Part No. 94817SL Service Manual ReelmasterR 4500–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 4500–D. REFER TO THE TRACTION UNIT AND CUTTING UNIT OPERATOR’S MANUALS FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. Space is provided in Chapter 2 of this book to insert the Operator’s Manuals and Parts Catalogs for your machine.
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Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . Equivalents and Conversions . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . Equipment Operational and Service Historical Report Record . . . . . . . . . . . . 2–1 2–2 2–3 2–5 Chapter 3 – Engine Chapter 5 – Electrical System Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Chapter 1 Safety Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 1 Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Maintenance and Service . . . . . . . . . . . . . . . . . . . . . 3 SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
C. Do not smoke while handling fuel. 9. Since diesel fuel is highly flammable, handle it carefully: D. Fill fuel tank outdoors and only to within an inch (25 mm) from the top of the tank, not the filler neck. Do not overfill. A. Use an approved fuel container. B. Do not remove fuel tank cap while engine is hot or running. E. Wipe up any spilled fuel. While Operating 10. Do not run engine in a confined area without adequate ventilation. Exhaust is hazardous and could be deadly. 11.
Maintenance and Service 27. Assure entire machine is properly maintained and in good operating condition. Frequently check all nuts, bolts and screws. 28. Frequently check all hydraulic line connectors and fittings. Assure all hydraulic hoses and lines are in good condition before applying pressure to the system. 29. Keep body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid. Use cardboard or paper to find hydraulic leaks.
Safety and Instruction Decals The following safety and instruction decals are installed on the traction unit. If any become damaged, replace them. Decals are listed in your Parts Catalog. Order replacements from your Authorized TORO Distributor. ON PANEL IN FRONT OF OPERATOR'S SEAT (Part No. 58-6540) ON LIFT ARMS (Part No. 61-3610) ON LEFT SIDE OF MACHINE (Part No. 59-7290) ON PANEL IN FRONT OF OPERATOR'S SEAT (Part No.
Safety NEAR RADIATOR FILL CAP (Part No. 58-6940) ON STEERING CONSOLE (Part No. 77-4830) UNDER SEAT NEAR OIL FILL CAP (Part No. 58-6530) ON FRAME ABOVE RIGHT REAR WHEEL (Part No. 88-6700) ON RADIATOR CAP (Part No. 59-8440) NEAR FUEL TANK FILL CAP (Part No. 49-2280) ON FRAME ABOVE REAR WHEELS (Part No. 58-5910) ON CUTTING UNIT (Part No. 76-8760) NEAR FRONT CUTTING UNIT RELEASE LEVER (Part No. 59-7960) ON FAN SHROUD (Part No. 76-8750) NEXT TO TRACTION PEDAL ON STEERING CONSOLE (Part No.
ON FRONT CARRIER & TOW BAR (Part No. 86-6120) ON RIGHT CONTROL PANEL (Part No. 58-6560) NEAR TEST PORTS (Part No. 58-6680) ON RIGHT CONTROL PANEL (Part No.
Chapter 2 Product Records and Manuals PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . 1 2 2 2 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . Capscrew Markings and Torque Values – U.S. . . Capscrew Markings and Torque Values – Metric . OPERATION AND SERVICE HISTORY REPORT .
Equivalents and Conversions Product Records and Manuals Page 2 – 2 Reelmaster 4500–D
Product Records and Manuals Torque Specifications Reelmaster 4500–D Page 2 – 3 Product Records and Manuals
Product Records and Manuals Page 2 – 4 Reelmaster 4500–D
EQUIPMENT OPERATION AND SERVICE HISTORY REPORT for REELMASTER® 450-D and 4500-D TORO Model and Serial Number:__________-_________ Engine Numbers: ____________________ Cutting Unit Serial Numbers: ____________________ ______________________ ____________________ ______________________ ____________________ ______________________ Date Purchased: ____________________ Warranty Expires__________ Purchased From: ____________________ ____________________ ____________________ Contacts: Parts _______________
REELMASTER® 450-D and 4500-D Maintenance Schedule Minimum Recommended Maintenance Intervals: Maintenance Procedure Lubricate Reel Control Valve Grease Fitting Lubricate Reel Speed Control Valve with Oil Lubricate all Grease Fittings Check Battery Condition and Connections Maintenance Interval & Service Type: Every 50hrs Every 100hrs Every 200hrs Every 400hrs Every 800hrs A Level Service ‡ Change Engine Oil and Filter Drain water from Hydraulic Tank † Check Engine Fan and Alternator Belt Inspect Cooli
REELMASTER® 450-D and 4500-D Daily Maintenance Check List Unit Designation:__________ Daily Maintenance:(duplicate this page for routine use) TORO ID#:_______-_______ Daily Maintenance Check For Week Of _____________ Maintenance Check Item MON TUES WED THURS FRI SAT SUN _____HRS _____HRS _____HRS _____HRS _____HRS _____HRS _____HRS Safety Interlock Operation Parking Brake Operation Engine Oil Level Fuel Level Cooling System Fluid Level Drain Water/Fuel Separator Dust Cup and Baffle (Air Filter) Radiator &
A B C D E Other Service to perform (circle): ____________-____________ TORO I.D.
Chapter 3 Engine Table of Contents GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 5 Alternator Belt Adjustment . . . . . . . . . . . . . . . . . . . . 5 Priming Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . 6 MITSUBISHI 4DQ7 ENGINE SERVICE MANUAL FUEL SYSTEM Engine SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications Item Make / Designation Description Mitsubishi 4DQ7 Water–cooled, 4–stroke, swirl–combustion chamber type Diesel Number of Cylinders 4 Bore x Stroke mm (in.) 88 x 94 (3.465 x 3.701) Total Displacement cc (cu. in.) 2286 (139.5) Compression Ratio 21.7:1 Firing Order 1–3–4–2 Dry Weight (approximate) kg (lb.) 200 (441) Fuel Grade No.
Special Tools Order special tools from TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (Commercial Products). Some tools may be listed in the Reelmaster 4500–D Parts Catalog. Tools may also be available from a local supplier. Filter Cleaner Engine Filter cleaner. Mix with water and use solution to wash the Donaldson air cleaner element. Figure 1 Diesel Engine Compression Test Kit Diesel engine compression test kit.
Nozzle Tester Nozzle tester. Tests condition and opening pressure of fuel injection nozzles. Figure 4 Nozzle Test Adapter Nozzle test adapter is required to test the fuel injection nozzles.
General Information Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Special Tools section. The use of some specialized test equipment is explained, however, the cost of the test equipment and the specialized nature of some repairs may dictate that the work be done at a engine repair facility. If no parts list is available be sure to provide your Distributor with the TORO Model Number and Serial Number.
Priming Fuel System IMPORTANT: The fuel system must be primed when a new engine is started for the first time, if it runs out of fuel or if maintenance is performed on the fuel system. 2 1 1. Raise engine cover. 2. Loosen fuel filter bleed plug one turn. Using a shop towel to absorb fuel, push priming plunger until a steady stream of fuel runs out of hole in plug. When fuel stops foaming, tighten plug during the downstroke of the priming plunger. Wipe up any spilled fuel.
Chapter 4 Hydraulic System Table of Contents Reelmaster 4500–D Reels Slow or Won’t Turn . . . . . . . . . . . . . . . . . . . . Steering Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cutting Units Lift Slow or Won’t Lift . . . . . . . . . . . Cutting Units Won’t Drop or Follow Ground Contours . . . . . . . . . . . . . . . . . TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test No. 1: Traction Pressure . . . . . . . . . . . . . . . . Test No.
Specifications Item Description Traction Pump Traction Relief Pressure Charge Pressure Variable displacement axial piston pump 5000 – 5200 PSI 50 – 150 PSI (2WD) 75 – 150 PSI (4WD) Steering Pump Steering Relief Pressure Gear pump with flow divider 1200 – 1300 PSI Traction Motor (front) Fixed axial piston motor Traction Motor (rear w/4WD) Geroler type wheel motors Reel Pump Cutting Circuit Relief Pressure Gear pump 2650 – 2750 PSI Reel Motor Cross–over Relief Pressure Gear Motor 1500 PSI Lift C
General Information Hydraulic Hoses When replacing a hydraulic hose, be sure that the hose is straight (not twisted) before tightening the fittings. This can be done by observing the imprint on the hose. Use two wrenches; one to hold the hose straight and one to tighten the hose swivel nut onto the fitting. WARNING Before disconnecting or performing any work on hydraulic system, all pressure in system must be relieved by stopping the engine and lowering or supporting the box and/or other attachment.
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 fitting 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.). Size 4 (1/4 in.
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 hydraulic system may be damaged. If traction unit must be moved a considerable distance, transport it on a truck or trailer. 4. Rotate by–pass valve 90 degrees.
Disengaging Planetary Wheel Drives 3. Install disengage covers so dimple on cover is facing in towards hub. Wheel hubs are now unlocked. (Fig. 12). In an emergency, the Reelmaster 4500–D can be moved by unlocking the front wheel hubs and towing the machine. DANGER Vehicle will roll with front wheel motors disengaged. Vehicle must be on level surface or wheels must be blocked. There is no effective braking with wheel motors disengaged.
Reelmaster 4500–D LH Page 4 – 7 A B B A RH TRACTION MOTORS 4WD VALVE BLOCK LC1 S1 STEERING ORBITROL 4 WHEEL DRIVE ONLY LC2 TRACTION FORWARD TRACTION REVERSE COUNTER–BALANCE STEERING CIRCUIT TEST PORTS STEER CYLINDER P1 (FWD) P2 L T LEFT SIDE TRACTION MOTOR TRACTION MOTOR RIGHT SIDE P R TEST PORT LIFT CYLS SHUT– DOWN WARNING 1200 +100 –0 PSI Hydraulic System OIL LEVEL SENSOR B (REV) 5000 + 100 –0 PSI T A (FWD) TEST PORT CHARGE PRESSURE 2100 100 PSI INLET T T IN
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 coupled to the engine. With all controls in neutral and the engine running, the steer–lift pump draws oil through the suction line from the reservoir. Priority output flow is directed to the steering function. Excess flow exits the secondary output of the pump and is directed to the lift valve.
Hydraulic System Engine Run – No Functions Reelmaster 4500–D Page 4 – 9 Hydraulic System
Traction Circuit Refer to “Traction Circuit – Forward” Flow Diagram A mechanical interlock between the traction pedal linkage and the parking brake prevents traction pedal movement unless the brake is released. inlet of the traction motors. The oil returns from the motor to the pump where it continues through the pump in a closed–loop circuit. System pressure may be monitored at pressure tap port 1.
Hydraulic System Traction Circuit – Forward Reelmaster 4500–D Page 4 – 11 Hydraulic System
Steering Circuit Refer to “Steering Right” Flow Diagram With the engine running, the priority flow of oil from the steer–lift pump is directed to the power steering unit at the base of the steering column and returns to the reservoir. cylinder for a right–hand turn. Turning the steering wheel to the left has the opposite effect. Cylinder movement returns oil from the low pressure side back through the power steering unit to the reservoir.
Hydraulic System Steering Right Reelmaster 4500–D Page 4 – 13 Hydraulic System
Lift/Lower Circuit Refer to “Lift Circuit” Flow Diagrams The lift cylinders are controlled by an open center valve with three spools. The number 4 and 5 cutting units are independently controlled. The center spool controls the number 1, 2, and 3 cutting units. To lift the cutting units, the engine must be running above half throttle. The flow of oil from the steer and lift pump is used to accomplish the lift function.
Hydraulic System Lift Circuit – Lift All Units Reelmaster 4500–D Page 4 – 15 Hydraulic System
Lift Circuit – Lower All Units Hydraulic System Page 4 – 16 Reelmaster 4500–D
Hydraulic System Lift Circuit – Free Float (Detent) Reelmaster 4500–D Page 4 – 17 Hydraulic System
Reel Circuit Refer to “Reel Circuit” Flow Diagrams The three reel shut–off valves in this circuit enable the cutting units to be operated in several configurations for easier control, better clearance, or closer trimming. The reel pump supplies a constant flow of oil to the reel speed control valve. The reel speed is variable and adjustable by the operator to supply a flow of oil to the reel “On–Off” valve.
Hydraulic System Reel Circuit – All Units Mow (Free Float) Reelmaster 4500–D Page 4 – 19 Hydraulic System
Reel Circuit – Units 1, 2 & 3 Mow (Free Float) Hydraulic System Page 4 – 20 Reelmaster 4500–D
Hydraulic System Reel Circuit – Units 1, 2, 3 & 5 Mow (Free Float) Reelmaster 4500–D Page 4 – 21 Hydraulic System
Reel Circuit – Any Unit Backup Hydraulic System Page 4 – 22 Reelmaster 4500–D
4WD Selector Valve Operation Hydraulic System 4WD Forward (“S1” OFF) Pressure Oil Pressure Free Reelmaster 4500–D Page 4 – 23 Hydraulic System
2WD Forward (“S1” ON) Pressure Oil Pressure Free Hydraulic System Page 4 – 24 Reelmaster 4500–D
Special Tools NOTE: Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Some tools may also be available from a local supplier. Hydraulic Pressure Test Kit Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings. Contains one each, 1000, 5000 and 10000 PSI gauges.
Hydraulic Tester – With Pressure and Flow Capabilities Figure 14 You must have o–ring face seal (ORFS) adapter fittings for this tester to use it on this machine. 1. INLET HOSE: Hose connected from the system circuit to the inlet side of the hydraulic tester. 2. LOAD VALVE: If required, upon turning the valve to restrict flow, a simulated working load is created in the circuit. 4. HIGH PRESSURE GAUGE: High range gauge to accommodate pressure beyond the capacity of the low pressure gauge, 0 – 5,000 PSI. 5.
Troubleshooting The cause of an improperly functioning hydraulic system is best diagnosed with the use of proper testing equipment and a thorough understanding of the complete hydraulic system. A hydraulic system with an excessive increase in heat or noise is a potential failure. Should either of these conditions be noticed, immediately stop the machine, turn off the engine, locate the cause of the trouble, and correct it before allowing the machine to be used again.
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Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks. (See the Special Tools section in this Chapter.) 1. Thoroughly clean the machine before disconnecting or disassembling any hydraulic components. Always keep in mind the need for cleanliness when working on hydraulic equipment. 2.
TEST NO. 1: Checking Traction Circuit Working Pressure Or Relief Pressure Procedure for Working Pressure Check: 1. Install a 10,000 psi gauge into the traction circuit quick disconnect for the function to be checked. 2. Operate the unit while monitoring gauge. NOTE: If the machine is equipped with 4WD, check working pressure in both 2WD and 4WD modes.
TEST NO. 2: Checking Counterbalance Oil Pressure Procedure: 1. Install a 10,000 psi gauge into the center quick disconnect as shown. 2. Start the engine and move throttle to full speed (2500 rpm). 3. Tester reading should be within the range listed: COLD OIL: 600 – 650 PSI HOT OIL: 500 – 550 PSI NOTE: Due to special conditions or customer preference, the counterbalance may require setting outside this recommended range. However, the range listed will be adequate for most conditions.
TEST NO. 3: Checking Reel Circuit Working Pressure or Relief Pressure Procedure For Working Pressure Check: 1. Install a 5,000 psi gauge into the cutting circuit quick disconnect. 2. Operate the unit while monitoring the gauge. RANGE OF TESTER READINGS 0 – 2750 PSI 3. If working pressure is too high or too low, perform relief pressure check. NOTE: Normal pressure during operation is 1500 – 2000 psi. However, the gauge may spike higher during initial engagement of the control lever.
TEST NO. 4: Checking Reel Circuit Hydraulic Oil Supply 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. 6. Position reel speed control knob at middle range (90 degree position). Figure 19 7.
TEST NO. 5: Checking Reel Motor Efficiency Procedure: 1. Hydraulic oil must be at operating temperature. 2. Start the engine and lower the cutting unit to be checked. 3. Turn the engine OFF. 4. Block the reel to be checked to prevent rotation. Use a substantial hardwood block inserted between the reel blades. 5. Disconnect inlet hose at reel motor. 6. 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.
TEST NO. 6: Checking Steering Circuit Working Pressure or Relief Pressure Procedure For Working Pressure Check: 1. Install a 5,000 psi gauge into the steering quick disconnect. 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 relief pressure check. Procedure For Relief Pressure Check: 1. Hydraulic oil must be at operating temperature. Figure 21 2. Install a 5,000 psi gauge into the steering quick disconnect. 3.
TEST NO. 7: Checking Lift Circuit Working Pressure or Relief Pressure Procedure For Working Pressure Check: 1. Install a 5,000 psi gauge onto the quick disconnect of the lift valve. 2. Operate the unit while monitoring the gauge. RANGE OF TESTER READINGS 500 – 2900 PSI 3. If working pressure is too high or too low, perform relief pressure check. Procedure For Relief Pressure Check: 1. Hydraulic oil must be at operating temperature. 2. Install a 5,000 psi gauge onto the quick disconnect of the lift valve.
TEST NO. 8: Checking Charge Pressure For Traction Procedure: 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. 3. Start the engine and position throttle at idle (1200 rpm). TESTER READING TO BE APPROXIMATELY 75 – 150 PSI Figure 23 Hydraulic System 4. If there is no pressure or pressure is too low, check for restriction in pump intake line. Inspect charge relief valve and valve seat. Check for sheared charge pump key.
Repairs Removing Hydraulic System Components 1. Thoroughly clean the machine before disconnecting, removing or disassembling any hydraulic components. Always keep in mind the need for cleanliness when working on hydraulic equipment. 2. Put caps or plugs on any hydraulic lines or fittings left open or exposed. 3. Put labels on disconnected hydraulic lines and hoses for proper installation after repairs are completed. 2. After repairs, check control linkage for proper adjustment, binding or broken parts. 3.
Steering Control Unit 1 11 2 3 12 4 5 6 7 8 28 13 12 27 26 25 24 14 15 23 9 12 22 10 21 19 18 Figure 24 15. 16. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 1. Seal 1” I.D. 2. Retaining Ring 3. Seal Gland Bushing 4. Seal 1.875 I.D. 5. Quad Ring Seal, 1.062 I.D. 6. Bearing Race 7. Thrust Bearing, Needle 8. Housing 9. Control Sleeve 10. Centering Spring Kit 11. Control Spool 12. Seal 13. Spacer Plate 14.
Meter (Gerotor) End Disassembly 1. Clamp unit in vise, meter end up. Clamp lightly on edges of mounting area, see Fig. 25. Use protective material on vise jaws. Housing distortion could result if jaws are over–tightened. Figure 25 2. Remove 5/16” cap screws. 3. Remove end cap. 4. Remove seal from end cap. Figure 26 5. Remove meter. Be careful not to drop star. 6. Remove seal from meter.
7. Remove drive spacer(s) (not used on 4.5 cu. in. displacement units). 8. Remove drive. 9. Remove spacer plate. 10. Remove seal from housing. Figure 28 Control End Disassembly Hydraulic System 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. 29. Figure 29 12. Rotate spool and sleeve until pin is horizontal.
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 31 15. Remove 2 bearing races and the needle thrust bearing from spool and sleeve assembly. Figure 32 16. Remove spool and sleeve assembly from 14–hole end of housing, see Fig. 33. Attention: Do not bind spool and sleeve in housing. Rotate spool and sleeve assembly slowly when removing from housing. 17. Push pin from spool and sleeve assembly.
18. Push spool partially from control end of sleeve, then remove 6 centering springs from spool carefully by hand, see Fig. 34. 19. Push spool back through and out of sleeve, see Fig. 34. Rotate spool slowly when removing from sleeve. Figure 34 20. Remove seal from housing, see Fig. 35. 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. 35. 22. Remove 2 seals from check valve seat. Hydraulic System 23.
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 damage. 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 section.
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 entire spring set into spring installation tool, as shown in Fig. 38, with spring notches facing sleeve. 7.
11. Place housing on clean, lint free cloth. Install 2–1/8” diameter seal in housing, see Fig. 40. 12. Install 2 bearing races and the needle thrust bearing in the order shown. Figure 40 13. Install 1–1/4” diameter dust seal in seal gland bushing, flat or smooth side of dust seal must face down towards bushing, see Fig. 42. 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. 42. 15.
17. Clamp housing in vise, as shown in Fig. 43. 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 housing. Attention: Clean the upper surface of the housing 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 cloth or paper to clean surfaces. Figure 43 18.
21. Install 3” diameter seal in meter. Figure 46 22. With seal side of meter toward spacer plate, align star valleys (ref. A) on drive (ref. B). Note the parallel relationship of reference lines A, B, C, and D in Fig. 47. Align bolt holes without disengaging meter from drive.
23. Install drive spacer(s), when used, in meter, see Fig. 48. 24. Install 3” diameter seal in end cap. 25. Install end cap on gerotor, align holes. Figure 48 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. 49.
Reel Motor Repair 21 2 3 4 5 6 5 7 8 9 15 10 7 17 16 18 19 20 14 13 12 11 Figure 50 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 2. Idler Gear 3. Drive Gear 4. Key 5. O–Ring 6. Body 7. Dowel Pin 8. Plate & Bushing Assembly 9. Socket Head Cap Screw 10. Set Screw 11. Drive Pulley Retaining Ring Shaft Seal Backup Washer Relief Valve Kit O–Ring Plug Shim Spring Ball Back Plate/Relief Assembly 2. Remove drive pulley (11) from drive shaft. 7.
2. Back plate assembly (21) should be replaced if I.D. of gear pocket exceeds 1.719. Inspection of Reel Motor GENERAL 2. Remove nicks and burrs from all parts with emery cloth. GEAR ASSEMBLY 1. Inspect drive gear assembly (3) for broken or cracked keyway. 2. Inspect both the drive gear (3) and idler gear (2) shafts at bearing point for rough surfaces and excessive wear. 3. If shaft measures less than .686 in bearing area, the gear assembly should be replaced. (One gear assembly may be replaced separately.
Steering Pump Repairs 7 1 11 2 10 3 4 13 4 20 19 12 14 15 16 17 18 21 9 8 2 6 16 22 26 25 24 23 Figure 51 1. Plug (includes #2) 2. O–Ring 3. Spool 4. Dowel Pin 6. Plug (includes #2) 7. Drive Gear Assembly 8. Disc 9. Spring 10. Idler Gear Assembly 11. Hex Head Cap Screw 12. Shaft Seal 13. Washer 14. Bushing Hydraulic System 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
Disassembly of Steering Pump GEAR ASSEMBLY 1. Thoroughly clean outside of pump. 1. Check drive shaft spline for twisted or broken teeth. 2. Use a sharp tool or marker to mark across front plate (15), body (21) and back plate (22). This will assure proper reassembly. 2. Inspect both drive gear (7) and idler gear (10) shafts at bushing points and seal area for rough surfaces and excessive wear. 3. Clamp pump in a vise, with the shaft up. 3. If shaft measures less than 0.
7 1 11 2 10 3 4 13 4 20 19 12 14 15 16 17 18 21 9 8 2 6 16 22 26 25 24 23 Figure 52 1. Plug (includes #2) 2. O–Ring 3. Spool 4. Dowel Pin 6. Plug (includes #2) 7. Drive Gear Assembly 8. Disc 9. Spring 10. Idler Gear Assembly 11. Hex Head Cap Screw 12. Shaft Seal 13. Washer 14. Bushing Hydraulic System 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
Assembly of Steering Pump It is important that the relationship of the back plate (22), body (21), wear plate (20) and front plate (15) is correct. You will note two half moon cavities in the body which must face away from the front plate. NOTE: The smaller half moon port cavity must be on the pressure side of the pump. Side of wear plate with mid section cut out must be on suction side of pump. Suction side of back plate is always side with larger port boss. 1.
Lift Control Valve 34 12 11 1 2 5 3 4 6 10 9 8 7 14 15 16 17 18 19 20 13 22 37 36 39 22 23 24 35 29 25 33 32 38 26 27 31 28 30 39 40 Figure 53 1. Plug Assembly 2. Disc 3. Spring 4. Detent Plunger 5. O–Ring 6. Plug Assembly 7. O–Ring 8. Body 9. O–Ring 10. Backup Washer 11. Plug Assembly 12. Washer 13. Spool 14. Plug Assembly 15. O–Ring 16. Washer 17. Washer 18. Washer 19. Spring 20. Poppet Hydraulic System 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40.
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 coating of clean hydraulic oil to parts prior to assembly. 2. Remove cap assemblies (28). Do not remove retaining 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).
Priority Flow Divider 16 15 14 13 12 11 10 9 8 7 6 5 2 4 19 3 1 18 1 17 2 Figure 54 1. Plug Assembly 2. O–Ring 3. Spool 4. Body 5. O–Ring 6. O–Ring 7. Backup Washer 8. Metering Stem 9. Groove Pin 10. Shim Hydraulic System 11. 12. 13. 14. 15. 16. 17. 18. 19.
Disassembly of Priority Flow Divider Reassembly of Priority Flow Divider 1. Plug all ports and thoroughly clean outside of valve. 1. Install new back–up washer (7) inside metering plug (16). 2. Remove plug (1), shims (17 & 18), spring (19), and flow control spool (3) from body (4). 2. Install new O–ring (6) inside metering plug (16). NOTE: Notice the position of the spool in relation to valve body when removing spool (3). 3. Oil metering stem (8) and install in metering plug (16).
Lift Cylinder 1 2 7 6 5 4 3 Figure 55 1. 2. 3. 4. Bleed Screw Washer Rod Wiper Hydraulic System 5. Seal 6. Snap Ring 7.
Disassembly of Lift Cylinder 4. Inspect O.D. of rod (3) for nicks, scratches or scoring. 1. Thoroughly clean outside of cylinder assembly. Reassembly of Lift Cylinder 2. Pull rod (3) out until end of rod and snap ring (6) can be seen through inlet port. 1. All parts should be cleaned and dried thoroughly. Metal parts should be lightly oiled prior to reassembly. 3. Insert screw driver in inlet port and slide snap ring (6) into deep groove in the rod assembly. 2. Install new seal (5) in barrel.
Reel Control Valve 1 34 33 2 3 4 5 32 6 31 7 30 8 29 28 27 10 11 26 12 13 25 24 14 16 17 18 15 23 22 9 19 20 21 Figure 56 1. Spool 2. Body 3. O–Ring 4. Plug 5. O–Ring 6. Backup Washer 7. O–Ring 8. Relief Valve 9. Detent Plug 10. Detent Spring 11. Detent Pawl 12. Locknut 13. Lock Washer 14. Circlip 15. Spring 16. Plug 17. Sleeve Hydraulic System 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34.
1. Plug all outlets and thoroughly clean outside of valve. 4. Inspection of O–rings and back–up washers is not necessary. It is recommended that these be replaced as new parts. 2. Remove plug (4) and O–ring (3). 5. Inspect seats in body for wear. 3. Remove relief valve components (8, 7, 6, & 5). Reassembly of Reel Control Valve Assembly 4. Remove screws (22) and lock washers (23). 1. Thoroughly clean and dry all parts. should be lightly oiled prior to assembly.
Reel Shut Off Valve 1 8 2 1 2 3 5 6 9 7 6 5 7 4 Figure 57 1. 2. 3. 4. 5. Circlip Washer Spacer Spring Wiper Hydraulic System 6. 7. 8. 9.
3. Inspect O.D. of spool (9). It should be smooth and free of nicks and burrs. Disassembly of Reel Shut–Off Valve Assembly 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). 4. Remove washers (2), spring (4), and spacer (3) from spool (9). 1.
Traction Pump 19 15 16 17 18 13 6 20 12 45 8 46 9 4 21 11 14 2 32 30 40 35 5 42 43 23 10 7 1 22 39 34 41 33 37 3 38 28 29 27 26 24 25 31 48 44 47 36 Figure 58 1. Hex Head Cap Screw 2. Charge Pump Adapter Assembly 3. Plug Assembly 4. Tow Valve Assembly 5. O–Ring 6. Needle Bearing 7. Gerotor Gear Assembly 8. Check Valve Assembly 9. Back Plate Assembly 10. Housing Gasket 11. Dowel Pin 12. Rotating Kit Assembly 13. Key 14. Camplate 15. Seal Cover 16. Shaft Seal 17. Washer 18.
1. Disconnect all control linkage, hydraulic lines and remove pump assembly from vehicle. 9. Remove the tow valve (4) from back plate (9). To disassemble tow valve, remove retaining ring from spreader, and pull spreader from spreader plug. 2. Plug all ports and thoroughly clean outside of pump. 10. Remove plug assembly (3), spring (41) and relief valve assembly (34) from back plate. 3.
6 19 15 16 17 18 13 20 12 45 8 46 9 4 21 11 14 2 32 30 40 35 5 42 43 23 10 7 1 22 39 34 41 33 37 3 38 28 29 27 26 24 25 31 48 44 47 36 Figure 59 1. Hex Head Cap Screw 2. Charge Pump Adapter Assembly 3. Plug Assembly 4. Tow Valve Assembly 5. O–Ring 6. Needle Bearing 7. Gerotor Gear Assembly 8. Check Valve Assembly 9. Back Plate Assembly 10. Housing Gasket 11. Dowel Pin 12. Rotating Kit Assembly 13. Key 14. Camplate 15. Seal Cover 16. Shaft Seal 17. Washer 18. Needle Bearing 19.
1. Inspect the charge pump relief valve seat inside the charge pump adaptor. It should be smooth and free of burrs or other defects. 2. Inspect the charge pump relief valve poppet (42) and spring (43). 3. Inspect the gerotor pocket inside the charge pump adaptor assembly (2). It should not be scored excessively. 4. Inspect the bearing (47) inside the charge pump adaptor assembly, if the needles are free of excessive play and remain in the bearing cage there is no need to replace the bearing. 5.
6 19 15 16 17 18 13 20 12 45 8 46 9 4 21 11 14 2 32 30 40 35 5 42 43 23 10 7 1 22 39 34 41 33 37 3 38 28 29 27 26 24 25 31 48 44 47 36 Figure 60 1. Hex Head Cap Screw 2. Charge Pump Adapter Assembly 3. Plug Assembly 4. Tow Valve Assembly 5. O–Ring 6. Needle Bearing 7. Gerotor Gear Assembly 8. Check Valve Assembly 9. Back Plate Assembly 10. Housing Gasket 11. Dowel Pin 12. Rotating Kit Assembly 13. Key 14. Camplate 15. Seal Cover 16. Shaft Seal 17. Washer 18. Needle Bearing 19.
Reassembly of Traction Pump 9. Install new housing gasket (10). 1. Clean all parts in suitable solvent, lubricate all critical moving parts before reassembly. If necessary, install new needle bearings in the housing. The camplate pivot bearings are slip fit; the needle bearing (6) is press fit, install with numbered end of the bearing outward. 10. Install back plate (9). 3. Install washers (17) and shaft seal (16) over cam pivot bearing. Install seal cover (15) and secure with screws (24). 4.
Front Traction Motor 2 1 3 4 20 5 6 7 21 22 8 19 18 9 17 16 13 14 15 14 13 12 11 10 Figure 61 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 1. Hex Head Cap Screw 2. Hex Head Cap Screw 3. Plug 4. O–Ring Seal 5. Back Plate Assembly 6. O–Ring 7. Bearing 8. Key 9. Retaining Ring 10. Drive Shaft 11. Shaft Seal Washer Retaining Ring Thrust Ring Thrust Bearing Bearing Housing Assembly Camplate Assembly Rotating Assembly Grass Shield Retaining Ring Shaft Seal Disassembly of Traction Motor 5.
8. Inspect the flat surface on the backplate (5); it should be free of excessive scoring or metal build–up. 11. Remove camplate assembly (18) from housing. 9. Inspect the drive shaft (10) for fretting in the bearing areas. Check spline area for twisted or broken teeth. If keyed shaft, check for cracked or chipped keyway. 12. Remove shaft seal (11) from housing. Reassembly of Traction Motor 13. Remove washer (12) and drive shaft (10) from housing. 1. Lubricate all critical moving parts before assembly.
Reel Pump 14 15 13 7 12 11 8 5 6 12 7 4 3 1 2 10 9 18 17 16 Figure 62 1. 2. 3. 4. 5. 6. 7. 8. 9. Nut Lock Washer Stud Stud Front Cover Gland Seal Wear Plate Center S/A Section Shaft Seal Hydraulic System 10. 11. 12. 13. 14. 15. 16. 17. 18.
2. Remove the retaining ring (18) with internal retaining ring pliers. During disassembly, pay particular attention to identification of the parts for correct assembly. 1. Clamp the port section (13) in a vise with protective jaws to avoid damage to the port section’s machined surfaces. 2. Remove gear coupling (14) from port section (13). 3. Remove eight nuts (1) and eight washers (2). 4. Remove front cover (4) from wear plate (7). 5.
14 15 13 7 12 11 8 5 6 12 7 4 3 1 2 10 9 18 17 16 Figure 63 1. 2. 3. 4. 5. 6. 7. 8. 9. Nut Lock Washer Stud Stud Front Cover Gland Seal Wear Plate Center S/A Section Shaft Seal Hydraulic System 10. 11. 12. 13. 14. 15. 16. 17. 18.
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 facilitate assembly and provide initial lubrication. Use small amount of petroleum jelly to hold seal glands (5) and retainers (6) in place during assembly. 1. Assemble seal packs by inserting the seal glands (5) into the seal retainers (6).
Rear Wheel Drive Valve Block NOTE: If cartridge valve seals appear pitted or damaged, the hydraulic system may be overheating or there may be water in the system. Figure 64 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.
Rear Wheel Drive Motor 8 6 7 1 1 1 1 2 3 4 5 10 9 13 Hydraulic System 11 12 Figure 66 1. 2. 3. 4. 5. 6. 7. 8. Bolt 9. Outer Seal 10. Inner Seal 11. Shaft Seal 12. Dust Seal 13. Slotted Nut O–Ring Seal Backup Washer Shaft Seal Key Sub Shaft Assembly Pin Spring Disassembly of the Rear Wheel Drive Motor Cleanliness is extremely important when repairing a hydraulic motor. Work in a clean area. Before disconnecting the lines, clean the port area of the motor thoroughly.
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 distortion. 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 67 2.
6. Remove 2 pins and 2 springs from balance ring assembly, see Fig. 71. 7. Remove balance ring assembly. 8. Remove inner and outer face seals from balance ring. 9. Remove the valve. Figure 71 10. Remove the valve plate. 11. Remove the 3[76] diameter seal from valve plate. 12. Remove the valve drive. Figure 72 Hydraulic System 13. Remove the Geroler. 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. 73.
19. You may need a press to remove shaft and bearing assembly from bearing housing. (Key must be removed before removing shaft.) Figure 75 20. Use a small screwdriver to remove shaft seal, back– up washer and exclusion seal from bearing housing, see Fig. 76. 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.
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. 77. Do not distort seal. 28. Install the wear plate, see Fig. 77. 29. Apply a light film of petroleum jelly to the 3[76] diameter 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 Geroler with the notch on the wear plate.
37. Apply petroleum jelly to inner and outer face seals. Install seals on balance ring as shown in Fig. 81. IMPORTANT: Install face seals in the positions shown in Fig. 81. or the motor will not operate properly. Do not force or bend the face seals. Any damage to these seals will affect the operation of the motor. 38. Align pin notches in balance ring with pins in bore of valve housing. Install balance ring assembly in valve housing. Figure 81 39. Insert your finger through port of valve housing.
Wheel Motor On wheel motors, a different bearing housing is used, see Fig. 85. Other than this the parts are the same as the standard motor and the same disassembly and reassembly procedures apply.
Steering Cylinder 1 2 3 4 5 6 7 8 10 11 12 13 14 15 16 17 9 18 Figure 86 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Set Screw Threaded Cap Rod Rod Wiper U–Cup Cap Head Backup Washer O–Ring O–Ring Spacer Servon O–Ring Piston Locknut Barrel Assembly Jam Nut Rod Tie, End Roll Pin 6. Securely mount piston, piston rod, and head into vise and remove nut.
11. Use a complete repair kit when rebuilding the cylinder. Put a coating of oil on all new seals, and O–rings. Install the new seal and O–rings. 14. Put a coating of oil on all cylinder parts to ease assembly. 15. Slide piston rod assembly into cylinder tube. 12. Install head onto piston rod. 16. Install head into tube. Install threaded cap and tighten set screw. Hydraulic System 13. Install piston onto piston rod with O–ring seal (9) and tighten hex nut.
Hydraulic System Page 4 – 88 Reelmaster 4500–D
Chapter 5 Electrical System Table of Contents ELECTRICAL SYSTEM QUICK CHECKS . . . . . . . Battery Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging System Test . . . . . . . . . . . . . . . . . . . . . . . Voltage Drop Testing . . . . . . . . . . . . . . . . . . . . . . . . Glow Plug System Test . . . . . . . . . . . . . . . . . . . . . . Starting System Test . . . . . . . . . . . . . . . . . . . . . . . . COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . .
Page 5 – 2 ����� ��0���� � 1 ������0��� �������� ��� ��� ��� ��� ���0��� ���� ���0��� ��� ��� ��� �����0����� ��� 4 ��� ������ ����� ���� � 4 � ����5 ����� ���0��� ������ � 1 ��� ������ 1����5��5�������1 00000������ 1 � � 1����5��5����1 0000������ 1 � �� �� �� ������ ��������� �� �� �� �� �� 1 � � � 4 ��� � �0 4 5 ���� ������ ���� ����� ����� �� ��� �� �� ����� ����� ����� ����� ���0����� ����� ����� ������ ���� 00���0��� �����050���� ������ ������ ���0���
Electrical System Reelmaster 4500–D Page 5 – 3 Electrical System
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Special Tools Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Some tools may also be available from a local supplier. Continuity Tester Battery powered test lamp which is helpful in testing for continuity of circuits and electrical components when the current is off. Figure 1 Multimeter The meter can test electrical components and circuits for current, resistance, or voltage draw.
Troubleshooting For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components used on this machine (see Wiring Schematics section of this chapter). CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage. If the machine has any interlock switches by–passed, they must be reconnected for proper troubleshooting and safety.
Starting Problems (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 (SW1) out of adjustment or faulty.
General Run and Transport Problems Problem Possible Causes Engine continues to run (but should not) when parking brake is released or mow–backlap lever is now or backlap with no operator on seat. Seat switch plunger depressed 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 mow–backlap lever is moved to mow or backlap. Operator sitting too far forward on seat (seat switch not depressed).
Verify Interlock System Operation 2 CAUTION THE INTERLOCK SWITCHES ARE FOR THE OPERATOR’S PROTECTION, SO DO NOT DISCONNECT THEM. CHECK OPERATION OF THE SWITCHES DAILY TO ASSURE INTERLOCK SYSTEM IS OPERATING. IF A SWITCH IS DEFECTIVE, REPLACE IT BEFORE OPERATING. REGARDLESS IF SWITCHES ARE OPERATING PROPERLY OR NOT, REPLACE THEM EVERY TWO YEARS TO ASSURE MAXIMUM SAFETY. 1 3 Figure 4 1. In a wide open area free of debris and bystanders, lower cutting units to the ground. Stop engine. 1. Parking Brake 2.
Electrical System Quick Checks Battery Test Use a volt–ohm multi–meter to measure the voltage between the battery terminals. Set the multi–meter to the DC Volts setting. The battery should be at a temperature of 60_ to 100_ F. The ignition key should be off and all accessories turned off. Connect the positive (+) Volt meter lead to the positive battery post and the negative (–) Voltmeter lead the the negative battery post. NOTE: This test provides a relative condition of the battery.
Glow Plug System Test This is a fast, simple test that can help you determine a Glow Plug system’s integrity and operation. The test should be run anytime hard starting (cold) is encountered on a diesel engine equipped with a Glow system. Remember – there are 2 types of Glow Plug systems that Toro uses: 1. Systems with resistors (Glow Plug Indicators) in series (Reelmaster 450/4500–D, Groundsmaster 325–D, etc.) 2. Systems without resistors (Reelmaster 335–D, Groundsmaster 455–D, Reelmaster 5100/5300–D, etc.
Component Testing For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before doing a continuity check). CAUTION When testing electrical components for continuity with a volt–ohm meter or continuity tester, make sure that power to the circuit has been disconnected.
Bosch Relay To test the relay, disconnect the relay wire connector and install a continuity tester between the relay terminals (terminals 30 and 87). The relay should make and break continuity at terminals 30 and 87 as 12 V.D.C. is connected and disconnected to terminal 85 with terminal 86 connected to ground.
Rear Wheel Drive Solenoid Electrical System Figure 8 1. Disconnect the wire connector. 2. Connect a 12 volt battery so the positive (+) battery terminal is connected to colored solenoid lead. Connect the negative (–) battery terminal to black lead. The valve spool should retract completely as 12V DC is applied across the leads. 3. If valve spool does not retract, check for binding or damage in valve. 4.
Repairs NOTE: See Mitsubishi 4DQ7 Engine Service Manual for more component repair information. Battery Service IMPORTANT: To prevent damage to the electrical components, do not operate the engine with the battery cables disconnected. Electrolyte Specific Gravity Keep the terminals and entire battery case clean. To clean the battery, wash the entire case with a solution of baking soda and water. Rinse with clear water.
Rear Wheel Drive Solenoid Replacement Electrical System Figure 11 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 equivalent to threads on end of valve stem before installing nut. Tighten nut to a torque of 15 in–lb. Over–tightening may damage the solenoid or cause the valve to malfunction. 5. Connect wiring connector.
Electrical System Page 5 – 26 Reelmaster 4500–D
Chapter 6 Axles and Brakes Table of Contents 2 3 3 4 REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Rear Wheel Bearings . . . . . . . . . . . . . . . . . . . . . . . . . 5 Planetary Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . 7 Axles and Brakes SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hand Brake and Traction Switches . . . . . . . . . . . . . .
Specifications Item Description Tire pressure 13 PSI front, 15 PSI rear Wheel nut torque 30 – 35 ft–lb rear, 60 – 85 ft–lb front Wheel planetary mounting cap screw torque 95–110 ft–lb Rear wheel toe–in 0.25 in. Wheel planetary lubricant (Fig. 1) SAE 80–90W EP gear lube 30 oz. capacity 1 Figure 1 1.
Adjustments Hand Brake and Traction Switches In time, the hand brake cable may stretch, causing the engine not to start. If this happens, adjust the cable (Fig. 2). 1. Pull hand brake lever to 3rd click. 2. Pull hand brake up one additional click. 3. Adjust four U–bracket nuts equally so spring has tension. Adjustment affects operation of traction switches. 4.
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 front and rear of steering tires (Fig. 3). Front measurement must be 1/8 in. less than rear measurement. 2. Loosen clamps at both ends of tie rods (Fig. 4). 3. Rotate tie rod to move front of tire inward or outward. 4. Tighten tie rod clamps when adjustment is correct. NOTE: Make sure tie rod clamps are positioned so they do not interfere with steering linkage.
Repairs Rear Wheel Bearing Service (2WD Only) 44 1 47 34 44 45 46 2 3 4 5 48 6 5 4 32 31 39 41 29 43 40 39 42 35 3433 29 31 49 28 29 38 7 30 8 37 9 10 11 12 13 14 15 36 27 26 25 24 22 23 21 20 19 50 17 18 16 Figure 5 Reelmaster 4500–D 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. Page 6 – 5 Lock Nut Tie Rod Assembly Cap Hex Hd.
1. Jack up rear of machine until tire is off the floor. Support machine with jack stands or blocks to prevent it from falling. Adjusting Rear Wheel Bearings 1. Remove dust cap (16) from end of wheel spindle. Remove cotter pin (15) retaining slotted nut (50) in place. 2. Remove dust cap (16) from end of wheel spindle. 3. Remove cotter pin (15), slotted nut and washer (18). Slide wheel off of spindle shaft. 4. Pull seal (22) out of wheel hub (9). 5. Remove bearings (11, 21) from both sides of wheel hub (9).
Planetary Wheel Drive 3 4 5 6 7 8 2 6 9 24 20 28 10 25 26 27 26 25 11 15 13 29 23 22 21 12 19 18 17 16 14 Figure 7 Reelmaster 4500–D 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. Page 6 – 7 Pipe Plug Hex Hd. Bolt Disengage Cover Large Cover Secondary Carrier Assembly O–Ring Disengage Plunger Thrust Washer Ring Gear Retaining Ring Washer Disengage Spring Retaining Ring Kit Retaining Ring Axles and Brakes 1. Coupling 2. Input Shaft 3. Spindle 4. Oil Seal 5. Bearing Cone 6.
Disassembly of the Planetary Wheel Drive 1. Slide the coupling (1) from splines on input shaft (2). 2. Position the assembly upright on face of spindle (3). 3. Remove the disengage cover (18). 4. Remove bolts (17) and large cover (19). The disengage plunger (22) usually remains with cover. Remove plunger and O–ring from cover on end of input shaft. 5. A thrust washer (23) will usually remain in position on thrust face of cover. 6. Remove primary sun gear (13) and thrust washer (12) from end of input shaft.
Chapter 7 Cutting Units Table of Contents 2 3 5 5 6 REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Backlapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Hydraulic Motor Installation . . . . . . . . . . . . . . . . . . 10 Servicing the Bedknife/Bedbar Assembly . . . . . . 12 Servicing the Reel Assembly . . . . . . . . . . . . . . . . . 13 Roller Removal and Installation . . . . . . . . . . . . . . . 16 8 8 8 Cutting Units SPECIFICATIONS . . . .
Specifications Bedknife to Reel Adjustment: Two lockable lead screw adjusters at each side of the frame adjust the reel to bedknife contact. Rear Roller: 3–1/2 in. (89 mm) diameter steel roller has greaseable tapered roller bearings. A double lip oil seal and wear sleeve isolates grit and moisture from the bearings. Height–of–Cut: 5 Blade – 1 to 3 in. (25 to 76 mm). 7 Blade – 1/2 to 1–3/4 in. (9.5 to 45 mm). 1 1 Blade – 3/8 to 3/4 in. (9.5 to 19 mm). Figure 1 1. Drive housing cover 2. Drive housing 3.
Special Tools Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Some tools may be listed in the Reelmaster 4500–D Parts Catalog. Some tools may also be available from a local supplier. Gauge Bar Assembly Use gauge bar to set final height of cut (floating cutting unit with front roller only). Figure 2 Handle Assembly For applying lapping compound to cutting units while keep hands a safe distance from the rotating reel.
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 in–lb. NOTE: Remove all rust, scale and corrosion from bedbar surface before installing bedknife. DO NOT use and air impact wrench with this tool.
Adjustments CAUTION Never install or work on the cutting units or lift arms with the traction unit engine running. Always stop the engine and remove the key first. Adjusting Reel to Bedknife Contact Before adjusting height–of–cut and each day before operating, check reel to bedknife contact, regardless if quality of cut had previously been acceptable. NOTE: A 3/4” wrench is required for making the reel to bedknife adjustment. A.
Height–of–Cut Adjustment (Floating Cutting Unit) Overview of Procedure: 1. Adjust reel to bedknife contact 2. Level rear roller to reel 3. Final height–of–cut adjustment using gauge bar. STEP 1 – Adjust Reel to Bedknife Contact A. Adjust reel to bedknife contact on all cutting units. (Refer to Adjusting Reel To Bedknife Contact). STEP 2 – Level Rear Roller to Reel B. Start engine and lower the cutting units onto a flat surface such as a piece of 3/4” or 1” plywood (at least 20” x 30” in size).
STEP 3 – Final Height–of–Cut Adjustment Using Gauge Bar F. Raise cutting units and lock in the transport position. Shut off the engine and remove the key. G. Use gauge bar (Toro Part No. 59–7900) to set final height–of–cut by adjusting front roller only. H. Loosen the gauge bar jam nut and adjust the screw to set dimension between underside of screw head and gauge bar for desired height–of–cut (Fig. 9). Tighten the jam nut to secure the adjustment.
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 (STEPÿ1) and the rear roller leveled to the reel (STEP 2), the cutting unit may be quickly changed from one height–of– cut to another by using the gauge bar (Part #59–7900) and adjusting the front roller only. In many cases, an entire machine can be done quickly by using the gauge bar to set the front roller of one cutting unit.
Repairs CAUTION Never install or work on the cutting units or lift arms with the traction unit engine running. Always stop the engine and remove the key first. Backlapping the #2 and #3 cutting units from the front of the machine. CAUTION C. Wait for 2nd person’s instruction to engage reels in BACKLAP mode, then pull up on reel switch and move it to ENGAGE position. DURING BACKLAP OPERATION REELS ARE UNDER POWER. CONTACT WITH ROTATING REELS CAN RESULT IN PERSONAL INJURY.
G. Check sharpness of the reel and bedknife with strips of newspaper. With light reel to bedknife contact, the paper should be cleanly sheared across the entire width of the reel. If the paper is not sheared acceptably, continue backlapping. ignition switch. Then proceed with the adjustment only after the reels have stopped rotating. E. Backlap each reel until the cutting edges are sharp, even, and consistent on all blades. Achieve a minimum of 1/32 in. (0.
3. Insert the two (2) reel drive motor mounting bolts (heads on inside of the drive housing – flat washer on top bolt) through the reel motor flange holes. Thread the locknuts onto the bolts. Rotate reel motor upward in the slotted hole in the housing to tension the drive belt and tighten the fasteners (Fig. 14) to approx. 25 ft–lbs (34 Nm). NOTE: Proper belt tension is achieved when belt deflects approximately 1/8” (3 mm) at mid–point when 7 lbs. force is applied. (Fig. 14).
Servicing the Bedknife/Bedbar Assembly NOTE: The bedbar on each cutting unit has a precision ground mounting surface to provide an excellent fit with a bedknife. Backlapping of replacement bedknives is often sufficient to achieve an excellent cutting edge with minimum material removed. Bedknife/Bedbar Removal: 1. Remove the shoulder bolts,bushings and spacers from each end of the unit and remove the bedbar/bedknife assembly (Fig. 16). 2.
Servicing the Reel Assembly Disassembly: 1. Remove the guards from each end of the cutting unit and the front and rear roller assemblies (Fig. 19). 2. Remove the shoulder bolts, bushings and spacers from each end of the unit and remove the bedbar/bedknife assembly (Fig. 20). 3. Remove the inboard locknut from the adjuster pin, the fasteners for the bracket and remove the adjusting handle assembly from the side plate (Fig. 20). Figure 19 Figure 20 1. Locknut 2. Belleville washer 3.
4. Disassemble the cone nut from the shoulder bolt securing the bearing housing to the side plate, remove the belleville washer and bolt and slide the bearing housing off the reel shaft (Fig. 21). 5. Disassemble the cover from the drive housing and remove the drive belt from the housing (Fig. 22). 6. Remove the reel capscrew, toothed washer and pulley washer from the reel shaft (Fig. 22). (Note: Capscrew is assembled with a thread locking compound). 7.
9. Install the woodruff key in the drive housing end of the reel shaft and install the driven pulley onto the shaft. Assembly: 1. Inspect the flange bushings in the mounting holes for the drive housing and bearing housing for wear (Fig. 20). Replace, if necessary. 2. Assemble the outer seal (lip facing in to retain grease) into the drive housing using Loctite 242 retaining compound on the outer diameter.
Roller Removal and Installation 1. Remove the fasteners securing the guard and roller adjustment housing to the side plate (Fig. 24) or unscrew the upper cone nut and drop the threaded rod out of the adjustment housing (Fig. 25). 2. The threaded rod and collar assembly can be removed from the roller by sliding it off the shaft at both ends (Fig. 25). IMPORTANT: When assembling a new roller to the cutting unit mount the roller so that the roller shaft ”locknut” is on the right side of the cutting unit (Fig.
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