Toro Reelmaster 4000?D Service Manual
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
Reelmaster 4000−D
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
Reelmaster 4000−D
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
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.
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
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.
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
0.09375
Rev. C
Reelmaster 4000−D
Page 2 − 2
Product Records and Maintenance
Equivalents and Conversions
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
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.
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
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
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
Rev. C
Reelmaster 4000−D
Page 2 − 8
Product Records and Maintenance
This Page Intentionally Left Blank
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
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.
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
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
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
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
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
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.
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
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
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
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
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
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
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