FORM NO. 3316445 MODEL NO. 03702 ~ 40001 & UP MODEL NO. 03703 ~ 40001 & UP MODEL NO. 03704 ~ 40001 & UP MODEL NG, 03708 ~ 40001 & UP OPERATOR’S MANUAL REEL MASTER 4500 D TRACTION UNIT To understand the product, and for safely and optimum performances, read this manual before starting the engine. Pay special attention to SAFETY INSTRUCTIONS highlighted by this symbol. &L 1t means CAUTION, WARNING or DANGER -~ personal safely instruction. Failure to comply with the Instruction may resell In personal Injury.
FOREWORD This operator’'s manual has instructions on safety, proper set—up and operation, adjustments and maintenance. Therefore, anyone involved with the product, including the operator, should read and understand this manual. Major sections are: Safety instructions Operating Instructions Specifications Maintenance — Before Operating ~ Schematics Know Your Controls This manual emphasizes safety, mechanical and general product information. DANGER, WARNING and CAUTION identify safety messages.
TABLE OF CONTENTS SAFETY INSTRUCTIONS SAFETY AND INSTRUCTION DECALS SPECIFICATIONS BEFORE OPERATING Check Engine Ofl Check Cooling System Fill Fuel Tank [ . Check Hydraulic System Check Reel to Bed knife Contact Check Tire Pressure Rear Ballast .. . KNOW YOUR CONTROLS OPERATING INSTRUCTIONS .. Starting and Stopping Priming Fuel System Checking Warning Indicator Lights Checking Interlock System Traction Pedal Response ..
A SAFETY INSTRUCTIONS WHILE OPERATING 10. Do not run engine in a confined area without adequate ventilation. Exhaust is hazardous and could be deadly. 11, Synthesis seat when starting and operating the machine. 12. Check interlock switches daily for proper operation, Hf a switch fails, replace it before operating the machine. The interlock systems for your protection, so do not bypass it. Replace all interlock switches every two years, 13.
A SAFETY INSTRUCTIONS 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 parts of the body away from cutting units and other moving parts. Keep everyone away. 34. Do not overspend the engine by changing governor setting. Maximum engine speed is 2500 rpm + or ~ 100 rpm.
A SAFETY AND INSTRUCTION DECALS EAR PROTECTION MUST BE WORN WHEN OPERATING. (P @ 4 SRO | IMPORTANT: HENCE #0R PAUPER PERFORMANCE ENGINE MUST BE AT FULL SPEER WHILE PRESS 10 NECK ON STEERING CONSOLE {Part No. 77-4830) NEAR RADIATOR FILL CAP (Part No. 58-6840) WAKING LIGHTS. B ON RADIATOR CAP (Part No. 59—8440) IMPORTANT THIS UNIT COMPLIES WITH ANAL B7 1.4+ 1390 WHEN EQUIPPED WITH REAR BALLAST PER OPERATOR'S MANUAL.
A SAFETY AND INSTRUCTION DECALS A DANGER ON LEVEL SURFACE OH WHELK BN HYDRAULIC TEST PORTS SEE ASPIRATORS MANURE FOR LATHE TE TOWING ON FRONT CARRIER & TOW BAR (Part No. 63—4380) TRACTION REVERSE ON FAN SHROUD COUNTER (Part No. 76--8750) BALANCE CUTTING CIRCUIT STEERING CIRCUIT ON CUTTING UNIT NEAR TEST PORTS (Part No, 76-8760) {Part No. 58--6680) NEXT TO TRACTION PEDAL ON STEERING CONSOLE Earl No., 634540, Model 03702 & 03704) Part No.
SPECIFICATIONS Engine: Mitsubishi, four—cycle, four cylinder, 138 cu~ in. displacement, water cooled diesel engine. Rated 40 hp @ 2300 rpm, 21:1 compression ratio. Low idle — 1200 rpm, high idle — 2500 rpm. Injection Timing — 18° DEBT. Oil capacity is 6.9 gt (6.5 1) with filter. Cooling System: Capacity is 3.7 gal. (14 L) of 50/50 mixture of ethylene glycol anti—freeze. Fuel System: Capacity is 10.5 gal. diesel fuel on models with serial numbers prior to 40500, Capacity is 15 gal. (56.
SPECIFICATIONS OPTIONAL EQUIPMENT 5 Blade L. M. Cutting Unit, Mo def No. 03752 (2 per machine) 5 Blade B, H. Cutting Nil, Model No. 03753 (3 per machine) 7 Blade L. H. Cutting Unit, Model No. 03754 (2 per machine) 7 Blade R. H. Cutting Unit, Model No, 03758 {3 per machine} 11 Blade L. H. Curling Unit, Model No. 03741 {2 per machine} 11 Blade R. H. Curling Unit, Model No. 03751 {3 per making) L. H. Thatcher Kit, Model No. 03730 {2 per machine) B. H.
BEFORE OPERATING Figure 3 . 01 Bill Cap 5. Install oil fill cap and dipstick. 6. Close engine cover and secure with the latches. CHECK COOLING SYSTEM Capacity of system is 3.7 gal. (14 L. 1. Remove radiator cap (Fig. 4). Coolant should be one inch from bottom of fill hot. 2. coolants low, add a 80/50 mixture of water and ethylene glycol anti—freeze. DO NOT USE WATER ONLY OR ALCOHOL / METHANOL BASE COOLANTS, 3. Install radiator cap.
BEFORE OPERATING 2. Soil level is low, add hydraulic oil to the reservoir. Refer to Hydraulic Ol Specifications. CHECK REEL TO BED KNIFE CONTACT Each day before operating, check reel to bed knife contact, regardless if quality of cut had previously been acceptable.
KNOW YOUR CONTROLS Warning Light Test Bunion (Fig. B) — Before operating, press test Hutton. Alt lights on the steering dower should Ruminate. Any light that does not come on indicates an electrical malfunction that should be repaired immediately. Oil pressure and no charge indicator lights laminate when turning key switch "ON”, Hydraulic and Engine Indicator Lights (Fig. 8) ~ If these lights come on, stop machine and make repairs immediately.
KNOW YOUR CONTROLS Ground Speed Limiter (Fig. 9) ~ Controls traction pedal movement. Limiter lever helps control the rate of clip and eliminates sudden speed variations over rough terrain, IMPORTANT: Cam lever nut {Fig. 9 inset) can be tightened If limiter stop will not hold traction pedal in desired position. Transport Larches (Fig. 9 and 10) — Latches secure cutting units in right position for transport operation, Lat eh for front cutting units is Cooperated (Fig. 9).
OPERATING INSTRUCTIONS STARTING AND STOPPING 1. Synthesis seat, keep foot off ration pedal. Assure parking brake is engaged (Fig. 11}, Traction pedal and backslapper lever must be in neutral. 2. engine or air temperature is below F G}, press and hold engine preheat switch in until indicator burns brightly (Fig. 11). Then release switch and proceed to step 3 o start engine. 3. Move throttle to SLOW and turn ignition key to START (Fig. 11). Release key when engine starts. 4.
OPERATING INSTRUCTIONS 2. Hesitation seat and engage parking brake (Fig. 14). Turn key and try io start engine with Mow-Back lap lever (Fig. 14} in both the MOW and BACK LAP positions. If engine cranks, there is a malfunction that must be repaired immediately. If engine does not crank, the cuter drive switch is operating properly. Figure 14 1. Parking Brake 2. Mia | Backpedal Lover 3. Koy 3. Sit on the seat and disengage the parking brake (Fig. 14}.
OPERATING INSTRUCTIONS 1. Front Panel 4. Ho late traction pedal adjusting knob clockwise ta increase pressure (slower response) and counterclockwise 1o decrease pressure {quicker response) {Fig. 18). : 5 Figure 18 1. Traction Pedal Adjusting Knot 5. Install front panel over mounting pins (Fig. 17} Lower seat to its normal position and secure with retainer clip (Fig. 16).
OPERATING INSTRUCTIONS OPERATING CHARACTERISTICS Familiarization — Before mowing grass practice operating inn open area. Start and stop engineering. Operate in forward and reverse. Lower and raise cutting hits simultaneously and individually. Engage and disengage reels. Operate with all curling units down, then with only an individual cutting unit. When you feel familiar with the machine, practice operating around iris and obstacles.
OPERATING INSTRUCTIONS Start engine and move throttle to FAST so engine is running at maximum speed. Move Mow-Back lap fever (Fig. 22} to MOW. Reels are now spinning. Disengage hand brake. To move forward and cut grass, press traction pedal forward (Fig. 21). Maintain traction pedal contact with ground speed limiter {Fig. 21) to assure consistent clip and quality —of—cut, CAUTION: This product may exceed noise levels 085 dB(A) at the operator position.
LUBRICATION HOT: Remove the plastic caps over the filings en the Coating or fixed head kit pivots and replace taller greasing {Fig. 26). CAUTION servicing or making adjustments lo the shoeshine, sip engine and remove key fem the switch, GREASING BEARINGS AND BUSHINGS The machine has grease filings that must be lubricated daily with No, 2 General Purpose Lithium Base Grease. The lubrication points are: it arms (5) (Fig. 243, rear axle {(6) (Fig. 28}, Coaling or fixed head kit pivots (Fig.
MAINTENANCE A CAUTION Before servicing or making adjustments to the machine, stop engine and remove key from the switch, GENERAL AIR CLEANER MAINTENANCE To prevent possible severe engine damage and ensure maximum engine service life, periodically inspect the air cleaner and hose assembly. 1. Assure hose between air cleaner and intake man told is clamped securely in place. Replace the hose fit is cracked or punctured. 2. Check air cleaner body for dent and other damage which could possibly cause an air leak.
MAINTENANCE ENGINE OIL AND FILTER Change oil and filter after the first 50 hours of operation and every 100 hours thereafter. 1. Remove drain plug {Fig. 29} and let oil flow into drain pan. When oil stops, install drain plug. Figure 29 1. Drain Hug 2. Remove loiterer (Fig.30}. Apply a light coalescent il to the new filter seal before screwing it on. DO NOT EVER-TIGHTEN, 3. Add oif to crankcase, Figure 30 . Oll Filter 22 FUEL SYSTEM 1. Draining Water From Fuel System (Fig.
MAINTENANCE ENGINE COOLING SYSTEM 1. Removing Debris — Remove debris from ofl cooler, radiator and rear screen daily, clean more frequently in dirty conditions. A. Turn engine off, release front engine cover latches and raise engine cover. Clean engine area thoroughly of all debris. BE. Loosen knobs securing rear screen to frame and remove screen (Fig. 33). Figure 33 1. Saar Screen C. Lift up on gif closer handles and pivot rearward in mounting slot.
MAINTENANCE Lott Figure 36 1. Battery Over 2. Caps craws . Battery 4. Check electrolyte level in each cell. 5. Install battery cover and secure with cap screws. ADJUSTING HAND BRAKE & TRACTION SWITCHES In lime, the hand brake cable may stretch, causing the engine not to start. i this happens, adjust the cable (Fig. 37). 1. Pull hand brake lever to 3rd click. Figure 37 1. Parking Brake 4, Traction Switches 2. Br aka Cable 8, Traction Pedal 3. Y-bracket Nuts 2. Pull hand brake up one additional click. 24 3.
MAINTENANCE IMPORTANT: To prevent contamination, clean top of hydrangea ofl containers before puncturing. Assure pour spout and funnel are clean. 3. Install reservoir cover, lower seat and secure with lock pin. DRAINING WATER FROM HYDRAULIC RESERVOIR After every 100 operating hours, drain water from hydraulic reservoir. 1. Open drain plug {Fig. 40) one—half turn and allow fluid to flow into drain pan until water is not noticed in hydraulic ofl. Figure 40 1. Drain Plug 2.
MAINTENANCE Nate: Under certain conditions, a bypass valve in the filter mounting piste allows oil to bypass the filter. Before the filter starts to bypass a warning light on the steering console will fulminate. The warning light may come on momentarily when the ofl Is cold. If the light does not go out after the oil is warm, the filter is clogged or an electrical problem exists. Correct problem before commencing operation.
MAINTENANCE HEAR WHEEL TOE-IN After every 800 operating hours or annually, check rear wheel toe —in. 1. Measure center—to—center distance f{at axle height} at front and rear of steering tires (Fig. 44). Front measurement must be 1/8 in. lass than rear measurement, Figure 44 2. Loosen clamps at both ends of te rods (Fig. 45). Figure 45 . Clamp 2. Tie Rod 3. Rotate tie rod to move front of tire inward or outward, 4. Tighten tie rod clamps when adjustment is correct.
SERVICE INTERVAL CHART Eats Hour Meter Reading Sarcastic Interval Check Parking Brake Operation Daily Check Interlock Switch Operation Dial Check Engine Ofl Level Daily Hack Cooling System Fluid Level Daily Check Reel fo Bed knife Contact Daily or A/R Check Hydraulic System Fluid Level Gaily Check Tire Pressure Daily of AR Drain Water From Fuse Separator Daily or AR Clean Debris From Radiator & Screen Daily of AR *Grease Five (5) Lift Arm Pivot Pins Daily *Grease Tufting Unit Rollers Daily *Grease Outing Un
PRODUCT IDENTIFICATION The traction unit has two identification numbers: a model number and a serial number that are stamped into a plate. The identification plate is located on a plate that is mounted on the frame, just ahead of the right front wheel {Fig. 47). In any correspondence concerning the traction unit, supply the model and serial numbers to ensure correct information and replacement parts are obtained.
Commercial Products The Toto Promise A One Year Limited Warranty The Toto Company promises to repair your TOR Product if defective in materials or workmanship. The following time periods from the date of purchase apply: The cost of parts, labor and transportation are included. recommended: 1. Contact your Authorized TOR Distributor or Commercial Dealer (the Yellow Pages of your telephone directory is a good reference source), 2.