PART NO. 98958SL, Rev. A Service Manual ReelmasterR 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. 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.
Reelmaster 4000–D
General Safety Instructions . . . . . . . . . . . . . . . . . . 1 – 1 Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 – 4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 3 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . 4 – 8 Hydraulic Flow Diagrams . . . . . . . . . . . . . . . . . . . . 4 – 9 4WD Selector Valve Operation . . . . . . . . . . . . . .
Reelmaster 4000–D
Chapter 1 Safety Safety Table of Contents GENERAL SAFETY INSTRUCTIONS . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . 1 1 2 3 SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 4 General Safety Instructions The Reelmaster 4000–D was tested and certified by TORO for compliance with the B71.
While Operating 10. Do not run engine in a confined area without adequate ventilation. Exhaust is hazardous and could be deadly. 11. Sit on the seat when starting and operating the machine. 12. Check interlock switches daily for proper operation. If a switch fails, replace it before operating the machine. The interlock system is for your protection, so do not bypass it. Replace all interlock switches every two years. 13. This product may exceed noise levels of 85 dB(A) at the operator position.
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 Reelmaster 4000–D. If any become damaged or illegible, replace them. Decal part numbers are listed below and in the parts catalog. Order replacements from your Authorized Toro Distributor. ON LIFT ARMS (Part No. 93–7331) ON PANEL IN FRONT OF OPERATOR’S SEAT (Part No. 93–9408) ON STEERING CONSOLE (Part No. 93–9399) ON LEFT SIDE OF MACHINE (Part No. 93–9406) ON FRAME ABOVE RIGHT REAR WHEEL (Part No.
Safety Safety and Instruction Decals ON FRAME ABOVE REAR WHEELS (Part No.93–9405) NEAR RADIATOR FILL CAP (Part No. 93–9404) ON FAN SHROUD (Part No. 93–6681) UNDER SEAT NEAR OIL FILL CAP (Part No. 93–8067) ON CUTTING UNIT (Part No. 76–8760) NEAR FUEL TANK FILL CAP (Part No. 93–6680) ON RADIATOR CAP (Part No. 59–8440) NEXT TO TRACTION PEDAL ON STEERING CONSOLE (Part No.
Safety and Instruction Decals ON FRONT CARRIER & TOW BAR (Part No. 93–9400) ON RIGHT CONTROL PANEL (Part No. 93–9402) ON EXHAUST SHIELD (Part No. 95–0645) ON FRONT ACCESS PANEL (Part No.
Chapter 2 Product Records and Maintenance Table of Contents 1 2 2 2 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . . . . . . . . . . . . . . . . Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) . . . . . . . . . . . . . . . Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) . . . . . . . . . . Other Torque Specifications . . . . . . . . . . . . . . . . . . Conversion Factors . . . . . . . . . . . . . . .
Equivalents and Conversions Product Records and Maintenance Page 2 – 2 Reelmaster 4000–D
Torque Specifications These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Service Manual.
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, 5, & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs, & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in–lb in–lb N–cm 10 + 2 13 + 2 147 + 23 # 6 – 32 UNC # 6 – 40 UNF # 8 – 32 UNC 13 + 2 25 + 5 # 10 – 24 UNC 30 + 5 SAE Grade 8 Bolts, Screws, Studs, & Sems with Regular Height Nuts (SAE J995 Grade 5 or Stronger Nuts) in–lb N–cm in–lb N–cm 15 + 2 170 + 20 23 + 2 260 +
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws, and Studs with Reg lar Height Nuts N ts Regular (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws, and Studs with Reg lar Height Nuts N ts Regular (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.
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 1/4 – 20 UNC 140 + 20 in–lb 73 + 12 in–lb 5/16 – 18 UNC 215 + 35 in–lb 145 + 20 in–lb 3/8 – 16 UNC 35 + 10 ft–lb 18 + 3 ft–lb 1/2 – 13 UNC 75 + 15 ft–lb 50 + 10 ft–lb 7/16 – 20 UNF Grade 5 65 + 10 ft–lb 88 + 14 N–m 1/2 – 20 UNF Grade 5 80 + 10 ft–lb 108 + 14 N–m M12 X 1.25 Class 8.
Lubrication GREASING BEARINGS AND BUSHINGS Product Records and Manuals The machine has grease fittings that must be lubricated after every 50 hours of operation with No. 2 General Purpose Lithium Base Grease. Lubricate fitting immediately after every washing regardless of interval listed. The lubrication 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).
Product Records and Maintenance Page 2 – 8 Reelmaster 4000–D
Product Records and Manuals EQUIPMENT OPERATION AND SERVICE HISTORY REPORT for REELMASTERR 4000–D TORO Model and Serial Number: ______________–______________ Engine Numbers: _____________________________ Transmission Numbers: _____________________________ Drive Axle(s) Numbers: _____________________________ Date Purchased: _____________________________ Warranty Expires____________ Purchased From: _____________________________ _____________________________ _____________________________ Contacts:
Reelmaster 4000–D Maintenance Schedule Minimum Recommended Maintenance Intervals Maintenance Procedure Maintenance Interval & Service Lubricate Reel Control Valve Grease Fitting Lubricate Reel Speed Valve with Oil Lubricate All Grease Fittings Check Battery Condition and Connections 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 Cooling System Hoses B Level
Reelmaster 4000–D Daily Maintenance Checklist n Safety Interlock Operation n Parking Brake Operation n Engine Oil Level n Fuel Level n Cooling System Fluid Level Product Records and Manuals Daily Maintenance: (duplicate this page for routine use) Check proper section of Operator’s Manual for fluid specifications Daily Maintenance Check For Week Of _________________ Maintenance Check Item b MON TUES WED THURS FRI SAT SUN Drain Water/Fuel Separator n Air Filter Restriction Indicator n Radiator
Product Records and Maintenance Page 2 – 12 Reelmaster 4000–D A B C D Other Service to perform (circle): __________________–__________________ TORO I.D.
Chapter 3 Kubota Diesel Engine INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . Check Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . Check Cooling System . . . . . . . . . . . . . . . . . . . . . . . Fill Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prime Fuel System . . . . . . . . . . . . . . . . . . . . .
Introduction This Chapter gives information about specifications, maintenance, troubleshooting, testing, and repair of the diesel engine used in the Reelmaster 4000–D. test equipment and the specialized nature of some repairs may dictate that the work be done at an engine repair facility. Most repairs and adjustments require tools, which are commonly available in many service shops. Special tools are described in the Kubota Workshop Manual, 03 Series, Diesel Engine.
Specifications Item 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) Fuel No. 2 Diesel Fuel per ASTM D975 Fuel Capacity liters (gallons) 56.8 (15.
General Information Check Engine Oil 1. Park machine on a level surface. Stop engine. Remove key from the ignition switch. 2. Release engine cover latches. Open engine cover (Fig. 1). 1 3. Remove dipstick, wipe clean and reinstall dipstick into tube and pull it out again. Oil level should be up to the FULL mark (Fig. 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.
Check Cooling System Check level of coolant at the beginning of each day. Capacity 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 removed. Remove radiator cap slowly and carefully if engine coolant is hot. 1. Park machine on a level surface. Stop engine. Remove key from the ignition switch. Figure 4 1. Radiator cap 2. Rear screen 3. Check level of coolant in radiator.
Prime Fuel System IMPORTANT: The fuel system must be primed when a new engine is started for the first time, if it runs out of fuel, or if maintenance is performed on the fuel system. 2 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 tank to fuel filter/water separator (Fig. 7). 3 1. Park machine on a level surface. Stop engine. Remove key from the ignition switch. 1 4 Figure 7 2.
Adjustments Adjust Alternator Belt Check condition and tension of belt after every 100 operating hours (Fig. 9). 1 1. Park machine on a level surface. Stop engine. Remove key from the ignition switch. 2 2. Proper belt tension will allow 3/8 inch (10 mm) deflection when a force of 10 lbs (44.4 N) is applied on the belt midway between both pulleys. Figure 9 1. Alternator Reelmaster 4000–D Page 3 – 7 2. Mounting bolt Kubota Diesel Engine Kubota Diesel Engine 3.
Service and Repairs Service Air Cleaner 1. Park machine on a level surface. Stop engine. Remove key from the ignition switch. 2. Remove knobs securing rear screen to frame . Remove 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 indicator light illuminates and warning signal sounds or every 400 hours (more frequently in extreme dusty or dirty conditions).
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 filter (Fig.13). 1 Figure 12 1. Drain plug 2. Starter 1 2 Figure 13 1. Oil filter Reelmaster 4000–D Page 3 – 9 2.
Drain Fuel System 3 DANGER Because diesel fuel is highly flammable, use caution 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 starting the engine. Store fuel in a clean, safety–approved container and keep cap in place.
Check Fuel Lines and Connections Check lines and connections every 400 hours or yearly, whichever comes first. Inspect for deterioration, damage, or loose connections. Replace Fuel Filter DANGER 1 2 Figure 15 There are 2 fuel filters on the RM 4000–D. A small in– line filter is located on top of the fuel tank and behind the the radiator (Fig. 15). The fuel filter/water seperator is located near the left rear end of the engine (Fig. 16). 1.
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. Remove 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). 4. Lift up on oil cooler handles and pivot rearward in mounting slot.
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 5 2 11 4 Kubota Diesel Engine 3. Disconnect and remove battery from the machine (see Battery Service in Chapter 5 – Electrical Systems). 2.
9. Clamp to prevent drainage, and disconnect the following fuel hoses: 1 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 2. Fuel pump suction 3. Fuel pump discharge 4. Fuel solenoid 10. Disconnect wire harness and electrical wires from the engine as follows: A.
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 pump adapter plate. 1 C. Support pump, and pull pump shaft from the spring coupling. 5 2 4 Figure 25 1. Damper 2. Bracket 3. Pump mounting flange 13. Remove three lock nuts and cap screws securing the upper exhaust tube to the exhaust bracket (Fig. 26). 4. Pump adapter plate 5.
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 filter. Suction and discharge hoses at the fuel pump (Fig. 22). One person should operate lift or hoist while the other person guides the engine into the frame. 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. 9.
Chapter 4 Hydraulic System Table of Contents Reelmaster 4000–D TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions for Hydraulic Testing . . . . . . . . . . . . . Test No. 1: Check Traction Working and Relief Pressures . . . . . . . . . . . . . . . . . . . . . . . Test No. 2: Check Counterbalance Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test No. 3: Check Reel Circuit Working and Relief Pressures . . . . . . . . . . . . . . . . . . . .
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) Geroter 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 Hydraulic hoses are subject to extreme conditions such as, pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage conditions or mishandling during operation or maintenance. These conditions can cause damage or premature deterioration. Some hoses are more susceptible to these conditions than others. Inspect the hoses frequently for signs of deterioration or damage.
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. 2 1. Remove the retainer clip from seat lock rod. 1 2.
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 disengaged. Vehicle must be on level surface or wheels must be blocked. There is no effective braking with wheel motors disengaged.
Check Hydraulic System Fluid 1. Look into sight glass (Fig. 11). Oil level should be even with arrows when checking warm oil. Oil will be 1/4 to 1/2 inch below arrows when cold. 2 2. If oil level is low, add hydraulic oil to the reservoir (see Add Hydraulic Fluid). 1 Figure 11 Hydraulic reservoir 2. Sight glass Hydraulic System 1.
Hydraulic System LH Page 4 – 8 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 OIL LEVEL SENSOR B (REV) 5000 + 100 –0 PSI T A (FWD) TEST PORT CHARGE PRESSURE 2100 100 PSI INLET T T IN 4 2 1 3 5 B
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.
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 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.
Traction Circuit – Forward Hydraulic System Page 4 – 12 Reelmaster 4000–D
Steering Circuit Refer to “Steering Right” Flow Diagram 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. Turning the steering wheel to the right moves the control spool in the steering unit to direct the oil to the steering System pressure may be monitored at pressure tap port 5.
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 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.
Lift Circuit – Lift All Units Hydraulic System Page 4 – 16 Reelmaster 4000–D
Hydraulic System Lift Circuit – Lower All Units 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 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. Oil not needed to obtain the selected reel speed is directed back to the sump tank through the drain block, oil cooler, and filter.
Reel Circuit – All Units Mow (Free Float) Hydraulic System Page 4 – 20 Reelmaster 4000–D
Hydraulic System Reel Circuit – Units 1, 2 & 3 Mow (Free Float) 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
Hydraulic System Reel Circuit – Any Unit Backup 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
Hydraulic System 2WD Forward (“S1” ON) Pressure Oil Pressure Free Reelmaster 4000–D Page 4 – 25 Hydraulic System
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 Tester – With Pressure and Flow Capabilities – TOR214678 Figure 12 You must have o–ring face seal (ORFS) adapter fittings for this tester to use it on Toro equipment. 1. INLET HOSE: Hose connected from the system circuit to the inlet side of the hydraulic tester. 2.
Hydraulic Pressure Test Kit – TOR47009 Use to take various pressure readings for diagnostic tests. A high pressure hose is provided for remote readings. 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.
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.
Problem Possible Causes Steering loss. Thermal shock after washing. NOTE: Normal functions will return after orbital temperatures stabilize (approximately 15 minutes). DO NOT ATTEMPT TO TURN STEERING WHEEL UNTIL TEMPERATURES STABILIZE WHEN THERMAL 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.
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.) Before Performing Hydraulic Tests IMPORTANT: All obvious areas such as oil supply, filter, binding linkages, loose fasteners, or improper adjustments must be checked before assuming that a hydraulic component is the source of the problem.
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 2WD and 2500 PSI in 4WD.
TEST NO. 2: Check Counterbalance Oil Pressure Procedure: 1. Install a 10,000 psi gauge into the center quick disconnect as shown. 2 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 preference, the counterbalance may require setting outside this recommended range. However, the range listed will be adequate for most conditions. Figure 16 1. 2.
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. 1 2. Operate the unit while monitoring the gauge. 2 RANGE OF TESTER READINGS 0 – 2750 PSI 3. If working pressure is too high or too low, perform relief pressure check. NOTE: Due to special conditions or customer preference, the counterbalance may require setting outside this recommended range.
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. 6. Position reel speed control knob at middle range (90 degree position). Figure 18 7.
TEST NO. 5: Check Reel Motor Cross–Over Relief Pressure FROM LIFT CIRCUIT CUTTING CIRCUIT TEST PORT T G T FROM GEAR PUMP PRIORITY B IN (TYP) IN A OUT 3000 PSI B A T B A TO HYDRAULIC OIL TANK Figure 19 Check Relief Pressure NOTE: The reel motor has an internal relief valve that relieves when the pressure across the motor exceeds 1500 + 100 PSID. 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes.
TEST NO. 6: Check Reel Motor Case Drain Flow FROM LIFT CIRCUIT T CUTTING CIRCUIT TEST PORT G T FROM GEAR PUMP PRIORITY B IN (TYP) IN A OUT B 3000 PSI A T QUART CONTAINER B A TO HYDRAULIC OIL TANK Figure 20 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Make sure machine is parked on a level surface. Lower cutting unit to be tested.
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 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. 1 Procedure For Relief Pressure Check: 1. Hydraulic oil must be at operating temperature. 2. Install a 5,000 psi gauge into the steering quick disconnect. Figure 21 1.
TEST NO. 8: Check Lift Circuit Working and Relief Pressure Procedure For Working Pressure Check: 2 1. Install a 5,000 psi gauge onto the quick disconnect of the lift valve. 1 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 relief pressure check. Procedure For Relief Pressure Check: Figure 22 1. 1. Hydraulic oil must be at operating temperature. Lift control test port 2. Lift control valve 2.
Service and 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.
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 20 16 19 18 Figure 25 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. 26. Use protective material 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. Hydraulic System Figure 27 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 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.
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 bearing from spool and sleeve assembly. Figure 33 Hydraulic System 16. Remove spool and sleeve assembly from 14–hole end of housing, see Fig. 34. IMPORTANT: Do not bind spool and sleeve in housing. Rotate spool and sleeve assembly slowly when removing from housing. 17.
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.
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. 39, with spring notches facing sleeve. 7.
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 bushing, flat or smooth side of dust seal must face down towards 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.
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 housing. IMPORTANT: 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 44 18.
21. Install 3” diameter seal in meter. Figure 47 Hydraulic System 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.
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.
Add Hydraulic Fluid Capacity of the hydraulic reservoir is approximately 9.3 gal. (35.2 L). With machine on a level surface, hydraulic oil level should be 1/4 to 1/2 inch below arrows on sight glass, when oil is cold. Warm oil should be even with arrows on sight glass. If level is low, add hydraulic oil. Refer to Hydraulic Oil Specifications (Fig. 51). 2 1. Remove seat lock pin, raise seat and hold open with support rod. 1 2. Clean around reservoir filler cap (Fig. 52).
Reel Motor 21 2 3 4 5 6 5 7 8 9 15 10 7 19 20 11 18 17 16 14 13 12 Figure 54 2. 3. 4. 5. 6. 7. Idler Gear Drive Gear Key O–Ring Body Dowel Pin 8. 9. 10. 11. 12. 13. 14. Plate & Bushing Assembly Socket Head Cap Screw Set Screw Drive Pulley Retaining Ring Shaft Seal Backup Washer Disassembly of Reel Motor 15. 16. 17. 18. 19. 20. 21. Relief Valve Kit O–Ring Plug Shim Spring Ball Back Plate/Relief Assembly 11.
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) 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. 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.
Steering Pump 7 1 11 2 12 4 13 10 3 4 19 14 15 16 17 18 20 21 9 8 2 6 16 22 26 25 24 23 Figure 55 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 12 4 13 10 3 4 19 14 15 16 17 18 20 21 9 8 2 6 16 22 26 25 24 23 Figure 56 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. 7.
Lift Control Valve 34 12 11 14 15 1 2 5 3 4 6 10 9 8 7 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 57 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 1 5 2 17 4 18 19 3 2 1 Figure 58 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 59 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 9 27 10 11 26 12 13 25 14 16 17 24 23 22 18 15 19 20 21 Figure 60 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.
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). 4. Remove screws (22) and lock washers (23). NOTE: All O–rings and back–up washers should be replaced as new parts. 5. Remove detent block (25).
Reel Shut Off Valve 1 5 6 8 2 5 6 9 7 7 4 1 2 3 Figure 61 1. 2. 3. 4. 5. Circlip Washer Spacer Spring Wiper Hydraulic System 6. 7. 8. 9.
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). 4. Remove washers (2), spring (4), and spacer (3) from spool (9). 1.
Traction Pump 6 19 15 16 17 18 13 20 12 9 8 4 22 10 46 21 11 24 45 14 7 1 23 25 26 2 27 32 28 29 30 40 35 42 43 5 39 34 41 33 37 3 38 31 48 44 47 36 Figure 62 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 9 8 4 22 10 46 21 11 24 45 14 7 1 23 25 26 2 27 32 28 29 30 40 35 42 43 5 39 34 41 33 37 3 38 31 48 44 47 36 Figure 63 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 9 8 4 22 10 46 21 11 24 45 14 7 1 23 25 26 2 27 32 28 29 30 40 35 42 43 5 39 34 41 33 37 3 38 31 48 44 47 36 Figure 64 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 65 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. 10. 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. 11. Remove shaft seal (11) from housing. Reassembly of Traction Motor 12. Remove washer (12) and drive shaft (10) from housing. 1. Lubricate all critical moving parts before assembly.
Reel Pump 14 15 13 12 7 11 8 6 12 7 5 4 3 1 2 10 9 18 17 16 Figure 66 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.
Disassembly of Reel Pump 2. Remove the retaining ring (18) with internal retaining ring pliers. 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. Remove seal retainer (6) and gland seal (5) from front cover (4) and discard. 6. Remove wear plate (7) from center section (8). 7.
14 15 13 12 7 11 8 6 12 7 5 4 3 1 2 10 9 18 17 16 Figure 67 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.
Reassembly of Reel Pump section and notch facing inlet port. Make sure wear plate and center section set flush against port section. 1. Assemble seal packs by inserting the seal glands (5) into the seal retainers (6). Install a seal pack into the cavity located on the face of the port section (13) with the seal retainer pointing up. 2. Place port section (13) in vise with studs (3) facing up. NOTE: The next five steps pertain to installation of front cover shaft seals (9 & 17).
Rear Wheel Drive Motor 8 6 7 1 1 1 5 4 1 2 9 3 10 11 12 13 Figure 68 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 69 2.
6. Remove 2 pins and 2 springs from balance ring assembly, see Fig. 73. 7. Remove balance ring assembly. 8. Remove inner and outer face seals from balance ring. 9. Remove the valve. Figure 73 10. Remove the valve plate. 11. Remove the 3[76] diameter seal from valve plate. 12. Remove the valve drive. Figure 74 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. 75. Figure 75 16.
19. You may need a press to remove shaft and bearing assembly from bearing housing. (Key must be removed before removing shaft.) Figure 77 20. Use a small screwdriver to remove shaft seal, back– up washer and exclusion seal from bearing housing, see Fig. 78. Do not damage bore of housing. NOTE: Individual parts of shaft and bearing assembly are not sold separately. Replace as a unit. Figure 78 Hydraulic System Check all mating surfaces.
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. 79. Do not distort seal. 28. Install the wear plate, see Fig. 79. 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 Geroter 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. 83. IMPORTANT: Install face seals in the positions shown in Fig. 83. 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 83 39. Insert your finger through port of valve housing.
Wheel Motor On wheel motors, a different bearing housing is used, see Fig. 87. Other than this the parts are the same as the standard motor and the same disassembly and reassembly procedures apply.
Rear Wheel Drive Valve 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 Figure 88 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.
Steering Cylinder 1 2 3 4 5 6 7 8 10 11 12 13 14 15 16 17 9 18 Figure 90 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 Steering Cylinder Repair 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.
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 stops draining (Fig. 91). 2 2. Fill reservoir with approximately 9.3 gallons of hydraulic oil.
Replace Hydraulic Oil Filter Initially, change filter after the first 50 operating hours, thereafter, every 800 operating hours, annually, or on indication. Use Toro replacement filter (Part No. 86–6110). 2 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 magnets) ahead of the seat. 2. Clean area around filter mounting area (Fig. 93).
This Page Intentionally Left Blank Hydraulic System Page 4 – 92 Reelmaster 4000–D
Chapter 5 Electrical System Table of Contents Reelmaster 4000–D COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glow Plug and Start Relays . . . . . . . . . . . . . . . . . Audio Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alarm Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page 5 – 2 Y R Start B+ BU 12 VOLT BATTERY STARTER L IG B ALTERNATOR PULL W R/BK FUSIBLE LINK SP R R Y R SP 87 BK VIO VIO BK IGNITION SWITCH T W VIO BN VIO 5 A FUSE RED W SEAT SWITCH (OPERATOR NOT PRESENT) 5 OHM R ORANGE 6500 MFD GY 7.5 A FUSE GRAY GY OR FUSIBLE LINK FL BLUE BU DARK GREEN BROWN DKGN ENGINE OVER TEMP. (OPENS AT 110 C) NC C OR OR S X A Y B OR I STOP –––– NONE RUN –––– B+I+A, X+Y START ––– B+I+S HYD. OIL LEVEL SW.
Reelmaster 4000–D Page 5 – 3 Electrical System (Rev. A) Electrical System All relays and solenoids are shown as de–energized. All ground wires are black.
Electrical System (Rev.
WIRE IDENTIFICATION LABELCOLOR ROUTE LABELCOLOR AWG TYPE ROUTE W1. R–66467 J15, SP1 W33. BRN P4–1, J20 W2. RED SP1, J19 W34. WHT P4–2, P9–1 BLU P4–3, P10–1 W3. R–66465 J15, SP2 W35. W4. RED SP2, J24 W36. RED P4–4, J2 W5. WHT J12, P2–B W37. BRN P7–2, J14 W6. RED J25, P12–1 W38. VIO P11–2, J17 W7. RED/BLK P12–2, P6–2 W39. VIO P11–2, P7–5 W8. RED J11, J9 W40. WHT P11–1, P5–A W9. RED/BLK J10, J3 W41. WHT P11–1, P7–3 W42. YEL P7–4, P5–C W43.
Electrical System (Rev.
Reelmaster 4000–D Page 5 – 7 Electrical System (Rev.
BLACK BLACK BLACK GREEN BLACK BLACK ORANGE RED BROWN BLACK/WHITE BLACK/WHITE BROWN BLUE BLK/WH BLACK BLUE GREEN BLACK/WHITE ORANGE TAN ORANGE WHITE BLACK WHITE BLUE RED BLACK BLK/WH BLUE YELLOW RED/BLACK VIOLET VIOLET VIOLET WHITE TAN W22 BLACK BLACK BLACK BLACK VIOLET ORANGE BLUE BROWN YELLOW BLK/WH VIOLET GREEN WHITE TAN Reelmaster 4000–D Main Harness Wiring Diagram (S/N 220000001 and up) RED/BLACK ORANGE ORANGE WHITE ORANGE BLACK BLACK/WHITE BLACK/WHITE BLK/WH BLACK RE
Reelmaster 4000–D Control Panel Harness Drawing P8 HOUR METER C(–) A(+) IGNITION SWITCH P2 MAIN HARNESS Electrical System J5 Reelmaster 4000–D Page 5 – 9 1 3 P1 MAIN HARNESS 2 REEL DRIVE P5 HARNESS 4 5 B A 6 J6 HIGH TEMP OVERIDE 1 P4 2 FUEL GAUGE 3 4 5 6 1 2 3 XXXXXXX J2 XXXXXXX J1 4WD SWITCH 3 2 1 P6 4 5 J7 B A B P7 GLOW INDICATOR 1 3 ROUTE P2–1, J7 P2–2, P6–2 P2–3, J1 P2–4, P4–3 P2–5, P6–1 P6–1, J6 P1–1, J2 P1–2, –6–3 P1–3, P6–4 P1–4, P7–A P7–A, P3–3 P3–3, P4–1 P4–1, P
Electrical System (Rev.
2 ALARM TEST SWITCH Reelmaster 4000–D Light Cluster Harness Drawing P3 1 3 4 5 J21 J17 J8 J7 J3 J4 SILENCE ALARM SWITCH J2 ALARM ALARM (+) ROUTE P5–4, J16 P5–3, J14 1P5–2, J15 P5–1, J13 J16, P2–5 J14, P2–4 J15, P2–1 J13, P2–2 P2–3, P2–6 P2–3, P1–3 P2–6, P3–1 P1–3, P1–6 1P4–4, J10 P4–2, J12 1P4–3, J11 P4–1, J9 J10, P1–4 J12, P1–5 J11, P1–1 1J9, P1–2 1P1–6, J1 1P3–5, J2 1P3–2, J5 1J17, J18 1J18, J19 J19, J20 1J20, J3 1J21, J22 1J22, J23 1J23, J24 J8, J24 J8, J5 J6, P3–3 1J2, J7 J7, P3–4 J1, P4–6
Electrical System (Rev.
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. 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.
Troubleshooting For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components used on this machine (see Electrical Schematics and Diagrams 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.
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.
General Run and Transport Problems Engine continues to run (but should not) when parking brake is released or mow–backlap lever is in mow 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).
Electrical System Quick Check Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the battery terminals. Set multimeter to the DC volts setting. The battery should be at a temperature of 60 to 100oF (16 to 38oC). The ignition key should be off and all accessories turned off. Connect the positive (+) meter lead to the positive battery post and the negative (–) meter lead the the negative battery post. Voltage Measured Battery Charge Level 12.
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). NOTE: For more component testing information, see the Kubota Workshop Manual for 03 Series Diesel Engine. CAUTION When testing electrical components for continuity with a multimeter (ohms setting), make sure that power to the circuit has been disconnected.
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.
Alarm Relay The alarm relay is located inside the steering tower. 1. Verify coil resistance between terminals 86 and 85 with a multimeter (ohms setting). Resistance should be from 80 to 90 ohms. There should be continuity between terminals 87A and 30. 2. 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 applied and removed from terminal 85.
Fuel Sender The sender is located on top of the fuel tank under the rear screen. 2 1 1. Remove gray wire and black ground wire from the sender. 3 4 2. Remove truss head screws and lock washers from the sender and fuel tank. 3. Remove sender and gasket from the fuel tank. Clean any fuel from the sender. Note: Before taking small resistance readings with a digital multimeter, short test leads together. The meter will display a small resistance value.
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 engine. It energizes a red warning light when too much water has collected in the fuel filter bowl. 2 1. Make sure engine is OFF. Disconnect fuel stop solenoid from the wiring harness. 7 2. Disconnect connector from the sensor. Verify circuitry to the sensor at the connector using a multimeter and the following steps: 6 A. Place ignition switch in RUN.
High Temperature Warning and Cutout Switches The high temperature warning and cutout switches are located on the water return pipe above the water pump, which is located on the rear end of the engine block. The warning switch has a green/white wire connected to it. The cutout switch has two orange wires and a violet wire connected to it (Fig. 16). 2 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. 2.
Rear Wheel Drive Solenoid 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 meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal resistance 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.
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 meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal resistance of the meter and test leads. Subtract this value from from the measured value of the component you are testing. 1.
Hydraulic Oil Level Switch The level switch is located on top of the hydraulic reservoir 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.
Glow Controller The controller is located under the right lower corner of the instrument panel. 2 Controller Operation When the ignition switch is placed in the RUN position, the controller energizes the glow plugs and lights up the glow lamp for 10 seconds. When the ignition switch is held in the START position, the glow plugs will energize while the switch is held in START and the glow lamp will not light.
Hydraulic Oil Filter Switch The oil filter switch is activate by the differential pressure across the oil filter. When differential pressure is between 16 to 20 PSID, a normally open contact closes. An alarm sounds and a warning light comes on at the instrument panel. When the differential pressure drops between 16 to 12 PSID the switch contact opens and the alarm and light go out. 1 2 The purpose of the oil filter switch, warning light, and alarm is to detect a clogged oil filter.
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.
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 caution 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.
terminals. B. Temperature correct each cell reading. For each 10oF (5.5oC) above 80oF (26.7oC) add 0.004 to the specific gravity reading. For each 10oF (5.5oC) below 80oF (26.7oC) subtract 0.004 from the specific gravity reading. Example: Cell Temperature G. Take a voltage reading at 15 seconds, then remove the load. 100oF 1.245 H. Using the table below, determine the minimum voltage for the cell temperature reading. 100oF minus 80oF equals 20oF (37.7oC minus 26.7oC equals 11.0oC) 20oF multiply by 0.
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 amp. If the reading is 0.1 amp or more, the unit’s electrical system should be tested and repaired. 8. Connect negative (ground) cable connector to the negative battery post. Tighten cap screw and lock nut with two wrenches.
Rear Wheel Drive Solenoid Replacement Electrical System Figure 28 1. Disconnect solenoid electrical connector. 2. Remove nut from solenoid. 3. Remove solenoid coil. 4. Install new solenoid coil. Make sure o–ring is installed at each end of coil. Apply ”Loctite 242” or equivalent 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.
Check Interlock System 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 properly. Even if the switches are operating properly, replace them every two years to assure maximum safety. 1. In a wide open area free of debris and bystanders, lower cutting units to the ground. Stop engine. 2. Sit on the seat and engage parking brake.
Chapter 6 Axles and Brakes Table of Contents 2 3 3 4 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 5 Rear Wheel Bearings (2WD Only) . . . . . . . . . . . . . . 5 Planetary Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . 7 Axles and Brakes SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hand Brake and Traction Switches . . . . . . . . . . . . . Rear Wheel Toe–In . . . . . . . . . .
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. Axles and Brakes 2.
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.
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 outward. NOTE: Make sure tie rod clamps are positioned so they do not interfere with steering linkage. Figure 3 4.
Service and 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 42 35 3433 31 49 29 7 28 29 39 38 8 30 9 10 37 11 12 13 14 15 36 27 26 25 24 22 23 21 20 RIGHT FRONT 19 50 17 18 16 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
1. Jack up rear of machine until tire is off the. Support machine with jack stands or blocks to prevent it from falling (see Jacking Instructions in Chapter 1 – Safety). 11. Adjust preload on the wheel bearings (Fig. 6). A. Tighten jam nut from 75 to 80 in–lb (86 to 270 kg– cm) while turning the hub to seat the bearings and remove all end play. 2. Remove dust cap (16) from the end of the wheel spindle. B. Loosen jam nut until it is away from the tab washer and the hub has end play.
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 Coupling Input shaft Spindle Oil seal Bearing cone Bearing cup Wheel bolt Hub Bearing cone Hex head bolt 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Flat washer Thrust washer Primary sun gear Hex head bolt Primary carrier assembly Pipe plug Hex head bolt Disengage cover Large cover Secondary carrier assembly 21. 22. 23. 24. 25. 26. 27. 28. 29.
Disassemble Planetary Wheel Drive 1. Slide coupling (1) from the splines on the input shaft (2). 2. Position assembly upright on the face of spindle (3). Remove disengage cover (18). 3. Remove bolts (17) and large cover (19). The disengage plunger (22) usually remains with the cover. Remove plunger and O–ring from the cover on the end of the input shaft. 4. A thrust washer (23) will usually remain in position on the thrust face of the cover. 5.
Chapter 7 Cutting Units Table of Contents 2 3 4 4 5 6 7 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 8 Backlapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Hydraulic Motor Installation . . . . . . . . . . . . . . . . . . . 9 Bedknife/Bedbar . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Preparing a Reel for Grinding . . . . . . . . . . . . . . . .
Specifications 2 1 4 11 6 3 5 7 8 10 9 Figure 1 1. 2. 3. 4. Drive housing cover drive housing Drive plate shield Grass deflector 5. 6. 7. 8. Rear roller adjuster (both ends) Reel–to–bedknife adjuster Guard cone nut Construction: The frame is welded steel. The reel uses heavy duty, self–aligning ball bearings. The heavy duty steel rear roller has tapered roller bearings. The rear roller and bedbar are isolated and mounted in rubber bushings for quiet, vibration–free operation.
Special Tools Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Some tools may be listed in the Reelmaster 4000–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 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.
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. Adjust Reel to Bedknife Contact The cutting units will provide optimum mowing performance when adjusted and maintained correctly. Keeping a precise reel to bedknife adjustment (light contact), at each end of the cutting unit will produce a continual self–sharpening action.
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).
3. Make final height–of–cut adjustment with gauge bar. A. Raise cutting units and lock in the transport position. Shut off the engine and remove the key from the ignition switch. B. Use gauge bar (Toro Part No. 59–7900) to set final 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). Tighten jam nut to secure the adjustment.
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.
Service and Repairs CAUTION Never remove, install, or work on the cutting units or lift arms with the traction unit engine running. 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 the engine and reels are operating.
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).
Bedknife/Bedbar Disassembly 1. Remove shoulder bolts, bushings and spacers from each end of the unit. Remove bedbar/bedknife assembly (Fig. 16). 2. Remove mounting screws for the bedknife. Separate bedknife from the bedbar. Discard screws (Fig. 17). Assembly 1. Clean bedknife mounting face on the bedbar thoroughly of all rust and scale. Remove any material on the mounting face of the bedbar that will affect a good match–up with the bedknife. Figure 16 1. Shoulder bolt (2 each side) 2. Bushing 3.
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 handle assembly from the side plate (Fig. 21). 4. Disassemble cone nut from the shoulder bolt securing the bearing housing to the side plate.
6. Disassemble cover from the drive housing and remove the drive belt from the housing (Fig. 23). Note: Reel capscrew is assembled with a thread locking 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, belleville washer, and shoulder bolt securing the drive housing to the side plate.
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 assembly through the seal from the opposite side (Fig 23). 3.
Preparing a Reel for Grinding Note: Check to make sure the reel bearings are in good condition before grinding the reel. Make sure the cutting unit frame and roller brackets are true and not bent or damaged. 4. After completing the grinding process: A. Install parts that were removed to mount the cutting unit onto grinder. 1. Remove the bedbar assembly (Bedknife/Bedbar Disassembly). B. Install bedbar assembly (see Bedknife/Bedbar Assembly). 2.
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 either 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) A. Unscrew upper cone nut from the collar assembly.
Roller Bearing Replacement 3 6 8 10 12 1 4 7 9 11 2 11 9 7 5 12 10 8 6 Figure 28 1. 2. 3. 4. Roller tube (front roller shown) Roller shaft Grease fitting Lock nut 5. 6. 7. 8. Jam nut Trust washer Outer grease seal Wear sleeve 9. 10. 11. 12. O–ring Bearing cone Bearing cup Inner grease seal Removal 1. Clean roller around the shaft, grease fittings, and bearing thoroughly. Both ends of the roller should be free of dirt and debris. 2. Secure roller tube in a vise keeping it level. 3.
3. On the rear, wiehle, and sectional rollers, press new inner grease seals into the roller tube with the garter spring of the seal facing towards the center of the roller (Fig. 30). 4 1 2 8 7 12 4. Press both bearing cups into the roller tube with the 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 7.
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 after washing the machine. This helps to minimize water 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.
Commercial Products The Toro Company