Toro Reelmaster 450-D User manual

Part No. 89723SL, Rev. A
Service Manual
Reelmaster450–D
Preface
The purpose of this publication is to provide the service
technician with information for troubleshooting, testing,
and repair of major systems and components on the
Reelmaster 450–D.
REFER TO THE TRACTION UNIT AND CUTTING
UNIT OPERATOR’S MANUALS FOR OPERATING,
MAINTENANCE AND ADJUSTMENT INSTRUC-
TIONS. Space is provided in Chapter 2 of this book to
insert the Operator’s Manuals and Parts Catalogs for
your machine. Replacement Operator’s Manuals are
available by sending complete Model and Serial Num-
ber to:
The Toro Company
8111 Lyndale Avenue South
Minneapolis, MN 55420
TheToroCompanyreservestherighttochangeproduct
specifications or this publication without notice.
This safety symbol means DANGER, WARN-
ING, or CAUTION, PERSONAL SAFETY
INSTRUCTION. When you see this symbol,
carefully read the instructions that follow.
Failure to obey the instructions may result in
personal injury.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing or re-
pair of the machine.
IMPORTANT: The IMPORTANT notice will give im-
portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.
The Toro Company – 1991, 1998

Reelmaster 4500–D

Rev. AReelmaster 450–D
Table Of Contents
Chapter 1 – Safety
Safety Instructions 1 – 1. . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 2 – Product Records and Manuals
Product Records 2 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions 2 – 2. . . . . . . . . . . . . . . .
Torque Specifications 2 – 3. . . . . . . . . . . . . . . . . . . . . . .
Equipment Operational and
Service Historical Report Record 2 – 5. . . . . . . . . . . .
Chapter 3 – Engine
Specifications 3 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Manual, Mitsubishi 4DQ5 Diesel Engine
Service Manual Supplement, Fuel System
Chapter 4 – Hydraulic System
Specifications 4 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Hose and Fitting Information 4 – 2. . . . . . . .
Schematics 4 – 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 4 – 16. . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing 4 – 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Eaton Char–Lynn Steering Control Repair Information
Cessna Service Instructions
Vickers Gear Pump Service Manual
Auburn Gear Power Wheel
Planetary Gear Drive Service Manual
Chapter 5 – Electrical System
Specifications 5 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Schematics (S/N 60001 – 80100) 5 – 2. . . .
Electrical Schematic (S/N 80101 – 09999) 5 – 12. . . .
Electrical Schematic (S/N 10001 & UP) 5 – 13. . . . . .
Chapter 6 – Cutting Units
Specifications 6 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 6 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments 6 – 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repairs 6 – 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reelmaster 4500–D

Rev. A
Reelmaster 450–D Page 2 – 1 Product Records and Manuals
Chapter 2
Product Records and Manuals
Table of Contents
PRODUCTRECORDS 1. . . . . . . . . . . . . . . . . . . . . . . . .
EQUIVALENTSAND CONVERSIONS 2. . . . . . . . . . .
Decimal and Millimeter Equivalents 2. . . . . . . . . . . .
U.S. to Metric Conversions 2. . . . . . . . . . . . . . . . . . .
TORQUE SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . .
Capscrew Markings and Torque Values – U.S. 3. .
Capscrew Markings and Torque Values – Metric 3.
OPERATION AND SERVICE HISTORY REPORT5.
Product Records
Record information about your Reelmaster 450–D on
the OPERATION AND SERVICE HISTORY REPORT
form. Use this information when referring to your ma-
chine.
Insert Operator’s Manuals and Parts Catalogs for your
Reelmaster 450–D at the end of this section.

Rev. A Reelmaster 450–D
Page 2 – 4
Product Records and Manuals
This page is blank.

Rev. A
Reelmaster 450–D Page 2 – 5 Product Records and Manuals
EQUIPMENT OPERATION AND SERVICE HISTORY REPORT
for
REELMASTER450–D and 4500–D
TORO Model and Serial Number: ______________–______________
Engine Numbers: _____________________________
Transmission Numbers: _____________________________
Drive Axle(s) Numbers: _____________________________
Date Purchased: _____________________________ Warranty Expires____________
Purchased From: _____________________________
_____________________________
_____________________________
Contacts: Parts _____________________________ Phone____________________
Service _____________________________ Phone____________________
Sales _____________________________ Phone____________________

Rev. A Reelmaster 450–D
Page 2 – 6
Product Records and Manuals
REELMASTER 450–D and 4500–D Maintenance Schedule
Minimum Recommended Maintenance Intervals
Lubricate Reel Control Valve Grease Fitting
Lubricate Reel Speed Control Valve with Oil
Lubricate all Grease Fittings
Check Battery Condition and Connections
}Change Engine Oil and Filter
Drain Water from Hydraulic Tank
{Check Fan and Alternator Belt
Inspect Cooling System Hoses
Service Air Cleaner Filter Element
Inspect Cutting Unit Reel Drive Belts
{Torque Wheel Lug Nuts
Replace Fuel Filter
Inspect Fuel Lines and Connections
}Torque Cylinder Head and Adjust Valves
}Check Engine RPM (idle and full throttle)
Drain and Clean Fuel Tank
}Replace Hydraulic Oil Filter
Replace Hydraulic Tank Breather
}Change Front Planetary Gear Lube
Pack Rear Axle Bearings (2wd)
Check Rear Wheel Toe–In
{Initial break in at 10 hours
}Initial break in at 50 hours
Replace all Moving Hoses
Replace Safety Switches
Cooling System – Flush / Replace Fluid
Change Hydraulic Oil
 
Every
50hrs Every
100hrs Every
200hrs Every
800hrs
   
Annual Recommendations:
Items listed are recommended every 1500
hours or 2 years, whichever occurs first.
Every
400hrs
A Level
Service
B Level
Service
C Level
Service
D Level
Service
E Level
Service

Rev. A
Reelmaster 450–D Page 2 – 7 Product Records and Manuals
REELMASTER 450–D and 4500–D Daily Maintenance Check List
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" '(&'( )* &% & '(*&() %+# &( #+  )'  * &%)
Maintenance Daily Maintenance Check For Week Of
_________________
Check Item bMON TUES WED THURS FRI SAT SUN
nSafety Interlock Operation
nParking Brake Operation
nEngine Oil Level
nFuel Level
nCooling System Fluid Level
Drain Water/Fuel Separator
nDust Cup and Baffle (Air Filter)
nRadiator & Screen for Debris1
Clean Traction Pedal Lockout
nUnusual Engine Noises2
nUnusual Operating Noises
nHydraulic System Oil Level
nHydraulic Hoses for Damage
nFluid Leaks
nTire Pressure
nInstrument Operation
nWarning Lamps Operation
nReel–to–Bedknife Adjustment
nHeight–of–Cut Adjustment
Lubricate All Grease Fittings3
Touch–up Damaged Paint
 ) &%#/ #&- '())+( &$'())  ( &( ( ) ($&,#    
 " #&- '#+ % %!*&( %&00#)  ( )*(* % .)) )$&" &( (&+ (+%% % ) %&*
 $$ *#/ *( ,(/ -) % ((#)) & * %*(,# # )*
     %)'* &% '(&($ /
*$ * %&($* &%

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

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

Rev. A Reelmaster 450–D
Page 2 – 8
Product Records and Manuals