Page 1 Minneapolis, MN 55420 portant instructions which must be followed to pre- vent damage to systems or components on the The Toro Company reserves the right to change product machine. specifications or this publication without notice. The Toro Company – 1995...
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Page 3 Table Of Contents Chapter 1 – Safety 4WD Selector Valve Operation ....4 – 23 Special Tools ......4 –...
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Page 5 The Toro Company 6. Wearing safety glasses, safety shoes, long pants and 8111 Lyndale Avenue South a helmet is advisable and required by some local ordi- Minneapolis, Minnesota 55420–1196...
Page 6 G. Reduce speed when driving downhill. 25. The optional TORO tow bar is for emergency towing only. Use only the special tow bar if it becomes neces- 16. Keep hands, feet and clothing away from moving sary to tow machine.
Page 7 37. Toro recommends that two people be used to back- tor or gangrene may occur. lap reels. Each person has specific duties and you must communicate with one another.
Page 8 Safety and Instruction Decals The following safety and instruction decals are installed on the traction unit. If any become damaged, replace them. Decals are listed in your Parts Catalog. Order replacements from your Authorized TORO Distributor. Safety Reelmaster 4500–D Page 1 – 4...
Page 9 Reelmaster 4500–D Safety Page 1 – 5...
Page 10 Safety Reelmaster 4500–D Page 1 – 6...
Page 11 Chapter 2 Product Records and Manuals Table of Contents PRODUCT RECORDS ......1 TORQUE SPECIFICATIONS ....3 EQUIVALENTS AND CONVERSIONS .
Page 12 Equivalents and Conversions Product Records and Manuals Reelmaster 4500–D Page 2 – 2...
Page 13 Torque Specifications Reelmaster 4500–D Product Records and Manuals Page 2 – 3...
Page 14 Product Records and Manuals Reelmaster 4500–D Page 2 – 4...
Page 15 ____________________ ______________________ ____________________ ______________________ Date Purchased: ____________________ Warranty Expires__________ Purchased From: ____________________ ____________________ ____________________ Contacts: Parts ____________________ Phone __________________ Service ____________________ Phone __________________ Sales ____________________ Phone __________________ See your TORO Distributor/Dealer for other Publications, Manuals, and Videos from The TORO Company.
Page 16 REELMASTER® 450-D and 4500-D Maintenance Schedule Minimum Recommended Maintenance Intervals: Maintenance Procedure Maintenance Interval & Service Type Every Every Every Every 800hrs Lubricate Reel Control Valve Grease Fitting Every 400hrs 200hrs 100hrs 50hrs Lubricate Reel Speed Control Valve with Oil Lubricate all Grease Fittings A Level Service...
Page 17 REELMASTER® 450-D and 4500-D Daily Maintenance Check List Unit Designation:__________ Daily Maintenance: TORO ID#:_______-_______ (duplicate this page for routine use) Daily Maintenance Check For Week Of _____________ TUES THURS _____ _____ _____ _____ _____ _____ _____ Maintenance Check Item Safety Interlock Operation...
Page 19: Table Of Contents
Chapter 3 Engine Table of Contents SPECIFICATIONS ......2 GENERAL INFORMATION ..... 5 SPECIAL TOOLS .
Page 20: Specifications
Specifications Item Description Make / Designation Mitsubishi 4DQ7 Water–cooled, 4–stroke, swirl–combustion chamber type Diesel Number of Cylinders Bore x Stroke mm (in.) 88 x 94 (3.465 x 3.701) Total Displacement cc (cu. in.) 2286 (139.5) Compression Ratio 21.7:1 Firing Order 1 –...
Page 21: Special Tools
Special Tools Order special tools from TORO SPECIAL TOOLS AND Some tools may be listed in the Reelmaster 4500–D APPLICATIONS GUIDE (Commercial Products ). Parts Catalog. Tools may also be available from a local supplier. Filter Cleaner Filter cleaner. Mix with water and use solution to wash the Donaldson air cleaner element.
Page 22 Nozzle Tester 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 Reelmaster 4500–D Page 3 – 4...
Page 23: General Information
General Information Most repairs and adjustments require tools which are be sure to provide your Distributor with the TORO Model commonly available in many service shops. Special Number and Serial Number. tools are described in the Special Tools section. The use The engine used in the Reelmaster 4500–D is manufac-...
Page 24: Priming Fuel System
Priming 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. 1. Raise engine cover. 2. Loosen fuel filter bleed plug one turn. Using a shop towel to absorb fuel, push priming plunger until a steady stream of fuel runs out of hole in plug.
Page 163 Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS ......Reels Slow or Won’t Turn ....27 GENERAL INFORMATION .
Page 164: Specifications
Specifications Item Description Traction Pump Variable displacement axial piston pump Traction Relief Pressure 5000 – 5200 PSI Charge Pressure 50 – 150 PSI (2WD) 75 – 150 PSI (4WD) Steering Pump Gear pump with flow divider Steering Relief Pressure 1200 – 1300 PSI Traction Motor (front) Fixed axial piston motor Traction Motor (rear w/4WD)
Page 165: General Information
General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such WARNING as, pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage condi- Before disconnecting or performing any work tions or mishandling during operation or maintenance. on hydraulic system, all pressure in system These conditions can cause damage or premature dete- must be relieved by stopping the engine and...
Page 166 SAE Straight Thread O–Ring Port – Non–adjustable 1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material. 2. Always replace the O–ring seal when this type of fit- ting shows signs of leakage. O–Ring 3.
Page 167: Pushing Or Towing Traction Unit
Pushing or Towing Traction Unit Using Traction Pump By–Pass Valve In an emergency, the traction unit can be pushed or 4. Rotate by–pass valve 90 degrees. Opening the valve towed for a very short distance by using the traction opens an internal passage in the traction pump, thereby pump by–pass valve.
Page 168 There is no effective braking with wheel motors disengaged. If towing with front wheel motors disengaged, Tow Bar Assembly, Toro part no. 58–7020, must be used. Figure 12 NOTE: The machine can also be moved slowly a short distance by opening the by-pass valve on the variable 4.
Page 169: Hydraulic Schematic
Hydraulic Schematic Reelmaster 4500–D Hydraulic System Page 4 – 7...
Page 170: Hydraulic Flow Diagrams
Hydraulic Flow Diagrams (2WD Machines Only) General Pump Flow Refer to “Engine Run – No Functions” Flow Diagram The traction, reel, and auxiliary pumps are directly After joining with oil returning from other functions coupled to the engine. With all controls in neutral and through the drain block, the oil flows through the oil cool- the engine running, the steer–lift pump draws oil through er to dissipate heat from the hydraulic system and then...
Page 171: Engine Run - No Functions
Engine Run – No Functions Reelmaster 4500–D Hydraulic System Page 4 – 9...
Page 172: Traction Circuit
Traction Circuit Refer to “Traction Circuit – Forward” Flow Diagram A mechanical interlock between the traction pedal link- inlet of the traction motors. The oil returns from the mo- age and the parking brake prevents traction pedal tor to the pump where it continues through the pump in movement unless the brake is released.
Page 173: Traction Circuit - Forward
Traction Circuit – Forward Reelmaster 4500–D Hydraulic System Page 4 – 11...
Page 174: Steering Circuit
Steering Circuit Refer to “Steering Right” Flow Diagram With the engine running, the priority flow of oil from the cylinder for a right–hand turn. Turning the steering steer–lift pump is directed to the power steering unit at wheel to the left has the opposite effect. Cylinder move- the base of the steering column and returns to the reser- ment returns oil from the low pressure side back through voir.
Page 175: Steering Right
Steering Right Reelmaster 4500–D Hydraulic System Page 4 – 13...
Page 176: Lift/Lower Circuit
Lift/Lower Circuit Refer to “Lift Circuit” Flow Diagrams The lift cylinders are controlled by an open center valve while the cutting unit is lowering will lock the cutting unit with three spools. The number 4 and 5 cutting units are at any position by trapping oil between the valve and cyl- independently controlled.
Page 177 Lift Circuit – Lift All Units Reelmaster 4500–D Hydraulic System Page 4 – 15...
Page 178 Lift Circuit – Lower All Units Hydraulic System Reelmaster 4500–D Page 4 – 16...
Page 179: Lift Circuits - Free Float (Detent)
Lift Circuit – Free Float (Detent) Reelmaster 4500–D Hydraulic System Page 4 – 17...
Page 180: Reel Circuit
Reel Circuit Refer to “Reel Circuit” Flow Diagrams The three reel shut–off valves in this circuit enable the 5 shut–off valve. If the Number 4 cutting unit is in the cutting units to be operated in several configurations for raised position, the oil will bypass the Number 4 reel mo- easier control, better clearance, or closer trimming.
Page 181: Reel Circuit - All Units Mow (Free Float)
Reel Circuit – All Units Mow (Free Float) Reelmaster 4500–D Hydraulic System Page 4 – 19...
Page 182: Reel Circuit - Units 1, 2 & 3 Mow (Free Float)
Reel Circuit – Units 1, 2 & 3 Mow (Free Float) Hydraulic System Reelmaster 4500–D Page 4 – 20...
Page 183: Reel Circuit - Units 1, 2, 3 & 5 (Free Float)
Reel Circuit – Units 1, 2, 3 & 5 Mow (Free Float) Reelmaster 4500–D Hydraulic System Page 4 – 21...
Page 184: Reel Circuit - Any Unit Backlap
Reel Circuit – Any Unit Backup Hydraulic System Reelmaster 4500–D Page 4 – 22...
Page 185: 4Wd Selector Valve Operation
4WD Selector Valve Operation 4WD Forward (“S1” OFF) Pressure Oil Pressure Free Reelmaster 4500–D Hydraulic System Page 4 – 23...
Page 186: 2Wd Forward
2WD Forward (“S1” ON) Pressure Oil Pressure Free Hydraulic System Reelmaster 4500–D Page 4 – 24...
Page 187: Special Tools
Special Tools NOTE: Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS ). Some tools may also be available from a local supplier. Hydraulic Pressure Test Kit Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools.
Page 188 Hydraulic Tester – With Pressure and Flow Capabilities Figure 14 You must have o–ring face seal (ORFS) adapter fittings 4. HIGH PRESSURE GAUGE: High range gauge to ac- for this tester to use it on this machine. commodate pressure beyond the capacity of the low pressure gauge, 0 –...
Page 189: Troubleshooting
Troubleshooting The cause of an improperly functioning hydraulic sys- Continued use of an improperly functioning hydraulic tem is best diagnosed with the use of proper testing system could lead to extensive internal component equipment and a thorough understanding of the com- damage.
Page 190: Steering Loss
Problem Possible Causes Steering loss. Thermal shock after washing. Note: Normal functions will return after orbitrol temperatures stabilize (approximately 15 minutes). DO NOT ATTEMPT TO TURN STEERING WHEEL UNTIL TEMPERATURES STABILIZE WHEN THERMAL SHOCK IS NOTED. Improper cylinder action. Low steering relief pressure. (See Test No. 6.) Worn or damaged steering cylinder.
Page 191: Testing
Testing The most effective method for isolating problems in the 1. Thoroughly clean the machine before disconnecting hydraulic system is by using hydraulic test equipment or disassembling any hydraulic components. Always such as pressure gauges and flow meters in the circuits keep in mind the need for cleanliness when working on during various operational checks.
Page 192 TEST NO. 1: Checking Traction Circuit Working Pressure Or Relief Pressure Procedure for Working Pressure Check: 1. Install a 10,000 psi gauge into the traction circuit quick disconnect for the function to be checked. 2. Operate the unit while monitoring gauge. NOTE: If the machine is equipped with 4WD, check working pressure in both 2WD and 4WD modes.
Page 193 TEST NO. 2: Checking Counterbalance Oil Pressure Procedure: 1. Install a 10,000 psi gauge into the center quick dis- connect as shown. 2. Start the engine and move throttle to full speed (2500 rpm). 3. Tester reading should be within the range listed: COLD OIL: 600 –...
Page 194 TEST NO. 3: Checking Reel Circuit Working Pressure or Relief Pressure Procedure For Working Pressure Check: 1. Install a 5,000 psi gauge into the cutting circuit quick disconnect. 2. Operate the unit while monitoring the gauge. RANGE OF TESTER READINGS 0 – 2750 PSI 3.
Page 195 TEST NO. 4: Checking Reel Circuit Hydraulic Oil Supply Procedure: 1. Hydraulic oil must be at operating temperature. 2. Start the engine and lower the No. 2 and 3 cutting units to the ground. 3. Turn the engine OFF. 4. Disconnect inlet hose at No. 2 reel motor. 5.
Page 196: Test No. 5: Reel Motor Efficiency
TEST NO. 5: Checking Reel Motor Efficiency Procedure: 1. Hydraulic oil must be at operating temperature. 2. Start the engine and lower the cutting unit to be checked. 3. Turn the engine OFF. 4. Block the reel to be checked to prevent rotation. Use a substantial hardwood block inserted between the reel blades.
Page 197 TEST NO. 6: Checking Steering Circuit Working Pressure or Relief Pressure Procedure For Working Pressure Check: 1. Install a 5,000 psi gauge into the steering quick dis- connect. 2. Operate the unit while monitoring the gauge. RANGE OF TESTER READINGS 0 – 1300 PSI 3.
Page 198 TEST NO. 7: Checking Lift Circuit Working Pressure or Relief Pressure Procedure For Working Pressure Check: 1. Install a 5,000 psi gauge onto the quick disconnect of the lift valve. 2. Operate the unit while monitoring the gauge. RANGE OF TESTER READINGS 500 – 2900 PSI 3.
Page 199 TEST NO. 8: Checking Charge Pressure For Traction Procedure: 1. Hydraulic oil must be at operating temperature. 2. Install a 1000 psi gauge onto the quick disconnect at the top of the pump package. 3. Start the engine and position throttle at idle (1200 rpm).
Page 200: Repairs
Repairs Removing Hydraulic System Components 1. Thoroughly clean the machine before disconnecting, 2. After repairs, check control linkage for proper adjust- removing or disassembling any hydraulic components. ment, binding or broken parts. Always keep in mind the need for cleanliness when 3.
Page 201: Steering Control Unit
Steering Control Unit Figure 24 1. Seal 1” I.D. 15. Gerotor 2. Retaining Ring 16. End Cap 3. Seal Gland Bushing 18. Cap Screw 4. Seal 1.875 I.D. 19. Pin Kit, Centering 5. Quad Ring Seal, 1.062 I.D. 20. Spring 6.
Page 202 Meter (Gerotor) End Disassembly 1. Clamp unit in vise, meter end up. Clamp lightly on edges of mounting area, see Fig. 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.
Page 203 7. Remove drive spacer(s) (not used on 4.5 cu. in. dis- placement units). 8. Remove drive. 9. Remove spacer plate. 10. Remove seal from housing. Figure 28 Control End Disassembly 11. Remove housing from vise. Place housing on a clean soft cloth to protect surface finish. Use a thin– blade screwdriver to pry retaining ring from housing, as shown in Fig.
Page 204 13. Remove quad ring seal from seal gland bushing. 14. Use a thin–blade screwdriver to pry dust seal from seal gland bushing. Do not damage bushing. Figure 31 15. Remove 2 bearing races and the needle thrust bear- ing from spool and sleeve assembly. Figure 32 16.
Page 205 18. Push spool partially from control end of sleeve, then remove 6 centering springs from spool carefully by hand, see Fig. 34. 19. Push spool back through and out of sleeve, see Fig. 34. Rotate spool slowly when removing from sleeve.
Page 206 Reassembly Check all mating surfaces. Replace any parts that have scratches or burrs that could cause leakage. Clean all metal parts in clean solvent. Blow dry with air. Do not wipe dry with cloth or paper towel because of lint or other matter can get into the hydraulic system and cause damage.
Page 207 6. Bring spring slots of both parts in line and stand parts on end of bench. Insert spring installation tool through spring slots of both parts. Tool is available from an Eaton hydraulics supplier as Eaton part no. 600057. Position 3 pairs of centering springs (or 2 sets of 3 each) on bench so that extended edge is down and arched center section is together.
Page 208 11. Place housing on clean, lint free cloth. Install 2–1/8” diameter seal in housing, see Fig. 40. 12. Install 2 bearing races and the needle thrust bearing in the order shown. Figure 40 13. Install 1–1/4” diameter dust seal in seal gland bush- ing, flat or smooth side of dust seal must face down to- wards bushing, see Fig.
Page 209 17. Clamp housing in vise, as shown in Fig. 43. Clamp lightly on edges of mounting area. Do not over–tighten jaws. NOTE: Check to insure that the spool and sleeve are flush or slightly below the 14–hole surface of the hous- ing.
Page 210 21. Install 3” diameter seal in meter. Figure 46 22. With seal 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.
Page 211 23. Install drive spacer(s), when used, in meter, see Fig. 48. 24. Install 3” diameter seal in end cap. 25. Install end cap on gerotor, align holes. Figure 48 26. Install 7 dry cap screws with new seal washers in end cap.
Page 212: Reel Motor
Reel Motor Repair Figure 50 2. Idler Gear 12. Retaining Ring 3. Drive Gear 13. Shaft Seal 4. Key 14. Backup Washer 5. O–Ring 15. Relief Valve Kit 6. Body 16. O–Ring 7. Dowel Pin 17. Plug 18. Shim 8. Plate & Bushing Assembly 9.
Page 213 Inspection of Reel Motor 2. Back plate assembly (21) should be replaced if I.D. of gear pocket exceeds 1.719. GENERAL 3. Check for scoring on face of front plate (8), body (6), 1. Clean and dry all parts. and back plate (21). If wear exceeds .0015, front plate, body, or back plate should be replaced.
Page 214 Steering Pump Repairs Figure 51 1. Plug (includes #2) 15. Front Plate Assembly 2. O–Ring 16. O–Ring 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 21.
Page 215 Disassembly of Steering Pump GEAR ASSEMBLY 1. Thoroughly clean outside of pump. 1. Check drive shaft spline for twisted or broken teeth. 2. Use a sharp tool or marker to mark across front plate 2. Inspect both drive gear (7) and idler gear (10) shafts (15), body (21) and back plate (22).
Page 216 Figure 52 1. Plug (includes #2) 15. Front Plate Assembly 2. O–Ring 16. O–Ring 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.
Page 217: Steering Pump
Assembly of Steering Pump 7. Apply a thin coat of heavy grease to both milled faces of body (21). Slip body onto plate – half moon port cavi- It is important that the relationship of the back plate (22), ties in body must face away from front plate. body (21), wear plate (20) and front plate (15) is correct.
Page 218: Lift Control Valve
Lift Control Valve Figure 53 1. Plug Assembly 22. O–Ring 2. Disc 23. Bushing 3. Spring 24. Washer 4. Detent Plunger 25. Spring 5. O–Ring 26. Spacer 6. Plug Assembly 27. Retaining Ring 7. O–Ring 28. Cap Assembly 8. Body 29.
Page 219 Disassembly of Lift Control Valve Assembly of Lift Control Valve 1. Plug all ports and clean outside of valve thoroughly. 1. Thoroughly clean and dry all parts. Apply a light coat- ing of clean hydraulic oil to parts prior to assembly. 2.
Page 220: Priority Flow Divider
Priority Flow Divider Figure 54 1. Plug Assembly 11. Shim 2. O–Ring 12. Shim 3. Spool 13. Shim 14. O–Ring 4. Body 5. O–Ring 15. Backup Washer 6. O–Ring 16. Metering Plug 7. Backup Washer 17. Shim 8. Metering Stem 18.
Page 221 Disassembly of Priority Flow Divider Reassembly of Priority Flow Divider 1. Plug all ports and thoroughly clean outside of valve. 1. Install new back–up washer (7) inside metering plug (16). 2. Remove plug (1), shims (17 & 18), spring (19), and flow control spool (3) from body (4).
Page 222: Lift Cylinder
Lift Cylinder Figure 55 1. Bleed Screw 5. Seal 2. Washer 6. Snap Ring 3. Rod 7. Seal Kit 4. Wiper Hydraulic System Reelmaster 4500–D Page 4 – 60...
Page 223 Disassembly of Lift Cylinder 4. Inspect O.D. of rod (3) for nicks, scratches or scoring. 1. Thoroughly clean outside of cylinder assembly. Reassembly of Lift Cylinder 2. Pull rod (3) out until end of rod and snap ring (6) can 1.
Page 224: Reel Control Valve
Reel Control Valve Figure 56 1. Spool 18. Plunger 2. Body 19. Micro Switch 3. O–Ring 20. Flat Washer 4. Plug 21. Machine Screw 5. O–Ring 22. Cap Head Screw 6. Backup Washer 23. Lock Washer 7. O–Ring 24. Grease Fitting 8.
Page 225 Disassembly of Reel Control Valve Assembly 4. Inspection of O–rings and back–up washers is not necessary. It is recommended that these be replaced as 1. Plug all outlets and thoroughly clean outside of valve. new parts. 2. Remove plug (4) and O–ring (3). 5.
Page 226: Reel Shut Off Valve
Reel Shut Off Valve Figure 57 1. Circlip 6. Backup Washer 2. Washer 7. O–Ring 3. Spacer 8. Body 4. Spring 9. Spool 5. Wiper Hydraulic System Reelmaster 4500–D Page 4 – 64...
Page 227 Disassembly of Reel Shut–Off Valve Assembly 3. Inspect O.D. of spool (9). It should be smooth and free of nicks and burrs. 1. Thoroughly clean outside of valve. 4. Inspect spring (4) for breakage. 2. Remove retaining ring (1) from end of spool (9). Reassembly of Reel Shut–Off Valve Assembly 3.
Page 228: Traction Pump
Traction Pump Figure 58 25. Retaining Ring 1. Hex Head Cap Screw 2. Charge Pump Adapter Assembly 26. Shaft Seal 3. Plug Assembly 27. Washer 4. Tow Valve Assembly 28. Retaining Ring 5. O–Ring 29. Thrust Ring 6. Needle Bearing 30.
Page 229 Disassembly of Traction Pump 9. Remove the tow valve (4) from back plate (9). To dis- assemble tow valve, remove retaining ring from spread- 1. Disconnect all control linkage, hydraulic lines and re- er, and pull spreader from spreader plug. move pump assembly from vehicle.
Page 230 Figure 59 25. Retaining Ring 1. Hex Head Cap Screw 2. Charge Pump Adapter Assembly 26. Shaft Seal 3. Plug Assembly 27. Washer 4. Tow Valve Assembly 28. Retaining Ring 5. O–Ring 29. Thrust Ring 6. Needle Bearing 30. Needle Bearing , Thrust 7.
Page 231 Inspection of Traction Pump 8. The pistons should move freely in the piston block bore. If they are sticky in the bore, examine the bore for 1. Inspect the charge pump relief valve seat inside the scoring or contamination. charge pump adaptor. It should be smooth and free of burrs or other defects.
Page 232 Figure 60 25. Retaining Ring 1. Hex Head Cap Screw 2. Charge Pump Adapter Assembly 26. Shaft Seal 3. Plug Assembly 27. Washer 4. Tow Valve Assembly 28. Retaining Ring 5. O–Ring 29. Thrust Ring 6. Needle Bearing 30. Needle Bearing , Thrust 7.
Page 233 Reassembly of Traction Pump 9. Install new housing gasket (10). 1. Clean all parts in suitable solvent, lubricate all critical 10. Install back plate (9). moving parts before reassembly. If necessary, install 11. Install ball and pin into check valve housing if re- new needle bearings in the housing.
Page 234: Front Traction Motor
Front Traction Motor Figure 61 1. Hex Head Cap Screw 12. Washer 2. Hex Head Cap Screw 13. Retaining Ring 3. Plug 14. Thrust Ring 4. O–Ring Seal 15. Thrust Bearing 5. Back Plate Assembly 16. Bearing 6. O–Ring 17. Housing Assembly 7.
Page 235 10. DO NOT attempt to disassemble the piston block 8. Inspect the flat surface on the backplate (5); it should and spring. The parts are not serviceable separately. be free of excessive scoring or metal build–up. The rotating assembly (19) must be replaced as an as- 9.
Page 236: Reel Pump
Reel Pump Figure 62 1. Nut 10. 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.
Page 237 Disassembly of Reel Pump 2. Remove the retaining ring (18) with internal retaining ring pliers. During disassembly, pay particular attention to identifi- cation of the parts for correct assembly. 3. Remove front cover S/A (4) from vise and place on work bench with mounting flange down.
Page 238 Figure 63 1. Nut 10. 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.
Page 239 Reassembly of Reel Pump section and notch facing inlet port. Make sure wear plate and center section set flush against port section. NOTE: Coat all parts with clean hydraulic fluid to facili- tate assembly and provide initial lubrication. Use small 10.
Page 240: Rear Wheel Drive Valve Block
Rear Wheel Drive Valve Block NOTE: If cartridge valve seals appear pitted or damaged, the hydraulic system may be overheating or there may be water in the system. Figure 64 Cleaning Solenoid Actuated Cartridge Valve Use a deep socket to remove the valve cartridge. Use mineral spirits to clean solenoid actuated cartridge valves.
Page 241: Rear Wheel Drive Motor
Rear Wheel Drive Motor Figure 66 1. O–Ring Seal 8. Bolt 2. Backup Washer 9. Outer Seal 3. Shaft Seal 10. Inner Seal 4. Key 11. Shaft Seal 5. Sub Shaft Assembly 12. Dust Seal 6. Pin 13. Slotted Nut 7.
Page 242 1. Place the motor in a vise with the output shaft down. Clamp across the mounting flange of the motor not the housing. Excessive clamping pressure will cause distor- tion. When clamping, use some protective device on the vise, such as special soft jaws, pieces of hard rubber or board.
Page 243 6. Remove 2 pins and 2 springs from balance ring as- sembly, see Fig. 71. 7. Remove balance ring assembly. 8. Remove inner and outer face seals from balance ring. 9. Remove the valve. Figure 71 10. Remove the valve plate. 11.
Page 244 19. You may need a press to remove shaft and bearing assembly from bearing housing. (Key must be removed before removing shaft.) Figure 75 20. Use a small screwdriver to remove shaft seal, back– up washer and exclusion seal from bearing housing, see Fig.
Page 245 26. Alignment studs can be very helpful in reassembly of the motor. If you use studs, install 2 studs diagonally opposed in the bearing housing. 27. Install the shaft face seal in the wear plate as shown in Fig. 77. Do not distort seal. 28.
Page 246 37. Apply petroleum jelly to inner and outer face seals. Install seals on balance ring as shown in Fig. 81. IMPORTANT: Install face seals in the positions shown in Fig. 81. or the motor will not operate properly. Do not force or bend the face seals.
Page 247 Wheel Motor On wheel motors, a different 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 Hydraulic System Page 4 –...
Page 248: Steering Cylinder
Steering Cylinder Figure 86 1. Set Screw 10. Spacer 2. Threaded Cap 11. Servon 3. Rod 12. O–Ring 4. Rod Wiper 13. Piston 5. U–Cup 14. Locknut 6. Cap Head 15. Barrel Assembly 7. Backup Washer 16. Jam Nut 8. O–Ring 17.
Page 249 11. Use a complete repair kit when rebuilding the cylin- 14. Put a coating of oil on all cylinder parts to ease as - der. Put a coating of oil on all new seals, and O–rings. sembly. Install the new seal and O–rings. 15.
Page 250 Hydraulic System Reelmaster 4500–D Page 4 – 88...
Page 251 Chapter 5 Electrical System Table of Contents WIRING SCHEMATICS ......2 ELECTRICAL SYSTEM QUICK CHECKS ..19 Engine and Safety Circuits .
Page 252: Wiring Schematics
Wiring Schematics Electrical System Reelmaster 4500–D Page 5 – 2...
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Page 264: Special Tools
Multimeter The meter can test electrical components 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.
Page 265: Troubleshooting
Troubleshooting For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and CAUTION components used on this machine (see Wiring Sche- matics section of this chapter). Remove all jewelry, especially rings and If the machine has any interlock switches by–passed, watches, before doing...
Page 266 Problem Possible Causes Engine cranks, but does not start. Engine run solenoid wiring loose or corroded. Engine run solenoid faulty. Low hydraulic oil level. Hydraulic oil low level switch is faulty. Hydraulic oil low level switch wiring loose, corroded or damaged.
Page 267 Problem Possible Causes Engine continues to run (but should not) when parking Seat switch plunger depressed with no operator on brake is released or mow–backlap lever is now or seat. backlap with no operator on seat. Seat switch faulty or out of adjustment. Short circuit or by–pass in seat switch circuit.
Page 268 Verify Interlock System Operation CAUTION THE INTERLOCK SWITCHES ARE FOR THE OPERATOR’S PROTECTION, SO DO NOT DIS- CONNECT THEM. CHECK OPERATION OF THE SWITCHES DAILY TO ASSURE INTERLOCK SYSTEM IS OPERATING. IF A SWITCH IS DE- FECTIVE, REPLACE IT BEFORE OPERATING. REGARDLESS IF SWITCHES ARE OPERATING PROPERLY OR NOT, REPLACE THEM EVERY TWO YEARS TO ASSURE MAXIMUM SAFETY.
Page 269: Electrical System Quick Checks
Electrical System Quick Checks Battery Test Use a volt–ohm multi–meter to measure the voltage be- Voltage Measured Battery Charge tween the battery terminals. 12.6 V (or higher) Fully charged (100%) Set the multi–meter to the DC Volts setting. The battery 12.4 V 75% charged should be at a temperature of 60 to 100 F.
Page 270: Glow Plug System Test
Remember – there are 2 types of Glow Plug systems DVOM on Volts scale. With the key off (or Glow Switch that Toro uses: in off position), place the inductive Ammeter around the main glow plug power supply wire(s) and read meter 1.
Page 271: Component Testing
Component Testing For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the CAUTION circuit (e.g. unplug the ignition switch connector before doing a continuity check). When testing electrical components for conti- NOTE: Electrical troubleshooting of any 12 Volt power nuity with a volt–ohm meter or continuity tes- connection can also be performed through voltage drop ter, make sure that power to the circuit has...
Page 272: Bosch Relay
Bosch Relay To test the relay, disconnect the relay wire connector and install a 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.
Page 273: Rear Wheel Drive Solenoid
Rear Wheel Drive Solenoid Figure 8 1. Disconnect the wire connector. 2. Connect a 12 volt battery so the positive (+) battery terminal is connected to colored solenoid lead. Connect the negative (–) battery terminal to black lead. The valve spool should retract completely as 12V DC is applied across the leads.
Page 274: Repairs
Repairs NOTE: See Mitsubishi 4DQ7 Engine Service Manual for more component repair information. Battery Service IMPORTANT: To prevent damage to the electrical Electrolyte Specific Gravity components, do not operate the engine with the bat- Fully charged: 1.250 – 1.280 tery cables disconnected. Discharged: less than 1.240 Keep the terminals and entire battery case clean.
Page 275: Rear Wheel Drive Solenoid Replacement
Rear Wheel Drive Solenoid Replacement Figure 11 1. Disconnect solenoid electrical connector. 2. Remove nut from solenoid. 3. Remove solenoid coil. 4. Install new solenoid 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.
Page 276 Electrical System Reelmaster 4500–D Page 5 – 26...
Page 277 Chapter 6 Axles and Brakes Table of Contents SPECIFICATIONS ......2 REPAIRS ........5 ADJUSTMENTS .
Page 278: Specifications
Specifications Item Description Tire pressure 13 PSI front, 15 PSI rear Wheel 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.
Page 279: Adjustments
Adjustments Hand Brake and Traction Switches In time, the hand brake cable may stretch, causing the engine not to start. If this happens, adjust the cable (Fig. 2). 1. Pull hand brake lever to 3rd click. 2. Pull hand brake up one additional click. 3.
Page 280: Rear Wheel Toe-In
Rear Wheel Toe–In After every 800 operating hours or annually, check rear wheel toe–in. 1. Measure center–to–center distance (at axle height) at front and rear of steering tires (Fig. 3). Front measure- ment must be 1/8 in. less than rear measurement. 2.
Page 281: Repairs
Repairs Rear Wheel Bearing Service (2WD Only) Figure 5 1. Hex Flange Hd. Screw 26. Lock Nut 27. Tie Rod Assembly 2. Spindle Cap 3. Retaining Ring 28. Cap Hex Hd. Screw 4. Thrust Washer 29. Cotter Pin 5. Flange Bushing 30.
Page 282: Rear Wheel Bearings
1. Jack up rear of machine until tire is off the floor. Sup- Adjusting Rear Wheel Bearings port machine with jack stands or blocks to prevent it from 1. Remove dust cap (16) from end of wheel spindle. Re- falling. move cotter pin (15) retaining slotted nut (50) in place.
Page 283: Planetary Wheel Drive
Planetary Wheel Drive 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.
Page 284 Disassembly of the Planetary Wheel Drive that can be assembled into ring grooves of spindle shaft above bearing cone. Bearing should have from 1. Slide the coupling (1) from splines on input shaft (2). .000–.006 inches (.00–.15mm) end play when proper retaining ring is installed.
Page 285 Chapter 7 Cutting Units Table of Contents SPECIFICATIONS ......2 REPAIRS ........9 SPECIAL TOOLS .
Page 286: Specifications
Specifications 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.
Page 287: Special Tools
Special Tools Order special tools from the TORO SPECIAL TOOLS 4500–D Parts Catalog. Some tools may also be avail- AND APPLICATIONS GUIDE (COMMERCIAL PROD- able from 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).
Page 288 Bedknife Screw Tool Fits Toro bedknife attaching screws. Use with torque wrench to secure 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.
Page 289: Adjustments
Adjustments CAUTION Never install or work on the cutting units or lift arms with the traction unit engine running. Al- ways stop the engine and remove the key first. Adjusting Reel to Bedknife Contact Before adjusting height–of–cut and each day before op- IMPORTANT: Adjusted correctly, the reel will cut pa- erating, check reel to bedknife contact, regardless if per (approx.
Page 290: Height Of Cut Adjustment (Floating Cutting Unit)
Height–of–Cut Adjustment (Floating Cutting Unit) Overview of Procedure: 1. Adjust reel to bedknife contact 2. Level rear roller to reel 3. Final height–of–cut adjustment using gauge bar. STEP 1 – Adjust Reel to Bedknife Contact A. Adjust reel to bedknife contact on all cutting units. (Refer to Adjusting Reel To Bedknife Contact).
Page 291 F. Raise cutting units and lock in the transport posi- tion. Shut off the engine and remove the key. G. Use gauge bar (Toro Part No. 59–7900) to set fi- nal height–of–cut by adjusting front roller only. H. Loosen the gauge bar jam nut and adjust the screw to set dimension between underside of screw head and gauge bar for desired height–of–cut (Fig.
Page 292: Quick Method For Changing Height Of Cut After Initial Set Up Of A Floating Cutting Unit
Quick Method For Changing Height–of–Cut After Initial Set Up of a Floating Cutting Unit If the reel to bedknife adjustment has been set (STEPÿ1) to set the front roller of one cutting unit. The remaining and the rear roller leveled to the reel (STEP 2), the cut- cutting units can then be set by loosening their front roll- ting unit may be quickly changed from one height–of–...
Page 293: Repairs
#1 cutting unit (center) and tighten fasteners to retain the deflector in the raised position. B. Dip 3 in. (76 mm) paint brush attached to Toro Part No. 29–9200 Handle Assembly into lapping 1st persons duties (Operator): compound.
Page 294: Hydraulic Motor Installation
F. Upon completion, stop the reel and turn off the en- gine. Remove the key from the ignition switch. Wash NOTE: See the Toro Sharpening Manual (Part the unit thoroughly with a low pressure stream of #80–300) for additional backlapping/sharpening in- formation.
Page 295 3. Insert the two (2) reel drive motor mounting bolts (heads on inside of the drive housing – flat washer on top bolt) through the reel motor flange holes. Thread the locknuts onto the bolts. Rotate reel motor upward in the slotted hole in the housing to tension the drive belt and tighten the fasteners (Fig.
Page 296: Servicing The Bedknife/Bedbar Assembly
Servicing the Bedknife/Bedbar Assembly NOTE: The bedbar on each cutting unit has a precision ground mounting surface to provide an excellent fit with a bedknife. Backlapping of replacement bedknives is often sufficient to achieve an excellent cutting edge with minimum material removed. Bedknife/Bedbar Removal: 1.
Page 297: Servicing The Reel Assembly
Servicing the Reel Assembly Disassembly: 1. Remove the guards from each end of the cutting unit and the front and rear roller assemblies (Fig. 19). 2. Remove the shoulder bolts, bushings and spacers from each end of the unit and remove the bedbar/bed- knife assembly (Fig.
Page 298 4. Disassemble the cone nut from the shoulder bolt se- curing the bearing housing to the side plate, remove the belleville washer and bolt and slide the bearing housing off the reel shaft (Fig. 21). 5. Disassemble the cover from the drive housing and re- move the drive belt from the housing (Fig.
Page 299 Assembly: 9. Install the woodruff key in the drive housing end of the reel shaft and install the driven pulley onto the shaft. 1. Inspect the flange bushings in the mounting holes for the drive housing and bearing housing for wear (Fig. 10.
Page 300: Roller Removal And Installation
Roller Removal and Installation 1. Remove the fasteners securing the guard and roller adjustment housing to the side plate (Fig. 24) or un- screw the upper cone nut and drop the threaded rod out of the adjustment housing (Fig. 25). 2.
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Toro Reelmaster 4500–D Service Manual

Chapter 3 Engine

Chapter 4 Hydraulic System

Table of Contents

Chapter 5 ELECTRICAL SYSTEM QUICK CHECKS

Chapter 6 REPAIRS

Chapter 7 Cutting Units

Quick Links

Chapters

Troubleshooting

Related Manuals for Toro Reelmaster 4500–D

Summary of Contents for Toro Reelmaster 4500–D

Table of Contents