Form No. 3353–159 Reelmaster) 4000–D Traction Unit Model No. 03706—250000001 and Up Model No.
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Air Cleaner Maintenance . . . . . . . . . . . . . Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . Engine Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Cooling System . . . . . . . . . . . . . . . . . . . . . Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction This manual uses two other words to highlight information. Important calls attention to special mechanical information and Note: emphasizes general information worthy of special attention. Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely.
• Before attempting to start the engine, disengage all blade attachment clutches, shift into neutral, and engage the parking brake. • inadequate braking; • the type of machine is unsuitable for its task; • lack of awareness of the effect of ground conditions, especially slopes; • Remember there is no such thing as a safe slope. Travel on grass slopes requires particular care. To guard against overturning: • incorrect hitching and load distribution.
• Be careful during adjustment of the machine to prevent entrapment of the fingers between moving blades and fixed parts of the machine. • Stop the engine and disengage drive to attachment – before refuelling; – before removing the grass catcher/catchers; • On multi-cylinder/multi-reel machines, take care as rotating one cylinder/reel can cause other cylinders/reels to rotate. – before making height adjustment unless adjustment can be made from the operator’s position.
• Do not operate the machine while wearing tennis shoes or sneakers. • Keep your body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not your hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. Seek immediate medical attention if fluid is injected into skin.
Safety and Instruction Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. 93-6681 59-8440 1. Cutting/dismemberment hazard, fan—stay away from moving parts. 1. Warning—contents under pressure. 93-7331 67-7960 1. Stored energy hazard—read the Operator’s Manual. 93-6686 1. Hydraulic oil 88-6700 2. Read the Operator’s Manual. 93-6680 100-6574 1.
93-9400 1. Warning—read the Operator’s Manual; do not tow the machine. 93-9406 1. Hydraulic oil level 2. Read the Operator’s Manual. 93-9407 1. Read the Operator’s Manual. 2. Lower the reels. 3. Neutral 4. Raise the reels. 107-1818 1. Reel—mowing speeds, slow to fast. 2. Fast 3. Continuous variable setting 4. Fast 5. Reel—mowing 6. 7. 8. 9. Disengage Reel—backlapping Pull and move the lever. Set the parking brake, set the controls to neutral, and start the engine. 93-9425 1.
107-1819 1. Temperature level 2. Four wheel drive flow divider 3. On 4. Off 5. Engine—stop 6. Engine—start 7. Engine—preheat 104-5203 1. Read the Operator’s Manual—do not tow the machine. 2. Warning—read the Operator’s Manual. 5. Warning—lock the parking brake, stop the engine, and remove the ignition key before leaving the machine. 6. Warning—use a rollover protection system and wear the seat belt. 3. Warning—keep bystanders a safe distance from the machine. 4.
4-5204 for CE 1. Read the Operator’s Manual—do not tow the machine. 2. Warning—read the Operator’s Manual. 3. Warning—keep bystanders a safe distance from the machine. 4. Cutting hazard of hand or foot—stay away from moving parts. 1. 7-blade reel 2. Height of cut 5. Warning—lock the parking brake, stop the engine, and remove the ignition key before leaving the machine. 6. Warning—use a rollover protection system and wear the seat belt. 7.
58-6520 1. Grease Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 2. No fire, open flames, or smoking. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 5. Read the Operator’s Manual. 6. Keep bystanders a safe distance from the battery. 7. Wear eye protection; explosive gases can cause blindness and other injuries 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 10.
Specifications Note: Specifications and design subject to change without notice. General Specifications Engine Cooling System Fuel System Kubota, four–cycle, four cylinder, 134 cu–in. displacement, water cooled diesel engine. Rated 40 hp @ 2300 rpm, 23:1 compression ratio. Low idle – 1200 rpm, high idle – 2500 rpm. Injection Timing – 17–18 BTDC. Oil capacity is 8 qt. (7.6 L) with filter. Capacity is 3.7 gal. (14 L) of 50/50 mixture of ethylene glycol anti–freeze. Capacity is 15 gal. (56.
Measurements Optional Equipment Width-of-cut 5 Blade L. H. Cutting Unit 5 Cutting Units 137 in. (348 cm) 4 Cutting Units 110 in. (279 cm) 3 Cutting Units 83 in. (211 cm) 1 Cutting Unit 5 Blade R. H. Cutting Unit 7 Blade L. H. Cutting Unit 29 1/2 in. (75 cm) Overall Width 7 Blade R. H. Cutting Unit Cutting Units Raised 91 1/2 in. (232 cm) Cutting Units Down 147 in. (373 cm) Overall Length 11 Blade L. H. Cutting Unit 110 in. (282 cm) 11 Blade R. H.
Before Operating 1 Note: Determine the left and right sides of the machine from the normal operating position. Checking the Engine Oil The engine is shipped with oil in the crankcase; however, the oil level must be checked before and after the engine is first started. Figure 3 Crankcase capacity is approximately 8 qt. (7.6 L) with the filter. 1. Dipstick Use high-quality engine oil that meets the following specifications: 4. If oil is below FULL mark, remove fill cap (Fig.
Caution 1 If the engine has been running, pressurized hot coolant can escape and cause burns if the radiator cap is removed. Allow the engine to cool at least 15 minutes or until the radiator cap is cool enough to touch without burning hands. 2 2. Check level of coolant in radiator. Radiator should be filled to the top of the filler neck and the expansion tank filled to the marks on its side Figure 6 1. Radiator cap 1 2.
Checking the Hydraulic Fluid The machines reservoir is filled at the factory with approximately 18.2 U.S. gallons of high quality hydraulic fluid. Check the level of the hydraulic fluid before the engine is first started and daily thereafter. The recommended replacement fluid is: Toro Premium All Season Hydraulic Fluid (Available in 5 gallon pails or 55 gallon drums. See parts catalog or Toro distributor for part numbers.
Operation Note: Determine the left and right sides of the machine from the normal operating position. 1 3 Controls Seat Adjusting Lever The seat adjusting lever (Fig. 8) allows 5.9 inch (15 cm) fore and aft adjustment in 19/32 inch (15 mm) increments. 2 Figure 9 1. Arm rest 2. Backrest knob 3. Suspension lever Caution 1 To assure interlock switch operates properly, seat suspension must be set for the weight of each operator.
Engine Oil Pressure Warning Hydraulic Oil Filter Warning Dangerously low engine oil pressure is indicated by both a warning indicator light and audible signal (Fig. 10). When this occurs, stop the engine immediately and correct problem. A warning indicator light and audible signal (Fig. 10) warn of clogged hydraulic filter. Air Cleaner Warning A warning indicator light and audible signal (Fig. 10) warn the filter is clogged and in need of service. 7 6 2 Alarm Silence Button 4 Pressing button (Fig.
Hour Meter Important Cam lever nut (Fig. 11, Inset) can be tightened if limiter stop will not hold traction pedal in desired position. Hour meter (Fig. 13) indicates total hours that machine has been operated. Transport Latches Note: Lines circling in the small window at left side of gauge indicate hour meter is operating. Latches secure cutting units in upright position for transport operation. Latch for front cutting units is foot–operated (Fig. 11).
1 2 3 5 4 11 6 8 10 9 7 Figure 13 1. Cutting unit lift controls 2. Mow/backlap lever 3. Throttle 4. Engine override button 5. Fuel gauge 6. Hour meter 7. Engine preheat indicator light 8. Key switch 9. Hand brake 20 10. Reel speed control 11.
Starting And Stopping 1. Sit on the seat, keep foot off traction pedal. Assure parking brake is engaged (Fig. 13). Traction pedal and mow/backlap lever must be in neutral. 2. Turn key switch to ON position. When glow plug indicator light goes off, engine is ready to START. 3. Turn key to START. Release key when engine starts. 1 4. To stop, disengage and move all controls to neutral and set parking brake. Raise and latch all cutting units in transport position. Turn key to OFF and remove it from switch.
Checking Interlock System. Pushing Or Towing Traction Unit Caution In an emergency, the traction unit can be pushed or towed for a very short distance, by using the traction pump by–pass valve. If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. Important Do not push or tow the traction unit faster than 2 to 3 MPH (3 to 5 Km/Hr) because hydraulic system may be damaged.
Danger When operating the machine, always use the seat belt and ROPS together. Do not use a seat belt without a ROPS. 1 Warning System If a warning light comes on during operation, stop the machine immediately and correct the problem before continuing operation. Serious damage could occur if the machine is operated with a malfunction. For short intervals, however, the emergency engine override button (Fig. 13) can be used to operate the engine if it stops because of overheating. Figure 19 1.
CAUTION: This product may exceed noise levels of 85 dB(A) at the operator position. Ear protectors are recommended for prolonged exposure to reduce the potential of permanent hearing damage. Mow–Backlap lever to MOW. Reels are now spinning. Maintain traction pedal contact with ground speed limiter (Fig. 21) to assure consistent clip and quality–of–cut. Transport When mowing is complete, move MOW–BACKLAP lever to STOP. Raise cutting units by pulling back on lift control levers.
CUTTING CHARTS Relate HOC and ground speed to required reel speed setting on a 1 thru 5 scale on reel speed knob. Note: 1 = 800 RPM; 2 = 900 RPM; 3 = 1000 RPM; 4 = 1100 RPM and 5 = 1200 RPM. * Speeds are approximate Recommended Reel Speed Settings 5 Blade Reel HOC 7 Blade Reel Ground Speed In MPH 3 4 5 6 7 HOC 11 Blade Reel Ground Speed In MPH 3 4 5 6 7 HOC Ground Speed In MPH 3 4 5 6 7 1 1 3 5 N/R N/R 1/2 2 5 N/R N/R N/R 3/8 1 3 5 N/R N/R 1.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule Maintenance Service Interval Maintenance Procedure After first 10 hours • Check the fan and alternator belt tension. • Torque the wheel lug nuts. After first 50 hours • • • • • Change the engine oil and filter. Check the engine RPM (idle and full throttle). Change the hydraulic filter.
Caution If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition and disconnect the wire from the spark plug before you do any maintenance. Set the wire aside so that it does not accidentally contact the spark plug. Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Maintenance Check Item Mon. Tues. Wed. Thurs. Check safety interlock operation.
Lubrication The machine has grease fittings that must be lubricated after every 50 hours of operation with No. 2 General Purpose Lithium Base Grease. Lubricate fitting immediately after every washing regardless of interval listed. The lubrication points are: lift arms (5) (Fig. 24), rear axle (6) (Fig. 25), floating or fixed head kit pivots (Fig. 26) and cutting unit reel and roller bearings (Fig. 27). Also, grease fitting on reel control valve (not shown), located under right hand console.
General Air Cleaner Maintenance new filter by applying pressure to the outer rim of the element to seat it in the canister. Do not apply pressure to the flexible center of the filter. • Check the air cleaner body for damage which could cause an air leak. Replace if damaged. Check the whole intake system for leaks, damage or loose hose clamps. 2 • Service the air cleaner filter every 200 hours or earlier if engine performance suffers due to extremely dusty, dirty conditions.
Fuel Lines and Connections Check lines and connections every 400 hours or yearly, whichever comes first. Inspect for deterioration, damage, or loose connections. Fuel Filter / Water Separator Drain water or other contaminants from fuel filter / water separator (Fig. 32) daily. 1. Locate fuel filter and place a clean container under it. 1 2. Loosen drain plug on bottom of filter canister. Tighten plug after draining. Figure 31 1.
Replacing Fuel Filter (Machines with serial numbers prior to 230000001) 1 Replace the fuel filter after every 400 operating hours or yearly, whichever occurs first. 1. Clean area where filter bowl mounts. 1 3 4 Figure 34 2 1. Fuel pre-filter Figure 33 1. Fuel filter mounting head 2. Filter bowl Bleeding Air From Injectors 3. Filter 4.
Engine Cooling System Maintaining Cooling System Removing Debris Capacity of the system is 3.7 gal. (14 L). Always protect cooling system with a 50/50 solution of water and ethylene glycol anti–freeze. DO NOT USE WATER ONLY IN COOLING SYSTEM. Remove debris from oil cooler, radiator and rear screen daily, clean more frequently in dirty conditions. • After every 100 operating hours, tighten hose connections. Replace any deteriorated hoses. 1.
4. Adjust four U–bracket nuts so engine will start and run when hand brake is at fourth click, but will not start or run when hand brake is at second click. 1 1 2 5 4 Figure 41 1. Reservoir cover Important To prevent contamination, clean top of hydraulic oil containers before opening. Assure pour spout and funnel are clean. 3. Install reservoir cover, lower seat and secure with lock pin. 3 Draining Water From Hydraulic Reservoir Figure 39 1. Parking brake 2. Brake cable 3. U–bracket nuts 4.
Changing Hydraulic Oil Normally, change hydraulic oil after every 2 years or 1500 operating hours. If oil becomes contaminated, contact your local TORO distributor because the system must be flushed. Contaminated oil looks milky or black when compared to clean oil. 1. Remove drain plug (Fig. 42) from reservoir and let hydraulic oil flow into drain pan. Tighten plug when hydraulic oil stops draining. 1 2. Fill reservoir with approximately 9.3 gallons of hydraulic oil. Refer to Checking the Hydraulic Oil.
Checking Hydraulic Lines And Hoses 2 1 5 Check hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration and chemical deterioration. Make all necessary repairs before operating. 4 3 Hydraulic System Test Ports The test ports (Fig. 45 & 46) are used to test the hydraulic circuits. Check all pressures when engine is at full speed and hydraulic oil is at normal operating temperature. Contact your local Toro distributor for assistance.
1 Figure 47 2. Loosen clamps at both ends of tie rods (Fig. 48). Figure 49 3. Rotate tie rod to move front of tire inward or outward. 1. Check/drain plug 4. Tighten tie rod clamps when adjustment is correct. Note: Make sure tie rod clamps are positioned so they do not interfere with steering linkage. Engine Valve Clearance Adjust every 800 operating hours. 2 1 Figure 48 1. Clamp 2.
LH 37 A B REAR B A RH 4 WHEEL DRIVE ONLY LC2 TRACTION FORWARD TRACTION REVERSE COUNTER-BALANCE TEST PORTS STEERING CIRCUIT LC1 S1 P1 (FWD) P2 L T LEFT SIDE RIGHT SIDE P R TEST PORT LIFT CYLS SHUTDOWN WARNING T P B (REV) 2100@50 PSI A (FWD) TEST PORT CHARGE PRESSURE INLET T T 2500 HI-IDLE 1100 LO-IDLE F E D C B A IN PRIORITY OUT 4 2 1 3 5 B 3000 PSI G T A A B TEST PORT CUTTING CIRCUIT B (TYP) IN A Hydraulic Schematic
87a BU Y L Start B+ W R/BK VIO/W 1 SEC. DELAY ON 83–2280 BK Y 12 VOLT BATTERY R B PULL IG STARTER ALTERNATOR VIO R/BK HOLD TIME DELAY RELAY ENGINE RUN SOLENOID 87 30 86 85 TD R R HYD. OIL LEVEL SW. (OPENS WHEN LOW) 20 A FUSE 40 A FUSE BK R Y OR I VIO NC C OR BK IGNITION SW. T W VIO VIO BN BN BK SEAT SW. (OPERATOR NOT PRESENT) ENGINE OVER TEMP.
Battery Care Warning Warning Incorrect battery cable routing could damage the tractor and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. CALIFORNIA Proposition 65 Warning • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. • Always connect the positive (red) battery cable before connecting the negative (black) cable.
The Toro General Commercial Products Warranty A Two-Year Limited Warranty Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial Product (“Product”) to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first.
