Page 1: Service Manual
Bloomington, MN 55420−1196 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, 2005, 2007...
Page 2 Reelmaster 4000−D...
Page 3: Table Of Contents
Table Of Contents Chapter 1 − Safety Chapter 4 − Hydraulic System General Safety Instructions ....1 − 1 Specifications ......4 −...
Page 4 Reelmaster 4000−D...
Page 5: General Safety Instructions
....General Safety Instructions The Reelmaster 4000−D was tested and certified by TORO for compliance with the B71.4−1984 specifica- WARNING tions of the American National Standards Institute for...
Page 6: While Operating
16. Keep hands, feet, andclothing away from moving chocked or blocked. 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.
Page 7 29. Keep body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid. Use 37. Toro recommends that two people be used to back- cardboard or paper to find hydraulic leaks. Hydraulic lap reels. Each person has specific duties and you must fluid escaping under pressure can penetrate skin and communicate with one another.
Page 8: Safety And Instruction Decals
Numerous safety and instruction decals are affixed to the Reelmaster 4000−D. If any decal becomes illegible or damaged, install a new decal. Part numbers for re- placement decals are listed in your Parts Catalog. Order replacement decals from your Authorized Toro Distribu- tor. Safety Reelmaster 4000−D Page 1 −...
Page 9 Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS ......MAINTENANCE ......EQUIVALENTS AND CONVERSIONS .
Page 10: Product Records
Equivalents and Conversions 0.09375 Product Records and Maintenance Reelmaster 4000−D Page 2 − 2 Rev. C...
Page 11: Torque Specifications
For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.
Page 12 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Grade 1, 5, & SAE Grade 1 Bolts, Screws, Studs, & SAE Grade 5 Bolts, Screws, Studs, & SAE Grade 8 Bolts, Screws, Studs, & Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts...
Page 13: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Metric Fasteners)
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws, and Studs with Class 10.9 Bolts, Screws, and Studs with Thread Size Thread Size Regular Height Nuts Regular Height Nuts Regular Height Nuts Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts) M5 X 0.8...
Page 14: Other Torque Specifications
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Thread Size Square Head Hex Socket 7/16 − 20 UNF 65 + 10 ft−lb 88 + 14 N−m Grade 5 1/4 −...
Page 15: Lubrication
Lubrication GREASING BEARINGS AND BUSHINGS Note: Remove plastic caps over the fittings on the floating or fixed head pivots and replace caps after The machine has grease fittings that must be lubricated greasing (Fig. 3). after every 50 hours of operation with No. 2 General Pur- pose Lithium Base Grease.
Page 16 This Page Intentionally Left Blank Product Records and Maintenance Reelmaster 4000−D Page 2 − 8 Rev. C...
Page 17: Adjustments
Chapter 3 Kubota Diesel Engine Table of Contents INTRODUCTION ......Change Engine Oil and Filter .
Page 18: Introduction
If no parts list is available, be sure to provide your distrib- 03 Series, Diesel Engine. The use of some specialized utor with the Toro model and serial number. test equipment is explained. However, the cost of the Kubota Diesel Engine Reelmaster 4000−D...
Page 19: Specifications
Specifications Item Description Make / Designation Kubota, V2203, 4−Cylinder, 4−Cycle, Water Cooled, In−line, Spherical Chamber, OHV, Diesel Engine Horse Power 39.4 HP @ 2300 RPM Torque 103 ft−lb @ 1600 RPM Firing Order 1 − 3 − 4 − 2 Bore mm (in.) 87.0 (3.43) Stroke mm (in.)
Page 20: General Information
General Information Check Engine Oil 1. Park machine on a level surface. Stop engine. Re- move key from the ignition switch. 2. Release engine cover latches. Open engine cover (Fig. 1). 3. Remove dipstick, wipe clean and reinstall dipstick into tube and pull it out again. Oil level should be up to the FULL mark (Fig.
Page 21: Check Cooling System
Check Cooling System Check level of coolant at the beginning of each day. Ca- pacity of system is 3.7 gal. (14 L). CAUTION If engine is hot, pressurized coolant can escape and cause burns when the radiator cap is re- moved.
Page 22: Prime Fuel System
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. Note: The fuel pump, located on left side of engine, under the fuel injection pump and behind the fuel stop solenoid.
Page 23: Adjustments
Adjustments Adjust Alternator Belt Check condition and tension of belt after every 100 op- erating hours (Fig. 9). 1. Park machine on a level surface. Stop engine. Re- move key from the ignition switch. 2. Proper belt tension will allow 3/8 inch (10 mm) deflection when a force of 10 lbs (44.4 N) is applied on the belt midway between both pulleys.
Page 24: Service And Repairs
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.
Page 25: Change Engine Oil And Filter
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.
Page 26: Drain Fuel System
Drain Fuel System DANGER Because diesel fuel is highly flammable, use cau- tion when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot, or when machine is in an enclosed area.
Page 27: Check Fuel Lines And Connections
Check Fuel Lines and Connections Check lines and connections every 400 hours or yearly, whichever comes first. Inspect for deterioration, dam- age, or loose connections. Replace Fuel Filter DANGER Because diesel fuel is highly flammable, use cau- tion when storing or handling it. Do not smoke while filling the fuel tank.
Page 28: Engine Cooling System
Engine Cooling System Debris Removal Remove debris from oil cooler, radiator and rear screen daily, clean more frequently in dirty conditions. 1. Park machine on a level surface. Stop engine. Re- move key from the ignition switch. 2. Release front engine cover latches and raise engine cover.
Page 29: Engine
Engine Engine Removal 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Pivot seat up. Lift front canopy and remove from the brackets (Fig. 19). Figure 19 1.
Page 30 9. Clamp to prevent drainage, and disconnect the fol- lowing fuel hoses: A. Suction hose at the injector pump from the fuel filter. Suction and discharge hoses at the fuel pump (Fig. 22). B. Return hose from the fuel injectors (Fig. 23). Figure 22 1.
Page 31 12. Separate hydraulic pump assembly from the engine (Fig. 25). A. Disconnect damper from the bracket. B. Remove four cap screws, lock washers, and flat washers securing the pump mounting flange to the pump adapter plate. C. Support pump, and pull pump shaft from the spring coupling.
Page 32: Engine Installation
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 One person should operate lift or hoist while the filter.
Page 33: Special Tools
Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS ......Test No. 1: Check Traction Working GENERAL INFORMATION .
Page 34: Specifications
Specifications Item Description Traction Pump Variable displacement axial piston pump Traction Relief Pressure 5000 − 5200 PSI Charge Pressure 50 − 150 PSI (2WD) 75 − 150 PSI (4WD) Steering Pump Gear pump with flow divider Steering Relief Pressure 1200 − 1300 PSI Traction Motor (front) Fixed axial piston motor Traction Motor (rear w/4WD)
Page 35: General Information
General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as, pressure differentials during operation and exposure WARNING to weather, sun, chemicals, very warm storage condi- tions or mishandling during operation or maintenance. Before disconnecting or performing any work These conditions can cause damage or premature dete- on hydraulic system, all pressure in system rioration.
Page 36 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.
Page 37: Pushing Or Towing Traction Unit
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 7 Front panel 4.
Page 38 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 1.
Page 39: Check Hydraulic System Fluid
Check Hydraulic System Fluid 1. Look into sight glass (Fig. 11). Oil level should be even with arrows when checking warm oil. Oil will be 1/4 to 1/2 inch below arrows when cold. 2. If oil level is low, add hydraulic oil to the reservoir (see Add Hydraulic Fluid).
Page 40: Hydraulic Schematic
Hydraulic Schematic Hydraulic System Page 4 − 8 Reelmaster 4000−D...
Page 41: Hydraulic Flow Diagrams
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 After joining with oil returning from other functions coupled to the engine. With all controls in neutral and the through the drain block, the oil flows through the oil cool- engine running, the steer−lift pump draws oil through the er to dissipate heat from the hydraulic system and then...
Page 42: Engine Run − No Functions
Engine Run − No Functions Hydraulic System Page 4 − 10 Reelmaster 4000−D...
Page 43: Traction Circuit
Traction Circuit Refer to “Traction Circuit − Forward” Flow Diagram A mechanical interlock between the traction pedal link- inlet of the traction motors. The oil returns from the mo- age and the parking brake prevents traction pedal tor to the pump where it continues through the pump in movement unless the brake is released.
Page 44: Traction Circuit − Forward
Traction Circuit − Forward Hydraulic System Page 4 − 12 Reelmaster 4000−D...
Page 45: Steering Circuit
Steering Circuit Refer to “Steering Right” Flow Diagram With the engine running, the priority flow of oil from the cylinder for a right−hand turn. Turning the steering steer−lift pump is directed to the power steering unit at wheel to the left has the opposite effect. Cylinder move- the base of the steering column and returns to the reser- ment returns oil from the low pressure side back through voir.
Page 46: Steering Right
Steering Right Hydraulic System Page 4 − 14 Reelmaster 4000−D...
Page 47: Lift/Lower Circuit
Lift/Lower Circuit Refer to “Lift Circuit” Flow Diagrams while the cutting unit is lowering will lock the cutting unit The lift cylinders are controlled by an open center valve with three spools. The number 4 and 5 cutting units are at any position by trapping oil between the valve and cyl- independently controlled.
Page 48: Lift Circuit − Lift All Units
Lift Circuit − Lift All Units Hydraulic System Page 4 − 16 Reelmaster 4000−D...
Page 49: Lift Circuit − Lower All Units
Lift Circuit − Lower All Units Reelmaster 4000−D Page 4 − 17 Hydraulic System...
Page 50 Lift Circuit − Free Float (Detent) Hydraulic System Page 4 − 18 Reelmaster 4000−D...
Page 51: Reel Circuit
Reel Circuit Refer to “Reel Circuit” Flow Diagrams 5 shut−off valve. If the Number 4 cutting unit is in the The three reel shut−off valves in this circuit enable the cutting units to be operated in several configurations for raised position, the oil will bypass the Number 4 reel mo- easier control, better clearance, or closer trimming.
Page 52: Reel Circuit − All Units Mow (Free Float)
Reel Circuit − All Units Mow (Free Float) Hydraulic System Page 4 − 20 Reelmaster 4000−D...
Page 53: Reel Circuit − Units 1, 2 & 3 Mow (Free Float)
Reel Circuit − Units 1, 2 & 3 Mow (Free Float) Reelmaster 4000−D Page 4 − 21 Hydraulic System...
Page 54: Reel Circuit − Units 1, 2, 3 & 5 (Free Float)
Reel Circuit − Units 1, 2, 3 & 5 Mow (Free Float) Hydraulic System Page 4 − 22 Reelmaster 4000−D...
Page 55: Reel Circuit − Any Unit Backlap
Reel Circuit − Any Unit Backup Reelmaster 4000−D Page 4 − 23 Hydraulic System...
Page 56: 4Wd Selector Valve Operation
4WD Selector Valve Operation 4WD Forward (“S1” OFF) Pressure Oil Pressure Free Hydraulic System Page 4 − 24 Reelmaster 4000−D...
Page 57: 2Wd Forward
2WD Forward (“S1” ON) Pressure Oil Pressure Free Reelmaster 4000−D Page 4 − 25 Hydraulic System...
Page 58: Special Tools
You must have o−ring face seal (ORFS) adapter fittings 4. HIGH PRESSURE GAUGE: High range gauge to for this tester to use it on Toro equipment. accommodate pressure beyond the capacity of the low pressure gauge, 0 − 5,000 PSI.
Page 59: Hydraulic Pressure Test Kit
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.
Page 60: Troubleshooting
Troubleshooting The cause of an improperly functioning hydraulic sys- Continued use of an improperly functioning hydraulic tem is best diagnosed with the use of proper testing system could lead to extensive internal component equipment and a thorough understanding of the com- damage.
Page 61: Steering Loss
Problem Possible Causes Steering loss. Thermal shock after washing. NOTE: Normal functions will return after orbital tem- peratures stabilize (approximately 15 minutes). DO NOT ATTEMPT TO TURN STEERING WHEEL UN- TIL TEMPERATURES STABILIZE WHEN THER- MAL SHOCK IS NOTED. Improper cylinder action. Low steering relief pressure.
Page 62: Testing
Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment WARNING such as pressure gauges and flow meters in the circuits during various operational checks. (See the Special Keep body and hands away from pin hole leaks Tools section in this Chapter.) or nozzles that eject hydraulic fluid under high pressure.
Page 63: Test No. 1: Check Traction Working And Relief Pressures
TEST NO. 1: Check Traction Circuit Working and Relief Pressures Procedure for Working Pressure Check: 1. Install a 10,000 psi gauge into the quick disconnect test port for the function to be checked. NOTE: If the machine is equipped with 4WD, check working pressure in both 2WD and 4WD modes.
Page 64: Test No. 2: Check Counterbalance Oil Pressure
TEST NO. 2: Check Counterbalance Oil Pressure Procedure: 1. Install a 10,000 psi gauge into the center quick dis- connect as shown. 2. Start the engine and move throttle to full speed (2500 rpm). 3. Tester reading should be within the range listed: COLD OIL: 600 −...
Page 65: Test No. 3: Check Reel Circuit Working And Relief Pressures
TEST NO. 3: Check Reel Circuit Working and Relief Pressures Procedure For Working Pressure Check: 1. Install a 5,000 psi gauge into the cutting circuit quick disconnect. 2. Operate the unit while monitoring the gauge. RANGE OF TESTER READINGS 0 − 2750 PSI 3.
Page 66: Test No. 4: Check Reel Circuit Flow
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.
Page 67: Test No. 5: Check Reel Motor Cross−Over Relief Pressure
TEST NO. 5: Check Reel Motor Cross−Over Relief Pressure FROM LIFT CIRCUIT CUTTING CIRCUIT TEST PORT PRIORITY (TYP) FROM GEAR PUMP 3000 TO HYDRAULIC OIL TANK Figure 19 NOTE: Before testing a reel motor for possible failure, CAUTION make sure to inspect the affected cutting unit for pos- sible causes of malfunction.
Page 68: Test No. 6: Check Reel Motor Case Drain Flow
TEST NO. 6: Check Reel Motor Case Drain Flow FROM LIFT CIRCUIT CUTTING CIRCUIT TEST PORT PRIORITY FROM (TYP) IN GEAR PUMP 3000 QUART CONTAINER TO HYDRAULIC OIL TANK Figure 20 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 CAUTION minutes.
Page 69: Test No. 7: Check Steering Circuit Working And Relief Pressures
TEST NO. 7: Check Steering Circuit Working and Relief Pressure Procedure For Working Pressure Check: 1. Install a 5,000 psi gauge into the steering quick dis- connect. 2. Operate the unit while monitoring the gauge. RANGE OF TESTER READINGS 0 − 1300 PSI 3.
Page 70: Test No. 8: Check Lift Circuit Working And Relief Pressures
TEST NO. 8: Check Lift Circuit Working and Relief Pressure Procedure For Working Pressure Check: 1. Install a 5,000 psi gauge onto the quick disconnect of the lift valve. 2. Operate the unit while monitoring the gauge. Gauge should read from 500 to 2900 PSI. 3.
Page 71: Service And Repairs
Service and Repairs Removing Hydraulic System Components 1. Thoroughly clean the machine before disconnecting, 2. After repairs, check control linkage for proper adjust- removing or disassembling any hydraulic components. ment, binding or broken parts. Always keep in mind the need for cleanliness when 3.
Page 72: Steering Control Unit
Steering Control Unit Figure 25 1. Seal 1” I.D. 15. Gerotor 2. Retaining Ring 16. End Cap 3. Seal Gland Bushing 18. Cap Screw 4. Seal 1.875 I.D. 19. Pin Kit, Centering 5. Quad Ring Seal, 1.062 I.D. 20. Spring 6.
Page 73 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 2. Remove 5/16” cap screws. 3.
Page 74 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.
Page 75 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.
Page 76 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.
Page 77 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.
Page 78 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.
Page 79 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.
Page 80 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.
Page 81 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.
Page 82 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.
Page 83: Add Hydraulic Fluid
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.
Page 84: Reel Motor
Reel Motor Figure 54 8. Plate & Bushing Assembly 15. Relief Valve Kit 1. Not used 2. Idler Gear 9. Socket Head Cap Screw 16. O−Ring 3. Drive Gear 10. Set Screw 17. Plug 4. Key 11. Drive Pulley 18. Shim 12.
Page 85 Inspection of Reel Motor Reassembly of Reel Motor GENERAL 1. If the relief valve kit was removed, install ball (20), spring (19), shim (18), new O−ring (16), and plug (17) 1. Clean and dry all parts. into the back plate (21). Torque plug from 10 to 12 ft−lb (1.4 to 1.7 kg−m).
Page 86: Steering Pump
Steering Pump Figure 55 1. Plug (includes #2) 15. Front Plate Assembly 2. O−Ring 16. O−Ring 17. Molded O−Ring 3. Spool 4. Dowel Pin 18. Bearing Seal 6. Plug (includes #2) 19. Backup Gasket 7. Drive Gear Assembly 20. Wear Plate 8.
Page 87 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 2. Inspect both drive gear (7) and idler gear (10) shafts (15), body (21) and back plate (22).
Page 88 Figure 56 1. Plug (includes #2) 15. Front Plate Assembly 2. O−Ring 16. O−Ring 3. Spool 17. Molded O−Ring 4. Dowel Pin 18. Bearing Seal 6. Plug (includes #2) 19. Backup Gasket 7. Drive Gear Assembly 20. Wear Plate 8. Disc 21.
Page 89 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- It is important that the relationship of the back plate (22), ties in body must face away from front plate. body (21), wear plate (20) and front plate (15) is correct.
Page 90: Lift Control Valve
Lift Control Valve Figure 57 1. Plug Assembly 22. O−Ring 2. Disc 23. Bushing 3. Spring 24. Washer 4. Detent Plunger 25. Spring 5. O−Ring 26. Spacer 6. Plug Assembly 27. Retaining Ring 28. Cap Assembly 7. O−Ring 8. Body 29.
Page 91 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.
Page 92: Priority Flow Divider
Priority Flow Divider Figure 58 1. Plug Assembly 11. Shim 2. O−Ring 12. Shim 3. Spool 13. Shim 4. Body 14. O−Ring 5. O−Ring 15. Backup Washer 6. O−Ring 16. Metering Plug 7. Backup Washer 17. Shim 8. Metering Stem 18.
Page 93 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).
Page 94: Lift Cylinder
Lift Cylinder Figure 59 1. Bleed Screw 5. Seal 2. Washer 6. Snap Ring 3. Rod 7. Seal Kit 4. Wiper Hydraulic System Page 4 − 62 Reelmaster 4000−D...
Page 95 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 1.
Page 96: Reel Control Valve
Reel Control Valve Figure 60 1. Spool 18. Plunger 2. Body 19. Micro Switch 20. Flat Washer 3. O−Ring 4. Plug 21. Machine Screw 5. O−Ring 22. Cap Head Screw 6. Backup Washer 23. Lock Washer 7. O−Ring 24. Grease Fitting 25.
Page 97 Disassembly of Reel Control Valve Assembly 5. Inspect seats in body for wear. 1. Plug all outlets and thoroughly clean outside of valve. Reassembly of Reel Control Valve Assembly 2. Remove plug (4) and O−ring (3). 1. Thoroughly clean and dry all parts. Metal parts should be lightly oiled prior to assembly.
Page 98: Reel Shut Off Valve
Reel Shut Off Valve Figure 61 1. Circlip 6. Backup Washer 2. Washer 7. O−Ring 3. Spacer 8. Body 4. Spring 9. Spool 5. Wiper 3. Inspect O.D. of spool (9). It should be smooth and free Disassembly of Reel Shut−Off Valve Assembly of nicks and burrs.
Page 99: Traction Rod Assembly
Traction Rod Assembly The traction rod assembly allows adjustment to prevent the machine from creeping when the traction pedal is in neutral. Additionally, the rod block on the traction rod prevents traction pedal movement unless the brake is released. If the traction rod is disassembled, use the following steps during assembly.
Page 100: Traction Pump
Traction Pump 16 17 42 43 Figure 64 1. Hex Head Cap Screw 25. Retaining Ring 26. Shaft Seal 2. Charge Pump Adapter Assembly 3. Plug Assembly 27. Washer 4. Tow Valve Assembly 28. Retaining Ring 5. O−Ring 29. Thrust Ring 6.
Page 101 Disassembly of Traction Pump 9. Remove the tow valve (4) from back plate (9). To dis- assemble tow valve, remove retaining ring from spread- 1. Disconnect all control linkage, hydraulic lines and re- er, and pull spreader from spreader plug. move pump assembly from vehicle.
Page 102 16 17 42 43 Figure 65 1. Hex Head Cap Screw 25. Retaining Ring 2. Charge Pump Adapter Assembly 26. Shaft Seal 3. Plug Assembly 27. Washer 4. Tow Valve Assembly 28. Retaining Ring 29. Thrust Ring 5. O−Ring 6. Needle Bearing 30.
Page 103 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 1. Inspect the charge pump relief valve seat inside the scoring or contamination. charge pump adaptor. It should be smooth and free of burrs or other defects.
Page 104 16 17 42 43 Figure 66 1. Hex Head Cap Screw 25. Retaining Ring 2. Charge Pump Adapter Assembly 26. Shaft Seal 3. Plug Assembly 27. Washer 4. Tow Valve Assembly 28. Retaining Ring 29. Thrust Ring 5. O−Ring 6. Needle Bearing 30.
Page 105 Reassembly of Traction Pump 9. Install new housing gasket (10). 1. Clean all parts in suitable solvent, lubricate all critical 10. Install back plate (9). moving parts before reassembly. If necessary, install 11. Install ball and pin into check valve housing if remo- new needle bearings in the housing.
Page 106: Front Traction Motor
Front Traction Motor 21 22 Figure 67 1. Hex Head Cap Screw 12. Washer 2. Hex Head Cap Screw 13. Retaining Ring 3. Plug 14. Thrust Ring 4. O−Ring Seal 15. Thrust Bearing 5. Back Plate Assembly 16. Bearing 6. O−Ring 17.
Page 107 IMPORTANT: Do not attempt to disassemble the 8. Inspect the flat surface on the backplate (5); it should piston block and spring. The parts are not service- be free of excessive scoring or metal build−up. able separately. The rotating assembly (19) must be 9.
Page 108: Reel Pump
Reel Pump Figure 68 1. Nut 10. Spline Drive Gear 2. Lock Washer 11. Driven Gear 3. Stud 12. O−Ring Seal 4. Stud 13. Rear Port Section 5. Front Cover 14. Coupling 6. Gland Seal 15. O−Ring 7. Wear Plate 16.
Page 109 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.
Page 110 Figure 69 1. Nut 10. Spline Drive Gear 2. Lock Washer 11. Driven Gear 3. Stud 12. O−Ring Seal 4. Stud 13. Rear Port Section 5. Front Cover 14. Coupling 6. Gland Seal 15. O−Ring 7. Wear Plate 16. Plug 17.
Page 111 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 10.
Page 112: Rear Wheel Drive Motor
Rear Wheel Drive Motor Figure 70 1. O−Ring Seal 8. Bolt 2. Backup Washer 9. Outer Seal 3. Shaft Seal 10. Inner Seal 4. Key 11. Shaft Seal 5. Sub Shaft Assembly 12. Dust Seal 6. Pin 13. Slotted Nut 7.
Page 113 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.
Page 114 6. Remove 2 pins and 2 springs from balance ring as- sembly, see Fig. 75. 7. Remove balance ring assembly. 8. Remove inner and outer face seals from balance ring. 9. Remove the valve. Figure 75 10. Remove the valve plate. 11.
Page 115 19. You may need a press to remove shaft and bearing assembly from bearing housing. (Key must be removed before removing shaft.) Figure 79 20. Use a small screwdriver to remove shaft seal, back− up washer and exclusion seal from bearing housing, see Fig.
Page 116 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. 81. Do not distort seal. 28.
Page 117 37. Apply petroleum jelly to inner and outer face seals. Install seals on balance ring as shown in Fig. 85. IMPORTANT: Install face seals in the positions shown in Fig. 85. 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.
Page 118 Wheel Motor On wheel motors, a different bearing housing is used, see Fig. 89. Other than this the parts are the same as the standard motor and the same disassembly and reas- sembly procedures apply. Figure 89 Hydraulic System Page 4 − 86 Reelmaster 4000−D...
Page 119: Rear Wheel Drive Valve Block
Rear Wheel Drive Valve Block RM 4000−D 4WD MANIFOLD BLOCK NOTE: If cartridge valve seals appear pitted or damaged, the hydraulic system may be overheating or there may be water in the hydraulic system. Figure 90 Cleaning Solenoid Actuated Cartridge Valve Use a deep socket to remove the valve cartridge.
Page 120: Steering Cylinder
Steering Cylinder Figure 92 1. Set Screw 10. Spacer 2. Threaded Cap 11. Servon 3. Rod 12. O−Ring 4. Rod Wiper 13. Piston 5. U−Cup 14. Locknut 6. Cap Head 15. Barrel Assembly 7. Backup Washer 16. Jam Nut 8. O−Ring 17.
Page 121 11. Use a complete repair kit when rebuilding the cylin- 14. Put a coating of oil on all cylinder parts to ease as- der. Put a coating of oil on all new seals, and O−rings. sembly. Install the new seal and O−rings. 15.
Page 122: Change Hydraulic Oil
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.
Page 123: Replace Hydraulic Oil Filter
Replace Hydraulic Oil Filter Initially, change filter after the first 50 operating hours, thereafter, every 800 operating hours, annually, or on in- dication. Use Toro replacement filter (Part No. 86−6110). IMPORTANT: Use of any other filter may void the warranty on some components.
Page 124 This Page Intentionally Left Blank Hydraulic System Page 4 − 92 Reelmaster 4000−D...
Page 125: Reelmaster 4000−D Electrical Schematic (S/N 240000001 And Up)
Chapter 5 Electrical System Table of Contents ELECTRICAL SCHEMATICS AND DIAGRAMS . . . COMPONENT TESTING ..... . Reelmaster 4000−D Electrical Schematic Ignition Switch .
Page 126: Electrical Schematics And Diagrams
Electrical Schematics and Diagrams Electrical System (Rev. C) Page 5 − 2 Reelmaster 4000−D...
Page 127 Reelmaster 4000−D Page 5 − 3 Electrical System (Rev. C)
Page 128 Electrical System (Rev. C) Page 5 − 4 Reelmaster 4000−D...
Page 129 Reelmaster 4000−D Page 5 − 5 Electrical System (Rev. C)
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Page 131 Reelmaster 4000−D Page 5 − 7 Electrical System (Rev. C)
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Page 133 Reelmaster 4000−D Page 5 − 9 Electrical System (Rev. C)
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Page 135 Reelmaster 4000−D Page 5 − 11 Electrical System (Rev. C)
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Page 137 Reelmaster 4000−D Page 5 − 13 Electrical System (Rev. C)
Page 138 Electrical System (Rev. C) Page 5 − 14 Reelmaster 4000−D...
Page 139: Special Tools
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.
Page 140: Troubleshooting
Troubleshooting For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and CAUTION components used on this machine (see Electrical Sche- matics and Diagrams section of this chapter). Remove all jewelry, especially rings and If the machine has any interlock switches by−passed, watches, before doing any electrical trouble- shooting or testing.
Page 141 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.
Page 142 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 seat. backlap with no operator on seat. Seat switch faulty or out of adjustment. Short circuit or by−pass in seat switch circuit.
Page 143: Electrical System Quick Check
Electrical System Quick Check Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the Voltage Measured Battery Charge Level battery terminals. 12.68 V (or higher) Fully charged (100%) Set multimeter to the DC volts setting. The battery 12.45 V 75% charged should be at a temperature of 60 to 100...
Page 144: Component Testing
Component Testing For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the CAUTION circuit (e.g. unplug the ignition switch connector before doing a continuity check). When testing electrical components for continu- NOTE: For more component testing information, see ity with a multimeter (ohms setting), make sure the Kubota Workshop Manual for 03 Series Diesel En- that power to the circuit has been disconnected.
Page 145: Hour Meter
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.
Page 146: Alarm Relay
Alarm Relay The alarm relay is located inside the steering tower. 1. Verify coil resistance between terminals 86 and 85 with a multimeter (ohms setting). Resistance should be from 80 to 90 ohms. There should be continuity between terminals 87A and 30. 2.
Page 147: Fuel Sender
Fuel Sender The sender is located on top of the fuel tank under the rear screen. 1. Remove gray wire and black ground wire from the sender. 2. Remove truss head screws and lock washers from the sender and fuel tank. 3.
Page 148: H 2 O In Fuel Sensor
O in Fuel Sensor The sensor is located on the fuel filter assembly, which is inside the center shroud area to the left side of the en- gine. It energizes a red warning light when too much wa- ter has collected in the fuel filter bowl. 1.
Page 149: High Temperature Warning And Cutout Switches
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.
Page 150: Rear Wheel Drive Solenoid
Rear Wheel Drive Solenoid RM 4000−D 4WD MANIFOLD BLOCK 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).
Page 151: Fuel Stop Solenoid
Fuel Stop Solenoid The solenoid must be energized for the engine to run. It is mounted on the engine block near the injection pump. In Place 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).
Page 152: Hydraulic Oil Level Switch
Hydraulic Oil Level Switch The level switch is located on top of the hydraulic reser- voir under the seat. It has an electrical connector from the wiring harness with two black, a black/white, and a orange wire. 1. Remove electrical connector from the level switch. 2.
Page 153: Glow Controller
Glow Controller The controller is located under the right lower corner of the instrument panel. Controller Operation When the ignition switch is placed in the RUN position, the controller energizes the glow plugs and lights up the glow lamp for 10 seconds. When the ignition switch is held in the START position, the glow plugs will energize while the switch is held in START and the glow lamp will not light.
Page 154: Hydraulic Oil Filter Switch
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.
Page 155: Service And Repairs
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.
Page 156: Battery Service
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 Fully charged: 1.265 corrected to 80 F (26.7 MADE IN U.S.A.
Page 157 B. Temperature correct each cell reading. For each terminals. F (5.5 C) above 80 F (26.7 C) add 0.004 to the F. Apply a test load of one half the Cranking Perfor- specific gravity reading. For each 10 F (5.5 C) be- mance (see Battery Specifications) rating of the bat- low 80...
Page 158 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 Battery Battery Charge Level amp. If the reading is 0.1 amp or more, the unit’s electri- Reserve (Percent of Fully Charged) cal system should be tested and repaired.
Page 159: Rear Wheel Drive Solenoid Replacement
Rear Wheel Drive Solenoid Replacement RM 4000−D 4WD MANIFOLD BLOCK 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.
Page 160: Check Interlock System
Check Interlock System 3. Sit on the seat and disengage the parking brake. Turn key and try to start engine with Mow−Backlap lever CAUTION in STOP. If engine cranks, there is a malfunction that must be repaired immediately. If engine does not crank, Do not disconnect safety switches.
Page 161 Chapter 6 Axles and Brakes Table of Contents SPECIFICATIONS ......SERVICE AND REPAIRS .
Page 162: Specifications
Specifications Item Description Front Tire Pressure 13 PSI (0.90 Bar) Rear Tire Pressure 15 PSI (1.04 Bar) Front Wheel Nut Torque 60 to 85 ft−lb (8.3 to 11.8 kg−m) Rear Wheel Nut Torque 30 to 35 ft−lb (4.1 to 4.8 kg−m) Wheel Planetary Mounting Cap Screw Torque 95−110 ft−lb (13.1 to 15.2 kg−m) Rear Wheel Toe−in...
Page 163: Adjustments
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.
Page 164: Rear Wheel Toe−In
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.
Page 165: Service And Repairs
Service and Repairs Rear Wheel Bearing Service (2WD Only) 44 45 46 28 29 11 12 13 14 15 RIGHT FRONT Figure 5 Hex flange head screw 18. Tab washer 35. Hydraulic hose Spindle cap 19. Valve stem 36. Steering cylinder Retaining ring 20.
Page 166 1. Jack up rear of machine until tire is off the. Support 11. Adjust preload on the wheel bearings (Fig. 6). machine with jack stands or blocks to prevent it from fal- A. Tighten jam nut from 75 to 80 in−lb (86 to 270 kg− ling (see Jacking Instructions in Chapter 1 −...
Page 167: Planetary Wheel Drive
Planetary Wheel Drive Figure 7 Coupling 11. Flat washer 21. O−ring Input shaft 12. Thrust washer 22. Disengage plunger Spindle 13. Primary sun gear 23. Thrust washer Oil seal 14. Hex head bolt 24. Ring gear Bearing cone 15. Primary carrier assembly 25.
Page 168 Disassemble Planetary Wheel Drive that can be assembled into the ring grooves of the spindle shaft above the bearing cone. Bearing should 1. Slide coupling (1) from the splines on the input shaft have from 0.000 to 0.006 inches (0.00 to 0.15mm) of (2).
Page 169 Chapter 7 Cutting Units Table of Contents SPECIFICATIONS ......SERVICE AND REPAIRS ..... . SPECIAL TOOLS .
Page 170: Specifications
Specifications Figure 1 1. Drive housing cover 5. Rear roller adjuster (both ends) 9. Reel 2. drive housing 6. Reel−to−bedknife adjuster 10. Optional front roller 3. Drive plate shield 7. Guard 11. Top covers 4. Grass deflector 8. cone nut Height−of−Cut: 5 Blade −...
Page 171: Special Tools
Special Tools Order special tools from the TORO SPECIAL TOOLS Some tools may be listed in the Reelmaster 4000−D AND APPLICATIONS GUIDE (COMMERCIAL PROD- Parts Catalog. Some tools may also be available from UCTS). a local supplier. Gauge Bar Assembly Use gauge bar to set final height−of−cut (floating cutting...
Page 172: Adjustments
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.
Page 173 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.
Page 174: Quick Method For Changing Height−Of−Cut After Initial Set Up Of A Floating Cutting Unit
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...
Page 175: Adjust Height−Of−Cut (Fixed Cutting Unit)
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).
Page 176: Service And Repairs
Good communication be- 2. Dip 3−inch (76 mm) wide paint brush attached to tween each person is necessary. Instruct opera- Toro Part No. 29−9200 Handle Assembly into lapping tor to stop the reels and shut the engine off when adjustment is necessary.
Page 177: Hydraulic Motor Installation
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.
Page 178: Bedknife/Bedbar
Bedknife/Bedbar Disassembly 1. Remove shoulder bolts, bushings and spacers from each end of the unit. Remove bedbar/bedknife assem- bly (Fig. 16). 2. Remove mounting screws for the bedknife. Sepa- rate bedknife from the bedbar. Discard screws (Fig. 17). Assembly 1. Clean bedknife mounting face on the bedbar thor- Figure 16 oughly of all rust and scale.
Page 179: Reel Assembly
Reel Assembly Disassembly 1. Remove the guards from each end of the cutting unit and the front and rear roller assemblies (Fig. 20). 2. Remove shoulder bolts, bushings and spacers from each end of the unit and remove the bedbar/bedknife assembly (Fig.
Page 180 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.
Page 181 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.
Page 182: Reel
Preparing a Reel for Grinding Note: Check to make sure the reel bearings are in 4. After completing the grinding process: good condition before grinding the reel. Make sure the A. Install parts that were removed to mount the cut- cutting unit frame and roller brackets are true and not ting unit onto grinder.
Page 183: Front And Rear Rollers
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.
Page 184: Roller Bearing Replacement
Roller Bearing Replacement Figure 28 1. Roller tube (front roller shown) 5. Jam nut 9. O−ring 2. Roller shaft 6. Trust washer 10. Bearing cone 3. Grease fitting 7. Outer grease seal 11. Bearing cup 4. Lock nut 8. Wear sleeve 12.
Page 185 3. On the rear, wiehle, and sectional rollers, press new inner grease seals into the roller tube with the garter spring of the seal facing towards the center of the roller (Fig. 30). 4. Press both bearing cups into the roller tube with the narrow end of the taper facing the inside of the roller tube.
Page 186: 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 minimize wa- ter entering the reel and roller bearings.
Page 188 Commercial Products E The Toro Company...

Toro Reelmaster 4000?D Service Manual

Table of Contents

Chapter 1 − Safety

Chapter 2 Product Records and Maintenance

Chapter 3 Kubota Diesel Engine

Chapter 2 − Product Records and Maintenance

Chapter 4 Hydraulic System

Chapter 6 − Axles and Brakes

Chapter 7 − Cutting Units

Chapter 5 Electrical System

Chapter 4 − Hydraulic System

Chapter 6 Axles and Brakes

Chapter 7 Cutting Units

Quick Links

Service Manual

Chapters

Troubleshooting

Related Manuals for Toro Reelmaster 4000?D

Summary of Contents for Toro Reelmaster 4000?D

Table of Contents