and snap ring (6) can
be seen through inlet port.
1. Allpartsshouldbecleanedanddriedthoroughly. Met-
al parts should be lightly oiled prior to reassembly.
3. Insert screw driver in inlet port and slide snap ring (6)
into deep groove in the rod assembly.
2. Install new seal (5) in barrel. Install new wiper (4) in
barrel with lips facing outward.
4. Remove rod assembly (3) from barrel assembly (7).
3. Install new snap ring (6) in deep groove of rod end (3).
5. Remove wiper seal (4) and seal (5) from I.D. of barrel
assembly.
4. Oil outside of piston rod (3) and carefully insert rod in
barrel assembly (7).
Inspection of Lift Cylinder
5. Push rod into barrel assembly until snap ring area of
rod can be seen through port.
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.
6. By using screwdriver through port, pop snap ring (6)
into lock position.
7. Extend rod (3) to full out position to make sure snap
ring (6) is locked.
2. Thoroughly clean all parts and remove all nicks and
burrs with emery cloth.
8. Cycle cylinder and check for leaks.
3. Inspect I.D. of barrel assembly (7) for excessive wear
or scoring.
Reelmaster 4000–D
Hydraulic System
Page 4 – 63
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Reel Control Valve
1
34
33
2
3
4
5
6
7
32
31
30
8
29
28
27
9
10
11
26
25
12
13
14
16
17
18
24
23
15
20
21
19
22
Figure 60
1. Spool
18. Plunger
2. Body
3. O–Ring
19. Micro Switch
20. Flat Washer
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
21. Machine Screw
22. Cap Head Screw
23. Lock Washer
24. Grease Fitting
25. Block Detent
26. Screw Spool
27. Shallow Washer
28. Wire Washer
29. Spring
30. Deep Washer
31. Washer
15. Spring
32. O–Ring
16. Plug
33. O–Ring
17. Sleeve
34. Wiper
Hydraulic System
Reelmaster 4000–D
Page 4 – 64
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Disassembly of Reel Control Valve Assembly
1. Plug all outlets and thoroughly clean outside of valve.
2. Remove plug (4) and O–ring (3).
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.
3. Remove relief valve components (8, 7, 6, & 5).
4. Remove screws (22) and lock washers (23).
5. Remove detent block (25).
NOTE: All O–rings and back–up washers should be re-
placed as new parts.
2. Position O–rings (5, 32, & 33) in body bore.
6. Remove detent plug (9), spring (10), and pawls (11)
from detent block (25).
3. Install O–rings and back–up washers on relief valve
and plugs.
7. Remove screw spool (26).
4. Install plug (4).
8. Remove shallow washer (27), wire washer (28),
spring (29), deep washer (30), washer (31), and O–ring
(32).
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.
9. Remove spool (1).
6. Insert spool (1) into body bore and screw spool screw
(26) into spool.
10. Remove all O–rings and back–up washers from all
plugs, relief valves, and body bore.
7. Install spring (10), pawls (11), spring (10) and detent
plug (9) into detent block (25).
11. Thoroughly clean all parts.
8. Slip detent block (25) over spool screw (26) and se-
cure to valve body (2) with lock washers (23) and cap
screws (22).
Inspection of Reel Control Valve Assembly
1. Remove nicks and burrs from all parts.
2. Inspect spool and body bore for excessive wear.
9. Install relief valve (8).
10. Run operational check.
NOTE: If 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. Spoolsorbodiescannotbeservicedseparately.
3. Inspect relief valve.
NOTE: Thepilot–operatedcartridge–typereliefvalveis
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. InspectionofO–ringsandback–upwashersisnotne-
cessary. It is recommended that these be replaced as
new parts.
Reelmaster 4000–D
Hydraulic System
Page 4 – 65
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Reel Shut Off Valve
1
5
6
8
7
9
7
6
5
2
4
3
2
1
Figure 61
1. Circlip
2. Washer
3. Spacer
4. Spring
5. Wiper
6. Backup Washer
7. O–Ring
8. Body
9. Spool
Hydraulic System
Reelmaster 4000–D
Page 4 – 66
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Disassembly of Reel Shut–Off Valve Assembly
1. Thoroughly clean outside of valve.
3. InspectO.D. ofspool(9). Itshouldbesmoothandfree
of nicks and burrs.
4. Inspect spring (4) for breakage.
2. Remove retaining ring (1) from end of spool (9).
3. Remove spool (9) from valve body (8).
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.
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.
2. Install new wipers (5) in spool bore.
3. Install washer (2), spacer (3), spring (4), and washer
(2) on spool (9).
Inspection of Reel Shut–Off Valve Assembly
1. Thoroughly clean and dry all parts.
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.
2. Inspect the spool bore inside the body. The surface
should be smooth and free of deep scratches.
5. Install retaining ring (1) on end of spool (9).
Reelmaster 4000–D
Hydraulic System
Page 4 – 67
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Traction Pump
19
6
15
16
13
17
18
20
21
22
12
11
23
10
4
9
46
8
24
25
45
14
7
26
2
1
27
32
3
28
29
30
34
37
41
31
33
38
39
40
48
35
42
43
44
5
47 36
Figure 62
1. Hex Head Cap Screw
25. Retaining Ring
26. Shaft Seal
27. Washer
28. Retaining Ring
29. Thrust Ring
2. Charge Pump Adapter Assembly
3. Plug Assembly
4. Tow Valve Assembly
5. O–Ring
6. Needle Bearing
7. Gerotor Gear Assembly
8. Check Valve Assembly
9. Back Plate Assembly
10. Housing Gasket
11. Dowel Pin
30. Needle Bearing , Thrust
31. Drive Shaft
32. Relief Valve Kit
33. O–Ring
34. Relief Valve Assembly
35. Key
12. Rotating Kit Assembly
13. Key
36. Hex Head Cap Screw
37. Cartridge
14. Camplate
38. O–Ring
15. Seal Cover
39. Spring
16. Shaft Seal
40. Poppet
17. Washer
41. Spring
18. Needle Bearing
19. Housing Assembly
20. Inner Race
42. Poppet
43. Spring
44. Spring Retainer
45. O–Ring
21. O–Ring
22. O–Ring Cover
23. Trunnion Cover
24. Screw
46. Back–up Washer
47. Bearing
48. Bearing
Hydraulic System
Reelmaster 4000–D
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Disassembly of Traction Pump
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.
1. Disconnect all control linkage, hydraulic lines and re-
move pump assembly from vehicle.
10. Remove plug assembly (3), spring (41) and relief
valve assembly (34) from back plate.
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 & 36) from the adapter plate of the pump.
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.
4. Use a plastic mallet and tap the charge pump adapter
(2) to loosen it, then pull the adaptor straight up until it
is free.
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.
5. Remove spring retainer (44) and remove spring (43)
and poppet (42) from adaptor assembly (2).
6. Remove the gerotor gear (7) and key (35) from the
pump shaft.
13. Remove retaining ring (25) from housing. Press
drive shaft (31) from housing (19) and remove shaft seal
(26) and washer (27).
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.
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 trun-
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).
8. Use screwdriver slots in housing and pry up on back
plate (9) or tap with plastic mallet to loosen, then pull the
back plate straight up to remove. Remove housing gas-
ket (10).
Reelmaster 4000–D
Hydraulic System
Page 4 – 69
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19
6
15
16
13
17
18
20
21
22
12
11
23
10
4
9
46
8
24
25
45
14
7
26
2
1
27
32
3
28
29
30
34
37
41
31
33
38
39
40
48
35
42
43
44
5
47 36
Figure 63
1. Hex Head Cap Screw
25. Retaining Ring
26. Shaft Seal
27. Washer
28. Retaining Ring
29. Thrust Ring
2. Charge Pump Adapter Assembly
3. Plug Assembly
4. Tow Valve Assembly
5. O–Ring
6. Needle Bearing
7. Gerotor Gear Assembly
8. Check Valve Assembly
9. Back Plate Assembly
10. Housing Gasket
11. Dowel Pin
30. Needle Bearing , Thrust
31. Drive Shaft
32. Relief Valve Kit
33. O–Ring
34. Relief Valve Assembly
35. Key
12. Rotating Kit Assembly
13. Key
36. Hex Head Cap Screw
37. Cartridge
14. Camplate
38. O–Ring
15. Seal Cover
39. Spring
16. Shaft Seal
40. Poppet
17. Washer
41. Spring
18. Needle Bearing
19. Housing Assembly
20. Inner Race
42. Poppet
43. Spring
44. Spring Retainer
45. O–Ring
21. O–Ring
22. O–Ring Cover
23. Trunnion Cover
24. Screw
46. Back–up Washer
47. Bearing
48. Bearing
Hydraulic System
Reelmaster 4000–D
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Inspection of Traction Pump
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.
1. Inspect the charge pump relief valve seat inside the
charge pump adaptor. It should be smooth and free of
burrs or other defects.
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 andsmooth.
DO NOT LAP THE PISTON SHOES.
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.
10. Examine the spider. It should be flat, no cracks and
no signs of wear in the pivot area.
4. Inspect the bearing (47) inside the charge pump
adaptor assembly, if the needles are free of excessive
play and remain in the bearing cage there is no need to
replace the bearing.
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.
5. Inspect the check valve assembly (8), make sure the
ball seat is in good condition and the ball is free to move.
13. Inspect the drive shaft (31) for fretting in the bearing
and spline areas.
6. Inspect the flat surfaces of the back plate (9), the fin-
ish on the gerotor side should show on galled surface.
Thefinishonthepistonblocksideshouldbesmoothand
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.
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.
7. Inspect the piston block. The surface that contacts
the back plate should be smooth and free of grooves.
Reelmaster 4000–D
Hydraulic System
Page 4 – 71
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19
6
15
16
13
17
18
20
21
22
12
11
23
10
4
9
46
8
24
25
45
14
7
26
2
1
27
32
3
28
29
30
34
37
41
31
33
38
39
40
48
35
42
43
44
5
47 36
Figure 64
1. Hex Head Cap Screw
25. Retaining Ring
26. Shaft Seal
27. Washer
28. Retaining Ring
29. Thrust Ring
2. Charge Pump Adapter Assembly
3. Plug Assembly
4. Tow Valve Assembly
5. O–Ring
6. Needle Bearing
7. Gerotor Gear Assembly
8. Check Valve Assembly
9. Back Plate Assembly
10. Housing Gasket
11. Dowel Pin
30. Needle Bearing , Thrust
31. Drive Shaft
32. Relief Valve Kit
33. O–Ring
34. Relief Valve Assembly
35. Key
12. Rotating Kit Assembly
13. Key
36. Hex Head Cap Screw
37. Cartridge
14. Camplate
38. O–Ring
15. Seal Cover
39. Spring
16. Shaft Seal
40. Poppet
17. Washer
41. Spring
18. Needle Bearing
19. Housing Assembly
20. Inner Race
42. Poppet
43. Spring
44. Spring Retainer
45. O–Ring
21. O–Ring
22. O–Ring Cover
23. Trunnion Cover
24. Screw
46. Back–up Washer
47. Bearing
48. Bearing
Hydraulic System
Reelmaster 4000–D
Page 4 – 72
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Reassembly of Traction Pump
9. Install new housing gasket (10).
10. Install back plate (9).
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.
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.
2. Insert camplate into housing. Insert the needle bear-
ings (18) over the arm and slide into the housing.
12. Install key (35) on shaft and install gerotor gear (7)
over shaft.
3. Install washers (17) and shaft seal (16) over cam piv-
ot bearing. Install seal cover (15) and secure with
screws (24).
13. Install new O–ring (5) in groove in charge pump
adaptor (2), hold in place with clean clear grease. As-
semble adaptor on pump back plate. Retain with four
cap screws (36 & 1) and torque to 27/31 ft. lbs.
4. On the opposite side of housing install needle bearing
(18), inner race (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).
14. Reassemble tow valve assembly (4) by installing
new O–rings, inserting spreader into separators plug,
and securing with retaining ring.
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).
15. Install tow valve assembly (4) in back plate (9) and
torque 27 to 30 ft. lbs.
16. Install relief valve assemblies (34) in back plate.
6. Install shaft in housing and install washer (27), shaft
seal (26), and retain with retaining ring (25).
17. Install new O–ring (33) and spring (41) on plug (3).
Install plugs (3) in back plate and torque 55/60 ft. lbs.
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.
18. Remove pump from vise and install poppet (42),
spring (43), and spring retainer (44).
8. Clamp pump assembly in a protected jaw vise with
the open end of the housing up.
Reelmaster 4000–D
Hydraulic System
Page 4 – 73
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Front Traction Motor
2
1
3
4
5
6
7
20
21
22
8
19
18
9
17
16
13
14
15
14
13
12
11
10
Figure 65
1. Hex Head Cap Screw
2. Hex Head Cap Screw
3. Plug
12. Washer
13. Retaining Ring
14. Thrust Ring
4. O–Ring Seal
5. Back Plate Assembly
6. O–Ring
15. Thrust Bearing
16. Bearing
17. Housing Assembly
7. Bearing
8. Key
9. Retaining Ring
10. Drive Shaft
11. Shaft Seal
18. Camplate Assembly
19. Rotating Assembly
20. Grass Shield
21. Retaining Ring
22. Shaft Seal
Disassembly of Traction Motor
1. Clean outside of unit thoroughly.
5. Remove capscrews (1 & 2) from backplate (5).
6. Use a plastic mallet and tap the backplate (5) to loos-
en it; then pull the backplate straight out.
2. Remove retaining ring (9) from housing assembly
(17).
7. Remove O–ring (6) from backplate.
3. Clamp shaft in a protected jaw vise with backplate
end up.
8. Remove the complete rotating assembly (19) from
the housing assembly (17).
4. Remove retaining ring (21) and shaft seal (22) from
backplate (5).
9. Removepistonassemblies, spider, andpivotfromthe
rotating assembly (19).
Hydraulic System
Reelmaster 4000–D
Page 4 – 74
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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.
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.
10. Remove camplate assembly (18) from housing.
11. Remove shaft seal (11) from housing.
Reassembly of Traction Motor
12. Remove washer (12) and drive shaft (10) fromhous-
ing.
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.
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.
3. Replace needle bearing (16) in housing (17) if neces-
sary. Installshaftinhousingassembly(17). Installwash-
er (12), shaft seal (11) and retain with retaining ring (9).
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.
4. Install the pivot, spider, and the piston assemblies in
the piston block assembly.
3. Inspect thrust races (14) and thrust bearing (15). All
surfaces should be free of any signs of wear or fretting.
5. Lubricate camplate assembly (18) and install in hous-
ing assembly with chamfered edge of race against
housing surface.
4. Inspect spider and pivot; conical surfaces should be
free of wear and score marks.
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.
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.
7. Install new bearing (7) in backplate (5) if necessary.
8. Install new O–ring (6) on backplate.
6. Inspect the piston block; the bores should be free of
scoring. The surface that contacts the backplate should
be smooth and free of grooves or metal build–up.
9. Install backplate (5) on housing.
10. Install capscrew (1 & 2) and torque 15–18 ft. lbs.
7. Inspect the camplate assembly (18); the surface op-
posite the chamfered side should show no signs of scor-
ing.
Reelmaster 4000–D
Hydraulic System
Page 4 – 75
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Reel Pump
15
14
13
12
7
11
8
7
12
6
5
4
3
2
1
10
9 18 17 16
Figure 66
1. Nut
2. Lock Washer
3. Stud
4. Stud
5. Front Cover
6. Gland Seal
10. Spline Drive Gear
11. Driven Gear
12. O–Ring Seal
13. Rear Port Section
14. Coupling
15. O–Ring
7. Wear Plate
16. Plug
8. Center S/A Section
9. Shaft Seal
17. Shaft Seal
18. Retaining Ring
Hydraulic System
Reelmaster 4000–D
Page 4 – 76
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Disassembly of Reel Pump
2. Remove the retaining ring (18) with internal retaining
ring pliers.
During disassembly, pay particular attention to identifi-
cation of the parts for correct assembly.
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.
1. Clamp the port section (13) in a vise with protective
jaws to avoid damage to the port section’s machined
surfaces.
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.
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. Inspectwearplates(7)forerosion, pitting, scratching,
an/or scoring. Replace if necessary.
5. Remove seal retainer (6) and gland seal (5) from front
cover (4) and discard.
6. Inspect the center S/A section (8) for porosity, cracks,
and scratches (.010 or deeper). Replace if necessary.
DO NOT deburr the figure eight section of the center
section.
6. Remove wear plate (7) from center section (8).
7. Remove spline drive gear (10) and driven gear (11)
from center section (8).
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. 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
8. Inspect the 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
All parts must be thoroughly cleaned and kept clean dur-
ing inspection 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 & 6) are required for assembly. Wash
the metal parts, blow dry them with air, and place on a
clean surface (Kraft paper) for inspection.
1. Place front cover S/A (4) in a vise (mounting flange
up). Usingascrewdriver, popouttheoutershaftseal(9),
being careful not to raise a burr on the shaft seal bore.
Reelmaster 4000–D
Hydraulic System
Page 4 – 77
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15
14
13
12
7
11
8
7
12
6
5
4
3
2
1
10
9 18 17 16
Figure 67
1. Nut
2. Lock Washer
3. Stud
10. Spline Drive Gear
11. Driven Gear
12. O–Ring Seal
13. Rear Port Section
14. Coupling
15. O–Ring
16. Plug
17. Shaft Seal
18. Retaining Ring
4. Stud
5. Front Cover
6. Gland Seal
7. Wear Plate
8. Center S/A Section
9. Shaft Seal
Hydraulic System
Reelmaster 4000–D
Page 4 – 78
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Reassembly of Reel Pump
section and notch facing inlet port. Make sure wear plate
and center section set flush against port section.
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.
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).
1. Assemble seal packs by inserting the seal glands (5)
intothesealretainers(6). Installasealpackintothecav-
ity located on the face of the port section (13) with the
seal retainer pointing up.
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.
2. Place port section (13) in vise with studs (3) facing up.
NOTE: The next five steps pertain to installation of front
cover shaft seals (9 & 17). Lubricate the shaft seals with
Marfak grease to provide initial lubrication.
13. Install seal pack (5 & 6) into cavity located on face
of front cover (4). Apply petroleum jelly around seal pack
area on face of front cover.
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.
14. Carefully position front cover (4) over studs (3),
gears (10 & 11), and center section guide pins. Gently
slide front cover over the gears until it is flush against
wear plate (7).
4. Install retaining ring (18) into front cover on top of
shaft seal (17).
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.
5. Placeaguideoverthepilotdiameteroffrontcover(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.
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).
7. Insert the driver and shaft seal though the guide and
press in place.
18. Install lubricated coupling (14) on spline of drive
gear (10).
8. Place wear plate (7) on port section (13) with bronze
face up and notch facing inlet port.
19. Turn the drive gear (10) one revolution with a suit-
able socket wrench. Not binding shall be evident during
this operation. The breakaway torque necessary to turn
the drive gear must not exceed 140 in–lb.
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) with major diameter facing port
Reelmaster 4000–D
Hydraulic System
Page 4 – 79
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Rear Wheel Drive Motor
8
7
6
1
1
1
5
4
9
3
2
10
1
11
12
13
Figure 68
1. O–Ring Seal
8. Bolt
2. Backup Washer
3. Shaft Seal
4. Key
5. Sub Shaft Assembly
6. Pin
9. Outer Seal
10. Inner Seal
11. Shaft Seal
12. Dust Seal
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-
ingthedisassemblyprocedures, draintheoilfrominside
the motor.
Hydraulic System
Reelmaster 4000–D
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1. Place the motor in a vise with the output shaft down.
Clamp across the mounting flange of the motor not the
housing. Excessive clamping pressure will cause distor-
tion. When clamping, use some protective device on the
vise, such as special soft jaws, pieces of hard rubber or
board.
Althoughnotalldrawingsshowthemotorinavise, we
recommendthatyoukeepthemotorintheviseduring
disassembly and reassembly. Follow the clamping
procedures explained throughout the manual.
Figure 69
Figure 70
Figure 71
Figure 72
2. Remove 4 bolts from motor.
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.
Reelmaster 4000–D
Hydraulic System
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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.
Figure 73
Figure 74
Figure 75
Figure 76
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.
16. Remove the wear plate.
17. Remove the shaft face seal from the wear plate.
18. Remove the 3[76] diameter seal from bearing hous-
ing.
Hydraulic System
Reelmaster 4000–D
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19. You may need a press to remove shaft and bearing
assembly from bearing housing. (Key must be removed
before removing shaft.)
Figure 77
20. Use a small screwdriver to remove shaft seal, back–
upwasherandexclusionsealfrombearinghousing, see
Fig. 78. Do not damage bore of housing.
NOTE: Individual 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 a coarse 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.
Figure 78
NOTE: Lubricate all seals (prior to installation) with pe-
troleum jelly such as Vaseline. Use new seals when
reassembling this motor.
21. Use a press to install exclusion seal in outer bore of
bearing housing. Lip of seal must face outward. See Fig.
79. Ifapressisnotavailableuseaplasticorrubberham-
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: Usetapeoverothershaftstopreventcuttingthe
seats.
25. Apply petroleum jelly to the 3[76] diameter seal.
Install seal into the bearing housing.
Figure 79
Reelmaster 4000–D
Hydraulic System
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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.
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:
1. Geroter
2. Valve Drive
3. Valve Plate
4. Valve
Timing Step #1–Locate the largest open pocket in the
Geroter and mark it on the outside edge of the Geroter.
Figure 80
Figure 81
Figure 82
33. Apply a light film of petroleum jelly to the 3[76] diam-
eter seal. Install seal in groove of valve plate.
34. Align the notch on the outside of the valve plate with
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.
Timing Step #3–Locate any one of the side openings of
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
provide the proper rotation when pressurized as shown
in Fig. 81.
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.
Hydraulic System
Reelmaster 4000–D
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37. Apply petroleum jelly to inner and outer face seals.
Install seals on balance ring as shown in Fig. 83.
IMPORTANT: Install face seals in the positions
shown in Fig. 83. or the motor will not operate prop-
erly. Do not force or bend the face seals. Any dam-
age to these seals will affect the operation of the
motor.
38. Align pin notches in balance ring with pins in bore of
valve housing. Install balance ring assembly in valve
housing.
Figure 83
Figure 84
Figure 85
Figure 86
39. Insert your finger through port of valve housing. Ap-
ply pressure to side of balance ring as shown in Fig. 84.
Hold ring in position until valve housing is in place
against valve plate. See Fig. 85.
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
lb–in[50Nm].
41. Install seal on case drain plug then install in valve
housing. Torque to 50 lb–in[6Nm].
Reelmaster 4000–D
Hydraulic System
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Wheel Motor
On wheel motors, a different bearing housing is used,
see Fig. 87. Other than this the parts are the same as the
standard motor and the same disassembly and reas-
sembly procedures apply.
Figure 87
Hydraulic System
Reelmaster 4000–D
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Rear Wheel Drive Valve Block
NOTE: If cartridge valve seals appear pitted or
damaged,the hydraulic system may be overheating or
there may be water in the
Figure 88
Cleaning Solenoid Actuated Cartridge Valve
Use a deep socket to remove the valve 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
notaffecttheO–ringmaterial. Particlesasfineastalcum
powder can affect the operation of high pressure hy-
draulic valves.
NOTE: Apply clean hydraulic oil to the O–rings before
installingthevalve. Useadeepsockettoinstallthevalve
into the manifold block. Tighten to a torque of 35 ft–lb (48
Nm). Install the solenoid coil. Make sure there is an O–
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 nut. Tighten
the nut to a maximum torque of 15 in–lb (1.7 Nm) to se-
cure the solenoid; do not over–tighten.
Figure 89
Reelmaster 4000–D
Hydraulic System
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Steering Cylinder
1
2
3
4
5
6
7
8
10
11
12
13
14
15
16
17
9
18
Figure 90
1. Set Screw
2. Threaded Cap
3. Rod
4. Rod Wiper
5. U–Cup
10. Spacer
11. Servon
12. O–Ring
13. Piston
14. Locknut
6. Cap Head
7. Backup Washer
8. O–Ring
15. Barrel Assembly
16. Jam Nut
17. Rod Tie, End
18. Roll Pin
9. O–Ring
Steering Cylinder Repair
6. Securely mount piston, piston rod, and head into vise
and remove nut.
IMPORTANT: To prevent damage when clamping
cylinder barrel or rod in a vise, clamp only on pivotal
ends.
IMPORTANT: Do not clamp vise jaws against
smooth piston rod surface; the piston rod will be-
come damaged.
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.
7. Remove piston. Slide head off of piston rod.
8. Remove all seals and O–rings.
2. Plug ports and clean outside of cylinder.
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.
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.
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.
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
Reelmaster 4000–D
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11. Use a complete repair kit when rebuilding the cylin-
der. Put a coating of oil on all new seals, and O–rings.
Install the new seal and O–rings.
14. Put a coating of oil on all cylinder parts to ease as-
sembly.
15. Slide piston rod assembly into cylinder tube.
12. Install head onto piston rod.
16. Install head into tube. Install threaded cap and tight-
en set screw.
13. Install piston onto piston rod with O–ring seal (9) and
tighten hex nut.
Reelmaster 4000–D
Hydraulic System
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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
1. Remove drain plug from reservoir and let hydraulic
oil flow into drain pan. Tighten plug when hydraulic oil
stops draining (Fig. 91).
2
2. Fill reservoir with approximately 9.3 gallons of hy-
draulic oil. Refer to Hydraulic Oil Specifications.
IMPORTANT: Use only hydraulic oils specified.
Other fluids could cause system damage.
Figure 91
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.
1. Drain plug
2. Right front fender
2
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).
1
Figure 92
1. Hydraulic reservoir
2. Sight glass
Hydraulic System
Reelmaster 4000–D
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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).
2
IMPORTANT: Use of any other filter may void the
warranty on some components.
1. Remove seat lock pin, raise seat and hold open with
supportrod. Alsoremovefrontpanel(securedwithmag-
nets) ahead of the seat.
2. Clean area around filter mounting area (Fig. 93).
Place drain pan under filter and remove filter.
1
3. Lubricate new filter gasket and fill the filter with hy-
draulic oil.
Figure 93
1. Hydraulic oil filter
2. Steering pump
4. Assure filter mounting area is clean. Screw filter on
until gasket contacts mounting plate. Then tighten filter
one–half turn.
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.
5. Start engine and let run for about two minutes to
purgeairfromthesystem. Stoptheengineandcheckfor
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
2
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.
Figure 94
1. Breather
2. Exhaust shield
Replace Hydraulic LInes and Hoses
Check hydraulic lines and hoses daily for leaks, kinked
lines, loose mounting supports, wear, loose fittings,
weather deterioration and chemical deterioration. Make
all necessary repairs before operating.
Reelmaster 4000–D
Hydraulic System
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Hydraulic System
Reelmaster 4000–D
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Chapter 5
Electrical System
Table of Contents
ELECTRICAL SCHEMATICS AND DIAGRAMS . . . 2
Reelmaster 4000–D Electrical Schematic
COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . 18
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Glow Plug and Start Relays . . . . . . . . . . . . . . . . . 19
Audio Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Alarm Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Hydraulic Oil Temperature Switch . . . . . . . . . . . . 20
Fuel Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
(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
H O in Fuel Sensor . . . . . . . . . . . . . . . . . . . . . . . . 22
2
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 Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Reelmaster 4000–D Control Panel
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Reelmaster 4000–D Light Cluster Harness . . . . . 11
Reelmaster 4000–D Light Cluster
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
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 14
Starting Problems . . . . . . . . . . . . . . . . . . . . . . . . . . 14
General Run & Transport Problems . . . . . . . . . . . 16
ELECTRICAL SYSTEM QUICK CHECKS . . . . . . . 17
Battery Test (Open Circuit) . . . . . . . . . . . . . . . . . . 17
Reelmaster 4000–D
Page 5 – 1
Electrical System (Rev. A)
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Electrical Schematics and Diagrams
R O T
G L O W I N D I C A
Y
G L O W R E L A
8 6
3 0
8 5
8 7
Y
R U N R E L A
8 5
8 6
8 7
3 0
F U S I B L E L I N K
F U S I B L E L I N K
Electrical System (Rev. A)
Page 5 – 2
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Reelmaster 4000–D
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Electrical System (Rev. A)
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+
+
+
+
+ +
+
+
+ +
Electrical System (Rev. A)
Page 5 – 4
Reelmaster 4000–D
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WIRE IDENTIFICATION
WIRE IDENTIFICATION
LABELCOLOR AWG TYPE ROUTE
LABELCOLOR ROUTE
W33.
W34.
W35.
W36.
W37.
W38.
W39.
W40.
W41.
W42.
W43.
W44.
W45.
W46.
W47.
W48.
W49.
W50.
W51.
W52.
W53.
W54.
W55.
W56.
W57.
W58.
W59.
W60.
W61.
W62.
W63.
W64.
W65.
BRN
WHT
BLU
RED
BRN
VIO
P4–1, J20
W1.
R–66467 J15, SP1
RED SP1, J19
R–66465 J15, SP2
P4–2, P9–1
P4–3, P10–1
P4–4, J2
W2.
W3.
W4.
RED
WHT
RED
SP2, J24
P7–2, J14
W5.
J12, P2–B
J25, P12–1
P11–2, J17
P11–2, P7–5
P11–1, P5–A
P11–1, P7–3
P7–4, P5–C
P7–1, P5–B
W6.
VIO
W7.
RED/BLK P12–2, P6–2
RED J11, J9
RED/BLK J10, J3
P15–1, P12–8
WHT
WHT
YEL
TAN
W8.
W9.
W10.
W11.
W12.
W13.
W14.
W15.
W16.
W17.
W18.
W19.
W20.
W21.
W22.
W23.
W24.
W25.
W26.
W27.
W28.
W29.
W30.
W31.
W32.
BLU
BLU
BLU
YEL
WHT
TAN
GRY
PNK
GRY
ORG
ORG
BRN
YEL
P12–8, P8–A
P15–1, P18–1
P15–2, P3–1
P17–1, P12–5
P17–2, J5
RED/BLK P10–4, P2–A
NOT USED
NOT USED
NOT USED
NOT USED
J6, J7
NOT USED
P17–3, P16–A
P17–4, J22
P17–5, J16
J16, P10–3
P18–2, P12–7
P18–3, P12–4
BLK
BLK
BLK
BLK
BLK
BLK
BLK
BLK
BLK
BLK
BLK
BLK
BLK
BLK
BLK
BLK
J4, SP3
SP3, P6–1
SP3, P10–2
P10–2, J1
J1, P9–2
P9–2, P4–5
SP3, P1–3
J4, P2–C
BLK/WHT P18–4, SP5
BLK/WHT SP5, P4–6
BLK/WHT SP5, P1–2
BLK/WHT SP5, P12–6
BLK/WHT P12–6, P13–2
SP3, P14–1
SP3, SP4
SP4, P8–B
SP4, P17–6
SP4, J23
VIO
P18–5, P14–2
P18–6, P13–1
GRN
GRN/WHT P3–2, J13
GRN P3–3, J18
YEL/BLU P3–4, P1–1
J23, J21
SP4, P16–B
SP4, J8
Reelmaster 4000–D
Supplement to Main Harness Drawing
(S/N below 220000000)
Reelmaster 4000–D
Page 5 – 5
Electrical System (Rev. A)
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W 3 8
W 1 0
W 2 1
W 2 6
W 2 7
W 1 4
W 2 2
W 1 9
W 2 4
W 3 6
W 3 4
W 5 5
W 3 5
W 5 5
Electrical System (Rev. A)
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Reelmaster 4000–D
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Electrical System (Rev. A)
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W 2 2
Y E L L O W
O R A N G E
Y
G R A
P I N K
N T A
V I O L E T
V I O L E T
W H I T E
B L A C K
B L A C K
B L A C K
B L A C K
R E D
B L A C K / W H I T E
G R E E N
B L U E
B R O W N
B L A C K / W H I T E
B L A C K / W H I T E
B L K / W H
W H I T E
Y E L L O W
B L A C K
R E D
B L A C K
B R O W N
O R A N G E
O R A N G E
N T A
B L A C K
R E D / B L A C K
R E D
B L K / W H
B L A C K
R E D
B L U E
W H I T E
B L A C K
W H I T E
R / B L K
R / B L K
Y E L L O W / B L U E
Y E L L O W
B L U E
B L A C K
B L A C K
B L A C K
B L A C K
R E D
B L A C K
R E D
W H I T E
Electrical System (Rev. A)
Page 5 – 8
Reelmaster 4000–D
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WIRE IDENTIFICATION
LABEL COLOR
ROUTE
W1
W2
W3
W4
W5
W6
W7
W8
WHT
TAN
PNK
GRY
ORG
ORG
BLU
BRN
YEL
P2–1, J7
P2–2, P6–2
P2–3, J1
P2–4, P4–3
P2–5, P6–1
P6–1, J6
P1–1, J2
P1–2, –6–3
P1–3, P6–4
W9
W10
W11
W12
W13
W14
W15
W16
W17
W18
W19
W20
W21
W22
W23
BLK/WHT P1–4, P7–A
BLK/WHT P7–A, P3–3
BLK/WHT P3–3, P4–1
BLK/WHT P4–1, P8–A
BLK/WHT P8–A, J5
BLK/WHT J5, P5–B
VIO
VIO
VIO
GRN
TAN
BLK
BLK
BLK
P1–5, P3–1
P3–1, PG–5
P6–5, P5–A
P1–6, P3–5
P3–2, P7–B
P2–6, P3–6
P3–6, P8–C
P8–C, P4–2
Reelmaster 4000–D
Page 5 – 9
Electrical System (Rev. A)
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Electrical System (Rev. A)
Page 5 – 10
Reelmaster 4000–D
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WIRE IDENTIFICATION
LABEL COLOR
YEL/BLU P5–4, J16
GRN P5–3, J14
GRN/WHT 1P5–2, J15
YEL P5–1, J13
YEL/BLU J16, P2–5
GRN J14, P2–4
GRN/WHT J15, P2–1
YEL J13, P2–2
ROUTE
W66.
W67.
W68.
W69.
W70.
W71.
W72.
W73.
W74.
W75.
W76.
W77.
W78.
W79.
W80.
W81.
W82.
W83.
W84.
W85.
W86.
W87.
W88.
W89.
W90.
W91.
W92.
W93.
W94.
W95.
W96.
W97.
W98.
W99.
BLK/WHT P2–3, P2–6
BLK/WHT P2–3, P1–3
BLK/WHT P2–6, P3–1
BLK/WHT P1–3, P1–6
RED
WHT
BLU
BRN
RED
WHT
BLU
BRN
1P4–4, J10
P4–2, J12
1P4–3, J11
P4–1, J9
J10, P1–4
J12, P1–5
J11, P1–1
1J9, P1–2
BLK/WHT 1P1–6, J1
GRY
ORG
1P3–5, J2
1P3–2, J5
GRN/BLK 1J17, J18
GRN/BLK 1J18, J19
GRN/BLK J19, J20
GRN/BLK 1J20, J3
ORG
ORG
ORG
ORG
ORG
YEL
1J21, J22
1J22, J23
1J23, J24
J8, J24
J8, J5
J6, P3–3
1J2, J7
GRY
W100. GRY
J7, P3–4
W101. BLK/WHT J1, P4–6
W102. BLK J4, P4–5
Reelmaster 4000–D
Page 5 – 11
Electrical System (Rev. A)
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W 1 7
W 1 0
W 2 0
Electrical System (Rev. A)
Page 5 – 12
Reelmaster 4000–D
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Special Tools
Order special tools from the TORO SPECIAL TOOLS
AND APPLICATIONS GUIDE (COMMERCIAL PROD-
UCTS).
Some tools may also be available from a local supplier.
Multimeter
The meter can test electrical components and 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.
Figure 1
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.
Figure 2
Reelmaster 4000–D
Page 5 – 13
Electrical System (Rev. A)
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Troubleshooting
For effective troubleshooting and repairs, you must
have a good understanding of the electrical circuits and
components used on this machine (see Electrical Sche-
matics and Diagrams section of this chapter).
CAUTION
Remove all jewelry, especially rings and
watches, before doing any electrical trouble-
shooting or testing. Disconnect the battery
cables unless the test requires battery voltage.
If the machine has any interlock switches by–passed,
they must be reconnected for proper troubleshooting
and safety.
Starting Problems
Problem
Possible Causes
Starter solenoid clicks, but starter will not crank
(if solenoid clicks, problem is not in safety interlock
system).
Low battery charge.
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
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Starting Problems (continued)
Problem
Possible Causes
Engine cranks, but does not start.
Engine run solenoid wiring loose or corroded.
Engine run solenoid faulty.
Low hydraulic oil level.
Hydraulic oil low level switch is faulty.
Hydraulic oil low level switch wiring loose, corroded or
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.
Reel drive neutral switch faulty.
Engine cranks (but should not) with mow–backlap
lever in mow or backlap.
Short circuit in Reel drive neutral switch circuit.
Reelmaster 4000–D
Page 5 – 15
Electrical System (Rev. A)
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General Run and Transport Problems
Engine continues to run (but should not) when parking Seat switch plunger depressed with no operator on
brake is released or mow–backlap lever is in mow or
backlap with no operator on seat.
seat.
Seat switch faulty or out of adjustment.
Short circuit or by–pass in seat switch circuit.
Engine kills when parking brake is released or
mow–backlap lever is moved to mow or backlap.
Operator sitting too far forward on seat (seat switch not
depressed).
Seat hinge, 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.
Engine kills during operation (operator sitting on seat). Operator moved too far forward on seat (seat switch
not depressed).
Low hydraulic oil level.
Engine overheated.
Wire broke or became disconnected.
4WD does not engage.
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.
Battery does not charge.
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.
Electrical System (Rev. A)
Page 5 – 16
Reelmaster 4000–D
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Electrical System Quick Check
Battery Test (Open Circuit Test)
Use a multimeter to measure the voltage between the
battery terminals.
Voltage Measured
12.68 V (or higher)
12.45 V
Battery Charge Level
Fully charged (100%)
75% charged
Set multimeter to the DC volts setting. The battery
o
o
should be at a temperature of 60 to 100 F (16 to 38 C).
The ignition key should be off and all accessories turned
off. Connect the positive (+) meter lead to the positive
battery post and the negative (–) meter lead the the neg-
ative battery post.
12.24 V
50% charged
12.06 V
25% charged
11.89 V
0% charged
NOTE: This test provides a relative condition of the bat-
tery. Load testing of the battery will provide additional
and more accurate information.
Reelmaster 4000–D
Page 5 – 17
Electrical System (Rev. A)
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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
doing a continuity check).
CAUTION
When testing electrical components for continu-
ity with a multimeter (ohms setting), make sure
that power to the circuit has been disconnected.
NOTE: For more component testing information, see
the Kubota Workshop Manual for 03 Series Diesel En-
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.
A
Y
B
S
I
SWITCH
POSITION
NORMAL
CIRCUITS
OTHER
CIRCUITS
X
OFF
RUN
NONE
B + A + I
B + S + I
NONE
X + Y
Figure 3
START
NONE
HEX NUT
KEY
SWITCH
LOCK WASHER
Figure 4
OFF
45 °
RUN
45 °
START
Figure 5
Electrical System (Rev. A)
Page 5 – 18
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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 (–) terminal 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.
87
86
85
87
1. Verify coil resistance between terminals 86 and 85
with a multimeter (ohms setting). Resistance should be
from 41 to 51 ohms.
30
30
85
86
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-
plied and removed from terminal 85.
Figure 7
3. Disconnect voltage and leads from the terminals.
Audio Alarm
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.
2
1
Figure 8
1. Top view
2. Side view
Reelmaster 4000–D
Page 5 – 19
Electrical System (Rev. A)
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Alarm Relay
The alarm relay is located inside the steering tower.
86
85
87A
87
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.
87
87A
86
85
30
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-
plied and removed from terminal 85.
30
3. Disconnect voltage from terminal 85 and multimeter
lead from terminal 87.
TOP VIEW
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.
Figure 9
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).
CAUTION
2
Make sure engine is cool before removing the
temperature switch.
2
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).
Figure 10
1. Side view
2. End view
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
o
o
close between 186 to 194 F (86 to 90 C).
Figure 11
4. Allow the oil to cool. The switch should open below
186 F (86 C).
o
o
Electrical System (Rev. A)
Page 5 – 20
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Fuel Sender
The sender is located on top of the fuel tank under the
rear screen.
2
3
1
1. Remove gray wire and black ground wire from the
sender.
4
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.
5
Note: Before taking small resistance readings with a
digital multimeter, short test leads together. The meter
will display a small resistance value. This internal resis-
tance of the meter and test leads should be subtract
from the measured value of the component.
Figure 12
1. Truss head screw
2. Lock washer
3. Fuel sender
4. Gasket
5. Fuel tank
CAUTION
1
2
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
1. Full position
2. Empty position
5. Replace sender as necessary. Reinstall sender into
fuel tank. Connect wires.
Fuel Gauge
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.
2
1
1. Connect the 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
RESISTANCE
B. The right edge of the green area (full); the resis-
tance setting should be from 28 to 38 ohms.
14 VDC
+
–
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)
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H2O 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.
2
7
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:
6
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.
5
6
4
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.
1
3
C. Check continuity from the pin for the black wire to
chassis ground. Continuity should be 1 ohm or
less.
Figure 15
D. Correct any problem circuitry if necessary.
1. Sensor
5. Filter element
6. Gasket
7. O–ring
2. Filter assembly
3. Drain plug
3. Drain fuel filter assembly into a suitable container.
4. Fuel filter bowl
4. Unscrew fuel filter bowl from the assembly. Remove
filter element, gaskets, and O–ring from the assembly.
Store seals in a clean place.
8. Disconnect connector from sensor. Reassemble
fuel filter assembly. Reconnect connector to sensor.
9. Replace sensor with new one if necessary.
5. Reconnect connector to the sensor. Fill fuel filter
bowl with tap water.
10. Reconnect fuel stop solenoid to the wiring harness.
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
Reelmaster 4000–D
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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
warning 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).
2
1
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).
1. High temp warning
2. High temperature cutout
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).
Figure 17
A. The high temperature warning switch is normally
o
open and should close between 216 to 226 F (102
o
to 108 C).
B. The high temperature cutout switch is normally
o
closed and should open between 225 to 235 F (107
o
to 113 C).
4. Allow oil to cool while observing temperature.
A. The high temperature warning switch should
o
o
open between 216 to 226 F (102 to 108 C).
B. The high temperature cutout switch should close
o
o
between 225 to 235 F (107 to 113 C).
Reelmaster 4000–D
Page 5 – 23
Electrical System (Rev. A)
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Rear Wheel Drive Solenoid
Figure 18
1. Disconnect the wire connector.
Note: Prior to taking small resistance readings with a
digital multi meter, short the test leads together. The me-
ter will display a small resistance value (usually 0.5
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.
2. Check resistance of coil with a digital multimeter.
Resistance should be about 7.2 ohms.
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. If valve operates smoothly, but does not retract
when 12V DC is applied to solenoid leads, replace sole-
noid coil.
4. If valve spool does not retract, check for binding or
damage in valve.
6. If valve still does not retract after replacing solenoid
coil, replace the valve.
Electrical System (Rev. A)
Page 5 – 24
Reelmaster 4000–D
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Fuel Stop Solenoid
The solenoid must be energized for the engine to run. It
is mounted on the engine block near the injection pump.
2
3
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.
4
1
Figure 20
1. Disconnect the connector from the solenoid.
1. Fuel stop solenoid
2. Red wire (hold coil)
3. White wire (pull coil)
4. black wire (common)
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 ”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
Electrical System (Rev. A)
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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.
1
2. Unscrew sender from the cover, and remove it from
the reservoir.
2
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).
5
3. Position float switch L2 against its lower float stop.
3
4. Check for continuity between electrical connector
leads associated with the yellow wires.
L2
L1
4
RED
5. Position float switch L2 against its upper float stop.
YELLOW
L2
L1
6. Check continuity between electrical connector
leads associated with the yellow wires. There should be
no continuity between connector leads.
YELLOW
RED
Figure 21
7. Replace switch as necessary. Install switch to hy-
draulic reservoir.
1. Electrical connector
2. Level switch
3. Float switch
4. Lower float stop
5. Upper float stop
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.
2
Testing
The diodes can be individually tested using a digital
multimeter (ohms setting) and the table below.
2
Figure 22
Red Lead (+)
on Terminal
Black Lead (–)
on Terminal
1. Bottom view
2. Side view
Continuity
YES
NO
AC1
+
+
AC1
+
AC2
+
YES
NO
AC2
AC1
–
AC1
AC2
–
YES
NO
AC1
–
AC2
–
YES
NO
AC2
Figure 23
Electrical System (Rev. A)
Page 5 – 26
Reelmaster 4000–D
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Glow Controller
The controller is located under the right lower corner of
the instrument panel.
2
Controller Operation
6
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.
2
1
5
4
1
Controller Checks
1. Make sure there is power from the battery.
3
Figure 24
2. Disconnect electrical connector to the fuel solenoid
to prevent the engine from starting.
1. End view
2. Top view
3. Side view
3. Place ignition switch in the RUN position. Verify the
following while in the RUN position:
5. If any of the conditions in step 3 are not met or power
to terminal 1 exists and any of the other conditions in
step 4 are not met,
A. Glow indicator lamp is on.
B. Glow relay is energized.
C. Glow plugs are energized.
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).
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).
C. Replace parts as necessary
6. Connect electrical connector to the fuel solenoid.
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
Electrical System (Rev. A)
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Hydraulic Oil Filter Switch
The oil filter switch is activate by 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.
1
2
The purpose of the oil filter switch, warning light, and
alarm is to detect a clogged oil filter. When the hydraulic
o
o
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).
Figure 25
Checks
1. Filter head
2. Filter element
1. Turn off engine. Disconnect electrical connector
from the oil filter switch. Check continuity across the
switch. The switch should indicate open.
1
2. If continuity across the switch indicates open, the
switch is good,
2
A. Check that the oil filter element or filter head is
not clogged.
3
B. Check circuitry to the alarm and warning light for
for possible faults.
WARNING
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.
4
Figure 26
1. Filter switch
2. O–rings
3. Filter head
4. Filter element
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.
3. If continuity across the switch indicates closed, Re-
move and replace switch with a new one.
Electrical System (Rev. A)
Page 5 – 28
Reelmaster 4000–D
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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
3. Leave cables disconnected if the battery is stored
on the machine.
1. Remove the battery and charge it fully (see Battery
Service).
4. Store battery in a cool atmosphere to avoid quick
deterioration of the battery charge.
2. Either store battery on a shelf or on the machine.
5. To help prevent the battery from freezing, make sure
it is fully charged (see Battery Service).
Battery Care
1. Battery electrolyte level must be properly main-
tained. The top of the battery must be kept clean. lf 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.
3. Battery cables must be tight on terminals to provide
good electrical contact.
WARNING
Connecting cables to the wrong post could re-
sult in personal injury and/or damage to the
electrical system.
WARNING
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 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.
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.
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
Electrical System (Rev. A)
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Battery Service
The battery is the heart of the electrical system. With
regular and proper service, battery life can be extend.
Additionally, battery and electrical component failure
can be prevented.
MAX. FILL
DO NOT OVERFILL
MIN. FILL
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.
TORO
Electrolyte Specific Gravity
RECYCLE
MADE IN U.S.A.
o
o
Fully charged: 1.265 corrected to 80 F (26.7 C)
Discharged: less than 1.240
Battery Specifications
Figure 27
BCI Group Size 24:
o
o
650 CCA at 0 F (–17.8 C)
Reserve Capacity of 105 minutes at 25 amp and at
80 F (26.7 C)
B. Check battery terminal posts for corrosion. Use
a terminal brush or steel wool to clean corrosion
from the battery terminal posts.
o
o
Dimensions (not including terminal posts and caps)
Length 10.22 inches (25.96 cm)
Width
Height
6.76 inches (17.17 cm)
9.20 inches (23.39 cm)
IMPORTANT: Before cleaning the battery, tape or
block vent holes to the filler caps and make sure the
caps are on tightly.
Removal
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.
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.
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.
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.
2. Conduct a hydrometer test of the battery electrolyte.
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.
IMPORTANT: Make sure the area around the cells is
clean before opening the battery caps.
Inspection, Maintenance, and Testing (Fig. 27)
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.
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
Reelmaster 4000–D
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B. Temperature correct each cell reading. For each
terminals.
o
o
o
o
10 F (5.5 C) above 80 F (26.7 C) add 0.004 to the
o
o
F. Apply a test load of one half the Cranking Perfor-
mance (see Battery Specifications) rating of the bat-
tery for 15 seconds.
specific gravity reading. For each 10 F (5.5 C) be-
o
o
low 80 F (26.7 C) subtract 0.004 from the specific
gravity reading.
o
G. Take a voltage reading at 15 seconds, then re-
move the load.
Example: Cell Temperature
Cell Gravity
100 F
1.245
H. Using the table below, determine the minimum
voltage for the cell temperature reading.
o
o
o
100 F minus 80 F equals 20 F
o
o
o
(37.7 C minus 26.7 C equals 11.0 C)
o
o
Minimum
Voltage
Battery Electrolyte
Temperature
20 F multiply by 0.004/10 F equals 0.008
o
(11 C multiply by 0.004/5.5oC equals 0.008)
o
9.6
9.5
9.4
9.3
9.1
8.9
8.7
8.5
70 F (and up)
21.1C (and up)
ADD (conversion above)
Correction to 80 F (26.7 C)
0.008
1.253
o
o
60 F
15.6 C
o
o
o
o
50 F
10.0 C
C. If 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.
o
o
40 F
4.4 C
o
o
30 F
–1.1 C
o
o
20 F
–6.7 C
o
o
10 F
–12.2 C
o
o
0 F
–17.8 C
I. 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.
3. Perform a high–discharge test with an adjustable
load tester.
Installation
This is one of the most reliable means of testing a battery
as it simulates the cold–cranking test. A commercial bat-
tery load tester is required to perform this test.
IMPORTANT: To prevent possible electrical prob-
lems, install only a fully charged battery.
1. Make sure ignition switch and all accessories are
off.
CAUTION
2. Make sure battery compartment is clean and re-
painted if necessary.
Follow the manufacturer’s instructions when us-
ing a battery tester.
3. Make sure all battery cables and connections are in
good condition and battery clamp or hold down has
been repaired or replaced.
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.
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.
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.
5. Secure battery retainer. Do not overtighten to pre-
vent cracking or distorting the battery case.
C. Make sure the battery terminals are free of corro-
sion.
6. Apply a light coat of grease on all battery posts and
cable connectors to reduce corrosion after connections
are made.
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
Electrical System (Rev. A)
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7. Connect a digital multimeter (set to amps) between
the negative battery post and the negative (ground)
cable connector. The reading should be less than 0.1
amp. If the reading is 0.1 amp or more, the unit’s electri-
cal system should be tested and repaired.
Battery
Reserve
Capacity
(Minutes)
Battery Charge Level
(Percent of Fully Charged)
75%
50%
25%
0%
8. Connect negative (ground) cable connector to the
negative battery post. Tighten cap screw and lock nut
with two wrenches.
80 or less 3.8 hrs
@
7.5 hrs 11.3 hrs 15 hrs
@
@
@
3 amps 3 amps 3 amps 3 amps
Charging
81 to 125 5.3 hrs 10.5 hrs 15.8 hrs 21 hrs
@
@
@
@
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.
4 amps 4 amps 4 amps 4 amps
126 to
170
5.5 hrs
@
11 hrs
@
16.5 hrs 22 hrs
@
@
5 amps 5 amps 5 amps 5 amps
171 to
250
5.8 hrs 11.5 hrs 17.3 hrs 23 hrs
@
@
@
@
6 amps 6 amps 6 amps 6 amps
CAUTION
above
250
6 hrs
@
12 hrs
@
18 hrs
@
24 hrs
@
Follow the manufacturer’s instructions when us-
ing a battery charger.
10 amps 10 amps 10 amps 10 amps
CAUTION
NOTE: Using specific gravity of the battery cells is the
most accurate method of determining battery condition.
Do not charge a frozen battery because it can ex-
plode and cause injury. Let the battery warm to
1. Determine the battery charge level from either its
open specific gravity or circuit voltage.
o
o
60 F (15.5 C) before connecting to a charger.
Charge the battery in 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.
Battery Charge
Level
Specific
Gravity
Open Circuit
Voltage
100%
75%
50%
25%
0%
1.265
1.225
1.190
1.155
1.120
12.68
12.45
12.24
12.06
11.89
3. Following the manufacturer’s instructions, con-
nect the charger cables to the battery. Make sure a good
connection is made.
2. Determine the charging time and rate using the
manufacturer’s battery charger instructions or the
following table.
4. Charge the battery following the manufacturer’s
instructions.
5. Occasionally check the temperature of the battery
o
o
electrolyte. If the temperature exceeds 125 F (51.6 C)
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.
Electrical System (Rev. A)
Page 5 – 32
Reelmaster 4000–D
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Rear Wheel Drive Solenoid Replacement
Figure 28
1. Disconnect solenoid electrical connector.
2. Remove nut from solenoid.
3. Remove solenoid coil.
4. Install new solenoid coil. Make sure o–ring is
installed at each end of coil. Apply ”Loctite 242” or equiv-
alent to threads on end of valve stem before installing
nut. Tighten nut to a torque of 15 in–lb (17.3 kg–cm).
Over–tightening may damage the solenoid or cause the
valve to malfunction.
5. Connect wiring connector.
Figure 29
Reelmaster 4000–D
Page 5 – 33
Electrical System (Rev. A)
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Check Interlock System
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.
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.
4. Engage 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.
1. In a wide open area free of debris and bystanders,
lower cutting units to the ground. Stop engine.
2. Sit on the seat and engage parking brake. Turn key
and try to start engine with Mow–Backlap 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.
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.
Electrical System (Rev. A)
Page 5 – 34
Reelmaster 4000–D
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Chapter 6
Axles and Brakes
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hand Brake and Traction Switches . . . . . . . . . . . . . 3
Rear Wheel Toe–In . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 5
Rear Wheel Bearings (2WD Only) . . . . . . . . . . . . . . 5
Planetary Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . 7
Reelmaster 4000–D
Axles and Brakes
Page 6 – 1
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Specifications
Item
Description
13 PSI (0.90 Bar)
Front Tire Pressure
Rear Tire Pressure
15 PSI (1.04 Bar)
Front Wheel Nut Torque
Rear Wheel Nut Torque
Wheel Planetary Mounting Cap Screw Torque
Rear Wheel Toe–in
60 to 85 ft–lb (8.3 to 11.8 kg–m)
30 to 35 ft–lb (4.1 to 4.8 kg–m)
95–110 ft–lb (13.1 to 15.2 kg–m)
0.125 inch (0.32 cm)
Wheel Planetary Lubricant (Fig. 1)
SAE 80–90W EP gear lube 30 oz. capacity
2
1
Figure 1
1.
1
oe .N d us
2. Planetary wheel drive
Axles and Brakes
Reelmaster 4000–D
Page 6 – 2
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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. Adjustfour 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.
Figure 2
1. Hand brake
2. Brake cable
3. U–bracket
4. Traction switches
5. Traction pedal
Reelmaster 4000–D
Axles and Brakes
Page 6 – 3
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Rear Wheel Toe–In
After every 800 operating hours or annually, check rear
wheel toe–in.
1. Measure center–to–center distance (at axle height)
at the front and rear of the steering tires (Fig. 3). Front
measurement must be 1/8 inch (0.32 cm) less than the
rear measurement.
2. Loosen clamps 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.
Figure 3
4. Tighten tie rod clamps when the adjustment is cor-
rect.
1
2
Figure 4
1. Clamp
2. Tie rod
Axles and Brakes
Reelmaster 4000–D
Page 6 – 4
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Service and Repairs
Rear Wheel Bearing Service (2WD Only)
44
47
1
2
3
4
32
34
44
45
46
31
42
5
48
29
41
6
5
4
7
39
33
34
43
40
49
35
31
29
8
28 29 30
9
39
10
38
11
12
13 14
15
37
36
27
26
25
22
24
21
23
20
RIGHT
FRONT
16
50
17
18
19
Figure 5
18. Tab washer
19. Valve stem
20. Bearing inner cup
21. Bearing inner cone
22. Inner seal
23. Ball joint (LH or RH)
24. Grease fitting
25. Clamp assembly
26. Lock nut
1. Hex flange head screw
2. Spindle cap
3. Retaining ring
4. Thrust washer
5. Flange bushing
6. Rear axle
7. Wheel spindle (LH)
8. Drive screw
9. Rear wheel hub
10. Outer bearing cup
11. Outer bearing cone
12. Tire
35. Hydraulic hose
36. Steering cylinder
37. Hydraulic hose
38. O–ring
39. Hydraulic fitting
40. O–ring
41. Roll pin
42. Pivot shaft
43. Hex nut
44. Grease fitting
45. Ball joint
46. Cap screw
47. Wheel spindle (RH)
48. Grease decal
27. Tie rod assembly
28. Cap screw
29. Cotter pin
30. Castle nut
31. Castle nut
13. Lug nut
14. Rim
15. Cotter pin
32. Lock nut
49. Grease fitting
50. Retaining nut
16. Hub cap
17. Jam nut
33. Flange bushing
34. Thrust washer
Reelmaster 4000–D
Axles and Brakes
Page 6 – 5
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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).
11. Adjust preload on the wheel bearings (Fig. 6).
A. Tightenjamnutfrom75to80in–lb(86to270kg–
cm) while turning the hub to seat the bearings and
remove all end play.
2. Remove dust cap (16) from the end of the wheel
spindle.
B. Loosen jam nut until it is away from the tab 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.
3. Remove cotter pin (15), slotted nut, and washer
(18). Slide wheel off of the spindle shaft.
4. Pull seal (22) out of wheel hub (9).
C. Putretaineroverthejamnut. Ifthecotterpinhole
is not aligned with a retainer slot, remove retainer
and reorient it until alignment occurs.
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.
D. Insert cotter pin. Bend both legs of the cotter pin
and tap out of the way. Install the cap.
8
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
9
10
7. UseNo. 2generalpurposelithiumbasegreasecon-
taining EP additive. Pack both bearings (11 and 21) with
grease. Install bearing (21) into the cup (20) on inboard
side of wheel hub.
11
6
12
1
IMPORTANT: The lip seal must be pressed in so it is
flush with the end of the hub. The lip of the seal must
be toward the bearing.
2
3
8. Lubricate the inside of the new lip seal (22) and
press it into the wheel hub.
5
4
9. Pack inside of wheel hub with some grease (not
full). Install remaining bearing (11) into bearing cup (10).
Figure 6
1. Cotter pin
2. Spindle
3. Cap
4. Washer
5. Seal
8. Wheel hub
9. Outer bearing cup
10. Outer bearing cone
11. Washer
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.
12. Retainer
6. Inner bearing cone
7. Inner bearing cup
13. Jam nut
Axles and Brakes
Reelmaster 4000–D
Page 6 – 6
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Planetary Wheel Drive
3
4
5
6
7
8
2
6
9
24
20
10
15
28
11
25
26
27
26
25
13
12
29
23
22
21
19
18
17
16
14
Figure 7
1. Coupling
2. Input shaft
3. Spindle
11. Flat washer
21. O–ring
12. Thrust washer
13. Primary sun gear
14. Hex head bolt
22. Disengage plunger
23. Thrust washer
24. Ring gear
4. Oil seal
5. Bearing cone
6. Bearing cup
7. Wheel bolt
8. Hub
9. Bearing cone
10. Hex head bolt
15. Primary carrier assembly
16. Pipe plug
17. Hex head bolt
18. Disengage cover
19. Large cover
25. Retaining ring
26. Washer
27. Disengage spring
28. Retaining ring kit
29. Retaining ring
20. Secondary carrier assembly
Reelmaster 4000–D
Axles and Brakes
Page 6 – 7
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Disassemble Planetary Wheel Drive
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.
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).
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.
3. Remove bolts (17) and large cover (19). The disen-
gage plunger (22) usually remains with the cover. Re-
move plunger and O–ring from the cover on the end of
the input shaft.
6. Assemble splined end of the input shaft down into
the spindle.
4. A thrust washer (23) will usually remain in position
on the thrust face of the cover.
7. Assemble secondary carrier splines over the
splined end of spindle.
5. Remove primary sun gear (13) and thrust washer
(12) from the end of the input shaft. Remove primary
carrier assembly (15).
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 bolt holes 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.
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.
Removeringgear(24). Itmaybenecessarytostrikering
gear with a rubber mallet to loosen from hub.
9. Assemble primary carrier and sun gear into 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.
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. 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.
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.
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-
semblecoverovertheplungerasholesofcoverandring
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).
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.
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).
3. Position spindle (3) upright on bench. Lubricate 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.
14. Invert Power Wheel assembly. Assemble coupling
(1) with the counterbore out to the input shaft.
4. Assemblebearing cone (9) over the spindle and into
the bearing cup (6). Select thickest retaining ring (28)
Axles and Brakes
Reelmaster 4000–D
Page 6 – 8
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Chapter 7
Cutting Units
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Adjust Reel to Bedknife Contact . . . . . . . . . . . . . . . 4
Adjust Height–of–Cut (Floating Cutting Unit) . . . . 5
Quick Method for Changing Height–of–Cut
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 8
Backlapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hydraulic Motor Installation . . . . . . . . . . . . . . . . . . . 9
Bedknife/Bedbar . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Preparing a Reel for Grinding . . . . . . . . . . . . . . . . 14
Front and Rear Rollers . . . . . . . . . . . . . . . . . . . . . . 15
Roller Bearing Replacement . . . . . . . . . . . . . . . . . 16
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
After Initial Set Up of a Floating Cutting Unit . . 6
Adjust Height–of–Cut (Fixed Cutting Unit) . . . . . . 7
Adjust Skids and Front Roller
(Fixed Cutting Unit) . . . . . . . . . . . . . . . . . . . . . . . . 7
Reelmaster 4000–D
Page 7 – 1
Cutting Units
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Specifications
2
1
4
11
6
3
5
7
8
10
9
Figure 1
5. Rear roller adjuster (both ends)
6. Reel–to–bedknife adjuster
7. Guard
1. Drive housing cover
2. drive housing
3. Drive plate shield
4. Grass deflector
9. Reel
10. Optional front roller
11. Top covers
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.
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.
Reel Configuration: The 5, 7, and 11 blade heavy duty
welded reels all have 8 inch (20.3 cm) diameters and are
29–3/4 in. (75.5 cm) wide.
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)
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.
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)
Bedknife to Reel Adjustment: Two lockable lead
screw adjusters at each side of the frame adjust the reel
to bedknife contact.
Lubrication: Easily accessible grease fittings for bear-
ings and all major pivot points are provided.
Drive: The reel drive motor turns a maintenance–free
cog belt that drives the reel. Drive pulley and cog belt are
encased in a drive housing for safety and protection
from contamination.
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.
Grass Deflector Shields: Shields are fully adjustable.
Cutting Units
Page 7 – 2
Reelmaster 4000–D
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Special Tools
Order special tools from the TORO SPECIAL TOOLS
AND APPLICATIONS GUIDE (COMMERCIAL PROD-
UCTS).
Some tools may be listed in the Reelmaster 4000–D
Parts Catalog. Some tools may also be available from
a local supplier.
Gauge Bar Assembly
Use gauge bar to set final height–of–cut (floating cutting
units with front rollers only).
Figure 2
Handle Assembly
For applying lapping compound to cutting units while
keeping hands a safe distance from the rotating reel.
Figure 3
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.
Figure 4
Reelmaster 4000–D
Page 7 – 3
Cutting Units
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Adjustments
CAUTION
Never install or work on the cutting units or lift
arms with the traction unit engine running. Al-
ways stop the engine and remove the key first.
Adjust Reel to Bedknife Contact
The cutting units will provide optimum mowing perfor-
mance when adjusted and maintained correctly. Keep-
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.
Figure 5
CAUTION
1. Adjuster locking nut
2. Adjustment knob
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.
IMPORTANT:Adjusted correctly so that the reel will
cut a piece of paper approximately 0.003 inch
(0.076mm) thick across its entire length.
3. Ifexcessivecontactisdetermined, turneachadjust-
ing knob equally and counter–clockwise until no contact
is noticed. Then turn both adjusting knobs equally and
clockwiseuntillightcontactisfeltandheardbetweenthe
reel and bedknife. Final adjustment should always be
in the tightening (clockwise) direction.
Note: A 3/4–inch wrench is required for making the
reel to bedknife adjustment.
CAUTION
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.
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.
4. Tighten adjuster locking nuts when adjustments are
complete.
2. If no contact is determined, loosen adjuster locking
nut on each adjuster (Fig. 5). Turn each adjuster knob
equallyandclockwiseuntillightcontactisfeltandheard.
Cutting Units
Page 7 – 4
Reelmaster 4000–D
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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 to
secure lockout. Raise front rollers up so they do not
contact the flat surface.
Figure 6
Cutting Unit Float Position
1. Lockout pin
2. Jam nut
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.
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).
Figure 7
Cutting Unit Fixed Position
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.
1. Lockout pin
2. Jam nut
HOC + 3/8 INCH
(+ 9.5 mm)
D. Rear roller is now leveled to the reel.
Figure 8
Leveling Rear Roller to Reel
Reelmaster 4000–D
Page 7 – 5
Cutting Units
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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).
Figure 9
Gauge Bar Assembly
APPROXIMATELY 3/8 INCH
(9.5 MM) HEEL UP*
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 the 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.
Figure 10
Final Height–of–Cut Adjustment Using Gauge Bar
E. Loosen lockout pin so cutting unit can float freely
(Fig. 6).
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
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.
Cutting Units
Page 7 – 6
Reelmaster 4000–D
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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).
HOC +3/8 INCH
(9.5 MM)
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 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).
Figure 11
6. Adjustrearrolleradjustmentknobsandjamnutsun-
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.
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:
6
4
3
7
1
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.
4
3
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).
2
5
5
Figure 12
Note: Proper adjustment is achieved when the cutting
1. Cap screw
2. Lock nut
3. Cap screw
4. Lock nut
5. Skid
6. Side plate
7. Skid bracket
unit does not scalp the grass in normal mowing condi-
tions and yet is set high enough not to mar the turf and
create undue wear on the skids or rollers. Skids and
front rollers used to prevent scalping should not ride on
the ground.
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).
3. Adjust each skid or front roller so it is 1/8 to 1/4 in.
(3 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
Page 7 – 7
Cutting Units
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Service and Repairs
CAUTION
Never remove, install, or work on the cutting
unitsorliftarmswiththetractionunitenginerun-
ning. Stop engine and remove key from ignition
switch first.
Backlapping
2nd Person’s Duties:
CAUTION
1. Instruct operator when to start and stop the reels.
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.
CAUTION
Never use a short–handle paint brush to apply
backlappingcompound. Arotatingreelcanpulla
short–handle paint brush and the users hand
into the reel causing serious personal injury.
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.
2. Dip 3–inch (76 mm) wide paint brush attached to
Toro Part No. 29–9200 Handle Assembly into lapping
compound. Stand clear and instruct operator to engage
the reel into the backlap mode.
Use a good grade of medium grit (80 coarseness) lap-
ping compound with a water soluble carrier. Mix dry lap-
ping compound with liquid detergent until it has a
free–flowing consistency.
3. Apply lapping compound evenly over the full length
ofthereel. Makesureallreelbladesarecovered. 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.
Note: Before starting the engine, raise grass deflector
on the center cutting unit and tighten fasteners to retain
the deflector in the raised position.
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.
Operator Duties:
1. Sit on seat and engage parking brake.
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.
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.
6. Upon completion, stop reel and turn off engine. Re-
move key from the ignition switch. Wash unit thoroughly
withalowpressurestreamofwatertoremovealllapping
material. Allow reel to dry. Lubricate grease fittings.
4. Wait for 2nd person’s instruction to engage reels in
backlap mode, then pull mow–backlap lever to the
BACKLAP position and hold.
7. Checksharpnessofthereelandbedknifewithnews
paper strips. Light reel to bedknife contact should shear
the paper cleanly across the reel’s entire width. If the pa-
per is not sheared acceptably, continue backlapping.
5. Follow 2nd person’s instructions. Be prepared to
stop reels and engine quickly in case of an emergency.
8. Proceed backlapping the remaining cutting units.
Note: See
Toro
Sharpening
Manual
(Part
#80–300PT) for additional backlapping information.
Page 7 – 8 Reelmaster 4000–D
Cutting Units
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Hydraulic Motor Installation
1. Install drive plate shield onto the reel drive motor
flange. Be sure the widest portion of the shield is at the
top (Fig. 13).
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 N) of force is applied.
3. Inserttwo(2)reeldrivemotormountingbolts(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).
Figure 13
1. Drive plate shield
2. Reel drive motor flange
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
suretheendsofthegasketareatthebottomofthehous-
ing to allow for drainage.
Figure 14
1. Hydraulic motor
2. Motor pulley
3. Drive belt
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 hydraulic
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.
2
Note: Refer to the Traction Unit Operator’s Manual for
instructions on setting the adjustable hydraulic counter-
balance.
Figure 15
1. Mounting bolts
2. Drive housing
Reelmaster 4000–D
Page 7 – 9
Cutting Units
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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-
oughly of all rust and scale. Remove any material on the
mounting face of the bedbar that will affect a good
match–up with the bedknife.
Figure 16
1. Shoulder bolt (2 each side)
3. Spacer
2. Bushing
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 torque wrench and
bedknife screw tool. Tighten screws to a torque of 250
to 300 in–lb (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
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
set–up and operation of the grinder.
1. Torque wrench
2. Bedknife screw tool
Note: When grinding, be careful to not overheat the
bedknife. Remove small amounts of material with each
pass of the grinder.
Top Face
Remove
Burr
Relief Angle
Front
Face
Bedknife Grinding Specifications
o
Relief Angle
5
o
o
Relief Angle Range
Front Angle
3 to 6
Front Angle
o
15
o
o
Front Angle Range
13 to 17
Figure 19
Cutting Units
Page 7 – 10
Reelmaster 4000–D
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Reel Assembly
Disassembly
1. Removetheguardsfromeachendofthecuttingunit
and the front and rear roller assemblies (Fig. 20).
2. Remove shoulder bolts, bushings and spacers from
each end of the unit and remove the bedbar/bedknife
assembly (Fig. 21).
3. Remove inboard locknut from the adjuster 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).
Figure 20
1. Guard
2. Mounting fasteners
3. Adjusting assembly
4. Dust cap
5. Disassembleconenutfromtheshoulderboltsecur-
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 21
1. Lock nut
2. Belleville washer
3. Shoulder bolt
4. Bearing housing
5. Reel shaft
6. Flange housing
Figure 22
1. Drive housing
2. Drive belt
Reelmaster 4000–D
Page 7 – 11
Cutting Units
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6. Disassemble cover from the drive housing and re-
move the drive belt from the housing (Fig. 23).
Note: Reel capscrew is assembled with a thread lock-
ing compound
7. Remove reel capscrew, toothed washer, and pulley
washer from the reel shaft (Fig. 23).
8. Remove driven pulley from the reel shaft 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. Slide reel assembly out of the slots in the side
plates.
Figure 23
1. Cap screw
5. Adjustment handle
6. Woodruff key
7. Drive housing fasteners
11. Inspect bearings and grease seals in their housings
as follows:
2. Pulley washer
3. Driven pulley
4. Drive housing
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
bearingandrearsealoutfromtheoutersideofthehous-
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
Page 7 – 12
Reelmaster 4000–D
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Assembly
1. Inspect flange bushings in the mounting holes of the
drive housing and bearing housing for wear (Fig. 21).
Replace, if necessary.
2. Assemble outer seal (lip facing in to retain grease)
into the drive housing using Loctite 242 (or equivalent)
retaining compound on the outer diameter. 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).
Figure 24
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).
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).
4. Apply a light 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 the housing and install the
dust cap into the housing.
11. Install reel adjustment assemblies to each side
plate. Install roll pins before tightening fasteners.
6. Assemble reel assembly to the frame. Ensure
shield washer is installed on the drive housing end of the
reelshaft. Aligndrivepinonreelshaftwithslotinbearing
and slide the drive housing onto the shaft.
12. Install bedbar/bedknife assembly.
13. Install front and rear roller assemblies or skids.
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).
14. Adjust reel to the bedknife (see Reel to Bedknife.
Adjust height–of–cut (see Adjust Height–of–Cut).
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 ft–lbs (6.2 to 7.6 kg–m).
Reelmaster 4000–D
Page 7 – 13
Cutting Units
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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.
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).
1. Remove the bedbar assembly (Bedknife/Bedbar
Disassembly).
C. Do a complete cutting unit set–up and adjust-
ment procedure (see Adjustments section).
2. Remove parts as necessary to mount the cutting
unit into the grinder (e.g., front roller, front roller brack-
ets).
Reel Grinding Specifications
3. Follow the grinder manufacturer’s instructions for
set–up and operation of the grinder.
Nominal Reel Diameter
Service Limit Reel Diameter
Blade Relief Angle
Relief Angle Range
Blade Land Width
8
in (206 mm)
7.2 in (182 mm)
Note: The cutting unit must be aligned so the grinding
wheel will travel parallel to the reel shaft. This will result
in the reel being ground to the desired cylinder shape.
o
30
o
o
20 to 40
0.060 in (1.5 mm)
0.050 to 0.090 in (1.3 to 2.3 mm)
0.060 in (1.5 mm)
Note: When grinding, be careful to not overheat the
reel blades. Remove small amounts of material with
each pass of the grinder.
Land Width Range
Max. Reel Taper
BLADE RELIEF ANGLE
REEL DIAMETER
BLADE
LAND
WIDTH
D
2
D
1
REEL DIAMETER TAPER = D – D
1
2
Figure 25
Cutting Units
Page 7 – 14
Reelmaster 4000–D
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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)
Figure 26
A. Unscrew upper cone nut from the collar assemb-
ly.
1. Guard
3. Side plate
4. Mounting fasteners
2. Roller adjustment housing
B. Drop collar assembly out of the adjustment
housing.
C. Separate both collar assemblies from both ends
of the roller shaft.
Installation
IMPORTANT:When 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).
Figure 27
1. Install roller adjustment housing to the side plate
(Fig. 26).
1. Cone nut
2. Collar assembly
3. Lock nut
A. Install roller adjustment housings to both ends of
the roller shaft.
C. Thread cone nut onto each collar assembly with
the cone facing down.
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.
D. Adjust height–of–cut (see Adjust Height–of–
Cut).
2. Installcollarassemblytotherolleradjustmenthous-
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
Cutting Units
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Roller Bearing Replacement
3
6
8
10
12
1
4
7
9
11
2
11
9
7
5
12
10
8
6
Figure 28
1. Roller tube (front roller shown)
2. Roller shaft
3. Grease fitting
5. Jam nut
9. O–ring
10. Bearing cone
11. Bearing cup
6. Trust washer
7. Outer grease seal
8. Wear sleeve
4. Lock nut
12. Inner grease seal
Removal
WARNING
1. Clean roller around the shaft, grease fittings, and
bearing thoroughly. Both ends of the roller should be
free of dirt and debris.
If removing bearing cups from a rear roller with
anarcwelder, makesuretheentirerollerisfreeof
oil. Clean inside and out side thoroughly.
2. Secure roller tube in a vise keeping it level.
3. Remove both grease fittings before removing the
bearings.
Note: An electric arc welder can be used to shrink the
bearingcuptosimplyitsremoval. Onlyasmallarcinone
location on the cup is required.
4. Remove jam nut, lock nut, and both thrust washers
from the roller shaft. Pull both outer grease seals from
inside the roller tube.
9. Remove both bearing cups from the roller tube.
Installation
5. Use a soft 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.
IMPORTANT: Replace both bearing cones and cups
with new ones, since both bearing cones and cups
may be damaged during removal.
6. Pull remaining wear sleeve, O–ring, and bearing
cone from the roller.
1. Make sure all parts are cleaned thoroughly. Inside
of roller tube should be free of dirt and debris.
7. Pull both inner grease seals from inside the roller
tube. Discard all four grease seals and both O–rings.
2. Onthefrontroller, pressnewinnergreasesealsinto
the roller tube with the garter spring of the seal facing
away from the center of the roller (Fig. 29).
8. If disassembling a rear roller, pour oil from the inside
the roller into a suitable container.
Cutting Units
Page 7 – 16
Reelmaster 4000–D
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1
4
2
3. On the rear, wiehle, and sectional rollers, press new
inner grease seals into the roller tube with the garter
spring of the seal facing towards the center of the roller
(Fig. 30).
8
7
12
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.
10
11
7. Make sure roller shaft is free of nicks and burrs that
could damage the grease seals. Make sure grease pas-
sages are clear.
6
9
3
8. Apply antiseize lubricant to the roller shaft. Insert
shaft through the roller tube and grease seals making
sure not to damage the seals.
5
Figure 29
1. Inner grease seal
2. Roller tube
3. Bearing cup
4. Roller shaft
5. Bearing cones
6. O–ring
7. Wear sleeve
9. Install both bearing cones to the roller shaft and into
the bearing cups.
8. Outer grease seal
9. Thrust washer
10. Jam nut
11. Lock nut
12. Grease fitting
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.
4
1
8
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).
2
7
12
12. On the rear, wiehle, and sectional rollers, press new
outer grease seal into the roller tube with the 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.
11
6
9
3
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.
5
Figure 30
1. Inner grease seal
2. Roller tube
3. Bearing cup
4. Roller shaft
5. Bearing cones
6. O–ring
7. Wear sleeve
Note: Starting torque may exceed 10 ft–lb (1.4 kg–m)
when torquing the lock nut the second time. This torque
will fall once the nut starts to turn.
8. Outer grease seal
9. Thrust washer
10. Jam nut
11. Lock nut
12. Grease fitting
16. Torque lock nut while rotating shaft from 10 to 15 ft–
lb (1.4 to 2.1 kg–m) a second time.
17. Installgreasefittings. Lubricateeachbearingwithat
least 1 oz. (33 ml) of No. 2 general purpose lithium base
grease.
Reelmaster 4000–D
Page 7 – 17
Cutting Units
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Lubrication
Use a hand–operated grease gun and No. 2 general
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 minimizewa-
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
allowswatertodrainfromtheendsoftherollersand
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).
Figure 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.
Figure 32
Figure 33
Cutting Units
Page 7 – 18
Reelmaster 4000–D
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Commercial Products
E The Toro Company
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