Toro REELMASTER 4500-D User manual

Part No. 94817SL
Service Manual
ReelmasterR4500–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 4500–D.
REFER TO THE TRACTION UNIT AND CUTTING
UNIT OPERATOR’S MANUALS FOR OPERATING,
MAINTENANCEAND 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.
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 that follow.
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.
EThe Toro Company – 1995

This page is blank.

Table Of Contents
Chapter 1 – Safety
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 1
Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 – 4
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 – 2
Mitsubishi 4DQ7 Engine Service Manual
Fuel System Supplement
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 3
General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 – 5
Chapter 4 – Hydraulic System
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 3
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 5
Chapter 7 – Cutting Units
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 3
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 5
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 9
SafetyProductRecords
and Manuals
Engine
Hydraulic
System
Electrical
System
Axles andCutting Units Brakes
Reelmaster 4500–D

This page is blank.

Chapter 1
Safety
Table of Contents
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 1
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Instructions
The REELMASTER 4500 D conforms to the American
National Standards Institute’s safety standards for rid-
ing mowers when rear tires are filled with calcium chlo-
ride and two rear wheel weight kits
(Part No. 11–0440) are installed.
Safety
Maintenance and Service . . . . . . . . . . . . . . . . . . . . . 3
SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 4
CAUTION
TO REDUCE THE POTENTIAL FOR INJURY
OR DEATH, COMPLY WITH THE FOLLOWING
SAFETY INSTRUCTIONS.
Before Operating
Improper use or maintenance by the operator or owner
of the machine can result in injury. Reduce the potential
for any injury by complying with the following safety in-
structions.
WARNING: Engine exhaust contains carbon monoxide
which is an odorless, deadly poison. Carbon monoxide
isalsoknowntothe StateofCaliforniatocause birthde-
fects. Do not run engine indoors or in an enclosed area.
1. Readandunderstandthecontentsofthetractionunit
andcuttingunitoperator’smanualsbeforeoperatingthe
machine. To get replacement manuals, send complete
model and serial number to:
The Toro Company
8111 Lyndale Avenue South
Minneapolis, Minnesota 55420–1196
UsetheModelandSerialNumberwhenreferringtoyour
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. Neverallowchildrentooperatethemachineoradults
to operate it without proper instruction.
3. Become familiar with the controls and know how to
stop the machine and engine quickly.
4. Keep all shields, safety devices and decals in place.
If a shield, safety device or decal is defective or dam-
aged, repair or replace it before operating the machine.
5. Always wear substantial shoes. Do not operate ma-
chine while wearing sandals, tennis shoes, sneakers or
when barefoot. Do not wear loose fitting clothing that
could get caught in moving parts and possibly cause
personal injury.
6. Wearingsafetyglasses,safetyshoes,longpantsand
a helmet is advisable and required by some local ordi-
nances and insurance regulations.
7. Make sure the work area is clear of objects which
might be picked up and thrown by the reels.
8. Do not carry passengers on the machine. Keep eve-
ryone,especiallychildrenandpets,awayfromtheareas
of operation.
Reelmaster 4500–D Page 1 – 1 Safety

9. Since diesel fuel is highly flammable, handle it care- C. Do not smoke while handling fuel.
fully: D. Fill fuel tank outdoors and only to within an inch
A. Use an approved fuel container. (25 mm) from the top of the tank, not the filler neck.
Do not overfill.
B. Donotremovefueltankcapwhileengineishotor
running. E. Wipe up any spilled fuel.
While Operating
10. Do not run engine in a confined area without ade-
quate ventilation. Exhaust is hazardous and could be
deadly.
11. Sit on the seat when starting and operating the ma-
chine.
12. Checkinterlock switchesdaily for properoperation.
Ifa switch fails, replaceitbefore operating themachine.
Theinterlocksystemisfor yourprotection, sodonotby-
pass it. Replace all interlock switches every two years.
13. This product may exceed noise levels of 85 dB(A)
at the operator position. Ear protectors are recom-
mended for prolonged exposure to reduce the potential
of permanent hearing damage.
14. Before starting the engine each day, test lamps,
warningbuzzerandsignallightstoassureproperopera-
tion.
15. Pay attention when using the machine. To prevent
loss of control:
A. Mow only in daylight or when there is good artifi-
cial light.
B. Watch for holes or other hidden hazards.
C. Be extremely careful when operating close to
sand traps, ditches, creeks, steep hillsides or other
hazards.
D. Reduce speed when making sharp turns. Avoid
sudden stops and starts. Use ground speed limiter
lever to set pedal travel so excessive ground speed
will be avoided during mowing and transport.
E. Look to the rear to assure no one is behind the
machine before backing up.
F. Watchfortrafficwhennearorcrossingroads. Al-
ways yield 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. Operatormust beskilledand trainedin how todrive
onhillsides.Failuretousecautiononslopesorhillsmay
causelossofcontrolandvehicletotiporrollpossiblyre-
sulting in personal injury or death.
19. Whenoperating4wheeldrive machine,alwaysuse
theseatbeltand ROPStogetherandhaveseatpivotre-
taining pin installed.
20. If engine stalls or loses headway and cannot make
it to the top of a slope, do not turn machine around. Al-
ways back slowly straight down the slope.
21. Raisecuttingunitsandlatchthemsecurelyintrans-
port position before driving from one work area to an-
other.
22. Do not touch engine, muffler or exhaust pipe while
engine is running or soon after it is stopped. These ar-
eas could be hot enough to cause burns.
23. Ifcuttingunitstrikesasolidobjectorvibratesabnor-
mally, stop immediately, turn engine off, set parking
brakeandwaitforallmotiontostop.Inspectfordamage.
Ifreelorbedknife isdamaged,repairorreplaceitbefore
operating. Do not attempt to free blocked cutting unit by
movingMow/BacklapleverrapidlybetweenFORWARD
andBACKLAP.Damagetohydraulicsystemmayresult.
Lever should easily return and hold in the STOP posi-
tion.
24. Before getting off the seat:
A. Move traction pedal to neutral.
B. Set parking brake.
C. Disengagecuttingunitsandwaitforreelstostop.
D. Stop engine and remove key from switch.
E. Do not park on slopes unless wheels are
chocked or blocked.
25. TheoptionalTOROtowbarisforemergencytowing
only. Use only the special tow bar if it becomes neces-
sary to tow machine. Use trailer for normal transport.
Reelmaster 4500–D
Page 1 – 2

Maintenance and Service
26. Before servicing or making adjustments, stop en-
gine and remove key from the switch.
27. Assure entire machine is properly maintained and
in good operating condition. Frequently check all nuts,
bolts and screws.
28. Frequently check all hydraulic line connectors and
fittings. Assure all hydraulic hoses and lines are in good
condition before applying pressure to the system.
29. Keep body and hands away from pin hole leaks or
nozzles that eject high pressure hydraulic fluid. Use
cardboard or paper to find hydraulic leaks. Hydraulic
fluid escaping under pressure can penetrate skin and
cause injury. Fluid accidentally injected into the skin
mustbesurgicallyremovedwithin afew hoursbyadoc-
tor or gangrene may occur.
30. Beforeanyhydraulicsystemmaintenance,stopen-
gineandlowercuttingunitstothegroundsoallpressure
is relieved.
31. For major repairs or other assistance, contact your
local Toro Distributor.
32. To reduce 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
partsofthebodyawayfromcuttingunitsandothermov-
ing parts. Keep everyone away.
34. Donotoverspeedtheenginebychanging governor
setting. Maximum engine speed is 2500 rpm + or – 100
rpm.Toassuresafetyandaccuracy,haveanAuthorized
Toro Distributor check maximum engine speed.
35. Shut engine off before checking or adding oil to the
crankcase.
36. Disconnect battery before servicing the machine.
If battery voltage is required for troubleshooting or test
procedures, temporarily connect the battery.
37. Toro recommends that twopeoplebe used toback-
lapreels. Each person hasspecificduties and youmust
communicate with one another.
38. For optimum performance and safety, use genuine
Toro replacement parts and accessories. Replacement
parts and accessories made by other manufacturers
could be dangerous and may void the product warranty
of The Toro Company.
Safety
Reelmaster 4500–D Page 1 – 3 Safety

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.
ON PANEL IN FRONT OF OPERATOR'S SEAT
(P rt No. 58-6540)
ON LIFT ARMS
(P rt No. 61-3610)
ON LEFT SIDE OF MACHINE
(P rt No. 59-7290)
ON PANEL IN FRONT OF OPERATOR'S SEAT
(P rt No. 93-9426)
Safety Page 1 – 4 Reelmaster 4500–D

NEAR RADIATOR FILL CA
( art No. 58-6940)
ON STEERING CONSOLE
( art No. 77-4830)
UNDER SEAT NEAR OIL FILL CA
( art No. 58-6530)
ON FRAME ABOVE RIGHT REAR WHEEL
( art No. 88-6700)
ON RADIATOR CA NEAR FUEL TANK FILL CA
( art No. 59-8440) ( art No. 49-2280)
ON FRAME ABOVE REAR WHEELS
( art No. 58-5910)
ON CUTTING UNIT
( art No. 76-8760)
NEAR FRONT CUTTING UNIT RELEASE LEVER
( art No. 59-7960)
( art No. 76-8750)
ON FAN SHROUD
NEXT TO TRACTION EDAL ON STEERING CONSOLE
( art No. 63-4540, Model 03702 & 03704) NEXT TO LIFT LEVERS
( art No. 63-4530, Model 03703 & 03705) ( art No. 62-6290)
Safety
Reelmaster 4500–D Page 1 – 5 Safety

ON FRONT CARRIER & TOW BAR
NEAR TEST PORTS
(Pa t No. 86-6120)
(Pa t No. 58-6680)
ON RIGHT CONTROL PANEL
(Pa t No. 58-6560)
ON RIGHT CONTROL PANEL
(Pa t No. 92-5656)
Safety Page 1 – 6 Reelmaster 4500–D

Chapter 2
Product Records and Manuals
Table of Contents
PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 1
EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . 2
Decimal and Millimeter Equivalents . . . . . . . . . . . . 2
U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . 2
Product Records
Record information about your Reelmaster 4500–D 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.
ProductRecords
and Manuals
Reelmaster 4500–D Page 2 – 1 Product Records and Manuals

Equivalents and Conversions
Product Records and Manuals Page 2 – 2 Reelmaster 4500–D

ProductRecords
and Manuals
Reelmaster 4500–D Page 2 – 3 Product Records and Manuals
Torque Specifications

Product Records and Manuals Page 2 – 4 Reelmaster 4500–D

____________________ ______________________
____________________ ______________________
____________________
____________________
____________________ __________________
____________________ __________________
____________________ __________________
EQUIPMENT OPERATION 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 TORODistributor/Dealer for other Publications, Manuals, and Videos from The TORO Company.

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
Lubricate Reel Speed Control Valve with Oil 50hrs
Lubricate all Grease Fittings A Level
Check Battery Condition and Connections Service
‡ Change Engine Oil and Filter
Drain water from Hydraulic Tank
† Check Engine Fan and Alternator Belt B Level
Inspect Cooling System Hoses Service
Service Air Cleaner Filter Element
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 Wheel Toe-in Service
† Initial break in at 10 hours
‡ Initial break in at 50 hours
Replace all Moving Hydraulic Hoses
Replace Safety Switches Annual Recommendations:
Items listed are recommended every 1500 hours
Cooling System - Flush/Replace Fluid or 2 years whichever occurs first.
Change Hydraulic Oil
See Operator's and Service Manual for specifications and procedures)

_____________
_____ _____ _____ _____ _____ _____ _____
REELMASTER® 450-D and 4500-D Daily Maintenance Check List
Unit Designation:__________
Daily Maintenance:(duplicate this page for routine use) TORO ID#:_______-_______
Maintenance Check Item
Daily Maintenance Check For Week Of
MON
HRS TUES HRS WED HRS THURS HRS FRI HRS SAT HRS SUN HRS
Safety Interlock Operation
Parking Brake Operation
Engine Oil Level
Fuel Level
Cooling System Fluid Level
Drain Water/Fuel Separator
Dust Cup and Baffle (Air Filter)
Radiator & Screen for Debris
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 Glow Plugs and Injector Nozzles, if hard starting, excess smoke, or rough running is noted.
3 = Immediatelyafter every washing, regardless of the interval listed.
Notation for areas of concern: Inspection performed by:________________
Item Date Information
1
2
3
4
5
6
7 (See Operator's and Service Manual for specifications and procedures)

______________________________ _______________________________
______________________________ _____________________________ _______________________________ ______________________________ ______________________________ _______________________________ ______________________________ ______________________________ _______________________________ ______________________________ ______________________________ _______________________________
_______________________________
______________________________ _______________________________ ______________________________ _______________________________ ______________________________ ______________________________ _______________________________ ______________________________ ______________________________ _______________________________
REELMASTER® 450-D and 4500-D Supervisor Maintenance Work Order Date:______________ (duplicate this page for routine use)
Unit Designation: TORO I.D. #: Remarks:
____________-____________
Service 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/Connections Inspect Cooling System Hoses A and B Service required
A-Service required
D -Service (every 400 hours) E -Service (every 800 hours) Other
Drain and Clean Fuel Tank Replace Moving Hoses
Inspect Fuel Lines and Connections Replace Safety Switches Torque Cylinder Head/Adjust Valves Replace Hydraulic Tank Breather Coolant System - Flush/Replace Fluid
Change Front Planetary Gear Lube Change Hydraulic Oil
A, B, and C Service required
Check Rear Wheel Toe-in A, B, C, and D Service required
Hours:
LubricateReel Control Valve Fitting Change Engine Oiland Filter Service Air Cleaner Filter Element
Lubricate allGrease Fittings
- Annual Service and Specials
Replace Fuel Filter
Replace Hydraulic OilFilter
Check Engine RPM (Idle/Full Throttle)
Pack RearAxle Bearings (2WD)
(See Operator's and Service Manual for specifications and procedures) Form No. 95-849-SL

Chapter 3
Engine
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

Specifications
Item Description
Make / Designation Mitsubishi 4DQ7
Water–cooled, 4–stroke, swirl–combustion chamber type Diesel
Number of Cylinders 4
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 – 3 – 4 – 2
Dry Weight (approximate) kg (lb.) 200 (441)
Fuel Grade 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 (U.S. qt.) 14 (14.8)
Starter 12VDC 2 KW
Alternator 12 VDC – 35 AMP
Glow Plug Sheathed type
Engine Page 3 – 2 Reelmaster 4500–D