Toro Reelmaster 4000-D Service Repair Manual

Table of Content – Reelmaster 4000-D

Preface
1 – Safety
General Safety Instructions
Before Operating
While Operating
Maintenance and Service
Safety and Instruction Decals
2 – Product Records and Maintenance
Product Records
Maintenance
Equivalents and Conversions
Torque Specifications
Lubrication
3 – Engine
Introduction
Specifications
General Information
Check Engine Oil
Check Cooling System
Fill Fuel Tank
Prime Fuel System
Adjustments
Alternator Belt
Service and Repairs
Service Air Cleaner
Change Engine Oil and Filter
Drain Fuel System
Check Fuel Lines and Connections
Replace Fuel Filter
Engine Cooling System
Engine Removal and Installation
Kubota Diesel Engine (S.N Below 250000000)
Kubota 03-E2B Series Workshop Manual (S.N 250000001 and up)
4 – Hydraulic System
Specifications
General Information
Hydraulic Hoses
Hydraulic Fitting Installation
Pushing or Towing Traction Unit
Check Hydraulic Fluid
Hydraulic Schematic
Hydraulic Flow Diagrams
General Pump Flow
Traction Circuit
Steering Circuit
Lift, Lower Circuit
Reel Circuit
4WD Selector Valve Operation
Special Tools
Troubleshooting
Testing
1: Traction Circuit Working and Relief Pressure
Before Performing Hydraulic Tests
2: Counterbalance Pressure
3: Reel Circuit Working and Relief Pressure
4: Reel Circuit Flow
5: Reel Mower Cross-Over Relief Pressure
6: Reel Motor Case Drain Flow
7: Steering Circuit Working and Relief Pressure
8: Lift Circuit Working and Relief Pressure
Service and Repairs
Removing Hydraulic System Components
Steering Control Unit
Add Hydraulic Fluid
Drain Water From Hydraulic Reservoir
Reel Motor
Steering Pump
Lift Control Valve
Priority Flow Divider
Lift Cylinder
Reel Control Valve
Reel Shut-off Valve
Traction Rod Assembly
Traction Pump
Front Traction Motor
Reel Drive Pump
Rear Wheel Drive Motor
Wheel Motor
Rear Wheel Drive Valve Block
Steering Cylinder
Change Hydraulic Oil
Replace Hydraulic Oil Filter
Replace Hydraulic System Breather
Replace Hydraulic Lines and Hoses
5 – Electrical System
Schematics and Diagrams
Electrical Schematic (S.N below 220000000)
Electrical Schematic (S.N 220000001 to 2309999999)
Electrical Schematic (S.N 2400000001 and up)
Main Harness (S.N below 220000000)
Main Wiring Diagram (S.N below 220000000)
Main Harness (S.N 220000001 to 2309999999)
Main Wiring Diagram (S.N 220000001 to 2309999999)
Main Harnesss (S.N 2400000001 & up)
Main Wiring Diagrams (S.N 2400000001 and up)
Control Panel Harness
Control Panel Wiring Diagram
Light Cluster Harness
Light Cluster Wiring Diagram
Special Tools
Troubleshooting
Starting Problems
General Run and Transport Problems
Electrical System Quick Check
Battery Test
Component Testing
Ignition Switch
Hourmeter
Glow Plug and Start Relays
Audio Alarm
Alarm Relay
Hyd Oil Temp Switch
Fuel Sender
Fuel Gauge
Water in Fuel Sensor
High Temp Warning and Cutout Switches
Rear Wheel Drive Solenoid
Fuel Stop Solenoid
Hyd Oil Level Switch
Bridge Rectifier
Glow Controller
Hyd. Oil Filter Switch
Service and Repairs
Battery Storage
Battery Care
Battery Service
Rear Wheel Drive Solenoid Replacement
Check Interlock System
6 – Axles and Brakes
Specifications
Adjustments
Hand Brake and Traction Switches
Rear Wheel Toe-in
Service and Repairs
Rear Wheel Bearing Service (2WD)
Planetary Wheel Drive
7 – Cutting Units
Specifications
Special Tools
Adjustments
Adjust Reel to Bedknife Contact
Height of Cut Adjustment
Quick Change
Fixed Cutting Unit
Adjust Skids and Front Roller
Service and Repairs
Backlapping
Hyd. Motor Installation
Bedknife, Bedbar
Reel Assembly
Reel Grinding
Rollers
Roller Bearing Replacement
Lubrication