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Reelmaster 4000–D
Page 1 – 6
Safety
Safety and Instruction Decals
ON FRONT CARRIER & TOW BAR
(Part No. 93–9400)
ON RIGHT CONTROL PANEL
(Part No. 93–9402)
ON EXHAUST SHIELD
(Part No. 95–0645)
ON FRONT ACCESS PANEL
(Part No. 93–9425)
Contents
Main
Service Manual
ReelmasterR 4000D
E The Toro Company 1998, 2003
Preface
Page
Page
Page
Chapter 1
Safety
General Safety Instructions
Before Operating
While Operating
Maintenance and Service
Page
Page
Page
Chapter 2
Product Records and Maintenance
Product Records
Page
Torque Specifications
Fastener Identification
Page 2 4
Product Records and Maintenance
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners)
Other Torque Specifications
Conversion Factors
inlb X 11.2985 = Ncm Ncm X 0.08851 = inlb
Lubrication
GREASING BEARINGS AND BUSHINGS
Page
Page
Reelmaster 4000D Maintenance Schedule
Minimum Recommended Maintenance Intervals Maintenance Procedure
(See Operators and Service Manual for specifications and procedures)
Maintenance Interval & Service
Reelmaster 4000D Daily Maintenance Checklist
Reelmaster 4000D Supervisor Maintenance Work Order Date: ________________
A B C D Other
Chapter 3
Kubota Diesel Engine
Introduction
Reelmaster 4000D Page 3 3 Kubota Diesel Engine
Engine
Kubota Diesel
General Information
Check Engine Oil
Check Cooling System
Fill Fuel Tank
Prime Fuel System
Adjust Alternator Belt
Service Air Cleaner
Change Engine Oil and Filter
Drain Fuel System
Check Fuel Lines and Connections
Replace Fuel Filter
Engine Cooling System
Engine
Page
Page
Page
Chapter 4
Hydraulic System
Reelmaster 4000D Page 4 2
Hydraulic System
General Information
Hydraulic Hoses
Hydraulic Fitting Installation
Page
Pushing or Towing Traction Unit
Page
Check Hydraulic System Fluid
Page 4 8
Hydraulic System
Hydraulic Schematic
4 WHEEL DRIVE ONLY
Hydraulic Flow Diagrams
General Pump Flow
Page
Traction Circuit
Page
Steering Circuit
Page
Lift/Lower Circuit
Page
Page
Page
Reel Circuit
Page
Page
Page
Page
Page
Page
TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS
Hydraulic Tester With Pressure and Flow Capabilities TOR214678
Hydraulic Pressure Test Kit TOR47009
Hydraulic Test Fitting Kit TOR4079
Troubleshooting
Page
Testing
TEST NO. 1: Check Traction Circuit Working and Relief Pressures
TEST NO. 2: Check Counterbalance Oil Pressure
TEST NO. 3: Check Reel Circuit Working and Relief Pressures
TEST NO. 4: Check Reel Circuit Flow
TEST NO. 5: Check Reel Motor CrossOver Relief Pressure
TEST NO. 6: Check Reel Motor Case Drain Flow
TEST NO. 7: Check Steering Circuit Working and Relief Pressure
TEST NO. 8: Check Lift Circuit Working and Relief Pressure
TEST NO. 9: Check Charge Pressure
Removing Hydraulic System Components
Steering Control Unit
Page
Page
Page
Page
Page
Page
Page
Page
Page
Page
Add Hydraulic Fluid
Drain Water from Hydraulic Reservoir
Reel Motor
Page
Steering Pump
Page
Page
Page
Lift Control Valve
Page
Priority Flow Divider
Page
Lift Cylinder
Page
Reel Control Valve
Page
Reel Shut Off Valve
Page
Traction Pump
Page
Page
Page
Page
Page
Front Traction Motor
Page
Reel Pump
Any discoloration war- rants replacement
Any of the preceding conditions shall warrant re- placement of the port section
Page
Page
Rear Wheel Drive Motor
Page
Page
Page
Page
Page
Page
Rear Wheel Drive Valve Block
Steering Cylinder
Page
Change Hydraulic Oil
Replace Hydraulic Oil Filter
Replace Hydraulic System Breather
Replace Hydraulic LInes and Hoses
Page
Chapter 5
Electrical System
Reelmaster 4000DPage 5 2Electrical System (Rev. A)
Electrical Schematics and Diagrams
All relays and solenoids
Electrical Schematic
4WD OPTION
are shown as deenergized. All ground wires are black.
Page
Reelmaster 4000DPage 5 4Electrical System (Rev. A)
Main Harness Drawing
Reelmaster 4000D Page 5 5 Electrical System (Rev. A)
WIRE IDENTIFICATION
Supplement to Main Harness Drawing
LABELCOLOR ROUTE
WIRE IDENTIFICATION
Reelmaster 4000DPage 5 6Electrical System (Rev. A)
Main Harness Wiring Diagram
SP2 SP1
SP3
Page
Reelmaster 4000DPage 5 8Electrical System (Rev. A)
Main Harness Wiring Diagram
(S/N 220000001 and up)
Reelmaster 4000D Page 5 9 Electrical System (Rev. A)
Control Panel Harness Drawing
WIRE IDENTIFICATION
Reelmaster 4000DPage 5 10Electrical System (Rev. A)
Control Panel Wiring Diagram
Reelmaster 4000D Page 5 11 Electrical System (Rev. A)
Light Cluster Harness Drawing
WIRE IDENTIFICATION
Reelmaster 4000DPage 5 12Electrical System (Rev. A)
Light Cluster Wiring Diagram
Multimeter
SkinOver Grease
Troubleshooting
Starting Problems
Starting Problems (continued)
General Run and Transport Problems
Electrical System Quick Check
Battery Test (Open Circuit Test)
Component Testing
Ignition Switch
Hour Meter
Glow Plug and Start Relays
Audio Alarm
Alarm Relay
Hydraulic Oil Temperature Switch
Fuel Sender
Fuel Gauge
H2O in Fuel Sensor
High Temperature Warning and Cutout Switches
Rear Wheel Drive Solenoid
Fuel Stop Solenoid
Hydraulic Oil Level Switch
Bridge Rectifier
Glow Controller
Hydraulic Oil Filter Switch
Battery Storage
Battery Care
Battery Service
Page
Page
Rear Wheel Drive Solenoid Replacement
Check Interlock System
Axles and Brakes
Page
Hand Brake and Traction Switches
Rear Wheel ToeIn
Reelmaster 4000D Page 6 5 Axles and Brakes
Rear Wheel Bearing Service (2WD Only)
Brakes
Axles and
FRONT
Figure 5
Page
Reelmaster 4000D Page 6 7 Axles and Brakes
Planetary Wheel Drive
Brakes
Figure 7
Axles and
Page
Chapter 7
Cutting Units
Page
TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PROD- UCTS)
Gauge Bar Assembly
Handle Assembly
Bedknife Screw Tool
Adjust Reel to Bedknife Contact
HeightofCut Adjustment (Floating Cutting Unit)
Quick Method For Changing HeightofCut After Initial Set Up of a Floating Cutting Unit
Adjust HeightofCut (Fixed Cutting Unit)
Adjust Skids and Front Roller (Fixed Cutting Unit)
Backlapping
Hydraulic Motor Installation
Bedknife/Bedbar
Reel Assembly
Page
Page
Preparing a Reel for Grinding
Front and Rear Rollers
Roller Bearing Replacement
Page
Lubrication