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PART NO. 98958SL, Rev. A
Service Manual
Reelmaster 4000–D
Preface
The purpose of this publication is to provide the service
technician with information for troubleshooting, testing,
and repair of major systems and components on the
Reelmaster 4000–D.
This safety symbol means DANGER, WARNING,
REFER TO THE TRACTION UNIT AND CUTTING
or CAUTION, PERSONAL SAFETY INSTRUC-
UNIT OPERATOR’S MANUALS FOR OPERATING, TION. When you see this symbol, carefully read
the instructions that follow. Failure to ob
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Reelmaster 4000–D
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Table Of Contents Chapter 1 – Safety Chapter 4 – Hydraulic System General Safety Instructions . . . . . . . . . . . . . . . . . . 1 – 1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 2 Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 – 4 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 3 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . 4 – 8 Chapter 2 – Product Records and Manuals Hydraulic Flow Di
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Reelmaster 4000–D
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Chapter 1 Safety Table of Contents GENERAL SAFETY INSTRUCTIONS . . . . . . . . . . . . 1 SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 4 Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Maintenance and Service . . . . . . . . . . . . . . . . . . . . 3 General Safety Instructions The Reelmaster 4000–D was tested and certified by TORO for compliance with the B71.4–1984 specifica- WARNING tions o
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While Operating 10. Do not run engine in a confined area without ade- 17. Traverse slopes carefully. Do not start or stop sud- quate ventilation. Exhaust is hazardous and could be denly when traveling uphill or downhill. deadly. 18. Operator must be skilled and trained in how to drive 11. Sit on the seat when starting and operating the ma- on hillsides. Failure to use caution on slopes or hills may chine. cause loss of control and vehicle to tip or roll possibly re- sulting in personal injury or
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Maintenance and Service 26. Before servicing or making adjustments, stop en- 34. Do not overspeed the engine by changing governor gine and remove key from the switch. setting. Maximum engine speed is 2500 rpm + or – 100 rpm. To assure safety and accuracy, have an Authorized 27. Assure entire machine is properly maintained and Toro Distributor check maximum engine speed. in good operating condition. Frequently check all nuts, bolts and screws. 35. Shut engine off before checking or adding oil to
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Safety and Instruction Decals The following safety and instruction decals are installed on the Reelmaster 4000–D. If any become damaged or illegible, replace them. Decal part numbers are listed below and in the parts catalog. Order replacements from your Authorized Toro Distributor. ON LIFT ARMS (Part No. 93–7331) ON PANEL IN FRONT OF OPERATOR’S SEAT (Part No. 93–9408) ON STEERING CONSOLE (Part No. 93–9399) ON LEFT SIDE OF MACHINE ON FRAME ABOVE RIGHT REAR WHEEL (Part No. 93–9406) (Part No. 88–6
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Safety and Instruction Decals ON FRAME ABOVE REAR WHEELS NEAR RADIATOR FILL CAP (Part No.93–9405) (Part No. 93–9404) ON FAN SHROUD (Part No. 93–6681) UNDER SEAT NEAR OIL FILL CAP (Part No. 93–8067) ON CUTTING UNIT NEAR FUEL TANK FILL CAP (Part No. 76–8760) (Part No. 93–6680) ON RADIATOR CAP (Part No. 59–8440) NEXT TO TRACTION PEDAL ON STEERING CONSOLE (Part No. 93–9397) Reelmaster 4000–D Safety Page 1 – 5 Safety
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Safety and Instruction Decals ON FRONT CARRIER & TOW BAR (Part No. 93–9400) ON RIGHT CONTROL PANEL (Part No. 93–9402) ON EXHAUST SHIELD (Part No. 95–0645) ON FRONT ACCESS PANEL (Part No. 93–9425) Safety Reelmaster 4000–D Page 1 – 6
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Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 1 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . 3 EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . 2 Fastener Identification . . . . . . . . . . . . . . . . . . . . . . . 3 Decimal and Millimeter Equivalents . . . . . . . . . . . . 2 Standard Torque for Dry, Zinc Plated, and U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . 2 Steel Fasteners
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Equivalents and Conversions Product Records and Maintenance Reelmaster 4000–D Page 2 – 2
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Torque Specifications Recommended fastener torque values are listed in the As noted in the following tables, torque values should be following tables. For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.
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Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Grade 1, 5, & SAE Grade 1 Bolts, Screws, Studs, & SAE Grade 5 Bolts, Screws, Studs, & SAE Grade 8 Bolts, Screws, Studs, & Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts Height Nuts (SAE J995 Grade 2 or Stronger Nuts) (SAE J995 Grade 2 or Stronger 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 +
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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 Thread Size Size Reg Regular lar Height Height N Nuts ts Reg Regular lar Height Height N Nuts ts (Class 8 or Stronger 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 +
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Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Thread Size Size Square Head Hex Socket 7/16 – 20 UNF 65 + 10 ft–lb 88 + 14 N–m Grade 5 1/4 – 20 UNC 140 + 20 in–lb 73 + 12 in–lb 1/2 – 20 UNF 80 + 10 ft–lb 108 + 14 N–m 5/16 – 18 UNC 215 + 35 in–lb 145 + 20 in–lb Grade 5 M12 X 1.25 80 + 10 ft–lb 108 + 14 N–m 3/8 – 16 UNC 35 + 10 ft–lb 18 + 3 ft–lb Class 8.8 1/2 – 13 UNC 75 + 15 ft–lb 50 + 10 ft–lb M12 X 1.
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Lubrication Note: Remove plastic caps over the fittings on the GREASING BEARINGS AND BUSHINGS floating or fixed head pivots and replace caps after The machine has grease fittings that must be lubricated greasing (Fig. 3). after every 50 hours of operation with No. 2 General Pur- pose Lithium Base Grease. Lubricate fitting immediately after every washing regardless of interval listed. The lu- brication points are: lift arms (Fig. 1), rear axle (Fig. 2), floating or fixed head kit pivots (Fig. 3),
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Product Records and Maintenance Reelmaster 4000–D Page 2 – 8
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EQUIPMENT OPERATION AND SERVICE HISTORY REPORT for REELMASTERR 4000–D TORO Model and Serial Number: ______________–______________ Engine Numbers: _____________________________ Transmission Numbers: _____________________________ Drive Axle(s) Numbers: _____________________________ Date Purchased: _____________________________ Warranty Expires____________ Purchased From: _____________________________ _____________________________ _____________________________ Contacts: Parts ______________________
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Reelmaster 4000–D Maintenance Schedule Minimum Recommended Maintenance Intervals Maintenance Procedure Maintenance Interval & Service Every Every Every Every 800hrs 400hrs Lubricate Reel Control Valve Grease Fitting Every 200hrs 100hrs 50hrs Lubricate Reel Speed Valve with Oil Lubricate All Grease Fittings A Level Check Battery Condition and Connections Service Change Engine Oil and Filter Drain Water from Hydraulic Tank Check Engine Fan and Alternator Belt B Level Inspect Cooling System Hos
