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Toro 98958SL service manual - page 4

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Reelmaster 4000–D

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