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Toro REELMASTER 4500-D, Service Manual

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Toro REELMASTER 4500-D Service Manual Download Page 283

Planetary Wheel Drive 

2

 

3

 

4

 

5

 

6

 

7

 

8

 

9

 

10

 

16

 

17

 

18

 

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11

 

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6

 

26

25

 

Figure 7 

1.  Coupling 

16.  Pipe Plug 

2.  Input Shaft 

17.  Hex Hd. Bolt 

3.  Spindle 

18.  Disengage Cover 

4.  Oil Seal 

19.  Large Cover 

5.  Bearing Cone 

20.  Secondary Carrier Assembly 

6.  Bearing Cup 

21.  O–Ring 

7.  Wheel Bolt 

22.  Disengage Plunger 

8.  Hub 

23.  Thrust Washer 

9.  Bearing Cone 

24.  Ring Gear 

10.  Hex Hd. Bolt 

25.  Retaining Ring 

11.  Flat Washer 

26.  Washer 

12.  Thrust Washer 

27.  Disengage Spring 

13.  Primary Sun Gear 

28.  Retaining Ring Kit 

14.  Hex Hd. Bolt 

29.  Retaining Ring 

15.  Primary Carrier Assembly 

Axles and

Brakes 

Reelmaster 4500–D 

Page 6 – 7 

Axles and Brakes 

Summary of Contents for REELMASTER 4500-D

Page 1: ... sending complete Model and Serial Num ber to The Toro Company 8111 Lyndale Avenue South Minneapolis MN 55420 The Toro Company reserves the right to change product specifications or this publication without notice ING or CAUTION PERSONAL SAFETY Failure to obey the instructions may result in This safety symbol means DANGER WARN INSTRUCTION When you see this symbol carefully read the instructions th...

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Page 3: ...cifications 4 2 General Information 4 3 Hydraulic Schematic 4 7 Hydraulic Flow Diagrams 4 8 4WD Selector Valve Operation 4 23 Special Tools 4 25 Troubleshooting 4 27 Testing 4 29 Repairs 4 38 Chapter 5 Electrical System Wiring Schematics 5 2 Special Tools 5 13 Troubleshooting 5 14 Electrical System Quick Checks 5 18 Component Testing 5 20 Repairs 5 23 Chapter 6 Axles and Brakes Specifications 6 2 ...

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Page 5: ...d serial number to The Toro Company 8111 Lyndale Avenue South Minneapolis Minnesota 55420 1196 Use the Model and Serial Number when referring to your machine If you have questions about this Service Manual please contact The Toro Company Commercial Service Department 8111 Lyndale Avenue South Minneapolis Minnesota 55420 2 Never allow children to operate the machine or adults to operate it without ...

Page 6: ...ield the right of way G Reduce speed when driving downhill 16 Keep hands feet and clothing away from moving parts and the reel 17 Traverse slopes carefully Do not start or stop sud denly when traveling uphill or downhill Safety 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...

Page 7: ...duce 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 mov ing parts Keep everyone away 34 Do not overspeed the engine by changing governor setting Maximum...

Page 8: ...amaged replace them Decals are listed in your Parts Catalog Order replacements from your Authorized TORO Distributor ON PANEL IN FRONT OF OPERATOR S SEAT Part No 58 6540 ON LIFT ARMS Part No 61 3610 ON LEFT SIDE OF MACHINE Part No 59 7290 ON PANEL IN FRONT OF OPERATOR S SEAT Part No 93 9426 Safety Page 1 4 Reelmaster 4500 D ...

Page 9: ...L TANK FILL CAP Part No 59 8440 Part No 49 2280 ON FRAME ABOVE REAR WHEELS Part No 58 5910 ON CUTTING UNIT Part No 76 8760 NEAR FRONT CUTTING UNIT RELEASE LEVER Part No 59 7960 Part No 76 8750 ON FAN SHROUD NEXT TO TRACTION PEDAL ON STEERING CONSOLE Part No 63 4540 Model 03702 03704 NEXT TO LIFT LEVERS Part No 63 4530 Model 03703 03705 Part No 62 6290 Safety Reelmaster 4500 D Page 1 5 Safety ...

Page 10: ...ON FRONT CARRIER TOW BAR NEAR TEST PORTS Part No 86 6120 Part No 58 6680 ON RIGHT CONTROL PANEL Part No 58 6560 ON RIGHT CONTROL PANEL Part No 92 5656 Safety Page 1 6 Reelmaster 4500 D ...

Page 11: ... on the OPERATION AND SERVICE HISTORY REPORT form Use this information when referring to your ma chine TORQUE SPECIFICATIONS 3 Capscrew Markings and Torque Values U S 3 Capscrew Markings and Torque Values Metric 3 OPERATION AND SERVICE HISTORY REPORT 5 Insert Operator s Manuals and Parts Catalogs for your Reelmaster 4500 D at the end of this section Product Records and Manuals Reelmaster 4500 D Pa...

Page 12: ...Equivalents and Conversions Product Records and Manuals Page 2 2 Reelmaster 4500 D ...

Page 13: ...Product Records and Manuals Reelmaster 4500 D Page 2 3 Product Records and Manuals Torque Specifications ...

Page 14: ...Product Records and Manuals Page 2 4 Reelmaster 4500 D ...

Page 15: ...ATION AND SERVICE HISTORY REPORT for REELMASTER 450 D and 4500 D TORO Model and Serial Number __________ _________ Engine Numbers ____________________ Cutting Unit Serial Numbers ____________________ ______________________ Date Purchased ____________________ Warranty Expires__________ Purchased From ____________________ Contacts Parts Phone Service Phone Sales Phone See your TORO Distributor Deale...

Page 16: ...ent Inspect Cutting Unit Reel Drive Belts C Level Torque Wheel Lug Nuts Service Replace Fuel Filter Inspect Fuel Lines and connections Torque Cylinder Head and Adjust Valves D Level Check Engine RPM idle and full throttle Service Drain and Clean Fuel Tank Replace Hydraulic Oil Filter Replace Hydraulic Tank Breather Change Front Planetary Gear Lube Pack Rear Axle Bearings 2wd E Level Check Rear Whe...

Page 17: ...s 1 Clean Traction Pedal Lockout Unusual Engine Noises2 Unusual Operating Noises Hydraulic System Oil Level Hydraulic Hoses for Damage Fluid Leaks Tire Pressure Instrument Operation Warning Lamps Operation Reel to Bedknife Adjustment Height of Cut Adjustment Lubricate All Grease Fittings 3 Touch up damaged paint 1 Use only low pressure compressed air for debris removal Do not use water 2 Check Glo...

Page 18: ...ervice to perform circle A B C D E Other Technician A Service every 50 hours B Service every 100 hours C Service every 200 hours Lubricate Reel Speed Valve with Oil Drain water from Hydraulic Tank Inspect Cutting Unit Reel Drive Belts Check Engine Fan and Alternator Belt Torque Wheel Lug Nuts Check Battery Condition Connecti o ns Inspect Cooling System Hoses A and B Service required A Service requ...

Page 19: ...e Table of Contents SPECIFICATIONS 2 GENERAL INFORMATION 5 SPECIAL TOOLS 3 Alternator Belt Adjustment 5 Priming Fuel System 6 MITSUBISHI 4DQ7 ENGINE SERVICE MANUAL FUEL SYSTEM Reelmaster 4500 D Page 3 1 Engine Engine ...

Page 20: ...rade No 2D diesel fuel ASTM specification Fuel Injection Pump CAV DPA type Governor Centrifugal flyweight Idle Speed no load 1150 20 RPM High Idle no load 2500 25 0 RPM Fuel Injector Nozzle Throttle type Fuel Injection Pressure kg cm2 psi 120 10 0 1706 142 0 Injection Timing 18_ B T D C Engine Oil SAE 10W30 SF CD Crankcase Oil Capacity liter U S qt 6 5 6 9 with filter Cooling System Capacity liter...

Page 21: ... air cleaner element Figure 1 Diesel Engine Compression Test Kit Diesel engine compression test kit 0 1000 PSI gauge allows testing of diesel engines to check general operat ing condition of engine Includes case gauge with hose glow plug hole adapters and instructions Figure 2 Piston Pin Tool Piston pin tool is used to remove and install the wrist pin without distorting the piston Includes an adap...

Page 22: ...Nozzle tester Tests condition and opening pressure of fuel injection nozzles Figure 4 Nozzle Test Adapter Nozzle test adapter is required to test the fuel injection nozzles Figure 5 Engine Page 3 4 Reelmaster 4500 D ...

Page 23: ...r and Serial Number The engine used in the Reelmaster 4500 D is manufac tured by Mitsubishi Heavy Industries Service and repair parts for Mitsubishi engines are supplied through TORO Distributors Repair parts may be ordered by TORO Part Number Alternator Belt 1 Proper tension will allow 3 8 in 10 mm deflection when a force of 10 lbs is applied on the belt midway be tween the pulleys 2 If deflectio...

Page 24: ... foaming tighten plug during the downstroke of the prim ing plunger Wipe up any spilled fuel Note It may be necessary to bleed the air out of the fuel line between the fuel filter and the injection Figure 7 pump To do this loosen the fitting on the injection and repeat bleeding procedure 1 Bleed plug 2 1 2 Priming plunger 3 Normally the engine will now start If engine does not start loosen each in...

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Page 163: ... 14 Test No 8 Traction Charge Pressure 37 Lift Circuit Lift All Circuits 15 REPAIRS 38 Lift Circuit Lower All Circuits 16 Removing Hydraulic System Components 38 Lift Circuits Free Float Detent 17 Steering Control Unit 39 Reel Circuit 18 Reel Motor 50 Reel Circuit All Units Mow Free Float 19 Steering Pump 52 Reel Circuit Units 1 2 3 Mow Free Float 20 Lift Control Valve 56 Reel Circuit Units 1 2 3 ...

Page 164: ...lve 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 Reservoir Fig 2 Reservoir capacity 15 gal U S System capacity approximately 18 2 gal U S 1 1 Figure 1 Figure 2 1 Hydraulic Filter 1 Hydraulic Reserv...

Page 165: ... 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 in jury or gangrene may result WARNING 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...

Page 166: ...ign material 2 Always replace the O ring seal when this type of fit ting shows signs of leakage 3 Lubricate the O ring with a light coating of oil Lock Nut O Ring Back up Washer 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 Figure 6 until the washer contact...

Page 167: ...port it in upright position with seat support rod Figure 8 3 Lift and remove front panel 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 hy draulic system 1 Figure 10 1 By Pass Valve IMPORTANT Make sure that hand brake is engaged before openin...

Page 168: ...el motors disen Vehicle must be on level surface or Tow Bar Assembly Toro part no 58 7020 distance by opening the by pass valve on the variable 4 Lock the wheel hubs immediately after towing is com displacement hydraulic pump and pushing or towing the pleted Remove disengage covers and reinstall so dim machine See Pushing or Towing in the General In ple on cover is facing away from hub formation s...

Page 169: ...CE TRACTION REVERSE L R T P 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...

Page 170: ... 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 cool er 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...

Page 171: ...Engine Run No Functions Hydraulic System Reelmaster 4500 D Page 4 9 Hydraulic System ...

Page 172: ...ess the brake is released Depressing the top of the traction pedal will shift the trac tion pump swash plate to direct a flow of oil to the forward inlet of the traction motors The oil returns from the mo tor to the pump where it continues through the pump in a closed loop circuit System pressure may be moni tored at pressure tap port 1 Hydraulic System Page 4 10 Reelmaster 4500 D ...

Page 173: ...Traction Circuit Forward Hydraulic System Reelmaster 4500 D Page 4 11 Hydraulic System ...

Page 174: ...oir 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 move ment 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 Syste...

Page 175: ...Steering Right Hydraulic System Reelmaster 4500 D Page 4 13 Hydraulic System ...

Page 176: ...o es cape 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 cyl inder The cylinders work against counterbalance pressure during lowering For this reason the cutting un...

Page 177: ...Lift Circuit Lift All Units Hydraulic System Reelmaster 4500 D Page 4 15 Hydraulic System ...

Page 178: ...Lift Circuit Lower All Units Hydraulic System Page 4 16 Reelmaster 4500 D ...

Page 179: ...Lift Circuit Free Float Detent Hydraulic System Reelmaster 4500 D Page 4 17 Hydraulic System ...

Page 180: ...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 mo tor 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 shu...

Page 181: ...Reel Circuit All Units Mow Free Float Hydraulic System Reelmaster 4500 D Page 4 19 Hydraulic System ...

Page 182: ...Reel Circuit Units 1 2 3 Mow Free Float Hydraulic System Page 4 20 Reelmaster 4500 D ...

Page 183: ...Reel Circuit Units 1 2 3 5 Mow Free Float Hydraulic System Reelmaster 4500 D Page 4 21 Hydraulic System ...

Page 184: ...Reel Circuit Any Unit Backup Hydraulic System Page 4 22 Reelmaster 4500 D ...

Page 185: ...4WD Selector Valve Operation 4WD Forward S1 OFF Pressure Oil Pressure Free Hydraulic System Reelmaster 4500 D Page 4 23 Hydraulic System ...

Page 186: ...2WD Forward S1 ON Pressure Oil Pressure Free Hydraulic System Page 4 24 Reelmaster 4500 D ...

Page 187: ...e to take various pressure readings for diagnostic tests Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools A high pressure hose is provided for remote readings Contains one each 1000 5000 and 10000 PSI gauges Use gauges as recommended in Testing section of this chapter Figure 13 Reelmaster 4500 D Page 4 25 Hydraulic System Hydraulic System ...

Page 188: ...range gauge to pro vide 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 ac commodate pressure beyond the capacity of the low pressure gauge 0 5 000 PSI 5 FLOW METER This meter measures actual oil flow in the operatio...

Page 189: ...ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Slow or no traction in either direction Á Á Á Á Á Á Á Á Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Low engine RPM Low hydrauli...

Page 190: ...ift slowly or won t lift ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Low engine RPM Low hydraulic oil level Binding lift arm pivot points ...

Page 191: ... or gan grene may result WARNING force to penetrate skin and do serious dam surgically removed within a few hours by a 1 Thoroughly clean the machine before disconnecting 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 left open or exposed during testing or removal of components 3 ...

Page 192: ...cted 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 circuitquick 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 re...

Page 193: ...nce the counterbalance may require setting outside Figure 16 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 de crease counterbalance pressure Adjust nearer the high end of the range for improved hi...

Page 194: ...ct 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 in serted between the reel blades CAUTION Stand clear of the reels during the following procedures 6 Place reel sp...

Page 195: ...ve of tester is OPEN 6 Position reel speed control knob at middle range 90 Figure 19 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 ...

Page 196: ...20 and reel motor flow direction is from hose to motor Make sure gate valve of tester is OPEN 7 Position reel speed control knob at minimum speed 8 Start engine and move throttle to idle speed 1200 rpm CAUTION Stand clear of reels during the following pro cedures 9 Gently ease the reel control lever into MOW while monitoring the tester NOTE It may be necessary to raise the throttle slightly to pre...

Page 197: ...e 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 pres su...

Page 198: ...le to full speed 2500 rpm 4 Engage the control lever into the LIFT position Mo mentarily hold the lever in the engaged position after full cylinder extension and read gauge TESTER READING TO BE APPROXIMATELY 2650 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 remov...

Page 199: ... 75 150 PSI 4 If there is no pressure or pressure is too low check for restriction in pump intake line Inspect charge relief Figure 23 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 sus pected of...

Page 200: ... Replacement of Components 1 Check oil level in hydraulic reservoir and add correct oil if necessary Drain and refill hydraulic system reser voir and change oil filter if component failure was severe or system is contaminated 2 After repairs check control linkage for proper adjust ment binding or broken parts 3 After disconnecting or replacing any hydraulic com ponents operate machine functions sl...

Page 201: ...ting lines clean port area of unit thoroughly Use a wire brush to remove foreign material and debris from around exterior joints of the unit 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 NOTE Troubleshooting information defines terms and problems possible causes f...

Page 202: ... 25 Use protective ma terial on vise jaws Housing distortion could result if jaws are over tightened Figure 25 2 Remove 5 16 cap screws 3 Remove end cap 4 Remove seal from end cap Figure 26 5 Remove meter Be careful not to drop star 6 Remove seal from meter Figure 27 Hydraulic System Page 4 40 Reelmaster 4500 D ...

Page 203: ...using on a clean soft cloth to protect surface finish Use a thin blade screwdriver to pry retaining ring from housing as shown in Fig 29 Figure 29 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 30 Remove bushing Figure 30 Reelmaster 4500 D Page 4 41 Hydraulic System Hydraulic Syst...

Page 204: ...ing races and the needle thrust bear ing from spool and sleeve assembly Figure 32 16 Remove spool and sleeve assembly from 14 hole end of housing see Fig 33 Attention Do not bind spool and sleeve in housing Rotate spool and sleeve assembly slowly when re moving from housing 17 Push pin from spool and sleeve assembly Figure 33 Hydraulic System Page 4 42 Reelmaster 4500 D ...

Page 205: ...ol slowly when removing from sleeve Figure 34 20 Remove seal from housing see Fig 35 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 35 22 Remove 2 seals from check valve seat 23 Tip housing to remove check ball and check ball re tainer Figure 35 Hydraulic System Reelmaster 4500 D Page 4 43 Hydraulic System ...

Page 206: ...k ball retainer into check valve hole of housing Make sure retainer is straight not tilted on edge in housing see Fig 36 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 36 4 Lubricate check ball seat and seals thoroughly before installing seat in housing When installing seat do not twist or damage seals Install c...

Page 207: ...urface 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 hous ing first see Fig 39 Attention Be extremely careful that the parts do not tilt out of position while inserting Push parts gently into place with slight rotating acti...

Page 208: ...l gland bushing Smooth seal in place with your finger Do not use any seal that falls freely into pocket of bushing see Fig 42 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 Figure 41 16 Install retaining ring see Fig 41 and 42 in housing After installing ring tap on ring e...

Page 209: ... when ready for reassembly Do not use cloth or paper to clean surfaces Figure 43 18 Install 3 diameter seal in housing see Fig 44 19 Install spacer plate Align bolt holes in spacer plate with tapped holes in housing Figure 44 Hydraulic System 20 Rotate spool and sleeve assembly until pin is paral lel with port face see Fig 45 Install drive make sure you engage drive with pin To assure proper align...

Page 210: ...al side of meter toward spacer plate align star valleys ref A on drive ref B Note the parallel relationship of reference lines A B C and D in Fig 47 Align bolt holes without disengaging meter from drive Figure 47 Hydraulic System Page 4 48 Reelmaster 4500 D ...

Page 211: ...cap 25 Install end cap on gerotor align holes Figure 48 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 49 Figure 49 Reelmaster 4500 D Page 4 49 Hydraulic System Hydraulic System ...

Page 212: ...move eight cap screws 9 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 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...

Page 213: ...s are not available as separate items 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 Reassembly of Reel Motor 1 Retaining ring 12 shaft seal 13 back up washer 14 and O rings 5 should be replaced as new parts 2 Install O rings 5 in grooves of front plate 8 and body 6 3 Install bod...

Page 214: ... 3 Spool 17 Molded O Ring 4 Dowel Pin 18 Bearing Seal 6 Plug includes 2 19 Backup Gasket 7 Drive Gear Assembly 20 Wear Plate 8 Disc 21 Body Assembly 9 Spring 22 Back Plate Assembly 10 Idler Gear Assembly 23 Relief Valve Assembly 11 Hex Head Cap Screw 24 O Ring 12 Shaft Seal 25 Back Up Washer 13 Washer 26 O Ring 14 Bushing Hydraulic System Page 4 52 Reelmaster 4500 D ...

Page 215: ...arts 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 as sembly may be replaced separately shafts ...

Page 216: ...ear Assembly 8 Disc 9 Spring 10 Idler Gear Assembly 11 Hex Head Cap Screw 12 Shaft Seal 13 Washer 14 Bushing 11 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 Hydraulic System Page 4 54 Reelmaster 4500 D ...

Page 217: ...art 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 cavi ties 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 gask...

Page 218: ... 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 Hydraulic...

Page 219: ...e 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 coat ing 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 In...

Page 220: ...5 2 1 1 11 Shim 12 Shim 13 Shim 14 O Ring 15 Backup Washer 16 Metering Plug 17 Shim 18 Shim 19 Spring Figure 54 1 Plug Assembly 2 O Ring 3 Spool 4 Body 5 O Ring 6 O Ring 7 Backup Washer 8 Metering Stem 9 Groove Pin 10 Shim Hydraulic System Page 4 58 Reelmaster 4500 D ...

Page 221: ...oth 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...

Page 222: ...Lift Cylinder 1 2 7 6 5 4 3 Figure 55 1 Bleed Screw 5 Seal 2 Washer 6 Snap Ring 3 Rod 7 Seal Kit 4 Wiper Hydraulic System Page 4 60 Reelmaster 4500 D ...

Page 223: ...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 Met al 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 gr...

Page 224: ...chine Screw 5 O Ring 22 Cap Head Screw 6 Backup Washer 23 Lock Washer 7 O Ring 24 Grease Fitting 8 Relief Valve 25 Block Detent 9 Detent Plug 26 Screw Spool 10 Detent Spring 27 Shallow Washer 11 Detent Pawl 28 Wire Washer 12 Locknut 29 Spring 13 Lock Washer 30 Deep Washer 14 Circlip 31 Washer 15 Spring 32 O Ring 16 Plug 33 O Ring 17 Sleeve 34 Wiper 18 Hydraulic System Page 4 62 Reelmaster 4500 D ...

Page 225: ...t 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 re placed 4 Inspection of O rings and back up washers is not necessary It is recommended that these be replaced as new parts 5 Inspect seats in body for wear Reassembly of Reel Control Valve Assembly 1 Th...

Page 226: ...Reel Shut Off Valve 1 2 3 4 5 6 7 8 9 1 2 5 6 7 Figure 57 1 Circlip 6 Backup Washer 2 Washer 7 O Ring 3 Spacer 8 Body 4 Spring 9 Spool 5 Wiper Hydraulic System Page 4 64 Reelmaster 4500 D ...

Page 227: ... spool bore inside the body The surface should be smooth and free of deep scratches 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 spo...

Page 228: ...n 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 Trunion 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 ...

Page 229: ...p to remove Remove housing gas ket 10 9 Remove the tow valve 4 from back plate 9 To dis assemble tow valve remove retaining ring from spread er and pull spreader from spreader plug 10 Remove plug assembly 3 spring 41 and relief valve assembly 34 from back plate 11 Remove pump from vise and remove rotating kit as sembly 12 from housing 19 12 If pistons did not come out with piston block you may rem...

Page 230: ...tating 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 Trunion 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 Ri...

Page 231: ...e 7 Inspect the piston block The surface that contacts the back plate should be smooth and free of grooves 8 The pistons should move freely in the piston block bore If they are sticky in the bore examine the bore for scoring or contamination 9 Examine the O D of the pistons for finish condition they should not show wear or deep scratches The shoes should be snug fit on the ball end of the pistons ...

Page 232: ...tating 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 Trunion 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 Ri...

Page 233: ...n block Install rotating assembly in the housing assembly the piston shoes must be in contact with the camplate 8 Clamp pump assembly in a protected jaw vise with the open end of the housing up 9 Install new housing gasket 10 10 Install back plate 9 11 Install ball and pin into check valve housing if re moved Install new O ring 45 and back up washer 46 on check valve assembly 8 Install O ring near...

Page 234: ... 22 Shaft Seal Disassembly of Traction Motor 5 Remove capscrews 1 2 from backplate 5 1 Clean outside of unit thoroughly 6 Use a plastic mallet and tap the backplate 5 to loos en it then pull the backplate straight out 2 Remove retaining ring 9 from housing assembly 17 7 Remove O ring 6 from backplate 3 Clamp shaft in a protected jaw vise with backplate 8 Remove the complete rotating assembly 19 fr...

Page 235: ...ect the camplate assembly 18 the surface op posite the chamfered side should show no signs of scor ing 8 Inspect the flat surface on the backplate 5 it should be free of excessive scoring or metal build up 9 Inspect the drive shaft 10 for fretting in the bearing areas Check spline area for twisted or broken teeth If keyed shaft check for cracked or chipped keyway Reassembly of Traction Motor 1 Lub...

Page 236: ...0 Spline Drive Gear 2 Lock Washer 11 Driven Gear 3 Stud 12 O Ring Seal 4 Stud 13 Rear Port Section 5 Front Cover 14 Coupling 6 Gland Seal 15 O Ring 7 Wear Plate 16 Plug 8 Center S A Section 17 Shaft Seal 9 Shaft Seal 18 Retaining Ring Hydraulic System Page 4 74 Reelmaster 4500 D ...

Page 237: ...ove front cover S A 4 from vise and place on work bench with mounting flange down Using a bronze drift and hammer drive inner shaft seal 17 out through mounting flange being careful not to damage bearing 4 Inspect the drive and driven gear bushings of front cover 4 for pickup scoring discoloration or excessive wear Any of the preceding conditions shall warrant re placement of the front cover S A 4...

Page 238: ...ine Drive Gear 2 Lock Washer 11 Driven Gear 3 Stud 12 O Ring Seal 4 Stud 13 Rear Port Section 5 Front Cover 14 Coupling 6 Gland Seal 15 O Ring 7 Wear Plate 16 Plug 8 Center S A Section 17 Shaft Seal 9 Shaft Seal 18 Retaining Ring Hydraulic System Page 4 76 Reelmaster 4500 D ...

Page 239: ...o locating holes of port section 13 with major diameter facing port section and notch facing inlet port Make sure wear plate and center section set flush against port section 10 Tape the spline area long spline of drive gear 10 to prevent cutting shaft seal s during assembly 11 Lubricate drive gear 10 and driven gear 11 Install drive gear 10 into port section 13 with short spline towards port sect...

Page 240: ...pirits does not affect the O ring material Particles as fine as talcum powder can affect the operation of high pressure hy draulic valves NOTE Apply clean hydraulic oil to the O rings before installingthe valve Use a deep socket to install the valve into the manifold block Tighten to a torque of 35 ft lb 48 Nm Install the solenoid coil Make sure there is an O ring at each end of the coil After put...

Page 241: ... clean the port area of the motor thoroughly Use a wire brush to remove foreign material and debris from around the exterior joints of the motor Check the shaft and keyslot remove all nicks burrs or sharp edges that might damage the bearing housing seals when installing the shaft and bearing assembly Before start ing the disassembly procedures drain the oil from inside the motor 8 Bolt 9 Outer Sea...

Page 242: ...r in a vise we recommend that you keep the motor in the vise during disassembly and reassembly Follow the clamping procedures explained throughout the manual Figure 67 2 Remove 4 bolts from motor Figure 68 3 Lift valve housing straight up If done carefully the pins springs balance ring assembly and valve will re main on the valve plate Figure 69 4 Carefully remove 3 76 diameter seal from valve hou...

Page 243: ... seal from valve plate 12 Remove the valve drive Figure 72 13 Remove the Geroler Be sure to retain the rollers in the outer ring if they are loose 14 Remove the drive 15 Remove the 3 76 diameter seal from wear plate see Fig 73 Figure 73 16 Remove the wear plate 17 Remove the shaft face seal from the wear plate 18 Remove the 3 76 diameter seal from bearing hous ing Figure 74 Reelmaster 4500 D Page ...

Page 244: ...eals when reassembling the bearing housing NOTE Lubricate all seals prior to installation with pe troleum jelly such as Vaseline Use new seals when reassembling this motor 21 Use a press to install exclusion seal in outer bore of bearing housing Lip of seal must face outward See Fig 77 If a press is not available use a plastic or rubber ham mer being careful not to damage or cock seal in the bore ...

Page 245: ...ocate the largest open pocket in the Geroler and mark it on the outside edge of the Geroler 33 Apply a light film of petroleum jelly to the 3 76 diam eter seal Install seal in groove of valve plate 34 Align the notch on the outside of the valve plate with the notch on the Geroler as shown in Fig 78 Timing Step 2 Locate the slot opening in the valve plate which is in line with the largest open pock...

Page 246: ...p ply pressure to side of balance ring as shown in Fig 82 Hold ring in position until valve housing is in place against valve plate See Fig 83 NOTE After installing the valve housing on the valve Figure 82 plate check for proper placement Push down on the valve housing You should get a slight spring action Figure 83 40 Install the tie bolts If you use alignment studs install 2 bolts opposite the s...

Page 247: ...fferent bearing housing is used see Fig 85 Other than this the parts are the same as the standard motor and the same disassembly and reas sembly procedures apply Figure 85 Reelmaster 4500 D Page 4 85 Hydraulic System Hydraulic System ...

Page 248: ...rod and use a twisting and pulling motion to carefully extract piston piston rod and head from cylinder barrel 10 Spacer 11 Servon 12 O Ring 13 Piston 14 Locknut 15 Barrel Assembly 16 Jam Nut 17 Rod Tie End 18 Roll Pin 6 Securely mount piston piston rod and head into vise and remove nut IMPORTANT Do not clamp vise jaws against smooth piston rod surface the piston rod will be come damaged 7 Remove ...

Page 249: ...new seals and O rings sembly Install the new seal and O rings 15 Slide piston rod assembly into cylinder tube 12 Install head onto piston rod 16 Install head into tube Install threaded cap and tight 13 Install piston onto piston rod with O ring seal 9 and en set screw tighten hex nut Reelmaster 4500 D Page 4 87 Hydraulic System Hydraulic System ...

Page 250: ...Hydraulic System Page 4 88 Reelmaster 4500 D ...

Page 251: ... Silence Circuit 2 11 Warning Lamp Circuit 12 Alarm Circuit 13 SPECIAL TOOLS 14 TROUBLESHOOTING 15 Verify Interlock Operation 18 ELECTRICAL SYSTEM QUICK CHECKS 19 Battery Test 19 Charging System Test 19 Voltage Drop Testing 19 Glow Plug System Test 20 Starting System Test 20 COMPONENT TESTING 21 Ignition Key Switch 21 Bosch Relay 22 Rear Wheel Drive Solenoid 23 REPAIRS 24 Battery Service 24 Rear W...

Page 252: ...0 050 0 0 0 0 0 0 7 7 0 0 0 0 1 5 5 1 1 5 5 1 0 0 0 0 0 10 0 7 0 1 0 0 7 7 0 7 40 0 7 5 4 0 74 0 4 5 0 0 00 000 0 0 0 10 0210 0 3 2 3 0 0 0 0 5 4 0 02 0 3 0 74 0 0 0 0 0 0 0 0 0 0 0 0 0000 00000 5 0 0 00 0 0 1 0 0 0 6 0 6 01400 02 00 3 00 0 00 0 0 0 0 Wiring Schematics ...

Page 253: ...Electrical System Reelmaster 4500 D Page 5 3 Electrical System ...

Page 254: ...Electrical System Page 5 4 Reelmaster 4500 D ...

Page 255: ...Electrical System Reelmaster 4500 D Page 5 5 Electrical System ...

Page 256: ...Electrical System Page 5 6 Reelmaster 4500 D ...

Page 257: ...Electrical System Reelmaster 4500 D Page 5 7 Electrical System ...

Page 258: ...Electrical System Page 5 8 Reelmaster 4500 D ...

Page 259: ...Electrical System Reelmaster 4500 D Page 5 9 Electrical System ...

Page 260: ...Electrical System Page 5 10 Reelmaster 4500 D ...

Page 261: ...Electrical System Reelmaster 4500 D Page 5 11 Electrical System ...

Page 262: ...Electrical System Page 5 12 Reelmaster 4500 D ...

Page 263: ...Electrical System Reelmaster 4500 D Page 5 13 Electrical System ...

Page 264: ...omponents and circuits for current resistance or voltage draw NOTE Toro recommends the use of a DIGITAL Volt Ohm Amp mutli meter when testing electrical circuits The high impedance internal resistance of a digital me ter will ensure that excess current is not allowed through the meter Excess current can cause damage to a circuit that is not designed to carry it Figure 2 Skin Over Grease Special no...

Page 265: ...t crank if solenoid clicks problem is not in safety interlock system Low battery charge Loose or corroded battery cables Loose or corroded ground Faulty wiring at starter Faulty starter solenoid Nothing happens when start attempt is made Battery is dead Loose or corroded battery cables Loose or corroded ground Parking brake is off Mow backlap lever is engaged Circuit breaker open Traction brake sw...

Page 266: ...ty Engine overheat shutdown switch wiring loose corroded or damaged Traction brake switch SW1 out of adjustment or faulty Traction brake switch SW1 wiring loose corroded or damaged Engine or fuel system problem Engine cranks but should not with parking brake off Traction brake switch SW2 is faulty Short circuit in Traction brake switch circuit Engine cranks but should not with mow backlap Reel dri...

Page 267: ...at switch from closing Seat switch is faulty or out of adjustment Seat switch wiring loose corroded or damaged Engine kills during operation operator sitting on seat Operator moved too far forward on seat seat switch not depressed Low hydraulic oil level Engine overheated Wire broke or became disconnected 4WD does not engage 4WD selector switch faulty 4WD selector switch wiring loose corroded or d...

Page 268: ...to start engine with Mow Back lap lever Fig 4 in the STOP position If engine cranks there is a malfunction that must be repaired immedi ately If engine does not crank brake switch is operating properly 4 Engage parking brake Fig 4 start engine and lower cutting units Move Mow Backlap lever Fig 4 to MOW Raise off the seat engine should stop within a few sec onds which indicates the interlock system...

Page 269: ...tput but not how much amps or what it is ca pable of Tool required Digital Multimeter DC volts setting Test instructions Connect the positive DVOM test Lead on the positive Battery Post and negative Lead on the negative Battery Post Leave test leads con At least 1 volt over Open Circuit test results Example Open Circuit Test results 12 5v Charging System Test results 13 5v Difference 1 0 v Voltage...

Page 270: ...instructions in Operator s Manual and re cord the final results The Reelmaster 4500 D glow plug system should have a reading of 25 30 Amps Starting System Test This is an excellent test to use when a slow crank no start problem is encountered It will tell you if the prob lem is due to an electrical open short or high resistance in the starter circuit NOTE The Battery condition and state of charge ...

Page 271: ... ohm meter or continuity tes been disconnected ter make sure that power to the circuit has Ignition Key Switch The ignition key switch has three positions OFF START and RUN The terminals are marked as shown The circuitry of the ignition switch is shown in the chart With the use of a continuity tester the switch func tions may be tested to determine whether all circuits are being completed while th...

Page 272: ...continuity tester between the relay termi nals terminals 30 and 87 The relay should make and break continuity at terminals 30 and 87 as 12 V D C is connected and disconnected to terminal 85 with termi nal 86 connected to ground Figure 7 Electrical System Page 5 22 Reelmaster 4500 D ...

Page 273: ...etract check for binding or damage in valve 4 If valve operates smoothly but does not retract when 12V DC is applied to solenoid leads replace solenoid coil 5 If valve still does not retract after replacing solenoid coil replace the valve NOTE To do a quick test without removing the solenoid coil or valve hold a screwdriver to top of valve When so lenoid is enertized screw driver should be attract...

Page 274: ...ve the plates inside the battery add water so the level is to the bottom of the cap tubes If the level is below the plates add wa ter only until the plates are covered and then charge the Electrolyte Specific Gravity Fully charged 1 250 1 280 Discharged less than 1 240 Battery Specifications BCI Group 48 Battery 440 Amp Cranking Performance at 0_ F 17_ C battery After charging fill the battery to ...

Page 275: ...enoid coil Make sure o ring is installed at each end of coil Apply Loctite 242 or equivalent to threads on end of valve stem before installing nut Tight en nut to a torque of 15 in lb Over tightening may dam age the solenoid or cause the valve to malfunction 5 Connect wiring connector Figure 12 Electrical System Reelmaster 4500 D Page 5 25 Electrical System ...

Page 276: ...Electrical System Page 5 26 Reelmaster 4500 D ...

Page 277: ...kes Table of Contents SPECIFICATIONS 2 REPAIRS 5 ADJUSTMENTS 3 Rear Wheel Bearings 5 Hand Brake and Traction Switches 3 Planetary Wheel Drive 7 Rear Wheel Toe In 4 Reelmaster 4500 D Page 6 1 Axles and Brakes Axles and Brakes ...

Page 278: ...eel nut torque 30 35 ft lb rear 60 85 ft lb front Wheel planetary mounting cap screw torque 95 110 ft lb Rear wheel toe in 0 25 in Wheel planetary lubricant Fig 1 SAE 80 90W EP gear lube 30 oz capacity 1 Figure 1 1 Check Fill Plug Axles and Brakes Page 6 2 Reelmaster 4500 D ...

Page 279: ...ional click 3 Adjust four U bracket nuts equally so spring has ten sion Adjustment affects operation of traction switches 4 Adjust four U bracket nuts so engine will start and run when hand brake is at fourth click but will not start or run when hand brake is at second click Figure 2 1 Hand Brake 4 Traction Switches 2 Brake Cable 5 Traction Pedal 3 U bracket Nuts Reelmaster 4500 D Page 6 3 Axles a...

Page 280: ...measure ment must be 1 8 in less than rear measurement 2 Loosen clamps at both ends of tie rods Fig 4 3 Rotate tie rod to move front of tire inward or outward 4 Tighten tie rod clamps when adjustment is correct NOTE Make sure tie rod clamps are positioned so they do not interfere with steering linkage Figure 3 1 2 Figure 4 1 Clamp 2 Tie Rod Axles and Brakes Page 6 4 Reelmaster 4500 D ...

Page 281: ...8 Drive Screw 33 Flange Bushing 9 Rear Wheel Hub 34 Thrust Washer 10 Outer Bearing Cup 35 Hydraulic Hose 11 Outer Bearing Cone 36 Steering Cylinder 12 Tire 37 Hydraulic Hose 13 Lug Nut 38 O Ring 14 Rim 39 Hydraulic Fitting 15 Cotter Pin 40 O Ring 16 Hub Cap 41 Roll Pin 17 Jam Nut 42 Pivot Shaft 18 Tab Washer 43 Hex Nut 19 Valve Stem 44 Grease Fitting 20 Bearing Inner Cup 45 Ball Joint 21 Bearing I...

Page 282: ... the wheel hub IMPORTANT The lip seal must be pressed in so it is flush with the end of the hub The lip of the seal must be toward the bearing 8 Pack inside of wheel hub with some grease not full Install remaining bearing 11 into bearing cup 10 9 Slide the wheel onto the spindle shaft and secure it in place with the flat washer 18 nut 17 and retainer nut 50 DO NOT tighten the nut or install the co...

Page 283: ...Cover 5 Bearing Cone 20 Secondary Carrier Assembly 6 Bearing Cup 21 O Ring 7 Wheel Bolt 22 Disengage Plunger 8 Hub 23 Thrust Washer 9 Bearing Cone 24 Ring Gear 10 Hex Hd Bolt 25 Retaining Ring 11 Flat Washer 26 Washer 12 Thrust Washer 27 Disengage Spring 13 Primary Sun Gear 28 Retaining Ring Kit 14 Hex Hd Bolt 29 Retaining Ring 15 Primary Carrier Assembly Axles and Brakes Reelmaster 4500 D Page 6 ...

Page 284: ... play when proper retaining ring is installed 5 Assemble a retaining ring 25 in groove opposite pi lot end of input shaft 2 Assemble a washer 26 spring 27 a second washer 26 a second retaining ring 25 and a third retaining ring 29 in the middle groove of input shaft Some shafts have a shoulder and require only one retaining ring 6 Assemble the splined end of the input shaft down into spindle 7 Ass...

Page 285: ...he Bedknife Bedbar Assembly 12 Height of Cut Adjustment Floating Cutting Unit 6 Servicing the Reel Assembly 13 Quick Method for Changing Height of Cut Roller Removal and Installation 16 After Initial Set Up of a Floating Cutting Unit 8 Height of Cut Adjustment Fixed Cutting Unit 8 Adjusting Skids and Front Roller Fixed Head Cutting Unit 8 Reelmaster 4500 D Page 7 1 Cutting Units Cutting Units ...

Page 286: ...ation isolation bushings Bedknife to Reel Adjustment Two lockable lead screw adjusters at each side of the frame adjust the reel to bedknife contact Rear Roller 3 1 2 in 89 mm diameter steel roller has greaseable tapered roller bearings A double lip oil seal and wear sleeve isolates grit and moisture from the bearings Height of Cut 5 Blade 1 to 3 in 25 to 76 mm 7 Blade 1 2 to 1 3 4 in 9 5 to 45 mm...

Page 287: ... a local supplier UCTS Some tools may be listed in the Reelmaster Gauge Bar Assembly Use gauge bar to set final height of cut floating cutting unit with front roller only Figure 2 Handle Assembly For applying lapping compound to cutting units while keep hands a safe distance from the rotating reel Figure 3 Reelmaster 4500 D Page 7 3 Cutting Units Cutting Units ...

Page 288: ...ecure bedknife to bedbar With clean bedbar threads and new screws tighten to a torque of 250 in lb NOTE Remove all rust scale and corrosion from bed bar surface before installing bedknife DO NOT use and air impact wrench with this tool Figure 4 Cutting Units Page 7 4 Reelmaster 4500 D ...

Page 289: ...ght contact is felt and heard between the reel and bedknife Final adjustment should always be in the tightening clockwise direction D Tighten adjuster locking nuts when completed making adjustments CAUTION gloves and use care when turning reels by hand Sharp edges can cut or pinch hands or fingers When adjusting the cutting units wear heavy IMPORTANT Adjusted correctly the reel will cut pa per app...

Page 290: ...8 and approximately 3 8 9 5 mm thicker than the desired height of cut under the reel and up against the bedknife cutting edge Fig 8 The reel not bedknife must contact the bar stock along its full length NOTE Using a bar 3 8 9 5 mm thicker than height of cut provides proper bedknife attitude heeled up in back required for excellent low height of cut perfor mance D Loosen rear roller jam nuts and ad...

Page 291: ... bar against bottom of front roller Fig 10 I Loosen front roller nuts and adjust both ends of the front roller until it contacts gauge bar at both ends With the gauge bar held firmly against the bottom of the rollers adjust the front roller so the screw head just slips over the lip of the bedknife Fig 10 Tight en front roller nuts IMPORTANT Set properly front and rear rollers will contact gauge ba...

Page 292: ... 8 6 Adjust rear roller adjustment knobs and jam nuts until Figure 11 full length of the rear roller contacts the flat surface and the full length of the reel not bedknife contacts the bar stock Tighten rear roller knobs and jam nuts Adjusting Skids and Front Roller Fixed Head Cutting Unit After skid kit or front rollers are installed installation instructions are included with each option make th...

Page 293: ...perate the controls opera tor the other performs the backlapping operation NOTE Before starting the engine raise the grass deflec tor on the 1 cutting unit center and tighten fasteners CAUTION UNDER NO USE A CIRCUMSTANCES SHORT HANDLED PAINT BRUSH TO APPLY BACKLAPPING COMPOUND A ROTATING REEL CAN ACTUALLY PULL A SHORT HAN DLED PAINT BRUSH AND THE USERS HAND INTO THE REEL CAUSING SERIOUS PER SONAL ...

Page 294: ...aper should be cleanly sheared across the entire width of the reel If the paper is not sheared acceptably continue backlapping H After backlapping the first cutting unit raise and latch this unit and proceed with the 2 and 3 cutting units NOTE See the Toro Sharpening Manual Part 80 300 for additional backlapping sharpening in formation Hydraulic Motor Installation 1 Install the drive plate shield ...

Page 295: ...e at the bottom of the 1 Reel motor fasteners housing to allow for drainage 1 3 Cutting unit IMPORTANT When hydraulic motors have been 2 Hose bracket mounted to the cutting units make sure hydraulic hoses lay flat and do not contact the frame of the machine when the cutting units are in the raised position There should also be sufficient slack SO hoses are above and not in contact with the floata ...

Page 296: ... the bedbar of all rust and scale Remove any material on the mounting face of the bedbar that will affect a good match up with the bedknife 2 Before installation apply a coating of Never Seez or any material that will ease future disassembly of the bedknife mounting screws to the threads before instal lation 3 Use a torque wrench and special bedknife screw tool to complete tightening of the screws...

Page 297: ...bar bed knife assembly Fig 20 3 Remove the inboard locknut from the adjuster pin the fasteners for the bracket and remove the adjusting han dle assembly from the side plate Fig 20 Figure 19 1 Guard 4 Adjusting assembly 2 Mounting fasteners 5 Dust cap 3 Bedbar mounting assembly Figure 20 1 Locknut 4 Bearing housing 2 Belleville washer 5 Reel shaft 3 Shoulder bolt 6 Flange bushing Reelmaster 4500 D ...

Page 298: ... and cone nut belleville washer and shoulder bolt securing the housing to the side plate Fig 22 Remove the housing 9 Slide the reel assembly out of the slots in the side Figure 21 plates 1 Drive housing cover removed 10 To remove the bearing and seals from the drive 2 Drive belt housing remove the retaining ring from inside the hous ing Pry the outer seal out of the belt drive case side Press the ...

Page 299: ...nd rear housing mounting hole Slide the bolt through the side plate mounting hole Fig 20 Install the cone nut locknut onto the bolt Tighten the cone nut to 45 55 ft lbs 8 Align the drive pinon the reel shaft with the notch in the bearing inner race and slide the bearing housing over the opposite end of the reel shaft Insert the shoulder bolt and belleville washer through the rear bearing hous ing ...

Page 300: ...sliding it off the shaft at both ends Fig 25 IMPORTANT When assembling a new roller to the cutting unit mount the roller so that the roller shaft locknut is on the right side of the cutting unit Fig 25 As viewed by the operator sitting on seat of ma chine This prevents the lock nut from loosening during operation Figure 24 1 Guard 2 Roller adjustment housing 3 Side plate 4 Mounting fasteners Figur...

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Page 302: ...Commercial Products The Toro Company ...

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