FORM NO. 3315869 MODEL NO. 03702 ~ 30001 & UP | MODEL NO. 03703 ~ 30001 & UP OPERATOR’S MODEL NO. 03704 — 30001 & UP MODEL NO. 03705 — 30001 & UP MANUAL REELMASTER® 4500 D TRACTION UNIT To understand this product, and for safety and optimum performance, read this manual before starting the engine. Pay special attention to SAFETY INSTRUCTIONS highlighted by this symbol. L it means CAUTION, WARNING or DANGER personal safety instruction. Failure to comply with the instruction may result 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 Ol Check Cooling System Fill Fuel Tank 10 Check Hydraulic System 10 Check Reed to Bed knife Contact 1t 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 . 16 Pushing or Towing Traction Unit 17 Operating Characteristics .
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. Seton the seat when starting and operating the machine 12, Check interlock switches dally for proper operation. If a switch fails, replace it before operating the machine. The interlock system is for your protection, sa 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 v (o EAR PROTECTION MUST 8F WORN WHEN OPERATING. @ TS IMPORTANT: FOR PROPER PERFORMANCE ENGINE MUST BE AT FULL SPEED WHILE MOWING. PRESS 10 CHECK WARNING LIGHTS, PRESS 1O HENCE ON STEERING CONSOLE (Part No. 77-4830) NEAR RADIATOR FILL CAP {Part No. 58-6940) KAW ¥ ON RADIATOR CAP (Part No. 59—8440) IMPORTANT THIS UNIT COMPLIES WITH ANS! 67 1.
A SAFETY AND INSTRUCTION DECALS [T Ry HYDRAULIC AED THERE (5 N DIRECTIVE BARING WITH REEL MOTORS TEST PORTS Lie 34 [ 0] 210 BEE OFFHANDED, MANUAL FOR ALTERNATE TOWING Isolation. Ll RSN S ON FRONT CARRIER & TOW BAR {Part No. 634380} TRACTION REVERSE ON FAN SHROUD COUNTER {Part No. 768750} 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 Part No. 634540, Mode! 03702 & 03704) ipecac No.
SPECIFICATIONS Engine: Mitsubishi, four—cycle, four cylinder. 139 cu— in. displacement, water cooled diesel engine. Rated 40 hp @ 2300 rpm, 21:1 compression rate. Low idle — 1200 rpm, high idle — 2500 rpm. Injection Timing ~ 18° DEBT. Ol capacity is 6.9 gt (6.5 L} with filter. Cooling System: Capacity is 3.7 gal. {14 L} of 50/50 mixture of ethylene glycol anti~freeze. Fuel Stern: Capacity is 10.5 gal. diesel tel. Hydraulic System: Reservoir capacity is 16 gal. {581} and total system capacity is 18.2 gal.
SPECIFICATIONS OPTIONAL EQUIPMENT 5 Blade L. H. Cutting Unit, Model No. 03752 {2 per machine} 5 Blade R. H. Cutting Unit, 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. 03756 (3 per machine) 11 Blade L. H. Cutting Unit, Mabel No. 03741 (2 per machine} 11 Blade R. H. Curling Unit, Model No. 03751 (3 per machine} L. H. Thatcher Kit, Model No. 03730 (2 per machine} R. H. Thatcher Kit, Model No.
Figure 3 1. Ol Fill Cap 5. Install oil fill cap and dipstick 8. Close engine cover and secure with the latches CHECK COOLING SYSTEM Capacity of system is 3.7 gal. (14 1. 1. Remove radiator cap (Fig. 4}. Coolant should be one inch from bottom of fill hole. 2. antisocial low, add a 50/50 mixture of water and ethylene glycol anti~freeze, DO NOT USE WATER ONLY OR ALCOHOL / METHANOL BASE COOLANTS. 3. Install radiator cap. A\ caution The best time to check coolant level is before the engine is started each day be
BEFORE OPERATING 2. Foil level is low, add hydraulic oil to the reservoir. Refer to Hydraulic Oil Specifications. CHECK REEL TO BED KNIFE CONTACT Each day before operating, check reel to penknife contact, regardless if quality of cut had previously been acceptable. There must be light contact across the full length of the reel and bed knife (refer to Adjusting Cutting Units in Cutting Unit Manual, Step #1 — Reel to Bed knife Adjustment).
KNOW YOUR CONTROLS Warning Light Test Burton (Fig. 8) — Before operating, press test button. All fights on the steering tower should illuminate. Any light that does not come on indicates an electrical malfunction that should be repaired immediately. Ol pressure and no charge indicator lights illuminate when turning key switch "ON", Hydraulic and Engine Indicator Lights (Fig. 8) -~ if these lights come on, stop machine and make repairs immediately, Engine Oil Pressure Warning (Fig.
KNOW YOUR CONTROLS Ground Speed Limiter (Fig. 8) ~ 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. ¢ Inset) can be tightened if limiter stop will not hold traction pedal in desired position. Transport Latches (Fig. 8 and 10} — Latches secure cutting units in upright position for transport operation. Lat eh for front cutting units is foot—operated (Fig. 9).
KNOW YOUR CONTROLS . Figure 11 1. Cutting Unit Lift Controls 8. Hour mater 2. Backlash Lever 10, Engine Pretest Button & Indicator 3. Throttler 11, Key Switch 4. Speedometer 12. Hand Brake . Engine Override Button 13. Real Speed Control 6. Coolant Temperature Gauge 14. Auxiliary Circuit Broker 7. Fuel Gauge 18. Crass Cut Link 8.
OPERATING INSTRUCTIONS STARTING AND STOPPING 1. Synthesis seat, keep foot off traction pedal. Assure parking brake is engaged (Fig. 11}. Traction pedal and backslapper lever must be in neutral. 2. engine or air temperature is below 45° -50" F Cj}, press and hold engine preheat switching until indicator burns brightly {Fig. 11). Then release switch and proceed to step 3 to start engine. 3. Move throttle to SLOW and turn ignition key to START {Fig. 11). Release key when engine starts. 4.
OPERATING INSTRUCTIONS 2. Synthesis seat and engage parking brake (Fig. 14}. Turn key and try to start engine with Backslapper lever {Fig. 14) in both the MOW and BACK LAP positions. i engine cranks, there is a malfunction that must be repaired immediately. If engine does not crank, the cutter drive switch is operating properly. Figure 14 1. Parking Brake 2. Mow j Back lap Lever 3.Kay 3. Sit on the seat and disengage the parking brake {Fig. 14).
OPERATING INSTRUCTIONS IMPORTANT: Do not push or tow the traction unit faster than 2 to 3 MPH Km/Hr) because hydraulic system may be damaged. If traction unit must be moved a considerable distance, transport iron a truck or trainer. 1. Remove retainer clip from seat lock rod {Fig. 15). 2. Raise seat and support it in upright position with seat support rod (Fig. 16). 3. Lift and remove front panel (Fig. 17). 4. Rotate by -pass valve 90 degrees {Fig. 19).
OPERATING INSTRUCTIONS OPERATING CHARACTERISTICS Familiarization — Before mowing grass practice operating inn open area, Start and stop the engine. Operate in forward and reverse. Lower and raise cutting units simultaneously and individually. Engage and disengage reels. Operate with all cutting units down, then with only an individual cutting unit. When you feel familiar with the machine, practice operating around trees and obstacles.
OPERATING INSTRUCTIONS Start engine and move throttle to FAST so engine is running at maximum speed. Move Backslapper lever {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 0f85 dB(A} at the operator position.
LUBRICATION NOTE: Remove the plastic caps over the fittings on the A CAUTION floating or fixed head kit pivots and replace after greasing {Fig. 26). Before servicing or making adjustments to the machine, stop engine and remove key from the switch. GREASING BEARINGS AND BUSHINGS The machine has grease fittings that must be lubricated daily with No. 2 General Purpose Lithium Base Grease. The lubrication points are: fight arms (5) (Fig. 24y, rear axle {3} {Fig. 25), floating 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 manifold 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 ofl flow into drain pan. When oil stops, install drain plug. Figure 28 1. Drain Plug 2. Remove oil filter {Fig.30}. Apply alight coat of clean oil to the new filter seal before screwing it on, DO NOT OVER-TIGHTEN. 3. Add oil to crankcase, Figure 30 1. Ot Filter 22 FUEL SYSTEM 1. Draining Water From Fuel System (Fig.
MAINTENANCE ENGINE COOLING SYSTEM 1. Removing Debris — Remove debris from oil 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. B. Loosen knobs securing rear screen to frame and remove screen {Fig. 33). Figure : 1. Rear Serene C. Lift up on oil cooler handles and pivot rearward in mounting slot.
MAINTENANCE ol Figure 36 1. Battery Cover 2. Caps craws 3. Battery 4. Check electrolyte level in each cell. 5. Install battery cover and secure with cap screws. ADJUSTING HAND BRAKE & TRACTION SWITCHES In time, the hand brake cable may stretch, causing the engine not to start. If this happens, adjust the cable (Fig. 37). 1. Pull hand brake fever to 3rd click. Figure 37 1. Parking Brake 4. Traction Switches 2. Brake Cable 5. Traction Pod at 3. U -bracket Nuts 2. Pull hand brake up one additional click. 24 3.
MAINTENANCE IMPORTANT: To prevent contamination, clean top of hydraulic oll 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 inch drain pan until water is not noticed in hydraulic oil. Figure 40 1. Drain Plug 2.
MAINTENANCE speed and hydraulic oils at normal operating temperature, Contact your local rota distributor for assistance. Note: Under certain conditions, a bypass valve in the filter mounting plate allows ol to bypass the fitter. Before the filter starts to bypass a warning light on the steering console will fulminate. The warning light may come on momentarily when the oil is cold.
MAINTENANCE 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. 44). Front measurement must be 1/8 in. less than rear measurement. Figaro A5 2. Loosen clamps at both ends of tie rods {Fig. 45). 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 Service Interval Check Parking Brake Operation Check Interlock Switch Operation Check Engineering Oif Level Check Cooling System Fluid Laval Check Reel to Bed knife Contact Check Hydraulic System Fluid Level Check Tire Pressure Drain Water From Fuel Separator Clean Debris From Radiator & Screen *Grease Five (5) Lift Arm Pivot Fins *Grease Outing Unit Rollers *Grease Cutting Unit Reel Bearings *Grease Rear Axis (3 firings] Service Air Cleaner Bowl, Dust Cup & Ba
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 nameplate 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 pairs are obtained.
The Toto Promise A One Year Limited Warranty The Toto Com pang_ promises to repair your TOR Product if defective in materials or workmanship. The following time periods from the date of purchase apply: Commercial Products The cost of parts, labor and transportation are included.