Page 1
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. Replacement Operator’s Manuals are
available by sending complete Model and Serial Number to:
PART NO. 98958SL (Rev. C)
Service Manual
Reelmaster 4000−D
This safety symbol means DANGER, WARNING,
or CAUTION, PERSONAL SAFETY INSTRUCTION. When you see this symbol, carefully read
the instructions that follow. Failure to obey the
instructions may result in personal injury.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing, or repair of the machine.
The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420−1196
The Toro Company reserves the right to change product
specifications or this publication without notice.
IMPORTANT: The IMPORTANT notice will give important instructions which must be followed to prevent damage to systems or components on the
machine.
The Toro Company − 1998, 2003, 2005, 2007
Page 2
Reelmaster 4000−D
Page 3
Table Of Contents
Chapter 1 − Safety
General Safety Instructions 1 − 1. . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 1 − 4. . . . . . . . . . . . . . . .
Chapter 2 − Product Records and Maintenance
Product Records 2 − 1. . . . . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions 2 − 2. . . . . . . . . . . . . . . .
Torque Specifications 2 − 3. . . . . . . . . . . . . . . . . . . . . . .
Lubrication 2 − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 3 − Kubota Diesel Engine
Introduction 3 − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 3 − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information 3 − 4. . . . . . . . . . . . . . . . . . . . . . . .
Adjustments 3 − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs 3 − 8. . . . . . . . . . . . . . . . . . . . . . . .
KUBOTA WORKSHOP MANUAL, 03 SERIES,
DIESEL ENGINE
Chapter 4 − Hydraulic System
Specifications 4 − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General 4 − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Schematic 4 − 8. . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Flow Diagrams 4 − 9. . . . . . . . . . . . . . . . . . . .
4WD Selector Valve Operation 4 − 24. . . . . . . . . . . . . .
Special Tools 4 − 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 4 − 28. . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing 4 − 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs 4 − 39. . . . . . . . . . . . . . . . . . . . . . .
Chapter 5 − Electrical System
Electrical Schematics and Diagrams 5 − 2. . . . . . . . . .
Special Tools 5 − 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 5 − 16. . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical System Quick Check 5 − 19. . . . . . . . . . . . . .
Component Testing 5 − 20. . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs 5 − 31. . . . . . . . . . . . . . . . . . . . . . .
Chapter 6 − Axles and Brakes
Specifications 6 − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments 6 − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs 6 − 5. . . . . . . . . . . . . . . . . . . . . . . .
SafetyProduct Records
and Maintenance
Engine
Kubota Diesel
Chapter 7 − Cutting Units
Specifications 7 − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 7 − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments 7 − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs 7 − 8. . . . . . . . . . . . . . . . . . . . . . . .
System
Hydraulic
System
Electrical
Brakes
Axles andCutting Units
Reelmaster 4000−D
Rev. C
Page 4
Reelmaster 4000−D
Page 5
Reelmaster 4000−D
Page 1 − 1
Safety
Chapter 1
Safety
Table of Contents
GENERAL SAFETY INSTRUCTIONS 1. . . . . . . . . . . .
Before Operating 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
While Operating 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and Service 3. . . . . . . . . . . . . . . . . . . .
SAFETY AND INSTRUCTION DECALS 4. . . . . . . . . .
General Safety Instructions
The Reelmaster 4000−D was tested and certified by
TORO for compliance with the B71.4−1984 specifications of the American National Standards Institute for
riding mowers when rear tires are filled with calcium
chloride and two rear wheel weight kits. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine,
these factors are also dependent upon the awareness,
concern, and proper training of the personnel involved
in the operation, transport, maintenance, and storage of
the machine. Improper use or maintenance of the machine can result in injury or death.
WARNING
To reduce the potential for injury or death,
comply with the following safety instructions.
Before Operating
1. Read and understand the contents of the traction
unit and cutting unit operator’s manuals before operating the machine. To get replacement manuals, send
complete model and serial number to:
The Toro Company
8111 Lyndale A venue South
Minneapolis, MN 55420−1196
2. Never allow children to operate the machine or
adults to operate it without proper instruction.
3. Become familiar with the controls and know how to
stop the machine and engine quickly.
4. Keep all shields, safety devices and decals in place.
If a shield, safety device or decal is defective or damaged, repair or replace it before operating the machine.
5. Always wear substantial shoes. Do not operate machine while wearing sandals, tennis shoes, sneakers or
when barefoot. Do not wear loose fitting clothing that
could get caught in moving parts and possibly cause
personal injury.
6. Wearing safety glasses, safety shoes, long pants
and a helmet is advisable and required by some local ordinances and insurance regulations.
7. Make sure the work area is clear of objects which
might be picked up and thrown by the reels.
8. Do not carry passengers on the machine. Keep everyone, especially children and pets, away from the
areas of operation.
9. Since diesel fuel is highly flammable, handle it carefully:
A. Use an approved fuel container.
B. Do not remove fuel tank cap while engine is hot
or running.
C. Do not smoke while handling fuel.
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.
E. Wipe up any spilled fuel.
Safety
Page 6
Reelmaster 4000−D
Page 1 − 2
Safety
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. Ear protectors are recommended for prolonged exposure to reduce the potential
of permanent hearing damage.
14. Before starting the engine each day, test lamps,
warning buzzer and signal lights to assure proper operation.
15. Pay attention when using the machine. To prevent
loss of control:
A. Mow only in daylight or when there is good artificial light.
B. Watch for holes or other hidden hazards.
C. Be extremely careful when operating close to
sand traps, ditches, creeks, steep hillsides or other
hazards.
D. Reduce speed when making sharp turns. Avoid
sudden stops and starts. Use ground speed limiter
lever to set pedal travel so excessive ground speed
will be avoided during mowing and transport.
E. Look to the rear to assure no one is behind the
machine before backing up.
F. Watch for traf fic when near or crossing roads. A l ways yield the right−of−way.
G. Reduce speed when driving downhill.
16. Keep hands, feet, andclothing away from moving
parts and the reels.
17. Traverse slopes carefully. Do not start or stop suddenly when traveling uphill or downhill.
18. Operator must be skilled and trained in how to drive
on hillsides. Failure to use caution on slopes or hills may
cause loss of control and vehicle to tip or roll possibly resulting in personal injury or death.
19. When operating 4 wheel drive machine, always use
the seat belt and ROPS together and have seat pivot retaining pin installed.
20. If engine stalls or loses headway and cannot make
it to the top of a slope, do not turn machine around. Always back slowly straight down the slope.
21. Raise cutting units and latch them securely in transport position before driving from one work area to another.
22. Do not touch engine, muffler or exhaust pipe while
engine is running or soon after it is stopped. These areas
could be hot enough to cause burns.
23. If cutting unit strikes a solid object or vibrates abnormally, stop immediately, turn engine off, set parking
brake and wait for all motion to stop. Inspect for damage.
If reel or bedknife is damaged, repair or replace it before
operating. Do not a t t e m p t t o free blocked cutting unit by
moving Mow/Backlap lever rapidly between FORWARD
and BACKLAP. Damage to hydraulic system may result.
Lever should easily return and hold in the STOP position.
24. Before getting off the seat:
A. Move traction pedal to neutral.
B. Set parking brake.
C. Disengage cutting units and wait for reels to
stop.
D. Stop engine and remove key from switch.
E. Do not park on slopes unless wheels are
chocked or blocked.
25. The optional TORO tow bar is for emergency towing
only. Use only the special tow bar if it becomes necessary to tow machine. Use trailer for normal transport.
Page 7
Reelmaster 4000−D
Page 1 − 3
Safety
Maintenance and Service
26. Before servicing or making adjustments, stop engine and remove key from the switch.
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. Hydraulic
fluid escaping under pressure can penetrate skin and
cause injury. Fluid accidentally injected into the skin
must be surgically removed within a few hours by a doctor or gangrene may occur.
30. Before any hydraulic system maintenance, stop engine and lower cutting units to the ground so all pressure
is relieved.
31. For major repairs or other assistance, contact your
local Toro Distributor.
32. To reduce potential fire hazard, keep engine area
free of excessive grease, grass, leaves and dirt. Clean
protective screen on back of engine frequently.
33. If engine must be running to perform maintenance
or an adjustment, keep hands, feet, clothing and other
parts of the body away from cutting units and other moving parts. Keep everyone away.
34. Do not overspeed the engine by changing governor
setting. Maximum engine speed is 2500 rpm + or − 100
rpm. To assure safety and accuracy , have an Authorized
Toro Distributor check maximum engine speed.
35. Shut engine off before checking or adding oil to the
crankcase.
36. Disconnect battery before servicing the machine. If
battery voltage is required for troubleshooting or test
procedures, temporarily connect the battery.
37. Toro recommends that two people be used to backlap reels. Each person has specific duties and you must
communicate with one another.
38. For optimum performance and safety, use genuine
Toro replacement parts and accessories. Replacement
parts and accessories made by other manufacturers
could be dangerous and may void the product warranty
of The Toro Company.
39. When changing attachments, tires, or performing
other service, use correct blocks, hoists, and jacks.
Make sure machine is parked on a solid level floor such
as a concrete floor. Prior to raising the machine, remove
any attachments that may interfere with the safe and
proper raising of the machine. Always chock or block
wheels. Used jack stands or solid wood blocks to support the raised machine. If the machine is not properly
supported by blocks or jack stands, the machine may
move or fall, which may result in personal injury.
Safety
Page 8
Rev. C
Reelmaster 4000−D
Page 1 − 4
Safety
Safety and Instruction Decals
Numerous safety and instruction decals are affixed to
the Reelmaster 4000−D. If any decal becomes illegible
or damaged, install a new decal. Part numbers for replacement decals are listed in your Parts Catalog. Order
replacement decals from your Authorized Toro Distributor.
Page 9
Rev. C
Reelmaster 4000−D
Page 2 − 1
Product Records and Maintenance
Chapter 2
Product Records and Maintenance
Table of Contents
PRODUCT RECORDS 1. . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EQUIVALENTS AND CONVERSIONS 2. . . . . . . . . . .
Decimal and Millimeter Equivalents 2. . . . . . . . . . . .
U.S. to Metric Conversions 2. . . . . . . . . . . . . . . . . . .
TORQUE SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . .
Fastener Identification 3. . . . . . . . . . . . . . . . . . . . . . .
Standard Torque for Dry, Zinc Plated, and
Steel Fasteners (Inch Series) 4. . . . . . . . . . . . . . .
Standard Torque for Dry, Zinc Plated, and
Steel Fasteners (Metric Fasteners) 5. . . . . . . . . .
Other Torque Specifications 6. . . . . . . . . . . . . . . . . .
Conversion Factors 6. . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product Records
Insert Operator’s Manual and Parts Catalog for your Reelmaster 4000−D at the end of this chapter . Additionally,
if any optional equipment or accessories have been
installed to your machine, insert the Installation Instructions, Operator’s Manuals and Parts Catalogs for those
options at the end of this chapter.
Maintenance
Maintenance procedures and recommended service intervals for the Reelmaster 4000−D are covered in the
Operator’s Manual. Refer to that publication when performing regular equipment maintenance.
Product Records
and Maintenance
Page 10
0.09375
Rev. C
Reelmaster 4000−D
Page 2 − 2
Product Records and Maintenance
Equivalents and Conversions
Page 11
Rev. C
Reelmaster 4000−D
Page 2 − 3
Product Records and Maintenance
Torque Specifications
Recommended fastener torque values are listed in the
following tables. For critical applications, as determined
by Toro, either the recommended torque or a torque that
is unique to the application is clearly identified and specified in this Service Manual.
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. The following factors shall be considered
when applying torque: cleanliness of the fastener, use
of a thread sealant (Loctite), degree of lubrication on the
fastener, presence of a prevailing torque feature, hardness of the surface underneath the fastener’s head, or
similar condition which affects the installation.
As noted in the following tables, torque values should be
reduced by 25% for lubricated fasteners to achieve
the similar stress as a dry fastener. Torque values may
also have to be reduced when the fastener is threaded
into aluminum or brass. The specific torque value
should be determined based on the aluminum or brass
material strength, fastener size, length of thread engagement, etc.
The standard method of verifying torque shall be performed by marking a line on the fastener (head or nut)
and mating part, then back off fastener 1/4 of a turn.
Measure the torque required to tighten the fastener until
the lines match up.
Fastener Identification
Grade 1 Grade 5 Grade 8
Inch Series Bolts and Screws
Class 8.8 Class 10.9
Metric Bolts and Screws
Product Records
and Maintenance
Page 12
Reelmaster 4000−D
Page 2 − 4
Product Records and Maintenance
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)
SAE Grade 5 Bolts, Screws, Studs, &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
SAE Grade 8 Bolts, Screws, Studs, &
Sems with Regular Height Nuts
(SAE J995 Grade 5 or Stronger Nuts)
in−lb in−lb N−cm in−lb N−cm in−lb N−cm
# 6 − 32 UNC
15 + 2 170 + 20 23 + 2 260 + 20
# 6 − 40 UNF
10 + 2
13 + 2
147 + 23
17 + 2 190 + 20 25 + 2 280 + 20
# 8 − 32 UNC
29 + 3 330 + 30 41 + 4 460 + 45
# 8 − 36 UNF
13 + 2
25 + 5
282 + 30
31 + 3 350 + 30 43 + 4 485 + 45
# 10 − 24 UNC
42 + 4 475 + 45 60 + 6 675 + 70
# 10 − 32 UNF
18 + 2
30 + 5
339 + 56
48 + 4 540 + 45 68 + 6 765 + 70
1/4 − 20 UNC 48 + 7 53 + 7 599 + 79 100 + 10 1125 + 100 140 + 15 1580 + 170
1/4 − 28 UNF 53 + 7 65 + 10 734 + 113 115 + 10 1300 + 100 160 + 15 1800 + 170
5/16 − 18 UNC 115 + 15 105 + 17 1186 + 169 200 + 25 2250 + 280 300 + 30 3390 + 340
5/16 − 24 UNF 138 + 17 128 + 17 1446 + 192 225 + 25 2540 + 280 325 + 30 3670 + 340
ft−lb ft−lb N−m ft−lb N−m ft−lb N−m
3/8 − 16 UNC 16 + 2 16 + 2 22 + 3 30 + 3 41 + 4 43 + 4 58 + 5
3/8 − 24 UNF 17 + 2 18 + 2 24 + 3 35 + 3 47 + 4 50 + 4 68 + 5
7/16 − 14 UNC 27 + 3 27 + 3 37 + 4 50 + 5 68 + 7 70 + 7 95 + 9
7/16 − 20 UNF 29 + 3 29 + 3 39 + 4 55 + 5 75 + 7 77 + 7 104 + 9
1/2 − 13 UNC 30 + 3 48 + 7 65 + 9 75 + 8 102 + 11 105 + 10 142 + 14
1/2 − 20 UNF 32 + 3 53 + 7 72 + 9 85 + 8 115 + 11 120 + 10 163 + 14
5/8 − 11 UNC 65 + 10 88 + 12 119 + 16 150 + 15 203 + 20 210 + 20 285 + 27
5/8 − 18 UNF 75 + 10 95 + 15 129 + 20 170 + 15 230 + 20 240 + 20 325 + 27
3/4 − 10 UNC 93 + 12 140 + 20 190 + 27 265 + 25 359 + 34 375 + 35 508 + 47
3/4 − 16 UNF 115 + 15 165 + 25 224 + 34 300 + 25 407 + 34 420 + 35 569 + 47
7/8 − 9 UNC 140 + 20 225 + 25 305 + 34 430 + 45 583 + 61 600 + 60 813 + 81
7/8 − 14 UNF 155 + 25 260 + 30 353 + 41 475 + 45 644 + 61 660 + 60 895 + 81
Note: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
oil, graphite, or thread sealant such as Loctite.
Note: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Note: The nominal torque values listed above for
Grade 5 and 8 fasteners are based on 75% of the minimum proof load specified in SAE J429. The tolerance is
approximately +
10% of the nominal torque value. Thin
height nuts include jam nuts.
Page 13
Rev. C
Reelmaster 4000−D
Page 2 − 5
Product Records and Maintenance
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners)
Class 8.8 Bolts, Screws, and Studs with
Class 10.9 Bolts, Screws, and Studs with
Thread Size
Regular Height Nuts
(Class 8 or Stronger Nuts)
Regular Height Nuts
(Class 10 or Stronger Nuts)
M5 X 0.8 57 + 5 in−lb 640 + 60 N−cm 78 + 7 in−lb 885 + 80 N−cm
M6 X 1.0 96 + 9 in−lb 1018 + 100 N−cm 133 + 13 in−lb 1500 + 150 N−cm
M8 X 1.25 19 + 2 ft−lb 26 + 3 N−m 27 + 2 ft−lb 36 + 3 N−m
M10 X 1.5 38 + 4 ft−lb 52 + 5 N−m 53 + 5 ft−lb 72 + 7 N−m
M12 X 1.75 66 + 7 ft−lb 90 + 10 N−m 92 + 9 ft−lb 125 + 12 N−m
M16 X 2.0 166 + 15 ft−lb 225 + 20 N−m 229 + 22 ft−lb 310 + 30 N−m
M20 X 2.5 325 + 33 ft−lb 440 + 45 N−m 450 + 37 ft−lb 610 + 50 N−m
Note: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
oil, graphite, or thread sealant such as Loctite.
Note: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Note: The nominal torque values listed above are
based on 75% of the minimum proof load specified in
SAE J1199. The tolerance is approximately +
10% of the
nominal torque value.
Product Records
and Maintenance
Page 14
Reelmaster 4000−D
Page 2 − 6
Product Records and Maintenance
Other Torque Specifications
SAE Grade 8 Steel Set Screws
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
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23, or Type F
Thread Size Baseline Torque*
No. 6 − 32 UNC 20 + 5 in−lb
No. 8 − 32 UNC 30 + 5 in−lb
No. 10 − 24 UNC 38 + 7 in−lb
1/4 − 20 UNC 85 + 15 in−lb
5/16 − 18 UNC 110 + 20 in−lb
3/8 − 16 UNC 200 + 100 in−lb
Wheel Bolts and Lug Nuts
Thread Size
Recommended Torque**
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 8.8
80 + 10 ft−lb 108 + 14 N−m
M12 X 1.5
Class 8.8
80 + 10 ft−lb 108 + 14 N−m
** For steel wheels and non−lubricated fasteners.
Thread Cutting Screws
(Zinc Plated Steel)
Thread
Threads per Inch
Size
Type A Type B
Baseline Torque*
No. 6 18 20 20 + 5 in−lb
No. 8 15 18 30 + 5 in−lb
No. 10 12 16 38 + 7 in−lb
No. 12 11 14 85 + 15 in−lb
* Hole size, material strength, material thickness & finish
must be considered when determining specific torque
values. All torque values are based on non−lubricated
fasteners.
Conversion Factors
in−lb X 11.2985 = N−cm N−cm X 0.08851 = in−lb
ft−lb X 1.3558 = N−m N−m X 0.7376 = ft−lb
Page 15
Rev. C
Reelmaster 4000−D
Page 2 − 7
Product Records and Maintenance
Lubrication
GREASING BEARINGS AND BUSHINGS
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). Also, grease fitting on
reel control valve (not shown), located under right
hand console.
Lift arms (5 fittings total)
Figure 1
Rear Axle (3 Fittings per side)
Figure 2
Note: Remove plastic caps over the fittings on the
floating or fixed head pivots and replace caps after
greasing (Fig. 3).
Floating of Fixed Kit Pivots (1 fitting per head)
(Floating Kit Shown)
Figure 3
Reel and Roller Bearings
(2 fittings per reel & 2 fittings per roller)
Figure 4
1. Park machine on a level surface. Stop engine. Remove key from the ignition switch.
2. Wipe grease fitting clean so foreign matter cannot
be forced into the bearing or bushing.
3. Pump grease into the bearing or bushing.
4. Wipe up excess grease.
Product Records
and Maintenance
Page 16
Rev. C
Reelmaster 4000−D
Page 2 − 8
Product Records and Maintenance
This Page Intentionally Left Blank
Page 17
Reelmaster 4000−D Page 3 − 1 Kubota Diesel Engine
Chapter 3
Kubota Diesel Engine
Table of Contents
INTRODUCTION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION 4. . . . . . . . . . . . . . . . . . . . .
Check Engine Oil 4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Cooling System 5. . . . . . . . . . . . . . . . . . . . . . .
Fill Fuel Tank 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prime Fuel System 6. . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTMENTS 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjust Alternator Belt 7. . . . . . . . . . . . . . . . . . . . . . . .
SERVICE AND REPAIRS 8. . . . . . . . . . . . . . . . . . . . . .
Service Air Cleaner 8. . . . . . . . . . . . . . . . . . . . . . . . . .
Change Engine Oil and Filter 9. . . . . . . . . . . . . . . . .
Drain Fuel System 10. . . . . . . . . . . . . . . . . . . . . . . . .
Check Fuel Lines and Connections 11. . . . . . . . . . . .
Replace Fuel Filters 11. . . . . . . . . . . . . . . . . . . . . . . . .
Engine Cooling System 12. . . . . . . . . . . . . . . . . . . . .
Engine 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Removal 13. . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Installation 16. . . . . . . . . . . . . . . . . . . . . . . .
KUBOTA WORKSHOP MANUAL, 03 SERIES, DIESEL
ENGINE
Kubota Diesel
Engine
Page 18
Reelmaster 4000−D
Page 3 − 2
Kubota Diesel Engine
Introduction
This Chapter gives information about specifications,
maintenance, troubleshooting, testing, and repair of the
diesel engine used in the Reelmaster 4000−D.
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. 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 an engine repair facility.
Service and repair parts for Kubota diesel engines are
supplied through your local Kubota dealer or distributor.
If no parts list is available, be sure to provide your distributor with the Toro model and serial number.
Page 19
Reelmaster 4000−D Page 3 − 3 Kubota Diesel Engine
Specifications
Item Description
Make / Designation Kubota, V2203, 4−Cylinder, 4−Cycle,
Water Cooled, In−line, Spherical Chamber, OHV, Diesel Engine
Horse Power 39.4 HP @ 2300 RPM
Torque 103 ft−lb @ 1600 RPM
Firing Order 1 − 3 − 4 − 2
Bore mm (in.) 87.0 (3.43)
Stroke mm (in.) 92.0 (3.64)
Total Displacement cc (cu. in.) 2197 (134.07)
Fuel No. 2 Diesel Fuel per ASTM D975
Fuel Capacity liters (gallons) 56.8 (15.0)
Fuel Pump Bosch Type Mini pump
Governor Centrifugal flyweight Mechanical Type
Low Idle (no load) 1250 + 50 RPM
High Idle (no load) 2500 + 50 RPM
Compression Ratio 23.0 : 1
Rotation Counterclockwise Facing Flywheel
Injection Nozzles Bosch Throttle Type
Engine Oil SAE 10W30 SF or CD
Oil Pump Trochoid Type
Crankcase Oil Capacity liters (U.S. qt.) 7.6 (8.0) with filter
Starter 12 VDC 1.4 KW
Alternator/Regulator 12 VDC 40 AMP
Weight Kg (Lb.) 190 (418)
Engine Coolant Capacity liters (U.S. qt.) 14.0 (14.8)
Timing BTDC 17 to 19 Degrees
Kubota Diesel
Engine
Page 20
Reelmaster 4000−D
Page 3 − 4
Kubota Diesel Engine
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).
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. Install oil fill cap and dipstick.
6. Close engine cover and secure with the latches.
Figure 1
1. Engine cover latch
1
Figure 2
1. Dipstick
1
Figure 3
1. Oil fill cap
1
Page 21
Reelmaster 4000−D Page 3 − 5 Kubota Diesel Engine
Check Cooling System
Check level of coolant at the beginning of each day. Capacity of system is 3.7 gal. (14 L).
CAUTION
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.
2. Carefully remove radiator cap (Fig. 4) and expansion tank cap (Fig. 5).
3. Check level of coolant in radiator. Radiator should
be filled to the top of the filler neck and the expansion
tank filled to the marks on its side.
IMPORTANT: Do not use water only. Do not use alcohol / methanol base coolants.
4. If coolant is low, add a 50/50 mixture of water and
ethylene glycol anti−freeze.
5. Install radiator cap and expansion tank cap.
Figure 4
1. Radiator cap 2. Rear screen
1
2
Figure 5
1. Expansion tank cap
1
Fill Fuel Tank
1. Park machine on a level surface. Stop engine. Remove key from the ignition switch.
2. Remove fuel tank cap (Fig. 6).
3. Fill tank to about one inch (25 mm) below bottom of
filler neck with No. 2 diesel fuel. Then install cap.
Figure 6
1. Fuel tank cap 2. Left rear tire
1
2
Kubota Diesel
Engine
Page 22
Reelmaster 4000−D
Page 3 − 6
Kubota Diesel Engine
Prime Fuel System
IMPORTANT: The fuel system must be primed when
a new engine is started for the first time, if it runs out
of fuel, or if maintenance is performed on the fuel
system.
Note: The fuel pump, located on left side of engine,
under the fuel injection pump and behind the fuel stop
solenoid. It can be manually primed to get fuel from fuel
tank to fuel filter/water separator (Fig. 7).
1. Park machine on a level surface. Stop engine. Remove key from the ignition switch.
2. Raise engine cover.
3. Insert a 3/16−inch hose over the bleed screw, and
run the other end of the hose into a container to catch the
fuel (Fig. 8).
IMPORTANT: Priming fuel filter without opening
bleed screw may damage priming plunger.
4. Loosen fuel filter/water separator bleed screw a few
turns. Pump priming plunger until a steady stream of fuel
comes out of hole in in bleed screw. When fuel stops
foaming, tighten the bleed screw during the down-
stroke of the priming plunger. Wipe up any spilled fuel
(Fig. 8).
Note: It may be necessary to bleed the air out of the
fuel line between the fuel filter / water separator and the
injection pump. To do this, loosen the knob on the injection pump (Fig. 7) and repeat bleeding procedure.
5. Pump priming plunger until resistance is felt. Try to
start engine. If engine does not start repeat step 4.
Figure 7
1. Bleed knob
2. Injection pump
3. Fuel pump
4. Priming lever
1
2
3
4
Figure 8
1. Primer plunger 2. Bleed screw
2
1
Page 23
Reelmaster 4000−D Page 3 − 7 Kubota Diesel Engine
Adjustments
Adjust Alternator Belt
Check condition and tension of belt after every 100 operating hours (Fig. 9).
1. Park machine on a level surface. Stop engine. Remove key from the ignition switch.
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.
3. If deflection is not 3/8 inch (10 mm), loosen alternator mounting bolt. Increase or decrease alternator belt
tension and tighten bolt. Make sure tension is correct;
check deflection of belt again.
Figure 9
1. Alternator 2. Mounting bolt
1
2
Kubota Diesel
Engine
Page 24
Reelmaster 4000−D
Page 3 − 8
Kubota Diesel Engine
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). Do not over service air filter.
5. Be sure cover is sealing around air cleaner body
(Fig. 11).
6. Release latches securing air cleaner cover to air
cleaner body. Separate cover from body. Clean inside of
air cleaner cover (Fig. 11).
7. Gently slide primary filter out of air cleaner body to
reduce the amount of dust dislodged. Avoid knocking filter against air cleaner body. Do not remove safety fil-
ter.
IMPORTANT: Never attempt to clean a safety filter
(Located inside primary filter). Replace the safety
filter with a new one after every three primary filter
services.
8. Inspect primary filter and discard if damaged. Do not
wash or reuse a damaged filter.
Washing Method
A. Prepare a solution of filter cleaner and water a
nd soak filter element about 15 minutes. Refer to
directions on filter cleaner carton for complete information.
B. After soaking filter for 15 minutes, rinse it with
clear water. Maximum water pressure must not e xceed 40 psi to prevent damage to the filter element.
Rinse filter from clean side to dirty to side.
C. Dry filter element using warm, flowing air of not
greater than 160
o
F (71oC), or allow element to air−
dry. Do not use a light bulb to dry the filter element
because damage could result.
Figure 10
1. Rear screen 2. Knob
1
2
Figure 11
1. Air cleaner body 2. Air cleaner cover
1
2
Compressed Air Method
A. Blow compressed air from inside to the outside
of dry filter element. Do not exceed 100 psi (6.9 Bar)
to prevent damage to the element.
B. Keep air hose nozzle at least 2 inches (5 cm)
from filter and move nozzle up and down while rotating the filter element. Inspect for holes and tears by
looking through the filter toward a bright light.
9. Inspect new filter for shipping damage. Check sealing end of filter. Do not install a damaged filter.
10. Insert new filter properly into air cleaner body. Make
sure filter is sealed properly by applying pressure to outer rim of filter when installing. Do not press on flexible
center of filter.
11. Reinstall cover and secure latches. Make sure cover is positioned with top side up.
Page 25
Reelmaster 4000−D Page 3 − 9 Kubota Diesel Engine
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).
3. Add oil to crankcase (see Check Engine Oil).
Figure 12
1. Drain plug 2. Starter
1
2
Figure 13
1. Oil filter 2. Fuel filter/water seperato
r
1
2
Kubota Diesel
Engine
Page 26
Reelmaster 4000−D
Page 3 − 10
Kubota Diesel Engine
Drain Fuel System
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. Use diesel fuel for the engine only; not for any other
purpose.
Fuel Tank
Drain and clean fuel tank every 800 hours of operation
or yearly, whichever comes first. Also, drain and clean
tank if fuel system becomes contaminated or if machine
is to be stored for an extended period. Use clean fuel to
flush out the tank.
Fuel Filter/Water Separator
Drain water or other contaminants from fuel filter/water
separator daily.
1. Park machine on a level surface. Stop engine. Remove key from the ignition switch.
2. Place a clean container under the fuel filter.
3. Loosen drain thumb screw on the side of fuel filter.
Press primer plunger until only fuel is evident draining
into container.
4. Tighten drain screw.
Figure 14
1. Fuel filter/water separator
2. Drain screw
3. Priming plunger
1
3
2
Page 27
Reelmaster 4000−D Page 3 − 11 Kubota Diesel Engine
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
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. Use diesel fuel for the engine only; not for any other
purpose.
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).
Replace fuel filters if fuel flow becomes restricted, after
every 400 hours of operation or annually, whichever
comes first.
1. Park machine on a level surface. Stop engine. Remove key from the ignition switch.
2. Unscrew bottom filter cap from filter assembly. Remove cap, gaskets, o-ring and filter from assembly. Note
position of gaskets and o-ring when disassembling from
filter.
3. Install new filter , gaskets, o-ring with filter assembly
cap.
4. Prime fuel system, refer to Priming Fuel System.
Figure 15
1. In−line fuel filter 2. Fuel tank
2
1
Figure 16
1. Fuel filter/water separator
2. Filter cap
3. Filter
1
3
2
Kubota Diesel
Engine
Page 28
Reelmaster 4000−D
Page 3 − 12
Kubota Diesel Engine
Engine Cooling System
Debris Removal
Remove debris from oil cooler, radiator and rear screen
daily, clean more frequently in dirty conditions.
1. Park machine on a level surface. Stop engine. Remove key from the ignition switch.
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. Clean both sides of oil cooler, radiator
and rear engine area thoroughly with compressed air
(Fig. 18).
5. Pivot oil cooler back into position and install rear
screen.
6. Lower engine cover and secure latches.
Cooling System Maintenance
Capacity of the system is 3.7 gal. (14 L). Always protect
cooling system with a 50/50 solution of water and ethylene glycol anti−freeze.
IMPORTANT: Do not use water only. Do not use alcohol / methanol base coolants.
1. Park machine on a level surface. Stop engine. Remove key from the ignition switch.
2. After every 100 operating hours, tighten hose connections. Replace any damaged of deteriorated hoses.
3. After every 800 ooperating hours, drain and flush
the cooling system. Add anti−freeze (see Check Cooling
System).
Figure 17
1. Rear screen 2. Knob
1
2
Figure 18
1. Oil cooler 2. Radiator
1
2
Page 29
Reelmaster 4000−D Page 3 − 13 Kubota Diesel Engine
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).
3. Disconnect and remove battery from the machine
(see Battery Service in Chapter 5 − Electrical Systems).
CAUTION
If engine is hot, pressurized coolant can escape
and cause burns when the radiator hoses are removed. The radiator and exhaust exhaust tube
may be hot. Avoid possible burns; allow engine,
radiator, and exhaust system to cool before removing radiator hoses or exhaust tube.
4. Drain radiator. Disconnect both hoses from the radiator (Fig. 20).
5. Remove air hose from air intake manifold (Fig. 20).
6. Remove exhaust shield from the engine (Fig. 20).
7. Remove fan guard and fan shroud from the radiator
(Fig. 20).
8. Remove fan from the fan pulley. Remove fan shroud
and fan from machine (Fig. 21). Remove fan shroud
from the machine.
Figure 19
1. Canopy 2. Brackets
2
1
Figure 20
1. Battery
2. Upper radiator hose
3. Lower radiator hose
4. Fan guard
5. Fan shroud
6. Exhaust shield
7. Starter
8. OIl pressure switch
9. Alternator
10. Air hose
11. Hi temp. warning switc
h
12. Hi temp. cutout switch
2
3
4
1
8
6
9
7
5
10
11
12
Figure 21
1. Fan
2. Fan pulley
3. Cap screws
2
1
3
Kubota Diesel
Engine
Page 30
Reelmaster 4000−D
Page 3 − 14
Kubota Diesel Engine
9. Clamp to prevent drainage, and disconnect the following fuel hoses:
A. Suction hose at the injector pump from the fuel
filter. Suction and discharge hoses at the fuel pump
(Fig. 22).
B. Return hose from the fuel injectors (Fig. 23).
10. Disconnect wire harness and electrical wires from
the engine as follows:
A. Disconnect wire and connector from the alternator, red cable from starter, three wires from the starter, wire from the oil pressure switch, and wires from
high temperature warning and shutdown switches
(Fig. 20).
B. Disconnect electrical connector from the fuel solenoid (Fig. 22).
C. Disconnect red/black wire from the glow plug
bus bar (Fig. 23).
11. Disconnect throttle control cable from the swivel lever and R−clamp from the engine plate (Fig. 24).
Figure 22
1. Injector pump suction
2. Fuel pump suction
3. Fuel pump discharge
4. Fuel solenoid
4
1
2
3
Figure 23
1. Injector return hose
2. Glow plug wire
3. Exhaust tube
4. Bracket
5. Lift tab
1
2
5
Figure 24
1. Throttle control cable
2. R−clamp
3. Swivel
4. Swivel lever
5. Engine plate
6. Screw
2
3
4
1
6
5
3
4
2
Page 31
Reelmaster 4000−D Page 3 − 15 Kubota Diesel Engine
12. Separate hydraulic pump assembly from the engine
(Fig. 25).
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.
C. Support pump, and pull pump shaft from the
spring coupling.
13. Remove three lock nuts and cap screws securing
the upper exhaust tube to the exhaust bracket (Fig. 26).
14. Remove hex nut, spring washer , cap screw, and flat
washers securing both front brackets to the engine
mounts (Fig. 26).
15. Connect hoist or lift to the engine.
CAUTION
Make sure lift or hoist can support the total
weight of the engine before removing the cap
screws from the rear bracket and engine.
16. Remove three cap screws and lock washers securing the engine to the rear bracket and spacer (Fig. 27).
CAUTION
One person should operate lift or hoist while the
other person guides the engine out of the machine.
IMPORTANT: Make sure not to damage the engine,
fuel and hydraulic lines, electrical harness, or other
parts while removing the engine.
17. Remove engine slowly from the machine. Save gasket for exhaust tube (Fig. 26).
Figure 25
1. Damper
2. Bracket
3. Pump mounting flange
4. Pump adapter plate
5. Spring coupling
4
3
1
2
5
4
Figure 26
1. Cap screw
2. Upper exhaust tube
3. Exhaust bracket
4. Hex nut
5. Spring washer
6. Cap screw
7. Flat washer
8. Flat washer
9. Front bracket
10. Engine mount
1
1
3
2
6
8
7
5
9
4
9
10
Figure 27
1. Rear bracket & spacer 2. Cap screw & lock washe
r
1
2
Kubota Diesel
Engine
Page 32
Reelmaster 4000−D
Page 3 − 16
Kubota Diesel Engine
Engine Installation
CAUTION
One person should operate lift or hoist while the
other person guides the engine into the frame.
1. Install engine to the front engine mounts and rear
brackets.
A. Attach a hoist or lift to the engine.
IMPORTANT: Make sure not to damage the engine,
fuel and hydraulic lines, electrical harness, or other
parts while installing the engine.
B. Place gasket onto exhaust bracket to receive exhaust tube (Fig. 26).
C. Lower engine slowly into the machine.
2. Secure both front brackets to the engine mounts
with cap screw , flat washers, spring washer, and hex nu.
Torque cap screw and hex nut from 59 to 73 ft−lb (8.2 to
10.1 kg−m)t (Fig. 26).
3. Secure engine to the spacers and rear brackets with
three cap screws and lock washers. Torque cap screws
from 61 to 75 ft−lb (8.4 to 10.4 kg−m) (Fig. 27).
4. Secure exhaust tube and gasket to the exhaust
bracket with three cap screws and lock nuts (Fig. 26).
5. Connect hydraulic pump assembly to the engine
(Fig. 25).
A. Position the pump shaft into the spring coupling.
B. Secure pump mounting flange to the pump
adapter plate with four cap screws, flat washers,
and lock washers. T orque cap screws from 60 to 80
ft−lb (8.3 to 11.1 kg−m).
C. Connect damper to the bracket.
6. Connect throttle control cable to the swivel lever.
Secure cable to engine plate with R−clamp (Fig. 24).
7. Connect wire harness and electrical wires to the engine as follows:
A. Connect wire and connector to the alternator,
red cable to starter, three wires to the starter, wire to
the oil pressure switch, and wires to high temperature warning and shutdown switches (Fig. 20).
B. Connect electrical connector to the fuel solenoid
(Fig. 22).
C. Connect red/black wire to the glow plug bus bar
(Fig. 23).
8. Connect the following fuel hoses:
A. Suction hose at the injector pump from the fuel
filter. Suction and discharge hoses at the fuel pump
(Fig. 22).
B. Return hose from the fuel injectors (Fig. 23).
C. Remove clamps used to prevent drainage.
9. Position fan shroud to the radiator. Install fan to the
fan pulley (Fig. 21).
A. Apply Loctite (Blue) 242 or equivalent to the
ends of the cap screws.
B. Torque cap screws from 80 to 110 in−lb (92 to
127 kg−cm).
10. Install fan shroud and guard to the radiator (Fig. 20).
11. Install exhaust shield to the engine (Fig. 20).
12. Install air hose to air intake manifold (Fig. 20).
13. Install battery the machine and connect cables (see
Battery Service in Chapter 5 − Electrical Systems).
14. Connect both hoses to the radiator (Fig. 20).
15. Secure canopy to the brackets (Fig. 19).
16. Fill radiator with coolant (see Check Cooling Sys-
tem).
17. Adjust control cable throttle cable (Fig. 24).
A. Push throttle lever to the FAST position.
B. Loosen screw on swivel that secures the cable to
the swivel lever.
C. Adjust position of swivel lever with cable so the
injector pump lever is contacting the stop in the full
throttle position.
D. Secure cable to swivel with screw.
18. Prime fuel system (see Prime Fuel System).
19. Check traction pedal adjustment for NEUTRAL.
Page 33
Reelmaster 4000−D Page 4 − 1 Hydraulic System
Chapter 4
Hydraulic System
Table of Contents
SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION 3. . . . . . . . . . . . . . . . . . . . .
Hydraulic Hoses 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Fitting Installation 3. . . . . . . . . . . . . . . . . . .
Pushing or Towing Traction Unit 5. . . . . . . . . . . . . . .
Check Hydraulic System Fluid 7. . . . . . . . . . . . . . . . .
HYDRAULIC SCHEMATIC 8. . . . . . . . . . . . . . . . . . . . .
HYDRAULIC FLOW DIAGRAMS 9. . . . . . . . . . . . . . . .
General Pump Flow 9. . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Run − No Functions 10. . . . . . . . . . . . . . . . . .
Traction Circuit 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Traction Circuit − Forward 12. . . . . . . . . . . . . . . . . . .
Steering Circuit 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Right 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lift/Lower Circuit 15. . . . . . . . . . . . . . . . . . . . . . . . . . .
Lift Circuit − Lift All Units 16. . . . . . . . . . . . . . . . . . . . .
Lift Circuit − Lower All Units 17. . . . . . . . . . . . . . . . . .
Lift Circuits − Free Float (Detent) 18. . . . . . . . . . . . .
Reel Circuit 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reel Circuit − All Units Mow (Free Float) 20. . . . . . .
Reel Circuit − Units 1, 2 & 3 Mow (Free Float) 21. .
Reel Circuit − Units 1, 2, 3 & 5 (Free Float) 22. . . .
Reel Circuit − Any Unit Backlap 23. . . . . . . . . . . . . .
4WD SELECTOR VALVE OPERATION 24. . . . . . . . .
4WD Forward 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2WD Forward 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 26. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Tester with Pressure and Flow
Capabilities 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Pressure Test Kit 27. . . . . . . . . . . . . . . . . .
Hydraulic Fitting Kit 27. . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 28. . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Oil Leak(s) 28. . . . . . . . . . . . . . . . . . . . . . . .
Slow or No Traction in Either Direction 28. . . . . . . .
Reels Slow or Won’t Turn 28. . . . . . . . . . . . . . . . . . . .
Steering Loss 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cutting Units Lift Slow or Won’t Lift 29. . . . . . . . . . .
Cutting Units Won’t Drop
or Follow Ground Contours 29. . . . . . . . . . . . . . . . .
TESTING 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions for Hydraulic Testing 30. . . . . . . . . . . . .
Test No. 1: Check Traction Working
and Relief Pressures 31. . . . . . . . . . . . . . . . . . . . . . .
Test No. 2: Check Counterbalance
Oil Pressure 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test No. 3: Check Reel Circuit Working
and Relief Pressures 33. . . . . . . . . . . . . . . . . . . . . . .
Test No. 4: Check Reel Circuit Flow 34. . . . . . . . . . .
Test No. 5: Check Reel Motor Cross−Over
Relief Pressure 35. . . . . . . . . . . . . . . . . . . . . . . . . . .
Test No. 6: Check Reel Motor Case Drain Flow 36.
Test No. 7: Check Steering Circuit Working
and Relief Pressures 37. . . . . . . . . . . . . . . . . . . . . . .
Test No. 8: Check Lift Circuit Working
and Relief Pressures 38. . . . . . . . . . . . . . . . . . . . . . .
Test No. 9: Check Charge Pressure 38. . . . . . . . . . .
SERVICE AND REPAIRS 39. . . . . . . . . . . . . . . . . . . . .
Removing Hydraulic System Components 39. . . . .
Steering Control Unit 40.
. . . . . . . . . . . . . . . . . . . . . . .
Add Hydraulic Fluid 51. . . . . . . . . . . . . . . . . . . . . . . . .
Drain Water from Hydraulic Reservoir 51. . . . . . . . .
Reel Motor 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Pump 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lift Control Valve 58. . . . . . . . . . . . . . . . . . . . . . . . . . .
Priority Flow Divider 60. . . . . . . . . . . . . . . . . . . . . . . .
Lift Cylinder 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reel Control Valve 64. . . . . . . . . . . . . . . . . . . . . . . . . .
Reel Shut Off Valve 66. . . . . . . . . . . . . . . . . . . . . . . . .
Traction Rod Assembly 67. . . . . . . . . . . . . . . . . . . . . .
Traction Pump 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Traction Motor 74. . . . . . . . . . . . . . . . . . . . . . . .
Reel Pump 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Wheel Drive Motor 80. . . . . . . . . . . . . . . . . . . . .
Rear Wheel Drive Valve Block 87. . . . . . . . . . . . . . . .
Steering Cylinder 88. . . . . . . . . . . . . . . . . . . . . . . . . . .
Change Hydraulic Oil 90. . . . . . . . . . . . . . . . . . . . . . .
Replace Hydraulic Oil Filter 91. . . . . . . . . . . . . . . . . .
Replace Hydraulic System Breather 91. . . . . . . . . . .
Replace Hydraulic Lines and Hoses 91. . . . . . . . . . .
Hydraulic
System
Page 34
Reelmaster 4000−DPage 4 − 2Hydraulic System
Specifications
Item Description
Traction Pump Variable displacement axial piston pump
Traction Relief Pressure 5000 − 5200 PSI
Charge Pressure 50 − 150 PSI (2WD) 75 − 150 PSI (4WD)
Steering Pump Gear pump with flow divider
Steering Relief Pressure 1200 − 1300 PSI
Traction Motor (front) Fixed axial piston motor
Traction Motor (rear w/4WD) Geroter type wheel motors
Reel Pump Gear pump
Cutting Circuit Relief Pressure 2650 − 2750 PSI
Reel Motor Gear Motor
Cross−over Relief Pressure 1500 PSI
Lift Control Valve Spool type directional control valve
Lift Relief Pressure 2650 − 2900 PSI
Counterbalance Pressure (Max. RPM) Hot oil 500 − 550 PSI, cold oil 600 − 650 PSI
Hydraulic Filter (Fig. 1) Spin−on cartridge type
Hydraulic Oil Mobil DTE 26/Shell Tellus 68 or equivalent (see Add Hydraulic Fluid)
Reservoir (Fig. 2) Reservoir capacity 15 gal. U.S.
System capacity approximately 18.2 gal. U.S.
Page 35
Reelmaster 4000−D Page 4 − 3 Hydraulic System
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.
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.
Keep body and hands away from pin hole leaks
or nozzles that eject hydraulic fluid under high
pressure. Use paper or cardboard, not hands,
to search for leaks. Hydraulic fluid escaping
under pressure can have sufficient force to
penetrate the skin and do serious damage. If
fluid is injected into the skin, it must be surgically removed within a few hours by a doctor
familiar with this type of injury or gangrene
may result.
Hydraulic Fitting Installation
O−Ring Face Seal
1. Make sure both threads and sealing surfaces are free
of burrs, nicks, scratches, or any foreign material.
2. Make sure the O−ring is installed and properly seated
in the groove. It is recommended that the O−ring be replaced any time the connection is opened.
3. Lubricate the O−ring with a light coating of oil.
4. Put the tube and nut squarely into position on the face
seal end of the fitting and tighten the nut until finger tight.
5. Mark the nut and fitting body. Hold the body with a
wrench. Use another wrench to tighten the nut to the correct flats from finger tight (F.F .F.T.). The markings on the
nut and fitting body will verify that the connection has
been tightened.
Size F.F.F.T.
4 (1/4 in. nominal hose or tubing) .75 +
.25
6 (3/8 in.) .75 +
.25
8 (1/2 in.) .75 +
.25
10 (5/8 in.) 1.00 +
.25
12 (3/4 in.) .75 +
.25
16 (1 in.) .75 +
.25
Nut
Sleeve
Seal
Body
Figure 1
Mark Nut
and Body
Final
Position
Extend Line
Initial
Position
Finger Tight After Proper Tightening
Figure 2
Hydraulic
System
Page 36
Reelmaster 4000−DPage 4 − 4Hydraulic System
SAE Straight Thread O−Ring Port − Non−adjustable
1. Make sure both threads and sealing surfaces are free
of burrs, nicks, scratches, or any foreign material.
2. Always replace the O−ring seal when this type of fitting shows signs of leakage.
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 F.F.F.T.
4 (1/4 in. nominal hose or tubing) 1.00 +
.25
6 (3/8 in.) 1.50 +
.25
8 (1/2 in.) 1.50 +
.25
10 (5/8 in.) 1.50 +
.25
12 (3/4 in.) 1.50 +
.25
16 (1 in.) 1.50 +
.25
O−Ring
Figure 3
SAE Straight Thread O−Ring Port − Adjustable
1. Make sure both threads and sealing surfaces are free
of burrs, nicks, scratches, or any foreign material.
2. Always replace the O−ring seal when this type of fitting shows signs of leakage.
3. Lubricate the O−ring with a light coating of oil.
4. Turn back the jam nut as far as possible. Make sure
the back up washer is not loose and is pushed up as far
as possible (Step 1).
5. Install the fitting into the port and tighten finger tight
until the washer contacts the face of the port (Step 2).
6. T o put the fitting in the desired position, unscrew it by
the required amount, but no more than one full turn
(Step 3).
7. Hold the fitting in the desired position with a wrench
and turn the jam nut with another wrench to the correct
flats from finger tight (F.F.F.T.) (Step 4).
Size F.F.F.T.
4 (1/4 in. nominal hose or tubing) 1.00 +
.25
6 (3/8 in.) 1.50 +
25
8 (1/2 in.) 1.50 +
.25
10 (5/8 in.) 1.50 +
.25
12 (3/4 in.) 1.50 +
.25
16 (1 in.) 1.50 +
.25
Lock Nut
Back−up Washer
O−Ring
Figure 4
Step 3Step 1
Step 2 Step 4
Figure 5
Page 37
Reelmaster 4000−D Page 4 − 5 Hydraulic System
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.
1. Remove the retainer clip from seat lock rod.
2. Raise seat and support it in upright position with seat
support rod (Fig. 6).
1. Seat 2. Support rod
Figure 6
2
1
3. Lift and remove front panel (Fig. 7).
1. Front panel
Figure 7
1
4. Rotate by−pass valve 90 degrees. Opening the valve
opens an internal passage in the traction pump, thereby
by−passing hydraulic oil. Because oil is by−passed,
traction unit can be moved without damaging the hydraulic system (Fig. 8).
1. Traction pump 2. By−pass valve
Figure 8
2
1
IMPORTANT: Make sure that hand brake is engaged
before opening the by−pass valve.
5. Before starting engine, close by−pass valve. Do not
start engine when valve is open.
IMPORTANT: Running the machine with the by−
pass valve open will cause the hydraulic system to
overheat.
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.
If towing, with front wheel motors disengaged,
Tow Bar Assembly, Toro part no. 58−7020, must
be used.
Hydraulic
System
Page 38
Reelmaster 4000−DPage 4 − 6Hydraulic System
Disengaging Planetary Wheel Drives
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.
If towing with front wheel motors disengaged,
Tow Bar Assembly, Toro part no. 58−7020, must
be used.
NOTE: The machine can also be moved slowly a short
distance by opening the by-pass valve on the variable
displacement hydraulic pump and pushing or towing the
machine (See Pushing or Towing in the General Information section of Chapter 4 − Hydraulic System).
1. Block the wheels or connect the machine to a towing
vehicle with a rigid towing device.
2. Remove bolts securing disengage covers to both
front wheel hubs (Fig. 9).
Figure 9
3. Install disengage covers so dimple on cover is facing
in towards hub. Wheel hubs are now unlocked. (Fig. 10).
2
Figure 10
1. Disengage cover − engaged (dimple facing out)
4. Lock the wheel hubs immediately after towing is completed. Remove disengage covers and reinstall so dimple on cover is facing away from hub.
CAUTION
Do not remove wheel blocks or towing devices
until wheel hubs are securely locked.
Page 39
Reelmaster 4000−D Page 4 − 7 Hydraulic System
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. If oil level is low, add hydraulic oil to the reservoir
(see Add Hydraulic Fluid).
1. Hydraulic reservoir 2. Sight glass
Figure 11
2
1
Hydraulic
System
Page 40
Reelmaster 4000−DPage 4 − 8Hydraulic System
Hydraulic Schematic
2500 HI−IDLE
1100 LO−IDLE
A
(FWD)
INLET
B
(REV)
TEST PORT
CHARGE
BA
PRIORITY
OUT
IN
S1
3000
PSI
LC1
(FWD)
T
B
A
TEST PORT
CUTTING
(TYP) IN
B
A
T
T
RIGHT SIDE
5
3
1
2
4
A
B
C
D
E
F
TRACTION FORWARD
STEERING CIRCUIT
COUNTER−BALANCE
TRACTION REVERSE
L
R
TP
TEST PORTS
TEST PORT
LIFT CYLS
B
B
LH
REAR
LEFT SIDE
WARNING
SHUT−
DOWN
G
P
T
RH
LC2
A
A
P1
P2
PRESSURE
CIRCUIT
4 WHEEL DRIVE ONLY
STEER
CYLINDER
STEERING
ORBITROL
TRACTION
MOTORS
4WD VALVE BLOCK
TRACTION
MOTOR
TRACTION
MOTOR
OIL LEVEL
SENSOR
PUMP
PACKAGE
OIL
COOLER
RETURN
FILTER
LO-SPEED
BACKLAP
REEL
SPEED
REELS
ON-OFF
LIFT VALVE
LIFT
CYLINDERS
REEL SHUT-OFF
REEL MOTORS
COUNTERBALANCE
350 25 PSI
2100 100 PSI
5000 + 100 −0 PSI
1200 +100
−0 PSI
Page 41
Reelmaster 4000−D Page 4 − 9 Hydraulic System
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.
The flow continues through the lift valve where it meets
the counterbalance valve. The counterbalance valve
“super−charges” the incoming oil before allowing the oil
to continue on its return path back to the sump tank. The
counterbalance pressure may be monitored at pressure
tap port 3.
The oil pressure provided by the counterbalance valve
will be used to reduce the cutting unit weight on the turf
during the mowing function.
After joining with oil returning from other functions
through the drain block, the oil flows through the oil cooler to dissipate heat from the hydraulic system and then
through the filter to collect any particles in the hydraulic
system.
Clean oil is collected at the filter by the charge pump.
This oil is used to maintain a supply of oil to the closed−
loop traction circuit to prevent cavitation. The charge
pressure is regulated by a relief internal to the traction
pump. The charge pressure may be monitored at the
pressure tap port on top of the charge pump.
Oil collected by the reel pump is directed to the reel
speed valve and split into two variable flows. Primary oil
is directed to the reel “On−Off” control valve. With the
valve in the “Off” position, the oil is returned directly to
the drain block. The remaining oil will also return to the
tank through the drain block.
Hydraulic
System
Page 42
Reelmaster 4000−DPage 4 − 10Hydraulic System
Engine Run − No Functions
Page 43
Reelmaster 4000−D Page 4 − 11 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.
Depressing the top of the traction pedal will shift the traction pump swash plate to direct a flow of oil to the forward
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
Page 44
Reelmaster 4000−DPage 4 − 12Hydraulic System
Traction Circuit − Forward
Page 45
Reelmaster 4000−D Page 4 − 13 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.
Turning the steering wheel to the right moves the control
spool in the steering unit to direct the oil to the steering
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.
System pressure may be monitored at pressure tap port
5.
Hydraulic
System
Page 46
Reelmaster 4000−DPage 4 − 14Hydraulic System
Steering Right
Page 47
Reelmaster 4000−D Page 4 − 15 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. Holding a
lever in the “LIFT” position will direct the flow of oil to the
lift cylinder and raise the cutting unit. Oil pressure to the
lift cylinder is monitored during LIFT by a relief at the
valve inlet. System pressure may be monitored at the
pressure tap port on the lift valve.
Moving the lever forward will open a path for oil to escape from the lift cylinder. The weight of the cutting unit
will push oil from the cylinders through the valve allowing
the cutting unit to lower. Moving the lever into “LIFT”
while the cutting unit is lowering will lock the cutting unit
at any position by trapping oil between the valve and cylinder.
The cylinders work against counterbalance pressure
during lowering. For this reason, the cutting units will
drop faster at slow engine speeds or low counterbalance pressures compared to full engine speed or high
counterbalance pressures. The counter balance pressure may be monitored at pressure tap port 3.
Since the lift levers are spring loaded from return to neutral, a detent plunger latches the spool in the valve to
hold the spool in a “Free Float” position. The position enables the cutting units to follow ground contours by allowing a two−way flow between the lift valve and lift
cylinders.
Hydraulic
System
Page 48
Reelmaster 4000−DPage 4 − 16Hydraulic System
Lift Circuit − Lift All Units
Page 49
Reelmaster 4000−D Page 4 − 17 Hydraulic System
Lift Circuit − Lower All Units
Hydraulic
System
Page 50
Reelmaster 4000−DPage 4 − 18Hydraulic System
Lift Circuit − Free Float (Detent)
Page 51
Reelmaster 4000−D Page 4 − 19 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. Oil not needed to obtain the selected
reel speed is directed back to the sump tank through the
drain block, oil cooler, and filter.
When the reel “On−Off” valve lever is moved into “Mow”
to engage the reels, a spool in the valve is shifted to direct oil to the shut−off valve at the front of the unit. With
the Number 1, 2, and 3 cutting units in mowing position,
the shut−off valve will allow oil to flow to the Number 2,
3, and 1 reel motors. The oil is also available for use at
the Number 4 shut−off valve. If the Number 1, 2, and 3
cutting units are in the raised position, the oil will bypass
these motors and be available directly to the Number 4
shut−off valve.
With the Number 4 cutting unit in the down and mowing
position, the Number 4 shut−off valve will allow the oil
through to drive the reel motor and then to the Number
5 shut−off valve. If the Number 4 cutting unit is in the
raised position, the oil will bypass the Number 4 reel motor and be available directly to the Number 5 shut−off
valve.
With the Number 5 cutting unit in the down and mowing
position, the Number 5 shut−off valve will allow the oil
through to drive the reel motor. If the Number 5 cutting
unit is in the raised position, the oil will bypass the Number 5 reel motor and return to the reel “On−Off” valve.
From the reel “On−Off” valve, the oil returns to the sump
tank through the drain block, oil cooler, and filter.
“Backlap” is provided by pulling the reel “On−Off” valve
lever up and back. The backlap function requires that
the lever be held in this position for safety. The direction
of flow in “Backlap” is the opposite of “Mow”. Some units
will include a low−speed backlap valve in the circuit to
remove some oil flow from the circuit during the backlap
function. The reduced oil flow results in a slower reel
speed in “Backlap”, but does not affect performance
during “Mow”.
System pressure may be monitored at pressure tap 4 for
either “Mow” or “Backlap”.
Hydraulic
System
Page 52
Reelmaster 4000−DPage 4 − 20Hydraulic System
Reel Circuit − All Units Mow (Free Float)
Page 53
Reelmaster 4000−D Page 4 − 21 Hydraulic System
Reel Circuit − Units 1, 2 & 3 Mow (Free Float)
Hydraulic
System
Page 54
Reelmaster 4000−DPage 4 − 22Hydraulic System
Reel Circuit − Units 1, 2, 3 & 5 Mow (Free Float)
Page 55
Reelmaster 4000−D Page 4 − 23 Hydraulic System
Reel Circuit − Any Unit Backup
Hydraulic
System
Page 56
Reelmaster 4000−DPage 4 − 24Hydraulic System
4WD Selector Valve Operation
4WD Forward (“S1” OFF)
Pressure Oil
Pressure Free
Page 57
Reelmaster 4000−D Page 4 − 25 Hydraulic System
2WD Forward (“S1” ON)
Pressure Oil
Pressure Free
Hydraulic
System
Page 58
Rev. C
Reelmaster 4000−DPage 4 − 26Hydraulic System
Special Tools
Order special tools from your Toro Distributor. Some
tools may also be available from a local supplier.
Hydraulic Tester − With Pressure and Flow Capabilities − TOR214678
Figure 12
You must have o−ring face seal (ORFS) adapter fittings
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. LOAD VALVE: If required, upon turning the valve to
restrict flow, a simulated working load is created in the
circuit.
3. LOW PRESSURE GAUGE: Low range gauge to
provide accurate reading at low pressure, 0 − 1000 PSI.
This gauge has a protector valve which cuts out
when pressure is about to exceed the normal range
for the gauge. The cutout pressure is adjustable.
4. HIGH PRESSURE GAUGE: High range gauge to
accommodate pressure beyond the capacity of the low
pressure gauge, 0 − 5,000 PSI.
5. FLOW METER: This meter measures actual oil flow
in the operation circuit, with a gauge rated at 15 GPM.
6. OUTLET HOSE: Hose from the outlet side of the hydraulic tester to be connected to the hydraulic system
circuit.
Page 59
Reelmaster 4000−D Page 4 − 27 Hydraulic System
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.
The kit includes: tee’s, unions, reducers, plugs, caps,
and male test fittings.
Figure 14
Hydraulic
System
Page 60
Reelmaster 4000−DPage 4 − 28Hydraulic 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.
Continued use of an improperly functioning hydraulic
system could lead to extensive internal component
damage.
The charts that follow contain information to assist in
troubleshooting. There may possibly be more than one
cause for a machine malfunction.
Refer to the Testing section of this Chapter for precautions and specific test procedures.
Problem
Possible Causes
Hydraulic oil leak(s). Fitting(s), hose, or tube loose or damaged.
Missing or damaged o−ring.
Slow or no traction in either direction. Low engine RPM.
Low hydraulic oil level.
Open or damaged traction pump by−pass valve.
Disengaged or damaged final drive.
Loose or damaged traction linkage.
Low charge pressure. (See Test No. 8.)
Low traction pressure. (See Test No. 1.)
Damaged or worn traction motors.
Reels slow or won’t turn. Low engine RPM.
Low hydraulic oil level.
Reel to bedknife adjustment too tight.
Improper reel drive motor belt adjustment.
Low reel shut−off valves.
Low reel system pressure. (See Test No. 3.)
Worn or damaged priority flow divider.
Low flow to reel motors. (See Test No. 4.)
Inefficient reel motor. (See Test No. 5.)
Page 61
Reelmaster 4000−D Page 4 − 29 Hydraulic System
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.
Low hydraulic oil level.
Binding lift arm pivot points or bushings.
Worn or damaged bushings.
Worn or damaged cylinders.
Improper counterbalance pressure.
(See Test No. 2.)
Worn or damaged counterbalance valve.
Low lift relief pressure. (See Test No.7.)
Plugged cylinder orifice.
Worn or damaged lift valve.
Worn or damaged steering/lift pump.
Cutting units won’t drop or follow ground contours. Low engine RPM.
Low hydraulic oil level.
Binding lift arm pivot points or bushings.
Worn or damaged bushings.
Worn or damaged cylinders.
Improper counterbalance pressure.
(See Test No. 2.)
Worn or damaged counterbalance valve.
Plugged cylinder orifice.
Worn or damaged spool detent in lift valve.
Worn or damaged lift valve.
Hydraulic
System
Page 62
Reelmaster 4000−DPage 4 − 30Hydraulic System
Testing
The most effective method for isolating problems in the
hydraulic system is by using hydraulic test equipment
such as pressure gauges and flow meters in the circuits
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.
Precautions for Hydraulic Testing
CAUTION
Failure to use gauges with recommended pressure (psi) rating as listed in test procedures
could result in damage to the gauge and possible
personal injury from leaking hot oil.
All testing should be performed by two (2)
people. One person should be in the seat to operate the machine, and the other should read and
record test results.
CAUTION
Operate all hydraulic controls to relieve system
pressure and avoid injury from pressurized hydraulic oil. Controls must be operated with the
ignition switch in OFF. Remove key from the ignition switch.
WARNING
Before disconnecting or performing any work
on the hydraulic system, all pressure in the
system must be relieved. Stop engine; lower or
support attachments.
WARNING
Keep body and hands away from pin hole leaks
or nozzles that eject hydraulic fluid under high
pressure. Do not use hands to search for
leaks; use paper or cardboard. Hydraulic fluid
escaping under pressure can have sufficient
force to penetrate the skin and cause serious
injury. If fluid is injected into the skin, it must
be surgically removed within a few hours by a
doctor familiar with this type of injury. Gangrene may result from such an injury.
1. Clean machine thoroughly before disconnecting or
disassembling any hydraulic components. Always keep
in mind the need for cleanliness when working on hydraulic equipment. Contamination will cause excessive
wear of components.
2. Put metal caps or plugs on any hydraulic lines left
open or exposed during testing or removal of components.
3. The engine must be in good operating condition.
Use a phototac when performing a hydraulic test. Engine speed can affect the accuracy of the tester readings.
4. The inlet and the outlet hoses must be properly connected and not reversed (tester with pressure and flow
capabilities) to prevent damage to the hydraulic tester or
components.
5. When using tester with pressure and flow capabilities, open load valve completely in the hydraulic tester
to minimize the possibility of damaging components.
6. Install fittings finger tight and far enough to make
sure that they are not cross−threaded before tightening
them with a wrench.
7. Position tester hoses to prevent rotating machine
parts from contacting and damaging the hoses or tester .
8. Check oil level in the hydraulic tank. After connecting test equipment, make sure tank is full.
9. Check control linkages for improper adjustment,
binding,or broken parts.
10. All hydraulic tests should be made with the hydraulic
oil at normal operating temperature.
Page 63
Reelmaster 4000−D Page 4 − 31 Hydraulic System
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.
NOTE: If the machine is equipped with 4WD, check
working pressure in both 2WD and 4WD modes.
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.
3. If working pressure is too low in 2WD, perform the
traction circuit relief pressure check.
NOTE: If pressure is good in 2WD but to low in 4WD,
check the cartridge valve seals in the 4WD valve block.
If 4WD pressure is low after making repairs to the valve
block the rear wheel motor(s) should be suspected of
wear and inefficiency. Maximum allowable bypass for
each rear wheel motor is 2 GPM.
Procedure for Relief
Pressure Check:
1. Hydraulic oil must be at operating temperature.
2. Install a 10,000 psi gauge into the traction circuit quick
disconnect for the function to be checked.
3. Set traction pedal stop for minimum ground speed (1
mph).
4. Start the engine and move throttle to full speed (2500
rpm) and release the parking brake.
5. Carefully drive the machine into position so it will push
against a strong wall or other immovable obstacle. Continue an attempt to go forward with the machine against
the obstacle and read the pressure gauge.
TESTER READING TO BE APPROXIMATELY
5000 − 5200 PSI
6. If traction pressure is too low, inspect the traction
pump check valves and relief valves. Clean or replace
relief valve(s) or check valves as necessary. If check
valves and relief valves are in good condition, the traction pump and / or motors should be suspected of wear
and inefficiency.
1. Reverse test port
2. Front wheel motor (RH)
3. Forward test port
Figure 15
1
2
3
Hydraulic
System
Page 64
Reelmaster 4000−DPage 4 − 32Hydraulic System
TEST NO. 2: Check 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.
4. If necessary, adjust the relief valve screw until the de-
sired pressure is attained. Turn the screw in to increase
counterbalance pressure and turn the screw out to decrease counterbalance pressure. Adjust nearer the high
end of the range for improved hill climbing or nearer the
low end for improved quality−of−cut.
1. Counter balance test port
2. Relief valve adjustment screw
Figure 16
1
2
Page 65
Reelmaster 4000−D Page 4 − 33 Hydraulic System
TEST NO. 3: Check Reel Circuit Working and Relief Pressures
Procedure For Working Pressure Check:
1. Install a 5,000 psi gauge into the cutting circuit quick
disconnect.
2. Operate the unit while monitoring the gauge.
RANGE OF TESTER READINGS 0 − 2750 PSI
3. If working pressure is too high or too low, perform re-
lief pressure check.
NOTE: Due to special conditions or customer prefer-
ence, the counterbalance may require setting outside
this recommended range. However, the range listed will
be adequate for most conditions.
Procedure For Relief
Pressure Check:
1. Hydraulic oil must be at operating temperature.
2. Install a 5,000 psi gauge into the cutting circuit quick
disconnect.
3. Start the engine and lower the No. 2 (left front) and 3
(right front) cutting units to the ground.
4. Turn the engine OFF.
5. Block the reel of the No. 2 cutting unit to prevent rota-
tion. The No. 2 cutting unit motor is the first in series flow
from the pump. Use a substantial hardwood block inserted between the reel blades.
CAUTION
Stand clear of the reels during the following procedures.
6. Place reel speed control knob at minimum.
7. Start engine and position throttle at idle.
8. Ease the reel control lever into “MOW” while monitor-
ing the gauge.
NOTE: It may be necessary to raise the throttle slightly
to prevent the engine from stalling.
TESTER READING TO BE 2650 − 2750 PSI
9. If reel circuit relief pressure is above 2750 psi or below
2650 psi, clean or replace relief valve in reel control
valve.
1. Cutting circuit test port 2. Reel control valve
Figure 17
2
1
Hydraulic
System
Page 66
Reelmaster 4000−DPage 4 − 34Hydraulic System
TEST NO. 4: Check Reel Circuit Flow
Procedure:
1. Hydraulic oil must be at operating temperature.
2. Start the engine and lower the No. 2 and 3 cutting
units to the ground.
3. Turn the engine OFF.
4. Disconnect inlet hose at No. 2 reel motor.
5. Install tester in series between disconnected hose
and reel motor (flow direction is from hose to motor).
Make sure gate valve of tester is OPEN.
6. Position reel speed control knob at middle range (90
degree position).
7. Start engine and move throttle to full speed
(2500 rpm).
8. Engage the reel control lever into the “MOW” position.
CAUTION
Reels will rotate when reel control lever is moved
into the “MOW” position. Keep clear of rotating
reels.
TESTER READING TO BE APPROXIMATELY
14 − 15 GPM.
9. If reel circuit oil flow is too low, check for restriction in
pump intake line. If not restricted, remove pump and repair or replace as necessary.
Figure 18
Page 67
Reelmaster 4000−D Page 4 − 35 Hydraulic System
TEST NO. 5: Check Reel Motor Cross−Over Relief Pressure
BA
PRIORITY
OUT
IN
3000
PSI
T
B
A
TEST PORT
CUTTING
(TYP)
B
A
T
T
G
CIRCUIT
FROM
GEAR PUMP
FROM
LIFT CIRCUIT
TO HYDRAULIC
OIL TANK
IN
Figure 19
NOTE: Before testing a reel motor for possible failure,
make sure to inspect the affected cutting unit for possible causes of malfunction. Eliminate such possible
causes as: bad reel bearings, bent or damaged reel,
jammed debris, etc. It is often helpful to remove the reel
motor from the unit when inspecting.
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 tem-
perature 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. Make sure engine is
OFF, and the parking brake is engaged.
3. Read Precautions for Hydraulic Testing.
4. Block reel being tested to prevent rotation. Use a
substantial hardwood block inserted between the reel
blades.
5. Disconnect supply hose from the motor. Install test
gauge with T−connector in series with the motor and disconnected supply hose.
6. Disconnect return hose from the motor. Install test
gauge with T−connector in series with the motor and disconnected return hose.
CAUTION
Keep away from reels during test to prevent personal injury from the rotating reel blades.
7. Position reel speed control knob to minimum
speed. Start engine and move throttle to low idle speed
of 1200 RPM.
IMPORTANT: Each reel motor has two cross−over
reliefs. Test relief in the backlap direction only if a
problem is expected.
8. Gently ease reel control lever to MOW. If testing the
reel motor in the backlap direction, gently ease reel control lever to BACKLAP. Slowly raise engine speed to
high idle speed of 2400 RPM while monitoring pressure.
The pressure difference between the two gauges
should be from 1400 to 1600 PSI.
A. If pressure is greater than the specified range,
stop the engine and repair or replace the reel motor.
B. If pressure is less than the specified range,
check reel pump output pressure (TEST NO. 3:
Check Reel Circuit Working and Relief Pressures).
If reel circuit pressure is correct, check reel motor
cross−over relief valve for damage.
9. Disengage cutting units by positioning reel control
lever to STOP position. Stop the engine.
10. Disconnect tester from motor and hose. Reconnect
hose to the pump. Remove hardwood block from reel.
Hydraulic
System
Page 68
Reelmaster 4000−DPage 4 − 36Hydraulic System
TEST NO. 6: Check Reel Motor Case Drain Flow
BA
PRIORITY
OUT
IN
3000
PSI
T
B
A
TEST PORT
CUTTING
(TYP) IN
B
A
T
T
G
CIRCUIT
FROM
GEAR PUMP
FROM
LIFT CIRCUIT
TO HYDRAULIC
OIL TANK
QUART
CONTAINER
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. Make sure engine is OFF
and the parking brake is engaged.
3. Read Precautions for Hydraulic Testing.
4. For the suspected bad motor, disconnect return
hose from the motor.
5. Install tester in series with the motor and return
hose. Make sure the flow control valve is fully open.
6. Follow hose from reel motor case drain to the hydraulic T−connector.
A. Disconnect hose from T−connector.
B. Plug T−connector to prevent drainage of fluid.
C. Put case drain hose into suitable container for
collecting case drain leakage.
7. One person should sit on the seat and operate the
machine while another person reads the tester and
measures case drain leakage. Make sure reel control lever in NEUTRAL. Start engine and move the throttle to
full speed (2400 RPM).
CAUTION
Keep away from reels during test to prevent personal injury from the rotating reel blades.
8. Engage reels by positioning reel control lever to
MOW position. While watching pressure gauges, slowly
close flow control valve until a pressure of 1200 PSI is
obtained.
9. Collect hydraulic fluid for 15 seconds by putting the
case drain hose into a 1 quart container graduated in
ounces (1 liter container graduated in milliliters).
10. Disengage cutting units by reel control lever to the
NEUTRAL position. Stop the engine.
11. Measure the amount of oil collected in the container.
Divide the number of ounces collected by 32 to get gallons per minute. (Divide the number of milliliters collected by 250 to get liters per minute).
12. Disconnect tester from motor and hose. Reconnect
hose to the pump.
13. Remove plug from T−connector. Reconnect case
drain hose to the T−connector.
14. If flow was greater than 0.7 GPM (2.6 LPM), repair
or replace the reel motor as necessary.
Page 69
Reelmaster 4000−D Page 4 − 37 Hydraulic System
TEST NO. 7: Check Steering Circuit Working and Relief Pressure
Procedure For Working Pressure Check:
1. Install a 5,000 psi gauge into the steering quick dis-
connect.
2. Operate the unit while monitoring the gauge.
RANGE OF TESTER READINGS 0 − 1300 PSI
3. If working pressure is too high or too low, perform re-
lief pressure check.
Procedure For Relief
Pressure Check:
1. Hydraulic oil must be at operating temperature.
2. Install a 5,000 psi gauge into the steering quick dis-
connect.
3. Start the engine and move the throttle to full speed
(2500 rpm).
4. Turn the steering wheel until heavy resistance is felt
indicating that the cylinder has reached maximum
stroke.
5. Momentarily hold the steering wheel against the re-
sistance and read gauge.
TESTER READING TO BE APPROXIMATELY
1200 − 1300 PSI
6. If pressure is too high, clean and adjust relief valve in
steering pump by removing the required shims. If pressure is too low, check for restriction in pump intake line.
Check the steering cylinder for internal leakage. If cylinder is not leaking, adjust the relief valve by adding the
required shims. If pressure is still too low, repair or replace steering pump.
1. Steering circuit test port 2. Steering pump
Figure 21
1
2
Hydraulic
System
Page 70
Reelmaster 4000−DPage 4 − 38Hydraulic System
TEST NO. 8: Check Lift Circuit Working and Relief Pressure
Procedure For Working Pressure Check:
1. Install a 5,000 psi gauge onto the quick disconnect of
the lift valve.
2. Operate the unit while monitoring the gauge. Gauge
should read from 500 to 2900 PSI.
3. If working pressure is too high or too low, perform 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.
3. Start the engine and move the throttle to full speed
(2500 rpm).
4. Engage the control lever into the “LIFT” position. Momentarily hold the lever in the engaged position after full
cylinder extension and read gauge. Tester reading
should be from 2650 to 2900 PSI.
NOTE: Always set counterbalance pressure to desired
amount before attempting to adjust lift pressure.
5. If pressure is too high, clean and adjust relief valve in
lift valve by removing the required shims. If pressure is
too low, check for restriction in pump intake line. Check
the lift cylinder for internal leakage. If cylinder is not leaking, adjust the relief valve by adding the required shims.
If pressure is still too low, repair or replace steering/lift
pump.
1. Lift control test port 2. Lift control valve
Figure 22
1
2
1. Lift control test port 2. Test gauge
Figure 23
1
2
TEST NO. 9: Check Charge Pressure
1. Hydraulic oil must be at operating temperature.
2. Install a 1000 psi gauge onto the quick disconnect at
the top of the pump package.
3. Start the engine and position throttle at idle
(1200 rpm). Tester reading should be from 75 to 150
PSI.
4. If there is no pressure or pressure is too low, check for
restriction in pump intake line. Inspect charge relief
valve and valve seat. Check for sheared charge pump
key. Disassemble charge pump and check for internal
damage or worn parts. If the charge pump is in good
condition (no scoring, scratches, or excessive wear),
the general condition of the piston pump might be suspected of wear and inefficiency.
1. Charge press. test port 2. Traction pump
Figure 24
1
2
Page 71
Reelmaster 4000−D Page 4 − 39 Hydraulic System
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.
After Repair or Replacement of Components
1. Check oil level in hydraulic reservoir and add correct
oil if necessary. Drain and refill hydraulic system reservoir and change oil filter if component failure was severe
or system is contaminated.
2. After repairs, check control linkage for proper adjustment, binding or broken parts.
3. After disconnecting or replacing any hydraulic components, operate machine functions slowly until air is
out of system.
4. Check for hydraulic oil leaks. Shut off engine and correct leaks if necessary. Check oil level in hydraulic reservoir and add correct oil if necessary.
Hydraulic
System
Page 72
Reelmaster 4000−DPage 4 − 40Hydraulic System
Steering Control Unit
1
2
3
4
5
6
7
8
9
10
16
18
19
20
21
22
23
24
25
26
27
28
11
12
13
14
15
12
12
Figure 25
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. Drive
15. Gerotor
16. End Cap
18. Cap Screw
19. Pin Kit, Centering
20. Spring
21. Retainer Plug
22. Check Ball
23. Check Ball, Retainer
24. Check Ball
25. Seal
26. Check Ball Seat
27. Seal
28. Set Screw
Disassembly
Cleanliness is extremely important when repairing a
steering control unit. Work in a clean area. Before disconnecting lines, clean port area of unit thoroughly. Use
a wire brush to remove foreign material and debris from
around exterior joints of the unit.
NOTE: Troubleshooting information defines terms and
problems, possible causes for problems, and recommends procedures for correcting problems.
Although not all drawings show the unit in a vise, we recommend that you keep the unit in the vise during disassembly. Follow the clamping procedure explained
throughout the manual.
Page 73
Reelmaster 4000−D Page 4 − 41 Hydraulic System
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.
2. Remove 5/16” cap screws.
3. Remove end cap.
4. Remove seal from end cap.
5. Remove meter. Be careful not to drop star.
6. Remove seal from meter.
Figure 26
Figure 27
Figure 28
Hydraulic
System
Page 74
Reelmaster 4000−DPage 4 − 42Hydraulic System
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.
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.
12. Rotate spool and sleeve until pin is horizontal. Push
spool and sleeve assembly forward with your thumbs
just far enough to free gland bushing from housing, see
Fig. 31. Remove bushing.
Figure 29
Figure 30
Figure 31
Page 75
Reelmaster 4000−D Page 4 − 43 Hydraulic System
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.
15. Remove 2 bearing races and the needle thrust bear-
ing from spool and sleeve assembly.
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. Push pin from spool and sleeve assembly.
Figure 32
Figure 33
Figure 34
Hydraulic
System
Page 76
Reelmaster 4000−DPage 4 − 44Hydraulic System
18. Push spool partially from control end of sleeve, then
remove 6 centering springs from spool carefully by
hand, see Fig. 35.
19. Push spool back through and out of sleeve, see
Fig. 35. Rotate spool slowly when removing from
sleeve.
20. Remove seal from housing, see Fig. 36.
21. Screw a #10−24 machine screw into end of check
ball seat. Then, by pulling on screw with a pliers, lift seat
out of housing, see Fig. 36.
22. Remove 2 seals from check valve seat.
23. Tip housing to remove check ball and check ball retainer.
Figure 35
Figure 36
Page 77
Reelmaster 4000−D Page 4 − 45 Hydraulic System
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.
Refer to parts listing covering your steering control unit
when ordering replacement parts. A good service policy
is to replace all old seals with new seals.
Control End Reassembly
1. Use a needle−nose pliers to lower check ball retainer
into check valve hole of housing. Make sure retainer is
straight (not tilted on edge) in housing, see Fig. 37.
2. Install check ball in housing.
3. Lubricate 5/8” diameter seal and 7/16” diameter seal.
Install seals on check ball seat as shown in Fig. 37.
4. Lubricate check ball seat and seals thoroughly before
installing seat in housing. When installing seat, do not
twist or damage seals. Install check ball seat in housing,
insert open end of seat first, see Fig. 37. Push check ball
seat to shoulder of hole.
5. Assemble spool and sleeve carefully so that the
spring slots line up at the same end. Rotate spool while
sliding parts together. Some spool and sleeve sets ha ve
identification marks, align these marks as shown in
Fig. 38. Test for free rotation. Spool should rotate
smoothly in sleeve with finger tip force applied at splined
end.
Figure 37
Figure 38
Hydraulic
System
Page 78
Reelmaster 4000−DPage 4 − 46Hydraulic System
6. Bring spring slots of both parts in line and stand parts
on end of bench. Insert spring installation tool through
spring slots of both parts. Tool is available from an Eaton
hydraulics supplier as Eaton part no. 600057. Position
3 pairs of centering springs (or 2 sets of 3 each) on
bench so that extended edge is down and arched center
section is together. In this position, insert one end of entire spring set into spring installation tool, as shown in
Fig. 39, with spring notches facing sleeve.
7. Compress extended end of centering spring set and
push into spool sleeve assembly withdrawing installation tool at the same time.
8. Center the spring set in the parts so that they push
down evenly and flush with the upper surface of the
spool and sleeve.
9. Install pin though spool and sleeve assembly until pin
become flush at both sides of sleeve.
10. Position the spool and sleeve assembly so that the
splined end of the spool enters the 14−hole end of housing first, see Fig. 40.
IMPORT ANT: Be extremely careful that the parts do
not tilt out of position while inserting. Push parts
gently into place with slight rotating action, keep pin
nearly horizontal. Bring the spool assembly entirely
within the housing bore until the parts are flush at
the meter end or 14−hole end of housing. Do not pull
the spool assembly beyond this point to prevent the
cross pin from dropping into the discharge groove
of the housing. With the spool assembly in this flush
position, check for free rotation within the housing
by turning with light finger tip force at the splined
end.
Figure 39
Figure 40
Page 79
Reelmaster 4000−D Page 4 − 47 Hydraulic System
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.
13. Install 1−1/4” diameter dust seal in seal gland bush-
ing, 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. Install seal gland bushing over the spool end with a
twisting motion. Tap the bushing in place with a rubber
hammer. Make sure the bushing is flush against the
bearing race.
16. Install retaining ring (see Fig. 42 and 43) in housing.
After installing ring, tap on ring end or pry with screwdriver around entire circumference of ring to properly seat
ring in groove.
Figure 41
Figure 42
Figure 43
Hydraulic
System
Page 80
Reelmaster 4000−DPage 4 − 48Hydraulic System
17. Clamp housing in vise, as shown in Fig. 44. Clamp
lightly on edges of mounting area. Do not over−tighten
jaws.
NOTE: Check to insure that the spool and sleeve are
flush or slightly below the 14−hole surface of the 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.
18. Install 3” diameter seal in housing, see Fig. 45.
19. Install spacer plate. Align bolt holes in spacer plate
with tapped holes in housing.
20. Rotate spool and sleeve assembly until pin is parallel with port face, see Fig. 46. (Install drive, make sure
you engage drive with pin. To assure proper alignment,
mark drive as shown in Fig. 48 (ref. B). Record the relationship between slotted end of drive to splined end of
drive when marking.
Figure 44
Figure 45
Figure 46
Page 81
Reelmaster 4000−D Page 4 − 49 Hydraulic System
21. Install 3” diameter seal in meter.
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.
Figure 47
Figure 48
Hydraulic
System
Page 82
Reelmaster 4000−DPage 4 − 50Hydraulic System
23. Install drive spacer(s), when used, in meter, see
Fig. 49.
24. Install 3” diameter seal in end cap.
25. Install end cap on gerotor, align holes.
26. Install 7 dry cap screws with new seal washers in
end cap. Pre−tighten screws to 150 inch pounds, ten
torque screws to 275 inch pounds in sequence shown
in Fig. 50.
Figure 49
Figure 50
Page 83
Reelmaster 4000−D Page 4 − 51 Hydraulic System
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 g l a s s . I f le vel is lo w, add hydraulic oil. Refer to Hydraulic Oil Specifications (Fig. 51).
1. Remove seat lock pin, raise seat and hold open with
support rod.
2. Clean around reservoir filler cap (Fig. 52). Remove
cover and add hydraulic oil until it is even with arrows on
sight glass (Fig.51).
IMPORTANT: To prevent contamination, clean top
of hydraulic oil containers before puncturing. Assure pour spout and funnel are clean.
3. Install reservoir cover, lower seat and secure with
lock pin.
Hydraulic Oils Specifications (Interchangeable):
Mobil DTE 26/Shell Tellus 68 Equivalent*
*Equivalent Hydraulic Oils (Interchangeable)
Mobil DTE 15 M
Amoco Rykon Oil #68
Conoco Super Hydraulic Oil 68
Exxon Nuto H 68
Kendall Kenoil R & 0 AW 68
Pennzoil Penreco 68
Phillips Magnus A 68
Standard Energol HLP 68
Sun Sunvis 831 WR
Union Unax AW 68
1. Hydraulic reservoir 2. Sight glass
Figure 51
2
1
1. Filler cap 2. Hydraulic reservoir
Figure 52
2
1
Drain Water from Hydraulic Reservoir
After every 100 operating hours, drain water from hydraulic reservoir.
1. Open drain plug one−half turn and allow fluid to flow
into drain pan until water is not noticed in hydraulic oil
(Fig. 53).
2. Tighten drain plug and add hydraulic oil (see Add
Hydraulic Oil).
1. Drain plug 2. Right front fender
Figure 53
1
2
Hydraulic
System
Page 84
Reelmaster 4000−DPage 4 − 52Hydraulic System
Reel Motor
2
3
4
5
6
7
8
9
10
11
12
13
14
5
7
20
19
18
16
17
15
21
1. Not used
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
12. Retaining Ring
13. Shaft Seal
14. Backup Washer
15. Relief Valve Kit
16. O−Ring
17. Plug
18. Shim
19. Spring
20. Ball
21. Back Plate/Relief Assembly
Figure 54
Disassembly of Reel Motor
1. Remove set screws (10) from drive pulley (11).
2. Remove drive pulley (11) from drive shaft.
3. Remove key (4) from drive shaft.
4. Clean outside of motor thoroughly. Scribe a line along
front plate assembly (8), body (6), and back plate assembly (21) to assure proper reassembly.
5. Clamp motor in vise, shaft up.
6. Remove eight cap screws (9).
7. Remove motor from vise, hold motor in hands and
bump shaft against wooden block to separate the front
plate assembly (8) from the back plate assembly (21).
The body (6) will remain with either the front or back
plate.
8. Separate body (6) from either the front or back plate.
9. Remove drive gear (3) and idler gear (2).
10. Remove retaining ring (12), shaft seal (13), and
back−up washer (14) from front plate assembly (8).
11. Remove the two O−rings (5) and two dowel pins (7)
between front plate assembly (8) and body (6), and between body (6) and back plate assembly (21).
IMPORTANT: Remove relief valve kit only if testing
indicates the relief valve is faulty.
12. Remove plug (17) and O−ring (16) from the back
plate (21). Remove shim (18), spring (19), and ball (20)
from the back plate.
Page 85
Reelmaster 4000−D Page 4 − 53 Hydraulic System
Inspection of Reel Motor
GENERAL
1. Clean and dry all parts.
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. Shafts and gears are available as assemblies only.)
4. If gear width is below 1.327, gear assembly should be
replaced.
5. Inspect gear face for scoring and excessive wear.
6. Retaining ring (12) on shaft assemblies should be in
groove.
7. If edge of gear teeth are sharp, break edge with
emery cloth.
FRONT PLATE, BODY, BACK PLATE, AND RELIEF
VALVE
1. Inspect I.D. of bushings in front plate (8), body (6),
and back plate (21). If I.D. exceeds .693, front plate,
body, or back plate should be replaced. (Bushings are
not available as separate items.)
2. Back plate assembly (21) should be replaced if I.D. of
gear pocket exceeds 1.719.
3. Check for scoring on face of front plate (8), body (6),
and back plate (21). If wear exceeds .0015, front plate,
body, or back plate should be replaced.
4. If the relief valve kit (15) was removed, inspect valve
bore in the back plate (21) for dirt, debris, and damage.
Clean bore of dirt and debris. Replace back plate if bore
or valve seating surfaces are damaged.
IMPORTANT: The plug (17), shim (18), spring (19),
and ball (20) must be replaced as a complete unit.
5. If the relief valve kit was removed, inspect plug (17),
shim (18), spring (19), and ball (20) for wear and damage. Replace parts as necessary.
Reassembly of Reel Motor
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. Retaining ring (12), shaft seal (13), back−up washer
(14), and O−rings (5) should be replaced as new parts.
3. Install O−rings (5) in grooves of front plate (8) and
body (6).
4. Install body (6) in front plate assembly (8) noting position of scribe line.
5. Install dowel pins (7) in body (6) and front plate assembly (8).
6. Dip gear assemblies (2 & 3) into oil and slip into body
and front plate bushing.
7. Install back plate assembly (21) noting position of
scribe line. Install cap screws (9), draw up bolts evenly
and torque to 22−25 ft. lbs.
8. Install new back−up washer (14) on drive shaft.
Oil shaft seal (13) liberally. Work shaft seal (13) over
drive shaft taking care not to cut rubber sealing lip.
9. Seat shaft seal (13) by tapping with plastic hammer.
Install new retaining ring (12).
10. Replace key (4) in drive shaft (3).
11. Install drive pulley (11) on drive shaft.
12. Tighten set screws (10) in drive pulley (11).
Hydraulic
System
Page 86
Reelmaster 4000−DPage 4 − 54Hydraulic System
Steering Pump
1
2
3
4
6
7
8
9
10
16
17
18
19
20
21
22
11
12
13
14
15
4
2
16
23
24
25
26
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
15. Front Plate Assembly
16. O−Ring
17. Molded O−Ring
18. Bearing Seal
19. Backup Gasket
20. Wear Plate
21. Body Assembly
22. Back Plate Assembly
23. Relief Valve Assembly
24. O−Ring
25. Back Up Washer
26. O−Ring
Page 87
Reelmaster 4000−D Page 4 − 55 Hydraulic System
Disassembly of Steering Pump
1. Thoroughly clean outside of pump.
2. Use a sharp tool or marker to mark across front plate
(15), body (21) and back plate (22). This will assure
proper reassembly.
3. Clamp pump in a vise, with the shaft up.
4. Remove capscrews (11).
5. Remove pump from vise, hold pump in hands and
bump shaft against a wood block to separate front plate
(15) from back plate (22). Body (21) will remain with either front plate or back plate.
6. If front plate (15) was removed first, remove wear
plate (20) from body gear pockets.
7. Remove drive gear assembly (7) and idler gear as-
sembly (10) from body (21).
8. To separate body (21) from plate it remains with, put
drive gear assembly (7) in a bushing and tap protruding
end with a plastic hammer or soft mallet.
9. Remove O−ring (16) from front plate (15) and back
plate (22).
10. Remove backup−up gasket (19) from front plate
(15).
11. Remove bearing seal (18) from front plate (15) by
prying with a sharp tool.
12. Remove molded O−ring (17) from front plate (15) by
prying with a screwdriver.
13. Remove shaft seal (12) from front plate (15) by pry-
ing with a screwdriver.
Disassembly of Back Plate Assembly (Flow Divider
/ Flow Control / Relief Valve)
1. Remove relief valve (23) from back plate (22).
NOTE: Do not disassemble relief valve cartridge assembly − it must be replaced as an assembly.
2. Remove hex plugs (1, 6) flow divider spool (3), spring
(9) and disk (8).
Inspect Steering Pump Parts
GENERAL
1. Clean and dry all parts.
2. Remove all nicks and burrs from all parts with emery
cloth.
GEAR ASSEMBLY
1. Check drive shaft spline for twisted or broken teeth.
2. Inspect both drive gear (7) and idler gear (10) shafts
at bushing points and seal area for rough surfaces and
excessive wear.
3. If shaft measures less than 0.748” in bushing area,
the gear assembly should be replaced (one gear assembly may be replaced separately; shafts and gears
are available as assemblies only).
4. Inspect gear face for scoring and excessive wear.
5. If gear width is less than 0.636”, the gear assembly
should be replaced.
6. Be sure snap rings are in grooves on either side of
drive and idler gears.
7. If edge of gear teeth are sharp, break edge with
emery cloth.
FRONT PLATE AND BACK PLATE
1. Oil groove in bushings in both front plate and back
plate should be in line with dowel pin holes and 1805
apart.
2. If I.D. of bushings in front plate (15) or back plate (22)
exceed 0.755”, front or back plate should be placed
(bushings are not available separately).
3. Bushings in front plate should be flush with face of
front plate.
4. Check for scoring on face of back plate. If wear exceeds 0.0015”, back plate should be replaced.
BODY
1. Check inside gear pockets for excessive scoring or
wear.
2. Body (21) should be replaced if I.D. of gear pocket ex ceeds 1.713”.
FLOW DIVIDER / FLOW CONTROL / RELIEF VALVE
1. Check disk (8) for wear.
2. Check spring (9) for weakness or breakage.
3. Wash back plate (22) in clean solvent, then direct
compressed air into relief valve and flow divider cavities
in back plate to remove any contamination.
Hydraulic
System
Page 88
Reelmaster 4000−DPage 4 − 56Hydraulic System
1
2
3
4
6
7
8
9
10
16
17
18
19
20
21
22
11
12
13
14
15
4
2
16
23
24
25
26
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
15. Front Plate Assembly
16. O−Ring
17. Molded O−Ring
18. Bearing Seal
19. Backup Gasket
20. Wear Plate
21. Body Assembly
22. Back Plate Assembly
23. Relief Valve Assembly
24. O−Ring
25. Back Up Washer
26. O−Ring
Page 89
Reelmaster 4000−D Page 4 − 57 Hydraulic System
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. Install relief valve (23) with new O−ring (24), back−up
washer (25), and O−ring (26).
2. Install flow divider spool (3), plug (1) with new O−ring
(2), and other plug (6) with new O−ring (2).
3. The wear plate (20), bearing seal (18), molded O−ring
(17), back−up gasket (19), shaft seal (12), and O−rings
(9) should be replaced as new parts.
4. Install O−ring (16) in groove of front plate (15).
5. Tuck back−up gasket (19) into groove in front plate
with open part of “V” section down.
6. Put molded O−ring (17) in groove in front plate. Put
bearing seal (18) over molded O−ring − groove side
down.
7. Apply a thin coat of heavy grease to both milled faces
of body (21). Slip body onto plate − half moon port cavities in body must face away from front plate.
NOTE: The small half moon port cavity must be on the
pressure side of the pump.
8. Put wear plate (20) on top of back−up gasket (19) with
bronze face up. The side with the mid section cut away
must be on suction side of pump.
Dip gear assemblies (10, 7) into oil and slip into front
plate bushings.
9. Install O−ring (16) in groove in back plate (22).
10. Slide back plate (22) over gear shafts until dowel
pins (4) are engaged.
Install bolts (11) and washers (13). Tighten evenly to a
torque of 25 − 28 ft.−lb.
11. Install washer (13). Liberally oil shaft seal (12) and
carefully work over drive shaft, being careful not to cut
rubber sealing lip.
12. Put a 1−5/16” O.D. sleeve over the shaft and press
in shaft seal until flush with front surface of front plate.
Hydraulic
System
Page 90
Reelmaster 4000−DPage 4 − 58Hydraulic System
Lift Control Valve
31
32
33
35
36
37
38
1
2
3
4
5
6
7
8
9
10
16
17
18
19
20
22
23
24
25
26
27
28
29
30
11
12
13
14
15
22
34
39
40
39
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
22. O−Ring
23. Bushing
24. Washer
25. Spring
26. Spacer
27. Retaining Ring
28. Cap Assembly
29. Plunger
30. Plug Assembly
31. Spring
32. Eyelet
33. Poppet Assembly
34. Locknut
35. Seat Assembly
36. O−Ring
37. Plunger
38. Seal Wiper
39. .047 Dia. Orifice
40. .052 Dia. Orifice
Page 91
Reelmaster 4000−D Page 4 − 59 Hydraulic System
Disassembly of Lift Control Valve
1. Plug all ports and clean outside of valve thoroughly.
2. Remove cap assemblies (28). Do not remove retain-
ing rings (26) from spools unless spring (25) is broken.
3. Remove spools (13) from body (8).
NOTE: Spools and spool bores are matched sets. Be
sure each spool is identified with the correct body spool
bore.
4. Remove bushings (23) and O−rings (22) from spools.
5. Remove plugs (11).
6. Remove plugs (30), springs (31), poppets (33), seats
(35) and plungers (37, 29).
IMPORTANT: Check location and positioning of
plungers when removing from body to assure proper assembly.
7. Remove plugs (6).
8. Remove plugs (1), discs (2), springs (3) and detent
plungers (4).
9. Remove locknut (34), washer (12), plug (14), wash-
ers (16, 17, 18), spring (19) and poppet (20).
10. Remove all O−rings and back−up rings from all
plugs and seats.
Inspection of Lift Control Valve
1. Remove all nicks and burns from parts and inspect for
excessive wear.
2. Inspect all plungers and poppet seats for burrs or
roughness.
3. Inspect spool springs (25), relief valve spring (19),
lockout springs (31), and detent springs (3) for breakage.
4. If spools (13) have excessive wear, the valve be-
comes non−serviceable as the spools and spool bores
are matched and damaged spools cannot be replaced.
5. Inspect relief valve poppet (20) for breakage or wear .
Assembly of Lift Control Valve
1. Thoroughly clean and dry all parts. Apply a light coating of clean hydraulic oil to parts prior to assembly.
NOTE: All O−rings, back−up washers, wiper seals and
nylon poppets should be replaced as new items.
2. Install new O−rings (22) in proper grooves in spool
bores.
3. Install relief valve components (20, 19, 18, 17, 16)
with new O−ring (15) on plug (14).
4. Install plugs (11) with new back−up washers (10) and
O−rings (9).
5. Install plungers (37, 29).
IMPORTANT: Check location and positioning of
plungers during installation.
6. Install new O−rings (36) on seats (35). Install new
back−up washers (10) and O−rings (9) on plugs (30).
7. Install seats (35), new poppets (33), and plugs (30).
8. Install plugs (6) with new O−rings (7).
9. Install detent plungers (4), springs (3), discs (2), and
plugs (1) with new O−rings (5).
10. If retaining ring (27) has been removed to replace
spool spring (25), install washer (24), spring (25),
spacer (26), and secure with retaining ring (27).
11. Slide bushings (23) over spools. Slide new O−rings
(22) over spools and position next to bushings. Dip
spools in clean hydraulic oil and install spool assemblies
in proper location.
12. Install spool caps (28) and tighten to a torque of
20 − 25 ft−lb.
13. Install new wiper seals (38).
Hydraulic
System
Page 92
Reelmaster 4000−DPage 4 − 60Hydraulic System
Priority Flow Divider
1
2
3
4
5
6
7
8
9
10
16
17
18
19
11
12
13
14
15
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
11. Shim
12. Shim
13. Shim
14. O−Ring
15. Backup Washer
16. Metering Plug
17. Shim
18. Shim
19. Spring
Page 93
Reelmaster 4000−D Page 4 − 61 Hydraulic System
Disassembly of Priority Flow Divider
1. Plug all ports and thoroughly clean outside of valve.
2. Remove plug (1), shims (17 & 18), spring (19), and
flow control spool (3) from body (4).
NOTE: Notice the position of the spool in relation to
valve body when removing spool (3).
3. Remove metering plug (16).
4. Remove shims (10, 11, 12, & 13) from metering plug
(16).
5. Remove O−rings (5 & 14) and back−up washer (15)
from metering plug (16).
6. Remove groove pin (9) and remove metering stem (8)
from metering plug (16).
7. Remove O−ring (6) and back−up washer (7) from in-
side metering screw (16).
Inspection of Priority Flow Divider
1. Thoroughly clean and dry all parts.
2. Remove all nicks and burrs with emery cloth.
3. Inspect the spool bore inside the body, the surface
should be smooth and free of deep score marks.
4. Inspect O.D. of spool, it should be smooth and free of
nicks and burrs. Spool should slide freely inside the
body bore.
5. Inspect surface of metering stem (8) for deep
scratches and burrs.
Reassembly of Priority Flow Divider
1. Install new back−up washer (7) inside metering plug
(16).
2. Install new O−ring (6) inside metering plug (16).
3. Oil metering stem (8) and install in metering plug (16).
Secure with groove pin (9).
4. Install new back−up washer (15) and new O−rings (5
& 14) on metering plug (16).
5. Install shims (10, 11, 12, & 13) on metering plug (16).
NOTE: Install the same number of shims that were re-
moved.
6. Install metering plug assembly and tighten.
7. Install new O−ring (2) on plug (1) and install plug.
8. Install flow control spool (3), spring (19) shims (18 &
17).
NOTE: Install same number of shims as were removed.
9. Install new O−ring (2) and plug (1) and install plug.
Hydraulic
System
Page 94
Reelmaster 4000−DPage 4 − 62Hydraulic System
Lift Cylinder
1
2
3
4
5
6
7
Figure 59
1. Bleed Screw
2. Washer
3. Rod
4. Wiper
5. Seal
6. Snap Ring
7. Seal Kit
Page 95
Reelmaster 4000−D Page 4 − 63 Hydraulic System
Disassembly of Lift Cylinder
1. Thoroughly clean outside of cylinder assembly.
2. Pull rod (3) out until end of rod and snap ring (6) can
be seen through inlet port.
3. Insert screw driver in inlet port and slide snap ring (6)
into deep groove in the rod assembly.
4. Remove rod assembly (3) from barrel assembly (7).
5. Remove wiper seal (4) and seal (5) from I.D. of barrel
assembly.
Inspection of Lift Cylinder
1. It is not necessary to inspect wiper (4), seal (5), or
snap ring (6). These parts should be replaced as new
items and are included in the seal repair kit available for
this cylinder.
2. Thoroughly clean all parts and remove all nicks and
burrs with emery cloth.
3. Inspect I.D. of barrel assembly (7) for excessive wear
or scoring.
4. Inspect O.D. of rod (3) for nicks, scratches or scoring.
Reassembly of Lift Cylinder
1. All parts should be cleaned and dried thoroughly. Metal parts should be lightly oiled prior to reassembly.
2. Install new seal (5) in barrel. Install new wiper (4) in
barrel with lips facing outward.
3. Install new snap ring (6) in deep groove of rod end (3).
4. Oil outside of piston rod (3) and carefully insert rod in
barrel assembly (7).
5. Push rod into barrel assembly until snap ring area of
rod can be seen through port.
6. By using screwdriver through port, pop snap ring (6)
into lock position.
7. Extend rod (3) to full out position to make sure snap
ring (6) is locked.
8. Cycle cylinder and check for leaks.
Hydraulic
System
Page 96
Reelmaster 4000−DPage 4 − 64Hydraulic System
Reel Control Valve
31
32
33
34
1
2
3
4
5
6
7
8
9
10
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
11
12
13
14
15
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
18. Plunger
19. Micro Switch
20. Flat Washer
21. Machine Screw
22. Cap Head Screw
23. Lock Washer
24. Grease Fitting
25. Block Detent
26. Screw Spool
27. Shallow Washer
28. Wire Washer
29. Spring
30. Deep Washer
31. Washer
32. O−Ring
33. O−Ring
34. Wiper
Page 97
Reelmaster 4000−D Page 4 − 65 Hydraulic System
Disassembly of Reel Control Valve Assembly
1. Plug all outlets and thoroughly clean outside of valve.
2. Remove plug (4) and O−ring (3).
3. Remove relief valve components (8, 7, 6, & 5).
4. Remove screws (22) and lock washers (23).
5. Remove detent block (25).
6. Remove detent plug (9), spring (10), and pawls (11)
from detent block (25).
7. Remove screw spool (26).
8. Remove shallow washer (27), wire washer (28),
spring (29), deep washer (30), washer (31), and O−ring
(32).
9. Remove spool (1).
10. Remove all O−rings and back−up washers from all
plugs, relief valves, and body bore.
11. Thoroughly clean all parts.
Inspection of Reel Control Valve Assembly
1. Remove nicks and burrs from all parts.
2. Inspect spool and body bore for excessive wear.
NOTE: If internal leakage with the spools in spring−
centered position has been experienced, wear is indicated between the spool and body bore. This can be
corrected by replacing the spool and body as an assembly. Spools or bodies cannot be serviced separately.
3. Inspect relief valve.
NOTE: The pilot−operated cartridge−type relief valve is
not adjustable and is pre−set at the factory. However, to
ensure cleanliness in the system; snap ring, washer,
and screens may be removed, cleaned with air, and replaced.
4. Inspection of O−rings and back−up washers is not ne-
cessary. It is recommended that these be replaced as
new parts.
5. Inspect seats in body for wear.
Reassembly of Reel Control Valve Assembly
1. Thoroughly clean and dry all parts. Metal parts should
be lightly oiled prior to assembly.
NOTE: All O−rings and back−up washers should be replaced as new parts.
2. Position O−rings (5, 32, & 33) in body bore.
3. Install O−rings and back−up washers on relief valve
and plugs.
4. Install plug (4).
5. Install O−ring (32), washer (31), deep washer (30),
spring (29), wire washer (28), and shallow washer (27)
into proper position in body casting.
6. Insert spool (1) into body bore and screw spool screw
(26) into spool.
7. Install spring (10), pawls (11), spring (10) and detent
plug (9) into detent block (25).
8. Slip detent block (25) over spool screw (26) and secure to valve body (2) with lock washers (23) and cap
screws (22).
9. Install relief valve (8).
10. Run operational check.
Hydraulic
System
Page 98
Rev. B
Reelmaster 4000−DPage 4 − 66Hydraulic System
Reel Shut Off Valve
1
2
3
4
5
6
7
8
9
1
2
5
6
7
Figure 61
1. Circlip
2. Washer
3. Spacer
4. Spring
5. Wiper
6. Backup Washer
7. O−Ring
8. Body
9. Spool
Disassembly of Reel Shut−Off Valve Assembly
1. Thoroughly clean outside of valve.
2. Remove retaining ring (1) from end of spool (9).
3. Remove spool (9) from valve body (8).
4. Remove washers (2), spring (4), and spacer (3) from
spool (9).
5. Remove wipers (5), back−up washers (6), and O−
rings (7) from spool bore.
Inspection of Reel Shut−Off Valve Assembly
1. Thoroughly clean and dry all parts.
2. Inspect the spool bore inside the body. The surface
should be smooth and free of deep scratches.
3. Inspect O.D. of spool (9). It should be smooth and free
of nicks and burrs.
4. Inspect spring (4) for breakage.
Reassembly of Reel Shut−Off Valve Assembly
1. Install new O−rings (7) and back−up washers (6) in
spool bore, with O−rings to the inside of the back−up
washers.
2. Install new wipers (5) in spool bore.
3. Install washer (2), spacer (3), spring (4), and washer
(2) on spool (9).
4. Dip spool (9) in oil and slide in body bore, taking care
not to cut O−rings (7). Be sure spool is installed in the
proper position.
5. Install retaining ring (1) on end of spool (9).
Page 99
Rev. B
Reelmaster 4000−D Page 4 − 67 Hydraulic System
Traction Rod Assembly
The traction rod assembly allows adjustment to prevent
the machine from creeping when the traction pedal is in
neutral. Additionally, the rod block on the traction rod
prevents traction pedal movement unless the brake is
released.
If the traction rod is disassembled, use the following
steps during assembly.
1. Position neutral lock bracket so that socket head
screws are in the center of mounting slots.
2. Assemble traction rod to machine using Figure 62 as
a guide. Make sure that rod block is positioned downward to engage traction lock lever. Overall traction rod
length (center to center) should be 26.060” (66.2 cm).
The distance between pump lever clevis center and rod
block should be from 8.250” to 8.310” (20.96 to 21.11
cm) (Fig. 63).
3. Attach traction rod to traction pedal and pump lever.
Do not fully tighten fasteners.
4. Make sure that ground speed control lever on ma-
chine is in the fully forward position.
5. Depress traction pedal fully to engage ground speed
control lever and make sure that pump lever has
reached the full rearward stoke. If pump lever does not
reach full stroke or if traction pedal does not engage
ground speed control lever, adjust traction control rod
ends as needed. Make sure that rod block stays in alignment with traction lock lever during any control rod adjustment.
6. Tighten all traction control rod fasteners.
7. Start engine and make sure that machine does not
creep when traction pedal is in the neutral position.
8. If machine creeps when in neutral, loosen two (2)
socket head screws that secure neutral lock bracket to
machine (Fig. 62). Slide neutral lock bracket until machine does not move when in neutral. Tighten socket
head screws.
9. Verify that hand brake functions correctly after trac-
tion rod assembly and adjustments are completed (see
Hand Brake and Traction Switches in the Adjustments
section of Chapter 6 − Axles and Brakes).
1. Traction pedal
2. Pump lever
3. Socket hd screw (2 used)
4. Flat washer (2 used)
5. Lock washer (2 used)
6. Neutral lock bracket
7. Switch
8. Traction rod
9. Rod block
Figure 62
3
4
1
2
7
8
5
6
9
Figure 63
26.060”
(66.2 cm)
8.250 to 8.310”
(20.96 to 21.11 cm)
Hydraulic
System
Page 100
Reelmaster 4000−DPage 4 − 68Hydraulic System
Traction Pump
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
1
2
3
4
5
6
7
8
9
10
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
11
12
13
14
15
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. Housing Assembly
20. Inner Race
21. O−Ring
22. O−Ring Cover
23. Trunnion Cover
24. Screw
25. Retaining Ring
26. Shaft Seal
27. Washer
28. Retaining Ring
29. Thrust Ring
30. Needle Bearing, Thrust
31. Drive Shaft
32. Relief Valve Kit
33. O−Ring
34. Relief Valve Assembly
35. Key
36. Hex Head Cap Screw
37. Cartridge
38. O−Ring
39. Spring
40. Poppet
41. Spring
42. Poppet
43. Spring
44. Spring Retainer
45. O−Ring
46. Back−up Washer
47. Bearing
48. Bearing
Loading...