PART NO. 98958SL (Rev.

C)

Service Manual

Reelmaster
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,
REFER TO THE TRACTION UNIT AND CUTTING or CAUTION, PERSONAL SAFETY INSTRUC-
UNIT OPERATOR’S MANUALS FOR OPERATING, TION. When you see this symbol, carefully read
MAINTENANCE AND ADJUSTMENT INSTRUC- the instructions that follow. Failure to obey the
TIONS. Space is provided in Chapter 2 of this book to instructions may result in personal injury.
insert the Operator’s Manuals and Parts Catalogs for
your machine. Replacement Operator’s Manuals are NOTE: A NOTE will give general information about the
available by sending complete Model and Serial Num- correct operation, maintenance, service, testing, or re-
ber to: pair of the machine.
The Toro Company IMPORTANT: The IMPORTANT notice will give im-
8111 Lyndale Avenue South portant instructions which must be followed to pre-
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.

 The Toro Company − 1998, 2003, 2005, 2007

Reelmaster 4000−D
Table Of Contents

Chapter 1 − Safety Chapter 4 − Hydraulic System

General Safety Instructions . . . . . . . . . . . . . . . . . . 1 − 1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 − 2

Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 − 4 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 − 3
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . 4 − 8

Safety
Chapter 2 − Product Records and Maintenance Hydraulic Flow Diagrams . . . . . . . . . . . . . . . . . . . . 4 − 9
4WD Selector Valve Operation . . . . . . . . . . . . . . 4 − 24
Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 − 26
Equivalents and Conversions . . . . . . . . . . . . . . . . 2−2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 − 28
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2−3 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 − 30

and Maintenance
Product Records
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−7 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 4 − 39
Chapter 3 − Kubota Diesel Engine Chapter 5 − Electrical System
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−2 Electrical Schematics and Diagrams . . . . . . . . . . 5 − 2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 − 15
General Information . . . . . . . . . . . . . . . . . . . . . . . . 3−4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 − 16
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−7

Kubota Diesel
Electrical System Quick Check . . . . . . . . . . . . . . 5 − 19
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 3−8 Component Testing . . . . . . . . . . . . . . . . . . . . . . . . 5 − 20

Engine
KUBOTA WORKSHOP MANUAL, 03 SERIES, Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 5 − 31
DIESEL ENGINE
Chapter 6 − Axles and Brakes

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 − 2
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 − 3

Hydraulic
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 6 − 5

System
Chapter 7 − Cutting Units

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−3
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7−4

Electrical
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 7−8

System
Axles and
Brakes
Cutting Units

Reelmaster 4000−D Rev. C

Reelmaster 4000−D
 Chapter 1

Safety
Table of Contents

Safety
GENERAL SAFETY INSTRUCTIONS . . . . . . . . . . . . 1 SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 4
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Maintenance and Service . . . . . . . . . . . . . . . . . . . . 3

General Safety Instructions

The Reelmaster 4000−D was tested and certified by
TORO for compliance with the B71.4−1984 specifica-
tions of the American National Standards Institute for WARNING
riding mowers when rear tires are filled with calcium
chloride and two rear wheel weight kits. Although haz- To reduce the potential for injury or death,
ard control and accident prevention partially are depen- comply with the following safety instructions.
dent upon the design and configuration of the machine,
these factors are also dependent upon the awareness,
concern, and proper training of the personnel involved
in the operation, transport, maintenance, and storage of
the machine. Improper use or maintenance of the ma-
chine can result in injury or death.

Before Operating
1. Read and understand the contents of the traction 6. Wearing safety glasses, safety shoes, long pants
unit and cutting unit operator’s manuals before operat- and a helmet is advisable and required by some local or-
ing the machine. To get replacement manuals, send dinances and insurance regulations.
complete model and serial number to:
7. Make sure the work area is clear of objects which
The Toro Company might be picked up and thrown by the reels.
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
2. Never allow children to operate the machine or areas of operation.
adults to operate it without proper instruction.
9. Since diesel fuel is highly flammable, handle it care-
3. Become familiar with the controls and know how to fully:
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- B. Do not remove fuel tank cap while engine is hot
aged, repair or replace it before operating the machine. or running.

5. Always wear substantial shoes. Do not operate ma- C. Do not smoke while handling fuel.
chine while wearing sandals, tennis shoes, sneakers or
when barefoot. Do not wear loose fitting clothing that D. Fill fuel tank outdoors and only to within an inch
could get caught in moving parts and possibly cause (25 mm) from the top of the tank, not the filler neck.
personal injury. Do not overfill.

E. Wipe up any spilled fuel.

Reelmaster 4000−D Page 1 − 1 Safety

While Operating

10. Do not run engine in a confined area without ade- 17. Traverse slopes carefully. Do not start or stop sud-
quate ventilation. Exhaust is hazardous and could be denly when traveling uphill or downhill.
deadly.
18. Operator must be skilled and trained in how to drive
11. Sit on the seat when starting and operating the ma- on hillsides. Failure to use caution on slopes or hills may
chine. cause loss of control and vehicle to tip or roll possibly re-
sulting in personal injury or death.
12. Check interlock switches daily for proper operation.
If a switch fails, replace it before operating the machine. 19. When operating 4 wheel drive machine, always use
The interlock system is for your protection, so do not by- the seat belt and ROPS together and have seat pivot re-
pass it. Replace all interlock switches every two years. taining pin installed.

13. This product may exceed noise levels of 85 dB(A) 20. If engine stalls or loses headway and cannot make
at the operator position. Ear protectors are recom- it to the top of a slope, do not turn machine around. Al-
mended for prolonged exposure to reduce the potential ways back slowly straight down the slope.
of permanent hearing damage.
21. Raise cutting units and latch them securely in trans-
14. Before starting the engine each day, test lamps, port position before driving from one work area to anoth-
warning buzzer and signal lights to assure proper opera- er.
tion.
22. Do not touch engine, muffler or exhaust pipe while
15. Pay attention when using the machine. To prevent engine is running or soon after it is stopped. These areas
loss of control: could be hot enough to cause burns.

A. Mow only in daylight or when there is good artifi- 23. If cutting unit strikes a solid object or vibrates abnor-
cial light. mally, stop immediately, turn engine off, set parking
brake and wait for all motion to stop. Inspect for damage.
B. Watch for holes or other hidden hazards. If reel or bedknife is damaged, repair or replace it before
operating. Do not attempt to free blocked cutting unit by
C. Be extremely careful when operating close to moving Mow/Backlap lever rapidly between FORWARD
sand traps, ditches, creeks, steep hillsides or other and BACKLAP. Damage to hydraulic system may result.
hazards. Lever should easily return and hold in the STOP posi-
tion.
D. Reduce speed when making sharp turns. Avoid
sudden stops and starts. Use ground speed limiter 24. Before getting off the seat:
lever to set pedal travel so excessive ground speed
will be avoided during mowing and transport. A. Move traction pedal to neutral.

E. Look to the rear to assure no one is behind the B. Set parking brake.
machine before backing up.
C. Disengage cutting units and wait for reels to
F. Watch for traffic when near or crossing roads. Al- stop.
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
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.

Safety Page 1 − 2 Reelmaster 4000−D

Maintenance and Service

26. Before servicing or making adjustments, stop en- 34. Do not overspeed the engine by changing governor
gine and remove key from the switch. setting. Maximum engine speed is 2500 rpm + or − 100
rpm. To assure safety and accuracy, have an Authorized
27. Assure entire machine is properly maintained and Toro Distributor check maximum engine speed.
in good operating condition. Frequently check all nuts,
bolts and screws. 35. Shut engine off before checking or adding oil to the

Safety
crankcase.
28. Frequently check all hydraulic line connectors and
fittings. Assure all hydraulic hoses and lines are in good 36. Disconnect battery before servicing the machine. If
condition before applying pressure to the system. 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 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.
cause injury. Fluid accidentally injected into the skin
must be surgically removed within a few hours by a doc- 38. For optimum performance and safety, use genuine
tor or gangrene may occur. Toro replacement parts and accessories. Replacement
parts and accessories made by other manufacturers
30. Before any hydraulic system maintenance, stop en- could be dangerous and may void the product warranty
gine and lower cutting units to the ground so all pressure of The Toro Company.
is relieved.
39. When changing attachments, tires, or performing
31. For major repairs or other assistance, contact your other service, use correct blocks, hoists, and jacks.
local Toro Distributor. Make sure machine is parked on a solid level floor such
as a concrete floor. Prior to raising the machine, remove
32. To reduce potential fire hazard, keep engine area any attachments that may interfere with the safe and
free of excessive grease, grass, leaves and dirt. Clean proper raising of the machine. Always chock or block
protective screen on back of engine frequently. wheels. Used jack stands or solid wood blocks to sup-
port the raised machine. If the machine is not properly
33. If engine must be running to perform maintenance supported by blocks or jack stands, the machine may
or an adjustment, keep hands, feet, clothing and other move or fall, which may result in personal injury.
parts of the body away from cutting units and other mov-
ing parts. Keep everyone away.

Reelmaster 4000−D Page 1 − 3 Safety

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 Page 1 − 4 Reelmaster 4000−D

Rev. C
 Chapter 2

Product Records and Maintenance

Table of Contents
PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 1
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . 2

and Maintenance
Product Records
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

Product Records
Insert Operator’s Manual and Parts Catalog for your Re-
elmaster 4000−D at the end of this chapter. Additionally,
if any optional equipment or accessories have been
installed to your machine, insert the Installation Instruc-
tions, Operator’s Manuals and Parts Catalogs for those
options at the end of this chapter.

Maintenance
Maintenance procedures and recommended service in-
tervals for the Reelmaster 4000−D are covered in the
Operator’s Manual. Refer to that publication when per-
forming regular equipment maintenance.

Reelmaster 4000−D Page 2 − 1 Product Records and Maintenance

Rev. C
Equivalents and Conversions

0.09375

Product Records and Maintenance Page 2 − 2 Reelmaster 4000−D

Rev. C
Torque Specifications
Recommended fastener torque values are listed in the As noted in the following tables, torque values should be
following tables. 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. into aluminum or brass. The specific torque value
should be determined based on the aluminum or brass
These Torque Specifications for the installation and material strength, fastener size, length of thread en-
tightening of fasteners shall apply to all fasteners which gagement, etc.
do not have a specific requirement identified in this Ser-
vice Manual. The following factors shall be considered The standard method of verifying torque shall be per-
when applying torque: cleanliness of the fastener, use formed by marking a line on the fastener (head or nut)

and Maintenance
of a thread sealant (Loctite), degree of lubrication on the and mating part, then back off fastener 1/4 of a turn.

Product Records
fastener, presence of a prevailing torque feature, hard- Measure the torque required to tighten the fastener until
ness of the surface underneath the fastener’s head, or the lines match up.
similar condition which affects the installation.

Fastener Identification

Grade1 Grade 5 Grade 8 Class 8.8 Class 10.9

Inch Series Bolts and Screws Metric Bolts and Screws

Reelmaster 4000−D Page 2 − 3 Product Records and Maintenance

Rev. C
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
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 N−cm in−lb N−cm

# 6 − 32 UNC 15 + 2 170 + 20 23 + 2 260 + 20

10 + 2 13 + 2 147 + 23
# 6 − 40 UNF 17 + 2 190 + 20 25 + 2 280 + 20

# 8 − 32 UNC 29 + 3 330 + 30 41 + 4 460 + 45

13 + 2 25 + 5 282 + 30
# 8 − 36 UNF 31 + 3 350 + 30 43 + 4 485 + 45

# 10 − 24 UNC 42 + 4 475 + 45 60 + 6 675 + 70

18 + 2 30 + 5 339 + 56
# 10 − 32 UNF 48 + 4 540 + 45 68 + 6 765 + 70

1/4 − 20 UNC 48 + 7 53 + 7 599 + 79 100 + 10 1125 + 100 140 + 15 1580 + 170

1/4 − 28 UNF 53 + 7 65 + 10 734 + 113 115 + 10 1300 + 100 160 + 15 1800 + 170

5/16 − 18 UNC 115 + 15 105 + 17 1186 + 169 200 + 25 2250 + 280 300 + 30 3390 + 340

5/16 − 24 UNF 138 + 17 128 + 17 1446 + 192 225 + 25 2540 + 280 325 + 30 3670 + 340

ft−lb ft−lb N−m ft−lb N−m ft−lb N−m

3/8 − 16 UNC 16 + 2 16 + 2 22 + 3 30 + 3 41 + 4 43 + 4 58 + 5

3/8 − 24 UNF 17 + 2 18 + 2 24 + 3 35 + 3 47 + 4 50 + 4 68 + 5

7/16 − 14 UNC 27 + 3 27 + 3 37 + 4 50 + 5 68 + 7 70 + 7 95 + 9

7/16 − 20 UNF 29 + 3 29 + 3 39 + 4 55 + 5 75 + 7 77 + 7 104 + 9

1/2 − 13 UNC 30 + 3 48 + 7 65 + 9 75 + 8 102 + 11 105 + 10 142 + 14

1/2 − 20 UNF 32 + 3 53 + 7 72 + 9 85 + 8 115 + 11 120 + 10 163 + 14

5/8 − 11 UNC 65 + 10 88 + 12 119 + 16 150 + 15 203 + 20 210 + 20 285 + 27

5/8 − 18 UNF 75 + 10 95 + 15 129 + 20 170 + 15 230 + 20 240 + 20 325 + 27

3/4 − 10 UNC 93 + 12 140 + 20 190 + 27 265 + 25 359 + 34 375 + 35 508 + 47

3/4 − 16 UNF 115 + 15 165 + 25 224 + 34 300 + 25 407 + 34 420 + 35 569 + 47

7/8 − 9 UNC 140 + 20 225 + 25 305 + 34 430 + 45 583 + 61 600 + 60 813 + 81

7/8 − 14 UNF 155 + 25 260 + 30 353 + 41 475 + 45 644 + 61 660 + 60 895 + 81

Note: Reduce torque values listed in the table above on the fastener size, the aluminum or base material
by 25% for lubricated fasteners. Lubricated fasteners strength, length of thread engagement, etc.
are defined as threads coated with a lubricant such as
oil, graphite, or thread sealant such as Loctite. Note: The nominal torque values listed above for
Grade 5 and 8 fasteners are based on 75% of the mini-
Note: Torque values may have to be reduced when mum proof load specified in SAE J429. The tolerance is
installing fasteners into threaded aluminum or brass. approximately + 10% of the nominal torque value. Thin
The specific torque value should be determined based height nuts include jam nuts.

Product Records and Maintenance Page 2 − 4 Reelmaster 4000−D

Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners)

Class 8.8 Bolts, Screws, and Studs with Class 10.9 Bolts, Screws, and Studs with
Thread Size Regular Height Nuts Regular Height Nuts
(Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts)

M5 X 0.8 57 + 5 in−lb 640 + 60 N−cm 78 + 7 in−lb 885 + 80 N−cm

M6 X 1.0 96 + 9 in−lb 1018 + 100 N−cm 133 + 13 in−lb 1500 + 150 N−cm

M8 X 1.25 19 + 2 ft−lb 26 + 3 N−m 27 + 2 ft−lb 36 + 3 N−m

M10 X 1.5 38 + 4 ft−lb 52 + 5 N−m 53 + 5 ft−lb 72 + 7 N−m

and Maintenance
Product Records
M12 X 1.75 66 + 7 ft−lb 90 + 10 N−m 92 + 9 ft−lb 125 + 12 N−m

M16 X 2.0 166 + 15 ft−lb 225 + 20 N−m 229 + 22 ft−lb 310 + 30 N−m

M20 X 2.5 325 + 33 ft−lb 440 + 45 N−m 450 + 37 ft−lb 610 + 50 N−m

Note: Reduce torque values listed in the table above on the fastener size, the aluminum or base material
by 25% for lubricated fasteners. Lubricated fasteners strength, length of thread engagement, etc.
are defined as threads coated with a lubricant such as
oil, graphite, or thread sealant such as Loctite.
Note: The nominal torque values listed above are
Note: Torque values may have to be reduced when based on 75% of the minimum proof load specified in
installing fasteners into threaded aluminum or brass. SAE J1199. The tolerance is approximately + 10% of the
The specific torque value should be determined based nominal torque value.

Reelmaster 4000−D Page 2 − 5 Product Records and Maintenance

Rev. C
Other Torque Specifications
SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts

Recommended Torque Thread Size Recommended Torque**

Thread Size
Square Head Hex Socket 7/16 − 20 UNF 65 + 10 ft−lb 88 + 14 N−m
Grade 5
1/4 − 20 UNC 140 + 20 in−lb 73 + 12 in−lb
1/2 − 20 UNF 80 + 10 ft−lb 108 + 14 N−m
5/16 − 18 UNC 215 + 35 in−lb 145 + 20 in−lb Grade 5

3/8 − 16 UNC 35 + 10 ft−lb 18 + 3 ft−lb M12 X 1.25 80 + 10 ft−lb 108 + 14 N−m

Class 8.8
1/2 − 13 UNC 75 + 15 ft−lb 50 + 10 ft−lb
M12 X 1.5 80 + 10 ft−lb 108 + 14 N−m
Class 8.8

** For steel wheels and non−lubricated fasteners.

Thread Cutting Screws Thread Cutting Screws
(Zinc Plated Steel) (Zinc Plated Steel)

Type 1, Type 23, or Type F Thread Threads per Inch

Size Baseline Torque*
Thread Size Baseline Torque* Type A Type B
No. 6 − 32 UNC 20 + 5 in−lb No. 6 18 20 20 + 5 in−lb
No. 8 − 32 UNC 30 + 5 in−lb No. 8 15 18 30 + 5 in−lb
No. 10 − 24 UNC 38 + 7 in−lb No. 10 12 16 38 + 7 in−lb
1/4 − 20 UNC 85 + 15 in−lb No. 12 11 14 85 + 15 in−lb
5/16 − 18 UNC 110 + 20 in−lb * Hole size, material strength, material thickness & finish
must be considered when determining specific torque
3/8 − 16 UNC 200 + 100 in−lb values. All torque values are based on non−lubricated
fasteners.

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 Page 2 − 6 Reelmaster 4000−D

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. Lubricate fitting immediately
after every washing regardless of interval listed. The lu-
brication points are: lift arms (Fig. 1), rear axle (Fig. 2),
floating or fixed head kit pivots (Fig. 3), and cutting unit
reel and roller bearings (Fig. 4). Also, grease fitting on
reel control valve (not shown), located under right
hand console.

and Maintenance
Product Records
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 Page 2 − 7 Product Records and Maintenance

Rev. C
 This Page Intentionally Left Blank

Product Records and Maintenance Page 2 − 8 Reelmaster 4000−D

Rev. C
 Chapter 3

Kubota Diesel Engine

Table of Contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Change Engine Oil and Filter . . . . . . . . . . . . . . . . . 9
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Drain Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . 10
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4 Check Fuel Lines and Connections . . . . . . . . . . . . 11
Check Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Replace Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . 11
Check Cooling System . . . . . . . . . . . . . . . . . . . . . . . 5 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . 12
Fill Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Prime Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . 16
Adjust Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . 7 KUBOTA WORKSHOP MANUAL, 03 SERIES, DIESEL
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 8 ENGINE

Kubota Diesel
Service Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Engine

Reelmaster 4000−D Page 3 − 1 Kubota Diesel Engine

Introduction
This Chapter gives information about specifications, test equipment and the specialized nature of some re-
maintenance, troubleshooting, testing, and repair of the pairs may dictate that the work be done at an engine re-
diesel engine used in the Reelmaster 4000−D. pair facility.

Most repairs and adjustments require tools, which are Service and repair parts for Kubota diesel engines are
commonly available in many service shops. Special supplied through your local Kubota dealer or distributor.
tools are described in the Kubota Workshop Manual, 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 Page 3 − 2 Reelmaster 4000−D

Specifications

Item Description

Make / Designation Kubota, V2203, 4−Cylinder, 4−Cycle,

Water Cooled, In−line, Spherical Chamber, OHV, Diesel Engine

Horse Power 39.4 HP @ 2300 RPM

Torque 103 ft−lb @ 1600 RPM

Firing Order 1−3−4−2

Bore mm (in.) 87.0 (3.43)

Stroke mm (in.) 92.0 (3.64)

Total Displacement cc (cu. in.) 2197 (134.07)

Kubota Diesel
Fuel No. 2 Diesel Fuel per ASTM D975

Engine
Fuel Capacity liters (gallons) 56.8 (15.0)

Fuel Pump Bosch Type Mini pump

Governor Centrifugal flyweight Mechanical Type

Low Idle (no load) 1250 + 50 RPM

High Idle (no load) 2500 + 50 RPM

Compression Ratio 23.0 : 1

Rotation Counterclockwise Facing Flywheel

Injection Nozzles Bosch Throttle Type

Engine Oil SAE 10W30 SF or CD

Oil Pump Trochoid Type

Crankcase Oil Capacity liters (U.S. qt.) 7.6 (8.0) with filter

Starter 12 VDC 1.4 KW

Alternator/Regulator 12 VDC 40 AMP

Weight Kg (Lb.) 190 (418)

Engine Coolant Capacity liters (U.S. qt.) 14.0 (14.8)

Timing BTDC 17 to 19 Degrees

Reelmaster 4000−D Page 3 − 3 Kubota Diesel Engine

General Information

Check Engine Oil

1. Park machine on a level surface. Stop engine. Re-
move key from the ignition switch.

2. Release engine cover latches. Open engine cover

(Fig. 1).

3. Remove dipstick, wipe clean and reinstall dipstick 1

into tube and pull it out again. Oil level should be up to
the FULL mark (Fig. 2).

4. If oil is below FULL mark, remove fill cap and add

SAE 10W−30 oil until level reaches the FULL mark. Do
not overfill. Crankcase capacity is 8 qt. (7.6 L) with filter
(Fig. 3).

5. Install oil fill cap and dipstick. Figure 1

1. Engine cover latch
6. Close engine cover and secure with the latches.

Figure 2
1. Dipstick

Figure 3
1. Oil fill cap

Kubota Diesel Engine Page 3 − 4 Reelmaster 4000−D

Check Cooling System
Check level of coolant at the beginning of each day. Ca-
pacity of system is 3.7 gal. (14 L).

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- 1. Radiator cap 2. Rear screen
sion tank cap (Fig. 5).

Kubota Diesel
3. Check level of coolant in radiator. Radiator should
be filled to the top of the filler neck and the expansion

Engine
tank filled to the marks on its side.

IMPORTANT: Do not use water only. Do not use al- 1

cohol / methanol base coolants.

4. If coolant is low, add a 50/50 mixture of water and

ethylene glycol anti−freeze.

5. Install radiator cap and expansion tank cap.

Figure 5
1. Expansion tank cap

Fill Fuel Tank

1. Park machine on a level surface. Stop engine. Re-
move key from the ignition switch.

2. Remove fuel tank cap (Fig. 6).

3. Fill tank to about one inch (25 mm) below bottom of 1

filler neck with No. 2 diesel fuel. Then install cap.

Figure 6
1. Fuel tank cap 2. Left rear tire

Reelmaster 4000−D Page 3 − 5 Kubota Diesel Engine

Prime Fuel System
IMPORTANT: The fuel system must be primed when
a new engine is started for the first time, if it runs out 2
of fuel, or if maintenance is performed on the fuel
system.

Note: The fuel pump, located on left side of engine,

under the fuel injection pump and behind the fuel stop
solenoid. It can be manually primed to get fuel from fuel 3
tank to fuel filter/water separator (Fig. 7).

1. Park machine on a level surface. Stop engine. Re-

move key from the ignition switch. 1 4
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
run the other end of the hose into a container to catch the
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. Pump priming plunger until a steady stream of fuel
comes out of hole in in bleed screw. When fuel stops 2
foaming, tighten the bleed screw during the down-
stroke of the priming plunger. Wipe up any spilled fuel
(Fig. 8).

Note: It may be necessary to bleed the air out of the

fuel line between the fuel filter / water separator and the
injection pump. To do this, loosen the knob on the injec-
tion pump (Fig. 7) and repeat bleeding procedure. 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 Page 3 − 6 Reelmaster 4000−D

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. Proper belt tension will allow 3/8 inch (10 mm) 2

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

Kubota Diesel
1. Alternator 2. Mounting bolt

Engine

Reelmaster 4000−D Page 3 − 7 Kubota Diesel Engine

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).

4. Service the air cleaner filters when ever air cleaner 2

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 Figure 10

(Fig. 11). 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
8. Inspect primary filter and discard if damaged. Do not 1. Air cleaner body 2. Air cleaner cover
wash or reuse a damaged filter.
Compressed Air Method
Washing Method
A. Blow compressed air from inside to the outside
A. Prepare a solution of filter cleaner and water a of dry filter element. Do not exceed 100 psi (6.9 Bar)
nd soak filter element about 15 minutes. Refer to to prevent damage to the element.
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-
B. After soaking filter for 15 minutes, rinse it with ing the filter element. Inspect for holes and tears by
clear water. Maximum water pressure must not ex- looking through the filter toward a bright light.
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
greater than 160oF (71oC), or allow element to air− 10. Insert new filter properly into air cleaner body. Make
dry. Do not use a light bulb to dry the filter element sure filter is sealed properly by applying pressure to out-
because damage could result. 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 Page 3 − 8 Reelmaster 4000−D

Change Engine Oil and Filter
Change oil and filter after the first 50 hours of operation
and every 100 hours thereafter.

1. Remove drain plug and let oil flow into drain pan.
When oil stops, install drain plug (Fig. 12).

2. Remove oil filter. Apply a light coat of clean oil to the

new filter seal before screwing it on. Do not overtighten 1
filter (Fig.13).
2
3. Add oil to crankcase (see Check Engine Oil).

Figure 12

Kubota Diesel
1. Drain plug 2. Starter

Engine
1

Figure 13
1. Oil filter 2. Fuel filter/water seperator

Reelmaster 4000−D Page 3 − 9 Kubota Diesel Engine

Drain Fuel System

3
DANGER
Because diesel fuel is highly flammable, use cau- 1
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. 2

Fuel Tank
Figure 14
Drain and clean fuel tank every 800 hours of operation
1. Fuel filter/water separator 3. Priming plunger
or yearly, whichever comes first. Also, drain and clean 2. Drain screw
tank if fuel system becomes contaminated or if machine
is to be stored for an extended period. Use clean fuel to
flush out the tank.

Fuel Filter/Water Separator

Drain water or other contaminants from fuel filter/water

separator daily.

1. Park machine on a level surface. Stop engine. Re-

move key from the ignition switch.

2. Place a clean container under the fuel filter.

3. Loosen drain thumb screw on the side of fuel filter.

Press primer plunger until only fuel is evident draining
into container.

4. Tighten drain screw.

Kubota Diesel Engine Page 3 − 10 Reelmaster 4000−D

Check Fuel Lines and Connections
Check lines and connections every 400 hours or yearly,
whichever comes first. Inspect for deterioration, dam-
age, or loose connections.

Replace Fuel Filter

DANGER
1
Because diesel fuel is highly flammable, use cau- 2
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-

Kubota Diesel
sel fuel for the engine only; not for any other

Engine
purpose.
Figure 15
There are 2 fuel filters on the RM 4000−D. A small in− 1. In−line fuel filter 2. Fuel tank
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-
move cap, gaskets, o-ring and filter from assembly. Note 2
position of gaskets and o-ring when disassembling from
filter.

3. Install new filter, gaskets, o-ring with filter assembly

cap.
Figure 16
4. Prime fuel system, refer to Priming Fuel System. 1. Fuel filter/water separator 3. Filter
2. Filter cap

Reelmaster 4000−D Page 3 − 11 Kubota Diesel Engine

Engine Cooling System
Debris Removal

Remove debris from oil cooler, radiator and rear screen

daily, clean more frequently in dirty conditions.

1. Park machine on a level surface. Stop engine. Re-

move key from the ignition switch.
2
2. Release front engine cover latches and raise engine
cover. Clean engine area thoroughly of all debris.

3. Remove knobs securing rear screen to frame and

remove screen (Fig. 17).
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 Figure 17
(Fig. 18). 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
2. After every 100 operating hours, tighten hose con- 1. Oil cooler 2. Radiator
nections. Replace any damaged of deteriorated hoses.

3. After every 800 ooperating hours, drain and flush

the cooling system. Add anti−freeze (see Check Cooling
System).

Kubota Diesel Engine Page 3 − 12 Reelmaster 4000−D

Engine
Engine Removal

1. Park machine on a level surface, lower cutting units,

stop engine, engage parking brake, and remove key
from the ignition switch.

2. 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

5 2

Kubota Diesel
(see Battery Service in Chapter 5 − Electrical Systems). 11

Engine
4
10

CAUTION 6

If engine is hot, pressurized coolant can escape

and cause burns when the radiator hoses are re- 12
moved. The radiator and exhaust exhaust tube 8
9
may be hot. Avoid possible burns; allow engine, 1
radiator, and exhaust system to cool before re-
moving radiator hoses or exhaust tube.
3 7
4. Drain radiator. Disconnect both hoses from the ra- Figure 20
diator (Fig. 20). 1. Battery 7. Starter
2. Upper radiator hose 8. OIl pressure switch
5. Remove air hose from air intake manifold (Fig. 20). 3. Lower radiator hose 9. Alternator
4. Fan guard 10. Air hose
5. Fan shroud 11. Hi temp. warning switch
6. Remove exhaust shield from the engine (Fig. 20). 6. Exhaust shield 12. Hi temp. cutout switch

7. Remove fan guard and fan shroud from the radiator

(Fig. 20).
1
8. Remove fan from the fan pulley. Remove fan shroud
and fan from machine (Fig. 21). Remove fan shroud
from the machine.
2

Figure 21
1. Fan 3. Cap screws
2. Fan pulley

Reelmaster 4000−D Page 3 − 13 Kubota Diesel Engine

9. Clamp to prevent drainage, and disconnect the fol-
1
lowing fuel hoses:

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 3. Fuel pump discharge
2. Fuel pump suction 4. Fuel solenoid

10. Disconnect wire harness and electrical wires from

the engine as follows:

A. Disconnect wire and connector from the alterna-

tor, red cable from starter, three wires from the start-
er, wire from the oil pressure switch, and wires from
high temperature warning and shutdown switches
(Fig. 20). 2
1
B. Disconnect electrical connector from the fuel so-
lenoid (Fig. 22).

C. Disconnect red/black wire from the glow plug

5
bus bar (Fig. 23).
Figure 23
1. Injector return hose 4. Bracket
2. Glow plug wire 5. Lift tab
3. Exhaust tube

11. Disconnect throttle control cable from the swivel le-

1
ver and R−clamp from the engine plate (Fig. 24).
3 2

2 6
3
4 4

5
Figure 24
1. Throttle control cable 4. Swivel lever
2. R−clamp 5. Engine plate
3. Swivel 6. Screw

Kubota Diesel Engine Page 3 − 14 Reelmaster 4000−D

12. Separate hydraulic pump assembly from the engine
(Fig. 25). 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 1
5
pump adapter plate.

C. Support pump, and pull pump shaft from the

spring coupling. 2

4
Figure 25
1. Damper 4. Pump adapter plate
2. Bracket 5. Spring coupling
3. Pump mounting flange

13. Remove three lock nuts and cap screws securing

9
the upper exhaust tube to the exhaust bracket (Fig. 26).

Kubota Diesel
4
14. Remove hex nut, spring washer, cap screw, and flat

Engine
washers securing both front brackets to the engine 5 1
mounts (Fig. 26).
2 3
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 6 1
screws from the rear bracket and engine. 7
Figure 26
16. Remove three cap screws and lock washers secur- 1. Cap screw 6. Cap screw
ing the engine to the rear bracket and spacer (Fig. 27). 2. Upper exhaust tube 7. Flat washer
3. Exhaust bracket 8. Flat washer
4. Hex nut 9. Front bracket
5. Spring washer 10. Engine mount

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.

17. Remove engine slowly from the machine. Save gas- 2 1

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

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. Suction and discharge hoses at the fuel pump
other person guides the engine into the frame. (Fig. 22).

B. Return hose from the fuel injectors (Fig. 23).

1. Install engine to the front engine mounts and rear
brackets. C. Remove clamps used to prevent drainage.

A. Attach a hoist or lift to the engine. 9. Position fan shroud to the radiator. Install fan to the
fan pulley (Fig. 21).
IMPORTANT: Make sure not to damage the engine,
fuel and hydraulic lines, electrical harness, or other A. Apply Loctite (Blue) 242 or equivalent to the
parts while installing the engine. ends of the cap screws.

B. Place gasket onto exhaust bracket to receive ex- B. Torque cap screws from 80 to 110 in−lb (92 to
haust tube (Fig. 26). 127 kg−cm).

C. Lower engine slowly into the machine. 10. Install fan shroud and guard to the radiator (Fig. 20).

2. Secure both front brackets to the engine mounts 11. Install exhaust shield to the engine (Fig. 20).
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 12. Install air hose to air intake manifold (Fig. 20).
10.1 kg−m)t (Fig. 26).
13. Install battery the machine and connect cables (see
3. Secure engine to the spacers and rear brackets with Battery Service in Chapter 5 − Electrical Systems).
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).

4. Secure exhaust tube and gasket to the exhaust 15. Secure canopy to the brackets (Fig. 19).
bracket with three cap screws and lock nuts (Fig. 26).
16. Fill radiator with coolant (see Check Cooling Sys-
5. Connect hydraulic pump assembly to the engine tem).
(Fig. 25).
17. Adjust control cable throttle cable (Fig. 24).
A. Position the pump shaft into the spring coupling.
A. Push throttle lever to the FAST position.
B. Secure pump mounting flange to the pump
B. Loosen screw on swivel that secures the cable to
adapter plate with four cap screws, flat washers,
the swivel lever.
and lock washers. Torque cap screws from 60 to 80
ft−lb (8.3 to 11.1 kg−m). C. Adjust position of swivel lever with cable so the
injector pump lever is contacting the stop in the full
C. Connect damper to the bracket.
throttle position.
6. Connect throttle control cable to the swivel lever.
D. Secure cable to swivel with screw.
Secure cable to engine plate with R−clamp (Fig. 24).
18. Prime fuel system (see Prime Fuel System).
7. Connect wire harness and electrical wires to the en-
gine as follows: 19. Check traction pedal adjustment for NEUTRAL.
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 Page 3 − 16 Reelmaster 4000−D

 Chapter 4

Hydraulic System
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Test No. 1: Check Traction Working
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 and Relief Pressures . . . . . . . . . . . . . . . . . . . . . . . 31
Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Test No. 2: Check Counterbalance
Hydraulic Fitting Installation . . . . . . . . . . . . . . . . . . . 3 Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Pushing or Towing Traction Unit . . . . . . . . . . . . . . . 5 Test No. 3: Check Reel Circuit Working
Check Hydraulic System Fluid . . . . . . . . . . . . . . . . . 7 and Relief Pressures . . . . . . . . . . . . . . . . . . . . . . . 33
HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . 8 Test No. 4: Check Reel Circuit Flow . . . . . . . . . . . 34
HYDRAULIC FLOW DIAGRAMS . . . . . . . . . . . . . . . . 9 Test No. 5: Check Reel Motor Cross−Over
General Pump Flow . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Engine Run − No Functions . . . . . . . . . . . . . . . . . . 10 Test No. 6: Check Reel Motor Case Drain Flow . 36
Traction Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Test No. 7: Check Steering Circuit Working
Traction Circuit − Forward . . . . . . . . . . . . . . . . . . . 12 and Relief Pressures . . . . . . . . . . . . . . . . . . . . . . . 37
Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Test No. 8: Check Lift Circuit Working
Steering Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 and Relief Pressures . . . . . . . . . . . . . . . . . . . . . . . 38
Lift/Lower Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Test No. 9: Check Charge Pressure . . . . . . . . . . . 38
Lift Circuit − Lift All Units . . . . . . . . . . . . . . . . . . . . . 16 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 39
Lift Circuit − Lower All Units . . . . . . . . . . . . . . . . . . 17 Removing Hydraulic System Components . . . . . 39
Lift Circuits − Free Float (Detent) . . . . . . . . . . . . . 18 Steering Control Unit . . . . . . . . . . . . . . . . . . . . . . . . 40

Hydraulic
System
Reel Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Add Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . 51
Reel Circuit − All Units Mow (Free Float) . . . . . . . 20 Drain Water from Hydraulic Reservoir . . . . . . . . . 51
Reel Circuit − Units 1, 2 & 3 Mow (Free Float) . . 21 Reel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Reel Circuit − Units 1, 2, 3 & 5 (Free Float) . . . . 22 Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Reel Circuit − Any Unit Backlap . . . . . . . . . . . . . . 23 Lift Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4WD SELECTOR VALVE OPERATION . . . . . . . . . 24 Priority Flow Divider . . . . . . . . . . . . . . . . . . . . . . . . 60
4WD Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2WD Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Reel Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 64
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Reel Shut Off Valve . . . . . . . . . . . . . . . . . . . . . . . . . 66
Hydraulic Tester with Pressure and Flow Traction Rod Assembly . . . . . . . . . . . . . . . . . . . . . . 67
Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Traction Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Hydraulic Pressure Test Kit . . . . . . . . . . . . . . . . . . 27 Front Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . 74
Hydraulic Fitting Kit . . . . . . . . . . . . . . . . . . . . . . . . . 27 Reel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 28 Rear Wheel Drive Motor . . . . . . . . . . . . . . . . . . . . . 80
Hydraulic Oil Leak(s) . . . . . . . . . . . . . . . . . . . . . . . . 28 Rear Wheel Drive Valve Block . . . . . . . . . . . . . . . . 87
Slow or No Traction in Either Direction . . . . . . . . 28 Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Reels Slow or Won’t Turn . . . . . . . . . . . . . . . . . . . . 28 Change Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . 90
Steering Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Replace Hydraulic Oil Filter . . . . . . . . . . . . . . . . . . 91
Cutting Units Lift Slow or Won’t Lift . . . . . . . . . . . 29 Replace Hydraulic System Breather . . . . . . . . . . . 91
Cutting Units Won’t Drop Replace Hydraulic Lines and Hoses . . . . . . . . . . . 91
or Follow Ground Contours . . . . . . . . . . . . . . . . . 29
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Precautions for Hydraulic Testing . . . . . . . . . . . . . 30

Reelmaster 4000−D Page 4 − 1 Hydraulic System

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) Geroter type wheel motors

Reel Pump Gear pump

Cutting Circuit Relief Pressure 2650 − 2750 PSI

Reel Motor Gear Motor

Cross−over Relief Pressure 1500 PSI

Lift Control Valve Spool type directional control valve

Lift Relief Pressure 2650 − 2900 PSI
Counterbalance Pressure (Max. RPM) Hot oil 500 − 550 PSI, cold oil 600 − 650 PSI

Hydraulic Filter (Fig. 1) Spin−on cartridge type

Hydraulic Oil Mobil DTE 26/Shell Tellus 68 or equivalent (see Add Hydraulic Fluid)

Reservoir (Fig. 2) Reservoir capacity 15 gal. U.S.

System capacity approximately 18.2 gal. U.S.

Hydraulic System Page 4 − 2 Reelmaster 4000−D

General Information

Hydraulic Hoses
Hydraulic hoses are subject to extreme conditions such
as, pressure differentials during operation and exposure
to weather, sun, chemicals, very warm storage condi- WARNING
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. Some hoses are more susceptible to these
conditions than others. Inspect the hoses frequently for must be relieved by stopping the engine and
signs of deterioration or damage. 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. Keep body and hands away from pin hole leaks
This can be done by observing the imprint on the hose. or nozzles that eject hydraulic fluid under high
Use two wrenches; one to hold the hose straight and one pressure. Use paper or cardboard, not hands,
to tighten the hose swivel nut onto the fitting. 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
System
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

Seal
in the groove. It is recommended that the O−ring be re-
placed any time the connection is opened.

3. Lubricate the O−ring with a light coating of oil.

4. 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. Use another wrench to tighten the nut to the cor-
rect flats from finger tight (F.F.F.T.). The markings on the
nut and fitting body will verify that the connection has
been tightened.

Size F.F.F.T. Final

Position
4 (1/4 in. nominal hose or tubing) .75 + .25 Mark Nut
6 (3/8 in.) .75 + .25 and Body
8 (1/2 in.) .75 + .25
10 (5/8 in.) 1.00 + .25 Initial
12 (3/4 in.) .75 + .25 Extend Line Position
16 (1 in.) .75 + .25
Finger Tight After Proper Tightening

Figure 2
Reelmaster 4000−D Page 4 − 3 Hydraulic System
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) 1.00 + .25

6 (3/8 in.) 1.50 + .25
8 (1/2 in.) 1.50 + .25
10 (5/8 in.) 1.50 + .25
12 (3/4 in.) 1.50 + .25
16 (1 in.) 1.50 + .25

SAE Straight Thread O−Ring Port − Adjustable

1. Make sure both threads and sealing surfaces are free

of burrs, nicks, scratches, or any foreign material.

2. Always replace the O−ring seal when this type of fit-

ting shows signs of leakage. 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 O−Ring
as possible (Step 1).

5. Install the fitting into the port and tighten finger tight Figure 4
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 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 2 Step 4

4 (1/4 in. nominal hose or tubing) 1.00 + .25

6 (3/8 in.) 1.50 + 25
8 (1/2 in.) 1.50 + .25
10 (5/8 in.) 1.50 + .25
12 (3/4 in.) 1.50 + .25
16 (1 in.) 1.50 + .25 Figure 5

Hydraulic System Page 4 − 4 Reelmaster 4000−D

Pushing or Towing Traction Unit
Using Traction Pump By−Pass Valve

In an emergency, the traction unit can be pushed or

towed for a very short distance by using the traction
pump by−pass valve.

IMPORTANT: Do not push or tow the traction unit

faster that 2 to 3 MPH (3 to 5 Km/Hr) because the hy- 2
draulic system may be damaged. If traction unit
must be moved a considerable distance, transport
it on a truck or trailer.

1. Remove the retainer clip from seat lock rod.

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

2 before opening the by−pass valve.

5. Before starting engine, close by−pass valve. Do not

start engine when valve is open.

IMPORTANT: Running the machine with the by−

1 pass valve open will cause the hydraulic system to

Hydraulic
overheat.

System
Figure 6 DANGER
1. Seat 2. Support rod
Vehicle will roll with front wheel motors disen-
3. Lift and remove front panel (Fig. 7). gaged. Vehicle must be on level surface or
wheels must be blocked. There is no effective
braking with wheel motors disengaged.

If towing, with front wheel motors disengaged,

Tow Bar Assembly, Toro part no. 58−7020, must
be used.

Figure 7
1. Front panel

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 Page 4 − 5 Hydraulic System

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 1. Disengage cover − engaged (dimple facing out)
distance by opening the by-pass valve on the variable
displacement hydraulic pump and pushing or towing the 4. Lock the wheel hubs immediately after towing is com-
machine (See Pushing or Towing in the General In- pleted. Remove disengage covers and reinstall so dim-
formation section of Chapter 4 − Hydraulic System). 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 Page 4 − 6 Reelmaster 4000−D

Check Hydraulic System Fluid
1. Look into sight glass (Fig. 11). Oil level should be
even with arrows when checking warm oil. Oil will be 1/4
2
to 1/2 inch below arrows when cold.

2. If oil level is low, add hydraulic oil to the reservoir

(see Add Hydraulic Fluid).

Figure 11
1. Hydraulic reservoir 2. Sight glass

Hydraulic
System

Reelmaster 4000−D Page 4 − 7 Hydraulic System

 2100 100 PSI
P

LIFT VALVE
T

STEER

Hydraulic System
5
CYLINDER
TEST PORT
B
LIFT CYLS
L R 3

LIFT
1 CYLINDERS
STEERING
ORBITROL
D

2
E

T P 4
Hydraulic Schematic

TEST PORTS F
STEERING CIRCUIT

COUNTER−BALANCE

TRACTION REVERSE REEL SHUT-OFF

T
TRACTION FORWARD RIGHT SIDE
COUNTERBALANCE REEL MOTORS
5000 + 100 −0 PSI 350 25 PSI
TEST PORT
TEST PORT CUTTING
CHARGE G CIRCUIT
PRESSURE T REEL
SPEED REELS
ON-OFF
TRACTION
P2 MOTOR B IN B
(REV)
TRACTION (TYP) IN
PRIORITY

MOTORS A
OUT

Page 4 − 8
S1
3000 B A
B A PSI

RH PUMP T
LH PACKAGE
LC2

REAR
A B

2500 HI−IDLE
1100 LO−IDLE B A
(FWD)
LO-SPEED
P1 1200 +100 OIL BACKLAP
LC1 −0 PSI COOLER

4WD VALVE BLOCK A INLET

(FWD)

TRACTION RETURN
MOTOR FILTER
4 WHEEL DRIVE ONLY

LEFT SIDE
WARNING
OIL LEVEL
SENSOR

SHUT−
DOWN

Reelmaster 4000−D
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
suction line from the reservoir. Priority output flow is di- through the filter to collect any particles in the hydraulic
rected to the steering function. Excess flow exits the system.
secondary output of the pump and is directed to the lift
valve. Clean oil is collected at the filter by the charge pump.
This oil is used to maintain a supply of oil to the closed−
The flow continues through the lift valve where it meets loop traction circuit to prevent cavitation. The charge
the counterbalance valve. The counterbalance valve pressure is regulated by a relief internal to the traction
“super−charges” the incoming oil before allowing the oil pump. The charge pressure may be monitored at the
to continue on its return path back to the sump tank. The pressure tap port on top of the charge pump.
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
The oil pressure provided by the counterbalance valve is directed to the reel “On−Off” control valve. With the
will be used to reduce the cutting unit weight on the turf valve in the “Off” position, the oil is returned directly to
during the mowing function. the drain block. The remaining oil will also return to the
tank through the drain block.

Hydraulic
System

Reelmaster 4000−D Page 4 − 9 Hydraulic System

Engine Run − No Functions

Hydraulic System Page 4 − 10 Reelmaster 4000−D

Traction Circuit
Refer to “Traction Circuit − Forward” Flow Diagram

A mechanical interlock between the traction pedal link- inlet of the traction motors. The oil returns from the mo-
age and the parking brake prevents traction pedal tor to the pump where it continues through the pump in
movement unless the brake is released. a closed−loop circuit. System pressure may be moni-
tored at pressure tap port 1.
Depressing the top of the traction pedal will shift the trac-
tion pump swash plate to direct a flow of oil to the forward

Hydraulic
System

Reelmaster 4000−D Page 4 − 11 Hydraulic System

Traction Circuit − Forward

Hydraulic System Page 4 − 12 Reelmaster 4000−D

Steering Circuit
Refer to “Steering Right” Flow Diagram

With the engine running, the priority flow of oil from the 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. the power steering unit to the reservoir.

Turning the steering wheel to the right moves the control System pressure may be monitored at pressure tap port
spool in the steering unit to direct the oil to the steering 5.

Hydraulic
System

Reelmaster 4000−D Page 4 − 13 Hydraulic System

Steering Right

Hydraulic System Page 4 − 14 Reelmaster 4000−D

Lift/Lower Circuit
Refer to “Lift Circuit” Flow Diagrams

The lift cylinders are controlled by an open center valve while the cutting unit is lowering will lock the cutting unit
with three spools. The number 4 and 5 cutting units are at any position by trapping oil between the valve and cyl-
independently controlled. The center spool controls the inder.
number 1, 2, and 3 cutting units.
The cylinders work against counterbalance pressure
To lift the cutting units, the engine must be running during lowering. For this reason, the cutting units will
above half throttle. The flow of oil from the steer and lift drop faster at slow engine speeds or low counterbal-
pump is used to accomplish the lift function. Holding a ance pressures compared to full engine speed or high
lever in the “LIFT” position will direct the flow of oil to the counterbalance pressures. The counter balance pres-
lift cylinder and raise the cutting unit. Oil pressure to the sure may be monitored at pressure tap port 3.
lift cylinder is monitored during LIFT by a relief at the
valve inlet. System pressure may be monitored at the Since the lift levers are spring loaded from return to neu-
pressure tap port on the lift valve. tral, a detent plunger latches the spool in the valve to
hold the spool in a “Free Float” position. The position en-
Moving the lever forward will open a path for oil to es- ables the cutting units to follow ground contours by al-
cape from the lift cylinder. The weight of the cutting unit lowing a two−way flow between the lift valve and lift
will push oil from the cylinders through the valve allowing cylinders.
the cutting unit to lower. Moving the lever into “LIFT”

Hydraulic
System

Reelmaster 4000−D Page 4 − 15 Hydraulic System

Lift Circuit − Lift All Units

Hydraulic System Page 4 − 16 Reelmaster 4000−D

Lift Circuit − Lower All Units

Hydraulic
System

Reelmaster 4000−D Page 4 − 17 Hydraulic System

Lift Circuit − Free Float (Detent)

Hydraulic System Page 4 − 18 Reelmaster 4000−D

Reel Circuit
Refer to “Reel Circuit” Flow Diagrams

The three reel shut−off valves in this circuit enable the 5 shut−off valve. If the Number 4 cutting unit is in 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. 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- With the Number 5 cutting unit in the down and mowing
justable by the operator to supply a flow of oil to the reel position, the Number 5 shut−off valve will allow the oil
“On−Off” valve. Oil not needed to obtain the selected through to drive the reel motor. If the Number 5 cutting
reel speed is directed back to the sump tank through the unit is in the raised position, the oil will bypass the Num-
drain block, oil cooler, and filter. ber 5 reel motor and return to the reel “On−Off” valve.
From the reel “On−Off” valve, the oil returns to the sump
When the reel “On−Off” valve lever is moved into “Mow” tank through the drain block, oil cooler, and filter.
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 “Backlap” is provided by pulling the reel “On−Off” valve
the Number 1, 2, and 3 cutting units in mowing position, lever up and back. The backlap function requires that
the shut−off valve will allow oil to flow to the Number 2, the lever be held in this position for safety. The direction
3, and 1 reel motors. The oil is also available for use at of flow in “Backlap” is the opposite of “Mow”. Some units
the Number 4 shut−off valve. If the Number 1, 2, and 3 will include a low−speed backlap valve in the circuit to
cutting units are in the raised position, the oil will bypass remove some oil flow from the circuit during the backlap
these motors and be available directly to the Number 4 function. The reduced oil flow results in a slower reel
shut−off valve. 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 System pressure may be monitored at pressure tap 4 for
through to drive the reel motor and then to the Number either “Mow” or “Backlap”.

Hydraulic
System

Reelmaster 4000−D Page 4 − 19 Hydraulic System

Reel Circuit − All Units Mow (Free Float)

Hydraulic System Page 4 − 20 Reelmaster 4000−D

Reel Circuit − Units 1, 2 & 3 Mow (Free Float)

Hydraulic
System

Reelmaster 4000−D Page 4 − 21 Hydraulic System

Reel Circuit − Units 1, 2, 3 & 5 Mow (Free Float)

Hydraulic System Page 4 − 22 Reelmaster 4000−D

Reel Circuit − Any Unit Backup

Hydraulic
System

Reelmaster 4000−D Page 4 − 23 Hydraulic System

4WD Selector Valve Operation

4WD Forward (“S1” OFF)

Pressure Oil
Pressure Free

Hydraulic System Page 4 − 24 Reelmaster 4000−D

2WD Forward (“S1” ON)

Hydraulic
System
Pressure Oil
Pressure Free

Reelmaster 4000−D Page 4 − 25 Hydraulic System

Special Tools
Order special tools from your Toro Distributor. 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 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.
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 6. OUTLET HOSE: Hose from the outlet side of the hy-
circuit. 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 Page 4 − 26 Reelmaster 4000−D

Rev. C
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.

Hydraulic
System
Figure 14

Reelmaster 4000−D Page 4 − 27 Hydraulic System

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.
plete hydraulic system.
The charts that follow contain information to assist in
A hydraulic system with an excessive increase in heat troubleshooting. There may possibly be more than one
or noise is a potential failure. Should either of these cause for a machine malfunction.
conditions be noticed, immediately stop the machine,
turn off the engine, locate the cause of the trouble, and Refer to the Testing section of this Chapter for precau-
correct it before allowing the machine to be used again. 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.

Slow or no traction in either direction. Low engine RPM.

Low hydraulic oil level.

Open or damaged traction pump by−pass valve.

Disengaged or damaged final drive.

Loose or damaged traction linkage.

Low charge pressure. (See Test No. 8.)

Low traction pressure. (See Test No. 1.)

Damaged or worn traction motors.

Reels slow or won’t turn. Low engine RPM.

Low hydraulic oil level.

Reel to bedknife adjustment too tight.

Improper reel drive motor belt adjustment.

Low reel shut−off valves.

Low reel system pressure. (See Test No. 3.)

Worn or damaged priority flow divider.

Low flow to reel motors. (See Test No. 4.)

Inefficient reel motor. (See Test No. 5.)

Hydraulic System Page 4 − 28 Reelmaster 4000−D

 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. (See Test No. 6.)

Worn or damaged steering cylinder.

Worn or damaged steering pump.

Worn or damaged steering control unit.

Cutting units lift slowly or won’t lift. Low engine RPM.

Low hydraulic oil level.

Binding lift arm pivot points or bushings.

Worn or damaged bushings.

Worn or damaged cylinders.

Improper counterbalance pressure.

Hydraulic
System
(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.

Cutting units won’t drop or follow ground contours. Low engine RPM.

Low hydraulic oil level.

Binding lift arm pivot points or bushings.

Worn or damaged bushings.

Worn or damaged cylinders.

Improper counterbalance pressure.

(See Test No. 2.)

Worn or damaged counterbalance valve.

Plugged cylinder orifice.

Worn or damaged spool detent in lift valve.

Worn or damaged lift valve.

Reelmaster 4000−D Page 4 − 29 Hydraulic System

Testing
The most effective method for isolating problems in the
hydraulic system is by using hydraulic test equipment
such as pressure gauges and flow meters in the circuits WARNING
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
Before Performing Hydraulic Tests pressure. Do not use hands to search for
leaks; use paper or cardboard. Hydraulic fluid
IMPORTANT: All obvious areas such as oil supply, escaping under pressure can have sufficient
filter, binding linkages, loose fasteners, or improper force to penetrate the skin and cause serious
adjustments must be checked before assuming that injury. If fluid is injected into the skin, it must
a hydraulic component is the source of the problem. be surgically removed within a few hours by a
doctor familiar with this type of injury. Gan-
Precautions for Hydraulic Testing grene may result from such an injury.

1. Clean machine thoroughly before disconnecting or

CAUTION disassembling any hydraulic components. Always keep
in mind the need for cleanliness when working on hy-
Failure to use gauges with recommended pres- draulic equipment. Contamination will cause excessive
sure (psi) rating as listed in test procedures wear of components.
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-
All testing should be performed by two (2) nents.
people. One person should be in the seat to oper-
ate the machine, and the other should read and 3. The engine must be in good operating condition.
record test results. 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
Operate all hydraulic controls to relieve system capabilities) to prevent damage to the hydraulic tester or
pressure and avoid injury from pressurized hy- components.
draulic oil. Controls must be operated with the
ignition switch in OFF. Remove key from the igni- 5. When using tester with pressure and flow capabili-
tion switch. 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

WARNING sure that they are not cross−threaded before tightening
them with a wrench.
Before disconnecting or performing any work
on the hydraulic system, all pressure in the 7. Position tester hoses to prevent rotating machine
system must be relieved. Stop engine; lower or parts from contacting and damaging the hoses or tester.
support attachments.
8. Check oil level in the hydraulic tank. After connect-
ing test equipment, make sure tank is full.

9. Check control linkages for improper adjustment,

binding,or broken parts.

10. All hydraulic tests should be made with the hydraulic

oil at normal operating temperature.

Hydraulic System Page 4 − 30 Reelmaster 4000−D

TEST NO. 1: Check Traction Circuit Working and Relief Pressures
Procedure for Working Pressure Check:

1. Install a 10,000 psi gauge into the quick disconnect

test port for the function to be checked.
2
NOTE: If the machine is equipped with 4WD, check
working pressure in both 2WD and 4WD modes. 3
2. Operate the unit while monitoring gauge.

RANGE OF TESTER READINGS: 50 − 5200 PSI

NOTE: Typical working pressure during operation

while going uphill, would be approximately 4000 PSI in 1
2WD and 2500 PSI in 4WD.

3. If working pressure is too low in 2WD, perform the

Figure 15
traction circuit relief pressure check.
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:

Hydraulic
System
1. Hydraulic oil must be at operating temperature.

2. Install a 10,000 psi gauge into the traction circuit quick

disconnect for the function to be checked.

3. Set traction pedal stop for minimum ground speed (1

mph).

4. Start the engine and move throttle to full speed (2500

rpm) and release the parking brake.

5. Carefully drive the machine into position so it will push

against a strong wall or other immovable obstacle. Con-
tinue an attempt to go forward with the machine against
the obstacle and read the pressure gauge.

TESTER READING TO BE APPROXIMATELY

5000 − 5200 PSI

6. If traction pressure is too low, inspect the traction

pump check valves and relief valves. Clean or replace
relief valve(s) or check valves as necessary. If check
valves and relief valves are in good condition, the trac-
tion pump and / or motors should be suspected of wear
and inefficiency.

Reelmaster 4000−D Page 4 − 31 Hydraulic System

TEST NO. 2: Check Counterbalance Oil Pressure
Procedure:

1. Install a 10,000 psi gauge into the center quick dis- 2

connect as shown.
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 Figure 16
be adequate for most conditions. 1. Counter balance test port
2. Relief valve adjustment screw
4. If necessary, adjust the relief valve screw until the de-
sired pressure is attained. Turn the screw in to increase
counterbalance pressure and turn the screw out to de-
crease counterbalance pressure. Adjust nearer the high
end of the range for improved hill climbing or nearer the
low end for improved quality−of−cut.

Hydraulic System Page 4 − 32 Reelmaster 4000−D

TEST NO. 3: Check Reel Circuit Working and Relief Pressures
Procedure For Working Pressure Check:

1. Install a 5,000 psi gauge into the cutting circuit quick

disconnect.

2. Operate the unit while monitoring the gauge. 1

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.

Hydraulic
4. Turn the engine OFF.

System
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. If reel circuit relief pressure is above 2750 psi or below

2650 psi, clean or replace relief valve in reel control
valve.

Reelmaster 4000−D Page 4 − 33 Hydraulic System

TEST NO. 4: Check Reel Circuit Flow
Procedure:

1. Hydraulic oil must be at operating temperature.

2. Start the engine and lower the No. 2 and 3 cutting

units to the ground.

3. Turn the engine OFF.

4. Disconnect inlet hose at No. 2 reel motor.

5. Install tester in series between disconnected hose

and reel motor (flow direction is from hose to motor).
Make sure gate valve of tester is OPEN.
Figure 18
6. Position reel speed control knob at middle range (90
degree position).

7. Start engine and move throttle to full speed

(2500 rpm).

8. Engage the reel control lever into the “MOW” position.

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 Page 4 − 34 Reelmaster 4000−D

TEST NO. 5: Check Reel Motor Cross−Over Relief Pressure

FROM
LIFT CIRCUIT CUTTING
T
CIRCUIT
TEST PORT
G
T
PRIORITY
IN B (TYP)
FROM
IN
GEAR PUMP A
OUT
3000 B A
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
CAUTION
causes as: bad reel bearings, bent or damaged reel,
jammed debris, etc. It is often helpful to remove the reel Keep away from reels during test to prevent per-
sonal injury from the rotating reel blades.
motor from the unit when inspecting.

Hydraulic
System
Check Relief Pressure 7. Position reel speed control knob to minimum
speed. Start engine and move throttle to low idle speed
NOTE: The reel motor has an internal relief valve that of 1200 RPM.
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
1. Make sure hydraulic oil is at normal operating tem- problem is expected.
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-
2. Make sure machine is parked on a level surface. trol lever to BACKLAP. Slowly raise engine speed to
Lower cutting unit to be tested. Make sure engine is high idle speed of 2400 RPM while monitoring pressure.
OFF, and the parking brake is engaged. The pressure difference between the two gauges
should be from 1400 to 1600 PSI.
3. Read Precautions for Hydraulic Testing.
A. If pressure is greater than the specified range,
4. Block reel being tested to prevent rotation. Use a stop the engine and repair or replace the reel motor.
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:
5. Disconnect supply hose from the motor. Install test Check Reel Circuit Working and Relief Pressures).
gauge with T−connector in series with the motor and dis- If reel circuit pressure is correct, check reel motor
connected supply hose. cross−over relief valve for damage.
6. Disconnect return hose from the motor. Install test 9. Disengage cutting units by positioning reel control
gauge with T−connector in series with the motor and dis- lever to STOP position. Stop the engine.
connected return hose.
10. Disconnect tester from motor and hose. Reconnect
hose to the pump. Remove hardwood block from reel.

Reelmaster 4000−D Page 4 − 35 Hydraulic System

TEST NO. 6: Check Reel Motor Case Drain Flow

FROM
LIFT CIRCUIT
T
CUTTING
CIRCUIT
G TEST PORT
T PRIORITY

IN B
FROM (TYP) IN
GEAR PUMP
A
OUT
3000 B A
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
2. Make sure machine is parked on a level surface. Keep away from reels during test to prevent per-
Lower cutting unit to be tested. Make sure engine is OFF sonal injury from the rotating reel blades.
and the parking brake is engaged.
8. Engage reels by positioning reel control lever to
3. Read Precautions for Hydraulic Testing. MOW position. While watching pressure gauges, slowly
close flow control valve until a pressure of 1200 PSI is
4. For the suspected bad motor, disconnect return
obtained.
hose from the motor.
9. Collect hydraulic fluid for 15 seconds by putting the
5. Install tester in series with the motor and return
case drain hose into a 1 quart container graduated in
hose. Make sure the flow control valve is fully open.
ounces (1 liter container graduated in milliliters).
6. Follow hose from reel motor case drain to the hy-
10. Disengage cutting units by reel control lever to the
draulic T−connector.
NEUTRAL position. Stop the engine.
A. Disconnect hose from T−connector.
11. Measure the amount of oil collected in the container.
B. Plug T−connector to prevent drainage of fluid. Divide the number of ounces collected by 32 to get gal-
lons per minute. (Divide the number of milliliters col-
C. Put case drain hose into suitable container for lected by 250 to get liters per minute).
collecting case drain leakage.
12. Disconnect tester from motor and hose. Reconnect
7. One person should sit on the seat and operate the hose to the pump.
machine while another person reads the tester and
measures case drain leakage. Make sure reel control le- 13. Remove plug from T−connector. Reconnect case
ver in NEUTRAL. Start engine and move the throttle to drain hose to the T−connector.
full speed (2400 RPM).
14. If flow was greater than 0.7 GPM (2.6 LPM), repair
or replace the reel motor as necessary.

Hydraulic System Page 4 − 36 Reelmaster 4000−D

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.

Procedure For Relief Pressure Check: 1

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-

Hydraulic
sistance and read gauge.

System
TESTER READING TO BE APPROXIMATELY
1200 − 1300 PSI

6. If pressure is too high, clean and adjust relief valve in

steering pump by removing the required shims. If pres-
sure is too low, check for restriction in pump intake line.
Check the steering cylinder for internal leakage. If cylin-
der is not leaking, adjust the relief valve by adding the
required shims. If pressure is still too low, repair or re-
place steering pump.

Reelmaster 4000−D Page 4 − 37 Hydraulic System

TEST NO. 8: Check Lift Circuit Working and Relief Pressure
Procedure For Working Pressure Check:

1. Install a 5,000 psi gauge onto the quick disconnect of 2

1
the lift valve.

2. Operate the unit while monitoring the gauge. Gauge

should read from 500 to 2900 PSI.

3. If working pressure is too high or too low, perform re-

lief pressure check.

Procedure For Relief Pressure Check:

Figure 22
1. Hydraulic oil must be at operating temperature. 1. Lift control test port 2. Lift control valve

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
5. If pressure is too high, clean and adjust relief valve in 1. Lift control test port 2. Test gauge
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 1
valve and valve seat. Check for sheared charge pump
key. Disassemble charge pump and check for internal
damage or worn parts. If the charge pump is in good
condition (no scoring, scratches, or excessive wear),
the general condition of the piston pump might be sus-
pected of wear and inefficiency. Figure 24
1. Charge press. test port 2. Traction pump

Hydraulic System Page 4 − 38 Reelmaster 4000−D

Service and Repairs

Removing Hydraulic System Components

1. Thoroughly clean the machine before disconnecting, 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
working on hydraulic equipment. 3. After disconnecting or replacing any hydraulic com-
ponents, operate machine functions slowly until air is
2. Put caps or plugs on any hydraulic lines or fittings left out of system.
open or exposed.
4. Check for hydraulic oil leaks. Shut off engine and cor-
3. Put labels on disconnected hydraulic lines and hoses rect leaks if necessary. Check oil level in hydraulic reser-
for proper installation after repairs are completed. voir and add correct oil if necessary.

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.

Hydraulic
System

Reelmaster 4000−D Page 4 − 39 Hydraulic System

Steering Control Unit

1 11
2
3
12
4
5
6 13
7
28 8
12
27
26 14
25
24
15
23
9

12
22

21 10 16
20 19

18

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. Bearing Race 21. Retainer Plug
7. Thrust Bearing, Needle 22. Check Ball
8. Housing 23. Check Ball, Retainer
9. Control Sleeve 24. Check Ball
10. Centering Spring Kit 25. Seal
11. Control Spool 26. Check Ball Seat
12. Seal 27. Seal
13. Spacer Plate 28. Set Screw
14. Drive

Disassembly NOTE: Troubleshooting information defines terms and

problems, possible causes for problems, and recom-
Cleanliness is extremely important when repairing a mends procedures for correcting problems.
steering control unit. Work in a clean area. Before dis-
connecting lines, clean port area of unit thoroughly. Use Although not all drawings show the unit in a vise, we rec-
a wire brush to remove foreign material and debris from ommend that you keep the unit in the vise during disas-
around exterior joints of the unit. sembly. Follow the clamping procedure explained
throughout the manual.

Hydraulic System Page 4 − 40 Reelmaster 4000−D

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. Remove end cap.

4. Remove seal from end cap.

Figure 27

Hydraulic
System
5. Remove meter. Be careful not to drop star.

6. Remove seal from meter.

Figure 28

Reelmaster 4000−D Page 4 − 41 Hydraulic System

7. Remove drive spacer(s) (not used on 4.5 cu. in. dis-
placement units).

8. Remove drive.

9. Remove spacer plate.

10. Remove seal from housing.

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 Page 4 − 42 Reelmaster 4000−D

13. Remove quad ring seal from seal gland bushing.

14. Use a thin−blade screwdriver to pry dust seal from

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.

Hydraulic
System
IMPORTANT: Do not bind spool and sleeve in hou-
sing. Rotate spool and sleeve assembly slowly
when removing from housing.

17. Push pin from spool and sleeve assembly.

Figure 34

Reelmaster 4000−D Page 4 − 43 Hydraulic System

18. Push spool partially from control end of sleeve, then
remove 6 centering springs from spool carefully by
hand, see Fig. 35.

19. Push spool back through and out of sleeve, see

Fig. 35. Rotate spool slowly when removing from
sleeve.

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 Page 4 − 44 Reelmaster 4000−D

Reassembly

Check all mating surfaces. Replace any parts that have

scratches or burrs that could cause leakage. Clean all
metal parts in clean solvent. Blow dry with air. Do not
wipe dry with cloth or paper towel because of lint or 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.

Hydraulic
System
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 Page 4 − 45 Hydraulic System

6. Bring spring slots of both parts in line and stand parts
on end of bench. Insert spring installation tool through
spring slots of both parts. Tool is available from an Eaton
hydraulics supplier as Eaton part no. 600057. Position
3 pairs of centering springs (or 2 sets of 3 each) on
bench so that extended edge is down and arched center
section is together. In this position, insert one end of en-
tire spring set into spring installation tool, as shown in
Fig. 39, with spring notches facing sleeve.

7. Compress extended end of centering spring set and

push into spool sleeve assembly withdrawing installa- Figure 39
tion tool at the same time.

8. Center the spring set in the parts so that they push

down evenly and flush with the upper surface of the
spool and sleeve.

9. Install pin though spool and sleeve assembly until pin

become flush at both sides of sleeve.

10. Position the spool and sleeve assembly so that the

splined end of the spool enters the 14−hole end of hous-
ing first, see Fig. 40.

IMPORTANT: Be extremely careful that the parts do

not tilt out of position while inserting. Push parts
gently into place with slight rotating action, keep pin
nearly horizontal. Bring the spool assembly entirely
within 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 Figure 40
of the housing. With the spool assembly in this flush
position, check for free rotation within the housing
by turning with light finger tip force at the splined
end.

Hydraulic System Page 4 − 46 Reelmaster 4000−D

11. Place housing on clean, lint free cloth. Install 2−1/8”
diameter seal in housing, see Fig. 41.

12. Install 2 bearing races and the needle thrust bearing

in the order shown.

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.

Hydraulic
System
After installing ring, tap on ring end or pry with screwdriv-
er around entire circumference of ring to properly seat
ring in groove.

Figure 43

Reelmaster 4000−D Page 4 − 47 Hydraulic System

17. Clamp housing in vise, as shown in Fig. 44. Clamp
lightly on edges of mounting area. Do not over−tighten
jaws.

NOTE: Check to insure that the spool and sleeve are

flush or slightly below the 14−hole surface of the hous-
ing.

IMPORTANT: Clean the upper surface of the hous-

ing by wiping with the palm of clean hand. Clean
each of the flat surfaces of the meter section part in
a similar way when ready for reassembly. Do not use
Figure 44
cloth or paper to clean surfaces.

18. Install 3” diameter seal in housing, see Fig. 45.

19. Install spacer plate. Align bolt holes in spacer plate

with tapped holes in housing.

20. Rotate spool and sleeve assembly until pin is paral-

lel with port face, see Fig. 46. (Install drive, make sure Figure 45
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.

Figure 46

Hydraulic System Page 4 − 48 Reelmaster 4000−D

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.

Hydraulic
System
Figure 48

Reelmaster 4000−D Page 4 − 49 Hydraulic System

23. Install drive spacer(s), when used, in meter, see
Fig. 49.

24. Install 3” diameter seal in end cap.

25. Install end cap on gerotor, align holes.

Figure 49

26. Install 7 dry cap screws with new seal washers in

end cap. Pre−tighten screws to 150 inch pounds, ten
torque screws to 275 inch pounds in sequence shown
in Fig. 50.

Figure 50

Hydraulic System Page 4 − 50 Reelmaster 4000−D

Add Hydraulic Fluid
Capacity of the hydraulic reservoir is approximately 9.3
gal. (35.2 L). With machine on a level surface, hydraulic
2
oil level should be 1/4 to 1/2 inch below arrows on sight
glass, when oil is cold. Warm oil should be even with ar-
rows on sight glass. If level is low, add hydraulic oil. Re-
fer to Hydraulic Oil Specifications (Fig. 51).

1. Remove seat lock pin, raise seat and hold open with
support rod.
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
IMPORTANT: To prevent contamination, clean top 1. Hydraulic reservoir 2. Sight glass
of hydraulic oil containers before puncturing. As-
sure pour spout and funnel are clean.

3. Install reservoir cover, lower seat and secure with 2

lock pin. 1

Hydraulic Oils Specifications (Interchangeable):

Mobil DTE 26/Shell Tellus 68 Equivalent*

*Equivalent Hydraulic Oils (Interchangeable)

Mobil DTE 15 M
Amoco Rykon Oil #68

Hydraulic
Figure 52

System
Conoco Super Hydraulic Oil 68 1. Filler cap 2. Hydraulic reservoir
Exxon Nuto H 68
Kendall Kenoil R & 0 AW 68
Pennzoil Penreco 68
Phillips Magnus A 68
Standard Energol HLP 68
Sun Sunvis 831 WR
Union Unax AW 68

Drain Water from Hydraulic Reservoir

After every 100 operating hours, drain water from hy-
draulic reservoir.

1. Open drain plug one−half turn and allow fluid to flow

into drain pan until water is not noticed in hydraulic oil
1
(Fig. 53).

2. Tighten drain plug and add hydraulic oil (see Add 2

Hydraulic Oil).

Figure 53
1. Drain plug 2. Right front fender

Reelmaster 4000−D Page 4 − 51 Hydraulic System

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 8. Plate & Bushing Assembly 15. Relief Valve Kit
2. Idler Gear 9. Socket Head Cap Screw 16. O−Ring
3. Drive Gear 10. Set Screw 17. Plug
4. Key 11. Drive Pulley 18. Shim
5. O−Ring 12. Retaining Ring 19. Spring
6. Body 13. Shaft Seal 20. Ball
7. Dowel Pin 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-
1. Remove set screws (10) from drive pulley (11). tween body (6) and back plate assembly (21).

2. Remove drive pulley (11) from drive shaft. IMPORTANT: Remove relief valve kit only if testing
indicates the relief valve is faulty.
3. Remove key (4) from drive shaft.
12. Remove plug (17) and O−ring (16) from the back
4. Clean outside of motor thoroughly. Scribe a line along plate (21). Remove shim (18), spring (19), and ball (20)
front plate assembly (8), body (6), and back plate as- from the back plate.
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 Page 4 − 52 Reelmaster 4000−D

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).
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
1. Inspect drive gear assembly (3) for broken or cracked body (6).
keyway.
4. Install body (6) in front plate assembly (8) noting posi-
2. Inspect both the drive gear (3) and idler gear (2) tion of scribe line.
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 6. Dip gear assemblies (2 & 3) into oil and slip into body
may be replaced separately. Shafts and gears are avail- and front plate bushing.
able as assemblies only.)
7. Install back plate assembly (21) noting position of
4. If gear width is below 1.327, gear assembly should be scribe line. Install cap screws (9), draw up bolts evenly
replaced. and torque to 22−25 ft. lbs.

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 Oil shaft seal (13) liberally. Work shaft seal (13) over
groove. drive shaft taking care not to cut rubber sealing lip.

Hydraulic
System
7. If edge of gear teeth are sharp, break edge with 9. Seat shaft seal (13) by tapping with plastic hammer.
emery cloth. Install new retaining ring (12).

FRONT PLATE, BODY, BACK PLATE, AND RELIEF 10. Replace key (4) in drive shaft (3).
VALVE
11. Install drive pulley (11) on drive shaft.
1. Inspect I.D. of bushings in front plate (8), body (6),
and back plate (21). If I.D. exceeds .693, front plate, 12. Tighten set screws (10) in drive pulley (11).
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 Page 4 − 53 Hydraulic System

Steering Pump

2 11

4 12
10 13
3

4
14
15
16
17
18
19
20

21

16
22
26
9 25
24
8 23
2
6

Figure 55

1. Plug (includes #2) 15. Front Plate Assembly

2. O−Ring 16. O−Ring
3. Spool 17. Molded O−Ring
4. Dowel Pin 18. Bearing Seal
6. Plug (includes #2) 19. Backup Gasket
7. Drive Gear Assembly 20. Wear Plate
8. Disc 21. Body Assembly
9. Spring 22. Back Plate Assembly
10. Idler Gear Assembly 23. Relief Valve Assembly
11. Hex Head Cap Screw 24. O−Ring
12. Shaft Seal 25. Back Up Washer
13. Washer 26. O−Ring
14. Bushing

Hydraulic System Page 4 − 54 Reelmaster 4000−D

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). This will assure at bushing points and seal area for rough surfaces and
proper reassembly. excessive wear.

3. Clamp pump in a vise, with the shaft up. 3. If shaft measures less than 0.748” in bushing area,
the gear assembly should be replaced (one gear as-
4. Remove capscrews (11). 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 4. Inspect gear face for scoring and excessive wear.
(15) from back plate (22). Body (21) will remain with ei-
ther front plate or back plate. 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 FRONT PLATE AND BACK PLATE
end with a plastic hammer or soft mallet.
1. Oil groove in bushings in both front plate and back
9. Remove O−ring (16) from front plate (15) and back plate should be in line with dowel pin holes and 1805
plate (22). apart.

Hydraulic
10. Remove backup−up gasket (19) from front plate 2. If I.D. of bushings in front plate (15) or back plate (22)

System
(15). 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 1. Check inside gear pockets for excessive scoring or
/ Flow Control / Relief Valve) 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

2. Remove hex plugs (1, 6) flow divider spool (3), spring 1. Check disk (8) for wear.
(9) and disk (8).
2. Check spring (9) for weakness or breakage.
Inspect Steering Pump Parts
3. Wash back plate (22) in clean solvent, then direct
GENERAL 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 Page 4 − 55 Hydraulic System

 7

2 11

4 12
10 13
3

4
14
15
16
17
18
19
20

21

16
22
26
9 25
24
8 23
2
6

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. Body Assembly
9. Spring 22. Back Plate Assembly
10. Idler Gear Assembly 23. Relief Valve Assembly
11. Hex Head Cap Screw 24. O−Ring
12. Shaft Seal 25. Back Up Washer
13. Washer 26. O−Ring
14. Bushing

Hydraulic System Page 4 − 56 Reelmaster 4000−D

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.
You will note two half moon cavities in the body which NOTE: The small half moon port cavity must be on the
must face away from the front plate. pressure side of the pump.

NOTE: The smaller half moon port cavity must be on 8. Put wear plate (20) on top of back−up gasket (19) with
the pressure side of the pump. Side of wear plate with bronze face up. The side with the mid section cut away
mid section cut out must be on suction side of pump. must be on suction side of pump.
Suction side of back plate is always side with larger port
boss. 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).

2. Install flow divider spool (3), plug (1) with new O−ring 10. Slide back plate (22) over gear shafts until dowel
(2), and other plug (6) with new O−ring (2). pins (4) are engaged.

3. The wear plate (20), bearing seal (18), molded O−ring Install bolts (11) and washers (13). Tighten evenly to a
(17), back−up gasket (19), shaft seal (12), and O−rings torque of 25 − 28 ft.−lb.
(9) should be replaced as new parts.
11. Install washer (13). Liberally oil shaft seal (12) and
4. Install O−ring (16) in groove of front plate (15). carefully work over drive shaft, being careful not to cut
rubber sealing lip.
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

Hydraulic
down.

System

Reelmaster 4000−D Page 4 − 57 Hydraulic System

Lift Control Valve

34
12
14
11
15 16
10 17
13 18
9
22 19 38
8
7 20
6
5
3 4
2
1

37 22
23
36 39 24
35 29 25
33 26
32 27
31
28
30

39
40

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
7. O−Ring 28. Cap Assembly
8. Body 29. Plunger
9. O−Ring 30. Plug Assembly
10. Backup Washer 31. Spring
11. Plug Assembly 32. Eyelet
12. Washer 33. Poppet Assembly
13. Spool 34. Locknut
14. Plug Assembly 35. Seat Assembly
15. O−Ring 36. O−Ring
16. Washer 37. Plunger
17. Washer 38. Seal Wiper
18. Washer 39. .047 Dia. Orifice
19. Spring 40. .052 Dia. Orifice
20. Poppet

Hydraulic System Page 4 − 58 Reelmaster 4000−D

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
NOTE: Spools and spool bores are matched sets. Be bores.
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.
4. Install plugs (11) with new back−up washers (10) and
5. Remove plugs (11). O−rings (9).

6. Remove plugs (30), springs (31), poppets (33), seats 5. Install plungers (37, 29).
(35) and plungers (37, 29).
IMPORTANT: Check location and positioning of
IMPORTANT: Check location and positioning of plungers during installation.
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. Remove plugs (1), discs (2), springs (3) and detent
plungers (4). 8. Install plugs (6) with new O−rings (7).

9. Remove locknut (34), washer (12), plug (14), wash- 9. Install detent plungers (4), springs (3), discs (2), and

Hydraulic
ers (16, 17, 18), spring (19) and poppet (20). plugs (1) with new O−rings (5).

System
10. Remove all O−rings and back−up rings from all 10. If retaining ring (27) has been removed to replace
plugs and seats. 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
1. Remove all nicks and burns from parts and inspect for (22) over spools and position next to bushings. Dip
excessive wear. spools in clean hydraulic oil and install spool assemblies
in proper location.
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- 13. Install new wiper seals (38).
age.

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 Page 4 − 59 Hydraulic System

Priority Flow Divider

16
15
14
13
12
11
10
9
8
7
6
1
5 2
4 17
18
19
3

2
1

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. Shim
9. Groove Pin 19. Spring
10. Shim

Hydraulic System Page 4 − 60 Reelmaster 4000−D

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 3. Oil metering stem (8) and install in metering plug (16).
valve body when removing spool (3). 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) NOTE: Install the same number of shims that were re-
from metering plug (16). moved.

6. Remove groove pin (9) and remove metering stem (8) 6. Install metering plug assembly and tighten.
from metering plug (16).
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: Install same number of shims as were removed.
1. Thoroughly clean and dry all parts.
9. Install new O−ring (2) and plug (1) and install plug.
2. Remove all nicks and burrs with emery cloth.

3. Inspect the spool bore inside the body, the surface

Hydraulic
System
should be smooth and free of deep score marks.

4. Inspect O.D. of spool, it should be smooth and free of

nicks and burrs. Spool should slide freely inside the
body bore.

5. Inspect surface of metering stem (8) for deep

scratches and burrs.

Reelmaster 4000−D Page 4 − 61 Hydraulic System

Lift Cylinder

6
5
4
3

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

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. All parts should be cleaned and dried thoroughly. Met-
be seen through inlet port. al parts should be lightly oiled prior to reassembly.

3. Insert screw driver in inlet port and slide snap ring (6) 2. Install new seal (5) in barrel. Install new wiper (4) in
into deep groove in the rod assembly. 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 4. Oil outside of piston rod (3) and carefully insert rod in
assembly. 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 6. By using screwdriver through port, pop snap ring (6)
items and are included in the seal repair kit available for into lock position.
this cylinder.
7. Extend rod (3) to full out position to make sure snap
2. Thoroughly clean all parts and remove all nicks and ring (6) is locked.
burrs with emery cloth.
8. Cycle cylinder and check for leaks.
3. Inspect I.D. of barrel assembly (7) for excessive wear
or scoring.

Hydraulic
System

Reelmaster 4000−D Page 4 − 63 Hydraulic System

Reel Control Valve

34

33
2
3
4

5
32 6
31 7
30 8
29
28

27 9
10
11
26 12
13
25 14 16
17
24 18
15
23
20
22 19 21

Figure 60

1. Spool 18. Plunger

2. Body 19. Micro Switch
3. O−Ring 20. Flat Washer
4. Plug 21. Machine Screw
5. O−Ring 22. Cap Head Screw
6. Backup Washer 23. Lock Washer
7. O−Ring 24. Grease Fitting
8. Relief Valve 25. Block Detent
9. Detent Plug 26. Screw Spool
10. Detent Spring 27. Shallow Washer
11. Detent Pawl 28. Wire Washer
12. Locknut 29. Spring
13. Lock Washer 30. Deep Washer
14. Circlip 31. Washer
15. Spring 32. O−Ring
16. Plug 33. O−Ring
17. Sleeve 34. Wiper

Hydraulic System Page 4 − 64 Reelmaster 4000−D

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.
3. Remove relief valve components (8, 7, 6, & 5).
NOTE: All O−rings and back−up washers should be re-
4. Remove screws (22) and lock washers (23). placed as new parts.

5. Remove detent block (25). 2. Position O−rings (5, 32, & 33) in body bore.

6. Remove detent plug (9), spring (10), and pawls (11) 3. Install O−rings and back−up washers on relief valve
from detent block (25). and plugs.

7. Remove screw spool (26). 4. Install plug (4).

8. Remove shallow washer (27), wire washer (28), 5. Install O−ring (32), washer (31), deep washer (30),
spring (29), deep washer (30), washer (31), and O−ring spring (29), wire washer (28), and shallow washer (27)
(32). 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-
Inspection of Reel Control Valve Assembly cure to valve body (2) with lock washers (23) and cap
screws (22).
1. Remove nicks and burrs from all parts.

Hydraulic
System
9. Install relief valve (8).
2. Inspect spool and body bore for excessive wear.
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. Spools or bodies cannot be serviced separately.

3. Inspect relief valve.

NOTE: The pilot−operated cartridge−type relief valve is

not adjustable and is pre−set at the factory. However, to
ensure cleanliness in the system; snap ring, washer,
and screens may be removed, cleaned with air, and re-
placed.

4. Inspection of O−rings and back−up washers is not ne-

cessary. It is recommended that these be replaced as
new parts.

Reelmaster 4000−D Page 4 − 65 Hydraulic System

Reel Shut Off Valve

5
6
8 7
9

7
6
5
2
4
3
2
1

Figure 61

1. Circlip 6. Backup Washer

2. Washer 7. O−Ring
3. Spacer 8. Body
4. Spring 9. Spool
5. Wiper

Disassembly of Reel Shut−Off Valve Assembly 3. Inspect O.D. of spool (9). It should be smooth and free
of nicks and burrs.
1. Thoroughly clean outside of valve.
4. Inspect spring (4) for breakage.
2. Remove retaining ring (1) from end of spool (9).
Reassembly of Reel Shut−Off Valve Assembly
3. Remove spool (9) from valve body (8).
1. Install new O−rings (7) and back−up washers (6) in
4. Remove washers (2), spring (4), and spacer (3) from spool bore, with O−rings to the inside of the back−up
spool (9). washers.

5. Remove wipers (5), back−up washers (6), and O− 2. Install new wipers (5) in spool bore.
rings (7) from spool bore.
3. Install washer (2), spacer (3), spring (4), and washer
Inspection of Reel Shut−Off Valve Assembly (2) on spool (9).

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
2. Inspect the spool bore inside the body. The surface proper position.
should be smooth and free of deep scratches.
5. Install retaining ring (1) on end of spool (9).

Hydraulic System Page 4 − 66 Rev. B Reelmaster 4000−D

Traction Rod Assembly
The traction rod assembly allows adjustment to prevent
2
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 1
released.

If the traction rod is disassembled, use the following

steps during assembly. 3
1. Position neutral lock bracket so that socket head 4
5
screws are in the center of mounting slots.
9
8
2. Assemble traction rod to machine using Figure 62 as
a guide. Make sure that rod block is positioned down- 6
ward to engage traction lock lever. Overall traction rod
length (center to center) should be 26.060” (66.2 cm).
The distance between pump lever clevis center and rod 7
block should be from 8.250” to 8.310” (20.96 to 21.11
Figure 62
cm) (Fig. 63).
1. Traction pedal 6. Neutral lock bracket
3. Attach traction rod to traction pedal and pump lever. 2. Pump lever 7. Switch
3. Socket hd screw (2 used) 8. Traction rod
Do not fully tighten fasteners. 4. Flat washer (2 used) 9. Rod block
5. Lock washer (2 used)
4. Make sure that ground speed control lever on ma-
chine is in the fully forward position.

5. Depress traction pedal fully to engage ground speed

Hydraulic
System
control lever and make sure that pump lever has
reached the full rearward stoke. If pump lever does not
reach full stroke or if traction pedal does not engage
ground speed control lever, adjust traction control rod
ends as needed. Make sure that rod block stays in align-
ment with traction lock lever during any control rod ad-
justment. 26.060”
(66.2 cm)
6. Tighten all traction control rod fasteners.
8.250 to 8.310”
7. Start engine and make sure that machine does not (20.96 to 21.11 cm)
creep when traction pedal is in the neutral position.
Figure 63
8. If machine creeps when in neutral, loosen two (2)
socket head screws that secure neutral lock bracket to
machine (Fig. 62). Slide neutral lock bracket until ma-
chine does not move when in neutral. Tighten socket
head screws.

9. Verify that hand brake functions correctly after trac-

tion rod assembly and adjustments are completed (see
Hand Brake and Traction Switches in the Adjustments
section of Chapter 6 − Axles and Brakes).

Reelmaster 4000−D Page 4 − 67 Rev. B Hydraulic System

Traction Pump

15 16 19 6
13 17 18
20
12 22
23

10
4
9
46
8 11 21
45 24
14
7 25
2 26
1 27
32
28
29
30

34
41 31
37 33
38 3
39
40
48
35

42 43
5 44

47 36

Figure 64

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
5. O−Ring 29. Thrust Ring
6. Needle Bearing 30. Needle Bearing, Thrust
7. Gerotor Gear Assembly 31. Drive Shaft
8. Check Valve Assembly 32. Relief Valve Kit
9. Back Plate Assembly 33. O−Ring
10. Housing Gasket 34. Relief Valve Assembly
11. Dowel Pin 35. Key
12. Rotating Kit Assembly 36. Hex Head Cap Screw
13. Key 37. Cartridge
14. Camplate 38. O−Ring
15. Seal Cover 39. Spring
16. Shaft Seal 40. Poppet
17. Washer 41. Spring
18. Needle Bearing 42. Poppet
19. Housing Assembly 43. Spring
20. Inner Race 44. Spring Retainer
21. O−Ring 45. O−Ring
22. O−Ring Cover 46. Back−up Washer
23. Trunnion Cover 47. Bearing
24. Screw 48. Bearing

Hydraulic System Page 4 − 68 Reelmaster 4000−D

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.
10. Remove plug assembly (3), spring (41) and relief
2. Plug all ports and thoroughly clean outside of pump. valve assembly (34) from back plate.

3. Clamp the end of the drive shaft in a protected jaw 11. Remove pump from vise and remove rotating kit as-
vise with the body of the pump up and remove the four sembly (12) from housing (19).
cap screws (1 & 36) from the adapter plate of the pump.
12. If pistons did not come out with piston block, you
4. Use a plastic mallet and tap the charge pump adapter may remove them, spider, and spider pivot.
(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-
5. Remove spring retainer (44) and remove spring (43) able separately. The rotating kit (12) must be re-
and poppet (42) from adaptor assembly (2). placed as an assembly.

6. Remove the gerotor gear (7) and key (35) from the 13. Remove retaining ring (25) from housing. Press
pump shaft. 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- 14. Remove retaining ring (28) from shaft and remove
en when removing check valve assembly so that pin and thrust race (29) and thrust bearing (30).
ball are not lost.
15. To remove the camplate (14) from housing, remove
8. Use screwdriver slots in housing and pry up on back screws (24) from the sides of the housing. Remove trun-
plate (9) or tap with plastic mallet to loosen, then pull the nion cover (23), seal cover (15), O−ring cover (22), O−
back plate straight up to remove. Remove housing gas- ring (21), washer (17), inner race (20), and needle
ket (10). bearing (18). Remove shaft seal (16), washer (17), and

Hydraulic
System
needle bearing (18).

Reelmaster 4000−D Page 4 − 69 Hydraulic System

 15 16 19 6
13 17 18
20
12 22
23

10
4
9
46
8 11 21
45 24
14
7 25
2 26
1 27
32
28
29
30

34
41 31
37 33
38 3
39
40
48
35

42 43
5 44

47 36

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
5. O−Ring 29. Thrust Ring
6. Needle Bearing 30. Needle Bearing, Thrust
7. Gerotor Gear Assembly 31. Drive Shaft
8. Check Valve Assembly 32. Relief Valve Kit
9. Back Plate Assembly 33. O−Ring
10. Housing Gasket 34. Relief Valve Assembly
11. Dowel Pin 35. Key
12. Rotating Kit Assembly 36. Hex Head Cap Screw
13. Key 37. Cartridge
14. Camplate 38. O−Ring
15. Seal Cover 39. Spring
16. Shaft Seal 40. Poppet
17. Washer 41. Spring
18. Needle Bearing 42. Poppet
19. Housing Assembly 43. Spring
20. Inner Race 44. Spring Retainer
21. O−Ring 45. O−Ring
22. O−Ring Cover 46. Back−up Washer
23. Trunnion Cover 47. Bearing
24. Screw 48. Bearing

Hydraulic System Page 4 − 70 Reelmaster 4000−D

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. 9. Examine the O.D. of the pistons for finish condition,
they should not show wear or deep scratches. The
2. Inspect the charge pump relief valve poppet (42) and shoes should be snug fit on the ball end of the pistons.
spring (43). The flat surfaces of the shoes should be flat and smooth.
DO NOT LAP THE PISTON SHOES.
3. Inspect the gerotor pocket inside the charge pump
adaptor assembly (2). It should not be scored exces- 10. Examine the spider. It should be flat, no cracks and
sively. no signs of wear in the pivot area.

4. Inspect the bearing (47) inside the charge pump 11. Examine the pivot. It should be smooth and show no
adaptor assembly, if the needles are free of excessive signs of wear.
play and remain in the bearing cage there is no need to
replace the bearing. 12. The camplate (14) should be inspected for the
condition of the finish of the polished shoe surface. It
5. Inspect the check valve assembly (8), make sure the should show no signs of scoring.
ball seat is in good condition and the ball is free to move.
13. Inspect the drive shaft (31) for fretting in the bearing
6. Inspect the flat surfaces of the back plate (9), the fin- and spline areas.
ish on the gerotor side should show on galled surface.
The finish on the piston block side should be smooth and 14. Inspect thrust bearing (30) and thrust race (29) for
free of grooves. The back plate should be replaced if it wear.
shows any of the wear characteristics outlined above.
The cam stop should be tight in the back plate. 15. Inspect the needle bearing (6) in the housing as-
sembly. If the needles are free of excessive play and re-
7. Inspect the piston block. The surface that contacts main in the bearing cage, there is no need to replace the
the back plate should be smooth and free of grooves. bearing.

Hydraulic
System

Reelmaster 4000−D Page 4 − 71 Hydraulic System

 15 16 19 6
13 17 18
20
12 22
23

10
4
9
46
8 11 21
45 24
14
7 25
2 26
1 27
32
28
29
30

34
41 31
37 33
38 3
39
40
48
35

42 43
5 44

47 36

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
5. O−Ring 29. Thrust Ring
6. Needle Bearing 30. Needle Bearing, Thrust
7. Gerotor Gear Assembly 31. Drive Shaft
8. Check Valve Assembly 32. Relief Valve Kit
9. Back Plate Assembly 33. O−Ring
10. Housing Gasket 34. Relief Valve Assembly
11. Dowel Pin 35. Key
12. Rotating Kit Assembly 36. Hex Head Cap Screw
13. Key 37. Cartridge
14. Camplate 38. O−Ring
15. Seal Cover 39. Spring
16. Shaft Seal 40. Poppet
17. Washer 41. Spring
18. Needle Bearing 42. Poppet
19. Housing Assembly 43. Spring
20. Inner Race 44. Spring Retainer
21. O−Ring 45. O−Ring
22. O−Ring Cover 46. Back−up Washer
23. Trunnion Cover 47. Bearing
24. Screw 48. Bearing

Hydraulic System Page 4 − 72 Reelmaster 4000−D

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
new needle bearings in the housing. The camplate pivot 11. Install ball and pin into check valve housing if remo-
bearings are slip fit; the needle bearing (6) is press fit, ved. Install new O−ring (45) and back−up washer (46)
install with numbered end of the bearing outward. 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 13. Install new O−ring (5) in groove in charge pump
screws (24). adaptor (2), hold in place with clean clear grease. As-
semble adaptor on pump back plate. Retain with four
4. On the opposite side of housing install needle bearing cap screws (36 & 1) and torque to 27/31 ft. lbs.
(18), inner race (20) with chambered I.D. inward, wash-
er (17), O−ring (21), and O−ring cover (22), and secure 14. Reassemble tow valve assembly (4) by installing
with trunnion cover (23) and screws (24). 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 15. Install tow valve assembly (4) in back plate (9) and
race (29), secure with second retaining ring (28). torque 27 to 30 ft. lbs.

6. Install shaft in housing and install washer (27), shaft 16. Install relief valve assemblies (34) in back plate.
seal (26), and retain with retaining ring (25).
17. Install new O−ring (33) and spring (41) on plug (3).
7. Install the pivot, spider and the piston assemblies in Install plugs (3) in back plate and torque 55/60 ft. lbs.
the piston block. Install rotating assembly in the housing
assembly, the piston shoes must be in contact with the 18. Remove pump from vise and install poppet (42),

Hydraulic
spring (43), and spring retainer (44).

System
camplate.

8. Clamp pump assembly in a protected jaw vise with

the open end of the housing up.

Reelmaster 4000−D Page 4 − 73 Hydraulic System

Front Traction Motor

1 2 3
4
5 6
7

20
21 22

19 8

18

9
17

16
13
14
15
14
13
12
11
10
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. Housing Assembly
7. Bearing 18. Camplate Assembly
8. Key 19. Rotating Assembly
9. Retaining Ring 20. Grass Shield
10. Drive Shaft 21. Retaining Ring
11. Shaft Seal 22. Shaft Seal

Disassembly of Traction Motor 5. Remove capscrews (1 & 2) from backplate (5).

1. Clean outside of unit thoroughly. 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 8. Remove the complete rotating assembly (19) from
end up. the housing assembly (17).

4. Remove retaining ring (21) and shaft seal (22) from 9. Remove piston assemblies, spider, and pivot from the
backplate (5). rotating assembly (19).

Hydraulic System Page 4 − 74 Reelmaster 4000−D

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
replaced as an assembly. 9. Inspect the drive shaft (10) for fretting in the bearing
areas. Check spline area for twisted or broken teeth. If
10. Remove camplate assembly (18) from housing. keyed shaft, check for cracked or chipped keyway.

11. Remove shaft seal (11) from housing. Reassembly of Traction Motor

12. Remove washer (12) and drive shaft (10) from hous- 1. Lubricate all critical moving parts before assembly.
ing.
2. Install one retaining ring (13) in rear groove on drive
13. Remove the two retaining rings (13), thrust races shaft (10). Install one thrust race (14), thrust bearing
(14), and thrust bearing (15) from drive shaft (10). (15), and second thrust race (14) on drive shaft (10).
Install second retaining ring (13) in front groove on drive
Inspection of Traction Motor shaft.

1. Wash all parts thoroughly in a suitable solvent. 3. Replace needle bearing (16) in housing (17) if neces-
sary. Install shaft in housing assembly (17). Install wash-
2. Examine bearings (16) and (7) in housing (17) and er (12), shaft seal (11) and retain with retaining ring (9).
backplate (5). If the needles are free of excessive play
and remain in the bearing cage, there is not need to re- 4. Install the pivot, spider, and the piston assemblies in
place the bearing. the piston block assembly.

3. Inspect thrust races (14) and thrust bearing (15). All 5. Lubricate camplate assembly (18) and install in hous-
surfaces should be free of any signs of wear or fretting. 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

Hydraulic
5. Inspect the pistons; the O.D. surface should be (18). Be sure all parts are in their proper position.

System
smooth and free of scoring. The shoes should be snug
fit to the piston. The face of the shoes should be flat and 7. Install new bearing (7) in backplate (5) if necessary.
free of scoring and flaking. Do not lap piston shoes.
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 9. Install backplate (5) on housing.
be smooth and free of grooves or metal build−up.
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 Page 4 − 75 Hydraulic System

Reel Pump

15
14

13

12
7

11

8
7
12
6
5
4

3
1 2
10

9 18 17 16
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. Plug
8. Center S/A Section 17. Shaft Seal
9. Shaft Seal 18. Retaining Ring

Hydraulic System Page 4 − 76 Reelmaster 4000−D

Disassembly of Reel Pump 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
1. Clamp the port section (13) in a vise with protective drift and hammer, drive inner shaft seal (17) out through
jaws to avoid damage to the port section’s machined mounting flange, being careful not to damage bearing.
surfaces.
4. Inspect the drive and driven gear bushings of front
2. Remove gear coupling (14) from port section (13). cover (4) for pickup, scoring, discoloration, or excessive
wear. Any of the preceding conditions shall warrant re-
3. Remove eight nuts (1) and eight washers (2). placement of the front cover S/A (4). Inspect mounting
flange for nicks and burrs. Remove with India stone.
4. Remove front cover (4) from wear plate (7).
5. Inspect wear plates (7) for erosion, pitting, scratching,
5. Remove seal retainer (6) and gland seal (5) from front
an/or scoring. Replace if necessary.
cover (4) and discard.
6. Inspect the center S/A section (8) for porosity, cracks,
6. Remove wear plate (7) from center section (8).
and scratches (.010 or deeper). Replace if necessary.
7. Remove spline drive gear (10) and driven gear (11) DO NOT deburr the figure eight section of the center
from center section (8). section.

8. Removal of the center section (8) may require the use 7. Inspect splines on the drive gear (10) and driven gear
of a plastic hammer. (11) for nicks or excessive wear. Inspect gear journals
fro scratches and discoloration. Any discoloration war-
9. Remove wear plate (7) from port section (13). rants replacement. Inspect gear teeth for spalling,
scratches, and/or excessive wear. Replace if necessa-
10. Remove seal retainer (6) and gland seal (5) from ry. Stoning teeth to remove burrs is permissible. The
port section (13) and discard. face of the gear teeth should also be inspected for
scratches.

Hydraulic
System
Inspection of Reel Pump
8. Inspect the drive and driven gear bushings on the port
All parts must be thoroughly cleaned and kept clean dur- section (13) for pickup, scoring, discoloration, and/or
ing inspection and assembly. The close tolerance of the wear. Any of the preceding conditions shall warrant re-
parts makes this requirement very important. Paint placement of the port section. Inspect inlet flange for
found on the edges of all parts must be removed. Clean nicks and burrs. Stone to remove. Inspect studs (3) for
all removed parts, using a commercial solvent that is cross threads, cracks, and burrs. if studs are defective,
compatible with the system fluid. Compressed air may remove as follows: Install a nut (1) on the stud as far as
be used in cleaning, but it must be filtered to remove wa- possible. Then install another nut over the first one and
ter and contamination. tighten to lock in place. Apply torque to the first nut and
remove the stud. Refer to the parts drawing for stud part
New seal kits (5 & 6) are required for assembly. Wash numbers and installation instructions
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). Using a screwdriver, pop out the outer shaft seal (9),
being careful not to raise a burr on the shaft seal bore.

Reelmaster 4000−D Page 4 − 77 Hydraulic System

 15
14

13

12
7

11

8
7
12
6
5
4

3
1 2
10

9 18 17 16
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
8. Center S/A Section 17. Shaft Seal
9. Shaft Seal 18. Retaining Ring

Hydraulic System Page 4 − 78 Reelmaster 4000−D

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. Tape the spline area (long spline) of drive gear (10)
amount of petroleum jelly to hold seal glands (5) and re- to prevent cutting shaft seal(s) during assembly.
tainers (6) in place during assembly.
11. Lubricate drive gear (10) and driven gear (11). Install
1. Assemble seal packs by inserting the seal glands (5) drive gear (10) into port section (13) with short spline to-
into the seal retainers (6). Install a seal pack into the cav- wards port section. Install driven gear (11).
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
2. Place port section (13) in vise with studs (3) facing up. bronze face towards center section and notch facing in-
let port.
NOTE: The next five steps pertain to installation of front
cover shaft seals (9 & 17). Lubricate the shaft seals with 13. Install seal pack (5 & 6) into cavity located on face
Marfak grease to provide initial lubrication. 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 14. Carefully position front cover (4) over studs (3),
inside of pump. Place the shaft seal (17) on shaft seal gears (10 & 11), and center section guide pins. Gently
driver and press in place. 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
5. Place a guide over the pilot diameter of front cover (4). nuts to 60 to 70 ft−lb.

6. Install a new outer shaft seal (9) on the driver. Make 16. Clamp port section (13) into vise with studs facing
sure the spring loaded member of shaft seal faces the down. Make sure port section is clamped securely.

Hydraulic
inside of pump.

System
17. Install O−ring (15) into groove located on face of port
7. Insert the driver and shaft seal though the guide and section (13).
press in place.
18. Install lubricated coupling (14) on spline of drive
8. Place wear plate (7) on port section (13) with bronze gear (10).
face up and notch facing inlet port.
19. Turn the drive gear (10) one revolution with a suit-
9. Lubricate bronze face of wear plate (7). Install center able socket wrench. Not binding shall be evident during
section (8) on top of wear plate (7) and into locating this operation. The breakaway torque necessary to turn
holes of port section (13) with major diameter facing port the drive gear must not exceed 140 in−lb.

Reelmaster 4000−D Page 4 − 79 Hydraulic System

Rear Wheel Drive Motor

7
6

1
1

5
4 9
3
2 10
1

11

12
13
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. Spring

Disassembly of the Rear Wheel Drive Motor

Cleanliness is extremely important when repairing a hy-

draulic motor. Work in a clean area. Before disconnect-
ing the lines, clean the port area of the motor thoroughly.
Use a wire brush to remove foreign material and debris
from around the exterior joints of the motor. Check the
shaft and keyslot, remove all nicks, burrs or sharp edges
that might damage the bearing housing seals when
installing the shaft and bearing assembly. Before start-
ing the disassembly procedures, drain the oil from inside
the motor.

Hydraulic System Page 4 − 80 Reelmaster 4000−D

1. Place the motor in 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.

Although not all drawings show the motor in a vise, we

recommend that you keep the motor in the vise during
disassembly and reassembly. Follow the clamping
procedures explained throughout the manual. Figure 71

2. Remove 4 bolts from motor.

Figure 72

Hydraulic
3. Lift valve housing straight up. If done carefully the

System
pins, springs, balance ring assembly, and valve will re-
main on the valve plate.

Figure 73

4. Carefully remove 3[76] diameter seal from valve

housing.

5. Remove case drain plug−with seal, from front valve

housing.

Figure 74

Reelmaster 4000−D Page 4 − 81 Hydraulic System

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. Remove the 3[76] diameter seal from valve plate.

12. Remove the valve drive.

Figure 76

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. 77.

Figure 77

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.

Figure 78

Hydraulic System Page 4 − 82 Reelmaster 4000−D

19. You may need a press to remove shaft and bearing
assembly from bearing housing. (Key must be removed
before removing shaft.)

Figure 79

20. Use a small screwdriver to remove shaft seal, back−

up washer and exclusion seal from bearing housing, see
Fig. 80. 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 Figure 80
parts. Check around the keyway and chamfered area of
the shaft for burrs, nicks or sharp edges that can dam-

Hydraulic
age the seals when reassembling the bearing housing.

System
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.
81. If a press is not available use a plastic or rubber ham-
mer, being careful not to damage or cock seal in the
bore.

22. Place back−up washer into seal bore. Place shaft

seal onto installation tool and press seal into seal bore
of the housing.

23. Clamp housing in vise, see Fig. 71.

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: Use tape over other shafts to prevent cutting the

seats.

25. Apply petroleum jelly to the 3[76] diameter seal.

Install seal into the bearing housing.
Figure 81

Reelmaster 4000−D Page 4 − 83 Hydraulic System

26. Alignment studs can be very helpful in reassembly
of the motor. If you use studs, install 2 studs diagonally
opposed in the bearing housing.

27. Install the shaft face seal in the wear plate as shown
in Fig. 81. Do not distort seal.

28. Install the wear plate, see Fig. 81.

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 Figure 82

Geroter and mark it on the outside edge of the Geroter.

33. Apply a light film of petroleum jelly to the 3[76] diam-

eter seal. Install seal in groove of valve plate.

34. Align the notch on the outside of the valve plate with
the notch on the Geroter as shown in Fig. 82.

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 Figure 83
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. 83.

35. Install 2 springs and 2 pins in the holes located in the

bore of the valve housing, as shown in Fig. 81.

36. Apply a light film of petroleum jelly to the 3[76] diam-

eter seal. Install seal in the valve housing.

Figure 84

Hydraulic System Page 4 − 84 Reelmaster 4000−D

37. Apply petroleum jelly to inner and outer face seals.
Install seals on balance ring as shown in Fig. 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.

38. Align pin notches in balance ring with pins in bore of

valve housing. Install balance ring assembly in valve
housing.
Figure 85

39. Insert your finger through port of valve housing. Ap-

ply pressure to side of balance ring as shown in Fig. 86.
Hold ring in position until valve housing is in place
against valve plate. See Fig. 87.

Figure 86

NOTE: Install face seals in the positions shown in Fig.

85. or the motor will not operate properly. Do not force

Hydraulic
System
or bend the face seals. Any damage to these seals will
affect the operation of the motor.

Figure 87

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].
Figure 88

Reelmaster 4000−D Page 4 − 85 Hydraulic System

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

Rear Wheel Drive Valve Block

RM 4000−D 4WD
MANIFOLD BLOCK

Hydraulic
System
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. Use

mineral spirits to clean solenoid actuated cartridge
valves. Submerge the valve in clean mineral spirits and
use a probe to push the internal spool in and out 20 to
30 times to flush out contamination. Mineral spirits does
not affect the O−ring material. Particles as fine as talcum
powder can affect the operation of high pressure hy-
draulic valves.

NOTE: Apply clean hydraulic oil to the O−rings before

installing the valve. Use a deep socket to install the valve
into the manifold block. Tighten to a torque of 35 ft−lb (48
Nm). Install the solenoid coil. Make sure there is an O− Figure 91
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.

Reelmaster 4000−D Page 4 − 87 Hydraulic System

Rev. C
Steering Cylinder

1
2

3
4 5
6
7 8
10
11
12
13
14

15

16
17

18

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. Rod Tie, End
9. O−Ring 18. Roll Pin

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 IMPORTANT: Do not clamp vise jaws against
ends. 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 7. Remove piston. Slide head off of piston rod.
out of cylinder bore.
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-
3. Mount cylinder in a vise so piston rod end of cylinder pressed air. DO NOT wipe them dry with a cloth or paper
is tilted up slightly. Do not close vise so firmly that cylin- as lint and dirt may remain.
der tube could become distorted.
10. Carefully inspect internal surface of barrel for dam-
4. Loosen set screw and remove threaded cap. age (deep scratches, out−of−round, etc.). Replace en-
tire cylinder if barrel is damaged. Inspect head, piston
5. Grasp clevis end of piston rod and use a twisting and rod, and piston for evidence of excessive scoring, pit-
pulling motion to carefully extract piston, piston rod, and ting, or wear. Replace any damaged parts.
head from cylinder barrel.

Hydraulic System Page 4 − 88 Reelmaster 4000−D

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. Slide piston rod assembly into cylinder tube.
12. Install head onto piston rod.
16. Install head into tube. Install threaded cap and tight-
13. Install piston onto piston rod with O−ring seal (9) and en set screw.
tighten hex nut.

Hydraulic
System

Reelmaster 4000−D Page 4 − 89 Hydraulic System

Change Hydraulic Oil
Normally, change hydraulic oil after every 2 years or
1500 operating hours. If oil becomes contaminated,
contact your local TORO distributor because the system
must be flushed. Contaminated oil looks milky or black
when compared to clean oil. 1
1. Remove drain plug from reservoir and let hydraulic
oil flow into drain pan. Tighten plug when hydraulic oil 2
stops draining (Fig. 93).

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.

3. Install reservoir cover, lower seat and secure with Figure 93

lock pin. Start engine and use all hydraulic controls to 1. Drain plug 2. Right front fender
distribute hydraulic oil throughout the system. Also
check for leaks. Then stop the engine.

4. With cutting units up and oil warm, look into sight 2

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. 94).

Figure 94
1. Hydraulic reservoir 2. Sight glass

Hydraulic System Page 4 − 90 Reelmaster 4000−D

Replace Hydraulic Oil Filter
Initially, change filter after the first 50 operating hours,
thereafter, every 800 operating hours, annually, or on in-
dication. Use Toro replacement filter (Part No. 2
86−6110).

IMPORTANT: Use of any other filter may void the

warranty on some components.

1. Remove seat lock pin, raise seat and hold open with
support rod. Also remove front panel (secured with mag-
nets) ahead of the seat.

2. Clean area around filter mounting area (Fig. 95).

Place drain pan under filter and remove filter. 1

3. Lubricate new filter gasket and fill the filter with hy-
draulic oil. Figure 95
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
NOTE: Under certain conditions, a bypass valve in the
one−half turn.
filter mounting plate allows oil to bypass the filter. Before
5. Start engine and let run for about two minutes to the filter starts to bypass a warning light on the steering
purge air from the system. Stop the engine and check for console will illuminate. The warning light may come on
leaks. 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-
6. Check hydraulic oil level (see Check Hydraulic Sys- cal problem exists. Correct problem before commenc-

Hydraulic
System
tem Fluid). ing operation.

Replace Hydraulic System Breather

Change hydraulic system breather after every 800 oper-
1 2
ating hours, or annually, whichever comes first. More
often in extremely dusty or dirty conditions.

1. Release latches and open engine cover.

2. Clean around the breather and unscrew it with a

wrench. Install new breather (Fig. 96).

3. Close engine cover and latch securely.

Figure 96
1. Breather 2. Exhaust shield

Replace Hydraulic LInes and Hoses

Check hydraulic lines and hoses daily for leaks, kinked weather deterioration and chemical deterioration. Make
lines, loose mounting supports, wear, loose fittings, all necessary repairs before operating.

Reelmaster 4000−D Page 4 − 91 Hydraulic System

 This Page Intentionally Left Blank

Hydraulic System Page 4 − 92 Reelmaster 4000−D

 Chapter 5

Electrical System
Table of Contents
ELECTRICAL SCHEMATICS AND DIAGRAMS . . . 2 COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . 20
Reelmaster 4000−D Electrical Schematic Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
(S/N below 220000000) . . . . . . . . . . . . . . . . . . . . 2 Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Reelmaster 4000−D Electrical Schematic Glow Plug and Start Relays . . . . . . . . . . . . . . . . . 21
(S/N 220000001 to 230999999) . . . . . . . . . . . . . 3 Audio Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Reelmaster 4000−D Electrical Schematic Alarm Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
(S/N 240000001 and up) . . . . . . . . . . . . . . . . . . . 4 Hydraulic Oil Temperature Switch . . . . . . . . . . . . 22
Reelmaster 4000−D Main Harness Drawing Fuel Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
(S/N below 220000000) . . . . . . . . . . . . . . . . . . . . 5 Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Reelmaster 4000−D Main Harness Wiring H2O in Fuel Sensor . . . . . . . . . . . . . . . . . . . . . . . . 24
Diagram (S/N below 220000000) . . . . . . . . . . . . 6 High Temperature Warning
Reelmaster 4000−D Main Harness Drawing and Cutout Switches . . . . . . . . . . . . . . . . . . . . . . 25
(S/N 220000001 to 230999999) . . . . . . . . . . . . . 7 Rear Wheel Drive Solenoid . . . . . . . . . . . . . . . . . . 26
Reelmaster 4000−D Main Harness Wiring Fuel Stop Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . 27
Diagram (S/N 220000001 to 230999999) . . . . . 8 Hydraulic Oil Level Switch . . . . . . . . . . . . . . . . . . . 28
Reelmaster 4000−D Main Harness Drawing Bridge Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
(S/N 240000001 and up) . . . . . . . . . . . . . . . . . . . 9 Glow Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Reelmaster 4000−D Main Harness Wiring Hydraulic Oil Filter Switch . . . . . . . . . . . . . . . . . . . 30
Diagram (S/N 240000001 and up) . . . . . . . . . . 10 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 31
Reelmaster 4000−D Control Panel Battery Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Harness Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Battery Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Reelmaster 4000−D Control Panel Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Rear Wheel Drive Solenoid Replacement . . . . . 35
Reelmaster 4000−D Light Cluster Harness Check Interlock System . . . . . . . . . . . . . . . . . . . . . 36

Electrical
Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

System
Reelmaster 4000−D Light Cluster
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 16
Starting Problems . . . . . . . . . . . . . . . . . . . . . . . . . . 16
General Run & Transport Problems . . . . . . . . . . . 18
ELECTRICAL SYSTEM QUICK CHECK . . . . . . . . 19
Battery Test (Open Circuit Test) . . . . . . . . . . . . . . 19

Reelmaster 4000−D Page 5 − 1 Electrical System (Rev. C)

 BK BLACK VIO VIOLET All relays and solenoids
BN BROWN W WHITE 2 are shown as de−energized.
4 WHEEL
DRIVE (+)
BU BLUE Y YELLOW I
All ground wires are black.
OPTIONAL DKGN DARK GREEN BK/W BLACK/WHITE 1 S
ROAD LIGHT
KIT OPTIONAL HR FUEL
FL FUSIBLE LINK GN/W GREEN/WHITE PK
CRUISE CONTROL G
KIT (−) GY
GY GRAY R/BK RED/BLACK
BK BK/W
OR ORANGE Y/BU YELLOW/BLUE BU FUEL GAUGE
R/BK SENDING UNIT
BU 4WD
R RED SP SPLICE SOLENOID
STOP −−−− NONE BK
40 A FUSE RUN −−−− B+I+A, X+Y
START −−− B+I+S 4WD OPTION
5 A FUSE
W BK/W
20 A FUSE 7.5 A FUSE

Electrical System (Rev. C)

B BK/W (+)
Y A BN BU 87a
Y ALARM
30
S Y T BK/W 87
OR
5 OHM (−)
R I X BK/W
IGNITION GY 85 86
SWITCH
BK BK/W
VIO
OR ALARM
VIO
OR

6500 GY
MFD SILENCE ALARM
GN/W
HIGH TEMP BU
OVERRIDE
HYD. OIL BN
ENGINE RUN C C
SOLENOID LEVEL SW. OR AIR FILTER
(OPENS WHEN LOW) REEL DRIVE
HOLD NEUTRAL SW. AIR FILTER
#1 #2
R/BK OR (DISENGAGED)
NC NC
NO NO
W VIO VIO R
PULL
HYD. OIL TEMP.
BK BK/W HYD. OIL TEMP.
W
CONTROLLER A
GLOW PLUG Y BU
OR R BU
KUBOTA
VIO

87
86
C HYD. OIL LOW
HYD. OIL LOW

86
1

30
ENGINE OVER TEMP. 4
B

GLOW INDICATOR
(OPENS AT 110 C)
5 2

Page 5 − 2
T BK/W

RUN RELAY
NC 6 3 W

85

30
W

GLOW RELAY
HYD.OIL FILTER

87
85
Y T HYD.OIL FILTER
ALTERNATOR
VIO
R BK GN
B R R/BK
Electrical Schematics and Diagrams

BK
IG BU
ALTERNATOR
L Y Y

SEAT SWITCH
(OPERATOR NOT PRESENT) GN
(105 C)
ENGINE OVER TEMP. OVER TEMP.
VIO W ENGINE
R
SP SP
GN/W
W PARKING BRAKE #1
(BRAKE OFF) OIL PRESSURE
OIL PRESSURE ENGINE
NC BK
R C BK/W
NO Y
VIO W

FUSIBLE LINK
FUSIBLE LINK
Y/BU
B+ NC
C WATER IN FUEL
NO BU
BN GN WATER IN FUEL
STARTER Start DKGN
PARKING BRAKE #2
(BRAKE OFF)

TEST ALARM

BK

12 VOLT
BATTERY GLOW PLUGS

Reelmaster 4000−D
Electrical Schematic
(S/N below 220000000)

Reelmaster 4000−D
 All relays and solenoids
are shown as de−energized.
All ground wires are black.

PK
GY
BU
BK R/BK BU BK BK/W

Reelmaster 4000−D
W BK/W

Y BN BU
Y
T BK/W
BK/W OR
R T

VIO BK BK/W OR
BK/W VIO
OR
GY
GN/W BU

R/BK
OR BN

R/BK OR

W VIO VIO R

BK BK/W Y W BU

OR R VIO

BK/W

Page 5 − 3
W
W
W
Y T
VIO
R BK R/BK GN
R
BK
BU

Y Y

GN

VIO W
R

GN/W

BK
W
OR
Y/BU BK/W
BK

BN
T DKGN

BK

Reelmaster 4000−D
Electrical Schematic
(S/N 220000001 to 230999999)

Electrical System (Rev. C)

Electrical
System
 All relays and solenoids
are shown as de−energized.
All ground wires are black.

Electrical System (Rev. C)

Page 5 − 4
Reelmaster 4000−D
Electrical Schematic
(S/N 240000001 and up)

Reelmaster 4000−D
 2 1 P3
3
RUN 4
4 3 1
SOLENOID
P2 SEAT SWITCH 2 TO LIGHT
P11 CLUSTER
P10
HYDRAULIC OIL
2 LEVEL SWITCH
1
C B A

1 4 1

Reelmaster 4000−D
P1
WATER 2 5 2 P4
IN FUEL 3 6 3

1
2
GLOW PLUGS
J3 P8
P6
CRUISE CONTROL
OPTIONAL
A A ROAD LIGHT
B B J2 J1 KIT
HYDRAULIC 2 1
OIL TEMP
P9
HYDRAULIC 4 5 6
GROUND OIL FILTER
J4 P7
B+ B+ START PARKING BRAKE
J15 J25 J14 1 3
2
ENGINE OVER
TEMP (110 C) 8 7
ALTERNATOR
ALTERNATOR P15 ENGINE 6 5
J16 OIL PRESSURE FUSE BLOCK
J19 4 3 P12
J17 J13
12 2 1

Page 5 − 5
J7 CAPACITOR
J18 SP1X SP2 X
J8
ENGINE OVER
TEMP (105 C)
1
P13
2

1 REEL DRIVE
J9 P5
2 GLOW RELAY

P14 C
J5 J6 J24 J10 B
RESISTOR J11 J12 A

AIR FILTER ENGINE RUN RELAY

J20
1 4
2 5 P17
3 6
J21

BA
4
5
P16 6
4WD SOLENOID 1
2 P18
Reelmaster 4000−D 3 CONTROL
J22 J23 PANEL
FUEL GAUGE BA Main Harness Drawing
SENDING UNIT
(S/N below 220000000)

Electrical System (Rev. C)

Electrical
System
 OPTIONAL HYDRAULIC OVER TEMP.
ROAD−LIGHT HYDRAULIC OIL OIL HYDRAULIC (OPENS AT 110 C) OPTIONAL
KIT LEVEL SWITCH FILTER OIL TEMP ENGINE FUSE BLOCK CRUISE CONTROL SEAT SWITCH
P6 P10 P9 J1 J2 J16 J17 P12 P8 P11
1 2 1 2 3 4 1 2 1 2 3 4 5 6 7 8 A B 1 2

BLK RED/ RED ORG VIO RED BLK

BLK BLU WHT BLK

VIO

YEL
BRN
RED/BLK BLU

BLU

WHT
SP3

BLK/WHT
BLK/WHT
FRAME GND J4 BLK BLK BLK 6
VIO 5 #1
ORG
ORG 4
BLK WHT WHT 3 P7 PARKING BRAKE
RED/
BLK BLK BLK BRN 2 #2
BLK
1
ENGINE RUN HOLD A YEL
PULL P2 B

Electrical System (Rev. C)

SOLENOID BLK
GND C TAN
WHT A 1−N0
B 2−NC P5 REEL DRIVE
C 1−NC NEUTRAL
”85” 1 SWITCH
”86” 2 VIO
WHT 1
RUN RELAY ”87” J12 TAN 2
PNK 3 (P2)
”30” J11 RED P17
4
ORG 5
”30” J24 RED 6 CONTROL
PANEL
BLU 1
BRN 2
YEL 3 P18 (P1)
B+ J19 RED 4
ALTERNATOR L VIO 5
P15 2 YEL
IG GRN 6
1 BLU
BLU
BLK/
WHT BLK GRY
F.L. RED

Page 5 − 6
B+ J15 F.L. SP1
SP2 J22
FUEL GAUGE
STARTER B+ J25 RED BLK
J23 SENDING UNIT
BLK
START J14 BRN BLK
BLK/WHT
A SOLENOID
BLK BLK B P16 4WD
SP4
WATER IN 1 YEL/BLU
FUEL P1 2 BLK/WHT BLK/WHT J5
(FUEL FILTER) RESISTOR
3 BLK SP5
BLK/WHT J6
ENGINE OVER J18 GRN GRY
TEMP 105 C
J7
CAPACITOR

WHT
RED
ENGINE OIL J13 GRN/WHT BLK J8
PRESSURE
BRN BLK/
WHT
GRN RED/
BLU
RED BLK
BLK

YEL
BLK

YEL/BLU
1 2
1 2 3 4 1 2 3 4 5 6 ”85” ”86” ”30” ”87” J3
P3 P4 J20 J21 GLOW PLUGS
P13 J9 J10
AIRFILTER
TO LIGHT CLUSTER TO GLOW
(P5) (P4) RELAY
Reelmaster 4000−D
Main Harness Wiring Diagram
(S/N below 220000000)

Reelmaster 4000−D
Electrical
System
Reelmaster 4000−D
SN 230000001
AND UP

SN 220000001
SN 220000001 TO 220999999
TO 220999999

Page 5 − 7
Reelmaster 4000−D
Main Harness Drawing
(S/N 220000001 to 230999999)

Electrical System (Rev. C)

 BLACK

RED

RED

WHITE
BLUE

BLACK
BLACK

BLACK
VIOLET

WHITE
YELLOW
BROWN
RED/BLACK RED/BLACK BLUE

VIOLET
BLACK BLACK BLACK VIOLET

ORANGE
WHITE

BLUE
ORANGE

BLACK
WHITE

R/BLK

BLACK
BLACK/WHITE
BLACK/WHITE
RED/BLACK

Electrical System (Rev. C)

ORANGE
YELLOW

BLACK
TAN

WHITE
R/BLK
VIOLET
WHITE

RED
ORANGE

BLUE
BROWN

BLACK
YELLOW

RED
BLK/WH
VIOLET
GREEN
BLUE
BLUE
ORANGE
YELLOW
ORANGE
VIOLET

RED

Page 5 − 8
BLACK
BLACK
GRAY

TAN
PINK

RED BLACK
BLACK
BLK/WH

BROWN
BLACK BLACK

BLACK
BLACK/WHITE BLACK/WHITE BLK/
BLACK

YELLOW/BLUE WH
BLACK/WHITE

GREEN

GREEN/WHITE BLACK
BROWN
GREEN

RED/BLACK
BLACK
RED

BLUE
RED
BLACK
BLACK
BLACK/WHITE

BLK/WH
BLACK

YELLOW/BLUE
WHITE
TAN
BROWN

YELLOW
ORANGE

RED/BLACK

Reelmaster 4000−D
Main Harness Wiring Diagram
(S/N 220000001 to 230999999)

Reelmaster 4000−D
Reelmaster 4000−D
Page 5 − 9
Reelmaster 4000−D
Main Harness Drawing
(S/N 240000001 and up)

Electrical System (Rev. C)

Electrical
System
 BLACK
VIOLET
BLACK

RED

RED

WHITE
BLUE
VIOLET

BLACK
BLACK

BLACK
VIOLET

WHITE
YELLOW

YELLOW
BROWN
RED/BLACK RED/BLACK BLUE

VIOLET
BLACK BLACK BLACK VIOLET

ORANGE
WHITE

BLUE

VIOLET
ORANGE

WHITE
VIOLET/
BLACK
WHITE

R/BLK

BLACK
BLACK/WHITE
BLACK/WHITE
RED/BLACK

Electrical System (Rev. C)

ORANGE
YELLOW

BLACK
TAN

WHITE
R/BLK
WHITE

RED
ORANGE

BLUE
BROWN

BLACK
YELLOW

RED
BLK/WH
VIOLET
GREEN
BLUE
BLUE
ORANGE
YELLOW
ORANGE
VIOLET

RED

Page 5 − 10
BLACK
BLACK
GRAY

TAN
PINK

RED BLACK
BLACK
BLK/WH

BROWN
BLACK BLACK

BLACK
BLACK/WHITE BLACK/WHITE BLK/
BLACK

YELLOW/BLUE WH
BLACK/WHITE

GREEN

GREEN/WHITE BLACK
BROWN
GREEN

RED/BLACK
BLACK
RED

BLUE
RED
BLACK
BLACK
BLACK/WHITE

BLK/WH
BLACK

YELLOW/BLUE
WHITE
TAN
BROWN

YELLOW
ORANGE

RED/BLACK

Reelmaster 4000−D
Main Harness Wiring Diagram
(S/N 240000001 and up)

Reelmaster 4000−D
Reelmaster 4000−D
FUEL 4WD SWITCH
GAUGE
J2
P4
J1 XXXXXXX
2
HIGH TEMP
OVERIDE 1 3
J6 J5 KUBOTA
XXXXXXX GLOW PLUG
CONTROLLER
P3
6 3
5 2
4 1

B B
REEL DRIVE P5 P7 GLOW
HARNESS A A INDICATOR

4 A(+)

Page 5 − 11
5 B
6 P8 HOUR
METER
2 C(−)
3
P1 1
3 4 J7
MAIN 2 5
HARNESS
1
1 2 3 P6
IGNITION
SWITCH
4 5 6
P2
MAIN
HARNESS

Reelmaster 4000−D
Control Panel Harness Drawing

Electrical System (Rev. C)

Electrical
System
 KUBOTA
GLOW PLUG 4WD
CONTROLLER SWITCH
P3 J1 J2
1 2 3 4 5 6 1 2 3

VIO TAN BLK/ GRN BLK PNK BLU

WHT

Electrical System (Rev. C)

BLK/
VIO WHT BLK

1 WHT BLK/WHT
2 TAN 1 I
P2 3 PNK 2 G P4 FUEL
GAUGE
(TO P17) 4 GRY GRY 3 S
5 ORG
6 BLK BLK/
WHT BLK

TO
MAIN A (+)
HARNESS BLK/WHT
B P8 HOUR
METER
C (−)
BLK

Page 5 − 12
1 BLU
2 BRN
3 YEL
P1
4 BLK/WHT
(TO P18)
5 VIO
6 GRN

ORG

BLK/ VIO BLK/WHT

WHT
BRN VIO
BLK/ BLK/
WHT TAN ORG TAN YEL WHT WHT

A B 1 2 3 4 5 A B NO C
P7 X Y A B S I P5 J6 J5
GLOW HARNESS
INDICATOR REEL DRIVE HIGH TEMP
P6 J7 OVERIDE
SWITCH
IGNITION
SWITCH

NOTE: THIS WIRE IS GREEN

ON SN 220000001 AND UP

Reelmaster 4000−D
Control Panel Wiring Diagram

Reelmaster 4000−D
Reelmaster 4000−D
TO LIGHT
CLUSTER
P1
1
2
TO MAIN 3
HARNESS
P4 4
1 5
2 6
3 J17
4 J18
5 J19 SILENCE
6 J20 ALARM
J1 SWITCH
ALARM J2
SILENCE

J8 J7 J5
(+)
1 3
P5

Page 5 − 13
TO MAIN 2 4
(−) J6
HARNESS

ALARM
J9

J10

J11 J16
6 J12
5
4 J15
3 5
J14 J24 J3 J4 1
2 J13 J23
1 3
P2 J22 4
TO LIGHT J21 ALARM TEST 2
CLUSTER SWITCH
P3
ALARM

Reelmaster 4000−D
Light Cluster Harness Drawing

Electrical System (Rev. C)

Electrical
System
 RECTIFIER #2 TEST ALARM
LIGHT CLUSTER #1
J22 J11 J18 J12 P1 J3 J4
1 2 3 4 5 6

ORG WH BRN RED BLK/

WH GRN/ BLK
GRN/ BLK
BLU BLK BLK/ BLK/
WH WH
BLU

WH

Electrical System (Rev. C)

ORG
J23
RED ORG
J10
ORG YEL
J13
J17 GRN/ YEL RECTIFIER #3
RECTIFIER #1 BLK GRN/BLK
J19
BRN GRN/BLK
J9
GRN
J14
GRN
J21
RED
BRN
BLK/WH 1 30
ORG 2 85
YEL 3 87A P3 ALARM
1 4 87
2 WH 5 86
TO MAIN 3 BLU
HARNESS P4 GRY
(P4) 4

Page 5 − 14
5 BLK
6 BLK/WH BLK/WH J1
BLK/WH
SILENCE ALARM
GRY
1 YEL J2
TO MAIN GRN/WH GRN/
HARNESS 2 GRN/WH BLK
P5
(P3) 3 GRN GRY
4 YEL/BLU
J7
GRN DIODE
ORG
J8
BLK/ ORG
GRN/ BLK/ WH
WH WH ORG ORG
YEL/ BLK/ GRN/ GRN/ YEL/ YEL/
YEL BLU WH ORG YEL ORG WH BLK BLU BLU

1 2 3 4 5 6 (+) (−)

P2 J5 J6 J24 J15 J20 J16

LIGHT CLUSTER #2
ALARM RECTIFIER #4

Reelmaster 4000−D
Light Cluster Wiring Diagram

Reelmaster 4000−D
Special Tools
Order special tools from your Toro Distributor. 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.
505−165) which forms a light protective skin which helps
waterproof electrical switches and contacts.

Electrical
System
Figure 2

Reelmaster 4000−D Page 5 − 15 Electrical System (Rev. C)

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
watches, before doing any electrical trouble- If the machine has any interlock switches by−passed,
shooting or testing. Disconnect the battery they must be reconnected for proper troubleshooting
cables unless the test requires battery voltage. and safety.

Starting Problems

Problem Possible Causes

Starter solenoid clicks, but starter will not crank Low battery charge.
(if solenoid clicks, problem is not in safety interlock
system). Loose or corroded battery cables.

Loose or corroded ground.

Faulty wiring at starter.

Faulty starter solenoid.

Nothing happens when start attempt is made. Battery is dead.

Loose or corroded battery cables.

Loose or corroded ground.

Parking brake is off.

Mow − backlap lever is engaged.

Circuit breaker open.

Traction (brake) switch (#2) out of adjustment or faulty.

Traction (brake) switch (#2) wiring loose, corroded or

damaged.

Reel drive neutral switch faulty.

Reel drive neutral switch wiring loose, corroded or

damaged.

Key switch faulty.

Key switch wiring loose, corroded or damaged.

Starter solenoid wiring loose, corroded or damaged.

Starter solenoid faulty.

Electrical System (Rev. C) Page 5 − 16 Reelmaster 4000−D

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.

Engine cranks (but should not) with mow−backlap Reel drive neutral switch faulty.
lever in mow or backlap.
Short circuit in Reel drive neutral switch circuit.

Electrical
System

Reelmaster 4000−D Page 5 − 17 Electrical System (Rev. C)

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.

Engine kills when parking brake is released or Operator sitting too far forward on seat (seat switch not
mow−backlap lever is moved to mow or backlap. 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. C) Page 5 − 18 Reelmaster 4000−D

Electrical System Quick Check

Battery Test (Open Circuit Test)

Use a multimeter to measure the voltage between the Voltage Measured Battery Charge Level
battery terminals.
12.68 V (or higher) Fully charged (100%)
Set multimeter to the DC volts setting. The battery 12.45 V 75% charged
should be at a temperature of 60 to 100oF (16 to 38oC).
12.24 V 50% charged
The ignition key should be off and all accessories turned
off. Connect the positive (+) meter lead to the positive 12.06 V 25% charged
battery post and the negative (−) meter lead the the neg- 11.89 V 0% charged
ative battery post.

NOTE: This test provides a relative condition of the bat-

tery. Load testing of the battery will provide additional
and more accurate information.

Electrical
System

Reelmaster 4000−D Page 5 − 19 Electrical System (Rev. C)

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 CAUTION
doing a continuity check).
When testing electrical components for continu-
NOTE: For more component testing information, see ity with a multimeter (ohms setting), make sure
the Kubota Workshop Manual for 03 Series Diesel En- that power to the circuit has been disconnected.
gine.

Ignition Switch

The ignition (key) switch has three positions (OFF, RUN,

and START). The terminals are marked as shown. The A
Y
circuitry of the ignition switch is shown in the chart. With
the use of a multimeter (ohms setting), the switch func- B
tions may be tested to determine whether continuity ex-
ists between the various terminals for each position. S
Verify continuity between switch terminals.
I
SWITCH NORMAL OTHER
POSITION CIRCUITS CIRCUITS X
OFF NONE NONE
Figure 3
RUN B+A+I X+Y
START B+S+I NONE HEX NUT
KEY

SWITCH LOCK WASHER

Figure 4

OFF
45 °
RUN

45 °

START

Figure 5

Electrical System (Rev. C) Page 5 − 20 Reelmaster 4000−D

Hour Meter

IMPORTANT: Make sure to observe polarity on the

meter label when testing. Damage to the meter may
result from an improper connection.

1. Connect the positive (+) terminal of a 12 VDC

source to the positive terminal of the hour meter.

2. Connect the negative (−) 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 87
1. Verify coil resistance between terminals 86 and 85
with a multimeter (ohms setting). Resistance should be
from 41 to 51 ohms.
85 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- Figure 7
plied and removed from terminal 85.

3. Disconnect voltage and leads from the terminals.

Electrical
System
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 2

the alarm. Reconnect alarm to the circuit.

Figure 8
1. Top view 2. Side view

Reelmaster 4000−D Page 5 − 21 Electrical System (Rev. C)

Alarm Relay

The alarm relay is located inside the steering tower.

1. Verify coil resistance between terminals 86 and 85 86 87A 87

87
with a multimeter (ohms setting). Resistance should be
87A
from 80 to 90 ohms. There should be continuity between 86 85
terminals 87A and 30.

2. Connect multimeter (ohms setting) leads to relay 30

terminals 30 and 87. Ground terminal 86 and apply +12 85 30
VDC to terminal 85. The relay should make and break
continuity between terminals 30 and 87 as 12 VDC is ap-
plied and removed from terminal 85.

3. Disconnect voltage from terminal 85 and multimeter

lead from terminal 87. 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 Figure 9

relay terminals.

Hydraulic Oil Temperature Switch

The high temperature switch is located on the the bot-
tom of the hydraulic reservoir with two black wires and
one red wire connected to it (Fig. 10).

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
close between 186 to 194oF (86 to 90oC).
Figure 11
4. Allow the oil to cool. The switch should open below
186oF (86oC).

Electrical System (Rev. C) Page 5 − 22 Reelmaster 4000−D

Fuel Sender
The sender is located on top of the fuel tank under the
rear screen. 1 2

1. Remove gray wire and black ground wire from the 3

sender.

2. Remove truss head screws and lock washers from 4

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 Figure 12
will display a small resistance value. This internal resis- 1. Truss head screw 4. Gasket
tance of the meter and test leads should be subtract 2. Lock washer 5. Fuel tank
3. Fuel sender
from the measured value of the component.

CAUTION
1
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.
2
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.

Electrical
System
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 1 2
variable resistance box.

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
B. The right edge of the green area (full); the resis- RESISTANCE
14 VDC
tance setting should be from 28 to 38 ohms.

3. Disconnect the voltage source, gauge, and variable − +

resistance.
Figure 14
1. Empty position 2. Full position

Reelmaster 4000−D Page 5 − 23 Electrical System (Rev. C)

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- 2
ter has collected in the fuel filter bowl.

1. Make sure engine is OFF. Disconnect fuel stop sole-

noid from the wiring harness.
7
2. Disconnect connector from the sensor. Verify cir-
6
cuitry to the sensor at the connector using a multimeter
and the following steps:

A. Place ignition switch in RUN. Battery voltage 5

from the pin for the yellow/blue wire to chassis
ground should be indicated and the red warning
light should come on. Turn switch OFF.

B. Hold ignition switch in START. Battery voltage 6

from the pin for the black/white wire to chassis
ground should be indicated. Turn switch OFF. 1

C. Check continuity from the pin for the black wire to 4 3

chassis ground. Continuity should be 1 ohm or
less.
Figure 15
D. Correct any problem circuitry if necessary. 1. Sensor 5. Filter element
2. Filter assembly 6. Gasket
3. Drain fuel filter assembly into a suitable container. 3. Drain plug 7. O−ring
4. Fuel filter bowl

4. Unscrew fuel filter bowl from the assembly. Remove

filter element, gaskets, and O−ring from the assembly. 8. Disconnect connector from sensor. Reassemble
Store seals in a clean place. fuel filter assembly. Reconnect connector to sensor.

5. Reconnect connector to the sensor. Fill fuel filter 9. Replace sensor with new one if necessary.
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. C) Page 5 − 24 Reelmaster 4000−D

High Temperature Warning and Cutout Switches
The high temperature warning and cutout switches are
located on the water return pipe above the water pump,
2
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).

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
1. High temp warning 2. High temperature cutout
and slowly heat the oil (Fig. 17).

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
open and should close between 216 to 226oF (102
to 108oC).

Electrical
System
B. The high temperature cutout switch is normally
closed and should open between 225 to 235oF (107
to 113oC).

4. Allow oil to cool while observing temperature.

A. The high temperature warning switch should

open between 216 to 226oF (102 to 108oC).

B. The high temperature cutout switch should close

between 225 to 235oF (107 to 113oC).

Reelmaster 4000−D Page 5 − 25 Electrical System (Rev. C)

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). 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
Figure 19
the negative (−) battery terminal to black lead. The valve
spool should retract completely as 12V DC is applied
5. If valve operates smoothly, but does not retract
across the leads.
when 12V DC is applied to solenoid leads, replace sole-
4. If valve spool does not retract, check for binding or noid coil.
damage in valve.
6. If valve still does not retract after replacing solenoid
coil, replace the valve.

Electrical System (Rev. C) Page 5 − 26 Reelmaster 4000−D

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

In Place Testing 3

Note: Prior to taking small resistance readings with a

digital multimeter, short the test leads together. The me- 4
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 1
testing.
Figure 20
1. Disconnect the connector from the solenoid. 1. Fuel stop solenoid 3. White wire (pull coil)
2. Red wire (hold 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.

Electrical
System
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 − 27 Electrical System (Rev. C)

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.

4. Check for continuity between electrical connector 3

leads associated with the yellow wires. L2
4 RED
5. Position float switch L2 against its upper float stop. YELLOW
L2 L1
6. Check continuity between electrical connector L1
leads associated with the yellow wires. There should be YELLOW
no continuity between connector leads. RED
Figure 21
7. Replace switch as necessary. Install switch to hy-
draulic reservoir. 1. Electrical connector 4. Lower float stop
2. Level switch 5. Upper float stop
3. Float switch

Bridge Rectifier

Each rectifier (Fig. 22) contains four diodes which form

a single phase bridge rectifier circuit (Fig. 23). The 2
diodes are used for circuit protection from inductive volt-
age spikes when the alarm relay is deenergized.

Testing

The diodes can be individually tested using a digital

multimeter (ohms setting) and the table below.
2
Figure 22
Red Lead (+) Black Lead (−)
on Terminal on Terminal Continuity 1. Bottom view 2. Side view

AC1 + YES
+ AC1 NO
AC2 + YES
+ AC2 NO AC1
− AC1 YES AC2
AC1 − NO
− AC2 YES
AC2 − NO
Figure 23

Electrical System (Rev. C) Page 5 − 28 Reelmaster 4000−D

Glow Controller

The controller is located under the right lower corner of

the instrument panel. 2

Controller Operation
3 6
When the ignition switch is placed in the RUN position,
the controller energizes the glow plugs and lights up the 2 5
glow lamp for 10 seconds. When the ignition switch is 1 4
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 1
glow lamp will remain off.

Controller Checks

1. Make sure there is power from the battery. 3

2. Disconnect electrical connector to the fuel solenoid Figure 24

1. End view 3. Side view
to prevent the engine from starting. 2. Top view

3. Place ignition switch in the RUN position. Verify the

5. If any of the conditions in step 3 are not met or power
following while in the RUN position:
to terminal 1 exists and any of the other conditions in
A. Glow indicator lamp is on. step 4 are not met,

B. Glow relay is energized. A. Verify continuity of the circuitry from the battery
to the glow relay and glow plugs (see Electrical
C. Glow plugs are energized. Schematics and Diagrams).

D. Glow indicator lamp goes out and glow plugs B. Verify continuity of the circuitry from the battery
deenergize after 10 seconds. to ignition switch, glow controller, glow lamp, glow
relay, and ground (see Electrical Schematics and
Note: If there is no power to terminal 1 of the glow con- Diagrams).

Electrical
System
troller, verify continuity of the circuitry from the ignition
switch to the controller and perform step 4 again (see C. Replace parts as necessary
Electrical Schematics and Diagrams).
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 − 29 Electrical System (Rev. C)

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- 1
tween 16 to 12 PSID the switch contact opens and the
alarm and light go out.

The purpose of the oil filter switch, warning light, and 2

alarm is to detect a clogged oil filter. When the hydraulic
oil is cold (below 68oF/15oC), 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 4
must be relieved by stopping the engine and
lowering or supporting the box and/or other at- Figure 26
tachment. 1. Filter switch 3. Filter head
2. O−rings 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. C) Page 5 − 30 Reelmaster 4000−D

Service and Repairs
NOTE: For more component repair information, see
Kubota Workshop Manual, 03 Series, Diesel Engine.

Battery Storage
If the machine will be stored for more than 30 days 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- 3. Battery cables must be tight on terminals to provide
tained. The top of the battery must be kept clean. lf the good electrical contact.
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.
WARNING
Connecting cables to the wrong post could re-
sult in personal injury and/or damage to the
WARNING electrical system.

Wear safety goggles and rubber gloves when

4. If corrosion occurs at terminals, disconnect cables.
working with electrolyte. Charge battery in a
Always disconnect negative (−) cable first. Scrape
well ventilated place so gasses produced
clamps and terminals separately. Reconnect cables
while charging can dissipate. Since the gases
with positive (+) cable first. Coat terminals with petro-
are explosive, keep open flames and electrical
leum jelly.
sparks away from the battery; do not smoke.

Electrical
Nausea may result if the gases are inhaled. Un-

System
5. Check electrolyte level every 25 operating hours,
plug charger from electrical outlet before con- and every 30 days if machine is in storage.
necting or disconnecting charger leads to or
from battery posts. 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 − 31 Electrical System (Rev. C)

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.

CAUTION MAX. FILL

DO NOT OVERFILL
MIN. FILL
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
Fully charged: 1.265 corrected to 80oF (26.7oC) MADE IN U.S.A.
Discharged: less than 1.240

Battery Specifications
BCI Group Size 24:
Figure 27
650 CCA at 0o F (−17.8o C)
Reserve Capacity of 105 minutes at 25 amp and at B. Check battery terminal posts for corrosion. Use
80oF (26.7oC)
a terminal brush or steel wool to clean corrosion
Dimensions (not including terminal posts and caps) from the battery terminal posts.
Length 10.22 inches (25.96 cm)
Width 6.76 inches (17.17 cm) IMPORTANT: Before cleaning the battery, tape or
Height 9.20 inches (23.39 cm)
block vent holes to the filler caps and make sure the
Removal caps are on tightly.

IMPORTANT: Be careful not to damage terminal C. Check for signs of wetness or leakage on the top
posts or cable connectors when removing the bat- of the battery which might indicate a loose or mis-
tery cables. sing filler cap, overcharging, loose terminal post, or
overfilling. Also, check battery case for dirt and oil.
1. Remove battery retainer from the battery. Clean the battery with a solution of baking soda and
water, then rinse it with clean water.
2. Remove lock nut and cap screw from ground cable
(−) post first and remove cable from battery. This should D. Check that the cover seal is not broken away.
prevent short circuiting the battery, other components, Replace the battery if the seal is broken or leaking.
or the operators hands.
E. Check the electrolyte level in each cell. If the lev-
3. Remove lock nut and cap screw from positive (+) el is below the tops of the plates in any cell, fill all
cable post and remove cable from battery. cells with distilled water between the minimum and
maximum fill lines. Charge at 15 to 25 amps for 15
4. Make sure battery vent caps are on tightly. minutes to allow sufficient mixing of the electrolyte.

5. Remove battery from the battery compartment to a 2. Conduct a hydrometer test of the battery electrolyte.
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
1. Perform following inspections and maintenance: hydrometer. Draw electrolyte in and out of the
hydrometer barrel prior to taking a reading to warm−
A. Check for cracks caused by overly tight hold− up the hydrometer. At the same time take the tem-
down clamp. Replace battery if cracked and leak- perature of the cell.
ing.

Electrical System (Rev. C) Page 5 − 32 Reelmaster 4000−D

 B. Temperature correct each cell reading. For each terminals.
10oF (5.5oC) above 80oF (26.7oC) add 0.004 to the
specific gravity reading. For each 10oF (5.5oC) be- F. Apply a test load of one half the Cranking Perfor-
low 80oF (26.7oC) subtract 0.004 from the specific mance (see Battery Specifications) rating of the bat-
gravity reading. tery for 15 seconds.

Example: Cell Temperature 100oF G. Take a voltage reading at 15 seconds, then re-
move the load.
Cell Gravity 1.245
H. Using the table below, determine the minimum
100oF minus 80oF equals 20oF voltage for the cell temperature reading.
(37.7oC minus 26.7oC equals 11.0oC)

20oF multiply by 0.004/10oF equals 0.008 Minimum Battery Electrolyte

(11oC multiply by 0.004/5.5oC equals 0.008) Voltage Temperature
9.6 70oF (and up) 21.1C (and up)
ADD (conversion above) 0.008
Correction to 80oF (26.7oC) 1.253 9.5 60oF 15.6oC
9.4 50oF 10.0oC
C. If the difference between the highest and lowest
cell specific gravity is 0.050 or greater or the lowest 9.3 40oF 4.4oC
cell specific gravity is less than 1.225, charge the 9.1 30oF −1.1oC
battery. Charge at the recommended rate and time 8.9 20oF −6.7oC
given in Charging or until all cells specific gravity is
1.225 or greater with the difference in specific grav- 8.7 10oF −12.2oC
ity between the highest and lowest cell less than 8.5 0oF −17.8oC
0.050. If these charging conditions can not be met,
replace the battery.
I. If the test voltage is below the minimum, replace
3. Perform a high−discharge test with an adjustable the battery. If the test voltage is at or above the mini-
load tester. mum, return the battery to service.

This is one of the most reliable means of testing a battery Installation

as it simulates the cold−cranking test. A commercial bat-
IMPORTANT: To prevent possible electrical prob-
tery load tester is required to perform this test.
lems, install only a fully charged battery.

1. Make sure ignition switch and all accessories are

Electrical
System
CAUTION off.

2. Make sure battery compartment is clean and re-

Follow the manufacturer’s instructions when us- painted if necessary.
ing a battery tester.
3. Make sure all battery cables and connections are in
A. Check the voltage across the battery terminals good condition and battery clamp or hold down has
prior to testing the battery. If the voltage is less than been repaired or replaced.
12.4 VDC, recharge the battery.
4. Place battery in its compartment. Make sure battery
B. If the battery has been charged, apply a 150 amp is level and flat. Connect positive cable connector onto
load for 15 seconds to remove the surface charge. positive battery post. Tighten cap screw and lock nut
Use a battery load tester following the manufactur- with two wrenches.
er’s instructions.
5. Secure battery retainer. Do not overtighten to pre-
C. Make sure the battery terminals are free of corro- vent cracking or distorting the battery case.
sion.
6. Apply a light coat of grease on all battery posts and
D. Measure the temperature of the center cell. cable connectors to reduce corrosion after connections
are made.
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 − 33 Electrical System (Rev. C)

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.
Capacity
(Minutes) 75% 50% 25% 0%
8. Connect negative (ground) cable connector to the
negative battery post. Tighten cap screw and lock nut 80 or less 3.8 hrs 7.5 hrs 11.3 hrs 15 hrs
with two wrenches. @ @ @ @
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 4 amps 4 amps 4 amps 4 amps
the battery to be fully charged, the slow charging meth-
od is presented here. This charging method can be ac- 126 to 5.5 hrs 11 hrs 16.5 hrs 22 hrs
170 @ @ @ @
complished with a constant current battery charger
5 amps 5 amps 5 amps 5 amps
which is available in most shops.
171 to 5.8 hrs 11.5 hrs 17.3 hrs 23 hrs
250 @ @ @ @
6 amps 6 amps 6 amps 6 amps
CAUTION above 6 hrs 12 hrs 18 hrs 24 hrs
250 @ @ @ @
Follow the manufacturer’s instructions when us- 10 amps 10 amps 10 amps 10 amps
ing a battery charger.

NOTE: Using specific gravity of the battery cells is the CAUTION

most accurate method of determining battery condition.

1. Determine the battery charge level from either its Do not charge a frozen battery because it can ex-
open specific gravity or circuit voltage. plode and cause injury. Let the battery warm to
60oF (15.5oC) before connecting to a charger.

Battery Charge Specific Open Circuit Charge the battery in a well−ventilated place to
Level Gravity Voltage dissipate gases produced from charging. These
gases are explosive; keep open flame and elec-
100% 1.265 12.68 trical spark away from the battery. Do not smoke.
75% 1.225 12.45 Nausea may result if the gases are inhaled. Un-
plug the charger from the electrical outlet before
50% 1.190 12.24 connecting or disconnecting the charger leads
25% 1.155 12.06 from the battery posts.
0% 1.120 11.89
3. Following the manufacturer’s instructions, con-
nect the charger cables to the battery. Make sure a good
2. Determine the charging time and rate using the
connection is made.
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

electrolyte. If the temperature exceeds 125oF (51.6oC)
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. C) Page 5 − 34 Reelmaster 4000−D

Rear Wheel Drive Solenoid Replacement

RM 4000−D 4WD
MANIFOLD BLOCK

Figure 28

Electrical
System
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 − 35 Electrical System (Rev. C)

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. They are for brake switch is operating properly.
the operator’s protection. Check the operation of
the interlock switches daily for proper operation. 4. Engage parking brake, start engine and lower cut-
Replace any malfunctioning switches before op- ting units. Move Mow−Backlap lever to MOW. Raise off
erating the machine. the seat; engine should stop within a few seconds, which
indicates the interlock system is operating properly. Also
1. In a wide open area free of debris and bystanders, raise off the seat with lever in BACKLAP. Engine should
lower cutting units to the ground. Stop engine. stop, indicating interlock system is operating. If engine
does not stop, there is a malfunction that must be re-
2. Sit on the seat and engage parking brake. Turn key paired immediately.
and try to start engine with Mow−Backlap lever in both
the MOW and BACKLAP positions. If engine cranks, 5. Engage parking brake, move Mow−Backlap lever to
there is a malfunction that must be repaired immediate- NEUTRAL, start engine, disengage hand brake and
ly. If engine does not crank, the cutter drive switch is op- raise off seat. If engine stops, interlock system is operat-
erating properly. ing. If engine does not stop, there is a malfunction that
must be repaired immediately.

Electrical System (Rev. C) Page 5 − 36 Reelmaster 4000−D

 Chapter 6

Axles and Brakes

Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 5
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Rear Wheel Bearings (2WD Only) . . . . . . . . . . . . . . 5
Hand Brake and Traction Switches . . . . . . . . . . . . . 3 Planetary Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . 7
Rear Wheel Toe−In . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Axles and
Brakes

Reelmaster 4000−D Page 6 − 1 Axles and Brakes

Specifications
Item Description

Front Tire Pressure 13 PSI (0.90 Bar)

Rear Tire Pressure 15 PSI (1.04 Bar)

Front Wheel Nut Torque 60 to 85 ft−lb (8.3 to 11.8 kg−m)

Rear Wheel Nut Torque 30 to 35 ft−lb (4.1 to 4.8 kg−m)

Wheel Planetary Mounting Cap Screw Torque 95−110 ft−lb (13.1 to 15.2 kg−m)

Rear Wheel Toe−in 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. Check/Fill Plug 2. Planetary wheel drive

Axles and Brakes Page 6 − 2 Reelmaster 4000−D

Adjustments

Hand Brake and Traction Switches

Over time the hand brake cable will stretch and cause
the engine not to start. If this happens, adjust the cable.

1. Pull hand brake lever to 3rd click.

2. Pull hand brake up one additional click.

3. Adjust four U−bracket nuts equally so the spring has

tension. Adjustment affects operation of traction
switches.

4. Adjust four U−bracket nuts so engine will start and

run when hand brake is at the fourth click, but will not
start or run when hand brake is at second click.

Figure 2
1. Hand brake 4. Traction switches
2. Brake cable 5. Traction pedal
3. U−bracket

Axles and
Brakes

Reelmaster 4000−D Page 6 − 3 Axles and Brakes

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.

Figure 4
1. Clamp 2. Tie rod

Axles and Brakes Page 6 − 4 Reelmaster 4000−D

Service and Repairs

Rear Wheel Bearing Service (2WD Only)

44
47 1
2
32
44 45 46 34 3
4
31
5
42 48
41 29
39 6
43 3433 49 5
35 31
40 4
29
7
28 29 30 8
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
1. Hex flange head screw 18. Tab washer 35. Hydraulic hose
2. Spindle cap 19. Valve stem 36. Steering cylinder
3. Retaining ring 20. Bearing inner cup 37. Hydraulic hose
4. Thrust washer 21. Bearing inner cone 38. O−ring
5. Flange bushing 22. Inner seal 39. Hydraulic fitting
6. Rear axle 23. Ball joint (LH or RH) 40. O−ring
7. Wheel spindle (LH) 24. Grease fitting 41. Roll pin
8. Drive screw 25. Clamp assembly
42. Pivot shaft
9. Rear wheel hub 26. Lock nut
43. Hex nut
10. Outer bearing cup 27. Tie rod assembly

Axles and
11. Outer bearing cone 28. Cap screw 44. Grease fitting

Brakes
12. Tire 29. Cotter pin 45. Ball joint
13. Lug nut 30. Castle nut 46. Cap screw
14. Rim 31. Castle nut 47. Wheel spindle (RH)
15. Cotter pin 32. Lock nut 48. Grease decal
16. Hub cap 33. Flange bushing 49. Grease fitting
17. Jam nut 34. Thrust washer 50. Retaining nut

Reelmaster 4000−D Page 6 − 5 Axles and Brakes

1. Jack up rear of machine until tire is off the. Support 11. Adjust preload on the wheel bearings (Fig. 6).
machine with jack stands or blocks to prevent it from fal-
ling (see Jacking Instructions in Chapter 1 − Safety). A. Tighten jam nut from 75 to 80 in−lb (86 to 270 kg−
cm) while turning the hub to seat the bearings and
2. Remove dust cap (16) from the end of the wheel remove all end play.
spindle.
B. Loosen jam nut until it is away from the tab wash-
3. Remove cotter pin (15), slotted nut, and washer er and the hub has end play. Tighten jam nut from 15
(18). Slide wheel off of the spindle shaft. to 20 in−lb (17 to 23 kg−cm) while rotating the hub.

4. Pull seal (22) out of wheel hub (9). C. Put retainer over the jam nut. If the cotter pin hole
is not aligned with a retainer slot, remove retainer
5. Remove bearings (11 and 21) from both sides of the and reorient it until alignment occurs.
wheel hub (9). Clean bearings in solvent. Make sure the
bearings are in good operating condition. Clean inside D. Insert cotter pin. Bend both legs of the cotter pin
of the wheel hub (9). Check bearing cups (10 and 20) for and tap out of the way. Install the cap.
wear, pitting, or other noticeable damage. Replace worn
or damaged parts.
8
6. If bearing cups (10 and 20) were removed from the 7
wheel hub (9), press them into the hub until they seat 9
against the shoulder.
10
7. Use No. 2 general purpose lithium base grease con- 11
taining EP additive. Pack both bearings (11 and 21) with 6
grease. Install bearing (21) into the cup (20) on inboard 12
side of wheel hub.
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 2
be toward the bearing.

8. Lubricate the inside of the new lip seal (22) and 5 3

press it into the wheel hub.
4
9. Pack inside of wheel hub with some grease (not
full). Install remaining bearing (11) into bearing cup (10).
Figure 6
10. Slide wheel onto the spindle shaft and secure it in 1. Cotter pin 8. Wheel hub
2. Spindle 9. Outer bearing cup
place with the flat washer (18), nut (17), and retainer nut 3. Cap 10. Outer bearing cone
(50). Do not tighten nut or install the cotter pin. 4. Washer 11. Washer
5. Seal 12. Retainer
6. Inner bearing cone 13. Jam nut
7. Inner bearing cup

Axles and Brakes Page 6 − 6 Reelmaster 4000−D

Planetary Wheel Drive

3 4
5
6
7
2 8
6
9

24

20

10
28 11 15
25
26 27
13
26 25 12
29

23
22 21
19
18
17
16
14

Figure 7
1. Coupling 11. Flat washer 21. O−ring
2. Input shaft 12. Thrust washer 22. Disengage plunger
3. Spindle 13. Primary sun gear 23. Thrust washer
4. Oil seal 14. Hex head bolt 24. Ring gear
5. Bearing cone 15. Primary carrier assembly 25. Retaining ring
6. Bearing cup 16. Pipe plug 26. Washer
7. Wheel bolt 17. Hex head bolt 27. Disengage spring
8. Hub 18. Disengage cover 28. Retaining ring kit
9. Bearing cone 19. Large cover 29. Retaining ring
10. Hex head bolt 20. Secondary carrier assembly

Axles and
Brakes

Reelmaster 4000−D Page 6 − 7 Axles and Brakes

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). end play when the proper retaining ring is installed.

2. Position assembly upright on the face of spindle (3). 5. Assemble retaining ring (25) in the groove opposite
Remove disengage cover (18). pilot end of the input shaft (2). Assemble washer (26),
spring (27), second washer (26), second retaining ring
3. Remove bolts (17) and large cover (19). The disen- (25), and third retaining ring (29) in the middle groove of
gage plunger (22) usually remains with the cover. Re- the input shaft. Some shafts have a shoulder and re-
move plunger and O−ring from the cover on the end of quire only one retaining ring.
the input shaft.
6. Assemble splined end of the input shaft down into
4. A thrust washer (23) will usually remain in position the spindle.
on the thrust face of the cover.
7. Assemble secondary carrier splines over the
5. Remove primary sun gear (13) and thrust washer splined end of spindle.
(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
6. Remove secondary carrier assembly (20). It may be of the ring gear having 6 or 12 bolt holes against the hub
necessary to remove the ring gear (24) first if difficulty with the bolt holes of the hub and ring gear aligned. As-
is encountered in removing the carrier. 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
7. Remove input shaft (2) from the spindle (3). Re-
are used, torque bolts from 52 to 60 ft−lb (7.2 to 8.3
move retaining rings, washers, and spring from the input
kg−m). Grade 8 bolts can be identified by the 6 radial
shaft only if replacement is required.
lines on bolt head.
8. Remove 6 or 12 bolts from the hub and ring gear.
9. Assemble primary carrier and sun gear into the ring
Remove ring gear (24). It may be necessary to strike ring
gear. It is necessary to rotate the carrier and pinion to
gear with a rubber mallet to loosen from hub.
align the sun gear teeth with the secondary pinion and
NOTE: Use snap ring expander tool to remove the re- primary pinions with ring gear teeth. Assemble primary
taining ring. sun gear (13) over the input shaft. Rotate sun gear to
align the shaft to gear splines and gear teeth.
9. Remove large retaining ring (28) from in front of
the tapered bearing. Lift hub (8) from the spindle. If 10. Assemble small thrust washer (12) over the input
bearings are not a loose fit, it may be necessary to shaft and against the shoulder of shaft.
press spindle from the hub.
11. Assemble O−ring (21) in the groove of the disen-
10. Remove oil seal (4) and bearing cones (5 and 9) gage plunger (22). Assemble plunger over the end of in-
from the hub. Inspect bearing cups (6) in position and re- put shaft and against the thrust washer.
move only if replacement is required.
12. Lubricate O−ring in the groove of the engage plung-
Assembly of the Planetary Wheel Drive er. Assemble thrust washer (23) with tangs engaged
with the large cover (19). Apply a bead of RTV com-
1. Press a new bearing cup (6) into each side of the pound or equivalent to the end face of the ring gear. As-
hub (8). semble cover over the plunger as holes of cover and ring
gear are aligned. Assemble eight 5/16−18x1 inch hex
2. Assemble bearing cone (5) into the cup (6) at the head bolts. Torque bolts from 20 to 25 ft−lb (2.8 to 3.5
seal end of the hub. Press a new oil seal (4) into the hub. kg−m).

3. Position spindle (3) upright on bench. Lubricate lips 13. If the wheel is to be used to drive the vehicle, as-
of oil seal (4) and lower hub onto the spindle. Hub (8) semble disengage cover (18) with the dimpled center
should be centered as it is lowered over the spindle to protruding out. Assemble and torque two 5/16−18x3/4
prevent seal damage. inch bolts. Torque bolts from 10 to 20 (1.4 to 2.8 kg−m).

4. Assemble bearing cone (9) over the spindle and into 14. Invert Power Wheel assembly. Assemble coupling
the bearing cup (6). Select thickest retaining ring (28) (1) with the counterbore out to the input shaft.

Axles and Brakes Page 6 − 8 Reelmaster 4000−D

 Chapter 7

Cutting Units
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 8
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Backlapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic Motor Installation . . . . . . . . . . . . . . . . . . . 9
Adjust Reel to Bedknife Contact . . . . . . . . . . . . . . . 4 Bedknife/Bedbar . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Adjust Height−of−Cut (Floating Cutting Unit) . . . . 5 Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Quick Method for Changing Height−of−Cut Preparing a Reel for Grinding . . . . . . . . . . . . . . . . 14
After Initial Set Up of a Floating Cutting Unit . . 6 Front and Rear Rollers . . . . . . . . . . . . . . . . . . . . . . 15
Adjust Height−of−Cut (Fixed Cutting Unit) . . . . . . 7 Roller Bearing Replacement . . . . . . . . . . . . . . . . . 16
Adjust Skids and Front Roller Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
(Fixed Cutting Unit) . . . . . . . . . . . . . . . . . . . . . . . . 7

Cutting Units

Reelmaster 4000−D Page 7 − 1 Cutting Units

Specifications

1 2 4 11
3 6

10 9

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

Construction: The frame is welded steel. The reel uses Height−of−Cut: 5 Blade − 1 to 3 inches (25 to 76 mm).
heavy duty, self−aligning ball bearings. The heavy duty 7 Blade − 1/2 to 1−3/4 inch (9.5 to 45 mm). 11 Blade −
steel rear roller has tapered roller bearings. The rear 3/8 to 3/4 inch (9.5 to 19 mm).
roller and bedbar are isolated and mounted in rubber
bushings for quiet, vibration−free operation. Adjustable Height−of−Cut Adjustment: Quick adjustment and
deflector shields are standard. Stainless steel compo- positive locking is provided by locking type cone nuts.
nents are used at key points for added durability. 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 Clip (variable to match cutting conditions):
29−3/4 in. (75.5 cm) wide.
5 Blade Cutting Unit: 0.176 inch per mph
Bedknife/Bedbar Assembly: A replaceable, single (0.352 inch at 2 mph to 1.32 inch at 7.5 mph)
edged, alloy steel bedknife is induction hardened. The
bedknife is fastened with steel screws to a precision 7 Blade Cutting Unit: 0.1 26 inch per mph
ground surface on the high strength, fabricated steel (0.252 inch at 2 mph to 0.945 inch at 7.5 mph)
bedbar. The stress−relieved machined bedbar is
11 Blade Cutting Unit: 0.080 inch per mph
mounted with four (4) vibration isolation bushings.
(0.16 inch at 2 mph to 0.600 inch at 7.5 mph)
Bedknife to Reel Adjustment: Two lockable lead
Lubrication: Easily accessible grease fittings for bear-
screw adjusters at each side of the frame adjust the reel
ings and all major pivot points are provided.
to bedknife contact.
Drive: The reel drive motor turns a maintenance−free
Rear Roller: 3−1/2 inch (89 mm) diameter steel roller
cog belt that drives the reel. Drive pulley and cog belt are
has greaseable tapered roller bearings. A double lip oil
encased in a drive housing for safety and protection
seal and wear sleeve isolates grit and moisture from the
from contamination.
bearings.
Grass Deflector Shields: Shields are fully adjustable.

Cutting Units Page 7 − 2 Reelmaster 4000−D

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
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).
Cutting Units

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

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.

CAUTION 1. Adjuster locking nut

Figure 5
2. Adjustment knob

Before adjusting reel to bedknife, raise and fully IMPORTANT:Adjusted correctly so that the reel will
latch cutting units. Remove key from the ignition
cut a piece of paper approximately 0.003 inch
switch. Keep others off machine while adjusting
cutting units. (0.076mm) thick across its entire length.

3. If excessive contact is determined, turn each adjust-

Note: A 3/4−inch wrench is required for making the ing knob equally and counter−clockwise until no contact
reel to bedknife adjustment. is noticed. Then turn both adjusting knobs equally and
clockwise until light contact is felt and heard between the
reel and bedknife. Final adjustment should always be
CAUTION in the tightening (clockwise) direction.

IMPORTANT:Cutting units with excessive contact

When adjusting the cutting units, wear heavy between the reel and bedknife are noisy, consume
gloves and use care when turning reels by hand. excessive power, shorten component life and result
Sharp edges can cut or pinch hands or fingers.
in overall poor performance. Light contact between
the reel and bedknife, once the cutting unit is
1. Rotate reel slowly and carefully while listening for warmed up, provides optimum mowing perfor-
light contact across the full length of the reel and bed- mance and component life.
knife.
4. Tighten adjuster locking nuts when adjustments are
2. If no contact is determined, loosen adjuster locking complete.
nut on each adjuster (Fig. 5). Turn each adjuster knob
equally and clockwise until light contact is felt and heard.

Cutting Units Page 7 − 4 Reelmaster 4000−D

Height−of−Cut Adjustment (Floating Cutting Unit)
Overview of Procedure:

1. Adjust reel to bedknife contact

2. Level rear roller to reel
3. Adjust initial height−of−cut using gauge bar.

1. Adjust reel to bedknife contact on all cutting units.

(see Adjust Reel to Bedknife Contact).

2. Level rear roller to the real.

A. Start engine and lower the cutting unit onto a flat

surface such as a piece of 3/4−inch (1.9 cm) plate
steel of at least 20 x 30 inches (50 x 76 cm). Stop
engine and remove key from ignition switch. Lock Figure 6
cutting units in the fixed position by loosening the Cutting Unit Float Position
jam nut on the lockout pin (Fig. 6) and screwing the 1. Lockout pin 2. Jam nut
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.

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. 1. Lockout pin 2. Jam nut
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.
HOC + 3/8 INCH
D. Rear roller is now leveled to the reel. (+ 9.5 mm) Cutting Units

Figure 8
Leveling Rear Roller to Reel

Reelmaster 4000−D Page 7 − 5 Cutting Units

3. Make final height−of−cut adjustment with gauge
bar.

A. Raise cutting units and lock in the transport posi-

tion. Shut off the engine and remove the key from
the ignition switch.

B. Use gauge bar (Toro Part No. 59−7900) to set fi-

nal height−of−cut by adjusting the front roller only.

C. Loosen gauge bar jam nut and adjust screw to

set dimension between underside of screw head
and gauge bar for desired height−of−cut (Fig. 9). Figure 9
Tighten jam nut to secure the adjustment. Hook Gauge Bar Assembly
screw head over cutting edge of the bedknife and
position bar against bottom of front roller (Fig. 10). 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
E. Loosen lockout pin so cutting unit can float freely Final Height−of−Cut Adjustment Using Gauge Bar
(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 cases, an entire machine can be done quickly by using
1 of Height−of−Cut Adjustment (Floating Cutting Unit) the gauge bar to set the front roller of one cutting unit.
and the rear roller leveled to the reel in STEP 2 of The remaining cutting units can then be set by loosening
Height−of−Cut Adjustment (Floating Cutting Unit), the their front roller jam nuts and turning each front roller ad-
cutting unit may be quickly changed from one height− justment knob the same number of turns and in the
of−cut to another by using the gauge bar (Part same direction as the first unit.
#59−7900) and adjusting the front roller only. In many

Cutting Units

Cutting Units Page 7 − 6 Reelmaster 4000−D

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-
Figure 11
knife (Fig. 11).

6. Adjust rear roller adjustment knobs and jam nuts un-

til the full length of the rear roller contacts the flat sur-
face, and the full length of the reel (not bedknife)
contacts the bar stock. Tighten rear roller knobs and jam
nuts.

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 4 6
uncut grass or scalping on undulating terrain: 7 3
1
Note: Skids are used only with the cutting unit in the
fixed position. Front rollers may be used with the cutting 4
unit in either the fixed or floating position. 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 2
30 inches (50 x 76 cm). 5 5
Figure 12
Note: Proper adjustment is achieved when the cutting 1. Cap screw 5. Skid
unit does not scalp the grass in normal mowing condi- 2. Lock nut 6. Side plate
tions and yet is set high enough not to mar the turf and 3. Cap screw 7. Skid bracket
4. Lock nut
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
3. Adjust each skid or front roller so it is 1/8 to 1/4 in. and skid braket. On some units, the rear of the skid
(3 to 6 mm) or higher above the level surface. Allow may be mounted to the side plate with a spacer (Fig.
greater clearance at the higher height−of−cut settings. 12).

A. The front roller is adjusted in the same manner

as the rear roller.
Reelmaster 4000−D Page 7 − 7 Cutting Units
Service and Repairs

CAUTION
Never remove, install, or work on the cutting
units or lift arms with the traction unit engine run-
ning. Stop engine and remove key from ignition
switch first.

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
CAUTION
the engine and reels are operating.
Never use a short−handle paint brush to apply
backlapping compound. A rotating reel can pull a
Two people are required to perform backlapping.
short−handle paint brush and the users hand
One person sits on the seat to operate the con-
into the reel causing serious personal injury.
trols (operator) and the other performs the back-
lapping operation. Good communication be-
tween each person is necessary. Instruct opera- 2. Dip 3−inch (76 mm) wide paint brush attached to
tor to stop the reels and shut the engine off when Toro Part No. 29−9200 Handle Assembly into lapping
adjustment is necessary. 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- 3. Apply lapping compound evenly over the full length
ping compound with liquid detergent until it has a of the reel. Make sure all reel blades are covered. When-
free−flowing consistency. ever noise of reel against the bedknife begins to disap-
pear or, an uneven concentration of material appears on
Note: Before starting the engine, raise grass deflector the reel, redistribute the compound with the brush.
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-
Operator Duties: gine, and remove key from the ignition switch. Make ad-
justment only after the reels have stopped rotating.
1. Sit on seat and engage parking brake.
5. Backlap each reel until the cutting edges are sharp,
2. Start engine and run at minimum throttle. Lower ei- even on all blades. Achieve a minimum of 1/32 inch
ther the center and two front cutting units, the left hand (0.79 mm) land area on newly sharpened reel assem-
cutting unit, or the right hand cutting unit. blies. Normally, a reel need only be backlapped for
approximately 3 minutes.
3. When both side cutting units are up and latched (au-
tomatically shut off) with the center and front cutting 6. Upon completion, stop reel and turn off engine. Re-
units down, backlap the center cutting unit from the rear move key from the ignition switch. Wash unit thoroughly
of the machine with the long handled brush. Backlap with a low pressure stream of water to remove all lapping
front cutting units from the front of the machine. material. Allow reel to dry. Lubricate grease fittings.

4. Wait for 2nd person’s instruction to engage reels in 7. Check sharpness of the reel and bedknife with news
backlap mode, then pull mow−backlap lever to the paper strips. Light reel to bedknife contact should shear
BACKLAP position and hold. 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.
Cutting Units Page 7 − 8 Reelmaster 4000−D
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. Insert two (2) reel drive motor mounting bolts (heads

on the inside of the drive housing with flat washer on the Figure 13
1. Drive plate shield 2. Reel drive motor flange
top bolt through the reel motor flange holes. Thread
locknuts onto the bolts. Rotate reel motor upward in the
slotted hole in the housing to tension the drive belt.
Tighten fasteners to 25 ft−lbs (34 Nm). NOTE: (Fig. 15).

IMPORTANT:Rotate motors by hand only. Never

place a bar between hose fittings on the hydraulic
motors; motor damage may result.

4. Install gasket and drive housing cover after making

sure the ends of the gasket are at the bottom of the hous-
ing to allow for drainage.
Figure 14
IMPORTANT:When hydraulic motors have been 1. Hydraulic motor 3. Drive belt
mounted to the cutting units, make sure hydraulic 2. Motor pulley
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 2
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.

Note: Refer to the Traction Unit Operator’s Manual for

instructions on setting the adjustable hydraulic counter- Figure 15
balance. 1. Mounting bolts 2. Drive housing
Cutting Units

Reelmaster 4000−D Page 7 − 9 Cutting Units

Bedknife/Bedbar
Disassembly

1. Remove shoulder bolts, bushings and spacers from

each end of the unit. Remove bedbar/bedknife assem-
bly (Fig. 16).

2. Remove mounting screws for the bedknife. Sepa-

rate bedknife from the bedbar. Discard screws (Fig. 17).

Assembly

1. Clean bedknife mounting face on the bedbar thor-

Figure 16
oughly of all rust and scale. Remove any material on the
1. Shoulder bolt (2 each side) 3. Spacer
mounting face of the bedbar that will affect a good 2. Bushing
match−up with the bedknife.

2. Before installation, apply a coating of anti−seize lu-

bricant to the threads of the bedknife mounting screws.

IMPORTANT: Do not use an impact wrench to tight-

en screws into the bedbar.

3. Begin with the center screw and tighten alternate

screws toward each end using a 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 1. Torque wrench 2. Bedknife screw tool
set−up and operation of the grinder.

Note: When grinding, be careful to not overheat the

Top Face
bedknife. Remove small amounts of material with each
Relief Angle Remove
pass of the grinder. Burr

Bedknife Grinding Specifications Front

Face
Relief Angle 5o
Relief Angle Range 3o to 6o Front Angle
Front Angle 15o
Front Angle Range 13o to 17o
Figure 19
Cutting Units Page 7 − 10 Reelmaster 4000−D
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. 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 Figure 20
shaft (Fig. 22). 1. Guard 3. Adjusting assembly
2. Mounting fasteners 4. Dust cap
5. Disassemble cone nut from the shoulder bolt secur-
ing the bearing housing to the side plate, remove the
belleville washer and bolt and slide the bearing housing
off the reel shaft (Fig. 22).

Figure 21
1. Lock nut 4. Bearing housing
2. Belleville washer 5. Reel shaft
3. Shoulder bolt 6. Flange housing

Cutting Units

Figure 22
1. Drive housing 2. Drive belt

Reelmaster 4000−D Page 7 − 11 Cutting Units

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
11. Inspect bearings and grease seals in their housings 1. Cap screw 5. Adjustment handle
2. Pulley washer 6. Woodruff key
as follows: 3. Driven pulley 7. Drive housing fasteners
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
bearing and rear seal out from the outer side of the hous-
ing.

13. Remove the dust cap (Fig. 20). Press the bearing
and seal out of the housing.

Inspection

1. Inspect reel as follows:

A. Check reel shaft for bending and distortion by

placing the shaft ends in V−blocks. Replace reel if
necessary.

B. Check reel blades for bending or cracking. Re-

place reel if necessary.

C. Check service limit of reel diameter (see Reel

Grinding Specifications in Preparing Reel for Grind-
ing).

Cutting Units Page 7 − 12 Reelmaster 4000−D

Assembly

1. Inspect flange bushings in the mounting holes of the

drive housing and bearing housing for wear (Fig. 21).
Replace, if necessary.

2. Assemble outer seal (lip facing in to retain grease)

into the drive housing using Loctite 242 (or equivalent)
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 9. Install woodruff key in the drive housing end of the
install (lip facing away from the bearing and toward the reel shaft and install the driven pulley onto the shaft.
reel) in the housing. Install retaining ring to secure the
assembly in the housing (Fig. 23). 10. Ensure slot in the pulley washer is aligned with the
roll pin in the pulley and install the washer, toothed
4. Apply a light coat of oil to the seal lips of the seal for washer and reel capscrew (Fig. 22). Apply a medium
the bearing housing and install (lip facing away from the strength thread locking compound to the reel capscrew
bearing) over the bearing assembly (Fig. 23). during assembly. Torque the capscrew to 45 to 55 ft−lb
(6.2 to 7.6 kg−m).
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 12. Install bedbar/bedknife assembly.
reel shaft. Align drive pin on reel shaft with slot in bearing
and slide the drive housing onto the shaft. 13. Install front and rear roller assemblies or skids.
7. Insert shoulder bolt through the Belleville washer 14. Adjust reel to the bedknife (see Reel to Bedknife.
and rear housing mounting hole. Slide bolt through the Adjust height−of−cut (see Adjust Height−of−Cut).
side plate mounting hole (Fig. 21). Install the cone nut
locknut onto the bolt. Tighten the cone nut to 45 to 55 ft−
lbs (6.2 to 7.6 kg−m).

8. Align the drive pinon the reel shaft with the notch in
the bearing inner race and slide the bearing housing
over the opposite end of the reel shaft. Insert the shoul-
der bolt and belleville washer through the rear bearing
housing mounting hole. Slide the bolt through the side
plate mounting hole. Install the cone onto the bolt. Tight-
en the cone nut to 45 to 55 ft−lbs (6.2 to 7.6 kg−m).

Cutting Units

Reelmaster 4000−D Page 7 − 13 Cutting Units

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
cutting unit frame and roller brackets are true and not A. Install parts that were removed to mount the cut-
bent or damaged. ting unit onto grinder.

1. Remove the bedbar assembly (Bedknife/Bedbar B. Install bedbar assembly (see Bedknife/Bedbar
Disassembly). Assembly).

2. Remove parts as necessary to mount the cutting C. Do a complete cutting unit set−up and adjust-
unit into the grinder (e.g., front roller, front roller brack- ment procedure (see Adjustments section).
ets).
Reel Grinding Specifications
3. Follow the grinder manufacturer’s instructions for
Nominal Reel Diameter 8 in (206 mm)
set−up and operation of the grinder.
Service Limit Reel Diameter 7.2 in (182 mm)
Note: The cutting unit must be aligned so the grinding Blade Relief Angle 30o
wheel will travel parallel to the reel shaft. This will result
Relief Angle Range 20o to 40o
in the reel being ground to the desired cylinder shape.
Blade Land Width 0.060 in (1.5 mm)
Note: When grinding, be careful to not overheat the Land Width Range 0.050 to 0.090 in (1.3 to 2.3 mm)
reel blades. Remove small amounts of material with Max. Reel Taper 0.060 in (1.5 mm)
each pass of the grinder.

BLADE RELIEF ANGLE

REEL DIAMETER

BLADE
LAND
WIDTH

D1 D2

REEL DIAMETER TAPER = D1 − D2

Figure 25

Cutting Units Page 7 − 14 Reelmaster 4000−D

Front and Rear Rollers
Note: Front and rear rollers can be removed and
installed in the same manner.

Removal

Note: Front and rear rollers can be removed using ei-

ther of two methods.

1. Remove roller adjustment housing from side plate

(Fig. 26).

A. Remove mounting fasteners securing both

guards and roller adjustment housings to the side
plate.

B. Pull housings from roller shafts.

2. Remove collar assembly from roller adjustment

housing (Fig. 27)
Figure 26
A. Unscrew upper cone nut from the collar assemb-
1. Guard 3. Side plate
ly. 2. Roller adjustment housing 4. Mounting fasteners

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).

1. Install roller adjustment housing to the side plate Figure 27

1. Cone nut 3. Lock nut
(Fig. 26). 2. Collar assembly

A. Install roller adjustment housings to both ends of

C. Thread cone nut onto each collar assembly with
the roller shaft.
the cone facing down.
B. Position roller adjustment housing and guard to
the side plate. Make sure mounting holes are D. Adjust height−of−cut (see Adjust Height−of−
aligned properly. Secure guards and housings to Cut).
the side plate with mounting fasteners.
Cutting Units

2. Install collar assembly to the roller adjustment hous-

ing (Fig. 27)

A. Install both collar assemblies to both ends of the

roller shaft.

B. Make sure cone nut is on collar assembly with

the cone facing up. Slide collar assembly into each
adjustment housing.

Reelmaster 4000−D Page 7 − 15 Cutting Units

Roller Bearing Replacement

3
6
8
10
12

4
7
9
11
2
11
9
7
5

12
10
8
6

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. Inner grease seal

Removal

1. Clean roller around the shaft, grease fittings, and WARNING

bearing thoroughly. Both ends of the roller should be
free of dirt and debris. If removing bearing cups from a rear roller with
an arc welder, make sure the entire roller is free of
2. Secure roller tube in a vise keeping it level. oil. Clean inside and out side thoroughly.

3. Remove both grease fittings before removing the

Note: An electric arc welder can be used to shrink the
bearings.
bearing cup to simply its removal. Only a small arc in one
4. Remove jam nut, lock nut, and both thrust washers location on the cup is required.
from the roller shaft. Pull both outer grease seals from
9. Remove both bearing cups from the roller tube.
inside 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 IMPORTANT: Replace both bearing cones and cups
wear sleeve, O−ring, and bearing cone from the shaft. 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. On the front roller, press new inner grease seals into
the roller tube with the garter spring of the seal facing
8. If disassembling a rear roller, pour oil from the inside
away from the center of the roller (Fig. 29).
the roller into a suitable container.

Cutting Units Page 7 − 16 Reelmaster 4000−D

 4 2 1
3. On the rear, wiehle, and sectional rollers, press new
inner grease seals into the roller tube with the garter 8
spring of the seal facing towards the center of the roller
(Fig. 30). 7

4. Press both bearing cups into the roller tube with the 12
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 5
sure not to damage the seals. Figure 29
1. Inner grease seal 7. Wear sleeve
9. Install both bearing cones to the roller shaft and into 2. Roller tube 8. Outer grease seal
the bearing cups. 3. Bearing cup 9. Thrust washer
4. Roller shaft 10. Jam nut
5. Bearing cones 11. Lock nut
10. Apply thin coat of No. 2 general purpose lithium 6. O−ring 12. Grease fitting
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 2
the roller with the garter spring of the seal facing away
from the center of the roller (Fig. 29). 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 10

the roller shaft with the shorter length. Tighten jam nut 11
all the way to the end of the threads. Allow Loctite to
cure before proceeding further. 6
9
15. Install lock nut to the other end of the shaft. Torque 3
lock nut while rotating shaft from 20 to 25 ft−lb (2.8 to 3.5 5
kg−m) to seat the bearings. Back off lock nut.
Figure 30
Cutting Units

1. Inner grease seal 7. Wear sleeve

Note: Starting torque may exceed 10 ft−lb (1.4 kg−m) 2. Roller tube 8. Outer grease seal
when torquing the lock nut the second time. This torque 3. Bearing cup 9. Thrust washer
will fall once the nut starts to turn. 4. Roller shaft 10. Jam nut
5. Bearing cones 11. Lock nut
6. O−ring 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. Install grease fittings. Lubricate each bearing with at

least 1 oz. (33 ml) of No. 2 general purpose lithium base
grease.

Reelmaster 4000−D Page 7 − 17 Cutting Units

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. If the
cutting units are washed in the raised position be
sure to lower them to the ground after washing. This
allows water to drain from the ends of the rollers and
reel bearing housings.

1. Wipe each grease fitting with a clean rag before

greasing.

IMPORTANT:Applying too much pressure will ruin

the seals and leaking grease could cause damage to
grass.

2. Lubricate reel shaft and roller bearings daily with 3 Figure 31

or 4 pumps of grease. Daily lubrication of these fittings
purges water and other contaminants, increasing ser-
vice life and maintaining excellent quality−of−cut (Fig
31).

3. Lubricate floatation kit pivots (Fig. 32) and Fixed

head pivots (Fig. 33) weekly with one pump of grease.

4. Wipe excess grease from the fittings.

Note: When greasing roller bearings−grease forced

from bearings will not be visible around the roller shaft.

Figure 32

Figure 33

Cutting Units Page 7 − 18 Reelmaster 4000−D

Commercial Products

 The Toro Company